Jay UDF User manual

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RADIOSAFE Series
Wireless emergency stop system
Installation and operating instructions
manual
- TRANSLATED IN ENGLISH FROM ORIGINAL FRENCH VERSION -
RSRA
SCI-B
URE
UDF

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TABLE OF CONTENTS
1Guidelines for safe use .........................................................................4
2Presentation of RADIOSAFE emergency stop system.......................6
2.1 Unpacking the product ............................................................................................................6
2.2 Configuration on delivery........................................................................................................6
2.3 Product code............................................................................................................................7
3Technical characteristics......................................................................7
3.1 Transmitter URE.......................................................................................................................7
3.1.1 Identity code.........................................................................................................................................................7
3.1.2 Electronic key.......................................................................................................................................................7
3.1.3 « Activity monitoring » function.............................................................................................................................8
3.1.4 Battery charge......................................................................................................................................................8
3.2 Receiver RSRA.........................................................................................................................9
3.3 IR startup option (IR)..............................................................................................................11
3.3.1 Presentation of infrared module (UDF)...............................................................................................................11
3.3.2 Positioning the infrared module UDF..................................................................................................................12
3.4 Configuring the receiver........................................................................................................12
3.4.1 Choice of receiver (RSRA) program...................................................................................................................12
3.4.2 Definition of receiver indicator lights and diagnostic outputs ..............................................................................13
3.5 Presentation of charger .........................................................................................................14
4Operating principle..............................................................................15
4.1 Intervention in equipment area. ............................................................................................15
5Product safety and intervention conditions......................................15
5.1 Product safety........................................................................................................................15
5.2 Intervention conditions..........................................................................................................15
5.3 Indications..............................................................................................................................16
6Receiver wiring diagram according to intervention condition ........16
6.1 Control of machine without area access control.................................................................16
6.2 Wiring diagram.......................................................................................................................16
6.2.1 Diagram of functions according to program selected..........................................................................................18
6.2.2 Control of machine with area access control......................................................................................................22
6.2.2.1 Recommended wiring diagram .........................................................................................................................................22
6.2.3 Diagram of functions according to program selected..........................................................................................24
7Installation recommendations............................................................26
7.1 General information...............................................................................................................26
7.2 Choice of utilization frequency .............................................................................................26
7.3 Receiver and charger installation precautions. ...................................................................26
7.3.1 Special case –Equipment area access..............................................................................................................27
7.3.2 Receiver antenna installation position ................................................................................................................27
8Commissioning....................................................................................28
8.1 Commissioning precautions .................................................................................................28
8.2 Starting up the radio remote control.....................................................................................28
8.3 Configuring the transmitter...................................................................................................29
8.3.1 Procedure for programming frequency...............................................................................................................29
8.3.2 Procedure for programming « transmitter activity monitoring » duration. ...........................................................30
8.3.3 Procedure for « locking –unlocking » access to transmitter programming.........................................................31
8.3.4 Procedure for « validation of an electronic key »................................................................................................32

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9Maintenance.........................................................................................33
9.1 Spare parts .............................................................................................................................33
9.2 Fault isolation.........................................................................................................................33
9.2.1 Transmitter fault isolation....................................................................................................................................33
9.2.2 Fault isolation relative to receiver parameter definitions or configuration ...........................................................34
9.2.3 Receiver input fault isolation...............................................................................................................................35
9.2.4 Receiver radio function fault isolation.................................................................................................................36
10 Warranty ............................................................................................37
11 CE declaration of conformity...........................................................38
12 Appendix A : Intervention in equipment area.................................39
12.1 Purpose...............................................................................................................................39
12.2 Need.....................................................................................................................................39
12.3 Application diagram ...........................................................................................................39
12.4 Wiring diagram....................................................................................................................39
12.5 Procedure............................................................................................................................40
12.6 Area access in manual mode.............................................................................................40

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1 Guidelines for safe use
The European Machinery Directive states that a radio remote control must be considered
both as a control unit and as a safety component for stopping a system. Safe use of a radio
remote control therefore calls for strict compliance of all applicable rules.
For maximum safety when handling the radio remote control, be sure to carefully observe
the instructions given in this manual.

The operator must be appropriately trained and qualified for use of the radio remote
control.

