Telemotive Controls E10647B Remote Control Transmitter User Manual Exhibit D Users Manual per 2 1033 b3

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Document Description	Exhibit D Users Manual per 2 1033 b3
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Date Submitted	2002-08-15 00:00:00
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Document Title	Exhibit D Users Manual per 2 1033 b3

INSTALLATION AND USERS MANUAL
TELEMOTIVE
telePilot SERIES
TR12 & TX12M-1, -2
TM
RADIO
CONTROL
telePilot Programming is
found on page 62.
SYSTEM
®
telemotive
Industrial Controls
175 Wall Street
Glendale Heights, IL 60139-1985
Phone: 630-582-1111, Toll Free: 888-687-4400
Website: http://www.telemotive.com/
TCTX12/TR12-0
Rev. F
This page intentionally left blank.
Table of Contents
1- Service Information............................................................................................................................3
2- Radio Controlled Crane Safety...........................................................................................................4
1. Warnings, Cautions and Notes......................................................................................4
2. Critical Installation Considerations...............................................................................4
3. General..........................................................................................................................5
4. Persons Authorized To Operate Radio Controlled Cranes ...........................................5
5. Training Checklist For Crane Operators.......................................................................5
6. Operating Area..............................................................................................................6
7. Transmitter Unit............................................................................................................6
8. Operating The Crane.....................................................................................................6
9. Boarding The Crane ......................................................................................................7
10. Crane Maintenance and Repair.....................................................................................7
11. Using The Crane As A Work Platform.........................................................................8
12. Condition Of The Radio Controlled Crane...................................................................8
13. Batteries ........................................................................................................................9
3- General System Information.............................................................................................................11
1. General System Information.......................................................................................11
2. TMS Low Power Signaling ........................................................................................11
3. Channel Designations .................................................................................................11
4. System Specifications .................................................................................................11
5. Transmitter Unit..........................................................................................................11
6. Receiver Unit ..............................................................................................................12
4- Installation Procedure.......................................................................................................................13
1. Pre-Installation Considerations...................................................................................13
2. Receiver Unit Mounting Location Considerations .....................................................13
3. Antenna Mounting Considerations .............................................................................13
4. Line Input Considerations...........................................................................................13
5. Wiring Considerations ................................................................................................13
6. Receiver Receiver/Equipment Interface Considerations ............................................14
7. Receiver Unit Cabinet Mounting................................................................................14
8. Receiver Installation ...................................................................................................14
Figure 4-1. Input Power Connections ................................................................................15
Figure 4-2A. Receiver Mounting Details Horizontal with Mounting Brackets.................15
Figure 4-2B. Receiver Mounting Details Vertical with Mounting Brackets .....................16
5- Operation..........................................................................................................................................17
Figure 5-1. telePilot, Pendant and Membrane Transmitters. ...........................................17
1. Transmitter Buttons ....................................................................................................17
2. ON/OFF LED Indicator ..............................................................................................18
3. Low Battery Indicator .................................................................................................18
4. Optional 4th Motor Select Indicator. ..........................................................................18
5. Operation.....................................................................................................................18
6. Additional telePilot Transmitter Operational Features ..............................................19
7. Battery Replacement...................................................................................................18
6- Wiring Diagram................................................................................................................................23
1. Wiring Diagrams.........................................................................................................23
2. Installation...................................................................................................................23
3. Alarms and Horns .......................................................................................................23
4. Single-Speed Pendant Transmitter Wiring .................................................................23
5. Two-Speed Pendant Transmitter Wiring....................................................................23
6. Relay Sequencing........................................................................................................23
7. Alarm After E-STOP ..................................................................................................23
8. Connecting Outputs to Drives ....................................................................................23
9. Optional Transfer Switch Wiring Configurations.......................................................24
Figure 6-1. Legend.............................................................................................................24
Figure 6-2. External Transfer Switch Wiring ....................................................................25
Figure 6-3A. External Transfer Switch System Wiring.....................................................26
Table of Contents (Continued)
Figure 6-3B. Optional Internal Transfer Switch System Wiring.......................................27
Table 1 TR12 Single-Speed Wiring Diagram. Standard Configuration Hoist, Trolley
and Bridge...................................................................................................................28
Table 2(A) TR12 2-Speed Wiring Diagram. Standard Configuration Hoist, Trolley
and Bridge...................................................................................................................30
Table 2(B) TR12 2-Speed Wiring Diagram. 2-Speed with Directional Controls: All
Motions. ......................................................................................................................32
Table 2(C) TR12 2-Speed Wiring Diagram. 2-Speed, 2-Windings: All Motions. ............34
Table 2(D) TR12 2-Speed Wiring Diagram. ACCO Controls: All Motions. ....................36
Table 2(E) TR12 2-Speed Wiring Diagram. P&H: 2-Speed, 2-Windings for Hoist and
Trolley; Standard Bridge.............................................................................................38
Table 2(F) TR12 2-Speed Wiring Diagram. P&H: 2-Speed, 2-Windings for Hoist;
Standard Trolley and Bridge.......................................................................................40
Table 2(G) TR12 2-Speed Wiring Diagram. Demag: 2-Speed, 2-Windings for Hoist;
Standard Trolley and Bridge.......................................................................................42
Table 2(H) TR12 2-Speed Wiring Diagram. Standard 2-Speed 4 Motor System. ............44
Table 2(I) TR12 2-Speed Wiring Diagram. Standard 2-Speed 3, 4 & 5 Motor System
using Select. ................................................................................................................46
7- Programming....................................................................................................................................48
1. Access Code Programming.........................................................................................48
Figure 7-1. Access Code Settings ......................................................................................48
2. Receiver Frequency Programming..............................................................................50
Figure 7-2. RF Receiver Board..........................................................................................50
3. Multibox......................................................................................................................52
Figure 7-3 SW4 Receiver Multibox Switches ...................................................................53
4. Custom Receiver Programming.................................................................................54
5. Receiver Programming ...............................................................................................54
6. Membrane Transmitter Programming.........................................................................55
Figure 7-4. Repositioning of Membrane Transmitter Motion Switch Functions ..............57
Figure 7-5. Membrane Transmitter Single-Speed Configurations.....................................58
7. Pendant Transmitter Programming.............................................................................59
Figure 7-6. Repositioning of Pendant Transmitter Motion Switch Functions ..................61
8. telePilot Programming ............................................................................ 62
Figure 7-7. Single-Speed 10K telePilot Modes.................................................................69
Figure 7-8. Single-Speed 10K telePilot Lockout Modes ..................................................72
Figure 7-9. 2-Speed 9001 and 9101 Series telePilot Functional Mapping ......................73
8- Servicing...........................................................................................................................................76
1. Receiver Servicing......................................................................................................76
Figure 8-1. Receiver Board Layout ...................................................................................76
Table 8-1. Receiver Board Diagnostic LED Functions .....................................................76
2. Receiver Testing .........................................................................................................78
Figure 8-2. Receiver Scope Wave Forms ..........................................................................79
3. Membrane Transmitter Servicing...............................................................................80
Figure 8-3. Membrane Transmitter M/C Module E10635.................................................80
4. Pendant Transmitter Servicing....................................................................................81
Figure 8-4. Pendant Transmitter M/C Module E10636 .....................................................81
5. telePilot Servicing......................................................................................................82
9- Spare Parts........................................................................................................................................83
Figure 9-1 telePilot Exploded View..................................................................................86
Appendix A- Transmitter Switch Programming.....................................................................................87
Section 1 - Service Information
1-1. Service Information.
For questions regarding service or technical
information or ordering replacement parts, ask
for Telemotive Customer Care. Telemotive’s
normal business hours are Monday through
Friday 8:00 AM to 5:00 PM Central Standard
Time. After hours emergency technical service is
available.
• DO NOT ATTEMPT TO OPEN OR SERVICE THE TELEPILOT UNIT.
For new product orders or quotations, ask for
Telemotive Sales.
• ONLY TRAINED QUALIFIED INDIVIDUALS SHOULD DO SERVICING.
Telemotive Industrial Controls
175 Wall Street
Glendale Heights, IL 60139-1985
USA
• STRICT ANTI-STATIC HANDLING
PROCEDURES MUST BE FOLLOWED.
Telephone:
(630) 582-1111
In the USA toll free:
(888) 687-4400
Website:
http://www.telemotive.com/
Manuals for downloading are available for many
products at the Telemotive website.
E-mail
Telemotive
Main:
Sales:
Customer Care:
info@telemotive.com
Fax Numbers:
(630) 582-1194
(630) 582-1204
(630) 582-1205
Telemotive Industrial Control trademarks:
Telemotive, TMS, telePilot, Laser Guard,
Teledrive, Teltec, TeleMotion are either
trademarks or registered trademarks of
Telemotive Industrial Controls.
Third-party trademarks: All other trademarks,
trade names or company names referenced
herein are used for identification only and are the
property of their respective owners
CAUTION
• FAILURE TO FOLLOW THIS CAUTION
COULD RESULT IN SERIOUS DAMAGE
TO EQUIPMENT AND/OR VOID THE
WARRANTY.
Section 2 – Radio Controlled Safety
2-1. Warnings, Cautions And Notes.
2-2. Critical Installation Considerations.
Through out this document WARNING, CAUTION
and NOTE statements have been deliberately placed
to highlight items critical to the protection of
personnel and equipment.
WARNING
WARNING – A warning highlights an essential
operating or maintenance procedure, practice, etc.
which if not strictly observed, could result in injury
or death of personnel, or long term physical hazards.
Warnings are highlighted as shown below:
ALL EQUIPMENT MUST HAVE A MAINLINE
CONTACTOR INSTALLED AND ALL TRACKED
CRANES AND SIMILAR EQUIPMENT MUST
HAVE A BRAKE INSTALLED. FAILURE TO
FOLLOW THIS WARNING COULD RESULT IN
SERIOUS INJURY OR DEATH AND DAMAGE
TO EQUIPMENT.
WARNING
CAUTION – A caution highlights an essential
operating or maintenance procedure, practice, etc.
which if not strictly observed, could result in damage
to, or destruction of equipment, or loss of functional
effectiveness. Cautions are highlighted as shown
below:
WARNING
ON ALL REMOTE CONTROLLED CRANES AN
AUDIBLE AND/OR VISUAL WARNING MEANS
MUST BE PROVIDED. THESE AUDIBLE
AND/OR VISUAL WARNING DEVICES MUST
MEET ALL GOVERNMENTAL REQUIREMENTS. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR
DEATH AND DAMAGE TO EQUIPMENT.
CAUTION
NOTE – A note highlights an essential operating or
maintenance procedure, condition or statement. Notes
are shown as below:
NOTE
WARNINGS, CAUTIONS AND NOTES SHOULD
NEVER BE DISREGARDED.
WARNING
The safety rules in this section are not intended to
replace any rules or regulations of any applicable
local, state, or federal governing organizations. The
following information is intended to be used in
conjunction with other rules or regulations already in
existence. It is important to read all of the safety
information contained in this section before installing
or operating the Radio Control System.
REMOVE ALL ELECTRICAL POWER FROM
THE CRANE OR MACHINERY BEFORE ATTEMPTING ANY INSTALLATION PROCEDURES. DE-ENERGIZE AND TAG OUT ALL
SOURCES OF ELECTRICAL POWER BEFORE
TOUCH TESTING ANY EQUIPMENT. FAILURE
TO FOLLOW THIS WARNING COULD RESULT
IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
Section 2 – Radio Controlled Safety (Continued)
Anyone being trained to operate a radio-controlled
crane should possess as a minimum the following
knowledge and skills before operating the crane:
WARNING
The operator should have knowledge of hazards
peculiar to crane operation.
THE DIRECT OUTPUTS OF THIS PRODUCT
ARE NOT DESIGNED TO INTERFACE DIRECTLY TO TWO STATE SAFETY CRITICAL
MAINTAINED FUNCTIONS, I.E., MAGNETS,
VACUUM
LIFTS,
PUMPS,
EMERGENCY
EQUIPMENT, ETC. A MECHANICALLY LOCKING INTERMEDIATE RELAY SYSTEM WITH
SEPARATE POWER CONSIDERATIONS MUST
BE PROVIDED. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
The operator should have knowledge of the safety
rules for radio-controlled cranes.
The operator should have the ability to judge distance
or moving objects.
The operator should have knowledge of the radio
transmitter.
The operator should know the limit switch test
procedure.
The operator should know, where authorized,
instructions for plugging motions.
2-3. General.
Radio controlled overhead cranes and other material
handling equipment operate in several directions.
They are large, bulky pieces of equipment that handle
heavy loads efficiently at high speeds. Quite
frequently, the equipment is operated in areas where
people are working on the floor below. The crane
operator must exercise extreme caution at all times.
Workers must constantly be alert to avoid accidents.
The following rules have been included to indicate
how your careful and thoughtful actions may prevent
injuries, damage to equipment, or even save a life. If
radio controlled material-handling equipment is
operated from the cab, special care must be taken to
secure the transmitter. Refer to section titled Section
2-10. Boarding The Crane for specific safety rules.
The operator should have knowledge of the use of
crane warning lights and alarms.
2-4. Persons Authorized To Operate Radio
Controlled Cranes.
The operator should be trained in transferring radio
control box to another person.
Only properly trained persons designated by
management should be permitted to operate radiocontrolled cranes.
The operator should be trained how and when to
report unsafe or unusual operating conditions.
The operator should have knowledge of observing
crane signal lights.
The operator should be trained to avoid striking any
obstructions.
The operator should have knowledge of the proper
clearance of lifts or hooks before moving bridge or
trolley.
The operator should have knowledge of the proper
storage space for radio control box when not in use.
The operator should be trained how to exhibit caution
in approaching bridge or trolley bumpers.
Radio controlled cranes should not be operated by
any person who cannot read or understand signs,
notices and operating instructions that pertain to the
crane.
The operator should know equipment capacity.
The operator should be trained in making lifts below
floor level.
Radio controlled cranes should not be operated by
any person with insufficient eyesight or hearing or by
any person who may be suffering from a disorder or
illness or is taking any medication that may cause
loss of crane control.
The operator should be trained in making side pulls.
The operator should know how to keep himself and
other people clear of lifts and to avoid "pinch" points.
2-5. Training Checklist For Crane Operators.
Section 2 – Radio Controlled Safety (Continued)
The operator should know cable and hook inspection
procedures.
The bridge and trolley brakes should be tested. On
transmitter units equipped with two or more speeds,
use the "lowest" speed when testing braking devices.
The operator should know procedures for testing
hoist, trolley, and bridge brakes.
2-6. Operating Area.
When lifting maximum loads, the crane operator
should test the hoist brakes by raising the load a few
inches from the floor. If the brakes do not hold, the
load should immediately be lowered to the floor.
Aisles between equipment, stock, etc., should be free
of obstructions so the crane operator can move freely.
These aisles should be a minimum of three feet (one
meter) wide, or meet local regulations.
If provided, test the lower-limit switch.
Test all warning devices.
Crane operators should always position themselves
for the best view of the crane they are controlling.
The crane should never be operated blindly. The
operator should stay as close to the crane load as
possible. Operators should never position themselves
in a "pinch" point.
Test all direction and speed controls for both bridge
and trolley travel.
2-7. Transmitter Unit.
Test the transmitter emergency stop.
Transmitter switches should never be mechanically
blocked ON or OFF for any crane motion. When not
in use turn the transmitter OFF. A secure storage
space should be provided for the transmitter unit and
the transmitter unit should always be placed there
when not in use. This precaution will prevent
unauthorized people from operating the crane.
Test the hoist brake to verify there is no drift without
a load.
Spare transmitters should be stored in a secure
storage space and only removed from the storage
space after the current transmitter in use has been
turned OFF, taken out of the service area and
secured.
Consult the crane manufacturer, local and
governmental regulations for complete rules of
operation. In general the following rules apply to
remotely controlled cranes:
Test all bridge and trolley limit switches, where
provided, if operation will bring the equipment in
close proximity to the limit switches.
If any crane or hoist that fails any of the above tests
notify the supervisor and lock out and tag for repair.
2-8.2. General Rules For Operation.
The limit switches should never be used as a regular
stopping device. They are intended to be protective
devices.
2-8. Operating The Crane.
2-8.1. Pre-operation Test.
Do not make lifts in excess of the equipment rated
capacity.
At the start of each work shift, or when a new operator takes control of the crane, operators shall do as
a minimum the following steps before making lifts
with any crane or hoist:
The bridge and trolley should be centered directly
over the load when the load is raised to prevent
swinging when making lifts.
Test the upper-limit switch. Slowly raise the
unloaded hook block until the limit switch trips.
When checking limit switches the hoist should be
centered over an area free of personnel and
equipment.
A crane designed for this purpose and only with
supervisor permission should make side pulls. When
a lift is being made, the crane operator should not be
positioned in the line of travel. The crane or hoist
should be operated from a position either to the side
or opposite from the direction of travel.
Visually inspect the hook, load lines, trolley, and
bridge as much as possible from the operator's
station; in most instances, this will be the floor of the
building.
When raising or lowering a load, proceed slowly and
make certain the load is under control. Tag lines
should be used for handling unusual lengths or bulky
loads. Remove slack from chains or slings gradually.
Section 2 – Radio Controlled Safety (Continued)
Make certain all personnel are clear before making a
lift.
If power to the crane is removed, the crane operator
should turn the transmitter unit OFF and keep it OFF
until power is restored.
The crane operator should keep all body parts away
from the lift and should never be positioned under the
lift.
If the crane fails to respond properly, the crane
operator should stop operation, turn the transmitter
unit OFF and immediately report the condition to
their supervisor.
Do not make a lift or move a load if anyone is in a
location where they could be struck by the crane or
the load.
Outdoor cranes, which are subject to movement by
wind, should be securely anchored when left
unattended. If the crane is equipped with bridge
brakes, the parking brake should be set immediately.
If the crane operator is being helped, the crane should
not be moved until the helper signals they are clear of
the crane and its load.
2-9. Boarding The Crane.
When a load is hanging from the crane hook and the
crane is being moved, the crane operator should
sound all warning devices frequently.
The crane should not be boarded without permission
of the supervisor.
Loads should not be carried over workers heads. If a
worker is in the path of crane travel, the crane
operator should stop the crane and clear the area
before proceeding.
The crane operator should turn off the transmitter and
take it with them when boarding the crane.
If more than one person is boarding the crane, one
person should be made responsible for ensuring all
personnel are off the crane before the system is
returned to operation.
Runway stops or other cranes should never be
bumped into.
When moving the crane, the crane operator should be
sure that the hook block and attachments or cables
would not catch on nearby equipment. Slings, chains,
or cables should never be dragged along the floor.
2-10. Crane Maintenance And Repair.
Qualified personnel must maintain a regularly, i.e.,
such as monthly, scheduled crane inspection. During
this crane inspection the functionality and safety of
the crane remote control must also be tested. The
inspection shall include, but be not limited to items
listed in Section 2-13. Condition Of The Radio
Controlled Crane. Consult crane manufacturer, local
and governmental regulations for recommended
inspection intervals
and
proper
inspection
procedures. Problems noted during this inspection
must be repaired before using the crane or the remote
control.
Unless required for operator safety, gloves should not
be worn when operating the transmitter unit.
All loose materials or parts should be removed from
the load before starting the lift.
The crane operator should always hoist lifts high
enough to clear all equipment and workers.
The crane operator should never permit anyone to
ride on the load or hook except when authorized by
the supervisor.
Minor repairs include routine maintenance and
repairs such as greasing, cleaning and control
troubleshooting. All other repairs should be considered major. If the repair crew consists of more
than one person, one person should be designated as
the repair crew leader with the following
responsibilities. If the repair crew consists of only
one person, that person has the following
responsibilities:
When another crane on the same runway is stationary
with a load hanging, the crane operator should
maintain a safe distance between the stationary crane
and the one under their control.
Never leave suspended loads unattended. In an
emergency, if the crane is inoperative and a load
suspended, notify the supervisor immediately,
barricade and post signs on the floor beneath crane
and load.
For minor repairs warning signs should be placed on
the floor beneath the crane or suspended from the
crane. For major repairs, the floor area below the
crane should be roped off.
Section 2 – Radio Controlled Safety (Continued)
If it is necessary to have the crane control circuits
energized, all power circuits for crane movement
must be opened prior to energizing the control
circuits.
When major repairs are to take place, all persons
operating other cranes on the same or adjacent
runways, if any, must be notified prior to starting
repairs. Notification should include the nature of the
repair, safeguards provided, and movement
limitations while repairs are in progress.
All personnel and tools should be moved to a safe
spot before moving the crane during repairs.
When practical, radio controlled cranes which cannot
be moved during repairs must be protected against
being bumped by other cranes on the runway.
Bumpers should be installed on the exposed side or
sides of the crane under repair. They should be
placed as far away as possible. The location of these
bumpers should be indicated by red lights placed so
that they are clearly visible to other crane operators
traveling on the same runway. When it is not possible
to use bumpers, red lights must be placed so they are
clearly visible to other crane operators traveling on
the same runway to indicate the restricted travel zone.
All crane operators on the same runway must be
informed of the repair effort and thoroughly
instructed to what their operations are limited to and
informed they will be notified when repairs are
completed.
Headroom is at a minimum in some crane cabs and
on some crane walkways. Caution should be
exercised when boarding or working on cranes. Hard
hats should be worn whenever possible.
When repairs are finished, all personnel, tools and
repair equipment should be removed before
energizing the crane circuits.
2-11. Using The Crane As A Work Platform.
When the crane is to be used as a stationary work
platform, follow all rules provided in Section 2-11.
Crane Maintenance and Repair. When it is necessary
for the crane to be moved from time to time, the
crane operator should board the crane with the
transmitter unit. The crane operator should ensure all
personnel working on the crane are in a secure
position before moving the crane to the next
workstation. It should also be the crane operators
responsibility to ensure the main switch is open and
locked down before work is resumed.
If any hazard involving the repairmen exists when
there is a runway adjacent to the crane under repair,
the adjacent runway should be blocked off as
described above. When it is necessary to continue
crane operation on the adjacent runways warning
lights must be installed and be visible to operators of
cranes on those runways. All cranes should come to a
complete stop prior to entering the restricted area and
should proceed through this area only after receiving
permission from a signal person designated for this
purpose. Access of persons to and from the crane
being repaired should be under control of the repair
crew leader.
WARNING
THE CRANE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY OF THE ITEMS
STATED BELOW. THE CRANE CONDITION
SHOULD BE REPORTED TO THE SUPERVISOR.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY OR DEATH AND
DAMAGE TO EQUIPMENT.
When boarding the crane, the transmitter should be
turned OFF and the transmitter should remain with
the repair crew leader. The leader should board the
crane first, open and lock out the main switch, and
then signal the other members of the crew it is safe to
board the crane.
2-12. Condition Of The Radio Controlled Crane.
If work on the crane is to be done in areas not
protected by standard handrails, the repair crew
should wear approved safety belts.
If the crane fails to respond properly, the crane
operator(s) should notify their supervisor. When
serious conditions are noticed (conditions that make
the crane unsafe to operate), the crane should be shut
down immediately and the supervisor notified. The
following is a list of some of the items that should be
included in the report. (See the crane manufacturer
for specifics and possible additional items):
All tools and equipment should be moved onto the
crane by the use of hand lines. The tools and
equipment should be adequately secured to the hand
lines.
