RCT Muirhead 12539 User manual

PRODUCT MANUAL
PRE-START WARNING CONTROLLER 12/24V
Part No. 12539 | 12727 | 12728

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LEGAL NOTICE
1. You acknowledge that this document is protected under copyright law and Remote Control Technologies Pty Ltd or its related bodies
corporate (“RCT”) owns the copyright in this document or otherwise have permission or licence from the relevant owner to use certain
specific works.
2. You must not make any changes, amendments, variations, alterations or modifications to the document.
3. You must not reproduce this document in any form or by any means, or to make copies of this document without RCT’s prior written
consent.
4. The contents in this document constitute confidential information of RCT. You must not circulate, distribute or otherwise allow the
document to be available in the public domain, or to disclose or share the document with any third party, without RCT’s prior written
consent.
5. RCT provides the document to you on an “as is” basis. RCT is not required to provide any updates to this version of the document.
RCT may make any change, amendment or modification to the contents in this document without notice to you.
6. RCT takes a best endeavour basis to ensure that the contents in this document are accurate, complete and reliable. RCT does not
warrant that the document will continue to be reliable, relevant, accurate or complete due to RCT’s continuous efforts in product
development, innovation and technology.
7. Any trademarks used in this document belongs to RCT or is used under a licence. The trademarks are not to be used for any
purposes, without RCT’s prior written consent.
8. Any illustrations used in this document are for illustration purposes only. Illustrations are intended as aids to facilitate your
understanding of the subject matter or issue.
9. RCT disclaims all liability, loss or damage that you suffer as a result of your reliance on this document.
10. By your conduct of using or reading this document, you agree to and accept the terms in this notice.

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Contents
GENERAL SAFETY WARNINGS 4
PRODUCT OVERVIEW 5
FEATURES AND FUNCTIONS 5
OPERATION AND USE 5
CONTROLLER STATUS INDICATOR OPERATION 5
INSTALLATION GUIDE 6
WIRING CONNECTIONS 6
UPGRADE CONNECTION DETAILS 7
EXTERNAL WIRING DIAGRAM (512a) 8
CALIBRATION 9
SERVICE INFORMATION 9
SERVICE SCHEDULE 9
SERVICE PROCEDURE 9
PARTS LIST 10
12727 KIT, PRE-START WARNING WITH ALARM 10
12728 KIT, PRE-START WARNING NO ALARM 10
TECHNICAL SPECIFICATIONS 11
COMPLIANCE AND STANDARDS 12
TROUBLESHOOTING 12
GLOSSARY 15
WARRANTY 15

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GENERAL SAFETY WARNINGS
PERSONAL SAFETY
■Everyone is responsible for safety.
■The installer/service personnel should be trained and authorized to complete the required work.
■Ensure that the machine is safely isolated during installation and testing to protect all personnel.
■Complete all required risk assessments and job safety analysis (JSA) before commencing work.
■Observe all site specific and machine OEM procedures regarding the following:
–working at heights
–working in heat
–working in confined spaces
–all other site specific occupational health and safety (OH&S) procedures
MACHINE
■Carry out all prestart operations as per site and machine OEM procedures.
■Ensure the machine is safely isolated during installation and testing to protect the machine and other
equipment in the area.
■Do not operate any machine with a known fault and report all findings to the supervisor in writing.
■Test and operate machine as per machine OEM and site procedures.
■Read and understand machine and site specific operational and testing instructions.
PRODUCT
Before applying power to the equipment, the user/repairer/ installer must read all product instructions. If in
doubt, seek assistance.
■Ensure electrical connections are made as per RCT’s recommendations. Test circuits prior to connecting
power to any component.
■The equipment contains no user serviceable parts inside. Return the unit to RCT for repairs.
■Retain product and installation instructions for future use.
■Ensure that RCT’s recommended service procedures are included in the machine’s service routine.
■Observe all machine, site and RCT product warnings.
■Follow all machine, site and RCT product operating procedures at all time.
The application of safety should not be limited to the above recommendations.

