FLEX4EX - Advanced Radiotech Corporation
Contents
1. M oC otm o CY o LM BB 7 Hc Fig 03 Fig 04 1 Encoder Board 6 LCHIP 2 Arial Antenna 7 Function Dip Switch 3 Transmitting Module 8 Channel Dip Switch 4 Status LED Display 9 Battery Contact Mechanism 5 Function LED Displays 1 External Illustration pl 2 8g d Fig 05 1 External Antenna Jack optional 5 COM LED Display 2 Power LED Display 6 Shock Mounts 3 Status LED Display 7 Output Contact Diagram 4 SQ LED Display 8 Cord Grip 2 Internal Illustration c Fig 06 1 Receiving Module top 2 Decoder Relay Board middle 3 Line Filter Board bottom 4 Power Transformer 4 Function Settings A TRANSMITTER HANDSET 1 System Channel Settings x T CHANNEL Fig 072. B Selector Push Button Settings 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 Type A selector sequence A B Ao B8 Type B selector sequence Off A B Off AB Type C selector sequence A B gt Type D selector sequence Off A B A B Off A B A B DIP PB1 PB2 PB3 PB4 6 00011101 Normal Normal A 1 amp 2 Normal 7 00011110 Normal Normal B 1 amp 2 Normal 8 00011111 Normal Normal C 1 amp 2 Normal 9 00100000 Normal Normal D 1 amp 2 Normal 10 00100001 Normal Normal Normal A 3 amp 4 11 00100010 Normal Normal Normal B 3 amp 4 12 00100011 Normal Normal Normal C 3 amp 4 13 00100100 Normal Normal Normal D 3 amp 4 14 00100101 Normal Normal A 1 amp 2 A 3 amp 4 15 00100110 Normal Normal A 1 amp 2 B 3 amp 4 16 00100111 Normal Normal A 1 amp 2 C 3 amp 4 17 00101000 Normal Normal A 1 amp 2 D 3 amp 4 18 00101001 Normal Normal B 1 amp 2 B 3 amp 4 19 00101010 Normal Normal B 1 amp 2 C 3 amp 4 20 00101011 Normal Normal B 1 amp 2 D 3 amp 4 21 00101100 Normal Normal C 1 amp 2 C 3 amp 4 22 00101101 Normal Normal C 1 amp 2 D 3 amp 4 23 00101110 Normal Normal D 1 amp 2 D 3 amp 4 PB1 PB4 Push button number Normal Normal momentary contact A 1 amp 2 D 3 amp 4 Selector type with designated LED Display LED
3. Set transmitter channel by adjusting the channel dip switch located the backside of 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 24 illustrates which dip switch setting corresponds to which channel Once the transmitter channel is altered do make sure to change receiver channel as well The channel on both transmitter and receiver must be identical in order for system to work To change receiver channel please refer to page 15 Example Top slot 1 Fig 08 Bottom slot 0 The above dip switch setting 1 0 0 1 0 0 corresponds to channel 36 in the system channels table on page 24 2 Continuous Transmitting Time Adjustment After the push button is released the transmitter will continue to Type 1 transmit neutral signals to the receiver for up to one 1 minute After one 1 minute the transmitter will cease transmission thus temporarily disconnecting the receiver MAIN After the push button is released the transmitter will continue to transmit neutral signals to the receiver for up to three 3 minutes Type 2 After three 3 minutes the transmitter will cease transmission thus temporarily disconnecting the receiver MAIN Please contact your local dealer if your application
4. External warning function requires installing an external warning device such as horn and rotating lights to the function relay output Page 20 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 3 speed and auxiliary stop Each dip switch on the decoder module corresponds to one 1 motion or two 2 adjacent push buttons left amp right push buttons Dip Dip Position Setting Function Position 2 4 left button J Function Description Code Setting amp 1 5 7 right button A 1 000 Normal momentary contact B 1 001 Toggled latching contact 1 010 Acceleration 3 speed Normal Start function For added safety you must first rotate and hold the power key D 1 100 switch at START position and then press the intended push button at the same time to activate the output relay E 1 111 Auxiliary Stop Example 1 Left button set to function code A right button set to function code 1 000 000 Example 2 Left button set to function code B right button set to function code 1 001 001 Example 3 Left button set to function code A right button set to function code 1
5. 6 I Chip Programming Port Fig 17 I CHIP programming port located 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 If you wish to transfer system information from receiver to I CHIP just insert the I CHIP onto the programming port JP6 jumper not inserted wait until the Status LED on the decoder module turned constant green within 2 seconds and then take the I CHIP out of the programming port programming completed At this time the I CHIP should also possess the same serial number ID code as the receiver If the Status LED on the decoder module displayed a constant red light after inserting the I CHIP programming failed then you must reinsert the I CHIP one more time On the other hand if you wish to transfer system information from I CHIP to receiver then you must first insert JP6 jumper prior to inserting the I CHIP then wait for the green light to appear on the Status LED At this time the receiver should also possess the same system information as the I CHIP Please note that the receiver unit mu
