Table of Contents
Table of Contents
Page
1. Introduction
3
2. Radio Controlled Safety
4
3. General System Information
A. Transmitter Handset
1. External Illustration (Standard Push Button Configuration)
2. Internal Illustration
B. Receiver Unit
1. External Illustration
2. Internal Illustration
4. Function Settings
7
8
5
6
A. Transmitter Handset
1. System Channel Settings
2. Continuous Transmitting Time Adjustment
3. Push Button Functions with LED Displays a. Standard Push Button Configuration (Transmitter Toggle) b. Standard Push Button Configuration (A/B Selector) c. Inline Push Button Configuration (Transmitter Toggle) d. Inline Push Button Configuration (A/B Selector)
4. Channel Change via Push Buttons
5. Program 4-digit Security Code
6. I-CHIP
B. Receiver Unit
1. System Channel Settings
2. Output Relay Configurations a. Output Relay Types b. Output Relay Action at 2 nd
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 i. 3 rd
Speed Push Button Function
Page 1
9
9
21
18
19
20
10
11~13
14
15~17
24
24
24
24
24
22
22~23
23
24
j. Auxiliary STOP Push Button Function k. Pitch & Catch 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
26
27
28
29
25
25
25
7. Voltage Settings 29
5. System Channels Table
30
6. Receiver Installation
A. Output Relay Contact Diagram
B. Pre-Installation Precautions
C. Step-By-Step Installation
D. System Testing
7. Operating Procedure
A. Transmitter Operation
1. General Operating Procedure
2. A/B Selector Push Button Operating Procedure
3. 3 rd
Speed Push Button Operating Procedure
4. Pitch & Catch Operating Procedure
5. Automatic Channel Scanning Operating Procedure
6. Changing Transmitter Batteries
B. Status Light Indicators & Warnings
1. Transmitter STATUS Light Indication
2. Receiver STATUS Light Indication
3. Receiver SQ Light Indication
4. Receiver POWER Light Indication
5. Receiver COM Light Indication
C. Trouble Shooting Tips 39
8. System Specifications
40
9. Spare Parts
41
10. EU Declaration of Conformity
42
Page 2
37
38
38
38
38
31
32
32~33
33
34~35
35
35
36
36
36
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. 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:
* 62 user-programmable channels – Advanced synthesized RF controls with 62 built-in channels, no more fixed channel and fragile quartz crystals to break.
* Automatic channel scanning receiver – No more hassle of climbing up the crane to change receiver channels.
* Over one 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&TTE, Machinery) and Industry Canada Specifications (IC).
Page 3
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. Radio remote controlled cranes should not be operated by any person with insufficient eyesight, hearing, illness, and under influence of drugs and medications that may cause loss of crane control.
Below are some general operating safety tips that should be strictly followed when operating a radio remote controlled crane.
1. Prior to crane operation always check the transmitter handset for any damage that might inhibit proper crane operation.
2. Always check if the red emergency stop button is working properly prior to crane operation.
3. Check the Status LED on the transmitter for any signs of low battery power (refer to page 37).
4. Check the Status LED on the transmitter for any signs of irregularities (refer to page 37).
5. The crane limit switches should be checked prior to crane operation or at the beginning of each shift.
When checking limit switches the hoist should be centered over an area free of personnel and equipment.
6. If the power to the crane is removed, the operator should turn off the transmitter power immediately until the power to the crane is restored.
7. If the crane fails to respond properly to operator ’s command the operator should stop operation, turn the transmitter power off, and then report 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 unless they are programmed with “Pitch & Catch” function. For information on the “Pitch & Catch” feature, please refer to page 25 and page 36 of this manual.
Page 4
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
2. Removable Power Key Switch 9. Push Button #1
15. Strap Ring
16. System Information
3. Push Button #2
4. Push Button #4
5. Push Button #6
6. Push Button #8
7. Push Button #10
10. Push Button #3
11. Push Button #5
12. Push Button #7
13. Push Button #9
14. Push Button #11
Page 5
17. System Channel
18. Crane Number
19. Battery Cover
20. Approval Information
2. Internal Illustration
(Fig. 03)
1. Encoder Board
2. Arial Antenna
3. Transmitting Module
4. Status LED Display
5.
Function LED Displays
Page 6
(Fig. 04)
6. I-CHIP
7. Function Dip-Switch
8. Channel Dip-Switch
9. Battery Contact Mechanism
B. RECEIVER UNIT
1. External Illustration
(Fig. 05)
1. Shock Mount
2. External Antenna (BNC) Jack
3. Power LED Display
4. Status LED Display
5. SQ LED Display
Page 7
6. COM LED Display
7. Output Contact Diagram
8. System Information
9. Cord Grip
2. Internal Illustration
(Fig. 06)
1. AC Line Filter
2. Power Transformer
3. Receiving Module
Page 8
4. Decoder Module
5. Output Relay Board
4. Function Settings
A. TRANSMITTER HANDSET
1. System Channel Settings
(Fig. 07)
CHANNEL
1 2 3 4 5 6 7 8
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. 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 21.
