schwing gen iii smart drum - mixer & plant parts mfg. mixer system gen iii (parts/operations...

Schwing Mixer System Gen III

(Parts/Operations Manual)

SMART DRUM

Version 1.0

Table of Contents

GEN III SYSTEM PARTS .........................................................................................................................1 REMOTE SYSTEM

BOM (Booster) .........................................................................................................................................1

(Conventional).................................................................................................................................3

Hardware and Controls ............................................................................................................................4

Harnesses and Sensors...........................................................................................................................5

Hydraulics ................................................................................................................................................6

Miscellaneous ..........................................................................................................................................7

TRANSFER PARTS (GEN II TO GEN III) ..............................................................................................7

Contact Information:

Mixer & Plant Parts PO Box 12219

Rock Hill, SC 29731 Bus: (803) 233-7913 Fax: (586) 601-1904 readymixparts.com

1

GEN III SMART SYSTEM-BOOSTER Description

Quantity

Units

Part Number

PUMP - HYD, CLOCKWISE HYDROSTATIC (EP) 1 EA

30386328PUMP - HYD, BOOSTER AXLE CLOCKWISE ROT 1 EA 30389205VALVE - HYD, BLOCK VBL-CLC-01 1 EA 10194869VALVE - HYD, BLOCK VBL-BCP-01-230 1 EA 10194886VALVE - HYDRAULIC PRESSURE CONTROL (Q2G0 1 EA 10200209ENCLOSURE - MIXER, CAB, GEN III 1 EA 30380835RADIO - TRANS, MIXER GEN III 1 EA 30380836ENCLOSURE - MIXER D160 GEN III 2 EA 30380837ENCLOSURE - MIXER GROUND MOD GEN III 1 EA 30380838OIL, MIXER WITH 160F TEMP. SWITCH AND RE 1 EA 30386360ANGLE - BRACKET, CABLE MOUNT, DRUM CONTR 1 EA 30356823PROTECTION - VEC, MIXER, GEN III 1 EA 30380822PLT - MOUNT OMNEX CONTROL 2 EA 30386545MOTOR - HYDRAULIC,MODEL 4633-135,W/ QUAD 1 EA 30386500ENCL - CABINET, 400 X 200 X 80 1 EA 30386883OPER - SENSOR, PROXIMITY W/6" CABLE 3 EA 30350926LED - INDICATOR LIGHT STRIP 1 EA 30386786HRNSS - MIXER, VEC, REMOTE GEN III 1 EA 30380810HARNESS - MIXER MAIN GEN III 1 EA 30380809HARNESS - ICC MIXER STAND, CPL 1 EA 30380811

WMT - MOUNT POST IN CB OMNEX 1 EA

30386547

BOOSTER LIGHTING TRUCK MIXER 1 EA

30389128PROTECTION - FUSE, 5A/32V, MINI 1 EA 30369488KIT - FLANGE 1" CODE 61 5151HK-16 2 EA 30307799FITTING - HYD, ELBOW 45 DEG 1" 61 FLANGE 1 EA 30389371FITTING - HYD, ELBOW 37 DEG MALE 3/4" 1 EA 30389166FITTING - HYD, ELB 90 DEG 1" FLANGE 61 1 EA 30389370FITTING - HYD, ELB 90 #16 SWIVEL X FLARE 1 EA 30389486FITTING - HYD, #16 ORB TO #16 FLARE 1 EA 30389365FITTING - HYD, ELBOW #16 ORB X #16 FLARE 1 EA 30389357FITTING - HYD, ELBOW #16 ORB X #16 FLARE 1 EA 30389357FITTING - HYD, ELBOW #16ORB X #12 FLARE 1 EA 30389358FITTING - HYD, MALE #8 SAE X #10 1 EA 30389213FITTING - HYD, ELBOW 37 DEG MALE 3/4" 2 EA 30389166

FITTING - HYD, MALE 3/8" X 1/2" 37 DEG 2 EA 30389170

FITTING - HYD, ELBOW #10 ORB X #8 FLARE 1 EA 30389390

FITTING - HYD, MALE #12 SAE 2 EA 30389210

FITTING - HYD, TEST PLUG SAE#4 1 EA 30335096

FITTING - HYD, UNION 3/4" SAE 2 EA 30389162

FITTING- HYD, 12 ORB TO #8 FLARE 2 EA 30389465

FITTING - HYD, ELBOW 37 DEG 3/8" 2 EA 30389160

FITTING - HYD, ELB 90 #6 SWIVEL X FLARE 1 EA 30389374

FITTING - HYD, #4 ORB TO #6 FLARE 1 EA 30389466

continued on next page……………..

