Hetronic ERGO-S-Programming Service-Manual 042024

PROGRAMMING & SERVICE MANUAL
ERGO S
PROGRAMMING & SERVICE MANUAL
04/2024
www.hetronic.com
PROGRAMMING AND SERVICE MANUAL | ERGO S
Table of Contents
1. Safety ....................................................................................................................................................................................... 4
1.1 Intended Use ............................................................................................................................................................................ 4
1.2 Symbol Notation ....................................................................................................................................................................... 4
1.3 Practices and Laws .................................................................................................................................................................. 4
1.4 Required Operator Training ...................................................................................................................................................... 4
1.5 Possible Sources of Danger ..................................................................................................................................................... 4
1.6 Protective Features .................................................................................................................................................................. 5
1.7 STOP in case of EMERGENCY ................................................................................................................................................ 5
1.8 Caring for your ERGO S ........................................................................................................................................................... 5
2. Introduction and Functional Description ......................................................................................................................................... 6
2.1 Production and System Numbers ............................................................................................................................................. 6
2.2 Before Operating Your Wireless Control Unit ............................................................................................................................ 6
2.3 Unit Labels ............................................................................................................................................................................... 6
3. Your ERGO S Transmitter ............................................................................................................................................................. 7
3.1 General Description .................................................................................................................................................................. 7
3.2 ERGO S Basic Features ........................................................................................................................................................... 7
3.3 Standard ERGO S 2.4GHz Configuration ................................................................................................................................. 7
3.4 Transmitter Operation Modes ................................................................................................................................................... 9
4. Operating Your Transmitter ......................................................................................................................................................... 10
4.1 Holding Your Transmitter ........................................................................................................................................................ 10
4.2 Visually Checking Your Transmitter ........................................................................................................................................ 10
4.3 Powering Up and Starting Your Transmitter ............................................................................................................................ 10
4.4 Transmitter Initialization with Standard Status LED Indicator .................................................................................................. 10
4.5 Transmitter Initialization with Graphic User Interface (TFT) and Standard Status LED Indicator ............................................. 10
4.6 Turning OFF the Transmitter and Stopping the Radio Remote Control ................................................................................... 10
4.7 LED Behaviour and Meanings ................................................................................................................................................ 11
4.8 Magnetic Belt Clip (if equipped) .............................................................................................................................................. 11
4.9 Start-Up Sequences ............................................................................................................................................................... 12
4.10 Front Switch LEDs ................................................................................................................................................................ 12
5. Configuring Your ERGO S ........................................................................................................................................................... 13
5.1 Using Hetronic PC-Link .......................................................................................................................................................... 13
5.2 Using the Transmitter in Service Mode ................................................................................................................................... 13
6. Setting up Your ERGO S for Operation ........................................................................................................................................ 15
6.1 Coder ..................................................................................................................................................................................... 15
6.2 Communication....................................................................................................................................................................... 16
6.3 DK Configuration .................................................................................................................................................................... 20
6.4 AK-DAC.................................................................................................................................................................................. 23
6.5 Graphical User Interface (Optional) ........................................................................................................................................ 23
6.6 Feedback Messages............................................................................................................................................................... 25
6.7 Access Codes ........................................................................................................................................................................ 26
6.8 USB Interface ......................................................................................................................................................................... 27
6.9 Data Logging .......................................................................................................................................................................... 27
6.10 Cable Control ....................................................................................................................................................................... 27
7. Theory of Operation ..................................................................................................................................................................... 29
7.1 Stop Function ......................................................................................................................................................................... 29
8. Flash Programming ..................................................................................................................................................................... 30
8.1 Programming the Stop Processor Firmware ........................................................................................................................... 30
8.2 Programming the Main Processor Firmware ........................................................................................................................... 30
8.3 Programming the Application .................................................................................................................................................. 30
9. Troubleshooting ........................................................................................................................................................................... 32
10. Specifications ............................................................................................................................................................................ 33
11. Warranty, Service, Repairs and Maintenance ............................................................................................................................ 34
12. Regulatory Information .............................................................................................................................................................. 35
12.1 Europe.................................................................................................................................................................................. 35
12.2 North America....................................................................................................................................................................... 35
12.3 Industry Canada (IC/ISED) Statement .................................................................................................................................. 36
Appendix A 37
Definition of terms ........................................................................................................................................................................ 37
Appendix B 38
B.1 Operator Safety Basics .......................................................................................................................................................... 38
B.2 Safety Checklist ..................................................................................................................................................................... 38
Appendix C 39
C.1 Spare Parts ............................................................................................................................................................................ 39
C.2 Battery 3V Button Cell Replacement Instructions ................................................................................................................... 39
C.3 Removal of USB Key ............................................................................................................................................................. 40
2
List of Figures
Figure 1. Blank Rating Plate ....................................................................................................................................................... 6
Figure 2. ERGO S Transmitter (Right, Front, Left) ...................................................................................................................... 8
Figure 3. Status and Feedback LEDs ......................................................................................................................................... 8
Figure 4. Stop Screen .............................................................................................................................................................. 11
Figure 5. Pages 1 and 2 of the Device Settings menu .............................................................................................................. 13
Figure 6. Low Battery Warning Configuration ........................................................................................................................... 15
Figure 7. Radio Mode menu selections on Hetronic PC-Link .................................................................................................... 16
Figure 8. Radio Settings menu ................................................................................................................................................. 17
Figure 9. Setting the Auto-OFF timer ........................................................................................................................................ 17
Figure 10. Half Duplex Configuration .......................................................................................................................................... 18
Figure 11. Full Duplex Configuration .......................................................................................................................................... 18
Figure 12. ERGO S MFS Configuration ...................................................................................................................................... 19
Figure 13. Pages 1 and 2 of the Service Mode menu showing Address Learn function .............................................................. 19
Figure 14. Address Learn page .................................................................................................................................................. 19
Figure 15. Initiating Learning page ............................................................................................................................................. 20
Figure 16. ERGO S changing channel notification ...................................................................................................................... 20
Figure 17. Successful Address Learn notification ....................................................................................................................... 20
Figure 18. Assigning DKs to switch number 3 ............................................................................................................................ 21
Figure 19. Enabling Switch Interlocks ......................................................................................................................................... 21
Figure 20. Assigning Telegram DK logic gates ........................................................................................................................... 21
Figure 21. Setting the Shut Down Delay timer ............................................................................................................................ 22
Figure 22. Setting the Sources for Feedback LED 2 ................................................................................................................... 22
Figure 23. Joystick AK configuration........................................................................................................................................... 23
Figure 24. Time, Date and Language menu ............................................................................................................................... 23
Figure 25. Information provided in the 'About' screen ................................................................................................................. 24
Figure 26. Logging of changes done to configuration file ............................................................................................................ 24
Figure 27. Adjusting TFT Brightness .......................................................................................................................................... 24
Figure 28. Button Diagnostic page on Transmitter ...................................................................................................................... 25
Figure 29. Changing TFT layout using Hetronic Graphics Programmer ...................................................................................... 25
Figure 30. Downloading Graphics File to coder from USB Key ................................................................................................... 26
Figure 31. Configuring Feedback Timeout ................................................................................................................................. 26
Figure 32. Optional image displayed when “Clear Data’ is selected ............................................................................................ 26
Figure 33. Updating the Operation Access Code ........................................................................................................................ 26
Figure 34. Making Changes to the Access Code ........................................................................................................................ 27
Figure 35. Enabling RS232 communication ................................................................................................................................ 27
Figure 36. Enabling CAN Communication .................................................................................................................................. 27
List of Tables
Table 1. ERGO S Transmitter features......................................................................................................................................... 8
Table 2. Status LED Behaviour and Meanings ........................................................................................................................... 11
Table 3. Start-Up Sequences ..................................................................................................................................................... 12
Table 4. Battery duration ............................................................................................................................................................ 15
Table 5. Radio parameters......................................................................................................................................................... 16
Table 6. Troubleshooting tips ..................................................................................................................................................... 32
Table 7. Transmitter Technical Specification .............................................................................................................................. 33
Table 8. Battery Pack Technical Specification ............................................................................................................................ 33
3
1. Safety
1.1 Intended Use
Your radio remote control is designed for remote operation of machines and systems using safe wireless communications technology. Any
modification, reconstruction or extension of the systems without a written agreement of Hetronic may lead to the loss of your warranty and
guarantee claims.
Hetronic assumes no liability for damages resulting out of the non-observance of this operating manual. All persons, working with this radio
remote control must
 Be suitably trained and qualified as required by the safety regulations.

