HETRONIC ERGO-S User manual

PROGRAMMING & SERVICE MANUAL
ERGO-S
PROGRAMMING & SERVICE MANUAL
03/2019
www.hetronic.com

PROGRAMMING AND SERVICE MANUAL | ERGO-S
2
Table of Contents
1. Safety ....................................................................................................................................................................................... 4
1.1 Intended Use ............................................................................................................................................................................ 4
1.2 Symbo Notation ....................................................................................................................................................................... 4
1.3 Practices and Laws .................................................................................................................................................................. 4
1.4 Required Operator Training ...................................................................................................................................................... 4
1.5 Possib e Sources of Danger ..................................................................................................................................................... 4
1.6 Protective Features .................................................................................................................................................................. 5
1.7 STOP in case of EMERGENCY ................................................................................................................................................ 5
1.8 Caring for your ERGO-S ........................................................................................................................................................... 5
2. Introduction and Functiona Description ......................................................................................................................................... 6
2.1 Production and System Numbers ............................................................................................................................................. 6
2.2 Before Operating Your Wire ess Contro Unit ............................................................................................................................ 6
2.3 Unit Labe s ............................................................................................................................................................................... 6
3. Your ERGO-S Transmitter ............................................................................................................................................................. 7
3.1 Genera Description .................................................................................................................................................................. 7
3.2 ERGO-S Basic Features ........................................................................................................................................................... 7
3.3 Standard ERGO-S 2.4GHz Configuration ................................................................................................................................. 7
3.4 Transmitter Operation Modes ................................................................................................................................................... 9
4. Operating Your Transmitter ......................................................................................................................................................... 10
4.1 Ho ding Your Transmitter ........................................................................................................................................................ 10
4.2 Visua y Checking Your Transmitter ........................................................................................................................................ 10
4.3 Powering Up and Starting Your Transmitter ............................................................................................................................ 10
4.4 Transmitter Initia ization with Standard Status LED Indicator .................................................................................................. 10
4.5 Transmitter Initia ization with Graphic User Interface (TFT) and Standard Status LED Indicator ............................................. 10
4.6 Turning OFF the Transmitter and Stopping the Radio Remote Contro ................................................................................... 10
4.7 LED Behaviour and Meanings ................................................................................................................................................ 11
4.8 Magnetic Be t C ip (if equipped) .............................................................................................................................................. 11
4.9 Start-Up Sequences ............................................................................................................................................................... 12
5. Configuring Your ERGO-S ........................................................................................................................................................... 13
5.1 Using Hetronic PC-Link .......................................................................................................................................................... 13
5.2 Using the Transmitter in Service Mode ................................................................................................................................... 13
6. Setting up Your ERGO-S for Operation ....................................................................................................................................... 15
6.1 Coder ..................................................................................................................................................................................... 15
6.2 Communication....................................................................................................................................................................... 16
6.3 DK Configuration .................................................................................................................................................................... 19
6.4 AK-DAC .................................................................................................................................................................................. 21
6.5 Graphica User Interface (Optiona ) ........................................................................................................................................ 21
6.6 Feedback Messages............................................................................................................................................................... 23
6.7 Access Codes ........................................................................................................................................................................ 24
6.8 USB Interface ......................................................................................................................................................................... 25
6.9 Data Logging .......................................................................................................................................................................... 25
6.10 Cab e Contro ....................................................................................................................................................................... 25
7. Theory of Operation ..................................................................................................................................................................... 27
7.1 Stop Function ......................................................................................................................................................................... 27
8. F ash Programming ..................................................................................................................................................................... 28
8.1 Programming the Stop Processor Firmware ........................................................................................................................... 28
8.2 Programming the Main Processor Firmware ........................................................................................................................... 28
8.3 Programming the App ication .................................................................................................................................................. 28
9. Troub eshooting ........................................................................................................................................................................... 30
10. Specifications ............................................................................................................................................................................ 31
11. Warranty, Service, Repairs and Maintenance ............................................................................................................................ 32
12. Regu atory Information .............................................................................................................................................................. 33
12.1 Europe .................................................................................................................................................................................. 33
12.2 North America....................................................................................................................................................................... 33
12.3 Industry Canada (IC/ISED) Statement .................................................................................................................................. 34
Appendix A ..................................................................................................................................................................................... 35
Definition of terms ........................................................................................................................................................................ 35
Appendix B ..................................................................................................................................................................................... 36
B.1 Operator Safety Basics .......................................................................................................................................................... 36
B.2 Safety Check ist ..................................................................................................................................................................... 36
Appendix C ..................................................................................................................................................................................... 37
C.1 Spare Parts List ..................................................................................................................................................................... 37
C.2 Battery 3V Button Ce Rep acement Instructions ................................................................................................................... 37
C.3 Remova of USB Key ............................................................................................................................................................. 39

