Fomotech TWISTER2X Industrial Remote Control User Manual Twister2X 99 910MHZ channels
Fomotech International Corp. Industrial Remote Control Twister2X 99 910MHZ channels
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user manual
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| Document ID | 1154817 |
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| Document Description | user manual |
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| Document Type | User Manual |
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| Date Submitted | 2009-08-18 00:00:00 |
| Date Available | 2009-08-18 00:00:00 |
| Creation Date | 2009-04-10 10:35:21 |
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| Document Lastmod | 2009-08-10 01:18:01 |
| Document Title | Microsoft Word - Twister2X_99_910MHZ_ channels.doc |
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| Document Author: | jocelyn |
TABLE OF CONTENTS Page 1. INTRODUCTION ................................................................................................. 2 2. SAFETY INSTRUCTIONS ................................................................................... 3 3. SYSTEM FUNCTIONS 3.1 TRANSMITTER JOYSTICK DESCRIPTIONS ........................................... 4 3.2 TRANSMITTER PUSHBUTTON DESCRIPTIONS ................................... 5 3.3 GENERAL FUNCTION DESCRIPTIONS ................................................... 6 4. TRANSMITTER OUTLINE 4.1 TRANSMITTER EXTERNAL DESCRIPTIONS ......................................... 7 4.2 TRANSMITTER EXTERNAL DESCRIPTIONS ......................................... 8 5. RECEIVER OUTLINE 5.1 RECEIVER EXTERNAL & INTERNAL DESCRIPTIONS ......................... 9~11 5.2 RECEIVER MOUNTING DIMENSION ....................................................... 12 6. SYSTEM SETTINGS 6.1 TRANSMIITTER ID CODE SETTINGS ..................................................... 13 6.2 TRANSMITTER FREQUENCY CHANNEL SETTINGS ........................... 13 6.3 RECEIVER LCD STATUS DISPLAYS ......................................................... 14 6.4 RECEIVER ID CODE & FREQUENCY CHANNEL SETTINGS ............... 15 6.5 FREQUENCY CHANNEL TABLE ............................................................... 16 7. RECEIVER SYSTEM STATUS DISPLAYS ......................................................... 17~18 8. RECEIVER INSTALLATION 8.1 PREPARATION ............................................................................................. 19 8.2 STEP-BY-STEP INSTALLATION ................................................................. 19 8.3 SYSTEM TESTING ....................................................................................... 20 9. OPERATING INSTRUCTION 9.1 POWER “ON” THE SYSTEM ....................................................................... 21 9.2 DUAL HOIST/TROLLEY OPERATION ..................................................... 22 9.3 TRANSMITTER SYSTEM STATUS DISPLAYS ........................................... 23 10. BATTERY CHARGING ....................................................................................... 24 11. SYSTEM SPECIFICATIONS ............................................................................... 25~26 12. PARTS LIST ........................................................................................................... 27 1. INTRODUCTION The Twister 2X is a highly sophisticated industrial radio remote control system. The versatile features of Twister 2X permit its usage in a wide range of industrial applications. The system can be used to control all types of industrial cranes, tower cranes, building construction equipment, automatic control systems, mining equipment, and many others. The Twister 2X incorporates numerous advanced safety features and software programming that will ensure maximum security and safety in the workplace. The major features of Twister 2X industrial radio remote control system are as follow: The system is equipped with highly evolved software that has redundant error checking and correcting capabilities to ensure 100% error-free transmission, decoding, and control of all output relays. This highly evolved software includes CRC (Cyclical Redundancy Check) and Hamming Codes (Error Recovery) programming. The encoding system utilizes advanced microprocessor control for 100% error-free data transmission. The availability of 65,536 sets of unique security ID codes + 20 distinct RF