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TORC-SafeStop_E-stop..

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1. cosets sosesessenstwetdveusuextest 4 Z Goeneral 31607 5 S Pa FICC ONDIS a E Searetceiesecces T E E TEA 6 4 SafeStop System Overview 8 5 SafeStop System Specifications 9 9 6 Transmitter Unit Re TT 10 6 1 TRANSMITTER SWITCH DETAIL ssssessesessessesresessesresessesreseesoseesossesscsosseesrssesresresosoesresessesreseesesossesoeeseno 11 0 2 TRANSMITTER POWER CONNECTOR cic caicciaccdiccie dee hesheavtiesdadas N adai 11 60 3 TRANSMITTER LED INDICATOR 0 12 G64 TRANSMITTER AUDIBLE ALARM 1 12 7 Reon OC RP E 13 7 1 POWER SERIAL CONNECTOR DETAIL 1212122211 14 ka STOP PAUSE CONNECTOR DETAIL manne ea es cc een nacre ce done 14 To RECEIVE BD EH By En ed ae eee 15 TLA RCE ER ED INDICATOR DETAIL a 15 7 5 RECEIVER RS 232 COMMUNICATIONS FORMAT cscecoececccccecscncncctcecscscscecscncascececscececscnsnsacaecececscsescnsaces 15 System E E EEES 17 S CHARGING THE TRANSMITTER BATTERY sckiccaidcsccccalciaaceinsiceceecsadaaiecsesaadacaesacdasdedos ANEA ANRA 17 INSTALLING THE ANTENNAS ee ee eee eee ee ee eee eee 17 8 3 INSTALLING THE RECEIVER CABLES INTO THE VEHICLE 1112 18 8 4 EXAMPLE STOP PAUSE WIRING SCHEMATIC wasdccsceecccvcccccsccaascivecnscosvecndaveuseueveassaveecsechesvodedaevedevcaeseevecaexe 18 5 5 VERIFY PROPER OPERATION OF THE SYSTEM 18 9 Physical ces seseansesestecessuecegee
2. WARNING Do not leave the ES 200T unattended while charging the battery A WARNING Only charge battery with one of the supplied adapters P N ESA 002 or ESA 003 i TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 6 3 Transmitter LED Indicator Detail Indicator Status Meaning Power Off Unit power is off Less than 20 battery life remaining Unit power is on Bypass mode activated Communications link has been lost Communications link is active Pause State of Pause contact is unknown due to lost link Pause Pause OUT connected to Pause GND Run Pause OUT connected to Pause VIN Stop Off State of Stop contact is unknown due to lost link Stop Stop OUT connected to Stop GND Release Stop OUT connected to Stop VIN Charge Off External Power Not Connected Status Battery Charging Battery Fully Charged 6 4 Transmitter Audible Alarm Detail The ES 200T transmitter features an audible alarm to indicate an error condition that requires immediate user intervention If the communication link is lost the ES 200T is no longer in communication with the receiver and the transmitter emits a constant tone The ES 200T transmitter needs to be brought back within range of the receiver before operation can resume If the battery drops to approximately 20 of its total capacity the audible alarm will start to sound 3 short tones every 10 seconds If this occurs
3. link to the receiver has been lost Switching the receiver Power Bypass switch to the down or BYPASS position overrides any signals being sent by the transmitter In Bypass mode the receiver LINK indicator will turn off to signify that the receiver is in Bypass mode Also both the Pause and Stop contacts will be activated resulting in the PAUSE and STOP indicators to turn green In Bypass mode the receiver ignores all commands sent from the transmitter and it is not possible to Stop or Pause a vehicle from the transmitter A WARNING It is not possible to stop or pause a vehicle from the transmitter when the receiver is placed in Bypass mode TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 9 PHYSICAL DIMENSIONS 91 ES 200T Transmitter Dimensions 4 77 10 4 a 4 23 1 66 2 58 All units in inches i TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 9 2 ES 200R Receiver Dimensions 5 27 0 N 4 72 All units in inches 7 TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 9 3 Receiver Mounting Template Scale 1 1 Use for mounting hole location TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 10 FCC COMPLIANCE This equipment has been approved for mobile applications where the equipment should be used at distances greater than 20cm from the human body with the exception of hands w
