Magnetek 900L8TX Machine Remote Control TX User Manual manual

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Document ID	83510
Application ID	vH4ojfHvRbAHvNHCQOhowA==
Document Description	manual
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Permanent Confidential	No
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Document Type	User Manual
Display Format	Microsoft Word - pdf
Filesize	633.82kB (7922689 bits)
Date Submitted	2000-01-26 00:00:00
Date Available	2000-02-11 00:00:00
Creation Date	2001-04-25 07:29:15
Producing Software	Acrobat Distiller 4.0 for Windows
Document Lastmod	2001-04-25 07:29:16
Document Title	manual

RADIO CONTROL SYSTEM MANUAL
FOR LOUIS A. GRANT’S
GOM-360BDRE MACHINE
(Version 2.0)
USER’S REFERENCE FOR THE
G.0.M. RADIO CONTROL SYSTEM
Sategg Precautions and Conditions
Any operator of industrial mobile equipment needs to be aware of the inherent dangers
associated with the operation of that equipment. Any number of single point failures in the
control mechanisms associated with mobile equipment could cause erratic movement of
the machine Typical radio control systems for hydraulic mobile equipment utilize a hand
held transmitter device with switches remotely driving a receiver with relay switches wired
to electrically driven solenoid hydraulic valves driving cylinders and motors, etc. thereby
allowing operation of the various functions of the machine Each of the devices in this
chain of control has a life expectancy and can and has failed to operate and/or react
erratically
We have provided all of the safety features available With today’s technology to avoid
erratic and/or non-response situations in our radio transmitters and receivers. This does
not eliminate the possibility of a failure in hardware
Any operator needs to be aware of the safety concerns and operate the machinery
accordingly In essence this means he must keep his body out of the way of potential
harm from erratic movements, maintain distance from moving, swinging and tramming
devices Machine Stop devices are available for the operator to shut down the machine,
the operator should be aware of and know the location of these devices as well as be
aware of the time it takes for these devices to react This time factor will help determine
the safe operating distance he needs to maintain from any moving part,
The advantage of a radio remote operating system is to allow the operator to maintain a
safe operating distance without being tied to the machine by tether and/or hand controls
This distinct feature should be taken advantage of and utilized making the overall machine
a safer piece of equipment to operate, Please recognize this capability and utilize it to its
full potential
Introduction
The following is a brief description of the radio control system for the (3.0 M. 360
line of machines The radio system will consist of a transmitter, receiver and a remote
antenna The radio system was designed to be a direct replacement for the current
umbilical system and operates on the same basis, but there are some differences Please
read the following for transmitter operation, receiver operation and diagnostics. Also there
are drawings of both to pick out areas of discussion
Transmitter In armatian
The transmitter is a hand-held controller approximately 9"H x 4 25"W x TD in
size and, weighs about 3 pounds The enclosure is built to aNEMA 4 standard, which
states the unit can with stand water splashes, but the unit can not be submerged in water
The transmitter is made out ofPVC plastic. This plastic is used for three reasons It is
strong, light. and it has good RF characteristics. Please keep metal away from the
transmitter Metal Wlll shield the RF signal and cause poor reception
The transmitter was designed to be a replica of the current umbilical controller
You will notice that the rocker levers on the front of the unit match the same functions on
the umbilical unit The controller was lengthened to include buttons for future use There
were some changes made to the bottom row of switches on the front cover A throttle
increase button and decrease button was included to replace the IDLE HI/LO button To
increase the machine idle press and hold the THROTTLE INCREASE button until the
engine reaches the desired RPM To decrease the RPM press and hold the THROTTLE
DECREASE button Please note at machine startup, the receiver will automatically
decrease the throttle for 2 seconds This is for safety reasons
The “HAMIVIER ON/OFF” switch remains in the same position as the old
controller One push activates the function, to deactivate the function push the button
again When the hammer is on, the yellow led at the top lefi of the transmitter will light
up When the hammer is turned offi the yellow led will go out
On top ofthe transmitter are three toggle switches and one pushbutton The
second toggle switch in from the lefi side, and the pushbutton start the entire system. To
power up the machine and transmitter the following sequences of events must happen The
“TX POWER” toggle must be switched from the off position to the on position Next the
start button is pushed. This button will start the machine's engine Please note that when
the green button is pushed, no other buttons can be activated For example, if an operator
has the “TILT” toggle in the “CW” position, the radio system will not let the machine
start For safety the machine will only stan when no commands are operated. This also
allows the radio system to scan for swttches that are broke If a button is stuck on, the
machine will not start Switch the TX POWER switch to the off position to remove power
from the transmitter The receiver will then shut the fuel solenoid elf to the engine The
receiver will go into a scan mode looking for any transmitters that has an address that
matches the receiver’s address.
