DOWNLOAD PDF CATTRON Theimeg AT & ATS 816 Series INSTALLATION, OPERATION & MAINTENANCE Manual

AT and ATS 816 SERIES PORTABLE REMOTE CONTROL SYSTEMS INSTALLATION, OPERATION & MAINTENANCE MANUAL Models AT4, AT8, AT12, and AT16

CUSTOMER: MODEL NUMBER: SERIAL NUMBER: FREQUENCY ASSIGNMENT: ADDRESS ASSIGNMENT: MANUAL P/N:

68C-816AT Rev. 008, 04/2006

AT and ATS 816 Series INSTALLATION, OPERATION & MAINTENANCE

IMPORTANT NOTICES This manual covers both the CATTRON-THEIMEG™ Advanced Technology (AT) and Advanced Technology Standard (ATS) 816 Series Portable Remote Control (PRC) systems, including auxiliary function kits and accessories. System installation information is included. In cases where more than one system is provided, it is advisable to mark the controlled equipment number on the manual cover to avoid confusion.

Your new PRC system has been pre-configured to operate on a specific address and frequency before leaving our factory. Thus, the address and frequency of the system controller is factory set to operate its corresponding 816 Series receiver/decoder.

Upon installation, CATTRON-THEIMEG™ strongly advises you to check that our pre-configured address and frequency is not duplicated in other CATTRON-THEIMEG™ remote control equipment located at, or around, your operating facility.

This equipment is firmware based, including encoder, decoder, transmitter and receiver. Any duplication of operating firmware without written consent of CATTRON-THEIMEG™ is prohibited.

All firmware, product listings, assembly files, and this manual are protected by U.S. Copyright Laws.

ã04/2006, CATTRON-THEIMEG™

Page i

List of Technical Abbreviations The following abbreviations (acronyms) are frequently used in CATTRON-THEIMEG™ Portable Remote Control Technology and may be used in this manual: AC AT ATS

MK ML NEMA

CS DC DP

Alternating Current Advanced Technology Advanced Technology Standard Automatic Safety Override Bose-ChaudhuriHocquenghem (data error detection routines) Complimentary Metal Oxide Semiconductor Crane Specific Direct Current Dual Pressure

EDP

Electronic Data Processing

RSSI

EEPROM

Electrically Erasable Programmable Read Only Memory Electro-Magnetic Interference Erasable Programmable Read Only Memory Federal Communications Commission Ground Input/Output Liquid Crystal Display Light Emitting Diode

ASO BCH

CMOS

EMI EPROM FCC GND I/O LCD LED

Page ii

Ni-Cad OPR

Metal Keypad Mainline National Electrical Manufacturer’s Association Nickel Cadmium Operate

PRC

Portable Remote Control

PTO RF RFI

RST

Push-to-Operate Radio Frequency Radio Frequency Interference Receive Signal Strength Indication Reset Relay

SP

Single Pressure

SYNC

Synchronization

TP

Test Point

TS VAC VDC VFD

Transfer Switch Volts Alternating Current Volts Direct Current Variable Frequency Drive

ã04/2006, CATTRON-THEIMEG™

Safety Summary WARNING and CAUTION statements have been strategically placed throughout all text prio r 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. All WARNINGS and CAUTIONS appearing in this manual are included below.

WARNINGS. WARNINGS: CATTRON-THEIMEG™ MAKES EVERY EFFORT TO ENSURE THE ADDRESS AND FREQUENCY ASSIGNED TO YOUR NEW PRC SYSTEM IS NOT DUPLICATED BASED UPON RECORDS WHICH ONLY INDICATE THE ADDRESS AND FREQUENCY OF ALL PAST PRC SYSTEMS AS SHIPPED FROM OUR FACILITY TO YOURS. THEREFORE, IT SHOULD BE FULLY UNDERSTOOD THAT; (1) WHEN A PRC SYSTEM HAS LEFT OUR FACTORY, CATTRON-THEIMEG™ HAS NO CONTROL OF ANY ADDRESSES AND FREQUENCIES SUBSEQUENTLY ASSIGNED AND PROGRAMMED BY YOURSELVES, OR OTHERS, EITHER NOW OR IN THE FUTURE AND, (2) CATTRON-THEIMEG™ HAS NO CONTROL OF THE ADDRESS AND FREQUENCY ASSIGNMENTS OF ANY OTHER PRC SYSTEMS(S) THAT MAY BE IN OPER ATION IN CLOSE PROXIMITY TO YOUR FACILITY. CONSEQUENTLY, AND PURSUANT TO STATEMENTS (1) AND (2) ABOVE, CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE ARISING FROM DUPLICATED ADDRESSES AND FREQUENCIES OF CONTROL SYSTEMS.

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Page iii

Safety Summary, continued WARNINGS, continued.

WARNINGS: CATTRON-THEIMEG™ ATS 816 SERIES PORTABLE REMOTE CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electromagnet circuits, vacuum circuits, grab, pump motors, fire suppression etc.).

WE SPECIFICALLY REFER YOU TO SECTION 2 PAGE 2 OF THIS MANUAL WHICH PROVIDES INFORMATION REGARDING PROPER INTERFACE TO SAFETY CRITICAL MAINTAINED FUNCTIONS USING A CATTRON-THEIMEG™ RELAY INTERFACE UNIT PART # RI004NE. ALTERNATIVELY, WE INCLUDE TYPICAL CIRCUIT DIAGRAMS IN SECTION 2 THAT ILLUS TRATE HOW TO PROPERLY INTERFACE YOUR CATTRON-THEIMEG™ ATS SERIES PRC SYSTEM TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS BEFORE OPERATIONAL USE. SHOULD CATTRON-THEIMEG™ ATS SERIES PRC SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY RESULT. IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM. 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. FAILURE TO COMPLY WI TH THESE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

Page iv

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Safety Summary, continued WARNINGS, continued.

WARNING: MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE, IF THE WRONG ADDRESS AND OPERATING FREQUENCY IS PROGRAMMED INTO A REMOTE CONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL. FAILURE TO COMPLY WI TH THIS WARNING MAY RESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD RESULT IN PERSONAL INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPM ENT. WARNING: ATS PORTABLE REMOTE CONTROL SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS, (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors, fire suppression, etc.). THE USE OF AN APPROPRIATE RELAY INTERFACE UNIT WILL BE REQUIRED FOR THESE APPLICATIONS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. 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. WARNING: FAILURE TO PROPERLY SELECT FREQUENCY AND ADDRESS MAY RESULT IN THE UNINTENTIONAL OPERATION OF OTHER MACHINERY. DO NOT DUPLICATE ADDRESS ASSIGNMENT. FAILUR E TO OBSERVE THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

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Page v

Safety Summary, continued WARNINGS, continued.

WARNING: DE-ENERGIZE AND TAG OUT ALL SOURCES OF ELECTRICAL POWER BEFORE CARRYING OUT TOUCH TESTS ON EQUIPMENT. FAILURE TO PROPERLY DE-ENERGIZE EQUIPMENT MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK. WARNING: HIGH VOLTAGE MAY BE PRESENT ON RELAY OUTPUT TERMINALS. EXERCISE CAUTION WHEN WORKING NEAR THE RELAY OUTPUT BOARDS. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK. WARNING: REMOVE POWER FROM THE CRANE OR MACHINE MOTORS BEFORE PERFORMING ASO TESTS. THESE TES TS REQUIRE THE ENERGIZING OF THE OUTPUT RELAYS USING JUMPERS. ENERGIZING THE RELAYS WHILE POWER IS APPLIED TO THE SYSTEM MOTORS MAY RESULT IN UNDESIRED MOVEMENT OF THE CRANE OR MACHINE. IN ADDITION, DAMAGE TO THE CIRCUIT BOARDS MAY RESULT IF THE TEST JUMPER CONTACTS THE WRONG COMPONENT. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

Page vi

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Safety Summary, continued CAUTIONS. CAUTIONS: On 12 VDC applications, incoming power must have a 1 Amp slow blow fuse in line with the positive lead near the battery or power source.

Insure the proper DC voltage is connected to the receiver/decoder.

Observe proper polarity when making all connections.

Failure to comply with these cautions will result in vehicle and equipment damage.

CAUTION: Electrostatic sensitive devices such as EPROMs are present on circuit boards. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving circuit boards and electrostatic sensitive devices. Failure to comply with this caution may result in equipment damage and will void our warranty.

CAUTION: EPROMs are electrostatic sensitive devices. Use an anti-static mat and personal grounding strap (wrist) when replacing or installing EPROMs. Failure to comply with this caution may result in equipment damage and will void our warranty.

ã04/2006, CATTRON-THEIMEG™

Page vii

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 maintenanc e 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. Do not replace components or make adjustments inside the equipment with the electrical supply turned on. Under certain conditions, danger may exist even when the power control is in the off position due to charges retained by capacitors. To avoid injuries, always remove power, discharge and ground a circuit before touc hing it. Adhere to all lock out/tag out requirements.

DO NOT SERVICE OR ADJUST ALONE. Whenever possible, do not attempt internal service or adjustment of equipment unless another person capable of rendering aid and resuscitation is present.

FINGER RINGS/JEWELRY. Finger rings have caused many serious injuries. Remove rings, watches and other metallic objects which may cause shock or burn hazards.

SOLDERING/DE-SOLDERING. Avoid breathing fumes generated by soldering/de-soldering.

Perform all operations in a ventilated area. Eye protection is required.

CLEANING SOLVENTS. Some cleaners and solvents have adverse effects on skin, eyes, respiratory tract and internal organs. These adverse effects range from discomfort to serious injury and death, depending on the material and degree of exposure. Observe manufacturers’ warning labels and contact your immediate supervisor if in any doubt.

Remember…. the person now reading these instructions is primarily responsible for his or her own health and safety.

Page viii

ã04/2006, CATTRON-THEIMEG™

Table of Contents Front Matter Important Notices ............................................................................................................. i List of Technical Abbreviations ...................................................................................... ii Safety Summary ............................................................................................................. iii Warnings ............................................................................................................ iii Cautions ............................................................................................................ vii General ............................................................................................................. viii

Section 1 - Functional Description General ........................................................................................................................ 1-1 Operability .................................................................................................................. 1-1 Advanced Control Functions ...................................................................................... 1-1 AT & ATS 816 Series Receiver/Decoders – Functional description ......................... 1-2 Specifications .............................................................................................................. 1-3 System Features .......................................................................................................... 1-4 Safety Considerations ................................................................................................. 1-5 Standard Safety & Security Features .............................................................. 1-5 Principle of Operation ................................................................................................. 1-6 Radio Remote Control .................................................................................... 1-6 AT & ATS 816 Series PRC Systems - model summary chart .................................... 1-7

Section 2 - Installation Pre-installation checks ................................................................................................ 2-1 Interface connections ................................................................................................... 2-1 Introduction ..................................................................................................... 2-1 Safety Interface Unit (ATS 816 Series only) ................................................... 2-2 The controlled machine ................................................................................... 2-4 Control transformer ......................................................................................... 2-4 Disconnect and outlet ...................................................................................... 2-5

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Page ix

Section 2 – Installation, continued Transfer switch ................................................................................................ 2-5 Relay outputs ................................................................................................... 2-6 R/C snubbing ................................................................................................... 2-6 Mainline circuit (operate and reset relays) ...................................................... 2-6 Attenuator ........................................................................................................ 2-8 Installation ................................................................................................................... 2-9 Getting started ................................................................................................. 2-9 Choosing a mounting location ......................................................................... 2-9 Remote antenna location ............................................................................... 2-10 Triple diversity antenna ................................................................................. 2-11 Direct DC wiring option ................................................................................ 2-12 Pre-set frequency selections (ATS 816 Series only) ................................................. 2-13 Post installation checks .............................................................................................. 2-14 System status display and LED indicators .................................................... 2-14 Check-out procedures .................................................................................... 2-16 Power-up messages ........................................................................... 2-16 Run-time Messages ........................................................................... 2-17 ASO Hexadecimal Codes .................................................................. 2-19

Section 3 - Operating Instructions General ........................................................................................................................ 3-1

Section 4 - Maintenance General ........................................................................................................................ 4-1 Preventive maintenance ............................................................................................... 4-2 Typical additional checks ................................................................................ 4-2 Primary power supply .......................................................................... 4-2 Fuses .................................................................................................. 4-2 Fuse holders ......................................................................................... 4-3 Unit assemblies .................................................................................... 4-3 Antenna system ................................................................................... 4-3 Page x

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Section 4 – Maintenance, continued Netting ................................................................................................. 4-3 Adjustments ................................................................................................................ 4-4 Troubleshooting .......................................................................................................... 4-5 Automatic Safety Override (ASO) .............................................................................. 4-9 ASO Circuit test procedure ............................................................................. 4-9 Receiver/Decoder repair ........................................................................................... 4-11 Replacing the EMI/RFI shielded chassis (gold box) .................................... 4-11 Relay replacement ......................................................................................... 4-12 Receiver replacement .................................................................................... 4-13 Decoder replacement ..................................................................................... 4-15 Code Plug replacement ................................................................................. 4-17 EPROM replacement .................................................................................... 4-20

Section 5 - Parts List and Accessories Introduction ................................................................................................................. 5-1 AT & ATS 816 Series Receiver/Decoder ....................................................... 5-2 EMI/RFI Shielded Chassis .............................................................................. 5-4 Accessories .................................................................................................................. 5-6 Two-step electro-hydraulic brake package ..................................................... 5-6 Transfer Switch ............................................................................................... 5-7

Appendix ‘A’ – R1014T2 Receiver Introduction ................................................................................................................ A-1 Additional Safety Feature .......................................................................................... A-2 Close Start Setup ........................................................................................................ A-2 Range Limit Setup ..................................................................................................... A-7 Range Extender Setup .............................................................................................. A-10 Scanner Setup ........................................................................................................... A-12 Attenuator Setup ...................................................................................................... A-13 Factory Set & Field Programmable Frequencies ..................................................... A-14 ã04/2006, CATTRON-THEIMEG™

Page xi

Appendix ‘B – New R1HN and R2HN Receiver Boards Frequency Programming Procedure ........................................................................... B-1

Index Addendum RECOMMENDED SAFETY RULES FOR PORTABLE REMOTE CONTROLLED (PRC) CRANES.

Page xii

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Section 1 – Functional Description General.

CATTRON-THEIMEG™ AT and ATS 816 Series PRC systems offer the safety and dependability required for harsh industria l control applications. These systems incorporate a high-performance microcomputer with a minimum number of components in their design. A single board decoder is under the direct control of a variety of lightweight, hand-held style control transmitters. All AT systems are custom designed for each application. A variety of ATS (AT Standard) systems exist that have been pre-configured for standard applications.

Operability.

All functions of these systems can be operated simultaneously and independently. This creates a more efficient and flexible system, increasing productivity. There are no confusing do's and do not’s to remember when selecting functions.

Systems can be provided which allow multiple operators to control one crane on a first-come, firstserved basis, two to four operators working one piece of equipment using ‘Pitch and Catch’, two operators simultaneously controlling a single decoder, or one operator with a Supervisory control overriding the second operator.

With the CATTRON-THEIMEG™ AT and ATS 816 Series systems, all speed steps are under direct operator control. This allows the operator to select the appropriate speed for his or her load and operating conditions with care.

Advanced Control Functions.

An optional Model R1014T2 Receiver Board is available which enables several advanced control functions such as ‘Close Start’, ‘Range Limit’, and ‘Range Extend’ to be programmed into the receiver/decoder when used in conjunction with a Triple Diversity Antenna System. In addition, this optional Model R1014T2 Receiver Board has a built- in attenuator, a field programmable frequency select function, and a frequency scanning option. Refer to APPENDIX ‘A’ of this manual for details of this board and its enhanced functions.

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Section 1, Page 1

AT and ATS 816 Series Receiver/decoder – functional description.

The receiving and decoding hardware, along with relay interface, is housed within a NEMA 12 or other optional enclosure. The decoder has a two digit display to show system status and act as central test point. The output interface is handled by plug- in relays rated for heavy duty resistive and inductive industrial loads. Each output function relay has 2 screw terminals, an output fuse, and an LED indicator. The decoder uses a secondary contact on each relay to sense and verify each of the outputs.

Upon detection of a fault condition, the Operate (OPR) relay and all outputs are disabled. This is the Automatic Safety Override function, a safety feature found on all CATTRON-THEIMEG™ Portable Remote Control systems.

Refer to Figure 1-1 and Table 1-1 below for a description of the AT and ATS 816 Series components.

Figure 1-1. Receiver/decoder components

Section 1, Page 2

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AT and ATS 816 Series Receiver/decoders – functional description, continued.

Table 1-1. Receiver/decoder components

Component EMI/RFI shielded chassis (Gold Box)

Description The enclosure, commonly known as the ‘gold box’ due to its gold anodized coating, contains the receiver and decoder circuit boards along with the power supply for the entire receiver/decoder. For ease of repair, the entire gold box can be quickly swapped out with a spare and returned to CATTRONTHEIMEG™ for repair.

Relay output boards

The relay output boards provide a common connection point for all user connections to the output relays. The AT/ATS system will contain one or two relay output boards depending on the number of outputs in the system.

Receiver

The receiver contains the electronic circuits that perform the radio reception functions. Several LEDs mounted on the receiver circuit board indicate the status of the radio communications link with the controller.

Decoder

The decoder contains the electronic circuits that control system functions. This includes checking the address of incoming signals, interpreting the controller’s commands, and controlling the status of the output relays.

Antenna

The antenna provides radio reception for the receiver/decoder. If the mounting location of the receiver/decoder does not provide good radio reception, optional remote mount antennas are available.

Power supply

The power supply inside the gold box provides all required power for the receiver/decoder. The power supply requires 115 VAC at 50-60 Hz. The receiver/decoder can also be supplied directly with 12 VDC nominal (13.5 VDC).

Other AC & DC supply voltages are available upon request. Contact CATTRON-THEIMEG™ for options.

Specifications.

AT and ATS Receiver/decoders: Interface type: Mechanical relays, NO contacts, 5 A @ 250 VAC or 30 VDC. Output termination: 2 screw terminals per relay contact allowing mixed control voltages and transformers.

Number of outputs: 4, 8, 12, or 16 independent and simultaneous, plus one ON/OFF OPR on 4 & 8 systems and two ON/OFF OPRs on 12 & 16 output systems.

