EGOpro Safe MOVE 4.
TABLE OF REVISIONS TABLE OF CONTENTS 1 TABLE OF REVISIONS 6 2 CONFORMITY 7 3 SAFETY INSTRUCTIONS 7 3.1 DISPOSAL 3.2 LIMITATIONS FOR USE 3.3 STATEMENTS FOR THE USE IN NORTH AMERICA 3.3.1 STATEMENTS FOR PLXSAFEMOVESENS4 AND PLXSAFEMOVESEN4M. 7 7 7 8 4 INTRODUCTION 8 4.1 INTENDED USE 4.2 SYMBOLS 8 8 5 BASIC KIT COMPONENTS 9 6 SYSTEM OPERATION 10 6.1 PEDESTRIAN WORKER PRE-WARNING 6.2 PEDESTRIAN WORKER WARNING 6.3 VEHICLE-VEHICLE WARNING 10 10 10 7 PLACING TAGS 11 7.1 HELMET TAG FITTING 7.
TABLE OF REVISIONS 8.4 INSTALLING THE SYSTEM WITH M12 CONNECTORS 8.4.1 LENGTH OF CONNECTIONS 8.5 EXPANSION OF THE NUMBER OF SENSORS 8.6 STOPPING DISTANCES AND ACTIVATION DISTANCES 8.7 VEHICLE DECELERATION AND DRIVER'S RESPONSE DISTANCES 8.8 SYSTEM ACTIVATION DISTANCES. SETTING THE POWERS TRANSMITTED 8.9 CALCULATING THE DISTANCE IN CASE OF VEHICLE-VEHICLE COLLISION. 26 27 28 29 29 31 32 9 TURNING-ON AND CONFIGURATION 33 9.1 TURNING ON THE SYSTEM 9.2 CONFIGURATION 9.2.1 STEP 1 | CONFIGURATION MENU 9.2.
TABLE OF REVISIONS 11.6.5 TAG SETTINGS 11.7 LANGUAGE 11.8 USERS 11.8.1 ADDING/EDITING USERS 11.8.2 IMPORTING/EXPORTING USERS 61 62 63 64 65 12 OPTIONAL MODULES 67 12.1 DISPLAY OVERVIEW WITH ACTIVE MODULES 12.2 NON-ACTIVE MODULE ALARM 67 68 13 VEHICLE-VEHICLE ANTI-COLLISION MODULE 69 13.1 INSTALLATION 13.2 ALARM VISUALISATION 13.3 SENSORS POWER 69 69 70 14 FILTER MODULE 71 14.1 14.2 14.3 14.4 14.
TABLE OF REVISIONS 18 AISLE MODULE 87 18.1 18.2 18.3 18.4 87 88 89 90 INSTALLATION VISUALISATION AISLE POWER SETTING AISLE POWER SETTING | VEHICLE- VEHICLE 19 WI-FI MODULE 91 19.1 INSTALLATION 19.1.1 WI-FI ANTENNA 19.1.2 CELLULAR ROUTER 19.2 VISUALISATION 19.3 DATA TRANSFER 19.4 REMOTE CONTROL 91 91 92 96 97 98 20 CHECKLIST MODULE 99 20.1 VISUALISATION 20.2 TEST RESULT 20.3 CONFIGURATION 20.3.1 UPLOADING SETTINGS 99 102 103 104 21 INDOOR SPEED MODULE 105 21.1 INSTALLATION 21.
TABLE OF REVISIONS 24.1 24.2 24.3 24.4 24.5 24.6 24.7 24.8 24.9 24.10 24.11 24.12 24.
CONFORMITY 2 CONFORMITY The manufacturer, Advanced Microwave Engineering Srl, hereby declares that the type of radio equipment P LX HUB SR, PLX TAGSAFETY 3T, PLX TAGSAFETY 3TH, P LX SAFEMOVE DIS, P LX SAFEMOVE CPU, PLX SAFEMOVE HUB 4, PLX SAFEMOVE HUB 4M, PLX SAFEMOVE SENS 4, PLX SAFEMOVE SENS 4M complies with the RED directive 2014/53/EC. The full text of the EU Declaration of Conformity is available on the following Internet address: http://www.ameol.
INTRODUCTION NOTE: 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 in a residential installation. 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.
