ehb electronics MCflex User manual

Translation of the original operating instructions
Most recent revision: 08/05/2018
Version: 3.0
Engine controller
MCflex

2
Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
Device Engine controller MCflex
Serial number Enter the serial number of your device here:
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
ehb product
number
ehb5200x
Publisher ehb electronics gmbh
Hans-Böckler-Straße 20
30851 Langenhagen
GERMANY
Tel: [phone] - 0
Fax: [phone] - 77
E-mail: [email protected]
www: www.ehb-electronics.de
www.ehbservice.de
www.ehbshop.de
The document is protected by copyright. All rights reserved. Copying, reproduc-
tion, translation or conversion into an electronic medium or into a machine-read-
able form, as a whole document or in partial sections, is not permitted without the
approval of ehb electronics gmbh.
Subject to change without notice.
Suggestions and
tips
... about this document or the device can be sent to the above address.
Last modification 08/05/2018
Version 3.0

Table of Contents
Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
3
1 DEVICE INFORMATION _________________________________________________________ 6
1.1 SPECIFICATIONS ................................................................................................................... 6
1.2 TYPE PLATE ......................................................................................................................... 6
1.3 SCOPE OF DELIVERY ............................................................................................................ 6
1.4 INTENDED USE...................................................................................................................... 7
1.5 IMPROPER USE ..................................................................................................................... 7
1.6 FUNCTIONAL DESCRIPTION.................................................................................................... 7
1.7 TECHNICAL DATA ................................................................................................................. 8
1.8 SPARE PARTS ...................................................................................................................... 9
1.9 EU DECLARATION OF CONFORMITY .................................................................................... 10
2 INFORMATION FOR THE READER _______________________________________________ 12
2.1 VALIDITY ............................................................................................................................ 12
2.2 TARGET GROUP.................................................................................................................. 12
2.3 ILLUSTRATIONS .................................................................................................................. 12
2.4 ABBREVIATIONS USED ........................................................................................................ 13
2.5 HIGHLIGHTING IN THE TEXT ................................................................................................. 14
2.5.1 PICTOGRAMS AND SYMBOLS ............................................................................. 14
2.5.2 NAVIGATION PATH ............................................................................................ 15
2.5.3 SAFETY INFORMATION ...................................................................................... 15
2.5.4 WARNINGS....................................................................................................... 15
2.5.5 HANDLING INSTRUCTION ................................................................................... 15
3 SAFETY _____________________________________________________________________ 16
3.1 SAFETY INFORMATION ........................................................................................................ 16
3.1.1 INFORMATION ABOUT OPERATIONAL SAFETY ...................................................... 16
3.1.2 INFORMATION ABOUT INITIAL COMMISSIONING .................................................... 16
3.1.3 INFORMATION ABOUT OPERATION ...................................................................... 16
3.1.4 INFORMATION ABOUT DECOMMISSIONING AND STORAGE..................................... 16
3.1.5 INFORMATION ABOUT MAINTENANCE AND REPAIRS ............................................. 17
3.1.6 INFORMATION ABOUT ENVIRONMENTAL PROTECTION .......................................... 17
3.1.7 IMPERMISSIBLE OPERATING CONDITIONS ........................................................... 17
3.2 DUTIES OF THE OPERATOR ................................................................................................. 18
3.3 LOCAL REGULATIONS ......................................................................................................... 18
3.4 QUALIFICATION OF PERSONNEL .......................................................................................... 19
3.5 PICTOGRAMS AND SYMBOLS ON THE DEVICE ....................................................................... 19
3.6 RESIDUAL RISK .................................................................................................................. 20
4 PARTS OF THE DEVICE________________________________________________________ 22
4.1 FRONT OF DEVICE .............................................................................................................. 22
4.2 DISPLAY VIEWS .................................................................................................................. 23
4.2.1 OPERATING PARAMETERS................................................................................. 23
4.2.2 DAILY OPERATING DURATION ............................................................................ 24
4.2.3 TOTAL OPERATING DURATION ........................................................................... 24
4.3 REAR OF DEVICE ................................................................................................................ 24
4.4 BOTTOM OF DEVICE............................................................................................................ 25