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Section 1, Page 3

Specifications, continued.

Enclosure: NEMA 12 (IP65) steel, NEMA 4 (IP66) steel, or NEMA 4X (IP66) stainless steel.

Control voltage range: 30 VDC or 120-250 VAC ±20%, fused at 5 A. Power requirements: 115 VAC 50-60 Hz, or 13.8 VDC @ less than 1 Amp. Optional 10-36 or 24-78 power regulators.

Receiver freque ncy: Synthesized 16 channel capability; whip antenna, Non- licensed Canadian, European, and US; 447-473 MHz High band, mid band receiver. Licensed Canadian and US 447473 MHz, High Band, wide band and narrow band receiver. European: 425-447 MHz mid band receiver.

Sensitivity: 0.5 mV (20 dB quieting).

Frequency stability: ±0.0005 of frequency range.

Environmental: Outdoors, -22°F to 140°F (-30°C to 60°C), RH 0 to 95% non-condensing.

Dimensions: Approximately 12"H x 10"W x 4.5"D (305 mm x 254 mm x 100 mm).

System Features.

CATTRON-THEIMEG™ AT and ATS 816 Series PRC systems offer the following features: · High message security. · Four, eight, twelve, or sixteen output functions, plus ON/OFF operate(s). · Synthesized controller and receiver frequency control. · Average response time of less than 60mS. · Power-on self diagnostics. · Multiple watchdog timers. · Automatic Safety Override (ASO) for output verification of all outputs. · Operate different control voltages from a single receiver/decoder. · EMI/RFI shielded sub-chassis contains the receiver/decoder electronics. · Custom engineered for each application (AT series only). · Proven CATTRON-THEIMEG™ reliability.

Section 1, Page 4

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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 must be equipped with a braking system which can only be released when an electrical signal is sent to the motor.

Removal of electrical power or loss of the radio transmitted signal results in application of the brakes.

One way to accomplish this is with a CATTRON-THEIMEG™ Electro-Hydraulic brake package – contact the factory for details.

In keeping with this philosophy - NO COMMAND, NO MOVEMENT - CATTRON-THEIMEG™ has designed your Portable Remote Control system with the following safety and security features.

Standard Safety & Security Features.

Unique address code : Each CATTRON-THEIMEG™ controller and receiver/decoder pair is configured with a unique address code so that the equipment will respond only to the controller whose address code matches that of the decoder.

Ope rate relay (OPR): The operate (OPR) output relay is wired to control a user-provided Electro- magnetic power contactor. The Electro- magnetic contactor opens and closes the main electrical supply circuit(s) to the controlled device.

ON/OFF power switch: A controller is provided with an ON/OFF switch that must be set to ‘ON’ in order to send commands to the receiver/decoder. If the power switch is set to ‘OFF’, the decoder will remove all commands from the controlled machinery, stopping all movement.

However, the mainline control relay (OPR) may be maintained for 10 minutes, depending on system configuration.

System STOP Switch: A controller is provided with a system STOP switch. Operating this switch while the controller is turned on will repeatedly send a burst of stop commands to all outputs including the mainline Operate (OPR) relay or, for AT12 & AT16 systems, two OPR relays. For continuous transmit systems, turning off the controller immediately de-energizes all outputs.

Automatic Safety Override : The Automatic Safety Override (ASO) function continually monitors all relays. If any relay closes without command from the controller, the Operate (OPR) Relay(s) immediately de-energizes. This prevents any movement of the controlled machine without command from the controller.

Close Start : The optional Close Start feature requires the operator to be within a specified distance of the controlled machine prior to the system activating.

Range Limit: The optional Range Limit feature ensures that the operator stays within a preset distance of the controlled machine. This keeps the operator within a safe distance of the machine.

Push To Operate: Some controllers have a Push To Operate (PTO) feature. This feature requires the operator to press and hold a large switch while operating the system. Releasing the PTO switch immediately stops all movement of the controlled system. ã04/2006, CATTRON-THEIMEG™

Section 1, Page 5

Standard Safety & Security Features, continued.

Intelligent digital message protocol: CATTRON-THEIMEG™ remote control systems utilize a unique message protocol for industrial control applications rather than the customary Electronic Data Processing (EDP) type of message format.

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.

Principle of Operation.

Radio Remote Control. Referring to Figure 1-2 below, the target receiver/decoder is controlled by a remote controller. Provided the correct address and frequency is programmed into the controller, the receiver/decoder receives signals from the controller using a UHF radio link. The signal is picked up by the antenna and passed on to the receiver. If the signal is the correct frequency and passes all required data tests, the signal is passed on to the decoder.

The decoder compares the address code of the signal to its own address code. If the signal’s address code does not match its address code, it is ignored and a message is displayed on a system status display located in the receiver/decoder unit. If the address code is correct, the decoder processes the message and energizes and de-energizes the appropriate relays mounted on the relay output board(s).

Figure 1-2. Simplified block diagram, RF PRC System 12 VDC

Tx

Rx

CONTROLLER

FREQ

ADDRESS

RECEIVER

DECODER

POWER SUPPLY

MAINS INPUT 50-60 HZ

WATCHDOG TIMER

ADDRESS FREQ

C W U I S R T I O N M G E R

OPR RELAY

RELAY 15

RELAY 1

C W U I S R T I O N M G E R

ASO

LH RELAY OUTPUT BOARD

Section 1, Page 6

RELAY 16

RELAY 14

RELAY 2

RELAY 13

RELAY 3

RELAY 12

RELAY 4

RELAY 11

RELAY 5

RELAY 10

RELAY 6

RELAY 9

RELAY 7

OPR RELAY

RELAY 8

RH RELAY OUTPUT BOARD

ã04/2006, CATTRON-THEIMEG™

Principle of Operation, continued.

An Automatic Safety Override (ASO) function continually monitors the state of all relay outputs. If a relay electrically fails closed without a command from the controller, the ASO circuit logic deenergizes the Operate (OPR) output relay(s). This prevents any movement of the controlled machine without command from the controller.

The relay output board(s) provides a mounting location for all the relays in the system. The relays control the high current loads required by the controlled machine. Mounted next to each relay is a fuse to provide overcurrent protection. All customer wiring for the output relays takes place at the relay output board(s).

During operation, the microprocessor on the decoder board resets multiple watchdog timer circuits whenever valid messages are received and decoded. If the microprocessor fails to reset the watchdog timers, the timer circuits shut down and de-activate all relay outputs. The decoder microprocessor requires continuously valid transmitted signals to be received and decoded or all relay output functions will be de-activated unless programmed otherwise. It should be noted that the mainline control relay (OPR) may be maintained for 10 minutes, depending on system configuration.

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Section 1, Page 7

AT and ATS 816 Series PRC System - model summary chart.

LEGEND =

AT12

AT16

NOT AVAILABLE NUMBER OF ITEMS SUPPLIED ACCESSORY ACCORDING TO FREQUENCY BAND, SPECIFY FREQUENCY BAND (WIDE, MEDIUM OR NARROW) AND CHANNEL SPACING

AT8

= = =

AT4

1,2 + #

1

1

1

1

+

+

+

+

+

+

+

+

+

+

+

+

1

1

1

1

#

#

#

#

R1014T1HN

Receiver, Synthesized, UHF, 450-470 Megahertz, 12.5kHz spacing

+

+

+

+

R1014T2HW

Receiver, Synthesized, UHF, 450-470 Megahertz, 25kHz spacing

1

1

1

1

D32GII

Decoder Circuit Board, Less EEPROM

+

+

+

+

51S-0832-ATX

EPROM, Decoder Board

-

-

1

1

CPA-0225

Cable, Ribbon with Connector, 2 Output Boards

1

1

-

-

CPA-0226

Cable, Ribbon with Connector, 1 Output Board

1

1

1

1

CPA-0342

Adapter, D32 to PB9R Board Cables, 50-pin

1

1

1

1

85C-0035

Antenna, Flex Whip UHF **

1

1

2

2

01C-PB9R

Rack, Relay Output, 9 Position, With Relays

+

+

+

+

10C-0096

Remote Antenna Mounting Kit, with 20 foot coax cable, PL259 connector (Optional for NEMA 12 enclosures)

+

+

+

+

10C-0096-BNC

Remote Antenna Mounting Kit, with 20 foot coax cable, BNC connector (Standard for NEMA 4 and 4X enclosures)

+

+

+

+

TS-XX

Transfer Switch Kit, 3-Position, XX denotes number of circuits

+

+

+

+

80C-0375

Relay, 1 N.O. Contact (Usable)

+

+

+

+

AT-SPARE-KIT

One 120VAC Power Supply, Two Relays, Miscellaneous Fuses

2

2

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68C-816AT

Instruction Manual, AT 816 Series Systems

PART NUMBER CPA-0228-12STL

ITEM DESCRIPTION Enclosure, Painted Steel, NEMA 12 (IP65), 12 x 10 x 5 inches, Pre-Wired W/Back Panel *

CPA-0228-4STL

Enclosure, Painted Steel, NEMA 4 (IP66), 12 x 10 x 5 inches, Pre-Wired W/Back Panel *

CPA-0228-4XSS

Enclosure, Stainless Steel, NEMA 4X (IP66), 12 x 10 x 6 inches, Pre-Wired W/Back Panel *

CPA-0228-4XFIB

Enclosure, Fiberglass, NEMA 4X (IP66), 12 x 10 x 5 inches, Pre-Wired W/Back Panel *

CPA-0216

EMI/RFI Chassis, Pre-Wired, less Decoder, with Lid (‘Gold Box’), and 120 VAC Power Supply

*NEMA 7 enclosures are available, **Optional antennas are available - consult CATTRON-THEIMEG™ for details.

END OF SECTION

Section 1, Page 8

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Section 2 - Installation Pre-installation check Before installing the receiver/decoder, the equipment must be checked to ensure that it is working properly. The pre- installation check is a test to ensure that all switches, relays, the display, and status indicators operate properly. To accomplish this check, the receiver/decoder should be positioned on a test bench with the appropriate input supply voltage connected to the Input Terminal Block located at the bottom right hand side of the Relay Output Board.

Refer to the drawings provided with your system for information on which relays correspond to which controller functions. Power up and cycle all the switches on the appropriate controller(s), observing the relay status LEDs next to each relay as a controller function is activated. The LED should illuminate, indicating that the relay is energized. Check each relay output with an ohm meter to ensure that the relay is closing properly, and that the fuse for the output is good. If any of the relays do not operate properly, contact CATTRON-THEIMEG™ immediately.

Interface connections.

Introduction.

Due to the wide variety of existing control systems and the many options available, CATTRONTHEIMEG™ provides customized schematic drawings for each installation. Study these drawings carefully before installing any wiring.

If there are any questions concerning the drawings or installation requirements, contact CATTRON-THEIMEG™ before proceeding. If any additions or corrections are made during the installation, note the changes on the drawings in red ink. Return the marked-up drawings to CATTRON-THEIMEG™ after the installation so final prints may be prepared and issued.

Each relay on the relay output board(s) is completely independent of all other relays. There are no common connections between any output contacts. This allows the connection of different power sources, AC and DC, to each of the separate relays. The contacts are rated at 5 Amps, 250 VAC or 5 Amps, 30 VDC. All contacts are individually fused with 250 Volt, 5 Amp fuses.

All relays have a single normally open contact. This contact is connected to Terminal Block #1 (TB-1) on the appropriate Relay Output Board. All connections to the relays are made at this terminal block.

Refer to the drawings provided with your system for information on which relays correspond to which controller functions.

Before installing the remote control system, we advise you to first read the following topics of discussion (pages 1 thru 8 of this section).

NOTE.

If you have an ATS 816 Series PRC system, start reading at ‘Safety Interface Unit’, below. If you have an AT 816 Series PRC system, skip ‘Safety Interface Unit’ and proceed to ‘The Controlled Machine’.

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Section 2, Page 1

Safety Interface Unit – ATS 816 Series systems only.

WARNINGS: CATTRON-THEIMEG™ ATS 816 SERIES PORTABLE REMOTE CONTROL SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors, fire suppression etc).

A PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS SHALL BE INSTALLED, IDEALLY USING A CATTRON-THEIMEG™ RELAY INTERFACE UNIT, PART # RI004NE. ALTERNATIVELY, EXAMPLE CIRCUIT DIAGRAMS ARE PROVIDED BELOW TO ENABLE YOU TO PROPERLY INTERFACE YOUR CATTRON-THEIMEG™ ATS SYSTEM WITH SAFETY CRITICAL BISTABLE MAINTAINED FUNCTIONS BEFORE OPERATIONAL USE. SHOULD CATTRON-THEIMEG™ ATS SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY RES ULT. IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM. When safety critical bi-stable maintained functions (i.e., electro- magnet circuits, vacuum circuits, grab, pump motors, fire suppression, etc.) are part of your controlled equipment, a proper interface must be installed between the CATTRON-THEIMEG™ ATS PRC and all such functions before operational use. We strongly recommend you use a CATTRON-THEIMEG™ Relay Interface Unit, Part # RI004NE. In addition, example circuit diagrams are provided below which illustrate how to properly interface your CATTRON-THEIMEG™ ATS PRC system with safety critical bi-stable maintained functions.

Section 2, Page 2

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Safety Critical Interfacing - example circuit diagrams (ATS 816 Series only).

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Section 2, Page 3

Safety Critical Interfacing - example circuit diagrams (ATS 816 Series only).

The Controlled Machine - all 816 Series systems.

The machine you are interfacing to may consist of single or multiple contactor panels, single or multiple manual controls, and single or multiple control transformers etc. Notice that there is no common connection between relay output contacts, allowing control of different power sources and combinations of AC and DC power. Application of the normally open relay contacts is similar to wiring that is required for any control switch, such as a pendant. Standard wiring practices should be observed. These can be found in the National Electrical Code and in local codes that may apply for your area.

Control Transformer - all 816 Series systems.

The power required to operate the remote control system is 115VAC, 50/60 Hertz, @ less than 1 Amp. The remote control system can be connected to an existing control transformer if the transformer’s size permits, otherwise, a control transformer must be supplied to provide the appropriate power for the remote control system.

Using a separate control transformer helps by reducing chances of a power slump if other electrical components connected to it fail. It can also be sized to allow installation of a utility outlet near the receiver/decoder for connection of a light or test equipment.

Section 2, Page 4

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Disconnect and Outlet - all 816 Series systems.

The receiver/decoder requires less than 1 Amp @ 115VAC to operate - refer to the drawings provided with your system for interconnection details. A larger 10 Amp circuit is recommended to allow installation of a utility outlet nearby for a light and test equipment. A fused disconnect switch provided by the installer should be installed as close to the power source as possible.

Transfer Switch - all 816 Series systems.

If the equipment is to be operated in the remote only mode and there are no manual controls, the Transfer Switch (TS) can be omitted. Otherwise, installation of a transfer switch is desirable to allow selection between remote or manual operation - refer to the drawings provided with your system fo r interconnection details. If a transfer switch is used, it should be connected so that power is removed from the remote control system when the transfer switch is in the ‘MANUAL’ position and vice versa.

The transfer switch provides an easy way to switch the controlled equipment from ‘MANUAL’ to ‘REMOTE’ control. Installing the transfer switch may require changes to the controlled equipment wiring. Prior to changing any existing wiring, create a wiring diagram of the planned changes. Use existing empty terminals on terminal boards as tie points.

When the transfer switch is in the ‘REMOTE’ position, the manual controls should be disconnected and vice versa. All power should be transferred to the radio control relays. When the transfer switch is placed in the ‘MANUAL’ position, manual control of the equipment should be restored. The equipment may now be controlled as it was prior to installation of the radio controls. Figure 2-1 below shows a typical transfer switch wiring setup. The transfer switch also contains an ‘OFF’ position. In this position all circuits are disconnected from both remote and manual controls.

Figure 2-1. Typical transfer switch wiring EXISTING CONTROL WIRING MANUAL CONTROLLER

CUT

ML

RECEIVER /DECODER OPR RELAY

M

C

TRANSFER SWITCH

R

NOTE: OPR RELAY CONNECTION SHOWN. OTHER RELAYS ARE SIMILAR

When switching the transfer switch between remote and manual control, observe the following precautions: · Do not transfer control of a crane with a load lifted. Always set down all loads prior to changing the position of the transfer switch. · If the crane is equipped with a magnet, it shall be set in the drop position prior to changing the position of the transfer switch. · When provided, set the STOP switch on the Portable Remote Controller to ‘STOP’ and the ON/OFF switch on the Portable Remote Controller to ‘OFF’. ã04/2006, CATTRON-THEIMEG™

Section 2, Page 5

Relay Outputs - all 816 Series systems.

Each output relay has a single Normally Open (NO) contact which is available for wiring at the relay board’s Terminal Block (TB). These contacts are rated at 5.0 Amps @ 120 – 250 VAC or 30 VDC. Each contact is individually fused at 5.0 Amps. Each relay has an internal secondary contact that is used by the decoder’s ASO circuitry to sense the relay’s status (energized or de-energized).

Each relay on the relay output boards is completely independent of all other relays. There are no common connections between any output contacts. This allows the connection of different power sources, AC and DC, to each of the separate relays.

R/C Snubbing - all 816 Series systems.

R/C snubbing circuits are provided on all relay outputs. These snubbing circuits provide protection for each relay contact when it is connected to an inductive load.

NOTE:

On some high-impedance loads, such as PLCs or VFDs, small leakage current (approximately 200 µA at 115 VAC), may present a problem. If this is the case, the snubbing circuit may be removed by cutting out either the resistor and/or capacitor located next to the affected relay.

Mainline Circuit (operate and reset relays) - all 816 Series systems.

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. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN PERSONAL INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. NOTE:

The remote control Operate (OPR) Relay is relay 0.

Referring to Figure 2-2 opposite, the Operate (OPR) relay output(s) is special. It should always be connected to the mainline (ML) contactor. If a fault were to occur with any one of the other output relays, the ‘OPR’ relay(s), which control the mainline contactor, would be the device that would safely bring the equipment to a stop. This makes the use of a mainline contactor mandatory for safe operation of this equipment.

Section 2, Page 6

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Mainline Circuit (operate and reset relays) - all 816 Series systems, continued.

