Autec s r l A08LA0AM Remote control User Manual LIUAIR1AE0 02

Autec s.r.l. Remote control LIUAIR1AE0 02

User Manual

23LIUAIR1AE0-02.fm AUTEC - AIR seriesINDEX1 Description of the AIR series' radio remote controls .............................................................. 241.1 How the radio remote control works ..................................................................................... 241.2 Applications ........................................................................................................................... 241.3 Technical Data ...................................................................................................................... 241.4 Safety Functions ................................................................................................................... 251.5 Identifying the radio remote control ....................................................................................... 262 Conformity and frequencies ...................................................................................................... 262.1 Frequency band 433.040-434.790 MHz ............................................................................... 262.2 Frequency band 915-928 MHz ............................................................................................. 273 Risk assessment ........................................................................................................................ 273.1 Risk assessment for radio remote controlled machines ....................................................... 283.2 Staff training .......................................................................................................................... 283.3 Working conditions ................................................................................................................ 294 A8 transmitting unit .................................................................................................................... 304.1 Description of the A8 unit ...................................................................................................... 304.2 Operation .............................................................................................................................. 304.3 Warnings for use ................................................................................................................... 324.4 Battery AIRBM3V7L .............................................................................................................. 344.5 Docking station AIRDOCK01 ................................................................................................ 345 Receiving unit ............................................................................................................................. 355.1 Description of G type receiving unit ...................................................................................... 355.2 Description of type L receiving unit ....................................................................................... 365.3 Operation .............................................................................................................................. 365.4 Warnings for installation ........................................................................................................ 376 Radio remote control maintenance .......................................................................................... 396.1 Routine maintenance ............................................................................................................ 396.2 Special maintenance ............................................................................................................. 416.3 Malfunctions .......................................................................................................................... 417 Machine maintenance ................................................................................................................ 438 Disposal ....................................................................................................................................... 43The documentation must be kept for the whole life of the radio remote control: afterreading it, keep it on hand for future reference.Contact Autec if any of the instructions and/or warnings provided in this documentare not clear. No part of this document may be reproduced, in any form or by anymeans, without written permission of Autec (including recording and photocopying).CAPTIONThis symbol indicates an important warning that, if disregarded, leadsto a hazardous situation for people and property.This symbol indicates a document that can be found in the specific sectionon Autec's website.@
AUTEC - AIR series24 Description of the AIR series' radio remote controlsHow the radio remote control works1 Description of the AIR series' radio remote controls1.1 How the radio remote control worksIndustrial radio remote controls are used to control machines from a distance, without phys-ical connection between the user and the machine (i.e. wires or connecting cables). Theyconsist of a portable transmitting unit, from which the user remotely controls the machine,and a receiving unit installed on board the machine itself.The two units constantly communicate with one another through a radio link. They automat-ically search for a free working frequency.The two units use messages coded through an address that is unique (produced by Auteconly once) and univocal (specific for each radio remote control).1.2 ApplicationsAIR series' radio remote controls can be installed on hoisting and material handling machines(i.e. overhead cranes).As required by standards ISO 12100 and ISO 14212, risk assessment must be carried outfor each machine (see chapter 3). The radio remote control can only be used if this assess-ment gives positive results. However, this radio remote control cannot be installed:- on machines installed in places where equipment with explosion-proof characteristics is re-quired- on machines for moving, raising and transporting people.