Located on the top of the transmitter are three LED‘s When the transmitter is held
in the operation position, the first LED to the lefi is the “HAMMER ON” led (yellow
color) This LED lights when the "HAMMER 0 ” operation has been activated The
middle LED (colored green) is used to indicated when any switches have been activated
This LED indicates a number of different operations. The green LED lights when any
switch has been operated For example if you push “TILT CW", the green LED will light
until the function is released. This light will also let the operator know when a button is
stuck For example, at starlupt if there is a stuck button the green LED will light when the
operator pushes the “START“ pushbutton. During operation ifthe green LED stays solid
afier a function has been released, immediately swrtch the “TX POWE ” toggle switch to
the off position Try to restart the transmitter afler power down The transmitter needs
repaired irthe green LED comes on when the green pushbutton is pressed during the start
up ofthe machine The third LED (red) shows the operator battery status when the
transmitter has fresh batteries the LED will be off The LED will blink when the batteries
need changed Please note that the transmitter starts monitoring battery life about ten
minutes afier the transmitter is staned A dead battery will start the transmitter, but as
soon as the battery monitoring starts. the transmitter will shut down This scenario will
make an operator think there is problem with the machine, or radio system, but the
batteries need changed. The batteries are two 9V batteries located under a protective
cover at the bottom of the transmitter Change both batteries at the same time. A bad
battery will drain power from a good battery when put together Two new alkaline
batteries will provide an estimated so hours ofcontinuous operation
Two toggle switches are located on the outer edges ofthe top plate These toggle
switches have a shorter handle than typical toggle switches Please note the difference
between their height and the “TX POWE " toggle switch These switches perform the
same function as on the umbilical The lefi toggle controls the “STICK” up and down
functions, and the right controls the "TILT" clockwise (CW), and counter-clockwise
(CCW) functions
On the front of the transmitter under the rocker switch assembly is a selector
switch This switch was provided to select different operating channels or frequencies The
selector switch has eight different channels labeled 1 to 3 If a radio system seems slow,
there is a good chance the radio system is seeing some interference The operator then
would select a different channel to operate the radio system on Please remember the
transmitter and the receiver channel selection must match If the transmitter is set to
channel 3, then the receiver must be set to channel 3 Please the attached drawings for
more information about setting the channel
Receiver I nlnrmation
The receiver was designed to be especially useful for the operator of the system
The receiver enclosure is approx 17.“L x S”W x Z”H in Size, and weighs about Slbs The
shell is made of a mgged extruded aluminum shell At one end of the unit is a twenty four
position connector This connects to the machine’ s solenoid block where the umbilical
controller now connects The receiver is connected Via a cable to that block At the other
end of the receiver is a blank cover
Located on the top of the receiver is a cluster ofvisihle LED diagnostics for
operator feed back At the end closest to the connector are the machine functions You
will notice that there is a single row ofLED‘s next to each function when the green LED
is lit under the label “OK" the function is being operated Ifthe green LED does not light,
a fuse has tripped insnle the receiver unit There is short between the receiver and the
solenoid The short circuit must be Corrected for the function to work The internal fuse
takes about 5 minutes to reset The fuse is thermal sensitive The green LED should light
afler the shon circuit has been corrected and adequate time was given for the fiise to reset
All 24 ninctlons are fused the same way
At the other end of the receiver is a bar graph along with six LED’s labeled 1
through 6 The bar graph indicates signal strength When the bar graph is fillly illuminated
(all 10 segments) the RF signal is strong The signal is weak when one segment is lit and it
is recommended to first check the antenna, and the cable that runs from the receiver to the
antenna. If damaged, the antenna or cable must be replaced If those two pieces are OK,
then try the system with another transmitter The current transmitter could be putting out
a low signal The transmitter should be sent back for adjustments The next six LED’s
perform a more detailed check between the receiver and transmitter The following occurs
when the labeled LED lights
LED 1- TX ON LINE- Solid ON for transmitter recognized, OFF for no
transmitter recognized Receiver has chull‘ed a transmitter and control has been awarded
to that one unique transmitter Continuous messages are required to keep the fuel solenoid
energized If a message is lost for one second, the system will reset all outputs except the
fuel solenoid Afier two seconds all outputs are reset, the engine will stop, and the
receiver will enter a search for transmitter mode
LED 2- MID MESSAGE DETECTv This LED flashes on receipt ofvalid
messages when LED 1 is ON. A message contains the commands sent by the transmitter
A valid command will consist of two identical messages sent by the transmitter A
transmitter needs to be on—line (i e LED #1 is on) This LED also serves as a system
watchdog The watchdog has a slow flash when no transmitters are on or recognized
(LED 1 OFF) This LED lets the operator know that receiver’s intemal processor is
operating and scanning for available transmitters (in watchdog mode LED l will be off)
LED 3 - 2 SECOND DATA LOSS- There is a lapse ofvalid data for more than 2
seconds The receiver will clear all outputs, including the fuel solenoid LED 16 will come
on {or 1 second indicating a total system shut down After this one second period the
receiver will re-enter the search mode (for a transmitter)
LED 4 - CONE/(ANDED POWER DOWN - The operator powers down the
transmitter LED 4 stays on for approx 1 second then the receiver goes into a search
Mode (LED 6 comes on).
