Cattron North America PS Industrial R/C Transmitter User Manual PS Controller Manaul

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Document Author:	Stuart Banks

PENDANT STATION CONTROLLER
OPERATION & MAINTENANCE MANUAL
CUSTOMER:
MODEL NUMBER:
SERIAL NUMBER:
FREQUENCY ASSIGNMENT:
ADDRESS ASSIGNMENT:
MANUAL P/N:
68C-PS REV 000 01/2001
PENDANT STATION CONTROLLER
OPERATION & MAINTENANCE INSTRUCTIONS
IMPORTANT NOTICES
The security ‘i-Key’ that accompanies your Pendant Station (PS) controller has been pre-programmed
with certain system operating parameters before leaving our factory. If your PS controller is of the
Advanced Technology (AT) family that is custom built to your specification, such ‘i-Key’ parameters
will include a specific address and operating frequency. However, CATTRON-THEIMEG™ strongly
advises you to check that our pre-configured address and frequency is not duplicated in other remote
control equipment located at, or around, your operating facility.
When returning an PSAT Pendant controller to CATTRON-THEIMEG™ for repair, the original coded
‘i-Key’ supplied with the unit shall be returned with the unit.
When returning a PSEZ or PSCS Pendant controller to CATTRON-THEIMEG™ for repair, we
recommend the coded ‘i-Key’ last used with the unit be returned with the unit.
Before returning a PSEZ or PSCS Pendant controller to CATTRON-THEIMEG™ for repair, we
strongly recommend you record the operating address and frequency assigned to the controller as you
will be required to re-program these operating parameters after we return your controller. Refer to
Frequency and Address Reports in Section 5 of this manual for recording details.
When a PSEZ or PSCS Pendant controller is returned to CATTRON-THEIMEG™ for repair, we make
every effort to establish the operating address and frequency assigned to your controller when it arrives
at our repair facility. Whenever such operands can be established, we will record the same on the
service documentation returned with your controller.
This equipment is firmware based. Any duplication of operating firmware without written consent of
CATTRON-THEIMEG™ is prohibited. U.S. Copyright Laws protect all firmware, parts and product
listings, assembly files, and this manual.
01/2001, CATTRON - THEIMEG
TM
Page i
List of Technical Abbreviations
The following abbreviations (acronyms) are frequently used in CATTRON-THEIMEG™ Radio
Remote Control Technology and may be used in this manual:
Page ii
AC
Alternating Current
LED
Light Emitting Diode
AT
Advanced Technology
ML
Mainline
ASO
Automatic Safety Override
NEMA
National Electrical
Manufacturer’s Association
BCH
Bose-ChaudhuriHocquenghem (data error
detection routines)
Ni-Cad
Nickel Cadmium
CMOS
Complimentary Metal Oxide
Semiconductor
OPR
Operate
CS
Crane Specific
PRC
Portable Remote Control
DC
Direct Current
PS
Pendant Station
DOC
Department of
Communication (Canada)
PTO
Push-to-Operate
DP
Dual Pressure
RF
Radio Frequency
EDP
Electronic Data Processing
RFI
Radio Frequency
Interference
EEPROM
Electrically Erasable
Programmable Read Only
Memory
RST
Reset Relay
EMI
Electro-Magnetic
Interference
SP
Single Pressure
EPROM
Erasable Programmable
Read Only Memory
SYNC
Synchronization
FCC
Federal Communications
Commission
TP
Test Point
GND
Ground
TS
Transfer Switch
I/O
Input/Output
VAC
Volts Alternating Current
IR
Infra-red
VDC
Volts Direct Current
LCD
Liquid Crystal Display
VFD
Variable Frequency Drive
01/2001, CATTRON - THEIMEG
TM
Introduction
How to use this Manual.
This manual contains generic operation and maintenance procedures applicable to the entire series of
CATTRON-THEIMEG™ Pendant Station (PS) Radio Remote Controllers.
If you are using our Advanced Technology (AT) family of controllers that have been customized and
pre-programmed to your exact specification, you should skip Section 5 in its entirety as the frequency
and address programming procedures contained therein do not apply to your controller.
If you are using our PSEZ or PSCS family of controllers, you should include Section 5, as you will be
required to verify/program the system address and operating frequency before using your
controller for the first time.
01/2001, CATTRON - THEIMEG
TM
Page iii
Safety Summary
WARNING and CAUTION statements have been strategically placed throughout all text prior to
operating or maintenance procedures, practices or conditions considered essential to the protection of
personnel (WARNING), or equipment and property (CAUTION). A WARNING and CAUTION will
apply each time the related step is repeated. Before starting any task, the WARNINGS or CAUTIONS
included in the text for the task shall be reviewed and understood. All WARNINGS and CAUTIONS
appearing in this manual are included below.
WARNINGS.
WARNINGS:
ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR
INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE
A BRAKE INSTALLED.
THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE
CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR
FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY
OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE
MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY
RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND
DAMAGE TO EQUIPMENT.
WARNINGS:
MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT,
AROUND,
OR
NEARBY
YOUR
OPERATING
FACILITY.
THEREFORE, BEFORE INSERTING AN ‘i-Key’ INTO A PS
CONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-Key’
IS SELECTED FOR THE DESIRED EQUIPMENT TO BE OPERATED.
IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES
CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS
PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER,
OTHER EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR
FACILITY MAY BECOME OPERATIONAL.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY
RESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH IN
TURN COULD RESULT IN SERIOUS INJURY OR DEATH TO
PERSONNEL AND DAMAGE TO EQUIPMENT.
Page iv
01/2001, CATTRON - THEIMEG
TM
Safety Summary, continued
WARNINGS, continued.
WARNING:
DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT
REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED
EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL
REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER
POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST
TIME A PUSHBUTTON IS DEPRESSED. CONSEQUENTLY, SPECIAL
CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS
EQUIPPED WITH A PARKING BRAKE THAT IS CONFIGURED TO
ENGAGE WHEN THE MAINLINE CONTACTOR DE-ENERGIZES.
TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU
SHOULD IMMEDIATELY PRESS THE RED ‘STOP’ BUTTON ON YOUR
REMOTE CONTROLLER AFTER COMPLETION OF CRANE
OPERATIONS. SUCH ACTION WILL INSURE THE PARKING BRAKE
(IF EQUIPPED AND CONFIGURED AS ABOVE) IS SET, PREVENTING
UNINTENTIONAL MOVEMENT OF THE CRANE OR TRACKED
MACHINE.
FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
WARNING:
ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN
AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN
ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM
INDICATIONS
MEETING
GOVERNMENTAL
REQUIREMENTS.
FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS
INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
01/2001, CATTRON - THEIMEG
TM
Page v
Safety Summary, continued
WARNINGS, continued.
WARNING:
FAILURE TO PROPERLY SELECT FREQUENCY AND ADDRESS MAY
RESULT IN THE UNINTENTIONAL OPERATION OF OTHER
MACHINERY AND COULD RESULT IN DEATH OR SERIOUS INJURY
TO PERSONNEL. DO NOT DUPLICATE ADDRESS ASSIGNMENT.
WARNING:
CATTRON-THEIMEG™ PSEZ AND PSCS PORTABLE REMOTE
CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE
DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED
FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors,
fire suppression etc.).
CONTACT CATTRON-THEIMEG™ FACTORY FOR INFORMATION
REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS.
SHOULD CATTRON-THEIMEG™ PSCS AND PSEZ PORTABLE REMOTE
CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO
INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE
TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY
RESULT.
IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL
NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT
OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER
CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM.
Page vi
01/2001, CATTRON - THEIMEG
TM
Safety Summary, continued
CAUTIONS.
CAUTION:
All PS Controller internal circuit boards are sensitive to electrostatic
discharge. Consequently, all maintenance procedures involving disassembly
and assembly of these controllers shall be carried out by qualified technicians
using anti-static mats and personal grounding straps. Failure to comply with
this caution may result in equipment damage and void our warranty.
CAUTION:
CATTRON-THEIMEG™ Battery Chargers and External Charging Units are
designed for use with CATTRON-THEIMEG™ Ni-Cad Battery packs only.
failure to comply with this caution may result in equipment and/or battery
damage and will void our warranty.
CAUTIONS:
CATTRON-THEIMEG™ Battery Adapters are designed for use with non rechargeable ‘AAA’ size Alkaline Batteries only. Carbon/Zinc, Lithium, or NiCad Batteries are not to be used with this adapter. Damage to batteries will
occur if this adapter is used for battery charging.
CAUTION:
All circuit boards are sensitive to electrostatic discharge. Use an anti-static
mat and personal grounding strap (wrist) for all maintenance procedures
involving disassembly and assembly of PS Controllers. Failure to comply with
this caution may result in equipment damage and will void our warranty.
CAUTION:
All control functions will be stopped if the PS Controller is used or left standing
in an upright position during heavy rain, or in hostile environments where
water could fill the top of the controller and cover the ‘i-Key’. To resume
control functions, simply invert and shake the controller to remove excess
water. There is no need to remove the ‘i-Key’. Ideally, to prevent such
occurences in wet weather and water spray environments, the controller should
(1) never be left standing upright, (2) be carried by the shoulder strap, and (3)
operated in a near horizontal position.
01/2001, CATTRON - THEIMEG
TM
Page vii
Safety Summary, continued
GENERAL.
The following are general safety precautions that are not related to any specific procedure and therefore
do not appear elsewhere in this manual. These are general safety precautions and instructions that
people must understand and apply during many phases of operation and maintenance to ensure personal
safety and health and the protection of your company property.
KEEP AWAY FROM LIVE CIRCUITS. Maintenance personnel must observe all safety
requirements at all times. Do not replace components or make adjustments inside the equipment with
the electrical supply turned on. Under certain conditions, danger may exist even when the power control
is in the off position due to charges retained by capacitors. To avoid injuries, always remove power,
discharge and ground a circuit before touching it. Adhere to all lock out/tag requirements.
DO NOT SERVICE OR ADJUST ALONE. Do not attempt internal service or adjustment of
equipment unless another person capable of rendering aid and resuscitation is present.
FINGER RINGS/JEWELRY. Finger rings have caused many serious injuries.
watches and other metallic objects that may cause shock or burn hazards.
Remove rings,
SOLDERING/DE-SOLDERING. Avoid breathing fumes generated by soldering/de-soldering.
Perform all operations in a ventilated area. Eye protection is required.
CLEANING SOLVENTS. Some cleaners and solvents have adverse effects on skin, eyes, respiratory
tract and internal organs. These adverse effects range from discomfort to serious injury and death,
depending on the material and degree of exposure. Observe manufacturers’ warning labels and contact
your immediate supervisor if in any doubt.
Remember…. the person now reading these instructions
is primarily responsible for his or her own health and
safety.
Page viii
01/2001, CATTRON - THEIMEG
TM
Table of Contents
Front Matter:
Important Notices ................................................................................................ i
List of Technical Abbreviations ......................................................................... ii
How to use this Manual .................................................................................... iii
Safety Summary ................................................................................................ iv
Warnings ............................................................................................... iv
Cautions ............................................................................................... vii
General ................................................................................................ viii
Section 1 – Product Data and Specifications:
Functional Description .................................................................................... 1-1
Specifications .................................................................................................. 1-3
Overview of CATTRON-THEIMEG™ Remote Control Systems .................. 1-5
Section 2 – Safety Information:
Safety Considerations ..................................................................................... 2-1
Typical Method of Operation .......................................................................... 2-2
Radio Control Operator’s Duties – General Equipment ................................. 2-4
Radio Control Operator’s Duties – E.O.T. Crane ........................................... 2-7
Section 3 – Operating Instructions:
‘i-Key’ configuration for continuous (FCC part 90) and non-continuous
(FCC part 15) transmit applications ............................................................... 3-1
Controls and Indicators ................................................................................... 3-2
Battery Charging Options ................................................................................ 3-4
Internal Charging ................................................................................ 3-5
External Charging ............................................................................... 3-5
Alkaline Battery Adapter (‘AAA size’) .......................................................... 3-6
Operating procedure – PS controller ............................................................... 3-7
01/2001, CATTRON - THEIMEG
TM
Page ix
Table of Contents, continued
Section 4 – Maintenance Instructions:
CATTRON-THEIMEG™ Maintenance Philosophy ....................................... 4-1
Maintenance Procedures ................................................................................. 4-2
Preventive Maintenance ....................................................................... 4-2
Troubleshooting .................................................................................. 4-2
Corrective Maintenance ...................................................................... 4-2
Functional check ................................................................................. 4-3
Replacement items .............................................................................. 4-3
Troubleshooting Guide ....................................................................... 4-4
Disassembly and Assembly Procedures .............................................. 4-5
Battery Pack ............................................................................ 4-6
Bottom Endcap ......................................................................... 4-7
Top Endcap .............................................................................. 4-8
Upper & Lower Main Body Housings ................................... 4-10
Rubber Side Grips ................................................................. 4-11
Section 5 – PSCS & EZ Series Controllers:
Introduction – PSEZ & CS Controllers .......................................................... 5-1
Installing different ‘i-Keys’ ............................................................................ 5-1
PSEZ & CS Control Systems – frequency & address assignment .................. 5-2
PSEZ & CS Controllers – address/frequency verification .............................. 5-3
Programming PSEZ & CS Controller address and frequency ........................ 5-4
Address digit #1 entry and report (CS only) ....................................... 5-6
Address digit #2 entry and report (CS only) ....................................... 5-8
Address digit #3 entry and report (EZ & CS) ...................................... 5-9
Address digit #4 entry and report (EZ & CS) .................................... 5-10
Frequency Bank entry and report (EZ & CS) .................................... 5-11
Frequency entry and report (EZ & CS).............................................. 5-12
Address, Frequency Bank and Frequency report only (EZ & CS) .... 5-14
Page x
01/2001, CATTRON - THEIMEG
TM
Table of Contents, continued
Section 6 – Parts List and Accessories:
Introduction ..................................................................................................... 6-1
Accessories/consumable items ........................................................................ 6-1
PS Controller – exploded view (illustrated parts breakdown) ........................ 6-2
PS Controller – Parts List ............................................................................... 6-3
Illustrations – accessories/consumable items ......................................... 6-4 – 6-8
Index.
Addendum
RECOMMENDED SAFETY RULES FOR PORTABLE REMOTE
CONTROLLED (PRC) CRANES.
01/2001, CATTRON - THEIMEG
TM
Page xi
Rx
Rx
AT
Tx
Rx
Rx
CS
Tx
Rx
EZ
Tx
Page xii
01/2001, CATTRON - THEIMEG
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Section 1 – Product Data & Specifications
Functional Description.
The CATTRON-THEIMEG™ Pendant Station (PS) remote controller is a lightweight, extremely rugged
customizable radio control unit for use with any CATTRON-THEIMEG™ Portable Remote Control
(PRC) System. CATTRON-THEIMEG™ PS controllers are offered in three family configurations:
PSEZ (Easy), PSCS (Crane Specific) and PSAT (Advanced Technology).
In all three CATTRON-THEIMEG™ families of PS controllers, operational security is advanced to its
maximum by the use of a removable stainless steel, electronic ‘i-Key’ which, when installed in the
controller, defines and enables the appropriate operating parameters. When the ‘i-Key’ is removed, the
controller is totally disabled. It should be noted that each family of PS controller has a specific colored
‘i-Key’ (green = EZ, blue = CS, and silver = AT) and that these ‘i-Keys’ are not interchangeable
between controller families.
The switch unit and electronics are contained in an extreme duty, water and dust resistant, aluminum
housing which has armorized rubber end-caps for switch protection and high impact resistance. The
controller housing is ergonomically designed with curved bottom and rubber side grips to allow
comfortable handling. The ‘i-Key’ is mounted in a receptacle located within the confines of the
armorized rubber ‘bumper’ that forms the top end-cap. Separate Power ON/OFF and STOP (red)
switches are also located next to the removable ‘i-Key’. The controller front face contains up to six
large pushbuttons that are engraved with their respective control function symbols. When pressed, each
pushbutton activates circuitry inside the controller. Pushbuttons may be of three-step or proportional
(stepless) operation.
