HETRONIC MEC-HL COMPACT User manual
INSTALLATION MANUAL
MEC-HL COMPACT
Electromechanical proportional actuators
for Hydraulic Applications
INSTALLATION MANUAL | MEC-HL C
2
Table of Contents
Legal Disclaimers, Copyright, Disclaimer, Safe system use, Customer Service Contact Information.3/4
A out this Manual, Your Manual, System Num er..................................................................................4/5
Introduction, Hetronic Innovation: MEC-HLC, Technical Information...............................................5/6
Installation Procedure, Phase 1: Positioning the Actuators...................................................6/7
Phase 2: Placement of the Receiver..8
Placement of Key Switch Box.........9
Phase 3: Connection Ca le, Ca le Positioning, Parts of Ca le.....9/10/11
Phase 4: Power Connections......12/13
Phase 5: Safety Valve Connection.....13/14
Phase 6: Adjustment and Settings.15/16/17
Hetronic Receiver Configuration....18/19/20
Mechanical Kit........21/22
Optional Accessories (Easy Kit).........23/24/25
List of Figures
Figure . System Num er La el..........5
Figure 2. Actuator installation and Figure 3. Close-up of the actuator.....7
Figure 4. Placement of the Receiver.......8
Figure 5. Placement of the Key Switch Box...9
Figure 6. Output ca le drawing for RX14-HL ADM-6 (6 Functions).....10
Figure 7. Receiver RX14-HL ADM-6................10
Figure 8. Output ca le drawing for RX DC-Mo ile (4 functions) and Figure 9. Receiver DC-Mo ile ...11
Figure 0. Power Connections
.
..........14
Figure . Power_Control Ca le for MEC-HLC .....15
Figure 2. Wiring Connections of NA Relay Box - limit device existing
..16
Figure 3. Wiring Connections of NA Relay Box with valve mounting
...16
Figure 4. NOVA-L 6L Transmitter layout and Figure 5. NOVA-L 6L Transmitter ....17
Figure 6. NOVA-L 4L Transmitter layout and Figure 7. NOVA-L 4L Transmitter.....18
Figure 8. DC-Mo ile Receiver Configuration Software....21
Figure 9. ADM Receiver Configuration Software ............22
Figure 20. Standard 4 Position Bracket....23
Figure 2 . Standard 6 Position Bracket...........23
Figure 22. Universal Assem led Clamp ..........24
INSTALLATION MANUAL | MEC-HL C
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Figure 23. Universal 4 Position Bracket
and
Figure 24. Universal 6 Position Bracket..
..25
Figure 25. HS-1 Receiver Kit Support and Figure 26. HS-2 Receiver Kit Support.......26
Figure 27. Key Switch Support
and
Figure 28. Bracket One Position..27
List of Tables
Table . Technical Information..........6
IMPORTANT INFORMATION
Please, Read the installation or operation of the Hetronic product
Before to install or get the operation of this product.
The installer and operator are responsible for reading and understanding the Installation Manual
they have to read it carefully and completely.
The Installation and Operator Manuals have to
Provide the installer and operator ith an understanding of the features and
Important safety information regarding your Hetronic product. Keep manuals in an
Accessible and secure location at all times and refer to them as necessary
Legal Disclaimers and Copyright
Information
Disclaimer
All information in this manual is provided ithout any arranty to its correctness. The material on these
pages reflects HETRONIC’s best judgment in light of the information available to it at the time of its
preparation. Any use hich a third party makes of these pages, on any reliance on or decision to be
made based on it, are the responsibility of such third parties. Hetronic accepts no responsibility for
damages, if any, suffered by any third party as a result of decisions made or actions based on these
pages.
Your system may be customized for your specific application, it is important to revie and be a are of
any and all custom configured modifications that may have been made to your specific system.
Copyright information
Copyright © By Hetronic, Inc. Intl.
October 2016
INSTALLATION MANUAL | MEC-HL C
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WARNING
Safety Information
The Hetronic system you purchased is a highly-engineered product and is of the highest caliber in
remote control performance and safety. Improperly used, ho ever, the MEC-HL C System can cause
severe injury. Those ho use and maintain this system should be trained in its proper use, arned of its
dangers, and should read all manuals before attempting to set up, operate, or service the system.
