PADDLE CONTROLLER OPERATION & MAINTENANCE INSTRUCTIONS CUSTOMER: MODEL NUMBER: SERIAL NUMBER: FREQUENCY ASSIGNMENT: ADDRESS ASSIGNMENT: MANUAL P/N: 68C-Paddle Rev.
PADDLE CONTROLLER OPERATION & MAINTENANCE INSTRUCTIONS IMPORTANT NOTICES Your new paddle controller has been pre-configured to operate on a specific frequency before leaving our factory which cannot be changed by yourselves. We have assigned this frequency based upon our existing records of control equipment previously supplied to yourselves.
OPERATION & MAINTENANCE INSTRUCTIONS IMPORTANT NOTICES, continued. Your Remote Control System may include an optional ‘Reset’ function that must be activated from the remote controller before motion control outputs are enabled on the controlled machine. You are advised to review the customized drawing package provided with your Portable Remote Control (PRC) system to see if this optional safety feature applies to your PRC system.
List of Technical Abbreviations The following abbreviations (acronyms) are frequently used in CATTRON-THEIMEG™ Radio Remote Control Technology and may be used in this manual: AC Alternating Current LED Light Emitting Diode ASO Automatic Safety Override MK Metal Keypad BCH Bose-ChaudhuriHocquenghem (data error detection routines) ML Mainline CMOS Complimentary Metal Oxide Semiconductor NEMA National Electrical Manufacturer’s Association CS Crane Specific Ni-Cad Nickel Cadmium DC Direct C
Introduction How to use this Manual. This manual contains generic operation and maintenance procedures applicable to the entire series of CATTRON-THEIMEG™ Radio Remote Paddle Controllers. Because no two Paddle Controllers or Portable Remote Control (PRC) applications are exactly the same, a General Operating Procedure is included in Section 3. This procedure is followed by Operator Instructions for the two most popular control applications: (1) Cranes, and (2) Locomotives.
Safety Summary WARNING and CAUTION statements have been strategically placed throughout all text prior to operating or maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING), or equipment and property (CAUTION). A WARNING and CAUTION will apply each time the related step is repeated. Before starting any task, the WARNINGS or CAUTIONS included in the text for the task shall be reviewed and understood.
WARNINGS, continued. WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNINGS: UNCODED ADDRESS PLUG(S) SHALL BE PROGRAMMED WITH THE SAME ADDRESS CODE AS SET IN THE TARGET RECEIVER/DECODER.
WARNINGS, continued. WARNINGS: ALL TRACKED EQUIPMENT (i.e. LOCOMOTIVES) MUST HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONFIGURED SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL SET THE THROTTLE TO IDLE, DISCONNECT THE GENERATOR FIELD, AND SET THE INDEPENDENT BRAKE. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
WARNINGS, continued. WARNING: DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST TIME A FUNCTION SWITCH IS ACTIVATED. CONSEQUENTLY, SPECIAL CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS EQUIPPED WITH A PARKING BRAKE THAT IS CONFIGURED TO ENGAGE WHEN THE MAINLINE CONTACTOR DE-ENERGIZES.
Safety Summary, continued GENERAL. The following are general safety precautions that are not related to any specific procedure and therefore do not appear elsewhere in this manual. These are general safety precautions and instructions that people must understand and apply during many phases of operation and maintenance to ensure personal safety and health and the protection of your company property. KEEP AWAY FROM LIVE CIRCUITS. Maintenance personnel must observe all safety requirements at all times.
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Table of Contents Front Matter: Important Notices ............................................................................................................ i List of Technical Abbreviations .................................................................................... iii How to use this Manual ................................................................................................ iv Safety Summary ............................................................................................
Section 3 – Operating Instructions, continued: Battery Packs and Battery Pack Charging ................................................................ Battery Pack Replacement ............................................................................ Battery Pack Conditioning/Charging – Ni-Cad Battery packs only ............. Pre-Programmed Frequency Selection ..................................................................... Pre-Programmed Option Selection ............................................
Section 1 – Product Data & Specifications Introduction. The CATTRON-THEIMEG™ Paddle Controller has a unique shape and style that provide the equipment operator with a controller that is extremely durable, convenient, and easy to operate. Designed specifically for heavy duty in harsh working environments, the controller is ideally suitable for both indoor and outdoor remote control applications within the steel, glass, automotive, shipping, mining, distribution, and railroad industries.
