Operating manual wireless hand wheel HBG 220-RF 220_R011_E.pdf · Operating manual HBG 220-RF Rev....

Operating manual HBG 220-RF Rev. 1.2 - 02/12 Hubitron Steuerungstechnik

Hubitron Steuerungstechnik, Hauptstr. 4/1, D-89611 Obermarchtal, Tel. +49(0)7375/922066, FAX +49(0)7375/922077 page 1 of 13

Operating manual wireless hand wheel HBG 220-RF

Contents

1. Description ................................................... 2

2. Technical Data.............................................. 22.1 Hand terminal HBG220-RF ........................... 22.2 Access point HBG 220-AP............................. 22.3 Charging station ............................................ 22.4 System timing................................................ 2

2.4.1 Emergency stop + safety buttons ............ 22.4.2 Digital outputs ....................................... 22.4.3 Analogue output..................................... 2

3. Scope of supply............................................ 2

4. Machine demands ........................................ 2

5. Environmental conditions............................ 25.1 Kind of conditions ......................................... 25.2 Tolerance range ............................................. 2

6. Operating elements...................................... 36.1 Hand terminal HBG 220-RF .......................... 36.2 Access point HBG 220-AP............................. 36.3 Charging station ............................................ 3

7. Installation .................................................... 47.1 Out of operation............................................. 4

8. Operation ...................................................... 48.1 ON / OFF of the hand terminal....................... 48.2 Safety Buttons ............................................... 48.3 LCD display .................................................. 4

9. Setup............................................................. 59.1 Used buttons.................................................. 59.2 Enter set up ................................................... 59.3 Change set up ................................................ 59.4 Description of the menue points ..................... 59.5 Test routines.................................................. 59.6 Set up overview............................................. 6

10. Start operation ............................................. 710.1 Channel selection........................................... 7

10.1.1 Field strength measurement .................... 710.2 Set transmitting power ................................... 710.3 Set minimum level ......................................... 7

11. Actions to avoid interruptions..................... 7

12. Error solutions ............................................. 812.1 Possible errors ............................................... 812.2 Cause of errors............................................... 812.3 LOW - BATT display .................................... 812.4 No function.................................................... 8

13. Maintenance and care.................................. 813.1 Change of rechargeable batteries .................... 9

13.1.1 Exchange of rechargeable batteries ......... 9

14. Frequency table............................................ 9

15. Safety instructions..................................... 10

16. LED's in the Access point.......................... 10

17. Spare parts ................................................. 11

18. EG Declaration of Conformity.................... 12

19 Connecting diagram................................... 13



1. DescriptionThe radio wave hand wheel HBG 220-RF isdesigned for wireless control of CNC machines. Ithas a number of outputs to control the mainfunctions of a CNC machine such as buttons for axisselection, axis movement, hand wheel, overridepotentiometer. The selected values are displayed ina LCD display.The safety functions (emergency stop + safetybutton) fulfil the safety category 3 EN954-1.The system is exclusively designed foroperation within the European market! Othermarkets require a written approval of themanufacturer!

2. Technical Data

2.1 Hand terminal HBG220-RFDimensions (l x w x h)...............approx. 180x105x80Weight.................................................approx. 400gPower supply.......... 3 x NiMh rechargeable batteriesDisplay ...........................................LCD, 2 x 8 digitsOperating elements ...................................9 buttons....................................................... 2 safety buttons..........................................1 emergency stop button.......................................................1 rotary encoder........................................................ 1 potentiometerOperating time.........................................> 10 hoursFrequency band..................................433 (SRD 1e)Channels ............................................................. 17RF power.............................................. max. 10mWRange...............................approx. 25 m (adjustable)Vibration alarm ...................................................yes

2.2 Access point HBG 220-APDimensions (l x w x h)...............approx. 200x120x60Weight.................................................approx. 550gPower supply...................................24VDC +/- 10%Current ................................................max. 420 mAInterface ...................... 1 x RS232 TTL (output only)Outputs............ 2 x emergency stops, ea. 3A, AC-15.....................................1 x safety button, 2A, AC-15....................... 1 analogue output 0 – 5 V or 0 – 10V......... 1 charging output for hand terminal 20/200mA............................... 10 x digital outputs 24V/100 mA............................... 1 x hand terminal output RS422Inputs ........2 x emergency stops for charging stationFrequency band......................................... 433 MHzChannels ............................................................. 17RF power.............................................. max. 10mWRange...............................approx. 25 m (adjustable)

2.3 Charging stationDimensions (l x w x h).................approx. 150x95x50Weight.................................................approx. 100gContacts ................................................................ 4