6. 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 30 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 The system channels table located on page 24 illustrates which dip switch setting corresponds to which channel Once the receiver channel is altered do make sure to change transmitter channel as well The channel on both transmitter and receiver must be identical in order for system to work To change transmitter channel please refer to page 9 HAHAHA AE Example Top slot 1 Bottom slot 0 arro m ario 4 m LI o m rr Fig 13 The above dip switch setting 1 0 0 1 0 0 corresponds to channel 36 in the system channels table on page 24 2 Output Relay Configurations a Output Relay Types 1 Three 3 output relays per motion shared 9M speed output relay Output relays with Forward 1 speed F1 Reverse 1 speed and Forward Reverse 2 speed F R2 Forward and Reverse 2 speed F R2 shared the same output relay F R2
7. Q O 2 Four 4 output relays per motion separate 1 and 2M speed output relays Output relays with Forward 1 speed F1 Reverse 1 speed Forward 2 speed F2 and Reverse 2 speed R2 Forward and Reverse 274 speed with separate output relays Fl RI F2 R2 b Output Relay Actions at 2 Speed 1 3 output relays configuration with Closed Closed contact at 2 speed At 2 speed both 1 speed F1 or R1 and 2 speed F R2 output relays are closed refer to page 20 on how to set to this function Forward 1 speed push button pressed Forward 274 speed push button pressed 2 4 output relays configuration with Opened Closed contact at 2 speed At 2 speed only the 2 speed F2 or R2 output relay is closed refer to page 20 on how to set to this function Forward 15 speed push button pressed Forward 2 speed push button pressed R2 F2 R2 3 4 output relays configuration with Closed Closed contact at 2 speed At 2 speed both 1 speed F1 or R1 and 2 speed F2 or R2 output relays are closed refer to page 20 on how to set t
8. PTF 07 PTF 08 PTF 09 PTF 10 PTF 11 PTF 12 TTC 01 TBC 01 TBC 04 RTC 05 RBC 05 RMP 05 CGR 03 SMT 02 PBN 02 SWT 01 PRB 01 EMS 01 PWK 01 WBT 01 STR 01 SMR 01 RLY 02 CVP 01 Product Multiple Listee Model No Manufacturer s Name Manufacturer s Address We herby declare that all the EEC Commission EMC R amp TTE SAFETY MACHINERY Test reports issued by EMC R amp TTE SAFETY MACHINERY Tom Jou President C EU Declaration of Conformity EMC R amp TTE SAFETY amp MACHINERY For the following equipment Flex Series Radio Remote Control System Flex 4ES EX Flex 8ES EX Flex 12ES EX Advanced Radiotech Corporation 1 288 1 Hsin Ya Road Chien Chen District Kaohsiung City Taiwan major safety requirements concerning the CE Mark Directive 2006 42 EC and Low Voltage Directive 2006 95 EC Electromagnetic Compatibility Directives 2004 108 EC R amp TTE Directive 1999 5 EC are fulfilled as laid out in the guideline set down by the member states of The standards relevant for the evaluation of the electrical safety requirements are as follow N 301 489 1 EN 301 489 3 N 300 220 1 V2 3 1 EN 300 220 2 V2 3 1 N 60950 2006 1 11 12 N 60204 32 2008 EN 13557 2003 A1 2008 N ISO 13849 1 2008 PL d EN 60529 IP66 mit 09 m 0 SGS SGS SGS SGS Person responsible for marking this declaration
9. 000 010 Example 4 Left button set to function code E right button set to function code A 1111000 When set to Auxiliary Stop do make sure that JP3 is inserted refer to jumper settings next page Jumper Settings Fig 16 Manufacture preset Jumper settings are applied to functions such as Start command system information serial number ID code programming and system testing The jumpers 3 7 are located on the decoder relay board between the receiving RF module and the output relays refer to Fig 16 below oo oo ao oo o Jumper Settings Function JP3 After 1 or 3 minutes of transmitter inactivity MAIN deactivated press Blank any push button on the transmitter to reactivate the receiver MAIN JP3 After 1 or 3 minutes of transmitter inactivity MAIN deactivated rotate the transmitter power key switch to START position to reactivate the Inserted f receiver MAIN JP6 Program system serial number ID code and channel from decoder module Blank to I CHIP JP6 Program system serial number ID code and channel from I CHIP Inserted to decoder module n For system test only receiver MAIN disabled Inserted y
