Itowa BOGGY User manual
User Manual
EN
Remote Control BOGGY
MATBGEN - Rev.2 - 03/2023
REMOTE CONTROL COMBI
USER MANUAL
2
PLEASE FULLY CHARGE THE BATTERIES
BEFORE USING THE EQUIPMENT FOR THE
FIRST TIME
IT’S FORBIDDEN TO FULLY OR PARTIALLY REPRODUCE THIS MANUAL WITHOUT THE
PRIOR WRITTEN AUTHORISATION FROM ITOWA.
IN THE EVENT OF INFRINGEMENT, ITOWA RESERVES THE RIGHT TO TAKE THE
ACTION IT DEEMS NECESSARY IN ACCORDANCE WITH THE CURRENT LAW.
ITOWA RESERVES THE RIGHT TO MODIFY THIS MANUAL WITHOUT PRIOR
NOTIFICATION.
REMOTE CONTROL BOGGY
USER MANUAL
3
INDEX:
1. INTRODUCTION 5
1.1. GCFI VERSION 5
2. GENERAL TERMS FOR THE CORRECT AND SAFE USE OF THE RADIO REMOTE CONTROL6
2.1. KEYBOARD LOCKING PROCESS 6
3. DESCRIPTION OF THE SET 7
3.1. REMOTE CONTROL 7
3.1.1. DESCRIPTION OF MANOEUVRES 7
3.1.2. LED INFORMATION 11
3.2. BATTERY CHARGER 11
3.2.1. BATTERY CHARGING PROCESS 12
4. TECHNICAL SPECIFICATIONS 13
4.1. TRANSMITTER 13
4.2. BATTERY CHARGER 13
5. INSTALLATION AND START-UP 14
5.1. INSTALLATION OF THE RECEIVER 14
5.2. START-UP 14
5.2.1. SETTING THE TRANSMISSION TIME 14
5.2.2. BATTERY STATUS 15
6. MAINTENANCE OF THE REMOTE CONTROL 16
6.1. MAINTENANCE OF THE CHARGER 17
6.2. BATTERY CHARGING 17
7. DISPLAY OF THE EQUIPMENT CODE 18
8. DISPLAY THE WORKING CHANNEL 19
9. CHANGE THE FREQUENCY BAND (NOT VALID FOR GCFI VERSIONS) 20
9.1. OPERATING MODE 20
9.2. AUTOMATIC CHANGE OF FREQUENCY PROCESS 21
9.3. MANUAL CHANGE OF FREQUENCY PROCESS 22
9.4. CHECKING THE SELECTED CHANNEL 24
9.5. CHANNEL ASSIGNMENT TABLE 255
10. POSSIBLE INCIDENTS ANS SOLUTIONS 266
11. QUICK DISPLAY GUIDE 28
11.1. SUMMARY OF FUNCTIONALITY OF THE REMOTE CONTROL LEDS 28
11.2. LED INFORMATION DURING CHANGE OF FREQUENCY 28
11.3. INFORMATION ABOUT FREQUENCY CHANNEL THROUGH LED 28
11.4. KEYBOARD LOCK 29
REMOTE CONTROL BOGGY
USER MANUAL
5
1. INTRODUCTION
The manual you have in your hands is a guide for the correct use of the BOGGY remote control.
This unit, together with the associated receiver, has been specifically designed for the wireless remote
control of electromechanically operated machinery.
The radio signals used employ FM frequency modulation and FFSK encoding. The most advanced
technology and the latest generation microprocessors have been used in electronic design. This allows
total safety in the use of the radio remote control.
To avoid unwanted operations, the system is provided with various security mechanisms that will be
described in the next chapters. Any self-detection of anomalies blocks the execution of the operations.
The receiver works in the UHF band at frequencies between 433,050 and 434,775 MHz (UN 30 and 32 of
the C.N.A,F.), or between 868,000 and 870,000 MHz (UN 39 of the C.N.A.F.) as prescribed in the
telecommunications regulations I-ETS 300 220.
1.1. GCFI VERSION
The GCFI (Intelligent Frequency Change Management) version provides the equipment with an intelligent
system enabling it to change to vacant frequencies automatically and at random, thereby avoiding
interferences which could cause continuous downtimes during operation.
ATTENTION!: EVERYTHING RELATED IN THIS MANUAL TO THE CHANGE OF
FREQUENCY AND THE WORKING CHANNEL, IS NOT VALID FOR THE GCFI
VERSION.
REMOTE CONTROL COMBI
USER MANUAL
6
2. GENERAL TERMS FOR THE CORRECT AND SAFE USE OF THE
RADIO REMOTE CONTROL
The user, in order to have the maximum security in the handling of the remote control, must follow the
rules described in this manual.