Three-step pushbuttons provide 3-speed operation with a single pushbutton. When pressed, each
pushbutton step has a distinct limit of travel that provides an enhanced tactile feel that is noticed by the
operator.
Proportional (stepless) pushbuttons provide variable frequency drive (VFD) operation with a single
pushbutton. In these applications, the drive motor speed is directly proportional to the amount of travel
of the pushbutton (more distance = more speed).
Additional maintained and momentary depression toggle switches are mounted within a recessed
channel alongside the large control function pushbuttons. Note that PSAT models may be provided
with variety of custom switches
All commands from CATTRON-THEIMEG™ PS controllers respond within milliseconds of pressing or
releasing a pushbutton. Additionally, a mainline ON command is sent when power is turned on and resent anytime a controller function pushbutton is pressed. Within the PS controller, a microprocessor
performs self–diagnostics, interprets pushbutton and switch commands, and controls the radio
transmitter.
01/2001, CATTRON - THEIMEG
TM
Section 1, Page 1
Functional Description, continued.
CATTRON-THEIMEG™ PS controllers are equipped with an internal antenna and the typical operating
(transmitter) range is in excess of 500 feet (160+ meters). It should be understood that operating range
varies with environmental conditions. Should the transmitter go out of operating range, all motions will
cease.
CATTRON-THEIMEG™ PSAT series controllers have been approved to comply with both FCC Part 15
(non-continuous transmission) and FCC Part 90 (continuous transmission) applications, and for DOC
RSS-210 (non-continuous transmission) and RSS-119 (continuous transmission) applications standards.
No United States of America FCC, or Canadian DOC license is required for operation of FCC Part 15 or
RSS-210 (non-continuous transmission) PS controllers. Non-licensed PS controllers transmit the very
secure CATTRON-THEIMEG™ Series digital message, using frequency modulation (FM) radio. These
radio transmitters are approved for use on frequencies between 425-447MHz (M) and 447-473MHz (H).
They can be used on any frequency within these bands, including normally licensed channels without
the need for a license.
An authorized station operating license is required for the operation of US Part 90 and Canadian RSS119 (continuous transmission) applications. If you need assistance in obtaining these licenses, please
contact CATTRON-THEIMEG™ Inside Sales Department in the first instance.
As previously mentioned, operational security is maximized by the need to use a stainless steel
electronic ‘i-Key’ for controller operation. However, there is an additional and very significant
operational advantage of the CATTRON-THEIMEG™ ‘i-Key’ concept. It is that individual system
address, operating frequency and keypad configuration may be permanently stored in the ‘i-Key’,
depending on the type of controller supplied. Therefore, CATTRON-THEIMEG™ PS controllers
belonging to the same family at a user location can be identical - only the ‘i-Keys’ are different. To
simplify, each ‘i-Key’ is color-coded and labeled for an individual control system family, thus, any
CATTRON-THEIMEG™ PS controller will run any CATTRON-THEIMEG™ receiver/decoder
belonging to the same family as long as the correct ‘i-Key’ is used. As the result, this unique operating
concept reduces the need for specific spare remote controllers. Our unique family of PS controllers is
identified on the next page.
All CATTRON-THEIMEG™ PS controllers are powered by disposable 3-Volt alkaline or re-chargeable
Ni-Cad battery packs. In normal operation, a green LED ‘flashes’ with each function command message
and a ‘beep’ is sounded when a pushbutton is depressed. When the battery voltage becomes low, a
separate yellow LED flashes, alerting the operator that the battery pack needs to be replaced or recharged soon. Battery packs are easily and quickly replaced without the need for tools by turning two
knurled thumbscrews and removing the battery cover-plate located within the confines of the armorized
rubber bottom end-cap. The battery pack makes positive contact without snaps or plugs and has no
wires to break; simply drop it in, and replace the battery cover-plate.
Section 1, Page 2
01/2001, CATTRON - THEIMEG
TM
Functional Description, continued.
Ni-Cad battery packs can be re-charged ‘in-situ’ and do not need to be removed from the controller
housing. To enable such battery charging to be carried out, a series of optional battery chargers are
available for all CATTRON-THEIMEG™ PS controllers. One end of the charger is connected to the
mains power outlet, the other plugs into a covered socket located within the bottom end cap. Additional
options include an ‘AAA’ size battery adapter, and an external battery-charging unit – refer to
accessories/consumable items in Section 6 for details and part numbers.
A shoulder-carrying strap is standard for all CATTRON-THEIMEG™ PS controllers. This is quickly
and simply installed to a pair of ‘D’-rings located on the side of the controller.
Specifications.
Case Material:
Extreme duty, dust and water resistant, aluminum housing.
Approximate weight:
2.3lbs. / 1.04 Kg (including battery pack)
Dimensions:
12.0" x 3.0" x 2.0" (30.0cm x 7.6cm x 5.1cm).
Environmental:
Consult CATTRON-THEIMEG™ factory for a wide range of environmental solutions.
Maximum Functions:
Up to 20 operator commands, depending on controller configuration.
Operator Control Functions – PSAT Series:
Up to six large pushbuttons (proportional type, three-step type, or any combination of
these two), plus additional toggle switches and/or pushbuttons, as required.
01/2001, CATTRON - THEIMEG
TM
Section 1, Page 3
Specifications, continued.
Operator Control Functions – PSEZ & PSCS:
Six large pushbuttons (three-step type only), plus two auxiliary function switches and a
selector for motors A or B, or both A+B.
Battery type:
3-Volt Alkaline Battery Pack (standard).
2.4 Volt re-chargeable Ni-Cad Battery Pack (optional).
3-Volt Alkaline Battery Adapter for use with quantity 2 ‘AAA’ size Alkaline
batteries only (optional).
Battery life (20% Duty Cycle):
3 Volt alkaline battery pack (standard) or re-chargeable Ni-Cad battery pack
(optional). In USA, Canada and non EU countries, battery life is:- Ni-Cad pack
– 50 hours, Alkaline pack – 115 hours, ‘AAA’ Alkaline batteries (using
optional adapter) – 50 hours. In EU countries, battery life is:- Ni-Cad pack – 30
hours, Alkaline pack – 65 hours, ‘AAA’ Alkaline batteries (using optional
adapter) – 25 hours.
Transmit indicator:
Green LED flashes with every transmission.
Low battery indication:
Yellow LED flashes for low battery, low battery alert signal beeps every 10 seconds.
Battery charging:
Internal Ni-Cad battery charging. Optional ‘Standard’ rate (10 hour) or ‘Rapid’
rate (1-hour) Battery Chargers are available for use in countries having 110-120
VAC mains input power. Alternatively, optional ‘Rapid’ or ‘Trickle’ Battery
chargers are available for use in countries having 220-240 VAC mains input
power. An External Battery Charging Unit is also available for use with all
optional CATTRON-THEIMEG™ battery chargers.
Audio speaker:
For function pushbutton ‘click’ and low battery indication.
Transmitter frequency:
425-447MHz (M) or 447-473MHz (H).
Section 1, Page 4
01/2001, CATTRON - THEIMEG
TM
Overview – CATTRON-THEIMEG™ Remote Control Systems.
Figure 1-1 below shows a simplified block diagram of a typical CATTRON-THEIMEG™ remote control
system. Refer to this figure and the following paragraphs for a functional description of the remote
control system.
The target receiver/decoder is controlled by the Pendant Station Controller. Provided the correct
coded ‘i-Key’ is inserted into the controller, the controller sends signals to the receiver/decoder using an
UHF radio link. The signal is picked up by the antenna and passed on to the receiver. If the signal is the
correct frequency and passes all required data tests, the signal is passed on to the decoder. The decoder
compares the address code of the signal to its own address code. If the signal’s address code does not
match its address code, it is ignored and a message is displayed on a system status display located in the
receiver/decoder unit. If the address code is correct, the decoder processes the message and energizes
and de-energizes the appropriate control, directional output, three-speed and auxiliary function relays
located within the control system.
An Automatic Safety Override (ASO) function continually monitors the state of all directional relay
outputs (i.e. Forward/Reverse). If a directional relay electrically fails closed without a command from
the controller, the ASO circuit logic de-energizes the master output relay (OPR).
During operation, the microprocessor on the decoder board resets multiple watchdog timer circuits
whenever valid messages are received and decoded. If the microprocessor fails to reset the watchdog
timers, the timer circuits shut down and de-activate all relay outputs. The decoder microprocessor
requires continuously valid transmitted signals to be received and decoded or all relay output functions
will be de-activated unless programmed otherwise. It should be noted that the mainline control relay
(OPR) would be maintained for up to 10 minutes, depending on system configuration.
Figure 1-1. Typical Radio Remote Control System, simplified block diagram
12 VDC
Rx
Tx
PENDANT
CONTROLLER
FREQ
ADDRESS
RECEIVER
DECODER
POWER
SUPPLY
115 VAC
50-60 HZ
WATCHDOG
TIMER
ADDRESS
ASO
FREQ
THREE-SPEED AND AUXILIARY
FUNCTION OUTPUT RELAYS
DIRECTIONAL OUTPUT RELAYS
MACHINE WIRING
END OF SECTION
01/2001, CATTRON - THEIMEG
TM
Section 1, Page 5
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Section 1, Page 6
01/2001, CATTRON - THEIMEG
TM
Section 2 – Safety Information
Safety Considerations.
CATTRON-THEIMEG™ believes that to safely operate any remotely controlled equipment, the overall
system needs to be configured so that movement or operation of the equipment will take place only
when the device is commanded to move or operate. For example; overhead cranes must be equipped
with a braking system, which can only be released when an electrical signal is sent to the motor.
Removal of electrical power or loss of the radio transmitted signal results in application of the brakes.
One way to accomplish this is with a CATTRON-THEIMEG™ Electro-Hydraulic brake package –
contact the factory for details.
In keeping with this philosophy - NO COMMAND, NO MOVEMENT - CATTRON-THEIMEG™ has
designed your radio remote control system with the following safety and security features.
‘i-Key’: Operational security is advanced to its maximum by the use of a removable
stainless steel, electronic, ‘i-Key’ which, when installed to the Pendant controller, defines
and enables the operating parameters. When the ‘i-Key’ is removed, the controller is totally
disabled.
Unique address code: Each PS series controller and receiver/decoder pair is configured
with a unique address code so that the equipment will respond only to the controller whose
address code matches that of the decoder.
Intelligent digital message protocol: CATTRON-THEIMEG™ remote control systems
utilize a unique message protocol for industrial control applications rather than the
customary Electronic Data Processing (EDP) type of message format.
ON/OFF power switch: The PS controller is provided with a rotary power ON/OFF switch
that must be set to ‘ON’ in order to send commands to the receiver/decoder. If the power
switch is set to ‘OFF’, the decoder will remove all commands from the controlled
machinery, stopping all movement. However, the mainline control relay (OPR) will be
maintained for up to 10 minutes, depending upon system configuration.
Red System STOP Switch: Operating the red STOP switch while the PS controller is
turned on will repeatedly send a burst of stop commands to all outputs including the
mainline control relay (OPR).
Operate relay (OPR): The operate (OPR) output relay shall be wired to control a userprovided electro-magnetic power contactor. The electro-magnetic contactor opens and
closes the main electrical supply circuit(s) to the controlled device.
Data Error Checking: All communications from the Pendant controller to the
receiver/decoder contain error-checking information (BCH data error detection routines).
The entire data command packet must pass error detection tests before being processed.
01/2001, CATTRON - THEIMEG
TM
Section 2, Page 1
Typical method of operation (incorporating above safety features) using a radio controlled overhead
crane as an example:
The Operate (OPR) relay(s) is energized for the first time when:
The red STOP and rotary ON/OFF switches on the PS Controller are operated in the
proper sequence (first unlatch and pull up STOP switch to ‘RUN’, then rotate ON/OFF
switch to ‘ON’), the correct coded ‘i-Key’ is installed, and the target receiver/decoder
has power applied. With all these conditions satisfied, a matching address code is sent by
way of RF signal from the PS controller to the decoder.
The OPR relay is wired to the mainline (ML) contactor on the crane. Once the mainline is energized, a
continuously repeated valid signal must be received for function outputs to engage. If this signal is
interrupted for any reason, all function outputs will turn off unless programmed otherwise.
When operating within the USA, FCC rules state that RF transmitters in non-licensed controllers must
switch off within five seconds after the operator releases a function pushbutton. Consequently, the OPR
output is programmed to stay on for up to ten minutes after the last valid message is received. During
this time all Automatic Safety Override (ASO) monitored outputs must stay off or the ASO sensing in
the decoder will interrupt this hold up time, de-energizing OPR.
Figure 2-1 below shows an Operate (OPR) contact wired directly to the mainline (ML) contactor.
Provided the red STOP switch on the Pendant Controller is pulled out and the correct coded ‘i-Key’ is
installed, setting the green ON/OFF power switch on the Pendant controller to ‘ON’ will energize the
mainline contactor.
Figure 2-1. Operate (OPR) contact wiring
MANUAL
DISCONNECT
ML
L1
OPR
5.0A
RECEIVER/DECODER
LL1
L2
LL2
L3
LL3
TO
MOTOR
120V
ML
EXISTING CONTROLS
An auxiliary function may be used as a Reset (RST) output that will only be effective when the Operate
(OPR) relay has been closed. Momentary closure of the Reset (RST) relay picks up the mainline (ML)
contactor, which is maintained under control of the OPR. Thus, power is supplied to the controlled
device. If OPR opens, the mainline contactor releases, removing power from the controlled device and
stopping all motion.
Section 2, Page 2
01/2001, CATTRON - THEIMEG
TM
Typical method of operation, continued.
Figure 2-2 below shows the Operate (OPR) relay and optional Reset (RST) relay wired to control a
mainline contactor. This configuration requires the operator to activate the reset function on the
controller after he/she has turned the unit on. Once reset, the ML contactor stays energized until OPR
de-energizes.
In addition to being energized by the presence of a signal from the controller, OPR is under supervision
of the Automatic Safety Override (ASO) circuit. The ASO circuit disables the OPR (shutting down the
controlled machinery) if a directional output relay is active when no corresponding command is being
received from the controller. In this event, no action is required by the operator to stop the equipment.
The ASO safety circuitry will stop motion automatically without any operator command when a
directional output relay fault is detected.
Figure 2-2. Operate (OPR) contactor and Reset Relay (RST) wiring
MANUAL
DISCONNECT
ML
L1
OPR
5.0A
LL1
L2
LL2
L3
LL3
ML
TO
MOTOR
120V
ML
RST
5.0A
RECEIVER/DECODER
01/2001, CATTRON - THEIMEG
TM
EXISTING CONTROLS
Section 2, Page 3
Radio Control Operator’s Duties – General Equipment.
WARNINGS:
ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR
INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A
BRAKE INSTALLED.
THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE
CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR
FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY
OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE
CONTACTOR AND SET THE EQUIPMENT BRAKE.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
WARNINGS:
MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT,
AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE,
BEFORE INSERTING AN ‘i-Key’ INTO A PS CONTROLLER, YOU MUST
INSURE THE CORRECT CODED ‘i-Key’ IS SELECTED FOR THE
DESIRED EQUIPMENT TO BE OPERATED.
IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES
CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS
PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER, OTHER
EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY
MAY BECOME OPERATIONAL.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN
OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD
RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND
DAMAGE TO EQUIPMENT.
WARNING:
ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN
AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN
ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM
INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE
TO IMPLEMENT THIS WARNING MAY RESULT IN PERSONAL INJURY
OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
Section 2, Page 4
01/2001, CATTRON - THEIMEG
TM
Radio Control Operator’s Duties – General Equipment, continued.
