Operator Manual

BMS-2 System
RX BMS2-PWM
RX BMS2-VC

www.hetronic.com
YOUR #1 PARTNER IN RADIO REMOTE CONTROLS

Hetronic USA Hetronic Canada

4300 Highline Blvd., Bldg. A 45 Sinclair Avenue
Oklahoma City, OK 73108 Halton Hills, Ontario L7G 4X4
405-946-3574 Fax 405-946-3564 +1-800-816-4459 Fax +1-905-702-0501

© 2004 Hetronic, Inc.

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval OPMN_BMS2_0001.0
system, or translated into any language in any form by any means without the written permission of Hetronic. 12/04
 TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety (Dump) Valve . . . . . . . . . . . . . . . . . . . . 9
Production and System Numbers . . . . . . . . . . 3 Proportional Functions . . . . . . . . . . . . . . . . . . 10
Unauthorized Replacement Parts . . . . . . . . . . 3 Joysticks or Paddle Levers . . . . . . . . . . . . . . 10
Before Attempting to Operate This System . . . 3 Option Controls . . . . . . . . . . . . . . . . . . . . . . . 10
System Components . . . . . . . . . . . . . . . . . . . . 4 Transmitter Shutdown . . . . . . . . . . . . . . . . . . 10
RX BMS2-PWM Standard Features . . . . . 4 Optical Displays and Acoustic Signals. . . . . . 10
RX BMS2-VC Standard Features . . . . . . . 4 Transmitter . . . . . . . . . . . . . . . . . . . . . . . 10
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 4 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 System Features . . . . . . . . . . . . . . . . . . . . . . 10
Safety Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Receiver Display . . . . . . . . . . . . . . . . . . . 10
Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Speed Reduction/Speed Select . . . . . . . . 11
Practices and Laws . . . . . . . . . . . . . . . . . . . . . 5 Ramp Function . . . . . . . . . . . . . . . . . . . . 11
Required Operator Training . . . . . . . . . . . . . . . 5 Interlocking Functions . . . . . . . . . . . . . . . 11
Possible Sources of Danger . . . . . . . . . . . . . . 5 Dead Man Function . . . . . . . . . . . . . . . . . 11
Operation and Work Area Safety . . . . . . . . . . . 6 Hold Function . . . . . . . . . . . . . . . . . . . . . 11
Protective Features . . . . . . . . . . . . . . . . . . . . . 6 Optional Feedback . . . . . . . . . . . . . . . . . 11
To Stop In An Emergency . . . . . . . . . . . . . . . . 7 Optional Cable Back-up. . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Quick-Set System . . . . . . . . . . . . . . . . . . . . . 12
Mount the Receiver . . . . . . . . . . . . . . . . . . . . . 7 Function Speed Adjustment . . . . . . . . . . . . . . 12
Install Receiver and Output Wiring . . . . . . 7 Hetronic Proprietary Software . . . . . . . . . 13
Mount the Actuators (Optional) . . . . . . . . . 8 Frequency and Address Settings. . . . . . . . . . 13
Attach Wiring Harness (Optional) . . . . . . . 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connect Electrical Wiring . . . . . . . . . . . . . 8 Diagnostic Panel Display Codes. . . . . . . . . . . . 16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Holding the Transmitter . . . . . . . . . . . . . . . . . . 8 Installation / Safety Data Sheet . . . . . . . . . . . . . 18
Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Definitions & Metric Conversions . . . . . . . . . . . 19
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . 9 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . 9 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2
 INTRODUCTION
INTRODUCTION Record the Production and System numbers here:
Thank you for purchasing the Hetronic radio remote
Transmitter Type
control system. Hetronic radio remote controls are the
highest caliber in remote control value, performance Transmitter Production Number
and safety.
Hetronic radio remote controls use the latest frequency
synthesizer technology to eliminate the problems Receiver Production Number
typically associated with radio remote control systems.

THE MANUAL
Before operation of unit, carefully and completely read System Number
your manuals. The contents will provide you with an
understanding of safety instructions and controls
during normal operation and maintenance. UNAUTHORIZED REPLACEMENT PARTS
The BMS-2 System is used with several different Use only Hetronic replacement parts. The replacement
transmitter types. For this reason, the photos or of any part with anything other than a Hetronic
illustrations of transmitters in this manual may not show authorized replacement part may adversely affect the
the transmitter purchased with this system. Please performance, durability, and safety of this system and
refer to the technical documentation for your specific may void the warranty. Hetronic disclaims liability for
transmitter for control panel layout and operational any claims or damages, whether warranty, property
instructions. damage, personal injury or death arising out of the use
of unauthorized replacement parts.
PRODUCTION AND SYSTEM NUMBERS
When contacting your dealer or Hetronic about service, BEFORE ATTEMPTING TO OPERATE THIS
repair or replacement parts, know the Production and SYSTEM:
System numbers of the transmitter and receiver.
1. Make sure all installation has been properly
The numbers are located on the label that is affixed to completed.
the unit itself.
2. ALWAYS be sure the crane/machine and radio
remote control Emergency-Stop functions work
1 properly before beginning any crane/machine
operation.
2 3 3. Understand all Safety Precautions provided in the
manuals.
4 4. Review control functions and operation of the
machine and this radio remote control system.
5
5. Surge suppressors (RC type only) must be used
1. Specific approvals such as BTZ, FCC, CE, etc. when the receiver is controlling magnetic
and the RF Unit. contactors.
2. The type of transmitter or receiver. 6. When not in use, turn the transmitter off and store
in a safe place to prevent unauthorized use.
3. Frequency channel.
7. If the crane/machine does not respond properly,
4. Production Number - The first digit indicates the stop operation immediately. Turn off the
manufacturing facility (1=H-Germany, 2=H-Malta, transmitter and report the condition to the
3=H-US, 4=H-Italy). The next four digits are the appropriate technician or supervisor.
production month and year. The last 6 digits are
the system address. 8. Turn off the transmitter and remove the battery
before any maintenance work is done.
5. System Number - The Hetronic Part Number of
the transmitter or receiver. IMPORTANT: AVOID SYSTEM DAMAGE - ALWAYS
disconnect receiver power supply and control wiring
before welding on any part of the crane/machine.
9. Turn off the transmitter when changing the
battery or taking a break.

