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

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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.

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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.