Industrial radio remote control systems FLEX4EX /4ES Instruction Manual
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).
Table of Contents Page 1. 2. 3. 4. 5. 6. 7. Introduction 4 Radio Controlled Safety 5 2.1. CRITICAL INSTALLATION CONSIDERATIONS 6 2.2. GENERAL 6 2.3. PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES 6 2.4. SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED EQUIPMENT OPERATORS 7 2.5. TRANSMITTER UNIT 8 2.6. PRE-OPERATION TEST 8 2.7. BATTERIES 8 General System Information 9 3.1. Transmitter 9 3.1.1. External Illustration 9 3.2. Receiver 10 3.2.1.
1. Introduction The Flex ES/EX 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 all other material handling equipment where wireless control is preferred. Each Flex ES/EX system consists of a transmitter handset and a receiver unit.
2. Radio Controlled Safety 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.
2.1. 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.
2.4. 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.
x operate any damaged or malfunctioning crane, hoist, lifting device or other material handling equipment x change any settings or controls without authorization and proper training x remove or obscure any warning or safety labels or tags x leave any load unattended while lifted x leave power on the radio controlled equipment when the equipment is not in operation x operate any material handling equipment using a damaged controller because the unit may be unsafe x operate manual motions with ot
3. General System Information 3.1. Transmitter 3.1.1. External Illustration 1. 2. 3. 4. 5. 6. STOP Button Power Key Switch Status LED Indicator Pushbutton 1 (PB1) Pushbutton 2 (PB2) Pushbutton 3 (PB3) 7. 8. 9. 10.
3.2. Receiver 3.2.1. External Illustration 1. 2. 3. 4. 5. 6. External Antenna Port (optional) COM LED Indicator Status LED Indicator Power LED Indicator Output Relay LED Indicators Infrared Sensors 7. 8. 9. 10. 11.
4. Function Settings 4.1. Transmitter 4.1.1. Transmitter Firmware Version 1) Rotate the power switch key to OFF ( 0 ) position. 2) With the STOP button elevated, press and hold PB1 and PB3 at the same time. 3) Rotate the power switch key to ON ( I ) position. 4) Let go PB1 and PB3 at the same time. The Status LED displays firmware version with red, green and orange blinks. 5) Exit Firmware Version mode by rotate the power switch key to OFF ( 0 ) position. 4.1.2. Transmitter Channel Settings A.
B. Assigned Channel Scheme (preset system channel) Both transmitter and receiver is assigned with a matching preset channel (channel 01~ ). Pitch & Catch, t-type, and multi-receiver configurations must set to assigned channel scheme. 1) Rotate the power switch key to OFF ( 0 ) position. 2) With the STOP button elevated, press and hold PB1 and PB2 at the same time. 3) Rotate the power switch key to ON ( I ) position. 4) Let go PB1 and PB2 at the same time (entered Channel Setting mode).
4.1.3. Remote Pairing A. Transmitter-to-Transmitter Pairing: 1) Rotate the power switch key to OFF ( 0 ) position. 2) With the STOP button elevated, press and hold PB1 and PB3 at the same time. 3) Rotate the power switch key to ON ( I ) position. 4) Let go PB1 and PB3 at the same time (entered Remote Pairing mode). The Status LED displays firmware version with red, green and orange blinks. 5) Output data (original transmitter) by press and hold PB2 (Status LED off).
Service Information Your New Radio Remote Control System Thank you for your purchase of ARC Flex ES/EX radio remote control system. Without a doubt, our Flex ES/EX system is the ultimate solution for providing precise, undeterred, and safe control of your material.
4.1.4. Transmitter Start Function Settings When transmitter goes into sleep mode the system is temporarily deactivated (MAIN relays opened). Execute the START command or press any pushbutton to wake up the system (MAIN relays closed). Dipswitch Settings Function 1 xxxxxxxxx0 START Reactivation 2 xxxxxxxxx1 Any Button Reactivation 4.1.5. Transmitter Inactivity Timer Settings Set how long the system enters the sleep mode when the transmitter is not in use (pushbutton not pressed).
