Control Chief TM2000 Owner`s manual

®
TeleChief Series
TM2000 / TM4000 /
TM6000
Owners Manual
Failure to return the Warranty Registration document (enclosed) to
Control Chief within 30 days of purchase will void any warranty
responsibilities on behalf of Control Chief Corporation
Control Chief Corporation
200 Williams Street Bradford, PA 16701
814-362-6811 * 1-800-233-3016 * 814-368-4133 (fax)
www.controlchief.com
95-00-0-036
Control Chief Corporation, a world leader in wireless radio and infrared
remote control products has developed and expanded upon this powerful
technology. More than three decades of experience in designing,
manufacturing and installing state-of-the-art remote communication
systems emphasize Control Chief’s mission.
Our systems are tailored to virtually any environment or application.
Control Chief provides training, technical support, and comprehensive
system design to maximize performance. It is our honor to uphold this
reputation of innovative engineering and superior product performance.
Publication: 95-00-0-036 Rev D
Copyright © 2002, 2003, 2007 Control Chief Corporation
All Rights Reserved.
200 Williams Street, Bradford, Pennsylvania, 16701
Web Page: www.controlchief.com
Telephone: (814) 362-6811, FAX: (814) 368-4133
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
1.0 Radio Warranty
1.1 Warranty
1.2 Warranty Period
1.3 Warranty Service
1.4 Excluded Parts
1.5 Remarks
2.0 Safety
2.1 Safety Considerations
2.2 Symbols
2.3 Warnings
3.0 Standard Components
3.1 Receiver (RX)
3.2 Transmitter (TX)
3.3 Accessories per Radio Transmitter
4.0 Installation Procedure
4.1 General Precautions
4.2 Receiver Preparation
4.2.1 Power Supply Selection
4.2.2 Open / Closed Setup
4.3 Receiver Installation
4.3.1 Radio Schematics
4.4 Remote Setting
4.5 Transmitter Setup
5.0 Operation
5.1 Standard Operation
5.2 Emergency Shutdown Procedure
6.0 Basic Troubleshooting and Maintenance
6.1 General Precautions
6.2 General Error Code and Resolutions
6.3 Change of Fuse
6.3.1 DC Type
6.4 Change of Frequency / Crystal
7.0 Function Settings
8.0 Specifications
8.1 General
8.2 Transmitter
8.3 Receiver
9.0 Receiver Mounting Diagram
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
1.0 Radio Warranty
1.1
Warranty. Control Chief Corporation guarantees that this equipment meets its published specifications at the
time of shipment from the factory. This equipment will perform as described if installed properly. However,
Control Chief cannot guarantee that operation of remote control system is absolutely error-free, or without
interruption.
1.2
Warranty Period. This equipment is warranted against defects in materials and workmanship for a period of
one (1 year from the date of shipment. During the warranty period, Control Chief is responsible for necessary
repairs/replacement as long as the product can be proven defective.
1.3
Warranty Service. For warranty service or repair, this equipment must be returned to Control Chief
Corporation. Customer is responsible for shipping charges to Control Chief. Control Chief’s warranty covers
only parts and factory labor. No onsite in and out charges are covered under this warranty.
1.4
Excluded Parts. This warranty does not include consumable parts such as joysticks, batteries, fuses,
buttons, and relays. Also, this warranty does not cover defects caused by improper installation,
improper/insufficient maintenance, unauthorized modification, improper operation, ignorance of environmental
specifications, and/or improper software/interfacing.
1.5
Remarks. No other warranty is expressed or implied, except for the above mentioned. The remedies
provided herein are the buyers’ sole and exclusive remedies. Control Chief shall not be liable for any
direct/indirect, special, incidental, or consequential damage. Consult Control Chief’s general warranty for
further information.
2.0 Safety
2.1
Safety Considerations
1. The safety guidelines in this manual are not intended to replace any rules or regulations or any applicable
local, state, or federal governing laws. The following information is intended to be used in conjunction with
other rules or regulations already in existence. It is important to read all safety information before operating
any wireless radio remote control system.
2. Only properly trained persons designated by management should be permitted to operate wireless radio
controlled equipment. Wireless radio controlled equipment should not be operated by any person who
cannot read or understand signs, notices and operating instructions that pertain to the equipment.
3. Wireless radio controlled equipment should not be operated by any person with insufficient eyesight or
hearing or by any person who may be suffering from a disorder or illness or is taking any medication that
may impair judgment or the ability to operate equipment.
