Rothenbuhler Engineering 1678-4 Test Box User Manual

Rothenbuhler Engineering Company Inc Test Box Users Manual

Users Manual

REMOTE FIRING DEVICE OPERATION MANUAL The information contained in this document is subject to change without notice. In no event shall Rothenbuhler Engineering Company be liable for errors contained herein or for special, indirect, or consequential damages or injuries of any nature resulting from use of information in this document. ROTHENBUHLER ENGINEERING P.O. BOX 708 524 RHODES ROAD SEDRO WOOLLEY, WA 98284 1678-A16 {Draft} 5/12/2011 ©2011 Rothenbuhler Engineering All Rights reserved
SPECIAL NOTICE WARNING TO USERS AND AFFECTED PERSONS The Remote Firing Device (RFD) is designed to be used in blasting operations. Explosives used in connection with the RFD may be extremely powerful. Improper use of explosives with or without the RFD or improper safety precautions taken with respect to personnel or property may result in death, serious personal injury, or property damage. Other manufacturers’ equipment that may not be in compliance with frequency coordination may inadvertently interfere with the operation of the RFD. Be aware of other operations within the receiving range of the RFD. The literature accompanying this warning contains information of a general nature for users of the RFD based upon the manufacturer’s experience in the design and manufacture of remote radio frequency devices. In addition, the manufacturer provides product literature and technical data sheets periodically which should be consulted for detailed information on the characteristics, specifications and recommendations for the RFD. The manufacturer does not purport to give information or advice on explosives or their use. The RFD and related explosive devices are intended for use only by trained professionals having comprehensive knowledge of the RFD, the explosives being used, and the application together with all related safety precautions. The manufacturer of the RFD is responsible only for the proper performance of the RFD itself and is not responsible for the performance, safety, or specifications of the explosive used, nor the suitability of the RFD for any particular purpose other than that expressly described in the manufacturer’s literature. LIMITED WARRANTY The manufacturer warrants the Model 1678 Remote Firing Device (RFD) to be free of defects in workmanship or materials for the period of one year from the date of purchase. In the event any RFD or component thereof is shown to be defective in workmanship or materials within one year, the system or component will be repaired or replaced without charge by the manufacturer at the manufacturer’s place of business. This warranty does not cover damage or injury to equipment resulting from abuse, neglect, or use in applications other than expressly described by the manufacturer as fit purposes for the RFD. This Limited Warranty is given in lieu of all other legal warranties express or implied and neither the manufacturer nor its representatives shall be liable for any direct, incidental or consequential loss or damages arising out of any occurrence or accident involving the use of this product. 1678 RFD OPERATION MANUAL {DRAFT} ii
FCC NOTICE This device complies with Part 15 of the FCC regulations. Operation is subject to the following two conditions: (1) That this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. RADIATION HAZARD WARNING This radio shall only be used during the course of employment by individuals aware of the hazards of radio frequency (RF) radiation exposure, and the ways to minimize such hazards. This radio is not intended for use by the "General Population." Further, this radio must not be co-located or operated in conjunction with any other antenna or transmitter. User should not allow antennas to come within 20 cm (8 inches) of the body during use. CANADA **This Class B digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations. Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada. Under Industry Canada regulations, this radio transmitter may only operate using an antenna of a type and maximum (or lesser) gain approved for the transmitter by Industry Canada. To reduce potential radio interference to other users, the antenna type and its gain should be so chosen that the equivalent isotropically radiated power (e.i.r.p.) is not more than that necessary for successful communication. This radio transmitters (IC: 2758A-166921 and 2758A-16784) have been approved by Industry Canada to operate with the antenna types listed below with the maximum permissible gain and required antenna impedance for each antenna type indicated. Antenna types not included in this list, having a gain greater than the maximum gain indicated for that type, are strictly prohibited for use with this device. Antenna: ¼ wave whip, gain 2.15 dBi 1678 RFD OPERATION MANUAL {DRAFT} iii
Conformément à la réglementation d'Industrie Canada, le présent émetteur radio peut fonctionner avec une antenne d'un type et d'un gain maximal (ou inférieur) approuvé pour l'émetteur par Industrie Canada. Dans le but de réduire les risques de brouillage radioélectrique à l'intention des autres utilisateurs, il faut choisir le type d'antenne et son gain de sorte que la puissance isotrope rayonnée équivalente (p.i.r.e.) ne dépasse pas l'intensité nécessaire à l'établissement d'une communication satisfaisante. Le présent émetteur radio (IC: 2758A-166921 and 2758A-16784) a été approuvé par Industrie Canada pour fonctionner avec les types d'antenne énumérés ci-dessous et ayant un gain admissible maximal et l'impédance requise pour chaque type d'antenne. Les types d'antenne non inclus dans cette liste, ou dont le gain est supérieur au gain maximal indiqué, sont strictement interdits pour l'exploitation de l'émetteur. Stabantenne: ¼ longueur d'onde, gain 2.15 dBi 1678 RFD OPERATION MANUAL {DRAFT} iv
TABLE OF CONTENTS Chapter PageSPECIAL NOTICE .......................................................................................................... II WARNING TO USERS AND AFFECTED PERSONS .................................................... II LIMITED WARRANTY....................................................................................................II FCC NOTICE ................................................................................................................. III RADIATION HAZARD WARNING.................................................................................III CANADA........................................................................................................................ III TABLE OF CONTENTS..................................................................................................V LIST OF ILLUSTRATIONS..........................................................................................VIII SAFETY INFORMATION................................................................................................X 1. INTRODUCTION.................................................................................................. 1 1.1. Purpose ............................................................................................................ 1 1.2. Storage and Environmental Conditions............................................................. 1 1.3. Maintenance ..................................................................................................... 3 2. INTRODUCTION TO RFD SYSTEM COMPONENTS ......................................... 4 2.1. System.............................................................................................................. 4 2.2. Mini Controller Unit ........................................................................................... 7 2.3. Mini Controller Unit Switch Operation ............................................................... 7 2.4. Mini Controller Unit Display Operation ............................................................ 10 2.5. Electric Remote Unit ....................................................................................... 13 2.6. Remote Shock Tube Initiator (RSTI) ............................................................... 16 2.7. 3 Position Battery Charger.............................................................................. 19 2.8. Test Box.......................................................................................................... 19 1678 RFD OPERATION MANUAL {DRAFT} v
2.9. Antenna Assembly .......................................................................................... 21 2.10. Carrying Case ............................................................................................. 22 2.11. Vent operation ............................................................................................. 25 2.12. Antenna / Battery Charger Connector ......................................................... 26 2.13. Connector Dust Cover Operation ................................................................ 27 3. SYSTEM SPECIFICATIONS.............................................................................. 28 3.1. Radio .............................................................................................................. 28 3.2. Physical .......................................................................................................... 29 3.3. Battery ............................................................................................................ 29 3.4. Timing ............................................................................................................. 30 3.5. Detonate Output.............................................................................................. 30 3.6. System Identification....................................................................................... 31 4. PRE-OPERATIONAL PROCEDURES............................................................... 32 4.1. Physical Inspection ......................................................................................... 32 4.2. Battery Charging With the 3-Position Charger ................................................ 32 4.3. Bench Testing the System .............................................................................. 34 5. OPERATIONAL PROCEDURES ....................................................................... 36 5.1. Ready the System at Site ............................................................................... 36 5.2. Placement of Remote Units ............................................................................ 37 5.3. System Operation – Remote Units Within 1 mile of Mini Controller Unit......... 38 5.4. System Operation – Remote Units More Than 1 mile From Mini Controller Unit 40 5.5. System Operation – Remote Units Both Within and In Excess of 1 mile and Less Than 5 miles from Mini Controller Unit ............................................................. 41 6. POST OPERATIONAL PROCEDURES ............................................................ 44 6.1. Securing the System....................................................................................... 44 6.2. Physical Inspection ......................................................................................... 44 6.3. Packaging ....................................................................................................... 44 1678 RFD OPERATION MANUAL {DRAFT} vi
6.4. Maintenance & Equipment Storage ................................................................ 44 7. BASIC TROUBLESHOOTING IN THE FIELD................................................... 45 7.1. Remote Units .................................................................................................. 45 7.2. Mini Controller Unit ......................................................................................... 45 7.3. Remote Shock Tube Initiator........................................................................... 45 8. OPTIMIZING RANGE......................................................................................... 47 9. TEST BOX.......................................................................................................... 52 9.1. Test Box Descriptions ..................................................................................... 52 9.2. Test Box Operation ......................................................................................... 53 9.3. Saving Test Box results to a file using HyperTerminal.................................... 61 10. RFD PROGRAMMING GUIDE........................................................................... 68 10.1. Programmable Parameters ......................................................................... 68 10.2. Required equipment .................................................................................... 68 10.3. Windows Configuration Software Operation (Setup RFD)........................... 68 10.4. Setup RFD Installation ................................................................................ 68 10.5. Configuring Setup RFD ............................................................................... 70 10.6. Using Setup RFD to Test RFD Units ........................................................... 71 10.7. Using Setup RFD to Program RFD Units .................................................... 76 11. BATTERY MAINTENANCE ............................................................................... 81 11.1. Battery Temperature ................................................................................... 81 11.2. Pre-operation............................................................................................... 81 11.3. Periodic ....................................................................................................... 81 11.4. Annual ......................................................................................................... 81 11.5. Extended non-use ....................................................................................... 81 1678 RFD OPERATION MANUAL {DRAFT} vii
LIST OF ILLUSTRATIONS Figure 2-1 RFD 4-Remote Case System......................................................................... 6 Figure 2-2 Mini Controller Unit ........................................................................................ 7 Figure 2-3 Mini Controller Isometric View with Antenna ................................................ 12 Figure 3-1 Electric Remote Unit .................................................................................... 13 Figure 3-2 Electric Remote Unit Angled View ............................................................... 15 Figure 3-3 Remote Shock Tube Initiator (RSTI) ............................................................ 16 Figure 3-4 RSTI Angled View with Shock Tube Spark Tip ............................................ 17 Figure 3-5 Shock Tube Tip............................................................................................ 18 Figure 3-7 3 POSITION CHARGER .............................................................................. 19 Figure 3-8 Test Box....................................................................................................... 20 Figure 3-9 Antenna Assembly ....................................................................................... 22 Figure 3-10 Carrying Case ............................................................................................ 23 Figure 3-11 Carrying Case (Half Case) ......................................................................... 24 Figure 3-12 Vent Operation........................................................................................... 25 Figure 3-13 3-Position Charger Connection .................................................................. 26 Figure 3-14 Connector Dust Cover Operation............................................................... 27 Figure 4-1 Mini Controller Unit Identification Label........................................................ 31 Figure 4-2 Remote Unit Front Identification Label......................................................... 31 Figure 9-1 Unit Normal Transmission Location ............................................................. 48 Figure 9-2 Remote Unit Elevated .................................................................................. 49 Figure 9-3 Mini Controller Unit Elevated........................................................................ 50 Figure 9-4 Antenna Radiation Pattern ........................................................................... 51 1678 RFD OPERATION MANUAL {DRAFT} viii
Figure 10-1 Test Box..................................................................................................... 52 1678 RFD OPERATION MANUAL {DRAFT} ix
SAFETY INFORMATION The following are WARNINGS and CAUTIONS, contained throughout this manual and are repeated here for emphasis. All personnel engaged in the handling, firing, and storage of the system covered in this manual must fully understand these WARNINGS and CAUTIONS, and procedures by which hazardous conditions are to be reduced or eliminated. Also listed are general safety precautions that are not related to any specific procedures and therefore don't appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance. WARNING Never rely on the equipment for your safety. WARNING Use of this system and its components must be restricted to personnel qualified and experienced in the field of explosives and detonating devices. Under no circumstances shall untrained personnel attempt to use this manual as a text for self-teaching. WARNING This system and its components should be stored in a secure area with no access to unauthorized personnel. This system can be used in conjunction with explosives as a deadly weapon. WARNING These radios contain batteries. The potential for activation is always present whether or not antennas are attached to the units. WARNING Employ standard blasting system safety standards when using this equipment with explosives. WARNING Lightning induced energy, caused by electrical storms, can detonate explosives. In the interest of safety, blasting on land, water and underground should be suspended and all personnel should be evacuated to a safe distance from the blast area whenever lightning storms are in the vicinity. Dangerous levels of static electricity can build up in the atmosphere. These levels can be sufficient to detonate explosives. WARNING Radio frequency energy of sufficient magnitude can cause blasting caps to detonate. WARNING To eliminate long wire runs, and to make the "shoot" from a safe distance, the Remote Firing Device uses low energy level radio frequency transmissions. WARNING Do not connect a blasting cap to a Remote Unit unless the green SAFE light is on, the red ARMED light is off, and the yellow ON/LOW BATT light is on steady. This indicates there is no voltage on the binding posts, the binding posts are electically isolated from the firing capacitor, the binding posts are shunted to each other, and the battery is not low. 1678 RFD OPERATION MANUAL {DRAFT} x
WARNING Ensure that blasting caps are not connected to any of the Remote Units during bench testing. WARNING This is a sensitive electronic radio system and it may be damaged. WARNING Do not use the Mini Controller Unit within 100 feet (30 meters) of explosives, blasting caps, or wires leading to them. The Mini Controller signal is 5 watts, which can cause detonation of caps if within 100 feet. The 5 watt Mini Controller complies with the Recommended Table of Distances established by the Institute for the Makers of Explosives (IME) when placed beyond 100 feet of explosives. WARNING Do not engage in RFD communications with the Remote Units when they are connected to explosive charges until the shot is prepared and all personnel are clear. The Remote Unit complies with the Recommended Table of Distances established by the Institute for the Makers of Explosives (IME) when placed 25 feet (8 meters) or more from blasting caps or wires leading to them. For further information, refer to the Institute for the Makers of Explosives Publication no. 20, Part II, Section (1). WARNING Do not touch the Shock Tube Tip Jacks on the side of the Remote Shock Tube Initiator (RSTI) when armed or firing. Lethal voltages may be present. CAUTION Do not assume the Disarm command has been received by the Remote Unit unless DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. If distance appears to be the problem, move closer to the Remote Unit following standard procedures for this type of situation. The “STATUS” and/or “DISARM” switches may be pressed repeatedly as the Remote Unit is approached. Maintain a safe distance from the Remote Unit. Do not approach the Remote Unit until DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. Under no conditions should the “FIRE” switch be pressed as the Remote Unit is approached. DO NOT bring the Mini Controller Unit closer than 100 feet (30 meters) to blasting caps, wires connected to blasting caps, or other explosives. CAUTION All units must be thoroughly tested and the batteries fully charged prior to operational use. CAUTION Unequal air pressure inside the Mini Controller Unit may affect the operation of membrane switch keypad. Extreme pressure differentials may irreversibly damage the keypad and/or cases. CAUTION Vents in all units should be momentarily opened and closed immediately before use. CAUTION Do not open a vent if there is water on or near the vent. Keep the vents closed when the relative humidity is above 90%. Take necessary precautions to ensure moisture does not enter the unit case. 1678 RFD OPERATION MANUAL {DRAFT} xi
1678 RFD OPERATION MANUAL {DRAFT} xiiCAUTION Do not use any component that is damaged, suspected of being damaged, or is not able to operate as designed. The safety of the operation could be compromised.