FAILURE TO FOLLOW INSTRUCTIONS AS TO THE SYSTEM’S INSTALLATION, OPERATION AND
MAINTENANCE CAN RESULT IN PERSONAL INJURY, DEATH AND/OR PROPERTY DAMAGE.
Those ho install, use and maintain this system should be properly trained, including being
kno ledgeable as to its dangers, and should read all manuals before attempting to set up, operate, or
service the system. Proper maintenance and regular inspection of the system is critical to the safe
operation of the system. Buyer specifically ackno ledges that it is a are of the risks of using a Hetronic
product if the product’s housing becomes cracked or broken, including the risk of serious injury, death
or property damage. In the event of a cracked or broken housing it is strongly recommended that the
product not be used and Hetronic or its authorized service point be contacted for service of your
system.
Ultimately, the operator is solely responsible for the safe operation of the system and any
vehicles, machines or equipment operated remotely. The operator must be a are of his
surroundings and all the related risks at all times.
Customer Service Contact Information
For more information and/or service, contact us on our eb site: www.hetronic.com
Hetronic Dealer:
About this Manual
Thank you for purchasing the Hetronic MEC-HL C Actuator system. Hetronic radio remote controls
provide outstanding remote control value, quality, performance, and safety. This manual is intended to
be used for product installation; refer to the Operator manual for information about system operation.
A separate Operator’s manual provides the information needed for the person ho ill be operating the
system.
Your Manuals
Each MEC-HL C System has been specifically configured for your application. Before installing your MEC-
HL C and Operator’s Control Unit, revie your dra ings and read the manuals for all of your system
components.
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INSTALLATION MANUAL | MEC-HL C
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System Numbers
Before contacting your dealer or Hetronic about service, repair, or replacement parts, note the
equipment System numbers. These numbers are located on the label affixed to the unit.
Figure 1.
System Number Label
Safety Alerts
The safety alert symbol is used in decals on the unit and ith 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 a oided, WILL RESULT in death or serious injury.
WARNING
POTENTIALLY HAZARDOUS SITUATION! If not a oided, COULD RESULT in death or serious injury.
CAUTION
POTENTIALLY HAZARDOUS SITUATION! If not a oided, 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 pre ent damage to unit or
attachment.
Introduction
The ne HETRONIC MEC-HL C Actuator is an innovative electronic modification kit designed to improve
efficiency and safety on any hydraulic application. This manual should only be used as a guideline for the
installation of actuators on end-customer applications. Hetronic recommends professional installations
using experienced and trained personnel. For training contact Hetronic.
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INSTALLATION MANUAL | MEC-HL C
Technical Information
POWER SUPPLY VOLTAGE 12 V or 24 V
CURRENT REQUIRED UNDER MAXIMUM STRESS ~ 1,9 A
PROTECTION CLASS IP 65
MAXIMUM SPEED MOVEMENT 6 mm/s
NOMINAL VALUE OF TRANSMISSIBLE FORCE 200 N ( 44,96 l )
ABSOLUTE VALUE OF TRANSMISSIBLE FORCE 350 N ( 76,68 l )
MAXIMUM STROKE 25 + 25 mm ( 1+1 inch )
MAXIMUM TOLERABLE AXIAL LOAD 400 N ( 89,92 l )
MAXIMUM TOLERABLE RADIAL LOAD 15 N ( 3,37 l )
AVERAGE MOVEMENT ACCURACY 0,1 mm ( 0,0039 inch )
OPERATING TEMPERATURE -25° ÷ + 70°C ( -18° ÷ 160° F )
WEIGHT 1580 g ( 3,48 l )
CONNECTION Amphenol 6P+PE
TOLERABLE MOUNTING POSITION 0° ÷ 360°
EXTERNAL DIMENSIONS 44 x 182 x 82 mm ( 1,73x7,16x3,22 inch )
LOCKING TO STEM M8
LOCKING HOLES N°2 M6x10
Table 1.
Technical Information
Installation Procedure
PHASE
Positioning the Actuators
1. Choose a point close enough to the hydraulic distributor to fix the mounting brackets, ensuring
that the movements of the machine on’t interfere in any ay ith the ne parts applied.
2. The actuator mounting brackets provided ith the actuator installation kit must be assembled to
a surface that has a thickness of at least 10 mm and a idth of at least 60 mm.
3. The bracket should be ell fixed to the truck structure, free from any mechanical bending or
distortions. Bolting is preferable to elding (operation ho ever allo ed in those cases in hich
there aren’t the conditions to avoid it). The mounting and installation might take a longer hen
using bolts. Ho ever there are many benefits during initial setting up of the installation and its
maintenance hen taking the bolt fixing approach.
