Remtron Patriot User manual

COMMAND PRO®
Patriot
USER’S MANUAL
25 Series
142130-H April 2009
Distributed by Tri-State Equipment Company Inc.
Email: [email protected]
Web: www.tsoverheadcrane.com
PH: 314-869-7200 | FAX: [phone]
1916 W. Mission Road, Escondido, CA 92029-1114
WARNING!
Read all safety rules and
warnings before installing and
operating this system.
AVERTISSEMENT!
Lire toutes les consignes de
sécurité et tous les
avertissements avant de faire
fonctionner ce systéme.

ADDENDUM – ADDITIONAL WARNINGS
IMPORTANT SAFETY NOTICE
WARNING:
THE USE OF UNAPPROVED COMPONENTS OR ACCESSORIES IN
THE SYSTEMS SOLD BY CATTRON GROUP INTERNATIONAL AND
ITS SUBSIDIARIES IS STRICTLY PROHIBITED. UNAPPROVED
COMPONENTS ARE DEFINED AS ANY COMPONENT NOT
INSPECTED AND SOLD BY CATTRON. THIS ALSO INCLUDES ANY
COMPONENT MODIFIED FROM ITS INTENDED USE AND/OR ANY
COMPONENT EXHIBITING OBSERVABLE DAMAGE OR DEFECT.
USE OF NON-CONFORMING PARTS, ASSEMBLIES AND
ACCESSORIES MAY LEAD TO INJURY OR DEATH.
WARNING:
THE REMOTE CONTROL SYSTEM YOU HAVE PURCHASED IS
DESIGNED TO STOP IN A SAFE MODE UNDER A VARIETY OF
CONDITIONS. SOME EXAMPLES OF THESE CONDITIONS ARE:
EXCESSIVE RADIO SIGNAL INTERFERENCE, LOSS OF BATTERY
OR ELECTRICAL POWER, FAILURE OF CERTAIN COMPONENTS
AND OPERATION BEYOND SIGNAL RANGE AND OTHERS.
ALTHOUGH CATTRON GROUP INTERNATIONAL AND ITS
SUBSIDIARIES DOES NOT SPECIFY THE POSITION OF THE
OPERATOR WHEN CONTROLLING THE EQUIPMENT WE ARE
AWARE THAT SOME USERS ARE INSTRUCTED AND TRAINED BY
THEIR EMPLOYER TO RIDE THE EQUIPMENT IN A SAFE MANNER.
IT IS IMPERATIVE THAT YOU ARE PREPARED FOR AN
UNPLANNED STOP OF THE EQUIPMENT AT ANY TIME AND DO
NOT PLACE YOURSELF OR OTHERS IN A POSITION WHERE THIS
SITUATION MAY CAUSE YOU TO FALL FROM THE EQUIPMENT.
FAILURE TO USE CAUTION MAY LEAD TO INJURY OR DEATH.
END

Patriot USER’S MANUAL
142130 H / April 2009 i
REMTRON, INC.
COMMAND PRO®RECEIVERS
FCC COMPLIANCE STATEMENT
COMMAND PRO®series receivers have been tested and found to comply with in the limits
for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference in a residential
installation.
This equipment generates, uses, and can radiate radio-frequency energy, and if not
installed and used in accordance with the user manual, may cause harmful interference to
radio communications. However, there is no guarantee that harmful interference will not
occur in a particular installation.
If this equipment does cause harmful interference to radio or television reception, which
can be determined by switching this equipment on and off, the user is encouraged to try to
correct the interference by one or more of the following measures:
•Re-orient or relocate the receiving antenna that is connected to the device that is
receiving the interference.
•Increase the separation between our equipment and the equipment that is receiving
the interference.
•Consult our factory or one of our Service Representatives for additional help.
Responsible Party:
Remtron Inc.
1916 W. Mission Rd.
Escondido, CA 92029

