OOPMN_LNO__009 April 2015

LOCOMOTIVE

OPERATING INSTRUCTIONS

LOCOMOTIVE SYSTEM

www.hetronic.com

LOCAL BUT GLOBAL

1

TABLE OF CONTENTS

SAFETY ................................................................................................................................................................ 4

SAFETY ALERTS ............................................................................................................................................ 4

NOTATIONS .................................................................................................................................................... 4

PRACTICES AND LAWS ................................................................................................................................. 4

REQUIRED OPERATOR TRAINING ............................................................................................................... 4

POSSIBLE SOURCES OF DANGER .............................................................................................................. 4

PROTECTIVE FEATURES .............................................................................................................................. 4

TO STOP IN AN EMERGENCY ...................................................................................................................... 4

MAINTENANCE ............................................................................................................................................... 4

DRAWINGS AND OPERATION GUIDE .......................................................................................................... 4

INTRODUCTION .................................................................................................................................................. 5

YOUR MANUALS ............................................................................................................................................ 5

PRODUCTION AND SYSTEM NUMBERS ..................................................................................................... 5

BEFORE OPERATING YOUR SYSTEM ......................................................................................................... 5

INSTALLATION CONSIDERATIONS .................................................................................................................. 6

COMPONENTS .................................................................................................................................................... 7

LOCOMOTIVE PNEUMATIC PANEL (H0-00133) ........................................................................................... 7

LOCOMOTIVE LCD PANEL (H0-00133) ......................................................................................................... 7

LOCOMOTIVE ISOLATION PANEL (H0-00132) ............................................................................................. 8

ISOLATION CONNECTION ............................................................................................................................. 8

JUMPER CABLE (H9-00769) .......................................................................................................................... 8

ESTOP JUMPER (H9-00644) .......................................................................................................................... 8

MU MOUNTING EQUIPMENT......................................................................................................................... 8

MU Cable (H9-00734) .................................................................................................................................. 8

Main Reservoir (K18009) – L Gladhand ...................................................................................................... 8

Train Brake (K18019) – F Gladhand............................................................................................................ 8

Independent & AP Brake (K18008) – H Gladhand ...................................................................................... 9

Pneumatic Horn (K18010)................................................................................................................................ 9

Electric Bell (K18138) ....................................................................................................................................... 9

REMOTE ESTOPS (HL0001) .......................................................................................................................... 9

REMOTE SPEED SENSOR (HL0004) ............................................................................................................ 9

MAST (HL0002) ............................................................................................................................................... 9

UPRIGHT ANTENNAS (K18064) ...................................................................................................................... 9

OPTIONAL EXTERNAL ANTENNAS (K18125) .............................................................................................. 9

2

CHANGING YOUR BATTERY ........................................................................................................................... 11

DISPOSABLE BATTERIES: ...................................................................................................................... 11

RECHARGEABLE BATTERIES (68108580.A): ........................................................................................ 11

RECHARGING YOUR BATTERIES (OPTIONAL)......................................................................................... 11

FAST CHARGE ......................................................................................................................................... 11

BATTERY DISPOSAL .................................................................................................................................... 12

OPERATING YOUR TRANSMITTER ................................................................................................................ 13

TRANSMITTER .............................................................................................................................................. 13

READ THIS FIRST ......................................................................................................................................... 13

YOUR OPERATING RANGE ......................................................................................................................... 13

HOLDING YOUR TRANSMITTER ................................................................................................................. 13

VISUALLY CHECKING YOUR TRANSMITTER ............................................................................................ 13

CHECKING HOSES AND THE CONNECTION ............................................................................................ 13

STARTING YOUR TRANSMITTER ............................................................................................................... 14

STOPPING YOUR TRANSMITTER .............................................................................................................. 14

SAFETY FEATURES ..................................................................................................................................... 14

LOW BATTERY INDICATOR .................................................................................................................... 14

VIGILANCE (RADIO CONTROL SYSTEM or RCS) S2 and S3 ............................................................... 14

TILT ALARM .............................................................................................................................................. 15

PUSH TO OPERATE THROTTLE (PTO) - Optional ................................................................................. 15

OPERATING THE TRAIN .............................................................................................................................. 15

RELEASING THE BRAKES ...................................................................................................................... 15

SELECTING DIRECTION .......................................................................................................................... 15

SAFE MODE CONSIDERATIONS ................................................................................................................ 15

AUTOMATIC SAFE MODE ACTIONS ...................................................................................................... 15

EXITING SAFE MODE .............................................................................................................................. 15

ENGAGING THE THROTTLE (S12) ......................................................................................................... 15

OPERATING THE TRAIN BRAKES .......................................................................................................... 16

OPERATING THE INDEPENDENT BRAKES (LOCOMOTIVE) ............................................................... 16

CHANGING DIRECTION ........................................................................................................................... 16

ADDITIONAL FUNCTIONS (OPTIONAL) ...................................................................................................... 16

SAND FUNCTION (S4) ............................................................................................................................. 16

BELL FUNCTION (S7) ............................................................................................................................... 16

HORN FUNCTION (S5) ............................................................................................................................. 16

PITCH and CATCH .................................................................................................................................... 16

