MAN-07-007 MC-3 Series Instruction Manual.pdf

InstructionManualMC3SeriesRadioremotecontrolsystems

MC3Seriesinstructionmanual

MAN07007Rev.112

ContentsSAFETYNOTES.............................................................................................................................................31 INTRODUCTION...................................................................................................................................4

1.1 MARKING.................................................................................................................................................42 SYSTEMDESCRIPTION..........................................................................................................................5

2.1 TERMINAL.................................................................................................................................................52.2 BASEUNIT................................................................................................................................................62.3 CABLECONNECTION(OPTIONAL)...................................................................................................................62.4 ANTENNA.................................................................................................................................................62.5 CARRYINGBELT/NECKSTRAP........................................................................................................................6

3 FUNCTIONALDESCRIPTION..................................................................................................................73.1 SYSTEMCONFIGURATION.............................................................................................................................73.2 SIGNALENCODING......................................................................................................................................73.3 FEEDBACK.................................................................................................................................................73.4 OPERATINGRANGE.....................................................................................................................................7

4 MAINDATA.........................................................................................................................................85 INSTALLATION.....................................................................................................................................9

5.1 INSTALLINGTHEBASEUNIT..........................................................................................................................95.2 INSTALLINGTHEANTENNA...........................................................................................................................9

6 COMMISSIONING...............................................................................................................................107 OPERATION.......................................................................................................................................11

7.1 OPERATIONOFTERMINAL..........................................................................................................................117.2 OPERATIONOFBASEUNIT.........................................................................................................................18

8 BATTERYCHARGERANDBATTERIES...................................................................................................228.1 CHANGINGTHEBATTERY............................................................................................................................228.2 STORAGERECOMMENDATIONOFBATTERY....................................................................................................228.3 BATTERYCHARGERINSTALLATIONANDUSE....................................................................................................238.4 CABLEMODE...........................................................................................................................................28

9 MAINTENANCE..................................................................................................................................289.1 SPARE/REPLACEMENT...............................................................................................................................289.2 SERVICE..................................................................................................................................................289.3 FAULTREPORTING....................................................................................................................................29

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


MAN07007Rev.113

Safetynotes

InspecttheMC3seriesequipmentbeforeusingit.

Checkforanydamagethatmaybeincurredduringshipping.

Donotopentheterminalunit.Therearenouserserviceableparts.

Donotusethedeviceifitappearstobedamaged.

UseonlyoriginalbatteriesfromCMC.

Avoidmechanicalshockandvibrationsifpossible.

Donotuseoutsidetemperaturerange.

Donotimmerseinwater.

ENSURETHATTHESUPPLYVOLTAGEISCORRECT.

INSTALLATIONSHOULDONLYBECARRIEDOUTBYQUALIFIEDPERSONNEL.CavotecMicrocontroltakesnoresponsibilityforprotectionimpairmentifusedinamannernotspecifiedintheinstructionmanualand/ortheprojectspecificdocumentation.

CavotecMicrocontrolreservestherighttomakeimprovementsand/orchangesintheproductsand/orspecificationsdescribedinthisinformationatanytimewithoutnotice.


MAN07007Rev.114

1 IntroductionTheMC3seriesradioremotecontrolisdesignedforuseinharshindustrialenvironmenttocontrolmachinerysuchasoverheadcranes,hoists,recoveryvehicles,concretepumps,sludgetrucksetc.Asthedifferentremotecontrolmodelsvaryaccordingtocustomerrequirements,thismanualdescribesonlyfunctionsthatarecommonforallMC3seriesdeliveries(includingMC3seriesEX).Forcustomerspecificsystemspleaserefertoprojectdocumentation.1.1 Marking1.1.1 Terminalunits

Theserialnumberandotherrelevantdatasuchasfrequency,projectnumberetc.isfoundonthebacksideoftherespectiveunit.

1.1.2 Baseunit

Theserialnumberandotherrelevantdatasuchasfrequency,projectnumberetc.isfoundontherighthandsideoftherespectiveunit.


MAN07007Rev.115

2 SystemdescriptionThesystemconsistsof

terminal(remotecontrolunit),withacarryingbeltorneckstrap

baseunitwithantenna (batterychargerandbatteries)Theterminalandthebaseunitarecommunicatesviaaradiolink.Somesystemsarealsodeliveredwithacableforcommunicationbetweenterminalandbaseunitastheonlywayofcommunicationorasabackupfortheradiolink.Whenthesystemcommunicatesonlybycable,batterychargerandbatteriesarenotpartofdelivery.Ascustomerrequirementsvarygreatly,thesystemcomesindifferentmodelswhichdifferinconfiguration,sizeandweight.