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142130 H / April 2009 iii
Table of Contents
SECTION 1 — INTRODUCTION 1
Purpose ....................................................................................................................1
Scope .......................................................................................................................1
Important Safety Rules ...............................................................................................1
SECTION 2 — OPERATIONS 4
How the System Works...............................................................................................4
Frequency. ................................................................................................................4
Range and Antenna Coverage ......................................................................................4
License Free Channels ................................................................................................5
Command Format ......................................................................................................5
Safety.......................................................................................................................6
Transmitter Operation and Features .............................................................................7
Operation..................................................................................................................7
Commands ................................................................................................................8
Command Switches ....................................................................................................8
Status Indicators........................................................................................................9
Transmitter Status Chart.............................................................................................9
Function Select LEDs ..................................................................................................9
SECTION 3 — INSTALLATION 10
General...................................................................................................................10
Locating the equipment.............................................................................................10
Antenna Location .....................................................................................................10
Receiver Location .....................................................................................................12
Installation Wiring ....................................................................................................12
Output Snubbers......................................................................................................13
Power/Control Wiring................................................................................................13
Installation Testing...................................................................................................14
SECTION 4 — MAINTENANCE & TROUBLESHOOTING 18
Monthly Inspection ...................................................................................................18
Installation Troubleshooting.......................................................................................18
Installation Troubleshooting Chart..............................................................................18
General Troubleshooting ...........................................................................................19
Transmitter Troubleshooting......................................................................................19
Normal Operation.....................................................................................................19
Transmitter Troubleshooting Chart .............................................................................19
Replacing the Transmitter Batteries............................................................................20
Changing the Transmitter ID Code .............................................................................21
Transmitter Spare Parts List ......................................................................................22
Receiver Troubleshooting ..........................................................................................24
General...................................................................................................................24
Receiver Testing ......................................................................................................24
Receiver Repairs ......................................................................................................25
Fuse Replacement ....................................................................................................25
Receiver Spare Parts List...........................................................................................26

Patriot USER’S MANUAL
iv 142130 H / April 2009
SECTION 5 — WARRANTY STATEMENT FOR P
PP
PATRIOT
ATRIOTATRIOT
ATRIOT REMOTE CONTROL SYSTEMS 29
Transmitters............................................................................................................29
Receivers and Accessories .........................................................................................29
General Terms of Warranty .......................................................................................29
Service ...................................................................................................................30
APPENDIX A: TRANSMITTER SPECIFICATIONS 31
Certifications ...........................................................................................................31
APPENDIX B: RECEIVER SPECIFICATIONS 32
List of Illustrations
FIGURE 1 REMTRON PATRIOT TRANSMITTERS 2
FIGURE 2 REMTRON PATRIOT RECEIVERS 2
FIGURE 3 TRANSMITTER/RECEIVER COMMUNICATION 11
FIGURE 4 ANTENNA CLEARANCE 11
FIGURE 5 PATRIOT RECEIVER (25R15A) 15
FIGURE 6 CONNECTIONS AND LABELS FOR PATRIOT RECEIVERS 16
FIGURE 7 HANDHELD TRANSMITTERS WITH BACK REMOVED 23
FIGURE 8 FUSE LOCATIONS 26

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142130 H / April 2009 v
SAFETY RULES
WARNING!
READ ALL INSTRUCTIONS
Failure to follow these rules can result in serious personal injury
INSTALLATION
•GROUND THE RECEIVER CASE In order to ensure safety of the system, the receiver
case must be firmly connected to earth ground.
•PROVIDE A SAFETY CUTOFF SWITCH If maintenance is required, the radio must be
disconnected from power to prevent accidental activation.
•USE PROPER WIRING Loose or frayed wires can cause accidental activation of
machinery.
•DO NOT INSTALL IN HOT AREAS This apparatus can be damaged by heat in excess
of 160° F.
•DO NOT INSTALL IN HIGH VIBRATION AREAS The life of this apparatus might be
shortened through long exposure to intense shaking or vibration.
ERSONAL SAFETY
•MAKE SURE MACHINERY IS CLEAR BEFORE OPERATING. Do not activate the
remote system unless it is safe to do so.
•SWITCH OFF THE RECEIVER POWER BEFORE WORKING ON MACHINERY Always
disconnect the remote system power before doing any maintenance to prevent
accidental operation of the machine.
CARE
•KEEP DRY If water or other liquids get inside, immediately dry the unit.
•KEEP ANTENNA(S) CLEAN Keep antenna connections clean and free of corrosion.
IMPORTANT NOTE: Throughout this manual, other safety rules appear under the following heading.
WARNING!
Failure to follow these rules can result in serious personal injury

