Telemotive TelePendant Montageanleitung

TCTX12P-0 Rev. D 8/2/2004

TELEMOTIVE

telePendantTM

TRANSMITTERS

N49 W13650 Campbell Drive

Menomonee Falls, WI 53051

Phone: 800-288-8178 Fax: 262-783-3510

Website: www.telemotive.com

telePendant programming is

found on page 20.

Table of Contents

1- Service Information .................................................................................................3

2- Radio Controlled Crane Safety................................................................................4

3- General System Information..................................................................................11

4- Operation................................................................................................................12

5- Programming..........................................................................................................18

6- Spare Parts .............................................................................................................30

Section 1 - Service Information

1-1. Service Information.

For questions regarding service or technical

information or ordering replacement parts, ask

for Telemotive Customer Care. Telemotive’s

normal business hours are Monday through

Friday 8:00 AM to 5:00 PM Central Standard

Time. After hours emergency technical service is

available.

For new product orders or quotations, ask for

Telemotive Sales.

Magnetek Material Handling Group

N49 W13650 Campbell Drive

Menomonee Falls, WI 53051

Telephone: 800-288-8178

Website: www.telemotive.com

e-mail: [email protected]

Fax Numbers

Main: 800-298-3503

Sales: 262-783-3510

Service: 262-783-3508

Telemotive Industrial Control trademarks:

Boommate, GateMate, 10K, inteleSmart,

Telemotive, telePilot, telePendant, Laser

Guard, Teledrive, Teltec, TeleMotion are either

trademarks or registered trademarks of

Telemotive Industrial Controls.

Third-party trademarks: All other trademarks,

trade names or company names referenced

herein are used for identification only and are the

property of their respective owners.

CAUTION

•DO NOT ATTEMPT TO OPEN OR SER-

VICE THE TELEPENDANT UNIT.

•ONLY TRAINED QUALIFIED INDIVIDU-

ALS SHOULD DO SERVICING.

•STRICT ANTI-STATIC HANDLING

PROCEDURES MUST BE FOLLOWED.

•FAILURE TO FOLLOW THIS CAUTION

COULD RESULT IN SERIOUS DAMAGE TO

EQUIPMENT AND/OR VOID THE

WARRANTY.

Section 2 – Radio Controlled Safety

2-1. Warnings, Cautions and Notes.

Through out this document WARNING, CAUTION

and NOTE statements have been deliberately placed

to highlight items critical to the protection of

personnel and equipment.

WARNING – A warning highlights an essential

operating or maintenance procedure, practice, etc.

which if not strictly observed, could result in injury

or death of personnel, or long term physical hazards.

Warnings are highlighted as shown below:

WARNING

CAUTION – A caution highlights an essential

operating or maintenance procedure, practice, etc.

which if not strictly observed, could result in damage

to, or destruction of equipment, or loss of functional

effectiveness. Cautions are highlighted as shown

below:

CAUTION

NOTE – A note highlights an essential operating or

maintenance procedure, condition or statement. Notes

are shown as below:

NOTE

WARNINGS, CAUTIONS AND NOTES SHOULD

NEVER BE DISREGARDED.

The safety rules in this section are not intended to

replace any rules or regulations of 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 installing

or operating the Radio Control System.

2-2. Critical Installation Considerations.

WARNING

ALL EQUIPMENT MUST HAVE A MAINLINE

CONTACTOR INSTALLED AND ALL TRACKED

CRANES AND SIMILAR EQUIPMENT MUST

HAVE A BRAKE INSTALLED. FAILURE TO

FOLLOW THIS WARNING COULD RESULT IN

SERIOUS INJURY OR DEATH AND DAMAGE

TO EQUIPMENT.

WARNING

ON ALL REMOTE CONTROLLED CRANES AN

AUDIBLE AND/OR VISUAL WARNING MEANS

MUST BE PROVIDED. THESE AUDIBLE

AND/OR VISUAL WARNING DEVICES MUST

MEET ALL GOVERNMENTAL REQUIRE-

MENTS. FAILURE TO FOLLOW THIS WARN-

ING COULD RESULT IN SERIOUS INJURY OR

DEATH AND DAMAGE TO EQUIPMENT.

WARNING

REMOVE ALL ELECTRICAL POWER FROM

THE CRANE OR MACHINERY BEFORE AT-

TEMPTING ANY INSTALLATION PROCE-

DURES. DE-ENERGIZE AND TAG OUT ALL

SOURCES OF ELECTRICAL POWER BEFORE

TOUCH TESTING ANY EQUIPMENT. FAILURE

TO FOLLOW THIS WARNING COULD RESULT

IN SERIOUS INJURY OR DEATH AND DAM-

AGE TO EQUIPMENT.

