REMOTE FIRING DEVICE OPERATION MANUAL The information contained in this document is subject to change without notice. In no event shall Rothenbuhler Engineering Company be liable for errors contained herein or for special, indirect, or consequential damages or injuries of any nature resulting from use of information in this document. ROTHENBUHLER ENGINEERING P.O.
SPECIAL NOTICE WARNING TO USERS AND AFFECTED PERSONS The Remote Firing Device (RFD) is designed to be used in blasting operations. Explosives used in connection with the RFD may be extremely powerful. Improper use of explosives with or without the RFD or improper safety precautions taken with respect to personnel or property may result in death, serious personal injury, or property damage.
FCC NOTICE This device complies with Part 15 of the FCC regulations. Operation is subject to the following two conditions: (1) That this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. RADIATION HAZARD WARNING This radio shall only be used during the course of employment by individuals aware of the hazards of radio frequency (RF) radiation exposure, and the ways to minimize such hazards.
Conformément à la réglementation d'Industrie Canada, le présent émetteur radio peut fonctionner avec une antenne d'un type et d'un gain maximal (ou inférieur) approuvé pour l'émetteur par Industrie Canada. Dans le but de réduire les risques de brouillage radioélectrique à l'intention des autres utilisateurs, il faut choisir le type d'antenne et son gain de sorte que la puissance isotrope rayonnée équivalente (p.i.r.e.
TABLE OF CONTENTS Chapter Page SPECIAL NOTICE .......................................................................................................... II WARNING TO USERS AND AFFECTED PERSONS .................................................... II LIMITED WARRANTY .................................................................................................... II FCC NOTICE .................................................................................................................
2.9. 5 Position Charger & Conditioner.................................................................... 20 2.10. Test Box ...................................................................................................... 22 2.11. Antenna Assembly ...................................................................................... 24 2.12. Carrying Case ............................................................................................. 25 2.13. Vent operation ......................
6. POST OPERATIONAL PROCEDURES ............................................................ 50 6.1. Securing the System....................................................................................... 50 6.2. Physical Inspection ......................................................................................... 50 6.3. Packaging ....................................................................................................... 50 6.4. Maintenance & Equipment Storage .................
LIST OF ILLUSTRATIONS Figure 2-1 RFD 4-Remote Case System......................................................................... 4 Figure 2-2 Controller Unit ................................................................................................ 6 Figure 2-3 Mini Controller Unit ........................................................................................ 7 Figure 2-4 Mini Controller Isometric View with Antenna ................................................
Figure 9-1 Test Box....................................................................................................... 56 SAFETY INFORMATION The following are WARNINGS and CAUTIONS, contained throughout this manual and are repeated here for emphasis. All personnel engaged in the handling, firing, and storage of the system covered in this manual must fully understand these WARNINGS and CAUTIONS, and procedures by which hazardous conditions are to be reduced or eliminated.
WARNING Do not connect a blasting cap to a Remote Unit unless the green SAFE light is on, the red ARMED light is off, and the yellow ON/LOW BATT light is on steady. This indicates there is no voltage on the binding posts, the binding posts are electically isolated from the firing capacitor, the binding posts are shunted to each other, and the battery is not low. WARNING Ensure that blasting caps are not connected to any of the Remote Units during bench testing.
CAUTION Do not open a vent if there is water on or near the vent. Keep the vents closed when the relative humidity is above 90%. Take necessary precautions to ensure moisture does not enter the unit case. CAUTION Do not use any component that is damaged, suspected of being damaged, or is not able to operate as designed. The safety of the operation could be compromised.
1. INTRODUCTION 1.1. PURPOSE 1.1.1. The primary purpose of this manual is to provide descriptive information, operational information, instructions in assembly, and instructions in testing and preparation for operational or training use of the Remote Firing Device (RFD). 1.1.2. The Remote Firing Device (RFD) is used to activate electric and non-electric detonator devices. The System is strictly an electronic device, containing no explosive.
