HETRONIC ERGO-F 2.4 GHz User manual

www.hetronic.com
YOUR #1 PARTNER IN RADIO REMOTE CONTROLS
OPERATING INSTRUCTIONS
ERGO F TRANSMITTER
OPMN_ER_001.0
October 2007

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TABLE OF CONTENTS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Practices and Laws . . . . . . . . . . . . . . . . . . . . . 1
Required Operator Training . . . . . . . . . . . . . . 1
Possible Sources of Danger . . . . . . . . . . . . . . 1
Protective Features . . . . . . . . . . . . . . . . . . . . . 1
To Stop In An Emergency . . . . . . . . . . . . . . . . 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Your Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 2
Production and System Numbers . . . . . . . . . . 2
Before Operating Your System . . . . . . . . . . . . 2
About Your Transmitter . . . . . . . . . . . . . . . . . . . 3
Description and Features . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . 3
Ergo F Features . . . . . . . . . . . . . . . . . . . . 3
Ergo F-V1 . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ergo F-V2 . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ergo F-V3 . . . . . . . . . . . . . . . . . . . . . . . . . 3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 5
Changing Your Battery . . . . . . . . . . . . . . . . . . . . 6
Disposable Batteries: . . . . . . . . . . . . . . . . 6
Rechargeable Batteries: . . . . . . . . . . . . . . 6
Recharging Your Batteries (Optional) . . . . . . . 6
Fast Charge . . . . . . . . . . . . . . . . . . . . . . . 7
Battery disposal . . . . . . . . . . . . . . . . . . . . . . . 7
Operating Your Transmitter . . . . . . . . . . . . . . . . 8
Holding Your Transmitter . . . . . . . . . . . . . . . . 8
Visually Checking Your Transmitter . . . . . . . . 8
Starting Your Transmitter . . . . . . . . . . . . . . . . 8
Stopping the Radio Control . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1
SAFETY
SAFETY ALERTS
The safety alert symbol is used in decals on the unit
and with proper operation procedures in this
manual.
Understand the safety message. It contains
important information about personal safety on or
near the unit.
NOTATIONS
NOTE: General reference information for proper
operation and maintenance practices.
IMPORTANT: Specific procedures or information
required to prevent damage to unit or
attachment.
PRACTICES AND LAWS
Practice usual and customary safe working
precautions for the benefit of yourself and others.
Be alert to unsafe conditions and the possibility of
minor, moderate, or serious injury or death. Learn
applicable rules and laws in your area.
REQUIRED OPERATOR TRAINING
Original purchaser of this unit was instructed by the
seller on safe and proper operation. If unit is to be
used by someone other than original purchaser;
loaned, rented or sold, ALWAYS provide this
manual and any needed safety training before
operation.
ALWAYS read and understand the documentation
for any machine to be controlled by radio remote
control.
POSSIBLE SOURCES OF DANGER
This device is part of a system that makes remote
control via radio signals possible. However, the
transmission of control commands can take place
around obstacles and out of the operator’s direct
sight. Take the following precautions to prevent
accidental start-up and possible injury or damage:
1. Switch "OFF" the transmitter when it is not in
use. If equipped, remove the key if the unit is
placed any distance away from the operator.
2. Disconnect the power supply from the receiver
before any assembly, maintenance or repair
work is done.
IMPORTANT: AVOID SYSTEM DAMAGE -
ALWAYS disconnect receiver power
supply and control wiring before
welding on any part of the machine
3. Never remove or alter any of the safety
features.
4. ALWAYS confirm that the machine and radio
remote control Stop functions work properly
BEFORE beginning any machine operation.
PROTECTIVE FEATURES
This system is equipped with electronic and
mechanical safety features. Control signals from
other transmitters cannot be processed because
transmission coding is unique to each system
TOSTOP INANEMERGENCY
1. Press the red STOP pushbutton.
2. If equipped, turn the key to "OFF".
3. Wait for all moving machine parts to stop.
4. Refer to machine’s operator manual for further
instructions.
MAINTENANCE
Always shut off power to the machine, transmitter
and receiver before any assembly, maintenance or
repair.
DANGER:IMMINENTLY HAZARDOUS
SITUATION! If not avoided, WILL
RESULT in death or serious injury.
WARNING: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, COULD
RESULT in death or serious injury.
CAUTION: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, MAY RESULT
in minor or moderate injury. It may also be
used to alert against unsafe practices.
!
!
!