Section 2 – Radio Controlled Safety (Continued)
Condition of hoisting cable and hook block (broken
strands, clipped sheave wheels, etc.).
Condition of warning or signal lights and horns.
(Burned out or broken).
Condition of brakes (hoist, trolley, and bridge). (No
bluing, rivets on shoes showing, glazing, etc.).
2-13. Batteries
Condition of trolley and rail stops.
Condition of bridge structure.
WARNING
Condition of festoon system.
KNOW AND FOLLOW PROPER BATTERY
HANDLING, CHARGING AND DISPOSAL PROCEDURES. IMPROPER BATTERY PROCEDURES CAN CAUSE BATTERIES TO EXPLODE
OR DO OTHER SERIOUS DAMAGE. FAILURE
TO FOLLOW THIS WARNING COULD RESULT
IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
Broken welds in any part of the crane structure.
Proper fluid levels and lubrication.
Condition of bridge and trolley stops.
Carbon dust or signs burning on the covers of motors.
Indication of fluid, oil or grease leaks.
2-13.1. Battery Handling.
Condition of rail sweeps.
Use only batteries approved by Telemotive for the
specific product.
Walkways required handrails and ladders are in
place, sturdy and not loose.
Do not dispose of a battery pack in fire; it may
explode.
Protective guards are in place for all moving parts.
Do not attempt to open the battery pack.
Alignment of bridge (screeching or squealing wheels
indicate bridge is out of line).
Do not short circuit battery.
Broken, cracked, or chipped rails on trolley or
runway.
For intrinsically safe environments only use specified
Telemotive intrinsically safe batteries.
Condition of limit switches.
Keep the battery pack environment cool during
charging operation and storage, (i.e., not in direct
sunlight or close to a heating source).
Condition of electrical and mechanical control
(electrical or mechanical defects which cause faulty
operation such as un-commanded stopping or starting
of any crane motions, warning devices, lights, or
auxiliary functions).
2-13.2. Battery Charging.
For those transmitters equipped with battery chargers,
please familiarize all users with the instructions of
the charger before attempting to use.
Condition of gears (grinding or squealing may
indicate foreign materials in gear teeth or a lack of
lubrication.
Use only Telemotive approved chargers for the
appropriate battery pack.
All controls especially E-STOPs are in place and in
working order.
Frequent relay tripping of power circuits.
Do not attempt to charge non-rechargeable battery
packs.
Mechanical parts loosened by vibration (loose rivets,
covers, bolts, etc.).
Avoid charging the battery pack for more than 24
hours.
Uneven riding (worn or damaged wheels).
Do not charge batteries in a hazardous environment.
Condition of collector shoes or bars.
Do not short charger.
Section 2 – Radio Controlled Safety (Continued)
Do not attempt to charge a damaged battery.
Do not attempt to use a battery that is leaking,
swollen or corroded.
Charger units are not intended for outdoor use. Use
only indoors.
2-13.3. Battery Disposal.
Before disposing of batteries consult local and
governmental regulatory requirements for proper
disposal procedures.
10
Section 3 – General System Information
3-1. General System Information.
3-3. Channel Designations:
The Telemotive Radio Control System (system)
provides remote control of overhead cranes using
radio signals. The system consists of a hand held
portable battery operated transmitter unit and a fixed
station receiver unit.
AK01 - 439.8 MHz
AK02 - 439.6 MHz
AK03 - 439.4 MHz
AK04 - 439.2 MHz
AK05 - 439.0 MHz
AK06 - 438.8 MHz
AK07 - 438.6 MHz
AK08 - 438.4 MHz
AK09 - 438.2 MHz
AK10 - 438.0 MHz
A unique 16-bit code (Access Code) for each system
is preset in every transmitter and receiver. The
receiver considers any received signal, which does
not match the receiver access code setting, invalid.
The Access Code is made up of 16-bits (65,000
combinations) and no two similar codes are assigned
to any two Telemotive systems.
AK11 - 437.8 MHz
AK12 - 437.6 MHz
AK13 - 437.4 MHz
AK14 - 437.2 MHz
AK15 - 437.0 MHz
AK16 - 436.8 MHz
AK17 - 436.6 MHz
AK18 - 436.4 MHz
AK19 - 436.2 MHz
AK20 - 436.0 MHz
AKA00 - 433.125 MHz
AKA01 - 433.325 MHz
AKA02 - 433.525 MHz
AKA03 - 433.725 MHz
AKA04 - 433.925 MHz
Up to four systems may be used with the same
frequency in a 600-foot area (220 meters). Each
transmitter operating on the same frequency may be
operated in close proximity, not less than six feet (1.9
meters), to each other.
AKA05 - 434.125
AKA06 - 434.325
AKA07 - 434.525
AKA08 - 434.725
MHz
MHz
MHz
MHz
3-4. System Specifications.
3-2. TMS Low Power Signaling.
Receiver housing: NEMA 4X, IP67
TMS (Time Multiplexed Signaling) is a Telemotive
proprietary high-speed packet data system. The
system software is structured to minimize "on the air"
transmission time of any transmitter. This allows for
multiple transmitters to share a common frequency.
The TMS system is designed so that a transmitter will
send a signal for a predetermined ON time, and then
will turn OFF. The length of transmitter ON time is
referred to as data burst or packet. The packet length
is a function of the quantity of data to be sent, and the
data rate (baud). Once the packet is sent, the
transmitter will turn OFF. This allows for other
transmitters to time-share the same frequency when a
transmitter has turned OFF. The TMS system software determines the OFF period and repetition rate of
the ON period. Since each system has its own access
code, up to 4 transmitters can share and have equal
access to the same frequency. TMS also allows for
reduced battery consumption and extended battery
life.
Transmitter housing: IP65.
These systems have low power pulsed signaling,
FCC certified under Part 15 Telecommunications
Code of Regulations, no license is required. The
transmitter unit is frequency modulated, low power
and is certified under the appropriate regulations. A
license is not required for the transmitter or operator.
Modifications to the RF section of this system are not
permitted and could void FCC certification.
A power down feature allows the transmitter and the
receiver unit to turn OFF if no keys are pressed for
predetermined number of minutes. The transmitter
unit must again be turned ON. The unit uses pulsed
operation for extremely long battery life. A
configuration of the system is available without
automatic timeout.
Operating Temperature: –22° F to +158° F (-30º C to
+70º C) ambient.
Humidity: up to 95 % (non-condensing).
Typical Operating Range: 200 feet (70 meters).
Rating of output relays (including Master Relay): 16
Amp 277 VAC/24 VDC, 1 HP 240 VAC.
3-5. Transmitter Unit.
The transmitter is battery operated has an ON and
OFF switch, E-STOP, motor controls and auxiliary
controls used for such item warning indicators.
LED’s mounted on the front panel provide indication
of battery voltage, ON/OFF, Modes and data
transmission status.
Housings are designed of high impact, chemical
resistant, materials. The antenna for the unit is
11
Section 3 – General System Information (Continued)
internal. A strap or belt is provided for carrying the
transmitter.
3-6. Receiver Unit.
The receiver unit consists of a synthesized RF
module, built in antenna, integral power supply,
microprocessor controlled output motor control and
auxiliary function relays and mainline contactor
relay. The receiver unit contains circuitry, which
matches the frequency and access code of the
transmitter.
12
Section 4 – Installation Procedure
4-4. Line Input Considerations.
4-1. Pre-Installation Considerations.
To ensure reliable and safe operation of the
system, the following items must be considered
before installing the receiver unit.
WARNING
THE UNIT MUST BE WIRED TO THE CORRECT VOLTAGE, AND BE CONNECTED TO
THE CORRECT TERMINAL AS REQUIRED
BY THE ACTUAL LINE VOLTAGE. FAILURE FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND
DAMAGE TO EQUIPMENT.
WARNING
THE RECEIVER UNIT OR RELAYS ARE
NOT RATED AS EXPLOSION PROOF. THE
RECEIVER UNIT MUST NOT BE INSTALLED IN EXPLOSIVE ENVIRONMENTS
UNLESS APPROPRIATE SECONDARY ENCLOSURE MEASURES ARE TAKEN. FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY OR DEATH
AND DAMAGE TO EQUIPMENT.
4-2. Receiver Unit
Considerations.
Mounting
The receiver unit has direct connect provisions
for operation from 120 (nominal), 50-60 Hz
power.
For applications where line voltage deviation
exceeds 20% of nominal values if line voltage is
not between
Location
95-130 VAC or 190-260 VAC or if 440 VAC
power is used, a step up or step down
transformer must be used.
Ensure the mounting location is as far as possible
from exposed trolley wires and sources of
electromagnetic or radiated noise
NOTE
The receiver cabinet is approximately 8" (20
cm) wide by 12" (30 cm) high. A depth of at
least 6" (15 cm) must be provided to allow the
cabinet door to open.
THE RECEIVER UNIT SHOULD NOT BE
CONNECTED TO LINES CONTAINING
EXCESSIVE POWER UP TRANSIENTS OR
CONTINUOUS COMMUTATOR NOISE. A
LINE CONDITIONER MAY BE NECESSARY
IN SOME INSTALLATIONS.
The mounting surface must be smooth and
continuous. Mounting the cabinet on uneven
surfaces could cause warpage or stress internal
components.
4-5. Wiring Considerations.
The receiver unit may be mounted in any
position. Greatest radio control range is obtained
when the receiver unit is mounted with the
antenna at the top.
1.
Read this manual before installation.
2. Please observe appropriate local and
National Electrical Codes when wiring electrical
devices.
If possible, avoid installing receiver unit to a
surface where high vibration or shock is present.
If this cannot be avoided, use appropriate shock
mounts.
3. Do not connect or disconnect wiring, or
perform circuit checks while the power is turned
on.
4. The motor wiring should be in a separate
metal conduit from the power wiring, which
should also be in metal conduit.
4-3. Antenna Mounting Considerations.
The antenna is internal and requires no
additional mounting. The antenna is at the top of
the receiver cabinet and should not be placed
near large metal objects that could be close to or
cover the top of the box. Allow at least six
inches above the top of the box for clearance.
5. Low voltage wires shall be wired with
proper low voltage class wiring procedures.
13
Section 4 – Installation Procedure (Continued)
6. Control wiring as well as antenna wiring
shall be in separate conduit and shall be kept as
short as possible.
or other parameters, if desired, see Section
7. Programming for details.
2.
Position the receiver. Locate as far as
possible from exposed trolley wire and
sources of electromagnetic or radiated noise.
Cabinet mounting dimensions and mounting
template is on next page see Figure 4-2A
and B. Receiver Mounting Details. Antenna
at top of unit should be kept as clear as
possible of any metal object.
3.
Mount the receiver. Mounting brackets are
provided to accommodate mounting on to a
metal strut mounting system. The four deep
mounting holes in corners of the receiver
mounting brackets use quantity four #10-24
combo drive round head screws 1 ½ “ in
length, four #10 lock washers and four #1024 hex nuts to mount to the mounting
brackets. Lock washers should be used in
front of hex nuts. Four flat washers are .400
I.D. x 1 ½” O.D. are supplied with use for
mounting the mounting brackets to a metal
strut.
4.
Wire the unit using the appropriate electrical
drawings for the specific transmitter and
crane orientation selected, see Section 6.
Wiring. For the Membrane or Pendant
transmitter determine crane orientation; if
the direction pair labeled on the transmitter
better describes the equipment movement.
Use this pair to wire the motor directionals
respectively. If you need to remove the main
board (4 screws) the antenna unplugs from
the RF Receiver, be sure to dress the
antenna cable under the hook on the RF
Receiver when reinstalling the antenna
cable.
Mounting brackets are provided. See next page
Figure 4-2. Receiver Mounting Details. Allow
room in mounting the receiver for the door to
swing open
5.
Wire the power to J1 input power connector.
The connections are Ground (GND), Neutral
(N) and 120 VAC 50-60 Hz (120V). See
Figure 4-1. Input Power Connections.
Mount receiver unit cabinet securely to mounting
surface. Actual cabinet mounting dimensions are
shown on next page Figure 4-2. Receiver
Mounting Details.
6.
Wiring of the system should now be
complete.
7.
Stand clear of the crane and apply AC power
to receiver unit. Turn switch SW2 OFF (MR
relay control) and SW1 ON (main power
switch). Check to see if four LEDs are lit:
(green; DS22, DS23 and DS24) and (red; RF
Receiver ON). If none are lit check AC
power, power switch SW1 and fuse.
7. All terminals shall be tightened to specified
terminal torque 4.4 IN-LBS (.5 N∙m). Unless
otherwise specified.
8. Remove excess metal screws, metal filings
and wire clippings from inside of unit.
9. Inspect to make sure no exposed wire has
contact with any other wiring or terminals.
10. Suppressors are strongly recommended on
all contactors.
4-6. Receiver/Equipme nt Interface
Considerations.
All output relay contacts are rated at 16 amps
250 VAC, however the system rating for the
contacts is 5 Amps. Connection to equipment or
contactors with higher voltage or current
requirements will require intermediate relays.
All relay outputs are normally open, momentary
contact. Since a relay closure is only active while
the transmitter unit key is pressed and held,
devices such as lights or lifting magnet must use
a mechanical auxiliary latching relay.
NOTE
FOR INFORMATION ON INTERFACING
WITH SYSTEMS WITH HIGH IMPEDANCE
INPUTS SEE SECTION 6-8. CONNECTING
OUTPUTS TO DRIVES OR CONTACT
TELEMOTIVE.
4-7. Receiver Unit Cabinet Mounting.
4-8. Receiver Installation.
1.
Normally it should not be necessary to set
the access codes, they are preset. Program
the unit for any special crane configurations
14
Section 4 – Installation Procedure (Continued)
8.
Turn transmitter ON. Check to see if the
yellow LED is now lit (DSMR1). At this
point the MR relay is disabled, the functions
of the transmitter can be checked by noting
the turning ON of the appropriate red LEDs
next to the control relays (DS7 to DS11).
After checking out the functions, turn switch
SW2 ON to enable the MR relay, check
function and direction by jogging each
motion. Installation should now be
complete.
9.
J1
GND N 120V
Figure 4-1. Input Power Connections.
16.02”
406.9 mm
14.02”
356.01 mm
7.09”
180 mm
.210” DIA.
5.34 mm
hole 4 places
12.02”
305.3 mm
If there are any problems see Section 8.
Servicing.
11.81”
300 mm
.281” DIA.
7.14 mm
hole 4 places
7.87”
200 mm
11.02”
279.9 mm
Receiver shown with
MP10278-0 mounting
brackets attached.
Drawing not to scale.
Overall Cabinet Depth
Cabinet
Cabinet and mounting bracket
Cabinet, mounting bracket & 1 ½” strut
With door
closed inches
5.26
5.44
6.94
With door
closed mm
133.60
138.07
176.17
With door
open inches
12.12
12.30
13.80
Figure 4-2A. Receiver Mounting Details with
Horizontal Mounting Brackets.
15
With door open
mm
307.98
312.44
350.54
Section 4 – Installation Procedure (Continued)
.281” DIA.
7.14 mm
hole 4 places
16.02”
406.9 mm
.210” DIA.
5.34 mm
hole 4 places
11.02”
279.9 mm
Receiver shown with
MP10278-0 mounting
brackets attached.
14.02”
356.01 mm
11.81”
300 mm
7.87”
200 mm
7.09”
180 mm
8.09”
206.6 mm
Drawing not to scale.
Overall Cabinet Depth
Cabinet
Cabinet and mounting bracket
Cabinet, mounting bracket & 1 ½” strut
With door
closed inches
5.26
5.44
6.94
With door
closed mm
133.60
138.07
176.17
With door
open inches
12.12
12.30
13.80
Figure 4-2B. Receiver Mounting Details with
Vertical Mounting Brackets.
16
With door open
mm
307.98
312.44
350.54
Section 5 – Operation
ON/OFF & Low Battery Indicators
ON/OFF E-STOP
Auxiliary
Controls
ON/
OFF
AUX 1
AUX 2
AUX 3
Motor 1
Dir 1
Dir 2
ON/
OFF
Motor 2
Dir 1
Dir 2
10
AUX 1
DOWN
Motor 3
Dir 1
Dir 2
11
AUX 2
NORTH
12
AUX 3
SOUTH
AUX 4
UP
A B BOTH
TX12M-2
E-STOP
ON/OFF
Indicators
UP
DN
EAST
STOP
WEST
ON
OFF
TX12M-1
Optional
4th Motor or Select Indicators
2-Speed and Single-Speed telePilot
Pendant and Me mbrane
Figure 5-1. telePilot, Pendant and Membrane
5-1. Transmitter Buttons.
NOTE
ON/OFF On the telePilot and Pendant
Transmitter ON and OFF is the same button.
Pushing this button toggles between turning the
transmitter ON and then sending the ON
command to the receiver and sending the OFF
command to the receiver and then turning the
transmitter OFF.
ON THE TELEPILOT TRANSMITTER THE
USER CAN CHOOSE AND CUSTOM LABEL
THE FUNCTIONS FOR A SPECIFIC MOTOR
THE
FUNCTIONAL
DESIGNATIONS
SHOWN BELOW ARE COMMON AND
TRADITIONAL DESIGNATIONS.
NOTE
Common 2-Speed Designations Listed Below:
IN THE TELEPILOT THE TRANSMITTER
DOES NOT TURN ON TILL THE ON PUSH
BUTTON IS RELEASED AFTER BEING
DEPRESSED TO TURN ON. THE OFF
FUNCTION
IS
IMMEDIATE
UPON
DEPRESSING THE ON/OFF PUSH BUTTON.
Motor 1 Dir 1, (Hoist) UP – Selects hoist
movement in the UP direction speed one (first
switch position) or speed two (second switch
position).
Motor 1 Dir 2, (Hoist) DN/DOWN – Selects
hoist movement in the DOWN direction speed
one (first switch position) or speed two (second
switch position).
(Membrane only) ON Turns the transmitter ON
and then sends the ON command to the receiver.
OFF Sends the OFF command to the receiver
and then turns the transmitter OFF.
Motor 2 Dir 1, (E Me mbrane)/NORTH
Pendant– Selects the appropriate direction of the
bridge or trolley (depending how unit is wired at
installation) speed one (first switch position) or
speed two (second switch position).
E-STOP (EMS) – Stops all equipment
movement and disables all functions except
Alarm. Reset the system for normal operation by
turning the transmitter “OFF” then “ON”. Use
for emergencies only. (NOT FOR NORMAL
SHUT DOWN).
Motor 2 Dir 2, (W Membrane)/SOUTH
Pendant – Selects the appropriate direction of
the bridge or trolley (depending how unit is
17
Section 5 – Operation (Continued)
wired at installation) speed one (first switch
position) or speed two (second switch position).
5-2. ON/OFF LED Indicator.
When the transmitter is ON the red LED flashes
slowly. When the unit transmits, the red LED
flashes rapidly. Top left indicator on telePilot.
Motor 3 Dir 1, (N Me mbrane)/EAST Pendant
– Selects the appropriate direction of the bridge
or trolley (depending how unit is wired at
installation) speed one (first switch position) or
speed two (second switch position).
5-3. Low Battery Indication.
In the telePilot transmitter there is a separate
low battery indicator located to the right of the
ON/OFF indicator. This is a yellow LED that
turns ON solid when it is time to replace the
batteries.
Motor 3 Dir 2, (S Membrane)/WEST Pendant
– Selects the appropriate direction of the bridge
or trolley (depending how unit is wired at
installation) speed one (first switch position) or
speed two (second switch position).
For Membrane and Pedant transmitters if the
ON/OFF LED indicator does not light at all after
turning ON the transmitter or while operating
crane with the transmitter, replace the batteries,
they are weak. See Section 5-6. Battery
Replacement for battery replacement.
(telePilot Only) Optional 4 th Motor Or Select
with Indicators
The AUX 3 pushbutton can be designated as an
auxiliary motor select. As an example for
systems that have a main and auxiliary hoist,
pushing this switch will toggle the function of
the set of motor 1 pushbuttons between the
outputs for main and auxiliary hoist.
5-4. Optional 4th Motor Select
Indicator.
For two speed telePilots with four motors
programmed, this indicator will toggle between
“A”, ”B” and both (for units programmed with
or without tandem operation). Pressing the push
button directly beneath the indicators toggles the
state.
There are two red LEDs above this pushbutton
labeled “A” and “B”. The “A” LED comes ON
for the main function and the “B” comes ON for
the auxiliary. As the pushbutton is toggled the
sequence of outputs and LEDs is as follows.
Normally the main output only is active and the
“A” LED is lit. Pushing the pushbutton lights
only the “B” LED and the auxiliary output only
is active. Pushing the pushbutton a second time
lights both “A” and “B” LEDs and both main
and auxiliary outputs are active in tandem. (This
tandem operation can be disabled See Section 78. telePilot Programming). When turning the
transmitter ON the default condition is always
“A”.
5-5. Operation.
WARNING
BEFORE TURNING ON OR OPERATING
THE CRANE, MAKE SURE ALL PERSONNEL ARE CLEAR OF THE OPERATING
AREA AND NO ONE IS STANDING UNDER
THE LOAD. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
This pushbutton can be used with the Select
function also. When used for the Select function
the “A” and “B” LEDs work as described in the
above paragraph toggling the Select 1 output and
the Select 2 outputs respectively.
1, 2 And 3 (AUX 1, AUX 2, and AUX 3) –
Selects the Auxiliary relay(s), which may be
used for a warning device as a horn or other
function.
18
8/15/2002
Section 5 – Operation (Continued)
WARNING
WARNING
IN AN EMERGENCY HIT “E-STOP” TO
STOP ALL CRANE MOVEMENT. WHEN
EMERGENCY HAS CLEARED TURN THE
TRANSMITTER OFF THEN ON AGAIN TO
RESUME NORMAL OPERATION. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND
DAMAGE TO EQUIPMENT.
WHEN OPERATING THE CRANE FOLLOW
LOCAL AND GOVERNMENTAL RULES ON
THE USE OF HORNS AND ALARMS. FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY OR DEATH
AND DAMAGE TO EQUIPMENT.
Make sure that all personnel are clear of the
crane movement and no one is under the crane or
load.
5-6. Additional telePilot Transmitter
Operational Features. (See Section 7-8.
telePilot Programming for information on
how to program these features).
Turn unit ON by pressing the ON/OFF (ON)
button. The red LED ON/OFF indicator
should flash rapidly for a few seconds indicating
the ON command is being sent to the receiver.
After the receiver is turned ON the red LED
should flash slowly indicating the transmitter is
now ready to send commands.
telePilot E-STOP Function.
The E-STOP command will be repeatedly sent as
long as the E-STOP pushbutton is depressed.
The E-STOP is always live on the telePilot
transmitter. Upon pushing the E-STOP
pushbutton the transmitter will send an E-STOP
command for the last selected Bank even if the
unit is turned OFF. (Obviously, if the battery is
dead this will not work).
Perform whatever safety checks are required. See
Section 2. Radio Controlled Safety. Operate any
horns or alarms as required by local and
governmental regulations.
To operate the crane, press and hold the desired
function button to maintain operation. Press the
directional buttons harder to second position to
engage second speed for those cranes having 2speed motors.
telePilot Low Battery Shutoff Function.
If the battery gets too low the unit will shut off
and send an OFF command to the receiver as it
turns OFF.
