Original instructions
Air series
User manual
Description, warnings and instructions
LIAIRE00-02
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. Always remember that:
- photos and drawings are useful examples that help understand the instructions and
warnings of each radio remote control conguration
- if necessary, contact Autec if any of the instructions and/or warnings are not clear
No part of the documentation may be reproduced, in any form or by any means, without
written permission of Autec (including recording and photocopying).
If documentation is lost or damaged, ask Autec for a copy. Please specify the serial number
of the related radio remote control.
The documentation must be kept for the whole life of the radio remote control: after reading
it, keep it on hand for future reference.
All installation, usage and maintenance operations must be carried out by qualied technicians
who are suitably trained with respect to the relevant norms and laws.
Information contained in the documentation adds to and completes the information provided
by the manufacturer of the remote controlled and/or by those who install the radio remote
control on the machine.
Therefore, this documentation must be read and understood in all its parts by the user and by:
- the radio remote control owner and/or installer
- the person responsible for and in charge of maintenance and/or safety in the workplace
where the radio remote control is used.
As for instructions and warnings regarding the machine where the radio remote control is
installed, follow the instructions given in the machine's manual.
Three symbols are employed throughout documentation, which are used to highlight specic
safety-related issues. They are classied according to the hazardous situation that may arise
and on the possible consequences:
If the highlighted instructions are not respected ...
Symbol
... a dangerous situation
will occur…
…highly probable.
...consequences for
people may be…
… critical (death or
physical damage).
...consequences for
property may be…
… critical.
… probable.
… probable.
… critical (death or
physical damage).
… moderate (non-severe
physical damage).
… critical.
… moderate.
This symbol is also used, and it identies texts to be read carefully.
AUTEC LIAIRE00-02
LIAIRE00-02 AUTEC
AIR SERIES
Part A: Description, warnings and instructions
INDEX
1 Radio remote control description ........................................................................ 6
1.1 How the radio remote control works ................................................................. 6
1.2 Applications ..................................................................................................... 6
1.3 Technical Data ................................................................................................. 6
1.4 Radio link ......................................................................................................... 6
1.5 Safety function: stop protection ........................................................................ 7
1.6 Protection against unintended movements from the rest position ..................... 7
1.7 Identifying the radio remote control .................................................................. 7
2 Risk assessment ................................................................................................... 8
2.1 Risk assessment for radio remote controlled machines .................................... 8
2.2 Sta training .................................................................................................... 9
2.3 Working conditions .......................................................................................... 9
3 Warnings for installation .................................................................................... 10
3.1 General .......................................................................................................... 10
3.2 Mounting and fastening the receiving unit in the best position ........................ 10
3.3 Positioning the antenna ................................................................................. 11
3.4 Wiring ............................................................................................................ 11
3.5 At end of installation ...................................................................................... 12
3.6 Testing ........................................................................................................... 13
4 Warnings for use ................................................................................................. 14
4.1 Before starting to work ................................................................................... 14
4.2 During normal operation ................................................................................ 14
4.3 After using the radio remote control ............................................................... 15
5 Radio remote control life cycle .......................................................................... 16
5.1 Transportation and storage ............................................................................ 16
5.2 Installation ..................................................................................................... 16
5.3 Use ................................................................................................................ 17
5.4 Radio remote control maintenance ................................................................. 18
5.5 Machine maintenance .................................................................................... 20
5.6 Disposal ......................................................................................................... 20
6 Troubleshooting .................................................................................................. 21
AUTEC LIAIRE00-02
6
Radio remote control description
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 Applications
AIR series' radio remote controls can be installed on hoisting and material handling machines
(i.e. overhead cranes).
AIR series radio remote controls cannot be installed:
- on machines installed in places where equipment with explosion-proof characteristics
is required
- on machines for people lifting and transportation (the machine's manufacturer may
authorize installation and use of a radio remote control on such applications under their
own responsibility, if the risk assessment they carried out gave positive results)
- on machines that may generate dangerous situations if they stop due to the loss of radio link
- on machines for which a risk assessment is not possible or gave negative results
Autec cannot be held responsible if the radio remote control is installed on forbidden
applications.