Notable Performance and Safety Features. POWER ON SELF TEST (POST) DIAGNOSTICS - When the operator first turns the power switch on, a sophisticated self-test routine tests the microcomputer and all function switch inputs to detect unwanted commands in the system. All lever style switches are tested for neutral at this time. A small speaker beeps twice when the test has been completed satisfactorily. TRANSMIT/BATTERY CHARGE INDICATOR - The low battery detection circuit is a two stage design.
Notable Performance and Safety Features, continued. LEVER GUARD BAR (optional) – When additional lever switch protection against physical damage is required, this fixed bar extends upwards from both ends and across the front of the controller. INTERNAL TILT SWITCH – If the controller is tilted in any axis beyond 60 degrees of upright for longer than the programmed time (typically 3 seconds), a programmable function is sent automatically.
Frequently Asked Questions, continued. Table 1-1. Paddle Controller, questions and answers QUESTION ANSWER RELIABILITY Durable case material? YES - Aluminum with epoxy coating. ‘Neoprene’ rubber bumper ends Enclosure water/dust/oil resistant? YES - NEMA 12 (IP-65) Long motion switch operating life? YES – Greater than 1 million operations Reliable switch wiring? YES – Switches are potentiometers, wired using silver coated multi-strand teflon coated wire and gold plated connectors.
Frequently Asked Questions, continued. Table 1-1. Paddle Controller, questions and answers QUESTION ANSWER OPERATIONAL FEATURES FCC approval for narrow band licensed operation in new 12.5 kHz channels? YES - Approved for both non-licensed and licensed services with ongoing designs for changing USA and Canadian rules and regulations. Transmitters can be assigned 12.5kHz channels.
Standard Specifications, continued. Number of Motor Functions: 3 (3-Paddle), 4 (4-Paddle), 5 (5-Paddle), or 6 (6-Paddle). Additional motor functions are available – contact your CATTRON-THEIMEG™ sales representative for details Auxiliary Functions: 15 digital ON/OFF. Push To Operate Safety Bar: Standard. Lever Guard Bar: Optional – extends from both sides across the front above the levers. Labeling: Mylar, Multi-layer, Large Keylock Switch: Optional (Power ON/OFF).
Overview – CATTRON-THEIMEG™ Radio Remote Control Systems Figure 1-1 below shows a simplified block diagram of a typical CATTRON-THEIMEG™ radio remote control system. Refer to this figure and the following paragraphs for a functional description of the remote control system. The target receiver/decoder is controlled by the Paddle Controller, which sends signals to the receiver/decoder using a UHF radio link. The signal is picked up by the antenna and passed on to the receiver.
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Section 2 – Safety Information Safety Considerations. CATTRON-THEIMEG™ believes that to safely operate any remotely controlled equipment, the overall system needs to be configured so that movement or operation of the equipment will take place only when the device is commanded to move or operate. For example, overhead cranes or locomotives must be equipped with a braking system that can only be released when an electrical signal is sent to the motor.
Safety & Security Features, continued. Data Error Checking: All communications from the controller to the receiver/decoder contain error-checking information (BCH data error detection routines). The entire data command packet must pass error detection tests before being processed. Push-To-Operate (PTO) Bar: This easily activated switch bar must be released when power is turned on, then pressed and held to enable the motion switch functions.
Typical method of operation (continued). Figure 2-1. Operate (OPR) contact wiring MANUAL DISCONNECT ML L1 L2 LL2 L3 LL3 TO MOTOR 120V R OPR LL1 C ML 5.0A EXISTING CONTROLS RECEIVER/DECODER Figure 2-2 below shows the Operate (OPR) relay and optional Reset (RST) relay wired to control a mainline (ML) contactor. This configuration requires the operator to activate the reset function on the controller after he/she has turned the unit on.
Radio Control Operator’s Duties – General Equipment. WARNINGS: WITH THE EXCEPTION OF LOCOMOTIVES, ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE.
Radio Control Operator’s Duties – General Equipment, continued. WARNING: DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST TIME A FUNCTION SWITCH IS ACTIVATED.
Radio Control Operator’s Duties – General Equipment, continued. The following procedures provide general guidelines for radio control operation of equipment and should not be used as a substitute for your plant operating procedures. 1. Before operating equipment, carry out the following: a. Insure the address code and frequency of your paddle controller exactly matches the address code and frequency of the target equipment to be operated.