The operator of the remote control, when he has to perform any command of the device, must be located
in a place where he can visualize at all times the manoeuvre he is performing. If it’s impossible to do so,
he must be located in a place where he can see the maximum possible manoeuvre, and in the hidden
places, an assistant is required. Never perform a manoeuvre that may have an uncontrolled part.
Do not leave the transmitter of the remote control on the floor or on top of metal blocks, in case you have
to do it, activate the emergency stop (STOP BUTTON) of the transmitter and put the key / switch in its
OFF position or lock the keyboard in if enabled (see section 2.1 - Keypad Lock Procedure).
When the operator of the remote control ends his working day or has to leave the remote control, he must
activate the emergency stop (STOP BUTTON) and place the battery in the charger for its recharging.
2.1. KEYBOARD LOCKING PROCESS
Optionally, the device can be equipped with a remote control locking/unlocking system using a sequence
of buttons.
The remote control keypad is locked by pressing the START button 5 times in less than 3 seconds, with
the STOP button engaged, and is indicated by the simultaneous lighting of the TX LED and the BAT LED
for 3 seconds.
To unlock the keypad, the start button is pressed 5 times in less than 3 seconds with the STOP BUTTON
engaged. However, as validation of the unlocking, the two LEDs indicated above flash three times.
It should be noted that if the START button is pressed when the remote control is locked, the TX LED and
the BAT LED flash simultaneously.
REMOTE CONTROL BOGGY
USER MANUAL
7
3. DESCRIPTION OF THE SET
•Remote control
•Batteries
•Charger
3.1. REMOTE CONTROL
This is a watertight (IP65) pushbutton panel made of highly resistant plastic material. The front part
contains the pushbuttons for manoeuvres, power switch, emergency stop button and indicative LEDs, and
the back part incorporates the housing for the interchangeable batteries.
The transmitter consists of three parts: push buttons, control circuit and UHF transmitter/transceiver.
For GCFI version, the diagram would be as follows:
The orders coming from the pushbuttons are acquired by the microprocessor, which is in charge of
preparing the FFSK signal by adding the codes of direction and control and injecting it into the UHF
transmitter. The transmitter incorporates the signal of that order to the carrier frequency, which previously
filtered, will be emitted by the antenna.
In the case of the models that incorporate the GCFI version, the transmitter becomes a transceiver in
order to establish a bi-directional communication with the receiver.
3.1.1. DESCRIPTION OF MANOEUVRES
Below are the different configurations of the standard BOGGY remote control model depending on the
application:
PUSHBUTTONS
SWITCHS
CONTROL
TRANSCEIVER
PUSHBUTTONS
SWITCHS
COMMUTATORS
MODULATOR
TRANSMITTER
REMOTE CONTROL COMBI
USER MANUAL
8
•Tower crane:
MANOEUVERS
Fig. 3-1. BOGGY 8 and BOGGY 12 for tower crane
STOP
TROLLEY BACKWARD
SLEWING LEFT
LOWER
START / HORN
*GVE
RISE
SLEWING RIGHT
TROLLEY FORWARD
MANOEUVERS
STOP
TROLLEY BACKWARD
SLEWING LEFT
LOWER
START / HORN
RISE
SLEWING RIGHT
TROLLEY FORWARD
TRAVELLING NORTH
TRAVELLING SOUTH
AUXILIARY 1
AUXILIARY 2
*GVE manoeuvre: this button will only activate
the relay when the equipment is running and
with any of the lift buttons activated.
REMOTE CONTROL BOGGY
USER MANUAL
9
MANOEUVERS
STOP
TROLLEY BACKWARD
SLEWING LEFT
LOWER
START / HORN
RISE
SLEWING RIGHT
TROLLEY FORWARD
TRAVELLING NORTH
TRAVELLING SOUTH
AUXILIARY 1
AUXILIARY 2
Fig.
3-2. BOGGY 12/4 for tower crane
REMOTE CONTROL COMBI
USER MANUAL
10
•Overhead crane
Optionally, this range of remote controls can incorporate the following functions:
•Tandem / Trolley preselection: the transmitter can communicate with two different receivers.
•Pitch & Catch: operating mode in which several transmitters (between 2 and 4) are associated at
1 receiver.
•Master/Slave: operating mode in which 2 transmitters are associated with 2 receivers.
•IR Safety: This infrared (IR) security blocking system allows you to limit the communication range
to a certain area, deactivating the manoeuvres (Range Control) or avoiding start-up (Start
Control).