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PRODUCT OVERVIEW
The Muirhead®Prestart Warning Controller, part number 12539, is designed to warn personnel that a machine
is about to start/crank by activating an alarm for a selected time period prior to allowing the machine to start.
The timer is automatically triggered when the ignition switch is turned to the start position. The pre-start time
duration is configurable to suit the application.
FEATURES AND FUNCTIONS
■Multi-voltage (12 to 24 volts)
■Configurable timer
■Compact and robust
■Simple installation
■Visual status indicators
OPERATION AND USE
When the start switch on the machine is activated, the audible alarm will sound and the timer is activated. After
the pre-start time period has elapsed, the controller will supply a positive output to the start solenoid and
start/crank the machine.
The time period is determined by connecting a selection of inputs (from the 12-pin connector) to ground. If no
inputs are connected, the pre-set minimum warning time will be used (four seconds, by default).
CONTROLLER STATUS INDICATOR OPERATION
STATE
INDICATOR SEQUENCE
Battery Power-up
■All indicators will turn on.
■All indicators will turn off.
■After power-up, the controller will revert to normal operation.
Status Indicator in Operation
RED –Fault.
■If outputs have problems, this will turn on.
■Outputs 1 & 2 –high current outputs: checked for over current.
■Output 3 –not checked as it is a low side driver.
■Output 4 –checked for correct output voltage.
■Temperature –checked for board temperature exceeding 80 °C.
YELLOW –Pulses during normal operation, indicates system OK.
■Flashes on and off at one-second intervals (on for one second, off for one
second).
GREEN –On for normal operation.
Alarm Indication
System Status
Power Indication

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INSTALLATION GUIDE
1. Install the controller in a suitable location.
2. Refer to the wiring table below and the wiring diagram in this manual to connect the controller.
It is recommended that the wiring is installed alongside the OEM wiring ensuring that it is secured at regular
intervals; this will provide protection from heat and abrasion, and any other excess damage that may occur
with extended vehicle operation. When securing the wiring to the OEM wiring, ensure that the loom is
away from moving vehicle parts which could lead to loom damage.
3. If using the 6162 alarm, ensure to mount it in a suitable location where it will be audible for the operator
inside the cabin and any personnel in the area surrounding the vehicle. If using the machine OEM horn,
connect the purple wire (pin 10) to the positive side of the OEM horn.
4. Remove the start output wire (engine crank) from the ignition key switch and connect it to the yellow/blue
wire (pin 3).
5. Connect the red wire (pin 1) to the engine start (crank) terminal previously occupied by the wire removed
in step 4.
WIRING CONNECTIONS
NO.
COLOUR
FUNCTION
DESCRIPTION
1
Red
Start Input
Start input from key switch (12 - 24 V)
2
Black
Ground
Ground 0 V
3
Yellow/Blue
Output 1
Start output (12 - 24 V)
4
Green
Output 3
Not used
5
White
Input 1
Connect to GND to increase prestart time by 2 seconds
6
Orange(Optional)
Input 3
Connect to GND to increase prestart time by 8 seconds
7
Pink
Input 4
Connect to GND to increase prestart time by 16 seconds
8
Yellow
Input 2
Connect to GND to increase prestart time by 4 seconds
9
Blue
Output 4
Not used
10
Purple
Output 2
Alarm +ve (12 - 24 V)
11
Black/White
Alarm -ve
Alarm -ve (12 - 24 V)
12
Red/White
Battery supply
Not used