2
INTRODUCTION
Thank you for purchasing the Hetronic radio remote
control system. Hetronic radio remote controls
provide outstanding remote control value, quality,
performance, and safety.
YOUR MANUALS
Before operation of your machine and radio remote
control system, read and understand the manuals
for all of your system components.
PRODUCTION AND SYSTEM NUMBERS
Before contacting your dealer or Hetronic about
service, repair or replacement parts, note the
equipment Production and System numbers. These
numbers are located on the label affixed to the unit.
BEFORE OPERATING YOUR SYSTEM
Confirm that installation of all your system
components has been properly completed.
Before start up, ALWAYS confirm that the machine
and radio remote control Stop functions work
properly.
Understand all Safety Precautions provided in the
manuals and review control functions and operation
of the machine and this radio remote control
system.
When not in use, turn the transmitter off and store in
a safe place to prevent unauthorized use.
If the machine does not respond properly,
immediately stop operation. Turn off the transmitter
and report the condition to your supervisor.
Turn off the transmitter and remove the key (if so
equipped) before any maintenance work is done.
Always have fresh batteries on hand or an optional
rechargeable battery pack in the battery charger to
ensure the availability of a fully charged battery.
Installation, setup and service must be performed by
authorized and qualified personnel only.
Figure 1: Unit Label Areas and Meanings
Type: Channel:
Production-No.:
System-No.:
www.hetronic.com
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2
3
4
5
1. Specific approvals, such
as BTZ, FCC, CE, etc.
2. Type of transmitter or receiver.
3. Frequency and RF unit.
4. Eleven-digit Production Number.
Unit Label Areas and Meanings
00000000000
00000000000
5. Eleven-digit System Number.

3
ABOUT YOUR TRANSMITTER
DESCRIPTION AND FEATURES
GENERAL DESCRIPTION
The Ergo F is an ergonomically-designed,
programmable radio control transmitter capable of
transmitting up to 32 on/off functions to control a
machine.
A Diagnostic LED Status Light on the face of the
unit provides continuous operating status
information:
• Green (Flashing) - transmitting telegram
• Red (Flashing) - transmitting STOP telegram
• Red (Steady) - Low Battery
• Red/Green (slow pulsing) - Configuration
Mode
• Red/Green (Flashing) - Invalid Memory Key
Your transmitter is encased in a rugged IP65 rated
housing, is battery-powered, and comes equipped
with built-in low battery detection.
Standard equipment includes a battery adapter
case for 3 AA size alkaline batteries. For your
convenience, there are optional rechargeable
battery systems available.
ERGO F FEATURES
• Fully programmable via H-Link
• Memory Key
• LCD graphic display capable of displaying
up to four feedback messages and welcome
note/logo upon transmitter power up.
• 12 pushbuttons with up to three detents
• One 3-position maintained toggle switch
• Up to 100 m (300 ft.) Range
• Internal Antenna
• Wrist Strap
• Hand Strap
• Auto power off feature
• Normal or advanced low battery detection
with battery icon
• Transmission Icon
• Pushbutton Activation Icon
• Diagnostic LED
STANDARD ERGO F CONFIGURATIONS
Your Ergo F transmitter is factory programmed to
one of the following configurations:
ERGO F-V1
• 11 single detent pushbutton
• 1 single detent START pushbutton
• 1 three position maintained toggle switch
• 1 Memory Key
ERGO F-V2
• 8 two detent pushbuttons
• 3 single detent pushbuttons
• 1 single detent START pushbutton
• 1 three position maintained toggle switch
• 1 Memory Key
ERGO F-V3
• 6 three detent pushbuttons
• 2 two detent pushbuttons
• 3 single detent pushbuttons
• 1 single detent START pushbutton
• 1 three position maintained toggle switch
• 1 Memory Key

