LIUDPP002_eng-00 Instruction Manual for the use and the maintenance of the Radio Remote Control Original instructions Part A: Information, instructions and general warnings DYNAMIC+P SERIES
THIS PART OF THE MANUAL CONSISTS OF Part A - Information, instructions and general warnings for the Autec Dynamic+P Series Radio Remote Control. The Manual consists of Part A – General, Part B – Conformity and Frequencies, Part C – Transmitting Unit, Part D – Receiving Unit and Part E – Battery and Battery Charger, plus the Technical Data Sheet.
It is also the responsibility of the Manufacturer and of the design professionals of the Machine on which the Autec Radio Remote Control is to be installed and used to be certain that the structure, condition, organization and markings of the Machine as installed at the facility is appropriate for and will allow for the safe and reliable use and control of the Machine through the Autec Radio Remote Control interface.
IT IS THE RESPONSIBILITY OF THE OWNER AND FACILITY OPERATOR, AND THEIR OFFICERS, MANAGERS AND SUPERVISORS, to be certain that all Users of the Autec Radio Remote Control and that all Persons who are or will be working with or near the Machine operated by or through the Autec Radio Remote Control are fully and properly educated and trained by qualified Personnel in the proper and safe use of the Autec Radio Remote Control and of the Machine, including without limitation complete familiarity with and understa
LIUDPP002_eng-00 AUTEC
INDEX 1 2 3 4 5 6 7 8 9 Information on the use of instructions ...................................................................... 9 1.1 Structure of the Instruction Manual ....................................................................... 9 1.2 Caption and terminology .................................................................................... 11 1.3 Symbols ............................................................................................................ 12 1.
10 Troubleshooting ...................................................................................................... 61 10.1 Radio Remote Controls with "Data Feedback" function ....................................... 61 10.2 Radio Remote Controls with cable control .......................................................... 61 10.3 Solutions in case of malfunction ......................................................................... 61 11 Decommissioning and disposal ................................
9 1 Information on the use of instructions 1.1 Structure of the Instruction Manual The Manual for the use and maintenance of Autec Radio Remote Controls consists of different parts, that altogether form the Manual; the Manual must be read carefully, understood and applied by the Radio Remote Control's Owner, User and by all those Persons that, for any reasons, may operate with the Radio Remote Control or with the Machine where it is installed.
Usage and maintenance instructions are supplemented by the Radio Remote Control's Technical Data Sheet, that: - Describes the Transmitting Unit's configuration - Indicates the relation between commands sent by the Transmitting Unit and those available on the Receiving Unit.
1.2 11 Caption and terminology Contact Autec if any of the instructions, symbols, warnings or images are not clear and understandable, or if you have doubts or questions. The terms listed here below have the stated meaning throughout the entire Manual, including all of its parts: - Unit: the single (Transmitting or Receiving) Units that comprise the Autec Radio Remote Control.
Functions indicated for the Manufacturer, the Installer, the User and the Maintenance Technician may be performed by a single Person, if he/she has the needed competence and undertakes the resulting responsibilities. Each Person must be aware of the instructions contained in the Manual, depending on the activity they carry out. For example, if a Manufacturer is also the Installer, and/or Maintenance Technician, he must also know and follow the instructions specifically addressed to those Persons.
13 The instructions concerning the installation and maintenance of the Radio Remote Control are addressed to qualified Personnel; their implementation requires qualified professional expertise: none of the operation for which qualified Personnel is required can be carried out by Persons or companies that do not have the required specific professional expertise. 1.
2 Brief product presentation 2.1 Series, Radio Remote Control and Unit The object of this part of the Manual is the Autec Dynamic+P series Radio Remote Control (see chapter 4). Autec Dynamic+P series' Radio Remote Controls are designed to be used on Machines and provide a command interface to their command and control system, to be used from an appropriate distance and position.
15 CRP MODEL: CRP TYPE NL055 12-24 max 8-30 AUTEC Srl 1000mA 1500mA FSAADC03A MADE IN ITALY Via Pomaroli, 65 - 36030 Caldogno (VI) - Italy TA1424-00 PUF555-00 CRP 2.2 Conformity with standards The conformity of Radio Remote Controls with standards and with working requirements and conditions in the single Countries is provided in the related specific part “Conformity and frequencies” (Part B) of the Manual. 2.