Example:
Top slot → “1”
(Fig. 08)
1 2 3 4 5 6 7 8
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 30.
2. Continuous Transmitting Time Adjustment
(Type 1)
1 2 3 4 5 6 7 8
After the push button is released the transmitter will continue to
→ 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.
(Type 2)
1 2 3 4 5 6 7 8
After the push button is released the transmitter will continue to transmit neutral signals to the receiver for up to three (3) minutes.
→
After three (3) minutes the transmitter will cease transmission thus temporarily disconnecting the receiver MAIN. Please contact your local dealer if your application requires transmitting on time other than the preset value above.
Page 9
3. 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
(Fig. 09)
FUNCTION
1 2 3 4 5 6 7 8
DIP PB7 PB8 PB9 PB10 PB11 PB12
1
00000000 Normal Normal Normal Normal Normal Normal
2
00001001 Normal Normal Normal LED 4 Normal Normal
3
00001010 Normal Normal LED 3 LED 4 Normal Normal
4
00001011 Normal LED 2 LED 3 LED 4 Normal Normal
5
00001100 LED 1 LED 2 LED 3 LED 4 Normal Normal
6
00001101 Normal Normal Normal Normal Normal LED 4
7
00001110 Normal Normal Normal Normal LED 3 LED 4
8
00001111 Normal Normal Normal LED 2 LED 3 LED 4
9
00010000 Normal Normal LED 1 LED 2 LED 3 LED 4
* PB7…PB12 → Push button number
* Normal → Normal momentary contact
* LED 1…LED 4 → Transmitter toggled with designated LED Display
Page 10
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.
Type-A selector sequence : A → B → A → B …
Type-B selector sequence :
Off → A → B → Off → A → B …
Type-C selector sequence :
A → B → A+B → A → B → A+B …
Type-D selector sequence : Off → A → B → A+B → Off → A → B → A+B …
DIP PB7 PB8 PB9 PB10 PB11 PB12
10
00101111 A/1&2 Normal Normal Normal Normal Normal
11
00110000 B/1&2 Normal Normal Normal Normal Normal
12
00110001 C/1&2 Normal Normal Normal Normal Normal
13
00110010 D/1&2 Normal Normal Normal Normal Normal
14
00110011 Normal A/3&4 Normal Normal Normal Normal
15
00110100 Normal B/3&4 Normal Normal Normal Normal
16
00110101 Normal C/3&4 Normal Normal Normal Normal
17
00110110 Normal D/3&4 Normal Normal Normal Normal
18
00110111 A/1&2 A/3&4 Normal Normal Normal Normal
19
00111000 A/1&2 B/3&4 Normal Normal Normal Normal
20
00111001 A/1&2 C/3&4 Normal Normal Normal Normal
21
00111010 A/1&2 D/3&4 Normal Normal Normal Normal
22
00111011 B/1&2 B/3&4 Normal Normal Normal Normal
23
00111100 B/1&2 C/3&4 Normal Normal Normal Normal
24
00111101 B/1&2 D/3&4 Normal Normal Normal Normal
25
00111110 C/1&2 C/3&4 Normal Normal Normal Normal
26
00111111 C/1&2 D/3&4 Normal Normal Normal Normal
27
01000000 D/1&2 D/3&4 Normal Normal Normal Normal
* PB7…PB12 → Push button number
* Normal → Normal momentary contact
* A/1&2…D/3&4 → A/B Selector type with designated LED Display (LED 1&2 or LED 3&4)
Page 11
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 A/1&2 A/3&4 Normal Normal
37
01001010 Normal Normal A/1&2 B/3&4 Normal Normal
38
01001011 Normal Normal A/1&2 C/3&4 Normal Normal
39
01001100 Normal Normal A/1&2 D/3&4 Normal Normal
40
01001101 Normal Normal B/1&2 B/3&4 Normal Normal
41
01001110 Normal Normal B/1&2 C/3&4 Normal Normal
42
01001111 Normal Normal B/1&2 D/3&4 Normal Normal
43
01010000 Normal Normal C/1&2 C/3&4 Normal Normal
44
01010001 Normal Normal C/1&2 D/3&4 Normal Normal
45
01010010 Normal Normal D/1&2 D/3&4 Normal Normal
* PB7…PB12 → Push button number
* Normal → Normal momentary contact
* A/1&2…D/3&4 → A/B Selector type with designated LED Display (LED 1&2 or LED 3&4)
Page 12
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 Normal Normal A/1&2 A/3&4
55
01011100 Normal Normal Normal Normal A/1&2 B/3&4
56
01011101 Normal Normal Normal Normal A/1&2 C/3&4
57
01011110 Normal Normal Normal Normal A/1&2 D/3&4
58
01011111 Normal Normal Normal Normal B/1&2 B/3&4
59
01100000 Normal Normal Normal Normal B/1&2 C/3&4
