HETRONIC EX Series User manual

Ex manual Rev 0 - Oct 29, 2014
HETRONIC
Installation and User’s Manual for Radio Remote
Controls used in hazardous environments
Ex manual Rev 0 - Oct 29, 2014
HETRONIC
Installation and User’s Manual for Radio Remote
Controls used in hazardous environments
Ex manual Rev 0 - Oct 29, 2014
HETRONIC
Installation and User’s Manual for Radio Remote
Controls used in hazardous environments

Ex manual Rev 0 - Oct 29, 2014
CONGRATULATIONS on purchasing this high quality safety radio remote control system from
HETRONIC. You have selected a quality product from one of the leading manufacturers of safety radio
remote control systems and therefore can be fully confident that it reflects state-of-the-art technology.
Disclaimer of Liability
Using the Radio Control is forbidden for anybody who has not read and fully understood this manual.
Special attention should be given to the safety instructions within this manual.
All reproduction rights, either through photocopies or computer means or supports are reserved. All texts,
illustrations, and drawings are the propriety of HETRONIC and their use can only be granted prior to the
formal permission of HETRONIC.
The technical features of the Radio Control as described in this manual may be subsequently modified
without notice with the sole purpose of improving the equipment to better satisfy the user.
HETRONIC Malta
Mriehel Industrial Estate
Mriehel BKR3000, Malta
Tel.: [phone]
Fax: [phone]
HETRONIC USA
3905 NW 36th Street Oklahoma City,
Oklahoma 73112 United States
Tel: [phone]
Fax: [phone]
http://www.hetronic.com
e-mail: [e-mail]
Ex manual Rev 0 - Oct 29, 2014
CONGRATULATIONS on purchasing this high quality safety radio remote control system from
HETRONIC. You have selected a quality product from one of the leading manufacturers of safety radio
remote control systems and therefore can be fully confident that it reflects state-of-the-art technology.
Disclaimer of Liability
Using the Radio Control is forbidden for anybody who has not read and fully understood this manual.
Special attention should be given to the safety instructions within this manual.
All reproduction rights, either through photocopies or computer means or supports are reserved. All texts,
illustrations, and drawings are the propriety of HETRONIC and their use can only be granted prior to the
formal permission of HETRONIC.
The technical features of the Radio Control as described in this manual may be subsequently modified
without notice with the sole purpose of improving the equipment to better satisfy the user.
HETRONIC Malta
Mriehel Industrial Estate
Mriehel BKR3000, Malta
Tel.: [phone]
Fax: [phone]
HETRONIC USA
3905 NW 36th Street Oklahoma City,
Oklahoma 73112 United States
Tel: [phone]
Fax: [phone]
http://www.hetronic.com
e-mail: inf[email protected]
Ex manual Rev 0 - Oct 29, 2014
CONGRATULATIONS on purchasing this high quality safety radio remote control system from
HETRONIC. You have selected a quality product from one of the leading manufacturers of safety radio
remote control systems and therefore can be fully confident that it reflects state-of-the-art technology.
Disclaimer of Liability
Using the Radio Control is forbidden for anybody who has not read and fully understood this manual.
Special attention should be given to the safety instructions within this manual.
All reproduction rights, either through photocopies or computer means or supports are reserved. All texts,
illustrations, and drawings are the propriety of HETRONIC and their use can only be granted prior to the
formal permission of HETRONIC.
The technical features of the Radio Control as described in this manual may be subsequently modified
without notice with the sole purpose of improving the equipment to better satisfy the user.
HETRONIC Malta
Mriehel Industrial Estate
Mriehel BKR3000, Malta
Tel.: [phone]
Fax: [phone]
HETRONIC USA
3905 NW 36th Street Oklahoma City,
Oklahoma 73112 United States
Tel: [phone]
Fax: [phone]
http://www.hetronic.com
e-mail: [e-mail]

Ex manual Rev 0 - Oct 29, 2014 3
Contents
1. SAFETY ..................................................................................................................................................5
1.1. Safety of this radio remote control....................................................................................................5
1.2. Safety Guidelines ...............................................................................................................................6
1.3. Sources of risk....................................................................................................................................6
1.4. Qualified Operators ...........................................................................................................................7
1.5. Safety Measures to be taken within the working area......................................................................7
1.6. Protection devices..............................................................................................................................8
1.7. How to react in case of Emergency....................................................................................................9
2. OPERATION.........................................................................................................................................10
2.1. Battery Use.......................................................................................................................................10
2.1.1. Replacing rechargeable batteries .............................................................................................10
2.1.2 Charging the Hetronic EX-battery using Charger MINI UCH-2-AC-EX or MINI UCH-2-DC-EX....11
2.1.3 Battery MINI-EX-_ _ _ ................................................................................................................13
2.2. Cable Control Function ....................................................................................................................14
2.2.1. Approved Control Cables..........................................................................................................14
2.2.2. Plugging the Control Cable........................................................................................................15
2.3. Control elements .............................................................................................................................15
2.4. Operation.........................................................................................................................................15
2.4.1. Visual checks.............................................................................................................................16
2.4.2. Safety checks and starting the radio remote control ...............................................................17
2.5. Fault troubleshooting table .............................................................................................................18

