FLEX U s e r ’s M a n u a l
Table of Contents Page 1. 2. 3. Introduction Radio Controlled Safety General System Information A. 4. B. 7. 2. Internal Illustration Receiver Unit 1. External Illustration 2. Internal Illustration 6 7 Transmitter Handset 1. System Channel Settings 2. Pushbutton Functions with LED Display Settings 8 9~13 Receiver Unit 1. System Channel Settings 2. Output Relay Configurations 3. Dip-switch Settings 4.
1. Introduction The ARC 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 Fig. 01 Fig. 02 1. Emergency Stop Button 8. Push button #12 15. Strap Holder 2. 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. FCC/CE Information 7. Push button #10 14.
2. Internal Illustration Fig. 03 Fig. 04 1. Arial Antenna 5 I-CHIP 2. Transmitting Board 6 Function Dip-Switch 3. Status LED Display 7 Channel Dip-Switch 4.
B. RECEIVER UNIT 1. External Illustration Fig. 05 1. Shock Absorber 6. COM LED Display 2. External Antenna BNC Jack 7. Output Contact Diagram 3. Power LED Display 8. System Information 4. Status LED Display 9. Cable Gland/ Cord Grip 5.
2. Internal Illustration Fig. 06 1. AC Line Filter 4. Decoder Board 2. Power Transformer 5. Relay Board 3.
4. Function Settings A. TRANSMITTER HANDSET 1. System Channel Settings CHANNEL FUNCTION 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Fig. 07 Set the transmitter channel simply by adjusting the channel dip-switch located on the backside of the transmitter encoder board. The system channel table located on page 19 will tell you which dip setting correspond to which channel. Do make sure that when you change the channel of the transmitter you must also change the channel of the receiver as well.
2. Push Button Functions with LED Display Settings A. 1-Stage Toggle Switch with LED Display Below are settings for toggle or latching functions. You can set each and every push button on the transmitter with toggle d (latching) relay contact. The number (1 to 4) below the push button tells you which LED on the transmitter will light up when the push button is pressed. CHANNEL FUNCTION 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Fig.
B.
3-Stage Selector Switch - Continued 43 00101011 A/1&2 A/3&4 44 00101100 A/1&2 B/3&4 45 00101101 A/1&2 C/3&4 46 00101110 A/1&2 D/3&4 47 00101111 B/1&2 B/3&4 48 00110000 B/1&2 C/3&4 49 00110001 B/1&2 D/3&4 50 00110010 C/1&2 C/3&4 51 00110011 C/1&2 D/3&4 52 00110100 D/1&2 D/3&4 53 00110101 A/1&2 54 00110110 B/1&2 55 00110111 C/1&2 56 00111000 D/1&2 57 00111001 A/3&4 58 00111010 B/3&4 59 00111011 C/3&4 60 00111100 D/3&4 61 00111101 A/1&2 A/3&4 62 0011111
3-Stage Selector Switch - Continued 78 01001110 D/3&4 79 01001111 A/1&2 A/3&4 80 01010000 A/1&2 B/3&4 81 01010001 A/1&2 C/3&4 82 01010010 A/1&2 D/3&4 83 01010011 B/1&2 B/3&4 84 01010100 B/1&2 C/3&4 85 01010101 B/1&2 D/3&4 86 01010110 C/1&2 C/3&4 87 01010111 C/1&2 D/3&4 88 01011000 D/1&2 D/3&4 C.
1-Stage Toggle + 3-Stage Selector Switch Combination - Continued 107 01101011 1 C/3&4 108 01101100 1 D/3&4 109 01101101 1 2 A/3&4 110 01101110 1 2 B/3&4 111 01101111 1 2 C/3&4 112 01110000 1 2 D/3&4 113 01110001 1 A/3&4 114 01110010 1 B/3&4 115 01110011 1 C/3&4 116 01110100 1 D/3&4 117 01110101 1 2 A/3&4 118 01110110 1 2 B/3&4 119 01110111 1 2 C/3&4 120 01111000 1 2 D/3&4 B. RECEIVER UNIT 1. System Channel Setting 1 2 3 4 5 6 7 8 Fig.
2. Output Relay Configurations 1. 3 Relays per Motion – Shared 2nd Speed Rely For connections with output relay configuration as Forward 1st speed (F1), Reverse 1st speed (R1) and Forward/Reverse 2nd speed (F/R2). Forward and Reverse 2nd speed (F/R2) shared the same output. 2. 4 Relays per Motion (Type A) – Separate 1st and 2nd Speed Relay For connections with output relay configuration as Forward 1st speed (F1), Reverse 1st speed (R1), Forward 2nd speed (F2) and Reverse 2nd speed (R2).
