DC Receiver System USERS MANUAL
Prima dell'accensione leggere il manuale duso. Attenersi alle norme di sicurezza. Togliere lalimentazione in caso di apertura. Before switching on please read the user manual. Adhere to safety rules. Disconnet power source before opening. Vor Inbetriebnahme die Gebrauchsanleitung lesen. Sicherheitsnormen beachten. Die Speisespannung muss ausgeschaltet werden, falls der Empfnger geffnet wird Avant dallumer lengine, lire le manuel de lutilisateur. Respecter le consignes de scurit. Couper lalimentation avant douvrir le botier. Antes de encenderlo leer el manual. Atenerse a las normas de seguridad. Desconectar la alimentacin antes de abrir. Follow the indications and warnings given by the machine producer regarding the machine controlled by the radio remote control. The information contained in this manual considers a representative configuration of the radio remote control: please find radio remote control real configuration in the technical data sheet (attached to the manual). If this manual is lost or damaged, ask for a copy from AUTEC. Please specify the serial number of the relative radio remote control. Contact AUTEC if any of the instructions and/or warnings given in this manual are not clear. The information contained in this manual is subject to modification without notice and is not binding. No parts of this manual may be reproduced by any means without the written permission of AUTEC (including recording and photocopying). LIE&LDA0 1 INDEX & CONVENTIONS INDEX 1 2 3 4 5 6 7 8 Index & Conventions Introduction Receiving units Warnings for installation Warnings for maintenance Light signals Programming Receiving unit diagnostic Page 1 2 5 8 10 11 12 14 CONVENTIONS In this manual, all important information is indicated using the following symbols and conventions:
abcd.
: WARNINGS abcd.
: INSTRUCTIONS abcd.
: TECHNICAL DATA abcd.
: IMPORTANT TEXTS THIS MANUAL REFERS EXCLUSIVELY TO THE RECEIVING UNIT: THE GENERAL USAGE WARNINGS ARE GIVEN IN THE TRANSMITTING UNIT MANUAL. BEFORE INSTALLING, STARTING AND USING THE RADIO REMOTE CONTROL, THIS MANUAL MUST BE READ AND UNDERSTOOD CAREFULLY BY ALL PEOPLE WHO INSTALL, USE AND CARRY OUT MAINTENANCE ON THE RADIO REMOTE CONTROL. Page 1 LIE&LDA0 2 INTRODUCTION Industrial radio remote controls are used to command machines from a distance. Each industrial radio remote control is made up of a portable transmitting unit, from which the user can remotely control the machine, and a receiving unit installed on board the machine itself. The transmitting unit uses radio frequencies to transmit a coded message which contains a value called address. Each receiving unit can only decode the messages coming from its own transmitting unit with the same address. This excludes the possibility of an interference activating any system function. If the radio frequency transmission is disturbed, incorrect or interrupted, the receiving unit autonomously stops the whole system. Transmitting unit Each radio remote control complies with Part 15 of the FCC Rules. Receiving unit 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 party responsible for compliance could void the users authority to operate the equipment.
Autec cannot be held responsible if the radio remote control is
installed on applications that are different from those permitted PERMITTED USES Material lifting machines (construction cranes, industrial bridge cranes,
. machines for moving material in general, . ) FORBIDDEN USES Machines installed in areas where equipment with explosion-proof characteristics are being used. Machines for moving, raising and transporting people. Page 2 LIE&LDA0 Alll machines must undergo a risk analysis; therefore it is necessary to evaluate, within the limits of this analysis, if the machine can be radio remote controlled. The machine producer and/or the person who decides upon radio remote control use and installation is responsible for this analysis. Autec cannot be held responsible if the risk analysis is not carried out correctly. To guarantee correct radio remote control operation, all current regulations regarding safety at work and accident prevention should be respected. All current user country national laws regarding the use of both the machine and the radio remote control MUST ALWAYS be respected. Autec cannot be held responsible if the radio remote control is used in unlawful working conditions. System must be installed by a licensed technician and in accordance with all relevant local, state/provincial and federal regulations, including but not limited to NEC, OSHA, CE etc.