Radio Control Operator’s Duties – General Equipment, continued. 2. You must report all defective or missing safety equipment, mechanical or electrical defects to your supervisor without delay. Do not continue operation until fully repaired. 3. If anyone is in the path of equipment travel, stop and sound the alarm before proceeding. Do not proceed until the pathway is clear 4. Persons operating this equipment shall not use a limit stop as a utility stopping device. 5.
Radio Control Operator’s Duties – Electrical Overhead Traveling (EOT) Crane. WARNINGS: ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE.
Radio Control Operator’s Duties – EOT Crane, continued. WARNING: DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST TIME A FUNCTION SWITCH IS ACTIVATED.
Radio Control Operator’s Duties – EOT Crane, continued. The following procedures provide general guidelines for radio control operation of an EOT crane and should not be used as a substitute for your plant operating procedures. Please note that a complete set of Recommended Safety Rules for Cranes is provided at the end of this manual. 1. Before lifting any loads, carry out the following: a.
Radio Control Operator’s Duties – EOT Crane, continued. 2. You must report all defective or missing safety equipment, mechanical or electrical defects to your supervisor without delay. Do not continue operation until fully repaired. 3. When raising or lowering a load, proceed slowly and make certain the load is under control. 4. When lifting maximum load, you should test the brakes by raising the load a few inches from the floor.
Radio Control Operator's Duties - Locomotive. WARNINGS: ALL TRACKED EQUIPMENT (i.e. LOCOMOTIVES) MUST HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONFIGURED SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL SET THE THROTTLE TO IDLE, DISCONNECT THE GENERATOR FIELD, AND SET THE INDEPENDENT BRAKE. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
Radio Control Operator's Duties - Locomotive, continued. The following procedures provide general guidelines for radio control operation of a locomotive and should not be used as a substitute for your plant operating procedures. Please note that a complete set of Recommended Safety Rules for Locomotives is provided at the end of this manual. 1. Perform all locomotive pre-departure tests according to the locomotive manufacturer's operation manual.
Radio Control Operator's Duties - Locomotive, continued. d. Check each brake function independently to be sure the locomotive is responding correctly to all brake applications, including emergency stop and release commands. Observe gages in the cab for proper readings and verify that the brake cylinders are moving properly. e. Test train brakes (if equipped). f. Check all auxiliary equipment, such as bell, headlight, sanders, uncouple, etc. 3.
Section 3 – Operating Instructions Controls and Indicators. Each paddle controller has been designed and custom built for a specific remote control application, therefore its operation will differ from model to model. For this reason, it is not possible to describe an individual controller’s switch and indicator configuration in this manual – there are too many variations. However, all paddle controllers incorporate some or all of the controls and indicators identified in Figure 3-1 below.
Controls and Indicators, continued. POWER ON/OFF KEY SWITCH – This key switch prevents unauthorized personnel from operating the control system. When the key switch is set to ‘ON’, internal battery power is applied to an RF encoder/transmitter within the controller and the operator can control all auxiliary (non-motion) functions without pressing the PUSH-TO-OPERATE (PTO) bar. The power ON/OFF key switch controls a mainline magnetic contactor on the machine.
Controls and Indicators, continued. In addition to the ‘Flag’ style lever paddle (illustrated), different style levers and knobs are available – refer to ‘Accessories’ in Section 5 of this manual for details. Finally, some controllers are built with a special two-axis joystick configuration - refer to special operation descriptions and the custom drawing package supplied with your controller for specific information.
Controls and Indicators, continued. Your customized controller and PRRC system drawings will show the exact operation of your control unit. A typical example of TALKBACK would be its use on radio controlled locomotives. On a locomotive there is usually a ‘Christmas Tree’ of four or five lights used as status indicators that is mounted on each side of the locomotive. These lights usually show the operator the status of ‘FORWARD’, ‘REVERSE’, ‘THROTTLE’, ‘BRAKES’, and Remote Control System ‘ON’.
General Operating Procedure. NOTE: Using a Carrying Harness to support the controller will greatly enhance operator comfort. Two harnesses are available, as illustrated below in Figures 3-2 and 3-3. Refer to these illustrations for details and CATTRON-THEIMEG™ Part Numbers. Figure 3-2. Standard carrying harness Standard Carrying Harnesses are available in 2 sizes as follows: CLN-6096 Small to Large CLN-6096XL Extra Large ©10/2002, CATTRON-THEIMEG™ 37.