SPEED CONTROL .................................................................................................................................... 16

INCREASE SPEED ................................................................................................................................... 16

3

INCREASE SPEED AGAIN ....................................................................................................................... 16

REDUCE SPEED ...................................................................................................................................... 16

COAST ....................................................................................................................................................... 17

ROLL BACK PROTECTION .......................................................................................................................... 18

DATA LOGGING (option) ............................................................................................................................... 18

GPS and/or GSM (option) .............................................................................................................................. 18

VIDEO (option) ............................................................................................................................................... 18

LCD, LED AND OPTIONAL RECEIVER DISPLAY INDICATOR MEANINGS .............................................. 19

Table 1: LCD Indicators and Meanings ..................................................................................................... 19

Table 2: Typical LED Indicator Meanings .................................................................................................. 19

Table 3: Receiver Graphic Display ............................................................................................................ 20

TROUBLESHOOTING ....................................................................................................................................... 22

MAINTENANCE ................................................................................................................................................. 23

PNEUMATIC FILTERS .............................................................................................................................. 23

MAIN RESERVOIR FILTER (AFF-EL11B) ................................................................................................ 23

MIST REMOVER FILTER (AF30P-060S) ................................................................................................ 23

PILOT FILTER (AFM30P-060AS).............................................................................................................. 23

Changing Filters ............................................................................................................................................. 23

SPECIFICATIONS .............................................................................................................................................. 23

SPECIFICATIONS FOR ALL MODELS ......................................................................................................... 23

WEIGHT, DIMENSIONS AND TRANSMITTER OPTIONS PER MODEL ..................................................... 24

4

SAFETY

SAFETY ALERTS

The safety alert symbol is used in decals on the unit

and with proper operation procedures in this manual.

Understand the safety message. It contains

important information about personal safety on or

near the unit.

DANGER: IMMINENTLY HAZARDOUS SITUATION! If not avoided, WILL RESULT in death or serious injury. DANGER: POTENTIALLY HAZARDOUS SITUATION! If not avoided, COULD RESULT in death or serious injury.

DANGER: POTENTIALLY HAZARDOUS SITUATION! If not avoided, MAY RESULT in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTATIONS

NOTE: General reference information for proper

operation and maintenance practices.

IMPORTANT: Specific procedures or information

required to prevent damage to unit or attachment.

PRACTICES AND LAWS

Practice usual and customary safe working

precautions for the benefit of yourself and others.

Be alert to unsafe conditions and the possibility of

minor, moderate, or serious injury or death. Learn

applicable rules and laws in your area.

REQUIRED OPERATOR TRAINING

Original purchaser of this unit was instructed by the

seller on safe and proper operation. If unit is to be

used by someone other than original purchaser;

loaned, rented or sold, ALWAYS provide this manual

and any needed safety training before operation.

ALWAYS read and understand the documentation

for any machine to be controlled by radio remote

control.

POSSIBLE SOURCES OF DANGER

This device is part of a system that makes remote

control via radio signals possible. However, the

transmission of control commands can take place

around obstacles and out of the operator’s direct

sight. Take the following precautions to prevent

accidental start-up and possible injury or damage: 1. Switch “OFF” the transmitter when it is not in

use. If equipped, remove the key if the unit is

placed any distance away from the operator.

2. Disconnect the power supply from the receiver before any assembly, maintenance or repair work is done.

IMPORTANT: AVOID SYSTEM DAMAGE - ALWAYS disconnect receiver power supply and control wiring before welding on any part of the machine.

3. NEVER remove or alter any of the safety

features.

4. ALWAYS confirm that the machine and

radio remote control Stop functions work

properly BEFORE beginning any machine

operation.

PROTECTIVE FEATURES

This system is equipped with electronic and

mechanical safety features. Control signals from

other transmitters cannot be processed because

transmission coding is unique to each system

TO STOP IN AN EMERGENCY

Push the emergency stop on the machine.

MAINTENANCE

ALWAYS shut off power to the machine, transmitter

and receiver before any assembly, maintenance or

repair.

DRAWINGS AND OPERATION GUIDE

ALWAYS refer to your system drawing and

Operational Guide if you have specific questions on

how your system should operate. This manual is

intended only as a supplement to your system

drawings for reference. Your system may be

customized for your specific application.

5

INTRODUCTION

Thank you for purchasing the Hetronic radio remote

control system. Hetronic radio remote controls

provide outstanding remote control value, quality,

performance, and safety.

YOUR MANUALS

Before operating your machine and radio remote

control system, review your drawings and read and

understand the manuals for all of your system

components.

PRODUCTION AND SYSTEM NUMBERS

Before contacting your dealer or Hetronic about

service, repair or replacement parts, note the

equipment Production and System numbers. These

numbers are located on the label affixed to the unit.

BEFORE OPERATING YOUR SYSTEM

Confirm that installation of all your system

components has been properly completed.

Before start up, ALWAYS confirm that the machine

and radio remote control Stop functions work

properly. Understand all Safety Precautions provided in the

manuals and review control functions and operation

of the machine and this radio remote control system. When not in use, turn the transmitter off and store in

a safe place to prevent unauthorized use. If the machine does not respond properly,

immediately stop operation, turn off the transmitter

and report the condition to your supervisor. Turn off the transmitter and remove the key (if so

equipped) before any maintenance work is done. Always have fresh batteries on hand or an optional

rechargeable battery pack in the battery charger to

ensure the availability of a fully charged battery. Installation, setup and service must be performed by

authorized and qualified personnel only.

