DOLD BI 5910 User manual

1
1
USER MAUAL
Multifunction Safety Module BI 5910
with radio control
04/2007
W
W
ireless
safety
SAFEMASTER
USER MAUAL
Multifunction Safety Module BI 5910
with radio control
04/2007
W
W
ireless
safety
SAFEMASTER

2
2
Multifunction Safety Module
BI 5910 with radio control
(electronic key, side view)
Key-number: .................................................................
Identnumber: ................................................................
Selected frequency:......................................................
1. alternative frequency: ...............................................
2. alternative frequency: ...............................................
Please note here the number of your
electronic key (6 figure number,
engraved on the electronic key) and
the Identity number of your remote
control or your BI5910
Multifunction Safety Module
BI 5910 with radio control
(electronic key, side view)
Key-number: .................................................................
Identnumber: ................................................................
Selected frequency:......................................................
1. alternative frequency: ...............................................
2. alternative frequency: ...............................................
Please note here the number of your
electronic key (6 figure number,
engraved on the electronic key) and
the Identity number of your remote
control or your BI5910

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3
Application notes ................................................................................................................10
1. Presentation of the Multifunction Safety module BI 5910
with radio control ........................................................................................... 13
1.1 Components of the Multifunction Safety module BI 5910
with radio control ........................................................................................... 16
1.2 Configuration on delivery.............................................................................. 17
2. Multifunction Safety module with radio receiver BI 5910/00MF9 ............... 18
2.1 Function of BI 5910....................................................................................... 21
2.1.1 Important notes ............................................................................................. 22
2.2 Remote control .............................................................................................. 23
2.3 Safety function .............................................................................................. 24
2.4 Semiconductor outputs ................................................................................. 25
2.5 Connection of sensors .................................................................................. 25
2.6 Manual start and reset .................................................................................. 26
Content
Application notes ................................................................................................................10
1. Presentation of the Multifunction Safety module BI 5910
with radio control ........................................................................................... 13
1.1 Components of the Multifunction Safety module BI 5910
with radio control ........................................................................................... 16
1.2 Configuration on delivery.............................................................................. 17
2. Multifunction Safety module with radio receiver BI 5910/00MF9 ............... 18
2.1 Function of BI 5910....................................................................................... 21
2.1.1 Important notes ............................................................................................. 22
2.2 Remote control .............................................................................................. 23
2.3 Safety function .............................................................................................. 24
2.4 Semiconductor outputs ................................................................................. 25
2.5 Connection of sensors .................................................................................. 25
2.6 Manual start and reset .................................................................................. 26
Content

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4
Content
2.7 Auto start ....................................................................................................... 26
2.8 Option start by infra-red signal (IR) ............................................................. 27
2.8.1 Connection of infra-red sensor RE5910/060 ............................................... 28
2.8.2 Position of infra-red sensor RE5910/060 .................................................... 29
2.9 Module set up................................................................................................ 30
2.9.1 Configuration of receiver .............................................................................. 37
2.10 Operating mode 1-4 application examples .................................................. 38
2.10.1 Function diagrams ........................................................................................ 42
2.11 Operating mode 8 and 9 – monitored zone access .................................... 52
2.11.1 Application examples .................................................................................... 56
2.11.2 Function diagrams ........................................................................................ 58
2.12 Indicators ....................................................................................................... 62
2.12.1 Status and failure codes ............................................................................... 65
Content
2.7 Auto start ....................................................................................................... 26
2.8 Option start by infra-red signal (IR) ............................................................. 27
2.8.1 Connection of infra-red sensor RE5910/060 ............................................... 28
2.8.2 Position of infra-red sensor RE5910/060 .................................................... 29
2.9 Module set up................................................................................................ 30
2.9.1 Configuration of receiver .............................................................................. 37
2.10 Operating mode 1-4 application examples .................................................. 38
2.10.1 Function diagrams ........................................................................................ 42
2.11 Operating mode 8 and 9 – monitored zone access .................................... 52
2.11.1 Application examples .................................................................................... 56
2.11.2 Function diagrams ........................................................................................ 58
2.12 Indicators ....................................................................................................... 62
2.12.1 Status and failure codes ............................................................................... 65