 Strictly comply with the contents of this operating manual.
Before starting the radio remote control you must have read and fully understood this operating manual. The Safety Checklist in Appendix B
is intended to be followed before each time the transmitter is powered up for operation.
1.2 Symbol Notation

The following symbols are used in this operating manual. 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.
STOP! This symbol gives you warning of imminent danger of life, risk of
accident and risk of injury, as well as damage to property in case of non-
observance of the working instructions.
ATTENTION! This symbol advises against a possible damage to the

system in case of non-observance of the working instructions.
TIP! This symbol points to features and information which allow for an
easier handling or operation.
1.3 Practices and Laws

Practice 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.
1.4 Required Operator Training

The 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.
1.5 Possible Sources of Danger

This device is part of a system that makes remote control via wireless radio signals possible. The transmission of control commands can
take place around obstacles and out of the operator’s direct line of sight. Take the following precautions to prevent accidental start-up and
possible injury or damage:
Switch “OFF” the transmitter when it is not in use. Unless the transmitter has user access control password configured, remove
the battery if unit is placed away from the operator.
Disconnect the power supply from the receiver before any assembly, maintenance or repair work is done.
AVOID SYSTEM DAMAGE - ALWAYS disconnect receiver power supply and control wiring before welding on any part of the
machine.
4
Never remove or alter any of the safety features.
ALWAYS confirm that the machine and radio remote control Stop functions work properly BEFORE beginning any machine
operation.
1.6 Protective Features

This transmitter is equipped with electronic and mechanical safety features. Control signals from other transmitters cannot be processed
because transmission coding is unique to each system.
1.7 STOP in case of EMERGENCY

Push the emergency stop on the machine.
1.8 Caring for your ERGO S

The enclosure materials employed on the ERGO S transmitter have been carefully selected to minimise maintenance requirements.
Buy a Hetronic ERGO S holster and screen protector. These will take care of your transmitter by preventing it from being
subject to knocks and scratches. This helps to keep the unit’s appearance longer and may also protect it from some internal
damage should you accidentally knock or drop it.
Always use genuine chargers and accessories. Cheaper ones that are not compatible or made for going with your ERGO S
can harm the unit or lessen its lifespan.
Do not keep your ERGO S stored in a closed container for extended periods of time unless it is powered off and the battery is removed from
the unit. Charging the ERGO S in a closed container is a potential fire hazard and may shorten its lifespan. Lithium-Ion batteries give off heat
when charging and when discharging. Keep your battery percentage between 40%-80% for longer battery life.
Clean your ERGO S regularly. Use damp cloth or alcohol wipes to clean the unit’s exterior surfaces. Do not use aggressive
cleaning agents that may inadvertently damage the unit.
5
2. Introduction and Functional Description

We congratulate you on the purchase of your new Hetronic ERGO S push button transmitter. You have chosen a high quality product.
Familiarise yourself with the unit before using it for the first time. In addition please carefully refer to the operating instructions and the safety
advise given in this manual. Only use the product as instructed and only for the intended field of application. Keep these instructions in a safe
place. If you pass the product on to anyone else, please ensure that you also pass on all the documentation with it.
2.1 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 silver label affixed to the unit.
2.2 Before Operating Your Wireless Control Unit

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. Ensure that the USB Dongle
(which acts as a security key to program the transmitter) is kept in a separate but safe and secure place. 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 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.
2.3 Unit Labels
2.3.1 Blank Rating Plate

1. Specific approvals, such as CE, FCC, IC, etc.
2. Type of ERGO S transmitter
3. Eleven-digit Production Number
4. Eleven-digit System Number
5. Frequency information
6. Current rating
7. Supply voltage
Figure 1. Blank Rating Plate
2.3.2 Read User Manual
The “Read User Manual” symbol on the transmitter acts as a reminder for the user to thoroughly read through the
manual before attempting to operate the system. The User Manual must always be placed in a safe and easily
accessible place when not being used for when there is the need to refer to it.
6
3. Your ERGO S Transmitter

3.1 General Description
The ERGO S is an ergonomically designed, programmable wireless industrial transmitter for remote machine control.
Your transmitter is encased in a rugged IP65 rated housing, is battery-powered, and comes equipped with built-in low battery detection.
Standard equipment includes two 3.45Ah Lithium-Ion batteries and battery charger.
3.2 ERGO S Basic Features

• Fully programmable via Hetronic PC-Link
• 8 push buttons with up to two detents
• 4 push buttons with single detent, one of which is the power button
• 1 proportional Joystick or Digital Selector switch
• Minimum 100 m (300 ft.) range using CS4XX and CS8xx modules
• Minimum 60 m (196 ft.) range using CS2400 RF module
• Typically 100 m (300 ft.) range using on board MFS 2G4 radio
• Internal Antenna
• Auto power off feature (configurable)
• Infrared (configurable)
• USB Interface
• Low Battery detection
• Status bi-colour LED Red/Green
• Feedback LEDs bi-colour Red/Green
• Cable Control
• Magnetic Belt Clip
• Data Logging (configurable)
• Rechargeable battery pack
3.3 Standard ERGO S 2.4GHz Configuration

Your ERGO S 2.4GHz transmitter is factory programmed to one of the following switch configurations:
A. ERGO S 2.4GHz-V1
 11 Single detent pushbutton
 1 Single detent POWER pushbutton
 1 Joystick or Selector Switch
B. ERGO S 2.4 GHz-V2

 3 Single detent pushbuttons
 8 Double detent pushbuttons
 1 Single detent POWER pushbutton
 1 Joystick or Selector Switch
7
15
14 16
22
17 18
19
12
9
10 1 2
11
3 4
13
5 6
7 8
20
21
Figure 2. ERGO S Transmitter (Right, Front, Left)
An optional 2.4” 240x320 TFT screen provides real-time visual information during operation of the ERGO S transmitter. It is used to change
configuration settings, provide two-way feedback and display transmitter diagnostic information such as battery life, signal strength and
button status. The status and feedback LEDs have the same positioning when the TFT is also present on the transmitter.
Feature # Description
1-8 Up to 2 Detent Momentary Pushbutton (S2-S9)
9-11 Single Detent Momentary Pushbutton (S10-S12)
12 Single Detent Power/Start Pushbutton (S1)
13 Joystick or Selector Switch (S13)
14 Infra Red
15 STOP Pushbutton (S0)
16 USB Port
17 TFT Display
18 Status bi-colour Red/Green LED
19 LED Feedback bi-colour Red/Green (L1-L3)
20 Customised Logo Area
21 Battery Compartment
22 Magnetic Belt Clip
Table 1. ERGO S Transmitter features
18
L1
L2 19
L3
Figure 3. Status and Feedback LEDs
8
3.4 Transmitter Operation Modes

Your ERGO S transmitter has following modes.
3.4.1. Transmission Mode
In which operator control unit can send the switch and joystick status to the machine control unit and display the information sent from
machine control unit on operator control unit LCD.
3.4.2. Service Mode
Your ERGO S transmitter’s parameters (Frequency, Baud rate, display brightness, access code, time, date and much more) can be
updated without connecting to Hetronic PC-Link. When the transmitter is in this mode the user can also check proper functioning of the
buttons.
3.4.3. Boot loader Mode
In which operator control unit's firmware can be updated. PC flash programming software should be used for uploading the firmware from
any computer with USB cable connected.
3.4.4. Charging Mode
In which operator control unit shuts down if the unit is placed on the docking station.
NOTE: When inserting the USB power cable in the transmitter, this does not charge the battery.
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4. Operating Your Transmitter

4.1 Holding Your Transmitter
Hold the 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 all shift changes.
4.2 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 a transmitter with worn out or damaged parts.
4.3 Powering Up and Starting Your Transmitter

NOTE: When the transmitter is not being used by the operator, it must be stored in a safe place.
1. Confirm that all safety measures required by the equipment manufacturer have been followed.
2. Insert a fully charged battery into the battery compartment of the transmitter.
3. Insert the USB key supplied with the transmitter in the ERGO S port (#16) and press Power (#12) button to power ON the transmitter unit.
4. Enter Access code (if enabled in Hetronic PC-Link configuration).
5. Power ON the receiver and press START (#12) on the transmitter unit to start and enable communication. The transmitter will perform a
routine initialization upon start up.
4.4 Transmitter Initialization with Standard Status LED Indicator

