Cattron North America PS90 Industrial Hand-held R/C TX User Manual PS Controller Manaul

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PENDANT STATION CONTROLLER OPERATION & MAINTENANCE MANUAL CUSTOMER: MODEL NUMBER: SERIAL NUMBER: FREQUENCY ASSIGNMENT: ADDRESS ASSIGNMENT: MANUAL P/N: 68C-PS REV 000 01/2001

01/2001, CATTRON - THEIMEGTM Page i PENDANT STATION CONTROLLER OPERATION & MAINTENANCE INSTRUCTIONS IMPORTANT NOTICES The security ‘i-Key’ that accompanies your Pendant Station (PS) controller has been pre-programmed with certain system operating parameters before leaving our factory. If your PS controller is of the Advanced Technology (AT) family that is custom built to your specification, such ‘i-Key’ parameters will include a specific address and operating frequency. However, CATTRON-THEIMEG™ strongly advises you to check that our pre-configured address and frequency is not duplicated in other remote control equipment located at, or around, your operating facility. When returning an PSAT Pendant controller to CATTRON-THEIMEG™ for repair, the original coded ‘i-Key’ supplied with the unit shall be returned with the unit. When returning a PSEZ or PSCS Pendant controller to CATTRON-THEIMEG™ for repair, we recommend the coded ‘i-Key’ last used with the unit be returned with the unit. Before returning a PSEZ or PSCS Pendant controller to CATTRON-THEIMEG™ for repair, we strongly recommend you record the operating address and frequency assigned to the controller as you will be required to re-program these operating parameters after we return your controller. Refer to Frequency and Address Reports in Section 5 of this manual for recording details. When a PSEZ or PSCS Pendant controller is returned to CATTRON-THEIMEG™ for repair, we make every effort to establish the operating address and frequency assigned to your controller when it arrives at our repair facility. Whenever such operands can be established, we will record the same on the service documentation returned with your controller. This equipment is firmware based. Any duplication of operating firmware without written consent of CATTRON-THEIMEG™ is prohibited. U.S. Copyright Laws protect all firmware, parts and product listings, assembly files, and this manual.

Page ii 01/2001, CATTRON - THEIMEGTM List of Technical Abbreviations The following abbreviations (acronyms) are frequently used in CATTRON-THEIMEG™ Radio Remote Control Technology and may be used in this manual: AC Alternating Current LED Light Emitting Diode AT Advanced Technology ML Mainline ASO Automatic Safety Override NEMA National Electrical Manufacturer’s Association BCH Bose-Chaudhuri-Hocquenghem (data error detection routines) Ni-Cad Nickel Cadmium CMOS Complimentary Metal Oxide Semiconductor OPR Operate CS Crane Specific PRC Portable Remote Control DC Direct Current PS Pendant Station DOC Department of Communication (Canada) PTO Push-to-Operate DP Dual Pressure RF Radio Frequency EDP Electronic Data Processing RFI Radio Frequency Interference EEPROM Electrically Erasable Programmable Read Only Memory RST Reset Relay EMI Electro-Magnetic Interference SP Single Pressure EPROM Erasable Programmable Read Only Memory SYNC Synchronization FCC Federal Communications Commission TP Test Point GND Ground TS Transfer Switch I/O Input/Output VAC Volts Alternating Current IR Infra-red VDC Volts Direct Current LCD Liquid Crystal Display VFD Variable Frequency Drive

01/2001, CATTRON - THEIMEGTM Page iii Introduction How to use this Manual. This manual contains generic operation and maintenance procedures applicable to the entire series of CATTRON-THEIMEG™ Pendant Station (PS) Radio Remote Controllers. If you are using our Advanced Technology (AT) family of controllers that have been customized and pre-programmed to your exact specification, you should skip Section 5 in its entirety as the frequency and address programming procedures contained therein do not apply to your controller. If you are using our PSEZ or PSCS family of controllers, you should include Section 5, as you will be required to verify/program the system address and operating frequency before using your controller for the first time.

Page iv 01/2001, CATTRON - THEIMEGTM Safety Summary WARNING and CAUTION statements have been strategically placed throughout all text prior to operating or maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING), or equipment and property (CAUTION). A WARNING and CAUTION will apply each time the related step is repeated. Before starting any task, the WARNINGS or CAUTIONS included in the text for the task shall be reviewed and understood. All WARNINGS and CAUTIONS appearing in this manual are included below. WARNINGS. WARNINGS: ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNINGS: MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE, BEFORE INSERTING AN ‘i-Key’ INTO A PS CONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-Key’ IS SELECTED FOR THE DESIRED EQUIPMENT TO BE OPERATED. IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

01/2001, CATTRON - THEIMEGTM Page v Safety Summary, continued WARNINGS, continued. WARNING: DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST TIME A PUSHBUTTON IS DEPRESSED. CONSEQUENTLY, SPECIAL CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS EQUIPPED WITH A PARKING BRAKE THAT IS CONFIGURED TO ENGAGE WHEN THE MAINLINE CONTACTOR DE-ENERGIZES. TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU SHOULD IMMEDIATELY PRESS THE RED ‘STOP’ BUTTON ON YOUR REMOTE CONTROLLER AFTER COMPLETION OF CRANE OPERATIONS. SUCH ACTION WILL INSURE THE PARKING BRAKE (IF EQUIPPED AND CONFIGURED AS ABOVE) IS SET, PREVENTING UNINTENTIONAL MOVEMENT OF THE CRANE OR TRACKED MACHINE. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

Page vi 01/2001, CATTRON - THEIMEGTM Safety Summary, continued WARNINGS, continued. WARNING: FAILURE TO PROPERLY SELECT FREQUENCY AND ADDRESS MAY RESULT IN THE UNINTENTIONAL OPERATION OF OTHER MACHINERY AND COULD RESULT IN DEATH OR SERIOUS INJURY TO PERSONNEL. DO NOT DUPLICATE ADDRESS ASSIGNMENT. WARNING: CATTRON-THEIMEG™ PSEZ AND PSCS PORTABLE REMOTE CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors, fire suppression etc.). CONTACT CATTRON-THEIMEG™ FACTORY FOR INFORMATION REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS. SHOULD CATTRON-THEIMEG™ PSCS AND PSEZ PORTABLE REMOTE CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY RESULT. IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM.

01/2001, CATTRON - THEIMEGTM Page vii Safety Summary, continued CAUTIONS. CAUTION: All PS Controller internal circuit boards are sensitive to electrostatic discharge. Consequently, all maintenance procedures involving disassembly and assembly of these controllers shall be carried out by qualified technicians using anti-static mats and personal grounding straps. Failure to comply with this caution may result in equipment damage and void our warranty. CAUTION: CATTRON-THEIMEG™ Battery Chargers and External Charging Units are designed for use with CATTRON-THEIMEG™ Ni-Cad Battery packs only. failure to comply with this caution may result in equipment and/or battery damage and will void our warranty. CAUTIONS: CATTRON-THEIMEG™ Battery Adapters are designed for use with non re-chargeable ‘AAA’ size Alkaline Batteries only. Carbon/Zinc, Lithium, or Ni-Cad Batteries are not to be used with this adapter. Damage to batteries will occur if this adapter is used for battery charging. CAUTION: All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving disassembly and assembly of PS Controllers. Failure to comply with this caution may result in equipment damage and will void our warranty. CAUTION: All control functions will be stopped if the PS Controller is used or left standing in an upright position during heavy rain, or in hostile environments where water could fill the top of the controller and cover the ‘i-Key’. To resume control functions, simply invert and shake the controller to remove excess water. There is no need to remove the ‘i-Key’. Ideally, to prevent such occurences in wet weather and water spray environments, the controller should (1) never be left standing upright, (2) be carried by the shoulder strap, and (3) operated in a near horizontal position.

Page viii 01/2001, CATTRON - THEIMEGTM Safety Summary, continued GENERAL. The following are general safety precautions that are not related to any specific procedure and therefore do not appear elsewhere in this manual. These are general safety precautions and instructions that people must understand and apply during many phases of operation and maintenance to ensure personal safety and health and the protection of your company property. KEEP AWAY FROM LIVE CIRCUITS. Maintenance personnel must observe all safety requirements at all times. Do not replace components or make adjustments inside the equipment with the electrical supply turned on. Under certain conditions, danger may exist even when the power control is in the off position due to charges retained by capacitors. To avoid injuries, always remove power, discharge and ground a circuit before touching it. Adhere to all lock out/tag requirements. DO NOT SERVICE OR ADJUST ALONE. Do not attempt internal service or adjustment of equipment unless another person capable of rendering aid and resuscitation is present. FINGER RINGS/JEWELRY. Finger rings have caused many serious injuries. Remove rings, watches and other metallic objects that may cause shock or burn hazards. SOLDERING/DE-SOLDERING. Avoid breathing fumes generated by soldering/de-soldering. Perform all operations in a ventilated area. Eye protection is required. CLEANING SOLVENTS. Some cleaners and solvents have adverse effects on skin, eyes, respiratory tract and internal organs. These adverse effects range from discomfort to serious injury and death, depending on the material and degree of exposure. Observe manufacturers’ warning labels and contact your immediate supervisor if in any doubt. Remember…. the person now reading these instructions is primarily responsible for his or her own health and safety.

