Opera perati ting ng Instr ns truct uctio ions ns Original Version
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radiomatic AD A DCON ex c h an g e Revision 1.4
Table of Content s Safety instruction s Pictographs General safety instructions Operator safety instructions Introduction ® radiomatic ADCON ® This has to be respected before the replacement of the radiomatic ADCON Determination of the functionality What has to be done in case of damage, loss or change of configuration Necessary tools ®
Replacement of the radiomatic ADCON on the tr ansmitt er Safety instructions ® Replacement of the radiomatic ADCON for the chip version ® Replacement of the radiomatic ADCON for the module version ®
Replacement of the radiomatic ADCON on the receiver Safety instructions ® Replacement of the radiomatic ADCON on the original receiver ® Replacement of the radiomatic ADCON on the replacement receiver ®
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radiomatic ADCON/iON-Set or radio matic ADCON/iLOG-Set Replacement Contact d ata in a service-event
Manufacturer: HBC-radiomatic GmbH • Haller Straße 45 – 53 • 74564 Crailsheim • Germany • Tel. +49 7951 393-0 • info@ra diomatic.com. HBC.radiomatic GmbH is not liable for any misprints or errors! – Specifications and design subject to change wi thout notice. ® radiomatic and radiobus are registered German trademarks. © 17 / 2013, HBC-radiomatic GmbH, 74564 Crailsheim, Germany No part of this document may be reproduced in any manner whatsoever without the expressed written permission of HBC-radiomatic GmbH.
Safety instruct ions Pictographs The following pictographs will be used throughout the present service manual: Warning o f electric volt age Contacting components under voltage may lead to death. Housings marked with this symbol may only be opened by qualified electricians after having disconnected the device from the mains supply (supply voltage, operating voltage or input terminal voltage). Warning of dangerous areas You will find this pictograph as an indicator for occupational safety measures. Neglecting such measures poses a serious hazard. Always observe the instructions and be par ticularly attentive and careful.
N o t i f i c at i o n o f i m p o r t a n t i n f o r m a t i o n This symbol brings your attention to important information or measures that are necessary to ensure a long serviceable life of the radio control system. Pay attention to the comments and instructions given.
General safety instr uctions Radio controls facilitate and increase the operating efficiency of cranes and machinery. Nevertheless, the operator first needs to adjust to the use of a radio control.
Read the service manual carefully and thoroughly before adjusting any settings at the radio system!
Only settings described in this service manual may be adjusted.
The operator undertakes to strictly adhere to the instructions and proceedings described in this manual, as well as to follow the general rules and regulations for worker safety and accident prevention. Ignoring any such instructions or regulations could pose a fatal threat to the operator or others. Keep this manual on location and readily available at all times! Only authorized and properly trained personnel may operate the radio control system. Anyone who is under the influence of drugs, alcohol or medication that has a detrimental effect on a person's reactions may at no time commission, operate, maintain or repair the radio control system. Before activating the radio control system ensure that no-one is or can be endangered by the initiated operation. Use only original HBC batteries. Using other batteries can result in performance and safety problems when charging (overheating or even explosion of the battery). With the first signs of any malfunction related to the operative safety and reliability of the device the operator must immediately shut down or not activate the radio system, which means to
switch off the transmitter.
protect the transmitter from unauthorized use.
cut off the receiver’s mains supply.
disconnect the cable on the receiver.
Disturbances have to be immediately removed. A defective radio system may only be repaired by qualified and competent personnel. Use only original HBC spare parts. The device security cannot be guaranteed with the use of spare parts other than HBC originals, and this voids our extended warranty. Only the legal warranty regulations apply in this case. Observe all periodical tests and inspections that are required by law, recommended in the operating instructions or in the present service manual! When using the radio receiver always observe the regulations and instructions stipulated in the authoritative worker safety and accident prevention regulations! The radio receiver has been manufactured in accordance with the regulations and guidelines stipulated in the German Trade Association's "Safety and Accident Prevention Regulations for Operating Cranes by Radio Controls" (BGV D6) and DIN EN 13557. The radio transmitter and receiver have been tested and approved in accordance with EMC guidelines and comply with the authoritative standards for emitted interference and interference immunity in industrial use. Use the radio control system carefully, especially when controlling a crane or machine by radio for the first time.