General Operating Procedure, continued. Figure 3-3. – ‘Low back’ support carrying harness REAR VIEW Shoulder Harness Harness Adjuster Right Hand Side Pull Left Hand Side Pull Press Studs Lower Back and Abdominal Support Carrying Strap Anchor Catches Middle Stay Strap Adjuster The Lower Back and Abdominal Support is a lightweight and comfortable device that acts as a reminder to lift properly. The Side Pulls give you the extra support needed when lifting.
General Operating Procedure, continued. Figure 3-4. Carrying harnesses, assembly and fitting LOW BACK SUPPORT CARRYING HARNESS ONLY 1-1. Place the Low Back Support around the body just below the navel, ensuring the Middle Stay (see Fig 3-3 above) locates in the center of the low back. Stretch the right end across the left and attach firmly. LOW BACK SUPPORT STANDARD AND LOW BACK SUPPORT CARRYING HARNESS ONLY CARRYING HARNESSES 1-2. Loosen elasticized Side Pulls and 1-3.
General Operating Procedure, continued. NOTES: Holding the PTO bar down when power is turned on places the controller in a technical diagnostic mode - refer to Maintenance Instructions (Section 4) for details. The PTO bar must be up when starting the controller or the system will not operate. On some controllers, the side mounted Power ON/OFF Key Switch may be replaced with a front panel mounted, 2-position maintained toggle switch.
General Operating Procedure, continued. 5. Place a convenient and comfortable part of either hand on the PUSH TO OPERATE BAR on top of the controller. This switch must be depressed and maintained before and when any motor or motion command is initiated. WARNING: NEVER DISABLE THE PUSH TO OPERATE (PTO) BAR SWITCH ON YOUR REMOTE CONTROLLER. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH. 6.
TYPICAL CRANE CONTROL FUNCTIONS. In addition to the controls and indicators described at the beginning of this section, some or all the control functions described and illustrated below may be applicable to your crane control application. Unless notified to the contrary, the following Control Functions do not require the PTO Bar to be pressed to enable their operation. Figure 3-5.
TYPICAL CRANE CONTROL FUNCTIONS, continued. 1. ALARM, RESET or ALARM/RESET SWITCH. When this momentary pushbutton switch located in the center of the PTO bar is used as an ALARM, it operates a bell, horn, or other warning device on the crane. When used as a RESET, this switch resets the mainline contactor when it has previously been switched or tripped OFF due to a relay failure or overload, thus allowing power to be supplied to the crane motors.
TYPICAL CRANE CONTROL FUNCTIONS, continued. 6. CRANE SELECT SWITCH - This rotary selector or key switch is used when the controller operates more than one crane. The switch is used to select the desired crane by changing the controller's digital address. If switched while the unit is on, the power is switched off automatically for 10 seconds, then starts up automatically on the new address. All motor and motion control lever switches on the controller must be neutral during this time.
TYPICAL LOCOMOTIVE CONTROL FUNCTIONS. In addition to the controls and indicators described at the beginning of this section, some or all the control functions described and illustrated below may be applicable to your locomotive control application. Unless notified to the contrary, the following Control Functions do not require the PTO Bar to be pressed to enable their operation. Figure 3-6. Locomotive Paddle Controller - Typical Configuration 1.
TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued. 3. DIRECTION SWITCH – this maintained 3-position paddle switch controls ‘FORWARD’ and ‘REVERSE’ functions. If the lever is moved to the ‘NEUT’ (neutral or center) position, direction is disabled. NOTE: A change in the Locomotive direction will not occur until the throttle is moved to idle for at least 3-seconds. Attempting to make a change in direction while the throttle is advanced will cause the throttle to return to idle.
TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued. 8. SAND – This momentary toggle switch applies sand to the rails in the direction of travel when held in the ‘SAND’ position. 9. BELL - Sounds the locomotive bell when set to ‘ON’. This function may be programmed to activate with throttle or direction. 10. HEADLIGHT ‘OFF/DIM/BRIGHT’ – this maintained 3-position switch selects the desired brightness of the headlight in the direction of travel.
TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued. In a typical locomotive ‘pitch and catch’ application, before a pitch can be made, the following conditions must be satisfied: • The Locomotive must be stopped. • Both controllers must be selecting ‘NEUTRAL’. • Both controllers must have the same selection on the ‘INDEPENDENT’ and ‘AUTOMATIC’ brake override switch. • The primary controller operator must depress the ‘OPERATOR RELEASE’ pushbutton.
Switch Diagnostic Mode. In this mode the operator can easily check that all function switches (motion and non-motion) are fully operational. WARNING: ELECTRICAL POWER TO THE TARGET CONTROLLED EQUIPMENT MUST BE COMPLETELY ISOLATED TO PREVENT OPERATION UNDER REMOTE CONTROL IN THE SWITCH DIAGNOSTIC MODE. FAILURE TO COMPLY WITH THE ABOVE WARNING MAY RESULT IN THE UNDESIRED OPERATION OF EQUIPMENT WHICH, IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
Battery Packs and Battery Pack Charging. The following battery pack and charging options are available for your controller and may be ordered from your nearest CATTRON-THEIMEG™ facility identified on the back page of this manual. Alkaline Battery Pack providing 75 hours of continuous operation. This battery pack is not rechargeable and should be discarded when exhausted. Nickel-Cadmium (Ni-Cad) Battery Pack providing approximately 23 hours of continuous operation.
Battery Pack Replacement, continued. 5. Close the battery door and secure by pressing firmly until it snaps into the locked position. 6. Set the controller’s Power ON/OFF Switch(es) to ‘ON’. Observe that the TRANSMIT/LOW BATTERY LED momentarily flashes yellow and two quick beeps are heard. When resuming your remote control operation, observe the TRANSMIT/LOW BATTERY LED as you operate a non-motion function toggle switch such as a horn or light.
Ni-Cad Battery Pack Conditioning/Charging (Figure 3-8). CAUTIONS: (1) CATTRON-THEIMEG™ Battery Conditioners are designed for use with CATTRON-THEIMEG™ Ni-Cad Battery Packs only. (2) Battery Packs must be removed or disconnected from Battery Conditioners within 48-hours of achieving the fully charged state. Failure to comply with these Cautions may result in equipment and/or battery damage and will void our warranty.
Ni-Cad Battery Pack Conditioning/Charging , continued. Figure 3-8. Ni -Cad Battery Pack Conditioning – interconnection details. 1. REAR VIEW - CONNECTING THE VAC ADAPTOR BATTERY CONDITIONER (PART # 70C-0004) MAINS VAC ADAPTOR VAC OUTLET 18 VDC INPUT SOCKET OUTPUT JACK FROM MAINS VAC ADAPTOR 2.
Pre-programmed Frequency Selection. If your Controller will be used to operate more than one crane, locomotive, or controlled machine, or be used as a spare controller for multiple remote control systems, up to sixteen selectable frequencies may have been factory pre-programmed into the controller’s EPROM. To see if this selectable frequency option applies to your controller, refer to Figure 3-7 above and locate the serial tag on the inside of the battery door.
Pre-programmed Frequency Selection, continued. WARNING: MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE, YOU MUST INSURE THE FREQUENCY OF YOUR PADDLE CONTROLLER EXACTLY MATCHES THE FREQUENCY OF THE DESIRED EQUIPMENT TO BE OPERATED. FAILURE TO COMPLY WITH THE ABOVE WARNING MAY RESULT IN THE UNDESIRED OPERATION OF OTHER EQUIPMENT WHICH, IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
Pre-programmed Frequency Selection, continued. Figure 3-9.
Pre-programmed Option Selection. Because each paddle controller has been designed and custom built for a specific remote control application, the OPTION SELECT SWITCH UNIT (refer to Figure 3-9, opposite) may have been preconfigured with one of three discrete programming options. It should be noted that the exact switch configuration will depend upon the firmware selected by your CATTRON-THEIMEG™ Applications Engineer at the time your PRRC system was designed.
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Section 4 – Maintenance Instructions CATTRON-THEIMEG™ Maintenance Philosophy. Our maintenance philosophy is that inoperative Paddle Controllers are returned as complete units to our workshops for repair.
