HETRONIC Nova-M-K Operator's Manual

Operator Manual Hetronic USA 4300 Highline Blvd., Bldg. A Oklahoma City, OK 73108 405-946-3574 Fax 405-946-3564 OPMN_ENG_0001.1 2/04 www.hetronic.com Hetronic Canada 45 Sinclair Avenue Halton Hills, Ontario L7G 4X4 +1-800-816-4459 Fax +1-905-702-0501 © 2004 Hetronic, Inc. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written permission of Hetronic. Engineered Systems Nova-M-K Nova-L-K Nova-XL-K GL-K GL-3-K GR-K

The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Production and System Numbers . . . . . . . . . . 3 Unauthorized Replacement Parts . . . . . . . . . . 3 Before Attempting to Operate This System . . . 3 Hetronic System Components . . . . . . . . . . . . . 4 Receiver Standard Features . . . . . . . . . . . 4 Transmitter Types . . . . . . . . . . . . . . . . . . . 4 Transmitter Standard Features . . . . . . . . . 4 System Overview. . . . . . . . . . . . . . . . . . . . . . . 4 Theory of Operation . . . . . . . . . . . . . . . . . 4 E-Stop Function. . . . . . . . . . . . . . . . . . . . . 4 Transmitter Sleep Mode . . . . . . . . . . . . . . 4 Receiver Safe Mode . . . . . . . . . . . . . . . . . 4 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Practices and Laws . . . . . . . . . . . . . . . . . . . . . 5 Required Operator Training . . . . . . . . . . . . . . . 5 Possible Sources of Danger . . . . . . . . . . . . . . 5 Operation and Work Area Safety. . . . . . . . . . . 5 Protective Features . . . . . . . . . . . . . . . . . . . . . 5 To Stop In An Emergency . . . . . . . . . . . . . . . . 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Receiver Installation . . . . . . . . . . . . . . . . . . . . . . 6 Receiver Components . . . . . . . . . . . . . . . . . . . 6 Receiver Location . . . . . . . . . . . . . . . . . . . . . . 7 Mounting the Receiver. . . . . . . . . . . . . . . . . . . 6 Car Antenna Installation . . . . . . . . . . . . . . 9 GainFlex Antenna Installation . . . . . . . . . . 9 Connect Electrical Wiring. . . . . . . . . . . . . . . . 10 Hetronic Transmitters . . . . . . . . . . . . . . . . . . . . 10 NOVA Transmitters . . . . . . . . . . . . . . . . . . . . 11 GL Transmitters . . . . . . . . . . . . . . . . . . . . . . . 12 GR Transmitter . . . . . . . . . . . . . . . . . . . . . . . 14 Frequency and Address Settings. . . . . . . . . . 15 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 16 Test the Receiver . . . . . . . . . . . . . . . . . . . . . . 16 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Holding the Transmitter . . . . . . . . . . . . . . . . . 17 Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . 17 Start-Up Procedure . . . . . . . . . . . . . . . . . . . . 17 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . 18 Safe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Joysticks or Paddle Levers . . . . . . . . . . . . . . 18 Option Controls . . . . . . . . . . . . . . . . . . . . . . . 18 Transmitter Shutdown . . . . . . . . . . . . . . . . . . 18 Optical Displays and Acoustic Signals. . . . . . 18 Transmitter Options . . . . . . . . . . . . . . . . . . . . 19 Back-Up Transmitter . . . . . . . . . . . . . . . . 19 Address Plugs . . . . . . . . . . . . . . . . . . . . . 19 Optical Low Battery Indicator. . . . . . . . . . 19 Advanced Low Battery Indication . . . . . . 19 Feedback. . . . . . . . . . . . . . . . . . . . . . . . . 19 RF Booster . . . . . . . . . . . . . . . . . . . . . . . 19 Priority Transmitter . . . . . . . . . . . . . . . . . 19 RF Units. . . . . . . . . . . . . . . . . . . . . . . . . . 19 Crane/Machine Control Multiple Transmitters 19 Pitch and Catch . . . . . . . . . . . . . . . . . . . . 19 Indep./Combined Crane/Machine Control 19 Universal Transmitter . . . . . . . . . . . . . . . 20 Optional Safety Features . . . . . . . . . . . . . . . . 20 PTO Safety Switch . . . . . . . . . . . . . . . . . 20 LTO Joystick . . . . . . . . . . . . . . . . . . . . . . 20 LTO Toggle Switch. . . . . . . . . . . . . . . . . . 20 Tilt Sensor Switch . . . . . . . . . . . . . . . . . . 20 Range Limitation . . . . . . . . . . . . . . . . . . . 20 Interlocking Functions . . . . . . . . . . . . . . . 20 Magnet Switch. . . . . . . . . . . . . . . . . . . . . 20 Corrosion Protection . . . . . . . . . . . . . . . . 20 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Battery Charging System. . . . . . . . . . . . . . . . 21 Features . . . . . . . . . . . . . . . . . . . . . . . . . 21 The Battery Charger . . . . . . . . . . . . . . . . 21 Battery Charger Technical Specs . . . . . . 21 LED Description. . . . . . . . . . . . . . . . . . . . 21 Charging the Battery . . . . . . . . . . . . . . . . 22 Fast Charge. . . . . . . . . . . . . . . . . . . . . . . 22 Hetronic Battery Information . . . . . . . . . . 22 Battery Technical Specs . . . . . . . . . . . . . 22 Changing the Battery. . . . . . . . . . . . . . . . 22 Battery Disposal. . . . . . . . . . . . . . . . . . . . . . . 22 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 23 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Installation / Safety Data Sheet . . . . . . . . . . . . . 27 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 AWG - Metric Conversion Chart . . . . . . . . . . . . 28 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Frequency Chart CS 458 . . . . . . . . . . . . . . . . . . 30 Frequency Chart CS 447 . . . . . . . . . . . . . . . . . . 31 Frequency Chart CS 434 . . . . . . . . . . . . . . . . . . 32 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 TABLE OF CONTENTS

