Instruction Manual MC‐3 Series Radio remote control systems MC‐3 Series instruction manual MAN‐07‐007 Rev.11 2 Contents SAFETY NOTES ............................................................................................................................................. 3 1 INTRODUCTION ................................................................................................................................... 4 1.1 MARKING ................................................................................................................................................. 4 2 SYSTEM DESCRIPTION .......................................................................................................................... 5 2.1 TERMINAL ................................................................................................................................................. 5 2.2 BASE UNIT ................................................................................................................................................ 6 2.3 CABLE CONNECTION (OPTIONAL) ................................................................................................................... 6 2.4 ANTENNA ................................................................................................................................................. 6 2.5 CARRYING BELT/ NECK STRAP ........................................................................................................................ 6 3 FUNCTIONAL DESCRIPTION .................................................................................................................. 7 3.1 SYSTEM CONFIGURATION ............................................................................................................................. 7 3.2 SIGNAL ENCODING ...................................................................................................................................... 7 3.3 FEEDBACK ................................................................................................................................................. 7 3.4 OPERATING RANGE ..................................................................................................................................... 7 4 MAIN DATA ......................................................................................................................................... 8 5 INSTALLATION ..................................................................................................................................... 9 5.1 INSTALLING THE BASE UNIT .......................................................................................................................... 9 5.2 INSTALLING THE ANTENNA ........................................................................................................................... 9 6 COMMISSIONING ............................................................................................................................... 10 7 OPERATION ....................................................................................................................................... 11 7.1 OPERATION OF TERMINAL .......................................................................................................................... 11 7.2 OPERATION OF BASE UNIT ......................................................................................................................... 18 8 BATTERY CHARGER AND BATTERIES ................................................................................................... 22 8.1 CHANGING THE BATTERY ............................................................................................................................ 22 8.2 STORAGE RECOMMENDATION OF BATTERY .................................................................................................... 22 8.3 BATTERY CHARGER INSTALLATION AND USE .................................................................................................... 23 8.4 CABLE MODE ........................................................................................................................................... 28 9 MAINTENANCE .................................................................................................................................. 28 9.1 SPARE/REPLACEMENT ............................................................................................................................... 28 9.2 SERVICE .................................................................................................................................................. 28 9.3 FAULT REPORTING .................................................................................................................................... 29 10 WARRANTY ....................................................................................................................................... 