Magnetek Laser Guard User manual

Laser Guard
Laser Anti-Collision System
Instruction Manual
TC14K-0 Rev. I October 2009
Part Number: 21316T
©Copyright 2009 Magnetek Material Handling

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Table of Contents
Telemotive Laser Guard Instruction Manual – October 2009
i
Section 1 – Service Information...............................................................................................................................................1
1-1. Service Information .........................................................................................................................................1
Section 2 – Crane Safety..........................................................................................................................................................3
2-1. Introduction ......................................................................................................................................................3
2-2. General .............................................................................................................................................................3
2-3. Persons Authorized To Operate Cranes ............................................................................................................3
2-4. Training Checklist For Crane Operators...........................................................................................................3
2-5. Operating Area .................................................................................................................................................3
2-6. Anti-collision Unit............................................................................................................................................3
2-7. Operating The Crane.........................................................................................................................................4
2-8. Boarding The Crane..........................................................................................................................................4
2-9. Crane Repair.....................................................................................................................................................5
2-10. Using The Crane As A Work Platform...........................................................................................................5
2-11. Condition Of The Crane .................................................................................................................................6
Section 3 – General System Information .................................................................................................................................7
3-1. Class 1 Laser Device ........................................................................................................................................7
3-2. Laser Anti-Collision System Description .........................................................................................................7
3-3. Optical Path Fault Detector...............................................................................................................................7
3-4. Fault Relay........................................................................................................................................................7
3-5. Specifications....................................................................................................................................................8
Section 4 – Installation Information.........................................................................................................................................9
4-1. Mounting Location Considerations...................................................................................................................9
4-2. Line Input Considerations.................................................................................................................................9
4-3. Wiring Considerations ......................................................................................................................................9
4-4. Mechanical Installation.....................................................................................................................................9
4-5. Electrical Installation ......................................................................................................................................10
4-6. Mechanical Alignment....................................................................................................................................10
4-7. Range Detector Settings (Static Method)........................................................................................................11
4-8. Optical Path Fault Detector Checkout ............................................................................................................11
4-9. Trouble Shooting ............................................................................................................................................11
Table 4-1. Range verses Test Point Voltage ..........................................................................................................13
Table 4-2. Laser Diagnostic LED Functions..........................................................................................................14
Section 5 - Laser Guard Replacement Parts List....................................................................................................................15
Section 6 – Installation Diagrams ..........................................................................................................................................16
Figure 6-1. Laser and Target Installation ...............................................................................................................16
Figure 6-2. Conduit Installation .............................................................................................................................17
Figure 6-3. Laser Support Unit E14008-0 Board Wiring (110 VAC and 240 VAC Unit) .....................................18
Figure 6-4. Laser Support Unit E14001-0 Board Wiring (110 VAC Unit) ............................................................19
Figure 6-5. Laser Support Unit E14008-0 and E14001-0 Board Wiring (250 VDC Unit) ....................................20
Figure 6-6A. Laser Support Unit E14008-0 and E14001-0 Board Wiring (8-30 VDC Unit).................................21
Figure 6-6B. Laser Support Unit E14008-0 and E14001-0 Board Alt. Wiring (10-40 VDC Unit)........................22
Figure 6-7. Laser Connector Wiring Diagram .......................................................................................................23
Figure 6-8. Laser Optical Unit and Mounting Assembly .......................................................................................24
Figure 6-9. Template for Laser Base Mounting Holes...........................................................................................25
Figure 6-10. Template for Laser Optical Mounting Holes.....................................................................................26
Figure 6-11. Target Dimensions.............................................................................................................................27
Figure 6-12. Enclosure Dimensions.......................................................................................................................28
Figure 6-13. Test Point Locations..........................................................................................................................29
Figure 6-14. Laser Guard Crane Magnetic Control, Protection in One Direction..................................................30
Figure 6-15. Laser Guard Crane Control with Timed Bypass, Protection in One Direction ..................................31
Figure 6-16. Laser Guard Stepped VFD or Magnetic Crane Control, Protection in Both Directions ....................32
Figure 6-17. Laser Guard Stepped VFD or Magnetic Crane Control, Protection in One Direction.......................33
Figure 6-18. Typical Laser Guard Interface with Stepless VFD Control ...............................................................34
Figure 6-19. Typical Laser Guard Interface with P&H Stepless VFD Control ......................................................35

Telemotive Laser Guard Instruction Manual – October 2009
ii
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Section 1 – Service Information
Telemotive Laser Guard Instruction Manual – October 2009
1
1-1. Service Information.
U.S. Service Information
For questions regarding service or technical information contact:
1-866-MAG-SERV
(1-866-624-7378).
Magnetek Material Handling
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: [phone]
Website: www.magnetekmh.com
e-mail: [email protected]
Fax Numbers:
Main: 800-298-3503
Sales: 262-783-3510
Service: 262-783-3508
Canada Service Information:
2610 Dunwin Drive
Mississauga, Ontario
L5L 1J5 Canada
Phone: [phone]
Fax: [phone]

