Rothenbuhler Engineering 1678 REMOTE FIRING DEVICE User manual

REMOTE FIRING DEVICE
OPERATION MANUAL
The information contained in this document is subject to change
without notice. In no event shall Rothenbuhler Engineering
Company be liable for errors contained herein or for special,
indirect, or consequential damages or injuries of any nature
resulting from use of information in this document.
ROTHENBUHLER ENGINEERING
P.O. BOX 708
524 RHODES ROAD
SEDRO WOOLLEY, WA 98284
1678-A16 {Draft}
5/12/2011
©2011 Rothenbuhler Engineering
All Rights reserved

SPECIAL NOTICE
WARNING TO USERS AND AFFECTED PERSONS
The Remote Firing Device (RFD) is designed to be used in blasting operations.
Explosives used in connection with the RFD may be extremely powerful. Improper use
of explosives with or without the RFD or improper safety precautions taken with respect
to personnel or property may result in death, serious personal injury, or property
damage. Other manufacturers’ equipment that may not be in compliance with
frequency coordination may inadvertently interfere with the operation of the RFD. Be
aware of other operations within the receiving range of the RFD.
The literature accompanying this warning contains information of a general nature for
users of the RFD based upon the manufacturer’s experience in the design and
manufacture of remote radio frequency devices. In addition, the manufacturer provides
product literature and technical data sheets periodically which should be consulted for
detailed information on the characteristics, specifications and recommendations for the
RFD. The manufacturer does not purport to give information or advice on explosives or
their use.
The RFD and related explosive devices are intended for use only by trained
professionals having comprehensive knowledge of the RFD, the explosives being used,
and the application together with all related safety precautions. The manufacturer of the
RFD is responsible only for the proper performance of the RFD itself and is not
responsible for the performance, safety, or specifications of the explosive used, nor the
suitability of the RFD for any particular purpose other than that expressly described in
the manufacturer’s literature.
LIMITED WARRANTY
The manufacturer warrants the Model 1678 Remote Firing Device (RFD) to be free of
defects in workmanship or materials for the period of one year from the date of
purchase. In the event any RFD or component thereof is shown to be defective in
workmanship or materials within one year, the system or component will be repaired or
replaced without charge by the manufacturer at the manufacturer’s place of business.
This warranty does not cover damage or injury to equipment resulting from abuse,
neglect, or use in applications other than expressly described by the manufacturer as fit
purposes for the RFD.
This Limited Warranty is given in lieu of all other legal warranties express or implied and
neither the manufacturer nor its representatives shall be liable for any direct, incidental
or consequential loss or damages arising out of any occurrence or accident involving
the use of this product.
1678 RFD OPERATION MANUAL {DRAFT} ii

FCC NOTICE
This device complies with Part 15 of the FCC regulations. Operation is subject to the
following two conditions: (1) That this device may not cause harmful interference, and
(2) this device must accept any interference received, including interference that may
cause undesired operation.
RADIATION HAZARD WARNING
This radio shall only be used during the course of employment by individuals aware of
the hazards of radio frequency (RF) radiation exposure, and the ways to minimize such
hazards. This radio is not intended for use by the "General Population." Further, this
radio must not be co-located or operated in conjunction with any other antenna or
transmitter. User should not allow antennas to come within 20 cm (8 inches) of the body
during use.
CANADA
**This Class B digital apparatus meets all requirements of the Canadian Interference-
Causing Equipment Regulations.
Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur
le matériel brouilleur du Canada.
Under Industry Canada regulations, this radio transmitter may only operate using an
antenna of a type and maximum (or lesser) gain approved for the transmitter by Industry
Canada. To reduce potential radio interference to other users, the antenna type and its
gain should be so chosen that the equivalent isotropically radiated power (e.i.r.p.) is not
more than that necessary for successful communication.
This radio transmitters (IC: 2758A-166921 and 2758A-16784) have been approved by
Industry Canada to operate with the antenna types listed below with the maximum
permissible gain and required antenna impedance for each antenna type indicated.
Antenna types not included in this list, having a gain greater than the maximum gain
indicated for that type, are strictly prohibited for use with this device.
Antenna: ¼ wave whip, gain 2.15 dBi
1678 RFD OPERATION MANUAL {DRAFT} iii