29 MC‐3 Series instruction manual MAN‐07‐007 Rev.11 3 Safety notes Inspect the MC‐3 series equipment before using it. Check for any damage that may be incurred during shipping. Do not open the terminal unit. There are no user serviceable parts. Do not use the device if it appears to be damaged. Use only original batteries from CMC. Avoid mechanical shock and vibrations if possible. Do not use outside temperature range. Do not immerse in water. ENSURE THAT THE SUPPLY VOLTAGE IS CORRECT. INSTALLATION SHOULD ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL. Cavotec Micro‐control takes no responsibility for protection impairment if used in a manner not specified in the instruction manual and/or the project specific documentation. Cavotec Micro‐control reserves the right to make improvements and/or changes in the products and/or specifications described in this information at any time without notice. ® MC‐3 Series instruction manual MAN‐07‐007 Rev.11 4 1 Introduction The MC‐3 series radio remote control is designed for use in harsh industrial environment to control machinery such as overhead cranes, hoists, recovery vehicles, concrete pumps, sludge trucks etc. As the different remote control models vary according to customer requirements, this manual describes only functions that are common for all MC‐3 series deliveries (including MC‐3 series EX). For customer‐specific systems please refer to project documentation. 1.1 Marking 1.1.1 Terminal units The serial number and other relevant data such as frequency, project number etc. is found on the backside of the respective unit. 1.1.2 Base unit The serial number and other relevant data such as frequency, project number etc. is found on the right hand side of the respective unit. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 5 2 System description The system consists of terminal (remote control unit), with a carrying belt or neck strap base unit with antenna (battery charger and batteries) The terminal and the base unit are communicates via a radio link. Some systems are also delivered with a cable for communication between terminal and base unit as the only way of communication or as a backup for the radio link. When the system communicates only by cable, battery charger and batteries are not part of delivery. As customer requirements vary greatly, the system comes in different models which differ in configuration, size and weight. 2.1 Terminal The terminal contains the Stop switch, pushbuttons, joysticks, toggle switches, LED indicator lamps and optionally a LCD display. The terminal is carried by the operator with a belt or a neck strap. All terminals are also available in EX proof versions except of MC‐3100. MC‐3200 MC‐3300 MC‐3‐5 MC‐3‐6 MC‐3100 MC‐3 Series instruction manual MAN‐07‐007 Rev.11 6 2.2 Base unit The base unit is the part of the system that is connected to the customer’s machine or PLC. CMC delivers output signals to control the machinery from the remote control, based on the customer’s specification. The base unit can be delivered in EX or NON‐EX. CMC has no responsibility for control elements that are part of machinery. 2.3 Cable connection (optional) The cable connects the terminal with the base unit and serves both as power supply and communication line. Cable can be used as backup or instead of radio communication. When the cable is connected, the system will automatically communicate on cable, and the radio will be disabled. 2.4 Antenna Located on or connected to the base unit with a coaxial cable. The antenna can be of internal or external type. External antenna can be mounted on the base unit or some distance away with an extension cable supplied by Cavotec Micro‐control. Depending of cable type, the recommended maximum length of the antenna extension cable is either 30 m or 50 m. 2.5 Carrying belt/ neck strap The carrying belt or strap should always be used whenever the terminal is operated to carry the terminal safely and keep the operator’s hands free. Failure to use the belt or strap may cause injury as you will not have proper control of the terminal. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 7 3 Functional description The terminal unit communicates by radio signals or by cable, with the base unit which is installed at the designated equipment. 3.1 System configuration The system may consist of more than one terminal/base unit operating together. Where several terminal units are used to control one base unit, it is customer’s responsibility to ensure that the operator always has control of which terminal unit is in operation, to avoid any dangerous uncontrolled movements. For tandem configurations, e.g. multiple cranes doing tandem lift of heavy equipment please refer to the specification SP‐11‐015 CMC Tandem configurations. 3.2 Signal encoding Unique encoding of the radio signal prevents unintentional operation caused by interference from other radio systems. 3.3 Feedback If feedback is configured, the operator can read information from the machine at the terminal unit, via a display or LEDS. The information could include e.g. % of load, rpm, torque, speed, text instruction, etc. If the feedback is a direct input from the machinery, customer is responsible for the information being presented. 