USER`S MANUAL CONSOLE TRANSMITTER
Contents
1. af a af of af ello of 2 af a of Pe 79 TM6OPi 02 02 PAG 6 3 3 Starting up Proceed with caution the equipment may not be connected correctly which may lead to unforeseeable movements on starting up Once the receiver has been connected disconnect the power supply to the motors for example by removing the fuses and power on the receiver The following receiver LEDs should now light up POWER indicates that the power supply is correct HARD two LEDs on the relay board and on the logic board indicate the absence of defects on the boards KSTOPI store Next place a charged battery in the transmitter and turn it ON To do this turn the contact key push and pull out the STOP button and press the start button The green LED should light up indicating that the transmitter is transmitting 1 LED 4 STOP button 2 Start button 5 Command elements 3 Contact key 6 Label for crane identification TM6OPi 02 02 PAG 7 On receiving a signal from the transmitter the following LEDs will light up on the receiver SIGNAL this indicates that it is receiving an RF signal at the working frequency DATA this means that the data format is correct ID this means that the receiver has recognised the transmitter s identification code Now the KSTOP 1 and KSTOP 2 relays will be activated K2 START relay is activated only meanwhile the start button is pushed AL2. Spurious preventing devices should also be fitted when installing the set on a spark combustion engine vehicle TM6OPi 02 02 PAG 9 NS IKUSI 4 USE To ensure correct use of the equipment follow the instructions below Make sure the transmitter you are going to use is the right one identifying the machine on the identification label Attach the belt to the transmitter unit Its use is recommended to prevent the equipment from falling Introduce a charged battery turn the contact key This will activate the transmitter To activate the system you must first pull out the STOP button the green LED should then give a green pulse then press the START button If you find that the STOP button has already been pulled out it is necessary to push it in and then pull it out again as this sequence will allow the check in of the STOP circuit If the unit has experienced a time out auto disconnection it is not necessary to repeat the STOP button procedure simply push the START button for 1 second The green LED should light up indicating that the transmitter has started transmitting From now on if any of the transmitters command buttons are pressed the corresponding manoeuvre will be activated To be able to start up the transmitter all the command controls associated with active manoeuvres must be in the neutral position not activated This is not the case for the selection functions When 4 minutes have passed and
3. 1102071 1 0 1 Spring return toggle switch 2c 1102070 0 1 Maintained toggle switch 1c 1102049 1 0 1 Maintained toggle switch 1c 1102047 Boot for toggle switch 1107007 STOP push button 2300146 Contact keylock 1102033 A60 Receiver antenna 1119015 PA3 BNC Antenna extension lead 1119020 Fuse 1105001 PS60 3 SM Console upper part customised 2303630 PS60 4 SM Console upper part customised 2303635 PI60 3 Console lower part 2303650 PI60 4 Console lower part 2303655 Handle 3 1175022 Handle 4 1175021 TM6OPi 02 02 PAG 14
4. Press on any of the transmitters manoeuvre buttons and its corresponding relay will be activated and its LED will light up In case of an active manoeuvre the safety relay K1 SEC will also activate Check to make sure all the other manoeuvres work in this way Turn off the transmitter using the STOP button and make sure that on doing so the relays are deactivated and the DATA ID and SIGNAL LEDs go out Reconnect the power supply to the motors move to the usual work position and check to see if all the manoeuvres and the STOP buttons are functioning correctly Remember that the receiver has several voltage powered circuits Even when the power has been cut off there is still a risk of electrical shocks TM6OPi 02 02 PAG 8 NS IKUSI 3 4 Spurious The receiver is designed to become blocked if there is intense spurious disturbance arising from galvanic inductive or capacitive coupling thus preventing unwanted manoeuvres As a precautionary measure it is recommended that spurious preventing devices diodes capacitors RC circuits be fitted at the source of the disturbance These devices should be connected directly to the contactor coil terminals electro valves etc and can be obtained from the usual contactor suppliers If the equipment is installed on a vehicle with a friction power supply where electric arcs are produced as a result of defective contact an RC circuit should be fitted between each phase and earth
5. no active manoeuvre command has been activated the transmitter automatically switches off To start it up once more press the start button The transmitter is equipped with a circuit for monitoring the battery level When this level drops below a pre established limit the transmitter LED starts to flash in red and a buzzer goes on 5 minutes later the transmitter switches off and the machine s main contactor is deactivated During this time the load has to be located on a safe position The console transmitters have tilt monitoring circuit to detect abnormal console positions The transmitter cannot work if it is not in the vertical position If the console is not in a vertical position the LED will flash red three times and a buzzer will go off If the console is tilted while transmitting after 2 seconds all manoeuvres will cease even if the main contactor is still on To reinitiate transmission the console must be put back in the upright position and the manoeuvres must be deactivated To switch off the transmitter press the STOP button or turn off the contact key Remember that you are going to remote control a moving piece of machinery The safety instructions described in chapter 2 of this manual must be strictly adhered to TM6OPi 02 02 PAG 10 NS IKUSI 5 MAINTENANCE 5 1 Guarantee IKUSI guarantees the TM60 remote control sets for a period of up to one year after the date of delivery This guarantee covers re