Upon turning the transmitter ON, all four front LEDs light up as solid colours and then switch off before the unit performs the routine
initialization.
During initialization, if the coder finds an error in the radio module, address, configuration or feedback, the transmitter will boot up and the
failure will be displayed as a blinking ORANGE (RED and GREEN simultaneously) status LED (#18) at the baud rate. The transmitter may
then be connected to Hetronic PC-Link (refer to Sections 5.1 Using Hetronic PC-Link and 6.5.7. Device Status and Button Diagnostic Checks
for instructions) for the Error to be corrected.
After a successful initialization, the ERGO S transmitter will enter Normal Operation Mode. The Green LED (#18) will blink at the baud rate
i.e. the LED toggles on with every transmitted telegram frame. All other LEDs switch off. Test all machine functions. Refer to your machine,
transmitter and receiver documentation as needed.
4.5 Transmitter Initialization with Graphic User Interface (TFT) and Standard Status LED Indicator
Upon turning the transmitter ON, the TFT screen turns ON and all the front LEDs light up as solid colours and then switch off before the unit
performs the routine initialization.
During initialization, if the coder finds an error in the radio module, address, configuration or feedback, the transmitter will boot up and the
failure will be displayed as a blinking ORANGE (RED and GREEN simultaneously) status LED (#18) at the baud rate. The error will also be
displayed on the screen. The transmitter may then be connected to Hetronic PC-Link (refer to Sections 5.1 Using Hetronic PC-Link and
6.5.7. Device Status and Button Diagnostic Checks for instructions) for the Error to be corrected.
After a successful initialization, the ERGO S transmitter will enter Normal Operation Mode and display the Splash screen. The correct
Operation Access Code must be inputted for the ERGO S to start operating, if this is enabled through Hetronic PC-Link configuration.
NOTE: This can be changed/enabled/disabled when the transmitter is in Service mode during operation or through Hetronic PC-Link. (Refer
to Section 6.7 for instructions).
The basic home screen will then be displayed and the Green LED (#18) will also blink at the baud rate i.e. the LED toggles on with every
transmitted telegram frame. All other LEDs switch off. Test all machine functions. Refer to your machine, transmitter and receiver
documentation as needed.
4.6 Turning OFF the Transmitter and Stopping the Radio Remote Control
Below are the steps to follow to turn off the transmitter:
1. Press the STOP button (#15).
The STOP screen appears, the RED status LED blinks at a fast rate and the transmitter sends a Stop telegram to the receiver. Upon
receiving the Stop telegram, the receiver goes into Safe Mode and turns OFF all receiver outputs.
10
Figure 4. Stop Screen
2. Press the Start button (#12) and the Shut Down Delay timer starts. The transmitter shuts off once the delay timer is over. This is normally
set to 2 seconds by default but can be programmed differently (refer to Section 6.3.4. STOP Button (#15)). The OFF state of the LED
indicates that the transmitter has switched off. If the Start/Power button is not pressed the Transmitter does not switch OFF.
Note: If the user wishes to resume operation, this is possible by deactivating the STOP switch.
WARNING: Holding the transmitter improperly while operating your machine could result in unexpected machine response.
WARNING: Test the stop function as described in the machine manufacturer’s operator manual before beginning any operation.
WARNING: To avoid accidental start-up, always press STOP when not in use.
Turn OFF your machine if there is a fault or problem with the safety check.
NEVER operate the machine if the STOP function does not work properly.
WARNING: Improper operation, maintenance or adjustment may cause serious injury or damage to equipment and may void the
warranty.
4.7 LED Behaviour and Meanings

The following table gives the meanings for the different behaviours of the Status LED (#18).
Result Meaning
Red & Green LED turns ON always. Service Mode.
Green LED Blinks. Data is being transmitted.
Red LED Blinks. Battery low.
Red LED Blinks at fast rate. Stop switch active. Stop Data is being transmitted.
Red & Green LED Blinks. H-link data transmitted to PC application.
Red & Green LED Blinks at fast rate. Boot loader mode to update the firmware.
Red & Green LED Blinks. FB / RF / Address / Configuration Error on Startup.
Table 2. Status LED Behaviour and Meanings
The other three bi-colour LEDs (#19) are configurable through H-Link and are typically used as feedback signals.
4.8 Magnetic Belt Clip (if equipped)

The practical magnetic belt clip allows the user to hang the ERGO S transmitter to any steel surface and continue operation hands free or
store the transmitter hung vertically when not in use and have easy access to it.
11
4.9 Start-Up Sequences

A number of sequences are available which will allow the user to enter different modes during Start-up. Below is a table which outlines these
sequences. In each case, the user needs to hold the respective sequence buttons to activate that particular mode.
Mode Sequence
Normal Operation Start Switch (#12)
Service Mode Stop Switch (#15) + Start Switch (#12)+ Top Left Switch (#9)
Copy USB H-Link Settings Stop Switch (#15) + Start Switch (#12) + Lower Right Switch (#10)
Copy USB Graphics Stop Switch (#15) + Start Switch (#12) + Lower Left Switch (#11)
Wireless Hetronic PC-Link Stop Switch (#15): Active only for the initial 5s after Power Up
Shutdown Stop Switch (#15) + Start Switch (#12)
Table 3. Start-Up Sequences
4.10 Front Switch LEDs

If your ERGO S transmitter includes the front switch LEDs feature, the front facing buttons (#1 - #8) will light up when the transmitter is in low
light conditions. The buttons will no longer be lit up when the lighting conditions improve. Lighting conditions are detected by the infra red
detector (#14).
12
5. Configuring Your ERGO S

5.1 Using Hetronic PC-Link
ERGO S units can be configured wirelessly using Hetronic’s PC-Link programming tool without being opened!
Hetronic PC-Link can access and set functions such as system address, transmission frequency channel, auto shut-off features, switch DK
assignments, device status and much more. Certain features can also be updated directly from the same transmitter when Service Mode is
selected (see Section 5.2 Using the Transmitter in Service Mode).
5.1.1 Connecting transmitter to Hetronic PC-Link
1. Insert the Hetronic Dongle in the PC where Hetronic PC-Link is installed and USB key in transmitter.
2. Make sure transmitter STOP button #15 is pressed and press ‘Connect’ on Hetronic PC-Link whilst pressing and holding ‘Start’ switch #12
on your ERGO S.
3. Input Hetronic PC-Link password from ‘Password > Login’ menu and configure ERGO S settings file as required.
4. Save settings to transmitter by selecting ‘Transfer settings to device’ from ‘File’ menu.
5. Release STOP switch, switch ERGO S on and settings are automatically saved to USB key.
5.1.2 Using Hetronic PC-Link to Save Settings File on USB key
Note: This method is an alternative to saving the configuration file from Hetronic PC-Link directly on the transmitter (as in 5.1.1).
1. Insert USB Key (provided with Transmitter) in the PC where Hetronic PC-Link is installed.
2. Make sure transmitter is switched off.
3. Select ‘ERGO S’ from list of devices on Hetronic PC-Link and click on ‘Offline’.
4. Load settings file from USB Key by clicking on ‘Read’ from ‘User: Control’ tab.
5. Input ‘Service Access’ Code (which is the same code as that used to enter Service Mode on transmitter).
6. Update as necessary, click on ‘Write’ in ‘User: Control’ tab and choose location on USB Key.
7. Remove USB key and insert in transmitter.
8. Switch on transmitter and select option 1 (‘Copy to Coder’) to save settings to coder.
5.2 Using the Transmitter in Service Mode

NOTE: Service Mode is only accessible on transmitters equipped with the optional graphic user interface. The units equipped with the
standard status LEDs can only have their settings updated via Hetronic PC-Link tool (Section 5.1 Using Hetronic PC-Link).
Service Mode can be used to edit configuration settings such as: Access code, RF module and Channel Selection, Screen Brightness, Date
and Time, TX Baud Rate, and others.
5.2.1 Entering Service Mode
1. Make sure STOP switch (#15) on transmitter is activated.
2. Switch on ERGO S by pressing the Start button (#12) and then keeping the side top switches (#9 and #12) pressed until the splash screen
disappears and the ‘Device Settings’ screen appears.
3. Input the ‘Service Access’ code if this is enabled in the Hetronic PC-Link configuration and perform the appropriate selections.
Figure 5. Pages 1 and 2 of the Device Settings menu
13
5.2.2 Adjusting Settings in Service Mode