Figure 2-2. Operate (OPR) contact wiring

MANUAL DISCONNECT

ML

L1

TB R

OPR

C 5.0A

RECEIVER/DECODER

L2

LL1 LL2

L3

LL3

TO MOTOR

120V ML

EXISTING CONTROLS

The Operate (OPR) relay(s) is energized for the first time when the receiver/decoder has power applied, the controller is turned on, and a matching address code is sent from the controller to the decoder. The OPR relay(s) is wired to the mainline (ML) contactor. Once the mainline is energized, a continuously repeated valid signal must be received for function outputs to engage. If this signal is interrupted for any reason, all function outputs will turn off. The mainline control in non- licensed systems is an exception. Because FCC rules state that RF transmitters in non- licensed controllers must switch off within five seconds after the operator releases the function button, the OPR output is programmed to stay on for ten minutes after the last valid message is received. During this time all other outputs must stay off unless programmed otherwise or the ASO sensing in the decoder will interrupt this hold up time, de-energizing OPR. In Figure 2-2 above, the Operate (OPR) contact is wired directly to the mainline (ML) contactor.

Switching the remote controller on energizes the mainline contactor.

Referring to Figure 2-3 below, an auxiliary function may be used as a Reset (RST) output that will only be effective when the Operate (OPR) relay has been closed.

Momentary closure of the Reset (RST) relay picks up the mainline (ML) contactor, which is maintained under control of the OPR. Thus, power is supplied to the controlled device. If OPR opens, the mainline contactor releases, removing power from the controlled device and stopping all motion.

Figure 2-3 shows the Operate (OPR) relay and optional Reset (RST) relay wired to control a mainline contactor. This configuration requires the operator to activate the reset function on the controller after he or she has turned the unit on. Once reset, the ML contactor stays energized until OPR de-energizes.

Refer to the drawings provided with your system for OPR contact wiring details.

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Section 2, Page 7

Mainline Circuit (operate and reset relays), continued.

Figure 2-3. Operate (OPR) contactor and Reset Relay (RST) wiring

MANUAL DISCONNECT TB R

OPR

C 5.0A

ML

L1

LL1

L2

LL2

L3

LL3

TO MOTOR

120V ML TB

ML

R

RST

C 5.0A

RECEIVER/DECODER

EXISTING CONTROLS

In addition to being energized by the presence of a signal from the controller, OPR is under supervision of the Automatic Safety Override (ASO) circuit. The ASO circuit disables the OPR (shutting down the controlled machinery) if an output relay is active when no corresponding command is being received from the controller. In this event, no action is required by the operator to stop the equipment. The ASO safety circuitry will stop motion automatically without any operator command when an output relay fault is detected.

Attenuator - all 816 Series systems.

An attenuator reduces the incoming signal levels from the controller. This has the effect of reducing the range at which the machine may be controlled. Using an attenuator also makes the receiver less susceptible to overloading and distortion caused by strong signals on other adjacent channels. All 816 Series receiver/decoders can use an external attenuator where varying levels of attenuation can be selected from a range of attenuators. To obtain an external attenuator for your receiver/decoder, contact CATTRON-THEIMEG™ .

NOTE: If your PRRC is provided with the Model R1014T2 receiver which has a built-in attenuator, refer to Appendix ‘A’ of this manual.

Section 2, Page 8

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Installation.

Getting Started.

As previously instructed, study the customized schematic drawings for your installation. If there are any questions concerning the drawings or installation requirements, contact CATTRON-THEIMEG™ before proceeding. If any additions or corrections are made during the installation, note the changes on the drawings in red ink. Return the marked- up drawings to CATTRON-THEIMEG™ after the installation so final prints may be prepared and issued.

Choosing a Mounting Location.

When selecting a location to install the receiver/decoder the re are a few items to consider. First, the receiver/decoder must be installed in a location that allows easy access for maintenance and service.

Adequate clearance must be allowed to open the door for access. The location must also provide adequate RF reception. Select a location to minimize any possible interference from RF sources such as motors. Ideally, the receiver/decoder should be installed as close as practical to the crane electrical cabinet and should be mounted so that the antenna is vertical. There should be a minimum of 48 inches clearance from obstructions in all directions of the antenna within the line of sight. If this clearance is not possible, the installation must be tested to ensure that interference does not impact the system’s performance. Contact CATTRON-THEIMEG™ for more information or for help in resolving any problems.

Figure 2-4 below shows the footprint drawing for the standard NEMA 12 receiver/decoder enclosure.

Mount the enclosure in the desired location using the four mounting holes provided - do not weld the enclosure in position.

Figure 2-4. Receiver/decoder enclosure mounting footprint

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Section 2, Page 9

Choosing a Mounting Location, continued.

Figure 2-5 below shows the recommended location for installing the wiring conduit. Do not install any wiring in the shaded areas indicated. The enclosure shall not be used as a junction box for other control equipment, (i.e., a pendant). All wiring entering the enclosure must be terminated inside the enclosure. Do not install any pass-through wiring.

The ¾" conduit hole is only provided in NEMA 12 enclosures. If the system uses a NEMA 4, 4X, or other enclosure, conduit penetrations must be made by the installer.

To prevent interference on signal lines, do not install high and low voltage cables in the same conduit.

If using the optional remote antenna, do not run the antenna coaxial cable in the same conduit as any signal lines. Keep the antenna wire separate from all other wiring, both inside and outside the receiver/decoder cabinet.

Figure 2-5. Wiring locations

Remote Antenna Location.

The standard antenna for a receiver/decoder with a NEMA 12 enclosure mounts on the bottom of the receiver/decoder enclosure. In situations where this mounting arrangement is not suitable, and for all receiver/decoders with a NEMA 4 and 4X enclosure, a remote mounting kit is used. The mounting kit contains a 20 ft. coaxial cable, an antenna mount, and a mounting bracket.

The remote antenna mounting bracket should be placed in a location away from any sources of RF interference. For overhead crane applications, the remote antenna should be mounted vertically to the underside of the crane. Ensure there is a minimum of 48 inches clearance from obstructions in all directions within the line of sight. If this clearance is not possible, the installation must be tested to ensure the interference does not impact the system’s performance. Contact CATTRON-THEIMEG™ for more information or for help in resolving any problems.

Section 2, Page 10

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Remote antenna location, continued.

For NEMA 12 installations, connect one PL259 connector on the coaxial cable to the connector on the receiver/decoder enclosure and the other end to the remote antenna mounting bracket. For NEMA 4 and 4X applications, connect the BNC end of the coaxial cable to the BNC connector on the bottom of the gold box, and the PL259 connector to the remote antenna mounting bracket. For NEMA 4 and 4X applications, a hole must be cut in the bottom of the receiver/decoder enclosure for passage of the antenna cable.

If the 20 ft. cable supplied with the remote antenna mounting kit is too long, simply coil the excess cable and hang it securely out of the way of any moving equipment. If the 20 ft. cable is not long enough, contact CATTRON-THEIMEG™ to obtain a longer cable.

Refer to Figure 2-6 below for a drawing of the remote antenna mounting bracket.

Figure 2-6. Remote antenna mounting bracket

0.28 (7,11) HOLE DIA 2-PLACES

2.25 (57,15)

1.13 (28,70) NOTE: DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESIS BNC CONNECTOR SHOWN PL259 USED FOR NEMA 12 APPLICATIONS

Triple Diversity Antenna.

The triple diversity antenna consists of three flex whip antennas mounted at different locations around the controlled machine. This is useful in applications where a single antenna cannot provide the coverage area required. The triple diversity antenna is also required for some of the advanced features of the Model R1014T2 receiver. For information on the Model R1014T2 receiver, see Appendix ‘A’ of this manual.

Each remote antenna mounting bracket should be placed in a location away from any sources of RF interference. Mount the antennas on the controlled machine or crane in such a way that the operator can keep one antenna in the line of sight at all times. For example, mount one antenna on each of three corners of the controlled machine. If this is not possible, then mount the antennas so as to keep one in line of sight from as much of the work area as possible. In addition, we recommend you physically tag each antenna and its associated line kit with a number (1, 2, and 3) and permanently record its individual location on the controlled machine or crane. Test the controlled machine thoroughly from the entire work area to verify adequate performance of the system. If satisfactory performance cannot be obtained, contact CATTRON-THEIMEG™ for assistance. ã04/2006, CATTRON-THEIMEG™

Section 2, Page 11

Direct DC Wiring Option.

The CATTRON-THEIMEG™ AT and ATS 816 Series PRC System receiver/decoders equipped for AC power may be powered directly from a proper1y filtered 13.8 VDC power source. This capability is normally used when the receiver/decoder is installed on a vehicle, such as a tow motor, truck, automated vehicle, or automobile. If this option is applicable, refer to the drawings provided with your system for actual wiring details.

CAUTIONS: On 12 VDC applications, incoming power must have a 1 Amp slow blow fuse in line with the positive lead near the battery or power source.

Insure that the proper DC voltage is connected to the receiver/decoder.

Observe proper polarity when making all connections.

Failure to comply with these cautions will result in vehicle and equipment damage.

The use of an external 13.8 VDC source requires the use of an external DC filter between the power supply and the receiver/decoder power terminals. When the receiver/decoder is supplied with DC voltage in this fashion, the circuit breaker on the gold box is non-functional. If an on/off switch is required, it must be provided in the power supply lines by the installer. The installer provides all wiring, switches, fuses, and terminals.

Referring to Figure 2-7 below, two screw terminals are provided for the 12 VDC wiring. These terminals are located on the side of the gold box. Connect the 12 VDC supply to the terminals marked Filtered DC Output. This bypasses the internal 115 VAC/12 VDC power supply. The AC/DC power supply may be left in place for use when bench testing the receiver/decoder. The Unfiltered DC Input terminals are not used when supplying power in this fashion.

Figure 2-7. 12 VDC wiring diagram

FILTERED + DC OUTPUT UNFILTERED + DC INPUT

RECEIVER/DECODER

Section 2, Page 12

INSTALLER SUPPLIED FILTER CATTR ON PN: CPA -0251 RED

NOT USED

BLK

18GA WIRE POWER SOURCE

OPTIONAL POWER ON/OFF SWITCH

1.0 AMP S.B.

18GA WIRE

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Pre-set Frequency Selections – ATS 816 Series only.

NOTE:

Each AT 816 Series PRC System has been custom designed by CATTRON-THEIMEG™ for a specific control application.

Consequently, the AT 816 series receiver frequency has been factory set and may not be changed by the customer.

In order for the receiver and the controller to communicate, they must be set to the same operating frequency and address. CATTRON-THEIMEG™ ATS 816 Series receivers offer several factory preconfigured frequency selections for maximum versatility. While the original factory setting should be adequate for most users, there may be conditions where it is necessary to change the operating frequency of an ATS 816 Series PRC system (installing a spare receiver circuit board, controller, or when other systems are emitting RF signals that interfere with safe operation). Before making any change to an ATS 816 Series frequency setting, remember that both the controller and the target receiver must be set to exactly the same operating frequency and address in order to communicate.

NOTES:

ATS 816 Series Receivers allow the customer to select any one of 16 factory pre -set frequencies. Refer to the radio frequency programming sheets supplied with the system for a list of the frequencies available on your ATS 816 Series receiver.

Frequencies for licensed systems must NOT be changed. If the frequency for a licensed system needs to be changed for any reason, including RF interference, contact CATTRON-THEIMEG™.

To change the frequency setting for the system controller, refer to the documentation provided with the controller. Follow the procedure below to change the ATS 816 Series receiver board frequency setting to one of the factory-preset frequencies: 1.

Open the cover of the receiver/decoder and remove power from the receiver/decoder by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

2.

Remove the lid from the gold box and locate the rotary frequency selector switch on the receiver circuit board. The switch is shown in Figure 2-8.

Figure 2-8. Rotary frequency selector switch location

RECEIVER CIRCUIT BOARD

ROTARY FREQUENCY SELECTOR SWITCH

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Section 2, Page 13

Pre-set Frequency Selections – ATS 816 Series only, continued.

3.

Using a small screwdriver, rotate the selector switch to the desired position.

4.

Replace the lid on the gold box.

5.

Restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

6.

Close the cover of the receiver/decoder.

Post Installation Checks.

The system and status display indicators described below are provided to assist you in carrying out the post installation checks. Please familiarize yourself with each indicator function before starting the checks.

System Status Display and LED Indicators.

A two character LED display is mounted on the decoder circuit board. A clear plastic window in the cover of the gold box provides for viewing of the display without removing the cover. The location of the system status display is shown in Figure 2-9 below.

AS O T.P.

Figure 2-9. System status display and status LED locations

ASO T.P.

1

Q-SYNC LED

CARRIER DETECT LED

VCO LOCK LED

RECEIVER POWER LED

RECEIVER BOARD

P1

0

DATA LED

RELAY OUTPUT BOARD

RELAY STATUS LED OPERATE (OPR) RELAY LED OPERATE (OPR) RELAY

OPTIONAL SUB-ADDRESS SELECTOR SWITCHES

SYSTEM STATUS DISPLAY

GII DECODER BOARD

Section 2, Page 14

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System Status Display and LED Indicators, continued.

During operation, the system status display shows the current status of the receiver/decoder. This includes any general status messages, hardware errors, data reception errors, and ASO errors.

The most common messages during normal operation include the address of the controller sending messages to the receiver and the message Fd. The Fd message simply indicates that the receiver has timed out while waiting for a message to be received from the controller. Refer to page 16 of this section which provides a complete description of system status display codes (Power- up and Runtime messages).

In addition to the two digit code, the system status display contains a decimal point to the right of the second digit. This decimal point flashes in synchronization with the signal LED on the controller when the decoder receives a signal from the controller.

Additional LED indicators are located on the receiver board and relay output board(s). These LEDs also indicate system status and are particularly useful in troubleshooting and adjusting the receiver. Refer to Table 2-1 below for an explanation of the LED indicators and Figure 2-9 above for the location of the LEDs. Table 2-1. LED indicator status codes

LED Relay Status (relay output board)

Description The red relay status LEDs energize whenever the corresponding relay is energized.

Receiver Power

This red LED indicates the presence of DC power on the receiver circuit board.

Carrier Detect

The green Carrier Detect LED on the receiver circuit board indicates that the receiver is receiving a RF signal.

Data

This yellow LED on the receiver circuit board indicates that the message received contains data.

Q-Sync

This orange LED on the receiver circuit board indicates that the receiver has synchronized with the incoming message.

VCO Lock

This red LED is located on the receiver circuit board underneath the EMI/RFI shield. This LED lights when the receiver frequency synthesizer is unable to lock onto the required frequency.

During normal operation the Carrier Detect, Data, and Q-Sync LEDs will flash when a signal is received from the controller. The flashing will match the flashing of the green transmit LED on the controller.

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Section 2, Page 15

Check-out procedures.

After installing the receiver/decoder, it is necessary to perform the following checks. Completing these checks will perform a complete test of all system functions. If the receiver/decoder does not function properly at any step, stop the procedure and fix the error. Repeat that step and then continue on with the remaining steps.

NOTE: Verify the following before starting the check-out procedure. · Double check to ensure there are no other remote control systems assigned to the same address as the system being tested. Multiple systems may use the same frequency, but no two systems should share the same address even if they are on different frequencies. · The crane or controlled machine must be equipped with the proper braking devices. If a fault occurs in the remote control system, the Operate (OPR) relay will de-energize.

The machine must be capable of stopping if this happens or if a loss of power occurs. · Before applying power to the receiver/decoder, verify the correct supply voltage. If the system uses DC power, verify the correct polarity also.

1.

Remove power from the crane or machine motors. This may be done by opening the motor control power switches at the control panel for each motor.

2.

Connect control power and turn on the receiver/decoder. Observe the following sequence on the receiver/decoder display panel: · The display shows Fb momentarily during the hardware timer failure test. · The decoder then reads the address code switch and displays the address. · After approximately 5 seconds the decoder times out. The display changes to Fd. During this power- up self check, the receiver/decoder may display an error message if any of the self checks fail. Refer to ‘POWER-UP MESSAGES’ and ‘RUNTIME MESSAGES’ below which provides a complete listing of all display codes. Refer to the troubleshooting information in Section 4 to correct any problems.

POWER-UP MESSAGES .

DISPLAY CODE A- x

DESCRIPTION An ASO fault has occurred on the relay that is indicated by the number that follows this message. The user shall see the “A-” message followed by the relay number that produced this condition. x = the applicable relay number whose value shall be between 01 and 16.

L- x

A Loop-check fault has occurred on the relay that is indicated by the number that follows this message. The user shall see the “L- ” message followed by the relay number that produced this condition. x = the applicable relay number whose value shall be between 01 and 16.

Section 2, Page 16

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Check-out procedures, continued.

POWER-UP MESSAGES. DISPLAY CODE 01 through 16

DESCRIPTION Second part of the ASO fault message or the Loop-check fault message informing the user which output relay number has produced the condition.

Fb

A watchdog timer test failure has occurred.

FC

The main output relay (RLY 0) has Failed Closed.

Fo

The main output relay (RLY 0) has Failed Open.

88

A test of the LED segments of the display. This message may be seen briefly during decoder power- up.

F1

The OPR watchdog is being tested. This message may be seen during decoder power-up.

F2

The motor watchdog is being tested. This message may be seen during decoder power-up.

---------------------------------------------------------------------------------------------------------------------------xx * This message represents the decoder code plug address. It shall be displayed immediately after the F2 message.

-x *

This message displays the rotary switch positions. If the top horizontal bar is illuminated, the rotary switch being displayed is the HUNDREDS rotary switch.

If the middle horizontal bar is illuminated, the rotary switch being displayed is the TENS rotary switch. If the bottom horizontal bar is illuminated, the rotary switch being displayed is the UNITS rotary switch. The values for x are 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, b, C, d, E, and F.

* These symbols are ONLY displayed in Sub-Address Active Mode ---------------------------------------------------------------------------------------------------------------------------CC The reading of the EEPROM has failed.

SS

System Shutdown: The decoder firmware has detected an error that has caused the system to shutdown.

RUN-TIME MESSAGES. DISPLAY CODE A- x

DESCRIPTION An ASO fault has occurred on the relay that is indicated by the number that follows this message. The user shall see the “A-” message followed by the relay number that produced this condition. x = the applicable relay number whose value shall be between 01 and 16.