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Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
5 UNPACKING, CONNECTING AND INSTALLING_____________________________________ 26
5.1 UNPACKING ........................................................................................................................ 26
5.2 CONNECTING ...................................................................................................................... 27
5.2.1 CONNECTION DIAGRAM AND PIN ASSIGNMENT .................................................... 27
5.2.2 CIRCUIT DIAGRAM............................................................................................. 28
5.2.3 CONNECTING THE DEVICE ................................................................................. 29
5.3 MOUNTING ......................................................................................................................... 30
5.3.1 TECHNICAL DRAWING........................................................................................ 30
5.3.2 MOUNTING THE DEVICE..................................................................................... 30
6 PARAMETRIZATION ___________________________________________________________ 34
6.1 DESIGN OF THE DISPLAY IN PARAMETRIZATION MODE........................................................... 34
6.2 NAVIGATING IN PARAMETRIZATION MODE ............................................................................. 34
6.3 PARAMETRIZING THE DEVICE ............................................................................................... 34
7 MENUS IN PARAMETRIZATION MODE____________________________________________ 35
7.1 OVERVIEW.......................................................................................................................... 35
7.2 MAIN MENU ........................................................................................................................ 36
7.3 SUBMENU – SETTINGS ........................................................................................................ 36
7.3.1 [1] SETTINGS.................................................................................................... 36
7.3.2 SUBMENU LANGUAGE........................................................................................ 37
7.3.3 SENSOR SUBMENU ........................................................................................... 38
7.3.4 HIGH-POWER OUTPUT SUBMENU ....................................................................... 40
7.3.5 GLOW TIMES SUBMENU ..................................................................................... 46
7.3.6 GENERATOR.ER SUBMENU................................................................................ 49
7.3.7 AUTOSTART SUBMENU ...................................................................................... 49
7.3.8 FAULT EVENT SUBMENU .................................................................................... 51
7.3.9 FAULT TIMES MENU........................................................................................... 54
7.3.10 LIMIT VALUES SUBMENU .................................................................................... 57
7.3.11 INPUTS/OUTPUTS SUBMENU .............................................................................. 59
7.4 SUBMENU – SERVICE.......................................................................................................... 61
7.4.1 [2] SERVICE ..................................................................................................... 61
7.4.2 [1] SERVICE SETTINGS ...................................................................................... 62
7.4.3 [2] FAULT LIST.................................................................................................. 62
7.4.4 [3] F.L. DELETE ................................................................................................ 63
7.5 SUBMENU – SAFETY ........................................................................................................... 63
7.5.1 [3] SAFETY....................................................................................................... 63
7.5.2 SUBMENU – PIN NUMBERS ............................................................................... 63
7.5.3 SUBMENU – SELF-TEST .................................................................................... 64
7.6 SUBMENU – DAILY OPERATING HOURS COUNTER ................................................................ 65
7.6.1 [4] DAY COUNTER............................................................................................. 65
7.6.2 SUBMENU – DAY COUNTER ............................................................................... 65
7.7 SUBMENU – OPERATING HOURS COUNTER .......................................................................... 65
7.7.1 [5] OHC COUNTER ........................................................................................... 65
7.7.2 SUBMENU – OHC – MENU ............................................................................... 66