2.1 TerminalTheterminalcontainstheStopswitch,pushbuttons,joysticks,toggleswitches,LEDindicatorlampsandoptionallyaLCDdisplay.Theterminaliscarriedbytheoperatorwithabeltoraneckstrap.AllterminalsarealsoavailableinEXproofversionsexceptofMC3100.

MC3200 MC3300

MC35 MC36

MC3100


MAN07007Rev.116

2.2 BaseunitThebaseunitisthepartofthesystemthatisconnectedtothecustomersmachineorPLC.CMCdeliversoutputsignalstocontrolthemachineryfromtheremotecontrol,basedonthecustomersspecification.ThebaseunitcanbedeliveredinEXorNONEX.

CMChasnoresponsibilityforcontrolelementsthatarepartofmachinery.2.3 Cableconnection(optional)

Thecableconnectstheterminalwiththebaseunitandservesbothaspowersupplyandcommunicationline.Cablecanbeusedasbackuporinsteadofradiocommunication.Whenthecableisconnected,thesystemwillautomaticallycommunicateoncable,andtheradiowillbedisabled.2.4 Antenna

Locatedonorconnectedtothebaseunitwithacoaxialcable.Theantennacanbeofinternalorexternaltype.ExternalantennacanbemountedonthebaseunitorsomedistanceawaywithanextensioncablesuppliedbyCavotecMicrocontrol.

Dependingofcabletype,therecommendedmaximumlengthoftheantennaextensioncableiseither30mor50m.2.5 Carryingbelt/neckstrap

Thecarryingbeltorstrapshouldalwaysbeusedwhenevertheterminalisoperatedtocarrytheterminalsafelyandkeeptheoperatorshandsfree.

Failuretousethebeltorstrapmaycauseinjuryasyouwillnothavepropercontroloftheterminal.


MAN07007Rev.117

3 FunctionaldescriptionTheterminalunitcommunicatesbyradiosignalsorbycable,withthebaseunitwhichisinstalledatthedesignatedequipment.

3.1 Systemconfiguration

Thesystemmayconsistofmorethanoneterminal/baseunitoperatingtogether.Whereseveralterminalunitsareusedtocontrolonebaseunit,itiscustomersresponsibilitytoensurethattheoperatoralwayshascontrolofwhichterminalunitisinoperation,toavoidanydangerousuncontrolledmovements.Fortandemconfigurations,e.g.multiplecranesdoingtandemliftofheavyequipmentpleaserefertothespecificationSP11015CMCTandemconfigurations.3.2 Signalencoding

Uniqueencodingoftheradiosignalpreventsunintentionaloperationcausedbyinterferencefromotherradiosystems.3.3 Feedback

Iffeedbackisconfigured,theoperatorcanreadinformationfromthemachineattheterminalunit,viaadisplayorLEDS.Theinformationcouldincludee.g.%ofload,rpm,torque,speed,textinstruction,etc.Ifthefeedbackisadirectinputfromthemachinery,customerisresponsiblefortheinformationbeingpresented.3.4 Operatingrange

Dependingontheinstallationtheoperatingrangecanbefrom1001000m,typically200mlineofsight.Therangemaychangeaccordingtothesurroundingsandotherequipment.Toachieveoptimalrange,careshouldbetakenwheninstallingtheantenna(Chapter5.2).


MAN07007Rev.118

4 Maindata Terminal Base unit

Dimensions(LWH)

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


MAN07007Rev.119

5 InstallationINSTALLATIONSHOULDONLYBECARRIEDOUTBYQUALIFIEDPERSONNEL.ENSURETHESUPPLYVOLTAGEISCORRECT.

ConsidertheambienttemperatureandIPrating.

Iftheinstallationissubjecttoharshvibrations,usevibrationdampersavailablefromCMC.5.1 InstallingtheBaseunit

1) Fastenthebaseunitsecurelyontoasuitablepartofthemachineorequipmentbeingcontrolled.a) Installthebaseunitinamechanicalprotectedareanotbeingexposedtodamageb) Makesurethebaseunitisnotinstallednearhighenergylinesc) Ensurethatthebaseunitisinstalledwhereitwillnotbeconflictingwithmovingpartsin

operation2) Reservespacearoundtheunittoensureeasyremovalofthelid/openingofthedoorandeasy

accesstotheconnectorsandbuttonsinthebaseunit3) Thesystemshallbeinstalled/wiredaccordingtothewiringdiagramandsystemdescription

givenintheprojectspecificdocumentation.Controlthattheload(valvesetc.)isconnectedcorrectandthatthespecificationontheloadiswithinthespecifiedminimum/maximumloadoftheCMCoutputrelays.

5.2 InstallingtheAntennaMounttheantennasothereislineofsightbetweentheantennaonthebaseunitandtheterminalcarriedbytheoperator.Largemetalobjectsbetweentheterminalandantennaonbaseunitmaystopthesignalandpreventoperation.