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5
Content
3. Remote control RE 5910 .............................................................................. 73
3.1 Type and specification of push buttons ....................................................... 73
3.2 Temporary disabling of function keys........................................................... 74
3.3 Assignment of push buttons to outputs ....................................................... 74
3.4 Identity check ................................................................................................ 75
3.5 Electronic key ................................................................................................ 76
3.6 Function activity monitoring.......................................................................... 78
3.7 Battery operation – Storage rules for remote control RE 5910 .................. 79
3.7.1 Load Battery .................................................................................................. 79
3.7.2 Indication of battery load state ..................................................................... 79
3.8 Power up remote control .............................................................................. 80
3.9 Configuration of remote control.................................................................... 82
3.9.1 Disabling – enabling of remote control programming ................................. 83
3.9.2 Programming of frequency ........................................................................... 85
Content
3. Remote control RE 5910 .............................................................................. 73
3.1 Type and specification of push buttons ....................................................... 73
3.2 Temporary disabling of function keys........................................................... 74
3.3 Assignment of push buttons to outputs ....................................................... 74
3.4 Identity check ................................................................................................ 75
3.5 Electronic key ................................................................................................ 76
3.6 Function activity monitoring.......................................................................... 78
3.7 Battery operation – Storage rules for remote control RE 5910 .................. 79
3.7.1 Load Battery .................................................................................................. 79
3.7.2 Indication of battery load state ..................................................................... 79
3.8 Power up remote control .............................................................................. 80
3.9 Configuration of remote control.................................................................... 82
3.9.1 Disabling – enabling of remote control programming ................................. 83
3.9.2 Programming of frequency ........................................................................... 85

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Content
3.9.3 Time delay for activity monitoring function .................................................. 88
3.9.3.1 Programming of time base activity monitoring function .............................. 88
3.9.3.2 Programming of time period activity monitoring function............................ 90
3.9.4 Copy of identity code from electronic key to remote control RE 5910 ....... 92
3.10 LED indicators of remote control.................................................................. 94
4. Product specification .................................................................................... 97
4.1 Remote control RE 5910 .............................................................................. 97
4.2 Multifunction safety module BI 5910 ............................................................ 98
4.3 Standard arrangement .................................................................................. 99
4.4 Accessories – remote control RE 5910 .....................................................100
4.5 Accessories – Multifunction safety module BI 5910 .................................101
Content
3.9.3 Time delay for activity monitoring function .................................................. 88
3.9.3.1 Programming of time base activity monitoring function .............................. 88
3.9.3.2 Programming of time period activity monitoring function............................ 90
3.9.4 Copy of identity code from electronic key to remote control RE 5910 ....... 92
3.10 LED indicators of remote control.................................................................. 94
4. Product specification .................................................................................... 97
4.1 Remote control RE 5910 .............................................................................. 97
4.2 Multifunction safety module BI 5910 ............................................................ 98
4.3 Standard arrangement .................................................................................. 99
4.4 Accessories – remote control RE 5910 .....................................................100
4.5 Accessories – Multifunction safety module BI 5910 .................................101

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Content
5 Technical data .............................................................................................102
5.1 Remote control RE 5910 ............................................................................102
5.2 Multifunction safety module BI 5910 ..........................................................104
6. Installation notes ......................................................................................... 111
6.1 Disturbance protection................................................................................ 111
6.2 Selection of operation frequency ............................................................... 112
6.3 Recommendations for movement control .................................................. 113
6.4 Position of receiver and aerial.................................................................... 114
6.5 Wiring........................................................................................................... 115
6.6 Protection of power supply ......................................................................... 116
6.7 Minimum and maximum output current...................................................... 116
6.8 Emergency operation.................................................................................. 116
Content
5 Technical data .............................................................................................102
5.1 Remote control RE 5910 ............................................................................102
5.2 Multifunction safety module BI 5910 ..........................................................104
6. Installation notes ......................................................................................... 111
6.1 Disturbance protection................................................................................ 111
6.2 Selection of operation frequency ............................................................... 112
6.3 Recommendations for movement control .................................................. 113
6.4 Position of receiver and aerial.................................................................... 114
6.5 Wiring........................................................................................................... 115
6.6 Protection of power supply ......................................................................... 116
6.7 Minimum and maximum output current...................................................... 116
6.8 Emergency operation.................................................................................. 116