2

Description Quantity Units Part Number

FITTING - HYD, ELB 37 DEG MALE 1/4" 1 EA 30389169

FITTING - HYD, MALE #8 SAE X #6 1 EA 30389434

FITTING - ELBOW LNG #8ORB TO #8 FLARE 1 EA 30386265



CARTRIDGE SUN CKCB-XCN 1 EA 30391007

ENCL - TERMINAL BOX, 7-TERMINAL MIDLAND 1 EA 30346562

ANNC - ALARM BACK-UP 12V 1 EA 30337019

HARNESS - BACKUP ALARM, MIXER, (Q3G06) 1 EA 30359462


REFLECTOR - DECK EDGE BLACK (Q7C13) 1 FT 30302690

3

GEN III SMART SYSTEM-CONVENTIONAL Description

Quantity

Units

Part Number

PUMP - HYD, CLOCKWISE HYDROSTATIC (EP) 1 EA

30386328

VALVE - HYD, BLOCK VBL-CC-01 1 EA 10194874

ENCLOSURE - MIXER, CAB, GEN III 1 EA 30380835

RADIO - TRANS, MIXER GEN III 1 EA 30380836

ENCLOSURE - MIXER D160 GEN III 2 EA 30380837

ENCLOSURE - MIXER GROUND MOD GEN III 1 EA 30380838

OIL, MIXER WITH 160F TEMP. SWITCH AND RE 1 EA 30386360

ANGLE - BRACKET, CABLE MOUNT, DRUM CONTR 1 EA 30356823

PROTECTION - VEC, MIXER, GEN III 1 EA 30380822

PLT - MOUNT OMNEX CONTROL 2 EA 30386545

MOTOR - HYDRAULIC,MODEL 4633-135,W/ QUAD 1 EA 30386500

ENCL - CABINET, 400 X 200 X 80 1 EA 30386883

OPER - SENSOR, PROXIMITY W/6" CABLE 2 EA 30350926

LED - INDICATOR LIGHT STRIP 1 EA 30386786

HRNSS - MIXER, VEC, REMOTE GEN III 1 EA 30380810

HARNESS - MIXER MAIN GEN III 1 EA 30380809

HARNESS - ICC MIXER STAND, CPL 1 EA 30380811

WMT - MOUNT POST IN CB OMNEX 1 EA

30386547

PROTECTION - FUSE, 5A/32V, MINI 1 EA

30369488

FITTING - HYD, TEST PLUG SAE#4 1 EA 30335096

KIT - FLANGE 1" CODE 61 5151HK-16 2 EA 30307799

FITTING - HYD, ELBOW 45 DEG 1" 61 FLANGE 1 EA 30389371

FITTING - HYD, ELBOW 37 DEG MALE 3/4" 1 EA 30389166

FITTING - HYD, ELB 90 DEG 1" FLANGE 61 1 EA 30389370



PUMP - HYD, GEAR CHUTE CLOCKWISE ROTAT 1 EA 30389206


FITTING - HYD, ELBOW #16ORB X #12 FLARE 1 EA 30389358

O-RING - 79 X 2 1 EA 10042863



FITTING - HYD, MALE #8 SAE X #10 1 EA 30389213



KIT - FLANGE 1" CODE 61 5151HK-16 2 EA 30307799


FITTING - HYD, ELB 90 DEG 1" FLANGE 61 2 EA 30389370

ANNC - ALARM BACK-UP 12V 1 EA 30337019


FITTING - HYD, ELB 37 MALE 1/4" X 3/8" 1 EA 30389167

HARNESS - BACKUP ALARM, MIXER, (Q3G06) 1 EA 30359462


REFLECTOR - DECK EDGE BLACK (Q7C13) 1 FT 30302690

4

HARDWARE AND CONTROLS

Description

ENCLOSURE - MIXER D160 GEN III

Quantity

2

Units

EA

Part Number

30380837

ENCLOSURE - MIXER GROUND MOD GEN III 1 EA 30380838

ENCLOSURE - MIXER, CAB, GEN III 1 EA 30380835RADIO - TRANS, MIXER GEN III 1 EA 30380836

ENCL - CABINET, 400 X 200 X 80 1 EA 30386883LED - INDICATOR LIGHT STRIP 1 EA 30386786WMT - MOUNT POST IN CB OMNEX 1 EA 30386547PROTECTION - VEC, MIXER, GEN III 1 EA 30380822


MOUNTED UNDER CAB

PROTECTION-VEC, MIXER, GEN III 30380822

MOUNTED IN CAB

LED-INDICATOR LIGHT STRIP 30386786

ENCLOSURE-MIXER, CAB, GEN III

30380836

RADIO - TRANS, MIXER GEN III

30380836

WMT-MOUNT POST IN CAB

30386547

5

MOUNTED ON OR NEAR FRONT PEDESTAL

Mounted inside cabinet (30386883)

Encl - Cabinet, 400 X 200 X 80

30386883

D160 Expansion 30386883

Ground Junction 30380838

HARNESSES AND SENSORS Description

Quantity

Units

Part Number

HRNSS - MIXER, VEC, REMOTE GEN III 1 EA

30380810HARNESS - MIXER MAIN GEN III 1 EA 30380809HARNESS - ICC MIXER STAND, CPL 1 EA 30380811HARNESS - BACKUP ALARM, MIXER, (Q3G06) 1 EA 30359462OPER - SENSOR, PROXIMITY W/6" CABLE 3 EA 30350926ANGLE - BRACKET, CABLE MOUNT, DRUM CONTR 1 EA 30356823

MOUNTED NEAR DRIVESHAFT

OPER-SENSOR, PROX. W/ 6” CABLE 30350926

SENSOR BRACKET FOR DRIVESHAFT AS SHOWN, 30386891

(Part will vary per truck, refer to individual truck BOM for part number)

OPER-SENSOR, PROX. W/ 6” CABLE 30350926

ANGLE-BRKT, DRUM CONTR 30356823

6

HYDRAULICS


PUMP - HYD, CLOCKWISE HYDROSTATIC (EP) 1 EA 30386328PUMP - HYD, BOOSTER AXLE CLOCKWISE ROT 1 EA 30389205VALVE - HYD, BLOCK VBL-CLC-01 1 EA 10194869VALVE - HYD, BLOCK VBL-BCP-01-230 1 EA 10194886VALVE - HYDRAULIC PRESSURE CONTROL (Q2G0 1 EA 10200209

OIL, MIXER WITH 160F TEMP. SWITCH AND RE 1 EA 30386360

MOTOR - HYDRAULIC,MODEL 4633-135,W/ QUAD 1 EA 30386500

Hydraulic fittings are particular to Booster and Conventional, refer to BOM section for correct parts

PUMP-HYD, BOOSTER CW 30389205

PUMP-HYD, CW HYDROSTATIC (EP) 30386328

OPER-QUAD. SPEED SENSOR 30386642

MOTOR-HYDRAULIC W/ QUAD

30386500

7

MISCELLANEOUS

Description BOOSTER LIGHTING TRUCK MIXER

Quantity

1

Units

EA

Part Number

30389128PROTECTION - FUSE, 5A/32V, MINI 1 EA 30369488

CARTRIDGE SUN CKCB-XCN 1 EA 30391007ANNC - ALARM BACK-UP 12V 1 EA 30337019

CARTRIDGE SUN CKCB-XCN 1 EA 30391007REFLECTOR - DECK EDGE BLACK (Q7C13) 1 FT 30302690

TRANSFER PARTS (GEN II TO GEN III)