WARNING:
CATTRON-THEIMEG™ PSEZ AND PSCS PORTABLE REMOTE
CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE
DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED
FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors,
fire suppression etc.).
CONTACT CATTRON-THEIMEG™ FACTORY FOR INFORMATION
REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS.
SHOULD CATTRON-THEIMEG™ PSCS AND PSEZ PORTABLE REMOTE
CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO
INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE
TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY
RESULT.
IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL
NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT
OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER
CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM.
The following procedures provide general guidelines for radio control operation of equipment and
should not be used as a substitute for your plant operating procedures.
1.
Before operating equipment, carry out the following:
a.
Install the correct coded ‘i-Key’ for the target equipment to be operated. If the wrong
coded ‘i-Key’ is installed to the PS controller, the target equipment will not operate.
However; other equipment located at, around, or nearby your facility may become
operational.
b.
Set (unlatch and pull out) PS controller red STOP switch to ‘RUN’ and turn Power
ON/OFF switch to ‘ON’. When transmitting with a good battery, two short ‘beeps’ will
be heard immediately after the ON/OFF power switch is set to ‘ON’ and the green
TRANSMIT LED will ‘flash’ rhythmically. When the battery starts to go low, the
yellow LOW BATTERY LED will ‘flash’ continuously, which means you should change
or re-charge the battery pack (refer to Battery Pack in Section 4 of this manual for
instructions on how to replace a battery pack).
01/2001, CATTRON - THEIMEG
TM
Section 2, Page 5
Radio Control Operator’s Duties – General Equipment, continued.
c.
When installed, activate the ALARM/RESET switch on the PS controller (this is
normally an optional function that sounds the equipment alarm and resets the main power
contactor).
d.
Check each function independently to be sure that equipment is responding correctly.
e.
Where a limit switch is provided, you should check the limit switch at the beginning of
each shift as defined by your plant operating procedures.
f.
Check Range Limiting if used.
g.
Check STOP operation
h.
Check brake operation.
2.
You must report all defective or missing safety equipment, mechanical or electrical defects to
your supervisor without delay. Do not continue operation until fully repaired.
3.
If anyone is in the path of equipment travel, stop and sound the alarm before proceeding.
4.
Persons operating this equipment shall not use a limit stop as a utility stopping device.
When leaving the equipment area for any reason, set (push down) the PS controller red STOP
switch to ‘STOP’ and turn power ON/OFF switch to ‘OFF’. Remove the ‘i-Key’ from the PS
controller and keep it on your person.
6.
Do not allow any unauthorized person to operate the PS controller.
7.
Do not operate the PS controller at a distance where the equipment and all surrounding objects
are not visible.
8.
Do not attempt to override any of the safety features built into the Radio Control System.
9.
If for any reason you or anyone has to board the radio-controlled equipment, set (push down) the
Pendant controller red STOP switch to ‘STOP’ and turn the power ON/OFF switch to ‘OFF’.
Remove the ‘i-Key’ from the PS controller and keep it on your person.
Section 2, Page 6
01/2001, CATTRON - THEIMEG
TM
Radio Control Operator’s Duties – E.O.T. Crane.
WARNINGS:
ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR
INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A
BRAKE INSTALLED.
THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE
CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR
FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY
OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE
CONTACTOR AND SET THE EQUIPMENT BRAKE.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
WARNING:
DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT
REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED
EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL
REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER
POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST
TIME A PUSHBUTTON IS DEPRESSED. CONSEQUENTLY, SPECIAL
CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS
EQUIPPED WITH A PARKING BRAKE THAT IS CONFIGURED TO
ENGAGE WHEN THE MAINLINE CONTACTOR DE-ENERGIZES.
TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU
SHOULD IMMEDIATELY PRESS THE RED ‘STOP’ BUTTON ON YOUR
REMOTE CONTROLLER AFTER COMPLETION OF CRANE
OPERATIONS. SUCH ACTION WILL INSURE THE PARKING BRAKE
(IF EQUIPPED AND CONFIGURED AS ABOVE) IS SET, PREVENTING
UNINTENTIONAL MOVEMENT OF THE CRANE OR TRACKED
MACHINE.
FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
01/2001, CATTRON - THEIMEG
TM
Section 2, Page 7
Radio Control Operator’s Duties – E.O.T. Crane, continued.
WARNINGS:
MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT,
AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE,
BEFORE INSERTING AN ‘i-Key’ INTO A PS CONTROLLER, YOU MUST
INSURE THE CORRECT CODED ‘i-Key’ IS SELECTED FOR THE
DESIRED EQUIPMENT TO BE OPERATED.
IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES
CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS
PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER, OTHER
EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY
MAY BECOME OPERATIONAL.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN
OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD
RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND
DAMAGE TO EQUIPMENT.
WARNING:
CATTRON-THEIMEG™ PSEZ AND PSCS PORTABLE REMOTE CONTROL
(PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO
SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electromagnet circuits, vacuum circuits, grab, pump motors, fire suppression etc.).
CONTACT CATTRON-THEIMEG™ FACTORY FOR INFORMATION
REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS.
SHOULD CATTRON-THEIMEG™ PSCS AND PSEZ PORTABLE REMOTE
CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO
INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE
TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY
RESULT.
IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL
NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT
OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER
CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM.
Section 2, Page 8
01/2001, CATTRON - THEIMEG
TM
Radio Control Operator’s Duties – E.O.T. Crane, continued.
WARNING:
ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN
AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN
ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM
INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE
TO IMPLEMENT THIS WARNING MAY RESULT IN PERSONAL INJURY
OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
The following procedures provide general guidelines for radio control operation of an Electrical
Overhead Traveling (EOT) crane and should not be used as a substitute for your plant operating
procedures.
1.
Before lifting any loads, carry out the following:
a.
Install the correct coded ‘i-Key’ for the desired equipment to be operated. If the wrong
coded ‘i-Key’ is installed to the PS controller, the target equipment will not operate.
b.
Set (unlatch and pull out) PS controller red STOP switch to ‘RUN’ and turn Power
ON/OFF switch to ‘ON’. When transmitting with a good battery, two short ‘beeps’ will
be heard immediately after the ON/OFF power switch is set to ‘ON’ and the green
TRANSMIT LED will ‘flash’ rhythmically. When the battery starts to go low, the
yellow LOW BATTERY LED will ‘flash’ continuously, which means you should change
or re-charge the battery pack (refer to Battery Pack in Section 4 of this manual for
instructions on how to replace a battery pack).
c.
When installed, activate the ALARM/RESET switch on the PS controller (this is
normally an optional function that sounds the equipment alarm and resets the main power
contactor).
d.
Where a limit switch is provided, you should check the limit switch at the beginning of
each shift as defined by your plant operating procedures.
e.
Check each function independently to be sure that equipment is responding correctly.
f.
Check range limiting if used.
g.
Check STOP operation.
h.
Check Brake operation
2.
You must report all defective or missing safety equipment, mechanical or electrical defects to
your supervisor without delay. Do not continue operation until fully repaired.
3.
When raising or lowering a load, proceed slowly and make certain the load is under control.
01/2001, CATTRON - THEIMEG
TM
Section 2, Page 9
Radio Control Operator’s Duties – E.O.T. Crane, continued.
4.
When lifting maximum load, you should test the brakes by raising the load a few inches from the
floor. If the brakes will not hold, the load shall be immediately lowered and not moved until
brakes are adjusted or repaired.
5.
Center the Trolley directly over the load before starting to hoist.
6.
Take slack out of chains or slings gradually and make sure hands and other objects are clear
before making the lift.
7.
Keep all parts of the body away from the lifts. Also, do not stand under a lift.
8.
Do not make a lift or move the equipment if anyone is in a position to be injured.
9.
Load should not be carried over workmen's heads.
10.
If anyone is in the path of travel, stop and sound the alarm before proceeding.
11.
Do not drag slings, chains, etc. along the floor.
12.
Persons operating this equipment shall not use a limit stop as a utility stopping device.
13.
Bumping other cranes or run-away stops is prohibited.
14.
When moving the equipment to the loading point, be sure that hook block, attachment, or cables
will not fall on the adjacent equipment.
15.
When leaving the crane area for any reason, be sure slings or chains are raised and push down
the PS controller red STOP switch to ‘STOP’. Turn the power ON/OFF switch to ‘OFF’.
Remove the ‘i-Key’ from the PS controller and keep it on your person.
16.
Do not allow any unauthorized person to operate the PS controller.
17.
Do not operate the PS controller from a location where the crane and all surrounding objects are
not visible.
18.
Do not attempt to override any of the safety features built into the Radio Control System.
19.
If for any reason you or anyone has to board a radio-controlled crane, push down the PS
controller red STOP switch to ‘STOP’ and turn the power ON/OFF switch to ‘OFF’. Remove the
‘i-Key’ from the PS controller and keep it on your person.
END OF SECTION
Section 2, Page 10
01/2001, CATTRON - THEIMEG
TM
Section 3 – Operating Instructions
‘i-Key’ configuration for continuous (FCC Part 90) and noncontinuous (FCC Part 15) transmit applications.
PSAT Pendant Controllers have been approved to comply with both United States FCC Part 15 (noncontinuous transmission) and FCC Part 90 (continuous transmission) applications, and for Canadian
DOC RSS-210 (non-continuous transmission) and RSS-119 (continuous transmission) applications
standards.
Only when the operator installs the ‘i-Key’ is the identifier defined for a particular FCC/DOC
application. Referring to Figure 3-1 below, continuous transmission (TX) configured ‘i-Keys’ will be
identified with an ‘*’ located next to the revision number on its label. Non-continuous TX configured
‘i-Keys’ have only the revision number with no ‘*’. Note that the controller-housing label has both
types of identifiers for each of the FCC and DOC applications standards; however, only the identifier
that matches the ‘i-Key’ label will apply.
Figure 3-1. ‘i-Key’ and Controller Housing Label identifiers.
Non-continuous TX
‘i-Key’ Label
Housing Label
FCC ID: CN2PS, * CN290PS
CANADA: 10071031992, * 1007195678
AT
Serial No.
* identifier applies only to units with
continuous transmit application.
1.10
Continuous TX
‘i-Key’ Label
NOTE: Regulations state that an authorized stationoperating license is required for US FCC
PART 90 or Canadian DOC RSS-119
Continuous Transmissions Applications. If
you need assistance in obtaining this license,
please
contact
your
CATTRONTHEIMEG™ inside Sales Department in the
first instance.
AT
Serial No.
* 1.10
01/2001, CATTRON - THEIMEG
TM
Section 3, Page 1
Typical Controls and Indicators.
Referring to Figure 3-2 below, your PS Controller may have some or all of the following Controls and
Indicators:
Figure 3-2. Operator controls and indicators
Green
‘TRANSMIT’ LED
‘ON/OFF’ Switch
Color Coded ‘i-Key’
Red ‘STOP’ Switch
STOP
Yellow ‘LOW
BATTERY’ LED
‘ALARM/RESET’
Pushbutton
Stepless Pushbutton
3-step Pushbutton
Maintained Toggle Switch
x=left/right
y=forward/backward
z=up/down
Section 3, Page 2
01/2001, CATTRON - THEIMEG
TM
Controls and Indicators, continued.
The standard PS Controller is a lightweight unit with six large pushbuttons (function keys), plus a rotary
power ON/OFF switch and a latched push/pull STOP switch. The color coded ‘i-Key’ sets the
operating parameters for your control system and has been pre-configured at our factory. Your PS
series controller has been engineered to duplicate some or all of the control functions normally found on
the equipment being controlled. The controller may be hand carried or supported using an optional
shoulder carry strap. PS series controllers are powered by disposable (Alkaline), or rechargeable (NiCad), battery packs.
With the correct color coded ‘i-Key’ inserted into the PS controller, setting the STOP and ON/OFF
switches to their respective ‘RUN’ and ‘ON’ positions will apply power to the transmitter. When
transmitting with a good battery, two short ‘beeps’ will be heard immediately after the ON/OFF power
switch is set to ‘ON’ and the green TRANSMIT LED will ‘flash’ rhythmically. In addition, any time a
pushbutton (function key) is pressed, the green TRANSMIT LED will ‘flash’ during each radio
transmission.
When the battery energy starts to go low, the yellow LOW BATTERY LED will ‘flash’ continuously,
signaling the operator to change or re-charge the battery pack (refer to Battery Pack in Section 4 of this
manual for instructions on how to replace a battery pack).
When the ON/OFF switch is set to the ‘OFF’ position, power is removed from the controller causing all
control functions to cease with the exception of OPR, which remains energized. Setting (pushing down)
the red STOP switch to ‘STOP’ before setting the ON/OFF switch to ‘OFF’ immediately sends a burst
of stop commands to the receiver/decoder unit. Immediately after the stop commands have been sent,
the transmitter within the Pendant controller switches OFF. STOP commands will automatically be
repeated for one minute or until the ON/OFF switch is set to the ‘OFF’ position, removing power from
the controller.
Referring to Figure 3-2, each large pushbutton is engraved with its control function symbol. When a
pushbutton is depressed, the controller transmits the corresponding motion command. The controller
stops sending commands five seconds after the last pushbutton is released. A ‘beep’ will be heard each
time a button is pressed or released.
On PSCS and PSEZ controllers, all large pushbuttons are of the three-step type. Each pushbutton step
is momentary and must be maintained by the operator. For example, pressing the pushbutton will set the
controlled machine in motion. The rate of motion may be increased by further pressure to the second or
third speed step, as required. All machine motion will continue for as long as the pushbutton is held.
Releasing the pushbutton at the third or second speed step causes the rate of motion to slow down.
Completely releasing the pushbutton will send an ‘OFF’ command that de-energizes the drive motor,
stopping all motion.
On PSAT controllers, the large pushbuttons may be three-step, proportional, or a combination of both,
dependant on the control application. Proportional pushbuttons are step-less and the speed of machine
motion is totally dependent upon the travel distance of the pushbutton, much the same as an accelerator
pedal on an automobile. Completely releasing the pushbutton will send an ‘OFF’ command that deenergizes the drive motor, stopping further motion.
01/2001, CATTRON - THEIMEG
TM
Section 3, Page 3
Battery Charging Options.
NOTE:
It is not recommended to re-charge the battery until the controller’s yellow ‘LOW
BATTERY’ LED flashes continuously.
Four CATTRON-THEIMEG™ battery chargers are offered for use with Ni-Cad battery packs only.
Using these ‘smart’ battery chargers, no damage will occur to a Ni-Cad battery pack left on charge for
longer than its recommended charging period. These battery pack charger options are:
• A CATTRON-THEIMEG™ ‘Standard’ rate charger that enables a Ni-Cad battery pack to be
charged within a period of 10 hours (Part # 70C-0001) from a 110-120 VAC mains supply.
Standard rate chargers include a yellow LED to indicate charge mode.
• A CATTRON-THEIMEG™ ‘Rapid’ rate charger that enables a Ni-Cad battery pack to be
charged within one hour (Part # 70C-0002) from a 110-120 VAC mains supply. Rapid rate
chargers include a red (battery/polarity fault) LED, a green (power ‘ON’) LED, and a
yellow (fast charge) LED. This charger uses automatic end of charge detection circuitry to
accurately sense when the battery is fully charged. When this condition has been detected,
the charger switches to a ‘trickle’ mode that keeps the battery fully charged and ready to
use.
• A CATTRON-THEIMEG™ ‘Trickle’ rate charger that enables a Ni-Cad battery pack to be
charged within a period of 10 hours (Part # 70C-0001-220UK) from a 220-240 VAC mains
supply. This charger includes a charge indicator LED.
• A CATTRON-THEIMEG™ ‘Rapid’ rate charger that enables a Ni-Cad battery pack to be
charged within one hour (Part # 70C-0002-220UK) from a 220-240 VAC mains supply.
This charger includes a charge indicator LED.
