Cervis TM70 User manual

2007-2008 Cervis, Inc.
TM70
Wireless Remote Control
User Manual
U003.3-TM70-R-082108
TM

ii U003.3-TM70-R-082108
Cervis, Inc.
www.cervis.net

2007-2008 Cervis, Inc. All rights reserved. Content is subject to change without notice.
This document is the property of Cervis, Inc. and cannot be copied, modified,
e-mailed, or reproduced without the express prior written consent of Cervis, Inc.
Cervis, Inc. reserves the right to change this manual or edit, delete, or modify
any information without prior notification.
FCC Statements
15.19 – Two Part Warning
This device complies with Part 15 of the FCC rules. Operation is subject to the follow-
ing 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.
15.21 – Unauthorized Modification
NOTICE: The manufacturer is not responsible for any radio or TV interference caused
by unauthorized modifications to this equipment. Such modifications could void the
user’s authority to operate the equipment.

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2007-2008 Cervis, Inc.
Contents
FCC Statements ........................................................................................................................... ii
Figures ...................................................................................................................................... ii
Tables ...................................................................................................................................... ii
Welcome to Cervis....................................................................................................................... 1
1.0 TM70 System Description ................................................................................................... 2
2.0 Safety Instructions............................................................................................................... 5
2.1 What You MUST Do .......................................................................................................... 5
2.2 What You MUST NOT Do.................................................................................................. 6
3.0 System Component Installation......................................................................................... 7
3.1 Transmitter Battery........................................................................................................... 7
3.2 CB70 Battery Charger ...................................................................................................... 9
3.2.1 Charging Tips............................................................................................................. 10
3.3 Receiver Installation....................................................................................................... 10
3.4 Starting Up....................................................................................................................... 13
4.0 Using the System............................................................................................................... 15
4.1 General Instructions....................................................................................................... 15
4.2 Battery Level Monitor..................................................................................................... 15
4.2.1 LCD Option Power Level Display............................................................................... 16
4.3 Programming a Spare Transmitter ............................................................................... 16
4.3.1 Transfer EP70 From Transmitter to Spare Transmitter ............................................. 16
4.3.2 Copy Receiver EP70 to Transmitter EP70................................................................. 17
4.4 Programming the Machine Identification in LCD Transmitters ................................. 19
4.5 LCD Display Analog Feedback Calibration.................................................................. 20
4.5.1 Calibrating Analog Feedback..................................................................................... 20
5.0 Maintenance ....................................................................................................................... 22
5.1 Precautions ..................................................................................................................... 22
5.2 Fault Identification.......................................................................................................... 22
5.2.1 Transmitter ................................................................................................................. 22
5.2.2 Receiver ..................................................................................................................... 22
5.3 Returning Equipment for Repair................................................................................... 23
5.4 Spare Parts...................................................................................................................... 24
6.0 Warranty.............................................................................................................................. 26

TM70 Wireless Remote Control
ii U003.3-TM70-R-082108
Figures
Figure 1: TM70 System Components with a TM70/1 Transmitter..............................................2
Figure 2: TM70/2 Transmitter Layout............................................................................................3
Figure 3: CB70 Battery Charger....................................................................................................9
Figure 4: Typical MOV Wiring Across Contactor Coil ............................................................. 10
Figure 5: Receiver Footprint....................................................................................................... 11
Figure 6: Receiver Antenna with Extension Kit........................................................................ 11
Figure 7: Main Board Connections, Relays, and LEDs............................................................ 12
Figure 8: TM70 Transmitter Details............................................................................................ 14
Figure 9: Extracting the EP70 Memory Module........................................................................ 17
Figure 10: Receiver EP70 Module Location.............................................................................. 18
Figure 11: TX Pushbutton/Switch Numbers/Names................................................................. 18
Figure 12: Transmitter Button Locations.................................................................................. 19
Tables
Table 1: TM70/02 Transmitter Component Descriptions............................................................3
Table 2: TM70 Main Specifications ...............................................................................................4
Table 3: Receiver LED States During Power-Up ...................................................................... 13
Table 4: Receiver LEDs Upon Receiving a Transmitter Signal............................................... 14
Table 5: LCD Power Level Interpretation .................................................................................. 16
Table 6: Transmitter Layout........................................................................................................ 18
Table 7: Transmitter Status LED Fault Identification............................................................... 22
Table 8: Receiver Status LED Fault Identification.................................................................... 23
Table 9:Available Spare Parts .................................................................................................... 24
CAUTION
The instructions in this manual must be read carefully and strictly
adhered to in order to:
•install and use the system properly
•keep it in working condition and
•reduce the risks of misuse.
Do not use this system on machines used for lifting people.
Do not use this system in potentially explosive atmospheres.
Any use other than that specified in this manual is DANGEROUS.

