ARC FLEX6EX Instruction Manual
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ARC FLEX6EX Instruction Manual

Industrial radio remote control systems
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Industrial radio remote control systems
FLEX6EX
/6ES
Instruction Manual

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Summary of Contents for ARC FLEX6EX

  • Page 1 Industrial radio remote control systems FLEX6EX /6ES Instruction Manual...
  • Page 2 Service Information Your New Radio Remote Control System Thank you for your purchase of ARC Flex ES/EX radio remote control system. Without a doubt, our Flex ES/EX system is the ultimate solution for providing precise, undeterred, and safe control of your material.
  • Page 3 It is the responsibility of the owners, users and operators of the ARC Products to know, understand and follow all of these requirements. It is the responsibility of the employer to make its employees aware of all of the above listed requirements and to make certain that all operators are properly trained.

  • Page 4: Table Of Contents

    Table of Contents Page Introduction Radio Controlled Safety 2.1. CRITICAL INSTALLATION CONSIDERATIONS 2.2. GENERAL 2.3. PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES 2.4. SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED EQUIPMENT OPERATORS 2.5. TRANSMITTER UNIT 2.6. PRE-OPERATION TEST 2.7. BATTERIES General System Information 3.1.

  • Page 5: Introduction

    1. Introduction The Flex ES/EX 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 all other material handling equipment where wireless control is preferred.

  • Page 6: Radio Controlled Safety

    2. Radio Controlled Safety WARNINGS and CAUTIONS Throughout this document WARNING and CAUTION statements have been deliberately placed to highlight items critical to the protection of personnel and equipment. WARNING – A warning highlights an essential operating or maintenance procedure, practice, etc. which if not strictly observed, could result in injury or death of personnel, or long term physical hazards.

  • Page 7: Critical Installation Considerations

    2.1. CRITICAL INSTALLATION CONSIDERATIONS WARNING PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT, READ AND DEVELOP AN UNDERSTANDING OF THE CONTENTS OF THIS MANUAL AND THE OPERATION MANUAL OF THE EQUIPMENT OR DEVICE TO WHICH THIS EQUIPMENT WILL BE INTERFACED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

  • Page 8: Safety Information And Recommended Training For Radio Controlled Equipment Operators

    2.4. SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED EQUIPMENT OPERATORS Anyone being trained to operate radio controlled equipment should possess as a minimum the following knowledge and skills before using the radio controlled equipment. The operator should:  have knowledge of hazards pertaining to equipment operation ...

  • Page 9: Transmitter Unit

     change any settings or controls without authorization and proper training  remove or obscure any warning or safety labels or tags  leave any load unattended while lifted  leave power on the radio controlled equipment when the equipment is not in operation ...

  • Page 10: General System Information

    3. General System Information 3.1. Transmitter 3.1.1. External Illustration STOP Button Pushbutton 4 (PB4) Power Key Switch Pushbutton 5 (PB5) Status LED Indicator Pushbutton 6 (PB6) Pushbutton 1 (PB1) TAC* and Inductive Charging Slot Pushbutton 2 (PB2) Battery Cover Screw Pushbutton 3 (PB3) Lanyard and Waist Belt Attachment Slot...

  • Page 11: Receiver

    3.2. Receiver 3.2.1. External Illustration External Antenna Port (optional) Remote Pairing Button COM LED Indicator System Information Status LED Indicator Cord Grip Power LED Indicator Mounting Bracket Output Relay LED Indicators Mounting Bracket Release Infrared Sensors Flex 6ES/EX Instruction Manual September 2016 Page 10 of 37...

  • Page 12: Function Settings

    4. Function Settings 4.1. Transmitter 4.1.1. Transmitter Firmware Version 1) Rotate the power switch key to OFF ( 0 ) position. 2) With the STOP button elevated, press and hold PB1 and PB3 at the same time. 3) Rotate the power switch key to ON ( I ) position. 4) Let go PB1 and PB3 at the same time.
  • Page 13 B. Assigned Channel Scheme (preset system channel) Both transmitter and receiver is assigned with a matching preset channel (channel 01~141). Pitch & Catch, t-type, and multi-receiver configurations must set to assigned channel scheme. 1) Rotate the power switch key to OFF ( 0 ) position. 2) With the STOP button elevated, press and hold PB1 and PB2 at the same time.

