HBtreeioniia SS Operating Instructions Original Operating Instructions — [aliiomatic ceS> Table of Contents Safety Instructions Intended Use ‘Safety Instructions for Installation and Operation Installation of the Radio Receiver Installation with Snap-In Wall Bracket Installation with integrated Mounting Loops Installation with Mounting Loops Electrical Connection Control Display Module focus C/D/T (Option) Technical Data Dimensions Receiver Housing HR268 Receiver Housing HR270 (Aluminum) and HR272 (Plastic) Connection Options Troubleshooting Maintenance Attachments: Frequency list for EU member states, EFTA states, and Turkey, EC Declaration of conformity, system specific views, circuit diagrams and /or output wiring Pictographs (Za) Danser due to electrical voltage. Touching live parts Inside the unit can be fatal or cause serious injuries. {JQ} Instructions for occupational health and safety. Not following these instructions can cause IAN) accidents, which can cause damage, serious injuries or even death | Important information about the operation ofthe radio system Manufacturer: Necrradornatic GmbH + Haller Strate 45 ~ 83 + 74584 Crallaheim + Germany + Tal. +49 7951 263-0 «info@radiomalc.com, HeGvadiomatie GmbN is ot Hable or any maprinis or erora! ~ Specifications and design subject to change without notice ‘®vadlomais and radiobue ara registered German vademark. 8 241 2012, HBC radiomatic GmbH, 74504 Craeheim, Germany No part of tha document ay be reproduced In’ any manner whatsoever without the expressed writen permission of Nactradiomatie GrbAS Read through these operating instructions carefully before working with the radio system. This applies in particular to the installation, commissioning and maintenance of the radio system. ‘The operating instructions are a constituent part of the radio control system and must always be kept close at hand for the responsible personnel. The term ‘machine’ is used in the operating instructions for the different possible uses of the radio system Intended Use + The radio system serves to control machines and for data transfer. Observe the job safety and accident prevention regulations applicable to each application + The intended use also includes reading the operating instructions and adhering to all safety information contained therein. + The radio system must not be used in areas where there is a risk of explosion, nor for the control of machines used to convey persons, unless it is explicitly approved by the manufacturer for these uses. + Modifications to the radio system may only be carried out by specialist personnel who have been trained and authorized by HBC-radiomatic. All modifications must be documented at the factory in the radio control master file + The radio control system safety devices must not be modified, removed or bypassed. In particular, modifications to any part of the radio system's complete E-STOP system are impermissible. Safety Instructions for Installation and Operation + The electrical connection per the accompanying output wiring diagram must be established by @ qualified electrician exclusively, + The receiver may only be opened by trained personnel. Components inside the receiver can be energized at life-threatening voltages. The supply voltage for the machine must be deactivated before the receiver is opened + Please also note with radio systems, that the presence of persons in the danger zone - in particular beneath the load (cranes!) - Is prohibited in every instance, + Select a safe location for radio control, from which you have a good and complete view of the working movements of the machine, the load movements and the surrounding working conditions. ‘+ [tis not permissible to put a radio transmitter unattended to one side whilst activated. Always switch the radio transmitter off when it is not required. This applios in particular if you change location, when working without radio control, during breaks and at the end of work. Always safeguard the radio transmitter against use by unauthorized persons, for example by locking it away. + In the event of an emergency and with all faults, switch the radio transmitter off immediately by pressing the STOP switch. + Only operate the radio system when it is in perfect working order. Faults and defects that could influence safety must be rectified before the system is put back into operation, by specialists who have been trained and authorized by HBC-radiomatic. + Note that the operational directions of the operating elements may appear inverted depending on location and viewing angle to the machino. This applies in particular to rotary cranes, if your location changes from inside to outside the radius of the crane. The operator must make himself familiar with the directional markings on the machine before the start of work. + Repairs may only be carried out by specialist personnel who have been trained and authorized by HBC-radiomatic. Use original replacement parts and accessories (0.9. rechargeable batteries) exclusively; otherwise it is possible that the equipment safety can no longer be guaranteed and our extended warranty will be voided. + Remain vigilant when working with the radio system and familiarize yourself with its functions. This applies in particular if you are working with it for the first time or if you work with it only occasionally.S Installation of the Radio Receiver + The receiver should be mounted vertically with the cable connection downwards. + Ensure that there are no metal parts within a radius of 1 m (3 feet) above the receiver. ‘+ When the receiver has to be mounted into a control cabinet, an offset antenna must be installed + Receivers with external antenna must be installed in such a way that the antenna stands freely and does not touch walls or metal parts. Otherwise an offset antenna must be used, which can bo supplied if necessary, + Receivers with plastic housing should be protected against direct sunlight (UV radiation) with appropriate measures. Minimum distance to metal parts 1 m Illustrations exemplary Installation with Snap-In Wall Bracket The receiver is mounted with the snap-in wall bracket provided. Fix the wall bracket in place via the holes provided. Only use screws (max. M6) which are sultable for the installation location. Receiver Housing HR145 (FSE 508, FSE 500) Push the receiver with the mounting device © from the top into the wall bracket and press the receiver downwards until it clicks into place. For removing the receiver, press the release device @ downwards and pull the receiver upwards out of the wall bracket.S Receiver Housing HR165, (FSE 510, FSE 911, FSE 512) Place the receiver with the eyelets on the wall bracket pins and press it on the wall bracket until it clicks into place, Press the engagement pins outwards with a large screwdriver, to remove the receiver from the wall brackat. This releases the receiver off the wall bracket from where it can be removed to the front. Installation with integrated Mounting Loops (FSE 516 with housing HR268, FSE 726/727 radiobus”) The receiver is installed via the integrated mounting loops on the receiver sides. Use the shock mounts’ provided for installation to dampen any vibrations that may occur. Installation with Mounting Loops (FSE 516 with housing HR270 or HR272, FSE 524, FSE 736/737/776/777 radiobus®) The receiver is installed via the provided mounting loops. Use the shock mounts provided for installation to dampen any vibrations that may occur. A detailed installation guide Is enclosed with the delivery.S Electrical Connection Depending on the version the radio receiver is connected either via a cable gland or with a Harting plug connection to the machine electrics. Please observe that the receiver may only be connected to the supply voltage indicated on the type plate! A Warning ~ shock hazard! ‘+The electrical connection may only be carried out by skilled personnel. ‘+ The electrical connection must comply with the enclosed wiring diagram. ‘+ Switch off the supply voltage before opening the receiver. There is a risk of fatality from touching live parts inside the housing! Control Display ‘The control display with LEDs indicating the operating state of the radio system is located behind the inspection window of the receiver cover lid The LEDs have the following significance: On (yellow) illuminates as soon as operating voltage is present at the receiver, i.e. the connection to the electronic of the machine is established and operating voltage (12 V) is present. RF (red) illuminates whenever the transmitter is switched off. It will be extinguished the very moment a signal is received by the receiver on its radio frequency. Si 1 (green) illuminates after the transmitter is switched on, i.e. the receiver has identified its specific transmitter on the basis of the common message address (code). Safety circuit Si 1 is enabled. Si 2 (green) refers to the internal safety circuit Si 2, responsible for a double switching off of the move ‘commands whenever the control station is in the off (zero) position, i.e. "Si 2" will not illuminate. It is not until one or several drive commands (e.g. turn, trolley traveling, lifting gear or crane traveling) are input that the "Si 2" LED may illuminate! Available for FSE 510, FSE 511, FSE 816, FSE 624, FSE 726/727/736/737/776/777 radiobus”: Feedback (yellow) illuminates whenever the receiver is sending a feedback telegram to the transmitter.S Module focus C/D/T (Option) focus C When several cranes are operated in tandem operation, a safe communication between the cranes is crucial. |. For example, one crane reaches the limit switch and is stopped automatically, the other crane has to be stopped as well in order to prevent dangerous situations. focus C ensures a smooth crane communication in tandem operation. Using a CAN interface saves a great amount of wiring effort and thus valuable time! focus D ‘As an external RF module with DECT interface, focus