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Welcome to Cervis
Thank you for choosing the TM70 Wireless Remote Control. We here at Cervis believe
you have purchased one of the most reliable industrial radio control systems available.
Specializing in wireless remote controls for mining and industry, we offer you over 60
years of combined machine control experience. We custom design and manufacture
control systems for OEM’s worldwide. We are dedicated to our customers’ success—
your needs, paramount to our success, have allowed us to become a leading innovator
of wireless machine control technologies.
We are honored to have served some of the most demanding and rewarding customers
in the world over the last 15 years. Called upon to solve the most challenging radio re-
mote control problems in the industry, our systems have earned a world-wide reputation
for affordability, superior engineering, ruggedness, and reliability.
Our goal is to provide our customers with the safest, most reliable wireless radio remote
control available at an affordable cost. And to meet our goal, we develop and use the
highest level, proven state-of-the-art technology backed by unparalleled customer sup-
port. Our systems increase our customers’ safety and productivity—no matter how de-
manding the environment.
We are extremely pleased to have you as a customer, and we thank you for your pur-
chase.

TM70 Wireless Remote Control
2 UOO3.2-TM70-R-082108
1.0 TM70 System Description
A standard TM70 system is comes complete with:
•One (1) Transmitter – either a TM70/1 or a TM70/2
•One (1) R70 Receiver
•One (1) CB70 Battery Charger
•Two (2) BT06K Batteries
•One (1) Antenna (internal or external)
The battery operated TM70/1 and TM70/2 push-button style transmitters are designed
for the remote control of industrial equipment. An operator using a handheld transmitter
can determine the safest location from which to carry out an operation. The receiver is
connected to the electrical system of the machine to be operated. Table 2 below lists
the Main Specifications of the TM70 system.
Figure 1: TM70 System Components with a TM70/1 Transmitter
Transmitter
Receiver
CB70 Charger with Batteries

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Figure 2: TM70/2 Transmitter Layout
Table 1: TM70/02 Transmitter Component Descriptions
Figure 2
Reference
Component
1 IR Range Limiter (optional)
2 LCD (optional display)
3 Diagnostic LED
4 Two-step pushbuttons
5 Maintained or spring return rotary switch
6 Safety key switch (Power ON/OFF)
7 Warning/Start switch
8 CAT3 Stop switch
9 Shock absorbers
10 Portable EEPROM
11 Battery

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Table 2: TM70 Main Specifications
TM70
Frequency band 914.150 – 915.875 MHz ERP < 1mW
Response Time 100 ms
Temperature Range 0 to 150 °F (-20 to 65 °C)
T70/1 and T70/2 Transmitters
Protection IP65
R70/13 and R70/21 Receivers
Power Supply 48, 115, 230 VAC ± 10% -- 50/60 Hz
Optional 12 or 24 VDC
Consumption 20 mW
Relays 230 VAC/8A
STOP Relays 230 VAC/6A
Protection IP65
Electrical Security Class II (EN50178)
CB70 Battery Charger
Power Supply 12/24 VDC, 115 VAC
BTO6K Batteries
Voltage 4.8 V
Capacity 750 mAh NiMH
Charging Temperature +41 to +95°F (0 to 35°C)
Battery Life 16 hrs. @ 15% duty cycle