Operator safety instructi ons
Before beginning crane operation, position yourself with a clear and complete overview of the working radius of the crane or machine. Please be careful of assumed changes of direction when you change position! In case of an emergency or any disturbances within the working range of the crane or machine, switch the transmitter off immediately by pressing the STOP push button. Should the transmitter show signs of technical failure or breakdown, disconnect the radio control system immediately! During breaks and after finishing work, always deactivate the radio transmitter. This prevents unintended crane / machine movements resulting from unintentional operation of the operating elements. This is particularly important in situations when you change your safe position or for example have to climb over obstacles. Never leave an activated transmitter unattended. The operator undertakes to follow and comply with the authoritative regulations for worker safety and accident prevention.
Note: In the event of an interruption of the radio link during a working cycle, both transmitter and receiver automatically shut down (so-called "c o m p u l s o r y s w i t c h - o f f " ): Release all operating elements and allow them to return to their zero position. After this, the crane or machine can react again to control commands. This feature prevents uncontrolled or unwanted crane or machine movement, should the radio link be interrupted.
Introduction ®
The data stored on the radiomatic ADCON is necessary for the activation of the radio system. ® radiomatic ADCON is both installed on the transmitter and the receiver. In case of a damage to the ® radio system, the radiomatic ADCON may have to be replaced. This service manual describes detailed, ® in which situations the radiomatic ADCON has to be replaced on the transmitter or the receiver and how this is done. Exceptions: On the receivers FSE 508 and FSE 509 as well as on the transmitters cubix and orbit (PCB version MTO10___), there is no radiomatic® ADCON installed. The data is stored on the PCB. ®
There are two types of radiomatic ADCON: the chip version and the module version. chip version
module version
radiomatic ® ADCON ®
There are four different types for fixing the radiomatic ADCON. The following pictures show the possible placements on the PCB of the transmitter or the receiver respectively (the pictures are exemplary):
Transmitter PCB – Possible types of fi xing Chip version: Fixing version 1 (on socket)
Module version: Fixing version 3
Fixing version 2 (on PCB)
Receiver PCB – Possibl e type of fixin g ®
In the receiver, the radiomatic ADCON is only used in the module version.
Fixing version 3
FSE 726 / 727 / 736 / 737 / 776 / 777 rad io bu s®
Fixing version 4
FSE 510 / 511 / 516 / 524
Exception: on the receiver FSE 512, the radiomatic® ADCON is placed on the PCB of the decoder.
Classifi cation of the PCBs int o the different fixing version s You can find the respective module code of the PCB in brackets.
Fixing version1:
keynote (MTK1001_); quadrix ( MTQ1_); micron 4 (MTM41_); micron 5 (MTM51_ / MTM52_); micron 6 (MTM60_ ); micron 7 (MTM71_); patrol S (MTPS1_); patrol D (MTPD1_); vector pro (MTVP1_ ); linus 4 (MTL_); linus 6 (MT032_); spectrum 1 (MTS110_); spectrum 2 (MTS210_); orbit (MTO11_)
Fixing version2:
eco (MTE1001_)
Fixing version3:
Sender: eco (MTE200_); eco / technos (MTE110_); eco / technos / spectrum 1 / 2 / 3 (MTE1104_ / MTE1105_ / MTE1106_ / MTE1107_); spectrum 1 (MTS12_); spectrum B (MTS2_); spectrum 3 (MTS31_) / spectrum D (MTS3101_) Empfänger: FSE 512 (DD512); FSE 726 / FSE 727 / FSE 736 / FSE 737 / FSE 776 / FSE 777 (CM737_)
Fixing version4:
FSE 510 (MR510_); FSE 511 (MR511_); FSE 516 (MR516_); FSE 524 (MR524_)
This has to be respected before the replacement of the radiomati c® ADCON ®
The proceeding for the replacement of the radiomatic ADCON depends on whether the transmitter is ® ® ® equipped with a key, radiomatic masterkey, radiomatic iON or radiomatic iLOG and what functionality they have. The following chapter describes how to get the information about the functionality. What you have to do in case of damage, loss or change of configuration, can be found on the table followed by this chapter.
Determination of t he functionality Summary of the possible functionalities L = lock (lock functionality for activating the transmitter) S = spare (spare transmitter functionality) M = master (spare transmitter functionality + further features)
key
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radiomatic masterkey
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radiomatic iON
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radiomatic iLOG
Functionalit y of a key Keys only function as a mechanical closing for the activation of the radio transmitter.
Functionality of radiomatic ® masterkey ®
System-specific data are stored on the radiomatic masterkey. Since frequency information is stored on ® ® the radiomatic masterkey it is possible to use a spare transmitter with the radiomatic masterkey of the original transmitter.
