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Telemotive Series 18K Receiver

1. DESCRIPTION INTERNAL WIRING CONTINUED WA1006 45 WA18002 13 WA18002 30 WA18002 45 WA1088 2 WA1037 0 W1098 2 W1098 4 MP803 0 TB2703 1 MP803 0 CB100 1 W 126 0 W127 0 K206 31 E1860 30 CR2105 0 F108 0 X110 0 X111 0 ANTENNA AN100 1 E2028 2 E525 0 E525 0 E104 0 E104 1 6 CONDUCTOR CABLE 45 INCH FOR DOOR MOUNTED RF TRANSLATOR BOARD TO CPU RS485 CABLE 13 INCH FOR BACK PANEL MOUNTED RF TRANSLATOR BOARD TO CPU RS485 CABLE 30 INCH FOR BACK PANEL MOUNTED CONTACT MONITORING BOARD RS485 CABLE 45 INCH FOR DOOR MOUNTED RF TRANSLATOR BOARD TO CPU LICENSED PART 90 RECEIVER TO RF TRANSLATOR BOARD CABLE CABLE JUMPERS CPU BOARD TO RELAY OUTPUT BOARDS JUMPER INSULATED 2 CIRCUITS JUMPER INSULATED 4 CIRCUITS CHANNEL MOUNT FOR TERMINAL BLOCKS TERMINAL BLOCK TERMINAL BLOCK CHANNEL MOUNT CIRCUIT BREAKER ASSEMBLY WIRE DUCT WIRE DUCT COVER CONTROL RELAY CONTROL RELAY ARC SUPPRESSOR SUPPRESSOR FUSE AND FUSE HOLDER ASSEMBLY 1 AMP ANTENNA 450 MHZ PART 15 OPTIONAL REMOTE EXTERNAL ANTENNA KIT 450 MHZ ANTENNA VHF 72 75 MHZ ANTENNA VHF IRAC BAND 42 MHZ ANTENNA UHF 450 MHZ ANTENNA UHF 410 MHZ Telemotive Series 18K Receiver Instruction Manual 6 2 Section 7 18K CPU Board 7 1 18K CPU Board Setup Information The 18K CPU Board is shown in Figure 7 1 18K CPU Board Refer to paragraphs 7 1 through 7 5 for servicing procedures RS 485 cable to Power Cable to RF RE In
2. High reference voltage The voltage for the speed desired at full lever travel equal to above or less R93 and R94 Float Direction 1 and 2 respectively Used for the float function for those units designed with this feature only Usually with Teltec or Laser Guard on the bridge output If the control lever is held at maximum and an input to the system is received from a Teltec or Laser Guard the system will then decrease the output to points that are set by R93 and R94 R91 and R92 Offset Direction 1 and 2 respectively Some systems require an offset that is done with R92 and R91 Telemotive Series 18K Receiver Instruction Manual 14 2 Section 14 18K Static Stepless Output Boards Continued 14 7 Level Setting To adjust outputs 1 Remove connectors for directional output module J3 2 Start system 3 Measuring output on stepless module move lever switch to maximum and adjust R95 for maximum output 4 Lever still at maximum adjust R96 for desired high level output 5 Move lever to directionals only and adjust R91 and R92 for O Volts output If an offset voltage is required set to that voltage NOTE Some cranes require 4 Volts for the hoist up function with just the directional activated 6 R93 and R94 if your system utilizes float adjust R93 output when float 1 is inputted to the output module This is done with speed at maximum Adjust R94 when float 2 is inputted 14 8 Indicato
3. 3 5 Part 15 TMS only For 18K systems with part 15 signaling the transmitter unit is frequency modulated lower power and is certified under part 15 of FCC rules and regulations A license is not required for the transmitter or operator The transmitter unit uses crystal controlled oscillators to set the operating frequency A power down feature turns the transmitter unit OFF if no keys are pressed for an extended approximately 15 minutes period of time The transmitter unit must again be turned ON A configuration of the transmitter unit is available without automatic timeout A LED mounted on the front panel provides battery voltage and data transmission status 3 6 Receiver Unit The receiver unit consists of an RF receiver module microprocessor control module output relay control modules and a power supply A power down feature turns the receiver unit OFF if no commands are received for an extended approximately 15 minutes period of time A configuration of the receiver unit is available without automatic time out 3 7 Part 15 System Specifications Channel Designations The channels listed here are for reference purposes and are not an indication of production stock Some channels may take extended delivery contact Telemotive for availability AKO1 439 8 MHz AK02 439 6 MHz AK03 439 4 MHz AK04 439 2 MHz AK05 439 0 MHz AK11 437 8 MHz AK12 437 6 MHz AK13 437 4 MHz AK14 437 2 MHz A
4. Telemotive Series 18K Receiver Radio Control Equipment Instruction Manual G MAGNETEK MATERIAL HANDLING Telemotive TC18K 0 Rev P July 2006 Part Number 24559T Copyright 2006 Magnetek Material Handling Telemotive Series 18K Receiver Instruction Manual Table of Contents Section Page Service Information a l 1 Radio Controlled Crane Safety ooocmomosmosmoss Zul General System InformationN oooommsmomssosscionssciscsssss J L Installation Procedure sessi essre seassa s AL 18K Receiver Overview nase 18K Receiver Spare Parts ssesssecssocesocesooscsoesssccssocesocecoocesoeessecssocesocssososssosessesssees Om L ISK CPU Board Transmitter Operation sescsssverescsveecscscevscesesvencssseneevssucsvevenseensnosvinnssenkievccesisvecsossenvers O7L 18K RF Translator Board nee J L 18K Relay Output Boards ssesssesssocesocesoocssoesssccssocesocesoosessesssesssocssocssosesssesssesssse 10 1 18K Power Supply Board oooomsssss L 1 1 18K Contact Monitoring Board eessoessoesssessssccssccssooesocesooeesoesssocesocesoosesoesssessse 12 1 18K Stepless Output Boards ooomssssss 1 1 18K Static Stepless Output Boards eessoesssesssccssocesocesoocesscessecssocesocssoosssoesssesssse 14 1 ISK DC Back plane eater asian olaa LOL Telemotive Series 18K Receiver Instruction Manual 1 Telemotive Series 18K Receiver Instruction Manual ii Section 1 Service Information Your New Radio R
5. 2 10 Condition Of The Radio Controlled Crane 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 super visor 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 Condition of hoisting cable and hook block bro ken strands clipped sheave wheels etc Condition of brakes hoist trolley and bridge No bluing rivets on shoes showing glazing etc Condition of trolley and rail stops Condition of bridge structure Condition of festoon system Broken welds in any part of the crane structure Proper fluid levels and lubrication Condition of bridge and trolley stops Carbon dust or signs of burning on the covers of motors Indication of fluid oil or grease leaks Condition of rail sweeps Walkways require handrails and ladders are sturdy and in place not loose Protective guards are in place for all moving parts Alignment of bridge screeching or squealing wheels indicate bridge is out of line Broken cracked or chipped rails on trolley or runway Condition of limit switches Condition of electrical and mechanical control electrical or mechanical defects which cause faulty operation such as uncommanded st
6. strength of a signal on that channel This feature can be helpful in identifying the best frequency for your Telemotive System If your transmitter is off and the signal indicator shows a number consider moving the system to another frequency Industry Canada Statement per Section 4 0 of RSP 100 The term IC before the certification registration number only signifies that the Industry Canada technical specifications were met Section 7 1 5 of RSS GEN Operation is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation Telemotive Series 18K Receiver Instruction Manual 9 7 Section 9 18K RF Translator Board Continued Telemotive Series 18K Receiver Instruction Manual 9 8 Section 10 18K Relay Output Boards 10 1 18K Relay Output Board Setup Information The 18K Relay Output Boards are shown in Figure 10 1 Refer to paragraphs 10 1 through 10 5 for servicing procedures Green colored Relay Output Board All 8 Normally Open Relays DS1 DS5 DS2 DS6 DS3 DS7 DS4 DS8 DS3 J3 Ooooooonolboooooon circuit board 4 Normally Closed Relays Relay Output Board Red colored circuit board 1 MOV suppressors CR260 0 4 Normally Open Relays 2 Fuses 10 Amp 250 V slow blow F2711 0 3 Relays 16 Amp 277 VAC
7. 24 VDC K1304 0 4 Terminal shorting jumpers 2 positions W1098 2 4 positions W1098 4 O OOOO NOoOoOoooo 12345678 12345678 12345678 An C E10112 0 AAA green 8 Normally Open Relays Paired J2 1 to J3 1 J2 5 to J3 5 4 Normally Closed Relays Paired 4 Normally Open Relays Paired J2 2 to J3 2 J2 6 to J3 6 J2 1 to J3 1 J2 3toJ3 3 J2 5 to J3 5 J2 7to J3 7 J2 3 to J3 3 J2 7 to J3 7 J2 2 to J3 2 J2 4toJ3 4 J2 6 to J3 6 J2 8 to J3 8 J2 4 to J3 4 J2 8 to J3 8 Figure 10 1 18K Relay Output Boards E10112 0 and E10115 0 10 2 Operation There are two different relay boards available One board green colored has 8 all normally opened relays the other red colored has 4 normally closed relays and 4 normally opened Both relay output boards were designed to interface directly into contactors Suppressors are highly recommended on the contactors for longer relay life The output consists of a 16 Amp relay fused at 10 Amps continuous load with an MOV The relays are programmed for specific functions See your custom wiring diagrams for specific relay functions 10 3 Indicators The LED indicators on the board indicate the following DS1 Red Switched power to relay K1 DS2 Red Switched power to relay K2 DS3 Red Switched power to relay K3 DS4 Red Switched power to relay K4 DS5 Red Switched power to relay K5 DS6 Red Switched power to relay K6 DS7 Red Switched power to r