In any cases of emergencies, faults or damaged parts, ALWAYS stop the machine + radio remote control system until the problem has been solved. Any damaged parts can ONLY be replaced by authorised Autec personnel or service representative, and only using original Autec spare parts. I H S L G N E Page 3 LIE&LDA0 INSTRUCTIONS FOR DOCUMENT MANAGEMENT The following minimum documentation is supplied with each radio remote control:
- transmitting unit manual
- receiving unit manual
- battery charger manual
- a guarantee certificate
- the radio remote control technical data sheet. Make sure that the following documents have been supplied: if they are not, request them from Autec. Please specify the radio remote control serial number. The conditions of the radio remote control guarantee are given in the Certificate of Guarantee. CERTIFICATE OF GUARANTEE TECHNICAL DATA SHEET The technical data sheet shows the wiring system between the receiving unit and the machine. It should be compiled and checked by the installer, who has the responsibility of correct wiring. Once all necessary checks have taken place the installer must sign the technical data sheet, which must be kept with the user's manual (always keep a copy of this data sheet in case it is needed for administrative purposes). IDENTIFICATION PLATES The radio remote control identification and approval data is given on plates that are on both the transmitting unit and the receiving unit. The plates MUST NOT be removed from where they are placed or damaged otherwise the warranty will be forfeited. TECHNICAL DATA Frequency band Programmable radio channel Hamming distance Probability of non-recognition of error Typical working range Time of reply to commands Time of reply to STOP Passive emergency time 902 - 928 MHz 32 8
<10 exp-11 100 m
<100 ms
<100 ms
* 0,35 / 1 sec.
* refer to paragraph Programming in the receiving unit manual, DIP nr. 1 settings. Page 4 LIE&LDA0 3 RECEIVING UNITS Type R202 and Type R302 can be used with the following transmitting The receiving unit unit:
- SERIES LIGHT
- SERIES MODULAR These receiving units are equipped with a safety function called SAFETY that protects the radio remote control + machine system, when it is in neutral (rest position), from involuntary movements caused by possible radio remote control faults. RECEIVING UNIT TYPE R202 B C A F A B C F E D cable holder (opt. plug) data technical plate identification plate POWER light ENABLE light coaxial cable exit for stylus antenna or for blinker (when present)) A B C D E F Drilling template A = 150mm B = 75 mm C = 357,5mm D = 118,5mm E = 167mm F = 350,5mm ED Page 5 LIE&LDA0 The master board in this type of receiving unit is E16B22DC for configurations of up to 22 commands (plus extension interface card). E16B22DC F1 F2 F3 F4 fuse SAFETY circuit protection fuse F1 STOP circuit protection F2 F3 F4 POWER SUPPLY protection fuse Receiving unit Type R202 TECHNICAL DATA Power supply Antenna Max switching capacity of STOP contacts Max switching capacity of SAFETY contacts Max switching capacity of command contacts Fuse F1 (STOP circuit) Fuse F2 and F3 (SAFETY circuit) Fuse F4 (POWER SUPPLY) Working temperature Housing Minimum protection grade Dimensions Weight 12 or 24 Vdc 25% (~15W) integrated or dedicated
* 10A (30Vdc) 2 x 5A (30Vdc)
* 10A (30Vdc)**
10A T 250V (5x20 mm) 5A T 250V (5x20 mm) 1A (24Vdc) or 2A (12Vdc)T 250V (5x20 mm)
-4F - +158F nylon (20% fg) IP65
(202x381x91) mm max 3,5 kg
*Capacity only valid if both terminals are used for each contact.
**If the radio remote control output have been cabled by Autec, please see technical data sheet. Page 6 LIE&LDA0 RECEIVING UNIT TYPE R302 A C B B A F E D A cable holder (opt. plug) B identification plate C data technical plate D POWER light E ENABLE light F antenna Drilling template A=106 mm B=213,5 mm The master board in this type of receiving unit is E16B10DC for configurations of up to 10 commands. E16B10DC F2 F1 F3 fuse F1 STOP circuit protection F2 SAFETY circuit protection fuse F3 POWER SUPPLY protection fuse Receiving unit Type R302 TECHNICAL DATA Power supply Antenna Max switching capacity of STOP contacts Max switching capacity of SAFETY contacts Max switching capacity of command contacts Fuse F1 (STOP circuit) Fuse F2 (SAFETY circuit) Fuse F3 (POWER SUPPLY) Working temperature Housing Minimum protection grade Dimensions Weight 8 - 30 Vdc (~7W) dedicated
* 10A (30Vdc)
* 10A (30Vdc)
** max 6A (30Vdc) 10A T 250V (5x20 mm) 10A T 250V (5x20 mm) 3.15A T 250V (5x20 mm)
-4F - +158F Polycarbonate IP65
(120x200x90) mm max 2 kg Page 7
*Capacity only valid if both terminals are used for each contact.