1.2.4. case. The battery pack and unit electronics are electrically isolated from the unit 1.2.5. The Controller and Remote Units have a operation temperature range from -22 ºF to +140 ºF (-30 ºC to +60 ºC). 1.3. COMPLIANCE STANDARDS • MIL-STD-810F, Method 501.4, Procedure II, High Temperature Test • MIL-STD-810F, Method 502.4, Procedure II, Low Temperature Test • MIL-STD-331C, A4.1, 5 feet (1.5 meter) Drop Test • MIL-STD-331C, Test C7, Thermal Shock • MIL-STD-331C, B1.6.2.
2. INTRODUCTION TO RFD SYSTEM COMPONENTS 2.1. SYSTEM 2.1.1. The RFD is a battery powered, hand held, radio remote controlled system to be used on land as a primary firing mechanism to detonate explosive charges. The RFD system consists of a either a Controller Unit or a Mini Controller Unit and up to either eight Remote Units (Controller Unit) or four Remote Units (Mini Controller). Any combination of Electric Remotes and RSTIs may be used. 2.1.2.
Figure 2-1 RFD 4-Remote Case System 1678 RFD OPERATION MANUAL 4
Table 2-1 RFD 4-Remote Case System Figure Index No.
2.2. CONTROLLER UNIT 2.2.1. Figure 2-2 shows the external features of the Controller Unit. The Controller is sealed at the manufacturer and should not be opened during field activity. The user interface features a keypad and intensity adjustable LED display panel. Figure 2-2 Controller Unit 2.3. MINI CONTROLLER UNIT 2.3.1. Figure 2-3 shows the external features of the Mini Controller Unit. The Mini Controller is sealed at the manufacturer and should not be opened during field activity.
Figure 2-3 Mini Controller Unit 2.4. CONTROLLER SWITCH OPERATION 2.4.1. The Controller Unit and Mini Controller operate in a very similar manner. The difference being the maximum number of Remote Units each can control. Unless otherwise noted, the following descriptions apply to both the Controller Unit and the Mini Controller. 2.4.2. Unit Power Control: Depress the “ON” switch for one second to turn the power on to the Controller when the Antenna is attached.
2.4.3. Power ON Self Test: Upon installing the antenna and pressing the “ON” switch, a rigorous self test is initiated. If a failure of the self test occurs, the green receive light (RX) will blink continuously and it will not be possible to operate the unit. Contact the Manufacturer for service. Do not attempt to use a failing unit. 2.4.4. Display Panel Light Dimmer Circuit: With the unit powered on, Repress the ‘ON’ switch briefly to toggle the LED display light’s intensity between bright and dim.
2.4.8. Disarm the Remote Unit: Depress the “DISARM” switch. The Controller will transmit the Disarm command to selected Remote Units. Selected Remote Units will internally discharge their firing capacitor. Selected Remote Units that receive the Disarm command will become disarmed within 3 seconds of receiving the command. The green SAFE light for selected Remote Units will begin to flash on the Controller display panel. The Controller will then request status of selected Remote Units.
• Depress “ARM” switch – all Remote Units will arm. • Depress the switches for the Remote Units that will not be fired initially. • Depress the “FIRE” switch. Only Remote Units still selected will fire. • Depress the switches for the Remote Units that were just fired. • Depress the switches for Remote Units to be fired next. • Depress the “FIRE” switch. Only Remote Units still selected will fire. • Repeat as necessary.
2.5.6. Remote Unit Safe: A green light next to each of the “1” though “4” or “8” switches is used to indicate when the corresponding Remote Unit is safe/disarmed. The light will be on steady when the Remote Unit transmitter is within range of the Controller and it is disarmed. If the Remote Unit transmitter is out of range of the Controller, the light will flash after a Disarm command has been sent. 2.5.7.
Figure 2-4 Mini Controller Isometric View with Antenna 2.5.14. Figure 2-4 shows an isometric view to further illustrate the exterior features of the Mini Controller. 2.5.15. Manual Air Vent: A manual vent is located on top of the unit. The vent is used to relieve any internal pressure that has accumulated within the unit as a result of temperature or altitude. The vent is opened when charging to release any gasses or pressures accumulated during charging.
2.6. ELECTRIC REMOTE UNIT 2.6.1. Figure 2-5 shows the external features of the Electric Remote Unit. The unit is sealed at the manufacturer or service depot and should not be opened during field activity. Figure 2-5 Electric Remote Unit 2.6.2. Power ON Self Test: Immediately after the Electric Remote is turned on by installing the Antenna, a rigorous self-test is performed. If a failure is detected, the red ARMED light will blink continuously and all other lights will be extinguished.