4. Do not use this device during electrical storms or under conditions of electrical interference, due to the
potential for equipment communication issues. Ensure transmitter batteries are in good condition and power
for receiver is correct. Installation and maintenance should be done only while the controlled equipment
main power and receiver’s power are off and locked out to prevent electrical shock.
5. Any person operating wireless radio controlled equipment should possess the following knowledge
and/or skills:
¾ Knowledge of hazards peculiar to equipment operation
¾ Knowledge of safety rules for radio controlled equipment
¾ Knowledge of standard methods of hand and/or non-verbal signaling
¾ Knowledge of the radio transmitter
¾ Limit switch test procedure
¾ Proper clearance of all moving parts on the radio controlled equipment
¾ Proper storage space for radio control transmitter when not in use
¾ Transferring radio control transmitter to another person
¾ Reporting unsafe or unusual operating conditions
¾ Remote controlled equipment capacity and limitations
¾ Procedures for testing controlled equipment
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
6. Aisles between equipment, stock, etc., should be free of obstructions so the radio control operator can
move freely. These aisles should meet local regulations.
7. Radio controlled operators should always position themselves for the best view of the equipment they are
controlling. The equipment should never be operated blindly. The operator should always remain at a safe
distance, without losing line of sight with the equipment.
8. Transmitter switches should never be mechanically blocked ON or OFF for any equipment motion. When
not in use turn the transmitter off (STOP).
9. After daily operation, shut off main power in crane/machine and the power to the receiver. A secure
storage space should be designated for the transmitter unit especially when not in use. This precaution is
intended to prevent unauthorized use of the equipment.
10. The equipment operator should keep all body parts away from any moving parts and should never be
positioned under a lifted load. Do not make a lift or move a load if anyone is in a location where they could
be struck by the crane/equipment or the load.
11. If the equipment fails to respond properly, the crane/equipment operator should stop operation, turn the
transmitter off (STOP). The operator should immediately report the condition to his/her supervisor.
12. The crane/equipment operator should turn off the transmitter and take it with him/her when and if
boarding the equipment.
13. Remote control operation should NEVER be used for “people moving” applications. Never use remote
operation if there are people aboard the controlled equipment. The remote control operator should NEVER
“ride” on the controlled equipment.
WARNING
ALWAYS PLACE CRANE/EQUIPMENT IN MANUAL OPERATION AND SECURE THE WIRELESS
REMOTE CONTROL TRANSMITTER PRIOR TO PERFORMING ANY MAINTENANCE.
14. The equipment has been tested for correct operation before delivery from the factory. However, it must
not be used in critical or hazardous operation where incorrect operation may cause personal or equipment
damage. If the equipment fails to respond or behaves improperly, the equipment operator should NOT
operate the equipment AND should notify his/her supervisor immediately. When serious conditions are
noticed (conditions that make the crane/equipment unsafe to operate), the equipment should be shut down
immediately and the supervisor notified.
CAUTION
THE RECEIVER UNIT OR RELAYS ARE NOT RATED AS EXPLOSION PROOF. THE RECEIVER UNIT
MUST NOT BE INSTALLED OR OPERATED IN EXPLOSIVE ENVIRONMENTS UNLESS APPROPRIATE
SECONDARY ENCLOSURE MEASURES ARE TAKEN.
WARNING
THE UNIT MUST BE WIRED TO THE CORRECT VOLTAGE; FAILURE TO DO SO MAY DAMAGE THE
SYSTEM.
NOTE
IN AN EMERGENCY, PUSH “STOP” TO STOP RADIO REMOTE CONTROLLED EQUIPMENT.
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
2.2
OWNER’S MANUAL
Symbols
1. This product and related documentation must be reviewed for familiarization with safety markings and
instructions before operation. This product requires strict adherence to instructions in order to ensure
operational safety. The following symbols may be found on the remote control or throughout the remote
control documentation. Their purpose is to alert you to potentially dangerous situations.
Refer To Manual
When the product is marked with this symbol refer to the instruction manual for additional
information.
High Voltage
Indicates presence of hazardous voltage. Unsafe practice could result in severe personal injury.
Protective Earth Ground
Indicates protective earth terminal.
Warning
Denotes hazard. Included text will give proper instructions. Failure to follow instructions could
result in severe personal injury and/or property damage.
Caution
Denotes hazard. Included text will give proper instructions. Failure to follow instructions could
result in minor personal injury and/or property damage.