Always turn system OFF by pressing the
ON/OFF (OFF) button on the transmitter when
done with crane operation. Do not use the ESTOP button as an ON/OFF button.
telePilot Self-Test Function.
When the unit turns on if any function key is
depressed the unit will fault, not send a turn on
command and not become operational. The red
LED will stay ON till the unit is turned OFF.
The unit will frequently scan the 2nd position of
the motion switches while the transmitter is ON
and if one of these is closed without the first
position closed, the unit will fault as above.
In an emergency always hit E-STOP (EMS)
immediately. To clear the emergency condition,
turn the transmitter OFF and ON again to resume
normal operation.
The receiver will time-out after approximately
15 minutes if there is no activity. The transmitter
is programmed to time-out if not used for 15
minutes also for membrane and pendant. For
telePilot the transmitter time out time is
selectable.
19
8/15/2002
Section 5 – Operation (Continued)
the Bank button is held down release the ON
pushbutton and then the Bank button. (The
sequence is important). The transmitter red LED
ON/OFF
indicator then stays ON (for five
seconds) till the password is entered. Once the
password is entered (see below) the transmitter
red LED ON/OFF
indicator flashes indicating
the current Bank the operator is in while the
transmitter is ON and not transmitting. One flash
then a pause repeatedly indicates Bank 1, two
quick flashes indicates Bank 2, three quick
flashes and a pause indicates Bank 3 and so on.
The transmitter will remember what Bank it is in
even if turned OFF and ON again.
telePilot Red LED ON/OFF Indicator.
The red LED, at the upper most left hand side of
the transmitter, operates as follows:
• Be OFF when the transmitter is OFF.
• Flash slowly when the transmitter is
ON, but not transmitting. If the
transmitter has Bank select enabled the
there will be a number of quick flashes
followed by a pause. The number of
quick flashes indicates the Bank the
transmitter is in.
• Flash rapidly when the transmitter is
transmitting, including during E-STOP
when the transmitter is OFF.
• Remain ON continuously for: waiting
password,
un-programmed
Bank
selected or a logic or pushbutton fault.
It is not necessary to program all four Banks, if
an un-programmed or turned “off” Bank is
selected the ON/OFF
indicator will remain
ON continuously, the transmitter will send no
commands and will turn itself off shortly.
telePilot Battery Yellow Indicator Light.
telePilot
Function.
The yellow LED to the right of the ON/OFF
indicator operates as follows:
• Be OFF when the transmitter is OFF.
• Be OFF when the transmitter is ON and
the battery is good.
• Remain ON continuously for a low
battery needing replacement.
Bank
Password
Protection
This enables the owner to create a four-stroke
password word to enable changing Banks. With
Password enabled the operator selects a fourbutton sequence to enable a Bank after different
Bank has been selected (see above). When the
transmitter is turned ON, after Bank Selection is
made and the ON/OFF
indicator will remain
lit until the correct password sequence is entered
with in five seconds. An incorrect password
sequence or failure to enter the sequence in time
shuts the unit OFF. The user is allowed to restart
and try again an unlimited amount of times. The
Bank Password is the same for all Banks.
telePilot Bank Select (Normally Password
Protected).
This feature is like having four completely
different transmitters in one unit. Up to four
banks (operational configurations) are possible.
A Bank is a specific configuration of userdefined parameters including:
System type
Frequency
Access codes
Also: Key arrangement
Relay configuration
Time-out-timer time
Mode selection
Alarm settings
WARNING
THIS PASSWORD FUNCTION IS NOT TO BE
USED AS A SECURITY DEVICE. THE PURPOSE OF THIS FUNCTION IS TO PREVENT
ACCIDENTAL BANK SWITCHING. THE
BEST FORM OF SECURITY IS ALWAYS TO
LOCKUP THE TRANSMITTER WHEN NOT
IN SERVICE. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
To select a specific bank, The ON/OFF push
button is pressed and held down while one of the
four upper most motion push buttons (buttons 1
through 4 see Figure 5-2. Bank and Password
Input Buttons) is pressed. Press push button 1 for
Bank 1, push button 2 for Bank 2, push button 3
for Bank 3 or push button 4 for Bank 4. While
20
8/15/2002
Section 5 – Operation (Continued)
When initially programming the unit the default
password is 6, 5, 4, 3. This password can be
easily changed by the PDA during initial
programming.
WARNING
DISABLING THE PASSWORD FUNCTION
PUTS THE SYSTEM IN ACTIVE BANK
SELECT. THIS ALLOWS THE CRANE
OPERATOR TO SWITCH BETWEEN BANKS
QUICKER. THE OPERATOR IN THIS MODE
MUST BE AWARE AND RESPONSIBLE FOR
ALL POSSIBLE CONTROLLED CRANES.
FAILURE TO FOLLOW THIS WARNING
COULD RESULT IN SERIOUS INJURY OR
DEATH AND DAMAGE TO EQUIPMENT.
A password is a sequence of four pushbutton
entries. These entries are any combination of
inputs from the upper most six buttons on the
right hand side of the telePilot transmitter. On 2Speed transmitters the second speed is ignored.
telePilot Time-Out-Timer Function.
The transmitter has a time-out timer and the
default condition is 15 minutes. Upon timing out
the transmitter will send an OFF command to the
receiver if Auto Turn Off is active. The
transmitter
time-out-timer
function
is
programmable in minute increments to up to and
including 15 minutes. After that it is
programmable in five-minute increments up to
and including one hour. Infinite time-out (none)
is also selectable. The time-out-timer measures
the time since the last pushbutton stroke and is
continuously reset by any pushbutton activation.
Bank Input Buttons
Password Designators for
Programming
Figure 5-2. Bank and Password Input Buttons.
Acceptable sequences could duplicate buttons
numbers such as 2, 2, 6, 6 or 1, 1, 1, 4.
NOTE
ALWAYS REMEMBER TO STORE THE
PASSWORD IN A SECURE LOCATION FOR
ACCESS IF THE PASSWORD IS LOST OR
FORGOTTEN. ONCE THE TRANSMITTER IS
PROGRAMMED THERE IS NO WAY TO DEFEAT THE PASSWORD WITHOUT USING A
PDA TO EITHER READ THE PASSWORD
OUT OR REPROGRAM A NEW ONE.
The Bank password can be disabled during
initial programming by the PDA.
21
8/15/2002
Section 5 – Operation (Continued)
Turn the transmitter OFF, loosen the two
thumbscrews on the bottom of the unit and open
the unit by pulling on the belt loop. (See below).
Pull out the battery holder until the batteries can
be accessed. Do not pull hard on the battery
holder as it is attached to the logic board by a
cable. Unsnap the battery cable (for battery
packs) or replace the two “AA” cells (for a
battery carrier) and replace the battery(s) with a
new battery(s), noting the polarity for “AA”
cells. (Best life can be obtained if the two “AA”
batteries used are a good quality alkaline type,
both cells of the same type and from the same
manufacturer). Replace the battery holder, belt
loop and tighten the thumbscrews. See Section 9
– Spare Parts for battery part numbers.
5-7. Battery Replacement.
Membrane And Pendant Battery
Replacement.
To replace the batteries, turn the transmitter
OFF, and then turn the unit over to access back
cover. Twist half moon shaped battery latch to
remove cover. Take out old batteries; replace
ALL batteries with new cells. For the Membrane
Transmitter note battery orientation, batteries in
backwards will blow fuse. Replace cover and
turn transmitter ON to use. See Section 9. Spare
Parts for battery and fuse part numbers.
telePilot Battery Replace ment.
On the telePilot if the yellow battery indicator
light
starts to flash replace the battery at
the earliest opportunity. If the light is on solid
replace the battery immediately.
NOTE
THERE IS NO NEED TO RUSH BATTERY
REPLACEMENT. THE PROGRAMMING IN
THE telePilot WILL NOT BE LOST BY
REMOVAL OF THE BATTERY OR
PROLONGED LOSS OF POWER.
Figure 5-3. telePilot Battery Replacement.
22
8/15/2002
Section 6 – Wiring
6-1. Wiring Diagrams.
Make sure that the installation includes the
proper alarms, horns, indicator lights and their
associated controls as required by local and
governmental regulations.
Your TELEPILOT system comes preprogrammed the following pages in this section
have individual wiring diagrams for different
crane configurations. Find the appropriate wiring
diagram and if necessary set the Configuration
Switch (SW3 in the transmitter) to match the
SW3 Transmitter Switch Settings shown in the
appropriate diagram. The location of the SW3
for Membrane and Pendant transmitters is shown
in Section 8-1. Servicing. Terminal designators
are marked on the wiring diagram corresponding
to designators found on the Receiver Board. For
terminal locations see Figure 8-1. Receiver
Layout. After selecting the appropriate motors
for each function remember to use the
appropriate label on your telePilot transmitter
for describing the appropriate command.
6-4. Single-Speed
Wiring.
Pendant
Transmitter
For the Single-Speed Pendant Transmitter the
only wiring configuration is the diagram in
Section 6. Wiring. Table 1, TR12 Single-Speed
Standard Configuration Hoist, Trolley and
Bridge.
6-5. 2-Speed Pendant Transmitter Wiring.
For the 2-Speed TR12 Pendant Transmitter the
functional labeling is different than the 2-Speed
Membrane. E/W and N/S are exchanged. By
setting dip switch SW3 position 1 in the “ON”
position the pushbuttons of the Pendant
Transmitter match the directional notations on
the 2-speed wiring diagrams in Section 6.
Wiring. Failure to turn switch SW3 position 1 to
“ON”
will
cause
EAST/WEST
and
NORTH/SOUTH to be exchanged respectively.
All other functions will remain the same.
For the Pendant and Membrane transmitters the
proper connections to use for the bridge and for
the trolley are best determined by that pair of
directional
designators
(North/South
or
East/West) best describes the crane’s movement.
Does the bridge travel East/West or
North/South? The trolley would use the other
directional pair as the bridge. Care should be
taken after a directional pair is selected to make
sure the specific motor directional inputs match
the desired direction of the bridge or trolley, i.e.,
if North/South is picked for the bridge make sure
the South traveling bridge motor directional is
wired to the South terminal of the unit.
6-6. Relay Sequencing.
When the second speed position is activated the
appropriate directional relay is still engaged.
6-7. Alarm After E-STOP.
Typically in the following wiring diagrams, the
bridge is shown as Motor 3 and Trolley as Motor
2. Since the labeling cannot be easily moved on
the Membrane Transmitter keypad, the two
directional pairs Motor 2 and 3 can be easily
exchanged by turning the dip switch SW3
position 1 in the Membrane Transmitter to
“ON”. See Section 7-6.8. Repositioning of
Membrane Transmitter Motion Switch Functions
for more details.
This is only for wiring configurations where the
Aux 3 (relay K12, output J5-6) is being used for
the Alarm function, placing a jumper on JU1 on
the Receiver Board will allow the alarm to
function after an E-STOP command. See Figure
8-1. Receiver Layout for jumper location.
6-8. Connecting Outputs To Drives.
MOV’s (transient protectors) are on all the
output relays to protect the relays from power
surges. MOV’s allow a small leakage current
that can affect some high impedance circuits.
When connecting output relays to drives, it may
be required to remove the MOV to prevent the
leakage current through the MOV from holding
in the drive. See Figure 8-1. Receiver Layout for
the location of the MOV's. The MOV’s are next
to the relays they protect. The MOV’s can be cut
6-2. Installation.
Follow Section 4. Installation Procedure for
instructions on how to install the receiver.
6-3. Alarms And Horns.
23
Section 6 – Wiring (Continued)
out of the circuit with a wire cutter. Remember
to do this with ALL power OFF on the crane and
all associated controls.
Legend
The following is the legend for the wiring
diagrams below:
An input with the terminal
number # matching the connector in the receiver.
6-9. Optional Transfer
Configurations.
K#
Matching relay contacts An output with the terminal
in radio receiver panel
number # matching the connector in the receiver.
by number.
Figure 6-1. Legend.
Switch
C#
Customer supplied
contactor coil with arc
suppressor in parallel.
Wiring
If a transfer switch is desired, a simple schematic
of an externally installed transfer switch
interface is shown on the next page. A complete
system drawing for this transfer switch is shown
on the following pages (see Figure 6-3A.). A
factory installed internal transfer switch is
available. A system drawing for this optional
factory installed internal transfer switch and
pigtail is shown on the following pages (See
Figure 6-3B.).
24
8/15/2002
Section 6 – Wiring (Continued)
10 Amp
Slo Blo
Fuse
K13 MR
MOV
Receiver Panel
N/C
N/C
J6-1
J6-2
J6-3
J6-4
J6-5
X1R
AC
X1
X1
INDICATES
TRANSFER SWITCH
IN RADIO MODE
J6-8
Optional
Transfer Switch
(2-pole doublethrow)
TS
TS
J7-2
J7-3
This connector used for
internal transfer switch
3P
Pendant
STOP
J7-1
TS
X1P
TS
J6-7
3R
TS
HOT
J6-6
MLC
RETURN
AC
X2
MAIN LINE
CONTACTOR
START
MLC
3P
TO PENDANT
COMMON
Figure 6-2. External Transfer Switch Wiring
25
8/15/2002
Figure 6-3A. External Transfer Switch System Wiring
Section 6 - Wiring (Continued)
26
Figure 6-3B. Optional Internal Transfer Switch System Wiring
Section 6 - Wiring (Continued)
27
Section 6 - Wiring (Continued)
TABLE 1 TR12 SINGLE-SPEED WIRING DIAGRAM.
STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
J5-3
K12
F6
J5-1
K11
F5
J4-4
K10
K9
F4
*Note
Jumper JU1, Receiver Board
for Alarm to function after
an E-Stop command. See
Figure 8-1. Receiver Layout
J3-4
F3
K7
K6
**Note
The outputs on this diagram
match the button designations
shown for the different Modes
shown in Figure 7.7 for the
Single-Speed Membrane and
telePilot transmitters
respectively. Page 69. F2
J2-4
K8
K5
K4
K3
K2
K1
MASTER RELAY
MAIN LINE CONTACTOR
Single Speed Transmitter Modes
Mode 1
Mode 2
Mode 3
C12
Alarm
C11
Light
C10
Bridge/
Trolley
DIR 2
P2
C9
Main Hoist
Up
Main Hoist
Up
C8
Bridge/
Trolley
DIR 1
P1
C7
Main Hoist
Down
Main Hoist
Down
C6
Aux Hoist
Up
Trolley /
Bridge
DIR 1
C5
Trolley /
Bridge
DIR 2
Aux Hoist
Down
C4
Aux Hoist
Down
C3
C2
Trolley /
Bridge
DIR 1
Aux Hoist
Up
Bridge/
Trolley
DIR 2
12
J5-6
J5-4
J5-2
J4-3
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
J2-1
C1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
28
Trolley /
Bridge
DIR 2
Bridge/
Trolley
DIR 1
10
11
Section 6 - Wiring (Continued)
TABLE 1 TR12 SINGLE-SPEED PROGRAMMING DIAGRAM.
STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE
OUTPUTS
J4-3
UP
DN
OUTPUTS
J3-3
J4-1
HOIST*
MOTOR 1
J2-2
J3-2
J4-2
Dir 2
OUTPUTS
J2-3
J3-1
1ST
1ST
TROLLEY*
MOTOR 2
1ST
BRIDGE*
MOTOR 3
1ST
Dir 2
1ST
1ST
AUX 4
AUX 5
AUX 6
MOTOR 2 CONNECTIONS
J3-3 TROLLEY DIR 1
J3-1 TROLLEY DIR 2
J3-4 HOT (J3-1, 2 & 3)
MOTOR 3 CONNECTIONS
J2-3 BRIDGE DIR 1
J2-1 BRIDGE DIR 2
J2-4 HOT (J2-1, 2 & 3)
INDEPENDENT CONNECTIONS
AUX 3 (HOT J4-4)
J3-2 AUX 2 (HOT J3-4)
AUX 4 (LATCHABLE S4-2)
J5-1 HOT AUX 4
AUX 6 (LATCHABLE S4-3)
J5-3 HOT AUX 6
AUX 5 ALARM
J5-5 HOT AUX 5
RECEIVER SWITCH SETTINGS SW3:
Dir 1
J2-1
INDEPENDENT OUTPUTS
J5-2
AUX 1
J5-6
AUX 2
J5-4
AUX 3
MOTOR 1 CONNECTIONS
J4-3 HOIST UP
J4-1 HOIST DOWN
J4-4 HOT (J4-1, 2 & 3)
J4-2
J5-2
J5-4
J5-6
Dir 1
J2-2 AUX 1 (HOT J2-4)
SW3 Position-5
ON
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in ON Position.
SINGLE SPEED ONLY TRANSMITTERS SWITCH SETTINGS
SINGLE SPEED telePilot USE PDA SCREEN (select single-speed transmitter style).
SINGLE SPEED MEMBRANE USE SW3 “C”,
SINGLE SPEED PENDANT USE SW “D”
TRANSMITTER SWITCH SETTINGS:
Position-5
OFF
1 2 3 4 5 6 7 8
Position -6
OFF
ON
Position -7
OFF
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to
define the motors differently.
29
Section 6 - Wiring (Continued)
TABLE 2(A) TR12 2-SPEED WIRING DIAGRAM.
STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
J5-3
F6
J5-1
F5
J4-4
F4
*Note:
Jumper JU1, Receiver Board
for Alarm to function after
an E-Stop command. See
Figure 8-1. Receiver Layout
J3-4
F3
The outputs match
the button labels
as defined in
Section 5-1.
J2-4
F2
MASTER
RELAY
MAIN LINE
CONTACTOR
J5-6
K12
C12
AUX 3
ALARM*
C11
AUX 2
(latchable S4-3)
C10
AUX 1
(latchable S4-2)
C9
MOTOR 1 (M1)
(M1) DIR 1
C8
(M1) 2ND SPD
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR 1
C5
(M2) 2ND SPD
C4
(M2) DIR 2
C3
MOTOR 3 (M3)
(M3) DIR 1
C2
(M3) 2ND SPD
C1
(M3) DIR 2
J5-4
K11
J5-2
K10
J4-3
K9
J4-2
K8
J4-1
K7
J3-3
K6
J3-2
K5
K4
J3-1
K3
J2-3
J2-2
K2
J2-1
K1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
30
Section 6 - Wiring (Continued)
TABLE 2(A) TR12 2-SPEED PROGRAMMING DIAGRAM.
STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE
OUTPUTS
J4-3
J4-2
J4-1
HOIST*
MOTOR 1
UP
2ND
1ST
DN
1ST
OUTPUTS
J3-3
J3-2
J3-1
2ND
TROLLEY*
MOTOR 2
J5-2
J5-4
J5-6
MOTOR 1 CONNECTIONS
J4-3 HOIST UP
J4-2 HOIST 2ND SPEED
J4-1 HOIST DOWN
J4-4 HOT (J4-1, 2 & 3)
Dir 1
2ND
Dir 2
1ST
OUTPUTS
J2-3
J2-2
J2-1
1ST 2ND
BRIDGE*
MOTOR 3
Dir 1
2ND
1ST
Dir 2
1ST
2ND
INDEPENDENT OUTPUTS
AUX 1
AUX 2
AUX 3 ALARM
MOTOR 2 CONNECTIONS
J3-3 TROLLEY DIR 1
J3-2 TROLLEY 2ND SPEED
J3-1 TROLLEY DIR 2
J3-4 HOT (J3-1, 2 & 3)
MOTOR 3 CONNECTIONS
J2-3 BRIDGE DIR 1
J2-2 BRIDGE 2ND SPEED
J2-1 BRIDGE DIR 2
J2-4 HOT (J2-1, 2 & 3)
INDEPENDENT CONNECTIONS
J5-2 AUX 1 (LATCHABLE S4-2)
J5-1
HOT AUX 1
J5-4 AUX 2 (LATCHABLE S4-3)
J5-3
HOT AUX 2
J5-6 AUX 3 ALARM
J5-5
HOT AUX 3 ALARM
TRANSMITTER SWITCH SETTINGS
telePilot USE PDA SCREEN (Program the configuration switches 5, 6 and 7 to OFF. Under “Main/Aux” select the
setting “Aux”).
MEMBRANE USE SW3 “C”
PENDANT, JLTX AND SLTX USE SW4 “D”
TRANSMITTER SWITCH SETTINGS:
Position-5
Position -6
Position -7
OFF
OFF
OFF
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
31
Section 6 - Wiring (Continued)
TABLE 2(B) TR12 2-SPEED WIRING DIAGRAM.
2-SPEED with DIRECTIONAL CONTROLS: ALL MOTIONS
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
J5-3
F6
J5-1
F5
J4-4
F4
K12
K11
K10
K9
K8
K7
J3-4
F3
The outputs match the
button labels as defined in
Section 5-1. except there
are no AUXs.
J2-4
F2
K6
K5
K4
K3
K2
K1
MASTER
RELAY
MAIN LINE
CONTACTOR
J5-6
C12
MOTOR 1
DIR1/DIR2
C11
MOTOR 2
DIR1/DIR2
C10
MOTOR 3
DIR1/DIR2
C9
MOTOR 1 (M1)
(M1) DIR 1
C8
(M1) 2ND SPD
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR1
C5
(M2) 2ND SPD
C4
(M2) DIR 2
C3
MOTOR 3 (M3)
(M3) DIR 1
C2
(M3) 2ND SPD
C1
(M3) DIR 2
J5-4
J5-2
J4-3
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
J2-1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
32
Section 6 - Wiring (Continued)
TABLE 2(B) TR12 2-SPEED PROGRAMMING DIAGRAM.
2-SPEED with DIRECTIONAL CONTROLS: ALL MOTIONS
OUTPUTS
J4-3
J4-2
J4-1
J5-6
HOIST*
MOTOR 1
UP
2ND
1ST
DN
1ST
MOTOR 1 CONNECTIONS
J4-3 HOIST UP
J4-2 HOIST 2ND SPEED
J4-1 HOIST DOWN
J4-4 HOT (J4-1, 2 & 3)
J5-6 HOIST DIR1/DIR2
J5-5 HOT HOIST DIR1/DIR2
OUTPUTS
J3-3
J3-2
J3-1
J5-4
2ND
TROLLEY*
MOTOR 2
Dir 1
2ND
Dir 2
1ST
OUTPUTS
J2-3
J2-2
J2-1
J5-2
1ST 2ND
BRIDGE*
MOTOR 3
Dir 1
2ND
1ST
Dir 2
1ST
2ND
MOTOR 2 CONNECTIONS
MOTOR 3 CONNECTIONS
J3-3 TROLLEY DIR 1
J2-3 BRIDGE DIR 1
J3-2 TROLLEY 2ND SPEED
J2-2 BRIDGE 2ND SPEED
J3-1 TROLLEY DIR 2
J2-1 BRIDGE DIR 2
J3-4 HOT (J3-1, 2 & 3)
J2-4 HOT (J2-1, 2 & 3)
J5-4 TROLLEY DIR1/DIR2
J5-2 BRIDGE DIR1/DIR2
J5-3 HOT TROLLEY DIR1/DIR2
J5-1 HOT BRIDGE DIR1/DIR2
NOTE
CHECK GOVERNMENTAL AND LOCAL REGULATIONS ON THE REQUIREMENTS OF HORNS OR ALARMS
BEFORE USING THIS CONFIGURATION, AS THERE IS NOT A SEPARATE ALARM CONTROL.