1.3 Technical Data
Command response time (typical) ........................................................................... 100ms
(Typical) working range ..................................................................... 75-100m (240-330ft)
Stop time (typical) ................................................................................................... 100ms
Max. stop time ............................................................................................................. 0.5s
Performance Level of safety functions according to ISO 13849-1:
Stop protection ........................................................................................................... PL d
1.4 Radio link
The transmitting unit constantly communicates with the receiving unit through a radio link.
This is an essential requirement to ensure safety for the radio remote controlled machine.
This address is unique (Autec produces it only once), univocal (specic for each radio remote
control) and not reproducible. Each unit can only decode the messages coming from the unit
with the same address.
This prevents messages from other radio equipment from activating any system function.
LIAIRE00-02
AUTEC - AIR SERIES
Radio remote control description 7
1.5 Safety function: stop protection
The stop function brings the machine to a safe state every time it is necessary to stop it due
to a potentially hazardous situation. Depending on the situation, this function can either be
deliberately activated by the operator through the STOP pushbutton, or it is automatically
activated when the radio link is incorrect or interrupted (the receiving unit autonomously
stops the radio remote control).
1.6 Protection against unintended movements from the rest position
This 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 function checks the neutral (rest) position of pushbuttons controlling the machine's
movements. Each time one of those pushbuttons is operated, the transmitting unit sends
both the movement command and the SAFETY command.
1.7 Identifying the radio remote control
As required by standard IEC 60204-32, each radio remote control is uniquely identied
through a serial number (SERIAL N.).
The SERIAL N. is provided in the identication plate on each radio remote control unit.
This is the only reference to be used both for maintenance operations and for declarations
to competent bodies.
These plates must not be:
- removed from their position (removal will invalidate the guarantee)
- altered or damaged (contact Autec for replacement)
AUTEC - AIR SERIES
LIAIRE00-02
8
Risk assessment
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.
The radio remote control can only be installed if this assessment gives positive results.
The machine manufacturer and/or the person who decides upon radio
remote control installation and use is responsible for this risk assessment.
Autec cannot be held responsible if this assessment has not been carried out correctly
or is incomplete.
If required by the risk assessment, draw up protection measures to prevent, reduce and
report potential hazard situations.
2.1 Risk assessment for radio remote controlled machines
When carrying out risk assessment for the machine or for the system where the radio remote
control is installed, the following must be considered:
- some machines cannot be radio remote controlled: check for forbidden applications (see
paragraph 1.2)
- the radio link between the two units may be interrupted due to persistent disturbance
or interference.
- all warnings related to installation, use and maintenance provided by Autec must be
taken into account
2.1.1 Aspects related to radio link
Whenever the radio link is interrupted (i.e. stop, low battery, automatic switch o, receiving
unit not powered):
- all outputs of the receiving unit are disabled
- it is not possible to enable or disable the machine commands until the radio remote
control is started up again.
LIAIRE00-02
AUTEC - AIR SERIES
Risk assessment 9
2.1.2 Delay in command response time
Due to the characteristics of radio propagation (i.e.: EM interference, outof-working-range condition), a delay up to the "Maximum stop time" may
occasionally occur from the moment a command in the transmitting unit
is released to the moment its corresponding output in the receiving unit
is deactivated.
Those who decide upon the installation of the radio remote control must make sure that this
delay never leads to a dangerous situation in the specic uses.
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. commands requiring two-hand operation, “dead-man” function) if particular
environments, equipment and working modes could cause accidental bumps to the actuators.
2.1.4 Command activation and loss of command
Please consider that it is possible to unintentionally activate a command and/or involuntarily
loose the selection of a command. Such anomalous events may be caused by electromechanical or mechanical damages in the "machine+radio remote control" system.
Carefully evaluate the possible consequences of such malfunction.
If required by the risk assessment, draw up protection measures to prevent, reduce and
report potential hazard situations.
2.2 Statraining
All installation, usage and maintenance operations must be carried out by qualied technicians
who are suitably trained with respect to:
- warnings resulting from risk assessment
- regulations and reference laws
- instructions and warnings provided in the documents related to the industrial radio remote
control and to the radio remote controlled machine
- instructions provided by those who install the radio remote control on the machine and
by the person in charge for workplace safety where the system machine+radio remote
control is used
2.3 Working conditions
To guarantee correct radio remote control operation, all current regulations regarding safety at
work and accident prevention should be respected. All applicable standards and regulations
valid in the user country 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.
