Operating Instructions

Original Operating Instructions

®
FSE 727 radiobus AO727G05
Table of Contents

Safety Instructions  
Intended Use  
Safety Instructions for Installation and Operation 
Installation of the Radio Receiver  
Installation with Snap-In Wall Bracket  
Installation with integrated Mounting Loops  
Installation with Mounting Loops  
Electrical Connection  
Control Display  
Module focus C/D/T (Option)  
Technical Data  
Dimensions  
Receiver Housing HR168  
Connection Options  
Troubleshooting  
Maintenance  

Attachments: EC Declaration of conformity, return delivery note, frequency list, system specific views,
circuit diagrams and /or output wiring

Pictographs
Danger due to electrical voltage. Touching live parts inside the unit can be fatal or cause
serious injuries.

Instructions for occupational health and safety. Not following these instructions can cause
accidents, which can cause damage, serious injuries or even death.

Important information about the operation of the radio system

Manufacturer:
HBC-radiomatic GmbH • Haller Straße 45 – 53 • 74564 Crailsheim • Germany • Tel. +49 7951 393-0 • info@radiomatic.com.
HBC.radiomatic GmbH is not liable for any misprints or errors! – Specifications and design subject to change without notice.
® radiomatic and radiobus are registered German trademarks.
© 47 / 2011, HBC-radiomatic GmbH, 74564 Crailsheim, Germany
No part of this document may be reproduced in any manner whatsoever without the expressed written permission of
HBC-radiomatic GmbH.
Safety Instructions
Read through these operating instructions carefully before working with the radio system. This applies in
particular to the installation, commissioning and maintenance of the radio system.
The operating instructions are a constituent part of the radio control system and must always be kept
close at hand for the responsible personnel.
The term ‘machine’ is used in the operating instructions for the different possible uses of the radio
system.

Intended Use
 The radio system serves to control machines and for data transfer. Observe the job safety and
accident prevention regulations applicable to each application.
 The intended use also includes reading the operating instructions and adhering to all safety
information contained therein.
 The radio system must not be used in areas where there is a risk of explosion, nor for the control of
machines used to convey persons, unless it is explicitly approved by the manufacturer for these uses.
 Modifications to the radio system may only be carried out by specialist personnel who have been
trained and authorized by HBC-radiomatic. All modifications must be documented at the factory in
the radio control master file.
 The radio control system safety devices must not be modified, removed or bypassed. In particular,
modifications to any part of the radio system's complete E-STOP system are impermissible.

Safety Instructions for Installation and Operation

 The electrical connection per the accompanying output wiring diagram must be established by a
qualified electrician exclusively.
 The receiver may only be opened by trained personnel. Components inside the receiver can be
energized at life-threatening voltages. The supply voltage for the machine must be deactivated
before the receiver is opened.
 Please also note with radio systems, that the presence of persons in the danger zone - in particular
beneath the load (cranes!) - is prohibited in every instance.
 Select a safe location for radio control, from which you have a good and complete view of the
working movements of the machine, the load movements and the surrounding working conditions.
 It is not permissible to put a radio transmitter unattended to one side whilst activated. Always switch
the radio transmitter off when it is not required. This applies in particular if you change location,
when working without radio control, during breaks and at the end of work. Always safeguard the
radio transmitter against use by unauthorized persons, for example by locking it away.
 In the event of an emergency and with all faults, switch the radio transmitter off immediately by
pressing the STOP switch.
 Only operate the radio system when it is in perfect working order. Faults and defects that could
influence safety must be rectified before the system is put back into operation, by specialists who
have been trained and authorized by HBC-radiomatic.
 Note that the operational directions of the operating elements may appear inverted depending on
location and viewing angle to the machine. This applies in particular to rotary cranes, if your location
changes from inside to outside the radius of the crane. The operator must make himself familiar with
the directional markings on the machine before the start of work.
 Repairs may only be carried out by specialist personnel who have been trained and authorized by
HBC-radiomatic. Use original replacement parts and accessories (e.g. rechargeable batteries)
exclusively; otherwise it is possible that the equipment safety can no longer be guaranteed and our
extended warranty will be voided.
 Remain vigilant when working with the radio system and familiarize yourself with its functions. This
applies in particular if you are working with it for the first time or if you work with it only occasionally.
Installation of the Radio Receiver
 The receiver should be mounted vertically with the cable connection downwards.
 Ensure that there are no metal parts within a radius of 1 m (3 feet) above the receiver.
 When the receiver has to be mounted into a control cabinet, an offset antenna must be installed.
 Receivers with external antenna must be installed in such a way that the antenna stands freely and
does not touch walls or metal parts. Otherwise an offset antenna must be used, which can be
supplied if necessary.
 Receivers with plastic housing should be protected against direct sunlight (UV radiation) with
appropriate measures.

