868 MHz Tanker Remote Control System

Transcription

1 868 MHz Tanker Remote Control System Installation & Operation Manual (0)

2 I DEX Installation procedures & directions for rigid tankers... 2 Component parts... 2 Installation instructions... 2 Electrical connections... 2 Control unit... 2 Antenna... 3 Receiver... 3 Warning horn... 3 Handheld transmitter (Ex rated)... 4 Pairing a transmitter and receiver for use... 4 To reset the receiver to factory defaults when replacing a transmitter... 4 SPNV (Safety Pneumatic Valve)... 5 DPNV (Delivery Pneumatic Valve)... 5 Operating instructions... 6 System description... 6 Function... 6 Start up procedure... 6 Stop procedure... 7 Emergency shutdown... 7 Trouble shooting... 8 This page is intentionally blank... 9 Drawings.. 10 Control unit mounting dimensions.. 10 Receiver mounting dimensions 11 DPNV & SPNV enclosure mounting dimensions...12 Receiver & control unit wiring diagram..13 DPNV & SPNV connections...14 Receiver parts identification 15 Transmitter

3 Installation procedures & directions for rigid tankers The RMS radio control system provides a stop start and deadman facility that complies with the requirements of the UK LPG codes of practice. It enables the operator to control the pumping system remotely. Component parts Control unit Antenna Receiver Warning horn Handheld transmitter Emergency shutoff solenoid valve (SPNV) Delivery start/stop solenoid valve (DPNV) Installation instructions Electrical connections Control Unit, Receiver, Warning Horn, SPNV and DPNV must be connected in accordance with the wiring diagram. Control Unit Receiver Warning horn DPNV SPNV Supply 24V DC (from handbrake warning light fused with a 5A fuse) Supply 12V DC (directly from Control Unit). Output 4 Control Unit (reset signal 30 sec). Output 1 Control Unit (24v) Output 2 Control Unit (24v) Control Unit outputs have a maximum allowable capacity of 0.5A. The electrical supply must be controlled by a relay, which is activated by the hand brake light contact in accordance with the wiring diagram. This ensures that the system is shut down when the vehicle is in motion. All wiring must be in accordance with the current UK regulations. Control unit The control unit must be fitted in the cab (usually beside the passenger seat) in such a manner that: The driver can reach the buttons. The cover can be removed when necessary. The cable glands can be easily reached to feed in the cable. All control unit outputs are protected by a fuse-element of 2,5A maximum. The lid of the control unit is fitted with two buttons (start/reset and stop). The control unit is not Ex approved. 2

4 Antenna The antenna must be fitted on the outside of the cab in as high a position as possible and requires a 12mm diameter mounting hole. The coaxial cable should be fitted with the BNC connector after being cut to the right length and routed to the receiver. It is essential that a proper crimping tool be used, as bad antenna connections are the main cause of poor transmitter range. Do not mount close to mobile phone or other antennae. Important The coaxial cable between the receiver and the antenna must be as short as possible. Receiver The receiver must be fitted in the cab in such a manner that it is situated as far as possible from any other radio devices (i.e. mobile phone, CB-radio) but as close as possible to the antenna. Ensure that the cover can be removed when necessary. The receiver is uniquely paired with a transmitter by means of an infrared link, ensuring complete isolation from the other tankers in the fleet. When using an external antenna the antenna select jumper must be removed and moved to the two pins on the left see drawing on page 15 for jumper location The lid of the receiver is fitted with eight LED s Icon Function 1 Receiving signal on channel 1 2 Receiving signal on channel 2 Not used Transmitter battery low TAUX Signal interference Not used Power Tamper The receiver is not Ex approved. Warning horn Fit the horn in a convenient position but protected from the direct ingress of rain. The maximum allowable horn capacity is 25 ma. The horn is not Ex approved 3

5 Handheld transmitter (Ex rated) Prior to use a new transmitter will require pairing with the receiver of the tanker it is to be used with. WAR I G There are no user serviceable parts inside the transmitter. If the battery becomes low or the unit stops functioning for any reason it should be returned to RMS for repair. Tampering with the transmitter will invalidate its warrantee and could cause an explosion if it is not repaired in a manner that maintains its EEXI rating. The transmitter is best carried in one of the breast pockets of the driver s uniform. It is conveniently fitted with a clip to prevent it falling out. The black top button is the reset/start button and the two orange side buttons must be pushed simultaneously to stop the delivery. To activate an emergency stop, the two orange buttons then the top reset/start button must be pushed immediately after each other. Pairing a transmitter and receiver for use Note: the receiver must be connected and powered on before pairing can commence. See the receiver parts identification drawing on page 15 for part locations 1. Remove receiver cover, the tamper warning LED will illuminate 2. Press SELECT once to enter programming mode the display shows Ln If the display shows another command press SELECT until Ln shows 3. Press SET the display shows C1 4. Press SET the display shows C1 then d- then S- as the receiver scans for the transmitter 5. Hold the transmitter s activity led within 25mm of the receiver s Infrared sensor and press the orange buttons on the transmitter. The receiver beeps twice 6. Press ESC/DEL to go back to the command menu 7. Press SELECT until the display shows GO 8. Press SET and the unit begins to beep 9. Replace the lid. After a few seconds the tamper LED will extinguish and the pairing is complete To reset the receiver to factory defaults when replacing a transmitter 1. Remove receiver cover, the tamper warning LED will illuminate 2. Press SELECT until the display shows dl 3. Press SET until the display shows C1 4. Press RESET the unit clears all previous settings then a new transmitter may be paired following instructions 2 8 above 4

