Cattron North America M840-90HP User Manual

Laird Controls North America Inc. Users Manual

Contents

Users Manual

1994 CATTRON INCORPORATED SECTION 1 – PAGE 1TOGGLE STYLE CONTROLLER SECTION 1PRODUCT DATA AND SPECIFICATIONSINTRODUCTION - Designed specifically for roughheavy duty applications, the T01 toggle style radio remotecontroller is ideal for steel mill, steel service center andother severe industrial applications. Its functionaloperation is customized to duplicate the operatingcharacteristics of the controls most commonly found incrane and locomotive cabs. Therefore the change frommanual to radio control is easily learned by operators.This controller has a sophisticated electronics circuitboard using micro-computer digital circuitry. It isprotected by a sturdy thick-walled, anodized aluminumhousing with specially designed tough rubber endcaps.Extensive use of seals and gaskets provides all weatherprotection for the electronics circuit board which usesindustrial rated digital components, a powerful micro-computer and flexible operating software code.Some significant performance and safety features:POWER ON SELF TEST DIAGNOSTICS - When theoperator first turns the power switch on, a sophisticatedself-test routine tests the microcomputer and inputintegrated circuits to detect a failure. Any optional paddlestyle switches are tested for neutral at this time. A smallspeaker beeps twice when the test is complete & all isokay.FAILURE MESSAGE - If a motion function switchcircuitry failure occurs, it is recognized as a problem and“locked out” from any further input. A special message issent to the receiver/decoder to advise maintenancepersonnel of the problem. The message is both displayedand stored in the datalog of the Cattron 864 decoder.TOGGLE SWITCH PLACEMENT - Each layout iscustomized according to user needs. The levers areplaced far enough apart to accommodate operators whowear heavy gloves.TRANSMIT/BATTERY CHARGE INDICATOR - Thelow battery detection circuit is a two stage design. With agood battery, this indicating light flashes green for eachburst of transmitted data. If the battery voltage dropsbelow the normal level, this LED flashes red during eachtransmission. A beeping sound every 10 seconds alertsthe operator. When this happens, the battery hasapproximately one hour of operating time remaining. Thecontroller stops transmitting before the voltage drops solow that erratic operation could occur. An optionalcharging jack allows battery recharging without batteryremoval.BATTERY OPTIONS - AA alkaline batteries, alkalinepacks, NICAD and mercury batteries are available.Whether you choose rechargeable or disposable batteries,changing the battery is easy - simply open the gasketedbattery cover, drop the battery in place and close the cover.There are no wires or connectors to insert into the battery,which improves long-term reliability of this unit.SAFETY BAR - A full length safety bar is provided tofunction as an enable device to all motion switches. It is alarge full-length switch that is easily and naturally activatedby the thumb or palm of the operator's hand any time heplaces his hand into position to move the motion switches.This push-to-operate (PTO) safety bar electronicallydisconnects all motion switches when it is released, thusstopping motion commands from' these switches. Thisfeature is programmable. Certain applications may havesome switches removed from control of the PTO bar. Anexample of this is the brake function of a locomotive.RUGGED HOUSING - The housing that surrounds andprotects the electronic circuitry is a thick-walled extrudedaluminum, which has a hard anodized exterior. The ends ofthe housing are rubber coated plates that make shockabsorbing end 'bumpers" which shield the toggle switches.DURABLE/OUTDOOR OPERATION - The toggleswitches are extremely long lived units that are sealed,providing water and dust protection. All modules and sub-components are gasketed, making this unit suitable foroutdoor operation in rain and snow.ADDITIONAL EMERGENCY STOP - An optional tiltswitch is available with this model. If the controller is tiltedin any axis beyond 451 of upright for longer than theprogrammed time (typically 5 seconds), a programmablefunction is sent automatically. This function can beassigned in the decoder to stop the equipment, sound analarm, or both. Reset time is also programmable.FREQUENCY OF OPERATION - A variety of RFtransmitters can be built into this model allowing operationin 72-76, 402-420, and 450-470 MHz bands on licensedradio channels and 447-471 MHz on unlicensed channels.Most models in the 450 MHz range are synthesized (16frequency max).
SECTION 1 – PAGE 21994 CATTRON INCORPORATEDAPPLICATIONS - The T01 toggle type control unit canoperate any digital Cattron Series receiver/decoder builtby Cattron Incorporated. It can be used with existingsystems as a replacement or as an extratransmitter/encoder.
1994 CATTRON INCORPORATED SECTION 3 - PAGE 3STANDARD SPECIFICATIONSCase Material................................................ Anodized Aluminum Extrusion with Molded Rubber End CapsWeight ...........................................................3 lbs. (1. 1 Kgs), (1 2 Toggle Unit) Including Battery PackDimensions....................................................Height: 9.75 in. (25.0 cm) Depth: 4 in. (1 0.0 cm) Width: 3.75 in. ( 9.5 cm)Environmental ..............................................