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Figure 1: Ergo F Transmitter (Left, Front, Right)
Table 1: Ergo F Transmitter (Left, Front, Right)
1 Up to 3 Detent Momentary Pushbutton (S2) 10 Single Detent Momentary Pushbutton (S12)
2 Up to 3 Detent Momentary Pushbutton (S4) 11 Single Detent Momentary Pushbutton (S13)
3 Up to 3 Detent Momentary Pushbutton (S6) 12 Three Position Maintained Toggle Switch, S13
Left and S14 Right
4 Up to 2 Detent Momentary Pushbutton (S8) 13 Diagnostic LED
5 Battery Compartment (located in the back) 14 Memory Key / STOP Pushbutton (S0)
6 Up to 2 Detent Momentary Pushbutton (S7) 15 Graphic Display (LCD)
7 Up to 3 Detent Momentary Pushbutton (S5) 16 Single Detent Momentary START Pushbutton
(S9)
8 Up to 3 Detent Momentary Pushbutton (S3) 17 Single Detent Momentary Pushbutton (S10)
9 Up to 3 Detent Momentary Pushbutton (S1)
82
3
4
5
6
7
9
10
11
12
13 14 15 16 17
1

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THEORY OF OPERATION
Your transmitter works with a receiving device to
transfer machine control commands via radio
frequency to your machine.
The transmitter electronically generates a carrier
frequency that allows it to communicate with the
receiver without the use of cables or wires. The
receiver then converts the carrier frequency
information into discrete machine control outputs
that interface with your machine’s controls.
Each transmitter and receiver that comprises a
system is programmed with a unique address code.
This code ensures that machine operations are
safe, and that other remote control equipment
cannot unintentionally control your machine.
The receiver only accepts commands from the
transmitter with the same address code. The
receiver and transmitter have the address code set
at the factory.
STOP FUNCTION
The most important feature of the radio remote
control system is the Stop function. When the
transmitter is turned on, it performs a self-test to
confirm that communications are within designated
parameters. If an error is detected, the transmitter
will not transmit any signals.
The transmitter sends the STOP pushbutton status
along with the specified machine functions. This
method confirms that ongoing operations are safe.
If the STOP pushbutton is pressed, the data
telegram changes so that only the stop command is
transmitted. No other motion command data is sent.
This special data telegram places the receiver in
Safe Mode, and the E-Stop relay in the receiver
opens. All other machine functions are disabled in
the receiver.
When the receiver is properly installed the STOP
pushbutton will shut down the machine.
DANGER:Pressing the STOP pushbutton
does not ensure the machine will stop.
ALWAYS test the STOP function at the
beginning of every operation session or
when there is change of operator.
!

6
CHANGING YOUR BATTERY
You may power your transmitter with disposable or
rechargeable batteries. Both types use adapter
cases that are inserted into the back of the
transmitter.
Follow the instructions below for your battery type.
DISPOSABLE BATTERIES:
1. Insert 3 AA batteries into the back of the
Standard Battery Adapter Case.
NOTE: Battery positions are shown in the battery
slots on the back of the Battery Adapter
Case housing.
2. Slide the loaded Battery Adapter Case into the
battery compartment on the back of the
transmitter housing and snap into place.
RECHARGEABLE BATTERIES:
1. Confirm that your batteries are fully-charged.
See “Recharging Your Batteries (Optional)” on
page 6.
2. Slide the recharged battery into the battery
compartment on the back of the transmitter as
shown, and snap it into place.
Figure 1: Inserting Battery
RECHARGING YOUR BATTERIES
(OPTIONAL)
1. Insert the spent optional rechargeable battery
adapter case into the battery charger and snap
into place as shown.
Figure 2: Charger and Rechargeable Battery
Adapter Case
The LED labeled “CHARGE” flashes for two
seconds, then stays lit during the charging process.
When the battery is fully charged, the “READY” LED
lights up and the “CHARGE” LED goes off.
NOTE: Charging time could take up to 5 hours,
depending on the condition of the battery.
Leave the battery in the charger until it is needed.
The charger supplies a “trickle” charge but will not
over-charge the battery.
Battery
Adapter Case
Ergo-F (Back)
Battery
Compartment
DANGER:EXPLOSIVEGASESANDFLYING
DEBRIS can cause death or serious injury.
Use only Hetronic replacement rechargeable
batteries. Use of unauthorized replacement
batteries could cause a battery explosion,
resulting in injury or death of the operator or
other people in the work area.
!
CHARGE
FAST CHARGE
READY
Battery
Compartment
Rechargeable
Battery