2.6.3. Safe Separation Time: Upon the installation of the Antenna, a safe separation countdown timer is initiated. During the safe separation time, the SAFE and ARMED lights will be on steady, while the ON light blinks rapidly. During the safe separation time, the unit will not accept any radio commands (i.e. Status, Arm, Disarm, or Fire). This is to provide a short but highly safe window of time for the user to exit the immediate vicinity of the blast area.
Figure 2-6 Electric Remote Unit Angled View 2.6.9. Binding Posts: The Binding Posts located on top of the Electric Remote Unit allow the firing cable to attach to the firing terminals. The insulation at the ends of the firing cable must be removed prior to attachment. One at a time, depress the top of the binding posts and insert a leg of the firing cable. Release the binding post, causing it to grab the lead. 2.6.10. Manual Air Vent: A manual vent is located on top of the unit.
2.6.12. System Configuration Label: The System Configuration Label contains information related to the settings of the unit within the system it operates. The information displayed on this label may be considered semi-permanent. 2.6.13. Model, Serial Number, FCC ID, and IC Label: The information displayed in this label is permanently assigned by the factory. 2.7. REMOTE SHOCK TUBE INITIATOR (RSTI) 2.7.1. Figure 2-7 shows the external features of the RSTI.
Figure 2-8 RSTI Angled View with Shock Tube Spark Tip 2.7.3. Figure 2-8 shows the installation of the Shock Tube Firing Tip onto the Firing Terminals on the RSTI.
Figure 2-9 Shock Tube Tip 2.7.4. Figure 2-9 shows the installation of the shock tube onto the shock tube firing tip when preparing for use. Care should be taken when handling the shock tube to prevent the incursion of debris or moisture into the tube. • Keep open tube ends capped during storage and transportation. • Keep the tip needle clean and dry. • Replace the tip every 200 shots or if misfiring occurs.
2.8. 3 POSITION BATTERY CHARGER 2.8.1. Figure 2-10 shows the 3 Position Charger that is configured with some 1678 RFD systems. The 3 Position Charger is a basic NiMH charger which provides a 3 to 4 hour recharge for up to three RFD units (e.g. one Mini Controller and two Remotes). It may be stored and used within the 1678 case/foam, or it can be stored and used as a stand-alone device. The 3 Position Charger comes with an AC adapter that can be configured for use internationally.
2.9. 5 POSITION CHARGER & CONDITIONER 2.9.1. Figure 2-10 shows the 5 Position Charger & Conditioner that is configured with some 1678 RFD systems. The 5 Position Charger & Conditioner charges 5 units of the 1678 RFD system in about 2 hours. The 5 Position Charger & Conditioner has advanced features that maximize the health and performance of the battery packs. It may be stored and used within the 1678 case/foam, or it can be stored and used as a stand-alone device.
Table 2-2 RFD 5 Position Charger & Conditioner Figure Index No. Description Figure 2-11 1 Cooling air inlets (x2). Figure 2-11 2 System Charge Mode Indicator (yellow). Indicates the attached units will be charged only (no discharge). Figure 2-11 3 System Discharge then Charge Mode Indicator (yellow). Indicates the attached units will receive a discharge, and then a charge. Figure 2-11 4 System Discharge Mode Indicator (yellow).
2.10. TEST BOX 2.10.1. Figure 2-12 provides a drawing of the Test Box. The Test Box is used to display information from and to evaluate the performance of the Controller, Mini Controller, Electric Remote Units and RSTIs. The Test Box can also be used to change settings and parameters of the units with certain restrictions. Figure 2-12 Test Box 2.10.2. Serial Communications Port: The Test Box can be connected to a USB port on a host PC. The connection can be used to log the results of the tests performed.
2.10.4. LCD Display: The LCD displays information both from the Test Box itself during its power on sequence, and while reading and testing a Controller, Mini Controller, Electric Remote, or RSTI. The LCD’s backlighting will turn on while the unit is active.
2.11. ANTENNA ASSEMBLY 2.11.1. Figure 2-13 provides the physical size, technical requirements and view of the Antenna Assembly. The power to the Controller and Remote Unit is interrupted when the Antenna Assembly is not connected.