- on machines that may generate dangerous situations if they stop due to the loss of radiolink1.3 Technical DataCommand response time (typical)..............................................................................100 msWorking range (typical) ..................................................................................................50 mStop time (typical)...................................................................................................... 100 msMax. stop response time ............................................................................................... 0.5 sPerformance Level of safety functions according to EN ISO 13849-1:Stop protection .............................................................................................................. PLdProtection against unintended movements from the standstill position (UMFS) .......... PL c
Description of the AIR series' radio remote controls 25Safety FunctionsLIUAIR1AE0-02.fm AUTEC - AIR seriesA8 transmitting unitPower supply (battery AIRBM3V7L) ................................................................ Li-ion 3.7 VAntenna..................................................................................................................... internalHousing material ............................................................................................ PA 6 (20% fg)Protection degree............................................................................................................IP65Dimensions ...................................................... 64.5 x 179 x 37.5 mm (25.5 x 70.5 x 15 In)Weight .......................................................................................................... 250 g (0.55 Lb)Run time (at 20°C / 68°F) .............................................................................................. 40 hReceiving unitPower supply .............................................................. 45 - 240 V~ (max 40 - 264 V~ 0.4 A) optional for type G receiving unit ............................... 12 - 24 V (max 9 - 30 V 1 A)Antenna..................................................................................................................... internal STOP contact rated current ...............................................................................4 A (250 V~)SAFETY contact rated current ...........................................................................4 A (250 V~)Command contact rated current.........................................................................6 A (250 V~)Housing material ............................................................................................ PA 6 (20% fg)Protection degree............................................................................................................IP65Dimensions .......................................................... 123 x 202 x 83 mm (48.5 x 79.5 x 33 In)Weight ........................................................................................................... 1.2 kg (2.7 Lb)1.4 Safety FunctionsAutec radio remote controls are equipped with some functions that provide high safety levels,in order to safeguard the safety of people and property.1.4.1 StopThe stop function brings the machine to a safe state every time it is necessary to stop it dueto a potentially hazardous situation. Depending on the situation, this function can either bedeliberately activated by the operator through the STOP pushbutton, or it is automatically ac-Temperature Relative Humidity Air PressureTransportation Radioremote controlClass 2K4-40°C to +70°C(-40°F to +158°F)Class 2K495%Class 2K4 70 kPa to 106 kPaStorage Radioremote controlClass 1K5-40°C to +70°C(-40°F to +158°F)Class 1K35% to 95%Class 1K570 kPa to 106 kPaUseTransmitting unitClass 4K4H-20°C to +55°C(-4°F to +130°F)Class 4K4H 4% to 100%Class 4K4H 70 kPa to 106 kPaReceiving unitClass 4K4H-20°C to +70°C(-4°F to +158°F)Class 4K4H 4% to 100%Class 4K4H 70 kPa to 106 kPa
AUTEC - AIR series26 Conformity and frequenciesIdentifying the radio remote controltivated when the radio link is incorrect or interrupted (the receiving unit autonomously stopsthe radio remote control). 1.4.2 Protection against unintended movements from the standstill position (UMFS)This safety function protects the system “machine+radio remote control” from unintendedmovements, namely machine movements not activated intentionally by the user, but result-ing from possible electrical and mechanical failure of the radio remote control.Such safety function checks the neutral (rest) position of pushbuttons controlling the ma-chine's movements. Each time one of those pushbuttons is operated, the transmitting unitsends both the movement command and the SAFETY command.1.5 Identifying the radio remote controlAs required by standard IEC 60204-32 , each radio remote control is uniquely identifiedthrough a serial number (S/N).The S/N is provided in the identification plate in the two units.2 Conformity and frequencies2.1 Frequency band 433.040-434.790 MHz2.1.1 ConformityEach AIR series' radio remote control working in the frequency band 433.040-434.790 MHzcomplies with the (R&TTE) Directive 1999/5/EC and its essential requirements.Each radio remote control is also in conformity with the harmonised standards provided inthe EC Declaration of Conformity.You can find the EC Declaration of Conformity in the specific section of Autec website,under “After Sales Service”.2.1.2 FrequenciesThe radio link between the units of Autec AIR series radio remote controls is built at one ofthe frequencies permitted by the European standards in force when the system is put on themarket.Frequencies used in the frequency band 433.040-434.790 MHz...................................... 64RF power................................................................................................................... <1 mWChannel spacing........................................................................................................ 25 kHz2.1.3 MarketAir series' radio remote controls working in the frequency band 433.040-434.790 MHz canbe used within the EU (European Union) and the EFTA (European Free Trade Association).@
