MAN-07-007 MC-3 Series Instruction Manual.pdf
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Transcript of MAN-07-007 MC-3 Series Instruction Manual.pdf
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InstructionManualMC3SeriesRadioremotecontrolsystems
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MC3Seriesinstructionmanual
MAN07007Rev.112
ContentsSAFETYNOTES.............................................................................................................................................31 INTRODUCTION...................................................................................................................................4
1.1 MARKING.................................................................................................................................................42 SYSTEMDESCRIPTION..........................................................................................................................5
2.1 TERMINAL.................................................................................................................................................52.2 BASEUNIT................................................................................................................................................62.3 CABLECONNECTION(OPTIONAL)...................................................................................................................62.4 ANTENNA.................................................................................................................................................62.5 CARRYINGBELT/NECKSTRAP........................................................................................................................6
3 FUNCTIONALDESCRIPTION..................................................................................................................73.1 SYSTEMCONFIGURATION.............................................................................................................................73.2 SIGNALENCODING......................................................................................................................................73.3 FEEDBACK.................................................................................................................................................73.4 OPERATINGRANGE.....................................................................................................................................7
4 MAINDATA.........................................................................................................................................85 INSTALLATION.....................................................................................................................................9
5.1 INSTALLINGTHEBASEUNIT..........................................................................................................................95.2 INSTALLINGTHEANTENNA...........................................................................................................................9
6 COMMISSIONING...............................................................................................................................107 OPERATION.......................................................................................................................................11
7.1 OPERATIONOFTERMINAL..........................................................................................................................117.2 OPERATIONOFBASEUNIT.........................................................................................................................18
8 BATTERYCHARGERANDBATTERIES...................................................................................................228.1 CHANGINGTHEBATTERY............................................................................................................................228.2 STORAGERECOMMENDATIONOFBATTERY....................................................................................................228.3 BATTERYCHARGERINSTALLATIONANDUSE....................................................................................................238.4 CABLEMODE...........................................................................................................................................28
9 MAINTENANCE..................................................................................................................................289.1 SPARE/REPLACEMENT...............................................................................................................................289.2 SERVICE..................................................................................................................................................289.3 FAULTREPORTING....................................................................................................................................29
10 WARRANTY.......................................................................................................................................29
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MC3Seriesinstructionmanual
MAN07007Rev.113
Safetynotes
InspecttheMC3seriesequipmentbeforeusingit.
Checkforanydamagethatmaybeincurredduringshipping.
Donotopentheterminalunit.Therearenouserserviceableparts.
Donotusethedeviceifitappearstobedamaged.
UseonlyoriginalbatteriesfromCMC.
Avoidmechanicalshockandvibrationsifpossible.
Donotuseoutsidetemperaturerange.
Donotimmerseinwater.
ENSURETHATTHESUPPLYVOLTAGEISCORRECT.
INSTALLATIONSHOULDONLYBECARRIEDOUTBYQUALIFIEDPERSONNEL.CavotecMicrocontroltakesnoresponsibilityforprotectionimpairmentifusedinamannernotspecifiedintheinstructionmanualand/ortheprojectspecificdocumentation.
CavotecMicrocontrolreservestherighttomakeimprovementsand/orchangesintheproductsand/orspecificationsdescribedinthisinformationatanytimewithoutnotice.
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MC3Seriesinstructionmanual
MAN07007Rev.114
1 IntroductionTheMC3seriesradioremotecontrolisdesignedforuseinharshindustrialenvironmenttocontrolmachinerysuchasoverheadcranes,hoists,recoveryvehicles,concretepumps,sludgetrucksetc.Asthedifferentremotecontrolmodelsvaryaccordingtocustomerrequirements,thismanualdescribesonlyfunctionsthatarecommonforallMC3seriesdeliveries(includingMC3seriesEX).Forcustomerspecificsystemspleaserefertoprojectdocumentation.1.1 Marking1.1.1 Terminalunits
Theserialnumberandotherrelevantdatasuchasfrequency,projectnumberetc.isfoundonthebacksideoftherespectiveunit.
1.1.2 Baseunit
Theserialnumberandotherrelevantdatasuchasfrequency,projectnumberetc.isfoundontherighthandsideoftherespectiveunit.
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2 SystemdescriptionThesystemconsistsof
terminal(remotecontrolunit),withacarryingbeltorneckstrap
baseunitwithantenna (batterychargerandbatteries)Theterminalandthebaseunitarecommunicatesviaaradiolink.Somesystemsarealsodeliveredwithacableforcommunicationbetweenterminalandbaseunitastheonlywayofcommunicationorasabackupfortheradiolink.Whenthesystemcommunicatesonlybycable,batterychargerandbatteriesarenotpartofdelivery.Ascustomerrequirementsvarygreatly,thesystemcomesindifferentmodelswhichdifferinconfiguration,sizeandweight.
