Drivecon PWR III Series User manual

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OPERATION & INSTALLATION
MANUAL
PWR Series III
PUSHBUTTON TRANSMITTERS

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I N DEX
PAGE.
1.- DECLARATION OF CONFORMITY ...................................................................................................................1
2.- SYSTEM DESCRIPTION........................................................................................................................................2
3.- SAFETY INSTRUCTIONS ......................................................................................................................................3
3.1.- WHAT YOU MUST DO .....................................................................................................................................3
3.2.- WHAT YOU MUST NOT DO ............................................................................................................................3
4.- INSTALLATION ......................................................................................................................................................4
4.1.- THE CB60 BATTERY CHARGER.....................................................................................................................4
4.2.- RECEIVER ..........................................................................................................................................................5
4.3.- STARTING UP ....................................................................................................................................................7
5.- USING THE SET ......................................................................................................................................................9
6.- MAINTENANCE ...................................................................................................................................................10
6.1.- WARRANTY.....................................................................................................................................................10
6.2.- PRECAUTIONS ................................................................................................................................................10
6.3.- FAULT FINDING..............................................................................................................................................11
6.4.- SPARES .............................................................................................................................................................13
ANNEX A - PROGRAMMING A SPARE TRANSMITTER. ...............................................................................14
ANNEX B- STANDARD WIRING DIAGRAMS 15

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1.- DECLARATION OF CONFORMITY
DECLARACION DE CONFORMIDAD
DECLARATION OF CONFORMITY
KONFORMITÄTSERKLÄRUNG
DECLARATION DE CONFORMITE
DICHIARAZIONE DI CONFORMITA'
DECLARAÇAO DE CONFORMIDADE
El Fabricante
The Manufacturer
Der Hersteller
Le Fabricant
Il Fabbricante
O Fabricante
ANGEL IGLESIAS, S.A.
Pol. Ind. 27, nº 30 20014
SAN SEBASTIAN - SPAIN
NIF: A-20-036.018
Tel : [phone]
Fax: [phone]
Declara que el producto: Telemando IKUSI
Declares that the product: Remote Control IKUSI
Erklärt, dass das Produkt: Funkfernsteuerung IKUSI
Déclare que le produit: Télécommande IKUSI
Dichiara che il prodotto: Radiocomando IKUSI
Declara que o produto: Radiocomando IKUSI
TM70/1
TM70/2
Cumple con las Directivas de Consejo:
Complies with the provisions of Council:
Erfüllt die Richtlinien des Rates:
Accompli les Directives du Conseil:
E´conforme alle Direttive del Consiglio:
Cumpre as Directivas del Consello:
93/44 EC
99/5 EC
Normas armonizadas utilizadas:
Applied harmonized standards:
Angewendete harmonisierte Normen:
Normes harmonisées utilisées:
Norme armonizate utilizzate:
Normas armonizadas utilizadas:
ETSI EN 300220
ETS EN 301489-3
EN 55022
EN 61000-4-2
EN 61000-4-3
EN 61000-4-4
EN 61000-4-5
EN 61000-4-6
EN 61000-4-11
EN 61000-3-2
EN 61000-3-3
EN 60950-1
EN 50178
EN 60204-32
EN 60529
PrEN 13557
PrEN 12077-1

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2.- SYSTEM DESCRIPTION
The PWRSIII6 and PWRSIII10 push-button transmitter type, radio remote control systems are
designed for the remote control of hoists and cranes, and are particularly suitable for
applications when the operator needs to be able to choose the best location from which to
carry out an operation.
The system consists of a transmitter for selecting commands and a receiver, which is
connected to the electrical system of the machine to be operated. The system also comes
with a battery charger and two rechargeable batteries.
The main specifications are as follows:
The PWRSIII
Frequency band 902.0 to 928.0 MHz; ERP <1mW
Response Time 100 ms
Temperature range -4ºF to +149ºF (-20º to +65ºC)
The PWRSIII6 and PWRSIII10 Transmitters
Protection IP65
The Receivers
Power supply 115 Vac ± 10%, 50/60 Hz
Optional 48, 230 Vac ± 10%, 50/60 Hz
12 or 24 Vdc
Consumption 20 W
Relays 230 Vac/8 A
STOP Relays 230 Vac/6 A
Protection IP55
Electrical Security Class II (EN50178)
The CB60 battery charger
Power supply 115 Vac ± 10%, 60Hz;
optional 230 Vac, 50/60 Hz; 24 Vdc; 12 Vdc
The BT06K batteries
Voltage 4.8 V
Capacity 750 mAh NiMH
Charging temperature 32º to 113ºF (0º to 45ºC)
Discharge temperature -4º to 122ºF (-20º to 50ºC)
Autonomy 10 h (operating at 50%)