8. 97 06 C 72 58 0 E 9 41 99 06 A 72 60 LR 5 0 E 8 49 61 070 72 62 0E7 49 63 0 6 E 72 64 0 E 6 49 65 06C 72 66 0 E 5 49 67 06 A 72 68 0 E 4 49 69 0 6 8 72 70 0 E 3 49 71 066 12 12 0E2 49 73 064 72 80 0 DE 49 75 0 6 2 72 90 0 D9 49 77 0 60 75 34 05 F 49 79 O 5 E 75 42 05B 49 81 05 C 75 44 LR 6 05A 49 83 05A 75 48 LR 7 05 8 49 85 05 8 75 52 LR 8 056 49 87 056 75 54 055 49 89 054 75 56 LR 9 054 49 91 052 75 58 0053 49 93 050 75 60 LR 10 052 49 95 04 E 75 62 051 49 97 04 C 75 64 050 49 99 04 A 75 66 04 F 72 02 LR 11 105 75 70 04D 72 04 LR 21 104 75 72 04 C 72 06 LR 12 1 0 3 75 82 047 72 08 LR 22 102 75 84 046 72 10 LR 13 101 75 86 045 72 12 LR 23 100 75 90 043 72 14 LR 14 OFF 467 750 021 72 16 LR 24 O FE 467 7625 042 72 18 LR 15 0 FD 467 775 020 72 20 LR 25 OFC 467 7875 0 4 0 72 22 LR 16 OFB 467 800 1 1 F 72 24 LR 26 OFA 467 8125 1 3 E 72 26 LR 17 0 F 9 467 825 1 1 E 72 28 LR 27 0 F 8 467 8375 13 C 72 30 LR 18 0 F 7 467 850 11D 72 32 LR 28 0 F 6 467 8625 13 A 72 34 LR 19 0 F 5 467 875 1 1 C 72 36 LR 29 0 F 4 467 8875 13 8 72 38 LR 20 0 F 3 467 900 1 1B 72 40 LR 30 0 F 2 467 9125 1 3 6 72 42 0 F 1 467 925 1 1 A 72 44 LR 1 0 F O 467 9375 13 4 72 46 OEF 467 9625 1 3 2 72 48 LR 2 OEE 467 9875 130 72 50 OED 468 0125 1 2 E Telemotive Series 18K Receiver Instruction Manual 9 6 Section 9 18K RF Translator Board Continued 9 7 Channel and Frequency Designations by Count Indicator Channel Actual Count
9. Designator Frequency 1 AKOI 439 8 MHz 2 AKO2 439 6 MHz 3 AK03 439 4 MHz 4 AK04 439 2 MHz 5 AK05 439 0 MHz 6 AK06 438 8 MHz 7 AK07 438 6 MHz 8 AK08 438 4 MHz 9 AK09 438 2 MHz 10 AK10 438 0 MHz 11 AK11 437 8 MHz 12 AK12 437 6 MHz 13 AK13 437 4 MHz 14 AK14 437 2 MHz 15 AK15 437 0 MHz 16 AK16 436 8 MHz 17 AK17 436 6 MHz 18 AK18 436 4 MHz 19 AK19 436 2 MHz 20 AK20 436 0 MHz 21 AKA00 433 125 MHz 22 AKAOI 433 325 MHz 23 AKA02 433 525 MHz 24 AKA03 433 725 MHz 25 AKA04 433 925 MHz 26 AKAOS 434 125 MHz 27 AKA06 434 325 MHz 28 AKA07 434 525 MHz 29 AKA08 434 725 MHz 30 AK38 432 4 MHz 31 AK50 430 0 MHz 9 8 Manually Reprogramming The Synthesizer To change the frequency find the indicator count on the Channel and Frequency Designation by Count for your desired frequency To increase the Indicator count press the up button until the proper indicator count is displayed Then press the set button To decrease the Indicator count press the down button until the proper indicator count is displayed Then press the set button Set Button Down Up Button Button Digital Display 9 9 Signal Strength Indicator Mode The new RF Module is capable of measuring the signal strength for the selected channel To set the RF Module to the signal strength indicator Mode press ad hold the set button until the digital display goes blank Then let off the set button Now the display will indicate the
10. LED is illuminated The LED is OFF if 5 VDC power is not present Check connectors the 5 VDC regulator or for shorts on the board DS3 Red Monitors closure of the Master Control Relay MCR relay K1 Part Part 15 only 15 Systems only No function on Part 90 systems Normally ON when receiver turned ON The LED will extinguish when an OFF command has been transmitted an E STOP condition is present or SW1 is set to OFF The MCR controls the 12 VDC power to the Master Relay on the Power Supply Board DS4 Yellow Monitors closure of the Security Relay output K2 Normally ON when receiver turned ON The LED will extinguish when an OFF command is transmitted or an E STOP condition is present The Security Relay controls the 12 VDC power to the MCR relay K2 and the power to the coils of the control relays K1 through K8 on the Relay Output Modules DS5 Yellow Monitors the AC bias pump line for the Security Relay K2 Normally FLASH when receiver turned ON The Security Relay is enabled by an AC signal generated by the slave microprocessor The AC signal is capacitively isolated from the slave microprocessor to help prevent the Security Relay from being latched ON if the slave microprocessor fails The LED will not be illuminated when an OFF command has been sent or an E STOP condition is present DS6 Yellow Monitors AC bias pump line for the Master Control Relay K1 Normally ON when receiver turned ON Co
11. an ON command is being received from the Transmitter While pushing the ON button on the Transmitter this should light DS12 Red Monitors the OFF command from the Transmitter The 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 Telemotive Series 18K Receiver Instruction Manual 7 3 Section 7 18K CPU Board Continued Table 7 1 CPU Board Diagnostic LED Functions Continued LED COLOR FUNCTION DS13 Red Monitors E STOP condition Part 15 only No function on Part 90 Part 15 only systems Normally OFF The LED will flash when an E STOP command is transmitted and illuminate continuously when the E STOP condition is in effect An E STOP condition may be created when an E STOP command is transmitted or when a failure mode is detected by the slave microprocessor A contact monitoring error for those units so equipped will cause an E STOP and illuminate DS13 If both DS9 and DS13 are illuminated the incoming data on the ICC bus has been corrupted DS14 Yellow Monitors the AC activity for the Security Relay K1 Normally ON If the system is ON and the light is not lit there is a serious microprocessor EPROM error DS15 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 fl
12. indicators on the slot 11 relay board the bottom LED indicator of the four output indicators on the slot 11 relay board DS13 DS16 Monitors Slot 12 DS13 monitors DS14 monitors DS15 monitors DS16 monitors DS14 monitors DS15 monitors DS16 monitors the top upper most LED indicator of the four output indicators on the slot 11 relay board the second down form the top LED indicator of the four output indicators on the slot 11 relay board the third down form the top LED indicator of the four output indicators on the slot 11 relay board the bottom LED indicator of the four output indicators on the slot 11 relay board the second down form the top LED indicator of the four output indicators on the slot 11 relay board the third down form the top LED indicator of the four output indicators on the slot 11 relay board the bottom LED indicator of the four output indicators on the slot 11 relay board Telemotive Series 18K Receiver Instruction Manual 15 1 Telemotive Series 18K Receiver Instruction Manual 15 2
13. never be used as a regular stopping device They are intended to be protective devices Do not make lifts in excess of the equipment rated capacity Telemotive Series 18K Receiver Instruction Manual 2 3 Section 2 Radio Controlled Safety Continued The bridge and trolley should be centered di rectly over the load when the load is raised to prevent swinging when making lifts 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 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 Make certain all personnel are clear before making a lift The crane operator should keep all body parts away from the lift and should never be posi tioned under the lift 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 If the crane operator is being assisted the crane should not be moved until the assistant signals they are clear of the crane and its load When a load is hanging from the crane hook and the crane is being moved the crane operator should sound all warning devic
14. 1 1 6 41 25 OB 4 40 29 114 41 27 0B2 40 31 112 41 29 0 BO 40 33 110 41 31 0AE 40 35 1 0E 41 33 0AC 40 37 10 C 41 35 0A A 40 39 10A 41 37 0 A 8 40 41 1058 41 39 0 A 6 40 43 106 41 41 0A 4 40 45 104 41 43 0 A 2 40 47 102 41 45 0 A O 40 49 100 41 47 09E 40 51 OFE 41 49 09C 40 53 OFC 41 51 09 A 40 55 OFA 41 53 09 8 40 57 0 FS 41 55 096 40 59 0F6 41 57 094 40 61 0F4 41 59 092 40 63 0F2 41 61 090 40 65 OFO 41 63 0 8E 40 67 OEE 41 65 08C 40 69 OEC 41 67 08A 40 71 0E A 41 69 0 8 8 40 73 0 E 8 41 71 0 8 6 40 75 0 E 6 41 73 0 8 4 40 77 OE4 41 75 0 8 2 40 79 0 E 2 41 77 0 8 0 40 81 0 E 0 41 79 07E 40 83 ODE 41 81 07 C 40 85 0 DC 41 83 07 A 40 87 0D A 41 85 07 8 40 89 0D 8 41 87 0 7 6 40 91 0 D 6 41 89 07 4 40 93 OD 4 41 91 0 7 2 40 95 0 D2 41 93 070 Telemotive Series 18K Receiver Instruction Manual 9 5 Section 9 18K RF Translator Board Continued Table 9 2 Synthesized Receiver Associated RF Translator Board Programming Continued RF Frequencies Setting Associated RF Translator Board In MHz T S4 S3 S2 RF Frequencies Setting 72 52 LR 3 OEC In MHz TH S4 S3 S2 72 54 OEB 41 95 0 6 E 72 56 LR 4 OEA 41
