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HETRONIC NOVA-M DIG-V04, Operator'S Manual

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HETRONIC NOVA-M DIG-V04 Operator'S Manual Download Page 19

19

CHANGING THE BATTERY

An acoustic pulse sounds to indicate a low battery 

warning. When the transmitter signals, the battery must 

be changed immediately.
Position the crane/machine into a safe place or safe 

condition within 30 seconds after hearing the signal.

Rechargeable Battery Pack

1. Remove fully charged rechargeable battery pack 

from the battery charger.

2. Insert the fully charged rechargeable battery pack 

into transmitter.

3. Place the spent rechargeable battery pack into 

the battery charger as shown.

4. The Radio Remote Control is ready for operation.
5. Follow the Start-Up Procedure and safety checks 

to begin operation.

Changing Optional Battery Adaptor with 

Disposable Batteries

1. Remove the spent disposable batteries from the 

battery adaptor pack, and dispose of properly.

2. Insert three fresh batteries into the battery 

adaptor pack as shown. Make sure to follow the 

polarity illustrations inside each battery 

compartment when inserting.

IMPORTANT: 

Use only AA 1.5V alkaline batteries or 

equivalent.

3. Insert the battery adaptor pack with fresh 

batteries into transmitter.

4. The Radio Remote Control is ready for operation.
5. Follow the Start-Up Procedure and safety checks 

to begin operation.

BATTERY DISPOSAL

IMPORTANT: 

AVOID ENVIRONMENTAL 

POLLUTION. Electronic equipment and components 

are considered to be hazardous waste. Discarded 

rechargeable batteries are hazardous waste and must 

not be disposed of with typical refuse. Contact a 

professional hazardous waste disposal service.

WARNING: 

The transmitter will switch to the 

EMERGENCY STOP condition after 30 
seconds.

MAINTENANCE

Depress here to release battery

Pivot battery pack to remove

Reverse procedure for installation

WARNING: 

EXPLOSIVE GASES AND 

FLYING DEBRIS can cause death or serious 
injury. Use only Hetronic replacement 
rechargeable batteries. Use of unauthorized 
replacement batteries could cause a battery 
explosion, resulting in injury or death of the 
operator or other people in the work area.

Depress here to release battery

Pivot battery pack to remove

Reverse procedure for installation

Summary of Contents for NOVA-M DIG-V04

Page 1: ...m 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 Nova M Digital Systems NOVA M DIG V04 NOVA M DIG V05 ...

Page 2: ...al Wiring 11 Nova M V04with RX 14 0004 Outputs 11 Nova M V04 with RX 20 Outputs 12 Nova M V05 with RX 20 Outputs 13 Overhead Traveling Crane Mat Handl 14 Nova M Digital Transmitters 15 Frequency and Address Settings 15 Nova M Digital Transmitter 15 Test the System 16 LED Designations Layout 16 Operation 17 Holding the Transmitter 18 Visual Check 18 Start Up Procedure 18 To Stop In An Emergency 18 ...

Page 3: ...ane machine and radio remote control Emergency Stop functions work properly before beginning any crane machine operation 3 Understand all Safety Precautions provided in the manuals 4 Review control functions and operation of the machine and this radio remote control system 5 Surge suppressors RC type only must be used when the receiver is controlling magnetic contactors 6 When not in use turn the ...

Page 4: ...erates 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 receiver only accepts commands from the transmitter with the same address code NOTE The receiver and transmitter have the address code set at the facto...

Page 5: ...ransmitter 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 activation power to the output relays and activates the E stop function To restart the system be sure the transmi...

Page 6: ...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...

Page 7: ... 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 7 8 1 Receiver enclosure 2 Receiver cover 3 E stop input fuse F2 6 3A slow blow 4 AC common input fuse F1 315mA slow blow 5 E stop output relay 6 E stop LED 7 Output mapping DK access and power access points 8 Receiver setting jumper block J1 J5 9 Receiver setting solder jumpers J6 J8 10 RF module w internal antenna 11 ADMO address mod...

Page 8: ...ction and System numbers in the boxes provided in the Introduction Section of this manual R F1 F2 Emergency Stop M32 M25 M20 K1 K2 K3 K K5 K6 K K8 K15 K16 K17 K18 K19 K20 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 9 10 11 12 9 10 1 Receiver enclosure 2 External miniflex antenna TNC mount 3 Receiver cover 4 E stop input fuse F2 6 3A slow blow 5 AC common...

Page 9: ...c minimum for power wiring 8 If the receiver includes an attached antenna mount the receiver so that the antenna points straight up The area around the antenna should be free of obstructions especially metal The receiver wiring is critical for proper system operation Make all connections with good quality contacts or solder joints to ensure proper electrical contact Supply voltage and ground wirin...

Page 10: ...ion may require the use of a GainFlex antenna The GainFlex antenna can extend the range of the radio remote control system up to 300 meters 1000 ft It can also be used where a standard antenna is difficult to mount If you are not sure which antenna is suitable for your application please contact Hetronic or your dealer When using a GainFlex antenna there must be no metal or conductive materials wi...

