Rail mounted receiver
USER’S MANUAL
Follow the indications and warnings given by the machine producer regarding the machine
controlled by the radio remote control.
The information contained in this manual considers a representative configuration of the
radio remote control: please find radio remote control real configuration in the technical data
sheet (attached to the manual).
If this manual is lost or damaged, ask for a copy from AUTEC. Please specify the serial
number of the relative radio remote control.
Contact AUTEC if any of the instructions and/or warnings given in this manual are not clear.
The information contained in this manual is subject to modification without notice and is not
binding.
No parts of this manual may be reproduced by any means without the written permission of
AUTEC (including recording and photocopying).
LIE&LQA0
1
Index & Conventions
1
INDEX & CONVENTIONS
INDEX
Page
1
2
Introduction
3
Receiving unit
4
Warnings for installation
5
Warnings for maintenance
6
Installation
7
Antenna assembly
8
Light signals
9
Programming
10
Receiving unit diagnostic
2
5
7
9
12
13
14
15
16
CONVENTIONS
In this manual, all important information is indicated using the following symbols and
conventions:
!
abcd. . .
abcd. . .
: WARNINGS
: TECHNICAL DATA
abcd. . .
abcd. . .
: INSTRUCTIONS
: IMPORTANT TEXTS
THIS MANUAL REFERS EXCLUSIVELY TO THE RECEIVING UNIT: THE GENERAL
USAGE WARNINGS ARE GIVEN IN THE TRANSMITTING UNIT MANUAL.
BEFORE INSTALLING, STARTING AND USING THE RADIO REMOTE CONTROL, THIS
MANUAL MUST BE READ AND UNDERSTOOD CAREFULLY BY ALL PEOPLE WHO
INSTALL, USE AND CARRY OUT MAINTENANCE ON THE RADIO REMOTE CONTROL.
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INTRODUCTION
Industrial radio remote controls are used to
command machines from a distance. Each
industrial radio remote control is made up of a
portable transmitting unit, from which the user can
remotely control the machine, and a receiving unit
installed on board the machine itself.
The transmitting unit uses radio frequencies to
transmit a coded message which contains a value
called address. Each receiving unit can only decode
the messages coming from its own transmitting unit
with the same address.
This excludes the possibility of an interference
activating any system function. If the radio
frequency transmission is disturbed, incorrect or
interrupted, the receiving unit autonomously stops
the whole system.
Each radio remote control complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) this device may not cause harmful interference, and
(2) this device must accept any interference received, including interference that may
cause undesired operation.
!
Changes or modifications not expressly approved by the party
responsible for compliance could void the user’s authority to operate
the equipment.
Transmitting
unit
Receiving
unit
NOTE: This equipment has been tested and found to comply with the
limits for a Class B digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment
generates, uses and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause
harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If
this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and
on, the user is encouraged to try to correct the interference by one or
more of the following measures:
-- Reorient or relocate the receiving antenna.
-- Increase the separation between the equipment and receiver.
-- Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
-- Consult the dealer or an experienced radio/TV technician for help.
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!
Autec cannot be held responsible if the radio remote control is
installed on applications that are different from those permitted
PERMITTED USES
:
Material lifting machines (construction cranes, industrial bridge cranes,
machines for moving material in general, . . . )
FORBIDDEN USES
Machines installed in areas where equipment with explosion-proof
characteristics are being used.
Machines for moving, raising and transporting people.
Alll machines must undergo a risk analysis; therefore it is necessary to evaluate, within
the limits of this analysis, if the machine can be radio remote controlled.
The machine producer and/or the person who decides upon radio remote control use
and installation is responsible for this analysis.
Autec cannot be held responsible if the risk analysis is not carried out correctly.
To guarantee correct radio remote control operation, all current regulations regarding
safety at work and accident prevention should be respected. All current user country
national laws 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.
System must be installed by a licensed technician and in accordance with all
relevant local, state/provincial and federal regulations, including but not limited to
NEC, OSHA, CE etc.
.
!
In any cases of emergencies, faults or damaged parts, ALWAYS stop
the “machine + radio remote control” system until the problem has
been solved.
