InstructionManual

MC3SeriesRadioremotecontrolsystems

MC3Seriesinstructionmanual

Contents
SAFETYNOTES.............................................................................................................................................3
1

INTRODUCTION...................................................................................................................................4
1.1

SYSTEMDESCRIPTION..........................................................................................................................5
2.1
2.2
2.3
2.4
2.5

MARKING.................................................................................................................................................4

TERMINAL.................................................................................................................................................5
BASEUNIT................................................................................................................................................6
CABLECONNECTION(OPTIONAL)...................................................................................................................6
ANTENNA.................................................................................................................................................6
CARRYINGBELT/NECKSTRAP........................................................................................................................6

FUNCTIONALDESCRIPTION..................................................................................................................7
3.1
3.2
3.3
3.4

SYSTEMCONFIGURATION.............................................................................................................................7
SIGNALENCODING......................................................................................................................................7
FEEDBACK.................................................................................................................................................7
OPERATINGRANGE.....................................................................................................................................7

MAINDATA.........................................................................................................................................8

INSTALLATION.....................................................................................................................................9
5.1
5.2

INSTALLINGTHEBASEUNIT..........................................................................................................................9
INSTALLINGTHEANTENNA...........................................................................................................................9

COMMISSIONING...............................................................................................................................10

OPERATION.......................................................................................................................................11
7.1
7.2

BATTERYCHARGERANDBATTERIES...................................................................................................22
8.1
8.2
8.3
8.4

OPERATIONOFTERMINAL..........................................................................................................................11
OPERATIONOFBASEUNIT.........................................................................................................................18

CHANGINGTHEBATTERY............................................................................................................................22
STORAGERECOMMENDATIONOFBATTERY....................................................................................................22
BATTERYCHARGERINSTALLATIONANDUSE....................................................................................................23
CABLEMODE...........................................................................................................................................28

MAINTENANCE..................................................................................................................................28
9.1
9.2
9.3

SPARE/REPLACEMENT...............................................................................................................................28
SERVICE..................................................................................................................................................28
FAULTREPORTING....................................................................................................................................29

10 WARRANTY.......................................................................................................................................29

MAN07007Rev.112

MC3Seriesinstructionmanual

Safety notes

InspecttheMC3seriesequipmentbeforeusingit.
Checkforanydamagethatmaybeincurredduringshipping.
Donotopentheterminalunit.Therearenouserserviceableparts.
Donotusethedeviceifitappearstobedamaged.
UseonlyoriginalbatteriesfromCMC.
Avoidmechanicalshockandvibrationsifpossible.
Donotuseoutsidetemperaturerange.
Donotimmerseinwater.
ENSURETHATTHESUPPLYVOLTAGEISCORRECT.
INSTALLATIONSHOULDONLYBECARRIEDOUTBYQUALIFIEDPERSONNEL.

CavotecMicrocontroltakesnoresponsibilityforprotectionimpairmentifusedinamannernot
specifiedintheinstructionmanualand/ortheprojectspecificdocumentation.

CavotecMicrocontrolreservestherighttomakeimprovementsand/orchangesinthe
productsand/orspecificationsdescribedinthisinformationatanytimewithoutnotice.

MAN07007Rev.113

MC3Seriesinstructionmanual

1 Introduction
TheMC3seriesradioremotecontrolisdesignedforuseinharshindustrialenvironmenttocontrol
machinerysuchasoverheadcranes,hoists,recoveryvehicles,concretepumps,sludgetrucksetc.
Asthedifferentremotecontrolmodelsvaryaccordingtocustomerrequirements,thismanual
describesonlyfunctionsthatarecommonforallMC3seriesdeliveries(includingMC3seriesEX).
Forcustomerspecificsystemspleaserefertoprojectdocumentation.

1.1 Marking
1.1.1 Terminal units
Theserialnumberandotherrelevantdatasuchasfrequency,projectnumberetc.isfoundonthe
backsideoftherespectiveunit.

1.1.2 Base unit

Theserialnumberandotherrelevantdatasuchasfrequency,projectnumberetc.isfoundonthe
righthandsideoftherespectiveunit.

MAN07007Rev.114

MC3Seriesinstructionmanual

2 System description
Thesystemconsistsof

terminal(remotecontrolunit),withacarrying
beltorneckstrap

baseunitwithantenna

(batterychargerandbatteries)

Theterminalandthebaseunitarecommunicatesvia
aradiolink.Somesystemsarealsodeliveredwitha
cableforcommunicationbetweenterminalandbase
unitastheonlywayofcommunicationorasabackup
fortheradiolink.Whenthesystemcommunicates
onlybycable,batterychargerandbatteriesarenotpartofdelivery.
Ascustomerrequirementsvarygreatly,thesystemcomesindifferentmodelswhichdifferin
configuration,sizeandweight.

2.1 Terminal
TheterminalcontainstheStopswitch,pushbuttons,joysticks,toggleswitches,LEDindicatorlamps
andoptionallyaLCDdisplay.Theterminaliscarriedbytheoperatorwithabeltoraneckstrap.
AllterminalsarealsoavailableinEXproofversionsexceptofMC3100.

MC3100

MC3200

MC3300

MC35

MC36

MAN07007Rev.115

MC3Seriesinstructionmanual

2.2 Base unit

ThebaseunitisthepartofthesystemthatisconnectedtothecustomersmachineorPLC.CMC
deliversoutputsignalstocontrolthemachineryfromtheremotecontrol,basedonthecustomers
specification.
ThebaseunitcanbedeliveredinEXorNONEX.

