Cattron North America M840-90HP User Manual

Laird Controls North America Inc. Users Manual

Contents

Users Manual

1994 CATTRON INCORPORATED SECTION 1 – PAGE 1
TOGGLE STYLE CONTROLLER SECTION 1
PRODUCT DATA AND SPECIFICATIONS
INTRODUCTION - Designed specifically for rough
heavy duty applications, the T01 toggle style radio remote
controller is ideal for steel mill, steel service center and
other severe industrial applications. Its functional
operation is customized to duplicate the operating
characteristics of the controls most commonly found in
crane and locomotive cabs. Therefore the change from
manual to radio control is easily learned by operators.
This controller has a sophisticated electronics circuit
board using micro-computer digital circuitry. It is
protected by a sturdy thick-walled, anodized aluminum
housing with specially designed tough rubber endcaps.
Extensive use of seals and gaskets provides all weather
protection for the electronics circuit board which uses
industrial rated digital components, a powerful micro-
computer and flexible operating software code.
Some significant performance and safety features:
POWER ON SELF TEST DIAGNOSTICS - When the
operator first turns the power switch on, a sophisticated
self-test routine tests the microcomputer and input
integrated circuits to detect a failure. Any optional paddle
style switches are tested for neutral at this time. A small
speaker beeps twice when the test is complete & all is
okay.
FAILURE MESSAGE - If a motion function switch
circuitry failure occurs, it is recognized as a problem and
“locked out” from any further input. A special message is
sent to the receiver/decoder to advise maintenance
personnel of the problem. The message is both displayed
and stored in the datalog of the Cattron 864 decoder.
TOGGLE SWITCH PLACEMENT - Each layout is
customized according to user needs. The levers are
placed far enough apart to accommodate operators who
wear heavy gloves.
TRANSMIT/BATTERY CHARGE INDICATOR - The
low battery detection circuit is a two stage design. With a
good battery, this indicating light flashes green for each
burst of transmitted data. If the battery voltage drops
below the normal level, this LED flashes red during each
transmission. A beeping sound every 10 seconds alerts
the operator. When this happens, the battery has
approximately one hour of operating time remaining. The
controller stops transmitting before the voltage drops so
low that erratic operation could occur. An optional
charging jack allows battery recharging without battery
removal.
BATTERY OPTIONS - AA alkaline batteries, alkaline
packs, NICAD and mercury batteries are available.
Whether you choose rechargeable or disposable batteries,
changing the battery is easy - simply open the gasketed
battery 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 to
function as an enable device to all motion switches. It is a
large full-length switch that is easily and naturally activated
by the thumb or palm of the operator's hand any time he
places his hand into position to move the motion switches.
This push-to-operate (PTO) safety bar electronically
disconnects all motion switches when it is released, thus
stopping motion commands from' these switches. This
feature is programmable. Certain applications may have
some switches removed from control of the PTO bar. An
example of this is the brake function of a locomotive.
RUGGED HOUSING - The housing that surrounds and
protects the electronic circuitry is a thick-walled extruded
aluminum, which has a hard anodized exterior. The ends of
the housing are rubber coated plates that make shock
absorbing end 'bumpers" which shield the toggle switches.
DURABLE/OUTDOOR OPERATION - The toggle
switches are extremely long lived units that are sealed,
providing water and dust protection. All modules and sub-
components are gasketed, making this unit suitable for
outdoor operation in rain and snow.
ADDITIONAL EMERGENCY STOP - An optional tilt
switch is available with this model. If the controller is tilted
in any axis beyond 451 of upright for longer than the
programmed time (typically 5 seconds), a programmable
function is sent automatically. This function can be
assigned in the decoder to stop the equipment, sound an
alarm, or both. Reset time is also programmable.
FREQUENCY OF OPERATION - A variety of RF
transmitters can be built into this model allowing operation
in 72-76, 402-420, and 450-470 MHz bands on licensed
radio channels and 447-471 MHz on unlicensed channels.
Most models in the 450 MHz range are synthesized (16
frequency max).
SECTION 1 – PAGE 21994 CATTRON INCORPORATED
APPLICATIONS - The T01 toggle type control unit can
operate any digital Cattron Series receiver/decoder built
by Cattron Incorporated. It can be used with existing
systems as a replacement or as an extra
transmitter/encoder.
1994 CATTRON INCORPORATED SECTION 3 - PAGE 3
STANDARD SPECIFICATIONS