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UPGRADE CONNECTION DETAILS
Refer to the following table if you are upgrading from an older RCT prestart warning timer (part number 2625
and 6337) to the 12539. The following connections can be re-used when upgrading any connections not listed
here will still need to be connected as per the previous wiring connection table.
2625
WIRE CONNECTION NUMBER
FUNCTION
12539
WIRE CONNECTION NUMBER
1
Battery negative
2
2
Start output
3
3
Start input
1
4
Alarm output
10
Ref 542e
6337
WIRE CONNECTION NUMBER
FUNCTION
12539
WIRE CONNECTION NUMBER
A
Start input
1
B
Battery negative
2
C
Start output
3
Note: When replacing the 6337, please be aware the 6162 audible alarm supplied in the 12727 kit is not
directly connected to the controller and will need to be mounted separately.
Ref 079s
1234
ON
56
PU
GN
GN/PU
(2625)
BK-FVT
3
4
2
1
S
I
B
OFF
KEY SWITCH
IGNITION
START
BATTERY 12/24V
RL 8586
30 87
87A
1
+
-EXTERNAL
ALARM
1 2 3 4 5 6 7 8 9 10 11 12
B
A
C
D
E
F
G
H
B
A
C
D
E
F
G
H
1 2 345 6 78 9 10 11 12
A4
COPYRIGHT - ALL RIGHTS RESERVED
This drawing is the property of REMOTE
CONTROL TECHNOLOGIES PTY LTD (RCT),
and is not to be copied or used in whole or in
part for any purpose without the express
authority of RCT. The drawing is to be returned
to RCT, on demand.
SUGGESTED CIRCUIT
FOR CONTROLLING A
POSITIVE/NEGATIVE
SWITCHING
EXTERNAL ALARM
EXTERNAL WIRING
www.rct.net.au
UNCONTROLLED DOCUMENT
REV
1
DWG No 542e
STATUS
NTS
SCALE
Released
SHEET 1 of 1
BY MT
DRN RH DATE 06/07/15
APPD MT DATE 06/07/15
STOCK
CODE ----
PART
NO ----
3rd ANGLE
PROJECTION
ALL DIMENSIONS IN MILLIMETERS
OPERATION:
WHEN THE START SWITCH IS ACTIVATED, THE AUDIBLE ALARM WILL
OPERATE AND THE 4 SECOND ADJUSTABLE TIMER IS ACTIVATED.
AFTER THE 4 SECOND TIME PERIOD, THE UNIT WILL SUPPLY A +VE
OUTPUT TO THE START SLAVE SOLENOID.
*FACTORY SET TO 4 SECONDS
TIME SETTINGS
0 = OFF
1 = ON
NOTE:
A RELAY MUST BE USED ON THE ALARM OUTPUT WHEN
CONNECTED TO AN EXISTING OEM HORN.
REV ZONE DESCRIPTION BY DATE
1 G9-11 amended time settings
table JB 01/06/16
TIME SWITCH
1 2 34
SEC
140 0 0 0
121 0 0 0
1 0 1 0 0
2 1 1 0 0
40 0 1 0
8 1 0 1 0
16 0 1 1 0
32 1 1 1 0
MIN
1 0 0 0 1
2 1 0 0 1
40 1 0 1
8 1 1 0 1
16 0 0 1 1
32 1 0 1 1
HR 00111
1 1 1 1 1
DEFAULT
+
-
GN-FVT
ALARM
A
B
C
BK-FVT

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EXTERNAL WIRING DIAGRAM (512a)
1
2
3
4
5
6
7 8 9
10
11
12
12-24V
START OUTPUT
+
-
GROUND 12-24V START
INPUT FROM KEY
!