Functionality of radiomatic ® iON The functionality can be determined by the module code, which is written on the label of the radiomatic iON. Depending on the version, there are different types of labels (pictures are exemplary): radiomatic iON H BC 5 16 M 5
KL M10001
KSM10001 516-0710930
KMM10001 516-0710930
KMM10001 516-0710930 EU-1 FB 001
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Label 1 (used until CW 13/2007).
Label 2 with module code for lock functionality.
Label 3 with module code for spare functionality and serial no. (fabrication no.) for allocation to the radio system. (used until CW 28/2010). Label 4 with module code for master functionality and serial no. (fabrication no.) for allocation to the radio system. (used until CW 28/2010). Label 5 with module code, serial no. (fabrication no.) and frequency information (for types with spare and master functionality).
Models equipped with label 1 come with "lock functionality" only. Models with the labels 2, 3, 4 or 5 are marked with a module code (e. g. KSM10001). The second position of the module code (subgroup) defines the functionality of the radiomatic® iON. Frequency information on the type plate identifies a spare transmitter functionality.
Functionality radiomatic ® iLOG ®
The functionality is identifiable by the module code, which is written on the label of the radiomatic iLOG. ®
The label is put directly on the radiomatic iLOG (pictures are exemplary):
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radiomatic iON-
KS510001 516-1017374
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The second position of the module code (subgroup) defines the functionality of the radiomatic iLOG.
Excepted are the transmitters cubix and orbit (PCB version MTO10___). For those transmitters all data is stored on the PCB. In case of damage the transmitter PCB eventually hast o be replaced as well as on ® receiver´s end the radiomatic ADCON.
What has to be done in case of damage, loss or change of con fig uratio n Type of transmitter
Problem / modif ication
Transmitter cubix
Transmitter is damaged.
Replace the transmitter PCB and possibly the ® radiomatic ADCON on the receiver.
Transmitter orbit
Transmitter is damaged.
Replace the transmitter PCB and possibly the ® radiomatic ADCON on the receiver.
Transmitter is damaged.
Remove the radiomatic ADCON from the damaged transmitter and fix it on the PCB of the spare transmitter. Remove the key from the damaged transmitter and use it for the spare transmitter.
Remedy
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Transmitter is equipped with key
Transmitter is equipped with ® radiomatic masterkey.
Loss of the key.
Use a spare key. If there is no spare key at hand, please contact the spare parts sales.
Change of configuration.
Information about the proceeding can be obtained from our technical service.
Transmitter is damaged.
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Loss of the radiomatic masterkey
Remove the radiomatic masterkey from the damaged transmitter and use it for the spare transmitter. If there is no structurally identical spare transmitter, please contact our technical service. Information about the proceeding can be obtained from our technical service.
Change of configuration.
Information about the proceeding can be obtained from our technical service.
Transmitter is damaged.
Remove the radiomatic ADCON from the damaged transmitter and fix it on the PCB of the spare ® transmitter. Remove the radiomatic iON from the damaged transmitter and use it for the spare transmitter.
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Transmitter is equipped with ® radiomatic iON "lock functionality"
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Loss of the radiomatic iON
Use a spare radiomatic iON. If there is no spare ® radiomatic iON at hand, please contact the spare parts sales.
Change of configuration.
Information about the proceeding can be obtained from our technical service.
Transmitter is damaged.
Remove the radiomatic iON from the damaged transmitter and use it for the structurally identical spare transmitter.
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Transmitter is equipped with ® radiomatic iON "spare/master functionality"
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Loss of the radiomatic iON
Change of configuration.
1. After signing a declaration of indemnation you will ® get a spare radiomatic iON from our technical service or 2. You will get a new set with a new address code, ® ® consisting of radiomatic iON and radiomatic ADCON for both transmitter and receiver.
Information about the proceeding can be obtained from our technical service.
Type of transmitter
Problem / modif ication
Remedy ®
Transmitter is damaged. Transmitter is equipped with ® radiomatic iLOG "lock functionality"
Remove the radiomatic ADCON from the damaged transmitter and fix it on the PCB of the spare ® transmitter. Remove the radiomatic iLOG from the damaged transmitter and use it for the spare transmitter. ®
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Loss of the radiomatic iLOG
Use a spare radiomatic iLOG. If there is no spare ® radiomatic iLOG at hand, please contact the spare parts sales.
Change of configuration.
Information about the proceeding can be obtained from our technical service.
Transmitter is damaged.
