Linde Operator Assistance System Original instructions Operating Instructions - X EN - 01/2020 I
id: GUID-65A8B73C-D7F8-47A0-820D-638850EC4862 - version: 9 - lang: EN - srclang: Linde Material Handling− Your Partner Selling over 125,000 forklift and warehouse trucks per year, Linde Material Handling ranks as one of the leading intralogistics manufacturers and solution providers. And there is a reason for this success.
Table of contents 1 Introduction Linde Operator Assistance System ............................................................................... 2 Intended use.................................................................................................................... 3 Limitations for commissioning or for the permission to operate .................................. 4 Symbols used .................................................................................................................
Table of contents Charging the Distance Beeper ........................................................................................ 43 Checking the operational readiness of the Truck Unit ..................................................... 44 Checking the operational readiness sensors ................................................................... 45 Performing a functional test ............................................................................................ 46 Operation .............
1 Introduction
1 Introduction Linde Operator Assistance System id: GUID-FF7E900D-28CE-4E6D-84DF-661186EB06A1 - version: 1 - lang: EN - srclang: Linde Operator Assistance System The Linde Operator Assistance System (LOAS) is a system for the working environment of industrial trucks. It gives signals to the driver and pedestrians in case of proximity.
Introduction 5th SENSOR Additional sensor for signaling that another industrial truck with Truck Unit is in proximity TRUCK UNIT SMALL Truck Unit Small to interact with fixed components and between trucks. Detection of mobile components is not possible. Fixed Components 1 User groups During the installation, setup and usage, different user groups are needed to ensure the correct usage of the system and the correct behavior of the people.
1 Introduction Installation report User report and training The installation report is an agreement between the To support users to be aware of the system as an operating company and the service partner (e.g. KION assistance system it is mandatory to: NORTH AMERICA or qualified resellers). 1. Initially train the users about functionality of The report contains all framework conditions plus the system details of the configuration of the system and any 2.
Introduction permanently connected to the onboard electronics. Only authorized service technicians with electrical knowledge and the relevant experience are permitted to install components at fixed points in the working area and to carry out servicing work and repairs. Usually, the persons that install the fixed components are not KION NA service technicians, but electricians. Environment The assistance system has to be tested by the service technician at the place of use.
1 Introduction id: GUID-818DC715-0A4F-4111-B579-B7CC736F7646 - version: 1 - lang: EN - srclang: Limitations for commissioning or for the permission to operate ● and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult KION NORTH AMERICA or your qualified reseller for further assistance This user guide belongs to the Linde Operator Assistance System.
Introduction 1 id: GUID-E866E8BE-A41F-4132-AABB-3A9086AC5BD9 - version: 3 - lang: EN - srclang: DE Symbols used The terms DANGER, WARNING, CAUTION, NOTICE and ENVIRONMENT NOTICE are used in these operating instructions for notes on particular hazards or for unusual information that needs to be highlighted: DANGER Means that failure to comply can cause risk to life and/or major damage to property WARNING Means that failure to comply can cause risk of serious injury and/or major damage to property.
1 Introduction 2 Safety 12 Operating Instructions - X EN - 01/2020
Safety information id: GUID-000895C0-567A-4534-AF55-EAEDADC2BEA0 - version: 1 - lang: EN - srclang: Safety information The operating company has to ensure that all people Heavy mechanical stress can lead to in the area of application of the Linde Operator malfunctions. In the event of a malfunction signified by smoke or an odor, switch off the Assistance System (LOAS) are informed of its use. industrial truck.
1 • Introduction Problems could weakness be caused Red/Green WARNING Connections that change the behavior of a third party system, for example a speed reduction of a truck or connections to a door-/gate-controlIn case of entering an signaling zone, the driving unit or other third party devices must be done by speed reduction for the truck can be activated by the certified technicians from the third parties. service technician. This drive speed reduction serves as a comfort feature for the driver.
which use a main power supply, the permission by law and profound knowledge in terms of electrical installations is required. Hence, these tasks must be performed by qualified licensed electricians. Usually, fork lift truck service technicians do not have this required knowledge and are, hence, not allowed to do installations of fixed components or only if they are qualified to do so. Contact your authorized service partner.