D ensures an optimal radio connection, even Under difficult circumstances. focus T As an external RF module, focus T offers a perfectly working radio connection, even under difficult circumstances over a great distance. Depending on the working situation, up to 15 modules can be installed in different positions. As additional radio receivers, they receive all commands from the radio transmitter and relay it to the central receiver. There, they are analyzed and sent to the machine as, output commands. Obstacles in the radio path can thus be efficiently avoided and even long distances can be bridged witti focus T can be combined with all HBC receivers of the radiobus” generation. Installation ‘+ Mount the module with 4 screws (M 5) via the provided drill holes (refer to chapter Dimensions) + Do not install the module into a niche or a control cabinet. ‘+ Ensure that there are no metal parts within a radius of 1 m (3 feet) above the module base, Electrical Connection The module is connected to a radio receiver via a 5-pin circular connector. Please observe that the module may only be connected to the supply voltage indicated on the type plate! [AA] Warning - shock hazard + The electrical connection may only be carried out by skilled personnel, ‘+ The electrical connection must comply with the enclosed wiring diagram.S Control LED ‘A dual LED is located next to the cable connection in the module base. ‘+ The LED illuminates red as soon as operating voltage is present at the module. The connection to the radio receiver is established and the internal operating voltage (10 ~ 30 V) is present. ‘+ The LED illuminates green when the transmitter is switched on and the module receives a valid signal on its radio frequency. Dimensions 143 mn (563°), Far 101 mm (2987) 253m(0244Technical Data Max. number of control commands 76 digital + 1 analog + E-STOP + infrared relay Unique system addresses ‘Over 1.000.000 combinations Supply voltage 24-48 VAC (see type plate) 42 ~ 240 VAC Power consumption 4—14W Digital inputs 4 via optocoupler Analog inputs 4 (0-10 Vor 4-20 mA/V24) Serial interface CANopen E-STOP resp, Sit, Si2 control unit _| 1 x E-STOP output, 2 relays 4 A Safety function E-STOP: Performance Level d, category 3 according to EN ISO 13849-1:2008 Frequency ranges 308 — 338 MHz, 405 — 475 MHz", 865 — 870 MHz, 902 ~ 928 MHz, 1210 ~ 1258 MHz’ 2402 - 2480 MHz DECT: 1790 - 1930 MHz * Not all frequency ranges available. Channel spacing 12,5 / 20/251 50 / 250 kHz 2.4 GHz: 1 MHz DECT: 1,728 MHz Connection possibilities Cable gland: HR 268 (metric M20/25) HR 270 / 272 (metric M20/32) Option: HR 270 / 272 (Harting Han 32) ‘Antenna Internal Option: external, FL 30 or FL 70 Option: car antenna with § m cable and BNC connector Internal (option DECT) focus D (option DECT) Operating temperature range “25 °C... #70 °C (-13 °F ... +158 F) Hazardous areas zone 2: -20 °C ... #60 °C (-4 °F. #140°F) Housing material Plastic Option: aluminum Dimensions 269 x 202 x 60 mm (8.0 x 10.6 x 2.4") (HR268) 270 x 160 x 115 mm (10.6 x 6.3 x 4.5 ") (HR270 and HR272) Weight ca. 1.3 kg (HR268) a, 2.0 kg (HR272) a. 3.5 kg (HR270) Protection class IP 65S Dimensions Receiver Housing HR268 (FSE 516) 65mm (0.26") 170 mm (669°) 269 mm (10.59 ") I + Height of housing: ‘60 mm (2.36 ")Receiver Housing HR270 (Aluminum) and HR272 (Plastic) (FSE 516, FSE 524, FSE 736/737 radiobus®) 115mm (0.45 ") QD ©)F 20mm (0.79) 240 mm (8.27 270 mm (10.63. 28,5 mm (033°) 7 © © 160 mm (6.30. 1190 mm (7.48, 210 mm (827°) 125 mm (4.92)S Connection Options Harting Plug Connections FSE 510, FSE 611, FSE 612 FSE 516, FSE 524, FSE 726/727/736/737/7761777 radiobus® ec] EQ 96 mm (3.77 " Metric Cable Glands FSE 510, FSE 511, FSE 512, FSE 516 FSE $24, FSE 726/727/736/737 radiobus® a ELL gs g¢ Es fm Eg 4100 mm (3.94") PG Cable Gland FSE 508, FSE 509 77 mm (3.03"S Troubleshooting re) Note: LL) Please check the functions using the cabin or cable controls first! Problem. Possible Cause Measures Transmitter does not react when switched on, No power. Check battery contacts for damage or contamination. Insert a fully charged battery into the battery compartment, Recharge battery Low-power indication after ‘minimal operating time. Battery contacts are contaminated or damaged. Battery not charged. Battery defective. Check battery contacts for damage or contamination Recharge battery. Ensure that recharging process runs correctly. Check transmitter functions using a fully charged or replacement battery. ‘Some commands are not carried out. Receiver defective. Interruption in the connecting cable to the Check if all connecting cables and cable junctions are tight. If none of the measures mentioned resolve the problem, then please contact your service technician, dealer or HBC-radiomatic GmbH.S Maintenance ‘The radio control system is virtually maintenance-free. Please observe the following points: + Never use a high pressure cleaner or sharp or pointed objects to clean the receiver. + Whenever