channels will ensure that only commands from a matching control transmitter can be carried out without any interference from other radio systems. The decoding system utilizes dual-microprocessor control, which will ensure 100% error-free calculating, bit checking and correcting of all incoming data. The system also utilizes an additional central microprocessor for data comparison and crosschecking between the two decoding microprocessors. When faults are detected via this central microprocessor, for maximum safety, the entire system will be shutdown immediately to avoid possibility of any accidents occurring. The system utilizes PLL synthesized RF transmission. It allows the user to select from 20 sets of frequency channels best suited for the environment. The frequency channel is selected via simple dip-switch settings inside the transmitter unit. The frequency channel for the receiver is selected via simple button setting on the receiver LCD control panel. The receiver also has the ability to auto-scan from these 20 sets of frequency channels. The receiver will search and locked on to the intended matching control transmitter. For added safety the receiver also utilizes dual Safety Relay for the receiver MAIN relay circuit. If the receiver MAIN relay is defective (example: fails to open or close during operation or not responding to a “Stop” command) a fault will be detected and the system will be shut down immediately to avoid possibility of any accidents occurring. The Twister 2X is equipped with numerous self-diagnosing functions, which include transmitter low-voltage detection/warning, faulty pushbutton/joystick detection, faulty safety MAIN relays detection, faulty relay boards detection, faulty EEPROM detection, faulty RX module detection, incorrect ID code detection, and receiver MAIN auto-deactivation when transmitter low-voltage is detected, when encountering strong radio interference, and when the transmitter/operator is out of receiving range. 2. SAFETY INSTRUCTIONS The Twister 2X system is relatively simple to use. However, it is very important to observe the proper safety procedures before, during, and after operation. When use properly the Twister 2X systems will enhance productivity and efficiency in the workplace. The following instructions should be strictly followed: 1. Make a daily check of the transmitter casing, joysticks and pushbuttons. Should it appear that anything could inhibit the proper operation of the transmitter unit, it should be immediately removed from service. 2. The transmitter voltage should be checked on a daily basis. If the voltage is low, the battery pack should be recharged or replaced (refer to page 23 for battery power status LED display). 3. The emergency stop button (EMS) should be checked at the beginning of each shift to ensure they are in the proper working order. 4. In the event of an emergency, activate the emergency stop button immediately by pressing the red EMS button down. This will immediately disconnect the transmitter power and receiver MAIN relays. Then turned the power “off” from the main power source of the equipment. 5. The transmitter power key, which is located on the right side of the transmitter box, should be turned “off” after each use and should never left the power key in “on” position when the unit is unattended. 6. Do not use the same frequency channel and ID code as any other unit in use at the same facility or within distance of 300 meters. 7. Ensure the waist belt and the shoulder strap is worn at all time during operation to avoid accidental damages to the transmitter box. 8. Never operate a crane or equipment with two (2) transmitter units at the same time with same frequency channel and ID code. 3. SYSTEM FUNCTIONS 3.1 Transmitter Joystick Descriptions All transmitter units are equipped with two joysticks, in single or double axis configurations. The table below illustrates the number of steps or speeds available for the Twister 2X in relation to each speed’s output contact relay configuration: TYPE FUNCTION 1-Speed 1 speed output contact relay for both forward and reverse motion (total of 2 output relays per axis or motion) 2-Speed Shared 2nd speed output contact relay for each forward and reverse motion (total of 3 output relays per axis or motion) 2-Speed* Separate 2nd speed output contact relay for each forward and reverse motion (total of 4 output relays per axis or motion) 3-Speed Shared 2nd