INSTALLATION AND USERS MANUAL TELEMOTIVE telePilot SERIES TR12 AND TX12 TM R A D IO CONTROL SYSTEM telemotive ® Industrial Controls 175 Wall Street Glendale Heights, IL 60139-1985 Phone: 630-582-1111, Toll Free: 888-687-4400 Website: www.telemotive.
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Table of Contents 1- Service Information...........................................................................................................................2 2- Radio Controlled Safety ....................................................................................................................3 3- General System Information .............................................................................................................9 4- Installation Procedure....................................
Section 1 – Service Information 1-1. Service Information. For questions regarding service or technical information or ordering replacement parts, ask for Telemotive Customer Care. Telemotive’s normal business hours are Monday through Friday 8:00 AM to 5:00 PM Central Standard Time. After hours emergency technical service is available. For new product orders or quotations, ask for Telemotive Sales.
Section 2 – Radio Controlled Safety 2-1. Warnings, Cautions and Notes. 2-2. Critical Installation Considerations. Through out this document WARNING, CAUTION and NOTE statements have been deliberately placed to highlight items critical to the protection of personnel and equipment. WARNING WARNING – A warning highlights a essential operating or maintenance procedure, practice, etc. which if not strictly observed, could result in injury or death of personnel, or long term physical hazards.
Section 2 – Radio Controlled Safety (Continued) Anyone being trained to operate a radio-controlled crane should possess as a minimum the following knowledge and skills before operating the crane: WARNING The operator should have knowledge of hazards peculiar to crane operation. THE DIRECT OUTPUTS OF THIS PRODUCT ARE NOT DESIGNED TO INTERFACE DIRECTLY TO TWO STATE SAFETY CRITICAL MAINTAINED FUNCTIONS, I.E., MAGNETS, VACUUM LIFTS, PUMPS, EMERGENCY EQUIPMENT, ETC.
Section 2 – Radio Controlled Safety (Continued) The bridge and trolley brakes should be tested. On transmitter units equipped with two or more speeds, use the "lowest" speed when testing braking devices. The operator should know cable and hook inspection procedures. The operator should know procedures for testing hoist, trolley, and bridge brakes. When lifting maximum loads, the crane operator should test the hoist brakes by raising the load a few inches from the floor.
Section 2 – Radio Controlled Safety (Continued) If power to the crane is removed, the crane operator should turn the transmitter unit OFF and keep it OFF until power is restored. Make certain all personnel are clear before making a lift. The crane operator should keep all body parts away from the lift and should never be positioned under the lift.
Section 2 – Radio Controlled Safety (Continued) If it is necessary to have the crane control circuits energized, all power circuits for crane movement must be opened prior to energizing the control circuits. When major repairs are to take place, all persons operating other cranes on the same or adjacent runways, if any, must be notified prior to starting repairs. Notification should include the nature of the repair, safeguards provided, and movement limitations while repairs are in progress.
Section 2 – Radio Controlled Safety (Continued) Condition of hoisting cable and hook block (broken strands, clipped sheave wheels, etc.). Condition of warning or signal lights and horns. (burned out or broken). Condition of brakes (hoist, trolley, and bridge). (no bluing, rivets on shoes showing, glazing, etc.). 2-13. Batteries Condition of trolley and rail stops. WARNING Condition of bridge structure. Condition of festoon system.
Section 2 – Radio Controlled Safety (Continued) Do not attempt to charge a damaged battery. Do not attempt to use a battery that is leaking, swollen or corroded. Charger units are not intended for outdoor use. Use only indoors. 2-13.3. Battery Disposal. Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedures.
Section 3 – General System Information Channel Designations: 3-1. General System Information. The Telemotive Radio Control System (system) provides remote control of overhead cranes using radio signals. The system consists of a hand held portable battery operated transmitter unit and a fixed station receiver unit. A unique 16-bit code (Access Code) for each system is preset in every transmitter and receiver.
Section 3 – General System Information (Continued) 3-5. Receiver Unit. The receiver unit consists of a synthesized RF module, built in antenna, integral power supply, microprocessor controlled output motor control and auxiliary function relays and mainline contactor relay. The receiver unit contains circuitry, which matches the frequency and access code of the transmitter.
Section 4 – Installation Procedure 4-3. Antenna Mounting Considerations. 4-1. Pre-Installation Considerations. The antenna is internal and requires no additional mounting. The antenna is at the top of the receiver cabinet and should not be placed near large metal objects that could be close to or cover the top of the box. Allow at least six inches above the top of the box for clearance.
Section 4 – Installation Procedure (Continued) a mounting template are shown on page 29 Figure 4-2. 4. The motor wiring should be in a separate metal conduit from the power wiring, which should also be in metal conduit. 4-8. Receiver Installation. 5. Low voltage wires shall be wired with proper low voltage class wiring procedures. 1. 6. Control wiring as well as antenna wiring shall be in separate conduit and shall be kept as short as possible.
Section 4 – Installation Procedure (Continued) 7. Wiring of the system should now be complete. 8. Stand clear of the crane and apply AC power to receiver unit. Turn switch SW2 OFF (MR relay control) and SW1 ON (main power switch). Check to see if three green LEDs are lit (DS22, DS23 and DS24). If none are lit check AC power, power switch SW1 and fuse. 9. J1 Turn transmitter ON. Check to see if the yellow LED is now lit (DSMR1).
Section 5– Operation ON/OFF Pushbutton ON/OFF E-STOP UP ON/OFF LED Indicator DOWN UP DN E W N S 1 2 NORTH SOUTH AUX 1 EAST WEST 3 E STOP ON OFF E-STOP Figure 5-1. telePilot Pendant and Membrane Transmitters. DN (HST DN and DOWN) – Selects hoist movement in the DOWN direction speed one (first switch position) or speed two (second switch position). For the Slider the HST DN is pressed and the finger is slid to the center (2SP) for 2nd speed.
