TOGGLE CONTROLLER OPERATION & MAINTENANCE INSTRUCTIONS CUSTOMER: MODEL NUMBER: SERIAL NUMBER: FREQUENCY ASSIGNMENT: ADDRESS ASSIGNMENT: MANUAL P/N: 68C-Toggle Rev.
TOGGLE CONTROLLER OPERATION & MAINTENANCE INSTRUCTIONS IMPORTANT NOTICES Your new Toggle 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.
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
Introduction How to use this Manual. This manual contains generic operation and maintenance procedures applicable to the entire series of CATTRON-THEIMEG™ Radio Remote Toggle Controllers. Because no two Toggle 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 three most popular control applications: (1) Cranes, (2) Locomotives, and (3) Railroad Ballast Cars.
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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.
Safety Summary 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.
Safety Summary 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.
Safety Summary 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.
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 ..................................................................................... ii How to use this Manual ................................................................................................ iii Safety Summary ...........................................................................................
Section 3 – Operating Instructions, continued: Switch Diagnostic Mode ........................................................................................... 3-15 Battery Packs and Battery Pack Charging ................................................................. 3-16 Battery Pack Conditioner .............................................................................. 3-16 Battery Pack Replacement .............................................................................
Section 1 – Product Data & Specifications Introduction. The CATTRON-THEIMEG™ Toggle Controller has a unique shape and style that provide the equipment operator with a controller that is durable, lightweight and convenient. Designed specifically for heavy duty in harsh working environments, the toggle 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 critical switch inputs to detect unwanted commands in the system. Any optional paddle 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. 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. This function can be assigned in the decoder to stop the equipment, sound an alarm, or both. Reset time is also programmable.
Frequently Asked Questions, continued. Table 1-1. Toggle Controller, questions and answers QUESTION ANSWER RELIABILITY Durable case material? YES - Aluminum with epoxy coating. Fiberglass ends coated in urethane Enclosure water/dust/oil proof? YES - NEMA 12 (IP-65) or optional NEMA 4 (IP-66) Long toggle switch operating life? YES – To military specification (mil-spec).
Frequently Asked Questions, continued. Table 1-1. Toggle 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. Side Mounted Lever Styles: Large Flag Type, Special Shaped Lever Knobs Optional. Push To Operate Safety Bar: Standard. Lever Guards: Optional. Labeling: Custom, Reverse Engraved Polycarbonate and Multi-layered Mylar. Keylock Switch: Standard (Power ON/OFF). Security: An optional ‘keyless entry code’ is available. Antenna: Internal (external optional). Low Battery Indicator: 2 Color LED: GREEN - Battery Normal, RED - Battery Low.
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 Toggle 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: 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. Note: Insure the address code and frequency of your toggle controller exactly matches the address code and frequency of the target equipment to be operated.
Radio Control Operator’s Duties – General Equipment, continued. 4. Persons operating this equipment shall not use a limit stop as a utility stopping device. 5 When leaving the equipment area for any reason, set the controller’s Power ON/OFF Switch to the ‘OFF’ position. If this is a Key Switch, remove the key from the controller and keep it on your person. 6. Do not allow any unauthorized person to operate the controller. 7.
Radio Control Operator’s Duties – Electrical Overhead Tracked (EOT) Crane. 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 – 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. 4. When lifting maximum load, you should test the brakes by raising the load a few inches from the floor. If the brakes will not hold, the load shall be immediately lowered and not moved until brakes are adjusted or repaired. 5. Center the Trolley directly over the load before starting to hoist. 6. Take slack out of chains or slings gradually and make sure hands and other objects are clear before making the lift. 7.
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 toggle 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 toggle 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 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.
General Operating Procedure. NOTE: Carrying the controller using a Shoulder Strap or Chest Harness will greatly enhance operator comfort. Refer to Figure 3-2 below for illustrative details and CATTRON-THEIMEG™ Part Numbers. 1. Referring to Figure 3-2 below, put on the shoulder strap or chest harness, attach the controller to the harness and adjust for comfortable operation. Figure 3-2.
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. 2. Set the controller’s Power ON/OFF Switch to ‘ON’.
General Operating Procedure, continued. 5. Place a convenient and comfortable part of the operator's 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 3-3.
TYPICAL CRANE CONTROL FUNCTIONS, continued. 2. MAGNET, VACUUM, or GRAB - Extra precautions are built into the MAGNET, VACUUM and GRAB functions to prevent accidental release. Two momentary switches (buttons or toggles) are normally used for these functions. Accidental operation of the magnet, vacuum or grab is minimized by locating these buttons as far as possible from other controls and requires two fingers to release the load.
