Operator Manual

TG Systems

TG DIG-V1

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

Hetronic USA Hetronic Canada

3905 N.W.36th Street 45 Sinclair Avenue
Oklahoma City, OK 73112 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_TG_0001.1
system, or translated into any language in any form by any means without the written permission of Hetronic. 5/12
 TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TG Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Frequency and Address Settings . . . . . . . . . 13
Production and System Numbers . . . . . . . . . . 3 TG DIG-V1 Transmitter . . . . . . . . . . . . . . . . . 13
Unauthorized Replacement Parts . . . . . . . . . . 3 Transmitter Setup. . . . . . . . . . . . . . . . . . . . . . . . 14
Before Attempting to Operate This System . . . 3 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hetronic System Components. . . . . . . . . . . . . 4 Test the System . . . . . . . . . . . . . . . . . . . . . . . 14
Receiver Standard Features . . . . . . . . . . . 4 LED Designations & Layout . . . . . . . . . . 15
Transmitter Standard Features . . . . . . . . . 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System Overview. . . . . . . . . . . . . . . . . . . . . . . 4 Holding the Transmitter . . . . . . . . . . . . . . . . . 16
Theory of Operation . . . . . . . . . . . . . . . . . 4 Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . 16
E-Stop Function . . . . . . . . . . . . . . . . . . . . 4 Start-Up Procedure . . . . . . . . . . . . . . . . . . . . 16
Transmitter Sleep Mode . . . . . . . . . . . . . . 4 To Stop In An Emergency . . . . . . . . . . . . . . . 17
Receiver Safe Mode . . . . . . . . . . . . . . . . . 4 Safe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Changing the Battery. . . . . . . . . . . . . . . . . . . 17
Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery Disposal . . . . . . . . . . . . . . . . . . . . . . 17
Practices and Laws . . . . . . . . . . . . . . . . . . . . . 5 Battery Charging System. . . . . . . . . . . . . . . . 17
Required Operator Training . . . . . . . . . . . . . . . 5 Features . . . . . . . . . . . . . . . . . . . . . . . . . 17
Possible Sources of Danger . . . . . . . . . . . . . . 5 The Battery Charger . . . . . . . . . . . . . . . . 17
Operation and Work Area Safety. . . . . . . . . . . 5 Charging the Battery . . . . . . . . . . . . . . . . 18
Protective Features . . . . . . . . . . . . . . . . . . . . . 5 Hetronic Battery Information . . . . . . . . . . 18
To Stop In An Emergency . . . . . . . . . . . . . . . . 5 RF Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance and Storage . . . . . . . . . . . . . . . . 5 Description of Functions . . . . . . . . . . . . . . . . 19
Receiver Installation . . . . . . . . . . . . . . . . . . . . . . 6 Setting the Frequency Channel . . . . . . . . . . . 19
RX 14-0004 Receiver Components. . . . . . . . . 6 CS 458 RF-Synthesizer . . . . . . . . . . . . . . . . . 20
RX 20 Receiver Components . . . . . . . . . . . . . 7 CS 447 RF-Synthesizer . . . . . . . . . . . . . . . . . 21
Receiver Location . . . . . . . . . . . . . . . . . . . . . . 7 CS 434 RF-Synthesizer . . . . . . . . . . . . . . . . . 22
Mounting the Receiver. . . . . . . . . . . . . . . . . . . 7 STD-402 RF-Synthesizer . . . . . . . . . . . . . . . 23
RX 14-0004 Mounting Dimensions . . . . . . 8 CS 429 RF-Synthesizer . . . . . . . . . . . . . . . . . 24
RX 20 Mounting Dimensions . . . . . . . . . . 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 25
Standard External Antenna Installation . . . 9 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
GainFlex Antenna Installation . . . . . . . . . . 9 Installation / Safety Data Sheet . . . . . . . . . . . . . 29
Connect Electrical Wiring . . . . . . . . . . . . . . . 10 Definitions & AWG Metric Conversions . . . . . . 30
TG Dig-V1 with RX 14-0004 Outputs . . . 10 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TG Dig-V1 with RX 20 Outputs . . . . . . . . 11 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overhead Traveling Crane (Mat. Handl.) 12