15. 5 20 20DB PAD FOR LICENSED RECEIVER PART 90 ONLY E10108 0 RF TRANSLATOR BOARD E10111 0 CPU COMPUTER or DIGITAL CONTROL BOARD E10171 0 POWER SUPPLY BOARD T122 0 POWER SUPPLY BOARD TRANSFORMER E10112 0 8 NORMALLY CLOSED RELAY BOARD GREEN E10109 0 4 NORMALLY CLOSED AND 4 NORMALLY OPEN RELAY BOARD RED E10115 X STEPLESS TWO MOTOR OUTPUT BOARD SEE SYSTEM DRAWINGS FOR SPECIFIC MODEL E10116 X STEPLESS ONE MOTOR TWO AUX OUTPUT BOARD SEE SYSTEM DRAWINGS FOR SPECIFIC MODEL E10110 X STATIC STEPLESS OUTPUT BOARD SEE SYSTEM DRAWINGS FOR SPECIFIC MODEL FW2874 0 CPU EPROM MUST ORDER WITH JOB NUMBER RF TRANSLATOR EPROMS FW2872 0 PART 15 FW2873 0 PART 90 TMS FW2890 0 PART 90 CONTINUOUS CARRIER FW2894 PART 90 TDMA E10191 X CONTACT MONITORING BOARD OPTIONAL SEE SYSTEM DRAWINGS FOR SPECIFIC MODEL 110VAC MODEL E10191 0 FW2871 0 CONTACT MONITORING BOARD EPROM K2116 1 RELAY DPST N O 25A 12VDC COIL POWER SUPPLY BOARD K1304 0 RELAY SPDT 16A 12VDC COIL RELAY OUTPUT BOARDS F2711 0 FUSE 10A 250V 5X20mm SLO BLO F2711 1 FUSE 1 0A 250V 5X20mm SLO BLO F2711 3 FUSE 0 3A 250V 5X20mm SLO BLO INTERNAL WIRING WA1039 0 POWER SUPPLY TO CPU BOARD CABLE WA1045 37 POWER CABLE CONTACT MONITORING TO POWER SUPPLY BOARD WA1006 13 6 CONDUCTOR CABLE 13 INCH FOR BACK PANEL MOUNTED RF TRANSLATOR BOARD TO CPU Telemotive Series 18K Receiver Instruction Manual 6 1 Section 6 18K Receiver Spare Parts PART NUMBER
16. DED THESE AU DIBLE AND OR VISUAL WARNING DE VICES MUST MEET ALL GOVERNMENTAL REQUIREMENTS FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERI OUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT A WARNING PLEASE FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE CONTROL EQUIPMENT ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE CRANE OR MACHINERY BEFORE ATTEMPTING ANY INSTALLATION PROCEDURES DE ENERGIZE AND TAGOUT 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 Telemotive Series 18K Receiver Instruction Manual 2 1 Section 2 Radio Controlled Safety Continued A WARNING THE DIRECT OUTPUTS OF THIS PRODUCT ARE NOT DESIGNED TO INTERFACE DI RECTLY TO TWO STATE SAFETY CRITI CAL MAINTAINED FUNCTIONS LE MAGNETS VACUUM LIFTS PUMPS EMERGENCY EQUIPMENT ETC A ME CHANICALLY 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 2 2 General Radio controlled overhead cranes and other ma terial handling equipment operate in several di rections They are large bulky pieces of equip ment that handle heavy loads efficiently at high speeds Quite frequently the equipment is oper ated in areas where people are working on the floor below The crane oper
17. EPROM itself 9 3 Address Programming Switch The programming switch S1 sets the address of this board if multiple boards are present Normally the two switches of S1 should be set to OFF If multiple boards are present the switches are set in binary from one sequentially up to four 9 4 Frequency Selector Switches Optional For Synthesized RF Devices The programming switches S2 S3 and S4 control the synthesizer programming These only apply to certain Part 90 licensed receivers Note use the switch designators listed here for programming some early boards were incorrectly marked See you System Drawings for frequency information 9 5 For specific programming for Part 90 licensed receivers see Table 9 2 Receiver Synthesizer Programming 9 6 Indicators The LED indicators on the board indicate the following See Table 9 1 RF Translator Board Diagnostic LED Functions Telemotive Series 18K Receiver Instruction Manual 9 1 Section 9 18K RF Translator Board Continued Table 9 1 RF Translator Board Diagnostic LED Functions LED COLOR FUNCTION DS1 Green Monitors the 12 VDC power to the RF Translator Board Normally ON If 12 VDC power is present then the LED is illuminated The LED is OFF if 12 VDC power is not present Check power supply fuses and if power is ON to receiver DS2 Green Monitors 5 VDC regulated voltage Normally ON If 5 VDC power is present then the LED is illumin
18. K15 437 0 MHz AK06 438 8 MHz AK07 438 6 MHz AKOS 438 4 MHz AK09 438 2 MHz AK10 438 0 MHz AK16 436 8 MHz AK17 436 6 MHz AK18 436 4 MHz AK19 436 2 MHz AK20 436 0 MHz Telemotive Series 18K Receiver Instruction Manual 3 1 Section 3 General System Information Continued AKA00 433 125 MHz AKAOS 434 125 MHz AKAOI 433 325 MHz AKA06 434 325 MHz AKA02 433 525 MHz AKA07 434 525 MHz AKAO3 433 725 MHz AKAOS 434 725 MHz AKA04 433 925 MHz AK38 432 4 MHz AK50 430 0MHz Ambient Operating Conditions 22 F to 158 F 30 C to 70 C Humidity up to 95 non condensing Typical Operating Range 300 feet Up to four transmitter units may operate on the same frequency while in close proximity not less than six feet to each other 3 8 Time Multiplex Shared TMS System Software 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 tur
19. al inputs to your VFD Consult your VFD manual for directional input locations A CAUTION THE MECHANICAL DIRECTIONAL RE LAYS ARE ONLY RATED FOR 8 AMPS DC THE SOLID STATE DIRECTIONALS RE LAYS IF SUPPLIED CANNOT SWITCH A CONTACTOR USE CAUTION ON HOOK ING OTHER DEVICES SUCH AS ALARMS DIRECTLY ON THE DIRECTIONAL RE LAYS FAILURE TO FOLLOW THIS CAU TION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF EQUIPMENT OR LOSS OF FUNCTIONAL EFFECTIVENESS 13 5 Adjustment Adjust the analog output 0 10VDC adjustment item 1 Above to 10 volts DC maximum with the transmitter switch fully depressed 13 6 Spare Parts Relay part numbers E10109 3 Mechanical K1 K4 K132 0 K5 K6 K2115 0 E10109 1 Solid state K1 K4 1IC2822 1 K5 K6 K2115 0 E10116 3 Mechanical K1 K2 K1304 0 K3 K4 K132 0 K5 K2115 0 E10116 0 Solid state K1 K2 K1304 0 K3 K4 IC2822 1 K5 K2115 0 Fuse part numbers E10109 3 Mechanical FIA F4A F2711 0 F5 F6 F2704 0 E10109 1 Solid state FIA F4A ES F6 F2704 0 E10116 3 Mechanical FIA F4A F2711 0 F6 F2704 0 E10116 0 Solid state FIA F2A F2711 0 F3A F4A F6 F2704 0 13 7 Check Out Complete the above for each crane motor function Verify all your connections and voltages before engaging the Master Relay Telemotive Series 18K Receiver Instruction Manual 13 2 Section 14 18K Static Stepless Output Boards 14 1 18K Static Stepless Output Board Setup Informat
20. ashing or on the microprocessor EPROM is not working properly If the 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 microprocessor EPROM may be defective Telemotive Series 18K Receiver Instruction Manual 7 4 Section 8 See Appropriate Transmitter Manual Telemotive Series 18K Receiver Instruction Manual 8 1 Section 9 18K RF Translator Board 9 1 18K RF Translator Board Setup Information The 18K RF Translator Board is shown in Figure 9 1 Refer to paragraphs 9 1 through 9 5 for setup and servicing procedures O un gt Frequency Selector Switches sc O sg E O OE EERHERRE 00000000 O Mounting location of Part 15 Receiver E13158 D Cable to Part 90 Receiver Module E7160 X or E7170 X Power cable B from CPU af Board J18 Address 1 Switch J YN o 2 RS 485 cable to CPU Board J6 Figure 9 1 RF Translator Board E10108 0 9 2 Operation The RF Translator Board consists of a microprocessor EPROM with built in custom programming The programming of the microprocessor EPROM will vary from application to application Inquiries about the functionality or replacement parts can be ordered by referencing the job number of the receiver unit found on the door label or the part number on the microprocessor
21. ated The LED is OFF if 5 VDC power is not present Check connectors the 5 VDC regulator or for shorts on the board DS3 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 microprocessor is not working properly If the 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 microprocessor EPROM on the RF Translator Board may be defective DS4 Yellow Monitors the connection of the RS485 port J3 to the CPU Board Normally ON When the LED is OFF solid the CPU Board is not connected to the RF Translator Board DS5 Red Looks for corrupted data to microprocessor Normally OFF When the LED is ON solid the CPU Board is not connected to the RF Translator Board DS6 Red Not used for licensed frequency transmitters Part 15 only Part 15 only ON indicates Multibox and or Pitch and Catch enabled If Pitch and Catch is enabled DS8 will be ON also DS7 Red Monitors data errors The LED will flash occasionally when a command is being received from the Transmitter Unit Continued flashing indicates corrupted data Telemotive Series 18K Receiver Instruction Manual 9 2 Section 9 18K RF Translator Board Continued Tabl
22. ator must exercise extreme caution at all times Workers must con stantly be alert to avoid accidents The following tules have been included to indicate how your careful and thoughtful actions may prevent inju ries 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 7 3 Boarding The Crane for specific safety rules 2 3 Persons Authorized To Operate Radio Controlled Cranes Only properly trained persons designated by management should be permitted to operate ra dio controlled cranes 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 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 medi cation that may cause loss of crane control 2 4 Training Checklist For Crane Operators Anyone being trained to operate a radio con trolled crane should possess as a minimum the following knowledge and skills before operating the crane The operator should have knowledge of hazards pertaining to crane operation The operator should have knowledge of the safety rules for radio controlled cranes The operator should have the ability to judge dis