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Section 2, Page 17

Check-out procedures, continued.

RUN-TIME MESSAGES. DISPLAY CODE L- x

01 through 16 EA Eb nP

DESCRIPTION A Loop-check fault has occurred on the relay that is indicated by the number that follows this message. The user shall see the “L- ” message followed by the relay number that produced this condition. x = the applicable relay number whose value shall be between 01 and 16.

Second part of the ASO fault message or the Loop-check fault message informing the user which output relay number has produced the condition.

Error Address: A bad address has been received by the decoder.

Error bch: A bad BCH has been received by the decoder. no Power-up: No power- up message was received by the decoder.

nn

no neutral: No neutral message was received by the decoder. This message must follow the power- up message.

EE Error Estop: An E-stop has occurred. The controller address that sent the E-stop command shall be shown immediately after the EE message is seen.

FC The main output relay (RLY 0) has Failed Closed.

Fo The main output relay (RLY 0) has Failed Open.

FE The code-plug address is invalid or is missing.

EL Error Ladder: There is a problem with the ladder network.

---------------------------------------------------------------------------------------------------------------------------EF * This indicates the sub-address of the encoder does not match the sub-address of the decoder. This message shall be followed by the positions of the rotary switches that reside on the D32GIIA printed circuit board. The rotary switch which designates the hundreds position is SW1. Its value shall be shown first in the display of the decoder sub-address. The user shall always see a ‘0’ in the left digit of the LED display with the hundreds rotary switch position being displayed in the right digit. The rotary switch which designates the tens position is SW2, and the rotary switch which designates the units position is SW3. The LED display shall show the tens rotary switch position in the left digit and the units rotary switch position in the right digit. The ‘EF’ message shall be shown, then the hundreds switch position, followed by the ‘EF’ message again, and finally, the tens and units switch positions. This display cycle shall continue until the sub-addresses match. * These symbols are ONLY displayed in Sub-Address Active Mode ---------------------------------------------------------------------------------------------------------------------------SS System Shutdown: The decoder firmware has detected an error that has caused the system to shutdown. oL

Section 2, Page 18

onLine: The encoder that has been powered down is online with the D32GII decoder board until the address timeout has expired. ã04/2006, CATTRON-THEIMEG™

Check-out procedures, continued.

Figure 2-10 below lists the hexadecimal codes displayed when the ASO circuit detects a relay closed with no corresponding command signal from the controller. Relays 1 through 8 are the relays on the right hand relay output board, labeled 1 through 8 downwards after the OPR relay. Relays 9 through 16 are the relays on the left hand relay output board labeled 9 through 16 upwards after the OPR relay.

Note that the OPR relay on each of the two relay output boards is not counted in the relay numbering/ hexadecimal code sequence. Consequently, ‘FC’ is a system status display code which indicates the OPR relay(s) has failed shut.

Figure 2-10. ASO hexadecimal codes

DISPLAY CODE

A0

DISPLAY CODE RELAY 16

OPR RELAY

FC = OPR relay failed shut

AF

RELAY 15

RELAY 1

A1

AE

RELAY 14

RELAY 2

A2

Ad

RELAY 13

RELAY 3

A3

AC

RELAY 12

RELAY 4

A4

Ab

RELAY 11

RELAY 5

A5

AA

RELAY 10

RELAY 6

A6

A9

RELAY 9

RELAY 7

A7

FC = OPR relay

OPR RELAY

RELAY 8

A8

LEFT HAND SIDE RELAY OUTPUT BOARD

RIGHT HAND SIDE RELAY OUTPUT BOARD

failed shut

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Section 2, Page 19

Check-out procedures, continued.

1.

2.

3.

· ·

·

·

Check the controller and receiver/decoder for matching frequencies and address codes.

The controller and receiver/decoder must have identical frequencies and address codes.

Remove the lid from the gold box. With the receiver/decoder power still on, switch on power to the controller.

While observing the receiver/decoder, press an auxiliary control button on the controller, such as a light, horn, or siren. Refer to Figure 2-9 on page 14 and observe the following indications on the receiver/decoder: The red Receiver Power LED on the receiver board is lit steadily, indicating power is present at the receiver circuit board.

The green Carrier Detect LED on the receiver flashes in sync with the green transmit LED on the controller. This indicates that the receiver is receiving the RF signal from the controller.

The yellow Data and orange Q-Sync LEDs on the receiver flash in sync with the green transmit LED on the controller. This indicates that the DATA and SYNC signals are being received and processed.

The two digit code on the system status display indicates the address of the decoder.

· The dot to the right of the first digit of the system status display flashes in sync with the green transmit LED on the controller. · The Operate (OPR) relay(s) on the output relay board(s) is energized. The Operate (OPR) relay LED next to the relay will light, indicating that the relay is energized.

During operation, the two-digit code on the system status display may momentarily display the code EA. This indicates that the receiver is receiving a signal with an improper address code which may be caused by RF interference. This occurrence may be OK, provided the amount of EA errors are minimal. If the dot to the right of the first digit of the decoder system status display is continuously illuminated, contact CATTRON-THEIMEG™ .

4.

Check all system functions in accordance with the specific custom model drawings.

Observe the relay status LEDs next to each relay as the function on the controller is activated. The red LED should light, indicating that the relay is energized. Check each output with a volt/ohm meter to ensure that the relay is closing properly, and that the fuse for the output is good.

5.

Press and hold one function on the controller. While holding the function, turn off power to the controller using the ON/OFF switch. All function outputs must de-energize within one second. On non- licensed systems the OPR relay will remain energized for 10 minutes. This test simulates a loss of the controller signal.

Section 2, Page 20

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Check-out procedures, continued.

6.

7.

8.

9.

For non-licensed systems only, restore power to the controller. Activate and maintain a function switch on the controller. While holding the function switch, observe the relays on the relay output board and push down the red System STOP button on the controller. All relays on the relay output board including OPR should immediately deenergize, as indicated by all LEDs turning off. The display on the decoder will display EE. To restore operation of the system, set the STOP switch on the controller to the ‘RUN’ position and cycle power to the controller by setting the ON/OFF switch to ‘OFF’ and then ‘ON’.

Return the machine motor control switches to the ON position.

Check each controller function carefully. Observe the system for proper operation of all functions.

Check for proper range of control. Operate the various machine functions while moving around in the system’s operating area. Move to the extreme edges of the operating area and ensure that the system functions still operate properly. Control should be maintained at all times.

If all the above steps are completed successfully, your 816 Series PRC system is now fully operational.

END OF SECTION

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Section 3 – Operating Instructions General.

During normal operation, the CATTRON-THEIMEG™ AT and ATS 816 series receiver/decoders require no operator action. The receiver/decoder is designed to operate completely unattended. All interfaces with the system are through the remote controller.

For controlling the system, CATTRON-THEIMEG™ offers several models of controllers. These models include single and dual pressure keypad controllers, toggle controllers, and paddle controllers.

For special installations, CATTRON-THEIMEG™ can custom-build a controller in any form to meet your exact specifications.

For information on operating the controller, refer to the instruction manual provided with the controller.

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Section 4 – Maintenance General.

CAUTION: Electrostatic sensitive devices such as EPROMs are present on circuit boards. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving circuit boards and electrostatic sensitive devices. Failure to comply with this caution may result in equipment damage and will void our warranty.

There are two basic types of maintenance: preventive and corrective. Preventive maintenance is a periodic check of the system to keep it functioning at peak performance. Preventive maintenance can also help prevent breakdowns and equipment outages by identifying potential problems before they become real problems. Corrective maintenance refers to fixing a problem once it has occurred. The goal of corrective maintenance is to get the system back on line as quickly as possible with a minimum impact on operations.

Any maintenance philosophy needs to encompass the entire system with the major components being the power supply, the receiver/decoder, the controller, and the antenna. A failure of any of these components prevents the entire system from functioning. As a result, the maintenance program needs to include all of these components.

When performing corrective maintenance, observe the following guidelines: · Tag all leads prior to de-soldering or removal from a terminal board. Use small wire tags or pieces of adhesive tape with handwritten numbers. Reconnect all wires to the same location from which they were removed.

NOTE:

Microprocessor devices, as used in CATTRON-THEIMEG™ PRC systems, use programmable EPROMs for program storage. Proper part numbers, version numbers and, in some cases, revision numbers must be used when installing spare circuit boards.

· Replace damaged or defective parts with identical parts. If it is necessary to use substitute parts, replace them with the correct part as soon as possible. The substitute part must have identical electrical properties. · Relocation of any part may result in a hum or other interference. Relocation of parts is not recommended.

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Section 4, Page 1

General, continued. · Before soldering any connections, carefully scrape all parts that will be touched by solder until all rust, corrosion, paint, and/or varnish are removed. Dust the parts with a small, clean, brush. Tin all surfaces to be soldered. Wrap the wire around the lug for a good mechanical connection and support prior to soldering. Solder the connection using a minimum of solder with sufficient heat to make the solder flow evenly around the tinned surface. · Inoperative systems are normally repaired by circuit board substitution. If possible, the entire EMI/RFI shielded chassis, the ‘gold box’, should be returned to CATTRONTHEIMEG™ for testing and repair. Make sure all optional jumpers are properly configured and the proper address code and frequency are set prior to applying power.

Failed circuit boards should be tagged with a description of the fault and sent to CATTRON-THEIMEG™ for repairs. · Mount all replacement parts in the same location using the same mounting arrangement as the previous part. Fasten all mounting hardware firmly.

Preventive maintenance.

Every three months perform the ‘post installation checks’ outlined in Section 2. This procedure provides a thorough check of the entire remote control system.

Typical additional checks.

The following additional checks should be performed on a periodic basis. Simple visual checks of the equipment provide a good early warning of any potential problems and take very little time to perform.

Additional checks such as fuses and power supply tests can be performed every three months when carrying out ‘post installation checks’.

Primary power supply.

Primary power sources should be the first step in performing preventive maintenance as they are always suspect in problems dealing with AC circuits. The supply voltages can often be too high as well as too low. Loose connections on fuses can occur even on an AC system. With the system deenergized, check for ‘hot’ fuses and connections.

Fuses.

Fuses, sometimes even when new, may have too high a resistance. Check the fuse and replace if the voltage drop across the fuse exceeds 0.1 volt.

Section 4, Page 2

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Preventive maintenance, continued.

Fuse holders.

Fuse holders may loosen or corrode. Accumulation of oil and dirt increases contact resistance. If this occurs, clean the contacts and tighten or replace the fuse holders.

Unit assemblies.

Unit assemblies include the receiver/decoder, controller, and relay output rack(s). To catch a maximum number of problems the technician must use his ears, eyes, sense of touch, and meter measurements, as well as past experience and good judgment.

Three types of basic observation are required: 1.

Visual inspection – Check for loose bolts, screws and clamps, arcing condition, and loose connections. A good visual inspection not only means quickly locating a source of potential problems, but also may prevent serious problems from developing later.

WARNING: DE-ENERGIZE AND TAG OUT ALL SOURCES OF ELECTRICAL POWER BEFORE CARRYING OUT TOUCH TESTS ON EQUIPMENT. FAILURE TO PROPERLY DE-ENERGIZE EQUIPMENT MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK.

2.

Touch tests – Fuses, fuse holders, resistors, and transformers that are too hot indicate possible trouble spots. Such tests are quick and should be used often.

3.

Status display interpretation – Simulation of faults, such as ASO, while observing the display will re-enforce the understanding of normal operating characteristics. This allows quick troubleshooting of any faults which may occur.

Antenna system.

Periodically conduct inspections of the antenna(s), antenna mounting device(s), cables, and connectors.

Perform meter checks to find any open or shorted lines or any high standing wave ratios. Performance checks are important to ensure that the minute voltages picked up from the transmitter are transferred properly to the receiver.

Netting.

Netting means that the receiver and transmitter of the radio control system are aligned on the same frequency. It is very important that the receiver is exactly tuned to the frequency required. This check should be done once a year by a qualified radio technician.

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Section 4, Page 3

Adjustments.

During normal system operation, there are no adjustments that need to be made to the receiver/decoder. Nearly all adjustments to the receiver/decoder are made during system installation.

The only setting that may require adjustment after installation is the squelch adjustment.

NOTE

The squelch control should not be adjusted except by trained personnel.

Tampering with the squelch could leave the receiver inoperable.

Referring to Figure 4-1 below, under normal operating conditions, when a carrier signal at a level just above the squelch limit of the receiver is detected, the receiver’s green Carrier Detect LED will turn on. If the carrier signal contains data and a Q-Sync pulse as would be the case if the signal had been transmitted from a CATTRON-THEIMEG™ controller, the receiver’s orange Data LED and yellow QSync LED would also turn on. In actual operation, these three LEDs will flash rhythmically with each transmission of the controller. This can be easily seen by observing the green transmit LED on the controller in conjunction with the receiver’s carrier detect, data, and Q-Sync LEDs. They will flash in unison.

In certain environments the squelch control may require adjustments. If the green Carrier Detect LED is on continuously, there may be an interfering signal on the selected operating frequency. The first option is to try to remove the interfering signal. If the signal cannot be removed, the squelch may need to be adjusted.

To adjust the squelch setting, turn on power to the receiver/decoder and turn off power to all controllers. Referring to Figure 4-1 opposite, while observing the green Carrier Detect LED, slowly rotate the squelch control potentiometer until the LED just turns off. This will set the receiver to a level where it will mask the interfering signals. Note that adjusting the squelch level will also reduce the receiver’s range. After adjusting the squelch, check the work area for range of control. Other options that may be affected by adjusting the squelch include the Range Limiter, Range Extender, and Close Start.

Adjustment of the squelch control is limited and may not be sufficient to solve the interference problem. A frequency change to another clearer channel, or the use of an attenuator to make the receiver less susceptible to overloading and distortion caused by strong signals on other adjacent channels may be required. Refer to Section 2 for attenuator details.

Section 4, Page 4

©04/2006, CATTRON-THEIMEG™

Adjustments, continued.

Figure 4-1. Squelch adjustment

Q-SYNC LED

SQUELCH CARRIER CONTROL DETECT LED

DATA LED

RECEIVER BOARD

816 Series Receiver/Decoder Troubleshooting.

Table 4-1 below, is arranged in a simple problem/cause/correction format. The possible faults are arranged in order from most likely to least. Perform all steps in the order listed when troubleshooting.

Table 4-1. Troubleshooting table

Problem

Cause

Correction

Receiver/Decoder ‘dead’. No status display light on decoder. No lights on receiver.

Loss of 110 VAC input power.

Check for 110 VAC power on input terminals in receiver/decoder.

Bad circuit breaker.

Check circuit breaker. Replace faulty circuit breaker.

Faulty power supply.

Check for 13.5 VDC output from power supply. If 13.5 VDC is not detected on power supply output terminals, replace power supply.

Faulty decoder.

Check for l3.5 VDC power to decoder. If 13.5 VDC is present, replace decoder.

Faulty wiring from power supply to decoder.

Measure DC voltage input to decoder at P6 from the red wire, V+, to the black wire, ground (see figure 4-6 on page 16 of this section for P6 location). If 13.5 VDC is present, replace decoder. Otherwise check and replace wiring from power supply to decoder as necessary.

Power on at receiver, but no power at decoder.

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Section 4, Page 5

816 Series Receiver/Decoder Troubleshooting , continued.

Table 4-1. Troubleshooting table (continued)

Problem

Cause

Correction

Decoder completes power on test correctly, but will not accept commands from controller.

Receiver LEDs do not flash.

Wrong controller, or wrong controller frequency.

Ensure the correct controller is being used for this system. When installed, ensure the STOP switch on the controller is in the ‘RUN’ position and the ON/OFF switch on the controller is set to ‘ON’.

Ensure the controller is set to the same frequency as the receiver. Refer to the controller manual for information on checking and setting the controller frequency.

Controller not functioning.

Activate a safe, non- motion, function on the controller and observe the green Carrier Detect LED on the receiver. If the LED does not blink, check the green Transmit LED on the controller. If it is not blinking, check and replace/re-charge the controller batteries, or replace controller.

Decoder and controller address code not matched.

Check the system status display. If the display shows the code EA when a function is commanded, the addresses for the controller and decoder do not match.

Check the address code displayed during decoder power up sequence. If address is not correct, replace the code plug. Refer to the Code Plug Replacement procedure later in this section for information on setting the address and replacing the code plug. If the displayed address code is correct, the controller address code may be incorrect. Check the controller manual for instructions on changing the controller address code.

Faulty receiver, or excessive RF interference.

If Carrier Detect LED on receiver circuit board is on steadily, then there may be excessive RF interference on the selected channel, or the receiver may be faulty.

Check the system status display code. The codes E5, EA, Eb, EC, and EF may all indicate RF interference. Replace receiver with a spare. If indications remain unchanged, contact CATTRONTHEIMEG™ or perform a site spectrum analysis to locate and correct the interfering RF source.

Decoder completes power on test correctly, but will not accept commands from controller.

Receiver LEDs flash.

Section 4, Page 6

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816 Series Receiver/Decoder Troubleshooting , continued.

Table 4-1. Troubleshooting table (continued)

Problem

Cause

Correction

Primary controller faulty but spare controller good.

Dead battery pack.

Replace/recharge battery packs.

Controller set to wrong address and/or frequency.

Check the system status display code. A code of EA indicates the controller and decoder are not set to the same address. Refer to controller manual and check/change address code and frequency.

Faulty controller.

If the above checks do not correct the problem, return the controller to CATTRON-THEIMEG™ for repair.

Antenna damaged or not installed properly.

Inspect antenna for any damage, including shorts, opens, and improper grounds. If a signal generator is available, test receiver sensitivity from the antenna location through the coaxial antenna cable to the receiver. Sensitivity should be 0.8 mV for 20dB quieting. Replace any antenna components found to be damaged.

Bad controller.

Substitute a spare controller.

Bad receiver.

Replace receiver. Refer to the Receiver Replacement procedure later in this section.

Decoder has registered an error.

Check decoder for any error messages. Refer to ‘POWER-UP MESSAGES’ and ‘RUNTIME MESSAGES’ in Section 2 for an explanation of system status display codes. Correct any faulty conditions resulting in error codes.

Decoder, relay, or interface wiring failure.