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
5
8 CANBUS FUNCTIONS _________________________________________________________ 67
8.1 FUNCTIONS AND DISPLAY DEVICES ...................................................................................... 67
8.2 MESSAGE ON DEN CANBUS ............................................................................................... 67
8.2.1 PGN 61444 ELECTRONIC ENGINE CONTROLLER 1 - EEC1 ............................... 67
8.2.2 PGN 65253 ENGINE HOURS, REVOLUTIONS - HOURS..................................... 67
8.2.3 PGN 65262 ENGINE TEMPERATURE 1 - ET1.................................................... 68
8.2.4 PGN 65263 ENGINE FLUID LEVEL/PRESSURE 1 - EFL/P1 ................................ 68
8.2.5 PGN 65271 (R) VEHICLE ELECTRICAL POWER 1 - VEP1.................................. 68
8.2.6 PGN 65269 AMBIENT CONDITIONS – AMB....................................................... 68
8.2.7 PGN 65276 DASH DISPLAY - DD..................................................................... 68
8.2.8 PGN 65278 AUX WATER PUMP PRESSURE- AWP ........................................... 69
8.2.9 ACTIVE DIAGNOSTIC TROUBLE CODES (DM1) ................................................... 69
8.2.10 PGN 42496 (R) AUXILIARY INPUT/OUTPUT STATUS 3 - AUXIO3 ...................... 69
8.3 MESSAGE FROM CANBUS .................................................................................................. 71
8.3.1 PGN 57344 CAB MESSAGE 1 - CM1 ............................................................... 71
9 OPERATION _________________________________________________________________ 72
9.1 SETTING PULSES PER ROTATION ......................................................................................... 72
9.1.1 SPEED MEASUREMENT USING AN INITIATOR (PICK UP) ........................................ 72
9.1.2 SPEED MEASUREMENT BASED ON THE PULSES OF THE "W” TERMINAL AT PIN 13. 73
9.2 INITIAL COMMISSIONING ...................................................................................................... 73
9.2.1 INFORMATION ABOUT INITIAL COMMISSIONING .................................................... 73
9.2.2 CARRYING OUT INITIAL COMMISSIONING............................................................. 74
9.3 OPERATING THE DEVICE ..................................................................................................... 74
9.4 SETTING THE DEVICE MODE ................................................................................................ 74
9.5 COMMISSIONING ................................................................................................................. 75
9.5.1 REQUIREMENTS FOR COMMISSIONING ............................................................... 75
9.5.2 SWITCHING ON THE DEVICE .............................................................................. 75
9.6 SWITCHING OFF THE DEVICE ............................................................................................... 75
9.7 OPERATIONAL FAULTS........................................................................................................ 76
10 MAINTENANCE, REPAIR AND DISPOSAL _________________________________________ 77
10.1 INFORMATION ABOUT MAINTENANCE AND REPAIRS .............................................................. 77
10.2 FAQ.................................................................................................................................. 77
10.3 REPAIR .............................................................................................................................. 77
10.4 CLEANING .......................................................................................................................... 78
10.5 COMMUNICATION WITH PC (OPTIONAL) ............................................................................... 78
10.6 DISPOSAL .......................................................................................................................... 78
10.6.1 DISPOSAL OF DEVICES...................................................................................... 78
10.6.2 DISPOSAL OF BATTERIES AND RECHARGEABLE BATTERIES ................................. 79

Specifications
Device information
6
Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
1 Device information
1.1 Specifications
Enter the serial number of your device in the field with the dashed line.
1.2 Type plate
The type plate is located on top of the housing of the device.
Representation of the type plate
1.3 Scope of delivery
The following parts are included in the scope of delivery of the device:
•one device "MCflex”
•two ignition keys
•one label "Do not clean with high-pressure cleaner”
•two mounting brackets
Specifications of the device
Device name Engine controller
Device type MCflex
Serial number _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
ehb product number ehb5200x
Legend
No. Designation Function
1Serial number Represents a unique and unambiguous number for
identification of the device.
2Date of manufacturer Represents the date of manufacturer in the "month -
year” format.
3ehb product number Represents the ehb product number of the device
series.
4Operating voltage Represents the operating voltage with which the device
may be operated.

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
7
Intended use
Device information
1.4 Intended use
This device is exclusively used to start and monitor mechanically controlled combustion
engines in machines.
The device is for the following use only:
•starting and monitoring the mechanically controlled combustion engines of mobile and
stationary construction machines
•starting and monitoring the mechanically controlled combustion engines of inland ships
Intended use also includes compliance with all specifications in these Translation of the orig-
inal operating instructions.
1.5 Improper use
Any use not mentioned in section "Intended use" (Page 7) is considered improper and may
result in personal injury and property damage.
The device is expressly not intended for the following:
•starting and monitoring the mechanically controlled combustion engines of road vehicles
•starting and monitoring the mechanically controlled combustion engines of aircraft
•starting and monitoring the mechanically controlled combustion engines of helicopters
•starting and monitoring the mechanically controlled combustion engines of deep-sea
vessels
•Unauthorised structural changes
•Unauthorised repairs
Info
The manufacturer is not liable for damage caused by improper use of the device. The risk for
this is borne solely by the user or operator.
The guarantee expires in the event of improper use.
1.6 Functional description
The device offers a multitude of functions for the control and monitoring of conventionally
controlled combustion engines. You can individually configure the settings for very diverse
applications and different engine variants. The device is capable of pre-glowing, by-glowing
and after-glowing the engine to up to 70 A, using time or temperature variables. Oil pressure
and engine temperature can be monitored with switches or sensors. One additional input is
provided for monitoring the generator. The operating magnet is actuated by the outputs for
excitation and pick-up winding. There is also an alarm output available. The engine can be
switched off via an "external stop” input (hood switch , cover switch / housing switch, for
example).