3 General safety warnings All the warnings and instructions provided in this chapter are safety-relevant. Failure to follow the instructions contained in the Manual provided by Autec, as well as all applicable safety-related legislations, even local ones, regulations and standards may generate serious damage to people and property.
17 Without limitation on the Laws, Regulations and Standards it is forbidden to use an Autec Radio Remote Control if the Manufacturer or those who want to install it on the Machine are not able to or do not: - Carry out an appropriate and comprehensive risk assessment in relation to the safety of the Machine, concerning the Radio Remote Control adoption and installation. - Ensure the required professional experience and/or technical competence to carry out the risk assessment correctly.
THE AUTEC RADIO REMOTE CONTROL IS NOT A STANDALONE PRODUCT AND IS INTENDED ONLY AS A COMPONENT ON A MACHINE: - ON WHICH AND WHERE THE USE OF A RADIO REMOTE CONTROL IS APPROPRIATE - THAT CAN BE OPERATED SAFELY AND IN ACCORDANCE WITH ALL APPLICABLE LAWS, REGULATIONS AND STANDARDS BY SUCH REMOTE CONTROL.
19 - Use of the Radio Remote Control in facilities or environments, or in weather and/or climate conditions, in which the use of the Radio Remote Control is not permitted or advisable under applicable Laws, Regulations and Standards, even local, not permitted according to the instructions contained in this Manual, or that may pose the risk of damage and/or incorrect operation of the Radio Remote Control (by way of example: temperature exceeding the limits indicated in paragraph 8.
4 Radio Remote Control features Dynamic+P series' Radio Remote Controls are used to control Machines from a distance, without physical connection (by way of example: wires or connecting cables) between the Transmitting Unit handled by the User and the Receiving Unit installed on the Machine, hence between the User and the Machine. They usually consist of a portable Transmitting Unit, from which the User can remotely control a Machine, and a Receiving Unit installed on board the Machine itself.
21 WARNING: The operating working range may be significantly and unpredictably reduced compared to the value indicated in the technical data (see paragraph 4.5) when special conditions occur in the working environment (by way of example: temporary presence of electromagnetic interference and/or metal obstructions). WARNING: The operating working range may be extended up to ten times compared to the value indicated in the technical data (see paragraph 4.
4.2 Control devices 4.2.1 Start up and switch off Start up and switch off functions are described in chapter "General instructions for operation" included in "Part C" of the Instruction Manual. Therefore, please refer to that part of the Manual. 4.
23 THE ACTIVATION OF THE PUSHBUTTON RELATED TO THE STOP FUNCTION (GSS OR EMS) CONTROLS THE MACHINE'S STOP FUNCTION, BUT THE TIME AND DISTANCE WITHIN WHICH THE LATTER WILL BE BROUGHT TO A SAFE STATE MAY VARY FROM MACHINE TO MACHINE, FOR EXAMPLE DUE TO THE PRESENCE OR ABSENCE OF A BRAKE. THE USER MUST BE FULLY AWARE OF THE MACHINE'S MOVEMENTS AND OPERATING ZONES AND MUST ALLOW FOR SUFFICIENT SAFE FUNCTIONING OF THE MACHINE, INCLUDING SUCH RESPONSE TIMES AND STOPPING DISTANCES.
4.3.1 General Safe Stop function (GSS) The User activates the GSS function by using the pushbutton identified with GSS or General Safe Stop in the Transmitting Unit. This manual stop first generates an active stop and then it switches off the Transmitting Unit. This working logic implicates that the Receiving Unit brings the Machine to a safe state when it receives the command generated by the active stop.
25 Never leave the Transmitting Unit unguarded to avoid uncertainty about the availability or unavailability of the GSS function. The “mission time” of the GSS function, as defined in international standards and requirements, is 20 years. In any case, the Radio Remote Control must be replaced within this period. The "mission time" must not be considered as a warranty period.
