TireHandler Radio Remote System

Transcription

1 Manual Part # TireHandler Radio Remote System Revised: August 15, 2016 IOWA MOLD TOOLING CO., INC. PO Box 189 Garner, IA Tel: FAX: Website: Copyright 2016 Iowa Mold Tooling Co., Inc. All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Iowa Mold Tooling Co., Inc. Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company. i

2 Contents SAFETY PRECAUTIONS Safety Precautions... 2 SECTION 1: List of Equipment 1 SECTION 2: Radio Transmitter 3 Transmitter Switch and LED Description... 4 Transmitter Battery Installation... 5 Transmitter Operation... 6 Associate Mode... 7 Transmitter Adjustments (Adjust Mode)... 8 Transmitter Configuration Details SECTION 3: Receiver 13 Hardware Configuration Details Safety Link Receiver Indicator Lights Receiver Channel Configuration Cable Wiring Information Receiver Mounting SECTION 4: Specifications 19 Specifications Transmitter Output Current De-rating Curve SECTION 5: Troubleshooting 23 Receiver Troubleshooting Guide i

3 Safety Precautions Read and follow all instructions. Failure to abide by Safety Precautions may result in equipment failure, loss of authority to operate the equipment, and personal injury. Use and maintain proper wiring. Follow equipment manufacturer instructions. Improper, loose, and frayed wiring can cause system failure, equipment damage, and intermittent operation. Changes or modifications made to equipment not expressly approved by the manufacturer will void the warranty. Owner/operators of the equipment must abide by all applicable Federal, State, and Local laws concerning installation and operation of the equipment. Failure to comply could result in penalties and could void user authority to operate the equipment. Make sure that the machinery and surrounding area is clear before operating. Do not activate the remote control system until certain that it is safe to do so. Turn off the transmitter remote and remove power from the receiver before attempting any maintenance. This will prevent accidental operation of the controlled machinery. Power is removed from the Receiver by detaching the 12-pin cable from the receiver connector P1 and P2, or by removing the source power from the circuit. Use a damp cloth to keep units clean. Remove mud, concrete, dirt, etc. after use to prevent obstructing or clogging the buttons, levers, wiring, and switches. Do not intentionally allow liquid to enter the transmitter or receiver enclosures. Do not use high pressure equipment to clean the transmitter remote or receiver. Operate and store units only within the specified operation and storage temperatures defined in this document. NOTE: Disconnect the radio receiver before welding on the body or chassis, or any component sitting on work bench or in vise. Failure to disconnect the receiver may result in destruction of or damage to the receiver. ii

4 RoHS Compliance Statement This system complies with the requirements of Restriction of Hazardous Substances (RoHS/WEEE) Specification based on in-house practice and declaration of compliance from the vendors. For additional information concerning RoHS compliance, please contact IMT. Iowa Mold Tooling Co., Inc. Highway 18 East Garner, IA Phone: Fax: This product may contain material that may be hazardous to human health and the environment. In compliance with EU Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE): Do not dispose of the product as unsorted municipal waste. This product should be recycled in accordance with local regulations. Contact local authorities for detailed information. This product may be returnable to the distributor for recycling. Contact your distributor for details. FCC Statements Two Part Warning 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 Unauthorized Modification NOTICE: The manufacturer is not responsible for any unauthorized modifications to this equipment made by the user. Such modifications could void the user s authority to operate the equipment (b) Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Industry Canada Statement This device complies with Canadian RSS-210. The installer of this radio equipment must ensure that the antenna is located or pointed such that it does not emit RF field in excess of Health Canada limits for the general population; consult Safety Code 6, obtainable from Health Canada s website iii

5 SECTION 1: List of Equipment 2.4 GHz, 4-single axis joysticks, 3-toggles, 1-STOP, Umbilical Connector GHz, internal antenna, 18-channel

6 TRANSMITTER RECEIVER QTY PART NUMBER DESCRIPTION Toggle Switch E-Stop Switch Joystick Transmitter, 2.4 GHz, Black, Fully Proportional Single Axis Joy Sticks Receiver, 2.4 GHz, Fully Proportional 18 FET Ch, 2 Analog Outputs, Internal Antenna PARTS Decal Set for Transmitter Cap & Chain Asm for Radio & Battery Elimination Cable Cover, Battery Compartment Magnet, Disc Faceplate for Transmitter Battery and Radio Elimination Cable 2