60
01100001 Normal Normal Normal Normal B/1&2 D/3&4
61
01100010 Normal Normal Normal Normal C/1&2 C/3&4
62
01100011 Normal Normal Normal Normal C/1&2 D/3&4
63
01100100 Normal Normal Normal Normal D/1&2 D/3&4
* PB7…PB12 → Push button number
* Normal → Normal momentary contact
* A/1&2…D/3&4 → A/B Selector type with designated LED Display (LED 1&2 or LED 3&4)
Page 13
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. 10)
DIP PB7 PB8 PB9 PB10 PB11 PB12
64
00000000 Normal Normal Normal Normal Normal Normal
65
00000101 Normal Normal Normal LED 4 Normal Normal
66
00010100 Normal Normal LED 3 LED 4 Normal Normal
67
00010101 Normal LED 2 LED 3 LED 4 Normal Normal
68
00010110 LED 1 LED 2 LED 3 LED 4 Normal Normal
69
00001001 Normal Normal Normal Normal LED 4 Normal
70
00010111 Normal Normal Normal LED 3 LED 4 Normal
71
00011000 Normal Normal LED 2 LED 3 LED 4 Normal
72
00011001 Normal LED 1 LED 2 LED 3 LED 4 Normal
73
00001101 Normal Normal Normal Normal Normal LED 4
74
00011010 Normal Normal Normal Normal LED 3 LED 4
75
00011011 Normal Normal Normal LED 2 LED 3 LED 4
76
00011100 Normal Normal LED 1 LED 2 LED 3 LED 4
* PB7…PB12 → Push button number
* Normal → Normal momentary contact
* LED 1…LED 4 → Transmitter toggled with designated LED Display
Page 14
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.
Type-A selector sequence : A → B → A → B …
Type-B selector sequence : Off → A → B → Off → A → B …
Type-C selector sequence :
A → B → A+B → A → B → A+B …
Type-D selector sequence : Off → A → B → A+B → Off → A → B → A+B …
DIP PB9 PB10 PB11 PB12
77
01110011 A/1&2
78
01110100 B/1&2
Normal
Normal
Normal
Normal
Normal
Normal
79
01110101 C/1&2
80
01110110 D/1&2
81
00110011 Normal
82
00110100 Normal
83
00110101 Normal
84
00110110 Normal
85
01110111 A/1&2
86
01111000 A/1&2
87
01111001 A/1&2
88
01111010 A/1&2
89
01111011 B/1&2
90
01111100 B/1&2
91
01111101 B/1&2
92
01111110 C/1&2
93
01111111 C/1&2
94
10000000 D/1&2
Normal
Normal
A/3&4
B/3&4
C/3&4
D/3&4
A/3&4
B/3&4
C/3&4
D/3&4
B/3&4
C/3&4
D/3&4
C/3&4
D/3&4
D/3&4
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
* PB7…PB12 → Push button number
* Normal → Normal momentary contact
* A/1&2…D/3&4 → A/B Selector type with designated LED Display (LED 1&2 or LED 3&4)
Page 15
95
96
97
98
DIP PB9
10000001 Normal
10000010 Normal
10000011 Normal
10000100 Normal
PB10
A/1&2
B/1&2
C/1&2
D/1&2
PB11
Normal
Normal
Normal
Normal
PB12
Normal
Normal
Normal
Normal
99
01000101 Normal Normal A/3&4
100
01000110 Normal Normal B/3&4
101
01000111 Normal Normal C/3&4
Normal
Normal
Normal
102
01001000 Normal Normal D/3&4 Normal
103
10000101 Normal A/1&2 A/3&4 Normal
B/3&4 Normal
104
10000110 Normal A/1&2
105
10000111 Normal A/1&2
106
10001000 Normal A/1&2
C/3&4
D/3&4
Normal
Normal
107
10001001 Normal B/1&2
108
10001010 Normal B/1&2
109
10001011 Normal B/1&2
110
10001100 Normal C/1&2
111
10001101 Normal C/1&2
112
10001110 Normal D/1&2
B/3&4
C/3&4
D/3&4
C/3&4
D/3&4
D/3&4
Normal
Normal
Normal
Normal
Normal
Normal
* PB7…PB12 → Push button number
* Normal → Normal momentary contact
* A/1&2…D/3&4 → A/B Selector type with designated LED Display (LED 1&2 or LED 3&4)
Page 16
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
B/3&4
122
10010100 Normal Normal A/1&2
123
10010101 Normal Normal A/1&2
124
10010110 Normal Normal A/1&2
C/3&4
D/3&4
125
10010111 Normal Normal B/1&2
126
10011000 Normal Normal B/1&2
127
10011001 Normal Normal B/1&2
128
10011010 Normal Normal C/1&2
129
10011011 Normal Normal C/1&2
130
10011100 Normal Normal D/1&2
B/3&4
C/3&4
D/3&4
C/3&4
D/3&4
D/3&4
* PB7…PB12 → Push button number
* Normal → Normal momentary contact
* A/1&2…D/3&4 → A/B Selector type with designated LED Display (LED 1&2 or LED 3&4)
Page 17
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. A 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 PB1 to increment the units
(+1) and PB2 to increment the tens (+10).