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Content
7. Set up .......................................................................................................... 117
7.1 Set up directives ......................................................................................... 117
7.1.1 Regular check ............................................................................................. 119
8. Available frequencies..................................................................................120
9. Marking of function keys of remote control RE 5910 ................................ 122
10. Accessories .................................................................................................125
11. Maintenance ................................................................................................126
12. Warranty ......................................................................................................128
Content
7. Set up .......................................................................................................... 117
7.1 Set up directives ......................................................................................... 117
7.1.1 Regular check ............................................................................................. 119
8. Available frequencies..................................................................................120
9. Marking of function keys of remote control RE 5910 ................................ 122
10. Accessories .................................................................................................125
11. Maintenance ................................................................................................126
12. Warranty ......................................................................................................128

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Content
Appendix .....................................................................................................................129
A Front of remote control ...............................................................................130
B Front of receiver .......................................................................................... 131
B Connection of receiver................................................................................132
C Dimensions ..................................................................................................134
D Exchange of rechargeable battery ............................................................. 136
Content
Appendix .....................................................................................................................129
A Front of remote control ...............................................................................130
B Front of receiver .......................................................................................... 131
B Connection of receiver................................................................................132
C Dimensions ..................................................................................................134
D Exchange of rechargeable battery ............................................................. 136

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Attention: A remote control is regarded as a control device and also as safety part
because of it’s facility to switch off by the European Machinery Directive.
Rules resulting from this fact have to be observed in operation.
Application Notes
•For optimum safety during operation of the remote control it is recommended to
observe the instructions stated in this manual.
•The operator must be trained and have a permission to use remote controls.
•A visible E-stop must always be active. When placed in the charger the remote
control is not active. Therefore the charger must be mounted in a way that the built
in e-stop button is not visible.
Attention: A remote control is regarded as a control device and also as safety part
because of it’s facility to switch off by the European Machinery Directive.
Rules resulting from this fact have to be observed in operation.
Application Notes
•For optimum safety during operation of the remote control it is recommended to
observe the instructions stated in this manual.
•The operator must be trained and have a permission to use remote controls.
•A visible E-stop must always be active. When placed in the charger the remote
control is not active. Therefore the charger must be mounted in a way that the built
in e-stop button is not visible.

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11
Application Notes
•The operator must have full overview on all actions created by him. If the visual
area of the operator is not sufficient lifting devices must be equipped with additional
systems to improve the visibility. When operating several lifting devices (self moving
devices) on rails they must be equipped with protective equipment to reduce the
effect of collision. If not all safety areas can be overlooked am manual start with the
remote control must only be possible by using the optional infra-red receiver.
•Do not leave the remote control unattended, especially not in operation.
•Do not place the remote control on the floor or on metal surfaces. If necessary
push the Off-button first.
Application Notes
•The operator must have full overview on all actions created by him. If the visual
area of the operator is not sufficient lifting devices must be equipped with additional
systems to improve the visibility. When operating several lifting devices (self moving
devices) on rails they must be equipped with protective equipment to reduce the
effect of collision. If not all safety areas can be overlooked am manual start with the
remote control must only be possible by using the optional infra-red receiver.
•Do not leave the remote control unattended, especially not in operation.
•Do not place the remote control on the floor or on metal surfaces. If necessary
push the Off-button first.

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12
Application Notes
•If several radio controlled devices are operated in the same working area, different
frequencies must be used with one channel in between (e.g. channel 5, 7, 9, …)
•Due to safety reasons the electronic key must be removed when the devices are
not in use.
•Do not forget to charge battery, when discharged
•Do not use transmitter when charging
•In the case of disturbance the device must be switched off by pressing the Off
button of the remote control and removing the electronic key.
•The equipment must be handled with care and be checked in regular intervals
depending on the usage frequency.
Application Notes
•If several radio controlled devices are operated in the same working area, different
frequencies must be used with one channel in between (e.g. channel 5, 7, 9, …)
•Due to safety reasons the electronic key must be removed when the devices are
not in use.
•Do not forget to charge battery, when discharged
•Do not use transmitter when charging
•In the case of disturbance the device must be switched off by pressing the Off
button of the remote control and removing the electronic key.
•The equipment must be handled with care and be checked in regular intervals
depending on the usage frequency.

