Instruction Manual IMIC-3 Series Radio Remote Control Systems MC-3-4 MC-3-5 MC-3-6 MC-3000 MC-3200 MC-3000+ MC-3300 ©Ocavortec Cavotec Micro-control AS Wesselsv 2, 7500 Stjardal, Norway E-mail: me@cavotec.com Tel.: + 47 74 83 98 60 www.cavotec.comContents 1. Introduction 2. Description 3. Functional Description 4. Main Data 5. Installation 6. Operation 7. Battery Charger and Batteries 8. Maintenance 9. Safety Compliances Safety Notes Inspect the MC-3 series equipment before using [zy teck for any damage that may be incurred during shipping. Do not open the housing. There are no user serviceable parts. Do not use the device if it appears to be damaged. Use only recommended batteries. Avoid shock and vibrations if possible. Avoid high temperature. Do not immerse in water. ENSURE THAT THE SUPPLY VOLTAGE IS CORRECT. INSTALLATION SHOULD ONLY BE CAR- RIED OUT BY QUALIFIED PERSONNEL. Vv Vv Vv Vv Vv @ @ ® Cavotec Micro-control AS reserves the right to make improvements and/or changes in the products and/or specifi cations described in this information at any time without notice. 1. Introduction The equipment of the MC-3 series is designed for use in harsh industrial environment to con- trol machinery such as overhead cranes, hoists, recovery vehicles, concrete pumps, sludge ‘trucks etc. The remote controls use joysticks, pushbuttons and toggle switches to control the designated equipment. As the different remote control models vary according to customer requirements, this manual describes only functions that are common for all MC-3 series deliveries. For cus- tomer-specific systems please refer to applied documentation. 1.1 Marking Qcavotec ese tee oat ee ona = The serial number is found on the backside of the respective unit. (cont.)1.1 Marking (cont.) Qowvorec = Sone Base unit MC-3300 2. Description The system consists of a terminal (remote control), with a carrying belt or neck strap, batteries, a base unit with an antenna and a battery charger. Some models are equipped with a cable. As customer specifications vary greatly, the terminal comes in different models which differ in configuration, size and weight. The graphic below shows two typical examples of a terminal Terminal - example 1 Contains the pushbuttons, joysticks, toggle switches and LED indicator lamps. The terminal is carried by the operator with a belt or a neck strap. Example for models MC-3000 MC-3000+ MC-3300 Cable (optional) Connects the terminal with the base unit and serves both as power supply and communica- tion line.Antenna Located on or connected to the base unit with a coaxial cable. Can be an internal or external type. External antenna can be mounted on the base unit or some distance away with an extension cable supplied by Cavotec Micro- Base unit control. The part of the system connected to the machine or PLC. Carrying belt/ neck strap Belt or strap to carry the terminal safely and keep the operator's hands free. Should be used whenever the terminal is being operated for safety and comfort. Failure to use the @ belt or strap may cause injury as you will not have prop- er control of the terminal. Terminal - example 2 Example for models MC-3-4 MC3-5 MC-3-63. Functional Description The remote control communicates by radio signals or by cable, with the base unit which is installed on the designated equipment. 3.1 Signal Encoding Unique encoding of the radio signal prevents unintentional operation caused by interfer- ence from other radio systems. 3.2 Feedback If configured the operator can read informa- tion from the machine at the operator termi- nal. The information could include e.g. % of load, rpm, torque, speed, text instruction, etc. 3.3 Operating Range Depending on the installation the operating range can be from 100-1000m. The range may change according to the surroundings and other equipment. 3.4 Base Unit Refer to system specific data. x YY Signal from operator terminal to base unit. 4. M. Data Terminal Base unit imensions MC-3-4 360x200x160mm Physical size and weight of the housing (L-W-H) MC-3-5 — 230x175x160mm will vary for each delivery. MC-3-6 — 330x220x200mm Please refer to system specific drawings MC-3000 250x158x180mm and order specific documentation. MC-3200 280x180x180mm MC-3000+ 305x200x190mm MC-3300 _340x230x185mm Weight 2-4 kg (the weight will vary with the terminal's equipment) IP class IP-range 65, 66 or 67 depending on requirements (Battery charger: IP-40) Temperature between -25°C and +50°C (Battery charger: between +10°C and +40°C) frequency | AUTO/Selectable 418-474MHz Radio power <10mW, according to regulations Operating range _| 100-1000m Batteries Use only MC-3-series batteries | Power | 12-24vDc from Cavotec. supply | 48-240VAC 380VAC 50/60Hz Operating time | Approx. 