4. the transmitter the power toggle switch the Pause Run toggle switch and the push to stop turn to release Stop Run button When the power toggle switch is in the up or ON position the transmitter is powered With the switch in the OFF or down position the transmitter is shut down and will no longer receive or transmit data The Pause Run toggle switch is used to activate or deactivate the Pause relay on the receiver With the switch in the PAUSE or down position on the transmitter the Pause contact is deactivated on the receiver When deactivated the Pause GND contact Pin 6 and the Pause OUT contact PIN 5 are connected When the switch is in the up or RUN position Pause VIN contact PIN 4 and the Pause OUT contact PIN 5 are connected The push to stop turn to release red Stop button controls the Stop relay on the ES 200R receiver When pushed the button is in the Stop position and deactivates the Stop contact on the receiver When the Stop contact is deactivated the Stop GND contact PIN 3 is connected to the Stop OUT contact PIN 2 When the button is turned or released the Stop VIN contact PIN 1 and the Stop OUT contact PIN 2 are connected 6 2 Transmitter Power Connector The transmitter Power Connector is used for charging the internal rechargeable transmitter battery and powering the transmitter off of external power The Power Connector is a 2 1mm center positive DC power plug
5. NOLOGIES LLC SafeStop User Manual Revision 1 2 5 SAFESTOP SYSTEM SPECIFICATIONS Performance Operating Distance Update Rate Wireless Link Frequency Band Transmit Power Modulation Channels Encryption FCC Approved Electrical ES 200T Battery Life ES 200R Input Voltage ES 200R Input Current Vehicle Interface Contact Ratings Digital Communications Data Rate Run Stop Contact Rating Run Pause Contact Rating Visual Indicators Power Link Status Pause Relay Stop Relay Charging Transmitter Only Audible Alarm Transmitter Only Link Lost Low Battery Environmental Dust Water Resistance Operational Temperature Operational Humidity Operational Shock Rating 6 mi line of sight 25 Hz 902 928 MHz 1W FHSS FSK 02 56 bit DES Key Yes 30 hours 12 VDC 20 0 5 A RS 232 9600 baud 24VDC 5A 24VDC 5A Bicolor LED Bicolor LED Bicolor LED Bicolor LED Bicolor LED Continuous Tone Three Beeps IP50 D C 70 C 10 90 non condensing 10 g TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 6 TRANSMITTER UNIT 8 DES Item Description Run Stop Push to stop turn to release button 6 ChargingPlug gt S 8 Dipole Antenna S 9 Run Pause toggle switch TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 6 1 Transmitter Switch Detail There are three switches located on
6. SafeStop User Manual Revision 1 2 TORC TECHNOLOGIES LLC SAFESTOP ES 200 WIRELESS EMERGENCY STOP USER MANUAL SAFESTOP TRANSMITTER SAFESTOP RECEIVER 2200 Kraft Drive Suite 1325 Blacksburg VA 24060 540 443 9262 www torctech com SafeStop User Manual Revision 1 2 Upon receiving your SafeStop system please verify the information below with the numbers printed on the transmitter and receiver This information will assist TORC Technologies in the support of your SafeStop system should you ever need assistance Transmitter Model Number Transmitter Serial Number Receiver Model Number Receiver Serial Number System ID Key Date of Purchase Channel Number Timeout Action NOTE Channel Number and Timeout Action can be changed by TORC Technologies upon request For technical assistance and repairs please use the following contact information TORC Technologies 2200 Kraft Dr Ste 1325 Blacksburg VA 24060 540 443 9262 www torctech com Copyright 2007 TORC Technologies LLC All Rights Reserved All information contained in this manual is believed to be accurate at the time of printing however TORC Technologies LLC reserves the right to make modifications to the specifications and operation of this product without obligation to notify any person or entity of such revision TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 TABLE OF CONTENTS L ASSICRMONCOE
7. alfunction do not operate in a wet or damp environment TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 Do Not Operate in Explosive Atmosphere To avoid a fire hazard do not operate in an explosive atmosphere such as in the presence of flammable liquids or gases Use Within Range To prevent unreliable operation do not use this product outside of its specified range A range check should be performed at the before using the SafeStop system Maintain Minimum Separation Distance To prevent receiver overload possibly causing loss of link and to ensure operator safety maintain a minimum operating distance of 10 feet between the antennas of the SafeStop system TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 3 PACKAGE CONTENTS After unpacking the contents of the SafeStop ES 200 System please verify the contents of the package includes the following items ES 200T SafeStop Transmitter unit ES 200R SafeStop Receiver unit ESA 001 Rubber Duck Antenna for ES 200T Transmitter ESA 002 AC Power Adapter Charger for ES 200T Transmitter ESA 003 Automotive Power Adapter Charger for ES 200T Transmitter ESA 004 Antenna for ES 200R Receiver w Magnetic Mount and 6 Cable ESA 005 6 Power and Serial Cable for ES 200R Receiver Red Black Serial _ ESA 006 6 Relay Cable for ES 200R Receiver Yellow Blue White Green SafeStop Transmitter SafeStop Re
