FLEXEXSeries User’s Manual CE Version
Table of Contents Page 1. 2. 3. A. B. 4. 3 Introduction Radio Controlled Safety General System Information 4 Transmitter Handset 1. External Illustration (Standard Push Button Configuration) 5 2. Internal Illustration 6 Receiver Unit 1. External Illustration 7 2. Internal Illustration 8 Function Settings A. B. Transmitter Handset 1. System Channel Settings 9 2. Push Button Functions with LED Displays a. Standard Push Button Configuration (Transmitter Toggle) 10 b.
5. 6. 7. Auxiliary STOP Push Button Function 25 k. Pitch & Catch Function 25 3. Receiver Auto-Scanning Settings 4. Dip-switch Settings 25 a. Interlocked Functions 26 b. Non-interlocked Functions 27 5. Jumpers Settings 28 6. I-Chip Programming Port 29 7. Voltage Settings 29 System Channels Table Receiver Installation 30 A. Output Relay Contact Diagram 31 B. Pre-Installation Precautions 32 C. Step-By-Step Installation 32~33 D. System Testing 33 Operating Procedure A.
1. Introduction The FLEX radio remote control systems are designed for control of industrial equipment and machinery such as overhead traveling cranes, jib cranes, gantry cranes, tower cranes, electric hoists, winches, monorails, conveyor belts, mining equipment and other material handling equipment where wireless control is preferred. Each FLEX system consists of a transmitter handset and receiver unit.
2. Radio Controlled Safety Flex radio remote control system should be operated by persons with sufficient amount of knowledge and skill in crane operation and safety. Persons being trained to operate a radio remote controlled crane should possess the knowledge of all hazards peculiar to radio remote controlled crane operation, ability to judge distance and moving objects, equipment capacity and radio remote controlled safety rules.
3. General System Information A. TRANSMITTER HANDSET 1. External Illustration (Standard Push Button Configuration) (Fig. 01) (Fig. 02) 1. Emergency Stop Button 8. Push Button #12 15. Strap Ring 2. Removable Power Key Switch 9. Push Button #1 16. System Information 3. Push Button #2 10. Push Button #3 17. System Channel 4. Push Button #4 11. Push Button #5 18. Crane Number 5. Push Button #6 12. Push Button #7 19. Battery Cover 6. Push Button #8 13. Push Button #9 20.
2. Internal Illustration 1 2 3 4 5 6 7 8 9 (Fig. 03) (Fig. 04) 1. Encoder Board 6. I-CHIP 2. Arial Antenna 7. Function Dip-Switch 3. Transmitting Module 8. Channel Dip-Switch 4. Status LED Display 9. Battery Contact Mechanism 5.
B. RECEIVER UNIT 1. External Illustration (Fig. 05) 1. Shock Mount 6. COM LED Display 2. External Antenna Jack 7. Output Contact Diagram 3. Power LED Display 8. System Information 4. Status LED Display 9. Cord Grip 5.
2. Internal Illustration (Fig. 06) 1. AC Line Filter 4. Decoder Module 2. Power Transformer 5. Output Relay Board 3.
4. Function Settings A. TRANSMITTER HANDSET 1. System Channel Settings CHANNEL 1 2 3 4 5 6 7 8 (Fig. 07) Set the transmitter channel by adjusting the channel dip-switch located on the backside of the transmitter encoder board (refer to Fig. 07 above). Only the first six (6) positions are used for channel programming (refer to Fig. 08 below). The system channels table located on page 30 illustrates which dip-switch setting corresponds to which channel.
2. Push Button Functions with LED Displays A. Standard Push Button (Transmitter Toggle) Set transmitter toggle (latching output relay) function by adjusting the 8-position function dip-switch located on the backside of the transmitter encoder board (refer to Fig. 09 below). The LED 1 through LED 4 shown inside the shaded box (see below) illustrates which LED on the transmitter will light up when the designated push button (PB7 ~ PB12) is pressed. LED 4 LED 3 LED 2 LED 1 FUNCTION 1 2 3 4 5 6 7 8 (Fig.
B. Standard Push Button Configuration (A/B Selector) There are four (4) different types of A/B selector sequence available on the Flex system. Choose the one that is most suitable for your application.