Remove the radiomatic iLOG from the damaged transmitter and use it for the structurally identical spare transmitter.
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Transmitter is equipped with ® radiomatic iLOG "spare/master functionality"
Loss of the radiomatic iLOG
1. After signing a declaration of indemnity you will get a ® spare radiomatic iLOG from our technical service or 2. You will get a new set with a new address c ode, ® ® consisting of radiomatic iLOG and radiomatic ADCON for both transmitter and receiver.
Change of configuration.
Information about the proceeding can be obtained from our technical service.
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Necessary tools ®
The following tools are necessary for the replacement of the radiomatic ADCON: For all transmitters and receivers: Suitable allen key / screwdriver for opening the housing. ®
For fixing versions 1 and 2 of the radiomatic ADCON: Extraction tool (available as HBC accessory). ®
Only for fixin g version 3 of the radiomatic ADCON: Flat head screwdriver / size 00 or 0. ®
Only for fixin g version 4 of the radiomatic ADCON: Circlip piers (available as HBC accessory). For fixing versions 3 and 4: Water resistant pen for labelling.
Replacement of t he radiomatic ® ADCON on t he transmi tter Safety instruct ions Please notice the following safety instructions before carrying out the service work: Danger from malfunc tion of th e radio syst em! ® radiomatic ADCON may only be used for another transmitter, if
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the fabrication no. (= serial no. on the type plate) of the transmitter and the radiomatic ADCON are identical. or
it is a structurally identical transmitter. The usage of a non-suitable transmitter could cause injury to persons or material damage!
Possible damage of the radiomatic ® ADCON! ® Due to improper removal or installation, the radiomatic ADCON can be damaged. ® Controlling of the radio system with a damaged radiomatic ADCON is no longer possible! In case of damage, please contact your distributor or HBC-radiomatic GmbH. ® To avoid a damage of the radiomatic ADCON, the following points are to be respected:
Use only the tools described in this service manual!
Do not remove the radiomatic ADCON by force (take care of the pins)!
Do not plug the radiomatic ADCON by force (take care of the pins)!
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Replacement of the radiomatic ® ADCON for t he chip versi on 1.
Switch off the transmitter and remove the battery.
2.
Open the housing with suitable tool.
3.
Lift the radiomatic® ADCON perpendicularly from the socket with the extraction tool.
4.
Plug the radiomatic ADCON on the PCB of the spare transmitter. Please notice that the notch on ® the radiomatic ADCON has to be on the same side as the marking on the PCB (see pictures).
5.
Close the housing. Be assured, that no lines will be trapped.
6.
After the replacement of the radiomatic ADCON check all commands for correct function on the machine. In case of malfunctions you have to deactivate the transmitter and contact our technical service.
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Fixing version 1 (on socket)
Fixing version 2 (on PCB) marking
notch
Replacement of the radiomatic ® ADCON for t he modul e versi on 1.
Switch off the transmitter and remove the battery.
2.
Open the housing with suitable tool.
3.
Remove the radiomatic ADCON by pushing the fastening bracket and pulling the radiomatic ADCON carefu lly f rom the PCB.
4.
Plug the radiomatic ADCON on the PCB of the spare transmitter. Take care of a complete snap in ® of the radiomatic ADCON.
5.
Close the housing. Be assured, that no lines will be trapped.
6.
After the replacement of the radiomatic ADCON check all commands for correct function on the machine. In case of malfunctions you have to deactivate the transmitter and contact our technical service.
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Fixing version 3
Fastening bracket
Replacement of t he radiomatic ® ADCON on th e receiver Safety instruct ions Please notice the following safety instructions before carrying out the service work: Danger by electrical voltage! Make absolutely sure, that the receiver is disconnected from the power. As long as there is an indicator flashing on the receiver, voltage on the device is to be expected in any case. Please wait until all indicators are out, before you start with the replacement of the ® radiomatic ADCON on the receiver. ®
Possible damage of the radiomatic ADCON! ® Due to improper removal or installation the radiomatic ADCON can be damaged. ® Controlling of the radio system with a damaged radiomatic ADCON is no longer possible! In case of damage, please contact your distributor or HBC-radiomatic GmbH. To avoid a damage of the radiomatic® ADCON, the following points are to be respected:
Use only tools described in this service manual! ® Do not remove the radiomatic ADCON by force (take care of the pins)!
Do not plug the radiomatic ADCON by force (take care of the pins)!
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Replacement of th e radiom atic ® ADCON on the ori ginal r eceiver 1.