control system. Hetronic radio remote controls are the highest caliber in remote control value, performance and safety. Hetronic radio remote controls use the latest frequency synthesizer technology to eliminate the problems typically associated with radio remote control systems. The Hetronic radio remote control system includes a transmitter and a receiver. These systems operate over the 400-470 MHz radio band range (70 cm band) and are FCC approved. The transmitter generates the electronic signal that communicates with the receiver. The transmitter and receiver are set with identical address codes and frequency channels. This allows operation of multiple systems within the same area without signal interference. THE MANUAL Before operation of the crane/machine and remote control system, read your manuals carefully and completely. The contents of this manual will provide you with an understanding of safety instructions and controls during normal operation and maintenance. PRODUCTION AND SYSTEM NUMBERS When contacting your dealer or Hetronic about service, repair or replacement parts, know the Production and System numbers of the transmitter and receiver. The numbers are located on the label that is affixed to the unit itself. Record the Production and System numbers here: UNAUTHORIZED REPLACEMENT PARTS Use only Hetronic replacement parts. The replacement of any part with anything other than a Hetronic authorized replacement part may adversely affect the performance, durability, and safety of this system and may void the warranty. Hetronic disclaims liability for any claims or damages, whether warranty, property damage, personal injury or death arising out of the use of unauthorized replacement parts. BEFORE ATTEMPTING TO OPERATE THIS SYSTEM: 1. Make sure all installation has been properly completed. 2. Understand all Safety Precautions provided in the manuals. 3. Review control functions and operation of the crane/machine and this radio remote control system. 4. Surge suppressors (RC type only) must be used when the receiver is controlling magnetic contactors. 5. When not in use, turn the transmitter off and store in a safe place to prevent unauthorized use. 6. If the crane/machine does not respond properly, stop operation immediately. Turn off the transmitter and report the condition to the appropriate technician or supervisor. 7. Turn off the transmitter key switch and remove the battery before any maintenance work is done. 8. Turn off the transmitter key switch when changing the battery or taking a break. 9. Always have a battery in the battery charger to ensure the availability of a fully charged battery. 10. Installation, setup and service must be performed by authorized personnel only. 11. Use only Hetronic spare parts. 1 2 3 5 4 1. Specific approvals such as BTZ, FCC, CE, etc. 2. The type of transmitter or receiver. 3. Frequency and RF unit. 4. Production Number - The first digit indicates the manufacturing facility (1=H-Germany, 2=H-Malta, 3=H-US, 4=H-International). The next four digits are the production month and year. The last 6 digits are the manufacturing number. 5. System Number - Eleven digit system identification number. Transmitter and receiver must match. Transmitter Production Number Receiver Production Number System Number INTRODUCTION