In addition, using all of the CATTRON-THEIMEG™ battery chargers referred to above:
• Ni-cad Battery packs can be charged within the controller (see Figure 3-3, below).
• Ni-cad battery packs may be charged externally (see Figure 3-4, below) provided an
additional CATTRON-THEIMEG™ External Battery Charging Unit is purchased (Part # 70C0003). This unit is connected to the appropriate CATTRON-THEIMEG™ battery charger.
CAUTION:
CATTRON-THEIMEG™ Battery Chargers and External Charging Units are
designed for use with CATTRON-THEIMEG™ Ni-Cad Battery Packs only.
Failure to comply with this Caution may result in equipment and/or battery
damage and will void our warranty.
Section 3, Page 4
01/2001, CATTRON - THEIMEG
TM
Battery Charging Options, continued.
Internal Charging. To re-charge the Ni-Cad Battery Pack within the controller, connect the
CATTRON-THEIMEG™ battery charger to the mains power supply. Referring to Figure 3-3 below,
position the Pendant Controller face upwards, open out the hinged cover protecting the battery-charging
socket and insert the charging jack. When the Ni-Cad battery pack is charging, the appropriate charge
indicator on the connected battery charger will illuminate.
Figure 3-3. Internal Ni-Cad Battery Pack Charging
View on ‘A’
(rotated 180 )
Charging
Socket
Charging Jack
Socket
Cover
‘A’
External Charging. To charge a Ni-Cad Battery Pack, refer to Figure 3-4 below and connect the
CATTRON-THEIMEG™ battery charger to the mains power supply. Install the charger jack plug to the
external battery charging unit socket as shown. Simply drop the battery pack into the charging unit,
ensuring the battery pack contacts are positioned as shown. When the Ni-Cad battery pack is properly
installed, the appropriate charge indicator on the connected battery charger will illuminate.
Figure 3-4. External Ni-Cad Battery Pack Charging
NI-CAD BATTERY PACK ONLY
PART # 60C-0060N
CHARGING JACK
FROM BATTERY
CHARGER
01/2001, CATTRON - THEIMEG
TM
Section 3, Page 5
Alkaline Battery Adapter.
CAUTION:
CATTRON-THEIMEG™ Battery Adapters are designed for use with non rechargeable ‘AAA’ size Alkaline Batteries only. Carbon/Zinc, Lithium, or NiCad Batteries are not to be used with this adapter. Damage to batteries will
occur if this adapter is used for battery charging.
Referring to Figure 3-5 below, a CATTRON-THEIMEG™ Battery Adapter is available which will
accept two ‘AAA’ size Alkaline 1.5-volt batteries only. It should be noted that when using ‘AAA’ size
Alkaline 1.5 volt batteries with this adapter, battery life would only be 40% of that provided by a
CATTRON-THEIMEG™ Alkaline Battery Pack.
Figure 3-5. ‘AAA’ Alkaline Battery Adapter.
BATTERY ADAPTER, 3 VOLT
(QUANTITY 2 x ‘AAA’ SIZE)
Section 3, Page 6
USE ‘AAA’ ALKALINE
BATTERIES ONLY
01/2001, CATTRON - THEIMEG
TM
Operating Procedure – PS Controller.
Three-step function pushbuttons are clearly marked with triple arrows on the face of the pushbutton and
have been pre-assigned through ‘i-Key’ programming for three-step operation. In other words, second
and third outputs are tied to the second and third levels of button depression.
Proportional (stepless) function pushbuttons are clearly marked with a single arrow.
WARNINGS:
ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR
INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A
BRAKE INSTALLED.
THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE
CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR
FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY
OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE
CONTACTOR AND SET THE EQUIPMENT BRAKE.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
WARNING:
DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT
REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED
EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL
REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER
POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST
TIME A PUSHBUTTON IS DEPRESSED. CONSEQUENTLY, SPECIAL
CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS
EQUIPPED WITH A PARKING BRAKE THAT IS CONFIGURED TO
ENGAGE WHEN THE MAINLINE CONTACTOR DE-ENERGIZES.
TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU
SHOULD IMMEDIATELY PRESS THE RED ‘STOP’ BUTTON ON YOUR
REMOTE
CONTROLLER
AFTER
COMPLETION
OF
CRANE
OPERATIONS. SUCH ACTION WILL INSURE THE PARKING BRAKE (IF
EQUIPPED AND CONFIGURED AS ABOVE) IS SET, PREVENTING
UNINTENTIONAL MOVEMENT OF THE CRANE OR TRACKED
MACHINE.
FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
01/2001, CATTRON - THEIMEG
TM
Section 3, Page 7
Operating Procedure – PS Controller, continued.
WARNINGS:
MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT,
AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE,
BEFORE INSERTING AN ‘i-Key’ INTO A PENDANT CONTROLLER, YOU
MUST INSURE THE CORRECT CODED ‘i-Key’ IS SELECTED FOR THE
DESIRED EQUIPMENT TO BE OPERATED.
IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES
CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS
PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER, OTHER
EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY
MAY BECOME OPERATIONAL.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN
OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD
RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE
TO EQUIPMENT.
WARNING:
CATTRON-THEIMEG™ PSEZ AND PSCS PORTABLE REMOTE CONTROL
(PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO
SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electromagnet circuits, vacuum circuits, grab, pump motors, fire suppression etc.).
CONTACT CATTRON-THEIMEG™ FACTORY FOR INFORMATION
REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS.
SHOULD CATTRON-THEIMEG™ PSCS AND PSEZ PORTABLE REMOTE
CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO
INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE
TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY
RESULT.
IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL
NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT
OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER
CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM.
Section 3, Page 8
01/2001, CATTRON - THEIMEG
TM
Operating Procedure – PS Controller, continued.
WARNING:
ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE
OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN ADDITION,
ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM
INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE
TO IMPLEMENT THIS WARNING MAY RESULT IN PERSONAL INJURY
OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
CAUTION:
All control functions will be stopped if the PS Controller is used or left standing
in an upright position during heavy rain, or in hostile environments where water
could fill the top of the controller and cover the ‘i-Key’. To resume control
functions, simply invert and shake the controller to remove excess water. There
is no need to remove the ‘i-Key’. Ideally, to prevent such occurences in wet
weather and water spray environments, the controller should (1) never be left
standing upright, (2) be carried by the shoulder strap, and (3) operated in a near
horizontal position.
1.
Insert correct color-coded ‘i-Key’. This coded electronic key sets the unique operating
parameters for a given control system. In the PSAT family of controllers, these parameters
include, address code, operating frequency and function key (pushbutton) configurations,
whereas in the PSEZ and PSCS families of controllers the ‘i-key’ only defines and enables the
pushbutton operating functions for a specific PRC system. The ‘i-key’ is simply installed by
pressing into its receptacle and may be further secured to the controller using the metal stud
located behind the rubber bumper. Note that a Pendant Station Controller will not operate
without an ‘i-Key’ installed.
2.
Set red STOP Switch to ‘RUN’. Pulling this switch upward enables power to be applied to the
PS controller. If the switch has been pushed down to the ‘STOP’ position, you will first have to
unlatch the switch knob by rotating in a clockwise direction.
3.
Set Power ON/OFF Switch to ‘ON’. Rotating this switch clockwise applies power to the PS
controller. Two quick ‘beeps’ with the green TRANSMIT LED flashing rhythmically indicates
the controller is ready for use and a power up message has been sent to the target
receiver/decoder. The targeted receiver/decoder will respond by energizing the mainline
contactor of your controlled equipment.
01/2001, CATTRON - THEIMEG
TM
Section 3, Page 9
Operating Procedure – PS Controller, continued.
4.
Press any large pushbutton. The PS Controller is now fully operational and transmitting a
signal as indicated by the green TRANSMIT LED flashing. Operate the pushbuttons and
switches as required, remembering that each large pushbutton must be maintained in order for
the function to continue to operate. Any or all functions may be operated simultaneously if the
controlled machine permits such operation.
NOTES:
(1) A system STOP may be initiated at any time during the control
function by pushing the red STOP switch downwards.
(2) When all control functions have been completed, we recommend
you initiate a system STOP (push red STOP switch down) before
setting the ON/OFF switch to the ‘OFF’ position. This will prevent the
Mainline contactor from remaining energized for up to 10 minutes via
control of OPR.
END OF SECTION
Section 3, Page 10
01/2001, CATTRON - THEIMEG
TM
Section 4 – Maintenance Instructions
CATTRON-THEIMEG™ Maintenance Philosophy.
CAUTION:
All PS Controller internal circuit boards are sensitive to electrostatic discharge.
Consequently, all maintenance procedures involving disassembly and assembly of
controllers shall be carried out by qualified technicians using anti-static mats and
personal grounding straps. Failure to comply with this caution may result in
equipment damage and void our warranty.
Our general maintenance philosophy is that inoperative PS Controllers are normally returned as
complete units to our workshops for repair. This is because (a) the internal circuit boards are extremely
sensitive to electrostatic discharge and (b) internal components are highly miniaturized and assembled to
within very close tolerances. Consequently, internal components may be irreparably damaged when
replaced by unqualified maintenance personnel. However, CATTRON-THEIMEG™ will permit
replacement for the sub-assemblies and components identified below, provided (1) replacements are
carried out by suitably qualified technicians, (2) all recommendations to eliminate electrostatic discharge
are implemented and (3) all defective items are returned to our workshops for repair.
In the CATTRON-THEIMEG™ Series of PS Controllers, five items may be easily and quickly replaced
– refer to the Illustrated Parts Breakdown in Section 6. These are:
1.
Battery Pack (Ni-Cad = Part # 60C-0060N. Alkaline = Part # 60C-0060A).
2.
Top End Cap sub-assembly (Part # CPA-0360), containing the ‘i-Key’ receptacle,
power ON/OFF switch, red system STOP switch, internal antenna module, all
surrounded by an armorized rubber bumper.
3.
Bottom End Cap sub-assembly (Part # CPA-0359), containing the battery door
assembly, battery-charging socket and surrounded by an armorized rubber bumper.
4.
Upper Main Body Housing (Part # 15C-0138R).
5.
Rubber Side Grips (Part # 15C-0126P).
01/2001, CATTRON - THEIMEG
TM
Section 4, Page 1
Maintenance Procedures.
Preventive Maintenance is a periodic check of the system to keep it functioning at peak
performance. Preventive maintenance can also help prevent breakdowns and equipment outages
by identifying potential problems before they become real problems.
Corrective Maintenance refers to fixing a problem once it has occurred. The goal of corrective
maintenance is to get the system back on line as quickly as possible with a minimum impact on
operations.
Preventive maintenance – PS Controllers.
Preventive maintenance for PS controllers is minimal because they are extremely durable and reliable
units. Preventive maintenance procedures are detailed in the following sub paragraphs:
Daily Visual Inspection.
Before use, visually inspect the controller for cleanliness, physical damage, and security of
external parts (screws, switches, rubber grips, etc.). CATTRON-THEIMEG™ emphasizes
that regular visual inspections not only mean quickly locating a source of potential problems,
but also may prevent serious problems from developing later.
Annual Netting Check.
Netting means that the receiver and transmitter of the radio control system are aligned on the
same frequency. It is very important that the receiver is exactly tuned to the frequency
required. This check should be done once a year by a qualified radio technician utilizing
calibrated test equipment.
Troubleshooting – PS Controllers.
A basic Troubleshooting Guide is provided on page 4 of this section. When troubleshooting the
controller, the other major components of the remote control system (power supply and
receiver/decoder) should be fully operational. The operator should also be located within 500 feet (160+
meters) of the target receiver/decoder.
Corrective maintenance – PS Controllers.
Corrective maintenance for PS Controllers is restricted to replacing the Battery Pack, Rubber Side Grips,
Top End Cap sub-assembly, Bottom End Cap sub-assembly and Upper Main Body Housing. Refer to
the Disassembly/Assembly procedures below when removing and replacing items. On completion of
any assembly procedure and before placing the PS Controller into operational service, carry out a
Functional Check as follows:
Section 4, Page 2
01/2001, CATTRON - THEIMEG
TM
Maintenance Procedures, continued.
Functional Check.
A functional check is accomplished by operating the PS Controller in
accordance with the Operating Procedures in Section 3 of this manual. Insure all system control
functions are fully operational.
Replacement Items – Pendant Controllers.
Replacement items may be ordered direct from CATTRON-THEIMEG™. To order replacement items,
refer to Section 6 of this manual for part numbers and quantities required.
In addition:
1.
If ordering replacement parts for PSAT controllers, provide the following
information: (1) the model type and revision number located on the serial tag
underneath the controller, and (2) the control system ID and serial number located
on the ‘i-Key’ label tag.
2.
If ordering replacement parts for PSEZ or PSCS controllers, provide the model
type and revision number located on the serial tag underneath the controller.
01/2001, CATTRON - THEIMEG
TM
Section 4, Page 3
Section 4, Page 4
01/2001, CATTRON - THEIMEG
TM
Pendant Controllers – Disassembly and Assembly.
Observe these guidelines when carrying out the following procedures:
• When requesting spare parts from CATTRON-THEIMEG™, provide the model type of the
controller (refer to the serial tag located on the underside if the controller).
• Tag defective items with a description of the fault and return the item to CATTRONTHEIMEG™ for repairs.
• Tag all leads before de-soldering or removal. Use small wire tags or pieces of adhesive tape
with handwritten numbers. Reconnect all wires to the same location from which they were
removed, observing proper polarity.
• Visually inspect all disassembled items for damage. Replace damaged or defective items with
identical items.
CAUTION:
All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat
and personal grounding strap (wrist) for all maintenance procedures involving
disassembly and assembly of PS Controllers. Failure to comply with this caution
may result in equipment damage and will void our warranty.
PS Controllers contain electrostatic sensitive devices that may be damaged (immediately or latently) by
electrostatic charges of less than 1,000 volts. Since electrostatic charges of up to 35,000 volts may be
present at the workbench, it is imperative that you take the following precautions before disassembly
and assembly of the controller.
• Ground the working surfaces of the workbench. This may be accomplished with an anti-static
kit containing a wrist strap, two ground cords, anti-static floor-mats, and anti-static tablemats.
• Remove nylon or double-knit polyester jackets, roll up long sleeves, and remove or tie back
hanging neckties.
• Eliminate static-generating material (plastics, styrofoams, synthetic materials, etc.) from the
workbench area.
01/2001, CATTRON - THEIMEG
TM
Section 4, Page 5
Battery Pack (Figure 4-1).
Remove the battery pack as follows:
a.
Lay Controller (1) face up.
b.
Release two knurled thumbscrews (2) and withdraw cover-plate (3).
c.
Withdraw battery pack (4) from battery compartment (5).
Figure 4-1. Battery Pack, removal and replacement
1.
2.
3.
4.
5.
Pendant Controller
Knurled Thumbscrew (2)
Cover Plate
Battery Pack
Battery Compartment
Replace the battery pack as follows:
a.
Position battery pack (4) with the four contact strips uppermost and facing forwards.
Install battery pack (4) by pushing fully home inside the battery compartment (5).
b.
Install cover-plate (3) and secure by evenly hand tightening two knurled thumbscrews
(2). Do not overtighten - a snug fit is all that is necessary.
NOTE:
Section 4, Page 6
If a new re-chargeable Ni-Cad Battery Pack has been installed to the
Pendant Controller, it will require charging in accordance with the
procedure in Section 3, Page 3 of this Manual.
01/2001, CATTRON - THEIMEG
TM
Bottom End Cap subassembly (Figure 4-2).
CAUTION:
All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat
and personal grounding strap (wrist) for all maintenance procedures involving
disassembly and assembly of PS controllers. Failure to comply with this caution
may result in equipment damage and will void our warranty.
Remove the subassembly as follows:
a.
Lay controller (1) face down on Anti-Static Mat and remove Battery Pack. Refer to
Removal of Battery Pack, above.
