Kar Tech VRTX Versa Remote Control User Manual VRTX VRTXM
Kar-Tech, Inc. Versa Remote Control VRTX VRTXM
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Users Manual1
TM VERSA REMOTE FULL FEATURED REMOTE CONTROL SYSTEM OPERATIONS AND INSTALLATION MANUAL 3B0181CJ. July 25, 2003 i VERSA REMOTE INDEX Description ................................................................... 1-3 Installation ................................................................... 7 Before applying power ..................................................... 7 Transmitter and Receiver ID Code Programming ...................... 7-8 Wiring chart.................................................................. 9-11 Routine Maintenance ....................................................... Maintenance precautions .................................................. Troubleshooting ............................................................. Troubleshooting chart ................................................. Error Code chart........................................................ 13 13 13 14 15 Specifications ................................................................ 17-18 Instructions to the User .................................................... 19 VERSA REMOTE DESCRIPTION: KAR-TECH's VERSA REMOTE is a state of the art microprocessor based Radio Frequency (RF) and Controller Area Network (CAN) remote control system designed to provide the machine operator with the ability to remotely operate equipment. The machine operator is still required to follow OSHA and other applicable standards when operating the equipment. This system is designed with Frequency Hopping Spread Spectrum (FHSS) Technology and Frequency Lock feature to eliminate the RF interference problem in Radio remote products. The control system consists of two major modules: the remote station (RF transmitter), and the Remote Receivers (Digital Controllers). Each transmitter is preprogrammed with a special radio ID code. The receiver is programmed to respond only to the transmitter with the ID code for which it is set. This feature allows the equipment to work in wireless mode in close vicinity of each other without interfering with each other. In the event that a transmitter becomes damaged and a new one is needed, the receiver can be reprogrammed to respond to the new transmitter. Please refer to TRANSMITTER AND RECEIVER ID CODE PROGRAMING section of this manual for additional information. The remote station has two LED indicators, the BATTERY and TRANSMIT indicators. The red BATTERY indicator starts blinking when the battery voltage drops below 9 volts and blinking speed increases while the voltage is decreasing. The transmitter is powered by a rechargeable battery and can be recharged by the +12 volt electrical system of the machine when connected to the machine by the CAN/charger cable or charger cable. An optional AC charger can be used to charge the battery. Both frequency and duration of use determine the operation time of the battery. Power is being used any time the transmitter power is on. To turn transmitter power off, turn off the power switch on the transmitter. To prolong the battery life and efficiency, the pendant should not VERSA REMOTE be left on charge for a long period of time and should be discharged periodically. A complete charge can be achieved in 8 hour. To save battery life, the transmitter is designed with an auto shut down feature. This feature turns transmitter off when none of the switches or buttons is used for specified period. To turn transmitter on again, toggle the power switch to off, then on position. The transmitter is also able to communicate with the receiver via CAN (Controller Area Network) protocol. This is done by connecting the CAN cable to the transmitter. This feature is designed to allow the user to operate the machine in case of radio interference or discharged transmitter battery. OUTPUTS: There are sourcing on/off outputs and proportional outputs on the receiver