CMChasnoresponsibilityforcontrolelementsthatarepartofmachinery.

2.3 Cable connection (optional)

Thecableconnectstheterminalwiththebaseunitandservesbothaspowersupplyand
communicationline.Cablecanbeusedasbackuporinsteadofradiocommunication.Whenthe
cableisconnected,thesystemwillautomaticallycommunicateoncable,andtheradiowillbe
disabled.

2.4 Antenna
Locatedonorconnectedtothebaseunitwithacoaxialcable.Theantennacanbeofinternalor
externaltype.Externalantennacanbemountedonthebaseunitorsomedistanceawaywithan
extensioncablesuppliedbyCavotecMicrocontrol.

Dependingofcabletype,therecommendedmaximumlengthoftheantennaextensioncableis
either30mor50m.

2.5 Carrying belt/ neck strap

Thecarryingbeltorstrapshouldalwaysbeusedwhenevertheterminalisoperatedtocarrythe
terminalsafelyandkeeptheoperatorshandsfree.
Failuretousethebeltorstrapmaycauseinjuryasyouwillnothavepropercontrolofthe
terminal.

MAN07007Rev.116

MC3Seriesinstructionmanual

3 Functional description
Theterminalunitcommunicatesbyradiosignalsorbycable,withthebaseunitwhichisinstalledat
thedesignatedequipment.

3.1 System configuration

Thesystemmayconsistofmorethanoneterminal/baseunitoperatingtogether.Whereseveral
terminalunitsareusedtocontrolonebaseunit,itiscustomersresponsibilitytoensurethatthe
operatoralwayshascontrolofwhichterminalunitisinoperation,toavoidanydangerous
uncontrolledmovements.
Fortandemconfigurations,e.g.multiplecranesdoingtandemliftofheavyequipmentpleasereferto
thespecificationSP11015CMCTandemconfigurations.

3.2 Signal encoding

Uniqueencodingoftheradiosignalpreventsunintentionaloperationcausedbyinterferencefrom
otherradiosystems.

3.3 Feedback
Iffeedbackisconfigured,theoperatorcanreadinformationfromthemachineattheterminalunit,
viaadisplayorLEDS.Theinformationcouldincludee.g.%ofload,rpm,torque,speed,text
instruction,etc.Ifthefeedbackisadirectinputfromthemachinery,customerisresponsibleforthe
informationbeingpresented.

3.4 Operating range

Dependingontheinstallationtheoperatingrangecanbefrom1001000m,typically200mlineof
sight.Therangemaychangeaccordingtothesurroundingsandotherequipment.Toachieve
optimalrange,careshouldbetakenwheninstallingtheantenna(Chapter5.2).

MAN07007Rev.117

MC3Seriesinstructionmanual

4 Main data

Terminal

Dimensions
(LWH)

Base unit

MC-3-5

230x175x160 mm

MC-3-6

330x220x200 mm

MC-3100

225x140x140 mm

MC-3200

280x180x180 mm

MC-3300

340x230x185 mm

Physical size and weight of the housing

will vary for each delivery. Please refer
to system specific drawings and order
specific documentation.

Weight

2-4 kg (the weight will vary with the terminals

equipment)
1,3 kg for MC-3100 incl. 2 joysticks, belt and battery.

IP class

IP 65, optional IP 66, depending on configuration.

Operating Temperature

Between -20C and +50C for radio systems

Between -25C and +60C for cable systems without radio

Radio frequency

CMC can provide systems for frequency bands in the range 335 Mhz 870 MHz.
Contact CMC for guidance on correct radio frequency.

Radio power

<10 mW, according to regulations

Operating range

Approx 200 m line of sight

Batteries

Rechargeable Li-ion, 7.4 V, 1100-2030 mAh

Power

12-24 V

supply
Use only MC-3-series batteries from Cavotec

Operating time

Typical 20 hours, depending on configuration and

base
unit

110-230 V

Input

Refer to system specific data

Output

Refer to system specific data

temperature
Time out

Adjustable, 0-99 min, 30 min. default

Time out is defined in SW, must be configured
before delivery of system

MAN07007Rev.118

MC3Seriesinstructionmanual

5 Installation
INSTALLATIONSHOULDONLYBECARRIEDOUTBYQUALIFIEDPERSONNEL.
ENSURETHESUPPLYVOLTAGEISCORRECT.
ConsidertheambienttemperatureandIPrating.
Iftheinstallationissubjecttoharshvibrations,usevibrationdampersavailablefromCMC.

5.1 Installing the Base unit

1) Fastenthebaseunitsecurelyontoasuitablepartofthemachineorequipmentbeingcontrolled.
a) Installthebaseunitinamechanicalprotectedareanotbeingexposedtodamage
b) Makesurethebaseunitisnotinstallednearhighenergylines
c) Ensurethatthebaseunitisinstalledwhereitwillnotbeconflictingwithmovingpartsin
operation
2) Reservespacearoundtheunittoensureeasyremovalofthelid/openingofthedoorandeasy
accesstotheconnectorsandbuttonsinthebaseunit
3) Thesystemshallbeinstalled/wiredaccordingtothewiringdiagramandsystemdescription
givenintheprojectspecificdocumentation.Controlthattheload(valvesetc.)isconnected
correctandthatthespecificationontheloadiswithinthespecifiedminimum/maximumloadof
theCMCoutputrelays.