LED 5- ADDRESS CONFLICT ERROR » More than one transmitter is on and set
to the same address codes The receiver will refuse all commands until it sees one
transmitter sending messages.
LED 6- M SECOND DATA LOSS - When a transmitter is en-hne, (LED 1 is
on) then this LED indicates there has been a one second lapse in valid messages from the
transmitter All momentary nulputs are cleared until the next valid message is detected
Latched functions (fuel solenoid) are not affected Normal operation will resume when a
valid message is detected, unless the total time frame reaches 2 seconds See LED if} for
further details
ifthere is no transmitter on-line, LED is] is off This LED indicates that the
receiver is aware of a transmitter, but it is refusing to accept it’s signal because of a
command being on (transmitter) For safety reasons all commands must be elf at the
transmitter before the receiver will award control to a transmitter For example, if the
operator walks out of range with the transmitters a two second data loss will occur If the
hammer (latched command) was on, the receiver will not re-recngnize the transmitter
when the operator comes back into ranges due to the hammer being on In this case, LED
an will be blinking slowly and LED we will be on The operator will need to turn otfthe
hammer function on the transmitter in order for the receiver to accept the signal
Above the antenna on the receiver is a selector switch for operating channels This
switch was provided to select difierent operating channels or frequencies. The selector
switch has eight different channels labeled 1 to B. If a radio system seems slow, there is a
good chance the radio system is seeing some interference The operator then would select
a different channel to operate the radio system on Please remember the transmitter and
the receiver channel selection must match. If the transmitter is set to channel 3, then the
receiver must be set to channel 3 The relationship between the channel number and
frequency are listed in the channel selection part ofthis manual
Transmitter and Receiver Pairing
The first prototype systems used a serial number system having a three digit code
for matching components. This serial number would match the machine's serial number
With the radio system The latest systems have the receiver and transmitter matched by
internal sofiware Each transmitter is specifically matched to a receiver For example
transmitter number 102, will only work with receiver number 102 No other transmitter
will work with receiver number 102 It'the transmitter or receiver malfunctions
(electronically), both units will need returned for servicing If a transmitter toggle switch
breaks, the unit does not need to be retumedv The top plate assembly Will be replaced with
a new assembly, The old assembly will be returned for repair The transmitter and receiver
will need to be returned when there is a RF problem, or a sefiware problem General
repairs can be done in the field The only items that need to be matched are the
channel settings!
Channel Selection
On the front of the transmitter under the rocker switch assembly, and above the
antenna on the receiver is a selector switch This switch was provided to select different
operating channels or frequencies. The selector switch has eight different channels labeled
1 to 8 If a radio system seems slow, there is a good chance the radio system is seeing
some interference, The operator then would select a dilTerent channel to operate the radio
system on. Please remember the transmitter and the receiver channel selection must
match| If the transmitter is set to channel 3, then the receiver must be set to channel 3
The relationship between the channel number and frequency are listed in the channel
selection part of this manual. The following list will show the operator what frequency
each channel represents. Please the attached drawings for more information.
Channel Frequency
903.3Mhz
906.3Mhz
907 .8Mhz
909.3Mhz
9l2.3Mhz
915.3Mhz
919.8Mhz
921 .3Mhz
OOxlcthbWN~
Drawing Listing
The drawings of the receiver and transmitter will illustrate the areas discussed above
Please read over and understand the system. This will help insure that the system is
operated correctly and safely.
1 ) GENERAL TRANSMITTER LAYOUT DRAWING 97095004 REV. 2
2 ) GENERAL RECEIVER LAYOUT DRAWING 97095003 REV. 1
3.) SETTING THE CHANNEL (TX) DRAWING 97095025 REV. 1
4.) SETTING THE CHANNEL (RX) DRAWING 97095026 REV. l
5 ) SYSTEM STARTUP DRAWING 97095007 REV. 2
6.) TRANSMITTER OPERATION DRAWING 97095008 REV. Z
7.) BATTERY INFORMATION DRAWING 97095010 REV 2
8.) RECEIVER LED FUNCTIONS DRAWING 97095012 REV. 3
9.) RECEIVER PIN OUT DRAWING DRAWING 97095152 REV. 2
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Create Date                     : 2001:04:25 07:29:15
Producer                        : Acrobat Distiller 4.0 for Windows
Modify Date                     : 2001:04:25 07:29:16-04:00
Page Count                      : 9

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