Ex manual Rev 0 - Oct 29, 2014 4
2.6. Frequencies and addressing ............................................................................................................19
3. INSTALLATION INSTRUCTIONS...........................................................................................................20
3.1. Connection information and start-up..............................................................................................20
3.2. Mounting the receiver................................................................................................................20
3.3 Antenna location...............................................................................................................................21
4. MAINTENANCE...................................................................................................................................22
5. DISPOSAL............................................................................................................................................22
6. TECHNICAL DATA................................................................................................................................23
6.1. General Information ........................................................................................................................23
6.2. Rechargeable batteries and battery charger...................................................................................24
6.2.1. Battery.......................................................................................................................................24
6.2.2. Battery charger:........................................................................................................................25
6.3. Transmitter ......................................................................................................................................25
6.4. Antenna............................................................................................................................................26
6.5. Receiver............................................................................................................................................26
6.6. Standard options..............................................................................................................................28
7. Appendix A .........................................................................................................................................29

Ex manual Rev 0 - Oct 29, 2014 5
Operating Instructions
1.Safety
1.1. Safety of this radio remote control
This radio remote control system is equipped with both electronic and mechanical protection
devices. Radios are equipped with unique identification code that prohibits control
commands from other radio remote controls.
Important advice
Safe operation of the radio remote control system is only valid:
If the product is used under the conditions described in the installation and operation
instructions, and the intended application as per the rating plate. In case of unauthorized
modifications carried out by the user Hetronic cannot be held responsible for any damage
caused.
When the specifications and markings on the rating plate are adhered to.
When the performance limits given in the datasheets and manuals are obeyed.
Monitoring and safety devices are correctly installed.
Services and repairs are to be carried out by Hetronic service centres.
Only original spare parts are used.
EC directives and regulations for installation of electrical equipment in hazardous areas
are respected.
In the event of incorrect operation or misuse, there is a risk of harm to
the health of the operator or other persons, and
the machine and other property.
All persons working with this radio remote control system
must be both suitably qualified and have been instructed as required by regulations.
must strictly comply with the contents of these operating instructions.

Ex manual Rev 0 - Oct 29, 2014 6
1.2. Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as
to prevent damage to property. The notices referring to your personal safety are highlighted in the
manual by a stop alert symbol, notices referring only to property damage have an alert symbol.
Notices shown below are graded according to the degree of danger.
1.3. Sources of risk
The system is designed for wireless remote control of equipment. Since control can go beyond your
range of vision and behind obstacles in the vicinity, you should always:
Put the transmitter down only in a safe and dry location, switch the transmitter off and pull
the key from the key switch (or if your transmitter does not have a key switch, remove the
rechargeable battery from the battery compartment).
Disconnect the power supply before you start any installation, maintenance or repair work.
Avoid removing or modifying any safety devices!
This symbol is used to warn you of the risk of fatal accidents or serious
injuries. Such risks can arise whenever operating or working instructions
are not strictly followed.
This symbol is used to warn you of the risk of damage to the machine or
to another property if the operating or working instructions are either not
followed or not followed properly. Disregarding these warnings may void
your warranty.
This symbol is used for important notes relevant for the explosion
protection of this radio remote control.
Ex manual Rev 0 - Oct 29, 2014 6
1.2. Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as
to prevent damage to property. The notices referring to your personal safety are highlighted in the
manual by a stop alert symbol, notices referring only to property damage have an alert symbol.
Notices shown below are graded according to the degree of danger.
1.3. Sources of risk
The system is designed for wireless remote control of equipment. Since control can go beyond your
range of vision and behind obstacles in the vicinity, you should always:
Put the transmitter down only in a safe and dry location, switch the transmitter off and pull
the key from the key switch (or if your transmitter does not have a key switch, remove the
rechargeable battery from the battery compartment).
Disconnect the power supply before you start any installation, maintenance or repair work.
Avoid removing or modifying any safety devices!
This symbol is used to warn you of the risk of fatal accidents or serious
injuries. Such risks can arise whenever operating or working instructions
are not strictly followed.
This symbol is used to warn you of the risk of damage to the machine or
to another property if the operating or working instructions are either not
followed or not followed properly. Disregarding these warnings may void
your warranty.
This symbol is used for important notes relevant for the explosion
protection of this radio remote control.
Ex manual Rev 0 - Oct 29, 2014 6
1.2. Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as
to prevent damage to property. The notices referring to your personal safety are highlighted in the
manual by a stop alert symbol, notices referring only to property damage have an alert symbol.
Notices shown below are graded according to the degree of danger.
1.3. Sources of risk
The system is designed for wireless remote control of equipment. Since control can go beyond your
range of vision and behind obstacles in the vicinity, you should always:
Put the transmitter down only in a safe and dry location, switch the transmitter off and pull
the key from the key switch (or if your transmitter does not have a key switch, remove the
rechargeable battery from the battery compartment).
Disconnect the power supply before you start any installation, maintenance or repair work.
Avoid removing or modifying any safety devices!
This symbol is used to warn you of the risk of fatal accidents or serious
injuries. Such risks can arise whenever operating or working instructions
are not strictly followed.
This symbol is used to warn you of the risk of damage to the machine or
to another property if the operating or working instructions are either not
followed or not followed properly. Disregarding these warnings may void
your warranty.
This symbol is used for important notes relevant for the explosion
protection of this radio remote control.