6

INSTALLATION CONSIDERATIONS

Read and understand the following considerations

to ensure the proper installation of your system:

• Isolate the radio control system from the

locomotive when operating in manual

mode.

• The relays in the radio control system are

rated for up to 5 amps unless otherwise

specified. We have an optional relay

intended to operate (turn on) the lights.

Please check your drawings to ensure this

was included on your order.

• When installing the antennas always touch

the ends of the antenna and connector at

the same time with your fingers to remove

any static charge.

• The system must have the antennas

installed on the receiver and transmitter

prior to turning the system on. Operating

the system without antennas will damage

the system over time.

• Depending on the locomotive condition,

please determine the need for isolation

(surge suppression) to protect our radio

control system. If necessary, please

contact the factory for parts.

7

COMPONENTS

Use the following as guidelines; always refer to your drawings for your specific system. The components

described in this section pertain to an MU installation system with isolation and a mast antenna. We are using

this system as a reference. Other systems may have different components and/or configurations. Again,

please refer to your drawings for your specific system as it may be different.

LOCOMOTIVE PNEUMATIC PANEL (H0-00133) This is not applicable for all other versions of locomotive panels. This panel provides all pneumatic control for the locomotive. There is a program (diagnostic) port (X3) for remote connection, programming updates and troubleshooting.

LOCOMOTIVE LCD PANEL (H0-00133) This is not applicable for all other versions of locomotive panels. This panel provides the electrical connection to the locomotive.

8

LOCOMOTIVE ISOLATION PANEL (H0-00132) This is not applicable for all other versions of locomotive panels. The isolation panel provides fusing for all external voltages from the locomotive. If a fuse or breaker has been overloaded, the locomotive LCD panel will display the error “FUSE”.

ISOLATION CONNECTION

This connects X12 to the locomotive LCD panel X5.

It also connects X11 to the locomotive pneumatic

panel’s X2. The ESTOP jumper (H9-00644) is

connected to X1. The MU cable (H9-00734) is

connected to X6.

JUMPER CABLE (H9-00769) This connects the locomotive pneumatic panel X1

with the locomotive LCD panel X4.

ESTOP JUMPER (H9-00644) This is connected to the Isolation panel’s X1.

MU MOUNTING EQUIPMENT

The Hetronic mounting equipment described is for H12-00344 only. Locomotives vary widely and Hetronic cannot guaranty the locomotive’s configuration. All locomotive documentation and procedures supersede information in this document.

MU CABLE (H9-00734)

This cable connects to the isolation panel’s X6 connector and the locomotive’s MU plug.

MAIN RESERVOIR (K18009) – L GLADHAND

Connects to locomotive pneumatic panel’s “MAIN”

and the locomotive main reservoir.

TRAIN BRAKE (K18019) – F GLADHAND

Connects to locomotive pneumatic panel’s “TRAIN

BK” and the locomotive train brake

9

INDEPENDENT & AP BRAKE (K18008) – H GLADHAND

This Connects to locomotive pneumatic panel

connection “IND BK” & “ACTUATING PIPE” and the

corresponding independent brake and actuating

pipe.

PNEUMATIC HORN (K18010) The horn is utilized when a man-down is present or when it is manually activated by the operator. It connects to the locomotive pneumatic panel’s pneumatic connection “HORN”.

ELECTRIC BELL (K18138) The bell is activated when locomotive motion is commanded or when it is manually activated by the operator. It connects to the locomotive pneumatic panel electrical connection X4.

REMOTE ESTOPS (HL0001) The remote estops provide a junction for the remote speed sensor, Estop and direction selection. The estops connect to the locomotive LCD panel at X1 & X2. The direction switch should always be switched to the direction of the locomotive pneumatic panel.

REMOTE SPEED SENSOR (HL0004) The remote speed sensor provides closed loop feedback to the locomotive LCD panel. X2. The direction switch should always be switched to the direction of the locomotive pneumatic panel.

MAST (HL0002) This is not applicable for all other versions. The mast provides additional range and clearance of antenna cables on the locomotive. The system requires external antennas for operation. Please refer to your drawing for assembly.

UPRIGHT ANTENNAS (K18064)

These are upright antennas that mount on the mast. They connect to the locomotive pneumatic panel at W1 and W2. The antennas are interchangeable. For a picture, see mast (HL0002).

OPTIONAL EXTERNAL ANTENNAS

(K18125) These are magnetic mount antennas that should be placed a minimum of five feet apart and as high as possible. The two antennas connect to the locomotive pneumatic panel at W1 and W2. The antennas are interchangeable.

10

11

CHANGING YOUR BATTERY

You may power your transmitter with disposable or

rechargeable batteries. Both types use adapter

cases that are inserted into the back of the

transmitter. Follow the instructions below for your battery type.