4.3.2 EMergency Stop (EMS) function The EMS function is never available in "Take&Release" Radio Remote Controls. The User activates EMS function by using the red pushbutton on a yellow background identified with EMS in the Transmitting Unit. This manual stop first generates an active stop and then it switches off the Transmitting Unit. This working logic implicates that the Receiving Unit brings the Machine to a safe state when it receives the command generated by the active stop.
27 The Radio Remote Control's stop function can be considered EMS only if: - It belongs to a Machine's emergency stop function compliant with the requirements of the Machinery Directive 2006/42/EC and of the ISO 13850 standard - It belongs to a Machine's emergency stop function that is always available and operational, independently from the Machine's working mode - The Transmitting Unit is the only control station of the Machine.
4.3.3 Automatic stop function (ATS) The automatic stop function (ATS) prevents hazardous operation of the radio remote controlled Machine and brings it to a safe state. This function is activated automatically: - By the Receiving Unit due to passive stop, when the Receiving Unit does not receive correct messages in a given time span (see paragraph 4.1). - When a Radio Remote Control malfunction is detected.
4.4 29 Protection against unintended movements from the standstill position UMFS Unintended movements of the Machine, that is Machine movements that are not activated by movements of the actuators, may occur due to electrical or mechanical failure or malfunction that may affect the Radio Remote Control. The rest position of the actuators on the Transmitting Unit is the neutral position.
MOVEMENT OF THE MACHINE MAY OCCUR WHENEVER AN ACTUATOR RELATED TO MOVEMENT COMMANDS IN THE TRANSMITTING UNIT IS MOVED FROM ITS NEUTRAL POSITION. EVEN INADVERTENT ACTIVATION OF COMMANDS MAY CAUSE MACHINE MOVEMENTS (SEE PARAGRAPH 7.3). EVEN THOUGH THIS RADIO REMOTE CONTROL IS EQUIPPED WITH ALL THE REASONABLE MEASURES TO PREVENT ACCIDENTAL ACTIVATION, IT CANNOT DETECT IF THE ACTUATOR HAS BEEN MOVED INTENTIONALLY OR ACCIDENTALLY.
31 4.5 Technical data Performance of the automatic stop function (ATS) SIL 3 / PL e ; cat.4 (4-wire wiring) SIL 2 / PL d ; cat.3 (2-wire wiring) Performance of the General Safe Stop (GSS) function SIL 3 / PL e ; cat.4 (4-wire wiring) Performance of the Emergency Stop (EMS) function SIL 3 / PL e ; cat.4 (4-wire wiring) Performance of the UMFS function SIL 2 / PL d ; cat.3 Cut in time of the automatic stop function (ATS) 0.
The Machine Manufacturer, the Installer, the Maintenance Technician and the People in charge for the usage of the Machine and of the working place are responsible for making sure that the Radio Remote Control's identification plate is a sufficient means to explain the correspondence between the Transmitting Unit and the Receiving Unit. If that were the case, it is necessary to provide additional, more visible identification. 4.
33 5 Radio Remote Control storage before installation or after removal Radio Remote Controls must always be transported and stored inside their packing until they are installed on the Machine.
The Autec Radio Remote Control may not be installed on Machines where it is used for applications or functions not permitted under this Manual and applicable Laws, Regulations and Standards, even local. INSTALLATION OF AN AUTEC RADIO REMOTE CONTROL ON OTHER MACHINE OR FOR OTHER FUNCTIONS MAY CAUSE SERIOUS INJURY OR DEATH OR PROPERTY DAMAGE. Autec is not and cannot be held responsible if the Radio Remote Control is used in unsafe or poor safety conditions.
35 In addition to the above, Dynamic+P series' Radio Remote Controls cannot be installed: - On Machines that are intended for the use in environments requiring explosion-proof features or in any Radio Remote Control usage situation that may pose the risk of explosion - On machines where the receiving unit power supply does not come from a battery or from a power supply unit with safety isolating transformer - On Machines that control loads that are not isolated from alternating current (AC) power supply
6.2 Staff training: installation and maintenance All installation and maintenance operations relating to the Autec Radio Remote Control system must be carried out ONLY by qualified technicians.