•Option with Data Feedback: the transmitter and receiver use bidirectional communication, so
the transmitter can receive information from the receiver and display it using the LEDs or the
screen.
MANOEUVERS
STOP
TRAVELLING SOUTH
RISE
START / HORN
LOWER
TRAVELLING NORTH
TROLLEY RIGHT
TROLLEY LEFT
MANOEUVERS
STOP
TRAVELLING SOUTH
RISE
START / HORN
LOWER
TRAVELLING NORTH
TROLLEY RIGHT
TROLLEY LEFT
Fig. 3-3. BOGGY 8 and BOGGY 8/6 for tower crane.
REMOTE CONTROL BOGGY
USER MANUAL
11
NOTE: in case of incorporating any of these options, an annex manual is provided.
3.1.2. LED INFORMATION
The various operating and fault diagnosis statuses are indicated by 2 LEDs:
LED
Indication
TX
Status of radio functions.
On indicates that the remote control is transmitting.
GCFI versions: flashing rapidly or temporarily off indicates successful
communication. If it stays on when activating a manoeuvre, it indicates that there
is no communication with the receiver.
BAT
Battery status. For details of the indication of this LED, see section 5.2.2 of this
manual.
NOTE: Details of the information provided by the LEDs can be found in section 10.
On some BOGGY remote control models, there may be additional LEDs that provide further information.
The function of these LEDs can be found in the enclosed documentation which will be delivered with the
special equipment.
3.2. BATTERY CHARGER
The charger is for indoor use. The charger allows fast and safe charge of batteries. The supplied batteries
are Ni-MH and the charger is designed to optimize their charge and its life time. It is capable of detecting
faulty, short-circuited or overheated batteries and can recover discharged batteries after a long period.
Overview of the battery charger
Power supply LED
Charging LED
REMOTE CONTROL COMBI
USER MANUAL
12
3.2.1. BATTERY CHARGING PROCESS
The charger has two indicator LED, one for power, which indicates that the appliance is connected to the
power supply, and another for charging, which indicates that charging is in progress. When inserting the
battery, the charger checks the charge level and can perform two actions based on it:
•If the charge level is low, a precharge is performed (LED flashing)
•A constant charging is performed for approx. 20 minutes (LED on fixed).
After this time, the charger verifies the state of the battery and adapts the load to each case. When the
charging process ends, the LED turns off. A full charge takes approximately 4 and a half hour.
Charging should be done at a temperature between -10 and 50 ºC.
Before using the remote control for the first time, make a full charge of the batteries.
REMOTE CONTROL BOGGY
USER MANUAL
13
4. TECHNICAL SPECIFICATIONS
4.1. TRANSMITTER
4.2. BATTERY CHARGER
Number of orders Up to 32 digital (up to 4 analogue optional)
Probability of wrong manoeuvre
10-18
Hamming distance
≥ 6
Programmable code
Till 16777216
Order response time
<50 ms
Active emergency time
<50 ms
Passive emergency time
1600 ms
Radius of action
100 meters
Frequency bands
(I-ETS 300 220)
433,050 to 434,775 MHz
868,000 to 870,000 MHz
Temperature range:
From -20ºC to +70ºC
Canalization:
25 kHz
Modulation:
FM
Codification:
FFSK
Transmit power:
10 mW P.R.A.
Frequency stability:
+ 2.5 ppm (-30ºC a +70ºC)
Harmonic attenuation:
> 70 dB
Consumption in emission :
< 80 mA
< 50 mA (GCFI)
Consumption in stand-by :
< 800 µA
Power: Removable Ni-MH battery, 7.2 V; 1,5 A/h
Autonomy:
18 hours + 10 minutes standby
25 hours + 10 minutes standby (GCFI)
Material: PA 6-6, 15 % glass fibre
Dimensions:
BOGGY 8
BOGGY 12
400 x 80 x 65 mm
535 x 92 x 65 mm
Weight (without
battery):
BOGGY 8
BOGGY 12
1,1 kg
1,5 kg
Battery weight :
200 g
Watertightness: IP 65
Power supply: 100 - 240 Vac
Consumption: 3,6 VA
Max. Power:
6 VA
Charging intensity: 400 mA
Charging time:
2,5 horas
Protection:
IP30
Charger dimensions:
90 x 105 x 65 mm
Approx. weight:
0,2 kg + 0,35 kg (feeder)
REMOTE CONTROL COMBI
USER MANUAL
14
5. INSTALLATION AND START-UP
5.1. INSTALLATION OF THE RECEIVER
The details of the receiver installation can be found in the corresponding manual.
It is indispensable that you consult the mentioned manual before starting up.
