Telecrane F24-J Manual Section General Specifications 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 Warranty/FCC Approval Information Installation Instructions Operation Instructions Safety Preventive Maintenance Checklist Troubleshooting Transmitter Function Settings.. Receiver Function Settings Programming Options Product Options Receiver Wiring Diagram Program and Button Labeling Page 12 3 4 5 6 7 9 10 11 13 14 15 17 This manual Copyright 2006 Intercontinental Technologies, Ltd. 1 This Page Intentionally Left Blank 2 Technical specifications for: F24-J Receiver input voltage: 110 volts AC. Other Input voltages available 220 VAC, 12V AC/DC, 24 VAC/DC Temperature: -35 deg C to 75 deg C (-31 deg F to 167 deg F) Receiver relay ratings: The receiver relays are rated at 10 amps at 250 volts AC. All COM wires are fused at 10A. The total current drawn through the receiver relays (through the COM wire) must not exceed 10A. Receiver dimensions: W 14.25 x D 4.5 x L 11.0 Frequency generation: Crystal (plug-in) Transmitter and receiver housing material: 30% glass fiber-reinforced nylon-6 Transmitter joysticks: 2 joysticks operating a total of 4 axis motions. Full 360-degree range of motion. Rated for 10 million cycles. Transmitter dials: 2 On/Off dials and 2 A, B dials. Transmitter button life: Tested to 2,000,000 operations Transmitter weight and dimensions: 2.3lbs with batteries. W 4.25 x D 4.25 x L 8.5 Control range: 500+ feet Transmitter batteries: 4 AA alkaline batteries. Channel Frequency Channel Frequency Channel Frequency Channel Frequency 318.0575 318.3250 318.5925 318.8600 319.1275 319.3950 319.6625 319.9300 310.0325 310.3000 310.5675 310.8350 311.1025 311.3700 311.6375 311.9050 312.1725 312.4400 428.5350 428.8025 429.0700 429.3375 429.6050 429.8725 430.1400 430.4075 430.6750 430.9425 431.2100 11 12 13 14 15 16 17 18 19 20 123 124 125 126 127 128 129 130 131 132 133 312.7075 312.9750 313.2425 313.5100 313.7775 314.0450 314.3125 314.5800 314.8475 315.1150 431.4775 431.7450 432.0125 432.2800 432.5475 432.8150 433.0825 433.3500 433.6175 433.8850 434.1525 21 22 23 24 25 26 27 28 29 30 134 135 136 137 138 139 140 141 142 143 144 315.3825 315.6500 315.9175 316.1850 316.4525 316.7200 316.9875 317.2550 317.5225 317.7900 434.4200 434.6875 434.9550 435.2225 435.4900 435.7575 436.0250 436.2925 436.5600 436.8275 437.0950 Channel Frequency Channel Frequency Channel Frequency Channel Frequency 437.3625 437.6300 437.8975 438.1650 438.4325 145 146 147 148 149 1 2 3 4 5 6 7 8 9 10 112 113 114 115 116 117 118 119 120 121 122 31 32 33 34 35 36 37 38 3 1.0 Warranty:
Intercontinental Technologies, Ltd. (ITL) guarantees that this product meets its published specifications at the time of shipment. 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. For warranty service, the product must ultimately be returned to ITL. The buyer must pay shipping charges to the ITL service facility, and ITL will pay return ground shipping charges. Warranty service on F21 and F24 units shall be provided by ITL only and ITL will not be responsible for service or repair costs charged by third parties. 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, or housings. 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. FCC and Industry Canada Approval Information The following information applies to transmitters:
This device complies with part 15 of the FCC Rules. 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. This device complies with RSS-210 of Industry Canada. Ce dispositif est conforme aux normes CNR-210 dIndustrie Canada. 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:
Model F24-J 4 2.0 Installation Instructions:
1. The receiver should be mounted in a location that is convenient to the control box and is securely attached to the equipment. The receiver is mounted by drilling four (6mm) holes
(see diagram below). Mount the receiver using the supplied hardware. It is best to keep the receiver as far away as possible (approximately 6 feet) from variable frequency drives and the motors and cables attached to them to avoid interference. F24-J-RX Receiver Mounting Diagram 2. The receiver wires are numbered. The wires are identified on the label on the top of the receiver. 3. All the contacts in the receiver are dry relay contacts. This means that is there is no internal source of power to the contacts. You will need to connect the common lead for each output or set of outputs that you plan to use to the same power supply that it would be connected to in a corded pendant. For most cranes this wire is X1 (the 120 volt AC control transformer hot side). Some cranes have separate hoist/trolley and bridge transformers. In these cases, connect each transformers X1 to the function(s) it powers. There is no requirement that the common leads be connected to a 120 volt AC supply- these are dry relay contacts; whatever you put into the common wire, comes out each functions wire when that relay closes. The only restrictions are, do not exceed 10 amps or 250 volts AC. For DC applications call the factory at 1-800-382-3558. 5 4. Put 4 AA alkaline batteries into each transmitter. To insert the batteries in the F24-J-TX