TRANSMITTER SWITCH SETTINGS
telePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).
MEMBRANE USE SW3 “C”
PENDANT, JLTX AND SLTX USE SW4 “D”
TRANSMITTER SWITCH SETTINGS:
Position-5
Position -6
Position -7
ON
OFF
OFF
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
33
Section 6 - Wiring (Continued)
TABLE 2(C) TR12 2-SPEED WIRING DIAGRAM.
2-SPEED, 2-WINDINGS: ALL MOTIONS
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
J5-3
F6
J5-1
F5
J4-4
F4
K12
K11
K10
K9
K8
K7
J3-4
F3
The outputs match the
button labels as defined
in Section 5-1. except
there are no AUXs.
J2-4
F2
K6
K5
K4
K3
K2
K1
MASTER
RELAY
MAIN LINE
CONTACTOR
J5-6
C12
MOTOR 1
ND
2 SPD
C11
MOTOR 2
ND
2 SPD
C10
MOTOR 3
ND
2 SPD
C9
MOTOR 1 (M1)
(M1) DIR 1
C8
(M1) 1ST SPD
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR 1
C5
(M2) 1ST SPD
C4
(M2) DIR 2
C3
MOTOR 3 (M3)
(M3) DIR 1
C2
(M3) 1ST SPD
C1
(M3) DIR 2
J5-4
J5-2
J4-3
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
J2-1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
34
Section 6 - Wiring (Continued)
TABLE 2(C) TR12 2-SPEED PROGRAMMING DIAGRAM.
2-SPEED, 2-WINDINGS: ALL MOTIONS
OUTPUTS
J4-3
J4-2
J4-1
J5-6
HOIST*
MOTOR 1
UP
2ND
1ST
DN
1ST
MOTOR 1 CONNECTIONS
J4-3 HOIST UP
J4-2 HOIST 1 ST SPEED
J4-1 HOIST DOWN
J4-4 HOT (J4-1, 2 & 3)
J5-6 HOIST 2ND SPEED
J5-5 HOT HOIST 2 ND SPEED
OUTPUTS
J3-3
J3-2
J3-1
J5-4
2ND
TROLLEY*
MOTOR 2
Dir 1
2ND
Dir 2
1ST
OUTPUTS
J2-3
J2-2
J2-1
J5-2
1ST 2ND
BRIDGE*
MOTOR 3
Dir 1
2ND
1ST
Dir 2
1ST
2ND
MOTOR 2 CONNECTIONS
MOTOR 3 CONNECTIONS
J3-3 TROLLEY DIR 1
J2-3 BRIDGE DIR 1
J3-2 TROLLEY 1 ST SPEED
J2-2 BRIDGE 1 ST SPEED
J3-1 TROLLEY DIR 2
J2-1 BRIDGE DIR 2
J3-4 HOT (J3-1, 2 & 3)
J2-4 HOT (J2-1, 2 & 3)
J5-4 TROLLEY 2ND SPEED
J5-2 BRIDGE 2ND SPEED
ND
J5-3 HOT TROLLEY 2 SPEED
J5-1 HOT BRIDGE 2ND SPEED
NOTE
CHECK GOVERNMENTAL AND LOCAL REGULATIONS ON THE REQUIREMENTS OF HORNS OR ALARMS
BEFORE USING THIS CONFIGURATION, AS THERE IS NOT A SEPARATE ALARM CONTROL.
TRANSMITTER SWITCH SETTINGS
telePilot USE PDA SCREEN (Program the configuration switches to match the pattern and position shown).
MEMBRANE USE SW3 “C”
PENDANT, JLTX AND SLTX USE SW4 “D”
TRANSMITTER SWITCH SETTINGS:
Position-5
Position -6
Position -7
OFF
ON
OFF
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
35
Section 6 - Wiring (Continued)
TABLE 2(D) TR12 2-SPEED WIRING DIAGRAM.
ACCO CONTROLS: ALL MOTIONS
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
J5-3
F6
J5-1
F5
J4-4
F4
K12
K11
K10
K9
K8
K7
J3-4
F3
The outputs match the
button labels as defined
in Section 5-1. except
there are no AUXs.
J2-4
F2
K6
K5
K4
K3
K2
K1
MASTER
RELAY
MAIN LINE
CONTACTOR
J5-6
C12
MOTOR 1
ND
2 SPD DIR 2
C11
MOTOR 2
ND
2 SPD DIR 2
C10
MOTOR 3
ND
2 SPD DIR 2
C9
MOTOR 1 (M1)
(M1) DIR 1
C8
(M1) 2ND SPD
DIR 1
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR 1
C5
(M2) 2ND SPD
DIR 1
C4
(M2) DIR 2
C3
MOTOR 1 (M3)
(M3) DIR 1
C2
(M3) 2ND SPD
DIR 1
C1
(M3) DIR 2
J5-4
J5-2
J4-3
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
J2-1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
36
Section 6 - Wiring (Continued)
TABLE 2(D) TR12 2-SPEED PROGRAMMING DIAGRAM.
ACCO CONTROLS: ALL MOTIONS
OUTPUTS
J4-3
J4-2
J4-1
J5-6
HOIST*
MOTOR 1
UP
2ND
1ST
DN
1ST
OUTPUTS
J3-3
J3-2
J3-1
J5-4
2ND
TROLLEY*
MOTOR 2
Dir 1
2ND
Dir 2
1ST
OUTPUTS
J2-3
J2-2
J2-1
J5-2
1ST 2ND
BRIDGE*
MOTOR 3
Dir 1
2ND
1ST
Dir 2
1ST
2ND
MOTOR 1 CONNECTIONS
MOTOR 2 CONNECTIONS
MOTOR 3 CONNECTIONS
J4-3 HOIST UP
J3-3 TROLLEY DIR 1
J2-3 BRIDGE DIR 1
J4-2 HOIST 2ND SPEED DIR 1
J3-2 TROLLEY 2ND SPEED DIR 1
J2-2 BRIDGE 2ND SPEED DIR 1
J4-1 HOIST DOWN
J3-1 TROLLEY DIR 2
J2-1 BRIDGE DIR 2
J4-4 HOT (J4-1, 2 & 3)
J3-4 HOT (J3-1, 2 & 3)
J2-4 HOT (J2-1, 2 & 3)
J5-6 HOIST 2ND SPEED DIR 2
J5-4 TROLLEY 2ND SPEED DIR 2
J5-2 BRIDGE 2ND SPEED DIR 2
ND
ND
J5-5 HOT HOIST 2 SPD DIR 2 J5-3 HOT TROLLEY 2 SPD DIR 2 J5-1 HOT BRIDGE 2ND SPD DIR 2
NOTE
CHECK GOVERNMENTAL AND LOCAL REGULATIONS ON THE REQUIREMENTS OF HORNS OR ALARMS
BEFORE USING THIS CONFIGURATION, AS THERE IS NOT A SEPARATE ALARM CONTROL.
TRANSMITTER SWITCH SETTINGS
telePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).
MEMBRANE USE SW3 “C”
PENDANT, JLTX AND SLTX USE SW4 “D”
TRANSMITTER SWITCH SETTINGS:
Position-5
Position -6
Position -7
ON
ON
OFF
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
37
Section 6 - Wiring (Continued)
TABLE 2(E) TR12 2-SPEED WIRING DIAGRAM.
P&H: 2-SPEED, 2-WINDINGS for HOIST and TROLLEY;
STANDARD BRIDGE
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
J5-3
F6
J5-1
F5
J4-4
F4
K12
K11
K10
K9
K8
K7
J3-4
F3
The outputs match the
button labels as defined
in Section 5-1. except
there is only AUX 1.
J2-4
F2
K6
K5
K4
K3
K2
K1
MASTER
RELAY
MAIN LINE
CONTACTOR
J5-6
C12
MOTOR 1
ND
2 SPD
C11
MOTOR 2
ND
2 SPD
C10
AUX 1
(latchable S4-2)
C9
MOTOR 1 (M1)
(M1) DIR 1
C8
(M1) 2ND SPD
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR 1
C5
(M2) 1ST SPD
C4
(M2) DIR 2
C3
MOTOR 3 (M3)
(M3) DIR 1
C2
(M3) 1ST SPD
C1
(M3) DIR 2
J5-4
J5-2
J4-3
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
J2-1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
38
Section 6 - Wiring (Continued)
TABLE 2(E) TR12 2-SPEED PROGRAMMING DIAGRAM.
P&H: 2-SPEED, 2-WINDINGS for HOIST and TROLLEY;
STANDARD BRIDGE
OUTPUTS
J4-3
J4-2
J4-1
J5-6
HOIST*
MOTOR 1
UP
2ND
1ST
DN
1ST
OUTPUTS
J3-3
J3-2
J3-1
J5-4
2ND
TROLLEY*
MOTOR 2
J5-2
MOTOR 1 CONNECTIONS
J4-3 HOIST UP
J4-2 HOIST 1ST SPEED
J4-1 HOIST DOWN
J4-4 HOT (J4-1, 2 & 3)
J5-6 HOIST 2ND SPEED
J5-5 HOT HOIST 2 ND SPEED
Dir 1
2ND
Dir 2
1ST
OUTPUTS
J2-3
J2-2
J2-1
1ST 2ND
BRIDGE*
MOTOR 3
Dir 1
2ND
1ST
Dir 2
1ST
2ND
INDEPENDENT OUTPUTS
AUX 1
MOTOR 2 CONNECTIONS
J3-3 TROLLEY DIR 1
J3-2 TROLLEY 1ST SPEED
J3-1 TROLLEY DIR 2
J3-4 HOT (J3-1, 2 & 3)
J5-4 TROLLEY 2ND SPEED
J5-3 HOT TROLLEY 2ND SPEED
MOTOR 3 CONNECTIONS
J2-3 BRIDGE DIR 1
J2-2 BRIDGE 2ND SPEED
J2-1 BRIDGE DIR 2
J2-4 HOT (J2-1, 2 & 3)
INDEPENDENT CONNECTIONS
J5-2 AUX 1 (LATCHABLE S4-2)
J5-1 HOT AUX 1
TRANSMITTER SWITCH SETTINGS
telePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).
MEMBRANE USE SW3 “C”
PENDANT, JLTX AND SLTX USE SW4 “D”
TRANSMITTER SWITCH SETTINGS:
Position-5
Position -6
Position -7
OFF
OFF
ON
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
39
Section 6 - Wiring (Continued)
TABLE 2(F) TR12 2-SPEED WIRING DIAGRAM.
P&H: 2-SPEED, 2-WINDINGS for HOIST;
STANDARD TROLLEY and BRIDGE
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
J5-3
F6
J5-1
F5
J4-4
F4
K12
K11
K10
K9
K8
K7
J3-4
F3
The outputs match the
button labels as defined in
Section 5-1. except there is
only AUX 1 and AUX 2.
J2-4
F2
K6
K5
K4
K3
K2
K1
MASTER
RELAY
MAIN LINE
CONTACTOR
J5-6
C12
MOTOR 1
ND
2 SPD
C11
AUX 2
(latchable S4-3)
C10
AUX 1
(latchable S4-2)
C9
MOTOR 3 (M1)
(M1) DIR 1
C8
(M1) 2ND SPD
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR 1
C5
(M2) 2ND SPD
C4
(M2) DIR 2
C3
MOTOR 1 (M3)
(M3) DIR 1
C2
(M3) 1ST SPD
C1
(M3) DIR 2
J5-4
J5-2
J4-3
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
J2-1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
40
Section 6 - Wiring (Continued)
TABLE 2(F) TR12 2-SPEED PROGRAMMING DIAGRAM.
P&H: 2-SPEED, 2-WINDINGS for HOIST;
STANDARD TROLLEY and BRIDGE
OUTPUTS
J4-3
J4-2
J4-1
J5-6
HOIST*
MOTOR 1
UP
2ND
1ST
DN
1ST
OUTPUTS
J3-3
J3-2
J3-1
2ND
TROLLEY*
MOTOR 2
J5-2
J5-4
MOTOR 1 CONNECTIONS
J4-3 HOIST UP
J4-2 HOIST 1ST SPEED
J4-1 HOIST DOWN
J4-4 HOT (J4-1, 2 & 3)
J5-6 HOIST 2ND SPD
J5-5 HOT HOIST 2 ND SPEED
Dir 1
2ND
Dir 2
1ST
OUTPUTS
J2-3
J2-2
J2-1
1ST 2ND
BRIDGE*
MOTOR 3
Dir 1
2ND
1ST
Dir 2
1ST
2ND
INDEPENDENT OUTPUTS
AUX 1
AUX 2
MOTOR 2 CONNECTIONS
J3-3 TROLLEY DIR 1
J3-2 TROLLEY 2ND SPEED
J3-1 TROLLEY DIR 2
J3-4 HOT (J3-1, 2 & 3)
MOTOR 3 CONNECTIONS
J2-3 BRIDGE DIR 1
J2-2 BRIDGE 2ND SPEED
J2-1 BRIDGE DIR 2
J2-4 HOT (J2-1, 2 & 3)
INDEPENDENT CONNECTIONS
J5-2 AUX 1 (LATCHABLE S4-2)
J5-1 HOT AUX 1
J5-4 AUX 2 (LATCHABLE S4-3)
J5-3 HOT AUX 2
TRANSMITTER SWITCH SETTINGS
telePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).
MEMBRANE USE SW3 “C”
PENDANT, JLTX AND SLTX USE SW4 “D”
TRANSMITTER SWITCH SETTINGS:
Position-5
Position -6
Position -7
ON
OFF
ON
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
41
Section 6 - Wiring (Continued)
TABLE 2(G) TR12 2-SPEED WIRING DIAGRAM.
DEMAG: 2-SPEED, 2-WINDINGS for HOIST;
STANDARD TROLLEY and BRIDGE
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
J5-3
F6
J5-1
F5
J4-4
F4
K12
K11
K10
K9
K8
K7
J3-4
F3
The outputs match
the button labels as
defined in Section 51. except there is only
AUX 1 and AUX 2.
J2-4
F2
K6
K5
K4
K3
K2
K1
MASTER
RELAY
MAIN LINE
CONTACTOR
J5-6
C12
MOTOR 1
ND
2 SPD DIR 2
C11
AUX 2
(latchable S4-3)
C10
AUX 1
(latchable S4-2)
C9
MOTOR 1 (M1)
(M1) DIR 1
C8
(M1) 2ND SPD
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR 1
C5
(M2) 2ND SPD
C4
(M2) DIR 2
C3
MOTOR 3 (M3)
(M3) DIR 1
C2
(M3) 2ND SPD
DIR 1
C1
(M3) DIR 2
J5-4
J5-2
J4-3
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
J2-1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
42
Section 6 - Wiring (Continued)
TABLE 2(G) TR12 2-SPEED PROGRAMMING DIAGRAM.
DEMAG: 2-SPEED, 2-WINDINGS for HOIST;
STANDARD TROLLEY and BRIDGE
UP
OUTPUTS
J4-3
J4-2
J4-1
J5-6
HOIST*
MOTOR 1
ND
1ST
DN
ST
OUTPUTS
J3-3
J3-2
J3-1
ND
TROLLEY*
MOTOR 2
J5-2
J5-4
Dir 1
2ND
Dir 2
1ST
OUTPUTS
J2-3
J2-2
J2-1
1ST 2ND
BRIDGE*
MOTOR 3
Dir 1
2ND
1ST
Dir 2
1ST
2ND
INDEPENDENT OUTPUTS
AUX 1
AUX 2
MOTOR 1 CONNECTIONS
MOTOR 2 CONNECTIONS
J4-3 HOIST UP
J3-3 TROLLEY DIR 1
J3-2 TROLLEY 2ND SPEED
J4-2 HOIST 2ND SPEED DIR 1
J4-1 HOIST DOWN
J3-1 TROLLEY DIR 2
J4-4 HOT (J4-1, 2 & 3)
J3-4 HOT (J3-1, 2 & 3)
J5-6 HOIST 2ND SPEED DIR 2
J5-5 HOT HOIST 2 ND SPEED DIR 2
MOTOR 3 CONNECTIONS
J2-3 BRIDGE DIR 1
J2-2 BRIDGE 2ND SPEED
J2-1 BRIDGE DIR 2
J2-4 HOT (J2-1, 2 & 3)
INDEPENDENT CONNECTIONS
J5-2 AUX 1 (LATCHABLE S4-2)
J5-1 HOT AUX 1
J5-4 AUX 2 (LATCHABLE S4-3)
J5-3 HOT AUX 2
TRANSMITTER SWITCH SETTINGS
telePilot USE PDA SCREEN (Program the configuration switches 5, 6 & 7 to match the settings shown below).
MEMBRANE USE SW3 “C”
PENDANT, JLTX AND SLTX USE SW4 “D”
TRANSMITTER SWITCH SETTINGS:
Position-5
Position -6
Position -7
OFF
ON
ON
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
43
Section 6 - Wiring (Continued)
TABLE 2(H) TR12 2-SPEED WIRING DIAGRAM.
STANDARD 2-SPEED 4 MOTOR SYSTEM
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J6-5
F7
J5-5
F6
J5-3
F5
J5-1
F4
J4-4
K12
K11
K10
K9
K8
K7
J3-4
F3
The outputs match the telePilot
button labels in Fig. 5-1. except
there are no AUXs. And the
AUX 3 position selects “A”
Motor 1 and/or “B” Motor 4 for
the upper most right hand side
pair of two speed buttons.
J2-4
F2
K6
K5
K4
K3
K2
K1
J5-6
MASTER
RELAY
MAIN LINE
CONTACTOR
C12
MOTOR 4 (M4)
(M4) DIR 1
C11
(M4) 2ND SPD
C10
(M4) DIR 2
C9
MOTOR 1 (M1)
(M1) DIR 1
C8
(M1) 2ND SPD
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR 1
C5
(M2) 2ND SPD
C4
(M2) DIR 2
C3
MOTOR 3 (M3)
(M3) DIR 1
C2
(M3) 2ND SPD
DIR 1
C1
(M3) DIR 2
J5-4
J5-2
J4-3
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
J2-1
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
44
Section 6 - Wiring (Continued)
TABLE 2(H) TR12 2-SPEED PROGRAMMING DIAGRAM.
STANDARD 2-SPEED 4 MOTOR SYSTEM
OUTPUTS
J4-3
J4-2
J4-1
MAIN HOIST*
MOTOR 1
UP
2ND
1ST
DN
1ST
OUTPUTS
J3-3
J3-2
J3-1
2ND
TROLLEY*
MOTOR 2
OUTPUTS
J5-6
J5-4
J5-2
AUX HOIST*
MOTOR 4
Dir 1
2ND
1ST
UP
2ND
Dir 2
Dir 1
OUTPUTS
J2-3
J2-2
J2-1
1ST 2ND
BRIDGE*
MOTOR 3
2ND
1ST
Dir 2
1ST
2ND
DN
1ST
1ST
MOTOR 1 CONNECTIONS
MOTOR 2 CONNECTIONS
J4-3 MAIN HOIST UP
J3-3 TROLLEY DIR 1
J3-2 TROLLEY 2ND SPEED
J4-2 MAIN HOIST 2ND SPEED
J4-1 MAIN HOIST DOWN
J3-1 TROLLEY DIR 2
J4-4 HOT (J4-1, 2 & 3)
J3-4 HOT (J3-1, 2 & 3)
2ND
MOTOR 3 CONNECTIONS
J2-3 BRIDGE DIR 1
J2-2 BRIDGE 2ND SPEED
J2-1 BRIDGE DIR 2
J2-4 HOT (J2-1, 2 & 3)
MOTOR 4 CONNECTIONS
J5-6 AUX HOIST UP
J5-5 HOT AUX HOIST UP
J5-4 AUX HOIST 2ND SPEED
J5-3 HOT AUX HOIST 2ND SPEED
J5-2 AUX HOIST DOWN
J5-1 HOT AUX HOIST DOWN
NOTE
CHECK GOVERNMENTAL AND LOCAL REGULATIONS ON THE REQUIREMENTS OF HORNS OR ALARMS
BEFORE USING THIS CONFIGURATION, AS THERE IS NOT A SEPARATE ALARM CONTROL.
TRANSMITTER SWITCH SETTINGS (This configuration does not apply to the Membrane transmitter).
telePilot USE PDA SCREEN (Program the configuration switches 5, 6 and 7 to OFF. Under “Main/Aux” select the
setting “Motor”).
PENDANT, JLTX AND SLTX TRANSMITTER SWITCH SW4 “D” SETTINGS:
Position-1
Position-2
Position-5
Position -6
Position –7
OFF
ON
OFF
OFF
OFF
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
45
Section 6 - Wiring (Continued)
TABLE 2(I) TR12 2-SPEED WIRING DIAGRAM.
STANDARD 2-SPEED 3, 4 & 5 MOTOR SYSTEM using SELECT
External jumper
in J6 connector
HOT
J6-2
K13
F8
RETURN
J6-3
MLC
J6-4
J5-5
J6-5
F7
K12
J5-6
C12
J5-3
F6
J5-1
F5
J4-4
F4
*Note:
Jumper JU1, Receiver Board
for Alarm to function after
an E-Stop command. See
Figure 8-1. Receiver Layout
J3-4
F3
The outputs match the telePilot
button labels in Fig. 5-1. except
AUX 2 is Alarm. And the AUX 3
position selects “A” Select 1
and/or “B” Select 2 set of relays
respectively.
K11
K10
K9
K8
K7
K6
K5
K4
K3
J2-4
MASTER RELAY
MAIN LINE
CONTACTOR
F2
K2
ALARM*
J5-4
C11
SELECT 1
C10
SELECT 2
J5-2
J4-3
C9
MOTOR 1 (M1)
(M1) DIR 1
C8
(M1) 2ND SPD
C7
(M1) DIR 2
C6
MOTOR 2 (M2)
(M2) DIR 1
C5
(M2) 2ND SPD
C4
(M2) DIR 2
C3
MOTOR 3 (M3)
(M3) DIR 1
J4-2
J4-1
J3-3
J3-2
J3-1
J2-3
J2-2
C2
K1
AUX 3 (AUX 2 position
on telePilot transmitter)
(M3) 2ND SPD
J2-1
C1
(M3) DIR 2
Receiver Panel
J7-3
J7-2
J7-1
J6-8
J6-7
J6-6
J6-5
J6-4
J6-3
J6-2
J6-1
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-4
J4-3
J4-2
J4-1
J3-4
J3-3
J3-2
J3-1
J2-4
J2-3
J2-2
J2-1
J1-3
J1-2
J1-1
46
Section 6 - Wiring (Continued)
TABLE 2(I) TR12 2-SPEED PROGRAMMING DIAGRAM.
