Kar Tech VRTX Users Manual

TM

VERSA REMOTE

FULL FEATURED REMOTE CONTROL SYSTEM

OPERATIONS AND INSTALLATION MANUAL

3B0181CJ.
July 25, 2003

VERSA REMOTE

INDEX

Description ................................................................... 1-3

Installation ................................................................... 7

Before applying power ..................................................... 7

Transmitter and Receiver ID Code Programming ...................... 7-8

Wiring chart.................................................................. 9-11

Routine Maintenance ....................................................... 13

Maintenance precautions .................................................. 13

Troubleshooting ............................................................. 13

Troubleshooting chart ................................................. 14

Error Code chart........................................................ 15

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Specifications ................................................................ 17-18

Instructions to the User .................................................... 19

VERSA REMOTE

1

DESCRIPTION:

KAR-TECH's VERSA REMOTE is a
state of the art microprocessor
based Radio Frequency (RF) and
Controller Area Network (CAN)
remote control system designed to
provide the machine operator
with the ability to remotely
operate equipment. The machine
operator is still required to follow
OSHA and other applicable
standards when operating the
equipment.

This system is designed with
Frequency Hopping Spread
Spectrum (FHSS) Technology and
Frequency Lock feature to
eliminate the RF interference
problem in Radio remote
products.

The control system consists of two
major modules: the remote
station (RF transmitter), and the
Remote Receivers (Digital
Controllers).

allows the equipment to work in
wireless mode in close vicinity of
each other without interfering
with each other. In the event that
a transmitter becomes damaged
and a new one is needed, the
receiver can be reprogrammed to
respond to the new transmitter.
Please refer to TRANSMITTER AND
RECEIVER ID CODE PROGRAMING
section of this manual for
additional information.

The remote station has two LED
indicators, the BATTERY and
TRANSMIT indicators. The red
BATTERY indicator starts blinking
when the battery voltage drops
below 9 volts and blinking speed
increases while the voltage is
decreasing. The transmitter is
powered by a rechargeable
battery and can be recharged by
the +12 volt electrical system of
the machine when connected to
the machine by the CAN/charger
cable or charger cable. An
optional AC charger can be used
to charge the battery.

Each transmitter is
preprogrammed with a special
radio ID code. The receiver is
programmed to respond only to
the transmitter with the ID code
for which it is set. This feature

Both frequency and duration of
use determine the operation time
of the battery. Power is being
used any time the transmitter
power is on. To turn transmitter
power off, turn off the power
switch on the transmitter. To
prolong the battery life and
efficiency, the pendant should not

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be left on charge for a long period
of time and should be discharged
periodically. A complete charge
can be achieved in 8 hour.

To save battery life, the
transmitter is designed with an
auto shut down feature. This
feature turns transmitter off when
none of the switches or buttons is
used for specified period. To turn
transmitter on again, toggle the
power switch to off, then on
position.

The transmitter is also able to
communicate with the receiver
via CAN (Controller Area Network)
protocol. This is done by
connecting the CAN cable to the
transmitter. This feature is
designed to allow the user to
operate the machine in case of
radio interference or discharged
transmitter battery.

OUTPUTS:

There are sourcing on/off outputs
and proportional outputs on the
receiver module. Each output is
designed with built in short circuit
and overload protection. The
on/off outputs are also designed

with no load or broken wire
status. These statuses are
reported to the machine operator
via the error code display in the
receiver. Refer to the error code
chart for a list of error codes.

The Proportional outputs are
current regulated and the
minimum and maximum requited
current as well as ramp for the
proportional output is calibrated
using a Palm Pilottm. Each
function is programmed for preset
factory settings when shipped
from Kar-Tech. Refer to factory
setting table at the end of this
manual.

DISPLAY:

The receiver is designed with an
integrated 4-character alpha­numeric red LED Intelligent
Display. This display is used to
report the status of the outputs,
radio communication, etc. to the
machine operator. For additional
information on error codes refer
error code chart of this manual.

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4

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5

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6

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INSTALLATION:

1.Refer to the wiring chart for
wiring connections.

2.The receiver should be mounted
on shock absorbing mounts. The
receiver is best mounted in a
protected location.