Risk assessment 27Frequency band 915-928 MHzLIUAIR1AE0-02.fm AUTEC - AIR series2.2 Frequency band 915-928 MHz2.2.1 ConformityEach AIR series' radio remote control working in the frequency band 915-928 MHz complieswith the essential requirements of the following regulations:- FCC (Federal Communication Commission) Part 15- IC (Industry Canada) RSS-102Operation 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 causeundesired operation.Changes or modifications not expressly approved by the party responsible for compliancecould void the user’s authority to operate the equipment.2.2.2 FrequenciesThe radio link between the units of Autec AIR series radio remote controls is built at one ofthe frequencies permitted by the US and Canadian standards in force when the system is puton the market.Frequencies used in the frequency band 915-928 MHz ................................................. 256RF power............................................................... complies with FCC and IC requirementsChannel spacing ........................................................................................................ 50 kHz2.2.3 MarketAir series' radio remote controls working in the frequency band 915-928 MHz can be used inthe US and Canadian markets.3 Risk assessmentAlways evaluate whether the machine can be radio remote controlled. In fact, as required bytechnical standards specific to the market where the system “machine+radio remote control”is used, each machine must undergo risk assessment and risk analysis.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 remotecontrol installation and use is responsible for this risk assessment.Autec cannot be held responsible if this assessment has not been carried out correct-ly or is incomplete.Unit FCC ID IC numberA8 OQA-A08LA0AM 9061A-A08LA0AMReceiving unit G OQA-RGAAA00M 9061A-RGAAA00M
AUTEC - AIR series28 Risk assessmentRisk assessment for radio remote controlled machinesIf required by the risk assessment, draw up protection measures to prevent, reduce and re-port potential hazard situations.3.1 Risk assessment for radio remote controlled machinesWhen carrying out risk assessment for the machine or for the system where the radio remotecontrol is installed, the following must be considered:- some machines cannot be radio remote controlled: check for forbidden applications (seeparagraph 1.2)- the radio link between the two units may be interrupted due to persistent disturbance orinterference.- all warnings related to installation, use and maintenance provided by Autec must be takeninto account3.1.1 Aspects related to radio linkWhenever the radio link is interrupted (i.e. stop, low battery, automatic switch off, receivingunit not powered):- all outputs in the receiving unit are disabled: if this generates a hazardous situation, thecorresponding commands on the machine must be kept active- it is not possible to enable or disable the machine commands until the radio remote controlis started up again.3.1.2 Delay in command response timeDue to the characteristics of radio propagation (i.e.: EM interference, out-of-working-rangecondition), a delay up to the "Maximum stop time" may occasionally occur from the momenta command in the transmitting unit is released to the moment its corresponding output in thereceiving unit is deactivated. Those who decide upon the installation of the radio remote control must make sure that thisdelay never leads to a dangerous situation in the specific uses.3.1.3 Protection from unintended activationThe transmitting unit housing is manufactured so that it protects the actuators from uninten-tional activation, while meeting at the same time the operating needs, the comfort require-ments and law limits.Assessment shall be made to establish possible additional protection measures for the actu-ators (i.e. commands requiring two-hand operation, “dead-man” function) if particular envi-ronments, equipment and working modes could cause accidental bumps to the actuators.3.2 Staff trainingAll installation, usage and maintenance operations must be carried out by qualified techni-cians 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 remotecontrol and to the radio remote controlled machine
Risk assessment 29Working conditionsLIUAIR1AE0-02.fm AUTEC - AIR series- instructions provided by those who install the radio remote control on the machine and bythe person in charge for workplace safety where the system machine+radio remote controlis used3.3 Working conditionsTo guarantee correct radio remote control operation, all current regulations regarding safetyat work and accident prevention should be respected. All applicable standards and regula-tions valid in the user country regarding the use of both the machine and the radio remotecontrol must always be respected.Autec cannot be held responsible if the radio remote control is used in unlawful work-ing conditions.