10. A eec OO Pd e ESSO a ss Name and signature of authorized person
11. The user can install an external warning device rotating lights horn etc to a special Function output relay located inside the receiver The user can choose which push button pairs or crane motions he desired to have external warnings when push button is pressed refer to page 20 on how to set to this function g Momentary Contact When push button is released the output relay corresponds to that push button will open refer to page 21 on how to set to this function This type of contact is usually applies to external application such as horns or buzzers h Toggled Contact When push button is released the output relay corresponds to that push button will remained closed maintained contact until next time the user presses the same push button again refer to page 21 on how to set to this function This type of contact is usually applies to external application such as lights i 3 Speed Push Button Function This function allows the crane to travel an additional step beyond 2 speed For example if the operator is pressing the UP push button down to 274 speed pressing the 3 speed push button with UP push button still hold at 2 speed will toggle between 2 speed and 3 speed refer to page 21 on how to set to this function j Auxiliary STOP Push Button Function must be inserted The auxiliary STOP function acts as a 2 emergency stop button Other than by
12. and skill in equipment operation and safety Persons being trained to operate a radio remote controlled equipment should possess the knowledge of all hazards peculiar to radio remote controlled equipment operation ability to judge distance and moving objects equipment capacity and radio remote controlled safety rules Radio remote controlled equipment should not be operated by any person with insufficient eyesight hearing illness and under influence of drugs and medications that may cause loss of equipment control Below are some general operating safety tips that should be strictly followed when operating radio remote controlled equipment 1 Prior to operation always check the transmitter handset for any damage that might inhibit proper operation 2 Always check if the red emergency stop button is working properly prior to operation 3 Check the Status LED on the transmitter for any signs of low battery power refer to page 31 4 Check the Status LED on the transmitter for any signs of irregularities refer to page 31 5 The equipment s limit switches if any should be checked prior to operation or at the beginning of each shift 6 Ifthe power to the equipment is removed the operator should turn off the transmitter power immediately until the power to the equipment is restored 7 equipment fails to respond properly to operator s command the operator should stop operation turn the transmitter power off and then repor
13. button functions and as well as the receiver MAIN Then press any push button on the transmitter to begin operation Pressing any push button prior to initiating the START command will result in no signal transmitted blinking orange light In case of an emergency press down 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 Please note that every time when you turn the transmitter power off and back on again or after resetting the emergency stop button all push button functions will be locked to avoid any unintentional controls For safety initiating the START command after turning on the transmitter power or after resetting the emergency stop button is strictly required After 1 minute of inactivity push button not pressed the receiver MAIN will be disconnected temporarily To resume operation just press any push button on the transmitter depending on JP3 setting on page 22 If this 1 minute inactivity time is not sufficient for your application you can also extend this inactivity time from minute up to 3 minutes refer to Continuous Transmitting Time Adjustment on page 9 The receiver MAIN will also be disconnec
14. emergency stop button and transmitter power key switch the receiver MAIN 15 also deactivated when this auxiliary stop push button 15 pressed refer to page 21 on how to set to this function 3 Receiver Auto Scanning Settings Receiver Channel Dip switch FAB EAE EA 1 Scans all 62 channels manufacture preset Go For standard operation RRRRRRRR 2 Single fixed channel HEHEHE Auto scanning function disabled HALE EAB AA 3 Scanning 2 channels only 78 ERRRRRRR 4 Scanning 3 channels only 78 fthe first 6 dip switch positions on the receiving module is set to Ch 01 000000 or 000001 when set to 2 channel scanning type 3 above then the receiver will only scan Ch 01 and Ch 02 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 forward and reverse motions Each dip switch on the decoder module corresponds to one 1 motion or two 2 adjacent push bu