23. awings A typical 18K cabinet layout is should is shown in Figure 4 1 Cabinet Layout MP18001 0 This is the most commonly used 18K cabinet An alternate smaller cabinet is shown in Figure 4 2 Small 18K Cabinet please verify either by the System Drawings or by physical measurement that this matches the cabinet supplied 4 7 Receiver Installation A WARNING MAKE SURE Si MASTER CONTROL RELAY MCR IS TURNED OFF BEFORE ATTEMPTING THIS TO PREVENT ACTIVATION OF EXTERNAL CIRCUITRY SEE SECTION 7 1 FOR SWITCH LOCATION FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT 1 Ensure mounting location is as far as possible from exposed Trolley wire and sources of electromagnetic or radiated noise Antenna should be pointed straight up 2 Mount unit and install antenna For remotely mounted antennas make sure the mounting base or plate of the antenna is grounded 3 Set switch SWI on power supply to off position towards right of cabinet See Section 11 1 for power supply switch location Set switch SI on CPU to OFF to disable receiver outputs See Section 7 1 for CPU switch S1 location 4 Wire unit up per supplied system drawings 5 Wiring of the 18K system should now be complete 6 Make sure all personnel are clear of equipment no load is on the crane turn ON power supply switch SW1 and apply power Switch S1 on the CPU is still turned OFF 7 A number of yellow and g
24. connection 3 0 10 Volt DC output for Main motor function Al Positive connection oe ESTES TEE ESE 4 0 10 Volt DC output TATE TATE ATE TAT OLS T EA for Auxiliary motor function A2 Positive connection 5 Directional relays 8 Amp or Solid State 6 Two 16 Amp Auxiliary relays 1A 1B 2A 2B Directional relays Directional relays 1A 1B 3A 3B 7 LED indicators 2A 2B 4A 4B 3A 3B Auxiliary relays 8 For relay and fuse part 4A 4B 1A 1B numbers see Section 13 6 2A 2B Spare Parts Figure 13 1 18K Stepless Output Boards E10109 X and E10116 X 13 2 Operation directional relay outputs are available on the two The Stepless Output Board was designed to motor board interface directly into VFD s The output consists of a continuously variable DC voltage NOTE from 0 to 10 volts plus two directional relays per motor The directional relays are rated for 8 Amps DC maximum E10109 3 and E10116 3 Low current solid state directional relays are also available for solid state logic only switching E10109 1 and E10116 0 For crane The 0 10 VDC outputs on any one stepless board are not independent They are to be used in tandem with the Main and Auxiliary selector switch on the transmitter motor functions such as Main and Aux Trolley The auxiliary relays are rated for 16 Amps DC or Main and Aux Hoist a second variable DC maximum and fused for 10 Amps continuous voltage from 0 to 10 volts plus 2 two additiona
25. d stop operation turn the trans mitter unit OFF and immediately report the con dition to their supervisor 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 immedi ately 2 7 3 Boarding The Crane The crane should not be boarded without permis sion of the supervisor 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 en suring all personnel are off the crane before the system is returned to operation 2 8 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 not be limited to items listed in Section 1 13 Condition of The Radio Controlled Telemotive Series 18K Receiver Instruction Manual 2 4 Section 2 Radio Controlled Safety Continued 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 Minor repairs include routine maintenance and repairs such as
26. e 9 1 RF Translator Board Diagnostic LED Functions Continued LED COLOR FUNCTION DS8 Red Not used for licensed frequency transmitters Part 15 only Part 15 only ON indicates Pitch and Catch enabled If Pitch and Catch is enabled DS6 will be ON also DS9 Yellow Monitors system activity Normally FLASHING very fast If not flashing the microprocessor EPROM is dead on the RF Translator Board DS10 Red Monitors received data errors Normally OFF A ON or flashing LED during data transmission may indicate interference of the received data If the 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 If the 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 DS11 Yellow Monitors the voltage level between RF Receiver Board and RF Translator Board Normally ON OFF indicates a malfunctioning RF Receiver Board Momentary OFF or sudden brightness could indicate RF interference DS12 Yellow Part 15 only Monitors data synchronization Flashes when a properly formatted data signal is received for Part 15 is ON when transmitter is transmitting or ON continuously for Part 90
27. eceiver Thank you for your purchase of Magnetek s Telemotive Brand 18K Receiver Magnetek has set a whole new standard in performance dependability and value with its unique new line of receivers Without a doubt our Telemotive 18K Receiver is the ultimate solution for having precise undeterred and safe control of your material If your product ever needs modification or service please contact one of our representatives at the following locations U S Service Information For questions regarding service or technical information contact 1 866 MAG SERV 1 866 624 7378 Magnetek Material Handling N49 W13650 Campbell Drive Menomonee Falls WI 53051 Telephone 800 288 8178 Website www magnetekmh com e mail info magnetekmh com Fax Numbers Main 800 298 3503 Sales 262 783 3510 Service 262 783 3508 For Canada Service Information Contact Berlet Electronics Phone 1 905 564 2710 Fax 1 905 564 2755 Telemotive Series 18K Receiver Instruction Manual 1 1 Telemotive Series 18K Receiver Instruction Manual 1 2 Section 2 Radio Controlled Safet Warnings Cautions And Notes Throughout this document WARNING CAUTION and NOTE statements have been deliberately placed to highlight items critical to the protection of personnel and equipment WARNING A warning highlights an essential operating or maintenance procedure practice etc which if not strictly observed could result in injury or death of pers
28. elay K7 DS8 Red Switched power to relay K8 Ground is switched to the relay coil to turn it ON which also turns ON the LED DS9 Yellow 12 VDC power to Relay Board for the relays 10 4 Wiring Disable the Master Relay and remove all power before servicing See Section 4 4 detailed wiring specifics 10 5 Check Out Verify all your relay connections and voltages before engaging the Master Relay Telemotive Series 18K Receiver Instruction Manual 10 1 Telemotive Series 18K Receiver Instruction Manual 10 2 Section 11 18K Power Supply Board 11 1 18K Power Supply Board Setup Information The 18K Power Supply Board is shown in Figure 11 1 Refer to paragraphs 11 1 through 11 4 for servicing procedures O 1 E10171 0 ps2 J3 POWER To Contact Monitoring SUPPLY Board J8 To CPU ODS1 BOARD A Board J2 F er m Fuse 1 Amp slow blow F2711 1 MASTER CONTROL Relay part RELAY K2116 1 Fuse 5 Amp slow 1A 1B 2A 2B3A3B 7 ON GND YN 130 240 blow F2711 2 1 Transformer Figure 11 1 18K Power Supply E10171 0 pee 11 2 Operation The supply is a switcher type which gives maximum noise immunity The output of the supply is 12 Volts DC The supply can source approximately 2 Amps DC The standard power supply can be operated from a 110VAC or a 240VAC 50 or 60 Hz power source The voltage of operation is determined by the wiring of connector J1 Please refer to the connec
29. ergized all power circuits for crane movement must be opened prior to energizing the control circuits All personnel and tools should be moved to a safe spot before moving the crane during repairs 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 9 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 1 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 operator s responsibility to ensure the main switch is open and locked down before work is resumed Telemotive Series 18K Receiver Instruction Manual 2 5 Section 2 Radio Controlled Safety Continued A WARNING THE CRANE OPERATOR SHOULD NOT AT TEMPT TO REPAIR ANY OF THE ITEMS STATED BELOW THE CRANE CONDITION SHOULD BE REPORTED TO THE SUPERVI SOR FAILURE TO FOLLOW THIS WARN ING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIP MENT
30. es frequently 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 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 attach ments or cables will not catch on nearby equipment Slings chains or cables should never be dragged along the floor Unless required for operator safety gloves should not be worn when operating the trans mitter 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 author ized by the supervisor When another crane on the same runway is sta tionary with a load hanging the crane operator should maintain a safe distance between the sta tionary 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 If power to the crane is removed the crane op erator should turn the transmitter unit OFF and keep it OFF until power is restored If the crane fails to respond properly the crane operator shoul
