Original instructions Dynamic Series User manual Description, warnings and instructions LIDYNE00-07
Warnings and caption for the documentation attached to the radio remote control The attached documentation is an integral part of the radio remote control and it aims at providing the instructions needed for using and maintaining the system, paying particular attention to the safety functions.
Three symbols are employed throughout documentation, which are used to highlight specific safety-related issues. They are classified according to the hazardous situation that may arise and on the possible consequences: Symbol If the highlighted instructions are not respected ... ... a dangerous situation will occur… ...consequences for people may be… ...consequences for property may be… …highly probable. … critical (death or physical damage). … critical. … probable.
Dynamic Series Part A: Description, warnings and instructions Index 1 Radio remote control description ......................................................................... 7 1.1 How the radio remote control works .................................................................. 7 1.2 Technical Data .................................................................................................. 7 1.3 Applications ........................................................................................
7 Troubleshooting ................................................................................................... 7.1 Radio remote controls with Data Feedback function ........................................ 7.2 Radio remote controls with wire control .......................................................... 7.3 Solutions in case of malfunction ......................................................................
Radio remote control description 7 1 Radio remote control description 1.1 How the radio remote control works Industrial radio remote controls are used to control machines from a distance, without physical connection between the user and the machine (i.e. wires or connecting cables). They consist of a portable transmitting unit, from which the user remotely controls the machine, and a receiving unit installed on board the machine itself. 1.2 Technical Data Command response time .......................
Radio remote control description 1.3 Applications Dynamic series radio remote controls can be installed on hoisting and material handling machines and on machines for moving, raising and transporting people (e.g. hydraulic cranes, aerial work platforms, telehandlers, concrete pumps).
Radio remote control description 1.5 9 Classification of commands Commands sent by the transmitting unit are classified according to their type. 1.5.1 Command type: analogue, digital or direction command Commands sent by the transmitting unit can either be analogue or digital. Analogue commands generate proportional outputs as a function of the position of the corresponding actuator. Digital commands switch the status of their corresponding output, according to the position of the related actuator.
Radio remote control description 1.6.2 Protection against unintended movements from the standstill position (UMFS) This safety function protects the system “machine+radio remote control” from unintended movements, namely machine movements not activated intentionally by the user, but resulting from possible electrical and mechanical failure of the radio remote control. Such safety function checks the neutral (rest) position of the actuators that control the machine's movements.
Risk assessment 11 2 Risk assessment When using and installing an industrial radio remote control it is therefore always necessary to evaluate if the machine can be radio remote controlled. In fact, as required by standards ISO 12100 and ISO 14121, all machines must undergo risk assessment and related analysis. The radio remote control can only be installed and used if this assessment gives positive results.
Risk assessment 2.1.3 Protection from unintended activation The transmitting unit housing is manufactured so that it protects the actuators from unintentional activation, while meeting at the same time the operating needs, the comfort requirements and law limits. Assessment shall be made to establish possible additional protection measures for the actuators (i.e.
Warnings for use 3 13 Warnings for use In addition to all instructions provided by the machine manufacturer, by the installer of the radio remote control and by the person responsible for the safety of the work area, users shall always respect the following warnings. 3.
Warnings for use Visually and directly follow all movements of the machine and its load and remain inside the radio remote control working range. Pay particular attention to warnings and visual and acoustic signals, and take all measurements and steps to avoid that movements of the remote controlled machine may lead to hazardous situations for people and/or property. In case of malfunction, disable the system “machine+radio remote control” until the problem has been completely solved.
Radio remote control life cycle 15 4 Radio remote control life cycle To ensure safe and long-lasting operation of industrial radio remote controls, carefully follow the instructions provided for each stage of the product life cycle. 4.1 Transportation and storage Radio remote controls must always be transported and stored inside their packing until they are installed on the machine. Environmental transportation and storage conditions are given in the following table.
4.3 Radio remote control life cycle Use The use of industrial radio remote controls is strictly limited to skilled and properly trained personnel. When the radio remote control is installed on machines on board vehicles, switch off the receiving unit while the vehicle is travelling. All warnings for correct use are given in chapter 3. All instructions for correct use are given in chapters 5 and 6. Environmental working conditions are given in the following table.
Radio remote control life cycle 17 Before any maintenance operation, remove the battery from the transmitting unit and disconnect power supply from the receiving unit. After each maintenance operation, always make sure that all commands sent by the transmitting unit only activate the corresponding expected operations. In case of malfunction or damaged parts, disable the system “machine+radio remote control” until the problem has been completely solved.
Radio remote control life cycle During normal operation: -- avoid causing structural damage to the transmitting unit -- make sure that materials that could endanger the transmitting unit usage and safety (such as concrete, sand, lime, dust) do not deposit on it. After using the radio remote control: -- clean the transmitting unit: never use solvents or flammable/corrosive materials and do not use high-pressure water cleaners or steam cleaners -- store the transmitting unit in clean and dry areas. 4.4.
Radio remote control life cycle 19 4.4.5 Preventive replacement of actuators (joysticks, pushbuttons and selectors) Each actuator on the transmitting units can be used for a maximum number of operations. Replace joysticks, pushbuttons and selectors on the transmitting unit before they reach the maximum number of operations, even though they are still working. Replacement prevents possible failures that may lead to loss of safety. Actuator Max. operations Actuator Max.