1 Introduction 3 Operating devices and display elements 16 Operating Instructions - X EN - 01/2020
3 Operating devices and display elements Overview id: GUID-D8B0EA5E-1B5B-4E91-A70D-62877D280F71 - version: 3 - lang: EN - srclang: Overview 12 1. Truck Unit 6. Distance Beeper 2. Truck Unit Small 7. Inductive Charger 3. Sensor Truck Unit (1-5 possible) 8. 4. Zone Marker Power Plug for Inductive Charger 5.
Operating devices and display elements 3 Truck Unit id: GUID-92CCF45B-8A01-42A0-BE6F-592EFA4639F3 - version: 3 - lang: EN - srclang: Truck Unit 8 1 2 7 6 5 4 3 1 2 3 4 No function No function Sensors, switching output (middle) Pairing active 5 6 7 8 Power supply No function Number of persons in the signaling zone Signaling zones The Truck Unit provides the driver of the industrial truck with an acoustic and visual signaling whenever a certain area or pedestrians are approached.
3 Operating devices and display elements The LEDs 1 to 4 indicate the status of the sensors. The following operating statuses are possible: • • • LED green: The Truck Unit is switching on. The sensors perform self-testing for 10 seconds. LED off: The Truck Unit is switched on. The sensors are ready for operation. LED red: The Truck Unit is switched on but the respective sensor is not ready for operation. Stop operation. Check the sensor. The middle LED displays the status of the switching output.
Operating devices and display elements 3 Power supply The LED indicates the operating status of the Truck Unit: ● LED flashes green: Truck Unit is ready for operation. ● LED flashes red: The Truck Unit has registered an error. The Truck Unit is in programming mode. ● LED lights up red: The Truck Unit has registered an error. The Truck Unit is in programming mode. Number of persons in the signaling zone The display indicates the number of people in the signaling zone.
3 ● Operating devices and display elements Multiple LEDs flash orange: There are several industrial trucks in the ex- tended area. The LEDs indicate the direction from which the industrial trucks are approaching. NOTICE This function must be switched on in the configurator. ● All LEDs flash red: There are several people in the extended area. The direction is not displayed. There are one or more people in the vicinity. ● All LEDs flash orange: There are several industrial trucks in the ex- tended area.
Operating devices and display elements 3 Truck Unit Small id: GUID-F332A2F4-C2B6-4E4E-BD06-DD895138D324 - version: 3 - lang: EN - srclang: Truck Unit Small 1 1 2 2 Operating status Signaling zones The Truck Unit Small is intended to give optical signals or optionally an automatic reduction in the driving speed as a comfort function in defined Zone Marker or Static Unit areas and through truck-to-truck signals.
3 Operating devices and display elements Truck Unit Small The "ON" LED indicates the operating status of the Truck Unit Small: ● LED flashes green: The Truck Unit Small is ready for operation. ● LED red / flashes red: The Truck Unit Small is signaling an error. ON The "S1" and "S2" LEDs indicate that the truck is in a static signaling zone. ● ● LEDs flash orange: Radio module or Static Unit in the extended area of the industrial truck. Truck-to-truck signaling in the extended area.
Operating devices and display elements Optional Speed reduction as comfort function via potential-free outputs The Truck Unit is intended to inform the driver through giving optical and/or acoustic signals or optionally an automatic reduction in the driving speed as a comfort function in defined Zone Marker- or Static Unit areas, when approaching pedestrians equipped with Distance Beepers and through truck-to-truck signals.