5.2 Installing the Antenna

Mounttheantennasothereislineofsightbetweentheantennaonthebaseunitandtheterminal
carriedbytheoperator.Largemetalobjectsbetweentheterminalandantennaonbaseunitmay
stopthesignalandpreventoperation.
Takecarethattheantennawillnotbedamagedbymovingmachinery.
Donotmounttheantennainsideametalenclosure.Thereshouldbenometalobjectswithina
radiusof1mfromthecentreoftheantenna
Otherwirelessequipmentmayinterferewiththeradioremotesystem.Frequencyplanningis
importanttoavoidthis.ContactCMCforguidance
Ifmorethanoneantennaismountedatthesamesite,particularcareshouldbetakenwith
regardstosufficientchannelspacinganddistancebetweenantennas.Rangemaybedegradedif
thesearenotconsidered.ContactCMCforguidance.

MAN07007Rev.119

MC3Seriesinstructionmanual

6 Commissioning
Thesystemhasbeenthrougha100%testbeforeleavingfactory,ensuringthatalloutputsare
controlledbythecorrectjoystick/switchontheterminalunit,andthattheoutputvaluesarecorrect
accordingtothespecificationfromcustomer.
Whenthesystemhasbeeninstalled,customerisresponsibleforcheckingofallfunctionsina
controlledandsafemannerbeforethesystemisputintonormaloperation:
1) Checkallcontrolfunctions
Validatethateachfunctioncontrolstheintendedoperation/movementonthe
machine,withminimumtomaximumdeflection/speedwhererelevant.
Whereconfigured,validatethatallinterlockingfunctionsworksasintended.
Whereconfigured,validatethatallselectorswitchesworksasintended.
Whereconfigured,validatethatmax/minprogrammingofanaloguefunctionsworks
asintended.
Wherefeedbackfrommachine(loadcell,sensoretc)toterminalunitisconfigured,
eithertodisplayorLED,validatethattheinputsignalgivescorrectcorresponding
valueintheterminalunit.
2) ValidatetheStopfunction:PresstheStopbuttonandcheckthatallmovements/functionality
connectedintheStoplooparedeactivated.
StartupafterStop:
ForSIL3/PLecertifiedsystemstheradioremotesystemisactivatedagainbyfirst
releasingtheStopbutton,checkingthatterminalunitisONandthenpressingthe
Startbutton.
ForsystemswithON/OFFandStopbuttontheradioremotesystemisactivated
againbyfirstpoweringOFFterminalunit,releasingtheStopbuttonandpowering
ONterminalunit
ForsystemswithON/OFF,StartandStopbuttontheradioremotesystemis
activatedagainbyfirstpoweringOFFterminalunit,releasingtheStopbutton,
poweringONterminalunitandthenpressingStart.
ForsystemswithoutON/OFFandStart,onlyStop,theradioremotesystemis
activatedagainbyreleasingtheStopbutton.

Ifmoduleshavebeenreplacedatservice,orothermodificationshavebeendoneonthesystem,
commissioningmustbedonebeforethemodifiedsystemisputintooperationagain.

MAN07007Rev.1110

MC3Seriesinstructionmanual

7 Operation
7.1 Operation of Terminal
MC3seriesterminalsareproducedtocontrolavarietyofequipment,andeachterminalunitis
configureduniquelyaccordingtocustomerspecification,foroptimalintegrationwiththecustomers
machine.Specificinstructionsarefoundintheprojectspecificdocumentation.
Identificationoftypicaloperatingcontrolsandplacement:

Keyswitch
LCDDisplay

Joystick,one

axis,analog
JoystickX/Y

Analogand/or

Toggleswitch
digital(V14)

Pushbutton

JoystickX/Y

Analogand/or

Pushbutton
digital(V20)

withLED

LED
Potentiometer
Rotaryswitch

Bottomrightside:STOPbutton
Bottom left side: Cable connector

Itisimportantthattheoperatorisfamiliarwiththemachinebeingcontrolled,andhasbeengiven
thenecessarytraining.

MAN07007Rev.1111

MC3Seriesinstructionmanual

7.1.1 Explanation of symbols

Eachterminalunitisaccordingcustomerspecificationandthesymbolscanvarybothinshapeand
meaning.Symbolscanbeconfiguredaccordingtocustomerspecificrequirements.
Thesearestandardsymbolswhichcanbeusedontheterminalunit:

UP(NORTH)

RIGHT(EAST)

DOWN(SOUTH)

LEFT(WEST)

BATTERYSTATUS

HORN

LIGHT

FAST(HIGHSPEED)

SLOW(LOWSPEED)

CLAMPOPEN

CLAMPCLOSE

CLAMPOFF

CLAMPON

SLEWCCW

SLEWCW

BOMUP

BOMDOWN

JIBIN

JIBOUT

MAN07007Rev.1112

MC3Seriesinstructionmanual

TELESCOPEIN

TELESCOPEOUT

WINCHUP

WINCHDOWN

MANRIDERDOWN

MANRIDERUP

LEFTTRACK

RIGHTTRACK

7.1.2 Start
Checkthatasufficientchargedbatteryisintheterminal.
1. Pullout/twisttheStopbutton.TheStopbuttonmustbedeactivatedandalloftheswitches
andjoystickshavetobeinneutralposition.
2. PuttheON/OFFswitchinpositionON.
3. PresstheStartbuttoniffitted.
Afteraselftest(approx.1sec.)theterminalwillestablishcontactwiththebaseunit.
AllSIL3/PLecertifiedsystemsareequippedwithaStartbutton,ON/OFFandStopbutton.Someof
theSIL3/PLecertifiedsystemsareequippedwithaLOCK/RELEASEswitch.ThisLOCK/RELEASE
switchisforsafetyreason.Whenaterminalislockedtoabaseunit,thereshouldbenopossibilityto
useotherterminaltothesamebaseunit.
ASIL3/PLesystemisstartedlikethis:
1.
2.
3.
4.