Minimum distance to
metal parts 1 m

Illustrations exemplary

Installation with Snap-In Wall Bracket

The receiver is mounted with the snap-in wall bracket provided. Fix the wall bracket in place via the
holes provided. Only use screws (max. M6) which are suitable for the installation location.

Receiver Housing HR145

(FSE 508, FSE 509)

Push the receiver with the mounting device  from the top into the wall bracket and press the receiver
downwards until it clicks into place.

For removing the receiver, press the release device  downwards and pull the receiver upwards out of
the wall bracket.
Receiver Housing HR165
(FSE 510, FSE 511, FSE 512)

Place the receiver with the eyelets on the wall bracket pins and press it on the wall bracket until it clicks
into place.

Press the engagement pins outwards with a large screwdriver, to remove the receiver from the wall
bracket. This releases the receiver off the wall bracket from where it can be removed to the front.

Installation with integrated Mounting Loops

(FSE 516 with housing HR268, FSE 726/727 radiobus ® )

The receiver is installed via the integrated mounting loops on the receiver sides. Use the shock mounts
provided for installation to dampen any vibrations that may occur.

Installation with Mounting Loops

(FSE 516 with housing HR270 or HR272, FSE 524, FSE 736/737/776/777 radiobus ® )

The receiver is installed via the provided mounting loops. Use the shock mounts provided for installation
to dampen any vibrations that may occur. A detailed installation guide is enclosed with the delivery.
Electrical Connection
Depending on the version the radio receiver is connected either via a cable gland or with a Harting plug
connection to the machine electrics.
Please observe that the receiver may only be connected to the supply voltage indicated on the type
plate!

Warning – shock hazard!

 The electrical connection may only be carried out by skilled personnel.
 The electrical connection must comply with the enclosed wiring diagram.
 Switch off the supply voltage before opening the receiver. There is a risk of fatality from
touching live parts inside the housing!

Control Display
The control display with LEDs indicating the operating state of the radio system is located behind the
inspection window of the receiver cover lid.

The LEDs have the following significance:

On (yellow) illuminates as soon as operating voltage is present at the receiver, i.e. the connection to the
electronic of the machine is established and operating voltage (12 V) is present.

RF (red) illuminates whenever the transmitter is switched off. It will be extinguished the very moment a
signal is received by the receiver on its radio frequency.

Si 1 (green) illuminates after the transmitter is switched on, i.e. the receiver has identified its specific
transmitter on the basis of the common message address (code). Safety circuit Si 1 is enabled.

Si 2 (green) refers to the internal safety circuit Si 2, responsible for a double switching off of the move
commands whenever the control station is in the off (zero) position, i.e. "Si 2" will not illuminate.
It is not until one or several drive commands (e.g. turn, trolley traveling, lifting gear or crane traveling)
are input that the "Si 2" LED may illuminate!

Available for FSE 510, FSE 511, FSE 516, FSE 524, FSE 726/727/736/737/776/777 radiobus ® :
Feedback (yellow) illuminates whenever the receiver is sending a feedback telegram to the transmitter.
Module focus C/D/T (Option)
Installation
 Mount the module with 4 screws (M 5) via the provided drill holes (refer to chapter Dimensions).
 Do not install the module into a niche or a control cabinet.
 Ensure that there are no metal parts within a radius of 1 m (3 feet) above the module base.

Electrical Connection
The module is connected to a radio receiver via a 5-pin circular connector.
Please observe that the module may only be connected to the supply voltage indicated on the type plate!

