Atlas Polar 9900R CONTROLS HYDRAULIC CRANES USING FHSS IN 902-928 MHZ User Manual USERS MANUAL

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Document ID	949361
Application ID	DkuTETfitIP93QfRmHVfhw==
Document Description	USERS MANUAL
Short Term Confidential	No
Permanent Confidential	No
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Document Type	User Manual
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Date Submitted	2008-05-30 00:00:00
Date Available	2008-06-02 00:00:00
Creation Date	2008-05-26 11:57:08
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Document Lastmod	0000-00-00 00:00:00
Document Title	USERS MANUAL
Document Creator	Canon iR5570/iR6570

RADIO REMOTE CONTROL
MANUAL
POLAR REMOTE CONTROLS PART NUMBER 600-369-07
DIVISION OF ATLAS POLAR COMPANY LTD. REV. #0
60 NORTHLINE RD. MARCH 2008
TORONTO ONTARIO M4B 3E5
WARRANTY REGISTRATION
Polar Radio Remote Control (Division of Atlas Polar Company Limited)
60 Northline Road, Toronto, Ontario M4B 3E5
1. ATLAS POLAR COMPANY LIMITED warrants the remote controls to be free from defects in
materials or workmanship for a period of one (1) year from the date of delivery to the purchaser.
NOTE: Control cables are specifically excluded from this or any other warranty.
2. During the Warranty period, Atlas Polar will repair or replace the detective goods at its sole
discretion.
3. Labour charges at authorized rates to correct such defects will be covered under warranty when f
incurred at Atlas Polar‘s premises or an authorized Atlas Polar distributor.
4. This warranty does not cover the repair of damage or failure brought about by abuse, neglect, wear
and tear, improper installation, drilling holes in the system or where evidence exists that the
equipment has been repaired, tampered with or altered by unauthorized personnel. Such
judgements shall be made at Atlas Polar's sole discretion.
5. Electronic modules which are part of the equipment shall have an extended period of ooverage.
Electronic modules, subject to the exceptions stated above, shall be repaired or replaced for a
period of two years from the date of delivery to the purchaser. This extended warranty shall not
cover any labour charges during the second year of coverage,
6. Atlas Polar Company Limited shall in no event be liable for consequential damages or contingent
liability assumed through the failure of the product to operate properly.
Date Installed (mm/ddlyr)
Polar Remote Type: D 100 D 450 D 2100 D 2100MV D 2206 D 4100 D 5200
D Serial #
Cable Controller Radio Remote (Transmitter & Receiver)
Serial # Serial it
Customer Information Dealer Information
Name Name
Address Address
City Prov City Prov
Telephone Telephone
NOTE:
1. This warranty is not valid outside the province of Ontario unless it is stamped and signed by the
authorized dealer.
2. In Ontario, this warranty must be approved and signed by an authorized representative of Atlas Polar
Company Limited.
3. To validate the warranty, this form must be filled out completely and returned to Polar
Remote Control within seven days of installation.
ATLAS POLAR COMPANY LIMITED
60 NORTHLINE ROAD
TORONTO, ONTARIO
M4B 3E5
Please note:
This manual will only discuss the operation of the Radio Remote Control System,
not the overall system. To understand the complete unit package, installation, operation
and maintenance, ALL equipment manuals should be read thoroughly.
The Polar 21008/4100/5200 works in conjunction with the Radio Remote, therefore the Polar
21008/4100/5200 operator’s manual should be read in its entirety.
POLAR RADIO REMOTE SYSTEM
This device complies with part 15 of the FCC rules. Operation is subject to the following
two conditions: (1) This devise may not cause harmful interference, and (2) This device
must accept any interference received, including interference that may cause undesired
operation.
NOTE: The manufacturer is not responsible for any radio or TV interference caused by
unauthorized modifications to this equipment. Such modifications could void the user’s
authority to operate the equipment.
POLICY
Our policy is one of continuous improvement and we reserve the right to alter
any detail of our products at any time without notice.