STANDARD 2-SPEED 3, 4 & 5 MOTOR SYSTEM using SELECT
OUTPUTS
J4-3
J4-2
J4-1
UP
MAIN HOIST* 2ND
MOTOR 1
1ST
DN
1ST
OUTPUTS
J3-3
J3-2
J3-1
2ND
J5-2
J5-4
J5-6
TROLLEY*
MOTOR 2
Dir 1
2ND
Dir 2
1ST
1ST 2ND
OUTPUTS
J2-3
J2-2
J2-1
BRIDGE*
MOTOR 3
Dir 1
2ND
1ST
Dir 2
1ST
2ND
INDEPENDENT OUTPUTS
SELECT 2
SELECT 1
AUX 3 ALARM
MOTOR 1 CONNECTIONS
MOTOR 2 CONNECTIONS
J4-3 MAIN HOIST UP
J3-3 TROLLEY DIR 1
J3-2 TROLLEY 2ND SPEED
J4-2 MAIN HOIST 2ND SPEED
J4-1 MAIN HOIST DOWN
J3-1 TROLLEY DIR 2
J4-4 HOT (J4-1, 2 & 3)
J3-4 HOT (J3-1, 2 & 3)
MOTOR 3 CONNECTIONS
J2-3 BRIDGE DIR 1
J2-2 BRIDGE 2ND SPEED
J2-1 BRIDGE DIR 2
J2-4 HOT (J2-1, 2 & 3)
INDEPENDENT CONNECTIONS
J5-2 SELECT 2
J5-1 HOT SELECT 2
J5-4 SELECT 1
J5-3 HOT SELECT 1
J5-6 AUX 3 ALARM
J5-5 HOT AUX 3 ALARM
TRANSMITTER SWITCH SETTINGS (This configuration does not apply to the Membrane transmitter).
telePilot USE PDA SCREEN (Program the configuration switches 5, 6 and 7 to OFF. Under “Main/Aux” select the
word “Select”).
PENDANT, JLTX AND SLTX TRANSMITTER SWITCH SW4 “D” SETTINGS:
Position-1
Position-2
Position-5
Position -6
Position –7
ON
ON
OFF
OFF
OFF
1 2 3 4 5 6 7 8
ON
For these switch
positions see
previous section.
OFF
Indicates Switch in OFF Position.
*NOTE: Hoist, Trolley and Bridge are listed here as traditional configurations, the installer may choose to define the
motors differently.
Additional programming available:
The select function can be inverted by turning switch position 4 to ON (the Configuration Switch on the telePilot or SW4
“D” for the Pendant, JLTX and SLTX).
Tandem select operation, both select 1 and 2 on at the same time, can be disabled by un-checking the box marked
“Tandem” on the telePilot or turning on the Configuration Switch SW 4 “D” for the Pendant, JLTX and SLTX.
47
Section 7 – Programming
7-1. Access Code Programming.
telePilot
Transmitter
B ON 8
OFF
OFF
Receiver access code
B OFF 1
SW2
OFF
ON
Indicates switch in OFF position
B ON 8
OFF
1 B1
A1
ON 8
Pendant Transmitter
A OFF 1
SW2 ON
OFF
SW1
ON
Membrane
Transmitter
SW1
TR12 Receiver
SW1
OFF 1
ON
SW2
NOTE
OFF 1
FOR
THE
MEMBRANE,
PENDANT
TRANSMITTER AND RECEIVER. DO NOT
USE A PENCIL TO TOGGLE THE
SWITCHES. THE LOOSE GRAPHITE FROM
THE PENCIL CAN DAMAGE THE SWITCH.
ON
Access Code Switches
Sample access code only, do not use
MODEL # -10KXXXXXXXX
S/N=XXXXXXXXXXXXXXXXX
ACCESS CODE SETTING
01000111
01100010
FREQ : = AK01
J # = XXXXX
WARNING
TWO OPERATIONAL TRANSMITTERS
WITH THE SAME ACCESS CODES OPERATING AT THE SAME TIME IS A DEFINITE
SAFETY HAZARD. FAILURE TO FOLLOW
THIS WARNING COULD RESULT IN
SERIOUS INJURY OR DEATH AND
DAMAGE TO EQUIPMENT.
Sample Me mbrane or Pendant Transmitter
Access Code Label
Sample access code only do not use
7-1.2.
Figure 7-1. Access Code Setting.
(A dot on a switch position or a “1” in the
label is an indication that the respective
switch position should be ON).
7-1.1.
Changing Transmitter Access Codes.
7-1.2.1. telePilot Access Code Programming.
For detailed instructions on setting parameters
including access codes see Section 7-8. telePilot
Programming.
Programming Access Codes.
The access code is set at the factory and should
not be changed unless absolutely necessary. If
you are reprogramming a spare or new
transmitter make sure the other transmitter is
securely taken out of service.
7-1.2.2. Membrane Transmitter Access Code
Setting.
Also a label on the transmitter lists the access
code settings inside. The positions on the
transmitter label match the switch settings. The
“1” by A1 means the switch position A1 should
be ”ON” and “0” means A1 should be “OFF”.
Remove the 6 screws on the front cover. Lift out
switch-pad, logic board and turn logic board
over.
Open the back battery door and take out the
batteries as a safety precaution.
Locate the dip switches marked “A” and “B”.
See Figure 8-3. Membrane Transmitter M/C
Module E10635. With a pen or pointed object
toggle the switches to match the Access Code on
48
Section 7 – Programming (Continued)
the receiver. A dot on the switch diagram means
that switch position is ON. For Membrane
transmitters the access code positions A1-A4 can
be accessed through the battery compartment.
outside of the transmitter, take note that positions
“A” and “B” number from the left 1 through 8.
Reassemble unit; replace the batteries and test.
IN EVENT PROGRAMMING OF ACCESS
CODES IS REQUIRED, TAKE SPECIAL
CARE TO CORRECTLY LOCATE ACCESS
CODE SWITCHES A AND B. LOOK FOR
THE LABELS A AND B ON THE PRINTED
CIRCUIT BOARD NEAR THE RESPECTIVE
SWITCHES. DETERMINE THEIR ORIENTATION. THE SWITCHES MAY NUMBER
FROM LEFT TO RIGHT OR RIGHT TO LEFT.
LOOK FOR THE NUMBERING ON THE
SWITCHES. MATCH ACCESS CODES A1,
A2, - -- B1, B2 ETC.
NOTE
7-1.2.3. Pendant Transmitter Access Code
Setting.
Open the back battery door and take out the
batteries as a safety precaution.
Remove the 8 screws on the front cover. Turn
transmitter over and remove back cover.
Locate the dip switches marked “A” and “B”.
See Figure 8-4. Pendant Transmitter M/C
Module E10636. With a pen or pointed object
toggle the switches to match the Pendant
Transmitter Code Diagram on the door of the
receiver. A dot on the switch diagram means that
switch position is ON.
After changing the access code, test the receiver
(s) with a matching transmitter. (If the red LED
DS9 comes ON in either receiver the code does
not match, recheck the access code settings).
Reassemble unit; replace the batteries and test.
WARNING
THE ACCESS CODES IN THE RECEIVER
ARE UNIQUE AND FACTORY PRESET. DO
NOT CHANGE THESE ACCESS CODES
UNLESS YOU ARE REPLACING AN EXISTING RECEIVER AND ITS ACCESS CODE.
CHANGING THIS CODE COULD MAKE IT
COMMON WITH ANOTHER RECEIVER
ACCESS CODE, WHICH COULD MOVE
ANOTHER CRANE. NO TWO SYSTEMS IN
ANY LOCATION SHOULD EVER HAVE
THE SAME ACCESS CODES INDEPENDENT
OF FREQUENCY. FAILURE TO FOLLOW
THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
WARNING
AFTER CHANGING THE ACCESS CODES
ON THE TRANSMITTER, TEST THE UNIT
BY TURNING IT ON AND OFF NEAR THE
APPROPRIATE RECEIVER. IF THE RECEIVER DOES NOT RESPOND, DO NOT
ACTIVATE A FUNCTION BUTTON! THE
TRANSMITTER MAY HAVE THE WRONG
ACCESS CODE, WHICH COULD MOVE
ANOTHER CRANE.
RE-CHECK
THE
ACCESS CODE IN THE TRANSMITTER
AND RETEST. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
7-1.3.
Receiver Access Code Setting.
The access code is preset at the factory and
should not be changed unless absolutely
necessary. The access code switches are labeled
“B” and “A”. See Figure 8-1. Receiver Layout
for switch location.
The programming in the receiver(s) must match
the transmitter. If looking at the label on the
49
Section 7 – Programming (Continued)
Red RF Receiver “ON” LED
7-2. Receiver Freque ncy Programming.
Red Channel Counting LED
The TR12 receiver is equipped with a frequency
synthesizer that allows frequencies to be easily
changed without retuning. Normally the
frequency does not have to be changed; the unit
comes programmed to a specific frequency listed
on the Frequency and Access Code Label on the
TR12 receiver door.
7-2.1. RF
Synthesizer.
Receiver
Board
Programming
Pins
Green Count Separating LED
Freque ncy
Located in the TR12 receiver is the RF Receiver
Board. The circuitry on this board contains a
digital oscillator and synthesizer that are
controlled by a microprocessor. This eliminates
the need for specific crystals to change
frequencies. A pair of programming pins allows
the unit to be reprogrammed in the field to a
different channel. The on board microprocessor
automatically retunes the RF receiver when the
channel is changed; no retuning or any other
adjustment is required.
7-2.2.
Reading The Channel (Freque ncy).
Using Figure 8-1. Receiver Layout. locate the
RF Receiver Board. Locate the Top Viewing
Window (see Figure 7-2. RF Receiver Board).
Looking in the Top Viewing Window close to
the edge of the board is a red LED that, with the
power to the receiver ON, is constantly lit. This
indicates the RF Receiver Board is ON and
working. Looking farther back into the Top
Viewing window there are two flashing LEDs, a
red one and a green one. These LEDs flash
repeatedly and slowly so allow some time to see
them flash. These flashing LEDs indicate the
channel (frequency) the unit is receiving.
Top Viewing Window
RF Receiver Board
Top View
RF Receiver Board
Side View
Figure 7-2. RF Receiver Board.
The repeated sequence for reading channel 4 is:
Long pause, green, red, red, red, red, short pause
green, green, (no red flash, zero).
The repeated sequence for reading channel 12 is:
Long pause, green, red, red, short pause, green,
green, red.
Other examples are (equals count):
AK01 (1): green, red, short pause, green, green.
AK02 (2): green, red, red, short pause, green,
green.
AK05 (5): green, red, red, red, red, red,
short pause, green, green.
AK07 (7): green, red, red, red, red, red, red, red
short pause, green, green.
AK10 (10): green, short pause, green, green, red.
AK11 (11): green, red, short pause, green, green,
red.
AK14 (14): green, red, red, red, red, short pause,
green, green, red.
AK20 (20): green, green, green, red, red.
AKA06 (27): green, red, red, red, red, red, red,
red, short pause, green, green, red, red.
The counting is done in two digits, where the
two digits indicate channel number. The red
LED counts (flashes) the channel number in two
digits; the green LED indicates (flashes) the
spacing and position of the counted digit. The
ones digit is counted first and then the tens digit
with one green LED flash indicating the
beginning of the count of ones digit and two
green LED flashes indicating the beginning of
the tens digit count.
An example is if the channel is AK04 the
channel number is 04. The ones digit is 4 (four
red flashes) and the second is zero (no red flash).
50
Section 7 – Programming (Continued)
7-2.3.
(If you have passed the channel number desired
wait a minute for the green LED to flash and reshort the pins, the count will begin again from
channel AK01).
Reprogramming The Synthesizer
The RF Receiver can be reprogrammed in the
unit without removing the RF Receiver Board.
Locate the Programming Pins by looking at the
side of the RF Receiver Board (see Figure 7-2.
RF Receiver Board). To reprogram the
synthesizer a small metal tipped blade
screwdriver or other tool is necessary to short the
two pins together to put in the reprogramming
mode.
Channel and Fre quency Designations by
Count.
Indicator
Count
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Having located the programming pins and while
watching the flashing red Channel Counting
LED, short the programming pins together and
keep them shorted. (Do not be concerned while
shorting these pins together about touching the
metal RF Receiver shield with the shorting tool,
it will not cause any damage to the circuitry).
When the Programming Pins are shorted the RF
Receiver will go into the programming mode.
KEEP THE PINS SHORTED UNTIL THE
PROGRAMMING IS COMPLETE. The green
and red channel indicating LEDs will complete
one last channel indication and then only the red
LED Channel Counting LED will start to flash.
The synthesizer will start programming from
channel AK01 and count up in sequence for each
channel with a pause in between each channel
count. A full count of flashes will be made for
each channel with a short pause in between each
channel counts by the red Channel Counting
LED. The channel counts will increase by one
channel after each pause. Keep track of the
individual channel counts to determine which
frequency the synthesizer is on.
21.
22.
23.
24.
25.
26.
27.
28.
29.
The flashing sequence is as follows: one flash
(AK01) short pause, two flashes (AK02), short
pause, three flashes (AK03), etc. For channel
numbers ten and greater the red LED will still
count these out completely, so for channel AK12
there will be twelve flashes. The green LED
DOES NOT flash during channel programming.
When you have reached the correct count for the
channel desired, remove the short from the
shorting pins immediately. Wait a minute for the
RF Receiver to automatically retune itself and
the green and red channel indicating light should
then start to flash indicating the current channel
number.
Check the channel count to verify that the RF
Receiver is programmed to the desired channel.
51
Channel
Designator
AK01
AK02
AK03
AK04
AK05
AK06
AK07
AK08
AK09
AK10
AK11
AK12
AK13
AK14
AK15
AK16
AK17
AK18
AK19
AK20
AKA00
AKA01
AKA02
AKA03
AKA04
AKA05
AKA06
AKA07
AKA08
Actual
Frequency
439.8 MHz
439.6 MHz
439.4 MHz
439.2 MHz
439.0 MHz
438.8 MHz
438.6 MHz
438.4 MHz
438.2 MHz
438.0 MHz
437.8 MHz
437.6 MHz
437.4 MHz
437.2 MHz
437.0 MHz
436.8 MHz
436.6 MHz
436.4 MHz
436.2 MHz
436.0 MHz
433.125 MHz
433.325 MHz
433.525 MHz
433.725 MHz
433.925 MHz
434.125 MHz
434.325 MHz
434.525 MHz
434.725 MHz
Section 7 – Programming (Continued)
transmitters (1-8) allowed to control the
receiver(s) is dip switch selectable on the
Receiver Board.
7-3. Multibox.
7-3.1.
Multibox Operation.
NOTE
WARNING
THE DESIRED MULTIBOX TRANSMITTERS
MUST HAVE CONSECUTIVE ACCESS
CODES BEGINNING FROM THE FIRST
ACCESS CODE.
IF YOUR UNIT WAS NOT ORDERED WITH
MULTIBOX DO NOT ATTEMPT TO PROGRAM MULTIBOX IN THE FIELD. TELEMOTIVE MUST COORDINATE ACCESS
CODE ASSIGNMENTS WITH THE TRANSMITTERS PRIOR TO ENABLING MULTIBOX. PLEASE CONTACT TELEMOTIVE IF
YOU NEED TO ADD MULTIBOX. FAILURE
TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY OR DEATH
AND DAMAGE TO EQUIPMENT.
7-3.2.
SW3 Switch Multibox Settings.
Dip switch settings on the Receiver Board
control the number of transmitters. This is done
by the Receiver Configuration Switch SW3 (dip
switch positions -1, -2 and -3). Different settings
are used for 2, 3, 4 and up to 8 transmitters. See
Table 7-1. Multibox Switch Settings for proper
Multibox settings.
The Receiver Configuration Switch, dip switch
SW3, is found on the Receiver Board. See Figure
8-1. Receiver Layout. On the transmitters
sequential access codes are required. These are
set on access code switch “A” positions “1”, “2”
and “3’ or more as required. The first transmitter
uses the same access code as the receiver. The
other transmitters have the there access code
sequentially incremented each by one extra bit.
With “A1” being the least significant bit. See
Figure 7-1. Access Code Settings.
WARNING
IF YOUR UNIT HAS MULTIBOX DO NOT
ATTEMPT TO PROGRAM ADDITIONAL
TRANSMITTERS IN THE FIELD. TELEMOTIVE MUST COORDINATE ACCESS CODE
ASSIGNMENTS WITH THE NEW TRANSMITTERS PRIOR TO EXPANDING MULTIBOX. PLEASE CONTACT TELEMOTIVE IF
YOU NEED TO ADD ADDITIONAL
TRANSMITTERS. FAILURE TO FOLLOW
THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
For Membrane transmitters the Access code
positions A1-A2 can be accessed through the
battery compartment. The Pendant Transmitter
requires the back to be removed.
See Table 7-1. Multibox Switch Settings below
for appropriate settings for both the transmitters
and receiver(s).
The TR12 has Multibox capability that allows up
to 8 transmitters to access a single system. Only
one transmitter may control the receiver(s) at a
given time. Access is on a first come first serve
basis. Once a transmitter has gained control,
another transmitter may not access the
receiver(s) until the controlling transmitter
relinquishes control by transmitting an OFF
command to the receiver(s) or the receiver(s)
times out due to inactivity.
The first transmitter to send an ON command
after the receiver has been released will then gain
control of the receiver(s). The number of
52
Section 7 – Programming (Continued)
OFF
8 7 6 5 4 3 2 1
ON
8 7 6 5 4 3 2 1
Figure 7-3. SW3 Receiver Multibox Dip
Switches
Table 7-1. Multibox Switch Settings.
Receiver (See Figure 8-1).
SW3 Switch
Settings
3-1
3-2
3-3
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
ON
ON
ON
ON
ON
Transmitter (Membrane and Pendant only).
Access Code Switch
Settings
Maximum
Transmitters
First Access Code
First Access Code + 1 bit
First Access Code + 2 bits
First Access Code + 3 bits
First Access Code + 4 bits
First Access Code + 5 bits
First Access Code + 6 bits
First Access Code + 7 bits
53
Section 7 – Programming (Continued)
Gives about 5 seconds of alarm when the
transmitter is first turned on.
7-4. Custom Programming.
7-4.1.
Receiver Programming Options.
To Enable.
The following parameters are programmable in
the receiver: (See below for details).
Auto Alarm – Sounds alarm on turn on.
E-STOP Alarm – Sends Alarm on E-STOP.
Single or 2-speed system – Assigns outputs.
Latching of auxiliary relays – Up to two relays.
Time-out-timer disable.
Number of Multibox transmitters.
7-4.2.
Connect an external alarm. Move dip switch
SW4-8 on the Receiver Board to the ON position.
See Section 6. Wiring for the location for the
location of the alarm relay.
7-5.3. E-STOP
Normally OFF.
(SW4-7).
To Enable.
Connect an external alarm. Move dip switch
SW4-7 on the Receiver Board to the ON position
and jumper JU1 to ON. See Figure 8-1. Receiver
Board Layout for the position of JU1. Jumper JU1
facilitates bypassing the E-STOP shutdown to the
Alarm Relay so it can be activated during an ESTOP shutdown See Section 6. Wiring. for the
location for the location of the alarm relay.
Switch Position – Hoist, Trolley Etc.
Timer-out-timer operation.
Modes – Single speed switch grouping.
Crane configuration Tandem disable – Eliminates “both”
Select invert – Inverts the select function.
7-5. Receiver Programming. (For the location
of specific programming switches see Figure 81. Receiver Layout).
7-5.4. 2-Speed Or Single-Speed Outputs
(SW3-5). Normally OFF for 2-Speed.
Turning ON switch SW3-5 changes the relay
output pattern to best match the needs of a singlespeed system. See Section 6. Wiring for
appropriate output pattern.
WARNING
7-5.5.
MAKE SURE S1 MASTER CONTROL RELAY
(MCR) IS TURNED OFF BEFORE ATTEMPTING TO REPROGRAM THE RECEIVER, TO
PREVENT ACTIVATION OF EXTERNAL
CIRCUITRY. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
Auxiliary Functions General.
The TR12 receiver has up to 3 auxiliary (Aux)
function capability. These Aux functions are
dedicated relays that can be used to sound horns,
light lights or other functions. Typically a TR12
has 3 Aux functions (for standard 2-speed). See
Section 6. Wiring for the location for the location
of the auxiliary relays. However, there are a
number of specialties and variations available. If
your transmitter does not have a document
describing these functions, the easiest way to
determine what the Aux functions do is to look at
the relay outputs and while depressing the
appropriate Aux switch on the transmitter see
which LED lights for which relay.
Auto Alarm And E-STOP Alarm.
The receiver can have either one of these
functions or both. The use of either one of these
two functions dedicates one specific control relay
to operate an external alarm. An external alarm
(not supplied) needs to be connected to this relay.
7-5.2.
Alarm
Gives about 5 seconds of alarm when the
Emergency Stop (E-STOP) is activated on the
transmitter.
Transmitter Programming Options.
The following parameters are programmable in
most transmitters: (See Sections 7-6., 7-7. and 78.
Membrane,
Pendant
and
telePilot
Programming for details).
7-5.1.
Stop
7-5.5.1. Auxiliary Function Relay Latching
(SW4-2 and -3). Normally All OFF.
Auto Alarm (SW4-8). Normally OFF.
54
Section 7 – Programming (Continued)
Enables the appropriate auxiliary function relay to
operate in a latched mode, on or off, rather than as
a momentary contact. Which function is latchable
and which relay is latched depends on the
particular transmitter used.
SW4
Position Controls
1-2 Mode Select. (Single-Speed only).
7-6.2. SW3 Positions 1-3 Switch Positioning,
2-Speed
Membrane
Only.
(Standard
configuration all “OFF”).
Switch S4, positions 2 and 3 on the Receiver
Board each enable a separate relay to be latched
when turned on. See Section 6. Wiring for the
specfic details on latchable auxilary relays
If replacing a Pendant Transmitter with a
Membrane Transmitter on an existing installation
or making them interchangeable and keeping the
existing receiver wiring, open the Membrane
Transmitter, find dip switch SW3 and move
position 1 (SW3) to “ON”. See Figure 8-3.
Membrane Transmitter M/C Module E10635. The
Membrane Transmitters labeling and functions
North and South, East and West will match the
Pendant Transmitter.
7-5.6. Time Out Timer Enable (SW3-8).
Normally OFF.
The receiver contains a time out timer. If a
receiver once turned on by a transmitter does not
receive a signal from a transmitter for a period of
15 minutes the receiver shuts down. Setting S3-8
to ON disables this function.
7-5.7. Multibox (SW3-1,
Normally All OFF.
-2,
and
-3).
7-6.3.
SW3 Position 4 Time-out-timer
Disable. (Normally keep turned “OFF”).
See Section 7-3. Multibox. One transmitter can
only control the TR12 receiver with a specific
access code at a time. However, Multibox capability allows the TR12 receiver to automatically
switch to a new transmitter when the current
controlling transmitter has been turned off and a
new transmitter turned on. Up to 8 different
transmitters can control one receiver. To enable
this function the receiver must be preprogrammed
from the factory for Multibox and the correct
access codes must be programmed into the
appropriate transmitters. (Note: access codes are
factory programmed into the receiver and the
access codes are sequential.).
The transmitter has an approximate 15-minute
time-out-timer. If the transmitter is not used for
over 15 minutes it will shut down. This
transmitter time-out-timer function is transmitter
dip switch selectable. SW3 position 4 disables the
time-out-timer. Turning SW3-8 “ON” disables the
time-out-timer. If disabling the transmitter timeout-timer, remember to also replace the
receiver(s) EPROM(s) to disable the time-outtimer in the receiver.
7-6.4. Positions 5-7 Special Crane Control
Configurations, 2-Speed Membrane Only.
(Standard all “OFF”).
7-6. Membrane Transmitter Programming.
The Single-Speed or the 2-Speed 10K12
Membrane Transmitter may be used with the
TR12 Receiver. The Membrane Transmitter M/C
Board is shown in Figure 8-3. Refer to paragraphs
below for programming details.