3.4 Operating range Depending on the installation the operating range can be from 100‐1000 m, typically 200 m line of sight. The range may change according to the surroundings and other equipment. To achieve optimal range, care should be taken when installing the antenna (Chapter 5.2). MC‐3 Series instruction manual MAN‐07‐007 Rev.11 8 4 Main data Terminal Base unit Dimensions (L‐W‐H) MC-3-5 230x175x160 mm MC-3-6 330x220x200 mm MC-3100 225x140x140 mm MC-3200 280x180x180 mm MC-3300 340x230x185 mm Physical size and weight of the housing will vary for each delivery. Please refer to system specific drawings and order specific documentation. Weight 2-4 kg (the weight will vary with the terminal’s equipment) 1,3 kg for MC-3100 incl. 2 joysticks, belt and battery. IP class IP 65, optional IP 66, depending on configuration. Operating Temperature Between -20°C and +50°C for radio systems Between -25°C and +60°C for cable systems without radio Radio frequency CMC can provide systems for frequency bands in the range 335 Mhz – 870 MHz. Contact CMC for guidance on correct radio frequency. Radio power MC‐3 Series instruction manual MAN‐07‐007 Rev.11 9 5 Installation INSTALLATION SHOULD ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL. ENSURE THE SUPPLY VOLTAGE IS CORRECT. Consider the ambient temperature and IP rating. If the installation is subject to harsh vibrations, use vibration dampers available from CMC. 5.1 Installing the Base unit 1) Fasten the base unit securely onto a suitable part of the machine or equipment being controlled. a) Install the base unit in a mechanical protected area not being exposed to damage b) Make sure the base unit is not installed near high energy lines c) Ensure that the base unit is installed where it will not be conflicting with moving parts in operation 2) Reserve space around the unit to ensure easy removal of the lid/opening of the door and easy access to the connectors and buttons in the base unit 3) The system shall be installed/wired according to the wiring diagram and system description given in the project specific documentation. Control that the load (valves etc.) is connected correct and that the specification on the load is within the specified minimum/maximum load of the CMC output relays. 5.2 Installing the Antenna Mount the antenna so there is line of sight between the antenna on the base unit and the terminal carried by the operator. Large metal objects between the terminal and antenna on base unit may stop the signal and prevent operation. Take care that the antenna will not be damaged by moving machinery. Do not mount the antenna inside a metal enclosure. There should be no metal objects within a radius of 1 m from the centre of the antenna Other wireless equipment may interfere with the radio remote system. Frequency planning is important to avoid this. Contact CMC for guidance If more than one antenna is mounted at the same site, particular care should be taken with regards to sufficient channel spacing and distance between antennas. Range may be degraded if these are not considered. Contact CMC for guidance. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 10 6 Commissioning The system has been through a 100 % test before leaving factory, ensuring that all outputs are controlled by the correct joystick/switch on the terminal unit, and that the output values are correct according to the specification from customer. When the system has been installed, customer is responsible for checking of all functions in a controlled and safe manner before the system is put in to normal operation: 1) Check all control functions Validate that each function controls the intended operation/movement on the machine, with minimum to maximum deflection/speed where relevant. Where configured, validate that all interlocking functions works as intended. Where configured, validate that all selector switches works as intended. Where configured, validate that max/min programming of analogue functions works as intended. Where feedback from machine (load cell, sensor etc) to terminal unit is configured, either to display or LED, validate that the input signal gives correct corresponding value in the terminal unit. 2) Validate the Stop function: Press the Stop button and check that all movements/functionality connected in the Stop loop are deactivated. Start up after Stop: For SIL 3/PL e certified systems the radio remote system is activated again by first releasing the Stop button, checking that terminal unit is ON and then pressing the Start button. For systems with ON/OFF and Stop button the radio remote system is activated again by first powering OFF terminal unit, releasing the Stop button and powering ON terminal unit For systems with ON/OFF, Start and Stop button the radio remote system is activated again by first powering OFF terminal unit, releasing the Stop button, powering ON terminal unit and then pressing Start. For systems without ON/OFF and Start, only Stop, the radio remote system is activated again by releasing the Stop button. If modules have been replaced at service, or other modifications have been done on the system, commissioning must be done before the modified system is put in to operation again. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 11 7 Operation 7.1 Operation of Terminal MC‐3 series terminals are produced to control a variety of equipment, and each terminal unit is configured uniquely according to customer specification, for optimal integration with the customer’s machine. Specific instructions are found in the project specific documentation. Identification of typical operating controls and placement: It is important that the operator is familiar with the machine being controlled, and has been given the necessary training. Joystick X/Y Analog and/or digital (V14) LCD Display Joystick, one axis, analog Joystick X/Y Analog and/or digital (V20) Key switch Push button with LED Toggle switch Push button Bottom left side: Cable connector Bottom right side: STOP button Potentiometer Rotary switchLED MC‐3 Series instruction manual MAN‐07‐007 Rev.11 12 7.1.1 Explanation of symbols Each terminal unit is according customer specification and the symbols can vary both in shape and meaning. Symbols can be configured according to customer‐specific requirements. These are standard symbols which can be used on the terminal unit: UP (NORTH) RIGHT (EAST) DOWN (SOUTH) LEFT (WEST) BATTERY STATUS HORN LIGHT FAST (HIGH SPEED) SLOW (LOW SPEED) CLAMP OPEN CLAMP CLOSE CLAMP OFF CLAMP ON SLEW CCW SLEW CW BOM UP BOM DOWN JIB IN JIB OUT MC‐3 Series instruction manual MAN‐07‐007 Rev.11 13 TELESCOPE IN TELESCOPE OUT WINCH UP WINCH DOWN MANRIDER DOWN MANRIDER UP LEFT TRACK RIGHT TRACK 7.1.2 Start Check that a sufficient charged battery is in the terminal. 1. Pull out/twist the Stop button. The Stop button must be deactivated and all of the switches and joysticks have to be in neutral position. 2. Put the ON/OFF switch in position ON. 3. Press the Start button if fitted. After a self test (approx. 1 sec.) the terminal will establish contact with the base unit. All SIL 3/PL e certified systems are equipped with a Start button, ON/OFF and Stop button. Some of the SIL3/PL e certified systems are equipped with a LOCK/RELEASE switch. This LOCK/RELEASE switch is for safety reason. When a terminal is locked to a base unit, there should be no possibility to use other terminal to the same base unit. A SIL3/PL e system is started like this: 1. Stop button must be deactivated and all of the switches have to be in neutral position. 2. Put the ON/OFF switch in position ON. 3. Put the LOCK/RELEASE switch in position LOCK. 4. Press start button. If the communication between terminal unit and base unit is broken, e.g due to radio loss, the Start button has to be activated to establish communication again. For some system configurations (all SIL 3/PL e certified systems) all safety related analogue functions and any selector functions enabling these, have to be deactivated before Start up is allowed. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 14 7.1.3 Stop Press the Stop button to activate the Stop. Twist or pull to release. The system is default equipped with a grey Stop button placed on the right hand side of the terminal. To start machinery again, after the Stop function has been activated, refer to chapter 6, point 2). 7.1.4 Time out If the system is not used for a time, it can be configured to go into power save mode to conserve the battery. Time out can be adjusted from 0‐99 minutes or turned off. Default time out is 30 min. 7.1.5 Selection and locking of terminal in systems with multiple terminals In systems where the operator can select between two or more terminal units to control the base unit, the operator should do a deliberate selection and release of the controlling terminal unit, to ensure safe control of machinery. Some of the SIL 3/PL e systems are configured with LOCK/RELEASE switch on the terminal units (also available on other systems). A terminal unit is locked to the base unit until the RELEASE switch on the terminal unit is activated. When the RELEASE switch on the terminal unit is activated, the base unit is detached and will now lock to the first terminal unit powered on. In systems configured with LOCK/RELEASE, the terminal unit will stay locked to the base unit also in the event of loss of power to base unit. In other systems, the base unit will detach in the event of power loss. A base unit can be released directly from the base unit: 1. Press A (SW1) on the PCB of MC‐IRX‐LITE. The button is located below the LCD. In the display you will see 1: System 2. Press A (SW1). In the display you will see 10: Remove lock 3. Press A (SW1) and hold the pressure on the button while SW3 is turned one step to the right, then let go of switch A. The base unit will now boot up and it is released from the terminal unit. Picture of MC‐IRX‐LITE module with its switches is located in chapter 7.2.1. Stop button MC‐3 Series instruction manual MAN‐07‐007 Rev.11 15 7.1.6 Activity check For safety reasons, activity check may be added for all, or for a range of functions. This will force the switch/joystick to be set in neutral position before the operator is allowed to start up terminal. As default, all functions have activity check. All SIL 3/PL e certified systems have activity check on all safety related functions. 