1. INTRODUCTION 1.1. PURPOSE 1.1.1. 1.1.2. 1.1.3. The primary purpose of this manual is to provide descriptive information, operational information, instructions in assembly, and instructions in testing and preparation for operational or training use of the Remote Firing Device (RFD). The Remote Firing Device (RFD) is used to activate electric and non-electric detonator devices. The System is strictly an electronic device, containing no explosive. The Mini Controller Unit shall be operated from 100 feet (30 meters) to five miles (8 km) from the explosive. The Electric Remote Unit shall be placed at the explosive site, with a two-conductor firing line running to the explosive. The Remote Shock Tube Initiator (RSTI) is placed at the explosive site, with 3mm non-electric shock tube running to the explosive. The Mini Controller Unit communicates to the Remote Units through a two-way RF transmitter data link, for a typical distance greater than Error! Reference source not found. (8 km). The Remote Unit can typically return communication for a distance greater than Error! Reference source not found. (1.6 km). Actual communication range is dependant upon a variety of factors such as terrain, obstacles, antenna height, and local interference. Throughout this manual, the tem “Remote Unit” is a generic term that is used for both the Electric Remote Unit and for the RSTI. 1.2. STORAGE AND ENVIRONMENTAL CONDITIONS 1.2.1. 1.2.2. 1.2.3. 1.2.4. 1.2.5. The Mini Controller Unit and Remote Unit have manual operated vents. The vents should always be CLOSED during air transport, underwater transport, storage and operational use to prevent moisture intake. The operator should momentarily open and close the vent after the unit has been subjected to changes in elevation or depth. This equalizes pressure within the case to the outside environment. DO NOT open the vent if there is water on or near the vent or if the relative humidity is above 90%. Towel dry vents prior to opening. The vents should be OPEN, when stored in a dry hot environment. The Mini Controller Unit and Remote Unit (with vents closed) are airtight to an altitude of 30,000 feet and watertight to a depth of 100 feet. The Mini Controller Unit and Remote Unit is shock resistant, drop tested from 5 feet onto 3 inches of steel plate backed by concrete. The battery pack and unit electronics are electrically isolated from the unit case. The Mini Controller Unit and Electric Remote Unit have a temperature operation from -22 ºF to +140 ºF (-30 ºC to +60 ºC). The RSTI has a temperature 1678 RFD OPERATION MANUAL {DRAFT} 1
operation range from -15 ºF to +140 ºF (-26 ºC to +60 ºC). 1678 RFD OPERATION MANUAL {DRAFT} 2
1.3. MAINTENANCE 1.3.1. 1.3.2. 1.3.3. 1.3.4. Batteries within the RFD require periodic charging and discharging to maintain health and service life. The battery packs within the RFD should be replaced every 3 years or 300 charge cycles, whichever comes first. Battery packs can be replaced by the user following strict procedures to maintain case sealing. It is recommended the battery packs be replaced by the manufacturer or by an authorized service center. Contact the manufacturer for details. Corrective maintenance shall be accomplished at the manufacturer or authorized service depot. Replacement of parts or disassembly by any other entity could result in the unsafe operation of the RFD and will void the manufacturer’s warranty. In case of failure of a component of the RFD System, the system will need to be shipped to the manufacturer or authorized service depot. 1678 RFD OPERATION MANUAL {DRAFT} 3
2. INTRODUCTION TO RFD SYSTEM COMPONENTS 2.1. SYSTEM 2.1.1. 2.1.2. 2.1.3. 2.1.4. 2.1.5. 2.1.6. The RFD is a battery powered, hand held, radio remote controlled system to be used on land as a primary firing mechanism to detonate explosive charges. The RFD system consists of a Mini Controller Unit and up to four Remote Units (any combination for Electric Remotes and RSTIs up to a total of four). The Mini Controller Unit and Remote Units in one system will not operate with Units from another system. The RFD is transportable over land, underwater to a depth of 100 feet (30 meters), and in the air to an altitude of 30,000 feet (9,100 meters). The units are shock resistant to a 5 foot (1.5 meter) drop and impervious to static discharge. The Mini Controller and Electric Remote Units will operate in a temperature range of -22 ºF to + 140 ºF (-30 ºC to +60 ºC). The RSTI will operate in a temperature range of -15 ºF to +140 ºF (-26 ºC to +60 ºC). The system has two modes of operation. The two modes are one-way, and the two-way mode. 2.1.5.1. Range for one-way mode is greater than Error! Reference source not found. (8 km) typically. 2.1.5.2. Range for two-way mode is greater than 1 mile (1.5 km) typically. The RFD System consists of the component parts in Table 2-1 and Figure 2-1. 1678 RFD OPERATION MANUAL {DRAFT} 4
Table 2-1 RFD 4-Remote Case System Figure Index No. Description Units per System Figure 2-2 1 Mini Controller Unit 1 Figure 2-2 2 Remote Unit, Electric Up to 4* Figure 2-2 3 Remote Unit, RSTI Up to 4* Figure 2-2 4 Battery Charger See note ** Figure 2-2 5 Antenna Assembly One per Unit Figure 2-2 6 Carrying Case Assembly 2 Figure 2-2 7 Test Box 1 Figure 2-2 8 Test Lamp 1 per Electric Remote Figure 2-2 9 Shock Tube Igniter Tip 2 per RSTI * Any combination of Electric Remotes and Remote Shock Tube Initiators (RSTIs) can be configured for a maximum total of 4 Remotes. ** The system is available with one or two 3-Position Chargers. Included with each Charger is a +12V power supply. 1678 RFD OPERATION MANUAL {DRAFT} 5
Figure 2-1 RFD 4-Remote Case System 1678 RFD OPERATION MANUAL {DRAFT} 6
2.2. MINI CONTROLLER UNIT 2.2.1. Figure 2-2 shows the external features of the Mini Controller Unit. The unit is sealed at the manufacturer and/or service depot and should not be opened during field activity. Figure 2-2 Mini Controller Unit 2.3. MINI CONTROLLER UNIT SWITCH OPERATION 2.3.1. Unit Power Control: Depress the “ON” switch for one second to turn the power on to the Mini Controller Unit when the Antenna is attached. The yellow light in the upper left quadrant of the “ON” switch will turn on. Depress the “OFF” switch to turn the power off to the Mini Controller Unit. 1678 RFD OPERATION MANUAL {DRAFT} 7
2.3.2. 2.3.3. 2.3.4. 2.3.5. 2.3.6. Power ON Self Test: Upon installing the antenna and pressing the “ON” switch, a rigorous self test is initiated. If a failure of the self test occurs, it will not be possible to activate the unit. The unit must be returned to the Manufacturer for service. Do not attempt to use a failing unit. Display Panel Light Dimmer Circuit: With the unit powered on, Repress the ‘ON’ switch briefly to toggle the LED display light’s intensity between bright and dim. When the unit is turned on, the last chosen intensity setting is restored. Select Remote Units: Depress the Select Switches “1” through “4” to select independently the Remote Units that will communicate with the Mini Controller Unit. Any combination of the four Remote Units may be selected. The yellow SELECT light on the switch indicates if the Remote Unit programmed for that switch is selected. Press the switch again and the yellow SELECT light for that Remote Unit will be turned off indicating the Remote Unit is not selected. Request Remote Unit Status: Depress the “STATUS” switch to transmit a status request signal to the selected Remote Units. The selected Remote Units will transmit their current status to the Mini Controller Unit. If none of the Remote Units are selected, the Mini Controller Unit will request status from all four Remote Units. Any answering Remote Units will be selected automatically. If the Mini Controller Unit is within range of the Remote Unit transmitter, the status of the selected Remote Unit will be presented on the display panel with a steady light. If the Mini Controller Unit is out of range of the Remote Unit transmitter, the status will be assumed from the last command sent to that Remote Unit. In that case the assumed status of the Remote Unit will flash on the display panel. Arm the Remote Unit: Depress the “ARM” switch for 1/2 second and the Mini Controller Unit will transmit the Arm command to the selected Remote Units. The red ARMED light at the selected Remote Units will flash on the Mini Controller Unit display panel until the firing capacitor charging time is completed. The Mini Controller Unit then requests status of the selected Remote Units. If the Mini Controller Unit is within range of the selected Remote Unit transmitter, the ARMED red light for that Remote Unit will be on steady on the Mini Controller Unit display panel. If the Mini Controller Unit is out of range of the selected Remote Unit transmitter, the red ARMED light for that Remote Unit will continue to flash on the Mini Controller Unit display panel. If the Fire command is not sent within the Arm Time Period, the system will disarm automatically. 1678 RFD OPERATION MANUAL {DRAFT} 8
2.3.7. 2.3.8. 2.3.9. Disarm the Remote Unit: Depress the “DISARM” switch. The Mini Controller Unit will transmit the Disarm command to selected Remote Units. Selected Remote Units will internally discharge their firing capacitor. Selected Remote Units that receive the Disarm command will become disarmed within 3 seconds of receiving the command. The green DISARMED light for selected Remote Units will begin to flash on the Mini Controller Unit display panel. The Mini Controller Unit will then request status of selected Remote Units. If the Mini Controller Unit is within range of the selected Remote Unit transmitter, the green DISARMED light for that Remote Unit will turn to steady on the Mini Controller Unit display panel. If the Mini Controller Unit is out of range of the selected Remote Unit transmitter, the green DISARMED light for that Remote Unit will continue to flash on the Mini Controller Unit display panel. If the Fire command is not sent within the Arm Time Period, the system will disarm automatically. CAUTION Do not assume the Disarm command has been received by the Remote Unit unless DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. If distance appears to be the problem, move closer to the Remote Unit following standard procedures for this type of situation. The “STATUS” and/or “DISARM” switches may be pressed repeatedly as the Remote Unit is approached. Maintain a safe distance from the Remote Unit. Do not approach the Remote Unit until DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. Under no conditions should the “FIRE” switch be pressed as the Remote Unit is approached. DO NOT bring the Mini Controller Unit closer than 100 feet (30 meters) to blasting caps, wires connected to blasting caps, or other explosives. Activate the Remote Unit Firing Circuit: Depress the “FIRE” switch for 1/2 second and the Mini Controller Unit will transmit the Fire command to selected Remote Units. The Mini Controller Unit will only transmit the Fire command to selected Remote Units whose status is Armed. The selected Remote Units will be placed in Fire Mode and discharge the firing capacitor across the binding posts. The red ARMED light will turn off and the green DISARMED light for each selected Remote Unit will begin to flash on the Mini Controller Unit display panel. The Mini Controller Unit will then request status from the selected Remote Units. If the Mini Controller Unit is within range of the selected Remote Unit transmitter, the DISARMED green light for that Remote Unit will turn to steady on the Mini Controller Unit display panel. If the Mini Controller Unit is out of range of the selected Remote Unit transmitter, the green DISARMED light for that Remote Unit will continue to flash on the Mini Controller Unit display panel. Multistage Firing of Remote Units: Multistage firing provides the ability to arm all four Remote Units at one time, and select any combination of the Remote Units to fire at different intervals within the Arm Time Period. The procedure for multistage firing is: • Depress “1” though “4” switches. • Depress “ARM” switch – all four Remote Units will arm. 1678 RFD OPERATION MANUAL {DRAFT} 9
