T245 Control System Installation and Operations Manual DMAN-2053-01 Issue 5 November 27, 2001 2001 OMNEX Control Systems Inc. All rights reserved.
T245 Control System Manual OMNEX Control Systems, Inc. #74 – 1833 Coast Meridian Road, Port Coquitlam, B.C. Canada V3C 6G5 Telephone: (604) 944-9247 Fax: (604) 944-9267 http://www.omnexcontrols.
T245 Control System Manual Revision History Issue 04 05 Description Pages Revision history added, T247 Hoffman box added to Part Numbers Added Throttle Enable O11, changed operation of Hydrosync shift Deleted obsolete part numbers iii iii, 2 10, 17 1
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T245 Control System Manual Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. Introduction..........................................................................................................................1 1.1. Part Numbers ...........................................................................................................1 Physical Installation .............................................................................................................3 2.1. Receiver/Controller........................
T245 Control System Manual Digger Transmission Type.....................................................................................29 Bucket/Pole-Claw Speed Ratio..............................................................................29 10. Warranty .................................................................................................................................
T245 Control System Manual 1. Introduction The T45 Control System consists of a custom Receiver/Controller (grey box), an optional T245 Radio Transmitter and/or an optional T247 Cable Remote. An interface is also provided for an optional user-supplied Emergency Override Panel. The main components of the Receiver/Controller are an R1300+ (TPCB-1225-10) circuit board, an S20 (TPCB-1458-03) board, and a DEX-900 radio receiver. The Receiver/Controller’s software is custom-designed for many applications.
T245 Control System Manual 1. Introduction The T45 Control System consists of a custom Receiver/Controller (grey box), an optional T245 Radio Transmitter and/or an optional T247 Cable Remote. An interface is also provided for an optional user-supplied Emergency Override Panel. The main components of the Receiver/Controller are an R1300+ (TPCB-1225-10) circuit board, an S20 (TPCB-1458-03) board, and a DEX-900 radio receiver. The Receiver/Controller’s software is custom-designed for many applications.
T245 Control System Manual 2. Physical Installation 2.1. Receiver/Controller The Receiver/Controller 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.
T245 Control System Manual Figure 2 Antenna Assembly 2.3. Platform Holster Magnet The magnet which indicates to the T245 Radio Transmitter that it is in the platform holster should be mounted with the plastic face up, towards the T245. The drawing below is an internal view of the T245 bottom half, indicating where the magnetic switch is. 4 3 2 1 REVISIONS REV DATE: 1 SWITCH , MAGNATIC REED (P/N: SX-MPS9WGN) INSTALLATION INSTRUCTION. A D 2.200 APPROVED: ECO 05-12-99 DESCRIPTION: T45 Bot.
T245 Control System Manual 3. Considerations for Electrowelding The electronics in the T245 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.
T245 Control System Manual 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.
T245 Control System Manual Function Wire # 54-pin (32A10P) M.S.
T245 Control System Manual Function Wire # 54-pin (32A10P) M.S. Pin Board References Lift Cylinder Piston-Side Pressure Sensor Input (0 PSI = 0.5V, 3000 PSI = 4.5V) 10 u J3 pin 4 (R1300) Lift Cylinder Rod-Side Pressure Sensor Input (0 PSI = 0.5V, 3000 PSI = 4.
T245 Control System Manual To control the engine throttle, use pin e for electronic throttles which take pulsewidth modulated signals (such as Caterpillar ECUs)†, or wire pins b and c to directioncontrol relays for motor-driven throttles. The Switch Inputs (pins m, n, p and q) are best switched to the +5V Power supplied from pin r, although they will work fine if switched to +12V. The +5V from pin r is preferred because it is already protected against short circuits. Do not feed +12V back into pin r.
T245 Control System Manual Function Wire # 16-pin (24-5S) M.S. Pin Board References Override Panel Upper Boom RETRACT 17 P J10 pin 7 (R1300) Override Panel Lower Boom LOWER 8 R J10 pin 8 (R1300) Override Panel Lower Boom RAISE 7 S J10 pin 9 (R1300) In systems which include a T247 or T47 Cable Remote, the 16-pin connector is used for connection to the Cable Remote.
