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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