The follo ing pictures sho some installation cases. Pictures are intended for illustration purposes only.
"Since various truck manufacturers exist and trucks from same manufacturer tend to vary as ell, it is
recommended to consider each installation a ne case by itself".
INSTALLATION MANUAL | MEC-HL C
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Figure 2.
Actuator installation to ards one
Figure 3.
Close-up of the actuator linkage end
of the existing lever rod mechanism
assembly
NOTES
1. Carefully align the mechanical support for the actuator assembly before it is tightened in place
using M6 bolts. The rods should slide freely and ith some residual backlash. It is al ays
recommended to fix the brackets from one end before fixing one or more motors and connecting
them to the corresponding forks and clamping them to the transmission rods. Once the optimum
alignment is reached, complete the final fixing.
2. Actuators have a springs return to centre position. It’s important to lock the clamp on the rod of
the double commands only after having bounded it to the actuator. In this ay the neutral
position of the motor ill correspond exactly to the one of the distributor, ensuring a correct
return to 0 position and ith the totally available on both the directions of movement.
3. The fixing kit includes 5 mm bolts ith self-locking head properly tightened during the assembly
of the mounting brackets to prevent the accidental loosening of mounts.
IMPORTANT
Any accidental loosening could considerably alter the radio control function and/or damage the
mechanical assembly.
4. Applications hich do not require multiple motors installed in parallel on same mounting bracket
offer a higher degree of flexibility during installation. Each motor can be aligned accurately along
the direction of the force to be applied in order to ensure precise and reliable movement.
5. The ne design of the MEC-HL-C actuators, thanks to a further reduced cross-section, facilitates
the positioning in situations here the space is drastically reduced.
INSTALLATION MANUAL | MEC-HL C
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6. An optional universal KIT, (Easy Kit), can be used in the direct application on the levers. Special
do els are inserted on the base of each lever. Connections bet een these do els and the forks
on the modules are done by a set of connecting rods designed and made based on the machine
specifications. The goal is to compensate the centre-to-centre distance difference bet een the
various levers and the set of modules, along ith the need to convert an angular motion (lever)
into a linear motion (module). The connecting rods are manufactured ith an offset bet een the
t o sockets to distribute the centre-to-centre difference progressively. As a result the
misalignment ill be extremely reduced thus ensuring smooth operation.
PHASE 2
Placement of the Receiver
The receiver should be placed in an open space on the edge of the truck avoiding close proximity or
interference ith the back of the vibrating cabin or the deck. The support seating of the receiver must be
such that a minimum of 150 mm along the 70-pole / 30pol connector area is available to facilitate
assembly and removal of same connector.
The receiver should be placed allo ing the diagnostic LED's to be completely visible by the operator.
Hetronic can provide as optional the supports of the receivers.
Figure 4.
Placement of the Recei er
INSTALLATION MANUAL | MEC-HL C
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Placement of the Key Switch Box
It is possible to use the same seating to mount the STOP button and the operation selector radio or manual
unit, hich are part of the supplied iring.
The STOP button has to be placed so that it can be easily activated by the operator in the event is necessary
to turn off the receiver.
Figure 5.
Placement of the Key Switch Box
PHASE 3
Cable Positioning
There is enough cable length provided in the MEC-HL kit to reach all of the connection points of the
different devices on the truck.
Note in the figure the possibility to mount the actuators also ith independent positioning and separated
brackets.
This flexibility is sometimes the only ay to reach a proper end result.
INSTALLATION MANUAL | MEC-HL C
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Parts of Cable
The cable consists of:
1) 12 or 24V POWER SUPPLY
2) 12 or 24V OUTPUT FOR THE NA CONTROL (OR OIL DRAIN SAFETY VALVE)
3) A MULTI-POLE CABLE FOR THE AUXILIARY FUNCTIONS CONTROL
4) STOP BUTTON
5) RADIO/MANUAL SELECTOR
6) SERIES OF CONNECTORS TO CONTROL THE MEC-HL C ACTUATORS
7) A MULTI-POLE CABLE FOR THE LIMIT INPUTS (WHERE AVAILABLE – ADM
SYSTEMS)
Figure 6.
Output cable drawing for RX14-HL ADM-6 (6 Functions)
Figure
.