2
 INTRODUCTION
INTRODUCTION UNAUTHORIZED REPLACEMENT PARTS
Thank you for purchasing the Hetronic radio remote Use only Hetronic replacement parts. The replacement
control system. Hetronic radio remote controls are the of any part with anything other than a Hetronic
highest caliber in remote control value, performance authorized replacement part may adversely affect the
and safety. performance, durability, and safety of this system and
Hetronic radio remote controls use the latest frequency may void the warranty. Hetronic disclaims liability for
synthesizer technology to eliminate the problems any claims or damages, whether warranty, property
typically associated with radio remote control systems. damage, personal injury or death arising out of the use
of unauthorized replacement parts.
THE MANUAL
BEFORE ATTEMPTING TO OPERATE THIS
Before operation of the crane/machine and remote
control system, read your manuals carefully and SYSTEM:
completely. The contents of this manual will provide 1. Make sure all installation has been properly
you with an understanding of safety instructions and completed.
controls during normal operation and maintenance. 2. ALWAYS be sure the crane/machine and radio
remote control Emergency-Stop functions work
PRODUCTION AND SYSTEM NUMBERS properly before beginning any crane/machine
When contacting your dealer or Hetronic about service, operation.
repair or replacement parts, know the Production and
System numbers of the transmitter and receiver. 3. Understand all Safety Precautions provided in the
manuals.
The numbers are located on the label that is affixed to
the unit itself. 4. Review control functions and operation of the
machine and this radio remote control system.
1 5. Surge suppressors (RC type only) must be used
when the receiver is controlling magnetic
contactors.
2 3
6. When not in use, turn the transmitter off and store
in a safe place to prevent unauthorized use.
4
7. If the crane/machine does not respond properly,
5 stop operation immediately. Turn off the
transmitter and report the condition to the
1. Specific approvals such as BTZ, FCC, CE, etc. appropriate technician or supervisor.
2. The type of transmitter or receiver. 8. Turn off the transmitter and remove the battery
3. Frequency and RF unit. before any maintenance work is done.
4. Production Number - The first digit indicates the IMPORTANT: AVOID SYSTEM DAMAGE - ALWAYS
manufacturing facility (1=H-Germany, 2=H-Malta, disconnect receiver power supply and control wiring
3=H-US, 4=H-Italy). The next four digits are the before welding on any part of the crane/machine.
production month and year. The last 6 digits are 9. Turn off the transmitter key switch when changing
the system address. the battery or taking a break.
5. System Number - The Hetronic Part Number of 10. Always have fresh batteries on hand or an
the transmitter or receiver. optional rechargeable battery pack in the battery
charger to ensure the availability of a fully
Record the Production and System numbers here: charged battery.
11. Installation, setup and service must be performed
Transmitter Production Number by authorized personnel only.
12. Use only Hetronic spare parts.

Receiver Production Number

System Number

3
HETRONIC SYSTEM COMPONENTS The E-Stop responds faster than any other function.
When E-Stop is engaged, the system ignores any other
The Hetronic radio remote control system consists of a
signal that is transmitted. The problem must be
receiver and transmitter with belt, battery charger, and
corrected before the system will respond to any other
two rechargeable batteries.
signal.
RX 14-0004 Receiver Standard Features The E-Stop is self-monitoring and redundant in the
Start relay, horn relay, E-Stop relay transmitter and receiver. The system performs a
• Up to 14 digital outputs self-test to ensure the E-Stop circuit is working properly.
If an error is detected, the system automatically goes
• Self-diagnostics
into Safe mode.
• 48 V, 115 V or 230 V for AC cranes/machines
When the transmitter is turned on, it performs a self-test
• 12VDC or 24VDC for DC cranes/machines
to be sure that communications are within designated
RX 20 Receiver Standard Features parameters. If an error is detected, the transmitter will
Start relay, horn relay, E-Stop relay, and two option not transmit any signals.
relays Transmitter Sleep Mode
• Up to 20 digital outputs The transmitter sleep mode is designed to prevent
• Self-diagnostics accidental operation. The transmitter can be set for the
• 48 V, 115 V or 230 V for AC cranes/machines following sleep modes:
• 12VDC or 24VDC for DC cranes/machines • 30 seconds
TG Dig-V1 Transmitter Standard Features • 2 minutes
• 5 minutes
• Removable key power switch
If the transmitter is not used for the set sleep mode
• E-stop switch period, it turns itself off. The controls are not operational
• 1 2-detent start pushbutton while the transmitter is in sleep mode. To restart the
• 1 2-detent horn pushbutton transmitter, turn the key switch off and then back on, and
• 8 2-speed motion pushbuttons press the Start button.
• 2 2-detent latching/momentary option pushbuttons IMPORTANT: If the transmitter has a latching
• Sleep mode pushbutton that is engaged, sleep mode will not occur.
• 100 m (300 ft.) range Receiver Safe Mode
• Internal antenna The following conditions cause the receiver to go into
• Shoulder strap Safe mode:
• The transmitter goes into Sleep Mode
SYSTEM OVERVIEW
• Radio signal interference
Theory of Operation • Transmitter out of operating range
The Hetronic radio remote control system includes a • E-Stop button is activated
transmitter and a receiver. These systems operate over • E-Stop circuit failure
the 400-470 MHz radio band range (70 cm band) and
• Low battery sends E-stop after time out
are FCC approved.
When the transmitter signal is no longer sensed by the
The transmitter generates the electronic signal that receiver, the Time Out process begins. The Time Out
communicates with the receiver. The transmitter and period is set to 450 msec at the factory. If the receiver
receiver are set with identical address codes and does not establish contact with the transmitter within
frequency channels. This allows operation of multiple that time period, it goes into the Safe Mode.
systems within the same area without signal
interference. In Safe Mode, the receiver shuts off activation power to
the output relays and activates the E-stop function.To
The receiver only accepts commands from the restart the system, be sure the transmitter signal is
transmitter with the same address code. active and sensed by the receiver. Then press the Start
NOTE: The receiver and transmitter have the address pushbutton.
code set at the factory.
E-Stop Function
The most important feature of the radio remote control
system is the E-Stop. The transmitter sends the E-stop
status signal along with the specified crane/machine
function. This method confirms that ongoing operations
are safe. If the E-stop pushbutton is pressed, the E-stop
relay in the receiver causes all crane/machine motions
to stop. The receiver goes into Safe mode.
To restart the system, disengage the E-stop button and
press the Start button.