AUTEC - AIR series30 A8 transmitting unitDescription of the A8 unit4 A8 transmitting unit4.1 Description of the A8 unit4.2 Operation4.2.1 Start up with PIN codeAs required by standard IEC 60204-32, the radio remote control start up is pro-tected by a PIN code, in order to prevent non authorised use of the machine.During the start up phase, press each pushbutton within 3 seconds from the release of theprevious pushbutton, or the transmitting unit will switch off.Start up through factory-set PINWhen the receiving unit is powered on, perform the following procedure:1) press the START pushbutton until the green LED illuminates2) press the FUNCTION pushbutton3) press the START pushbutton until the green LED blinks slowly.LEDsSTOP pushbuttonCommand pushbuttonsTechnical data plateIdentification plateSTART pushbuttonFUNCTION pushbuttonContacts for rechargeScrew and battery coverSTARTFUNCT.1234RGSTOPS1 S2STARTFUNCT.1234RGSTOPS1 S21) START 2) FUNCTION 3) STARTSTARTFUNCT.1234RGSTOPS1 S2
A8 transmitting unit 31OperationLIUAIR1AE0-02.fm AUTEC - AIR seriesStart up through customised PINIf the risk analysis requires this, the PIN code may be modified to prevent unauthorised use.The procedure to set a customised PIN is provided in the document “Menu of Trans-mitting Unit (MTU)”; you can find this document in the dedicated section on Autec'swebsite.When the receiving unit is powered on, perform the following procedure:1) press the START pushbutton until the green LED illuminates2) press the pushbutton sequence PIN 1, PIN 2 and PIN 3 related to the PIN code providedin the technical data sheet (if PIN 1 and/or PIN 3 is the START pushbutton, it is not to beconsidered as part of the code sequence)3) press the START pushbutton until the green LED blinks slowly.4.2.2 Command activationPress pushbuttons related to the commands you want to carry out.4.2.3 Light signals during operationsGreen LED- steady on: transmitting and receiving unit do not com-municate with each other- blinks fast: the radio remote control starts when theSTART pushbutton is pressed- blinks slowly (one blink per second): it is possible tosend commandsRed LED- steady on at power on: the STOP pushbutton is activated or damaged- blinks twice at power on: at least one of the commands is activated or damaged- blinks 3 times at power on: the unit is discharged- on for 2 s: the unit does not work correctly- blinks slowly: approx. 4 h run time left- blinks fast: 10 min run time leftSignals from the other four LEDs depend on the function matching the FUNCTION pushbut-ton (or on digital inputs, if wired on the G receiving unit).@STARTFUNCT.1234RGSTOPS1 S2STARTFUNCT.1234RGSTOPS1 S2STARTFUNCT.1234RGSTOPS1 S2STARTFUNCT.1234RGSTOPS1 S2STARTFUNCT.1234RGSTOPS1 S21) START 3) STARTPIN 1 PIN 2 PIN 32) PINSTOPPD5580-00Red LEDGreen LED
AUTEC - AIR series32 A8 transmitting unitWarnings for use4.2.4 FUNCTION pushbuttonThe FUNCTION pushbutton can be matched with different relay functions on the receiver'sside (see technical data sheet).4.2.5 STOPThe STOP pushbutton should be pressed when it is necessary to stop the machine immedi-ately when a dangerous condition should occur.When the STOP pushbutton is pressed, the machine stops and the transmitting unit switchesoff.To start working again after the STOP pushbutton has been pressed, do the following:- make sure that the working and usage conditions are safe- pull or turn the STOP pushbutton in the arrow direction to unlock it- start up the radio remote control.4.2.6 Switching offThe A8 unit automatically switches off in the following cases:- voluntary switch off when the START pushbutton and immediately afterward the FUNC-TION pushbutton are deeply pressed for 3 seconds- as a response when the STOP pushbutton is pressed- automatic switch off when there are no enabled commands for a predetermined timeframe.This timeframe is provided tin the technical data sheet (SWITCH-OFF).Before the A8 unit switches off automatically, the green and red LEDs blink alternating for30 seconds.4.3 Warnings for useIn addition to all instructions provided by the machine manufacturer, by the installer of theradio remote control and by the person responsible for the safety