AUTEC - AIR SERIES
LIAIRE00-02
10
Warnings for installation
3 Warnings for installation
Besides instructions established by the machine's manufacturers, installers must always
observe the following warnings.
3.1 General
Respect and enforce the provisions of all reference standards relevant in
theconcernedapplicationeld(i.e.IEC60204-32forhoistingmachines.)
Always follow the instructions provided in the technical data sheet and
respect values given in the technical data to carry out correct installation.
3.2 Mounting and fastening the receiving unit in the best position
Place the receiving unit so that it can be easily reached in case of need.
Place the receiving unit vertically, with the cable gland or plug facing down.
Fixthereceivingunitinfourpoints,usingthespecicholesinthehousing.
LIAIRE00-02
Do not perforate the receiving unit in any case.
Wheninstallingonmachines that vibrate, it is recommended to x the
receiving unit to the machine with the appropriate vibration dampers.
AUTEC - AIR SERIES
Warnings for installation 11
3.3 Positioning the antenna
The antenna is inside the receiving unit. Hence, install the receiving units
towards the working area, so that shields, structures or materials do not
obstruct the radio link. In particular, the receiving unit must be placed at
least 50 cm far from metal objects in its surroundings and never inside
closed metal containers.
WARNING: If the receiving unit is shielded by metal structures or is installed
inside metal cabinets, use the appropriate extension kit for the antenna.In
this case, install the antenna in a vertical position, and possibly towards
the work area.
If this warning is disregarded, the radio remote control working range may be reduced.
3.4 Wiring
The power supply of the receiving unit must be connected using an omnipolar
switch with a switch-contact gap of at least 3 mm, that allows power supply
disconnection during installation, wiring and/or maintenance operations.
The receiving unit's power supply shall be protected from short circuits by
means of a device ensuring a suitable interruption performance (e.g. fuse).
PayspecialattentiontocurrentsandvoltagesowingintheSAFETYand
STOP outputs: they shall not exceed the maximum permitted values.
To obtain the protection from unintended movements from the rest position,
connectthecontactofthe SAFETY relay in series with the movement
commands.
The STOP circuit in the receiving unit has two contacts connected in series
through a wire jumper (manufacturer's standard wiring). If the machine needs
a STOP circuit with two separate contacts (four wires), this bridge can be
removed. In this case, the installer is responsible for wiring in a way that
assures the required safety level.
AUTEC - AIR SERIES
LIAIRE00-02
12
Group the wiring away from the electronic module, in order to avoid
interferences and hazards related to electrical safety.
Evaluate the radio remote control's wiring and remember that if the output
dedicated to the machine's horn, siren or blinker is used for another command
due to application's and/or functional reasons, some procedures in the
“CongurationMenu”mayresultunavailablelateron.
To wire the terminals corresponding to the commands' outputs, to the STOP
outputs and to the SAFETY outputs, it is recommended to use a 3.5x0.4mm slot
screwdriver (e.g. WAGO code 210-720).
3.5 At end of installation
Make sure that during installation the safety mechanisms on the radio remote
controland/orinthemachinehavenotbeenmadeineectivebypossible
procedures carried out.
Warnings for installation
LIAIRE00-02
Look up in the technical data sheet and check that the frequency band set
in the radio remote control is permitted in the Country of use.
Correctly close the receiving unit so that the protection degree from dust
and water is not jeopardised: check that the gasket is intact, correctly put
the housing parts one over the other so that they overlap, and screw in the
screws.
AUTEC - AIR SERIES
Warnings for installation 13
3.6 Testing
The installer must check and complete the technical data sheet in all its parts, adding the
date the system has been put into service, his stamp and signature.
After installing and wiring the receiving unit, test the system “machine+radio
remotecontrol”,andcheckthattheoperationscarriedoutcorrespondexactly
to the commands sent (in particular check the STOP command).
Incaseofmalfunction,disablethesystem“machine+radioremotecontrol”
until the problem has been completely solved.
AUTEC - AIR SERIES
LIAIRE00-02
14
Warnings for use
4 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.