Case Material................................................ Anodized Aluminum Extrusion with Molded Rubber End Caps
Weight ...........................................................3 lbs. (1. 1 Kgs), (1 2 Toggle Unit) Including Battery Pack
Dimensions....................................................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-condensing
Number 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 Optional
Push To Operate Safety Bar.........................Standard
Lever Guards.................................................Optional
Labeling ........................................................Custom, Reverse Engraved Polycarbonate and Multi-layered Mylar
Diagnostic Port to IBM
PC .......................Standard
Keylock 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 Low
Micro-Controller...........................................80C51 Family
Short Circuit Protection ...............................Automatically Resetable Pollyswitch (No Fuses)
Conformal Coating.......................................Standard on PC Board
Transmitter Frequency.................................Synthesized 425-447 MHz or 447-471 MHz
Power Output................................................447-473 MHz: 450 mW Maximum
425-447 MHz: 450 mW Maximum
Emission/Modulation ...................................14KOF1 D ± 2.5 KHz for 100%
Synthesized Channels ...................................16 Maximum (Factory Programmed)
SECTION 3 – PAGE 4 1994 CATTRON INCORPORATED
FEATURES SUMMARY
• Material
Extruded aluminum body with fiberglass sides covered with molded rubber. These sides are designed as a switch
guard. They are held in place with stainless steel screws.
• Battery Compartment and Door
A 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 Protection
Electrical connections are by stainless steel springs with a wiping action that makes contact when the battery is
placed into the tray. Electrical short-circuit protection is built into the battery tray via a Pollyswitch' device. This
device resets once the short is cleared and there are no fuses to replace.
• Weight and Dimensions
The standard 12 toggle unit weighs approximately 3 pounds and is 9.75 inches high x 3.75 inches wide x 4 inches
deep. (A chest pack unit with one or two side-mounted lever switches is the same height, 2 inches wider per switch
added, and has little noticeable weight change.)
• Battery Management
There is a two stage battery condition indicator light, which FLASHES GREEN when the unit is ON and the battery
is OK. It FLASHES RED when the battery is low and sounds a beeper to alert the operator. The indicator is OFF
when the battery is dead. A LOW BATTERY CUTOFF CIRCUIT stops the micro-processor when voltage goes
below safe operating range. RF transmitters always operate at full power over the entire life of the battery.
• Labeling
A large easy-to-read reverse engraved custom faceplate is nearly indestructible. It has large letters that won't wear
off or fill with dirt.
• Waterproofing/Dustproofing
There is extensive gasketing throughout construction. Each switch is totally sealed as are the battery door and end
plates. The circuit board is conformal coated.
• Switch Protection From Accidental Operation
Rubber sides guard the toggle switches from most accidental bumps. A convenient palm-operated bar must be
pressed to allow any motion switch electrical operation. Simply releasing the PTO bar stops all motion.
• Side-mounted Lever Styles
One or two side-mounted lever pods can be installed as an option. Standard units have a large easy-to-locate and
comfortable 'FLAG' style paddle. Shaped knobs are available as an option.
• Self Diagnostics Capabilities
There is extensive power ON self-testing with two beeps from the beeper. A standard tilt switch and beeper are used
to check all switches (ACTIVATED BY HAVING THE UNIT TILTED WHEN POWER IS TURNED ON). A
diagnostic port is standard to allow connection to an IBMO PC for in-depth analysis by technicians.
• Interconnection Circuitry and Connectors
Flex circuits are used intensively to reduce wiring and improve reliability. Connectors are goldplated throughout.
• Synthesized RF Transmitters
Used in most 450 MHz operations, it reduces the spare controller requirements. Models with up to 16 RF channels
are available.
1994 CATTRON INCORPORATED SECTION 3 - PAGE 5
TOGGLE STYLE CONTROLLER SECTION 3
OPERATION INSTRUCTIONS (GENERAL)
The custom Radio Remote controller unit attempts to duplicate all functions normally found in the cab of a
crane or locomotive that is being remote controlled. It contains all basic control functions and may also be
equipped with some of the auxiliary control functions described. It is carried and operated at the hip or chest
position using a specially designed carrying strap.
BASIC CONTROL FUNCTIONS
1. Power On/Off Switch - This switch is located on the
left side of the unit, prevents unauthorized personnel
