FCC ID: JI9-F22-24E0032 Industrial Radio Remote Control Transmitter

TELECRANE F22 Radio Remote Controls for Product Manuals Handheld and Joystick Models August 1, 2004 Revision 3.0.1 Intercontinental Technologies, Ltd. 558-2 Plate Drive East Dundee, IL 60118 Phone: (847) 426-9597 Fax: (847) 426-9724 www.telecrane.com FCC and Industry Canada Approval Information The following information applies to transmitters:

This device complies with part 15 of the FCC Rules and RSS-210 of Industry Canada. 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. Changes or modifications not expressly approved by Intercontinental Technologies, Ltd. could void the users authority to operate equipment. Ce dispositif est conforme aux normes CNR-210 dIndustrie Canada et la partie 15 des rgles de la FCC. Lutilisation de ce dispositif est autorise seulement aux conditions suivantes: 1) il ne doit pas produire de brouillage et 2) lutilisateur du dispositif doit tre prt accepter tout brouillage radioelectrique reu, mme si ce brouillage est susceptible de compromettre le fonctionnement du dispositif . This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. The following information applies to receivers:

Models F22-2D, F22-2D1, F22-2S, F22-2S1, F22-4D, F22-4D1, F22-4S, F22-4S1, F22-6D, F22-6D1, F22-6S, F22-6S1, F22-12D, F22-10D1, F22-12S, F22-10S1, F22-J:

Intercontinental Technologies, Ltd. Table of Contents Part 1: Operators Manual 2.1 2.2 2.3 2.4 2.5 3.1 3.2 3.3 3.4 3.5 3.6 Chapter 1 Warranty .............................................................................................................1 1.1 Warranty ............................................................................................................................... 1 1.2 Warranty Period.................................................................................................................... 1 1.3 Warranty Service .................................................................................................................. 1 1.4 Disclaimers ........................................................................................................................... 1 1.5 Warranty Contact Information.............................................................................................. 2 Chapter 2 Safe Operation....................................................................................................3 Emergency Procedures.......................................................................................................... 3 General Safety Information................................................................................................... 3 Installation Safety ................................................................................................................. 3 Operational Safety ................................................................................................................ 3 Safety When Performing User Maintenance ........................................................................ 4 Chapter 3 Overview of Parts and Features .........................................................................5 Large Chassis Mini-Style Transmitter.................................................................................. 5 Small Chassis Mini-Style Transmitter.................................................................................. 6 N1-Style Transmitter ............................................................................................................ 6 Typical Receiver for Handheld Models................................................................................ 7 Transmitter for the Model F22-J Joystick Controller ........................................................... 8 Receiver for the Model F22-J Joystick Controller................................................................ 9 Chapter 4 Operation of the F22 Series Industrial Radio Remote Controller .....................11 Normal Operation of the Handheld and Joystick Models................................................... 11 Special Functions of Handheld Models .............................................................................. 14 Special Functions of Joystick Models................................................................................. 15 Chapter 5 User Maintenance.............................................................................................17 Safety Aspects of User Maintenance .................................................................................. 17 Unusual Alarms .................................................................................................................. 17 Battery Changing Procedure (Handheld Models)............................................................... 17 Battery Changing Procedure (Joystick Models) ................................................................. 17 Chapter 6 Basic Troubleshooting ......................................................................................19 Reliability............................................................................................................................ 19 Self-Diagnostics and Error Codes....................................................................................... 19 User Troubleshooting.......................................................................................................... 19 Chapter 7 Safe Installation ................................................................................................21 Emergency Procedures........................................................................................................ 21 General Safety Information................................................................................................. 21 Installation Safety ............................................................................................................... 21 Installation.........................................................................................................23 Transmitter Installation....................................................................................................... 23 Receiver Installation ........................................................................................................... 23 Installation of Optional Accessories ................................................................................... 24 5.1 5.2 5.3 5.4 Chapter 8 4.1 4.2 4.3 8.1 8.2 8.3 7.1 7.2 7.3 6.1 6.2 6.3 F22 Series Industrial Radio Remote Controllers: Product Manuals i Intercontinental Technologies, Ltd. 9.1 Chapter 9 Programming By Computer...............................................................................25 Overview............................................................................................................................. 25 Chapter 10 Function Settings...............................................................................................27 10.1 Description.......................................................................................................................... 27 10.2 F22 Series Handheld Transmitter Function Settings .......................................................... 27 10.3 F22 Series Joystick Transmitter Function Settings............................................................. 30 10.4 F22 Handheld Series Receiver Function Settings............................................................... 31 10.5 F22-J Receiver Function Settings ....................................................................................... 32 Chapter 11 Alarm Codes......................................................................................................35 Chapter 12 Principles of Operation of Major Subcomponents.............................................39 12.1 Transmitter.......................................................................................................................... 39 12.2 Receiver .............................................................................................................................. 40 Chapter 13 Customer-Specific Information..........................................................................43 13.1 Serial Numbers and Security Codes ................................................................................... 43 13.2 Function Settings ................................................................................................................ 43 Chapter 14 Product Technical Sheets .................................................................................45 14.1 F22 Series Systems ............................................................................................................. 45 14.2 F22 Transmitter and Receiver Part Numbers...................................................................... 46 14.3 F22 Series: Accessories ...................................................................................................... 46 14.4 Extended Antenna Kit......................................................................................................... 47 14.5 Technical and Programming Sheets.................................................................................... 48 ii F22 Series Industrial Radio Remote Controllers: Product Manuals Intercontinental Technologies, Ltd. Table of Figures FIGURE 1: F22-12D TRANSMITTER....................................................................................................... 5 FIGURE 2: F22-6D TRANSMITTER......................................................................................................... 6 FIGURE 3: F22-10S1 TRANSMITTER ..................................................................................................... 6 FIGURE 4: TYPICAL RECEIVER FOR HANDHELD MODELS (FRONT AND BACK) ....................................... 7 FIGURE 5: F22-J JOYSTICK TRANSMITTER (TOP AND BOTTOM).............................................................. 8 FIGURE 6: F22-J RECEIVER (FRONT AND BACK) .................................................................................... 9 FIGURE 7: EMS BUTTON AND START KEY .......................................................................................... 12 FIGURE 8: ENCODER/BUTTON PCB ..................................................................................................... 39 FIGURE 9: TRANSMITTER RF MODULE ............................................................................................... 39 FIGURE 10: LED PRINTED CIRCUIT BOARD ON JOYSTICK RECEIVER ................................................. 40 FIGURE 11: LOCATION OF RUN/TEST SWITCH IN RECEIVER FOR HANDHELDS.................................... 41 FIGURE 12: LOCATION OF RUN/TEST SWITCH IN RECEIVER FOR JOYSTICK......................................... 42 FIGURE 13: PROGRAMMING SHEET LEGEND ........................................................................................ 48 F22 Series Industrial Radio Remote Controllers: Product Manuals iii Intercontinental Technologies, Ltd. THIS PAGE INTENTIONALLY LEFT BLANK iv F22 Series Industrial Radio Remote Controllers: Product Manuals Intercontinental Technologies, Ltd. Chapter 1 Warranty Part 1: Operators Manual 1.1 Warranty Intercontinental Technologies, Ltd. (ITL) guarantees that this product meets its published specifications at the time of shipment. 1.2 Warranty Period This equipment is warranted against defects in material and manufacturing for a period of one year from the date of shipment. During the warranty period, ITL will repair or replace defective components at no charge, if the failure of the product was due to defective material or manufacturing. 1.3 Warranty Service For warranty service, this product must ultimately be returned to ITL. The buyer must pay shipping charges to the ITL service facility, and ITL will pay return shipping charges. Warranty service on F22 units shall be provided by ITL only and ITL will not be responsible for service or repair costs charged by third parties. Your Distributor is:

Your ITL service facility is located at:

558-2 Plate Drive East Dundee, IL 60118 phone: (847) 426-9597 1.4 Disclaimers ITL will not be liable for any damage to the warranted product, and no other warranty is expressed or implied, except as explicitly described. ITL does not warranty any consumable parts, including batteries, fuses, buttons, relays, and transmitter and receiver cases. This warranty does not include damage caused by improper installation (including ignoring environmental specifications), improper or insufficient maintenance, any modifications, improper operation, or improper software interfacing. The remedies provided herein are the buyers sole and exclusive remedies. ITL shall not be liable for any direct, indirect, special, incidental or consequential damages. Chapter 1 Page 1 of 87 Intercontinental Technologies, Ltd. 1.5 Warranty Contact Information Please contact us at the address below for further help or if you have any questions:

Intercontinental Technologies 558-2 Plate Drive East Dundee, IL 60118 USA Phone: 847-426-9597 Fax: 847-426-9724 Or Call Us Toll Free at (800) 382-3558 Page 2 of 87 Chapter 1 Intercontinental Technologies, Ltd. Safe Operation In case of emergency, perform these steps IN ORDER:

Emergency Procedure 1. Press the Red STOP Button. 2. Turn the Green Rotary Key Switch to the OFF position and remove the key from the transmitter. 3. Switch off the main power to the crane. 4. Contact your distributor or installer. Chapter 2 NOTE: Read ALL safety information before you operate this product. 2.1 Emergency Procedures If the F22 unit detects an error or system fault, it will issue an emergency STOP command and deactivate all systems programmed for a STOP command. It is therefore important to install the F22 system correctly so that if it detects a fault, it can perform an emergency stop and the crane will shut down safely. 2.2 General Safety Information This manual is intended for the user as a general reference only. Please consult your distributor for installation or assistance with specific technical issues. In an industrial environment, safety must always be a top priority. Persons responsible for installation, operation, and maintenance must make certain that both their actions and the equipment on which they work are safe. This chapter includes a list of safety rules that must be followed when working with TELECRANE products, as well as cranes in general. This list is not intended to be all-inclusive. General industrial safety rules must always be followed. If there is any doubt about how to proceed, always take the safest course of action. 2.3 Only qualified personnel should install this product. For installation instructions and safety information, refer to Part 2 of this manual. 2.4 Operational Safety Operating any piece of equipment in an industrial facility can be dangerous; therefore, provide Installation Safety adequate training to operators of cranes that use this equipment. At least once each shift, check the amount of power remaining in the transmitter batteries (see Section 4.1.3, Checking Battery Power). If it is low, change all four batteries before beginning operation. Operating the unit with excessively discharged batteries can be unsafe. Chapter 2 Page 3 of 87 Intercontinental Technologies, Ltd. If the transmitter battery power becomes insufficient, the transmitter will send out an Emergency Stop signal (EMS). This signal will stop all actions previously set to shut down when a STOP signal is received. The LED on the transmitter will illuminate red continuously and the buzzer on the transmitter will buzz continuously until the batteries are removed. If this occurs, replace all four batteries before using the product again. The magnetic safety key should be removed from the transmitter whenever it is not in use and should only be issued to authorized personnel. All TELECRANE F22 Radio Remote Controls are tested before they leave the factory. However, they should not be used in dangerous situations or in a manner such that damage might result. Although the transmitter is very durable and weather-resistant, precautions should always be taken to limit its exposure to weather, physical impact, and corrosives. After use, or if the unit will not be used for a long interval, turn off the power to the crane and remove the magnetic safety key from the transmitter. Remove the batteries from the transmitter if the transmitter will not be used for two weeks or Transmitters that are not in use, including spare transmitters, should be secured to prevent Before each shift, check that the limit switches on the crane function correctly. Before each shift, check that the movement of the crane corresponds to the button being pressed longer. accidental operation. on the transmitter. Do not use the product during lightning storms or high electrical interference conditions. 2.5 Safety When Performing User Maintenance Before performing any maintenance on this product, review Chapter 5, User Maintenance. Page 4 of 87 Chapter 2 Intercontinental Technologies, Ltd. Chapter 3 Overview of Parts and Features This Chapter describes the major parts and features of the F22 Series Industrial Radio Remote Controller. F22 Series radio remote controls are available in different styles to meet different needs. The two basic configurations are handheld and joystick. Handheld controllers are available in two configurations: Mini-Style and N1-Style. The Mini-

Style handhelds are new, advanced designs that are sleek and compact. They are easily held and operated using one hand. The Mini-Style is available in two different chassis sizes: Large and Small. Mini-Style transmitters are pictured in Sections 3.1 and 3.2. N1-Style transmitters are designed for more severe service and include a heavy-duty chassis. They are recognizable by their larger round buttons. N1-Style model numbers end in 1. An N1-Style transmitter is pictured in Section 3.3. Both handheld models are available in different sizes and configurations, and can be customized to a specific application. Both styles of transmitters utilize a similar receiver, pictured in Section 3.4. The Joystick controller provides advanced functions and extended customization in a compact, two-

joystick configuration. The Joystick transmitter and receiver are pictured in Sections 3.5 and 3.6. 3.1 Large Chassis Mini-Style Transmitter The following models are available in the large chassis Mini-Style:

F22-12D F22-12S Figure 1 is a picture of the F22-12D, a Large Chassis Mini-Style transmitter. Figure 1: F22-12D Transmitter Chapter 3 Page 5 of 87 Intercontinental Technologies, Ltd. 3.2 Small Chassis Mini-Style Transmitter Figure 2: F22-6D Transmitter 3.3 N1-Style Transmitter The following models are available in the small chassis Mini-Style:

F22-2S F22-2D F22-4S F22-4D F22-6S F22-6D Figure 2 is a picture of the F22-6D, a Small Chassis Mini-Style transmitter. The following models are available in the N1-

Style:

F22-2S1 F22-2D1 F22-4S1 F22-4D1 F22-6S1 F22-6D1 F22-10S1 F22-10D1 Figure 3 is a picture of the F22-10S1, an N1-

Style transmitter. Figure 3: F22-10S1 Transmitter Page 6 of 87 Chapter 3 Intercontinental Technologies, Ltd. 3.4 Typical Receiver for Handheld Models Figure 4 below shows the front and back of a typical receiver for handheld models. Figure 4: Typical Receiver for Handheld Models (front and back) Chapter 3 Page 7 of 87 Intercontinental Technologies, Ltd. 3.5 Transmitter for the Model F22-J Joystick Controller Figure 5 below shows the top and bottom of the F22-J joystick transmitter. Figure 5: F22-J Joystick Transmitter (top and bottom) Page 8 of 87 Chapter 3 Intercontinental Technologies, Ltd. 3.6 Receiver for the Model F22-J Joystick Controller Figure 6 below shows the front and back of the receiver for the F22-J joystick controller. Figure 6: F22-J Receiver (front and back) Chapter 3 Page 9 of 87 Intercontinental Technologies, Ltd. THIS PAGE INTENTIONALLY LEFT BLANK Page 10 of 87 Chapter 3 Intercontinental Technologies, Ltd. Chapter 4 Operation of the F22 Series Industrial Radio Remote Controller Note: Operating industrial equipment can be hazardous. Use TELECRANE equipment only in accordance with the directions specified in this manual and follow all safety guidelines. Only trained personnel should use TELECRANE equipment. 4.1 Normal Operation of the Handheld and Joystick Models The F22 Series Industrial Radio Remote Controls offer flexibility for a variety of applications and functions that can be specified and set at the factory. The system consists of a receiver and two transmitters, and uses a series of pushbuttons and other controls to operate a crane or industrial equipment. This chapter describes the general operation of the TELECRANE system, and provides specific information related to both the handheld and joystick models. 4.1.1 Pre-Operational Checks Before you operate this product, perform the following checks to ensure that the unit is in proper working order:

Periodically inspect the limit switches on the crane and ensure that they actuate correctly and stop the motion they control. Inspect the position and location of the equipment to ensure that the transmitter and receiver are not exposed to a damaging environment such as high temperatures or high impact. 4.1.2 Power-On Procedure Inspect the transmitter and receiver at the start of each work day to ensure safe operation of this product. Note: If the password feature has been enabled, follow the Power-On procedure described in Section 4.2.1. (Password feature available only on handheld models). To turn on the transmitter:

1. Retrieve the green Rotary Key and place it in the transmitter. 2. Disable the Emergency Stop by turning the red EMS button clockwise until it pops out, then 3. Turn the green Rotary Key Switch clockwise past ON to the START position, note the LED color, then release. The switch will spring back to the ON position and a tone will sound. The transmitter is now active. releasing. Chapter 4 Page 11 of 87 Intercontinental Technologies, Ltd. EMS Button Start Key At the start of each shift, perform the following safety checks:

1. Confirm that there is sufficient battery power to operate the transmitter: If the LED color during the power-on procedure was green, then there is sufficient battery power to operate the transmitter. If the LED color was yellow or red, then battery power is low and all four batteries should be replaced immediately. See Table 4-1-3 below for more details. 2. Test the emergency stop function by pressing Figure 7: EMS Button and Start Key the red EMS button (shown in Figure 7). A tone will sound and the LED will flash red and green alternately to indicate actuation of the emergency stop. If this does not occur, do not use the transmitter. If the emergency stop function works correctly, then restart the transmitter. 3. Confirm that the movement of the crane or other equipment corresponds to the appropriate control being activated on the transmitter. 4.1.3 Checking Battery Power The transmitter will not work properly unless sufficient battery power is available. Before each use, check the battery power and, if needed, replace the batteries following the battery changing procedure in Section 5.3 (handheld models) or 5.4 (joystick model). Remaining battery power is indicated by the color of the transmitters LED display (the circular light adjacent to the green Rotary Key Switch). When the unit is turned on and whenever any button is pressed, the LED will turn green, yellow, or red to indicate the remaining power. To avoid motion of the crane or other equipment, use the Rotary Key Switch during a manual battery check. To do this, turn the green Rotary Key Switch clockwise past ON to the START position and hold it there. The LED will indicate the remaining power according to Table 4-1-3 below (Note: Ensure that the R0 Relay is not connected to any device because this step will activate that relay):

Table 4-1-3 Battery Power Indicator Battery Power Level Sufficient power to operate. Battery power is too low. Change the batteries as soon as it is safe to do so. A warning beep will sound every 4 seconds when any button is depressed. Follow the battery changing procedure in Chapter 1, Section 5.3 (handheld models) or 5.4 (joystick model). There is insufficient power to operate normally and the transmitter will send an emergency stop signal to the receiver. Follow the battery changing procedure in Chapter 1, Section 5.3

(handheld models) or 5.4 (joystick model). LED Color Green Yellow Red Page 12 of 87 Chapter 4 Intercontinental Technologies, Ltd. 4.1.4 Pushbutton Operation The F22 Series transmitters can control a large number of motions and include factory programming customized to your application. As a result, the specific function of each button will vary depending on the application. See Chapter 10 of this manual for descriptions of the standard and custom button functions that are available. Operate the transmitter by pressing the appropriate motion and auxiliary buttons for your application. Depending on which model you select, some or all of the following types of pushbuttons are available:

Table 4-1-4. Pushbutton Types and Descriptions Pushbutton Type Normal

(Non-Interlocked) Normal

(Interlocked) Toggle On-Off 2-Step Description Non-interlocked pushbuttons are standard ON/OFF pushbuttons. The relay is ON when the pushbutton is pressed and held, and OFF when the pushbutton is released. A typical application for a non-interlocked button would be a horn. Interlocked pushbuttons are pairs of buttons programmed to prevent simultaneous operation of certain relays. A typical example of interlocked pushbuttons would be to prevent simultaneous operation of relays that actuate EAST and WEST motions of a trolley. If two interlocked pushbuttons are pressed at the same time, then both relays are switched OFF. The relay is switched ON when the button is pressed once and released. The relay is switched OFF when the same button is pressed again and released. A typical application for a toggle button would be lights. A set of two buttons where one latches the relay ON and the other latches the relay OFF. A typical application for on-off buttons would be a magnet. A 2-step button has two ON positions: Half- and fully-depressed. A typical application for a 2-step button is to control a 2-speed motion; the half-depressed position could correspond to a slow speed and the fully-depressed position could correspond to a faster speed. They can also control variable speed drives as well, such as infinitely variable type applications. 4.1.5 Power-Down Procedures To turn off the transmitter:

1. Press the red Emergency Stop (EMS) button. 2. Rotate the green Rotary Key Switch counterclockwise to the OFF position. 3. Remove the key and store it in a secure place. 4. If the transmitter will not be used for two weeks or longer, then remove the batteries and store them in a cool, dry place. Chapter 4 Page 13 of 87 Intercontinental Technologies, Ltd. 4.2 Special Functions of Handheld Models 4.2.1 Entering a Password (Optional) The F22 Series Handheld models provide the ability to require a four-character password before use. This feature helps prevent unauthorized or inadvertent use of industrial equipment. This feature must be enabled, and the password set, at the factory. If this option has been enabled, then the operator will be required to enter a four-character password before operating the transmitter. To enter a password, follow the steps below during normal power-

on (Note: Do not follow the steps listed in Section 4.1.2):

1. Rotate the red EMS Button clockwise 45 and pull out. 2. Turn the green Rotary Key Switch clockwise to the ON position (Note: Do not turn the switch all the way to START). 3. While the LED is flashing green, press the pushbuttons sequentially to enter the four-character password (Note: There is a 10-second time limit). 4. If the password was entered correctly, then the buzzer will sound one long tone. 5. After the buzzer stops, turn the Rotary Key Switch to the START position and release. It will spring back to the ON position. The transmitter is now ready for normal use. 6. If the password was entered incorrectly, then the buzzer will sound two short and one long tone. 7. After the buzzer stops, re-enter the correct password. Table 4-2-1. Signals for Correct / Incorrect Password Correct Password Incorrect Password Transmitter Sounds 1 Long Tone, LED Lights Green Transmitter Sounds 2 Short and 1 Long Tone. Try again. Note: The password must be re-entered to return to normal operation if either:

1. The EMS Button is pressed; OR 2. An emergency stop signal is sent to the receiver due to a (factory-settable) period of inactivity

(see Sections 10.4 and 10.5 for a description of the Auto-Shutdown feature). 4.2.2 Ratcheting Operation Ratcheting is the ability to increase or decrease speed in discrete steps. This function is available on handheld models F22-10D1, F22-12D, F22-6D and F22-6D1. The ratchet up button is 5 on F22-10D1 and F22-12D, and South on F22-6D and F22-6D1. The ratchet down button is 6 on F22-10D1 and F22-12D, and North on F22-6D and F22-6D1. To use ratcheting:

1. Press and hold the button controlling the desired motion, then press the ratchet up pushbutton to incrementally increase the speed of the equipment, or the ratchet down pushbutton to incrementally decrease the speed of the equipment. 2. When a motion button is fully depressed, one touch of the ratchet up button will move to the next highest speed. Repeated touches will increase the speed up to four more times (six total speeds, including the initial 2-step button press). Page 14 of 87 Chapter 4 Intercontinental Technologies, Ltd. 3. To reduce the speed, press the ratchet down button once. Repeated pressing will reduce the speed to the lowest speed of the ratcheting feature. To get to the lowest speed, lift the motion button from the second step to the first step. Note: When accelerating or decelerating with the ratchet function, the motion button must be fully depressed. If the motion button is fully released, then the speed will return to zero. If a two-step motion button is partially released, then the speed will return to the lowest setting. Table 4-2-2 Pushbuttons for Ratcheting Any Motion Button/Second Speed + Pushbutton 5 or South Any Motion Button/Second Speed + Pushbutton 6 or North Increase Speed Decrease Speed 4.2.3 Inching Operation Inching is the ability to move a load in small increments so that it can be more precisely controlled, without requiring the user to press and release buttons very rapidly. This function is available on all handheld models with pushbutton 5. To use the inching function:

1. Ensure that all pushbuttons are released and that the equipment is motionless. 2. Press and hold the 5 pushbutton. 3. Press the applicable motion pushbutton to move the load a small distance in that direction. 4.3 Special Functions of Joystick Models The Model F22-J Joystick Type Remote Controller offers broad flexibility on a variety of applications through user-specific, customizable functions that are pre-programmed at the factory. The system includes a transmitter and a spare transmitter, each with two joysticks, six pushbuttons, and four rotary dials. The F22-J controller transmitter offers the most flexibility for a wide range of applications. 4.3.1 Buttons on the Joystick Controller The Joystick controller includes pushbuttons similar to those on the F22 Series Handheld units. The pushbuttons can control motion or auxiliary functions and are custom-programmed at the factory for your specific application. See Chapter 10 for detailed descriptions of the functions that are available, and Section 10.2 for a discussion of button types. 4.3.2 Joystick Operation: Direction of Movement The F22-J includes two joysticks, each of which can control four primary directions of motion. The directions of motion can be combined so that, for example, a bridge/trolley combination can move North and East simultaneously. The functions for axial movements of Joystick 1 and Joystick 2 are preset at the factory based on your application. A typical setting might be:

Chapter 4 Page 15 of 87 Intercontinental Technologies, Ltd. Joystick 1

(Controls Bridge and Trolley) Motion Direction Forward Bridge moves North Bridge moves South Back Trolley moves West Left Right Trolley moves East Joystick 2

(Controls Hoists) Motion Direction Forward Hoist moves UP Back Left Right Hoist moves DOWN Aux Hoist moves DOWN Aux Hoist moves UP 4.3.3 Joystick Operation: Speed Settings In each of the four directions of motion, the joysticks can have up to five detent positions. For example, there could be five detents in the forward direction, each of which could be associated to a speed setting. A smaller number of detent positions can also be specified and set at the factory. The time elapsed between a change from one speed to the next can be customized for your particular application. 4.3.4 Joystick Operation: Rotary Switch Operation The F22-J joystick type transmitter is supplied with four rotary switches labeled A, B, C, and D. Rotary switches A and D are simple ON/OFF switches designed to control items like magnets and lights. The B and C switches are three-position switches normally used to switch between different systems. For example, rotary switch B could control Hoist 1, Hoist 2, or both Hoist 1 and Hoist 2 simultaneously. The table below summarizes the available switches and switch positions:

Switch A Switch B*

Switch C*

Switch D On Available Positions Off

*Three-position switch

(A+B) or Neither

(A+B) or Neither A B On Off A B Note that the names of Switches A and B are not related in any way to the names of Positions A and B. Page 16 of 87 Chapter 4 Chapter 5 User Maintenance Intercontinental Technologies, Ltd. height. 5.1 Safety Aspects of User Maintenance In general, maintenance on this product should only be performed by your installer, distributor, or ITL. Ensure that anyone performing maintenance on the unit is thoroughly familiar with its operation. The cranes power sources should be shut off before any maintenance begins, unless absolutely required for troubleshooting the unit. When the power to the crane is on, use extreme caution. High voltage or unexpected movement of the crane can cause death or severe injury. Fall prevention devices should be used when anyone is working on the crane at an elevated Only ITL-certified maintenance personnel should attempt a repair more involved than the swapping of printed circuit boards. Improper repair can compromise the built-in safety features and can cause unexpected operation and damage. This product uses four AA alkaline batteries. When replacing batteries, all four must be replaced at the same time. ITL does not recommend use of nickel-cadmium batteries due to voltage characteristics that cause a sudden loss of power when discharged. They also have less capacity than AA alkaline batteries. 5.2 Unusual Alarms The F22 Series Industrial Radio Remote Controller is equipped with a self-diagnostic program. If a malfunction is detected during the operation of the equipment, the system will sound an alarm on the receiver to indicate a receiver malfunction, or a buzzer on the transmitter to indicate a transmitter malfunction. If this occurs, review Chapter 6 of the Operators Manual, Basic Troubleshooting. 5.3 Battery Changing Procedure (Handheld Models) 1. Unscrew the cover of the battery compartment. 2. Remove and discard the old batteries. 3. Install 4 new AA alkaline batteries into the battery compartment, noting the polarity markings. 4. Replace the cover of the battery compartment. 5. Confirm proper installation: If the batteries were installed correctly, the transmitter will beep twice. If the transmitter does not beep twice, check battery polarity. 5.4 Battery Changing Procedure (Joystick Models) 1. Unscrew and open the hinged battery cover. 2. Remove the battery caddy and discard the old batteries. 3. Install 4 new AA alkaline batteries into the battery caddy noting the polarity markings. 4. Replace the battery caddy and close the hinged battery cover. 5. Confirm proper installation: If the batteries were installed correctly, the transmitter will beep twice. If the transmitter does not beep twice, check battery polarity. Chapter 5 Page 17 of 87 Intercontinental Technologies, Ltd. THIS PAGE INTENTIONALLY LEFT BLANK Page 18 of 87 Chapter 5 Chapter 6 Basic Troubleshooting Intercontinental Technologies, Ltd. 6.1 Reliability The F22 Series of remote controllers are designed for high reliability in an industrial environment. Design features include:

Heavy duty, shock-resistant design Constructed from corrosion-resistant materials Button life in excess of 2,000,000 cycles Self-diagnostics to simplify troubleshooting and maintenance In addition to these features, all handheld and joystick models are delivered with two complete transmitters. This provides the ultimate in reliability; in the event that one transmitter is damaged, you can switch to the backup transmitter. 6.2 Self-Diagnostics and Error Codes Both the transmitter and receiver of the F22 Series are designed with sophisticated self-diagnostics to simplify troubleshooting and maintenance. This allows for detection of malfunctions in the pushbuttons, joystick, RF circuit, and relay driver circuits. The system will sound an alarm signal in Morse Code if a malfunction occurs in either the transmitter or receiver (see Chapter 11 for a table of error codes). If an error message is detected by the self-diagnostic program, then the appropriate alarm signal will sound and a Power-Off of the system will be initiated. Until the malfunction is corrected, the system will remain shut down (see Section 7.1 for more information). 6.3 User Troubleshooting In the event that a problem occurs, follow the listed steps in order until the unit is functioning normally. If you are unable to solve the problem, then return the unit to your distributor for service. 1. Check the EMS switch. If it is depressed, reset it by rotating clockwise until it pops up. 2. Check the green Rotary Start Switch. If it is missing, replace it. If it is present, turn it to OFF. Then turn it clockwise past ON to the START position, then release. The switch will spring back to the ON position and a tone should sound. 3. Ensure that the batteries are present and charged (see Section 4.1.3) and replace if necessary. 4. Turn off the transmitter and try using the backup transmitter. (Note: Before using the backup transmitter, check its battery power (see Section 4.1.3) and replace batteries if necessary). If use of the backup transmitter solves the problem, return the malfunctioning transmitter to your distributor for service. If the backup transmitter does not work, then the problem may be with the receiver. If the transmitter is damaged or malfunctioning, then return it to your distributor for service and use the backup transmitter in the meantime. Chapter 6 Page 19 of 87 Intercontinental Technologies, Ltd. If the receiver appears to be damaged or malfunctioning, then ensure that the green carrier light illuminates when a button on a working transmitter is pressed. This light is one of the LEDs on the front cover of the receiver. If the carrier light does not illuminate, contact your distributor. Both the transmitter and receiver are equipped with self-diagnostics. If either one detects a malfunction, it will sound an error message in Morse code. If this occurs, record the error message

