BWI Eagle AIR-EAGLE XLT PLUS 497-5100-CHx-DC Manual

PRODUCT INFORMATION
BULLETIN
105 Bonnie Drive
Butler, PA 16002
724-283-4681
724-283-5939 (fax)
www.bwieagle.com
AIR-EAGLE®XLT PLUS
REMOTE STOP SWITCH
900 MHz RF Transmitter
MODEL 497-5100-CHx-DC
DESCRIPTION
The AIR-EAGLE XLT PLUS RADIO REMOTE STOP SWITCH IS a machine
mounted R.F. REMOTE STOP SWITCH designed to transmit a unique
STOP signal to the AIR-EAGLE XLT PLUS RECEIVER. This system is
designed to monitor and protect up to 8 dozer operators operating on a
coal stock pile(s). The large center mounted STOP switch allows easy
access by the operator. The unit includes a log-in/log-out button for
system activation and raw coal/clean coal receiver selection. The log-in
relay channel is user selectable and must be designated for each
transmitter (see DOZER LOG-IN CHANNEL & RECEIVER LOG-IN
OPTIONS SELECTION table). Dual color LED's provide a visual
display of system status, linked receiver, and signal strength.
SYSTEM OVERVIEW
Once operator has reached the hazardous area he must log-in to Base
Receiver 1 or 2 to alert thesystem to his presence and allow monitoring to
begin. LEDindicators guidethis process and providevisual indication of
various statuses. If at any time the operator pushes the STOP button, the
stop signal is immediately sent to the receiver to shut down underground
feeders and alert emergency personnel. When the operator wishes to
leave the area, prior to exceeding the range of the transmitter, he must
push the LOG-OUT button to avoid having an unnecessary shut-down
signal sent to the receiver.
Note –If the RF link is broken or DC power is lost, this will also
initiate a stop condition at the remote receiver.
LOGGING IN & OUT TO THE RECEIVER
TO LOG IN
By default, the transmitter is set to log in to
Receiver #1 only. By using the dip switches on
SEL1, you can change the set-up to have the
transmitter login to Receiver #2 only, or give the
user the ability to select which receiver to log into.
(See RECEIVER LOG-IN OPTIONS) When the
transmitter is set up to give a choice of receivers to
log into (SW6 CLOSED), use the following
procedure:
Press the LOG-IN BUTTON momentarily to log
into Receiver #1. The RX.1 LED will blink for 3
seconds then illuminate solid when link
established. If the LOG-IN BUTTON is depressed
a second time during this 3 second period, the unit
will attempt to log in to Receiver #2 instead and
the RX.2 LED will blink for 3 seconds then
illuminate solid when link established
TO SWITCH
RECEIVERS
(SW6 CLOSED)
Tap the LOG-IN BUTTON to switch between “raw
coal” and “clean coal” receivers. LED for new
receiver will blink then illuminate solid with link
established. Old receiverwill logout and
extinguish LED
TO LOG OUT
Press and hold the LOG-INBUTTON for 3-4
seconds. Current receiver’s LED will blink until log
out occurs, then extinguish. LED will not go out
until the unit has received verification that the
logout process was successful.
CONTROLS & INDICATORS
STOP
ACTUATOR
Latching pushbuttontransmits a unique code
continuously to the remote receiver until the
operator resets the pushbutton.
LOG-IN/LOG-OUT
BUTTON
A momentary pushbutton used to set
which receiver the transmitter is to
link with and alert the systemthat the
user is entering or leaving the
hazardous location
PWR/SIG/TX
LED
Dual color LED usedto indicate power (when not
logged in) and signalstrength (when logged in)
Solid Green
Indicates PowerOn (when not logged in)
Indicates High Signal Strength (when logged in)
Blinking Green
Indicates Medium SignalStrength (when logged in)
Blinking Red
Indicates LowSignal Strength (when logged in)
Solid Red
Indicates STOP button depressed (when logged in)
RECEIVER
LEDs
Green LEDs indicate which receiver the unit is
logged into
RX.1 - On solid
Indicates logged into receiver #1
RX. 2 –On solid
Indicates logged into receiver #2
RX1 or RX2 -
Blinking
Indicates unit is switching receivers

