HETRONIC BMS 1 Operator Manual

Operator Manual

BMS-1 System

HETRONIC AUSTRALIA PTY LTD CRANE CONTROL AND MONITORING
Trading as HETRONIC AUSTRALIA remote controls
4/11 DURIE RD / PO BOX 619 hoist limits
CARDIFF NSW 2285. antisway
PHONE: [phone] load display
FAX : [phone] ABN : 71 100 928 050 www.hetronic.com.au

……………………………….……..…………………..………control your bottom line

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Production and System Numbers . . . . . . . . . . 3

Unauthorized Replacement Parts . . . . . . . . . . 3

Before Attempting to Operate This System . . . 3

Theory of Operation. . . . . . . . . . . . . . . . . . . . . 3

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Practices and Laws . . . . . . . . . . . . . . . . . . . . . 4

Required Operator Training . . . . . . . . . . . . . . . 4

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Possible Sources of Danger . . . . . . . . . . . . . . 4

Operation and Work Area Safety . . . . . . . . . . . 4

Protective Features . . . . . . . . . . . . . . . . . . . . . 4

To Stop In An Emergency . . . . . . . . . . . . . . . . 4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mount the Receiver . . . . . . . . . . . . . . . . . . . . . 5

Install Receiver and Output Wiring . . . . . . 5

Mount the Actuators . . . . . . . . . . . . . . . . . 6

Attach Wiring Harness. . . . . . . . . . . . . . . . 6

Connect Electrical Wiring . . . . . . . . . . . . . 6

ME-3 Module Calibration (Optional) . . . . . 6

Install Battery Charger . . . . . . . . . . . . . . . . . . . 6

Battery Handling . . . . . . . . . . . . . . . . . . . . . . . 6

Insert the Battery - GL and Nova . . . . . . . . . . . 6

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Quick-Set System . . . . . . . . . . . . . . . . . . . . . . 7

Function Speed Adjustment. . . . . . . . . . . . . . . 7

Address Settings . . . . . . . . . . . . . . . . . . . . . . . 8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Holding the Transmitter . . . . . . . . . . . . . . . . . . 8

Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . 8

Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . 9

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . 9

Safe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Proportional Functions. . . . . . . . . . . . . . . . . . . 9

Joysticks or Paddle Levers . . . . . . . . . . . . . . 10

Option Controls . . . . . . . . . . . . . . . . . . . . . . . 10

Transmitter Shutdown . . . . . . . . . . . . . . . . . . 10

Optical Displays and Acoustic Signals. . . . . . 10

Transmitter . . . . . . . . . . . . . . . . . . . . . . . 10

Receiver . . . . . . . . . . . . . . . . . . . . . . . . . 10

Frequencies and Addresses . . . . . . . . . . . . . 10

Transmitter Options . . . . . . . . . . . . . . . . . . . . 10

Back-up Transmitter . . . . . . . . . . . . . . . . 10

ADMO Address Plugs . . . . . . . . . . . . . . . 11

Optical Low Battery Indicator. . . . . . . . . . 11

Advanced Low Battery Indication . . . . . . 11

Feedback. . . . . . . . . . . . . . . . . . . . . . . . . 11

RF Booster . . . . . . . . . . . . . . . . . . . . . . . 11

Priority Transmitters . . . . . . . . . . . . . . . . 11

RF Units. . . . . . . . . . . . . . . . . . . . . . . . . . 11

Crane/Machine Control Multiple Transmitters 11

Pitch and Catch . . . . . . . . . . . . . . . . . . . . 11

Independent/Combined Control. . . . . . . . 11

Universal Transmitter . . . . . . . . . . . . . . . 11

Optional Safety Features . . . . . . . . . . . . . . . . 12

"Press to Operate" (PTO) Safety Switch . 12

"Lift to Operate" (LTO) Joystick . . . . . . . . 12

"Lift to Operate" (LTO) Toggle Switch . . . 12

Tilt Sensor Switch . . . . . . . . . . . . . . . . . . 12

Range Limitation . . . . . . . . . . . . . . . . . . . 12

Interlocking Functions . . . . . . . . . . . . . . . 12

Magnet Switch . . . . . . . . . . . . . . . . . . . . . 12

Corrosion Protection . . . . . . . . . . . . . . . . 12

Solid State DC Outputs . . . . . . . . . . . . . . 12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Battery Charging System . . . . . . . . . . . . . . . . 13