Takecarethattheantennawillnotbedamagedbymovingmachinery.

Donotmounttheantennainsideametalenclosure.Thereshouldbenometalobjectswithinaradiusof1mfromthecentreoftheantenna

Otherwirelessequipmentmayinterferewiththeradioremotesystem.Frequencyplanningisimportanttoavoidthis.ContactCMCforguidance

Ifmorethanoneantennaismountedatthesamesite,particularcareshouldbetakenwithregardstosufficientchannelspacinganddistancebetweenantennas.Rangemaybedegradedifthesearenotconsidered.ContactCMCforguidance.


MAN07007Rev.1110

6 CommissioningThesystemhasbeenthrougha100%testbeforeleavingfactory,ensuringthatalloutputsarecontrolledbythecorrectjoystick/switchontheterminalunit,andthattheoutputvaluesarecorrectaccordingtothespecificationfromcustomer.Whenthesystemhasbeeninstalled,customerisresponsibleforcheckingofallfunctionsinacontrolledandsafemannerbeforethesystemisputintonormaloperation:1) Checkallcontrolfunctions

Validatethateachfunctioncontrolstheintendedoperation/movementonthemachine,withminimumtomaximumdeflection/speedwhererelevant.

Whereconfigured,validatethatallinterlockingfunctionsworksasintended. Whereconfigured,validatethatallselectorswitchesworksasintended. Whereconfigured,validatethatmax/minprogrammingofanaloguefunctionsworks

asintended. Wherefeedbackfrommachine(loadcell,sensoretc)toterminalunitisconfigured,

eithertodisplayorLED,validatethattheinputsignalgivescorrectcorrespondingvalueintheterminalunit.

2) ValidatetheStopfunction:PresstheStopbuttonandcheckthatallmovements/functionalityconnectedintheStoplooparedeactivated.StartupafterStop:

ForSIL3/PLecertifiedsystemstheradioremotesystemisactivatedagainbyfirstreleasingtheStopbutton,checkingthatterminalunitisONandthenpressingtheStartbutton.

ForsystemswithON/OFFandStopbuttontheradioremotesystemisactivatedagainbyfirstpoweringOFFterminalunit,releasingtheStopbuttonandpoweringONterminalunit

ForsystemswithON/OFF,StartandStopbuttontheradioremotesystemisactivatedagainbyfirstpoweringOFFterminalunit,releasingtheStopbutton,poweringONterminalunitandthenpressingStart.

ForsystemswithoutON/OFFandStart,onlyStop,theradioremotesystemisactivatedagainbyreleasingtheStopbutton.

Ifmoduleshavebeenreplacedatservice,orothermodificationshavebeendoneonthesystem,commissioningmustbedonebeforethemodifiedsystemisputintooperationagain.


MAN07007Rev.1111

7 Operation7.1 OperationofTerminal

MC3seriesterminalsareproducedtocontrolavarietyofequipment,andeachterminalunitisconfigureduniquelyaccordingtocustomerspecification,foroptimalintegrationwiththecustomersmachine.Specificinstructionsarefoundintheprojectspecificdocumentation.Identificationoftypicaloperatingcontrolsandplacement: Itisimportantthattheoperatorisfamiliarwiththemachinebeingcontrolled,andhasbeengiventhenecessarytraining.

JoystickX/YAnalogand/ordigital(V14)

LCDDisplay

Joystick,oneaxis,analog

JoystickX/YAnalogand/ordigital(V20)

Keyswitch

PushbuttonwithLED

Toggleswitch

Pushbutton

Bottom left side: Cable connector Bottomrightside:STOPbutton

Potentiometer RotaryswitchLED


MAN07007Rev.1112

7.1.1 ExplanationofsymbolsEachterminalunitisaccordingcustomerspecificationandthesymbolscanvarybothinshapeandmeaning.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.1113

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.SomeoftheSIL3/PLecertifiedsystemsareequippedwithaLOCK/RELEASEswitch.ThisLOCK/RELEASEswitchisforsafetyreason.Whenaterminalislockedtoabaseunit,thereshouldbenopossibilitytouseotherterminaltothesamebaseunit.ASIL3/PLesystemisstartedlikethis:

1. Stopbuttonmustbedeactivatedandalloftheswitcheshavetobeinneutralposition.2. PuttheON/OFFswitchinpositionON.3. PuttheLOCK/RELEASEswitchinpositionLOCK.4. Pressstartbutton.

Ifthecommunicationbetweenterminalunitandbaseunitisbroken,e.gduetoradioloss,theStartbuttonhastobeactivatedtoestablishcommunicationagain.Forsomesystemconfigurations(allSIL3/PLecertifiedsystems)allsafetyrelatedanaloguefunctionsandanyselectorfunctionsenablingthese,havetobedeactivatedbeforeStartupisallowed.