of the work area, users shallalways respect the following warnings.Before starting to work, the user shall do the following:- stand in a position that allows the direct supervision of the remote controlledmachine and its load, and stay in a place ensuring safety conditions in re-spect of other operations and/or activities and/or processes that are carriedout in the working environment;- never start up or use the transmitting unit if the working conditions presentthe risk of losing balance or tripping;- always check that the mechanical operation of the STOP pushbutton is cor-rect. If it is impossible or difficult to press this pushbutton, do not use the ra-dio remote control;- only start up the transmitting unit when starting work: improper use maycause hazardous situations;- never start up or use the transmitting unit in closed spaces, with the machinenot in sight, or outside the radio remote control working range: in such casesit is in fact still possible to build a radio link, thus causing the risk that un-wanted commands be carried out by the machine;
A8 transmitting unit 33Warnings for useLIUAIR1AE0-02.fm AUTEC - AIR series- get familiar with the correspondence between the pushbuttons and the ma-chine's movements (this is indicated in the attached technical data sheet) andlearn symbols on the panel of the A8 unit (symbols used are defined by themachine manufacturer and/or installer depending on the machine's operationand functions).During normal operation, the user shall do the following:- visually and directly follow all movements of the machine and its load and re-main inside the radio remote control working range;- use the transmitting unit in a simple and comfortable way, avoiding acciden-tal falls; the hand strap (wrist band) provided with the radio remote control isused for that purpose;- pay particular attention to warnings and visual/acoustic signals, and take allmeasurements and steps to avoid that movements of the remote controlledmachine leads to hazardous situations for people and/or property;- pay attention to the entire work area. Immediately press the STOP pushbuttonwhen a hazardous situation occurs;- pay attention to the low battery signals. The A8 unit cannot be used duringthe charging process; all dangerous operations (i.e. hanging load) musttherefore be brought to an end before the battery is completely flat;- in case of malfunction, disable the system “machine+radio remote control”until the problem has been completely solved.After using the radio remote control, the user shall do the following:- switch off the transmitting unit when work is stopped or temporarily inter-rupted. Do not leave the load hanging (even while recharging the unit);- never leave the transmitting unit unattended if it is on.
AUTEC - AIR series34 A8 transmitting unitBattery AIRBM3V7L4.4 Battery AIRBM3V7LThe A8 unit contains a rechargeable battery; the provided battery is partially charged.The document “Battery AIRBM3V7L” shall be understood and kept into account tocorrectly use the A8 unit and its battery; you can find this document in the dedicatedsection on Autec website.Do not throw the batteries away with domestic trash. Apply local rules whendisposing of them: different collection and recycling schemes for batteries incompliance with are the 2006/66/EC Directive and amendments.4.4.1 Recharging the A8 unitFirst power on the docking station with its power supply unit and then:1) insert the A8 unit into the docking station: a steady on redLED indicates that charging has started (max. 4 h)2) remove the A8 unit from the docking station when necessaryNote: when the green LED switches on, the A8 unit is complete-ly charged.Charge the unit at a temperature between 5°C and 45°C.4.4.2 Indication of A8 unit run timePerform the following procedure to check the transmitting unit's run time:1) switch off the transmitting unit and unlock the STOP pushbutton2) keep pushbuttons S1 and START pressed until the 3 left LEDs illuminateshowing the unit's run time (3 illuminated LEDs correspond to the highestrun time).Run time indication disappears after some seconds.4.5 Docking station AIRDOCK01The docking station AIRDOCK01 is used to recharge the A8 unit.Plug in the adapter in the socket on the back of the docking station.The adapter works with 100 - 240 V~ (optional 10 - 30 V ).Respect instructions provided in the document “Docking sta-tion AIRDOCK01” to correctly use the docking station itself;you find this document in the dedicated section on Autec web-site.@1b1a2a2bSTARTFUNCT.1234RGSTOPS1 S2STARTS11234RG1234RG1234RGMAX. MIN.@