Check status LED for the Operate (OPR) relay. If LED is not lit when a function is activated, replace decoder per Decoder Replacement paragraph later in this section. If LED lights when the function is activated, inspect the wiring and associated fuse.

Replace relay per Relay Replacement procedure later in this section.

Unit works up close, but fails at longer ranges.

Controller, and receiver/decoder function properly, but mainline contactor will not pick up.

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Section 4, Page 7

816 Series Receiver/Decoder Troubleshooting , continued.

Table 4-1. Troubleshooting table (continued)

Problem

Cause

Correction

Mainline contactor picks up, but certain output functions don’t work.

Controller is not sending a command.

If the controller is equipped with a PTO bar switch, it must be depressed along with the function switch to send certain commands.

Controller is defective.

Observe the green Carrier Detect LED on the receiver circuit board. It should blink rapidly whenever a function switch is activated on the controller. If the Carrier Detect LED does not blink, replace the controller.

Faulty relay, ribbon cable, or decoder board.

If the Carrier Detect LED blinks when the controller is activated but the Relay Status LED is not lighting, swap the relay out with another known functional relay. If that relay does not function, check the ribbon cable for damage and ensure all connector pins are within the header. If the ribbon cable is serviceable, the decoder is faulty. Replace the decoder circuit board per Decoder Replacement paragraph, later in this section.

Faulty wiring, no power to device being controlled.

Check the following items: power to the device being controlled, output relay operational in another position, associated fuse is in good condition, interface wiring to the driven device is in good condition, terminal screws tight, driven device functional. Repair all defective components.

Error code displayed on system status display.

The system status display shows an error code any time a malfunction occurs.

Refer to ‘POWER-UP MESSAGES’ and ‘RUNTIME MESSAGES’ in Section 2 for a complete description of all error codes. Correct any faulty conditions found.

Blown fuses on relay output board.

Overload condition in controlled machinery.

Check for shorted motor starters, contactors, or interface wiring. Ensure controlled device is in good functioning condition. Repair any defective equipment identified and replace fuse.

Section 4, Page 8

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Automatic Safety Override (ASO).

The Automatic Safety Override (ASO) feature continually monitors the status of all relays. If any relay energizes when there is no corresponding signal from the controller, the ASO circuit will immediately de-energize the Operate (OPR) relay(s). This safety feature prevents uncommanded movement of any controlled equipment due to a shorted relay output by disconnecting power to the mainline contactor on the controlled equipment.

A simple test checks the functionality of the ASO circuit. Refer to Figure 4-2 below and the following procedure to test the ASO circuit.

WARNING: HIGH VOLTAGE MAY BE PRESENT ON THE RELAY OUTPUT TERMINALS. EXERCISE CAUTION WHEN WORKING NEAR THE RELAY OUTPUT BOARD(S). FAILURE TO OBSERVE THIS WARNING MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK. WARNING: REMOVE POWER FROM THE CRANE OR MACHINE MOTORS BEFORE PERFORMING ASO TESTS. THESE TESTS REQUIRE THE ENERGIZING OF THE OUTPUT RELAYS USING JUMPERS. ENERGIZING THE RELAYS WHILE POWER IS APPLIED TO THE SYSTEM MOTORS MAY RESULT IN UNDESIRED MOVEMENT OF THE CRANE OR MACHINE. IN ADDITION, DAMAGE TO THE CIRCUIT BOARDS MAY RESULT IF THE TEST JUMPER CONTACTS THE WRONG COMPONENT. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

ASO Circuit Test Procedure.

1.

When installed to the controller, set the system STOP switch to ‘STOP’ and the ON/OFF switch to ‘OFF’. This will completely isolate the controller.

2.

Remove power from the crane or machine motors. This is normally done by opening the circuit breakers for the motors at the motor control panels.

3.

Open the receiver/decoder door to access the relay output boards.

4.

Referring to Figure 4-2 below, touch one end of a test jumper to the GND (TEST) test point on the relay output board. Touch the other end of the jumper to the ASO TP test point next to relay #0, the Operate (OPR) relay.

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Section 4, Page 9

ASO Circuit Test Procedure, continued.

Figure 4-2. ASO test points P2

P1

Relay 8

Relay 7

Relay 6

Relay 5

Relay 4

Relay 3

ASO T.P.

Relay 2

Relay 1

Relay 0 (OPR)

RELAY OUTPUT BOARD

GND (TEST) TEST POINT ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

GND (TEST)

ASO TP TEST POINT

5.

Relay #0 will energize, simulating a fault in the OPR relay circuit. The system status display will show the fault as an error code FC. Set the controller to ‘ON’ and activate a non- motion function, such as a horn, siren, or light. The decoder should not operate, and the commanded action should not occur. Set the controller to ‘OFF’ and remove the jumper end from the ASO TP test point.

6.

Apply power to the controller (set the controller to ‘OFF’ and then to ‘ON’). Relay #0 should energize.

7.

Touch the free end of the jumper to the ASO TP test point for each of the remaining relays one at a time. The relay should energize. The ASO circuit will detect the relay energizing without a controller command and immediately de-energize relay #0, preventing any uncommanded movement of the machine. The system status display will show an error code indicating which relay activated the ASO circuit. For example, an error code of A4 indicates rela y #4 failed.

8.

If any relay fails the ASO test, replace the relay and repeat the test. If the relay fails again, replace the decoder board per the procedure later in this section.

9.

After testing all relays, remove the jumper from the ASO TP and GND (TEST) test points and close the cover of the receiver/decoder.

10.

Switch off and isolate the controller before restoring power to the crane or machine motors.

Section 4, Page 10

©04/2006, CATTRON-THEIMEG™

Receiver/Decoder Repair.

Replacing the EMI/RFI shielded chassis (gold box).

Replacing the EMI/RFI shielded chassis, or ‘gold box’, with a spare unit is the easiest and fastest way of correcting problems with the receiver/decoder. The gold box can then be returned to CATTRONTHEIMEG™ for repair. This is the recommended method of repair when the technician has not been trained on repairing CATTRON-THEIMEG™ receiver/decoders. Due to the interaction between the various electronic circuits, some errors may be difficult or impossible to track down without proper training or test equipment. This could result in sending the wrong part back to the factory for repair. In most cases it is simpler to just remove and replace the entire gold box.

Referring to Figure 4-3 below, replace the ‘gold box’ as follows: 1.

Open the cover of the receiver/decoder.

2.

Remove power from the gold box by turning off the circuit breaker on the bottom.

3.

Note the receiver frequency and decoder address printed on a label on the side of the gold box. The replacement gold box must be set to the same frequency and address.

Figure 4-3. EMI/RFI shielded chassis replacement

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Section 4, Page 11

Replacing the EMI/RFI shielded chassis , continued.

4.

Disconnect the plug between the 110 VAC power input line and the gold box.

5.

Disconnect the antenna connector from the bottom of the gold box.

NOTE:

Take care not to bend the gold box connector pins in the following step.

When disconnecting the ribbon cable, carefully work the header slowly away from the connector pins.

6.

Disconnect the ribbon cable connecting the gold box to the relay output boards.

7.

Loosen the four nuts securing the gold box to the cover of the receiver/decoder and withdraw the gold box from the receiver/decoder.

8.

Place the new gold box on the door of the receiver/decoder and secure with the four nuts loosened in step 7.

NOTE:

When connecting the ribbon cable in the following step, the red strip on the ribbon cable header should align with the red spot on the gold box connector. Insure all gold box connector pins are located within the ribbon cable header.

9.

Make sure the ribbon cable adapter is connected in- line with the ribbon cable from the relay output board and the ribbon cable to the gold box.

10.

Connect the antenna cable to the connector on the bottom of the gold box.

11.

Connect the 110 VAC power cable to the plug from the input terminal block.

12.

Compare the frequency and address code for the new gold box to the frequency and address code from the old gold box. When applicable, set the frequency per Section 2 of this manual and replace the code plug using the procedure found later in this section.

13.

Restore power to the receiver/decoder. Close and secure the cover on the receiver/decoder.

14.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

Relay replacement.

Referring to Figure 4-4 below, replace an output relay as follows: 1.

Open the cover of the receiver/decoder.

2.

Remover power from the receiver/decoder by turning off the circuit breaker located on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

3.

Gently pull away the two retaining tabs on the sides of the relay being removed.

4.

Pull the relay from the relay output board.

5.

Verify that the replacement relay is the same type as the relay removed.

Section 4, Page 12

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Relay replacement, continued.

6.

Install the new relay on the relay output board. Ensure that the relay orientation matches the orientation of the other relays installed. The relay is keyed to only fit in one direction. Do not force the relay onto the board. If it does not fit easily into the socket, remove the relay, check the orientation and pins, and try again.

7.

After installing the new relay, ensure the retaining tabs snap into place to hold the relay.

8.

If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

9.

Close and fasten the cover of the receiver/decoder.

Figure 4-4. Relay replacement RETAINING TABS

ASO T.P.

RELAY ASO T. P. GND (T EST)

Receiver replacement.

CAUTION: Electrostatic sensitive devices such as EPROMs are present on circuit boards.

Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving circuit boards and electrostatic sensitive devices. Failure to comply with this caution may result in equipment damage and will void our warranty.

When replacing the receiver circuit board, the new receiver must have the same frequency as the old receiver. Failure to match the frequencies will result in the receiver/decoder not receiving commands from the desired controller. Matching frequencies is accomplished by (1) verifying the EPROM part number (see next paragraph), and (2) setting the rotary frequency selector switch to the same position on the new receiver as the old receiver. Refer to the programming information provided with your customized documentation package.

As indicated above, the new receiver must have the same EPROM as the old receiver. The EPROM determines frequency and contains the program for the receiver. Check the part number on the label of the EPROM before replacing the receiver. If the EPROM does not match, contact CATTRON-THEIMEG™ . ©04/2006, CATTRON-THEIMEG™

Section 4, Page 13

Receiver replacement, continued.

Referring to Figure 4-5 below, replace the receiver circuit board as follows: Figure 4-5. Receiver replacement

RECEIVER CIRCUIT BOARD

GOLD BOX

ROTARY FREQUENCY SELECTOR SWITCH

MOUNTING SCREW

ANTENNA LEAD GOLD BOX LID

POWER AND SIGNAL WIRING CONNECTOR

1.

Open the cover of the receiver/decoder.

2.

Remove power from the EMI/RFI shielded chassis, or ‘gold box’, by turning off the circuit breaker on the bottom. Remove the lid from the gold box.

3.

Note the receiver frequency by checking the EPROM part number and noting the position of the rotary frequency selector switch. The new receiver circuit board must have the same EPROM part number and also be set to the same frequency.

4.

Disconnect the antenna lead from the receiver circuit board.

5.

Disconnect the power and signal wiring connector from the header on the receiver circuit board.

Section 4, Page 14

©04/2006, CATTRON-THEIMEG™

Receiver replacement, continued.

6.

Remove the four mounting screws securing the receiver.

7.

Remove the receiver circuit board from the gold box.

8.

Set the frequency of the new receiver to the same frequency as the old receiver. This is done by matching EPROM part numbers and the positions of the rotary frequency selector switches.

9.

Install the new receiver into the gold box and secure with the four mounting screws.

10.

Connect the power and signal wiring connector to the receiver terminal strip.

11.

Connect the antenna lead to the receiver.

12.

Install the lid on the gold box.

13.

If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

14.

Close the cover of the receiver/decoder.

15.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

Decoder replacement.

CAUTION: Electrostatic sensitive devices such as EPROMs are present on circuit boards.

Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving circuit boards and electrostatic sensitive devices. Failure to comply with this caution may result in equipment damage and will void our warranty.

When replacing the decoder circuit board, the new decoder must have the same address code as the old decoder. Failure to match the address code will result in the receiver/decoder not receiving commands from the desired controller. Matching the address code is accomplished by removing the code plug from the old decoder and installing it in the new decoder.

The code plug is secured in place by silicon sealant. This sealant prevents the code plug from vibrating free of its socket. Proper care must be taken to ensure that no components are damaged when removing the silicon sealant. After inserting the new code plug, it must be secured in place with a new application of silicon sealant. If the new decoder has the correct code plug installed, then the code plug will not need to be replaced. The address code of the decoder board may be checked by observing the address code displayed when the receiver/decoder is powered up.

The new decoder must also have the same EPROM as the old decoder. The EPROM contains the program for the decoder governing the behavior of the receiver/decoder. Check the part number on the label of the EPROM prior to replacing the decoder. If the EPROM does not match, contact CATTRON-THEIMEG™ .

When swapping out or installing an EPROM, refer to EPROM Replacement at the end of this Section. ©04/2006, CATTRON-THEIMEG™

Section 4, Page 15

Decoder replacement, continued.

Referring to Figure 4-6 below, replace the decoder circuit board as follows: 1.

Open the cover of the receiver/decoder.

2.

Remove power from the receiver/decoder by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

3.

Remove the lid from the gold box.

4.

Disconnect the power and signal wiring connector from the header on the decoder circuit board.

5.

Observe and record the EPROM part number. The replacement decoder circuit board must have the same EPROM part number.

6.

Remove the four mounting screws securing the decoder circuit board.

7.

Carefully lift the left side of the decoder circuit board. Slide the board to the left to disengage the connector from the pins on the side of the gold box.

Figure 4-6. Decoder replacement

DECODER CIRCUIT BOARD POWER AND SIGNAL CONNECTOR

POWER AND SIGNAL HEADER (P6)

GOLD BOX

GOLD BOX CONNECTOR PINS CODE PLUG

GOLD BOX LID

EPROM

Section 4, Page 16

MOUNTING SCREW

©04/2006, CATTRON-THEIMEG™

Decoder replacement, continued.

NOTE:

When installing a new decoder circuit board in the following step, insure all gold box connector pins are aligned with and properly located within the circuit board header.

8.

Install the new decoder circuit board by carefully lining up the header on the right side of the circuit board with the connector pins on the side of the go ld box and sliding the circuit board firmly to the right.

9.

Install the four mounting screws securing the decoder circuit board to its mounting studs.

10.

Connect the power and signal wiring connector to the decoder header.

11.

Note the address codes of the new and old decoder circuit boards, as marked on their respective code plugs (the address of the old decoder is also printed on a label attached to the outside of the gold box). If the address of the new decoder does not match the address of the old decoder, the code plug installed in the new decoder circuit board may be replaced with the code plug from the old decoder circuit board.

12.

To replace the code plug, turn off the power to the receiver/decoder. Carefully cut away the silicon sealant holding the code plug. Remove the code plug by pulling straight up and away from the board. Remove the code plug from the old decoder circuit board in the same fashion. Install the code plug in the new circuit board and secure in place with a new application of silicon sealant.

13.

Install the lid on the gold box.

14.

If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

15.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

Code plug replacement.

Each CATTRON-THEIMEG™ receiver/decoder and controller is equipped with a code plug. This code plug contains the address of the receiver/decoder or controller. 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. If the addresses do not match, the signal is ignored and an error message is displayed on the receiver/decoder. For safety reasons, it is important that no two receiver/decoders at a location use the same address and frequency settings. This could cause operation of undesired equipment resulting in damage to equipment and/or personal injury.

While the factory settings should be adequate for most users, there may be conditions where it is necessary to change the address code. This may be necessary when installing a spare receiver/decoder or controller. Prior to making any change in the address setting, check the address settings on both the receiver/decoder and the controller.

©04/2006, CATTRON-THEIMEG™

Section 4, Page 17

Code plug replacement, continued.

On some controllers, the factory assigned address code can be found by removing the battery cover and battery. For information on setting the code for your controller, refer to the documentation provided with the controller.

The code assigned to the receiver/decoder at the factory is found on a label placed on the side of the ‘gold box’. A code plug installed on the decoder circuit board sets the code. CATTRON-THEIMEG™ sets the code of all receiver/decoders before they leave the factory. If the code must be changed, a new code plug with the new code must be obtained from CATTRON-THEIMEG™ . In some circumstances CATTRON-THEIMEG™ may provide blank, or unset, code plugs. An unset code plug must have a code set prior to installing in the decoder. This is described in the procedure below. Installing an unset code plug will produce an error code and the receiver/decoder will not operate.

To replace the code plug for the receiver/decoder, follow the procedure below: 1.

Open the cover of the receiver/decoder.

2.

Remove power from the receiver/decoder by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

3.

Remove the lid from the gold box.

4.

Find the code plug located on the decoder circuit board. The code plug location is shown in Figure 4-7.

5.

Carefully cut away the silicon sealant holding the code plug. Remove the old code plug by pulling straight up and away from the decoder board.

Figure 4-7. Code plug location DECODER BOARD

6.

CODE PLUG LOCATION

If the new code plug is blank, set the new code. To set the code, leads 2 through 8 must be cut in a specific pattern. Figure 4-8 opposite shows all possible codes for the code plug. For example, to set the code plug to code 26, leads 3, 4, and 7 must be cut.

Section 4, Page 18

©04/2006, CATTRON-THEIMEG™

Code plug replacement, continued.

Figure 4-8. Code plug settings

©04/2006, CATTRON-THEIMEG™

Section 4, Page 19

Code plug replacement, continued.

7.

8.

9.

10.

Install the new code plug and secure in place with a new application of silicon sealant.

Replace the lid on the gold box.

Close the cover of the receiver/decoder. If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

EPROM replacement.

Replace an EPROM as follows: CAUTION: EPROMs are electrostatic sensitive devices. Use an anti-static mat and personal grounding strap (wrist) when replacing or installing EPROM’s.

Failure to comply with this caution may result in equipment damage and will void our warranty.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11

Open the cover of the receiver/decoder.

Remove power from the receiver/decoder by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

Remove the lid from the gold box.

Find the EPROM located on the decoder circuit board. The EPROM location is shown in Figure 4-6.

Observe and record the exact orientation of the EPROM within its circuit board location.

Remove the EPROM. Carefully install the new EPROM in the vacated circuit board location, making sure its orientation is exactly the same as recorded in step 5 above.

Replace the lid on the gold box.

Close the cover of the receiver/decoder. If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

Return the EPROM to CATTRON-THEIMEG™ .

END OF SECTION

Section 4, Page 20

©04/2006, CATTRON-THEIMEG™

Section 5 – Parts List and Accessories Introduction.