• Depress the switches for the Remote Units that will not be fired initially. • Depress the “FIRE” switch. Only Remote Units still selected will fire. • Depress the switches for the Remote Units that were just fired. • Depress the switches for Remote Units to be fired next. • Depress the “FIRE” switch. Only Remote Units still selected will fire. • Repeat as necessary. Remote Units will automatically disarm if not fired within the Arm Time Period. 2.3.10. Misfires: If a Remote Unit does not fire when the Fire command is sent, repeat the fire sequence up to 3 times. If the Remote Unit continues not to fire, then a thirty-minute wait prior to approaching is mandatory. Follow your standard operating procedures for misfires. 2.4. MINI CONTROLLER UNIT DISPLAY OPERATION 2.4.1. 2.4.2. 2.4.3. 2.4.4. 2.4.5. Nighttime Panel Switch Locator: There are ten red lights used for backlighting the Mini Controller Unit switches. When the Mini Controller is powered on, the lights turn on to help locate the switch positions. Display Panel Dimmer Circuit: Repressing the ‘ON’ switch toggles the LED display light’s intensity between bright and dim. When the unit is turned on, the last chosen intensity setting is restored. Mini Controller Unit Battery Status: The yellow light at the “ON” switch displays the Mini Controller Unit BATTERY status. If the Mini Controller Unit battery is low, the yellow light at the “ON” switch will flash. Otherwise this light will be on steady. Remote Unit Battery Status: The yellow select light at each of the “1” through “4” switches will indicate the selected Remote Units’ battery status after a status request command is issued. If the selected Remote Unit transmitter is within range of the Mini Controller Unit and Remote Unit's battery is low, the yellow select light for that Remote Unit will flash. Else, the select light will be on steady. Remote Unit Safe: A green light next to each of the “1” though “4” switches is used to indicate when the corresponding Remote Unit is safe/disarmed. The light will be on steady when the Remote Unit transmitter is within range of the Mini Controller Unit and it is disarmed. If the Remote Unit transmitter is out of range of the Mini Controller Unit, the light will flash after a Disarm command has been sent. 1678 RFD OPERATION MANUAL {DRAFT} 10
2.4.6. 2.4.7. 2.4.8. 2.4.9. 2.4.10. 2.4.11. 2.4.12. Remote Unit Armed: A red light next to each of the “1” though “4” switches is used to indicate when the corresponding Remote Unit is armed. The ARMED light for selected Remote Units will flash after the Arm command is sent to the selected Remote Units. The ARMED light will go to steady after the firing capacitor charge time if the Mini Controller Unit is within range of the selected Remote Unit's transmitter. If the Remote Unit transmitter is out of range of the Mini Controller Unit, the ARMED light will continue to flash. Status: A yellow light at the “STATUS” switch lights when the “STATUS” switch is pressed. The light remains on until the display panel has been updated with results of the status request. All new commands are blocked while this light is on. Arm: A yellow light at the “ARM” switch lights when the “ARM” switch is pressed. This light will stay on for the firing capacitor charge time. Disarm: A yellow light at the “DISARM” switch lights when the “DISARM” switch is pressed. This light will stay on until the display panel is updated for the Disarm command. Other commands will not be sent until this light is turned off. Fire: A yellow light at the “FIRE” switch lights when the “FIRE” switch is pressed. This light will stay on until the display panel is updated for the Fire command. Other commands will not be sent until this light is turned off. “TX” (Transmit): A red light at the “TX” position lights while Mini Controller Unit is transmitting. Switch presses (DISARM, STATUS, ARM, FIRE, and 1-4) are not recognized while the Mini Controller Unit is transmitting. “RX” (Receive): During operation the green “RX” light turns on while receiving a status response from a Remote Unit. The RX light will also turn on in the presence of another on channel radio signal or from background radio noise. 1678 RFD OPERATION MANUAL {DRAFT} 11
Figure 2-3 Mini Controller Isometric View with Antenna 2.4.13. 2.4.14. 2.4.15. 2.4.16. Figure 2-3 shows an isometric view to further illustrate the exterior features of the Mini Controller. Manual Air Vent: A manual vent is located on top of the unit. The vent is used to relieve any internal pressure that has accumulated within the unit as a result of temperature or altitude. The vent is opened when charging to release any gasses or pressures accumulated during charging. The vent is closed during normal use or when the unit is exposed to moisture. Battery Compartment: In the back of the unit is a compartment which stores the rechargeable battery pack. The battery compartment is isolated from the units electronics. System Configuration Label: The System Configuration Label contains information related to the settings of the unit within the system it operates. The information displayed on this label may be considered semi-permanent. 1678 RFD OPERATION MANUAL {DRAFT} 12
2.5. ELECTRIC REMOTE UNIT 2.5.1. Figure 2-4 shows the external features of the Electric Remote Unit. The unit is sealed at the manufacturer or service depot and should not be opened during field activity. Figure 2-4 Electric Remote Unit 2.5.2. Power ON Self Test: Immediately after the Electric Remote is turned on by installing the Antenna, a rigorous self-test is performed. If a failure is detected, the red ARMED light will blink continuously and all other lights will be extinguished. It is not possible to use the unit once an error has been detected. The unit must be returned to the Manufacturer for service. Do not attempt to use a failing unit. 1678 RFD OPERATION MANUAL {DRAFT} 13
2.5.3. 2.5.4. 2.5.5. 2.5.6. 2.5.7. 2.5.8. Safe Separation Time: Upon the installation of the Antenna, a safe separation countdown timer is initiated. During the safe separation time, the SAFE and ARMED lights will be on steady, while the ON light blinks rapidly. During the safe separation time, the unit will not accept any radio commands (i.e. Status, Arm, Disarm, or Fire). This is to provide a short but highly safe window of time for the user to exit the immediate vicinity of the blast area. After the safe separation time is complete, the unit may still be considered safe as long as it does not receive an Arm or a Fire radio command from the system’s mated Mini Controller. Thus, it is recommended that the mated Mini Controller be rendered unusable while personnel are within the hazard area. This can be accomplished by the removal of the Mini Controller’s antenna and its secure storage until ready for use. The default Safe Separation Time is 15 seconds. Green SAFE Light: After the Safe Separation Time is complete, the green SAFE light turns on to indicate that the unit is disarmed; the internal firing capacitor is fully discharged, and that the unit is operating correctly. The SAFE light will be extinguished when the unit has entered Sleep Mode (See 2.5.7). Yellow ON Light: After the unit is activated and has completed its Safe Separation Time, the yellow ON light will remain illuminated. The ON light will blink slowly to indicate that its battery needs to be recharged before use. The ON light will be extinguished when the unit has entered Sleep Mode (See 2.5.7). Red ARMED Light: After the Safe Separation Time is complete, the red ARMED light indicates that the unit is armed; the capacitor is charged and the unit is ready to fire. Appropriate caution of the unit should be observed when the unit is armed. Sleep Mode: The Electric Remote Unit operates in a sleep mode to extend the battery’s run time during periods of inactivity. To enter sleep mode, the unit must be disarmed (safe and capacitor discharged) and the battery must not be low. Approximately one minute after activity (power on or a radio command), the unit will enter sleep mode. In sleep mode, the display lights extinguish and all non-essential functions are suspended. Sleep mode can be exited by sending the unit a radio command from its mated Mini Controller. Upon receipt of a radio command, the unit will be immediately awakened and ready for operation. While in sleep mode, units may run for 200+ hours. Actual sleep mode run time is affected by a variety of factors such as the sleep mode setting of your system, the state of charge of the battery, the health of the battery, and the ambient temperatures the unit will be exposed to. Figure 2-5 provides an angled view of the Electric Remote to show the System Configuration Label as well as the Battery Compartment Lid. Also illustrated are various hardware items such as the Binding Posts, Manual Air Vent, and the labels. 1678 RFD OPERATION MANUAL {DRAFT} 14
Figure 2-5 Electric Remote Unit Angled View 2.5.9. 2.5.10. 2.5.11. Binding Posts: The Binding Posts located on top of the Electric Remote Unit allow the firing cable to attach to the firing terminals. The insulation at the ends of the firing cable must be removed prior to attachment. One at a time, depress the top of the binding posts and insert a leg of the firing cable. Release the binding post, causing it to grab the lead. Manual Air Vent: A manual vent is located on top of the unit. The vent is used to relieve any internal pressure that has accumulated within the unit as a result of temperature or altitude. The vent is opened when charging to release any gasses or pressures accumulated during charging. The vent is closed during normal use or when the unit is exposed to moisture. Battery Compartment: In the back of the unit is a compartment which stores the rechargeable battery pack. The battery compartment is isolated from the units electronics. 1678 RFD OPERATION MANUAL {DRAFT} 15
2.5.12. 2.5.13. System Configuration Label: The System Configuration Label contains information related to the settings of the unit within the system it operates. The information displayed on this label may be considered semi-permanent. Model, Serial Number, FCC ID, and IC Label: The information displayed in this label is permanently assigned by the factory. 2.6. REMOTE SHOCK TUBE INITIATOR (RSTI) 2.6.1. Figure 2-6 shows the external features of the RSTI. The unit is sealed at the manufacturer or service depot and should not be opened during field activity. Figure 2-6 Remote Shock Tube Initiator (RSTI) 2.6.2. The RSTI operates similar to the Electric Remote Unit as described in Section 2.5, but initiates non-electric tubing instead of electric detonators. The RSTI develops 2,500V at the Shock Tube Tip Firing Terminals when firing. 1678 RFD OPERATION MANUAL {DRAFT} 16
Figure 2-7 RSTI Angled View with Shock Tube Spark Tip 2.6.3. Figure 2-7 shows the installation of the Shock Tube Firing Tip onto the Firing Terminals on the RSTI. 1678 RFD OPERATION MANUAL {DRAFT} 17
Figure 2-8 Shock Tube Tip 2.6.4. Figure 2-8 shows the installation of the shock tube onto the shock tube firing tip when preparing for use. Care should be taken when handling the shock tube to prevent the incursion of debris or moisture into the tube. • Keep open tube ends capped during storage and transportation. • Keep the tip needle clean and dry. • Replace the tip every 200 shots or if misfiring occurs. WARNING Do not touch the Shock Tube Tip Firing Terminals on the Remote Shock Tube Initiator (RSTI) when armed or firing. Lethal voltages may be present. 1. Make a fresh cut with a sharp knife removing the last 6 inches of shock tube. 2. Insert the shock tube through the guide hole on the tip as shown in Figure 2-8. The guide hole secures the tube to the tip and prevents pulling out. 3. Insert the tube into the center hole on the flat side. Feed the tube through the hole observing the side view hole. The tube should slide onto the igniter needle until the needle is no longer visible and the tube is resting against the plastic tip housing. 1678 RFD OPERATION MANUAL {DRAFT} 18
2.7. 3 POSITION BATTERY CHARGER 2.7.1. Figure 2-9 shows the 3 Position Charger that is used in some of the 1678 RFD Kits. The 3 Position Charger provides a basic 3 to 4 hour recharge for up to three RFD units (e.g. one Mini Controller and two Remotes). It may be stored and used within the 1678 case/foam, or it can be stored and used as a stand-alone device. The unit is sealed at the manufacturer or repair depot and should not be opened during field activity. The 3 Position Charger comes with an AC adapter that can be configured for use internationally. Figure 2-9 3 POSITION CHARGER 2.8. TEST BOX 2.8.1. Figure 2-10 provides a drawing of the Test Box. The Test Box is used todisplay information from and to evaluate the performance of the Mini Controller and Electric Remote Units and RSTIs. The Test Box can also be used to change settings and parameters of the units with certain restrictions. 1678 RFD OPERATION MANUAL {DRAFT} 19