module. Each output is designed with built in short circuit and overload protection. The on/off outputs are also designed with no load or broken wire status. These statuses are reported to the machine operator via the error code display in the receiver. Refer to the error code chart for a list of error codes. The Proportional outputs are current regulated and the minimum and maximum requited current as well as ramp for the proportional output is calibrated using a Palm Pilottm. Each function is programmed for preset factory settings when shipped from Kar-Tech. Refer to factory setting table at the end of this manual. DISPLAY: The receiver is designed with an integrated 4-character alphanumeric red LED Intelligent Display. This display is used to report the status of the outputs, radio communication, etc. to the machine operator. For additional information on error codes refer error code chart of this manual. VERSA REMOTE VERSA REMOTE VERSA REMOTE VERSA REMOTE VERSA REMOTE INSTALLATION: each mating pin terminal. 1.Refer to the wiring chart for wiring connections. 3.Read the rest of this manual. 2.The receiver should be mounted on shock absorbing mounts. The receiver is best mounted in a protected location. 3.When installing the unit, the main power should run from the battery, through a 20 amps fast blow fuse, to a power switch or relay; then into the receiver unit. For best results connect the receiver main power connections to the auxiliary terminal of the ignition switch, PTO switch, or ignition relay. Use 18 gauge or heavier wire. 4.All connections must be properly insulated to protect against shorts. 5.Seal all connections with a nonconductive silicone grease to prevent against corrosion. BEFORE APPLYING POWER: 1.Check polarity. power and ground 2.Check wiring harness for possible shorts before connecting remote control to output devices (i.e., valves, relays) by checking TRANSMITTER AND RECEIVER ID CODE PROGRAMMING: Each transmitter is preprogrammed with a special radio ID code. The user can change the ID code by the following procedure. 1. Press the switch down (off) 2. Move the switch. In this state, both LEDs on the remote start toggling until the user operates a function switch on the remote. After the lights stop flashing, a new ID has been chosen. The receiver is programmed to respond only to the transmitter with the ID code for which it is set. This feature allows the equipment to work in wireless mode in close vicinity of each other without interfering with each other. In the event that a transmitter becomes damaged and a new one is needed, the receiver can be reprogrammed to respond to the new transmitter ID. A code reset is done by connecting power to the programming pin or installing the mate to the 2 pin WeatherPack connector provided on harnesses (short 2 ft. cable) to short power to program pin. This VERSA REMOTE connector must be removed after programming ID code is set to prevent from reprogramming ID codes. VERSA REMOTE WIRING CHART RECEIVER WIRING CONNECTOR P1: DEUTSCH 40 PIN PIN# FUNCTION +12V BATTERY POWER POWER TO PENDANT NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION 10 NO CONNECTION 11 LOWER BOOM RAISE OUTPUT 12 NO CONNECTION 13 RF ID PROGRAMMING PIN 14 SOURCE LOWER OUTPUT 15 NO CONNECTION 16 SOURCE RAISE OUTPUT 17 NO CONNECTION 18 UNLOADER VALVE OUTPUT 19 NO CONNECTION 20 E-STOP OUTPUT 21 NO CONNECTION 22 SPARE ON/OFF OUTPUT 23 NO CONNECTION 24 SPARE ON/OFF OUTPUT 25 DETECTOR LOWER OUTPUT 26 NO CONNECTION 27 DETECTOR RAISE OUTPUT 28 LOWER BOOM LOWER OUTPUT 29 ROTATE CW OUTPUT 30 ROTATE CCW OUTPUT 31 NO CONNECTION 32 KNUCKLE FOLD OUTPUT 33 KNUCKLE UNFOLD OUTPUT 34 NO CONNECTION 35 NO CONNECTION 36 CAN COMMUNICATIONS TO PENDANT (HIGH) 37 CAN COMMUNICATIONS TO PENDANT (LOW) 38 GROUND TO PENDANT 39 SPARE GROUND 40 BATTERY GROUND VERSA REMOTE CONNECTOR P2: DEUTSCH 24 PIN PIN# FUNCTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION 10 NO CONNECTION 11 NO CONNECTION 12 NO CONNECTION 13 NO CONNECTION 14 NO CONNECTION 15 NO CONNECTION 16 