01/2001, CATTRON - THEIMEGTM Page ix Table of Contents Front Matter: Important Notices ................................................................................................ i List of Technical Abbreviations ......................................................................... ii How to use this Manual .................................................................................... iii Safety Summary ................................................................................................ iv Warnings ............................................................................................... iv Cautions ............................................................................................... vii General ................................................................................................ viii Section 1 – Product Data and Specifications: Functional Description .................................................................................... 1-1 Specifications .................................................................................................. 1-3 Overview of CATTRON-THEIMEG™ Remote Control Systems .................. 1-5 Section 2 – Safety Information: Safety Considerations ..................................................................................... 2-1 Typical Method of Operation .......................................................................... 2-2 Radio Control Operator’s Duties – General Equipment ................................. 2-4 Radio Control Operator’s Duties – E.O.T. Crane ........................................... 2-7 Section 3 – Operating Instructions: ‘i-Key’ configuration for continuous (FCC part 90) and non-continuous (FCC part 15) transmit applications ............................................................... 3-1 Controls and Indicators ................................................................................... 3-2 Battery Charging Options ................................................................................ 3-4 Internal Charging ................................................................................ 3-5 External Charging ............................................................................... 3-5 Alkaline Battery Adapter (‘AAA size’) .......................................................... 3-6 Operating procedure – PS controller ............................................................... 3-7

Page x 01/2001, CATTRON - THEIMEGTM Table of Contents, continued Section 4 – Maintenance Instructions: CATTRON-THEIMEG™ Maintenance Philosophy ....................................... 4-1 Maintenance Procedures ................................................................................. 4-2 Preventive Maintenance ....................................................................... 4-2 Troubleshooting .................................................................................. 4-2 Corrective Maintenance ...................................................................... 4-2 Functional check ................................................................................. 4-3 Replacement items .............................................................................. 4-3 Troubleshooting Guide ....................................................................... 4-4 Disassembly and Assembly Procedures .............................................. 4-5 Battery Pack ............................................................................ 4-6 Bottom Endcap ......................................................................... 4-7 Top Endcap .............................................................................. 4-8 Upper & Lower Main Body Housings ................................... 4-10 Rubber Side Grips ................................................................. 4-11 Section 5 – PSCS & EZ Series Controllers: Introduction – PSEZ & CS Controllers .......................................................... 5-1 Installing different ‘i-Keys’ ............................................................................ 5-1 PSEZ & CS Control Systems – frequency & address assignment .................. 5-2 PSEZ & CS Controllers – address/frequency verification .............................. 5-3 Programming PSEZ & CS Controller address and frequency ........................ 5-4 Address digit #1 entry and report (CS only) ....................................... 5-6 Address digit #2 entry and report (CS only) ....................................... 5-8 Address digit #3 entry and report (EZ & CS)...................................... 5-9 Address digit #4 entry and report (EZ & CS).................................... 5-10 Frequency Bank entry and report (EZ & CS).................................... 5-11 Frequency entry and report (EZ & CS).............................................. 5-12 Address, Frequency Bank and Frequency report only (EZ & CS) .... 5-14

01/2001, CATTRON - THEIMEGTM Page xi Table of Contents, continued Section 6 – Parts List and Accessories: Introduction ..................................................................................................... 6-1 Accessories/consumable items ........................................................................ 6-1 PS Controller – exploded view (illustrated parts breakdown) ........................ 6-2 PS Controller – Parts List ............................................................................... 6-3 Illustrations – accessories/consumable items ......................................... 6-4 – 6-8 Index. Addendum RECOMMENDED SAFETY RULES FOR PORTABLE REMOTE CONTROLLED (PRC) CRANES.

Page xii 01/2001, CATTRON - THEIMEGTM EZ CS ATRxRxTxTxTxRxRxRx

01/2001, CATTRON - THEIMEGTM Section 1, Page 1 Section 1 – Product Data & Specifications Functional Description. The CATTRON-THEIMEG™ Pendant Station (PS) remote controller is a lightweight, extremely rugged customizable radio control unit for use with any CATTRON-THEIMEG™ Portable Remote Control (PRC) System. CATTRON-THEIMEG™ PS controllers are offered in three family configurations: PSEZ (Easy), PSCS (Crane Specific) and PSAT (Advanced Technology). In all three CATTRON-THEIMEG™ families of PS controllers, operational security is advanced to its maximum by the use of a removable stainless steel, electronic ‘i-Key’ which, when installed in the controller, defines and enables the appropriate operating parameters. When the ‘i-Key’ is removed, the controller is totally disabled. It should be noted that each family of PS controller has a specific colored ‘i-Key’ (green = EZ, blue = CS, and silver = AT) and that these ‘i-Keys’ are not interchangeable between controller families. The switch unit and electronics are contained in an extreme duty, water and dust resistant, aluminum housing which has armorized rubber end-caps for switch protection and high impact resistance. The controller housing is ergonomically designed with curved bottom and rubber side grips to allow comfortable handling. The ‘i-Key’ is mounted in a receptacle located within the confines of the armorized rubber ‘bumper’ that forms the top end-cap. Separate Power ON/OFF and STOP (red) switches are also located next to the removable ‘i-Key’. The controller front face contains up to six large pushbuttons that are engraved with their respective control function symbols. When pressed, each pushbutton activates circuitry inside the controller. Pushbuttons may be of three-step or proportional (stepless) operation. Three-step pushbuttons provide 3-speed operation with a single pushbutton. When pressed, each pushbutton step has a distinct limit of travel that provides an enhanced tactile feel that is noticed by the operator. Proportional (stepless) pushbuttons provide variable frequency drive (VFD) operation with a single pushbutton. In these applications, the drive motor speed is directly proportional to the amount of travel of the pushbutton (more distance = more speed). Additional maintained and momentary depression toggle switches are mounted within a recessed channel alongside the large control function pushbuttons. Note that PSAT models may be provided with variety of custom switches All commands from CATTRON-THEIMEG™ PS controllers respond within milliseconds of pressing or releasing a pushbutton. Additionally, a mainline ON command is sent when power is turned on and re-sent anytime a controller function pushbutton is pressed. Within the PS controller, a microprocessor performs self–diagnostics, interprets pushbutton and switch commands, and controls the radio transmitter.

Section 1, Page 2 01/2001, CATTRON - THEIMEGTM Functional Description, continued. CATTRON-THEIMEG™ PS controllers are equipped with an internal antenna and the typical operating (transmitter) range is in excess of 500 feet (160+ meters). It should be understood that operating range varies with environmental conditions. Should the transmitter go out of operating range, all motions will cease. CATTRON-THEIMEG™ PSAT series controllers have been approved to comply with both FCC Part 15 (non-continuous transmission) and FCC Part 90 (continuous transmission) applications, and for DOC RSS-210 (non-continuous transmission) and RSS-119 (continuous transmission) applications standards. No United States of America FCC, or Canadian DOC license is required for operation of FCC Part 15 or RSS-210 (non-continuous transmission) PS controllers. Non-licensed PS controllers transmit the very secure CATTRON-THEIMEG™ Series digital message, using frequency modulation (FM) radio. These radio transmitters are approved for use on frequencies between 425-447MHz (M) and 447-473MHz (H). They can be used on any frequency within these bands, including normally licensed channels without the need for a license. An authorized station operating license is required for the operation of US Part 90 and Canadian RSS-119 (continuous transmission) applications. If you need assistance in obtaining these licenses, please contact CATTRON-THEIMEG™ Inside Sales Department in the first instance. As previously mentioned, operational security is maximized by the need to use a stainless steel electronic ‘i-Key’ for controller operation. However, there is an additional and very significant operational advantage of the CATTRON-THEIMEG™ ‘i-Key’ concept. It is that individual system address, operating frequency and keypad configuration may be permanently stored in the ‘i-Key’, depending on the type of controller supplied. Therefore, CATTRON-THEIMEG™ PS controllers belonging to the same family at a user location can be identical - only the ‘i-Keys’ are different. To simplify, each ‘i-Key’ is color-coded and labeled for an individual control system family, thus, any CATTRON-THEIMEG™ PS controller will run any CATTRON-THEIMEG™ receiver/decoder belonging to the same family as long as the correct ‘i-Key’ is used. As the result, this unique operating concept reduces the need for specific spare remote controllers. Our unique family of PS controllers is identified on the next page. All CATTRON-THEIMEG™ PS controllers are powered by disposable 3-Volt alkaline or re-chargeable Ni-Cad battery packs. In normal operation, a green LED ‘flashes’ with each function command message and a ‘beep’ is sounded when a pushbutton is depressed. When the battery voltage becomes low, a separate yellow LED flashes, alerting the operator that the battery pack needs to be replaced or re-charged soon. Battery packs are easily and quickly replaced without the need for tools by turning two knurled thumbscrews and removing the battery cover-plate located within the confines of the armorized rubber bottom end-cap. The battery pack makes positive contact without snaps or plugs and has no wires to break; simply drop it in, and replace the battery cover-plate.