8 hours continuous Input | Refer to system specific data. operation with fully charged batteries, Time out Adjustable Output | Refer to system specific data.5. Installation © © Vv [a] the installation is subject to harsh vibrations use isolating mountings INSTALLATION SHOULD ONLY BE CAR- RIED OUT BY QUALIFIED PERSONNEL. ENSURE THE SUPPLY VOLTAGE IS CORRECT. Consider the ambient temperature and IP rating, available from Cavotec Micro-control AS. 5.1 Installing the Base Unit 1)_ Fasten the base unit securely onto a suit- able part of the machine or equipment being controlled. a) Install if possible, in direct line of sight with the operator. b) Ensure that the base unit is installed where it will not be conflicting with moving parts in operation 2) Reserve space around the unit to ensure easy removal of the lid/opening of the door and easy access to the connectors and buttons in the base unit. Connect the base unit according to the system specific drawings. 5.2 Installing the Antenna The best location for the antenna is some- where in free space, and with a free line to the operator's position. Vv Take care that the antenna will not be damaged by moving machinery. Do not mount the antenna inside a metal enclosure. 6. Operation 6.1 Operation of Terminal MC-3 series terminals are produced to control a variety of equipment. Specific instructions are not given here. It is important that the operator is familiar with the machine being controlled and has been given the necessary training. Start Check that a fully charged battery is in the terminal. Pull outtwist the Emergency Stop button and turn the terminal ON. Press the Start button if fitted. After a self test (approx. 1 sec.) the terminal will establish contact with the base unit. Stop and Emergency Stop Press the Emergency Stop button. Emergency stop button Time Out If the system is not used for a time it can be configured to go into to power save mode to conserve the battery. Time Out can be adjusted from 0-99 minutes or turned off.Status indications on the terminal Flashing pattern Description Action Steady light Normal condition. Terminal is turned on, battery voltage is OK, no fault is detected None Slow flashing light wio stop (1 flash/sec.) Low battery voltage Replace battery with a fully charged one. Short flashes (2 flashes/sec.) Programming mode Turn terminal off and on again to start normal operation. 1 flash with long stop (every 2nd sec.) Processor fault or test mode. Indicates a processor module fault and/or a processor fault. Ensure that the processor module BOOT-jumper is not turned on. Replace processor module and/or Processor. 2 flashes with a stop Activity at start-up. A joystick is out of centre position, or a switch is in ON-position. Set all switches/joysticks to OFF-posi- tion and/or neutral position 3 flashes with a stop Radio fault Change/replace radio module. 4 flashes with a stop Shutdown due to low battery voltage Replace battery with a fully charged one. 5 flashes with a stop Keyboard fault. Terminal is not able to “read” switches, joysticks etc. There is a fault at the input module. 6 flashes with a stop Shutdown due to inactivity. The terminal will soon "turn itself off” since no switches, joysticks etc. have been activated. Turn terminal off and on again to start normal operation. 7 flashes with a stop Priority stop. Stop button or shock detector have been activated Ensure stop button is out and turn terminal OFF and ON again to start normal operation. No LED Ensure terminal contains a charged battery and is turned on. If the terminal has turned itself off due to inactivity, turn it off and on again to start normal operation.6.2. Operation of Base Unit All the MC-3-series base units are produced according to customer specifications, the wiring diagram shows how the base uni connected. If the base unit does not operate correctly, check the LED indication and display for mes- sages, see below. All repairs must be carried out by a rep- resentative from Cavotec Micro-control AS. Possible indications in the base unit During normal operation, the display is divided into three fields, an upper line, the status and the timer. Base unit display when there is no communication with the terminal. Base unit display when the operator terminal is switched on. When a fatal (non recoverable) error occurs, the display shows: is a text describing the cause. Turn the supply Off and On. If the message reappears, the main board is faulty and needs replacing. The display is also used for a menu system al- lowing viewing of all operational parameters and service information. ‘The timer field shows the time elapsed since the last change of operational mode (online/ passivefidle/locked/blocked) in hours, minutes and seconds: 01:43:12 Indications in the upper line: [Error: £003] Failure in radio module. [Brroz: £010] ‘Aux port