PUMP - HYD, CLOCKWISE HYDROSTATIC (EP) 1 EA 30386328PUMP - HYD, BOOSTER AXLE CLOCKWISE ROT 1 EA 30389205VALVE - HYD, BLOCK VBL-CLC-01 1 EA 10194869VALVE - HYD, BLOCK VBL-BCP-01-230 1 EA 10194886VALVE - HYDRAULIC PRESSURE CONTROL (Q2G0 1 EA 10200209OIL, MIXER WITH 160F TEMP. SWITCH AND RE 1 EA 30386360MOTOR - HYDRAULIC,MODEL 4633-135,W/ QUAD 1 EA 30386500OPER - SENSOR, PROXIMITY W/6" CABLE 1 EA 30350926KIT - FLANGE 1" CODE 61 5151HK-16 4 EA 30307799FITTING - HYD, #16 ORB TO #16 FLARE 1 EA 30389365FITTING - HYD, ELB 90 #16 SWIVEL X FLARE 1 EA 30389486FITTING - HYD, MALE 3/8" X 1/2" 37 DEG 2 EA 30389170FITTING - HYD, ELBOW #10 ORB X #8 FLARE 1 EA 30389390FITTING - HYD, ELBOW 37 DEG MALE 3/4" 1 EA 30389166FITTING - HYD, ELBOW #16ORB X #12 FLARE 1 EA 30389358FITTING - HYD, ELBOW #16 ORB X #16 FLARE 1 EA 30389357FITTING - HYD, ELBOW 37 DEG MALE 3/4" 1 EA 30389166

DMAN-3186-01 (Rev 1.0) www.omnexcontrols.com call toll free: 1-800-663-8806

Schwing Mixer System Gen III

Installation / Configuration Manual

Transmitter

Control Panel

I/O Module

March 27, 2007

Version 4

DMAN - 3186 - 01

PO Box 12219 Rock Hill SC • 29731

Ph# (803) 233-7913 • Fax# (586) 601-1904

Toll Free 1-877-327-2116


2

www.mixerandplantparts.com3

call: 1-803-233-7913

Table of Contents

Safety Precautions ....................................................................................................................................... 4

System Overview ........................................................................................................................................ 5

Features ....................................................................................................................................................... 5

T151 Dimensions and Controls .................................................................................................................... 5

Control Panel Dimensions and Controls ...................................................................................................... 6

Special Functions......................................................................................................................................... 9

Installation Considerations ........................................................................................................................... 9

Battery Installation and Charging ................................................................................................................. 9

Power the Transmitter .................................................................................................................................. 11

Test the Transmitter / Control panel Link ..................................................................................................... 12

Download ID Code ....................................................................................................................................... 13

Drum Control ................................................................................................................................................ 13

Operating the Control Panel Menu............................................................................................................... 14

LCD Contrast Adjustment ............................................................................................................................ 14

Diagnostics—T151 Transmitter.................................................................................................................... 15

Alarms—Control Panel................................................................................................................................. 16

Diagnostics—Control Panel ......................................................................................................................... 17

Diagnostics—D160 Receiver ....................................................................................................................... 18

Troubleshooting Guide ................................................................................................................................. 19

Parts & Accessories ..................................................................................................................................... 23

Specifications ............................................................................................................................................... 23

Warranty Information.................................................................................................................................... 23


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Safety Precautions

NOTE: These instructions are intended only for installing and operating the remote control equipment described here. This is not a complete Operator’s Manual for the Mixer Truck. For complete operating instructions of the Mixer Truck, please read the Operator’s Manual appropriate for your particular model.

READ ALL INSTRUCTIONS

CAUTION: Changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.

Failure to follow the SAFETY PRECAUTIONS may result in radio equipment failure and serious personal injury Installation

PROVIDE A SAFETY CUTOFF SWITCH. If maintenance is required, the radio must be disconnected from power

USE PROPER WIRING. Loose or frayed wires can cause system failure, intermittent operation, machine damage, etc.

DO NOT INSTALL IN HOT AREAS. This apparatus can be damaged by heat in excess of 158° F (70° C)

Personal Safety

MAKE SURE MACHINERY AND SURROUNDING AREA IS CLEAR BEFORE OPERATING. Do not activate the remote system unless it is safe to do so.

TURN OFF THE RECEIVER POWER BEFORE WORKING ON MACHINERY. Always disconnect the remote system before doing any maintenance to prevent accidental operation of the machine

Care

KEEP DRY. Do not clean the transmitter / receiver under high pressure. If water or other liquids get inside the transmitter battery or control panel compartment, immediately dry the unit. Remove the case and let the unit air dry

CLEAN THE UNIT AFTER OPERATION. Remove any mud, dirt, concrete, etc. from the unit to prevent clogging of buttons, switches, etc. by using a damp cloth.

Maintenance / Welding

DISCONNECT THE RADIO CONTROL PANEL AND I/O MODULES BEFORE WELDING on the machine the modules are connected to. Failure to disconnect will result in the destruction of the radio control panel and/or modules.


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System Overview

The Schwing Mixer System is a portable, long range, programmable radio remote control system. Designed as a compact and easy-to-use product, this system puts complete control of your mixer where it’s needed most, with the operator. It’s robust, easy to install and has complete self-diagnostics. The system consists of a portable transmitter, a Contactless Charging control panel, two I/O modules and a ground junction.

The Schwing Mixer System uses Frequency Hopping Spread Spectrum (FHSS) technology. FHSS devices concen- trate their full power into a very narrow signal that randomly hops from frequency to frequency within a designated band. This transmission pattern, along with CRC-16 error-checking techniques, enables signals to overcome interference that commonly affects licensed radios.