2.12. CARRYING CASE 2.12.1. Figure 2-14 shows the Carrying Case, providing a view of the storage location for each system subassembly. The Carrying Case has a pressure equalization vent near the handle. The vent operation is automatic. There are foam inserts for the Battery Charger, depending on which model of charger the system is equipped.
2.13. VENT OPERATION 2.13.1. In Figure 2-15, the unit vents shown are manually operated and relieve internal pressure due to heat and altitude. When the vent is closed, it will not leak in 100 feet of water (30 meters) or up to 30,000 feet (9,100 meters) in altitude. 2.13.2. The vent is opened when charging to release any gasses or pressures accumulated during charging. The vent is closed during normal use or when the unit is exposed to moisture. 2.13.3.
2.14. ANTENNA / BATTERY CHARGER CONNECTOR 2.14.1. Figure 2-16 shows the connections when using the 3 Position Charger. The connections for the 5 Position Charger are similar. 2.14.2. The chargers do not discriminate between Controller and Remote units; any unit may be connected to any charge connector. 2.14.3. There is a key on the charge connector that must be aligned with a slot on the unit’s charge connector. Align the key and insert. Turn clockwise until the connector locks into place.
3. SYSTEM SPECIFICATIONS 3.1. RADIO CARRIER FREQUENCY 150 - 174 MHz FCC Certified OPERATING TEMPERATURE RANGE -30ºC to 60ºC -22ºF to 140ºF -26ºC to 60ºC (RSTI) -15ºF to 140ºF (RSTI)
3.2. PHYSICAL Mini Controller Unit Controller Unit Electric Remote Unit and RSTI SIZE (w/out antenna) (in) 6.4H x 3.5W x 2.6D 7.2H x 3.5W x 2.6D SIZE (w/out antenna) (in) 6.4H x 3.5W x 2.4D SIZE (w/out antenna) (cm) 16.3H x 8.9W x 6.6D 18.3H x 8.9W x 6.6D SIZE (w/out antenna)(cm) 16.3H x 8.9W x 6.1D WEIGHT (w/battery) 2.7 lbs., 1.2 kg 3 lbs., 1.4kg WEIGHT (w/battery) 2.5 lbs., 1.
(*) At the end of the 200 hours, the Electric Remote Unit can initiate 14 (2-Ohm) blasting caps connected in series and attached to 100 feet (30 meters) of 18AWG firing cable. (**) Actual charge time depends on the model of charger used, initial charge of the battery, and the condition of the battery. This estimate does not include discharge or reconditioning operations. 3.4. TIMING ARM TIME 4 ± 0.
3.6. SYSTEM IDENTIFICATION 3.6.1. Each Unit within the RFD system is marked with an identification label. 3.6.2. Figure 3-1 shows the front label for the Electric Remote and RSTI Units. Provided on this label are the Model and Serial Numbers. Also shown are the FCC and Industry Canada Certification identifiers. Depending on the radio version, the FCC ID and Industry Canada identifiers may differ from those shown (CW21678-1-V2 & 2758A-167801V2 respectively).
3.6.4. Figure 3-3 shows the identification label of the Mini Controller Unit located on the right side. The Mini Controller’s label has the unit’s Model, System, S/N (Serial Number), Frequency, and the FCC and IC (Industry Canada) certification numbers. Depending on the radio version, the FCC ID and Industry Canada identifiers may differ from those shown (CW21678-1-V2 & 2758A-167801V2 respectively). REMOTE FIRING DEVICE MINI CONTROLLER UNIT MODEL: 1678-6 SYSTEM: 0000000001 SN: 0001 FREQUENCY: 151.
4. PRE-OPERATIONAL PROCEDURES 4.1. PHYSICAL INSPECTION CAUTION Inspect all components for physical damage. Do not use any component that is damaged, suspected of being damaged, or is not able to operate as designed. The safety of the operation could be compromised. 4.1.1. Ensure the antenna / battery charger connector on the Controller and Remote Unit is not damaged. 4.1.2. Remove the antenna / battery charger connector dust cover and ensure the electrical pin area is clean and free of foreign material.