4.1 Before starting to work
Stand in a position that allows the direct supervision of the remote controlled
machine and its load, and stay in a place ensuring safety conditions in respect
of other operations and/or activities and/or processes that are carried out
in the working environment.
Always check that the mechanical operation of the STOP pushbutton is
correct.Ifitisimpossibleordiculttopressthispushbutton,donotuse
the radio remote control.
Never start up or use the transmitting unit if the working conditions present
the risk of losing balance or tripping.
Only start up the transmitting unit when starting work: improper use may
cause hazardous situations.
Never start up or use the transmitting unit in closed spaces, with the machine
not in sight, or outside the radio remote control working range: in such
cases it is in fact still possible to build a radio link, thus causing the risk
that unwanted commands be carried out by the machine.
Get familiar with the correspondence between the actuators and the
machine's movements (this is indicated in the attached technical data
sheet) and learn symbols on the transmitting unit's panel (symbols used
aredenedbythemachinemanufacturerand/orinstallerdependingonthe
machine's operation and functions).
4.2 During normal operation
Pay attention to the entire work area. Immediately press the STOP pushbutton
when a hazardous situation occurs.
LIAIRE00-02
AUTEC - AIR SERIES
Warnings for use 15
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.
Incaseofmalfunction,disablethesystem“machine+radioremotecontrol”
until the problem has been completely solved.
Pay attention to the low battery signals. The A8 unit cannot be used during
the charging process; all dangerous operations (i.e. hanging load) must
thereforebebroughttoanendbeforethebatteryiscompletelyat.
Use the transmitting unit in a simple and comfortable way, avoiding accidental
falls. The pouch supplied with the radio remote control is used for this
purpose.
4.3 After using the radio remote control
Switch off the transmitting unit when work is stopped or temporarily
interrupted. Do not leave the load hanging (even while recharging the unit).
Never leave the transmitting unit unattended if it is on.
AUTEC - AIR SERIES
LIAIRE00-02
16
Radio remote control life cycle
5 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.
5.1 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.
Temperature Relative Humidity Air pressure
Transportation
Storage
5.2 Installation
The radio remote control can only be installed and tested by competent sta that
masters the technical knowledge required to carry out these procedures and is
qualied according to the regulation of the country where the radio remote control
is mounted.
Only if the radio remote control is installed correctly can it be used safely.
Always follow the instructions provided in the technical data sheet to carry
out correct installation.
Please contact the machine manufacturer or the person who decided upon
the installation of the radio remote control for instructions and warnings
regarding the installation.
Class 2K4
-40°C to +70°C
(-40°F to +158°F)
Class 1K5
-40°C to +70°C
(-40°F to +158°F)
Class 2K4
95%
Class 1K3
5% to 95%
Class 2K4
70kPa to 106kPa
Class 1K5
70kPa to 106kPa
LIAIRE00-02
AUTEC - AIR SERIES
Radio remote control life cycle 17
All warnings for correct installation are given in chapter 3.
All instructions for correct installation are given in "Part D" (related to the receiving unit).
5.3 Use
The use of industrial radio remote controls is strictly limited to skilled and properly trained
personnel.
All warnings for correct use are given in chapter 4.
All instructions for correct use are given in "Part C" (related to the transmitting unit).
Environmental working conditions are given in the following table.
Temperature Relative Humidity Air pressure
Use
of the
transmitting
unit
Use
of the receiving
unit
Class 4K4H
-20°C to +55°C
(-4°F to +130°F)
Class 4K4H
-20°C to +70°C
(-4°F to +158°F)
Class 4K4H
4% to 100%
Class 4K4H
70kPa to 106kPa
AUTEC - AIR SERIES
LIAIRE00-02
18
Radio remote control life cycle
5.4 Radio remote control maintenance
The following instructions provide information to safely carry out routine and special
maintenance operations for the radio remote control.
They shall be completed by:
- instructions provided by the machine manufacturer
- directions provided by the installer of the radio remote control on the machine
- regulations regarding safety at work and accident prevention in force in the country where
the radio remote control is used.
All ne-tuning, checking and maintenance actions carried out on the radio remote control shall
be veried and recorded by the person in charge of carrying out maintenance on the machine.
Before any maintenance operation, 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
remotecontrol”untiltheproblemhasbeencompletelysolved.
