ARC FLEX User Manual

FLEX

User’s Manual

1

Table of Contents

Page

1. Introduction 2

2. Radio Controlled Safety 3

3. General System Information

A. Transmitter Handset

1. External Illustration 4

2. Internal Illustration 5

B. Receiver Unit

1. External Illustration 6

2. Internal Illustration 7

4. Function Settings

A. Transmitter Handset

1. System Channel Settings 8

2. Pushbutton Functions with LED Display Settings 9~13

B. Receiver Unit

1. System Channel Settings 13

2. Output Relay Configurations 14~15

3. Dip-switch Settings 16~17

4. Jumpers Settings 18

5. System Channels Table 19

6. Receiver Installation

A. Output Relay Contact Diagrams 20
B. Receiver Mounting

1. Pre-installation Precautions 21

2. Step-by-Step Installation 21~22

3. System Testing 22

7. Operating Procedure

A. Transmitter Operation 23
B. Status Light Indicators & Warnings

1. Transmitter STATUS Light Indication 24

2. Receiver STATUS Light Indication 25

3. Receiver SQ Light Indication 25

4. Receiver Power Light Indication 25

5. Receiver COM Light Indication 25

C. Trouble Shooting Tips 26

8. System Specification 27

9. Spare Parts 28

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1. Introduction

The ARC 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 standa rd-equipped

accessories include transmitter waist belt, “AA” batteries, compass direction decal sheet and user’s manual.

List of notable features include:

* 62 user-adjustable channels – no more fixed channels and fragile quartz crystals to break.

* Over one million sets of unique ID codes (20-bit) – unlike many other radio control systems on the

market, the FLEX system never repeats ID codes.

* Advanced microprocessor controls with 32-bit CRC and Hamming Codes programming – ultra fast,

safe, precise and error-free encoding and decoding.

* Ultra-durable transmitter push button – good for up to one million press cycles.

* Ultra power-saving transmitter – requires only two “AA” Alkaline or rechargeable batteries

(2000mA or above) for more than 100 hours of continuous operating time between replacements or

recharging.

* Ultra durable nylon and fiberglass composite enclosures – resist breakage from high impacts and

frequent drops ; no more fragile casings to replace.

* 100% water and shock resistant

* Adjustable waist belt for easy carry and operation.

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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 battery status LED on the transmitter for any signs of low battery power.

4. Check the Status LED on the transmitter for any signs of irregularities. Please refer to the

“Transmitter Status Light Indicators & Warnings ” on page 24.

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 power to the crane is removed, the ope rator 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. Even though Flex system is capable of allowing up to four systems with same channel in use

without interfering with one another, it is always a good practice not to use the same RF channel as
any other Flex systems in use within a distance of 200 feet.

10. Never operate a crane or equipment with two identical channel and ID transmitter handsets at the

same time within the same facility.

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3. General System Information

A. TRANSMITTER HANDSET

1. External Illustration

Fig. 01 Fig. 02

1. Emergency Stop Button 8. Push button #12 15. Strap Holder

2. Power Key Switch 9. Push button #1 16. System Information

3. Push button #2 10. Push button #3 17. System Channel

4. Push button #4 11. Push button #5 18. Crane Number

5. Push button #6 12. Push button #7 19. Battery Cover

6. Push button #8 13. Push button #9 20. FCC/CE Information

7. Push button #10 14. Push button #11

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2. Internal Illustration

Fig. 03 Fig. 04

1. Arial Antenna 5 I-CHIP

2. Transmitting Board 6 Function Dip-Switch

3. Status LED Display 7 Channel Dip-Switch

4. Function LED Display

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B. RECEIVER UNIT

1. External Illustration

Fig. 05

1. Shock Absorber 6. COM LED Display

2. External Antenna BNC Jack 7. Output Contact Diagram

3. Power LED Display 8. System Information

4. Status LED Display 9. Cable Gland/ Cord Grip

5. SQ LED Display

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2. Internal Illustration

Fig. 06

1. AC Line Filter 4. Decoder Board

2. Power Transformer 5. Relay Board

3. Receiving Board

8

71 42 3 5 6 8

4. Function Settings

A. TRANSMITTER HANDSET

1. System Channel Settings

Fig. 07

Set the transmitter channel simply by adjusting the channel dip-switch located on the backside of the
transmitter encoder board. The system channel table located on page 19 will tell you which dip setting
correspond to which channel. Do make sure that when you change the channel of the transmitter you
must also cha nge the channel of the receiver as well. The channel on both transmitter and receiver must
be identical in order for the system to work.

Example:

Top slot ? “1”
(Fig. 08 ) Bottom slot ? “0”

The above dip setting would be “100100”, which corresponds to “channel 36” in the system
channels table on page 19.

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

CHANNEL FUNCTION