4.1.6. Infrared Programming Other custom functions and settings not listed in this manual can be programmed via the infrared IR programmer unit, such as the system serial number, frequency range, relay output status feedback, new and updated functions, and many others. Please contact ARC representative for more details. 4.1.7. Pushbutton Function Settings 1) Rotate the power switch key to OFF ( 0 ) position.. 2) With the STOP button elevated, press and hold PB3 and PB4 at the same time.
4.1.7.2. A/B Pushbutton Select with LED Indication – Standard Right/ Left Pushbutton Configuration There are 4 different types of A/B selector sequence available. Choose one that is most suitable for your application. Refer to section 5.1 output relay connections.
4.1.7.3. Toggled Pushbutton with LED Indication – Inline Top/Bottom Pushbutton Configuration Set pushbutton toggled function (latching output relay) with LED indications. LED 1 ~ 4 shown inside the shaded box illustrates which LED on the transmitter lights up when the designated pushbutton is pressed. Refer to section 4.2.4 JP4/JP5 inline jumper settings.
106 1 orange + 6 Reds Normal Normal A/1&2 B/3&4 107 1 orange + 7 Reds Normal Normal A/1&2 C/3&4 108 1 orange + 8 Reds Normal Normal A/1&2 D/3&4 109 1 orange + 9 Reds Normal Normal B/1&2 B/3&4 110 1 orange + 1 Green Normal Normal B/1&2 C/3&4 Normal Normal B/1&2 D/3&4 Normal Normal C/1&2 C/3&4 Normal Normal C/1&2 D/3&4 Normal Normal D/1&2 D/3&4 111 112 113 114 1 orange + 1 Green + 1 Red 1 orange + 1 Green + 2 Reds 1 orange + 1 Green + 3 Reds 1 orange + 1 Green +
of the Function output relays (K25, K26 or K30). This horn output setting requires the infrared IR programmer unit. Please contact ARC representative for more details. 4.2. Receiver 4.2.1. Receiver Channel Settings Set the receiver channel by configuring the channel dipswitch located on the decoder board, only the first 6 dip positions are used for channel programming. The system channels table on section 4.2.8 illustrates which dipswitch setting corresponds to which channel.
4.2.2.2. Output Relay Actions at 2nd Speed (Flex 4EX only) 3 output relays configuration with Closed/Closed contact at 2nd speed 1. F1 (or R1) output relay closed at 1st speed and F1 + F/R2 (or R1 + F/R2) output relays closed at 2nd speed. Refer to section 4.2.3.1 on how to set to this function. Forward 1st speed pushbutton pressed Forward 2nd speed pushbutton pressed F1 2.
5. 4 output relays configuration with Slow and Fast output relays (Type B) Fwd + Slow (or Rev + Slow) output relays closed at 1st speed and Fwd + Slow + Fast (or Rev + Slow + Fast) output relays closed at 2nd speed. Refer to section 4.2.3.1 on how to set to this function. Forward 1st speed pushbutton pressed Fwd Rev ġ Slow ġ Forward 2nd speed pushbutton pressed ġ ġ Fast ġ Fwd ġġ Rev ġġġġġ Slow Fast 4.2.2.3.
4.2.2.8. Momentary Contact When pushbutton is released the corresponding output relay will open or deactivate. This type of relay action usually applies to external applications such as horn and buzzer. Refer to section 4.2.3.2 on how to set to this function. 4.2.2.9. Toggled Contact When pushbutton is released the corresponding output relay will maintained contact or closure until next time the user presses the same pushbutton again.
Example: If the first 6 dipswitch positions are set to channel 01 (000001), when set to 2-channel scanning (type-2 above) the receiver will only scan channel 01 and 02. 4.2.3. Dipswitch Settings 4.2.3.1. Interlocked Pushbutton Pair Interlocked means any pushbutton pair can not be pressed simultaneously as it will cancel each other out. Interlocked setting usually applies to electric motor’s forward & reverse motion and On & Off switches. Each dipswitch on the decoder board corresponds to a pushbutton pair.