7.1.7 Frequency selection MC 3‐series systems can be delivered with automatic or manual frequency selection. If automatic, the system will scan a set of 2 to 8 predefined frequencies and find an available frequency (not occupied/with low noise). All system types have the possibility for manual frequency selection. There will be a frequency select button on the terminal or a rotary switch to select the next frequency programmed into the system. The base unit will automatically scan to find the frequency the terminal is set to. The function should be used if there is bad link to base unit, either no connection or often interrupted. When changing frequency, all outputs will go to neutral position for a short time. The system starts again as described in chapter 7.1.1. After power off and on, the system will either start with a predefined frequency or with the last selected one, depending on system setup. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 16 7.1.8 MIN / MAX programming (optionally) Optionally there is an easy, quick and exact possibility to program analogue output from the terminal side. If so, you will find two buttons for MIN/MAX on the terminal. Adjustment procedure: 1. Turn the terminal off. 2. Press the PROGRAM buttons MIN and MAX at the same time. 3. While pressing the MIN/MAX buttons, turn the terminal on. 4. Release the PROGRAM buttons MIN and MAX. The terminal is now in programming mode, indicated with short flashes at the battery status LED. If the terminal has a LCD‐display, this will show A‐00, indicating programming mode. When a function is being programmed the display shows: A‐XX where XX shows which analog channel is being programmed, and is a number between 01….13. 5. Adjustment: Move the function at your choice to adjust until you get the wanted response. If this shall be your minimum response, press MIN. If this shall be your maximum response, press MAX. The terminal will then automatically adjust the increase of the response so that the whole area of the joystick output is between the two chosen points. 6. Each function is adjusted separately for each direction (up/down/right/left). 7. Reset: Move the function you select to reset out from the center. Press MIN and MAX at the same time. The function is now reset. 8. When the programming is finished, the transmitter must be turned off and on again to start in normal mode. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 17 7.1.9 Status indications on the terminal The terminal is delivered with a LED for status indications; this is usually marked with STATUS or BAT. On systems delivered with LCD screen, error codes and explanations are also found there. LED flashing pattern Description Action Steady light Normal condition. Terminal is turned on, battery voltage is OK, no fault is detected None Slow flashing light without stop (1 flash/sec.) Low battery voltage Replace battery with a fully charged one. Short flashes (2 flashes/sec.) Terminal in MIN/MAX Programming mode (Only on terminals with MIN‐ MAX programming) Min/Max programming of analog functions. Turn terminal off and on again to start normal operation. See chapter 7.1.8 for further explanation. 1 flash with long stop (every 2nd sec.) Processor fault or test mode. Indicates a processor module fault and/or a processor fault. Ensure that the processor module BOOT‐jumper is not turned on. Replace processor module and/or processor. 2 flashes with a stop Activity at start‐up. A joystick is out of centre position, or a switch is in ON‐position. Set all switches/joysticks to OFF‐position and/or neutral position. 3 flashes with a stop Radio fault Change/replace radio module. 4 flashes with a stop Shutdown due to low battery voltage Replace battery with a fully charged one. 5 flashes with a stop Keyboard fault. Terminal is not able to ”read” switches, joysticks etc. There is a fault at the input module. 6 flashes with a stop Shutdown due to inactivity. The terminal will soon ”turn itself off” since no switches, joysticks etc. have been activated. Turn terminal off and on again to start normal operation. 7 flashes with a stop Priority stop. Stop button or shock detector have been activated. Not relevant for SIL 3 certified system. Ensure stop button is out and turn terminal OFF and ON again to start normal operation. No LED Terminal off Ensure terminal contains a charged battery and is turned on. If the terminal has turned itself off due to inactivity, turn it off and on again to start normal operation. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 18 7.2 Operation of Base unit All the MC‐3‐series base units are produced according to customer specifications, the wiring diagram shows how the base unit is connected. Under normal conditions, no operation of the base unit is necessary. If the base unit does not operate correctly, check the display for messages. See info below, for your type of base unit. All repairs must be carried out by a representative from CMC. Your local representative is found at www.cavotec.com 7.2.1 MC‐IRX‐LITE and MC‐IRX2 base units The display on MC‐IRX‐LITE and MC‐IRX base units is a menu system allowing viewing of all operational parameters and service information. Navigation through the menu system is done by A, B and SW3, see picture. During normal operation, the display is divided into three fields: an upper line, and a bottom line with a status field and a timer field. The upper line may also indicate error codes. Indications in the upper line Description [..3......0......] Normal operation: Shows activated relays, in this case relays #3 and #10. [Error: E003] Failure in radio module. [Error: E010] Aux port communication error. [Error: E011] MUS bus communication error. [Micro‐control as] No communication with a terminal and no onboard relays active. [fatal: ] A fatal error has occurred. is a text in the status field describing the cause. Turn the supply Off and On. If the message reappears, contact CMC. Display on MC‐IRX‐LITE A (SW1 ‐ selection) SW3 (navigation in menu system) B (SW2 ‐ back) MC‐3 Series instruction manual MAN‐07‐007 Rev.11 19 Indications in the status field Description A4:‐30 % Most active analog output. In this case channel 4 with output value of ‐30 %. Online Normal operation, base unit communicates with a terminal. Passive Base unit communicates with a terminal, but the Stop relay is de‐ energized. May be caused by too low supply voltage. It is not possible to operate equipment when in passive mode. Idle Base unit does not communicate with a terminal. Locked If several terminals are configured for one base unit, the base unit communicates with selected terminal and does not search for additional terminals (first come first serve mode). Blocked Base unit communicates with a terminal, but is inactive due to softplc function (e.g. start button is not activated). The timer field shows the time elapsed since the last change of operational mode (online/passive/idle/locked/blocked) in hours, minutes and seconds: 01:43:12 Base unit display when there is no communication with the terminal. Normal operation. Base unit communicates with terminal and relay 1 and 7 are activated. A fatal (non recoverable) error has occurred. is a text describing the cause. Turn the supply Off and On. If the message reappears, contact CMC. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 20 7.2.2 Field bus base units Field bus base units are always delivered with a 4 digit segment display. The display may be stacked on the PCB or placed on the outside of the enclosure. The display indicates different fault statuses as well as what terminal is online at any given time. On start‐up the display also show the terminal IDs that is supported in this base unit. Indication in display Description E001 CPU in PM faulty E003 Radio error or no radio present E010 No communication with PLC E011 No communication with slave PM 7.2.3 MC‐LINK‐CAN base units The MC‐LINK‐CAN is equipped with a 3 digit segment display. This display indicates operation status and error messages. The display is found on the upper right corner of the module. Operation status During normal operation digit 1 will be off, and the display will indicate ‐ ‐ Digit 1 (from the left) Description 2 Remote status 3 CanOpen status E Error, the next two digit is an error code (see table below for error codes) F Fatal error, the next two digit is an error code (see table below for error codes) Display on MC‐LINK‐CAN MC‐3 Series instruction manual MAN‐07‐007 Rev.11 21 Digit 2 (from the left) Description 0 No terminal communication ‐ Communicating with terminal E Stop function is activated on the terminal Digit 3 (from the left) Description P Pre‐operational ‐ operational S Stopped U Unknown state Possible error indications in display Display Description E01 Waiting for setup file to be downloaded E03 Radio error or no radio present E10 No communication on CAN bus Fxx Fatal error, power cycle is required to resume normal operation. If message reappears, contact CMC. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 22 8 Battery charger and batteries 8.1 Changing the battery Use only batteries provided by CMC. 1. Put the machine being controlled in to a safe position. 2. Turn the terminal OFF. 3. Remove the battery and insert a fully charged one. 4. Turn the terminal ON. 5. Hot swap Terminals with 2 battery compartments can continue to operate without being switched off. Replace only one battery at a time. 8.2 Storage recommendation of battery The capacity loss of the Li‐Ion battery during storing is approx. 5 ‐ 10% per month. The batteries should be fully charged when stored. Ensure that the batteries are stored in a non condensing atmosphere with no corrosive gas. Avoid direct sunlight, high temperature and high humidity. Recommended storing temperatures: Less than 30 days: ‐20 to +45C. Between 30 and 90 days: ‐20 to +30C. More than 90 days: ‐20 to +20C. Life expectation of the battery depends of storage and use. With correct use you can expect 500 cycles without a significant drop in battery capacity. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 23 8.3 Battery charger installation and use Read these instructions before using the charger Consult instructions for use, symbols on charger are meant to support, not replace, these operating instructions. This charger applies to the essential requirement of the applicable EC directives. The charger is designed for indoor use and should not be exposed to water or dust. Do not cover up the charger when in use. The charger is turned on by connecting it to mains socket (100 V to 230 V ) or to 12‐24 V. Disconnecting turns it off. Control that the power cord is not damaged. If the cord is damaged, the charger must not be used. The mains socket should be easily accessible. If an operational error occurs, the plug should be immediately removed from the mains socket. The charger is double isolated (insulation class II). The charger contains dangerous voltages and the cover should not be removed. The charger is not serviceable. In case of not working it has to be replaced by a new charger. Contact nearest Cavotec sales representative (www.cavotec.com). Avoid the charger from coming into contact with oils, grease etc., as most types of plastic can be broken down by chemicals and solvents. Electrical and electronic equipment shall not be discarded with the municipal waste, but be disposed of using separate collection, treatment, recovery/recycling and environmentally sound disposal, according to local rules. The charger is intended to charge MC‐3 series batteries from Cavotec Micro‐control AS, Cavotec Micro‐control AS have no responsibility for any injuries caused by other usage, not according to intended use. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 24 Important The charger is designed for indoor use only! 8.3.1 Placing and mounting of the charger When the charger is connected to AC or DC current it shall be placed on a plane surface or mounted vertically on its longitudinal direction. See illustration pictures below. On the battery chargers back side there is four rubber knobs which secure a stable placing. There are also two mounting holes for wall mounting on the back side. It is recommended to use 4mm screws with head diameter of Ø 5,5 – 7mm and head height of 1,5 – 2mm. Screw type and length need to be adapted to which material and thickness of the wall it shall be mounted on. See illustration pictures below. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 25 8.3.2 Charger description and functionality The MC‐3 series charger is designed for CMC battery packs, MC‐BATTERY3 and MC‐EX‐BATTERY3. The battery packs contain two 3,7 V Lithium Ion batteries connected in series. Charge end voltage is 8.4 V. Capacity of the battery pack is 1600‐2030 mAh for the MC‐BATTERY3 and 1100‐1230 mAh for the MC‐EX‐BATTERY3. The MC‐3 series charger is an advanced charger for Li‐Ion batteries. It is developed for optimal performance and battery power conservation. The charger is equipped with one tri‐color LED (light emitting diode) at the front displaying charge status. The charger may be used for 100‐230 VAC/50 and 60Hz or for 12VDC‐24 VDC. (only AC or DC at a time, not both). The charger is designed for DC operation in vehicles. AC and DC has separate inputs.The battery compartment is on the top of the charger. The charger should not be used to charge other batteries than Micro‐control batteries! The MC‐3 series charger is a constant current charger during the main period of charging. When the battery voltage is below a certain level, the charger is in constant current mode, delivering close to 1100 mA. Fast charge continues until voltage is close to 8.4 V, then the charger goes into constant voltage mode and charge current decreases. Charge termination occurs when charge current is about 100 mA. Typical charge time for MC‐BATTERY3 is 2,5 hours and for the MC‐EX‐BATTERY3 is 1,5 hours. The battery capacity will decrease during the battery lifecycle, when capacity is to low (to low operational time) then replace the batteries with new ones. 8.3.3 Charger operating instructions Normal charge cycle To charge a MC‐BATTERY3 or MC‐EX‐BATTERY3, simply place it into the MC‐3 series charger. Charging will start automatically when the battery is inserted. Red LED light indicates charging. If the charger/battery is outside temperature limits, charging will not take place and the LED will indicate yellow. Green LED indicates a fully charged battery. The charger is not intended for continuous use, after a charge cycle is completed the battery shall be removed and the power disconnected. DC power cord Connection of the DC power is on the ROKA connector on the left side of the charger. The center lead is +. This is also marked on the cord. The –lead is the ribbed cord, +lead is at the smooth cord . MC‐3 Series instruction manual MAN‐07‐007 Rev.11 26 Indicators The MC‐3 series charger is equipped with one LED, placed on front, close to the battery compartment. Charger status is indicated by the following