MAN07007Rev.1114

7.1.3 StopPresstheStopbuttontoactivatetheStop.Twistorpulltorelease.ThesystemisdefaultequippedwithagreyStopbuttonplacedontherighthandsideoftheterminal.

Tostartmachineryagain,aftertheStopfunctionhasbeenactivated,refertochapter6,point2).7.1.4 Timeout

Ifthesystemisnotusedforatime,itcanbeconfiguredtogointopowersavemodetoconservethebattery.Timeoutcanbeadjustedfrom099minutesorturnedoff.Defaulttimeoutis30min.7.1.5 Selectionandlockingofterminalinsystemswithmultipleterminals

Insystemswheretheoperatorcanselectbetweentwoormoreterminalunitstocontrolthebaseunit,theoperatorshoulddoadeliberateselectionandreleaseofthecontrollingterminalunit,toensuresafecontrolofmachinery.SomeoftheSIL3/PLesystemsareconfiguredwithLOCK/RELEASEswitchontheterminalunits(alsoavailableonothersystems).AterminalunitislockedtothebaseunituntiltheRELEASEswitchontheterminalunitisactivated.WhentheRELEASEswitchontheterminalunitisactivated,thebaseunitisdetachedandwillnowlocktothefirstterminalunitpoweredon.InsystemsconfiguredwithLOCK/RELEASE,theterminalunitwillstaylockedtothebaseunitalsointheeventoflossofpowertobaseunit.Inothersystems,thebaseunitwilldetachintheeventofpowerloss.Abaseunitcanbereleaseddirectlyfromthebaseunit:

1. PressA(SW1)onthePCBofMCIRXLITE.ThebuttonislocatedbelowtheLCD.Inthedisplayyouwillsee1:System

2. PressA(SW1).Inthedisplayyouwillsee10:Removelock3. PressA(SW1)andholdthepressureonthebuttonwhileSW3isturnedonesteptothe

right,thenletgoofswitchA.Thebaseunitwillnowbootupanditisreleasedfromtheterminalunit.

PictureofMCIRXLITEmodulewithitsswitchesislocatedinchapter7.2.1.

Stopbutton


MAN07007Rev.1115

7.1.6 ActivitycheckForsafetyreasons,activitycheckmaybeaddedforall,orforarangeoffunctions.Thiswillforcetheswitch/joysticktobesetinneutralpositionbeforetheoperatorisallowedtostartupterminal.Asdefault,allfunctionshaveactivitycheck.AllSIL3/PLecertifiedsystemshaveactivitycheckonallsafetyrelatedfunctions.7.1.7 Frequencyselection

MC3seriessystemscanbedeliveredwithautomaticormanualfrequencyselection.Ifautomatic,thesystemwillscanasetof2to8predefinedfrequenciesandfindanavailablefrequency(notoccupied/withlownoise).Allsystemtypeshavethepossibilityformanualfrequencyselection.Therewillbeafrequencyselectbuttonontheterminalorarotaryswitchtoselectthenextfrequencyprogrammedintothesystem.Thebaseunitwillautomaticallyscantofindthefrequencytheterminalissetto.Thefunctionshouldbeusedifthereisbadlinktobaseunit,eithernoconnectionorofteninterrupted.Whenchangingfrequency,alloutputswillgotoneutralpositionforashorttime.Thesystemstartsagainasdescribedinchapter7.1.1.Afterpoweroffandon,thesystemwilleitherstartwithapredefinedfrequencyorwiththelastselectedone,dependingonsystemsetup.


MAN07007Rev.1116

7.1.8 MIN/MAXprogramming(optionally)Optionallythereisaneasy,quickandexactpossibilitytoprogramanalogueoutputfromtheterminalside.Ifso,youwillfindtwobuttonsforMIN/MAXontheterminal.Adjustmentprocedure:

1. Turntheterminaloff.2. PressthePROGRAMbuttonsMINandMAXatthesametime.3. WhilepressingtheMIN/MAXbuttons,turntheterminalon.4. ReleasethePROGRAMbuttonsMINandMAX.Theterminalisnowinprogrammingmode,

indicatedwithshortflashesatthebatterystatusLED.IftheterminalhasaLCDdisplay,thiswillshowA00,indicatingprogrammingmode.Whenafunctionisbeingprogrammedthedisplayshows:AXXwhereXXshowswhichanalogchannelisbeingprogrammed,andisanumberbetween01.13.

5. Adjustment:Movethefunctionatyourchoicetoadjustuntilyougetthewantedresponse.Ifthisshallbeyourminimumresponse,pressMIN.Ifthisshallbeyourmaximumresponse,pressMAX.Theterminalwillthenautomaticallyadjusttheincreaseoftheresponsesothatthewholeareaofthejoystickoutputisbetweenthetwochosenpoints.