7 SECTION 2: Radio Transmitter Transmitter Switch and LED Description... 4 Transmitter Battery Installation... 5 Transmitter Operation... 6 Associate Mode... 7 Transmitter Adjustments (Adjust Mode)... 8 Transmitter Configuration Details

8 Transmitter Switch and LED Description Switch and LED Description Switch/LED Function Switch Type/Description S1+ ON S1- OFF S6+ FALLBACK ARMS FORWARD S6- FALLBACK ARMS REVERSE S7+ CLAMP RELEASE ENABLE S7- CLAMP RELEASE ENABLE 3 POSITION MOMENTARY TOGGLE 3 POSITION MOMENTARY TOGGLE 3 POSITION MOMENTARY TOGGLE ST STOP PUSH/TWIST RELEASE BUTTON JS1Y+ PAD ROTATE CW SINGLE AXIS JOYSTICK JS1Y- PAD ROTATE CCW SINGLE AXIS JOYSTICK JS2Y+ SIDE SHIFT LEFT SINGLE AXIS JOYSTICK JS2Y- SIDE SHIFT RIGHT SINGLE AXIS JOYSTICK JS3+ BODY ROTATE CW SINGLE AXIS JOYSTICK JS3- BODY ROTATE CCW SINGLE AXIS JOYSTICK JS4+ CLAMP SINGLE AXIS JOYSTICK JS4- CLAMP RELEASE SINGLE AXIS JOYSTICK LED 1 TX (Green) TRANSMIT LED 2 RX (Amber) RECEIVE LED 3 BATTERY (Amber) BATTERY INDICATION LED 4 ERROR (Red) ERROR INDICATION Transmitter Operational LED Diagnostic Information LED Information Condition Color TX blinking, short Handheld is transmitting Green TX blinking, long Switch active on handheld Amber RX blinking (indication of RF signal integrity) Base unit message received Amber BATT slow blinking Low battery Amber ERR 1 ERR 2 1 LED s 1 and 3 will blink alternately with 2 and 4 2 LED s 1 and 2 will blink alternately with 3 and 4 Switch fault at power-up Machine STOP depressed at power-up Red 4

9 Transmitter Battery Installation This handheld unit is powered by four size AA batteries. When installing batteries, be sure to observe proper polarity as marked on the inside of the compartment to avoid damaging the unit. To replace or install batteries in the handheld: 1. Loosen the four captive battery compartment cover screws on the rear of the remote and lift the cover from the handheld. 2. Install (or replace with) four (4) fresh size AA batteries. Observe the proper polarity by positioning the batteries as shown in Figure Replace the compartment cover and tighten the four screws. These screws should not be overtightened, but they must be tight enough to assure the gasket provides a proper environmental seal. NOTE: Be sure to observe proper polarity when placing batteries in the transmitter battery compartment. Transmitter Battery Installation NOTE: Cover screws must be tightened enough to assure the sealing gasket is compressed. Do not over-tighten screws. 5

10 Transmitter Operation Turn ON the Unit This remote is powered ON by releasing (pull UP) the large red STOP button and then activating the ON toggle switch (S1+). Turn OFF the Unit The remote is turned OFF by pushing the large red STOP button IN or by activating the OFF toggle switch (S1-) and holding for 1 second. This unit is programmed in software to power down after 4 minutes of inactivity. If the unit powers down due to inactivity, use the ON switch to reactivate the unit. Proportional Control The single-axis proportional joysticks are used for proportional control. Joysticks will have a Minimum from center position and joystick control is programmable using the configuration set-up feature of the Transmitter Adjustments (Adjust Mode) section. Toggle Switches S1 through S7 Toggle switches S1, S6 and S7 are three position momentary. S1 turns on the handheld remote by pushing the switch forward. S7 in either direction enables the Clamp release joystick function. Label Control Designations for Joysticks and Switches 6