UPPER BOOM RETRACT OUTPUT 17 UPPER BOOM EXTEND OUTPUT 18 PWM/PROPORTIONAL OUTPUT 19 PTO OUTPUT 20 NO CONNECTION 21 NO CONNECTION 22 NO CONNECTION 23 NO CONNECTION 24 NO CONNECTION SYSTEM EXTENSION MODULE WIRING CONNECTOR: DEUTSCH DTM13-12PA PIN# FUNCTION GROUND CAN COMMUNICATIONS TO RECEIVER (HIGH) CAN COMMUNICATIONS TO RECEIVER (LOW) 4-11 N/C 12 +12V POWER CONNECTOR DEUTSCH DTM13-12PB PIN# FUNCTION C/S AXLE DOWN C/S AXLE UP S/S AXLE DOWN S/S AXLE UP 5-9 N/C 10 RS-232 GROUND 11 RS-232 RX TO PALM PILOT 12 RS-232 TX TO PALM PILOT 10 VERSA REMOTE REMOTE TRANSMITTER STATION WIRING CONNECTOR: CXC3102A14S-5P-300 PIN# FUNCTION POWER GROUND CAN COMMUNICATIONS TO RECEIVER (HIGH) CAN COMMUNICATIONS TO RECEVIER (LOW) CABLE SHIELD (GROUND) WIRED PENDANT STATION WIRING CONNECTOR: DEUTSCH HDP26-24-23SN PIN# FUNCTION POWER IN(+12 VDC) S/S AXLE RETRACT S/S AXLE EXTEND C/S AXLE RETRACT C/S AXLE EXTEND DETECTOR RAISE DETECTOR LOWER SOURCE RAISE SOURCE LOWER KNUCKLE UNFOLD KNUCKLE FOLD ROTATE CCW ROTATE CW UPPER BOOM EXTEND UPPER BOOM RETRACT LOWER BOOM RAISE LOWER BOOM LOWER SPEED CONTROL GROUND UNLOADER VALVE 11 VERSA REMOTE 12 VERSA REMOTE ROUTINE MAINTENANCE: 1. Clean transmitter and receiver regularly with a damp cloth and mild detergent. 2. Periodically check receiver antenna for tightness. 3. Inspect electrical wiring for wear points or other damage. Repair as required. 4. Inspect all connections for looseness or corrosion. Tighten and/or "seal" as necessary. MAINTENANCE PRECAUTIONS: When performing any inspection or maintenance work on the VERSA REMOTE system, always exercise care to prevent injury to yourself and others or damage to the equipment. The following are general precautions that should be closely followed in carrying out any maintenance work. 1. Do not have hydraulic power available to the valves when performing electrical tests or downloading programs. 2. Never operate or test any function if any person is in an area where they could be hurt by being hit or squeezed by the 13 hydraulic equipment. 3. Turn power off before connecting or disconnecting valve coils or other electrical loads. TROUBLESHOOTING: This section provides basic operator level troubleshooting for the VERSA REMOTE system. If, after following these instructions, the system still does not function, check the hydraulic system then contact your KAR-TECH representative for further instructions or servicing. 14 VERSA REMOTE TROUBLE SHOOTING CHART PROBLEM 1. No operation of all functions when a function switch is activated. SOLUTION 1. Check to see if the selector switch is in the proper position. 2. Check that transmitter power is on. 3. Check that receiver power switch is on. 4. Check vehicle wiring for power into the system. 5. Check LED status display for system status. 6. Check for proper grounding of vehicle's electrical circuit. 7. Check vehicle's hydraulic system 2. Certain functions do not work 1. Check the wiring connection from the system to the valve coil or the output function that does not work. 2. Check LED status display for system status. 3. Use frequency lock and lock to a good channel. 4. Check vehicle's hydraulic system 5. Check vehicle's electrical system 3. Function operates intermittently. 1. Check for loose connections. 2. Check LED status display for system status. 3. Check receiver antenna for any damage and proper connection. 4. Use frequency lock and lock to a good channel. 5. Check vehicle's hydraulic system VERSA REMOTE ERROR CODE CHART EC01 EC02 EC03 EC04 EC05 EC06 EC07 EC08 EC09 EC10 EC11 EC12 EC13 EC14 EC15 EC16 EC17 EC18 EC19 EC20 EC21 EC22 EC23 NO SIGNAL FROM PENDANT OR PENDANT POWER OFF SHORT OR OPEN CONNECTION ON SOURCE LOWER OUTPUT SHORT OR OPEN CONNECTION ON SOURCE RAISE OUTPUT SHORT OR OPEN CONNECTION ON C/S AXLE DOWN OUTPUT SHORT OR OPEN CONNECTION ON C/S AXLE UP OUTPUT SHORT OR OPEN CONNECTION ON S/S AXLE DOWN OUTPUT SHORT OR OPEN CONNECTION ON S/S AXLE UP OUTPUT SHORT OR OPEN CONNECTION ON DETECTOR LOWER OUTPUT SHORT OR OPEN CONNECTION ON DETECTOR RAISE OUTPUT SHORT