Ex manual Rev 0 - Oct 29, 2014 7
When taking the spare battery into the hazardous area, it is absolutely necessary
for the operator to keep it with him.
The antenna and battery of the Ex-Transmitter must ONLY be changed OUTSIDE
the hazardous area.
1.4. Qualified Operators
(Refer to the operating instructions for the machine you intend to operate with remote control).
The operator is responsible for ensuring that when the transmitter is put aside, it cannot be used by
unauthorized persons. This can be done either by pulling the key from the key switch, by removing
the rechargeable battery or by storing the transmitter in a locked location.
The owner of the controlled equipment must:
Provide the operator with these operating instructions
Ensure that the operator has read and understood them.
The operator of the system is committed to:
Keep radio in a good and safe working condition.
Operate the systems properly.
Regularly check the radio remote control unit to ensure that the explosion
protection is still guaranteed.
1.5. Safety Measures to be taken within the working area
The user should ensure that the working area in which the radio control will be used is free from any
risks for the movement or other potential hazards that could jeopardize the safe operation of the
controller equipment. Before every use of the radio remote control unit, the user must check that
nobody is within the working area of remote controlled equipment. If a carrying aid is prescribed for
your transmitter, this must be worn during use.
Ex manual Rev 0 - Oct 29, 2014 7
When taking the spare battery into the hazardous area, it is absolutely necessary
for the operator to keep it with him.
The antenna and battery of the Ex-Transmitter must ONLY be changed OUTSIDE
the hazardous area.
1.4. Qualified Operators
(Refer to the operating instructions for the machine you intend to operate with remote control).
The operator is responsible for ensuring that when the transmitter is put aside, it cannot be used by
unauthorized persons. This can be done either by pulling the key from the key switch, by removing
the rechargeable battery or by storing the transmitter in a locked location.
The owner of the controlled equipment must:
Provide the operator with these operating instructions
Ensure that the operator has read and understood them.
The operator of the system is committed to:
Keep radio in a good and safe working condition.
Operate the systems properly.
Regularly check the radio remote control unit to ensure that the explosion
protection is still guaranteed.
1.5. Safety Measures to be taken within the working area
The user should ensure that the working area in which the radio control will be used is free from any
risks for the movement or other potential hazards that could jeopardize the safe operation of the
controller equipment. Before every use of the radio remote control unit, the user must check that
nobody is within the working area of remote controlled equipment. If a carrying aid is prescribed for
your transmitter, this must be worn during use.
Ex manual Rev 0 - Oct 29, 2014 7
When taking the spare battery into the hazardous area, it is absolutely necessary
for the operator to keep it with him.
The antenna and battery of the Ex-Transmitter must ONLY be changed OUTSIDE
the hazardous area.
1.4. Qualified Operators
(Refer to the operating instructions for the machine you intend to operate with remote control).
The operator is responsible for ensuring that when the transmitter is put aside, it cannot be used by
unauthorized persons. This can be done either by pulling the key from the key switch, by removing
the rechargeable battery or by storing the transmitter in a locked location.
The owner of the controlled equipment must:
Provide the operator with these operating instructions
Ensure that the operator has read and understood them.
The operator of the system is committed to:
Keep radio in a good and safe working condition.
Operate the systems properly.
Regularly check the radio remote control unit to ensure that the explosion
protection is still guaranteed.
1.5. Safety Measures to be taken within the working area
The user should ensure that the working area in which the radio control will be used is free from any
risks for the movement or other potential hazards that could jeopardize the safe operation of the
controller equipment. Before every use of the radio remote control unit, the user must check that
nobody is within the working area of remote controlled equipment. If a carrying aid is prescribed for
your transmitter, this must be worn during use.

Ex manual Rev 0 - Oct 29, 2014 8
Either turn the key switch to the off position and pull the key, or remove the
rechargeable battery or the battery compartment from the receptacle when
putting the transmitter down. This will prevent undesired use or misuse of
the transmitter by third parties.
1.6. Protection devices
All of Hetronic’s industrial radio Controls are fitted with a STOP button on the transmitting unit.
Some other protection devices exist in the Radio Control system which automatically intervene
whenever:
The transmission range is exceeded. Under this circumstance, the radio control immediately
activates the STOP circuit and interrupts any outgoing signal of the receiving unit whilst
maintaining continuous and constant radio contact between the transmitter and receiver.
There is radio interference in the working area that affects the frequency range of the Hetronic
Industrial Radio Control.
The rechargeable battery is removed.
The rechargeable battery or non-rechargeable batteries is/are run down.
These protection devices are included for the safety of both persons and property, and MUST NOT
be modified, removed or bypassed under any circumstances or in any way whatsoever.
Additional protection devices (depending on transmitter version)
Guard rim, guard clip or recessed function buttons. These safety devices protect against
undesired actuation of the control elements, which in turn prevents unintentional control
commands from being transmitted.
Both transmitter and batteries are intrinsically safe (protection type “i”). The transmitter has got an
antistatic surface (surface resistance between 101Ω and 109Ω). The non-antistatic projected
surface of the batteries is < 20 cm². The contacts of the Zone 1 and 2 EX-batteries are
interchanged to those of the standard batteries, in order to avoid use of the wrong batteries.

Ex manual Rev 0 - Oct 29, 2014 9
1.7. How to react in case of Emergency
In an emergency, immediately press the red EMERGENCY STOP button on the
machine or the STOP button on the transmitter. Proceed as instructed in the
operating instructions for your machine.