2.8.2. Serial Communications Port: The Test Box can be connected to a serial RS-232 port on a host PC. The connection can be used to log the results of the tests performed. The serial communications port is also used when performing parameter changes. Figure 2-10 Test Box 2.8.3. 2.8.4. Test Probe: The Test Probe connects to the antenna/charge connector on the top of the Mini Controller, Electric Remote, or RSTI. Through the Test Probe, the Test Box communicates with the test unit to read the various settings, parameters, and to measure firing circuit and loaded battery voltages. LCD Display: The LCD displays information both from the Test Box itself during its power on sequence, and while reading and testing a Mini Controller, Electric Remote, or RSTI. The LCD’s backlighting will turn on while the unit is active. The information that may be displayed on the LCD is listed below: • Serial Number • Date of Manufacture • System Number • Unit ID • Frequency Assignments • Firmware Checksum and Version 1678 RFD OPERATION MANUAL {DRAFT} 20
• Battery Temperature and Charge Cycle Count • Fire Count • Battery voltage of unit under test while the battery is being loaded down. • Electric Remote Units and RSTIs under test are armed and fired. The firing voltages are displayed. 2.8.5. 2.8.6. Power Input Jack: The Test Box is powered from +12VDC from an AC adapter. The AC adapter is capable of international use. Serial Identification Label: This label provides information such as the Model Number, Serial Number, System Number, Assigned Frequency, and certification numbers. 2.9. ANTENNA ASSEMBLY 2.9.1. Figure 2-11 provides the physical size, technical requirements and view of theAntenna Assembly. The power to the Mini Controller Unit and Remote Unit is interrupted when the Antenna Assembly is not connected. 1678 RFD OPERATION MANUAL {DRAFT} 21
Figure 2-11 Antenna Assembly 2.10. CARRYING CASE 1678 RFD OPERATION MANUAL {DRAFT} 22
2.10.1. Figure 2-12 Carrying Case shows the full system Carrying Case and Figure 2-13 Carrying Case (Half Case)shows the Carrying Case (Half-Case). Shown are the physical sizes of the Carrying Cases and a view of the storage location for System assemblies in the Carrying Cases. The Carrying Cases have a pressure equalization vent near the handle. The vent operation is automatic. Figure 2-12 Carrying Case 1678 RFD OPERATION MANUAL {DRAFT} 23
Figure 2-13 Carrying Case (Half Case) 1678 RFD OPERATION MANUAL {DRAFT} 24
2.11. VENT OPERATION 2.11.1. In Figure 2-14, the unit vents shown are manually operated and relieve internal pressure due to heat and altitude. When the vent is closed, it will not leak in 100 feet of water (30 meters) or up to 30,000 feet (9,100 meters) in altitude. CAUTION Unequal air pressure inside the Mini Controller Unit may affect the operation of membrane switch keypad. Extreme pressure differentials may irreversibly damage the keypad and/or cases. CAUTION Vents in all units should be momentarily opened and closed immediately before use. CAUTION Do not open a vent if there is water on or near the vent. Keep the vents closed when the relative humidity is above 90%. Take necessary precautions to ensure moisture does not enter the unit case. Figure 2-14 Vent Operation 1678 RFD OPERATION MANUAL {DRAFT} 25
2.12. ANTENNA / BATTERY CHARGER CONNECTOR 2.12.1. 2.12.2. Figure 2-15 shows the connections when using the 3-Position Charger. The chargers do not discriminate between Mini Controller units and Remote units; any unit may be connected to any charge connector. Figure 2-15 3-Position Charger Connection 1678 RFD OPERATION MANUAL {DRAFT} 26
2.13. CONNECTOR DUST COVER OPERATION 2.13.1. In Figure 2-16, the Mini Controller Unit and Remote Unit have an antenna / battery charger connector dust cover that protects the connector pins from shorting out and damage when the Antenna Assembly or Battery Charger Assembly is not connected. The connector dust cover should be connected to the connector when the connector is not in use. Figure 2-16 Connector Dust Cover Operation 1678 RFD OPERATION MANUAL {DRAFT} 27
3. SYSTEM SPECIFICATIONS 3.1. RADIO CARRIER FREQUENCY 150 - 174 MHz OPERATING TEMPERATURE RANGE -30ºC to 60ºC -22ºF to 140ºF -26ºC to 60ºC (RSTI) -15ºF to 140ºF (RSTI) FCC Certified <freq. diff. 800 HZ (±400) MINI CONTROLLER UNIT & TEST BOX ELECTRIC REMOTE & RSTI FREQUENCY STABILITY ±2.5PPM OR (0.000025%) FREQUENCY STABILITY ±2.5PPM OR (0.000025%) MODULATION 11K2F3D (AFSK) MODULATION 11K2F3D (AFSK) TRANSMIT POWER 2-5 Watts (Mini Controller) 1 Watt (Test Box) TRANSMIT POWER 2 Watts (Electric Remote) 2-5 Watts (RSTI) OPERATING POWER 7.2 VDC OPERATING POWER 7.2 VDC TRANSMISSION RANGE (LOS) 5-12 Miles* 3 feet (Test Box) TRANSMISSION RANGE (LOS) 1-12 miles* RECEIVER SENSITIVITY 12 dB Sinad at 0.28uV RECEIVER SENSITIVITY 12 dB Sinad at 0.28uV (*) Range is specified as line-of sight. The typical transmission range is based on transmitter power, antenna gain, frequency used, local geography, and local radio interference. 1678 RFD OPERATION MANUAL {DRAFT} 28
3.2. PHYSICAL Mini Controller Unit Electric Remote Unit and RSTI SIZE (w/out antenna) (in) 8H x 3W x 2.5D SIZE (w/out antenna)(in) 6H x 3W x 2.5D SIZE (w/out antenna) (cm) 20.32H x 7.62W x 6.35D SIZE (w/out antenna)(cm) 15.24H x 7.62W x 6.35D WEIGHT (w/battery) 2.5 lbs., 1.14 kg WEIGHT (w/battery) 2 lbs., 0.91 kg CASE Die cast aluminum CASE Die cast aluminum COLOR Black COLOR Black 3.3. BATTERY Mini Controller Unit Electric Remote Unit and RSTI BATTERY PACK Rechargeable NiMH BATTERY PACK Rechargeable NiMH BATTERY LIFE 6 Hours BATTERY LIFE Adjustable between 100-300 Hours Typical User Setting is 200 hours* BATTERY RECHARGE 240 Min BATTERY RECHARGE 240 Minutes STANDBY CURRENT 110 milliamps STANDBY CURRENT 80 milliamps TRANSMIT CURRENT 2.5 Amp TRANSMIT CURRENT 1-2.5 Amp (*) At the end of the 200 hours, the Electric Remote Unit can detonate 13 (2-Ohm) blasting caps connected in series and attached to 100 feet (30 meters) of 18AWG firing cable. 1678 RFD OPERATION MANUAL {DRAFT} 29
3.4. TIMING Mini Controller Unit ARM time: 1/2 ± 0.1 Seconds Electric Remote Unit ARM time: 7 ± 0.5 Seconds RSTI Unit ARM time: 4 ± 0.5 Seconds Mini Controller Unit Arm Time Period: 1 – 60 Minutes (20 Minute Default) ** Remote Unit Arm Tim Period: 1 – 60 Minutes (20 Minute Default) ** Mini Controller Unit DISARM time: 3 ± 0.1 Seconds Remote Unit DISARM time: 3 ± 0.1 Seconds Mini Controller Unit FIRE time: 1 ± 0.1 Seconds Remote Unit FIRE time:* 20 Milliseconds *This is the delay after the Remote Unit receives the command signal from the Mini Controller Unit to Fire. **The system’s Arm Time Period is factory set. Consult Rothenbuhler Engineering for details. 3.5. DETONATE OUTPUT The Remote Unit detonation output pulse is from a 2200 microfarad capacitor charged to 50 volts. Stored Energy Level: 2.8 Joule (typical), 1.8 Joule (minimum) Pulse Voltage Level: 50 VDC (typical), 45 VDC (minimum) Maximum Firing Resistance:* 28Ω *This includes firing cables, detonators, & detonator leg wires. The Remote Shock Tube Initiator (RSTI)’s output pulse is from a 0.15 microfarad capacitor charged to 2,500 volts. Stored Energy Level: 0.470 Joule (typical), 0.350 Joule (minimum) 1678 RFD OPERATION MANUAL {DRAFT} 30
Pulse Voltage Level: 2,500 VDC (typical), 2,250 VDC (minimum) 3.6. SYSTEM IDENTIFICATION 3.6.1. Each Mini Controller Unit and Remote Unit is marked with an identification label. Figure 3-1 shows how the Mini Controller Unit identification label should be interpreted. Figure 3-2 shows the Remote Unit identification label. The Mini Controller Unit will only communicate with Remote Units from the same system. 0000100107 System Number Figure 3-1 Mini Controller Unit Identification Label S/N: 1669-20-S00001Address: 12345 Frequency: 151.505 System #: 0001 R#: 1 FCC ID: CW21669-20 IC: 2758A-166920 System Number Figure 3-2 Remote Unit Front Identification Label 1678 RFD OPERATION MANUAL {DRAFT} 31
4. PRE-OPERATIONAL PROCEDURES 4.1. PHYSICAL INSPECTION CAUTIs onnector on the Mini Controller Unit ve the antenna / battery charger connector dust cover and ensure the electrical pin area is clean and free of foreign material. Replace the dust cover. mbly whip is not broken and that the whip has not separated from the sealing compound at the top of the connector. its are not damaged. s are clean and not damaged. ove the yellow dust cover from the Antenna Assembly and ensure that there is no foreign material in the electrical contact area. Replace the yellow dust cover. TERY CHARGING WITH THE 3-POSITION CHARGERON Inspect all components for physical damage.Do not use any component that is damaged, suspected of being damaged, or is not able to operate adesigned. The safety of the operation could be compromised. 4.1.1. Ensure the antenna / battery charger cand Remote Unit is not damaged. 4.1.2. Remo4.1.3. Ensure the Antenna Asse4.1.4. Ensure that the spring-loaded binding posts on the Electric Remote Un4.1.5. Ensure the Shock Tube Tip Jacks on the top of the RSTI4.1.6. Rem4.2. BAT antenna / battery charger connector on each unit. 4.2.2. For each new battery charge cycle, the charger increments a charge cycle co ed nt rmance. 4.2.3. ons. Each charge station has a CHARGE and a SLOW light. The 3-Position Charger has a single POWER light. The 3-Position Charger does not have a discharge function. Two 3-Position Chargers can be employed to charge all 6 units of the Half Case kit during one charge session. 4.2.1. The battery packs in the Mini Controller Unit, Remote Unit and Test Box contain rechargeable NiMH batteries. The battery packs are recharged through the unter stored within the packs of each unit. The charge cycle count can be displayusing the Test Box. Battery pack replacement is recommended when the charge coureaches 300 charge cycles to ensure reliable perfoThe battery pack in the Mini Controller Unit, Remote Units and Test Box should be charged before the system is used each time. The 3-Position Charger will charge the Mini Controller Unit, Remote Units and the Test Box in 240 minutes typically. Each 3-Position Charger has three independent charge stati1678 RFD OPERATION MANUAL {DRAFT} 32
4.2.4. n VDC @ 2.5A which can also be supplied by an optional 12V auto accessory adapter. the side CAUTION Do not open a vent if there is water on or near the vent. Keep the vents clo nsure 4.2.7. Open the vent on each unit to be charged. the 3-Position Charger. The charger does between Mini Controller units, Remote units and Test Boxes; any unit onnected unit will flash for approximately 5 seconds. The flashing CHARGE light indicates that charging is pending. 4.2.10. In normal operation, the CHARGE light will be on steady (non-blinking) after 5 se4.2.11. The battery must be within the temperature range 32 ºF and 104 ºF (0 to +40 ºC4.2.12. If the detected battery voltage is less than 6 volts, the battery will be slow chithin the battery, the green SLOW light will blink continuously. 4.2.13. off. 4.2.14. 4.2.15. If a unit is left turned on beyond the low battery point, the battery pack may noThe 3-Position Charger does not feature a discharge function. To conditiothe batteries of the units, they should periodically be left on until the low battery condition occurs before recharging. A full discharge will help to rejuvenate batteries that have been stored for extended periods or that may have developed a memory. 4.2.5. Plug the supplied AC Power Adapter into an AC outlet. The AC Power Adapter will operate from 100-240VAC, 50-60 Hz. The charger itself requires 11-14 4.2.6. Insert the DC plug from the AC Power Adapter into the power jack on of the charger. The POWER light will turn on. sed when the relative humidity is above 90%. Take necessary precautions to emoisture does not enter the unit case. 4.2.8. Connect each unit to be charged to not discriminatemay be connected to any of the 3 charge connectors. 4.2.9. The CHARGE light for each cconds has passed. The steady CHARGE light indicates that the battery is being charged. ) for fast charging to occur. arged until the voltage is high enough for rapid charge. If the battery pack is defective and the voltage does not rise to the correct level, or if an internal error is detected wWhen rapid charging terminates, the green SLOW light will be on steady, and the CHARGE light will be turnedRapid charging terminates when the charger detects the battery pack is charged. Rapid charging will also terminate after 4 hours, or if the battery pack’stemperature is out of range. t fully charge before the 4 hour rapid charge time limit expires. In that case, charge the battery pack again. 1678 RFD OPERATION MANUAL {DRAFT} 33