01/2001, CATTRON - THEIMEGTM Section 1, Page 3 Functional Description, continued. Ni-Cad battery packs can be re-charged ‘in-situ’ and do not need to be removed from the controller housing. To enable such battery charging to be carried out, a series of optional battery chargers are available for all CATTRON-THEIMEG™ PS controllers. One end of the charger is connected to the mains power outlet, the other plugs into a covered socket located within the bottom end cap. Additional options include an ‘AAA’ size battery adapter, and an external battery-charging unit – refer to accessories/consumable items in Section 6 for details and part numbers. A shoulder-carrying strap is standard for all CATTRON-THEIMEG™ PS controllers. This is quickly and simply installed to a pair of ‘D’-rings located on the side of the controller. Specifications. Case Material: Extreme duty, dust and water resistant, aluminum housing. Approximate weight: 2.3lbs. / 1.04 Kg (including battery pack) Dimensions: 12.0" x 3.0" x 2.0" (30.0cm x 7.6cm x 5.1cm). Environmental: Consult CATTRON-THEIMEG™ factory for a wide range of environmental solutions. Maximum Functions: Up to 20 operator commands, depending on controller configuration. Operator Control Functions – PSAT Series: Up to six large pushbuttons (proportional type, three-step type, or any combination of these two), plus additional toggle switches and/or pushbuttons, as required.

Section 1, Page 4 01/2001, CATTRON - THEIMEGTM Specifications, continued. Operator Control Functions – PSEZ & PSCS: Six large pushbuttons (three-step type only), plus two auxiliary function switches and a selector for motors A or B, or both A+B. Battery type: 3-Volt Alkaline Battery Pack (standard). 2.4 Volt re-chargeable Ni-Cad Battery Pack (optional). 3-Volt Alkaline Battery Adapter for use with quantity 2 ‘AAA’ size Alkaline batteries only (optional). Battery life (20% Duty Cycle): 3 Volt alkaline battery pack (standard) or re-chargeable Ni-Cad battery pack (optional). In USA, Canada and non EU countries, battery life is:- Ni-Cad pack – 50 hours, Alkaline pack – 115 hours, ‘AAA’ Alkaline batteries (using optional adapter) – 50 hours. In EU countries, battery life is:- Ni-Cad pack – 30 hours, Alkaline pack – 65 hours, ‘AAA’ Alkaline batteries (using optional adapter) – 25 hours. Transmit indicator: Green LED flashes with every transmission. Low battery indication: Yellow LED flashes for low battery, low battery alert signal beeps every 10 seconds. Battery charging: Internal Ni-Cad battery charging. Optional ‘Standard’ rate (10 hour) or ‘Rapid’ rate (1-hour) Battery Chargers are available for use in countries having 110-120 VAC mains input power. Alternatively, optional ‘Rapid’ or ‘Trickle’ Battery chargers are available for use in countries having 220-240 VAC mains input power. An External Battery Charging Unit is also available for use with all optional CATTRON-THEIMEG™ battery chargers. Audio speaker: For function pushbutton ‘click’ and low battery indication. Transmitter frequency: 425-447MHz (M) or 447-473MHz (H).

01/2001, CATTRON - THEIMEGTM Section 1, Page 5 Overview – CATTRON-THEIMEG™ Remote Control Systems. Figure 1-1 below shows a simplified block diagram of a typical CATTRON-THEIMEG™ remote control system. Refer to this figure and the following paragraphs for a functional description of the remote control system. The target receiver/decoder is controlled by the Pendant Station Controller. Provided the correct coded ‘i-Key’ is inserted into the controller, the controller sends signals to the receiver/decoder using an UHF radio link. The signal is picked up by the antenna and passed on to the receiver. If the signal is the correct frequency and passes all required data tests, the signal is passed on to the decoder. The decoder compares the address code of the signal to its own address code. If the signal’s address code does not match its address code, it is ignored and a message is displayed on a system status display located in the receiver/decoder unit. If the address code is correct, the decoder processes the message and energizes and de-energizes the appropriate control, directional output, three-speed and auxiliary function relays located within the control system. An Automatic Safety Override (ASO) function continually monitors the state of all directional relay outputs (i.e. Forward/Reverse). If a directional relay electrically fails closed without a command from the controller, the ASO circuit logic de-energizes the master output relay (OPR). During operation, the microprocessor on the decoder board resets multiple watchdog timer circuits whenever valid messages are received and decoded. If the microprocessor fails to reset the watchdog timers, the timer circuits shut down and de-activate all relay outputs. The decoder microprocessor requires continuously valid transmitted signals to be received and decoded or all relay output functions will be de-activated unless programmed otherwise. It should be noted that the mainline control relay (OPR) would be maintained for up to 10 minutes, depending on system configuration. Figure 1-1. Typical Radio Remote Control System, simplified block diagram END OF SECTION PENDANTCONTROLLERADDRESS ADDRESS FREQFREQRxTxRECEIVERDECODER12 VDCPOWERSUPPLYWATCHDOGTIMER115 VAC50-60 HZDIRECTIONAL OUTPUT RELAYSMACHINE WIRINGTHREE-SPEED AND AUXILIARYFUNCTION OUTPUT RELAYSASO

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01/2001, CATTRON - THEIMEGTM Section 2, Page 1 Section 2 – Safety Information Safety Considerations. CATTRON-THEIMEG™ believes that to safely operate any remotely controlled equipment, the overall system needs to be configured so that movement or operation of the equipment will take place only when the device is commanded to move or operate. For example; overhead cranes must be equipped with a braking system, which can only be released when an electrical signal is sent to the motor. Removal of electrical power or loss of the radio transmitted signal results in application of the brakes. One way to accomplish this is with a CATTRON-THEIMEG™ Electro-Hydraulic brake package – contact the factory for details. In keeping with this philosophy - NO COMMAND, NO MOVEMENT - CATTRON-THEIMEG™ has designed your radio remote control system with the following safety and security features. ‘i-Key’: Operational security is advanced to its maximum by the use of a removable stainless steel, electronic, ‘i-Key’ which, when installed to the Pendant controller, defines and enables the operating parameters. When the ‘i-Key’ is removed, the controller is totally disabled. Unique address code: Each PS series controller and receiver/decoder pair is configured with a unique address code so that the equipment will respond only to the controller whose address code matches that of the decoder. Intelligent digital message protocol: CATTRON-THEIMEG™ remote control systems utilize a unique message protocol for industrial control applications rather than the customary Electronic Data Processing (EDP) type of message format. ON/OFF power switch: The PS controller is provided with a rotary power ON/OFF switch that must be set to ‘ON’ in order to send commands to the receiver/decoder. If the power switch is set to ‘OFF’, the decoder will remove all commands from the controlled machinery, stopping all movement. However, the mainline control relay (OPR) will be maintained for up to 10 minutes, depending upon system configuration. Red System STOP Switch: Operating the red STOP switch while the PS controller is turned on will repeatedly send a burst of stop commands to all outputs including the mainline control relay (OPR). Operate relay (OPR): The operate (OPR) output relay shall be wired to control a user-provided electro-magnetic power contactor. The electro-magnetic contactor opens and closes the main electrical supply circuit(s) to the controlled device. Data Error Checking: All communications from the Pendant controller to the receiver/decoder contain error-checking information (BCH data error detection routines). The entire data command packet must pass error detection tests before being processed.