Ex manual Rev 0 - Oct 29, 2014 10
2.Operation
It is extremely important to read the information regarding the safety features and safe operation of
the radio remote control in section 1 before moving on to the operating instructions in this section.
The remote control cannot be used until you have done so.
2.1. Battery Use
HETRONIC radio remote control systems are delivered with an HETRONIC EX-battery charger 10-
30VDC or 90-270VAC and two rechargeable EX HETRONIC batteries. The operating time with a
charged battery is approximately 10 hours, depending on the transmitter type.
2.1.1. Replacing rechargeable batteries
Ensure that there is no dirt or grime in the rechargeable battery compartment, as this can lead
to intermittent contact. The working voltage of the transmitter is constantly monitored by its
electronics. Should it fall below a certain value, an intermittent buzzer will be heard for about
30 seconds before the system automatically shuts down. Should the battery run down, apply
the following procedure:
Bring the machine to a safe state as soon as possible.
Switch off the transmitter by turning the key switch to “0” position.
HETRONIC rechargeable EX-batteries
Move outside the hazardous zone.
Place the transmitter on a clean and dry surface.
Remove the run down rechargeable battery by pressing the edge lip or battery cover
forward, then pull up and out.
Take a charged Hetronic EX-battery and insert it in the designated pockets of the
transmitter battery compartment with both contact points forward both guide rails down.
Then press the rechargeable battery in the direction of the battery receptacle until the
battery fully locks into place.
Only original Hetronic battery type MINI-EX-_ _ _ must be
used on explosion-proof devices within the hazardous
area. Pay attention that the battery locks fully and
correctly into place and fits firmly.
Ex manual Rev 0 - Oct 29, 2014 10
2.Operation
It is extremely important to read the information regarding the safety features and safe operation of
the radio remote control in section 1 before moving on to the operating instructions in this section.
The remote control cannot be used until you have done so.
2.1. Battery Use
HETRONIC radio remote control systems are delivered with an HETRONIC EX-battery charger 10-
30VDC or 90-270VAC and two rechargeable EX HETRONIC batteries. The operating time with a
charged battery is approximately 10 hours, depending on the transmitter type.
2.1.1. Replacing rechargeable batteries
Ensure that there is no dirt or grime in the rechargeable battery compartment, as this can lead
to intermittent contact. The working voltage of the transmitter is constantly monitored by its
electronics. Should it fall below a certain value, an intermittent buzzer will be heard for about
30 seconds before the system automatically shuts down. Should the battery run down, apply
the following procedure:
Bring the machine to a safe state as soon as possible.
Switch off the transmitter by turning the key switch to “0” position.
HETRONIC rechargeable EX-batteries
Move outside the hazardous zone.
Place the transmitter on a clean and dry surface.
Remove the run down rechargeable battery by pressing the edge lip or battery cover
forward, then pull up and out.
Take a charged Hetronic EX-battery and insert it in the designated pockets of the
transmitter battery compartment with both contact points forward both guide rails down.
Then press the rechargeable battery in the direction of the battery receptacle until the
battery fully locks into place.
Only original Hetronic battery type MINI-EX-_ _ _ must be
used on explosion-proof devices within the hazardous
area. Pay attention that the battery locks fully and
correctly into place and fits firmly.
Ex manual Rev 0 - Oct 29, 2014 10
2.Operation
It is extremely important to read the information regarding the safety features and safe operation of
the radio remote control in section 1 before moving on to the operating instructions in this section.
The remote control cannot be used until you have done so.
2.1. Battery Use
HETRONIC radio remote control systems are delivered with an HETRONIC EX-battery charger 10-
30VDC or 90-270VAC and two rechargeable EX HETRONIC batteries. The operating time with a
charged battery is approximately 10 hours, depending on the transmitter type.
2.1.1. Replacing rechargeable batteries
Ensure that there is no dirt or grime in the rechargeable battery compartment, as this can lead
to intermittent contact. The working voltage of the transmitter is constantly monitored by its
electronics. Should it fall below a certain value, an intermittent buzzer will be heard for about
30 seconds before the system automatically shuts down. Should the battery run down, apply
the following procedure:
Bring the machine to a safe state as soon as possible.
Switch off the transmitter by turning the key switch to “0” position.
HETRONIC rechargeable EX-batteries
Move outside the hazardous zone.
Place the transmitter on a clean and dry surface.
Remove the run down rechargeable battery by pressing the edge lip or battery cover
forward, then pull up and out.
Take a charged Hetronic EX-battery and insert it in the designated pockets of the
transmitter battery compartment with both contact points forward both guide rails down.
Then press the rechargeable battery in the direction of the battery receptacle until the
battery fully locks into place.
Only original Hetronic battery type MINI-EX-_ _ _ must be
used on explosion-proof devices within the hazardous
area. Pay attention that the battery locks fully and
correctly into place and fits firmly.

