Telemotive Controls E10647B Remote Control Transmitter User Manual Exhibit D Users Manual per 2 1033 b3

Telemotive Industrial Controls Remote Control Transmitter Exhibit D Users Manual per 2 1033 b3

Exhibit D Users Manual per 2 1033 b3

TCTX12/TR12-0 Rev. FIINNSSTTAALLLLAATTIIOONN AANNDD UUSSEERRSS MMAANNUUAALLTELEMOTIVEtelePilotTM SERIESTR12 & TX12M-1, -2RRAADDIIOOCCOONNTTRROOLLSSYYSSTTEEMMtelemotive®Industrial Controls175 Wall StreetGlendale Heights, IL 60139-1985Phone: 630-582-1111, Toll Free: 888-687-4400Website: http://www.telemotive.com/telePilot Programming isfound on page 62.
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Table of Contents31- Service Information............................................................................................................................32- Radio Controlled Crane Safety...........................................................................................................41. Warnings, Cautions and Notes......................................................................................42. Critical Installation Considerations...............................................................................43. General..........................................................................................................................54. Persons Authorized To Operate Radio Controlled Cranes ...........................................55. Training Checklist For Crane Operators.......................................................................56. Operating Area..............................................................................................................67. Transmitter Unit............................................................................................................68. Operating The Crane.....................................................................................................69. Boarding The Crane......................................................................................................710. Crane Maintenance and Repair.....................................................................................711. Using The Crane As A Work Platform.........................................................................812. Condition Of The Radio Controlled Crane...................................................................813. Batteries ........................................................................................................................93- General System Information.............................................................................................................111. General System Information.......................................................................................112. TMS Low Power Signaling ........................................................................................113. Channel Designations .................................................................................................114. System Specifications .................................................................................................115. Transmitter Unit..........................................................................................................116. Receiver Unit..............................................................................................................124- Installation Procedure.......................................................................................................................131. Pre-Installation Considerations...................................................................................132. Receiver Unit Mounting Location Considerations.....................................................133. Antenna Mounting Considerations .............................................................................134. Line Input Considerations...........................................................................................135. Wiring Considerations ................................................................................................136. Receiver Receiver/Equipment Interface Considerations ............................................147. Receiver Unit Cabinet Mounting................................................................................148. Receiver Installation...................................................................................................14Figure 4-1. Input Power Connections ................................................................................15Figure 4-2A. Receiver Mounting Details Horizontal with Mounting Brackets.................15Figure 4-2B. Receiver Mounting Details Vertical with Mounting Brackets.....................165- Operation..........................................................................................................................................17Figure 5-1. telePilot, Pendant and Membrane Transmitters. ...........................................171. Transmitter Buttons ....................................................................................................172. ON/OFF LED Indicator..............................................................................................183. Low Battery Indicator.................................................................................................184. Optional 4th Motor Select Indicator. ..........................................................................185. Operation.....................................................................................................................186. Additional telePilot Transmitter Operational Features..............................................197. Battery Replacement...................................................................................................186- Wiring Diagram................................................................................................................................231. Wiring Diagrams.........................................................................................................232. Installation...................................................................................................................233. Alarms and Horns .......................................................................................................234. Single-Speed Pendant Transmitter Wiring.................................................................235. Two-Speed Pendant Transmitter Wiring....................................................................236. Relay Sequencing........................................................................................................237. Alarm After E-STOP ..................................................................................................238. Connecting Outputs to Drives ....................................................................................239. Optional Transfer Switch Wiring Configurations.......................................................24Figure 6-1. Legend.............................................................................................................24Figure 6-2. External Transfer Switch Wiring ....................................................................25Figure 6-3A. External Transfer Switch System Wiring.....................................................26
Table of Contents (Continued)Figure 6-3B. Optional Internal Transfer Switch System Wiring.......................................27Table 1 TR12 Single-Speed Wiring Diagram. Standard Configuration Hoist, Trolleyand Bridge...................................................................................................................28Table 2(A) TR12 2-Speed Wiring Diagram. Standard Configuration Hoist, Trolleyand Bridge...................................................................................................................30Table 2(B) TR12 2-Speed Wiring Diagram. 2-Speed with Directional Controls: AllMotions. ......................................................................................................................32Table 2(C) TR12 2-Speed Wiring Diagram. 2-Speed, 2-Windings: All Motions.............34Table 2(D) TR12 2-Speed Wiring Diagram. ACCO Controls: All Motions. ....................36Table 2(E) TR12 2-Speed Wiring Diagram. P&H: 2-Speed, 2-Windings for Hoist andTrolley; Standard Bridge.............................................................................................38Table 2(F) TR12 2-Speed Wiring Diagram. P&H: 2-Speed, 2-Windings for Hoist;Standard Trolley and Bridge.......................................................................................40Table 2(G) TR12 2-Speed Wiring Diagram. Demag: 2-Speed, 2-Windings for Hoist;Standard Trolley and Bridge.......................................................................................42Table 2(H) TR12 2-Speed Wiring Diagram. Standard 2-Speed 4 Motor System. ............44Table 2(I) TR12 2-Speed Wiring Diagram. Standard 2-Speed 3, 4 & 5 Motor Systemusing Select.................................................................................................................467- Programming....................................................................................................................................481. Access Code Programming.........................................................................................48Figure 7-1. Access Code Settings ......................................................................................482. Receiver Frequency Programming..............................................................................50Figure 7-2. RF Receiver Board..........................................................................................503. Multibox......................................................................................................................52Figure 7-3 SW4 Receiver Multibox Switches ...................................................................534. Custom Receiver Programming.................................................................................545. Receiver Programming...............................................................................................546. Membrane Transmitter Programming.........................................................................55Figure 7-4. Repositioning of Membrane Transmitter Motion Switch Functions ..............57Figure 7-5. Membrane Transmitter Single-Speed Configurations.....................................587. Pendant Transmitter Programming.............................................................................59Figure 7-6. Repositioning of Pendant Transmitter Motion Switch Functions ..................618. telePilot Programming............................................................................62Figure 7-7. Single-Speed 10K telePilot Modes.................................................................69Figure 7-8. Single-Speed 10K telePilot Lockout Modes..................................................72Figure 7-9. 2-Speed 9001 and 9101 Series telePilot Functional Mapping ......................738- Servicing...........................................................................................................................................761. Receiver Servicing......................................................................................................76Figure 8-1. Receiver Board Layout ...................................................................................76Table 8-1. Receiver Board Diagnostic LED Functions .....................................................762. Receiver Testing .........................................................................................................78Figure 8-2. Receiver Scope Wave Forms ..........................................................................793. Membrane Transmitter Servicing...............................................................................80Figure 8-3. Membrane Transmitter M/C Module E10635.................................................804. Pendant Transmitter Servicing....................................................................................81Figure 8-4. Pendant Transmitter M/C Module E10636.....................................................815. telePilot Servicing......................................................................................................829- Spare Parts........................................................................................................................................83Figure 9-1 telePilot Exploded View..................................................................................86Appendix A- Transmitter Switch Programming.....................................................................................87
Section 1 - Service Information1-1. Service Information.For questions regarding service or technicalinformation or ordering replacement parts, askfor Telemotive Customer Care. Telemotive’snormal business hours are Monday throughFriday 8:00 AM to 5:00 PM Central StandardTime. After hours emergency technical service isavailable.For new product orders or quotations, ask forTelemotive Sales.Telemotive Industrial Controls175 Wall StreetGlendale Heights, IL 60139-1985USATelephone: (630) 582-1111In the USA toll free: (888) 687-4400Website: http://www.telemotive.com/Manuals for downloading are available for manyproducts at the Telemotive website.E-mail info@telemotive.comTelemotive Fax Numbers:Main: (630) 582-1194Sales: (630) 582-1204Customer Care: (630) 582-1205Telemotive Industrial Control trademarks:Telemotive, TMS, telePilot, Laser Guard,Teledrive, Teltec, TeleMotion are eithertrademarks or registered trademarks ofTelemotive Industrial Controls.Third-party trademarks: All other trademarks,trade names or company names referencedherein are used for identification only and are theproperty of their respective owners CAUTION•••• DO NOT ATTEMPT TO OPEN OR SER-VICE THE TELEPILOT UNIT.•••• ONLY TRAINED QUALIFIED INDIVIDU-ALS SHOULD DO SERVICING.•••• STRICT ANTI-STATIC HANDLINGPROCEDURES MUST BE FOLLOWED.• FAILURE TO FOLLOW THIS CAUTIONCOULD RESULT IN SERIOUS DAMAGETO EQUIPMENT AND/OR VOID THEWARRANTY..
Section 2 – Radio Controlled Safety42-1. Warnings, Cautions And Notes.Through out this document WARNING, CAUTIONand NOTE statements have been deliberately placedto highlight items critical to the protection ofpersonnel and equipment.WARNING – A warning highlights an essentialoperating or maintenance procedure, practice, etc.which if not strictly observed, could result in injuryor death of personnel, or long term physical hazards.Warnings are highlighted as shown below: WARNINGCAUTION – A caution highlights an essentialoperating or maintenance procedure, practice, etc.which if not strictly observed, could result in damageto, or destruction of equipment, or loss of functionaleffectiveness. Cautions are highlighted as shownbelow: CAUTIONNOTE – A note highlights an essential operating ormaintenance procedure, condition or statement. Notesare shown as below:NOTEWARNINGS, CAUTIONS AND NOTES SHOULDNEVER BE DISREGARDED.The safety rules in this section are not intended toreplace any rules or regulations of any applicablelocal, state, or federal governing organizations. Thefollowing information is intended to be used inconjunction with other rules or regulations already inexistence. It is important to read all of the safetyinformation contained in this section before installingor operating the Radio Control System.2-2. Critical Installation Considerations. WARNINGALL EQUIPMENT MUST HAVE A MAINLINECONTACTOR INSTALLED AND ALL TRACKEDCRANES AND SIMILAR EQUIPMENT MUSTHAVE A BRAKE INSTALLED. FAILURE TOFOLLOW THIS WARNING COULD RESULT INSERIOUS INJURY OR DEATH AND DAMAGETO EQUIPMENT. WARNINGON ALL REMOTE CONTROLLED CRANES ANAUDIBLE AND/OR VISUAL WARNING MEANSMUST BE PROVIDED. THESE AUDIBLEAND/OR VISUAL WARNING DEVICES MUSTMEET ALL GOVERNMENTAL REQUIRE-MENTS. FAILURE TO FOLLOW THIS WARN-ING COULD RESULT IN SERIOUS INJURY ORDEATH AND DAMAGE TO EQUIPMENT. WARNINGREMOVE ALL ELECTRICAL POWER FROMTHE CRANE OR MACHINERY BEFORE AT-TEMPTING ANY INSTALLATION PROCE-DURES. DE-ENERGIZE AND TAG OUT ALLSOURCES OF ELECTRICAL POWER BEFORETOUCH TESTING ANY EQUIPMENT. FAILURETO FOLLOW THIS WARNING COULD RESULTIN SERIOUS INJURY OR DEATH AND DAM-AGE TO EQUIPMENT.
Section 2 – Radio Controlled Safety (Continued)5 WARNINGTHE DIRECT OUTPUTS OF THIS PRODUCTARE NOT DESIGNED TO INTERFACE DI-RECTLY TO TWO STATE SAFETY CRITICALMAINTAINED FUNCTIONS, I.E., MAGNETS,VACUUM LIFTS, PUMPS, EMERGENCYEQUIPMENT, ETC. A MECHANICALLY LOCK-ING INTERMEDIATE RELAY SYSTEM WITHSEPARATE POWER CONSIDERATIONS MUSTBE PROVIDED. FAILURE TO FOLLOW THISWARNING COULD RESULT IN SERIOUS IN-JURY OR DEATH AND DAMAGE TO EQUIP-MENT.2-3. General.Radio controlled overhead cranes and other materialhandling equipment operate in several directions.They are large, bulky pieces of equipment that handleheavy loads efficiently at high speeds. Quitefrequently, the equipment is operated in areas wherepeople are working on the floor below. The craneoperator must exercise extreme caution at all times.Workers must constantly be alert to avoid accidents.The following rules have been included to indicatehow your careful and thoughtful actions may preventinjuries, damage to equipment, or even save a life. Ifradio controlled material-handling equipment isoperated from the cab, special care must be taken tosecure the transmitter. Refer to section titled Section2-10. Boarding The Crane for specific safety rules.2-4. Persons Authorized To Operate RadioControlled Cranes.Only properly trained persons designated bymanagement should be permitted to operate radio-controlled cranes.Radio controlled cranes should not be operated byany person who cannot read or understand signs,notices and operating instructions that pertain to thecrane.Radio controlled cranes should not be operated byany person with insufficient eyesight or hearing or byany person who may be suffering from a disorder orillness or is taking any medication that may causeloss of crane control.2-5. Training Checklist For Crane Operators.Anyone being trained to operate a radio-controlledcrane should possess as a minimum the followingknowledge and skills before operating the crane:The operator should have knowledge of hazardspeculiar to crane operation.The operator should have knowledge of the safetyrules for radio-controlled cranes.The operator should have the ability to judge distanceor moving objects.The operator should have knowledge of the radiotransmitter.The operator should know the limit switch testprocedure.The operator should know, where authorized,instructions for plugging motions.The operator should have knowledge of the use ofcrane warning lights and alarms.The operator should have knowledge of observingcrane signal lights.The operator should be trained to avoid striking anyobstructions.The operator should have knowledge of the properclearance of lifts or hooks before moving bridge ortrolley.The operator should have knowledge of the properstorage space for radio control box when not in use.The operator should be trained in transferring radiocontrol box to another person.The operator should be trained how and when toreport unsafe or unusual operating conditions.The operator should be trained how to exhibit cautionin approaching bridge or trolley bumpers.The operator should know equipment capacity.The operator should be trained in making lifts belowfloor level.The operator should be trained in making side pulls.The operator should know how to keep himself andother people clear of lifts and to avoid "pinch" points.
Section 2 – Radio Controlled Safety (Continued)6The operator should know cable and hook inspectionprocedures.The operator should know procedures for testinghoist, trolley, and bridge brakes.2-6. Operating Area.Aisles between equipment, stock, etc., should be freeof obstructions so the crane operator can move freely.These aisles should be a minimum of three feet (onemeter) wide, or meet local regulations.Crane operators should always position themselvesfor the best view of the crane they are controlling.The crane should never be operated blindly. Theoperator should stay as close to the crane load aspossible. Operators should never position themselvesin a "pinch" point.2-7. Transmitter Unit.Transmitter switches should never be mechanicallyblocked ON or OFF for any crane motion. When notin use turn the transmitter OFF. A secure storagespace should be provided for the transmitter unit andthe transmitter unit should always be placed therewhen not in use. This precaution will preventunauthorized people from operating the crane.Spare transmitters should be stored in a securestorage space and only removed from the storagespace after the current transmitter in use has beenturned OFF, taken out of the service area andsecured.2-8. Operating The Crane.2-8.1. Pre-operation Test.At the start of each work shift, or when a new op-erator takes control of the crane, operators shall do asa minimum the following steps before making liftswith any crane or hoist:Test the upper-limit switch. Slowly raise theunloaded hook block until the limit switch trips.When checking limit switches the hoist should becentered over an area free of personnel andequipment.Visually inspect the hook, load lines, trolley, andbridge as much as possible from the operator'sstation; in most instances, this will be the floor of thebuilding.The bridge and trolley brakes should be tested. Ontransmitter units equipped with two or more speeds,use the "lowest" speed when testing braking devices.When lifting maximum loads, the crane operatorshould test the hoist brakes by raising the load a fewinches from the floor. If the brakes do not hold, theload should immediately be lowered to the floor.If provided, test the lower-limit switch.Test all warning devices.Test all direction and speed controls for both bridgeand trolley travel.Test all bridge and trolley limit switches, whereprovided, if operation will bring the equipment inclose proximity to the limit switches.Test the transmitter emergency stop.Test the hoist brake to verify there is no drift withouta load.If any crane or hoist that fails any of the above testsnotify the supervisor and lock out and tag for repair.2-8.2. General Rules For Operation.Consult the crane manufacturer, local andgovernmental regulations for complete rules ofoperation. In general the following rules apply toremotely controlled cranes:The limit switches should never be used as a regularstopping device. They are intended to be protectivedevices.Do not make lifts in excess of the equipment ratedcapacity.The bridge and trolley should be centered directlyover the load when the load is raised to preventswinging when making lifts.A crane designed for this purpose and only withsupervisor permission should make side pulls. Whena lift is being made, the crane operator should not bepositioned in the line of travel. The crane or hoistshould be operated from a position either to the sideor opposite from the direction of travel.When raising or lowering a load, proceed slowly andmake certain the load is under control. Tag linesshould be used for handling unusual lengths or bulkyloads. Remove slack from chains or slings gradually.
Section 2 – Radio Controlled Safety (Continued)7Make certain all personnel are clear before making alift.The crane operator should keep all body parts awayfrom the lift and should never be positioned under thelift.Do not make a lift or move a load if anyone is in alocation where they could be struck by the crane orthe load.If the crane operator is being helped, the crane shouldnot be moved until the helper signals they are clear ofthe crane and its load.When a load is hanging from the crane hook and thecrane is being moved, the crane operator shouldsound all warning devices frequently.Loads should not be carried over workers heads. If aworker is in the path of crane travel, the craneoperator should stop the crane and clear the areabefore proceeding.Runway stops or other cranes should never bebumped into.When moving the crane, the crane operator should besure that the hook block and attachments or cableswould not catch on nearby equipment. Slings, chains,or cables should never be dragged along the floor.Unless required for operator safety, gloves should notbe worn when operating the transmitter unit.All loose materials or parts should be removed fromthe load before starting the lift.The crane operator should always hoist lifts highenough to clear all equipment and workers.The crane operator should never permit anyone toride on the load or hook except when authorized bythe supervisor.When another crane on the same runway is stationarywith a load hanging, the crane operator shouldmaintain a safe distance between the stationary craneand the one under their control.Never leave suspended loads unattended. In anemergency, if the crane is inoperative and a loadsuspended, notify the supervisor immediately,barricade and post signs on the floor beneath craneand load. If power to the crane is removed, the crane operatorshould turn the transmitter unit OFF and keep it OFFuntil power is restored.If the crane fails to respond properly, the craneoperator should stop operation, turn the transmitterunit OFF and immediately report the condition totheir supervisor.Outdoor cranes, which are subject to movement bywind, should be securely anchored when leftunattended. If the crane is equipped with bridgebrakes, the parking brake should be set immediately.2-9. Boarding The Crane.The crane should not be boarded without permissionof the supervisor.The crane operator should turn off the transmitter andtake it with them when boarding the crane.If more than one person is boarding the crane, oneperson should be made responsible for ensuring allpersonnel are off the crane before the system isreturned to operation.2-10. Crane Maintenance And Repair.Qualified personnel must maintain a regularly, i.e.,such as monthly, scheduled crane inspection. Duringthis crane inspection the functionality and safety ofthe crane remote control must also be tested. Theinspection shall include, but be not limited to itemslisted in Section 2-13. Condition Of The RadioControlled Crane. Consult crane manufacturer, localand governmental regulations for recommendedinspection intervals and proper inspectionprocedures. Problems noted during this inspectionmust be repaired before using the crane or the remotecontrol.Minor repairs include routine maintenance andrepairs such as greasing, cleaning and controltroubleshooting. All other repairs should be con-sidered major. If the repair crew consists of morethan one person, one person should be designated asthe repair crew leader with the followingresponsibilities. If the repair crew consists of onlyone person, that person has the followingresponsibilities:For minor repairs warning signs should be placed onthe floor beneath the crane or suspended from thecrane. For major repairs, the floor area below thecrane should be roped off.