DIP PB7 PB8 PB9 PB10 PB11 PB12 28 01000001 Normal Normal A/1&2 Normal Normal Normal 29 01000010 Normal Normal B/1&2 Normal Normal Normal 30 01000011 Normal Normal C/1&2 Normal Normal Normal 31 01000100 Normal Normal D/1&2 Normal Normal Normal 32 01000101 Normal Normal Normal A/3&4 Normal Normal 33 01000110 Normal Normal Normal B/3&4 Normal Normal 34 01000111 Normal Normal Normal C/3&4 Normal Normal 35 01001000 Normal Normal Normal D/3&4 Normal Normal 36 01001001 Normal Normal
DIP PB7 PB8 PB9 PB10 PB11 PB12 46 01010011 Normal Normal Normal Normal A/1&2 Normal 47 01010100 Normal Normal Normal Normal B/1&2 Normal 48 01010101 Normal Normal Normal Normal C/1&2 Normal 49 01010110 Normal Normal Normal Normal D/1&2 Normal 50 01010111 Normal Normal Normal Normal Normal A/3&4 51 01011000 Normal Normal Normal Normal Normal B/3&4 52 01011001 Normal Normal Normal Normal Normal C/3&4 53 01011010 Normal Normal Normal Normal Normal D/3&4 54 01011011 Normal Normal
C. Inline Push Button Configuration (Transmitter Toggle) The push button arrangement for inline push button setup starts from top to bottom and then from right column to left column (refer to Fig. 10 below). To set inline push button configuration please refer to JP4 and JP5 jumpers setting on page 28. With inline push buttons configuration, PB1 & PB2 still corresponds to output relay K1~K4, PB3 & PB4 corresponds to relay K5~K8, etc… (Fig.
D. Inline Push Button Configuration (A/B Selector) There are four (4) different types of A/B selector sequence available on the Flex system. Choose the one that is most suitable for your application.
DIP PB9 PB10 PB11 PB12 95 10000001 Normal A/1&2 Normal Normal 96 10000010 Normal B/1&2 Normal Normal 97 10000011 Normal C/1&2 Normal Normal 98 10000100 Normal D/1&2 Normal Normal 99 01000101 Normal Normal A/3&4 Normal 100 01000110 Normal Normal B/3&4 Normal 101 01000111 Normal Normal C/3&4 Normal 102 01001000 Normal Normal D/3&4 Normal 103 10000101 Normal A/1&2 A/3&4 Normal 104 10000110 Normal A/1&2 B/3&4 Normal 105 10000111 Normal A/1&2 C
DIP PB9 PB10 PB11 PB12 113 10001111 Normal Normal A/1&2 Normal 114 10010000 Normal Normal B/1&2 Normal 115 10010001 Normal Normal C/1&2 Normal 116 10010010 Normal Normal D/1&2 Normal 117 01010111 Normal Normal Normal A/3&4 118 01011000 Normal Normal Normal B/3&4 119 01011001 Normal Normal Normal C/3&4 120 01011010 Normal Normal Normal D/3&4 121 10010011 Normal Normal A/1&2 A/3&4 122 10010100 Normal Normal A/1&2 B/3&4 123 10010101 Normal Nor
3. Channel Change via Push Buttons Other than CHANNEL dip-switch on the encoder board, the transmitter channel can also be changed directly on the push buttons. Please refer to the instruction below on how to change transmitter channel via push buttons. a. Press and hold PB1, PB2 and PB3 and rotate the power key to START position at the same time. A series of green and red blinks will appear on the Status LED showing the current channel setting.
4. Program 4-digit Security Code Prior to rotating the transmitter power key-switch to START position to begin operation, you must first enter a 4-digit security code in order to proceed further. When this 4-digit security code is input correctly after turning on the transmitter power, a green light will appear on the Status LED... proceed to START activation. If this 4-digit security code is input incorrectly, an orange light will appear on the Status LED… system locked.
5. I-Chip I-CHIP functioned in a way that is very similar to a SIM card inside a mobile phone, which stores information such as your phone number, account number, phone book and other settings. I-CHIP works exactly the same way, as it stores information such as system serial number/ID code, channel and push button configurations. When replacing a transmitter handset, just take the I-CHIP out of the old transmitter and install it into the new one (refer to Fig. 11 below).