www.rct.net.au
N12596
PRESTART WARNING
CONTROLLER
12539
(12539)
PRESTART WARNING CONTROLLER
GN-FVT
YL/BU-4
BK-4
RD-4
WH-FVT
OR-4
PK-FVT
YL-FVT
BU-FVT
PU-FVT
BK/WH-3
RD/WH-3
(NOT USED) (NOT USED) (NOT USED)
NOTE: IF CONNECTING TO MACHINE
HORN, CONNECT PIN 10 DIRECTLY
TO THE POSITIVE HORN INPUT
12345678910 11 12
B
A
C
D
E
F
G
H
B
A
C
D E
F
G
H
12345678910 11 12
A4
COPYRIGHT - ALL RIGHTS RESERVED
This drawing is the property of REMOTE
CONTROL TECHNOLOGIES PTY LTD (RCT),
and is not to be copied or used in whole or in
part for any purpose without the express
authority of RCT. The drawing is to be returned
to RCT, on demand.
PRESTART WARNING
CONTROLLER
EXTERNAL WIRING
www.rct.net.au
UNCONTROLLED DOCUMENT
REV
2
DWG No 512a
STATUS
NTS
SCALE
Released
SHEET 1 of 1
BY BT DRN EH DATE 27/05/14
APPD CAMB DATE 02/11/15
STOCK
CODE MH-PSW-MV
PART NO 12539
3rd ANGLE
PROJECTION
ALL DIMENSIONS IN MILLIMETERS
12 PIN PLUG CONNECTIONS
1RD ENGINE START/CRANK INPUT 12/24V
2BK GROUND
3YL/BU ENGINE START/CRANK OUTPUT 12/24V
4GN NOT USED
5WH INCREASE PRE-START TIME BY 2 SECONDS WHEN CONNECTED TO GROUND
6OR INCREASE PRE-START TIME BY 8 SECONDS WHEN CONNECTED TO GROUND
7PK INCREASE PRE-START TIME BY 16 SECONDS WHEN CONNECTED TO GROUND
8YL INCREASE PRE-START TIME BY 4 SECONDS WHEN CONNECTED TO GROUND 9BU NOT USED
10 PU ALARM OUTPUT 12/24V
11 BK/WH ALARM GROUND
12 RD/WH NOT USED
REV ZONE DESCRIPTION BY DATE
1 C7-D7
Pin 5-8 Wires joined and
coloured blue (optional),
pin 4,9,12 marked not
used, 12 Pin Table
changed
JB 09/03/16
2E6
added note re: connecting
to machine horn JB 18/05/17

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CALIBRATION
The alarm period for the prestart warning timer is configured by connecting a selection of inputs to GND at
installation. Each input connected adds a set number of seconds to the default prestart warning time of 4
seconds. For example, if inputs 1 and 4 are connected to GND and inputs 2 and 3 are not connected the total
prestart warning time would be 4+2+16 = 22 seconds. The default pre-start warning time can be adjusted
between 4 and 10 seconds via the programmable controller utility program available from RCT.
INPUT 1
INPUT 2
INPUT 3
INPUT 4
GND
4 seconds
6 seconds
8 seconds
10 seconds
12 seconds
14 seconds
16 seconds
18 seconds
20 seconds
22 seconds
24 seconds
26 seconds
28 seconds
30 seconds
32 seconds
34 seconds
Note: The table above should only be used as a reference if the unit is set to the factory defaults.
SERVICE INFORMATION
SERVICE SCHEDULE
The manufacturer recommends that the following service procedure should be performed at each machine’s
scheduled service interval.
SERVICE PROCEDURE
1. Perform a visual inspection; include the following:
a) Controller
b) Wiring connections and looms
2. Perform a system test as per the Operation and Use section of this manual for the operation of the
controller.

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PARTS LIST
12727 KIT, PRE-START WARNING WITH ALARM
PART NO.
DESCRIPTION
QUANTITY
INCLUDED PARTS
SUGGESTED SPARES
12539
Controller
1
1
12738
Generic Loom
1
-
6162
Alarm warning 102 dB 12/24 V
1
-
0824
Terminal to suit Alarm
2
-
12728 KIT, PRE-START WARNING NO ALARM
PART NO.
DESCRIPTION
QUANTITY
INCLUDED PARTS
SUGGESTED SPARES
12539
Controller
1
1
12738
Generic Loom
1
-