Telemotive Laser Guard Instruction Manual – October 2009
2
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Section 2 - Crane Safety
Telemotive Laser Guard Instruction Manual – October 2009
3
2-1. Introduction.
The safety rules in this section are not intended to
replace any rules or regulations or any applicable
local, state, or federal governing organizations. The
following information is intended to be used in
conjunction with other rules or regulations already in
existence. It is important to read all of the safety
information contained in this section before operating
the Radio Control System.
2-2. General.
Overhead cranes and other material handling
equipment operate in several directions. They are
large, bulky pieces of equipment that handle heavy
loads efficiently at high speeds. Quite frequently, the
equipment is operated in areas where people are
working on the floor below. The crane operator must
exercise extreme caution at all times. Workers must
constantly be alert to avoid accidents. The following
rules have been included to indicate how your careful
and thoughtful actions may prevent injuries, damage
to equipment, or even save a life. If radio controlled
material-handling equipment is operated from the
cab, special care must be taken to secure the trans-
mitter. Refer to paragraph titled "Boarding The
Crane" for specific safety rules.
2-3. Persons Authorized To Operate Cranes.
Only properly trained persons designated by
management should be permitted to operate cranes.
Any person who cannot read or understand signs,
notices and operating instructions that pertain to the
crane should not operate Cranes.
Cranes should not be operated by any person with
insufficient eyesight or hearing or by any person who
may be suffering from a disorder or illness or is
taking any medication that may cause loss of crane
control.
2-4. Training Checklist For Crane Operators.
Anyone being trained to operate a radio-controlled
crane should possess the following knowledge and
skills before operating the crane:
Knowledge of hazards peculiar to crane operation.
Knowledge of safety rules for cranes.
Ability to judge distance or moving objects.
Knowledge of the crane control device.
Limit switch and anti-collision test procedure.
Where authorized, instructions for plugging motions.
Observing crane signal lights.
Avoid striking any obstructions.
Proper clearance of lifts or hooks before moving
bridge or trolley.
Transferring crane control to another person.
Reporting unsafe or unusual operating conditions.
Caution in approaching bridge or trolley bumpers.
Equipment capacity.
Making lifts below floor level.
Making side pulls.
Keeping body clear of lifts and avoiding "pinch"
points.
Cable and hook inspection.
Procedures for testing hoist, trolley, and bridge
brakes.
2-5. Operating Area.
Aisles between equipment, stock, etc., should be free
of obstructions so the crane operator can move freely.
These aisles should be a minimum of 3 feet wide, or
meet local regulations.
Crane operators should always position themselves
for the best view of the crane they are controlling.
The crane should never be operated blindly. The
operator should stay as close to the crane load as
possible. Operators should never position themselves
in a "pinch" point.
2-6. Anti-collision Unit
Range detector relays should never be electrically or
mechanically disabled to be ON or OFF for any crane
motion. If the unit is for any reason disengaged or
turned off the crane operating personnel must be
notified immediately and proper alternate operation
precautions taken.

Section 2 - Crane Safety (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
4
2-7. Operating The Crane.
The crane anti-collision unit and limit switches if any
should be checked at the beginning of each shift or
when a new operator takes control of the crane.
When checking anti-collision unit and limit switches
the hoist should be centered over an area free of
personnel and equipment.
The anti-collision unit and limit switches should
never be used as a regular stopping device. They are
intended to be protective devices.
The bridge and trolley brakes should be tested at the
beginning of each shift or when a new operator takes
control of the crane. On cranes so equipped with two
or more speeds, use the "lowest" speed when testing
braking devices.
When lifting maximum loads, the crane operator
should test the hoist brakes by raising the load a few
inches from the floor. If the brakes do not hold, the
load should immediately be lowered to the floor and
a report made to the supervisor.
Do not make lifts in excess of the equipment rated
capacity.
The bridge and trolley should be centered directly
over the load when the load is raised to prevent
swinging when making lifts.
Side pulls should be made by a crane designed for
this purpose and only with supervisor permission.
When a lift is being made, the crane operator should
not be positioned in the line of travel. The crane or
hoist should be operated from a position either to the
side or opposite from the direction of travel.
When raising or lowering a load, proceed slowly and
make certain the load is under control. Tag lines
should be used for handling unusual lengths or bulky
loads. Remove slack from chains or slings gradually.
Make certain all personnel are clear before making a
lift.
The crane operator should keep all body parts away
from the lift and should never be positioned under the
lift.
Do not make a lift or move a load if anyone is in a
location where they could be struck by the crane or
the load.
If the crane operator is being helped, the crane should
not be moved until the helper signals they are clear of
the crane and its load.
When a load is hanging from the crane hook and the
crane is being moved, the crane operator should
sound all warning devices frequently.
Loads should not be carried over workers heads. If a
worker is in the path of crane travel, the crane
operator should stop the crane and clear the area
before proceeding.
Runway stops or other cranes should never be
bumped into.
When moving the crane, the crane operator should be
sure that the hook block and attachments or cables
would not catch on nearby equipment. Slings, chains,
or cables should never be dragged along the floor.
Unless required for operator safety, gloves should not
be worn when operating the transmitter unit.
All loose materials or parts should be removed from
the load before starting the lift.
The crane operator should always hoist lifts high
enough to clear all equipment and workers.
The crane operator should never permit anyone to
ride on the load or hook except when authorized by
the supervisor.
When another crane on the same runway is stationary
with a load hanging, the crane operator should
maintain a safe distance between the stationary crane
and the one under their control.
If power to the crane is removed, the crane operator
should turn the transmitter unit OFF and keep it OFF
until power is restored.
If the crane fails to respond properly, the crane
operator should stop operation, turn the transmitter
unit OFF and immediately report the condition to
their supervisor.
Outdoor cranes, which are subject to movement by
wind, should be securely anchored when left
unattended. If the crane is equipped with bridge
brakes, the parking brake should be set immediately.