Section 2 – Radio Controlled Safety (Continued)8When major repairs are to take place, all personsoperating other cranes on the same or adjacentrunways, if any, must be notified prior to startingrepairs. Notification should include the nature of therepair, safeguards provided, and movementlimitations while repairs are in progress.When practical, radio controlled cranes which cannotbe moved during repairs must be protected againstbeing bumped by other cranes on the runway.Bumpers should be installed on the exposed side orsides of the crane under repair. They should beplaced as far away as possible. The location of thesebumpers should be indicated by red lights placed sothat they are clearly visible to other crane operatorstraveling on the same runway. When it is not possibleto use bumpers, red lights must be placed so they areclearly visible to other crane operators traveling onthe same runway to indicate the restricted travel zone.All crane operators on the same runway must beinformed of the repair effort and thoroughlyinstructed to what their operations are limited to andinformed they will be notified when repairs arecompleted.If any hazard involving the repairmen exists whenthere is a runway adjacent to the crane under repair,the adjacent runway should be blocked off asdescribed above. When it is necessary to continuecrane operation on the adjacent runways warninglights must be installed and be visible to operators ofcranes on those runways. All cranes should come to acomplete stop prior to entering the restricted area andshould proceed through this area only after receivingpermission from a signal person designated for thispurpose. Access of persons to and from the cranebeing repaired should be under control of the repaircrew leader.When boarding the crane, the transmitter should beturned OFF and the transmitter should remain withthe repair crew leader. The leader should board thecrane first, open and lock out the main switch, andthen signal the other members of the crew it is safe toboard the crane.If work on the crane is to be done in areas notprotected by standard handrails, the repair crewshould wear approved safety belts.All tools and equipment should be moved onto thecrane by the use of hand lines. The tools andequipment should be adequately secured to the handlines.If it is necessary to have the crane control circuitsenergized, all power circuits for crane movementmust be opened prior to energizing the controlcircuits.All personnel and tools should be moved to a safespot before moving the crane during repairs.Headroom is at a minimum in some crane cabs andon some crane walkways. Caution should beexercised when boarding or working on cranes. Hardhats should be worn whenever possible.When repairs are finished, all personnel, tools andrepair equipment should be removed beforeenergizing the crane circuits.2-11. Using The Crane As A Work Platform.When the crane is to be used as a stationary workplatform, follow all rules provided in Section 2-11.Crane Maintenance and Repair. When it is necessaryfor the crane to be moved from time to time, thecrane operator should board the crane with thetransmitter unit. The crane operator should ensure allpersonnel working on the crane are in a secureposition before moving the crane to the nextworkstation. It should also be the crane operatorsresponsibility to ensure the main switch is open andlocked down before work is resumed. WARNINGTHE CRANE OPERATOR SHOULD NOT AT-TEMPT TO REPAIR ANY OF THE ITEMSSTATED BELOW. THE CRANE CONDITIONSHOULD BE REPORTED TO THE SUPERVISOR.FAILURE TO FOLLOW THIS WARNING COULDRESULT IN SERIOUS INJURY OR DEATH ANDDAMAGE TO EQUIPMENT.2-12. Condition Of The Radio Controlled Crane.If the crane fails to respond properly, the craneoperator(s) should notify their supervisor. Whenserious conditions are noticed (conditions that makethe crane unsafe to operate), the crane should be shutdown immediately and the supervisor notified. Thefollowing is a list of some of the items that should beincluded in the report. (See the crane manufacturerfor specifics and possible additional items):
Section 2 – Radio Controlled Safety (Continued)9Condition of hoisting cable and hook block (brokenstrands, clipped sheave wheels, etc.).Condition of brakes (hoist, trolley, and bridge). (Nobluing, rivets on shoes showing, glazing, etc.).Condition of trolley and rail stops.Condition of bridge structure.Condition of festoon system.Broken welds in any part of the crane structure.Proper fluid levels and lubrication.Condition of bridge and trolley stops.Carbon dust or signs burning on the covers of motors.Indication of fluid, oil or grease leaks.Condition of rail sweeps.Walkways required handrails and ladders are inplace, sturdy and not loose.Protective guards are in place for all moving parts.Alignment of bridge (screeching or squealing wheelsindicate bridge is out of line).Broken, cracked, or chipped rails on trolley orrunway.Condition of limit switches.Condition of electrical and mechanical control(electrical or mechanical defects which cause faultyoperation such as un-commanded stopping or startingof any crane motions, warning devices, lights, orauxiliary functions).Condition of gears (grinding or squealing mayindicate foreign materials in gear teeth or a lack oflubrication.All controls especially E-STOPs are in place and inworking order.Frequent relay tripping of power circuits.Mechanical parts loosened by vibration (loose rivets,covers, bolts, etc.).Uneven riding (worn or damaged wheels).Condition of collector shoes or bars.Condition of warning or signal lights and horns.(Burned out or broken).2-13. Batteries WARNINGKNOW AND FOLLOW PROPER BATTERYHANDLING, CHARGING AND DISPOSAL PRO-CEDURES. IMPROPER BATTERY PROCE-DURES CAN CAUSE BATTERIES TO EXPLODEOR DO OTHER SERIOUS DAMAGE. FAILURETO FOLLOW THIS WARNING COULD RESULTIN SERIOUS INJURY OR DEATH AND DAM-AGE TO EQUIPMENT.2-13.1. Battery Handling.Use only batteries approved by Telemotive for thespecific product.Do not dispose of a battery pack in fire; it mayexplode.Do not attempt to open the battery pack.Do not short circuit battery.For intrinsically safe environments only use specifiedTelemotive intrinsically safe batteries.Keep the battery pack environment cool duringcharging operation and storage, (i.e., not in directsunlight or close to a heating source).2-13.2. Battery Charging.For those transmitters equipped with battery chargers,please familiarize all users with the instructions ofthe charger before attempting to use.Use only Telemotive approved chargers for theappropriate battery pack.Do not attempt to charge non-rechargeable batterypacks.Avoid charging the battery pack for more than 24hours.Do not charge batteries in a hazardous environment.Do not short charger.
Section 2 – Radio Controlled Safety (Continued)10Do not attempt to charge a damaged battery.Do not attempt to use a battery that is leaking,swollen or corroded.Charger units are not intended for outdoor use. Useonly indoors.2-13.3. Battery Disposal.Before disposing of batteries consult local andgovernmental regulatory requirements for properdisposal procedures.
Section 3 – General System Information113-1. General System Information. The Telemotive Radio Control System (system)provides remote control of overhead cranes usingradio signals. The system consists of a hand heldportable battery operated transmitter unit and a fixedstation receiver unit. A unique 16-bit code (Access Code) for each systemis preset in every transmitter and receiver. Thereceiver considers any received signal, which doesnot match the receiver access code setting, invalid.The Access Code is made up of 16-bits (65,000combinations) and no two similar codes are assignedto any two Telemotive systems. Up to four systems may be used with the samefrequency in a 600-foot area (220 meters). Eachtransmitter operating on the same frequency may beoperated in close proximity, not less than six feet (1.9meters), to each other.3-2. TMS Low Power Signaling. TMS (Time Multiplexed Signaling) is a Telemotiveproprietary high-speed packet data system. Thesystem software is structured to minimize "on the air"transmission time of any transmitter. This allows formultiple transmitters to share a common frequency.The TMS system is designed so that a transmitter willsend a signal for a predetermined ON time, and thenwill turn OFF. The length of transmitter ON time isreferred to as data burst or packet. The packet lengthis a function of the quantity of data to be sent, and thedata rate (baud). Once the packet is sent, thetransmitter will turn OFF. This allows for othertransmitters to time-share the same frequency when atransmitter has turned OFF. The TMS system soft-ware determines the OFF period and repetition rate ofthe ON period. Since each system has its own accesscode, up to 4 transmitters can share and have equalaccess to the same frequency. TMS also allows forreduced battery consumption and extended batterylife. These systems have low power pulsed signaling,FCC certified under Part 15 TelecommunicationsCode of Regulations, no license is required. Thetransmitter unit is frequency modulated, low powerand is certified under the appropriate regulations. Alicense is not required for the transmitter or operator.Modifications to the RF section of this system are notpermitted and could void FCC certification.3-3. Channel Designations: AK01 - 439.8 MHz AK06 - 438.8 MHzAK02 - 439.6 MHz AK07 - 438.6 MHzAK03 - 439.4 MHz AK08 - 438.4 MHzAK04 - 439.2 MHz AK09 - 438.2 MHzAK05 - 439.0 MHz AK10 - 438.0 MHz AK11 - 437.8 MHz AK16 - 436.8 MHzAK12 - 437.6 MHz AK17 - 436.6 MHzAK13 - 437.4 MHz AK18 - 436.4 MHzAK14 - 437.2 MHz AK19 - 436.2 MHzAK15 - 437.0 MHz AK20 - 436.0 MHzAKA00 - 433.125 MHz AKA05 - 434.125 MHzAKA01 - 433.325 MHz AKA06 - 434.325 MHzAKA02 - 433.525 MHz AKA07 - 434.525 MHzAKA03 - 433.725 MHz AKA08 - 434.725 MHzAKA04 - 433.925 MHz3-4. System Specifications.Receiver housing: NEMA 4X, IP67Transmitter housing: IP65. Operating Temperature: –22° F to +158° F (-30º C to+70º C) ambient. Humidity: up to 95 % (non-condensing). Typical Operating Range: 200 feet (70 meters). Rating of output relays (including Master Relay): 16Amp 277 VAC/24 VDC, 1 HP 240 VAC.3-5. Transmitter Unit. The transmitter is battery operated has an ON andOFF switch, E-STOP, motor controls and auxiliarycontrols used for such item warning indicators. LED’s mounted on the front panel provide indicationof battery voltage, ON/OFF, Modes and datatransmission status. A power down feature allows the transmitter and thereceiver unit to turn OFF if no keys are pressed forpredetermined number of minutes. The transmitterunit must again be turned ON. The unit uses pulsedoperation for extremely long battery life. Aconfiguration of the system is available withoutautomatic timeout. Housings are designed of high impact, chemicalresistant, materials. The antenna for the unit is
Section 3 – General System Information (Continued)12internal. A strap or belt is provided for carrying thetransmitter.3-6. Receiver Unit.The receiver unit consists of a synthesized RFmodule, built in antenna, integral power supply,microprocessor controlled output motor control andauxiliary function relays and mainline contactorrelay. The receiver unit contains circuitry, whichmatches the frequency and access code of thetransmitter.
Section 4 – Installation Procedure134-1. Pre-Installation Considerations.To ensure reliable and safe operation of thesystem, the following items must be consideredbefore installing the receiver unit. WARNINGTHE RECEIVER UNIT OR RELAYS ARENOT RATED AS EXPLOSION PROOF. THERECEIVER UNIT MUST NOT BE IN-STALLED IN EXPLOSIVE ENVIRONMENTSUNLESS APPROPRIATE SECONDARY EN-CLOSURE MEASURES ARE TAKEN. FAIL-URE TO FOLLOW THIS WARNING COULDRESULT IN SERIOUS INJURY OR DEATHAND DAMAGE TO EQUIPMENT.4-2. Receiver Unit Mounting LocationConsiderations.Ensure the mounting location is as far as possiblefrom exposed trolley wires and sources ofelectromagnetic or radiated noiseThe receiver cabinet is approximately 8" (20cm) wide by 12" (30 cm) high. A depth of atleast 6" (15 cm) must be provided to allow thecabinet door to open.The mounting surface must be smooth andcontinuous. Mounting the cabinet on unevensurfaces could cause warpage or stress internalcomponents.The receiver unit may be mounted in anyposition. Greatest radio control range is obtainedwhen the receiver unit is mounted with theantenna at the top.If possible, avoid installing receiver unit to asurface where high vibration or shock is present.If this cannot be avoided, use appropriate shockmounts.4-3. Antenna Mounting Considerations.The antenna is internal and requires noadditional mounting. The antenna is at the top ofthe receiver cabinet and should not be placednear large metal objects that could be close to orcover the top of the box. Allow at least sixinches above the top of the box for clearance.4-4. Line Input Considerations. WARNINGTHE UNIT MUST BE WIRED TO THE COR-RECT VOLTAGE, AND BE CONNECTED TOTHE CORRECT TERMINAL AS REQUIREDBY THE ACTUAL LINE VOLTAGE. FAIL-URE FOLLOW THIS WARNING COULD RE-SULT IN SERIOUS INJURY OR DEATH ANDDAMAGE TO EQUIPMENT.The receiver unit has direct connect provisionsfor operation from 120 (nominal), 50-60 Hzpower.For applications where line voltage deviationexceeds 20% of nominal values if line voltage isnot between95-130 VAC or 190-260 VAC or if 440 VACpower is used, a step up or step downtransformer must be used.NOTETHE RECEIVER UNIT SHOULD NOT BECONNECTED TO LINES CONTAININGEXCESSIVE POWER UP TRANSIENTS ORCONTINUOUS COMMUTATOR NOISE. ALINE CONDITIONER MAY BE NECESSARYIN SOME INSTALLATIONS.4-5. Wiring Considerations.1. Read this manual before installation.2. Please observe appropriate local andNational Electrical Codes when wiring electricaldevices.3. Do not connect or disconnect wiring, orperform circuit checks while the power is turnedon.4. The motor wiring should be in a separatemetal conduit from the power wiring, whichshould also be in metal conduit.5. Low voltage wires shall be wired withproper low voltage class wiring procedures.
Section 4 – Installation Procedure (Continued)146. Control wiring as well as antenna wiringshall be in separate conduit and shall be kept asshort as possible.7. All terminals shall be tightened to specifiedterminal torque 4.4 IN-LBS (.5 N∙m). Unlessotherwise specified.8. Remove excess metal screws, metal filingsand wire clippings from inside of unit.9. Inspect to make sure no exposed wire hascontact with any other wiring or terminals.10. Suppressors are strongly recommended onall contactors.4-6. Receiver/Equipment InterfaceConsiderations.All output relay contacts are rated at 16 amps250 VAC, however the system rating for thecontacts is 5 Amps. Connection to equipment orcontactors with higher voltage or currentrequirements will require intermediate relays.All relay outputs are normally open, momentarycontact. Since a relay closure is only active whilethe transmitter unit key is pressed and held,devices such as lights or lifting magnet must usea mechanical auxiliary latching relay.NOTEFOR INFORMATION ON INTERFACINGWITH SYSTEMS WITH HIGH IMPEDANCEINPUTS SEE SECTION 6-8. CONNECTINGOUTPUTS TO DRIVES OR CONTACTTELEMOTIVE.4-7. Receiver Unit Cabinet Mounting.Mounting brackets are provided. See next pageFigure 4-2. Receiver Mounting Details. Allowroom in mounting the receiver for the door toswing openMount receiver unit cabinet securely to mountingsurface. Actual cabinet mounting dimensions areshown on next page Figure 4-2. ReceiverMounting Details.4-8. Receiver Installation.1. Normally it should not be necessary to setthe access codes, they are preset. Programthe unit for any special crane configurationsor other parameters, if desired, see Section7. Programming for details.2. Position the receiver. Locate as far aspossible from exposed trolley wire andsources of electromagnetic or radiated noise.Cabinet mounting dimensions and mountingtemplate is on next page see Figure 4-2Aand B. Receiver Mounting Details. Antennaat top of unit should be kept as clear aspossible of any metal object.3. Mount the receiver. Mounting brackets areprovided to accommodate mounting on to ametal strut mounting system. The four deepmounting holes in corners of the receivermounting brackets use quantity four #10-24combo drive round head screws 1 ½ “ inlength, four #10 lock washers and four #10-24 hex nuts to mount to the mountingbrackets. Lock washers should be used infront of hex nuts. Four flat washers are .400I.D. x 1 ½” O.D. are supplied with use formounting the mounting brackets to a metalstrut.4. Wire the unit using the appropriate electricaldrawings for the specific transmitter andcrane orientation selected, see Section 6.Wiring. For the Membrane or Pendanttransmitter determine crane orientation; ifthe direction pair labeled on the transmitterbetter describes the equipment movement.Use this pair to wire the motor directionalsrespectively. If you need to remove the mainboard (4 screws) the antenna unplugs fromthe RF Receiver, be sure to dress theantenna cable under the hook on the RFReceiver when reinstalling the antennacable.5. Wire the power to J1 input power connector.The connections are Ground (GND), Neutral(N) and 120 VAC 50-60 Hz (120V). SeeFigure 4-1. Input Power Connections.6. Wiring of the system should now becomplete.7. Stand clear of the crane and apply AC powerto receiver unit. Turn switch SW2 OFF (MRrelay control) and SW1 ON (main powerswitch). Check to see if four LEDs are lit:(green; DS22, DS23 and DS24) and (red; RFReceiver ON). If none are lit check ACpower, power switch SW1 and fuse.
Section 4 – Installation Procedure (Continued)158. Turn transmitter ON. Check to see if theyellow LED is now lit (DSMR1). At thispoint the MR relay is disabled, the functionsof the transmitter can be checked by notingthe turning ON of the appropriate red LEDsnext to the control relays (DS7 to DS11).After checking out the functions, turn switchSW2 ON to enable the MR relay, checkfunction and direction by jogging eachmotion. Installation should now becomplete.9. If there are any problems see Section 8.Servicing.Figure 4-1. Input Power Connections.GND N 120VJ11Figure 4-2A. Receiver Mounting Details withHorizontal Mounting Brackets.Drawing not to scale.12.02”305.3 mm16.02”406.9 mm7.87”200 mmReceiver shown withMP10278-0 mountingbrackets attached..210” DIA.5.34 mmhole 4 places11.02”279.9 mm.281” DIA.7.14 mmhole 4 places11.81”300 mmOverall Cabinet Depth With doorclosed inches With doorclosed mm With dooropen inches With door openmmCabinet 5.26 133.60 12.12 307.98Cabinet and mounting bracket 5.44 138.07 12.30 312.44Cabinet, mounting bracket & 1 ½” strut 6.94 176.17 13.80 350.5414.02”356.01 mm7.09”180 mm
Section 4 – Installation Procedure (Continued)16Drawing not to scale.Figure 4-2B. Receiver Mounting Details withVertical Mounting Brackets..281” DIA.7.14 mmhole 4 placesReceiver shown withMP10278-0 mountingbrackets attached..210” DIA.5.34 mmhole 4 places16.02”406.9 mm7.09”180 mm11.02”279.9 mm14.02”356.01 mm8.09”206.6 mm11.81”300 mm7.87”200 mmOverall Cabinet Depth With doorclosed inches With doorclosed mm With dooropen inches With door openmmCabinet 5.26 133.60 12.12 307.98Cabinet and mounting bracket 5.44 138.07 12.30 312.44Cabinet, mounting bracket & 1 ½” strut 6.94 176.17 13.80 350.54
Section 5 – Operation175-1. Transmitter Buttons.ON/OFF On the telePilot and PendantTransmitter ON and OFF is the same button.Pushing this button toggles between turning thetransmitter ON and then sending the ONcommand to the receiver and sending the OFFcommand to the receiver and then turning thetransmitter OFF.NOTEIN THE TELEPILOT THE TRANSMITTERDOES NOT TURN ON TILL THE ON PUSHBUTTON IS RELEASED AFTER BEINGDEPRESSED TO TURN ON. THE OFFFUNCTION IS IMMEDIATE UPONDEPRESSING THE ON/OFF PUSH BUTTON.(Membrane only) ON Turns the transmitter ONand then sends the ON command to the receiver.OFF Sends the OFF command to the receiverand then turns the transmitter OFF.E-STOP (EMS) – Stops all equipmentmovement and disables all functions exceptAlarm. Reset the system for normal operation byturning the transmitter “OFF” then “ON”. Usefor emergencies only. (NOT FOR NORMALSHUT DOWN).NOTEON THE TELEPILOT TRANSMITTER THEUSER CAN CHOOSE AND CUSTOM LABELTHE FUNCTIONS FOR A SPECIFIC MOTORTHE FUNCTIONAL DESIGNATIONSSHOWN BELOW ARE COMMON ANDTRADITIONAL DESIGNATIONS.Common 2-Speed Designations Listed Below:Motor 1 Dir 1, (Hoist) UP – Selects hoistmovement in the UP direction speed one (firstswitch position) or speed two (second switchposition).Motor 1 Dir 2, (Hoist) DN/DOWN – Selectshoist movement in the DOWN direction speedone (first switch position) or speed two (secondswitch position).Motor 2 Dir 1, (E Membrane)/NORTHPendant– Selects the appropriate direction of thebridge or trolley (depending how unit is wired atinstallation) speed one (first switch position) orspeed two (second switch position).Motor 2 Dir 2, (W Membrane)/SOUTHPendant – Selects the appropriate direction ofthe bridge or trolley (depending how unit is UP DN E W N S 1 2 3 ON OFFESTOPAUX 1AUX 2AUX 3AUX 4A B BOTHON/OFF E-STOPON/OFFIndicatorsFigure 5-1. telePilot, Pendant and MembraneE-STOPON/OFF & Low Battery IndicatorsMotor 1 Dir 1 Dir 2Motor 2 Dir 1 Dir 2Motor 3 Dir 1 Dir 2ON/OFFOptional4th Motor or Select IndicatorsAuxiliaryControls AUX 1 AUX 2 AUX 32-Speed and Single-Speed telePilot Pendant and Me mbraneON/OFF654327891011121TX12M-2 TX12M-1A BUPDOWNNORTHSOUTHEASTWEST
Section 5 – Operation (Continued)18 8/15/2002wired at installation) speed one (first switchposition) or speed two (second switch position).Motor 3 Dir 1, (N Membrane)/EAST Pendant– Selects the appropriate direction of the bridgeor trolley (depending how unit is wired atinstallation) speed one (first switch position) orspeed two (second switch position).Motor 3 Dir 2, (S Membrane)/WEST Pendant– Selects the appropriate direction of the bridgeor trolley (depending how unit is wired atinstallation) speed one (first switch position) orspeed two (second switch position).(telePilot Only) Optional 4th Motor Or Selectwith IndicatorsThe AUX 3 pushbutton can be designated as anauxiliary motor select. As an example forsystems that have a main and auxiliary hoist,pushing this switch will toggle the function ofthe set of motor 1 pushbuttons between theoutputs for main and auxiliary hoist.There are two red LEDs above this pushbuttonlabeled “A” and “B”. The “A” LED comes ONfor the main function and the “B” comes ON forthe auxiliary. As the pushbutton is toggled thesequence of outputs and LEDs is as follows.Normally the main output only is active and the“A” LED is lit. Pushing the pushbutton lightsonly the “B” LED and the auxiliary output onlyis active. Pushing the pushbutton a second timelights both “A” and “B” LEDs and both mainand auxiliary outputs are active in tandem. (Thistandem operation can be disabled See Section 7-8. telePilot Programming). When turning thetransmitter ON the default condition is always“A”.This pushbutton can be used with the Selectfunction also. When used for the Select functionthe “A” and “B” LEDs work as described in theabove paragraph toggling the Select 1 output andthe Select 2 outputs respectively.1, 2 And 3 (AUX 1, AUX 2, and AUX 3) –Selects the Auxiliary relay(s), which may beused for a warning device as a horn or otherfunction.5-2. ON/OFF LED Indicator.When the transmitter is ON the red LED flashesslowly. When the unit transmits, the red LEDflashes rapidly. Top left indicator on telePilot.5-3. Low Battery Indication.In the telePilot transmitter there is a separatelow battery indicator located to the right of theON/OFF indicator. This is a yellow LED thatturns ON solid when it is time to replace thebatteries.For Membrane and Pedant transmitters if theON/OFF LED indicator does not light at all afterturning ON the transmitter or while operatingcrane with the transmitter, replace the batteries,they are weak. See Section 5-6. BatteryReplacement for battery replacement.5-4. Optional 4th Motor SelectIndicator.For two speed telePilots with four motorsprogrammed, this indicator will toggle between“A”, ”B” and both (for units programmed withor without tandem operation). Pressing the pushbutton directly beneath the indicators toggles thestate.5-5. Operation. WARNINGBEFORE TURNING ON OR OPERATINGTHE CRANE, MAKE SURE ALL PERSON-NEL ARE CLEAR OF THE OPERATINGAREA AND NO ONE IS STANDING UNDERTHE LOAD. FAILURE TO FOLLOW THISWARNING COULD RESULT IN SERIOUSINJURY OR DEATH AND DAMAGE TOEQUIPMENT.A BA B
Section 5 – Operation (Continued)19 8/15/2002 WARNINGWHEN OPERATING THE CRANE FOLLOWLOCAL AND GOVERNMENTAL RULES ONTHE USE OF HORNS AND ALARMS. FAIL-URE TO FOLLOW THIS WARNING COULDRESULT IN SERIOUS INJURY OR DEATHAND DAMAGE TO EQUIPMENT.Make sure that all personnel are clear of thecrane movement and no one is under the crane orload.Turn unit ON by pressing the ON/OFF (ON)button. The red LED ON/OFF indicatorshould flash rapidly for a few seconds indicatingthe ON command is being sent to the receiver.After the receiver is turned ON the red LEDshould flash slowly indicating the transmitter isnow ready to send commands.Perform whatever safety checks are required. SeeSection 2. Radio Controlled Safety. Operate anyhorns or alarms as required by local andgovernmental regulations.To operate the crane, press and hold the desiredfunction button to maintain operation. Press thedirectional buttons harder to second position toengage second speed for those cranes having 2-speed motors.Always turn system OFF by pressing theON/OFF (OFF) button on the transmitter whendone with crane operation. Do not use the E-STOP button as an ON/OFF button.In an emergency always hit E-STOP (EMS)immediately. To clear the emergency condition,turn the transmitter OFF and ON again to resumenormal operation.The receiver will time-out after approximately15 minutes if there is no activity. The transmitteris programmed to time-out if not used for 15minutes also for membrane and pendant. FortelePilot the transmitter time out time isselectable. WARNINGIN AN EMERGENCY HIT “E-STOP” TOSTOP ALL CRANE MOVEMENT. WHENEMERGENCY HAS CLEARED TURN THETRANSMITTER OFF THEN ON AGAIN TORESUME NORMAL OPERATION. FAILURETO FOLLOW THIS WARNING COULD RE-SULT IN SERIOUS INJURY OR DEATH ANDDAMAGE TO EQUIPMENT.5-6. Additional telePilot TransmitterOperational Features. (See Section 7-8.telePilot Programming for information onhow to program these features).telePilot E-STOP Function.The E-STOP command will be repeatedly sent aslong as the E-STOP pushbutton is depressed.The E-STOP is always live on the telePilottransmitter. Upon pushing the E-STOPpushbutton the transmitter will send an E-STOPcommand for the last selected Bank even if theunit is turned OFF. (Obviously, if the battery isdead this will not work).telePilot Low Battery Shutoff Function.If the battery gets too low the unit will shut offand send an OFF command to the receiver as itturns OFF.telePilot Self-Test Function.When the unit turns on if any function key isdepressed the unit will fault, not send a turn oncommand and not become operational. The redLED will stay ON till the unit is turned OFF.The unit will frequently scan the 2nd position ofthe motion switches while the transmitter is ONand if one of these is closed without the firstposition closed, the unit will fault as above.