Recei er RX14-HL ADM-6
INSTALLATION MANUAL | MEC-HL C
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Figure 8.
Output cable drawing for RX DC-Mobile (4 functions)
Figure 9.
Recei er DC-Mobile
INSTALLATION MANUAL | MEC-HL C
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Phase 4
Power Connections
Po er supply is taken from the main battery of the vehicle, ith the positive ire connected through a
po er relay (suggested 20 A) hose control signal can be the PTO (Po er Take Off) of the vehicle or the
crane voltage presence.
Cable marked “+ and –“supplies the general po er to the radio control.
WARNING
Positi e poles ha e to be protected with a 20A fuse.
Figure 10.
Po er Connections
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INSTALLATION MANUAL | MEC-HL C
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WARNING
When replacing a 1000C actuator (this is 12V only) or MEC-HL with a MEC-HL-C actuator, choose the
ersion with the supply oltage matching the one of your plant. A special optional power control cable
allows the compatibility of the new 6P+PE Amphenol connector with the Deutsch connector of the pre ious
plants.
Figure 11.
Po er Control Cable for MEC-HLC
Phase 5
Safety Valve Connection
WARNING
The cable ith NA label plate controls the general safety valve. It ensures that the hydraulic circuit holding
the oil bet een the pump and hydraulic distributor under pressure is open. This means that the crane
moves only hen this valve is energized. When voltage is present, the valve closes keeping oil pressure
constant. Pressing any emergency button on the machine results in an immediate fall of such voltage as
ell as in an immediate shut-off of all the crane functions.
The valve MUST be mounted and connected to the radio control NA cable. This applies to older crane
models as ell as ne er models.
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INSTALLATION MANUAL | MEC-HL C
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WARNING
Failure to follow the instructions abo e indicated in Phase 5, “Safety Val e Connection “, can seriously
compromise the safety conditions required
by the Norms.
The most common installations are the follo ing:
1.
The crane main valve is directly controlled by the crane limiting controller if existing, ith a po er
relay to close the electrical circuit hen the NA output of the receiver is activated.
2. The crane main valve is directly connected to the NA output of the receiver, if the crane doesn’t
have a limiting controller.
The follo ing picture sho s the possible connection options to control the NA valve.
Figure 12.
Wiring Connections of NA Relay Box
–
Figure 13.
Wiring Connections of NA Relay
limit de ice existing Box with al e mounting
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INSTALLATION MANUAL | MEC-HL C
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Phase 6
Adjustments and Settings
It is necessary for the installer or operator to adjust the stroke that each actuator ill make to move each
element of the hydraulic distributor. This is necessary since the mechanical stroke required to open the
distributor valve has an unkno n value and varies bet een different crane models and manufacturers.
Slight differences may exist bet een one valve and another on t o identical trucks. Final adjustments of
installation are made using the transmitter model used in your application.
The follo ing dra ings sho the main transmitter models that can be used.
Figure 14.
NOVA-L 6L Transmitter layout
Figure 15.
NOVA-L 6L Transmitter
INSTALLATION MANUAL | MEC-HL C
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Figure 16.
NOVA-M 4L Transmitter layout
Figure 1 .
NOVA-M 4L Transmitter
INSTALLATION MANUAL | MEC-HL C
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The follo ing steps should be follo ed for final adjustment of the installation.
CAUTION
Adjustments can only be done by using the RED Key on the Transmitter; the BLACK Key will not allow the
operator to make adjustments or changes to the setup.
Red Key should only be handed out to personnel trained to make adjustments or changes to setup of the
system.
1. Provide a supply to the equipment: receiver po ered, RADIO/HAND selector put in the Radio
position, STOP button released and joysticks / s itches in their neutral position.
2. Check that the first yello LED on the receiver side (OPERATION) is on and flashing regularly.
3. Insert the red programming key into the transmitter.
4. Turn on the transmitter (first click of the key). The green LED on the receiver side ill start flashing
regularly after approx. 3 seconds. The yello LED (NORMAL) on the receiver side ill turn on and
stay lit up. This means that regular operation is ready, the system is in safe mode and the radio
control is ready to be engaged.
5. Press the start button (green button on Transmitter, check dra ing of position on different
Transmitter types). Each actuator moving the corresponding section of the hydraulic distributor
should be adjusted individually and according to the running direction.