ATLAS POLAR COMPANY
POLAR REMOTE CONTROL DIVISION
RADIO REMOTE MANUAL
FOREWARD
POLAR 9900R
SYSTEM
Frequency:
Operating Temperature
Transmission Range
Data Transmission
Addressing
Approved by
Operating Licensing
RECEIVER
Operating power
System
TRANSMITTER
Power supply
Operating Time
Functions
Housing
Dimensions
ATLAS POLAR COMPANY LIMITED
TECHNICAL DATA
902—924 MHz Frequency Hopping Spread Spectrum
-25°C to +50°C
122 m or 400 feet
11 bytes including Identity and CRC error values
Programmable. 65,500 unique addresses
Pending
Not required
9900 RX
12V DC (Obtained directly from Polar Remote unit)
Narrow band tuner for FM frequency hopping spread
spectrum
9900 TX
8.4V high performance NiMH rechargeable battery with
internal smart charging using AC adapter, or cigarette lighter
8 — 10 hours of continuous operating time
Standard Polar Remote lever version controlling 6
proportional functions
Extra on/off functions available with either latching or
momentary operation
Weather resistant and durable casing equipped with guard
and belt
51/2"x12”x 5” (H x L x D)
V RADIO REMOTE MANUAL
FOREWARD
l‘ln - on
SECTION TWO
OPERATION
TRANSMITTER
The radio controller transmitter is the part of the Radio Remote Control system, used by the
operator to inform the receiver to manipulate the actuator box and control the crane.
The controls available to the operator include a red mushroom head switch and six control
levers, one for each crane function.
The mushroom head switch (E—stop) places the entire system in STAND BY or OPERATE
MODE, works as ON/OFF switch too.
The control levers are spring loaded and always return to the centre position when released by
the operator. The control levers are directly attached to potentiometers. As a control lever is
moved, a signal from the potentiometer changes. This change is sensed by the electronic
module at the main unit that in turn drives the corresponding actuator to a new position. The
greater the movement of control lever the further the actuator travels, and the faster the crane
moves.
The system is designed to allow all six functions to be electronically controlled so that they may
operate simultaneously. However, the hydraulic flow from the pump will not produce enough oil
for all six functions at one time.
Auto Shutdown
if there is no movement of the control lever or multifunction switches for 6 minutes, the
LED #1 will be solid red. This alarm state & state timer will reset each time control lever is
moved or multi function switch is activated (red LED #1 will go off). If the alarm state is allowed
to go toranothere minutes (total ot12 minutes), the unit will stop transmitting the LED #1 will go
out but LED #2 will stay green. The transmitter will stay active for 12 minutes and will go in
shutdown mode. To operate again, the radio control system mushroom switch on the transmitter
has to be reset.
RADIO REMOTE CONTROL MANUAL
SECTION TWO
TRANSMITTER POWER/BATTERY INDICATOR
FUNCTION STATUS STATUS
LED 1 LED 2
Charger plugged in to transmitter and charger voltage okay. Green solid ON OFF
Charger plugged into transmitter and no battery installed Green solid ON stays green OFF
in the transmitter.
Charger plugged into transmitter (battery installed) Red flashing 1/2 second ON OFF
10 second OFF
(when red OFF, green ON)
Charger plugged into transmitter. After 10 minutes of Red flashing OFF
verifying condition of battery full charge begins 1/2 second ON
1/2 second OFF
Battery fully charged (as long as charger plugged in) Red solid ON OFF
Transmitter switch ON with mushroom head switch out. Flashes red twice. Solid Green
Transmitter battely charge is good. ON
Transmitter switch ON and no levers or push buttons Red solid ON Solid Green
operated for 6 minutes. The transmitter will go into alarm 0N
mode.
If the alarm modes is allowed to go on for 6 minutes OFF Solid Green
(transmitter will go out of alarm mode whenever any control ON
lever, or pushbutton is activated), the transmitter will stop
transmitting.
Flashes red 3 times and '
Transmitter switched ON with mushroom head switch OUT. oscillates every 10 seconds. SOI'd Green
Transmltter battery low power.
R d Id 0 '
Transmitter switched ON and any levers or switch [not in e SDI N gill” Green
neutral position at start up.
(Function out of neutral position will default to no output,
until it centers. All other functions will operate)
Ab . . . . Red flashes twice and goes Solid Green
ove function not in neutral posmon at start up when OFF ON
returned back to neutral position.
RADlO REMOTE CONTROL MANUAL
SECTION TWO
TRANSMITTER POWER SUPPLY
Transmitter module is powered by a 8.4 volt NiMH rechargeable battery pack.
NiMH is a relatively new battery technology, having higher charge capacities and longer run
times than older NiCd batteries, and do not suffer from the dreaded “memory effect“.
NiMH has a much more continuous voltage response than NiCd. Only towards the very end
of its charge does it begin to fall off. When you see this happening, recharge your batteries
immediately for best performance.
NiMH batteries reach their absolute maximum charge capacity within 2—5 hour full
charge/discharge cycles. It is not required to “condition" them by charging/discharging
several times. Simply use the cells normally, knowing they will attain full capacity after
several charge cycles.
TRANSMITTER BATTERY CHARGING INSTRUCTIONS
The battery can be charged with a spare battery charger, a Polarcigarette lighter adapter, orthe
Polar 115V AC adapter.
