FCC ID: IA92072 Crane Anti Two Block Transmitter

www.patamerica.com PAT America, Inc. RADIO ANTI-TWO-BLOCK INSTALLATION, OPERATORS & CALIBRATION MANUAL P/N 031-300-190-136 Rev. F 03/26/203 Installation, Operators & Calibration Manual Radio Anti-Two-Block NOTICE PAT America, Inc. makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose. PAT America, Inc. will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual. This document contains proprietary information, which is protected by copyright, and all rights are reserved. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of PAT America, Inc. PAT America, Inc. reserves proprietary rights to all drawings, photos and the data contained therein. The drawings, photos and data are confidential and cannot be used or reproduced without the written consent of PAT America, Inc. The drawings and/or photos are subject to technical modification without prior notice. All information in this document is subject to change without notice. MANUAL REVISIONS REV DATE 7/19/01 8/29/01 10/25/01 02/20/02 04/19/02 11/18/02 03/26/03

A B C D E F NAME DESCRIPTION KH GJO JR JR JR CH CH CREATED OPERATORS MANUAL, ECN 01-213 REFER TO ECN 01-245 UPDATED WIRING DIAGRAM UPDATED PHOTOS Updated photos ECN 02-275 ECN 03-037 2001 PAT GmbH, D-76275 Ettlingen / Germany 2001 PAT America, Chambersburg, PA 17201, USA PAT Rev. F 03/26/03 190136_f Installation, Operators & Calibration Manual Radio Anti-Two-Block TABLE OF CONTENTS 1 GENERAL INFORMATION ...............................................................................................1 2 WARNINGS.......................................................................................................................1 4 3 SYSTEM DESCRIPTION...................................................................................................2 3.1 RECEIVER .................................................................................................................................. 3 3.1.1 LEDs : ...................................................................................... Error! Bookmark not defined. 3.1.2 ID button.............................................................................................................................. 3 3.2 TRANSMITTER / SWITCH.......................................................................................................... 4 3.2.1 Transmitter LED.................................................................................................................. 4 3.2.2 Storage of the A2B transmitter for Travel........................................................................ 4 INSTALLATION.................................................................................................................5 4.1 TRANSMITTER/SWITCH............................................................................................................ 5 4.2 RECEIVER .................................................................................................................................. 6 5 SETUP/CALIBRATION .....................................................................................................7 5.1.1 Setup Overview .................................................................................................................. 7 5.1.2 Clear Existing Setup Switches.......................................................................................... 7 5.1.3 First ID Setup ...................................................................................................................... 7 5.1.4 Second ID Setup................................................................................................................. 8 6 OPERATION......................................................................................................................8 7 SYSTEM TESTING............................................................................................................9 8 MAINTENANCE ..............................................................................................................11 8.1 BATTERY REPLACEMENT ..................................................................................................... 11 9 TROUBLESHOOTING.....................................................................................................12 9.1 LEDS ........................................................................................................................................ 13 10 RADIO A2B SPARE PARTS...........................................................................................15 PAT Rev. F 03/26/03 190136_f General Information 1 1 GENERAL INFORMATION The PAT AntiTwo-block System has been designed to warn the crane operator of a two-blocking condition of the crane. If a two-blocking condition is approached, the system will warn the operator by sounding an audible alarm, lighting a warning light and locking out those functions which may aggravate the crane's condition, whenever applicable. NOTE: The term "two-block" is a crane term that refers to a condition when the load handling device comes in contact with the boom head. This condition, if not prevented, may cause the wire rope to break, allowing the load to fall. Either raising the load into the boom head, or telescoping the boom out without paying attention to the hoist line can cause a "two- block" condition. 2 WARNINGS The PAT Anti-Two- Block System is an operational aid, which warns a crane operator of approaching two-block conditions, which could cause damage to equipment and personal injury. This device is not, and must not be a substitute for good, sound operator judgment, experience and use of accepted safe crane operating procedures. The responsibility for the safe operation of the crane remains with the crane operator who must ensure that all warnings and instructions supplied are fully understood and observed. Prior to operating the crane, the operator must carefully and thoroughly read and understand the information in this manual to ensure that the operation and limitations of the system and the crane are known. Proper functioning is dependent upon proper daily inspection and observations of the operating instructions set forth in this manual. Caution: changes or modifications to this product which are not expressly approved by PAT could void the user's authority to operate the equipment. PAT Rev. F 03/26/03 190136_f 2 Installation, Operators & Calibration Manual Radio Anti-Two-Block 3 SYSTEM DESCRIPTION The PAT Radio Anti Two Block, RATB, uses state-of-the-art technology. The radio communication electronics were designed cooperatively between PAT and OMNEX controls. OMNEX was chosen because of its established name and proven experience with wireless communications in the construction equipment industry. Our system transmits an OK signal ~ every two seconds on up to three separate channels. This is to ensure accurate and consistent reception of data and to reduce the possibility of unnoticed failure. The separate channels greatly reduce the probability of failure due to external interferences. Unique, serialized transmitter identifiers are used to ensure proper operation even though other cranes are in the area. The PAT RATB is easily configured to communicate with up to two transmitters. Simply by pressing and holding the ID button for five seconds, the receiver can sense the transmitters being used and configure the receiver to listen to only those transmitters. There are no numbers, IDs or codes to remember or write down. The PAT RATB has been designed to be easily and quickly installed. It can be installed in an OEM application in under an hour. The PAT RATB works like our normal Anti-Two-Block. It alerts to an impending two-block condition. This alert can come in the form of an audible alarm and visual LED or with the optional function lockout if the crane is so equipped. The PAT RATB transmitter is modular by design, containing three separate parts, the transmitter, the switch and the battery housing. It was designed so these individual components can be replaced easily and separately. The receiver is mounted into a receiver box, which is water-tight when submerged in up to three feet of water. The receiver box provides the following indications: Power (status), LINK, Low Battery, and A2B. If battery saving measures are used, the battery life will be greater than one year or up to two years, even with transmitting every two seconds. Several power saving methods are incorporated into the design of the electronics as well as the other hardware. The receiver will work with either 12VDC or 24 VDC. It is fused to 1 Amp and protected to 36 VDC. PAT Rev. F 03/26/03 190136_f System Description 3.1 RECEIVER 3 Radio Anti-Two-Block Receiver 3.1.1 LEDs:

1.The POWER LED (Green) 2.The LINK LED (Green) 3.The LOW BATTERY LED (Yellow) 4. The A2B LED (Red) Receiver Box Shows that there is power to the system. Indicates the status of the communication link between the main hoist A2B transmitter and the receiver. Failure of the communication link will turn off the Green LED and turn off the output to the lockout relay. Indicates that the battery of the main transmitter needs to be replaced. Indicates an impending two-block condition of the main hoist. The Red LED will light when the load-

handling device has lifted the A2B weight. This LED will light simultaneously with the engaging of the lock out solenoids (if installed). 3.1.2 The yellow ID button, located in the lower right-hand corner of the receiver board, is used to set the transmitter ID of the transmitter into the receiver. ID button PAT Rev. F 03/26/03 190136_f 4 Installation, Operators & Calibration Manual Radio Anti-Two-Block 3.2 TRANSMITTER / SWITCH The transmitter and battery housing are made of a special plastic that resists impact and will not become brittle even in low temperatures. 3.2.1 Transmitter LED The transmitter has an LED on the bottom for diagnostics. The LED should be on when in a two-block condition or when the weight is lifted. The LED will flash rapidly during a 2-block condition and will stop flashing after the switch is in a two-block condition for more than 15 seconds. The LED will flash randomly approximately every 2 seconds when the switch is transmitting. When in sleep mode, the LED will not flash. 3.2.2 Storage of the A2B transmitter for Travel The weight should remove from the switch when traveling to extend battery life. The system is in permanent lockout and the system will not function until the chain is unhooked. To use the feature, attach any part of the chain into the hook. When it is desired to use the switch again, simply unhook the chain to allow the switch to close. The weight and chain must be hung from the switch and/or the chain must be unhooked before the crane is operated. PAT Rev. F 03/26/03 190136_f Installation 5 INSTALLATION 4 4.1 TRANSMITTER/SWITCH Install the standoff to the boom head using a 5/16x3/4 HEX bolt. The hole pattern for the standoff is the same as that of conventional PAT A2B switches. In most cases the standoff can be mounted in the same location as the conventional switch. If not replacing an existing switch, the proper location would be one that allows the switch to rotate freely without being obstructed by any part of the boom head. It should be mounted close to the dead end mounting gusset. The switch should normally be mounted on the cab side of the crane. For jib installations, locate the switch close to the jib head. Remove the lynch pin from the standoff. Slide the A2B switch onto the standoff. Replace the lynch pin into the standoff. Install the weight and chain onto the A2B switch. PAT Rev. F 03/26/03 190136_f 6 Installation, Operators & Calibration Manual Radio Anti-Two-Block POWER LINK LOW BATT. A2B ALARM RECEIVER MODULE INTERNAL RELAY RELAY SHOWN DEENERGIZED