3 Operating devices and display elements id: GUID-6C01C3E5-F1CC-4C52-90FB-C336A0797B43 - version: 4 - lang: EN - srclang: Distance Beeper 1 Switch on 2 3 Rechargeable battery charge state Signaling zone The Distance Beeper provides the pedestrian with an audible, visual and vibration signal. The Distance Beeper responds to the following components: ● ● ● Truck Unit Optionally Static Unit Optionally Zone Marker CAUTION A Lithium-ion battery can be destroyed as a result of deep discharge.
Operating devices and display elements 3 Distance Beeper Switching on You can use the "switch on / switch off" push button to switch the Distance Beeper on and off. To switch on the unit, push and hold the push button until the Distance Beeper starts up. The unit vibrates as it is switched on. A feedback tone sounds. To switch off the unit, push and hold the push button until the Distance Beeper shuts down.
3 Operating devices and display elements Charging station id: GUID-35F3779D-D9E1-4429-BCDA-42777B891ED5 - version: 1 - lang: EN - srclang: Charging station 2 3 4 5 1 1 2 3 Charge indicator Charging area Mini USB cable The inductive charging station charges the Distance Beepers. To charge a Distance Beeper, place it on the charging area (2). The charging station is connected to the power supply unit using a mini USB cable (3) via the corresponding port (5). 4 5 power supply.
Operating devices and display elements 1 2 3 Connection Mounting magnet The Sensors are mounted on the industrial truck and connected to the Truck Unit. The Sensors create the signaling zones around the industrial truck. The sensor does not fit to the Truck Unit Small. The installation shall be accomplished by a trained technician. It is important to install the antennas free of obstructions.
3 Operating devices and display elements id: GUID-4CA209AB-3E83-4E62-B27B-1EAAF750012D - version: 3 - lang: EN - srclang: Static Unit 1 2 4 1 2 Operating status Signaling zone 3 3 4 Acoustic signal transmitter Power supply The Static Unit is an infrastructure unit. The Static Unit provides acoustic and visual sig- nals regarding pedestrians and industrial trucks. The Static Unit is used at blind spots or in the event of poor radio communication.
Operating devices and display elements 3 Static Unit Operating status The LED indicates the operating status of the Static Unit. The following operating statuses are possible: ● ● ● LED off: The Static Unit is not connected to the power supply. LED flashes green: The Static Unit is ready for operation. ON LED flashes red: The Static Unit is signaling an error. Signaling zone The LEDs flash red if industrial trucks with a Truck Unit or a communication unit enter the signaling zone of the Static Unit.
3 Operating devices and display elements KION NA provides light-products or third party low-voltage optical signaling-products like LEDs or Flashlights that work with less than 240V are allowed to use. The outputs may only be used to activate or deactivate a relay to which the light-product is connected to. The installation and wiring must only be executed by certified personal, that are trained and certified to work with electrical current.
Operating devices and display elements 3 id: GUID-7492D5D6-AF93-4FBF-9957-F1B9E3F35838 - version: 3 - lang: EN - srclang: Zone Marker 1 1 Operating status 2 2 Signaling zones The Zone Marker creates a stationary signaling zone and triggers further actions on industrial trucks present in this signaling zone.
3 Operating devices and display elements Operating status The LED indicates the operating status of the Zone Marker. The following operating statuses are possible: ● ● ● ON LED off: The Zone Marker is not connected to the power supply. LED flashes green: The Zone Marker is ready for operation. LED lights up green or red or flashes red: The Zone Marker is signalling an error.
Operating devices and display elements 3 id: GUID-40A3FE29-2307-4F85-8687-ECA924C327B8 - version: 3 - lang: EN - srclang: Programmer 1. 4-pole Connection for specific USB cable The programmer is not intended to be used by customers. It is intended to be used for either programming or configuring the Linde Operating Instructions - X EN - 01/2020 Operator Assistance System devices as shown in the following Figure. The device is only used by trained service technicians.
3 Operating devices and display elements Connection of the programmer to your PC Use the additional USB Cable to connect the programmer to your computer. With the software tool “Wireless Flasher”, the programmer enables you to send new firmware to the devices. Furthermore, the provided configuration tool enables the service technician to configure the signaling zones. Wireless Flashing Tool Start the software via the corresponding *.exe file. Then, the following pop-up window will show up.