TYPICAL CRANE CONTROL FUNCTIONS, continued. WARNING: AFTER CHANGING AN ADDRESS OR FREQUENCY SELECTOR SWITCH, YOU MUST, IN THE FIRST INSTANCE, INSURE THE TARGETED MACHINE IS UNDER REMOTE CONTROL BEFORE OPERATING ANY MOTION FUNCTION SWITCH. THIS MAY BE ACCOMPLISHED BY OPERATING A NON MOTION FUNCTION SWITCH ON THE REMOTE CONTROLLER SUCH AS A HORN OR LIGHT.
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 3-4.
TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued. 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. Some systems require that an independent brake is applied for 3 seconds, or a specific brake cylinder pressure has been reached, before a change in direction can occur. 4.
TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued. 8. ‘EMG BRAKE’ SWITCH – When set to the ‘EMG BRAKE’ position, this maintained 2position switch applies the independent brakes, together with the application of sand. 9. ‘TRAIN’ BRAKES - This 3-position switch controls the train brakes and has the following functions: APPLY (Momentary) – Applies the railcar brakes by reducing the air supply to the train air line. HOLD (Maintained) - Seals off the train air line so no further reduction or release will occur.
TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued. 16. OPERATOR RELEASE ‘PITCH AND CATCH’ (Optional) – Locomotive ‘pitch and catch’ allows two operators to swap control to and from each other, based upon which operator should be commanding movement. Typically, a selector switch mounted on the side of the locomotive mounted Receiver/decoder enclosure is used to select single or dual operator control.
TYPICAL RAILCAR CONTROL FUNCTIONS – BALLAST CAR. 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 railcar. In the example application given below, up to two remote control operators are able to control the distribution of ballast to the rail track. The two operators can safely open and close all four hopper car doors, directing ballast to the left, center, or right of each rail.
TYPICAL RAILCAR CONTROL FUNCTIONS, continued. 2. CAR I.D. TOGGLE SWITCH – These 3-position, spring return-to-center switches are used to set the targeted ballast car identification (I.D.) number. This I.D. number consists of the last three digits of the serial number located on the outside of the ballast car. Starting with the HUNDREDS switch, pushing upwards increments the first (hundred’s) digit of the CAR I.D. DISPLAY.
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. Close the battery door and secure by latching the battery door catch. 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. If this LED is now flashing green, your controller is fully operational. Figure 3-6.
Ni-Cad Battery Pack Conditioning/Charging (Figure 3-7). 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 3-7. 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 3-6 above and locate the serial tag on the inside of the battery door.
Pre-programmed Frequency Selection, continued. Figure 3-8.
Controller Operating Position for Mining Applications. Remote control operation in underground mining locations may be carried out in areas where space for the operator is severely restricted. Frequently, the operator is required to sit, kneel, crouch, and stand when performing remote control operations. To insure safe remote controlled operation at all times, the preferred Toggle Controller operating position is illustrated below.
Section 4 – Maintenance Instructions CATTRON-THEIMEG™ Maintenance Philosophy. Our maintenance philosophy is that inoperative Toggle 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 CONTROLLER TRANSMISSION 4 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 Toggle Controller is restricted to replacing the Battery Pack, Address Code Plug and, when installed, Side Lever(s) and External Antenna. Refer to the Replacement Procedures below when removing and replacing items. Having replaced an item, and before placing the Toggle Controller into operational service, carry out a Functional Check as follows: Functional Check. 1. Set the controller’s Power ON/OFF Switch to ‘ON’.
Battery Pack Replacement, continued. Figure 4-1. Battery Pack Replacement. BATTERY DOOR CATCH HINGED BATTERY DOOR SERIAL TAG BATTERY PACK BATTERY PICKUP CONTACTS BATTERY DOOR LATCH Address Code Plug Replacement. Each CATTRON-THEIMEG™ Toggle 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.
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. 3. Referring to Figure 4-1 above, unlatch the battery door catch, open the battery door and lift the battery pack out of the tray. 4. 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.
Address Code Plug Replacement, continued. Figure 4-3. Code plug settings.
Address Code Plug Replacement, continued. 6. Write the newly set address code on the side of the code plug using a permanent marker. 7. Carefully install the new code plug, making sure the dot (Pin 1) faces the top of the controller – see Figure 4-2, above. 8. 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.