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2.0 Safety Instructions
CAUTION
These instructions must be read carefully in order to install and
use the system properly, to keep it in safe working condition,
and to reduce the risks of misuse.
Do not use this system on machines used for lifting people.
Do not use this system in potentially explosive atmospheres.
Any use other than that specified in this manual is DANGER-
OUS.
Strict adherence to the following instructions is a MUST.
 Note: To comply with FCC RF exposure compliance requirements, this device and
its antenna must not be co-located or operating in conjunction with any other
antenna or transmitter.
2.1 What You MUST Do
•Str ictly adhere to the installation instructions contained in this manual.
•Make sure that professional and competent personnel carry out the installa-
tion.
•Make sure that all site and prevailing safety regulations are fully followed.
•Make sure that this manual is permanently available to the operator and
maintenance personnel.
•Keep the transmitter out of reach of unauthor ized personnel.
•R emove the transmission key when the transmitter is not in use.
•At the beginning of each work day, check to make sure that the S top B utton
and other safety measures are working.
•When in doubt, press the Stop B utton.
•Whenever several systems have been installed, make sure the transmitter
you are about to use is the right one. I dentif y the machine controlled by the
transmitter on the transmitter label (customer supplied).
•An audible or visual warning device indicating the machine is electrically
active and that the transmitter has control should be installed on the machine.
•S er vi ce the equipment periodically.
•When carrying out repairs, only use parts supplied by Cervis dealers.

TM70 Wireless Remote Control
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2.2 What You MUST NOT Do
•Never make changes to the system that have not been studied and approved
by Cervis.
•Never power the equipment with anything other than with the specified power
supply.
•Never allow unqualified personnel to operate the equipment.
•Never leave the equipment ON after use. Always use the ON/OFF K ey or
the Stop B utton to avoid accidental movements.
•Never use the system when visibility is limited.
•Never abuse the transmitter. Avoid dropping.
•Never use the system if failure is detected.

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3.0 System Component Installation
3.1 Transmitter Battery
CAUTION
THE BATTERIES MUST BE INITIALLY CHARGED BE-
FORE USE. Batteries must be charged for a full twelve (12)
hours before they can be installed in the transmitter. Using
a battery before initially charging will shorten its life span
and can possibly result in an immediate degradation of ser-
vice.
 Note: You must fully charge the batteries before installing and using in the transmit-
ter. It takes twelve (12)hours to initially charge or recharge an exhausted bat-
tery. Once a battery is charged, do NOT charge it again until the transmitter
indicates a low charge. You will shorten the battery life by charging it before it
is exhausted. To guard against disruption of service, be sure to have one bat-
tery fully charged or in the process of being fully charged while the other is in
use at all times.
Upon initial start-up, place a fully charged battery in the transmitter. Continue to use it
until the transmitter LED slowly flashes red. The flashing LED indicates you have ap-
proximately five (5) minutes of operation until the transmitter automatically shuts down
(see Topic 0 Use the following instructions to properly operate the equipment:
1. Attach the harness to the transmitter to prevent the equipment from fall-
ing.
2. Make sure of the transmitter you are going to use. Verify that the machine
you want to operate matches the transmitter identification label—the label
allows the operator to identify the machine before starting the equipment.
3. Install a fully charged battery into the transmitter.
4. Make sure all command controls are in the neutral position. All the com-
mand controls associated with active motions must be in the neutral posi-
tion (inactive) to enable the transmitter.
5. Turn the ON/OFF key ON (clockwise) to enable the transmitter.
6. Pull out the Stop B utton. The LED should pulse green telling you the
transmitter is ready for use.
 Note: If you find that the Stop Button is already pulled out, you must push it in and
then pull it out again. This sequence permits proper operation of the Stop cir-
cuit. If the unit has experienced a time-out auto-disconnect, it is not necessary
to repeat the Stop Button procedure; instead, push and hold the START But-
ton for one (1) second.
7. Press and hold the ST AR T B utton. This activates the warning/start
alarm if one is installed on the crane/machine and indicates to you the re-
ceiver is under your control.