-4° F to + 140° F (-20° C to + 60° C), RH 0 to 95% Non-condensingNumber of Functions ...................................40 On/Off (space permitting) or 2 Analog with 30 On/Off max.Switch Type...................................................Spring Return to Center, Maintained, Pushbutton, Rotary Select, etc.Lever Switch Choices....................................Detented (5 Steps Each Side of Center) or Stepless (Analog)(2 maximum, side mounted)..........................Spring Forward Idle and 8 Steps For Throttle, etc.Lever Styles (side mounted)..........................Large Flag Type, Special Shapes OptionalPush To Operate Safety Bar.........................StandardLever Guards.................................................OptionalLabeling ........................................................Custom, Reverse Engraved Polycarbonate and Multi-layered MylarDiagnostic Port to IBM PC .......................StandardKeylock Switch..............................................Standard (Power On/Off)Security..........................................................An optional ‘keyless entry code" is available.Antenna.........................................................Internal (External Optional)Low Battery Indicator...................................2 Color LED: Green - Battery Normal; Red - Battery LowMicro-Controller...........................................80C51 FamilyShort Circuit Protection ...............................Automatically Resetable Pollyswitch (No Fuses)Conformal Coating.......................................Standard on PC BoardTransmitter Frequency.................................Synthesized 425-447 MHz or 447-471 MHzPower Output................................................447-473 MHz: 450 mW Maximum 425-447 MHz: 450 mW MaximumEmission/Modulation ...................................14KOF1 D ± 2.5 KHz for 100%Synthesized Channels ...................................16 Maximum (Factory Programmed)
SECTION 3 – PAGE 4 1994 CATTRON INCORPORATEDFEATURES SUMMARY• MaterialExtruded aluminum body with fiberglass sides covered with molded rubber. These sides are designed as a switchguard. They are held in place with stainless steel screws.• Battery Compartment and DoorA large, hinged door with gaskets covers the battery tray, which is separated from the electronics by the main body.A metal latch holds the door in place.• Battery Connection and Electrical ProtectionElectrical connections are by stainless steel springs with a wiping action that makes contact when the battery isplaced into the tray. Electrical short-circuit protection is built into the battery tray via a Pollyswitch' device. Thisdevice resets once the short is cleared and there are no fuses to replace.• Weight and DimensionsThe standard 12 toggle unit weighs approximately 3 pounds and is 9.75 inches high x 3.75 inches wide x 4 inchesdeep. (A chest pack unit with one or two side-mounted lever switches is the same height, 2 inches wider per switchadded, and has little noticeable weight change.)• Battery ManagementThere is a two stage battery condition indicator light, which FLASHES GREEN when the unit is ON and the batteryis OK. It FLASHES RED when the battery is low and sounds a beeper to alert the operator. The indicator is OFFwhen the battery is dead. A LOW BATTERY CUTOFF CIRCUIT stops the micro-processor when voltage goesbelow safe operating range. RF transmitters always operate at full power over the entire life of the battery.• LabelingA large easy-to-read reverse engraved custom faceplate is nearly indestructible. It has large letters that won't wearoff or fill with dirt.• Waterproofing/DustproofingThere is extensive gasketing throughout construction. Each switch is totally sealed as are the battery door and endplates. The circuit board is conformal coated.• Switch Protection From Accidental OperationRubber sides guard the toggle switches from most accidental bumps. A convenient palm-operated bar must bepressed to allow any motion switch electrical operation. Simply releasing the PTO bar stops all motion.• Side-mounted Lever StylesOne or two side-mounted lever pods can be installed as an option. Standard units have a large easy-to-locate andcomfortable 'FLAG' style paddle. Shaped knobs are available as an option.• Self Diagnostics CapabilitiesThere is extensive power ON self-testing with two beeps from the beeper. A standard tilt switch and beeper are usedto check all switches (ACTIVATED BY HAVING THE UNIT TILTED WHEN POWER IS TURNED ON). Adiagnostic port is standard to allow connection to an IBMO PC for in-depth analysis by technicians.• Interconnection Circuitry and ConnectorsFlex circuits are used intensively to reduce wiring and improve reliability. Connectors are goldplated throughout.• Synthesized RF TransmittersUsed in most 450 MHz operations, it reduces the spare controller requirements. Models with up to 16 RF channelsare available.
1994 CATTRON INCORPORATED SECTION 3 - PAGE 5TOGGLE STYLE CONTROLLER SECTION 3OPERATION INSTRUCTIONS (GENERAL)The custom Radio Remote controller unit attempts to duplicate all functions normally found in the cab of acrane or locomotive that is being remote controlled. It contains all basic control functions and may also beequipped with some of the auxiliary control functions described. It is carried and operated at the hip or chestposition using a specially designed carrying strap.BASIC CONTROL FUNCTIONS1. Power On/Off Switch - This switch is located on theleft side of the unit, prevents unauthorized personnelfrom operating the system, and controls the batterypower of the control transmitter. When the switch isON, the operator can control all auxiliary functionswithout pressing the PUSH-TO-OPERATE bar (nomotor functions). The power on/off switch controls amainline magnetic contactor on the machine which inturn controls the main power to the motors.2. Push-To-Operate Bar (PTO) - This bar is a spring-return switch located on top of the unit and MUST beoperated simultaneously with all motion control toggleswitches. (Not required for auxiliary functions, i.e.magnet, lights, etc.) In special cases like locomotivebrakes, the PTO is not required. Refer to the customdescription of controller functions for each job. Thissafety