Technical data
Device information
8
Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
In the event of a fault, the display returns a corresponding message after an adjustable delay
time and an LED illuminates. If a corresponding function is programmed, the engine is
switched off. The input lock allows the clear identification of the cause of error and requires an
active acknowledgement of the fault message.
By pressing the arrow keys of the device, the operating hours, oil pressure, temperature and
number of revolutions of the engine are displayed in sequence on the two-line display. Other
parameters can be displayed using customised software.
1.7 Technical data
Electrical data
Voltage range 6 V to 32 V (typically 12 V to 24 V)
Current consumption typically 50 mA (for UB 8 V to 24 V)
Operating temperature -20°C to+70°C
Storage temperature -30°C to+80°C
Inputs Inputs:
•PIN 01 | Oil pressure as NO/NC, programmable,
switching or analogue sensor
•PIN 02 | Generator monitoring, terminal D+
•PIN 03 | Temperature as NO/NC, programmable,
switching or analogue sensor
•PIN 04 | Diverse, NO/NC
•PIN 07 | Autostart, NO/NC
•PIN 09External stop, NO/NC
•PIN 13 | Speed monitoring, terminal W, sensor or
magnetic pick-up
Outputs Outputs:
•all outputs are short circuit-proof
•PIN 02 | Generator excitation, terminal D+, 0.5 A
•PIN 06 | Freely parametrisable, 7.5 A (maximum 1s)
/ 6.0 A
•PIN 08 | Freely parametrisable, 40 A (maximum 1s)
/ 20 A
•PIN 10 | Freely parametrisable, 70 A (maximum 1s)
/ 35 A
•PIN 11 | Freely parametrisable, 40 A (maximum 1s)
/ 20 A
•PIN 12 | Freely parametrisable, 70 A (maximum 1s)
/ 35 A
•PIN 15 | Freely parametrisable, 3.5 A (maximum 1s)
/ 3.0 A
•PIN 18 | Freely parametrisable, 40 A (maximum 1s)
/ 20 A
CAN bus interface PIN 17 / 19, CAN2.0B, 250kBit, SAE J1939, EEC1, ET1,
EFL/P1, VEP1, AMB, DM1 fault alarms/auto start, speed
adjustment, optionally adaptable
Operating hours counter Integrated
Daily operating hours counter Integrated

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
9
Spare parts
Device information
1.8 Spare parts
No spare parts are available for this device. If the device is faulty, contact the manufacturer.
Visualisation
Display type Dot matrix LCD, transflective, dark-blue representation,
grey background
Resolution 16 x 2 characters, 5 x 8 dots per character
Brightness >1,000 cd/m²
Contrast ratio (CR) 8.24
Background lighting LED, white
Mechanical data
Housing dimensions (L x W) 72 mm x 72 mm
Installation dimensions (W x H x
D)
66 mm x 66 mm x 130 mm
Installation cut-out (W x H) 66 mm x 66 mm
Housing material PA 6 30 GB, black, UV-stabilised
Weight 340 g
Installation Mounting bracket or screw-fastening, 3 x M6
Protection class IP67
Connection Deutsch connector type HDP24-24-19PE
Test standards
Humidity DIN EN 60068-2-3
Vibration DIN EN 60068-2-6
Shock DIN EN 60068-2-27
CE marking According to Directive 2014/30/EU
Accessories
Connection cable, 19-pole, 3 m ehb2268
Deutsch plug set ehb1469
CANdongle with PC software
ehbTools
ehb5365
MCflex starter kit
CAN dongle, ehbTools,
connecting cable, power supply
unit
ehb5378