4.2.16. E SYSTEMClose the vent on each Remote Unit and the Mini Controller Unit 4.3. BENCH TESTING TH WARNING Radio frequency energy of sufficient magnitude can cause blasting caps to detonate. 4.3.1. The System test must be conducted in an area that is at least 100 feet (30 me other explosives. 4.3.2. All RFD System controls are described in detail in section 2. of troller Unit. Ensure the Mini Controller Unit is off. 4.3.4. er connectors of ts. The ON/LOW BATT and SAFE lights will come on steady. If the e with section 4.1.6. 4.3.5. will turn on steady. If the yellow light does not turn on steady, but flashes, this indicates a low battery for the Miimately 5 seconds. During that time the Mini Controller Unit is requesting status from the Remote Units. A flashing DISARMED light indicates the Mini Controller Unit did not receive the Remote Unit’s staters) from the nearest blasting caps, wires connected to blasting caps, orCAUTION All units must be thoroughly tested and the batteries fully charged prior to operational use. 4.3.3. Install the Antenna Assembly on the antenna / battery charger connectorthe Mini ConInstall the Antenna Assemblies on the antenna / battery chargthe Remote UniON/LOW BATT light is flashing, the Remote Unit has a low battery. Recharge the battery in accordancTurn the Mini Controller Unit on by pressing the “ON” switch for 1 second. Ayellow light located in the upper left quadrant of the “ON” switchni Controller Unit. Recharge the battery in accordance with section 4.1.6. 4.3.6. Press the “STATUS” switch for 1 second. The red TX light on the Mini Controller Unit will start blinking for approx4.3.7. When the TX light stops flashing, the green DISARMED light will come on steady adjacent to the switches numbered “1” through “4”. A steady DISARMED light indicates that Remote Unit answered back with its status and it is disarmed. tus transmission. WARNING Ensure that blasting caps are not connected to any of the Remote Units during bench testing. 4.3.8. Select all of the Remote Units by pressing switches “1” through “4”. A yellowlight will be lit in each switch to indicate the corresponding Remote Unit is selected. 1678 RFD OPERATION MANUAL {DRAFT} 34
4.3.9. Press the “ARM” switch for ½ second. The red ARMED light for each selected Remote Unit will flash on the Mini Controller Unit display panel for approximately 5 seconds and then come on steady. The ARMED light for each se 4.3.10. e hts at the the 4.3.11. Re-Arm the Remote Units. Before the Arm Time Period expires, press the “D t will 4.3.12. e RMED to DISARMED. Proceed to 4.3.14. that ntroller DISARMED. Note: t e RSTI and the Shock Tube Igniter Tip hots on your tip before replacement. If 4.3.14. Turn off the Mini Controller Unit by pressing the “OFF” switch. Turn off the lected Remote Unit will grow brighter and then stay on steady. The Remote Units arenow armed. Observe the Mini Controller Unit and Remote Units. After the Arm TimPeriod expires, the Remote Units will automatically disarm. The ARMED ligMini Controller Unit and Remote Units should turn off. The DISARMED lights at Mini Controller Unit and SAFE lights at the Remote Units should turn on. ISARM” switch on the Mini Controller Unit. The Mini Controller Unit's ARMED lighbe turned off. The DISARMED lights at the Mini Controller Unit should blink for approximately 3 seconds and then turn on steady. The ARMED lights at the RemoteUnits will turn off and the Remote Units’ SAFE lights will turn on. If firing RSTI Units, proceed to 4.3.13. Connect a test bulb assembly to the binding posts of each Electric Remote Unit. Arm the Electric Remote Units. Press the “FIRE” switch on the Mini Controller Unit. The test bulb should flash brightly. ThARMED light will turn off and the SAFE light will turn on at each Electric Remote Unit. The displayed status at the Mini Controller Unit will change from A4.3.13. Install the firing tip into the Shock Tube Tip Jacks on the top of each RSTI. Arm the RSTI Units. Press the “FIRE” switch on the Mini Controller Unit. Observe bright sparks should be heard and seen on each unit. The ARMED light will turn off andthe SAFE light will turn on at each RSTI. The displayed status at the Mini CoUnit will change from ARMED to When firing the RSTI with no tip or with a faulty tip, the green DISARMED lighfor that unit may not initially turn on following a FIRE operation. A subsequent press of the “STATUS” switch illuminates the green DISARMED light. Note: Refer to Section 2.6 for details about thhandling and replacement. Never exceed 200 syou notice the spark is weak or if misfires occur, the tip needs replacement. Always keep a spare tip as a backup. Keep the tip needle clean and dry. Remote Units by removing their Antenna Assemblies. 4.3.15. The RFD system is now ready to use operationally. 1678 RFD OPERATION MANUAL {DRAFT} 35
5. OPERATIONAL PROCEDURES WARNING WARNING Use of this system and its components must be restricted to personnel qualified and experienced in the field of explosives and detonating devices. Under no circumstances shall untrained personnel attempt to use this manual as a text for self-teaching. WARNING Employ standard blasting system safety standards when using this equipment with explosives. WARNING All units must be thoroughly tested and the batteries fully charged prior to operational use. 5.1. READY THE SYSTEM AT SITE 5.1.1. Remote Units. Select the number of Electric Remote Units or RSTIs required for the operation. Remove the dust cover from the antenna / battery charger connector. Install the Antenna Assembly on to the antenna / battery charger connector. This will turn on the Remote Unit. The yellow ON/LOW BATT light and green SAFE light will be turned on. The green SAFE light will be on for the first minute, whenever the Remote Unit is turned on and it is disarmed. In the disarmed state, the firing capacitor charge circuit is disabled, the firing terminals are electrically isolated from the firing capacitor, and the firing terminals are shunted to each other. If the yellow ON/LOW BATT light is flashing, the Remote Unit battery is low and should be recharged before use. 5.1.2. Remote Sleep Mode. After 1 minute, the display lights on the Remote Units will extinguish. During this time, the Remote unit is in a low power ‘sleep’ state to conserve battery power. Sleep Mode can only be entered if the Remote Unit is disarmed. The Remote units are quickly awakened by the Mini Controller’s radio signal when needed for use. WARNING Do not connect a blasting cap to a Remote Unit unless the green SAFE light is on, the red ARMED light is off, and the yellow ON/LOW BATT light is on steady. This indicates there is no voltage on the binding posts, the binding posts are electically isolated from the firing capacitor, the binding posts are shunted to each other, and the battery is not low. 5.1.3. Open and close the vent on each Remote Unit and the Mini Controller Unit to equalize the case pressure. Unscrew the vent, one revolution, to open. 5.1.4. Remove the dust cover from the antenna / battery charger connector of the Mini Controller Unit. Install the Antenna Assembly on to the antenna / battery charger connector. This will enable the keypad on the Mini Controller Unit. 1678 RFD OPERATION MANUAL {DRAFT} 36
WARNING Do not use the Mini Controller Unit within 100 feet (30 meters) of explosives, blasting caps, or wires leading to them. Thwhich can cause detonation of caps if within 100 feet. The 5 watt Mini Controller e Mini Controller signal is 5 watts, drant of the “ON” switch will turn on steady. If does not turn on steady, but flashes, this indicates a low battery for the the Mini Controller Unit. The red TX light will green DISARMED light corresponding to each Reto shoot. complies with the Recommended Table of Distances established by the Institute for the Makers of Explosives (IME) when placed beyond 100 feet of explosives. 5.1.5. Turn the Mini Controller Unit on by pressing the “ON” switch for 1 second. Ayellow light located in the upper left quathe yellow lightMini Controller Unit. Recharge the battery in accordance with section 4.1.6. 5.1.6. Adjust the intensity of the LED display on the Mini Controller for the desired setting by repressing the ‘ON’ switch on the Mini Controller. 5.1.7. Press the “STATUS” switch onflash for approximately 5 seconds. The mote Unit will come on steady if the Mini Controller Unit receives a status message from that Remote Unit. If the Mini Controller Unit does not receive a status message from a Remote Unit, the green DISARMED light for that Remote Unit will flash on the Mini Controller Unit display panel. Note: The Mini Controller Unit battery life is approximately 6 hours when in the “ON” condition. To conserve battery life, the Mini Controller Unit should be turned off when not being used. 5.1.8. Turn the Mini Controller Unit “OFF” until Remote Units are in place and wired 5.2. PLACEMENT OF REMOTE UNITS WARNING Do not connect a blasting cap to a Remote Unit unless the green SAFE light is on, the red ARMED light is off, and the yellow ON/LOW BATT light is on e r, and free from obstruction within 100 feet (30 meters) of the shot. Use sandbags or other suitable mareen light on steady). steady. This indicates there is no voltage on the binding posts, the binding posts arelectically isolated from the firing capacitor, the binding posts are shunted to each otheand the battery is not low. 5.2.1. The range of the RFD is typically Error! Reference source not found. under most conditions. 5.2.2. Place the Remote Units with the antenna in a vertical position terials to protect the Remote Units from the shot. 5.2.3. Ensure that all Remote Units indicate a SAFE condition (g1678 RFD OPERATION MANUAL {DRAFT} 37
5.2.4. If using the RSTI, proceed to Section 5.2.7. After performing standard demolition circuit checks and before placing initiator into the main charge, depress the two spring-loaded binding posts on the Electric Remote Unit. 5.2.5. Insert one leg of the demolition wire in each binding post and allow the binding posts to close on the wire ends. 5.2.7. Install the non-electric shock tubing onto the Shock Tube Tip and mount the tip. 5.2.8. f cated more Error! Reference source not found. than from the Mini Controller Unit, refer to section 5.3.11. i Controller Unit, and other Remote Units are more than Error! Reference source not found. from the Mini Controller Unit, refer to section 5.4.11. STEM OPERATION – REMOTE UNITS WITHIN ERROR! REFERENCE 5.2.6. Ensure the wire is held securely by the binding posts and that the wire ends are not touching the Electric Remote’s case or each other. Proceed to Section 5.2.8. onto the RSTI according to Section 2.6. Take care to ensure no moisture or debris enter the shock tube or contact the Shock Tube Tip’s needlePrepare the shot and return to the safe firing area. 5.2.9. If all Remote Units are located within Error! Reference source not found. othe Mini Controller Unit, refer to section 5.2.11. 5.2.10. If all Remote Units are lo5.2.11. If some Remote Units are located within Error! Reference source not found. of the Min5.3. SYSOURCE NOT FOUND. OF MINI CONTROLLER UNIT Note: If the distance between the Mini Controller Unit and the Remote Units is in ions he erence source not found. of the Remote Units. The only difference is the method the status indication Unit nits ntroller Unit display panel to indicate the Mini Controller Unit did not receive a status message from the Remote Unit. Once the Remote Units are set up forexcess of Error! Reference source not found., the Remote Units status transmissmay not be received by the Mini Controller Unit. The Mini Controller Unit will commandthe Remotes from a distance greater than Error! Reference source not found., but tRemote Status may not be confirmed. The Mini Controller Unit performs just as it would when it is within Error! Refs are displayed on the Mini Controllerdisplay panel. The ARMED and DISARMED status lights for out of range Remote Uwill flash on the Mini Co the shot, the operator must assume the Remote Units have received the command. 5.3.1. Ensure the area is clear. 5.3.2. Turn the Mini Controller Unit on. 1678 RFD OPERATION MANUAL {DRAFT} 38
