Operating manual wireless hand wheel HBG 410-RF SE Funkhandrad HBG...Operating manual HBG 410-RF SE Rev. 1.0 – 06/13 Hubitron Steuerungstechnik Hubitron Steuerungstechnik, Hauptstr

Operating manual HBG 410-RF SE Rev. 1.0 – 06/13 Hubitron Steuerungstechnik

Hubitron Steuerungstechnik, Hauptstr. 4/1, D-89611 Obermarchtal, Tel. +49(0)7375/922066, FAX +49(0)7375/922077 Page 1 of 16

Operating manual wireless hand wheel HBG 410-RF SE

Contents

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

2. Technical Data.............................................. 22.1 Hand terminal HBG410-RF SE ...................... 22.2 Access point HBG 410-AP............................. 22.3 Charging station............................................. 22.4 System timing................................................ 2

2.4.1 Emergency stop + safety buttons............. 22.4.2 All other buttons..................................... 2

3. Scope of supply............................................ 23.1 Optional accessoires....................................... 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 410-RF SE ..................... 36.2 Access point HBG 410-AP............................. 36.3 Charging station............................................. 46.4 Special functions............................................ 46.5 Switching on and off of the hand terminal ...... 56.6 LCD display................................................... 5

7. Installation .................................................... 57.1 Out of operation............................................. 5

8. Set up............................................................ 68.1 Used buttons .................................................. 68.2 Enter Set up ................................................... 68.3 Change Set up................................................ 68.4 Description of the menue points ..................... 68.5 Test routines .................................................. 68.6 Set up overview ............................................. 7

9. Start operation ............................................. 89.1 Channel selection ...........................................8

9.1.1 Field strength measurement ....................89.2 Set transmitting power....................................89.3 Set minimum level .........................................8

10. Actions to avoid interruptions..................... 9

11. Error solutions ............................................. 911.1 Possible errors................................................911.2 Cause of errors ...............................................911.3 LOW - BATT display.....................................911.4 No function ....................................................911.5 Service address...............................................9

12. Maintenance and care................................ 1012.1 Change of rechargeable batteries .................. 10

12.1.1 Exchange of rechargeable batteries........ 10

13. Frequency table.......................................... 11

14. Safety instructions..................................... 11

15. Accessories................................................ 1215.1 Holder for charging station ........................... 12

16. LED's in the access point .......................... 12

17. Retrofitting on older machines.................. 1317.1 Emergency stop contacts .............................. 1317.2 Safety circuits .............................................. 13

18. Spare parts ................................................. 14

19. EG Declaration of Conformity.................... 15

20 Assignment of LED's and buttons............. 16



1. DescriptionThe radio wave hand wheel HBG410-RF SE is forwireless control of CNC machines with Heidenhaincontrol systems and connecting possibilities for theHeidenhain hand wheel unit HR420. It replacesnearly all functions of the orginal hand wheel unitHR420 or HR520.The safety functions (emergency stop + safetybutton) fulfil the safety category 3, EN954-1. Theconcept is approved by the German Institute forHealth and Safety - BGIA.The system is exclusively designed foroperation within the European market! Othermarkets require a written approval of themanufacturer!

2. Technical Data

2.1 Hand terminal HBG410-RF SEDimensions (l x w x h)...............approx. 220x116x80Weight.................................................approx. 600gPower supply.......... 3 x NiMh rechargeable batteriesDisplay .........................................LCD, 2 x 12 digits.................................................................. 12 LED‘sOperating elements ................................. 16 buttons....................................................... 2 safety buttons..........................................1 emergency stop button.......................................................1 rotary encoder...................................................... 2 potentiometersOperating time.........................................> 24 hoursFrequency band........... 433 + 869 MHz (SRD 1e/1k)Channels ............................................................. 21RF power............................max. 10mW at 433 MHz.............................................max. 5mW at 869 MHzRange...............................approx. 15 m (adjustable)Vibration alarm ...................................................yes

2.2 Access point HBG 410-APDimensions (l x w x h)...........approx. 220 x 130 x 70Weight................................................ approx. 1,4kgPower supply...................................12VDC +/- 10%Current ................................................max. 300 mAInterfaces ................................ hand wheel interfaceOutputs............ 2 x emergency stops, ea. 3A, AC-15............................. 2 x safety buttons, ea. 2A, AC-15......... 1 charging output for hand terminal 20/240mAInputs ........2 x emergency stops for charging stationFrequency band............................... 433 + 869 MHzChannels ............................................................. 21RF power............................max. 10mW at 433 MHz.............................................max. 5mW at 869 MHzRange...............................approx. 15 m (adjustable)