3
 10. Always have batteries in the battery charger to THEORY OF OPERATION
ensure the availability of fully charged batteries.
The BMS-2 is the Hetronic designation for a receiver
11. Installation, setup and service must be performed with specific functions and capabilities. The system
by authorized personnel only. transmitter generates the electronic signal that
12. Use only Hetronic spare parts. communicates with the receiver. Several different
Hetronic transmitter types can be used with this
HETRONIC SYSTEM COMPONENTS system.
The Hetronic radio remote control system consists of a • GR
receiver and transmitter with belt, battery charger, and • GL
two rechargeable batteries.
• GL-3
RX BMS2-PWM Receiver Standard Features • Nova-S
• 1 E-Stop output • Nova-M
• 1 safety valve output • Nova-L
• 11 hardwired digital outputs • Nova-XL
• Expansion of up to 16 additional digital outputs Hetronic radio remote control systems operate in the
• 8x2 PWM outputs 400-470 MHZ range (70 cm band). The transmitter and
• 6 digital inputs receiver are set with identical address codes and
• CAN interface for control and feedback frequency channels. This allows operation of multiple
systems within the same area without signal
• RS232 interface for cable control, programming interference.
• Expanded self-diagnostics with 3 segment LED Some of the key features of the BMS-2 System are:
display
• Double Monitored E-Stop
• Back-up cable control interface with sure seal
connector • Optional Feedback Function
• 12VDC or 24VDC supply power for DC • CAN or RS232 Interface
cranes/machines • Setup/Adjustment Software
• Built-in Hetronic 70 pin quick disconnect • Quick-Set Function
connector • Receiver Status Display
• External antenna
E-Stop Function
RX BMS2-VC Receiver Standard Features The most important feature of the radio remote control
• 1 E-Stop output system is the E-Stop. The transmitter sends the E-stop
• 1 safety valve output status signal along with the specified crane/machine
function. This method confirms that ongoing operations
• 11 hardwired digital outputs are safe. If the E-stop pushbutton is pressed, the
• Expansion of up to 16 additional digital outputs E-stop relay circuitry in the receiver causes all
• 8 analog outputs crane/machine motions to stop. The receiver goes into
• 8 switching outputs for valve power supply Safe mode.
• 6 digital inputs The BMS-2 receiver display will show "0 0 2" indicating
an active E-Stop condition.
• 8 error inputs for Sauer-Danfoss valve
To restart the system, disengage the E-stop button and
• CAN interface for control and feedback
press the Start button.
• RS232 interface for cable control, programming
The E-Stop responds faster than any other function.
• Expanded self-diagnostics with 3 segment LED When E-Stop is engaged, the system ignores any other
display signal that is transmitted. E-Stop must be disengaged
• Back-up cable control interface with sure seal before the system will respond to any other signal.
connector The E-Stop is self-monitoring and redundant in the
• 12VDC or 24VDC supply power for DC transmitter and receiver. The system performs a
cranes/machines self-test to ensure the E-Stop circuit is working
• Built-in Hetronic 70 pin quick disconnect properly. If an error is detected, the system
connector automatically goes into Safe mode.
• External antenna The BMS-2 receiver display will show "0 0 1" indicating
an E-Stop condition in the receiver.

4
When the transmitter is turned on, it performs a • Low battery sends E-stop after time out
self-test to be sure that the circuitry is within When the transmitter is turned off, the Time Out
designated parameters. If an error is detected, the process begins. The Time Out period is set to 450
transmitter will not transmit any motion signals. msec at the factory. If the receiver does not establish
The BMS-2 receiver display will show "0 0 4" indicating contact with the transmitter within that time period, it
a passive E-Stop condition in the transmitter. goes into the Safe Mode. In Safe Mode, the receiver
shuts off power to the output modules and activates the
Receiver Safe Mode E-stop function.
The following conditions cause the receiver to go into
The BMS-2 receiver display will show "0 0 1" indicating
its Safe mode:
an E-Stop condition in the receiver.
• Radio signal interference
NOTE: For descriptions of other display codes, see the
• Transmitter out of operating range Operation Section of this manual, the Diagnostic
• E-Stop button is activated Display Codes table on page 16, or the technical
• E-Stop circuit failure documentation supplied with your radio remote control
system.

SAFETY
SAFETY ALERTS PRACTICES AND LAWS
Look for this symbol to point out Practice usual and customary safe working
important safety precautions. They precautions, for the benefit of yourself and others.
mean: Understand and follow all safety messages. Be alert to
unsafe conditions and the possibility of minor,
Attention! moderate, or serious injury or death. Learn applicable
Personal Safety Is Involved! rules and laws in your area.
Become Alert! REQUIRED OPERATOR TRAINING
Obey The Message! Original purchaser of this unit was instructed by the
The safety alert symbol is used in decals on the unit seller on safe and proper operation. If unit is to be used
and with proper operation procedures in this manual. by someone other than original purchaser; loaned,
Understand the safety message. It contains important rented or sold, ALWAYS provide this manual and any
information about personal safety on or near the unit. needed safety training before operation.
ALWAYS review the operators manual of any machine
DANGER: IMMINENTLY HAZARDOUS to be controlled by radio remote control.
SITUATION! If not avoided, WILL RESULT in
death or serious injury. POSSIBLE SOURCES OF DANGER
This system makes remote control via radio signals
WARNING: POTENTIALLY HAZARDOUS possible. However, the transmission of control
SITUATION! If not avoided, COULD RESULT commands can take place around obstacles and out of
in death or serious injury. the operator’s direct sight. To prevent accidental
start-up and possible injury or damage:
CAUTION: POTENTIALLY HAZARDOUS 1. Always engage the E-stop button and switch
SITUATION! If not avoided, MAY RESULT in "OFF" the transmitter when it is not in use.
minor or moderate injury. It may also be used Remove the key if the unit is placed any distance
to alert against unsafe practices. away from the operator.
2. Disconnect the power supply from the receiver
before any assembly, maintenance or repair work
NOTATIONS
is done.
NOTE: General reference information for proper
IMPORTANT: AVOID SYSTEM DAMAGE - ALWAYS
operation and maintenance practices.
disconnect receiver power supply and control wiring
IMPORTANT: Specific procedures or information before welding on any part of the crane/machine
required to prevent damage to unit or attachment.
3. Never remove or alter any of the safety features
of this system.
4. ALWAYS be sure the crane/machine and radio properly before beginning any crane/machine
remote control Emergency-Stop functions work operation.