and 3rd speed output contact relays for each forward and reverse motion (total of 4 output relays per axis or motion) 4-Speed Shared 2nd, 3rd and 4th speed output contact relays for each forward and reverse motion (total of 5 output relays per axis or motion) 5-Speed Shared 2nd, 3rd, 4th and 5th speed output contact relays for each forward and reverse motion (total of 6 output relays per axis or motion) 0-Speed** Addition of 0-speed (neutral position) output contact relay for connection to crane’s braking system Separate 2nd speed output contact relay - For travel motion that required individual output contact relay for the 2nd speed function (example: hoist motion with dual motors). ** By adding a 0-speed output contact relay, when the joystick is at center or neutral position, this 0-speed relay will be energized. This feature is best suited for cranes or equipment with special breaking system. 3.2 Transmitter Pushbutton Descriptions There are many different types of pushbuttons and switches available for the Twister 2X, please refer to the chart below. TYPE FUNCTION 1-Step Pushbutton Pushbutton with momentary output contact relay 1-Step Electronic Toggled Pushbutton Mechanical Toggled Pushbutton Resets itself when the transmitter unit is turned “off” or when EMS button is activated Maintained toggled even after transmitter unit is turned “off” or when EMS button is activated 2-Stage Mechanical Rocker Switch 0-T (refer to note 1 & 2) 2-Stage Mechanical Rocker Switch 0-R (refer to note 1) 3-Stage Mechanical Rocker Switch T-0-T (refer to note 1 & 2) 3-Stage Mechanical Rocker Switch R-0-T (refer to note 1 & 2) 3-Stage Mechanical Rocker Switch T-0-R (refer to note 1 & 2) 3-Stage Mechanical Rocker Switch R-0-R (refer to note 1) 2-Stage Mechanical Selector Switch 0-T (refer to note 1 & 2) 2-Stage Mechanical Selector Switch 0-R (refer to note 1) 3-Stage Mechanical Selector Switch T-0-T (refer to note 1 & 2) 3-Stage Mechanical Selector Switch T-0-R (refer to note 1 & 2) 3-Stage Mechanical Selector Switch R-0-T (refer to note 1 & 2) 3-Stage Mechanical Selector Switch R-0-R (refer to note 1) “ON/OFF” 1-Step Pushbuttons Will reset to “off” position when transmitter unit is turned “off” or after EMS reset Note 1: Note 2: 0 → Neutral position. T → Maintained position (toggled contact). R → Retract back to 0-position (momentary contact). 1-step pushbuttons, 2 & 3 stage mechanical rocker and selector switches with maintained toggled function (T) will remained energized (or closed) even when the power of the transmitter is turned off or when EMS is activated (Receiver Hold function). 3.3 General Function Descriptions Emergency Stop Button (Standard Equipped) In case of an emergency, press down the red emergency stop button (EMS) will immediately deactivates the transmitter power and the receiver safety MAIN contact relays (refer to section 4.1 on page 7). Transmitter Power Key (Standard Equipped) All transmitters are equipped with two detachable power keys (one for spare) for turning the transmitter power “on” and “off” (refer to section 4.1 on page 7). START button (Standard Equipped) All transmitters are equipped with a START button for purpose of activating the receiver MAIN contact relay after turning on the transmitter power. After turning “on” the transmitter unit via the transmitter power key, press and hold the START button for up to a second will activate the receiver MAIN contact relay. After resetting the EMS button, by twisting the button 1/4 turn clockwise, the operator must also press and hold the START button for up to a second to reenergize the receiver MAIN contact relay. Also, when the system is left unattended for 5 minutes or longer (system will go into sleep mode), the operator must again press and hold the START button for up to a second to reenergize the receiver MAIN contact relay. Removable Relay Cards (Standard Equipped) Special designed relay cards provided easy service maintenance and as well as for simplifying the inventory of spare parts. Auto-Scanning Receiver (Standard Equipped) When transmitter’s frequency channel (from channel 01 ~ 20) is changed via simple dip-switch setting inside the transmitter belly box, the receiver will search and locked on to the intended matching transmitter. Tandem Feature / Dual-Crane Operation Feature (optional) This feature allows two operators controlling two crane systems independently or one operator controlling two