Special RF Test, continued. With PTO Bar switch depressed, setting the ON/OFF KEYSWITCH to ‘ON’ will transmit a continuous beep and the green LED will illuminate continuously. Continually cycling (pressing and releasing) the PTO bar switch three times will initiate the RF diagnostic sequence (the beep will stop). Further PTO bar switch cycling will make the controller transmit the following: CYCLE 4 5 6 7 8 CONTROLLER TRANSMISSION Maximum Low Frequency (a frequency 2.
Troubleshooting Guide. WARNING ELECTRICAL POWER TO THE TARGET CONTROLLED EQUIPMENT MUST BE COMPLETELY ISOLATED TO PREVENT OPERATION UNDER REMOTE CONTROL IN THE SWITCH DIAGNOSTIC MODE. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN THE UNDESIRED OPERATION OF EQUIPMENT WHICH, IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
Corrective maintenance. Corrective maintenance for the Paddle Controller is restricted to replacing the Battery Pack, Address Code Plug, Paddle Levers and, when installed, the External Antenna. Refer to the Replacement Procedures below when removing and replacing items. Having replaced an item, and before placing the Paddle Controller into operational service, carry out a Functional Check as follows: Functional Check. 1. 2. 3. 4. Set the controller’s Power ON/OFF Switch(es) to ‘ON’.
Battery Pack Replacement, continued. Figure 4-1. Battery Pack Replacement. Address Code Plug Replacement. Each CATTRON-THEIMEG™ Paddle Controller is equipped with a code plug. This code plug sets the address of the controller which should always match the address of the target receiver/decoder. When a command is received by the receiver/decoder, the address of the controller sending the signal is checked against the address of the receiver/decoder.
Address Code Plug Replacement, continued. WARNINGS: UNCODED ADDRESS PLUG(S) SHALL BE PROGRAMMED WITH THE SAME ADDRESS CODE AS SET IN THE TARGET RECEIVER/DECODER. IT SHOULD BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ SHALL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE ARISING FROM DUPLICATED, INCORRECTLY PROGRAMMED OR INCORRECT CODE PLUG USAGE.
Address Code Plug Replacement, continued. 5. Referring to Figure 4-2 below, using a pair of small flat nosed pliers, remove the existing ‘set’ code plug by pulling it straight up and away from its battery compartment location. We recommend you: (1) tag the removed code plug with the serial number of the controller, and (2) deposit the code plug in a safe place under lock and key. Figure 4-2. Code Plug Location.
Address Code Plug Replacement, continued. 6. If the new code plug is blank (unset), set the new address code previously recorded in Step 2. To set the code, pins 2 through 8 must be cut in a specific pattern. Figure 4-3 below shows all possible address codes for the code plug. For example, to set the code plug to Address Code 14, pins 4, and 6 must be cut. DO NOT cut Pins 1, 9 and 10.
Address Code Plug Replacement, continued. 7. Write the newly set address code on the side of the code plug using a permanent marker. 8. Carefully install the new code plug, making sure the spot (Pin 1) is positioned as shown in Figure 4-2, above. 9. Referring to Figure 4-1 above, replace the battery pack in the unit, making sure the contacts on the underside of the battery pack locate with their corresponding pick-up contacts in the battery tray. 10.
External Antenna Replacement, continued. Figure 4-5. External Antenna Replacement.
Section 5 – Replacement Items and Accessories Notable differences between Paddle Controllers will include the quantity, type, and placement of toggle, paddle, and pushbutton switches. For an individual controller’s exact switch and indicator configuration, including quantities and part numbers, you should refer to the schematic drawing originally supplied with the paddle controller.
Section 5, Page 2 ©10/2002, CATTRON-THEIMEG™ 16 14 15 18 19 16 1 17 19 2 27 13 26 3 25 24 23 6 7 11 20 TOGGLE SWITCH ASSEMBLIES (see Table 5-3) 22 21 PUSHBUTTON SWITCH ASSEMBLIES (see Table 5-2) 9 Figure 5-1.
Table 5-3.
Consumable Items and Optional Accessories. Consumable Items and Optional Accessories are listed in Table 5-4 below and illustrated on the following pages. Table 5-4. Consumable Items and Optional Accessories Item Number 1 2 3 4 * * 5 * * * * * * 6 7 8 9 10 11 12 13 CATTRONOrder Item Description THEIMEG™ Quantity Part Number 60C-0023 1 Battery pack, Alkaline, 12.5V, non-rechargeable C-8096 1 Battery pack, Ni-Cad, re-chargeable, 12.