Section 2 – Radio Controlled Safety (Continued)

WARNING

THE DIRECT OUTPUTS OF THIS PRODUCT

ARE NOT DESIGNED TO INTERFACE DI-

RECTLY TO TWO STATE SAFETY CRITICAL

MAINTAINED FUNCTIONS, I.E., MAGNETS,

VACUUM LIFTS, PUMPS, EMERGENCY

EQUIPMENT, ETC. A MECHANICALLY LOCK-

ING INTERMEDIATE RELAY SYSTEM WITH

SEPARATE POWER CONSIDERATIONS MUST

BE PROVIDED. FAILURE TO FOLLOW THIS

WARNING COULD RESULT IN SERIOUS IN-

JURY OR DEATH AND DAMAGE TO EQUIP-

MENT.

2-3. General.

Radio controlled 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 transmitter. Refer to section titled Section

2-9. Boarding The Crane for specific safety rules.

2-4. Persons Authorized To Operate Radio

Controlled Cranes.

Only properly trained persons designated by

management should be permitted to operate radio-

controlled cranes.

Radio controlled cranes should not be operated by

any person who cannot read or understand signs,

notices and operating instructions that pertain to the

crane.

Radio controlled 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.

2-5. Training Checklist for Crane Operators.

Anyone being trained to operate a radio-controlled

crane should possess as a minimum the following

knowledge and skills before operating the crane:

The operator should have knowledge of hazards

peculiar to crane operation.

The operator should have knowledge of the safety

rules for radio-controlled cranes.

The operator should have the ability to judge distance

or moving objects.

The operator should have knowledge of the radio

transmitter.

The operator should know the limit switch test

procedure.

The operator should know, where authorized,

instructions for plugging motions.

The operator should have knowledge of the use of

crane warning lights and alarms.

The operator should have knowledge of observing

crane signal lights.

The operator should be trained to avoid striking any

obstructions.

The operator should have knowledge of the proper

clearance of lifts or hooks before moving bridge or

trolley.

The operator should have knowledge of the proper

storage space for radio control box when not in use.

The operator should be trained in transferring radio

control box to another person.

The operator should be trained how and when to

report unsafe or unusual operating conditions.

The operator should be trained how to exhibit caution

in approaching bridge or trolley bumpers.

The operator should know equipment capacity.

The operator should be trained in making lifts below

floor level.

The operator should be trained in making side pulls.

The operator should know how to keep himself and

other people clear of lifts and to avoid "pinch" points.

Section 2 – Radio Controlled Safety (Continued)

The operator should know cable and hook inspection

procedures.

The operator should know procedures for testing

hoist, trolley, and bridge brakes.

2-6. 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 three feet (one

meter) 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.

2-7. Transmitter Unit.

Transmitter switches should never be mechanically

blocked ON or OFF for any crane motion. When not

in use turn the transmitter OFF. A secure storage

space should be provided for the transmitter unit and

the transmitter unit should always be placed there

when not in use. This precaution will prevent

unauthorized people from operating the crane.

Spare transmitters should be stored in a secure

storage space and only removed from the storage

space after the current transmitter in use has been

turned OFF, taken out of the service area and

secured.

Before putting the transmitter in service the

transmitter unit should be inspected for any damage

or excessive wear. Units with, but not limited to, any

of the following: broken housings, broken or sticking

switches and levers or broken handles, missing

battery doors, damaged or missing switch boots or

damaged or missing switch knobs should be repaired

before putting into service.

2-8. Operating the Crane.

2-8.1. Pre-operation Test.

At the start of each work shift, or when a new op-

erator takes control of the crane, operators shall do as

a minimum the following steps before making lifts

with any crane or hoist:

Test the upper-limit switch. Slowly raise the

unloaded hook block until the limit switch trips.

When checking limit switches the hoist should be

centered over an area free of personnel and

equipment.

Visually inspect the hook, load lines, trolley, and

bridge as much as possible from the operator's

station; in most instances, this will be the floor of the

building.

The bridge and trolley brakes should be tested. On

transmitter units 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.

If provided, test the lower-limit switch.

Test all warning devices.

Test all direction and speed controls for both bridge

and trolley travel.

Test all bridge and trolley limit switches, where

provided, if operation will bring the equipment in

close proximity to the limit switches.

Test the transmitter emergency stop.

Test the hoist brake to verify there is no drift without

a load.

If any crane or hoist fails any of the above tests notify

the supervisor and lock out and tag for repair.

2-8.2. General Rules for Operation.

Consult the crane manufacturer, local and

governmental regulations for complete rules of

operation. In general the following rules apply to

remotely controlled cranes:

The limit switches should never be used as a regular

stopping device. They are intended to be protective

devices.

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.

A crane designed for this purpose and only with

supervisor permission should make side pulls. When

a lift is being made, the crane operator should not be

Section 2 – Radio Controlled Safety (Continued)

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.

Never leave suspended loads unattended. In an

emergency, if the crane is inoperative and a load

suspended, notify the supervisor immediately,

barricade and post signs on the floor beneath crane

and load.