DISPOSABLE BATTERIES: 1. Insert 3 AA batteries into the back of the

Standard Battery Adapter Case

(11243600). NOTE: Battery positions are shown in the battery

slots on the back of the Standard Battery

Adapter Case housing. 2. Slide the loaded Standard Battery Adapter

Case into the battery compartment on the back

of the transmitter housing and snap into place.

RECHARGEABLE BATTERIES (68108580.A): 1. Confirm that your batteries are fully-charged.

See “Recharging Your Batteries (Optional)” on

page 11. 2. Slide a fully-charged battery into the battery

compartment on the back of the transmitter as

shown, and snap it into place.

RECHARGING YOUR BATTERIES

(OPTIONAL)

DANGER:EXPLOSIVE GASES AND FLYING DEBRIS can cause death or serious injury. Use only Hetronic replacement rechargeable batteries. Use of unauthorized replacement batteries can cause a battery explosion, resulting in injury or death of the operator or other people in the work area.

1. Insert the spent optional rechargeable battery

adapter case into the battery charger and snap

into place as shown.

The LED labeled “CHARGE” flashes for two

seconds, then stays lit during the charging process.

When the battery is fully charged, the “READY”

LED lights up and the “CHARGE” LED goes off. NOTE: Charging time could take up to 5 hours,

depending on the condition of the battery. Leave the battery in the charger until it is needed.

The charger supplies a “trickle” charge but will not

over-charge the battery.

FAST CHARGE Insert the battery into the charger as described

above. The LED labeled “CHARGE” flashes for two

seconds, then stays lit. Press the “FAST CHARGE” button. The FAST

CHARGE LED lights also and stays lit during the

charge process. When the battery is fully charged, the “READY” LED

lights up and the “CHARGE” and “FAST CHARGE”

LEDs turn off.

12

BATTERY DISPOSAL

AVOID ENVIRONMENTAL POLLUTION.

Recycle your rechargeable batteries according to

local recycling rules and regulations. If you have questions or problems operating your

battery charger, please contact your dealer or

Hetronic. 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.

13

OPERATING YOUR TRANSMITTER

TRANSMITTER Use the following as guidelines; always refer to your drawings for your specific system.

READ THIS FIRST Understand the following safety considerations and

take the appropriate actions: • Always store your transmitter key in a safe

location to avoid unauthorized use • Do not allow your transmitter batteries to

completely run down. Your transmitter is

programmed to notify you when there are 10

minutes of remaining battery life. • The transmitter sends STOP messages

when battery power has 30 seconds or less

battery life. • When the battery is removed, the transmitter

enters STOP mode, brakes are applied and

all functions are disabled.

YOUR OPERATING RANGE The standard system range is 3,000 feet (line of

sight) in an interference free environment. More

range is available upon request.

HOLDING YOUR TRANSMITTER Hold your transmitter upright with the front facing

you. Confirm that you are able to easily read and

understand any operation text or symbols. Complete the following procedures once a day,

before the start of an operation and at shift changes.

WARNING: Test the stop function as described in the locomotive manufacturer’s documentation prior to operation.

VISUALLY CHECKING YOUR

TRANSMITTER Always check the transmitter for any physical

damage before any operation. Check equipment for wear or damage and confirm

that you can read and understand all of the safety

labels. Never operate with worn or damaged parts.

CHECKING HOSES AND THE

CONNECTION Before starting the transmitter, ensure that all hoses

and the MU connection is properly seated.

14

STARTING YOUR TRANSMITTER WARNING: To avoid accidental start-up, always press STOP when not in use. NEVER operate the locomotive if the stop

function does not work properly. NOTE: When the transmitter is not in use, store the

transmitter in a secure place.

WARNING: Improper operation, maintenance or adjustment may cause serious injury or equipment damage, and may void the warranty.

1. Confirm that all safety measures required by

the equipment manufacturer were followed.

2. Insert a battery adapter with fresh ‘AA’

batteries into the battery compartment.

NOTE: If using rechargeable batteries, confirm

that they are fully charged.

3. Verify that all switches, levers and joysticks

are turned OFF or neutral position.

4. Follow the equipment manufacture

guidelines and testing for switching the

locomotive from manual mode to trail mode.

The receiver powers ON and Isolation is set

to RUN, engages STOP, sets any applicable

brakes and disengages any set functions.

5. Rotate the KEY SWITCH (Q1) to the ON

position.

A buzzer sounds, the transmitter LEDs flash

and the antenna icon appears on the LCD

display.

On the receiver, a radio link and safe mode

message appears.

6. Press the green START button (S1).

Main reservoir and preset brake pressures

are verified. See the LEDs light green.

7. Wait for the system to complete the following

checks:

NOTE: If pressures are out of range, the STOP

command will be transmitted.

• Main reservoir pressure check—if the

pressure is in range (default 90 psi), the Main

Reservoir LED lights green.

• Locomotive independent brake fully applied

check—if the pressure is in range (default 45

psi), the Loco Brake Fully Applied LED lights

green. • Train brake fully applied check—if the

pressure is in range (55 psi is the default,

your application may vary from 0 to 70psi),

the Train Brake Fully Applied LED lights

green.