4
 SAFETY
SAFETY ALERT POSSIBLE SOURCES OF DANGER
Look for this symbol to point out This system makes remote control via radio signals
important safety precautions. They possible. However, the transmission of control
mean: commands can take place around obstacles and out of
the operator’s direct sight. To prevent accidental
Attention! start-up and possible injury or damage:
Personal Safety Is Involved! 1. Always engage the E-stop button and switch
Become Alert! "OFF" the transmitter when it is not in use.
Remove the key if the unit is placed any distance
Obey The Message! away from the operator.
The safety alert symbol is used in decals on the unit 2. Disconnect the power supply before any
and with proper operation procedures in this manual. assembly, maintenance or repair work is done.
Understand the safety message. It contains important 3. Never remove or alter any of the safety features
information about personal safety on or near the unit. of this system.
DANGER: IMMINENTLY HAZARDOUS OPERATION AND WORK AREA SAFETY
SITUATION! If not avoided, WILL RESULT in
The work area must be free from obstacles, debris or
death or serious injury. other tripping hazards. Avoid uneven work areas and
any rough terrain. Always be sure of your footing.
WARNING: POTENTIALLY HAZARDOUS Be aware of overhead obstacles that may interfere with
SITUATION! If not avoided, COULD RESULT machine operation.
in death or serious injury.
PROTECTIVE FEATURES
This radio remote control system is equipped with
CAUTION: POTENTIALLY HAZARDOUS electronic and mechanical safety features. Processing
SITUATION! If not avoided, MAY RESULT in of control signals transmitted from other transmitters is
minor or moderate injury. It may also be used not possible, since transmission coding is unique to
to alert against unsafe practices. each system.
These safety features help protect the operator, as well
NOTATIONS as others within the work area. The machine functions
can be stopped by pushing the emergency stop button
NOTE: General reference information for proper on the transmitter (EMERGENCY STOP).
operation and maintenance practices.
NOTE: The E-stop command is initiated within
IMPORTANT: Specific procedures or information approximately 0.5 seconds (450 ms) after the switch is
required to prevent damage to unit or equipment. turned to the "OFF" position.
PRACTICES AND LAWS
Practice usual and customary safe working WARNING: Accidental start-up can cause
precautions, for the benefit of yourself and others. serious injury or death. NEVER remove or
Understand and follow all safety messages. Be alert to modify any safety feature.
unsafe conditions and the possibility of minor,
moderate, or serious injury or death. Learn applicable TO STOP IN AN EMERGENCY
rules and laws in your area. 1. Press the red "EMERGENCY STOP" pushbutton.
REQUIRED OPERATOR TRAINING 2. Turn the key to "OFF".
Original purchaser of this unit was instructed by the 3. Wait for all moving machine parts to stop.
seller on safe and proper operation. If unit is to be used 4. Refer to machine’s operator manual for further
by someone other than original purchaser; loaned, instructions.
rented or sold, ALWAYS provide this manual and any
needed safety training before operation. MAINTENANCE AND STORAGE
ALWAYS review the operators manual of any machine Always shut off power to the machine and the radio
to be controlled by radio remote control. remote control system before any assembly,
maintenance or repair.