The Control Panel and Modules are designed to be powered from a 12VDC or 24VDC system. Each module features up to 19 solid state, high-side driver input / output controls and a reliable E-Stop control.

The T151 transmitter comes with 14 digital controls. A unique ID code is used by each T151 to ensure that no two systems will conflict on a job site.

Features • FCC, ISC, CE approved

• License free

• Hand held / weatherproof / ergonomic

• Contactless Battery Charging

• Auto Battery Type Detect

• Transmitter Missing Detection

• 1200 foot range @ 900 MHz

• Simple “wire-and-use” installation

• Resilient to impact and shock

• Tether cable included

• Diagnostic Indicators

T151 Transmitter

D160 Expansion

Ground Junction

Control Panel

T151 Dimensions and Controls

4.92” 3.75”

Battery / Tether LED

Hopper UP / DOWN

Throttle UP / DOWN

Active LED

Remote ON / OFF

4.75”

Drum START / STOP

Drum CHARGE / DISCHARGE

Chute LOCK / UNLOCK

Chute UP / DOWN


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Control Panel Dimension and Controls

5.75” Charge Status LED

Display

Constant Speed (Hold for Setup)

3.75”

7.5”

Link LED

Error LED

Status LED

RS 485 LED

STAT

RS-485

Function Select

Mode Control

1. Selecting Functions

A. Each Function Select button selects A. the column content directly above it. A highlight box will appear around the function that is currently selected.

B. Once a column is selected, press the

Function Select button a second time to move the highlight to the desired function (Except for Drum Control, see NOTE below). Each press of the button will toggle the highlighted area

B.

between the functions. Press once and CHUTE LOCK / UNLOCK is highlighted

Press again and CHUTE UP / DOWN is highlighted

NOTE: Drum Control functionality operates differently. Please refer to the Drum Control section for precise control operation directions.

2. Turning ON / OFF (Modifying) Functions

A. The Mode (Speed) Control buttons selects the top or bottom function within the highlighted group.

B. To change a setting, press the top

Mode Control button to select the top function in the highlighted box and press the bottom Mode Control button to select the bottom function in the highlighted box.

A. B.

Press to change from CHUTE UNLOCK to CHUTE LOCK

Press to change from CHUTE LOCK to CHUTE UNLOCK


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Special Functions

Installation Considerations

NOTE: The FCC and ISC require that the antenna be restricted to that supplied by the manufacturer and approved for use with this product. An op- tional 0dB coax wire antenna may be supplied. For other antenna options, please contact OMNEX Control Systems ULC

Mounting and Installation

The I/O Module can be mounted by fastening two ¼” bolts through the two mounting holes in the unit’s enclosure. When mounting, ensure that the I/O Module is oriented so that the text is reading right and the connectors are pointing down.

When selecting a mounting point for the I/O Module, it is recommended that the location require only a minimal length of wiring to connect it to the control panel, that it will be in a visible area where it has good exposure to the operator and that it is mounted on a surface that is protected from the weather and sustains minimal vibration. It is also recommended that the control panel have the best possible line of sight with the transmitter

Power Connections and Wiring Whenever a power connection is made to an electronic device, it is a good practice to make both the Power (+) and Ground (-) connections directly to the Battery and avoid connecting the power from the charging side of existing wiring or making use of existing "ACC" or other peripheral connection points.

Make sure that wire of sufficient gauge and insulator type is used when connecting the outputs of the receiver to the control panel. Observe any component manufacturer's instructions and recommendations for proper integration of their product. This includes the power ratings and requirements of such components as relays, valves, solenoids, etc.

Be sure to test each of the outputs with a multi-meter prior to connecting the outputs to your end devices. This will ensure that each output has been programmed to operate in the manner required by each end device.

Filtering and Noise Suppression

Whenever a solenoid or electromagnetic switch is controlled by the receiver, it is a good practice to install a Diode across its terminals to ensure that surges and spikes do not continue back into the circuit. Appropriate 36V Bi-directional Diodes kits can be ordered under the OMNEX part number “AKIT-2492-01”.


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Battery Installation and Charging

When the control panel has been installed, install batteries into the transmitter.

1. Install Batteries

Remove the battery cover on the back of the transmitter using a slotted screwdriver and insert the 4 "AA" rechargeable batteries. Orientation of the batteries is embossed inside the battery housing. No batteries are required when the transmitter is connected to the control panel by a tether cable.

NOTE: For operation at temperatures below –10° C, lithium batteries are recommended. Low temperatures reduce battery performance for both alkaline and lithium types. Refer to the battery manufacturer’s specifications for detailed information on low temperature performance.

T151 Battery

WARNING: do not install batteries backwards, charge, put in fire, or mix with other battery types. May explode or leak causing injury. Replace all batteries at the same time as a complete set and do not mix and match battery types.

2. Charge Batteries

Place the transmitter in the Charge Cradle. The cradle will detect the transmitter and start charging. The (Charge Status) light on the transmitter will slow flash YELLOW. Fully charge the batteries for 8 hours or until the (Charge Status) light on the transmitter turns solid YELLOW. The charging time may be longer in hot or cold temperature extremes. The (Status) light will be solid GREEN when charging is complete.

A. Cradle detects the transmitter and the batteries are charging

B. Batteries are fully charged

A. B.

NOTE: should the batteries need charging during a job, 15 minutes of charging will provide about 3-4 hours of operation, 1 hour of charging should provide approximately 12-16 hours of operation.

Tips for best performance:

1. The system was designed to work best with NiMH batteries. Regular alkaline batteries and NiCad batteries will work, however, system performance may not meet all specifications.

2. Charge the batteries at the end of every shift. Temperature extremes (freezing and hot temperatures) will diminish battery performance, therefore, keep the batteries as fully charged as possible at all times to maximize operation time.