8. Press the START button (S1) again if needed.

9. The safe mode indicator disappears and

brake pressure readings appear on the

transmitter display. 10. The word ACTIVE appears on the

receiver display and the safe mode

message disappears. You are now in

radio remote control of the locomotive. NOTE: The independent brake must be fully applied

(S9) before activating the reverser switch

(S10) or the system will enter safe mode. NOTE: See “Safety Features” on page 15 to

understand the safety features designed to

shut down the system if it is not activated in a

specified amount of time.

DANGER: If the locomotive does not operate as expected. Shut down the system and contact your supervisor for next steps.

STOPPING YOUR TRANSMITTER Press STOP (S0). The following actions automatically occur:

• Locomotive throttle is set to idle. • Locomotive brake pressure is adjusted to

the preset level (typically above 45 psi).

• Train brake pressure is adjusted to preset

level (typically 55 psi or below).

SAFETY FEATURES

LOW BATTERY INDICATOR When the low battery indicator LED lights red, insert

fresh batteries. The battery compartment is located

on the back of the transmitter. NOTE: The low battery indicator LED lights red when

there is about 10 minutes of remaining

battery life.

VIGILANCE (RADIO CONTROL SYSTEM OR RCS)

S2 AND S3 For safety reasons, if the throttle, brakes, horn, sand

or bell functions are not used within a specified

amount of time (default-50 seconds, some

applications require a longer time), a warning buzzer

will sound for up to a specified amount of time

(default-10 seconds) before system shutdown. To avoid system shutdown, touch handle S2 or S3 (optional RCS buttons are available). The touch sensors are looking for a change in state. So you may have to let go of the handles. Please see your system drawings if you have any questions.

15

TILT ALARM For safety reasons, if the transmitter is tilted at an

angle of 45 degrees or more for a specified amount

of time (default -2 seconds), the tilt alarm will sound

for a specified amount of time (default- 10 seconds). If the transmitter is not tilted back to an acceptable

angle within a specified amount of time, the system

will shutdown (some models may have the optional

audio out to the walky-talky system).

** Cellular Man Down Feature

1) This should not be considered as a

PRIMARY SAFETY feature.

2) SUPPLIER DOES NOT GUARANTEE YOU

UNINTERRUPTED SERVICE OR COVERAGE.

3) SUPPLIER MAKES NO WARRANTY,

EXPRESS OR IMPLIED, FOR THE SUITABILITY,

ACCURACY, SECURITY, TIMING, OR

PERFORMANCE REGARDING THE “MAN DOWN”

ALERT, AND IN NO EVENT SHALL SUPPLIER BE

LIABLE, WHETHER OR NOT DUE TO THEIR OWN

NEGLIGENCE, FOR DAMAGE OR INJURY

CAUSED BY FAILURE OR DELAY IN

TRANSMITTING THE “MAN DOWN” ALERT.

PUSH TO OPERATE THROTTLE (PTO) - OPTIONAL The touch sensor (S2 and S3) in the handle may

also be used as a type of PTO. Please refer to

your drawings if you have any questions on

operating your specific system.

OPERATING THE TRAIN

RELEASING THE BRAKES Always follow the manufacture

recommendation for testing brakes. 1. Hold the Independent (Locomotive) Brake lever

or joystick (S9) in the release position until the

brakes are fully released (pressures vary per

application).

2. Any time the Independent brake is released,

you systems will automatically put 90 psi to the

actuating pipe. If this is not necessary, please

plug this port. 3. Hold the Train Brake lever or joystick (S8) in

the full release position. As a standard, the

system puts 90 psi to the train brake line

(pressures may vary per application).

SELECTING DIRECTION With the independent brakes applied, place the Reverser switch (S10) in the desired position. As a standard, the independent brakes are automatically applied if the operator fails to set the brake prior to a direction change. Refer to you drawings for more details.

SAFE MODE CONSIDERATIONS

If a fault is detected, the system will automatically

enter safe mode. Faults include, but may not be

limited to, the following conditions: • Main reservoir below preset level; • Communication has not taken place in the

preset amount of time (transmitter is turned

off, battery is removed from the transmitter,

and the transmitter goes out of range);

• Train brake pressure below preset level • Change of direction without the independent

brake set.

AUTOMATIC SAFE MODE ACTIONS The following actions automatically occur in safe

mode: • The preset brakes are applied (typically the

independent brake); • Directional outputs are disabled; • The transmitter LCD will alternately display

the “!!” symbol and brake pressure numbers.

EXITING SAFE MODE To exit safe mode, confirm that the following

conditions have been met: • Main reservoir LED is ON; • The train brake BELOW 45 PSI LED is OFF

(if applicable); • The INDEPENDENT BRAKE LED is ON; • The TRAIN BRAKE LED is ON; • The throttle (S12) is set to the IDLE position; • The FORWARD/REVERSE (S10) toggle

switch is in the CENTER or NEUTRAL

position.

ENGAGING THE THROTTLE (S12) Refer to your drawing to determine the type of

throttle used with your application and take

the appropriate steps to engage the throttle: • Non-push to Operate—press the joystick or

lever in the desired direction. • Push to Operate—Touch handle S2 or S3

and then press the joystick or lever in the

desired direction. (S12).