6. Eachfunctionisadjustedseparatelyforeachdirection(up/down/right/left).7. Reset:

Movethefunctionyouselecttoresetoutfromthecenter.PressMINandMAXatthesametime.Thefunctionisnowreset.

8. Whentheprogrammingisfinished,thetransmittermustbeturnedoffandonagaintostartinnormalmode.


MAN07007Rev.1117

7.1.9 StatusindicationsontheterminalTheterminalisdeliveredwithaLEDforstatusindications;thisisusuallymarkedwithSTATUSorBAT.OnsystemsdeliveredwithLCDscreen,errorcodesandexplanationsarealsofoundthere.LEDflashingpattern Description ActionSteadylight Normalcondition.Terminalis

turnedon,batteryvoltageisOK,nofaultisdetected

None

Slowflashinglightwithoutstop(1flash/sec.)

Lowbatteryvoltage Replacebatterywithafullychargedone.

Shortflashes(2flashes/sec.) TerminalinMIN/MAXProgrammingmode(OnlyonterminalswithMINMAXprogramming)

Min/Maxprogrammingofanalogfunctions.Turnterminaloffandonagaintostartnormaloperation.Seechapter7.1.8forfurtherexplanation.

1flashwithlongstop(every2ndsec.)

Processorfaultortestmode.Indicatesaprocessormodulefaultand/oraprocessorfault.

EnsurethattheprocessormoduleBOOTjumperisnotturnedon.Replaceprocessormoduleand/orprocessor.

2flasheswithastop Activityatstartup.Ajoystickisoutofcentreposition,oraswitchisinONposition.

Setallswitches/joystickstoOFFpositionand/orneutralposition.

3flasheswithastop Radiofault Change/replaceradiomodule.4flasheswithastop Shutdownduetolowbattery

voltageReplacebatterywithafullychargedone.

5flasheswithastop Keyboardfault.Terminalisnotabletoreadswitches,joysticksetc.

Thereisafaultattheinputmodule.

6flasheswithastop Shutdownduetoinactivity.Theterminalwillsoonturnitselfoffsincenoswitches,joysticksetc.havebeenactivated.

Turnterminaloffandonagaintostartnormaloperation.

7flasheswithastop Prioritystop.Stopbuttonorshockdetectorhavebeenactivated.NotrelevantforSIL3certifiedsystem.

EnsurestopbuttonisoutandturnterminalOFFandONagaintostartnormaloperation.

NoLED Terminaloff Ensureterminalcontainsachargedbatteryandisturnedon.Iftheterminalhasturneditselfoffduetoinactivity,turnitoffandonagaintostartnormaloperation.


MAN07007Rev.1118

7.2 OperationofBaseunitAlltheMC3seriesbaseunitsareproducedaccordingtocustomerspecifications,thewiringdiagramshowshowthebaseunitisconnected.Undernormalconditions,nooperationofthebaseunitisnecessary.Ifthebaseunitdoesnotoperatecorrectly,checkthedisplayformessages.Seeinfobelow,foryourtypeofbaseunit.

AllrepairsmustbecarriedoutbyarepresentativefromCMC.Yourlocalrepresentativeisfoundatwww.cavotec.com7.2.1 MCIRXLITEandMCIRX2baseunits

ThedisplayonMCIRXLITEandMCIRXbaseunitsisamenusystemallowingviewingofalloperationalparametersandserviceinformation.NavigationthroughthemenusystemisdonebyA,BandSW3,seepicture.Duringnormaloperation,thedisplayisdividedintothreefields:anupperline,andabottomlinewithastatusfieldandatimerfield.Theupperlinemayalsoindicateerrorcodes.Indicationsintheupperline Description[..3......0......] Normaloperation:Showsactivatedrelays,inthiscaserelays#3

and#10.[Error:E003] Failureinradiomodule.[Error:E010] Auxportcommunicationerror.[Error:E011] MUSbuscommunicationerror.[Microcontrolas] Nocommunicationwithaterminalandnoonboardrelaysactive.[fatal:] Afatalerrorhasoccurred.

isatextinthestatusfielddescribingthecause.TurnthesupplyOffandOn.Ifthemessagereappears,contactCMC.

DisplayonMCIRXLITE

A(SW1 selection)SW3(navigationinmenusystem)

B(SW2 back)


MAN07007Rev.1119

Indicationsinthestatusfield DescriptionA4:30% Mostactiveanalogoutput.Inthiscasechannel4withoutput

valueof30%.Online Normaloperation,baseunitcommunicateswithaterminal.Passive Baseunitcommunicateswithaterminal,buttheStoprelayisde

energized.Maybecausedbytoolowsupplyvoltage.Itisnotpossibletooperateequipmentwheninpassivemode.

