COOPER FH1848D User Manual
TIME/Versalift
Digger Derrick
Control System
Installation and Operations Manual
Issue 10
March 21, 2000
2000 OMNEX Control Systems Inc.
All rights reserved.
Contents
1. Introduction..........................................................................................................................1
1.1. Part Numbers...........................................................................................................1
2. Physical Mounting................................................................................................................4
3. Considerations for Electrowelding.......................................................................................5
4. Electrical Connections.........................................................................................................6
5. Fuses, Configuration Jumpers ............................................................................................11
5.1. R1300 Board..........................................................................................................11
5.2. S20 Board...............................................................................................................11
6. Setting Up the Radio Receiver..................................................................................................12
6.1. Unique Identifier (Radio ID)......................................................................................12
6.2. No-Link Data Mode...................................................................................................13
6.3. Changing Switch Settings...........................................................................................13
7. Operations..........................................................................................................................14
7.1. Receiver/Controller................................................................................................14
7.1.1. Error Codes................................................................................................14
7.2. T45 Radio Transmitter ...........................................................................................14
7.2.1. Switching The Transmitter ON and OFF....................................................14
7.2.2. Operator Controls:......................................................................................15
7.2.3. Tilt Failsafe.................................................................................................15
7.2.4. Low Battery Indicator................................................................................16
7.2.5. Battery Charging and Replacement...........................................................16
7.2.6. Transmitter Light Summary .......................................................................16
7.2.7. Numeric Display.........................................................................................17
7.3. T47 Cable Remote .................................................................................................18
7.4. Emergency Override Panel....................................................................................18
8. Proportional Drive Adjustments.........................................................................................19
9. Factory Parameters............................................................................................................24
9.1. Types of Factory Parameters.................................................................................24
9.2. Changing the Factory Parameters..........................................................................24
9.3. List of Factory Parameters.....................................................................................25
PWM Drive Frequency Parameters.......................................................................28
Boom Load Moment Limit ....................................................................................28
Boom Derating Factors..........................................................................................28
Emergency Override Panel Function Speed ..........................................................28
Auger Shake Speed ................................................................................................28
Digger Transmission Type......................................................................................28
10. Warranty.................................................................................................................................29
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1. Introduction
The TIME/Versalift Digger Derrick Control System consists of a custom
Controller/Receiver (grey box), an optional T45 Radio Transmitter and/or an optional
T47 Cable Remote. An interface is also provided for an optional user-supplied
Emergency Override Panel. The main components of the Controller/Receiver are an
R1300+ (APCB-1225-10) circuit board, a PWM/V Converter Board, an S20 (APCB1458-xx) board, and a REX-900 radio receiver.
The Controller/Receiver’s software is custom-designed for the Digger Derrick
application. Various sensors mounted on the machine chassis se nd feedba ck information
to the Controller/Receiver. This feedback information together with the operator
commands determine the drive outputs to the Apitech™ electric-over-hydraulic valves.
A sophisticated computer program, permanently encoded into the firmware chips of the
Controller/Receiver, governs the mapping of inputs to outputs.
Features of the computer program include safety interlocks to prevent injury to
personnel as well as damage t o the machine. The program inc orporate s a “ resta rt” c heck
which ensures that functions do not act uate unexpec tedly due to ope rator pa nel switches
being left “on” by accident.
All wiring to the Controller/Receiver is through waterproof circular M.S.
connect ors on the outside of the fibregla ss enclosure, to ensure tha t the NEMA 4X rating
of the enclosure is preserved. This manual describes considerations which should be
taken during inst alla tion and operation, and gives procedures for “ tuning” the system to
match the exact characteristics of your hydraulic valves.
1.1. Part Numbers
The list below gives the part numbers of the major components of the Digger
Derrick Control System. You will need these numbers when ordering spare parts.