Remove five screws (2) using Phillips screwdriver.
Carefully withdraw endcap sub-assembly (3) to expose charging socket wiring harness
(4). Using long nosed pliers, carefully disconnect 2-pin connector (5) from its socket
located on the underside of the encoder board.
b.
c.
Figure 4-2. Bottom Endcap Sub-assembly, removal and replacement
Replace the subassembly as follows:
a.
Observing correct orientation as illustrated in the cutout above, connect 2-pin connector
(5) to its socket located on the underside of the encoder board.
b.
Carefully align endcap subassembly (3) to controller housing (1), taking care not to pinch
charging socket wiring harness (4).
c.
Secure endcap sub-assembly (3) using five screws (2).
d.
Replace the Battery Pack. Refer to Replacement of Battery Pack, above.
01/2001, CATTRON - THEIMEG
TM
Section 4, Page 7
Top End Cap subassembly (Figures 4-3 and 4-3A).
CAUTION:
All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat
and personal grounding strap (wrist) for all maintenance procedures involving
disassembly and assembly of PS controllers. Failure to comply with this caution
may result in equipment damage and will void our warranty.
Remove the subassembly as follows:
a.
Lay Controller (1) face down on Anti-Static Mat and remove Battery Pack. Refer to
Removal of Battery Pack, above.
b.
Remove five screws (2) using Phillips screwdriver.
c.
Carefully withdraw endcap sub-assembly (3) to expose switch and antenna wiring
harnesses (4 and 5). Disconnect 2 and 6-pin connectors (6 and 7) from their respective
Transmitter and Encoder Board sockets (see figure 4-3A below).
Figure 4-3. Top Endcap Sub-assembly, removal and replacement
1..
2.
3.
4.
Section 4, Page 8
Pendant Controller Housing (part)
Screw, Phillips, 4-40 x ½ in. (5)
Top Endcap Sub-Assembly
Antenna Wiring Harness
5. Switch Wiring Harness
6. 2-Pin Connector
7. 6-Pin Connector
01/2001, CATTRON - THEIMEG
TM
Top End Cap subassembly (Figures 4-3 and 4-3A), continued.
Replace the subassembly as follows (refer to Figure 4-3 above, unless stated otherwise):
Figure 4-3A. 2-pin and 6-pin connector orientation
NOTE:
Orientation of the 2-pin and 6-pin connectors is critical in the following
step. If the 2-pin connector is reversed, the transmitter range will be
significantly reduced.
a.
Connect 2 and 6-pin connectors (6 and 7) to their respective Transmitter and Encoder
Board sockets, observing orientation of connectors as shown in Figure 4-3A above.
b.
Carefully align endcap sub-assembly (3) to controller (1) housing, taking care not to
pinch wiring harnesses (4 and 5).
c.
Secure endcap sub-assembly (3) using five screws (2).
d.
Replace Battery Pack. Refer to Replacement of Battery Pack, above.
01/2001, CATTRON - THEIMEG
TM
Section 4, Page 9
Upper and Lower Main Body Housings (Figure 4-4, opposite).
CAUTION:
All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat
and personal grounding strap (wrist) for all maintenance procedures involving
disassembly and assembly of PS controllers. Failure to comply with this caution
may result in equipment damage and will void our warranty.
Separate and remove the housings as follows:
a.
Lay Controller face down on Anti-Static Mat and remove Battery Pack, Bottom Endcap
sub-assembly, and Top Endcap subassembly. Refer to Removal of Battery Pack,
Bottom Endcap sub-assembly, and Top Endcap subassembly, above.
b.
Remove two rubber side grips (1) by sliding or pulling away from upper and lower main
body housings (2 and 3).
c.
Completely separate upper and lower main body housings (2 and 3) by sliding them
apart.
Replace the housings as follows:
a.
Apply a thin film of lubricant (Dow Corning MOLYKOTE 557 or equivalent) to upper
and lower main body housing (2 and 3) joints. Slide or snap the two housings together.
b.
Install two rubber side grips (1) along their grooved upper and lower main body housing
(2 and 3) locations. To facilitate installation, a light application of window cleaning
spray or liquid (Windex or equivalent) may be applied to lubricate the inside channels of
each rubber grip.
c.
Install Top Endcap subassembly, Bottom Endcap sub-assembly and Battery Pack. Refer
to Replacement of Top Endcap sub-assembly, Bottom Endcap sub-assembly and
Battery Pack, above.
Section 4, Page 10
01/2001, CATTRON - THEIMEG
TM
Upper and Lower Main Body Housings (Figure 4-4), continued.
Figure 4-4. Upper and Lower Main Body Housings, removal and replacement
1. Rubber Side Grip (2)
2. Upper Main Body Housing
3. Lower Main Body Housing
Rubber Side Grips.
Procedures for replacing the Rubber Side Grips are described above. Note that it will be necessary to
remove the bottom endcap sub-assembly before replacing the rubber side grips.
END OF SECTION
01/2001, CATTRON - THEIMEG
TM
Section 4, Page 11
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Section 4, Page 12
01/2001, CATTRON - THEIMEG
TM
Section 5 – PSEZ & CS Series Controllers
Introduction – PSEZ & CS Controllers.
In the PSAT controller family previously described in this manual, the ‘i-Key’ supplied with the
controller is pre-programmed with the system operating address, operating frequency and controller
pushbutton/function switch layout for a given control system. Note that PSAT pushbuttons may be
either of the 3-step type, the proportional (stepless) type, or a combination of both, dependent upon
system requirements.
In the PSEZ and CS controller families, the ‘i-Key’ is only pre-programmed with the controller
pushbutton/function switch layout for a given control system. Note that PSEZ and CS pushbuttons
are of the 3-step variety only.
In addition:
1.
When your PSEZ or CS Controller is supplied as part of a complete CATTRONTHEIMEG™ control system package (controller, receiver/decoder and appropriate
hardware), the system operating address and operating frequency is preprogrammed into the controller at our factory and advised to yourselves. Such
programming has been carried out using the top four large pushbuttons.
2.
When your PSEZ or CS Controller is supplied as a stand-alone item to complement
your existing CATTRON-THEIMEG™ EZ or CS Control System, or has been
returned after repairs, address and operating frequency has not been preprogrammed into the controller at our factory.
Given the circumstances described in 1 and 2, above, you will be required to verify/program the system
address and operating frequency before using your PSEZ or CS controller for the first time.
Installing Different PSCS (blue) & EZ (green) ‘i-Keys’.
As an additional safeguard, your PSCS and EZ controller’s internal programming software has
been designed to prevent accidental operation of your remote controlled equipment immediately a
different (wrong control system) ‘i-Key’ is inserted into the controller.
All PSCS and EZ ‘i-Keys’ are electronically coded with an individual serial number. This unique ‘iKey’ serial number is automatically registered with the host controller’s programming software when
the target remote control system operating address and frequency are programmed using the controller
keypad.
Consequently, inserting any ‘i-Key’ into your controller except the ‘i-Key’ installed when the operating
address and frequency was last programmed (the original ‘i-Key’) will prevent any further remote
control operations. When a different (or defective) ‘i-Key’ is installed, the controller will indicate a
fault condition by emitting four long ‘beeps’ immediately after you apply power to the remote
controller.
01/2001, CATTRON - THEIMEG
TM
Section 5, Page 1
Installing Different PSCS (blue) & EZ (green) ‘i-Keys’, continued.
If you wish to continue remote control operations, it will be necessary to choose one of the following
options:
1.
Install the original ‘i-Key’ into the controller,
or,
2.
Re-program the address code and frequency of the controller with a different ‘iKey’ installed – refer to page 5 of this Section onwards for programming
procedures. This unique ‘i-Key’ serial number will then be registered with the host
controller’s programming software immediately upon entering one of the
controller’s keypad programming menu options.
NOTE. If option 2 above has been selected, inserting the original ‘i-Key’ (referred
to in option 1 above) or any other ‘i-Key’ into the controller will prevent
any further remote control operations.
PSEZ & CS Control Systems - frequency and address
assignment.
WARNING:
FAILURE TO PROPERLY SELECT FREQUENCY AND
ADDRESS MAY RESULT IN THE UNINTENTIONAL
OPERATION OF OTHER MACHINERY AND COULD RESULT
IN DEATH OR SERIOUS INJURY TO PERSONNEL. DO NOT
DUPLICATE ADDRESS ASSIGNMENT.
To enable a CATTRON-THEIMEG™ PSEZ & PSCS controller and receiver/decoder to communicate,
they must use the same RF frequency and digital address. PSEZ PRC system controllers and
receiver/decoders are capable of operating on up to 79 different frequencies and 126 addresses. PSCS
PRC system controllers and receiver/decoders are capable of operating on up to 127 different
frequencies and 65,000 addresses for maximum versatility.
Section 5, Page 2
01/2001, CATTRON - THEIMEG
TM
PSEZ & CS Control Systems - frequency and address
assignment, continued.
NOTE:
CS PRC system receiver/decoder board address codes are permanently
assigned at the factory for the life of the equipment. They may not be changed
by yourself.
However, you may be required to change the frequency and address code of the PS Series controller.
This may be necessary when: (1) The factory preset address code assigned to the system
receiver/decoder is different to that set in the PS controller, (2) installing more than one control system
at a single location, (3) replacing a receiver/decoder board, (4) other radio remote control systems emit
RF signals that interfere with normal or safe operation, and (5) inserting any ‘i-Key’ into a controller
except the one installed when the address and frequency was last programmed. Before making any
change to PS controller frequency and address settings, check the factory settings on the target
receiver/decoder to determine what changes are necessary for the controller.
A CATTRON-THEIMEG™ PSEZ controller sends a two-digit address code with every transmission. A
CATTRON-THEIMEG™ PSCS controller sends a four-digit address code with every transmission. For
the system to operate, the same address code must be set in the receiver/decoder. When a transmission
is received by the target control system receiver/decoder, the address of the PS controller sending the
signal is checked against the address of the receiver/decoder. If these addresses do not match, the signal
is ignored and an error message is displayed on the receiver/decoder status display. For safety reasons,
it is recommended that each plant maintain a central record of frequency and address assignments
so that no two PS controllers at any single location use the same address or frequency settings.
Ignoring this recommendation could cause unintentional operation of other machinery resulting in
damage to equipment and/or personal injury or death.
PSEZ & CS Controllers - address/frequency verification.
NOTES: (1) The PSEZ controller has two programmable address code digits which are
selected using Pushbuttons #3 (High digit) and #4 (Low digit) on the keypad.
(2) The PSCS controller has four programmable address code digits which are
selected using Pushbuttons #1 (High digit) thru #4 (Low digit) on the keypad.
Verify the desired address (address consists of two or four digits, all of which must be programmed) and
the frequency of the receiver/decoder unit that is intended to be operated. The original factory settings
can be found on the label affixed to the side of the receiver/decoder housing, or on the front inside cover
of the manual originally supplied with the PS Series system.
EXAMPLE #1: Sample EZ System Label -
01/2001, CATTRON - THEIMEG
TM
Factory Settings:
Frequency 448.9000MHz
Address: F E
/ \
Digit #1
Digit #2
(‘High’ digit) (‘Low’ digit)
Section 5, Page 3
PSEZ & CS Controllers - address/frequency verification, continued.
EXAMPLE #2: Sample CS System Label -
Factory Settings:
Frequency 448.9000MHz
Address: 3 B F E
/ | | \
Digit #1 | | Digit #4
(‘High’ digit) | | (‘Low’ digit)
/ \
Digit #2 Digit #3
To determine a PS controller’s current settings, skip ahead to the paragraph on page 13 of this section
titled ‘Address, Frequency Bank, and Frequency report only’ for detailed instructions.
Programming PSEZ &CS Controller address and frequency.
WARNING:
FAILURE TO PROPERLY SELECT FREQUENCY AND ADDRESS MAY
RESULT IN THE UNINTENTIONAL OPERATION OF OTHER
MACHINERY AND COULD RESULT IN DEATH OR SERIOUS INJURY
TO PERSONNEL. DO NOT DUPLICATE ADDRESS ASSIGNMENT.
NOTES: (1) The ‘i-Key’ must match the two letter designation of the model
number, i.e. EZ, or CS. This is found on a label located on the
underside of the controller, and also on a label located inside the
battery compartment.
(2) The controller will not operate your target control system without
the correct address and operating frequency programmed.
Referring to Figure 5-1 below and the keypad function menu on the next page, the top four large
pushbuttons of the PSEZ and PSCS controller are used during the data entry mode.
As required, proceed to verify/program PS Controller address and frequency using the following
procedures:
Section 5, Page 4
01/2001, CATTRON - THEIMEG
TM
Programming PSEZ &CS Controller address and frequency,
continued.
PSEZ & CS Keypad programming menu.
MAIN MENU
FREQUENCY BANK ENTRY & REPORT
FREQUENCY ENTRY & REPORT
REPORT ALL
ADDRESS DIGIT SELECT
DIGIT #2
DIGIT #3
DIGIT #4
ADDRESS SELECT & STATUS
REPORT ADDRESS
FREQUENCY BANK
SELECT & STATUS
REPORT STATUS
FREQUENCY
SELECT & STATUS
REPORT STATUS
REPORT STATUS
FREQUENCY BANK SELECT 2
FREQUENCY VALUE
01/2001, CATTRON - THEIMEG
TM
ADDRESS DIGIT VALUE
DIGIT #2
DIGIT #3
DIGIT #4
Section 5, Page 5
Address digit #1 entry and report (CS controller only).
NOTE: The following Address Digit #1 and # 2 entry and reporting procedures are
not applicable to PSEZ Controllers. When programming a PSEZ Controller,
go directly to Address digit #3 entry and report and Address digit #4 entry
and report on pages 9 and 10 of this section.
Figure 5-1. PSEZ & CS Remote Controllers, keypad-programming layout
Color Coded i-Key
‘ON/OFF’Switch
Red STOP Switch
STOP
NOTE: Button #1 and #2
are not used for
address digit select
or reports on EZ
controllers
BUTTON #1
BUTTON #2
BUTTON #3
BUTTON #4
1. Referring to Figure 5-1 above, set the ON/OFF switch on the PSCS controller to ‘OFF’.
Make sure the red STOP Switch on the controller is unlatched and set to the ‘RUN’ (pulled
up) position.
NOTE: Provided a Frequency and Address has been programmed in the controller,
applying power to the controller with the red STOP Switch set to ‘STOP’
(pushed down) will immediately place the Controller in a STOP message
transmit cycle. If a Frequency and Address has not been pre-programmed in the
controller, the STOP message transmit cycle cannot be sent. Instead, the
controller will emit three long beeps and reset.
Section 5, Page 6
01/2001, CATTRON - THEIMEG
TM
Address digit #1 entry and report (CS controller only), continued.
2. Press and hold down buttons #1 and #2 and set ON/OFF switch to ‘ON’. Pause
approximately for one second or until the green LED illuminates, then release buttons #1 and
#2. The controller will emit one long ‘beep’, which means you are now in the Main Menu
of the address and frequency program.
NOTE: The yellow LED will flash instead of the green LED when low battery voltage is
detected.
3. Press and release button #1 (see Figure 5-1 above). The controller will emit one long ‘beep’
followed by one short ‘beep’ and the green LED will flash with the short ‘beep’. This
indicates you are now in the Address Data Entry and Report Mode.
4. To select Address Digit #1 Data Entry Mode, press and release button #1. To find the present
Address Digit #1 value, press and release button #4. The unit will emit one long beep to alert
you, then will beep out the Address Digit #1 setting count with short beeps. (i.e., three short
beeps if the Address Digit #1 is ‘3’). The green LED will also flash with each short
beep/count. (‘0’ is represented by a long beep with no LED flash). Look, listen, and count to
determine the existing value. Repeat as necessary by pressing button #4. See Address Table
below to convert number of ‘Beeps’ to ‘Address Digit’ setting.