Page 11: ... 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 7 8 X1 X2 X3 X4 X2 3 1st Detent 1st Detent 1st Detent 1st Detent 1st Detent 1st Detent X2 4 X2 5 X2 6 X2 7 X2 8 X2 9 X2 10 X2 11 X2 12 X3 1 X3 2 X3 3 X3 4 K1 K2 K3 K4 K5 K6 K7 X3 5 X3 6 X3 7 X3 8 X3 9 X3 10 X4 1 X4 2 X4 3 X4 4 X4 5 X4 6 X4 7 X4 8 K8 K9 K10 K11 K12 1 K13 2 K14 2nd Detent 2nd Detent 2nd Detent 2nd Detent 2nd Detent X2 1 X2 2 E STOP E Stop X1 1 X1 2...

Page 12: ... 8 K8 K9 K10 K11 K12 K13 K14 X2 1 X2 2 E STOP E Stop X1 1 X1 2 240VAC HOT 120VAC HOT X1 3 X1 4 50VAC HOT VAC NEUTRAL X1 5 X1 6 12 24VDC DC Ground S4 S4 S3 S3 S3 S3 DK25 DK26 DK27 DK28 DK29 DK30 DK17 DK18 DK19 DK20 DK21 DK22 DK14 REL6 RX X2 X1 K15 DK23 K16 DK24 K17 DK11 K18 DK12 K19 DK13 K20 DK20 1 2 3 4 5 6 7 8 1 2 3 4 5 6 X6 X5 X5 1 X6 5 X6 6 X6 7 X6 8 K15 K19 K20 X5 2 K15 X5 3 X5 4 K16 X5 6 K16 ...

Page 13: ...9 K10 K11 K12 K13 K14 X2 1 X2 2 E STOP E Stop X1 1 X1 2 240VAC HOT 120VAC HOT X1 3 X1 4 50VAC HOT VAC NEUTRAL X1 5 X1 6 12 24VDC DC Ground S1 S4 S4 S4 S4 S3 DK1 DK7 DK8 DK27 DK28 DK3 DK4 DK12 DK13 DK9 DK10 DK15 DK16 REL6 RX X2 X1 K15 DK25 K16 DK26 K17 DK5 K18 DK6 K19 DK2 K20 DK30 1 2 3 4 5 6 7 8 1 2 3 4 5 6 X6 X5 X5 1 X6 5 X6 6 X6 7 X6 8 K15 K19 K20 X5 2 K15 X5 3 X5 4 K16 X5 6 K16 X5 5 X6 3 X6 4 K...

Page 14: ...tart E Stop Wiring for RX 20 0020 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 7 8 X2 MAINLINE CONTACTOR X2 X1 MC X1 X2 X3 X4 NOTE Material Handling Only 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 7 8 X2 MAINLINE CONTACTOR X2 X1 MC X1 X2 X3 X4 NOTE Material Handling Only ...

Page 15: ...itter and receiver do not match the system will not function NOVA M DIGITAL TRANSMITTERS NOVA M DIGITAL TRANSMITTERS WARNING The transmitter coder settings are set at the factory and should be changed by Hetronic service personnel only Incorrectly changing the settings of the transmitter coder board could result in damage to equipment serious injury or death CAUTION AVOID INJURY OR DAMAGE Operatin...

Page 16: ... result in personal injury and or damage to equipment Read and understand the safety instructions in all manuals provided Testing or service must be performed by authorized personnel only There must be no load on the crane machine Clear the crane machine operating area of obstructions REL6 RX F1 F2 Emergency Stop K1 K2 K3 K4 K5 K6 K7 K8 K15 K16 K17 K18 K19 K20 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3...

Page 17: ...in line contactor will activate at this time depending on crane wiring 11 Activate the motion joysticks to test the crane machine functions IMPORTANT The crane machine functions will operate during this check Be certain that there are no obstacles near the crane machine 12 Confirm that the crane machine moves appropriately and that the correct LEDs illuminate for each crane machine motion 13 Activ...

Page 18: ...smitter OFF when not in use When the transmitter is not attached to the operator the key switch should be removed and stored in a secure place 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 SAFE MODE When the transmitter battery power is nea...

Page 19: ...ent when inserting IMPORTANT Use only AA 1 5V alkaline batteries or equivalent 3 Insert the battery adaptor pack with fresh batteries into transmitter 4 The Radio Remote Control is ready for operation 5 Follow the Start Up Procedure and safety checks to begin operation BATTERY DISPOSAL IMPORTANT AVOID ENVIRONMENTAL POLLUTION Electronic equipment and components are considered to be hazardous waste ...

Page 20: ...place 3 The LED labeled CHARGE flashes for two seconds then stays lit during the charging process 4 When the battery is fully charged the READY LED lights up and the CHARGE LED goes off Charging time could take up to 5 hours depending on the condition of the battery 5 Leave the battery in the charger until it is needed The charger supplies a trickle charge but will not over charge the battery Fast...

Page 21: ... the correct frequency channel in the transmitter and receiver The frequencies may need to be changed if a transmitter receiver or RF module of either unit has been replaced The frequencies of the transmitter and receiver must be identical 1 Remove the lower housing from the transmitter 2 Locate the RF Module inside the transmitter 3 Locate the Frequency Channel Jumper Block on the RF module shown...