5
OPERATION AND WORK AREA SAFETY TO STOP IN AN EMERGENCY
The work area must be free from obstacles, debris or 1. Press the red "EMERGENCY STOP" pushbutton.
other tripping hazards. Avoid uneven work areas and 2. Turn the key to "OFF".
any rough terrain. Always be sure of your footing.
3. Wait for all moving machine parts to stop.
Be aware of overhead obstacles that may interfere with
4. Refer to machine’s operator manual for further
machine operation.
instructions.
If a belt or strap is provided with your transmitter, use it
at all times.
Typical
PROTECTIVE FEATURES Emergency Stop
Pushbutton
This radio remote control system is equipped with
electronic and mechanical safety features. Processing
of control signals transmitted from other transmitters is
not possible, since transmission coding is unique to
each system.
These safety features help protect the operator, as well
as others within the work area. The machine functions
can be stopped by pushing the emergency stop button
on the transmitter control panel (EMERGENCY STOP). MAINTENANCE
NOTE: The e-stop command is transmitted within Always shut off power to the machine and the radio
approximately 0.5 seconds (450 ms) after the switch is remote control system transmitter and receiver before
turned to the "OFF" position. any assembly, maintenance or repair.
IMPORTANT: AVOID SYSTEM DAMAGE - ALWAYS
WARNING: Accidental start-up can cause disconnect receiver power supply and control wiring
serious injury or death. NEVER remove or before welding on any part of the crane/machine.
modify any safety feature.

INSTALLATION

WARNING: FAILURE TO FOLLOW

INSTRUCTIONS could result in personal DRILL PATTERN
injury and/or damage to equipment. Read and 4.57" Drill 4 holes 9/32" (7mm).
understand the safety instructions in all (116 mm) Use 1/4" or 6mm bolts.
manuals provided.

MOUNT THE RECEIVER

Install Receiver and Output Wiring 9.13"
(232 mm)
Select a position for the receiver so that the display is
easily visible, accessible and that provides protection If the receiver includes an attached antenna, mount the
from violent impact from debris or thrown materials. receiver so that the antenna points straight up. The
The receiver housing is rated IP65 and is protected area around the antenna should be free of
against penetration of dust and moisture. Therefore, obstructions, especially metal.
weather and elements should not be the primary
concern when installing the receiver.
Four mounting holes are required when installing the
receiver unit. The drill pattern and recommended
hardware are shown in the following illustration.

6
 Supply voltage and ground wiring are crucial and must
Antenna must Area must be be connected to reliable connecting circuitry. Do not
be vertical free of use a chassis ground for this equipment. The ground
(pointing up). obstructions wire must be connected directly to the vehicle battery
negative post.
Diagnostic
Display Panel IMPORTANT: Power supply wiring must be at least
AWG 12 to prevent power drop.
4.25" The output control signals to the proportional control
(106.3 mm)
valves should be routed separately from any wiring that
could produce transient voltage interference.
Interference or "induced voltage spikes" could cause
erratic performance of the proportional controls.
Mount the Actuators (Optional)
6.40" Mount and attach the actuators to the hydraulic valves
8.29" (160.0 mm) or to the mechanical linkage with the brackets supplied.
(210.5 mm)
Attach Wiring Harness (Optional)
Plug the wiring harness into the receiver and into the
corresponding actuators.
1.00" Connect Electrical Wiring
(25.0 mm)
Connect all remaining wires (power supply, engine
start-stop, etc.) according to the wiring diagram of the
9.72" crane/machine and the radio remote control.
(246.8 mm)

Be sure that the Diagnostic Display panel is clearly

visible.

Area must
be free of
obstructions

4.25"
(106.3 mm)

4.47" Do not block

(113.5 mm) visibility of
6.38" diagnostic
(162 mm)
panel.

1.00"
(25.0 mm)
1.00"
(25.0 mm)
The receiver wiring is critical for proper system
operation. Make all connections with good quality
contacts or solder joints to ensure proper electrical
contact.

