ARC FLEX 12EX User manual

FLEX12EX
User’s Manual

Page 1
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) 5
2. InternalIllustration 6
B. Receiver Unit
1. ExternalIllustration 7
2. InternalIllustration 8
4. Function Settings
A. Transmitter Handset
1. System Channel Settings 9
2. Continuous Transmitting Time Adjustment 9
3. Push Button Functions with LED Displays
a. Standard Push Button Configuration (Transmitter Toggle) 10
b. Standard Push Button Configuration (A/B Selector) 11~13
c. Inline Push Button Configuration (Transmitter Toggle) 14
d. Inline Push Button Configuration (A/B Selector) 15~17
4. Channel Change via Push Buttons 18
5. Program4-digitSecurityCode 19
6. I-CHIP 20
B. Receiver Unit
1. SystemChannelSettings 21
2. Output Relay Configurations
a.OutputRelayTypes 22
b. Output Relay Action at 2nd Speed 22~23
c.ON/OFFPushButtonFunction 23
d. Magnet ON/OFF Push Button Function 24
e.BrakeFunction 24
f.ExternalWarningFunction 24
g.MomentaryContact 24
h.ToggledContact 24
i. 3rd SpeedPushButtonFunction 24

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j. Auxiliary STOP Push Button Function 25
k.Pitch&CatchFunction 25
3. Receiver Auto-Scanning Settings 25
4. Dip-switch Settings
a. Interlocked Functions 26
b. Non-interlocked Functions 27
5. Jumpers Settings 28
6.I-CHIPProgrammingPort 29
7. Voltage Settings 29
5. SystemChannelsTable 30
6. Receiver Installation
A.OutputRelayContactDiagram 31
B.Pre-InstallationPrecautions 32
C. Step-By-StepInstallation 32~33
D. SystemTesting 33
7. Operating Procedure
A. Transmitter Operation
1. General Operating Procedure 34~35
2. A/B Selector Push Button Operating Procedure 35
3. 3rd Speed Push Button Operating Procedure 35
4. Pitch & Catch Operating Procedure 36
5. Automatic Channel Scanning Operating Procedure 36
6. Changing Transmitter Batteries 36
B. Status Light Indicators & Warnings
1. Transmitter STATUS Light Indication 37
2. Receiver STATUS Light Indication 38
3. Receiver SQ Light Indication 38
4. Receiver POWER Light Indication 38
5. Receiver COM Light Indication 38
C. TroubleShootingTips 39
8. SystemSpecifications 40
9. SpareParts 41
10. EU Declaration of Conformity 42

Page 3
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).

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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 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.

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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 15. Strap Ring
2. Removable 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. Approval Information
7. Push Button #10 14. Push Button #11

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2. Internal Illustration
(Fig.03) (Fig.04)
1.EncoderBoard 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.Function LED Displays

Page 7
B. RECEIVER UNIT
1. External Illustration
(Fig.05)
1. Shock Mount 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. Cord Grip
5.SQLEDDisplay

Page 8
2. Internal Illustration
(Fig. 06)
1. AC Line Filter 4. Decoder Module
2. Power Transformer 5. Output Relay Board
3. Receiving Module

Page 9
71423 56 8
CHANNEL
71 423 56 8
41 23 65 78
41 2 3 65 78
4. Function Settings
A. TRANSMITTER HANDSET
1. System Channel Settings
(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 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) 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 TimeAdjustment
After the push button is released the transmitter will continue to
(Type 1) →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.
After the push button is released the transmitter will continue to
transmit neutral signals to the receiver for up to three (3) minutes.
(Type 2) →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.

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LED 1LED 2
LED 3
LED 4
52134 867
FUNCTION
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.
(Fig.09)
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

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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)

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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)

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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)

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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

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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 Normal Normal Normal
78 01110100 B/1&2 Normal Normal Normal
79 01110101 C/1&2 Normal Normal Normal
80 01110110 D/1&2 Normal Normal Normal
81 00110011 Normal A/3&4 Normal Normal
82 00110100 Normal B/3&4 Normal Normal
83 00110101 Normal C/3&4 Normal Normal
84 00110110 Normal D/3&4 Normal Normal
85 01110111 A/1&2 A/3&4 Normal Normal
86 01111000 A/1&2 B/3&4 Normal Normal
87 01111001 A/1&2 C/3&4 Normal Normal
88 01111010 A/1&2 D/3&4 Normal Normal
89 01111011 B/1&2 B/3&4 Normal Normal
90 01111100 B/1&2 C/3&4 Normal Normal
91 01111101 B/1&2 D/3&4 Normal Normal
92 01111110 C/1&2 C/3&4 Normal Normal
93 01111111 C/1&2 D/3&4 Normal Normal
94 10000000 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)

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DIP PB9 PB10 PB11 PB12
95 10000001 Normal A/1&2 Normal Normal
96 10000010 Normal B/1&2 Normal Normal
97 10000011 Normal C/1&2 Normal Normal
98 10000100 Normal D/1&2 Normal Normal
99 01000101 Normal Normal A/3&4 Normal
100 01000110 Normal Normal B/3&4 Normal
101 01000111 Normal Normal C/3&4 Normal
102 01001000 Normal Normal D/3&4 Normal
103 10000101 Normal A/1&2 A/3&4 Normal
104 10000110 Normal A/1&2 B/3&4 Normal
105 10000111 Normal A/1&2 C/3&4 Normal
106 10001000 Normal A/1&2 D/3&4 Normal
107 10001001 Normal B/1&2 B/3&4 Normal
108 10001010 Normal B/1&2 C/3&4 Normal
109 10001011 Normal B/1&2 D/3&4 Normal
110 10001100 Normal C/1&2 C/3&4 Normal
111 10001101 Normal C/1&2 D/3&4 Normal
112 10001110 Normal D/1&2 D/3&4 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)

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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
122 10010100 Normal Normal A/1&2 B/3&4
123 10010101 Normal Normal A/1&2 C/3&4
124 10010110 Normal Normal A/1&2 D/3&4
125 10010111 Normal Normal B/1&2 B/3&4
126 10011000 Normal Normal B/1&2 C/3&4
127 10011001 Normal Normal B/1&2 D/3&4
128 10011010 Normal Normal C/1&2 C/3&4
129 10011011 Normal Normal C/1&2 D/3&4
130 10011100 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)

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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.

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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.