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FAST CHARGE
Insert the battery into the charger as described
above. The LED labeled “CHARGE” flashes for two
seconds, then stays lit.
Press the “FAST CHARGE” button. The FAST
CHARGE LED lights also and stays lit during the
charge process.
When the battery is fully charged, the “READY” LED
lights up and the “CHARGE” and “FAST CHARGE”
LEDs turn off.
BATTERY DISPOSAL
AVOID ENVIRONMENTAL POLLUTION. Recycle
your rechargeable batteries according to local
recycling rules and regulations.
If you have questions or problems operating your
battery charger, please contact your dealer or
Hetronic.
Standard Hetronic rechargeable batteries are the
nickel metal hydride type. These batteries have no
“memory effect” when charging a battery that is not
fully discharged.

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OPERATING YOUR TRANSMITTER
HOLDING YOUR TRANSMITTER
Hold the transmitter upright with the front facing you.
Confirm that you are able to easily read and
understand any operation text or symbols.
Complete the following procedures once a day,
before the start of an operation and at all shift
changes.
VISUALLY CHECKING YOUR TRANSMITTER
Always check the transmitter for any physical
damage before any operation.
Check equipment for wear or damage and onfirm
that you can read and understand all of the safety
labels.
Never operate a transmitter with worn or damaged
parts.
STARTING YOUR TRANSMITTER
NOTE: When the transmitter is not attached to the
operator, remove and store the Memory Key
(the red cap on top of the transmitter) in a
secure place.
1. Confirm that all safety measures required by
the equipment manufacturer have been
followed.
2. Turn ON the receiver.
3. Insert a battery adapter with fresh ‘AA’
batteries into the battery compartment.
NOTE: If using rechargeable batteries, confirm that
they are fully charged.
4. Press START (S1). The following results will
quickly appear in the order given:
Table 1: Transmitter Results and Meanings
5. Test all machine functions. Refer to your
machine, transmitter and receiver
documentation as needed.
STOPPING THE RADIO CONTROL
Press STOP.
The word STOP appears and the transmitter sends
an E-Stop telegram to the receiver for 2 seconds.
Upon receiving the E-Stop telegram, the receiver
goes into Safe Mode and turns OFF all receiver
outputs.The transmitter shuts off in about 2
seconds.
WARNING: Holding the transmitter
improperly while operating your machine
could result in unexpected machine
response.
WARNING: Test the stop function as
described in the machine manufacturer’s
operator manual before beginning any
operation.
WARNING: To avoid accidental start-up,
always press STOP (Memory Key) when not
in use.
Turn OFF your machine if there is a fault or
problem with the safety check.
NEVER operate the machine if the stop
function does not work properly.
WARNING: Improper operation,
maintenance or adjustment may cause
serious injury or damage to equipment and
may void the warranty.
!
!
!
!
Result: Meaning:
Diagnostic LEDs turn
ON. Checking for Memory Key.
All LDC segments flash
ON and OFF. LCD screen is working.
LEDs turn OFF. Memory Key check is
complete.
Green LED starts
blinking and Settings
Screen appears.
Transmitterdatais being
transmitted.
NOTE: If the user display is activated, a welcome
screen appears, and then the Settings
Screen appears.
Operation screen
appears. Transmitter is operational.
NOTE: If Feedback is enabled, feedback status
messages also appear on the screen.
DANGER:If your machine does not operate
as expected. Shut down the system
immediately and contact your supervisor for
next steps.
!