2.1 TerminalTheterminalcontainstheStopswitch,pushbuttons,joysticks,toggleswitches,LEDindicatorlampsandoptionallyaLCDdisplay.Theterminaliscarriedbytheoperatorwithabeltoraneckstrap.AllterminalsarealsoavailableinEXproofversionsexceptofMC3100.
MC3200 MC3300
MC35 MC36
MC3100
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2.2 BaseunitThebaseunitisthepartofthesystemthatisconnectedtothecustomersmachineorPLC.CMCdeliversoutputsignalstocontrolthemachineryfromtheremotecontrol,basedonthecustomersspecification.ThebaseunitcanbedeliveredinEXorNONEX.
CMChasnoresponsibilityforcontrolelementsthatarepartofmachinery.2.3 Cableconnection(optional)
Thecableconnectstheterminalwiththebaseunitandservesbothaspowersupplyandcommunicationline.Cablecanbeusedasbackuporinsteadofradiocommunication.Whenthecableisconnected,thesystemwillautomaticallycommunicateoncable,andtheradiowillbedisabled.2.4 Antenna
Locatedonorconnectedtothebaseunitwithacoaxialcable.Theantennacanbeofinternalorexternaltype.ExternalantennacanbemountedonthebaseunitorsomedistanceawaywithanextensioncablesuppliedbyCavotecMicrocontrol.
Dependingofcabletype,therecommendedmaximumlengthoftheantennaextensioncableiseither30mor50m.2.5 Carryingbelt/neckstrap
Thecarryingbeltorstrapshouldalwaysbeusedwhenevertheterminalisoperatedtocarrytheterminalsafelyandkeeptheoperatorshandsfree.
Failuretousethebeltorstrapmaycauseinjuryasyouwillnothavepropercontroloftheterminal.
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3 FunctionaldescriptionTheterminalunitcommunicatesbyradiosignalsorbycable,withthebaseunitwhichisinstalledatthedesignatedequipment.
3.1 Systemconfiguration
Thesystemmayconsistofmorethanoneterminal/baseunitoperatingtogether.Whereseveralterminalunitsareusedtocontrolonebaseunit,itiscustomersresponsibilitytoensurethattheoperatoralwayshascontrolofwhichterminalunitisinoperation,toavoidanydangerousuncontrolledmovements.Fortandemconfigurations,e.g.multiplecranesdoingtandemliftofheavyequipmentpleaserefertothespecificationSP11015CMCTandemconfigurations.3.2 Signalencoding
Uniqueencodingoftheradiosignalpreventsunintentionaloperationcausedbyinterferencefromotherradiosystems.3.3 Feedback
Iffeedbackisconfigured,theoperatorcanreadinformationfromthemachineattheterminalunit,viaadisplayorLEDS.Theinformationcouldincludee.g.%ofload,rpm,torque,speed,textinstruction,etc.Ifthefeedbackisadirectinputfromthemachinery,customerisresponsiblefortheinformationbeingpresented.3.4 Operatingrange
Dependingontheinstallationtheoperatingrangecanbefrom1001000m,typically200mlineofsight.Therangemaychangeaccordingtothesurroundingsandotherequipment.Toachieveoptimalrange,careshouldbetakenwheninstallingtheantenna(Chapter5.2).
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4 Maindata Terminal Base unit
Dimensions(LWH)
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 terminals 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 -20C and +50C for radio systems
Between -25C and +60C 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
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5 InstallationINSTALLATIONSHOULDONLYBECARRIEDOUTBYQUALIFIEDPERSONNEL.ENSURETHESUPPLYVOLTAGEISCORRECT.
ConsidertheambienttemperatureandIPrating.
Iftheinstallationissubjecttoharshvibrations,usevibrationdampersavailablefromCMC.5.1 InstallingtheBaseunit
1) Fastenthebaseunitsecurelyontoasuitablepartofthemachineorequipmentbeingcontrolled.a) Installthebaseunitinamechanicalprotectedareanotbeingexposedtodamageb) Makesurethebaseunitisnotinstallednearhighenergylinesc) Ensurethatthebaseunitisinstalledwhereitwillnotbeconflictingwithmovingpartsin
operation2) Reservespacearoundtheunittoensureeasyremovalofthelid/openingofthedoorandeasy
accesstotheconnectorsandbuttonsinthebaseunit3) Thesystemshallbeinstalled/wiredaccordingtothewiringdiagramandsystemdescription
givenintheprojectspecificdocumentation.Controlthattheload(valvesetc.)isconnectedcorrectandthatthespecificationontheloadiswithinthespecifiedminimum/maximumloadoftheCMCoutputrelays.
5.2 InstallingtheAntennaMounttheantennasothereislineofsightbetweentheantennaonthebaseunitandtheterminalcarriedbytheoperator.Largemetalobjectsbetweentheterminalandantennaonbaseunitmaystopthesignalandpreventoperation.
Takecarethattheantennawillnotbedamagedbymovingmachinery.