Ex manual Rev 0 - Oct 29, 2014 11
Use Hetronic original spare parts only! If not, there is
danger of an explosion. Chemical substances that leak or
parts that detach themselves can cause irreparable
damage.
2.1.2 Charging the Hetronic EX-battery using Charger MINI UCH-2-AC-
EX or MINI UCH-2-DC-EX
Make sure that the EX battery charger is meant for
charging explosion proof batteries and that you are
outside the hazardous area or in a room which is
specially shielded and marked for charging.
The battery charger must have two reduction blocks as otherwise charging the batteries
is not mechanically possible.
Insert the battery in the designated pockets of the charger´s battery compartment with
both contact pins forward and both guide rails down. Now press the edge lip until the
battery fully locks into place.
If no LED turns ON after inserting battery on power at charger or the yellow LED is
flashing continuously, the battery is bad and should be disposed safely.
The yellow LED on the battery charger is ON as long as the battery is charging.
The green LED turns ON when charging is finished.
It is recommended to always leave the battery in the transmitter and have the second
battery on charge to have a charged battery available all the time.
Ex manual Rev 0 - Oct 29, 2014 11
Use Hetronic original spare parts only! If not, there is
danger of an explosion. Chemical substances that leak or
parts that detach themselves can cause irreparable
damage.
2.1.2 Charging the Hetronic EX-battery using Charger MINI UCH-2-AC-
EX or MINI UCH-2-DC-EX
Make sure that the EX battery charger is meant for
charging explosion proof batteries and that you are
outside the hazardous area or in a room which is
specially shielded and marked for charging.
The battery charger must have two reduction blocks as otherwise charging the batteries
is not mechanically possible.
Insert the battery in the designated pockets of the charger´s battery compartment with
both contact pins forward and both guide rails down. Now press the edge lip until the
battery fully locks into place.
If no LED turns ON after inserting battery on power at charger or the yellow LED is
flashing continuously, the battery is bad and should be disposed safely.
The yellow LED on the battery charger is ON as long as the battery is charging.
The green LED turns ON when charging is finished.
It is recommended to always leave the battery in the transmitter and have the second
battery on charge to have a charged battery available all the time.
Ex manual Rev 0 - Oct 29, 2014 11
Use Hetronic original spare parts only! If not, there is
danger of an explosion. Chemical substances that leak or
parts that detach themselves can cause irreparable
damage.
2.1.2 Charging the Hetronic EX-battery using Charger MINI UCH-2-AC-
EX or MINI UCH-2-DC-EX
Make sure that the EX battery charger is meant for
charging explosion proof batteries and that you are
outside the hazardous area or in a room which is
specially shielded and marked for charging.
The battery charger must have two reduction blocks as otherwise charging the batteries
is not mechanically possible.
Insert the battery in the designated pockets of the charger´s battery compartment with
both contact pins forward and both guide rails down. Now press the edge lip until the
battery fully locks into place.
If no LED turns ON after inserting battery on power at charger or the yellow LED is
flashing continuously, the battery is bad and should be disposed safely.
The yellow LED on the battery charger is ON as long as the battery is charging.
The green LED turns ON when charging is finished.
It is recommended to always leave the battery in the transmitter and have the second
battery on charge to have a charged battery available all the time.

Ex manual Rev 0 - Oct 29, 2014 12
Transmitter Battery charger
(Fig. 2) (Fig. 3)
The battery charger includes a charging processor which controls and regulates the whole
charging process. The battery charger recognizes automatically when the battery is fully
charged and switches to trickle charge. The battery charger delivers only as much current as
is necessary to avoid a self-discharge of the battery.
The polarity of the battery charger is interchanged to
be able to charge batteries type MINI-EX-_ _ _. Never
try to charge batteries of any other type, as both
battery charger and battery will be destroyed.
To achieve a long durability of your batteries they
should only be charged when the low-battery
indication of the corresponding transmitter emits
either an acoustical or an optical signal, depending
on transmitter type.
The battery charger MINI UHC-2-AC-EX or MINI UHC-
2-DC-EX must only be operated outside hazardous
areas.
Battery
Battery
Reduction
Blocks
Ex manual Rev 0 - Oct 29, 2014 12
Transmitter Battery charger
(Fig. 2) (Fig. 3)
The battery charger includes a charging processor which controls and regulates the whole
charging process. The battery charger recognizes automatically when the battery is fully
charged and switches to trickle charge. The battery charger delivers only as much current as
is necessary to avoid a self-discharge of the battery.
The polarity of the battery charger is interchanged to
be able to charge batteries type MINI-EX-_ _ _. Never
try to charge batteries of any other type, as both
battery charger and battery will be destroyed.
To achieve a long durability of your batteries they
should only be charged when the low-battery
indication of the corresponding transmitter emits
either an acoustical or an optical signal, depending
on transmitter type.
The battery charger MINI UHC-2-AC-EX or MINI UHC-
2-DC-EX must only be operated outside hazardous
areas.
Battery
Battery
Reduction
Blocks
Ex manual Rev 0 - Oct 29, 2014 12
Transmitter Battery charger
(Fig. 2) (Fig. 3)
The battery charger includes a charging processor which controls and regulates the whole
charging process. The battery charger recognizes automatically when the battery is fully
charged and switches to trickle charge. The battery charger delivers only as much current as
is necessary to avoid a self-discharge of the battery.
The polarity of the battery charger is interchanged to
be able to charge batteries type MINI-EX-_ _ _. Never
try to charge batteries of any other type, as both
battery charger and battery will be destroyed.
To achieve a long durability of your batteries they
should only be charged when the low-battery
indication of the corresponding transmitter emits
either an acoustical or an optical signal, depending
on transmitter type.
The battery charger MINI UHC-2-AC-EX or MINI UHC-
2-DC-EX must only be operated outside hazardous
areas.
Battery
Battery
Reduction
Blocks

Ex manual Rev 0 - Oct 29, 2014 13
2.1.3 Battery MINI-EX-_ _ _
The explosion-proof battery type MINI-EX-_ _ _ is destined for the supply of portable,
intrinsically safe devices (e.g. radio transmitters) in hazardous areas. It has the duty to
restrict current to < 1,1 A in case of a short-circuit of the feeder clamp.
For the discharging process the battery is inserted in a corresponding battery compartment
of the operating device to be supplied. The battery should never be changed within the
hazardous area.
The spare battery can be taken into a hazardous area, but the operator has to keep it safe
at all times.
The battery must only becharged in HETRONIC battery chargers specially marked with EX,
type MINI UHC-2-AC-EX or MINI UHC-2-DC-EX and ONLY outside hazardous areas.
The battery housing consists of a black polyester moulding material. The non-antistatic
projected surface of the batteries is < 20 cm². The contacts of the EX-batteries are
interchanged to those of the standard batteries, in order to avoid operation of the intrinsically
safe device with wrong batteries.
Rechargeable battery packs are hazardous waste! Use a specialist
disposal company for recycling or disposal! Defective battery packs can
also be disposed of directly through HETRONIC!