Any damaged parts can ONLY be replaced by authorised
Autec personnel or service representative, and only using original Autec
spare parts.
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INSTRUCTIONS FOR DOCUMENT MANAGEMENT
The following minimum documentation is supplied with each radio remote
control:
- transmitting unit manual
- receiving unit manual
- battery charger manual
- a guarantee certificate
- the radio remote control technical data sheet.
Make sure that the following documents have been supplied: if they are not, request
them from Autec. Please specify the radio remote control serial number.
The conditions of the radio remote control guarantee are given in the “Certificate of
Guarantee”.
The technical data sheet shows the wiring system between the receiving unit and the
machine. It should be compiled and checked by the installer, who has the responsibility
of correct wiring. Once all necessary checks have taken place the installer must sign the
technical data sheet, which must be kept with the user's manual (always keep a copy of
this data sheet in case it is needed for administrative purposes).
The radio remote control identification and approval data is given on plates that are on
both the transmitting unit and the receiving unit.
The plates MUST NOT be removed from where they are placed or damaged
otherwise the warranty will be forfeited.
CERTIFICATE OF GUARANTEE
TECHNICAL DATA SHEET
IDENTIFICATION PLATES
TECHNICAL DATA
Frequency band
Programmable radio channel
Hamming distance
Probability of non-recognition of error
Typical working range
Time of reply to commands
Time of reply to STOP
Passive emergency time
* refer to paragraph “Programming” in the receiving unit manual, DIP nr. 1 settings.
902 - 928 MHz
32
³ 8
<10 exp-11
100 m
<100 ms
<100 ms
* 0,35 / 1 sec.
!
Following from the status of dip switch no.1 or possibly due to a failure
(of the dip switch itself), a delay up to max 1 second may occasionally
occur between command release and actual deactivation of outputs.
This is due to the characteristics of radio propagation (i.e.: EM
interferences, near out-of-range condition). Care must be taken to
ensure that this could never lead to.
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RECEIVING UNIT
The receiving unit Type R102 may be used with the following transmitting units:
- LIGHT SERIES
- MODULAR SERIES.
F2
F3
D
B
A
C
F
E
F1
These receiving units are equipped
with a safety function called
SAFETY that protects the “radio
remote control + machine” system,
when it is in neutral (rest position),
from involuntary movements
caused by possible radio remote
control faults.
RECEIVING UNIT TECHNICAL DATA
Power supply
Antenna
Number of available commands
Max switching capacity of STOP contacts
Max switching capacity of SAFETY contacts
Max switching capacity of command contacts
Fuse F3 (STOP circuit)
Fuse F2 (SAFETY circuit)
Fuse F1 (POWER SUPPLY)
Working temperature
Housing
Minimum protection grade
Dimensions
Weight
light signals
A
data technical plate
B
identification plate
C
output terminal block
D
power supply terminal block
E
connector for antenna
F
!
SUPPLY THE RECEIVING UNIT
BY A SAFETY ISOLATING
TRANSFORMER (or corresponding IEC 60204-32 paragraph).
10 - 30 Vac/dc (~7 W)
14 (+ start + stop)
4A T 250V (5x20 mm)
4A T 250V (5x20 mm)
1A T 250V (5x20 mm)
(160x110x75) mm
dedicated
4A (250 Vac)
4A (250 Vac)
4A (250 Vac)
-4°F - +158°F
NORIL ®
IP20
500 g
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RECEIVER EXTENSION
Also available is a receiver extension, which adds another 6 commands to those on the base
unit.
D
F4
output terminal block
D
flat cable for connection
G
G
In order to connect the receiving unit to its extension,
insert the ribbon cable into the connector, which is
positioned next to the antenna connector (F).
receiving unit
extension
RECEIVING UNIT EXTENSION TECHNICAL DATA
Number of available commands
Max switching capacity of SAFETY contacts
Max switching capacity of command contacts
Fuse F4 (SAFETY circuit)
Housing
Minimum protection grade
Dimensions
Weight
G
6
4A (250 Vac)
4A (250 Vac)
4A T 250V (5x20 mm)
NORIL ®
IP20
(72x110x75) mm
200 g
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4
WARNINGS FOR INSTALLATION
Installation should only be carried out by qualified people and in
accordance with installation country rules.