6 SP V (Safety Pneumatic Valve) This valve operates the device that shuts down the engine in an emergency. On some vehicles electronic shutdown may be possible direct from the control unit, the voltage and polarity of the vehicle must be compatible as the control system is negative switching and may require a relay to provide the correct polarity for the vehicle. The SPNV needs to be incorporated into the vehicle air supply. The solenoid valves supplied with the system are not Ex approved. Pneumatic system hose diameter: 6 mm. Attach the pneumatic hose directly to the valve connectors. Port P Port A Port EA Port B Compressed air supply. Output to air actuator. Exhaust. Plugged. DP V (Delivery Pneumatic Valve) DPNV operates the air-actuated valve in the delivery transfer line. Pneumatic system hose diameter: 6 mm. Attach the pneumatic hose directly to the valve connectors. Port P Port A Port EA Port B Compressed air supply. Output to air actuator. Exhaust. Plugged 5

7 Operating instructions System description The system allows the remote control of the pumping operation when transferring gas. It has two main functions: Start & stop of the gas delivery Emergency/Automatic shutdown of the tanker The system consists of a hand held transmitter, a dual channel receiver and a control unit incorporating a microprocessor and relays. The relays control a warning horn and the operation of pneumatic solenoid valves connected to air actuators on the valves to be controlled. Function When started the system delivers for the run time specified by the chip type after which the warning horn sounds. While the horn is sounding the start button on the transmitter must be pressed to allow the system to continue with the delivery (types A & C). Failure to press the button within the time will cause automatic shutdown of the tanker. Type D chips allow the system to be reset and continue delivering at any time so the warning horn does not sound, this is recommended when delivering at night as it keeps noise to a minimum. The transmitter can also be used in an emergency to shut down at any time during the delivery Chip type Run time Horn time Comments A 2 minutes 30 seconds Best suited to rigid tankers. C 25 seconds 5 seconds Best suited to large tankers. D 2 minutes 30 seconds Night delivery Other features available include control of PTO and engine revs, signals to data logger s etc. details of which are available on request. Start up procedure Apply the hand brake of the vehicle, this will power-up the system and the green light on the receiver will illuminate. Press the start button on the transmitter or the green button on the control unit, this will prepare the system for use. Depending on the valve control configuration proceed as follows. Configuration 1 - Unit controls hose end valve Open bottom outlet valve Engage the PTO or start hydraulic drive. Pump is now running on bypass. With hose connected to tank and valve opened, press the top button. The actuated ball valve will open and gas will transfer. If the first press of the button does not allow gas to transfer, wait 10 seconds and repress the top button. 6

8 Configuration 2 - Unit controls bottom outlet valve Connect hose to tank and open customer tank valve. Press the top button to open the bottom outlet valve. If the first press of the button does not allow gas to transfer, wait 10 seconds and repress the top button. Engage the PTO or start hydraulic drive. Pump should now be pumping gas. When after 2 minutes (or 25 seconds) the beeper sounds, push the start button on the transmitter you must respond within 30seconds (or 5 seconds) or system will perform an emergency shutdown. After each reset, the beeper will sound again after 2 minutes (or 25 seconds). Each transmission by the transmitter whether start, stop or reset is indicated by a red LED in the top of the transmitter during transmission. Stop procedure Press both of the orange buttons on the transmitter at the same time. Disengage the PTO or hydraulic drive. If the system controls the main unloading valve this must be done immediately to prevent the pump cavitating and running dry. In addition to any other safety features fitted, releasing the handbrake to drive off shuts down the power supply to the system. Emergency shutdown In the case of an emergency such as a ruptured hose press the two orange buttons then the top reset/start button immediately after each other, this will close the delivery valves and shut down the engine. After an emergency stop the system must be reset before it will function again or the engine will start. 7

9 Trouble shooting Problem Possible cause Recommended action No power to the system Handbrake not applied. Apply handbrake. Transmitter light does not come on when buttons pressed Receiver lights do not come on when transmitter buttons pressed Receiver lights come on when transmitter buttons pressed but lights on control unit do not Reduced range. (Low battery light on the receiver on) Reduced range. (Low battery light on the receiver off) Blown fuse in the power supply from the handbrake Wiring incorrect Loose connection Control unit faulty Transmitter fault or battery flat Transmitter faulty Receiver faulty Control unit faulty Receiver faulty DPNV faulty Actuator faulty Transmitter battery flat Antenna missing or damaged Loose BNC connector within receiver Replace fuse, if fuse blows again there is another fault, do not replace fuse again until fault is rectified. Check wiring for faults. Check wiring for loose connections. Return control unit to RMS for repair. Return transmitter to RMS for repair/battery replacement. Try another transmitter. Return receiver to RMS for repair Reset the system by letting off and reapplying the handbrake. Try to start delivery using the buttons on the front of the control unit. Check DPNV has power & air supply. Check actuator. Return to RMS for battery replacement. Replace antenna. Retighten BNC connector. 8

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