welding the machine: = Switch off the radio control system. Switch off the machine. = Disconnect all electrical connections to the receiver. Otherwise the receiver electronics can be destroyed, In the Event of a Fault Warning: Never operate a machine with a faulty or defective radio control system! ‘+ Never try to repair the electronics of the radio control system! Opening the transmitter or receiver housing terminates the manufacturer guarantee. = Send any defective or faulty equipment to your local distributor or to the manufacturer. They are experts and have the necessary know-how and OEM spare parts, - Always send in the complete radio system (transmitter, receiver, batteries, battery charger, connection cables, and other equipment) and attach a detailed fault description = Do not forget to enclose your address and telephone number so that we can get in touch with you quickly if necessary. + To avoid damage during transport, use the original packing supplied with the radio control system, otherwise pack securely. Send the consignment to your distributor or to the following address: HBC-radiomatic GmbH Haller Str. 45 ~ 53 74564 Crailsheim, Germany Phone: +49 7951 393-0 Fax: +49 7951 393-50 E-Mail: info@radiomatic.com + If you wish to bring a defective radio system to your distributor or the factory by yourself, we kindly ask you to make an appointment in advance. For an overview of our worldwide service and sales contact: www.hbe-radiomatic.com under "Contact". please visit our websiIPEJ-OBH © ‘96ueY9 0} 199[qNs ubIsap pue suonedyloods e1eid adh} Axeiduioxg Fa TRIRT RT DAT TAF aura vgn oom ogo fen = FPP PPL rE = Sea xn tea x xan eae gna er rrr ele osu ey ~ ono | pire veais eee eae ee ee ee ae tie ober girs reiterate rte oer ella aos eros 2 Tore ee eee ee Te A ee ele ore so -o5 90 oxic =ea.0¥0| AE PAPA Pr risscnelsrsirir rset ri sic eels ae zl DEPP PPP PAA LAPP APPA SASL AP AP ALP a Tree eae eer ee LTT LLL LAP LL ey 3 to 518707 Co pun sry ose Pager ye ee reer Ye dee ea ee Pe ee eee 73 st DA 97 = oa c= C0007 trexxaasie xx cars r can era r exp a re OR P= BEE EEE se ees Esse EEE ESE a eying pure ‘seyeys v1.43 ‘Sereys sequiew 3 40} 3s1] AouanbasyEC Declaration of Conformity In accordance with EC Machinery Directive 2008/42/EC, Annex lA and RATTE Directive 1998I5IEC, Annex I ce “The manufacturer HEC-radiomatie GmbH Haller Strale 45 ~53 = 74564 Cralishelm + Germany hereby declares that he folowing product: Receiver FSE 516 ‘safety component according to the Machinery Directive (2006/42/EC), Contos to all apleable provisions of tho Machinery Directive (2008/42/EC), ‘The designated product also adheres tothe folowing European directives in regards to thelr protective gots 2008/98/66 Low Voltage Directive (oe Annex 1.5.1 ofthe Machinery Directive 2006/42/EC) 2008/4082 Electromagnetic Compatbilty ‘The following harmonized standards were applied: EN ISO 19849-1:2008/4C:2009.....» Safety of machinery - Safly-eated parts of control systems. Pant: General principles for design EN’60204°1'2008iAC 2610 ‘Safety of machinery - Electncal equipment of machines Part: General requirements EN 6020432°2008 ‘Safely f machinery - Electrical equipment of machines Part $2: Requirements fr hoisting machines EN/80860-1'2006~A11 26086A1:20406 Information technology equipment - Saety atzz0t1 Part t: General requirements, EN 49567:2008 + A2:2008 (Annex C).. Cranes - Controls and contol statons EN 308 480-1:200804 V1.8. Electromagnetic compat and Radio spectrum Matters (ERM) Part 1: Common lechrical requirements iin Shor Range Devices: EN 301 489-3:2002-08Vi.4.1 Electomagnete compatilly and Radio spectrum Matters (ERM) Part 3: Speci conalons for Shor-Range Devices (SED) EN'300'230°2 2007%06 "V2.42. Electromagnetic compat and Radio spectrum Mattos (ERM) Part 2: Harmonized EN covering essental requirements under arile 3.2 ofthe RATTE Directive With BEET systems: EN'301 480-6:200808 V1.3. Electromagnetic compattilly and Radio spectrum Matters (ERM) Pant 6: Specific conattons for DECT equipment EN'301 408:2008-07 v2.11 Digital Enhanced Corcess Telecommunications (DECT) covering the ‘essential requrements under article 3.2 ofthe RATTE Directive ~ Generic radio. With 3.4 Ghe systems: EN'301 489-17 2008-05 V2.4.4..... Electromagnetic compatoity and Radio spectrum Mattos (ERO) Part 17: Specie conditions fr Broadband Data Transmission Systems EN 360 538:3000-08 047 4 \Wideband transmission systems; Data ransmission equipment operating Inthe 2.4 Ge ISM band and using wide band modulation tecnnques; Harmonized EN covering essential requirements under aie 32 ofthe the RATTE recive ‘The following national regulations were applied: 2H 1847:1976 CGuideines fr rac control units of cranes {except of umber 12: key switch) BGR 140:1005, Rules forthe safety of equipment for wireless transmission of ‘contol commands Person responsible for documentation: Martin Schuster Place and date: Craisheim, 44.2014 Valid signature: Name: woffa tor (Wanaging Director)