Features . . . . . . . . . . . . . . . . . . . . . . . . . 13

The Battery Charger . . . . . . . . . . . . . . . . 13

Battery Charger Technical Specs . . . . . . 13

LED Description. . . . . . . . . . . . . . . . . . . . 13

Charging the Battery . . . . . . . . . . . . . . . . 14

Fast Charge. . . . . . . . . . . . . . . . . . . . . . . 14

Hetronic Battery Information . . . . . . . . . . 14

Battery Technical Specs . . . . . . . . . . . . . 14

Changing the Battery. . . . . . . . . . . . . . . . 14

Battery Disposal. . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 15

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installation / Safety Data Sheet . . . . . . . . . . . . . 17

Definitions & Metric Conversions . . . . . . . . . . . 18

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Frequency Chart CS 458 . . . . . . . . . . . . . . . . . . 20

Frequency Chart CS 447 . . . . . . . . . . . . . . . . . . 21

Frequency Chart CS 434 . . . . . . . . . . . . . . . . . . 22

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2

INTRODUCTION

INTRODUCTION

Thank you for purchasing the Hetronic radio remote
control system. Hetronic radio remote controls are the
highest caliber in remote control value, performance
and safety.

Hetronic radio remote controls use the latest frequency
synthesizer technology to eliminate the problems
typically associated with radio remote control systems.

The Hetronic radio remote control system includes a
transmitter and a receiver. These systems operate over
the 400-470 MHz radio band range (70 cm band) and
are FCC approved.

The transmitter generates 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 MANUAL

Before operation of unit, carefully and completely read
your manuals. The contents will provide you with an
understanding of safety instructions and controls
during normal operation and maintenance.

PRODUCTION AND SYSTEM NUMBERS

When contacting your dealer or Hetronic about service,
repair or replacement parts, know the Production and
System numbers of the transmitter and receiver.

The numbers are located on the label that is affixed to
the unit itself.

1

2

1. Specific approvals such as BTZ, FCC, CE, etc.

2. The type of transmitter or receiver.

3. Frequency and RF unit.

4. Production Number - The first digit indicates the
manufacturing facility (1=H-Germany, 2=H-Malta,
3=H-US, 4=H-International). The next four digits
are the production month and year. The last 6
digits are the manufacturing number.

5. System Number - Eleven digit system
identification number. Transmitter and receiver
must match.

3

4

5

Record the Production and System numbers here:

Transmitter Production Number

Receiver Production Number

System Number

UNAUTHORIZED REPLACEMENT PARTS

Use only Hetronic replacement parts. The replacement
of any part with anything other than a Hetronic
authorized replacement part may adversely affect the
performance, durability, and safety of this system and
may void the warranty. Hetronic disclaims liability for
any claims or damages, whether warranty, property
damage, personal injury or death arising out of the use
of unauthorized replacement parts.

BEFORE ATTEMPTING TO OPERATE THIS
SYSTEM:

1. Make sure all installation has been properly
completed.

2. Understand all Safety Precautions provided in the
manuals.

3. Review control functions and operation of the
machine and this radio remote control system.

THEORY OF OPERATION

The BMS System includes a transmitter and a receiver.
The transmitter generates the electronic signal that
communicates with the receiver. Hetronic radio remote
control systems operate in the 400-470 MHZ range (70
cm band). 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

.

3

SAFETY

SAFETY ALERTS

Look for this symbol to point out
important safety precautions. They
mean:

Attention!

Personal Safety Is Involved!

Become Alert!

Obey The Message!

The safety alert symbol is used in decals on the unit
and with proper operation procedures in this manual.
Understand the safety message. It contains important
information about personal safety on or near the unit.

DANGER: IMMINENTLY HAZARDOUS
SITUATION! If not avoided, WILL RESULT in
death or serious injury.

WARNING: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, COULD RESULT
in death or serious injury.

CAUTION: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, MAY RESULT in
minor or moderate injury. It may also be used
to alert against unsafe practices.

NOTATIONS

NOTE: General reference information for proper oper­ation and maintenance practices.

IMPORTANT: Specific procedures or information
required to prevent damage to unit or attachment.

PRACTICES AND LAWS

Practice usual and customary safe working
precautions, for the benefit of yourself and others.
Understand and follow all safety messages. Be alert to
unsafe conditions and the possibility of minor,
moderate, or serious injury or death. Learn applicable
rules and laws in your area.