Donotmounttheantennainsideametalenclosure.Thereshouldbenometalobjectswithinaradiusof1mfromthecentreoftheantenna
Otherwirelessequipmentmayinterferewiththeradioremotesystem.Frequencyplanningisimportanttoavoidthis.ContactCMCforguidance
Ifmorethanoneantennaismountedatthesamesite,particularcareshouldbetakenwithregardstosufficientchannelspacinganddistancebetweenantennas.Rangemaybedegradedifthesearenotconsidered.ContactCMCforguidance.
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6 CommissioningThesystemhasbeenthrougha100%testbeforeleavingfactory,ensuringthatalloutputsarecontrolledbythecorrectjoystick/switchontheterminalunit,andthattheoutputvaluesarecorrectaccordingtothespecificationfromcustomer.Whenthesystemhasbeeninstalled,customerisresponsibleforcheckingofallfunctionsinacontrolledandsafemannerbeforethesystemisputintonormaloperation:1) Checkallcontrolfunctions
Validatethateachfunctioncontrolstheintendedoperation/movementonthemachine,withminimumtomaximumdeflection/speedwhererelevant.
Whereconfigured,validatethatallinterlockingfunctionsworksasintended. Whereconfigured,validatethatallselectorswitchesworksasintended. Whereconfigured,validatethatmax/minprogrammingofanaloguefunctionsworks
asintended. Wherefeedbackfrommachine(loadcell,sensoretc)toterminalunitisconfigured,
eithertodisplayorLED,validatethattheinputsignalgivescorrectcorrespondingvalueintheterminalunit.
2) ValidatetheStopfunction:PresstheStopbuttonandcheckthatallmovements/functionalityconnectedintheStoplooparedeactivated.StartupafterStop:
ForSIL3/PLecertifiedsystemstheradioremotesystemisactivatedagainbyfirstreleasingtheStopbutton,checkingthatterminalunitisONandthenpressingtheStartbutton.
ForsystemswithON/OFFandStopbuttontheradioremotesystemisactivatedagainbyfirstpoweringOFFterminalunit,releasingtheStopbuttonandpoweringONterminalunit
ForsystemswithON/OFF,StartandStopbuttontheradioremotesystemisactivatedagainbyfirstpoweringOFFterminalunit,releasingtheStopbutton,poweringONterminalunitandthenpressingStart.
ForsystemswithoutON/OFFandStart,onlyStop,theradioremotesystemisactivatedagainbyreleasingtheStopbutton.
Ifmoduleshavebeenreplacedatservice,orothermodificationshavebeendoneonthesystem,commissioningmustbedonebeforethemodifiedsystemisputintooperationagain.
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7 Operation7.1 OperationofTerminal
MC3seriesterminalsareproducedtocontrolavarietyofequipment,andeachterminalunitisconfigureduniquelyaccordingtocustomerspecification,foroptimalintegrationwiththecustomersmachine.Specificinstructionsarefoundintheprojectspecificdocumentation.Identificationoftypicaloperatingcontrolsandplacement: Itisimportantthattheoperatorisfamiliarwiththemachinebeingcontrolled,andhasbeengiventhenecessarytraining.
JoystickX/YAnalogand/ordigital(V14)
LCDDisplay
Joystick,oneaxis,analog
JoystickX/YAnalogand/ordigital(V20)
Keyswitch
PushbuttonwithLED
Toggleswitch
Pushbutton
Bottom left side: Cable connector Bottomrightside:STOPbutton
Potentiometer RotaryswitchLED
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7.1.1 ExplanationofsymbolsEachterminalunitisaccordingcustomerspecificationandthesymbolscanvarybothinshapeandmeaning.Symbolscanbeconfiguredaccordingtocustomerspecificrequirements.Thesearestandardsymbolswhichcanbeusedontheterminalunit:
UP(NORTH)
RIGHT(EAST)
DOWN(SOUTH)
LEFT(WEST)
BATTERYSTATUS
HORN
LIGHT
FAST(HIGHSPEED) SLOW(LOWSPEED)
CLAMPOPEN CLAMPCLOSE
CLAMPOFF
CLAMPON
SLEWCCW SLEWCW
BOMUP
BOMDOWN
JIBIN
JIBOUT
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MAN07007Rev.1113
TELESCOPEIN
TELESCOPEOUT
WINCHUP WINCHDOWN
MANRIDERDOWN MANRIDERUP
LEFTTRACK
RIGHTTRACK
7.1.2 Start
Checkthatasufficientchargedbatteryisintheterminal.1. Pullout/twisttheStopbutton.TheStopbuttonmustbedeactivatedandalloftheswitches
andjoystickshavetobeinneutralposition.2. PuttheON/OFFswitchinpositionON.3. PresstheStartbuttoniffitted.