5.3.3. s from come on steady for the Remote Units that the Mini Controller Unit receives a disarmed status message from. re to be used in the shot by pressing the corresponding numbered switches “1” through “4”. Press the numbered switches one at a time. System Safety Feature Once armed, the Remote Units must be sent a Fire co will remain isolated from the firing capacitor and the binding posts will remain shunted together. 5.3.5. To arm the selected Remote Units, press the “ARM” switch. The red ARMED lig Units are now ARMED! 5.3.6. e MED light will go out and the green DISARMED light for each selected Remote Unit will come on steady on the Mini Coht for that unit may not initially turn on following a FIRE operation. A subsequent press of 5.3.7. If not all the Remote Units were selected for the shot, repeat above steps to Remote Unit is approached. Maintain a safe distance from the Remote Unit. Do not approach the Remote Unit until DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. Under no conditions should the “FIRE” switch be pressed as the Remote Unit is approached. DO NOT bring the Mini Controller Unit closer than 100 feet (30 meters) to blasting caps, wires connected to blasting caps, or other explosives. Press the “STATUS” switch. The Mini Controller Unit will request statuall Remote Units. The red TX light will flash for approximately 5 seconds. The green DISARMED light on the Mini Controller Unit display panel will 5.3.4. Select the Remote Units that ammand within the Arm Time Period. If the Remote Units do not receive a Fire command within the Arm Time Period, they will automatically disarm. The firing capacitor will be safely internally discharged, the binding postsht next to each selected Remote Unit switch will flash for approximately 5 seconds and then come on steady. The selected RemoteTo fire the Remote Units, press the “FIRE” switch and hold for 1 second. Thoperator should get an indication of shot initiation. The ARntroller Unit display panel. Note: When firing the RSTI with no tip or with a faulty tip, the green DISARMED ligthe “STATUS” switch illuminates the green DISARMED light. initiate the remaining shots. 5.3.8. To disarm any Remote Units that have been armed, select the Remote Units and press the “DISARM” switch. All selected Remote Units will return to the DISARMED mode in approximately 3 seconds. CAUTION Do not assume the Disarm command has been received by the Remote Unit unless DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. If distance appears to be the problem, move closer to the Remote Unit following standard procedures for this type of situation. The “STATUS” and/or “DISARM” switches may be pressed repeatedly as the 1678 RFD OPERATION MANUAL {DRAFT} 39
5.3.9. 5.3.11. Refer to Post Operational Procedures in chapter 5.5.14. Turn off the Mini Controller Unit. 5.3.10. Recover the fielded Remote Units. 5.4. SYSTEM OPERATION – REMOTE UNITS MORE THAN ERROR! REFERENCE SOURCE NOT FOUND. FROM MINI CONTROLLER UNIT ssions mand just as it would when it is within Error! Reference source not found. of the Remote Units. The only difits roller Unit did not receive a status message from the Remote Unit. Once the Remote Units are set up for5.4.2. Turn the Mini Controller Unit on. 5 seconds. The green DISARMED light on the Mini Controller Unit display panel will flash for all Remote Units tha5.4.4. Select the Remote Units that are to be used in the shot by pressing the co ty Feature Once armed, the Remote Units must be sent a Fire re D Note: If the distance between the Mini Controller Unit and the Remote Units is inexcess of Error! Reference source not found., the Remote Units status transmimay not be received by the Mini Controller Unit. The Mini Controller Unit will comthe Remotes from a distance greater than Error! Reference source not found., but the Remote status may not be confirmed. The Mini Controller Unit performsference is the method the status indications are displayed on the Mini Controller Unit display panel. The ARMED and DISARMED status lights for out of range Remote Unwill flash on the Mini Controller Unit display panel to indicate the Mini Cont the shot, the operator must assume the Remote Units have received the command. 5.4.1. Ensure the area is clear. 5.4.3. Press the “STATUS” switch. The Mini Controller Unit will request status fromall Remote Units. The red TX light will flash for approximately t the Mini Controller Unit does not receive a status message from. rresponding numbered switches “1” through “4”. Press the numbered switches one ata time. System Safecommand within the Arm Timeout Period. If the Remote Units do not receive a Ficommand within the Arm Timeout Period, they will automatically disarm. The firing capacitor will be safely internally discharged, the binding posts will remain isolated from the firing capacitor and the binding posts will remain shunted together. 5.4.5. To arm the selected Remote Units, press the “ARM” switch. The red ARMElight next to each selected Remote Unit switch will flash for 5 seconds, then come on steady for two seconds, and then continue to flash. The selected Remote Units are nowassumed to be ARMED! 1678 RFD OPERATION MANUAL {DRAFT} 40
5.4.6. e “FIRE” switch. The operator should get an indication of shot initiation. The ARMED light will go out and the green DISARMED lig n the Mini Controller Unit display panel. 5.4.7. eat above steps to initiate the remaining shots. d, select the Remote Units and press the “DISARM” switch. All selected Remote Units will return to the wi other explosives. 5.4.9. 5.4.10. To fire the Remote Units, press thht for each selected Remote Unit will flash oIf not all the Remote Units were selected for the shot, rep5.4.8. To disarm any Remote Units that have been armeDISARMED mode in approximately 3 seconds. CAUTION Do not assume the Disarm command has been received by the Remote Unit unless DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. If distance appears to be the problem, move closer to the Remote Unit following standard procedures for this type of situation. The “STATUS” and/or “DISARM” switches may be pressed repeatedly as the Remote Unit is approached. Maintain a safe distance from the Remote Unit. Do not approach the Remote Unit until DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. Under no conditions should the “FIRE” switch be pressed as the Remote Unit is approached. DO NOT bring the Mini Controller Unit closer than 100 feet (30 meters) to blasting caps,res connected to blasting caps, orTurn off the Mini Controller Unit. Recover the fielded Remote Units. 5.4.11. Refer to Post Operational Procedures in chapter 5.5.14. 5.5. SYSTEM OPERATION – REMOTE UNITS BOTH WITHIN AND IN EXCESS OF ERROR! REFERENCE SOURCE NOT FOUND. AND LESS THAN ERROR! REFERENCE SOURCE NOT FOUND. FROM MINI CONTROLLER UNIT Note: If the distance between the Mini Controller Unit and the Remote Units is in ssions nd the i Controller Unit disexcess of Error! Reference source not found., the Remote Units status transmimay not be received by the Mini Controller Unit. The Mini Controller Unit will commathe Remotes from a distance greater than Error! Reference source not found., butRemote status may not be confirmed. The Mini Controller Unit performs just as it would when it is within Error! Reference source not found. of the Remote Units. The only difference is the method the status indications are displayed on the Minplay panel. The ARMED and DISARMED status lights for out of range Remote Units will flash on the Mini Controller Unit display panel to indicate the Mini Controller Unit did not receive a status message from the Remote Unit. Once the Remote Units are set up for the shot, the operator must assume the Remote Units have received the command. 1678 RFD OPERATION MANUAL {DRAFT} 41
5.5.1. 5.5.2. the Remote Units (ON/LOW BATT, ARMED, and SAFE) will be displayed with steady lights on the display panel of the Mini Controller Unit. Unit, the d their status lights will flash on the nit display panel to indicate unconfirmed status. Accordingly the 5.5.6. ontroller Unit will request status from all r approximately 5 seconds. The green DISARME splay panel will flash for all the Remote Un e from. Remote Units are armed. The RFD will operate in a two-way mode (confirmed communications – rangeto Error! Reference source not found.) and one-way mode (unconfirmed communications – range greater than Error! Reference source not found.). If the Remotes are within Error! Reference source not found. of the Mini Controller Unit, the status of 5.5.3. If one or more Remote Units are out of range of the Mini Controller status of these Remote Units will be assumed anMini Controller Uoperator must assume the following: • Commands have been received by the Remote Units. • The Remote Unit battery is sufficiently charged to activate the firing circuit. • A DISARM command should not be assumed. 5.5.4. Ensure the area is clear. 5.5.5. Turn the Mini Controller Unit on. Press the “STATUS” switch. The Mini C Remote Units. The red TX light will flash foD light on the Mini Controller Unit diits that the Mini Controller Unit does not receive a status messag5.5.7. Select the Remote Units that are to be used in the shot by pressing the corresponding numbered switches “1” through “4”. Press the numbered switches one at a time. System Safety Feature Once armed, the Remote Units must be sent a Fire command within the Arm Time Period. If the Remote Units do not receive a Fire command within the Arm Time Period, they will automatically disarm. The firing capacitor will be safely internally discharged, the binding posts will remain isolated from the firing capacitor and the binding posts will remain shunted together. 5.5.8. To arm the selected Remote Units, press the “ARM” switch. The red ARMED light next to each selected Remote Unit switch will flash for 5 seconds, and then come on steady for two seconds. ARMED lights for selected Remote Units that the Mini Controller Unit did not receive a status message from will begin to flash again. The selected Remote Units are now assumed to be ARMED! For unconfirmed communications, count to 5 from when the "ARM" switch is pressed and assume the 1678 RFD OPERATION MANUAL {DRAFT} 42
5.5.9. ISARMED panel. 5.5.10. 5.5.11. To disarm any Remote Units that have been armed, select Remote Units and prearm command has been received by the Remote appears to be the problem, move closer to the Remote Unit following standard procedures for this type of e Remote Unit is approached. Maintain a safe distance from the Remote Unit. Do not irmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. Under no conditions should the “FIRE” switch be pressed as the Remote Unit is approached. DO NOT bring the Mini Controller Unit closer than 100 feet (30 meters) to blasting caps, wi xplosives. 5.5.12. 5.5.14. Refer to Post Operational Procedures in chapter 5.5.14. To fire the Remote Units, press the “FIRE” switch. The operator should get an indication of shot initiation. The ARMED light will go out and the green Dlight for each selected Remote Unit will flash on the Mini Controller Unit displayIf not all the Remote Units were selected for the shot, repeat above steps toinitiate the remaining shots. ss the “DISARM” switch. All selected Remote Units will return to the DISARMED mode in approximately 3 seconds. CAUTION Do not assume the DisUnit unless DISARMED status is confirmed with a steady DISARMED light for that Remote Unit on the Mini Controller Unit display panel. If distancesituation. The “STATUS” and/or “DISARM” switches may be pressed repeatedly as thapproach the Remote Unit until DISARMED status is confres connected to blasting caps, or other eTurn off the Mini Controller Unit. 5.5.13. Recover the fielded Remote Units. 1678 RFD OPERATION MANUAL {DRAFT} 43
6. POST OPERATIONAL PROCEDURES 6.1. SECURING THE SYSTEM 6.1.1. Turn the Mini Controller Unit off and remove the Antenna Assembly. This action disables the Mini Controller Unit. plastic cap on the Antenna Assembly. 6.1.2. Replace the dust cover on the antenna / battery charger connector on the Mini Controller Unit and replace the6.1.3. Remove the Antenna Assemblies from the Remote Units. This action turns off the Remote Units. 6.1.4. Replace the dust cover on the antenna / battery charger connector on the Remote Units and replace the plastic cap on the Antenna Assembly. 6.2. PHYSICAL INSPECTION 6.2.1. Inspect the Mini Controller Unit and Remote Units for physical damage. 6.2.2. Inspect the units for dirt or corrosion around/on connector pins and vent. 6.2.3. amage. Return unit to manufacturer. 6.2.4. . 6.2.5. nt is closed securely and wash units in warm soapy water. 6.2.6. Rinse units with clean water and dry thoroughly. 6.2.7. Inspect units for damage. Replace as necessary. 6.3. PACKAGINGReplace any unit found to have dClean units using a soft bristle brushIf a unit cannot be cleaned by brushing, make sure the ve 6.3.1. Re-package all components in carrying case. 6.4. MAINTENANCE & EQUIPMENT STORAGE 6.4.1. Periodic battery charging 6.4.2. Check for signs of corrosion around and on connector pins. 1678 RFD OPERATION MANUAL {DRAFT} 44