REQUIRED OPERATOR TRAINING

Original purchaser of this unit was instructed by the
seller on safe and proper operation. If unit is to be used
by someone other than original purchaser; loaned,
rented or sold, ALWAYS provide this manual and any
needed safety training before operation.

ALWAYS review the operators manual of any machine
to be controlled by radio remote control.

SAFETY RULES

This radio remote control system is equipped with
electronic and mechanical safety features. Processing
of control signals transmitted from other transmitters is
not possible, since transmission coding is unique to
each system.

POSSIBLE SOURCES OF DANGER

This system makes remote control via radio signals
possible. However, the transmission of control
commands can take place around obstacles and out of
the operator’s direct sight. To prevent accidental
start-up and possible injury or damage:

1. Always engage the E-stop button and switch
"OFF" the transmitter when it is not in use.
Remove the key if the unit 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 obstacles that may interfere with
machine operation.

Always operate the transmitter with its carrying belt.

PROTECTIVE FEATURES

These safety features help protect the operator, as well
as others within the work area. The machine functions
can be stopped by pushing the emergency stop button
on the transmitter control panel (EMERGENCY STOP).

NOTE: The e-stop command is transmitted within
approximately 0.5 seconds (450 ms) after the switch is
turned to the "OFF" position.

The protective guard around the upper section of the
transmitter housing helps protect against accidental
activation of controls and unintentional operation.

WARNING: Accidental start-up can cause
serious injury or death. NEVER remove or
modify any safety feature.

TO STOP IN AN EMERGENCY

1. Press the red "EMERGENCY STOP" pushbutton.

2. Turn the key to "OFF".

3. Wait for all moving machine parts to stop.

4

4. Refer to machine’s operator manual for further
instructions.

GL-2

Emergency

Stop

Pushbutton

Nova-L

GL2_0020

INSTALLATION

WARNING: FAILURE TO FOLLOW
INSTRUCTIONS could result in personal
injury and/or damage to equipment. Read and
understand the safety instructions in all
manuals provided.

MOUNT THE RECEIVER

Install Receiver and Output Wiring

Select a position for the receiver that provides
protection from violent impact from debris or thrown
materials and is easily accessible. The receiver
housing is rated IP65 and can withstand direct water jet
spray and is protected against penetration of dust.
Therefore, weather and elements should not be the
primary concern when installing the receiver.

Four mounting holes are required when installing the
receiver unit. The drill pattern and recommended
hardware are shown in the following illustration.

NVL_0010

Emergency

Stop

NVL_0020

Pushbuttons

MAINTENANCE

Always shut off power to the machine and the radio
remote control before any assembly, maintenance or
repair.

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.

Antenna must be
vertical (pointing up).

8.29"

(210.5 mm)

Area must be
free of
obstructions

4.57"

(116 mm)

DRILL PATTERN

Drill 4 holes 9/32" (7mm).

Use 1/4" or 6mm bolts.

9.13"

(232 mm)

BMS_0030

9.72"

(246.8 mm)

BMS_0040

5

Be sure that the diagnostic LED panel is clearly visible.

Area must be free
of obstructions

ME-3 Module Calibration (Optional)

Determine the maximum stroke of the actuator and set
the ME-3 module accordingly. See the ME-3 Module
Instruction Sheet in the Technical Data Sheet section
for detailed instructions.

2.80"

(71.1 mm)

Operation

Signal

Error

Normal

6.38"

(162 mm)

4.47"

(113.5 mm)

Do not block
visibility of
diagnostic
panel.

6.61"

(167.9 mm)

BMS_0040

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 wiring are crucial and must
be connected to reliable connecting circuitry. Do not
use a chassis ground for this equipment. The ground
wire must be connected directly to the vehicle battery
negative post.

The output control signals to the proportional control
valves should be routed separately from any wiring that
could produce transient voltage interference.
Interference or "induced voltage spikes" could cause
erratic performance of the proportional controls.

INSTALL BATTERY CHARGER

The battery charger unit should be installed in the
vehicle and connected to the vehicle battery with a
fuse. The charger must be operational even when the
vehicle ignition is turned off. The battery charger’s
energy consumption impact is minimal. The charging
system is protected against polarity reversal. Install
and operate the charger in a dry, protected location
inside the vehicle. Optional battery chargers may be
powered by an AC wall plug or a DC cigarette lighter
adapter.

BATTERY HANDLING

Each Hetronic radio remote control system is delivered
with two fully charged batteries. One is inserted in the
battery compartment located on the bottom of the
transmitter. The operating time of the 3.6 V charged
battery is approximately 25-30 hours.