The four topmost buttons on the front panel are used to navigate through Service Mode and also to change setting parameters within the
menus. The menu selection changes with every screen and the description of what each of the four buttons will do is explained next to the
button number.
Note: Once the user exits ‘Service Mode’ the changes are automatically saved to the USB Key, only if it already contains a settings
file. Whenever a USB Key with different configuration settings is inserted in the transmitter, the user is prompted to choose
whether the settings on the USB Key are to be saved to the coder (“Copy to Coder”) or whether the settings on the coder are to
replace the existing ones (“Copy to USB Key”).
Note: When the USB Key is not detected, a warning message is displayed stating that the key is missing and unit is shutting down.
14
6. Setting up Your ERGO S for Operation

6.1 Coder
6.1.1 Address
The coder address with which the ERGO S transmitter has been programmed from the factory can be found listed on the datasheet. This
can be updated via Hetronic PC-Link in the ‘RF’ tab and any number between 1 and 999999 can be used. The user is also able to read the
coder address from the transmitter when the option ‘About’ is selected when the transmitter is in Service Mode (refer to Section 6.5.5. About
the Transmitter).
6.1.2 Telegram Type
Three types of telegrams are available for selection. These are
a) 32DK
b) 32DK + 8AK
c) 80DK + 2AK
When the transmitter is set to MFS mode, the 32DK telegram can only be used.
6.1.3 Battery Level Indication
Unless the transmitter is equipped with a TFT screen, in which case the Battery Level is also displayed on the status bar, the transmitter
uses two different warning signs to show the user that the battery needs replacement.
When the Low Battery level warning has been triggered, the RED status LED (#18) will blink at the baud rate. The Low Battery detection
threshold can be set through the ‘Low Batt Warning’ field in the ‘RF’ tab on Hetronic PC-Link. This can be set to either ‘Short’, ‘Medium’ or
‘Long’ and is related to the battery voltage.
Figure 6. Low Battery Warning Configuration
Approximate battery duration for each of the above options, assuming a brand new and fully charged battery, are as follows:
Full Duplex Half Duplex MFS

Short 7hr 15mins 8hr 30mins 10hr 15mins
Medium 6hr 15mins 7hr 10mins 9hr 30mins
Long 5hr 15mins 6hr 7hr 45mins
Table 4. Battery duration
In addition to low battery warning, a fixed critical battery level is also monitored. When critical battery level is reached, the RED Status LED
will blink faster. The coder will automatically trigger the Stop telegram for about 5 seconds until it shuts off.
15
6.2 Communication
Following are the standard communication parameters which can be set using H-Link for your ERGO S transmitter from the ‘RF’ tab.
Parameter Description
Address  0-999999
 32DK
Telegram Type  32DK + 8AK
 80DK + 2AK
 CS419TR
 CS429TR
 CS434TR
 CS458TR
 CS868TR
 CS434TXN
Radio Module
 CS458TXN
 CS480TR
 CS9xxTR
 CS1216TR
 CS2400TR
 MFS2G4
Frequency Standard frequencies for each RF module
Low Battery Warning Short, Medium, Long
4800, 9600bps for standard 4xxx-8xx MHz radio modules
TX Baud
115200bps for standard 2400MHz radio modules
Auto off 1min – 1hour
Feedback Disabled, Half duplex, Full duplex
DK sync1 DK2 – DK30
DK sync2 DK2 – DK30
Interval 0-30
FB Delay 1 – 100ms
FD Baud TxBaud, 2400-115200
Radio Module Standard Hetronic RF module range
Frequencies Standard frequencies for RF module
Primary MFS channel MFS channel Standard channels for MFS 2.4Ghz (1-16)
Secondary MFS channel MFS channel Standard channels for MFS 2.4Ghz (1-16)
Duty cycle EU/USA
Table 5. Radio parameters
N.B. For setting specific RF channels/groups refer to respective frequency table in RF module appendix.
N.B. When in MFS mode, only 32DK telegram format is used.
Certain communication settings can be also be updated from the ‘Radio Settings’ page when the transmitter is in Service Mode (refer to
respective sections for instructions).
6.2.1 Radio Settings
The ERGO S coder is designed with the possibility to connect two on board RF modules either operating in the sub 1GHz range as well as
MFS2G4 and CS2400. When the RF module is plugged directly on to the coder (onboard), the user may select the frequency channel or
group to use for communication. If the RF module is connected to the coder externally (through a cable set inside the transmitter) the
channel will depend on the SIP switch settings as outlined in the RF module and Frequency Bands charts. The RF module is used for either
transmitting only the control telegram or else operating in half duplex mode. For the coder to operate in full duplex mode then a second RF
module has to be connected and configured using Hetronic PC-Link.
Figure 7. Radio Mode menu selections on Hetronic PC-Link
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The user also has the possibility of checking or changing the Radio Settings directly from the transmitter from the below menus in Service
Mode.
Figure 8. Radio Settings menu
 RF Module
1. Press button #1 to enter Radio Settings menu.
2. Press button #1 to go through the list of RF module options until the desired one is visible.
3. Press button #4 to save selection and return to main ‘Device Settings’ page.
 Frequency Channel or Group

2. Press button #2 to scroll through the list of channels or groups until the desired one is visible.
 Transmitter Baud Rate

The allowable baud rates of the control telegram that may be configured are 4800 or 9600bits/second for the Hetronic standard 4xx-8xx MHz
radio modules. The standard baud rate of 115200 bits/second is used for Hetronic standard 2.4GHz radio modules. To change the TX Baud
Rate when the transmitter is in Service Mode one has to:
2. Press button #3 to scroll through the available baud rates and stop when the desired one is visible.
The baud rate for the transmitter must be identical to that of the receiver. Whenever the baud rate of a unit is changed, the
baud rate of the paired unit must be changed accordingly.
Note: The coder still supports all other baud rates for cases when non-standard radio modules are used.
6.2.2 Auto-OFF
A transmitter Auto-OFF timer can also be set which powers down the coder if it remains idle for a configured period of time. The Auto-OFF
timer can also be disabled so that the coder remains always ON until either switched OFF manually or else when the critical battery voltage
is reached and thus the transmitter switches off automatically.
Figure 9. Setting the Auto-OFF timer
17
6.2.4 Half Duplex Communication

For half duplex feedback configurations the below parameters have to be set:
 DK Sync 1 – Can be any DK between DK2 and DK30 from the control telegram. The coder triggers the sync DK after an assigned
interval and then switches to receive mode. Once a valid feedback frame is received, the coder switches back to transmit mode.
 DK Sync 2 – The second sync DK can be used to prompt a sensor or other device to send a feedback telegram. This operates in
the same way as DK Sync 1.
 Interval – The value of the interval defines after how many sent control messages should a feedback telegram be received. If the
interval is set to 0, then for every control message, 1 feedback telegram is received. If set to 1, then for every 2 control messages
sent, 1 feedback telegram is received.
 HD Baud – A different feedback baud rate to the transmit baud rate can be used when operating in half duplex. This also can be
configured to a value from 2400 to 115200bits/second.
 FB Delay – The feedback delay configures how much time to wait for a feedback telegram after the sync DK has been sent. If
after the FB delay period is over, a valid feedback telegram has not yet been received, then the coder switches back to
transmitting.
Figure 10. Half Duplex Configuration
6.2.4 Full Duplex Communication

The RF module, baud rate and frequency channel have to be configured when full duplex is selected.
NOTE: These settings have to match those on the receiver.
Figure 11. Full Duplex Configuration
6.2.5 MFS 2.4GHz Radio Mode

The presence of internal 2G4 radio allows the ERGO S coder to operate in MFS 2G4 mode.
 MFS Channels – There are 16 channels available for selection of the primary and secondary channels of operation. The
primary and secondary channels are used alternately in transmitting and receiving MFS data frames.
 MFS Duty Cycle – The user can choose between EU and USA duty cycles depending on the country regulations in place.
18
Figure 12. ERGO S MFS Configuration
 MFS 2G4 Feedback – ERGO S supports the reception of MFS 2G4 default feedback with digital and analogue data. The
feedback data can control either the LCD or the LEDs. Standard Hetronic Feedback telegrams can all be processed in MFS
2G4.
6.2.6 Address Learn Function

If your ERGO S transmitter includes an address learn function for quick pairing to a receiver unit, the option will show on Page 2 of the
Service Mode menu.
Figure 13. Pages 1 and 2 of the Service Mode menu showing Address Learn function
1. Press button #4 to enter Page 2 of the Service Mode menu.