15. 1 amp 2 or LED 3 amp 4 4 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 green blink represents the tens 10 and a red blink represents the units 1 Examples 2 green blinks followed by 5 red blinks represents channel 25 6 red blinks represents channel 06 b Select new channel by pressing PB1 and PB2 on the transmitter Press 1 to increment the units 1 and PB2 to increment the tens 10 oy 1 Examples Press PB2 two times and then 1 four times will give you channel 24 Press PB1 nine times with give you channel 09 c When finished the newly selected channel will appear on the Status LED via series of green and red blinks again d Exitthe channel programming by turning off the transmitter power e Make sure the receiver channel is set identical to the transmitter Please refer to page 15 and page 30 on how to change receiver channel f Please note that when the CHANNEL dip switch inside the transmitter 1s changed the priority will re
16. EL Z gt lt User s Manual ARC ADVANCED RADIOTECH CORPORATION CE Version Table of Contents Introduction Radio Controlled Safety General System Information A Transmitter Handset External Illustration 2 Internal Illustration B Receiver Unit External Illustration 2 Internal Illustration Function Settings A Transmitter Handset 1 System Channel Settings 2 Continuous Transmitting Time Adjustment 3 Push Button Functions with LED Displays a Transmitter Toggle Push Button Settings b Selector Push Button Settings 4 Channel Change via Push Buttons 5 Program 4 digit Security Code 6 LChip B Receiver Unit 1 System Channel Settings 2 Output Relay Configurations a Output Relay Types b Output Relay Action at 2 Speed c ON OFF Push Button Function d Magnet ON OFF Push Button Function e Brake Function f External Warning Function g Momentary Contact h Toggled Contact Page 10 1 3 Speed Push Button Function 1 Auxiliary STOP Push Button Function 3 Receiver Auto Scanning Settings 4 Dip switch Settings a Interlocked Functions b Non interlocked Functions 5 Jumpers Settings 6 I Chip Programming Port 7 Fuse Ratings System Channels Table Receiver Installation A Output Relay Contact Diagram B Pre Installation Precautions C Step By Step Installation D System Testing Operating Procedure A C Transmitter O
17. Z 010101 53 434 300MHZ 110101 22 433 525MHZ 010110 54 434 325MHZ 110110 23 433 550MHZ 010111 55 434 350MHZ 110111 24 433 575MHZ 011000 56 434 375MHZ 111000 25 433 600MHZ 011001 57 434 400MHZ 111001 26 433 625MHZ 011010 58 434 425MHZ 111010 27 433 650MHZ 011011 59 434 450MHZ 111011 28 433 675MHZ 011100 60 434 475MHZ 111100 29 433 700MHZ 011101 61 434 500MHZ 111101 30 433 725MHZ 011110 62 434 525 2 111110 31 433 750MHZ 011111 6 Receiver Installation A OUTPUT RELAY CONTACT DIAGRAM Push button 1 2 Push button 3 4 F1 5A F3 5A COM1 COM 3 e MAIN Function F7 5A COM 7 O O K26 FUNC O K27A NC Power MAIN Transformer K27B NO K27A NO MAIN 8 O O 3 relay shared 274 speed and 4 relay separate 214 speed configuration please refer to page 16 20 For 4 relay closed closed and 4 relay opened closed relay configuration please refer to page 16 20 For9 36VDC power supply wire 1 corresponds to the negative charge and wire 3 corresponds to the positive charge wire 2 is for GROUND Wire 6 is for Normal Close single main output and wire 8 is for Normal Open dual main outputs 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 sam
18. e channel as any other systems in use in the surrounding area 3 Make sure that the crane or equipment 1s 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 STEP BY STEP INSTALLATION 150mm 82mm x Va W E E 9 9 H L 1 LZ Sd 2 f a Fig 18 D SYSTEM TESTING For best reception the location of the receiver should be visible to the operator at all time 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 Ensure the selected location has adequate space to accommodate the receiver refer to Fig 18 on page 26 For better reception make sure the receiver is in an upright position Drill two holes 8mm in diameter on the control panel or location where the receiver is to be installed see diagram below Make sure the two bolts are tightened after installation For system wiring please refer to page 25 170mm 6 69 ur 1 Turn on the power source to the