To charge the E—Stop switch should be in OFF position. Full charge cycle does not begin until
after 10 minutes of being in charge mode. it is recommended to leave the charger plugged for at
least 341 hours with E—Stop in the OFF position.
The battery charging system is integrated in the transmitter and uses a quick charge system.
The charging system uses intelligent voltage sensing to prevent over charging of the battery.
Leaving the charger plugged in after the charging is complete or disconnecting the charger
before the charge is complete will not damage the battery, but as batteries have a finite number
of charge/discharge cycles it may result in replacement of battery more often.
harge battery should provide approximate
RADlO REMOTE CONTROL MANUAL
SECTION TWO
STEP 1
(SEE NOTE) AC SOCKET
AC CHARGER
NOTE:
~ TO AVOID ANY SHORTS
PLUG IT STRAIGHT
P 052— 01—1130
TRANSMITTER BATTERY CHARGING
RADIO REMOTE CONTROL MANUAL
SECTION TWO
EMERGENCY SWITCH
The emergency switch on your radio remote system, is incorporated into the complete
Polar 2100814100/5200 system in the form of a locking red mushroom head switch.
When this switch is pressed in and locked, two safety features are activated:
(1) The hydraulic oil is diverted from the crane and dumped back to the tank,
to prevent accidental hydraulic movement.
(2) The Polar 2100814100/5200 is placed in a standby mode.
To regain radio control, release the emergency button by turning clockwise the
mushroom head switch so that it pops into the OUT position.
RADlO REMOTE CONTROL MANUAL
SECTION TWO
N.
N.
WAIST BELT INSTALLATION. LOWER POSITIONA
RECEIVER
The receiver processes all data that is transmitted by the transmitter.
Before data is accepted, the receiver will first confirm that the correct communicator link
has been received. After this has been verified, it will begin to process the data input and
relay the information to the Polar 21008/4100/5200 actuator.
During the transfer of information, the receiver continuously checks the data for the correct
communication link.
The receiver obtains its power and sends its control signals to the Polar actuator through
the standard 10 pin connector and cable.
To operate the remote control, simply plug the receiver into the actuator connector point.
With the transmitter and main power ON, the receiver will power up and begin
communicating with the Polar actuator.
The receiver must be powered up before the transmitter. Upon powering up the
transmitter, there is about a 1 second delay while the transmitter and receiver synchronize
communication before the system is active. When the communication task is completed,
the transmitter should be powered down with the e—stop to preserve battery power. If the
communication has been stopped due to pressing ofan E-stop, powering down, or loss of
range, the communication may be resumed by cycling the power switch.
RADIO REMOTE CONTROL MANUAL
SECTION TWO
RECEIVER INSTALLATION
The receiver circuit board is installed inside a weatherproof enclosure and must be
mounted behind the polar actuatoras shown in the drawing. The control cable connec or
can be left plugged into the unit and locked in place permanently. The sealing ring of the
connector will provide protection against water damage and corrosion.
POLAR RECEIVER
Pneumbw—m
2100 [783755200
JUhéI'IDN aux
RECEIVER
MOUNTING BRACKET
PTJGUD-SSE—DJ
POLAR ACTUATOR
uoummc BRACKET
PR1051~GDI—1RD
RADIO REMOTE CONTROL MANUAL
SECTION TWO
Brown
Red
Orange
Yellow
Blue/Back
Blue
Yellow/Black
Red/Black
Black
Orange/Black
Figure 3: Shows the Control Cable Connector Wiring.
10
10
_—I—_
RADIO REMOTE CONTROL MANUAL
SECTION TWO
ORANGE/sum MONITOR
mum/Bum a m ;
snow. cum/r
09mm ouwur
opmm oun’vr
9?an ourPur
99mm. ouwur
cu wnn ANY 09mm 11qu
ALWAYS oN mm REWVER an
5m; FUllcm‘lM c
BLUE/SLACK rummu 5
wow Fuficflon 4
(mm: nmcmm 3
an flmcnmi z
Bfilmll mncmu |
MACK 5mm —
Ran/sum BATTERY +
RECEIVER LABEL PR800—807—01—7R0
Figure 4: Shows the Radio Receiver connector strip with control cable wires
Identified by colour code.
11
RADIO REMOTE CONTROL MANUAL
SECTION TWO
SAFETY
AT ANY SIGN OF RADIO REMOTE CONTROL SYSTEM FAILURE YOU SHOULD:
(1) PRESS THE EMERGENCY SWITCH.
(2) DISENGAGE THE P.T.O.
(3) TURN THE MAIN POWER CAB SWITCH OFF
You may want to investigate further by substituting the cable controller, with the P.T.O.
off, to see if the problem still occurs.