Warning - shock hazard

 The electrical connection may only be carried out by skilled personnel.
 The electrical connection must comply with the enclosed wiring diagram.

Control LED
A dual LED is located next to the cable connection in the module base.
 The LED illuminates red as soon as operating voltage is present at the module. The connection to
the radio receiver is established and the internal operating voltage (10 – 30 V) is present.
 The LED illuminates green when the transmitter is switched on and the module receives a valid
signal on its radio frequency.

Dimensions
Technical Data

Max. number of control commands 26 digital (8 via change-over contacts)

or
18 digital (4 via change-over contacts) + 8 analog
Unique system addresses Over 1.000.000 combinations
Supply voltage 10 – 30 V DC
Power consumption max. 10 W
Digital inputs Depending on equipment with input modules
Analog inputs Depending on equipment with input modules
Serial interfaces CANopen, Profibus-DP, RS485, RS232, DeviceNet
E-STOP resp. Si1, Si2 control unit 1 x E-STOP output, high-side switch 10 A
Safety function E-STOP:
Performance Level d, category 3 according to
EN ISO 13849-1:2008
Frequency ranges 308 – 338 MHz, 405 – 475 MHz 1 , 865 – 870 MHz,
902 – 928 MHz, 1210 – 1258 MHz 1
DECT: 1880 – 1900 MHz
1
Not all frequency ranges available.
Channel spacing 12,5 / 20 / 25 / 50 / 250 kHz
DECT: 1,728 MHz
Connection possibilities Harting Han 32
Option: Harting Han 25 or Han 50
Option: cable gland (metric M20/32)
Antenna External, FL 30 or FL 70
Option: offset antenna with 5 m cable and BNC connector
Internal (option DECT)
focus D (option DECT
Operating temperature range -25 °C … +70 °C (-13 °F … +158 °F)
Hazardous areas zone 2: -20 °C … +60 °C (-4 °F … +140°F)
Housing material Plastic
Dimensions 165 x 165 x 115 mm (6.5 x 6.5 x 4.5 ")
Weight ca. 2.6 kg (5.7 lb.)
Protection class IP 65
Dimensions
Receiver Housing HR168
(FSE 726/727 radiobus ® )

Height of housing:
115 mm (4.53 ")
Connection Options

Harting Plug Connections

FSE 510, FSE 511, FSE 512 FSE 516, FSE 524, FSE 726/727/736/737/776/777 radiobus ®

Metric Cable Glands

FSE 510, FSE 511, FSE 512, FSE 516 FSE 524, FSE 726/727/736/737 radiobus ®

PG Cable Gland

FSE 508, FSE 509

Troubleshooting
Note:
Please check the functions using the cabin or cable controls first!
Problem
Transmitter does not react
when switched on.
Low-power indication after
minimal operating time.
Some commands are not
carried out.
If none of the measures mentioned resolve the problem, then please contact your service technician,
dealer or HBC-radiomatic GmbH.
Possible Cause
 No power.
 Battery contacts are
contaminated or damaged.
 Battery not charged.
 Battery defective.
 Receiver defective.
 Interruption in the
connecting cable to the
crane or machine.
Measures
 Check battery contacts for
damage or contamination.
 Insert a fully charged battery
into the battery
compartment.
 Recharge battery.
 Check battery contacts for
damage or contamination.
 Recharge battery.
 Ensure that recharging
process runs correctly.
 Check transmitter functions
using a fully charged or
replacement battery.
 Check if all connecting
cables and cable junctions
are tight.
Maintenance
The radio control system is virtually maintenance-free. Please observe the following points:

 Never use a high pressure cleaner or sharp or pointed objects to clean the receiver.
 Whenever welding the machine:
 Switch off the radio control system.
 Switch off the machine.
 Disconnect all electrical connections to the receiver.
Otherwise the receiver electronics can be destroyed.

In the Event of a Fault

Warning:
Never operate a machine with a faulty or defective radio control system!