5
Standard External Antenna Installation GainFlex Antenna Installation
If the receiver must be located inside a control panel or Your application may require the use of a GainFlex
other enclosure, an external car antenna may be antenna. The GainFlex antenna can extend the range
required. Mount the antenna onto a metal surface with of the radio remote control system up to 300 meters
the same ground as the receiver circuit board. Remove (1000 ft.). It can also be used where a standard
any burrs from the antenna mounting hole and scrape antenna is difficult to mount. If you are not sure which
away any paint which may insulate the antenna base antenna is suitable for your application, please contact
from making positive contact. Hetronic or your dealer.
NOTE: Improper installation of the antenna will cause When using a GainFlex antenna, there must be no
intermittent signal loss. metal or conductive materials within 2 meters (6 feet)
1. Drill a hole 14 mm (.56 in.) dia. through the of the antenna. This material will interfere with the
control panel or enclosure at the external car transmitter signal and cause intermittent signal loss.
antenna location. For the best reception, the antenna should point
upward.
2. Insert the connector base through the hole with
the antenna on the outside. Seat the base firmly NOTE: Improper installation of the antenna can cause
against the enclosure surface. intermittent signal loss.
3. Assemble the antenna as shown below. 1. Secure the GainFlex antenna base to a mounting
surface with the tie wraps included. Mount the
antenna vertically with the base pointed upward.

1 1. Gainflex Antenna
1. Antenna Pole 2. Antenna Extension Base 1
2. Enclosure 3. Tie Wrap
3. Antenna Base 4. Antenna Extension Cable
4. Antenna Cable

2
2

3
3
4
4

4. Screw the antenna pole onto the antenna base.

5. Remove the Miniflex antenna from the receiver
housing by unscrewing it from the antenna base. 2. Screw the GainFlex antenna pole onto the base.
6. Connect the external antenna cable to the 3. Unscrew the Miniflex antenna from the receiver
antenna base on the receiver housing. housing.
7. Bundle any excess antenna cable and secure 4. Connect the GainFlex antenna cable connector to
with tie wraps or equivalent. the existing antenna base on the receiver
IMPORTANT: DO NOT run the antenna cable with housing.
power or control wiring. Intermittent signal loss will 5. Bundle any excess antenna cable and secure
result. with tie wraps or equivalent.
IMPORTANT: DO NOT run the antenna cable with
power or control wiring. Intermittent signal loss will
result.

9
 TG TRANSMITTER
Each Hetronic radio remote control system is delivered
with two fully charged NiMH batteries. One is inserted CAUTION: AVOID INJURY OR DAMAGE -
in the battery compartment located on the back of the
Operating the transmitter without its antenna
transmitter. Refer to the “Charging the Battery” on
could destroy the final stage of the RF
page 18 for information on charging a discharged
battery. module. DO NOT attempt to change the
Hetronic pre-set frequency or the 20-bit
WARNING: The transmitter coder settings are address. Personal injury and property
set at the factory and should be changed by damage could result from transmission
Hetronic service personnel only. Incorrectly interference and may void the warranty.
changing the settings of the transmitter coder
The address settings are pre-set at the factory in the
board could result in damage to equipment,
ADMO module. However, if the transmitter coder
serious injury or death. board, the base board, or if the entire transmitter or
receiver are replaced, the ADMO address must match
FREQUENCY AND ADDRESS SETTINGS the system.
Each Hetronic radio remote control system contains a IMPORTANT: If the ADMO settings of the transmitter
radio frequency (RF) unit. Each system consists of a and receiver do not match, the system will not function.
transmitter RF unit and a receiver RF unit.
TG DIG-V1 TRANSMITTER

1 2 3 4 5 6 7 8

1. Upper Housing
2. Lower Housing
S1 S2
3. Start Push-button DK1/17 DK2/18

4. Horn Pushbutton
5. Top Bezel and Membrane
S3 S4
6. Power LED DK3/11 DK4/12

7. Motion Push-button
8. Carrying Belt Fastener S5 S6
9. Battery DK5/13 DK6/14
9
10. E-Stop Push-button
11. Key Switch S7 S8
12. Key Cap DK7/15 DK8/16