16

OPERATING THE TRAIN BRAKES

Use the following as guidelines; always refer to

your drawing for your specific system. • Releasing the Train Brakes: Hold the Train

Brake lever (S8) in the full release position.

As a standard 90 psi will be put into the train

brake line.

• Applying the Train Brakes: Move the Train

Brake lever (S8) to the desired train brake

position and release it when the desired

pressure is reached. NOTE: Refer to your locomotive manufacture

recommendations for applying and

releasing train brakes.

OPERATING THE INDEPENDENT BRAKES

(LOCOMOTIVE) Use the following as guidelines; always refer to

your drawings for your specific system. NOTE: Independent brake pressures increase and

decrease as the locomotive brake lever (S9)

is held in the desired position. • Applying the Independent Brakes: Hold the

Independent Brake lever (S9) toward

Independent Brake, and release it when the

desired pressure is reached.

• Releasing the Independent Brakes: Hold the

Locomotive Brake lever (S9) in the Release

position, and release it when the desired

pressure is reached.

CHANGING DIRECTION WARNING: Failure to bring the locomotive to a complete stop before changing direction may result in damage to the locomotive.

Take the following steps to change direction:

1. Bring the locomotive to a complete stop. 2. Fully apply the independent brake (S9) if this

was not already completed 3. Place the Reverser switch (S10) in the

desired position.

4. Release the independent brake (S9) as

needed

ADDITIONAL FUNCTIONS (OPTIONAL)

SAND FUNCTION (S4)

Press the Sand button to release sand onto the

track.

BELL FUNCTION (S7)

Press the Bell button or toggle to sound the bell.

HORN FUNCTION (S5) Press the Horn button or toggle to sound the horn.

PITCH AND CATCH

Note: Both Transmitters must be in the same state. The locomotive must be stopped and the reverse switch (S10) be in the neutral position

1. Operator 2 requests control of the locomotive

by pressing S1 for five seconds. Both

transmitters will flash 1/2 to indicate P&C

mode.

2. Operator 1 (identified as transmitter 1 on the

transmitter) releases control of the

locomotive (S1 for five seconds).

3. Operator 2 now has control of the locomotive. Operators 2’s transmitter will now be identified as transmitter 1.

SPEED CONTROL

Use the following as guidelines; always refer to your drawings for your specific system. Also, not all

locomotive MU plugs are equipped for excitation. Please

refer to your locomotive’s manual.

INCREASE SPEED

1. Move S6 to the desired position for your application

a. Yard (left) – Speed Control using notch for flat grade

b. Manual (center) - Manual control like the cab

c. Hump (right) – Speed Control using excitation for a track with a grade

2. Follow you locomotive manufacture recommendation for releasing the train brakes and independent brake (see Operating the Train Brake and Operating the Independent Brake sections in this manual)

3. Touch the transmitter handles (S2/3) see the blue vigilance LED turn on

4. Move the throttle joystick (S12) into the desired speed position

INCREASE SPEED AGAIN

1. Touch the transmitter handles (S2/3) see the blue vigilance LED turn on

2. Move the throttle joystick S12) into the new speed position.

REDUCE SPEED

Use the following as guidelines; always refer to your drawings for your specific system.

1. Move the throttle (S12) back to the new desired speed position.

2. As a standard, it is not necessary to touch the RCS (if applicable) or the transmitter

17

handles (S2/3) to reduce speed.

COAST

Use the following as guidelines; always refer to your drawings for your specific system.

1. Move the throttle (S12) back to the coast position.

2. As long as the locomotive is not exceeding 5

mph, the locomotive will coast to a stop and the brakes will apply after 20 seconds of no movement.

3. If the locomotive is exceeding 5 mph, the brakes will apply in a set amount of time at a set rate until the locomotive goes below 5mph, at which time the brakes will release and coasting can proceed.

18

ROLL BACK PROTECTION

Use the following as guidelines; always refer to your drawings for your specific system.

1. If applicable, please confirm that the direction switches on the remote Estop (HL0001) point toward the locomotive system.

2. If the wheel sensors detect the locomotive rolling the opposite direction than what is selected, the independent brakes will be applied to stop the roll back.

DATA LOGGING (OPTION) Check your drawings to confirm you system includes this option. Your locomotive system has the capability of working with a data logger. The data logger captures all the inputs and outputs of the system. It also captures any status information. The information is stored on a removable card. The information can also be remotely accessed. Please see your drawings for more information.

GPS AND/OR GSM (OPTION) Check your drawings to confirm you system includes this option. Your locomotive system has the capability of working with a GPS/GSM for speed control, tracking, fencing, area restriction (3 set points), and communication. Please check your drawings for more information.

VIDEO (OPTION) Check your drawings to confirm you system includes this option. Your locomotive system has the capability of working with up to four video cameras. These cameras are able to send a signal back to some of our displays. Please check your drawings for more information.

19

LCD, LED AND OPTIONAL RECEIVER DISPLAY INDICATOR MEANINGS The following icons appear on your transmitter LCD.

See the meanings listed below:

TABLE 1: LCD INDICATORS AND MEANINGS

!! Safe Mode

** Return the throttle to NEUTRAL

Antenna icon Transmitter is not receiving

with a line feedback and is in control of the

through it locomotive.