Afteraselftest(approx.1sec.)theterminalwillestablishcontactwiththebaseunit.AllSIL3/PLecertifiedsystemsareequippedwithaStartbutton,ON/OFFandStopbutton.SomeoftheSIL3/PLecertifiedsystemsareequippedwithaLOCK/RELEASEswitch.ThisLOCK/RELEASEswitchisforsafetyreason.Whenaterminalislockedtoabaseunit,thereshouldbenopossibilitytouseotherterminaltothesamebaseunit.ASIL3/PLesystemisstartedlikethis:
1. Stopbuttonmustbedeactivatedandalloftheswitcheshavetobeinneutralposition.2. PuttheON/OFFswitchinpositionON.3. PuttheLOCK/RELEASEswitchinpositionLOCK.4. Pressstartbutton.
Ifthecommunicationbetweenterminalunitandbaseunitisbroken,e.gduetoradioloss,theStartbuttonhastobeactivatedtoestablishcommunicationagain.Forsomesystemconfigurations(allSIL3/PLecertifiedsystems)allsafetyrelatedanaloguefunctionsandanyselectorfunctionsenablingthese,havetobedeactivatedbeforeStartupisallowed.
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7.1.3 StopPresstheStopbuttontoactivatetheStop.Twistorpulltorelease.ThesystemisdefaultequippedwithagreyStopbuttonplacedontherighthandsideoftheterminal.
Tostartmachineryagain,aftertheStopfunctionhasbeenactivated,refertochapter6,point2).7.1.4 Timeout
Ifthesystemisnotusedforatime,itcanbeconfiguredtogointopowersavemodetoconservethebattery.Timeoutcanbeadjustedfrom099minutesorturnedoff.Defaulttimeoutis30min.7.1.5 Selectionandlockingofterminalinsystemswithmultipleterminals
Insystemswheretheoperatorcanselectbetweentwoormoreterminalunitstocontrolthebaseunit,theoperatorshoulddoadeliberateselectionandreleaseofthecontrollingterminalunit,toensuresafecontrolofmachinery.SomeoftheSIL3/PLesystemsareconfiguredwithLOCK/RELEASEswitchontheterminalunits(alsoavailableonothersystems).AterminalunitislockedtothebaseunituntiltheRELEASEswitchontheterminalunitisactivated.WhentheRELEASEswitchontheterminalunitisactivated,thebaseunitisdetachedandwillnowlocktothefirstterminalunitpoweredon.InsystemsconfiguredwithLOCK/RELEASE,theterminalunitwillstaylockedtothebaseunitalsointheeventoflossofpowertobaseunit.Inothersystems,thebaseunitwilldetachintheeventofpowerloss.Abaseunitcanbereleaseddirectlyfromthebaseunit:
1. PressA(SW1)onthePCBofMCIRXLITE.ThebuttonislocatedbelowtheLCD.Inthedisplayyouwillsee1:System
2. PressA(SW1).Inthedisplayyouwillsee10:Removelock3. PressA(SW1)andholdthepressureonthebuttonwhileSW3isturnedonesteptothe
right,thenletgoofswitchA.Thebaseunitwillnowbootupanditisreleasedfromtheterminalunit.
PictureofMCIRXLITEmodulewithitsswitchesislocatedinchapter7.2.1.
Stopbutton
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7.1.6 ActivitycheckForsafetyreasons,activitycheckmaybeaddedforall,orforarangeoffunctions.Thiswillforcetheswitch/joysticktobesetinneutralpositionbeforetheoperatorisallowedtostartupterminal.Asdefault,allfunctionshaveactivitycheck.AllSIL3/PLecertifiedsystemshaveactivitycheckonallsafetyrelatedfunctions.7.1.7 Frequencyselection
MC3seriessystemscanbedeliveredwithautomaticormanualfrequencyselection.Ifautomatic,thesystemwillscanasetof2to8predefinedfrequenciesandfindanavailablefrequency(notoccupied/withlownoise).Allsystemtypeshavethepossibilityformanualfrequencyselection.Therewillbeafrequencyselectbuttonontheterminalorarotaryswitchtoselectthenextfrequencyprogrammedintothesystem.Thebaseunitwillautomaticallyscantofindthefrequencytheterminalissetto.Thefunctionshouldbeusedifthereisbadlinktobaseunit,eithernoconnectionorofteninterrupted.Whenchangingfrequency,alloutputswillgotoneutralpositionforashorttime.Thesystemstartsagainasdescribedinchapter7.1.1.Afterpoweroffandon,thesystemwilleitherstartwithapredefinedfrequencyorwiththelastselectedone,dependingonsystemsetup.