BASIC KIT COMPONENTS 5 BASIC KIT COMPONENTS The EGOpro Safe MOVE 4.0 basic kit consists of: 1 P LX SAFEMOVE DIS - Display with cable (plate and joint included) 3 P LX SAFEMOVE SENS4 - SAFE MOVE 4.0 multifunction sensor. 1 P LX SAFEMOVE HUB4 - HUB SAFEMOVE 4.0. 1 P LX SAFEMOVE CPU - CPU for SAFE MOVE.
SYSTEM OPERATION 6 SYSTEM OPERATION The solution offered by the EGOpro Safe MOVE 4.0 proximity warning & alert system minimises the potential for accidents between forklifts and operators on foot in common working areas. Through visual and sound alarms, the system warns the driver, in real time, of the presence and position of pedestrian workers wearing active PPE who enter the danger zones around the vehicle in motion.
PLACING TAGS 7 PLACING TAGS 7.1 HELMET TAG FITTING To fit the PLX TAGSAFETY 03TH Tag, you first need to clean the helmet. Then, you have to suitably remove the grease from the surface with the napkin supplied. Now you can affix the Tag as shown in the figure. 7.2 WEARABLE TAG ACCESSORIES The wearable Tag is supplied together with a series of accessories that guarantee a wide range of options for wearing it. Clip for band Slot for strap Snap fastener Use the screws supplied: 2.
PLACING TAGS 7.3 PROCEDURE FOR CHANGING THE BATTERY The battery inside the Tag is a CR2450 button cell battery. To replace it, remove the yellow rubber piece, and then replace the battery. Caution: respect the correct polarity; insert the battery with the negative pole towards the circuit. While replacing the battery in the helmet tag, be careful not to damage or disconnect the small coaxial cables connected to the circuit board.
INSTALLATION ON THE VEHICLE 8 INSTALLATION ON THE VEHICLE 8.1 SYSTEM ARCHITECTURE AND GENERAL INSTRUCTIONS The basic KIT of the EGOpro Safe MOVE 4.0 system that is installed on the vehicle consists of the following devices: 3 Sensors 1 HUB 1 CPU 1 Display It is advisable to follow the workflow indicated in the following table and described in detail in the subsequent sections in order to minimise installation problems.
INSTALLATION ON THE VEHICLE 14 The technical materials and information contained in this document are strictly confidential and the exclusive property of Advanced Microwave Engineering s.r.l. These materials and information are intended solely for the purpose designated and may not be used otherwise. It is not permitted to disclose or reproduce them in whole or in part without express written permission.
INSTALLATION ON THE VEHICLE 8.2 POSITIONING THE DEVICES To position the devices, take into account the operation characteristics of the system, the mechanical restrictions and the IP protection degree of the devices. For these reasons, two categories are identified: Devices outside the driver’s cabin Sensors are usually positioned outside the driver’s cabin, except for exceptional cases such as exposure to high temperatures.
INSTALLATION ON THE VEHICLE 8.2.1 Positioning the control unit (CPU) The CPU is the basic element of the system and it can be positioned at any point inside the driver's cabin. The position of the CPU must not obstruct the driver’s and the vehicle operability, and it should be handy to connect the HUB and the Display. To fix the CPU, use the 4 holes on the box that can be accessed by removing the device cover.
INSTALLATION ON THE VEHICLE 8.2.2 Positioning the Display The Display must be positioned inside the driver’s cabin in accordance with the driver’s visibility requirements and taking into account the CPU position: the connection cable between Display and CPU is 2.5 m long. When installing the Display and laying the connection cable, be careful so that they do not disturb the driver’ movements and the driver’s visibility remains unaffected. The Display has an IP 20 protection degree.
INSTALLATION ON THE VEHICLE NOTE: the mechanical joint supplied can be used to obtain the desired inclination. Front sensors must have a slight orientation towards the outside. For example, for a counterbalanced vehicle, they must be positioned outside the moulding of the fork/gripper holder mounting, and they must have an orientation angle towards the outside of around 20°. Be careful not to place the sensors behind obstacles such as the turret of the forks or the vehicle chassis.
INSTALLATION ON THE VEHICLE 8.3 CONNECTIONS 8.3.1 General instructions The necessary connections on the systems can be summarised in two categories: Data Connections Power Supply Connections Data Connections The data connection between the system devices is established with a UTP cable. As a minimum requirement, it is recommended to use a UTP cable belonging to category 5E or higher.
INSTALLATION ON THE VEHICLE Power Supply Connection The system must be powered in direct current (VDC) ranging from 12V to 24V (±10%). The devices to be powered are the CPU and the HUB. A direct positive wire (VIN) and a positive wire under key (VQ) must arrive to the CPU, whereas only the direct positive wire protected by an ATO fuse (4A/32V) must arrive to the Hub. Apply the supplied Fair Rite 0443178281 ferrite on the CPU power cables.
