Magnetek telePilot TX12M-1 Installation And User Manual
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Magnetek telePilot TX12M-1 Installation And User Manual

Magnetek telePilot TX12M-1 Installation And User Manual

Telemotive transmitter
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TELEMOTIVE
telePilot
TRANSMITTERS
TX12M-1, -2
telePilot Programming is
found on page 69.
TCTX12/TR12-0
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N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Phone: 800-288-8178 Fax: 262-783-3510
Website:
http://www.magnetek.com/
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Summary of Contents for Magnetek telePilot TX12M-1

  • Page 1 TELEMOTIVE telePilot TRANSMITTERS TX12M-1, -2 telePilot Programming is found on page 69. N49 W13650 Campbell Drive Menomonee Falls, WI 53051 Phone: 800-288-8178 Fax: 262-783-3510 Website: http://www.magnetek.com/ TCTX12/TR12-0 Rev. G...
  • Page 2 This page intentionally left blank.

  • Page 3: Table Of Contents

    Table of Contents Service Information .......................... 3 Radio Controlled Crane Safety ......................4 Warnings, Cautions and Notes ..................4 Critical Installation Considerations ................5 General ........................5 Persons Authorized To Operate Radio Controlled Cranes .......... 6 Training Checklist For Crane Operators ..............
  • Page 4 Table of Contents (Continued) Figure 6-3B. Optional Internal Transfer Switch System Wiring ........32 Table 1 TR12 Single-Speed Wiring Diagram. Standard Configuration Hoist, Trolley and Bridge......................... 33 Table 2(A) TR12 2-Speed Wiring Diagram. Standard Configuration Hoist, Trolley Bridge......................... 35 Table 2(B) TR12 2-Speed Wiring Diagram.

  • Page 5: Service Information

    Section 1 - Service Information 1-1. Service Information. ® Thank you for your purchase of the Magnetek’s Telemotive Brand telePilot transmitter. Magnetek has set a whole new standard in performance, dependability, and value with its unique new line of receivers. Without a doubt, our Telemotive telePilot transmitter is the ultimate solution for having...

  • Page 6: 2- Radio Controlled Crane Safety

    Section 2 – Radio Controlled Safety 2-1. Warnings, Cautions And Notes. Through out this document WARNING, CAUTION and NOTE statements have been deliberately placed to highlight items critical to the protection of personnel and equipment. WARNING – A warning highlights an essential operating or maintenance procedure, practice, etc. which if not strictly observed, could result in injury or death of personnel, or long term physical hazards.

  • Page 7: Critical Installation Considerations

    Section 2 – Radio Controlled Safety (Continued) 2-2. Critical Installation Considerations. WARNING ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES AND SIMILAR EQUIPMENT MUST HAVE A BRAKE INSTALLED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. WARNING ON ALL REMOTE CONTROLLED CRANES AN AUDIBLE AND/OR VISUAL WARNING MEANS MUST BE PROVIDED.

  • Page 8: Persons Authorized To Operate Radio Controlled Cranes

    Section 2 – Radio Controlled Safety (Continued) is operated in areas where people are working on the floor below. The crane operator must exercise extreme caution at all times. Workers must constantly be alert to avoid accidents. The following rules have been included to indicate how careful and thoughtful actions may prevent injuries, damage to equipment, or even save a life.

  • Page 9: Operating Area

    Section 2 – Radio Controlled Safety (Continued) The operator should know procedures for testing hoist, trolley, and bridge brakes. 2-6. Operating Area. Aisles between equipment, stock, etc., should be free of obstructions so the crane operator can move freely. These aisles should be a minimum of three feet (one meter) wide, or meet local regulations.
  • Page 10 Section 2 – Radio Controlled Safety (Continued) 2-8.2. General Rules For Operation. Consult the crane manufacturer, local and governmental regulations for complete rules of operation. In general the following rules apply to remotely controlled cranes: The limit switches should never be used as a regular stopping device. They are intended to be protective devices. Do not make lifts in excess of the equipment rated capacity.

  • Page 11: Boarding The Crane

    Section 2 – Radio Controlled Safety (Continued) Outdoor cranes, which are subject to movement by wind, should be securely anchored when left unattended. If the crane is equipped with bridge brakes, the parking brake should be set immediately. 2-9. Boarding The Crane. The crane should not be boarded without permission of the supervisor.

  • Page 12: Using The Crane As A Work Platform

    Section 2 – Radio Controlled Safety (Continued) If it is necessary to have the crane control circuits energized, all power circuits for crane movement must be opened prior to energizing the control circuits. All personnel and tools should be moved to a safe spot before moving the crane during repairs. Headroom is at a minimum in some crane cabs and on some crane walkways.

  • Page 13: Batteries

    Section 2 – Radio Controlled Safety (Continued) Walkways required handrails and ladders are in place, sturdy and not loose. Protective guards are in place for all moving parts. Alignment of bridge (screeching or squealing wheels indicate bridge is out of line). Broken, cracked, or chipped rails on trolley or runway.
  • Page 14 Section 2 – Radio Controlled Safety (Continued) 2-13.2. Battery Charging. For those transmitters equipped with battery chargers, please familiarize all users with the instructions of the charger before attempting to use. Use only Telemotive approved chargers for the appropriate battery pack. Do not attempt to charge non-rechargeable battery packs.

  • Page 15: General System Information

    Section 3 – General System Information 3-1. General System Information. The Telemotive Radio Control System (system) provides remote control of overhead cranes using radio signals. The system consists of a hand held portable battery operated transmitter unit and a fixed station receiver unit. A unique 16-bit code (Access Code) for each system is preset in every transmitter and receiver.