Component OMNEX Part
Number
R1302 Controller (works with T47 and
T247 only)
R1300+ Board, 12V (main board) TPCB-1225-10 —
Firmware (EPROM chip) for R1300+
board
PWM/V Converter Board TPCB-1496-05 —
S20 Board TPCB-1458-03 —
R1305 Receiver (supports T45, T47 and
T247)
R1300+ Board, 12V (main board) TPCB-1225-10 —
Firmware (EPROM chip) for R1300+ AFRM-1438-30 —
ASSY-1732-01 19423-1
AFRM-1438-30 —
ASSY-1732-02 19290-1
Versalift Part
Number
board
S20 Board TPCB-1458-03 —
PWM/V Converter Board TPCB-1496-05 —
Radio Transmitter Board TPCB-1756-01 —
REX-900 Radio Receiver ASSY-1190-01 —
R2305 Receiver (supports T245, T47 and
ASSY-1732-02 19425-1
T247)
R1300+ Board, 12V (main board) TPCB-1225-10 —
Firmware (EPROM chip) for R1300+
AFRM-1438-?? —
board
S20 Board TPCB-1458-03 —
DEX-900 Radio Receiver —
Factory Key for Controller/Receiver ACAB-1355-02
User Key for Controller/Receiver ACAB-1355-01
Shock Mount Kit for
AKIT-1498-01
Controller/Receiver
Output Cable with 54-pin Connector, 6
ACAB-1733-01 —
feet
Emergency Override Panel Interface
ACAB-1734-01 —
Cable with 16-pin Connector, 6 feet
Custom Output Harness ACAB-1974-01 19293-1
Custom Emergency Override Panel
ACAB-1975-01 19388-1
Harness
Engine Interface Module, Navistar
®
T45 Radio Transmitter ASSY-1326-25 19291-1
TX50 Board (long board) TPCB-1185-01 —
Interface Board (small board) TPCB-1302-01 —
Display Board TPCB-1736-01 —
T245 Radio Transmitter ASSY-1993-01 19291-1
TX50 Board (long board) TPCB-1847-01 —
Interface Board (small board) TPCB-1302-01 —
Display Board TPCB-1966-02 —
Platform Magnet for T45/T245
T47 Cable Remote (no display) ASSY-1312-15 —
UMB Board (long board) TPCB-1235-01 —
Interface Board (small board) TPCB-1302-01 —
2
T247 Cable Remote 19424-1
UMB Board (long board) TPCB-1235-01 —
Interface Board (small board) TPCB-1302-01 —
Display Board TPCB-1736-02 —
Umbilical Cable for T47 or T247, 20 feet
Dual-Axis Joystick with Trigger-Style
Deadman Button
Dual-Axis Joystick with Trigger-Style
Deadman Button
Boot Kit for Dual-Axis Joystick AKIT-9033-02
Paddle-Style Joystick AKIT-1610-01
T45/T245 Battery B0001 —
Battery Charger, 120VAC B0008 —
Battery Charger, 12V with Cigar
Lighter Plug
Installation and Operations Manual DMAN-1976-01
for RIGHT joystick
for LEFT joystick
AKIT-9048-01
AKIT-9048-02
B0007 —
3
2. Physical Mounting
The Controller/Receiver should be mounted with the connectors down, and in a
location so that the enclosure door may be opened conveniently for access to the inside.
Shock mounts must be used to mount the enc losure !
should the enclosure be directly bolted to the machine. Figure 1 below illus t ra t e s ho w t h e
shock mounts should be installed:
Figure 1
The Controller/Receiver enclosure is sealed and has a NEMA-4 rating. When
inst a llin g, e n su r e t ha t n o t hin g is done to c ompromise the wate rtightness of the enc losure.
When performing maintenance it may be necessary to gain access to the inside of the
enclosure; take care to re-close the door securely when you are done.
Enclosure Mounting
Under no circumstances
The receiver antenna should be mounted pointing up and as high as possible,
preferably with a large metal surface below it but no metal above or to the side. The
antenna must be mounted on the outside of the machine; do not mount it inside an
operator’s ca b or in a toolbox. Assemble the ante nna as shown in Figure 2 below, and
thread (finger-tight only) the connector onto the matching receptacle on the
Controller/Receiver.
Figure 2
Antenna Assembly
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3. Considerations for Electrowelding
The electronics in the Digger Derrick Control System can be damaged by the high
currents and voltages employed in electrowelding. If ele ctrowelding must be performed
after the Control System has been installed, observe the following precautions to reduce
the risk of damage:
• Do not connect the ground clip to a point on the chassis close to the
enclosures.
• Disconnect the harnesses to the enclosures and sensors at the M.S. connectors.
Also disconnect the battery (PTO switch) and ground connections going into
the enclosures.
• Do not strike an arc close to the enclosures and sensors, or wiring leading into
the enclosures and sensors.
• Do not weld to the sensors.
5
4. Electrical Connections
The Receiver/Controller has two circular M.S. connect ors for connection to your
chassis wiring. A 54-pin M.S. c onnector is used for power and function outputs. A 16pin M.S. connector is provided for connection to the T47 Cable Remote or Emergency
Override Panel. The following tables specify the assignment of each pin, with
corresponding markings on the circuit boards for reference. The wire numbers refer to
the old-style Output Cable and not the new Custom Output Harness.