External Antenna Replacement, continued. Figure 4-5. External Antenna Replacement. TOP OF CONTROLLER 1 2 1. EXTERNAL ANTENNA 2.
Section 5 – Replacement Items and Accessories Notable differences between controllers will include the quantity, type, and placement of toggle 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 toggle controller.
Section 5, Page 2 ©09/2002, CATTRON-THEIMEG™ 3 2 4 1 2 5 6 PUSHBUTTON SWITCH ASSEMBLY (see Table 5-2) 10 TOGGLE SWITCH ASSEMBLY (see Table 5-1) 6 8 21 22 20 PUSHBUTTON SWITCH ASSEMBLY (see Table 5-2) 7 9 23 24 26 25 19 26 18 17 13 16 10 13 15 14 10 12 11
Table 5-3. Common items FIGURE 1, ITEM NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 COMPONENT DESCRIPTION Screw, Truss Head, Phillips, 4-40 x 3/16 Nut, Hex, Encl Top 15-32 Washer, Sealing, 15/32-32, Switch Panel Face Plate* Gasket, Sponge, 0.125" thick Screw, Truss Head, Phillips, 8-32 x 1/4" Bracket, Delrin, 3.0" x 0.
Consumable Items and Optional Accessories. Consumable Items and Optional Accessories are listed in Table 5-4 below and illustrated on the following pages. When ordering replacement items from CATTRON-THEIMEG™, contact our sales department for pricing and provide the Controller model/serial number located on the serial tag inside the battery compartment door. Table 5-4.
Consumable Items and Optional Accessories, continued.
Consumable Items and Optional Accessories, continued.
Consumable Items and Optional Accessories, continued.
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Index F A Accessories ..................................... 5-4 Frequency options ......................... 1-3 Address code ................................... 2-1 Frequency selection .................... 3-18 Applications .................................... 1-3 Frequency verification ............... 3-18 Automatic safety override ............... 2-1 Frequently asked questions .............. 1-3 Functional check ........................... 4-4 B Battery Conditioner ...............
Index S P Power On Self Test (POST) .......... 1-2 Safety considerations ................... 2-1 Power ON/OFF switch .................. 3-2 Safety & security features ............ 2-1 Pre-programmed Frequency ........ 3-18 Side mounted levers................ 1-2, 3-2 Standard specifications ................ 1-5 Preventive maintenance ................. 4-2 Switches ....................................... 3-2 Push To Operate bar switch...... 2-2, 3-2 Switch diagnostic mode................
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. OPERATOR SAFETY BASICS, continued. 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.
5. THE OPERATING AREA FOR THE REMOTE CONTROLLED CRANE. • 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. • Plugging shall not be used as a regular means of stopping the crane and should be used for emergency stops only. If approved, plugging should only be performed as dictated by plant operating procedures. • If PRC crane operators are asked to do something they believe unsafe, they shall call their supervisors for advice. • PRC crane operators shall never permit anyone to ride on the load or hook except when authorized by their supervisor.
9. ON BOARD THE REMOTE CONTROLLED CRANE, continued. • • • • • 10. All tools and equipment shall be moved onto the crane by the use of hand lines. All tools and equipment shall be securely attached to hand lines. If it is necessary to have the control circuits on the crane energized, the repair crew leader shall open all power circuits to the motions before closing the main switch.
10. REMOTE CONTROLLED CRANE UNDER REPAIR, continued. • The floor area below the point where crane repairs are being made shall be roped off and posted with danger signs. • Handling of all small tools and materials, etc. from ground level to workers above shall be accomplished through the use of hand lines. Tools, materials, etc. shall not be tossed from the crane to the ground level and vice versa.
11. THE CONDITION OF THE REMOTE CONTROLLED CRANE, continued. • • • • • Bumpy riding (worn wheels). Worn collector shoes or bars. Burned out, broken, or inoperable warning or signal lights. Unintended stopping or starting of any crane motion, warning device, light or auxiliary function. Condition of walkways and ladders (missing or loose handrails, ladder rungs, etc.) Portable Remote-controlled Crane operators shall not attempt to make any repairs by themselves.
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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. 7. PRE-DEPARTURE CHECKS UNDER MANUAL CONTROL, continued. • 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. • All braking functions shall be checked independently to insure the locomotive is responding correctly to all brake applications and release commands. Observe gages in the cab for proper readings and verify the brake mechanisms/cylinders operate properly.
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.