4 Operation
4 Operation Installation id: id: GUID-65900DDA- D562-41FE-8215-640261E05F30 - version: 2 - lang: EN - srclang: Attaching the Distance Beeper Switch on the Distance Beeper. To do this, push and hold the push button (2) for one second. The Distance Beeper starts. A signal tone is heard, the LEDs of the signaling zones light up and the device vibrates briefly. Check the charge state of the battery. The LED must flash green. If the LED flashes red, the Distance Beeper needs charging.
Operation 4 Installing a Static Unit The Static Unit is mounted at points that are difficult to see and thus allows the early detection of approaching industrial trucks. NOTICE Position the Static Unit so that the LED display is easy to see. Install the Static Unit between a height of 2m (78inch) but not higher than 7m (275inch) in order to guarantee optimal radio coverage. Installation via magnet The Static Unit can be mounted to metal surfaces using a magnet. 1.
4 Operation id: GUID-5C5A263B-1DD4-4BA1-8FF0-8BA-CA3B3C65E - version: 2 - lang: EN - srclang: Installing the Zone Marker The Zone Marker creates a stationary signaling zone and triggers further actions on industrial trucks present in this signaling zone. NOTICE Install the Zone Marker between a height of 2m (78inch) but not higher than 7m (275inch) in order to guarantee optimal radio coverage. Installation via magnet The Zone Marker can be mounted to metallic surfaces using a magnet. 1.
Operation 4 Pre-shift checks id: GUID-1CBA5C39-F759-40BE-9748-432976AE25CE - version: 5 - lang: EN - srclang: Service plan Distance Beeper Check the charge state of the battery Check that the unit is attached to the outside of the clothing Checking for correct function Truck Unit Check for operational readiness Checking for correct function Check the pairing with the driver's Distance Beeper Truck Unit Small Check for operational readiness Sensors Check the mounting and position Check the connection to t
4 Operation id: GUID-8ABB286F-CCBD-42D8-8CF3-BE59244C0231 - version: 3 - lang: EN - srclang: Checking the charge state of the Distance Beeper WARNING The Distance Beeper must be charged before use. 1. Switch on the Distance Beeper. 2. A short signal tone must be audible and the device must vibrate. 3. LED (1) continually flashes in green. 4. If the LED flashes red, charge the Distance Beeper.
4 Operation id: GUID-AD66DD7D-A851-488D-B8F9-AACB75F051BD - version: 3 - lang: EN - srclang: Charging the Distance Beeper 2 WARNING Risk of accident due to discharged battery! Charge the Distance Beeper after use 3 NOTICE Prior to initial commissioning, the Distance Beeper must be fully charged once. If the Distance Beeper is removed from the charging station too early, the LED flashes red even when the charge capacity is over 90%.
4 Operation id: GUID-EA774CD9-24F1-426A-927A-0E124FD5F33- version: 2 - lang: EN - srclang: Checking the operational readiness of the Truck Unit Check for operational readiness 1. Switch on the industrial truck. 2. The Truck Unit switches on and is ready for operation after approx. 15 seconds. Check LED (1) on the Truck Unit. The LED must flash green. Checking pairing with a Distance Beeper NOTICE If the driver is carrying a Distance Beeper, it must be paired with the Truck Unit.
Operation 4 id: GUID-EA6A1A2F-AE1A-4567-A1CD-ED60159480D6 - version: 3 - lang: EN - srclang: Performing a functional test of the Truck Unit DANGER Note that the signals given by the system are additional information for the driver. However, the driver is still responsible to drives Safely and keep the control over the fork lift truck at any time! Always perform a functional test before starting work. NOTICE The signaling zones are preconfigured by the manufacturer.