4.3. BATTERY CHARGING WITH THE 3 POSITION CHARGER 4.3.1. The battery pack in the Controller, Remote Units should be sufficiently charged before use. The 3 Position Charger will charge each unit in about 3-4 hours. It will take less time for units that are partially charged. Each 3 Position Charger has three independent charge stations. Each charge station has a CHARGE and a SLOW light. The 3 Position Charger has a single POWER light. The 3 Position Charger does not have a discharge function.
4.3.11. When rapid charging terminates, the green SLOW light will be on steady, and the CHARGE light will be turned off. 4.3.12. Rapid charging terminates when the charger detects the battery pack is charged. Rapid charging will also terminate after 4 hours, or if the battery pack’s temperature is out of range. 4.3.13. If a unit is left turned on beyond the low battery point, the battery pack may not fully charge before the 4 hour rapid charge time limit expires. In that case, charge the battery pack again.
4.4. 5 POSITION CHARGER & CONDITIONER 4.4.1. The battery pack in the Controller, Remote Units should be sufficiently charged before use. Each 5 Position Charger & Conditioner has five independent charge stations. Full charge time is about 2 hours. It will take less time for units that are partially charged. Figure 4-1 and Table 4-1 provides details of the user interface.
Table 4-1 RFD 5 Position Charger & Conditioner Figure Index No. Description Figure 2-11 1 Cooling air inlets (x2). Figure 2-11 2 System Charge Mode Indicator (yellow). Indicates the attached units will be charged only (no discharge). Figure 2-11 3 System Discharge then Charge Mode Indicator (yellow). Indicates the attached units will receive a discharge, and then a charge. Figure 2-11 4 System Discharge Mode Indicator (yellow).
4.4.5. Condition (Restore) Mode helps to rejuvenate batteries. The Condition (Restore) causes the battery to be discharged and charged repetitively until the battery has reached its maximum charge capability. The Condition (Restore) Mode is normally used to restore units from storage and to condition new batteries. The Condition (Restore) Mode is also recommended for occasional use when low capacity due to having developed a “battery memory” is suspected.
4.5.10. If a problem is detected during the charge cycle, the yellow ERROR light will illuminate. Errors are used to indicate that the battery may be outside of its charge temperature range, a faulty battery, or when an interruption to the charge process has occurred. 4.5.11. The battery must be within the temperature range 32 ºF and 104 ºF (0 to +40 ºC) for fast charging to occur. 4.5.12. Close the vent on each Remote Unit and the Controller after charging has completed.
4.6. BENCH TESTING THE SYSTEM WARNING Radio frequency energy of sufficient magnitude can cause blasting caps to detonate. 4.6.1. The System test must be conducted in an area that is at least 100 feet (30 meters) from the nearest blasting caps, wires connected to blasting caps, or other explosives. 4.6.2. All RFD System controls are described in detail in Section 2. CAUTION All units must be thoroughly tested and the batteries fully charged prior to operational use. 4.6.3.
4.6.9. Press the “ARM” switch for ½ second. The red ARMED light for each selected Remote Unit will flash on the Controller display panel for approximately 5 seconds and then come on steady. The ARMED light for each selected Remote Unit will grow brighter and then stay on steady. The Remote Units are now armed. 4.6.10. Observe the Controller and Remote Units. After the Arm Time Period expires, the Remote Units will automatically disarm. The ARMED lights at the Controller and Remote Units should turn off.
5. OPERATIONAL PROCEDURES WARNING Use of this system and its components must be restricted to personnel qualified and experienced in the field of explosives and detonating devices. Under no circumstances shall untrained personnel attempt to use this manual as a text for selfteaching. WARNING Employ standard blasting system safety standards when using this equipment with explosives. WARNING All units must be thoroughly tested and the batteries fully charged prior to operational use. 5.1.
WARNING Do not use the Controller within 100 feet (30 meters) of explosives, blasting caps, or wires leading to them. The Controller signal is 5 watts, which can cause detonation of caps if within 100 feet. The 5 watt Controller complies with the Recommended Table of Distances established by the Institute for the Makers of Explosives (IME) when placed beyond 100 feet of explosives. 5.1.5. Turn the Controller on by pressing the “ON” switch for 1 second.