(a series of long and short tones) and inform your distributor. Page 20 of 87 Chapter 6 Intercontinental Technologies, Ltd. Part 2: Technicians Manual Chapter 7 Safe Installation In case of emergency, perform these steps IN ORDER:

Emergency Procedure 1. Press the Red STOP Button. 2. Turn the Green Rotary Key Switch to the OFF position and remove the key from the transmitter. 3. Switch off the main power to the crane. 4. Contact your distributor or installer. NOTE: Read ALL safety information before you install or operate this product. 7.1 Emergency Procedures If the F22 unit detects an error or system fault, it will issue an emergency STOP command and deactivate all systems programmed for a STOP command. It is therefore important to install the F22 system correctly so that if it detects a fault, it can perform an emergency stop and the crane will shut down safely. 7.2 General Safety Information In an industrial environment, safety must always be a top priority. Persons responsible for installation, operation, and maintenance must make certain that both their actions and the equipment on which they work are safe. This chapter includes a list of safety rules that must be followed when working with TELECRANE products, as well as cranes in general. This list is not intended to be all-

inclusive. General industrial safety rules must always be followed. If there is any doubt about how to proceed, always take the safest course of action. 7.3 Before installing or operating this product, read this manual thoroughly. If you have any Installation Safety questions, please contact ITL. Only qualified personnel who are familiar with the product and who have read these safety instructions should install TELECRANE products. All sources of power to the crane or controlled equipment must be de-energized and applicable lockout/tag out procedures executed before installing the unit. Before installing the receiver, energize it in a controlled environment (for example, an office) where it can be tested and set up properly before it is mounted in the field. Chapter 7 Page 21 of 87 Intercontinental Technologies, Ltd. Before installation, be certain to understand the electrical functioning of the crane, including the order and relationship of motions and contactors. Fall prevention devices should be used when anyone is working on the crane. The receiver must be securely attached and located where it will not be hit by any moving part of the building, crane, or load. The crane must be equipped with limit switches for each motion and a main power contactor that cuts off all power to the motors of the crane when it is de-energized. Special care must be taken for magnets and other load-carrying devices; ensure that if the crane is de-energized the load remains supported. The receiver must be located so that it receives sufficient signal strength from the transmitter. The preferred location is in sight of the operator. However, if this is not possible (e.g., if the receiver unit is in a metal box), then an external antenna should be mounted such that it is in sight of the operator. Test the unit before placing it in service. If the crane does not work exactly as intended, fix the problem and test it again. Page 22 of 87 Chapter 7 Chapter 8 Installation Intercontinental Technologies, Ltd. 8.1 Transmitter Installation No special installation is required for F22 Series Industrial Radio Remote Controller transmitters. However, before the unit can be operated, check the battery power (see Section 4.1.3). If fresh batteries are required, install them as described below:

8.1.1 Battery Installation (Handheld Models Only) 1. Unscrew the cover of the battery compartment. 2. If present, remove and discard the old batteries. 3. Install 4 new AA alkaline batteries into the battery compartment, noting the polarity markings. 4. Replace the cover of the battery compartment. 5. Confirm proper installation: If the batteries were installed correctly, the transmitter will beep twice. If the transmitter does not beep twice, check battery polarity. 8.1.2 Battery Installation (Joystick Models Only) 1. Unscrew and open the hinged battery cover. 2. If present, remove the battery caddy and discard the old batteries. 3. Install 4 new AA alkaline batteries into the battery caddy noting the polarity markings. 4. Replace the battery caddy and close the hinged battery cover. 5. Confirm proper installation: If the batteries were installed correctly, the transmitter will beep twice. If the transmitter does not beep twice, check battery polarity. 8.2 Receiver Installation Precautions During Receiver Installation 1. Observe all safety precautions and use fall protection devices when climbing the crane. electrical shock. 2. Turn off the main power source to the crane before installation to prevent 3. Securely fasten the receiver to the crane and ensure that it is located such that it does not touch any part of the building during operation. 4. Inspect the cranes limit switches and other applicable safety devices before installation to ensure that they are in proper working condition. 5. Understand the crane power and control circuits and the function settings of the remote controller before installation. 6. Locate the receiver away from motors, frequency converters, and power cables to avoid radio interference. 7. Use an extended antenna if the receiver is installed in a metal enclosure. 8.2.1 Preparing for Receiver Installation 1. Select a proper location. Select a stable place. Chapter 8 Page 23 of 87 Intercontinental Technologies, Ltd. If possible, select a place where you can see the receiver or antenna during operation. Select a place away from motors, relays, high-voltage wiring, magnetic switches, and power cables. The receiver must be at least 3 cm away from any obstacles. 2. Determine the available power source. The standard input voltage for the handhelds receiver is 120 VAC, 60 Hz (240 VAC and 12 or 24 V, AC or DC, are also available). The joysticks receiver auto-detects the power source and can accept either 120 VAC, 60 Hz or 240 VAC, 60 Hz, with no action required by the installer. 8.2.2 Mounting and Connecting the Receiver To mount and connect the receiver, perform the following steps:

1. Turn off the main power of the crane. 2. Drill the holes for the mounting screws, install the receiver, and then mount the receiver using 6mm nuts on the vibration-resistant rubber stand-offs. Refer to the Technical Sheet for the receiver for the size and location of the mounting holes. 3. Connect the wires from the cable to the control circuit of the crane. Refer to the Technical Sheets in Chapter 14 for a schematic diagram of the receiver (or see the schematic on the front of the receiver itself). Note that the numbers in parentheses on the schematic correspond to the wire number in the cable. 4. Secure the cables to avoid wear due to the vibration of the crane or other factors. 5. Twist and pull out the red Stop button on the receiver. 8.2.3 Receiver Installation Test Plan The Run/Test toggle switch inside the receiver is provided to enable testing of the unit before it is placed in service. When the switch is in the RUN position, the unit functions normally. When the switch is in the TEST position, relay power is interrupted; the LEDs will light but the relays will not actuate. To test the unit:

1. Open the top cover of the receiver and set the Run/Test switch to the TEST position (see Section 2. Turn on the main power for crane. 3. Using the transmitter, test each button and function; the relays will not actuate but the LEDs will 4. After testing, set the Run/Test switch to the RUN position and replace the top cover of the 12.2.5). illuminate. receiver. Installation of Optional Accessories 8.3 For installation of any optional accessories such as the Extended Antenna Kit, refer to the accessorys Technical Sheet in Chapter 14. Page 24 of 87 Chapter 8 Intercontinental Technologies, Ltd. Chapter 9 Programming By Computer 9.1 Overview The Telecrane F22 Series Radio Remote Controls use a Windows based application program to read, write, and change their programming. This programming is generally performed at the factory when a unit is ordered, and is selected by the customer from the options in Chapter 10 and communicated by means of the Programming Sheets in Chapter 14. In some specific cases, for example, when a large distributor wishes to stock a number of units, for which the programming requirements are not known when the units are ordered from ITL, this programming must be accomplished outside the factory. ITL can provide to such a distributor a laptop computer, preloaded with the application program and other required programs. Instructions for use of the computer and program are provided with the unit. Chapter 9 Page 25 of 87 Intercontinental Technologies, Ltd. THIS PAGE INTENTIONALLY LEFT BLANK Page 26 of 87 Chapter 9 Intercontinental Technologies, Ltd. Chapter 10 Function Settings Industrial Radio Remote Controllers are used in diverse operating environments and have a wide range of applications and uses. This creates a need for flexibility and control over the setting of the functions designed into these controllers. Default parameters are set at the factory, but many functions and parameters can be customized to provide particular operating functions. This Chapter provides a detailed list of the available functions of the F22 Series and the range of settings for each. The Technical Sheets in Chapter 14 also include a summary list of parameters and settings that can be customized to meet your specific needs. Please note that the F22 Series includes many customizable functions that are set at the factory and not usually changed. To avoid confusion, only those functions that are typically specified by the user are listed here. However, if you have a need for a function setting that is not listed, please contact ITL to determine if that function is available. 10.1 Description Many of the functions of the F22 Series are set at the factory to meet most users requirements, and, in most cases, no change is required. However, if you have a need that requires changes from the default setting, your unit can be specially programmed at the factory. The tables below list the transmitter and receiver functions, default settings, and custom settings available on the F22 Series Handheld and F22-J Joystick Model Industrial Radio Remote Controllers. Please contact ITL or your local distributor for more information regarding alternate function settings, or refer to the Technical Sheets in Chapter 14 of this Manual. 10.2 F22 Series Handheld Transmitter Function Settings The table below shows the functions available on the handheld F22 Series models, their available settings, and their default settings. Note: This table lists all functions for the F22 Handheld models depending on which buttons are available on each specific model number. Refer to the Technical Sheets in Chapter 14 for a list of functions available by model. Table 10.2: Handheld Transmitter Functions and Default Settings Function/Setting Enabled Enable Disabled Password 4 character Password password Normal, Enable or disable the Password Function Password to be entered by user before operation Control button Description /Notes Available Settings Default Setting UP Button Disabled N/A Normal, interlocked with button DOWN interlocked Normal, not interlocked Toggle (on/off) On (off is button DOWN) Chapter 10 Page 27 of 87 Intercontinental Technologies, Ltd. Function/Setting DOWN Button Control button Description /Notes EAST Button Control button WEST Button Control button SOUTH Button Control button NORTH Button Control button 1 Button Control button Default Setting Normal, interlocked with button UP Normal, interlocked with button WEST Normal, interlocked with button EAST Normal, interlocked with button NORTH Normal, interlocked with button SOUTH Normal, not interlocked Available Settings Normal, interlocked Normal, not interlocked Toggle (on/off) Off (on is button UP) Normal, interlocked Normal, not interlocked Toggle (on/off) On (off is button WEST) Normal, interlocked Normal, not interlocked Toggle (on/off) Off (on is button EAST) Normal, interlocked Normal, not interlocked Toggle (on/off) On (off is button NORTH) Normal, interlocked Normal, not interlocked Toggle (on/off) Off (on is button SOUTH) Normal, not interlocked Normal, interlocked with button 2 Toggle (on/off) On (off is button 2) Page 28 of 87 Chapter 10 Intercontinental Technologies, Ltd. Available Settings Normal, not interlocked Normal, interlocked with button 1 Toggle (on/off) Off (on is button 1) Normal, not interlocked Normal, interlocked with button 4 Toggle (on/off) On (off is button 4) Normal, not interlocked Normal, interlocked with button 3 Toggle (on/off) Off (on is button 3) Normal, not interlocked Toggle (on/off) Ratchet up Inching:

o 0.1 seconds o 0.2 seconds o 0.3 seconds o 0.4 seconds o 0.5 seconds Normal, not interlocked Toggle (on/off) Ratchet down Default Setting Normal, not interlocked Normal, not interlocked Normal, not interlocked Normal, not interlocked No inching Normal, not interlocked Function/Setting 2 Button Description /Notes Control button 3 Button Control button 4 Button Control button 5 Button Control button 6 Button Control button Chapter 10 Page 29 of 87 Intercontinental Technologies, Ltd. 10.3 F22 Series Joystick Transmitter Function Settings The table below shows the functions available on the F22-J (Joystick) model, the available settings, and the default settings. Table 10.3 Joystick Transmitter Functions and Default Settings Function/Setting 1 Button Description /Notes Available Settings Control button Default Setting Normal, interlocked with button 2 2 Button Control button 3 Button Control button 4 Button Control button 5 Button Control button Normal, not interlocked Normal, interlocked with button 2 Toggle (on/off) On (off is button 2) Specific, for dual motor systems Normal, not interlocked Normal, interlocked with button 1 Toggle (on/off) Off (on is button 1) Specific, for dual motor systems Normal, not interlocked Normal, interlocked with button 4 Toggle (on/off) On (off is button 4) Normal, not interlocked Normal, interlocked with button 3 Toggle (on/off) Off (on is button 3) Normal, not interlocked Normal, interlocked with button 6 Toggle (on/off) On (off is button 6) Normal, interlocked with button 1 Normal, interlocked with button 4 Normal, interlocked with button 3 Normal, interlocked with button 6 Page 30 of 87 Chapter 10 Function/Setting 6 Button Description /Notes Control button A Dial B Dial C Dial D Dial Joystick 1 Control Dial Control Dial Control Dial Control Dial 2-axis (X and Y) joystick controller Joystick 2 2-axis (X and Y) joystick controller Intercontinental Technologies, Ltd. Default Setting Normal, interlocked with button 5 On/off A, A+B, B A, A+B, B On/off 4 directions, 5 detents in each direction 4 directions, 5 detents in each direction Available Settings Normal, not interlocked Normal, interlocked with button 5 Toggle (on/off) Off (on is button 5) On/off A, A+B, B A, Off, B A, A+B, B A, Off, B On/off 4 directions, 5 or fewer detents* in each direction, interlocking Extensive custom programming available, see Technical Sheet in Chapter 14 4 directions, 5 or fewer detents* in each direction, interlocking Extensive custom programming available, see Technical Sheet in Chapter 14

*Refer to Chapter 14 for additional detent settings 10.4 F22 Handheld Series Receiver Function Settings The table below shows the functions available on the F22 Handheld Series receivers, their available settings, and their default settings. Note: This table lists all functions for the F22 Series receivers;

certain models may not have all listed functions. Chapter 10 Page 31 of 87 Intercontinental Technologies, Ltd. Available Settings Description /Notes Elapsed idle time before receiver automatically shuts itself down Table 10.4 Handheld Receiver Functions and Default Settings Function/Setting Never Auto-

10 minutes Shutdown Time 20 minutes 30 minutes 1 hour 2 hours 3 hours 4 hours 0 seconds 0.3 seconds 1 second 1.5 seconds 2 seconds 3 seconds 4 seconds Sound alarm Close R0 Time between actuation of relays when button is fully depressed Turning key to START after already started. Acceleration Delay Second Function of Start Position momentary Close R0 toggle Default Setting 1 hour 0 seconds Sound Alarm 10.5 F22-J Receiver Function Settings The table below shows the functions available on the F22-J (Joystick) Receiver, the available settings, and the default settings. Table 10.5 Joystick Receiver Functions and Default Settings Function/Setting Auto-