  • Page 16: Channel Designations

    Section 3 – General System Information (Continued) 3-3. Channel Designations: AK01 - 439.8 MHz AK06 - 438.8 MHz AK02 - 439.6 MHz AK07 - 438.6 MHz AK03 - 439.4 MHz AK08 - 438.4 MHz AK04 - 439.2 MHz AK09 - 438.2 MHz AK05 - 439.0 MHz AK10 - 438.0 MHz AK11 - 437.8 MHz...

  • Page 17: Installation Procedure

    Section 4 – Installation Procedure 4-1. Pre-Installation Considerations. To ensure reliable and safe operation of the system, the following items must be considered before installing the receiver unit. WARNING THE RECEIVER UNIT OR RELAYS ARE NOT RATED AS EXPLOSION PROOF. THE RECEIVER UNIT MUST NOT BE INSTALLED IN EXPLOSIVE ENVIRONMENTS UNLESS APPROPRIATE SECONDARY ENCLOSURE MEASURES ARE TAKEN.

  • Page 18: Wiring Considerations

    Section 4 – Installation Procedure (Continued) NOTE THE RECEIVER UNIT SHOULD NOT BE CONNECTED TO LINES CONTAINING EXCESSIVE POWER UP TRANSIENTS OR CONTINUOUS COMMUTATOR NOISE. A LINE CONDITIONER MAY BE NECESSARY IN SOME INSTALLATIONS. 4-5. Wiring Considerations. 1. Read this manual before installation. 2.

  • Page 19: Figure 4-1. Input Power Connections

    Section 4 – Installation Procedure (Continued) 2. Position the receiver. Locate as far as possible from exposed trolley wire and sources of electromagnetic or radiated noise. Cabinet mounting dimensions and mounting template is on next page (see Figure 4-2A and B. Receiver Mounting Details). Antenna at top of unit should be kept as clear as possible of any metal object.
  • Page 20 Section 4 – Installation Procedure (Continued) 16.02” 406.9 mm 14.02” 356.01 mm 7.09” 180 mm .210” DIA. 5.34 mm 11.81” .281” DIA. hole 4 places 7.14 mm 300 mm 12.02” hole 4 places 305.3 mm 7.87” 200 mm 11.02” 279.9 mm Receiver shown with MP10278-0 mounting brackets attached.
  • Page 21 Section 4 – Installation Procedure (Continued) .281” DIA. 7.14 mm hole, 4 places 16.02” 406.9 mm .210” DIA. 11.02” 5.34 mm 279.9 mm hole, 4 places Receiver shown with 14.02” MP10278-0 mounting 11.81” 356.01 mm brackets attached. 300 mm 7.87” 200 mm 7.09”...

  • Page 22: Operation

    AUX 4 EAST STOP A B B WEST E-STOP TX12M-2 TX12M-1 Optional Motor or Select Indicators Pendant and Membrane 2-Speed and Single-Speed telePilot Figure 5-1. telePilot, Pendant and Membrane 5-1. Transmitter Buttons. ON/OFF On the telePilot and Pendant Transmitter ON and OFF is the same button. Pushing this button toggles between turning the transmitter ON and then sending the ON command to the receiver and sending the OFF command to the receiver and then turning the transmitter OFF.
  • Page 23 Section 5 – Operation (Continued) Motor 2 Dir 1, (E Membrane)/NORTH Pendant– Selects the appropriate direction of the bridge or trolley (depending how unit is wired at installation) speed one (first switch position) or speed two (second switch position). Motor 2 Dir 2, (W Membrane)/SOUTH Pendant – Selects the appropriate direction of the bridge or trolley (depending how unit is wired at installation) speed one (first switch position) or speed two (second switch position).

  • Page 24: On/Off Led Indicator

    Section 5 – Operation (Continued) 5-2. ON/OFF LED Indicator. When the transmitter is ON the red LED flashes slowly. When the unit transmits, the red LED flashes rapidly. Top left indicator on telePilot. 5-3. Low Battery Indication. In the telePilot transmitter there is a separate low battery indicator located to the right of the ON/OFF indicator.

  • Page 25: Additional Telepilot Transmitter Operational Features

    Section 5 – Operation (Continued) WARNING WHEN OPERATING THE CRANE FOLLOW LOCAL AND GOVERNMENTAL RULES ON THE USE OF HORNS AND ALARMS. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. Make sure that all personnel are clear of the crane movement and no one is under the crane or load. Turn unit ON by pressing the ON/OFF (ON) button.
  • Page 26 Section 5 – Operation (Continued) telePilot Low Battery Shutoff Function. If the battery gets too low the unit will shut off and send an OFF command to the receiver as it turns OFF. telePilot Self-Test Function. If any function key is depressed when the unit turns on the unit will fault, not send a turn on command, and not become operational.
  • Page 27 Section 5 – Operation (Continued) It is not necessary to program all four Banks, if an un-programmed or turned “off” Bank is selected the ON/OFF indicator will remain ON continuously, the transmitter will send no commands and will turn itself off shortly. telePilot Bank Password Protection Function.

  • Page 28: Battery Replacement

    Section 5 – Operation (Continued) NOTE ALWAYS REMEMBER TO STORE THE PASSWORD IN A SECURE LOCATION FOR ACCESS IF THE PASSWORD IS LOST OR FORGOTTEN. ONCE THE TRANSMITTER IS PROGRAMMED THERE IS NO WAY TO DEFEAT THE PASSWORD WITHOUT USING A PDA TO EITHER READ THE PASSWORD OUT OR REPROGRAM A NEW ONE.
  • Page 29 Section 5 – Operation (Continued) battery packs) or replace the two “AA” cells (for a battery carrier) and replace the battery(s) with a new battery(s), noting the polarity for “AA” cells. (Best life can be obtained if the two “AA” batteries used are a good quality alkaline type, both cells of the same type and from the same manufacturer).