2.4 System timing

2.4.1 Emergency stop + safety buttonsmin. 30,2 msmax. 155 msaverage reaction: approx. 35 ms

2.4.2 Digital outputsmin. 28 msmax. 143 msaverage reaction : approx. 30 ms

2.4.3 Analogue outputmin. 28 msmax. 143 msaverage reaction : 30 ms

The power range of Access point is set withthe jumper:1+2: 0 – 10V2+3: 0 – 5V

3. Scope of supply1 Hand terminal HBG 220-RF1 Access point HBG 220-AP1 Charging station with cable 2m1 Antenna1 Mounting set

4. Machine demandso An emergency stop must be stored at the

machine control if the emergency stop relayshows different levels.

o An emergency stop must be confirmed at themachine control.

o The power supply has to comply with EN 50178and IEC 742 (safe interruption from the poweroutlet, protection of over voltage, PELV), this isgiven on the Heidenhain interface.

o A machine movement directed by the handwheel is only allowed, if both safety buttons arepushed and have been opened before!

o A hard wired emergency off on the machine isimperative!

5. Environmental conditions

5.1 Kind of conditionsThe wireless hand wheel is exclusively constructedfor the operation in closed plants. Direct sun lightrays are harmful and can cause damage.The protection classification rating is IP 64.

5.2 Tolerance rangeOperating temperatur: +5° to +45°CStorage temperatur: -20° to +70°CMax. humidity: 90%, no condensation



6. Operating elements

6.1 Hand terminal HBG 220-RF

9

1

2

3

M4

5

3

87

6

1 Emergency stop button2 Potentiometer3 Safety button4 Feed setting5 Axis movement buttons6 Axis selection buttons7 Free programmable function buttons8 LCD display9 Rotary encoder

M Magnet to disconnect accus for transportsor when not in use for longer period

On the backside is a magnet with hook, chargingcontacts and the label.

6.2 Access point HBG 220-AP10

1112

10 Antenna socket11 Cable fitting PG 16 for connecting cable12 Cable fitting PG 7 for charging station

6.3 Charging station13

14

15

16

14

13 Connecting cable14 Mounting holes Ø 5,5 mm15 Emergency stop contacts16 Charging contacts



7. InstallationMachine must be turned off before installation!

o Mount the charging station on a suitable andeasy accessable location onto the 3 mountingholes (14). The cable connector is on top. Ifneeded use the supplied mounting angle. Do notbend the charging station!

o Install the Access point on the machine controlpanel, preferably above the control panel. Openthe lid, beneath are 4 mounting holes for M4screws for mounting (hole distance: 188 x 88mm). The connector for the antenna (10) must beon top.

o Lead the cable of the charging station throughthe cable fitting (12) and connect with clamp X2with the Access point. The numbering of thecable must be aligned with the clamp numbers.

o Screw the antenna into the antenna socket (10).o Lead the machine connecting cable through the

cable fitting (11). Connect in accordance with theconnecting diagram attached. The cable must bea shielded cable with min. 0,34² (24 x 0,34²).

o Tiden the cable fitting.o Remove sticker ("remove before use") with

magnet from the hand terminal.

Mounting positions:

��

��

Attention!On machines with only one emergency stop circuitboth emergency stop contacts of the HBG 220-RFmust be connected in series!

7.1 Out of operationIs the hand wheel cut off from the supply voltage fora longer time period, it is very important to attach themagnet with an adhesive tape to the hand terminal.The magnet causes an internal reed contact todisconnect the supply voltage, this avoids damageto the accus.For correct placement:- Push and hold safety buttons – LED's are on.- Run with the magnet over the right side of the

hand terminal in height of the housing slits untilthe LED's turn off.

- Fix the magnet in this position with adhesivetape.

- Push the safety buttons again, if LED's are off,the magnet is installed correctly.

8. Operation

8.1 ON / OFF of the hand terminalThe hand terminal is switched on with one of thesafety buttons (3).The connection builds up after both safetybuttons are released again!

The switching off is possible in two ways:1. push the emergency stop2. return the hand terminal to the charging

station

Remark:To avoid an accidental emergency stop the handterminal has to be turned on with the safety buttonsbefore you take it out of the charging station! To dothis, simply push one of the safety buttons andrelease again.

After enabling the hand terminal on the machinecontrol the wireless hand wheel is ready to beoperated.

8.2 Safety ButtonsThe Safety output will only output a signal if thesafety buttons will be pressed at the same time.Time shifted pressing will give no output!

