Crane Boss 200 User manual
TABLE OF CONTENTS
PAGE
SECTION 1 GENERAL INFORMATION
1.1 SCOPE 1-1
1.2 SYSTEM DESCRIPTION 1-1
1.3 WARRANTY 1-4
SECTION 2 OPERATION
2.1 RECEIVING EQUIPMENT 2-1
2.2 TRANSMITTER 2-1
2.3 OPERATING PROCEDURE 2-1
2.4 MISCELLANEOUS OPERATING INFORMATION 2-2
SECTION 3 PRINCIPLE OF OPERATION
3.1 RADIO CONTROL SYSTEM 3-1
3.2 TRANSMITTER 3.2
3.3 RECEIVING EQUIPMENT 3-5
SECTION 4 INSTALLATION INFORMATION
4.1 SCOPE 4-1
4.2 MOUNTING 4-1
4.3 TRANSFER SWITCH 4-2
4.4 OUTPUT CIRCUITRY 4-5
4.5 INTERFACE LOGIC PANELS 4-6
4.6 START-UP PROCEDURE 4-7
SECTION 5 MAINTENANCE
5.1 PREVENTIVE MAINTENANCE 5-1
5.2 CORRECTIVE MAINTENANCE 5-1
5.3 REPLACEABLE PARTS 5-11
APPENDICES
IINDEX I-1
II OPTIONS II-1
TABLE OF FIGURES
FIGURE TITLE PAGE
3-1 BLOCK DIAGRAM, TRANSMITTER 3-3
3-2 BLOCK DIAGRAM, RECEIVING EQUIPMENT 3-4
4-1 TYPICAL TRANSFER SWITCH & MAIN LINE
4-2 CONTACTOR CIRCUIT 4-3
4-2 OUTPUT CIRCUIT FUNCTIONAL DIAGRAMS 4-4
5-1H TRANSMITTER COMPONENTS 5-3
5-2 CONTROLLER 5-7 & 5-8
DRAWING LIST
NUMBER TITLE
12-1606 OUTPUT CIRCUITS, CRANE BOSS 200
12-1607 SCHEMATIC, CONTROLLER, CRANE BOSS 200
12-1608 OUTLINE, CRANE RADIO CONTROL, CRANE BOSS 200
SECTION 1
GENERAL INFORMATION
1.1 SCOPE
This manual contains information necessary to install, operate and maintain Crane
Boss 200 Radio Remote Control Systems, which use a Hand-Held Transmitter.
Receiving equipment information is generally applicable to all Crane Boss 200 systems
manufactured by Robinson Engineering Company.
1.2 SYSTEM DESCRIPTION
1.2.1 General – The “200” system is equipped with controls and accessories required
for reliable electrical operation of a crane or other machinery from a portable
wireless control transmitter.
1.2.2 Control functions provided:
On/Off/Emergency Stop/Indicating Light
‘H1’ - Down / Up, Lo & Hi speed
‘T1’ - Forward / Reverse, Lo & Hi speed
‘B’ - Forward / Reverse, Lo & Hi speed
‘Aux 1’ - On/Off (Maintained Toggle)
‘Aux 2’ - On/Off (Maintained Toggle)
‘Aux A’ - (Momentary Pushbutton)
‘Aux B’ - (Momentary Pushbutton)
1-1
1.2.3 Characteristic features are:
1. Each system consists of a portable control transmitter, which operates, in
conjunction with receiving equipment installed on the machinery structure
and electrically connected to the magnetic controllers.
2. “Fail-safe” circuits are used throughout the system.
3. The command link is capable of handling all motions simultaneously.
4. The system uses digital pulse code frequency modulation. It was
developed specifically for industrial control.
5. The system utilizes fully solid-state electronic circuits, with heavy-duty
relay contact output circuits.
6. Maintenance requirements are greatly reduced by modular design and use
of digital switching circuits. No special test equipment is required.
7. Radio control of several units in the same plant without interference is
entirely practical. Each transmitter transmits a unique address code, which
prevents response by other than the intended unit. In addition, the
operating frequencies of different units are staggered within the frequency
band to prevent interference. Proper selection of address codes and
operating frequencies with respect to physical separation provides control
of multiple installations with no practical limitation on the number at one
location.