  • Page 30: Wiring

    Section 6 – Wiring 6-1. Wiring Diagrams. Your TELEPILOT system comes pre-programmed the following pages in this section have individual wiring diagrams for different crane configurations. Find the appropriate wiring diagram and if necessary set the Configuration Switch (SW3 in the transmitter) to match the SW3 Transmitter Switch Settings shown in the appropriate diagram.

  • Page 31: Alarm After E-Stop

    Section 8 – Servicing and Programming (Continued) 6-7. Alarm After E-STOP. This is only for wiring configurations where the Aux 3 (relay K12, output J5-6) is being used for the Alarm function, placing a jumper on JU1 on the Receiver Board will allow the alarm to function after an E-STOP command.

  • Page 32: Figure 6-2. External Transfer Switch Wiring

    Section 6 – Wiring (Continued) 10 Amp K13 MR Slo Blo Fuse Receiver Panel J6-1 J6-2 J6-3 J6-4 J6-5 J6-6 J6-7 J6-8 J7-1 J7-2 J7-3 This connector used for internal transfer switch Optional Transfer Switch RETURN (2-pole double- throw) MAIN LINE CONTACTOR Pendant START...
  • Page 33 Section 6 - Wiring (Continued)
  • Page 34 Section 6 - Wiring (Continued)

  • Page 35: Table 1 Tr12 Single-Speed Wiring Diagram. Standard Configuration Hoist, Trolley And Bridge

    Section 6 - Wiring (Continued) TABLE 1 TR12 SINGLE-SPEED WIRING DIAGRAM. STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE External jumper RETURN in J6 connector J6-2 J6-3 MASTER RELAY MAIN LINE CONTACTOR Single Speed Transmitter Modes J6-4 J6-5 Mode 1 Mode 2 Mode 3 J5-5 J5-6...
  • Page 36 Section 6 - Wiring (Continued) TABLE 1 TR12 SINGLE-SPEED PROGRAMMING DIAGRAM. STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-1 J3-1 J2-1 HOIST* TROLLEY* BRIDGE* MOTOR 1 MOTOR 2 MOTOR 3 INDEPENDENT OUTPUTS J2-2...

  • Page 37: Table 2(A) Tr12 2-Speed Wiring Diagram. Standard Configuration Hoist, Trolley And Bridge

    Section 6 - Wiring (Continued) TABLE 2(A) TR12 2-SPEED WIRING DIAGRAM. STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE External jumper in J6 connector RETURN J6-2 MASTER J6-3 RELAY MAIN LINE J6-4 J6-5 CONTACTOR J5-5 J5-6 AUX 3 ALARM* J5-4 J5-3 AUX 2 (latchable S4-3) J5-1 J5-2...
  • Page 38 Section 6 - Wiring (Continued) TABLE 2(A) TR12 2-SPEED PROGRAMMING DIAGRAM. STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 HOIST* TROLLEY* BRIDGE* MOTOR 1 MOTOR 2 MOTOR 3...

  • Page 39: Table 2(B) Tr12 2-Speed Wiring Diagram. 2-Speed With Directional Controls: All Motions

    Section 6 - Wiring (Continued) TABLE 2(B) TR12 2-SPEED WIRING DIAGRAM. 2-SPEED with DIRECTIONAL CONTROLS: ALL MOTIONS External jumper in J6 connector RETURN MASTER J6-2 J6-3 RELAY MAIN LINE J6-4 J6-5 CONTACTOR J5-6 J5-5 MOTOR 1 DIR1/DIR2 J5-4 J5-3 MOTOR 2 DIR1/DIR2 J5-2 J5-1...
  • Page 40 Section 6 - Wiring (Continued) TABLE 2(B) TR12 2-SPEED PROGRAMMING DIAGRAM. 2-SPEED with DIRECTIONAL CONTROLS: ALL MOTIONS Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 J5-6 J5-4 J5-2 HOIST* TROLLEY* BRIDGE*...

  • Page 41: Table 2(C) Tr12 2-Speed Wiring Diagram. 2-Speed, 2-Windings: All Motions

    Section 6 - Wiring (Continued) TABLE 2(C) TR12 2-SPEED WIRING DIAGRAM. 2-SPEED, 2-WINDINGS: ALL MOTIONS External jumper in J6 connector RETURN MASTER J6-2 J6-3 RELAY MAIN LINE J6-4 J6-5 CONTACTOR J5-6 J5-5 MOTOR 1 J5-4 J5-3 MOTOR 2 J5-1 J5-2 MOTOR 3 J4-3 J4-4...
  • Page 42 Section 6 - Wiring (Continued) TABLE 2(C) TR12 2-SPEED PROGRAMMING DIAGRAM. 2-SPEED, 2-WINDINGS: ALL MOTIONS Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 J5-6 J5-4 J5-2 HOIST* TROLLEY* BRIDGE* MOTOR 1 MOTOR 2...

  • Page 43: Table 2(D) Tr12 2-Speed Wiring Diagram. Acco Controls: All Motions

    Section 6 - Wiring (Continued) TABLE 2(D) TR12 2-SPEED WIRING DIAGRAM. ACCO CONTROLS: ALL MOTIONS External jumper in J6 connector RETURN MASTER J6-2 J6-3 RELAY MAIN LINE J6-4 J6-5 CONTACTOR J5-6 J5-5 MOTOR 1 SPD DIR 2 J5-4 J5-3 MOTOR 2 SPD DIR 2 J5-1 J5-2...
  • Page 44 Section 6 - Wiring (Continued) TABLE 2(D) TR12 2-SPEED PROGRAMMING DIAGRAM. ACCO CONTROLS: ALL MOTIONS Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 J5-6 J5-4 J5-2 HOIST* TROLLEY* BRIDGE* MOTOR 1 MOTOR 2...