Conformément à la réglementation d'Industrie Canada, le présent émetteur radio peut
fonctionner avec une antenne d'un type et d'un gain maximal (ou inférieur) approuvé
pour l'émetteur par Industrie Canada. Dans le but de réduire les risques de brouillage
radioélectrique à l'intention des autres utilisateurs, il faut choisir le type d'antenne et son
gain de sorte que la puissance isotrope rayonnée équivalente (p.i.r.e.) ne dépasse pas
l'intensité nécessaire à l'établissement d'une communication satisfaisante.
Le présent émetteur radio (IC: 2758A-166921 and 2758A-16784) a été approuvé par
Industrie Canada pour fonctionner avec les types d'antenne énumérés ci-dessous et
ayant un gain admissible maximal et l'impédance requise pour chaque type d'antenne.
Les types d'antenne non inclus dans cette liste, ou dont le gain est supérieur au gain
maximal indiqué, sont strictement interdits pour l'exploitation de l'émetteur.
Stabantenne: ¼ longueur d'onde, gain 2.15 dBi
1678 RFD OPERATION MANUAL {DRAFT} iv

TABLE OF CONTENTS
Chapter Page
SPECIAL NOTICE..........................................................................................................II
WARNING TO USERS AND AFFECTED PERSONS....................................................II
LIMITED WARRANTY....................................................................................................II
FCC NOTICE .................................................................................................................III
RADIATION HAZARD WARNING.................................................................................III
CANADA........................................................................................................................III
TABLE OF CONTENTS..................................................................................................V
LIST OF ILLUSTRATIONS..........................................................................................VIII
SAFETY INFORMATION................................................................................................X
1. INTRODUCTION..................................................................................................1
1.1. Purpose ............................................................................................................ 1
1.2. Storage and Environmental Conditions............................................................. 1
1.3. Maintenance ..................................................................................................... 3
2. INTRODUCTION TO RFD SYSTEM COMPONENTS .........................................4
2.1. System.............................................................................................................. 4
2.2. Mini Controller Unit ........................................................................................... 7
2.3. Mini Controller Unit Switch Operation ............................................................... 7
2.4. Mini Controller Unit Display Operation ............................................................ 10
2.5. Electric Remote Unit ....................................................................................... 13
2.6. Remote Shock Tube Initiator (RSTI) ............................................................... 16
2.7. 3 Position Battery Charger.............................................................................. 19
2.8. Test Box.......................................................................................................... 19
1678 RFD OPERATION MANUAL {DRAFT} v

2.9. Antenna Assembly .......................................................................................... 21
2.10. Carrying Case ............................................................................................. 22
2.11. Vent operation ............................................................................................. 25
2.12. Antenna / Battery Charger Connector ......................................................... 26
2.13. Connector Dust Cover Operation ................................................................ 27
3. SYSTEM SPECIFICATIONS..............................................................................28
3.1. Radio .............................................................................................................. 28
3.2. Physical .......................................................................................................... 29
3.3. Battery ............................................................................................................ 29
3.4. Timing ............................................................................................................. 30
3.5. Detonate Output.............................................................................................. 30
3.6. System Identification....................................................................................... 31
4. PRE-OPERATIONAL PROCEDURES...............................................................32
4.1. Physical Inspection ......................................................................................... 32
4.2. Battery Charging With the 3-Position Charger ................................................ 32
4.3. Bench Testing the System .............................................................................. 34
5. OPERATIONAL PROCEDURES.......................................................................36
5.1. Ready the System at Site ............................................................................... 36
5.2. Placement of Remote Units ............................................................................ 37
5.3. System Operation – Remote Units Within 1 mile of Mini Controller Unit......... 38
5.4. System Operation – Remote Units More Than 1 mile From Mini Controller Unit
40
5.5. System Operation – Remote Units Both Within and In Excess of 1 mile and
Less Than 5 miles from Mini Controller Unit ............................................................. 41
6. POST OPERATIONAL PROCEDURES ............................................................44
6.1. Securing the System....................................................................................... 44
6.2. Physical Inspection ......................................................................................... 44
6.3. Packaging ....................................................................................................... 44
1678 RFD OPERATION MANUAL {DRAFT} vi