Receiving unit 35Description of G type receiving unitLIUAIR1AE0-02.fm AUTEC - AIR series5 Receiving unit5.1 Description of G type receiving unitENABLE LED Cable glandTechnical data platePOWER LEDIdentification plateFuse F1 ......................................................................................... 1.6 A F 250 V (5x20 mm)Fuses F2 and F3 ............................................................................. 4 A T 250 V (5x20 mm)Fuses F4 and F5 ............................................................................. 4 A T 250 V (5x20 mm)Electronic moduleDIP switchesInternal light signalsCommand outputsSAFETY outputsSTOP outputsF1: power supply fuseConnector for power supplyDigital inputsFuses of STOP circuitFuses of SAFETY circuit
AUTEC - AIR series36 Receiving unitDescription of type L receiving unit5.2 Description of type L receiving unit5.3 Operation5.3.1 Electronic moduleThe electronic module contains the address key, where the radio remote control configura-tion data are also stored. The receiving unit cannot work without this address key.5.3.2 DIP switchesThese two DIP SWITCHes shall always be set at OFF: do not modify this setting.5.3.3 External signal lightsThe ENABLE LED is off: the receiving and transmitting units are not communicating.The ENABLE LED blinks: receiving unit G is ready to receive commands sent by the trans-mitting unitThe POWER LED is on: the receiving unit is powered on.Electronic moduleDIP switchesInternal light signalsCommand outputsSAFETY outputsSTOP outputsFuses of STOP circuitPower supply fuseFuses of SAFETY circuitFuse F1 ......................................................................................... 1.6 A F 250 V (5x20 mm)Fuses F2 and F3 ............................................................................. 4 A T 250 V (5x20 mm)Fuses F4 and F5 ............................................................................. 4 A T 250 V (5x20 mm)Connector for power supply
Receiving unit 37Warnings for installationLIUAIR1AE0-02.fm AUTEC - AIR series5.3.4 Internal light signalsThe activation of each relay on the mother board is signalled by an LED near the relay.5.3.5 Command outputsThe data sheet contains information regarding the correspondence between the commandssent by the transmitting unit and the related output enabled in the receiving unit.5.4 Warnings for installationThe radio remote control can only be installed and tested by competent staff that masters thetechnical knowledge required to carry out such procedure and is qualified according to theregulation of the country where the radio remote control is installed. Only if the radio remotecontrol is installed correctly can it be used safely.Besides instructions established by the machine's manufacturers, installers must always ob-serve the following warnings.5.4.1 GeneralRespect and enforce the provisions of all reference standards relevant in theconcerned application field (i.e. EN IEC 60204-32 for hoisting machines).Always follow the instructions provided in the technical data sheet to carry outcorrect installation.5.4.2 Mounting and fastening the unit in the best positionThe receiving unit shall be positioned as follows:- in a place that can be easily reached in case of need- vertical, with the cable gland or the plug facing down, and possibly facing thework area- at least 50 cm far from metal objects in its surroundings and never insideclosed metal containers.If this warning is disregarded, the radio remote control working range may be re-duced.Fix the receiving unit in four points, using the specific holes in the housing.When installing on machines that vibrate, it is recommended to fix the receivingunit to the machine with the appropriate vibration dampers.Do not perforate the receiving unit in any case.