4 Operation Pre-shift checks Functional test of the Static Unit NOTICE The functional test must be completed regardless of the industrial truck component configuration. When using the Truck Unit Small, per- form the following steps as well. The functional test checks the signaling zones that have been set and any responses that have been set on the industrial truck. • Switch on the industrial truck. The Truck Unit switches on. • Check the operational readiness of the Static Unit.
Operation 4 Functional test of the Zone Marker NOTICE The functional test must be completed regard- less of the industrial truck component configuration. When using the Truck Unit Small, perform the following steps as well. The functional test checks the signaling zone that have been configured and any responses that have been set on the industrial truck. • Switch on the industrial truck. The Truck Unit switches on. • Check the operational readiness of the Zone Marker.
4 Operation Switching on the Truck Unit Switch on the industrial truck. The Truck Unit starts as follows and runs a selftest: • The numerical display lights up • Depending on the number of sensors, the numerical display counts down from 3 or 4 to 0.
Operation 4 Pairing the Distance Beeper WARNING If a Distance Beeper is within the pairing zone of the industrial truck, the unit is paired automatically with the Truck Unit and muted. As long as it is in the paired zone, it does interact with any Truck Unit. NOTICE The pairing function has to be activated by a service partner. • Move the Distance Beeper into the pairing zone of the Truck Unit. The LED display (1) on the Truck Unit lights up green. The Truck Unit does not issue a signal message.
4 Operation Operation operating status that are displayed when the Truck Unit makes contact with other components of the system are described below.
Operation 4 Operation Distance Beeper in the extended area WARNING If an industrial truck stops abruptly, this can result in an accident that may cause serious injury and material damage! • You must abruptly not reduce speed to 0 mp/h. People with a Distance Beeper enter the extended area of the industrial truck with the Truck Unit. The LEDs for the signaling zones on the Truck Unit flash red.
4 Operation Operation Distance Beeper in the immediate vicinity People with a Distance Beeper enter the immediate vicinity of the industrial truck with the Truck Unit. All the LEDs for the signaling zones on the Truck Unit flash red. A signal tone is emitted. In addition, the number of people in the immediate vicinity is displayed. Depending on the programming and equipment, the industrial truck reduces the driving speed and the LED switching output lights up red.
Operation 4 Static Unit WARNING ON If an industrial truck stops abruptly, this can result in an accident that may cause serious injury and mate- rial damage! You must abruptly not reduce speed to 0 mp/h Adjust the speed before entering the signaling zone. ALWAYS keep the surrounding area in view. Industrial trucks with Truck Unit The industrial truck enters the signaling zone for the Static Unit. The switching output LED lights up red on the Truck Unit.
4 Operation Industrial trucks with Truck Unit Small The industrial truck enters the signaling zone for the Static Unit. The LEDs for the signaling zones light up red on the truck unit small. All the LEDs for the signaling zone flash on the Static Unit. An optional signal tone is also possible. Depending on the programming and the equipment, responses on the industrial truck and additional signal lights can be activated.
Operation 4 Zone Marker WARNING If an industrial truck stops abruptly, this can result in an accident that may cause serious injury and mate- rial damage! • You must abruptly not reduce speed to 0mp/h Adjust the speed before entering the signaling zone. • ALWAYS keep the surrounding area in view. Industrial trucks with Truck Unit The industrial truck enters the signaling zone of the Zone Marker. The switching output LED lights up red on the Truck Unit.
4 Operation Industrial trucks with Truck Unit Small The industrial truck enters the signaling zone of the Zone Marker. The LEDs for the signaling zones light up red on the Zone Marker. An optional signal tone is also possible. Depending on the programming and the equipment, responses on the industrial truck and additional signaling lights can be activated.
Operation 4 Signaling between industrial trucks The signaling between industrial trucks works when the industrial trucks are equipped with Truck Units and a fifth Sensor Truck Unit. Alternatively, the signaling works if the industrial trucks are equipped with a Truck Unit Small (figure LSG_0043). Industrial trucks with Truck Unit The display is the same as for contact with a Distance Beeper. The industrial truck with Truck Unit enters the extended area.