7-6.1. Membrane
Settings.
Transmitter
No function. Should be set to OFF.
The 10K12 2-Speed Membrane transmitter is
available
with
special
crane
control
configurations. These options are switch
configurable on the transmitter. Section 6. Wiring
shows all the different crane configurations and
the switch positioning needed to achieve them.
The standard transmitter comes with the output
standard output configuration. For 2-speed
See
special crane control configurations:
Section 6. Wiring and program SW3 respectively
on the transmitter.
Switch
SW3
Position Controls
1-3 Switch positioning. (2-Speed only).
ON disables Transmitter Time-out-timer
5-7 Special Crane Control Configurations. (2Speed only).
7-6.5. Position 8 No function. (Keep turned
“OFF”).
55
Section 7 – Programming (Continued)
7-6.6. Transmitter
Programming
SW4
Positions 1-2 Mode Enable. (All 2-speed
configurations all “OFF”).
Mode 0, SW4 1 turned “OFF” and SW4 2 turned
“OFF”. From the factory the standard 2-Speed
Membrane Transmitter is configured this way.
This mode in the Membrane Transmitter is for all
2-speed applications. If
the
Membrane
Transmitter has a 2-speed keypad SW4 must be
set to all “OFF” positions.
7-6.7. Single-Speed Modes
1-3.
(The
following three different single-speed modes
are listed for single-speed Me mbrane
Transmitters only). See Section 7-6.9 for
details.
Mode 1, SW4 1 turned “ON” and SW4 2 turned
“OFF”. This configuration gives four-motor
single-speed with up to four auxiliaries. This
configuration uses the single-speed keypad with
two auxiliaries labeled P1 and P2.
Mode 2, SW4 1 turned “OFF” and SW4 2 turned
“ON”. This configuration gives four-motor singlespeed with four auxiliaries. This configuration
uses the single-speed keypad with four auxiliaries
labeled Aux 1 through Aux 4.
Mode 3, SW4 1 turned “ON” and SW4 2 turned
“ON”. Allows for 12 independent ON/OFF
functions (relays) per transmitter button pushed.
56
Section 7 – Programming (Continued)
7-6.8. Repositioning
Of
Membrane
Transmitter Motion Switch Functions (for 2Speed Me mbrane Transmitter only).
WARNING
SW3 positions 1 through 3 can change the
functional positions of the switches controlling
bridge, hoist and trolley. This can be useful to
align East/West and North/South. This
reconfiguration does NOT affect receiver wiring.
See Figure 8-3. Membrane Transmitter M/C
Module E10635 for switch location.
CHANGING THESE SWITCHES CHANGES
THE FUCTIONAL OPERATION OF THE
CRANE IN RELATIONSHIP TO THE
TRANSMITTER BUTTON BEING DEPRESSED. THE FUNCTIONAL OPERATION OF THE
CRANE SHOULD NEVER BE CHANGED
WITHOUT ALL PERSONNEL RESPONSIBLE
FOR CRANE OPERATION BEING NOTIFIED
PRIOR TO MODIFICATION. FAILURE TO
FOLLOW THIS WARNING COULD RESULT
IN SERIOUS INJURY OR DEATH AND
DAMAGE TO EQUIPMENT.
Figure 7-4. Membrane Transmitter Motion
Switch Positioning.
HOIST
HOIST
TROLLEY
TROLLEY
BRIDGE
BRIDGE
BRIDGE
TROLLEY
HOIST
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
OFF
ON
1 2 3 4 5 6 7 8
ON
OFF
OFF
TROLLEY
BRIDGE
BRIDGE
HOIST
HOIST
TROLLEY
BRIDGE
TROLLEY
HOIST
Standard Configuration
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
OFF
OFF
57
1 2 3 4 5 6 7 8
ON
OFF
Section 7 – Programming (Continued)
See Figure 8-3. Membrane Transmitter M/C
Module E10635 for location of SW3 and SW4. A
single-speed keypad (part number S313-1) with
special inserts (part number A9657-1) is required
for these configurations. The single-speed modes
1 through 3 do not change the outputs, but change
the directional lockouts, i.e., E and W cannot be
used at the same time. Mode 3 has no lockouts.
As for which outputs are controlled by the singlespeed transmitter, the switch positions as
numbered in the Mode 3 diagram below are
indicated on each of the wiring diagrams in
Section 6. Wiring.
7-6.9. Single-Speed Membrane Transmitter
Configurations.
Normally single-speed transmitters are not
provided with the 10K6/9. This section is for
reference only when using a Single-Speed
Membrane Transmitter. All single-speed modes
require that the transmitter switch SW3 positions
1 through 3 are all set to OFF.
The EPROM’s for the single-speed unit is
FW2904-0T and FW2904-0N where 0T means
with 15-minute-time-out-timer and 0N means no
time-out-timer.
Mode 0:
For all two-speed
applications SW4
settings.
ON
OFF
Four-motor singlespeed with four
auxiliaries.
1 2
ON
OFF
Mode 1:
Four-motor singlespeed with four
auxiliaries.
STOP
ON
OFF
SW4
*TR12
Receiver
Outputs
Mode 2:
SW4
DN
SW4
UP
AUX
UP
UP
J4-3
J3-2
AUX
DN
DN
J4-1
J4-2
P1
J3-3
J5-2
P2
J3-1
J5-6
ALARM
J2-3
*TR12
Receiver
Outputs
J2-2
UP
J4-3
J3-2
DN
J4-1
J4-2
AUX
UP
J3-3
J5-2
AUX
DN
J3-1
J5-6
J2-3
J5-4
J2-1
S TOP
OFF
*TR12
Receiver
Outputs
LIGHT
ON
J2-2
J5-4
*TR12
Receiver
Outputs
Mode 3:
Allows for 12
independent
ON/OFF functions.
SW4
J2-1
ON
*TR12
Receiver
Outputs
J2-2
J4-3
J3-2
J4-1
J4-2
J3-3
J5-2
10
J3-1
J5-6
11
J2-3
J5-4
12
J2-1
OFF
S TOP
*TR12
Receiver
Outputs
S TOP
*Single-Speed TR12
Receiver Configuration Only.
Figure 7-5. Membrane Transmitter Single-Speed Configurations.
58
Section 7 – Programming (Continued)
transmitter time-out-timer function is transmitter
dip switch selectable. SW3 position 8 disables
the time-out-timer. Turning SW3-8 “ON”
disables the time-out-timer.
7-7. Pendant Transmitter Programming.
The Single-Speed or the 2-Speed 10K12
Pendant Transmitter may be used with the TR12
Receiver. The Pendant Transmitter M/C Board is
shown in Figure 8-4. Refer to paragraphs below
for programming details Procedures.
7-7.1.
7-7.7.
7-7.8. Position 1-2 Mode Enable. (Standard
Mode 1 keep 1-2 turned “OFF”).
Pendant Transmitter Switch Settings.
Mode 1, SW4 1-2 all “OFF”. The 10K12 singlespeed system comes standard configured this
way from the factory with three motion controls
and six auxiliaries (controlled by the toggle
switches). The 10K12 2-speed system comes
standard configured this way from the factory
with three 2-speed controls and three auxiliaries
(controlled by the toggle switches, the rotary is
non-functional).
SW3
Position Controls
1-3. Switch Positioning. (2-Speed only).
4-7. No function, keep off.
8.
Time-out-timer disable, turn “ON” to
disable time-out-timer.
SW4
Position Controls
1-2 Mode Select. (Single-Speed Only).
3.
Disable Tandem Hoist. (2-Speed only).
4.
Invert Crane Select. (2-Speed only).
5-7. Special Crane Configurations. (2-Speed
only).
8.
No function, keep OFF.
Mode 2, SW4 1 turned “OFF” and SW4 2 turned
“ON”. The 10K12 2-speed system configured
this way is able to control four 2-speed motion
controls and no auxiliaries this give bridge,
trolley, main and aux hoist. The rotary selector
switch functions are H1 main hoist, H2 aux hoist
and B both main and aux hoist (the toggle
switches are non-functional).
7-7.2. Transmitter Switches SW3 And SW4
Programming. (See Section 8-2. Pendant
Transmitter Servicing for physical location of
transmitter switches).
7-7.3.
Transmitter Programming SW4
Mode 3, SW4 1 and 2 turned “ON”. The 10K12
2-speed system will control up to 5 motors using
the rotary selector switch. This mode
reconfigures two of the 10K12 auxiliary outputs
(Aux 1 and Aux 2) to be external motor select
functions by the rotary switch. In this mode the
auxiliary toggle switch Aux 1 and Aux 2 is
disabled. When the rotary switch is in the H1 or
H2 position Aux 1 relay or Aux 2 relay will pull
in respectively when ever trolley or hoist
pushbuttons are pressed. When the rotary switch
is in B position both Aux 1 and Aux 2 relays will
pull in.
Transmitter programming SW3
7-7.4. Positions 1-3 Switch Positioning, 2Speed Only. (Standard configuration all
“OFF”).
The functional positions of the various buttons
controlling the hoist trolley and bridge can be
moved by transmitter dip switch SW3 also.
Positions SW3-1 through SW3-3 control these
functions. No change in receiver wiring is
needed to use these functions. See Section 77.13. for switch verses button configurations.
7-7.9. Position 3 Disable Tandem For Hoist
And Trolley. (Normally keep turned “OFF”).
7-7.5. Position 4-7 No Function. (Keep
turned “OFF”).
7-7.6. Position 8 Time-out-timer Disable.
(Normally keep turne d “OFF”).
For cranes with auxiliary hoists and/or trolleys,
turning this switch “ON” disables the transmitter
selector switch “B” position (both function) that
selects tandem operation of hoist or trolley.
The transmitter has an approximate 15-minute
time-out-timer. If the transmitter is not used for
over 15 minutes it will shut down. This
7-7.10. Position 4 Invert Crane Select Aux.
Outputs. (Normally keep turne d “OFF”).
59
Section 7 – Programming (Continued)
For cranes that use the select function only,
turning this switch “ON” inverts the select
function operation so that the relay closes for the
unselected function.
7-7.11. Positions 5-7 Special Crane Control
Configurations. (Standard all “OFF”).
The 10K12 2-Speed Pendant and SLTX
transmitter is available with special crane control
configurations. These options are switch
configurable on the transmitter. Section 6.
Wiring shows all the different crane
configurations and the switch positioning needed
to achieve them. The standard transmitter comes
with the output standard output configuration
For
2-speed
special
crane
control
configurations: See Section 6. Wiring and
program SW4 respectively on the transmitter.
7-7.12. Position 8 No Function. (Keep turned
“OFF”).
60
Section 7 – Programming (Continued)
7-7.13. Repositioning
Of
Pendant
Transmitter Motion Switch Functions (for 2Speed Pendant Transmitter only).
WARNING
SW3 positions 1 through 3 can change the
functional positions of the switches controlling
bridge, hoist and trolley. This reconfiguration
does NOT affect receiver wiring.
CHANGING THESE SWITCHES CHANGES
THE FUCTIONAL OPERATION OF THE
CRANE IN RELATIONSHIP TO THE
TRANSMITTER BUTTON BEING DEPRESSED. THE FUNCTIONAL OPERATION OF
THE CRANE SHOULD NEVER
BE
CHANGED WITHOUT ALL PERSONNEL
RESPONSIBLE FOR CRANE OPERATION
BEING NOTIFIED PRIOR TO MODIFICATION. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY
OR DEATH AND DAMAGE TO EQUIPMENT
Figure 7-6. Pendant Transmitter Motion Switch
Positioning.
1 2 3 4 5 6 7 8
HOIST
HOIST
BRIDGE
TROLLEY
BRIDGE
TROLLEY
BRIDGE
TROLLEY
HOIST
ON
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
OFF
OFF
OFF
Standard Configuration
BRIDGE
HOIST
TROLLEY
ON
1 2 3 4 5 6 7 8
TROLLEY
TROLLEY
HOIST
BRIDGE
BRIDGE
HOIST
ON
1 2 3 4 5 6 7 8
OFF
OFF
61
ON
1 2 3 4 5 6 7 8
OFF
Section 7 – Programming (Continued)
After loading the telePilot program the first screen is the
initial setup screen.
7-8. telePilot Programming.
Read Section 5-5. Additional telePilot Operational
Features to familiarize you with the features listed
below. The telePilot transmitter remote unit for
programming uses a PDA (Personal Digital Assistant).
Such products as Palm Pilot® or many other products
using Palm OS® can be used to run the telePilot
programming software. If unsure if your PDA will work
or for a recommended product contact the appropriate
Telemotive representative or check our website. The
software for the PDA is available on a disk shipped with
your unit, can be emailed from your Telemotive
representative or downloaded from our Website at
www.telemotive.com.
telePilot Programmer
Tx Type
2 SPD
Use bank password
First press
Second press
Third press
Fourth press
Bank 1
Bank 2
off
off
Button 6
Button 5
Button 4
Button 3
Bank 3
off
off
Tx Type (Must be selected).
Load the telePilot programming software into your
PDA, refer to your PDA manual or contact Telemotive
for the appropriate procedure. Once loaded, look for the
Telemotive circle and hook logo labeled telePilot for the
appropriate application. Select this application to begin
programming.
Bank Password (Can be disabled).
With the telePilot programmer you can load up to four
different transmitter types for use on 10K, 9000 and/or
9100 systems. Each transmitter configuration is stored in
a “Bank”. There are up to four banks available. This
Bank feature is like having four completely different
transmitters in one unit. Up to four Banks (operational
configurations) are possible. A Bank is a specific
configuration of user-defined parameters including:
System type
Frequency
Access codes
Also possible:
Key arrangement
Relay configuration
Tandem disable
Invert crane select
Time-out-timer time
Mode selection
Alarm settings
62
Bank 4
Name: ……………………………..…. M
telePilot PDA software is quite user friendly and is
intended to mimic the dip switch settings used in other
Telemotive products without the inconvenience of
having to open the transmitter case. The PDA software
allows you to select frequency, access code, time-outtimer settings, switch arrangement and crane
configuration as in other Telemotive transmitter
products.
telePilot
1 SPD
2 SPD
First select the transmitter type being used (single-speed
“1 SPD” or 2-speed “2 SPD”). See Section 5. Operation
for differences in the two transmitters. With your PDA
stylus tap the arrow after transmitter “Tx Type”. A pull
down menu will appear, select “1 SPD” or “2 SPD” and
the menu will close showing your selection.
Bank password protection is available in changing the
transmitter once it has turned OFF. The Bank Password
is the same for all Banks. Bank password protection is
described in the telePilot operational description in
Section 5-5. Additional telePilot Operational Features.
Please familiarize yourself with this section before
programming. A check appears in the box and a list of
four buttons. These buttons list the first through fourth
buttons and are in the order of entry for the appropriate
buttons. Select the four transmitter buttons in the
sequence that you wish to be the password by tapping
the arrow by “Button #” and making a selection from the
pull down menu for each of the four password entries.
Be sure to write this password down in a safe place for
future reference. The default password is 6, 5, 4, 3.
telePilot Programmer
Tx Type
2 SPD
Use bank password
First press
Second press
Third press
Fourth press
Bank 1
off
Bank 2
off
Button 6
Button 5
Button 4
Button 3
Bank 3
off
Bank 4
off
Name: ……………………………..…. M
Button 1
Button 2
Button 3
Button 4
Button 5
Button 6
Section 7 - Programming (Continued)
NOTE
ALWAYS
REMEMBER
TO
STORE
THE
PASSWORD IN A SECURE LOCATION FOR
ACCESS IF THE PASSWORD IS LOST OR
FORGOTTEN. ONCE THE TRANSMITTER IS PROGRAMMED THERE IS NO WAY TO DEFEAT THE
PASSWORD WITHOUT USING A PDA TO EITHER
READ THE PASSWORD OUT OR REPROGRAM A
NEW ONE.
The screen should switch to the Setup Bank screen
shown below. Complete the Bank setup as described
below and hit save. The PDA will revert to the initial
screen and the cell for the just programmed Bank should
darken and the word “on” appears. Tap on the cell
labeled with the next bank you wish to program and a
similar “Setup” screen to the one shown below will
appear. Continue doing this until you have programmed
the four Banks.
You do not have to use all Banks and you do not have to
use them in order.
WARNING
THIS PASSWORD FUNCTION IS NOT TO BE USED
AS A SECURITY DEVICE. THE PURPOSE OF THIS
FUNCTION IS TO PREVENT ACCIDENTAL BANK
SWITCHING. THE BEST FORM OF SECURITY IS
ALWAYS TO LOCKUP THE TRANSMITTER WHEN
NOT IN SERVICE. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS INJURY
OR DEATH AND DAMAGE TO EQUIPMENT.
The Bank password can be disabled during initial
programming by the PDA. To disable password
protection, tap the check in the box next to the phase
“Use bank password”. Disabling the Bank password is
not recommended unless the operator has access and
visibility to all possible cranes controlled.
Even after programming a Bank you can turn it back
“off”. A programmed Bank will not lose its
programming by turning it “off”. By turning ON and
OFF Banks you can easily save certain transmitter
configurations in the transmitter to turn them on at a later
time with the PDA without having to completely
reprogram them.
Bank Programming Setup Screen (Must select
system).
Setup Bank #
System
A1
10K
S3-1
Bank Selection (At least one must be selected).
When done with the password section. Select the number
of Bank you wish to program and tap the cell labeled
with the appropriate Bank number.
Bank 2
off
Bank 3
off
1-SPD
2-SPD
10K
9000
9100
10K
9001
9101
Timer
Save
Main/Aux
DISABLING THE PASSWORD FUNCTION IS PUTS
THE SYSTEM IN ACTIVE BANK SELECT. THIS
ALLOWS THE CRANE OPERATOR TO SWITCH
BETWEEN BANKS QUICKER. THE OPERATOR IN
THIS
MODE
MUST
BE
AWARE
AND
RESPONSIBLE FOR ALL POSSIBLE CONTROLLED
CRANES. FAILURE TO FOLLOW THIS WARNING
COULD RESULT IN SERIOUS INJURY OR DEATH
AND DAMAGE TO EQUIPMENT.
off
AK01
Switch conf.: H,T,B
WARNING
Bank 1
Freq
1 B1
Receiver access code
Multibox
Auto Turn Off
Bank 4
off
63
Aux
Cancel
The number of the Bank will appear at the top of the
screen. Before selecting any programming feature
first go to “System” and select the system type. Tap
on the “System" arrow and select 10K, 9000, 9001, 9100
or 9101 type system. The TR12 Receiver is a 10K type
system. If you are unsure of the type of system you have
refer to the cover of the systems operating manual for the
appropriate system or call your Telemotive
representative. After selecting
system type, your
programming screen will change to match the type of
system selected.
Section 7 - Programming (Continued)
The respective screens appear as shown below (the 10K
screen is shown first):
Setup Bank #
System
10K
Freq
AK01
1 B1
Receiver access code
Multibox
Tx #
Auto Turn Off
Auto Alarm
A1
S3-1
This section appears
for 2-Speed only.
Timer
Switch conf.: H,T,B
Save
Main/Aux
Aux
Cancel
10K Programming Screen
Setup Bank #
System
9000(1)
Freq
Receiver access code
A1
Auto Turn Off
Timer
None
Save
Cancel
9000 and 9001 Programming Screen
Setup Bank #
System
9100(1)
Freq
Receiver access code
A1
This appears for 9100
Single-Speed only.
Auto Turn Off
Timer
Mode
None
A0
Save
Cancel
9100 and 9101 Programming Screen
The following next three sections of this programming
guide are written specifically for each of the three
64
system configurations. They are in order of 10K, 9000(1)
and 9100(1). Please skip to the appropriate section for
your system. Do this in turn for each Bank until all
desired Banks are programmed.
Section 7 - Programming (Continued)
7-8.1.
10K telePilot Programming.
After you have entered 10K as your system type enter
the following items in order for your system:
The Tx # goes up to 8. Many Multibox systems only go
to four. Check with your Telemotive representative if
you need more then 4 transmitters on a Multibox system.
Setup Bank #
Frequency (Must be inputted for system to work):
System
There should be a label either on the receiver or the
transmitter listing frequency, it should be a channel
number between AK01 to AK20. Find this number and
tap the “Freq” arrow and select that channel number.
A1
10K
Freq
1 B1
Receiver access code
Multibox
Tx #
Auto Turn Off
Timer
Mode
Screen switch operation.
The screen switches are labeled from left to right “A”,
“B” and S3. They are numbered from left to right 1 to 8.
The darken rectangle to the bottom is “OFF” or “0” the
darken rectangle to the top is “ON” or a “1”. Tapping the
lighten rectangle will cause the switch to toggle.
Screen switches
AK01
None
Save
Cancel
10K Single-Speed Programming Screen
Setup Bank #
Access Code (Must be inputted for system to work):
See Section 7.1. Access Code Programming for details
on access code programming. There should be a label
either on the receiver or the transmitter showing the
access code, it should be numbered A1 through A8 and
B1 though B8. Find this number and tap the respective
switches on the screen. If you cannot find a label with
access code information, copy directly from the access
code dip switches in your transmitter or receiver, being
careful to match the designation and switch position as
they do vary from model to model.
System
10K
Freq
1 B1
A1
Receiver access code
Multibox
Tx #
Auto Turn Off
S3-1
AK01
Timer
Switch conf.: H,T,B
Save
Main/Aux
Aux
Cancel
10K 2-Speed Programming Screen
Multibox (Optional, skip if you do not wish to use the
Multibox feature):
Auto Turn Off (Optional, can be skippe d):
See Section 7-3. Multibox for details on Multibox
programming. If your current receiver does not have
Multibox do not attempt to use this function. This
function WILL NOT turn Multibox on in the receiver. It
only assists you in programming the correct transmitter
access code for a receiver that already has Multibox.
Make sure when you are using the Multibox feature that
the access code of the receiver is programmed into the
access code above and not one copied from an existing
transmitter on a Multibox system. If you cannot find the
receiver transmitter code and wish to copy existing
transmitter on a Multibox system, put the transmitters
access code in the access code switches above and DO
NOT check the Multibox box on the PDA.
Select the Tx # this should be the next number in the
series of transmitter being put on a Multibox system. If
the are two transmitters on already and you are adding a
third, select the number 3. Make sure as stated in the
Multibox section the receiver is programmed for the
appropriate number of transmitters.
65
The telePilot transmitter has a variable length Time-outtimer. To facilitate operation of this timer with various
models of receiver the Auto Turn Off feature was
created. If this feature is enabled, when the transmitter
times out and the transmitter turns OFF, it will before
shutting down send an OFF command to the receiver.
Check (tap) the box to enable.
Section 7 - Programming (Continued)
10K telePilot Programming (Continued).
7-8.1.1.
Single-Speed 10K telePilot Only:
Skip to next section7-7.1.2 (below) if 2-speed.
Setup Bank #
Timer (If unsure of a numbe r start with 15 minutes):
Enables the transmitter time-out-timer. The selections
are “None” (meaning the transmitter will never shut off
on it own if not used, this is not recommended for
battery life) or numbers of minutes till shut down. The
minutes are selectable in one-minute steps from 1 to 10
and five minutes steps up to an hour. Tap on the “Timer”
arrow; scroll down through the number of minute and
tap on the desired number.