INSTALLATION ON THE VEHICLE 8.3.2 CPU Wiring All the devices of the system must be connected to the CPU.
INSTALLATION ON THE VEHICLE To connect the HUB, an UTP cable belonging to Cat. 5e or higher must be connected to one of the Sensors ports. The CPU has 2 relays that can be controlled independently. There are 3 pins for each relay: - NO | normally open - C | common - NC | normally closed. The default configuration indicates that: Relay 1 (RL1) remains active until the system detects one or more TAGs in the long-range detection area, i.e. in pre-Warning.
INSTALLATION ON THE VEHICLE A1 – MW transmission antenna uFL connector (antenna already connected) A2 – MW reception antenna uFL connector (antenna to be connected) A3 – RF test uFL connector J9 – RF antenna connector (antenna already connected) J3 – LF antenna connector (antenna to be connected) J1 – data BUS and power supply connector J8 – relay terminal board and stand-alone power supply LED1 – vehicle-vehicle reception signal (flashing) LED2 – LF transmission (flashing) and diagnosis error (steady off
INSTALLATION ON THE VEHICLE 8.3.4 Connecting the HUB Connect the sensors to BUS 2 by means of UTP cable following the indications given in the sensor connection section. When crimping the UTP cable, follow the same sequence of colours on each cable end. Connect the HUB to the CPU by means of the BUS 1 connector using a cable belonging to CAT. 5e or higher. Connect the power supply to the EXT POWER connector using an AWG 18/0.75 mm2 bipolar cable or a cable with a higher cross section.
INSTALLATION ON THE VEHICLE If the device is installed on electric vehicles, add a power line filter, for instance an FN2090-3-06 Schaffner filter. If requested, the relays present on the board can be connected following the diagram foreseen. The default configuration indicates that: Relay 1 (RL1) remains active until the system detects one or more TAGS in the short-range detection area, i.e. in Warning. Relay 2 (RL2) is activated with a delay time, which can be configured once relay 1 is activated.
INSTALLATION ON THE VEHICLE 8.4 INSTALLING THE SYSTEM WITH M12 CONNECTORS The PLX SAFEMOVE SENS 4 and PLX SAFEMOVE HUB 4 devices are available in a version fitted with M12 connectors. Such version has been designed in order to make the system installation and removal simpler and quicker. The table below summarises the codes used in the system fitted with connectors.
INSTALLATION ON THE VEHICLE FEMALE (FRONT VIEW) PIN Colour Function 1 Brown VDC 2 Blue VDC 3 White GND 4 Green GND 5 Pink Normally Open Relay 1 6 Yellow Common Relay 1 7 Black Normally Closed Relay 1 8 Grey Normally Open Relay 2 9 Red Common Relay 2 10 Violet Normally Closed Relay 2 11 Grey-Pink Not Used 12 Red-Blue Not Used 8.4.1 LENGTH OF CONNECTIONS The cables supplied are 5-m long, and they are AWG 24.
INSTALLATION ON THE VEHICLE 8.5 EXPANSION OF THE NUMBER OF SENSORS The system can manage up to a maximum of 8 sensors. To add additional sensors to the basic kit, one or more splitters must be installed, as required: - up to 6 sensors, one splitter is needed - for 7-8 sensors, two splitters are needed The splitter must be connected to one of the 3 ports available in the HUB, and this makes 4 ports available for connecting just as many sensors.
INSTALLATION ON THE VEHICLE 8.6 STOPPING DISTANCES AND ACTIVATION DISTANCES When installing a safety supporting system to be used for reducing the risk of man-vehicle and vehicle-vehicle collisions, it is necessary to take into account which activation distances have to be considered for the system operation. The purpose of this is to adjust the system so that a truly helpful signal can be given to the pedestrian worker.
INSTALLATION ON THE VEHICLE 16 17 18 19 20 21 22 23 24 6.4 7.1 7.8 8.5 9.3 10.1 10.9 11.8 12.7 4.4 4.7 5.0 5.3 5.6 5.8 6.1 6.4 6.7 10.9 11.8 12.8 13.8 14.8 15.9 17.0 18.2 19.3 Driver reaction distance @1s [m] 0.8 1.1 1.4 1.7 1.9 2.2 2.5 2.8 3.1 3.3 3.6 3.9 4.2 4.4 4.7 5.0 5.3 5.6 5.8 6.1 6.4 6.7 Total braking time [m] 1.8 2.5 3.4 4.1 4.8 5.5 6.2 6.9 7.6 8.3 9.0 9.8 10.8 11.9 13.0 14.1 15.2 16.4 17.6 18.9 20.2 21.
