TIME/Versalift Digger Derrick Control System Installation and Operations Manual Issue 10 March 21, 2000 2000 OMNEX Control Systems Inc. All rights reserved.
Contents 1. Introduction..........................................................................................................................1 1.1. Part Numbers ...........................................................................................................1 2. Physical Mounting................................................................................................................4 3. Considerations for Electrowelding..................................................................
1. Introduction The TIME/Versalift Digger Derrick Control System consists of a custom Controller/Receiver (grey box), an optional T45 Radio Transmitter and/or an optional T47 Cable Remote. An interface is also provided for an optional user-supplied Emergency Override Panel. The main components of the Controller/Receiver are an R1300+ (APCB-1225-10) circuit board, a PWM/V Converter Board, an S20 (APCB1458-xx) board, and a REX-900 radio receiver.
board S20 Board PWM/V Converter Board Radio Transmitter Board REX-900 Radio Receiver TPCB-1458-03 TPCB-1496-05 TPCB-1756-01 ASSY-1190-01 — — — — R2305 Receiver (supports T245, T47 and T247) R1300+ Board, 12V (main board) Firmware (EPROM chip) for R1300+ board S20 Board DEX-900 Radio Receiver ASSY-1732-02 Factory Key for Controller/Receiver ACAB-1355-02 User Key for Controller/Receiver ACAB-1355-01 Shock Mount Kit for Controller/Receiver AKIT-1498-01 Output Cable with 54-pin Connector, 6 feet ACA
T247 Cable Remote UMB Board (long board) Interface Board (small board) Display Board TPCB-1235-01 TPCB-1302-01 TPCB-1736-02 19424-1 — — — Umbilical Cable for T47 or T247, 20 feet Dual-Axis Joystick with Trigger-Style Deadman Button for RIGHT joystick AKIT-9048-01 Dual-Axis Joystick with Trigger-Style Deadman Button for LEFT joystick AKIT-9048-02 Boot Kit for Dual-Axis Joystick AKIT-9033-02 Paddle-Style Joystick AKIT-1610-01 T45/T245 Battery B0001 — Battery Charger, 120VAC B0008 — Battery Ch
2. Physical Mounting The Controller/Receiver should be mounted with the connectors down, and in a location so that the enclosure door may be opened conveniently for access to the inside. Shock mounts must be used to mount the enclosure! Under no circumstances should the enclosure be directly bolted to the machine. Figure 1 below illustrates how the shock mounts should be installed: Figure 1 Enclosure Mounting The Controller/Receiver enclosure is sealed and has a NEMA-4 rating.
3. Considerations for Electrowelding The electronics in the Digger Derrick Control System can be damaged by the high currents and voltages employed in electrowelding. If electrowelding must be performed after the Control System has been installed, observe the following precautions to reduce the risk of damage: • Do not connect the ground clip to a point on the chassis close to the enclosures. • Disconnect the harnesses to the enclosures and sensors at the M.S. connectors.
4. Electrical Connections The Receiver/Controller has two circular M.S. connectors for connection to your chassis wiring. A 54-pin M.S. connector is used for power and function outputs. A 16pin M.S. connector is provided for connection to the T47 Cable Remote or Emergency Override Panel. The following tables specify the assignment of each pin, with corresponding markings on the circuit boards for reference. The wire numbers refer to the old-style Output Cable and not the new Custom Output Harness.
Boom Rotate CW 13 U O2 (S20) Pole Guide/Platform OPEN 12 V O3 (S20) Pole Guide/Platform CLOSE 21 W O4 (S20) Digger Shift HIGH 27 X O5 (S20) Digger Shift LOW 4 Y O6 (S20) Auger LATCH 2 Z D4 (R1300) Auger UNLATCH 20 a D5 (R1300) Throttle UP 31 b D6 (R1300) Throttle DOWN 7 c D7 (R1300) Emergency Power 9 d D3 (R1300) Electronic Throttle Output (0 to 5V) 1 e O9 (S20) via PWM/V Converter Board Hydraulic Tool Valve 43 f D8 (R1300) Upper Boom Extended Switch (N.O.
Lift Cylinder Rod-Side Pressure Sensor Input (0 PSI = 0.5V, 3000 PSI = 4.
