Rothenbuhler Engineering 1678-4 Test Box User Manual

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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

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 Page

SPECIAL 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

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} xii

CAUTION 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 to

display 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 the

Antenna 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.

00001

00107 System Number

Figure 3-1 Mini Controller Unit Identification Label

S/N: 1669-20-S00001

Address: 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

CAUTI

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 CHARGER

ON Inspect all components for physical damage.Do not use any

component that is damaged, suspected of being damaged, or is not able to operate a

designed. The safety of the operation could be compromised.

4.1.1. Ensure the antenna / battery charger c

and Remote Unit is not damaged.

4.1.2. Remo

4.1.3. Ensure the Antenna Asse

4.1.4. Ensure that the spring-loaded binding posts on the Electric Remote Un

4.1.5. Ensure the Shock Tube Tip Jacks on the top of the RSTI

4.1.6. Rem

4.2. 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

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 display

using the Test Box. Battery pack replacement is recommended when the charge cou

reaches 300 charge cycles to ensure reliable perfo

The 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 stati

1678 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

4.2.11. The battery must be within the temperature range 32 ºF and 104 ºF (0 to +40

ºC

4.2.12. If the detected battery voltage is less than 6 volts, the battery will be slow

ithin 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

The 3-Position Charger does not feature a discharge function. To conditio

the 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 e

moisture does not enter the unit case.

4.2.8. Connect each unit to be charged to

not discriminate

may be connected to any of the 3 charge connectors.

4.2.9. The CHARGE light for each c

conds 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 w

When rapid charging terminates, the green SLOW light will be on steady, and

the CHARGE light will be turned

Rapid charging terminates when the charger detects the battery pack is

charged. Rapid charging will also terminate after 4 hours, or if the battery pack’s

temperature 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 SYSTEM

Close 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.

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

imately 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

sta

ters) from the nearest blasting caps, wires connected to blasting caps, or

CAUTION 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 connector

the Mini Con

Install the Antenna Assemblies on the antenna / battery charg

the Remote Uni

ON/LOW BATT light is flashing, the Remote Unit has a low battery. Recharge the

battery in accordanc

Turn the Mini Controller Unit on by pressing the “ON” switch for 1 second. A

yellow light located in the upper left quadrant of the “ON” switch

ni 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 approx

4.3.7. 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 yellow

light 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

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.

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 are

now armed.

Observe the Mini Controller Unit and Remote Units. After the Arm Tim

Period expires, the Remote Units will automatically disarm. The ARMED lig

Mini 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 ligh

be 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 Remote

Units 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. Th

ARMED 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 A

4.3.13. 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 and

the SAFE light will turn on at each RSTI. The displayed status at the Mini Co

Unit will change from ARMED to

When firing the RSTI with no tip or with a faulty tip, the green DISARMED ligh

for 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 th

handling and replacement. Never exceed 200 s

you 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. Th

which 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

to 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. A

yellow light located in the upper left qua

the yellow light

Mini 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 on

flash 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

and free from

obstruction within 100 feet (30 meters) of the shot. Use sandbags or other suitable

reen light on

steady).

steady. This indicates there is no voltage on the binding posts, the binding posts ar

electically isolated from the firing capacitor, the binding posts are shunted to each othe

and 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 (g

1678 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.

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 needle

Prepare the shot and return to the safe firing area.

5.2.9. If all Remote Units are located within Error! Reference source not found. o

the Mini Controller Unit, refer to section 5.2.11.

5.2.10. If all Remote Units are lo

5.2.11. If some Remote Units are located within Error! Reference source not

found. of the Min

5.3. SY

SOURCE NOT FOUND. OF MINI CONTROLLER UNIT

Note: If the distance between the Mini Controller Unit and the Remote Units is in

ions

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

for

excess of Error! Reference source not found., the Remote Units status transmiss

may not be received by the Mini Controller Unit. The Mini Controller Unit will command

the Remotes from a distance greater than Error! Reference source not found., but t

Remote Status may not be confirmed. The Mini Controller Unit performs just as it would

when it is within Error! Ref

s are displayed on the Mini Controller

display panel. The ARMED and DISARMED status lights for out of range Remote U

will 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

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

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 statu

all 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 a

mmand 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

ht next to each selected Remote Unit switch will flash for approximately 5 seconds

and then come on steady. The selected Remote

To fire the Remote Units, press the “FIRE” switch and hold for 1 second. Th

operator should get an indication of shot initiation. The AR

ntroller Unit display panel.

Note: When firing the RSTI with no tip or with a faulty tip, the green DISARMED lig

the “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

dif

its

roller Unit did

not receive a status message from the Remote Unit. Once the Remote Units are set up

for

5.4.2. 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

tha

5.4.4. Select the Remote Units that are to be used in the shot by pressing the

ty Feature Once armed, the Remote Units must be sent a Fire

Note: If the distance between the Mini Controller Unit and the Remote Units is in

excess of Error! Reference source not found., the Remote Units status transmi

may not be received by the Mini Controller Unit. The Mini Controller Unit will com

the Remotes from a distance greater than Error! Reference source not found., but the

Remote status may not be confirmed. The Mini Controller Unit performs

ference 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 Un

will 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 from

all 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 at

a time.

System Safe

command within the Arm Timeout Period. If the Remote Units do not receive a Fi

command 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 ARME

light 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 now

assumed 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 th

ht for each selected Remote Unit will flash o

If not all the Remote Units were selected for the shot, rep

5.4.8. To disarm any Remote Units that have been arme