NOTE: Unless specified by the customer, LCD

screens are not backlit. Optional

backlighting features are available.

TABLE 2: TYPICAL LED INDICATOR MEANINGS

LED Color State Meaning

Main Reservoir Green ON Pressure above 90 psi

OFF Pressure below 90 psi

Independent Brake Red ON Actuating pipe pressure above 30 psi, Ind. brake applied

OFF Independent brake pressure below 30 psi

Train Brake Green

ON Train brake pressure below 55 psi (may vary per your specs)

Fully Applied OFF Train brake pressure above 55 psi

Independent Brake Green

ON Independent (locomotive) brake pressure above 45 psi

Fully Applied OFF Independent (locomotive) brake pressure below 45 psi

Low Oil Pressure Red ON Receiving low oil pressure signal from locomotive (72 VDC)

OFF Not Receiving low oil pressure signal from loco. (72 VDC)

Hot Engine Red ON Receiving Hot Engine signal from locomotive (72 VDC)

OFF Not Receiving Hot Engine signal from locomotive (72 VDC)

Wheel Slip Red ON Receiving Wheel Slip signal from locomotive (72 VDC)

OFF Not Receiving Wheel Slip signal from locomotive (72 VDC)

20

TABLE 3: RECEIVER GRAPHIC DISPLAY

Graphic Color Image State Meaning

STOP Text

Red

ON

STOP activated, brakes fully applied, functions disengaged

Blue

STOP not activated

LOW AIR PRESSURE

Red

ON

Low air pressure warning from locomotive

Text

Blue

No low air pressure warning from locomotive

LOW OIL PRESSURE

Red

ON

Low oil pressure warning from locomotive

Text

Blue

No low oil pressure warning from locomotive

HOT ENGINE Text

Red

ON

Hot Engine warning from locomotive

Blue

No Hot Engine warning from locomotive

WHEEL SLIP Text Block

Red

ON

Wheel Slip warning from locomotive

Blue

No Wheel Slip warning from locomotive

GROUND RELAY Text

Red

ON

Ground Relay warning from locomotive

Blue

No Ground Relay warning from locomotive

HORN Icon/Text ON Horn output is active

BELL Icon/Text ON Bell output is active

LIGHTS Icon/Text ON Lights output is active

SAND Icon/Text ON Sand output is active

FORWARD Icon/Text ON Toggle is in the FORWARD position

REVERSE Icon/Text ON Toggle is in the REVERSE position

Throttle Icons

ON

Joystick throttle selection (displayed in gauge and

numbers)

21

TRAIN/LOCO BRAKE

Numbers represent psi for each brake. The gauge

ON

represents the joystick location. If bars fill the gauge,

Icons/Text

brakes are fully applied, If no bars, brakes are fully

released.

RADIO LINK Icon/Text

ON Transmitter is communicating with receiver

SAFE MODE Text ON System is in Safe Mode

ACTIVE Text ON Transmitter is completely controlling system

RETURN THROTTLE TO

ON Return the throttle to the idle position.

IDLE Text

SPEED/SPEED

ON See your drawings for your specifications

SETTINGS

22

TROUBLESHOOTING

If the system does not operate after normal start-up,

follow the recommended troubleshooting sequence

to help isolate the cause and determine corrective

action.

If you need more information, contact your dealer or

Hetronic.

PROBLEM PROBABLE CAUSE CORRECTION

Batteries not charging No power to the charger Apply power to the charger

System not initializing after STOP engaged Disengage STOP

normal START

Batteries fully discharged Replace batteries

Receiver not powered ON Apply power to the receiver

The transmitter is turned on, but Battery is discharged Replace battery with a fully charged

does not transmit battery

Component issue Contact your supervisor.

Transmitter is transmitting, but Transmitter out of range

Take the transmitter back into the

locomotive not responding range of the receiver and retry

Transmitter/receiver frequency Contact your supervisor

channels do not match

Switches, levers and toggles in Place all switches, levers and toggles

ON positions in OFF positions

Receiver not powered ON Apply power to the receiver

Blown fuse in receiver Check all fuses and replace if needed

All machine motions operate Receiver antenna connection is Tighten or replace antenna

intermittently loose or missing

Interference Correct interference

Connector inside receiver is Check all connectors, reseat if

loose needed

Some machine motions operate Loose machine motion wiring Check wiring from receiver to plug

intermittently and plug to machine motion actuator

Loose connector inside receiver

Check all connectors, reseat if

needed

23

MAINTENANCE

PNEUMATIC FILTERS

Pneumatic maintenance is dependent

on the quality of the air in the

locomotive. If not dictated, all air

filters should be replaced quarterly.

There are three air filters.

MAIN RESERVOIR FILTER (AFF-EL11B)

This filter protects the main air entering the unit.

MIST REMOVER FILTER (AF30P-060S)

This filter removes moisture from the air.

PILOT FILTER (AFM30P-060AS)

Provides filtering for the pilot lines.

CHANGING FILTERS

See Appendix B.

SPECIFICATIONS

NOTE: All Hetronic systems are custom-designed to user specifications. For your exact

system specifications and drawings, see the documentation provided with your system.