INSTALLATION ON THE VEHICLE 8.8 System activation distances. Setting the powers transmitted The section above dealt with how to calculate stopping distances for an industrial vehicle. When estimating the distances at which a tag potentially in danger of collision should be detected, a distance margin should be considered as well. A zero distance cannot and should not be set. Besides, the detection system has reaction times that have to be taken into account.
INSTALLATION ON THE VEHICLE 8.9 Calculating the distance in case of vehicle-vehicle collision. In case of vehicle-vehicle collision, we can consider that the same assessments described in the sections above are applicable. The worst case to be considered is the one in which vehicles move at maximum speed against each other. In this case, the calculated distance is twice the one that was calculated before.
TURNING-ON AND CONFIGURATION 9 TURNING-ON AND CONFIGURATION 9.1 TURNING ON THE SYSTEM The system turns on automatically when the power supply (12/24VDC) is connected. While the system is turned on for the first time, the initialisation screen is displayed. Once initialisation is completed, the following screen is showed. The first time the system is turned on takes more time. The sensors, even if they are correctly installed, are not displayed by the system until the search procedure is followed.
TURNING-ON AND CONFIGURATION 9.2 CONFIGURATION In order for sensors to be recognised by the system, they must be configured from the configuration menu via the touchscreen. The following procedure describes the steps to be followed in order to configure the system and make sure that the peripheral devices are correctly connected.
TURNING-ON AND CONFIGURATION 9.2.3 STEP 3 | SENSORS The first screen when accessing the configuration menu is the following one. To configure the sensors press the SENSORS key. To configure the sensors press the SENSORS SEARCH key. The technical materials and information contained in this document are strictly confidential and the exclusive property of Advanced Microwave Engineering s.r.l. These materials and information are intended solely for the purpose designated and may not be used otherwise.
TURNING-ON AND CONFIGURATION 9.2.4 STEP 4 | SENSORS SEARCH Each sensor has an unequivocal ID that must be saved to the CPU: first perform the ID SEARCH and then the SENSORS SEARCH. Before starting the ID SEARCH, make sure that the selectors present on the HUB and on each sensor are set to 0. The sensors and the HUB, if they have an M12 connector, are already correctly set, and they must not be opened.
TURNING-ON AND CONFIGURATION 9.2.5 STEP 5 | SEARCHING SENSORS BY ID The search sensors by ID function is used to associate each sensor ID (Factory Code uniquely assigned by the manufacturer) with a number from 1 to 8 that identifies its position compared to the vehicle, in order to facilitate the subsequent system calibration operations. Press the SEARCH STARTING key to display all the sensors connected to the system. This operation may take several seconds.
TURNING-ON AND CONFIGURATION If some sensors have not been identified, try repeating the search operation. If it still fails, check: Position of all selectors (they must be set to 0) Connections between sensor and HUB. If no sensor is identified, check: Connections between HUB and CPU HUB power supply. Make sure that each ID matches those that had been previously noted down, and then associate to each ID a position identified with a number from 1 to 8.
TURNING-ON AND CONFIGURATION If the allocation procedure has been successful, the sensors turn green and the associated IDs move to the new positions. In case of error, try making the allocation again. Press BACK and return to the previous screen. The technical materials and information contained in this document are strictly confidential and the exclusive property of Advanced Microwave Engineering s.r.l.
TURNING-ON AND CONFIGURATION 9.2.6 STEP 6 | SEARCHING SENSORS BY POSITION This step checks the correct operation of the sensors and saves them to the system. Press SENSORS SEARCH (STEP 4 screen). The search for sensors starts automatically. If the ID search has been correctly performed, the selected sensors (e.g. 2, 5 and 8) will turn yellow. Press the SAVE SETTINGS key: the colour of the sensors will change from yellow to green, and, as of that moment, the sensors will be associated to the vehicle.
TURNING-ON AND CONFIGURATION 9.2.7 SEARCHING SENSORS WITHOUT ID A fixed position can be assigned to the sensors without making the ID search. In this case, place the selector present on each sensor in the desired position. For example, for the basic kit: FRONT LEFT: 2 FRONT RIGHT: 8 REAR: 5 The selector present on the HUB must be set to 0. In this case, the SEARCH SENSORS BY ID procedure (STEP 5) must not be followed. 9.