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1. Presentation of the Multifunction Safety module BI 5910
with radio control
We thank you for selecting this Dold product. You have purchased an
industrial extremely compact remote control RE 5910.
The remote control can be used to control lifting devices like cranes and also for remote control of
applications that have previously been wire bound or had a stationary control panel. The usage of
the remote control makes it possible to monitor the operation from any place not excluded by
safety rules (e.g. not stepping below the load). The remote control does not replace the existing
safety circuits (e.g. e-stop) but adds additional performance.
Main features of the remote control RE 5910
• User friendly, compact transmitter
• Comfortable single hand operation
• With perceptible 2 step push buttons
• With marking space besides the push buttons
• Protection against unintentional activation
• Speed charging and high battery capacity
• Speed charging and high battery capacity
•Pocket for remote control as option
1. Presentation of the Multifunction Safety module BI 5910
with radio control
We thank you for selecting this Dold product. You have purchased an
industrial extremely compact remote control RE 5910.
The remote control can be used to control lifting devices like cranes and also for remote control of
applications that have previously been wire bound or had a stationary control panel. The usage of
the remote control makes it possible to monitor the operation from any place not excluded by
safety rules (e.g. not stepping below the load). The remote control does not replace the existing
safety circuits (e.g. e-stop) but adds additional performance.
Main features of the remote control RE 5910
• User friendly, compact transmitter
• Comfortable single hand operation
• With perceptible 2 step push buttons
• With marking space besides the push buttons
• Protection against unintentional activation
• Speed charging and high battery capacity
• Speed charging and high battery capacity
•Pocket for remote control as option

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14
1. Presentation of the Multifunction Safety module BI 5910
with radio control
Main features of the multi function safety module BI 5910
•Compact device easy to install
•Mounting on DIN rail
•Removable terminal blocks
Solutions and options to increase the application safety of the application
•Additional inputs for wired e-stop buttons or light barriers
•Automatic detection of the remote control when taking from the charger
•Safety category 4, EN 954-1 for disconnection of remote control and Hamming
distance ≥4 for every transmitted message
•Access only for staff with permission by electronic key
•Start by infra-red transmitter (as option) only from a restricted area to identify the
working people
•Storage of number of working steps and duration of movements (as option)
User-friendly maintenance
•Identification stored in electronic key
•Indicator LEDs for diagnostics
1. Presentation of the Multifunction Safety module BI 5910
with radio control
Main features of the multi function safety module BI 5910
•Compact device easy to install
•Mounting on DIN rail
•Removable terminal blocks
Solutions and options to increase the application safety of the application
•Additional inputs for wired e-stop buttons or light barriers
•Automatic detection of the remote control when taking from the charger
•Safety category 4, EN 954-1 for disconnection of remote control and Hamming
distance ≥4 for every transmitted message
•Access only for staff with permission by electronic key
•Start by infra-red transmitter (as option) only from a restricted area to identify the
working people
•Storage of number of working steps and duration of movements (as option)
User-friendly maintenance
•IIdentification stored in electronic key
•Indicator LEDs for diagnostics

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15
1. Presentation of the Multifunction Safety module BI 5910
with radio control
This remote control is corresponding to the safety requirements of the valid or
pending standards and are conform to the following European Directives:
Machines, disconnection of the remote control to safety category 4, EN 954-1 RTTE Radio
control and telecommunication terminals (Low voltage, EMC, radio electrical spectrum)
If technical questions occur, please contact our service
Telephone: (+49) 77 23 / 654-0
Telefax: (+49) 77 23 / 654-356
e-mail: [email protected]
1. Presentation of the Multifunction Safety module BI 5910
with radio control
This remote control is corresponding to the safety requirements of the valid or
pending standards and are conform to the following European Directives:
Machines, disconnection of the remote control to safety category 4, EN 954-1 RTTE Radio
control and telecommunication terminals (Low voltage, EMC, radio electrical spectrum)
If technical questions occur, please contact our service
Telephone: (+49) 77 23 / 654-0
Telefax: (+49) 77 23 / 654-356
e-mail: [email protected]