5.2.5. Insert one leg of the demolition wire in each binding post and allow the binding posts to close on the wire ends. 5.2.6. Ensure the wire is held securely by the binding posts and that the wire ends are not touching the Electric Remote’s case or each other. Proceed to Section 5.2.8. 5.2.7. Install the non-electric shock tubing onto the Shock Tube Tip and mount the tip onto the RSTI according to Section 2.7.
System Safety Feature Once armed, the Remote Units must be sent a Fire command within the Arm Time Period. If the Remote Units do not receive a Fire command within the Arm Time Period, they will automatically disarm. The firing capacitor will be safely internally discharged, the binding posts will remain isolated from the firing capacitor and the binding posts will remain shunted together. 5.3.5. To arm the selected Remote Units, press the “ARM” switch.
Note: If the distance between the Controller and the Remote Units is in excess of 1 mile, the Remote Units status transmissions may not be received by the Controller. The Controller will command the Remotes from a distance greater than 1 mile, but the Remote status may not be confirmed. The Controller performs just as it would when it is within 1 mile of the Remote Units. The only difference is the method the status indications are displayed on the Controller display panel.
CAUTION Do not assume the DISARM command has been received by the Remote Unit unless disarmed status is confirmed with a steady SAFE light for that Remote Unit on the Controller display panel. If distance appears to be the problem, move closer to the Remote Unit following standard procedures for this type of situation. The “STATUS” and/or “DISARM” switches may be pressed repeatedly as the Remote Unit is approached. Maintain a safe distance from the Remote Unit.
• The Remote Unit battery is sufficiently charged to activate the firing circuit. • A DISARM command should not be assumed. 5.5.4. Ensure the area is clear. 5.5.5. Turn the Controller on. 5.5.6. Press the “STATUS” switch. The Controller will request status from all Remote Units. The red TX light will flash for approximately 5 seconds. The green SAFE light on the Controller display panel will flash for all the Remote Units that the Controller does not receive a status message from. 5.5.7.
CAUTION Do not assume the DISARM command has been received by the Remote Unit unless disarmed status is confirmed with a steady SAFE light for that Remote Unit on the Controller display panel. If distance appears to be the problem, move closer to the Remote Unit following standard procedures for this type of situation. The “STATUS” and/or “DISARM” switches may be pressed repeatedly as the Remote Unit is approached. Maintain a safe distance from the Remote Unit.
6. POST OPERATIONAL PROCEDURES 6.1. SECURING THE SYSTEM 6.1.1. Turn the Controller off and remove the Antenna Assembly. This action disables the Controller. 6.1.2. Replace the dust cover on the antenna / battery charger connector on the Controller and replace the plastic cap on the Antenna Assembly. 6.1.3. Remove the Antenna Assemblies from the Remote Units. This action turns off the Remote Units. 6.1.4.
7. BASIC TROUBLESHOOTING IN THE FIELD 7.1. REMOTE UNITS 7.1.1. ON and SAFE lights do not illuminate when the Antenna Assembly is installed. a) Check Antenna Assembly and make sure it is seated, “clicks” on to the connector. b) Recharge the battery. c) Try a different Antenna Assembly. 7.2. CONTROLLER 7.2.1. ON Light does not stay on. a) Check Antenna Assembly and make sure it is seated, “clicks” on to the connector. b) Press and hold the “ON” switch for 5 seconds.
8. OPTIMIZING RANGE 8.1.1. When power lines are in the area, the radio transmission distance is reduced. The system can operate at the following distance, when the Controller is elevated to a maximum transmission location angle to the Remote Unit location (see Figure 8-1).
8.1.2. If the Controller and Remote Unit must be placed in a position other than location in Figure 8-1, use Figure 8-2 or Figure 8-3. The minimum transmission will occur when the Controller antenna and the Remote Unit antenna are placed in the line of site. The maximum transmission occurs when the line of site lays in a path of 5 to 25 degrees above unit top plane perpendicular to the antenna.
Figure 8-3 Mini Controller Unit Elevated 1678 RFD OPERATION MANUAL 54
Figure 8-4 Antenna Radiation Pattern (All Units) 1678 RFD OPERATION MANUAL 55
9. TEST BOX The Test Box allows the user to test display system information of the Electric Remote, RSTI, and Mini Controller Units as well as perform diagnostic checks. The Test Box also serves as the programming interface between a computer and a RFD Unit. Figure 9-1 Test Box 9.1. TEST BOX OPERATION WARNING Do not touch the firing terminals of the Remote units while testing. A potentially lethal voltage is present during the Fire test. 9.1.1.