Examples: Press PB2 two times and then PB1 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. Exit the channel programming by turning off the transmitter power. e. Make sure the receiver channel is set identical to the transmitter. Please refer to page 21 and page
36 on how to change receiver channel. f. Please note that when the CHANNEL dip-switch inside the transmitter is changed, the priority will revert back to the new channel set on the CHANNEL dip-switch. g. Please note that when channel is set beyond channel 62 via PB1 and PB2 (i.e. channel 63, 68, 88, etc…), the system will recognize it as channel 62.
Page 18
5. 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, a green light will appear on the Status LED. 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. A constant orange light will appear on the Status LED telling you that you are in the security code programming mode. c. For newly purchased system with the security code function deactivated (default setting), press
PB1 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 or 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 → press PB1 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. If you wish to cancel the security code function, then repeat a, b, c above and press PB1 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.
Page 19
6. I-CHIP
I-Chip functioned in a way that is very similar to a SIM card inside a mobile phone, which stores system 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). For complete information transfer, do make sure both the
Channel and Function dip-switch is set to all “1”. If both dip-switches are set to all “1”, then the transmitter will operate according to the push button configurations and channel stored inside the
I-CHIP. If both Channel and Function dip-switch is set to other values other than all “1”, then the transmitter will operate according to the channel and push button configurations set on these two dip-switches, not the ones stored inside the I-CHIP. Every time when the settings on these two dip-switches have changed, the new settings will be stored into the I-CHIP automatically. In this case the previous channel and push button configurations stored inside the I-CHIP will be erased and be replaced by the new settings.
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 29 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.
(Fig. 11)
Page 20
B. RECEIVER UNIT
1. System Channel Settings
(Fig. 12)
1 2 3 4 5 6 7 8
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). The system channels table located on page 30 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.
Example:
Top slot → “1”
(Fig. 13)
1 2 3 4 5 6 7 8
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 30.
Page 21
2. Output Relay Configurations a. Output Relay Types
1. Three (3) output relays per motion – shared 2 nd
speed output relay
Output relays with Forward 1 st
speed (F1), Reverse 1 st
speed (R1) and Forward/Reverse 2 nd speed (F/R2). Forward and Reverse 2 nd
speed (F/R2) shared the same output relay.
F1 R1 F/R2
2. Four (4) output relays per motion – separate 1 st
and 2 nd
speed output relays
Output relays with Forward 1 st
speed (F1), Reverse 1 st
speed (R1), Forward 2 nd speed (F2) and Reverse 2 nd
speed (R2). Forward and Reverse 2 nd
speed with separate output relays.
F1 R1 F2 R2
b. Output Relay Actions at 2
nd
Speed
1. 3-output relays configuration with Closed/Closed contact at 2 nd
speed
At 2 nd
speed, both 1 st
speed (F1 or R1) and 2 nd
speed (F/R2) output relays are closed
(refer to page 26 on how to set to this function).
Forward 1 st
speed push button pressed Forward 2 nd
speed push button pressed
↓ ↓
F1 R1 F/R2 F1 R1 F/R2
Page 22
2. 4-output relays configuration with Opened/Closed contact at 2 nd
speed
At 2 nd
speed, only the 2 nd
speed (F2 or R2) output relay is closed (refer to page 26 on how to set to this function).
Forward 1 st
speed push button pressed Forward 2 nd
speed push button pressed
↓
↓
F1 R1 F2 R2 F1 R1 F2
3. 4-output relays configuration with Closed/Closed contact at 2 nd
speed
At 2 nd
speed, both 1 st
speed (F1 or R1) and 2 nd
speed (F2 or R2) output relays are closed
R2
(refer to page 26 on how to set to this function).
Forward 1 st
speed push button pressed Forward 2 nd
speed push button pressed
↓ ↓
F1 R1 F2 R2 F1 R1 F2
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 & OFF rocker switch (refer to page 26 on how to set to this function). When
“On” output relay is closed (“On” push button pressed), the “Off” output relay will open
R2 automatically, or vise versa.
