Magnetek Enrange XLTX User Manual
Enrange XLTX Transmitter
(Intrinsically Safe)
Wireless Controls
Part Number: 198-80202-1001 R0
©Copyright 2014 Magnetek Material Handling
April 2014
Your New Radio Remote
Thank you for your purchase of Magnetek’s EnrangeTM brand XLTX Radio Wireless Controls.
Magnetek has set a whole new standard in radio-remote performance, depen dability, and value
with this unique new line of bellybox transmitters.
If your product ever needs modification or service, please contact one of our representatives at
the following locations:
U.S. Service Information
For questions regarding service or technical information contact:
+1.866.MAG.SERV
+1.866.624.7378
International Service
+1.262.783.3500
World Headquarters:
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: +1.800.288.8178
Website: www.magnetek.com
e-mail: mhcustomerservice@magnetek.com
Fax Numbers:
Main: +1.800.298.3503
Sales: +1.262.783.3510
Service: +1.262.783.3508
Canada Service Information:
4090B Sladeview Crescent
Mississauga, Ontario
L5L 5Y5 Canada
Phone: +1.800.792.7253
Fax: +1.905.828.5707
+1.416.424.7617 (24/7 Service pager)
EU Market Contact:
Brian Preston
Magnetek (UK) Ltd.
Unit 3 Bedford Business Centre
Mile Road
Bedford, MK42 9TW UK
Phone: +44.1234.349191
Fax: +44.1234.268955
©2014 MAGNETEK
All rights reserved. This notice applies to all copyrighted materials included with this product,
including, but not limited to, this manual and software embodied within the product. This manual
is intended for the sole use of the person(s) to whom it was provided, and any unauthorized
distribution of the manual or dispersal of its contents is strictly forbidden. This manual may not be
reproduced in whole or in part by any means whatsoever without the expressed written
permission of MAGNETEK.
Enrange XLTX Intrinsically Safe
Transmitter Instruction Manual
April 2014
Page 2 of 24
TABLE OF CONTENTS
1.0 INTRODUCTION .................................................................................................................. 4
1.1 PRODUCT MANUAL SAFETY INFORMATION ............................................................... 4
1.2 WARNINGS and CAUTIONS ............................................................................................ 5
2.0 CRITICAL INSTALLATION CONSIDERATIONS ................................................................. 6
2.1 GENERAL ......................................................................................................................... 6
2.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT ........... 7
2.3 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO
CONTROLLED EQUIPMENT OPERATORS .............................................................................. 7
2.4 TRANSMITTER UNIT ....................................................................................................... 8
2.5 PRE-OPERATION TEST .................................................................................................. 9
2.6 HANDLING BATTERIES ................................................................................................... 9
2.7 BATTERY DISPOSAL ....................................................................................................... 9
2.8 SPECIFIC CONDITIONS OF SAFE USE ....................................................................... 10
3.0 XLTX TRANSMITTER STANDARD CONFIGURATION AND OPERATION ..................... 11
3.1 INSTALLING BATTERY PACK ....................................................................................... 12
3.1.1 Approved Batteries for Intrinsically Safe Operation ................................................. 12
3.1.2 Intrinsically Safe Alkaline Battery Pack .................................................................... 12
3.1.3 Spare Battery Storage Compartment ...................................................................... 14
3.2 TURNING THE TRANSMITTER ON AND OFF .............................................................. 14
3.2.1 Turning On the Transmitter ...................................................................................... 15
3.2.2 Pulling In the Machine Stop Relay ........................................................................... 15
3.2.3 Turning Off the Transmitter ...................................................................................... 15
3.3 MACHINE STOP SWITCH (For Emergency Stopping Only) .......................................... 15
3.4 STATUS LED .................................................................................................................. 15
3.5 NORMAL OPERATING MODE ....................................................................................... 15
3.5.1 Watch Dog Indicator (Steady Blinking Status LED) ................................................. 15
3.5.2 Switch Change Indicator (Rapidly Blinking Status LED) ......................................... 16
3.5.3 Low Level Battery Indicator (Blinking Red Status LED) .......................................... 16
3.6 JOYSTICKS AND PADDLES/LEVERS .......................................................................... 16
3.7 ROTARY SELECTOR SWITCH ..................................................................................... 16
3.8 AUXILIARY SWITCHES ................................................................................................. 16
3.9 CONNECTING THE XLTX TO A COMPUTER............................................................... 17
4.0 TRANSMITTER SETUP ..................................................................................................... 18
4.1 TRANSMITTER SETUP SETTINGS WITH STANDARD STATUS LEDS .................. 18
5.0 TRANSMITTER CHANNEL CONFIGURATION SETTINGS ............................................. 20
5.1 FCC/ATEX/IECEx STATEMENTS ................................................................................. 20
5.2 CHANNEL AND FREQUENCY DESIGNATIONS BY COUNT ....................................... 21
5.3 OPTIONAL FREQUENCIES AND CHANNELS ............................................................. 22
6.0 GENERAL TROUBLESHOOTING .................................................................................... 23
6.1 ASSEMBLY AND REPLACEMENT PARTS ................................................................... 23
7.0 TECHNICAL SPECIFICATIONS ........................................................................................ 24
Enrange XLTX Intrinsically Safe
Transmitter Instruction Manual
April 2014
Page 3 of 24
1.0 INTRODUCTION
Thank you for your purchase of Magnetek’s Enrange™ brand XLTX Radio Wireless Controls.