Shutdown Time Description /Notes Elapsed idle time before receiver is automatically shut down Available Settings 1 hour Default Setting Never 10 minutes 20 minutes 30 minutes 1 hour 2 hours 3 hours 4 hours Page 32 of 87 Chapter 10 Intercontinental Technologies, Ltd. Function/Setting Joystick 1 X-axis Acceleration Delay Joystick 1 Y-axis Acceleration Delay Joystick 2 X-axis Acceleration Delay Joystick 1 Y-axis Acceleration Delay Acceleration Delay for Buttons 1 to 6 Relays Description /Notes Time between actuation of relays when joystick is moved Time between actuation of relays when button is fully depressed Second Function of Start Position Turning key to START after already started Available Settings 0 seconds 0.3 seconds 0.5 seconds 0.8 seconds 1 second 1.3 seconds 1.6 seconds 1.8 seconds 2.1 seconds 2.4 seconds 2.6 seconds 2.9 second 3.1 seconds 3.4 seconds 3.7 seconds 3.9 seconds 0 seconds 0.3 seconds 0.5 seconds 0.8 seconds 1 second 2 seconds 2.1 seconds 2.4 seconds 2.6 seconds 2.9 seconds 3 seconds 3.1 seconds 3.4 seconds 3.7 seconds 3.9 seconds 5 seconds Sound alarm Close R0 momentary Close R0 toggle Default Setting 0.5 seconds 0 seconds Sound alarm Chapter 10 Page 33 of 87 Intercontinental Technologies, Ltd. THIS PAGE INTENTIONALLY LEFT BLANK Page 34 of 87 Chapter 10 Intercontinental Technologies, Ltd. Chapter 11 Alarm Codes This Chapter provides a listing of Alarm Codes to be used during diagnostics and repair activities. Please refer to Chapter 6 for troubleshooting information. 1. If the F22 detects an error, an alarm tone may sound. The alarm tones are given in Morse code, where . (dot) indicates a short alarm for a duration of 0.26 second and (dash) a long alarm for a duration of 0.78 second. The interval between each alarm tone is 0.26 second. 2. If the units self-diagnostics detect an error and sound the alarm tones, then the unit will be disabled and will not function until the malfunction is corrected. Maintenance technicians can use these error codes for troubleshooting, however the best solution is usually replacement of the defective module. Table 11.1: Alarm Codes for Transmitters Description Possible Correction Item 1 2 3 4 5 6 7 8 9 Error Message Alarm Code E R F

. - . - . Low Battery (warning) Batteries excessively low Pushbutton Malfunction

(shorted) X K Y 1 S C

- . - . Joystick 1 Forward and Backward Malfunction Joystick 1 Left and Right Malfunction Joystick 2 Forward and Backward Malfunction Joystick 2 Left and Right Malfunction RF Module Malfunction EEPROM in handheld transmitter is faulty. 10 D

- . 11 H

. EEPROM in the encoder does not have function settings set or the settings are incomplete (handheld only). EEPROM in joystick transmitter is faulty. Replace batteries. Replace batteries. 1. Release all pushbuttons and start key when inserting batteries. 2. Replace the encoder module Replace Joystick 1. Replace Joystick 1. Replace Joystick 2. Replace Joystick 2. 1. Ensure antenna is tight. 2. Replace RF module. 1. Replace the encoder module 2. Reprogram function settings

(see Chapter 9). Reprogram function settings

(see Chapter 9). 1. Replace the encoder module 2. Reprogram function settings

(see Chapter 9). Chapter 11 Page 35 of 87 Intercontinental Technologies, Ltd. Table 11.2: Alarm Codes for Receivers Description Possible Correction Replace the relay module. Item 1 2 3 4 5 6 7 8 9 10 C D E F G H I J 11 K 12 L 13 M 14 N 15 O 16 Q Error Message Alarm Code

- . A B

- . - . UP Relay Coil bad

(Hand-held) Joystick 2 Relay Coil bad U/D 2S Relay Coil bad

(Hand-held) DOWN Relay Coil bad

(Hand-held) EAST Relay Coil bad

(Hand-held) R1~R6 Relay Coil bad

(Joystick) E/W 2S Relay Coil bad

(Hand-held) Joystick 1 Relay Coil bad WEST Relay Coil bad

(Hand-held) SOUTH Relay Coil bad

(Hand-held) S/N Relay Coil bad

(Hand-held) NORTH Relay Coil bad

(Hand-held)

- - . - - - R1 Relay Coil bad

- - . - MAIN Relay Coil bad

(Hand-held) R1/R2 2S Relay Coil bad

(Hand-held) R2 Relay Coil bad

(Hand-held) R3 Relay Coil bad

(Hand-held) R3/R4 Relay Coil bad

(Hand-held) R4 Relay Coil bad

(Hand-held)

(Hand-held) Page 36 of 87 Chapter 11 Intercontinental Technologies, Ltd. Table 11.2: Alarm Codes for Receivers Description Possible Correction Item 17 R Error Message Alarm Code

. - . The voltage input exceeds tolerance. 1. Disconnect the cable from the receiver. 2. Turn off the main power to the crane and check the power-input voltage. 3.Check to see that the voltage select plug is at the correct position. (handhelds only) 4. Inspect and make sure the power is normal before resuming operation. 1. Ensure antenna is tight. 2. Replace the receiver/

decoder module. 1.Install a less sensitive antenna. 2.Change to a new frequency.

(Contact ITL or your dealer). 1. If the interference is not serious or is short term, start the Remote Controller when the interference is over. 2. If the interference is serious, change to a new frequency.

(Contact ITL or your dealer). Reprogram function settings

(see Chapter 9). 18 S

. RF Circuit malfunction 19 Y

Interference by the same model of Remote Controller 20 1

Interference by another radio signal on the same frequency 21 Z

- - . EEPROM in the receiver/decoder does not have function settings set or are incomplete. Chapter 11 Page 37 of 87 Intercontinental Technologies, Ltd. THIS PAGE INTENTIONALLY LEFT BLANK Page 38 of 87 Chapter 11 Intercontinental Technologies, Ltd. Chapter 12 Principles of Operation of Major Subcomponents This Chapter provides an overview of the major functions of the F22 Series, including a description of the transmitter, the receiver, and the major parts of each. 12.1 Transmitter The most important components of the transmitter are the Encoder/Button printed circuit board, the RF Module, and an EEPROM. 12.1.1 Encoder/Button PCB This module is the heart of the transmitter. It contains the pushbuttons, power control circuitry, micro-controller, and EEPROM (see Figure 8). The micro-

controller encodes the information from the pushbuttons, along with security code and error correction data, into a serial data stream. This data stream, after passing through an audio-

frequency-shift-keying circuit, is sent to the transmitter RF module. 12.1.2 Transmitter RF Module This module is a narrowband FM transmitter with a digitally synthesized frequency output using a phase locked loop circuit

(see Figure 9). 12.1.3 EEPROM This component, found on both the Encoder/Button PCB and Receiver/Decoder Module, contains all of the programming and security code information used by the micro-controller. It is a non-volatile memory device, meaning that it does not require constant supply of power to hold its contents. Figure 8: Encoder/Button PCB Figure 9:

Transmitter RF Module Chapter 12 Page 39 of 87 Intercontinental Technologies, Ltd. 12.2 Receiver The most important components of the receiver are the Receiver/Decoder Module, the Relay printed circuit board, the LED printed circuit board, the EEPROM, the Mainline Indicator printed circuit board, and the Run/Test Switch. 12.2.1 Receiver/Decoder Module This module combines a narrowband FM receiver, the frequency of which is digitally synthesized, with a decoder circuit, which converts the audio signal from the receiver to a serial data stream of relay commands. It contains a micro-controller, which examines the incoming signal and determines, by means of the security code and other information, whether it contains valid commands to change the state of the relays. It then issues these commands to the Relay PCB. 12.2.2 Relay PCB This module latches the serial relay command data and drives the output relays. It also contains the power supply for the rest of the receiver. 12.2.3 LED PCB This module displays the state of all of the receivers relays by means of green LEDs

(see Figure 10). Figure 10: LED Printed Circuit Board on Joystick Receiver Page 40 of 87 Chapter 12 Intercontinental Technologies, Ltd. 12.2.4 Mainline Indicator Lamp PCB This module indicates, by means of several bright red LEDs, when the mainline relay is activated and the unit is ready to operate. 12.2.5 Run/Test Switch This switch, part of the Relay PCB, interrupts the flow of power to the operating coils of the relays, thus rendering them inoperative. The LED PCB is unaffected by this switch, and can be used to test the equipment without movement of the crane. The switch functions in the same manner for both the handheld and joystick models (see Figures 11 and 12). Run/Test Switch Figure 11: Location of Run/Test Switch in Receiver for Handhelds Chapter 12 Page 41 of 87 Intercontinental Technologies, Ltd. Run/Test Switch Figure 12: Location of Run/Test Switch in Receiver for Joystick Page 42 of 87 Chapter 12 Chapter 13 Customer-Specific Information Intercontinental Technologies, Ltd. 13.1 Serial Numbers and Security Codes An F22 System typically includes one receiver and two transmitters, however, it is possible to include more components such as additional transmitters or receivers. Each component has a unique serial number, composed of two parts separated by a dash. The security code (system serial number) is the first part, and the component serial number is the second part. Serial numbers are used to track individual components for repair and warranty purposes. Security codes are used to track system-

wide parameters such as frequency and programming information. When you purchase a system, record the serial and system numbers below for later reference:

List of Serial Numbers Here 13.2 Function Settings The F22 Series of Industrial Radio Remote Controllers are customizable to meet the specific needs of each user. Chapter 10 of this Manual provides a detailed list of the available functions and settings, and the Technical Sheets in Chapter 14 provide a summary list. When you purchase a system, record the custom settings below for later reference:

List of Function Settings Here Chapter 13 Page 43 of 87 Intercontinental Technologies, Ltd. THIS PAGE INTENTIONALLY LEFT BLANK Page 44 of 87 Chapter 13 Intercontinental Technologies, Ltd. Chapter 14 Product Technical Sheets This Chapter contains tables of transmitters, receivers, accessories, and Technical Sheets for each system model. 14.1 F22 Series Systems The table below lists all F22 Systems by feature and application. Technical Sheets for each system are provided later in this Chapter. Table 14-1. Available Models by Feature and Applications System Model General Application Transmitter Buttons No. F22-2S F22-4S F22-6S Type Mini Mini Mini F22-12S F22-2S1 F22-4S1 F22-6S1 F22-10S1 F22-2D F22-4D F22-6D F22-12D F22-2D1 F22-4D1 F22-6D1 F22-10D1 F22-J Mini N1 N1 N1 N1 Mini Mini Mini Mini N1 N1 N1 N1 Joystick

(Belly-Box)

(includes 2 transmitters) Hoist or Winch, Single-Speed Monorail, Single-Speed 3-Motion Crane, Single-Speed 6-Motion Crane, Single-Speed or A, B, A+B type applications Hoist or Winch, Single-Speed Monorail, Single-Speed 3-Motion Crane, Single-Speed 5-Motion Crane, Single-Speed or A, B, A+B type applications Hoist, Two-Speed Monorail, Two-Speed 3-Motion Crane, Two-Speed Up/Down Up/Down, East/West Up/Down, East/West, North/South Up/Down, East/West, North/South, 1, 2, 3, 4, 5, 6 Up/Down Up/Down, East/West Up/Down, East/West, North/South Up/Down, East/West, North/South, 1, 2, 5, 6 Up/Down Up/Down, East/West Up/Down, East/West, North/South Up/Down Up/Down, East/West Up/Down, East/West, North/South Up/Down, East/West, North/South, 1, 2, 3, 4, 5, 6 6-Motion Crane, Two-Speed or A, B, A+B type applications Hoist, Two-Speed Monorail,Two-Speed 3-Motion Crane, Two-Speed Up/Down, East/West, North/South, 1, 2, 5, 6 2 independent joysticks, 4 dial switches, 6 pushbutton 5-Motion Crane, Two-Speed or A, B, A+B type applications Extensive applications, refer to Technical Sheets. switches Chapter 14 Page 45 of 87 Intercontinental Technologies, Ltd. 14.2 F22 Transmitter and Receiver Part Numbers The table below lists the correct transmitter and receiver part numbers for each system model number:

Table 14-2: Available F22 Transmitters and Receivers System Model No. F22-2S F22-2S1 F22-4S F22-4S1 F22-6S F22-6S1 F22-10S1 F22-12S F22-2D F22-2D1 F22-4D F22-4D1 F22-6D F22-6D1 F22-10D1 F22-12D F22-J Transmitter Part No. F22-2S-TX F22-2S1-TX F22-4S-TX F22-4S1-TX F22-6S-TX F22-6S1-TX F22-10S1-TX F22-12S-TX F22-2D-TX F22-2D1-TX F22-4D-TX F22-4D1-TX F22-6D-TX F22-6D1-TX F22-10D1-TX F22-12D-TX F22-J-TX Receiver Part No. F22-6S-RX F22-12S-RX F22-6D-RX F22-12D-RX F22-J-RX 14.3 F22 Series: Accessories The table below provides a summary of available optional accessories used to enhance the function and operation of the F22 Series. Table 14-3: Available Optional Accessories Model Application Feature Permits the unit to be used in 24 volt applications. This optional accessory allows the unit to be used with 24 volt input power, instead of the standard 110/220 volts. This optional accessory allows the standard antennas to be extended to a more suitable position to the operator. This can be used when the location for mounting the receiver could cause a problem with the signal coming from the transmitter, such as being mounted in a box on the crane 24 Volt Converter Extended Antenna Kit Page 46 of 87 This provides flexibility in where the Receiver can be installed within a work environment. See Section 14.4 for details. Chapter 14 Intercontinental Technologies, Ltd. 14.4 Extended Antenna Kit The table below lists the part numbers for Extended Antenna Kits based on system model numbers:

Table 14-4: Extended Antenna Kit Part Numbers Description Used on Models Extended Antenna Kit Part No. 24B0102 24B0103 24B0104 24B0105 24B0106 24B0110 24B0120 24B0100 24B0204 24B0220 24B0200 Extended antenna kit with 2 foot coax cable and Extended antenna kit with 3 foot coax cable and Extended antenna kit with 4 foot coax cable and Extended antenna kit with 5 foot coax cable and Extended antenna kit with 6 foot coax cable and Extended antenna kit with 10 foot coax cable and Extended antenna kit with 20 foot coax cable and Extended antenna kit with custom length of coax cable and antenna. Extended antenna kit with 4 foot coax cable and Extended antenna kit with 20 foot coax cable and Extended antenna kit with custom length of coax cable and antenna. antenna. antenna. antenna. antenna. antenna. antenna. antenna. antenna antenna. All Handheld models All Handheld models All Handheld models All Handheld models All Handheld models All Handheld models All Handheld models All Handheld models F22-J F22-J F22-J Chapter 14 Page 47 of 87