Address Table – PSEZ & CS Controllers
NUMBER OF COUNTS OF
BEEPS AND GREEN LED
FLASHES
10
11
12
13
14
15
01/2001, CATTRON - THEIMEG
TM
ADDRESS DIGIT
Section 5, Page 7
Address digit #1 entry and report (CS controller only), continued.
5. To increment the Address Digit #1, press and release button #1. Each depression will
increment the Address Digit #1 by one, continuing from its present value until it reaches F,
then will roll over to zero and start again (the unit will beep each time button #1 is
depressed).
NOTE: On CS Controller, address codes 0000 and FFFF are not valid.
6. Press button #4 to confirm your desired setting.
7. Once you have entered the desired Address Digit #1, set the ON/OFF switch on the PSCS
controller to ‘OFF’ to permanently store the Address Digit #1.
Address digit #2 entry and report (CS controller only).
1. Referring to Figure 5-1 above, set the ON/OFF switch on the PSCS controller to ‘OFF’.
Make sure the red STOP Switch on the controller is unlatched and set to the ‘RUN’ (pulled
up) position.
NOTE: Provided a Frequency and Address has been programmed in the controller,
applying power to the controller with the red STOP Switch set to ‘STOP’
(pushed down) will immediately place the Controller in a STOP message
transmit cycle. If a Frequency and Address has not been pre-programmed in the
controller, the STOP message transmit cycle cannot be sent. Instead, the
controller will emit three long beeps and reset.
2. Press and hold down buttons #1 and #2 (see Figure 5-1 above) and set ON/OFF switch to
‘ON’. Pause approximately for one second or until the green LED illuminates, then release
buttons #1 and #2. The controller will emit one long ‘beep’, which means you are now in the
Main Menu of the address and frequency program.
NOTE: The yellow LED will flash instead of the green LED when low battery voltage is
detected.
3. Press and release button #1. The controller will emit one long ‘beep’ followed by one short
‘beep’ and the green LED will flash with the short ‘beep’. This indicates you are now in the
Address Data Entry and Report Mode.
4. To select Digit #2 Data Entry Mode, press and release button #2. To find the present
Address Digit #2 value, press and release button #4. The unit will emit one long beep to alert
you, then will beep out the Address Digit #2 setting count with short beeps. (i.e., eleven short
beeps if the Digit is ‘B’). The green LED will also flash with each short beep/count. (‘0’ is
represented by a long beep with no LED flash). Look, listen, and count to determine the
existing value. Repeat as necessary by pressing button #4. See above Address Table to
convert number of ‘Beeps’ to ‘Address Digit’ setting.
Section 5, Page 8
01/2001, CATTRON - THEIMEG
TM
Address digit #2 entry and report (CS controller only), continued.
5. To increment the Address Digit #2 press and release button #1. Each depression will
increment the Address Digit by one, continuing from its present value until it reaches 15,
then will roll over to zero and start again (the unit will beep each time button #1 is
depressed).
6. Press button #4 to confirm your desired setting.
7. Once you have entered the desired Address Digit #2, set the ON/OFF switch on the PSCS
controller to ‘OFF’ to permanently store Address Digit #2.
Address digit #3 entry and report (PSEZ and CS controllers).
NOTES: (1) On the PSEZ Controller, address codes 00 and FF are not valid.
(2) On the PSEZ Controller, Digit #3 is the ‘High’ Digit and Digit #4
is the ‘Low’ Digit.
1. Referring to Figure 5-1 above, set the ON/OFF switch on the PS controller to ‘OFF’. Make
sure the red STOP Switch on the controller is unlatched and set to the ‘RUN’ (pulled up)
position.
NOTE: Provided a Frequency and Address has been programmed in the controller,
applying power to the controller with the red STOP Switch set to ‘STOP’
(pushed down) will immediately place the Controller in a STOP message
transmit cycle. If a Frequency and Address has not been pre-programmed in the
controller, the STOP message transmit cycle cannot be sent. Instead, the
controller will emit three long beeps and reset.
2. Press and hold down buttons #1 and #2 (see Figure 5-1 above) and set ON/OFF switch to
‘ON’. Pause approximately for one second or until the green LED illuminates, then release
buttons #1 and #2. The controller will emit one long ‘beep’, which means you are now in the
Main Menu of the address and frequency program.
NOTE: The yellow LED will flash instead of the green LED when low battery voltage is
detected.
3. Press and release button #1. The controller will emit one long ‘beep’ followed by one short
‘beep’ and the green LED will flash with the short ‘beep’. This indicates you are now in the
Address Data Entry and Report Mode.
01/2001, CATTRON - THEIMEG
TM
Section 5, Page 9
Address digit #3 entry and report (PSEZ and CS controllers), continued.
4. To select Digit #3 (‘High’ digit on PSEZ controllers) Data Entry Mode, press and release
button #3. To find the present Address Digit #3 value, press and release button #4. The unit
will emit one long beep to alert you, then will beep out the Address Digit #3 setting count
with short beeps. (i.e., five short beeps if the Digit is ‘5’). The green LED will also flash with
each short beep/count. (‘0’ is represented by a long beep with no LED flash). Look, listen,
and count to determine the existing value. Repeat as necessary by pressing button #4. See
Address Table on page 7 of this section to convert number of ‘Beeps’ to ‘Address Digit’
setting.
5. To increment the Address Digit #3 press and release button #1. Each depression will
increment the Address Digit #3 by one, continuing from its present value until it reaches 15,
then will roll over to zero and start again. (The unit will beep each time button #1 is
depressed).
6. Press button #4 to confirm your desired setting.
7. Once you have entered the desired Address Digit #3, set the ON/OFF switch on the PSEZ or
CS controller to ‘OFF’ to permanently store the Address Digit #3.
Address digit #4 entry and report (PSEZ and CS controllers).
NOTES: (1) On the PSEZ Controller, address codes 00 and FF are not valid.
(2) On the PSEZ Controller, Digit #3 is the ‘High’ Digit and Digit #4
is the ‘Low’ Digit.
1. Referring to Figure 5-1 above, set the ON/OFF switch on the PS controller to ‘OFF’. Make
sure the red STOP Switch on the controller is unlatched and set to the ‘RUN’ (pulled up)
position.
NOTE: Provided a Frequency and Address has been programmed in the controller,
applying power to the controller with the red STOP Switch set to ‘STOP’
(pushed down) will immediately place the Controller in a STOP message
transmit cycle. If a Frequency and Address has not been pre-programmed in the
controller, the STOP message transmit cycle cannot be sent. Instead, the
controller will emit three long beeps and reset.
2. Press and hold down buttons #1 and #2 (see figure 5-1 above) and set ON/OFF switch to
‘ON’. Pause approximately for one second or until the green LED illuminates, then release
buttons #1 and #2. The controller will emit one long ‘beep’, which means you are now in the
Main Menu of the address and frequency program.
NOTE: The yellow LED will flash instead of the green LED when low battery voltage is
detected.
Section 5, Page 10
01/2001, CATTRON - THEIMEG
TM
Address digit #4 entry and report (PSEZ and CS controllers), continued.
3. Press and release button #1. The controller will emit one long ‘beep’ followed by one short
‘beep’ and the green LED will flash with the short ‘beep’. This indicates you are now in the
Address Data Entry and Report Mode.
4. To select Address Digit #4 (‘Low’ digit on PSEZ controllers) Data Entry Mode, press and
release button #4. To find the present Address Digit #4 value, press and release button #4
again. The unit will emit one long beep to alert you, then will beep out the Address Digit #4
setting count with short beeps. (i.e., fourteen short beeps if the Digit is ‘E’). The green LED
will also flash each short beep/count. (‘0’ is represented by a long beep with no LED flash).
Look, listen, and count to determine the existing value. Repeat as necessary by pressing
button #4. See Address Table on page 7 of this section to convert number of ‘Beeps’ to
‘Address Digit’ setting.
5. To increment the Address Digit #4 press and release button #1. Each depression will
increment the Address Digit #4 by one, continuing from its present value until it reaches 15,
then will roll over to zero and start again. (the unit will beep each time button #1 is
depressed).
6. Press button #4 to confirm your desired setting.
7. Once you have entered the desired Address Digit #4, set the ON/OFF switch on the PSEZ or
CS controller to ‘OFF’ to permanently store the Address digit #4.
Frequency Bank entry and report (PSEZ and CS Controllers).
1. Referring to Figure 5-1 above, set the ON/OFF switch on the PS controller to ‘OFF’. Make
sure the red STOP Switch on the controller is unlatched and set to the ‘RUN’ (pulled up)
position.
NOTE: Provided a Frequency and Address has been programmed in the controller,
applying power to the controller with the red STOP Switch set to ‘STOP’
(pushed down) will immediately place the Controller in a STOP message
transmit cycle. If a Frequency and Address has not been pre-programmed in the
controller, the STOP message transmit cycle cannot be sent. Instead, the
controller will emit three long beeps and reset.
2. Press and hold down buttons #1 and #2 (see figure 5-1 above) and set ON/OFF switch to
‘ON’. Pause approximately for one second or until the green LED illuminates, then release
buttons #1 and #2. The controller will emit one long ‘beep’, which means you are now in the
Main Menu of the address and frequency program.
NOTE: The yellow LED will flash instead of the green LED when low battery voltage is
detected.
01/2001, CATTRON - THEIMEG
TM
Section 5, Page 11
Frequency Bank entry and report (PSEZ and CS Controllers), continued.
3. Press and release button #2. The controller will emit one long ‘beep’ followed by two short
‘beeps’ and the green LED will flash rhythmically with each short ‘beep’. This indicates you
are now in the Frequency Bank Data Entry and Report Mode.
4. To find the present Frequency Bank value, press and release button #4. The unit will emit
one long beep to alert you, then will beep out the Frequency Bank setting count with short
beeps. (i.e., zero beeps for frequency table USA 1, two beeps for frequency table USA 3 –
see Table 5-1 below). The green LED will also flash with each short beep/count. (‘0’ is
represented by a long beep with no LED flash). Look, listen, and count to determine the
existing value. Repeat as necessary by pressing button #4.
5. To increment the Frequency Bank, press and release button #2 (Frequency Bank). Each
depression will increment the Frequency Bank by one, continuing from its present value until
it reaches 4, then will roll over to zero and start again. (The unit will beep each time button
#2 is depressed). See Table 5-1 below for frequency bank assignment.
6. Press button #4 to confirm your desired setting.
7. Once you have entered the desired Frequency Bank, set the ON/OFF switch on the PS
controller to ‘OFF’ to permanently store the Frequency Bank.
Frequency entry and report (PSEZ and CS Controllers).
1. Referring to Figure 5-1 above, set the ON/OFF switch on the PS controller to ‘OFF’. Make
sure the red STOP Switch on the controller is unlatched and set to the ‘RUN’ (pulled up)
position.
NOTE: Provided a Frequency and Address has been programmed in the controller,
applying power to the controller with the red STOP Switch set to ‘STOP’
(pushed down) will immediately place the Controller in a STOP message
transmit cycle. If a Frequency and Address has not been pre-programmed in the
controller, the STOP message transmit cycle cannot be sent. Instead, the
controller will emit three long beeps and reset.
2. Press and hold down buttons #1 and #2 (see figure 5-1 above) and set ON/OFF switch to
‘ON’. Pause approximately for one second or until the green LED illuminates, then release
buttons #1 and #2. The controller will emit one long ‘beep’, which means you are now in the
Main Menu of the address and frequency program.
NOTE: The yellow LED will flash instead of the green LED when low battery voltage is
detected.
Section 5, Page 12
01/2001, CATTRON - THEIMEG
TM
Frequency entry and report (PSEZ and CS Controllers), continued.
Table 5-1. Controller Frequency Bank and Frequency Selections
BEEP
COUNT
10
11
12
13
14
15
USA 1
(Bank 0)
Not
Programmed
448.1000
448.2000
448.3000
448.4000
448.6000
448.7000
448.8000
448.9000
449.1000
449.2000
465.7125
465.8125
460.7125
460.8125
457.0000
USA 2
(Bank 1)
449.3000
USA 3
(Bank 2)
457.5375
CAN 1
(Bank 3)
455.0000
USA 4
(Bank 4)
460.4875
* UK 1
(Bank 5)
458.5125
* UK 2
(Bank 6)
458.7125
449.3000
449.4000
449.6000
449.7000
449.8000
449.9000
460.6625
460.7625
460.8625
460.9125
465.6625
465.7625
465.8625
465.9125
457.0000
467.7875
460.6875
460.7375
460.7875
460.8375
460.8875
465.6875
465.7375
465.7875
465.8375
465.8875
467.3375
467.7625
467.8625
457.0000
457.5250
457.5500
457.5625
457.5750
467.7500
467.7750
467.7875
467.8000
467.8500
467.8750
467.9000
467.9250
455.0000
461.4625
467.9250
460.5125
460.5375
460.5625
460.9375
460.9625
460.9875
465.0125
465.4875
465.5125
465.5375
465.5625
465.9375
465.9625
465.9875
457.0000
458.5250
458.5375
458.5500
458.5625
458.5750
458.5875
458.6000
458.6125
458.6250
458.6375
458.6500
458.6625
458.6750
458.6875
458.7000
458.7250
458.7375
458.7500
458.7625
458.7750
458.7875
458.8000
458.8125
458.8500
458.8625
458.8750
458.8875
458.9125
458.9250
458.9375
* PSCS controllers supplied to United Kingdom customers only.
3. Press and release button #3. The controller will emit one long ‘beep’ followed by three short
‘beeps’ and the green LED will flash rhythmically with each short ‘beep’. This indicates you
are now in the Frequency Entry and Report Mode.
4. To find the present Frequency value, press and release button #4. The unit will emit one long
beep to alert you, then will beep out the Frequency setting count with short beeps. (i.e., for
frequency table USA 1, eight beeps will be emitted for 448.9000 MHz – see Table 5-1
above). The green LED will also flash with each short beep/count. (‘0’ is represented by a
long beep with no LED flash). Look, listen, and count to determine the existing value.
Repeat as necessary by pressing button #4.
5. To increment the Frequency, press and release button #3. Each depression will increment the
Frequency by one, continuing from its present value until it reaches 15, then will roll over to
zero and start again. (the unit will beep each time button #3 is depressed). See Table 5-1
above for frequency assignment.
6. Press button #4 to confirm your desired setting.
7. Once you have entered the desired Frequency, set the ON/OFF switch on the PS controller to
‘OFF’ to permanently store the Frequency.
01/2001, CATTRON - THEIMEG
TM
Section 5, Page 13
Address, Frequency Bank, and Frequency report only.
NOTES: (1) This mode allows confirmation of Address, Frequency Bank, and Frequency
settings. Changes cannot be programmed while in this mode.
(2) The following Address Digit #1 and # 2 address reporting procedures are
not applicable to PSEZ Controllers.
1. Referring to Figure 5-1 above, set the ON/OFF switch on the PS controller to ‘OFF’. Make
sure the red STOP Switch on the controller is unlatched and set to the ‘RUN’ (pulled up)
position.
NOTE: Provided a Frequency and Address has been programmed in the controller,
applying power to the controller with the red STOP Switch set to ‘STOP’
(pushed down) will immediately place the Controller in a STOP message
transmit cycle. If a Frequency and Address has not been pre-programmed in the
controller, the STOP message transmit cycle cannot be sent. Instead, the
controller will emit three long beeps and reset.
2. Press and hold down buttons #1 and #2 (see figure 5-1 above) and set ON/OFF switch to
‘ON’. Pause approximately for one second or until the green LED illuminates, then release
buttons #1 and #2. The controller will emit one long ‘beep’, which means you are now in the
Main Menu of the address and frequency program.
NOTE: The yellow LED will flash instead of the green LED when low battery voltage is
detected.
3. Press and release button #4. The controller will emit one long ‘beep’ followed by four short
‘beeps’ and the green LED will flash rhythmically with each short ‘beep’. This indicates
you are now in the Address, Frequency Bank, and Frequency report Mode.