6.4 37 Warnings for installation The Installer of the Radio Remote Control must always read, understand and follow all the instructions and warnings contained in this Manual. These instructions and warnings are not exhaustive.
6.4.2 Mounting and fastening the Receiving Unit in the best position Place the Receiving Unit so as to avoid damage due to incidental contact. Place the Receiving Unit so that it can be easily reached in case of need. Place the Receiving Unit so that it can be easily reached, and far from heat sources (e.g. exhaust pipes, heat exchangers, radiators). Place the Receiving Unit vertically, with the cable gland or the plug facing down.
6.4.3 39 Positioning the antenna The Receiving Unit may be configured with internal antenna or external antenna (see Technical Data Sheet). If the antenna is external, it cannot be mounted directly on the Receiving Unit's casing, but it must be installed with the antenna cable-extension kit.
If the antenna is external to the Receiving Unit, install the antenna vertically as far as possible from the Receiving Unit and from other electrical and electronic devices. The antenna must not be placed inside closed metal containers. Install the antenna at least 50 cm far from metal objects in the surroundings, in a free area of the Machine; protections, panels, parts, surfaces or anything else should not be present, so that shields, structures or materials do not obstruct the radio link.
41 6.4.4 Wiring Wiring is understood as the electrical cable connections that can be found: - Inside the Receiving Unit - Between the Receiving Unit and the Machine. ALL ELECTRICAL CONNECTIONS MUST BE PERFORMED AND MADE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE AND ALL APPLICABLE LAWS, REGULATIONS AND STANDARDS, EVEN LOCAL.
The Installer must avoid that a power supply positive or negative pole is connected to the outputs. If a Receiving Unit's output is connected to a direct current inductive load (by way of example: solenoid valves, relays), it is advisable to connect a freewheeling diode in anti-parallel with the driven load, to reduce the effects of demagnetizing currents. voltage must always be applied to the power supply input of A 12 or 24 V solid state outputs.
43 Since the "Take & Release" Radio Remote Control consists of two Transmitting Units an one Receiving Unit, the Installer must carefully assess the risks generated by the presence of multiple Units, and adopt the necessary risk reduction measures. 6.4.5 At the end of installation Make sure that during installation the protection measures on the Radio Remote Control and/or in the Machine have not been made ineffective by improper installation works.
6.4.6 Testing The Installer must check and fill in the Technical Data Sheet in all its parts, adding the date in which the radio remote controlled Machine has been put into service, their stamp and signature. After installing and wiring the Receiving Unit, test the Machine controlled by the Radio Remote Control and verify that the operations carried out correspond exactly to the commands sent, including in particular but not limited to the functionality of the STOP command.
45 7 Safety 7.
7.2 Delay in command response time Under normal conditions, the delay between the activation/deactivation of a command in the Transmitting Unit and the activation/deactivation of the corresponding output in the Receiving Unit requires the "Command response time" indicated in the Technical Data (see paragraph 4.5).
47 The Machine Manufacturer and/or the Installer must assess and adopt possible additional protection measures for the actuators (by way of example: commands requiring two-hand operation, “dead-man” function) if particular environments, equipment and working modes could generate risk situations, and if Laws, Regulations and Standards in force in the country where the Radio Remote Control and the Machine are used should require it. 7.
8 Instructions for the User The chapter "Instructions for the User" in "Parts C" of the Instruction Manual contains the warnings and instructions for the use that add to those provided in this chapter. Therefore, please refer to that part of the Manual. FAILURE TO READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS AND WARNINGS CONTAINED IN ALL PARTS OF THIS MANUAL FOR THE AUTEC RADIO REMOTE CONTROL MAY RESULT IN PERSONAL INJURY OR DEATH, OR PROPERTY DAMAGE. 8.
49 YES 8.2 YES YES Warnings for the User The User must: - Observe and comply with all instructions and warnings provided by the Machine Manufacturer. - Observe and comply with all instructions and warnings provided by the Installer. - Observe and comply with all instructions and warnings provided by the Person responsible for the Machine commissioning or making the Machine available for work. - Observe and comply with all instructions and warnings provided in the Radio Remote Control Manual.