B. RECEIVER UNIT 1. System Channel Settings EXT INT 1 2 3 4 5 6 7 8 (Fig. 12) Even though Flex system is equipped with automatic channel scanning receiver, the user can also set the receiver channel manually. Please refer to page 36 on how automatic channel scanning receiver works. Set the receiver channel by adjusting the channel dip-switch located on the receiver module (refer to Fig. 12 above), only the first six (6) positions are used for channel programming (refer to Fig. 13 below).
a. Output Relay Types 1. Three (3) output relays per motion – shared 2nd speed output relay Output relays with Forward 1st speed (F1), Reverse 1st speed (R1) and Forward/Reverse 2nd speed (F/R2). Forward and Reverse 2nd speed (F/R2) shared the F1 R1 F/R2 same output relay. 2. Four (4) output relays per motion – separate 1st and 2nd speed output relays Output relays with Forward 1st speed (F1), Reverse 1st speed (R1), Forward 2nd speed (F2) and Reverse 2nd F1 R1 F2 R2 speed (R2).
2nd speed At 2nd speed, both 1st speed (F1 or R1) and 2nd speed (F2 or R2) output relays are closed (refer to page 26 on how to set to this function). Forward 1st speed push button pressed Forward 2nd speed push button pressed ↓ ↓ F1 4. R2 F1 R1 F2 R2 Forward 1st speed push button pressed Forward 2nd speed push button pressed ↓ ↓ Rev Slow Fast Fwd Rev Slow Fast 4-output relays configuration with Forward, Slow, and Fast output relays engaged at 2nd speed.
d. Magnet ON/OFF Push Button Function The user can set any of the two adjacent push buttons on the transmitter to control a magnet. To activate the magnet just press the push button with the Magnet symbol. To deactivate the magnet, for safety purpose, you must first press and hold the Magnet push button and then press the OFF push button. Press the OFF push button by itself can not deactivate the magnet (refer to page 26 on how to set to this function). OFF e.
j. Auxiliary STOP Push Button Function (JP3 must be inserted) The auxiliary STOP function acts as a 2nd emergency stop button. Other than by emergency stop button and transmitter power key switch, the receiver MAIN is also deactivated when this auxiliary stop push button is pressed (refer to page 27 on how to set to this function). Aux STOP k.
4. Dip-Switch Settings a. Interlocked Functions Interlocked means the two adjacent push buttons can not be activated simultaneously at the same time as it will cancel each other out. Interlocked settings are usually applied to crane’s forward and reverse motions. Each dip-switch on the decoder module corresponds to one (1) motion or two (2) adjacent push buttons (refer to Fig. 14 & 15 below).
b. Non-Interlocked Functions Contrary to interlocked settings, non-interlocked settings allow the two adjacent push buttons be used simultaneously at the same time. Non-interlocked settings are usually applied to crane’s auxiliary functions such as lights, horn, 3rd speed, auxiliary stop and Pitch & Catch. Each dip-switch on the decoder module corresponds to one (1) motion or two (2) adjacent push buttons (left & right push buttons).
5. Jumper Settings Jumper settings are applied to functions such as Start command, transmitter push button layout, system information (serial number/ID code) programming, and system testing. The jumpers #3 ~ #7 are located on the decoder module above the six (6) dip-switches (refer to Fig.16 below). (Fig.
6. I-Chip Programming Port (Fig. 17) I-CHIP programming port located on the decoder module (refer to Fig. 17 above) inside the receiver is designed for the purpose of transferring system serial number/ID code either from I-CHIP to receiver or from receiver to I-CHIP.
5. System Channels Table Channel Frequency Dip-switch Setting Channel Frequency Dip-switch Setting 01 433.000MHZ 000000 32 433.775MHZ 100000 01 433.000MHZ 000001 33 433.800MHZ 100001 02 433.025MHZ 000010 34 433.825MHZ 100010 03 433.050MHZ 000011 35 433.850MHZ 100011 04 433.075MHZ 000100 36 433.875MHZ 100100 05 433.100MHZ 000101 37 433.900MHZ 100101 06 433.125MHZ 000110 38 433.925MHZ 100110 07 433.150MHZ 000111 39 433.950MHZ 100111 08 433.