On an installation, an emergency stop button which is visible must always be
operational. When the transmitter is not being used, it must be placed on its charger ; its
emergency stop button is therefore no longer operational. For this reason, it is important to
install the charger so that the transmitter emergency stop button is not visible when the
transmitter is placed on its charger.
The operator must have an uninterrupted view of the manoeuvre which he is
performing. When the direct field of view is insufficient, the systems controlled must be
equipped with auxiliary devices improving visibility.
When several moving systems are controlled simultaneously, the systems must be equipped
to reduce the consequences of a possible collision.
If all the safety areas are not always visible simultaneously, one of the following startup
modes must be used :
Manual startup using a wired ON pushbutton placed at a location from which all the
safety areas are visible.
Radio-controlled startup by infrared. The IR receiver must also be placed to force the
user to go to a location where all the safety areas are visible.
Never leave the transmitter unattended in any haphazard location, especially when it is
switched on.
Never leave the transmitter on the ground. If doing so becomes indispensable, press the
stop palm switch on the transmitter.
If several radio remote controls are used at the same site, different radio frequencies
should be used, spaced by at least 2 channels (example, channels 5, 7, 9,. ….) of 5 channels
if several systems are operating together within a radius of 10 meters.
When not in use, for safety purposes, remove the electronic key.
Do not forget to recharge the battery when discharged.
Do not use the transmitter when it is in charge.
In the event of a malfunction, immediately shut down the installation by pressing the
emergency stop palm switch on the transmitter.
Ensure your equipment is properly serviced and perform periodic checks in accordance
with the intensity of use of your equipment.

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A functional test (automatic or manual) to detect failures shall be performed within the
following test intervals:
at least every month for PL e with Category 3 or Category 4 (according to EN ISO
13849-1) [or SIL 3 with HFT (hardware fault tolerance) = 1 (according to EN 62061)];
at least every 12 months for PL d with Category 3 (according to EN ISO 13849-1) [or
SIL 2 with HFT (hardware fault tolerance) = 1 (according to EN 62061)].“
Important :
As installer or manufacturer of the machine, you are also required to indicate these
guidelines for safe use in your own user manual.
Caution :
This manual describes the functions of the RSRA / A002 receivers with a software
version PN5910_BI_A_01_0F_01_03 or higher. Operating modes 8 and 9 (§ 6.2.2
«Control of machine with area access control») have been modified with respect to
the previous versions of the RSRA modules.
The modules having this new function carry the type designation « RSRA / A002 »
engraved on the side of the housing. The software version is glued to the back of the
housing.

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2 Presentation of RADIOSAFE emergency stop system
2.1 Unpacking the product
The RADIOSAFE product comprises:
One receiver RSRA (1)
One transmitter URE (2)
One 24VDC-5VDC voltage adapter UCC4 (3)
One charger support SCI-B (4)
Two sheets of labels UWE202 and UWE207 (5)
One key identification sheet (6)
One CD (or USB memory key) including the installation and operating instructions manual (7)
One BNC elbow VUB060 (8)
One antenna extension VUB170 (9)
One ¼ quarter wave antenna VUB084 (10)
2.2 Configuration on delivery
Product
• The product is supplied factory-set for radio channel 01, i.e. 433.100 MHz.
Transmitter
• The transmitter “activity monitoring” function (transmitter automatically stops if not used for an extended period of time)
is factory-set for 15 min.
To modify the duration or change the counting unit to « seconds », refer to the “Transmitter activity monitoring function”
section.
• Electronic key number :
- A unique number is engraved on the key.
IMPORTANT : When unpacking the products, be sure to stick the electronic key identification label on the key sheet
supplied with the product.
• Locking the transmitter :
- The transmitter is supplied « unlocked » ; the « activity monitoring » and « frequency » configurations corresponding to
the electronic key can be directly modified by a qualified operator.
Receiver
• The receiver has 10 different application programs. It is supplied factory-set for program « 0 » selectable by 2 selectors
"B". For information on the different programs, refer to the section entitled “Choice of receiver (RSRA) program”.
• The receiver has a time delay function. It is supplied with a time delay of 10 seconds for transmitter take-over according
to the position "0" of 2 selectors A. Refer to the section covering “adjustment of time delay” if this duration is not sufficient.
1
2
3
4
5
6
7
8
9
10