6. 0 8 transmitters Transmission power 10mW Protection IP65 The R60 9 R60 18 R60 26 and R60 38 receivers Power supply 48 115 230 Vac 10 50 60 Hz Optional 12 or 24 Vdc Consumption 30 to 40 W depending on models Relays 230 Vac 8 A Protection IP55 The CB60 battery charger Power supply 230 Vac 10 50 Hz optional 115 Vac 60 Hz or 24 Vdc The BT12 batteries Voltage 7 2V Capacity 1200 mAh Charging temperature 5 a 35 C Autonomy 8 to 12 h depending on models TM6OPi 02 02 PAG 1 NS IKUSI 2 SAFETY PRECAUTIONS These instructions must be read carefully in order to install and use the set properly and to keep it in perfect working condition and to reduce the risks of misuse Do not use this set on machines for the lifting of persons or in potentially explosive atmospheres Any use other than that specified in this manual is dangerous The following instructions must be strictly adhered to Important note To comply with FCC RF exposure compliance requirements this device and its antenna must not be co located or operating in conjunction with any other antenna or transmitter 2 1 What you must do Strictly adhere to the instructions for installation contained in this manual Make sure that the installation is carried out by professional and competent personnel Ensure that all site and prevailing safety regulations are fully respected Make sure that this manual is permanently available to t
7. NS IKUSI USER S MANUAL TM60 CONSOLE TRANSMITTER VIGUHI IKUSI reserves the right to modify this information without prior notification NS IKUSI 1 DESCRIPTION 2 SAFETY PRECAUTIONS 2 1 What you must do 2 2 What you must not do 3 INSTALLATION 3 1 CB60 Battery charger 3 2 Receiver 3 3 Starting up 3 4 Spurious 4 USING THE SET 5 MAINTENANCE 5 1 Guarantee Se ee O O NA C CQ Im m PD k 5 2 Precautions N 5 3 Preventive maintenance Co 5 4 Identifying faults k D 5 5 Spare parts TM6OPi 02 02 PAG i NS IKUSI 1 DESCRIPTION The TM60 3 TM60 4 TM60 5 TM60 6 TM60 7 and TM60 8 console type transmitter radio remote control systems are designed for the remote control of hoists and cranes overhead cranes tower cranes hydraulic loader cranes concrete pumps driverless vehicles etc and are particularly suitable for applications when the operator needs to be able to choose the best location from which to carry out an operation The system consists of a transmitter for selecting commands and a receiver which is connected to the electrical system of the machine to be operated The system also comes with a battery charger and two rechargeable batteries The main specifications are as follows The TM60 Frequency band 405 a 475 MHz Response Time 100 ms Temperature range 20 a 65 C The TM60 3 TM60 4 TM60 5 TM60 6 TM60 7 and TM6
8. any intense radioelectric disturbance source and install the receiver cabinet using 4 elastic absorbers M8 The receiver antenna must be placed free of shielding by metal parts which could obstruct reception of the signal If this is not possible please request an antenna with cable extension TM6OPi 02 02 PAG 4 There are three ways to connect the receiver box to the crane s electrical installations Using multiwire cable Using a multipin connector in the receiver box TM6OPi 02 02 PAG 5 Connect the power supply and the receiver outputs on the corresponding relay board plug in terminals Do this following the outputs diagram which is supplied with the set This diagram indicates the connection between the transmitter commands and the receiver outputs The KSTOP1 and KSTOP2 relays are in series and must be connected to the main contactor coil circuit The K2 START is activated once the start up command is held down The K1 SEC relay is a security relay which is activated when certain commands predefined as active on configuration of the set i e commands which give rise to manoeuvres are activated KSTOPI Ca KSTOP2 Si illl zu wn na e AX ca C gt 29 24Vv0c SE BISRT 1A7250VAC R o FUSE K1 5EC Remember to connect the ground cable Only use fireproof cables for connections Select the appropriate voltage on the receiver 230 115 or 48 Vac WWW TY
9. he operator and maintenance personnel Keep the transmitter out of reach of unauthorised personnel Remove the transmission key when the set is not in use On starting each working day check to make sure that the STOP button and other safety measures are working When in doubt press the STOP button Whenever several sets have been installed make sure the transmitter you are going to use is the right one Identify the machine controlled on the label for this purpose on the transmitter Service the equipment periodically When carrying out repairs only use spare parts supplied by IKUSI dealers 2 2 What you must not do Never make any changes to the set which have not been studied and approved by the manufacturer Never power the equipment other than with the specified power supply Never allow unqualified personnel to operate the equipment After use never leave the equipment ON Always use the contact key or the STOP button to avoid accidentally activating manoeuvres Do not use the set when visibility is limited Avoid knocking or dropping the set Do not use the set if failure is detected TM6OPi 02 02 PAG 2 3 INSTALLATION 3 1 The CB60 battery charger TM6OPi 02 02 Connect the charger to the mains using the power source and cable supplied On installing the battery charger bear in mind that the batteries must be charged at temperatures over 5 C and that the power