crane systems simultaneously (Crane A, Crane B, Crane A+B). “Pitch And Catch” Feature (optional) This feature allows two operators controlling one crane system from opposite ends of a long or cross travel. Random Access Feature (optional) This feature allows for up to 8 operators randomly accessing up to 8 crane systems via a 16-position mechanical selector switch and operate pitch/catch function via START/PITCH button. Infrared Initial Startup Feature (optional) The feature allows system activation under or in close proximity to the crane or receiver via infrared transmission. After infrared initial system activation, the frequency transmission will take over. 4. TRANSMITTER OUTLINE 4.1 Transmitter External Descriptions (Fig. 1) Transmitter Top View 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. (Fig. 2) Transmitter Bottom View Battery Power LED Display Status LED Display Information Top Plate (engraved) Left Joystick Right Joystick START Pushbutton AUX/RES Pushbutton (side panel) AUX/RES Pushbutton (top panel) AUX/RES Pushbutton (top panel) Emergency Stop Button (EMS) Power Key (detachable) Battery Contact (gold-plated) System Information Battery slot A B C (Fig. 3) Transmitter Exterior Views MODEL CHANNEL VOLTAGE BAND POWER S/NO. : TX m W RX A B C MHz 4.2 Transmitter Internal Descriptions (Fig. 4) RF Module, Encoder Board and Power Switch Views 1. 2. 3. 4. 5. 6. 7. 8. Encoder Shielding Plate Ribbon Type Connector Port Power Input Connector Port Charger Connector Port TX Module Connector Port ID Code Dip-Switch Frequency Channel Dip-Switch External Programming Port 9. 10. 11. 12. 13. 14. 15. Power Key Switch Connector Port Power Fuse (0.5A) Infrared Startup Interface Port Antenna Port TX module Connector Power Key Switch Connector Power Key Switch 5. RECEIVER OUTLINE 5.1 Receiver External and Internal Descriptions >>>>>> 00000000000000000000 00000000000000000000 TEC I T ' A BC MODEL CHANNEL : VOLTAGE : BAND POWER : TX S/NO. m W RX A B C MHz (Fig. 5) Receiver External and Internal View 1. 2. 3. 4. 5. 6. 7. 8. 9. Antenna Antenna Port AC Power Display SQ-1 Display (for RX-1) SQ-2 Display (for RX-2 / optional) Central CPU Status Display System LCD Display System Information Plate Mounting Bracket + Shock Absorber18. 10. Multi-Pin Cable Connector (optional) 11. RX Module Card 12. Decoder Card 13. Reserved Relay Card Slot 14. Relay Card #1 15. Relay Card # 2 16. Relay Card # 3 17. Relay Card # 4 Power Supply Card RX Module Card 1. 2. 3. 4. 5. RX Module Card Release Clip RX-1 Antenna Port RX-2 Antenna Port (optional) RX module Shielding Plate RX Module Card-to-Motherboard Connector (Fig. 6) Receiver RX Module Card Decoder Card 1. 2. 3. 4. 5. 6. 7. 8. Power Display (LED #1) SQ-1 Display (LED #2) SQ-2 Display (LED #3) Central CPU Status Display (LED #4) Reserved Function Display (LED #5) LED Display Panel LCD Screen Dual Decoding CPU Status Display (LED #6 and LED #7) 9. Function Settings Buttons 10. Decoder Shielding Plate 11. Decoder Card-to-Motherboard Connector (Fig. 7) Receiver Decoder Card 10 Output Relay Card 1. 2. 3. 4. 5. 6. 7. Relay LED Display Relay Card Release Clip Relay Output Contact Connector Port Contact Relays Relay Card-to-Motherboard Connector Relay Power LED Display Relay Card Position/Address Dip-Switch (see note below). (Fig. 8) Receiver Output Relay Card Note: The relay card position (address) dip-switch must be adjusted according to the wiring diagram sheet located on the last page of this manual and on the backside of the receiver cover plate. Relay Card Position 1 → Address: 0000000 Relay Card Position 2 → Address: 0000001 Relay Card Position 3 → Address: 0000010 Relay Card Position 4 → Address: 0000011 Relay Card Position 5 → Address: 0000100 Power Supply Card 1. 2. 3. 4. 5. 6. 7. Power AC Fuse #1 (2.0A) Power AC Fuse #2 (2.0A) VAC Input / VDC Output Connector MAIN Contact Relay Fuse (3.0A) Dual MAIN Contact Relays Power Supply Card-to-Motherboard Connector VDC Fuse (Fig. 9) Receiver Power Supply Card 11 5.2 Receiver Mounting Dimension (Fig. 10) Receiver Exterior View (Fig. 11) Receiver Mounting Dimension 12 6. SYSTEM SETTINGS 6.1 Transmitter ID Code Settings Transmitter ID code are set via an 8-position dip-switch located on the encoder board (refer to fig. 4 on page 8). For receiver ID code settings please refer to section 6.3 & 6.4. Example: ID code → 10010110 Top location : “1” Bottom location : “0” Note: When transmitter ID code is altered please also make sure to readjust the receiver ID code accordingly. System will not operate if the ID code on both the transmitter and receiver are different. 