Page 23
OFF ON
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. Brake Function
When the transmitter push button is released from 2 nd
speed up to 1 st
speed, both 1 st
and 2 nd speed output relays will open for up to 1.0 second and then with 1 st
speed output relay closed thereafter (refer to page 26 on how to set to this function).
f. External Warning Function
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 26 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 27 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 27 on how to set to this function). This type of contact is usually applies to external application such as lights.
i. 3
rd
Speed Push Button Function
This function allows the crane to travel an additional step beyond 2 nd
speed. For example, if the operator is pressing the “UP” push button down to 2 nd
speed, pressing the 3 rd
speed push button
(with “UP” push button still hold at 2 nd
speed) will toggle between 2 nd
speed and 3 rd
speed (refer to page 27 on how to set to this function).
Page 24
3rd
SPEED
j. Auxiliary STOP Push Button Function (JP3 must be inserted)
The auxiliary STOP function acts as a 2 nd
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. Pitch & Catch Function
This function allows two operators controlling one crane from opposite ends of a cross or long travel (refer to page 27 on how to set to this function). When set to “Pitch & Catch” make sure the 2 nd
transmitter is set to the next upper channel (channel X*+1). For example, if the system is preset at “Ch.01” then the channel of the 2 nd
transmitter should be set to “Ch.02”. Furthermore, the dip-switch position #7 and #8 on the receiving module should be set to “01”, this will allow the receiver to scan only Ch.01 and Ch.02 (please refer to the illustration below). On the other hand, since there are only 62 available channels on the Flex system, the system preset at channel
62 is ineffective because the 2 nd
transmitter can not be set to Ch.63. If your system is preset at
Ch.62 do make sure to change it to another channel.
3. Receiver Auto-Scanning Settings
Receiver Channel Dip-switch
↓
(1)
1 2 3 4 5 6 7 8
→
Scanning all 62 channels (manufacture preset)
For standard operation
(2)
1 2 3 4 5 6 7 8
→
Single fixed channel (channel X*)
Auto scanning function disabled
(3)
1 2 3 4 5 6 7 8
→
Scanning 2 channels only (channel X*, channel X*+1)
For Pitch & Catch, Tandem, and Random Access operation with 2 receivers
(4)
→
Scanning 3 channels only (channel X*, channel X*+1, channel X*+2)
For Random Access operation with 3 receivers
1 2 3 4 5 6 7 8
* Channel X → Channel set on the receiving module
Example: If the 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.
Page 25
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). Only the first 7 dip-switch positions are used
(counting from left to right), the 8 th
dip-switch position (far right) is not used.
(Fig. 14)
1 2 3 4 5 6 7 8
RELAY FUNCTIONS
(Fig. 15)
▇
Manufacture preset
0001010
0010000
0010001
0010010
0010011
0100001
0100010
0100011
0110001
0110010
Dip
Settings
Function Descriptions
0000000 Normal (single speed only, F2 & R2 relays not used)
0000001 Closed/Closed Relay Action at 2 nd
Speed (separate 2 nd
speed relay)
0000010 Closed/Closed Relay Action at 2 nd
Speed (shared 2 nd
speed relay)
0000011 Opened/Closed Relay Action at 2 nd
Speed (separate 2 nd
speed relay)
0000110 On (right button) & Off (left button)
0001001
On + Start / Off + Start -- Prior to pressing the button you must first rotate and hold the power key switch at START position
to activate On or Off relays.
# of Relays
Used
3
4
2
2
4
2
0000111 Safety Magnet On & Off
2
FWD/REV toggled (latching)
Normal + External Warning*
Closed/Closed Relay Action + External Warning*
Closed / Closed Relay Action + External Warning*
Opened/Closed Relay Action + External Warning*
Closed/Closed + Brake
Closed/Closed Relay Action + Brake
Opened/Closed Relay Action + Brake
Closed/Closed Relay Action + Brake + External Warning*
Closed/Closed Relay Action + Brake + External Warning*
3
4
4
4
4
3
4
3
2
2
0110011 Opened/Closed Relay Action + Brake + External Warning*
4
* External warning function requires installing an external warning device such as horn and rotating lights to the function relay output.
Page 26
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 rd
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).
Function
Code
Dip
Position
Setting
#1
Dip Position Setting
#2 ~ #4 (left button)
&
#5 ~ #7 (right button)
Function Description
A 1 000
Normal (momentary) contact
B
C
D
E
1
1
1
1
001
010
100
110
Toggled (latching) contact
Acceleration (3 rd
speed)
Normal + Start function. For added safety, you must first rotate and hold the power key switch at “START” position and then press the intended push button at the same time to activate the output relay.
Pitch & Catch
F 1 111
Auxiliary Stop
Example #1: Left button (set to function code A) / right button (set to function code A) → 1 000 000
Example #2: Left button (set to function code B) / right button (set to function code B) → 1 001 001
Example #3: Left button (set to function code A) / right button (set to function code C) → 1 000 010
Example #4: Left button (set to function code F) / right button (set to function code A) → 1 111 000
!