OR OPEN CONNECTION ON LOWER BOOM LOWER OUTPUT SHORT OR OPEN CONNECTION ON LOWER BOOM RAISE OUTPUT SHORT OR OPEN CONNECTION ON UPPER BOOM RETRACT OUTPUT SHORT OR OPEN CONNECTION ON UPPER BOOM EXTEND OUTPUT SHORT OR OPEN CONNECTION ON ROTATE CCW OUTPUT SHORT OR OPEN CONNECTION ON ROTATE CW OUTPUT SHORT OR OPEN CONNECTION ON KNUCKLE FOLD OUTPUT SHORT OR OPEN CONNECTION ON KNUCKLE UNFOLD OUTPUT SHORT OR OPEN CONNECTION ON UNLOADER VALVE OUTPUT SHORT OR OPEN CONNECTION ON E-STOP OUTPUT SIGNAL RECEIVED FROM TRANSMITTER WITH INCORRECT ID CODE REMOTE SYSTEM JOYSTICK PROBLEM REMOTE SYSTEM JOYSTICK NOT ALLOWED DATA LINK PROBLEM BETWEEN CONTROLLERS 15 VERSA REMOTE 16 VERSA REMOTE 17 SPECIFICATIONS TRANSMITTER Power supply ....................................................... 9.6 Volt Rechargeable, NIMH battery. Operating temperature - Radio ............................................ -30˚C to +70˚C Storage temperature........................................................ -40˚C to +100˚C Frequency ......................................................................... 902-928 MHz Transmit power ............................................................................ 1 mW Vibration ............................................................................ 3G to 200Hz Shock ...........................................................................................50G RECEIVER Power supply voltage ................................... 12V nominal, 9V to 35V transient Operating temperature - Radio ............................................ -30˚C to +70˚C Storage temperature........................................................ -40˚C to +100˚C Frequency ......................................................................... 902-928 MHz On/Off outputs ........................................................ 5.0 Amp. (Protected) Proportional outputs Frequency ...................................................... 200 Hz Vibration ............................................................................ 3G to 200Hz Shock ......................................................................................... 100G NEMA ........................................................................................ 12/13 VERSA REMOTE 18 There are no user-serviceable parts inside the Transmitter or the Receiver. Return the units to the KAR-TECH for service. Note: For operation with negative ground vehicles only. WARNING: The KAR-TECH VERSA REMOTE must be operated in compliance with all applicable safety regulations, rules, and practices. Failure to follow required safety practices may result in death or serious injury. The information, specifications, and illustrations in this manual are those in effect at the time of printing. KAR-TECH reserves the right to change specifications or design at any time without notice. VERSA REMOTE 19 INSTRUCTION TO THE USER: This equipment has been tested and found to comply with the limits for a class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: * Reorient or relocate the receiving antenna. * Increase the separation between the equipment and receiver. * Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. * Consult the dealer or an experienced radio/TV technician for help. This equipment has been certified to comply with the limits for a class B computing device, pursuant to FCC Rules. In order to maintain compliance with FCC regulations, shielded cables must be used with this equipment. Operation with non-approved equipment or unshielded cables is likely to result in interference to radio and TV reception. The user is cautioned that changes and modifications made to the equipment without the approval of manufacturer could void the user's authority to operate this equipment. The term "IC:" before the certification/registration number only signifies that the Industry Canada technical specifications were met. Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device. VERSA REMOTE 20
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