11 Associate Mode Associate Mode is used to establish the communications link between a remote and base unit on a 1-to-1 association basis. To associate there must be a clear line of sight between the handheld and the base, and both units must be OFF (powered down). Note: The remote is turned off by pushing the oversized mushroom STOP button. The SmaRT base unit is safely powered down by disconnecting P1 and P2 or by removing/turning-off the power source from the unit. NOTE: Be sure to remove power from the receiver by disconnecting P1 and P2 before attempting to enter associate mode. Do not connect P2 while in associate mode. Reconnect only after associate mode is complete and all power is OFF. Associate Mode To Associate 1. Stand near to the base unit with the remote OFF and power removed (disconnect P1 and P2 or turn the source power OFF) from the base unit. 2. Release the STOP button on the handheld by pulling up. 3. Push and hold S6 UP and then immediately push and hold S1 UP (ON). All four LEDs light solid. 4. Observe the LEDs. When RX goes OFF, power up the base unit. When the RX LED blinks, release S6 and S1. A successful Association is indicated when LEDs TX and RX are rapidly blinking while the Battery and Warning LEDs are unlit. 7

12 Transmitter Adjustments (Adjust Mode) Fundamentals Adjust Mode is entered by holding S1 and S7 up for four (4) seconds while the controller is on (ON following the initial release of the STOP button and activation of S1 ON). Adjust Mode is indicated when holding S1 and S7 up for 4 seconds, the bottom three base unit LEDS OUT, IN, and ERR begin flashing. Release S1 and S7. Operate any of the function toggles either UP or DOWN and hold. Continue to hold the function switch throughout the entire Calibrate procedure. The base unit ERR LED (bottom) will light solid indicating MIN calibration mode. LEDs IN and OUT will go out (extinguish). When the desired value is achieved, move S1 DOWN to the store the MIN value. The base unit OUT LED will activate. Release all switches. The system switches to MAX adjustment mode. While the base unit ERR LED goes out and the IN LED lights solid indicating MAX calibration mode. Engage and hold a function switch. When the desired value is achieved, move S1 DOWN to store the MAX value. The OUT LED will activate. Release all switches. The system returns to minimum calibration. Adjust Mode is exited by pressing the STOP button or by waiting for 10 seconds without operating any of the function switches on the unit. Adjust Mode timeout defaults to a 10 second window of opportunity, where the unit returns to normal operating mode if none of the function switches are operated within the 10 second window. The timer resets to 10 seconds each time a switch is operated while in Adjustment Mode. After a Joystick has been selected to adjust, that Joystick can be deselected by moving it and letting it return to the neutral position without saving a value. System defaults to Minimum adjust upon entering Adjust Mode. Default Settings: o o 15% Duty Cycle for Minimum; 65% Duty Cycle for Maximum Command Minimum and Maximum Command may be adjusted for each direction of each joystick. Joysticks JS1Y, JS2Y, JS3Y and JS4Y are individually adjusted for Minimum and Maximum Command. Adjustment procedure is the same for each. 8

13 Label Control Designations for Joysticks and Switches Handheld Adjustment Procedures The following procedures use S6, S7, and the proportional joysticks of the Remote controller JS1Y, JS2Y, JS3Y and JS4Y (all are single axis) that may need to be adjusted for use. Adjustments can be made for each direction of a joystick (forward and reverse). NOTE: In all instances of adjustment or setting the Minimum and Maximum Command the handheld must be active with the STOP button in the UP position and the Handheld ON. NOTE: The default mode when entering Adjust Mode is Minimum. The system can be toggled between Minimum and Maximum Command modes by operating S1 UP. Adjust Mode Minimum is the magnitude for the starting point of proportional control when the joystick is first sensed as being operated. It is the jump to amount. It is intended to bypass the lower region of the valve curve where the electrical signal does not produce any hydraulic response. Typically in well-designed hydraulic systems, the minimum will vary between 20% and 40% duty cycle for open loop control systems. Electrical signals below this value will not shift the valve sufficiently to produce any noticeable movement or machine action. Any joystick stroke which varies the system output below the minimum point is effectively wasted. 9