Ex manual Rev 0 - Oct 29, 2014 14
2.2. Cable Control Function
Hetronic Radio Remote Controls can optionally be equipped with cable control function. This enables
the use of the system in areas where strong high-frequency interferences are occurring as well as at
times or locations at which the use of radio equipment is prohibited.
The transmitter unit is equipped with a connector to use it along
with the control cable. Only Hetronic control cables may be
attached to the connector.
The connector provides the necessary protection against ignition
of any gas mixture, even when the contacts are shorted.
2.2.1. Approved Control Cables
The use of the transmitter unit is only allowed with an approved control cable. The control
cable must be labelled "belongs to transmitter xxx-K-L-yyy" as follows:
x x x
y y y
NOVA-L
IIB
NOVA-XL
IIC
GL
GR
Transmitters labelled with ...EX-IIC may only be used with a control cable with a max.
length of 25m.
Transmitters labelled with ...EX-IIB may only be used with a control cable with a max.
length of 90m.
Ex manual Rev 0 - Oct 29, 2014 14
2.2. Cable Control Function
Hetronic Radio Remote Controls can optionally be equipped with cable control function. This enables
the use of the system in areas where strong high-frequency interferences are occurring as well as at
times or locations at which the use of radio equipment is prohibited.
The transmitter unit is equipped with a connector to use it along
with the control cable. Only Hetronic control cables may be
attached to the connector.
The connector provides the necessary protection against ignition
of any gas mixture, even when the contacts are shorted.
2.2.1. Approved Control Cables
The use of the transmitter unit is only allowed with an approved control cable. The control
cable must be labelled "belongs to transmitter xxx-K-L-yyy" as follows:
x x x
y y y
NOVA-L
IIB
NOVA-XL
IIC
GL
GR
Transmitters labelled with ...EX-IIC may only be used with a control cable with a max.
length of 25m.
Transmitters labelled with ...EX-IIB may only be used with a control cable with a max.
length of 90m.
Ex manual Rev 0 - Oct 29, 2014 14
2.2. Cable Control Function
Hetronic Radio Remote Controls can optionally be equipped with cable control function. This enables
the use of the system in areas where strong high-frequency interferences are occurring as well as at
times or locations at which the use of radio equipment is prohibited.
The transmitter unit is equipped with a connector to use it along
with the control cable. Only Hetronic control cables may be
attached to the connector.
The connector provides the necessary protection against ignition
of any gas mixture, even when the contacts are shorted.
2.2.1. Approved Control Cables
The use of the transmitter unit is only allowed with an approved control cable. The control
cable must be labelled "belongs to transmitter xxx-K-L-yyy" as follows:
x x x
y y y
NOVA-L
IIB
NOVA-XL
IIC
GL
GR
Transmitters labelled with ...EX-IIC may only be used with a control cable with a max.
length of 25m.
Transmitters labelled with ...EX-IIB may only be used with a control cable with a max.
length of 90m.

Ex manual Rev 0 - Oct 29, 2014 15
2.2.2. Plugging the Control Cable
Take hold of the control cable and identify the end connector with female contacts
corresponding to the receiver. Connect this plug to the corresponding connector at the
receiver unit.
Switch off the transmitter by rotating the key switch to the “0” position and unscrew the blind
cap of the connector at the transmitter.
Take the other end of the control cable with pin contacts and insert this into the female plug
at the transmitter unit and lock it in place.
You can now switch on the transmitter unit again. The control of the machine is now done by
control cable.
Note: The transmitter automatically switches off the radio transmission when control cable is
detected.
2.3. Control elements
Please refer to the transmitter and receiver diagram included with these operating instructions for the
control element arrangement of your radio remote control system. The diagram forms an integral part
of these operating instructions.
The following is a description of those control elements that are standard on HETRONIC radio
remote control systems.
2.4. Operation
Before you use the system, you must carry out the safety
checks described in sections 2.4.1. and 2.4.2. below. These
safety checks must be carried out at least once each day
before you start using the system or before each change of
shift.