13. Option Push-buttons

14. Option select LEDs S9 S10
DK9/25 DK10/26

DK27/19 DK28/20
Option Option
1 2

S11 S12

10
14 13
12 11

13
 TRANSMITTER SETUP
This section describes the steps to properly label the 3. Place the new label into the pushbutton cover
transmitter for operation. face down, so the label shows when the cover is
turned right-side up.
Placing the Pushbutton Labels
4. Snap the pushbutton base back into the cover.
If your TG transmitter came with pushbutton labels,
insert them into the transmitter as shown below. 5. Repeat these steps for each label to be replaced.
6. If necessary, clean the transmitter housing with
1. Bezel with Membrane rubbing alcohol to remove any traces of dirt, oil or
2. Pushbutton Cover 1 other debris.
3. Pushbutton Label 7. Place the pushbuttons on the transmitter
4. Pushbutton Base according to the layout for your application.
5. Housing 8. Remove the adhesive strip from the back of the
2 bezel and carefully place it on the enclosure.
9. Press the bezel firmly into place.
NOTE: DO NOT use any type of glue or adhesive to
3 secure the bezel to the transmitter housing. Incorrect
adhesives can damage the transmitter and will void the
warranty.
4
WARNING: FAILURE TO FOLLOW
5 INSTRUCTIONS could result in personal
injury and/or damage to equipment. Read and
understand the safety instructions in all
manuals provided.
Testing or service must be performed by
authorized personnel only.
There must be no load on the crane/machine.
Clear the crane/machine operating area of
obstructions.
1. Remove the pushbutton cover from the
pushbutton base.
2. Remove the pushbutton label.

TEST PROCEDURES
TEST THE SYSTEM
WARNING: FAILURE TO FOLLOW • Remove the cover from the receiver.
INSTRUCTIONS could result in personal • Position yourself in front of the receiver so that all
injury and/or damage to equipment. Read and LEDs and connections are visible.
understand the safety instructions in all
manuals provided.
Testing or service must be performed by
authorized personnel only.
There must be no load on the crane/machine.
Clear the crane/machine operating area of
obstructions.

Check the following list before turning the transmitter

on.
• Be sure there is a fully charged battery pack in
the transmitter.
• Push in the E-Stop button.
• Be sure the motion pushbuttons are in their OFF
(neutral) positions.

14
LED Designations and Layout

1. CPU Yellow LED

2. Transmission Green LED
3. E-stop Fault Red LED 5 1 2 3 4
4. Telegram Type Red LED
5. E-stop Relay Activated Red LED
6. Output Relays K1 - K20 Activated
Red LEDs

F1
EXAMPLE ONLY Emergency

K17
K18
K19
F2 Stop

K20
K15
K16
K1
K2
K3

K5
K6

K8
K

K
1 2 3 4 5 6

6 1 2 3 4 5 6 7 8

1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8

M25 M32 M20

1. Be sure that all safety measures required by the 4. Place a fully charged battery pack into the battery
equipment manufacturer have been followed. compartment located at the back of the
transmitter.
2. Turn on power to the receiver. The CPU Standby 5. Turn the key switch to the ON position. The
LED (1) should flash yellow to indicate the Power LED on the transmitter flashes GREEN
microprocessor is working properly. once and an acoustic pulse sounds to indicate
there is a diagnostic test in progress.The LED on
the transmitter continuously flashes GREEN and
a second acoustic pulse sounds to indicate
successful diagnostic testing.
Power LED 6. Immediately following the diagnostic test, the
Receiver Transmission LED (2) should flash. This
indicates that the receiver is detecting a valid
signal from the transmitter.
7. Pull out the E-Stop pushbutton. The Receiver
E-Stop Relay LED (5) should illuminate.
8. Push in the E-Stop pushbutton. The E-Stop Relay
LED should go off.
9. Pull out the E-Stop pushbutton.
10. Press the Start pushbutton on the transmitter.
The Start Relay LED should illuminate. The main
Option
1
Option
2
line contactor will activate at this time (depending
on crane wiring).
11. Activate the motion pushbuttons to test the
E-Stop Key crane/machine functions.
Switch Switch IMPORTANT: The crane/machine functions will
operate during this check. Be certain that there are no
3. Place the key switch on the transmitter in the obstacles near the crane/machine.
OFF position and the E-Stop pushbutton in the 12. Confirm that the crane/machine moves
OFF position (i.e. pull it out). appropriately and that the correct LEDs illuminate
for each crane/machine motion.
13. Activate the Option functions, if supplied, to test optional crane/machine functions.

15
 14. Push in the E-Stop pushbutton and turn the key
.

switch to the OFF position. The E-stop and relay WARNING: The Receiver settings are set at
output LEDs in the receiver should turn off. the factory and should be changed by
15. If transmitter and receiver function properly, the Hetronic service personnel only. Incorrectly
system is ready for use. changing the settings of the receiver could
16. Install the cover onto the receiver. result in damage to equipment, serious injury
17. If the receiver or transmitter does not operate or death.
properly, or if the crane/machine does not react
as directed, shut the entire system down and
refer to the Troubleshooting Section. If necessary,
contact Hetronic or your Dealer.