Section 5 – Operation (Continued)20 8/15/2002telePilot Red LED ON/OFF Indicator.The red LED, at the upper most left hand side ofthe transmitter, operates as follows:• Be OFF when the transmitter is OFF.• Flash slowly when the transmitter isON, but not transmitting. If thetransmitter has Bank select enabled thethere will be a number of quick flashesfollowed by a pause. The number ofquick flashes indicates the Bank thetransmitter is in.• Flash rapidly when the transmitter istransmitting, including during E-STOPwhen the transmitter is OFF.• Remain ON continuously for: waitingpassword, un-programmed Bankselected or a logic or pushbutton fault.telePilot Battery Yellow Indicator Light.The yellow LED to the right of the ON/OFFindicator operates as follows:• Be OFF when the transmitter is OFF.• Be OFF when the transmitter is ON andthe battery is good.• Remain ON continuously for a lowbattery needing replacement.telePilot Bank Select (Normally PasswordProtected).This feature is like having four completelydifferent transmitters in one unit. Up to fourbanks (operational configurations) are possible.A Bank is a specific configuration of user-defined parameters including:System typeFrequencyAccess codesAlso: Key arrangementRelay configurationTime-out- ti mer timeMode selectionAlarm settingsTo select a specific bank, The ON/OFF pushbutton is pressed and held down while one of thefour upper most motion push buttons (buttons 1through 4 see Figure 5-2. Bank and PasswordInput Buttons) is pressed. Press push button 1 forBank 1, push button 2 for Bank 2, push button 3for Bank 3 or push button 4 for Bank 4. Whilethe Bank button is held down release the ONpushbutton and then the Bank button. (Thesequence is important). The transmitter red LEDON/OFF indicator then stays ON (for fiveseconds) till the password is entered. Once thepassword is entered (see below) the transmitterred LED ON/OFF indicator flashes indicatingthe current Bank the operator is in while thetransmitter is ON and not transmitting. One flashthen a pause repeatedly indicates Bank 1, twoquick flashes indicates Bank 2, three quickflashes and a pause indicates Bank 3 and so on.The transmitter will remember what Bank it is ineven if turned OFF and ON again.It is not necessary to program all four Banks, ifan un-programmed or turned “off” Bank isselected the ON/OFF indicator will remainON continuously, the transmitter will send nocommands and will turn itself off shortly.telePilot Bank Password ProtectionFunction.This enables the owner to create a four-strokepassword word to enable changing Banks. WithPassword enabled the operator selects a four-button sequence to enable a Bank after differentBank has been selected (see above). When thetransmitter is turned ON, after Bank Selection ismade and the ON/OFF indicator will remainlit until the correct password sequence is enteredwith in five seconds. An incorrect passwordsequence or failure to enter the sequence in timeshuts the unit OFF. The user is allowed to restartand try again an unlimited amount of times. TheBank Password is the same for all Banks. WARNINGTHIS PASSWORD FUNCTION IS NOT TO BEUSED AS A SECURITY DEVICE. THE PUR-POSE OF THIS FUNCTION IS TO PREVENTACCIDENTAL BANK SWITCHING. THEBEST FORM OF SECURITY IS ALWAYS TOLOCKUP THE TRANSMITTER WHEN NOTIN SERVICE. FAILURE TO FOLLOW THISWARNING COULD RESULT IN SERIOUSINJURY OR DEATH AND DAMAGE TOEQUIPMENT.
Section 5 – Operation (Continued)21 8/15/2002When initially programming the unit the defaultpassword is 6, 5, 4, 3. This password can beeasily changed by the PDA during initialprogramming.A password is a sequence of four pushbuttonentries. These entries are any combination ofinputs from the upper most six buttons on theright hand side of the telePilot transmitter. On 2-Speed transmitters the second speed is ignored.Acceptable sequences could duplicate buttonsnumbers such as 2, 2, 6, 6 or 1, 1, 1, 4.NOTEALWAYS REMEMBER TO STORE THEPASSWORD IN A SECURE LOCATION FORACCESS IF THE PASSWORD IS LOST ORFORGOTTEN. ONCE THE TRANSMITTER ISPROGRAMMED THERE IS NO WAY TO DE-FEAT THE PASSWORD WITHOUT USING APDA TO EITHER READ THE PASSWORDOUT OR REPROGRAM A NEW ONE.The Bank password can be disabled duringinitial programming by the PDA. WARNINGDISABLING THE PASSWORD FUNCTIONPUTS THE SYSTEM IN ACTIVE BANKSELECT. THIS ALLOWS THE CRANEOPERATOR TO SWITCH BETWEEN BANKSQUICKER. THE OPERATOR IN THIS MODEMUST BE AWARE AND RESPONSIBLE FORALL POSSIBLE CONTROLLED CRANES.FAILURE TO FOLLOW THIS WARNINGCOULD RESULT IN SERIOUS INJURY ORDEATH AND DAMAGE TO EQUIPMENT.telePilot Time-Out-Timer Function.The transmitter has a time-out timer and thedefault condition is 15 minutes. Upon timing outthe transmitter will send an OFF command to thereceiver if Auto Turn Off is active. Thetransmitter time-out-timer function isprogrammable in minute increments to up to andincluding 15 minutes. After that it isprogrammable in five-minute increments up toand including one hour. Infinite time-out (none)is also selectable. The time-out-timer measuresthe time since the last pushbutton stroke and iscontinuously reset by any pushbutton activation.Figure 5-2. Bank and Password Input Buttons.123456123456Bank Input ButtonsPassword Designators forProgramming
Section 5 – Operation (Continued)22 8/15/20025-7. Battery Replacement.Membrane And Pendant BatteryReplacement.To replace the batteries, turn the transmitterOFF, and then turn the unit over to access backcover. Twist half moon shaped battery latch toremove cover. Take out old batteries; replaceALL batteries with new cells. For the MembraneTransmitter note battery orientation, batteries inbackwards will blow fuse. Replace cover andturn transmitter ON to use. See Section 9. SpareParts for battery and fuse part numbers.telePilot Battery Replacement.On the telePilot if the yellow battery indicatorlight starts to flash replace the battery atthe earliest opportunity. If the light is on solidreplace the battery immediately.NOTETHERE IS NO NEED TO RUSH BATTERYREPLACEMENT. THE PROGRAMMING INTHE telePilot WILL NOT BE LOST BYREMOVAL OF THE BATTERY ORPROLONGED LOSS OF POWER.Turn the transmitter OFF, loosen the twothumbscrews on the bottom of the unit and openthe unit by pulling on the belt loop. (See below).Pull out the battery holder until the batteries canbe accessed. Do not pull hard on the batteryholder as it is attached to the logic board by acable. Unsnap the battery cable (for batterypacks) or replace the two “AA” cells (for abattery carrier) and replace the battery(s) with anew battery(s), noting the polarity for “AA”cells. (Best life can be obtained if the two “AA”batteries used are a good quality alkaline type,both cells of the same type and from the samemanufacturer). Replace the battery holder, beltloop and tighten the thumbscrews. See Section 9– Spare Parts for battery part numbers.Figure 5-3. telePilot Battery Replacement.
Section 6 – Wiring236-1. Wiring Diagrams.Your TELEPILOT system comes pre-programmed the following pages in this sectionhave individual wiring diagrams for differentcrane configurations. Find the appropriate wiringdiagram and if necessary set the ConfigurationSwitch (SW3 in the transmitter) to match theSW3 Transmitter Switch Settings shown in theappropriate diagram. The location of the SW3for Membrane and Pendant transmitters is shownin Section 8-1. Servicing. Terminal designatorsare marked on the wiring diagram correspondingto designators found on the Receiver Board. Forterminal locations see Figure 8-1. ReceiverLayout. After selecting the appropriate motorsfor each function remember to use theappropriate label on your telePilot transmitterfor describing the appropriate command.For the Pendant and Membrane transmitters theproper connections to use for the bridge and forthe trolley are best determined by that pair ofdirectional designators (North/South orEast/West) best describes the crane’s movement.Does the bridge travel East/West orNorth/South? The trolley would use the otherdirectional pair as the bridge. Care should betaken after a directional pair is selected to makesure the specific motor directional inputs matchthe desired direction of the bridge or trolley, i.e.,if North/South is picked for the bridge make surethe South traveling bridge motor directional iswired to the South terminal of the unit.Typically in the following wiring diagrams, thebridge is shown as Motor 3 and Trolley as Motor2. Since the labeling cannot be easily moved onthe Membrane Transmitter keypad, the twodirectional pairs Motor 2 and 3 can be easilyexchanged by turning the dip switch SW3position 1 in the Membrane Transmitter to“ON”. See Section 7-6.8. Repositioning ofMembrane Transmitter Motion Switch Functionsfor more details.6-2. Installation.Follow Section 4. Installation Procedure forinstructions on how to install the receiver.6-3. Alarms And Horns.Make sure that the installation includes theproper alarms, horns, indicator lights and theirassociated controls as required by local andgovernmental regulations.6-4. Single-Speed Pendant TransmitterWiring.For the Single-Speed Pendant Transmitter theonly wiring configuration is the diagram inSection 6. Wiring. Table 1, TR12 Single-SpeedStandard Configuration Hoist, Trolley andBridge.6-5. 2-Speed Pendant Transmitter Wiring.For the 2-Speed TR12 Pendant Transmitter thefunctional labeling is different than the 2-SpeedMembrane. E/W and N/S are exchanged. Bysetting dip switch SW3 position 1 in the “ON”position the pushbuttons of the PendantTransmitter match the directional notations onthe 2-speed wiring diagrams in Section 6.Wiring. Failure to turn switch SW3 position 1 to“ON” will cause EAST/WEST andNORTH/SOUTH to be exchanged respectively.All other functions will remain the same.6-6. Relay Sequencing.When the second speed position is activated theappropriate directional relay is still engaged.6-7. Alarm After E-STOP.This is only for wiring configurations where theAux 3 (relay K12, output J5-6) is being used forthe Alarm function, placing a jumper on JU1 onthe Receiver Board will allow the alarm tofunction after an E-STOP command. See Figure8-1. Receiver Layout for jumper location.6-8. Connecting Outputs To Drives.MOV’s (transient protectors) are on all theoutput relays to protect the relays from powersurges. MOV’s allow a small leakage currentthat can affect some high impedance circuits.When connecting output relays to drives, it maybe required to remove the MOV to prevent theleakage current through the MOV from holdingin the drive. See Figure 8-1. Receiver Layout forthe location of the MOV's. The MOV’s are nextto the relays they protect. The MOV’s can be cut
Section 6 – Wiring (Continued)24 8/15/2002out of the circuit with a wire cutter. Rememberto do this with ALL power OFF on the crane andall associated controls.LegendThe following is the legend for the wiringdiagrams below:6-9. Optional Transfer Switch WiringConfigurations.If a transfer switch is desired, a simple schematicof an externally installed transfer switchinterface is shown on the next page. A completesystem drawing for this transfer switch is shownon the following pages (see Figure 6-3A.). Afactory installed internal transfer switch isavailable. A system drawing for this optionalfactory installed internal transfer switch andpigtail is shown on the following pages (SeeFigure 6-3B.).Matching relay contactsin radio receiver panelby number.#An input with the terminalnumber # matching the con-nector in the receiver.#An output with the terminalnumber # matching the con-nector in the receiver.Customer suppliedcontactor coil with arcsuppressor in parallel.C#K#Figure 6-1. Legend.
Section 6 – Wiring (Continued)25 8/15/2002Figure 6-2. External Transfer Switch WiringJ6-1 J6-2 J6-3 J6-4 J6-5 J6-6 J6-7 J6-8 J7-1 J7-2 J7-3K13 MRMOV10 AmpSlo BloFuse Receiver PanelN/COptionalTransfer Switch (2-pole double-throw)HOTMLC RETURN ACX2ACX1MAIN LINECONTACTOR3P33RX1RX1PX1TSTSTSTS2MLCSTARTPendantTO PENDANTCOMMONINDICATESTRANSFER SWITCHIN RADIO MODESTOPTS3PN/CThis connector used forinternal transfer switch
Section 6 - Wiring (Continued)26Figure 6-3A. External Transfer Switch System Wiring
Section 6 - Wiring (Continued)27Figure 6-3B. Optional Internal Transfer Switch System Wiring
Section 6 - Wiring (Continued)28TABLE 1 TR12 SINGLE-SPEED WIRING DIAGRAM.STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGEMASTER RELAYMAIN LINE CONTACTOR Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8*NoteJumper JU1, Receiver Boardfor Alarm to function afteran E-Stop command. SeeFigure 8-1. Receiver Layout**NoteThe outputs on this diagrammatch the button designationsshown for the different Modesshown in Figure 7.7 for theSingle-Speed Membrane andtelePilot transmittersrespectively. Page 69.Mode 141Bridge/TrolleyDIR 2Main HoistUpBridge/TrolleyDIR 1Main HoistDownAux HoistUpTrolley /BridgeDIR 2Aux HoistDown3Trolley /BridgeDIR 12Mode 2AlarmLightP2Main HoistUpP1Main HoistDownTrolley /BridgeDIR 1Aux HoistDownTrolley /BridgeDIR 2Bridge/TrolleyDIR 1Aux HoistUpBridge/TrolleyDIR 2Mode 3213748951011612Single Speed Transmitter Modes
Section 6 - Wiring (Continued)29TABLE 1 TR12 SINGLE-SPEED PROGRAMMING DIAGRAM.STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGEMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-1 HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)INDEPENDENT CONNECTIONSJ4-2 AUX 3 (HOT J4-4) J3-2 AUX 2 (HOT J3-4) J2-2 AUX 1 (HOT J2-4)J5-2 AUX 4 (LATCHABLE S4-2) J5-1 HOT AUX 4J5-4 AUX 6 (LATCHABLE S4-3) J5-3 HOT AUX 6J5-6 AUX 5 ALARM J5-5 HOT AUX 5RECEIVER SWITCH SETTINGS SW3: SW3 Position-5ONSINGLE SPEED ONLY TRANSMITTERS SWITCH SETTINGSSINGLE SPEED telePilot USE PDA SCREEN (select single-speed transmitter style).SINGLE SPEED MEMBRANE USE SW3 “C”, SINGLE SPEED PENDANT USE SW “D”TRANSMITTER SWITCH SETTINGS: Position-5 Position -6 Position -7OFF OFF OFF*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose todefine the motors differently.OUTPUTSJ2-3J2-1BRIDGE*MOTOR 3 1STDir 1 Dir 2OUTPUTSJ4-3J4-1HOIST*MOTOR 1 1ST UP DN1ST 1STOUTPUTSJ3-3J3-1TROLLEY*MOTOR 2 1STDir 1 Dir 21STJ2-2J3-2J4-2AUX 1AUX 2AUX 3INDEPENDENT OUTPUTSJ5-2J5-6J5-4AUX 4AUX 5AUX 6OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in ON Position.
Section 6 - Wiring (Continued)30TABLE 2(A) TR12 2-SPEED WIRING DIAGRAM.STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGEMASTERRELAYMAIN LINECONTACTORAUX 3ALARM*AUX 2 (latchable S4-3)AUX 1 (latchable S4-2)MOTOR 1 (M1) (M1) DIR 1 (M1) 2ND SPD (M1) DIR 2MOTOR 2 (M2) (M2) DIR 1 (M2) 2ND SPD (M2) DIR 2MOTOR 3 (M3) (M3) DIR 1 (M3) 2ND SPD (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8*Note:Jumper JU1, Receiver Boardfor Alarm to function afteran E-Stop command. SeeFigure 8-1. Receiver LayoutThe outputs matchthe button labelsas defined inSection 5-1.
Section 6 - Wiring (Continued)31TABLE 2(A) TR12 2-SPEED PROGRAMMING DIAGRAM.STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGEMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 HOIST 2ND SPEED J3-2 TROLLEY 2ND SPEED J2-2 BRIDGE 2ND SPEEDJ4-1 HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)INDEPENDENT CONNECTIONSJ5-2 AUX 1 (LATCHABLE S4-2) J5-1 HOT AUX 1J5-4 AUX 2 (LATCHABLE S4-3) J5-3 HOT AUX 2J5-6 AUX 3 ALARM J5-5 HOT AUX 3 ALARMTRANSMITTER SWITCH SETTINGStelePilot USE PDA SCREEN (Program the configuration switches 5, 6 and 7 to OFF. Under “Main/Aux” select thesetting “Aux”).MEMBRANE USE SW3 “C”PENDANT, JLTX AND SLTX USE SW4 “D”TRANSMITTER SWITCH SETTINGS: Position-5 Position -6 Position -7OFF OFF OFF*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 3 1ST 2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1HOIST*MOTOR 1 1ST 2NDUP DN2ND 1ST 2ND 1STJ5-2J5-4J5-6AUX 1AUX 2AUX 3 ALARMINDEPENDENT OUTPUTSOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 2 1ST 2NDDir 1 Dir 22ND 1STOFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.
Section 6 - Wiring (Continued)32TABLE 2(B) TR12 2-SPEED WIRING DIAGRAM.2-SPEED with DIRECTIONAL CONTROLS: ALL MOTIONSMASTERRELAYMAIN LINECONTACTORMOTOR 1DIR1/DIR2MOTOR 2DIR1/DIR2MOTOR 3DIR1/DIR2MOTOR 1 (M1) (M1) DIR 1 (M1) 2ND SPD (M1) DIR 2MOTOR 2 (M2) (M2) DIR1 (M2) 2ND SPD (M2) DIR 2MOTOR 3 (M3) (M3) DIR 1 (M3) 2ND SPD (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8The outputs match thebutton labels as defined inSection 5-1. except thereare no AUXs.