Page 22: ... ON OFF OFF OFF OFF OFF OFF OFF OFF Channel B0 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 Channel A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 Frequency MHz 458 800 458 825 458 850 458 875 458 900 458 925 458 950 458 975 459 000 459 025 459 050 459 075 459 100 459 152 459 150 459 175 Group USA Jumper J3 Open Group GB Jumper J3 Closed The Hetronic Radio Remote Control System addres...

Page 23: ...N ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF Channel B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 Channel A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 Frequency MHz 447 275 447 300 447 325 447 350 447 400 447 450 447 500 447 550 447 600 447 650 447 700 447 750 447 775 447 800 447 825 447 850 Group A Jumper J3 Closed Group B Jumper J3 Open The Hetronic Radio Remote Control System ...

Page 24: ...ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF Frequency MHz 433 875 433 925 433 975 434 025 434 075 434 125 434 175 434 225 434 275 434 325 434 375 434 425 434 475 434 525 434 575 434 625 Channel B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 Channel A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 Group A Jumper J3 Closed Group B Jumper J3 Open The Hetronic Radio Remote Contr...

Page 25: ...f the Receiver Module Depending on the DIP switch array configuration the RF Unit continuously scans for valid frequency channels or scans for an individual frequency In the continuous scan mode it locks onto a valid frequency channel once it receives an input signal on the 2 pin Dubox connector see picture The RF unit has two SMB diversity antenna inputs Input power and TTL signal output is provi...

Page 26: ...429 6375 429 6500 429 6625 429 6750 429 6875 429 7000 429 7125 429 7250 429 7375 Channel 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 D3 ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON D4 OFF ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF ...

Page 27: ...ons Is there a fully charged battery pack installed Did you take the transmitter out of its operating range 100 meters or 328 feet Receiver Remove the receiver enclosure lid and observe the receiver circuit board Check the following Refer to the drawing in the section Test the System on page 16 that shows the location of each diagnostic LED Is machine power being applied to the receiver Are any in...

Page 28: ...hing but crane machine will not respond E Stop switch engaged Twist and pull out the E Stop pushbutton and press the Start horn pushbutton Transmitter out of range Take the transmitter back into the range of the receiver Press the Start horn pushbutton A motion function was not in OFF neutral position when transmitter turned on Ensure that all control devices are in OFF neutral position when the S...

Page 29: ... transmitter may be interfering with the system NOTE This does not apply for STD 402 RF modules If another Hetronic system is located within 75 meters the frequency channels must be at least 2 channels apart If another system is within 20 meters the channels must be at least 3 channels apart Contact Hetronic or your Dealer for assistance Some crane machine motions operate intermittently Crane mach...

Page 30: ...ck 1 single axis 360o control digital three step spring return to center joystick RECEIVER RX 14 Size 246 x 160 x 90 mm 9 7 x 6 3 x 3 5 inches Weight 1690 g 3 7 lbs Operating power 48 110 240 VAC 50 60 Hz 20 12 24 VDC 20 Current 100 mA Safety features Self monitoring E Stop circuits Fail safe spring forced E Stop relay Self test during start up and operation On board diagnostic system with indicat...

Page 31: ... supply DC 12 24 VDC polarity protected AC 110 220 VAC US Japan or EU plug NOTE Will also charge 9 6 V batteries Internal modification and mechanical limiters must be removed BATTERY Battery type NiMh nickel metal Hydrite Capacity typical 1200 mAh 3 6V Typical operation time Up to 20 hours with one charge depending on TX configuration Memory effect None Duty cycle Can be recharged at least 500 tim...

Page 32: ...g correctly The operator is responsible for understanding and following all safety precautions in this and other applicable operator manuals INSTALLATION AND SAFETY TEST DATA Crane machine Data Manufacturer Model Number Serial Number Year of Production Radio Remote Control Data Manufacturer Hetronic Model System Type Transmitter Production Number Receiver Production Number System Number I We insta...

Page 33: ...ly contactor to the crane machine controls Maintained control The function activates when the control is placed in the ON position The function stops when the control is placed in the OFF position Momentary control The function activates when the control is placed in the ON position The control must be held in place to stay ON When the control is released it returns to the OFF position and the fun...

Page 34: ... to operate mAH Milliampere hours mA Millampere msec Millisecond MHz Megahertz MOV Metal Oxide Varistor type of surge suppressor mW Milliwatt NiCd Nickel Cadmium NiMH Nickel Metal Hydrite PLC Programmable logic controller PLL Phased locked loop PTO Press to operate PWM Pulse width modulation R C Resistor Capacitor type of surge suppressor RF Radio frequency RMS Root mean squared Rx Receiver RxD Re...

Page 35: ... the use of any Company supplied items or materials List prices or discounts are subject to change without notice Quoted prices will be honored for a period of 90 days from the date of the written quotation unless otherwise stated Orders are not subject to alteration or cancellation except upon written consent of Company and payment of proper cancellation charges when deemed applicable by Company ...

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