  • Page 14: Remote Pairing

    4.1.3. Remote Pairing A. Transmitter-to-Transmitter Pairing: 1) Rotate the power switch key to OFF ( 0 ) position. 2) With the STOP button elevated, press and hold PB1 and PB3 at the same time. 3) Rotate the power switch key to ON ( I ) position. 4) Let go PB1 and PB3 at the same time (entered Remote Pairing mode).

  • Page 15: Transmitter Start Function Settings

    4.1.4. Transmitter Start Function Settings When transmitter goes into sleep mode the system is temporarily deactivated (MAIN relays opened). Execute the START command or press any pushbutton to wake up the system (MAIN relays closed). Dipswitch Function Settings START xxxxxxxxx0 Reactivation Any Button xxxxxxxxx1...

  • Page 16: Infrared Programming

    TAC, relay output status feedback, new and updated functions, and many others. Please contact ARC representative for more details. 4.1.7. Pushbutton Function Settings 1) Rotate the power switch key to OFF ( 0 ) position..
  • Page 17 4.1.7.2. A/B Pushbutton Select with LED Indication There are 4 different types of A/B selector sequence available. Choose one that is most suitable for your application. Refer to section 5.1 output relay connections. Type-A selector sequence : A → B Type-B selector sequence : Off →...

  • Page 18: Transmitter Access Card (Tac) Settings

    4.1.8. Transmitter Access Card (TAC) Settings Follow the instruction below on how to program the TAC into the transmitter. The infrared IR programmer unit is required to complete the programming. Please contact ARC representative for more details. 1) Rotate the power switch key to OFF ( 0 ) position.

  • Page 19: Display Frequency Band

    Please contact ARC representative for more details. 4.1.11. Infrared Function Settings The transmitter is embedded with infrared sensors for infrared start function. These settings require using the infrared IR programmer unit. Please contact ARC representative for more details. 4.1.12. Zero-G Sensor Settings The transmitter is embedded with a Zero-G sensor to guard against any unintended control of the crane or equipment when transmitter is thrown or dropped.

  • Page 20: Receiver

    4.2. Receiver 4.2.1. Receiver Channel Settings Set the receiver channel by configuring the channel dipswitch located on the decoder board, only the first 6 dip positions are used for channel programming. The system channels table on section 4.2.7 illustrates which dipswitch setting corresponds to which channel.
  • Page 21 4.2.2.2. Output Relay Actions at 2 Speed (Flex 6EX only) 3 output relays configuration with Closed/Closed contact at 2 speed F1 (or R1) output relay closed at 1 speed and F1 + F/R2 (or R1 + F/R2) output relays closed at 2 speed.
  • Page 22 (refer to section 4.2.3.1 on how to set to this function). The manufacture preset START + AUX function on section 4.2.2.3 must be disabled when set to this function. Please contact ARC representative on how to disable the START + AUX function.
  • Page 23 → “11” scans 4 channels (channel X… channel X+3)** 1 2 3 * Channel X → channel set on the Channel dipswitch. ** Please contact ARC representative if your application requires scanning more than 4 channels. Flex 6ES/EX Instruction Manual...

  • Page 24: Dipswitch Settings

    Example: If the first 6 dipswitch positions are set to channel 01 (000001), when set to 2-channel scanning (type-2 above) the receiver will only scan channel 01 and 02. 4.2.3. Dipswitch Settings 4.2.3.1. Interlocked Pushbutton Pair Interlocked means any pushbutton pair can not be pressed simultaneously as it will cancel each other out.
  • Page 25 * External warning function requires installing an external warning device such as horn and lights to the K25 Function output relay (refer to section 4.2.2.7). 4.2.3.2. None-Interlocked Pushbutton Pair Non-interlocked setting allows the pushbutton pair be pressed simultaneously. It usually applies to equipment’s auxiliary functions such as lights, horn or buzzer. Each dipswitch on the decoder board corresponds to a pushbutton pair.