Section 2, Page 2 01/2001, CATTRON - THEIMEGTM Typical method of operation (incorporating above safety features) using a radio controlled overhead crane as an example: The Operate (OPR) relay(s) is energized for the first time when: The red STOP and rotary ON/OFF switches on the PS Controller are operated in the proper sequence (first unlatch and pull up STOP switch to ‘RUN’, then rotate ON/OFF switch to ‘ON’), the correct coded ‘i-Key’ is installed, and the target receiver/decoder has power applied. With all these conditions satisfied, a matching address code is sent by way of RF signal from the PS controller to the decoder. The OPR relay is wired to the mainline (ML) contactor on the crane. Once the mainline is energized, a continuously repeated valid signal must be received for function outputs to engage. If this signal is interrupted for any reason, all function outputs will turn off unless programmed otherwise. When operating within the USA, FCC rules state that RF transmitters in non-licensed controllers must switch off within five seconds after the operator releases a function pushbutton. Consequently, the OPR output is programmed to stay on for up to ten minutes after the last valid message is received. During this time all Automatic Safety Override (ASO) monitored outputs must stay off or the ASO sensing in the decoder will interrupt this hold up time, de-energizing OPR. Figure 2-1 below shows an Operate (OPR) contact wired directly to the mainline (ML) contactor. Provided the red STOP switch on the Pendant Controller is pulled out and the correct coded ‘i-Key’ is installed, setting the green ON/OFF power switch on the Pendant controller to ‘ON’ will energize the mainline contactor. Figure 2-1. Operate (OPR) contact wiring An auxiliary function may be used as a Reset (RST) output that will only be effective when the Operate (OPR) relay has been closed. Momentary closure of the Reset (RST) relay picks up the mainline (ML) contactor, which is maintained under control of the OPR. Thus, power is supplied to the controlled device. If OPR opens, the mainline contactor releases, removing power from the controlled device and stopping all motion. 120VL1 MLMLMANUALDISCONNECTL2L3 LL1LL2LL3 TOMOTORRECEIVER/DECODEREXISTING CONTROLS OPRRC5.0A

01/2001, CATTRON - THEIMEGTM Section 2, Page 3 Typical method of operation, continued. Figure 2-2 below shows the Operate (OPR) relay and optional Reset (RST) relay wired to control a mainline contactor. This configuration requires the operator to activate the reset function on the controller after he/she has turned the unit on. Once reset, the ML contactor stays energized until OPR de-energizes. In addition to being energized by the presence of a signal from the controller, OPR is under supervision of the Automatic Safety Override (ASO) circuit. The ASO circuit disables the OPR (shutting down the controlled machinery) if a directional output relay is active when no corresponding command is being received from the controller. In this event, no action is required by the operator to stop the equipment. The ASO safety circuitry will stop motion automatically without any operator command when a directional output relay fault is detected. Figure 2-2. Operate (OPR) contactor and Reset Relay (RST) wiring OPR120VRSTRRCC5.0A5.0AL1MLMLMLMANUALDISCONNECTL2L3 LL1LL2LL3 TOMOTORRECEIVER/DECODEREXISTING CONTROLS

Section 2, Page 4 01/2001, CATTRON - THEIMEGTM Radio Control Operator’s Duties – General Equipment. WARNINGS: ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNINGS: MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE, BEFORE INSERTING AN ‘i-Key’ INTO A PS CONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-Key’ IS SELECTED FOR THE DESIRED EQUIPMENT TO BE OPERATED. IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN PERSONAL INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

01/2001, CATTRON - THEIMEGTM Section 2, Page 5 Radio Control Operator’s Duties – General Equipment, continued. WARNING: CATTRON-THEIMEG™ PSEZ AND PSCS PORTABLE REMOTE CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors, fire suppression etc.). CONTACT CATTRON-THEIMEG™ FACTORY FOR INFORMATION REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS. SHOULD CATTRON-THEIMEG™ PSCS AND PSEZ PORTABLE REMOTE CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY RESULT. IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM. The following procedures provide general guidelines for radio control operation of equipment and should not be used as a substitute for your plant operating procedures. 1. Before operating equipment, carry out the following: a. Install the correct coded ‘i-Key’ for the target equipment to be operated. If the wrong coded ‘i-Key’ is installed to the PS controller, the target equipment will not operate. However; other equipment located at, around, or nearby your facility may become operational. b. Set (unlatch and pull out) PS controller red STOP switch to ‘RUN’ and turn Power ON/OFF switch to ‘ON’. When transmitting with a good battery, two short ‘beeps’ will be heard immediately after the ON/OFF power switch is set to ‘ON’ and the green TRANSMIT LED will ‘flash’ rhythmically. When the battery starts to go low, the yellow LOW BATTERY LED will ‘flash’ continuously, which means you should change or re-charge the battery pack (refer to Battery Pack in Section 4 of this manual for instructions on how to replace a battery pack).

Section 2, Page 6 01/2001, CATTRON - THEIMEGTM Radio Control Operator’s Duties – General Equipment, continued. c. When installed, activate the ALARM/RESET switch on the PS controller (this is normally an optional function that sounds the equipment alarm and resets the main power contactor). d. Check each function independently to be sure that equipment is responding correctly. e. Where a limit switch is provided, you should check the limit switch at the beginning of each shift as defined by your plant operating procedures. f. Check Range Limiting if used. g. Check STOP operation h. Check brake operation. 2. You must report all defective or missing safety equipment, mechanical or electrical defects to your supervisor without delay. Do not continue operation until fully repaired. 3. If anyone is in the path of equipment travel, stop and sound the alarm before proceeding. 4. Persons operating this equipment shall not use a limit stop as a utility stopping device. 5 When leaving the equipment area for any reason, set (push down) the PS controller red STOP switch to ‘STOP’ and turn power ON/OFF switch to ‘OFF’. Remove the ‘i-Key’ from the PS controller and keep it on your person. 6. Do not allow any unauthorized person to operate the PS controller. 7. Do not operate the PS controller at a distance where the equipment and all surrounding objects are not visible. 8. Do not attempt to override any of the safety features built into the Radio Control System. 9. If for any reason you or anyone has to board the radio-controlled equipment, set (push down) the Pendant controller red STOP switch to ‘STOP’ and turn the power ON/OFF switch to ‘OFF’. Remove the ‘i-Key’ from the PS controller and keep it on your person.

01/2001, CATTRON - THEIMEGTM Section 2, Page 7 Radio Control Operator’s Duties – E.O.T. Crane. WARNINGS: ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNING: DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST TIME A PUSHBUTTON IS DEPRESSED. CONSEQUENTLY, SPECIAL CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS EQUIPPED WITH A PARKING BRAKE THAT IS CONFIGURED TO ENGAGE WHEN THE MAINLINE CONTACTOR DE-ENERGIZES. TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU SHOULD IMMEDIATELY PRESS THE RED ‘STOP’ BUTTON ON YOUR REMOTE CONTROLLER AFTER COMPLETION OF CRANE OPERATIONS. SUCH ACTION WILL INSURE THE PARKING BRAKE (IF EQUIPPED AND CONFIGURED AS ABOVE) IS SET, PREVENTING UNINTENTIONAL MOVEMENT OF THE CRANE OR TRACKED MACHINE. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

Section 2, Page 8 01/2001, CATTRON - THEIMEGTM Radio Control Operator’s Duties – E.O.T. Crane, continued. WARNINGS: MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE, BEFORE INSERTING AN ‘i-Key’ INTO A PS CONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-Key’ IS SELECTED FOR THE DESIRED EQUIPMENT TO BE OPERATED. IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNING: CATTRON-THEIMEG™ PSEZ AND PSCS PORTABLE REMOTE CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors, fire suppression etc.). CONTACT CATTRON-THEIMEG™ FACTORY FOR INFORMATION REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS. SHOULD CATTRON-THEIMEG™ PSCS AND PSEZ PORTABLE REMOTE CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY RESULT. IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM.

01/2001, CATTRON - THEIMEGTM Section 2, Page 9 Radio Control Operator’s Duties – E.O.T. Crane, continued. WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN PERSONAL INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. The following procedures provide general guidelines for radio control operation of an Electrical Overhead Traveling (EOT) crane and should not be used as a substitute for your plant operating procedures. 1. Before lifting any loads, carry out the following: a. Install the correct coded ‘i-Key’ for the desired equipment to be operated. If the wrong coded ‘i-Key’ is installed to the PS controller, the target equipment will not operate. b. Set (unlatch and pull out) PS controller red STOP switch to ‘RUN’ and turn Power ON/OFF switch to ‘ON’. When transmitting with a good battery, two short ‘beeps’ will be heard immediately after the ON/OFF power switch is set to ‘ON’ and the green TRANSMIT LED will ‘flash’ rhythmically. When the battery starts to go low, the yellow LOW BATTERY LED will ‘flash’ continuously, which means you should change or re-charge the battery pack (refer to Battery Pack in Section 4 of this manual for instructions on how to replace a battery pack). c. When installed, activate the ALARM/RESET switch on the PS controller (this is normally an optional function that sounds the equipment alarm and resets the main power contactor). d. Where a limit switch is provided, you should check the limit switch at the beginning of each shift as defined by your plant operating procedures. e. Check each function independently to be sure that equipment is responding correctly. f. Check range limiting if used. g. Check STOP operation. h. Check Brake operation 2. You must report all defective or missing safety equipment, mechanical or electrical defects to your supervisor without delay. Do not continue operation until fully repaired. 3. When raising or lowering a load, proceed slowly and make certain the load is under control.