Section 6 - Wiring (Continued)33TABLE 2(B) TR12 2-SPEED PROGRAMMING DIAGRAM.2-SPEED with DIRECTIONAL CONTROLS: ALL MOTIONSMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 HOIST 2ND SPEED J3-2 TROLLEY 2ND SPEED J2-2 BRIDGE 2ND SPEEDJ4-1 HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)J5-6 HOIST DIR1/DIR2 J5-4 TROLLEY DIR1/DIR2 J5-2 BRIDGE DIR1/DIR2J5-5 HOT HOIST DIR1/DIR2 J5-3 HOT TROLLEY DIR1/DIR2 J5-1 HOT BRIDGE DIR1/DIR2NOTECHECK GOVERNMENTAL AND LOCAL REGULATIONS ON THE REQUIREMENTS OF HORNS OR ALARMSBEFORE USING THIS CONFIGURATION, AS THERE IS NOT A SEPARATE ALARM CONTROL.TRANSMITTER SWITCH SETTINGStelePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).MEMBRANE USE SW3 “C”PENDANT, JLTX AND SLTX USE SW4 “D”TRANSMITTER SWITCH SETTINGS: Position-5 Position -6 Position -7ON OFF OFF*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 3 1ST 2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1HOIST*MOTOR 1 1ST 2ND UP DN2ND 1ST 2ND 1STOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 2 1ST 2NDDir 1 Dir 22ND 1ST J5-2J5-6 J5-4
Section 6 - Wiring (Continued)34TABLE 2(C) TR12 2-SPEED WIRING DIAGRAM.2-SPEED, 2-WINDINGS: ALL MOTIONSMASTERRELAYMAIN LINECONTACTORMOTOR 12ND SPDMOTOR 22ND SPDMOTOR 32ND SPDMOTOR 1 (M1) (M1) DIR 1 (M1) 1ST SPD (M1) DIR 2MOTOR 2 (M2) (M2) DIR 1 (M2) 1ST SPD (M2) DIR 2MOTOR 3 (M3) (M3) DIR 1 (M3) 1ST SPD (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8The outputs match thebutton labels as definedin Section 5-1. exceptthere are no AUXs.
Section 6 - Wiring (Continued)35TABLE 2(C) TR12 2-SPEED PROGRAMMING DIAGRAM.2-SPEED, 2-WINDINGS: ALL MOTIONSMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 HOIST 1 ST SPEED J3-2 TROLLEY 1 ST SPEED J2-2 BRIDGE 1 ST SPEEDJ4-1 HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)J5-6 HOIST 2ND SPEED J5-4 TROLLEY 2ND SPEED J5-2 BRIDGE 2ND SPEEDJ5-5 HOT HOIST 2ND SPEED J5-3 HOT TROLLEY 2ND SPEED J5-1 HOT BRIDGE 2ND SPEEDNOTECHECK GOVERNMENTAL AND LOCAL REGULATIONS ON THE REQUIREMENTS OF HORNS OR ALARMSBEFORE USING THIS CONFIGURATION, AS THERE IS NOT A SEPARATE ALARM CONTROL.TRANSMITTER SWITCH SETTINGStelePilot USE PDA SCREEN (Program the configuration switches to match the pattern and position shown).MEMBRANE USE SW3 “C”PENDANT, JLTX AND SLTX USE SW4 “D”TRANSMITTER SWITCH SETTINGS: Position-5 Position -6 Position -7OFF ON OFF*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 3 1ST 2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1HOIST*MOTOR 1 1ST 2NDUP DN2ND 1ST 2ND 1STOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 2 1ST 2NDDir 1 Dir 22ND 1STJ5-2J5-6 J5-4
Section 6 - Wiring (Continued)36TABLE 2(D) TR12 2-SPEED WIRING DIAGRAM.ACCO CONTROLS: ALL MOTIONSMASTERRELAYMAIN LINECONTACTORMOTOR 12ND SPD DIR 2MOTOR 22ND SPD DIR 2MOTOR 32ND SPD DIR 2MOTOR 1 (M1) (M1) DIR 1 (M1) 2ND SPD DIR 1 (M1) DIR 2MOTOR 2 (M2) (M2) DIR 1 (M2) 2ND SPD DIR 1 (M2) DIR 2MOTOR 1 (M3) (M3) DIR 1 (M3) 2ND SPD DIR 1 (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8The outputs match thebutton labels as definedin Section 5-1. exceptthere are no AUXs.
Section 6 - Wiring (Continued)37TABLE 2(D) TR12 2-SPEED PROGRAMMING DIAGRAM.ACCO CONTROLS: ALL MOTIONSMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 HOIST 2ND SPEED DIR 1 J3-2 TROLLEY 2ND SPEED DIR 1 J2-2 BRIDGE 2ND SPEED DIR 1J4-1 HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)J5-6 HOIST 2ND SPEED DIR 2 J5-4 TROLLEY 2ND SPEED DIR 2 J5-2 BRIDGE 2ND SPEED DIR 2J5-5 HOT HOIST 2ND SPD DIR 2 J5-3 HOT TROLLEY 2ND SPD DIR 2 J5-1 HOT BRIDGE 2ND SPD DIR 2NOTECHECK GOVERNMENTAL AND LOCAL REGULATIONS ON THE REQUIREMENTS OF HORNS OR ALARMSBEFORE USING THIS CONFIGURATION, AS THERE IS NOT A SEPARATE ALARM CONTROL.TRANSMITTER SWITCH SETTINGStelePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).MEMBRANE USE SW3 “C”PENDANT, JLTX AND SLTX USE SW4 “D”TRANSMITTER SWITCH SETTINGS: Position-5 Position -6 Position -7ON ON OFF*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 3 1ST 2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1HOIST*MOTOR 1 1ST 2ND UP DN2ND 1ST 2ND 1STOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 2 1ST 2NDDir 1 Dir 22ND 1STJ5-2J5-6 J5-4
Section 6 - Wiring (Continued)38TABLE 2(E) TR12 2-SPEED WIRING DIAGRAM.P&H: 2-SPEED, 2-WINDINGS for HOIST and TROLLEY;STANDARD BRIDGEMASTERRELAYMAIN LINECONTACTORMOTOR 12ND SPDMOTOR 22ND SPDAUX 1 (latchable S4-2)MOTOR 1 (M1) (M1) DIR 1 (M1) 2ND SPD (M1) DIR 2MOTOR 2 (M2) (M2) DIR 1 (M2) 1ST SPD (M2) DIR 2MOTOR 3 (M3) (M3) DIR 1 (M3) 1ST SPD (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8The outputs match thebutton labels as definedin Section 5-1. exceptthere is only AUX 1.
Section 6 - Wiring (Continued)39TABLE 2(E) TR12 2-SPEED PROGRAMMING DIAGRAM.P&H: 2-SPEED, 2-WINDINGS for HOIST and TROLLEY;STANDARD BRIDGEMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 HOIST 1ST SPEED J3-2 TROLLEY 1ST SPEED J2-2 BRIDGE 2ND SPEEDJ4-1 HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)J5-6 HOIST 2ND SPEED J5-4 TROLLEY 2ND SPEEDJ5-5 HOT HOIST 2ND SPEED J5-3 HOT TROLLEY 2ND SPEEDINDEPENDENT CONNECTIONSJ5-2 AUX 1 (LATCHABLE S4-2) J5-1 HOT AUX 1TRANSMITTER SWITCH SETTINGStelePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).MEMBRANE USE SW3 “C”PENDANT, JLTX AND SLTX USE SW4 “D”TRANSMITTER SWITCH SETTINGS: Position-5 Position -6 Position -7OFF OFF ON*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 31ST2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1HOIST*MOTOR 1 1ST2NDUP DN2ND 1ST2ND 1STOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 2 1ST 2NDDir 1 Dir 22ND1STJ5-6 J5-4J5-2 AUX 1INDEPENDENT OUTPUTS
Section 6 - Wiring (Continued)40TABLE 2(F) TR12 2-SPEED WIRING DIAGRAM.P&H: 2-SPEED, 2-WINDINGS for HOIST;STANDARD TROLLEY and BRIDGEMASTERRELAYMAIN LINECONTACTORMOTOR 12ND SPDAUX 2 (latchable S4-3)AUX 1 (latchable S4-2)MOTOR 3 (M1) (M1) DIR 1 (M1) 2ND SPD (M1) DIR 2MOTOR 2 (M2) (M2) DIR 1 (M2) 2ND SPD (M2) DIR 2MOTOR 1 (M3) (M3) DIR 1 (M3) 1ST SPD (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8The outputs match thebutton labels as defined inSection 5-1. except there isonly AUX 1 and AUX 2.
Section 6 - Wiring (Continued)41TABLE 2(F) TR12 2-SPEED PROGRAMMING DIAGRAM.P&H: 2-SPEED, 2-WINDINGS for HOIST;STANDARD TROLLEY and BRIDGEMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 HOIST 1ST SPEED J3-2 TROLLEY 2ND SPEED J2-2 BRIDGE 2ND SPEEDJ4-1 HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)J5-6 HOIST 2ND SPDJ5-5 HOT HOIST 2ND SPEEDINDEPENDENT CONNECTIONSJ5-2 AUX 1 (LATCHABLE S4-2) J5-1 HOT AUX 1J5-4 AUX 2 (LATCHABLE S4-3) J5-3 HOT AUX 2TRANSMITTER SWITCH SETTINGStelePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).MEMBRANE USE SW3 “C”PENDANT, JLTX AND SLTX USE SW4 “D”TRANSMITTER SWITCH SETTINGS: Position-5 Position -6 Position -7ON OFF ON*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 31ST2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1HOIST*MOTOR 1 1ST2NDUP DN2ND 1ST2ND1STOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 21ST2NDDir 1 Dir 22ND1STJ5-6INDEPENDENT OUTPUTSJ5-2 AUX 1J5-4 AUX 2
Section 6 - Wiring (Continued)42TABLE 2(G) TR12 2-SPEED WIRING DIAGRAM.DEMAG: 2-SPEED, 2-WINDINGS for HOIST;STANDARD TROLLEY and BRIDGEMASTERRELAYMAIN LINECONTACTORMOTOR 12ND SPD DIR 2AUX 2 (latchable S4-3)AUX 1 (latchable S4-2)MOTOR 1 (M1) (M1) DIR 1 (M1) 2ND SPD (M1) DIR 2MOTOR 2 (M2) (M2) DIR 1 (M2) 2ND SPD (M2) DIR 2MOTOR 3 (M3) (M3) DIR 1 (M3) 2ND SPD DIR 1 (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8The outputs matchthe button labels asdefined in Section 5-1. except there is onlyAUX 1 and AUX 2.
Section 6 - Wiring (Continued)43TABLE 2(G) TR12 2-SPEED PROGRAMMING DIAGRAM.DEMAG: 2-SPEED, 2-WINDINGS for HOIST;STANDARD TROLLEY and BRIDGEMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 HOIST 2ND SPEED DIR 1 J3-2 TROLLEY 2ND SPEED J2-2 BRIDGE 2ND SPEEDJ4-1 HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)J5-6 HOIST 2ND SPEED DIR 2J5-5 HOT HOIST 2ND SPEED DIR 2INDEPENDENT CONNECTIONSJ5-2 AUX 1 (LATCHABLE S4-2) J5-1 HOT AUX 1J5-4 AUX 2 (LATCHABLE S4-3) J5-3 HOT AUX 2TRANSMITTER SWITCH SETTINGStelePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).MEMBRANE USE SW3 “C”PENDANT, JLTX AND SLTX USE SW4 “D”TRANSMITTER SWITCH SETTINGS: Position-5 Position -6 Position -7OFF ON ON*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 31ST 2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1HOIST*MOTOR 1 1ST 2NDUP DN2ND 1ST 2ND 1STOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 21ST 2NDDir 1 Dir 22ND 1STJ5-6INDEPENDENT OUTPUTSJ5-2 AUX 1J5-4 AUX 2
Section 6 - Wiring (Continued)44TABLE 2(H) TR12 2-SPEED WIRING DIAGRAM.STANDARD 2-SPEED 4 MOTOR SYSTEMMASTERRELAYMAIN LINECONTACTORMOTOR 4 (M4) (M4) DIR 1 (M4) 2ND SPD (M4) DIR 2MOTOR 1 (M1) (M1) DIR 1 (M1) 2ND SPD (M1) DIR 2MOTOR 2 (M2) (M2) DIR 1 (M2) 2ND SPD (M2) DIR 2MOTOR 3 (M3) (M3) DIR 1 (M3) 2ND SPD DIR 1 (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8The outputs match the telePilotbutton labels in Fig. 5-1. exceptthere are no AUXs. And theAUX 3 position selects “A”Motor 1 and/or “B” Motor 4 forthe upper most right hand sidepair of two speed buttons.
Section 6 - Wiring (Continued)45TABLE 2(H) TR12 2-SPEED PROGRAMMING DIAGRAM.STANDARD 2-SPEED 4 MOTOR SYSTEMMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 MAIN HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 MAIN HOIST 2ND SPEED J3-2 TROLLEY 2ND SPEED J2-2 BRIDGE 2ND SPEEDJ4-1 MAIN HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)MOTOR 4 CONNECTIONSJ5-6 AUX HOIST UP J5-5 HOT AUX HOIST UPJ5-4 AUX HOIST 2ND SPEED J5-3 HOT AUX HOIST 2ND SPEEDJ5-2 AUX HOIST DOWN J5-1 HOT AUX HOIST DOWNNOTECHECK GOVERNMENTAL AND LOCAL REGULATIONS ON THE REQUIREMENTS OF HORNS OR ALARMSBEFORE USING THIS CONFIGURATION, AS THERE IS NOT A SEPARATE ALARM CONTROL.TRANSMITTER SWITCH SETTINGS (This configuration does not apply to the Membrane transmitter).telePilot USE PDA SCREEN (Program the configuration switches 5, 6 and 7 to OFF. Under “Main/Aux” select thesetting “Motor”).PENDANT, JLTX AND SLTX TRANSMITTER SWITCH SW4 “D” SETTINGS:Position-1 Position-2 Position-5 Position -6 Position –7OFF ON OFF OFF OFF*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 31ST 2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1MAIN HOIST*MOTOR 11ST 2NDUP DN2ND 1ST 2ND 1STOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 21ST 2NDDir 1 Dir 22ND 1STOUTPUTSJ5-6J5-4J5-2AUX HOIST*MOTOR 4 1ST 2NDUP DN2ND 1STOFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.
Section 6 - Wiring (Continued)46TABLE 2(I) TR12 2-SPEED WIRING DIAGRAM.STANDARD 2-SPEED 3, 4 & 5 MOTOR SYSTEM using SELECTMASTER RELAYMAIN LINECONTACTORAUX 3 (AUX 2 positionon telePilot transmitter) ALARM* SELECT 1 SELECT 2MOTOR 1 (M1) (M1) DIR 1 (M1) 2ND SPD (M1) DIR 2MOTOR 2 (M2) (M2) DIR 1 (M2) 2ND SPD (M2) DIR 2MOTOR 3 (M3) (M3) DIR 1 (M3) 2ND SPD (M3) DIR 2 Receiver PanelJ6-2J5-5J5-3J5-1J4-4J3-4J2-4J6-3J5-6J5-4J5-2J4-3J4-2J4-1J3-3J3-2J3-1J2-3J2-2J2-1HOT RETURNK13K12K11K10K9K8K7K6K5K4K3K2K1MLCC12C11C10C9C8C7C6C5C4C3C2C1F7F6F5F4F3F2J7-3J7-2J7-1J6-8J6-7J6-6J6-5J6-4J6-3J6-2J6-1J5-6J5-5J5-4J5-3J5-2J5-1J4-4J4-3J4-2J4-1J3-4J3-3J3-2J3-1J2-4J2-3J2-2J2-1J1-3J1-2J1-1External jumperin J6 connectorJ6-4 J6-5F8*Note:Jumper JU1, Receiver Boardfor Alarm to function afteran E-Stop command. SeeFigure 8-1. Receiver LayoutThe outputs match the telePilotbutton labels in Fig. 5-1. exceptAUX 2 is Alarm. And the AUX 3position selects “A” Select 1and/or “B” Select 2 set of relaysrespectively.
Section 6 - Wiring (Continued)47TABLE 2(I) TR12 2-SPEED PROGRAMMING DIAGRAM.STANDARD 2-SPEED 3, 4 & 5 MOTOR SYSTEM using SELECTMOTOR 1 CONNECTIONS MOTOR 2 CONNECTIONS MOTOR 3 CONNECTIONSJ4-3 MAIN HOIST UP J3-3 TROLLEY DIR 1 J2-3 BRIDGE DIR 1J4-2 MAIN HOIST 2ND SPEED J3-2 TROLLEY 2ND SPEED J2-2 BRIDGE 2ND SPEEDJ4-1 MAIN HOIST DOWN J3-1 TROLLEY DIR 2 J2-1 BRIDGE DIR 2J4-4 HOT (J4-1, 2 & 3) J3-4 HOT (J3-1, 2 & 3) J2-4 HOT (J2-1, 2 & 3)INDEPENDENT CONNECTIONSJ5-2 SELECT 2 J5-1 HOT SELECT 2J5-4 SELECT 1 J5-3 HOT SELECT 1J5-6 AUX 3 ALARM J5-5 HOT AUX 3 ALARMTRANSMITTER SWITCH SETTINGS (This configuration does not apply to the Membrane transmitter).telePilot USE PDA SCREEN (Program the configuration switches 5, 6 and 7 to OFF. Under “Main/Aux” select theword “Select”).PENDANT, JLTX AND SLTX TRANSMITTER SWITCH SW4 “D” SETTINGS:Position-1 Position-2 Position-5 Position -6 Position –7ON ON OFF OFF OFF*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define themotors differently.Additional programming available:The select function can be inverted by turning switch position 4 to ON (the Configuration Switch on the telePilot or SW4“D” for the Pendant, JLTX and SLTX).Tandem select operation, both select 1 and 2 on at the same time, can be disabled by un-checking the box marked“Tandem” on the telePilot or turning on the Configuration Switch SW 4 “D” for the Pendant, JLTX and SLTX.OFF1 2 3 4 5 6 7 8 ON For these switchpositions seeprevious section.Indicates Switch in OFF Position.OUTPUTSJ2-3J2-2J2-1BRIDGE*MOTOR 3 1ST 2NDDir 1 Dir 2OUTPUTSJ4-3J4-2J4-1MAIN HOIST*MOTOR 1 1ST 2NDUP DN2ND 1ST 2ND 1STOUTPUTSJ3-3J3-2J3-1TROLLEY*MOTOR 2 1ST 2NDDir 1 Dir 22ND 1STJ5-2J5-4J5-6SELECT 2SELECT 1AUX 3 ALARMINDEPENDENT OUTPUTS
Section 7 – Programming487-1. Access Code Programming.7-1.1. Programming Access Codes.The access code is set at the factory and shouldnot be changed unless absolutely necessary. Ifyou are reprogramming a spare or newtransmitter make sure the other transmitter issecurely taken out of service.Also a label on the transmitter lists the accesscode settings inside. The positions on thetransmitter label match the switch settings. The“1” by A1 means the switch position A1 shouldbe ”ON” and “0” means A1 should be “OFF”.NOTEFOR THE MEMBRANE, PENDANTTRANSMITTER AND RECEIVER. DO NOTUSE A PENCIL TO TOGGLE THESWITCHES. THE LOOSE GRAPHITE FROMTHE PENCIL CAN DAMAGE THE SWITCH. WARNINGTWO OPERATIONAL TRANSMITTERSWITH THE SAME ACCESS CODES OPER-ATING AT THE SAME TIME IS A DEFINITESAFETY HAZARD. FAILURE TO FOLLOWTHIS WARNING COULD RESULT INSERIOUS INJURY OR DEATH ANDDAMAGE TO EQUIPMENT.7-1.2. Changing Transmitter Access Codes.7-1.2.1. telePilot Access Code Programming.For detailed instructions on setting parametersincluding access codes see Section 7-8. telePilotProgramming.7-1.2.2. Membrane Transmitter Access CodeSetting.Open the back battery door and take out thebatteries as a safety precaution.Remove the 6 screws on the front cover. Lift outswitch-pad, logic board and turn logic boardover.Locate the dip switches marked “A” and “B”.See Figure 8-3. Membrane Transmitter M/CModule E10635. With a pen or pointed objecttoggle the switches to match the Access Code onFigure 7-1. Access Code Setting.(A dot on a switch position or a “1” in thelabel is an indication that the respectiveswitch position should be ON).Sample Membrane or Pendant TransmitterAccess Code LabelSample access code only do not useSW1MembraneTransmitter Pendant TransmitterSW1OFF 1 A 8ONOFFON 8 B 1 MODEL # -10KXXXXXXXXS/N=XXXXXXXXXXXXXXXXX ACCESS CODE SETTING1 A 8 1 B 80 1 0 0 0 1 1 1 0 1 1 0 0 0 1 0FREQ : = AK01 J # = XXXXX Access Code SwitchesSample access code only, do not useSW2 ONONSW1 8 A 1OFFOFF 8 B 1TR12 ReceiverON 8 A 1SW2OFF 8 A 1 1 B 8OFFONSW2 OFFA1telePilotTransmitter 1 A 8ONOFF 1 B 8ONOFFB1Receiver access code1010Indicates switch in OFF position
Section 7 – Programming (Continued)49the receiver. A dot on the switch diagram meansthat switch position is ON. For Membranetransmitters the access code positions A1-A4 canbe accessed through the battery compartment.Reassemble unit; replace the batteries and test.7-1.2.3. Pendant Transmitter Access CodeSetting.Open the back battery door and take out thebatteries as a safety precaution.Remove the 8 screws on the front cover. Turntransmitter over and remove back cover.Locate the dip switches marked “A” and “B”.See Figure 8-4. Pendant Transmitter M/CModule E10636. With a pen or pointed objecttoggle the switches to match the PendantTransmitter Code Diagram on the door of thereceiver. A dot on the switch diagram means thatswitch position is ON.Reassemble unit; replace the batteries and test. WARNINGAFTER CHANGING THE ACCESS CODESON THE TRANSMITTER, TEST THE UNITBY TURNING IT ON AND OFF NEAR THEAPPROPRIATE RECEIVER. IF THE RE-CEIVER DOES NOT RESPOND, DO NOTACTIVATE A FUNCTION BUTTON! THETRANSMITTER MAY HAVE THE WRONGACCESS CODE, WHICH COULD MOVEANOTHER CRANE. RE-CHECK THEACCESS CODE IN THE TRANSMITTERAND RETEST. FAILURE TO FOLLOW THISWARNING COULD RESULT IN SERIOUSINJURY OR DEATH AND DAMAGE TOEQUIPMENT.7-1.3. Receiver Access Code Setting.The access code is preset at the factory andshould not be changed unless absolutelynecessary. The access code switches are labeled“B” and “A”. See Figure 8-1. Receiver Layoutfor switch location.The programming in the receiver(s) must matchthe transmitter. If looking at the label on theoutside of the transmitter, take note that positions“A” and “B” number from the left 1 through 8.NOTEIN EVENT PROGRAMMING OF ACCESSCODES IS REQUIRED, TAKE SPECIALCARE TO CORRECTLY LOCATE ACCESSCODE SWITCHES A AND B. LOOK FORTHE LABELS A AND B ON THE PRINTEDCIRCUIT BOARD NEAR THE RESPECTIVESWITCHES. DETERMINE THEIR ORIENTA-TION. THE SWITCHES MAY NUMBERFROM LEFT TO RIGHT OR RIGHT TO LEFT.LOOK FOR THE NUMBERING ON THESWITCHES. MATCH ACCESS CODES A1,A2, - -- B1, B2 ETC.After changing the access code, test the receiver(s) with a matching transmitter. (If the red LEDDS9 comes ON in either receiver the code doesnot match, recheck the access code settings). WARNINGTHE ACCESS CODES IN THE RECEIVERARE UNIQUE AND FACTORY PRESET. DONOT CHANGE THESE ACCESS CODESUNLESS YOU ARE REPLACING AN EXIST-ING RECEIVER AND ITS ACCESS CODE.CHANGING THIS CODE COULD MAKE ITCOMMON WITH ANOTHER RECEIVERACCESS CODE, WHICH COULD MOVEANOTHER CRANE. NO TWO SYSTEMS INANY LOCATION SHOULD EVER HAVETHE SAME ACCESS CODES INDEPENDENTOF FREQUENCY. FAILURE TO FOLLOWTHIS WARNING COULD RESULT IN SERI-OUS INJURY OR DEATH AND DAMAGE TOEQUIPMENT.