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.

2-9. 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.

2-10. Crane Maintenance and Repair.

Qualified personnel must maintain a regularly, i.e.,

such as monthly, scheduled crane inspection. During

this crane inspection the functionality and safety of

the crane remote control must also be tested. The

inspection shall include, but be not limited to items

listed in Section 2-12. Condition of the Radio

Controlled Crane. Consult crane manufacturer, local

and governmental regulations for recommended

inspection intervals and proper inspection

procedures. Problems noted during this inspection

must be repaired before using the crane or the remote

control.

Minor repairs include routine maintenance and

repairs such as greasing, cleaning and control

troubleshooting. All other repairs should be con-

sidered 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:

Section 2 – Radio Controlled Safety (Continued)

For minor repairs 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.

2-11. Using the Crane as a Work Platform.

When the crane is to be used as a stationary work

platform, follow all rules provided in Section 2-10.

Crane Maintenance and Repair. When it is necessary

for the crane to be moved from time to time, the

crane operator should board the 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 operator’s

responsibility to ensure the main switch is open and

locked down before work is resumed.

WARNING

THE CRANE OPERATOR SHOULD NOT AT-

TEMPT TO REPAIR ANY OF THE ITEMS

STATED BELOW. THE CRANE CONDITION

SHOULD BE REPORTED TO THE SUPERVISOR.

FAILURE TO FOLLOW THIS WARNING COULD

RESULT IN SERIOUS INJURY OR DEATH AND

DAMAGE TO EQUIPMENT.

2-12. Condition of the Radio Controlled Crane.

If the crane fails to respond properly, the crane

operator(s) should notify their supervisor. When

serious conditions are noticed (conditions that make

the crane unsafe to operate), the crane should be shut

Section 2 – Radio Controlled Safety (Continued)

down immediately and the supervisor notified. The

following is a list of some of the items that should be

included in the report. (See the crane manufacturer

for specifics and possible additional items):

Condition of hoisting cable and hook block (broken

strands, clipped sheave wheels, etc.).

Condition of brakes (hoist, trolley, and bridge). (No

bluing, rivets on shoes showing, glazing, etc.).

Condition of trolley and rail stops.

Condition of bridge structure.

Condition of festoon system.

Broken welds in any part of the crane structure.

Proper fluid levels and lubrication.

Condition of bridge and trolley stops.

Carbon dust or signs burning on the covers of motors.

Indication of fluid, oil or grease leaks.

Condition of rail sweeps.

Walkways required handrails and ladders are in

place, sturdy and not loose.

Protective guards are in place for all moving parts.

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.

All controls especially E-STOPs are in place and in

working order.

Frequent relay tripping of power circuits.

Mechanical parts loosened by vibration (loose rivets,

covers, bolts, etc.).

Uneven riding (worn or damaged wheels).

Condition of collector shoes or bars.

Condition of warning or signal lights and horns.

(Burned out or broken).

2-13. Batteries

WARNING

KNOW AND FOLLOW PROPER BATTERY

HANDLING, CHARGING AND DISPOSAL PRO-

CEDURES. IMPROPER BATTERY PROCE-

DURES CAN CAUSE BATTERIES TO EXPLODE

OR DO OTHER SERIOUS DAMAGE. FAILURE

TO FOLLOW THIS WARNING COULD RESULT

IN SERIOUS INJURY OR DEATH AND DAM-

AGE TO EQUIPMENT.

2-13.1. Battery Handling.

Use only batteries approved by Telemotive for the

specific product.

Do not dispose of a battery pack in fire; it may

explode.

Do not attempt to open the battery pack.

Do not short circuit battery.

Do not attempt to use a battery that is leaking,

swollen or corroded.

For intrinsically safe environments only use specified

Telemotive intrinsically safe batteries.

Keep the battery pack environment cool during

charging operation and storage, (i.e., not in direct

sunlight or close to a heating source).

Do not submerse battery in water.

If battery leaks avoid contact with electrolyte.

Section 2 – Radio Controlled Safety (Continued)

2-13.2. Battery Charging.

For those transmitters equipped with battery chargers,

please familiarize all users with the instructions of

the charger before attempting to use.

Use only Telemotive approved chargers for the

appropriate battery pack.

Do not attempt to charge non-rechargeable battery

packs.

Avoid charging the battery pack for more than 24

hours.

Do not charge batteries in a hazardous environment.

Do not short charger.

Do not attempt to charge a damaged battery.

Charger units are not intended for outdoor use. Use

only indoors.

Always unplug the charger when not in use.

Do not store, place or use the charger where it could

come into contact with water or moisture.

To reduce the risk of electric shock, unplug your

charger from the wall outlet before cleaning.

2-13.3. Battery Disposal.

Before disposing of batteries consult local and

governmental regulatory requirements for proper

disposal procedures.

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