Section 2, Page 10 01/2001, CATTRON - THEIMEGTM Radio Control Operator’s Duties – E.O.T. Crane, continued. 4. When lifting maximum load, you should test the brakes by raising the load a few inches from the floor. If the brakes will not hold, the load shall be immediately lowered and not moved until brakes are adjusted or repaired. 5. Center the Trolley directly over the load before starting to hoist. 6. Take slack out of chains or slings gradually and make sure hands and other objects are clear before making the lift. 7. Keep all parts of the body away from the lifts. Also, do not stand under a lift. 8. Do not make a lift or move the equipment if anyone is in a position to be injured. 9. Load should not be carried over workmen's heads. 10. If anyone is in the path of travel, stop and sound the alarm before proceeding. 11. Do not drag slings, chains, etc. along the floor. 12. Persons operating this equipment shall not use a limit stop as a utility stopping device. 13. Bumping other cranes or run-away stops is prohibited. 14. When moving the equipment to the loading point, be sure that hook block, attachment, or cables will not fall on the adjacent equipment. 15. When leaving the crane area for any reason, be sure slings or chains are raised and push down the PS controller red STOP switch to ‘STOP’. Turn the power ON/OFF switch to ‘OFF’. Remove the ‘i-Key’ from the PS controller and keep it on your person. 16. Do not allow any unauthorized person to operate the PS controller. 17. Do not operate the PS controller from a location where the crane and all surrounding objects are not visible. 18. Do not attempt to override any of the safety features built into the Radio Control System. 19. If for any reason you or anyone has to board a radio-controlled crane, push down the PS controller red STOP switch to ‘STOP’ and turn the power ON/OFF switch to ‘OFF’. Remove the ‘i-Key’ from the PS controller and keep it on your person. END OF SECTION

01/2001, CATTRON - THEIMEGTM Section 3, Page 1 Section 3 – Operating Instructions ‘i-Key’ configuration for continuous (FCC Part 90) and non-continuous (FCC Part 15) transmit applications. PSAT Pendant Controllers have been approved to comply with both United States FCC Part 15 (non-continuous transmission) and FCC Part 90 (continuous transmission) applications, and for Canadian DOC RSS-210 (non-continuous transmission) and RSS-119 (continuous transmission) applications standards. Only when the operator installs the ‘i-Key’ is the identifier defined for a particular FCC/DOC application. Referring to Figure 3-1 below, continuous transmission (TX) configured ‘i-Keys’ will be identified with an ‘*’ located next to the revision number on its label. Non-continuous TX configured ‘i-Keys’ have only the revision number with no ‘*’. Note that the controller-housing label has both types of identifiers for each of the FCC and DOC applications standards; however, only the identifier that matches the ‘i-Key’ label will apply. Figure 3-1. ‘i-Key’ and Controller Housing Label identifiers. NOTE: Regulations state that an authorized station-operating license is required for US FCC PART 90 or Canadian DOC RSS-119 Continuous Transmissions Applications. If you need assistance in obtaining this license, please contact your CATTRON-THEIMEG™ inside Sales Department in the first instance. AT Serial No. 1.10 FCC ID: CN2PS, * CN290PS CANADA: 10071031992, * 1007195678 Housing Label Non-continuous TX ‘i-Key’ Label Continuous TX ‘i-Key’ Label * identifier applies only to units with continuous transmit application. AT Serial No. * 1.10

Section 3, Page 2 01/2001, CATTRON - THEIMEGTM Typical Controls and Indicators. Referring to Figure 3-2 below, your PS Controller may have some or all of the following Controls and Indicators: Figure 3-2. Operator controls and indicators STOP xxxx=left/rightzz=up/downzzyyy=forward/backwardyColor Coded ‘i-Key’‘ON/OFF’ SwitchGreen‘TRANSMIT’ LEDRed ‘STOP’ SwitchYellow ‘LOW BATTERY’ LED‘ALARM/RESET’ PushbuttonStepless Pushbutton3-step PushbuttonMaintained Toggle Switch

01/2001, CATTRON - THEIMEGTM Section 3, Page 3 Controls and Indicators, continued. The standard PS Controller is a lightweight unit with six large pushbuttons (function keys), plus a rotary power ON/OFF switch and a latched push/pull STOP switch. The color coded ‘i-Key’ sets the operating parameters for your control system and has been pre-configured at our factory. Your PS series controller has been engineered to duplicate some or all of the control functions normally found on the equipment being controlled. The controller may be hand carried or supported using an optional shoulder carry strap. PS series controllers are powered by disposable (Alkaline), or rechargeable (Ni-Cad), battery packs. With the correct color coded ‘i-Key’ inserted into the PS controller, setting the STOP and ON/OFF switches to their respective ‘RUN’ and ‘ON’ positions will apply power to the transmitter. When transmitting with a good battery, two short ‘beeps’ will be heard immediately after the ON/OFF power switch is set to ‘ON’ and the green TRANSMIT LED will ‘flash’ rhythmically. In addition, any time a pushbutton (function key) is pressed, the green TRANSMIT LED will ‘flash’ during each radio transmission. When the battery energy starts to go low, the yellow LOW BATTERY LED will ‘flash’ continuously, signaling the operator to change or re-charge the battery pack (refer to Battery Pack in Section 4 of this manual for instructions on how to replace a battery pack). When the ON/OFF switch is set to the ‘OFF’ position, power is removed from the controller causing all control functions to cease with the exception of OPR, which remains energized. Setting (pushing down) the red STOP switch to ‘STOP’ before setting the ON/OFF switch to ‘OFF’ immediately sends a burst of stop commands to the receiver/decoder unit. Immediately after the stop commands have been sent, the transmitter within the Pendant controller switches OFF. STOP commands will automatically be repeated for one minute or until the ON/OFF switch is set to the ‘OFF’ position, removing power from the controller. Referring to Figure 3-2, each large pushbutton is engraved with its control function symbol. When a pushbutton is depressed, the controller transmits the corresponding motion command. The controller stops sending commands five seconds after the last pushbutton is released. A ‘beep’ will be heard each time a button is pressed or released. On PSCS and PSEZ controllers, all large pushbuttons are of the three-step type. Each pushbutton step is momentary and must be maintained by the operator. For example, pressing the pushbutton will set the controlled machine in motion. The rate of motion may be increased by further pressure to the second or third speed step, as required. All machine motion will continue for as long as the pushbutton is held. Releasing the pushbutton at the third or second speed step causes the rate of motion to slow down. Completely releasing the pushbutton will send an ‘OFF’ command that de-energizes the drive motor, stopping all motion. On PSAT controllers, the large pushbuttons may be three-step, proportional, or a combination of both, dependant on the control application. Proportional pushbuttons are step-less and the speed of machine motion is totally dependent upon the travel distance of the pushbutton, much the same as an accelerator pedal on an automobile. Completely releasing the pushbutton will send an ‘OFF’ command that de-energizes the drive motor, stopping further motion.

Section 3, Page 4 01/2001, CATTRON - THEIMEGTM Battery Charging Options. NOTE: It is not recommended to re-charge the battery until the controller’s yellow ‘LOW BATTERY’ LED flashes continuously. Four CATTRON-THEIMEG™ battery chargers are offered for use with Ni-Cad battery packs only. Using these ‘smart’ battery chargers, no damage will occur to a Ni-Cad battery pack left on charge for longer than its recommended charging period. These battery pack charger options are: • A CATTRON-THEIMEG™ ‘Standard’ rate charger that enables a Ni-Cad battery pack to be charged within a period of 10 hours (Part # 70C-0001) from a 110-120 VAC mains supply. Standard rate chargers include a yellow LED to indicate charge mode. • A CATTRON-THEIMEG™ ‘Rapid’ rate charger that enables a Ni-Cad battery pack to be charged within one hour (Part # 70C-0002) from a 110-120 VAC mains supply. Rapid rate chargers include a red (battery/polarity fault) LED, a green (power ‘ON’) LED, and a yellow (fast charge) LED. This charger uses automatic end of charge detection circuitry to accurately sense when the battery is fully charged. When this condition has been detected, the charger switches to a ‘trickle’ mode that keeps the battery fully charged and ready to use. • A CATTRON-THEIMEG™ ‘Trickle’ rate charger that enables a Ni-Cad battery pack to be charged within a period of 10 hours (Part # 70C-0001-220UK) from a 220-240 VAC mains supply. This charger includes a charge indicator LED. • A CATTRON-THEIMEG™ ‘Rapid’ rate charger that enables a Ni-Cad battery pack to be charged within one hour (Part # 70C-0002-220UK) from a 220-240 VAC mains supply. This charger includes a charge indicator LED. In addition, using all of the CATTRON-THEIMEG™ battery chargers referred to above: • Ni-cad Battery packs can be charged within the controller (see Figure 3-3, below). • Ni-cad battery packs may be charged externally (see Figure 3-4, below) provided an additional CATTRON-THEIMEG™ External Battery Charging Unit is purchased (Part # 70C-0003). This unit is connected to the appropriate CATTRON-THEIMEG™ battery charger. CAUTION: CATTRON-THEIMEG™ Battery Chargers and External Charging Units are designed for use with CATTRON-THEIMEG™ Ni-Cad Battery Packs only. Failure to comply with this Caution may result in equipment and/or battery damage and will void our warranty.