3.When installing the unit, the
main power should run from the
battery, through a 20 amps fast
blow fuse, to a power switch or
relay; then into the receiver unit.
For best results connect the
receiver main power connections
to the auxiliary terminal of the
ignition switch, PTO switch, or
ignition relay. Use 18 gauge or
heavier wire.

each mating pin terminal.

3.Read the rest of this manual.

TRANSMITTER AND RECEIVER ID
CODE PROGRAMMING:

Each transmitter is
preprogrammed with a special
radio ID code. The user can
change the ID code by the
following procedure.

1. Press the switch down (off)

2. Move the switch.

In this state, both LEDs on the
remote start toggling until the
user operates a function switch on
the remote. After the lights stop
flashing, a new ID has been
chosen.

4.All connections must be
properly insulated to protect
against shorts.

5.Seal all connections with a non­conductive silicone grease to
prevent against corrosion.

BEFORE APPLYING POWER:

1.Check power and ground
polarity.

2.Check wiring harness for
possible shorts before connecting
remote control to output devices
(i.e., valves, relays) by checking

The receiver is programmed to
respond only to the transmitter
with the ID code for which it is
set. This feature allows the
equipment to work in wireless
mode in close vicinity of each
other without interfering with
each other. In the event that a
transmitter becomes damaged and
a new one is needed, the receiver
can be reprogrammed to respond
to the new transmitter ID. A code
reset is done by connecting power
to the programming pin or
installing the mate to the 2 pin
WeatherPack connector provided
on harnesses (short 2 ft. cable) to
short power to program pin. This

VERSA REMOTE

connector must be removed after
programming ID code is set to
prevent from reprogramming ID
codes.

8

VERSA REMOTE

WIRING CHART

RECEIVER WIRING
CONNECTOR P1: DEUTSCH 40 PIN

PIN# FUNCTION

1 +12V BATTERY POWER
2 POWER TO PENDANT
3 NO CONNECTION
4 NO CONNECTION
5 NO CONNECTION
6 NO CONNECTION
7 NO CONNECTION
8 NO CONNECTION
9 NO CONNECTION
10 NO CONNECTION
11 LOWER BOOM RAISE OUTPUT
12 NO CONNECTION
13 RF ID PROGRAMMING PIN
14 SOURCE LOWER OUTPUT
15 NO CONNECTION
16 SOURCE RAISE OUTPUT
17 NO CONNECTION
18 UNLOADER VALVE OUTPUT
19 NO CONNECTION
20 E-STOP OUTPUT
21 NO CONNECTION
22 SPARE ON/OFF OUTPUT
23 NO CONNECTION
24 SPARE ON/OFF OUTPUT
25 DETECTOR LOWER OUTPUT
26 NO CONNECTION
27 DETECTOR RAISE OUTPUT
28 LOWER BOOM LOWER OUTPUT
29 ROTATE CW OUTPUT
30 ROTATE CCW OUTPUT
31 NO CONNECTION
32 KNUCKLE FOLD OUTPUT
33 KNUCKLE UNFOLD OUTPUT
34 NO CONNECTION
35 NO CONNECTION
36 CAN COMMUNICATIONS TO PENDANT (HIGH)
37 CAN COMMUNICATIONS TO PENDANT (LOW)
38 GROUND TO PENDANT
39 SPARE GROUND
40 BATTERY GROUND

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CONNECTOR P2: DEUTSCH 24 PIN

PIN# FUNCTION

1 NO CONNECTION
2 NO CONNECTION
3 NO CONNECTION
4 NO CONNECTION
5 NO CONNECTION
6 NO CONNECTION
7 NO CONNECTION
8 NO CONNECTION
9 NO CONNECTION
10 NO CONNECTION
11 NO CONNECTION
12 NO CONNECTION
13 NO CONNECTION
14 NO CONNECTION
15 NO CONNECTION
16 UPPER BOOM RETRACT OUTPUT
17 UPPER BOOM EXTEND OUTPUT
18 PWM/PROPORTIONAL OUTPUT
19 PTO OUTPUT
20 NO CONNECTION
21 NO CONNECTION
22 NO CONNECTION
23 NO CONNECTION
24 NO CONNECTION

