Cattron-Theimeg i-Key Manual
PENDANT STATION CONTROLLER
OPERATION & MAINTENANCE MANUAL
CUSTOMER:
MODEL NUMBER:
SERIAL NUMBER:
FREQUENCY ASSIGNMENT:
ADDRESS ASSIGNMENT:
MANUAL P/N: 68C-PS REV 000 01/2001
01/2001, CATTRON-THEIMEGTM Page i
PENDANT STATION CONTROLLER
OPERATION & MAINTENANCE INSTRUCTIONS
IMPORTANT NOTICES
The security ‘i-Key’ that accompanies your Pendant Station (PS) controller has been pre-programmed
with certain system operating parameters before leaving our factory. If your PS controller is of the
Advanced Technology (AT) family that is custom built to your specification, such ‘i-Key’ parameters
will include a specific address and operating frequency. However, CATTRON-THEIMEG™strongly
advises you to check that our pre-configured address and frequency is not duplicated in other remote
control equipment located at, or around, your operating facility.
When returning an PSAT Pendant controller to CATTRON-THEIMEG™for repair, the original coded
‘i-Key’ supplied with the unit shall be returned with the unit.
When returning a PSEZ or PSCS Pendant controller to CATTRON-THEIMEG™for repair, we
recommend the coded ‘i-Key’ last used with the unit be returned with the unit.
Before returning a PSEZ or PSCS Pendant controller to CATTRON-THEIMEG™for repair, we
strongly recommend you record the operating address and frequency assigned to the controller as you
will be required to re-program these operating parameters after we return your controller. Refer to
Frequency and Address Reports in Section 5 of this manual for recording details.
When a PSEZ or PSCS Pendant controller is returned to CATTRON-THEIMEG™for repair, we make
every effort to establish the operating address and frequency assigned to your controller when it arrives
at our repair facility. Whenever such operands can be established, we will record the same on the
service documentation returned with your controller.
This equipment is firmware based. Any duplication of operating firmware without written consent of
CATTRON-THEIMEG™is prohibited. U.S. Copyright Laws protect all firmware, parts and product
listings, assembly files, and this manual.
Page ii 01/2001, CATTRON-THEIMEGTM
List of Technical Abbreviations
The following abbreviations (acronyms) are frequently used in CATTRON-THEIMEG™Radio
Remote Control Technology and may be used in this manual:
AC Alternating Current LED Light Emitting Diode
AT Advanced Technology ML Mainline
ASO Automatic Safety Override NEMA National Electrical
Manufacturer’s Association
BCH Bose-Chaudhuri-
Hocquenghem (data error
detection routines)
Ni-Cad Nickel Cadmium
CMOS Complimentary Metal Oxide
Semiconductor OPR Operate
CS Crane Specific PRC Portable Remote Control
DC Direct Current PS Pendant Station
DOC Department of
Communication (Canada) PTO Push-to-Operate
DP Dual Pressure RF Radio Frequency
EDP Electronic Data Processing RFI Radio Frequency
Interference
EEPROM Electrically Erasable
Programmable Read Only
Memory
RST ResetRelay
EMI Electro-Magnetic
Interference SP Single Pressure
EPROM Erasable Programmable
Read Only Memory SYNC Synchronization
FCC Federal Communications
Commission TP Test Point
GND Ground TS Transfer Switch
I/O Input/Output VAC Volts Alternating Current
IR Infra-red VDC Volts Direct Current
LCD Liquid Crystal Display VFD Variable Frequency Drive
01/2001, CATTRON-THEIMEGTM Page iii
Introduction
How to use this Manual.
This manual contains generic operation and maintenance procedures applicable to the entire series of
CATTRON-THEIMEG™Pendant Station (PS) Radio Remote Controllers.
If you are using our Advanced Technology (AT) family of controllers that have been customized and
pre-programmed to your exact specification, you should skip Section 5 in its entirety as the frequency
and address programming procedures contained therein do not apply to your controller.
If you are using our PSEZ or PSCS family of controllers, you should include Section 5, as you will be
required to verify/program the system address and operating frequency before using your
controller for the first time.
Page iv 01/2001, CATTRON-THEIMEGTM
Safety Summary
WARNING and CAUTION statements have been strategically placed throughout all text prior to
operating or maintenance procedures, practices or conditions considered essential to the protection of
personnel (WARNING), or equipment and property (CAUTION). A WARNING and CAUTION will
apply each time the related step is repeated. Before starting any task, the WARNINGS or CAUTIONS
included in the text for the task shall be reviewed and understood. All WARNINGS and CAUTIONS
appearing in this manual are included below.
WARNINGS.
WARNINGS:
ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR
INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE
A BRAKE INSTALLED.
THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE
CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR
FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY
OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE
MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY
RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND
DAMAGE TO EQUIPMENT.
WARNINGS:
MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT,
AROUND, OR NEARBY YOUR OPERATING FACILITY.
THEREFORE, BEFORE INSERTING AN ‘i-Key’ INTO A PS
CONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-Key’
IS SELECTED FOR THE DESIRED EQUIPMENT TO BE OPERATED.
IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES
CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS
PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER,
OTHER EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR
FACILITY MAY BECOME OPERATIONAL.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY
RESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH IN
TURN COULD RESULT IN SERIOUS INJURY OR DEATH TO
PERSONNEL AND DAMAGE TO EQUIPMENT.