01/2001, CATTRON - THEIMEGTM Section 3, Page 5 Battery Charging Options, continued. Internal Charging. To re-charge the Ni-Cad Battery Pack within the controller, connect the CATTRON-THEIMEG™ battery charger to the mains power supply. Referring to Figure 3-3 below, position the Pendant Controller face upwards, open out the hinged cover protecting the battery-charging socket and insert the charging jack. When the Ni-Cad battery pack is charging, the appropriate charge indicator on the connected battery charger will illuminate. Figure 3-3. Internal Ni-Cad Battery Pack Charging ‘A’‘A’Charging JackChargingSocketSocketCoverView on ( )rotated 180 External Charging. To charge a Ni-Cad Battery Pack, refer to Figure 3-4 below and connect the CATTRON-THEIMEG™ battery charger to the mains power supply. Install the charger jack plug to the external battery charging unit socket as shown. Simply drop the battery pack into the charging unit, ensuring the battery pack contacts are positioned as shown. When the Ni-Cad battery pack is properly installed, the appropriate charge indicator on the connected battery charger will illuminate. Figure 3-4. External Ni-Cad Battery Pack Charging CHARGING JACKFROM BATTERY CHARGERNI-CAD BATTERY PACK ONLYPART # 60C-0060N

Section 3, Page 6 01/2001, CATTRON - THEIMEGTM Alkaline Battery Adapter. CAUTION: CATTRON-THEIMEG™ Battery Adapters are designed for use with non re-chargeable ‘AAA’ size Alkaline Batteries only. Carbon/Zinc, Lithium, or Ni-Cad Batteries are not to be used with this adapter. Damage to batteries will occur if this adapter is used for battery charging. Referring to Figure 3-5 below, a CATTRON-THEIMEG™ Battery Adapter is available which will accept two ‘AAA’ size Alkaline 1.5-volt batteries only. It should be noted that when using ‘AAA’ size Alkaline 1.5 volt batteries with this adapter, battery life would only be 40% of that provided by a CATTRON-THEIMEG™ Alkaline Battery Pack. Figure 3-5. ‘AAA’ Alkaline Battery Adapter. USE ‘AAA’ ALKALINE BATTERIES ONLYBATTERY ADAPTER, 3 VOLT(QUANTITY 2 x ‘AAA’ SIZE)

01/2001, CATTRON - THEIMEGTM Section 3, Page 7 Operating Procedure – PS Controller. Three-step function pushbuttons are clearly marked with triple arrows on the face of the pushbutton and have been pre-assigned through ‘i-Key’ programming for three-step operation. In other words, second and third outputs are tied to the second and third levels of button depression. Proportional (stepless) function pushbuttons are clearly marked with a single arrow. WARNINGS: ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNING: DUE TO FCC PART 15 AND DOC RSS-210 RADIO TRANSMIT REGULATIONS, THE OPR OUTPUT TO WHICH YOUR CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET TO ‘OFF’, OR FOR TEN MINUTES AFTER THE LAST TIME A PUSHBUTTON IS DEPRESSED. CONSEQUENTLY, SPECIAL CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS EQUIPPED WITH A PARKING BRAKE THAT IS CONFIGURED TO ENGAGE WHEN THE MAINLINE CONTACTOR DE-ENERGIZES. TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU SHOULD IMMEDIATELY PRESS THE RED ‘STOP’ BUTTON ON YOUR REMOTE CONTROLLER AFTER COMPLETION OF CRANE OPERATIONS. SUCH ACTION WILL INSURE THE PARKING BRAKE (IF EQUIPPED AND CONFIGURED AS ABOVE) IS SET, PREVENTING UNINTENTIONAL MOVEMENT OF THE CRANE OR TRACKED MACHINE. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

Section 3, Page 8 01/2001, CATTRON - THEIMEGTM Operating Procedure – PS Controller, continued. WARNINGS: MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE, BEFORE INSERTING AN ‘i-Key’ INTO A PENDANT CONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-Key’ IS SELECTED FOR THE DESIRED EQUIPMENT TO BE OPERATED. IF THE WRONG ‘i-Key’ IS INSERTED INTO A PSAT SERIES CONTROLLER, OR IF THE WRONG ADDRESS AND FREQUENCY IS PROGRAMMED INTO A PSEZ OR PSCS SERIES CONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNING: CATTRON-THEIMEG™ PSEZ AND PSCS PORTABLE REMOTE CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors, fire suppression etc.). CONTACT CATTRON-THEIMEG™ FACTORY FOR INFORMATION REGARDING PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS. SHOULD CATTRON-THEIMEG™ PSCS AND PSEZ PORTABLE REMOTE CONTROL SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY RESULT. IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM.

01/2001, CATTRON - THEIMEGTM Section 3, Page 9 Operating Procedure – PS Controller, continued. WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN PERSONAL INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. CAUTION: All control functions will be stopped if the PS Controller is used or left standing in an upright position during heavy rain, or in hostile environments where water could fill the top of the controller and cover the ‘i-Key’. To resume control functions, simply invert and shake the controller to remove excess water. There is no need to remove the ‘i-Key’. Ideally, to prevent such occurences in wet weather and water spray environments, the controller should (1) never be left standing upright, (2) be carried by the shoulder strap, and (3) operated in a near horizontal position. 1. Insert correct color-coded ‘i-Key’. This coded electronic key sets the unique operating parameters for a given control system. In the PSAT family of controllers, these parameters include, address code, operating frequency and function key (pushbutton) configurations, whereas in the PSEZ and PSCS families of controllers the ‘i-key’ only defines and enables the pushbutton operating functions for a specific PRC system. The ‘i-key’ is simply installed by pressing into its receptacle and may be further secured to the controller using the metal stud located behind the rubber bumper. Note that a Pendant Station Controller will not operate without an ‘i-Key’ installed. 2. Set red STOP Switch to ‘RUN’. Pulling this switch upward enables power to be applied to the PS controller. If the switch has been pushed down to the ‘STOP’ position, you will first have to unlatch the switch knob by rotating in a clockwise direction. 3. Set Power ON/OFF Switch to ‘ON’. Rotating this switch clockwise applies power to the PS controller. Two quick ‘beeps’ with the green TRANSMIT LED flashing rhythmically indicates the controller is ready for use and a power up message has been sent to the target receiver/decoder. The targeted receiver/decoder will respond by energizing the mainline contactor of your controlled equipment.

Section 3, Page 10 01/2001, CATTRON - THEIMEGTM Operating Procedure – PS Controller, continued. 4. Press any large pushbutton. The PS Controller is now fully operational and transmitting a signal as indicated by the green TRANSMIT LED flashing. Operate the pushbuttons and switches as required, remembering that each large pushbutton must be maintained in order for the function to continue to operate. Any or all functions may be operated simultaneously if the controlled machine permits such operation. NOTES: (1) A system STOP may be initiated at any time during the control function by pushing the red STOP switch downwards. (2) When all control functions have been completed, we recommend you initiate a system STOP (push red STOP switch down) before setting the ON/OFF switch to the ‘OFF’ position. This will prevent the Mainline contactor from remaining energized for up to 10 minutes via control of OPR. END OF SECTION

01/2001, CATTRON - THEIMEGTM Section 4, Page 1 Section 4 – Maintenance Instructions CATTRON-THEIMEG™ Maintenance Philosophy. CAUTION: All PS Controller internal circuit boards are sensitive to electrostatic discharge. Consequently, all maintenance procedures involving disassembly and assembly of controllers shall be carried out by qualified technicians using anti-static mats and personal grounding straps. Failure to comply with this caution may result in equipment damage and void our warranty. Our general maintenance philosophy is that inoperative PS Controllers are normally returned as complete units to our workshops for repair. This is because (a) the internal circuit boards are extremely sensitive to electrostatic discharge and (b) internal components are highly miniaturized and assembled to within very close tolerances. Consequently, internal components may be irreparably damaged when replaced by unqualified maintenance personnel. However, CATTRON-THEIMEG™ will permit replacement for the sub-assemblies and components identified below, provided (1) replacements are carried out by suitably qualified technicians, (2) all recommendations to eliminate electrostatic discharge are implemented and (3) all defective items are returned to our workshops for repair. In the CATTRON-THEIMEG™ Series of PS Controllers, five items may be easily and quickly replaced – refer to the Illustrated Parts Breakdown in Section 6. These are: 1. Battery Pack (Ni-Cad = Part # 60C-0060N. Alkaline = Part # 60C-0060A). 2. Top End Cap sub-assembly (Part # CPA-0360), containing the ‘i-Key’ receptacle, power ON/OFF switch, red system STOP switch, internal antenna module, all surrounded by an armorized rubber bumper. 3. Bottom End Cap sub-assembly (Part # CPA-0359), containing the battery door assembly, battery-charging socket and surrounded by an armorized rubber bumper. 4. Upper Main Body Housing (Part # 15C-0138R). 5. Rubber Side Grips (Part # 15C-0126P).