Section 7 – Programming (Continued)507-2. Receiver Frequency Programming.The TR12 receiver is equipped with a frequencysynthesizer that allows frequencies to be easilychanged without retuning. Normally thefrequency does not have to be changed; the unitcomes programmed to a specific frequency listedon the Frequency and Access Code Label on theTR12 receiver door.7-2.1. RF Receiver Board Freque ncySynthesizer.Located in the TR12 receiver is the RF ReceiverBoard. The circuitry on this board contains adigital oscillator and synthesizer that arecontrolled by a microprocessor. This eliminatesthe need for specific crystals to changefrequencies. A pair of programming pins allowsthe unit to be reprogrammed in the field to adifferent channel. The on board microprocessorautomatically retunes the RF receiver when thechannel is changed; no retuning or any otheradjustment is required.7-2.2. Reading The Channel (Frequency).Usi ng Figure 8-1. Receiver Layout. locate theRF Receiver Board. Locate the Top ViewingWindow (see Figure 7-2. RF Receiver Board).Looking in the Top Viewing Window close tothe edge of the board is a red LED that, with thepower to the receiver ON, is constantly lit. Thisindicates the RF Receiver Board is ON andworking. Looking farther back into the TopViewing window there are two flashing LEDs, ared one and a green one. These LEDs flashrepeatedly and slowly so allow some time to seethem flash. These flashing LEDs indicate thechannel (frequency) the unit is receiving.The counting is done in two digits, where thetwo digits indicate channel number. The redLED counts (flashes) the channel number in twodigits; the green LED indicates (flashes) thespacing and position of the counted digit. Theones digit is counted first and then the tens digitwith one green LED flash indicating thebeginning of the count of ones digit and twogreen LED flashes indicating the beginning ofthe tens digit count.An example is if the channel is AK04 thechannel number is 04. The ones digit is 4 (fourred flashes) and the second is zero (no red flash).The repeated sequence for reading channel 4 is:Long pause, green, red, red, red, red, short pausegreen, green, (no red flash, zero).The repeated sequence for reading channel 12 is:Long pause, green, red, red, short pause, green,green, red.Other examples are (equals count):AK01 (1): green, red, short pause, green, green.AK02 (2): green, red, red, short pause, green,green.AK05 (5): green, red, red, red, red, red,short pause, green, green.AK07 (7): green, red, red, red, red, red, red, redshort pause, green, green.AK10 (10): green, short pause, green, green, red.AK11 (11): green, red, short pause, green, green,red.AK14 (14): green, red, red, red, red, short pause,green, green, red.AK20 (20): green, green, green, red, red.AKA06 (27): green, red, red, red, red, red, red,red, short pause, green, green, red, red.RF Receiver BoardTop View RF Receiver BoardSide ViewRed RF Receiver “ON” LEDRed Channel Counting LEDGreen Count Separating LEDFigure 7-2. RF Receiver Board.Top Viewing WindowProgrammingPins
Section 7 – Programming (Continued)517-2.3. Reprogramming The SynthesizerThe RF Receiver can be reprogrammed in theunit without removing the RF Receiver Board.Locate the Programming Pins by looking at theside of the RF Receiver Board (see Figure 7-2.RF Receiver Board). To reprogram thesynthesizer a small metal tipped bladescrewdriver or other tool is necessary to short thetwo pins together to put in the reprogrammingmode.Having located the programming pins and whilewatching the flashing red Channel CountingLED, short the programming pins together andkeep them shorted. (Do not be concerned whileshorting these pins together about touching themetal RF Receiver shield with the shorting tool,it will not cause any damage to the circuitry).When the Programming Pins are shorted the RFReceiver will go into the programming mode.KEEP THE PINS SHORTED UNTIL THEPROGRAMMING IS COMPLETE. The greenand red channel indicating LEDs will completeone last channel indication and then only the redLED Channel Counting LED will start to flash.The synthesizer will start programming fromchannel AK01 and count up in sequence for eachchannel with a pause in between each channelcount. A full count of flashes will be made foreach channel with a short pause in between eachchannel counts by the red Channel CountingLED. The channel counts will increase by onechannel after each pause. Keep track of theindividual channel counts to determine whichfrequency the synthesizer is on.The flashing sequence is as follows: one flash(AK01) short pause, two flashes (AK02), shortpause, three flashes (AK03), etc. For channelnumbers ten and greater the red LED will stillcount these out completely, so for channel AK12there will be twelve flashes. The green LEDDOES NOT flash during channel programming.When you have reached the correct count for thechannel desired, remove the short from theshorting pins immediately. Wait a minute for theRF Receiver to automatically retune itself andthe green and red channel indicating light shouldthen start to flash indicating the current channelnumber.Check the channel count to verify that the RFReceiver is programmed to the desired channel.(If you have passed the channel number desiredwait a minute for the green LED to flash and re-short the pins, the count will begin again fromchannel AK01).Channel and Fre quency Designations byCount.Indicator Channel ActualCount Designator Frequency1. AK01 439.8 MHz2. AK02 439.6 MHz3. AK03 439.4 MHz4. AK04 439.2 MHz5. AK05 439.0 MHz6. AK06 438.8 MHz7. AK07 438.6 MHz8. AK08 438.4 MHz9. AK09 438.2 MHz10. AK10 438.0 MHz11. AK11 437.8 MHz12. AK12 437.6 MHz13. AK13 437.4 MHz14. AK14 437.2 MHz15. AK15 437.0 MHz16. AK16 436.8 MHz17. AK17 436.6 MHz18. AK18 436.4 MHz19. AK19 436.2 MHz20. AK20 436.0 MHz21. AKA00 433.125 MHz22. AKA01 433.325 MHz23. AKA02 433.525 MHz24. AKA03 433.725 MHz25. AKA04 433.925 MHz26. AKA05 434.125 MHz27. AKA06 434.325 MHz28. AKA07 434.525 MHz29. AKA08 434.725 MHz
Section 7 – Programming (Continued)527-3. Multibox.7-3.1. Multibox Operation. WARNINGIF YOUR UNIT WAS NOT ORDERED WITHMULTIBOX DO NOT ATTEMPT TO PRO-GRAM MULTIBOX IN THE FIELD. TELE-MOTIVE MUST COORDINATE ACCESSCODE ASSIGNMENTS WITH THE TRANS-MITTERS PRIOR TO ENABLING MULTI-BOX. PLEASE CONTACT TELEMOTIVE IFYOU NEED TO ADD MULTIBOX. FAILURETO FOLLOW THIS WARNING COULDRESULT IN SERIOUS INJURY OR DEATHAND DAMAGE TO EQUIPMENT. WARNINGIF YOUR UNIT HAS MULTIBOX DO NOTATTEMPT TO PROGRAM ADDITIONALTRANSMITTERS IN THE FIELD. TELEMO-TIVE MUST COORDINATE ACCESS CODEASSIGNMENTS WITH THE NEW TRANS-MITTERS PRIOR TO EXPANDING MULTI-BOX. PLEASE CONTACT TELEMOTIVE IFYOU NEED TO ADD ADDITIONALTRANSMITTERS. FAILURE TO FOLLOWTHIS WARNING COULD RESULT IN SERI-OUS INJURY OR DEATH AND DAMAGE TOEQUIPMENT.The TR12 has Multibox capability that allows upto 8 transmitters to access a single system. Onlyone transmitter may control the receiver(s) at agiven time. Access is on a first come first servebasis. Once a transmitter has gained control,another transmitter may not access thereceiver(s) until the controlling transmitterrelinquishes control by transmitting an OFFcommand to the receiver(s) or the receiver(s)times out due to inactivity.The first transmitter to send an ON commandafter the receiver has been released will then gaincontrol of the receiver(s). The number oftransmitters (1-8) allowed to control thereceiver(s) is dip switch selectable on theReceiver Board.NOTETHE DESIRED MULTIBOX TRANSMITTERSMUST HAVE CONSECUTIVE ACCESSCODES BEGINNING FROM THE FIRSTACCESS CODE.7-3.2. SW3 Switch Multibox Settings.Dip switch settings on the Receiver Boardcontrol the number of transmitters. This is doneby the Receiver Configuration Switch SW3 (dipswitch positions -1, -2 and -3). Different settingsare used for 2, 3, 4 and up to 8 transmitters. SeeTable 7-1. Multibox Switch Settings for properMultibox settings.The Receiver Configuration Switch, dip switchSW3, is found on the Receiver Board. See Figure8-1. Receiver Layout. On the transmitterssequential access codes are required. These areset on access code switch “A” positions “1”, “2”and “3’ or more as required. The first transmitteruses the same access code as the receiver. Theother transmitters have the there access codesequentially incremented each by one extra bit.With “A1” being the least significant bit. SeeFigure 7-1. Access Code Settings.For Membrane transmitters the Access codepositions A1-A2 can be accessed through thebattery compartment. The Pendant Transmitterrequires the back to be removed. See Table 7-1. Multibox Switch Settings belowfor appropriate settings for both the transmittersand receiver(s).
Section 7 – Programming (Continued)53Receiver (See Figure 8-1). Transmitter (Membrane and Pendant only).SW3 Switch Maximum Access Code SwitchSettings Transmitters Settings3-1 3-2 3-3OFF OFF OFF 1 First Access CodeON OFF OFF 2 First Access Code + 1 bitOFF ON OFF 3 First Access Code + 2 bitsON ON OFF 4 First Access Code + 3 bitsOFF OFF ON 5 First Access Code + 4 bitsON OFF ON 6 First Access Code + 5 bitsOFF ON ON 7 First Access Code + 6 bitsON ON ON 8 First Access Code + 7 bitsTable 7-1. Multibox Switch Settings.Figure 7-3. SW3 Receiver Multibox DipSwitchesON8 7 6 5 4 3 2 1OFF8 7 6 5 4 3 2 1
Section 7 – Programming (Continued)547-4. Custom Programming.7-4.1. Receiver Programming Options.The following parameters are programmable inthe receiver: (See below for details).Auto Alarm – Sounds alarm on turn on.E-STOP Alarm – Sends Alarm on E-STOP.Single or 2-speed system – Assigns outputs.Latching of auxiliary relays – Up to two relays.Time-out-timer disable.Number of Multibox transmitters.7-4.2. Transmitter Programming Options.The following parameters are programmable inmost transmitters: (See Sections 7-6., 7-7. and 7-8. Membrane, Pendant and telePilotProgramming for details).Switch Position – Hoist, Trolley Etc.Timer-out-timer operation.Modes – Single speed switch grouping.Crane configuration -Tandem disable – Eliminates “both”Select invert – Inverts the select function.7-5. Receiver Programming. (For the locationof specific programming switches see Figure 8-1. Receiver Layout). WARNINGMAKE SURE S1 MASTER CONTROL RELAY(MCR) IS TURNED OFF BEFORE ATTEMPT-ING TO REPROGRAM THE RECEIVER, TOPREVENT ACTIVATION OF EXTERNALCIRCUITRY. FAILURE TO FOLLOW THISWARNING COULD RESULT IN SERIOUSINJURY OR DEATH AND DAMAGE TOEQUIPMENT.7-5.1. Auto Alarm And E-STOP Alarm.The receiver can have either one of thesefunctions or both. The use of either one of thesetwo functions dedicates one specific control relayto operate an external alarm. An external alarm(not supplied) needs to be connected to this relay.7-5.2. Auto Alarm (SW4-8). Normally OFF.Gives about 5 seconds of alarm when thetransmitter is first turned on.To Enable.Connect an external alarm. Move dip switchSW4-8 on the Receiver Board to the ON position.See Section 6. Wiring for the location for thelocation of the alarm relay.7-5.3. E-STOP Stop Alarm (SW4-7).Normally OFF.Gives about 5 seconds of alarm when theEmergency Stop (E-STOP) is activated on thetransmitter.To Enable.Connect an external alarm. Move dip switchSW4-7 on the Receiver Board to the ON positionand jumper JU1 to ON. See Figure 8-1. ReceiverBoard Layout for the position of JU1. Jumper JU1facilitates bypassing the E-STOP shutdown to theAlarm Relay so it can be activated during an E-STOP shutdown See Section 6. Wiring. for thelocation for the location of the alarm relay.7-5.4. 2-Speed Or Single-Speed Outputs(SW3-5). Normally OFF for 2-Speed.Turning ON switch SW3-5 changes the relayoutput pattern to best match the needs of a single-speed system. See Section 6. Wiring forappropriate output pattern.7-5.5. Auxiliary Functions General.The TR12 receiver has up to 3 auxiliary (Aux)function capability. These Aux functions arededicated relays that can be used to sound horns,light lights or other functions. Typically a TR12has 3 Aux functions (for standard 2-speed). SeeSection 6. Wiring for the location for the locationof the auxiliary relays. However, there are anumber of specialties and variations available. Ifyour transmitter does not have a documentdescribing these functions, the easiest way todetermine what the Aux functions do is to look atthe relay outputs and while depressing theappropriate Aux switch on the transmitter seewhich LED lights for which relay.7-5.5.1. Auxiliary Function Relay Latching(SW4-2 and -3). Normally All OFF.
Section 7 – Programming (Continued)55Enables the appropriate auxiliary function relay tooperate in a latched mode, on or off, rather than asa momentary contact. Which function is latchableand which relay is latched depends on theparticular transmitter used.Switch S4, positions 2 and 3 on the ReceiverBoard each enable a separate relay to be latchedwhen turned on. See Section 6. Wiring for thespecfic details on latchable auxilary relays7-5.6. Time Out Timer Enable (SW3-8).Normally OFF.The receiver contains a time out timer. If areceiver once turned on by a transmitter does notreceive a signal from a transmitter for a period of15 minutes the receiver shuts down. Setting S3-8to ON disables this function.7-5.7. Multibox (SW3-1, -2, and -3).Normally All OFF.See Section 7-3. Multibox. One transmitter canonly control the TR12 receiver with a specificaccess code at a time. However, Multibox capabil-ity allows the TR12 receiver to automaticallyswitch to a new transmitter when the currentcontrolling transmitter has been turned off and anew transmitter turned on. Up to 8 differenttransmitters can control one receiver. To enablethis function the receiver must be preprogrammedfrom the factory for Multibox and the correctaccess codes must be programmed into theappropriate transmitters. (Note: access codes arefactory programmed into the receiver and theaccess codes are sequential.).7-6. Membrane Transmitter Programming.The Single-Speed or the 2-Speed 10K12Membrane Transmitter may be used with theTR12 Receiver. The Membrane Transmitter M/CBoard is shown in Figure 8-3. Refer to paragraphsbelow for programming details.7-6.1. Membrane Transmitter SwitchSettings. SW3Position Controls1-3 Switch positioning. (2-Speed only).4 ON disables Transmitter Time-out-timer5-7 Special Crane Control Configurations. (2-Speed only).8 No function. Should be set to OFF. SW4Position Controls1-2 Mode Select. (Single-Speed only).7-6.2. SW3 Positions 1-3 Switch Positioning,2-Speed Membrane Only. (Standardconfiguration all “OFF”).If replacing a Pendant Transmitter with aMembrane Transmitter on an existing installationor making them interchangeable and keeping theexisting receiver wiring, open the MembraneTransmitter, find dip switch SW3 and moveposition 1 (SW3) to “ON”. See Figure 8-3.Membrane Transmitter M/C Module E10635. TheMembrane Transmitters labeling and functionsNorth and South, East and West will match thePendant Transmitter.7-6.3. SW3 Position 4 Time-out-timerDisable. (Normally keep turned “OFF”).The transmitter has an approximate 15-minutetime-out-timer. If the transmitter is not used forover 15 minutes it will shut down. Thistransmitter time-out-timer function is transmitterdip switch selectable. SW3 position 4 disables thetime-out-timer. Turning SW3-8 “ON” disables thetime-out-timer. If disabling the transmitter time-out-timer, remember to also replace thereceiver(s) EPROM(s) to disable the time-out-timer in the receiver.7-6.4. Positions 5-7 Special Crane ControlConfigurations, 2-Speed Membrane Only.(Standard all “OFF”).The 10K12 2-Speed Membrane transmitter isavailable with special crane controlconfigurations. These options are switchconfigurable on the transmitter. Section 6. Wiringshows all the different crane configurations andthe switch positioning needed to achieve them.The standard transmitter comes with the outputstandard output configuration. For 2-speedspecial crane control configurations: SeeSection 6. Wiring and program SW3 respectivelyon the transmitter.7-6.5. Position 8 No function. (Keep turned“OFF”).
Section 7 – Programming (Continued)567-6.6. Transmitter Programming SW4Positions 1-2 Mode Enable. (All 2-speedconfigurations all “OFF”).Mode 0, SW4 1 turned “OFF” and SW4 2 turned“OFF”. From the factory the standard 2-SpeedMembrane Transmitter is configured this way.This mode in the Membrane Transmitter is for all2-speed applications. If the MembraneTransmitter has a 2-speed keypad SW4 must beset to all “OFF” positions.7-6.7. Single-Speed Modes 1-3. (Thefollowing three different single-speed modesare listed for single-speed Me mbraneTransmitters only). See Section 7-6.9 fordetails.Mode 1, SW4 1 turned “ON” and SW4 2 turned“OFF”. This configuration gives four-motorsingle-speed with up to four auxiliaries. Thisconfiguration uses the single-speed keypad withtwo auxiliaries labeled P1 and P2.Mode 2, SW4 1 turned “OFF” and SW4 2 turned“ON”. This configuration gives four-motor single-speed with four auxiliaries. This configurationuses the single-speed keypad with four auxiliarieslabeled Aux 1 through Aux 4.Mode 3, SW4 1 turned “ON” and SW4 2 turned“ON”. Allows for 12 independent ON/OFFfunctions (relays) per transmitter button pushed.