3. Charging will not occur when vehicle is shut off.

Light Legend Solid

Slow Flash 1x / sec

Double Flash

Fast Flash Red Light

Green Light

Yellow Light


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Power the Transmitter

1. Turn the Transmitter ON or OFF

Refer to the Light Legend below for diagram details.

A. Turn Transmitter ON B. Turn Transmitter OFF

Press [Remote] UP If the transmitter's (Active) light does not flash, check the battery orientation.

Press [Remote] DOWN

Test the Transmitter / Control panel Link

Follow these steps to ensure that there is a radio link between the transmitter and control panel. Refer to the Light Legend below for diagram details

1. Ensure the Transmitter is OFF

2. Power the Control Panel CHARGE

LINK

ERROR

STAT

RS 485

CHARGE

LINK

ERROR

STAT

RS 485

With T151 out of Cradle With T151 in Cradle

3. Power the T151 CHARGE

LINK

ERROR

STAT

RS 485

If the (Active) light on the transmitter is flashing and the (Link) light on the control panel is flashing GREEN, a link between the two exists.

If the control panel’s (Link) light does not flash GREEN, follow the steps under Download ID Code.

The ORIGA system is now ready for use.

Light Legend Solid

Slow Flash 1x / sec

Double Flash


Green Light

Yellow Light


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Download ID Code (Use in case of Link Test failure)

Follow these steps to download the transmitter’s unique ID Code into the control panel. This will allow the control panel to establish a radio link with that transmitter.

Refer to the Light Legend below for diagram details. Refer to Troubleshooting Chart #4 for Tips and Considerations

NOTE: It is necessary to download the ID Code when replacing either the transmitter or the control panel.

1. Prepare the Control Panel for Download

A. Press & hold [Setup] for 4 seconds until System Control screen appears

B. Highlight “Link with Remote” using [Mode] buttons

A. CHARGE

LINK

ERROR

STAT

RS 485

DRUM SPEED 0.0RPM 0 PW M

BP 0 PSI

DRUM CHUTE THROTTLE BOOSTER

ST LK UP UP

SP UN DN DN

CH UP HOPPER LIGHTS

B.

USER SETUP

BOOSTER ENABLED: YES

DRUM TOTAL REVS: 000 RESET

LINK WITH REMOTE

DISPLAY FIRMWARE VERSION

2. Put Control Panel into Setup Mode

A. Press the [Select] button to place the

control panel into Setup Mode

A. B.

USER SETUP

BOOSTER ENABLED: YES

DRUM TOTAL REVS: 000 RESET

LINK WITH REMOTE

DOWNLOAD FIRMWARE

CHARGE

LINK

LINK W ITH REMOTE

LINK TO REMOTE

C.

CHARGE

LINK

LINK W ITH REMOTE

LINK TO REMOTE

B. The display should now indicate that the control panel is ready for the download

ERROR

STAT

RS 485

RF ID UPLOADING ... ERROR

STAT

RS 485

RF ID UPLOADING ... FAILED

NOTE: If left idle in Setup Mode for over 30 seconds, the control panel will time out. The (Link) light and (Status) light will flash RED rapidly and the display will read “RF ID UPLOADING FAILED”. To return to Setup Mode, Press [ESC] to go back to the main screen and repeat steps 1 and 3. If you do not re-enter Setup Mode, you will need to turn off then turn on the control panel to remove the flashing (LINK) and (STAT) light condition.

3. Power T151 into Configuration Mode A. B.

A. Hold [Hopper] switch UP

B. Press [Remote] switch DOWN

C. Release [Remote] switch

D. Release [Hopper] switch. The (Active) C. D. light should be flashing.

4. Download ID Code

NOTE: When downloading a new ID to a receiver, a safety feature requires that the transmitter be in close proximity to the receiver. This will prevent a transmitter from accidentally reprogramming a different receiver in the area.

A. Press [Hopper] switch UP and Release

B. (Link) light goes to GREEN

A. B. CHARGE

LINK

ERROR

STAT

RS 485

LINK TO REMOTE

LINK W ITH REMOTE

RF ID UPLOADING...

5. Download Complete

A. Once complete, (Link) light goes to

RED as the transmitter turns off

A.

CHARGE

LINK

LINK W ITH REMOTE

LINK TO REMOTE

B. The display will now indicate that downloading is complete

ERROR

STAT

RS 485

RF ID UPLOADING ... COMPLETE

Light Legend Solid

Slow Flash

Fast Flash

Red Light

Green Light

Yellow Light

Alternating Red & Green Light


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Drum Control

A. Press the [Function Select] button to highlight the Drum control column

B. Pressing this button toggles the START and STOP function of the drum

A. Press the top and bottom [Mode] buttons to adjust the drum rotation speed and direction

B. Observe the PWM value in the top right corner of the screen to determine increase and decrease direction.

A.

A.

B.

B.

Note: To select DC (Discharge) or CH (Charge), you must toggle between the settings by reducing the PWM value to minimum value. Once this min. value is reached, the controller will toggle directions. Continue pressing the same button to increase the drum speed. Press the opposite button to reduce speed and once min. is reached, the controller will switch directions and now the button will increase the value.

A. From the transmitter use the Start/Stop switch to toggle the start/stop function of the drum

B. The Charge/Discharge switch works in exactly the same fashion as the [Mode] button on the Control Panel. Once the switch is toggled and the PWM speed hits minimum, the drum will switch direction and the switch will act as a speed control switch

A. B.

A. Press the [Constant Speed] button to set the drum rotation’s RPM to the default setting

Note: Constant Speed engages auto- matically when vehicle speed exceeds 15 mph.

A.

Note: You can press the [Constant Speed] button from the start position as a “quick start” function to set the system in motion.

Light Legend Solid

Slow Flash 1x / sec

Double Flash


Green Light

Yellow Light


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Operating the Control Panel Menu

To access the Control Panel menu, press and hold the [Constant Speed] button for about 4 seconds until the System Menu screen appears

Use the [Mode] buttons to move the highlighted area up and down to select the desired Menu item.