feature, commonly referred to as the “DeadmanControl,” is conveniently located so that it may bepressed with the thumb or palm of either hand, leavingthe fingers free to operate other switches. This switchis used to select diagnostic mode if held down whilepower is turned on. See the maintenance section fordetails.3. Motor Control Toggle Switches - These switches,located across the front of the unit, are the motorfunction control switches.These switches are usually three (3)position, spring return-to-center switches,maintained two (2) position switches, orpushbuttons. For cranes with steppedoutput there are forward (or down)positions, reverse (or up) positions, and acenter “off” (or neutral) position. Each ofthe toggle switches selects a differentmotor speed. The motor speed increasesas the different switches are selected andmoved away from the center position ineach direction.Locomotive controllers with optional sidelever positions are laid out according toyour requirements and you should refer tothe special drawings in the back of thismanual. Normal configuration is: Leversfor the THROTTLE on the right side, forthe BRAKE on the left side, and all otherfunctions use toggle or pushbuttonswitches.Refer to special operation descriptions and“as built” drawings for specificinformation.
SECTION 3 – PAGE 6 1994 CATTRON INCORPORATEDCARRYING HARNESSThe carrying harness consists of a shoulder strap with hooks.A special carrying harness with a chest carrying design is available - see the accessory section of this manualfor details of wearing and ordering.OPERATING PROCEDUREPut on the carrying harness, following instructions for the particular harness used. Attach the controller tothe harness and adjust for comfortable operation.Basic Control Unit Operation:CAUTION: Make certain that the Push-To-Operate bar is not jammed down.The PTO bar must be up when starting the controller. Holding the PTO bardown places they system in diagnostic mode. The system will not operate.See the maintenance section for details.1. If equipped, insert the key into the key switch on the left side of the unit and turn the key to the ONposition. Observe that the transmit LED is flashing green If red, refer to battery charging instructions. Ifsteady green, it is in diagnostic mode, refer to the maintenance section.If equipped with the optional "Keyless Entry Code" feature, an assigned sequence of function switchesmust be operated within 10 seconds after the power switch is turned on. The switches will not operate anyfunctions. The controller power comes on only after the correct sequence has been entered.2. Place the thumb or palm of either hand on the push-to-operate bar on top of the unit. This switch must bedepressed before any motor command may be initiated.3. Operate the motion control toggle switches as required, remembering that the toggles must be pulledupward for all reverse and up motions and pushed down for all forward and down motions. A speedincrease is obtained by selecting different, appropriately marked toggle switches. Compass directionlabels may be engraved by appropriate switches. Custom engraving is provided by CATTRON with allnew controllers if notified prior to assembly.4. While commanding a motion with a switch, release the Push-To-Operate bar without centering the switch .The motion must stop - if this does not happen, turn off the power and notify your supervisor immediately.OPERATOR ACCESSIBLE ADDRESS SELECTOR SWITCHESFor a variety of reasons, these controllers are sometimes equipped with address and frequency select switches,allowing control of multiple cranes or locomotives with one controller. Extreme caution should be used toinsure that the operator does not inadvertently select the wrong crane.
1994 CATTRON INCORPORATED SECTION 3 - PAGE 7CAUTION: After changing a frequency select, crane select switch, trolley select, hoist select, orany other selector switch, be extra cautious and verify that the desired unit is under control. Start bycommanding a function like HORN and proceed with care - Failure to do so can cause injury or death.
SECTION 3 – PAGE 8 1994 CATTRON INCORPORATEDTOGGLE STYLE CONTROLLER SECTION 4FCC REGULATIONS & COMPUTER SOFTWARE COPYRIGHTSFCC REGULATIONSFCC Regulations state that:1. These toggle style controllers are approved by the FCC for licensed operation . No modifications tothe design are permitted. A station license is required by the FCC.2. The RF power output of a radio transmitter shall be no more than that required for satisfactorytechnical operation considering the area to be covered and local conditions.3. Frequency and deviation of a transmitter must be checked before it is placed into service and should berechecked once each year thereafter.COMPUTER SOFTWARE COPYRIGHTSThe Cattron Incorporated products described in this manual may include copyrighted Cattron Incorporatedcomputer programs stored in semiconductor memories or other media. Laws in the United States and othercountries preserve for Cattron Incorporated certain exclusive rights for copyrighted computer programs,including the exclusive right to copy or reproduce in any form the copyrighted computer program.Accordingly, any copyrighted Cattron Incorporated computer programs contained in the Cattron Incorporatedproducts described in this manual may not be copied or reproduced in any manner without the express writtenpermission of Cattron Incorporated. Furthermore, the purchase of Cattron Incorporated products shall not bedeemed to grant either directly or by implication, estoppel, or otherwise, and license under the copyrights,patents, or patent applications of Cattron Incorporated, except for the normal non-exclusive, royalty freelicense to use that arises by operation of law in the sale of a product.

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