PROGRAMMING AND SERVICE MANUAL | ERGO-S
3
List of Figures
Figure 1. B ank Rating P ate ....................................................................................................................................................... 6
Figure 2. ERGO-S Transmitter (Right, Front, Left) ...................................................................................................................... 8
Figure 3. Status and Feedback LEDs ......................................................................................................................................... 8
Figure 4. Stop Screen .............................................................................................................................................................. 11
Figure 5. Pages 1 and 2 of the Device Settings menu .............................................................................................................. 13
Figure . Low Battery Warning Configuration ........................................................................................................................... 15
Figure 7. Radio Mode menu se ections on Hetronic PC-Link .................................................................................................... 16
Figure 8. Radio Settings menu ................................................................................................................................................. 17
Figure 9. Setting the Auto-OFF timer ........................................................................................................................................ 17
Figure 10. Ha f Dup ex Configuration .......................................................................................................................................... 18
Figure 11. Fu Dup ex Configuration .......................................................................................................................................... 18
Figure 12. ERGO-S MFS Configuration ...................................................................................................................................... 19
Figure 13. Assigning DKs to switch number 3 ............................................................................................................................ 19
Figure 14. Enab ing Switch Inter ocks ......................................................................................................................................... 19
Figure 15. Assigning Te egram DK ogic gates ........................................................................................................................... 20
Figure 1 . Setting the Shut Down De ay timer ............................................................................................................................ 20
Figure 17. Setting the Sources for Feedback LED 2 ................................................................................................................... 20
Figure 18. Joystick AK configuration........................................................................................................................................... 21
Figure 19. Time, Date and Language menu ............................................................................................................................... 21
Figure 20. Information provided in the 'About' screen ................................................................................................................. 22
Figure 21. Logging of changes done to configuration fi e ............................................................................................................ 22
Figure 22. Adjusting TFT Brightness .......................................................................................................................................... 22
Figure 23. Button Diagnostic page on Transmitter ...................................................................................................................... 23
Figure 24. Changing TFT ayout using Hetronic Graphics Programmer ...................................................................................... 23
Figure 25. Down oading Graphics Fi e to coder from USB Key ................................................................................................... 24
Figure 2 . Configuring Feedback Timeout .................................................................................................................................. 24
Figure 27. Optiona image disp ayed when “C ear Data’ is se ected ............................................................................................ 24
Figure 28. Updating the Operation Access Code ........................................................................................................................ 24
Figure 29. Making Changes to the Access Code ........................................................................................................................ 25
Figure 30. Enab ing RS232 communication ................................................................................................................................ 25
Figure 31. Enab ing CAN Communication .................................................................................................................................. 25
List of Tables
Table 1. ERGO-S Transmitter features ........................................................................................................................................ 8
Table 2. Status LED Behaviour and Meanings ........................................................................................................................... 11
Table 3. Start-Up Sequences ..................................................................................................................................................... 12
Table 4. Battery duration ............................................................................................................................................................ 15
Table 5. Radio parameters ......................................................................................................................................................... 16
Table 6. Troub eshooting tips ..................................................................................................................................................... 30
Table . Transmitter Technica Specification .............................................................................................................................. 31
Table 8. Battery Pack Technica Specification ............................................................................................................................ 31
Table 9. List of Spare Parts ........................................................................................................................................................ 37