31. greasing cleaning and control troubleshooting All other repairs should be con sidered major If the repair crew consists of more than one person one person should be desig nated as the repair crew leader with the follow ing responsibilities If the repair crew consists of only one person that person has the following responsibilities For minor repairs warning signs should be placed on the floor beneath the crane or sus pended from the crane For major repairs the floor area below the crane should be roped off 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 When practical radio controlled cranes which cannot be moved during repairs must be pro tected 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 indi cated 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 operator
32. he board on constantly DS16 DS1 red Out check for shorts or bad connection on J1 1 Switched output boards LEDS in parallel with LED s on each output board lights with corresponding fault indicated on output board DS1 DS4 Monitors Slot 1 DS1 monitors DS2 monitors DS3 monitors DS4 monitors the top upper most LED indicator of the four output indicators on the slot relay board the second down form the top LED indicator of the four output indicators on the slot 1 relay board the third down form the top LED indicator of the four output indicators on the slot 1 relay board the bottom LED indicator of the four output indicators on the slot 1 relay board DS5 DS8 Monitors Slot 2 DS5 monitors DS6 monitors DS7 monitors DS8 monitors DS9 DS12 Mo DS9 monitors DS10 monitors DS11 monitors DS12 monitors the top upper most LED indicator of the four output indicators on the slot 2 relay board the second down form the top LED indicator of the four output indicators on the slot 2 relay board the third down form the top LED indicator of the four output indicators on the slot 2 relay board the bottom LED indicator of the four output indicators on the slot 2 relay board nitors Slot 11 the top upper most LED indicator of the four output indicators on the slot 11 relay board the second down form the top LED indicator of the four output indicators on the slot 11 relay board the third down form the top LED indicator of the four output
33. imity not less than six feet to each other Access Code Any received signal which does not match the receiver access code is considered invalid by the receiver NOTE DETERMINE IF YOUR SYSTEM IS FCC PART 15 OR PART 90 IF THE RECEIVER HAS THE PART NUMBER 18087 ON THE DOOR OR YOUR TRANSMITTER HAS A PUSH BUTTON FOR ON OFF RATHER THAN A TOGGLE SWITCH IT IS FCC PART 15 3 2 FCC Regulations There are two types of radio controlled systems One is high power licensed FCC Part 90 and low power unlicensed FCC Part 15 Both give more than adequate range security and features however there are subtle differences in operation required by FCC rules and regulations It is helpful to know with system type you have to troubleshooting and servicing 3 3 Signaling TMS and Continuous TMS Time Multiplexed Signaling is a Telemotive propriety high speed packet data system That transmits data in pulses Continuous Carrier signaling means the transmitter is continuously transmitting power whether or not a lever or function is activated Continuous carrier systems tend to be older systems 3 4 Part 90 TMS And Continuous Carrier For 18K licensed systems the transmitter unit is frequency modulated has relatively high power greater than 100 mW typically and a licensed is required licensed under Part 90 of FCC rules and regulations The transmitter unit uses crystal controlled oscillators to set the operating frequency
34. ing For those transmitters equipped with battery chargers please familiarize all users with the instructions of the charger before attempting to use Do not attempt to charge non rechargeable bat tery packs Avoid charging the battery pack for more than 24 hours at a time Do not charge batteries in a hazardous environ ment Do not short the charger Do not attempt to charge a damaged battery Use only Telemotive approved chargers for the appropriate battery pack 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 14 Battery Disposal Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure Telemotive Series 18K Receiver Instruction Manual 2 7 Telemotive Series 18K Receiver Instruction Manual 2 8 Section 3 General System Information 3 1 General System Information The Series 18K 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 Each system has its own access code which permits a receiver unit to respond only to a transmitter unit with the same access code Up to four transmitters may be used with the same frequency Each transmitter operating on the same frequency may be operated in close prox
35. ion The 18K Stepless Output Boards are shown in Figure 14 1 Refer to paragraphs 14 1 through 14 7 for servicing procedures Module designator or a o o JU3 JU4 OOOO O el F1 F2 D2 VOUT HZ TP10 oes JU5 e JU7 550 y 3 2 EIS STV 20 Ms Ja Cd CHOP VOUT 12 GND 12 Figure 14 1 18K Static Stepless Output Boards E10110 0 through 10 14 2 18K Static Stepless Operation This unit is designed for stepless motors that require a unique output range voltage for operation other than typically found with VFD s The Static Stepless Output Board converts the binary digital signal from the transmitter to a variable output voltage The directional inputs to board invert the voltage Jumpers change the voltages and the inversion Output levels such as offset float and maximum can be adjusted 14 3 18K Static Stepless Modules Near the edge of the circuit board by connector J3 is the module designator The designator should be a number from 0 10 This number indicates for what output the board is jumpered The eleven E10110 series modules are E10110 0 10 VDC non inverting DC output E10110 1 10 VDC inverting DC output E10110 2 20 VDC non inverting DC output E10110 3 20 VDC inverting DC output E10110 4 40 VDC non inverting DC output E10110 5 40 VDC inverting DC output E10110 6 10 VAC AC output E10110 7 20 VAC AC output E10110 8 40 VAC AC output E10110 9 10 VDC
36. ired Consult your System drawings to determine how the alarms if any are wired up The Auto Alarm is field configurable See Section 4 7 3 below In the Part 15 system only the E STOP Alarm turns ON when the E STOP is depressed on the transmitter It stays ON till the E STOP is released To clear an E STOP condition the transmitter must be turned OFF and ON again In the Part 15 system to disable the E STOP Alarm the Auto Alarm must also be turned OFF To disable both Auto Alarm and E STOP Alarm turn S2 1 OFF and S2 2 ON on the CPU Board See Section 7 3 NOTE DO NOT USE THE E STOP FOR NORMAL ON AND OFF OF SYSTEM WHILE THE E STOP IS DEPRESSED THE TRANSMITTER IS CONTINUOUSLY TRANSMITTING LEAVING THE TRANSMITTER IN THE E STOP CONDITION WILL IMPAIR BATTERY LIFE 4 8 3 Auto Alarm S2 1 Gives about 5 seconds of alarm when the transmitter is first turned ON To enable connect an external alarm Move dip switch S2 1 on the CPU Board to the ON position See Section 7 1 18K CPU Board for switch details For location of the Alarm Relay See the appropriate wiring diagram supplied with your system 4 8 4 Time Out Timer Enable S3 2 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 2 to ON disables this function See Section 7 1 18K CPU Board for switch details Telemoti
37. l be in a separate metal conduit from the power wiring which shall also be in metal conduit 3 Low voltage wires shall be wired with Class 1 wiring 4 Control wiring as well as antenna wiring shall be in separate conduit and shall be kept as short as possible Telemotive Series 18K Receiver Instruction Manual 4 1 Section 4 Installation Information Continued 5 Control wiring for stepless devices shall be shielded twisted pair The shield should be grounded at both ends 6 All terminals shall be tightened to specified terminal torque 4 4 IN LBS unless otherwise specified 7 Please observe National Electric Code NEC when wiring electrical devices 8 When cutting holes in cabinet take care to prevent metal filings from shorting circuitry 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 All receiver relays should drive contactors Suppressors are strongly recommended on all contactors 4 6 Receiver Unit Cabinet Mounting Recommended mounting hardware is 1 4 20 hex machine screws of appropriate length four 1 4 20 x 7 16 keps or elastic stop nuts Flat washers should be used in front of nuts when receiver unit is mounted to a non structural surface Mount receiver unit cabinet securely to mounting surface Actual cabinet mounting dimensions are supplied with your system dr