**If the radio remote control output have been cabled by Autec, please see technical data sheet. LIE&LDA0
WARNINGS FOR INSTALLATION 4 Installation should only be carried out by qualified people and in accordance with installation country rules. THE INSTALLER MUST PLACE the receiving unit vertically, with the cable holder (or plug) facing down. DO NOT MODIFY or TAMPER WITH the radio remote control, the machine or its electric panel. DO NOT PERFORATE the receiving unit for any reason whatsoever. CHECK that the receiving unit power supply is inside the voltage range given in the Technical Data, and that the voltages and currents being used do not exceed the maximum permitted values. DO NOT EXCLUDE the radio remote control safety mechanisms and/or those present inside the machine. RESPECT all the
(see corresponding prescriptions for machines and for hoisting machines EN60204-1 and EN60204-32 prescriptions
). NEVER SUPPLY the receiving unit directly from the mains. A main switch should always be present to permit power supply removal. PLACE the receiving unit so that it is not completely screened by metal parts and that it must be easily reachable. REMEMBER to carefully wire the SAFETY contacts in series with the movement commands inside the receiving unit. After installation and wiring, ALWAYS CHECK that the maneuvers carried out are exactly the same as the commands given (in particular check the STOP command). FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. Page 8 LIE&LDA0 WARNING: The stylus of dedicated antenna (always present in the receiving unit Type R302, optional for the receiving unit Type R202), must never come in contact with metal parts. If installing on machines that vibrate, it is advisable to fix the receiving unit to the machine with the appropriate antivibration absorbers. The receiving unit should also be positioned away from heat sources (for example motor/exhaust pipes).
When welding on the machine, REMOVE POWER SUPPLY by disconnecting all the electric connections (both during installation and during normal operation). If present, the switch that is enable to open the ground (e.g. battery negative) MUST OPEN also the receiving unit ground as well. The installer must CHECK and/or COMPLETE the "Technical Data Sheet" indicating the date of activation of the system, putting his signature and stamp. Page 9 LIE&LDA0
WARNINGS FOR MAINTENANCE 5 ALWAYS ENSURE THAT THE RECEIVING UNIT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE CARRYING OUT ANY MAINTENANCE WORK. All the faults should be repaired by authorised Autec personnel using original Autec spare parts only. E V I C R E S
The receiving unit requires no special maintenance, but some simple things are necessary to work with apparatus that is always reliable and safe:
- check for signs of damage,
- remove dust or any other material that has deposited on the receiving unit with a cloth that has been dampened with water (never use solvents or flammable/corrosive materials to clean, and do not use high pressure water cleaners or stream cleaners). The correct operation of SAFETY function must be checked every six months. The check can be carried out by inspection of the correct operation of the SAFETY relay when a movement command is activated. In order to close the r e c e i v i n g u n i t , t i g h t e n t h e upper two screws first and then the lower two. AUTHORIZED SERVICE CENTER When it is necessary to carry out special maintenance (radio remote control repair and replacement of damaged or faulty parts), do not contact anyone other than our Authorized Service Center. In order to make the intervention faster and more reliable, please help us identify the radio remote control correctly and completely by giving:
- the serial number
- the purchase date (given on the guarantee)
- description of the problem found
- the address and telephone number of the place where the radio remote control is being used
- the name of the person to be contacted
- the name of the company that supplied the radio remote control. Before speaking with a service technician, it is advisable to make sure that the given instructions have been followed correctly. Entrust the radio remote control and the its battery to the separate scrap collecting services in the user country. DISPOSAL Page 10 LIE&LDA0 6 LIGHT SIGNALS On each receiving unit there are:
a POWER lamp indicates the presence of power supply in the receiving unit an ENABLE lamp which indicates radio link on between the transmitting unit and receiving unit a LED for each relay on the master board, which indicates the activation of that relay On the receiver module there are three LEDs, which indicate:
1. power supply 2. radio connection 3. frequency scanning search. 1 2 3 Page 11 LIE&LDA0
7 PROGRAMMING The dip switches must be programmed when the receiving unit is not powered and can be done only by authorised personnel. DIP SWITCHES ON E16SRXUS1 RADIO RECEIVING MODULE The group of eight dip switches found in the module permits the programming of different operating mode and the setting of operating frequency. The programming set in the other group of four dip switches must never be modified. Group of 8 dip switches Group of 4 dip switches Group of 8 dip switches DIP 1 (*) 2 (**) 3 POS. ON OFF ON OFF ON OFF 3 - 7 ON/OFF 8 ON OFF DESCRIPTION Passive emergency at 0,35 second Passive emergency at 1 second Deactivated of low battery warning from horn on machine Activation of low battery warning from horn on machine With DIP 8 OFF automatic scan mode of the frequencies With DIP 8 OFF automatic scan mode of the frequencies in the 915 - 928 MHz in the 902 - 915 MHz With DIP 8 ON see Appendix: Frequency Table Manual selection of frequencies with DIP 3 - DIP 7 (see Appendix: Frequency Tab le) Automatic scan mode of frequencies in the band selected with DIP 3
(DIP 4 DIP 7 not relevant)
(*) With the MK12 transmitting unit the dip switch should be at ON.