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SYSTEM EXTENSION MODULE WIRING
CONNECTOR: DEUTSCH DTM13-12PA

PIN# FUNCTION

1 GROUND
2 CAN COMMUNICATIONS TO RECEIVER (HIGH)
3 CAN COMMUNICATIONS TO RECEIVER (LOW)
4-11 N/C
12 +12V POWER

CONNECTOR DEUTSCH DTM13-12PB

PIN# FUNCTION

1 C/S AXLE DOWN
2 C/S AXLE UP
3 S/S AXLE DOWN
4 S/S AXLE UP
5-9 N/C
10 RS-232 GROUND
11 RS-232 RX TO PALM PILOT
12 RS-232 TX TO PALM PILOT

VERSA REMOTE

REMOTE TRANSMITTER STATION WIRING
CONNECTOR: CXC3102A14S-5P-300

PIN# FUNCTION

A POWER
B GROUND
C CAN COMMUNICATIONS TO RECEIVER (HIGH)
D CAN COMMUNICATIONS TO RECEVIER (LOW)
E CABLE SHIELD (GROUND)

WIRED PENDANT STATION WIRING
CONNECTOR: DEUTSCH HDP26-24-23SN

PIN# FUNCTION

A POWER IN(+12 VDC)
B S/S AXLE RETRACT
C S/S AXLE EXTEND
D C/S AXLE RETRACT
E C/S AXLE EXTEND
F DETECTOR RAISE
G DETECTOR LOWER
H SOURCE RAISE
J SOURCE LOWER
K KNUCKLE UNFOLD
L KNUCKLE FOLD
M ROTATE CCW
N ROTATE CW
O UPPER BOOM EXTEND
P UPPER BOOM RETRACT
Q LOWER BOOM RAISE
R LOWER BOOM LOWER
S SPEED CONTROL
TGROUND
UUNLOADER VALVE

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13

ROUTINE MAINTENANCE:

1. Clean transmitter and
receiver regularly with a damp
cloth and mild detergent.

2. Periodically check receiver
antenna for tightness.

3. Inspect electrical wiring for
wear points or other damage.
Repair as required.

4. Inspect all connections for
looseness or corrosion. Tighten
and/or "seal" as necessary.

MAINTENANCE PRECAUTIONS:

hydraulic equipment.

3. Turn power off before
connecting or disconnecting
valve coils or other electrical
loads.

TROUB

LESHOOTING:

This section provides basic
operator level troubleshooting
for the VERSA REMOTE system.
If, after following these
instructions, the system still
does not function, check the
hydraulic system then contact
your KAR-TECH representative
for further instructions or
servicing.

When performing any inspection
or maintenance work on the
VERSA REMOTE system, always
exercise care to prevent injury
to yourself and others or
damage to the equipment. The
following are general
precautions that should be
closely followed in carrying out
any maintenance work.

1. Do not have hydraulic power
available to the valves when
performing electrical tests or
downloading programs.

2. Never operate or test any
function if any person is in an
area where they could be hurt
by being hit or squeezed by the

VERSA REMOTE

TROUBLE SHOOTING CHART

PROBLEM SOLUTION

14

1. No operation of all functions when a
function switch is activated.

2. Certain functions do not work 1. Check the wiring connection from the

1. Check to see if the selector switch is in
the proper position.

2. Check that transmitter power is on.

3. Check that receiver power switch is on.

4. Check vehicle wiring for power into the
system.

5. Check LED status display for system
status.

6. Check for proper grounding of vehicle's
electrical circuit.

7. Check vehicle's hydraulic system

system to the valve coil or the output
function that does not work.

2. Check LED status display for system
status.

3. Use frequency lock and lock to a good

channel.