THE INSTALLER
MUST
MOUNT the receiving unit so that the output terminal blocks always
faces upwards.
DO NOT MODIFY or TAMPER WITH the radio remote control, the
machine or its electric systems. DO NOT PERFORATE the receiving unit
for any reason whatsoever.
CHECK that the receiving unit power supply is inside the voltage range
given in the “Technical Data”, and that the voltages and currents being
used do not exceed the maximum permitted values.
DO NOT EXCLUDE the radio remote control safety mechanisms and/or
those present inside the machine.
RESPECT the (for hoisting machines) and/or
prescriptions
NEVER SUPPLY the receiving unit directly from the mains. A switch
should always be present to permit isolation of the system for service.
INSTALL the receiving unit always inside electric cabinets.
USE electric cabinets that guarantee a protection level of IP54 or higher
(level IP65 is recommended if the cabinet is outdoors).
INSTALL the receiving unit away from devices that generate
electromagnetic fields (e.g. transformers).
REMEMBER to carefully wire the SAFETY contacts in series with the
movement commands inside the receiving unit.
After installation and wiring, ALWAYS CHECK that the maneuvers
carried out are exactly the same as the commands given (in particular
check the STOP command).
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
EN60204-32 EN60204-1
(for machines).
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The presence of vibrations can compromise receiving unit performance: it is therefore
advisable to use suitable rubber mountings.
Antenna assembly is covered in the installation instructions (refer to chapter 7 for
details and warnings).
!
SUPPLY THE RECEIVING UNIT BY A SAFETY ISOLATING
TRANSFORMER.
The source of POWER SUPPLY must be protected from short circuit.
WHEN WELDING ON THE MACHINE during installation or use, remove
all electrical connections including the aerial from the receiver unit.
WHEN WIRING, all relevant standards and regulations must be
complied with.
The installer must CHECK and/or COMPLETE the "Technical Data Sheet" indicating the
date of activation of the system, putting his signature and stamp.
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5
WARNINGS FOR MAINTENANCE
While carrying out maintenance operations,
THE RELEVANT PERSONNEL MUST ENSURE
THAT THE ELECTRIC PANEL IS
DISCONNECTED FROM ALL SOURCES OF
SUPPLY.
Any faults should be repaired by authorised
Autec personnel using original Autec spare
parts only. Failure to comply with this requirement may invalidate the guarantee offered.
All control and maintenance interventions carried out on the radio remote control must be
verified and recorded by the person in charge of carrying out maintenance on the machine.
!
Before carrying out maintenance and/or diagnostics it is
recommended to replace the battery with a charged one and ensure the
efficiency of the START key.
Routine maintenance in accordance to the instructions given in this
manual is fundamental for the safe use of the radio remote control.
Read and strictly respect the warnings given in the battery charger
manual in order to lengthen the life of the battery itself.
After each maintenance intervention, always make sure that only the
expected manoeuvres are carried out when the relative commands are
sent by the transmitting unit.
Ensure that it is all always completely closed with the
relative strip.
strip
SERV
ICE
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ROUTINE MAINTENANCE
The following instructions allow to maintain the radio remote control in a perfect condition,
guaranteeing it to function safely and correctly for a long period.
Special applications may need more specific routine maintenance interventions to be carried
out at different periods.
These instructions do not in any case substitute the norms and laws that regulate work
safety, nor do they limit the responsibility of the purchaser and user of the radio remote
control.
All given instructions must be followed correctly each time the machine and the radio
remote control are started.
!
If irregularities are noted while carrying out routine maintenance, put
the "machine+radio remote control" system out of order, following the
indications given (see “Receiving unit diagnostic”)
Receiving unit
It is recommended every three months to:
1. remove dust or accumulations of other material from the receiving unit. Never use solvents
or flammable/corrosive materials to clean, and do not use high pressure water cleaners or
steam cleaners.
2. make sure that the receiving unit are structurally integral
3. verify the integrity and connection of the internal wiring to the receiving unit
4. make sue that the panel symbols can be easily seen. If necessary, replace the panel.