7. BASIC TROUBLESHOOTING IN THE FIELD 7.1. REMOTE UNITS 7.1.1. . LER UNITON and SAFE lights do not illuminate when the Antenna Assembly is installed. a) Check Antenna Assembly and make sure it is seated, “clicks” on to the connectorb) Recharge the battery. c) Try a different Antenna Assembly. 7.2. MINI CONTROL a) Check Antenna Assembly and make sure it is seated, “clicks” on to the connector. witch for 5 seconds. 7.2.2. rence source not found. away from the bly on the Mini Controller Unit. The antenna is not positioned vertically. nna is next to another radio antenna. • Use optional magnetic mount antenna for improved gain. This antenna is 7.3. IATOR7.2.1. ON Light does not stay on. b) Press and hold the “ON” sc) Mini Controller Unit battery needs to be recharged. Command receipt is not confirmed by Remote Unit. a) Remote Unit is more than Error! Reference source not found. from Mini ControllerUnit. b) If the Remote Unit is less than Error! RefeMini Controller Unit. Check for damage to Mini Controller Unit Antenna Assembly. Try a different Antenna AssemMove at least 25 feet in any direction and try again. Reposition the Remote Unit if: •• The ante• The antenna is surrounded by metallic objects.available by special order only. REMOTE SHOCK TUBE INIT 7.3.1. a) The Shock Tube Tip may be worn or damaged. Replace tip. Unit will not ignite the shock tube. 1678 RFD OPERATION MANUAL {DRAFT} 45
b) The shock tube may be damaged from moisture. Try a fresh cut or replace the needle and tubing. Ensure the tube covers the entire needle. Ensure both thethe shock tube lead-in is dry when mating. 1678 RFD OPERATION MANUAL {DRAFT} 46
8. O8.1.1. When power lines are in the area, the radio transmission distance is reduced. The system can operate at the following distance, when the Mini Controller Unit is elevated to a maximum transmission location angle to the Remote Unit location (see Figure 8-1). OverPTIMIZING RANGE Minimum Distance Open Land or Water with Power Lines Error! Reference source not found. Dense Vegetation without Power Lines Error! Reference source not found. Open Land or Water without Power Lines Greater than 5 Miles 1678 RFD OPERATION MANUAL {DRAFT} 47
Figure 8-1 Unit Normal Transmission Location 8.1.2. If the Mini Controller Unit and Remote Unit must be placed in a position other than location in Figure 8-1, use Figure 8-2 or Figure 8-3. The minimum transmission will occur when the Mini Controller Unit antenna and the Remote Unit antenna are placed in the line of site. The maximum transmission occurs when the line of site lays in a path of 5 to 25 degrees above unit top plane perpendicular to the antenna. Both the Mini Controller Unit antenna and the Remote Unit antenna have the same radiant energy pattern as shown in Figure 8-4. 1678 RFD OPERATION MANUAL {DRAFT} 48
Figure 8-2 Remote Unit Elevated 1678 RFD OPERATION MANUAL {DRAFT} 49
Figure 8-3 Mini Controller Unit Elevated 1678 RFD OPERATION MANUAL {DRAFT} 50
Figure 8-4 Antenna Radiation Pattern 1678 RFD OPERATION MANUAL {DRAFT} 51
9. TEST BOX The Test Box allows the user to test display system information of the Electric Remote, RSTI, and Mini Controller Units as well as perform diagnostic checks. The Test Box also serves as the programming interface between a computer and a RFD Unit. Figure 9-1 Test Box 9.1. TEST BOX DESCRIPTIONS 9.1.1. Power Supply/Connector: The Test Box is powered from an external +12VDC wall adapter. The adapter can be configured for international use by choosing the correct power plug adapter. The default plug adapter for your country was supplied with your kit. 9.1.2. Probe: The Test Box has a probe that plugs into the Remote or Mini Controller under test. The Test box communicates to the Unit under test through the probe and by using a radio transmitter that is internal to the Test Box. 1678 RFD OPERATION MANUAL {DRAFT} 52
9.1.3. Serial Connection: the information displayed on the Test Box screen out the serial cable. A terminal program such as Hyper Terminal may be set up to capture this information to a file. The file can then be saved and printed. 9.2. TEST BOX OPERATIONA serial cable connects the Test Box to a computer serial port operating at 1200 baud. The serial cable must be connected to a computer when the Test Box is being used to program Mini Controller and Remote Units. The serial cable may also be used when the Test Box is in the test mode. While in the test mode, the Test Box transmits WARNING Do not touch the firing terminals of the Remote units while testing. A potentially lethal voltage is present during the Fire test. 9.2.1. Test Box Messages When the Test Box is turned on, the following message is displayed. The “1678 Test Box” part of the message identifies the system types that the Test Box is designed to operate with. “04/13/2011” is the date of the Test Box firmware. “Ver 3.0” is the version of the Test Box firmware. The Test Box will automatically step to the next message “Connect Unit to Test”. o the top connector on the Mini Controller Unit. Then press the ‘ON’ Switch while pressing the Select ‘3’ switch. The Mini Controller turns on with the yellow light next to the Select ‘3’ switch illuminated. The Test Box will display the following message. 1678 Test Box 03/13/2011 Ver 3.0 Connect Unit to Test 9.2.2. Testing the Mini Controller To test a Mini Controller Unit, plug the Test Box probe intMini Controller Detected 1678 RFD OPERATION MANUAL {DRAFT} 53
Next the Test Box will display the Battery Charge Count as shown below. This is the number of charge cycles the battery within the Mini Controller has experienced. he current battery’s temperature (+22C +72F) and chemistry type (NiMH). The next message shows the battery serial number (Battery SN 0001) and the battery’s The next message displayed shows the assigned Frequency and the Message Number. Next the Test Box displays tBattery Charge Count 83 Battery Temp +22C +72F Battery Type: 1400mAh NiMH date of manufacture (Battery DOM 02/03/2011). Battery SN 0001 Battery DOM 02/03/2011 The next message displayed shows the System Number or Address (0000000001) thatthe Mini Controller is assigned to and the Unit assigned to the Mini Controller (Default isUnit 1). Address 0000000001 Unit 1 Frequency 174 MHz Message Number 010000 1678 RFD OPERATION MANUAL {DRAFT} 54
The next message displayed is the Mini Controller’s serial number (S/N), unit Type (Model) date of manufacture (DOM), firmware version (Ver). Next the Mini Controller begins a Battery Test. The Battery Test places a load on the battery and a countdown timer is started. At the end of the test, the loaded battery voltage is displayed along with the test limit of (7.00). After testing is complete, the following message is displayed. 9.2.3. Testing the Electric Remote WARNING S/N 00101 Type 1678-6 r 1.0 DOM 06/29/2010 VeThe next message displayed is the firmware Checksum and the Fire Count. Checksum 4C42 Fire Count 87 Battery Test – Standby 30 Loaded Battery 7.24 <Low Battery = 7.00> Testing Completed Do not touch the firing terminals of the Remote units while testing. A potentially lethal voltage is present during the Fire test. To test an Electric Remote, plug the Test Box probe into the top connector on the Electric Remote. The Electric Remote turns on with the yellow light fast blinking and the green light on. The Test Box will display the following message. 1678 RFD OPERATION MANUAL {DRAFT} 55
Next the Test Box will display the Battery Charge Count as shown below. This is the number of charge cycles the battery within the Electric Remote has experienced. Next the Test Box displays the current battery’s temperature (+22C +72F) and dress (0000000001) and the Unit number assigned to the Electric Remote. The next message displayed shows the assigned Frequency and the Message Number. Electric Remote Detected Battery Charge Count 83 chemistry type (NiMH). Battery Temp +22C +72F Ah NiMBattery Type: 1650m H The next message shows the battery serial number (Battery SN 0001) and the battery’s date of manufacture (Battery DOM 02/03/2011). Battery SN 0001 Battery DOM 02/03/2011 The next message displayed shows the System Number or AdAddress 0000000001 Unit 2 Frequency 174 MHz Message Number 010000 1678 RFD OPERATION MANUAL {DRAFT} 56
The next message displayed is the Electric Remote’s serial number (S/N), unit Type (M , firmware version (Ver). The next message displayed is the firmware Checksum and the Fire Count. ic Arm/Fire Test. The Test Box Arms the Electric Remote and begins 5 second countdown. level is shown. end of the test, the loaded battery voltage is displayed along with the test limit of (7.00). odel) date of manufacture (DOM) S/N 00101 Type 1678-6 DOM 06/29/2010 Ver 1.0 Next the Electric Remote begins the ElectrChecksum 4C42 Fire Count 87 At the end of the countdown the Electric Remote is fired. The firing voltage and pass Electric Arm/Fire Test 05 Next the Electric Remote begins a Battery Test. Arm/Fire Voltage 50.23 <Pass Level = 45.00> Battery Test – Standby 30 The Battery Test places a load on the battery and a countdown timer is started. At the 1678 RFD OPERATION MANUAL {DRAFT} 57
Aing m ssage is displayed. 9.2.4. Loaded Battery 7.24 <Low Battery = 7.00> fter testing is complete, the follow eTesting Completed Testing the RSTI WARNING Do not touch the firing terminals of the Remote units while testing. Apotentially lethal voltage is present during the Fire t est. To test an RSTI, install the firing tip on the top of the RSTI and plug the Test Box probe in turns on with the yellow light fast blinking aTest Box will display the following message. Next the Test Box will display the Battery Charge Count as shown below. This is the number of charge cycles the battery within the RSTI has experienced. Next the Test Box dis battery’s temperature (+22C +72F) and chemistry type (NiMH). The next message shows the battery serial number (Battery SN 0001) and the battery’s date of manufacture (Battery DOM 02/03/2011). to the top connector on thnd the green light on. The e RSTI. The RSTI RSTI Detected Battery Charge Count 83 plays the current Battery Temp +22C +72F Battery Type: 1650mAh NiMH 1678 RFD OPERATION MANUAL {DRAFT} 58
Battery SN 0001 Battery DOM 02/03/2011 The next message displayed shows the System Number or Address (0000000001) and the Unit that the RSTI is assigned to. The next message dis shows the assigned Frequency and the Message Number. del) date of manufacture (DOM), firmware version (Ver). unt. ins 5 Address 0000000001 Unit 3 played The next messages displayed are the serial number (S/N), unit Type (MoFrequency 174 MHz Message Number 010000 S D/N 00101 Type 1678-3 OM 06/29/2010 Ver 1.0 The next message displayed is the firmware Checksum and the Fire CoChecksum 4624 Fire Count 87 Next the RSTI begins the Arm/Fire Test. The Test Box Arms the RSTI and begsecond countdown. RSTI Arm/Fire Test 05 At the end of the countdown, the RSTI fires resulting in the formation of a spark at the tip. The firing voltage and pass level is shown. 1678 RFD OPERATION MANUAL {DRAFT} 59
Firing Voltage 2652 <Pass Level = 2250> Next the RSTI begins a Battery Test. The Battery Test places a load on the battery and a countdown timer is started. At the Battery Test – Standby 30 end of the test, the loaded battery voltage is displayed along with the test limit of (7.00). Loaded Battery 7.24 <Low Battery = 7.00> After testing is complete, the following message is displayed. Testing Completed 1678 RFD OPERATION MANUAL {DRAFT} 60
9.3. A FILE USING HYPERTERMINALSAVING TEST BOX RESULTS TO A situation might occur where the end users want to be able to record the Test Box results, but they may not be authorized to use the ‘RFD Test Utility’ program because of case the output of the Test Box serial cable can as HyperTerminal. Cen click “Rits capability of reprogramming. In thatbe captured to a terminal program suchlick the Windows “Start“ button, th un…”. The dialog box shown below should appear. Type “HYPERTRM” in the open box (without the quote marks)button. , and then click the “OK” The dialog box shown below should appear. 1678 RFD OPERATION MANUAL {DRAFT} 61
Enter a name and choose an icon for the connection. Click the “OK” button. The dialog box shown below should appear. 1678 RFD OPERATION MANUAL {DRAFT} 62
Click on the “Connect using:” list box and select either “Direct to Com1” or “Direct to Com2”. Select the one that corresponds with an unused serial port connector on the computer. Click the “OK” button. The dialog box shown below should appear. 1678 RFD OPERATION MANUAL {DRAFT} 63