OPERATION
START-UP PROCEDURE
WARNING: FAILURE TO FOLLOW 1. Be sure that all safety measures required by the
INSTRUCTIONS could result in personal equipment manufacturer have been followed.
injury and/or damage to equipment. Read and 2. Turn on power to the receiver.
understand the safety instructions in all 3. Place the key switch on the transmitter in the
manuals provided. OFF position and the E-Stop pushbutton in the
OFF position (i.e. pull it out).
HOLDING THE TRANSMITTER 4. Place a fully charged battery pack into the battery
Hold the transmitter with the control panel facing you. compartment located at the back of the
Be sure that you are able to easily read any text and transmitter.
understand the operation symbols. 5. Turn the key switch to the ON position. The
Power LED on the transmitter flashes GREEN
WARNING: FAILURE TO FOLLOW once and an acoustic pulse sounds to indicate
INSTRUCTIONS could result in personal there is a diagnostic test in progress.The LED on
the transmitter continuously flashes GREEN and
injury and/or damage to equipment. Always
a second acoustic pulse sounds to indicate
hold the transmitter in the proper orientation. successful diagnostic testing.
Holding the transmitter improperly while
6. Press the Start pushbutton
operating the crane/machine could result in
unexpected crane/machine response. 7. The system is now ready to use.

The procedures described in the following paragraphs

must be completed before the radio remote control
system is activated. These checks must be performed Power LED
at least once a day, before the start of any operation
and at all shift changes.

WARNING: FAILURE TO FOLLOW

INSTRUCTIONS could result in personal
injury and/or damage to equipment. Test the
"E-STOP" function as described in the
crane/machine manufacturer’s operator
manual before beginning any operation.
Option Option
1 2

VISUAL CHECK
Always check the transmitter for any physical damage E-Stop Key
before any operation. Switch Switch
• Check equipment for wear or damage.
IMPORTANT: To avoid accidental start-up, always
• Check rubber cuffs and pushbutton caps for wear
engage the E-stop pushbutton and switch the
or damage.
transmitter "OFF" when not in use. When the
IMPORTANT: Never operate a transmitter with worn or transmitter is not attached to the operator, the key
damaged parts. Replace immediately with only switch should be removed and stored in a secure
Hetronic parts. Contact Hetronic or your Dealer. place.

16
 2. Turn the key to "OFF".
WARNING: TO AVOID SERIOUS INJURY 3. Wait for all moving crane/machine parts to stop.
OR DEATH. Switch the crane/machine "OFF" 4. Refer to crane/machine’s operator manual for
if there is a fault or any problems with the further instructions.
safety check. Contact Hetronic or your dealer
immediately to repair the system. NEVER SAFE MODE
operate the crane/machine when the When the transmitter battery power is nearly
"EMERGENCY STOP" function does not exhausted, the system automatically goes into Safe
operate properly. Mode. An acoustic pulse sound for 30 seconds to
indicate a low battery warning.
Improper operation, maintenance or
adjustment may cause serious injury or At the end of the warning period, the transmitter sends
damage to equipment and may void the the E-Stop signal to the receiver and all crane/machine
warranty. motion commands are stopped.
To restart the system, a fully charged battery must be
TO STOP IN AN EMERGENCY inserted into the transmitter. Proceed with startup
instructions. Always have a fully charged battery
1. Press the red "EMERGENCY STOP" pushbutton.
available to continue operation of radio remote control.

MAINTENANCE
CHANGING THE BATTERY BATTERY DISPOSAL
An acoustic pulse sounds to indicate a low battery IMPORTANT: AVOID ENVIRONMENTAL
warning. When the transmitter signals, the battery must POLLUTION. Electronic equipment and components
be changed immediately. are considered to be hazardous waste. Discarded
Position the crane/machine into a safe place or safe rechargeable batteries are hazardous waste and must
condition within 30 seconds after hearing the signal. not be disposed of with typical refuse. Contact a
professional hazardous waste disposal service.

WARNING: The transmitter will switch to the WARNING: EXPLOSIVE GASES AND
EMERGENCY STOP condition after 30 FLYING DEBRIS can cause death or serious
seconds injury. Use only Hetronic replacement
rechargeable batteries. Use of unauthorized
1. Remove fully charged battery pack from the replacement batteries could cause a battery
battery charger. explosion, resulting in injury or death of the
2. Insert the fully charged battery pack into operator or other people in the work area.
transmitter.
BATTERY CHARGING SYSTEM
1 2 Features
• Gold plated contacts ensure clean, positive
contact between battery and charger.
• LED status light indicate charging process
The Battery Charger
One battery charger is designed for 115/230 VAC and
PRESS

another charger is designed for 12/24 VDC. Both

chargers function the same.
The charger electronics checks the capacity of the
battery until the battery is fully charged. The maximum
Depress here to charging time is six hours. When the battery is fully
Pivot battery pack
release battery. charged, the green charge LED begins to flash. Leave
to remove.
the battery in the charger until needed to ensure it is
3. Place the spent battery pack into the battery fully-charged.
charger for recharging. If the power supply to the charger is interrupted, or the
4. The Radio Remote Control is ready for operation. battery is removed and then reinserted into the charger
5. Follow the “Start-Up Procedure” on page 16 and (before the battery was fully charged), the charger
safety checks to begin operation. detects how much charge the battery has left and
resumes the charging process.