T47 Cable Control / Override Panel Connector: Function Wire # 16-pin (24-5S) M.S.
In systems which include a T47 Cable Remote, the 16-pin connector is used for connection to the T47. However, in T45-only systems, a truck-mounted Emergency Override Panel must be provided; use either the old-style Emergency Override Panel Interface Cable or the new Custom Emergency Override Panel Harness to make connections from the 16-pin connector to this Panel. The Emergency Override Panel must provide a normally-closed Emergency-Stop button across pins E and F.
5. Fuses, Configuration Jumpers The R1300+ and S20 circuit boards have a number of fuses and configuration jumpers which must be specific values for operation. 5.1. R1300 Board F2 = 10A F3 = 15A F4 = 1A F5 = (omit) JP1 (MAIN BYPASS) = OFF JP4 (RADIO STATUS) = OFF JP2 (INPUTS 1) = GND JP3 (INPUTS 2) = GND J25/J29/J34 = (no jumper installed) J26 (PWM PWR) jumpered to J22 J28 (OUT PWR) jumpered to J23 J27 (DIGITAL PWR) jumpered to J24 SW1 = (all positions OFF) SW2 = (all positions OFF) 5.2.
6. Setting Up the Radio Receiver If you have purchased the optional Radio Transmitter and Receiver, you will need to verify that the Radio Receiver is set up to respond to your particular Radio Transmitter. This section describes how to set the configuration switches (see Figure 3) on the front of the DEX-900 Radio Receiver (mounted to the S20 Board inside the enclosure lid). Figure 3 Radio Receiver 6.1. Unique Identifier (Radio ID) Each T45 Radio Transmitter is identified by a unique Radio ID.
set switches 1 through 8 to OFF, ON, ON, OFF, OFF, ON, OFF, ON, and switches 9 through 16 to ON, ON, ON, ON, OFF, OFF, OFF, ON. 6.2. No-Link Data Mode The last bank of switches (“MODE”) on the DEX-900 is used to select various features on DEX-900. For the Versalift Controller/Receiver, only position 5 should be ON. This sets the DEX-900 to clear all its output data whenever there is no link or signal from the Radio Transmitter of the right ID. 6.3.
7. Operations This chapter briefly describes how to operate the Digger Derrick Control System. These instructions are intended to give you an understanding of basic operating principles; this is not a complete Operator’s Manual. Once installation has been completed and checked, we recommend that you read this section carefully and operate the system to become accustomed to the controls. 7.1. Receiver/Controller The Receiver/Controller does not contain an on/off switch.
2. The EMERGENCY STOP button test is two-part; the transmitter needs to see both states (pressed and released) of the button before it will allow you to operate. If the STO P light is flashing slowly, press the EMERGENCY STOP STO P button. If the light is flashing quickly, release the EMERGENCY STOP button. When the test is done, the button will be released. 3. The transmitter now checks to ensure that all switches and joysticks are in their “off” or “neutral” positions.
7.2.4. Low Battery Indicator (battery) light is the “low battery” indicator. When the battery voltage The is acceptable, the lamp will be off. If the voltage becomes too low, the lamp will begin to blink and the battery should be recharged, or replaced, as soon as possible. The control system will not become erratic with a low battery; it will simply cease to operate when the voltage falls below the minimum operating level. 7.2.5. Battery Charging and Replacement ® The transmitter is powered by a Makita 9.
$ $ N/A $ $ " " # " N/A N/A N/A " " ! " $/" N/A " $ $ ! N/A # " # " E-Stop Test E-Stop Test Part two Functions not all off on EMERGENCY STOP release All Okay, all functions off All Okay, 1+ functions on Emergency Stop Low Battery Module failure: Joystick Module failure: Radio Press E-STOP Button Release E-STOP Button Set all functions off OK, continue as required OK, continue as required E-STOP Button Pressed Replace/Recharge Battery Cycle Power--if not remedied, call service Cycle Power--if not
7.3. T47 Cable Remote If you have purchased the optional T47 Cable Remote, you may operate the Digger Derrick Control System with all of the electronic safety features afforded with the Radio Transmitter, but via a hardwire (cable). To activate the T47 Cable Remote, release the red Emergency Stop button and switch on the T47’s POWER switch—the control of the machine is now taken away from the Radio Transmitter and given to the T47 Cable Remote. All control functions operate as in the T45 Transmitter.