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vi 142130 H / April 2009
CONSIGNES DE SÉCURITÉ
AVERTISSEMENT!
Le non respect des consignes peut causer des blessures sérieuses
INSTALLATION
•RACCORDER LE BOÎTIER À LA MASSE Pour que le système fonctionne en toute
sécurité, le boîtier du récepteur doit être solidement raccordé à la masse.
•FOURNIR UN INTERRUPTEUR DE SÉCURITÉ. Lors de travaux d’entretien du
dispositif, déconnecter le poste radio afin d’éviter une mise en marche accidentelle.
•UTILISER LES FILS APPROPRIÉS Des fils découverts ou usés peuvent provoquer un
démarrage accidentel de la machinerie.
•NE PAS INSTALLER DANS DES ENDROITS CHAUDS Des températures supérieures à
160° F (71° C) peuvent endommager l’appareil.
•NE PAS INSTALLER DANS LES ENDROITS SOUMIS À DE FORTES VIBRATIONS
L’exposition prolongée de cet appareil à des vibrations ou des secousses intenses peut
en réduire la durée de vie.
SÉCURITÉ
•S’ASSURER QUE LA MACHINERIE EST DÉGAGÉE AVANT DE LA FAIRE
FONCTIONNER Ne pas faire fonctionner le système de téléguidage à moins que cela
puisse être fait en toute sécurité.
•METTRE LE RÉCEPTEUR HORS TENSION AVANT D’EFFECTEUR DES TRAVAUX
SUR LA MACHINERIE Afin de prévenir la mise en marche accidentelle de la
machinerie, toujours débrancher le système de téléguidage avant de d’effectuer des
travaux d’entretien.
ENTRETIEN
•GARDER AU SEC Sécher immédiatement l’appareil, s’il est exposé à de l’eau ou tout
autre liquide.
•GARDER LES ANTENNES PROPRES Garder les raccordements d’antenne propres et
exempts de corrosion. Le non respect des consignes peut causer des blessures
sérieuses.
Le non respect des consignes peut causer des blessures sérieuses

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Section 1 — Introduction
Purpose
This manual provides information on the safe installation and operation of the
Remtron Patriot wireless control systems. Information is also included on the
maintenance and repair of the Patriot systems.
Scope
Information is included on all Remtron Patriot transmitters and receivers. See
the detailed information contained in each section of this manual for your particular
equipment.
The transmitters covered in this manual contain enhanced features that expand the
types of applications for the systems.
Many new features have been added, but most changes are transparent to the user. If
you are already familiar with Remtron transmitters, you are encouraged to read the
section on operating the transmitters, where you will find information about the latest
changes in operation.
To help you identify your system, Figures 1 and 2 on page 2 provide a reference for
the transmitters and the receivers covered in this manual.
Important Safety Rules
Using wireless control systems with heavy industrial equipment can improve the
safety of the equipment.
It is important to adhere to the safety rules presented throughout this manual,
especially during installation, in order to achieve the safest operating system possible.

Patriot USER’S MANUAL
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Figure 1. Remtron Patriot Transmitters
Figure 2. Remtron Patriot Receivers

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Section 2 — Operations
Remtron Patriot Wireless Control Systems are designed for control of industrial
machinery. These rugged controls are built to survive the wear and tear of life in factories,
mills, and foundries.
These systems comply with requirements for operation under Part 15 of the FCC Rules and
Regulations. This means that neither the operator nor the company need apply or register for
a license to operate this equipment.
The basic system consists of a transmitter and a receiver. The transmitter sends commands to
the receiver by means of radio waves in the 900 MHz band. Receivers operate at 120 VAC
50/60 Hz power.
How the System Works
Frequency
Remtron Patriot equipment operates in the 902 to 928 Megahertz (MHz)
frequency band. A wavelength at our frequency is 12.9 inches.
Like light, 900 MHz radio signals will pass through glass and plastics, and will
reflect off of walls, buildings, and metal structures. Unlike light, 900 MHz radio
signals will penetrate all plastics, including those that you cannot see through,
thin-gauge steel, dry wood, dry concrete, plasterboard, fog, and rain.
However, trees, earth, water, people, aluminum, copper, and some window tints
will not readily pass our signals.
Range and Antenna Coverage
Antennas convert radio signals into radio waves and convert radio waves back
into radio signals. They can send and receive in all directions or in a single
direction, depending on their design.
An omni-directional antenna is like a light bulb, and a directional antenna is like a
flashlight. Metal objects reflect radio waves, just as a mirror next to a light bulb
will reflect light. Metal objects near an antenna alter the intended pattern of an
antenna by either shading or reflecting signals.
Our standard antennas are omni-directional; they ‘see’ equally well in all
directions. We have other antennas that will ‘see’ further in one direction for
special applications.