When set to Pitch & Catch function make sure the 2 nd
transmitter is set to the next upper channel. For example, if the system is preset at Ch.01 then the 2 nd transmitter should be set to Ch.02. Furthermore, you must also set the dip-switch on the receiving module (position #7 & #8) to “10” position (2-channel scanning), please refer to page 25.
!!
When set to “Auxiliary Stop” do make sure that JP3 is inserted (refer to jumper settings next page).
Page 27
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. 16)
▇
Manufacture preset
Jumper Settings Function
JP3
(Blank)
After 1 or 3 minutes of transmitter inactivity (MAIN deactivated), press any push button on the transmitter to reactivate the receiver MAIN.
JP3
(Inserted)
After 1 or 3 minutes of transmitter inactivity (MAIN deactivated), rotate the transmitter power key-switch to “START” position to reactivate the receiver MAIN.
JP4
(Blank)
JP5
(Blank)
JP4
(Inserted)
JP5
(Blank)
JP4
(Blank)
JP5
(Inserted)
JP4
(Inserted)
JP5
(Inserted)
JP6
(Blank)
Standard right-to-left push button configuration for all models.
In-line push button configuration (top to bottom) for FLEX 8ES/EX.
In-line push button configuration (top to bottom) for FLEX 12ES/EX.
In-line push button configuration (top to bottom) for FLEX 4ES/EX.
Program system serial number/ID code and channel from decoder module to I-CHIP.
Program system serial number/ID code and channel from I-CHIP to decoder module.
JP6
(Inserted)
JP7
(Inserted)
For system test only, receiver MAIN disabled.
Page 28
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. 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 must be powered in order to proceed with the programming.
7. Voltage Settings
Prior to installation always check the voltage setting is correct for your application (refer to Fig. 18 below).
Position 1 → 110~120VAC
Position 2 → 220~240VAC or 24VAC*
Position 3 → 380VAC or 42VAC*
Position 4 → 400~460VAC or 48VAC* or 12~24VDC**
COM 1 2
* For system with 24/42/48VAC power supply.
(Fig. 18)
** For system with 12~24VDC power supply.
3
F9 and F10 power fuse ratings:
4
FUSE # 110~120VAC 220~240VAC 380VAC 400~460VAC 24VAC 42 & 48VAC 12~24VDC
F9
1.0A (red) 1.0A (red) 1.0A (red) 0.5A (blue) 3.0A (yellow) 2.0A (purple) 2.0A (purple)
F10
1.0A (red) 1.0A (red) 1.0A (red) 0.5A (blue) 3.0A (yellow) 2.0A (purple) 2.0A (purple)
* Output relay fuse → 5.0A (clear)
Page 29
5. System Channels Table
Channel Frequency
Dip-switch
Setting
Channel Frequency
01
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
433.050MHZ
433.050MHZ
433.075MHZ
433.100MHZ
433.125MHZ
433.150MHZ
433.175MHZ
433.200MHZ
433.225MHZ
433.250MHZ
433.275MHZ
433.300MHZ
433.325MHZ
433.350MHZ
433.375MHZ
433.400MHZ
433.425MHZ
433.450MHZ
433.475MHZ
433.500MHZ
433.525MHZ
433.550MHZ
000000
000001
000010
000011
000100
000101
000110
000111
001000
001001
001010
001011
001100
001101
001110
001111
010000
010001
010010
010011
010100
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
21
010101
53
22
23
24
25
26
27
433.575MHZ
433.600MHZ
433.625MHZ
433.650MHZ
433.675MHZ
433.700MHZ
433.725MHZ
010110
010111
011000
011001
011010
011011
54
55
56
57
58
59
28
29
30
433.750MHZ
433.775MHZ
011100
011101
011110
60
61
62
31
433.800MHZ 011111
I-CHIP
* When set to all “1” the priority goes to the channel assigned inside the I-CHIP.
Page 30
434.375MHZ
434.400MHZ
434.425MHZ
434.450MHZ
434.475MHZ
434.500MHZ
434.525MHZ
434.550MHZ
434.575MHZ
433.825MHZ
433.850MHZ
433.875MHZ
433.900MHZ
433.925MHZ
433.950MHZ
433.975MHZ
434.000MHZ
434.025MHZ
434.050MHZ
434.075MHZ
434.100MHZ
434.125MHZ
434.150MHZ
434.175MHZ
434.200MHZ
434.225MHZ
434.250MHZ
434.275MHZ
434.300MHZ
434.325MHZ
434.350MHZ
Dip-switch
Setting
100000
100001
100010
100011
100100
100101
100110
100111
101000
101001
101010
101011
101100
101101
101110
101111
110000
110001
110010
110011
110100
110101
110110
110111
111000
111001
111010
111011
111100
111101
111110
111111*
6. Receiver Installation
A. OUTPUT RELAY CONTACT DIAGRAM
／ ／
* For 3-relay (shared 2 nd
speed) and 4-relay (separate 2 nd
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.