Section 4, Page 2 01/2001, CATTRON - THEIMEGTM Maintenance Procedures. Preventive Maintenance is a periodic check of the system to keep it functioning at peak performance. Preventive maintenance can also help prevent breakdowns and equipment outages by identifying potential problems before they become real problems. Corrective Maintenance refers to fixing a problem once it has occurred. The goal of corrective maintenance is to get the system back on line as quickly as possible with a minimum impact on operations. Preventive maintenance – PS Controllers. Preventive maintenance for PS controllers is minimal because they are extremely durable and reliable units. Preventive maintenance procedures are detailed in the following sub paragraphs: Daily Visual Inspection. Before use, visually inspect the controller for cleanliness, physical damage, and security of external parts (screws, switches, rubber grips, etc.). CATTRON-THEIMEG™ emphasizes that regular visual inspections not only mean quickly locating a source of potential problems, but also may prevent serious problems from developing later. Annual Netting Check. Netting means that the receiver and transmitter of the radio control system are aligned on the same frequency. It is very important that the receiver is exactly tuned to the frequency required. This check should be done once a year by a qualified radio technician utilizing calibrated test equipment. Troubleshooting – PS Controllers. A basic Troubleshooting Guide is provided on page 4 of this section. When troubleshooting the controller, the other major components of the remote control system (power supply and receiver/decoder) should be fully operational. The operator should also be located within 500 feet (160+ meters) of the target receiver/decoder. Corrective maintenance – PS Controllers. Corrective maintenance for PS Controllers is restricted to replacing the Battery Pack, Rubber Side Grips, Top End Cap sub-assembly, Bottom End Cap sub-assembly and Upper Main Body Housing. Refer to the Disassembly/Assembly procedures below when removing and replacing items. On completion of any assembly procedure and before placing the PS Controller into operational service, carry out a Functional Check as follows:

01/2001, CATTRON - THEIMEGTM Section 4, Page 3 Maintenance Procedures, continued. Functional Check. A functional check is accomplished by operating the PS Controller in accordance with the Operating Procedures in Section 3 of this manual. Insure all system control functions are fully operational. Replacement Items – Pendant Controllers. Replacement items may be ordered direct from CATTRON-THEIMEG™. To order replacement items, refer to Section 6 of this manual for part numbers and quantities required. In addition: 1. If ordering replacement parts for PSAT controllers, provide the following information: (1) the model type and revision number located on the serial tag underneath the controller, and (2) the control system ID and serial number located on the ‘i-Key’ label tag. 2. If ordering replacement parts for PSEZ or PSCS controllers, provide the model type and revision number located on the serial tag underneath the controller.

Section 4, Page 4 01/2001, CATTRON - THEIMEGTM

01/2001, CATTRON - THEIMEGTM Section 4, Page 5 Pendant Controllers – Disassembly and Assembly. Observe these guidelines when carrying out the following procedures: • When requesting spare parts from CATTRON-THEIMEG™, provide the model type of the controller (refer to the serial tag located on the underside if the controller). • Tag defective items with a description of the fault and return the item to CATTRON-THEIMEG™ for repairs. • Tag all leads before de-soldering or removal. Use small wire tags or pieces of adhesive tape with handwritten numbers. Reconnect all wires to the same location from which they were removed, observing proper polarity. • Visually inspect all disassembled items for damage. Replace damaged or defective items with identical items. CAUTION: All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving disassembly and assembly of PS Controllers. Failure to comply with this caution may result in equipment damage and will void our warranty. PS Controllers contain electrostatic sensitive devices that may be damaged (immediately or latently) by electrostatic charges of less than 1,000 volts. Since electrostatic charges of up to 35,000 volts may be present at the workbench, it is imperative that you take the following precautions before disassembly and assembly of the controller. • Ground the working surfaces of the workbench. This may be accomplished with an anti-static kit containing a wrist strap, two ground cords, anti-static floor-mats, and anti-static tablemats. • Remove nylon or double-knit polyester jackets, roll up long sleeves, and remove or tie back hanging neckties. • Eliminate static-generating material (plastics, styrofoams, synthetic materials, etc.) from the workbench area.

Section 4, Page 6 01/2001, CATTRON - THEIMEGTM Battery Pack (Figure 4-1). Remove the battery pack as follows: a. Lay Controller (1) face up. b. Release two knurled thumbscrews (2) and withdraw cover-plate (3). c. Withdraw battery pack (4) from battery compartment (5). Figure 4-1. Battery Pack, removal and replacement Replace the battery pack as follows: a. Position battery pack (4) with the four contact strips uppermost and facing forwards. Install battery pack (4) by pushing fully home inside the battery compartment (5). b. Install cover-plate (3) and secure by evenly hand tightening two knurled thumbscrews (2). Do not overtighten - a snug fit is all that is necessary. NOTE: If a new re-chargeable Ni-Cad Battery Pack has been installed to the Pendant Controller, it will require charging in accordance with the procedure in Section 3, Page 3 of this Manual. 2. Knurled Thumbscrew (2)3. Cover Plate4. Battery Pack5. Battery Compartment1. Pendant Controller12345

01/2001, CATTRON - THEIMEGTM Section 4, Page 7 Bottom End Cap subassembly (Figure 4-2). CAUTION: All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving disassembly and assembly of PS controllers. Failure to comply with this caution may result in equipment damage and will void our warranty. Remove the subassembly as follows: a. Lay controller (1) face down on Anti-Static Mat and remove Battery Pack. Refer to Removal of Battery Pack, above. b. Remove five screws (2) using Phillips screwdriver. c. Carefully withdraw endcap sub-assembly (3) to expose charging socket wiring harness (4). Using long nosed pliers, carefully disconnect 2-pin connector (5) from its socket located on the underside of the encoder board. Figure 4-2. Bottom Endcap Sub-assembly, removal and replacement Replace the subassembly as follows: a. Observing correct orientation as illustrated in the cutout above, connect 2-pin connector (5) to its socket located on the underside of the encoder board. b. Carefully align endcap subassembly (3) to controller housing (1), taking care not to pinch charging socket wiring harness (4). c. Secure endcap sub-assembly (3) using five screws (2). d. Replace the Battery Pack. Refer to Replacement of Battery Pack, above. 54213

Section 4, Page 8 01/2001, CATTRON - THEIMEGTM Top End Cap subassembly (Figures 4-3 and 4-3A). CAUTION: All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving disassembly and assembly of PS controllers. Failure to comply with this caution may result in equipment damage and will void our warranty. Remove the subassembly as follows: a. Lay Controller (1) face down on Anti-Static Mat and remove Battery Pack. Refer to Removal of Battery Pack, above. b. Remove five screws (2) using Phillips screwdriver. c. Carefully withdraw endcap sub-assembly (3) to expose switch and antenna wiring harnesses (4 and 5). Disconnect 2 and 6-pin connectors (6 and 7) from their respective Transmitter and Encoder Board sockets (see figure 4-3A below). Figure 4-3. Top Endcap Sub-assembly, removal and replacement 71. 1. Pendant Controller Housing (part)2. Screw , Phillips, 4-40 x ½ in. (5)3. Top Endcap Sub-Assembly4. A ntenna W iring H arness5. Sw itch W iring H arness6. 2-Pin C onnector7. 6-Pin C onnector23465

01/2001, CATTRON - THEIMEGTM Section 4, Page 9 Top End Cap subassembly (Figures 4-3 and 4-3A), continued. Replace the subassembly as follows (refer to Figure 4-3 above, unless stated otherwise): Figure 4-3A. 2-pin and 6-pin connector orientation NOTE: Orientation of the 2-pin and 6-pin connectors is critical in the following step. If the 2-pin connector is reversed, the transmitter range will be significantly reduced. a. Connect 2 and 6-pin connectors (6 and 7) to their respective Transmitter and Encoder Board sockets, observing orientation of connectors as shown in Figure 4-3A above. b. Carefully align endcap sub-assembly (3) to controller (1) housing, taking care not to pinch wiring harnesses (4 and 5). c. Secure endcap sub-assembly (3) using five screws (2). d. Replace Battery Pack. Refer to Replacement of Battery Pack, above.