17
Charging the Battery
1. Insert the battery with both guide pins in the
corresponding guide bars into the battery
compartment of the battery charger.
2. Press the battery on the marked spot until it
latches into its compartment. The charge LED
illuminates.
3. When the battery is fully charged, the charge LED
flashes.
4. Leave the battery in the charger until it is needed.
The charger supplies a “trickle” charge but will not
over-charge the battery.

Charge LED

Battery
guide bar

Battery
guide pin

DC Only

Optional DC US/Japan AC European AC

Cigarette
Lighter
Adapter
Battery Charger Power Options
Hetronic Battery Information
Standard Hetronic rechargeable batteries are the nickel
metal hydride type. These batteries have no “memory
effect” when charging a battery that is not fully
discharged.

18
 TROUBLESHOOTING

QUESTIONS TO ASK • Is the receiver grounded to the proper machine

grounding point?
When reporting a problem to Hetronic you may be
asked several questions pertaining to the TG system. • Is the yellow CPU LED (LD1) flashing?
Asking these questions to the person who reported the • Is the green Telegram LED (LD2) flashing?
problem prior to calling Hetronic will speed up the • Is the EMERGENCY STOP circuit LED (LD3)
troubleshooting process. flashing?
Please locate the Hetronic system labels (example • Is the EMERGENCY STOP LED (LD5) on the
shown below) which is located inside the transmitter receiver printed circuit board lit?
battery cavity, and on the side of the receiver. This • Are the connections/screw terminals tight?
label contains information that identifies the system. • Is the internal antenna securely connected?
• Is the external antenna assembly outside the
enclosure securely connected and properly
grounded to the machine frame?
• Are all incoming power supply and ground wires
properly connected?
• Are the signal wires separated from the high
power wires?
• Are surge suppressors installed on any magnetic
contactors being controlled by the receiver?
Warranty Validity
Warranty validity is based on regular inspection and
cleaning of the radio remote control equipment.

COMMON PROBLEMS
The following are common problems associated with
General using the Hetronic TG system, and their possible
• What is the Production Number and System solutions. For help in diagnosing problems in the
Number of the transmitter and receiver? This receiver, refer to the drawing in the “Test Procedures”
information is provided on the Hetronic system on page 14 of this manual that shows the location of
labels. each diagnostic LED.
• Are there other Hetronic systems at or near the
machine site?
Transmitter
• Is the EMERGENCY STOP pushbutton pulled
out?
• Is the key switch in the ON position?
• Did you press the START pushbutton?
• Were the pushbuttons in the off position prior to
turning on the transmitter?
• Did you press the START pushbutton while
accidently holding in one of the other
pushbuttons?
• Is there a fully charged battery pack installed?
• Did you take the transmitter out of its operating
range (100 meters or 328 feet)?
Receiver
Remove the receiver enclosure lid and observe the
receiver circuit board. Check the following. Refer to the
drawing in the section “Test Procedures” on page 14
that shows the location of each diagnostic LED.
• Is machine power being applied to the receiver?
• Are any input power fuses blown?

25
PROBLEM PROBABLE CAUSE CORRECTION
System will not E-Stop switch engaged Pull out E-Stop switch. Restart system by
initialize after normal pressing Start.
start-up procedure
Batteries fully discharged Check battery to ensure a full charge.
Replace with fully charged battery if
necessary.

No power to the receiver Check the diagnostic LEDs in the receiver

to be sure power is applied. Ensure that the
system is properly grounded.

The transmitter is Battery is discharged Replace battery with a fully charged battery.
turned on, but does
not transmit (Power Broken key switch Check wiring on key switch. Replace key
switch, wiring or contact element.
LED not flashing)
Coder board failure Contact Hetronic or your Dealer.

Transmitter is E-Stop switch engaged Pull out the E-Stop pushbutton and press
transmitting (Power the Start pushbutton
LED flashing), but
Transmitter out of range Take the transmitter back into the range of
crane/machine will the receiver. Press the Start pushbutton.
not respond
A motion function was not in OFF Ensure that all control devices are in OFF
position when transmitter turned on (neutral) position when the Start button is
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 Contact Hetronic or your Dealer

E-Stop LED on PCB is illuminated

Transmitter/receiver frequency Check frequency settings to be sure

channels do not match transmitter and receiver are set to same
frequency channel
NOTE: Always match the transmitter
frequency channel to the receiver. NEVER
change the receiver frequency channel.
Contact Hetronic or your Dealer.

