Industrial radio remote control systems FLEX8EX Instruction Manual
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.
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. 7. 8. STOP Button Power Key Switch Status LED Indicator Pushbutton 1 (PB1) Pushbutton 2 (PB2) Pushbutton 3 (PB3) Pushbutton 4 (PB4) Pushbutton 5 (PB5) 9. 10. 11. 12. 13. 14. 15.
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).
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, TAC, 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.
Function Number Display Type PB5 PB6 PB7 PB8 5 5 Reds Normal Normal Normal LED 4 6 6 Reds Normal Normal LED 3 LED 4 7 7 Reds Normal LED 2 LED 3 LED 4 8 8 Reds LED 1 LED 2 LED 3 LED 4 * PB1…PB8 Pushbutton number. * Normal Normal momentary contact. * LED 1 ~ LED 4 Pushbutton toggled function with designated LED indication. 4.1.7.2.
* A/1&2 ~ D/3&4 A/B pushbutton select function with designated LED indication. 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.
4.1.7.4. A/B Pushbutton Select with LED Indication – Inline Top/Bottom 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 4.2.4 JP4/JP5 inline jumper settings and section 5.1 output relay connections.
4.1.8. Transmitter Access Card (TAC) Settings Follow the instruction below on how to program the TAC into the transmitter. The infrared IR programmer unit is required to complete the programming. Please contact ARC representative for more details. 1) Rotate the power switch key to OFF ( 0 ) position. 2) With the STOP button elevated, press and hold PB1, PB2, PB3 and PB4 at the same time. 3) Rotate the power switch key to ON ( I ) position.
4.1.9. Display Frequency Band 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 PB2 and PB4 at the same time (entered Frequency Band Display mode). 5) The Status LED displays the preset transmitter frequency band with orange, green and red blinks.
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. Once the receiver channel is altered do make sure to change the transmitter channel as well.
4.2.2.2. Output Relay Actions at 2nd Speed (Flex 8EX 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.
* Channel X channel set on the Channel dipswitch. ** Please contact ARC representative if your application requires scanning more than 4 channels. 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.
01100010 4 output relays Closed/Closed relay action + Brake + External warning* 4 01100100 3 output relays Closed/Closed relay action + Brake + External warning* 3 01100110 4 output relays Opened/Closed relay action + Brake + External warning* 4 * External warning function requires installing an external warning device such as horn and lights to the K26 Function output relay. 4.2.3.2. None-Interlocked Pushbutton Pair Non-interlocked setting allows the pushbutton pair be pressed simultaneously.
Pitch & Catch (type B) 1 F 101 Receiver MAIN relays maintained closure during switchovers 1 G 111 2 steps with Closed/Closed relay action Example #1: Left button (set to function code A) / right button (set to function code B) 1 000 001 Example #2: Left button (set to function code C) / right button (set to function code D) 1 011 100 4.2.4.
4.2.5. Voltage Settings Prior to installation always check the voltage setting is correct for your application. Position 1 110~120VAC Position 2 220~240VAC or 48VAC* or 24VAC** Position 3 380~400VAC or 110~120VAC* or 42VAC** Position 4 410~460VAC or 220~240VAC* or 48VAC** or 9~36VDC*** * For system equipped with 48/110~120/220~240VAC power supply. ** For system equipped with 24/42/48VAC power supply. *** For system equipped with 9~36VDC power supply.
5. Receiver Installation 5.1. Output Relay Contact Diagrams Flex 8ES (single speed model) Flex 8EX (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 PB7 (or PB8) is set to A/B pushbutton select or A/B rotary switch select function (AB models), connect output A to K13 relay (or K14) and output B to K15 relay (or K16). 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 8ES/EX Standard, AB and Tandem Instruction Manual September 2016 Page 33 of 42
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 6.10.1 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.
Master Transmitter-B Takeover Procedure Press PITCH Rotate to A position Rotate to START (After 2 seconds) Transmitter-A b. Transmitter-B Transmitter-B Once the transmitter is locked on to both receivers, rotate the selector switch to either A, B, or A+B position for independent or simultaneous operation. c. At beginning of each shift prior to turning on the transmitter power, always check if the selector switch is correctly positioned for the intended receiver or receivers. d.
Master Transmitter Takeover Procedure Press PITCH Rotate to B position Rotate to START (After 2 seconds) Slave transmitter Master transmitter Master transmitter Slave Transmitter Takeover Procedure Rotate to B position Press PITCH Rotate to START (After 2 seconds) Master transmitter b. Master transmitter Slave transmitter Once the transmitter is locked on to both receivers, rotate the selector switch to either A, B, or A+B position for independent or simultaneous operation. c.
6.4. A/B Pushbutton Select Operation Press the “A/B” pushbutton repeatedly toggles between output relay A, B and A+B respectively. There are 4 different types of Select A/B sequence available (refer to section 4.1.8.2). Standard – Output relay A activated at A position, output relay B activated at B position, both output relays activated at A+B position. Reversed logic - Output relay A activated at B position, output relay B activated at A position, both output relays deactivated at A+B position.
6.8. Changing Batteries Changing transmitter batteries (“AA” alkaline battery x 2) by unscrewing the battery cover located on the backside of the transmitter. During battery installation make sure the batteries are installed correctly, with “+” to “+” charge and “–” to “–” charge. Also make sure the screw is tightened after battery installation to avoid water, moisture, dirt, grease, and other liquid penetration. 6.9.
6.10. System Status Light Indications 6.10.1 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.
3 slow red blinks 11 6.10.1.
1 On Power to relay Board 2 Off No power to relay board Flex 8ES/EX Standard, AB and Tandem Instruction Manual September 2016 Page 42 of 42
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.