PROGRAMMING AND SERVICE MANUAL | ERGO-S
4
1. Safety
1.1 Intended Use
Your radio remote contro is designed for remote operation of machines and systems using safe wire ess communications techno ogy. Any
modification, reconstruction or extension of the systems without a written agreement of Hetronic may ead to the oss of your warranty and
guarantee c aims.
Hetronic assumes no iabi ity for damages resu ting out of the non-observance of this operating manua . A persons, working with this radio
remote contro must
 Be suitab y trained and qua ified as required by the safety regu ations.
 Strict y comp y with the contents of this operating manua .
Before starting the radio remote contro you must have read and fu y understood this operating manua . The Safety Check ist in Appendix B
is intended to be fo owed before each time the transmitter is powered up for operation.
1.2 Symbol Notation
The fo owing symbo s are used in this operating manua . The safety a ert symbo is used in deca s on the unit and with proper operation
procedures in this manua .
Understand the safety message. It contains important information about persona safety on or near the unit.
STOP! This symbo gives you warning of imminent danger of ife, risk of
accident and risk of injury, as we as damage to property in case of non-
observance of the working instructions.
ATTENTION! This symbo advises against a possib e damage to the
system in case of non-observance of the working instructions.
TIP! This symbo points to features and information which a ow for an
easier hand ing or operation.
1.3 Practices and Laws
Practice safe working precautions for the benefit of yourse f and others.
Be a ert to unsafe conditions and the possibi ity of minor, moderate, or serious injury or death. Learn app icab e ru es and aws in your area.
1.4 Required Operator Training
The origina purchaser of this unit was instructed by the se er on safe and proper operation. If unit is to be used by someone other than
origina purchaser; oaned, rented or so d, ALWAYS provide this manua and any needed safety training before operation. ALWAYS read and
understand the documentation for any machine to be contro ed by radio remote contro .
1.5 Possible Sources of Danger
This device is part of a system that makes remote contro via wire ess radio signa s possib e. The transmission of contro commands can
take p ace around obstac es and out of the operator’s direct ine of sight. Take the fo owing precautions to prevent accidenta start-up and
possib e injury or damage:
Switch “OFF” the transmitter when it is not in use. Un ess the transmitter has user access contro password configured, remove
the battery if unit is p aced away from the operator.
Disconnect the power supp y from the receiver before any assemb y, maintenance or repair work is done.
AVOID SYSTEM DAMAGE - ALWAYS disconnect receiver power supp y and contro wiring before we ding on any part of the
machine.

PROGRAMMING AND SERVICE MANUAL | ERGO-S
5
Never remove or a ter any of the safety features.
ALWAYS confirm that the machine and radio remote contro Stop functions work proper y BEFORE beginning any machine
operation.
1.6 Protective Features
This transmitter is equipped with e ectronic and mechanica safety features. Contro signa s from other transmitters cannot be processed
because transmission coding is unique to each system.
1. STOP in case of EMERGENCY
Push the emergency stop on the machine.
1.8 Caring for your ERGO-S
The enc osure materia s emp oyed on the ERGO-S transmitter have been carefu y se ected to minimise maintenance requirements.
Buy a Hetronic ERGO-S holster and screen protector. These wi take care of your transmitter by preventing it from being
subject to knocks and scratches. This he ps to keep the unit’s appearance onger and may a so protect it from some interna
damage shou d you accidenta y knock or drop it.
Always use genuine chargers and accessories. Cheaper ones that are not compatib e or made for going with your ERGO-S
can harm the unit or essen its ifespan.
Do not keep your ERGO-S stored in a c osed container for extended periods of time un ess it is powered off and the battery is removed from
the unit. Charging the ERGO-S in a c osed container is a potentia fire hazard and may shorten its ifespan. Lithium-Ion batteries give off heat
when charging and when discharging. Keep your battery percentage between 40%-80% for onger battery ife.
Clean your ERGO-S regularly. Use damp c oth or a coho wipes to c ean the unit’s exterior surfaces. Do not use aggressive
c eaning agents that may inadvertent y damage the unit.

PROGRAMMING AND SERVICE MANUAL | ERGO-S
6
2. Introduction and Functiona Description
We congratu ate you on the purchase of your new Hetronic ERGO-S push button transmitter. You have chosen a high qua ity product.
Fami iarise yourse f with the unit before using it for the first time. In addition p ease carefu y refer to the operating instructions and the safety
advise given in this manua . On y use the product as instructed and on y for the intended fie d of app ication. Keep these instructions in a safe
p ace. If you pass the product on to anyone e se, p ease ensure that you a so pass on a the documentation with it.
2.1 Production and System Numbers
Before contacting your dea er or Hetronic about service, repair or rep acement parts, note the equipment Production and System numbers.
These numbers are ocated on the si ver abe affixed to the unit.
2.2 Before Operating Your Wireless Control Unit
Confirm that insta ation of a your system components has been proper y comp eted. Before start up, ALWAYS confirm that the machine
and radio remote contro Stop functions work proper y.
Understand a Safety Precautions provided in the manua s and review contro functions and operation of the machine and this radio remote
contro system. When not in use, turn the transmitter off and store in a safe p ace to prevent unauthorized use. Ensure that the USB Dong e
(which acts as a security key to program the transmitter) is kept in a separate but safe and secure p ace. If the machine does not respond
proper y, immediate y stop operation. Turn off the transmitter and report the condition to your supervisor.
Turn off the transmitter before any maintenance work is done. A ways have fresh batteries on hand or an optiona rechargeab e battery pack
in the battery charger to ensure the avai abi ity of a fu y charged battery. Insta ation, setup and service must be performed by authorized and
qua ified personne on y.
2.3 Unit Labels
2.3.1 Blank Rating Plate
1. Specific approva s, such as CE, FCC, IC, etc.
2. Type of ERGO-S transmitter
3. E even-digit Production Number
4. E even-digit System Number
5. Frequency information
6. Current rating
7. Supp y vo tage
2.3.2 Read User Manual
The “Read User Manua ” symbo on the transmitter acts as a reminder for the user to thorough y read through the
manua before attempting to operate the system. The User Manua must a ways be p aced in a safe and easi y
accessib e p ace when not being used for when there is the need to refer to it.
Figure 1. B ank Rating P ate