These instructions are to be used as a reference for personnel operating the Enrang e brand XLTX Radio
Wireless Controls and the equipment that this Enrange brand XLTX Radio Wireless Control is attached to.
The user of these instructions should have basic knowledge in the handling of electronic equipment.
1.1 PRODUCT MANUAL SAFETY INFORMATION
Magnetek, Inc. (Magnetek) offers a broad range of radio wireless controls products, control products and
adjustable frequency drives, and industrial braking systems for overhead material handling applications.
This manual has been prepared by Magnetek to provide information and recommendations for the
installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek
Products). Anyone who uses, operates, maintains, services, installs or owns Magnetek Products should
know, understand and follow the instructions and safety recommendations in this manual for Magnetek
Products.
The recommendations in this manual do not take precedence over any of the following requirements relating
to cranes, hoists and lifting devices:
Instructions, manuals and safety warnings of the manufacturers of the equipment where the radio
system is used,
Plant safety rules and procedures of the employers and the owners of facilities where the
Magnetek Products are being used,
Regulations issued by the Occupational Health and Safety Administration (OSHA),
Applicable local, state or federal codes, ordinances, standards and requirements, or
Safety standards and practices for the overhead material handling industry.
This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners, users and
operators of the Magnetek Products to know, understand and follow all of these requirements. It is the
responsibility of the owner of the Magnetek Products to make its employees aware of all of the above listed
requirements and to make certain that all operators are properly trained. No one should use Magnetek
Products prior to becoming familiar with and being trained in these requirements.
WARRANTY INFORMATION
FOR INFORMATION ON MAGNETEK’S PRODUCT WARRANTIES BY PRODUCT TYPE, PLEASE VISIT
WWW.MAGNETEKMOBILEHYDRAULIC.COM.
Enrange XLTX Intrinsically Safe
Transmitter Instruction Manual
April 2014
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1.2 WARNINGS and CAUTIONS
Throughout this document WARNING and CAUTION statements have been deliberately placed to highlight
items critical to the protection of personnel and equipment.
WARNING – A warning highlights an essential operating or maintenance procedure, practice, etc.
which, if not strictly observed, could result in injury or death of personnel, or long term physical
hazards. Warnings are highlighted as shown below:
WARNING
CAUTION – A caution highlights an essential operating or maintenance procedure, practice, etc.
which, if not strictly observed, could result in damage to, or destruction of equipment, or loss of
functional effectiveness. Cautions are highlighted as shown below:
CAUTION
WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED.
The safety rules in this section are not intended to replace any rules or regulations of any applicable local,
state, or federal governing organizations. Always follow your local lockout and tagout procedure when
maintaining any radio equipment. The following information is intended to be used in conjunction with other
rules or regulations already in existence. It is important to read all of the safety information contained in this
section before installing or operating the Radio Control System.
Enrange XLTX Intrinsically Safe
Transmitter Instruction Manual
April 2014
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2.0 CRITICAL INSTALLATION CONSIDERATIONS
WARNING
PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT, READ AND DEVELOP AN
UNDERSTANDING OF THE CONTENTS OF THIS MANUAL AND THE OPERATION MANUAL OF THE
EQUIPMENT OR DEVICE TO WHICH THIS EQUIPMENT WILL BE INTERFACED. FAILURE TO FOLLOW
THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES,
HOISTS, LIFTING DEVICES OR SIMILAR EQUIPMENT MUST HAVE A BRAKE INSTALLED. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
AN AUDIBLE AND/OR VISUAL WARNING MEANS MUST BE PROVIDED ON ALL REMOTE
CONTROLLED EQUIPMENT AS REQUIRED BY CODE, REGULATION, OR INDUSTRY STANDARD.
THESE AUDIBLE AND/OR VISUAL WARNING DEVICES MUST MEET ALL GOVERNMENTAL
REQUIREMENTS. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR
DEATH AND DAMAGE TO EQUIPMENT.
FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE
CONTROLLED EQUIPMENT. ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE CRANE,
HOIST, LIFTING DEVICE OR SIMILAR EQUIPMENT BEFORE ATTEMPTING ANY INSTALLATION
PROCEDURES. DE-ENERGIZE AND TAGOUT ALL SOURCES OF ELECTRICAL POWER BEFORE
TOUCH-TESTING ANY EQUIPMENT. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN
SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
THE DIRECT OUTPUTS OF THIS PRODUCT ARE NOT DESIGNED TO INTERFACE DIRECTLY TO TWO
STATE SAFETY CRITICAL MAINTAINED FUNCTION, I.E., MAGNETS, VACUUM LIFTS, PUMPS,
EMERGENCY EQUIPMENT, ETC. A MECHANICALLY LOCKING INTERMEDIATE RELAY SYSTEM
WITH SEPARATE POWER CONSIDERATIONS MUST BE PROVIDED. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
WARNING
SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY.
2.1 GENERAL
Radio controlled material handling equipment operates in several directions. Cranes, hoists, lifting devices
and other material handling equipment can be large, and operate at high speeds. Quite frequently, the
equipment is operated in areas where people are working in close proximit y to the material handling
equipment. The operator must exercise extreme caution at all times. Workers must constantly be alert
to avoid accidents. The following recommendations have been included to indicate how careful and
thoughtful actions may prevent injuries, damage to equipment, or even save a life.
Enrange XLTX Intrinsically Safe
Transmitter Instruction Manual
April 2014
Page 6 of 24
2.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT
Only properly trained persons designated by management should be permitted to operate radio controlled
equipment.
Radio controlled cranes, hoists, lifting devices and other material handling equipment should not be
operated by any person who cannot read or understand signs, notices and operating i nstructions that p ertain
to the equipment.
Radio controlled equipment should not be operated by any person with insufficient eyesight or hearing or by
any person who may be suffering from a disorder or illness, is taking any medication that may cause loss of
equipment control, or is under the influence of alcohol or drugs.
2.3 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO
CONTROLLED EQUIPMENT OPERATORS
Anyone being trained to operate radio controlled equipment should possess as a minimum the following
knowledge and skills before using the radio controlled equipment.
The operator should:
have knowledge of hazards pertaining to equipment operation
have knowledge of safety rules for radio controlled equipment
have the ability to judge distance of moving objects
know how to properly test prior to operation
be trained in the safe operation of the radio transmitter as it pertains to the crane, hoist, lifting device
or other material handling equipment being operated
have knowledge of the use of equipment warning lights and alarms
have knowledge of the proper storage space for a radio control transmitter when not in use
be trained in transferring a radio control transmitter to another person
be trained how and when to report unsafe or unusual operating conditions
test the transmitter emergency stop and all warning devices prior to operation; testing should be done
on each shift, without a load
be thoroughly trained and knowledgeable in proper and safe operation of the crane, hoist, lifting
device, or other material handling equipment that utilizes the radio control
know how to keep the operator and other people clear of lifted loads and to avoid “pinch” points
continuously watch and monitor status of lifted loads
know and follow cable and hook inspection procedures
know and follow the local lockout and tagout procedures when servicing radio controlled equipment
know and follow all applicable operating and maintenance manuals, safety procedures, regulatory
requirements, and industry standards and codes
Enrange XLTX Intrinsically Safe
Transmitter Instruction Manual
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April 2014
The operator shall not:
lift or move more than the rated load
operate the material handling equipment if the direction of travel or function engaged does not
agree with what is indicated on the controller
use the crane, hoist or lifting device to lift, support or transport people
lift or carry any loads over people
operate the crane, hoist or lifting device unless all persons, including the operator, are and remain
clear of the supported load and any potential pinch points
operate a crane, hoist or lifting device when the device is not centered over the load
operate a crane, hoist or lifting device if the chain or wire rope is not seated properly in the
sprockets, drum or sheave
operate any damaged or malfunctioning crane, hoist, lifting device or other material handling
equipment
change any settings or controls without authorization and proper training
remove or obscure any warning or safety labels or tags
leave any load unattended while lifted
leave power on the radio controlled equipment when the equipment is not in operation
operate any material handling equipment using a damaged controller because the unit may be
unsafe
operate manual motions with other than manual power
operate radio controlled equipment when low battery indicator is on
WARNING
THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER. IF ANY PRODUCT
PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED, THE EQUIPMENT SHOULD
IMMEDIATELY BE TAKEN OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR. DAMAGED
AND INOPERABLE RADIO CONTROLLER EQUIPMENT SHOULD BE RETURNED TO MAGNETEK FOR
EVALUATION AND REPAIR. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
2.4 TRANSMITTER UNIT
Transmitter switches should never be mechanically blocked ON or OFF. When not in use, the operator
should turn the transmitter OFF. A secure storage space should be provided for the transmitter unit, and the
transmitter unit should always be placed there when not in use. This precaution will help prevent
unauthorized people from operating the material handling eq uipment.
Spare transmitters should be stored in a secure storage space and only removed from the storage space
after the current transmitter in use has been turned OFF, taken out of the service area and secured.
Enrange XLTX Intrinsically Safe
Transmitter Instruction Manual
April 2014
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