2. Press button #3 to access the Address Learn function. The following page will be displayed.
Figure 14. Address Learn page
3. Start the Address Learn function on your machine.
19
The next few steps will need to be performed within 10 seconds of starting the Address Learn function from the machine.
Otherwise, the Address Learn procedure will need to be restarted.
4. On the ERGO S, press and hold button #1 to Start Address Learning. The following page will be displayed.
Figure 15. Initiating Learning page
5. Keep holding button #1 to Send Tx Learn Command.

6. If the below notification shows up, it means that the ERGO S is changing its frequency channel to continue trying to detect the
receiver on the machine. Keep holding button #1.
Figure 16. ERGO S changing channel notification
7. If successful, the following notification will be displayed. You can then stop the Address Learn function from the machine and restart
the ERGO S transmitter.
Figure 17. Successful Address Learn notification
8. If the above notification does not show after 10 seconds, then you may need to restart the address learn procedure from the
beginning.
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6.3 DK Configuration
6.3.1 DK Assignment
Your ERGO S transmitter can have 8 front and 4 side switches (for V1 and V2 type). These switches can be configured from the H-Link DK
tab and each switch can be assigned with 3 different DK’s. The front switches can be 1 step or 2 step switches, depending on the coder, and
the side switches can only be 1 step. In order to assign DKs to a particular switch, it must be selected from the image of the transmitter
shown on the left side of the window.
Figure 18. Assigning DKs to switch number 3

6.3.2. Switch Interlocks
The front and side switch pairs can be configured with switch interlocks. If this feature is enabled, then whenever both switches of the
interlocking pair are pressed, only the DK/s assigned to the first one which has been pressed is/are set to ON. Thus, the first switch which
has been pressed takes priority and whenever this switch is released will the DK/s of the second switch being pressed be set as ON. The
switch interlock pairs are switch 1&2, 3&4, 5&6, 7&8, A&B and C&D.
Figure 19. Enabling Switch Interlocks
6.3.3. Telegram DK Assignment

All 80 telegram DKs are configurable via H-Link using logic gates having a maximum of four inputs each. DK31 and DK32 are exclusively
assigned to the Stop switch but can have additional logic signals controlling their states.
Figure 20. Assigning Telegram DK logic gates
6.3.4. STOP Button (#15)
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When the STOP button is pressed, the Stop screen (Figure 3) is displayed (if equipped with the optional TFT) and the stop telegram is
continuously transmitted. The Shut Down Delay timer starts once the Start button (#12) is pressed and as soon as the timer is over, the
device switches off. This is normally 2 seconds after #15 is pressed, however the shut down delay can be configured to last up to 7.5
seconds. This can be set on Hetronic PC-Link from the ‘Shut Down Delay’ Timer on the DK tab.
Figure 21. Setting the Shut Down Delay timer
6.3.5. LED Feedback assignment

The three feedback bi-colour LEDs (L1-L3) can be configured to switch ON when either of two ‘Sources’ is ON. The Green LED switches on
with Colour 1 and the Red LED switches on with Colour 2. The ‘Source’ can be a DK, logic gate result, feedback bit (16bit, 4bit LCD, 4 bit
short), etc.
Figure 22. Setting the Sources for Feedback LED 2
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6.4 AK-DAC
All 8 configurable AK channels (AK1-AK8) can be assigned to an independent ‘Signal’. When no ‘Signal’ is assigned, the corresponding AK
channel will remain in neutral position, which can be either 0x7F or 0x00 hex value depending on the ‘Type’ selected (Vref/2 or 0-Vref
respectively).
6.4.1. Joystick up/down and left/right (Optional)
Whenever a joystick is to be used on an ERGO S transmitter, it must be connected to 4 analogue inputs. As a safety precaution, AK1 and
AK2 must have the same values of AK3 and AK4, respectively. Thus, the joystick must have a redundant circuit as a safety measure in case
the joystick fails. When configuring the AKs to the telegram AK1/AK3 are mapped to joystick up/down movements while AK2/AK4 are
mapped to joystick left/right movements.
The safety DKs for the AKs are also configurable via Hetronic PC-Link, however, these are only set if the settings for AK1 are identical to
those of AK3 and those of AK2 are identical to those of AK4. This ensures that the joystick is operating correctly.
When setting the ‘Type’ to Vref/2 the user can select direction DKs. When the direction DK is ON then the joystick value will be available in
the telegram, thus ensuring that the joystick function is permitted only when a button is pressed or a specific condition is met.
By adjusting the joystick analogue input sensitivity level from the bar in Hetronic PC-Link, the speed by which the analogue input updates is
configured. Higher sensitivity means that the AK updates very fast whilst very low sensitivity means that the joystick updates slowly.
Figure 23. Joystick AK configuration
6.5 Graphical User Interface (Optional)

Your ERGO S transmitter’s TFT has following display features:
6.5.1. Splash Screen (Logo)
Splash screen is the Logo that will be displayed during transmitter start up. The ERGO S default screen is the Hetronic Logo. This can be
enabled or disabled using 'LCD Splash screen' in the Feedback tab of Hetronic PC-Link and can also be changed using the Hetronic
Graphics Programming tool (as outlined in Section 6.6 Feedback Messages). Its duration can also be set from the ‘On time’ field.
6.5.2. Time & Date
Time displayed on the status bar of your ERGO S transmitter can only be in 24hrs format. The time and date are automatically downloaded
on to the transmitter with the configuration and can be updated either from the User Control tab on Hetronic PC-Link, or through the second
page of the ‘General Settings’ menu when the transmitter is in Service Mode.
6.5.3. Language
The language of the menus in Service Mode can be changed to English, Spanish, French, Italian or German from the second page of the
‘General Settings’ menu. The choice of languages available is displayed in a cyclic manner every time button 3 is pressed. The user selects
the preferred language by then pressing button #4 to confirm the selection and return to previous page.
Figure 24. Time, Date and Language menu
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6.5.4. Received Signal Strength Indicator (RSSI)

Received signal strength is displayed on status bar of your ERGO S transmitter indicates the transmitter signal strength. If feedback is
enabled then it shows the strength of the receiver signal.
6.5.5. About the Transmitter

Basic transmitter and software information, including address, can be viewed from the ‘About’ option found in the second page of the ‘Device
Settings’ menu. The number of hours of operation is also shown here. To return back to previous page, button #4 must be pressed.
Figure 25. Information provided in the 'About' screen
The user can also check when the configuration file was last updated from the User Control tab.
Figure 26. Logging of changes done to configuration file

6.5.6. Brightness
TFT brightness can be adjusted from page 1 of the General Settings menu when the transmitter is in Service Mode.
Figure 27. Adjusting TFT Brightness
The user can choose the optimal screen brightness by pressing buttons #1 or #2. Brightness can be adjusted between setting 1 and setting
8, with 8 being the brightest. Pressing button number #3 will save the new setting and return to the General Settings menu.
6.5.7. Device Status and Button Diagnostic Checks
Your ERGO S transmitter’s switch DKs, AK settings and communication parameters can be monitored from the Hetronic PC-Link ‘Device
Status’ tab. All the configured parameters must be cross checked before using the transmitter with any receiver. After connecting the
transmitter to Hetronic PC-Link, the user has to click on “Connect” on the ‘Device Status’ tab and the status bar changes to green which
denotes communication. The ‘Device Status’ tab acts as a receiver thus all the logic gate results, interlocking features, delays, etc can be
seen when activated.
The button diagnostic checks can also be carried out directly from the transmitter to ensure that all 1-Step and 2-Step switches are working
properly. The user needs to access ‘Device Settings’ page when in Service Mode and button #2 for the ‘Button Diagnostic’ page.
24
Front panel
Side switch switch
diagnostic diagnostic
identifier identifier
Figure 28. Button Diagnostic page on Transmitter
When pressing the first step of a 2-Step button, the respective diagnostic identifier for that button switches on blue. When the second step is
pressed, the identifier will change to green. 1-Step switches will only use the blue identifier. If a button is not functioning well, the diagnostic
identifier remains on.
Once all checks are made, the user can return to the main screen by making sure the STOP button is pressed whilst holding buttons #1 and
#2 pressed simultaneously.
6.6 Feedback Messages

Customized LCD feedback is used for ERGO S and this is handled through the LCD and LEDs next to the LCD. This mode allows the
display of images in any location on the LCD and decoding of the feedback data as required by user without the need to follow any particular
graphics mode.
6.6.1. LCD Customizable Graphics
The TFT’s background colour, splash screen, graphics, feedback images and positions, text and status bar can all be configurable using a
custom graphics programming tool which can be provided upon request.
Figure 29. Changing TFT layout using Hetronic Graphics Programmer
Steps to upload new graphics on to the transmitter:

1. Insert USB Key in PC where Hetronic Graphics Programmer software is installed. Edit the screen layouts to be used and save onto the
USB Key.
2. Remove USB Key and insert in ERGO S. Release Stop switch and switch on transmitter.
3. The graphics file will automatically be downloaded on the coder and the progress will be shown on the display.
NOTE: The user can also choose to copy the graphics file manually by selecting the option ‘Copy to Coder’ following the Start-Up sequence
outlined in section 4.9.
25
KEY
Figure 30. Downloading Graphics File to coder from USB Key
6.6.2. Feedback Timeout

The LCD screen can show LCD timeout if no feedback has been received for a pre-set amount of time. If no feedback is received during this
time then the LCD can either be set to keep on showing the last feedback message received by selecting ‘Keep Data’ or else the last
feedback message can be cleared by selecting ‘Clear Data’. When ‘Clear Data’ is selected, the feedback timeout can be configured from
500ms to 5 seconds and the image displayed can be configured through the Hetronic Graphics Programmer. Should the user not wish to
have a timeout image being displayed then a blank white screen can be set in the GUI timeout screen settings.
Figure 31. Configuring Feedback Timeout
Figure 32. Optional image displayed when “Clear Data’ is selected
6.7 Access Codes

If the Operational Access is enabled, the user is asked to input the Access Code every time the transmitter is switched on. This is done as a
safety measure to prevent unauthorized use of the transmitter. Thus, the operator must keep this code confidential and must not leave it
easily accessible to unauthorized personnel. Setting the access code as ‘0’ will disable the function. The Service Access code can be
identical to the Operational Access code, however, the Service Access code can only be changed through Hetronic PC-link configuration.
Updating of the Operational Access code can be done through the ‘User: Control’ tab.
Figure 33. Updating the Operation Access Code
26
The user can also change the Operational Access Code from the transmitter when in Service Mode using the following steps:
1. Press button #3 to enter General Settings menu.
2. Press button #2 to go to Access Code page.
3. Press button #3 to increment (or button #4 to decrement) the highlighted digit and button #2 to confirm and move on to the next digit.
4. When all the required changes have been made, press button #2 to confirm the new access code.
Figure 34. Making Changes to the Access Code
6.8 USB Interface

Your ERGO S transmitter’s USB port is used for following features:
1. Updating firmware: Memory key must be replaced with USB cable for your ERGO S transmitter to update the firmware in Boot loader
mode.
2. USB key: USB stick acts as a hardware key to operate the transmitter. Without the USB Key the transmitter will not operate.
3. Power bank: Can be plugged with power bank to operate the transmitter without battery (In current design power switch is bypassed for
this feature).
4. Basic Configuration: The transmitter configuration settings can also be saved on the USB key and this is then inserted in the Transmitter
before switching it on.
Note: Always make sure to keep the USB key in a safe place when it is not being used.
6.9 Data Logging

The user can choose to log all commands which are transmitted during operation. The 80DKs can be selected for monitoring and each time
their state changes this will be logged together with the date, time and battery voltage. The user can choose to save the data by selecting
‘Read’ in the User Control tab, then exporting the data to a document.
6.10 Cable Control

Cable control is also possible on ERGO S Transmitters and this allows for the operation of the transmitter with no wireless radio
transmission. This feature requires an additional cable to be ordered and this is plugged in the battery compartment in the ERGO S in place
of the battery. The special battery enclosure consists of a module which has to be configured via Hetronic PC-Link (from ‘RF’ tab) for CAN or
RS232 communication. The CAN communication supports both CANopen and J1939 while RS232 communication is by default set to full
duplex communication.
Figure 35. Enabling RS232 communication
Figure 36. Enabling CAN Communication
27
When CAN is selected, the ‘CAN’ tab becomes available to configure the required CAN settings.
The following three standard cable options are available to choose from depending on the application. However, customized variants can
also be ordered.
a) 10m CAN cable without termination jumper (#1051512510)
b) 10m CAN cable with termination jumper (#1051512610)
c) 10m RS232 cable (#1051513510)
The cable side to be connected to the receiver unit has a plug connector attached to it. Pin outs are as follows:
RS232 Cable CAN Cable

Pin number Function Pin number Function
1 Vcc 1 Vcc
2 RS232 TX 2 CAN H
3 RS232 RX 3 CAN L
4 GND 4 GND
6.10.1 Installation of Cable Control Cable

1. Switch off ERGO S and remove the battery.
2. Plug in the cable in the ERGO S, making sure the clips are securely fastened.
6.10.2 Operation of ERGO S in Cable Control Mode

With cable control cable attached, switch on transmitter following the start up sequence as outlined in Section 4. During start up, the
transmitter will automatically recognize that the cable is attached and communicating and thus will switch into cable control mode. This will
turn off all wireless transmission and send/receive all command and feedback signals through the cable.
All controls on the transmitter will function the same regardless of whether the transmitter is in cable control mode or
wireless mode.
6.10.3 Returning Transmitter to Wireless Mode

To return to wireless mode, the transmitter must be powered off and the cable disconnected. Following the start up sequence from Section 4,
restart the transmitter. This will automatically detect that it is no longer in cable control mode and will start the unit in its normal wireless
mode.
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7. Theory of Operation
Your ERGO S transmitter works with a receiving device to transfer machine control commands via radio frequency to your machine. The
transmitter electronically generates a carrier frequency that allows it to communicate with the receiver without the use of cables or wires. The
receiver then converts the carrier frequency information into discrete machine control outputs that interface with your machine’s controls.
Each transmitter and receiver that comprises a system is programmed with a unique address code. This code ensures that machine
operations are safe, and that other remote control equipment cannot unintentionally control your machine. The receiver only accepts
commands from the transmitter with the same address code. The receiver and transmitter have the address code set at the factory.
7.1 Stop Function

The most important feature of the radio remote control system is the STOP function. When the transmitter is turned on, it performs a self-test
to confirm that communications are within designated parameters. If an error is detected, the transmitter will not transmit any signals. The
transmitter sends the STOP pushbutton status along with the specified machine functions. This method confirms that ongoing operations are
safe. If the STOP pushbutton (#15) is pressed, the data telegram changes so that only the stop command is transmitted. No other motion
command data is sent.
This special data telegram places the receiver in Safe Mode, and the stop relays in the receiver open. All other machine functions are
completely disabled in the receiver.
The STOP button (#15) on the transmitter is only a remote stop and will operate only when the transmitter is powered up.
Pressing the STOP pushbutton (#15) does not ensure the machine will stop. STOP button functionality is subject to the wiring of
receiver STOP relays to machine emergency stop circuit and controlled machine logic where applicable.
ALWAYS test the STOP function at the beginning of every operation session or when there is change of operator.
29
8. Flash Programming
8.1 Programming the Stop Processor Firmware

Tools required: AVRISP mkII programmer and AVRStudio v4.18 or later
1. Connect the AVRISP programmer to the board’s ISP2 connector. Square pad is pin 1.
2. Turn on power to the board.
3. Start AVRStudio.
4. From the “tools” menu, select “Program AVR/Connect” or click the AVR Programmer icon.
5. Under “Main” tab, set Device to ATmega168 and ISP Frequency to 125.0 kHz.
6. Under “Program” tab, select the firmware file under “ELF Production File Format.”
7. Under “Program” tab, click “Program.”
8.2 Programming the Main Processor Firmware

Tools required: Keil ULink 2 and uVision 4
1. Connect the “ULINK USB-JTAG Adapter” to the ERGO S board’s JTAG (JTAG designator) connector. Square pad is pin 1.
2. Press the Power on button of the transmitter and keep it held until programming is completed.
3. Start the “Keil uVision4” program.
4. From the "Project" menu select "Open Project”", locate the folder which contains the “Bootloader /Application” file and open the
“Bootloader /Application” file.
5. Select “LOAD” button to flash code into hardware.
8.3 Programming the Application

Tools required: USB flash programmer v0.96 and USB cable
1. Remove the battery. Press the power switch with stop button activated and connect the USB cable.
2. Run the USB flash programmer.
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3. ERGO S LED’s (Green and Red) will blink at a fast rate and LCD displays “Bootloader mode”.
4. The application will display as ‘scanning port’ and indicate the details of the board connected.
Note: - Application should displace device name as “ERGO S” with Boot loader memory from ‘0’ to ‘4000h’ and Application memory
from ‘4000h’ to ‘0x3C000h’.
5. Change the ‘Memory space’ drop down to ‘Application’.