(DURING NORMAL OPERATION RELAY IS ENERGIZED) BOX MAXIMUM HEIGHT 1.375"

Wiring For Power Cable to Receiver Board Module

. 4.2 RECEIVER The receiver comes packaged in a waterproof housing. The module must be mounted into a suitable location using the supplied hardware. The location of the receiver should be in direct line of site of the transmitter and not blocked by any metal between the transmitter and receiver. PAT Rev. F 03/26/03 190136_f Setup/Calibration 7 5 SETUP/CALIBRATION 5.1.1 Setup Overview The PAT RATB is easily configured to communicate with up to 2 transmitters. Simply by pressing and holding the yellow ID button for 7 seconds, the receiver can sense the transmitters being used and configure the receiver to listen to only those transmitters. There are no numbers, IDs or codes to remember or write down. ID SET BUTTON 5.1.2 Clear Existing Setup Switches Press and hold the yellow ID button for 15 seconds, the ID LED will begin to blink and then go off when cleared. Note: It is only necessary to complete this operation when changing from a duel switch setup to a single switch. When setup is complete, the new transmitter switch will over write the old ID code with a new one. 5.1.3 First ID Setup To configure the system, install batteries into the transmitter to be used. Turn on the crane power. Open the receiver enclosure and slide out the receiver board. Press and hold the yellow ID button on the OEM module for 7 seconds until the ID 1 LED blinks. Release the yellow ID button. The receiver will search for a transmitter for the next 30 seconds. Pull on the cable of the transmitter and then release it. The yellow ID 1 LED should now be on solid. The transmitter and receiver are now set up and will work only with each other. PAT Rev. F 03/26/03 190136_f Radio Anti-Two-Block Installation, Operators & Calibration Manual 8 5.1.4 Second ID Setup To program second radio a2b switch: Ground pin 3 of ithe receiver (as shown below). Install batteries into the transmitter to be used. Turn on the crane power. Open the receiver enclosure and slide out the receiver board. Press and hold the yellow ID button on the OEM module for 7 seconds until the ID 2 LED blinks. Release the yellow ID button. The receiver will search for a transmitter for the next 30 seconds. Pull on the cable of the transmitter and then release it. The yellow ID 1 LED should now be on solid. The transmitter and receiver are now set up and will work only with each other. The transmitter(s) and receiver are now set up to work only with each other. Test the system using the instructions in section 7, System Testing. 6 OPERATION The function of the system must be tested daily before each use of the crane hoist. Refer to Pre-

Operation Inspection and Calibration Verification. During the normal operation of the system the LINK and POWER LEDs should be on. POWER LED The POWER LED shows that the OEM module is getting power from the crane. The receiver is on any time the crane is operating and supplying power to the system. LINK LED The LINK LED indicates the status of communication of the transmitter(s). During normal operation of the system, the LED will be on. The LED is off when there is an interruption in the transmission. The system should not be operated if the LINK LED is not lit. LOW BATTERY LED The low battery indicator will light indicating that you have a limited time to operate before the system goes dead. When the battery level is to the point that it is too low to operate, the system will stop functioning. Use any off-the-shelf alkaline C-cells; Duracell, Eveready, etc. A2B ALARM LED Indicates an impending two-block condition of the main hoist. The Red LED will light when the load-

handling device has lifted the A2B weight. This LED will light simultaneously with the engaging of the lock out solenoids (if installed). Test the electronics Cycle the power to the system, each LED on the receiver will light for 2 seconds when the system is powered. All of the indicator lights must come on or the system is not functioning properly. If any light does not function, do not use the system until it has been repaired. PAT Rev. F 03/26/03 190136_f System Testing 9 7 SYSTEM TESTING To test the electronics:

Each LED on the receiver will light for 2 seconds when the system is powered. All of the indicator lights must come on or the system is not functioning properly. If any light does not function, do not use the system until it has been repaired. Following the successful testing, the LINK LED should come on. If the LEDs do not come on, there is an error in the transmission. Do not use the system until it has been repaired or replaced. (Refer Troubleshooting section.) To test the hoist limiting:

After the electrical connections have been checked to ensure that the system is properly connected for the crane configuration, the following checks must be made:

The following tests must be performed with care to prevent damage to the machine or injury to personnel. Proper functioning of the system requires successful completion of these tests before operating the machine. Check the anti two-block switches and weights for free movement. If the operator cannot see the load-handling device approaching the boom nose, an assistant (signal person) must watch the load-handling device. The operator must be prepared to stop the machine immediately should the RATB system not function properly. This is indicated by lighting the red warning light, sounding the audible alarm and locking the following crane movements: hoist up, telescope out and boom down. Manually lift the weight attached to the anti two-block switches. When the weight is lifted, the audible alarm should sound, the anti two-block alarm light should light. PAT Rev. F 03/26/03 190136_f Installation, Operators & Calibration Manual 10 With optional lockout installed the following additional tests must be performed:

Slowly raise the main boom load-handling device to create a potential two-block condition. When the load-handling device lifts the weight, the audible alarm should sound, the anti two- block alarm light should light and the motion of the load-handling device should be stopped. Lower the load-

handling device slightly to eliminate this condition. Radio Anti-Two-Block Slowly lower the boom to create a potential two-block condition. When the load-handling device lifts the weight, the audible alarm should sound, the anti two-block alarm light should light and the boom lowering function should be stopped. Lower the load-handling device slightly to eliminate this condition. Slowly extend (telescope) the boom to create a potential two-block condition. When the load-

handling device lifts the weight, the audible alarm should sound, the anti two-block alarm light should light and the boom telescope out function should be stopped. Lower the load-handling device slightly to eliminate this condition. If the light and audible alarm does not function as described and the crane movements are not stopped, the system is not working properly. The malfunction must be corrected before operating the crane. If the crane is equipped with a second transmitter, repeat the test on the second transmitter. PAT Rev. F 03/26/03 190136_f Maintenance 8 MAINTENANCE 11 The only maintenance required is to change the batteries when required. Also, check the mounting hardware daily to ensure that there is no damage. Replace any damaged parts before operating the crane. 8.1 BATTERY REPLACEMENT To replace the batteries, remove the 4 screws from the transmitter housing. Install 4 fresh batteries into the proper location and direction as indicated on the battery holder. Make sure that the cardboard tube is installed as shown. LOOSEN 4 SCREWS BATTERY DIRECTION LABLE CARDBOARD TUBE INSTALLED BATTERIES PAT Rev. F 03/26/03 190136_f 12 9 TROUBLESHOOTING Installation, Operators & Calibration Manual Radio Anti-Two-Block LEDs Receiver Board Numbers from left to right on Receiver Board, above, are:

1. Link1 Green 2. A2B1 Red 3. LO BAT1 Red 4. Link2 Green 5. A2B2 Red 6. LO BAT2 Red 7. ID1 Orange 8. ID2 Orange Note: The board must be removed from the housing in order to see the LEDs PAT Rev. F 03/26/03 190136_f Troubleshooting 13 9.1 LEDS