The Hetronic radio remote control system consists of a receiver and transmitter. Each system is designed to customer specifications. Some systems contain multiple receivers and transmitters. Receiver Standard Features Start relay, horn relay, E-Stop relay, and option relay • Up to 32 digital outputs • Up to 8 proportional channels (0 to 10V, 0 to 20 mA, etc.) • Self-diagnostics • 48 V, 115 V or 230 V for AC cranes/machines • 12VDC or 24VDC for DC cranes/machines Transmitter Types • Nova-M belly box • Nova-L belly box • Nova-XL belly box • GL belly box • GL-3 belly box • GR belly box Transmitter Standard Features • E-stop • Sleep mode • Removable key • 100 m (300 ft.) range • Internal antenna • Start/Horn pushbutton • Carrying belt or shoulder strap SYSTEM OVERVIEW Theory of Operation The Hetronic radio remote control system includes a transmitter and receiver. The transmitter electronically generates a carrier frequency which allows it to communicate with the receiver. Each system is programmed with a unique address code. This code allows the operation of multiple systems in the same general vicinity. The receiver only accepts commands from the transmitter with the same address code. NOTE: The receiver and transmitter have the address code set at the factory. E-Stop Function The most important feature of the radio remote control system is the E-Stop. The transmitter sends the E-stop status signal along with the specified crane/machine function. This method confirms that ongoing operations are safe. If the E-stop pushbutton is pressed, the relay module in the receiver causes all crane/machine motions to stop. The receiver goes into Safe mode. To restart the system, disengage the E-stop button and press the Start/Horn button. The E-Stop responds faster than any other function. When E-Stop is engaged, the system ignores any other signal that is transmitted. The problem must be corrected before the system will respond to any other signal. The E-Stop is self-monitoring and redundant in the transmitter and receiver. The system performs a self-test to ensure the E-Stop circuit is working properly. If an error is detected, the system automatically goes into Safe mode. When the transmitter is turned on, it performs a self-test to be sure that communications are within designated parameters. If an error is detected, the transmitter will not transmit any signals. Transmitter Sleep Mode The transmitter sleep mode is designed to prevent accidental operation. If the transmitter is not used for 10 minutes, it turns itself off. The controls are not operational while the transmitter is turned off. To restart the transmitter, turn the key switch off and then back on, and press the Start/Horn button. The sleep mode can be enabled or disabled by the operator. IMPORTANT: If the transmitter has a selector switch or latching pushbutton that is engaged, the sleep mode will not occur. The engaged selector switch or latched pushbutton is constantly sending a signal to the receiver. Receiver Safe Mode The following conditions cause the receiver to go into its Safe mode: • The transmitter goes into Sleep Mode • Radio signal interference • Transmitter out of operating range • E-Stop button is activated • E-Stop circuit failure • Low battery sends E-stop after time out When the transmitter signal is no longer sensed by the receiver, the Time Out process begins. The Time Out period is set to 450 msec at the factory. If the receiver does not establish contact with the transmitter within that time period, it goes into the Safe Mode. In Safe Mode, the receiver shuts off power to the output modules and activates the E-stop function. To restart the system, be sure the transmitter signal is active and sensed by the receiver. Then press the Start/Horn pushbutton.

important safety precautions. They mean: Attention! Personal Safety Is Involved! Become Alert! Obey The Message! The safety alert symbol is used in decals on the unit and with proper operation procedures in this manual. Understand the safety message. It contains important information about personal safety on or near the unit. NOTATIONS NOTE: General reference information for proper operation and maintenance practices. IMPORTANT: Specific procedures or information required to prevent damage to unit or equipment. PRACTICES AND LAWS Practice usual and customary safe working precautions, for the benefit of yourself and others. Understand and follow all safety messages. Be alert to unsafe conditions and the possibility of minor, moderate, or serious injury or death. Learn applicable rules and laws in your area. REQUIRED OPERATOR TRAINING Original purchaser of this unit was instructed by the seller on safe and proper operation. If unit is to be used by someone other than original purchaser; loaned, rented or sold, ALWAYS provide this manual and any needed safety training before operation. ALWAYS review the operator’s manual of any crane/machine to be controlled by radio remote control. POSSIBLE SOURCES OF DANGER This system makes remote control via radio signals possible. The transmission of control commands can take place around obstacles and out of the operator’s direct sight. To prevent accidental start-up and possible injury or damage: 1. Always engage the E-stop button and switch "OFF" the transmitter when it is not in use. Remove the key if the unit is placed any distance away from the operator. 2. Disconnect the power supply before any assembly, maintenance or repair work is done. 3. Never remove or alter any of the safety features of this system. OPERATION AND WORK AREA SAFETY The work area must be free from obstacles, debris or other tripping hazards. Avoid uneven work areas and any rough terrain. Always be sure of your footing. Be aware of overhead obstacles that may interfere with crane/machine operation. Always operate the transmitter with its carrying belt or shoulder strap. PROTECTIVE FEATURES This radio remote control system is equipped with electronic and mechanical safety features. Processing control signals transmitted from other transmitters is not possible, since transmission coding is unique to each system. These safety features help protect the operator, as well as others within the work area. The crane/machine functions can be stopped by pushing the emergency stop button on the transmitter control panel (EMERGENCY STOP). NOTE: The receiver goes into the Safe mode within approximately 0.5 seconds (450 ms) after the transmitter switch is turned to the "OFF" position. TO STOP IN AN EMERGENCY 1. Press the red "EMERGENCY STOP" pushbutton. 2. Turn the key to "OFF". 3. Wait for all moving crane/machine parts to stop. 4. Refer to crane/machine’s operator manual for further instructions. SAFETY DANGER: IMMINENTLY HAZARDOUS SITUATION! If not avoided, WILL RESULT in death or serious injury. WARNING: POTENTIALLY HAZARDOUS SITUATION! If not avoided, COULD RESULT in death or serious injury. CAUTION: POTENTIALLY HAZARDOUS SITUATION! If not avoided, MAY RESULT in minor or moderate injury. It may also be used to alert against unsafe practices. WARNING: Accidental start-up can cause serious injury or death. NEVER remove or modify any safety feature.