4. Check vehicle's hydraulic system

5. Check vehicle's electrical system

3. Function operates intermittently. 1. Check for loose connections.

2. Check LED status display for system
status.

3. Check receiver antenna for any damage
and proper connection.

4. Use frequency lock and lock to a good
channel.

5. Check vehicle's hydraulic system

VERSA REMOTE

ERROR CODE CHART

EC01 - NO SIGNAL FROM PENDANT OR PENDANT POWER OFF
EC02 - SHORT OR OPEN CONNECTION ON SOURCE LOWER OUTPUT
EC03 - SHORT OR OPEN CONNECTION ON SOURCE RAISE OUTPUT
EC04 - SHORT OR OPEN CONNECTION ON C/S AXLE DOWN OUTPUT
EC05 - SHORT OR OPEN CONNECTION ON C/S AXLE UP OUTPUT
EC06 - SHORT OR OPEN CONNECTION ON S/S AXLE DOWN OUTPUT
EC07 - SHORT OR OPEN CONNECTION ON S/S AXLE UP OUTPUT
EC08 - SHORT OR OPEN CONNECTION ON DETECTOR LOWER OUTPUT
EC09 - SHORT OR OPEN CONNECTION ON DETECTOR RAISE OUTPUT
EC10 - SHORT OR OPEN CONNECTION ON LOWER BOOM LOWER OUTPUT
EC11 - SHORT OR OPEN CONNECTION ON LOWER BOOM RAISE OUTPUT
EC12 - SHORT OR OPEN CONNECTION ON UPPER BOOM RETRACT OUTPUT
EC13 - SHORT OR OPEN CONNECTION ON UPPER BOOM EXTEND OUTPUT
EC14 - SHORT OR OPEN CONNECTION ON ROTATE CCW OUTPUT
EC15 - SHORT OR OPEN CONNECTION ON ROTATE CW OUTPUT
EC16 - SHORT OR OPEN CONNECTION ON KNUCKLE FOLD OUTPUT
EC17 - SHORT OR OPEN CONNECTION ON KNUCKLE UNFOLD OUTPUT
EC18 - SHORT OR OPEN CONNECTION ON UNLOADER VALVE OUTPUT
EC19 - SHORT OR OPEN CONNECTION ON E-STOP OUTPUT
EC20 - SIGNAL RECEIVED FROM TRANSMITTER WITH INCORRECT ID CODE
EC21 - REMOTE SYSTEM JOYSTICK PROBLEM
EC22 - REMOTE SYSTEM JOYSTICK NOT ALLOWED
EC23 - DATA LINK PROBLEM BETWEEN CONTROLLERS

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SPECIFICATIONS

TRANSMITTER

Power supply

....................................................... 9.6 Volt Rechargeable, NIMH battery.

Operating temperature - Radio ............................................ -30˚C to +70˚C

Storage temperature........................................................ -40˚C to +100˚C

Frequency ......................................................................... 902-928 MHz

Transmit power ............................................................................ 1 mW

Vibration ............................................................................ 3G to 200Hz

Shock ...........................................................................................50G

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RECEIVER

Power supply voltage ................................... 12V nominal, 9V to 35V transient

Operating temperature - Radio ............................................ -30˚C to +70˚C

Storage temperature........................................................ -40˚C to +100˚C

Frequency ......................................................................... 902-928 MHz

On/Off outputs ........................................................ 5.0 Amp. (Protected)

Proportional outputs Frequency ...................................................... 200 Hz

Vibration ............................................................................ 3G to 200Hz

Shock ......................................................................................... 100G

NEMA ........................................................................................ 12/13

VERSA REMOTE

There are no user-serviceable parts inside the Transmitter or the
Receiver. Return the units to the KAR-TECH for service.

Note: For operation with negative ground vehicles only.

WARNING:

The KAR-TECH VERSA REMOTE must be operated in compliance with all
applicable safety regulations, rules, and practices. Failure to follow
required safety practices may result in death or serious injury.

The information, specifications, and illustrations in this manual are those in effect at
the time of printing. KAR-TECH reserves the right to change specifications or design at
any time without notice.

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VERSA REMOTE

INSTRUCTION TO THE USER:

This equipment has been tested and found to comply with 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 instructions, may cause harmful interference to radio
communications. However, there is no guarantee that 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 turning the equipment off and on,
the user is encouraged to try to correct the interference by one or more of the
following measures:

* Reorient or relocate the receiving antenna.

* Increase the separation between the equipment and receiver.

* Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.

* Consult the dealer or an experienced radio/TV technician for help.

This equipment has been certified to comply with the limits for a class B computing
device, pursuant to FCC Rules. In order to maintain compliance with FCC regulations,
shielded cables must be used with this equipment. Operation with non-approved
equipment or unshielded cables is likely to result in interference to radio and TV
reception. The user is cautioned that changes and modifications made to the
equipment without the approval of manufacturer could void the user's authority to
operate this equipment.

The term "IC:" before the certification/registration number only signifies that the
Industry Canada technical specifications were met.

Operation is subject to the following two conditions: (1) this device may not cause
interference, and (2) this device must accept any interference, including interference
that may cause undesired operation of the device.

VERSA REMOTE

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