Consumable Items and Optional Accessories, continued.
Consumable Items and Optional Accessories, continued. Item 4 – Part Number CLN-609Series STANDARD CARRYING HARNESS Standard Carrying Harnesses are available in 2 sizes as follows: CLN-6096 CLN-6096XL Small to Large Extra Large 37.
Consumable Items and Optional Accessories, continued.
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Index A G Accessories ..................................... Address code ................................... Applications .................................... Automatic safety override ............... 5-3 2-1 1-3 2-1 General operating procedure .......... 3-5 I Intelligent digital message protocol 2-1 L B Battery Pack Conditioner ...... 3-18, 5-2 Battery door ................................. 3-18 Battery pack conditioning ............ 3-20 Battery pack options ..............
Index S P Safety considerations ................... 2-1 Safety & security features ............ 2-1 Side mounted levers ............... 1-2, 3-2 Standard specifications ................. 1-5 Switches ................................. 3-2, 3-3 Switch diagnostic mode ................ 3-17 Paddle switch placement ................ 1-2 Power On Self Test (POST) ........... 1-2 Power ON/OFF switch ............. 3-1, 3-2 Preventive maintenance ................. 4-2 Push To Operate bar switch ......
RECOMMENDED SAFETY RULES FOR PORTABLE REMOTE CONTROLLED (PRC) CRANES For the purpose of these rules, Portable Remote Control or PRC refers to either Radio Frequency (RF) or Infra-Red (IR) Controls. The information contained herein is based on data gathered from various users of portable remote control crane systems.
2. OPERATOR SAFETY BASICS. Before starting your shift as the crane operator, you should make sure the crane has a current inspection certificate and that qualified personnel have carried out the following inspections and checks. If any item below does not pass inspection, you should notify your supervisor immediately. In many cases, the problem will need to be fixed before you are allowed to operate the crane.
2-3. Operational Safety Check. As a crane operator, you should satisfy yourself of the following. If any item below does not meet the checklist criteria, you shall immediately notify your supervisor. In many cases, the problem will need to be fixed before you are allowed to operate the crane. Remember that the person now reading these instructions is primarily responsible for his or her own health and safety! • Horns, buzzers and all other warning devices shall be in working order.
5. THE OPERATING AREA FOR THE REMOTE CONTROLLED CRANE. • • 6. Unobstructed aisles between equipment, stock, etc. shall be maintained for the PRC crane operator's movement. These aisles should be a minimum of 3 feet wide (1m) or per local regulations. PRC crane operators shall always position themselves in a safe location with the best view of the crane they are controlling and never operate the crane blindly.
7. OPERATING THE REMOTE CONTROLLED CRANE. • All crane limit switches shall be checked at the beginning of each turn or when a new operator takes control of the crane. While checking the limit switches, the hoist shall be centered over an area free of personnel and equipment so that if the limit switches fail, and the hook and block assembly falls, no one will be injured and no equipment will be damaged. • The limit switches shall never be used as a regular stopping devices.
7. OPERATING THE REMOTE CONTROLLED CRANE, continued. • • • • • • • • All loose material or parts shall be removed from the load before starting the lift. Such material can fall and injure people below. The PRC crane operator shall hoist lifts high enough to clear all apparatus and workers below the crane. Plugging shall not be used as a regular means of stopping the crane and should be used for emergency stops only.
9. ON BOARD THE REMOTE CONTROLLED CRANE, continued. • • • • • • • 10. Warning signs shall be placed on the floor beneath the crane or suspended from the crane indicating the crane is being serviced. If any work to be done on the crane is carried out in locations unprotected by standard handrails, safety belts shall be worn by all crew members working in such unprotected locations. All tools and equipment shall be moved onto the crane by the use of hand lines.
10. REMOTE CONTROLLED CRANE UNDER REPAIR, continued. • When there is a runway adjacent to the runway on which the crane is being repaired, and if any hazard exists involving repairmen, red lights shall be placed in clear view of persons traveling on the adjacent runway to indicate the restricted travel zone. It is desirable that such red lights be located a minimum of 20 ft. (approx. 6.1 m) from the crane under repair.