6. Click on ‘Browse’ and select the latest .hex file.
7. Click on ‘Upload’. If the flashing was successful then the application will display ‘Verification successful’.
8. Disconnect the USB and deactivate the stop switch to run the application.
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9. Troubleshooting
If your ERGO S 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
Incorrect Access code (if enabled) Enter correct access code

Transmitter won’t start
Battery fully discharged Replace with fully charged battery if needed
The transmitter is turned on, but Battery is discharged Replace battery with a fully charged battery
does not transmit (Power LED not
flashing) Contact your supervisor or nearest Hetronic
Component failure
Service Centre
Check the diagnostic LEDs in the receiver
No power to the receiver to be sure power is applied. Ensure that the
system is properly grounded
Follow instructions under “Setting
Transmitter/receiver frequency channels do
Frequency and channels” or contact your
not match
supervisor
Transmitter is transmitting (Power Take the transmitter back into the range of
Transmitter out of range
LED flashing), but machine will not the receiver, press START
respond
Receiver power off Turn on power to receiver
Blown fuse in receiver Check all fuses and replace if needed
STOP failure in receiver. Red STOP LED on

Contact your supervisor
PC board is illuminated
Receiver antenna connection is loose or

Tighten or replace antenna
missing
Tighten antenna and ground connection.

External antenna (if used) has loose
Contact Hetronic or your Dealer for more
All machine motions operate connection, poor grounding or interference
information
intermittently
Connector inside receiver is loose Check all connectors, reseat if needed
Another frequency may be interfering with

Contact your supervisor
the system
Missing or damaged USB Check the USB
USB Key Missing Contact Hetronic to get the latest firmware

Firmware Update is Needed
and check the programming section
when a new USB is used on transmitters
(Section 8) on how to update firmware on
built before 2024
the coder
Table 6. Troubleshooting tips
32
10. Specifications
Transmitter
Housing Ergonomically designed Impact Resistant Polymer Composite
Environmental Protection IP 65 (Exceeds Nema 12/13)
~450g (1.21lbs) including battery
Weight
And full duplex configuration
Height: 240 mm (9.4 in.)
Dimensions Width: 110 mm (4.2 in.)
Depth: 80 mm (3.1 in.)
Antenna Internal
Battery +B: 3.0 to 5.0Vdc
Power Supply Optional Cable Control +B: 6.5 to 32Vdc
Battery Charge: 3.0 to 4.2Vdc
Diagnostics Status LED for operation and standard/advanced low battery detection
Operation Time Up to 11 hrs continuous transmission*
V1 – 11 single detent push buttons, start + stop
Control Configuration
V2 – 8 two detent push buttons, 3 single detent push buttons, start + stop
4xxMHz or 8xxMhz or 9xxMHz or 2.4GHz (subject to purchased
Frequency Range
configuration) **
Power (RF Output) Typically ≤ 10 mW E.I.R.P; depends on country legislation
Typically 120 m. (400 ft.) for ≤ 1GHz, 100m (300ft) for MFS2G4,
Typical Operating Range
50-60m (170 ft) for ≥ 1GHz
20-bit programmable address concept with up to 1,000,000 combinations
Safety
Hamming Distance 4
Operating Temperature Range -20°C . . . 70°C (-4°F . . . 158°F)
Storage Temperature Range -40°C . . . 85°C (-40°F . . . 185°F)
Humidity Range 95% IEC 60068-2-78
Response Time Less than 100 msec.
Fully programmable via Hetronic PC-Link
USB (Type A) Interface with 4Gb Memory key for configuration settings
Status LED for std/adv. low battery detection and Feedback LEDs
Standard Features STOP Button EN 60204-1, ISO 13850, IEC60947 Compliant
User programmable RTC
Start and Function Interlock
User programmable Infrared ACK Start-Up
Prop Joystick 2-axis
Central control options Selector switch 3 position
Blank
240(RGB)*320 2.4” TFT with Backlight
Colour 65K/262K
TFT
Sunlight Readable
User-replaceable protection cover
Table 7. Transmitter Technical Specification
*assuming brand new, fully charged battery at 20°C temperature
** for full Channel Lists refer to Frequency Bands Radio Modules Charts
Battery Pack
Rated Capacity 3.7V, 3400mAh, 0.2C discharging
-20°C . . . 45°C, 90%RH max (for short periods less than 1month)
Storage Environment Conditions -10°C . . . 45°C, 90%RH max (for long periods more than 3 months)
15°C . . . 35°C, 85%RH max (recommended storage)*
Charging Temperature Range 0°C . . . 45°C (32°F . . . 113°F), max 90%RH
Discharging Temperature Range -20°C . . . 70°C (-4°F . . . 158°F) , max 90%RH
Charging Time (hrs) 3-4
Table 8. Battery Pack Technical Specification
* for long time storage, the cell’s storage voltage should be 3.6-3.9V and it is recommended to charge the cell every six months.
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11. Warranty, Service, Repairs and Maintenance

Before any service or maintenance intervention on remote controlled equipment always:
 Remove all electrical power from the equipment

 Follow lock out procedures
Hetronic products are covered by a guarantee/warranty against material, construction and manufacturing faults. During the
guarantee/warranty period, Hetronic may replace the product or faulty parts. Work under guarantee/warranty must be carried out by
Hetronic, or by an authorized service centre specified by Hetronic. Any modification, reconstruction or extension of the systems without a
written agreement of Hetronic may lead to the loss of your warranty and guarantee claims.
The following are not covered by the guarantee/warranty:
 Faults resulting from normal wear and tear

 Consumables e.g. batteries
 Products that have been subject to unauthorized modifications
 Faults resulting from incorrect installation and use
Maintenance and Preventive Care
 Repairs and maintenance must be carried out by qualified personnel

 Only use original Hetronic spare parts
 Contact your representative for service or any other assistance
 Keep the product in a clean, dry place
 Keep battery contacts clean
 Wipe off dust using a slightly damp, clean cloth
 Keep rubber over-mould clean
 Remove dust from inside gaps, docking recesses and battery contacts using a vacuum. Special care must be taken when cleaning
the battery compartment of the transmitter as detachment of the pressure balance element may lead to ingress protection
problems
NEVER USE:
 Abrasive cleaning solutions or high-pressure water jets.

 Sharp, pointed objects or any hard items as these may tear the over-mould or rubber parts.
 Compressed air as this may lead to ingress protection issues.
 Petroleum based solvents including Diesel and Gasoline to clean the unit as these may react with the silicone rubber of the
joystick gaiter.
Note: Refer to Appendix C for Spare Parts List and Instructions on how to replace Button Cell on coder and USB Key.
34
12. Regulatory Information

12.1 Europe
CE Marking
Hetronic hereby declares that the radio equipment types listed in this manual are in compliance with Directive 2014/53/EU.
The latest version of the complete EU Declaration of Conformity is available on the Hetronic website www.hetronic.com.
WEEE Directive
This symbol means that inoperative electrical and electronic products must not be mixed with household waste. The European
Union has implemented collection and recycling system for which producers are responsible. For proper treatment, recovery
and recycling, please dispose of the product in a designated collection point.
REACH Compliance
Hetronic confirms that, to the best of its knowledge and continual communication with its respective suppliers, chemical Substances of Very
High Concern (SVHC) are not included in our products. Based on the response statements of our suppliers no materials from the ECHA are
included on Hetronic products. For the latest version of the complete Declaration of Conformity please visit the Hetronic website
www.hetronic.com.
RoHS Compliance
As a designer and manufacturer of electrical and electronic products covered by RoHS and RoHS2, Hetronic confirms that to the best of its
knowledge at the date of this statement, none of the products supplied by it contain any of the hazardous substances in excess of permitted
levels referred to in the Directive 2002/95/EC. The latest version of the complete Declaration of Conformity is available on the Hetronic
website www.hetronic.com
12.2 North America
FCC ID: LW9-ERGOS2G4

