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Magnetek Telemotive TR12 inteleSmart Instruction Manual

Summary of Telemotive TR12 inteleSmart

  • Page 1

    Tctr12-pda rev. J march 2007 part number 30033t ©copyright 2007 magnetek material handling telemotive tr12 intelesmart™ receiver radio control equipment instruction manual.

  • Page 2: Table of Contents

    Table of contents telemotive tr12 intelesmart receiver instruction manual – 03/01/07 service information .....................................................................................................1 radio controlled crane safety..................................................................

  • Page 3: Your New Radio Receiver

    Section 1 – service information telemotive tr12 intelesmart receiver instruction manual – 03/01/07 1 your new radio receiver thank you for your purchase of magnetek’s telemotive ® brand tr 12 intelesmart receiver. Magnetek has set a whole new standard in radio-remote performance, dependability, and ...

  • Page 4: Caution

    Section 2 - radio controlled crane safety telemotive tr12 intelesmart receiver instruction manual – 03/01/07 2 telemotive industrial control trademarks: boommate, gatemate, 10k, intelesmart , telemotive, telepilot , telependant , laser guard, teledrive, teltec, and telemotion are either trademarks o...

  • Page 5: Warning

    Section 2 - radio controlled crane safety (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 3 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...

  • Page 6

    Section 2 - radio controlled crane safety (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 4 the operator should be trained in transferring radio transmitter to another person. The operator should be trained how and when to report unsafe or unusual operating conditions....

  • Page 7

    Section 2 - radio controlled crane safety (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 5 2-7.2. General rules for operation. Consult the crane manufacturer, local and governmental regulations for complete rules of operation. In general the following rules apply to r...

  • Page 8

    Section 2 - radio controlled crane safety (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 6 2-9. Crane maintenance and repair. Qualified personnel must maintain a regularly, i.E., such as monthly, scheduled crane inspection. During this crane inspection the functionali...

  • Page 9: Warning

    Section 2 - radio controlled crane safety (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 7 warning the crane operator should not attempt to repair any of the items stated below. The crane condition should be reported to the supervsor. Failure to follow this warning co...

  • Page 10

    Section 2 - radio controlled crane safety (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 8 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 intrinsical...

  • Page 11

    Section 3 - general system information telemotive tr12 intelesmart receiver instruction manual – 03/01/07 9 17. Ak17 436.6 mhz 18. Ak18 436.4 mhz 19. Ak19 436.2 mhz 20. Ak20 436.0 mhz 21. Aka00 433.125 mhz 22. Aka01 433.325 mhz 23. Aka02 433.525 mhz 24. Aka03 433.725 mhz 25. Aka04 433.925 mhz 26. Ak...

  • Page 12: Section 4 - Installation

    Section 4 - installation telemotive tr12 intelesmart receiver instruction manual – 03/01/07 10 4-1. Pre-installation considerations. To ensure reliable and safe operation of the system, the following items must be considered before installing the receiver unit. Warning the receiver unit or relays ar...

  • Page 13

    Section 4 – installation (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 11 6. Control wiring as well as antenna wiring shall be in separate conduit and shall be kept as short as possible. 7. All terminals shall be tightened to specified terminal torque 4.4 in-lbs (.5 ...

  • Page 14

    Section 4 – installation (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 12 6. Wiring of the system should now be complete. Install antenna. 7. Turn switch sw2 off (mr relay control) and sw1 on (main power switch). Stand clear of the crane and apply ac power to receive...

  • Page 15: Section 5

    Telemotive tr12 intelesmart receiver instruction manual – 03/01/07 13 section 5 see appropriate transmitter manual.

  • Page 16: Section 6 - Wiring

    Section 6 - wiring telemotive tr12 intelesmart receiver instruction manual – 03/01/07 14 6-1. Wiring diagrams. The system comes pre-programmed; t he following pages in this section have individual wiring diagrams for different crane configurations. Find the appropriate wiring diagram and if necessar...

  • Page 17

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 15 6-11. Legend. Matching relay contacts in radio receiver panel by number . # an input with the terminal number # matching the con- nector in the receiver. # an output with the terminal number # matchi...

  • Page 18

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 16 wiring for intern al transfer switch usin g optional pigtail..

  • Page 19

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 17 wiring fo r external transfer sw it ch using optional pig ta il..

  • Page 20

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 18 note: move jumper ju1 on the receiver board for alarm after an e-stop command to function. See figure 8-1. Receiver layout for jumper ju1 location and position. Table 1. Single-speed wiring diagram. ...

  • Page 21

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 19 table 1. Single-speed programming diagram. Standard configuration hoist, trolley and bridge note for details on transmitter switch pair interlocks see telepilot manual programming section, section 5-...

  • Page 22

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 20 table 2(a) 2-speed wiring diagram. Standard configuration hoist, trolley and bridge master relay main line contactor aux 3 alarm* aux 2 (latchable s2-3) aux 1 (latchable s2-2) motor 1 (m1) (m1) dir 1...