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3.- SAFETY INSTRUCTIONS
These instructions must be read carefully in order to install and use the
set properly and to keep it in perfect working condition and to reduce
the risks of misuse.
Do not use this set on machines for the lifting of persons or in
potentially explosive atmospheres.
Any use other than that specified in this manual is dangerous. The
following instructions must be strictly adhered to.
3.1.- WHAT YOU MUST DO
 Strictly adhere to the instructions for installation contained in this manual
 Make sure that professional and competent personnel carry out the installation.
 Ensure that all site and prevailing safety regulations are fully respected.
 Make sure that this manual is permanently available to the operator and maintenance
personnel.
 Keep the transmitter out of reach of unauthorized personnel.
 Remove the transmission key when the set is not in use.
 On starting each working day, check to make sure that the STOP button and other
safety measures are working.
 When in doubt, press the STOP button.
 Whenever several sets have been installed, make sure the transmitter you are going to
use is the right one. Identify the machine controlled on the label for this purpose on the
transmitter.
 Service the equipment periodically.
 When carrying out repairs, only use spare parts supplied by Drivecon, Inc.
3.2.- WHAT YOU MUST NOT DO
 Never make any changes to the set that have not been approved by manufacturer.
 Never power the equipment with power supply other than specified.
 Never allow unqualified personnel to operate the equipment.
 After use, never leave the equipment ON. Always use the contact key or the STOP
button to avoid accidentally activating manoeuvres.
 Do not use the set when visibility is limited.
 Avoid knocking or dropping the set.
 Do not use the set if failure is detected.

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4.- INSTALLATION
4.1.- THE CB60 BATTERY CHARGER
The battery charger CB60 has two charging compartments that can simultaneously
charge battery types BT06, BT12, BT06K and BT08K.
Connect the charger to the mains
using the power source and cable
supplied. On installing the battery
charger, bear in mind that the
batteries must be charged at
temperatures over 32ºF (0ºC) and
that the power supply must be left on
all night. Also remember that the
charger must not be left in direct
sunlight, as the batteries will not
become fully charged at temperatures
exceeding 113ºF (45ºC).
Place the batteries in the charger.
The LED’s should light up, indicating that recharging is in process. Complete recharging
takes 12 hours, but the batteries may remain in the charger for an unlimited period of
time.
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
following is recommended:
 Do not recharge the battery until it is completely flat. The transmitter indicates this.
 Always charge the batteries at temperatures between 32ºF and 113ºF (0º and
45ºC).
 Charge the batteries at least once every six months.
 Avoid short-circuits between the battery contacts. Do not carry charged batteries in
toolboxes or next to other metal objects (keys, coins, etc.).
 Always keep contacts clean.
 Never leave batteries in direct sunlight.
Only use Drivecon supplied batteries.
When the batteries are exhausted they can be disposed of or recycled
safely according to local standards.

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4.2.- RECEIVER
Make sure that the crane is stopped for the entire duration of the
assembly process, keep the work area free and wear protective
clothing.
Park the crane and position stop-ends (if these are not available use
appropriate signs) at a suitable distance so that other cranes on the
same runway do not hit it.
Check the power-supply voltage and turn off the mains switch.
Remember that the receiver has several voltage-powered circuits. Even
when the power has been cut off, there is still a risk of electrical
shocks.
Find a suitable location for the receiver with easy access, in a place designated for
reception of the radio transmitter signal, and away from any intense radio electric
disturbance sources.
Install the receiver cabinet using 4 elastic absorbers.