* For 12~24VDC power supply, wire #1 corresponds to the negative charge (-) and wire #3 corresponds to the positive charge (+), wire #2 is for GROUND.
Page 31
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. STEP-BY-STEP INSTALLATION
(Fig. 19)
Page 32
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). If an external antenna is used, to avoid the possibility of antenna damage always locate the receiver where the antenna is free from any obstacles from all directions (refer to diagram
432 mm at right).
4. When installing an external antenna you must also connect the SMA jack located inside the receiver and as well as cut or unsolder the existing spring antenna out, as both can not be connected at the same time.
CUT
Control
Panel
5. For better reception, make sure the receiver is in an upright position.
6. Drill two holes (10mm in diameter) on the control panel or location where the receiver is to be installed
(refer to Fig. 19 on page 32).
7. Make sure the two bolts are tightened after installation.
8. For system wiring please refer to page 31.
D. SYSTEM TESTING
1. Turn on the power source to the 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.
2. Test the operation of each function to ensure it corresponds to the transmitter direction labels or the pendent it is replacing.
3. Test the limit switches (if any) to see if they are working properly.
4. 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.
Page 33
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 & Warnings” on page 37). If the system is normal the Status LED will light up green for two (2) seconds. d. If there 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 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).
Page 34
e. In case of an emergency, pressing 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. 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. f. 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 to resume operation (depending on JP3 setting on page 28). If this 1-minute inactivity time is not sufficient for your application, you can also extend this inactivity time from 1 minute up to 3 minutes (refer to Continuous Transmitting Time Adjustment on page 9). The receiver MAIN will also be disconnected temporarily when the receiver encounters strong radio interference or when the operator is controlling the crane or equipment beyond the transmitting range. g. To turn off the transmitter power just rotate the power key to “Off” position, it will disconnect the transmitter power and the receiver MAIN altogether.
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 11~13 for instructions on how to set Select A/B functions.
A
B
3. 3
rd
Speed Push Button Operating Procedure
When a push button is hold at 2 nd
speed, pressing the 3 rd
Speed push button one time will activate the 3 rd speed output relay (toggled). If the operator wants 2 nd
speed again, just press the 3 rd
Speed push button one more time.
Page 35
3rd
SPEED
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 2 nd
operator “can not” take control of the crane unless the 1 st 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.
CATCH
O
N
F
O
F
PITC
H
→
→
CATCH
CATCH
PITC
H
5. 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 ~ channel 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 25 if you do not want the receiver to auto-scan all 62 channels.
Change Transmitter Channel
→
6. Changing Transmitter Batteries
Changing transmitter batteries by unscrewing the battery cover located on the backside of the transmitter
(refer to Fig. 20 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.
2
1
(Fig. 20)
↓
Page 36
B. STATUS LIGHT INDICATORS & WARNINGS
1. Transmitter STATUS Light Indication
Type Display Type
1
Constant red
Indication
Voltage below 1.9V at initial power on, transmitter power and receiver MAIN shuts off.
Voltage below 1.8V during operation, transmitter power and receiver MAIN shuts off.
2
1 red blinks followed by a 2-second pause
Voltage below 1.85V during operation, warning, change batteries suggested.
3
4
5
6
7
2 red blinks followed by a 2-second pause
The pushbutton is defective after turning on the transmitter power.
No light displayed
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 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 pause
EEPROM error.
4 red blinks followed by a 2-second pause
Transmitting error, system can not locked on to the designated channel.
Constant green for up to 2 seconds Transmitter power on with no faults detected.
8
9
Blinking green
Blinking orange
Transmission in progress.
Transmitter push button functions locked.
Page 37
2. Receiver STATUS Light Indication
Type Display Type
(Green & Red)
1
Fast green blinks
2
3
Slow green blinks
Two red blinks
Indication
Decoding in process
Decoding on standby
Receiver MAIN jammed or defective
4
5
Fast red blinks
Constant red
Incorrect transmitter serial number/ID code
Receiver under-voltage, LV output relay activated
6
No light displayed
3. Receiver SQ Light Indication
Type Display Type
(Red)
1
Fast blinks
2
Completely off
3
Blinks intermittently
4. Receiver POWER Light Indication
Type Display Type
(Red)
1
On
Decoding microprocessor is defective
Indication
Transmission received
No transmission
Other radio interference
Indication
Power to receiver
2
Off
5. Receiver COM Light Indication
Type Display Type
(Red)
1
On
No power to receiver
Indication
Power to relay Board
2
Off No power to relay board
Page 38
C. TROUBLE SHOOTING TIPS
Problems Possible Reasons Suggestions
No responds when transmitter push button is pressed
(Improper startup & settings)
No responds when transmitter push button is pressed
(Damaged hardware)
No AC power to the receiver
Transmitter low battery power Check the transmitter battery level.
