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