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Connect the power supply and the receiver outputs on the corresponding relay board
plug-in terminals. Do this following the outputs diagram, which is supplied with the set.
This diagram indicates the correspondence between the transmitter commands and the
receiver outputs.
The STOP relays KSTOP1 and KSTOP2 are in series and must be connected to the
main contactor coil circuit.
The K2/START and K12 relays are activated when the start-up command is held down.
Remember to connect the ground cable.
Only use fireproof cables for connections.
Select the appropriate voltage on the receiver, (230, 115 or 48 Vac)

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4.3.- STARTING UP
Proceed with caution; the equipment may not be connected correctly
which may lead to unforeseeable movements on starting-up.
Once the receiver has been connected, disconnect the power supply to the motors, (for
example, by removing the fuses) and power on the receiver. With this, the receiver will
enter into a ‘SCANNING’ mode and the following LED’s will be lit in the receiver;
POWER: ON, indicates that the power supply is correct.
HARDOK: ON, indicates the absence of faults on the boards.
SIGNAL: OFF, in the case of the channels being signal free. Blinks ON when
there is a RF signal on the channels.
DATA: OFF, when there is not another TM70 system active in the area. Blinks
ON in the opposite case.
ID: OFF
Next, turn transmitter ON to OPERATION mode, as follows:

Place a charged battery in the transmitter.

Turn the contact key.

Push and pull out the STOP button, (LED flashes orange-green). If the transmitter
has LCD, it displays the identification of the machine, as well as the battery level.

Press the start button. The green LED should now light indicating that the
transmitter is transmitting.
1.- Label for crane identification.
2.- LED.
3.- Manoeuvre button.
4.- Contact key.
5.- Start button.
6.- STOP button.
7.-Option: Range Limitation.

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On receiving a signal from the transmitter, the receiver enters in OPERATION mode; the
following LED’s will light up on the receiver:
POWER: ON, indicates that the power supply is correct.
HARDOK: ON, indicates that defects have not been detected on the board.
SIGNAL: ON, indicates that it is receiving a RF signal at the working frequency.
DATA: When ON indicates that the data received has a correct format.
ID: When ON indicates that the receiver has recognized the transmitter’s
identification code.
Now, the STOP relays KSTOP1 and KSTOP2 will be activated. The K2/START and
K12 relays are activated when the start button is pushed in.
Press on any of the transmitter’s manoeuvre buttons and its corresponding relay will be
activated.
Check to make sure all the other manoeuvres work in this way.
Turn off the transmitter using the STOP button, and make sure that on doing so the
relays are deactivated and the DATA, ID and SIGNAL LED’s go out. They behave
exactly as in ‘SCANNING’ mode.
Reconnect the power supply to the motors, move to the usual work position and check
to see if all the manoeuvres and the stop button are functioning correctly.

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5.- USING THE SET
To ensure correct use of the equipment, follow the instructions below:
 Make sure the transmitter you are going to use is the right one, identifying the machine
on the identification label.
 Attach the belt to the transmitter unit. Its use is recommended to prevent the equipment
from falling.
 Insert a charged battery, turn the contact key and activate the transmitter.
 To activate the system, you must first pull out the STOP button, the LED should then
give an orange-green pulse; then press the START button. If you find that the STOP
button has already been pulled out, it is necessary to push it in and then pull it out
again, as this sequence will allow the check in of the STOP circuit. If the unit has
experienced a time-out auto-disconnection, it is not necessary to repeat the STOP
button procedure, simply push the START button for 1 second.
 The green LED should light up, indicating that the transmitter has started transmitting.
From now on, if any of the transmitter’s command buttons are pressed, the
corresponding manoeuvre will be activated.
 To be able to start up the transmitter, all the command controls associated with active
manoeuvres must be in the neutral position (not activated). This is not the case for the
selection functions.
 When 4 minutes have passed and no active manoeuvre command has been activated,
the transmitter automatically goes to STAND BY mode, indicated by green pulses each
3 seconds. To start it up once more, press the start button.
 The transmitter is equipped with a circuit for monitoring the battery level. When this level
drops below a pre-established limit, the transmitter LED starts to flash in red; 5 minutes
later the transmitter switches off, and the machine’s main contactor is deactivated.
During this time, the load has to be located on a safe position. If the STOP button is
activated during this time, transmitter will not start again, unless battery is replaced.
 To switch off the transmitter, press the STOP button or turn off the contact key.
Remember that you are going to remote control a moving piece of machinery.
The safety instructions described in chapter 2 of this manual must be strictly
adhered to.