19. g and receiving module Check the SQ display on the face of the receiver unit If it does not light up when push button is pressed then either the transmitting or receiving module is defective First replace the transmitting module If SQ display still not lid when push button is pressed then go ahead and replace the receiving module Defective encoder board or decoder module If still no responds then replace the transmitter encoder board If still doesn t work then the decoder module is defective No AC power to the receiver Incorrect input voltage Make sure the source voltage is set correctly Blown fuse Check for any blown fuse Incorrect wiring Check input voltage connection Outputs do not correspond to transmitter Incorrect output connection Check the system wiring again Please refer to the output contact diagram inside this manual or on the receiver cover 8 System Specifications Frequency Range Number of Channels Channel Spacing Modulation Encoder amp Decoder Transmitting Range Hamming Distance Frequency Control Receiver Type Receiver Sensitivity Spurious Emission Antenna Impedance Responding Time Transmitting Power Enclosure Type Enclosure Rating Output Contact Rating Transmitter Operating Voltage Receiver Power Consumption Operating Temperature Transmitter Dimension Receiver Dimens
20. ion Transmitter Weight Receiver Weight 433 434 MHz 62 channels 25 KHz Digital Frequency Modulation based on Manchester Code 20bit address 32bit CRC Parity Check and Hamming Code Microprocessor controlled gt 100 Meters 300 Feet gt 6 Synthesized PLL Phase Lock Loop Frequency Auto Scanning 116dBm 50dB 50 ohms 40 Milliseconds average 1 0mW NEMA 4 IP 66 250V 8 Amps DC 3 0V 2 5 8 0 VA 25 C 75 C 13 F 167 138mm L x 69mm W x 34mm H 180mm L x 150mm W x 82mm H 192g 6 80z 2 1kg 4 6lb include output cable Z9 A ee 19 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 9 Spare Parts Transmitting Module 433 434MHz Encoder Board complete with push buttons I CHIP complete Receiving Module Decoder Relay Board AC Line Filter Board Power Transformer DC 9 36V AC 24V AC 42V AC 48V AC 110 120V AC 220 240V AC 380 400V AC 410 460V Transmitter Top Casing Transmitter Bottom Casing Transmitter Battery Cover Receiver Top Casing Receiver Bottom Casing Receiver Mounting Plate Cord Grip Shock Mount 2 Step Push Button 3 Stage Mechanical Selector Switch Push Button Rubber Boot Emergency Stop Button Transmitter Power Keys Switch Waist Belt Strap Ring Safety MAIN relay Regular Output Relay Clear Vinyl Pouch TRB 01 ENB 04 ICP 01 RVB 01 DRB 13 LFB 07 PTF 14 PTF 06
21. l 62 and lock onto the newly selected transmitter channel automatically Please note that in order for the receiver to switch to auto scanning mode prior to changing the transmitter channel you must first deactivate the receiver MAIN by shutting off the transmitter power or press down the emergency stop button Please refer to page 19 if you do not want the receiver to auto scan all 62 channels Change Transmitter Channel Changing Transmitter Batteries Changing transmitter batteries by unscrewing the battery cover located on the backside of the transmitter refer to Fig 19 below During battery installations make sure that the blue ribbon is centered between the two batteries After changing the batteries also make sure that all screws are tightened to avoid water moisture dirt grease or other liquid penetration S 2 AS S B STATUS LIGHT INDICATORS amp WARNINGS 1 Transmitter STATUS Light Indication Type Display Type Indication Voltage below 1 9V at initial power on transmitter power and receiver MAIN shuts off 1 Constant red Voltage below 1 8 during operation transmitter power and receiver MAIN shuts off 2 1 red blinks followed by a 2 second Voltage below 1 85V during operation warning pause change batteries suggested 3 2 red blinks followed by a 2 second The pushbutton is defective after tur
22. ning on the pause transmitter power When defective push button condition occurs 2 red blinks type 3 above find out which push button is defective by pressing all the push buttons on the transmitter one at a time If the 4 No light displayed push button is in good working order the LED will not light up when pressed If the push button is defective the LED will continue to display 2 red blinks when pressed 3 red blinks followed by a 2 second 5 EEPROM error pause 6 4 red blinks followed by a 2 second Transmitting error system can not locked on pause to the designated channel 7 Constant green for up to 2 seconds Transmitter power on with no faults detected 8 Blinking green Transmission in progress 9 Blinking orange Transmitter push button functions locked 2 Receiver STATUS Light Indication Type Display Type Green amp 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 Receiver SQ Light Indication Type Display Type Red Indication yp p 1 Fast blinks Transmission received 2 Completely off No transmissi