6.4. Maintenance & Equipment Storage ................................................................ 44
7. BASIC TROUBLESHOOTING IN THE FIELD...................................................45
7.1. Remote Units .................................................................................................. 45
7.2. Mini Controller Unit ......................................................................................... 45
7.3. Remote Shock Tube Initiator........................................................................... 45
8. OPTIMIZING RANGE.........................................................................................47
9. TEST BOX..........................................................................................................52
9.1. Test Box Descriptions ..................................................................................... 52
9.2. Test Box Operation ......................................................................................... 53
9.3. Saving Test Box results to a file using HyperTerminal.................................... 61
10. RFD PROGRAMMING GUIDE...........................................................................68
10.1. Programmable Parameters ......................................................................... 68
10.2. Required equipment .................................................................................... 68
10.3. Windows Configuration Software Operation (Setup RFD)........................... 68
10.4. Setup RFD Installation ................................................................................ 68
10.5. Configuring Setup RFD ............................................................................... 70
10.6. Using Setup RFD to Test RFD Units ........................................................... 71
10.7. Using Setup RFD to Program RFD Units .................................................... 76
11. BATTERY MAINTENANCE...............................................................................81
11.1. Battery Temperature ................................................................................... 81
11.2. Pre-operation............................................................................................... 81
11.3. Periodic ....................................................................................................... 81
11.4. Annual ......................................................................................................... 81
11.5. Extended non-use ....................................................................................... 81
1678 RFD OPERATION MANUAL {DRAFT} vii

LIST OF ILLUSTRATIONS
Figure 2-1 RFD 4-Remote Case System......................................................................... 6
Figure 2-2 Mini Controller Unit ........................................................................................ 7
Figure 2-3 Mini Controller Isometric View with Antenna ................................................ 12
Figure 3-1 Electric Remote Unit .................................................................................... 13
Figure 3-2 Electric Remote Unit Angled View ............................................................... 15
Figure 3-3 Remote Shock Tube Initiator (RSTI) ............................................................ 16
Figure 3-4 RSTI Angled View with Shock Tube Spark Tip ............................................ 17
Figure 3-5 Shock Tube Tip............................................................................................ 18
Figure 3-7 3 POSITION CHARGER .............................................................................. 19
Figure 3-8 Test Box....................................................................................................... 20
Figure 3-9 Antenna Assembly ....................................................................................... 22
Figure 3-10 Carrying Case ............................................................................................ 23
Figure 3-11 Carrying Case (Half Case) ......................................................................... 24
Figure 3-12 Vent Operation........................................................................................... 25
Figure 3-13 3-Position Charger Connection .................................................................. 26
Figure 3-14 Connector Dust Cover Operation............................................................... 27
Figure 4-1 Mini Controller Unit Identification Label........................................................ 31
Figure 4-2 Remote Unit Front Identification Label......................................................... 31
Figure 9-1 Unit Normal Transmission Location ............................................................. 48
Figure 9-2 Remote Unit Elevated .................................................................................. 49
Figure 9-3 Mini Controller Unit Elevated........................................................................ 50
Figure 9-4 Antenna Radiation Pattern ........................................................................... 51
1678 RFD OPERATION MANUAL {DRAFT} viii

Figure 10-1 Test Box..................................................................................................... 52
1678 RFD OPERATION MANUAL {DRAFT} ix