from operating the system, and controls the battery
power of the control transmitter. When the switch is
ON, the operator can control all auxiliary functions
without pressing the PUSH-TO-OPERATE bar (no
motor functions). The power on/off switch controls a
mainline magnetic contactor on the machine which in
turn 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 be
operated simultaneously with all motion control toggle
switches. (Not required for auxiliary functions, i.e.
magnet, lights, etc.) In special cases like locomotive
brakes, the PTO is not required. Refer to the custom
description of controller functions for each job. This
safety feature, commonly referred to as the “Deadman
Control,” is conveniently located so that it may be
pressed with the thumb or palm of either hand, leaving
the fingers free to operate other switches. This switch
is used to select diagnostic mode if held down while
power is turned on. See the maintenance section for
details.
3. Motor Control Toggle Switches - These switches,
located across the front of the unit, are the motor
function control switches.
These switches are usually three (3)
position, spring return-to-center switches,
maintained two (2) position switches, or
pushbuttons. For cranes with stepped
output there are forward (or down)
positions, reverse (or up) positions, and a
center “off” (or neutral) position. Each of
the toggle switches selects a different
motor speed. The motor speed increases
as the different switches are selected and
moved away from the center position in
each direction.
Locomotive controllers with optional side
lever positions are laid out according to
your requirements and you should refer to
the special drawings in the back of this
manual. Normal configuration is: Levers
for the THROTTLE on the right side, for
the BRAKE on the left side, and all other
functions use toggle or pushbutton
switches.
Refer to special operation descriptions and
“as built” drawings for specific
information.
SECTION 3 – PAGE 6 1994 CATTRON INCORPORATED
CARRYING HARNESS
The 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 manual
for details of wearing and ordering.
OPERATING PROCEDURE
Put on the carrying harness, following instructions for the particular harness used. Attach the controller to
the 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 bar
down 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 ON
position. Observe that the transmit LED is flashing green If red, refer to battery charging instructions. If
steady 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 switches
must be operated within 10 seconds after the power switch is turned on. The switches will not operate any
functions. 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 be
depressed before any motor command may be initiated.
3. Operate the motion control toggle switches as required, remembering that the toggles must be pulled
upward for all reverse and up motions and pushed down for all forward and down motions. A speed
increase is obtained by selecting different, appropriately marked toggle switches. Compass direction
labels may be engraved by appropriate switches. Custom engraving is provided by CATTRON with all
new 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 SWITCHES
For 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 to
insure that the operator does not inadvertently select the wrong crane.
1994 CATTRON INCORPORATED SECTION 3 - PAGE 7
CAUTION: After changing a frequency select, crane select switch, trolley select, hoist select, or
any other selector switch, be extra cautious and verify that the desired unit is under control. Start by
commanding a function like HORN and proceed with care - Failure to do so can cause injury or death.
SECTION 3 – PAGE 8 1994 CATTRON INCORPORATED
TOGGLE STYLE CONTROLLER SECTION 4
FCC REGULATIONS & COMPUTER SOFTWARE COPYRIGHTS
FCC REGULATIONS
FCC Regulations state that:
1. These toggle style controllers are approved by the FCC for licensed operation . No modifications to
the 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 satisfactory
technical 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 be
rechecked once each year thereafter.
COMPUTER SOFTWARE COPYRIGHTS
The Cattron Incorporated products described in this manual may include copyrighted Cattron Incorporated
computer programs stored in semiconductor memories or other media. Laws in the United States and other
countries 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 Incorporated
products described in this manual may not be copied or reproduced in any manner without the express written
permission of Cattron Incorporated. Furthermore, the purchase of Cattron Incorporated products shall not be
deemed 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 free
license to use that arises by operation of law in the sale of a product.

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