EU Declaration of Conformity
Device information
10
Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
1.9 EU Declaration of Conformity
EU Declaration of Conformity according to EMC Directive (1/2)
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Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
11
EU Declaration of Conformity
Device information
EU Declaration of Conformity according to EMC Directive (2/2)
As soon as the device is improperly used, this declaration and the guarantee claim will expire.
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Validity
Information for the reader
12
Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB
2 Information for the reader
2.1 Validity
Safety information: Carefully read the Translation of the original operating instructions
Carefully read through these Translation of the original operating instructions before use.
Keep these Translation of the original operating instructions for future consultation.
These Translation of the original operating instructions contain information and rules of
conduct for the safe use of the device.
Please hand over the Translation of the original operating instructions when passing on the
device.
To operate the device effectively, the Translation of the original operating instructions provide
you with information on the following topics, among others:
•Connecting and mounting the device
•Putting the device into operation
•Making settings on the device
•Maintaining the device
•Disposing of the device
2.2 Target group
These Translation of the original operating instructions are intended for the operator, user and
service personnel of the machine with integrated device "MCflex”.
Info
The service personnel must have certain qualifications in order to work on or with the device.
You can find the qualification of personnel in chapter "Safety" > "Qualification of personnel"
(Page 19).
2.3 Illustrations
The illustrations in these operating instructions show the device in simplified form in some
cases.

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13
Abbreviations used
Information for the reader
2.4 Abbreviations used
The following abbreviations are used in these operating instructions:
Abbreviations used
°C Degrees Celsius
AAmpere
AW Pick-up winding
bar Unit of pressure [force/area]
OHC Operating hours counter
Cd Cadmium
ECU Electronic Control Unit
FMI Failure Mode Identifier
GND Ground
hhours
Hg Mercury
HW Excitation winding
ID Identification
PPR Pulses per rotation
kg kilogram
LCD Liquid Crystal Display
LED Light Emitting Diode
mA Milliampere
NC Normally Closed
NO Normally Opened
NTC Negative Temperature Coefficient
Pb Lead
PC Personal Computer
PTC Positive Temperature Coefficient
ssecond
SPN Suspect Parameter Number
rpm revolutions per minute
VVolt
ZSS Ignition starter switch

Highlighting in the text
Information for the reader
14
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2.5 Highlighting in the text
In these Translation of the original operating instructions, important information is highlighted
with pictograms, symbols or special notations. The following examples show the most impor-
tant highlights.
2.5.1 Pictograms and symbols
Pictograms and symbols
Pictogram /
symbol
Meaning
Further useful information.
Conditions that must be met to perform an action.
Tool or material required to perform an action.
The disposal of electrical and electronic equipment with household waste is
not permitted.
The disposal of rechargeable batteries and other batteries with household
waste is not
permitted.

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15
Highlighting in the text
Information for the reader
2.5.2 Navigation path
The following representation helps you to navigate through the menus. Here you can see the
path of the menus that must be selected one after the other in order to reach the desired
submenu. In the digital version of the operating instructions, you can jump to the menu item
by clicking on the relevant path.
Main menu (page 0) > Submenu (page 0) > Current submenu (page 0)
2.5.3 Safety information
Safety information: Special note for an informative section.
Explanation of the note.
•This item indicates measures to take the note into account.
2.5.4 Warnings
WARNING
Warning of serious injuries.
Failure to follow the warning may result in serious damage to health or even death.
►The arrow indicates a precautionary measure that you must take to avert the hazard.
NOTICE
Warning of material damage.
Failure to observe the warning notice can result in considerable damage to the device or its
surroundings.
►The arrow indicates a precautionary measure that you must take to avert the hazard.
2.5.5 Handling instruction
Complete the following work steps: = Start of a handling instruction.
1. First step in a sequence of actions.
Required settings . . . . . . . . . . . . . . Setting values
2. Second step in a sequence of actions.
▼Result of this step.
» Done Handling is completed, the goal is achieved.