SAFETY INFORMATION
The following are WARNINGS and CAUTIONS, contained throughout this manual and
are repeated here for emphasis. All personnel engaged in the handling, firing, and
storage of the system covered in this manual must fully understand these WARNINGS
and CAUTIONS, and procedures by which hazardous conditions are to be reduced or
eliminated. Also listed are general safety precautions that are not related to any specific
procedures and therefore don't appear elsewhere in this publication. These are
recommended precautions that personnel must understand and apply during many
phases of operation and maintenance.
WARNING Never rely on the equipment for your safety.
WARNING Use of this system and its components must be restricted to personnel
qualified and experienced in the field of explosives and detonating devices. Under no
circumstances shall untrained personnel attempt to use this manual as a text for self-
teaching.
WARNING This system and its components should be stored in a secure area with
no access to unauthorized personnel. This system can be used in conjunction with
explosives as a deadly weapon.
WARNING These radios contain batteries. The potential for activation is always
present whether or not antennas are attached to the units.
WARNING Employ standard blasting system safety standards when using this
equipment with explosives.
WARNING Lightning induced energy, caused by electrical storms, can detonate
explosives. In the interest of safety, blasting on land, water and underground should be
suspended and all personnel should be evacuated to a safe distance from the blast
area whenever lightning storms are in the vicinity. Dangerous levels of static electricity
can build up in the atmosphere. These levels can be sufficient to detonate explosives.
WARNING Radio frequency energy of sufficient magnitude can cause blasting
caps to detonate.
WARNING To eliminate long wire runs, and to make the "shoot" from a safe
distance, the Remote Firing Device uses low energy level radio frequency
transmissions.
WARNING Do not connect a blasting cap to a Remote Unit unless the green
SAFE light is on, the red ARMED light is off, and the yellow ON/LOW BATT light is on
steady. This indicates there is no voltage on the binding posts, the binding posts are
electically isolated from the firing capacitor, the binding posts are shunted to each other,
and the battery is not low.
1678 RFD OPERATION MANUAL {DRAFT} x

WARNING Ensure that blasting caps are not connected to any of the Remote
Units during bench testing.
WARNING This is a sensitive electronic radio system and it may be damaged.
WARNING Do not use the Mini Controller Unit within 100 feet (30 meters) of
explosives, blasting caps, or wires leading to them. The Mini Controller signal is 5 watts,
which can cause detonation of caps if within 100 feet. The 5 watt Mini Controller
complies with the Recommended Table of Distances established by the Institute for the
Makers of Explosives (IME) when placed beyond 100 feet of explosives.
WARNING Do not engage in RFD communications with the Remote Units when
they are connected to explosive charges until the shot is prepared and all personnel are
clear. The Remote Unit complies with the Recommended Table of Distances
established by the Institute for the Makers of Explosives (IME) when placed 25 feet (8
meters) or more from blasting caps or wires leading to them. For further information,
refer to the Institute for the Makers of Explosives Publication no. 20, Part II, Section (1).
WARNING Do not touch the Shock Tube Tip Jacks on the side of the Remote
Shock Tube Initiator (RSTI) when armed or firing. Lethal voltages may be present.
CAUTION Do not assume the Disarm command has been received by the
Remote Unit unless DISARMED status is confirmed with a steady DISARMED light for
that Remote Unit on the Mini Controller Unit display panel. If distance appears to be the
problem, move closer to the Remote Unit following standard procedures for this type of
situation. The “STATUS” and/or “DISARM” switches may be pressed repeatedly as the
Remote Unit is approached. Maintain a safe distance from the Remote Unit. Do not
approach the Remote Unit until DISARMED status is confirmed with a steady
DISARMED light for that Remote Unit on the Mini Controller Unit display panel. Under
no conditions should the “FIRE” switch be pressed as the Remote Unit is approached.
DO NOT bring the Mini Controller Unit closer than 100 feet (30 meters) to blasting caps,
wires connected to blasting caps, or other explosives.
CAUTION All units must be thoroughly tested and the batteries fully charged prior
to operational use.
CAUTION Unequal air pressure inside the Mini Controller Unit may affect the
operation of membrane switch keypad. Extreme pressure differentials may irreversibly
damage the keypad and/or cases.
CAUTION Vents in all units should be momentarily opened and closed
immediately before use.
CAUTION Do not open a vent if there is water on or near the vent. Keep the vents
closed when the relative humidity is above 90%. Take necessary precautions to ensure
moisture does not enter the unit case.
1678 RFD OPERATION MANUAL {DRAFT} xi

1678 RFD OPERATION MANUAL {DRAFT} xii
CAUTION Do not use any component that is damaged, suspected of being
damaged, or is not able to operate as designed. The safety of the operation could be
compromised.