The following two figures and tables provide an exploded view of the CATTRON-THEIMEG™ AT and ATS 816 Series receiver/decoder. Figure 5-1 shows the entire receiver/decoder. Figure 5-2 shows only the EMI/RFI shielded chassis (Gold Box) and its internal components. Cross refer to Table 5-1 or Table 5-2, respectively, for a complete part listing for that drawing.

The Accessories section, following the parts lists, provides information on some optional equipment to enhance the functionality of the receiver/decoder.

ã04/2006, CATTRON-THEIMEG™

Section 5, Page 1

Figure 5-1. AT & ATS 816 Series PRC Receiver/decoder - exploded view (illustrated parts breakdown)

Table 5-1. AT & ATS 816 Series PRC Receiver/decoder parts list

Index #

Part Number

Description

1

CPA-0228-12STL

Enclosure, painted steel, NEMA 12 (IP65), pre-wired with back panel *

16C-0087

Same as above, enclosure only

CPA-0228-4STL

Enclosure, painted steel, NEMA 4 (IP66), pre -wired with back panel *

16C-0220

Same as above, enclosure only

CPA-0228-4XSS

Enclosure, stainless steel, NEMA 4X (IP66), pre-wired with back panel *

16C-0247

Same as above, enclosure only

CPS-0228-4XFIB

Enclosure, fiberglass, NEMA 4X (IP66), pre-wired with back panel *

16C-0251

Same as above, enclosure only

Section 5, Page 2

ã04/2006, CATTRON-THEIMEG™

Table 5-1. AT & ATS 816 Series PRC Receiver/decoder parts list, continued

Index #

Part Number

Description

2

CPA-0217

Cable, antenna (includes items 3, 4, and 5 below)

3

Connector, antenna, PL259

4

Lock washer

5

Nut

6

85C-0035

Antenna, flex-whip, UHF

Not shown

CPA-0150

Antenna assembly, triple diversity, for Range Limit/Range Extender capabilities of R1014T2 receivers

7

Wing nut

8

Washer

9

Seal

10

32C-0021

Hole seal, conduit (Includes items 7, 8, and 9)

11

Back panel, chassis 816, DEC, aluminum

12

Screw, mounting

13

31C-0009

Barrier block, 141, 3 terminal, dual row

14

43C-0071

Spacer, threaded, male/female, 6-32

15

33C-0004

Nameplate, caution, 110 VAC, red/white

16

02C-0002

Nut, acorn, 6-32 x 0.315, brass, nickel

17

Screw, terminal

18

Ground wire

19

09C-0298

Socket, power harness, 3-prong, 110 VAC

20

01C-PB9R

Rack, relay output, 9 position, with relays, RC snubbing, includes items 21, 22, 23, and 24)

21

65C-0173

Fuse, 5 A

22

Screw, terminal, captive washer

23

Screw, mounting

24

80C-0375

Relay, 1 N.O. contact

25

CPA-0225

Cable, ribbon, with connector, 2 output boards

Not shown

CPA-0226

Cable, ribbon, with connector, 1 output board

Not shown

CPA-0342

Adapter, D32 to PB9R Board Cables, 50-pin

26

CPA-0216

EMI/RFI chassis, pre-wired, with lid, 120 VAC power supply

27

Nut, hex, 8-32 x 5/16, steel

28

Screw, machine, button head, 8-32 x 1/2, stainless

29

54C-0092

Label, CATTRON-THEIMEG™

Not shown

10C-0096-BNC

Remote antenna mount kit, 20 feet coax cable, BNC connector

Not shown

10C-0096

Remote antenna mount kit, 20 feet coax cable, PL259 connector

Not shown Not shown

Transfer switch kit, 3 position, 4 circuits AT-SPARE-KIT

One 120 VAC power supply, two relays, miscellaneous fuses

* Includes items 2 through 5, 7 through 19, and 27 through 29. Items 2 through 10 not included on NEMA 4 and 4X models. Items 15 through 19 not included on models equipped for DC power.

Parts with no part number listed are not available for individual sale. Contact CATTRON-THEIMEG™ for more information.

ã04/2006, CATTRON-THEIMEG™

Section 5, Page 3

Figure 5-2. EMI/RFI shielded chassis - exploded view (illustrated parts breakdown) 30 26 25

29 27

24 20

28

1

23 21 18

10

22

2 3

17

19 31

6

4

15 16 5

7 14

13

11

12

9 8

Section 5, Page 4

ã04/2006, CATTRON-THEIMEG™

Table 5-2. EMI/RFI shielded chassis parts list

Index #

Part Number

Description

1

Chassis, 816, decoder, aluminum

2

Barrier block, 4 termina l

3

Washer

4

Terminal screw

5

30C-0032

Cord, power, 3 conductor, 110 VAC

6

65C-0124

Circuit breaker, 1 Amp, SPST

7

Label plate, circuit breaker

8 9

Nut 01C-0089

Power supply, 120 VAC/12 VDC, 0.85A, 10W (AC powered systems only)

CPA-0251L

Convertor, 10-36 VDC/13.8 VDC @ 8A, 12W (DC powered synthesized systems only)

CPA-0251-13.8

12 VDC filter assembly (non synthesized, DC powered systems only)

10

Screw, mounting

11

Terminal block, bulkhead pass through

12 13

Nut R1014T1HW (see ƒ)

Receiver, 447-473 MHz, 25 kHz (High wide band) spacing, less EPROM

R1014T1HN (see ƒ)

Receiver, 447-473 MHz, 13.5 kHz (High narrow band) spacing, less EPROM

R1014T1MN (see ƒ)

Receiver, 425-447 MHz, 13.5 kHz (Mid narrow band) spacing, less EPROM

14

Screw, machine, pan, slot, 4-40 x 1/2, steel

15

51S-1014T-XXX

EPROM, basic synth. receiver, programmed

16

09C-0245

Connector, bulkhead BNC, right angle, soldered

17

Washer, lock

18

Nut

19

01C-0094SYN

Antenna cable, internal 816 chassis

20

D32GII

Decoder, less EPROM and code plug

21

Screw, machine, pan, slot, 6-32 x 5/8, steel

22

51S-0832-ATX

EPROM, decoder, programmed, AT system

23

06C-0335P

Code plug, high profile

24

Terminal block, bulkhead pass through

25

Washer

26

Nut

27

Harness, decoder power and signal

28

Harness, receiver power and signal

29

CPA-0220

30 31

Assembly, filter board, 50 pin Nut

01C-27C-0002L

Lid, chassis, 816 decoder, aluminum

ƒ = Other frequency bands/channel spacings available upon request, contact CATTRON-THEIMEG™ for details.

Item 5 through 8 not included on models equipped for DC power.

Parts with no part number listed are not available for individual sale. Contact CATTRON-THEIMEG™ for more information.

ã04/2006, CATTRON-THEIMEG™

Section 5, Page 5

Accessories.

A popular accessory that enhances the functio nality of CATTRON-THEIMEG™ AT 816 Series receiver/decoders is described below. In addition, we emphasize that a Transfer Switch will be necessary when the controlled equipment has both manual control and remote control (refer to page 7 for schematic diagram). Please contact the CATTRON-THEIMEG™ factory or your sales representative for further details.

1. Two-step electro-hydraulic brake package.

The CATTRON-THEIMEG™ Two-Step Electro-Hydraulic Brake Package allows a convenient and easy conversion of an electric overhead traveling (EOT) crane from cab control to remote or pendant control. The brake system is designed for installation in parallel to the existing foot brake. This eliminates the need to replace the current system. CATTRON-THEIMEG™ offers the brake package in several models for use with many different crane power sources, including 110, 220, 440 VAC and 250 VDC. Any model of CATTRON-THEIMEG™ PRC, as well as a pendant or other brand of remote control can control brake operation.

The standard brake package offers two steps of brake application and a brake release function. This allows precise control of crane brakes. Optional parking brake release and three step braking are available on some models.

Each braking step is individually adjustable. The PRC or pendant operator selects the amount of brake application pressure. Normally a soft brake is applied when the bridge control is in neutral. Hard brake pressure is selected through the controller and applied when a need for a faster stop arises.

The CATTRON-THEIMEG™ Two-Step Electro-Hydraulic Brake Package provides safety for the crane system. When properly installed, the brake package will not allow operation of the crane unless sufficient brake pressure exists to stop the crane in case of an emergency. Brake pressure is stored using a hydraulic accumulator. Any loss of power automatically results in application of the crane brake. This provides braking even when crane power is lost or turned off for a short period of time.

For more information on the CATTRON-THEIMEG™ Two-Step Electro-Hydraulic Brake Package, contact CATTRON-THEIMEG™ .

Section 5, Page 6

ã04/2006, CATTRON-THEIMEG™

2. Transfer Switch. Refer to Section 2, page 5 of this manual for description and typical wiring diagram.

END OF SECTION ã04/2006, CATTRON-THEIMEG™

Section 5, Page 7

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Section 5, Page 8

ã04/2006, CATTRON-THEIMEG™

Appendix A – R1014T2 Receiver Introduction.

The optional Model R1014T2 receiver contains several advanced functions that can be used to enhance the functionality of all CATTRON-THEIMEG™ Portable Radio Remote Control (PRRC) systems.

These functions are: · Close Start. ·

Range Limit.

·

Range Extend.

·

Scanner (optional) – may require ‘gold box’ modifications, contact CATTRONTHEIMEG™ .

·

Attenuator.

·

Field Programmable Frequency Selection.

Close Start, Range Limit, and Range Extend require the use of a Triple Diversity Antenna system.

When installing a triple diversity antenna system, we recommend you physically tag each antenna and its associated line kit with a number (1, 2, and 3) and permanently record its individual location on the controlled machine. Such identification will be required when setting up the advanced functions described on the following pages.

The Model R1014T2 receiver can be easily identified by its LCD display and two display control pushbuttons, shown in Figure A-1.

Figure A-1. R1014T2 receiver

ANTENNA #1 INPUT ANTENNA #2 INPUT ANTENNA #3 INPUT

NOTE: Pushbutton #1 increments the display Pushbutton #2 decrements the display

CARRIER DETECT LED

#2 #1

DISPLAY CONTROL PUSHBUTTONS

ã04/2006, CATTRON-THEIMEG™

LCD DISPLAY

ROTARY FREQUENCY SELECTOR SWITCH

Appendix A – Page 1

Additional Safety Feature.

As an additional safety measure, we have recently implemented a ‘Power- up/Neutral’ feature on all AT & ATS systems. To accomplish this, the R1014T2 Receiver has been factory programmed to clamp the data being sent to the decoder when the operator moves out of range with ‘Range Limiting’ enabled. Consequently, as the result of the decoder not receiving any valid messages, the OPR (Operate) Relay is de-energized, which in turn opens the Mainline Contactor of the controlled machine, preventing any machine movement.

When the operator moves back into range and the receiver again begins passing data to the decoder, the mainline contactor will not close because the OPR Relay remains de-energized until the decoder receives a new ‘Power- up/Neutral’ message from the controller.

Referring to the existing ‘Range Limiting’ and Close Start’ operating procedures in this Appendix: To resume remote control operations with ‘Range Limiting’ enabled, the operator must first move closer to the controlled machine to activate the Range Limit. In addition, the operator must now set the controller to ‘OFF’ and then back to ‘ON’ in order to regain full machine control.

If the ‘Close Start’ function is also enabled, and the operator stays out of range for longer than the programmed close start time, he or she must first walk forwards into the preset close start range of the machine. In addition, the operator must now set the controller to ‘OFF’ and then back to ‘ON’ in order to regain full machine control.

Close Start setup.

The Close Start option is a safety feature that prevents the controlled machine from operating until the operator is close enough to the machine to visually observe all machine control functions. Once the operator is within a preset, programmable operating range of the machine, he or she will be required to ‘unlock’ the Close Start function before being allowed to proceed with remote control operations.

There are three parameters you will be required to set: 1.

Time – determine the time the operator can be off the air before remote control operation is locked out and close start must be satisfied.

2.

Select Close Start Antenna – determine which antenna (1, 2, or 3) the operator will be closest to in order to capture (enable) the controlled machine.

3.

Signal level – determine the RF signal strength level of the controller that the receiver must select for the operator to unlock the Close Start function and perform remote control operation. This is a directly related function of the distance between the operator and machine.

Appendix A – Page 2

ã04/2006, CATTRON-THEIMEG™

Close Start setup, continued.

Close Start requires the use of the triple diversity antenna system. When setting the Close Start options, one of the three antennas must be selected (programmed) as the antenna used to unlock the Close Start function. Once operations have begun, the operator may be any distance from the machine up to the maximum operating range. This may be the maximum range of the controller, or it may be limited using the Range Limit option.

If a preset time limit passes without any operator commands (the programmable Close Start lockout time), the Close Start system will lock out all further operations until the operator moves back within the Close Start unlocking range.

Read and thoroughly understand this entire procedure prior to setting the Close Start options. It is recommended that two people work together to perform this procedure. For example: One person with the remote controller will need to assume the desired Close Start capture position when starting the controlled equipment on the ground. The second person will board the controlled equipment to (1) ensure the receiver/decoder is fully operational before setting the Close Start options, and (2) observe the RF signal strength indication on the LCD display while setting the desired close start parameters using the two control pushbuttons on the receiver.

Close Start utilizes RF signal strength to determine the close start distance and therefore is not a precision setting. Many factors may affect the RF signal strength, such as controller position, antenna position and direction, building environment, and background RF noise. After setting Close Start, check the system performance several times. You may have to repeat the setup procedure to optimize system performance.

Refer to Figure A-2 overleaf which shows the typical ranges for the Close Start option.

ã04/2006, CATTRON-THEIMEG™

Appendix A – Page 3

Close Start setup, continued.

Figure A-2. Close Start ranges

Close Start unlock circle.

Operator must be within this circle to unlock Close Start and allow data messages to the decoder. After Close Start unlock, operating range extends beyond this circle.

Receiver Close Start Antenna Location Unlock distance (Typical 10-20 ft) (3 - 6 m)

d

e na ng te n a R an g in an y t) t a f er o m 00 Op e f r l3 ) a c ic m ta n (Typ (9 0 is

To set Close Start, proceed as follows: 1.

Determine the length of time the operator can be off the air before he or she is required to satisfy the Close Start ‘unlock’ requirement. This time may be set from 0.1 minute to 15 minutes, depending on the application and user preference. It is factory set to 2 minutes.

2.

The person with the remote controller should assume a position on the ground at the desired distance to unlock Close Start. This distance is typically 10 to 20 feet from the controlled machine where he or she can visually observe all machine control functions.

Appendix A – Page 4

ã04/2006, CATTRON-THEIMEG™

Close Start setup, continued.

3.

Note which machine mounted antenna is closest to the person with the remote controller – this will be designated the Close Start Antenna. Record the number of this antenna – this may be 1, 2, or 3, as previously tagged and recorded when the triple diversity antenna system was installed.

4.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

5.

Board the controlled machine, open the receiver/decoder and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

6.

Set the gold box power to ‘ON’.

7.

Instruct the person with the remote controller on the ground to apply power to the controller. NOTE: (1) If FCC Part 90 requirements apply to your PRRC system the controller will transmit a continuous RF signal once power is applied. (2) If FCC Part 15 requirements apply to your PRRC system, you must also activate and maintain a controller function that will not cause any movement of the controlled machine. This function could be a horn, light, or other indicator and must be maintained until you are instructed otherwise. Observe the Transmit LED on the controller which should flash green when the controller is transmitting. Confirm that the green Carrier Detect LED on the receiver circuit board also flashes in sympathy. This indicates that the receiver is receiving a RF signal from the transmitter.

8.

Press and hold both display control pushbuttons on the receiver until the following message appears on the LCD display: PROGRAM OPTIONS *****MODE***** It should be noted that all remote control functions on the controlled machine are disabled any time the PROGRAM OPTIONS MODE is selected on the receiver.

Therefore, activating a controller function will not cause any machine movement.

Release both display control pushbuttons. The display now shows the first option to be set.

SET CLOSE START LOCK-OUT TIME 2.0 2.0 is the factory pre-set timeout value in minutes. This Close Start Lock Out Time represents the number of minutes that can elapse in which the receiver does not receive a message from the controller with the correct ‘unlock’ address. A new Close Start unlock requirement will be needed if this pre-set timeout expires.

ã04/2006, CATTRON-THEIMEG™

Appendix A – Page 5

Close Start setup, continued.

9.

Press either of the two display control pushbuttons on the receiver to set the required timeout value on the LCD display. This value may be set anywhere between 0.1 and 15 minutes in 0.1 minute increments. Note that (1) depressing Pushbutton #1 or Pushbutton #2 will increment or decrement their respective display values, and (2) it will take approximately two seconds for the receiver to register a key press.

10.

After setting the lock-out time, set the antenna which will be used for Close Start. To unlock the system, momentarily press and release both receiver buttons to show the following screen: SET CLOSE START ANTENNA: 1

11.

The number 1 indicates that antenna 1 is currently selected for use with Close Start.

Press either of the two buttons to select the designated Close Start Antenna noted in step 3, above. It will take approximately two seconds for the receiver to register a key press.

12.

The last parameter to be set is the Close Start RF signal level. This is directly related to the unlock distance. Momentarily press and release both receiver buttons to show the following screen: CLOSE START -dBm RSSI-65 SET-70 The example display above shows the controller’s Receive Signal Strength Indication (RSSI) value at -65dBm and the Close Start set value at -70dBm. The close start set signal level should be set slightly below the RSSI from the controller. This ensures repeatability while limiting the close start distance.

13.

14.

The RSSI level is the strength of the RF signal received from the controller which should be transmitting, or the background noise level if no signal is being broadcast.

The Set value is the signal strength limit for three consecutive controller transmissions with the same address for the receiver to unlock. In the above example, the signal strength must be at least -70dBm for three consecutive controller transmissions before Close Start will unlock and pass data to the decoder. Note that an RSSI of –65dBm is a stronger RF signal than –70dBm and, in this example, the receiver needs to see an RF signal greater than –70dBm to unlock.

The person with the controller should slowly turn around whilst transmitting, as well as moving within two or three feet of his or her normal operating position in all directions.

Observe the displayed RSSI from the controller while the operator is moving about the normal operating position, noting the weakest received signal.