  • Page 45: Trolley; Standard Bridge

    Section 6 - Wiring (Continued) TABLE 2(E) TR12 2-SPEED WIRING DIAGRAM. P&H: 2-SPEED, 2-WINDINGS for HOIST and TROLLEY; STANDARD BRIDGE External jumper in J6 connector RETURN MASTER J6-2 J6-3 RELAY MAIN LINE J6-4 J6-5 CONTACTOR J5-6 J5-5 MOTOR 1 J5-4 J5-3 MOTOR 2 J5-2...
  • Page 46 Section 6 - Wiring (Continued) TABLE 2(E) TR12 2-SPEED PROGRAMMING DIAGRAM. P&H: 2-SPEED, 2-WINDINGS for HOIST and TROLLEY; STANDARD BRIDGE Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 J5-6 J5-4 HOIST*...

  • Page 47: Standard Trolley And Bridge

    Section 6 - Wiring (Continued) TABLE 2(F) TR12 2-SPEED WIRING DIAGRAM. P&H: 2-SPEED, 2-WINDINGS for HOIST; STANDARD TROLLEY and BRIDGE External jumper in J6 connector RETURN MASTER J6-2 J6-3 RELAY MAIN LINE J6-4 J6-5 CONTACTOR J5-6 J5-5 MOTOR 1 J5-4 J5-3 AUX 2 (latchable S4-3)
  • Page 48 Section 6 - Wiring (Continued) TABLE 2(F) TR12 2-SPEED PROGRAMMING DIAGRAM. P&H: 2-SPEED, 2-WINDINGS for HOIST; STANDARD TROLLEY and BRIDGE Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 J5-6 DD 2 HOIST*...

  • Page 49: Standard Trolley And Bridge

    Section 6 - Wiring (Continued) TABLE 2(G) TR12 2-SPEED WIRING DIAGRAM. DEMAG: 2-SPEED, 2-WINDINGS for HOIST; STANDARD TROLLEY and BRIDGE External jumper in J6 connector RETURN MASTER J6-2 J6-3 RELAY MAIN LINE J6-4 J6-5 CONTACTOR J5-6 J5-5 MOTOR 1 SPD DIR 2 J5-4 J5-3 AUX 2...
  • Page 50 Section 6 - Wiring (Continued) TABLE 2(G) TR12 2-SPEED PROGRAMMING DIAGRAM. DEMAG: 2-SPEED, 2-WINDINGS for HOIST; STANDARD TROLLEY and BRIDGE Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 J5-6 HOIST* TROLLEY*...

  • Page 51: Table 2(H) Tr12 2-Speed Wiring Diagram. Standard 2-Speed 4 Motor System

    Section 6 - Wiring (Continued) TABLE 2(H) TR12 2-SPEED WIRING DIAGRAM. STANDARD 2-SPEED 4 MOTOR SYSTEM External jumper in J6 connector RETURN MASTER J6-3 J6-2 RELAY MAIN LINE J6-4 J6-5 CONTACTOR J5-6 J5-5 MOTOR 4 (M4) (M4) DIR 1 J5-4 J5-3 (M4) 2 J5-2...
  • Page 52 Section 6 - Wiring (Continued) TABLE 2(H) TR12 2-SPEED PROGRAMMING DIAGRAM. STANDARD 2-SPEED 4 MOTOR SYSTEM Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 MAIN HOIST* TROLLEY* BRIDGE* MOTOR 1 MOTOR 2 MOTOR 3...

  • Page 53: Table 2(I) Tr12 2-Speed Wiring Diagram. Standard 2-Speed 3, 4 & 5 Motor System Using Select

    Section 6 - Wiring (Continued) TABLE 2(I) TR12 2-SPEED WIRING DIAGRAM. STANDARD 2-SPEED 3, 4 & 5 MOTOR SYSTEM using SELECT External jumper in J6 connector RETURN MASTER RELAY J6-2 J6-3 MAIN LINE CONTACTOR J6-4 J6-5 AUX 3 (AUX 2 position J5-6 J5-5 on telePilot transmitter)
  • Page 54 Section 6 - Wiring (Continued) TABLE 2(I) TR12 2-SPEED PROGRAMMING DIAGRAM. STANDARD 2-SPEED 3, 4 & 5 MOTOR SYSTEM using SELECT Dir 1 Dir 2 Dir 1 Dir 2 OUTPUTS OUTPUTS OUTPUTS J4-3 J3-3 J2-3 J4-2 J3-2 J2-2 J4-1 J3-1 J2-1 MAIN HOIST* TROLLEY*...

  • Page 55: Programming

    Section 7 – Programming 7-1. Access Code Programming. Membrane telePilot Pendant Transmitter Transmitter Transmitter Receiver access code Indicates switch in OFF position TR12 Receiver Access Code Switches Sample access code only, do not use MODEL # -10KXXXXXXXX S/N=XXXXXXXXXXXXXXXXX ACCESS CODE SETTING 0 1 0 0 0 1 1 1 0 1 1 0 0 0 1 0 FREQ : = AK01...
  • Page 56 Section 7 - Programming (Continued) NOTE FOR THE MEMBRANE, PENDANT TRANSMITTER AND RECEIVER. DO NOT USE A PENCIL TO TOGGLE THE SWITCHES. THE LOOSE GRAPHITE FROM THE PENCIL CAN DAMAGE THE SWITCH. WARNING TWO OPERATIONAL TRANSMITTERS WITH THE SAME ACCESS CODES OPERATING AT THE SAME TIME IS A DEFINITE SAFETY HAZARD.