The “1678 Test Box” part of the message identifies the system types that the Test Box is designed to operate with. “01/13/2011” is the date of the Test Box firmware. “Ver 3.0” is the version of the Test Box firmware. The Test Box will automatically step to the next message “Connect Unit to Test”. Connect Unit to Test 9.1.2. Testing the Controller To test a Controller, plug the Test Box probe into the top connector on the Controller. Then press the ‘ON’ Switch while pressing the Select ‘3’ switch.
The next message displayed shows the System Number or Address (0000000001) that the Controller is assigned to and the Unit assigned to the Controller (Default is Unit 1). Address 0000000001 Unit 1 The next message displayed shows the assigned Frequency. Frequency 174 MHz The next message displayed is the Controller’s serial number (S/N), unit Type (Model) date of manufacture (DOM), firmware version (Ver). The actual message will depend on the model of Controller.
After testing is complete, the Controller’s loaded battery voltage is displayed. Battery Voltage 7.24 9.1.3. Testing the Electric Remote WARNING Do not touch the firing terminals of the Remote units while testing. A potentially lethal voltage is present during the Fire test. To test an Electric Remote, plug the Test Box probe into the top connector on the Electric Remote. The Electric Remote turns on with the yellow light fast blinking and the green light on.
The next message displayed shows the System Number or Address (0000000001) and the Unit number assigned to the Electric Remote. Address 0000000001 Unit 2 The next message displayed shows the assigned Frequency. Frequency 174 MHz The next message displayed is the Electric Remote’s serial number (S/N), unit Type (Model) date of manufacture (DOM), firmware version (Ver). S/N 00101 Type 1678-2 DOM 06/29/2010 Ver 1.0 The next message displayed is the firmware Checksum and the Fire Count.
Next the Electric Remote begins a Battery Test. Battery Test – Standby 30 The Battery Test places a load on the battery and a countdown timer is started. At the end of the test, the loaded battery voltage is displayed along with the test limit of (7.00). Loaded Battery 7.24 After testing is complete, Electric Remote’s loaded battery voltage and firing voltage are displayed. Battery Voltage 7.24 Firing Voltage 51.54 9.1.4.
Next the Test Box displays the current battery’s temperature (+22C +72F) and chemistry type (NiMH). Battery Temp +22C +72F Battery Type: 1650mAh NiMH The next message shows the battery serial number (Battery SN 0001) and the battery’s date of manufacture (Battery DOM 02/03/2011). Battery SN 0001 Battery DOM 02/03/2011 The next message displayed shows the System Number or Address (0000000001) and the Unit that the RSTI is assigned to.
Next the RSTI begins the Arm/Fire Test. The Test Box Arms the RSTI and begins 5 second countdown. RSTI Arm/Fire Test 05 At the end of the countdown, the RSTI fires resulting in the formation of a spark at the tip. The firing voltage and pass level is shown. Firing Voltage 2652 Next the RSTI begins a Battery Test. Battery Test – Standby 30 The Battery Test places a load on the battery and a countdown timer is started.
RFD Programming Guide 9.2. PROGRAMMABLE PARAMETERS 9.3. REQUIRED EQUIPMENT 9.3.1. 1678 Test Box 9.3.2. A personal computer running Microsoft Windows® 95, 98, 2000, or XP and an available USB port. 9.3.3. The software utility ‘RFD HS Terminal Utility’ located on the CD at the back of this manual. 9.4. WINDOWS CONFIGURATION SOFTWARE (RFD HS TERMINAL UTILITY) RFD HS Terminal Utility is a Windows program which allows users to log the test results from the Text Box into a PC. 9.5.
RFD Terminal Utility is now installed on the computer.
9.6. INSTALLING TEST BOX USB CABLE DRIVERS 1. Connect the USB cable from the 1678-4 RFD Test Box to a USB port on the PC. 2. If the automatic installation takes place there is no need to continue with the procedure outlined below. If the automatic installation does not find the USB drivers, browse to the RFD HS Terminal Utility install disk and then the “Rothenbuhler USB Drivers” folder. The folder contains the required drivers and the automatic installation should then be able to complete. 3.