AUTEC - AIR series38 Receiving unitWarnings for installation5.4.3 Positioning the antennaThe antenna is inside the receiving unit. Hence, install the receiving units sothat shields, structures or materials do not obstruct the radio link; in particular:- the receiving unit shall not be placed inside closed metal containers- the receiving unit must be placed at least 50 cm far from metal objects in itssurroundings.If this warning is disregarded, the radio remote control working range may be re-duced.5.4.4 WiringThe receiving unit's AC power supply must be as follows:- be protected against short circuit- have a switch that allows power supply disconnection during installation,wiring and/or maintenance operations. Pay special attention to the currents flowing in the SAFETY and STOP outputs:they shall not exceed the maximum permitted values.To obtain the UMFS protection, connect the contact of the SAFETY relay in se-ries with the movement commands.Group the wiring away from the electronic module, in order to avoid interferenc-es and hazards related to electrical safety.The STOP circuit in the receiving unit has two contacts connected in seriesthrough the bridge between terminal 34 and 35 (producer standard wiring). Ifthe machine needs a STOP circuit with two separate contacts (four wires), thisbridge can be removed. In this case, the installer is responsible for wiring in away that assures the required safety level.5.4.5 At end of installationMake sure that during installation the safety mechanisms on the radio remotecontrol and/or in the machine have not been made ineffective by possible pro-cedures carried out.Correctly close the receiving unit so that the protection degree from dust andwater is not jeopardised: check that the gasket is intact, correctly put the hous-ing parts one over the other so that they overlap, and screw in the screws.movement commands common wirefusecommon wire inputselection commands common wire
Radio remote control maintenance 39Routine maintenanceLIUAIR1AE0-02.fm AUTEC - AIR series5.4.6 TestingAfter installing and wiring the receiving unit, test the system “machine+radioremote control”, and check that the operations carried out correspond exactlyto the commands sent (in particular check the STOP command).The installer must check and complete the "Technical Data Sheet" in all itsparts, adding the date the system has been put into service, his stamp and sig-nature.In case of malfunction, disable the system “machine+radio remote control” un-til the problem has been completely solved.6 Radio remote control maintenanceThe following instructions provide information to safely carry out routine and special mainte-nance 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 wherethe radio remote control is used.All fine-tuning, checking and maintenance actions carried out on the radio remote controlshall be verified and recorded by the person in charge of carrying out maintenance on themachine.In case of malfunction or damaged parts, disable the system “machine+radioremote control” until the problem has been completely solved.Before any maintenance operation, disconnect power supply from the receiv-ing unit.After any maintenance operation:- always make sure that commands sent by the transmitting unit only activatethe corresponding expected operations- if the transmitting unit has been opened, close it correctly, in order not to en-danger its protection degree from dust and water: check that the gasket is in-tact, correctly overlay the two parts of the housing and tighten the screws.6.1 Routine maintenanceRoutine maintenance consists of operations needed to preserve the radio remote control nor-mal usage conditions, thus implementing fine-tuning, checks, planned replacement actionsthat 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.
AUTEC - AIR series40 Radio remote control maintenanceRoutine maintenanceRoutine maintenance carried out as described in this manual is fundamental for using the ra-dio remote control safely.Special applications may need more specific routine maintenance actions to be carried outat different periods (i.e. if the working environment is particularly dirt, in case of heavy appli-cations or if the system is used very frequently, some maintenance actions may be requiredmore frequently, depending on the decision of the person in charge for safety in the worksite).6.1.1 Daily routine maintenanceBefore starting to work:- make sure that the recharging contacts are always clean- make sure that the pushbuttons' gaskets are intact, soft and elastic- make sure that the transmitting unit panel symbols can be easily recognised and replacethe 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 (suchas concrete, sand, lime, dust) do not deposit on it.After using the radio remote control:- clean the transmitting unit: never use solvents or flammable/corrosive materials and do notuse high-pressure water cleaners or steam cleaners- store the transmitting unit in clean and dry areas.6.1.2 Three-month routine maintenanceEvery three months:- remove dust or deposit of material from the receiving unit: never use solvents or flamma-ble/corrosive materials to clean it, and do not use high-pressure water cleaners or steamcleaners- 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 thepanel if necessary- check that the plates on the receiving unit are readable and intact.6.1.3 Six-month routine maintenanceEvery six months:- make sure that all the relay contacts of the receiving unit operate correctly, and check thatthe contact closes when the corresponding manoeuvre is enabled and opens when themanoeuvre is disabled- check the correct correspondence between the commands that are sent and the manoeu-vres that are carried out by the machine
Radio remote control maintenance 41Special maintenanceLIUAIR1AE0-02.fm AUTEC - AIR series- check that the contact of the SAFETY relay is open when no movement command hasbeen sent. This is safety critical maintenance: it is necessary to keep a record (date, sig-nature, comments) showing that this check has been regularly carried out. Keep the recordtogether with other installation documents.6.2 Special maintenanceSpecial maintenance consists of repairs needed due to radio remote control failure, damageor malfunction, carried out with the aim of restoring the original usage and working condi-tions.Prior to contacting the support service technicians:- read and understand all documents related to the radio remote control, and make sure thatall 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 serv-ice 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 fast-er and more reliable:- radio remote control serial number (S/N)- purchase date (given on the certificate of guarantee)- description of the problem found- address and telephone number of the place where the device is being used (with the nameof the person to contact)- local supplier.6.3 MalfunctionsWhen the radio remote control does not work:- bring the transmitting unit close to the receiving unit to avoid radio interference and distur-bances- establish whether the problem lies with the radio remote control or with the machine.Therefore, before any inspection, try to control the machine from a control unit different fromthe radio remote control, if present.If the problem persists, it lies with the machine.Look for radio remote control malfunctions as follows.