2.3
Warnings
1. Read this manual carefully before operating and installing this product.
2. Due to the complex nature of equipment, it is necessary to read the entire manual before installation.
3. Only authorized personnel should service this equipment. Unauthorized work on this unit will void the
warranty.
4. This manual is for reference only; please call your distributor or Control Chief if further assistance is
required.
5. The equipment has been tested for correct operation before delivery from the factory. However, it must
not be used in critical or hazardous operation where incorrect operation may cause personal or
equipment damage.
6. After daily operation, please shut off main power in crane/machine and the power to the receiver.
7. Transmitter should be placed in a safe place when not in use to avoid accidental pressing of buttons.
8. The crane/machine should be equipped with mainline contactor, limit switches, and other required safety
devices as dictated by CMAA, OSHA, or all other applicable governing regulations.
9. The GND (ground) of receiver must be connected to ground of crane/machine, or electrical shock can
occur.
10. Do not use this device during electrical storms or under conditions of electrical interference.
11. Ensure transmitter batteries are in good condition and power for receiver is correct.
12. Installation and maintenance should be done only while the crane/machine’s main power and receiver’s
power are off and locked out to prevent electrical shock.
13. Contents of the manual may be amended by the manufacturer without notice.
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
3.0 Standard Components
®
A standard TeleChief wireless pendant system consists of a single (1) receiver and one (1) or two (2) handheld
transmitters. AC and DC input voltage receivers are available. See paragraph 4.2.1 for available variants.
Note:
3.1
All replacement part orders require the System Serial Number and the Channel Number for proper
frequency matching.
Receivers
TM2000 AC Receiver, Part Number = 701P0040
TM2000 DC Receiver, Part Number = 701P0040-DC
TM4000 AC Receiver, Part Number = 701P0060
TM4000 DC Receiver, Part Number = 701P0060-DC
TM6000 AC Receiver, Part Number = 701P0080 (shown)
TM6000 DC Receiver, Part Number = 701P0080-DC
3.2
Transmitters
TM2000 Transmitter, Part Number = 701P0004
TM4000 Transmitter, Part Number = 701P0006
TM6000 Transmitter, Part Number = 701P0008
3.3
Accessories Per Radio Transmitter
1. Alkaline batteries (2 pieces)
2. Strap for transmitter (1 piece)
3. Owners manual (Part number 95-00-0-036)
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
4.0 Installation Procedure
4.1
General Precautions
1. Observe all safety precautions when climbing or working on the machine.
2. Turn off the main power source of crane/machines before installation to avoid electric shock.
Lockout/Tagout the main power source.
3. Receiver must be installed as to not touch any part of the crane/machine or structure during the operation,
except for mounting provisions.
4. The receiver must be fastened securely via shock-proof mount provided.
5. Before installation, inspect the crane/machine’s safety devices and make sure everything is in proper
working condition.
6. To avoid any interference, the receiver must be located away from motors, frequency drives, and power
cables (Section 4.3).
7. Coil suppressors are recommended on all contactor coils and relay coils. Control Chief
recommends RC type suppressors (Control Chief part number 0700-8002).
8. In outdoor applications make sure all case fasteners are tightened firmly. The recommended torque
setting is 35-40 inch-pounds. Make sure cord grip is secure. If the receiver is mounted with the antenna
facing sideways or upwards, wiring pigtail must be positioned with a drip loop. See illustration for preferred
mounting.
Cord Grip
Case Fasteners x4
Case Fasteners x4
Cord Grip
XXXXXXX
XXXXX
XXXX
XXXX
XXXXXXXXXXXX
XXXX
Drip Loop
Drip Loop
4.2
Receiver Preparation
4.2.1
Power Supply Selection
There are two types of power voltage (DC and AC) available for the TeleChief® Series:
DC Type
Input voltage: 12~24VDC. Wire + DC to Power 1 (black) and DC - to Power 2 (white).
Relay Contact: 15A-32VDC
AC Type (3 different transformers: 48/110V, 110/220V, 220/380V)
The voltage selection jumper is:
1. AC 48 / 110 V
Transformer
2. AC 110 / 220 V
Transformer
3. AC 220 / 380 V
Transformer
1.
2.
Note:
LOW
HI
48V
110V
110V
220V
220V
380V
Locate the Hi/Low jumper to the lower left of the transformer.
Place the jumper connecting the two pins to enable the correct transformer setting as shown in
the chart above.
The default transformer is the 48V/110V version and jumper is normally set on Hi. Please contact
your distributor for other options and lead-times.