5.2. START-UP
Once the receiver is installed, activating the general switch of the machine will light up the LEDs located
on the front of the receiving equipment to verify its correct operation.
Insert a charged battery into the remote control and the LEDs on the button panel will light up sequentially
to verify its operation. In the event that there is a problem with the EEPROM of the button panel, the S1
LED will switch on.
Unlock the emergency stop button (E-STOP BUTTON). When the START button is pressed, the remote
control will start working by activating the stop relays and start relay, and the general contactor will be
locked. The LED of the remote control will be activated indicating that the remote control is in operating
mode. From this moment on, the activation of any button will result in the activation of the corresponding
operation. The selected manoeuvre will remain active as long as the button is pressed.
To keep the radio channel free and prevent the operator from accidentally leaving the machine running
when not in use, the remote control has been fitted with an automatic stop system. If no intervention is
made, this system acts after 180 seconds (configurable) sending a stop sequence to the receiver, which
will cause the machine to stop.
At the time the machine stops it will be displayed by pulses on the LEDs & the receiver the frequency
channel on which the equipment is working. The display begins with the tens pulses through the LED and
will continue indicating the units using the LED . In case that the value of tens or units will be zero, the
display of this LED will be skipped. More details on this channel display are provided in Chapter 8.
5.2.1. SETTING THE TRANSMISSION TIME
The configuration of the automatic stop time (default 180 seconds) is done from the pushbutton panel,
and this time can be changed between three values as follows:
Lock the STOP BUTTON and turn the ON/OFF switch or key to OFF position.1)
ATTENTION!: REMEMBER THAT LOCKING THE E- STOP BUTTON IS THE SAME AS
STOPPING THE REMOTE CONTROL, THAT MEANS, TO DEACTIVATE IMMEDIATELY
ANY RELAY OPERATED IN THE RECEIVER.
Press either direction of the button marked TIME in the figure below and, while holding it down, turn2) the on/off switch or key to the ON position.
REMOTE CONTROL BOGGY
USER MANUAL
15
Fig. 5-1. Buttons used to change the emission time.
Wait for approx. 3 to 5 seconds and release the STOP BUTTON.3) Release the activation of TIME and re-activate it.4) The TX and BAT LEDs will flash simultaneously from one to three times indicating the time that has5) been programmed, which may be :
•Mode 1: 180 seconds (one flash).
•Mode 2: 330 seconds (two flashes).
•Mode 3: continuous emission (three flashes).
Repeat the sequence successively to switch from one mode to the other in a cyclical way. To reactivate
the transmitter, press the START button.
5.2.2. BATTERY STATUS
The transmitter is fitted with a battery status indicator LED. When the remote control detects that the
battery is at a low level of charge (standby condition), the BAT LED will start flashing and the horn
manoeuvre will be activated intermittently. After approximately 10 minutes, the transmitter shuts down,
sends a stop sequence to the receiver and the BAT LED lights steady (battery empty).
When the battery is in standby condition, it is recommended to charge the battery.
ATTENTION!: WHEN THE BATTERY IS IN RESERVE, IT IS NOT POSSIBLE TO
PERFORM THE FOLLOWING FUNCTIONS: MODE FREQUENCY CHANGE,
FREQUENCY CHANGE, KEYBOARD LOCK AND CHANGE THE AUTOMATIC
DISCONNECTION TIME.
TIME
TIME
STOP BUTTON
REMOTE CONTROL COMBI
USER MANUAL
16
6. MAINTENANCE OF THE REMOTE CONTROL
The equipment you have purchased is manufactured using top quality materials to ensure perfect working
order and operation of the remote control. Similarly to all machinery and equipment, the remote control
requires minimum basic maintenance tasks that should be performed.
ATTENTION!: IF ANY ANOMALY IS DETECTED IN THE OPERATION OF THE
EQUIPMENT, IT MUST BE PUT OUT OF SERVICE IMMEDIATELY.
In order to increase the life of your equipment as much as possible, and avoid unnecessary repair costs,
we recommend that you carefully follow the following conservation and maintenance tips:
•Avoiding unnecessary hits on the equipment.
•Use the attachment accessories, shoulder strap, properly and adjust it so that the use of the
equipment is comfortable and safe.
•Although the equipment has a high degree of water tightness (IP65), it shouldn't be totally or partially
submerged and shouldn't be left in places where it could flood if it rains.
•The pushbuttons of the set are made of an elastic material to give them elasticity, texture and water
tightness, so you must take special care to avoid touching them with sharp objects that could damage
the structure of the button. When the button is worn-out or damaged it must be replaced immediately.
•It’s also advisable not to leave the remote unnecessarily exposed to the sun's rays.