Section 2 - Crane Safety (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
5
2-8. Boarding The Crane.
The crane should not be boarded without permission
of the supervisor.
The crane operator should turn off the transmitter and
take it with them when boarding the crane.
If more than one person is boarding the crane, one
person should be made responsible for ensuring all
personnel are off the crane before the system is
returned to operation.
2-9. Crane Repair.
Minor repairs include routine maintenance and
repairs such as greasing, cleaning and control
troubleshooting. All other repairs should be
considered major. If the repair crew consists of more
than one person, one person should be designated as
the repair crew leader with the following
responsibilities. If the repair crew consists of only
one person, that person has the following
responsibilities:
Warning signs should be placed on the floor beneath
the crane or suspended from the crane. For major
repairs, the floor area below the crane should be
roped off.
When major repairs are to take place, all persons
operating other cranes on the same or adjacent
runways, if any, must be notified prior to starting
repairs. Notification should include the nature of the
repair, safeguards provided, and movement
limitations while repairs are in progress.
When practical, radio controlled cranes which cannot
be moved during repairs must be protected against
being bumped by other cranes on the runway.
Bumpers should be installed on the exposed side or
sides of the crane under repair. They should be
placed as far away as possible. The location of these
bumpers should be indicated by red lights placed so
that they are clearly visible to other crane operators
traveling on the same runway. When it is not possible
to use bumpers, red lights must be placed so they are
clearly visible to other crane operators traveling on
the same runway to indicate the restricted travel zone.
All crane operators on the same runway must be
informed of the repair effort and thoroughly
instructed to what their operations are limited to and
informed they will be notified when repairs are
completed.
If any hazard involving the repairmen exists when
there is a runway adjacent to the crane under repair,
the adjacent runway should be blocked off as
described above. When it is necessary to continue
crane operation on the adjacent runways warning
lights must be installed and be visible to operators of
cranes on those runways. All cranes should come to a
complete stop prior to entering the restricted area and
should proceed through this area only after receiving
permission from a signal person designated for this
purpose. Access of persons to and from the crane
being repaired should be under control of the repair
crew leader.
When boarding the crane, the transmitter should be
turned OFF and the transmitter should remain with
the repair crew leader. The leader should board the
crane first, open and lock out the main switch, and
then signal the other members of the crew it is safe to
board the crane.
If work on the crane is to be done in areas not
protected by standard handrails, the repair crew
should wear approved safety belts.
All tools and equipment should be moved onto the
crane by the use of hand lines. The tools and
equipment should be adequately secured to the hand
lines.
If it is necessary to have the crane control circuits
energized, all power circuits for crane movement
must be opened prior to energizing the control
circuits.
All personnel and tools should be moved to a safe
spot before moving the crane during repairs.
Headroom is at a minimum in some crane cabs and
on some crane walkways. Caution should be
exercised when boarding or working on cranes. Hard
hats should be worn whenever possible.
When repairs are finished, all personnel, tools and
repair equipment should be removed before
energizing the crane circuits.
2-10. Using The Crane As A Work Platform.
When the crane is to be used as a stationary work
platform, follow all rules provided in "Crane Repair"
section.
When it is necessary for the crane to be moved from
time to time, the crane operator should board the