Disconnect the receiver from the power supply.
2.
Open the housing with the tools described in this service manual.
3.
Remove the radiomatic ADCON by pushing the fastening bracket (fixing version 3) or by pushing ® apart the fastening brackets with a circlip piers (fixing version 4) and pulling the radiomatic ADCON carefully from the PCB.
4.
Plug the replacement radiomatic ADCON on the PCB of the receiver. Make sure that the radiomatic ® ADCON snaps in completely.
5.
Close the housing. Make sure that no lines will be trapped.
6.
After the replacement of the radiomatic® ADCON check all commands for correct function on the machine. In case of malfunctions, you have to deactivate the transmitter and contact our technical service.
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Fixing version 3
Fixing version 4
Fastening bracket
Fastening bracket
Replacement of th e radiom atic ® ADCON on t he replacement receiver 1.
Disconnect the replacement receiver from the power supply.
2.
Open the housing with the tools described in this service manual.
3.
Plug the radiomatic ADCON oft he original receiver on the PCB of the replacement receiver. Make ® sure that the radiomatic ADCON snaps in completely.
4.
Check the setting of the DIP switches on the replacement receiver. Make sure that they are identical to the DIP switch settings on the original receiver.
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DIP switches
Example receiver mainboard FSE 511
Danger from malfuncti oning of the radio system! Different DIP switch settings can effect the functioning of the machine.
5.
Close the housing. Make sure that no lines will be trapped.
6.
After the replacement of the radiomatic ADCON check all commands for correct function on the machine. In case of malfunctions, you have to deactivate the transmitter and contact our technical service.
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Fixing version 3
Fixing version 4
Fastening bracket
Fastening bracket
radiomatic ® ADCON/iON-Set o r r adio matic ® ADCON/iL OG-Set ®
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The radiomatic iON or radiomatic iLOG is installed on your transmitter. If the radiomatic iON or ® radiomatic iLOG is damaged or missing, the radio system cannot be operated. In this case you must not ® ® ® only replace the radiomatic iON or radiomatic iLOG on the transmitter, but also the radiomatic ® ® ADCON on the re ceiver’s end. Ther efore use the radiomatic ADCON/iON-Set or radiomatic ADCON/iL OG- Se t. If you want to modify the configuration on certain radio systems, you will also get a new radiomatic® ® ADCON/iON-Set or radiomatic ADCON/iLOG-Set, which has to be replaced on the present radio system. The radiomatic ® ADCON-iON/iLOG Set is available as spare part and consists of the following elements: - radiomatic® ADCON for the receiver. ®
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- radiomatic iON or radiomatic iLOG for the transmitter. - self-adhesive laminate foil (protection for the labels). - labels (marking with water resistant pen). - guarantee seal (blue)
Replacement Please notice the following points when replacing the set: ®
1.
Replace the radiomatic ADCON on the receiver according to the corresponding version described in this service manual.
2.
Affix the provided guarantee seal for the radiomatic ADCON on the same position as before.
3.
Mark the labels included in the delivery for the radiomatic iON or the radiomatic iLOG with the fabrication n o. of the receiver (= serial no. on the type pl ate) of the corresponding radio system.
4.
Paste-over the label with the laminate foil.
5.
Affix the radiomatic iON or radiomatic iLOG on the transmitter (see pictures).
6.
After the replacement, check all commands for correct function on the machine. In case of malfunctions, you have to deactivate the transmitter and contact our technical service.
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A f fi x at i o n o f th e r ad i o m at i c iON
Pictures are exemplary
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Affixation of the radiomatic iLOG
Contact data in a service-event You require spare parts or technical support? Then please contact our after-sales service. Therefore, please keep ready the serial no. from the type plate of the corresponding transmitter and/or the receiver. You can find the type plate in the battery compartment on the bottom of the transmitters’ housing and on receivers’ end on the side of the housing (see the following picture).
Contact data of th e spare parts sales of HBC-radiomatic HBC-radiomatic GmbH Haller Strasse 45 – 53 74564 Crailsheim Germany Fon: +49 7951 393 - 520 Fax: +49 7951 393 - 802 E-Mail:
[email protected]
Contact data of the technical servi ce of HBC-radiomatic HBC-radiomatic GmbH Haller Strasse 45 – 53 74564 Crailsheim Germany Fon: +49 7951 393 - 510 Fax: +49 7951 393 - 802 E-Mail:
[email protected] For an overview of our worldwide service www.hbc-radiomatic.com under "Contact".
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