Section 7 – Programming (Continued)577-6.8. Repositioning Of MembraneTransmitter Motion Switch Functions (for 2-Speed Membrane Transmitter only).SW3 positions 1 through 3 can change thefunctional positions of the switches controllingbridge, hoist and trolley. This can be useful toalign East/West and North/South. Thisreconfiguration does NOT affect receiver wiring.See Figure 8-3. Membrane Transmitter M/CModule E10635 for switch location. WARNINGCHANGING THESE SWITCHES CHANGESTHE FUCTIONAL OPERATION OF THECRANE IN RELATIONSHIP TO THETRANSMITTER BUTTON BEING DEPRESS-ED. THE FUNCTIONAL OPERATION OF THECRANE SHOULD NEVER BE CHANGEDWITHOUT ALL PERSONNEL RESPONSIBLEFOR CRANE OPERATION BEING NOTIFIEDPRIOR TO MODIFICATION. FAILURE TOFOLLOW THIS WARNING COULD RESULTIN SERIOUS INJURY OR DEATH ANDDAMAGE TO EQUIPMENT.HOISTTROLLEYBRIDGEHOISTBRIDGETROLLEYTROLLEYBRIDGEHOIST1 2 3 4 5 6 7 8TROLLEYHOISTBRIDGEBRIDGEHOISTTROLLEYBRIDGETROLLEYHOISTStandard ConfigurationONOFFONOFFONOFFONOFFONOFFONOFF1 2 3 4 5 6 7 81 2 3 4 5 6 7 8 1 2 3 4 5 6 7 81 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8Figure 7-4. Membrane Transmitter MotionSwitch Positioning.
Section 7 – Programming (Continued)587-6.9. Single-Speed Membrane TransmitterConfigurations.Normally single-speed transmitters are notprovided with the 10K6/9. This section is forreference only when using a Single-SpeedMembrane Transmitter. All single-speed modesrequire that the transmitter switch SW3 positions1 through 3 are all set to OFF.The EPROM’s for the single-speed unit isFW2904-0T and FW2904-0N where 0T meanswith 15-minute-time-out-timer and 0N means notime-out-timer.See Figure 8-3. Membrane Transmitter M/CModule E10635 for location of SW3 and SW4. Asingle-speed keypad (part number S313-1) withspecial inserts (part number A9657-1) is requiredfor these configurations. The single-speed modes1 through 3 do not change the outputs, but changethe directional lockouts, i.e., E and W cannot beused at the same time. Mode 3 has no lockouts.As for which outputs are controlled by the single-speed transmitter, the switch positions asnumbered in the Mode 3 diagram below areindicated on each of the wiring diagrams inSection 6. Wiring.SW4For all two-speedapplications SW4settings.SW4Four-motor single-speed with fourauxiliaries.Mode 3:1 2 ONOFF 1 2 ONOFFMode 1:ONOFF1 21 2 ONOFFMode 0: EUPWDNNSAUXUPAUXDNESTOP2134675849310211121ESTOPAUXUP UPAUXDN DNP1 EP2 WALARM SNLIGHTESTOP123ESTOPON OFFEWNSUP DNSW4SW4Allows for 12independentON/OFF functions.Four-motor single-speed with fourauxiliaries.Mode 2:Figure 7-5. Membrane Transmitter Single-Speed Configurations.*TR12ReceiverOutputsJ2-2J3-2J4-2J5-2J5-6J5-4*TR12ReceiverOutputsJ4-3J4-1J3-3J3-1J2-3J2-1*TR12ReceiverOutputsJ2-2J3-2J4-2J5-2J5-6J5-4*TR12 ReceiverOutputsJ4-3J4-1J3-3J3-1J2-3J2-1*TR12ReceiverOutputsJ2-2J3-2J4-2J5-2J5-6J5-4*TR12ReceiverOutputsJ4-3J4-1J3-3J3-1J2-3J2-1*Single-Speed TR12Receiver Configuration Only.
Section 7 – Programming (Continued)597-7. Pendant Transmitter Programming.The Single-Speed or the 2-Speed 10K12Pendant Transmitter may be used with the TR12Receiver. The Pendant Transmitter M/C Board isshown in Figure 8-4. Refer to paragraphs belowfor programming details Procedures.7-7.1. Pendant Transmitter Switch Settings. SW3Position Controls1-3. Switch Positioning. (2-Speed only).4-7. No function, keep off.8. Time-out-timer disable, turn “ON” todisable time-out-timer. SW4Position Controls1-2 Mode Select. (Single-Speed Only).3. Disable Tandem Hoist. (2-Speed only).4. Invert Crane Select. (2-Speed only).5-7. Special Crane Configurations. (2-Speedonly).8. No function, keep OFF.7-7.2. Transmitter Switches SW3 And SW4Programming. (See Section 8-2. PendantTransmitter Servicing for physical location oftransmitter switches).7-7.3. Transmitter programming SW37-7.4. Positions 1-3 Switch Positioning, 2-Speed Only. (Standard configuration all“OFF”).The functional positions of the various buttonscontrolling the hoist trolley and bridge can bemoved by transmitter dip switch SW3 also.Positions SW3-1 through SW3-3 control thesefunctions. No change in receiver wiring isneeded to use these functions. See Section 7-7.13. for switch verses button configurations.7-7.5. Position 4-7 No Function. (Keepturned “OFF”).7-7.6. Position 8 Time-out-timer Disable.(Normally keep turned “OFF”).The transmitter has an approximate 15-minutetime-out-timer. If the transmitter is not used forover 15 minutes it will shut down. Thistransmitter time-out-timer function is transmitterdip switch selectable. SW3 position 8 disablesthe time-out-timer. Turning SW3-8 “ON”disables the time-out-timer.7-7.7. Transmitter Programming SW47-7.8. Position 1-2 Mode Enable. (StandardMode 1 keep 1-2 turned “OFF”).Mode 1, SW4 1-2 all “OFF”. The 10K12 single-speed system comes standard configured thisway from the factory with three motion controlsand six auxiliaries (controlled by the toggleswitches). The 10K12 2-speed system comesstandard configured this way from the factorywith three 2-speed controls and three auxiliaries(controlled by the toggle switches, the rotary isnon-functional).Mode 2, SW4 1 turned “OFF” and SW4 2 turned“ON”. The 10K12 2-speed system configuredthis way is able to control four 2-speed motioncontrols and no auxiliaries this give bridge,trolley, main and aux hoist. The rotary selectorswitch functions are H1 main hoist, H2 aux hoistand B both main and aux hoist (the toggleswitches are non-functional).Mode 3, SW4 1 and 2 turned “ON”. The 10K122-speed system will control up to 5 motors usingthe rotary selector switch. This modereconfigures two of the 10K12 auxiliary outputs(Aux 1 and Aux 2) to be external motor selectfunctions by the rotary switch. In this mode theauxiliary toggle switch Aux 1 and Aux 2 isdisabled. When the rotary switch is in the H1 orH2 position Aux 1 relay or Aux 2 relay will pullin respectively when ever trolley or hoistpushbuttons are pressed. When the rotary switchis in B position both Aux 1 and Aux 2 relays willpull in.7-7.9. Position 3 Disable Tandem For HoistAnd Trolley. (Normally keep turned “OFF”).For cranes with auxiliary hoists and/or trolleys,turning this switch “ON” disables the transmitterselector switch “B” position (both function) thatselects tandem operation of hoist or trolley.7-7.10. Position 4 Invert Crane Select Aux.Outputs. (Normally keep turned “OFF”).
Section 7 – Programming (Continued)60For cranes that use the select function only,turning this switch “ON” inverts the selectfunction operation so that the relay closes for theunselected function.7-7.11. Positions 5-7 Special Crane ControlConfigurations. (Standard all “OFF”).The 10K12 2-Speed Pendant and SLTXtransmitter is available with special crane controlconfigurations. These options are switchconfigurable on the transmitter. Section 6.Wiring shows all the different craneconfigurations and the switch positioning neededto achieve them. The standard transmitter comeswith the output standard output configurationFor 2-speed special crane controlconfigurations: See Section 6. Wiring andprogram SW4 respectively on the transmitter.7-7.12. Position 8 No Function. (Keep turned“OFF”).
Section 7 – Programming (Continued)617-7.13. Repositioning Of PendantTransmitter Motion Switch Functions (for 2-Speed Pendant Transmitter only).SW3 positions 1 through 3 can change thefunctional positions of the switches controllingbridge, hoist and trolley. This reconfigurationdoes NOT affect receiver wiring. WARNINGCHANGING THESE SWITCHES CHANGESTHE FUCTIONAL OPERATION OF THECRANE IN RELATIONSHIP TO THETRANSMITTER BUTTON BEING DEPRESS-ED. THE FUNCTIONAL OPERATION OFTHE CRANE SHOULD NEVER BECHANGED WITHOUT ALL PERSONNELRESPONSIBLE FOR CRANE OPERATIONBEING NOTIFIED PRIOR TO MODIFICA-TION. FAILURE TO FOLLOW THIS WARN-ING COULD RESULT IN SERIOUS INJURYOR DEATH AND DAMAGE TO EQUIP-MENTHOISTTROLLEYBRIDGEHOISTBRIDGETROLLEYBRIDGETROLLEYHOISTBRIDGEHOISTTROLLEYTROLLEYHOISTBRIDGETROLLEYBRIDGEHOIST12345678ONOFFStandard Configuration12345678 ONOFF12345678 ONOFF12345678 ONOFF12345678 ONOFF12345678ONOFFFigure 7-6. Pendant Transmitter Motion SwitchPositioning.
Section 7 – Programming (Continued)627-8. telePilot Programming.Read Section 5-5. Additional telePilot OperationalFeatures to familiarize you with the features listedbelow. The telePilot transmitter remote unit forprogramming uses a PDA (Personal Digital Assistant).Such products as Palm Pilot® or many other productsusing Palm OS® can be used to run the telePilotprogramming software. If unsure if your PDA will workor for a recommended product contact the appropriateTelemotive representative or check our website. Thesoftware for the PDA is available on a disk shipped withyour unit, can be emailed from your Telemotiverepresentative or downloaded from our Website atwww.telemotive.com.telePilot PDA software is quite user friendly and isintended to mimic the dip switch settings used in otherTelemotive products without the inconvenience ofhaving to open the transmitter case. The PDA softwareallows you to select frequency, access code, time-out-timer settings, switch arrangement and craneconfiguration as in other Telemotive transmitterproducts.Load the telePilot programming software into yourPDA, refer to your PDA manual or contact Telemotivefor the appropriate procedure. Once loaded, look for theTelemotive circle and hook logo labeled telePilot for theappropriate application. Select this application to beginprogramming.With the telePilot programmer you can load up to fourdifferent transmitter types for use on 10K, 9000 and/or9100 systems. Each transmitter configuration is stored ina “Bank”. There are up to four banks available. ThisBank feature is like having four completely differenttransmitters in one unit. Up to four Banks (operationalconfigurations) are possible. A Bank is a specificconfiguration of user-defined parameters including:System typeFrequencyAccess codesAlso possible:Key arrangementRelay configurationTandem disableInvert crane selectTime-out- ti mer timeMode selectionAlarm settingsAfter loading the telePilot program the first screen is theinitial setup screen.Tx Type (Must be selected).First select the transmitter type being used (single-speed“1 SPD” or 2-speed “2 SPD”). See Section 5. Operationfor differences in the two transmitters. With your PDAstylus tap the arrow after transmitter “Tx Type”. A pulldown menu will appear, select “1 SPD” or “2 SPD” andthe menu will close showing your selection.Bank Password (Can be disabled).Bank password protection is available in changing thetransmitter once it has turned OFF. The Bank Passwordis the same for all Banks. Bank password protection isdescribed in the telePilot operational description inSection 5-5. Additional telePilot Operational Features.Please familiarize yourself with this section beforeprogramming. A check appears in the box and a list offour buttons. These buttons list the first through fourthbuttons and are in the order of entry for the appropriatebuttons. Select the four transmitter buttons in thesequence that you wish to be the password by tappingthe arrow by “Button #” and making a selection from thepull down menu for each of the four password entries.Be sure to write this password down in a safe place forfuture reference. The default password is 6, 5, 4, 3.telePilotButton 1Button 2Button 3Button 4Button 5Button 6Name: ……………………………..…. MTx Type 2 SPDUse bank passwordtelePilot ProgrammerFirst press Button 6Second press Button 5Third press Button 4Fourth press Button 3Bank 1 Bank 2 Bank 3 Bank 4offoff off off1 SPD2 SPDName: ……………………………..…. MTx Type 2 SPDUse bank passwordtelePilot ProgrammerFirst press Button 6Second press Button 5Third press Button 4Fourth press Button 3Bank 1 Bank 2 Bank 3 Bank 4offoff off off
Section 7 - Programming (Continued)63NOTEALWAYS REMEMBER TO STORE THEPASSWORD IN A SECURE LOCATION FORACCESS IF THE PASSWORD IS LOST ORFORGOTTEN. ONCE THE TRANSMITTER IS PRO-GRAMMED THERE IS NO WAY TO DEFEAT THEPASSWORD WITHOUT USING A PDA TO EITHERREAD THE PASSWORD OUT OR REPROGRAM ANEW ONE. WARNINGTHIS PASSWORD FUNCTION IS NOT TO BE USEDAS A SECURITY DEVICE. THE PURPOSE OF THISFUNCTION IS TO PREVENT ACCIDENTAL BANKSWITCHING. THE BEST FORM OF SECURITY ISALWAYS TO LOCKUP THE TRANSMITTER WHENNOT IN SERVICE. FAILURE TO FOLLOW THISWARNING COULD RESULT IN SERIOUS INJURYOR DEATH AND DAMAGE TO EQUIPMENT.The Bank password can be disabled during initialprogramming by the PDA. To disable passwordprotection, tap the check in the box next to the phase“Use bank password”. Disabling the Bank password isnot recommended unless the operator has access andvisibility to all possible cranes controlled. WARNINGDISABLING THE PASSWORD FUNCTION IS PUTSTHE SYSTEM IN ACTIVE BANK SELECT. THISALLOWS THE CRANE OPERATOR TO SWITCHBETWEEN BANKS QUICKER. THE OPERATOR INTHIS MODE MUST BE AWARE ANDRESPONSIBLE FOR ALL POSSIBLE CONTROLLEDCRANES. FAILURE TO FOLLOW THIS WARNINGCOULD RESULT IN SERIOUS INJURY OR DEATHAND DAMAGE TO EQUIPMENT.Bank Selection (At least one must be selected).When done with the password section. Select the numberof Bank you wish to program and tap the cell labeledwith the appropriate Bank number.The screen should switch to the Setup Bank screenshown below. Complete the Bank setup as describedbelow and hit save. The PDA will revert to the initialscreen and the cell for the just programmed Bank shoulddarken and the word “on” appears. Tap on the celllabeled with the next bank you wish to program and asimilar “Setup” screen to the one shown below willappear. Continue doing this until you have programmedthe four Banks.You do not have to use all Banks and you do not have touse them in order.Even after programming a Bank you can turn it back“off”. A programmed Bank will not lose itsprogramming by turning it “off”. By turning ON andOFF Banks you can easily save certain transmitterconfigurations in the transmitter to turn them on at a latertime with the PDA without having to completelyreprogram them.Bank Programming Setup Screen (Must selectsystem).The number of the Bank will appear at the top of thescreen. Before selecting any programming featurefirst go to “System” and select the system type. Tapon the “System" arrow and select 10K, 9000, 9001, 9100or 9101 type system. The TR12 Receiver is a 10K typesystem. If you are unsure of the type of system you haverefer to the cover of the systems operating manual for theappropriate system or call your Telemotiverepresentative. After selecting system type, yourprogramming screen will change to match the type ofsystem selected.Bank 1 Bank 2 Bank 3 Bank 4offoff off offSystem 10K Freq AK01Setup Bank #A1Receiver access code10B1 10Multibox Auto Turn OffS3-1 10TimerSwitch conf.: H,T,BMain/Aux Aux SaveCancel10K9000910010K900191011-SPD 2-SPD
Section 7 - Programming (Continued)64The respective screens appear as shown below (the 10Kscreen is shown first):The following next three sections of this programmingguide are written specifically for each of the threesystem configurations. They are in order of 10K, 9000(1)and 9100(1). Please skip to the appropriate section foryour system. Do this in turn for each Bank until alldesired Banks are programmed.System 9000(1) Freq ASetup Bank #A1Receiver access code10Auto Turn OffTimer NoneSaveCancel9000 and 9001 Programming ScreenSystem 9100(1) Freq ASetup Bank #A1Receiver access code10Auto Turn OffTimer NoneSaveCancel9100 and 9101 Programming ScreenThis section appearsfor 2-Speed only.10K Programming ScreenSystem 10K Freq AK01Setup Bank #A1Receiver access code10B1 10Multibox Tx # 1Auto Turn Off Auto AlarmS3-1 10TimerSwitch conf.: H,T,BMain/Aux Aux SaveCancelMode A0This appears for 9100Single-Speed only.
Section 7 - Programming (Continued)657-8.1. 10K telePilot Programming.After you have entered 10K as your system type enterthe following items in order for your system:Frequency (Must be inputted for system to work):There should be a label either on the receiver or thetransmitter listing frequency, it should be a channelnumber between AK01 to AK20. Find this number andtap the “Freq” arrow and select that channel number.Screen switch operation.The screen switches are labeled from left to right “A”,“B” and S3. They are numbered from left to right 1 to 8.The darken rectangle to the bottom is “OFF” or “0” thedarken rectangle to the top is “ON” or a “1”. Tapping thelighten rectangle will cause the switch to toggle.Access Code (Must be inputted for system to work):See Section 7.1. Access Code Programming for detailson access code programming. There should be a labeleither on the receiver or the transmitter showing theaccess code, it should be numbered A1 through A8 andB1 though B8. Find this number and tap the respectiveswitches on the screen. If you cannot find a label withaccess code information, copy directly from the accesscode dip switches in your transmitter or receiver, beingcareful to match the designation and switch position asthey do vary from model to model.Multibox (Optional, skip if you do not wish to use theMultibox feature):See Section 7-3. Multibox for details on Multiboxprogramming. If your current receiver does not haveMultibox do not attempt to use this function. Thisfunction WILL NOT turn Multibox on in the receiver. Itonly assists you in programming the correct transmitteraccess code for a receiver that already has Multibox.Make sure when you are using the Multibox feature thatthe access code of the receiver is programmed into theaccess code above and not one copied from an existingtransmitter on a Multibox system. If you cannot find thereceiver transmitter code and wish to copy existingtransmitter on a Multibox system, put the transmittersaccess code in the access code switches above and DONOT check the Multibox box on the PDA.Select the Tx # this should be the next number in theseries of transmitter being put on a Multibox system. Ifthe are two transmitters on already and you are adding athird, select the number 3. Make sure as stated in theMultibox section the receiver is programmed for theappropriate number of transmitters.The Tx # goes up to 8. Many Multibox systems only goto four. Check with your Telemotive representative ifyou need more then 4 transmitters on a Multibox system.Auto Turn Off (Optional, can be skipped):The telePilot transmitter has a variable length Time-out-timer. To facilitate operation of this timer with variousmodels of receiver the Auto Turn Off feature wascreated. If this feature is enabled, when the transmittertimes out and the transmitter turns OFF, it will beforeshutting down send an OFF command to the receiver.Check (tap) the box to enable.10K Single-Speed Programming ScreenSystem 10K Freq AK01Setup Bank #A1Receiver access code10B1 10Multibox Tx # 1Auto Turn OffTimer NoneMode 1SaveCancelSystem 10K Freq AK01Setup Bank #A1Receiver access code10B1 10Multibox Tx # 1Auto Turn OffS3-1 10TimerSwitch conf.: H,T,BMain/Aux Aux SaveCancel10K 2-Speed Programming ScreenScreen switches
Section 7 - Programming (Continued)6610K telePilot Programming (Continued).7-8.1.1. Single-Speed 10K telePilot Only:Skip to next section7-7.1.2 (below) if 2-speed.Timer (If unsure of a number start with 15 minutes):Enables the transmitter time-out-timer. The selectionsare “None” (meaning the transmitter will never shut offon it own if not used, this is not recommended forbattery life) or numbers of minutes till shut down. Theminutes are selectable in one-minute steps from 1 to 10and five minutes steps up to an hour. Tap on the “Timer”arrow; scroll down through the number of minute andtap on the desired number.Modes 1-3 (The correct mode must be selected forsafe operation):Please refer to Figure 7-7. Single-Speed 10K telePilotfor specific mode details. Modes are various patterns offunctional lockouts. If you have UP and a DOWNbuttons on a single-speed transmitter controlling a hoist,the transmitter must not be able to send Up and DOWNcommands at the same time.Mode determines the respective buttons that are lockedout to each other. Modes do NOT change theconfigurations of the output relays. Find the desiredmode and select its number on the “Mode” selection.This completes the 10K single-speed programming,when completed with the above tap “Save”.Save will take you back to the initial start screen andturn the Bank ON. At this point select another Bank toprogram or go to Section 7-9. Loading And Saving TheProgram.10K telePilot Programming (Continued).7-8.1.2. 2-Speed 10K telePilot Only:Programming Switch S3-1NOTEIF REPLACING A MEMBRANE OR PENDANTTRANSMITTER, YOU CAN COPY THE SWITCHSETTINGS ON THE EXISTING TRANSMITTER.Membrane: Copy Switch 3 (all positions) settings onthe Membrane transmitter to S3 on the PDA.Pendant: Copy Switch 3 (positions 1, 2, 3 and 8)settings on the Pendant transmitter to S3 (positions 1, 2,3 and 8 respectively) on the PDA. Copy Switch 4(positions 5, 6 and 7) settings on the Pendant transmitterto S3 (positions 5, 6 and 7 respectively) on the PDA. IfSwitch 4 on the Pendant transmitter has positions 1 andor 2 Switched ON see the write-up on Main/Aux Menubelow. If SW4 position 3 is switched “ON” un-checkTandem box on PDA. If SW4 position 4 is switched“ON” check Invert box on PDA.10K Single-SpeedProgramming ScreenSystem 10K Freq AK01Setup Bank #A1Receiver access code10B1 10Multibox Tx # 1Auto Turn OffTimer NoneMode 1SaveCancelSystem 10K Freq AK01Setup Bank #A1Receiver access code10B1 10Multibox Tx # 1Auto Turn OffS3-1 10TimerSwitch conf.: H,T,BMain/Aux Aux SaveCancel10K 2-SpeedProgramming Screen A detailed table of Transmitter switch programmingversus telePilot is in Appendix A.