Press the button under the SEL [Select] to select that menu item

Menu Item Descriptions

Booster Enable—Enables and Disables the booster axle control system

Drum Total Revs—Monitors and counts the total number of drum revolutions

Link with Remote—Used to place the Control Panel into Download ID mode.

Display Firmware Version—Display the software version currently installed in the Control Panel.

LCD Contrast—View and adjust current contrast setting

LCD Contrast Adjustment

A. To increase or decrease the LCD Con- trast, select the LCD menu item and press the [SEL] button.

B. Press the buttons under [-] or [+] to in-

crease or decrease the contrast.

Once completed press the [ESC] button to return back to the main screen

Light Legend Solid

Slow Flash 1x / sec

Double Flash


Green Light

Yellow Light


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Diagnostics—T151 Transmitter

Tether connection detected

Low battery. Unit will run approximately 10 hours after Battery light starts flashing.

Flashing rapidly for 10 seconds indicates a transmitter failure.

Normal Operation The Active light will flash several times per second, indicating that the transmitter is sending signals to the control panel. The Active light will remain on momentarily whenever a function changes

Normal Operation The transmitter is in Download Mode.

Stuck switch detected. Ensure that all switches are in a centered position. The transmitter will not power up when a function is ON.

On Power Down Unit is still powered. Check for stuck switches, as the transmitter will not power down when a function is ON. Alternating flash means that the transmitter is in Calibration Mode.

The transmitter is in the Control Panel charge cradle and the batteries are charging.

The batteries in the transmitter are fully charged.

Transmitter is in the powered cradle and attempting to charge but the temperature of the batteries is either above 60° C or below 0° C. Either cool or heat the batteries to bring them within charging temperature

A problem with the batteries has been detected. (No batteries, no contact to batteries, non- rechargeable batteries, backward batteries, dead batteries) This is a common error if using alkaline batteries or other non-rechargeable batteries.

Light Legend Solid

Slow Flash 1x / sec

Double Flash


Green Light

Yellow Light


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Alarms—Control Panel

Sensors located throughout the machine provide feedback to the Control Panel. When a parameter is not within accept- able operating range an alarm will sound and the appropriate warning label will appear on the Control Panel screen. The following are the list of alarms in the mixer system.

No Signal—This is indicated by a “NO SIG” symbol replacing the Drum Speed RPM indicator. The alarm is activated when the Pulse Counter input from the drum is lost.

BP—This is indicated by a blinking “BP” symbol. This alarm sounds when the Booster is being driven down and the Booster pressure has fallen by at least 500 psi.

REM—This is indicated by a “REM” symbol located next to the BP indicator. The Control Panel has indicated that the remote control is not in the Charge Cradle and the vehicle is traveling over 15 mph. This is to prevent the driver from leaving the work site and forgetting the remote control outside or on the truck.

OIL—This is indicated by a “OIL” symbol located directly under the Drum Speed RPM indicator. This alarm indicates that the oil cooler fan has turned on.

BIM—Booster in Motion is indicated by a “BIM” symbol located under the Drum Speed indicator. This alarm alerts the driver that the Booster is either up or down. This lets the driver know not to drive the truck while it is in transition between the up and down position.

CHUTE—This is indicated by a “CHUTE” symbol located under the Drum Speed indicator. This occurs when the chute is not in the center and up position. This will let you know if it is safe to move the booster up or not.


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Diagnostics—Control Panel

Normal Operation

CHARGE

LINK

ERROR

STAT

RS 485

CHARGE

LINK

ERROR

STAT

RS 485

Transmitter is OFF The Transmitter is recognized by the Control Panel cradle and being in the cradle. Output status is correct and the E-Stop relay is open and working properly. Transmitter is ON The Transmitter is recognized by the Control Panel cradle and being in the cradle. Output status is correct and the E-Stop relay is open and working properly. Transmitter and Control Panel have a radio link.

CHARGE

LINK

ERROR

STAT

RS 485

CHARGE

LINK

ERROR

STAT

RS 485

Transmitter is OFF The Transmitter is not recognized by the Control Panel cradle as the Transmitter is not in the cradle. Output status is correct and the E-Stop relay is open and working properly. Transmitter is ON The Transmitter is not recognized by the Control Panel cradle as the Transmitter is not in the cradle. Output status is correct and the E-Stop relay is open and working properly. Transmitter and Control Panel have a radio link.

Trouble Indicators

Note: In some cases, the indicator lights will be different depending on whether the transmitter is on or off. These will be reflected in the (CHARGE) light and (LINK) light. Please note the these status lights in the Normal Operation section.

Indicator Lights

Description Solution

CHARGE

LINK

ERROR

STAT

RS 485

Transmitter - ON When the (ERROR) light activates, text will appear on the display to indicate the error type.

Read the error code to determine what the issue is. Refer to theAlarm—Control Panel on page 15 for alarm descriptions. Once determined, correct the issue or refer to Vehicle’s Operators Manual to determine the appropriate steps.

CHARGE

LINK

ERROR

STAT

RS 485

Transmitter - ON The Control Panel has lost communication with the I/O Modules.

Refer to the I/O Module diagnostic indicators to determine module status and refer to the D160 diagnostic page for a solution. If the D160 modules appear to be in working order, check the Control Panel to Module connections.

CHARGE

LINK

ERROR

STAT

RS 485

Transmitter - ON Irrecoverable internal fault.

Call for service.

CHARGE

LINK

ERROR

STAT

RS 485

Transmitter - ON The internal temperature of the cradle is above +60° C (140° F).

If possible cool down the cradle to within operating temperaturerange

CHARGE

LINK

ERROR

STAT

RS 485

Transmitter - ON No remote control unit has been linked with the Charge Cradle control panel

Download ID code of the remote control to the control panel

CHARGE

LINK

ERROR

STAT

RS 485

Transmitter - ON The voltage to the Charge Cradle is not within 9—29 VDC

Bring the power supply to within operating parameters

Light Legend Solid

Slow Flash 1x / sec

Double Flash


Green Light

Yellow Light


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Diagnostics - D160 I/O Module

Normal Operation

ESTOP FAULT LINK STATUS If the control panel is off, the module is operating properly.