7
 OPERATION
START-UP PROCEDURE
WARNING: FAILURE TO FOLLOW This procedure must be carefully followed before
INSTRUCTIONS could result in personal beginning any operation.
injury and/or damage to equipment. Read and 1. Be sure that all safety measures required by the
understand the safety instructions in all equipment manufacturer have been followed. (i.e.
manuals provided. crane level, stabilizers down, etc.)
HOLDING THE TRANSMITTER 2. Be sure the transmitter battery is fully charged.
3. Be sure that power is supplied to the receiver.
Hold the transmitter with the control panel facing you.
The receiver display should read "0 0 4".
Be sure that you are able to easily read any text and
understand operation symbols. If your transmitter 4. Push in the transmitter E-stop pushbutton.
contains a Tilt Sensor Switch, be sure it is not activated 5. Be sure that all controls, joysticks or paddle
or the transmitter will not start. levers are in the Off (neutral) position.
If a belt or strap is provided with your transmitter, use it NOTE: If any control, joystick or paddle lever is NOT in
at all times. The belt or strap is designed to reduce the Off (neutral) position when the Start/Horn button is
stress and increase safety. pushed, the transmitter will not transmit.
6. Switch the transmitter "ON". A short buzzer signal
WARNING: FAILURE TO FOLLOW will sound.
INSTRUCTIONS could result in personal 7. Wait for the second buzzer signal (approx. 3
injury and/or damage to equipment. Always seconds).
hold the transmitter in the proper orientation. 8. Press the Start/Horn button again.
Holding the transmitter improperly while
9. The green LED on the transmitter control panel
operating the crane/machine could result in
will flash.This indicates that the transmitter is
unexpected crane/machine response.
working and is ready to use. The receiver display
The safety checks described in the following should read "0 0 2".
paragraphs must be completed before the radio remote 10. Disengage the E-stop pushbutton. The receiver
control system is activated. These checks must be display should now read "0 0 0".
performed at least once a day, before the start of any 11. Push the green "Start/horn" pushbutton on the
operation and at all shift changes. transmitter.
IMPORTANT: A transmitter drawing is included with 12. Check that the machine functions correspond
each system. Transmitter layout and inscriptions may with the transmitter functions. The receiver
vary according to customer requests. display will change according to which motion is
activated.
WARNING: FAILURE TO FOLLOW IMPORTANT: The machine functions will operate
INSTRUCTIONS could result in personal during this check. Be certain that there are no
injury and/or damage to equipment. Test the obstacles near the machine.
"E-STOP" function as described in the 13. Push the "EMERGENCY STOP" pushbutton on
crane/machine manufacturer’s operator the transmitter. Be sure that no functions can be
manual before beginning any operation. activated with the "EMERGENCY STOP"
pushbutton depressed. The receiver display
VISUAL CHECK should again read "0 0 2".
Always check the transmitter for any physical damage IMPORTANT: If any function of the radio remote
before any operation. control activates with the "EMERGENCY STOP"
• Always keep safety features, guards and controls engaged, the radio remote control must not be used
in good repair, in place and securely fastened. until it is repaired.
• Check equipment for wear or damage. 14. Pull out the "EMERGENCY STOP" pushbutton.
• Check rubber cuffs and pushbutton caps for wear 15. Push the green pushbutton "Start/horn" on the
or damage. transmitter.
IMPORTANT: Never operate a transmitter with worn or 16. Both the radio remote control and the machine
damaged parts. Replace immediately with only are now ready for operation.
Hetronic parts. Contact Hetronic or your Dealer.

8
IMPORTANT: To avoid accidental start-up, always PROPORTIONAL FUNCTIONS
engage the E-stop pushbutton and switch the
The proportional functions and speed ranges are set
transmitter "OFF" when not in use. When the
with the Hetronic proprietary software included with
transmitter is not attached to the operator, the key
your system. You can modify the adjustments at any
switch should be removed and stored in a secure
time. Please refer to the software technical
place.
documentation that is specific for your system.

WARNING: TO AVOID SERIOUS INJURY JOYSTICKS OR PADDLE LEVERS

OR DEATH. Switch the machine "OFF" if Joysticks and paddle levers are equipped with a spring
there is a fault or any problems with the safety return to the center (OFF) position. If the
check. Contact Hetronic or your dealer crane/machine motion is multi-speed, the farther the
immediately to repair the system. NEVER lever is pushed, the faster the crane/machine motion
operate the machine if the "EMERGENCY will move. Return the lever to the center position to
STOP" function does not operate properly. stop the crane/machine motion.
Improper operation, maintenance or
adjustment may cause serious injury or OPTION CONTROLS
damage to equipment and may void the Each transmitter can be equipped with a variety of
warranty. rotary switches, toggle switches or pushbuttons. Each
function is labeled. For specific operational
EMERGENCY STOP instructions, refer to the technical documentation
For all emergency situations, push the E-Stop supplied with your transmitter, or contact Hetronic.
pushbutton in. To restart the system, disengage the
E-Stop pushbutton and press the Start/Horn TRANSMITTER SHUTDOWN
pushbutton. Be sure any dangerous conditions are To shut down the transmitter, turn the key switch to
corrected and follow the Start Up Procedure above. OFF. Remove the key and place it in a secure location
to prevent unauthorized or unintentional use.
SAFE MODE
When the transmitter battery voltage drops below OPTICAL DISPLAYS AND ACOUSTIC
approximately 3.4 volts, the system signals a low SIGNALS
battery condition. The factory setting is 10 minutes to The radio remote control system uses optical displays
locate the crane/machine in a safe position and turn and acoustic signals to show current working status.
the transmitter off. When 9 minutes have passed, the
buzzer activates. There is then one minute remaining Transmitter
before the system automatically goes into Safe Mode. 1. Turn keyswitch to "ON".
At the end of the timeout period, the transmitter sends 2. One long acoustic signal (buzzer) sounds.
the E-Stop signal and all crane/machine motion
3. After the self-test routine, another buzzer sounds
commands are stopped.
to indicate that the system is ready to operate.
To restart the system, a fully charged battery must be
4. Then press the Start/Horn button to begin system
inserted into the transmitter. Proceed with startup
operation.
instructions. Always place the discharged battery
directly into the charger. NOTE: If the Start/Horn button is pressed before the
second buzzer, the system will not start up.
If transmitter start-up is attempted with a discharged
battery (less than 3.1 V), the system will shut down During transmitter operation, a buzzer signal indicates
within 2 seconds after detecting the E-stop signal. This when the battery is nearly discharged. The transmitter
safeguard helps ensure the transmitter has enough will operate for another 30 seconds before going into
power to safely operate the crane/machine. E-Stop. Use this time to place the crane/machine in a
safe position.
SAFETY (DUMP) VALVE A green LED on the transmitter control panel
The BMS-2 provides an output which is activated every illuminates while the system is operational.
time a joystick/paddle is moved out of the neutral Receiver
position. This output should be connected to the safety
The 3 digit display shows operational status and error
(dump) valve to ensure that there is no hydraulic
codes. A label on the receiver shows the basic
system pressure when the system is in standby mode
operational status codes.
(joystick/paddle in neutral position).