Radio remote control life cycle 4.4.6 Additional maintenance operations in environments with corrosive agents If the radio remote control is used in environments where corrosive agents are present (e.g. sea water, salt fog, salt...), apply grease to the electrical connections to protect them. Only use electrically non-conductive, polyalphaolefin and silicate-based grease for electrical contacts. Do not use polyether-, polyoilester- and polyphenyl ether-based grease.
Radio remote control life cycle 21 4.5 Machine maintenance Follow instructions provided by the machine manufacturer and by the installer of the radio remote control, in order to carry out machine maintenance. When carrying out maintenance on the machine, always disconnect power supply from the receiving unit. In the event of necessary maintenance on the machine (i.e. soldering), disconnect all the electrical connections of the receiving unit. 4.
General operating instructions 5 General operating instructions 5.1 Starting up the radio remote control As required by standards IEC 60204-1 and IEC 60204-32, non authorised use of the machine must be prevented. The power keyswitch used to start up the radio remote control complies with this requirement. Starting up the radio remote control consists in establishing a radio link between the transmitting unit and the receiving unit. For this purpose, you need to: 1.
General operating instructions 5.3 23 Data Feedback Function The user receives information and/or signals concerning the controlled machine by means of the Data Feedback function. During normal radio remote control operation, pay particular attention to the indications displayed and signalled by the display or through the LEDs: they can be helpful to evaluate the machine working status.
5.5 General operating instructions Transmitting unit automatic switch off The transmitting unit automatically switches off when: -- the battery is flat (see paragraph 5.5.1) -- the radio remote control is not used for a certain time (see paragraph 5.5.2) -- the transmitting unit is powered and never switched off for eight hours non-stop (see paragraph 5.5.3). The green LED on the transmitting unit switches off. The POWER LED on the receiving unit switches from blinking to steady on.
General operating instructions 5.6 25 Switching off the transmitting unit The transmitting unit shall be switched off each time work is stopped. Voluntary transmitting unit's switch off occurs: -- when the power keyswitch (if present) is turned anti-clockwise -- when battery is removed (see paragraph 6.1.2) -- when the STOP pushbutton is pressed. 5.7 Switching off the receiving unit The receiving unit shall be switched off each time the radio remote control is not used to control the machine.
Operation 6 Operation 6.1 Battery The Dynamic series' transmitting units can only be powered by Autec rechargeable batteries. See the battery charger manual enclosed in the packaging with the battery charger for any warnings and instructions regarding the batteries. 6.1.1 Battery insertion Push the battery towards the contacts on the transmitting unit (1) and insert it inside the housing (2).
Operation 6.3 27 Power keyswitch The transmitting unit have a power keyswitch. It can either be: -- mechanical key (see paragraph 6.3.1) -- Key ID 0-1 (see paragraph 6.3.2). 6.3.1 Mechanical key The mechanical key makes it possible to power the transmitting unit. When the mechanical key is required to be used in a transmitting unit, the radio remote control cannot work if it is not inserted. When is required the mechanical key is always required the "ID internal tx memory". 6.3.
Operation 6.3.5 BACK-UP UNIT If the main transmitting unit cannot be used because it has been lost or damaged, it can be replaced with a transmitting unit called "BACK-UP UNIT". It is identical to the unit that cannot be used anymore; the only difference is the presence of the plate “BACK-UP UNIT” on the battery housing.
Operation 6.5 29 STOP pushbutton The STOP pushbutton should be pressed when it is necessary to immediately stop the machine when a dangerous condition occurs. When the STOP pushbutton is pressed, the machine stops (active stop: see paragraph 1.6.1), and the transmitting unit switches off. To start working again after the STOP pushbutton has been pressed: 1. make sure that the working and usage conditions are safe 2. turn the STOP pushbutton in the arrow direction to unlock it 3.
Operation 6.6.2 TEACH switch (during REMOTE SETUP) This switch is used to calibrate minimum and maximum values of proportional outputs. Symbol Meaning This symbol identifies the TEACH+ command. This symbol identifies the TEACH- command. 6.6.3 MOVEMENT SPEED SELECTOR This switch is used to modify the movement speed. Depending on the configuration: -- it sets two or three speed levels -- it increases and/or decreases speed. Symbol Meaning This symbol indicates the normal machine's speed.
Operation 6.6.4 31 Engine on/off switch This switch is used to switch on and off the engine of the remote controlled machine. Symbol Meaning This symbol indicates that the engine is powered on. This symbol indicates that the engine is switched off. 6.7 Low Power function The LOW POWER function allows transmission at a lower power than the nominal power (see paragraph 1.2) and reduces the radio remote control working range.
Operation 6.8 Cable control The wire control is used: -- in particular working conditions, established by the machine manufacturer -- when it is not possible to build a radio link between the radio remote control units -- when working in environments where using radio frequencies is not allowed or is dangerous -- when a fully charged battery is not available.
Troubleshooting 7 33 Troubleshooting When the radio remote control does not work: -- bring the transmitting unit close to the receiving unit to avoid radio interference and disturbances -- establish whether the problem lies with the radio remote control or with the machine. Therefore, before any inspection, try to control the machine from a control unit different from the radio remote control, if present. If the problem persists, it lies with the machine.
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