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License-Free Channels
The 902 to 928 MHz spectrum is set aside by the FCC as an ISM Band
(Industrial, Scientific, and Medical), and this spectrum accommodates many
license-free users. We have the ability to change frequencies in this band, and we
have 81 different channels that we can assign to our transmitters and receivers.
The actual frequency is coded into the receiver and transmitter at the factory, but
it can be changed to one of the other 80 channels in the field.
Other devices in this band include wireless phones, computer data links, and
inventory equipment. As a condition of using this band, we must accept and
handle interference from other users.
The 900 MHz band has worked well for most users, and not being burdened with
licensing regulations is desirable. The FCC has allowed 50,000 microvolts per
meter field strength on this band, which is 250 times higher than other unlicensed
frequencies below this band. This allows our systems to operate very reliably in
the presence of other signals.
Command Format
We use packet-mode, Frequency Modulation (FM) to carry commands in a packet
form from our transmitter to our receiver.
To reduce battery drain, our transmitter transmits for a hundredth of a second,
which is long enough to send one packet to our receiver at a repetition rate of 16
or four times per second.
The rate varies: 16 times per second for three times when sending a command and
four times per second when there is no change in commands and the transmitter is
still on. Any time a lever or switch is activated, we send all control settings three
times at the 16-per-second rate and then return to the slower rate of four times per
second.
Our receiver uses the slower rate for maintaining transmitter timing and provides
for a maintained link where one is used. The only exception to this is the ‘STOP’
switch, which transmits at 16 times per second as long as it is depressed. In
addition to lever and switch positions, each packet contains a unique address and
CRC check sum (described in the next paragraph).

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Safety
Safety and preventing loss of control are very important issues at Remtron. We
use a unique identification (ID) code for each user. There are provisions in our
system for 65,535 individual codes.
Each transmission includes a CRC check sum, which is a polynomial created by
factoring all of the previous bits transmitted. Once our receiver receives a valid
start command from our transmitter, our receiver tracks the time of the transmitter
and ignores all other transmissions that do not fall within the expected time frame
of our transmitter.
Maintained link systems must receive at least one valid transmission each second
in order to allow the remote-controlled equipment to function. Our receiver
provides a loss-of-signal control output that safely shuts down the equipment if a
loss of signal occurs.
Our receiver will not allow restart of equipment under its control after a loss of
signal until a valid system start command is received from our transmitter. This
prevents an unintended start-up from occurring if the transmitter returns within
range of our receiver and is still operating.
Our transmitters also check the position of all controls upon start-up. Our
transmitter will not issue a start command if any of the controls are pressed at the
time the start command is invoked.

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Transmitter Operation and Features
WARNING!
Do not operate the system until you are familiar
with radio controlled operation. If you are not
familiar with radio controlled operation, contact your
supervisor before attempting to use the radio
control system.
AVERTISSEMENT!
Ne pas fair fonctionner le système avant de bien
connaître le fonctionnement d’une grue par
téléguidage. Contacter lesuperviseur avant de faire
toute tentative de mise en marche par téléguidage,
si le fonctionnement n’est pas connu.
IM ORTANT! To stop the system in an emergency, press and hold
the OFF/STOP button. Pressing and holding this
button down stops all functions.
IM ORTANT! Le bouton d’arrêt d’urgence (STOP) pour ce système
est le bouton OFF/STOP. Appuyer et amintenir le
loutn pour arrêter toutes les functions.
Operation
1. Press and release the ON/ALARM button. Verify that the status LED starts
flashing at a low rate. If equipped, the Alarm function should sound.
2. Press the required switches to operate the desired function. Note that more
than one function can be controlled at any time.
3. To stop sending any command, release the switch.
4. To switch the transmitter off, press the OFF/STOP button. (Note that the
transmitter will switch itself off if no commands are sent for a
predetermined time if Auto Off is enabled).

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Commands
Command Switches
The command switches are labeled according to their function.
• If opposing commands are attempted, that is, two commands that conflict
with each other, in most cases no function will result. In the case of
ON/OFF functions, OFF will predominate.
• If more than one speed command is sent for the same function, the lower
speed will predominate.
ON / ALARM
Turns on the transmitter and puts the system in the active mode. Sends an
ALARM command to the receiver while the switch is depressed. The transmitter
will remain active until the OFF/STOP button is pressed or the transmitter
switches itself off (see Auto Off).
OFF / STOP
While depressed, sends a STOP command to the receiver. The transmitter does
not need to be switched ‘ON’ to send this command. When this switch is released,
the transmitter will be switched off.
A–B SWITCH
(25T15A only) A Selector switch is provided to control more than one similar
function with the same controls (that is, controlling hoist/trolley A, hoist/trolley
B, or both A and B simultaneously). A single button will cycle between A, B,
BOTH, and OFF each time the button is pressed. LED indicators show the control
status.
AUTO OFF
The transmitter will switch itself off if no commands have been sent for a
predetermined time. This time is normally set to 15 minutes but can be re-set to
0–60 minutes (or disabled) using a RAC16A series Programmer (01 to 60 =
minutes, 00 = disabled).