1-2
1.2.4 Transmitter – The transmitter is a portable unit, which is carried by the operator.
Switches on the transmitter control all functions as labeled.
The portable transmitter weight is just over 1 pound. The transmitter includes an
external antenna and has a battery assembly attached. The battery assembly uses
a 3-volt expendable battery. The Lithium battery Type 123A supplied with the
transmitter will provide approximately 80 hours of continuous transmitter
operation.
1.2.5 Receiving Equipment – The receiving equipment cabinet is mounted on the
machinery and contains the radio-receiving unit, decoding equipment and relays
to convert the radio signal from the transmitter to signals suitable for operation of
magnetic controls’ contactors.
1-3
1.3 GUARANTEE
Manufacturer Warrants the delivered remote control system to be free of
defective material and workmanship and agrees to remedy any such defect within one
year of first party purchase at no charge to the purchaser upon return of defective parts to
factory. Defects caused by improper installation, maintenance, misuse, tampering,
neglect, accident, or use in violation of manufacturer’s written instructions shall not be
covered by this warranty. Manufacturer guarantees that remote control system will
perform as outlined in this manual.
Transferring of this warranty is acceptable and recommended. Please
notify this factory of any and all transfers.
1-4
SECTION 2
OPERATION
2.1 RECEIVING EQUIPMENT
Normal operating procedures is to leave receiving equipment energized at all
times. (Power switch “On”, neon indicator lighted). The unit can then be readily
placed in operation by means of the portable control transmitter.
2.2 TRANSMITTER
The transmitter should be stored in a secure location when not being used.
2.3 OPERATING PROCEDURE
To place the unit in operation, proceed as follows:
1. Operator should position himself so as to have a clear view of the motions
and actions.
2. Turn the Transmitter ON: With all operating controls in “Open” position,
push “Start” Pushbutton. “OK” indicating light will flash on transmitter.
Master relay and main line contactor are energized.
3. Move the Bridge, Trolley, and/or Hoist: Machinery can now be moved by
operating desired control operators. All motion controls are spring loaded
to “Open”. Pressing the desired directional pushbutton actuates the low
Speed.
4. “2nd” or “H1” speed: With the desired directional pushbutton depressed,
press the pushbutton marked “+” next to it.
5. In the event of an emergency situation, press the “Stop” button.
6. Upon completion of use, turn transmitter “Off” by pressing the “Stop”
pushbutton and replace transmitter in designated storage location
with “Power” OFF.
NOTE: The transmitter will automatically “power down” (turn off) if no motions
are activated over a time period.
2-1
2.4 MISCELLANEOUS OPERATING INFORMATION
Abnormal electrical conditions during operation will de-energize control circuits,
stopping motion. This can be caused by any one of a number of abnormal
conditions. Among these are:
1. Weak or improper radio signal.
2. Interruption of power to receiving equipment.
3. Radio interference.
4. Malfunction of radio equipment.
5. Malfunction of machine electrical equipment.
If the abnormal condition is temporary, control can be resumed by repeating steps
2. through 4. of paragraph 2.3 above. The exact sequence of operation must be
followed to accomplish operation of safety circuits in the receiving equipment.
2-2
SECTION 3
PRINCIPLE OF OPERATION
3.1 RADIO CONTROL SYSTEM
The Crane Boss system is simple to operate. The transmitter unit
incorporates an easily operated control pushbutton for each crane motion.
Pressing the pushbutton moves the crane in the requested direction. A
“Start” pushbutton energizes the master circuits and, hence, the main line
contactor. All function control pushbuttons return to an “open” condition
(dead-man action) when released, and motion stops. Fail-safe features are
used throughout the circuitry. All crane motion stops in case of
malfunction.
The transmitter(s) in your Crane Boss system transmit unique digital crane
address codes to each crane. This prevents any mix-up in crane response.