Stopbuttonmustbedeactivatedandalloftheswitcheshavetobeinneutralposition.
PuttheON/OFFswitchinpositionON.
PuttheLOCK/RELEASEswitchinpositionLOCK.
Pressstartbutton.

Ifthecommunicationbetweenterminalunitandbaseunitisbroken,e.gduetoradioloss,theStart
buttonhastobeactivatedtoestablishcommunicationagain.Forsomesystemconfigurations
(allSIL3/PLecertifiedsystems)allsafetyrelatedanaloguefunctionsandanyselectorfunctions
enablingthese,havetobedeactivatedbeforeStartupisallowed.

MAN07007Rev.1113

MC3Seriesinstructionmanual

7.1.3 Stop
PresstheStopbuttontoactivatetheStop.Twistorpulltorelease.
ThesystemisdefaultequippedwithagreyStopbuttonplacedontherighthandsideofthe
terminal.

Stopbutton

Tostartmachineryagain,aftertheStopfunctionhasbeenactivated,refertochapter6,point2).
7.1.4 Time out
Ifthesystemisnotusedforatime,itcanbeconfiguredtogointopowersavemodetoconservethe
battery.Timeoutcanbeadjustedfrom099minutesorturnedoff.Defaulttimeoutis30min.
7.1.5 Selection and locking of terminal in systems with multiple terminals
Insystemswheretheoperatorcanselectbetweentwoormoreterminalunitstocontrolthebase
unit,theoperatorshoulddoadeliberateselectionandreleaseofthecontrollingterminalunit,to
ensuresafecontrolofmachinery.
SomeoftheSIL3/PLesystemsareconfiguredwithLOCK/RELEASEswitchontheterminalunits(also
availableonothersystems).AterminalunitislockedtothebaseunituntiltheRELEASEswitchon
theterminalunitisactivated.WhentheRELEASEswitchontheterminalunitisactivated,thebase
unitisdetachedandwillnowlocktothefirstterminalunitpoweredon.
InsystemsconfiguredwithLOCK/RELEASE,theterminalunitwillstaylockedtothebaseunitalsoin
theeventoflossofpowertobaseunit.Inothersystems,thebaseunitwilldetachintheeventof
powerloss.
Abaseunitcanbereleaseddirectlyfromthebaseunit:
1. PressA(SW1)onthePCBofMCIRXLITE.ThebuttonislocatedbelowtheLCD.Inthedisplay
youwillsee1:System
2. PressA(SW1).Inthedisplayyouwillsee10:Removelock
3. PressA(SW1)andholdthepressureonthebuttonwhileSW3isturnedonesteptothe
right,thenletgoofswitchA.Thebaseunitwillnowbootupanditisreleasedfromthe
terminalunit.
PictureofMCIRXLITEmodulewithitsswitchesislocatedinchapter7.2.1.

MAN07007Rev.1114

MC3Seriesinstructionmanual

7.1.6 Activity check

Forsafetyreasons,activitycheckmaybeaddedforall,orforarangeoffunctions.Thiswillforcethe
switch/joysticktobesetinneutralpositionbeforetheoperatorisallowedtostartupterminal.
Asdefault,allfunctionshaveactivitycheck.AllSIL3/PLecertifiedsystemshaveactivitycheckonall
safetyrelatedfunctions.

7.1.7 Frequency selection

MC3seriessystemscanbedeliveredwithautomaticormanualfrequencyselection.
Ifautomatic,thesystemwillscanasetof2to8predefinedfrequenciesandfindanavailable
frequency(notoccupied/withlownoise).
Allsystemtypeshavethepossibilityformanualfrequencyselection.Therewillbeafrequencyselect
buttonontheterminalorarotaryswitchtoselectthenextfrequencyprogrammedintothesystem.
Thebaseunitwillautomaticallyscantofindthefrequencytheterminalissetto.Thefunctionshould
beusedifthereisbadlinktobaseunit,eithernoconnectionorofteninterrupted.Whenchanging
frequency,alloutputswillgotoneutralpositionforashorttime.Thesystemstartsagainas
describedinchapter7.1.1.Afterpoweroffandon,thesystemwilleitherstartwithapredefined
frequencyorwiththelastselectedone,dependingonsystemsetup.