Section 2 - Crane Safety (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
6
crane with the transmitter unit. The crane operator
should ensure all personnel working on the crane are
in a secure position before moving the crane to the
next workstation. It should also be the crane
operators responsibility to ensure the main switch is
open and locked down before work is resumed.
WARNING
THE CRANE OPERATOR SHOULD NOT AT-
TEMPT TO MAKE ANY OF THE REPAIRS
STATED BELOW. THE CRANE CONDITION
SHOULD BE REPORTED TO THE SUPERVISOR.
2-11. Condition Of The Crane.
If the crane fails to respond properly, the crane
operator should notify their supervisor. When serious
conditions are noticed (conditions that make the
crane unsafe to operate), the crane should be shut
down immediately and the supervisor notified. The
following is a list of what should be included in the
report:
Condition of hoisting cable and hook block
(broken strands, clipped sheave wheels, etc.).
Condition of brakes (hoist, trolley, and bridge).
Alignment of bridge (screeching or squealing wheels
indicate bridge is out of line).
Broken, cracked, or chipped rails on trolley or
runway.
Condition of limit switches.
Condition of electrical and mechanical control
(electrical or mechanical defects which cause faulty
operation such as un-commanded stopping or starting
of any crane motions, warning devices, lights, or
auxiliary functions).
Condition of gears (grinding or squealing may
indicate foreign materials in gear teeth or a lack of
lubrication.
Frequent relay tripping of power circuits.
Mechanical parts loosened by vibration (loose rivets,
covers, bolts, etc.).
Uneven riding (worn wheels).
Condition of collector shoes or bars.
Condition of warning or signal lights (burned out or
broken).

Section 3 – General System Information
Telemotive Laser Guard Instruction Manual – October 2009
7
3-1. Class 1 Laser Device
The Telemotive Anti-Collision System contains a
Class 1 laser because of this no special protection on
the part of the installer or user is needed. However, it
is recommended that no one look directly into the
laser with their eye close to the lens of the laser unit.
Do not open the laser unit to service it since there are
no serviceable parts inside.
3-2. Laser Anti-Collision System Description
Telemotive's Anti-Collision System measures the
distance between the laser unit's lens and its
companion retro-reflective target by means of pulse
timing techniques that allow for very accurate
measurements. The laser communicates with the
range detector module by means of a 4 mA to 20 mA
current loop. This type of communications link has
very high noise immunity and provides the necessary
accuracy for a collision avoidance system. The laser
used in the Laser Guard system is set to measure
distances from 5 ft. to 150 ft. with an output current
of 4 mA at 5 ft. and 20 mA at 150 ft. Should a fault
occur within the laser unit, the output will drop to 0
ma. The laser unit uses a modified light beam making
system alignment very easy. On the back of the laser
are two LEDs. The red LED indicates a laser self-
check when power is first applied, and a laser failure
if it stays on. The green LED displays laser received
signal strength and is used for alignment purposes.
The laser unit is connected to range detector and
power supply modules by means of a shielded
twisted pair cable.
A rugged, fully adjustable (azimuth/elevation) mount
is also supplied with the system, along with a
reflective target. The target is mounted on the wall or
other crane that you wish to avoid hitting.
The range detector module contains three fully
adjustable range detectors; a fault detector, and two
out-of-sequence detectors. The range detectors are
adjustable from 10 ft. to 150 ft. where the first point
detector is set for the distance that you want the first
stage of crane deceleration to take place. Range
detector two sets stage two of deceleration, and the
third detector is used to set the point where you want
the crane brakes to be applied. The relationship
between these points is as follows:
150 ft. ≥RANGE 1> RANGE 2> RANGE 3≥10 ft.
If the above sequence is not maintained, an out-of-
sequence error will occur which will dropout the
third range point and the fault detector. This will stop
the crane and prevent it from being moved in the
protected direction until the sequence is corrected.
One or both of the out-of-sequence LEDs will be on
identifying which range detectors must be readjusted.
Adjusting the third range detector for less than 10 ft.
will cause the third range detector and the fault
detector to drop out. Setting the other range detectors
for less than 10 ft. will cause an out-of-sequence
error because the third range detector cannot be set
for less than 10 ft. Each range detector and the fault
detector have a form C relay output that is normally
energized until a range point or a fault is detected.
The markings on the range detector module show the
de-energized state of the relays. Also contained in the
range detector unit are the power supply and power
input modules.
3-3. Optical Path Fault Detector
This Laser Anti-Collision System contains a Laser
Optical Fault Degradation Detector. When this
system detects a loss in the optical path due to dirty
optics, dirty target, obstructions between the two or
misalignment of the laser and its target, it will
produce a 30 second fault. This will cause the fault
relay and the third range point relay to drop out for
30 seconds. After this 30-second period, the system
will return back to normal operation until the fault is
detected again. This is the only fault condition that
lasts 30 seconds, (all other fault conditions do not
time out) thereby making it easy to determine that an
optical path problem has occurred and maintenance is
needed to clean the lenses of the laser unit and/or the
target. In some instances, the laser may have become
loose and may need to be realigned. This unique
circuitry performs a dynamic test every time the first
range point is detected. It will produce the above
described fault condition any time that this point is
detected approximately 10% or more below its preset
range.
3-4. Fault Relay
A separate form C relay is provided to drive a
warning light or enunciator in the event of a fault.
The relay is normally energized and if a fault occurs
the relay switches. Faults can be the loss of the
target, setting out of sequence, laser head failure, or
circuit failures.

