FLEX8EX User’s Manual INDUSTRIAL RADIO CONTROLS #5 Four Coins Drive, Canonsburg PA 15317, Phone 1-724-746-3313 Fax 1-724-746-3379 Web: www.enrange.
Table of Contents Page 1. Introduction 3 2. 3. Radio Controlled Safety General System Information 4 A. B. 4. Transmitter Handset 1. External Illustration (Standard Push Button Configuration) 5 2. Internal Illustration 6 Receiver Unit 1. External Illustration 7 2. Internal Illustration 8 Function Settings A. Transmitter Handset 1. System Channel Settings 2. Push Button Functions with LED Displays 3. B. 9 a. Standard Push Button Configuration (Transmitter Toggle) 10 b.
. Receiver Auto-Scanning Settings 4. Dip-switch Settings a. Interlocked Functions 20 b. Non-interlocked Functions 21 5. Jumpers Settings 22 6. I-CHIP Programming Port 23 7. Voltage Settings 23 5. System Channels Table 6. Receiver Installation 7. 24 A. Output Relay Contact Diagram 25 B. Pre-Installation Precautions 26 C. Step-By-Step Installation 26~27 D. System Testing 27 Operating Procedure A. B. C. 8. 9. 19 Transmitter Operation 1.
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.
2. Radio Controlled Safety Flex radio remote control system should be operated by persons with sufficient amount of knowledge and skill in crane operation and safety. Persons being trained to operate a radio remote controlled crane should possess the knowledge of all hazards peculiar to radio remote controlled crane operation, ability to judge distance and moving objects, equipment capacity and radio remote controlled safety rules.
3. General System Information A. TRANSMITTER HANDSET 1. External Illustration (Standard Push Button Configuration) (Fig. 01) (Fig. 02) 1. Emergency Stop Button 9. Push Button #5 2. Removable Power Key Switch 10. Push Button #7 3. Push Button #2 11. Strap Ring 4. Push Button #4 12. System Information 5. Push Button #6 13. System Channel 6. Push Button #8 14. Crane Number 7. Push Button #1 15. Battery Cover 8. Push Button #3 16.
2. Internal Illustration (Fig. 03) (Fig. 04) 1. Encoder Board 6. I-CHIP 2. Arial Antenna 7. Function Dip-Switch 3. Transmitting Module 8. Channel Dip-Switch 4. Status LED Display 9. Battery Contact Mechanism 5.
B. RECEIVER UNIT 1. External Illustration (Fig. 05) 1. Shock Mount 6. COM LED Display 2. Optional External Antenna (BNC) Jack 7. Output Contact Diagram 3. Power LED Display 8. System Information 4. Status LED Display 9. Cord Grip 5.
2. Internal Illustration (Fig. 06) 1. AC Line Filter 4. Decoder Module 2. Power Transformer 5. Output Relay Board 3.
4. Function Settings A. TRANSMITTER HANDSET 1. System Channel Settings CHANNEL 1 2 3 4 5 6 7 8 (Fig. 07) 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 24 illustrates which dip-switch setting corresponds to which channel.
2. Push Button Functions with LED Displays A. Standard Push Button Configuration (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 (PB-5 ~ PB-8) is pressed.
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.
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 22. With inline push buttons configuration, push button #1 & #2 still corresponds to output relay K1~K4, push button #3 & #4 corresponds to relay K5~K8, etc… (Fig.
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.
3. 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).
B. RECEIVER UNIT 1. System Channel Settings 1 2 3 4 5 6 7 8 (Fig. 12) Even though Flex system is equipped with automatic channel scanning receiver, the user can also set the receiver channel manually. Please refer to page 30 on how automatic channel scanning receiver works. Set the receiver channel by adjusting the channel dip-switch located on the receiver module (refer to Fig. 12 above), only the first six (6) positions are used for channel programming (refer to Fig. 13 below).
2. Output Relay Configurations a. Output Relay Types 1. Three (3) output relays per motion – shared 2nd speed output relay Output relays with Forward 1st speed (F1), Reverse 1st speed (R1) and Forward/Reverse 2nd speed (F/R2). Forward and Reverse 2nd speed (F/R2) shared the same output relay. F1 2. R1 F/R2 Four (4) output relays per motion – separate 1st and 2nd speed output relays Output relays with Forward 1st speed (F1), Reverse 1st speed (R1), Forward 2nd speed (F2) and Reverse 2nd speed (R2).