Modes 1-3 (The correct mode must be selected for
safe operation):
Please refer to Figure 7-7. Single-Speed 10K telePilot
for specific mode details. Modes are various patterns of
functional lockouts. If you have UP and a DOWN
buttons on a single-speed transmitter controlling a hoist,
the transmitter must not be able to send Up and DOWN
commands at the same time.
Mode determines the respective buttons that are locked
out to each other. Modes do NOT change the
configurations of the output relays. Find the desired
mode and select its number on the “Mode” selection.
10K telePilot Programming (Continued).
7-8.1.2.
Freq
1 B1
A1
Receiver access code
Multibox
Tx #
Auto Turn Off
S3-1
A1
Timer
Mode
None
Save
Cancel
10K Single-Speed
Programming Screen
This completes the 10K single-speed programming,
when completed with the above tap “Save”.
Save will take you back to the initial start screen and
turn the Bank ON. At this point select another Bank to
program or go to Section 7-9. Loading And Saving The
Program.
NOTE
Pendant: Copy Switch 3 (positions 1, 2, 3 and 8)
settings on the Pendant transmitter to S3 (positions 1, 2,
3 and 8 respectively) on the PDA. Copy Switch 4
(positions 5, 6 and 7) settings on the Pendant transmitter
to S3 (positions 5, 6 and 7 respectively) on the PDA. If
Switch 4 on the Pendant transmitter has positions 1 and
or 2 Switched ON see the write-up on Main/Aux Menu
below. If SW4 position 3 is switched “ON” un-check
Tandem box on PDA. If SW4 position 4 is switched
“ON” check Invert box on PDA.
Timer
Save
Aux
1 B1
Receiver access code
Multibox
Tx #
Auto Turn Off
AK01
AK01
Switch conf.: H,T,B
Main/Aux
Freq
Membrane: Copy Switch 3 (all positions) settings on
the Membrane transmitter to S3 on the PDA.
Setup Bank #
10K
10K
IF REPLACING A MEMBRANE OR PENDANT
TRANSMITTER, YOU CAN COPY THE SWITCH
SETTINGS ON THE EXISTING TRANSMITTER.
2-Speed 10K telePilot Only:
System
System
Cancel
10K 2-Speed
Programming Screen
A detailed table of Transmitter switch programming
versus telePilot is in Appendix A.
Programming Switch S3-1
66
Section 7 - Programming (Continued)
SW3 Positions 1-3 Repositioning of telePilot
Transmitter Motion Switch Functions. (Standard
configuration all “OFF”).
This programming redefines the function of the (AUX 3)
button just above the E-STOP.
S3 positions 1 through 3 can change the functional
positions of the switches controlling hoist, trolley and
bridge. This reconfiguration does NOT affect receiver
wiring. As these switches are changed the motor controls
are moved.
Standard, Motor 1 is H (Hoist) Motor 2 is T (Trolley)
and Motor 3 is B (Bridge). The standard configuration
(all switches OFF) is, starting at the top right hand pair
of buttons on the transmitter, Motor 1. Moving down to
the middle two right hand pair of buttons that is Motor 2.
The bottom pair on the right is Motor 3. This is indicated
the display “Switch config: H,T,B. The order of Hoist,
Trolley and Bridge will vary as S3-1 to 3 switch
positions are changed. For an example of switch
configurations versus switch settings see Section 7-.13.
Repositioning of Pendant Transmitter Motion Switch
Functions. The settings match the operation of the
telePilot.
SW3 Position 4 And 8 Time-out-timer Disable.
(Normally turne d “OFF”).
Disables the transmitter time-out-timer if turned ON. If
the time-out-timer is active, the length of time for time
out can be selected for numbers of minutes till shut
down. The minutes are selectable in one-minute steps
from 1 to 10 and five minutes steps up to an hour. Tap
on the “Timer” arrow and scroll down through the
number of minutes and tap on the desired number.
Positions 5-7 Special Crane Control Configurations.
(Standard all “OFF”).
Section 6. Wiring shows all the different crane
configurations and the switch positioning needed to
achieve them. The standard transmitter comes with the
output standard output configuration. For special crane
control configurations program S3 positions 5-7 to
match the programming information shown for the
respective wiring diagram. When any of the special
crane configuration switches is turned ON, the words
“Crane control enabled” appears on the display and
Main/Aux disappears.
Position 8, Same as Switch Position 4. See write up
for switch 4 above (Normally turne d “OFF”).
Main/Aux Menu for controlling the “AUX 3” Push
Button
This menu shows only if no Special Crane
Configurations are selected (Switch 3 positions 5-7).
67
(If a three motor crane use “Aux”, for standard four
motor use “Motor ”, for Select function use Select).
If replacing a pe ndant transmitter: if Switch 4 on the
pendant transmitter has position 1 “OFF” and position 2
“ON” use “Motor”, if Switch 4 has position 1 “ON” and
position 2 “ON” use “Select”.
For three motor stand system this button is an auxiliary
relay control button. (AUX 3).
For four motor systems this button controls a main and
aux motor such as a hoist. (See Section 5. Operation for
details on the operation of this button.) To program a
fourth motion select (Motor). This four motor
application can only be used with special crane
configuration TABLE 2(H) Standard 2-Speed 4 Motor
System. The AUX 3 button becomes a switch to toggle
between “A” and “B” or both. Where “A” and “B” are
main and auxiliary motors respectively. The main motor
output is motor 1 and the auxiliary motor output is motor
4.
For up to 5 motors using the select function this button
is available to use select relays. This select function can
only be used with special crane configuration TABLE
2(I) Standard 2-Speed 3, 4 & 5 Motor System using
Select. To program in the select function tap the word
“Select”.
Tande m For Hoist, Trolley or Bridge. (Normally
checked).
This function appears if a four motor system or select
function is chosen. Normally the box is checked
meaning “Both A and B” operation is enabled (both
MAIN and Aux or Select 1 and Select 2 can be ON at
the same time). Removing the check from the box by
tapping on it disables the “Both” function. (“A” and “B”
will not come ON at the same time). This function maps
to Pendant Switch 4 position 3, if SW4 position 3 is
switched “ON” un-check Tandem box on PDA.
Section 7 - Programming (Continued)
Position 4 Invert Crane Select Aux. Outputs.
(Normally not checked).
This function appears if a system using select is
programmed in. Turning this switch “ON” inverts the
select function operation so that the relay closes for the
unselected function. This function maps to Pendant
Switch 4 position 4, if SW4 position 4 is switched “ON”
check Invert box on PDA.
Setup Bank #
System
10K
Freq
AK01
1 B1
A1
Receiver access code
Multibox
Auto Turn Off
Tx #
S3-1
Timer
Switch conf.: H,T,B
Save
Main/Aux
Tandem
Invert
Aux
Cancel
Crane control enabled
10K 2-Speed
Programming Screen
This completes the 10K 2-speed programming, when
completed with the above tap “Save”.
7-8.1.3. Save will take you back to the Initial start
screen. At this point select another Bank to program or
go to Section 7-9. Saving And Loading The Program.
68
Section 7 - Programming (Continued)
Single-Speed 10K telePilot Lockout Modes.
The Modes shown are equivalent to the same Modes in
the single-speed Membrane transmitter. Auxilary relay
functionl labeling shown is in reference to the traditional
labeling of the Single-Speed Membrane Transmitter for
the respective modes. Each pair of directionals shown
for its respective mode is locked out.
(Main Hoist)
UP
(Aux Hoist)
DOWN
UP
DOWN
(Aux Hoist)
UP
P1
DOWN
ON/
OFF
(Trolley/Bridge)
Dir 1
Dir 2
The dark rectangles on the
drawings
below
represent
buttons pairs that are locked out
from both working at the same
time.
(Bridge/Trolley)
Dir 1
Dir 2
P2
Alarm
ESTOP
(Trolley/Bridge)
Dir 1
Dir 2
(Bridge/Trolley)
Dir 1
Dir 2
Light
ESTOP
Mode 1
*TR12
Receiver
Outputs
(Main Hoist)
UP
DOWN
ON/
OFF
Mode 2
*TR12
Receiver
Outputs
ON/
OFF
J4-3
J2-2
J4-1
J3-2
J4-2
J5-2
J5-6
*Single-Speed TR12
Receiver Configuration
Only.
Original 10K Single-Speed
Keypad Layout.
J3-3
10
J3-1
11
J2-3
10
12
J2-1
11
J5-4
12
ESTOP
Functional Mapping of 10K
Series Single-Speed Controls to
telePilot Controls.
Matching numbers indicate the
same function. Mapping not affected by Modes shown on this
page or by Original 10K Keypad
Labeling (Inserts).
Mode 3
Figure 7-7. Single-Speed 10K telePilot Modes.
69
ESTOP
(EMS)
Section 7 - Programming (Continued)
7-8.2.
9000 and 9001 telePilot Programming.
After you have entered 9000 or 9001 as your system type
enter the following items in order for your system:
battery life) or numbers of minutes till shut down. The
minutes are selectable in one-minute steps from 1 to 10
and five minutes steps up to an hour. Tap on the “Timer”
arrow; scroll down through the number of minutes and
tap on the desired number.
Frequency (Must be inputted for system to work):
There should be a label either on the receiver or the
transmitter listing frequency, it should be a channel
number between A to K. Find this letter and tap the
“Freq” arrow and select that channel letter. As the
frequency letter is entered the last five positions of the
programming automatically sets itself to the positions
used in previous 9000(1) systems to program in that
frequency.
If you are unable to find a channel letter designation for
frequency, copy the last 5 positions of the access code
dip switch, from an existing unit. The correct channel
number will appear in the “Freq” window.
Setup Bank #
System
9000(1)
Freq
A1
Receiver access code
Auto Turn Off
Screen switches
Timer
None
Save
Cancel
9000 and 9001 Programming Screen
9000(1) Channel Code versus Frequency.
Channel Frequency
Channel Frequency
448.0 MHz
447.5 MHz
448.5 MHz
447.1 MHz
449.0 MHz
446.7 MHz
449.5 MHz
446.3 MHz
450.0 MHz
445.9 MHz
This completes the 9000(1) programming tap “Save”.
Access Code (Must be inputted for system to work):
The first four positions of the switch shown is the access
code copy these four switch positions from an existing
piece of equipment.
Screen switch operation. The screen switches are
labeled from left to right “A”, “B” and S3. They are
numbered from left to right 1 to 8. The darken rectangle
to the bottom is “OFF” or “0” the darken rectangle to the
top is “ON” or a “1”. Tapping the lighten rectangle will
cause the switch to toggle.
Auto Turn Off (Optional, can be skippe d):
Save will take you back to the Initial start screen. At this
point select another Bank to program or to Section 7-9.
Saving And Loading The Program.
Original 9000
Keypad Layout.
10
10
12
11
12
ON/
OFF
ESTOP
The telePilot transmitter has a variable length Time-outtimer. To facilitate operation of this timer with various
models of receiver the Auto Turn Off feature was
created. If this feature is enabled, when the transmitter
times out and the transmitter turns OFF, it will before
shutting down send an OFF command to the receiver.
Check (tap) the box to enable.
Timer (If unsure of a numbe r start with 15 minutes):
Enables the transmitter time-out-timer. The selections
are “None” (meaning the transmitter will never shut off
on it own if not used, this is not recommended for
70
11
Dark rectangles
indicate locked
out functional
groups on both
transmitters.
ESTOP
(EMS)
Functional Mapping of Original 9000 Series Single-Speed
Controls to telePilot Controls.
Matching numbers indicate the
same function. Mapping not
affected by Original 9000 Keypad Labeling (Inserts).
For functional mapping of 2-Speed Controls from
9001 to telePilot see Section 7-9.
Section 7 - Programming (Continued)
7-8.3.
9100 and 9101 telePilot Program-
ming.
After you have entered 9100 or 9101 as your system type
enter the following items in order for your system:
Frequency (Must be inputted for system to work):
There should be a label either on the receiver or the
transmitter listing frequency, it should be a channel
number between A to K. Find this letter and tap the
“Freq” arrow and select that channel letter. As the
frequency letter is entered the last five positions of the
programming automatically sets itself to the positions
used in previous 9100 and 9101 systems to program in
that frequency. For specific frequency information see
the Channel Code versus Frequency listing below.
If you are unable to find a channel letter designation for
frequency, copy the last 5 positions of the access code
dip switch, from an existing unit. The correct channel
number will appear in the “Freq” window.
9100(1) Channel Code versus Frequency.
Channel Frequency
Channel Frequency
448.0 MHz
447.5 MHz
448.5 MHz
447.1 MHz
449.0 MHz
446.7 MHz
449.5 MHz
446.3 MHz
450.0 MHz
445.9 MHz
Enables the transmitter time-out-timer. The selections
are “None” (meaning the transmitter will never shut off
on it own if not used, this is not recommended for
battery life) or numbers of minutes till shut down. The
minutes are selectable in one-minute steps from 1 to 10
and five minutes steps up to an hour. Tap on the “Timer”
arrow; scroll down through the number of minutes and
tap on the desired number.
Setup Bank #
System
9100(1)
Freq
A1
Receiver access code
9100 Single
Speed Only
Auto Turn Off
Screen switches.
Timer
Mode
15
A0
Save
Cancel
9100 and 9101
Programming Screen
Modes A0-A4 (9100 Single-Speed Only). (The correct
mode must be selected for safe operation):
Access Code (Must be inputted for system to work):
The first four positions of the switch shown is the access
code copy these four switch positions from an existing
piece of equipment.
Screen switch operation. The screen switches are
labeled from left to right “A”, “B” and S3. They are
numbered from left to right 1 to 8. The darken rectangle
to the bottom is “OFF” or “0” the darken rectangle to the
top is “ON” or a “1”. Tapping the lighten rectangle will
cause the switch to toggle.
Auto Turn Off (Optional, can be skippe d):
The telePilot transmitter has a variable length Time-outtimer. To facilitate operation of this timer with various
models of receiver the Auto Turn Off feature was
created. If this feature is enabled, when the transmitter
times out and the transmitter turns OFF, it will before
shutting down send an OFF command to the receiver.
Check (tap) the box to enable.
Timer (If unsure of a numbe r start with 15 minutes):
71
Please refer to Figure 7-8. Single-Speed 9100 telePilot
Lockout Modes for specific mode details and functional
mapping of 9100 controls to telePilot. Modes are
various patterns of functional lockouts. If you have UP
and a DOWN buttons on a single-speed transmitter
controlling a hoist, the transmitter must not be able to
send Up and DOWN commands at the same time. Mode
determines the respective buttons that are locked out to
each other. Modes do NOT change the configurations of
the output relays. Find the desired mode and select its
number on the “Mode” selection.
For functional mapping of 2-Speed Controls from
9001 to telePilot see Section 7-9.
This completes the 9100(1) programming, when
completed with the above tap “Save”.
Save will take you back to the initial start screen. At this
point select another Bank to program or go to Section 79. Saving And Loading The Program.
Section 7 - Programming (Continued)
Single-Speed 9100 Series telePilot
Lockout Modes.
7-8.4.
The Modes and Mode labeling shown relate to the
similar, but not identical, Modes in the Single-Speed
9100 Transmitter. Choose the lockout pair that most
closely matches your needs. If you are unsure of the
Lockout Mode in your existing unit, read dip switch
SW3 in the existing 9100 transmitter and compare it to
the chart below. Lockout pairs are shown below:
Original 9100 SW3 Transmitter dip
switch settings:
SW3 Switch
Use Mode
ON
ON
ON
A0
OFF
ON
ON
A1
OFF
OFF
ON
A2
ON
ON
OFF
A3
OFF
ON
OFF
A4
ON
OFF
ON
NA
ON
OFF
OFF
NA
OFF
OFF
OFF
NA
Original 9100
Keypad Layout.
ON/
OFF
10
10
12
11
12
ESTOP
11
Mode A0
NA means not applicable
ESTOP
(EMS)
Functional Mapping of 9100
Series Single-Speed Controls to
telePilot Controls.
Matching numbers indicate the
same function. Mapping not affected by Modes shown below or
by Original 9100 Keypad Labeling
(Inserts).
The dark rectangles on the drawings below represent
buttons pairs that are locked out from both working at
the same time.
Mode A1
Mode A2
Mode A3
Figure 7-8. Single-Speed 9100 telePilot Lockout Modes.
72
Mode A4
Section 7 - Programming (Continued)
2-Speed 9001 and 9101
telePilot Functional Mapping.
7-8.5.
Auxiliary
Controls
Series
Motor 1
Dir 1
Dir 2
ON/
OFF
Motor 2
Dir 1
Dir 2
AUX 1
AUX 2
AUX 3
TX12M-2
Motor 2
Dir 1
Motor 1
Dir 1
2 nd
Speed
2 nd
Speed
Motor 2
Dir 2
Motor 1
Dir 2
Motor 3
Dir 1
Dir 2
AUX 1
E-STOP
AUX 3
AUX 2
Motor 3
Dir 1
2 nd
Speed
Motor 3
Dir 2
EMS
2-Speed telePilot
Switch Layout
2-Speed 9001 and 9101
Switch Layout
Figure 7-9. Functional Mapping of 9001 and 9101
Series 2-Speed Controls to telePilot Controls.
Matching designators indicate the same function.
Mapping not affected by Keypad Labeling (Inserts).
73
Section 7 - Programming (Continued)
7-9. Saving, Downloading, Reading The
Programs and Other PDA Functions.
Saving The Programming File.
With the initial telePilot screen displayed, tap in the
lower left corner of your PDA, the title bar at the top of
the screen will show a menu or tap on the word
“telePilot”. Choose the way you wish to save the file.
Tap on your choice and follow the instructions on the
PDA to complete file saving. Old files can be deleted,
called up, modified and renamed by this same menu.
Setting Admin
Tx Type
New
Open
Rename Current
Delete Current
Save Current
Save Current As
First press
Second press
Third press
Fourth press
Button 6
Button 5
Button 4
Button 3
Bank 1 Bank 2
Bank 3
Bank 4
on
off
off
Figure 7-9. telePilot Infrared Port Access.
2.
2 SPD
Use bank password
on
Battery pack
3.
4.
Turn transmitter unit ON. Note that the Tx Red
LED is ON.
From the application file’s main menu click on
the PDA a dropdown menu icon located at
bottom left corner or tap on the word
“Programmer” at the top of the screen. Select
“Admin.”
Under “Admin.” select “Send Setting.”
Name: ……………………………..…. M
Setting Admin
Sending a Program To The telePilot.
Tx Type
2 SPD
Use bank password
WARNING
AFTER EVERY PROGRAMMING OF THE TRANSMITTER, TEST THE UNIT BY TURNING IT ON
AND OFF NEAR THE APPROPRIATE RECEIVER. IF
THE RECEIVER DOES NOT RESPOND, DO NOT
ACTIVATE A FUNCTION BUTTON! THE TRANSMITTER MAY HAVE INCORRECT PROGRAMMING, WHICH COULD MOVE ANOTHER CRANE.
RE-CHECK THE PROGRAMMING IN THE TRANSMITTER AND RETEST. AFTER ACTIVATION OF
RECEIVER, FUNCTIONALLY TEST ALL COMMANDS ON THE TRANSMITTER BY INITIALLY
JOGGING THE BUTTONS, THEN WITH A FULL
MOVEMENT BEFORE RETUNING TO SERVICE.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY OR DEATH AND
DAMAGE TO EQUIPMENT.
To send a program file which consists of four banks to a
telePilot Transmitter:
1. Line up the PDA’s infrared port with the
transmitters infrared port (remove battery end
cap and pull battery pack back and expose the
telePilot’s infrared port. See Figure 7-9.
telePilot Infrared Port Access).
74
Send Setting
Receive Setting
Beam Setting
TelePilot ID
History
About
First press
Second press
Third press
Fourth press
Button 6
Button 5
Button 4
Button 3
Bank 1 Bank 2
Bank 3
Bank 4
on
off
on
off
Name: ……………………………..…. M
5.
6.
7.
Select a name you want for the telePilot unit
being programmed and tap “OK”.
Wait for confirmation text on PDA screen:
After programming, always operationally test
all the functions the transmitter by using the
appropriate receiver with the MR relay disabled
before retuning transmitter to service.
Receiving (Reading) The telePilot Programming.
To read a program file from the telePilot Transmitter:
1. Line up the PDA’s infrared port as sets 1 to 3
above, with the transmitter ON. Select “Admin”
2. Select “Receive Setting.”
3. PDA will confirm reception and automatically
display current programming in the telePilot
unit.
Section 7 - Programming (Continued)
Reading The telePilot ID.
To read an identity (an identity is the name that was
programmed in by step 5 of Sending a Program To The
telePilot, listed above) from the telePilot Transmitter:
1. Line up the PDA’s infrared port as sets 1 to 3
above, with the transmitter ON. Select “Admin”
2. Select “telePilot ID.”
3. PDA will read: Name, Serial/Job Number, and
Manufacturing information of the telePilot
unit.
Reading The telePilot History.
To read Service information from the telePilot
Transmitter:
1. Line up the PDA’s infrared port as sets 1 to 3
above, with the transmitter ON. Select “Admin”
2. Select “History”
4. Unit will read: Past Service Orders of the
telePilot unit.
Reading The PDA telePilot Software Version.
To read PDA Software Version from the telePilot
Transmitter:
1. Select “Admin”
2. Select “About”
3. Unit will read: telePilot Programmer Software
Version number.
Beaming (Sending) the Configuration(s) to another
PDA.
To send a configuration setting to another PDA.
1. Line up the PDA’s infrared port as, with the
other PDA, which is turned ON.
2. Select “Beam Setting.”
3. Select the item(s) you wish to send.
4. Wait for confirmation text on PDA screen:
Error Statements and Codes.
Tx Type Mismatch; If while attempting to program a
telePilot you receive an error code such as “Error
AAAB” you have selected a different style transmitter
on the PDA than you are attempting to program. Most
common cause is trying to program a 2-speed telePilot
with single-speed selected or visa versa.
75
Section 8 – Servicing
DS19
DS17
DS15
DS14
DS13
DS23
DS22
DS24
RF Receiver “ON” Indicator
RF Receiver Board
DS21
DS20
DS18
DS16
WDT
+12V REG
+12V
5V DC
DS15
+5V
TP5 AGC
TP7 DATA
TP6 ANALOG
TP2 GND
8 7 6 54 32 1
Dip Switches
TP1
EPROM
+5V
8 7 6 54 32 1
8 7 6 54 32 1
SW1 ON
8 7 6 54 32 1
SW2 ON
SW3 ON
SW4 ON DSMR1
KMR1
TP4
TP3
+12V
DS1
JU2
DS2
DS3
DS4
DS5
DS6
DS7
DS8
DS9
JU1
DS10 DS11
SW2
ON
DS12 DSMR2
Master Relay
Relays
K1
ON
K2
K3
K4
K5
K6
MR Disable
Switch for
Diagnostics
K7
K8
K9
K10
K11 K12
K13
SW1
MOV’s
F1
J2
J3
J4
J5
J6
J7
GND N 120V
F2
Main ON/OFF
power Switch
F3
F4
F5
F6
F7
Figure 8-1. Receiver Layout
F8
Jumpe rs:
JU1 - IN - Alarm to work after E-STOP.
JU2 - Not used.
NOTE
IF THE SYSTEM STOPS WORKING CHECK THE RED INDICATOR ON THE TRANSMITTER. IF IT
DOES NOT COME ON WITH PUSHING THE ON BUTTON OR THE YELLOW WEAK BATTERY
LIGHT IS ON (FOR THE telePilot TRANSMITTER) REPLACE THE TRANSMITTER BATTERIES.