Section 3 – General System Information (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
8
3-5. System Specifications
Operating range: 10 to 150 ft.
Laser Rating: Certified as Class 1 (eye safe)
Accuracy: Better than 0.5 ft. over the total range
Laser Beam: Modified for anti-collision applications
Control Outputs: Three relay contacts with 1 form C
rated at 10 Amps, 270 VAC, 27 VDC
Fault Output: Relay output 1 form C rated at 10
Amps
Power Source: 95 to 130 VAC, 140 to 260 VAC,
180 to 300 VDC, and 8 to 30 VDC
Operating Temperature: -30°C to +70°C
Enclosure: NEMA 4 rating
Laser Unit Dimensions: Approximately 5.5" x 5.5" x
2.5"
Weight: 3.3 lbs.
Laser Support Unit Dimensions: Approximately 10"
x 10" x 6"
Weight: 12.2 lbs.
Reflective Panel Dimensions: Approximately 24" x
24"

Section 4 – Installation Information
Telemotive Laser Guard Instruction Manual – October 2009
9
CAUTION
THE LASER CONTROL UNIT AND RELAYS
ARE NOT RATED AS EXPLOSION PROOF. THE
UNIT MUST NOT BE INSTALLED IN EXPLO-
SIVE ENVIRONMENTS UNLESS APPROPRIATE
SECONDARY ENCLOSURE MEASURES ARE
TAKEN.
4-1. Mounting Location Considerations.
Ensure the mounting location is as far as possible
from exposed trolley wires and sources of
electromagnetic or radiated noise.
If possible, avoid installing receiver unit to a surface
where high vibration or shock is present. If this
cannot be avoided, use appropriate shock mounts.
4-2. Line Input Considerations.
Check the system drawings for proper line input
voltage. If there is any question as to proper line
input voltage contact Telemotive before applying
power to the unit.
WARNING
THE UNIT MUST BE WIRED TO THE CORRECT
VOLTAGE, FAILURE TO DO SO MAY DAMAGE
THE SYSTEM.
NOTE
THE UNIT SHOULD NOT BE CONNECTED TO
LINES CONTAINING EXCESSIVE POWER UP
TRANSIENTS OR CONTINUOUS COMMUTA-
TOR NOISE. A LINE CONDITIONER MAY BE
NECESSARY IN SOME INSTALLATIONS.
4-3. Wiring Considerations.
1. Do not connect or disconnect wiring, or perform
circuit checks while the power is turned on.
2. The motor wiring shall be in a separate metal
conduit from the power wiring, which shall also
be in metal conduit.
3. Low voltage wires shall be wired with Class 1
wiring.
4. Control wiring shall be in separate conduit and
shall be kept as short as possible.
5. Control wiring for stepless devices shall be
shielded twisted pair. The shield should be
grounded at both ends.
6. All terminals shall be tightened to specified
terminal torque (4.4 IN-LBS. unless otherwise
specified).
7. Please observe National Electric Code (NEC)
when wiring electrical devices.
8. When cutting holes in cabinet take care to
prevent metal filings from shorting circuitry.
Remove excess metal screws, metal filings and
wire clippings from inside of unit.
9. Inspect to make sure no exposed wire has contact
with any other wiring or terminals.
10. Suppressors are strongly recommended on all
contactors.
4-4. Mechanical Installation
The Anti-Collision System measures the distance
between the laser unit's lens and the target surface.
There must be no projections on the wall or the
overhead crane that may extend in front of either (or
both) the laser unit or the companion target.
Make sure the laser is mounted such that nothing can
come between the laser's view of the target and at
least 5 ft. (preferably 10 ft.) from walls or other
objects that may act as a target. If your particular
installation is a crane-to-crane application, do not
mount the lasers on each crane so that their beam
centers as they face each other are closer than 5 ft.
(preferably 10 ft.) apart.
Determine the mounting position for the laser and the
target such that the center of the laser's faceplate and
the center of the target are the same distance above
the plane the crane rails are in. The laser and target
center point should also be the same distance from
the rails. This is the most important part of a
successful installation since the laser beam must stay
on the target at all range points anywhere in the bay.
Refer to Figures 6-8, 6-9 and 6-10 for mounting
information.
Install the laser and the target in the positions found
in steps above (refer to Figure 6-1). Mount the laser
securely to a solid surface so that the crane’s load or
movement will not affect the laser’s alignment. The
laser should also be mounted as close