10. Magnet ON/OFF Function The user can set the two adjacent push buttons to control a magnet. To activate the magnet just press the button with the Magnet symbol. To deactivate the magnet, for safety purpose, you must press and hold the button with the Magnet symbol and press the OFF button. Pressing the OFF button alone can and will not deactivate the magnet. 11.
3. Dip-Switch Settings There are six dip-switches located on the decoder board, which is one dip-switch per motion or push button pair (1 dip-switch per left and right push button). Fig.
Dip-Switch Settings - Continued Dip Settings Relay Function for the Relay Function for the # of Relays Left Push Button Right Push Button Used 1000000 Momentary Contact Momentary Contact 2 1001000 Toggled Contact Momentary Contact 2 1000001 Momentary Contact Toggled Contact 2 1001001 Toggled Contact Toggled Contact 2 1000010 Momentary Contact 3rd Speed 2 1001010 Toggled 3rd Speed 2 1010000 3rd Speed Momentary Contact 2 1010001 3rd Speed Toggle Contact 2 1000111 Momentary C
4. Jumper Settings Jumper settings are applied to functions such as MAIN cutoff time, system startup and transmitter push button layout. The jumpers are located on top of the dip-switches. Fig. 11 Jumper Settings Function JP1 (Blank) JP2 (Blank) Receiver MAIN never deactivates unless transmitter power is turned off or emergency stop command is initiated JP1 (Inserted) JP2 (Blank) Receiver MAIN deactivates automatically after 5 minutes of inactivity.
5.
6. Receiver Installation A. OUTPUT RELAY CONTACT DIAGRAM Fig.
B. RECEIVER MOUNTING 1. Pre-installation Precautions 1. Make sure that the transmitter and receiver are with identical serial number, channel and ID code. 2. Make sure the receiver is not set to the same channel as any other systems in use in the surrounding area. 3. Prior to installation, 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.
2. Step-By-Step Installation 1. For better 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. 4.
7. Operation Procedure A. TRANSMITTER OPERATION a. Reset the 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 onto the power key slot located on the top right hand side of the transmitter handset and rotate it clockwise to “On” position. c.
B. STATUS LIGHT INDICATORS & WARNINGS 1. Transmitter STATUS Light Indication Type Display Type Indication Voltage below 2.3V at initial power on, 1 transmitter shuts off, change batteries Constant red Voltage below 1.8V during operation, transmitter shuts off, change batteries Blinking red 2 Voltage below 2.2V during operation, warning, “on” → 0.15 second change batteries suggested “off” → 1.85 seconds 3 4 5 6 7 2 red blinks followed by a The pushbutton 1.
2. Receiver STATUS Light Indication Type Display Type Indication 1 Blinking red 2 Blinking green (fast) Decoding in process 3 Blinking green (slow) Decoding on standby Stop command initiated with MAIN disconnected 3. Receiver SQ Light Indication Type Display Type (Red) Indication 1 On Transmission received 2 Off No transmission 3 Blinks intermittently (fast) Other radio interference 4.
C. TROUBLE SHOOTING TIPS Problems Possible Causes Recommendation Transmitter low battery power Check the transmitter battery level Emergency stop button activated prior to startup Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated. Redo the startup procedure by holding No responds when transmitter push button is pressed Improper startup procedure the power key at “START ” position for up to 1.
8. System Specifications Frequency Range : 433~434 MHz Number of Channels : 62 channels adjustable Channel Spacing : 25 KHz Modulation : Digital Frequency Modulation based on Manchester Code, 20bit address, 32bit CRC Parity Check and Hamming Code. Decoder : Microprocessor-controlled Hamming Distance : 4 Frequency Control : Synthesized PLL (Phase Lock Loop) Receiver Sensitivity : -112dBm Spurious Emission : -50dB Antenna Impedance : 50 ohms Transmitting Power : 0.
9. Spare Parts 1. Transmitting Board (433/434MHz) TRB 01 2. Encoder Board (complete with push buttons) ENB 06 3. I-CHIP (complete) ICP 01 4. Receiver Board RVB 01 5. Decoder Board DEB 01 6. Receiver Relay Board RLB 06 7. AC Line Filter Board LFB 01 8. Power Transformer PTF 01 9. Transmitter Top Casing TTC 03 10. Transmitter Bottom Casing TBC 03 11. TBC 04 Transmitter Battery Cover 12. Receiver Top Casing RTC 01 13. Receiver Bottom Casing RBC 01 14.