Section 7 - Programming (Continued)67SW3 Positions 1-3 Repositioning of telePilotTransmitter Motion Switch Functions. (Standardconfiguration all “OFF”).S3 positions 1 through 3 can change the functionalpositions of the switches controlling hoist, trolley andbridge. This reconfiguration does NOT affect receiverwiring. As these switches are changed the motor controlsare moved.Standard, Motor 1 is H (Hoist) Motor 2 is T (Trolley)and Motor 3 is B (Bridge). The standard configuration(all switches OFF) is, starting at the top right hand pairof buttons on the transmitter, Motor 1. Moving down tothe middle two right hand pair of buttons that is Motor 2.The bottom pair on the right is Motor 3. This is indicatedthe display “Switch config: H,T,B. The order of Hoist,Trolley and Bridge will vary as S3-1 to 3 switchpositions are changed. For an example of switchconfigurations versus switch settings see Section 7-.13.Repositioning of Pendant Transmitter Motion SwitchFunctions. The settings match the operation of thetelePilot. SW3 Position 4 And 8 Time-out-timer Disable.(Normally turned “OFF”).Disables the transmitter time-out-timer if turned ON. Ifthe time-out-timer is active, the length of time for timeout can be selected for numbers of minutes till shutdown. The minutes are selectable in one-minute stepsfrom 1 to 10 and five minutes steps up to an hour. Tapon the “Timer” arrow and scroll down through thenumber of minutes and tap on the desired number.Positions 5-7 Special Crane Control Configurations.(Standard all “OFF”).Section 6. Wiring shows all the different craneconfigurations and the switch positioning needed toachieve them. The standard transmitter comes with theoutput standard output configuration. For special cranecontrol configurations program S3 positions 5-7 tomatch the programming information shown for therespective wiring diagram. When any of the specialcrane configuration switches is turned ON, the words“Crane control enabled” appears on the display andMain/Aux disappears.Position 8, Same as Switch Position 4. See write upfor switch 4 above (Normally turned “OFF”).Main/Aux Menu for controlling the “AUX 3” PushButtonThis menu shows only if no Special CraneConfigurations are selected (Switch 3 positions 5-7).This programming redefines the function of the (AUX 3)button just above the E-STOP.(If a three motor crane use “Aux”, for standard fourmotor use “Motor ”, for Select function use Select).If replacing a pendant transmitter: if Switch 4 on thependant transmitter has position 1 “OFF” and position 2“ON” use “Motor”, if Switch 4 has position 1 “ON” andposition 2 “ON” use “Select”.For three motor stand system this button is an auxiliaryrelay control button. (AUX 3).For four motor systems this button controls a main andaux motor such as a hoist. (See Section 5. Operation fordetails on the operation of this button.) To program afourth motion select (Motor). This four motorapplication can only be used with special craneconfiguration TABLE 2(H) Standard 2-Speed 4 MotorSystem. The AUX 3 button becomes a switch to togglebetween “A” and “B” or both. Where “A” and “B” aremain and auxiliary motors respectively. The main motoroutput is motor 1 and the auxiliary motor output is motor4.For up to 5 motors using the select function this buttonis available to use select relays. This select function canonly be used with special crane configuration TABLE2(I) Standard 2-Speed 3, 4 & 5 Motor System usingSelect. To program in the select function tap the word“Select”.Tandem For Hoist, Trolley or Bridge. (Normallychecked).This function appears if a four motor system or selectfunction is chosen. Normally the box is checkedmeaning “Both A and B” operation is enabled (bothMAIN and Aux or Select 1 and Select 2 can be ON atthe same time). Removing the check from the box bytapping on it disables the “Both” function. (“A” and “B”will not come ON at the same time). This function mapsto Pendant Switch 4 position 3, if SW4 position 3 isswitched “ON” un-check Tandem box on PDA.
Section 7 - Programming (Continued)68Position 4 Invert Crane Select Aux. Outputs.(Normally not checked).This function appears if a system using select isprogrammed in. Turning this switch “ON” inverts theselect function operation so that the relay closes for theunselected function. This function maps to PendantSwitch 4 position 4, if SW4 position 4 is switched “ON”check Invert box on PDA.This completes the 10K 2-speed programming, whencompleted with the above tap “Save”.7-8.1.3. Save will take you back to the Initial startscreen. At this point select another Bank to program orgo to Section 7-9. Saving And Loading The Program.10K 2-SpeedProgramming ScreenSystem 10K Freq AK01Setup Bank #A1Receiver access code10B1 10Multibox Tx # 1Auto Turn OffS3-1 10TimerSwitch conf.: H,T,BMain/Aux Aux SaveCancelCrane control enabledTandem Invert
Section 7 - Programming (Continued)69Single-Speed 10K telePilot Lockout Modes.The Modes shown are equivalent to the same Modes inthe single-speed Membrane transmitter. Auxilary relayfunctionl labeling shown is in reference to the traditionallabeling of the Single-Speed Membrane Transmitter forthe respective modes. Each pair of directionals shownfor its respective mode is locked out.(Main Hoist) UP DOWN(Aux Hoist) UP DOWN321 (Trolley/Bridge) Dir 1 Dir 2(Bridge/Trolley) Dir 1 Dir 24Figure 7-7. Single-Speed 10K telePilot Modes.Mode 1(Main Hoist) UP DOWN(Trolley/Bridge) Dir 1 Dir 2(Bridge/Trolley) Dir 1 Dir 2Light (Aux Hoist) UP DOWNP1P2AlarmMode 2The dark rectangles on thedrawings below representbuttons pairs that are locked outfrom both working at the sametime.Mode 3ON/OFF65432E-STOP7891011121789101112E-STOP(EMS)654321Functional Mapping of 10KSeries Single-Speed Controls totelePilot Controls.Matching numbers indicate thesame function. Mapping not af-fected by Modes shown on thispage or by Original 10K KeypadLabeling (Inserts).Original 10K Single-SpeedKeypad Layout.*TR12ReceiverOutputsJ2-2J3-2J4-2J5-2J5-6*TR12ReceiverOutputsJ4-3J4-1J3-3J3-1J2-3J2-1J5-4*Single-Speed TR12Receiver ConfigurationOnly.ON/OFFE-STOPON/OFFE-STOP
Section 7 - Programming (Continued)707-8.2. 9000 and 9001 telePilot Programming.After you have entered 9000 or 9001 as your system typeenter the following items in order for your system:Frequency (Must be inputted for system to work):There should be a label either on the receiver or thetransmitter listing frequency, it should be a channelnumber between A to K. Find this letter and tap the“Freq” arrow and select that channel letter. As thefrequency letter is entered the last five positions of theprogramming automatically sets itself to the positionsused in previous 9000(1) systems to program in thatfrequency.If you are unable to find a channel letter designation forfrequency, copy the last 5 positions of the access codedip switch, from an existing unit. The correct channelnumber will appear in the “Freq” window.9000(1) Channel Code versus Frequency.Channel Frequency Channel FrequencyA 448.0 MHz F 447.5 MHzB 448.5 MHz G 447.1 MHzC 449.0 MHz H 446.7 MHzD 449.5 MHz J 446.3 MHzE 450.0 MHz K 445.9 MHzAccess Code (Must be inputted for system to work):The first four positions of the switch shown is the accesscode copy these four switch positions from an existingpiece of equipment.Screen switch operation. The screen switches arelabeled from left to right “A”, “B” and S3. They arenumbered from left to right 1 to 8. The darken rectangleto the bottom is “OFF” or “0” the darken rectangle to thetop is “ON” or a “1”. Tapping the lighten rectangle willcause the switch to toggle.Auto Turn Off (Optional, can be skipped):The telePilot transmitter has a variable length Time-out-timer. To facilitate operation of this timer with variousmodels of receiver the Auto Turn Off feature wascreated. If this feature is enabled, when the transmittertimes out and the transmitter turns OFF, it will beforeshutting down send an OFF command to the receiver.Check (tap) the box to enable.Timer (If unsure of a number start with 15 minutes):Enables the transmitter time-out-timer. The selectionsare “None” (meaning the transmitter will never shut offon it own if not used, this is not recommended forbattery life) or numbers of minutes till shut down. Theminutes are selectable in one-minute steps from 1 to 10and five minutes steps up to an hour. Tap on the “Timer”arrow; scroll down through the number of minutes andtap on the desired number.This completes the 9000(1) programming tap “Save”.Save will take you back to the Initial start screen. At thispoint select another Bank to program or to Section 7-9.Saving And Loading The Program.For functional mapping of 2-Speed Controls from9001 to telePilot see Section 7-9.Original 9000Keypad Layout.Dark rectanglesindicate lockedout functionalgroups on bothtransmitters.ON/OFF13579E-STOP246810121124681012E-STOP(EMS)1357911Functional Mapping of Origi-nal 9000 Series Single-SpeedControls to telePilot Controls.Matching numbers indicate thesame function. Mapping notaffected by Original 9000 Key-pad Labeling (Inserts).System 9000(1) Freq ASetup Bank #A1Receiver access code10Auto Turn OffTimer NoneSaveCancel9000 and 9001 Programming ScreenScreen switches
Section 7 - Programming (Continued)717-8.3. 9100 and 9101 telePilot Program-ming.After you have entered 9100 or 9101 as your system typeenter the following items in order for your system:Frequency (Must be inputted for system to work):There should be a label either on the receiver or thetransmitter listing frequency, it should be a channelnumber between A to K. Find this letter and tap the“Freq” arrow and select that channel letter. As thefrequency letter is entered the last five positions of theprogramming automatically sets itself to the positionsused in previous 9100 and 9101 systems to program inthat frequency. For specific frequency information seethe Channel Code versus Frequency listing below.If you are unable to find a channel letter designation forfrequency, copy the last 5 positions of the access codedip switch, from an existing unit. The correct channelnumber will appear in the “Freq” window.9100(1) Channel Code versus Frequency.Channel Frequency Channel FrequencyA 448.0 MHz F 447.5 MHzB 448.5 MHz G 447.1 MHzC 449.0 MHz H 446.7 MHzD 449.5 MHz J 446.3 MHzE 450.0 MHz K 445.9 MHzAccess Code (Must be inputted for system to work):The first four positions of the switch shown is the accesscode copy these four switch positions from an existingpiece of equipment.Screen switch operation. The screen switches arelabeled from left to right “A”, “B” and S3. They arenumbered from left to right 1 to 8. The darken rectangleto the bottom is “OFF” or “0” the darken rectangle to thetop is “ON” or a “1”. Tapping the lighten rectangle willcause the switch to toggle.Auto Turn Off (Optional, can be skipped):The telePilot transmitter has a variable length Time-out-timer. To facilitate operation of this timer with variousmodels of receiver the Auto Turn Off feature wascreated. If this feature is enabled, when the transmittertimes out and the transmitter turns OFF, it will beforeshutting down send an OFF command to the receiver.Check (tap) the box to enable.Timer (If unsure of a number start with 15 minutes):Enables the transmitter time-out-timer. The selectionsare “None” (meaning the transmitter will never shut offon it own if not used, this is not recommended forbattery life) or numbers of minutes till shut down. Theminutes are selectable in one-minute steps from 1 to 10and five minutes steps up to an hour. Tap on the “Timer”arrow; scroll down through the number of minutes andtap on the desired number.Modes A0-A4 (9100 Single-Speed Only). (The correctmode must be selected for safe operation):Please refer to Figure 7-8. Single-Speed 9100 telePilotLockout Modes for specific mode details and functionalmapping of 9100 controls to telePilot. Modes arevarious patterns of functional lockouts. If you have UPand a DOWN buttons on a single-speed transmittercontrolling a hoist, the transmitter must not be able tosend Up and DOWN commands at the same time. Modedetermines the respective buttons that are locked out toeach other. Modes do NOT change the configurations ofthe output relays. Find the desired mode and select itsnumber on the “Mode” selection.For functional mapping of 2-Speed Controls from9001 to telePilot see Section 7-9.This completes the 9100(1) programming, whencompleted with the above tap “Save”.Save will take you back to the initial start screen. At thispoint select another Bank to program or go to Section 7-9. Saving And Loading The Program.Screen switches.System 9100(1) Freq ASetup Bank #A1Receiver access code10Auto Turn OffTimer 15SaveCancel9100 and 9101Programming ScreenMode A09100 SingleSpeed Only
Section 7 - Programming (Continued)727-8.4. Single-Speed 9100 Series telePilotLockout Modes.The Modes and Mode labeling shown relate to thesimilar, but not identical, Modes in the Single-Speed9100 Transmitter. Choose the lockout pair that mostclosely matches your needs. If you are unsure of theLockout Mode in your existing unit, read dip switchSW3 in the existing 9100 transmitter and compare it tothe chart below. Lockout pairs are shown below:Figure 7-8. Single-Speed 9100 telePilot Lockout Modes.Mode A1 Mode A2 Mode A3 Mode A4The dark rectangles on the drawings below representbuttons pairs that are locked out from both working atthe same ti me.Original 9100 SW3 Transmitter dipswitch settings:SW3 Switch Use Mode123ON ON ON A0OFF ON ON A1OFF OFF ON A2ON ON OFF A3OFF ON OFF A4ON OFF ON NAON OFF OFF NAOFF OFF OFF NANA means not applicableMode A0ON/OFF13579E-STOP246810121124681012E-STOP(EMS)1357911Functional Mapping of 9100Series Single-Speed Controls totelePilot Controls.Matching numbers indicate thesame function. Mapping not af-fected by Modes shown below orby Original 9100 Keypad Labeling(Inserts).Original 9100Keypad Layout.
Section 7 - Programming (Continued)737-8.5. 2-Speed 9001 and 9101 SeriestelePilot Functional Mapping.E-STOPMotor 1 Dir 1 Dir 2Motor 2 Dir 1 Dir 2Motor 3 Dir 1 Dir 2ON/OFFAuxiliaryControls AUX 1 AUX 2 AUX 32-Speed telePilot 2-Speed 9001 and 9101 Switch Layout Switch LayoutTX12M-2EMS2 ndSpeed 2 ndSpeed2 ndSpeedFigure 7-9. Functional Mapping of 9001 and 9101Series 2-Speed Controls to telePilot Controls.Matching designators indicate the same function.Mapping not affected by Keypad Labeling (Inserts).Motor 1 Dir 1Motor 1 Dir 2Motor 2 Dir 1Motor 2 Dir 2Motor 3 Dir 1Motor 3 Dir 2 AUX 1 AUX 2 AUX 3
Section 7 - Programming (Continued)747-9. Saving, Downloading, Reading ThePrograms and Other PDA Functions.Saving The Programming File.With the initial telePilot screen displayed, tap in thelower left corner of your PDA, the title bar at the top ofthe screen will show a menu or tap on the word“telePilot”. Choose the way you wish to save the file.Tap on your choice and follow the instructions on thePDA to complete file saving. Old files can be deleted,called up, modified and renamed by this same menu.Sending a Program To The telePilot. WARNINGAFTER EVERY PROGRAMMING OF THE TRANS-MITTER, TEST THE UNIT BY TURNING IT ONAND OFF NEAR THE APPROPRIATE RECEIVER. IFTHE RECEIVER DOES NOT RESPOND, DO NOTACTIVATE A FUNCTION BUTTON! THE TRANS-MITTER MAY HAVE INCORRECT PROGRAM-MING, WHICH COULD MOVE ANOTHER CRANE.RE-CHECK THE PROGRAMMING IN THE TRANS-MITTER AND RETEST. AFTER ACTIVATION OFRECEIVER, FUNCTIONALLY TEST ALL COM-MANDS ON THE TRANSMITTER BY INITIALLYJOGGING THE BUTTONS, THEN WITH A FULLMOVEMENT BEFORE RETUNING TO SERVICE.FAILURE TO FOLLOW THIS WARNING COULDRESULT IN SERIOUS INJURY OR DEATH ANDDAMAGE TO EQUIPMENT.To send a program file which consists of four banks to atelePilot Transmitter:1. Line up the PDA’s infrared port with thetransmitters infrared port (remove battery endcap and pull battery pack back and expose thetelePilot’s infrared port. See Figure 7-9.telePilot Infrared Port Access).2. Turn transmitter unit ON. Note that the Tx RedLED is ON.3. From the application file’s main menu click onthe PDA a dropdown menu icon located atbottom left corner or tap on the word“Programmer” at the top of the screen. Select“Admin.”4. Under “Admin.” select “Send Setting.”5. Select a name you want for the telePilot unitbeing programmed and tap “OK”.6. Wait for confirmation text on PDA screen:7. After programming, always operationally testall the functions the transmitter by using theappropriate receiver with the MR relay disabledbefore retuning transmitter to service.Receiving (Reading) The telePilot Programming.To read a program file from the telePilot Transmitter:1. Line up the PDA’s infrared port as sets 1 to 3above, with the transmitter ON. Select “Admin”2. Select “Receive Setting.”3. PDA will confirm reception and automaticallydisplay current programming in the telePilotunit.Figure 7-9. telePilot Infrared Port Access.Battery packName: ……………………………..…. MTx Type 2 SPDUse bank passwordSetting AdminBank 1onBank 2offBank 3onBank 4offSend SettingReceive SettingBeam SettingTelePilot IDHistoryAboutFirst press Button 6Second press Button 5Third press Button 4Fourth press Button 3Name: ……………………………..…. MTx Type 2 SPDUse bank password Setting AdminBank 1onBank 2offBank 3onBank 4offFirst press Button 6Second press Button 5Third press Button 4Fourth press Button 3NewOpenRename CurrentDelete CurrentSave CurrentSave Current As
Section 7 - Programming (Continued)75Reading The telePilot ID.To read an identity (an identity is the name that wasprogrammed in by step 5 of Sending a Program To ThetelePilot, listed above) from the telePilot Transmitter:1. Line up the PDA’s infrared port as sets 1 to 3above, with the transmitter ON. Select “Admin”2. Select “telePilot ID.”3. PDA will read: Name, Serial/Job Number, andManufacturing information of the telePilotunit.Reading The telePilot History.To read Service information from the telePilotTransmitter:1. Line up the PDA’s infrared port as sets 1 to 3above, with the transmitter ON. Select “Admin”2. Select “History”4. Unit will read: Past Service Orders of thetelePilot unit.Reading The PDA telePilot Software Version.To read PDA Software Version from the telePilotTransmitter:1. Select “Admin”2. Select “About”3. Unit will read: telePilot Programmer SoftwareVersion number.Beaming (Sending) the Configuration(s) to anotherPDA.To send a configuration setting to another PDA.1. Line up the PDA’s infrared port as, with theother PDA, which is turned ON.2. Select “Beam Setting.”3. Select the item(s) you wish to send.4. Wait for confirmation text on PDA screen:Error Statements and Codes.Tx Type Mismatch; If while attempting to program atelePilot you receive an error code such as “ErrorAAAB” you have selected a different style transmitteron the PDA than you are attempting to program. Mostcommon cause is trying to program a 2-speed telePilotwith single-speed selected or visa versa.