(transmitter), unscrew and open the hinged battery cover on the bottom of the unit. Remove the battery pack. Insert the batteries as indicated on the label inside the battery pack noting polarity markings. Insert the battery pack into the bottom of the transmitter. Replace the cover and tighten the thumbscrew until the cover is fully seated against the transmitter body. 5. Test the system thoroughly before releasing it for use. 6. If the transmitter does not work check battery polarity. 3.0 Operation Instructions:
1. Battery Indicator:
The LED on the front of the transmitter indicates the condition of the batteries. It will flash green during operation if the battery power is sufficient, and will flash red if the battery power is low. If the LED is flashing red, or if the operation becomes erratic, or will only work from a short distance, replace all 4 batteries with new AA alkaline batteries using the procedure given in section 2.4. 2. Fuses There are seven fuses in the F24-J-RX. There is one fuse in the AC power line that operates the receiver (0.5A, 250V), and one in the internal 12 volt DC supply (1.5A, 250V). There are five fuses in the COM wires (10A, 250V). The fuses on the COM wires are for relay contact protection in the event of a short circuit in the equipment being controlled by the radio. To replace a fuse, push down the fuse cover and turn counter-clockwise turn with thumb and forefinger or a flat-blade screwdriver. Remove the fuse from the cover and insert a new one of the same rating. Insert the fuse and cover into the fuse holder, press down, and turn clockwise turn. For protection from fire hazard, damage, or injury, always replace a blown fuse with one of the same rating. 3. Start Procedures for the F24-J 1. If the red STOP knob is pushed in, turn it clockwise about 45 degrees to reset it and allow it to pop up. This knob must be in the up position in order to operate the transmitter. 2. Put the green key into its socket in the front of the transmitter. 3. Turn the green key clockwise to the ON position, and then press the green (START) pushbutton. This will engage the mainline contactor and prepare the radio for operation. 4. Use the joysticks and/or pushbuttons to control the equipment. 5. Press the red STOP knob or turn the green key to OFF to stop movement immediately and drop out the mainline contactor. 6 6. Turn the green key to OFF and remove it whenever the transmitter is not in use to prevent unintentional operation. 7. The receiver has an extra relay labeled R0. Pushing the green start button after the equipment has already been started will close this relay. This relay will not engage the first time the Start pushbutton is pressed when starting up the equipment. See section 8.0 for detailed information on this option. 4.0 Safety:
EMERGENCY PROCEDURE: In case of emergency, perform these steps IN ORDER. 1. Press the red STOP button. 2. Turn the green key to OFF position. 3. Switch off the main power to the equipment. 4. Contact qualified service personnel. This manual is intended for the user as a general reference only. Please consult your distributor for specific installation or assistance with 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. Following are a list of safety rules that must be followed when working with TELECRANE products, as well as cranes and industrial equipment 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.
- Only qualified personnel who are familiar with the product and who have read these safety instructions should install TELECRANE products.
- Before installing or operating this product, read this manual thoroughly. If you have any questions, please contact ITL.
- All sources of power to the crane or controlled equipment must be de-energized and locked out before installing the unit.
- Before installing the receiver, energize it in a controlled environment (such as an office) where it can be tested and set up properly before it is mounted in the field. If it does not work exactly as intended, fix the problem and test it again.