ADMO address codes of transmitter Check that the ADMO address code is the
and receiver do not match same for the transmitter and receiver.
Contact Hetronic or your Dealer.

26
PROBLEM PROBABLE CAUSE CORRECTION
All crane/machine Receiver antenna connection is Tighten or replace antenna.
motions operate loose or missing
intermittently
External antenna (if used) has loose Tighten antenna and ground connection.
connection, poor grounding or Contact Hetronic or your Dealer for more
interference information on external antennas.

Surge suppressors not installed on Install RC type surge suppressors on all

contactors magnetic contactors that are controlled by
the radio remote control system

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

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

Another Hetronic transmitter may If another Hetronic system is located within

be interfering with the system. 75 meters, the frequency channels must be
NOTE: This does not apply for at least 2 channels apart. If another system
STD-402 RF modules is within 20 meters, the channels must be at
least 3 channels apart. Contact Hetronic or
your Dealer for assistance.

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

Surge suppressors not installed on Install RC type surge suppressors on all

contactors magnetic contactors that are controlled by
the radio remote control system

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

27
 SPECIFICATIONS
RECEIVER RX 20
TG SYSTEM Size 246 x 160 x 90 mm (does not
Operating range 100 m (330 ft.) typical include external antenna)
Frequency range 400 - 470 MHz 9.7 x 6.3 x 3.5 inches

Deviation +/- 2 kHz Weight 1690 g 3.7 lbs

HF output power 10 mW max. Operating power 48/110/240 VAC 50/60 Hz (+/- 20%)

Operating -25° to +70° C 12/24 VDC (+/- 20%)

temperature range (-18° F to 158° F) Current <100 mA

Enclosures IP65 weatherproof (exceeds NEMA Safety features Self-monitoring E-Stop circuits
12/13) Fail-safe, spring forced E-Stop relay
Transmitter antenna Built-in Self-test during start-up and
operation
TX Weight 2.1 lb (950 g) (incl. battery)
On-board diagnostic system with
TX Size (L, W, H) 255 x 88 x 58 mm
indicators for RF communication,
10 x 3.5 x 2.3 inches power status, active outputs
TX Power supply 9.6V/1200mAh NiMH rechargeable Outputs 1 NO Potential-free E-Stop relay at
battery pack 8A 30VDC/240VAC
Operation time Up to 20 hours for CS 434, CS 447 18 NO Potential-free relays at 8A
and CS 458 30VDC/240VAC
2 NO/NC Potential-free relays at 8A
Up to 18 hours for STD 402
30VDC/240VAC

TG DIG-V1
Functions E-Stop pushbutton BATTERY CHARGER
Key power switch Charging current Normal: 200 mAh
1 two-detent START pushbutton
1 two-detent HORN pushbutton Charge time Normal: approx. 6 hours
8 two-speed motion pushbuttons Temperature range -20C to +75C
2 two-detent OPTION pushbuttons
Power supply DC - 12-24 VDC, polarity
protected
AC - 110-220 VAC, US/Japan or
RECEIVER RX 14 EU plug
Size 246 x 160 x 90 mm
9.7 x 6.3 x 3.5 inches
Weight 1690 g 3.7 lbs BATTERY
Operating power 48/110/240 VAC 50/60 Hz (+/- 20%) Battery type NiMh (nickel metal hydride)
12/24 VDC (+/- 20%) Capacity (typical) 1200 mAh @ 9.6V
Current <100 mA Typical operation Up to 20 hours with one charge
Safety features Self-monitoring E-Stop circuits time (depending on TX configuration)
Fail-safe, spring forced E-Stop relay Memory effect None
Self-test during start-up and
Duty cycle Can be recharged at least 500 times
operation
(after 500 charges, over 80% of
On-board diagnostic system with capacity remains and will diminish
indicators for RF communication, gradually)
power status, active outputs
Outputs 1 NO Potential-free E-Stop relay at
8A 30VDC/240VAC
14 NO Potential-free relays at 8A
30VDC/240VAC

28
 INSTALLATION AND SAFETY TEST DATA
This form must be completed and signed by the person The operator must also ensure that all safety devices
responsible for installation of this radio remote control and features are in place and operating correctly. The
system. operator is responsible for understanding and following
Hetronic assumes no responsibility for the correct all safety precautions in this and other applicable
installation of the radio remote control system. The operator manuals.
equipment operator must ensure that the radio remote
control system and the crane/machine operate
correctly together.

Crane/machine Data

Manufacturer

Model Number

Serial Number

Year of Production

Radio Remote Control Data

Manufacturer Hetronic

Model

System 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 crane/machine type are followed.

Place

Date

Company

Name of Installation Technician

Signature

29
 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

30
 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

31
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

32