T245 Control System Manual 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.
T245 Control System Manual 6. Setting Up the Radio Receiver If you have purchased the optional T245/T45 Radio Transmitter, 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 banks of configuration switches (see Figure 4) on the front of the DEX-900 or REX-900 Radio Receiver (mounted to the S20 Board inside the enclosure lid). 1 8 9 16 1 8 9 16 Figure 4 Radio Receivers 6.1.
T245 Control System Manual 6.2. No-Link Data Mode The third bank of switches (“MODE” 1 through 8) on the DEX-900 and REX-900 is used to select various features on the radio receiver. For the Versalift Receiver/Controller, only position 5 should be ON. This sets the DEX-900 or REX-900 to clear all its output data whenever there is no link or signal from the Radio Transmitter of the right ID. 6.3.
T245 Control System Manual 7. Operations This chapter briefly describes how to operate the T245 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.
T245 Control System Manual 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 STOP light is flashing slowly, press the EMERGENCY STOP STOP light is flashing quickly, release the EMERGENCY STOP button. If the 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.
T245 Control System Manual 7.2.3. Tilt Failsafe The transmitter is equipped with a tilt sensor which automatically engages the EMERGENCY STOP if the transmitter is tipped more than 90° from its normal horizontal operating position. This is a failsafe mechanism that protects the operator in case he or she falls or is struck by the machine itself. To resume operation from a tilt condition, press and release the EMERGENCY STOP button after righting the transmitter. 7.2.4.
T245 Control System Manual 7.2.6. Transmitter Light Summary The following table describes all the conditions indicated by various states of the three transmitter lights. Note that the transmitter performs some self-diagnostics, and can indicate joystick and radio failures in addition to the “usual” operating status.
T245 Control System Manual Legend (Right Digit) Information Shown (Left Three Digits) adjusted and will only appear in Factory Setup mode. Please see 9. Factory Parameters for more information. 1 Boom Extension Switches†: 100 = Upper Boom Extended, 10 = Intermediate Boom Retracted, 1 = Upper Boom Retracted 2 Boom Stow Switches: 100 = Auger Overstow, 10 = Boom Stowed To change between these displays, press the DISPLAY button.
T245 Control System Manual The numeric display in the T247 Cable Remote does not have any distance limitation as in the T45. The display will work as long as the T247’s cable is connected, the T247’s POWER switch is turned on and the EMERGENCY STOP is released. 7.4. Emergency Override Panel If you have not purchased the T247/T47 Cable Remote, you must have an Emergency Override Panel connected in place of the Cable Remote.
T245 Control System Manual 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.
T245 Control System Manual Proportional Output Set-Up Panel Indicator Function 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 7) consisting of three columns of indicator lights, seven push buttons, and a socket for a plug-in “key”.
T245 Control System Manual Output Param 1_ 2_ 3_ 4_ 5_ 6_ Threshold Value Key MAX Start PWM Max PWM Ramp Up + - Ramp Down MIN Store Figure 7 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.
T245 Control System Manual 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. Also, a flashing “Value” light will show the actual function output value.
T245 Control System Manual 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.
T245 Control System Manual 9. Factory Parameters The Control System has a number of “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.
T245 Control System Manual 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.
T245 Control System Manual Parameter Display Type Min. 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 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.
T245 Control System Manual Parameter Display Type Boom Derating Factor, Platform Operation (%) Min. Max. Increm. Default Cannot Go Below Cannot Go Above 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.
T245 Control System Manual 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.
T245 Control System Manual 10. Warranty OMNEX Control Systems Inc. Warrants to the original purchaser that the OMNEX products are free from defects in materials and workmanship under normal use and service for a period of ONE YEAR, parts (EXCLUDING: SWITCHES, CRYSTALS, OR PARTS SUBJECT TO UNAUTHORIZED REPAIR OR MODIFICATION) and labor from the date of delivery as evidenced by a copy of the receipt.
