Radio Controls

Making a
Reliable
Connection
Presented by:

Sponsored by:

Norm Davis

Business Development Manager

Magnetek, Inc.

2014 MHI
Copyright claimed as to audiovisual works of seminar sessions and
sound recordings of seminar sessions. All rights reserved.

Electrification and Controls Manufacturers

Association

What is ECMA?
Group of the industrys leading suppliers of
electrification and controlling devices for
material handling equipment, particularly
overhead cranes and hoists.

Mission Statement
Develop and promote the standards for
electrification and control products that
enhance the safe operation and reliability
of material handling equipment.
Educate the end-user community on the
application of these current and emerging
technologies.

Electrification & Controlling Devices

Radio remote controls
Adjustable frequency
drives
Festoon systems
Pushbutton pendants
Conductor bar
Feedback devices
Programmable logic
controllers

Motors
Collision-avoidance
Weigh systems
Industrial brakes
Resistors
Cable
Disconnects
Protective devices

Association Goals
Create a formal liaison with other
organizations

CMAA Crane Manufacturers Association of America

HMI Hoist Manufacturers Institute
MMA Monorail Manufacturers Association
AIST Association for Iron and Steel Technology

Develop and promote standard

nomenclature and a code of ethics in the
industry

Association Goals
Prepare and distribute educational
materials
Develop and promote codes, standards,
and safety/training materials
Work with private and government groups
to establish standards and/or safety codes
pertinent to the ECMA product section

Association Goals
Offer annual scholarships through The
Material Handling Education Foundation,
Inc.
2012/2013 Winner: Merv Olson, Ph.D.
student at University of Wisconsin-Madison
majoring in Industrial & Systems Management
with a concentration in Supply Chain &
Logistics

ECMA Membership Benefits

Industry information

Access to industry expertise within MHI

Participate in MHI directed market research studies
Benefit from industry research projects led by MHI
Participate in statistical and marketing programs

Standards development
ANSI ECMA 15: 2010 Specification for Cable-less Controls
ANSI ECMA 25: Specification for Adjustable Frequency Drives
(in process)
Ongoing standards development for the industry

ECMA Membership Benefits

Education & professional development
Gain access to MHI library of published resources
Participate in Professional Development and Educational
Seminars available at semi-annual meetings
Access educational leaders through CIC-MHE member institutions

Networking and planning

Meet with industry leaders and peers at semi-annual meetings
Participate in round table discussions
Participate with compatible material handling companies that often
lead to joint installation programs

Current Member Companies

Join ECMA
www.mhi.org/industrygroups/ecma
Semi-annual meetings
April Charlotte, NC
September/October Location varies

Attendance is required at 1 of 2 meetings each year

First year dues at a reduced rate
PE continuing education credits

Attend your first meeting as a guest of ECMA!

Radio Controls
Making
a Reliable
Connection

Presentation Goal
Help make your operations safer, more
productive and less costly by the reliable
use of radio controls.
Learn the key factors to consider when
planning, installing maintaining radio
controls.

Building Blocks

Benefits of radio controls

Frequency ranges pros & cons
Frequency management best practices
Product designs
Application requirements
Installation best practices

Radio Control

Benefitting from Radio Controls

Feature

Benefit

Radio controls allow the

operator more mobility
than a wired pendant or
crane cab.

Operators visibility is
increased
Workplace safety is
increased
Efficiency is increased

Benefitting from Radio Controls

Feature

Benefit

Radio controls allow the

operator to use more
vantage points
throughout the lift.

Operators not dependent

on others to relay
information to operator,
reducing the chance of a
miscommunication
Workplace safety is
increased
Efficiency is increased

Benefitting from Radio Controls

Feature

Benefit

A spare radio transmitter

can be put into operation
in less time than it takes
to rewire a pendant or
repair cab controls.

Downtime is kept to a
minimum and saves
money

Benefitting from Radio Controls

Feature

Benefit

Radio systems can cost

less than the control
festooning, cabling and
pendant required to
achieve the same
controls.

Money saved by keeping

maintenance / installation
costs at a minimum.