10. llowing checks to be made from time to time Transmitter Checkthe transmitter s closing screws to make sure they are securely tightened gt Check the rubber protection seals on the transmitters command buttons from time to time Replace them if they are found to have deteriorated This will protect the unit s watertightness Keep the battery contacts clean Receiver Check to make sure the cable fixture screws are tight Check the contacts on the fuses and the fuse holders Check the connectors between the different receiver modules Check the state of the receiver antenna its connectors and cables Battery charger and batteries gt Keep all contacts clean TM60Pi 02 02 PAG 12 NS IKUSI 5 4 Locating Break downs The transmitter and receiver both have status monitoring LEDs which help to identify irregularities The transmitter also has an acoustic buzzer The most common signals are contained in the tables below TRANSMITTER BUZZER VES Green double flashing Off Transmitter ready for start up f Transmitter transmitting normall Red flashing Slow single buzz Battery level low f Red double flashing Rapid double buzz Transmitter cannot start up because al manoeuvre command button is on Red triplet flashing Rapid triplet buzz Abnormal console position Solid red Transmitter failure RECEIVER In normal circumstances the 6 green LEDs and the 2 red LEDs associated with the STOP relays
11. pairs and the replacement of defective pieces at our Technical Service Department Both the transmitter and receiver will be necessary if any repairs or replacements need to be carried out The guarantee does not cover damage resulting from the following transport incorrect installation repairs or alterations made to the equipment by personnel other than from IKUSI obvious misuse or incorrect maintenance of the equipment Our Technical Service reserves the right to evaluate break downs and damage Under no circumstances will IKUSI be held responsible for hold ups at work accidents or expenses incurred as a result of equipment malfunctioning 5 2 Precautions This equipment is designed for use in an industrial environment However we recommend you follow the instructions below to extend the life span of your remote control set Use the belt provided with the transmitter to prevent the transmitter from falling Do not clean the transmitter with solvents or pressurised water Use a damp cloth or soft brush Use and recharge the battery regularly Check every day that the STOP button is working Disconnect the receiver cables if soldering welding work is going to be carried out on the crane TM6OPi 02 02 PAG 11 NS IKUSI 5 3 Preventive maintenance A few simple checks can bring to light certain defects which can later be the cause of subsequent break downs and which can be readily rectified We recommend the fo
12. should be lighting If this is so press the transmitter manoeuvre buttons and observe the response of the output relays If the response is normal the problem is not related to the remote control equipment and the installation must be checked If any of the relays is not activated the problem is associated with the remote control equipment If this happens observe the appearance of the LEDs Relay Board POWER Power supply OK Power failure HARD Board OK Failure in the relay or logic board RELAYS Red Output activated Output not activated Logic Board HARD Board OK Failure in board SIGNAL Green Radio signal present Channel free on the channel ID Green ID Code OK Does not recognise ID Code If the problem is associated with the equipment please send both the transmitter and the receiver to the your Technical Assistance Service together with a description of the problem and the status of the LEDs TM6OPi 02 02 PAG 13 NS IKUSI 5 5 Spare parts BT12 Battery 2303696 CB60 Battery Charger 2303685 Power supply for CB60 230 Vac 1106018 Power supply for CB60 230 Vac UK 1106026 Power supply for CB60 115 Vac 1106027 C60C Padded belt 1175029 B60C padded strap 1175030 MO60 Optical joystick 2303668 Optical joystick cover CMO60 2303669 Electrical joystick 4x1 1102029 Paddle joystick 1102061 0 1 Push button 1c 1102050 0 1 Push button 2c 1102069 Boot for push button 1107006 0 1 Spring return toggle switch 2c
13. supply must be left on all night Also remember that the charger must not be left in direct sunlight as the batteries will not become fully charged at temperatures exceeding 35 C Place the batteries in the charger The LEDs should light up indicating that recharging is in process Complete recharging takes 12 hours but the batteries may remain in the charger for an unlimited period of time The capacity of the batteries decreases with use Their life span is estimated to be 500 recharging cycles but this depends largely on the conditions of use for which the following is recommended gt gt gt gt gt Do not recharge the battery until it is completely flat The transmitter indicates this Always charge the batteries at temperatures between 5 and 35 C Avoid short circuits between the battery contacts Do not carry charged batteries in tool boxes or next to other metal objects keys coins etc Always keep contacts clean Never leave batteries in direct sunlight PAG 3 3 2 Receiver Make sure that the crane is stopped for the entire duration of the assembly process keep the work area free and wear protective clothing Park the crane and position stop ends if these are not available use appropriate signs at a suitable distance so that it is not hit by other cranes on the same runway Check the power supply voltage and turn off the mains switch Find a suitable location for the receiver away from
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