AIR-EAGLE®XLT PLUS
REMOTE STOP SWITCH
900 MHz RF Transmitter
MODEL 497-5100-CHx-DC
INSTALLATION
1. Mounttransmitter in cab of dozer where operator will have
easy access to the STOPbutton and can see LEDs.
2. Select Dozer Log-In Channel Number and Receiver Log-In
Options
3. Install external antenna on vehicle roofat least 3 feet from
any other antenna and connectthe antenna’s coax plug
onto the TNC connector on the side of the transmitter.
4. A ten foot 2-conductor pigtail has been provided for DC
power. DCpower should be wired directly to the dozer
battery!!
(Black = -9-36VDC/ Red = +9-36VDC) Note! Be careful to
observe polarity.
5. Make sure that the base receivers and/or repeaters are
properly installed and powered up prior to attempting to
“Log-In”
DOZER LOG-IN CHANNEL &
RECEIVER LOG-IN OPTIONS SELECTION
TERMINAL STRIP WIRING INFORMATION
Note -This unit has been pre-wired at the factory –the following
information is for reference only.
TERMINAL STRIP WIRING (TER1)
Terminal 1
Negative (-) 9-36VDC INPUT
Terminal 2
Positive (+) 9-36VDC INPUT
Terminal 3
Log-In Button (N/O)
Terminal 4
Log-In Button (Common)
Terminal 5
Stop Button (N/O)
Terminal 6
Stop Button (Common)
Terminal 7
Not Used
Terminal 8
Not Used
Terminal 9
Ch.1 Relay (N/O)
Terminal 10
Ch. 1 Relay (Common)
Terminal 11
Ch. 1 Relay (N/C)
Terminal 12
Ch.2 Relay (N/O)
Terminal 13
Ch. 2 Relay (Common)
Terminal 14
Ch. 2 Relay (N/C)
Terminal 15
N/O Relay 3
Terminal 16
C Relay 3
Terminal 17
N/C Relay 3
Terminal 18
Not Used
SPECIFICATIONS
Power Supply
External 9-36VDC from mobile vehicle
Maximum Number of
Transmitters
8 Transmitters to 1 Receiver
Transmit Frequency
900 MHz - 74 Channel Auto-Select
RF Output Power
1 Watt
Transmit Range
Approximately 4500 feet
USING SEL1 DIP SWITCHES:
DOZER LOG-IN CHANNEL NUMBER
Dozer
Channel
SW1
SW2
SW3
CH.1 (default)
OPEN
OPEN
OPEN
CH.2
CLOSED
OPEN
OPEN
CH.3
OPEN
CLOSED
OPEN
CH.4
CLOSED
CLOSED
OPEN
CH.5
OPEN
OPEN
CLOSED
CH.6
CLOSED
OPEN
CLOSED
CH.7
OPEN
CLOSED
CLOSED
CH.8
CLOSED
CLOSED
CLOSED
RECEIVER LOG-IN OPTIONS
Receiver Selection
SW5
SW6
RECEIVER 1 ONLY (default)
OPEN
OPEN
RECEIVER 2 ONLY
CLOSED
NOT USED
EITHER RECEIVER
OPEN
CLOSED
Note –SW4 is not used and should be left open

AIR-EAGLE®XLT PLUS
REMOTE STOP SWITCH
900 MHz RF Transmitter
MODEL 497-5100-CHx-DC
APPROVALS
United States (FCC)
MCQ-XBPSX
Canada (IC)
1846A-XBPSX
DIMENSIONS
LIMITED WARRANTY STATEMENT
BWI Eagle Inc. warrants theAir-Eagle Remote Control System, if properly
used and installed, will be free from defects inmaterial and workmanship
for a period of 1 year after date of purchase. Said warranty to includethe
repair or replacement of defective equipment. This warranty does not
cover damage due to external causes, including accident, problems with
electrical power, usage not in accordance with product instructions,
misuse, neglect, alteration, repair,improperinstallation, or improper
testing. This limited warranty, andany implied warranties that may exist
under state law, apply only to the original purchaser of the equipment, and
last only for as long as such purchaser continues to own the equipment.
This warranty replaces all other warranties, express or implied including,
but not limited to, the implied warranties or merchantability and fitnessfor
a particular purpose. BWI Eaglemakes noexpress warranties beyond
thosestated here. BWI disclaims without limitation, implied warranties of
merchantability and fitness for a particular purpose. Some jurisdictions do
not allowthe exclusion of implied warranties so this limitation may not
apply to you. To obtain warranty service, contact BWI Eagle for a return
material authorization. When returning equipment to BWI Eagle, the
customer assumes the risk of damage or loss duringshipping and is
responsible for the shipping costs incurred.
DOCUMENT DATE: 1/30/20 / PRODUCT REV.6
105 Bonnie Drive
Butler, PA 16002
[phone]
Fax [phone]
www.bwieagle.com
Top View
Side View
5.50 "
6.30"
STOPCH1
Power Input cable
STOP
PUSHBUTTON