Ex manual Rev 0 - Oct 29, 2014 16
A diagram of your transmitter version is included with these operating instructions. The diagram
forms part of the operating instructions. The arrangement of the control elements and the transmitter
labeling will vary subject to customer requirements, but generally will be the same as the labeling of
the previous controls. The only essential difference, in fact, is that you will now be able to exert
control without the need for cable connections.
Refer also to the manufacturer's operating instructions for your machine and the diagram of
your transmitter version to familiarize yourself with the arrangement of the control elements
and their functions!
The section below deals with the radio remote control system’s control elements and special
features.
Risk to life and property!
Check the EMERGENCY STOP function each time before
use as described in the manufacturer’s manual.
2.4.1. Visual checks
ALWAYS check the transmitter for damage each time before use!
Are all protection devices present and intact?
Are there any broken parts?
Are all the rubber sleeves, pushbutton caps and potentiometer knobs present and damage
free?
Are there any damaged or peeled labels?
Never work with a transmitter that is not complaint in any of
these ways!
Ensure that transmitter unit is repaired immediately by a
competent service person!
The explosion protection of this control is fully guaranteed only
when the housing and all mounted control elements show no
mechanical defect. At least protection class IP 54 has to be
guaranteed.
Ex manual Rev 0 - Oct 29, 2014 16
A diagram of your transmitter version is included with these operating instructions. The diagram
forms part of the operating instructions. The arrangement of the control elements and the transmitter
labeling will vary subject to customer requirements, but generally will be the same as the labeling of
the previous controls. The only essential difference, in fact, is that you will now be able to exert
control without the need for cable connections.
Refer also to the manufacturer's operating instructions for your machine and the diagram of
your transmitter version to familiarize yourself with the arrangement of the control elements
and their functions!
The section below deals with the radio remote control system’s control elements and special
features.
Risk to life and property!
Check the EMERGENCY STOP function each time before
use as described in the manufacturer’s manual.
2.4.1. Visual checks
ALWAYS check the transmitter for damage each time before use!
Are all protection devices present and intact?
Are there any broken parts?
Are all the rubber sleeves, pushbutton caps and potentiometer knobs present and damage
free?
Are there any damaged or peeled labels?
Never work with a transmitter that is not complaint in any of
these ways!
Ensure that transmitter unit is repaired immediately by a
competent service person!
The explosion protection of this control is fully guaranteed only
when the housing and all mounted control elements show no
mechanical defect. At least protection class IP 54 has to be
guaranteed.
Ex manual Rev 0 - Oct 29, 2014 16
A diagram of your transmitter version is included with these operating instructions. The diagram
forms part of the operating instructions. The arrangement of the control elements and the transmitter
labeling will vary subject to customer requirements, but generally will be the same as the labeling of
the previous controls. The only essential difference, in fact, is that you will now be able to exert
control without the need for cable connections.
Refer also to the manufacturer's operating instructions for your machine and the diagram of
your transmitter version to familiarize yourself with the arrangement of the control elements
and their functions!
The section below deals with the radio remote control system’s control elements and special
features.
Risk to life and property!
Check the EMERGENCY STOP function each time before
use as described in the manufacturer’s manual.
2.4.1. Visual checks
ALWAYS check the transmitter for damage each time before use!
Are all protection devices present and intact?
Are there any broken parts?
Are all the rubber sleeves, pushbutton caps and potentiometer knobs present and damage
free?
Are there any damaged or peeled labels?
Never work with a transmitter that is not complaint in any of
these ways!
Ensure that transmitter unit is repaired immediately by a
competent service person!
The explosion protection of this control is fully guaranteed only
when the housing and all mounted control elements show no
mechanical defect. At least protection class IP 54 has to be
guaranteed.

Ex manual Rev 0 - Oct 29, 2014 17
2.4.2. Safety checks and starting the radio remote control
Check the charge state of your transmitter’s rechargeable battery
In the event that your transmitter is equipped with a STOP button, ensure that it is not
activated. If the button is activated, unlock it.
Start the machine to be controlled remotely.
If your transmitter has a green START button, press it or start the transmitter by turning the
key switch. The radio signal and the STOP relay remain active until the transmitter is
switched off.
Press one of the function buttons of the transmitter and keep it depressed.
Check the EMERGENCY STOP function as described in the manufacturer's manual,
however, instead of pressing the EMERGENCY STOP button on the machine, press the
STOP button on the control panel of the transmitter.
Press the STOP button on the transmitter. Once you have pressed the stop button on the
transmitter, it should no longer be possible to exercise control over any of the machine’s
functions!
Have you completed the checks and does the STOP system function properly?
Next release the function button and unlock the STOP button on the transmitter again.
After the STOP button has been unlocked and the transmitter restarted, the system is ready
for operation again.
Push-Pull STOP button Push-Turn STOP button
(Fig. 4) (Fig. 5)

Ex manual Rev 0 - Oct 29, 2014 18
2.5. Fault troubleshooting
Your radio remote control system has been designed and manufactured using state-of-the art
technology. Every individual device is subjected to a stringent quality control process at the
manufacturer’s factory before being released for delivery to the customer. Check the following points
in the event of a fault.
Trouble symptom
Possible causes
Remedies
On/Off function cannot be
actuated or controlled.
Self-test routine
The transmitter is ready for operation after a 3
second self-test
routine.
Rechargeable
battery/nonrechargeable run down
Insert charged rechargeable battery or check non-
rechargeable batteries. Switch on the master
switch of the machine.
No reaction to keying the
transmitter.
Interruption to receiver power
supply.
Check connectors.
Measure the power supply of the receiver.
Rechargeable battery or battery
compartment is defective (contact
corrosion).
Batteries are run down.
Check to see if the same effect occurs with the
second rechargeable battery or with new batteries.
Check the battery compartment and rechargeable
battery compartment and clean if required. Please
contact your dealer.
A non-compatible transmitter and
receiver combination is being used.
Addresses of transmitter and
receiver do not correspond with
each other.
Check the device number on the stickers of the
transmitter and receiver to see if you are using two
compatible devices. The device numbers
correspond to the system address and therefore
must be identical.
Operating time is too short.
Incorrect or run down rechargeable
batteries/non-rechargeable
batteries were inserted.
Check if the power supply for the charger was
switched off, or if the connection is faulty or loose.
Only use rechargeable batteries approved by
HETRONIC.
There is interference with the
transmission of the control
commands to the machine.
No radio link.
Check that a yellow and red LED flash on the
receiver. If not, please contact your dealer.
(Within the hazardous area this is only
possible after ascertaining that where is no
atmosphere able to explode)
Check to see if there is a large
metal surface located between the
transmitter and receiver.
A projecting aerial must be installed outside the
steel cabinet, vehicle or the machine to be
controlled. Try an alternative frequency setting for
the transmitter and receiver.
(EX-transmitters or EX-receivers must only be
opened by specially authorised personnel.)
Please contact your dealer.
The range has been exceeded.
Please contact your dealer.
The receiver is located in a steel