Section 4 – Installation Information (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
10
to the control panel as possible to minimize long
cable runs. The range detector unit should be
mounted next to the crane's control panel (refer to
Figure 6-12).
Mounting of the reflector target is not as critical as
the laser (refer to Figure 6-11).
For outdoor applications, care must be taken to assure
all conduits and enclosures are sealed to prevent
water from entering.
4-5. Electrical Installation
The laser unit interface cable and all other wiring
should be run in separate 1/2" or 3/4" conduit. Do not
run any other cables in the same conduit with the
laser head cable.
A suitable disconnect should be provided by the
installer.
Run conduit between the range detector unit and the
crane's control panel.
Run conduit from the range detector unit to about 1
ft. from the laser unit. Putting a slight downward
bend in the conduit at the laser transceiver will help
keep dirt and water out. Place a protective end piece
on the open end of the conduit to protect the laser
cable from sharp edges.
Pull the supplied laser cable by the end that does not
have a connector on it through the conduit starting
from the opened laser unit end and into the range
detector unit. Leave enough cable on the laser end so
that it is twice as long as the distance between the end
of the conduit and the laser unit (about 2 ft. to 3 ft.).
This will produce a service loop, which will also help
keep dirt and water out of the open end of conduit
(refer to Figure 6-2). This cable consists of two
twisted pairs of red and black wire and an un-
insulated GND drain wire. See Figures 6-3, 6-4, 6-5,
6-6A and 6-7 for wiring information for this cable.
Plug the connector into the laser unit. The connector
is keyed; do not force.
Two styles range detector boards are available; style
A (E14001) with an external supply and style B
(E14008) with integral regulator. Figures 6-3
(110/240 VAC), 6-5 (250 VDC), and 6-6A (8-30
VDC) show the connections for style B. Figures 6-4
(110/240 VAC), 6-5 (250 VDC) and 6-6A (8-30
VDC) show the connections for style A. Style B
boards can directly replace style A boards.
Wire the outputs of the range detector unit (J1) to the
crane control panel (refer to Figures 6-3, 6-4, 6-5, 6-
6A and 6-7). Please note that the "NO" and "NC"
markings on the range detector module are the
conditions of the output relays when a range point or
a fault has been detected. Place snubbers across the
contactor coils in the crane's control panel that are to
be controlled as necessary.
Run power to the power input module in the range
detector unit (refer to Figures 6-3, 6-4, 6-5, 6-6A and
6-7). Make certain that the input power you provide
matches the input requirements of the power supply
used in this system. If it does not, stop here and
notify Telemotive Customer Service.
Turn the power switch in the range detector unit on
and note that the red LED on the laser head blinks on
momentarily, and the green LED is blinking or on
continuously. If the above does not occur, turn the
power off and recheck all wiring.
For wiring special crane configurations such as
magnetic control, timed bypass, stepped or stepless
VFD, see the figures listed below in the back of the
manual.
Figure 6-14. Laser Guard Crane Magnetic Control,
Protection in One Direction
Figure 6-15. Laser Guard Crane Control with
Timed Bypass, Protection in One Direction
Figure 6-16. Laser Guard Stepped VFD or
Magnetic Crane Control, Protection in Both
Directions
Figure 6-17. Laser Guard Stepped VFD or
Magnetic Crane Control, Protection in One
Direction
Figure 6-18. Typical Laser Guard Interface with
Stepless VFD Control
Figure 6-19. Typical Laser Guard Interface with
P&H Stepless VFD Control
4-6. Mechanical Alignment
Make initial adjustments of the range detectors as
follows:
With a voltmeter connected between GND (TP4) and
TP1, adjust the 1st range pot for 10V. (Refer to
Figure 6-13. for location of test points). Move the
meter to TP2 and adjust the 2nd range pot for 5 V.
Finally, move the meter to TP3 and adjust the 3rd
range pot for 3 V. At this point, all out-of-sequence

Section 4 – Installation Information (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
11
LEDs (DS5 and DS6) should be off. If the out-of-
sequence LEDs are on, recheck the above
adjustments. Should these LEDs still be on, stop here
and notify Telemotive Customer Service.
Move the crane with the laser to about 50 ft. to 75 ft.
from its target. Turn all unnecessary power to the
crane off, except for the laser system. Turn the power
switch to the laser system on. If the power was on,
turn it off and then back on again. Note that the red
LED on the back of the laser head flashes on
momentarily, and then the green LED on the back of
the laser head will start blinking or be on
continuously. If the red LED stays on, there is a fault
condition with the laser unit and it will have to be
replaced.
Loosen the two bolts on both sides of the "U" bracket
of the laser mount and the one bolt at the bottom of
the "U" bracket so the laser head can be moved up
and down, and from left to right with just enough
friction so the laser head does not fall over on its
own.
By "eye sighting", try to point the laser head at the
target. If the green LED on the back of the laser head
should come on "steady", you are aimed "on target".
Otherwise, you will find the target in the steps below:
While watching the green LED on the back of the
laser head, move the laser head slowly up and down,
and at the same time moving the laser even more
slowly from side to side. Stop when the green LED
starts blinking fast or comes on continuously.
Slowly move the laser head upward until the green
LED starts to blink slowly. Note this point. Now
move laser unit downward until the LED again blinks
slowly. Note this point and position the laser unit
halfway between these points. If you cannot find a
point that makes the green LED blink fast or stay on
continuously, then move the crane a little closer to
the target and repeat the above steps. Alternately
tighten the two bolts on the sides of the "U" bracket a
little at a time until they are tight. This will prevent
the laser unit from moving while tightening the bolts.
Now move the laser unit from side-to-side and note
the points on both sides of the target that the green
LED starts to blink slowly. Position the laser unit to
the center of these two points. While keeping the
laser unit from moving, carefully tighten the one bolt
at the bottom of the "U" bracket.
4-7. Range Detector Settings (Static Method)
1. Park the crane in a safe place with all power
removed from the crane controls. Apply power
to the laser system. During the following
adjustments, disregard the out-of-sequence
lights.
2. Determine the range for the first point of crane
deceleration (maximum range point). Determine
the reference voltage for that range using the
curve in Figure 4-1, at the end of this Section.
3. With your voltmeter connected between GND
(TP4) and TP1, (refer to Figure 6-13 for test
point location) adjust the first range point pot
until the meter reads the same as the voltage in
step (.2).
4. Determine the range for the second point of
crane deceleration. This range point must be less
than that in step (2). Determine the reference
voltage for that range as in step (2).
5. With your voltmeter connected between the
GND (TP4) and TP2, adjust the second range
point pot until the meter reads the same as the
voltage in step (4).
6. Determine the range for the third point where the
brakes are to be applied. This range point must
be less than that in step (4). Determine the
reference voltage for that range as in step (2).
7. With your voltmeter connected between the
GND (TP4) and TP3, adjust the third range point
pot until the meter reads the same as the voltage
in step (6). At this time, the out-of-sequence
lights should not be lit. If they are, refer to the
troubleshooting section in this manual.
8. Power up the crane and cautiously run the crane
up and down the bay to verify that your settings
are correct and the system functions properly for
your application. You may "fine tune" these
adjustments as necessary. Refer to the
troubleshooting section (Section 4-9 and Table
4-2) of this manual if out-of-sequence lights
come on when fine-tuning.
4-8. Optical Path Fault Detector Checkout
This circuitry may be triggered while you are doing
the installation and adjustment of the system, and it
will not have any affect on the installation, since it is