 Never try to repair the electronics of the radio control system! Opening the transmitter or receiver
housing terminates the manufacturer guarantee.
 Send any defective or faulty equipment to your local distributor or to the manufacturer. They are
experts and have the necessary know-how and OEM spare parts.
 Always send in the complete radio system (transmitter, receiver, batteries, battery charger,
connection cables, and other equipment) and attach a detailed fault description.
 Do not forget to enclose your address and telephone number so that we can get in touch with
you quickly if necessary.
 To avoid damage during transport, use the original packing supplied with the radio control system,
otherwise pack securely. Send the consignment to your distributor or to the following address:
HBC-radiomatic GmbH
Haller Str. 45 – 53
74564 Crailsheim, Germany
Phone: +49 7951 393-0
Fax: +49 7951 393-50
E-Mail: info@radiomatic.com
 If you wish to bring a defective radio system to your distributor or the factory by yourself, we kindly
ask you to make an appointment in advance.

For an overview of our worldwide service and sales contacts, please visit our website
www.hbc-radiomatic.com under "Contact".
Frequency List for Europe (11/2011)
f-liste-en-2011-v2

RF module with EU-1 RF module with EU-4

433,050 MHz–434,790 MHz 434,040 MHz–434,790 MHz
(100 % duty cycle / 10 mW ERP / (100 % duty cycle / 10 mW ERP /
channel spacing ≤ 25 kHz) channel spacing ≤ 25 kHz)
Austria X
Belgium X
Bosnia and Herzegovina X
Bulgaria X
Croatia X
Cyprus X
Czech Republic X X
Denmark X
Estonia X
Finland X
France X X
Germany X X
Greece X
Hungary X
Iceland X
Ireland X
Italy X
Latvia X X
Liechtenstein X
Lithuania X
Luxembourg X
Macedonia X
Malta X
Montenegro X
Norway X
Poland X
Portugal X
Romania X
Serbia X
Slovakia X
Slovenia X
Spain X
Sweden X
Switzerland X
The Netherlands X X
Turkey X
United Kingdom X

Important note:
Equipment with marking may only be placed on the market in countries marked
with X. Please observe the list with the frequency information indicated on the name
plate of the equipment.

Important note:
Equipment with marking may be placed on the market in all EU member states.
Please observe the frequency information indicated on the name plate of the equipment.
Additional national frequencies available on request.
Copying of this document, and giving it to others and the use or communication of the
contents thereof, are forbidden without express authority. Offenders are liable to the
payment of damages. All rights are reserved in the event of the grant of patent or the

Form Return Delivery Note

HBC-radiomatic GmbH Phone: + 49 (0)7951 393 800

Haller Str. 45 – 53 Transaction No. (provided by HBC): Fax: + 49 (0)7951 393 802
Email: service@radiomatic.com
74564 Crailsheim, Germany ...................................................................... Internet: www.hbc-radiomatic.com

Contact for further information:

registration of a utility model or design.

Contact person: ....................................... …….. Phone: ...................................... Fax: ……………………………….

.......................................................................... Email: ………………………………

Reason for return *):

Repair Estimate required? yes no
Modification
Wrong order customer’s order no.: ..…………………………………………………….
Wrong delivery
For credit corresponding invoice no.: ……............................................ ….….

*) in order to work on your return rapidly, please state precisely the fault report and invoice no.
GMBH

HBC Fabr. No.: .............................. Description of problem:

HBC-radiomatic

Transmitter: ................................... .............................................................................................................

Receiver: ........................................ .............................................................................................................

Charger: ......................................... .............................................................................................................

Batteries: ........................................ .............................................................................................................

Cable: ............................................ .............................................................................................................

Other accessories: ......................... .............................................................................................................

Absolutely necessary information::

Weitergabe sowie Vervielfältigung dieser Unterlage, Verwertung und Mitteilung ihres In-
halts sind nicht gestattet, soweit nicht ausdrücklich zugestanden. Zuwiderhandlungen
verpflichten zu Schadensersatz. Alle Rechte für den Fall der Patentierung oder GM-Ein-

PCB .............................. from system Problem appears: due to vibration / shock

if warm or hot
Fabr. No.: ....................................... if cold
..................................... sometimes commonness: ………………..
..................................... always
..................................... never (in good order, not needed pcb)

Note:

For system repairs, please send (if possible) the complete system including transmitter, receiver, batteries, charger and cable
with detailed description of the problem.