Press either of the two buttons to select the desired Close Start signal level which should be set to a va lue between 3 and 5dBm less than the weakest RSSI from the controller noted in step 13 above. Remember that –65dBm is a stronger signal than –70dBm. It will take approximately two seconds for the receiver to register a key press.

Appendix A – Page 6

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Close Start setup, continued.

15.

Press and hold both buttons for approximately three seconds to exit the options menu.

The receiver will then cycle through its power-up self check.

16.

If applicable, de-activate the controller function previously maintained in step 7 above.

Set the controller power to ‘OFF’.

17.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

After making any changes to the Close Start options above, test the system for proper operation. Have an operator take the controller to the desired distance to unlock Close Start. Set the controller power to ‘ON’ and operate a switch/pushbutton function that will not cause any movement of the controlled machine, such as a horn, siren, or light. Ensure the selected control function activates. Referring to figure A-2 above, move out of the close start unlock circle into the normal operating area, ensuring the controller remains operational. Discontinue controller operation for longer than the timeout period selected above. Operate the controller to make sure close start has timed out (no control function should activate). Move back into the close start unlock circle and operate the controller, ensuring the selected control function activates. If not, repeat the Close Start Setup procedure as many times as required to optimize system performance.

Range Limit setup.

Range limit is a programmable option that restricts the maximum range between the remote control operator and the equipment he or she is controlling.

The Range Limit feature uses RF signal strength to determine the distance between the controller and receiver. This feature requires the use of the triple diversity antenna system. If the signal strength from all three antennas falls below a preset value, the controller is too far from the receiver and Range Limit becomes active. Once the Range Limit feature activates, the signal strength must increase to 3dB greater than the Range Limit set point before the receiver will return to normal operating mode.

This requires the operator to move closer to one of the antennas to reduce intermittent operation at the extremes of the range limit perimeter.

Range Limit is not a precision feature as many factors may affect the setting, such as controller position, antenna position & direction, building environment, floor obstructions, and background RF noise.

See Figure A-3 below for a pictorial representation of the Range Limit feature.

ã04/2006, CATTRON-THEIMEG™

Appendix A – Page 7

Range Limit setup, continued.

Figure A-3. Range Limit operation

+3dBm distance.

= Remote Control Operator Check signal strengths with remote control operator transmitting from various positions at the extremities of the Operating Range. Note that Signal strengths may vary due to materials and obstructions on the floor between the controller and antennas. Whenever possible, all such materials and obstructions are to be moved out of the operating area.

Range limit output becomes active beyond this point.

Remote control is disabled.

Once Range Limit becomes active, the operator must move closer to the antennas by a distance where the received signal is +3dBm stronger to de-activate range limit.

e ng Ra ft )

Triple Diversity Antenna.

ng 0 0 ati l 3

e r ic a m ) Op (Typ (90

Range Limit outer limit control circle.

It is recommended that two people work together to perform this procedure. For example: The person with the remote controller should be positioned on the ground at the required distance to activate the range limit. The second person is required to board the controlled equipment to (1) ensure the receiver and decoder are fully operational before setting the Range Limit option, and (2) observe the LCD display while setting the desired range limit using the two control pushbuttons on the receiver/decoder.

To set the Range Limit option, proceed as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

Appendix A – Page 8

ã04/2006, CATTRON-THEIMEG™

Range Limit setup, continued.

3.

Set the gold box power to ‘ON’

4.

Position the person with the remote controller on the ground at the desired distance to activate the Range Limit.

5.

Instruct the person with the remote controller on the ground to apply power to the controller. NOTE: (1) If FCC Part 90 requirements apply to your PRRC system the controller will transmit a continuous RF signal once power is applied. (2) If FCC Part 15 requirements apply to your PRRC system, you must also activate and maintain a controller function that will not cause any movement of the controlled machine. This function could be a horn, light, or other indicator and must be maintained until you are instructed otherwise. Observe the Transmit LED on the controller which should flash green when the controller is transmitting. Confirm that the green Carrier Detect LED on the receiver circuit board also flashes in sympathy. This indicates that the receiver is receiving a RF signal from the transmitter.

6.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** It should be noted that all remote control functions on the controlled machine are disabled any time the PROGRAM OPTIONS MODE is selected on the receiver.

Therefore, activating a controller function will not cause any machine movement.

7.

Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

8.

Momentarily press and release both display control buttons until the following message appears on the display: RANGE LIMIT -dBm RSSI-120 SET OFF The example display above shows the controller’s Receive Signal Strength Indication (RSSI) value at -120dBm with the Range Limit option disabled

9.

The RSSI level is the strength of the RF signal received from the controller which should be transmitting, or the background noise level if no signal is being broadcast.

Referring to Figure A-3 above, check signal strengths with the remote control operator transmitting from various positions at the extremities of the operating range. Observe the displayed RSSI from the controller while the operator is transmitting from each of these positions, noting that received signal strengths will vary due to materials and obstructions on the ground between the controller and antennas. Whenever possible, remove all such obstructions out of the operating area to harmonize the received signal strengths from these operating positions.

ã04/2006, CATTRON-THEIMEG™

Appendix A – Page 9

Range Limit setup, continued.

10.

Press and release either button to change the Range Limit status. A display of a number enables the Range Limit option.

The setpoint can be set to any value between -50dBm and -126dBm. In this example, attempting to set a value below -120dBm will enable the Range Extend option and change the display to EXT. Setting a value higher than -50dBm disables the Range Limit and changes the display to OFF. - Remember that –117dBm is a stronger signal than –120dBm.

11.

Once the desired Range Limit status is set, press and hold both display control buttons for approximately three seconds. The status will be saved and the receiver will cycle through its power-up self check.

12.

If applicable, de-activate the controller function previously maintained in step 5 above.

Set the controller power to ‘OFF’

13.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

After making any changes to the Range Limit function, test the system for proper operation. Have an operator take the controller to the desired range and operate a control that will not cause any crane movement, such as a horn, siren, or light. Have the operator move closer to, and farther from, the controlled machine to activate and de-activate the Range Limit. If necessary, repeat the Range Limit Setup procedure to achieve the desired range limits.

Range Extend setup.

The Range Extend option is the opposite of Range Limit and requires the use of the triple diversity antenna system. When Range Limiting is not in use, the receiver can be put into Range Extend mode.

When a system with the Range Extend option enabled receives a signal, the signal strength is measured from each antenna. The signal from the antenna with the strongest signal strength is used to receive the remainder of the signal. This ensures that the best possible signal is used thereby optimizing the range of the system.

Note:

The Range Extend feature cannot be used in conjunction with the Range Limit feature.

Set the Range Extend option, as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

Appendix A – Page 10

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Range Extend setup, continued.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** It should be noted that all remote control functions on the controlled machine are disabled any time the PROGRAM OPTIONS MODE is selected on the receiver.

Therefore, activating a controller function will not cause any machine movement.

Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: RANGE LIMIT -dBm RSSI-120 SET OFF The example display above shows the controller’s Receive Signal Strength Indication (RSSI) value at -120dBm with the Range Limit option disabled The RSSI level is the strength of the RF signal received from the controller, or the background noise level if no signal is being broadcast.

6.

Press and release either button to change the Range Extend status. A display of ‘EXT’ enables the Range Extend option. A display of ‘OFF’ disables the Range Extend option.

A display of a number disables the Range Extend feature and enables the Range Limit feature described in the last topic.

7.

Once the desired Range Extend status is set, press and hold both display control buttons for approximately three seconds. The status will be saved and the receiver will cycle through its power-up self check.

8.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

ã04/2006, CATTRON-THEIMEG™

Appendix A – Page 11

Scanner setup.

The Optional Scanner function allows the receiver to scan up to 16 frequencies for signals from the controller. This feature can be used in multi-controller applications where the controllers operate on multiple frequencies.

NOTE The EMI/RFI shielded chassis, or ‘gold box’, must be modified to enable the scanner function to operate properly. Consult CATTRONTHEIMEG™ before enabling this feature.

Set the Scanner option as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: SCANNER MODE IS TURNED………. OFF The display above shows the Scanner option disabled.

6.

Press and release either button to toggle the Scanner mode on and off.

7.

Once the desired Scanner status is set, press and hold both display control buttons for approximately three seconds. The status will be saved, and the receiver will cycle through its power-up self check.

8.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

The Scanner function starts scanning at the frequency indicated by the position of the rotary frequency selector switch. The receiver switches to the next sequential frequency every 0.5 second. The interval may be changed in 0.5 second increments.

Appendix A – Page 12

ã04/2006, CATTRON-THEIMEG™

Scanner setup, continued.

Note that the Scanner function will scan through all 16 frequencies when using factory programmed frequencies and all 14 frequencies when using field programmable frequencies. If scanning of all the frequenc ies is not desired, a field programmable frequency table must be created. Refer to Field Programmable Frequencies in this appendix for information on programming the frequency table. For example, to create a scan pattern that scans three separate frequencies in Field Programmable Frequency mode, set the following frequencies in the field programmable frequency table: Channel Channel 1

Frequency Frequency 1

Channel 2

Frequency 2

Channel 3

Frequency 3

Channel 4

Frequency 1

Channel 5

Frequency 2

Channel 6

Frequency 3

Etc…

Attenuator setup.

An attenuator reduces the incoming radio frequency signal level seen by the receiver from the controller or from other RF sources. The R1014T2 receiver’s attenuator is fixed and is 22dBm to 28dBm. Enabling the attenuator option has the effect of reducing the range at which the machine may be controlled and also makes the receiver less susceptible to interference caused by RF signals on, or adjacent to, the equipment operating frequency. An external attenuator can be used if a different amount of attenuation is necessary.

To obtain an external attenuator for your receiver/decoder, contact CATTRON-THEIMEG™ . To set the built- in attenuator on the Model R1014T2 receiver, perform the following procedure: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

ã04/2006, CATTRON-THEIMEG™

Appendix A – Page 13

Attenuator setup, continued.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: ATTENUATOR STATUS OUT The display above shows the attenuator status as being disabled.

6.

Press and release either button to toggle the attenuator status from ‘OUT’ to ‘IN’, and vice versa.

7.

Once the desired attenuator status is set, press and hold both display control buttons for approximately three seconds. The attenuator status will be saved and the receiver will cycle through its power-up self check.

8.

Confirm the operating range of the controller, setting the attenuator to ‘OUT’ if the range is less than required

9.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

Factory Preset and Field Programmable Frequencies.

NOTE: Frequencies for licensed (FCC Part 90) systems must NOT be programmed to frequencies other than those you have been licensed for. If the frequency for a licensed system needs to be changed to a frequency that is not included in the factory preset table, refer to the radio frequency documentation supplied with the system for a list of the frequencies preset on your receiver.

In order for the receiver and the controller to communicate, they must be set to the same frequency.

CATTRON-THEIMEG™ receivers and controllers offer multiple frequency selections for maximum versatility. While the factory preset frequencies should be adequate for most users, there may be conditions where it is necessary to program a frequency. This may be necessary whe n installing a spare receiver/decoder or controller that operates on a frequency that has not been preset at the factory, or when other sources systems are emitting RF signals that interfere with safe operation. Prior to making any change in the frequency setting, check the frequency settings on both the receiver/decoder and the controller.

Appendix A – Page 14

ã04/2006, CATTRON-THEIMEG™

Factory Preset and Field Programmable Frequencies.

To change the frequency setting for the controller, refer to the documentation provided with the controller.

The receiver has the capability of selecting one of 16 factory preset frequencies using a rotary switch on the receiver circuit board. The Model R1014T2 receiver also allows for field programming of 14 additional frequencies to any frequency desired between 447MHz and 472MHz. When using field programmed frequencies, positions 0 and F of the rotary switch are not used. Selecting either of these positions will cause the receiver/decoder to stop functioning until the rotary switch is set to a valid position.

Factory Preset (default) Frequencies.

If more than one factory preset frequency has been set in your receiver, you may change to another factory preset frequency as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: FREQUENCY TABLE: FACTORY PGM ROM This indicates that the receiver is currently using the factory programmed frequency table in Read only Memory (ROM).

6.

Locate the rotary frequency selector switch on the receiver circuit board. The switch is shown in Figure A-1 on Page 1.

7.

Using a small screwdriver, rotate the rotary selector switch to the desired position.

NOTE: The selected frequency will be displayed on the LCD display.

8.

Press and hold both display control buttons for approximately three seconds to exit the options menu. The receiver/decoder will then cycle through the power-up self check.

9.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

ã04/2006, CATTRON-THEIMEG™

Appendix A – Page 15

Field Programmable Frequencies.

Select and program the field programmable frequencies as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: FREQUENCY TABLE: FACTORY PGM ROM This indicates that the receiver is currently using the factory programmed frequency table in ROM.

6.

Press and release one button. The display will change to the following: FREQUENCY TABLE: FIELD PGM EEPROM This indicates that the receiver is now using the field programmed frequency table stored in EEPROM.

7.

To select a frequency channel to program, press and release both display control buttons. The display will change to the following: CHANNEL NUMBER FOR FREQ ADJ.#1 This indicates that the frequency for channel one can now be programmed.

Press and release one button to select the channel number for the frequency to be changed.

8.

When the proper channel number is displayed, momentarily press and release both display control buttons. The display will change to the following: ADJ. CHANNEL # 1 FREQ: 448.2500 This indicates that channel 1 is currently set to 448.2500MHz.

Appendix A – Page 16

ã04/2006, CATTRON-THEIMEG™

Field Programmable Frequencies, continued.

9.

Press and hold either button to scroll the display to the desired frequency value from 447 MHz to 472MHz. After holding a button for approximately five seconds, the scrolling speed for the frequency will increase.

10.

When the desired frequency for the channel is displayed, momentarily press and release both display control buttons. This stores the frequency value in non-volatile EEPROM. The display will now change back to that shown in Step 7. Press and release one button to select the next channel number for the frequency to be changed, repeating steps 8 through 11 for each new frequency to be set.

11.

Press and hold both display control buttons for approximately three seconds to exit the options menu. The receiver/decoder will then cycle through the power-up self check..

12.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

13.

Press and release one button. The display will change to the following: FREQUENCY TABLE: FIELD PGM EEPROM

14.

Locate the rotary frequency selector switch on the receiver circuit board. The switch is shown in Figure A-1 on Page 1.

15.

Using a small screwdriver, select the desired frequency from the field programmed frequency table using the rotary frequency selector switch.

NOTE: Since there only 14 programmable frequencies and the rotary switch has 16 positions, positions 0 and F are not used with the field programmable frequency table. Selecting position 0 or F will cause the receiver/decoder to become non-functional until a valid frequency is selected on the rotary frequency selector switch.

16.

Press and hold both display control buttons for approximately three seconds to exit the options menu. The receiver/decoder will then cycle through the power-up self check.

17.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

END OF APPENDIX

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Appendix A – Page 17

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Appendix A – Page 18

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Appendix B – NEW R1HN and R2HN RECEIVER BOARDS FREQUENCY PROGRAMMING PROCEDURE – NEW R1HN and R2HN RECEIVER BOARDS. Programming Receiver Frequency.

NOTE:

R1HN and R2HN Receiver Boards allow the customer to select up to eight Frequency Banks, with individual Frequency Banks containing up to sixteen Frequencies. Refer to the radio frequency programming sheets supplied with your pre -engineered system for the Frequency Bank and corresponding Frequency allocations that apply to your installation.

To change the frequency setting for the system controller, refer to the documentation provided with the controller. Follow the procedure below to change the Receiver Board frequency: 1. Open the door of the receiver/decoder enclosure and remove power by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

2. Remove the lid from the ‘gold box’ and locate the frequency bank selector binary SIP switches on the Receiver Circuit Board. (Refer to Figure B-1 below for location).

3. Using the radio frequency programming sheets supplied with your pre-engineered system, locate and set the allocated frequency bank on the binary SIP switches as shown in Figure B1.

4. Locate the rotary frequency selector switch on the Receiver Circuit Board. (Refer to Figure B-1 for location).

5. Using a small screwdriver, rotate the selector switch to the desired frequency position (refer to frequency programming sheets supplied with your pre-engineered system).

6. Replace the lid on the ‘gold box’.

7. Restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the ‘gold box’.

8. Close the door of the receiver/decoder enclosure.

ã04/2006, CATTRON-THEIMEG™

Appendix B – Page 1

Programming Receiver Frequency, continued.

Figure B-1. Frequency Bank and rotary Frequency Selector Switch locations

OFF

FREQUENCY BANK SELECTOR BINARY SIP SWITCH

ROTARY FREQUENCY SELECTOR SWITCH

* Binary Weight shown - see NOTE 1

ON OFF

8

* 4 * 2 * 1*

OFF

(FREQUENCY BANK 0)

8

4

1

2

OFF

2

8

1

OFF

8

ON Left

4

4

OFF

1

(FREQUENCY BANK 6)

1

Right * * * * 1 2 3 4

ON

2

8

(FREQUENCY BANK 5)

ON

2

1

*

(FREQUENCY BANK 3)

(FREQUENCY BANK 4) 4

8

ON

4

ON

2

(FREQUENCY BANK 1)

(FREQUENCY BANK 2)

OFF

4

ON

2

OFF

8

4

OFF

2

1

ON

8

(FREQUENCY BANK 7)

END Appendix B – Page 2

ã04/2006, CATTRON-THEIMEG™

Index A

G

Accessories ............................................... 5-6

General

Two-step electro-hydraulic brake ...... 5-6

Functional description .........

1-1

Additional safety features ........................ A-2

Maintenance ................................. 4-1

Adjustments ............................................. 4-4

Operating instructions .................. 3-1

Antenna installation ................................. 2-10 Attenuator setup ...................................... A-13

I

Automatic safety override ....................... 4-9

Installation ..............................................

2-9

Interface Connections .............................

2-1

B Before installation checks .......................... 2-1

L LED indicators ........................................ 2-14

C

List of acronyms .......................................... ii

Checkout procedure following installation ............................................... 2-16

M

Choosing a mounting location .................. 2-9 Close start setup ...................................... A-3 Code plug replacement ............................ 4-17

Mainline Circuit ......................................... 2-6 Maintenance .............................................. 4-1 Mechanical installation for RF units ......... 2-9

D

Model summary chart ................................ 1-7

Decoder replacement ................................ 4-15

O

Direct DC wiring option ........................... 2-12

F

Operate and reset relays ..........................

2-6

Operating instructions ............................