9
 BMS-2: System Status Indicators xx0 Receiving correct signal, no E-Stop, system
x x 0 - Normal Operation x x x . - Dot blinks = Telgram OK started
x x 1 - System Not Started x x . x - Dot on = Program Mode
x x 3 - Communication Error E x x - Error Code Example: 0 0 0 means the receiver is getting a
1 x x - Analog Channel 1 active valid control telegram and all joysticks are in
x x 2 - Active E-Stop 2 x x - Analog Channel 2 active
x x 4 - Passive E-Stop ... up to Analog Channel 8 neutral position

001
xx1 Receiving correct signal, BMS-2 in E-Stop, no
E-Stop from TX
Example: 0 0 1 means the receiver is getting a
www.hetronic.com valid control telegram, all joysticks are in neutral
position, with E-Stop condition in receiver
SYSTEM FEATURES
xx2 Receiving correct signal, BMS-2 in E-Stop,
Receiver Display E-Stop transmission from TX
The receiver has a 3-digit, 7-segment display on the Example: 0 0 2 means the receiver is getting a
outside of the housing to show operation status and valid E-Stop telegram and the transmitter
Error Codes. The following table shows basic E-Stop is engaged
operational status codes. Error Codes are assigned xx3 RF interference
per specific customer requirements.
004 Not receiving signal, no RF communication, or
TX is turned off

000. Flashing dot after third digit, change the status

with each correct received telegram (green
LED)

00.0 Flashing dot after second digit indicates

programming mode (Quick-Set)

1xx Analog output 1 (up to 8) activated, joystick not

in neutral position. System will not start if
joystick is not in neutral position.

Exx Error Codes are assigned numbers based on

customer requirements. See Technical
Documentation for specific codes.

Speed Reduction/Speed Select Function

This radio remote control system is equipped with a
speed control function. It allows speed reduction to
75%, 50%, and 25% of the maximum speed using a
switch on the transmitter. Other speed select options
can be programmed with the BMS-2 software.
Ramp Function
The purpose of the Ramp Function is to allow a gradual
start or stop to a machine movement to help prevent
load or basket swing. The rate of increase and
decrease is set with the BMS-2 software.
Interlocking Functions
This feature prevents contradictory operator
commands from the transmitter. Certain functions can
be enabled or disabled when another function is
activated or inactive. An example is hoist up and hoist
down. Activating both functions would most likely
damage the equipment. Therefore, hoist up is
interlocked with hoist down so that when one is
activated the other can not be.

10
Dead Man Function Optional Feedback
With this function activated, it is necessary to press a This feature allows the transmitter to receive and
switch at the same time as a joystick/paddle in order for display information such as crane/machine status,
the crane/machine motion to operate. warnings, etc. The feedback can be displayed as visual
graphics or buzzers.
Hold Function
This function makes it possible to "Hold" a position of a Optional Cable Back-Up
joystick without actually holding the joystick in place. This option makes it possible to operate the
Pressing the "Hold" button when the joystick is in its crane/machine with the transmitter connected to the
desired position allows the operator to release the receiver with a cable. It is useful in situations where
joystick while having the crane/machine motion still radio interference or the absence of a fully charged
active. The crane/machine motion remains active until battery make radio remote control impossible. The
the "Hold" button is released. cable provides power to the transmitter, so a battery is
not necessary. The system will operate even if a
battery is not present in the battery compartment.

ADJUSTMENTS

QUICK-SET SYSTEM CAUTION: AVOID INJURY AND PROPERTY

The Quick-Set System provides easier installation, DAMAGE - The crane may respond differently
adjustment and service of the radio remote control with radio remote controls than with manual
system. Quick-Set allows adjustment of all proportional controls. During the adjustment procedure,
function speeds (valve travel) from the transmitter. A use extreme caution with joystick/lever
red Program Key is provided to control the movements. Avoid sudden movements and
programming mode. When adjustments are complete, observe crane motions carefully. The operator
remove the Program Key and store it in a secure must be standing on dry, level, stable ground
location. Function speeds can be readjusted at any that is free of oil and debris.
time.
NOTE: Receiver should be wired to machine’s horn in
The system includes a base board, or mother board,
order to adjust Quick-Set.
which includes all of the common function circuitry
found in most Hetronic receivers. These functions 1. Use the crane’s manual controls to raise the
include power regulation, decoding the received signal, boom from its rest. Extend the boom to a safe
16 digital output functions, and the Quick-Set function. starting point.
The receiver also contains diagnostic Error Codes that 2. The transmitter must be attached to the operator
are visible on the outside of the housing to help quickly with the belt adjusted to a firm fit.
diagnose problems. 3. Turn the receiver power "ON".
FUNCTION SPEED ADJUSTMENT 4. Remove the black key from the transmitter
keyswitch.
This procedure requires that the receiver is connected
5. Insert the red programming key into the
to the machine with power applied, all necessary wiring
keyswitch.
is complete and a fully charged battery is in the
transmitter. 6. Turn the transmitter "ON".
IMPORTANT: The crane must be located in an open
area so that sudden or unexpected crane movements OFF
will not damage buildings or property. All power lines
must be out of reach of the boom. Set the outriggers in
the "out and down" position as recommended by the ON
crane manufacturer and be sure the crane is stable.
For specific instructions, refer to the crane
manufacturer’s operator manual. Allow the truck
engine to run at "Idle".
KEY

PROGRAM

11
 7. Wait approximately 3 seconds until the second 11. For Program Toggle Switch - To set maximum
buzzing sound has finished. speed - Deflect the joystick/paddle to its
8. Twist the key one quarter turn further to the maximum position. Push the program toggle
program position. (This is only possible with the switch toward "+" to increase speed, toward "-" to
red programming key.) Press the "Start/horn" decrease speed.
button for at least one second. For Program Pushbuttons (shown) - Adjust the
speed of this function by using the program
pushbuttons. Press the "+" to increase speed,
Start/Horn Button press the "-" to decrease speed.