DANGER
During phases 6/7, is highly recommended to perform this operation with the truck engine turned off.
6. After positioning the red key in to the Key s itch Q1 turn Key into second Position “P”, press the
joystick of the function to be adjusted to the end-of-travel. The lever of the actuator should move
to a generic point along the stroke.
7. Press and release the “P+ or P-” key (PB or TS), repeat action till you achieve the desired maximum
speed / stroke setting. The maximum stroke of the Joystick should reflect 100% the mechanical
stroke of the valve and never exit the same. If electrical set value from RRC is higher than the
mechanical stroke of Valve the Motor ill open the internal MEC-HL clutch and brings the motor
back in central position.
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INSTALLATION MANUAL | MEC-HL C
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WARNING
During the programming phases of each actuator, it is important to erify that this mo ement occurs
without any residual mechanical stress between the actuator and the al e mechanical limit switch.
Long-term damage to the linkage mechanism or the actuator itself may result if unwanted mechanical
stress demonstrated by bent or deformed rods or strange noise during actuator mo ement is noted. It is
recommended to push button “P+ or P-” until any residual stress is eliminated completely and the
actuator mechanism is mo ing smooth.
8. Once this initial adjustment step is over, the stroke start value should be set. Move the joystick
from its neutral position, until the first reaction of the actuator is noted. Press and release the “P+
or P-” key (PB or TS), repeat action till you achieve the desired initial speed / stroke setting. Repeat
the point 7 and 8 individual on all Joysticks / MEC-HL Motors
9. At the end of this operation, change Red key to Black key and check that the crane function does
not move before the joystick is out of its initial position or exits the maximum stroke of mechanical
valve. Engine of vehicle should be running no and rpm (Gas) setting should be set to its usual
operation speed. In case final changes have to be made insert Red key again and use the “P+ or
P-“button to make final setup changes.
HETRONIC RECEIVER CONFIGURATION
Hetronic receivers have a factory default configuration that is not electrically driving the actuators back
to neutral position. The default configuration is not monitoring the position of the actuator hen it
returns back to neutral,
modifications to these setting are possible but should only be made by trained
and authorized personnel.
Monitoring the Actuator out of Neutral Position
DC Mobile Receiver Hetronic H-Link tool, available as an option, is required. Only for trained and
authorised personnel.
STEPS FOR USE OF H-LINK TOOL
a. Connect DC Mobile receiver to computer using micro-USB cable and launch PC H-Link soft are.
b. Once connected to receiver, select PWM tab.
c. Enable the Neutral Position checkbox.
d. Set tolerance value on actuator neutral position. A small tolerance value requires high mechanical
precision of actuator installation.
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INSTALLATION MANUAL | MEC-HL C
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Figure 18.
DC-Mobile Recei er Configuration Software
RX14-HL ADM-6 Receiver Hetronic H-Link tool, available as an option, is required. Only for trained and
authorised personnel.
a. Connect RX14-HL ADM-6 receiver to computer using micro-USB cable and launch PC H-Link
soft are.
b. Once connected to receiver, select ADM6 tab.
c. Enable the Neutral Position checkbox.
d. Set tolerance value on actuator neutral position. A small tolerance value requires high mechanical
precision of actuator installation.
INSTALLATION MANUAL | MEC-HL C
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Figure 19.
ADM Recei er Configuration Software
WARNING
The Neutral Position applies for actuator applications where a neutral position is kept. It is the position of
the potentiometer feedback when the control AK signal is in neutral or the safety DK assigned is not acti e.
If there is no neutral position, the reference neutral position will always be changed to the position while
the control AK signal is neutral.
When the neutral position is selected fixed, the neutral position must be specified manually or
automatically memorized after an H-Link update.
When the neutral position is selected Acti e, the neutral position is automatically renewed e ery power
ON reset condition. In this case the recei ers check that the actuators go back to the neutral position when
the control AK signal is in neutral. If the actuators remain out of neutral position while the control AK
signals are neutral, it will release the control of the actuators and will be in Manual status until a alid
neutral is erified for all enabled PWM outputs.
By acti ating Return to Neutral option, The Hetronic recei er will control the actuator in returning to
neutral position and release after a alid neutral is erified.
WARNING
Any changes to the setting files ha e to be sa ed and it is the full responsibility of the person performing
the changes that they are made in accordance to the worldwide norms of safety to a oid any dangerous
or uncontrolled action by the user.
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