Click on the “Bits per second:” list box and select 1200. Leave the “Data bits:” set to ‘8’, “Parity:” set to ‘None’, “Stop bits:” set to ‘1’, and “Flow control:” set to ‘Hardware’ as shown in the following dialog box. 1678 RFD OPERATION MANUAL {DRAFT} 64
Click the “OK” button. The dialog box shown below should appear. Click “Transfer” and then “Capture Text…”. The dialog box shown below should appear. Enter a file name for the text output from the Test Box and click the “Start” button. The dialog box shown below should appear. 1678 RFD OPERATION MANUAL {DRAFT} 65
Connect the Test Box serial cable to the serial port at the rear of the computer. This serial port must match up with the earlier selection of either “Direct to Com1” or “Direct to Com2”. Refer to documentation provided by computer manufacturer for more information on available serial ports. Turn the Test Box on by installing its antenna. The following text should appear in the window. 1678 RFD OPERATION MANUAL {DRAFT} 66
Proceed with testing the 1678 system. The test results will be saved to a file. Select “File” and then “Print” to print the test results to the computer’s printer. Select “File” and then “Save” to save this onfiguration. For future tests on the same computer, start HyperTerminal, Select “Fcile” and then “Open”, select the configuration name. Select “Transfer” and then “Capture text…”. If the same capture file name is used, the new test results will be appended to the end of the previous test results. Close the HyperTerminal window when the testing is completed. If the above (or similar) text does not appear shortly after installing the Test Box antenna, check that the serial cable is connected from the Test Box to the computer correctly and that the selection under “Connect using:” matches the computer serial port number that the Test Box serial cable is connected to. 1678 RFD OPERATION MANUAL {DRAFT} 67
10. RFD PROGRAMMING GUIDE 10.1. PROGRAMMABLE PARAMETERS 10.1.1. Mini Controller Unit • Operating frequency: Frequency is programmable, but if the new frequency is greater than 2MHz away from factory set frequency, the Mini Controller will have to be retuned at a factory authorized service center for optimum performance. 10.1.2. Remote Unit / RSTI • Operating frequency: Frequency is programmable, but if the new frequency is greater than 2MHz away from factory set frequency, the Remote Unit or RSTI will have to be retuned at the factory for optimum performance. • Unit ID: The Unit ID is a number from 1 to 4, and corresponds to the numbers on the Mini Controller Unit keypad. quency. • Address: This is the address for the system. Remotes can be moved fromone system to another by matching up the system address and fre10.2. REQUIRED EQUIPMENT 10.2.1. Test Box 10.2.2. A personal computer running Microsoft Windows® 95, 98, 2000, or XP and an anual. available DB-9 RS-232 serial port. 10.2.3. The software utility ‘Setup RFD’ located on the CD at the back of this m10.3. WINDOWS CONFIGURATION SOFTWARE OPERATION (SETUP RFD) Setup RFD is a Windows program designed for depot personnel to determine system formation, make permissible changes to the system, and create a log file of test 10.4. SETUP RFD INSTALLATIONinresults. The Setup RFD install files are distributed on a CD. Follow the listed steps to install Setup RFD on a computer. • Install the CD and browse to the file ‘Setup.exe’. 1678 RFD OPERATION MANUAL {DRAFT} 68
• Run the setup.exe file from the folder. ear. Typical dialog boxes are • Follow the prompts in the dialog boxes that appshown below. 1678 RFD OPERATION MANUAL {DRAFT} 69
Setup 1669 RFD is now installed on the computer. 10.5. CONFIGURING SETUP RFD Follow the listed instructions to configure Setup RFD. • Click on the Windows “Start” button. • Go to “Programs” then “Setup RFD” and then click on “Setup RFD”. • The program will start and display the following dialog box. • Click on the Serial Port list box and select the serial port that will be used with the 1678 Series RFD Test Box. • The serial port selection will be retained for future sessions automatically. • The Setup RFD program is now configured. 1678 RFD OPERATION MANUAL {DRAFT} 70
10.6. USING SETUP RFD TO TEST RFD UNITS The Setup RFD program may be used with the 166x Series Test Box to test 166x Series Units and record the results of those tests. 10.6.1. Creating a Test Results Log File: • If a log file of test results is desired, click “File” and then “Open Log File…”. The r. following dialog box will appea • Type in a file name for the log file or select an existing file to use. Click the “Open” button. 1678 RFD OPERATION MANUAL {DRAFT} 71
• If the file already exists, the following prompt appears. Click “Y •es” to append (add to) existing data or “No” to overwrite the existing file. • The following window appears. • A time and date stamp is added to the window. • Notes can be added to the log file by clicking the note card icon and typing the note in the dialog box that appears. Multiple notes can be added as required. • Connect the Test Box serial cable to the serial port selected in a previous step. • Turn on the Test Box by installing its antenna. The following window is displayed. 1678 RFD OPERATION MANUAL {DRAFT} 72
• Connect the Test Box Probe to a Remote Unit. • Connect the Test Box Probe Leads to the Remote Unit binding posts. It does not matter which lead goes to which binding post. • The Test Box reads and displays the system information from the Remote Unit, and then executes an arm/fire test followed by a battery test. The results are displayed as shown in the next window. 1678 RFD OPERATION MANUAL {DRAFT} 73
• To test the Remote Unit again, remove the Test Box Probe from the Remote Unit for a few seconds, and then reconnect the Test Box Probe to the Remote Unit. • To end the testing and save the log file, click “File” and then “Close Log File…” 1678 RFD OPERATION MANUAL {DRAFT} 74
10.6.2. Printing Test Results to a Log File • The log file must be printed from another Windows application such as Microsoft Word. • Start Word, click “File” and then “Open”. • Change the “Files of type:” list box to “All Files (*.*)” • Browse to the folder that contains the log file to print, and select the file. • Print the file by clicking “File” and then “Print”. 1678 RFD OPERATION MANUAL {DRAFT} 75
10.7. FD UNITSUSING SETUP RFD TO PROGRAM R • Click on the Windows “Start” button. • Go to “PFollow the listed instructions to use Setup RFD to Program RFD Units. rograms” then “Setup RFD” and then click on “Setup RFD”. • The program will start and display the following dialog box. • Click on the Serial Port list box and select the serial port that will be used with the Series Test Box. • Click on “Program” and the following window appears. • For standard ‘User’ mode, click ‘Ok’. The passadvanced features and the tune up mode. The word protected mode is for following screen should appear. 1678 RFD OPERATION MANUAL {DRAFT} 76
• Connect the Test Box Probe to the Unit to be programmed. • The box labeled ‘Status’ updates automatically showing the type of unit connected. 1669-1 and 1669-21 designate Mini Controllers, 1669-2 and 1669-20 designate Remotes, 1669-14 and 1669-19 designate RSTIs. 1678 RFD OPERATION MANUAL {DRAFT} 77
• With ‘Polling’ checked, the program will automatically read and display the unit’s current settings. • The “System Address” box displays the system address for the Unit. This number is unique to each system. • The “Unit Number” box displays the number for the Unit within the system. Remotes will be 1 through 8 and the Mini Controller will be Unit 0. • The “Frequency (MHz)” box displays the transmitter and receiver frequencies, in Mega Hertz, for the Unit. • The “Fire Count” box displays the number of times the Remote has been fired. • The “Serial Number” box displays the Manufacturer’s serial number for the Unit. • The “Date of Manufacture” box displays when the Unit was manufactured. The “Type” box displays the Manufacture’s type code for the Unit. • Boxes that are displayed in gray are not programmable and are for information purposes only. • • The “Firmware Version” box displays the version of firmware that is programmed into the Unit. 1678 RFD OPERATION MANUAL {DRAFT} 78
10.7.1. Changing the System Address rogrammable only on Remote and RSTI Units. It may not be changed on Mini Controller Units. The System Address should only be changed by personnel having that authority. A possible scenario for changing the System Address is that a Remote Unit in system 12345 has become unserviceable. A Remote Unit from another system may be reprogrammed to have a System Address of 12345 to complete the system. The Unit Number for the replacement Remote Unit should be reprogrammed to match the Unit Number of the Remote Unit it is replacing. To change the System Address follow the listed steps. • Click on the “System Address” box and then type the desired System Address in the box. Allowable entries are in the range of 1 to 65535. • Press the “Enter” Key or click the mouse to another box. • Click the “Read” button to re-read the Unit information and confirm that the desired System Address was accepted. 10.7.2. Changing the Unit Number The Unit Number is used to assign a uniquehin a ck the mouse to another box. • Click the “Read” button to re-read the Unit information and confirm that the Units, STIs, and RFD Test Box use to communicate with each other. All Units within a o change the Frequency, follow the listed steps. The System Address is p ID to each Remote Unit within a system. The same Unit Number should not be assigned to more than one Remote Unit witsystem. To change the Unit Number follow the listed steps. • Click on the “Unit Number” box and then type the desired Unit Number in the box. Allowable entries are in the range of 1 to 8. • Press the “Enter” Key or clidesired Unit Number was accepted. 10.7.3. Changing the Frequency The Frequency is the radio frequency that the Mini Controller Unit, RemoteRsystem must have the same Frequency. T1678 RFD OPERATION MANUAL {DRAFT} 79
• Click on the “Frequency (MHz)” box and then type the desired Frequency in Mega Hertz in the box for both the transmit (TX) and receive (RX) boxes. ation and confirm that the desired frequency was accepted. or later), click the box “Is EUT a Test Box” and perform the steps outlined above. 10.7.4. End of Programming , perform a “Read” operation and confirm all of the fields are entered as intended. • Press the “Verify” button. This causes the unit to verify the integrity of all the data hen all the changes are confirmed and verified, test the system by following the Bench Test Procedure in Section 4.3. Allowable entries are in the range of 150 to 174 Mega Hertz. CAUTION Changes to the TX operating frequency by more than 2 MHz on either side of the original frequency require retuning and must be performed by an authorized service center. • Press the “Enter” Key or click the mouse to another box. • Click the “Read” button to re-read the Unit inform• To change the frequency of the RFD Text Box (Version 2.0• When programming has been completedstored in the unit’s memory. Reprogram any fields that fail and re-verify. • W1678 RFD OPERATION MANUAL {DRAFT} 80
11. BATTERY MAINTENANCE The battery packs will provide optimum performance and maximum life when the following recommendations are adhered to. 11.1. BATTERY TEMPERATURE 10 and 30 degrees y For maximum efficiency charge batteries when they are between Celsius. DO NOT attempt to CHARGE BATTERIES that are BELOW 0 degrees orABOVE 40 degrees Celsius. Permanent damage to batteries and or equipment maresult. 11.2. PRE-OPERATION Use the Battery Charger Assembly to discharge and then charge the battery of each unit. 11.3. PERIODIC Every two months perform two discharge and then charge cycles using the Battery Charger Assembly on the battery of each unit. 11.4. ANNUAL Have the battery packs replaced every 3 years or 300 charge / discharge cycles, whichever comes first. 11.5. EXTENDED NON-USE If the battery has not been discharged and charged within four months, repeat the discharge / charge cycle four times and check the battery capacity prior to operational use. Do not exceed storage temperature guidelines as it may reduce battery capacity and/or cause physical deterioration of battery components. Storage Time Storage Temperature <30 days -4 to 122°F (-20 to +50°C) 30 - 90 days -4 to 104°F (-20 to +40°C) >90 days -4 to 86 °F (-20 to +30°C) 1678 RFD OPERATION MANUAL {DRAFT} 81
1678 RFD OPERATION MANUAL {DRAFT} 82 Revision History:

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