Section 4 – Installation Information (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
12
done in a static mode. Therefore, disregard the
operation of these circuits during the installation.
After the installation has been completed, you may
have to wait 30 seconds before you can perform a
dynamic test of the system.
The Laser Optical Path Fault Detector may be tested
by bringing the laser to a distance from the target that
is between the first and second range points, then
momentarily block the laser’s view of the target.
This should cause a 30 second fault, which will light
DS7 on the control board. If it does not, reduce the
distance between the laser and the target and repeat
the test. The required point to perform this test will
vary with the application, depending on the range
point settings used for the application.
CAUTION
DO NOT WAIT FOR A FAULT TO OCCUR BE-
FORE PERFORMING PREVENTIVE MAINTE-
NANCE. DO NOT CONTINUE TO RELY ON
THE LASER GUARD SYSTEM IF A FAULT HAS
OCCURRED UNTIL MAINTENANCE HAS COR-
RECTED THE PROBLEM.
4-9. Troubleshooting (refer to Table 4-2).
If the red LED on the laser head comes on
continuously, replace the laser unit. Do not try to
service it. Return it to the factory.
If the red LED on the laser head is blinking or the
green LED on the back of the laser head is not on or
blinking, check for +12V at terminals marked 12V
and 12V COM at J2 on the range detector module. If
12V is not present, check the power supply and
power input modules in the range detector unit. If
12V is present, turn the power off and check the
continuity of the cable (refer to Figures 6-3, 6-4, 6-5,
6-6A and 6-7). Replace defective sub-assemblies as
necessary. If none are found, replace the laser head.
When the laser head is greater than 150 ft. from its
target, or a piece of black paper is placed over one of
the laser's lenses (do not touch or scratch the lenses)
the following conditions should exist on the range
detector module:
The three red LEDs (DS1, DS2 and DS3) (refer to
Figure 6-13) next to each range detector should be lit,
and the red LED (DS4) by the fault detector should
be lit. The two out-of-sequence red LEDs (DS5 and
DS6) should be off. If one or both of the out-of-
sequence LEDS are on, check the three test point
voltages and see that they meet the following
relationship:
150 ft. ≥RANGE 1> RANGE 2> RANGE 3≥10 ft.
If the above relationship is not correct, redo range
detector module settings. (Refer to Section 4-7)
If the out-of-sequence LEDs (DS5 and DS6) are not
on, and any of the range detector or fault LEDs (DS1,
DS2, DS3 and DS4) are off, check the voltage
between signal in and COM at J2. Your meter should
read between 0.3 VDC and 1.5 VDC. If the voltage is
less than 0.3 VDC, either the laser cable is open or
the laser unit has detected a fault condition within
itself and must be replaced. If the voltage is within
range, then check the third range detector test point
and make sure it is above 2 VDC. If it is not, then
redo the range detector module settings.
If 12 VDC is not present at the range detector
module, check the fuse, power to the input of the
power supply, power at the output of the power
supply and power to the 12 VDC terminals of J2 on
the range detector module. Correct any problems
found.
If you cannot determine the source of your problem,
please contact Telemotive.
If a laser head fault is detected with the style B
(E14008) range detector board the unit will
momentary shut down the power to the head to
attempt to reset the fault. If the fault is not reset after
the first reset. The range detector board will not
attempt another reset.