5. check identification plate readability and integrity
Electrical operation
It is recommended every six months to:
1. make sure that all the relay contacts of the receiving unit operate correctly, controlling
contact closing when the corresponding manoeuvre is enabled and contact opening when
the manoeuvre is disabled.
2. verify the correct correspondence between the commands that are sent and the
manoeuvres that are carried out.
3. verify that the contact for the SAFETY relay is open when no movement command has
been sent.
External electric conductors
It is recommended every twelve months to:
1. verify integrity along the full length of the cable which connects the receiving unit to the
machine.
2. verify the integrity and the electrical connection of the plugs and the connection socket
3. verify and if necessary replace the strips or other fixing systems
4. make sure that the connecting cable has not deteriorated, above all near the cable holder
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!
SPECIAL MAINTENANCE
Any fault should be repaired by authorised Autec personnel (contact
Service), using original Autec spare parts only.
When it is necessary to carry out special maintenance (radio remote control repair and
replacement of damaged or faulty parts), do not contact anyone other than our
Authorized Service Center. In order to make the intervention faster and more reliable,
please help us identify the radio remote control correctly and completely by giving:
- the serial number
- the purchase date (given on the guarantee)
- description of the problem found
- the address and telephone number of the place where the radio remote control is being
used
- the name of the person to be contacted
- the name of the company that supplied the radio remote control.
Before speaking with a service technician, it is advisable to make sure that the
given instructions have been followed correctly.
When scrapping, entrust the radio remote control to the separate scrap collecting
services in the country of use.
Please pay particular attention when recycling the batteries, applying local rules. Do not
throw them away with domestic trash.
AUTHORIZED SERVICE CENTER
DISPOSAL
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6
INSTALLATION
If installed inside an electric cabinet, the receiving unit must be installed exclusively
on DIN EN 60 715 rail (ex DIN EN 50 022). Follow instructions below for easy and fast
assembly and disassembly.
ASSEMBLY
Clip the upper part of the receiving unit
over the DIN rail.
Using a screwdriver, push the hook on the
base of the receiving unit downwards until
the receiving unit pushes easily onto the
DIN rail.
DISASSEMBLY
Using a screwdriver, push the hook on the base of the receiving unit downwards until the
receiving unit is released from the DIN rail.
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7
ANTENNA ASSEMBLY
!
The antenna must only be assembled by qualified technicians.
The antenna stylus should never come into contact with metallic parts.
An antenna must be installed outside the electric cabinet to ensure a reliable radio link
from the transmitting unit to the receiving unit.
Insert the antenna cable into the connector on the
receiving unit (see photo 1) and fit the antenna on a
metallic surface (e.g. electric panel, bracket . . .)
(see photo 2).
antenna
cable
1
antenna
stylus
2
antenna
cable
metallic
surface
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8
LIGHT SIGNALS
Each receiving unit has lights that indicate
the state of the receiving unit and its relays.
RL 1
RL 2
RL 3
RL 4
RL 5
RL 6
RL 7
RL 8
RL 9
RL 11
RL 10
RL 12
RL 13
POWER
START/
SAFETY
STOP/ENA
POWER: indicates that the receiving unit is powered
STOP/ENABLE: indicates that the radio link from the transmitter is active.
SAFETY: indicates that the SAFETY function has been activated (this function should
activate with any movement commands)
START/ : indicates activation of the START pushbutton or the horn
RL _: indicates that the relay of the corresponding command has been activated (see
radio remote control technical data sheet)
RL 14
On the internal receiver module there are three LEDs, which indicate:
1. power supply
1 2 3
2. radio connection
3. frequency scanning.
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!
9
PROGRAMMING
The dip switches must be programmed when the receiving unit is not
powered and can be done only by authorised personnel.
DIP SWITCHES ON E16SRXUS1 RADIO RECEIVING MODULE
The group of eight dip switches found in
the module permits the programming of
different operating mode and the setting
of operating frequency.
The programming set in the other group
of four dip switches must never be
modified.
Group of 8 dip switches
DIP POS.