23. nsmitter handset just take the I CHIP out of the old transmitter and install it into the new one refer to Fig 11 below The new transmitter handset will then operate according to the information stored in the I CHIP unless the settings on both Channel and Function dip switch are changed thereafter Basically the microprocessor will operate according to the last setting change either on I CHIP or the dip switches For safety purposes system serial number ID code stored inside the I CHIP can not be changed directly on the transmitter encoder board Only channels and push button configurations can be changed directly on the encoder board via Channel and Function dip switches There are only two ways that you can change transmitter serial number ID code 1 via I CHIP programming port located on the decoder module inside the receiver unit please refer to page 23 on how to program the I CHIP serial number ID code via receiver unit 2 via an external I CHIP programmer or duplicator unit available from the factory Please ask your local dealers for assistance if your system requires serial number ID code adjustments gt r1 f q F gt Fig 11 B RECEIVER UNIT 1 System Channel Settings ETT Bi ES HBHBHBHB
24. o this function Forward 2 speed push button pressed Forward 1 speed push button pressed F1 RI F2 R2 1 8 c ON OFF Push Button Function The user can set any of the two adjacent push buttons on the transmitter to behave like a mechanical ON amp OFF rocker switch refer to page 20 on how to set to this function When output relay is closed On push button pressed the Off output relay will open automatically or vise versa 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 20 on how to set to this function e Brake Function When the transmitter push button is released from 274 speed up to 1 speed both 1 and 2 speed output relays will open for up to 1 0 second and then with 1 speed output relay closed thereafter refer to page 20 on how to set to this function f External Warning Function
25. on 3 Blinks intermittently Other radio interference 4 Receiver POWER Light Indication Type Display Type Red Indication 1 On Power to receiver 2 Off No power to receiver 5 Receiver COM Light Indication Type Display Type Red Indication 1 On Power to relay Board 2 Off No power to relay board C TROUBLE SHOOTING TIPS Problems Possible Reasons Suggestions No responds when transmitter push button is pressed Improper startup amp settings 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 Transmitter push button functions locked Incorrect system RF channel Initiate the Start command by rotating the power key switch to START position Check and make sure that the transmitter handset and receiver unit both have the same channel Incorrect system serial number ID code Check and make sure that the transmitter handset and receiver unit both have the same serial number ID code System out of range Make sure that the operating distance is within the control range No responds when transmitter push button is pressed Damaged hardware Defective transmittin
26. peration 1 2 3 4 5 General Operating Procedure A B Selector Push Button Operating Procedure 34 Speed Push Button Operating Procedure Automatic Channel Scanning Operating Procedure Changing Transmitter Batteries Status Light Indicators amp Warnings 1 2 3 4 5 Transmitter STATUS Light Indication Receiver STATUS Light Indication Receiver SQ Light Indication Receiver POWER Light Indication Receiver COM Light Indication Trouble Shooting Tips System Specifications Spare Parts EU Declaration of Conformity 20 21 22 23 23 24 25 26 26 27 27 28 29 29 29 30 30 31 32 32 32 32 33 34 35 36 1 Introduction The FLEX radio remote control systems 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 Other standard equipped accessories include transmitter waist belt spare transmitter power key clear vinyl pouch AA alkaline batteries compass direction decal sheet and user s manual List of notable features include 62user programmable channels Advanced synthesized RF controls with 62 built in channels no more fixed channel and fragile quartz c