ESTOP FAULT LINK STATUS

When the control panel is turned on, the Link light (fast flashing) and E-Stop (GREEN) indicates the module is operating properly.


When a function is activated on the transmitter or the control panel, the Fault light will turn on GREEN. This indicates the module is operating properly.


When a latched function is activated then the transmitter is turned off, the Fault light will stay on GREEN. The system was intentionally designed this way, the module is operating properly.

Trouble Indicators

Note: In some cases, the indicator lights will be different depending on whether the transmitter is on or off. Please note the transmitter status in the “Description” column for each case.

Indicator Lights Description Solution ESTOP FAULT LINK STATUS

The reason is the control panel is not communicating with the module.

Refer to Troubleshooting Chart #3 for solutions.


A low battery condition has been detected.

To detect intermittent conditions caused by poor or corroded ground or power circuits, the GREEN light will continue to flash for 30 seconds after the condition has been removed.


An internal fault with the E-Stop has been detected.

Inspect E-Stop wiring for short circuit. Disconnect E-Stop wire as close to the control panel output as possible. If the Status light changes to: • GREEN, a short occurs after disconnection point. • Stays flashing RED, send it in for service .


A short to ground or excessive current draw on an output. It is most likely caused by a wiring fault.

Ensure transmitter is functioning properly, check status of each output connection: Press each function button and observe Fault Light. • If GREEN, everything is OK. • If RED, there is a short in that connection.


The E-Stop output has been connected with one of the other outputs.

Follow the wire and check for connections with other wires, disconnect to see if condition clears. If not, call for service.

A wiring short to the battery has been detected.



The module has detected an internal fault.




Blown fuse detected.

Refer to Page 8 for instructions on how to open the I/O module case to access fuse. Check wiring for shorts or bare spots. If fuses continue to blow, call for service.


The module is powered incorrectly. Most likely cause of this condition is that an output wire or the E-Stop wire has been connected to the power supply while the power wire is disconnected from the power supply.

Light Legend Solid

Slow Flash

Fast Flash

Red Light

Green Light

Yellow Light

Alternating Red & Green Light


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Troubleshooting Guide Chart #1

Test the D160 I/O Module

Start Initial Condition: Turn transmitter off Cycle power to module (turn off and back on)

Problem state: Status—RED

What is the state of the lights on the module?

OK state: Status—GREEN Link—RED Fault—OFF E-Stop—RED Note: If there is a short to ground on an output, it is not indicated at this stage. To test for short to ground, refer to the “*Fault Light is RED*” procedure at the bottom of this page and follow the instructions.

Problem state: Status—flashing GREEN & RED

The system is wired incorrectly. Most likely cause is one of the input/output wires has been connected to the power source.

Go to Chart 2

Is the Status light flashing

RED?

YES

Fuse is blown, change fuse 1. Inspect wiring looking for short circuits (e.g. bare wires) 2. If problem re-occurs, call for service.

NO Inspect E-Stop wiring looking for short circuits (e.g. bare wires) Disconnect the E-Stop output as close to the

What is the state of the E-

Stop light ?

Problem state: E-Stop— Flashing RED

receiver output as possible. If the Status light changes to: • GREEN, there is a short is the wiring after the discon-

nection point. • Stays flashing RED, call for service .

OK state: E-Stop—RED

Fault Light is

OFF

Call for service.

What is the state of the Fault light ?

Fault Light is Flashing RED

There is a short to supply. 1. Disconnect A & B connectors from receiver and check all

outputs for power (e.g. bare wires, improper connections) make the correct adjustments

2. Call for service.

*Fault Light is

RED*

There is a short to ground. Note: This should only occur when the transmitter is on and a function button is pressed. In this case the Status light will be GREEN and will turn RED at the same time as the Fault light.

Go to Chart 2 to test the transmitter. If the transmitter is functioning properly, proceed to check the status of each of the output connections: Press each of the function buttons and observe the Fault Light. If the light turn GREEN, everything is OK. If the Light turns RED, there is a short in that connection.


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Troubleshooting Guide (con’t) Chart #2

Test the Transmitter—T151

Turn off the control panel Ensure there are good batteries in the transmitter Turn on the transmitter

What is the state of the lights?

OK state: Active light—steady for about 3 seconds then goes to fast flash. Battery light—OFF E-Stop light—OFF

Activate a function

Go to Chart 3 YES Does the Active light go to solid

YELLOW?

No light comes on at any time

Complete the following steps in order: 1. Check battery orientation 2. Clean battery contacts 3. Check or Replace batteries 4. Call for service

NO

Either the switch is defective or the switch connection to the circuit board is broken.

Call for service

Both the Active light and the Battery light flash at the same time

Stuck switch: 1. Return all switches to neutral (OFF)

position 2. Toggle the switch a few times 3. Call for service

Active light is flashing rapidly and Battery light flashing slowly

Low Battery—Change/Charge Batteries Note: Low batteries will last approximately 10 hours once the Low Battery light begins to flash. Replace /Charge batteries by next shift.

Battery light and Active light flash alternately.

The transmitter is in Calibration mode 1. Turn unit OFF, then turn back ON 2. If condition persists, call for service.

Battery light flashes for 10 seconds then all lights are OFF

Press and release E-Stop if the condition persists, then either there is a faulty E- Stop or transmitter failure—call for service


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Troubleshooting Guide (con’t) Chart #3

Testing the Transmitter / Control Panel Communication

Transmitter: Active light is flashing

Control Panel: Status—GREEN Link—RED

What is the status of the lights of both the

transmitter and receiver?

Transmitter: Active light is flashing Control Panel: Status—GREEN Link—Flashing GREEN

There is no link between the transmitter and receiver

Transmitter and receiver should be working properly. The problem may rest with the machine instead of the radio system Call for service

Do you have a matched set? (i.e. the

transmitter and receiver should have identical ID codes

YES

Call for service.