  • Page 26: Jumper Settings

    4.2.6. Other Function Output Relays Settings Listed below are other types of functions that can be outputted through the K25 Function output relay via the infrared IR programmer unit. Please contact ARC representative for more details. Function relay closes when receiver voltage is low.
  • Page 27 TOG&E START function + AUX with toggled/latching output. The relay opens when STOP button is pressed down and transmitter power off. Function relay closes when START command is executed and opens only when transmitter power is turned off. Function relay works simultaneously with the receiver MAIN relays. TDM A+B Function relay closes when selector switch is rotated to the A+B position and opens when rotate to A or B positions (tandem monitoring output).

  • Page 29: Receiver Installation

    5. Receiver Installation 5.1. Output Relay Contact Diagrams Flex 6ES (single speed model) Flex 6EX (dual speed model) * For 9~36VDC power supply, wire #1 corresponds to the negative charge (-) and wire #3 corresponds to the positive charge (+), wire #2 is GROUND. * If PB5 (or PB6) is set to A/B pushbutton select function, connect output A to K9 (or K10) and output B to K11 (or K12).

  • Page 30: Pre-Installation Precautions

    5.2. Pre-installation Precautions 1. Make sure the transmitter and receiver are with identical serial number 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 the crane or equipment is working properly prior to installation. 4.
  • Page 31 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 300 mm variable frequency drive may cause radio interference.
  • Page 32 Install Mounting Bracket Type 1 Mounting Bracket Type 2 Remove Mounting Bracket Type 1 Mounting Bracket Type 2 Flex 6ES/EX Instruction Manual September 2016 Page 31 of 37...

  • Page 33: Operating Procedures

    6. Operating Procedures 6.1. General Operation Reset the STOP button located on the top left hand corner of the transmitter by rotating it clockwise or counter clockwise, the button will pop up. Turn on the transmitter power by inserting the power switch key and rotate to ON ( I ) position. →...

  • Page 34: A/B Pushbutton Select Operation

    After 5 or 30 minutes of inactivity (pushbutton not pressed) the receiver MAIN relays are temporarily disconnected (refer to section 4.1.5 Inactivity Timer Settings). The Status LED blinks 3 reds and then shuts off. Press any pushbutton or execute the START command to resume operation (refer to section 4.1.4 Start Function Settings).

  • Page 35: Changing Batteries

    6.5. Changing Batteries Changing transmitter batteries (“AA” alkaline battery x 2) by unscrewing the battery cover located on the backside of the transmitter. During battery installation make sure the batteries are installed correctly, with “+” to “+” charge and “–” to “–” charge. Also make sure the screw is tightened after battery installation to avoid water, moisture, dirt, grease, and other liquid penetration.

  • Page 36: System Status Light Indications

    6.7. System Status Light Indications 6.7.1. Transmitter Status Indications Type Display Type Indication Voltage below 1.8V at initial power on or Constant red during operation Voltage below 1.75V during operation 3 red blinks and then off (receiver MAIN relays shut off) Voltage below 1.85V during operation 1 red blink followed by a 2-second pause...

  • Page 37: Receiver Status Indications

    6.7.2. Receiver Status Indications Type Display Type (Green & Red) Indication Fast green blinks Decoding in process Slow green blinks Decoding on standby 2 red blinks Receiver MAIN relays jammed or defective 3 red blinks Decoding processors defective 4 red blinks Receiving RF board defective Fast red blinks Incorrect transmitter serial number...

  • Page 38: General Specifications

    7. General Specifications Frequency Range 433MHz ~ 440MHz 141 channels Number of Channels Channel Spacing 50 KHz Modulation Digital Frequency Modulation based on Manchester Code, 20bit address, 32bit CRC and Hamming Code. Encoder & Decoder Microprocessor-controlled Transmitting Range ＞100 Meters (300 feet) Hamming Distance ＞6 Frequency Control...

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Flex6es

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