8. ceiver rubber duck antenna installed Transmitter Rubber Duck Antenna AC Power Adapter Automotive Power Adapter ESA 001 ESA 002 ESA 003 Receiver Magnetic Mount Antenna Receiver Power and Serial Cable Receiver Relay Cable ESA 004 ESA 005 ESA 006 7 TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 4 SAFESTOP SYSTEM OVERVIEW The SafeStop ES 200 multi level wireless emergency stop system consists of the ES 200T transmitter and the ES 200R receiver The SafeStop system provides the ability to safely disable an unmanned or autonomous vehicle from a remote location up to 6 miles away The compact lightweight transmitter contains an internal rechargeable battery that allows the SafeStop system to operate up to 30 hours ona single charge Two independently controlled contacts allow a vehicle to be placed in a paused state as well as disable power to actuators fuel valves etc An audible alarm and indicator lights provide user feedback of contact position link status and battery life Additionally a serial port is provided for interfacing to an onboard computer and a bypass switch allows for manual override of the system Upon detecting a lost link the ES 200R can be programmed by TORC Technologies LLC to either activate the Pause contact or both the Pause and Stop contacts This functionality can only be changed by TORC Technologies LLC and should be specified at the time of order TORC TECH
9. d transmit the results over the RS 232 communications link An example startup screen can be seen below After the initial diagnostic outputs the standard serial output protocol will be continuously displayed File Edit View Cal Transfer Help TORC Technologies SafeStop TH 5 208 System Receiver Firmware Yersion 1 3 Loading Hardware Self Test Version 1 0 Serial Number RSB66661 Temperature 25 C Radio Configuration C Address 00 50 6 27 98 62 System ID 0 Key TORC Channel 8 Mode Server Restoring Settings Timeout Delay 660 ms Timeout Action Pause Only Connected 0 00 51 Auto detect 9600 8 H 1 NUM Example RS 232 Output Terminal a TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 8 SYSTEM INTEGRATION Before your remote relay system can be used you need to perform the following steps fully charge the transmitter battery install the antennas install the receiver cables and verify proper system operation 8 1 Charging the Transmitter Battery Before using the Remote Relay System the transmitter battery must be fully charged for 5 hours The transmitter can be charged using the supplied AC adapter P N ESA 002 or the 12VDC automotive power adapter P N ESA 003 To charge the battery plug one of the supplied power supplies into the charging plug When connected to an external power supply the Charge Indicator LED should be red while the batter
10. he ES 200T transmitter power on while the receiver is still powered Once power to the transmitter is turned on the POWER indicator should be green signifying that it is powered on The LINK indicator should turn green indicating that a communications link has been established between the transmitter and receiver The PAUSE and STOP indicators should depict the state of the Pause switch and Stop button respectively Changing the state of the Pause switch on the transmitter will change the state of the Pause contact on the receiver which will switch the PAUSE indicator accordingly Likewise pushing or releasing the Stop button will change the state of the Stop contact and update the STOP indicator Turning off power to the transmitter while the receiver is still powered will result in a loss of communications between the receiver and transmitter resulting in the LINK indicator on the receiver to turn red and the PAUSE and or STOP indicators to turn red depending on the preset timeout action Turning off power to the receiver while the transmitter is still powered will also result in a lost communications link and turn the LINK led on the transmitter red Since there is no feedback from the receiver about the state of the contacts both the PAUSE indicator and the STOP indicator will turn off Upon a loss of link the transmitter will also emit a constant tone indicating that the