Idle Baseunitdoesnotcommunicatewithaterminal.Locked Ifseveralterminalsareconfiguredforonebaseunit,thebase

unitcommunicateswithselectedterminalanddoesnotsearchforadditionalterminals(firstcomefirstservemode).

Blocked Baseunitcommunicateswithaterminal,butisinactiveduetosoftplcfunction(e.g.startbuttonisnotactivated).

Thetimerfieldshowsthetimeelapsedsincethelastchangeofoperationalmode

(online/passive/idle/locked/blocked)inhours,minutesandseconds: 01:43:12Baseunitdisplaywhenthereisnocommunicationwiththeterminal.Normaloperation.Baseunitcommunicateswithterminalandrelay1and7areactivated.

Afatal(nonrecoverable)errorhasoccurred.isatextdescribingthecause.TurnthesupplyOffandOn.Ifthemessagereappears,contactCMC.


MAN07007Rev.1120

7.2.2 FieldbusbaseunitsFieldbusbaseunitsarealwaysdeliveredwitha4digitsegmentdisplay.ThedisplaymaybestackedonthePCBorplacedontheoutsideoftheenclosure.Thedisplayindicatesdifferentfaultstatusesaswellaswhatterminalisonlineatanygiventime.OnstartupthedisplayalsoshowtheterminalIDsthatissupportedinthisbaseunit.

Indicationindisplay Description

E001 CPUinPMfaultyE003 RadioerrorornoradiopresentE010 NocommunicationwithPLCE011 NocommunicationwithslavePM

7.2.3 MCLINKCANbaseunits

TheMCLINKCANisequippedwitha3digitsegmentdisplay.Thisdisplayindicatesoperationstatusanderrormessages.Thedisplayisfoundontheupperrightcornerofthemodule.OperationstatusDuringnormaloperationdigit1willbeoff,andthedisplaywillindicateDigit1(fromtheleft) Description2 Remotestatus3 CanOpenstatusE Error,thenexttwodigitisanerrorcode(seetablebelowfor

errorcodes)F Fatalerror,thenexttwodigitisanerrorcode(seetablebelow

forerrorcodes)

DisplayonMCLINKCAN


MAN07007Rev.1121

Digit2(fromtheleft) Description0 Noterminalcommunication CommunicatingwithterminalE StopfunctionisactivatedontheterminalDigit3(fromtheleft) DescriptionP Preoperational operationalS StoppedU UnknownstatePossibleerrorindicationsindisplayDisplay DescriptionE01 WaitingforsetupfiletobedownloadedE03 RadioerrorornoradiopresentE10 NocommunicationonCANbusFxx Fatalerror,powercycleisrequiredtoresume

normaloperation.Ifmessagereappears,contactCMC.


MAN07007Rev.1122

8 Batterychargerandbatteries8.1 Changingthebattery

UseonlybatteriesprovidedbyCMC.1. Putthemachinebeingcontrolledintoasafeposition.2. TurntheterminalOFF.3. Removethebatteryandinsertafullychargedone.4. TurntheterminalON.5. Hotswap

Terminalswith2batterycompartmentscancontinuetooperatewithoutbeingswitchedoff.Replaceonlyonebatteryatatime.

8.2 StoragerecommendationofbatteryThecapacitylossoftheLiIonbatteryduringstoringisapprox.510%permonth.Thebatteriesshouldbefullychargedwhenstored.Ensurethatthebatteriesarestoredinanoncondensingatmospherewithnocorrosivegas.Avoiddirectsunlight,hightemperatureandhighhumidity.Recommendedstoringtemperatures:

Lessthan30days: 20to+45C.Between30and90days: 20to+30C.Morethan90days: 20to+20C.

Lifeexpectationofthebatterydependsofstorageanduse.Withcorrectuseyoucanexpect500cycleswithoutasignificantdropinbatterycapacity.


MAN07007Rev.1123

8.3 Batterychargerinstallationanduse

Readtheseinstructionsbeforeusingthecharger Consultinstructionsforuse,symbolsonchargeraremeanttosupport,notreplace,

theseoperatinginstructions.

ThischargerappliestotheessentialrequirementoftheapplicableECdirectives.

Thechargerisdesignedforindooruseandshouldnotbeexposedtowaterordust. Donotcoverupthechargerwheninuse. Thechargeristurnedonbyconnectingittomainssocket(100Vto230V )

orto1224V. Disconnectingturnsitoff.

Controlthatthepowercordisnotdamaged.Ifthecordisdamaged,thechargermustnotbeused.

Themainssocketshouldbeeasilyaccessible.Ifanoperationalerroroccurs,theplugshouldbeimmediatelyremovedfromthemainssocket.

Thechargerisdoubleisolated(insulationclassII). Thechargercontainsdangerousvoltagesandthecovershouldnotberemoved.The

chargerisnotserviceable.Incaseofnotworkingithastobereplacedbyanewcharger.ContactnearestCavotecsalesrepresentative(www.cavotec.com).