Safety information
Safety
16
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3 Safety
3.1 Safety information
This safety information is addressed to the operator, user and service personnel of the
device.
3.1.1 Information about operational safety
The device is safe to operate. It was built according to the current state of science and tech-
nology.
However, the device may constitute a hazard:
•if the device is used not as intended.
•if the device is improperly used.
•If the device is operated under impermissible conditions.
Safety information: Protect against unauthorised opening!
The device has a protective seal to prevent it being opened without authorisation. Note that
any unauthorised opening of the device will lead to it being irreparably damaged.
The following information applies to everyone who works on or with the device:
•Never insert any objects into the device openings not intended for this purpose. There is
a risk of interfering with the electronics.
•Protect the locking cylinder of the ignition starter switch from penetrating dirt and water.
•Only open a battery master switch in an emergency or when the engine is at standstill
and the device is switched off.
•When operating the device, comply with the general accident prevention regulations.
•Operate the device under the conditions specified by the manufacturer (see page 8:
Device information > Technical data).
•Never open the housing of the device. The device does not contain components that can
be serviced, replaced or repaired by the customer or third-party service personnel.
3.1.2 Information about initial commissioning
The following principles apply for initial commissioning:
•Make sure that the device is only connected and installed by personnel qualified for this.
•Make sure that no one can be injured when switching on the device.
3.1.3 Information about operation
Safety-conscious and precautionary behaviour of personnel avoids dangerous situations
during operation.
Observe the following points when handling the device:
•The device may only be connected and installed by personnel qualified for this. Observe
the information from the manufacturer of the plugs and cable harnesses.
•The environment must be free of interfering electrical installations (high frequency) and
electromagnetic compatibility (EMC Directive) must be observed.
•Never make any structural changes to the device.
•Only operate the device with accessories approved by the manufacturer.
3.1.4 Information about decommissioning and storage
The following principles apply for decommissioning and storage:
•Clean all dirt from the device.
•Store the device according to the specifications of the manufacturer (see page 8: Device
information > Technical data).

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17
Safety information
Safety
3.1.5 Information about maintenance and repairs
The following principles apply for maintenance and repairs:
•The device requires no maintenance and no special actions.
•Only clean the device with a mild cleaning agent.
•Never clean the device with a high-pressure cleaner.
•The device is to be shipped either in its original packaging or in suitable sturdy alternative
packaging. Improper packaging is regarded as negligence and results in any claims for
repair under guarantee being forfeited.
3.1.6 Information about environmental protection
Safety-conscious and precautionary behaviour of personnel avoids adverse effects on the
environment.
All packaging materials and devices are equipped with markings and test seals for proper and
professional disposal.
The following principles apply for environmentally-friendly actions:
•Always comply with the regulations for the prevention, disposal and recycling of waste.
•Always dispose of packaging materials and electrical devices and their components
through collection points or disposal companies authorised for this.
•Used electrical devices and electronic devices must not be disposed of with household
waste.
The devices comply with legal requirements, in particular the Electrical and Electronic Equip-
ment Act and the REACH Regulation.
3.1.7 Impermissible operating conditions
Operational safety cannot be guaranteed under impermissible operating conditions. Always
avoid impermissible operating conditions.
Do not operate the device under the following conditions:
•Operation could injure persons.
•Objects could be damaged or destroyed unintentionally during operation.
•Malfunctions have been detected.
•Damage has been detected.
•Impermissible changes to operating parameters have been made.
•For example, the device has been modified.

Duties of the operator
Safety
18
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3.2 Duties of the operator
This chapter contains information on the duties of the operator of the machine in which the
device is installed.
It is the operator’s duty of care to plan safety measures and to check their implementation.
The following principles apply to minimise the risk of injury:
•Make sure that damaged devices are no longer used.
•Make sure that the device is installed and connected by authorised specialist personnel.
The following principles apply for faultless operation:
•Only use the device for its intended purpose.
•Only operate the device when it is in a perfect and functional condition.
•Make sure that the device is never opened by personnel. Damage caused by opening the
device will void the warranty.
•Make sure that the device is properly transported and stored by personnel.
•Make sure that the device is never cleaned with a high-pressure cleaner. Give the service
personnel comprehensive instructions that cleaning with a high-pressure cleaner will
cause damage and that the warranty will be excluded.
Info
Carry out regular checks. This allows you to ensure that these measures are actually
followed.
3.3 Local regulations
In addition to these instructions, correct operation of the device is regulated by laws and regu-
lations.
The following regulations also apply for the operation of the device:
•Regulations for operating machines in which the device is installed (laws and regulations
not expressly mentioned here as well).
•Accident prevention regulations.
•Internal company regulations.
•Information on the device.