6.2 Transmitter Frequency Channel Settings The transmitter frequency channel is also set via an 8-position dip-switch located on the encoder board (refer to fig. 4 on page 8). For receiver frequency channel settings please refer to section 6.3 & 6.4. For the below dip-switch with 00000001 setting, the RF channel is “01”, which also represents frequency “910.500MHz” (refer to frequency channel table on page 16). Top location : “1” Note: Bottom location : “0” When the frequency channel of the transmitter is altered please also make sure to readjust the receiver frequency channel accordingly. System will not operate if the frequency channel on both the transmitter and receiver are different. 13 6.3 Receiver LCD Status Displays (Screen “1”) 00000000000000000000 00000000000000000000 P: 1 I : 77 - 1 1 1 1 1: 5 2: 5 SYS I F (Screen “2”) (Fig. 12) Receiver LCD Screen 1. 2. 3. 4. 5. 6. 7. 8. RX-1 Signal Strength RX-2 Signal Strength (optional) System at Work Contact Relay Activation Display “0”→ relay OFF; “1”→ relay ON EXIT/DOWN (-) Button (PS1) EDIT/UP (+) Button (PS2) MODE/ENTER Button (PS3) System Type 9. 10. 11. 12. 13. 14. 15. 16. 14 ID Code-1 (regional code) ID Code-2 (system ID code) Decoder System-1 Decoder System-2 RX–1 Signal Strength RX–2 Signal Strength (optional) RX–1 Frequency Channel RX–2 Frequency Channel (optional) 6.4 Receiver ID Code & Frequency Channel Settings Unlike the dip-switch setting on the transmitter, the receiver ID code and frequency channel can be easily adjusted via the LCD control panel on the receiver unit. Please follow the step-by-step instructions illustrated below on how to change receiver ID code and frequency channel. P : 1 I : 7 7 - 1 1 1 _1 1 : ___ 2 : ___ ___ (Screen “3”) 1) 2) 3) 4) 5) 6) To enter into screen “2”, press MODE/ENTER button one time. To enter into Screen “3”, press EDIT/UP (+) button for up to 5 seconds. TP (System type) and Country code cannot be changed (manufacture preset). Press EXIT/DOWN (-) button and EDIT/UP (+) buttons to change the ID code. Press MODE/ENTER button to proceed to the RX-1 setting column. Press EXIT/DOWN (-) button and EDIT/UP (+) button to change frequency channel of RX-1. 7) Press MODE/ENTER button to proceed to RX-2 setting column. 8) Press EXIT/DOWN (-) button and EDIT/UP (+) button to change frequency channel of RX-2. 9) Press MODE/ENTER button to proceed to the UPDATE setting column. 10) Press EDIT/UP (+) button to input “YES” as to save changes. 11) Press EXIT/DOWN (-) button to input “NO” as to cancel changes. 12) Press MODE/ENTER button to exit screen “3”. Note A: If new values are not inputted within 25 seconds, the system will exit the setup screen (screen “3”) and returned to screen “1”. Note B: If your system is not equipped with dual RX module, please skip step 7 through 8 described above. 15 6.5 Frequency Channel Table FREQUENCY DIP-SWITCH SETTING CHANNEL 910.500 MHz 910.550 MHz 910.600 MHz 910.650 MHz 910.700 MHz 910.750 MHz 910.800 MHz 910.850 MHz 910.900 MHz 910.950 MHz 911.000 MHz 911.050 MHz 911.100 MHz 911.150 MHz 911.200 MHz 911.250 MHz 911.300 MHz 911.350 MHz 911.400 MHz 911.450 MHz 911.500 MHz 911.550 MHz 911.600 MHz 911.650 MHz 911.700 MHz 911.750 MHz 911.800 MHz 911.850 MHz 911.900 MHz 911.950 MHz 912.000 MHz 912.050 MHz 912.100 MHz 00000001 00000010 00000011 00000100 00000101 00000110 00000111 00001000 00001001 00001010 00001011 00001100 00001101 00001110 00001111 00010000 00010001 00010010 00010011 00010100 00010101 00010110 00010111 00011000 00011001 00011010 00011011 00011100 00011101 00011110 00011111 00100000 00100001 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 16 FREQUENCY DIP-SWITCH SETTING CHANNEL 912.150 MHz 912.200 MHz 912.250 MHz 912.300 MHz 912.350 MHz 912.400 MHz 912.450 MHz 912.500 MHz 912.550 MHz 912.600 MHz 912.650 MHz 912.700 MHz 912.750 MHz 912.800 MHz 912.850 MHz 912.900 MHz 912.950 MHz 913.000 MHz 913.050 MHz 913.100 MHz 913.150 MHz 913.200 MHz 913.250 MHz 913.300 MHz 913.350 MHz 913.400 MHz 913.450 MHz 913.500 MHz 913.550 MHz 913.600 MHz 913.650 MHz 913.700 MHz 913.750 MHz 913.800 MHz 913.850 MHz 913.900 MHz 913.950 MHz 00100010 00100011 00100100 00100101 00100110 00100111 00101000 00101001 00101010 00101011 00101100 00101101 00101110 00101111 00110000 00110001 00110010 00110011 00110100 