Avoidthechargerfromcomingintocontactwithoils,greaseetc.,asmosttypesofplasticcanbebrokendownbychemicalsandsolvents.

Electricalandelectronicequipmentshallnotbediscardedwiththemunicipalwaste,

butbedisposedofusingseparatecollection,treatment,recovery/recyclingandenvironmentallysounddisposal,accordingtolocalrules.

ThechargerisintendedtochargeMC3seriesbatteriesfromCavotecMicrocontrolAS,Cavotec

MicrocontrolAShavenoresponsibilityforanyinjuriescausedbyotherusage,notaccordingtointendeduse.


MAN07007Rev.1124

ImportantThechargerisdesignedforindooruseonly!8.3.1 Placingandmountingofthecharger

WhenthechargerisconnectedtoACorDCcurrentitshallbeplacedonaplanesurfaceormountedverticallyonitslongitudinaldirection.Seeillustrationpicturesbelow.

Onthebatterychargersbacksidethereisfourrubberknobswhichsecureastableplacing.Therearealsotwomountingholesforwallmountingonthebackside.Itisrecommendedtouse4mmscrewswithheaddiameterof5,57mmandheadheightof1,52mm.Screwtypeandlengthneedtobeadaptedtowhichmaterialandthicknessofthewallitshallbemountedon.Seeillustrationpicturesbelow.


MAN07007Rev.1125

8.3.2 Chargerdescriptionandfunctionality

TheMC3serieschargerisdesignedforCMCbatterypacks,MCBATTERY3andMCEXBATTERY3.Thebatterypackscontaintwo3,7VLithiumIonbatteriesconnectedinseries.Chargeendvoltageis8.4V.Capacityofthebatterypackis16002030mAhfortheMCBATTERY3and11001230mAhfortheMCEXBATTERY3.TheMC3serieschargerisanadvancedchargerforLiIonbatteries.Itisdevelopedforoptimalperformanceandbatterypowerconservation.ThechargerisequippedwithonetricolorLED(lightemittingdiode)atthefrontdisplayingchargestatus.Thechargermaybeusedfor100230VAC/50and60Hzorfor12VDC24VDC.(onlyACorDCatatime,notboth).ThechargerisdesignedforDCoperationinvehicles.ACandDChasseparateinputs.Thebatterycompartmentisonthetopofthecharger.ThechargershouldnotbeusedtochargeotherbatteriesthanMicrocontrolbatteries!TheMC3serieschargerisaconstantcurrentchargerduringthemainperiodofcharging.Whenthebatteryvoltageisbelowacertainlevel,thechargerisinconstantcurrentmode,deliveringcloseto1100mA.Fastchargecontinuesuntilvoltageiscloseto8.4V,thenthechargergoesintoconstantvoltagemodeandchargecurrentdecreases.Chargeterminationoccurswhenchargecurrentisabout100mA.TypicalchargetimeforMCBATTERY3is2,5hoursandfortheMCEXBATTERY3is1,5hours.Thebatterycapacitywilldecreaseduringthebatterylifecycle,whencapacityistolow(tolowoperationaltime)thenreplacethebatterieswithnewones.8.3.3 Chargeroperatinginstructions

NormalchargecycleTochargeaMCBATTERY3orMCEXBATTERY3,simplyplaceitintotheMC3seriescharger.Chargingwillstartautomaticallywhenthebatteryisinserted.RedLEDlightindicatescharging.Ifthecharger/batteryisoutsidetemperaturelimits,chargingwillnottakeplaceandtheLEDwillindicateyellow.GreenLEDindicatesafullychargedbattery.Thechargerisnotintendedforcontinuoususe,afterachargecycleiscompletedthebatteryshallberemovedandthepowerdisconnected.DCpowercordConnectionoftheDCpowerisontheROKAconnectorontheleftsideofthecharger.Thecenterleadis+.Thisisalsomarkedonthecord.Theleadistheribbedcord,+leadisatthesmoothcord

.


MAN07007Rev.1126

IndicatorsTheMC3serieschargerisequippedwithoneLED,placedonfront,closetothebatterycompartment.ChargerstatusisindicatedbythefollowingLEDcolors:Chargestatus LEDBatteryabsent GreenTemperaturechargecutoff YellowBatteryinsertedwithnosupplyvoltage YellowFastcharging RedChargecomplete Green8.3.4 ChargerorderingnumbersfromCMC