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TECHNICAL SPECIFICATIONS
Dimensions, controller only
Length: 119 mm | Width: 80 mm | Height/Depth: 65 mm
Dimensions, boxed for freight
Length: 220 mm | Width: 120 mm | Height/Depth: 120 mm
Weight, controller only
255 g
Weight, including loom / packaging
for freight
600 g
Input nominal voltage
12 to 24 V DC
Ignition output continuous current
maximum
10 A
Auxiliary output continuous
current maximum
0.7 A
Operating temperate range
−40 °C to +85 °C
Connection types
12-pin receptacle
Inputs
Ignition supply, battery supply, chassis ground
Min & max input voltage
9 to 35 V DC
Circuit protection
External control
Enclosure type
Polycarbonate alloy
Environmental protection IP rating
IP65
Programming/adjustment
Refer to Calibration section

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COMPLIANCE AND STANDARDS
RCT has an obligation as a manufacturer to comply with the regulations as required by the relevant regulatory
bodies, depending on the market and location.
This product currently complies with the following:
ACMA
■IEC 61000-6-1:2005 Electromagnetic Compatibility (EMC) –Part 6-1: Generic Standards –Immunity for
Residential, Commercial and Light Industrial Environments.
■IEC 61000-6-3:2006, A1:2010 Electromagnetic Compatibility (EMC) –Part 6-3: Generic Standards –
Emissions for Residential, Commercial and Light Industrial Environments.
EU
■IEC 61000-6-1:2005 Electromagnetic Compatibility (EMC) –Part 6-1: Generic Standards –Immunity for
Residential, Commercial and Light Industrial Environments.
■IEC 61000-6-3:2006, A1:2010 Electromagnetic Compatibility (EMC) –Part 6-3: Generic Standards –
Emissions for Residential, Commercial and Light Industrial Environments.
■RoHS 2 Directive 2011/65/EU
FCC
This device is exempt from FCC regulations under 47 CFR 15.103 Exempted devices.
IC
This device is exempt from IC regulations under ICES-003 —Information Technology Equipment (ITE) —
Limits and Methods of Measurement.
TROUBLESHOOTING
FAULT
POSSIBLE CAUSE
Device not working.
Check wiring and connections.
Intermittent fault.
Check wiring and connections.

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NOTES

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NOTES

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15 | 16
GLOSSARY
WARRANTY
Please see the RCT standard warranty, available on our website - www.rct-global.com.
A
Amp (Ampere)
mW
Milli Watts
AC
Alternating Current
N/A
Not Applicable
AMS
Advanced Management System
N/C
Normally Closed
Aux
Auxiliary Output
N/O
Normally Open
CAN
Controller Area Network
OEM
Original Equipment Manufacturer
CMIO
Control Master Input Output PCB
O/P
Outputs
CMR
Control Master Receiver
Out
Output
CMT
Control Master Transmitter
PB
Push Button
CM2200
Control Master 2200 Remote Set
PC
Personal Computer
COMMS
Communications
PCB
Printed Circuit Board
CPU
Central Processor Unit
PIN
Personal Identification Number
DC
Direct Current
PLC
Programmable Logic Controller
E.G.
For example
POT
Potentiometer
ETR
Energised To Run
PPM
Pulses Per Metre
ETS
Energised To Stop
PWM
Pulse Width Modulation
ESD
Engine Shutdown
PWR
Power
FET
Field Effect Transistor
RCT
Remote Control Technologies Pty Ltd
GND
Ground
Rev
Revision
H
Hours
RF
Radio Frequency
HEX
Hexidecimal Numbering System
RH
Relative Humidity
ID
Identity
RPM
Revolutions per minute
i.e
That is
RX
Receiver
In
Input
RS232
Recommended Standard (number 232) for
serial data transfer
IP
Ingress Protection
Source
The output can supply/drive current out
kg
Kilogram
SYS
System
Km/h
Kilometres Per Hour
TOV
Text On Video
LCD
Liquid Crystal Display
TX
Transmitter
LED
Light Emitting Diode
V
Volts
LK
Link
°C
Degrees Centigrade
M
Minutes
#
Number
mA
Milli Amps
<
Less Than
MAX
Maximum
>
Greater Than
MCU
Multi Control Unit
%
Percentage
MFU
Multi Function Unit
MHz
Mega Hertz (million(s) cycles per
second)
MIN
Minimum
mm
millimetres

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