38. l service Telemotive Series 18K Receiver Instruction Manual 13 1 Section 13 18K Stepless Output Boards Continued 13 3 Indicators The LED indicators on the board indicate the following DS1 Red Power to relay KIA DS2 Red Power to relay K2A DS3 Red Power to relay K3A DS4 Red Power to relay K4A Ground is switched to the relay coils K1A K4A to turn them ON which also turns ON the respective LED DSS to DS8 Red These LEDs light in an increasing binary pattern to indicate increasing voltage output DS9 Yellow Power to Stepless Board 13 4 Wiring Disable the Master Relay before servicing See Section 4 4 detailed wiring specifics A CAUTION ALL CONTROL WIRES SHOULD BE RUN THROUGH SEPARATE CONDUIT ALL ANALOG SIGNAL CONTROL WIRES SUCH AS THE ANALOG SIGNALS OUT OF THIS BOARD SHOULD BE RUN THROUGH SEPARATE CONDUIT AND MUST BE SHIELDED TWISTED PAIR TRY TO KEEP CONTROL WIRING AS SHORT AS POSSI BLE PLEASE OBSERVE NATIONAL ELEC TRIC CODE NEC WHEN WIRING DE VICES FAILURE TO FOLLOW THIS CAU TION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF EQUIPMENT OR LOSS OF FUNCTIONAL EFFECTIVENESS To interface a unit to a VFD select the appropriate motor you wish to control Connect the appropriate output Al or A2 to the appropriate VFD analog input noting polarity Consult your VFD manual for specific analog input locations For each motor connect the appropriate direction
39. n Manual 11 2 Section 12 18K Contact Monitoring Board 12 1 18K Contact Monitoring Board Setup Information The 18K Contact Monitoring Board is shown in Figure 12 1 Refer to paragraphs 12 1 through 12 5 for servicing procedures RS 485 cable to CPU Board J13 Module designator Pairs of monitoring contacts ei Power from Power Supply gt Board J5 12 Volts DC RS 485 cable to Optional Boards DS15 DS16 Figure 12 1 18K Contact Monitoring Board E10191 0 Through 5 12 2 Operation The Contact Monitoring Board features true Load Monitoring A voltage 110 VAC across a pair of inputs to the Contact Monitoring Board indicates the successful closure of a relay The inputs are paired J1 1 to J3 1 J1 2 to J3 2 J1 3 to J3 3 etc and J4 1 to J2 1 J4 2 to J2 2 J4 3 to J2 3 etc Typically the neutrals can be jumpered together Consult the specific wiring diagram for your system The standard contact monitoring circuitry E10191 0 is designed for being across loads of 110 VAC The series resistors R1 through R16 to the opto isolators can be changed for other voltages please contact your Telemotive representative for part numbers if necessary Typically only the directionals are monitored in crane applications To disable contact monitoring turn switch S2 4 to ON on the CPU Board See Section 7 3 12 3 18K Contact Monitoring Modules Near the edge of the circuit board by connect
40. ned OFF The TMS system software determines the OFF period and repetition rate of the ON period This allows up to 4 transmitters to share and have equal access to the same frequency and also allows for reduced battery consumption and extended battery life Telemotive Series 18K Receiver Instruction Manual 3 2 Section 4 Installation Information 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 NOTE THIS MANUAL IS A GENERAL MANUAL FOR 18K SYSTEMS EVERY 18K SYSTEM COMES WITH A COMPLETE SET OF SYSTEM DRAWINGS SPECIFIC TO THE CUSTOMER S ORDER THESE DRAWINGS SUPPLY NEEDED INFORMATION ABOUT SPECIFIC FEATURES OPERATION WIRING AND MOUNTING DO NOT ATTEMPT TO INSTALL OR OPERATE THIS SYSTEM WITHOUT THEM IF YOU NEED ADDITIONAL COPIES PLEASE CONTACT TELEMOTIVE IN ALL CORRESPONDENCE WITH TELEMOTIVE ABOUT YOUR SPECIFIC SYSTEM PLEASE REFERENCE THE JOB LISTED ON THE FRONT OF YOUR EQUIPMENT A WARNING THE RECEIVER UNIT OR RELAYS ARE NOT RATED AS EXPLOSION PROOF THE RECEIVER UNIT MUST NOT BE IN STALLED IN EXPLOSIVE ENVIRONMENTS UNLESS APPROPRIATE SECONDARY EN CLOSURE MEASURES ARE TAKEN FAIL URE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT The receiver unit should not be subjected to moisture 4 2 Receiver Unit Mounting Location Considerations Ensure
41. non inverting Locomotive E10110 10 10 VDC non inverting Brake Telemotive Series 18K Receiver Instruction Manual 14 1 Section 14 18K Static Stepless Output Boards Continued 14 4 Module Jumper Programming The jumper programming for each module is as follows X means add jumper Module JU2 JU3 JU4 JUS JU6 JU7 JUS JU9 JU10 JU11 JUI2 JU13 JU14 JUIS 0 x x x x x X X 1 X X X X X X X 2 X x x x x x 3 x x x x x x 4 x x x x x x x 5 x X X X X X 6 X X X X X X X 7 X X X X X X 8 X x X x X X X X 9 X X X X X X X 10 x X X X X X X 14 5 Wiring 14 6 Adjustments Disable the Master Relay before servicing See Section 4 4 detailed wiring specifics A CAUTION ALL CONTROL WIRES SHOULD BE RUN THROUGH SEPARATE CONDUIT ALL ANALOG SIGNAL CONTROL WIRES SUCH AS THE ANALOG SIGNALS OUT OF THIS BOARD SHOULD BE RUN THROUGH SEPARATE CONDUIT AND MUST BE SHIELDED TWISTED PAIR TRY TO KEEP CONTROL WIRING AS SHORT AS POSSI BLE PLEASE OBSERVE NATIONAL ELEC TRIC CODE NEC WHEN WIRING DE VICES FAILURE TO FOLLOW THIS CAU TION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF EQUIPMENT OR LOSS OF FUNCTIONAL EFFECTIVENESS There six output voltage adjustments on the unit They are as follows R95 Maximum possible output voltage Maximum output with function lever at maximum Upper limit to motor input R96
42. ntinued on next page Telemotive Series 18K Receiver Instruction Manual 7 2 Table 7 1 CPU Section 7 18K CPU Board Continued Board Diagnostic LED Functions Continued LED COLOR FUNCTION DS6 continued Yellow The Master Control Relay K1 is enabled by an AC signal generated by the slave microprocessor The AC signal is capacitively isolated from the slave microprocessor to help prevent the MCR from being latched ON if the slave microprocessor fails The LED will not be illuminated when an OFF command has been sent or is in an E STOP mode DS7 Yellow Monitors the connection through the RS485 port J6 to the RF Translator Board Normally ON and dim or rapidly flashing When the LED is out CPU Board is not properly connected to the RF Translator Board DS8 Yellow Monitors the connection through the RS485 port J13 to the Contact Monitoring Board Optional Normally ON and DIM or rapidly flashing When the LED is out CPU Board is not connected to the Contact Monitoring Board Optional or contact monitoring is disabled Setting switch S2 on CPU Board to ON disables contact monitoring DS9 Red Not used in this model Normally OFF DS10 Yellow Monitors system activity Normally FLASHING If not flashing the microprocessor EPROM is dead DS11 Red Monitors the ON command from the Transmitter The LED will flash when
43. onnel or long term physi cal hazards Warnings are highlighted as shown below A 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 high lighted as shown below A CAUTION NOTE A note highlights an essential operating or maintenance procedure condition or state ment Notes are shown as below NOTE WARNINGS CAUTIONS AND NOTES SHOULD NEVER BE DISREGARDED The safety rules in this section are not intended to replace any rules or regulations of any appli cable local state or federal governing organiza tions Always follow your local lockout and tagout procedure when maintaining any radio equipment 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 2 1 Critical Installation Considerations A WARNING ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES AND SIMILAR EQUIPMENT MUST HAVE A BRAKE IN STALLED FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT A WARNING ON ALL REMOTE CONTROLLED CRANES AN AUDIBLE AND OR VISUAL WARNING MEANS MUST BE PROVI
44. opping or starting of any crane motions warning de vices lights or auxiliary functions Condition of gears grinding or squealing may indicate foreign materials in gear teeth or a lack of lubrication All controls especially E STOPs are in place and in working order Frequent relay tripping of power circuits Mechanical parts loosened by vibration loose rivets covers bolts etc Uneven riding worn or damaged wheels Condition of collector shoes or bars Condition of warning or signal lights and horns burned out or broken 2 11 Batteries A WARNING KNOW AND FOLLOW PROPER BATTERY HANDLING CHARGING AND DISPOSAL PROCEDURES IMPROPER BATTERY PRO CEDURES CAN CAUSE BATTERIES TO EXPLODE OR DO OTHER SERIOUS DAM AGE FAILURE TO FOLLOW THIS WARN ING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIP MENT 2 12 Battery Handling Telemotive Series 18K Receiver Instruction Manual 2 6 Section 2 Radio Controlled Safety Continued Use only batteries approved by Telemotive for the specific product Do not dispose of a battery pack in fire it may explode Do not attempt to open the battery pack Do not short circuit battery For intrinsically safe environments only use specified Telemotive intrinsically safe batteries Keep the battery pack environment cool during charging operation and storage i e not in direct sunlight or close to a heating source 2 13 Battery Charg
45. or J3 is the module designator The designator should be a number from 0 5 This number indicates for what voltage the board is designed to monitor The six E10191 series modules are E10191 0 110VAC E10191 1 24V AC DC E10191 2 12VAC DC E10191 3 36V AC DC E10191 4 48V AC DC E10191 5 64V AC DC 12 4 Alarms If a voltage is detected across the output of a relay and the relay is not energized an alarm will be generated A contact monitoring alarm fault will cause the MCR relay to open up until the fault is corrected If a fault is present the Telemotive Series 18K Receiver Instruction Manual 12 1 Section 12 18K Contact Monitoring Board Continued appropriate contact monitoring LED DS1 through DS16 will be lit during the fault indicating a voltage present and the matching LED on the driver board for the output relay will not be lit indicating the relay should be open Once the MCR relay opens power is removed from the Contact Monitoring Board and the fault will not exist An alarm condition will activate an E STOP command and light the red LED DS13 on the CPU Board See Section 7 18K CPU Board for location of DS13 If a contact monitoring LED DS1 through DS16 is lit indicating a voltage present and the matching LED on the driver board for the output relay is lit indicating the relay should be closed this is a normal condition 12 5 Programming Each Contact Monitoring Board can support