Air-Eagle XLT Plus, Dozer Stop Switch System
Installation Notes
Dozer E-Stop Placement
Dozer components:
1) Dozer stop switch transmitter (Model 497-5100-CHx-DC)
2) Magnetic roof-mount antenna (Model 49-2102)
The transmitter should be located in the cab of the vehicle, mount so the operator can see the visual status LED’s
and be able to reach and depress the STOP SWITCH if needed.
A two-conductor cable is supplied to power the dozer transmitter. The black lead is always negative.
Depending on the cable/ plug supplied, the white wire (or red) will go directly to the vehicle battery power. The
voltage range is 9VDC up to 36VDC.
If using, connect tilt switch inputs to the proper terminals on the input terminal strip.
Next, mount the magnetic roof-mount antenna on the roof of the dozer. Always try to find a location as far as
possible (at least 3 feet) from any other antennas that may be on the roof of the dozer. Feed the cable into the
cab of the dozer and attach by screwing the “TNC” connector to the “RF” connector on the right side of the
transmitter.
Receiver & Optional Repeater Placement –See Placement Per Your Configuration Below:
Configuration #1 - If your PLC I/O controls are located at the stock pile, the receiver is to be mounted
there on the stacking tubes.
Receiver components:
1) 16 Relay receiver in NEMA 4 enclosure (Model # 497-5280)
2) TNC “T” adapter (Model 49-5001)
3) Two Coax cables with connectors (Model 49-4000-XX)
4) Two Omni directional antennas with mounting hardware (Model 49-3101)
Locate a 120VAC source for powering the receiver.
Mount two omni antennas on the rail or floor of the cat walk. It is recommended to have the antennas mounted
on opposite corners of the cat walk, pointing “down”, below the cat walk floor, at the dozer stock pile to get a
good 360-degree reception pattern around the stacking tube(s).
Attach coax cables to each antenna then connect to the receiver via the “T” adapter which connects to the TNC
antenna connector on the side of the receiver.

Configuration #2 - If your PLC I/O controls are located in a separate control room, a repeater is to be
mounted at the stock pile and the receiver is to be located at the control room
Repeater components:
1) Repeater in NEMA 4 enclosure (Model 497-4500-120VAC)
2) TNC “T” adapter, (Model 49-5001)
3) Two Coax cables with connectors (Model 49-4000-XX)
4) Two Omni directional antennas with mounting hardware (Model 49-3101)
Locate a 120VAC source for powering the repeater.
Mount two omni antennas on the rail or floor of the cat walk. It is recommended to have the antennas mounted
on opposite corners of the cat walk, pointing “down”, below the cat walk floor, at the dozer stock pile to get a
good 360-degree reception pattern around the stacking tube(s).
Attach coax cables to each antenna then connect to the repeater via the “T” adapter which connects to the TNC
antenna connector on the side of the repeater.
Receiver components:
1) 16 relay receiver in a NEMA 4 enclosure (Model # 497-5280)
2) Coax cable with connectors (Model 49-4000-XX)
3) Omni directional antenna with mounting hardware (Model 49-3101)
The receiver is recommended to be located at the PLC I/O cabinet in the control room.
Locate a 120VAC power source for this receiver.
Mount the omni antenna on the outside of the plant, as high as possible so the antenna can “see” the antenna
from the repeater located at the stacker tube for maximum performance and range.
Attach coax cable to the antenna then connect to the TNC antenna connector on the side of the receiver.
Install control wiring from the relays in the receiver to the belt feeder control circuits. See product information
bulletin for relay output logic.