27. r PB4 on the transmitter four presses randomly At this time a fast orange blinks is displayed on the Status LED telling you to reconfirm the 4 digit security code you have just entered A green light will appear once you have re entered the same 4 digit security code again programming completed If red light is shown on the Status LED after you have re entered the security code incorrect input then you must reset the transmitter power and then repeat step a b and c again Steps Press and hold PB1 PB4 and rotate power key to START position constant orange gt press four times for new systems or 4 digit security code slow orange blinks enter the new 4 digit security code fast orange blinks re enter the same 4 didgit security code again green light d Ifyou wish to cancel the security code function then repeat a b c above and press 1 four times as your new security code security code function disabled e If you do not remember the 4 digit security code then you must contact your dealer or distributor for further assistance 6 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 tra
28. receiver and test the MAIN relay output by pressing the red emergency stop button and observe that it properly opens and closes the mainline disconnect contactor Test the operation of each function to ensure it corresponds to the transmitter direction labels or the pendent it Is replacing Test the limit switches if any to see if they are working properly If your new remote control is replacing an existing pendant make sure it is completely disconnected and placed in a safe location to prevent unwanted control command 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 After turning the transmitter power on check the Status LED on the transmitter handset for any sign of system irregularities refer to Status Light Indicators amp Warnings on page 31 If the system is normal the Status LED will light up green for two 2 seconds d Ifthere are no signs of any system irregularities then rotate the power key switch further to START position for up to 1 0 second to activate all transmitter push
29. requires transmitting on time other than the preset value above 3 Push Button Functions with LED Displays A Transmitter Toggle Push Button Settings 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 amp 10 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 is pressed LED4 LED3 LED2 LED 1 E ze a STATUS FUNCTIO N SS 3 e BBBHRBBB 1 ay y 26 amp js lt 12345678 Os c gt E Fig 09 DU EM aderit Fig 10 DIP PB1 PB2 PB3 PB4 1 00000000 Normal Normal Normal Normal 2 00000001 Normal Normal Normal LED 4 3 00000010 Normal Normal LED 3 LED 4 4 00000011 Normal LED 2 LED 3 LED 4 5 00000100 LED 1 LED 2 LED 3 LED 4 PB1 PB4 Push button number Normal Normal momentary contact LED I LED 4 Transmitter toggled with designated LED Display
30. rystals to break Automatic channel scanning receiver No more hassle of climbing up the crane to change receiver channels Overone million unique ID codes 20bit Each and every Flex system has its own unique ID codes and serial number never repeats Advanced controls The Flex system utilizes advanced microprocessor controls with 32bit CRC and Hamming Code which provide ultra fast safe precise and error free encoding and decoding Unique I CHIP design The I CHIP functions in a way that is very similar to SIM card used on mobile phones with the ability to transfer system information and settings from one transmitter to another without the hassle of resetting the spares Reliable push buttons The in house designed push buttons with gold plated contacts are rated for more than one million press cycles Low power consumption Requires only two AA Alkaline batteries for more than 150 hours of operating time between replacements Ultra durable nylon and fiberglass composite enclosures Highly resistance to breakage and deformation even in the most abusive environments Full compliance All systems are fully complied with the FCC Part 15 Rules European Directives Safety EMC R amp TTE Machinery and Industry Canada Specifications IC 2 Radio Controlled Safety Flex radio remote control system should be operated by persons with sufficient amount of knowledge
31. st be powered in order to proceed with the programming 7 Fuse Ratings FUSE 110 120VAC 220 240VAC 380 400VAC 410 460VAC 24VAC 42 amp 48 9 36VDC 5 0A clear 5 0A clear 5 0A clear 5 0A clear 5 0A clear 5 0A clear 5 0A clear F9 F10 0 5A blue 0 5 blue 0 5A blue 0 5A blue 1 0A red 1 0A red 2 0A purple 5 System Channels Table Channel Frequency Mu Channel Frequency y i 01 433 000MHZ 000000 32 433 775 2 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 175MHZ 001000 40 433 975MHZ 101000 09 433 200MHZ 001001 41 434 000MHZ 101001 10 433 225MHZ 001010 42 434 025MHZ 101010 11 433 250MHZ 001011 43 434 050MHZ 101011 12 433 275MHZ 001100 44 434 075MHZ 101100 13 433 300MHZ 001101 45 434 100MHZ 101101 14 433 325MHZ 001110 46 434 125MHZ 101110 15 433 350MHZ 001111 47 434 150MHZ 101111 16 433 375MHZ 010000 48 434 175MHZ 110000 17 433 400MHZ 010001 49 434 200MHZ 110001 18 433 425MHZ 010010 50 434 225MHZ 110010 19 433 450MHZ 010011 51 434 250MHZ 110011 20 433 475MHZ 010100 52 434 275MHZ 110100 21 433 500MH