8. Select the Rothenbuhler RFD Test Box USB Serial Convertor, and right click to open its properties.
9. Open the Advanced tab and make sure the Load VCP box is checked. It maybe necessary to disconnect and reconnect the USB cable to refresh the list. 10. Note the COM number that has been assigned to the Test Box. The COM number will be necessary when connecting to the RFD HS Terminal Utility Software. 11. Note that the COM port assigned to the Test Box may change if the USB cable is plugged into a different USB port on the computer. 12.
14. Plug in the power input jack on the top right of the Test Box. Observe the display on the Test Box. It should read “Connect Unit to Test.
15. The information from the Test Box should be displayed in the Terminal window. 9.7. USING RFD HS TERMINAL UTILITY TO TEST RFD UNITS The RFD HS Terminal Utility program may be used with the 1678-4-V2 Test Boxes for recording test results. It is also compatible with 1678-4 Test Boxes with a firmware version of 3.0 or greater. Creating a Test Results Log File: • If a log file of test results is desired, click “File” and then “Open Log File…”. The following dialog box will appear.
• Type in a file name for the log file or select an existing file to use. Click the “Open” button. • If the file already exists, the following prompt appears. • Click “Yes” to append (add to) existing data or “No” to overwrite the existing file. • A time and date stamp is added to the window.
• Notes can be added to the log file by clicking the note card icon and typing the note in the dialog box that appears. Multiple notes can be added as required. • • Connect the Test Box Probe to an Electric Remote Unit, RSTI, or Controller. If testing the Controller, place the unit in Program mode by turning the unit on while holding the select switch for #3.
• Changes to unit parameters and settings are not permitted with RFD HS Terminal Utility. Advanced user software is available which allows some system parameter changes to be made. Advanced user software permits changes to the Unit ID# and System number assignments of the Electric Remote & RSTIs as well as sleep mode settings and repeater delays. Please contact the factory to discuss your application if you feel that advanced user software may be required.
10. MAINTENANCE The units will provide optimum performance and maximum life when the following recommendations are adhered to. 10.1. SCHEDULED SERVICING It is recommended that you return your RFD System to the manufacturer or an authorized service shop every 2-3 years for service. During servicing, each unit is evaluated and adjusted to maintain optimal performance. The hardware of the unit is checked and replaced as needed.
10.3. BATTERY PACK REPLACEMENT It is recommended that the battery packs contained in each unit should be replaced every 300 charge / discharge cycles. This number can be read and displayed with the optional RFD Test Box. If a Test Box is not available, this number can be estimated by your typical usage. It is recommended that the battery pack is replaced by the factory so that the case seals can be fully tested prior to re-deployment.
4. Push the tab on the 3-wire battery connector plug and gently pull to release it from the receptacle. 5. Gently pry the battery pack from the main body. 6. Replace battery pack with the new pack. Carefully route the wires to the inside of the seal wall to prevent pinching when the case is closed. Snap the battery pack’s 3-wire plug into the connector housing. Install the cable tie as shown to ensure the battery pack does not detach under mechanical stress. Trim the excess portion of the cable tie. 7.
8. Restore the lid and screws. Tighten screws in a criss-cross pattern. Torque all screws to 10 inch-lbs. 9. Charge the battery before use. If the 5 Position Charger Conditioner is available, perform a Condition (Restore) operation to maximize the batteries useable capacity.
10.4. EXTENDED NON-USE 3 Position Charger: For optimal storage life, store units with their batteries discharged to a low battery. Several full charge/discharge cycles may be necessary before the battery’s capacity is restored to full. Units should be stored without the antennas attached. 5 Position Charger Conditioner: For optimal battery health, use the Discharge (Store) function to discharge the battery before storage. Use the Condition (Restore) function prior to use.
Revision History: Rev A, January 31, 2012: Added instruction to install and use the virtual USB Software. Rev B, March, 5, 2012: Updated Figure 2-1 and Figure 2-13 to show the new case foam and decals. Rev C, March 8, 2013: Added 1678-1-V2 Controller Unit. Made references to Controllers be more generic where possible. Updated Test Box photo and Windows RFD Terminal Utility screen captures.