46. or testing hoist trolley and bridge brakes The operator should know and follow the local lockout and tagout procedures 2 5 Operating Area 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 Crane operators should always position them selves 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 2 6 Transmitter Unit Transmitter switches should never be mechani cally blocked ON or OFF for any crane motion When not in use turn the transmitter OFF A se cure 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 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 2 7 Operating The Crane 2 7 1 Pre operation Test 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 Test the
47. reen lights should be ON on the CPU board Check to see that the red DS3 is out at this time indicating the outputs are disabled Switch S1 on the CPU turned off Check out radio functions Check each function and direction by first jogging the appropriate button After the check put S1 to the ON position the red DS3 should light 8 With Sl on the CPU ON check crane operation under power Again check each function and direction by first jogging the Telemotive Series 18K Receiver Instruction Manual 4 2 Section 4 Installation Information Continued appropriate button Installation should now be complete 4 8 Special Receiver Functions Special programming exists to allow some of the Aux relays to be dedicated for special system functions Setting certain dip switches on the CPU Board enables this programming 4 8 1 Master Control Relay MCR Enable S1 This switch when turned to OFF disables the MCR and removes all output power to all output relays This allows testing of the receiver control circuitry without activating any external functions such as motors and horns 4 8 2 Auto Alarm And E STOP Alarm S2 1 S2 2 E STOP Alarm only available on Part 15 system 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 The E STOP Alarm is designed into certain Part 15 systems if requ
48. resent Check connectors the 5 VDC regulator or for shorts on the board DS35 Yellow Monitors system activity Normally FLASHING If not flashing the microprocessor EPROM is dead DS36 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 microprocessor is not working properly If the 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 microprocessor EPROM on the Contact Monitoring Board may be defective DS37 and Yellow Monitors the connection through the RS485 port J9 to the CPU DS38 Board Normally ON and dim or rapidly flashing When the LED is OFF the CPU Board is not connected to the Contact Monitoring Board Telemotive Series 18K Receiver Instruction Manual 12 3 Telemotive Series 18K Receiver Instruction Manual 12 4 Section 13 18K Stepless Output Boards 13 1 18K Stepless Output Board Setup Information The 18K Stepless Output Boards are shown in Figure 13 1 Refer to paragraphs 13 1 through 13 7 for servicing procedures 1 0 10 Volt DC E10109 3 Mechanical E10116 3 Mechanical adjustment E10109 1 Solid State E10116 0 Solid State 2 0 10 Volt DC output for Main motor function A2 Positive
49. rs The indicators S1 S2 S4 and S8 count up in a binary sequence as the transmitter lever is moved up D1 D2 Fl and F2 indicate the activation of directionals D and floats F 1 and 2 respectively 14 9 Special Power Supply For some static stepless boards a negative 12VDC output from the power supply is required as well as a plus 12 VDC Depending on the mains the following power supplies are used in lieu of the standard supply in static stepless systems 10 40 Volts AC orDC A5664 40 90 Volts ACorDC A5670 90 300 Volts AC or DC A8505 Telemotive Series 18K Receiver Instruction Manual 14 3 Telemotive Series 18K Receiver Instruction Manual 14 4 Section 15 18K DC Backplane 15 1 E18002 DC Back plane for 18K with contact monitoring has the following diagnostic indicators LEDs Color Monitors Function DS36 yellow TX data present Monitors data to the main CPU Flashes constantly Out bad cable to CPU Board DS37 red CPU watchdog Lights if processor dead DS36 yellow RX data present Monitors data to the main CPU Flashes constantly Out bad cable to CPU Board DS35 yellow On board CPU Monitors the on board CPU Flashes constantly Out CPU problem DS19 red Main relay kl closed Monitors enabling of MR relay on back panel check to see Unit is turned on power across J27 3 amp J27 4 DS18 green 5V Monitors 5v to the board on constantly Out check for shorts or bad connection on J1 2 DS17 green 12V Monitors 12v to t
50. s 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 If any hazard involving the repairperson exists when there is a runway adjacent to the crane un der repair the adjacent runway should be blocked off as described above When it is nec essary to continue crane operation on the adja cent 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 re ceiving permission from a signal person desig nated for this purpose Access of persons to and from the crane being repaired should be under control of the repair crew leader 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 lockout the main switch and then signal the other members of the crew it is safe to board the 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 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 If it is necessary to have the crane control cir cuits en
51. tance of moving objects The operator should have knowledge of the radio transmitter The operator should know how to properly test limit switches The operator should know where authorized instructions for plugging motions The operator should have knowledge of the use of crane warning lights and alarms 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 transmitter when not in use The operator should be trained in transferring radio control transmitter to another person The operator should be trained how and when to report unsafe or unusual operating conditions The operator should be trained how to exhibit caution in approaching bridge or trolley bump ers The operator should know equipment capacity The operator should be trained in making lifts below floor level Telemotive Series 18K Receiver Instruction Manual 2 2 Section 2 Radio Controlled Safety Continued 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 The operator should know cable and hook inspection procedures The operator should know procedures f
52. terface Interface Board J1 m ZU Board J3 re Jug 16 I J17 DS7 O DS8 O DSI O DS10 O DS11 O DS12 Ef We DS13 DS14 0 E Nn Eh I ae ET arre gt TZEPSILS Master Control Relay Enable Switch AH Ds6 O El Ds4 O St 2 m0 gt DS5 O Fuse 3 Amp DS1O slow blow E OFF o 5 MUA JU3 87654321 GER OFF no AMENA Fuse 1 Amp 97654321 slow blow 113 E Power cable from Power Supply Board J3 RS 485 cable to Contact Monitoring Board J9 Figure 7 1 18K CPU Board E10111 0 7 2 Operation The CPU Computer Processor Unit Board consists of a microprocessor EPROM with built in custom programming The programming of the microprocessor EPROM will vary from application to application Inquiries about the functionality or replacement parts can be ordered by referencing the job number of the receiver unit found on the door label or the part number on the microprocessor EPROM itself 7 3 Programming Switches The programming switches S2 and S3 control the following features These only apply to units originally programmed to utilize these features Time out Timer Disable Switch S3 position 2 turn ON to disable receiver time out timer Auto Alarm Enable Switch S2 position 1 turn ON to enable Auto Alarm E STOP Alarm In the Part 15 system only Disable To disable the E STOP Alarm the A
53. the mounting location is as far as possible from exposed trolley wires and sources of electromagnetic or radiated noise 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 4 3 Antenna Mounting Considerations It is best to mount the antenna so that it is visible to the operator Usually this is accomplished by mounting the antenna under the crane and pointed down You should always try to avoid power sources motors drives brakes etc If necessary we offer an external antenna kit 4 4 Line Input Considerations Check the system drawings for proper line input voltage If there is any question as to proper line input voltage contact Telemotive before applying power to the unit A WARNING THE UNIT MUST BE WIRED TO THE COR RECT VOLTAGE AND BE CONNECTED TO THE CORRECT TERMINAL AS REQUIRED BY THE ACTUAL LINE VOLTAGE PLEASE CONSULT YOU SYSTEM DRAWINGS FOR PROPER SUPPLY VOLTAGES FAILURE FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT NOTE 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 4 5 Wiring Considerations 1 Do not connect or disconnect wiring or perform circuit checks while the power is turned ON 2 The motor wiring shal