  • Page 57: Receiver Frequency Programming

    Section 7 - Programming (Continued) WARNING AFTER CHANGING THE ACCESS CODES ON THE TRANSMITTER, TEST THE UNIT BY TURNING IT ON AND OFF NEAR THE APPROPRIATE RECEIVER. IF THE RECEIVER DOES NOT RESPOND, DO NOT ACTIVATE A FUNCTION BUTTON! THE TRANSMITTER MAY HAVE THE WRONG ACCESS CODE, WHICH COULD MOVE ANOTHER CRANE.

  • Page 58: Figure 7-2. Rf Receiver Board

    Section 7 - Programming (Continued) crystals to change frequencies. A pair of programming pins allows the unit to be reprogrammed in the field to a different channel. The on board microprocessor automatically retunes the RF receiver when the channel is changed; no retuning or any other adjustment is required. 7-2.2.
  • Page 59 Section 7 - Programming (Continued) The repeated sequence for reading channel 4 is: Long pause, green, red, red, red, red, short pause green, green, (no red flash, zero). The repeated sequence for reading channel 12 is: Long pause, green, red, red, short pause, green, green, red. Other examples are (equals count): AK01 (1): green, red, short pause, green, green.
  • Page 60 Section 7 - Programming (Continued) Channel and Frequency Designations by Count. Indicator Channel Actual Count Designator Frequency AK01 439.8 MHz AK02 439.6 MHz AK03 439.4 MHz AK04 439.2 MHz AK05 439.0 MHz AK06 438.8 MHz AK07 438.6 MHz AK08 438.4 MHz AK09 438.2 MHz AK10...

  • Page 61: Multibox

    Section 7 - Programming (Continued) 7-3. Multibox. 7-3.1. Multibox Operation. WARNING IF YOUR UNIT WAS NOT ORDERED WITH MULTIBOX DO NOT ATTEMPT TO PROGRAM MULTIBOX IN THE FIELD. TELEMOTIVE MUST COORDINATE ACCESS CODE ASSIGNMENTS WITH THE TRANSMITTERS PRIOR TO ENABLING MULTIBOX. PLEASE CONTACT TELEMOTIVE IF YOU NEED TO ADD MULTIBOX.

  • Page 62: Custom Receiver Programming

    Section 7 - Programming (Continued) For Membrane transmitters the Access code positions A1-A2 can be accessed through the battery compartment. The Pendant Transmitter requires the back to be removed. See Table 7-1. Multibox Switch Settings below for appropriate settings for both the transmitters and receiver(s).

  • Page 63: Receiver Programming

    Section 7 – Programming (Continued) 7-5. Receiver Programming. (For the location of specific programming switches see Figure 9-1. Receiver Layout). WARNING MAKE SURE S1 MASTER CONTROL RELAY (MCR) IS TURNED OFF BEFORE ATTEMPTING TO REPROGRAM THE RECEIVER, TO PREVENT ACTIVATION OF EXTERNAL CIRCUITRY. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

  • Page 64: Membrane Transmitter Programming

    Section 7 – Programming (Continued) 7-5.5.1. Auxiliary Function Relay Latching (SW4-2 and -3). Normally All OFF. Enables the appropriate auxiliary function relay to operate in a latched mode, on or off, rather than as a momentary contact. Which function is latchable and which relay is latched depends on the particular transmitter used.
  • Page 65 Section 7 – Programming (Continued) SW3 position 4 disables the time-out-timer. Turning SW3-8 “ON” disables the time-out-timer. If disabling the transmitter time-out-timer, remember to also replace the receiver(s) EPROM(s) to disable the time-out- timer in the receiver. 7-6.4. Positions 5-7 Special Crane Control Configurations, 2-Speed Membrane Only. (Standard all “OFF”).
  • Page 66 Section 7 – Programming (Continued) 7-6.8. Repositioning Of Membrane Transmitter Motion Switch Functions (for 2-Speed Membrane Transmitter only). SW3 positions 1 through 3 can change the functional positions of the switches controlling bridge, hoist and trolley. This can be useful to align East/West and North/South. This reconfiguration does NOT affect receiver wiring.

  • Page 67: Figure 7-5. Membrane Transmitter Single-Speed Configurations

    Section 7 – Programming (Continued) 7-6.9. Single-Speed Membrane Transmitter Configurations. Normally single-speed transmitters are not provided with the 10K6/9. This section is for reference only when using a Single-Speed Membrane Transmitter. All single-speed modes require that the transmitter switch SW3 positions 1 through 3 are all set to OFF. The EPROM’s for the single-speed unit is FW2904-0T and FW2904-0N where 0T means with 15-minute- time-out-timer and 0N means no time-out-timer.

  • Page 68: Pendant Transmitter Programming

    Section 7 – Programming (Continued) 7-7. Pendant Transmitter Programming. The Single-Speed or the 2-Speed 10K12 Pendant Transmitter may be used with the TR12 Receiver. The Pendant Transmitter M/C Board is shown in Figure 8-6. Refer to paragraphs below for programming details Procedures.
  • Page 69 Section 7 – Programming (Continued) Mode 3, SW4 1 and 2 turned “ON”. The 10K12 2-speed system will control up to 5 motors using the rotary selector switch. This mode reconfigures two of the 10K12 auxiliary outputs (Aux 1 and Aux 2) to be external motor select functions by the rotary switch.
  • Page 70 Section 7 – Programming (Continued) 7-7.13. Repositioning Of Pendant Transmitter Motion Switch Functions (for 2-Speed Pendant Transmitter only). SW3 positions 1 through 3 can change the functional positions of the switches controlling bridge, hoist and trolley. This reconfiguration does NOT affect receiver wiring. WARNING CHANGING THESE SWITCHES CHANGES THE FUCTIONAL OPERATION OF THE CRANE IN RELATIONSHIP TO THE TRANSMITTER BUTTON BEING DEPRESS-ED.