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1.1 Components of the Multifunction Safety module BI 5910
The multifunction safety module includes:
•Remote control with integrated E-stop and additional function keys
•Electronic key for transmitter
•Labels for marking the transmitter push buttons
•Battery charger
•Safety module with radio receiver that accepts and operates the signals from the
remote control
The following inputs/outputs are available:
Inputs
- depending on application 1 or 2 E-stop buttons or light barriers type 4
- depending on application 1 or 2 control contacts to locate remote control on battery charger
- 1 Start button
- 1 Feed back circuit to monitor external relays
Outputs
- NO safety contacts or 2 NO safety contacts and 1 NC contact
- 6 semiconductor outputs to control movements by remote control
- 3 Semiconductor outputs to indicate the actual status of the multifunctional safety module
1.1 Components of the Multifunction Safety module BI 5910
The multifunction safety module includes:
•Remote control with integrated E-stop and additional function keys
•Electronic key for transmitter
•Labels for marking the transmitter push buttons
•Battery charger
•Safety module with radio receiver that accepts and operates the signals from the
remote control
The following inputs/outputs are available:
Inputs
- depending on application 1 or 2 E-stop buttons or light barriers type 4
- depending on application 1 or 2 control contacts to locate remote control on battery charger
- 1 Start button
- 1 Feed back circuit to monitor external relays
Outputs
- NO safety contacts or 2 NO safety contacts and 1 NC contact
- 6 semiconductor outputs to control movements by remote control
- 3 Semiconductor outputs to indicate the actual status of the multifunctional safety module

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1.2 Configuration on delivery
Operating mode of BI 5910
Rotary switch A = 0:
- Maximum time to activate remote control
after taking from charger unit 5 sec.
Rotary switch B = 0:
- Sensor inputs S11-S14 and S21-S24 always
active, manual start only with start button on
S42
- Remote control active when control contact
on S32 or S34 is open
- Reset from remote e-stop with remote start
button (+ Infra-red)
Number of frequency channel
Channel 01, 433.100 MHz
Activity monitoring function time period
Standard programming is off.
Number of electronic key
IIndividual number generated at production
and engraved on the key.
Please note on unpacking the number of the
electronic key on the first page of this manual,
with this number an identical key can be
ordered from DOLD.
Configuration of push buttons and outputs
Fixed assignment of push buttons to outputs
(see section 3.3)
Locking of the remote control
The remote control is delivered in unlocked
state (with disabled activity monitoring function
– 99). The activity monitoring function period,
the frequency and the lock of the programming
according to the electronic key can be modified
by a trained user (see section 3.9).
1.2 Configuration on delivery
Operating mode of BI 5910
Rotary switch A = 0:
- Maximum time to activate remote control
after taking from charger unit 5 sec.
Rotary switch B = 0:
- Sensor inputs S11-S14 and S21-S24 always
active, manual start only with start button on
S42
- Remote control active when control contact
on S32 or S34 is open
- Reset from remote e-stop with remote start
button (+ Infra-red)
Number of frequency channel
Channel 01, 433.100 MHz
Activity monitoring function time period
Standard programming is off.
Number of electronic key
IIndividual number generated at production
and engraved on the key.
Please note on unpacking the number of the
electronic key on the first page of this manual,
with this number an identical key can be
ordered from DOLD.
Configuration of push buttons and outputs
Fixed assignment of push buttons to outputs
(see section 3.3)
Locking of the remote control
The remote control is delivered in unlocked
state (with disabled activity monitoring function
– 99). The activity monitoring function period,
the frequency and the lock of the programming
according to the electronic key can be modified
by a trained user (see section 3.9).

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2. Multifunction safety module BI 5910/00MF9
with radio control
According to EU directive for machines
2006/42/EG
•According to IEC/EN 60 204-1, EN 954-1
•Safety category 4 to EN 954-1
•To connect:
-2-channel e-stop buttons, safety gate
contacts or light barriers type 4 to
EN61 496
- 1 start button
-Depending on application 1 or 2 control
contacts to monitor the radio control
operation
•Radio receiver for:
-E-stop
-Control signals for 6 non-safety
semiconductor outputs
•Functions adjustable by rotary switches:
-Manual or auto start
-When remote control is removed from
charger (open control contact), manual
start via remote control
-Bridging of access protection with
active remote control
•Broken wire and short circuit detection with
fault indication
•3 semiconductor outputs for status
indication
•LEDs for status indication
•67.5 mm width
2. Multifunction safety module BI 5910/00MF9
with radio control
According to EU directive for machines
2006/42/EG
•According to IEC/EN 60 204-1, EN 954-1
•Safety category 4 to EN 954-1
•To connect:
-2-channel e-stop buttons, safety gate
contacts or light barriers type 4 to
EN61 496
- 1 start button
-Depending on application 1 or 2 control
contacts to monitor the radio control
operation
•Radio receiver for:
-E-stop
-Control signals for 6 non-safety
semiconductor outputs
•Functions adjustable by rotary switches:
-Manual or auto start
-When remote control is removed from
charger (open control contact), manual
start via remote control
-Bridging of access protection with
active remote control
•Broken wire and short circuit detection with
fault indication
•3 semiconductor outputs for status
indication
•LEDs for status indication
•67.5 mm width