8.3 LCD displayOn the 2 line LCD error codes, warnings, axisinformation, potentiometer and axis position aredisplayed.



9. Setup

9.1 Used buttonsFor the Set up the following buttons are used:

1

6

5

4

1

3

2

1 Safety buttons (to switch on)2 Enable set up3 Enter4 Change values5 Change letters6 Exit set up

9.2 Enter set upIf you enter the set up, the communication with themachine is interrupted. This causes an emergencystop!

1 Turn off hand terminal with the emergency stopbutton. Pull emergency stop button!

2 Push and hold both buttons (2)3 Turn on the hand terminal with a quick push on

the safety buttons (1)

The display must show: SETUPPower

9.3 Change set upIn the set up the following menue points can beselected:Menue Description Setting rangePower Transmitting power 0 – 7Kanal Channel setting 0 – 16Range Range setting 20 – 60Achse Number of axis 1 - 7Name A4 Name axis 4Name A5 Name axis 5Name A6 Name axis 6Name A7 Name axis 7Pot N Name

potentiometerVS N Name feedPmax Max. potentiometer

value1 – 255

Pulse Encoder resolution 1 - 4Test-Nr Help functions 0 – 8o Start set up menue as described in 9.2o Select menue point with buttons +/- (4)o Enter menue point with button F1 (3)o Change value with buttons +/- (4)o Confirm selection with button F1 (3)o Exit set up with button F3 (6)

To change names select a letter with buttons (5) andgo to the next letter with button

When changing the channel be sure that the Accesspoint is turned on and within range!

9.4 Description of the menue pointsPower RF transmitting power

Kanal ChannelRange Level to activate vibration alarm

(high value -> large range)

Achse Number of available axisName Ax Name of the axis

Pot N Name of the potentiometer (pic. F)VS N Name of the feed (pic. I)

Pmax Max. value of the potentiometer

Pulse Resolution of the encoderTest-Nr: Test routines and enabling of additional

options

9.5 Test routinesThe following test routines are integrated:

0 No test, regular operation

1 Measurement of the receiving field strength inoperation, Access point must be running

2 Autom. search of the selected channel inAccess point. The hand terminal is searchingall channels and reports the programmedchannel on the display.Remark: The operation of other wirelesshand wheels may be disrupted temporarily!

3 Display of the battery power level, Access pointmust be running.

4 Display of the software version, Access pointmust be running.

5 Autom. field strength measurement to searchfor an available channel. All channels will bescanned continuously. To stop function pushbutton F1 (3). The display shows 6 favouritechannels, the best in the upper left the worst inthe lower right.

6 Manual field strength measurement to searchfor an available channel. The channel can bechanged with buttons +/-.

7 Transmitting test for service.

8 Enabling additional options.



9.6 Set up overview



10. Start operation

10.1 Channel selectionThe wireless hand wheel HBG 220-RF offers achoice of 17 channels.

Upon delivery channel 0 is set.

To select a suitable channel please acknowledgethe following:

1 Are there further hand wheels or other unitsnearby working in the ISM band 433 MHz ?

2 If yes, with what frequencies do they workexactly?

3 If other wireless hand wheels are in use, theused channel should possibly be on a differentfrequency band or otherwise the channelseparation should be at least 3 channels (i.e.channel 4 + channel 7).

4 If machines are located side by side the channelseparation should be at least 5 channels (themore the better).

Compare the frequencies of other units with thefrequency listing attached and choose only onesetting which is at least 250 kHz away from thetransmitting frequency of the adjoining units!

10.1.1 Field strength measurementTo search for a free channel a measuring routine isintegrated in the hand terminal:

o Switch on all existing wireless units (measuringsensor, crane controll systems, etc..)

o Enter hand terminal set up (see 9.2)o Set menue point „Test-Nr“ to 5 (see 9.4)o Exit set up to run routine

Now the hand terminal scanns continuously allchannels until the routine is stopped with button F1(3). The available channels show on the display, thebest on the upper left, the worst on the lower right.

Alternatively the channels can be scanned manuallywith test routine 6. The channels can be changedwith the buttons +/-.The maximum value can be reset with button F1 (3).

With the hand terminal walk up the operating range.The maximum value should remain < 25! If this isnot the case, repeat the measurement using adifferent channel.When selecting a channel please note the additionalpoints described under 10.1!

If you have found a suitable channel, inform theAccess point of this channel accordingly:

o Change to the new channel on the hand terminal.While exiting the set up in the hand terminal thenew parameters will be transmitted to the Accesspoint. The connection is interrupted and must bestarted again afterwards.