14 Constraints and Boundaries The Minimum sets the minimum boundary for Maximum Command and also forces the Maximum Command to be bumped upwards if required (based on the Minimum). Note also that as 127 counts is 100% duty cycle, each count equals 0.79% duty cycle (1/127). Sixteen counts will be approximately 12.6% duty cycle. Therefore, the tightest duty cycle span for the full joystick stroke is 12.6% duty cycle. The largest span is the full 0% to 100% span of duty cycle. Optimum Adjustment Level The optimum adjustment level is to have the system output set to be just at the amount of signal to begin hydraulic response when the joystick is at the beginning of its stroke (just barely operated). Furthermore, it is desirable to have the system output be at the amount where the valve has produced its full response when the joystick reaches its full stroke. In this way, they are matched as the full stroke of the joystick is spread across the full breath of the operational span of the valve. As an alternative, in the event that hydraulic actuating is not needed or desired, values can be set according to the base unit. Each joystick position (+Y Axis, and Y Axis) for J1, J2, J3 and J4 are individually adjusted and the value saved in the same manner. 1. Pull up the Machine Stop button. 2. Activate the handheld remote by pushing S1 to ON. 3. Enter Adjust Mode by holding S1 and S7 UP until the base unit reads CAL. 4. Release S1 and S7. The base unit should indicate that you are now in Adjust Mode, default Minimum Adjust. The unit will remain in Adjust Mode for 10 seconds of inactivity. If there is no switch or joystick activity within the 10 second window of opportunity, the unit returns to normal operating mode. 5. Push S1 UP (ON) while all Joysticks are in the neutral position to toggle between Maximum and Minimum Adjust Mode. 6. Select a joystick command function by moving a joystick to the maximum position corresponding to that function, then release the joystick. 7. Push S1 UP (ON) while maintaining the joystick position to store the changed value. 8. After saving the value, the unit automatically toggles between Adjustment Modes (Min/Max Mode). 9. Repeat Steps 5 through 8 for each Joystick function. 10

15 Function Default Settings The values expressed in the following table are typical and may be adjusted depending on specific circumstances. Transmitter Configuration Details Clamp Release (JS4Y ) requires S7 to operate in either direction S1+ turns the handheld ON, S1- turns the handheld OFF 11

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17 SECTION 3: Receiver Hardware Configuration Details Safety Link Receiver Indicator Lights Receiver Channel Configuration Cable Wiring Information Receiver Mounting

18 Hardware Configuration Details Receiver Hardware Configuration Details Required Fields Interface Description Notes Control Power 7-28VDC 12VDC supply expected: 15A MAX Number of I/O 18 Digital ON/OFF, PWM: CURRENT COMP Output Composition Antenna Option Digital Interface Solid State FET INTERNAL ON/OFF Proportional 1.2A Max Discrete 4A MAX HAWE: D77002-en Coil 250 Hz / 6.7Ω Set all Minimums to 16% Set all Gains to 65% Safety Link Receiver Safety Link X ENABLED Base Unit Safety Link DISABLED When any of the following occurs: When any of the following occurs: Machine Stop is pressed Machine Stop is pressed HH unit goes out of range HH unit goes out of range HH unit deactivates due to loss of power, Inactivity timeout, or deliberate deactivation (off switch) Then, all latched outputs unlatch and all momentary outputs that are active deactivate. Upon activation of the HH, no outputs are allowed to be activated until all switches (unless masked) are first centered or returned to their neutral state. HH unit deactivates due to loss of power, Inactivity timeout, or deliberate deactivation (off switch) Then all latched outputs remain latched but all momentary commands that are active deactivate. Note: If HH unit is powered on and a momentary command that was deactivated due to range, is still active when the HH returns in range the output will immediately be active again. 14

19 Receiver Indicator Lights 15

20 Receiver Channel Configuration Receiver Channel Configuration Channel # Type Output Style Channel Logic M1 AXIAL FORWARD M2 AXIAL REVERSE M3 SIDE SHIFT RIGHT M4 SIDE SHIFT LEFT M5 CLAMP RELEASE M6 CLAMP M7 BODY ROTATE CCW M8 BODY ROTATE CW M9 FALLBACK ARMS REVERSE M10 FALLBACK ARMS FORWARD M11 UNUSED M12 CLAMP ENABLE M13 Hour Meter M14-15 UNUSED M16 LINK/STOP M17-M18 UNUSED PWM Momentary JS1Y+ PWM Momentary JS1Y- PWM Momentary JS2Y- PWM Momentary JS2Y+ PWM Momentary JS4Y- AND M12 PWM Momentary JS4Y+ PWM Momentary JS3Y- PWM Momentary JS3Y+ LEVEL Momentary S6 LEVEL Momentary S6+ LEVEL Momentary S7+ OR S7 LEVEL LEVEL Momentary Latched ON Latched OFF With M1, M2, M3, M4, M5, M6, M7 or M8 With system RF LINK Loss of LINK or STOP command 16