2.3 Charging stationDimensions (l x w x h).............approx. 190 x 95 x 55Weight.................................................approx. 100gContacts ................................................................ 4

2.4 System timing

2.4.1 Emergency stop + safety buttonsmin. 23,2 msmax. 155 msaverage reaction: approx. 31 ms

2.4.2 All other buttonsmin. 21 msmax. 142 msaverage reaction: approx. 27 ms

3. Scope of supply1 Hand terminal HBG 410-RF SE1 Access point HBG 410-AP1 Charging station2 Antennas (long & short)1 Connecting cable for hand wheel interface 2m1 Mounting set

3.1 Optional accessoireso Holder for charging station to keep the Termainal

in a save position

4. Machine demandso iTNC530 control, SW 340 422-09 or newero MP7640 must be set to 11 or 13o Heidenhain handwheel interfaceo An emergency stop must be stored at the

machine if the emergency stop relay showsdifferent 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 temperature: +5° to +45°CStorage temperature: -20° to +70°Cmax. humidity: 90%, no condensationVibration resistance: 5gShock resistance: 10g



6. Operating elements

6.1 Hand terminal HBG 410-RF SE1 emergency stop button2 potentiometer 13 potentiometer 24 NC + spindle start/stop5 change resolution6 actual value transfer7 Handwheel activation8 axis movement buttons9 LCD display10 rotary encoder11 axis selection buttons with LED‘s12 change resolution13 Special functions14 fast movement15 safety button 116 safety button 2

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

6.2 Access point HBG 410-AP

1415

16

151718

14 antenna socket X315 covers16 type label17 maschine connection X118 socket for charging station X2

Remark: The mounting holes are underneath thecovers!



6.3 Charging station

20

2019

20

21 22

19 connecting cable with plug20 mounting holes Ø 5,5 mm21 charging contacts22 contacts for emergency stop

6.4 Special functions

select axis 4 – 5 - 6

switch display

switch OPM, if LED is on

activate/deactivate override

call M-Function, if LED is on. Selectwith handwheel, start with NC-Start orcancel with CTRL

NC Start

NC Stop

Spindle Start/Stop

(must be programmed in the PLC,M4664+M4665)



6.5 Switching on and off of the handterminal

The hand terminal is switched on with one of thesafety buttons (15 or 16).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 wheel on the machinecontrol the wireless hand wheel can be operatedexactly as the original hand wheel:Axis selection, teach in, feed selection, axismovements, etc.The symbols on the buttons are nearly identical andhave the same functions!

6.6 LCD displayIn the 2 line LCD display the axis position, errorcodes, potentiometer positions are displayed.

With the buttons + the display can beswitched:

7. InstallationMachine must be turned off before installation!

o Mount the charging station onto the 3 mountingholes (20) on a suitable location with easyaccess. The cable must be on top. Do not bendthe loading station!

o Install the access point on the machine controlpanel near to the hand wheel interface,preferably above the control panel. Underneaththe 2 covers (15) are 2 mounting holes each forM5 screws (hole distance: 102 x 202 mm). Theconnector for the anenna (14) must be on top.

o Install the charging station onto the access point(X2, 18).

o Screw the short antenna into the antenna socket(X3, 14).

o Connect the cable supplied with the access point(X1, 17) and then with the hand wheel interfaceof the machine.

o remove Sticker ("remove before use") withmagnet from the hand terminal.

Mounting positions:

��

��

Attention!If machines have only one emergency stop channel,both emergency stop contacts of the HBG 410-RFSE must be connected in series!

Set the machine parameter MP7640 to 11 (withoutLED control) or to 13 (with LED control).More information you can find in the technicalmanual of your control unit.

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 way damage tothe accus is avoided.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. Set up

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

1 safety button to turn on2 enable Set up3 enter4 change values5 exit Set up

8.2 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

8.3 Change Set upIn the Set up the following menue points can beselected:

menue description setting rangePower transmitting power 0 – 7Kanal channel setting 0 – 20Range range setting 20 – 60Test-Nr test functions 0 – 8

o start Set up menue as described in 8.2o select menue point with buttons +/- (4)o enter menue point with button X (3)o change value with buttons +/- (4)o confirm selection with button X (3)o exit Set up with button 5

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

8.4 Description of the menue pointsPower RF transmitting power

Kanal channel

Range level to activate vibration alarm

Test-Nr: test routine and enabling additionaloptions

Additional options (if Test-Nr = 6)

Taster service functions

Option service functions

Stay On to deactivate the automatic shutdown inthe charging station

8.5 Test routinesThe following test routines are integrated:

0 no test, standard 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 X (3). The display shows 8 favouritechannels, the best in the upper left the worst inthe lower right.