1.INTRODUCTION
1.1. PURPOSE
1.1.1.
1.1.2.
1.1.3.
The primary purpose of this manual is to provide descriptive information,
operational information, instructions in assembly, and instructions in testing and
preparation for operational or training use of the Remote Firing Device (RFD).
The Remote Firing Device (RFD) is used to activate electric and non-electric
detonator devices. The System is strictly an electronic device, containing no explosive.
The Mini Controller Unit shall be operated from 100 feet (30 meters) to five miles (8 km)
from the explosive. The Electric Remote Unit shall be placed at the explosive site, with
a two-conductor firing line running to the explosive. The Remote Shock Tube Initiator
(RSTI) is placed at the explosive site, with 3mm non-electric shock tube running to the
explosive. The Mini Controller Unit communicates to the Remote Units through a two-
way RF transmitter data link, for a typical distance greater than Error! Reference
source not found. (8 km). The Remote Unit can typically return communication for a
distance greater than Error! Reference source not found. (1.6 km). Actual
communication range is dependant upon a variety of factors such as terrain, obstacles,
antenna height, and local interference.
Throughout this manual, the tem “Remote Unit” is a generic term that is used
for both the Electric Remote Unit and for the RSTI.
1.2. STORAGE AND ENVIRONMENTAL CONDITIONS
1.2.1.
1.2.2.
1.2.3.
1.2.4.
1.2.5.
The Mini Controller Unit and Remote Unit have manual operated vents. The
vents should always be CLOSED during air transport, underwater transport, storage
and operational use to prevent moisture intake. The operator should momentarily open
and close the vent after the unit has been subjected to changes in elevation or depth.
This equalizes pressure within the case to the outside environment. DO NOT open the
vent if there is water on or near the vent or if the relative humidity is above 90%. Towel
dry vents prior to opening. The vents should be OPEN, when stored in a dry hot
environment.
The Mini Controller Unit and Remote Unit (with vents closed) are airtight to an
altitude of 30,000 feet and watertight to a depth of 100 feet.
The Mini Controller Unit and Remote Unit is shock resistant, drop tested from
5 feet onto 3 inches of steel plate backed by concrete.
The battery pack and unit electronics are electrically isolated from the unit
case.
The Mini Controller Unit and Electric Remote Unit have a temperature
operation from -22 ºF to +140 ºF (-30 ºC to +60 ºC). The RSTI has a temperature
1678 RFD OPERATION MANUAL {DRAFT} 1

operation range from -15 ºF to +140 ºF (-26 ºC to +60 ºC).
1678 RFD OPERATION MANUAL {DRAFT} 2

1.3. MAINTENANCE
1.3.1.
1.3.2.
1.3.3.
1.3.4.
Batteries within the RFD require periodic charging and discharging to
maintain health and service life.
The battery packs within the RFD should be replaced every 3 years or 300
charge cycles, whichever comes first. Battery packs can be replaced by the user
following strict procedures to maintain case sealing. It is recommended the battery
packs be replaced by the manufacturer or by an authorized service center. Contact the
manufacturer for details.
Corrective maintenance shall be accomplished at the manufacturer or
authorized service depot. Replacement of parts or disassembly by any other entity
could result in the unsafe operation of the RFD and will void the manufacturer’s
warranty.
In case of failure of a component of the RFD System, the system will need to
be shipped to the manufacturer or authorized service depot.
1678 RFD OPERATION MANUAL {DRAFT} 3

2.INTRODUCTION TO RFD SYSTEM COMPONENTS
2.1. SYSTEM
2.1.1.
2.1.2.
2.1.3.
2.1.4.
2.1.5.
2.1.6.
The RFD is a battery powered, hand held, radio remote controlled system to
be used on land as a primary firing mechanism to detonate explosive charges. The
RFD system consists of a Mini Controller Unit and up to four Remote Units (any
combination for Electric Remotes and RSTIs up to a total of four).
The Mini Controller Unit and Remote Units in one system will not operate with
Units from another system.
The RFD is transportable over land, underwater to a depth of 100 feet (30
meters), and in the air to an altitude of 30,000 feet (9,100 meters). The units are shock
resistant to a 5 foot (1.5 meter) drop and impervious to static discharge.
The Mini Controller and Electric Remote Units will operate in a temperature
range of -22 ºF to + 140 ºF (-30 ºC to +60 ºC). The RSTI will operate in a temperature
range of -15 ºF to +140 ºF (-26 ºC to +60 ºC).
The system has two modes of operation. The two modes are one-way, and
the two-way mode.
2.1.5.1. Range for one-way mode is greater than Error! Reference source not
found. (8 km) typically.
2.1.5.2. Range for two-way mode is greater than 1 mile (1.5 km) typically.
The RFD System consists of the component parts in Table 2-1 and Figure
2-1.
1678 RFD OPERATION MANUAL {DRAFT} 4