00110101 00110110 00110111 00111000 00111001 00111010 00111011 00111100 00111101 00111110 00111111 01000000 01000001 01000010 01000011 01000100 01000101 01000110 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 17 FREQUENCY DIP-SWITCH SETTING CHANNEL 914.000 MHz 914.050 MHz 914.100 MHz 914.150 MHz 914.200 MHz 914.250 MHz 914.300 MHz 914.350 MHz 914.400 MHz 914.450 MHz 914.500 MHz 914.550 MHz 914.600 MHz 914.650 MHz 914.700 MHz 914.750 MHz 914.800 MHz 914.850 MHz 914.900 MHz 914.950 MHz 915.000 MHz 915.050 MHz 915.100 MHz 915.150 MHz 915.200 MHz 915.250 MHz 915.300 MHz 915.350 MHz 915.400 MHz 01000111 01001000 01001001 01001010 01001011 01001100 01001101 01001110 01001111 01010000 01010001 01010010 01010011 01010100 01010101 01010110 01010111 01011000 01011001 01011010 01011011 01011100 01011101 01011110 01011111 01100000 01100001 01100010 01100011 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 18 7. RECEIVER STATUS LED DISPLAYS (Fig 13) Receiver Status LED Display 1. 2. 3. Receiver Power Display SQ-1 (RX-1) Status Display SQ-2 (RX-2) Status Display 4. 5. Central CPU Status Display LCD System Information Display Receiver Power Display Should be lighted at all time when the system is turned on, if not, please check the input power source. SQ-1 and SQ-2 Status Displays Lights “on” → Transmitted signals detected and received. Lights “off” → No transmitted signals detected. Blinking lights when transmitter is turned “off” → Other radio interference. Dual Decoding CPU Status Display (refer to Fig. 7 on page 10) → → Lights “on” 0.1 second and “off” 1.0 second Lights “on” 0.1 second and “off” 0.1 second Decoders on Standby. Decoding in Process. Receiver Central CPU Status LED Display LED INDICATION REASON Slow Blinks (Green) Standby Fast Blinks (Green) Transmitted signals received Fast Blinks (Red) MAIN contact relays jammed or defective 3 Fast Blinks (Red) RX module defective 4 Fast Blinks (Red) EEPROM error 5 Fast Blinks (Red) Incorrect transmitted ID code 6 Fast Blinks (Red) Incorrect system type 19 Receiver Central CPU Status LCD Display Some of the system status indications described on page 17 are also displayed on the receiver LCD screen for easy readout (screen “2”). 1) 2) 3) 4) 5) 6) ID_ER MAIN_ER PLL_ER WORK SEARCH SCAN → → → → → → Incorrect transmitted ID code Defective MAIN contact relay or relays Defective RX module Transmitted signals received and decoded System on standby System scanning for new frequency channel P: 1 I : 77 - 1 1 1 1 1: 5 2: 5 SYS I F 20 8. RECEIVER INSTALLATION 8.1 Preparation 1. 2. Required Tools: 1) Flat Head Screwdriver (- ) 2) Phillips Head Screwdriver (+) 3) Multi-Meters 4) 14 mm Wrench X 2 5) Power Drill with 10.5 ~ 11mm Drill-Bit 6) Output Cables Ensure receiver is not set to the same frequency channel and ID code as any other units in use at the same facility or within distance of 300 meters. 3. Prior to installation, make sure that the crane system itself is working properly. 4. Use the multi-meter to check the voltage source available and ensure receiver voltage setting is correct for this voltage. 5. Prior to installation, switch off the main power source to the equipment. 8.2 Steps-By-Steps Installation 1. Select a suitable location to mount the receiver. 2. As much as possible, the location selected should have the antenna visible from all areas where the transmitter is to be used. 3. The location selected should not be exposed to high levels of electrical noise. 4. Ensure the selected location has adequate space to accommodate the receiver enclosure. 5. The distance between the antenna and the control panel should be as far apart as possible. 6. Drill four holes on the control panel (10.5mm). 7. Tightened all screws provided. 8. For system wiring, please refer to the wiring diagram located on the last page of this manual and on the backside of the receiver cover plate. 9. Ensure all wiring is correct and safely secured and all screws are fastened. 21 8.3 System Testing 1. Connect the power source to the receiver and test the operation of each function to ensure it operates in the same manner as the pendant controller. 2. Ensure the MAIN contact relay can be properly controlled by the remote control. 3. Ensure the limit switches on the crane that limit all travels are working properly. 4. Ensure the pendant controller is located in a safe location where it would not interfere with remote operation. 