6 enabling additional options

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

8 transmitting test for service

9 test for frequency adjustment



8.6 Set up overview



9. Start operation

9.1 Channel selectionThe wireless hand wheel HBG 410-RF SE offers achoice of 21 channels. These channels areseparated into 2 frequency bands:Channel 0 – 3: 869 MHz (for short antenna)Channel 4 – 20: 433 MHz (for long antenna)

Upon delivery channel 0 is set.

To select a suitable channel please acknowledgethe following:

1 Are there further hand wheels or other unitsworking in the ISM band 433 MHz or 869 MHznearby?

2 If yes, with what frequencies do they workexactly?

3 When using several wireless hand wheels theused channels must be seperated. If possibleuse different frequency bands, otherwise thechannel separation should be at least 3channels (i.e. channel 4 + channel 7).

4 If machines are located side by side the channelseparation should be at least 6 channels (themore the better) or use a different frequencyband! (i.e. channel 0 + 4)

Compare the frequencies of other units with thefrequency listing attached and choose only onesetting which is at least 300 kHz away from thetransmitting frequency of the adjoining units!

9.1.1 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 8.2)o set menue point „Test-Nr“ to 5 (see 8.4)o exit set up to run routine

Now the hand terminal scanns continuously allchannels until the routine is stopped with button X.The eight best available channels show on thedisplay, the best on the upper left, the worst on thelower right.

Alternatively the channels can be scanned manuallywith test routine 7. The channels can be changedwith the buttons +/-.The maximum value can be reset with button X.

With the hand terminal walk up the operation range,the maximum value should remain < 23! If this is notthe case, repeat the measurement using a differentchannel. To do this, first switch off the hand terminalwith an emergency stop. After that start the setupagain and change the channel.When selecting a channel please note the additionalpoints described under 9.1!

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

o change to the new channel on the hand terminal(8.3). While exiting the set up in the handterminal the new parameters will be transmittedto the access point. The connection is interruptedand must be started again afterwards.

9.2 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 then the transmittingpower must be increased. With a value of > 45 thepower should be decreased.

9.3 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.The range value should be set to:

Range value = 70 – measured value

Suggested range value: 35 - 45



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

taking it out of the charging station2. During the loading of work pieces and during

tasks where a hand wheel is not required,always return the hand terminal to the chargingstation

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 mobile phones nearby.Especially the D net can cause interruptions onchannel 0 through 3

6. Clean the loading contacts on the chargingstation and the hand terminal from time to time

11. Error solutions

11.1 Possible errorsIf an error in the access point occurs, 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 occure at the same time, the sum oferror codes is displayed, i.e. error 002 and error004, the display will read error 006!

11.2 Cause of errorsError 1 and 2 indicate problems with the hardware inthe access point. Should this occur frequently - callfor 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 fed by X1 pin 3 of theHeidenhain hand wheel adaptors.

Is there a frequent emergency stop without errorduring the operation (hand terminal is on), the causecan be an integrated exit control in the access point– call for service!

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

If there is no more connection possible, there mightbe a defective internal fuse on the access point (finefuse 5 x 20, 0,5AT).

11.3 LOW - BATT displayIf during operation the LOW - BATT is displayed, thehand terminal should be returned to the chargingstation!Further operation for approx. 3 hours is still possiblebefore the hand terminal shuts down and causes anemergency stop.

11.4 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, 0,5AT)- check channel setting (run test 2)- Compare the serial number of access point and

hand terminal (they need to be the same!)- check rechargeable batteries in the hand

terminal

2. Machine does not react

- confirm error codes on the machine control- turn on power of the control

11.5 Service addressINNOTROL GmbHRheinstrasse 96, E3D-56235 Ransbach-BaumbachPhon: +49 (0) 26 23 / 92 94 90Fax: +49 (0) 26 23 / 92 94 92 8



12. 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!