Section 4 – Installation Information (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
13
5 10 15 20 25 30 35 40 45
Range in Meters
Range in Feet
5 25 40 55 75 90 105 125 150
10
9
8
7
6
5
4
3
2
1
TEST POINT (TP) VOLTAGE
Table 4-1. Range Verses Test Point Voltage
9
8
7
6
5
4
3
2

Section 4 – Installation Information (Continued)
Telemotive Laser Guard Instruction Manual – October 2009
14
Table 4-2. Laser Diagnostic LED Functions (see Figure 6-13. for LED locations).
LED COLOR FUNCTION
Laser Head
Fault
Red Monitors the internal circuitry to the Laser Head
Normally OFF.
If a Laser head malfunction is taken place the LED will light. Cycle
power if the light remains on continuously replace head. If the LED is
blinking check the 12 Volts to the head.
Laser Head
Align
Green Monitors target acquisition.
Normally ON when target is acquired. Flashes when head is working
and target out of range.
If unit is not working and the green light is flashing check connections
to head from control unit and target alignment.
Control Unit
DS1, DS2 and
DS3
Red Monitors closure of the 1st, 2nd and 3rd Range Point Relays K1, K2 and
K3 respectively.
Normally ON when unit turned ON and out of range points.
The LEDs indicate power to the relay. The relays are normally
energized. As the unit moves closer to the target the ranges point
sequentially drop out thus turning of the LEDs in sequence.
Control Unit
DS4
Red Monitors engagement of the Fault Relay K4.
Normally ON when receiver turned ON.
The LED will extinguish when an OFF a fault of some type has been
detected, thus tripping the relay. Check LEDS on laser head. DS5,
DS6, DS7, DS8 and DS9 for possible fault conditions.
Control Unit
DS5 and DS6
Red Monitors the range set points between 1st and 2nd (2nd Sequence LED)
also 2nd and 3rd (3rd Sequence LED) respectively.
Normally OFF.
If the trip points of the three ranges are not set in sequence one or both
of these LEDs will light
Control Unit
DS7
Red Optical Path Fault Indicator.
Normally OFF.
The LED will go ON for dirty lens, misaligned target or Laser Head.
Clean lens, target and check laser head alignment to target.
Control Unit
E14008-0
Board only
DS8
Green Monitors regulated 12 VDC.
Normally ON.
DS2 off and DS1 on, check for shorts on regulated output or blown
regulator. or a short on board.
Control Unit
E14008-0
Board only
DS9
Green
Monitors unregulated 12 VDC.
Normally ON.
Check fuse, wiring to unit and AC power to unit.

Section 5 – Laser Guard Replacement Parts
Telemotive Laser Guard Instruction Manual – October 2009
15
5-1. PARTS LIST
Description Part Number
Laser Optical Unit E14002-0
Laser Unit Mounting Kit A14004-0
Interface Cable, 120 ft. WA14001-120
NEMA 4 Enclosure MP14005-0
Laser Range Detector Board (Style A) E14001-1
Laser Range Detector Board (Style B) E14008-0
Relay, 12 VDC, 10A, SPDT, Plug-In K2110-0
Power Input Module (8-30 VDC Unit) E10121-0
Power Input Module (10-40 VDC Unit) A12160-5A
Power Input Module (110 VAC Unit) (Style A only) A12160-202
Power Input Module (250 VDC Unit) 15W A12160-0D5
Power Input Module (250 VDC Unit) 25W A12160-0A8
Power Supply Module (110 VAC Unit) (Style A only) E10186-1
Power Supply Module (250 VDC Unit) 15W A5659-0
Power Supply Module (250 VDC Unit) 25W A5661-0
Power Supply Module (10-40 VDC Unit) 15W A5663-0
Power Supply Module (10-40 VDC Unit) 25W A5656-0
Reflector Target A14006-0
Bracket, Mounting Kit (for E14003-X) MP1306-0
User / Installation Manual TC14K-0

Section 6 – Installation Diagrams
Telemotive Laser Guard Instruction Manual – October 2009
16
CRANE CRANE
DIRECTION
OF TRAVEL
10 FT. MIN (SEE T EXT)
STAGGER THE
LOCATION OF
EACH LAS ER
& TARGET PAIR
THAT FACES THE
SAME DIRECTION
END OF
RUNW AY
HITTING W RON G
LASER BEAM FROM
-THIS PREVENTS
TARGET.
CENTER OF LASER
BEAM MUST BE
IN-LINE W ITH
CENTER OF TARGET
LASER
TARGET
TARGET LASER
APPLIC ATIONS, THE CENTER OF THE LASER BEAM MUST
FOR BOTH BRIDGE-TO-WALL AND BRIDGE-TO-BRIDGE
BE AT THE SAME H EIGHT AS THE CENTER OF THE TARGET.
SO THAT THEY
FROM THE RAILS.
ARE EQUIDI STANT
Figure 6-1. Laser and Target Installation