LED colors: Charge status LED Battery absent Green Temperature charge cutoff Yellow Battery inserted with no supply voltage Yellow Fast charging Red Charge complete Green 8.3.4 Charger ordering numbers from CMC Versions There is only one version of the MC‐3 series charger covering virtually all different supply voltages. To apply to different main supply voltage standards there is different mains supply cords. All ordering numbers are listed below. M5‐1080‐3600 Charger MC‐3 series M5‐1140‐3600 Power cord EUR/C7 M5‐1140‐3603 Power cord US/C7 M5‐1140‐3601 Power cord UK/C7 M5‐1140‐3602 Power cord AUSTR/C7 M5‐1140‐3604 DC power cord with plug M5‐1080‐3699 Kit with charger and all 5 power cord. M5‐1051‐3600 MC‐BAT3 M9‐1051‐3600 MC‐EX‐BAT3 8.3.5 Charger general specifications Input voltage AC input: 100 - 230V , max 150mA, 50 - 60 Hz DC input: 12 – 24V Operating Temperature Ambient -20C - +40C Charging takes place in the temperatur interval +10C - +40C only Storage Temperature -25C - +80C Humidity 10-90% Max height for usage 2000 meters above sea level Mounting of the PSU Two key holes on the bottom of the unit support wall mounting in two directions Galvanic Separation Yes Power inlet AC: IEC conn 2,5A PCB RA DC: DC-connector 1,9mm pin Roka 520 2550 - terminal is the ribbed cord, + terminal is the smooth cord Output connector 2x gold plated pin MC‐3 Series instruction manual MAN‐07‐007 Rev.11 27 8.3.6 Charger mechanical outline: 8.3.7 Charger cleaning/maintenance With no battery or power connected to the charger, the charger can be carefully cleaned with a damp cloth. 8.3.8 Charger marking 37,5 mm202,00 mm 76,00 mm MC‐3 Series instruction manual MAN‐07‐007 Rev.11 28 8.4 Cable mode Some terminal models are equipped with a cable and batteries, and some with only a cable. The cable is connected to the base unit, and serves as both power supply for the terminal unit and communication link to the base unit. For models with both radio function and cable, the radio mode is automatic deactivated as soon as the cable is connected. The terminal and the base unit then communicate via the cable. After connecting or disconnecting the cable, press Start button to establish communication with base unit again. 9 Maintenance The terminal and base unit do not need any regular maintenance. However, the units should be inspected for damage and cleaned regularly with a damp cloth, for all displays, labels and symbols to be read properly. If opening the terminal housing, ensure the gasket is fixed properly when closing the terminal. The terminal unit shall only be opened by qualified personnel; failure in fixing the gasket may degrade the IP degree. If the rubber boots on the terminal’s joysticks/switches are damaged, they should be replaced at once. Contact your local CMC distributor. Your local CMC distributor is found at www.cavotec.com 9.1 Spare/Replacement Spare parts can be ordered through your local CMC distributor. You will need the serial number (ID code) from the system, see section 1.1 Marking, and the part number. Dispose of electronic products according to local rules. Your local CMC distributor is found at www.cavotec.com 9.2 Service Service can be arranged with your local distributor. You will need the serial number from the system and description of the service required. Plug for cable mode MC‐3 Series instruction manual MAN‐07‐007 Rev.11 29 9.3 Fault reporting CMC is continuously working to improve our products, to be able to deliver as safe and good products as possible. For best possible improvement, it is crucial to get feedback from customers. Non‐conformities on the product, functionality or quality should be reported back to CMC. If a hazardous situation or a fatal error should occur on the delivered system, please report back to CMC for analysis. Reporting of non‐conformities can be done via your local distributor. You will need the serial number from the system and description of the service required. Your local CMC distributor is found at www.cavotec.com 10 Warranty All the deliveries are thoroughly tested and packed before they leave CMC. If the delivery is found to be damaged when it is opened, inform the carrier immediately. CMC does not cover any damages caused by transport. All systems are delivered with 12 months warranty against material and manufacturing faults. The warranty covers repairs authorized by CMC at a Cavotec premises. Expenses for service outside CMC are not included. Repairs done without authority from CMC may invalidate any warranty. Information in this document is subject to change without notice. MC‐3 Series instruction manual MAN‐07‐007 Rev.11 30 MC‐3 Series instruction manual MAN‐07‐007 Rev.11 31 MC‐3 Series instruction manual MAN‐07‐007 Rev.11 32 Cavotec Micro-control AS Gevinglia 112, 7517 Hell Norway Phone: + 47 74 84 31 00 E‐mail:
[email protected] Service E‐mail:
[email protected] Cavotec Micro-control GmbH Gewerbering 3, 93345 Hausen Germany Phone: +49 9448‐90120‐0 E‐mail: micro‐
[email protected] Your local distributor is found at www.cavotec.com © 2013 Cavotec Micro‐control AS All rights reserved