Key Factors for Reliable Radio

Operation

Frequency
Design
Application
Installation

Making a Reliable Connection

FREQUENCY

Frequency

Frequency Considerations
Licensed / Unlicensed
Frequency range
Frequency management

Part 15 - Unlicensed
Advantages

Disadvantages

No FCC coordination to
obtain licenses
No FCC fees for
maintaining licenses
Field selectable channels
Readily available
High data throughput

Low power / shorter

distances
Competition with other
unlicensed products in
same frequency range

Part 90 - Licensed
Advantages

Disadvantages

High power / longer

distances
You own the frequency
for a geographic area
Can be on air
continuously

Must coordinate receipt

and maintain licensed
frequency from FCC with
yearly fees
Low data throughput
No field select ability

Licensed or Unlicensed
Unlicensed / FCC Part 15

Licensed / FCC Part 90

Frequency ranges

Frequency ranges

430-440 MHz
902-928 MHz
2.4 GHz

On air time low

Bursts

72-76 MHz (VHF)

450-470 MHz (UHF)

On air time can be high

Bursts
Continuous

Messaging Styles
On air usage
Continuous

Bursts

Frequency Management
Planned prevention to minimize disruptive
interference between wireless equipment
in order to maximize reliability.

Frequency Management
Ambient Noise

Single Frequency

Frequency Management
Disruptive Interference

Well Spaced Frequencies

Frequency Management
Check to see if your company has a
frequency management group
Consider a site survey to identify available
frequency ranges
Plan ahead to maximize reliability
Maintain accurate records of what
frequencies are used where in your facility

Making a Reliable Connection

DESIGN

Design Aspects

Housing style
Input types
Output types
Environmental ratings
Ergonomics

Housing Styles
Bellybox

Handheld

Transmitter Design
Input types

Output types

Pushbutton
Lever
Toggle
Rotary potentiometer
Selector switch
Key switch
Code plug

Display
LED
Audible
Haptics

Environmental Ratings
NEMA
IP
Hazardous location
NEC
Class
Division
Group

Temperature ratings

Ergonomics

Crane class / duty cycle

Button versus lever
Operator fatigue
Transmitter layout
Operator comprehension

Making a Reliable Connection

APPLICATION

Application

Number of controls
Speed control
Crane class / duty cycle
Environment
Distance
Feedback

Number of controls
Ensure the transmitter can accommodate
all crane controls
Choose a transmitter housing that can
clearly indicate all crane operations
Consider required physical motions from
an operator viewpoint

Speed and Class

Speed control
Make sure the transmitters input types can
match the required outputs from the receiver

Crane class / duty cycle

Select a transmitter that is consistent with
expected crane use

Environmental
Be sure to pick products whose ratings
meet or exceed your applications
requirements
Water sealing
Dust sealing
Hazardous location
Temperature rating

Distance and Feedback

Distance
Select a frequency that is capable of
operating at the maximum expected range

Feedback
Select a frequency and design that provides
required features

Making a Reliable Connection

INSTALLATION

Installation Best Practices

Antenna location
Antenna mounting
Cable routing
Receiver location
Receiver wiring

Antenna Location
Maximize line of sight between transmitter
and antenna
Clear of obstacles through full range of
motion
Locate antennas as far as possible from
sources of radio frequency interference
(RFI)

RFI Sources
RFI is generated by inductance. Inductance
can occur where strong electromagnetic
fields are present.
High amperage lines
Welders
Variable frequency drives
Motors

Antenna Mounting
Maximize surface area towards transmitter
Provide a good ground plane

Antenna Cable Routing

Avoid sources of RFI / inductive noise

Do not run alongside high amperage lines
Do not use more than is needed
Coiled extra cable is exceptionally
susceptible to inductive noise
Minimize flex points

External Receiver
External mounting for receivers
with internal antenna or
external antenna mounted
directly to the receiver
Follow guidelines
for antennas grounding should
be handled by receiver

Internal Receiver
For receivers mounted inside of a steel
enclosure
Must install a remote antenna
Follow antenna cable routing guidelines
Install inside separate enclosure when
installed by high RFI sources

Receiver Wiring
Treat wires routed to receivers like
antenna cables
Snubber are installed across
inductive loads that are wired
directly to the receiver

Radio Control Manufacturers

This presentation covers general content and
typical situations
Atypical situations abound and should be
addressed as required
Consult with the manufacturer of the products
that you use or are planning to use to ensure
proper installation and operation

Questions?

For More Information:

ECMA
www.mhi.org/industrygroups/ecma
Managing Executive
Carmen Murphy
cmurphy@mhi.org