35.0°

Program Pushbuttons

-RPM +
- P +

9. To set minimum speed - Deflect the requested WARNING: AVOID INJURY - The crane is
joystick/paddle slowly until you hear the vehicle’s moving during the adjustment of the
horn. If the horn is connected to the receiver, it functions. Be sure the work area is clear of
will sound for a brief moment when the obstacles and bystanders.
joystick/paddle reaches the minimum movement
position. Keep the joystick/paddle in this position. The receiver can program only one function at a time.
For joysticks, make sure that only one axis is deflected
at a time. When function adjustment is complete in one
7.5°
direction, repeat the procedure above for the other
Program Pushbuttons directions and functions. Remember to set values for
both high and low ranges.
After all adjustments are complete, wait at least 10
seconds before turning the transmitter off. The new
values will be automatically stored into the system’s
-RPM
- P
+
+
memory.
Hetronic Proprietary Software
The software that accompanies this radio remote
10. For Program Toggle Switch - Adjust the speed of control system is customized per each customer’s
this function by using the program "T-O-T" toggle requirements. Refer to the Software Technical
switch (momentary - zero - momentary). Push the Documentation for specific instructions on the set-up
toggle switch toward "+" to increase speed, and operation of this system.
toward "-" to decrease speed.
For Program Pushbuttons (shown) - Adjust the
FREQUENCY AND ADDRESS SETTINGS
speed of this function by using the program Each Hetronic radio remote control system contains a
pushbuttons. Press the "+" to increase speed, transmitter RF unit and a receiver RF unit.
press the "-" to decrease speed. The address settings are pre-set at the factory in the
Adjust the function speed to move as slowly as ADMO module. However, if the transmitter coder
possible. This helps to achieve a smooth start board, the base board, or if the entire transmitter or
when this function is activated. receiver are replaced, the ADMO addresses must
match in the system.

12
 CAUTION: AVOID INJURY OR DAMAGE -
Operating the transmitter without its antenna
could destroy the final stage of the RF
module. DO NOT attempt to change the
Hetronic pre-set frequency or the 16-bit
address. Personal injury and property
damage could result from transmission
interference and may void the warranty.

IMPORTANT: If the ADMO settings of the transmitter

and receiver do not match, the system will not function.

13
 TROUBLESHOOTING
If the system does not operate after normal start-up as Error Codes are defined by the customer. See
described in Operation Section of this manual, follow Technical Documentation provided with your system for
the recommended troubleshooting sequence to help specific Error Codes. If the Error Code is not listed in
isolate the cause and determine corrective action. your Technical Documentation, please contact Hetronic
The BMS-2 Receiver displays Operational Status and or your Dealer for more information.
Error Codes to help diagnose problems that may occur If the system will not respond to the steps below or the
with the system. The Operational Status codes are Receiver Display indicates a failure, contact the
shown in the Operation Section of this manual. Hetronic Service Department or your authorized dealer.

PROBLEM PROBABLE CAUSE CORRECTION

System will not initialize E-Stop reset Push the Start button again. If the system is
after normal start-up being initialized from an E-Stop condition,
procedure the Start button must be pressed twice - first
to clear the E-Stop, then again, to start the
system.

Joystick or paddle lever not in Be sure that all joysticks and paddle levers
center position are in center position when the Start button
is activated.

E-Stop switch engaged Pull out E-Stop switch. Restart system by

pressing Start twice.

Battery fully discharged Check battery to ensure a full charge.

Replace with fully charged battery if
necessary.

No power to the receiver Check the diagnostic Display on the side of

the receiver to be sure power is applied.
Ensure that the system is securely
grounded to the negative battery terminal.
The Display also indicates normal
transmitter communication, interference,
and E-Stop conditions.

The transmitter is Battery is discharged Replace battery with a fully charged battery.
turned on, but does not
transmit (Power LED Coder board fuse Check fuse and replace if necessary.
not flashing) Broken key switch Check wiring on key switch. Replace key
switch, wiring or contact element.

Coder board failure Contact Hetronic or your Dealer.

14
PROBLEM PROBABLE CAUSE CORRECTION
Transmitter is E-Stop switch engaged Pull out the E-Stop pushbutton and press
transmitting (Power the Start/Horn pushbutton
LED flashing), but
crane/machine will not Transmitter out of range Take the transmitter back into the range of
respond the receiver. Press the Start/Horn
pushbutton.

Joystick, paddle lever or switch Ensure that all control devices are in center
not in center position when (neutral) position when the Start button is
transmitter turned on activated.

Receiver power off Turn on power to receiver.

Blown fuse in receiver Check all fuses. Replace if necessary.

E-Stop failure in transmitter Check E-Stop pushbutton for damage.

Check wiring to contact element for broken
or disconnected wires. Repair or replace
E-stop pushbutton or wiring.

E-Stop failure in receiver. Red Check wiring on E-Stop module, decoder

E-Stop LED on decoder board is module, E-Stop decoder module. Secure
illuminated any loose connections.

E-Stop module failure Replace E-Stop module.

All crane/machine Receiver antenna loose or Tighten or replace antenna.

motions operate missing
intermittently
External antenna (if used) has Tighten antenna and ground connection.
loose connection, poor grounding See "Connecting an External Antenna"
or interference Section for operational precautions.

Connector wiring too close to Control wiring must be run separately from
power wiring power wiring.

Connector inside receiver is loose Check all connectors, reseat if necessary.

Some crane/machine Crane/machine motion wiring Check wiring from receiver to plug and from
motions operate may be loose. plug to crane/machine motion actuator.
intermittently
Connector inside receiver is loose Check all connectors, reseat if necessary.

Connector wiring too close to Control wiring must be run separately from
power wiring power wiring.