PROGRAMMING AND SERVICE MANUAL | ERGO-S
7
3. Your ERGO-S Transmitter
3.1 General Description
The ERGO-S is an ergonomica y designed, programmab e wire ess industria transmitter for remote machine contro .
Your transmitter is encased in a rugged IP65 rated housing, is battery-powered, and comes equipped with bui t-in ow battery detection.
Standard equipment inc udes two 3.45Ah Lithium-Ion batteries and battery charger.
3.2 ERGO-S Basic Features
• Fu y programmab e via Hetronic PC-Link
• 8 push buttons with up to two detents
• 4 push buttons with sing e detent, one of which is the power button
• 1 proportiona Joystick or Digita Se ector switch
• Minimum 100 m (300 ft.) range using CS4XX and CS8xx modu es
• Minimum 60 m (196 ft.) range using CS2400 RF modu e
• Typica y 100 m (300 ft.) range using on board MFS 2G4 radio
• Interna Antenna
• Auto power off feature (configurab e)
• Infrared (configurab e)
• USB Interface
• Low Battery detection
• Status bi-co our LED Red/Green
• Feedback LEDs bi-co our Red/Green
• Cab e Contro
• Magnetic Be t C ip
• Data Logging (configurab e)
• Rechargeab e battery pack
3.3 Standard ERGO-S 2.4GHz Configuration
Your ERGO-S 2.4GHz transmitter is factory programmed to one of the fo owing switch configurations:
A. ERGO-S 2.4GHz- 1
 11 Sing e detent pushbutton
 1 Sing e detent POWER pushbutton
 1 Joystick or Se ector Switch
B. ERGO-S 2.4 GHz- 2
 3 Sing e detent pushbuttons
 8 Doub e detent pushbuttons
 1 Sing e detent POWER pushbutton
 1 Joystick or Se ector Switch

An optiona 2.4” 240x320 TFT screen provides rea
configuration settings, provide two-
way feedback and disp ay transmitter diagnostic i
button status
. The status and feedback LEDs have the same positioning when the TFT is a so present on the transmitter.
Figure 2.
Feature #
1-8
9-11
12
13
14
15
16
1
18
19
20
21
22
12
10
PROGRAMMING AND SERVICE
8
An optiona 2.4” 240x320 TFT screen provides rea
-time visua information during operation of the ERGO
-
way feedback and disp ay transmitter diagnostic i
nformation such as battery ife,
. The status and feedback LEDs have the same positioning when the TFT is a so present on the transmitter.
Figure 2.
ERGO-
S Transmitter (Right, Front, Left)
Feature #
Description
Up to 2 Detent Momentary Pushbutton (S2-S9)
Sing e Detent Momentary Pushbutton (S10-S12)
Sing e Detent Power/Start Pushbutton (S1)
Joystick or Se ector Switch (S13)
Infra Red
STOP Pushbutton (S0)
USB Port
TFT Disp ay
Status bi-co our Red/Green LED
LED Feedback bi-co our Red/Green (L1-L3)
Customised Logo Area
Battery Compartment
Magnetic Be t C ip
Table 1. ERGO-S Transmitter features
Figure 3. Status and Feedback LEDs
L1
L2
L3
18
13
1
3
2
5
7
6
8
4
22
14
15
16
17
18
19
20
21
MANUAL | ERGO-S
-
S transmitter. It is used to change
nformation such as battery ife,
signa strength and
. The status and feedback LEDs have the same positioning when the TFT is a so present on the transmitter.
19
9
11

PROGRAMMING AND SERVICE MANUAL | ERGO-S
9
3.4 Transmitter Operation Modes
Your ERGO-S transmitter has fo owing modes.
3.4.1. Transmission Mode
In which operator contro unit can send the switch and joystick status to the machine contro unit and disp ay the information sent from
machine contro unit on operator contro unit LCD.
3.4.2. Service Mode
Your ERGO-S transmitter’s parameters (Frequency, Baud rate, disp ay brightness, access code, time, date and much more) can be
updated without connecting to Hetronic PC-Link. When the transmitter is in this mode the user can a so check proper functioning of the
buttons.
3.4.3. Boot loader Mode
In which operator contro unit's firmware can be updated. PC f ash programming software shou d be used for up oading the firmware from
any computer with USB cab e connected.
3.4.4. Charging Mode
In which operator contro unit shuts down if the unit is p aced on the docking station.
NOTE: When inserting the USB power cab e in the transmitter, this does not charge the battery.