MAN07007Rev.1115

MC3Seriesinstructionmanual

7.1.8 MIN / MAX programming (optionally)

Optionallythereisaneasy,quickandexactpossibilitytoprogramanalogueoutputfromthe
terminalside.
Ifso,youwillfindtwobuttonsforMIN/MAXontheterminal.
Adjustmentprocedure:
1. Turntheterminaloff.
2. PressthePROGRAMbuttonsMINandMAXatthesametime.
3. WhilepressingtheMIN/MAXbuttons,turntheterminalon.
4. ReleasethePROGRAMbuttonsMINandMAX.Theterminalisnowinprogrammingmode,
indicatedwithshortflashesatthebatterystatusLED.IftheterminalhasaLCDdisplay,this
willshowA00,indicatingprogrammingmode.Whenafunctionisbeingprogrammedthe
displayshows:
AXXwhereXXshowswhichanalogchannelisbeingprogrammed,andisanumberbetween
01.13.
5. Adjustment:
Movethefunctionatyourchoicetoadjustuntilyougetthewantedresponse.Ifthisshallbe
yourminimumresponse,pressMIN.Ifthisshallbeyourmaximumresponse,pressMAX.The
terminalwillthenautomaticallyadjusttheincreaseoftheresponsesothatthewholearea
ofthejoystickoutputisbetweenthetwochosenpoints.
6. Eachfunctionisadjustedseparatelyforeachdirection(up/down/right/left).
7. Reset:
Movethefunctionyouselecttoresetoutfromthecenter.PressMINandMAXatthesame
time.
Thefunctionisnowreset.
8. Whentheprogrammingisfinished,thetransmittermustbeturnedoffandonagaintostart
innormalmode.

MAN07007Rev.1116

MC3Seriesinstructionmanual

7.1.9 Status indications on the terminal

TheterminalisdeliveredwithaLEDforstatusindications;thisisusuallymarkedwithSTATUSor
BAT.OnsystemsdeliveredwithLCDscreen,errorcodesandexplanationsarealsofoundthere.
LEDflashingpattern

Description

Steadylight

Normalcondition.Terminalis
turnedon,batteryvoltageis
OK,nofaultisdetected
Slowflashinglightwithoutstop Lowbatteryvoltage
(1flash/sec.)

Action
None

Replacebatterywithafully
chargedone.

Shortflashes(2flashes/sec.)

TerminalinMIN/MAX
Programmingmode
(OnlyonterminalswithMIN
MAXprogramming)

Min/Maxprogrammingof
analogfunctions.
Turnterminaloffandonagain
tostartnormaloperation.See
chapter7.1.8forfurther
explanation.
Ensurethattheprocessor
moduleBOOTjumperisnot
turnedon.Replaceprocessor
moduleand/orprocessor.

1flashwithlongstop(every
2ndsec.)

Processorfaultortestmode.
Indicatesaprocessormodule
faultand/oraprocessorfault.

2flasheswithastop

Activityatstartup.Ajoystickis
outofcentreposition,ora
switchisinONposition.

Setallswitches/joysticksto
OFFpositionand/orneutral
position.

3flasheswithastop

Radiofault

Change/replaceradiomodule.

4flasheswithastop

Shutdownduetolowbattery
voltage

Replacebatterywithafully
chargedone.

5flasheswithastop

Keyboardfault.Terminalisnot
abletoreadswitches,
joysticksetc.

Thereisafaultattheinput
module.

6flasheswithastop

Shutdownduetoinactivity.The Turnterminaloffandonagain
tostartnormaloperation.
terminalwillsoonturnitself
offsincenoswitches,joysticks
etc.havebeenactivated.

7flasheswithastop

Ensurestopbuttonisoutand
Prioritystop.Stopbuttonor
turnterminalOFFandONagain
shockdetectorhavebeen
activated.NotrelevantforSIL3 tostartnormaloperation.
certifiedsystem.

NoLED

Terminaloff

Ensureterminalcontainsa
chargedbatteryandisturned
on.Iftheterminalhasturned
itselfoffduetoinactivity,turn
itoffandonagaintostart
normaloperation.

MAN07007Rev.1117

MC3Seriesinstructionmanual

7.2 Operation of Base unit

AlltheMC3seriesbaseunitsareproducedaccordingtocustomerspecifications,thewiringdiagram
showshowthebaseunitisconnected.
Undernormalconditions,nooperationofthebaseunitisnecessary.
Ifthebaseunitdoesnotoperatecorrectly,checkthedisplayformessages.Seeinfobelow,for
yourtypeofbaseunit.
AllrepairsmustbecarriedoutbyarepresentativefromCMC.
Yourlocalrepresentativeisfoundatwww.cavotec.com

DisplayonMCIRXLITE
SW3(navigationinmenusystem)

7.2.1 MCIRXLITE and MCIRX2 base units

A(SW1 selection)
B(SW2 back)

ThedisplayonMCIRXLITEandMCIRXbaseunitsisamenusystemallowingviewingofall
operationalparametersandserviceinformation.NavigationthroughthemenusystemisdonebyA,
BandSW3,seepicture.
Duringnormaloperation,thedisplayisdividedintothreefields:anupperline,andabottomline
withastatusfieldandatimerfield.Theupperlinemayalsoindicateerrorcodes.
Indicationsintheupperline

Description

[..3......0......]

Normaloperation:Showsactivatedrelays,inthiscaserelays#3
and#10.

[Error:E003]

Failureinradiomodule.

[Error:E010]

Auxportcommunicationerror.

[Error:E011]

MUSbuscommunicationerror.

[Microcontrolas]

Nocommunicationwithaterminalandnoonboardrelaysactive.