11. ivate the relays placing both the Stop and Pause relays in a run state and turn off the LINK indicator A WARNING While in Bypass Mode the receiver will not accept Stop or Pause commands from the transmitter 7 4 Receiver LED Indicator Detail Indicator Status Meaning Power Unit power is off Unit is powered on Bypass mode activated Communications link to transmitter has been lost Link Green Communications link to transmitter is active Pause Pause OUT connected to Pause GND Run Pause OUT connected to Pause VIN Stop Stop OUT connected to Stop GND Release Stop OUT connected to Stop VIN 7 5 Receiver RS 232 Communications Format The ES 200R continuously monitors the status of the relay outputs and communication link This information is sent serially over RS 232 communications The data bit format is set to communicate at 9600bps 8 data bits 1 stop bit no parity and no flow control The serial protocol consists of 3 data bytes followed by a carriage return and line feed for a total of 5 bytes updated at a frequency of 25 Hz in the following format lt Link Status gt lt Run Pause Status gt lt Release Stop Status gt lt CR gt lt LF gt 0 TORC TECHNOLOGIES LLC SafeStop User Manual lt Link Status gt lt Run Pause Status gt Value Description B _ Bypass Mode lt Release Stop Status gt Revision 1 2 Upon startup the ES 200R will perform a diagnostic check an
12. nsists of properly wiring the POWER SERIAL connector and the STOP PAUSE connector Using the supplied power cable P N ESA 005 power the receiver using a constant 12V power source not included capable of 0 5 amps The power cable s P N ESA 005 red wire should be connected to a positive 12 volts DC and the black wire should be connected to ground If using the RS 232 output the DB9 serial connector on the power cable should be connected to a computer s line level serial port A CAUTION Reversing the polarity may cause damage to the ES 200R 8 4 Example STOP PAUSE Wiring Schematic D BTO VIN VEHICLE 12V MAIN POWER RELAY eee 8 5 Verify Proper Operation of the System After connecting the power cable to the ES 200R receiver turn the power to the receiver on by switching the power switch to the up or ON position the transmitter should not be powered at this time Once power to the receiver is TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 turned on the POWER indicator should turn green after a brief self test indicating that this unit is powered on The LINK indicator should turn red indicating that there is no signal from the transmitter The PAUSE and STOP indicators should also be red indicating that both the Pause and Stop contacts are deactivated To verify the operation of the receiver and transmitter working together turn t
13. power the transmitter off external power with either the supplied AC adapter P N ESA 002 or automotive adapter P N ESA 003 Alarm Meaning Continuous Communication link with receiver has been lost 3 Short Beeps Low batter TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 7 RECEIVER UNIT D 6 D Item Description 1 6 RP SMA Antenna Connection 8 Stop Pause Connector _ _ 0 TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 7 1 POWER SERIAL Connector Detail The POWER SERIAL connector is used to supply power to the ES 200R receiver and for RS 232 communications Mating connector Switchcraft EN3C7F Description 4 7 2 STOP PAUSE Connector Detail The STOP PAUSE connector is used for the contact connections of both the Run Pause and Release Stop contacts Mating connector Switchcraft EN3C6F Description 14 TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 7 3 Receiver Switch Detail The Power Bypass switch is a three position toggle switch used to power the receiver and for placing the unit in Bypass mode With the switch in the up or ON position the receiver is in normal operation and accepts commands form the transmitter The center or OFF position of the switch cuts power to the receiver With the switch in the down or BYPASS position the receiver will act
14. rists feet and ankles Operation at distances less than 20 cm is strictly prohibited This device complies with Part 15 of the FCC Rules Operation is subject to the following 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 FCC ID KQL AC4490 0 TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 11 LIMITED WARRANTY TORC Technologies LLC herein referred to as TORC guarantees that the product s you have purchased from TORC are free from defects in materials or workmanship for a period of one year from the original date of purchase Within this period TORC will at its sole discretion repair or replace any components which fail under normal use This warranty does not cover failures due to abuse misuse accident or unauthorized alterations or repairs There are no other warranties expressed or implied which extend beyond the description contained herein including the implied warranty of merchantability and fitness for a particular purpose TORC expressly excludes all other warranties TORC s liability is limited to the cost of repair or replacement of the product Such remedy shall be the sole and exclusive remedy for any breach of warranty TORC shall not be liable for 1 Damage to other property caused by any defects in the product damages based upon inconvenience loss of u