Only one crane responds to one special code when transmitted. Hundreds
of these address codes are available. For added protection, operating
frequencies of each transmitter in the same area can be staggered within
the frequency band to prevent interference. The proper selection of digital
address codes and operating frequencies relative to physical separation
permits control of an unlimited number of cranes in the same plant, area or
city.
3-1
3.2 TRANSMITTER
The transmitter is a battery operated frequency modulation radio
transmitter. Incorporated with the transmitter is an antenna and disposal
battery. Transmitter carrier frequency is crystal controlled. When the
various switches are actuated, coded control signals are sent to the
receiving equipment via the antenna. A block diagram of the transmitter
is shown by Fig. 3-1.
The RF Assembly generates the radio frequency signal radiated by the
antenna, and is frequency modulated by a pulse code modulation signal.
This modulation signal is generated by the Coder Assembly and consists
of a series of synchronizing pulses that are determined by the position of
the various function controls, which are actuated by the operator.
Coder Assembly used in all transmitters is identical in function and is
interchangeable. Variation in code format between systems is
accomplished by means of factory connections on the Junction Board, by
the Address Plug, and by writing to the various control devices. All RF
Boards for the same frequency bands are identical and interchangeable
except for the frequency.
In multiple system installations a given transmitter may be converted from
control of one crane to another by changing the Address Plug installed in
the transmitter**. The Scanning Receivers used in multiple systems
installations are normally supplied with capability of receiving all
transmitting frequencies used at that installation.
** See 5.2.2.3
3-2
3.3 RECEIVING EQUIPMENT
Figure 3-2 shows a block diagram. The radio signal from the transmitter
is received by the antenna, which is connected to the Receiver by coaxial
cable. Receiver data output is fed to the Decoder, where it is decoded and
signals suitable for operation of the output relays are generated. The
output relays provide heavy-duty control circuits to the basic machine
electrical controllers.
3.3.1 Antenna
- The Antenna is pre-tuned for the frequency band used.
3.3.2 Receiver - The Receiver amplifies and detects the frequency
modulated pulse code signal and includes filtering and shaping
circuits to process the signal. Data output consists of rectangular
pulses of 5 volts amplitude which are a replica of the transmitter
coder output.
The Receiver is a synthesized frequency controlled scanning type
receiver which continuously scans all selected channels until a
signal is received which contains the proper address code. When
proper address code is received, scanning stops and, the receiver
remains “locked-on” that channel for as long as the code remains.
Channels can be turned “Off” or “locked-out” when unused or
turned “On” when other equipment is added.
A “VOLUME” control is provided to permit audio monitoring, via
internal loudspeaker, of the received signal for test and
maintenance purposes. This control has no effect on the control
function of the system and should be left in the full (CCW) off
position during normal operation.
3-5
3.3.3 Decoder - The receiver data output is connected to the Decoder
through the Controller, where it is processed into form suitable for
operation of the Relays. The Decoder also performs certain
synchronization, safety interlock, and digital filtering and noise
rejection functions. All DC voltages originate in the Decoder.
3.3.4 Address Code - The address is a two digit hexi-decimal number
that is set at the factory. The number for each system is shown in
the “Code” number block on the Controller.
3.3.5 Output Relays - Relay contact logic circuits provide additional
safety sequencing and interlocking functions. Output circuits are
connected to terminal blocks for connection to magnetic
controllers. Output relay circuits are rated for operation of up to
NEMA size 3 contactors at a maximum coil voltage of 125 volts
A.C.
3-6
SECTION 4
INSTALLATION INFORMATION
4.1 SCOPE
This section is intended as aid to preparing for mounting and interconnection of
Crane Boss to machinery, crane or monorail. The examples and suggestions
made as to the mounting and interconnection are based upon typical uses and past
experience; depending upon application, these may or may not be applicable or
appropriate.
The installer is cautioned to assure that requirements of applicable Codes and
Ordinances are complied with.
4.2 MOUNTING - RECEIVING EQUIPMENT
4.2.1 Refer to Outline Drawing for mounting dimensions and clearances
required.
4.2.2 Rigidly mount, as for any control panel, the Receiving Cabinet to
the structure of the equipment to be remotely controlled. Allow
access for conduit entry as noted on the Outline Drawing.