  • Page 23

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 21 table 2(a) 2-speed programming diagram. Standard configuration hoist, trolley and bridge motor 1 connections motor 2 connections motor 3 connections j8-6 hoist up (hot j8-5) j7-6 trolley dir 1 (hot j...

  • Page 24

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 22 table 2(b) 2-speed wiring diagram. 2-speed with directional controls: all motions master relay main line contactor motor 1 dir1/dir2 motor 2 dir1/dir2 motor 3 dir1/dir2 motor 1 (m1) (m1) dir 1 (m1) 2...

  • Page 25

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 23 table 2(b) 2-speed programming diagram. 2-speed with directional controls: all motions motor 1 connections motor 2 connections motor 3 connections j8-6 hoist up (hot j8-5) j7-6 trolley dir 1 (hot j7-...

  • Page 26

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 24 table 2(c) 2-speed wiring diagram. 2-speed, 2-windings: all motions master relay main line contactor motor 1 2 nd spd motor 2 2 nd spd motor 3 2 nd spd motor 1 (m1) (m1) dir 1 (m1) 1 st spd (m1) dir ...

  • Page 27

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 25 table 2(c) 2-speed programming diagram. 2-speed, 2-windings: all motions motor 1 connections motor 2 connections motor 3 connections j8-6 hoist up (hot j8-5) j7-6 trolley dir 1 (hot j7-5) j6-6 bridge...

  • Page 28

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 26 table 2(d) 2-speed wiring diagram. Acco controls: all motions master relay main line contactor motor 1 2 nd spd dir 2 motor 2 2 nd spd dir 2 motor 3 2 nd spd dir 2 motor 1 (m1) (m1) dir 1 (m1) 2 nd s...

  • Page 29

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 27 table 2(d) 2-speed programming diagram. Acco controls: all motions motor 1 connections motor 2 connections motor 3 connections j8-6 hoist up (hot j8-5) j7-6 trolley dir 1 (hot j7-5) j6-6 bridge dir 1...

  • Page 30

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 28 table 2(e) 2-speed wiring diagram. P&h: 2-speed, 2-windings for hoist and trolley; standard bridge master relay main line contactor motor 1 high spd motor 2 high spd aux 1 (latchable s2-2) motor 1 di...

  • Page 31

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 29 table 2(e) 2-speed programming diagram. P&h: 2-speed, 2-windings for hoist and trolley; standard bridge motor 1 connections motor 2 connections bridge connections j8-6 hoist up (hot j8-5) j7-6 trolle...

  • Page 32

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 30 table 2(f) 2-speed wiring diagram. P&h: 2-speed, 2-windings for hoist; standard trolley and bridge master relay main line contactor hoist high spd aux 2 (latchable s2-3) aux 1 (latchable s2-2) hoist ...

  • Page 33

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 31 table 2(f) 2-speed programming diagram. P&h: 2-speed, 2-windings for hoist; standard trolley and bridge hoist connections motor 2 connections motor 3 connections j8-6 hoist up (hot j8-5) j7-6 trolley...

  • Page 34

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 32 table 2(g) 2-speed wiring diagram. Demag: 2-speed, 2-windings for hoist; standard trolley and bridge master relay main line contactor hoist down 2 nd spd aux 2 (latchable s2-3) aux 1 (latchable s2-2)...

  • Page 35

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 33 table 2(g) 2-speed programming diagram. Demag: 2-speed, 2-windings for hoist; standard trolley and bridge hoist connections motor 2 connections motor 3 connections j8-6 hoist up (hot j8-5) j7-6 troll...

  • Page 36

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 34 receiver panel table 2(h) 2-speed wiring diagram. Standard 2-speed 4 motor system master relay main line contactor motor 4 (m4) (m4) dir 1 (m4) 2 nd spd (m4) dir 2 motor 1 (m1) (m1) dir 1 (m1) 2 nd s...

  • Page 37

    Section 6 - wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 35 table 2(h) 2-speed programming diagram. Standard 2-speed 4 motor system motor 1 connections motor 2 connections motor 3 connections j8-6 main hoist up (hot j8-5) j7-6 trolley dir 1 (hot j7-5) j6-6 br...

  • Page 38

    Section 6 – wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 36 table 2(i) 2-speed wiring diagram. Standard 2-speed 3, 4 & 5 motor system using select master relay main line contactor aux 3 (aux 2 position on telepilot transmitter) alarm* select 1 select 2 motor ...

  • Page 39

    Section 6 – wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 37 table 2(i) 2-speed programming diagram. Standard 2-speed 3, 4 & 5 motor system using select motor 1 connections motor 2 connections motor 3 connections j8-6 main hoist up (hot j8-5) j7-6 trolley dir ...