  • Page 71: Telepilot Programming

    Section 7 – Programming (Continued) 7-8. telePilot Programming. Read Section 5-5. Additional telePilot Operational Features to familiarize you with the features listed below. The telePilot ® transmitter remote unit for programming uses a PDA (Personal Digital Assistant). Such products as Palm Pilot or many ®...
  • Page 72 Section 7 - Programming (Continued) Tx Type (Must be selected). First select the transmitter type being used (single-speed “1 SPD” or 2-speed “2 SPD”). See Section 5. Operation for differences in the two transmitters. With your PDA stylus tap the arrow after transmitter “Tx Type”. A pull down menu will appear, select “1 SPD”...
  • Page 73 Section 7 - Programming (Continued) WARNING DISABLING THE PASSWORD FUNCTION IS PUTS THE SYSTEM IN ACTIVE BANK SELECT. THIS ALLOWS THE CRANE OPERATOR TO SWITCH BETWEEN BANKS QUICKER. THE OPERATOR IN THIS MODE MUST BE AWARE AND RESPONSIBLE FOR ALL POSSIBLE CONTROLLED CRANES. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
  • Page 74 Section 7 - Programming (Continued) The respective screens appear as shown below (the 10K screen is shown first): Setup Bank # System Freq AK01 Receiver access code Multibox Tx # Auto Turn Off Auto Alarm This section appears Timer S3-1 for 2-Speed only.
  • Page 75 Section 7 - Programming (Continued) 10K telePilot Programming. 7-8.1. After you have entered 10K as your system type, enter the following items in order for your system: Frequency (Must be inputted for system to work): There should be a label either on the receiver or the transmitter listing frequency; it should be a channel number between AK01 to AK20.
  • Page 76 Section 7 - Programming (Continued) Setup Bank # System Freq AK01 Receiver access code Multibox Tx # Auto Turn Off Timer None Mode Screen switches Save Cancel 10K Single-Speed Programming Screen Setup Bank # System Freq AK01 Receiver access code Multibox Tx # Auto Turn Off...
  • Page 77 Section 7 - Programming (Continued) 10K telePilot Programming (Continued). Single-Speed 10K telePilot Only: 7-8.1.1. Skip to next section7-7.1.2 (below) if 2-speed. Timer (If unsure of a number start with 15 minutes): Enables the transmitter time-out-timer. The selections are “None” (meaning the transmitter will never shut off on it own if not used, this is not recommended for battery life) or numbers of minutes till shut down.
  • Page 78 Section 7 - Programming (Continued) 10K telePilot Programming (Continued). 2-Speed 10K telePilot Only: 7-8.1.2. Setup Bank # System Freq AK01 Receiver access code Multibox Tx # Auto Turn Off Timer S3-1 Switch conf.: H,T,B Save Main/Aux Cancel 10K 2-Speed Programming Screen Programming Switch S3-1 NOTE IF REPLACING A MEMBRANE OR PENDANT TRANSMITTER, YOU CAN COPY THE SWITCH SETTINGS ON...
  • Page 79 Section 7 - Programming (Continued) Positions 5-7 Special Crane Control Configurations. (Standard all “OFF”). Section 6. Wiring shows all the different crane configurations and the switch positioning needed to achieve them. The standard transmitter comes with the output standard output configuration. For special crane control configurations program S3 positions 5-7 to match the programming information shown for the respective wiring diagram.
  • Page 80 Section 7 - Programming (Continued) Position 4 Invert Crane Select Aux. Outputs. (Normally not checked). This function appears if a system using select is programmed in. Turning this switch “ON” inverts the select function operation so that the relay closes for the unselected function. This function maps to Pendant Switch 4 position 4, if SW4 position 4 is switched “ON”...