SPECIFICATIONS FOR ALL MODELS

Housing: Impact resistant polymer composite

Environmental Protection: IP 65 (Exceeds Nema 12/13)

Antenna: Internal, optional external

Power Supply: 3 LR6 Size AA 1.5 V Alkaline batteries

3.6V 1.2Ah NiMH rechargeable battery

Diagnostics: Status LED for operation

Operation Time: Varies, based on battery type and output power

Frequency Range: 419 MHz, 429 MHz, 434 MHz, 447 MHz, 458 MHz and 868 MHz

RF Unit: Type CS synthesized with multiple frequencies, switch selectable

Power (RF Output): Varies, based on customer specifications

Typical Operating Range: Approximately 3000 ft (1000 m) more range is an option

Safety Address: 20-bit with (over 999,999 possibilities)

Address module (ADMO)

Safety Active and passive STOP function

Parity and checksum

Temperature Range: -11 to +158 degrees F (-25 to +70 degrees C) Limited by LCD Specification

Humidity Range: 0 - 97% maximum non-condensing

Response Time: Less than 100 msec.

Baud Rate: Up to 4800 Kbps

24

WEIGHT, DIMENSIONS AND TRANSMITTER OPTIONS PER MODEL

Nova XL

Weight: Up to 4 lbs (1840 g), with

batteries

Length: 11.2 in (285 mm)

Dimensions:

Height: 6.5 in (165 mm)

Depth: 5.6 in (143 mm)

• • Single axis 8-step

joysticks

• • Multiple axis joysticks

with and without detent

• Momentary pushbutton

•

for START/HORN

• 3-position maintained

•

Transmitter toggle switch

Options: • • 3-position maintained-

off-momentary toggle

switch

• Push mushroom head

STOP switch

• Maintained ON/OFF TX

power key switch with

removable key cap

25

LOCOMOTIVE

www.hetronic.com

© 2008 HETRONIC All rights reserved. No part of this publication may be reproduced, transmitted,

transcribed, stored in a retrieval system, or translated into any language in any

form by any means without the written permission of HETRONIC. Technical information subject to change without notice. HETRONIC reserves the right to discontinue, make changes to, and add

improvements upon its products at any time without public notice or

obligation. HETRONIC disclaims liability for any claims or damages, whether

regarding property, personal injury or death arising out of the use of

unauthorized replacement parts or service.

i

APPENDIX A

Spare Parts

Description Part Number List Price

Pneumatic Panel with display See your drawings Call Factory

Nova XL Transmitter See your drawings Call Factory

System isolation Kit H0-00118 Call Factory

System Isolation Kit w/ head light relay H0-00124 Call Factory

E-Stop box HL0001 Call Factory

Antenna Mast Assembly HL0002 Call Factory

Break Away 4 point Harness HL0003 Call Factory

Wheel Mounted Speed Sensor HL0004 Call Factory

Excitation Amplifier Board HL0005 Call Factory

Speed Control Joystick 6717544169 Call Factory

Code Plug, CAN RX Replacment Pkg HL0006 Call Factory

Head Light Relay Pkg HL0007 Call Factory

Pneumatic Horn K18010 Call Factory

Electric Bell K18138 Call Factory

Extended Range 5' Antenna K18064 Call Factory

Antenna Cable per foot LMR400 Call Factory

Phantom Antenna Mag Mount K18125 Call Factory

Strobe Light Mag Mount 145697-AMB Call Factory

MU Cable H9-00575 Call Factory

Gladhand Hose Assembly L K18008 Call Factory

Gladhand Hose Assembly H K18009 Call Factory

Gladhand Hose Assembly F K18019 Call Factory

Y Strainer AIR.59005IHI Call Factory

OCU NiMH Battery 2.0Ah 68300990 Call Factory

AAA Battery Pack (batts. Not included) 11243600 Call Factory

Battery Charger 68108580.A Call Factory

Main Filter Element AFF-EL11B Call Factory

Moisture Filter Element AF30P-060S Call Factory

2nd Filter Element AFM30P-060AS Call Factory

HED LCD Display SG-028-103-ES Call Factory

i

APPENDIX B

REPLACING FILTERS

MAIN RESERVOIR FILTER

• Remove the top 4 screws

• Carefully lower the filter housing

• Carefully pull the top of the filter housing toward you

• Remove the filter and rubber ring 1

ii

• Remove rubber ring 2 and replace with new ring.

• Insure rubber ring 1 is removed and replaced with the new ring. (Sometimes rubber ring 1 will be attached to filter top housing.)

Replace filter hole up

Re-assemble main reservoir filter housing using the four

screws.

iii

To remove the Air filter;

1. Pull down the latch and push up on the

bottom housing, turning it at the same time.

2. Then pull down on the bottom housing

AIR FILTERS

iv

• Unscrew the first air filter from the post

• Discard the old filter

• Replace with new filter AF30-060S. Insure proper seating and reinstall.

FIRST AIR FILTER

v

• Unscrew the second air filter from the post

• Discard the old filter

• Replace with new filter AFM30P-060AS. Insure proper seating and reinstall.

SECOND AIR FILTER

vi

Install both the air filter housings;

• Pull down the latch and push up on the bottom housing, turning it at the same time.