FCC Recommendations:
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may cause undesired operation.
Changes or modifications not expressly approved by the manufacturer could void the user's authority to operate the equipment.
To comply with FCC RF exposure compliance requirements, this device and its antenna must not be co-located with, or operating in
conjunction with, any other antenna or transmitter.
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These
limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial
environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions,
may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna
• Increase the separation between the equipment and receiver
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
35
12.3 Industry Canada (IC/ISED) Statement
IC ID: 2119B-ERGOS2G4
IC RF Exposure Statement
This device meets the IC requirements for RF exposure in public or uncontrolled environments.
IC Warning
This product complies with Industry Canada’s licence-exempt RSSs. Operation is subject to the following two conditions:
1. This device may not cause interference, and
2. This device must accept any interference, including interference that may cause undesired operation of device.
www.hetronic.com
© 2020 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.
36
Appendix A
Definition of terms
The following terms are used throughout the ERGO S Programming and Service Manual.
Term Definition
baud rate The transmitting speed measured in bits per second.
hamming distance A measurement of data transmission safety. The amount of failures in the data stream which has to
occur during the transmission in order to create a wrong signal. A low hamming distance means
that the test is not very sensitive to data transmission errors and could potentially be unsafe. A high
hamming distance means that the system is very sensitive and could potentially be unreliable due
to potential noise interference.
interlock Prevents a component from functioning when another component is functioning or operating in a
particular way.
37
Appendix B
B.1 Operator Safety Basics

Before starting your shift, you should make sure that the equipment has a current inspection certificate and that the necessary inspections
and risk assessment checks have been carried out and are up to date. Also, the equipment must be operated in accordance with the
manufacturer’s instructions.
Furthermore, it is of utmost importance that you know that YOU are primarily responsible for YOUR OWN health and safety. Wear
appropriate Personal Protective Equipment and make sure that you have had all the necessary training to operate the equipment. The
following basic safety precautions must be adhered to at all times:
1. Transmitter switches must never be mechanically blocked ON or OFF for any motion. When not in use the transmitter must be
turned off. A safe and secure storage space should be provided for the transmitter unit and the unit should always be placed there
when not in use. This precaution will prevent unauthorized people from operating the crane. Receivers must be removed from the
equipment when it is unlikely that it will be used for a period of time, and properly stored.
2. All defective or missing safety equipment, mechanical or electrical defects must be reported to the supervisor without delay.
Operation must not continue until all required repairs are completed. Any changes to the condition of the remote or equipment must be
recorded and communicated to or made accessible by the following operators on shift.
3. Ensure that there is nobody in the path of the travel of the equipment. If there is, stop and sound the alarm before proceeding.
4. When leaving the equipment area for any reason, switch off the transmitter, remove the USB Key and store it in a safe and secure
place to prevent unauthorized operation.
5. Do not allow any unauthorized person to operate the transmitter at any point.
6. Do not operate the transmitter at a distance where the equipment and all surrounding objects are not visible. Make sure that your
view is not obstructed.
7. Do not attempt to override any of the safety features built into the Radio Remote Control.
8. Put rechargeable batteries on charge at the end of each shift.
9. Use protective gloves when surface temperature of unit exceeds 58°C (136°F) as per IEC 62368-1:2014.
B.2 Safety Checklist

The following checklist provides general safety guidelines for radio control operation of equipment by fully qualified and trained operators.
These recommendations do not take precedence over any of the following requirements relating to cranes, hoists, lifting devices or other
equipment which use or include Hetronic products:
 Instructions, manuals, and safety warnings of the manufacturers of the equipment where Hetronic products are used,
 Plant safety rules and procedures of the employers and the owners of the facilities where the Hetronic products are being
used,
 Occupational Health and Safety Administration (OSHA) regulations,
 Safety standards and practices for the industries in which Hetronic products are used.
Transmitter Start-up and Safety Checklist
1 Are batteries fully charged?

2 Are all switch labels clear and legible?
3 Is the transmitter free from cracks and damages?
4 Are the battery enclosures free from cracks and damages?
5 Is the STOP function working as it should be?
6 Is the correct USB Key being used?
Has each function of the transmitter been tested independently to ensure the equipment is responding
7
correctly?
8 Is the TFT free from cracks, deep scratches and damages?
Is there any debris inside the USB port which will prevent the USB Key from being inserted /functioning
9
properly?
10 Are the Status LEDs on the transmitter clearly visible?
11 Are the charger and plug in good working condition?
12 Is the cable control cable (where applicable) free from kinks and damages?
38
Appendix C
C.1 Spare Parts

Keep the safety instructions for future reference. Always download the User Manual instructions from our website for the latest version
available.
Refer to the online web shop for respective part numbers of any parts that may need replacement:
https://shop.hetronic.com.mt/en/home
NOTE: Any service/maintenance work and replacement of parts must be carried out by an authorized dealer or service centre specified by
Hetronic.
C.2 Battery 3V Button Cell Replacement Instructions

The below steps are to be followed cautiously so as to replace a drained RTC button battery without causing any damage to the housing or
parts inside the transmitter:
1. Remove the Li-Ion 3.7V Battery from the transmitter and the eight screws and O-rings closing the transmitter.
2. Open the transmitter carefully, ensuring that the ribbons and wires are not stretched.
3. Slide open the metal cover of the battery cell on the coder and replace the battery cell (#68301651) with a new one, ‘+’ side up.
4. Close the metal cover and make sure it clips in place.
5. Make sure that all ribbons, joystick wires and RF antenna are well aligned and secured in place and none of them are within the range
of the closing walls of the housing to avoid pinching/damaging them.
The LED and LCD ribbons are to be bent as shown below, curving on top of the RF. Gently close the unit ensuring that nothing is
damaged.
39
6. Turn the transmitter face down and use the same set of eight screws (#291142585) and O-rings (#21949093) to close the top and
bottom housings together. Use a cordless screwdriver with torque value set to between 0.725Nm and 0.820Nm to close the screws in the
following manner.
C.3 Removal of USB Key

The USB Key can be removed from the transmitter to be replaced by another one or to update graphics or configuration file. The below steps
are to be followed cautiously so as to replace a USB Key without causing any damage to the housing, rubber or USB Key itself:
1. Remove the USB rubber cover by simultaneously lifting the two areas indicated by the green arrows in the photo below, using two
fingers.
2. Pull the USB Key by grabbing it from its plastic casing and lifting it using two fingers.
3. Once available, slide the updated/new USB Key in the USB port, noting its orientation with respect to the port and ensuring it is
pushed completely in.
4. Close the USB interface by placing the rubber cover back in its place and ensuring it seals all round the USB Key.
40

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PROGRAMMING & SERVICE MANUAL

PROGRAMMING & SERVICE MANUAL

 Be suitably trained and qualified as required by the safety regulations.

1.2 Symbol Notation

ATTENTION! This symbol advises against a possible damage to the

1.3 Practices and Laws

1.4 Required Operator Training

1.5 Possible Sources of Danger

Never remove or alter any of the safety features.

1.6 Protective Features

1.7 STOP in case of EMERGENCY

1.8 Caring for your ERGO S

2. Introduction and Functional Description

2.1 Production and System Numbers

2.2 Before Operating Your Wireless Control Unit

2.3 Unit Labels

2.3.1 Blank Rating Plate

Figure 1. Blank Rating Plate

2.3.2 Read User Manual

3. Your ERGO S Transmitter

3.2 ERGO S Basic Features

3.3 Standard ERGO S 2.4GHz Configuration

B. ERGO S 2.4 GHz-V2

Figure 3. Status and Feedback LEDs

3.4 Transmitter Operation Modes

4. Operating Your Transmitter

4.2 Visually Checking Your Transmitter

4.3 Powering Up and Starting Your Transmitter

4.4 Transmitter Initialization with Standard Status LED Indicator

Figure 4. Stop Screen

4.7 LED Behaviour and Meanings

4.8 Magnetic Belt Clip (if equipped)

4.9 Start-Up Sequences

4.10 Front Switch LEDs

5. Configuring Your ERGO S

5.2 Using the Transmitter in Service Mode

Figure 5. Pages 1 and 2 of the Device Settings menu

5.2.2 Adjusting Settings in Service Mode

6. Setting up Your ERGO S for Operation

Figure 6. Low Battery Warning Configuration

Full Duplex Half Duplex MFS

Figure 7. Radio Mode menu selections on Hetronic PC-Link

Figure 8. Radio Settings menu

 Frequency Channel or Group

 Transmitter Baud Rate

Figure 9. Setting the Auto-OFF timer

6.2.4 Half Duplex Communication

Figure 10. Half Duplex Configuration

6.2.4 Full Duplex Communication

Figure 11. Full Duplex Configuration

6.2.5 MFS 2.4GHz Radio Mode

Figure 12. ERGO S MFS Configuration

6.2.6 Address Learn Function

1. Press button #4 to enter Page 2 of the Service Mode menu.

Figure 14. Address Learn page

3. Start the Address Learn function on your machine.

Figure 15. Initiating Learning page

5. Keep holding button #1 to Send Tx Learn Command.

Figure 16. ERGO S changing channel notification