32. t the condition to their supervisor 8 The transmitter power should be turned off after each use If the transmitter handset is not in use always turn the power off and stored it in a safe or designated location Never leave the transmitter handset unattended in the working area 9 Make sure the system is not set to the same channel as any other Flex systems in use within a distance of 300 meters 900 feet 10 Never operate a crane or equipment with two transmitter handsets at the same time 3 General System Information A TRANSMITTER HANDSET 1 External Illustration STATUS pq Cy 6 a x i ___ E 10 D ep x x x Fig 01 Fig 02 1 Push Button 1 7 Strap Ring 2 Push Button 2 8 System Information 3 Push Button 3 9 System Channel 4 Push Button 4 10 Crane Number 5 Removable Power Key Switch 1 Battery Cover 6 Emergency Stop Button 12 Approval Information 2 Internal Illustration D N N e lt 9 24
33. ted temporarily when the receiver encounters strong radio interference or when the operator is controlling the crane or equipment beyond the transmitting range Turn off the transmitter power by rotating the power key counter clockwise to Off position it will disconnect the transmitter power and the receiver MAIN altogether Turn it further counter clockwise to release the key 2 A B Selector Push Button Operating Procedure Pressing the Select A B push button will toggle between output relay A B A B respectively There are 4 different types of Select A B sequence available please refer to page 11 for instructions on how to set Select A B functions th Select i A B 1 37 Speed Push Button Operating Procedure When a push button is hold at 2 speed pressing the 3 Speed push button one time will activate the 3 speed output relay toggled If the operator wants 2 speed again just press the 3 Speed push button one more time 4 Automatic Channel Scanning Operating Procedure After changing transmitter channel refer to page 9 turn on the transmitter power and rotate the power key switch to Start position and hold it there for up to 1 0 minute Within this 1 minute period the receiver will search channel 01 channe
34. ttons refer to Fig 14 amp 15 below Only the first 7 dip switch positions are used counting from left to right the 8 dip switch position far right is not used AARAA BAR ld Fig 14 ma F 1234567 Fig 15 Manufacture preset Dip C of Relays 4 Function Descriptions Settings Used 0000000 Normal single speed only F2 amp R2 relays not used 2 0000001 Closed Closed Relay Action at 2 Speed separate 2 speed relay 4 0000010 Closed Closed Relay Action at 274 Speed shared 274 speed relay 3 0000011 Opened Closed Relay Action at 2 Speed separate 2 speed relay 4 0000110 On right button amp Off left button 2 On Start Off Start Prior to pressing the button you must 0001001 first rotate and hold the power key switch at START position 2 to activate On or Off relays 0000111 Safety Magnet On amp Off 2 0001010 FWD REV toggled latching 2 0010000 Normal External Warning 2 0010001 Closed Closed Relay Action External Warning 4 0010010 Closed Closed Relay Action External Warning 3 0010011 Opened Closed Relay Action External Warning 4 0100001 Closed Closed Brake 4 0100010 Closed Closed Relay Action Brake 3 0100011 Opened Closed Relay Action Brake 4 0110001 Closed Closed Relay Action Brake External Warning 4 0110010 Closed Closed Relay Action Brake External Warning 3 0110011 Opened Closed Relay Action Brake External Warning 4
35. vert back to the new channel set on the CHANNEL dip switch g Please note that when channel is set beyond channel 62 via and PB2 i e channel 63 68 88 etc the system will recognize it as channel 62 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 If this occurs then you must reset the e stop button and input the correct 4 digit code Please refer to the instruction below on how to program the 4 digit security code a Press and hold PB1 PB2 PB3 and PB4 and rotate the power key to START position at the same time b Aconstant orange light will appear on the Status LED telling you that you are in the security code programming mode For newly purchased system with the security code function deactivated default setting press four times 1111 to activate the security code function At this time the Status LED on the transmitter will blink orange slowly telling you that the 4 digits entered is correct Then select your own 4 digit security code by pressing PB1 PB2 PB3 o
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