commu- nication error. (Error: E011] MUS bus commu- nication error. (Micro-control as] | No communication with a terminal and no onboard relays active. Shows activated relays, in this case relays #3 and #10. Indications in the status field: Most active analogue output. In this case channel 4 with output value of -30% . Online | Base unit communicates with a terminal and E-stop is active. Passive | Base unit communicates with a terminal, but E-stop relay is inactive. May be caused by too low supply voltage. Idle Base unit does not communicate with a terminal. Locked Base unit does not communicate and does not search for add tional terminals (first come first serve mode). Blocked | Base unit communicates with a terminal and E-stop is inactive due to active stop or softplc function.7. Battery Charger and Batteries The operating time for a fully charged battery is approximately 8 hours. The rechargeable battery has a lifetime of approximately 1000 charging cycles or 2-3 years. These times can vary according to usage, system specifications and ambient temperature. Vv Vv Vv Risk of electric shock if used incorrectly. Do not use the device if it appears to be damaged. The battery charger is intended for indoor use only. Keep away from high humidity and heat. 7.1 Changing the Battery Use only batteries provided by Cavotec Micro-control AS. 1) Put the machine being controlled in to a safe position. 2) Turn the terminal OFF. 3) Remove the battery and insert a fully charged one. 4) Turn the terminal ON. 5) Terminals with 2 batteries fitted can con- tinue to operate, replace only one battery ata time. 7.2 Battery Charger Installation and Use Use only the battery charger supplied with the system or a replacement from Cavotec Micro-control AS. 1) _ Install the battery charger in a clean and dry environment (+10°C to +40°0). 2) Connect the charger to the correct supply voltage. 3) _ Insert the battery to be charged. 4) Wait to see the indication that charging is normal. An indicator shows when the battery is charged. 5) Leave the battery in the charger until it is required for use. 6) Batteries not in constant use should be charged at least once every 2 months 7.3 Disposing of the Batteries (-] Batteries are hazardous waste and must not be disposed of with normal rubbish. You should dispose of the batteries ac- cording to local laws and rules, or return them to Cavotec Micro-control AS. 7.4 Power Supply (if applicable) Some terminal models are equipped with a cable and batteries and some with only a cable. The cable is connected to the base unit and serves as both power supply and commu nication line to the base unit. For models with both radio function and cable, the radio mode is deactivated as soon as the cable is con- nected. The terminal and the base unit then communicate via the cable. Plug socket on the terminal8. Maintenance The terminal and base unit do not need any maintenance. However, the units should be inspected for damage and cleaned regularly, so all displays, labels and symbols can be read properly. YI" the rubber boots of the terminals joysticks are damaged, replace them at once. 8.1 Spare/Replacement Spare parts can be ordered through your local istributor. You will need the serial number from the system, see section 1.1 Marking, and the part number. [ik] Dispote of electronic products according to local rules. 8.2 Service Service can be arranged with your local distributor. You will need the serial number from the system and description of the service required MC-3 Series Instruction Manual MAN-07-007-02 9. Safety Compliances The MC-3-series is designed in accordance with: - Low Voltage Directive (73/23/EEC) - EMC Directive (89/336/EEC) - Machinery Directive (89/392/EEC, 91/368, 93/44/EEC) = R&TTE Directive (99/5/EC) Further standards and certificates may be included depending on the application. The system is certified according to the Federal Communications Commission rules Part 90 sub clause 217. To maintain the distance of 20 cm from the body to the antenna as required in the rules the terminal should only be used with the carrying belt. 9.1 Warranty All the deliveries are thoroughly tested and packed before they leave Cavotec Micro-con- trol AS. If the delivery is found to be damaged when it is opened, inform the carrier imme ately. Cavotec Micro-control AS does not cover any damages caused during transport All systems are delivered warranted against material and manufacturing faults. The war- ranty covers repairs authorised by Cavotec Micro-control. Expenses for service outside Cavotec Micro-control AS are not included. Repairs done without authority from Cavotec Micro-control AS may invalidate any warranty. Information in this document is subject to change without notice. © 2008 Cavotec Micro-control. All rights reserved