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
4.2.2
OWNER’S MANUAL
Normally Open / Normally Closed Setup
The TeleChief® Series provides 2 different outputs for the R0/START relay: N.O. and N.C. The
N.O. is the default setting. If an N.C. output is necessary, please remove the No. 8 wire (RO/Start)
from the connector and insert it into No. 10 as shown in steps 1 through 4 below:
NC Procedure:
4.3
Receiver Installation
TeleChief® Series Receiver
1. Turn off main power to the crane/machine.
2. Locate a proper place for the receiver.
a. Select a stable place free from electrical noise,
vibration, excessive heat, etc.
b. Select a location that is visible from the operator’s
location.
c. Select a location at least 3 feet away from motors,
relays, power cables, and frequency converters.
d. Keep away from high voltage wiring and devices.
Minimum of 3 feet separation
e. The receiver box must be at least 1.5” (4cm) from
other obstacles.
Frequency
3. Drill four (4) 6 mm holes for the receiver mounting the unit
MOTOR
Cable
Converter
with the included hardware.
4. Connect wires to the control circuit of the crane/machine
according to the wiring diagram of the receiver. (Shown in
Section 4.3.1)
5. Secure the cable between the receiver and the machine so that the cable sheath will not wear out due
to vibration.
6. Complete Section 4.5 and test every function of the radio control making sure all motors are correct.
7. Secure the cover making sure not to pinch any wires between the case and the lid.
8. This completes the receiver installation.
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
4.3.1 Radio Schematics
AC Models
TM2000
TM4000
TM6000
4-button wiring schematic
6-button wiring schematic
8-button wiring schematic
TM2000
TM4000
TM6000
4-button wiring schematic
6-button wiring schematic
8-button wiring schematic
DC Models
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
4.4
OWNER’S MANUAL
Remote Setting
Remote setting allows you to pair the new transmitter and receiver if either of them becomes damaged. In
order for the radios to work the transmitter and receiver must have the same ID codes and frequency. Using
remote setting will set both the transmitter and receiver to have the same ID codes.
1.
Please ensure the following conditions are met before attempting the remote setting procedure.
a. Both the transmitter and receiver are of the SAME model and frequency.
b. To place the transmitter as close as possible to the receiver to avoid any interference.
c. Turn off the receiver power and turn it on again.
d. Complete the “remote setting” within 4 minutes after turning on the receiver. The receiver will NOT
accept the remote setting signal after 4 minutes has elapsed.
2.
Remote Setting instructions
a. Press and hold the transmitter STOP pushbutton.
b. Press the DOWN pushbutton and hold it.
c. Press the UP pushbutton 4 times and release “STOP & DOWN” pushbuttons when the red light
flashes.
d. Start the system per General Operation (Section 5.0).
2. Press and hold the DOWN button.
1. Press and hold the STOP button.
3. Press the UP button 4 times.
ATTENTION:
* In case the remote setting procedure fails, repeat the instructions above within 4 minutes.
* The remote setting procedure will update the ID code only. It will not change function settings.
* All same model systems within the operating distance on the same frequency will be paired with the
transmitter’s ID code.
4.5
Transmitter Setup
Two (2) AA size alkaline batteries are required for the transmitter. The LED will flash GREEN when the battery
power is sufficient. The LED will flash RED when the battery power is low.
Note 1: The operating distance will decrease when the batteries are low.
Note 2: Replace with new batteries when battery power is low.
Note 3: Re-chargeable batteries are NOT recommended, use only alkaline batteries.
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
5.0 Operation
5.1
Standard Operation
1. Turn-on the main power switch of the equipment.
2. Install two (2) AA size alkaline batteries in the transmitter.
3. Press the Start/RO pushbutton to turn on the main relay inside the receiver.
4. Operate normally according to the function settings.
5. Please perform the following procedure when done operating
a. Press STOP pushbutton
b. Place the transmitter in safe storage location
6. Turn off the main power switch to the equipment
5.2
Emergency Operation
In case of any emergency please:
1. Press STOP pushbutton.
2. Switch off the main power of crane/machine. If the problem persists, contact your local distributor for
service.
6.0 Basic Troubleshooting and Maintenance
6.1
General Precautions
Daily inspection is important and will ensure safe operation. Inspection should include testing the emergency
stop and other safety devices and functions. If there is any doubt, operation must be stopped immediately and
problems be corrected before operation is resumed.
6.2
General LED Error Codes and Resolutions
1. Transmitter LED flashes RED quickly (every 0.2 seconds)
when any button is pressed:
One of the pushbuttons is jammed.