15
DIAGNOSTIC DISPLAY PANEL CODES E13 DV1 (Y0) read back error
The following table is a brief description of diagnostic, E14 SW output 1 read back error
operational and error codes that may be displayed. E15 Valve Supply 1 read back error (VC)
E16 Valve Supply 2 read back error (VC)
Error codes can be designated for specific customer
E17 Valve Supply 3 read back error (VC)
requirements and may not be listed here. Refer to the
E18 Valve Supply 4 read back error (VC)
technical documentation that accompanies your
E19 Valve Supply 5 read back error (VC)
system for specific customer defined error code
E20 Valve Supply 6 read back error (VC)
designations.
E21 Valve Supply 7 read back error (VC)
(VC - Voltage control version only) E22 Valve Supply 8 read back error (VC)
(PWM - Pulse width modulation version only) E23 AK1 analog output read-back error (VC)
E24 AK2 analog output read-back error (VC)
Operational Codes E25 AK3 analog output read-back error (VC)
xx0 Receiving correct signal, no E-Stop, system E26 AK4 analog output read-back error (VC)
started E27 AK5 analog output read-back error (VC)
xx1 Receiving correct signal, BMS-2 in E-Stop, no E28 AK6 analog output read-back error (VC)
E-Stop from TX E29 AK7 analog output read-back error (VC)
xx2 Receiving correct signal, BMS-2 in E-Stop, E30 AK8 analog output read-back error (VC)
E-Stop transmission from TX E31 PWM output shortcut detection (PWM)
xx3 RF interference E32 Valve 1 error input (VC)
004 Not receiving signal, no RF communication, or E33 Valve 2 error input (VC)
TX is turned off E34 Valve 3 error input (VC)
000. Flashing dot after third digit, change the status E35 Valve 4 error input (VC)
with each correct received telegram (green E36 Valve 5 error input (VC)
LED) E37 Valve 6 error input (VC)
00.0 Flashing dot after second digit indicates E38 Valve 7 error input (VC)
programming mode (Quick-Set) E39 Valve 8 error input (VC)
1xx Output 1 (up to 8) activated, joystick not in E40 CAN bus data timeout error (Hetronic and
neutral position. System will not start if joystick HMF)
is not in neutral position.
E41 Start locking input error
Error Codes E42 RF-DK start locking error, start locked DK is not
Exx Error Codes are assigned numbers based on in neutral position during system start
customer requirements.The errors listed below Error codes of 50 or greater are start-up or online test
may or may not be applicable to your system. errors and require device re-start to clear.
See Technical Documentation for specific E50 CPU_TEST_FAILED
codes.
E51 WATCHDOG_TEST_FAILED
E00 Joystick 1 error - joystick 1 out of neutral
E52 INTERRUPT_TEST_FAILED
without closed safety switch
E53 TIMER_TEST_FAILED
E01 Joystick 2 error - joystick 2 out of neutral
E54 EXTRAM_TEST_FAILED
without closed safety switch
E55 INTRAM_TEST_FAILED
E02 Joystick 3 error - joystick 3 out of neutral
without closed safety switch E56 INTPRAM_TEST_FAILED
E03 Joystick 4 error - joystick 4 out of neutral E57 PFLASH_TEST_FAILED
without closed safety switch E58 STACK_OVERFLOW_DETECTED
E04 Joystick 5 error - joystick 5 out of neutral E59 MAIN_LOOP_TIME_FAILED
without closed safety switch E60 OP_COUNTER_ERROR
E05 Joystick 6 error - joystick 6 out of neutral E61 Serial EEPROM checksum error
without closed safety switch E62 Internal HW error - E-stop pulses timeout
E06 Joystick 7 error - joystick 7 out of neutral
without closed safety switch
E07 Joystick 8 error - joystick 8 out of neutral
without closed safety switch
E08 Over-current 0 error, over-current on E-Stop
circuit
E09 Over-current 1 error, over-current on switching
output 1-6
E10 Over-current 2 error, over-current on switching
output 7-12
E11 Over-voltage error >35V
E12 Under-voltage error <8V

16
 SPECIFICATIONS
Model BMS-2
(Baseboard Module System)

System GA 610

General Data
Frequency 70 cm Band (Selectable
458.800 Mhz to 459.175
Mhz) or CS434

Range approx. 100 m ( 328 ft.)

Address 20-bit - 1,000,000 possible

Operating temperature -30° to +70° C

(-22° F to 158° F)

Data Format 2400/4800 Baud, even

parity, 8 data bits, 2 stop bits,
hamming distance 4

Receiver
Protective System IP 65

System Synthesizer Technology

Voltage Supply 12 to 24 VDC (-50% - +20%)

Decoding Multiple bit scanning,

self-monitoring

Fuses 7.5 amp. / 80 V car fuse

Output Intrinsically safe emergency

stop with double - FET, 1
safety valve (dump valve), 11
digital, 16 internal digital

Antenna connection TNC - socket

Dimensions 245 mm x 161 mm x 90 mm

LxBxH (10.4 in x 6.3 in x 4.4 in)

Weight - 2,5 kg ( 5.5 lbs)

Transmitter
Protective System IP 65

Battery Pack 3.6 V / 1200 mAh (NiMh)

Transmitting power < 10 mW

Current rating, Self test approx. 75 mA

Current rating, approx. 83 mA

Transmission

Dimensions Depends on Transmitter type

Weight - including battery Depends on Transmitter type

17
 INSTALLATION AND SAFETY TEST DATA
This for must be completed and signed by the person Hetronic assumes no responsibility for the correct
responsible for installation of this radio remote control installation of the radio remote control system. The
system. equipment operator must ensure that the radio remote
control system and the crane/machine operate
correctly together. The operator must also ensure that
all safety devices and features are in place and
operating correctly. The operator is responsible for
understanding and following all safety precautions in
this and other applicable operator manuals.

Crane Data

Manufacturer

Model Number

Serial Number

Year of Production

Radio Remote Control Data

Manufacturer Hetronic

Model BMS-2

System/Transmitter Type

Transmitter Production Number

Receiver Production Number

System Number

I/We installed the radio remote control system, performed the safety test and inspected the crane/machine. The
appropriate instructions and rules of this machine type are followed.