The return is subject to the conditions described in paragraph 8 (Guarantee) in our standard terms & conditions.

Returns will only be accepted CIF Crailsheim, Germany. Preferred shipping via DPD and UPS Standard.
Please use the original HBC packaging if possible. Please use proper packaging to avoid electrostatic discharge hazards with
pcbs and/or modules. Warranty claims may not be accepted in case of improper packaging.
Returns shipped ex works or unpaid will not be accepted without express written consent by HBC.
tragung vorbehalten.

HBC Date: 27.07.2004 Revision: 9

U. Weissmann / G. Brose / A. Hemming Page: 1 of 1
Copying of this document, and giving it to others and the use or communication of the
contents thereof, are forbidden without express authority. Offenders are liable to the
payment of damages. All rights are reserved in the event of the grant of patent or the

Formblatt Rücklieferschein

HBC-radiomatic GmbH Tel.: + 49 (0)7951 393 800

Haller Str. 45 – 53 Vorgangs-Nr. (von HBC vergeben) Fax: + 49 (0)7951 393 802
E-Mail: service@radiomatic.com
74564 Crailsheim …………………………………………………. Internet: www.hbc-radiomatic.com

Kontakt bei Rückfragen

registration of a utility model or design.

Ansprechpartner: ..................................... …….. Telefon: .................................... Fax: ……………………………….

.......................................................................... Email: ………………………………

Grund der Rücklieferung *):

Reparatur Kostenvoranschlag gewünscht? ja nein
Umbau
Falschbestellung zu Bestell-Nr.: …………………………………………………………….
Falschlieferung
zur Gutschrift zu Rechnungs-Nr.: .......................................................................

*) Um Ihre Rücklieferung rasch bearbeiten zu können, geben Sie bitte die Fehlerbeschreibung sowie die Rechnungs-Nr. der Ware an.
GMBH

HBC Fabr. Nr.: ............................... Fehlerbeschreibung:

HBC-radiomatic

Sender: .......................................... .............................................................................................................

Empfänger: .................................... .............................................................................................................

Ladegerät: ...................................... .............................................................................................................

Akkus: ............................................ .............................................................................................................

Anschlusskabel: ............................. .............................................................................................................

Sonstiges Zubehör: ........................ .............................................................................................................

unbedingt auszufüllen::
Weitergabe sowie Vervielfältigung dieser Unterlage, Verwertung und Mitteilung ihres In-
halts sind nicht gestattet, soweit nicht ausdrücklich zugestanden. Zuwiderhandlungen
verpflichten zu Schadensersatz. Alle Rechte für den Fall der Patentierung oder GM-Ein-

Platine........................... aus System Mangel tritt auf: bei Erschütterung

bei Wärme
mit Fabr. Nr.: .................................. bei Kälte
manchmal Häufigkeit: ..............................
immer
nie (intakte, nicht benötigte Platine)

Hinweis:

Bitte senden Sie bei System-Reparaturen möglichst das komplette System zurück - inkl. Sender, Empfänger, Akkus, Ladege-
rät und eventuell Anschlusskabel mit einer detaillierten Fehlerbeschreibung.

Die Rücksendung erfolgt unter Beachtung der in Ziffer 8 (Gewährleistung) unserer Allgemeinen Geschäftsbedingungen enthal-
tenen Bestimmungen.

Bitte liefern Sie die Ware frei Haus an uns zurück! Bevorzugte Speditionen: DPD und UPS Standard. Verwenden Sie mög-
lichst die original HBC Umverpackung für die Rücklieferung. Für elektronische Bauteile und/oder Platinen ist eine ESD-Schutz-
Verpackung zu verwenden. Garantieansprüche können bei Fehlen der ESD-Schutz-Verpackung erlöschen.
Anlieferungen „unfrei“ ohne vorherige schriftliche Freigabe durch HBC werden nicht akzeptiert.
tragung vorbehalten.

HBC Erstellt am: 27.07.2004 Revision: 9

Von: U. Weissmann / G. Brose / A. Hemming Seite: 1 von 1