8. Proportional Drive Adjustments Each proportional valve output can be adjusted to match the characteristics of the individual valve. There are proportional functions which come out of the R1300 circuit board, as well as out of the S20. The proportional outputs from the S20 are numbered O1 through O16, and the proportional outputs from the R1300 are numbered 1+ through 6-; their assigned functions are indicated in the table below.
O11 (S20) Flashing 6+ (not used) O12 (S20) Flashing 6- (not used) O13 (S20) Solid 1 (not used) O14 (S20) Solid 2 (not used) O15 (S20) Solid 3 (not used) O16 (S20) Solid 4 (not used) Built-in to the R1300 is a Set-Up Panel (see Figure 6) consisting of three columns of indicator lights, seven push buttons, and a socket for a plug-in “key”.
( ) $% ! "# &' Figure 6 R1300 Set-Up Panel The Ramp parameters control how fast the output builds up or down to the final value according to a first-order difference equation. The separate Ramp Up and Ramp Down time constants allow you to tune the valve response for smooth, non-jerky actuation.
In order to customize various parameters for the PWM outputs, the configuration panel must be “enabled” by plugging in the Factory Key or User Key (supplied); you will then be in Proportional Drive Setup mode. The display will initially be displaying “Output” 1 +, no “Param” lights will be illuminated, and the “Value” lights will be displaying the Start PWM and Max PWM as solid lights, and the actual function output value as a flashing light.
As you are adjusting any of the parameters, you can “try” the new setting right away by moving the joystick and watching the hydraulic/pneumatic response.
9. Factory Parameters The Digger Derrick Control System has 10 “Factory Parameters” which may be configured to match the model of valves installed in the machine, and to set the load limit. They are called “Factory Parameters” because they are usually set at your factory before the machine is shipped to the end customer.
3. To change or view a particular Factory Parameter, press the up or down Output buttons until you reach the desired parameter (see table below). Note that if you press the up button when you are already at the “top” (parameter 1, solid “1+”), the display will “wrap around” to the last parameter (parameter 48, flashing “6±”). A similar wrap-around happens when you press the down button when you are already at the last parameter. 4.
Parameter Display Type PWM Drive Frequency for R1300 Proportional Outputs 1+/- through 4+/- Solid 1+ Mult.Choice PWM Drive Frequency for R1300 Proportional Outputs 5+/- and 6+/- PWM Drive Frequency for S20 Proportional Outputs O1 through O8 Min. Max. Increm. Default Cannot Go Below Cannot Go Above A = 33 Hz B = 50 Hz C = 80 Hz D = 125 Hz E = 250 Hz A N/A N/A Solid 1- Mult.Choice A = 33 Hz B = 50 Hz C = 80 Hz D = 125 Hz E = 250 Hz A N/A N/A Solid 2+ Mult.
Boom Derating Factor, Platform Operation (%) Solid 4+ Variable 20 Value 150 2 66 N/A N/A Emergency Override Panel Function Speed (%) Solid 4- Variable 5 Value 100 5 25 N/A N/A Auger Shake Speed (%) Solid 5+ Variable 5 Value 100 5 100 N/A N/A Digger Transmission Type Solid 5- Mult.
PWM Drive Frequency Parameters These 4 parameters allow you to use the Receiver/Controller in heterogeneous valve systems. Grouping valves requiring different drive frequencies into separate banks, you can provide each valve with the drive frequency most suited to it. Boom Load Moment Limit This parameter allows you to select from up to five load moment limits, to match the exact model of digger derrick on which you are installing the Control System.
10. Warranty OMNEX Control Systems Inc. (“OMNEX”) warrants, to the original purchaser, that the OMNEX Control System is free from defects in materials and workmanship, subject to normal use and service, for a period of ONE YEAR from the original date of delivery as evidenced by a copy of the sales invoice. This warranty covers parts (excluding crystals, parts subjected to unauthorized repair or modification, and wear and tear on switches, knobs, and joysticks) and labour.