The User must not: - Use the radio remote control without receiving prior complete training by qualified personnel, and if he does not completely master the instructions and warnings regarding the radio remote control usage - Use the Radio Remote Control if he suspects malfunction on the Radio Remote Control, the Machine, or one of their components - Use the Radio Remote Control if the warnings and labels on the Machine or the symbols on the Radio Remote Control cannot be read, are worn or dirty - Al
51 Start up the Transmitting Unit only to use it according to its intended use or for operational needs (by way of example: maintenance, checks): improper use may cause dangerous situations.
Pay attention to low battery signals: all dangerous operations (by way of example: hanging load) must be concluded before the battery is completely flat. Use the Transmitting Unit with the complements provided with the Radio Remote Control (by way of example: pouch, waist belt, shoulder harness) to avoid that it accidentally falls, or that actuators come into contact with external bodies, or that the Unit is used improperly.
53 8.3 Operational use The use of Radio Remote Controls is strictly limited to properly trained Personnel. All instructions for correct use are given in "Part C" of the Manual (related to the Transmitting Unit). When the Radio Remote Control is installed on Machines on board vehicles, switch off the Receiving Unit while the vehicle is travelling. Environmental working conditions are given in the following table.
9 Maintenance 9.1 Radio Remote Control maintenance - general directions The Maintenance Technician must: - Observe and comply with all instructions and warnings provided by the Machine Manufacturer. - Observe and comply with all instructions and warnings provided by the Installer. - Observe and comply with all instructions and warnings provided by the Person responsible for the Machine commissioning or making the Machine available for work.
55 Before any maintenance operation, disconnect the Receiving Unit from the power supply, using the devices and instructions provided by the Machine Manufacturer and by the Installer. After each maintenance operation, always make sure that all commands sent by the Transmitting Unit activate only the corresponding expected operations.
When carrying out maintenance on the Machine, always disconnect power supply from the Receiving Unit. In the event of necessary maintenance on the Machine (by way of example: welding), disconnect all the electrical connections of the Receiving Unit. 9.2.1 Daily routine maintenance Before starting to work: - Make sure that the symbols on panel on the Transmitting Unit and on the Receiving Unit are clearly visible and replace the panel if necessary.
57 - Start up the Radio Remote Control and check in the Receiving Unit that the STOP outputs activate. Then press the GSS or the EMS pushbutton and check in the Receiving Unit that the STOP outputs deactivate. Before testing the STOP outputs, make sure that no dangerous situations may arise due to the activation of the STOP outputs in the Receiving Unit. 9.
9.4 Additional maintenance operations in environments with corrosive agents If the Radio Remote Control is used in environments where corrosive agents are present (by way of example: 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.
9.5 59 Preventive replacement of the Radio Remote Control's electromechanical components 9.5.1 Actuators (joysticks, pushbuttons and switches) As provided by the Manufacturer of each actuator in the corresponding technical specification, each actuator of the Transmitting Unit can be used for a defined “maximum number of operations”, as shown in the table below. The “maximum number of operations” must not be considered as a warranty period.
Actuator Max. operations 5x104 Actuator Max.
10 61 Troubleshooting If the Radio Remote Control does not work correctly, carry out the following preliminary checks: 1. Move all other Transmitting Units in the working area away from the Autec Transmitting Unit in use to avoid possible radio interference. 2. Bring the Autec Transmitting Unit closer to the matching Autec Receiving Unit to avoid possible radio interference, always positioning yourself in a safe place and with full view of the Machine, its operational area and the load, if any.
11 Decommissioning and disposal 11.1 Decommissioning If you want to remove the Receiving Unit from the Machine: - Make sure that the Receiving Unit and the Machine are not powered. - Remove all electrical connections between the Receiving Unit and the Machine. If the Radio Remote Control needs to be stored after it has been decommissioned, follow the directions provided in chapter 5.
Via Pomaroli, 65 - 36030 Caldogno (VI) - Italy Tel. +39 0444 901000 - Fax +39 0444 901011 info@autecsafety.com - www.autecsafety.