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7.1.8 MIN/MAXprogramming(optionally)Optionallythereisaneasy,quickandexactpossibilitytoprogramanalogueoutputfromtheterminalside.Ifso,youwillfindtwobuttonsforMIN/MAXontheterminal.Adjustmentprocedure:
1. Turntheterminaloff.2. PressthePROGRAMbuttonsMINandMAXatthesametime.3. WhilepressingtheMIN/MAXbuttons,turntheterminalon.4. ReleasethePROGRAMbuttonsMINandMAX.Theterminalisnowinprogrammingmode,
indicatedwithshortflashesatthebatterystatusLED.IftheterminalhasaLCDdisplay,thiswillshowA00,indicatingprogrammingmode.Whenafunctionisbeingprogrammedthedisplayshows:AXXwhereXXshowswhichanalogchannelisbeingprogrammed,andisanumberbetween01.13.
5. Adjustment:Movethefunctionatyourchoicetoadjustuntilyougetthewantedresponse.Ifthisshallbeyourminimumresponse,pressMIN.Ifthisshallbeyourmaximumresponse,pressMAX.Theterminalwillthenautomaticallyadjusttheincreaseoftheresponsesothatthewholeareaofthejoystickoutputisbetweenthetwochosenpoints.
6. Eachfunctionisadjustedseparatelyforeachdirection(up/down/right/left).7. Reset:
Movethefunctionyouselecttoresetoutfromthecenter.PressMINandMAXatthesametime.Thefunctionisnowreset.
8. Whentheprogrammingisfinished,thetransmittermustbeturnedoffandonagaintostartinnormalmode.
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7.1.9 StatusindicationsontheterminalTheterminalisdeliveredwithaLEDforstatusindications;thisisusuallymarkedwithSTATUSorBAT.OnsystemsdeliveredwithLCDscreen,errorcodesandexplanationsarealsofoundthere.LEDflashingpattern Description ActionSteadylight Normalcondition.Terminalis
turnedon,batteryvoltageisOK,nofaultisdetected
None
Slowflashinglightwithoutstop(1flash/sec.)
Lowbatteryvoltage Replacebatterywithafullychargedone.
Shortflashes(2flashes/sec.) TerminalinMIN/MAXProgrammingmode(OnlyonterminalswithMINMAXprogramming)
Min/Maxprogrammingofanalogfunctions.Turnterminaloffandonagaintostartnormaloperation.Seechapter7.1.8forfurtherexplanation.
1flashwithlongstop(every2ndsec.)
Processorfaultortestmode.Indicatesaprocessormodulefaultand/oraprocessorfault.
EnsurethattheprocessormoduleBOOTjumperisnotturnedon.Replaceprocessormoduleand/orprocessor.
2flasheswithastop Activityatstartup.Ajoystickisoutofcentreposition,oraswitchisinONposition.
Setallswitches/joystickstoOFFpositionand/orneutralposition.
3flasheswithastop Radiofault Change/replaceradiomodule.4flasheswithastop Shutdownduetolowbattery
voltageReplacebatterywithafullychargedone.
5flasheswithastop Keyboardfault.Terminalisnotabletoreadswitches,joysticksetc.
Thereisafaultattheinputmodule.
6flasheswithastop Shutdownduetoinactivity.Theterminalwillsoonturnitselfoffsincenoswitches,joysticksetc.havebeenactivated.
Turnterminaloffandonagaintostartnormaloperation.
7flasheswithastop Prioritystop.Stopbuttonorshockdetectorhavebeenactivated.NotrelevantforSIL3certifiedsystem.
EnsurestopbuttonisoutandturnterminalOFFandONagaintostartnormaloperation.
NoLED Terminaloff Ensureterminalcontainsachargedbatteryandisturnedon.Iftheterminalhasturneditselfoffduetoinactivity,turnitoffandonagaintostartnormaloperation.
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MAN07007Rev.1118
7.2 OperationofBaseunitAlltheMC3seriesbaseunitsareproducedaccordingtocustomerspecifications,thewiringdiagramshowshowthebaseunitisconnected.Undernormalconditions,nooperationofthebaseunitisnecessary.Ifthebaseunitdoesnotoperatecorrectly,checkthedisplayformessages.Seeinfobelow,foryourtypeofbaseunit.
AllrepairsmustbecarriedoutbyarepresentativefromCMC.Yourlocalrepresentativeisfoundatwww.cavotec.com7.2.1 MCIRXLITEandMCIRX2baseunits
ThedisplayonMCIRXLITEandMCIRXbaseunitsisamenusystemallowingviewingofalloperationalparametersandserviceinformation.NavigationthroughthemenusystemisdonebyA,BandSW3,seepicture.Duringnormaloperation,thedisplayisdividedintothreefields:anupperline,andabottomlinewithastatusfieldandatimerfield.Theupperlinemayalsoindicateerrorcodes.Indicationsintheupperline Description[..3......0......] Normaloperation:Showsactivatedrelays,inthiscaserelays#3
and#10.[Error:E003] Failureinradiomodule.[Error:E010] Auxportcommunicationerror.[Error:E011] MUSbuscommunicationerror.[Microcontrolas] Nocommunicationwithaterminalandnoonboardrelaysactive.[fatal:] Afatalerrorhasoccurred.
isatextinthestatusfielddescribingthecause.TurnthesupplyOffandOn.Ifthemessagereappears,contactCMC.