- Before installation, be certain to understand the electrical functioning of the crane or equipment, including the sequence and relationship of motions and contactors. 7
- Fall prevention devices should be used when anyone is working at an elevated height.
- 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 or hoist 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 to 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.
- Operating any piece of equipment in an industrial facility can be dangerous. Adequate training must be provided to operators of cranes or other equipment using a TELECRANE product.
- At least once each shift, check the amount of power remaining in the transmitter batteries. If it is low, change all four batteries before beginning operation. Operating the unit with excessively discharged batteries can be unsafe.
- The safety key should be removed from the transmitter whenever it is not in use and should only be issued to authorized personnel.
- All TELECRANE 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 power to the crane or equipment and remove the safety key from the transmitter.
- Remove the batteries from the transmitter if the transmitter will not be used for two weeks or longer.
- Transmitters that are not in use, including spare transmitters, should be stored with batteries removed, and secured to prevent accidental operation.
- Before each shift, check that the limit switches function correctly and that movement corresponds to the button being pressed or joystick being operated on the transmitter.
- Do not use the equipment during lightning storms or high electrical interference
conditions. In general only authorized service facilities should perform maintenance on this product. 8
- Ensure that anyone performing maintenance on the unit is thoroughly familiar with its operation.
- Power should be shut off to the crane or equipment before any maintenance begins, unless absolutely required for troubleshooting the unit. When the power is on, use extreme caution. High voltage or unexpected movement could cause death or severe injury.
- Only 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 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 or nickel-metal-hydride batteries due to voltage characteristics that cause a sudden loss of power when discharged. They also have less capacity than alkaline batteries and therefore will not last as long. 5.0 Preventive Maintenance Checklist 1. Inspection A. Look for damage such as, cracks, holes, missing parts, etc. 1. External parts includes:
a. Guard bar b. Joystick boots- stretch them slightly to find any holes c. Case- twist and flex slightly 2. Internal problems a. Cleanliness- any dust indicates a hole somewhere. Inspect external parts b. Ensure that wires are routed away from moving parts of joysticks. c. Excessive backlash in joystick mechanism- may indicate wear or loosened parts in mechanism. Examination by factory is required. d. Grinding sounds from joystick mechanism- indicate prior dust or grit intrusion. Examination and repair by factory is required. 9 2. Cleaning A. External 1. Case- general 2. Emergency stop knob. 3. Start key and socket. Remove key and blow out socket with low-pressure compressed air. 4. Around dials and buttons. B. Internal 1. Battery compartment and holder. 2. The inside of the unit should not require cleaning if covers, gaskets, and joystick boots are intact. Low-pressure compressed air may be used sparingly if desired. 3. Test the unit thoroughly A. Verify all functions are operating correctly. 1. A thorough, discriminating test of all transmitter functions will disclose most problems before they can cause trouble. Use the TEST/RUN switch in the receiver to prevent crane movement. Set this switch to TEST position. Match functions with corresponding LED on receiver. 6.0 Troubleshooting Common Mistakes In Installation:
Receiver dead: Is 120 volt AC applied between X1 and X2 wires? These are wires 1 and 2. You must provide both the hot and the neutral sides of the control transformer secondary to power the unit. Relays close but there is no movement from the crane: Are the COMMON wires hooked up properly? The receivers have dry contacts. Even though X1 and X2 have been applied to power the receiver, you still need to apply power to the common side of the relay contacts in order to get power to your contactors. These are the COM wires for each of the outputs on the receiver. Each COM wire is completely isolated from the others as well as the power wires. In most cranes, the COM wires will be connected to the X1 supply. If the transmitter does not work: Check that all four batteries have sufficient power and verify correct battery polarity as shown on the battery pack. If you have any problems or questions not covered above, please call ITL at 1-800-382-3558. 10 7.0 Transmitter Function Settings Description
/Notes Control button Function/
Setting Second Function of the Start Button F1 Button Control button 1 Button Control button 2 Button Control button 3 Button Control button 4 Button Control button Available Settings Normal control of R0 Toggle (on/off) control of R0 Inching (in seconds) o 0.05 o 0.1 o 0.2 o 0.3 o 0.4 o 0.5 o 0.6 o 0.8 Normal Toggle (on/off) Normal, not interlocked Normal, interlocked with button 2 Toggle (on/off) On (off is button 2) 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) Default Settings Normal control of R0 Normal Normal, interlocked with button 2 Normal, interlocked with button 1 Normal, interlocked with button 4 Normal, interlocked with button 3 11 7.0 Transmitter Function Settings Cont. A Dial B Dial Control dial Control dial C Dial Control dial Control dial D Dial Joystick 1 2-axis (X and Y) joystick controller Joystick 2 2-axis (X and Y) joystick controller 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. Extensive custom programming available, see Technical Sheet in Section 11. 4 directions, 5 or fewer detents* in each direction. Extensive custom programming available, see Technical Sheet in Section 11. 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
* Refer to Section 11 for additional detent settings 8.0 Receiver Function Settings Function/Setting Auto-Shutdown Time Description Notes Elapsed idle time before receiver is automatically shut down Time between actuation of relays when joystick is moved Joystick 1 X-Axis Acceleration Delay Joystick 1 Y-Axis Acceleration Delay Joystick 2 X-Axis Acceleration Delay Joystick 2 Y-Axis Acceleration Delay Available Settings Default Settings 1 hour 0.5 seconds Never 10 minutes 20 minutes 30 minutes 1 hour 2 hours 3 hours 4 hours 0 seconds 0.3 seconds 0.5 seconds 1.0 seconds 1.5 seconds 2.0 seconds 3.0 seconds 4.0 seconds 12 9.0 Programming options:
- Auto-shut-down time. An auto-shut-down feature is available. If the radio has not been used for a period of time the receiver automatically drops out the main line contactor. The default setting is 1 hour. Auto-shut-down times can be set between 0 and 4 hours. Typical selections are available on the programming data sheets in the back of this manual.
- Pushbutton options. Each pushbutton is set by default to momentary (relay closes when a button is pressed and opens when released), and interlocked in opposed motion pairs
(UP-DOWN, EAST-WEST, SOUTH-NORTH). When set as momentary, they can be set as un-interlocked. They can also be set as toggle (press once to close relay, press again to open) or as On-Off pairs (press On to close relay, press Off to open relay). When programmed as toggle or On-Off, they will be set as controlled by Stop (opening automatically when the STOP button is pressed). They can be reprogrammed by the factory for uncontrolled by Stop (unaffected by STOP button); please call for more information.
- Acceleration delay. Delay between actuation of relays for each of the detents of the joysticks can be programmed. This delay time can be set between 0 and 4 seconds;
default is 0 seconds. Typical selections are available on the programming data sheet.
- R0 function. The R0 relay operates only when the START button is pushed after the unit has already been started. It is by default set to momentary (closed when START button is pressed, open when released). It can also be set to toggle (push the START button once to close, then push the button again to open), or inching (does not activate the R0 relay, but instead only allows pushbuttons pressed, after pushing the START button, to remain on for a preset length of time, no matter how long the button is held). For inching, the inch time may be set to a minimum of 0.05 seconds or anywhere from 0.1 to 0.8 seconds in 0.1-second increments. Typical selections are available on the programming data sheet. Call Factory for more information 1-800-382-3558. 13 10.0 Product Options