[fatal:]

Afatalerrorhasoccurred.
<msg>isatextinthestatusfielddescribingthecause.Turnthe
supplyOffandOn.Ifthemessagereappears,contactCMC.

MAN07007Rev.1118

Indicationsinthestatusfield
A4:30%
Online

MC3Seriesinstructionmanual

Description
Mostactiveanalogoutput.Inthiscasechannel4withoutput
valueof30%.
Normaloperation,baseunitcommunicateswithaterminal.

Passive

Baseunitcommunicateswithaterminal,buttheStoprelayisde
energized.Maybecausedbytoolowsupplyvoltage.Itisnot
possibletooperateequipmentwheninpassivemode.

Idle

Baseunitdoesnotcommunicatewithaterminal.

Locked

Ifseveralterminalsareconfiguredforonebaseunit,thebase
unitcommunicateswithselectedterminalanddoesnotsearch
foradditionalterminals(firstcomefirstservemode).

Blocked

Baseunitcommunicateswithaterminal,butisinactivedueto
softplcfunction(e.g.startbuttonisnotactivated).

Thetimerfieldshowsthetimeelapsedsincethelastchangeofoperationalmode
(online/passive/idle/locked/blocked)inhours,minutesandseconds:

01:43:12

Baseunitdisplaywhenthereisnocommunicationwiththe
terminal.

Normaloperation.Baseunitcommunicateswithterminaland
relay1and7areactivated.

Afatal(nonrecoverable)errorhasoccurred.
<msg>isatextdescribingthecause.TurnthesupplyOffandOn.
Ifthemessagereappears,contactCMC.

MAN07007Rev.1119

MC3Seriesinstructionmanual

7.2.2 Field bus base units

Fieldbusbaseunitsarealwaysdeliveredwitha4digitsegmentdisplay.Thedisplaymaybestacked
onthePCBorplacedontheoutsideoftheenclosure.Thedisplayindicatesdifferentfaultstatusesas
wellaswhatterminalisonlineatanygiventime.OnstartupthedisplayalsoshowtheterminalIDs
thatissupportedinthisbaseunit.

Indicationindisplay
E001
E003
E010
E011

Description
CPUinPMfaulty
Radioerrorornoradiopresent
NocommunicationwithPLC
NocommunicationwithslavePM

7.2.3 MCLINKCAN base units

DisplayonMCLINKCAN

TheMCLINKCANisequippedwitha3digitsegmentdisplay.Thisdisplayindicatesoperationstatus
anderrormessages.Thedisplayisfoundontheupperrightcornerofthemodule.
Operationstatus
Duringnormaloperationdigit1willbeoff,andthedisplaywillindicate
Digit1(fromtheleft)
2
3
E
F

Description
Remotestatus
CanOpenstatus
Error,thenexttwodigitisanerrorcode(seetablebelowfor
errorcodes)
Fatalerror,thenexttwodigitisanerrorcode(seetablebelow
forerrorcodes)

MAN07007Rev.1120


Digit2(fromtheleft)
0

Digit3(fromtheleft)
P

S
U

MC3Seriesinstructionmanual

Description
Noterminalcommunication
Communicatingwithterminal
Stopfunctionisactivatedontheterminal
Description
Preoperational
operational
Stopped
Unknownstate

Possibleerrorindicationsindisplay
Display
E01
E03
E10
Fxx

Description
Waitingforsetupfiletobedownloaded
Radioerrorornoradiopresent
NocommunicationonCANbus
Fatalerror,powercycleisrequiredtoresume
normaloperation.Ifmessagereappears,contact
CMC.

MAN07007Rev.1121

MC3Seriesinstructionmanual

8 Battery charger and batteries

8.1 Changing the battery

UseonlybatteriesprovidedbyCMC.
1.
2.
3.
4.
5.

Putthemachinebeingcontrolledintoasafeposition.
TurntheterminalOFF.
Removethebatteryandinsertafullychargedone.
TurntheterminalON.
Hotswap
Terminalswith2batterycompartmentscancontinuetooperatewithoutbeingswitched
off.Replaceonlyonebatteryatatime.

8.2 Storage recommendation of battery

ThecapacitylossoftheLiIonbatteryduringstoringisapprox.510%permonth.Thebatteries
shouldbefullychargedwhenstored.
Ensurethatthebatteriesarestoredinanoncondensingatmospherewithnocorrosivegas.Avoid
directsunlight,hightemperatureandhighhumidity.
Recommendedstoringtemperatures:
Lessthan30days:

20to+45C.
Between30and90days:
20to+30C.
Morethan90days:

20to+20C.

Lifeexpectationofthebatterydependsofstorageanduse.Withcorrectuseyoucanexpect500
cycleswithoutasignificantdropinbatterycapacity.

MAN07007Rev.1122

MC3Seriesinstructionmanual

8.3 Battery charger installation and use

Readtheseinstructionsbeforeusingthecharger

Consultinstructionsforuse,symbolsonchargeraremeanttosupport,notreplace,
theseoperatinginstructions.

ThischargerappliestotheessentialrequirementoftheapplicableECdirectives.

Thechargerisdesignedforindooruseandshouldnotbeexposedtowaterordust.
Donotcoverupthechargerwheninuse.
Thechargeristurnedonbyconnectingittomainssocket(100Vto230V
)
orto1224V.
Disconnectingturnsitoff.