01/2001, CATTRON-THEIMEGTM Page v
Safety Summary, continued
WARNINGS, continued.
WARNING:
DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT
REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED
EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL
REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER
POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST
TIME A PUSHBUTTON IS DEPRESSED. CONSEQUENTLY, SPECIAL
CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS
EQUIPPED WITH A PARKING BRAKE THAT IS CONFIGURED TO
ENGAGE WHEN THE MAINLINE CONTACTOR DE-ENERGIZES.
TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU
SHOULD IMMEDIATELY PRESS THE RED ‘STOP’ BUTTON ON YOUR
REMOTE CONTROLLER AFTER COMPLETION OF CRANE
OPERATIONS. SUCH ACTION WILL INSURE THE PARKING BRAKE
(IF EQUIPPED AND CONFIGURED AS ABOVE) IS SET, PREVENTING
UNINTENTIONAL MOVEMENT OF THE CRANE OR TRACKED
MACHINE.
FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
WARNING:
ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN
AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN
ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM
INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS.
FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS
INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
Page vi 01/2001, CATTRON-THEIMEGTM
Safety Summary, continued
WARNINGS, continued.
WARNING:
FAILURE TO PROPERLY SELECT FREQUENCY AND ADDRESS MAY
RESULT IN THE UNINTENTIONAL OPERATION OF OTHER
MACHINERY AND COULD RESULT IN DEATH OR SERIOUS INJURY
TO PERSONNEL. DO NOT DUPLICATE ADDRESS ASSIGNMENT.
WARNING:
CATTRON-THEIMEG™PSEZ AND PSCS PORTABLE REMOTE
CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE
DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED
FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors,
fire suppression etc.).
CONTACT CATTRON-THEIMEG™FACTORY FOR INFORMATION
REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS.
SHOULD CATTRON-THEIMEG™PSCS AND PSEZ PORTABLE REMOTE
CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO
INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE
TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY
RESULT.
IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™WILL
NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT
OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER
CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM.
01/2001, CATTRON-THEIMEGTM Page vii
Safety Summary, continued
CAUTIONS.
CAUTION:
All PS Controller internal circuit boards are sensitive to electrostatic
discharge. Consequently, all maintenance procedures involving disassembly
and assembly of these controllers shall be carried out by qualified technicians
using anti-static mats and personal grounding straps. Failure to comply with
this caution may result in equipment damage and void our warranty.
CAUTION:
CATTRON-THEIMEG™Battery Chargers and External Charging Units are
designed for use with CATTRON-THEIMEG™Ni-Cad Battery packs only.
failure to comply with this caution may result in equipment and/or battery
damage and will void our warranty.
CAUTIONS:
CATTRON-THEIMEG™Battery Adapters are designed for use with non re-
chargeable ‘AAA’ size Alkaline Batteries only. Carbon/Zinc, Lithium, or Ni-
Cad Batteries are not to be used with this adapter. Damage to batteries will
occur if this adapter is used for battery charging.
CAUTION:
All circuit boards are sensitive to electrostatic discharge. Use an anti-static
mat and personal grounding strap (wrist) for all maintenance procedures
involving disassembly and assembly of PS Controllers. Failure to comply with
this caution may result in equipment damage and will void our warranty.
CAUTION:
All control functions will be stopped if the PS Controller is used or left standing
in an upright position during heavy rain, or in hostile environments where
water could fill the top of the controller and cover the ‘i-Key’. To resume
control functions, simply invert and shake the controller to remove excess
water. There is no need to remove the ‘i-Key’. Ideally, to prevent such
occurences in wet weather and water spray environments, the controller should
(1) never be left standing upright, (2) be carried by the shoulder strap, and (3)
operated in a near horizontal position.
Page viii 01/2001, CATTRON-THEIMEGTM
Safety Summary, continued
GENERAL.
The following are general safety precautions that are not related to any specific procedure and therefore
do not appear elsewhere in this manual. These are general safety precautions and instructions that
people must understand and apply during many phases of operation and maintenance to ensure personal
safety and health and the protection of your company property.
KEEP AWAY FROM LIVE CIRCUITS. Maintenance personnel must observe all safety
requirements at all times. Do not replace components or make adjustments inside the equipment with
the electrical supply turned on. Under certain conditions, danger may exist even when the power control
is in the off position due to charges retained by capacitors. To avoid injuries, always remove power,
discharge and ground a circuit before touching it. Adhere to all lock out/tag requirements.
DO NOT SERVICE OR ADJUST ALONE. Do not attempt internal service or adjustment of
equipment unless another person capable of rendering aid and resuscitation is present.
FINGER RINGS/JEWELRY. Finger rings have caused many serious injuries. Remove rings,
watches and other metallic objects that may cause shock or burn hazards.
SOLDERING/DE-SOLDERING. Avoid breathing fumes generated by soldering/de-soldering.
Perform all operations in a ventilated area. Eye protection is required.
CLEANING SOLVENTS. Some cleaners and solvents have adverse effects on skin, eyes, respiratory
tract and internal organs. These adverse effects range from discomfort to serious injury and death,
depending on the material and degree of exposure. Observe manufacturers’ warning labels and contact
your immediate supervisor if in any doubt.
Remember…. the person now reading these instructions
is primarily responsible for his or her own health and
safety.
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