- Below are the legend sets that are available to change the button labels of the F24 series transmitters. Part # 22A3001 Part # 22A3003
- An antenna kit is available for the joystick models effectively extending the range to 1500+ feet (line of sight). Call factory for details. 1-800-382-3558
- Cables are available as well for mounting the stock antenna outside an enclosure. Call Factory for details. 1-800-382-3558 14 11.0 F24-J Wiring Diagram (Standard) 15 This Page Intentionally Left Blank 16 12.0 Programming and button labeling Custom labels for F24-J The words in bold appear on the joystick motion if you do not fill in the squares below. WEST EAST aux DOWN aux UP NORTH SOUTH UP DOWN Restrict maximum speed position of any motion Ciircle the last detent that the that motion can achieve. Default detent is all the way through to the 5th step. 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 If you wish to eliminate all the detents from any of the 4 motions write NONE above the motions arrow instead of circling a number. 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 Customize travel path of joystick To customize where the joystick can travel circle one of the drawings below for each joystick or fill in the blank circle with the path desired. The fully black circle represents the default setting of complete 360 degree range of motion. 17 This Page Intentionally Left Blank 18 Button and Dials Programming Sheet: F24-J Auto Shut Down time Default setting of 1 hour 1 hour 2 hours 3 hours 4 hours 20 minutes 30 minutes never F1 Start 1 3 2 4 The A & B associated with dial B pertain to only dial B. The A & B associated with dial C pertain to only dial C. Normal Toggle (on/off) Controlled by stop Not controlled by stop Inching 0.05 0.1 0.2 0.3 0.4 0.5 0.6 0.8 normal, interlocked with button 1 Normal, not interlocked Toggle (on/off) Off (on is button 1) Controlled by stop Not controlled by stop normal, interlocked with button 3 Normal, not interlocked Toggle (on/off) Off (on is button 3) Controlled by stop Not controlled by stop Normal Toggle (on/off) Controlled by stop Not controlled by stop normal, interlocked with button 2 Normal, not interlocked Toggle (on/off) On (off is button 2) Controlled by stop Not controlled by stop normal, interlocked with button 4 Normal, not interlocked Toggle (on/off) On (off is button 4) Controlled by stop Not controlled by stop A B C D On / Off Controlled by stop Not controlled by stop A, A+B, B A, OFF, B Controlled by stop Not controlled by stop A, A+B, B A, OFF, B Controlled by stop Not controlled by stop On / Off Controlled by stop Not controlled by stop 19 This Page Intentionally Left Blank 20 Custom relay configuration sheet for model:
Standard Configurations Custom Configurations F24-J WEST WEST EAST 5 4 3 2 1 0 1 2 3 4 5 1X1 X X X X X 1X2 1X3 X X X X 1X4 X X X 1X5 X X 1X6 X Acceleration delay in seconds: 0.0, 0.3, 0.5 , 1.0, 1.5, 2.0, 3.0, 4.0, X X X X X X X X X X X X X X X 1X1 1X2 1X3 1X4 1X5 1X6 5 4 3 2 1 0 1 2 3 4 5 EAST NORTH SOUTH NORTH 5 4 3 2 1 0 1 2 3 4 5 1Y1 X X X X X 1Y2 1Y3 X X X X 1Y4 X X X 1Y5 X X 1Y6 X Acceleration delay in seconds: 0.0, 0.3, 0.5 , 1.0, 1.5, 2.0, 3.0, 4.0, X X X X X X X X X X X X X X X 1Y1 1Y2 1Y3 1Y4 1Y5 1Y6 5 4 3 2 1 0 1 2 3 4 5 SOUTH UP 5 4 3 2 1 0 1 2 3 4 5 AUX DOWN AUX UP AUX DOWN AUX UP 2X1 2X2 2X3 2X4 2X5 2X6 DOWN 5 4 3 2 1 0 1 2 3 4 5 X X X X X X X X X X X X X X X 5 4 3 2 1 0 1 2 3 4 5 2X1 X X X X X 2X2 2X3 X X X X 2X4 X X X 2X5 X X 2X6 X Acceleration delay in seconds: 0.0, 0.3, 0.5 , 1.0, 1.5, 2.0, 3.0, 4.0, 2Y1 X X X X X 2Y2 2Y3 X X X X 2Y4 X X X 2Y5 X X 2Y6 X Acceleration delay in seconds: 0.0, 0.3, 0.5 , 1.0, 1.5, 2.0, 3.0, 4.0, Notes:
*The default relay configuration chart is on the left side. If you want the relays to close in different combinations than the default settings then mark the appropriate chart to the right with Xs in the appropriate squares. 5 4 3 2 1 0 1 2 3 4 5 X X X X X X X X X X X X X X X 2Y1 2Y2 2Y3 2Y4 2Y5 2Y6 DOWN UP This Page Intentionally Left Blank 22 Intercontinental Technologies Ltd. 558 Plate Drive Bldg. #2, East Dundee, IL 60118 Ph: 847-426-9597, Fax: 847-426-9724, TELECRANE.COM