Main Connector (Power and Functions):
Function Wire # 54-pin (32A10P)
M.S. Pin
Ground 48,38 A, AF J15 (R1300), J3 (S20)
Power for Electronics (Battery
Positive)
Power for Function Outputs (Batt. +) yellow
Dump Valve Output (drives power out
when radio signal is being received
from transmitter)
Engine START 24 D D2 (R1300)
Engine STOP 47 E D1 (R1300)
Winch DOWN 29 F 1+ (R1300)
Winch UP 25 G 1- (R1300)
Digger DIG 46 H 2+ (R1300)
Digger CLEAN 45 J 2- (R1300)
39 AG J12 (R1300), J1 (S20)
B J14 (R1300)
+green
49 C J13 (R1300), J2 (S20)
Board References
Lower Boom LOWER 5 K 3+ (R1300)
Lower Boom RAISE 14 L 3- (R1300)
Intermediate Boom EXTEND 23 M 4+ (R1300)
Intermediate Boom RETRACT 26 N 4- (R1300)
Upper Boom EXTEND 3 O 5+ (R1300)
Upper Boom RETRACT 22 P 5- (R1300)
Pole Guide/Platform LOWER 44 R 6+ (R1300)
Pole Guide/Platform RAISE 30 S 6- (R1300)
Boom Rotate CCW 6 T O1 (S20)
6
Boom Rotate CW 13 U O2 (S20)
Pole Guide/Platform OPEN 12 V O3 (S20)
Pole Guide/Platform CLOSE 21 W O4 (S20)
Digger Shift HIGH 27 X O5 (S20)
Digger Shift LOW 4 Y O6 (S20)
Auger LATCH 2 Z D4 (R1300)
Auger UNLATCH 20 a D5 (R1300)
Throttle UP 31 b D6 (R1300)
Throttle DOWN 7 c D7 (R1300)
Emergency Power 9 d D3 (R1300)
Electronic Throttle Output (0 to 5V) 1 e O9 (S20) via PWM/V
Converter Board
Hydraulic Tool Valve 43 f D8 (R1300)
Upper Boom Extended Switch (N.O.
contact)
Intermediate Boom Retracted Switch
(N.O. contact)
Upper Boom Retracted Switch (N.O.
contact)
(not used) — k —
Auger Overstow Switch (N.O. contact)
Input
(spare switch input) 15 n J2 pin 3 (R1300)
(spare switch input) 17 p J2 pin 4 (R1300)
Boom Stowed Switch (N.O. Contact)
Input
+5V Power for N.O. Switches 42 r J2 pin 1 (R1300)
+5V for Proportional Pressure and
Angle Sensors
32 g J2 pin 6 (R1300)
28 h J2 pin 7 (R1300)
8 j J2 pin 8 (R1300)
33 m J2 pin 2 (R1300)
11 q J2 pin 5 (R1300)
34 s J3 pin 1 (R1300)
Angle Sensor Input
(-20.00° = 0.2V, +73.12° = 5.0V)
Lift Cylinder Piston-Side Pressure
Sensor Input (0 PSI = 0.5V, 3000 PSI =
4.5V)
16 t J3 pin 3 (R1300)
10 u J3 pin 4 (R1300)
7
Lift Cylinder Rod-Side Pressure Sensor
Input (0 PSI = 0.5V, 3000 PSI = 4.5V)
19 v J3 pin 5 (R1300)
Ground for Proportional Pressure and
Angle Sensors
(spare 0-5V proportional input) — x J40 pin 2 (R1300)
(spare 0-5V proportional input) — y J40 pin 3 (R1300)
(spare 0-5V proportional input) — z J40 pin 4 (R1300)
(spare 0-5V proportional input) 18 AA J40 pin 5 (R1300)
(spare pulse input) 36 AB P1 (S20)
(spare pulse input) 41 AC P2 (S20)
Turret Brake Release 37 AD O7 (S20)
(not available) 40 AE O8 (S20)
There are two separat e power (+12V) and ground pins on the Main Connector. If
you are using the old-st yle Output Cable or are making your own wire harness, the two
ground pins (A and AF) should be connected t o a good ground point a t the batt ery or on
the chassis. The two power pins (AG and B) should be connecte d to a good switched
source, usually at the vehicle’s PTO switch. While the Controller/Receiver contains
internal fusing, it is highly recomme nded that in-line fuses be used to protect the wiring
harness in case of short circuits;
use a 3A fuse for pin AG, and a 15A fuse for pin B
35 w J3 pin 6 (R1300)
.
The Dump Valve Output (pin C) is a safety feat ure, and must be used to c ontrol a
dump valve in the hydraulic pressure circuit.
energized, the dump valve must divert the hydraulic flow back to tank
hydraulically-powered movements stop. Only when this output is energized (driving
+12V out) should the machine have hydraulic power.
The rest of the output functions except for the E lectronic Throttle Output (pin e)
are designed to drive either proportional or on/off sole noids at up to 3A each. Note that
the total simultaneous load must not, of course, exceed the ratings of the power fuses
(both inside the Controller/Receiver and your harness fuses). As the power distribution is
complex, please contact OMNEX for information before changing the fuse ratings from
their original values.
To control the engine throttle, use pin e for electronic throttles which take 0 to 5V,
or wire pins b and c to direction-control relays for motor-driven throttles.
The Switch Inputs (pins m, n, p and q) are best switched to the +5V Power
supplied from pin r, although they will wor k fin e if swit c h e d t o + 1 2 V. The +5 V fr om p in
r is preferred because it is already protected against short circuits. Do not feed +12V
back into pin r.
The proportional sensors must be powered from pin s (+5V) and pin w
(ground).
Do not power them from +12V or any other ground.
Whenever this output becomes de-
so that all
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