Controlthatthepowercordisnotdamaged.Ifthecordisdamaged,thechargermustnotbe
used.

Themainssocketshouldbeeasilyaccessible.Ifanoperationalerroroccurs,theplug
shouldbeimmediatelyremovedfromthemainssocket.

Thechargerisdoubleisolated(insulationclassII).
Thechargercontainsdangerousvoltagesandthecovershouldnotberemoved.The
chargerisnotserviceable.Incaseofnotworkingithastobereplacedbyanew
charger.ContactnearestCavotecsalesrepresentative(www.cavotec.com).

Avoidthechargerfromcomingintocontactwithoils,greaseetc.,asmosttypesofplasticcanbe
brokendownbychemicalsandsolvents.
Electricalandelectronicequipmentshallnotbediscardedwiththemunicipalwaste,
butbedisposedofusingseparatecollection,treatment,recovery/recyclingand
environmentallysounddisposal,accordingtolocalrules.
ThechargerisintendedtochargeMC3seriesbatteriesfromCavotecMicrocontrolAS,Cavotec
MicrocontrolAShavenoresponsibilityforanyinjuriescausedbyotherusage,notaccordingto
intendeduse.

MAN07007Rev.1123

MC3Seriesinstructionmanual

Important
Thechargerisdesignedforindooruseonly!
8.3.1 Placing and mounting of the charger
WhenthechargerisconnectedtoACorDCcurrentitshallbeplacedonaplanesurfaceormounted
verticallyonitslongitudinaldirection.Seeillustrationpicturesbelow.

Onthebatterychargersbacksidethereisfourrubberknobswhichsecureastableplacing.
Therearealsotwomountingholesforwallmountingonthebackside.Itisrecommendedtouse
4mmscrewswithheaddiameterof5,57mmandheadheightof1,52mm.Screwtypeand
lengthneedtobeadaptedtowhichmaterialandthicknessofthewallitshallbemountedon.See
illustrationpicturesbelow.

MAN07007Rev.1124

MC3Seriesinstructionmanual

8.3.2 Charger description and functionality

TheMC3serieschargerisdesignedforCMCbatterypacks,MCBATTERY3andMCEXBATTERY3.
Thebatterypackscontaintwo3,7VLithiumIonbatteriesconnectedinseries.Chargeendvoltageis
8.4V.Capacityofthebatterypackis16002030mAhfortheMCBATTERY3and11001230mAhfor
theMCEXBATTERY3.
TheMC3serieschargerisanadvancedchargerforLiIonbatteries.Itisdevelopedforoptimal
performanceandbatterypowerconservation.
ThechargerisequippedwithonetricolorLED(lightemittingdiode)atthefrontdisplayingcharge
status.Thechargermaybeusedfor100230VAC/50and60Hzorfor12VDC24VDC.(onlyACorDCata
time,notboth).ThechargerisdesignedforDCoperationinvehicles.ACandDChasseparate
inputs.Thebatterycompartmentisonthetopofthecharger.
ThechargershouldnotbeusedtochargeotherbatteriesthanMicrocontrolbatteries!
TheMC3serieschargerisaconstantcurrentchargerduringthemainperiodofcharging.Whenthe
batteryvoltageisbelowacertainlevel,thechargerisinconstantcurrentmode,deliveringcloseto
1100mA.Fastchargecontinuesuntilvoltageiscloseto8.4V,thenthechargergoesintoconstant
voltagemodeandchargecurrentdecreases.Chargeterminationoccurswhenchargecurrentis
about100mA.TypicalchargetimeforMCBATTERY3is2,5hoursandfortheMCEXBATTERY3is1,5
hours.Thebatterycapacitywilldecreaseduringthebatterylifecycle,whencapacityistolow(tolow
operationaltime)thenreplacethebatterieswithnewones.
8.3.3 Charger operating instructions
Normalchargecycle
TochargeaMCBATTERY3orMCEXBATTERY3,simplyplaceitintotheMC3seriescharger.
Chargingwillstartautomaticallywhenthebatteryisinserted.RedLEDlightindicatescharging.Ifthe
charger/batteryisoutsidetemperaturelimits,chargingwillnottakeplaceandtheLEDwillindicate
yellow.GreenLEDindicatesafullychargedbattery.Thechargerisnotintendedforcontinuoususe,
afterachargecycleiscompletedthebatteryshallberemovedandthepowerdisconnected.
DCpowercord
ConnectionoftheDCpowerisontheROKAconnectorontheleftsideofthecharger.Thecenter
leadis+.Thisisalsomarkedonthecord.Theleadistheribbedcord,+leadisatthesmoothcord
.