  • Page 40

    Section 6 – wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 38 return table 3. 3-speed wiring diagram. Standard 3-speed 2 motor system (using a 3-speed transmitter). Master relay main line contactor aux 4 alarm* aux 3 (latchable rx s2-3) aux 2 (latchable rx s2-2...

  • Page 41

    Section 6 – wiring (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 39 table 3. 3-speed programming diagram. Standard 3-speed 2 motor system (using a 3-speed transmitter) motor 1 connections motor 2 connections j8-4 hoist up (hot j8-3) j6-2 trolley dir 1 (hot j6-1) j7-6...

  • Page 42: Section 7 – Programming

    Section 7 – programming telemotive tr12 intelesmart receiver instruction manual – 03/01/07 40 7-1. Receiver programming overview. Historically in telemotive’s 10k systems the user had to program the transmitter for frequency, access code plus all number of additional parameters for a special crane a...

  • Page 43

    Section 7 – programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 41 7-3. Receiver programming. The intelesmart receiver comes preprogrammed. Additional programming is not normally needed. After loading and opening the intelesmart program the first screen is the ...

  • Page 44

    Section 7 – programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 42 7-7. Programming access code. Enter the access code (must be inputted and match the respective transmitter for system to work): the access code is a unique string of sixteen 1’s and 0’s. The scr...

  • Page 45

    Section 7 – programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 43 figure 7-8. Set status word screen. (with definitions). Set status word screen with definitions shown. Definitions appear on the pda on a single line below all the switches for a respective swit...

  • Page 46: Warning

    Section 7 – programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 44 7-11. Status word programming. 7-11.1. Rx status word s1- 1, -2, -3 and -8. (group code). Group code differs from multibox in that the access codes do not have to be sequential. Definition: grou...

  • Page 47

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 45 7-11.3. Rx status word s1-5 (2-speed or single- speed outputs). Normally off (0) for 2-speed. Definition: this reconfigures the relay outputs on the receiver for single-speed applications using ...

  • Page 48

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 46 7-11.9. Tx status word s3-1, -2 and -3. (transmitter motion switch rearrangement). Normally all off. Definition: through this feature the conventional arrangement of transmitter motion switch pa...

  • Page 49

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 47 7-11.13. Tx status word s4-4. (invert crane select outputs). Normally off. Definition: this feature is only for custom crane relay configurations using select relays. Turning this switch on (1) ...

  • Page 50

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 48 7-12. Using custom mapping (for advanced programming only): custom mapping step 1: with the custom mapping determined that needed for your system, program in all other receiver parameters, frequ...

  • Page 51

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 49 motor 1 dir 1 dir 2 motor 2 dir 1 dir 2 motor 3 dir 1 dir 2 aux 1 aux 2 aux 3 aux 4 aux 5 aux 6 auxiliary controls motor 1 dir 1 dir 2 motor 2 dir 1 dir 2 motor 3 dir 1 dir 2 on/ off auxiliary c...

  • Page 52

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 50 this page intentionally blank..

  • Page 53: Warning

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 51 7-13. Access codes. 7-13.1. Access code programming. The access code is set at the factory and should not be changed unless absolutely necessary. The programming in the receiver(s) must match th...

  • Page 54

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 52 down button up button set button 7-14. Receiver frequency programming. The receiver is equipped with a frequency synthesizer that allows frequencies to be easily changed without retuning. Normal...

  • Page 55

    Section 7 - programming (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 53 7-14.4. Signal strength indicator mode the new rf module is capable of measuring the signal strength for the selected channel. To set the rf module to the signal strength indicator mode, press a...

  • Page 56: Section 8 – Servicing

    Section 8 – servicing telemotive tr12 intelesmart receiver instruction manual – 03/01/07 54 note if the system stops working, check the battery indicator on the transmitter. If it does not come on with pushing the on button or a weak battery is indicated on the transmitter replace the transmitter ba...

  • Page 57

    Section 8 – servicing (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 55 table 8-1. Receiver diagonostic led functions (see figure 8-1, receiver layout for led locations) led color function rf receiver on red power is on to the rf receiver. Normally on. Monitors power ...

  • Page 58

    Section 8 – servicing (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 56 table 8-1. Receiver diagonostic led functions (see figure 8-1, receiver layout for led locations) led color function ds8 red monitors the on command from the transmitter. Led will flash when an on...

  • Page 59

    Section 8 – servicing (continued) telemotive tr12 intelesmart receiver instruction manual – 03/01/07 57 table 8-1. Receiver diagonostic led functions (see figure 8-1, receiver layout for led locations) led color function the led will be on when a specific relay has been enabled by the respective com...

  • Page 60: Section 9 - Spare Parts

    Section 9 - spare parts telemotive tr12 intelesmart receiver instruction manual – 03/01/07 58 receiver part number description e13158-d rf synthesized receiver module assembly h310-0 rf receiver module assembly mounting screws (4) mp18005-0 rf receiver module mounting bracket top side (left) mp18005...