22 9. OPERATING INSTRUCTION 9.1 Power “ON” the System 1. Insert the transmitter power key into the key-switch slot located on the right side of the transmitter belly box. 2. Push the transmitter power key inward and then rotate it clockwise to “1” position. “1” → “ON” “0” → “OFF” 3. Make sure both joysticks are in their neutral (0-speed) position when transmitter power is turned “on”. If the transmitter is turned “on” with the joystick in a non-neutral position, the transmitter will be temporarily disabled to avoid any unexpected crane movement at system startup. If this situation occurs, just turn the transmitter power key “off” and then back “on” again with joystick in neutral position. 4. Make sure that the red emergency stop button (EMS) is elevated before the transmitter power is turned on. 5. To activate the receiver MAIN relay, press and hold the “START” pushbutton for up to 1.0 second. The START pushbutton is located on the right side of the belly box, above the transmitter power key switch. 6. After receiver MAIN relay activation (relay closed), if the operator did not give any command by pressing any pushbuttons or moving the joysticks to a non-neutral position, after 5 minutes of inactivity, the transmitter unit will go into “sleep mode” with receiver MAIN relay temporarily deactivated (relay opened). To resume operation after 5 minutes of inactivity, just press and hold the “START” pushbutton again to reactivate the system. 7. After 1 hour of inactivity, the transmitter power will be temporarily deactivated to save power. 8. If the frequency channel of the transmitter unit is altered via simple dip-switch setting inside the transmitter (refer to page 13), you must then also change the frequency RF channel in the receiver (refer to page 15~16). Since the receiver is equipped with frequency channel auto-scanning feature, after changing the frequency channel in the transmitter, you must then press and hold the START pushbutton for up to 20 seconds after turning “on” the transmitter power in order for the auto-scanning receiver to identify the newly selected channel. 23 9.2 Dual Hoist/Trolley Operation For system with dual hoist/trolley operation, use the 3-stage mechanical selector switch located between the two joysticks (refer to diagram below) to select which hoist and/or trolley to operate. At position “I”, the main hoist and/or trolley are activated. At position “II”, the auxiliary hoist and/or trolley are activated. At position “I+II”, both main and auxiliary hoists and/or trolleys are activated with simultaneous travel movement. During system wiring, make sure to connect the Select-I output to the main hoist and/or trolley and Select-II output to auxiliary hoist and/or trolley. When the selector switch is at position “I”, Select-I contact relay will close. At position “II”, Select-II contact relay will close. At position “I+II”, both Select-I and Select-II contact relay will close. For system wiring, please refer to the system wiring schematic located on the last page of this manual or on the inner side of the receiver cover. 24 9.3 Transmitter System Status Displays 1. 2. Battery Power LED Display Transmitter Status LED Display Transmitter Battery Power LED Display POWER DISPLAY REASON Constant Green Battery level normal Slow Blinking Red Low battery power (1st warning) Fast Blinking Red Constant Red Low battery power (2nd warning) Transmitter unit will stop transmitting at anytime Low battery power (3rd warning) Transmitter power and receiver MAIN relay deactivated Transmitter Status LED Display STATUS DISPLAY REASON No Light Displayed Transmitter in sleep mode with receiver MAIN relay deactivated Slow Blinks (Green) Transmitter on standby Fast Blinks (Green) Transmitter active Constant Red Light Jammed or defective pushbutton, switch or joystick contacts Fast Blinks (Red) The contact point currently in use is operative (refer to note A) 3 Fast Blinks (Red) PLL TX module defective 4 Fast Blinks (Red) EEPROM error Note A: When there is a defective or jammed pushbutton, switch or joystick contacts, the transmitter status LED will display a constant red light without flashes. To find out which contact is defective or jammed, activate each pushbuttons, switches or joysticks a step at a time by holding at each position for up to 2 seconds. If a flashing red light (blinks rapidly) is displayed at a specific position, it means that the contact point for that particular position is operative. If the lights remained constantly red at a certain position, then it means that this position’s contact is either jammed or defective. The main purpose of function is to let the user realize which contact on the transmitter is not working properly and required service immediately. 