TM70 Wireless Remote Control
8 UOO3.2-TM70-R-082108
8. The green LED should light indicating that the transmitter is now transmit-
ting. Now when any of the transmitter command pushbuttons are
pressed, the corresponding motion is activated.
9. Press the Stop B utton or turn the ON/OFF K ey counter clockwise to
turn the transmitter OFF.
Battery Level Monitor). If the Stop Button is pushed during the time the LED is flashing,
all control functions immediately cease and the transmitter will not start again until a
fresh battery is installed. It is recommended to put the machine you are controlling in a
safe state or safe place during this five minute warning so that it will not pose a hazard
while you are changing the exhausted battery with a fully charged battery.
CAUTION
If the STOP button is pushed during the time the LED is indicating an
imminent shutdown, be aware that the transmitter will not restart until a
fresh battery is installed. Be sure to place the machine your are control-
ling in a safe state or place during the warning period so that it does not
pose a hazard while the battery is being changed.
Under normal duty cycles, you can expect approximately 10 to 16 hours (cumulative) of
actual usage before a battery is exhausted and needs to be recharged. An exhausted
battery will take approximately 12 hours to become fully charged.
 Note: A battery can be left on the charger for extended periods of time without dam-
age to either the battery or the charger.

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3.2 CB70 Battery Charger
The CB70 battery charger, Figure 3, has two charging compartments that can simulta-
neously charge two batteries. Battery types BT06K (TM70 transmitter battery) BT06,
BT12, and BT20K can be charged in any combination using the charger.
Figure 3: CB70 Battery Charger
 Note: The Charging LED lights when the battery is first seated in the cradle indicat-
ing the battery is properly seated, and is charging. The Charging LED goes
out after 12 hours of charging.
1. Connect the charger to the proper power source using adaptor supplied
for your system.
When installing the battery charger, bear in mind that the batteries must be charged at
temperatures over 41ºF (5ºC) and that the power supply must be left for the entire time
that it takes to charge, without interruption. Also remember that the charger must not be
left in direct sunlight as the batteries will not become fully charged at temperatures ex-
ceeding 95ºF (35ºC).
2. Place the batteries in the charger. The LED’s should illuminate indicating
that recharging is in process. Complete recharging takes 12 hours. Batte-
ries may remain in the charger for an unlimited period of time after they
are fully charged.
If the LED does not illuminate when the battery is seated for charging, there is an im-
proper connection. Remove the battery from the charger, check that the terminals are
clean and unobstructed, and reseat the battery firmly in its cradle; check to see that the
LED is on. Should this fail, contact Cervis Customer Support.
The capacity of the batteries decreases with use. Their life span is estimated to be 500
recharging cycles, but this depends largely on the conditions of use, for which the fol-
lowing is recommended:
CAUTION
Only use batteries certified by Cervis. When the batteries are
exhausted, they should be safely disposed of or recycled ac-
cording to local regulations.

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Figure 4
: Typical MOV Wiring
Across Contactor Coil
3.2.1 Charging Tips
•Do not recharge the battery until it is completely flat (fully discharged). The
transmitter indicates when the battery is nearing a charge cycle when the
LED flashes red; this also indicates the transmitter will switch OFF in five (5)
minutes. See Topic 0 below.
•Always charge the batteries at temperatures between 41ºF and 95ºF.
•Avoid short-circuits between the battery contacts. Do not carry charged batte-
ries in toolboxes or next to other metal objects (keys, coins, etc.).
•Always keep the contacts clean.
•Never leave batteries in direct sunlight.
CAUTION
Never carry batteries in your pockets with other metal objects where a short
across the terminals may occur resulting in burns or injuries.
3.3 Receiver Installation
CAUTION
Make sure the machine on which the receiver is to be attached is
disabled while during installation.
Turn off the main line disconnect switch. Check the power supply
voltage. MAKE SURE THE POWER SUPPLY IS OFF.
For a crane, park the crane and position the end stops at a suitable
distance so that other cranes on the same runway do not hit it. If end
stops are not available, use appropriate signs instead.
Keep the work area free from unnecessary clutter.
Wear protective clothing.
 Note: Before installing the receiver, make sure that the outputs diagram supplied
with the system is available.
 Note: Installations subject to vibration should install the optional Shock Absorber Kit
part # 1166074 available at Cervis. The kit has four absorbers that you place
between the receiver and the mounting surface as per the kit directions.
 Note: Always mount the receiver and antenna away
from any intense radio or electric disturbance
sources.
 Note: When using contactors with the system, it is ad-
visable to use the MOV’s provided by installing
them across the coil of the contactors as shown
in Figure 4.