DisplayonMCIRXLITE
A(SW1 selection)SW3(navigationinmenusystem)
B(SW2 back)
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Indicationsinthestatusfield DescriptionA4:30% Mostactiveanalogoutput.Inthiscasechannel4withoutput
valueof30%.Online Normaloperation,baseunitcommunicateswithaterminal.Passive Baseunitcommunicateswithaterminal,buttheStoprelayisde
energized.Maybecausedbytoolowsupplyvoltage.Itisnotpossibletooperateequipmentwheninpassivemode.
Idle Baseunitdoesnotcommunicatewithaterminal.Locked Ifseveralterminalsareconfiguredforonebaseunit,thebase
unitcommunicateswithselectedterminalanddoesnotsearchforadditionalterminals(firstcomefirstservemode).
Blocked Baseunitcommunicateswithaterminal,butisinactiveduetosoftplcfunction(e.g.startbuttonisnotactivated).
Thetimerfieldshowsthetimeelapsedsincethelastchangeofoperationalmode
(online/passive/idle/locked/blocked)inhours,minutesandseconds: 01:43:12Baseunitdisplaywhenthereisnocommunicationwiththeterminal.Normaloperation.Baseunitcommunicateswithterminalandrelay1and7areactivated.
Afatal(nonrecoverable)errorhasoccurred.isatextdescribingthecause.TurnthesupplyOffandOn.Ifthemessagereappears,contactCMC.
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7.2.2 FieldbusbaseunitsFieldbusbaseunitsarealwaysdeliveredwitha4digitsegmentdisplay.ThedisplaymaybestackedonthePCBorplacedontheoutsideoftheenclosure.Thedisplayindicatesdifferentfaultstatusesaswellaswhatterminalisonlineatanygiventime.OnstartupthedisplayalsoshowtheterminalIDsthatissupportedinthisbaseunit.
Indicationindisplay Description
E001 CPUinPMfaultyE003 RadioerrorornoradiopresentE010 NocommunicationwithPLCE011 NocommunicationwithslavePM
7.2.3 MCLINKCANbaseunits
TheMCLINKCANisequippedwitha3digitsegmentdisplay.Thisdisplayindicatesoperationstatusanderrormessages.Thedisplayisfoundontheupperrightcornerofthemodule.OperationstatusDuringnormaloperationdigit1willbeoff,andthedisplaywillindicateDigit1(fromtheleft) Description2 Remotestatus3 CanOpenstatusE Error,thenexttwodigitisanerrorcode(seetablebelowfor
errorcodes)F Fatalerror,thenexttwodigitisanerrorcode(seetablebelow
forerrorcodes)
DisplayonMCLINKCAN
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Digit2(fromtheleft) Description0 Noterminalcommunication CommunicatingwithterminalE StopfunctionisactivatedontheterminalDigit3(fromtheleft) DescriptionP Preoperational operationalS StoppedU UnknownstatePossibleerrorindicationsindisplayDisplay DescriptionE01 WaitingforsetupfiletobedownloadedE03 RadioerrorornoradiopresentE10 NocommunicationonCANbusFxx Fatalerror,powercycleisrequiredtoresume
normaloperation.Ifmessagereappears,contactCMC.
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8 Batterychargerandbatteries8.1 Changingthebattery
UseonlybatteriesprovidedbyCMC.1. Putthemachinebeingcontrolledintoasafeposition.2. TurntheterminalOFF.3. Removethebatteryandinsertafullychargedone.4. TurntheterminalON.5. Hotswap
Terminalswith2batterycompartmentscancontinuetooperatewithoutbeingswitchedoff.Replaceonlyonebatteryatatime.
8.2 StoragerecommendationofbatteryThecapacitylossoftheLiIonbatteryduringstoringisapprox.510%permonth.Thebatteriesshouldbefullychargedwhenstored.Ensurethatthebatteriesarestoredinanoncondensingatmospherewithnocorrosivegas.Avoiddirectsunlight,hightemperatureandhighhumidity.Recommendedstoringtemperatures:
Lessthan30days: 20to+45C.Between30and90days: 20to+30C.Morethan90days: 20to+20C.
Lifeexpectationofthebatterydependsofstorageanduse.Withcorrectuseyoucanexpect500cycleswithoutasignificantdropinbatterycapacity.
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8.3 Batterychargerinstallationanduse
Readtheseinstructionsbeforeusingthecharger Consultinstructionsforuse,symbolsonchargeraremeanttosupport,notreplace,
theseoperatinginstructions.
ThischargerappliestotheessentialrequirementoftheapplicableECdirectives.
Thechargerisdesignedforindooruseandshouldnotbeexposedtowaterordust. Donotcoverupthechargerwheninuse. Thechargeristurnedonbyconnectingittomainssocket(100Vto230V )
orto1224V. Disconnectingturnsitoff.