Section 4, Page 10 01/2001, CATTRON - THEIMEGTM Upper and Lower Main Body Housings (Figure 4-4, opposite). CAUTION: All circuit boards are sensitive to electrostatic discharge. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving disassembly and assembly of PS controllers. Failure to comply with this caution may result in equipment damage and will void our warranty. Separate and remove the housings as follows: a. Lay Controller face down on Anti-Static Mat and remove Battery Pack, Bottom Endcap sub-assembly, and Top Endcap subassembly. Refer to Removal of Battery Pack, Bottom Endcap sub-assembly, and Top Endcap subassembly, above. b. Remove two rubber side grips (1) by sliding or pulling away from upper and lower main body housings (2 and 3). c. Completely separate upper and lower main body housings (2 and 3) by sliding them apart. Replace the housings as follows: a. Apply a thin film of lubricant (Dow Corning MOLYKOTE 557 or equivalent) to upper and lower main body housing (2 and 3) joints. Slide or snap the two housings together. b. Install two rubber side grips (1) along their grooved upper and lower main body housing (2 and 3) locations. To facilitate installation, a light application of window cleaning spray or liquid (Windex or equivalent) may be applied to lubricate the inside channels of each rubber grip. c. Install Top Endcap subassembly, Bottom Endcap sub-assembly and Battery Pack. Refer to Replacement of Top Endcap sub-assembly, Bottom Endcap sub-assembly and Battery Pack, above.

01/2001, CATTRON - THEIMEGTM Section 4, Page 11 Upper and Lower Main Body Housings (Figure 4-4), continued. Figure 4-4. Upper and Lower Main Body Housings, removal and replacement Rubber Side Grips. Procedures for replacing the Rubber Side Grips are described above. Note that it will be necessary to remove the bottom endcap sub-assembly before replacing the rubber side grips. END OF SECTION 1.RubberSideGrip(2)2.UpperMainBodyHousing3.LowerMainBodyHousing321

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01/2001, CATTRON - THEIMEGTM Section 5, Page 1 Section 5 – PSEZ & CS Series Controllers Introduction – PSEZ & CS Controllers. In the PSAT controller family previously described in this manual, the ‘i-Key’ supplied with the controller is pre-programmed with the system operating address, operating frequency and controller pushbutton/function switch layout for a given control system. Note that PSAT pushbuttons may be either of the 3-step type, the proportional (stepless) type, or a combination of both, dependent upon system requirements. In the PSEZ and CS controller families, the ‘i-Key’ is only pre-programmed with the controller pushbutton/function switch layout for a given control system. Note that PSEZ and CS pushbuttons are of the 3-step variety only. In addition: 1. When your PSEZ or CS Controller is supplied as part of a complete CATTRON-THEIMEG™ control system package (controller, receiver/decoder and appropriate hardware), the system operating address and operating frequency is pre-programmed into the controller at our factory and advised to yourselves. Such programming has been carried out using the top four large pushbuttons. 2. When your PSEZ or CS Controller is supplied as a stand-alone item to complement your existing CATTRON-THEIMEG™ EZ or CS Control System, or has been returned after repairs, address and operating frequency has not been pre-programmed into the controller at our factory. Given the circumstances described in 1 and 2, above, you will be required to verify/program the system address and operating frequency before using your PSEZ or CS controller for the first time. Installing Different PSCS (blue) & EZ (green) ‘i-Keys’. As an additional safeguard, your PSCS and EZ controller’s internal programming software has been designed to prevent accidental operation of your remote controlled equipment immediately a different (wrong control system) ‘i-Key’ is inserted into the controller. All PSCS and EZ ‘i-Keys’ are electronically coded with an individual serial number. This unique ‘i-Key’ serial number is automatically registered with the host controller’s programming software when the target remote control system operating address and frequency are programmed using the controller keypad. Consequently, inserting any ‘i-Key’ into your controller except the ‘i-Key’ installed when the operating address and frequency was last programmed (the original ‘i-Key’) will prevent any further remote control operations. When a different (or defective) ‘i-Key’ is installed, the controller will indicate a fault condition by emitting four long ‘beeps’ immediately after you apply power to the remote controller.

Section 5, Page 2 01/2001, CATTRON - THEIMEGTM Installing Different PSCS (blue) & EZ (green) ‘i-Keys’, continued. If you wish to continue remote control operations, it will be necessary to choose one of the following options: 1. Install the original ‘i-Key’ into the controller, or, 2. Re-program the address code and frequency of the controller with a different ‘i-Key’ installed – refer to page 5 of this Section onwards for programming procedures. This unique ‘i-Key’ serial number will then be registered with the host controller’s programming software immediately upon entering one of the controller’s keypad programming menu options. NOTE. If option 2 above has been selected, inserting the original ‘i-Key’ (referred to in option 1 above) or any other ‘i-Key’ into the controller will prevent any further remote control operations. PSEZ & CS Control Systems - frequency and address assignment. WARNING: FAILURE TO PROPERLY SELECT FREQUENCY AND ADDRESS MAY RESULT IN THE UNINTENTIONAL OPERATION OF OTHER MACHINERY AND COULD RESULT IN DEATH OR SERIOUS INJURY TO PERSONNEL. DO NOT DUPLICATE ADDRESS ASSIGNMENT. To enable a CATTRON-THEIMEG™ PSEZ & PSCS controller and receiver/decoder to communicate, they must use the same RF frequency and digital address. PSEZ PRC system controllers and receiver/decoders are capable of operating on up to 79 different frequencies and 126 addresses. PSCS PRC system controllers and receiver/decoders are capable of operating on up to 127 different frequencies and 65,000 addresses for maximum versatility.

$01/2001, CATTRON - THEIMEGTM Section 5, Page 3 PSEZ & CS Control Systems - frequency and address assignment, continued. NOTE: CS PRC system receiver/decoder board address codes are permanently assigned at the factory for the life of the equipment. They may not be changed by yourself. However, you may be required to change the frequency and address code of the PS Series controller. This may be necessary when: (1) The factory preset address code assigned to the system receiver/decoder is different to that set in the PS controller, (2) installing more than one control system at a single location, (3) replacing a receiver/decoder board, (4) other radio remote control systems emit RF signals that interfere with normal or safe operation, and (5) inserting any ‘i-Key’ into a controller except the one installed when the address and frequency was last programmed. Before making any change to PS controller frequency and address settings, check the factory settings on the target receiver/decoder to determine what changes are necessary for the controller. A CATTRON-THEIMEG™ PSEZ controller sends a two-digit address code with every transmission. A CATTRON-THEIMEG™ PSCS controller sends a four-digit address code with every transmission. For the system to operate, the same address code must be set in the receiver/decoder. When a transmission is received by the target control system receiver/decoder, the address of the PS controller sending the signal is checked against the address of the receiver/decoder. If these addresses do not match, the signal is ignored and an error message is displayed on the receiver/decoder status display. For safety reasons, it is recommended that each plant maintain a central record of frequency and address assignments so that no two PS controllers at any single location use the same address or frequency settings. Ignoring this recommendation could cause unintentional operation of other machinery resulting in damage to equipment and/or personal injury or death. PSEZ & CS Controllers - address/frequency verification. NOTES: (1) The PSEZ controller has two programmable address code digits which are selected using Pushbuttons #3 (High digit) and #4 (Low digit) on the keypad. (2) The PSCS controller has four programmable address code digits which are selected using Pushbuttons #1 (High digit) thru #4 (Low digit) on the keypad. Verify the desired address (address consists of two or four digits, all of which must be programmed) and the frequency of the receiver/decoder unit that is intended to be operated. The original factory settings can be found on the label affixed to the side of the receiver/decoder housing, or on the front inside cover of the manual originally supplied with the PS Series system. EXAMPLE #1: Sample EZ System Label - Factory Settings: Frequency 448.9000MHz Address: F E / \ Digit #1 Digit #2 (‘High’ digit) (‘Low’ digit)$

$Section 5, Page 4 01/2001, CATTRON - THEIMEGTM PSEZ & CS Controllers - address/frequency verification, continued. EXAMPLE #2: Sample CS System Label - Factory Settings: Frequency 448.9000MHz Address: 3 B F E / | | \ Digit #1 | | Digit #4 (‘High’ digit) | | (‘Low’ digit) / \ Digit #2 Digit #3 To determine a PS controller’s current settings, skip ahead to the paragraph on page 13 of this section titled ‘Address, Frequency Bank, and Frequency report only’ for detailed instructions. Programming PSEZ &CS Controller address and frequency. WARNING: FAILURE TO PROPERLY SELECT FREQUENCY AND ADDRESS MAY RESULT IN THE UNINTENTIONAL OPERATION OF OTHER MACHINERY AND COULD RESULT IN DEATH OR SERIOUS INJURY TO PERSONNEL. DO NOT DUPLICATE ADDRESS ASSIGNMENT. NOTES: (1) The ‘i-Key’ must match the two letter designation of the model number, i.e. EZ, or CS. This is found on a label located on the underside of the controller, and also on a label located inside the battery compartment. (2) The controller will not operate your target control system without the correct address and operating frequency programmed. Referring to Figure 5-1 below and the keypad function menu on the next page, the top four large pushbuttons of the PSEZ and PSCS controller are used during the data entry mode. As required, proceed to verify/program PS Controller address and frequency using the following procedures:$