  • Page 81: Figure 7-7. Single-Speed 10K Telepilot Modes

    Section 7 - Programming (Continued) Single-Speed 10K telePilot Lockout Modes. 7-8.1.3. The Modes shown are equivalent to the same Modes in the single-speed Membrane transmitter. Auxiliary relay functionl labeling shown is in reference to the traditional labeling of the Single-Speed Membrane Transmitter for the respective modes.
  • Page 82 Section 7 - Programming (Continued) 9000 and 9001 Programming. 7-8.2. telePilot After you have entered 9000 or 9001 as your system type enter the following items in order for your system: Frequency (Must be inputted for system to work): There should be a label either on the receiver or the transmitter listing frequency, and it should list a channel number between A and K.
  • Page 83 Section 7 - Programming (Continued) Save will take you back to the Initial start screen. At this point select another Bank to program or to Section 7-9. Saving And Loading The Program. Original 9000 Keypad Layout. Dark rectangles indicate locked out functional groups on both transmitters.
  • Page 84 Section 7 - Programming (Continued) 9100 and 9101 telePilot Programming. 7-8.3. After you have entered 9100 or 9101 as your system type enter the following items in order for your system: Frequency (Must be inputted for system to work): There should be a label either on the receiver or the transmitter listing frequency, and it should list a channel number between A and K.
  • Page 85 Section 7 - Programming (Continued) Modes A0-A4 (9100 Single-Speed Only). (The correct mode must be selected for safe operation): Please refer to Figure 7-8. Single-Speed 9100 telePilot Lockout Modes for specific mode details and functional mapping of 9100 controls to telePilot. Modes are various patterns of functional lockouts. If you have UP and a DOWN buttons on a single-speed transmitter controlling a hoist, the transmitter must not be able to send UP and DOWN commands at the same time.
  • Page 86 Section 7 - Programming (Continued) Single-Speed 9100 Series telePilot Lockout Modes. 7-8.4. The Modes and Mode labeling shown relate to the similar, but not identical, Modes in the Single-Speed 9100 Transmitter. Choose the lockout pair that most closely matches your needs. If you are unsure of the Lockout Mode in your existing unit, read dip switch SW3 in the existing 9100 transmitter and compare it to the chart below.
  • Page 87 Section 7 - Programming (Continued) 2-Speed 9001 and 9101 Series telePilot Functional Mapping. Motor 2 Motor 1 Dir 1 Dir 1 Motor 1 2 nd 2 nd Dir 1 Auxiliary Speed Speed Dir 2 Controls Motor 2 Motor 1 Motor 2 AUX 1 Dir 2 Dir 2...
  • Page 88 Section 7 - Programming (Continued) Saving, Downloading, Reading The Programs and Other PDA Functions. Saving The Programming File. With the initial telePilot screen displayed, tap in the lower left corner of your PDA, the title bar at the top of the screen will show a menu or tap on the word “telePilot”.
  • Page 89 Section 7 - Programming (Continued) Admin Setting Tx Type 2 SPD Send Setting Receive Setting Use bank password Beam Setting First press Button 6 TelePilot ID Second press Button 5 History Third press Button 4 About Fourth press Button 3 Bank 1 Bank 2 Bank 3...
  • Page 90 Section 7 - Programming (Continued) Error Statements and Codes. Tx Type Mismatch: If, while attempting to program a telePilot, you receive an error code such as “Error AAAB” you have selected a different style transmitter on the PDA than you are attempting to program. Most common cause is trying to program a 2-speed telePilot with single-speed selected or vice versa.

  • Page 91: Access Codes

    Section 8 – RCP Programming 8-1 Access Codes. telePilot Transmitter Receiver access code Indicates switch in OFF position TR12 Receiver Figure 8-1. Access Code Setting. (A dot on a switch position or a “1” in the label is an indication that the respective switch position should be ON).

  • Page 92: Rcp Programming

    Section 8 – RCP Programming (Continued) 8-1.1. Changing Transmitter Access Codes. 8-1.1.1. telePilot Access Code Programming. For detailed instructions on setting parameters, including access codes, see Section 5-3.2. telePilot Programming. WARNING AFTER CHANGING THE ACCESS CODES ON THE TRANSMITTER, TEST THE UNIT BY TURNING IT ON AND OFF NEAR THE APPROPRIATE RECEIVER.

  • Page 93: Programming

    RCP (Radio Control Programmer) software. RCP can be ordered from your Magnetek distributor. Magnetek RCP software is user friendly and is intended to provide plain language descriptions of all transmitter functions and options. Help is provided for each function at the bottom of the RCP screen. The RCP software allows you to select frequency, access code, time-out-timer settings, switch arrangement and crane configuration as in other Telemotive transmitter products.
  • Page 94 Section 8 – RCP Programming (Continued) Click on New Project or Open Project Select New Project if you are creating a new program file. Select Open Project if you want to retrieve an existing program file. A list of recent projects will appear under Open Project. Clicking on one of these will open that project. It is recommended that you create a folder in which to save all programming files.
  • Page 95 Section 8 – RCP Programming (Continued) A menu will open listing the available project types. Select the one that matches the product you wish to program (selecting a project type will display a picture of the product for verification). The telePilot transmitter is identified by the number of buttons on the right hand side of the transmitter.
  • Page 96 Section 8 – RCP Programming (Continued) The Bank password can be disabled during initial programming by the RCP software. To disable password protection, uncheck the box next to the phase “Use bank password”. Disabling the Bank password is not recommended unless the operator has access and visibility to all possible cranes controlled.
  • Page 97 Section 8 – RCP Programming (Continued) This will open the bank programming screen. NOTE IF YOU HAVE AN INTELESMART RECEIVER, FREQUENCY AND ACCESS CODES CAN EASILY BE DOWNLOADED DIRECTLY INTO THE RCP SOFTWARE. Downloading Parameters from an InteleSmart receiver. Select the Bank you wish to program, and then cycle the power to the InteleSmart receiver. Within the first 10 seconds of the receiver turning ON, point the IR Adaptor at the receiver’s IR port (see receiver manual for location) and click the “Rx Setting”...
  • Page 98 Section 8 – RCP Programming (Continued) Enter the Access Code (Must be set for system to work): Screen switch operation. The screen switches are labeled from left to right, “A” and “B”. They are numbered from left to right 1 to 8. The black rectangle to the bottom is “OFF”...
  • Page 99 Section 8 – RCP Programming (Continued) See Section 7-3. Multibox for details on Multibox programming. If your current receiver does not have Multibox, do not attempt to use this function. This function WILL NOT turn Multibox on in the receiver; it only assists you in programming the correct transmitter access code for a receiver that already has Multibox.
  • Page 100 Section 8 – RCP Programming (Continued) check from the box disables the “Both” function (“A” and “B” will not come ON at the same time). This function maps to Pendant Switch 4 position 3; if SW4 position 3 is switched “ON”, un-check Tandem box. Invert Crane Select Aux.
  • Page 101 Section 8 – RCP Programming (Continued) 1. Turn the transmitter ON and line up the IR adaptor as above. 2. Click “Receive” and follow onscreen prompts. 3. RCP will confirm reception and automatically display current programming in the telePilot unit. Reading the telePilot ID and history.