2. 4-output relays configuration with Opened/Closed contact at 2nd speed At 2nd speed, only the 2nd speed (F2 or R2) output relay is closed (refer to page 20 on how to set to this function). Forward 1st speed push button pressed Forward 2nd speed push button pressed ↓ F1 R1 3.
d. START/AUX Function After initiating the START function the Start position will become an auxiliary function with momentary contact. For auxiliary application such as horn or buzzer, please connect it to the FUNC output relay (wire #6) located inside the receiver unit. e. 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.
j. Auxiliary STOP Push Button Function The auxiliary STOP function acts as a 2nd 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 21 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 21 on how to set to this function).
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).
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, 3rd 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).
5. Jumper Settings Jumper settings are applied to functions such as mainline-disconnect time, Start function, transmitter push button layout, system information (serial number/ID code and channel) programming and system testing. The jumpers #1 ~ #7 are located on the decoder module above the four (4) dip-switches (refer to Fig.16 below). JP7 JP6 JP5 JP4 JP3 JP2 JP1 (Fig.
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.
5. System Channels Table Channel Frequency Dip-switch Setting Channel Frequency Dip-switch Setting 01 433.000MHZ 000000 32 433.775MHZ 100000 01 433.000MHZ 000001 33 433.800MHZ 100001 02 433.025MHZ 000010 34 433.825MHZ 100010 03 433.050MHZ 000011 35 433.850MHZ 100011 04 433.075MHZ 000100 36 433.875MHZ 100100 05 433.100MHZ 000101 37 433.900MHZ 100101 06 433.125MHZ 000110 38 433.925MHZ 100110 07 433.150MHZ 000111 39 433.950MHZ 100111 08 433.
6. Receiver Installation A. OUTPUT RELAY CONTACT DIAGRAM ／ ／ * For 3-relay (shared 2nd speed) and 4-relay (separate 2nd speed) configuration please refer to page 16~20. * For 4-relay closed/closed and 4-relay opened/closed relay configuration please refer to page 16~20. * For different voltage settings please refer to page 23. * For F9 and F10 power fuse ratings please refer to page 23.
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.
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 26).
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.
e. Now press any push button on the transmitter handset to operate the crane or equipment. f. In case of an emergency, pressing down the red emergency stop button will immediately disconnect the receiver mainline (Status LED blinks red). To reset the emergency stop button just rotate the red button either clockwise or counter clockwise, it will pop up. When green light appears, rotate the power key to “Start” position to resume operation (depends on JP3 setting on page 22). g.
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 2nd operator “can not” take control of the crane unless the 1st 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.
B. STATUS LIGHT INDICATORS & WARNINGS 1. Transmitter STATUS Light Indication Type Display Type (Green & Red) Indication Voltage below 1.9V at initial power on, 1 transmitter power and receiver MAIN shuts off. Constant red Voltage below 1.8V during operation, transmitter power and receiver MAIN shuts off. 2 3 1 red blinks followed by a 2-second Voltage below 1.85V during operation, warning, pause change batteries suggested.
2. Receiver STATUS Light Indication Type Display Type (Green & Red) Indication 1 Fast green blinks Decoding in process 2 Slow green blinks Decoding on standby 3 Slow red blinks 4 Two red blinks Receiver MAIN jammed or defective 5 Fast red blinks Incorrect transmitter serial number/ID code 6 Constant red Receiver under-voltage, LV output relay activated 7 No light displayed Decoding microprocessor is defective Stop command initiated with receiver MAIN deactivated 3.
C. TROUBLE SHOOTING TIPS Problems Possible Reasons Suggestions Transmitter low battery power Check the transmitter battery level. Emergency stop button activated prior to startup Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated. Redo the startup procedure by holding No responds when Improper startup procedure up to 2.0 seconds and then release.
8. System Specifications Frequency Range : 433 ~ 434 MHz Number of Channels : 62 channels Channel Spacing : 25 KHz Modulation : Digital Frequency Modulation based on Manchester Code, 20bit address, 32bit CRC Parity Check and Hamming Code.
9. Spare Parts 1. Transmitting Module (433/434MHz) TRB 01 2. Encoder Board (complete with push buttons) ENB 05 3. I-CHIP (complete) ICP 01 4. Receiving Module RVB 01 5. Decoder Module DEB 02 6. Receiver Relay Board RLB 05 7. AC Line Filter Board LFB 01 8. Power Transformer AC 110~120V/220~240V/380~410V/440~460V PTF 01 AC 24V/42V/48V PTF 02 DC 12V/24V PTF 03 9. Transmitter Top Casing TTC 02 10. Transmitter Bottom Casing TBC 02 11. Transmitter Battery Cover TBC 04 12.
Memo Page 36