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6.- MAINTENANCE
6.1.- WARRANTY
Drivecon guarantees the PWRSIII remote control sets for a period of up to Two years
after the date of delivery. This guarantee covers repairs and the replacement of
defective pieces at our Technical Service Department. Both the transmitter and receiver
will be necessary if any repairs or replacements need to be carried out.
The guarantee does not cover damage resulting from the following:
- Transport.
- Incorrect installation.
- Repairs or alterations made to the equipment by personnel other than from
Drivecon.
- Obvious misuse or incorrect maintenance of the equipment.
Our Technical Service reserves the right to evaluate breakdowns and damage.
Under no circumstances will Drivecon be held responsible for hold-ups at work,
accidents or expenses incurred as a result of equipment malfunctioning.
6.2.- PRECAUTIONS
This equipment is designed for use in an industrial environment. However, we
recommend you follow the instructions below to extend the life span of your remote
control set:
 Use the belt provided with the transmitter to prevent the transmitter from falling.
 Do not clean the transmitter with solvents or pressurised water. Use a damp cloth
or soft brush.
 Use and recharge the battery regularly.
 Check every day that the STOP pushbutton is working.
 Disconnect the receiver cables if soldering/welding work is going to be carried out
on the crane.
 Periodically check the condition of the transmitter rubber seals. Change these
over if they show signs of deterioration to ensure they remain watertight.
 Clean the battery contacts.

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6.3.- FAULT FINDING
The transmitter and receiver have status monitoring LED’s, which help to identify
irregularities. The most common signals are contained in the tables below:
TRANSMITTER
LED MEANS
Solid green Transmitter transmitting normally. OPERATION mode.
Green pulses. Transmitter ready for start-up. STAND BY mode.
Red slow flashing Battery level low
Red fast flashing Probably, EEPROM module is not plugged in.
Red double flashing Transmitter cannot start up because a manoeuvre command
is present. The pushbutton is depressed or damaged.
Solid red Transmitter failure
RECEIVER
In OPERATION mode the 5 LED’s must be lit as has been previously described in
section 4.3 Starting. If this is so, press the transmitter manoeuvre buttons and observe
the response of the output relays. If the response is normal, the problem is not related
to the remote control equipment and the installation must be checked. If any of the
relays is not activated, the problem is associated with the remote control equipment. If
this happens, observe the appearance of the LED’s:
LED LIT FLASHING OFF
POWER Power Supply OK -- Power Supply not OK
HARDOK Board OK Slow: fault in the board
Fast: error in EEPROM Fault in the board
SIGNAL RF signal OK RF signal detection in
SCANNING mode The receiver is not receiving RF signals
DATA -- Is receiving the correct
data from a PWRSIII Signal received is not correct
ID -- ID Code OK ID not recognised
There are also two LEDs in the received which will describe the status of the CAN-BUS.
If the CAN connection is not working, check the status of next LEDs:

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LED LIT FLASHING OFF
CAN_RUN Operating status Pre-operating status CAN communication non
active
CAN_ERR Communication
OK
Communication error CAN controller
disconnected
If the problem is associated with the equipment, please send both the transmitter and
the receiver to the your Technical Assistance Service Agent, together with a description
of the problem and the status of the LED’s.
If the transmitter becomes so damaged that a spare has to be arranged, it can be
quickly substituted by following the instructions in ANNEX A.