12.1 Change of rechargeable batteriesThe batteries should be preventatively changedevery 2 years. Only use NiMh-rechargeablebatteries (Size AA) with a capacity of min. 2000mAh.

Suggested types:

manufacturer capacityGP 2100 mAhPanasonic 2100 mAhSanyo 2100 mAh

12.1.1 Exchange of rechargeable batteries

- push the emergency stop on the hand terminal- take out the 6 screws S from the housing

S

S

SS

S

S

- Carefully lift the housing lid and pull offconnection X

- Put housing cover aside

X- pull off plug A, B, C + D- remove the 4 screws E- take out and turn conductor board P

A B C D

E

EE

EP

- 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!



13. Frequency table

channel no. frequency (MHz) antenna0 869,75 short1 869,85 short2 869,94 short3 869,35 short4 433,10 long5 433,20 long6 433,30 long7 433,40 long8 433,50 long9 433,60 long

10 433,70 long11 433,80 long12 433,90 long13 434,00 long14 434,10 long15 434,20 long16 434,30 long17 434,40 long18 434,50 long19 434,60 long20 434,70 long

14. 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 HBG410-RF SE have to be connected in series



15. Accessories

15.1 Holder for charging station

To keep the hand terminal in the charging stationvery save, also during strange vibration of themachine

16. LED's in the access point

In the access point are 10 LED's. They show thestatus and function of the unit:

LED1: ready status / operation

LED2: transmitting

LED3: hand terminal in charging stationblinking: fast charge

LED4: hand terminal in charging stationblinking: error in supply voltageor defekt in the unit

In addition each relay has a LED which displays thestatus of the output relay.

With the jumper it is possible to select the source ofthe 24V supply for the access point. See description17 on the following page.In general the jumper is set on 1+2



17. Retrofitting on older machines

17.1 Emergency stop contacts

Older machines are partially equipped with only one emergency stop circuit. In this case both emergency stopcircuits of the HBG 410-RF SE must be connected in series.

To recognise the number see the circuits on the connecting adaptor of the hand wheel:

Machine with 2 emergency stopcircuits- no change necessary

Machine with only one emergencystop circuit

Serial connection of both emergencystop circuits

emergencystop circuits

safety circuits


safety circuits


safetycircuits

17.2 Safety circuits

If the machine has only one safety circuit, the circuit has to be slightly modified, because the HBG 410-RF SEuses the +24V voltage of the safety circuits as additional supply:

Machine with two safety circuits- no change necessary

Machine with only one safety circuit Inner circuit of the HBG 410-RF


safety circuitsset jumper to 1-2

+24V


safety circuitsset jumper to 2-3

on units older serial no. 34 theconnection is fixed on 1+2

The setting of the jumper in the access point (serial no. greater 33) selects, whether the +24V supply comes fromX1.3 or X1.1 (X1.1 both safety circuits in series). Jumper setting 1-2, the supply comes from X1.3, jumper setting2-3 the supply comes from X1.1.

The jumper is placed in the access point next to the 20 pol. green plug at the connecting socket.



18. Spare parts

2

2b3

4

5a 5b

7

6

1 emergency stop button2 potentiometer HBG 410-RF2b potentiometer label3 front foil HBG 410-RF SE4 magnet for disconnecting

accus5a rotary encoder5b rotary knob6 safety button7 magnetic clamp with hook

9

8

10

8

11

8 cover9 antenna long 433 MHz10 antenna short 868 MHz11 charging station HBG 410-RF

12 connecting cableHBG 410-RF, 12 pole, 2m(no picture)



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

10.06.2013Manufacturer: Hubitron Steuerungstechnik

Hauptstr. 4/189611 ObermarchtalGermany

Product: Wireless hand wheel HBG 410-RF SEContaining: Hand terminal HBG 410-RF SE

Access point HBG 410-APCharging station HBG 410-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 d (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, 10.06.2013

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]



20 Assignment of LED's and buttonsIf you want to do the interpretation of the LED's and buttons through the PLC, use the following assignment:

only NC only NC M4661LED: M4681

M4664LED: M4684

only NC only NC M4662LED: 4682

M4665LED: M4685

only NC only NC only NC LED: M4689

M4668 M4663 M4667 M4666

Documents

Operating manual wireless hand wheel HBG 410-RF SE Funkhandrad HBG...Operating manual HBG 410-RF SE Rev. 1.0 – 06/13 Hubitron Steuerungstechnik Hubitron Steuerungstechnik, Hauptstr