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Qualification of personnel
Safety
3.4 Qualification of personnel
All work on the device requires special training of the personnel.
Everyone working on the device must meet the following requirements:
•Persons between the ages of 14 and 18 may only work on and with the device under the
supervision of a person trained to use the device.
•Personally suitable for the respective activity.
•Sufficiently qualified for the respective activity.
•Trained to handle the device.
•Familiar with these operating instructions, especially with safety information and with the
sections that are relevant for the activity.
•Familiar with basic occupational safety and accident prevention regulations.
These operating instructions distinguish between the following user groups:
3.5 Pictograms and symbols on the device
Pictograms and symbols are attached to the device. The following table explains the mean-
ings of the pictograms and symbols.
User groups
Personnel Qualification
Operating
personnel
Training by the operator of the machine in which the device is installed.
The following topics must be covered in this training:
•Intended operation of the device
•Correct behaviour in the event of malfunctions, errors, damage
•Cleaning the device
•Competences and responsibilities for the activity
The required knowledge for the operating personnel is given in these
operating instructions. The operator must train the user to use the
machine in which the device is installed. Operating personnel must have
read and understood the operating instructions.
Service
personnel
Training as a mechatronics engineer or at least equivalent training.
The tasks of the service personnel include the following activities:
•Connecting the device
•Mounting the device
•Parametrizing the device
Service personnel must have sound knowledge of the design and func-
tion of the device and must have read and understood the operating
instructions.
Pictograms and symbols on the device
Pictogram /
symbol
Meaning
Prohibited: Cleaning with a high-pressure cleaner is prohibited.

Residual risk
Safety
20
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3.6 Residual risk
The device is built according to the currently valid rules of technology and is safe to operate.
The device has been tested and has left the factory in a perfectly safe condition.
Residual hazards cannot be completely ruled out. Safety-conscious and precautionary behav-
iour of personnel avoids dangerous situations. Read and observe the safety information and
warnings to prevent risks.
Residual risks at the device and measures
Danger Cause Measure
Material damage due to
missing protective func-
tion of the starter!
The starter of the
engine can be damaged
due to the missing
signal. The signal is
required for the inte-
grated protective func-
tion of the starter.
Make sure that a speed signal is
connected to pin 13 (terminal "W”).
Make sure that the transmission ratio
(PPR) and the maximum start speed are
set correctly.
Material damage due to
incorrect wiring of the
outputs!
If the outputs are
connected in parallel,
there is a risk that tran-
sistors may blow.
Never connect the outputs in parallel.
Risk of injury due to
misuse of pin 9
(external stop) for the
emergency stop func-
tion of the engine!
Misuse of pin 9
(external stop) for the
engine emergency stop
function may cause
serious injury at parts of
the engine. The input is
not designed for this
purpose. This can result
in delays of up to one
second.
Never use pin 9 (external stop) for the
emergency stop function of the engine!
Material damage due to
incorrect type of instal-
lation!
Installation with
mounting brackets is
intended exclusively for
locations without the
influence of vibrations. If
the device with
mounting brackets is
mounted at locations
subject to vibration,
there is a risk of serious
damage to the device!
Mount the device at locations subject to
vibration with rubber-bonded metals
(accessories).
Only carry out installation with mounting
brackets if you can ensure that no vibra-
tions can have an effect! (For example,
in a switch cabinet)
Material damage due to
load on ignition starting
switch!
If weight is attached to
the ignition key (e.g.
heavy keychain,...),
there is a risk of
damaging the ignition
lock.
Do not hang any other weight or other
objects on the ignition key.