Ex manual Rev 0 - Oct 29, 2014 19
cabinet or a vehicle, or is installed
inside the machine to be controlled.
The aerial is inadequate.
A radio remote control system with
the same frequency is being used
within the vicinity.
Individual functions cannot be
actuated or controlled.
Break in the control lead between
the machine and the receiver.
Check that the connector plug is properly seated.
Check the connecting cable to the machine. Check
the wiring and carry out cable-based control
checks of the individual functions if necessary.
Output module in receiver is
defective.
Check that a LED illuminates on the output
modules in the receiver in response to actuating
the corresponding function.
(EX-receivers must only be opened by
authorised and trained personnel.)
Contact your dealer for details.
2.6. Frequencies and addressing
Radio remote control systems from HETRONIC include a CS419, CS429, CS434, CS447 or CS458
RF module synthesizer.
The transmitter must never be used without an aerial, as this can
destroy the RF module.
The address is preset by HETRONIC. If you should experience
difficulties with the radio link in your system, please contact your
dealer or closest HETRONIC’s Service Centre.

Ex manual Rev 0 - Oct 29, 2014 20
3.Installation instructions
3.1. Connection information and start-up
The Hetronic radio remote control may only be connected by a qualified expert familiar with the
machine to be operated (see section 4., “Maintenance”).
Before starting any work switch on the cabinet or the receiver,
switch off the power supply to the machine to be controlled.
HETRONIC will not accept liability or provide a guarantee in the
event of personal injury, damage to property and consequential
damage resulting from improper or negligent handling of this
product or from handling that does not comply with the
regulations and standards on which these operating instructions
are based.
Identify an easily accessible place for the installation of the receiver outside the vehicle, the machine
to be controlled such as a switch cabinet or any other similar equipment. A projecting antenna must
be installed if the receiver is mounted inside a switch cabinet. Suitable antennas can be purchased
from your closest Hetronic dealer.
If this control is equipped with a receiver for the hazardous area,
also the operating manual and instructions attached to this
receiver have to be considered for connection and startup.
3.2. Mounting the receiver
The receiver should be mounted on the vehicle or controlled equipment with the screwed glands or
connections underneath. If your receiver is to be installed on a vehicle or on a mobile machine, four
rubber dampers should be used to minimise machine vibrations from damaging the receiver
electronics. Suitable dampers to match your receiver housing can be purchased from your closest
Hetronic dealer. Drawings of your transmitter and receiver version are included with this manual.
Ex manual Rev 0 - Oct 29, 2014 20
3.Installation instructions
3.1. Connection information and start-up
The Hetronic radio remote control may only be connected by a qualified expert familiar with the
machine to be operated (see section 4., “Maintenance”).
Before starting any work switch on the cabinet or the receiver,
switch off the power supply to the machine to be controlled.
HETRONIC will not accept liability or provide a guarantee in the
event of personal injury, damage to property and consequential
damage resulting from improper or negligent handling of this
product or from handling that does not comply with the
regulations and standards on which these operating instructions
are based.
Identify an easily accessible place for the installation of the receiver outside the vehicle, the machine
to be controlled such as a switch cabinet or any other similar equipment. A projecting antenna must
be installed if the receiver is mounted inside a switch cabinet. Suitable antennas can be purchased
from your closest Hetronic dealer.
If this control is equipped with a receiver for the hazardous area,
also the operating manual and instructions attached to this
receiver have to be considered for connection and startup.
3.2. Mounting the receiver
The receiver should be mounted on the vehicle or controlled equipment with the screwed glands or
connections underneath. If your receiver is to be installed on a vehicle or on a mobile machine, four
rubber dampers should be used to minimise machine vibrations from damaging the receiver
electronics. Suitable dampers to match your receiver housing can be purchased from your closest
Hetronic dealer. Drawings of your transmitter and receiver version are included with this manual.
Ex manual Rev 0 - Oct 29, 2014 20
3.Installation instructions
3.1. Connection information and start-up
The Hetronic radio remote control may only be connected by a qualified expert familiar with the
machine to be operated (see section 4., “Maintenance”).
Before starting any work switch on the cabinet or the receiver,
switch off the power supply to the machine to be controlled.
HETRONIC will not accept liability or provide a guarantee in the
event of personal injury, damage to property and consequential
damage resulting from improper or negligent handling of this
product or from handling that does not comply with the
regulations and standards on which these operating instructions
are based.
Identify an easily accessible place for the installation of the receiver outside the vehicle, the machine
to be controlled such as a switch cabinet or any other similar equipment. A projecting antenna must
be installed if the receiver is mounted inside a switch cabinet. Suitable antennas can be purchased
from your closest Hetronic dealer.
If this control is equipped with a receiver for the hazardous area,
also the operating manual and instructions attached to this
receiver have to be considered for connection and startup.
3.2. Mounting the receiver
The receiver should be mounted on the vehicle or controlled equipment with the screwed glands or
connections underneath. If your receiver is to be installed on a vehicle or on a mobile machine, four
rubber dampers should be used to minimise machine vibrations from damaging the receiver
electronics. Suitable dampers to match your receiver housing can be purchased from your closest
Hetronic dealer. Drawings of your transmitter and receiver version are included with this manual.