Place

Date

Company

Name of Installation Technician

Signature

18
 DEFINITIONS
Acoustic signal A buzzer or other sound intended to be heard as an alert.
Analog signal Proportional - stepless or infinite control
Belly box A transmitter that is secured to the front of the operator’s body by a belt,
strap or breastplate/harness.
Coder Converts parallel signals into a serial data message
Decoder Coverts a serial data message into parallel signals
Digital signal On/off control
Latching control The function activates when the control is pushed and released. The function
stays on until the control is pushed and released again.
Mainline contactor The primary power supply contactor to the crane/machine controls.
Maintained control The function activates when the control is placed in the ON position. The
function stops when the control is placed in the OFF position.
Momentary control The function activates when the control is placed in the ON position. The
control must be held in place to stay ON. When the control is released, it
returns to the OFF position and the function is stopped.
Proportional control A multi-speed function control that goes faster as the control is pressed
further.

AWG - METRIC CONVERSIONS

AWG Metric Equivalent mm sq. Metric Cable Size mm sq.
20 0.52 0.75
18 0.82 1.0
16 1.32 1.5
14 2.1 2.5
12 3.3 4
10 5.32 6
8 8.5 10
6 13.5 15
4 21.3 25
2 33.7 35
1/0 (0) 53 70.0 (50.0 if current capacity not
exceeded)
2/0 (00) 67.6 70
3/0 (000) 84.4 95
4/0 (0000) 107 120

19
 ABBREVIATIONS
A/D Analog to digital conversion
AK Analog channel (German: Analog Kanal)
AMP Ampere
AWG American Wire Gauge
BPS Bits per second
CPU Central Processing Unit
DK Digital channel (German: Digital Kanal)
EMC Electromagnetic compatibility
EMI Electromagnetic immunity
EPROM Electrical programmable read-only memory
FM Frequency modulation
GND Ground
HF High frequency
KHz Kilohertz
LED Light emitting diode
LTO Lift to operate
mAH Milliampere hours
mA Millampere
msec Millisecond
MHz Megahertz
MOV Metal Oxide Varistor type of surge suppressor
mW Milliwatt
NiCd Nickel Cadmium
NiMH Nickel Metal Hydrite
PLC Programmable logic controller
PLL Phased locked loop
PTO Press to operate
PWM Pulse width modulation
R/C Resistor/Capacitor type of surge suppressor
RF Radio frequency
RMS Root mean squared
Rx Receiver
RxD Receiving data
SMD Surface mount device
SMT Surface mount technology
TTL Transistor transistor logic
Tx Transmitter
TxD Transmitting data
Ub Operating power
Uv Microvolts
VAC Volts alternating current
VDC Volts direct current

20
WARRANTY

Hetronic USA
Limited Warranty and
Terms of Sale WRTY_002 Warranty & Terms
April 2003

Price: Subject to Change Without Notice

Terms: Net 30 Days
F.O.B: Hetronic USA, Inc.
Oklahoma City, Oklahoma

Hetronic, Inc., hereafter referred to as Company, guarantees all items manufactured by it against any defects
of material and/or workmanship for a period of one year from the date of shipment. Company makes NO
OTHER WARRANTY, EXPRESSED OR IMPLIED, AS TO THE MERCHANTABILITY OR FITNESS OF THE
ITEMS FOR THEIR INTENDED USE OR AS TO THEIR PERFORMANCE. Any statement, description or
specification in Company's literature is for the sole purpose of identification of items sold by the Company
and imparts no guarantee, warranty or undertaking by Company of any kind. Components and accessories
not manufactured by Hetronic are not included in this warranty and are warranted separately by their
respective manufacturers.
Company's sole liability shall to be to repair at its factory, or replace, any item returned to it within one year
from date of shipment, which Company finds to contain defective material or workmanship. All items to be
repaired or replaced shall be shipped to Company (Note: return authorization by Company is required) within
said one year period, freight prepaid, as a condition to repair or replace defective material or workmanship.
Company's herein assumed responsibility does not cover defects resulting from improper installation,
maintenance, or improper use. Any corrective maintenance performed by anyone other than the Company
during the warranty period shall void the warranty. Company shall not be liable for damages of any kind from
any cause whatsoever beyond the price of the defective Company supplied items involved. Company shall
not be liable for economic loss, property damage, or other consequential damages or physical injury
sustained by the purchaser or by any third party as a result of the use of any Company supplied items or
materials.
List prices or discounts are subject to change without notice. Quoted prices will be honored for a period of 90
days from the date of the written quotation unless otherwise stated.
Orders are not subject to alteration or cancellation except upon written consent of Company and payment of
proper cancellation charges, when deemed applicable by Company.
Materials or items may not be returned for credit, without the prior written consent of the Company. Any
authorized return of materials or items shall be subject to a restocking charge equal to 20% of the net
invoiced amount after Company determines that the material or item is in good condition and may be resold
without alteration or service.
Terms of payment are NET 30 days. All materials and items are sold F.O.B. Company's shipping point.
Company retains a security interest in all items sold by it so long as they remain in Company's possession to
secure all obligations of purchaser to Company. A processing fee will be applied to all invoices for requested
prepaid freight charges other than UPS. A service charge will be incurred on past due accounts extending
beyond the terms of sale described above, at a rate of 1.5% per month of the net balance extending beyond
30 days.
The buyer should inspect the goods immediately on their arrival and shall within five days of their arrival give
written notice to the Company of the claim that the goods do not conform with the terms of the contract. If the
buyer shall fail to give such notice, the goods shall be deemed to conform with the terms of the contract. Any
claim for material or item shortages must be accompanied by copies of the bill of lading and packing slip.
Delivery schedules or commitments are based upon current production
capacities, material or component availability and inventory and may be
changed as conditions require. Company shall not be liable for loss or
damage of any kind resulting from delay or inability to deliver on account of
fire, labor troubles, accident, acts of civil or military authorities, or from any
other cause beyond Company's control.

www.hetronic.com

21