Section 8 – Servicing76NOTEIF THE SYSTEM STOPS WORKING CHECK THE RED INDICATOR ON THE TRANSMITTER. IF ITDOES NOT COME ON WITH PUSHING THE ON BUTTON OR THE YELLOW WEAK BATTERYLIGHT IS ON (FOR THE telePilot TRANSMITTER) REPLACE THE TRANSMITTER BATTERIES.Table 8-1. Receiver Diagnostic LED Functions. (See Figure 8-1. Receiver Layout for LED locations).LED COLOR FUNCTIONRFReceiverONRed Power is on to the RF Receiver.Normally ON.Monitors power to the RF Receiver Board. If the main receiver is ON and the RF Receiver ONLED is OFF. Check to see if the RF Receiver Board is properly plugged in to the main board.DSMR1 Yellow Monitors closure of the Security Relay output (KMR1).The LED will be illuminated when the Security Relay has been enabled by an ON commandreceived from the Transmitter Unit. LED will extinguish when an OFF command is transmitted,or an EMS condition is present.The Security Relay controls the 12 VDC power to the MCR relay (K13) and the power to the coilsof the control relays (K1 through K12) on the Relay Output Modules.Figure 8-1. Receiver LayoutGND N 120V F18 7 6 5 4 3 2 18 7 6 5 4 3 2 18 7 6 5 4 3 2 18 7 6 5 4 3 2 1SW4 ON SW3 ONA SW2 ONB SW1 ONDS1 DS2 DS3 DS4 DS5 DS6 DS7 DS8 DS9 DS10 DS11 DS12 DSMR2TP4 TP5 AGC TP7 DATA TP6 ANALOG TP2 GNDDS13DS23DS22DS24DS21DS20DS18DS16TP3+12VTP1+5VDS15+5VRF Receiver BoardMOV’sDip Switches KMR1EPROMWDT+12V REG+12V5V DCK1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13DSMR1SW2 ONON SW1DS19DS17DS15DS14F2 F3 F4 F5 F6 F7 F8J2 J3 J4 J5 J6 J7JU2 JU1Relays Master Relay1111 1 11RF Receiver “ON” IndicatorJumpers:JU1 - IN - Alarm to work after E-STOP.JU2 - Not used.Main ON/OFFpower SwitchMR DisableSwitch forDiagnostics
Section 8 – Servicing (Continued)77DSMR2 Red Monitors closure of the Master Control Relay (MCR) relay (K13).LED will be illuminated when the MCR relay has been enabled by an ON command recievedfrom the Transmitter Unit. Led will extinguish, when an OFF command has been transmitted, anEMS condition is present, or SW2 is set to OFF.The MCR controls the 12 VDC power to the Master Relay on the Power Supply Board.DS1-DS12 Red Monitors closure of the output relays (K1-K12).Normally ON for a function when that specific function is enabled.The LED will be illuminated when a specific relay has been enabled by the respective commandreceived from the Transmitter Unit. The LED will extinguish, when the command is no longerdetected.DS13 Red Monitors the watchdog timer.Normally OFF.The LED will illuminate momentarily when power is applied to or removed from the system. Ifthe LED is continuously flashing or on, the computer is not working properly. If LED isilluminated constantly (no flashing), the +5 VDC is probably too low. This could be caused byshorts on the board or by a defective voltage regulator. If the LED flashes at a constant rate, themicrocomputer chip or EPROM may be defective.DS14 Yellow Monitors data synchronization. (Flashes when a properly formatted data signal is received fromthe transmitter).This LED will flash rapidly when data is transmitted. The LED can be used with DS16 to analyzeincoming data. If DS16 is illuminated or flashing when DS14 also is flashing, another TransmitterUnit on the same frequency may be present. This is normal. As more Transmitter Units operatedon the same frequency, LED will flash brighter and more often.DS15 Yellow Monitors continuity between receiver RF module and CPU module.Normally ON.Off indicates a malfunctioning receiver.DS16Checkthisfirst!Red Monitors received data errors. Wrong Access Code.Normally OFF.If LED is illuminated continuously when data is transmitted and the system will not respond theAccess Code of the Receiver and Transmitter Units may not match. A flashing LED during datatransmission may indicate interference of the received data. If LED is illuminated when data is nottransmitted, another Transmitter Unit may be present on the same frequency with a differentAccess Code. The presence of activity on this LED does not necessarily indicate a problem. Itshould be used with other indicators in analyzing system status.DS17 Yellow Monitors system acitivty.Normally FLASHING.If not flashing the microprocessor is dead.DS18 Red Monitors the ON command from the Transmitter.
Section 8 – Servicing (Continued)78LED will flash when an ON command is being received from the Transmitter.While pushing the ON button on the Transmitter this should light.DS19 Red Monitors EMS condition.Normally OFF.LED will flash when an EMS command is transmitted and illuminate continuously when the EMScondition is in effect. An EMS condition may be created when an EMS command is transmitted orwhen a failure mode is detected by the slave microcomputer. If both DS18 and DS19 areilluminated, a contact monitoring error has been detected. If both DS16 and DS19 are illuminated,the incoming data on the ICC bus has been corrupted.DS20 Red Monitors the OFF command from the Transmitter.LED will flash when an OFF command is being received from the Transmitter Unit.While pushing the OFF button on the Transmitter this should light.DS21 Yellow Monitors the activity for the Security Relay (KMR1).Normally ON when the receiver is enabled.If the system is ON and the light is not lit there is a serious microprocessor error.DS22 Green Monitors the unregulated DC power to the 12 volt regulatorNormally ON when AC line is present.If AC Power is present and the AC to DC converter is working then the LED is illuminated. TheLED is off if DC power is not present. Check power supply, fuses and if power is applied to thereceiver.DS23 Green Monitors the regulated 12 VDC power to the Board (receiver board).Normally ON when AC line is present.If 12 VDC power is present then the LED is illuminated. The LED is off if 12 VDC power is notpresent. Check the 12 VDC regulator and for shorts on the Board.DS24 Green Monitors regulated 5 VDC power to the Board.Normally ON when AC line is present.If 5 VDC power is present then the LED is illuminated. The LED is off if 5 VDC power is notpresent. Check the 5 VDC regulator and for shorts on the Board.8-2. Receiver Testing.8-2.1. Receiver test points.Test points are shown as dark circles on Figure 8-1. Receiver Layout.TP1 – Monitors regulated 5 VDC.TP2 – Ground for monitoring other test points.TP3 – Monitors regulated 12 VDC.
Section 8 – Servicing (Continued)79TP4 – Not used.
Section 8 – Servicing (Continued)80NOTETHE FOLLOWING TEST POINTS NEED ANOSCILLOSCOPE, SEE 8-2. RECEIVER SCOPEWAVE FORMS.TP5 – Monitors AGC (Automatic Gain Control) from RF Receiver module.TP6 – Monitors analog signal from RF Receiver module.TP7 – Monitors received data from RF Receiver module.8-2.2. Typical Wave Forms on an Oscilloscope.Receiving Data Not Receiving DataScope Settings:Sweep – 1 millisecond per division.Sensitivity – TP6, 1 volt per division 10X probe.TP7, 2 volts per division 10X probe.TP5, 1 volt per division 10X probe.TP6ANALOGTP7DATATP5AGCFigure 8-2. Receiver Scope Wave Forms.
Section 8 – Servicing (Continued)818-3. Membrane Transmitter Servicing.The Membrane Transmitter M/C board is shownin Figure 8-3. Refer to paragraphs below forServicing Procedures.8-3.1. To Check Data. 1.) For data input use “DATA” connection toRF Head 2.) Use “RF SW” for External Trigger input. 3.) Use TP2 for Ground8-3.2. Battery Monitor Adjustment.Connect power supply to battery leads observingpolarity and set supply voltage to 5.8 volts.Adjust Battery Monitor Potentiometer R21 tojust turn off red LED on the front of thetransmitter.8-3.3. Red LED Not Flashing.If the red LED indicator on the transmitter doesnot flash when the transmitter is turned ON orwhile operating crane with the transmitter,replace the batteries they are weak. Weakbatteries may operate the crane for a while, butthe LED will not flash. If the battery is too lowthe battery monitor will shut the transmitter OFF.See Section 5-6. Battery Replacement for properprocedure.NOTEIF THE BATTERIES ARE INSTALLEDBACKWARDS IN THE MEMBRANETRANSMITTER THE FUSE IN THE BAT-TERY COMPARTMENT WILL BLOW TOPROTECT THE INTERNAL CIRCUITRY.8-3.4. Battery Fusing.The Membrane Transmitter is protected fromreverse battery polarity and shorts by a fuse, partnumber F2712-1.5 (1.5 Amp, 250V, Fast Acting,4.) SW3 Two-Speed ModeSwitch.5.) Battery MonitorAdjustment. Set for 5.8Volts.6.) Battery CableConnections, J2A plugand J2 alternate style.7.) SW4 Single-Speed ModeSwitch.8.) Data check points.1.) EPROM FW2903-0Tactile 2-SP, FW2904-0T1 & 2-SP Non-tactile.2.) SW1 “A” Access CodeSwitch.3.) SW2 “B” Access Code Switch.NOTETO DISABLE TIME-OUT-TIMERIN TRANSMITTER TURN SW3POSITION 3 TO ON.Figure 8-3.MembraneTransmitter M/CModule E10635J1 Keyboard ConnectorRF HeadBONABSW3SW4ONONON1111_+1U3R21J2J2A4.2.3.TP1 +5VJU7JU5JU6TP2 GNDRF SW DATA8.1.5. 6. 7.
Section 8 – Servicing (Continued)822 AG). If the batteries are installed in backwardsthis fuse will blow to protect the internal electronics
Section 8 – Servicing (Continued)838-4. Pendant Transmitter Servicing.The Single-Speed or the 2-Speed 10K12 PendantTransmitter may be used with the 10K6/9Receiver. The Pendant Transmitter M/C Board isshown in Figure 8-4. Refer to paragraphs belowfor Servicing Procedures.8-4.1. To Check Data. 1.) For data input use pin 1 of J1. 2.) Use TP1 for External Trigger input. 3.) Use TP4 for Ground.8-4.2. Battery Monitor Adjustment.Battery monitor is factory preset no adjustmentavailable.8-4.3. Red LED Not Flashing.If the red LED indicator on the transmitter doesnot flash when the transmitter is turned ON orwhile operating crane with the transmitter,replace the batteries, they are weak. Weakbatteries may operate the crane for a while, butthe LED will not flash. If the battery is too lowthe battery monitor will shut the transmitter OFF.See Section 5-6. Battery Replacement for properprocedure.1ABONON1SW1SW2SW3SW4CDTP4GNDTP1TP2+REFJU8JU5JU3JU2 JU1J6J1J2J3J4J5R115. 7.4.2. 3.8.1.9. 10.6. 11.1. ) J1 Pin 1 Data Input.2. ) Stepless Switch LevelAdjustment. (Factory Set).3. ) Battery Connector.4. ) SW4 “D” Mode Switch.5. ) SW2 “A” Access CodeSwitch.6. ) SW1 “B” Access CodeSwitch.7. ) SW3 “C” ConfigurationSwitch. SW3 position 8 “ON”disables Time-out-timer.8. ) Test Point 1 ExternalTrigger for Data.9. ) Software version label.10. ) Flash ROM.11. ) Flash ROM SerialProgramming Port.Figure 8-4.PendantTransmitter M/CModule E1063611ON ONNOTETO DISABLE TIME-OUT-TIMER IN TRANS-MITTER TURN SW3POSITION 3 TO ON.
Section 8 – Servicing (Continued)848-4.4. Stepless Switch Adjustment.R1 is factory preset and controls the upper levelof the stepless switch range.8-4.5. Pendant Transmitter Software.There is no EPROM in the Pendant Transmitter;software is stored internally in non-volatile flashmemory. Software updates are done in thefactory through the serial port. A softwareversion label on the board indicates the softwareversion loaded into flash memory.8-5. telePilot Servicing.There are no user adjustments inside thetelePilot unit. All internal adjustments are doneby software. Internally there is a single circuitboard that requires proper handling to replace.The individual switch packs can be replaced without opening the unit. Contact TelemotiveCustomer Care for details. See Figure 9-1.telePilot Exploded View View. CAUTION•••• DO NOT ATTEMPT TO OPEN OR SER-VICE THE TELEPILOT UNIT.•••• ONLY TRAINED QUALIFIED INDIVIDU-ALS SHOULD DO SERVICING.•••• STRICT ANTI-STATIC HANDLINGPROCEDURES MUST BE FOLLOWED.•••• FAILURE TO FOLLOW THIS CAUTIONCOULD RESULT IN SERIOUS DAMAGETO EQUIPMENT AND/OR VOID THEWARRANTY.
Section 9 – Spare Parts85RECEIVERPART NUMBER DESCRIPTIONFW2912-0 EPROME13157-S RF SYNTHESIZED RECEIVER MODULE ASSEMBLYH310-0 RF RECEIVER MODULE ASSEMBLY MOUNTING SCREWS (4)MP18005-0 RF RECEIVER MODULE MOUNTING BRACKET TOP SIDE (LEFT)MP18005-1 RF RECEIVER MODULE MOUNTING BRACKET TOP SIDE(RIGHT)H906-0 RF RECEIVER MODULE MOUNTING BRACKET BOLT (2)H934-0 RF RECEIVER MODULE MOUNTING BRACKET NUT (2)E10199-0 MAIN BOARDH1224-1 MAIN BOARD MOUNTING SCREWS (5)E10197-2 ANTENNA ASSEMBLY (INTERNAL)CONNECTOR PLUG IN:TS1060-3 3 POSITION (2)TS4655-4 3 POSITION (3)J4655-0 6 POSITIONTS1060-8 8 POSITIONCR260-0 MOV K1304-0 RELAY (OUTPUT) (13)S2721-8 DIP SWITCH (ACCESS CODE) (4)MP10276-0 HOUSING ASSEMBLY, WITH DOORSH1223-1 SCREW ROUND HEAD #10-24 X 1 ½”H1226-0 HEX NUT #10-24 (4)H2079-0 LOCK WASHER #10 SPLITTCTX12/TR12-0 INSTRUCTION MANUALF2711-2 FUSE ½ AMP, SLO BLO 250VF2711-0 FUSE 10 AMP SLO BLO 250V (7)H1127-0 FUSE COVERS, VINYL (7)WA12038-0 EXTERNAL ANTENNA ADAPTER (Does not include antenna).A525-1 ANTENNA (For use with WA12038-0).WA104-20 CABLE ASSMBLY, 20 FOOT (For remote antenna mounting requiresWA12038-0 and A525-1).telePilot TRANSMITTER (SEE FIGURE 9-1.)PART NUMBER DESCRIPTIONE10647-0 MAIN CIRCUIT BOARD 2-SPEEDE10727-0 MAIN CIRCUIT BOARD SINGLE-SPEEDN10705-0 LABELSMP10620-0 SHOULDER STRAPTCTX12/TR12-0 MANUALFW3045-0 PDA PROGRAMMING SOFTWAREMP10709-0 BELT LOOP ASSEMBLYA10708-0 BATTERY DOOR ASSEMBLYH1113-0 HEX STANDOFF (4)H1114-0 ROD, ALL THREAD, 2-SPEED (2)H1121-0 ROD, ALL THREAD, SINGLE-SPEED (2)E10713-0 SWITCH PACK 2-SPEED RIGHTE10712-0 SWITCH PACK 2-SPEED LEFTE10715-0 SWITCH PACK SINGLE-SPEED RIGHTE10714-0 SWITCH PACK SINGLE-SPEED LEFTWA1050-0 SWITCH RIBBON CABLE (2)MP10706-0 TOP END CAPMP10707-0 BOTTOM END CAPA10724-0 HOUSING ASSEMBLY SINGLE-SPEED
Section 9 – Spare Parts (Continued)86telePilot TRANSMITTER CONTINUED (SEE FIGURE 9-1.)PART NUMBER DESCRIPTIONA10722-0 HOUSING ASSEMBLY 2- SPEEDWA1052-0 BATTERY CABLE, 2-SPEEDWA1053-0 BATTERY CABLE, SINGLE-SPEEDMP10721-0 BATTERY HOLDER FOR TWO “AA” CELLSBT111-0 DISPOSABLE HIGH CAPACITY BATTERY PACKBT111-1 RECHARGEABLE BATTERY PACKA10723-0 BATTERY CHARGER FOR BT111-1MEMBRANE TRANSMITTERPART NUMBER DESCRIPTIONF2712-1.5 FUSE 1.5 AMP, 250V FAST ACTING 2 AGFW22903-0 TWO SPEED TACTILE MEMBRANE EPROM FOR TRANSMITTERM/C MODULE E10635A9654-0 STRAP ASSEMBLYA10662-1 TRANSMITTER CASE ASSEMBLYE9654-0 BATTERY HOLDER ASSEMBLYA10664-2 BATTERY DOOR ASSEMBLYE10640-2 BEZEL ASSEMBLY (2-SPEED TRANSMITTER)S2803-0 MEMBRANE SWITCH PAD (TACTILE)MP9656-0 VINYL POUCHA9665-0 RUBBER BOOT ASSEMBLYBT646-0 BATTERY AA CELL 1.5 VOLTS (5)PENDANT TRANSMITTERPART NUMBER DESCRIPTIONMP10668-1 CASE ONLY, TOP PENDANT TRANSMITTERH634-0 BOOT, GRAY (PUSHBUTTON)H635-0 BOOT, RED (PUSHBUTTON)H2055-3 LENS/MOUNT, LED W/SPACER, REDS1058-0 SWITCH, PUSHBUTTON, 2-SPEED SBRU-SDS1026-0 SWITCH, PUSHBUTTON, MOM N/0S1041-0 SWITCH, TOGGLE, SPDT, CTR OFFMP10666-0 KNOB, ROTARY 1/2" DIA., BLACKMP10675-0 BOOT, TOGGLE SW., BLACKA10667-5 BOTTOM CASE W/O BATTERY DOORA10669-1 BATTERY DOOR W/FOAM, W/O SCREWS AND LATCHMP10676-0 FOAM, BATTERY DOORMP10677-0 GASKET FOR BOTTOM CASEH1047-0 COVER SCREWS (8)MP1049-0 SWITCH GUARDE10668-11LT SAME AS E1066-11 BUT WITH SWITCH GUARD AND LARGETOGGLESMP10668-3 CASE TOP ONLY, LARGE TOGGLESMP10650-3 LATCH FOR BATTERY DOORS605-0 SWITCH, TOGGLE SPDT CENTER OFF, LARGEA1011–X BOOTS (6) (SEE *NOTE 1 BELOW FOR THE PROPER SUFFIX)H251-0 SCREW FOR BATTERY DOOR LATCHH252-0 WAVE WASHER FOR BATTERY DOOR LATCHH2034-0 FLAT WASHER FOR BATTERY DOOR LATCHN13653-2 FCC LABELE10688-0 BATTERY HOLDER ASSEMBLY, W/CABLEMP10680-0 O'RINGMP10678-0 SHOULDER STRAPBT10KP-0 BATTERY, ALKALINE
Section 9 – Spare Parts (Continued)87PENDANT TRANSMITTER CONTINUEDPART NUMBER DESCRIPTIONBT10KP-1 BATTERY, NICADBT10KP-0 BATTERY, ALKALINEBT10KP-1 BATTERY, NICADE10670-1 BATTERY CHARGER*NOTE 1 UP DOWN EAST WEST NORTH SOUTHYELLOW 2324313229 30BLACK 3 4 11 12 9 10
Section 9 – Spare Parts (Continued)88 CAUTIONDO NOT ATTEMPT TO OPEN OR SERVICE THE TELEPILOT UNIT.ONLY TRAINED QUALIFIED INDIVIDUALS SHOULD DO SERVICING. STRICT ANTI-STATIC HANDLING PROCEDURES MUST BE FOLLOWED. FAILURE TO FOLLOW THISCAUTION COULD RESULT IN SERIOUS DAMAGE TO EQUIPMENT AND/OR VOID THEWARRANTY.Figure 9-1. telePilot Exploded View.E10713-0SWITCH PACK2-SPEED RIGHTE10715-0SWITCH PACKSINGLE-SPEEDRIGHTE10712-0SWITCH PACK2-SPEED LEFTE10714-0SWITCH PACKSINGLE-SPEEDLEFTA10722-0HOUSING ASSEMBLY2- SPEEDA10724-0HOUSING ASSEMBLYSINGLE-SPEEDWA1050-0 SWITCHRIBBON CABLES (2)E10647-2SP MAIN CIRCUITBOARD 2-SPEEDE10647-1SP MAIN CIRCUITBOARD SINGLE-SPEEDMP10706-0TOP END CAPA10708-0 BATTERYDOOR ASSEMBLYH1113-0HEX STANDOFF #10-24 (4)MP10707-0BOTTOM END CAP2-SPEED MODEL SHOWN
Appendix A - Transmitter Switch Programming89Switch POS. Membrane Pendant SLTX JLTX telePilotSW3 1 Switch Orientation 1 Switch Orientation 1 N/A Code Plug Select Switch Orientation 1 2Switch Orientation 2 Switch Orientation 2 N/A N/A Switch Orientation 2 3Switch Orientation 3 Switch Orientation 3 N/A N/A Switch Orientation 3 4Time-out-timer Disable N/A N/A N/A Time-out-timer Disable 5Crane Configuration 1 N/A N/A N/A Crane Configuration 1 6Crane Configuration 2 RS232 enable RS232 enable RS232 enable Crane Configuration 2 7Crane Configuration 3 N/A N/A Tilt Switch Disable Crane Configuration 3 8 N/A Time-out-timer Disable Time-out-timer Disable Time-out-timer Disable Time-out-timer DisableSW4 1 Mode EnableSee Table A below Mode EnableSee Table B below Mode EnableSee Table B below Mode EnableSee Table B below 2Mode EnableSee Table A below Mode EnableSee Table B below Mode EnableSee Table B below Mode EnableSee Table B below 3 N/ATandem DisableUn-check “Tandem”on telePilotTandem DisableUn-check “Tandem”on telePilotTandem DisableUn-check “Tandem”on telePilot 4 N/ASelect InvertCheck “Invert”on telePilotSelect InvertCheck “Invert”on telePilotSelect InvertCheck “Invert”on telePilot 5 N/A Crane Configuration 1copy to telePilot S3-5 Crane Configuration 1copy to telePilot S3-5 Crane Configuration 1copy to telePilot S3-5 6 N/A Crane Configuration 2copy to telePilot S3-6 Crane Configuration 2copy to telePilot S3-6 Crane Configuration 2copy to telePilot S3-6 7 N/A Crane Configuration 3copy to telePilot S3-7 Crane Configuration 3copy to telePilot S3-7 Crane Configuration 3copy to telePilot S3-7 8 N/A N/A N/A N/ASW4 POS. Table A (Membrane only)Mode 0 1 OFF 2OFF Use 2-Speed telePilotMode 1 1 ON 2OFF Use Single-Speed telePilot “Mode 1”Mode 2 1 OFF 2ON Use Single-Speed telePilot “Mode 2”Mode 3 1 ON 2ON Use Single-Speed telePilot “Mode 3”SW4 POS. Table BMode 1 1 OFF For Single Speed Use Single-Speed telePilot “Mode 3” For 2-Speed Transmitter Use 2-Speed 2OFF telePilot Under “Main/Aux” use "AUX"Mode 2 1 ON Use 2-Speed telePilot Under “Main/Aux” use "Motor" 2OFF Mode 3 1 ON Use 2-Speed telePilot Under “Main/Aux” use "Select" 2ON

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