These eight dip switches must be programmed in the same manner as the group of 8 dip switches (excluding DIP 1) present in the radio module of the transmitting unit (see manual). Page 12 LIE&LDA0 DIP SWITCHES ON MASTER BOARDS There are a number of dip switches on the E16B22DC and E16B10DC master boards for programming various functions of the radio remote control, as explained in the following tables:
DIP SWITCHES ON E16B22DC MASTER BOARD DIP SWITCH 1 1 2 2 3 3 4 4 DESCRIPTION function disabled POS. SEL. ON E9 and E10 excite FLOW OFF ON E11 and E12 excite FLOW OFF ON E16 activated also E15 OFF ON E18 activated also E17 OFF function disabled function disabled function disabled DIP SWITCHES ON E16B10DC MASTER BOARD DIP SWITCH 1 1 2 2 DESCRIPTION POS. SEL. ON E5 and E6 excite SAFETY / FLOW OFF ON E15 and E17 excite SAFETY / FLOW OFF function disabled function disabled Page 13 LIE&LDA0 8 RECEIVING UNIT DIAGNOSTIC If the machine+radio remote control system does not start, check if the problem is caused by the radio remote control or the machine. Before carrying out any verifications, check the functioning of the machine with the cable control panel: if it does not switch on, the problem lies with the machine itself. If, on the other hand, the machine can only be switched on using the cable control panel, the problem lies with the radio remote control. In this case, follow diagnostics procedure for the transmitter unit and then proceed as follows:
Is the POWER light lit?
NO Is the connecting plug between the radio remote control and the machine correctly connected?
YES YES Is the ENABLE light lit?
YES Remove power from the receiving unit and open it. Check fuses. Are they blown?
NO YES NO NO Correctly insert the connecting plug and start the radio remote control. Check the power supply connections. Carry out the frequency change procedure
(see transmitting unit manual) Does the machine start?
NO CALL TECHNICAL ASSISTANCE NO Replace blown fuses. Connect to power source and switch on radio remote control. Does the machine start?
Page 14 Appendix: FREQUENCY TABLE E16SRXUS1 DIP SWITCH 4 7 6 5 MHz 8 3 DIP SWITCH 7 5 6 4 8 MHz 902.150 903.050 903.850 904.650 905.525 906.325 907.175 907.975 908.850 909.650 910.450 911.250 912.125 912.925 913.775 914.525 3 OFF OFF OFF OFF OFF ON OFF OFF OFF ON OFF ON OFF OFF OFF OFF ON ON OFF OFF OFF ON ON ON OFF ON OFF OFF OFF ON OFF ON OFF ON OFF ON OFF ON OFF OFF ON ON OFF ON OFF ON ON ON OFF OFF ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF OFF ON OFF ON ON OFF OFF ON ON ON ON OFF ON ON OFF OFF ON OFF ON ON ON OFF ON OFF ON ON OFF ON ON OFF ON ON ON ON ON ON 915.350 916.250 917.050 917.850 918.675 919.525 920.375 921.175 922.050 922.850 923.650 924.450 925.325 926.175 926.925 927.725 ON OFF OFF OFF OFF ON ON OFF OFF ON OFF ON ON OFF OFF OFF ON ON OFF OFF ON ON ON ON OFF OFF OFF ON ON OFF ON OFF ON ON OFF OFF ON ON ON ON ON ON ON ON OFF ON ON ON ON OFF ON OFF OFF ON ON OFF ON ON OFF ON ON ON ON ON OFF ON OFF ON ON OFF ON ON ON ON ON ON ON OFF OFF ON ON ON OFF ON ON ON ON OFF ON ON ON ON ON ON ON ON Via Pomaroli, 65 36030 Caldogno (VI) ITALY Tel : ++39 - 0444/901000 r.a. Fax: ++39 - 0444/901011 email: info@autec.it http://www.autec.it