Controlthatthepowercordisnotdamaged.Ifthecordisdamaged,thechargermustnotbeused.
Themainssocketshouldbeeasilyaccessible.Ifanoperationalerroroccurs,theplugshouldbeimmediatelyremovedfromthemainssocket.
Thechargerisdoubleisolated(insulationclassII). Thechargercontainsdangerousvoltagesandthecovershouldnotberemoved.The
chargerisnotserviceable.Incaseofnotworkingithastobereplacedbyanewcharger.ContactnearestCavotecsalesrepresentative(www.cavotec.com).
Avoidthechargerfromcomingintocontactwithoils,greaseetc.,asmosttypesofplasticcanbebrokendownbychemicalsandsolvents.
Electricalandelectronicequipmentshallnotbediscardedwiththemunicipalwaste,
butbedisposedofusingseparatecollection,treatment,recovery/recyclingandenvironmentallysounddisposal,accordingtolocalrules.
ThechargerisintendedtochargeMC3seriesbatteriesfromCavotecMicrocontrolAS,Cavotec
MicrocontrolAShavenoresponsibilityforanyinjuriescausedbyotherusage,notaccordingtointendeduse.
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ImportantThechargerisdesignedforindooruseonly!8.3.1 Placingandmountingofthecharger
WhenthechargerisconnectedtoACorDCcurrentitshallbeplacedonaplanesurfaceormountedverticallyonitslongitudinaldirection.Seeillustrationpicturesbelow.
Onthebatterychargersbacksidethereisfourrubberknobswhichsecureastableplacing.Therearealsotwomountingholesforwallmountingonthebackside.Itisrecommendedtouse4mmscrewswithheaddiameterof5,57mmandheadheightof1,52mm.Screwtypeandlengthneedtobeadaptedtowhichmaterialandthicknessofthewallitshallbemountedon.Seeillustrationpicturesbelow.
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MAN07007Rev.1125
8.3.2 Chargerdescriptionandfunctionality
TheMC3serieschargerisdesignedforCMCbatterypacks,MCBATTERY3andMCEXBATTERY3.Thebatterypackscontaintwo3,7VLithiumIonbatteriesconnectedinseries.Chargeendvoltageis8.4V.Capacityofthebatterypackis16002030mAhfortheMCBATTERY3and11001230mAhfortheMCEXBATTERY3.TheMC3serieschargerisanadvancedchargerforLiIonbatteries.Itisdevelopedforoptimalperformanceandbatterypowerconservation.ThechargerisequippedwithonetricolorLED(lightemittingdiode)atthefrontdisplayingchargestatus.Thechargermaybeusedfor100230VAC/50and60Hzorfor12VDC24VDC.(onlyACorDCatatime,notboth).ThechargerisdesignedforDCoperationinvehicles.ACandDChasseparateinputs.Thebatterycompartmentisonthetopofthecharger.ThechargershouldnotbeusedtochargeotherbatteriesthanMicrocontrolbatteries!TheMC3serieschargerisaconstantcurrentchargerduringthemainperiodofcharging.Whenthebatteryvoltageisbelowacertainlevel,thechargerisinconstantcurrentmode,deliveringcloseto1100mA.Fastchargecontinuesuntilvoltageiscloseto8.4V,thenthechargergoesintoconstantvoltagemodeandchargecurrentdecreases.Chargeterminationoccurswhenchargecurrentisabout100mA.TypicalchargetimeforMCBATTERY3is2,5hoursandfortheMCEXBATTERY3is1,5hours.Thebatterycapacitywilldecreaseduringthebatterylifecycle,whencapacityistolow(tolowoperationaltime)thenreplacethebatterieswithnewones.8.3.3 Chargeroperatinginstructions
NormalchargecycleTochargeaMCBATTERY3orMCEXBATTERY3,simplyplaceitintotheMC3seriescharger.Chargingwillstartautomaticallywhenthebatteryisinserted.RedLEDlightindicatescharging.Ifthecharger/batteryisoutsidetemperaturelimits,chargingwillnottakeplaceandtheLEDwillindicateyellow.GreenLEDindicatesafullychargedbattery.Thechargerisnotintendedforcontinuoususe,afterachargecycleiscompletedthebatteryshallberemovedandthepowerdisconnected.DCpowercordConnectionoftheDCpowerisontheROKAconnectorontheleftsideofthecharger.Thecenterleadis+.Thisisalsomarkedonthecord.Theleadistheribbedcord,+leadisatthesmoothcord
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MC3Seriesinstructionmanual
MAN07007Rev.1126
IndicatorsTheMC3serieschargerisequippedwithoneLED,placedonfront,closetothebatterycompartment.ChargerstatusisindicatedbythefollowingLEDcolors:Chargestatus LEDBatteryabsent GreenTemperaturechargecutoff YellowBatteryinsertedwithnosupplyvoltage YellowFastcharging RedChargecomplete Green8.3.4 ChargerorderingnumbersfromCMC