DO NOT engage the P.T.0. until you are confident the unit is working properly.
If a problem continues, do not operate the equipment. Take your equipment to a Polar
Remote Control authorized service outlet.
If problem does not continue with cable remote operate crane with cable remote and
ship radio remote (transmitter and receiver) to authorized service outlet.
PRE-OPERATIONAL CHECKS
Before operating the equipment always check your remote control system thoroughly as
part of your pre—operation inspection routine before engaging the P.T.O. and operating
the crane. (Refer to Polar 21008/4100/5200 operator manual for instructions on pre-
operational check).
NEVER use the equipment of there is any sign of jerky, unsafe or intermittent
operation.
12
RADlO REMOTE CONTROL MANUAL
SECTION TWO
OPERATIONAL
Using the Polar Radio Remote Control system allows the operator a greater range of
movement around the crane. With this added manoeuvrability, it is possible that the
operator will not be in view of others who enter the job site.
It is very important to place safety pylons and signs around the working area to indicate that
the crane is in operation and may start to move at any time.
To prevent erratic operation when using the Radio Remote Control, please note the
following:
DO NOT...
1. ...operate the unit with low battery power.
2 ...operate during heavy rain or snowstorms.
3. ...operate in temperatures lower that -25°C.
IN ALL THE ABOVE SITUATIONS, THE CABLE HAND-HELD CONTROLLER SHOULD
BE USED.
A NOTE REGARDING THE OPERATION OF THE RECEIVER:
A special safety feature has been built into the receiver. If radio contact between the
transmitter and the receiver happens to be lost, the receiver is designed to enter into a
‘FAIL-SAFE" condition.
In the fail-safe condition, the receiver will cause the Polar 2100814100/5200 actuator to
quickly decelerate and then stop any crane movement. The Polaractuator is then disabled
and the oil is diverted away from the crane, back to the tank.
To regain crane control, the operator must first restore the Radio contact (it may be possible
to restore radio contact if the operator simply walks a few steps to a different position)
and then reset the Emergency Stop switch once.
The receiver will recognize the Emergency Stop reset operation as a signal to restore
the Polar 21008/4100/5200 to an operational condition.
TOE EVENT PERSO.
VER OPERAT o
13
RADIO REMOTE CONTROL MANUAL
SECTION TWO
CARE AND MAINTENANCE
TRANSMITTER:
The Polar Remote transmitter is a ruggedly designed instrument and will withstand normal
field use. However, as with any electronic device, care should be taken not to subject the
transmitter to excessive abuse.
The transmitter housing is made of a durable material and will serve through many years of
usage. The toggle switches are of industrial grade and are environmentally sealed.
The battery pack will provide several years of reliable service under normal conditions.
Service life may be reduced by extreme temperatures or excessive overcharging. Use the
Quick Charger supplied to recharge the battery pack. The battery pack will need
replacement when it no longer holds a charge.
To remove dirt, grease, oil etc. from the housing, wipe with a cloth soaked with soap and
water. for more difficult stains, a light alcohol—based cleaner should be used.
RECEIVER:
The receiver should be protected from moisture such as rain, snow, mud or spray.
Dirt and grease can be removed from the chassis using soap and a damp cloth. Mild
petroleum solvents can be used if they are washed away using soap and a damp cloth.
There are no user serviceable parts inside the receiver chassis. Note that damage to the
receiver‘s electrical may result due to static electricity if the electronic circuit board inside the
receiver chassis is handled improperly.
For service, contact a Polar Remote Control authorized service facility.
14
RADIO REMOTE CONTROL MANUAL
SECTlON TWO
POLAR RADIO REMOTE CONTROL WARRANTY
ATLAS POLAR COMPANY LlMITED warrants the Radio remote controls to be free
from defects in materials or workmanship for a period of one (1 ) year from the date
of delivery to the purchaser.
NOTE: Control cables are specifically excluded from this or any other
warranty.
During the Warranty period, Atlas Polar will repair or replace the defective goods
at its sole discretion.
Labour charges at authorized rates to correct such defects will be covered
undewvarranty when incurred at our or authorized Atlas Polar distributor's
premises.
This warranty does not cover the repair of damage or failure brought about by
abuse, neglect, wear and tear, and improper installation or where evidence exists
that the equipment has been repaired, tampered with or altered by unauthorized
personnel. Such judgements shall be made at Atlas Polal‘s sole discretion.
Atlas PolarCompany Limited shall in no event be liable for consequential damages
or contingent liability assumed through the failure of the product to operate
properly.
15
RADIO REMOTE CONTROL MANUAL
SECTION TWO

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