Table 2-1 RFD 4-Remote Case System
Figure Index No. Description Units per System
Figure 2-2 1 Mini Controller Unit 1
Figure 2-2 2 Remote Unit, Electric Up to 4*
Figure 2-2 3 Remote Unit, RSTI Up to 4*
Figure 2-2 4 Battery Charger See note **
Figure 2-2 5 Antenna Assembly One per Unit
Figure 2-2 6 Carrying Case Assembly 2
Figure 2-2 7 Test Box 1
Figure 2-2 8 Test Lamp 1 per Electric
Remote
Figure 2-2 9 Shock Tube Igniter Tip 2 per RSTI
* Any combination of Electric Remotes and Remote Shock Tube Initiators (RSTIs) can
be configured for a maximum total of 4 Remotes.
** The system is available with one or two 3-Position Chargers. Included with each
Charger is a +12V power supply.
1678 RFD OPERATION MANUAL {DRAFT} 5

Figure 2-1 RFD 4-Remote Case System
1678 RFD OPERATION MANUAL {DRAFT} 6

2.2. MINI CONTROLLER UNIT
2.2.1. Figure 2-2 shows the external features of the Mini Controller Unit. The unit is
sealed at the manufacturer and/or service depot and should not be opened during field
activity.
Figure 2-2 Mini Controller Unit
2.3. MINI CONTROLLER UNIT SWITCH OPERATION
2.3.1. Unit Power Control: Depress the “ON” switch for one second to turn the
power on to the Mini Controller Unit when the Antenna is attached. The yellow light in
the upper left quadrant of the “ON” switch will turn on. Depress the “OFF” switch to turn
the power off to the Mini Controller Unit.
1678 RFD OPERATION MANUAL {DRAFT} 7

2.3.2.
2.3.3.
2.3.4.
2.3.5.
2.3.6.
Power ON Self Test: Upon installing the antenna and pressing the “ON”
switch, a rigorous self test is initiated. If a failure of the self test occurs, it will not be
possible to activate the unit. The unit must be returned to the Manufacturer for service.
Do not attempt to use a failing unit.
Display Panel Light Dimmer Circuit: With the unit powered on, Repress
the ‘ON’ switch briefly to toggle the LED display light’s intensity between bright and dim.
When the unit is turned on, the last chosen intensity setting is restored.
Select Remote Units: Depress the Select Switches “1” through “4” to select
independently the Remote Units that will communicate with the Mini Controller Unit.
Any combination of the four Remote Units may be selected. The yellow SELECT light
on the switch indicates if the Remote Unit programmed for that switch is selected.
Press the switch again and the yellow SELECT light for that Remote Unit will be turned
off indicating the Remote Unit is not selected.
Request Remote Unit Status: Depress the “STATUS” switch to transmit a
status request signal to the selected Remote Units. The selected Remote Units will
transmit their current status to the Mini Controller Unit. If none of the Remote Units are
selected, the Mini Controller Unit will request status from all four Remote Units. Any
answering Remote Units will be selected automatically. If the Mini Controller Unit is
within range of the Remote Unit transmitter, the status of the selected Remote Unit will
be presented on the display panel with a steady light. If the Mini Controller Unit is out of
range of the Remote Unit transmitter, the status will be assumed from the last command
sent to that Remote Unit. In that case the assumed status of the Remote Unit will flash
on the display panel.
Arm the Remote Unit: Depress the “ARM” switch for 1/2 second and the
Mini Controller Unit will transmit the Arm command to the selected Remote Units. The
red ARMED light at the selected Remote Units will flash on the Mini Controller Unit
display panel until the firing capacitor charging time is completed. The Mini Controller
Unit then requests status of the selected Remote Units. If the Mini Controller Unit is
within range of the selected Remote Unit transmitter, the ARMED red light for that
Remote Unit will be on steady on the Mini Controller Unit display panel. If the Mini
Controller Unit is out of range of the selected Remote Unit transmitter, the red ARMED
light for that Remote Unit will continue to flash on the Mini Controller Unit display panel.
If the Fire command is not sent within the Arm Time Period, the system will disarm
automatically.
1678 RFD OPERATION MANUAL {DRAFT} 8