VersionsThereisonlyoneversionoftheMC3serieschargercoveringvirtuallyalldifferentsupplyvoltages.Toapplytodifferentmainsupplyvoltagestandardsthereisdifferentmainssupplycords.Allorderingnumbersarelistedbelow.M510803600 ChargerMC3seriesM511403600 PowercordEUR/C7M511403603 PowercordUS/C7M511403601 PowercordUK/C7M511403602 PowercordAUSTR/C7M511403604 DCpowercordwithplugM510803699 Kitwithchargerandall5powercord.M510513600 MCBAT3M910513600 MCEXBAT38.3.5 Chargergeneralspecifications
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
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MC3Seriesinstructionmanual
MAN07007Rev.1127
8.3.6 Chargermechanicaloutline:
8.3.7 Chargercleaning/maintenance
Withnobatteryorpowerconnectedtothecharger,thechargercanbecarefullycleanedwithadampcloth.8.3.8 Chargermarking
37,5 mm202,00 mm
76,00 mm
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MC3Seriesinstructionmanual
MAN07007Rev.1128
8.4 CablemodeSometerminalmodelsareequippedwithacableandbatteries,andsomewithonlyacable.Thecableisconnectedtothebaseunit,andservesasbothpowersupplyfortheterminalunitandcommunicationlinktothebaseunit.Formodelswithbothradiofunctionandcable,theradiomodeisautomaticdeactivatedassoonasthecableisconnected.Theterminalandthebaseunitthencommunicateviathecable.Afterconnectingordisconnectingthecable,pressStartbuttontoestablishcommunicationwithbaseunitagain.
9 MaintenanceTheterminalandbaseunitdonotneedanyregularmaintenance.However,theunitsshouldbeinspectedfordamageandcleanedregularlywithadampcloth,foralldisplays,labelsandsymbolstobereadproperly.
Ifopeningtheterminalhousing,ensurethegasketisfixedproperlywhenclosingtheterminal.Theterminalunitshallonlybeopenedbyqualifiedpersonnel;failureinfixingthegasketmaydegradetheIPdegree.
Iftherubberbootsontheterminalsjoysticks/switchesaredamaged,theyshouldbereplacedatonce.ContactyourlocalCMCdistributor.YourlocalCMCdistributorisfoundatwww.cavotec.com9.1 Spare/Replacement
SparepartscanbeorderedthroughyourlocalCMCdistributor.Youwillneedtheserialnumber(IDcode)fromthesystem,seesection1.1Marking,andthepartnumber.Disposeofelectronicproductsaccordingtolocalrules.YourlocalCMCdistributorisfoundatwww.cavotec.com9.2 Service
Servicecanbearrangedwithyourlocaldistributor.Youwillneedtheserialnumberfromthesystemanddescriptionoftheservicerequired.
Plugforcablemode
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MC3Seriesinstructionmanual
MAN07007Rev.1129
9.3 FaultreportingCMCiscontinuouslyworkingtoimproveourproducts,tobeabletodeliverassafeandgoodproductsaspossible.Forbestpossibleimprovement,itiscrucialtogetfeedbackfromcustomers.Nonconformitiesontheproduct,functionalityorqualityshouldbereportedbacktoCMC.Ifahazardoussituationorafatalerrorshouldoccuronthedeliveredsystem,pleasereportbacktoCMCforanalysis.Reportingofnonconformitiescanbedoneviayourlocaldistributor.Youwillneedtheserialnumberfromthesystemanddescriptionoftheservicerequired.YourlocalCMCdistributorisfoundatwww.cavotec.com
10 WarrantyAllthedeliveriesarethoroughlytestedandpackedbeforetheyleaveCMC.Ifthedeliveryisfoundtobedamagedwhenitisopened,informthecarrierimmediately.CMCdoesnotcoveranydamagescausedbytransport.Allsystemsaredeliveredwith12monthswarrantyagainstmaterialandmanufacturingfaults.ThewarrantycoversrepairsauthorizedbyCMCataCavotecpremises.ExpensesforserviceoutsideCMCarenotincluded.RepairsdonewithoutauthorityfromCMCmayinvalidateanywarranty.
Informationinthisdocumentissubjecttochangewithoutnotice.
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MC3Seriesinstructionmanual
MAN07007Rev.1130
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MC3Seriesinstructionmanual
MAN07007Rev.1131
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MC3Seriesinstructionmanual
MAN07007Rev.1132
Cavotec Micro-control AS
Gevinglia112,7517HellNorwayPhone:+4774843100Email:[email protected]:[email protected]
Cavotec Micro-control GmbH
Gewerbering3,93345HausenGermanyPhone:+499448901200Email:[email protected]
Yourlocaldistributorisfoundat
www.cavotec.com2013CavotecMicrocontrolAS
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