21 Cable Wiring Information Receiver Wiring Table Receiver P1 and P2 Pinout Pin Signal Name Pin Signal Name P1:1 +VDC P2:1 M5: CLAMP RELEASE P1:2 M17: UNUSED P2:2 M6: CLAMP P1:3 M9: FALLBACK ARMS REV P2:3 M7: BODY ROTATE CCW P1:4 M10: FALLBACK ARMS FWD P2:4 M8: BODY ROTATE CW P1:5 M11: UNUSED P2:5 CAN H: RADIO ELIMINATION CABLE P1:6 M12: CLAMP ENABLE P2:6 UMBILICAL POWER: RADIO ELIMINATION P1:7 M13: HOUR METER P2:7 +VDC P1:8 M14: UNUSED P2:8 CAN L: RADIO ELIMINATION CABLE P1:9 M15: UNUSED P2:9 M1: AXIAL FORWARD P1:10 M16: LINK/STOP P2:10 M2: AXIAL REVERSE P1:11 M18: UNUSED P2:11 M3: SIDE SHIFT RIGHT P1:12 -VDC P2:12 M4: SIDE SHIFT LEFT 17

22 Receiver Mounting Receiver Mounting Dimensions 18

23 SECTION 4: Specifications Specifications Transmitter Output Current De-rating Curve

24 Specifications Receiver Specifications Item Description Power V in Vin +1.6V to +3.2VDC Batteries Four (4) AA Battery Life 175 to 200 hours (ADJUSTED) Low V Shutdown 1.6VDC Auto-shutdown 4 min. of button inactivity Environment Operating Temp -20 C to 55 C (-4 F to 131 F) -40 C to 55 C (-40 F to 131 F) Humidity 0 to 100% Radio Frequency MHz RF Power 2mW License License free Modulation DSSS Antenna Internal Enclosure Dimensions mm: 230.6x133.9x146.9 inch: 9.1 x 5.3 x 5.8 Total Weight 3 lbs Durability High Impact Glass Filled Polymer case Faceplate Aluminum or Polycarbonate Indicators (5) LEDs TX Blinking transmitting, no switch active Solid transmitting, switch active RX Blinking receiving, no output of interest active Solid receiving, output of interest active ERR Indicates error with handheld remote BATT Low battery indication Control Switches Toggle 3 momentary (4) single axis joysticks Proportional controls Mushroom Oversized Machine Stop 20

25 Transmitter Specifications Item Description Power V in Vin +1.6V to +3.2VDC Radio Frequency MHz 2.4GHz RF Power License Modulation Antenna 2mW License free DSSS Internal Environment Operating Temp See Derating Curve chart below for details Storage Temp Humidity 0 to 100% Vibration/Shock -40 C to 85 C (-40 F to 185 F) IEC Hz to 1.0g peak acceleration 10.0g peak shock acceleration Indicators (11) +V1 OK when active solid +V2 OK when active solid +V3 OK when active solid 1 (Health) OK when active blinking 2 (RF TX) Blinks when active 3 (RF RX) Solid when receiving 4 (CAN TX) Blinks when active 5 (CAN RX) Solid when active 6 (OUT) Solid when active 7 (IN) Solid when active 8 (Error) Solid when active Enclosure Dimensions 119mm x 133mm x 36mm (5.24 x 4.69 x 1.42 ) Durability Mounting Holes OUTPUTS Eighteen FET Open Drain Output Current High Impact Polymer 7.4mm (0.29 ) dia. 102mm center-to-center (4 center-to-center) 2A per channel 15A Max. 55º C 21

26 Transmitter Output Current De-rating Curve 22

27 SECTION 5: Troubleshooting Receiver Troubleshooting Guide

28 Receiver Troubleshooting Guide Troubleshooting Indication Power LED (+V1,+ V2, +V3) not active Health LED steady ON TX/RX not active CTX/CRX not active Out LED not active Error LED active In LED not active when expected Suggestions Is +VDC input power present? Check input power polarity. Indicates an internal component failure. Check for obstructions preventing line-of-sight transmission. Check that the handheld remote is active. Re-associate the handheld remote to the base unit. Check CAN connection. Check that the handheld LEDs are active when the appropriate buttons are pushed. Check the outputs for loose wiring, etc. Over-temperature channel indication. Over-current channel indication. Error condition exists. Active channel current consumption less than 1A typical. (This is not a problem in cases where less than 1A draw is a normal condition.) Check that the input signal is referenced to P1:12. 24

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30 Iowa Mold Tooling Co., Inc. 26