Table 8-1. Receiver Diagnostic LED Functions. (See Figure 8-1. Receiver Layout for LED locations).
LED
RF
Receiver
ON
COLOR
Red
FUNCTION
Power is on to the RF Receiver.
Normally ON.
Monitors power to the RF Receiver Board. If the main receiver is ON and the RF Receiver ON
LED is OFF. Check to see if the RF Receiver Board is properly plugged in to the main board.
DSMR1
Yellow
Monitors closure of the Security Relay output (KMR1).
The LED will be illuminated when the Security Relay has been enabled by an ON command
received from the Transmitter Unit. LED will extinguish when an OFF command is transmitted,
or an EMS condition is present.
The Security Relay controls the 12 VDC power to the MCR relay (K13) and the power to the coils
of the control relays (K1 through K12) on the Relay Output Modules.
76
Section 8 – Servicing (Continued)
DSMR2
Red
Monitors closure of the Master Control Relay (MCR) relay (K13).
LED will be illuminated when the MCR relay has been enabled by an ON command recieved
from the Transmitter Unit. Led will extinguish, when an OFF command has been transmitted, an
EMS condition is present, or SW2 is set to OFF.
The MCR controls the 12 VDC power to the Master Relay on the Power Supply Board.
DS1-DS12
Red
Monitors closure of the output relays (K1-K12).
Normally ON for a function when that specific function is enabled.
The LED will be illuminated when a specific relay has been enabled by the respective command
received from the Transmitter Unit. The LED will extinguish, when the command is no longer
detected.
DS13
Red
Monitors the watchdog timer.
Normally OFF.
The LED will illuminate momentarily when power is applied to or removed from the system. If
the LED is continuously flashing or on, the computer is not working properly. If LED is
illuminated constantly (no flashing), the +5 VDC is probably too low. This could be caused by
shorts on the board or by a defective voltage regulator. If the LED flashes at a constant rate, the
microcomputer chip or EPROM may be defective.
DS14
Yellow
Monitors data synchronization. (Flashes when a properly formatted data signal is received from
the transmitter).
This LED will flash rapidly when data is transmitted. The LED can be used with DS16 to analyze
incoming data. If DS16 is illuminated or flashing when DS14 also is flashing, another Transmitter
Unit on the same frequency may be present. This is normal. As more Transmitter Units operated
on the same frequency, LED will flash brighter and more often.
DS15
Yellow
Monitors continuity between receiver RF module and CPU module.
Normally ON.
Off indicates a malfunctioning receiver.
DS16
Red
Check
this
first!
DS17
Monitors received data errors. Wrong Access Code.
Normally OFF.
If LED is illuminated continuously when data is transmitted and the system will not respond the
Access Code of the Receiver and Transmitter Units may not match. A flashing LED during data
transmission may indicate interference of the received data. If LED is illuminated when data is not
transmitted, another Transmitter Unit may be present on the same frequency with a different
Access Code. The presence of activity on this LED does not necessarily indicate a problem. It
should be used with other indicators in analyzing system status.
Yellow
Monitors system acitivty.
Normally FLASHING.
If not flashing the microprocessor is dead.
DS18
Red
Monitors the ON command from the Transmitter.
77
Section 8 – Servicing (Continued)
LED will flash when an ON command is being received from the Transmitter.
While pushing the ON button on the Transmitter this should light.
DS19
Red
Monitors EMS condition.
Normally OFF.
LED will flash when an EMS command is transmitted and illuminate continuously when the EMS
condition is in effect. An EMS condition may be created when an EMS command is transmitted or
when a failure mode is detected by the slave microcomputer. If both DS18 and DS19 are
illuminated, a contact monitoring error has been detected. If both DS16 and DS19 are illuminated,
the incoming data on the ICC bus has been corrupted.
DS20
Red
Monitors the OFF command from the Transmitter.
LED will flash when an OFF command is being received from the Transmitter Unit.
While pushing the OFF button on the Transmitter this should light.
DS21
Yellow
Monitors the activity for the Security Relay (KMR1).
Normally ON when the receiver is enabled.
If the system is ON and the light is not lit there is a serious microprocessor error.
DS22
Green
Monitors the unregulated DC power to the 12 volt regulator
Normally ON when AC line is present.
If AC Power is present and the AC to DC converter is working then the LED is illuminated. The
LED is off if DC power is not present. Check power supply, fuses and if power is applied to the
receiver.
DS23
Green
Monitors the regulated 12 VDC power to the Board (receiver board).
Normally ON when AC line is present.
If 12 VDC power is present then the LED is illuminated. The LED is off if 12 VDC power is not
present. Check the 12 VDC regulator and for shorts on the Board.
DS24
Green
Monitors regulated 5 VDC power to the Board.
Normally ON when AC line is present.
If 5 VDC power is present then the LED is illuminated. The LED is off if 5 VDC power is not
present. Check the 5 VDC regulator and for shorts on the Board.
8-2. Receiver Testing.
8-2.1.
Receiver test points.
Test points are shown as dark circles on Figure 8-1. Receiver Layout.
TP1 – Monitors regulated 5 VDC.
TP2 – Ground for monitoring other test points.
TP3 – Monitors regulated 12 VDC.
78
Section 8 – Servicing (Continued)
TP4 – Not used.
79
Section 8 – Servicing (Continued)
NOTE
THE FOLLOWING TEST POINTS NEED AN
OSCILLOSCOPE, SEE 8-2. RECEIVER SCOPE
WAVE FORMS.
TP5 – Monitors AGC (Automatic Gain Control) from RF Receiver module.
TP6 – Monitors analog signal from RF Receiver module.
TP7 – Monitors received data from RF Receiver module.
8-2.2.
Typical Wave Forms on an Oscilloscope.
TP6
ANALOG
TP7
DATA
TP5
AGC
Receiving Data
Not Receiving Data
Figure 8-2. Receiver Scope Wave Forms.
Scope Settings:
Sweep –
1 millisecond per division.
Sensitivity –
TP6, 1 volt per division 10X probe.
TP7, 2 volts per division 10X probe.
TP5, 1 volt per division 10X probe.
80
Section 8 – Servicing (Continued)
8-3. Membrane Transmitter Servicing.
The Membrane Transmitter M/C board is shown
in Figure 8-3. Refer to paragraphs below for
Servicing Procedures.
1.
_J2
NOTE
TO DISABLE TIME-OUT-TIMER
IN TRANSMITTER TURN SW3
POSITION 3 TO ON.
2.
3.
ON
J1 Keyboard Connector
4.
ON
SW3
JU7
U3
B1
TP1 +5V
DATA
J2A
JU5
R21
RF SW
ON
TP2 GND
Figure 8-3.
Membrane
Transmitter M/C
Module E10635
RF Head
8.
JU6
SW4
6.
5.
1.) EPROM FW2903-0
4.)
Tactile 2-SP, FW2904-0T
1 & 2-SP Non-tactile.
5.)
2.) SW1 “A” Access Code
Switch.
7.
SW3 Two-Speed Mode
Switch.
Battery Monitor
Adjustment. Set for 5.8
Volts.
3.) SW2 “B” Access Code Switch.
8-3.1.
7.) SW4 Single-Speed Mode
Switch.
while operating crane with the transmitter,
replace the batteries they are weak. Weak
batteries may operate the crane for a while, but
the LED will not flash. If the battery is too low
the battery monitor will shut the transmitter OFF.
See Section 5-6. Battery Replacement for proper
procedure.
2.) Use “RF SW” for External Trigger input.
3.) Use TP2 for Ground
NOTE
Battery Monitor Adjustment.
Connect power supply to battery leads observing
polarity and set supply voltage to 5.8 volts.
Adjust Battery Monitor Potentiometer R21 to
just turn off red LED on the front of the
transmitter.
8-3.3.
6.) Battery Cable
Connections, J2A plug
and J2 alternate style.
8.) Data check points.
To Check Data.
1.) For data input use “DATA” connection to
RF Head
8-3.2.
1 ON
IF THE BATTERIES ARE INSTALLED
BACKWARDS
IN
THE
MEMBRANE
TRANSMITTER THE FUSE IN THE BATTERY COMPARTMENT WILL BLOW TO
PROTECT THE INTERNAL CIRCUITRY.
Red LED Not Flashing.
8-3.4. Battery Fusing.
The Membrane Transmitter is protected from
reverse battery polarity and shorts by a fuse, part
number F2712-1.5 (1.5 Amp, 250V, Fast Acting,
If the red LED indicator on the transmitter does
not flash when the transmitter is turned ON or
81
Section 8 – Servicing (Continued)
2 AG). If the batteries are installed in backwards
this fuse will blow to protect the internal
electronics
82
Section 8 – Servicing (Continued)
8-4. Pendant Transmitter Servicing.
The Single-Speed or the 2-Speed 10K12 Pendant
Transmitter may be used with the 10K6/9
Receiver. The Pendant Transmitter M/C Board is
shown in Figure 8-4. Refer to paragraphs below
for Servicing Procedures.
1.
2.
3.
J2
J1
JU8
J5
TP4
GND
J3
Figure 8-4.
Pendant
Transmitter M/C
Module E10636
ON
R1
J4
JU5
SW2
JU3
DON
SW4
1B
ON
SW1
J6
JU2
ON
TP2
+REF
SW3
TP1
4.
5.
6.
1. ) J1 Pin 1 Data Input.
2. ) Stepless Switch Level
Adjustment. (Factory Set).
7.
JU1
8.
9.
10.
NOTE
TO DISABLE TIMEOUT-TIMER IN TRANSMITTER TURN SW3
POSITION 3 TO ON.
11.
5. ) SW2 “A” Access Code
Switch.
8. ) Test Point 1 External
Trigger for Data.
6. ) SW1 “B” Access Code
Switch.
9. ) Software version label.
3. ) Battery Connector.
10. ) Flash ROM.
7. ) SW3 “C” Configuration
4. ) SW4 “D” Mode Switch. Switch. SW3 position 8 “ON”
disables Time-out-timer.
11. ) Flash ROM Serial
Programming Port.
8-4.1.
To Check Data.
1.) For data input use pin 1 of J1.
8-4.3.
2.) Use TP1 for External Trigger input.
If the red LED indicator on the transmitter does
not flash when the transmitter is turned ON or
while operating crane with the transmitter,
replace the batteries, they are weak. Weak
batteries may operate the crane for a while, but
the LED will not flash. If the battery is too low
the battery monitor will shut the transmitter OFF.
See Section 5-6. Battery Replacement for proper
procedure.
3.) Use TP4 for Ground.
8-4.2.
Battery Monitor Adjustment.
Battery monitor is factory preset no adjustment
available.
83
Red LED Not Flashing.
Section 8 – Servicing (Continued)
8-4.4.
Stepless Switch Adjustment.
R1 is factory preset and controls the upper level
of the stepless switch range.
8-4.5.
Pendant Transmitter Software.
There is no EPROM in the Pendant Transmitter;
software is stored internally in non-volatile flash
memory. Software updates are done in the
factory through the serial port. A software
version label on the board indicates the software
version loaded into flash memory.
8-5. telePilot Servicing.
There are no user adjustments inside the
telePilot unit. All internal adjustments are done
by software. Internally there is a single circuit
board that requires proper handling to replace.
The individual switch packs can be replaced with
out opening the unit. Contact Telemotive
Customer Care for details. See Figure 9-1.
telePilot Exploded View View.
CAUTION
• DO NOT ATTEMPT TO OPEN OR SERVICE THE TELEPILOT UNIT.
• ONLY TRAINED QUALIFIED INDIVIDUALS SHOULD DO SERVICING.
• STRICT ANTI-STATIC HANDLING
PROCEDURES MUST BE FOLLOWED.
• FAILURE TO FOLLOW THIS CAUTION
COULD RESULT IN SERIOUS DAMAGE
TO EQUIPMENT AND/OR VOID THE
WARRANTY.
84
Section 9 – Spare Parts
RECEIVER
PART NUMBER
FW2912-0
E13157-S
H310-0
MP18005-0
MP18005-1
H906-0
H934-0
E10199-0
H1224-1
E10197-2
TS1060-3
TS4655-4
J4655-0
TS1060-8
CR260-0
K1304-0
S2721-8
MP10276-0
H1223-1
H1226-0
H2079-0
TCTX12/TR12-0
F2711-2
F2711-0
H1127-0
WA12038-0
A525-1
WA104-20
DESCRIPTION
EPROM
RF SYNTHESIZED RECEIVER MODULE ASSEMBLY
RF RECEIVER MODULE ASSEMBLY MOUNTING SCREWS (4)
RF RECEIVER MODULE MOUNTING BRACKET TOP SIDE (LEFT)
RF RECEIVER MODULE MOUNTING BRACKET TOP SIDE
(RIGHT)
RF RECEIVER MODULE MOUNTING BRACKET BOLT (2)
RF RECEIVER MODULE MOUNTING BRACKET NUT (2)
MAIN BOARD
MAIN BOARD MOUNTING SCREWS (5)
ANTENNA ASSEMBLY (INTERNAL)
CONNECTOR PLUG IN:
3 POSITION (2)
3 POSITION (3)
6 POSITION
8 POSITION
MOV
RELAY (OUTPUT) (13)
DIP SWITCH (ACCESS CODE) (4)
HOUSING ASSEMBLY, WITH DOORS
SCREW ROUND HEAD #10-24 X 1 ½”
HEX NUT #10-24 (4)
LOCK WASHER #10 SPLIT
INSTRUCTION MANUAL
FUSE ½ AMP, SLO BLO 250V
FUSE 10 AMP SLO BLO 250V (7)
FUSE COVERS, VINYL (7)
EXTERNAL ANTENNA ADAPTER (Does not include antenna).
ANTENNA (For use with WA12038-0).
CABLE ASSMBLY, 20 FOOT (For remote antenna mounting requires
WA12038-0 and A525-1).
telePilot TRANSMITTER (SEE FIGURE 9-1.)
PART NUMBER
DESCRIPTION
E10647-0
MAIN CIRCUIT BOARD 2-SPEED
E10727-0
MAIN CIRCUIT BOARD SINGLE-SPEED
N10705-0
LABELS
MP10620-0
SHOULDER STRAP
TCTX12/TR12-0
MANUAL
FW3045-0
PDA PROGRAMMING SOFTWARE
MP10709-0
BELT LOOP ASSEMBLY
A10708-0
BATTERY DOOR ASSEMBLY
H1113-0
HEX STANDOFF (4)
H1114-0
ROD, ALL THREAD, 2-SPEED (2)
H1121-0
ROD, ALL THREAD, SINGLE-SPEED (2)
E10713-0
SWITCH PACK 2-SPEED RIGHT
E10712-0
SWITCH PACK 2-SPEED LEFT
E10715-0
SWITCH PACK SINGLE-SPEED RIGHT
E10714-0
SWITCH PACK SINGLE-SPEED LEFT
WA1050-0
SWITCH RIBBON CABLE (2)
MP10706-0
TOP END CAP
MP10707-0
BOTTOM END CAP
A10724-0
HOUSING ASSEMBLY SINGLE-SPEED
85
Section 9 – Spare Parts (Continued)
telePilot TRANSMITTER CONTINUED (SEE FIGURE 9-1.)
PART NUMBER
DESCRIPTION
A10722-0
HOUSING ASSEMBLY 2- SPEED
WA1052-0
BATTERY CABLE, 2-SPEED
WA1053-0
BATTERY CABLE, SINGLE-SPEED
MP10721-0
BATTERY HOLDER FOR TWO “AA” CELLS
BT111-0
DISPOSABLE HIGH CAPACITY BATTERY PACK
BT111-1
RECHARGEABLE BATTERY PACK
A10723-0
BATTERY CHARGER FOR BT111-1
MEMBRANE TRANSMITTER
PART NUMBER
DESCRIPTION
F2712-1.5
FUSE 1.5 AMP, 250V FAST ACTING 2 AG
FW22903-0
TWO SPEED TACTILE MEMBRANE EPROM FOR TRANSMITTER
M/C MODULE E10635
A9654-0
STRAP ASSEMBLY
A10662-1
TRANSMITTER CASE ASSEMBLY
E9654-0
BATTERY HOLDER ASSEMBLY
A10664-2
BATTERY DOOR ASSEMBLY
E10640-2
BEZEL ASSEMBLY (2-SPEED TRANSMITTER)
S2803-0
MEMBRANE SWITCH PAD (TACTILE)
MP9656-0
VINYL POUCH
A9665-0
RUBBER BOOT ASSEMBLY
BT646-0
BATTERY AA CELL 1.5 VOLTS (5)
PENDANT TRANSMITTER
PART NUMBER
DESCRIPTION
MP10668-1
CASE ONLY, TOP PENDANT TRANSMITTER
H634-0
BOOT, GRAY (PUSHBUTTON)
H635-0
BOOT, RED (PUSHBUTTON)
H2055-3
LENS/MOUNT, LED W/SPACER, RED
S1058-0
SWITCH, PUSHBUTTON, 2-SPEED SBRU-SD
S1026-0
SWITCH, PUSHBUTTON, MOM N/0
S1041-0
SWITCH, TOGGLE, SPDT, CTR OFF
MP10666-0
KNOB, ROTARY 1/2" DIA., BLACK
MP10675-0
BOOT, TOGGLE SW., BLACK
A10667-5
BOTTOM CASE W/O BATTERY DOOR
A10669-1
BATTERY DOOR W/FOAM, W/O SCREWS AND LATCH
MP10676-0
FOAM, BATTERY DOOR
MP10677-0
GASKET FOR BOTTOM CASE
H1047-0
COVER SCREWS (8)
MP1049-0
SWITCH GUARD
E10668-11LT
SAME AS E1066-11 BUT WITH SWITCH GUARD AND LARGE
TOGGLES
MP10668-3
CASE TOP ONLY, LARGE TOGGLES
MP10650-3
LATCH FOR BATTERY DOOR
S605-0
SWITCH, TOGGLE SPDT CENTER OFF, LARGE
A1011–X
BOOTS (6) (SEE *NOTE 1 BELOW FOR THE PROPER SUFFIX)
H251-0
SCREW FOR BATTERY DOOR LATCH
H252-0
WAVE WASHER FOR BATTERY DOOR LATCH
H2034-0
FLAT WASHER FOR BATTERY DOOR LATCH
N13653-2
FCC LABEL
E10688-0
BATTERY HOLDER ASSEMBLY, W/CABLE
MP10680-0
O'RING
MP10678-0
SHOULDER STRAP
BT10KP-0
BATTERY, ALKALINE
86
Section 9 – Spare Parts (Continued)
PENDANT TRANSMITTER CONTINUED
PART NUMBER
DESCRIPTION
BT10KP-1
BATTERY, NICAD
BT10KP-0
BATTERY, ALKALINE
BT10KP-1
BATTERY, NICAD
E10670-1
BATTERY CHARGER
*NOTE 1
UP
DOWN
EAST
WEST
NORTH
SOUTH
YELLOW
BLACK
23
24
31
11
32
12
29
30
10
87
Section 9 – Spare Parts (Continued)
CAUTION
DO NOT ATTEMPT TO OPEN OR SERVICE THE TELEPILOT UNIT.
ONLY TRAINED QUALIFIED INDIVIDUALS SHOULD DO SERVICING. STRICT ANTISTATIC HANDLING PROCEDURES MUST BE FOLLOWED. FAILURE TO FOLLOW THIS
CAUTION COULD RESULT IN SERIOUS DAMAGE TO EQUIPMENT AND/OR VOID THE
WARRANTY.
2-SPEED MODEL SHOWN
MP10706-0
TOP END CAP
E10647-2SP MAIN CIRCUIT
BOARD 2-SPEED
WA1050-0 SWITCH
RIBBON CABLES (2)
E10647-1SP MAIN CIRCUIT
BOARD SINGLE-SPEED
E10712-0
SWITCH PACK
2-SPEED LEFT
E10713-0
SWITCH PACK
2-SPEED RIGHT
E10714-0
SWITCH PACK
SINGLE-SPEED
LEFT
E10715-0
SWITCH PACK
SINGLE-SPEED
RIGHT
MP10707-0
BOTTOM END CAP
A10722-0
HOUSING ASSEMBLY
2- SPEED
A10724-0
HOUSING ASSEMBLY
SINGLE-SPEED
A10708-0 BATTERY
DOOR ASSEMBLY
H1113-0
HEX STANDOFF #10-24 (4)
Figure 9-1. telePilot Exploded View.
88
Appendix A - Transmitter Switch Programming
Switch POS.
SW3
SW4
SW4
Mode 0
Mode 1
Mode 2
Mode 3
SW4
Mode 1
Mode 2
Mode 3
Membrane
Switch Orientation 1
Switch Orientation 2
Switch Orientation 3
Pendant
Switch Orientation 1
Switch Orientation 2
Switch Orientation 3
SLTX
N/A
N/A
N/A
JLTX
Code Plug Select
N/A
N/A
Switch Orientation 1
Switch Orientation 2
Switch Orientation 3
Time-out-timer Disable
Crane Configuration 1
Crane Configuration 2
Crane Configuration 3
N/A
N/A
RS232 enable
N/A
N/A
N/A
RS232 enable
N/A
N/A
N/A
RS232 enable
Tilt Switch Disable
Time-out-timer Disable
Crane Configuration 1
Crane Configuration 2
Crane Configuration 3
N/A
Mode Enable
See Table A below
Mode Enable
See Table B below
Mode Enable
See Table B below
Mode Enable
See Table B below
Mode Enable
See Table A below
N/A
N/A
Mode Enable
See Table B below
Tandem Disable
Un-check “Tandem”
on telePilot
Select Invert
Check “Invert”
on telePilot
Mode Enable
See Table B below
Tandem Disable
Un-check “Tandem”
on telePilot
Select Invert
Check “Invert”
on telePilot
Mode Enable
See Table B below
Tandem Disable
Un-check “Tandem”
on telePilot
Select Invert
Check “Invert”
on telePilot
N/A
Crane Configuration 1 Crane Configuration 1 Crane Configuration 1
copy to telePilot S3-5 copy to telePilot S3-5 copy to telePilot S3-5
N/A
Crane Configuration 2 Crane Configuration 2 Crane Configuration 2
copy to telePilot S3-6 copy to telePilot S3-6 copy to telePilot S3-6
N/A
N/A
Crane Configuration 3 Crane Configuration 3
copy to telePilot S3-7 copy to telePilot S3-7
N/A
N/A
POS.
Time-out-timer Disable Time-out-timer Disable Time-out-timer Disable Time-out-timer Disable
Table A
OFF
OFF
ON
OFF
OFF
ON
ON
ON
POS.
telePilot
Crane Configuration 3
copy to telePilot S3-7
N/A
(Membrane only)
Use 2-Speed telePilot
Use Single-Speed telePilot “ Mode 1”
Use Single-Speed telePilot “ Mode 2”
Use Single-Speed telePilot “Mode 3”
Table B
OFF
OFF
ON
OFF
ON
ON
For Single Speed Use Single-Speed telePilot “ Mode 3”
For 2-Speed Transmitter Use 2-Speed
telePilot Under “Main/Aux” use "AUX"
Use 2-Speed telePilot Under “Main/Aux” use "Motor"
Use 2-Speed telePilot Under “Main/Aux” use "Select"
89

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