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Status Indicators
Status LED
The status LED provides an indication of the transmitter operation. When the
transmitter is operating normally, the LED indicator will emit short flashes at a
low rate when no commands are activated and at a higher rate when a command
is activated. Some transmitters use a red LED only. Others use a multicolored
LED that flashes GREEN when no problems are present and changes to RED
under low battery conditions or when other problems are encountered. See Status
Chart below.
Transmitter Status Chart
LED Indication Possible Cause
LED is off Transmitter is off – switch transmitter ON.
Batteries are dead – replace batteries.
Transmitter failure – call for service.
LED flashes at low rate Transmitter is operating in a normal mode.
LED flashes at high rate Command Switch is pressed.
LED flashes Red/Green
(‘A’ series only)
Batteries getting low. Batteries should be
changed at the next convenient opportunity.
LED flashes on off at a
slow rate (½ second on
and ½ second off)
Batteries getting low. Batteries should be
changed at the next convenient opportunity.
LED remains on
continuously (LED might
flicker slightly)
Either a switch was activated at the time the
transmitter was switched on or a general failure
occurred that requires factory service. Ensure no
other switches are pressed while attempting to
switch the transmitter on.
LED will not light when
ON/OFF button is
pushed
Replace batteries. If this does not correct the
problem, the transmitter must be repaired.
Function Select LEDs
Two LEDs are used on 25T15A transmitters to indicate which control functions
are active (such as hoist/trolley A, hoist/trolley B) and are intended to be used
with pilot relays. When both are lit, both controls are active. When both LEDs
are unlit, neither control is active.

Patriot USER’S MANUAL
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Section 3 — Installation
General
Check all of the components to confirm that they are the components you ordered for
your system and that they are in good condition. If any components are missing, or if
any are not in good condition, contact Remtron.
WARNING!
READ ALL INSTRUCTIONS! Failure to follow the
SAFETY RULES can result in serious personal injury.
Before starting this installation, ensure that the
crane power has been disconnected and that all
applicable safety precautions are followed.
AVERTISSEMENT!
Le non respect des CONSIGNES DE SÉCURITÉ peut
causer des blessures sérieuses. Avant de procéder à
l’installation, s’assurer que le bras élévateur ou la
grue est hors tension et que toutes les consignes de
sécurité ont été respectées.
Figure 5 on page 14 shows a typical Patriot receiver. See this figure for mounting
dimensions and antenna connector location.
Locating the equipment
Antenna Location
The antenna is one of the most important components of a radio receiving system.
Proper placement of the receiver antenna will ensure reliable operation under the
most severe conditions. A direct ‘line-of-sight’ path between the transmitter and
receiver antenna provides the best performance (see Figure 3 on page 10).

Patriot USER’S MANUAL
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Figure 3. Transmitter/Receiver Communication
In most cases, the antenna can be mounted directly on the receiver enclosure. In
determining the mounting location, the following items should be considered:
• The antenna should be mounted vertically.
• For optimum performance, the antenna itself should have a minimum of
eight (8) inches of clearance in all directions, excluding the wall or plate to
which the receiver enclosure is mounted (see Figure 4). If the receiver
enclosure location cannot provide this clearance and the antenna must be
mounted at a remote location, the Remtron Remote Antenna Mounting Kit
should be used. Call your Remtron dealer for information.
Figure 4. Antenna Clearance

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Receiver Location
To ensure safe and reliable system operation, the following items must be
considered when selecting a location for mounting the receiver:
•Install the receiver in an environment where the ambient temperature
during operation does not drop below -20º F (-28º C) or rise above +160º F
(+71º C).
•To ensure that the receiver enclosure is electrically at earth ground, connect
the green wire in the interface cable to earth ground.
•Mount the receiver enclosure securely using appropriate locking-type
hardware.
Installation Wiring
WARNING! Before starting this installation, ensure that the
crane power has been disconnected and that all
applicable safety precautions are followed.
MISE EN GARDE! Avant de procéder à l’installation, s’assurer que le
bras élévateur ou la grue est hors tension et que
toutes les consignes de sécurité ont été respectées.
CAUTION! Connection to equipment or contactors with higher
voltage or current requirements requires
intermediate relays.
AVERTISSEMENT!
La connexion à des équipements ou à des contacts
soumis à des tensions électriques élevées ou à de
fortes intensités de courant nécessite l’installation
d’interface à relais.