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2.3 Product code
Refer to the technical sales brochure ref. E800 For all information concerning the product code. This information is
accessible on our internet site at http://www.jay-electronique.com/
3 Technical characteristics
3.1 Transmitter URE
Housing
Material
Tightness
ABS
IP65
Radio
Carrier
Frequencies
Frequency band
HF power
Average range
Complies with ETS 300 220
UHF, frequency modulated (FM)
64 programmable frequencies
433.1 to 434.675 MHz
< 10 mW (without license)
150 m in typical industrial environment
400 m in open space
Battery
Storage type
Charge / Discharge cycles
Fast charge time
Full charge time
Lithium ion
500 cycles min.
2h max. (80%)
4 h max. (100%)
Endurance
For typical use of function buttons
50 H at 50% utilisation at +20°C
Storage temperature
-20°C to +50°C
Battery charge temperature range
0°C to +40°C
Caution ! : Fast charging outside this
temperature range can result in damage to
battery.
Operating temperature range
-20°C to +45°C
Weight (with battery)
240 g
Dimensions
46 x 78 x 143 mm
3.1.1 Identity code
The transmitter and receiver are linked by a frequency and an identity code.
A receiver will only recognize and execute commands from the associated transmitter (same identity code and frequency).
- The frequency is programmable by the user
- The transmitter identity code is contained in the electronic key and in the transmitter (URE).
- The receiver identity code is unique and frozen ; this code is programmed in factory.
The identity code can have 65536 different combinations.
3.1.2 Electronic key
The electronic key used with the RADIOSAFE radio remote control system ensures a dual function :
- It enables startup of the transmitter while limiting access to the remote control to trained, qualified persons only.
- It contains all the information defined for operation of the product, including :
- the last frequency programmed
- the system identity code
- The “activity monitoring” function
- the configuration of the function buttons on the transmitter and the type of button (button or rotary).
- When removed, the electronic key prevents use of the transmitter and cuts off the transmitter power supply.
If the identity code of the electronic key matches the identity code stored in the URE, the transmitter can be started up.
- If the identity code of the electronic key and that of the transmitter do not match, the transmitter indicates the problem by its
two indicator lights (3 flashes); you must then perform the key programming procedure.

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In the event of a transmitter failure
You can recover the electronic key and connect it to a « maintenance » transmitter which buttons are configured in the
same way as those of the failed transmitter. When this is not the case, the differing buttons will not operate.
To perform this procedure, you must re-program the identity code of the key in a new transmitter (URE) by following the
procedure described in the corresponding section.
In the event of loss of electronic key
You can order a new electronic key (reference RSWE21 B), by specifying the unique 6-digit number of the old key on the
order (written down when you unpacked your product).
Caution, the initial key is supplied programmed on frequency channel 01 with « activity monitoring » duration set for 15
minutes. You must define these parameters again on your new key.
3.1.3 « Activity monitoring » function
The « Activity monitoring » function automatically deactivates the remote control (radio transmission cut off) when the
buttons (BPSV, BPDV and “ON”) are not actuated for a duration defined for N minutes or seconds.
The N parameter is configurable by the user and can take the values of 01 to 98 minutes or seconds.
In its standard configuration, the time delay unit is defined for minutes. On delivery, this duration is defined for
15 minutes.
- If the time delay unit is defined for minutes and the N value is defined for 99 minutes, the transmitter considers that the
time delay duration is infinite (up to complete discharge of its battery).
- If the time delay unit is defined for seconds (configured by you), and the N value is defined for 99 seconds, the
transmitter will be deactivated after 99 seconds if none of the function buttons or the “ON” button is used.
Note 1 : The switches (COM2, COM3) do not act on the « Activity monitoring » function.
Note 2: The duration and the type of counting unit for the « Activity monitoring » function (minute or second) are stored in
the electronic key of the transmitter (URE).
3.1.4 Battery charge
To ensure optimum battery performance, start by charging and fully discharging the battery the first time.
During the charge, the orange indicator light on the transmitter comes on continuously ; the green indicator light
indicates the charge level :
Green indicator light flashes : fast charge
Green indicator light on steady : slow or upkeep charge (URE charge greater than 80%)
Display of transmitter battery charge status (when not charging)
Two battery charge status display functions are provided on the transmitter.
- On power up of the remote control (emergency stop palmswitch up), the orange indicator light on the transmitter
indicates the charge level of the storage batteries :
Orange indicator light off : ........................... battery charge is > 50%
Orange indicator light flashes slowly : ....... battery charge is between 50% and 10 %
Orange indicator light flashes fast : ........... battery must be recharged (battery charge < 10%)
Orange indicator light on for 2 seconds : ... transmitter initialization as soon as the stop palmswitch is raised.
- During operation of the remote control (radio transmission), a LOW BATT level (charge < 10%) is indicated by the
orange indicator light which flashes quickly. This indication is used to inform you that the remote control will soon
be unavailable (within less than 15 minutes).
Display of transmitter battery charge status (transmitter charging)
Transmitter status
Red indicator light
Green indicator light
Function
Battery charging
ON
Flashing
Fast charge
Battery charging
ON
ON
Slow or upkeep charge
Bornier
contacts NO