4.2.3 Mounting of the Indicating Light (if used) is accomplished by
normal electrical wiring procedures. Be sure of visibility from
operating area. Also, that it be conveniently accessible for service
(changing bulb, etc.). Terminals IL and X2 are used for the
Indicating Light.
4-1
4.2.4 The antenna is installed by plugging into the jack on the bottom of
the Crane Radio Control cabinet.
4.2.4.1 If an antenna location other than the bottom of the cabinet
is required, an optional kit for remote installation is
available*
4.2.4.2 Proper mounting and location of antenna is imperative for
signal to reach decoding and output circuits. (See Notes on
Outline Drawing.)
4.2.4.3 Mounting of the Receiving enclosure should allow for the
Antenna to be:
1. Clear of large metal objects, bring greater than one foot
away from bridge girders, hoist mechanism, etc;
2. In view from the entire operating area, in all directions;
3. And not in close proximity to crane electrification, like
runway conductors, bridge cross conductors, festooning,
conduit or wire way.
If any of these conditions cannot be met, a Remote Antenna Kit
should be used. *
4.2.5 Wherever the “other” means of control (console, pendant, etc.) is
located (trolley, bridge) is probably the simplest wiring location for
the radio control cabinet. The only distinct difference between
pushbutton and radio control is that 117 VAC must be available for
radio power supply. Pushbuttons will have as a common the “hot”
lead. The other leg of the transformer (X2) must often be added
by conductor bar, festooning, or by other means.
4.3 TRANSFER SWITCH
4.3.1 Mutually exclusive transferring of control modes is often used:
“Pushbutton-Radio”, “Cab-Radio”, “Pendant-Radio”, “Console-
Radio”, etc. The mutual exclusivity is most simply obtained by
appropriately defeating the other mode’s power feed, as well as,
opening any normally closed circuits. See Fig. 4-1.
* See “Options” Appendix.
4-2
FIG. 4-1:
TYPICAL TRANSFER SWITCH & MAIN LINE CONTACTOR CIRCUIT
4-3
C
Main
M
Other Radio
M
Stop Start
X1
X2
Radio
Power
MOL's
Transfer
Switch
Crane
Radio
Control
Control Station may have
varying configurations
including a maintained
switch ('2 wire control').
Crane
Transformer
117VAC
If Radio Power is to be separate from Main Power,
omit jumper from C (Main) to X1 and add Transfer
Switch contact with dashed line connection as shown.
X2 must be connected to the same power source as X1.
NOTE: This diagram is an example only. Equipment control circuits may vary
greatly. Control connections should be carefully considered to provide
proper operation and avoid feedback circuits.
C
C
D
D2
Lo
U
U2
Lo
H3
HTransmitter
Switch
123 321
X X XO O O
O O O O X X
O O O X O O
X X X O O O
OX X O O O
XO O O O O
X O O O O X
UP DOWN
3
X
O
C
T2
R
F
T
C
FWD
OX
O
X
O X
REV
2 1
Transmitter
Switch
1
O
X
O
X
2 3
X X
OXX O
REV
B
R
B2
C
F
C
XXX
X X O
O
3
O O
2 1
Transmitter
Switch FWD
X
2
X
OO
O
X
1
O
X
X
3
X: Indicates Closed Circuit
O: Indicates Open Circuit
: Indicates Optional Circuit
FIG. 4-2(G): OUTPUT CIRCUIT FUNCTIONAL DIAGRAMS
4-4
R
Robinson Engineering Co.
Garland, Texas
CONTROL TRANSMITTER
FCC TX DATA: TYPE 400-72
SERIAL NO.
3 Volts Type 123A
+
+
+
B
2
A
1
T
OK
Low
BATT.
oss
Crane
B
+
â
S
T
S
A
P
O
T
A O O O OOX
REV
Aux A
C
B3
3
Transmitter
Switch
2 1 32
FWD
1
Transmitter
Switch
B O O O
Aux B
C
T3
UP
3 2 1
OOX
3
DOWN
21
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