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 Note: If necessary, it is possible to improve signal reception by using the extension
cables and external antenna kit. See Figure 6 below.
1. Find a suitable location for the receiver with clear access to the transmit-
ter radio signal. Figure 5 below shows the footprint of the receiver and il-
lustrates the distance between the mounting holes.
Figure 5: Receiver Footprint
J501 (Antenna) J502 (Cable) J503 (Bracket)
Figure 6: Receiver Antenna with Extension Kit

TM70 Wireless Remote Control
12 UOO3.2-TM70-R-082108
2. Follow the Outputs Diagram supplied with the system to connect the
power supply and the receiver outputs on the relay board plug-in termin-
als. The Output Diagram indicates the relationship between the transmit-
ter commands and the receiver outputs.
•The STOP relays K 15 and K 16 are in series and must be connected to the
main contactor coil circuit.
•The K2/START is activated once the Warning/START command is held
down.
•The K1/SEC relay is a security relay. It is activated when certain commands
predefined as A ctive—commands that give rise to movements—are acti-
vated.
Figure 7: Main Board Connections, Relays, and LEDs
3. Select the appropriate voltage on the receiver.
4. Be certain to connect the gr ound cable.
CAUTION
Use only fireproof cables for connections.
K16
K15
K12
K2
K14
K13
K11
K1
K10
K9
K7
K8
K6
K5
K3
K4
SIGNA
POWE
HARDO
ID
DATA
FUSE 1A
K14
K13
K12
STOP
K2
K1
K11
K10
K9
K8
K7
K6
K3
K4
K5
N230/AC
+/AC
PE
N115/AC
- /DC
N48/AC

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3.4 Starting Up
1. Once the receiver has been connected, disconnect the power supply to
the motors—by removing the fuses for example—and then power up the
receiver. The receiver enters into a SCANNING mode upon power-up;
the receiver LED power-up states are defined in Table 3.
Table 3: Receiver LED States During Power-Up
LED
State
Indication
POWER ON Power supply is correct
HARDOK ON Absence of faults on the boards
SIGNAL OFF
Blinks Channels are signal free
An RF signal on the channels
DATA OFF Another TM70 system is not active in the area
Blinks Another TM70 system is active in the area
ID OFF System Transmitter not on.
2. Turn the transmitter (Figure 8) ON to OPERATION Mode as follows:
a. Place a char ged batter y in the transmitter.
b. Turn the Contact Key clockwise to ON.
c. Push in and then pull out the STOP B utton. The transmitter LED
flashes orange once, and then illuminates green for three (3)
seconds. If the transmitter has an LCD, it displays the identifica-
tion of the machine and the battery level.
d. Press and hold the ST AR T B utton. The green LED should now
light indicating that the transmitter is transmitting. Release the
START Button.
At this point the STOP relays K 15 and K 16 are energized as long as the TX is active.
These relays are typically used to control a main-line contactor, hydraulic pump, or oth-
er device that determines that the machinery is on.
The K 2/S T A R T relay is energized when the ST AR T B utton is pushed. It is typically is
also connected to a warning device.

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14 UOO3.2-TM70-R-082108
Figure 8: TM70 Transmitter Details
Table 4 below shows the receiver LEDs upon receiving a signal from the transmitter.
Table 4: Receiver LEDs Upon Receiving a Transmitter Signal
LED
State
Indication
POWER ON Power supply is correct
HARKOK ON Defects have not been detected on the board
SIGNAL ON Channels are signal free
DATA ON Data received has a correct format
ID ON Receiver has recognized the transmitter ID code
3. Press any of the transmitter’s movement pushbuttons. Its corresponding
relay is energized. In case of an active movement, the safety relay
K1/SAFETY is also energized.
4. Check to make sure all the other movements work as described in Step 3.
5. Turn off the transmitter using the ST OP B utton, and make sure that
when doing so the relays are not energized and the DAT A, ID, and
SIGNAL LEDsgo out. They should behave exactly as when in the
SCANNING mode.
6. Reconnect the power supply to the motors, move to a safe position, and
check to see if all the movement pushbuttons and the STOP Button cor-
rectly function.
Crane ID Label
Option: LCD Display
LED
Command Button
Contact Key
Start Button
Stop Button
Option: IR Range Limiter