4. To find one of the four CS or two EZ controller Address Digit Values, press and release
button #1. Then press buttons #1 thru #4 corresponding to the desired Address Digit (for EZ,
press buttons # 3 and #4 only). The controller will emit one long beep to alert you, then will
beep out the Address Digit setting count with short beeps. The green LED will also flash
with each beep/count. (‘0’ is represented by a long beep with no LED flash). Look, listen,
and count to determine the existing value. Repeat as necessary by pressing buttons #1 thru #4
for CS controllers or #3 and #4 for EZ controllers. See Address Table on page 7 of this
section to convert number of ‘Beeps’ to ‘Address Digit’ setting. Set the ON/OFF switch on
the controller to ‘OFF’. Repeat the above procedure to check Frequency Bank and
Frequency settings.
Section 5, Page 14
01/2001, CATTRON - THEIMEG
TM
Address, Frequency Bank, and Frequency report only, continued.
5. To find the present Frequency Bank value, press and release button #2. The controller will
emit one long beep to alert you, then will beep out the Frequency Bank setting count with
short beeps. The green LED will also flash with each beep/count. (‘0’ is represented by a
long beep with no LED flash). Look, listen, and count to determine the existing value. Repeat
as necessary by pressing button #2. See Table 5-1 above to convert number of ‘Beeps’ to
‘Frequency Bank’ setting.
6. To find the present Frequency value press and release button #3. The controller will emit one
long beep to alert you, then will beep out the Frequency setting count with short beeps. The
green LED will also flash with each beep/count. (‘0’ is represented by a long beep with no
LED flash). Look, listen, and count to determine the existing value. Repeat as necessary by
pressing button #3. See Table 5-1 above to convert number of ‘Beeps’ to ‘Frequency’
setting.
7. Set the ON/OFF switch on the PSEZ or CS controller to ‘OFF’, then set the switch to ‘ON’
again for normal operation. While in normal operating mode all buttons perform as labeled frequency and address will not change.
END OF SECTION
01/2001, CATTRON - THEIMEG
TM
Section 5, Page 15
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Section 5, Page 16
01/2001, CATTRON - THEIMEG
TM
Section 6 – Parts List and Accessories
Introduction.
For parts identification, Figure 6-1 on page 2 of this section provides an exploded view of the
CATTRON-THEIMEG™ PS Series Controller that should be cross-referenced to the Parts Listing in
Table 6-2.
When ordering spare parts from CATTRON-THEIMEG™, contact our sales department for pricing and
provide: (1) the Controller model number located on the serial tag, and (2) the controller family type and
revision number as labeled on the ‘i-Key’. In addition, please note the following:
• When returning a complete PSAT controller to CATTRON-THEIMEG™ for repair, the
coded ‘i-Key’ last installed and used with the unit shall be returned with the unit.
• When returning a complete PSEZ or CS controller to CATTRON-THEIMEG™ for repair,
we recommend you record the operating address and frequency assigned to the controller
as you will be required to re-program these operating parameters after we return your
controller. Refer to Frequency and Address Reports in Section 5 of this manual for how
to record these details.
• When a PSEZ or PSCS controller is returned to CATTRON-THEIMEG™ for repair, we
make every effort to establish the operating address and frequency assigned to your
controller when it arrives at our repair facility. Whenever such operands can be
established, we will record the same on the service documentation returned with your
controller.
Contact CATTRON-THEIMEG™ sales department for
availability and pricing of the following accessories and consumable items. These items are itemized in
Table 6-1 below and illustrated on pages 4, 5, 6, 7, & 8 of this section.
Accessories/consumable items.
Table 6-1. Optional Accessories
Item #
Part Number
Order
Quantity
60C-0060A
60C-0060N
70C-0001
70C-0002
70C-0001-220UK
70C-0002-220UK
42C-0057
70C-0003
60C-0062
01/2001, CATTRON - THEIMEG
TM
Item Description
Battery pack, Alkaline, non-rechargeable, 3V, 2,500 mAH
Battery pack, Ni-Cad, re-chargeable, 2.4V, 1,100 mAH
Battery Charger, Ni-Cad, standard rate (10-hour), 110VAC
Battery Charger, Ni-Cad, rapid rate (1-hour), 110VAC
Battery Charger, Ni-Cad, trickle charge (10-hour), 220VAC
Battery Charger, Ni-Cad, rapid charge (1-hour), 220VAC
Carrying strap, shoulder
External Battery Charging Unit (used with items 2, 3, 4, 5, &
6 above)
Battery Adapter, 3 Volt, for quantity 2 x ‘AAA’ Alkaline
batteries only
Section 6, Page 1
Figure 6-1. PS Series Controller, exploded view (illustrated parts breakdown)
3A
3B
Section 6, Page 2
01/2001, CATTRON - THEIMEG
TM
Parts Listing.
Table 6-2. PS Series Controller parts list
Fig. 6-1
Index #
Part Number
Quantity
Required
CPA-0359
3A
15C-0129G
60C-0060A
3B
60C-0060N
or
03C-0142
CPA-0360
10
15C-0138R
15C-0126P
54C-0221
01/2001, CATTRON - THEIMEG
TM
Item Description
Bottom endcap sub-assembly, c/w charging jack,
battery door hardware, screws
Plate, battery door, c/w hardware, sealing gasket
Battery pack, alkaline, non-rechargeable, 3V,
2,500 mAH
Battery pack, Ni-Cad, re-chargeable, 2.4V, 1,100
mAH
Screw, Phillips, 4 - 40 x ½ in.
Top endcap sub-assembly, c/w antenna, 2 switches, ‘iKey’ receptacle, 2 wiring harnesses, screws
Upper housing sub-assembly
Cover, nitrile, grip, 10.225"L
Label, FCC, Caution, Lexan, PS
Section 6, Page 3
Accessories/consumable items - illustrations.
White color
Item 1. Battery pack, alkaline, non-rechargeable, 3V, 2,500 mAH – Part # 60C-0060A
Yellow color
Item 2. Battery pack, Ni-Cad, re-chargeable, 2.4V, 1,100 mAH – Part # 60C-0060N
Section 6, Page 4
01/2001, CATTRON - THEIMEG
TM
Item 3. Battery Charger, Ni-Cad, standard rate (10-hour), 110VAC - Part # 70C-0001
Item 4. Battery Charger, Ni-Cad, rapid rate (1-hour), 110VAC – Part # 70C-0002
01/2001, CATTRON - THEIMEG
TM
Section 6, Page 5
Item 5. Battery Charger, Ni-Cad, trickle charge (10-hour), 220VAC - Part # 70C-0001-220UK
Item 6. Battery Charger, Ni-Cad, rapid charge (1-hour), 220VAC - Part # 70C-0002-220UK
Section 6, Page 6
01/2001, CATTRON - THEIMEG
TM
Item 7. Carrying strap, shoulder - Part # 42C-0057
01/2001, CATTRON - THEIMEG
TM
Section 6, Page 7
NI-CAD BATTERY PACK ONLY
PART # 60C-0060N
CHARGING JACK
FROM ‘RAPID’ OR
‘STANDARD’
BATTERY CHARGER
Item 8. External Battery Charging Unit (used with items 2, 3, 4, 5, & 6 above) - Part # 70C-0003
BATTERY ADAPTER, 3 VOLT
(QUANTITY 2 x ‘AAA’ SIZE)
USE ‘AAA’ ALKALINE
BATTERIES ONLY
Item 9. Battery Adapter for Quantity 2 x ‘AAA’ Alkaline Batteries - Part # 60C-0062
END OF SECTION
Section 6, Page 8
01/2001, CATTRON - THEIMEG
TM
Index
Accessories/consumables ................ 6-1
Address Assignment (EZ & CS) ..... 5-2
Data error checking ......................... 2-1
Address Programming (EZ & CS) .. 5-4
EZ Controllers ................................ 5-1
Address Verification (EZ & CS) ..... 5-3
AT Controllers ......................... i, iii, xii
Automatic safety override ............... 1-5
Family Tree ..................................
xii
Frequency Assignment (EZ/CS) .... 5-2
Frequency Programming (EZ/CS)
5-4
Frequency Verification (EZ/CS) ... 5-3
Battery charger options
Rapid Rate (1-hr)..................... 6-1
Functional description .................
1-1
Functional check ..........................
4-3
Standard Rate (10-hr) .............. 6-1
External Charging Unit .......... 6-1
Battery charging options ................ 3-4
Internal charging...................... 3-4
External charging .................... 3-5
Green ‘i-Key’ ........................... xii, 1-1
‘i-Key’ ...................... xii, 1-1, 2-1, 3-1
Battery door cover-plate ................ 4-6
Battery Pack ............................. 4-1, 4-6
Battery specifications ..................... 6-1
5-1
Illustrated parts breakdown ..........
6-2
Intelligent digital message protocol 2-1
Blue ‘i-Key’ ............................. xii, 1-1
Bottom endcap sub-assembly ........ 4-1
Installing different ‘i-Keys’ .........
LED indicators ................... ............ 3-2
Carrying strap .................. 1-3, 6-1, 6-7
Controller disassembly/assembly ... 4-5
List of Abbreviations ......................... ii
Lower main body housing ........... 4-10
Controls and indicators ................... 3-2
Corrective maintenance
4-2
CS Controllers
TM
01/2001, CATTRON - THEIMEG
5-1
Index i
M
CATTRON-THEIMEG™ Maintenance
Replacement:
Philosophy .............................. 4-1
Battery pack ........................... 4-6
Bottom endcap sub-assembly .. 4-7
Top endcap sub-assembly ...... 4-8
Netting Check ..............................
4-2
Main body housings ............. 4-10
Rubber side grips .................. 4-11
ON/OFF power switch ............ 2-1, 3-2
Operating procedures ................... .. 3-5
Operate (OPR) relay output ......... .. 1-5
Safety considerations ...................
2-1
Safety features .............................
2-1
Security features ..........................
2-1
Silver ‘i-Key’ ............................ xii, 1-1
Parts list .......................................... 6-3
Specifications ...............................
Preventive maintenance ................. 4-2
1-3
System ‘STOP’ Switch .......... 2-1, 3-2
Radio remote control system .......
1-5
Radio control operator’s duties 2-5, 2-7
Removal:
Battery pack ..........................
4-6
Bottom endcap sub-assembly
4-7
Top endcap sub-assembly ....
4-8
Technical Abbreviations ..............
ii
Troubleshooting guide ..................
4-4
Main body housings ............. 4-10
Rubber side grips .................. 4-11
Rubber side grips
Index ii
4-11
012/2001, CATTRON - THEIMEG
TM
RECOMMENDED SAFETY RULES
FOR PORTABLE REMOTE CONTROLLED (PRC) CRANES
For the purpose of these rules, Portable Remote Control or PRC refers to either Radio Frequency (RF)
or Infra-Red (IR) Controls. The information contained herein is based on data gathered from various
users of portable remote control crane systems. We emphasize that the recommendations contained
herein are not intended to supersede the rules or regulations of our customers, or the rules and
regulations of any applicable local, state, or federal government organizations. It must be fully
understood that the recommendations contained herein are provided solely for your consideration
and possible adoption.
TABLE OF CONTENTS
SECTION TITLE
PAGE
Preface
Operator Safety Basics
2-1
Area Inspection
2-2
Crane Inspection (mechanical & structural)
2-3
Operational Safety Check
Persons Authorized to Operate Remote Controlled cranes
Training Check List for Operation of Remote Controlled cranes
Operating Area for Remote Controlled Cranes
The Hand-held Portable Remote Controller
Operating the Remote Controlled Crane
Boarding the Remote Controlled Crane
On Board the Remote Controlled Crane
10
Remote Controlled Crane under Repair
11
The Condition of the Remote Controlled Crane
1.
1-1.
1-2.
1-3.
1-4.
PREFACE.
Electric Overhead Travelling (EOT) Cranes typically operate in three motions. They are large,
bulky pieces of equipment that handle heavy loads efficiently at comparatively high speeds.
Frequently, they are operated in restricted areas where workmen are engaged in various tasks on
the floor below. Under these conditions crane operators using Portable Remote Control (PRC)
must take great care, and workmen must be constantly on the alert if accidents are to be avoided.
The following guidelines have been carefully assembled and are promoted to indicate just how
important your careful and thoughtful actions are in helping to protect you and your fellow
workers from harm, and also to prevent equipment damage.
These guidelines cover cranes when they are operational in Portable Remote Control (PRC)
mode, either by Radio Frequency (RF) or Infra-Red (IR). If a crane is operated from cab or
pendant control, the PRC system’s controller(s) should be completely isolated by removing the
battery and held under lock and key.
A routine pre-shift inspection of the crane takes a lot less time than repairing a crane suffering
from a major problem. In addition, such pre-shift inspections are to be considered as ‘safety
basics’, which are an important part of a crane operator’s duties.
01/2001, CATTRON - THEIMEG
TM
Cranesafety 1
2.
OPERATOR SAFETY BASICS. Before starting your shift as the crane operator, you should
make sure the crane has a current inspection certificate and that qualified personnel have carried
out the following inspections and checks. If any item below does not pass inspection, you should
notify your supervisor immediately. In many cases, the problem will need to be fixed before you
are allowed to operate the crane. In addition, did you realize that the person now reading these
instructions is primarily responsible for his or her own health and safety?
2-1
Area Inspection.
Take a good look around the work area for any obstructions.
Check that the rails are intact and not bent or damaged.
Make sure there are no oil or brake fluid leaks on the area below where the crane
travels.
Make sure rail stops are present, physically secure, and free of damage at the end of
all crane rails.
Check that walkways are sturdy and have handrails. Ladders are not to be loose and
all rungs are to be in place.
2-2.
Crane Inspection (mechanical & structural).
Make sure all moving machinery has protective guards installed over moving parts.
Make sure all bridge and trolley rail stops are welded or bolted in position with no
evidence of damage from bridge or trolley impact.
Check for proper fluid levels and make sure all grease fittings are lubricated to
manufacturer recommendations.
Check for broken welds and cracks in the bridge structure.
Check for wheel damage, broken welds on the frame, and drum damage.
Check the wheels for flange wear, cracks, holes, or visible signs of bearing damage.
Make sure wire rope drums show proper wire rope lay; for example, each wire rope
must lay in its own groove. This does not mean in the non-grooved area in the center
of the drum.
Make sure wire rope size is correct for the sheaves. Look for either oversized or
undersized rope that will not lay in the sheaves correctly. Make sure the sheaves
show no evidence of rope corrugation and have the proper wall thickness.
Look for any type of bluing on the brake drums, which indicates excessive heat.
Make sure there are no protruding rivets from the brake shoes. Examine the shoes for
glazing.
Look for carbon dust around the inspection covers of electric motors. Smell for any
type of burning smells. Check for any type of burning on electrical covers. Make
sure all protective covers are installed.
Check the festoon system for proper connections and inspect all hooks connecting the
festoon to the holding wire.
Load bearing parts such as blocks and hooks shall have no signs of damage and be in
perfect working order.
Cranesafety 2
01/2001, CATTRON - THEIMEG
TM
2-3.
Operational Safety Check. As a crane operator, you should satisfy yourself of the following.
If any item below does not meet the checklist criteria, you shall immediately notify your
supervisor. In many cases, the problem will need to be fixed before you are allowed to operate
the crane. Remember that the person now reading these instructions is primarily responsible for
his or her own health and safety!
Horns, buzzers and all other warning devices shall be in working order.
All controls shall be in good working order.
STOP Buttons (when equipped) shall be in working order.
The load brakes shall hold the load safely at all times. The only way to ensure this is
through a load test and inspection.
The ‘raise’ and ‘lower’ limit switches shall work correctly to help prevent twoblocking and accidental floor contact.
3.
PERSONS AUTHORIZED TO OPERATE REMOTE CONTROLLED CRANES.
Only properly trained employees who have been designated by management shall be
permitted to operate the crane.