4.2.3.2. None-Interlocked Pushbutton Pair Non-interlocked setting allows the pushbutton pair be pressed simultaneously. It usually applies to equipment’s auxiliary functions such as lights, horn or buzzer. Each dipswitch on the decoder board corresponds to a pushbutton pair. Only the first 7 dipswitch positions are used (counting from left to right), the 8th dipswitch position (far right) is not used.
4.2.4. Jumper Settings Jumper setting applies to functions such as the standard or reversed logic A/B selector sequence, cable-free configurations, transmitter inline pushbutton configurations, firmware version, system testing and remote pairing methods. Jumper Settings Function JP3 (Opened) Standard A/B selector sequence - Output relay A activated at A position, output relay B activated at B position, both relays activated at A+B position.
4.2.5. Fuse Ratings FUSE # 110~120VAC 220~240VAC 380~400VAC 410~460VAC 24VAC 42 & 9~36VDC 48VAC F3 ~ F10 5.0A 5.0A 5.0A 5.0A 5.0A 5.0A 5.0A F1 ~ F2 0.5A 0.5A 0.5A 0.5A 1.0A 1.0A 2.0A 4.2.6. Indicator Light and Buzzer Installation The miniature indicator light and buzzer can be easily fitted onto the receiver enclosure. The indicator light or the buzzer works simultaneously with the receiver MAIN relays (manufacture preset).
5. Receiver Installation 5.1. Output Relay Contact Diagrams Flex 4ES (single speed model) Flex 4EX (dual speed model) * For 9~36VDC power supply, wire #1 corresponds to the negative charge (-) and wire #3 corresponds to the positive charge (+), wire #2 is GROUND. * If PB3 (or PB4) is set to A/B pushbutton select function, connect output A to K5 (or K6) and output B to K7 (or K8). Refer to section 4.1.8.2 on how to set to this function.
5.2. Pre-installation Precautions 1. Make sure the transmitter and receiver are with identical serial number 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 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. 5.3.
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 radio interference. Always locate the receiver as far away from variable frequency drive and electric motor as possible. 3. Ensure the selected location has adequate space to accommodate the receiver.
Install! ! Mounting Bracket Type 1 Mounting Bracket Type 2 ! ! ! ! !! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Remove! ! Mounting Bracket Type 1 Mounting Bracket Type 2 ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Flex 4ES/EX Instruction Manual September 2016 Page 31 of 37
6. Operating Procedures 6.1. General Operation a. Reset the STOP button located on the top left hand corner of the transmitter by rotating it clockwise or counter clockwise, the button will pop up. Turn on the transmitter power by inserting the power switch key and rotate to ON ( I ) position. b. After turning on the transmitter power, check the Status LED on the transmitter for any sign of system irregularities (refer to section 6.6.1 Transmitter Status Indications).
f. After 5 or 30 minutes of inactivity (pushbutton not pressed) the receiver MAIN relays are temporarily disconnected (refer to section 4.1.5 Inactivity Timer Settings). The Status LED blinks 3 reds and then shuts off. Press any pushbutton or execute the START command to resume operation (refer to section 4.1.4 Start Function Settings). g.
6.5. Battery Charging The transmitter is designed to accept any off-the-shelf Ni-MH rechargeable batteries. When charging both transmitter and individual batteries at the same time the priority always goes to the transmitter charging. The individual battery charging begins only after the transmitter charging is completed. Depending on the battery capacity the average charging time is approximately 2.5 hours from completely drained to fully charged.
6.6. System Status Light Indications 6.6.1. Transmitter Status Indications Type Display Type Indication 1 Constant red Voltage below 1.8V at initial power on or during operation 2 3 red blinks and then off 3 1 red blink followed by a 2-second pause Voltage below 1.
6.6.2.
7. General Specifications Frequency Range : 433MHz ~ 440MHz Number of Channels : channels Channel Spacing : 50 KHz Modulation : Digital Frequency Modulation based on Manchester Code, 20bit address, 32bit CRC and Hamming Code.