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4.0 Using the System
4.1 General Instructions
Use the following instructions to properly operate the equipment:
7. Attach the harness to the transmitter to prevent the equipment from fall-
ing.
8. Make sure of the transmitter you are going to use. Verify that the machine
you want to operate matches the transmitter identification label—the label
allows the operator to identify the machine before starting the equipment.
9. Install a fully charged battery into the transmitter.
10. Make sure all command controls are in the neutral position. All the com-
mand controls associated with active motions must be in the neutral posi-
tion (inactive) to enable the transmitter.
11. Turn the ON/OFF key ON (clockwise) to enable the transmitter.
12. Pull out the Stop B utton. The LED should pulse green telling you the
transmitter is ready for use.
 Note: If you find that the Stop Button is already pulled out, you must push it in and
then pull it out again. This sequence permits proper operation of the Stop cir-
cuit. If the unit has experienced a time-out auto-disconnect, it is not necessary
to repeat the Stop Button procedure; instead, push and hold the START But-
ton for one (1) second.
13. Press and hold the ST AR T B utton. This activates the warning/start
alarm if one is installed on the crane/machine and indicates to you the re-
ceiver is under your control.
14. The green LED should light indicating that the transmitter is now transmit-
ting. Now when any of the transmitter command pushbuttons are
pressed, the corresponding motion is activated.
15. Press the Stop B utton or turn the ON/OFF K ey counter clockwise to
turn the transmitter OFF.
4.2 Battery Level Monitor
TM70 transmitters are equipped with a battery-level monitoring circuit. When the charge
level drops below a pre-defined limit, the transmitter LED flashes red indicating the
transmitter will switch OF F and be disabled in five (5) minutes. When the transmitter is
disabled, the machine’s main contactor is de-energized. If the Stop Button is pushed
during this 5-minute warning period, the transmitter will not start again until a
fresh battery is installed.
CAUTION
For safety sake, the load
must
be located to a safe position and area
during the 5-minute warning prior to Low Battery automatic shutdown.
Beware: If the STOP Button is pushed during this warning time,
you cannot use the transmitter again until a fresh battery is in-
stalled.

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16 UOO3.2-TM70-R-082108
4.2.1 LCD Option Power Level Display
Transmitters with the LCD option indicate the battery power level by showing seg-
ments—black dashes—in the display. The more dashes shown, the more charged the
battery. Power levels are interpreted in Table 5.
Table 5: LCD Power Level Interpretation
Segments Displayed
Battery Charge
Three segments Greater than 50%
Two segments Between 10% and 50%
One segment Between 5% and 10%
None Less than 5%
 Note: The transmitter will automatically go to STAND BY mode after four (4) mi-
nutes of inactivity. Standby mode is indicated by 3-second green LED pulses.
Press the START Button to restart the transmitter. The 4-minute default can
be changed or eliminated through a software modification. If a change is de-
sired, please contact Customer Service.
CAUTION
Keep in mind at all times that you are controlling a moving piece
of machinery. You must strictly adhere to the safety instructions
described in Section 2.0 of this manual.
4.3 Programming a Spare Transmitter
If a transmitter is damaged, it is possible to quickly restore service by transferring the
EP70 Memory Module EEPROM from the original damaged transmitter to a similar
spare transmitter. This ensures that you use the exact parameters of the original in the
spare. The EP70 Memory Module EEPROM is easily accessible from the exterior of the
transmitter. To transfer the EP70 Memory Module:
4.3.1 Transfer EP70 From Transmitter to Spare Transmitter
1. The EP70 module is a part of the cover located on the back of the trans-
mitter. Turn the damaged unit over and remove the two screws as shown
in Figure 9A. If there is an EEPROM in the spare transmitter, remove the
cover screws on it, too.
2. Extract the EP70 module from the damaged transmitter as shown in Fig-
ure 9B. Handle module during the transfer by touching only the cover;
avoid touching the actual EEPROM located beneath the cover.
3. Install the original transmitter EP70 module into the spare transmitter. The
module is keyed so that it will only fit in one way.
4. Install the cover screws on the spare transmitter.