6. Receiver Installation A. OUTPUT RELAY CONTACT DIAGRAM * For 3-relay (shared 2nd speed) and 4-relay (separate 2nd speed) configuration please refer to page 22~26. * For 4-relay closed/closed and 4-relay opened/closed relay configuration please refer to page 22~26. * For different voltage settings please refer to page 29. * For F9 and F10 power fuse ratings please refer to page 29.
B. PRE-INSTALLATION PRECAUTIONS 1. Make sure the transmitter and receiver are with identical serial number/ID code and channel. 2. Make sure the receiver is not set to the same channel as any other systems in use in the surrounding area. 3. Make sure that the crane or equipment is working properly prior to installation. 4. Make sure the power source to the receiver is set correctly. 5. Switch off the main power source to the crane or equipment prior to installation. C.
1. For best reception the location of the receiver should be visible to the operator at all time. 2. The location selected should not be exposed to high levels of electric noise. Mounting the receiver next to an unshielded variable frequency drive may cause minor interference. Always locate the receiver as far away from variable frequency drive as possible. 3. Ensure the selected location has adequate space to accommodate the receiver (refer to Fig. 19 on page 32).
7. Operating Procedure A. TRANSMITTER OPERATION 1. General Operating Procedure a. Reset the red emergency stop button located on the top left hand side of the transmitter handset by rotating it either clockwise or counter clockwise, the red button will pop up. b. Turn on the transmitter power by inserting the black-colored key into the power key slot located on the top right hand side of the transmitter handset and rotate it clockwise to “On” position. c.
e. In case of an emergency, press down the red emergency stop button will immediately disconnect the receiver MAIN and as well as the transmitter power. To resume operation, rotate the red button clockwise or counter-clockwise, it will pop up. Then rotate the power key-switch to START position for up to 1.0 second to activate all transmitter push button functions and the receiver MAIN.
4. Pitch & Catch Operating Procedure To release control of the crane, press the “Pitch” push button. To take over control of the crane, rotate the power key switch to “Catch” position for up to 2 seconds. The 2nd operator “can not” take control of the crane unless the 1st operator presses the “Pitch” push button (2.0 seconds). If the operator unintentionally presses the “Pitch” push button during operation, just rotate the power key to “Catch” position for up to 2 seconds to regain control again.
B. STATUS LIGHT INDICATORS & WARNINGS 1. Transmitter STATUS Light Indication Type Display Type Indication Voltage below 1.9V at initial power on, 1 transmitter power and receiver MAIN shuts off. Constant red Voltage below 1.8V during operation, transmitter power and receiver MAIN shuts off. 2 3 1 red blinks followed by a 2-second Voltage below 1.85V during operation, warning, pause change batteries suggested.
2. Receiver STATUS Light Indication Type Display Type (Green & Red) Indication 1 Fast green blinks Decoding in process 2 Slow green blinks Decoding on standby 3 Two red blinks Receiver MAIN jammed or defective 4 Fast red blinks Incorrect transmitter serial number/ID code 5 Constant red Receiver under-voltage, LV output relay activated 6 No light displayed Decoding microprocessor is defective 3.
C. TROUBLE SHOOTING TIPS Problems Possible Reasons Suggestions Transmitter low battery power Check the transmitter battery level. Emergency stop button activated prior to startup No responds when transmitter push button is pressed (Improper startup & Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated. Transmitter push button Initiate the Start command by rotating functions locked the power key-switch to START position.
8. System Specifications Frequency Range : 433.000 ~ 434.525 MHz Number of Channels : 62 channels Channel Spacing : 25 KHz Modulation : Digital Frequency Modulation based on Manchester Code, 20bit address, 32bit CRC Parity Check and Hamming Code.
EU Declaration of Conformity (EMC, R&TTE, SAFETY & MACHINERY) For the following equipment: Product : Flex Series Radio Remote Control System Multiple Listee Model No.
PRODUCT MANUAL SAFETY INFORMATION Advanced Radiotech Corporation (ARC) offers a broad range of radio remote control product for material handling applications. This manual has been prepared by ARC to provide information and recommendations for the installation, use, operation and service of ARC’s material handling products and systems (ARC Products).