10.2 Set transmitting powerActivate the test function 1 in the hand terminal.Now the display shows the actual receiving fieldstrength and the minimum field strength.With the hand terminal walk up the operating range.Is the minimum value < 30, the transmitting powermust be increased. With a value of > 45 the powershould be decreased.

10.3 Set minimum levelThe BG Institute demands a limitation in workingrange. Therefore, a range value must be defined. Ifthe range value is violated, the vibration alarm setsoff and delays the forced shut off of the machine(emergency stop).Activate test routine 1 in the hand terminal anddetermine the minimum value outside the operatingrange.

Range value = 70 – minimum level

Suggested range value 35 - 45.

11. Actions to avoid interruptions1. The hand terminal must be turned on before

taking it out of the charging station.2. During the loading of work pieces and during

tasks where a hand wheel is not required,return the hand terminal to the charging station.

3. Do not put larger objects into your way thatblock your direct visible contact between thehand terminal and the Access point.

4. When the vibration alarm sets off, change yourposition quickly. Most of the time a slight turn issufficient.

5. Avoid the use of wireless crane controllsystems near the Access point or handterminal.

6. Clean the loading contacts on the chargingstation and the hand terminal regularly.



12. Error solutions

12.1 Possible errorsIf an error occurs in the Access point, the error codeis displayed on the hand terminal:

Error 001 wrong positioning of the emergencystop relay

Error 002 wrong positioning of the safety relayError 004 emergency stop due to disconnec-

tionError 008 discrepancy between the two

controllersError 016 24V supply is missing or defect in

charging electronicKeyboard Err failing button or a button was

pressed during turn on of the handterminal.

If several errors occur at the same time, the sum oferror codes is displayed, i.e. error 002 and error004, the display will read error 006!

12.2 Cause of errorsError 1 and 2 indicate problems with the hardware inthe Access point. Should this happen frequently -call for service.

Error 4 indicates a radio wave interruption.The following steps can assist:

- increase transmitting power- increase range setting- change channel

Error 8 is a discrepancy in the transmitting protocolcaused either by the Access point or the handterminal - call for service.

Error 16 points out a missing supply of the chargingcontrol - required is +24V +/- 10%.

If during operation (hand terminal on) frequentemergency stops occur without error code, thecause can be an integrated exit control in theAccess point – call for service!

An emergency stop while the hand terminal is in thecharging station can be caused by dirty loadingcontacts or the emergency stop button is defect.

If no connection is possible, there might be adefective internal fuse on the Access point (fine fuse5 x 20, 0,5AT).

12.3 LOW - BATT displayIf during operation the LOW - BATT is displayed,return the hand terminal to the charging station!Further operation is possible for approx. 1 hourbefore the hand terminal shuts down and causes anemergency stop.

12.4 No functionThe following possibilities have to be evaluated:

1. The hand terminal cannot build up aconnection to the Access point

- Check the cable- Check internal fuse in the Access point (fine

fuse 5 x 20, 2AT)- Check LED's in the accesspoint (see Cap. 16)- Check channel setting

Run test routine 2 (autom search for Accesspoint)

- Compare the serial number of Access pointand hand terminal (they must be the same!)

- Check rechargeable batteries in the handterminal

2. Machine does not react

- Confirm error codes on the machine control- Turn on power of the control

13. Maintenance and careFor a continuous and safe operation the followingpoints need to be attended regularly:

- Clean the hand terminal monthly from any dirt,wipe off coolant residues and other fluidsimmediately.

- Clean the charging contacts on the chargingstation and the hand terminal monthly, i.e. withspirit (Danger: be careful with flammablefluids).

- Always clean the magnet on the hand terminalfrom swarf or splinters before returning it to thecharging station!

- Once a month run the batteries from the handterminal down without charging to LOW-BATT -this increases the strength of the batterycharge.

- Change rechargeable batteries every 2 years.- Check the emergency stop monthly!-



13.1 Change of rechargeablebatteriesThe batteries should be preventatively changedevery 2 years. Only use NiMh-rechargeablebatteries type Micro (size AAA) with a capacity ofmin. 800mAh.

Suggested types:

Manufacturer CapacityGP 850 mAhPanasonic 800 mAhSanyo 800 mAh

13.1.1 Exchange of rechargeable batteries

- Push the emergency stop on the hand terminal.- Unscrew the 6 screws S of the housing.

S S

S

S

S

S

- Lift housing cover carefully and put on top.

- Exchange the 3 batteries, ensure correctpolarisation!