Emergency stop button activated prior to startup
Transmitter push button functions locked
Incorrect system RF channel
Incorrect system serial number/ID code
Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated.
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.
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.
Defective transmitting and receiving module
Defective encoder board or decoder module
Incorrect input voltage
Blown fuse
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.
If still no responds, then replace the transmitter encoder board. If still doesn’t work then the decoder module is defective.
Make sure the source voltage is set correctly.
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.
Page 39
8. System Specifications
Frequency Range
Number of Channels
Channel Spacing
Modulation
:
:
:
:
433 ~ 434 MHz
62 channels
25 KHz
Digital Frequency Modulation based on
Manchester Code, 20bit address, 32bit CRC
Encoder & 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
4ES/4EX Models
8ES/8EX Models
12ES/12EX Models
Receiver Dimension (All Models)
Transmitter Weight
4ES/4EX Models
8ES/8EX Models
12ES/12EX Models
Receiver Weight (All Models)
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Parity Check and Hamming Code.
Microprocessor-controlled
100 Meters / 300 Feet (indoors)
＞6
Synthesized PLL (Phase Lock Loop)
Frequency Auto Scanning
-113dBm
-50dB
50 ohms
40 Milliseconds (average)
1.0mW
NEMA-4X
IP-66
250V @ 10 Amps
DC 3.0V
11.0 VA
-25
℃ ~ 75℃ / -13℉ ~ 167℉
138mm (L) x 69mm (W) x 34mm (H)
184mm (L) x 69mm (W) x 34mm (H)
230mm (L) x 69.0mm (W) x 35mm (H)
363mm (L) x 228mm (W) x 70mm (H)
192g / 6.8oz
242g / 8.5oz
296g / 10.4oz
2.5kg / 5.5lb
Page 40
9. Spare Parts
1. Transmitting Module (433/434MHz)
2. Encoder Board (complete with push buttons)
3. I-CHIP (complete)
4. Receiving Module
5.
6.
7.
Decoder Module
Receiver Relay Board
AC Line Filter Board
8. Power Transformer
AC 110~120V/220~240V/380V/400~460V
AC 24V/42V/48V
DC 12V/24V
9. Transmitter Top Casing
10. Transmitter Bottom Casing
11. Transmitter Battery Cover
12. Receiver Top Casing
13. Receiver Bottom Casing
14. Cord Grip
15. Shock Mount
16. 2-Step Push Button
17. 3-Stage Mechanical Selector Switch
18. Push Button Rubber Boot
19. Emergency Stop Button
20. Transmitter Power Keys Switch
21. Waist Belt
22. Strap Ring
23. Safety MAIN relay
24. Regular Output Relay
25. Clear Vinyl Pouch
26. External Receiver Antenna
Page 41
TRB 01
ENB 06
ICP 01
RVB 01
DEB 03
RLB 06
LFB 01
SMT 01
PBN 02
SWT 01
PRB 01
EMS 01
PWK 01
WBT 01
STR 01
SMR 01
RLY 01
CVP 03
ANT 01
PTF 01
PTF 02
PTF 03
TTC 03
TBC 03
TBC 04
RTC 01
RBC 01
CGR 01
EU Declaration of Conformity
(EMC, R&TTE, SAFETY & MACHINERY)
For the following equipment:
Product
Multiple Listee Model No.
Manufacturer’s Name
Manufacturer’s Address
: Flex Series Radio Remote Control System
: Flex 4ES/EX, Flex 8ES/EX, Flex 12ES/EX
: Advanced Radiotech Corporation
: 1F, 288-3, Hsin Ya Road, Chien Chen District,
Kaohsiung City, Taiwan
We herby declare, that all major safety requirements, concerning the CE Mark Directive (93/68/EEC) and
Low Voltage Directive (73/23/EEC), Electromagnetic Compatibility Directives (89/336/EEC, 92/31/EEC),
R&TTE Directive 1999/5/EC and 98/482/EC are fulfilled, as laid out in the guideline set down by the member states of the EEC Commission.
The standards relevant for the evaluation of the electrical safety requirements are as follow:
EMC : EN 301 489-3 V1.4.1 (2002-04)
R&TTE :
SAFETY :
MACHINERY:
Test reports issued by:
EMC :
R&TTE :
SAFETY :
EN 300 220-3 V1.1.1 (2000-09)
EN 60950:1999 (3 rd
Edition) / 2000 (3 rd
Edition)
EN 60204-32:1998; EN954-1:1996; ISO 13849-1:1999
Category 3
NEMKO Canada
NEMKO Canada
NEMKO Canada
MACHINERY: NEMKO Norway
Person responsible for marking this declaration:
Tom Jou / President
Name and signature of authorized person
Page 42
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