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2. Multifunction safety module BI 5910/00MF9
with radio control
A2
K1
K2
S12
S11
S13
S14
S21
S22
S23
S24
S31
S32
S33
S34
S42
Y1
Y2
BNC
IR
A1(+)
A2(-)
13 23 33 A3+ A3+A3+
27 3717
A1+
A3+ A3+ A3+
A1+
A3+
58
57 67 77
48
47
14 24 34
M9374
A1
(+) 48 S12 S14 S21 17
13 27 23 3733 IR
A2
(-) 58 S32 S34 S42 4714 57
24 67
34 77
S11 S13 S22 A3
(+)
S24 A2
(-)
S23 A5
(IR)
S31 S33 Y1 A4
(+)
Y2 A2
(-)
BNC
BI 5910.03/00MF9
A2
S12
S11
S13
S14
S21
S22
S23
S24
S31
S32
S33
S34
S42
Y1
Y2
BNC
IR
A3+ A3+A3+
27 3717
A1+
A3+ A3+ A3+
A1+
A3+
58
57 67 77
48
47
M9375
A1
(+) 48 S12 S14 S21 17
13 27 23 3731 IR
A2
(-) 58 S32 S34 S42 4714 57
24 67
32 77
S11 S13 S22 A3
(+)
S24 A2
(-)
S23 A5
(IR)
S31 S33 Y1 A4
(+)
Y2 A2
(-)
BNC
K1
K2
A1(+)
A2(-)
13 23 31
14 24 32
BI 5910.22/00MF9
Applications
2. Multifunction safety module BI 5910/00MF9
with radio control
A2
K1
K2
S12
S11
S13
S14
S21
S22
S23
S24
S31
S32
S33
S34
S42
Y1
Y2
BNC
IR
A1(+)
A2(-)
13 23 33 A3+ A3+A3+
27 3717
A1+
A3+ A3+ A3+
A1+
A3+
58
57 67 77
48
47
14 24 34
M9374
A1
(+) 48 S12 S14 S21 17
13 27 23 3733 IR
A2
(-) 58 S32 S34 S42 4714 57
24 67
34 77
S11 S13 S22 A3
(+)
S24 A2
(-)
S23 A5
(IR)
S31 S33 Y1 A4
(+)
Y2 A2
(-)
BNC
BI 5910.03/00MF9
A2
S12
S11
S13
S14
S21
S22
S23
S24
S31
S32
S33
S34
S42
Y1
Y2
BNC
IR
A3+ A3+A3+
27 3717
A1+
A3+ A3+ A3+
A1+
A3+
58
57 67 77
48
47
M9375
A1
(+) 48 S12 S14 S21 17
13 27 23 3731 IR
A2
(-) 58 S32 S34 S42 4714 57
24 67
32 77
S11 S13 S22 A3
(+)
S24 A2
(-)
S23 A5
(IR)
S31 S33 Y1 A4
(+)
Y2 A2
(-)
BNC
K1
K2
A1(+)
A2(-)
13 23 31
14 24 32
BI 5910.22/00MF9
Applications

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Approvals and marking
ET
*
* pending
2. Multifunction safety module BI 5910/00MF9
with radio control
Protection of men and machines in mobile
and large plants where a fixed wiring is not
possible, e.g. production halls, mounting
scaffolds, plants and dangerous accessible
areas.
Anwendungen
Approvals and marking
ET
*
* pending
2. Multifunction safety module BI 5910/00MF9
with radio control
Protection of men and machines in mobile
and large plants where a fixed wiring is not
possible, e.g. production halls, mounting
scaffolds, plants and dangerous accessible
areas.
Anwendungen