PROGRAMMING AND SERVICE MANUAL | ERGO-S
10
4. Operating Your Transmitter
4.1 Holding Your Transmitter
Ho d the transmitter upright with the front facing you. Confirm that you are ab e to easi y read and understand any operation text or symbo s.
Comp ete the fo owing procedures once a day, before the start of an operation and at a shift changes.
4.2 Visually Checking Your Transmitter
A ways check the transmitter for any physica damage before any operation. Check equipment for wear or damage and confirm that you can
read and understand a of the safety abe s. Never operate a transmitter with worn out or damaged parts.
4.3 Powering Up and Starting Your Transmitter
NOTE: When the transmitter is not being used by the operator, it must be stored in a safe p ace.
1. Confirm that a safety measures required by the equipment manufacturer have been fo owed.
2. Insert a fu y charged battery into the battery compartment of the transmitter.
3. Insert the USB key supp ied with the transmitter in the ERGO-S port (#16) and press Power (#12) button to power ON the transmitter unit.
4. Enter Access code (if enab ed in Hetronic PC-Link configuration).
5. Power ON the receiver and press START (#12) on the transmitter unit to start and enab e communication. The transmitter wi perform a
routine initia ization upon start up.
4.4 Transmitter Initialization with Standard Status LED Indicator
Upon turning the transmitter ON, a four front LEDs ight up as so id co ours and then switch off before the unit performs the routine
initia ization.
During initia ization, if the coder finds an error in the radio modu e, address, configuration or feedback, the transmitter wi boot up and the
fai ure wi be disp ayed as a b inking ORANGE (RED and GREEN simu taneous y) status LED (#18) at the baud rate. The transmitter may
then be connected to Hetronic PC-Link (refer to Sections 5.1 Using Hetronic PC-Link and 6.5.7. Device Status and Button Diagnostic Checks
for instructions) for the Error to be corrected.
After a successfu initia ization, the ERGO-S transmitter wi enter Norma Operation Mode. The Green LED (#18) wi b ink at the baud rate
i.e. the LED togg es on with every transmitted te egram frame. A other LEDs switch off. Test a machine functions. Refer to your machine,
transmitter and receiver documentation as needed.
4.5 Transmitter Initialization with Graphic User Interface (TFT) and Standard Status LED Indicator
Upon turning the transmitter ON, the TFT screen turns ON and a the front LEDs ight up as so id co ours and then switch off before the unit
performs the routine initia ization.
During initia ization, if the coder finds an error in the radio modu e, address, configuration or feedback, the transmitter wi boot up and the
fai ure wi be disp ayed as a b inking ORANGE (RED and GREEN simu taneous y) status LED (#18) at the baud rate. The error wi a so be
disp ayed on the screen. The transmitter may then be connected to Hetronic PC-Link (refer to Sections 5.1 Using Hetronic PC-Link and
6.5.7. Device Status and Button Diagnostic Checks for instructions) for the Error to be corrected.
After a successfu initia ization, the ERGO-S transmitter wi enter Norma Operation Mode and disp ay the Sp ash screen. The correct
Operation Access Code must be inputted for the ERGO-S to start operating, if this is enab ed through Hetronic PC-Link configuration.
NOTE: This can be changed/enab ed/disab ed when the transmitter is in Service mode during operation or through Hetronic PC-Link. (Refer
to Section 6.7 for instructions).
The basic home screen wi then be disp ayed and the Green LED (#18) wi a so b ink at the baud rate i.e. the LED togg es on with every
transmitted te egram frame. A other LEDs switch off. Test a machine functions. Refer to your machine, transmitter and receiver
documentation as needed.
4.6 Turning OFF the Transmitter and Stopping the Radio Remote Control
Be ow are the steps to fo ow to turn off the transmitter:
1. Press the STOP button (#15).
The STOP screen appears, the RED status LED b inks at a fast rate and the transmitter sends a Stop te egram to the receiver. Upon
receiving the Stop te egram, the receiver goes into Safe Mode and turns OFF a receiver outputs.