TURNING-ON AND CONFIGURATION 9.3.2 TAG DETECTION TEST Move a Tag close to each of the sensors installed and check their operation. The transponder detection in Pre-Warning is yellow. The yellow sectors correspond to the sensor that has detected the Tag and indicate the Tag position with respect to the vehicle. The transponder detection in Warning is red. In this case, the TAG position with respect to the vehicle is not indicated: there is one single indication with a red ring.
OPERATION MODES 10 OPERATION MODES 10.1 DISPLAY OVERVIEW Main screen of EGOpro Safe MOVE 4.0 with 3 sensors installed without any detection of pedestrian workers or vehicles. 1 2 7 3 4 5 6 In addition, the following elements are also displayed on the screen: 1. Date and time 2. System Identification Code 3. Key to access configurations/settings 4. Key to access the section for data/log downloading 5. Key for the driver login 6. Position and status of the sensors installed.
OPERATION MODES 10.2 PEDESTRIAN WORKER’S TAG DISPLAY ALARM: PRE-WARNING The presence of the pedestrian worker wearing an active TAG within the PRE-WARNING activation range is signalled to the driver via the display that shows the position of the pedestrian worker around the vehicle. Lighted up sectors are associated to the sensor and they are coloured according to the sensor detecting the Tag, and so the pedestrian worker’s position.
OPERATION MODES 10.3 PEDESTRIAN WORKER’S TAG DISPLAY ALARM: WARNING The presence of the pedestrian worker wearing an active TAG within the WARNING activation range is signalled to the driver via the display by means of a clearly visible red ring. The PRE-WARNING alarm indication remains visible and helps the driver locate the personnel on foot. The red ring will remain lit up, together with the two lateral LEDs in the display, as long as the Tag is in this area.
OPERATION MODES 10.4 SENSORS AND HUB DIAGNOSIS Active sensors are displayed matching their position on the vehicle. Only fitted and configured sensors are shown on the display. The system is equipped with a self-diagnosis function that constantly checks the correct operation of the devices. If the icon of the sensor is GREEN, it means that the diagnosis system did not detect any anomalies on that specific sensor.
OPERATION MODES 10.5 DRIVER LOGIN The LOGIN operation is used to check which operator is driving the vehicle at the date and time requested, and it is essential to exclude the driver’s TAG from the anti-collision system. When the system is turned on, the main interface presents a lateral red message inviting the user to LOGIN, which is signalled by a yellow icon. Press the yellow login icon- a closed padlock- to login, and enter your driver’s code/Tag code.
OPERATION MODES For the login operation, enter the unequivocal ID in the space: USERCODE: unequivocal numerical code of 6 figures: the code usually coincides with the TAG own code. Use the numerical keyboard to enter the code. To delete only one character: To delete all characters together: Once the code has been entered, press OK. The system automatically returns to the main screen. In order to log in, the list of users must have been added to the system (see section 11.8).
OPERATION MODES 10.6 DATA ACCESS Press the key with the USB icon and enter the relevant password to access the data page in which the history of events is shown. Up to 1,000 events can be displayed, including: • TAGS detected with the following information: detected TAG code - activated sensor - date and time - position (if the GPS module is enabled) • Configurations carried out: type of configuration and saved data.
BASIC CONFIGURATION 11 BASIC CONFIGURATION 11.1 ACCESS TO MENU Press the CONFIGURATION icon to access the menu To access the system configuration section, a password must be entered so that only the enabled user can view this screen. The default password is 1234. 50 The technical materials and information contained in this document are strictly confidential and the exclusive property of Advanced Microwave Engineering s.r.l.
BASIC CONFIGURATION 11.2 REBOOT To reboot or stop the system, enter the specific password and open the configuration menu. CLOSE key to reboot the system. If necessary, press this key to reboot the system. This key is shown in all the configuration screens If the system is turned off, you will need to disconnect and reconnect power to restart it. The technical materials and information contained in this document are strictly confidential and the exclusive property of Advanced Microwave Engineering s.r.l.
BASIC CONFIGURATION 11.3 CONFIGURATION MENU In the configuration menu, you can: Set the system Time and Date Configure the Modes of the alarms Configure the sensors (System Calibration) Select the language preferred Set the master data of users/drivers ADVANCED configurations: only authorised installers can have access to them. Press the dedicated key to select the function.