25 10.BATTERY CHARGING 1. Plug in the power cord and the power indicator will light up. 2. When a battery pack is inserted, the green charging light will blink to indicate charging is taking place at the current moment. 3. If discharging of battery pack is desired (strongly recommended for 600mA NiCd battery pack), press the “DISCHARGE” button. At discharging mode, the green blinking light will now turned into a constant red light indicating that the battery pack is now being discharged. If you want to cancel the discharge, just press “DISCHARGE” button again. 4. When discharging is completed, the charger will automatically switch to the charging mode where the green blinking light will reappear again. 5. The charging time for a 600mA NiCd battery pack is approximately 3 ~ 6 hours. As for the 1450mA NiMH battery pack, the charging time is approximately 7 ~ 9 hours. 6. When charging is completed, a constant green light will appear to indicate that the battery pack is fully charged. 7. When the battery pack is at 90% charged state, trickle charging will take over to ensure the longevity of the battery pack and as well as to ensure the battery pack is 100% charged. 8. When the battery pack’s temperature exceeds 50℃, the charger will go into protective mode and charging will be discontinued. 9. To prolong the life of the battery pack (600mA NiCd battery pack), it is recommended that the battery pack be fully discharged prior to every re-charging. 26 11.SYSTEM SPECIFICATION Transmitter Unit Frequency Range PLL 910.500 ~915.400 MHz Transmitting Range: 100 Meters Continuous Operating Time 37.7+ Hours (1650mA) Security ID Code 65,536 sets (16 + 1 bit) Channel Spacing 50KHz Hamming Distance ≧ 6 Frequency Control Synthesizer (PLL) Frequency Drift < 3ppm @ -25℃ ~ 75℃ Frequency Deviation < 1ppm @ 25℃ Spurious Emission > 60dBc Transmitting Power 0.043mW Emission F1D Antenna Impedance 50 ohms Enclosure Rating IP-66 Source Voltage 7.2 V (1650mA) Current Drain ~80mA Operating Temperature -10℃ ~ 75℃ Dimension 247mm X 154mm X 182mm Weight 1,600g (with 1650mA battery pack) Note: Longer or shorter transmitting ranges are available upon request. 27 Receiver Unit Frequency Range PLL910.500 ~915.400 MHz Channel Spacing 50KHz Hamming Distance ≧ 6 Frequency Control Synthesizer (PLL) Frequency Drift < 3ppm @ -10℃ ~ 75℃ Frequency Deviation 1ppm @ 25℃ Sensitivity -115dBm Decoding Reference FSK Antenna Impedance 50 ohms Data Decoder Reference Quartz Crystals Responding Time 100mS ~ 300mS Enclosure Rating IP-66 Source Voltage 100 ~ 240VAC @ 50/60 Hz. (standard equipped) Power Consumption 36VA Operating Temperature -10℃ ~ 75℃ Output Contact Rating 250V @ 10A Dimension 417mm X 309mm X 167mm Weight 8,800g (without the output cable) Note: Other types of source voltages are available upon request. 28 12.PARTS LIST 1. TX module (please specify frequency band) TX5000 2. RX module card (please specify frequency band) RX5000 3. Encoder board EN5000 4. Decoder card DE5000 5. Relay card RY5000 6. Power supply card (100 ~ 240VAC) PS5000 Power supply card (48VAC) PS5001 Power supply card (24VDC) PS5002 Power supply card (380VAC) PS5003 Power supply card (400 ~ 420VAC) PS5004 7. Single axis joystick unit (complete) 2 speeds / steps JOY-12 3 speeds / steps JOY-13 4 speeds / steps JOY-14 5 speeds / steps JOY-15 8. Double axis joystick unit (complete) 2 speeds / steps JOY-22 3 speeds / steps JOY-23 4 speeds / steps JOY-24 5 speeds / steps JOY-25 9. 1-step pushbutton (side panel) PB-1S 10. 1-step pushbutton (top panel) PB-1T 11. 2-stage selector switch SW-2T 12. 3-stage selector switch SW-3T 13. 2-stage toggle switch TW-2T 14. 3-stage toggle switch TW-3T 15. Emergency stop button EM5000 16. Transmitter casing (complete) TC5000 18. Transmitter protective guardrail PG5000 19. Transmitter power key PW5000 20. 1650mA NiMH battery pack BAT1650 21. Receiver antenna (433 MHz ~ 434 MHz) ANT433 22. Receiver antenna (910.500 ~915.400 MHz) ANT910 23. Receiver enclosure (complete) RC5000 24. Intelligent charger (please specify voltage) CH5000 25. Waist Belt WB5000 26. Shoulder Strap SS5000 29
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