54. tor labeling for proper connection points Switch S1 turns OFF the 12 VDC output For 11 3 Servicin power supplies with a none standard power were source or for static stepless systems see Section Disconnect power to the power supply before 11 5 servicing 11 4 Indicators The LEDs on the board indicate the following LED COLOR FUNCTION DS1 Green Monitors unregulated 12 VDC Normally ON Check fuse wiring to unit and AC power to unit DS2 Green Monitors regulated 12 VDC Normally ON DS2 OFF and DS1 on check for shorts on regulated output or blown regulator Disconnect power supply connector to CPU Board if DS2 light comes back on there is a short on one of the other boards Telemotive Series 18K Receiver Instruction Manual 11 1 Section 11 18K Power Supply Board Continued 11 5 Alternative Power Supplies A different power supply may used if the mains supply is not 110 or 220 VAC The following are the part numbers of power supply modules used for different mains voltages 10 40 Volts AC orDC A5665 0 40 90 Volts AC orDC A5671 0 90 300 Volts AC or DC A5672 0 If the system uses static stepless boards a negative 12VDC output from the supply is required as well as a plus 12VDC Depending on the mains the following supplies are used in static stepless systems 10 40 Volts AC orDC A5664 0 40 90 Volts AC orDC A5670 0 90 300 Volts AC or DC A8505 0 Telemotive Series 18K Receiver Instructio
55. transmitter turned ON This LED will light rapidly when data is transmitted The LED can be used with DS10 to analyze incoming data If DS10 is illuminated or flashing when DS12 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 DS13 Yellow Monitors the connection of RS485 port J3 to the CPU Board Part 15 only Normally rapidly flashing When the LED is ON solid the CPU Board is not connected to the RF Translator Board Telemotive Series 18K Receiver Instruction Manual 9 3 Section 9 18K RF Translator Board Continued Telemotive Series 18K Receiver Instruction Manual 9 4 Section 9 18K RF Translator Board Continued Table 9 2 Part 90 Receiver Programming Associated RF Translator Board Associated RF Translator Board RF Frequencies Setting RF Frequencies Setting In MHz T S4 S3 S2 In MHz T S4 S3 S2 40 97 0DO 40 01 130 40 99 OCE 40 03 1 2 E 41 01 oC C 40 05 12 C 41 03 OCA 40 07 12 A 41 05 0 C 8 40 09 1258 41 07 0C6 40 11 126 41 09 0C4 40 13 124 41 11 0C2 40 15 1 22 41 13 oco 40 17 120 41 15 O BE 40 19 1 1E 41 17 0 BC 40 21 1 1 C 41 19 OBA 40 23 1 1 A 41 21 OB 8 40 25 1 1 8 41 23 0 B 6 40 27
56. up to 16 different loads For more than 16 loads the Contact Monitoring Boards can be cascaded on the RS 485 port Switches S1 and S2 are used to set unique addresses for multiple boards For single board applications the switches in S1 should all be set to the OFF position 12 6 Indicators The LED indicators on the board indicate the following See Table 12 1 Contact Monitoring Board Diagnostic LED Functions Telemotive Series 18K Receiver Instruction Manual 12 2 Section 12 18K Contact Monitoring Board Continued Table 12 1 Contact Monitoring Board Diagnostic LED Functions LED COLOR FUNCTION DS1 through Red Monitors the load on the switched output of certain relays DS16 Normally OFF If a voltage is present then the LED is illuminated A LED illuminated ON and the appropriate output driver LED OFF represents a power relay or wiring failure and requires immediate repair The specific LED illuminated refers to a corresponding specific contact and load Consult your system s wiring diagram for specific connections DS17 Green Monitors 12 VDC power from Power Supply Board Normally ON If 12 VDC power is present then the LED is illuminated The LED is OFF if 12 VDC power is not present Check connectors the Power Supply Board or for broken cables DS18 Green Monitors 5 VDC regulated voltage Normally ON If 5 VDC power is present then the LED is illuminated The LED is OFF if 5 VDC power is not p
57. 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 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 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 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 If provided test the lower limit switch Test all warning devices Test all direction and speed controls for both bridge and trolley travel Test all bridge and trolley limit switches where provided if operation will bring the equipment in close proximity to the limit switches Test the transmitter emergency stop Test the hoist brake to verify there is no drift without a load If any crane or hoist fails any of the above tests notify the supervisor and lockout and tagout for repair 2 7 2 General Rules For Operation Consult the crane manufacturer local and governmental regulations for complete rules of operation In general the following rules apply to remotely controlled cranes The limit switches should
58. uto Alarm must also be turned OFF To disable both Auto Alarm and E STOP Alarm turn S2 1 OFF and S2 2 ON on the CPU Board Contact Monitor Enable Switch S2 position 4 turn ON to disable contact monitoring 7 4 Access Code Switches Switches A and B on the CPU Board program the access code If the access needs to be set to match the transmitter or visa versa please match switch A to corresponding A position on the transmitter Do the same for B on both the receiver and transmitter If the codes do not match you will get an error light DS9 on the CPU Board while transmitting For Part 15 systems all 16 switches are used For Part 90 systems the 12 bit access code is assigned starting with position Al through A8 then B1 through B4 For 8 bit access codes switch B is not used 7 5 Indicators The LED indicators on the board indicate the following See Table 7 1 CPU Board Diagnostic LED Functions Telemotive Series 18K Receiver Instruction Manual 7 1 Section 7 18K CPU Board Continued Table 7 1 CPU Board Diagnostic LED Functions LED COLOR FUNCTION DS1 Green Monitors the 12 VDC power to the CPU Board Normally ON If 12 VDC power is present then the LED is illuminated The LED is OFF if 12 VDC power is not present Check power supply fuses and if power is ON to receiver DS2 Green Monitors 5 VDC regulated voltage Normally ON If 5 VDC power is present then the
59. utput Boards selected per system the Bill of Materials in the System Drawings E10112 0 8 NO Contacts green E10115 0 4 NO amp 4 NC Contacts red E10109 X Stepless Two Motor Circuit Fuses E10116 X Stepless One Motor 2 Aux Breaker i Suppressor LEN Ra Part 15 CB100 1 CR2105 0 E13158 D 18K CPU Board E10111 0 HE RF Translator R i HE E10108 X K206 31 EN l Transformer Contact Monitoring Board T122 0 optional E10191 X q l 2 1 Power Supply o Wire Duct W126 0 4 Wire Duct Cover W127 Board E10171 0 H fee en SN Il Fa MRA Terminal Blocks TB2703 0 For one block typical 70 blocks Channel Mount MP803 0 Figure 5 1 Typical 18K Receiver Cables Part numbers 1 RS485 cable WA18002 30 2 DC power cable WA1045 37 3 Power supply cable WA1039 0 4 RS485 cable WA18002 13 5 6 conductor cable WA1006 13 Telemotive Series 18K Receiver Instruction Manual 5 1 Telemotive Series 18K Receiver Instruction Manual 5 2 Section 6 18K Receiver Spare Parts 6 1 18K Receiver Spare Parts The following parts are listed for reference only Please always check the Bill of Materials in the System Drawings to verify part numbers PART NUMBER DESCRIPTION BOARD LEVEL E13158 D UHF RECEIVER MODULE PART 15 ONLY E7160 X VHF RECEIVER MODULE LICENSED ONLY SEE SYSTEM DRAWINGS FOR SPECIFIC MODEL E7170 X UHF RECEIVER MODULE LICENSED ONLY SEE SYSTEM DRAWINGS FOR SPECIFIC MODEL E805
60. ve Series 18K Receiver Instruction Manual 4 3 Section 4 Installation Information Continued Figure 4 1 Cabinet Layout Cabinet Part Number MP18001 0 Check System Drawings to verify this is correct cabinet some systems need different cabinets Systems with a different cabinet come with unique mounting information RD 2 S E on 5 i S gt n S a bp N N in D a N en 2 en N a a x a 7 S ES Bw oO lt S Q g g o 3 N gS e N S E yo lt NOTE For MP18001 0 Cabinet the Mounting Tabs must be remounted turned outward on back of cabinet before installation These are shipped attached to the back of the cabinet but turned inward for shipping Telemotive Series 18K Receiver Instruction Manual 4 4 Section 4 Installation Information Continued Figure 4 2 Small 18K Cabinet ENCLOSURE 2 25 6 35 12 50 10 25 ENCLOSURE ANCE 17 750 DOOR CLEAR ALL MTG HOLES ARE 33 DIA Telemotive Series 18K Receiver Instruction Manual 4 5 Section 5 18K Receiver Overview 5 1 18K Receiver Overview An optional smaller cabinet is available for A typical 18K receiver back panel layout is smaller sized systems see the System Drawings shown in Figure 5 1 Refer to Section 6 18K for layout and mounting details Receiver Spare Parts for additional part numbers For specific part numbers for the system refer to O

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