9
TROUBLESHOOTING
If the system does not operate after normal start-up,
follow the recommended troubleshooting sequence
to help isolate the cause and determine corrective
action.
If you need more information, contact your dealer or
Hetronic.
PROBLEM PROBABLE CAUSE CORRECTION
Transmitter won’t start Missing Memory Key Insert Memory key
Batteries fully discharged Replace with fully charged batteries if
needed
The transmitter is turned on, but
does not transmit (Power LED
not flashing)
Battery is discharged Replace battery with a fully charged
battery
Component failure Contact your supervisor.
Transmitter is transmitting
(Power LED flashing), but
machine will not respond
No power to the receiver
Check the diagnostic LEDs in the
receiver to be sure power is applied.
Ensure that the system is properly
grounded
Transmitter/receiver frequency
channels do not match Contact your supervisor
Transmitter out of range Take the transmitter back into the
range of the receiver, press START
Receiver power off Turn on power to receiver
Blown fuse in receiver Check all fuses and replace if needed
E-Stop failure in receiver. Red E-
Stop LED on PC board is
illuminated Contact your supervisor
All machine motions operate
intermittently
Receiver antenna connection is
loose or missing Tighten or replace antenna
External antenna (if used) has
looseconnection,poorgrounding
or interference
Tighten antenna and ground
connection. Contact Hetronic or your
Dealer for more information
Control wiring too close to high
power machine wiring Contact your supervisor
Connector inside receiver is
loose Check all connectors, reseat if needed
Another frequency may be
interfering with the system Contact your supervisor

10
Somemachinemotions operate
intermittently
Loose machine motion wiring Check wiring from receiver to plug
and plug to machine motion actuator
Loose connector inside receiver Check all connectors, reseat if
needed
Surge suppressors not installed
on contactors Contact your supervisor
Control wiring too close to high
power machine wiring Control wiring must be run separately from high power machine wiring

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SPECIFICATIONS
Housing: Ergonomically designed PC-ABS blend housing, one-hand operation
Environmental Protection: IP 65 (Exceeds Nema 12/13)
Weight: Up to 400 g (14.2 oz.), including battery
Dimensions: Height: 186 mm (7.3 in.)
Width: 82 mm (3.2 in.)
Depth: 33 mm (1.3 in.)
Antenna: Internal
Power Supply: 3 AA batteries (3 Mignon LR6-AA 1.5V)
Optional 3.6V NiMH rechargeable battery
Diagnostics: Status LED for operation and standard/advanced low battery detection
Transmission icon Battery usage icon
Push button activation icon
Operation Time: Up to 20 h continuous transmission
Control Configuration: V1 - 11 Single detent push buttons, 1 three position maintained toggle switch,
start + stop
V2 - 8 Two detent push buttons, 3 single detent push buttons, 1 three position
maintained toggle switch, start + stop
V3 - 6 Three detent push buttons, 2 Two detent push buttons, 3 single detent
push buttons, 1 3-position maintained toggle switch, start + stop
Frequency Range: 419 MHz, 429 MHz, 434 MHz, 447 MHz, 458 MHz, 480 MHz, and 868 MHz
RF Unit: Type CS synthesized with programmable frequencies
Power (RF Output): < 10 mW
Typical Operating Range: Approximately 100 m. (328 ft.)
Safety: 20-bit programmable address concept with up to 1,000,000 combinations
Hamming Distance 3
Temperature Range: -25 to +70 degrees C (-11 to +158 degrees F)
Humidity Range: 0 - 97% maximum non-condensing
Response Time: Approx. 100 msec.
Baud Rate: Up to 9600 Kbps
Standard Features: Fully programmable via Pocket PC with H-Link modem
Integrated LCD graphics display with feedback capability
Combination stop/Memory Key cap that stores configuration settings
Cable back-up ready
Push button monitoring
Hand and wrist strap

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© 2007 Hetronic
All rights reserved. No part of this publication may be reproduced,
transmitted, transcribed, stored in a retrieval system, or translated into any
language in any form by any means without the written permission of
Hetronic.
Technical information subject to change without notice.
Hetronic reserves the right to discontinue, make changes to, and add
improvements upon its products at any time without public notice or
obligation. Hetronic disclaims liability for any claims or damages, whether
regarding property, personal injury or death arising out of the use of
unauthorized replacement parts or service.