  • Page 102: Servicing

    Section 9 – Servicing RF Receiver “ON” Indicator TP5 AGC TP7 DATA RF Receiver Board TP6 ANALOG TP2 GND 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Dip Switches DS15...
  • Page 103 Section 9 – Servicing (Continued) DSMR2 Monitors closure of the Master Control Relay (MCR) relay (K13). LED will be illuminated when the MCR relay has been enabled by an ON command recieved from the Transmitter Unit. LED will extinguish when an OFF command has been transmitted, an EMS condition is present, or SW2 is set to OFF.

  • Page 104: Receiver Testing

    Section 9 – Servicing (Continued) DS18 Monitors the ON command from the Transmitter. LED will flash when an ON command is being received from the Transmitter. While pushing the ON button on the Transmitter this should light. DS19 Monitors EMS condition. Normally OFF.

  • Page 105: Figure 9-2. Receiver Scope Wave Forms

    Section 9 – Servicing (Continued) NOTE THE FOLLOWING TEST POINTS NEED AN OSCILLOSCOPE, SEE 9-2. RECEIVER SCOPE WAVE FORMS. TP5 – Monitors AGC (Automatic Gain Control) from RF Receiver module. TP6 – Monitors analog signal from RF Receiver module. TP7 – Monitors received data from RF Receiver module. 9-2.2.

  • Page 106: Membrane Transmitter Servicing

    Section 9 – Servicing (Continued) 9-3. Membrane Transmitter Servicing. The Membrane Transmitter M/C board is shown in Figure 9-3. Refer to the following paragraphs for Servicing Procedures NOTE TO DISABLE TIME-OUT-TIMER IN TRANSMITTER TURN SW3 POSITION 3 TO ON. J1 Keyboard Connector Figure 9-3.

  • Page 107: Pendant Transmitter Servicing

    Section 9 – Servicing (Continued) NOTE IF THE BATTERIES ARE INSTALLED BACKWARDS IN THE MEMBRANE TRANSMITTER, THE FUSE IN THE BATTERY COMPARTMENT WILL BLOW TO PROTECT THE INTERNAL CIRCUITRY. 9-3.4. Battery Fusing. The Membrane Transmitter is protected from reverse battery polarity and shorts by a fuse, part number F2712-1.5 (1.5 Amp, 250V, Fast Acting, 2 AG).

  • Page 108: Telepilot Servicing

    Section 9 – Servicing (Continued) 9-4.1. To Check Data. 1.) For data input use pin 1 of J1. 2.) Use TP1 for External Trigger input. 3.) Use TP4 for Ground. 9-4.2. Battery Monitor Adjustment. Battery monitor is factory preset; no adjustment is available. 9-4.3.

  • Page 109: Spare Parts

    Section 10 – Spare Parts RECEIVER PART NUMBER DESCRIPTION FW2912-0 EPROM E13157-S RF SYNTHESIZED RECEIVER MODULE ASSEMBLY H310-0 RF RECEIVER MODULE ASSEMBLY MOUNTING SCREWS (4) MP18005-0 RF RECEIVER MODULE MOUNTING BRACKET TOP SIDE (LEFT) MP18005-1 RF RECEIVER MODULE MOUNTING BRACKET TOP SIDE (RIGHT) H906-0 RF RECEIVER MODULE MOUNTING BRACKET BOLT (2)
  • Page 110 Section 10 – Spare Parts (Continued) telePilot TRANSMITTER CONTINUED (SEE FIGURE 10-1.) PART NUMBER DESCRIPTION A10722-0 HOUSING ASSEMBLY 2- SPEED WA1052-0 BATTERY CABLE, 2-SPEED WA1053-0 BATTERY CABLE, SINGLE-SPEED MP10721-0 BATTERY HOLDER FOR TWO “AA” CELLS BT111-0 DISPOSABLE HIGH CAPACITY BATTERY PACK BT111-1 RECHARGEABLE BATTERY PACK A10723-0...
  • Page 111 Section 10 – Spare Parts (Continued) PENDANT TRANSMITTER CONTINUED PART NUMBER DESCRIPTION BT10KP-1 BATTERY, NICAD BT10KP-0 BATTERY, ALKALINE BT10KP-1 BATTERY, NICAD E10670-1 BATTERY CHARGER 178-01702-0100 RADIO CONTROL PROGRAMMER WITH ADAPTER COMMUNICATION *NOTE 1 DOWN EAST WEST NORTH SOUTH YELLOW BLACK...

  • Page 112: Figure 10-1 Telepilot Exploded View

    Section 10 – Spare Parts (Continued) CAUTION DO NOT ATTEMPT TO OPEN OR SERVICE THE TELEPILOT UNIT. ONLY TRAINED QUALIFIED INDIVIDUALS SHOULD DO SERVICING. STRICT ANTI- STATIC HANDLING PROCEDURES MUST BE FOLLOWED. FAILURE TO FOLLOW THIS CAUTION COULD RESULT IN SERIOUS DAMAGE TO EQUIPMENT AND/OR VOID THE WARRANTY.

  • Page 113: Appendix A- Transmitter Switch Programming

    Appendix A - Transmitter Switch Programming Switch POS. Membrane Pendant SLTX JLTX telePilot Switch Orientation 1 Switch Orientation 1 Code Plug Select Switch Orientation 1 Switch Orientation 2 Switch Orientation 2 Switch Orientation 2 Switch Orientation 3 Switch Orientation 3 Switch Orientation 3 Time-out-timer Disable Time-out-timer Disable...

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