4 Operation Industrial trucks with Truck Unit Small The industrial truck with a Truck Unit Small reaches the extended area. The industrial truck with the Truck Unit Small reaches the immediate vicinity.
5 Maintenance and disposal
5 Maintenance and disposal Maintenance CAUTION Risk of surface damage from using incorrect cleaning materials. • Do not use aggressive cleaning materials. • Do not use cleaning materials containing abrasive particles Regularly cleaning the components of the Linde Operator Assistance System increases the service life of the system. After daily use, perform the following steps: • Check the Truck Units, the sensors and the signaling units for contamination. • Remove coarse dirt with a soft brush.
Maintenance and disposal 5 Disposal NOTICE Waste electronic equipment and batteries are raw materials and are not considered household waste. Disposal with household waste is not permitted. At the end of their service life, waste equipment and batteries must be disposed of in accordance with the national regulations NOTICE We recommend working management company requirements.
5 Maintenance and disposal 6 Technical data 64 Operating Instructions - X EN - 01/2020
6 Technical data Truck Unit Performance data Operating voltage Max. power consumption Unit VDC W Value 12 / 24 Max. 6.5 M ft Max. 25 Max. 82 Ultrawide band Channel MHz No.5 (CF = 6489.6) Frequency (Occupied Bandwidth) MHz Transmission power dBm/ Hz 6143.2 to 6820.8 -42.76 Range Operating temperature Air humidity Dimensions w/o accessories (LxWxH) Weight °C °F –20 up to +45 -4 up to +113 % mm in 10-85 120 x 76 x 24 4.72 x 3 x 0.94 g Oz 193 6.
Technical data Sensor Truck Unit Performance data Operating voltage Max. power consumption Range Ultrawide band Channel 6 Sensor Truck Unit Unit VDC W M ft MHz Value 5 1 Max. 25 Max. 82 No.5 (CF =6489.6) MHz 6166.2 to 6804.8 Frequency (Occupied Bandwidth) Transmission power Operating temperature Air humidity Dimensions w/o accessories (LxWxH) Weight dBm/M Max. -41.95 Hz °C °F % mm in –40 up to +85 -40 up to +185 10-85 85 x 45 x 22 3.34 x 1.77 x 0.86 g Oz 81 2.
6 Technical data Static Unit Static Unit Performance data Operating voltage Max. power consumption Range Ultrawide band Channel Frequency(Occupied Bandwidth) Transmission power Operating temperature Air humidity Dimensions w/o accessories (LxWxH) Weight Unit VAC W M ft MHz Value 90 - 264 Max. 6 Max. 25 Max. 82 No.5 (CF =6489.6) MHz 6164.2 to 6853.8 dBm/ MHz Max. -43.23 °C °F % mm in –40 up to +85 -40 up to +185 10-85 180 x 150 x 60 7.09 x 5.9 x 2.36 g Oz 935 32.
Technical data 6 Zone Marker Performance data Ultrawide band Channel Unit MHz MHz Frequency (Occupied Bandwidth) Transmission power Operating temperature Air humidity Dimensions w/o accessories (LxWxH) Weight Value No.5 (CF =6489.6) 6158.2 to 6804.8 dBm/ MHz Max. -41.9 °C °F % mm in –40 up to +85 -40 up to +185 10-85 100 x 60 x 40 3.93 x 2.36 x 1.57 g Oz 149 5.26 Programmer Performance data Operating voltage Max.
Index Switching on the Distance Beeper. ....... 49 C Switching on the Truck Unit. ................. 49 Care P Distance Beeper. ...................................... 26 D Pre-shift checks D2Sense system components. ................. 12 Charging the Distance Beeper.............. 43 Disposal ................................................... 63 Checking the operational readiness of F the Truck Unit. ................................... 44 Functional test .........................................
Linde Material Handling GmbH X EN - 01/2020