MAN07007Rev.1125

MC3Seriesinstructionmanual

Indicators
TheMC3serieschargerisequippedwithoneLED,placedonfront,closetothebattery
compartment.ChargerstatusisindicatedbythefollowingLEDcolors:
Chargestatus
Batteryabsent
Temperaturechargecutoff
Batteryinsertedwithnosupplyvoltage
Fastcharging
Chargecomplete

LED
Green
Yellow
Yellow
Red
Green

8.3.4 Charger ordering numbers from CMC

Versions
ThereisonlyoneversionoftheMC3serieschargercoveringvirtuallyalldifferentsupplyvoltages.
Toapplytodifferentmainsupplyvoltagestandardsthereisdifferentmainssupplycords.All
orderingnumbersarelistedbelow.
M510803600
M511403600
M511403603
M511403601
M511403602
M511403604
M510803699
M510513600
M910513600

ChargerMC3series
PowercordEUR/C7
PowercordUS/C7
PowercordUK/C7
PowercordAUSTR/C7
DCpowercordwithplug
Kitwithchargerandall5powercord.
MCBAT3
MCEXBAT3

8.3.5 Charger general specifications

Input voltage
Operating
Temperature Ambient
Storage Temperature
Humidity
Max height for usage
Mounting of the PSU
Galvanic Separation
Power inlet

Output connector

AC input: 100 - 230V

, max 150mA, 50 - 60 Hz
DC input: 12 24V
-20C - +40C
Charging takes place in the temperatur interval +10C - +40C only
-25C - +80C
10-90%
2000 meters above sea level
Two key holes on the bottom of the unit support wall mounting in two
directions
Yes
AC: IEC conn 2,5A PCB RA
DC: DC-connector 1,9mm pin Roka 520 2550
- terminal is the ribbed cord, + terminal is the smooth cord
2x gold plated pin

MAN07007Rev.1126

MC3Seriesinstructionmanual

8.3.6 Charger mechanical outline:

76,00 mm

202,00 mm

37,5 mm

8.3.7 Charger cleaning/maintenance
Withnobatteryorpowerconnectedtothecharger,thechargercanbecarefullycleanedwitha
dampcloth.
8.3.8 Charger marking

MAN07007Rev.1127

MC3Seriesinstructionmanual

8.4 Cable mode

Someterminalmodelsareequippedwithacableandbatteries,andsomewithonlyacable.The
cableisconnectedtothebaseunit,andservesasbothpowersupplyfortheterminalunitand
communicationlinktothebaseunit.Formodelswithbothradiofunctionandcable,theradiomode
isautomaticdeactivatedassoonasthecableisconnected.Theterminalandthebaseunitthen
communicateviathecable.Afterconnectingordisconnectingthecable,pressStartbuttonto
establishcommunicationwithbaseunitagain.

Plugforcablemode

9 Maintenance
Theterminalandbaseunitdonotneedanyregularmaintenance.However,theunitsshouldbe
inspectedfordamageandcleanedregularlywithadampcloth,foralldisplays,labelsandsymbolsto
bereadproperly.
Ifopeningtheterminalhousing,ensurethegasketisfixedproperlywhenclosingtheterminal.
Theterminalunitshallonlybeopenedbyqualifiedpersonnel;failureinfixingthegasketmay
degradetheIPdegree.
Iftherubberbootsontheterminalsjoysticks/switchesaredamaged,theyshouldbereplacedat
once.ContactyourlocalCMCdistributor.
YourlocalCMCdistributorisfoundatwww.cavotec.com

9.1 Spare/Replacement
SparepartscanbeorderedthroughyourlocalCMCdistributor.Youwillneedtheserialnumber(ID
code)fromthesystem,seesection1.1Marking,andthepartnumber.
Disposeofelectronicproductsaccordingtolocalrules.
YourlocalCMCdistributorisfoundatwww.cavotec.com

9.2 Service
Servicecanbearrangedwithyourlocaldistributor.Youwillneedtheserialnumberfromthesystem
anddescriptionoftheservicerequired.

MAN07007Rev.1128

MC3Seriesinstructionmanual

9.3 Fault reporting

CMCiscontinuouslyworkingtoimproveourproducts,tobeabletodeliverassafeandgood
productsaspossible.Forbestpossibleimprovement,itiscrucialtogetfeedbackfromcustomers.
Nonconformitiesontheproduct,functionalityorqualityshouldbereportedbacktoCMC.
Ifahazardoussituationorafatalerrorshouldoccuronthedeliveredsystem,pleasereportbackto
CMCforanalysis.
Reportingofnonconformitiescanbedoneviayourlocaldistributor.Youwillneedtheserialnumber
fromthesystemanddescriptionoftheservicerequired.
YourlocalCMCdistributorisfoundatwww.cavotec.com

10 Warranty
AllthedeliveriesarethoroughlytestedandpackedbeforetheyleaveCMC.Ifthedeliveryisfoundto
bedamagedwhenitisopened,informthecarrierimmediately.CMCdoesnotcoveranydamages
causedbytransport.
Allsystemsaredeliveredwith12monthswarrantyagainstmaterialandmanufacturingfaults.The
warrantycoversrepairsauthorizedbyCMCataCavotecpremises.ExpensesforserviceoutsideCMC
arenotincluded.
RepairsdonewithoutauthorityfromCMCmayinvalidateanywarranty.
Informationinthisdocumentissubjecttochangewithoutnotice.

MAN07007Rev.1129

MC3Seriesinstructionmanual

MAN07007Rev.1130

MC3Seriesinstructionmanual

MAN07007Rev.1131

MC3Seriesinstructionmanual

Cavotec Micro-control AS

Cavotec Micro-control GmbH

Gevinglia112,7517Hell
Norway
Phone:+4774843100
Email:mc@cavotec.com
ServiceEmail:support.cmc@cavotec.com

Gewerbering3,93345Hausen
Germany
Phone:+499448901200
Email:microcontrol.de@cavotec.com

Yourlocaldistributorisfoundat
www.cavotec.com
2013CavotecMicrocontrolAS
Allrightsreserved

MAN07007Rev.1132