INSERT THE BATTERY

Be sure the battery compartment is clean. Dirt or debris
can cause contact problems.

GL

1. Insert the battery with both guide pins in the
corresponding guide bars of the battery
compartment.

2. Press the battery on the marked spot until it
latches into place.

GL-2

Battery

Mount the Actuators (Optional)

Mount and attach the actuators to the hydraulic valves
or to the mechanical linkage with the brackets supplied.

Attach Wiring Harness (Optional)

Plug the wiring harness into the receiver and into the
corresponding actuators.

Connect Electrical Wiring

Connect all remaining wires (power supply, engine
start-stop, etc.) according to the wiring diagram of the
crane and the radio remote control.

GL2_0010

Nova

1. Insert the battery with both guide bars on the
lower side of the battery in the corresponding
guide slots of the battery compartment.

2. Press the battery until it latches into place.

Nova-L

Battery

NVL_0040

6

ADJUSTMENTS

QUICK-SET SYSTEM

The Quick-Set System provides easier installation,
adjustment and service of the radio remote control
system. Quick-Set allows adjustment of all proportional
function speeds (valve travel) from the transmitter. A
red Program Key is provided to control the
programming mode. When adjustments are complete,
remove the Program Key and store it in a secure
location. Function speeds can be readjusted at any
time.

The system includes a base board, or mother board,
which includes all of the common function circuitry
found in most Hetronic receivers. These functions
include power regulation, decoding the received signal,
12 digital output functions, and the Quick-Set function.
The base board also contains diagnostic LEDs that are
visible on the outside of the transmitter housing to help
quickly diagnose problems.

FUNCTION SPEED ADJUSTMENT

This procedure requires that the receiver is connected
to the machine, all necessary wiring is complete and a
fully charged battery is in the transmitter.

IMPORTANT: The crane must be located in an open
area so that sudden or unexpected crane movements
will not damage buildings or property. All power lines
must be out of reach of the boom. Set the outriggers in
the "out and down" position as recommended by the
crane manufacturer and be sure the crane is stable.
For specific instructions, refer to the crane
manufacturer’s operator manual. Allow the truck
engine to run at "Idle".

5. Insert the red programming key into the
keyswitch.

6. Turn the transmitter "ON".

7. Wait approximately 3 seconds until the second
buzzing sound has finished.

8. Twist the key one quarter turn further to the
program position. (This is only possible with the
red programming key.) Press the "Start/horn"
button for at least one second.

9. To set minimum speed - Deflect the requested
joystick slowly until you hear the vehicle’s horn. If
the horn is connected to the receiver, it will sound
for a brief moment when the joystick reaches the
minimum movement position. Keep the joystick in
this position.

10. Adjust the speed of this function by using the
program "T-O-T" toggle switch (momentary - zero

- momentary). Push the toggle switch toward "+"
to increase speed, toward "-" to decrease speed.

Adjust the function speed to move as slowly as
possible. This helps to achieve a smooth start
when this function is activated.

11. To set maximum speed - Deflect the joystick to its
maximum position. Push the program toggle
switch toward "+" to increase speed, toward "-" to
decrease speed.

WARNING: AVOID INJURY - The crane is
moving during the adjustment of the
functions. Be sure the work area is clear of
obstacles and bystanders.

CAUTION: AVOID INJURY AND PROPERTY
DAMAGE - The crane may respond differently
with radio remote controls than with manual
controls. During the adjustment procedure,
use extreme caution with joystick/lever
movements. Avoid sudden movements and
observe crane motions carefully. The operator
must be standing on dry, level, stable ground
that is free of oil and debris.

1. Use the crane’s manual controls to raise the
boom from its rest. Extend the boom to a safe
starting point.

2. The transmitter must be attached to the operator
with the belt adjusted to a firm fit.

3. Turn the receiver power "ON".

4. Remove the black key from the transmitter
keyswitch.

The receiver can program only one function at a time.
Make sure that only one axis is deflected at a time.
When function adjustment is complete in one direction,
repeat the procedure above for the other directions and
functions. Remember to set values for both high and
low ranges.

After all adjustments are complete, wait at least 10
seconds before turning the transmitter off. The new
values will be automatically stored into the system’s
memory.

If problems occur during the adjustment procedure,
you can revert to the default values of the system.
Remove the receiver lid and press the reset button on
the board. Reinstall the receiver lid.

7