- Assemble unit vice versa.- Return the hand terminal to the charging

station to load the batteries.

Remark:In accordance with the battery regulations dated.01.10.98 old batteries & rechargeable batteries musteither be returned to the store or given to acommunal collecting place. They are not allowed tobe discarded in regular garbage!

14. Frequency table

Channel no. Frequency (MHz)0 433,151 433,252 433,353 433,454 433,555 433,656 433,757 433,858 433,959 434,05

10 434,1511 434,2512 434,3513 434,4514 434,5515 434,6516 434,73



15. Safety instructions- Before making changes on the machine or the

hand terminal make sure there is no voltage! Onthe hand terminal the emergency stop must bepressed.

- Self made reconstructions or other changes on theunit cause an immediate expiration of themanufacturers declaration and warranty. There isno liability for any damage caused!

- The end user of the superior working unit isresponsible to comply in each individualapplication with the national and internationalsafety and accident regulations.

- During the machine planning and the use of amanual unit the valid specific national andinternational safety and accident regulations haveto be followed, i.e.

EN 60204, Electronic equipment of machines

EN 292, Safety of machines

EN 954, Safety relevant parts of controls

- A machine movement through the hand wheel isonly allowed if both safety buttons are pressed!

- It is not allowed to give orders causing dangeroussituations with the safety buttons only. A seconddeliberate start up command is required.

- When handling the hand wheel injuries can becaused through the strong pull of the magnet.Keep a safe distance with a pace maker, magneticdata supports (loss of data), electrical andelectronic units.

- The operator of the hand wheel must always havea clear view to the tool and the work piece.

- „Remote controls“ from a large distance are notpermitted. There is no liability for any damagecaused.

- Always return the hand terminal to the chargingstation when the machine is working in automaticoperation!

- On machines with only one emergency stopcircuit both emergency stop contacts HBG220-RF have to be connected in series

16. LED's in the Access pointIn the Access point each digital output has a LED toshow the status. The output relays are alsoequipped with LED’s. In addition 3 LED’s areintegrated for the operating status:

LED

1LE

D 2

LED

3

Safety Relay

Emergency Relay 1

Emergency Relay 2

Fuse 0,5AT

Jum

per

1 2

3

X1

X2

1

2

3

41

2

4

LED1: Ready status / operationLED2: TransmittingLED3: Hand terminal in charging station

blinking: fast charge

With the jumper select the source of the outputpower range of the analogue output:

1+2 0 – 10V2+3 0 – 5V

In general the jumper is set on 2 + 3



17. Spare parts

1

2

3

4

5a

5b

7

6

1 Emergency stop button2 Potentiometer HBG 220-RF3 Front foil HBG 220-RF4 Magnet for disconnecting

accus5a Rotary encoder5b Rotary knob6 Safety button7 Magnetic clamp with hook

8

9

10

8 Antenna 433 MHz9 Accesspoint10 Charging station HBG 220-RF



18. EG Declaration of Conformity(Article 4 § 2 EG Regulation 2006/42/EC)

02.01.2012Manufacturer: Hubitron Steuerungstechnik

Hauptstr. 4/189611 ObermarchtalGermany

Product: Wireless hand wheel HBG 220-RFcontaining: Hand terminal HBG 220-RF

Access point HBG 220-APCharging station HBG 220-RF

The described product is exclusively an attachment to a superior control. The operation is prohibited as long asthe conformity of the end product with regulation 2006/42/EC is not ascertained.

We confirm the conformity of the above described product with

Low voltage regulation 73/23/EWGAs well as: EMV regulations 89/336/EWG.

Especially: EN 50081-2, EN 50082-2 and EN 61326-3 if applicable.IEC 61326-3EN 13849-1, PL c (safety buttons + emergency stop)EN 300 220, EN 301 489-1, -3, EN 60950EN 61508-2 and EN 61508-3 (if applicable).

Issuer: Hubitron Steuerungstechnik

Place, date: Obermarchtal, 02.01.2012

Signature: ( Werner Huber )

This declaration does not include any guarantee of property rights.

Hubitron SteuerungstechnikHauptstr. 4/189611 ObermarchtalTel. 07375/92 20 66Fax 07375/92 20 77Mobil: 0178/2310073Werner HubereMail: [email protected]



19 Connecting diagram

Operating manual wireless hand wheel HBG 220-RF 220_R011_E.pdf · Operating manual HBG 220-RF Rev....

Documents

Transcript of Operating manual wireless hand wheel HBG 220-RF 220_R011_E.pdf · Operating manual HBG 220-RF Rev....