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6.4.- SPARE PARTS
Transmitter Bumper Kit 714SPII1051
BT06K Battery 714SPIII3692
CB60 Battery Charger 714SPIII3685
Power supply for CB60, 230 Vac 714SPIII6018
Power supply for CB60, 230 Vac UK 714SPIII6026
Power supply for CB60, 230 Vac AUS 714SPIII6036
Power supply for CB60, 115 Vac 714SPIII6027
Elastic Transmitter Strap 714SPIII5035
Strap B60 714SPIII5022
Reinforced strap B60C 714SPIII5030
Reinforced belt C60C 714SPIII5029
Pushbutton P70 714SPIII3670
Pushbutton Cover CP70 714SPIII3730
Start Key K60 714SPIII0170
Mushroom STOP EMS60 714SPIII3666
Selector Switch 1-0-1 M70 714SPIII3770
Selector Switch 1-0-1 S70 714SPIII3760
External antenna 900 MHz AE70 714SPIII9025
Cable MCX/BNC for external antenna 714SPIII5122
Fuse 714SPIII5001
6 Button Upper Cover PS70/1 714SPIII3731
6 Button Bottom Cover PI70/1 714SPIII3677
10 Button Upper Cover PS70/2 714SPIII3732
10 Button Bottom Cover PI70/2 714SPIII3678

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ANNEX A - PROGRAMMING OF A REPLACEMENT TRANSMITTER.
In case of damage to the transmitter, it is possible to quickly
restore service, if a replacement transmitter is available. To
achieve this the replacement transmitter has to be programmed
with the exact parameters of the system it is to work with.
These parameters are stored in the EEPROM memory modules
located in both the transmitter and the receiver. The
replacement transmitter can be programmed with the EEPROM
memory module from either the transmitter or the receiver, if old
transmitter memory module is not available.
The EEPROM module can be easily accessed from the exterior
of the transmitter. In order to do so, switch off the damaged
transmitter and extract the EEPROM module by loosening the
two screws, as shown, and then insert this module into the replacement transmitter.
Next, proceed as follows:
1. With the replacement transmitter off, remove its EEPROM module as described above,
and insert the EEPROM module
containing system information (old
transmitter or receiver module).
2. Insert a charged battery, turn on the
ON/OFF key, push and extract the
STOP button. The LED will pulse green
for around 15 seconds.
3. To copy EEPROM memory module
contents into the internal memory of the
transmitter, press and hold pushbutton
number 6 followed by the START. Keep
both buttons depressed until the LED
starts to blink orange, then release. The
LED will light up green once parameters
have been copied. (In case the LED
remains red, repeat the process.)
4. With the transmitter still ON, extract the
EEPROM and replace it into the original transmitter or receiver. Insert the empty
EEPROM into the replacement transmitter and again press pushbutton 6. The LED will
flash orange, which indicates that the empty EEPROM is being written with the stored
parameters. Wait for the orange LED to turn off. In case the LED remains in red repeat
the process.
5. Press the STOP button. This completes the programming processes.

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RADIO RECEIVER
NEUTRAL
WIRE #
PWRSIII-6213
STANDARD WIRING DIAGRAM
K4 RL2
RL2
1
K10
K11
K9
RL2
5
K7
K8
K6
3
RL2
2
RL2
RL2
4
RL2
7
6
RL2
8
RL2
11
EXTERNAL 110VAC
POWER
(X1)
WIRE #
GND
RL2
9
K5
K3
K12
HORNRL1
11
RL1
13
K2
STARTRL1
9
7
RL1
RL1
10
STOP
12
10
RL2
RL2
RL1
8
16 AWG
1
110VAC
230VAC
RL0
RL0
HOT
2
1
48VAC
2ND SPEED
BRIDGE FORWARD
1ST SPEED
BRIDGE REVERSE
1ST SPEED
7
8BRIDGE
6
TROLLEY
2ND SPEED
2ND SPEED
TROLLEY RIGHT
1ST SPEED
TROLLEY LEFT
1ST SPEED
15
14
13
11 HOIST
EXTERNAL 110VAC
MAINLINE (MAINTAINED)
START (MOMENTARY)
HORN
(ALL CONTROL CONTACTS "DRY")
(IF CONTROL POWER NOT AVAILABLE CONNECT WITH WIRE #1)
HOIST UP
1ST SPEED
HOIST DOWN
1ST SPEED
CONTROL POWER
9
10
5
12
WIRE #
3
4
ACCORDING TO
AC LINE SUPPLY VOLTAGE.
CONFIGURE
JUMPER JP1
RL0
4
16 AWG
WIRE #
NEUTRAL
2
(X2)