1 (*)
2 (**)
3
3 - 7 ON/OFF
8
(*) With the MK10, MK12, MJ transmitting unit the dip switch should be at ON.
(**) With the MK12 transmitting unit the dip switch should be at ON.
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Deactivated of low battery warning from horn on machine
Activation of low battery warning from horn on machine
With DIP 8 OFF automatic scan mode of the freque ncies
With DIP 8 OFF automatic scan mode of the frequencies
With DIP 8 ON see “Appendix: Frequency Table”
DIP 3 - DIP 7 (see “Appendix: Frequency Tab le”)
Automatic scan mode of frequencies in the band selected with DIP 3
Group of 8
dip switches
DESCRIPTION
Passive emergency at 0,35 second
Passive emergency at 1 second
in the 915 - 928 MHz
in the 902 - 915 MHz
Manual selection of frequencies with
(DIP 4 – DIP 7 not relevant)
Group of 4
dip switches
!
These eight dip switches must be programmed in the same manner
as the group of 8 dip switches (excluding DIP 1) present in the radio
module of the transmitting unit (see manual).
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RECEIVING UNIT DIAGNOSTICS
If the "machine+radio remote control" system does not start, firstly determine whether the
problem is caused by the radio remote control or the machine. Before carrying out any
detailed tests, check if the machine functions with the cabled control panel: if it does not
operate normally, the problem lies with the machine itself.
If, however, the machine operates normally using the cabled control panel, the problem lies
with the radio remote control. In this case, firstly follow the diagnostics procedure for the
transmitter unit. If the problem remains, check the receiving unit as follows:
Is the “POWER”
light lit?
YES
Is the “ENABLE”
light lit?
NO
Carry out the
frequency change
procedure (refer to
the transmitting
unit manual) Does
the machine start?
NO
YES
NO
Are terminal
blocks correctly
connected?
YES
Remove power
from the receiving
unit and open it.
Check fuses with
a continuity tester.
Are they blown?
Is the antenna
correctly
connected?
NO
Correctly
connect
the antenna.
NO
NO
YES
terminal blocks
and start the
radio remote control.
blown fuses. Connect
to power source
and switch on radio
remote control. Does
the machine start?
CALL TECHNICAL
ASSISTANCE
Secure the
Replace
NO
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Appendix: FREQUENCY TABLE
E16SRXUS1
DIP SWITCH DIP SWITCH
MHz MHz
4
3
OFF OFF OFF
OFF
902.150
903.050
903.850
904.650
905.525
906.325
907.175
907.975
908.850
909.650
910.450
911.250
912.125
912.925
913.775
914.525
OFF OFF
OFF
OFF OFF
OFF
OFF OFF OFF
OFF OFFONOFF
OFF
OFF OFF
OFF
ON
OFFONOFF
OFF
OFFOFF
ON
ON
OFF
ON
OFF
OFF
ON
OFF
OFF
OFF
OFF
ON
OFF OFF
OFF
ONON
OFF
ON
ON
OFF
8
7
ON
OFF OFF OFF OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
ON
ON
ONON
ON
ON
ON
ONON
ON
ON
OFFOFF
OFF
ON
ON
OFF
ON
ON
OFF
ONONON
ON
ONON
OFF
ON
OFF
OFF
ON
ON ON
ON
ONONON ON
915.350
916.250
917.050
917.850
918.675
919.525
920.375
921.175
922.050
922.850
923.650
924.450
925.325
926.175
926.925
927.725
3
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
4
OFF OFF
OFF OFF
OFF OFF
ON
ON
ON
OFF
OFF
OFF
ON
ON
5566
OFF OFFONOFF
OFF OFF
OFFONOFF
OFF
ON
ON
ON
ON
ONON
ON
ONON ON
7
8
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ONON
ON
OFFOFF
OFF
ON
ON
OFF
ON
ON
OFF
ONON
ON
ON
ON
OFF
OFF
OFF
ON
ONON
ON
OFF
ON
ON
ON
Via Pomaroli, 65
36030 Caldogno (VI) ITALY
Tel : ++39 - 0444/901000 r.a.
Fax: ++39 - 0444/901011
email: info@autec.it
http://www.autec.it
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