After each maintenance operation, if a unit has been opened, close it
correctly, in order not to endanger its protection degree from dust and
water: check that the gasket is intact, correctly overlay the two parts of the
housing and tighten the screws.
5.4.1 Routine maintenance
Routine maintenance consists of operations needed to preserve the radio remote control
normal usage conditions, thus implementing ne-tuning, checks, planned replacement actions
that necessarily arise from the normal use of the product.
All given instructions must be followed correctly at each commissioning, that is:
- whenever the radio remote control and/or the machine is installed or assembled
- whenever the machine location/position changes
- after special maintenance.
Routine maintenance carried out as described in this manual is fundamental for using the
radio remote control safely.
Special applications may need more specic routine maintenance actions to be carried out at
dierent periods (i.e. if the working environment is particularly dirt, in case of heavy applications
or if the system is used very frequently, some maintenance actions may be required more
frequently, depending on the decision of the person in charge for safety in the work site).
LIAIRE00-02
AUTEC - AIR SERIES
Radio remote control life cycle 19
5.4.2 Daily routine maintenance
Before starting to work:
- make sure that the transmitting unit panel symbols can be easily recognised and replace
the panel if necessary
- check that the three plates on the transmitting unit are readable and intact
- make sure that the mechanical operation of the STOP pushbutton is correct.
During normal operation:
- check structural integrity of 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 ammable/corrosive materials and do
not use high-pressure water cleaners or steam cleaners
- store the transmitting unit in clean and dry areas.
5.4.3 Three-month routine maintenance
Every three months:
- remove dust or deposit of material from the receiving unit: never use solvents or ammable/
corrosive materials to clean it, and do not use high-pressure water cleaners or steam
cleaners
- check structural integrity of the receiving unit
- make sure that the wiring of the receiving unit is intact and connected
- make sure that the receiving unit panel symbols can be easily recognised and replace
the panel if necessary
- check that the plates on the receiving unit are readable and intact.
5.4.4 Six-month routine maintenance
Every six months:
- check the correct correspondence between the commands that are sent and the
manoeuvres that are carried out by the machine
- check that the contact of the SAFETY relay is open when no movement command has
been sent. This is safety critical maintenance: it is necessary to keep a record (date,
signature, comments) showing that this check has been regularly carried out. Keep the
record together with other installation documents.
- make sure that all the relay contacts of the receiving unit operate correctly, and check
that the contact closes when the corresponding manoeuvre is enabled and opens when
the manoeuvre is disabled.
AUTEC - AIR SERIES
LIAIRE00-02
20
5.4.5 Special maintenance
Special maintenance consists of repairs needed due to radio remote control failure, damage
or malfunction, carried out with the aim of restoring the original usage and working conditions.
Prior to contacting the support service technicians:
- read and understand all documents related to the radio remote control, and
make sure that all the instructions they contain have been accomplished
correctly
- follow the instructions to detect possible malfunctions and their origins.
Any fault should be repaired by authorised personnel only (contact the
support service of the machine's manufacturer), using original Autec spare
parts only.
The following radio remote control data must be reported in order to make interventions
faster and more reliable:
- radio remote control serial number (S/N)
- purchase date (given on the certicate of guarantee)
- description of the problem found
- address and telephone number of the place where the device is being used (with the
name of the person to contact)
- local supplier.
Radio remote control life cycle
5.5 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.
Disconnect all receiving unit's electrical connections whenever machine
maintenance is carried out (i.e. when soldering).
When carrying out maintenance on the machine, always disconnect power
supply from the receiving unit.
5.6 Disposal
When disposing of a radio remote control, give it to the waste separate collecting services
in the user's country.
LIAIRE00-02
AUTEC - AIR SERIES
Troubleshooting 21
6 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 dierent
from the radio remote control, if present. If the problem persists, it lies with the machine.
If not, the problem may lie with the radio remote control.
Look up in “Part C” and/or in “Part D” to identify the radio remote control malfunction signalled
by light signals on the units.
AUTEC - AIR SERIES
LIAIRE00-02
LIAIRE00-02 AUTEC
AUTEC SRL via pomaroli 65 Caldogno (VI) Italy - phone: +39 0444 901000 - mail: info@autecsafety.com - www.autecsafety.com
Loading...