(Refer to Numbers below photo on previous page) 1.The LINK 1 LED Link1 (Green) 2. The A2B 1 LED A2B1(Red) 3.The LOW BATTERY 1 LO BAT1 LED (Red) 4. The LINK 2 LED Link2 (Green) 5. The A2B 2 LED A2B2(Red) 6.The LOW BATTERY 2 LED LO BAT2 (Red) 7. The ID 1 LED ID1(Orange) 8. The ID 2 LED ID2(Orange) Indicates the status of the communication link between the main hoist A2B transmitter and the receiver. Failure of the communication link will turn off the Green LED and turn off the output to the lockout relay. Indicates an impending two-block condition of the main hoist. The Red LED will turn off when the load-handling device has lifted the A2B weight. This LED will light simultaneously with the engaging of the lock-out solenoids (if installed). When the light goes off, it indicates that the battery of the main transmitter needs to be replaced. Indicates the status of the communication link between the auxiliary hoist A2B transmitter and the receiver. Failure of the communication link will turn off the Green LED and turn off the output to the lockout relay. Indicates an impending two-block condition of the auxiliary hoist. The LED will turn off when the load-handling device has lifted the A2B weight. This LED will light simultaneously with the engaging of the lock-out solenoids (if installed). When the light goes off, it indicates that the battery of the main transmitter needs to be replaced. Lights to show the successful setup of the main transmitter. This LED will stay on once the transmitter is set up. Lights to show the successful setup of the AUX. Transmitter. This LED will stay on once the transmitter is set up. PAT Rev. F 03/26/03 190136_f Installation, Operators & Calibration Manual Radio Anti-Two-Block Cause No power to receiver Make sure the module is getting power from the crane. Solution 14 All LEDs are located inside the receiver box. Problem No LEDs light on receiver Crane functions locked out all the time No power to the receiver Crane functions locked out all the time Crane functions locked out all the time Crane functions locked out all the time Transmitter LED does not flash Link 1 LED not on Link 1 LED not on Link 1 LED not on Incorrect wiring No reception. Fault in receiver module. ID1 not set. Poor communication caused by interference. Object blocking the transmission path. Link 1 LED not on Fault in the main transmitter. Link 2 LED not on ID2 not set. Link 2 LED not on Link 2 LED not on Poor Communication caused by interference. Object blocking the transmission path. Link 2 LED not on Fault in the aux transmitter. LO BAT1 or LO BAT2 LED off No or low batteries in the transmitter. Check wiring. Ensure correct polarity of the power. Replace OEM receiver Check LED lights on module. Make sure the module is getting power from the crane. Check wiring. Ensure correct polarity of the power. Replace OEM receiver Check for power to lockout device. Check if the green Link LED is on. The green Link1 LED must be on for single hoist operation. Link1 and Link2 must be on for 2-hoist operation. See Link 1 LED troubleshooting. Check relay output voltage from receiver to lockouts Pull switch wire rope. Red LED will flash ~each 2 sec. Replace batteries. Replace transmitter. Set the ID of the transmitter. See Section 5, Setup. Remove potential interference sources from the area. Mount the receiver in a different location. Improper location of the receiver. Move the receiver to a line of site location. Check antenna Pull main switch wire rope. Replace batteries. Replace transmitter. Set the ID of the transmitter. See Section 5, Setup. Remove potential interference sources from the area. Mount the receiver in a different location. Improper location of the receiver. Move the receiver to a line of site location. Check antenna. Pull main switch wire rope. Replace batteries. Replace transmitter. Replace batteries. PAT Rev. F 03/26/03 190136_f Radio A2B Spare Parts 15 10 RADIO A2B SPARE PARTS 031-300-060-488 Radio A2B receiver 1 031-300-060-377 Cable Assembly 12 Note: part number may change depending on length 2 1) 031-300-060-484 Radio A2B transmitter assembly 2) 031-300-100-722 A2B flag assembly 031-300-050-262 Radio A2B transmitter 031-300-050-537 Battery cover PAT Rev. F 03/26/03 190136_f 16 Installation, Operators & Calibration Manual Radio Anti-Two-Block 031-300-050-536 Card board tube 031-300-060-022 Radio A2B switch 031-300-050-276 A2B Mounting standoff 031-300-050-264 A2B mounting plate 031-300-050-272 Lynch pin 031-300-210-012 Weight and chain 031-300-100-037 Chain connector, quick link PAT Rev. F 03/26/03 190136_f