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3.2 Receiver RSRA
Housing ABS, black/yellow
IP 40
Weight 495 g (approx.)
Dimensions 67 x 84 x 129mm (not including antenna)
Operating temperature range 0 °C to + 50 °C
Storage temperature range - 30 °C to + 70 °C
Connection Spring terminals for wires 0.08² to 2.5²
Characteristics compliant with ETS 300 220
Frequency 64 frequencies programmable in 433-434 MHz
Antenna
Sensitivity < -100 dBm
Power supply voltage Un 24 VDC
Voltage range (at max., 5% ripple) 0.85 to 1.15 Un
Consumption max., 120 mA (Static output, not loaded)
Contacts 3 NO
Type of contacts Linked contact relays
Pull-in time at Un Automatic start 800 ms max. (power up)
Automatic restart 70 ms max.
Manual start 110 ms max.
Trip time (reaction) S12-S14, S22-S24, S32-S34 25 ms max.
Stop (remote control): 170 ms max.
Assigned output voltage AC250V
Low voltage switching
> 100 mV
Thermal current Ith 5 A
Switching capacity Per AC 15 : AC 3A/230 V for NO contacts EN60947-5-1
AC 2A/230 V for NC contacts EN60947-5-1
Per DC 13 : DC 8A/24 V at 0.1 Hz EN60947-5-1
Electrical service life Per AC15 at 2A, AC230V 100 000 cycles EN60947-5-1
Short-circuit rating Maximum fuse rating 6 A gL EN60947-5-1
Mechanical service life 10 x 10^6 cycles
Type of outputs Static outputs, PNP
Nominal voltage Un (A3, A4) DC 24 V
Voltage range 0.85 to 1.15 Un
Output voltage DC 24V, max. 100mA thermal
max. 400 mA for 0.5s
Overload and temperature protection
Indicators 2 yellow indicator lights: state of safety module
2 red indicator lights: state of safety relays
1 green indicator light: radio reception quality
Radio characteristics
Electrical characteristics
1 red indicator light: wrong identity code or diagnostic
Secure relay outputs (terminals 13-14, 23-24, 33-34 or 31-32)
Static outputs (terminals 48, 58, 17, 27, 37, 47, 57, 67, 77)
1/4 wave, as accessory, plugs in to BNC connector
Mechanical characteristics and environmental withstand capacity

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The RSRA receiver has the following outputs :
100 mA opto-coupled static outputs :
6 function outputs
Safety relays :
2 guided-contact safety relays « 3 N0 ».
Safety outputs and inputs
Terminals
Function
A1+
24VDC power supply for safety modules of receiver (RSRA)
A2-
Common ground
48
24V static output: safety module status
58
24V static output: safety module status ( of witch catch transmitter of charger)
S11
S12
Input 1 for 1st emergency stop or 1st safety barrier
S13
S14
Input 2 for 1st emergency stop or 1st safety barrier
S21
S22
Input 1 for 2nd emergency stop or 2nd safety barrier
S23
S24
Input 2 for 2nd emergency stop or 2nd safety barrier
S31
S32
Input for test of 1st charger
S33
S34
Input for test of 2nd charger
S42
Input for wired “ON” button
Y1
Y2
Input for auxiliary relay return loop
13
14
1st safety output (NO contact)
23
24
2nd safety output (NO contact)
33
34
3rd safety output (NO contact)
Removable connection
block, screw terminals
White. lights, V1 & V2
«Safety module status»
Green ind. lights, K1 and K2
«Safety relay status»
Green indicator light V4
«Radio reception quality»
Antenna BNC connector
Red indicator light V3
«wrong identity code»