VersionsThereisonlyoneversionoftheMC3serieschargercoveringvirtuallyalldifferentsupplyvoltages.Toapplytodifferentmainsupplyvoltagestandardsthereisdifferentmainssupplycords.Allorderingnumbersarelistedbelow.M510803600 ChargerMC3seriesM511403600 PowercordEUR/C7M511403603 PowercordUS/C7M511403601 PowercordUK/C7M511403602 PowercordAUSTR/C7M511403604 DCpowercordwithplugM510803699 Kitwithchargerandall5powercord.M510513600 MCBAT3M910513600 MCEXBAT38.3.5 Chargergeneralspecifications

Input voltage AC input: 100 - 230V , max 150mA, 50 - 60 Hz DC input: 12 24V

Operating Temperature Ambient

-20C - +40C Charging takes place in the temperatur interval +10C - +40C only

Storage Temperature -25C - +80C

Humidity 10-90% Max height for usage 2000 meters above sea level Mounting of the PSU Two key holes on the bottom of the unit support wall mounting in two

directions Galvanic Separation Yes Power inlet 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

Output connector 2x gold plated pin


MAN07007Rev.1127

8.3.6 Chargermechanicaloutline:

8.3.7 Chargercleaning/maintenance

Withnobatteryorpowerconnectedtothecharger,thechargercanbecarefullycleanedwithadampcloth.8.3.8 Chargermarking

37,5 mm202,00 mm

76,00 mm


MAN07007Rev.1128

8.4 CablemodeSometerminalmodelsareequippedwithacableandbatteries,andsomewithonlyacable.Thecableisconnectedtothebaseunit,andservesasbothpowersupplyfortheterminalunitandcommunicationlinktothebaseunit.Formodelswithbothradiofunctionandcable,theradiomodeisautomaticdeactivatedassoonasthecableisconnected.Theterminalandthebaseunitthencommunicateviathecable.Afterconnectingordisconnectingthecable,pressStartbuttontoestablishcommunicationwithbaseunitagain.

9 MaintenanceTheterminalandbaseunitdonotneedanyregularmaintenance.However,theunitsshouldbeinspectedfordamageandcleanedregularlywithadampcloth,foralldisplays,labelsandsymbolstobereadproperly.

Ifopeningtheterminalhousing,ensurethegasketisfixedproperlywhenclosingtheterminal.Theterminalunitshallonlybeopenedbyqualifiedpersonnel;failureinfixingthegasketmaydegradetheIPdegree.

Iftherubberbootsontheterminalsjoysticks/switchesaredamaged,theyshouldbereplacedatonce.ContactyourlocalCMCdistributor.YourlocalCMCdistributorisfoundatwww.cavotec.com9.1 Spare/Replacement

SparepartscanbeorderedthroughyourlocalCMCdistributor.Youwillneedtheserialnumber(IDcode)fromthesystem,seesection1.1Marking,andthepartnumber.Disposeofelectronicproductsaccordingtolocalrules.YourlocalCMCdistributorisfoundatwww.cavotec.com9.2 Service

Servicecanbearrangedwithyourlocaldistributor.Youwillneedtheserialnumberfromthesystemanddescriptionoftheservicerequired.

Plugforcablemode


MAN07007Rev.1129

9.3 FaultreportingCMCiscontinuouslyworkingtoimproveourproducts,tobeabletodeliverassafeandgoodproductsaspossible.Forbestpossibleimprovement,itiscrucialtogetfeedbackfromcustomers.Nonconformitiesontheproduct,functionalityorqualityshouldbereportedbacktoCMC.Ifahazardoussituationorafatalerrorshouldoccuronthedeliveredsystem,pleasereportbacktoCMCforanalysis.Reportingofnonconformitiescanbedoneviayourlocaldistributor.Youwillneedtheserialnumberfromthesystemanddescriptionoftheservicerequired.YourlocalCMCdistributorisfoundatwww.cavotec.com

10 WarrantyAllthedeliveriesarethoroughlytestedandpackedbeforetheyleaveCMC.Ifthedeliveryisfoundtobedamagedwhenitisopened,informthecarrierimmediately.CMCdoesnotcoveranydamagescausedbytransport.Allsystemsaredeliveredwith12monthswarrantyagainstmaterialandmanufacturingfaults.ThewarrantycoversrepairsauthorizedbyCMCataCavotecpremises.ExpensesforserviceoutsideCMCarenotincluded.RepairsdonewithoutauthorityfromCMCmayinvalidateanywarranty.

Informationinthisdocumentissubjecttochangewithoutnotice.


MAN07007Rev.1130


MAN07007Rev.1131


MAN07007Rev.1132

Cavotec Micro-control AS

Gevinglia112,7517HellNorwayPhone:+4774843100Email:[email protected]:[email protected]

Cavotec Micro-control GmbH

Gewerbering3,93345HausenGermanyPhone:+499448901200Email:[email protected]

Yourlocaldistributorisfoundat

www.cavotec.com2013CavotecMicrocontrolAS

Allrightsreserved

Documents

MAN-07-007 MC-3 Series Instruction Manual.pdf