2.
Transmitter LED flashes RED slowly (every 0.5 seconds):
The transmitter memory is defective.
3.
Transmitter LED is steady RED when any button is pressed:
The transmitter batteries are low.
4.
Receiver Error LED flashes slowly (every 0.5 seconds):
The receiver memory is defective.
Note:
The receiver error LED is located on the inside of the receiver. Observe the
appropriate precautions when opening the unit.
IF A PROBLEM IS FOUND, PLEASE CONTACT THE DISTRIBUTOR FOR REPAIR.
6.3
Change of Fuses
Depress the fuse cover and turn counter-clockwise with a flat screwdriver to open up the fuse cover. Remove
the old fuse and insert a new fuse into the cover. Place fuse cover along with the fuse into the fuse holder
base. Depress the fuse cover and turn clockwise with flat screwdriver.
DC Type Relay
Board Reference:
Relay board
shown left is for
701P0080-DC
AC Type Relay
Board Reference:
Relay board
shown left is for
701P0080
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
6.3.1
6.4
OWNER’S MANUAL
Change of fuse, DC Type
Unplug the yellow fuse “F5” (20A) and replace with a new one
Ref Fuse Number
F1
F2
F3
F4
Size
.5A
.5A
10A
1.5A
Fuse Type
5 x 20 mm
5 x 20 mm
5 x 20 mm
5 x 20 mm
F5
20A
Std Double spade
Change of Frequency/Crystal
The frequency of the TeleChief® Series can be simply changed by replacing the correspondent crystal
frequency in both the transmitter and receiver. Please refer to below procedure in regards to replacing the
crystal.
1. Gently pry up the crystal unit with a flat screwdriver
2. Remove the crystal unit from the system
3. Use needle nose pliers to straighten both pins of the new crystal unit
4. Insert the new crystal unit vertically into the PC board
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TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
5. Add dot of RTV to clip and press the new crystal down into the socket, bending the pins.
Dot of RTV.
Attention: The frequency is different when
plugging the same crystal into the transmitter or
receiver.
For example:
T = 311 MHz
Frequency for transmitting is 311 MHz
R = 321.7 MHz
Frequency for receiving is 321.7 MHz
Contact your distributor for different matched crystal sets.
7.0 Function Settings
The TeleChief® Series offers the following function settings in the transmitter:
Momentary
ON-OFF
Maintained
Interlocked
By default they are set in an interlocked momentary mode. TeleChief® Series radios can be custom programmed at
the factory based on requirements and specific applications. Please contact your distributor for more information.
8.0 Specifications
8.1 General
1. Enclosure: IP65
2. Structure: Glass Fiber/Nylon
3. Operating Temperature: -45° ~ +80° C
-50° ~ +175° F
4. Relay: 10A/250VAC (AC Power);
15A/12VDC (DC Power)
5. ID Code: 32 bit (Greater than 4 Billion Unique Codes
6. Hamming distance > 4 bits
7. Static > 15KV
8. Remote ID Code Setting
9. Operating range: up to 328 ft (100 meters)
8.2 Transmitter
1. L x W x H: 4.72 x 2.17 x 1.00 in.
(120 x 55 x 25 mm)
2. Weight: 5.47 oz. (155g) (w/ batteries)
3. Uses 2 AA alkaline batteries
4. Low power indicator (LED flash red
5. Pushbutton jammed detector
6. Shock resistance
7. Output power < 4mW
8. Normal power consumption : 10 mA
9. Sleep mode consumption : < 1 µA
10. Modulation: FM
8.3 Receiver
1. L x W x H: 6.34 x 2.91 x 2.05
(161 x 74 x 52 mm)
2. Weight: 2.43 lbs. (1.1 kg) (without cable)
3. AC type: 48/110, 110/220, 220/380VAC
DC type: 12V~24VDC
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4. Sensitivity: approx. -105dBm
5. Shock resistant design
6. Four independent common lines (U/D, E/W, S/N,RO)
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Control Chief Corporation
TELECHIEF® SERIES TM2000 / TM4000 / TM6000
OWNER’S MANUAL
9.0 Receiver Mounting Diagram
Installation Questions?
Technical assistance is available from Control Chief.
Please call us at 814-362-6811 or email the service
department at prodserv@controlchief.com
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Control Chief Corporation
Control Chief Corporation
200 Williams Street
PO Box 141
Bradford, PA 16701
814-362-6811 * 1-800-233-3016 * 814-368-4133 (fax)
www.controlchief.com