820 Lakeside Dr 
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Gurnee, IL 60031 
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3
RL2 RL2
RL2
RL2
RL2 RL2
RL2
RL2
RL2 RL2
RL2
RL2
STOP
RL1 RL1
7 8
K2
STARTRL1 RL1
9 10
RL1 RL1
K12
HORN
11 13
16 AWG
K13
K14
RLO
RLO
RLO
RLO
64
31
16 AWG
21 WIRE #WIRE #
9
10
11
13
14
15
6
7
8
WIRE #
4
3
12
WIRE #
5
16
17
SELECT I
SELECT II
TROLLEY
2ND SPEED
HOIST
2ND SPEED
BRIDGE
2ND SPEED
HOIST UP
1ST SPEED
HOIST DOWN
1ST SPEED
TROLLEY RIGHT
1ST SPEED
TROLLEY LEFT
1ST SPEED
BRIDGE FORWARD
1ST SPEED
BRIDGE REVERSE
1ST SPEED
EXTERNAL 110VAC
POWER
(X1)
EXTERNAL 110VAC
NEUTRAL
(X2)
MAINLINE (MAINTAINED)
START (MOMENTARY)
HORN
CONTROL POWER
(ALL CONTROL CONTACTS "DRY")
(IF CONTROL POWER NOT AVAILABLE CONNECT WITH WIRE #1)
PWRSIII-10213
STANDARD WIRING DIAGRAM
K9
K6
K3
48VAC
RL0
1
RL0
2
RL0
GND
110VAC
230VAC
RADIO RECEIVER
CONFIGURE
JUMPER JP1
ACCORDING TO
AC LINE SUPPLY VOLTAGE.
K5
K4
K8
K7
K11
K10
HOT NEUTRAL
4
9 12
10
11
5 8
6
7
1 4
2

820 Lakeside Dr 

Gurnee, IL 60031 

Ph: [phone]

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13
RL2RL2
19
19
4 6
K14
1
RLO RLO
3
1K2
K13
RLO
R8CAN
RLO
20
16
17
20
1K3
1K1
R8CAN
1
R8CAN
R8CAN
18
K10
K11
RL2
3
RL2
2
18
8
7
K7
K9
1
RL2
4
RL2
RL2
7
K8
5
RL2
6
8
6
15
14
STANDARD WIRING DIAGRAM
PWRSIII-10221
AC LINE SUPPLY VOLTAGE.
K4
K6
11
RL2
K5
K3
RL2
9
RL2
10
RL2
12
10
11
9
HORN RL1RL1
11 13
RL1
9
K12
RL1 START
K2
10
WIRE #
5
16 AWG
WIRE # 1
RL0
STOP
7
RL1
GND
8
RL1
RL0
2
1
HOT
RL0
48VAC
230VAC
110VAC
ACCORDING TO
JUMPER JP1
CONFIGURE
4
NEUTRAL
RADIO RECEIVER
4
12
3
WIRE #
WIRE #
16 AWG
2
1ST SPEED
2ND SPEED
BRIDGE
1ST SPEED
1ST SPEED
2ND SPEED
TROLLEY
1ST SPEED
1ST SPEED
(IF CONTROL POWER NOT AVAILABLE CONNECT WITH WIRE #1)
(ALL CONTROL CONTACTS "DRY")
CONTROL POWER
HOIST DOWN
1ST SPEED
2ND SPEED
HOIST
1ST SPEED
HOIST UP
(X1)
POWER
EXTERNAL 110VAC
MAINLINE (MAINTAINED)
HORN
START (MOMENTARY)
EXTERNAL 110VAC
(X2)
NEUTRAL
TROLLEY RIGHT
AUX HOIST DOWN
AUX HOIST UP
BRIDGE REVERSE
BRIDGE FORWARD
TROLLEY LEFT
1ST SPEED
SELECT II
SELECT I
AUX HOIST
2ND SPEED