15. se of the product loss of time loss of profits loss of business opportunity loss of goodwill interference with business relationships or other commercial loss even if advised of the possibility of such damages 2 Any indirect or other damages whether incidental consequential or otherwise 3 Any claim against the customer by any other party i TORC TECHNOLOGIES LLC
16. svasmeceeccsueneudaseoaet 20 ES 200T TRANSMITTER 11 4 4 5100 20 Fp OUR RECEIVER DIMENSIONS deus Gonckowsdanaueedd seed ved cauesaedaouceeusacdoss 21 9O93 ABC EIVER MOUNTING A ANARAN AEEA TARANA 22 10 FCC gt 23 A Tine Vya N OR E 24 TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 1 ASSIGNMENT OF LIABILITY TORC Technologies LLC does not assume any responsibility for the safe operation of any vehicle machinery or related equipment connected to the SafeStop system This product has been tested for proper functionality and safe operation however it is the responsibility of the consumer to ensure the safe operation and testing of all connected components By using the SafeStop system the customer agrees to accept full responsibility and legal liability for any systems connected to the device and to indemnify defend and hold harmless TORC Technologies LLC from all associated legal liability and recourse Each operator should read the entire user manual prior to using the device Failure to read understand and strictly follow these instructions could result in serious personal injury and or property damage TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 2 GENERAL SAFETY INFORMATION The following symbols are used throughout the user manual to indicate a particularly hazardous condition WARNING Indicates a hazardous condition
17. that could result in serious injury or loss of life if not performed properly CAUTION Indicates a hazardous condition or procedure that could result in damage to this product or loss related to equipment malfunction Use Redundant Safety Measures This product is not intended to be used as the only safety stop device It is the user s responsibility to ensure that adequate and redundant safety measures are implemented for the system that this product is used in Use Proper Supplied Accessories To prevent damage to the product use only the recommended accessories including power adapters antennas and cables Observe All Connector Ratings To avoid shock hazard and or damage to the product do not exceed any voltage or current specifications on any of the connectors Do Not Charge Unattended To avoid fire hazard and or damage to the product monitor the SafeStop transmitter when connected to an external power supply Do Not Operate With Suspected Failures If you suspect there is damage to the product contact TORC Technologies to have it inspected before further use Do Not Modify or Disassemble To avoid shock hazard and or damage to the product do not attempt to open the case make modifications or repair the device Opening modifying or repairing this device will void any applicable warranty and could prevent the device from operating properly Do Not Operate in Wet Damp Conditions To avoid shock hazard and or product m
18. y is charging and green when the battery is fully charged Operating the SafeStop system while connected to external power will not drain the battery or reduce the charge time as long as the power adapter is properly connected A WARNING Do not leave the ES 200T transmitter unattended while charging the battery A WARNING Only charge battery with one of the supplied adapters P N ESA 002 or ESA 003 8 2 Installing the Antennas Before turning power to either the ES 200T transmitter or ES 200R receiver on the device antennas must be connected The supplied antenna with magnetic mount and 6 coaxial cable P N ESA 004 installs on the receiver s antenna connector Install the antennas by threading it clockwise onto the corresponding antenna jacks A CAUTION Do not over tighten antenna connectors A CAUTION Antennas must be installed before applying power to the SafeStop system The receiver antenna is connected to a magnetic base that may be attached to a ferrous object The antenna should be mounted to the highest point possible away from any other communications antennas and sources of electro magnetic interference such as engines and electric motors Care should be taken when routing the coaxial cable to avoid tight bends smaller than 1 radius TORC TECHNOLOGIES LLC SafeStop User Manual Revision 1 2 8 3 Installing the Receiver Cables into the Vehicle System The installation of the receiver co

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