NO

Was the transmitter accidentally swapped with another one on

the job site?

POSSIBLY

Search the job site for the correct transmitter.

NO YES Was it found?

NO

Turn on the transmitter to check if the units function correctly. If not, proceed to Chart 1

The transmitter code may need to be re-downloaded to the receiver

!!Caution!! Note: Before you proceed with the Download ID procedure located on Page 12, great care and caution must be adhered to. Also, refer to Chart #4 for Tips and Considerations. If by accident, the transmitters have been switched with another unit, by downloading the ID code to a new receiver, it is possible for the transmitter to operate 2 units at the same time (if the original receiver unit is still on the job site). Therefore it must be certain that the transmitter / receiver pair are the correct set. Secondly, once the download procedure is completed, ensure all other units on the job site are stopped. Test the operation of the newly configured set to ensure no other machines on the site work with the same transmitter. Once you are certain that the transmitter / receiver pair are a unique set, continue normal operations.


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Troubleshooting Guide Chart #4

Considerations when Downloading the ID

Potential downloading issues

If testing of the control panel and transmitter both show the system as working (Chart 2 & 3), then the transmitter and control panel will both go into Download/Configuration mode.

Possible issues could arise during Step 4, the download phase of reprogramming. In this case there are 2 symptoms to look for:

1. The Link light on the control panel will not turn GREEN when the power switch is toggled on the transmitter to download

2. The control panel will “time out” indicating that it didn’t receive a signal from the transmitter within the 30 seconds from the time the control panel was put into Setup Mode.

If all indications appear normal during the download phase, test the link by turning on the transmitter (note: the transmitter shuts off after transmitting the ID code in Step 4)

1. If the Link light on the control panel doesn’t turn GREEN, the control panel didn’t receive all of the information that

was sent from the transmitter.

Possible Solutions

1. Try the Downloading steps again

2. If this doesn’t correct the problem, send both the transmitter and control panel in for service.

Note: you could try to determine whether the fault lies with the transmitter or control panel by completing the downloading procedure with a different transmitter. If this step works, then the fault lies with the original transmitter. If not, the fault may lie with the control panel.

!!Caution!!

Note: Before attempting downloading with another transmitter, understand that reprogramming the control panel with another transmitter, could result in two control panels on the job site responding to the one transmitter. If the original transmitter was sent in for repair, Disconnect the control panel (disconnect connector A) to continue using the machine without remote capability and without fear of inadvertently operating the machine with the other transmitter.

Connector A

23


Parts & Accessories

Part Part Number Description

Batteries B0010 4 x AA alkaline

T151 Tether Cable (8 m. / 25 ft.) ACAB-2455-02 see illustration

Toggle Switch

AKIT-1504-04 Honeywell 1TL1-7

Magnet Back AKIT-2498-02 see illustration

Bipolar Diode Kit AKIT-2492-01 36V, Bi-directional, Motorols P6KE36CA

Fuse F0039 Bussman ATC-15

Socket Connectors

J0418 Grey, 12-pin, Deutsch DTM06-12SA

J0419 Black, 12-pin, Deutsch DTM06-12SB

Wedge J0420 12 pos., Deutsch WM12S

Pin J0417 Female, Size 20, Deutsch 0462-201-20141

Sealing Plug J0421 Size 20, Deutsch 0413-204-2005

D160 Connector Kit

AKIT-2337-01 Includes Deutsch socket connectors, wedges, pins and sealing plugs.

Specifications

D160 I/O Module T151 Transmitter

Size 5.1” x 4.7” x 1.4” (130mm x 119mm x 36mm)

7.9” x 4.2” x 4.1” (200mm x 125mm x 105mm)

Weight 0.65lbs (0.295kg) 1.8lbs (0.817kg)

Construction

High impact plastic, weatherproof High impact, low temperature plastic, weatherproof

Input Power +9V to 30VDC 4AA alkaline batteries or NiMH rechargeable

Battery Life N/A 160 hours (continuous use)

Operating Temperature Range

-40F to 158F (-40C to 70C) -40F to 158F (-40C to 70C)

Outputs 3A (max) each (sourcing), 10A (max) each (combined)

N/A

Antenna Internal Internal

Approvals USA- FCC part 15.247 Canada- ISC RSS 210 Issue 6, Sept. Europe- EN 440 Australia- C-Tick

FCC Rules and Compliance

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause unde- sired operation.

FCC Part 15.247 ISC RSS 210 Issue 6, Sept.

2005

Warranty

OMNEX Control Systems ULC warrants to the original purchaser that the OM- NEX products are free from defects in materials and workmanship under normal use and service for a period of ONE YEAR, parts (EXCLUDING: SWITCHES, CRYSTALS, OR PARTS SUBJECT TO UNAUTHORIZED REPAIR OR MODIFI- CATION) and labor from the date of delivery as evidenced by a copy of the receipt. OMNEX's entire liability and your exclusive remedy shall be, at OM- NEX's option, either the (a) repair or (b) replacement of the OMNEX product which is returned within the warranty period to OMNEX freight collect by the OMNEX APPROVED carrier with a copy of the purchase receipt and with the return authorization of OMNEX. If failure has resulted from accident, abuse or misapplication, OMNEX shall have no responsibility to repair or replace the product under warranty. In no event shall OMNEX be responsible for incidental or consequential damage caused by defects in its products, whether such damage occurs or is discovered before or after replacement or repair and whether or not such damage is caused by the negligence of OMNEX Control Systems ULC.

MPPM PO Box 12219 Rock Hill, SC 29731 Tel: 803-233-7913 Fax: 586-601-1904 Visit us online: www.readymixparts.com

Contact Information: Mixer & Plant Parts

PO Box 12219 Bus: (803) 233-7913 Fax: (586) 601-1904 readymixparts.com

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