Section 5 – Operation (Continued) FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. TROLL N is pressed and the finger is slid to the center (2SP) for 2nd speed. The first direction is maintained while the second speed key is held. S (TROLL S and SOUTH) – Selects the appropriate direction of the bridge or trolley (depending how unit is wired at installation) speed one (first switch position) or speed two (second switch position).
Section 5 – Operation (Continued) To replace the batteries, turn transmitter over to access back cover. Twist half moon shaped battery latch to remove cover. Take out old batteries; replace ALL batteries with new cells. For the Membrane Transmitter note battery orientation, batteries in backwards will blow fuse. Replace cover and turn transmitter ON to use. See Section 9. Spare Parts for battery and fuse part numbers.
Section 6 – Wiring on the single and Two-Speed Membrane per their respective diagrams. 6-1. Wiring Diagrams. The following pages in this section have individual wiring diagrams for different crane configurations. Find the appropriate wiring diagram and set the Configuration Switch (SW3 in the receiver) in the appropriate receiver(s) to match the SW3 Receiver Configuration Switch settings shown in the diagram. The location of the Configuration Switch is shown in Figure 8-1. Receiver Layout.
Section 6 – Wiring (Continued) Legend The following is the legend for the wiring diagrams below: # # K# C# An input with the terminal number # matching the connector in the receiver. 6-9. Optional Transfer Configuration. Matching relay contacts An output with the terminal Customer supplied number # matching the con- contactor coil with arc in radio receiver panel nector in the receiver. suppressor in parallel. by number. Figure 6-1. Legend.
Section 6 - Wiring (Continued) TABLE 1 TR12 SINGLE SPEED WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 1 TR12 SINGLE SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(A) TR12 2-SPEED WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(A) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(B) TR12 2-SPEED WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(B) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 1(C) TR12 WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(C) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 1(D) TR12 WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(D) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 1(E) TR12 WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(E) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 1(F) TR12 WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(F) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 1(G) TR12 WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(G) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 1(H) TR12 WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(H) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 1(I) TR12 WIRING DIAGRAM.
Section 6 - Wiring (Continued) TABLE 2(I) TR12 2-SPEED PROGRAMMING DIAGRAM.
Section 7 – Programming 7-1. Programming Access Codes. System “10K” Frequency 0 1 A1 0 1 B1 Receiver Access Code Multibox 1 Tx # Auto Turn Off Auto Alarm 1 0 S3- 1 Switch Conf. H, T, B Timer Main/Aux “Aux” The access code is set at the factory and should not be changed unless absolutely necessary. If you are reprogramming a spare or “Minuteman” transmitter make sure the other transmitter is securely taken out of service.
Section 7 - Programming (Continued) for additional reliability. The two pairs of access code switches are labeled “A1, B1” and “A2, B2”. A1 must match the settings of A2 and B1 must match the settings of B2 or the unit will not work. See Figure 7-2. Access Code Setting. WARNING AFTER CHANGING THE ACCESS CODES ON THE TRANSMITTER, TEST THE UNIT BY TURNING IT ON AND OFF NEAR THE APPROPRIATE RECEIVER.
Section 7 - Programming (Continued) 42
Section 7 - Programming (Continued) 43
Section 8 – Servicing DS19 DS17 DS15 DS14 DS13 DS23 DS22 DS24 RF Receiver Assembly DS21 DS20 DS18 DS16 WAC1 EMS1 +12V 5V DC TP5 AGC TP7 DATA TP6 ANALOG TP2 GND 87654321 Dip Switches DS15 +5V TP1 EPROM +5V 87654321 87654321 B A SW1 ON 87654321 SW3 ON SW2 ON SW4 ON KMR1 TP4 TP3 +12V DS1 JU2 DS2 DS3 DS4 DS5 DS6 DS7 DS8 DS9 JU1 DS10 DS11 SW2 ON K3 1 1 K4 K5 K6 ON DS12 DSMR2 Relays K1 K2 DSMR1 Master Relay K7 K8 K9 K10 K11 K12 K13 SW1 1 GND N 120V MOV’s F1 F2
Section 8 – Servicing (Continued) DS1-DS12 Red Monitors closure of the output relays (K1-K12). Normally ON for a function when that specific function is enabled. The LED will be illuminated when a specific relay has been enabled by the respective command received from the Transmitter Unit. The LED will extinguish, when the command is no longer detected. DS13 Red Monitors the watchdog timer. Normally OFF. The LED will illuminate momentarily when power is applied to or removed from the system.
Section 8 – Servicing (Continued) condition is in effect. An EMS condition may be created when an EMS command is transmitted or when a failure mode is detected by the slave microcomputer. If both DS18 and DS19 are illuminated, a contact monitoring error has been detected. If both DS16 and DS19 are illuminated, the incoming data on the ICC bus has been corrupted. DS20 Red Monitors the OFF command from the Transmitter. LED will flash when an OFF command is being received from the Transmitter Unit.
Section 8 – Servicing (Continued) 8-2. Typical Wave Forms on an Oscilloscope. TP6 ANALOG TP7 DATA TP5 AGC Not Receiving Data Receiving Data Figure 8-2. Receiver Scope Wave Forms. Scope Settings: Sweep – 1 millisecond per division. Sensitivity – TP6 1 volt per division 10X probe. TP7 2 volts per division 10X probe. TP5 1 volt per division 10X probe.
Section 9 – Spare Parts PART NUMBER RECEIVER FW2911-0 E13151-3.
Section 9 – Spare Parts (Continued) MP10661-0 A10667-5 A10669-1 MP10676-0 BOOT, TOGGLE SW.