3-1

Features .................................................... 1-4 Field programmable frequencies .............. A-14 Frequency selections (ATS only) ...............2-13 Functional description .............................. 1-1 ã04/2006, CATTRON-THEIMEG™

Index - 1

P

S

Parts list .............................................

5-1

Safety considerations ................................. 1-5

Pre-installation checks ............................ 2-1

Safety Interface Unit (ATS Systems only) 2-2

Preventive maintenance .......................... 4-2

Scanne r setup .......................................

A-12

Principle of Operation ............................. 1-6

Specifications ......................................

1-2

Power-up Messages ................................. 2-16

Standard Safety & Security features .......... 1-4 System status display ...........................

2-14

R R1014T2 receiver .................................... A-1

T

Range Extender setup .............................. A-10

Transfer switch .................................... 2-5, 5-7

Range Limit setup ................................... A-7

Triple diversity antenna .......................... 2-11

Relay outputs ........................................... 2-6

Troubleshooting ......................................

Receiver/decoder repair .......................... 4-11

Two-step electro-hydraulic brake package 5-6

Code plug replacement ...................... 4-17

Typical additional checks .......................... 4-2

4-5

Decoder replacement ......................... 4-15 EPROM replacement ........................ 4-20 Receiver replacement ........................ 4-13 Relay replacement ............................. 4-12 Replacing the EMI/RFI shielded chassis (gold box) ............... 4-11 Run-time Messages ................................. 2-17

Index - 2

ã04/2006, CATTRON-THEIMEG™

RECOMMENDED SAFETY RULES FOR PORTABLE REMOTE CONTROLLED (PRC) CRANES For the purpose of these rules, Portable Remote Control or PRC refers to Radio Frequency (RF) Controls. The information contained herein is based on data gathered from vario us users of portable remote control crane 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 . It must be fully understood that the recommendations contained herein are provided solely for your consideration and possible adoption.

TABLE OF CONTENTS SECTION TITLE PAGE 1 Preface 1 2 Operator Safety Basics 2 2-1 Area Inspection 2 2-2 Crane Inspection (mechanical & structural) 2 2-3 Operational Safety Check 3 3 Persons Authorized to Operate Portable Remote Controlled cranes 3 4 Training Check List for Operation of Remote Controlled cranes 3 5 Operating Area for Remote Controlled Cranes 4 6 The Hand-held Portable Remote Controller 4 7 Operating the Remote Controlled Crane 5 8 Boarding the Remote Controlled Crane 6 9 On Board the Remote Controlled Crane 7 10 Remote Controlled Crane under Repair 7 11 The Condition of the Remote Controlled Crane 8 1.

PREFACE. 1-1. Electric Overhead Traveling (EOT) Cranes typically operate in three motions. They are large, bulky pieces of equipment that handle heavy loads efficiently at comparatively high speeds.

Frequently, they are operated in restricted areas where workmen are engaged in various tasks on the floor below. Under these conditions crane operators using Portable Remote Control must take great care, and workmen must be constantly on the alert if accidents are to be avoided.

1-2. The following guidelines have been carefully assembled and are promoted to indicate just how important your careful and thoughtful actions are in helping to protect you and your fellow workers from harm, and also to prevent equipment damage.

1-3. These guidelines cover cranes when they are operational in Portable Remote Control (PRC) mode. If a crane is operated from cab or pendant control, the PRC system’s controller(s) should be completely isolated by removing the battery and held under lock and key.

1-4. A routine pre-shift inspection of the crane takes a lot less time than repairing a crane suffering from a major problem. In addition, such pre-shift inspections are to be considered as ‘safety basics’ which are an important part of a crane operator’s duties. ã04/2006, CATTRON-THEIMEG™

Cranesafety - 1

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. In addition, did you realize that the person now reading these instructions is primarily responsible for his or her own health and safety?

2-1.

Area Inspection. · Take a good look around the work area for any obstructions. · Check that the rail sweeps are intact and not bent or damaged. · Make sure there are no oil or brake fluid leaks on the area below where the crane travels. · Make sure rail stops are present, physically secure, and free of damage at the end of all crane rails. · Check that walkways are sturdy and have handrails. Ladders are not to be loose and all rungs are to be in place.

2-2.

Crane Inspection (mechanical & structural). · Make sure all moving machinery has protective guards installed over moving parts. · Make sure all bridge and trolley rail stops are welded or bolted in position with no evidence of damage from bridge or trolley impact. · Check for proper fluid levels and make sure all grease fittings are lubricated to manufacturer recommendations. · Check for broken welds and cracks in the bridge structure. · Check for wheel damage, broken welds on the frame, and drum damage. · Check the wheels for flange wear, cracks, holes, or visible signs of bearing damage. · Make sure wire rope drums show proper wire rope lay; for example, each wire rope must lay in its own groove. This does not mean in the non-grooved area in the center of the drum. · Make sure wire rope size is correct for the sheaves. Look for either oversized or undersized rope that will not lay in the sheaves correctly. Make sure the sheaves show no evidence of rope corrugation and have the proper wall thickness. · Look for any type of bluing on the brake drums which indicates excessive heat. Make sure there are no protruding rivets from the brake shoes. Examine the shoes for glazing. · Look for carbon dust around the inspection covers of electric motors. Smell for any type of burning smells. Check for any type of burning on electrical covers. Make sure all protective covers are installed. · Check the festoon system for proper connections and inspect all hooks connecting the festoon to the holding wire. · Load bearing parts such as blocks and hooks shall have no signs of damage and be in perfect working order.

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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. · All controls shall be in good working order. · Emergency Stop Buttons (when equipped) shall be in working order. · The load brakes shall hold the load safely at all times. The only way to ensure this is through a load test and inspection. · The ‘raise’ and ‘lower’ limit switches shall work correctly to help prevent two-blocking and accidental floor contact.

3.

PERSONS AUTHORIZED TO OPERATE PORTABLE REMOTE CONTROLLED CRANES. · Only properly trained employees who have been designated by management shall be permitted to operate the crane. · Both the operator and management shall insure the correct controller to operate the crane is selected and that any spare equipment capable of controlling the crane is completely isolated and held under lock and key. · The crane shall not be operated by personnel who cannot read and understand the signs, notices and operating instructions. · The crane shall not be operated by personnel with seriously defective eyesight or hearing, personnel under the influence of drugs or alcohol that will impair judgment, or personnel who may be suffering from a disease which may cause physical failure.

4.

TRAINING CHECKLIST FOR OPERATORS OF PORTABLE REMOTE CONTROLLED CRANES. As a minimum, Portable Remote Control Operators shall: · have knowledge of hazards inherent to crane operation. · have knowledge of safety guidelines for portable remote controlled cranes. · have the ability to judge distance to stationary objects. · have knowledge of the portable remote control system controller’s operation. · have performed limit switch test procedure before operating the crane. · have performed hoist, trolley and bridge brake test procedure before operating the crane. · have instructions as to plugging of crane motions when and where authorized. · observe signal lights on crane. · avoid striking any obstructions. · check for proper clearance of lifts or hooks before moving bridge or trolley. · properly store the portable remote controller when not in use. · know how to properly transfer the portable remote controller to another person.

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4.

TRAINING CHECKLIST FOR OPERATORS CONTROLLED CRANES, continued. · report unsafe or unusual operating conditions. · use caution in approaching bridge or trolley end-stops. · know the crane’s capacity. · keep body clear of lifts, avoiding ‘pinch’ points. · inspect cables and hooks.

5.

THE OPERATING AREA FOR THE PORTABLE REMOTE CONTROLLED CRANE. · Unobstructed aisles between equipment, stock, etc. shall be maintained for the Portable Remote-controlled crane operator's movement. These aisles should be a minimum of 3 feet wide (1m) or per local regulations. · Portable Remote-controlled 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. They shall always keep the crane and load in sight, staying as close as practical to the crane load while maintaining a safe harms-way distance. Operators shall never position themselves or others underneath the load or in a ‘pinch’ point.

6.

THE HAND-HELD PORTABLE REMOTE CONTROLLER. · Typically, the portable remote controller incorporates a Push-To-Operate (PTO) bar or START button, and its motion switches are spring return to OFF. The PTO bar acts as a guard for these switches to prevent movement of the crane if one of the switches is accidentally bumped. These switches and the PTO bar must never be mechanically blocked in any ‘ON’ position. · Using the power ON/OFF switch(es), the portable remote controller shall be switched ‘OFF’ when not in use. When the controller is equipped with a STOP button, it shall be set to the ‘STOP’ position before switching off power to the controller. In addition, if equipped with a key, the key should be removed after use and kept in a secure location. · A prescribed, controlled, storage space shall be provided for portable remote controllers.

All controllers shall have their batteries removed and be placed there when not in use. This precaution is intended to prevent unauthorized personnel from operating the remote controlled crane. · When an operator is putting on or taking off the controller by means of its belt loop strap, carrying harness, or shoulder strap, the controller shall be switched OFF beforehand, using the appropriate ON/OFF switch(es). When the controller is equipped with a STOP button, it shall be set to the ‘STOP’ position before switching off power to the controller. · The portable remote controller shall always be switched ‘OFF’ when not in use and, when practical, held under lock and key.

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7.

OPERATING THE PORTABLE 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. They are intended to be protective devices only. · The bridge and trolley brakes shall be tested at the beginning of each turn or when a new operator takes control of the crane. They should be tested with the bridge and trolley at low speed. · When lifting maximum or near maximum loads, the operator shall test the hoist brakes by raising the load a few inches from the floor. If hoist brakes do not hold, the load shall be immediately lowered to the floor and a report made to the supervisor. · Do not make lifts in excess of the rated capacity of the crane. · When making lifts, the bridge and trolley shall be centered directly over the load to prevent load swinging when the load is raised. · Side pulls shall be made only with the permission of, and under direct supervision of management. When such a lift is being made, operators shall not position themselves in the line or path of travel of the load, but shall operate the crane from a position to the side opposite to the path of travel. · When raising or lowering a lo ad, proceed slowly and make certain the load is under control. Tag lines shall be used for handling lengths or bulky loads. Take the slack out of the chains or slings gradually. Make sure all personnel are clear before making a lift. · Portable remote control crane operators shall keep all parts of their bodies away from the load and never position themselves under the load. · Do not make a lift or move the crane if anyone is in a position to be injured. · If a portable remote control crane operator is being helped, he or she shall not move the crane until he or she receives an ‘all clear’ signal from the helper(s). · Loads shall not be carried over workers' heads. · If anyone is in the path of travel, the portable remote control crane operator shall stop and clear the area before proceeding. · Bumping into runway stops or into other cranes on the same runway is prohibited. · When moving the crane, the portable remote control crane operator shall make sure the hook block, attachment and/or cables will not fall on nearby equipment. · The portable remote control crane operator shall not drag slings, chains, etc. along the floor. These could snag on something on the floor, causing the cables to break and strike the operator or a fellow worker.

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7.

OPERATING THE PORTABLE REMOTE CONTROLLED CRANE, continued. · If gloves are not required for safety reasons, they shall not be used when operating the portable remote controller. · All loose material or parts shall be removed from the load before starting the lift. Such material can fall and injure people below. · The portable remote control 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. If approved, plugging should only be performed as dictated by plant operating procedures. · If portable remote control crane operators are asked to do something they believe unsafe, they shall call their supervisors for advice. · Portable remote control crane operators shall never permit anyone to ride on the load or hook except when authorized by their supervisor. · When another crane on the same runway is stationary with or without a load, the portable remote control crane operator shall maintain a safe distance between the crane being operated and the stationary crane. In a power outage, the portable remote control crane operator shall set the ON/OFF switch(es) on the controller to ‘OFF’, keeping them in the OFF position until power is restored. · If the Portable Remote-controlled crane fails to respond correctly, the operator shall stop operation immediately by setting the ON/OFF switch(es) on the controller to ‘OFF’. When the controller is equipped with a STOP button, this shall be set to the ‘STOP’ position before switching off power to the controller. The fault condition shall be reported immediately to a supervisor. · Outside cranes subject to movement by winds, storms, etc. shall be securely anchored when left unattended. If the crane is equipped with a bridge parking brake, it shall also be set.

8.

BOARDING THE PORTABLE REMOTE CONTROLLED CRANE. · The Portable Remote-controlled crane shall not be boarded without permission of the supervisor in charge of crane operations in the area. · Using the power ON/OFF switch(es), the person boarding the Portable Remote-controlled crane shall switch the portable remote controller to ‘OFF’ and take it with him or her on to the crane. When the controller is equipped with a STOP button, this shall be set to the ‘STOP’ position before switching off power to the controller. · If the boarding party consists of more than one person, one person shall be designated as the leader of the boarding party. · The leader shall board the crane first, open and lock out the main switch (securing it with a padlock), and then signal the other members of the party that it is safe for them to board the crane.

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9.

ON BOARD THE PORTABLE REMOTE CONTROLLED CRANE. · Head room is at a minimum in some crane cabs and on some crane walkways. Caution shall be exercised by all people on board such cranes. Hard hats shall be worn at all times. · If the repair crew consists of more than one person, one person shall be designated as the crew leader. · 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. 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. · If, during the course of repairs, it becomes necessary to move the crane, it shall be the responsibility of the crew leader to insure that all personnel located on, and within the operational area of the crane are in a safe position out of harms-way. In addition the crew leader shall insure all tools and materials are stowed or tightly restrained before the crane is moved. · When the repair work is completed, the crew leader shall see that all crew members are off of the crane before he or she closes the main switch. · If more that one person is on board the remote controlled crane, one person shall be made responsible for seeing that all workers are off the crane before the portable remote controller is returned to operational use.

10.

PORTABLE REMOTE CONTROLLED CRANE UNDER REPAIR. · All persons operating other cranes on the same or adjacent runways shall be notified before anyone boards the subject crane. Such notification should include limitations of adjacent crane movement while others are on board. · Portable remote controlled cranes which have been pre-positioned for repairs and cannot be moved should be protected against being bumped by other cranes on the runway. Suitable bumpers adequate for the job should be installed on the exposed sides of the crane under repair and as far away from the crane as possible, with a minimum distance of 20 ft. (approximately. 6.1 m). The location of these bumpers shall be indicated by red lights so that they are clearly visible to other persons operating cranes traveling on the same runway.

When it is impossible to use bumpers for protection, red lights shall be placed in clear view of other persons operating cranes on the same 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. · All operators of cranes on the same runway must be informed of the repair work, thoroughly instructed as to what their conduct should be for the duration of said repairs, and informed when repairs are completed.

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10.

PORTABLE 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 exis ts 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.

When it is necessary to operate cranes on adjacent runways, such cranes shall come to a full stop before entering the restricted area. Cranes traveling on adjacent runways may only proceed through the restricted area when permission has been received from a signalman posted for this purpose. · Access of persons to and from the crane being repaired shall be under the control of the repair crew leader. · 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. · If crane repairs make it necessary for crew members to work on areas of the crane other than those protected by standard handrails, such crew members shall wear approved safety belts. · If it is necessary to move the crane to check the performance of operation, the crew leader shall designate who remains on the crane. The crew leader shall insure that all personnel located on, and within the operational area of the crane are physically located in a safe position out of harms-way. In addition the crew leader shall insure all tools and materials are stowed or tightly restrained before the main switch is closed and the crane is put into operation. · Upon completion of repairs, it is the crew leader's duty to personally insure that each person has left the crane and is clear before he or she removes the lock above the main switch and the crane is put back in operation.

11.

THE CONDITION OF THE PORTABLE REMOTE CONTROLLED CRANE. It is recommended that a written report be sent to your supervisor whenever you detect any conditio n that makes the crane unsafe. Many plants supply printed forms for this purpose. The Portable Remotecontrolled crane operator shall fill out these forms and turn them in at the end of each shift. Certain faults which the radio control crane operator may detect may be so critical that the crane shall be shut down at once and not operated until the fault is corrected. Typical check list items may include some or all of the following: · Condition of hoisting cable, drum, and hook blocks (broken strands, clipped sheave wheels, etc.). · Condition of brakes (hoist, trolley and bridge). · Oil or brake fluid leaks on the runway area. · Alignment of bridge (screeching or squealing wheels indicate that bridge is out of line). · Condition of bridge structure (broken welds, cracks and distortion).

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11.

THE CONDITION OF THE PORTABLE REMOTE CONTROLLED CRANE, continued. · Broken, cracked or chipped rails on bridge or runway. · 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). · Frequent overload relay tripping of power circuits. · Mechanical parts loosened by vibration (loose rivets, covers, etc.). · Wheel condition (flange wear, cracks, holes, or visible signs of bearing damage). · 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.

The condition shall be reported to a supervisor to enable repairs to be carried out by suitably qualified personnel.

END

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United States of America Cattron-Theimeg Inc. 58 West Shenango Street Sharpsville, PA 16150-1198 Phone: 1- 724- 962-3571 Fax: 1-724- 962-4310 e-mail: mail@cattron-theimeg.com Canada Cattron-Theimeg Canada Ltd. 150 Armstrong Avenue, Units 5 & 6 Georgetown, Ontario L7G 5G8 Phone: 1-905-873-9440 Fax: 1-905-873-9449 e-mail: salescdn@cattron-theimeg.com United Kingdom Cattron-Theimeg (UK) Ltd. Riverdene Industrial Estate, Molesey Road, Hersham Walton-on- Thames, Surrey KT12 4RY Phone: 44-1932-247511 Fax: 44-1932-220937 e-mail: sales@cattronuk.com

South Africa Cattron-Theimeg Africa (PTY.) Ltd. 24 O'Rielly Merry Road, Rynfield, Benoni P.O. Box 15444, Farrarmere, Benoni Gauteng 1518, South Africa Phone: 27-11-425-1123 Fax: 27-11-849-5717 e-mail: cattron@iafrica.com South America (Brazil) Cattron-Theimeg Américas Ltda.

Rua Antonio Rodrigues de Carvalho, 435 13033-220 - Campinas – SP Phone: 55-19-3243-7803 Fax: 55-19-3243-9258 e-mail: cattronamericas@cattron-theimeg.com Europe (Germany) Cattron-Theimeg Europe GmbH & Co. Krefelder Straße 423-425 41066 Mönchengladbach Phone: 49-2161-63630 Fax: 49-2161-6363100 e-mail: theimeg@theimeg.de

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