11. THE CONDITION OF THE REMOTE CONTROLLED CRANE, continued. • Condition and security of trolley and bridge rail end-stops (missing or damaged from impact). • Condition of all limit switches. • Conditions of controls (electrical or mechanical defects that may lead to faulty operation). • Condition of electric motors (carbon dust around inspection covers indicate worn brushes). • Condition of gears (grinding or squealing may mean a lack of lubrication or foreign materials in gear teeth).
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RECOMMENDED SAFETY RULES FOR PORTABLE RADIO REMOTE CONTROLLED (PRRC) LOCOMOTIVES The information contained herein is based on data gathered from various users of portable radio remote control locomotive systems. We emphasize that the recommendations contained herein are not intended to supersede the rules or regulations of our customers, or the rules and regulations of any applicable local, state, or federal government organizations.
2. OPERATOR SAFETY BASICS. Before starting your shift as the locomotive operator, you should make sure the locomotive has a current inspection certificate and that qualified personnel have carried out the following inspections and checks. If any item below does not pass inspection, you should notify your supervisor immediately. In many cases, the problem will need to be fixed before you are allowed to operate the locomotive.
4. TRAINING CHECKLIST FOR OPERATORS OF REMOTE CONTROLLED LOCOMOTIVES.
6. PRE-DEPARTURE CHECKS UNDER MANUAL CONTROL, continued. • Perform all locomotive pre-departure tests according to the locomotive manufacturer's operation manual. Do not proceed unless the locomotive is operating satisfactorily according to the manufacturer's instructions. • All non-motion control functions (Horn, headlight, bell, sanders, uncouple, etc.) shall be checked at the beginning of each turn or when a new operator takes control of the locomotive.
8. TRANSFERRING THE LOCOMOTIVE TO RADIO REMOTE CONTROL. • Both the operator and management shall insure the correct controller to operate the locomotive is identified and selected. • Both the operator and management shall insure that any spare equipment capable of locomotive control is completely isolated and stored under lock and key.
9. PRE-DEPARTURE CHECKS UNDER RADIO REMOTE CONTROL, continued. • • • • • • • • 10. Move direction lever on remote controller to center ‘NEUTRAL’ position. ‘NEUTRAL’ should be selected as indicated by both amber and clear lights extinguished. With independent brakes released (PTO must be depressed and maintained) and a direction selected, advance THROTTLE lever on remote controller to first ‘step’. The green external locomotive lights (if equipped) should illuminate and the locomotive should move.
10. OPERATING THE REMOTE CONTROLLED LOCOMOTIVE, continued. • If gloves are not required for safety reasons, they shall not be used when operating the portable remote controller. • PRRC operators shall not use a STOP switch, VIGILANCE switch or Push-to-Operate bar as a utility stopping device. • If PRRC locomotive operators are asked to do something they believe unsafe, they shall contact their supervisor for advice.
12. ON BOARD THE REMOTE CONTROLLED LOCOMOTIVE (MAINTENANCE CREW). • Headroom is at a minimum in some locomotive cabs and on some engine walkways. Caution shall be exercised by all people on board such locomotives. Hard hats shall be worn at all times. • If the maintenance crew consists of more than one person, one person shall be designated as the crew leader. • The leader shall mark all locomotives that have been pre-positioned for maintenance with a blue flag.
13. REMOTE CONTROLLED LOCOMOTIVE UNDER REPAIR, continued. • When it is impossible to use derailers for protection, red lights shall be placed in clear view of other persons operating locomotives on the same or adjacent tracks to indicate the restricted travel zone. It is desirable that such red lights be located a minimum of 100 feet (approx. 30.5 m) from the locomotive under repair.
14. THE CONDITION OF THE REMOTE CONTROLLED LOCOMOTIVE. It is recommended that a written report be sent to your supervisor whenever you detect any condition that makes the locomotive unsafe. Many plants supply printed forms for this purpose. The radio control locomotive operator should fill out these forms and turn them in at the end of each shift.
United States Cattron-Theimeg Inc. 58 West Shenango Street Sharpsville, PA 16150-1198 Phone: (724) 962-3571 Fax: (724) 962-4310 e-mail: mail@cattron.com Canada Cattron-Theimeg Canada Ltd. 150 Armstrong Avenue, Units 5 & 6 Georgetown, Ontario L7G 5G8 Phone: (905) 873-9440 Fax: (905) 873-9449 e-mail: salescdn@cattron.com United Kingdom Cattron-Theimeg (UK) Ltd.