•Check that the battery holder contacts are free of dirt and rust and that they exert the spring return
force correctly.
ATTENTION!: BEFORE ANY MANIPULATION PROCEED TO DEACTIVATE THE MAIN
SWITCH OF THE MACHINE.
Generally, it’s advisable to carry out a complete revision of the water tightness devices that protect both
the receiver and the transmitter from bad weather conditions every now and then. It’s advisable that this
revision is done by a Technical Assistance Service accredited by ITOWA, since a bad waterproofing can
cause irreparable damage to the equipment.
In the case of the remote control, pay particular attention to the joints and rubber protections of the
different drives, replacing them immediately if they have been cut or suffered other damages.
ATTENTION!: ORIGINAL SPARE PARTS SHOULD BE USED FOR ANY REPAIRS, AND
THE SAFETY FEATURES AS WELL AS THOSE OF THE UHF TRANSMITTER AND
RECEIVER, SHOULD NEVER BE ALTERED.
To test the function of the active safety, simply actuate the EMERGENCY STOP BUTTON on the
transmitter while it is running. The general contactor must fall down immediately.
To check the operation of the passive safety, disconnect the power or remove the battery from the
transmitter. The general contactor should drop after within a maximum of 1.6 seconds.
REMOTE CONTROL BOGGY
USER MANUAL
17
6.1. MAINTENANCE OF THE CHARGER
The following parts will be checked:
•Contacts (which must be free of dirt and rust)
•The correct display and indication of the LEDs.
If you have any questions or doubts, please do not hesitate to contact our Technical Assistance Service
or any of our authorized technicians.
6.2. BATTERY CHARGING
The batteries included in the ITOWA equipment have no memory effect, which means that they can be
put into charge without being completely discharged. For this reason, and in order to extend their useful
life, it’s recommended to use one battery every half working day.
REMOTE CONTROL COMBI
USER MANUAL
18
7. DISPLAY OF THE EQUIPMENT CODE
In case you need to know the equipment's code, the receiver allows you to display it. You can consult the
manual of the receiver associated to this remote control to see the procedure that has to be followed, in
order to see this code.
REMOTE CONTROL BOGGY
USER MANUAL
19
8. DISPLAY THE WORKING CHANNEL
It’s important to know the frequency channel in which you are working to make a frequency change or to
detect possible interferences from other equipment on the communication between the transmitter and
receiver.
To know the frequency channel of the transmitter, please follow the below steps:
Lock the STOP BUTTON.1) Turn the key/switch to the OFF position.2) Activate the START button and, while holding it pressed, move the switch/key to the ON position.3) The frequency channel is then displayed using the TX and BAT LEDs in the following way:4)
•First the TX LED will blink as many times as there are tens in the frequency channel. If it is zero, it will
not flash at all.
•Then the BAT LED will flash as many times as there are units in the frequency channel. If it is zero, it
will not flash at all.
•Once tens and units have been displayed, the transmitter can be started up.
REMOTE CONTROL COMBI
USER MANUAL
20
9. CHANGE THE FREQUENCY BAND (NOT VALID FOR GCFI
VERSIONS)
ATTENTION!: THE CHANGE OF WORK FREQUENCY MUST BE DONE BY
AUTHORIZED PERSONNEL ONLY.
ATTENTION!: IF THE BATTERY HAVE ARRIVED TO THE RESERVE FOR LOW
CHARGE, IT WILL NOT BE POSSIBLE TO SELECT A CHANGE OF FREQUENCY
MODE OR CHANGE THE FREQUENCY.
9.1. OPERATING MODE
The system can operate in three modes:
•Mode 1: frequency change disabled.
•Mode 2: frequency change in manual mode.
•Mode 3: frequency change in automatic mode.
¡ATTENTION!: THE SYSTEM IS DELIVERED WITH THE CHANGE OF FREQUENCY IN
AUTOMATIC MODE.
To change the operating mode:
Unlock the STOP BUTTON and turn the ON/OFF switch or key to OFF position.1) Press START and the UNITS button (see Fig. 9 1) at the same time and, while holding them down,2) turn the key/switch to the ON position. The TX and BAT LEDs will flash simultaneously from one to
three times indicating the mode of operation that has been programmed, which can be:
•Mode 1: frequency change disabled (one flash).
•Mode 2: frequency change in manual mode (two flashes).
•Mode 3: frequency change in automatic mode (three flashes).
Fig. 9-1. Buttons used to set the frequency change mode.
STOP BUTTON
UNITS
TENS
VALIDATE
START
BUTTON
OR
Other Itowa Remote Control manuals