Both the operator and management shall insure the correct controller to operate the
crane is selected and that any spare equipment capable of controlling the crane is
completely isolated and held under lock and key.
Personnel who cannot read and understand the signs, notices and operating
instructions shall not operate the crane.
The crane shall not be operated by personnel with seriously defective eyesight or
hearing, personnel under the influence of drugs or alcohol that will impair judgement,
or personnel who may be suffering from a disease which may cause physical failure.
4.
TRAINING CHECKLIST FOR OPERATORS OF REMOTE CONTROLLED CRANES.
As a minimum, Portable Remote Control Operators shall:
have knowledge of hazards inherent to crane operation.
have knowledge of safety guidelines for portable remote controlled cranes.
have the ability to judge distance to stationary objects.
have knowledge of the portable remote control system controller’s operation.
have performed limit switch test procedure before operating the crane.
have performed hoist, trolley and bridge brake test procedure before operating the
crane.
have instructions as to plugging of crane motions when and where authorized.
01/2001, CATTRON - THEIMEG
TM
Cranesafety 3
4.
TRAINING CHECKLIST FOR OPERATORS OF REMOTE CONTROLLED CRANES,
continued.
As a minimum, Portable Remote Control Operators shall:
observe signal lights on crane.
avoid striking any obstructions.
check for proper clearance of lifts or hooks before moving bridge or trolley.
properly store the portable remote controller when not in use.
know how to properly transfer the portable remote controller to another person.
report unsafe or unusual operating conditions.
use caution in approaching bridge or trolley end-stops.
know the crane’s capacity.
keep body clear of lifts, avoiding ‘pinch’ points.
Inspect cables and hooks.
5.
THE OPERATING AREA FOR THE REMOTE CONTROLLED CRANE.
6.
Unobstructed aisles between equipment, stock, etc. shall be maintained for the PRC
crane operator's movement. These aisles should be a minimum of 3 feet wide (1m) or
per local regulations.
PRC crane operators shall always position themselves in a safe location with the best
view of the crane they are controlling and never operate the crane blindly. They shall
always keep the crane and load in sight, staying as close as practical to the crane load
while maintaining a safe harms-way distance. Operators shall never position
themselves or others underneath the load or in a ‘pinch’ point.
THE HAND-HELD PORTABLE REMOTE CONTROLLER.
Cranesafety 4
Typically, the portable remote controller incorporates a Push-To-Operate (PTO) bar
or START button, and its motion switches are spring return to OFF. The PTO bar
acts as a guard for these switches to prevent movement of the crane if one of the
switches is accidentally bumped. These switches and the PTO bar must never be
mechanically blocked in any ‘ON’ position.
Using the power ON/OFF switch(es), the portable remote controller shall be switched
‘OFF’ when not in use. When the controller is equipped with a STOP button, it shall
be set to the ‘STOP’ position before switching off power to the controller. In
addition, if equipped with a key, the key should be removed after use and kept in a
secure location.
A prescribed, controlled, storage space shall be provided for portable remote
controllers. All controllers shall have their batteries removed and be placed there
when not in use. This precaution is intended to prevent unauthorized personnel from
operating the remote controlled crane.
01/2001, CATTRON - THEIMEG
TM
6.
THE HAND-HELD PORTABLE REMOTE CONTROLLER, continued.
7.
When an operator is putting on or taking off the controller by means of its belt loop
strap, carrying harness, or shoulder strap, the controller shall be switched OFF
beforehand, using the appropriate ON/OFF switch(es). When the controller is
equipped with a STOP button, it shall be set to the ‘STOP’ position before switching
off power to the controller.
The portable remote controller shall always be switched ‘OFF’ when not in use and,
when practical, stored under lock and key.
OPERATING THE REMOTE CONTROLLED CRANE.
All crane limit switches shall be checked at the beginning of each turn or when a new
operator takes control of the crane. While checking the limit switches, the hoist shall
be centered over an area free of personnel and equipment so that if the limit switches
fail, and the hook and block assembly falls, no one will be injured and no equipment
will be damaged.
The limit switches shall never be used as a regular stopping devices. They are
intended to be protective devices only.
The bridge and trolley brakes shall be tested at the beginning of each turn or when a
new operator takes control of the crane. They should be tested with the bridge and
trolley at low speed.
When lifting maximum or near maximum loads, the operator shall test the hoist
brakes by raising the load a few inches from the floor. If hoist brakes do not hold, the
load shall be immediately lowered to the floor and a report made to the supervisor.
Do not make lifts in excess of the rated capacity of the crane.
When making lifts, the bridge and trolley shall be centered directly over the load to
prevent load swinging when the load is raised.
Side pulls shall be made only with the permission of, and under direct supervision of
management. When such a lift is being made, operators shall not position themselves
in the line or path of travel of the load, but shall operate the crane from a position to
the side opposite to the path of travel.
When raising or lowering a load, proceed slowly and make certain the load is under
control. Tag lines shall be used for handling lengths or bulky loads. Take the slack
out of the chains or slings gradually. Make sure all personnel are clear before making
a lift.
PRC crane operators shall keep all parts of their bodies away from the load and never
position themselves under the load.
Do not make a lift or move the crane if anyone is in a position to be injured.
If a PRC crane operator is being helped, he or she shall not move the crane until he or
she receives an ‘all clear’ signal from the helper(s).
Loads shall not be carried over workers' heads.
01/2001, CATTRON - THEIMEG
TM
Cranesafety 5
7.
OPERATING THE REMOTE CONTROLLED CRANE, continued.
Cranesafety 6
If anyone is in the path of travel, the portable remote control crane operator shall stop
and clear the area before proceeding.
Bumping into runway stops or into other cranes on the same runway is prohibited.
When moving the crane, the PRC crane operator shall make sure the hook block,
attachment and/or cables will not fall on nearby equipment.
The PRC crane operator shall not drag slings, chains, etc. along the floor. These
could snag on something on the floor, causing the cables to break and strike the
operator or a fellow worker.
If gloves are not required for safety reasons, they shall not be used when operating the
portable remote controller.
All loose material or parts shall be removed from the load before starting the lift.
Such material can fall and injure people below.
The PRC crane operator shall hoist lifts high enough to clear all apparatus and
workers below the crane.
Plugging shall not be used as a regular means of stopping the crane and should be
used for emergency stops only. If approved, plugging should only be performed as
dictated by plant operating procedures.
If PRC crane operators are asked to do something they believe unsafe, they shall call
their supervisors for advice.
PRC crane operators shall never permit anyone to ride on the load or hook except
when authorized by their supervisor.
When another crane on the same runway is stationary with or without a load, the PRC
crane operator shall maintain a safe distance between the crane being operated and
the stationary crane. In a power outage, the PRC crane operator shall set the ON/OFF
switch(es) on the controller to ‘OFF’, keeping them in the OFF position until power is
restored.
If the PRC crane fails to respond correctly, the operator shall stop operation
immediately by setting the ON/OFF switch(es) on the controller to ‘OFF’. When the
controller is equipped with a STOP button, this shall be set to the ‘STOP’ position
before switching off power to the controller. The fault condition shall be reported
immediately to a supervisor.
Outside cranes subject to movement by winds, storms, etc. shall be securely anchored
when left unattended. If the crane is equipped with a bridge parking brake, it shall
also be set.
01/2001, CATTRON - THEIMEG
TM
8.
BOARDING THE REMOTE CONTROLLED CRANE (MAINTENANCE CREW).
9.
The PRC crane shall not be boarded without permission of the supervisor in charge of
crane operations in the area.
Using the power ON/OFF switch(es), the person boarding the PRC crane shall switch
the portable remote controller to ‘OFF’ and take it with him or her on to the crane.
When the controller is equipped with a STOP button, this shall be set to the ‘STOP’
position before switching off power to the controller.
If the boarding party consists of more than one person, one person shall be designated
as the leader of the boarding party.
The leader shall board the crane first, open and lock out the main switch (securing it
with a padlock), and then signal the other members of the party that it is safe for them
to board the crane.
ON BOARD THE REMOTE CONTROLLED CRANE (MAINTENANCE CREW).
Headroom is at a minimum in some crane cabs and on some crane walkways. All
people on board such cranes shall exercise caution. Hard hats shall be worn at all
times.
If the repair crew consists of more than one person, one person shall be designated as
the crew leader.
Warning signs shall be placed on the floor beneath the crane or suspended from the
crane indicating the crane is being serviced.
If any work to be done on the crane is carried out in locations unprotected by standard
handrails, safety belts shall be worn by all crew members working in such
unprotected locations. All tools and equipment shall be moved onto the crane by the
use of hand lines. All tools and equipment shall be securely attached to hand lines.
If it is necessary to have the control circuits on the crane energized, the repair crew
leader shall open all power circuits to the motions before closing the main switch.
If, during the course of repairs, it becomes necessary to move the crane, it shall be the
responsibility of the crew leader to insure that all personnel located on, and within the
operational area of the crane are in a safe position out of harms-way. In addition the
crew leader shall insure all tools and materials are stowed or tightly restrained before
the crane is moved.
When the repair work is completed, the crew leader shall see that all crewmembers
are off of the crane before he or she closes the main switch.
If more that one person is on board the PRC crane, one person shall be made
responsible for seeing that all workers are off the crane before the portable remote
controller is returned to operational use.
01/2001, CATTRON - THEIMEG
TM
Cranesafety 7
10.
REMOTE CONTROLLED CRANE UNDER REPAIR.
Cranesafety 8
All persons operating other cranes on the same or adjacent runways shall be notified
before anyone boards the subject crane. Such notification should include limitations
of adjacent crane movement while others are on board.
PRC cranes, which have been pre-positioned for repairs and cannot be moved should
be protected against being bumped by other cranes on the runway. Suitable bumpers
adequate for the job should be installed on the exposed sides of the crane under repair
and as far away from the crane as possible, with a minimum distance of 20 ft.
(approximately. 6.1 m). The location of these bumpers shall be indicated by red
lights so that they are clearly visible to other persons operating cranes travelling on
the same runway. When it is impossible to use bumpers for protection, red lights
shall be placed in clear view of other persons operating cranes on the same runway to
indicate the restricted travel zone. It is desirable that such red lights be located a
minimum of 20 ft. (approx. 6.1 m) from the crane under repair.
All operators of cranes on the same runway must be informed of the repair work,
thoroughly instructed as to what their conduct should be for the duration of said
repairs, and informed when repairs are completed.
When there is a runway adjacent to the runway on which the crane is being repaired,
and if any hazard exists involving repairmen, red lights shall be placed in clear view
of persons travelling on the adjacent runway to indicate the restricted travel zone. It
is desirable that such red lights be located a minimum of 20 ft. (approx. 6.1 m) from
the crane under repair. When it is necessary to operate cranes on adjacent runways,
such cranes shall come to a full stop before entering the restricted area. Cranes
traveling on adjacent runways may only proceed through the restricted area when
permission has been received from a signalman posted for this purpose.
Access of persons to and from the crane being repaired shall be under the control of
the repair crew leader.
The floor area below the point where crane repairs are being made shall be roped off
and posted with danger signs.
Handling of all small tools and materials, etc. from ground level to workers above
shall be accomplished through the use of hand lines. Tools, materials, etc. shall not
be tossed from the crane to the ground level and vice versa.
If crane repairs make it necessary for crew members to work on areas of the crane
other than those protected by standard handrails, such crew members shall wear
approved safety belts.
01/2001, CATTRON - THEIMEG
TM
10.
REMOTE CONTROLLED CRANE UNDER REPAIR, continued.
11.
If it is necessary to move the crane to check the performance of operation, the crew
leader shall designate who remains on the crane. The crew leader shall insure that all
personnel located on, and within the operational area of the crane are physically
located in a safe position out of harms-way. In addition the crew leader shall insure
all tools and materials are stowed or tightly restrained before the main switch is
closed and the crane is put into operation.
Upon completion of repairs, it is the crew leader's duty to personally insure that each
person has left the crane and is clear before he or she removes the lock above the
main switch and the crane is put back in operation.
THE CONDITION OF THE REMOTE CONTROLLED CRANE. It is recommended that a
written report be sent to your supervisor whenever you detect any condition that makes the crane
unsafe. Many plants supply printed forms for this purpose. The PRC crane operator shall fill out
these forms and turn them in at the end of each shift. Certain faults that the PRC crane operator
may detect will be so critical that the crane must be shut down at once and not operated until the
fault is corrected. Typical checklist items may include some or all of the following:
Condition of hoisting cable, drum, and hook blocks (broken strands, clipped sheave
wheels, etc.).
Condition of brakes (hoist, trolley and bridge).
Oil or brake fluid leaks on the runway area.
Alignment of bridge (screeching or squealing wheels indicate that bridge is out of
line).
Condition of bridge structure (broken welds, cracks and distortion).
Broken, cracked or chipped rails on bridge or runway.
Condition and security of trolley and bridge rail end-stops (missing or damaged from
impact).
Condition of all limit switches.
Conditions of controls (electrical or mechanical defects that may lead to faulty
operation).
Condition of electric motors (carbon dust around inspection covers indicate worn
brushes).
Condition of gears (grinding or squealing may mean a lack of lubrication or foreign
materials in gear teeth).
Frequent overload relay tripping of power circuits.
Mechanical parts loosened by vibration (loose rivets, covers, etc.).
Wheel condition (flange wear, cracks, holes, or visible signs of bearing damage).
Bumpy riding (worn wheels).
01/2001, CATTRON - THEIMEG
TM
Cranesafety 9
11.
THE CONDITION OF THE REMOTE CONTROLLED CRANE, continued.
Worn collector shoes or bars.
Burned out, broken, or inoperable warning or signal lights.
Unintended stopping or starting of any crane motion, warning device, light or
auxiliary function.
Condition of walkways and ladders (missing or loose handrails, ladder rungs, etc.)
Portable Remote-controlled Crane operators shall not attempt to make any repairs by themselves.
The fault condition(s) shall be reported to a supervisor to enable repairs to be carried out by suitably
qualified personnel.
END
Internet Address for All CATTRON-THEIMEG™ Companies: www.cattron.com
Cranesafety 10
01/2001, CATTRON - THEIMEG
TM
United States
Cattron-Theimeg Inc.
58 West Shenango Street
Sharpsville, PA 16150-1198
Phone:
(724) 962-3571
Fax:
(724) 962-4310
e-mail:
mail@cattron.com
Germany
Cattron-Theimeg Europe GmbH & Co.
Krefelder Straße 423-425
41066 Mönchengladbach
Phone:
011-49-2161-63630
Fax:
011-49-2161-6363100
e-mail:
theimeg@theimeg.de
Canada
Cattron-Theimeg Canada Ltd.
150 Armstrong Avenue, Units 5 & 6
Georgetown, Ontario L7G 5G8
Phone:
(905) 873-9440
Fax:
(905) 873-9449
e-mail:
rgrimshaw@cattron.com
United Kingdom
Cattron-Theimeg (UK) Ltd.
Riverdene Industrial Estate,
Molesey Road, Hersham
Walton-on-Thames, Surrey KT12 4RY
Phone:
011-44-1932-247511
Fax:
011-44-1932-220937
e-mail:
sales@cattronuk.com
Brazil
Cattron-Theimeg Americas Ltda.
Rua Antonio Rodrigues de Carvalho, 435
13033-220 - Campinas – SP
Phone:
011-55-19-3243-7803
Fax:
011-55-19-3243-9258
e-mail:
cattronamericas@usa.net
Africa
Cattron-Theimeg Africa (PTY.) Ltd.
24 O'Rielly Merry Road, Rynfield, Benoni
P.O. Box 15444, Farrarmere, Benoni
Gauteng 1518, South Africa
Phone:
011-27-11-425-1123
Fax:
011-27-11-849-5717
e-mail:
cattron@iafrica.com
Internet Address for All CATTRON-THEIMEG™ Companies: www.cattron.com

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