AUTEC - AIR series42 Radio remote control maintenanceMalfunctions6.3.1 Signals on the transmitting unitIf the problem persists after the suggested solution has been carried out, contact the supportservice.LED Signals Possible reason SolutionsGreenSteady on The transmitting and receivingunit do not communicate.Start up the radio remote control.If the radio remote control doesnot start up, check that the re-ceiving unit is powered on.BlinksfastThe radio remote control is notstarted up.Press the START pushbutton un-til the green LED blinks slowly.Blinks slowly(one blink per second)The radio remote control isstarted up.See paragraph “Signals on thereceiving unit”.RedSteady on at power on The STOP pushbutton islocked or damaged. Unlock the STOP pushbutton.Blinks twice at power onAt least one of the commandsis enabled or damaged.Bring the actuators to the rest po-sition.Blinks three timesat power on The unit is discharged. Recharge the unit.On for 2 s The unit does not work cor-rectly. Contact the support service.Blinks slowly Approx. 4 h run time leftBring the system “machine+radioremote control“ to a safe state assoon as possible and rechargethe unit.Blinksfast 10 min run time left.Bring the system “machine+radioremote control“ to a safe stateand recharge the unit.Green and RedBlink alternating 30 s left before the unit auto-matically switches off.The auto switch off time is resetby pressing any pushbutton.The green LED blinks at power on and the red LED is steady onThe transmitting unit is notpaired with any receiving unit.Perform the PAIR procedure tomatch the transmitting unit with areceiving unit.
Machine maintenance 43MalfunctionsLIUAIR1AE0-02.fm AUTEC - AIR series6.3.2 Signals on the receiving unitIf the problem persists after the suggested solution has been carried out, contact the supportservice.7 Machine maintenanceFollow instructions provided by the machine manufacturer and by the installer of the radioremote control, in order to carry out machine maintenance.When carrying out maintenance on the machine, always disconnect power sup-ply from the receiving unit.Disconnect all receiving unit's electrical connections whenever machine main-tenance is carried out (i.e. when soldering).8 DisposalWhen disposing of a radio remote control, give it to the waste separate collecting services inthe user's country.LED Signals Possible reason SolutionsPOWERSwitched offThe connecting plug betweenthe radio remote control andthe machine is not connectedcorrectly.Correctly plug in the connectingplug.Fuse F1 is damaged. Replace the fuse.Wrong or no power supply.Make sure that power supplywires are correctly connectedand that the power supply valueis within the limits specified in thetechnical data.Illuminated Receiving unit is powered.Make sure that the outputs arecorrectly wired and that the pow-er supply is within the limits pro-vided the technical data.Start up the radio remote control.ENABLESwitched off The transmitting and receivingunit do not communicate. Start up the radio remote control.BlinksRadio remote control is start-ed up: the unit is ready to re-ceive commands from thetransmitting unit.Make sure that commands sentenable the corresponding relaysand that the relays go back to therest position when the commandis released.
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