REMdevice BRICK 09K User manual

INSTALLATION - START UP
AND OPERATING MANUAL

Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
CONTENTS
•Description.................................................................... 3
•Instructions for the correct & safe use of the equipment.. 3
•Correct installation of the equipment ............................ 10
•Position and description of controls .............................. 13
•Electrical and connections layouts ................................ 15
•Keeping the RC system in good working order .............. 21
•Change of frequency.................................................... 22
•Changing the functions ............................................... 28
•The TWIN SYSTEM ................................................... 29
•Working principles ....................................................... 31
•Working principles of the TWIN SYSTEM .................... 33
•Identifying and replacing fuses .................................... 34
•Technical features ....................................................... 35
•Conditions of guarantee .............................................. 36
WARNING !
The use and installation of the radio control should be
made only by authorized personnel and qualified,
incorrect use or installation can cause serious damage to
people and things.
This instruction manual must be READ CAREFULLY
before any attempt is made to install and/or operate the
radio control REMdevice.
2REMdevice®
- ITALY

Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
DESCRIPTION
The equipment consists of transmitter unit that can be BRICK or PAIL,
receiver RxDIN-CL or RxDIN with antenna and contact-less recharge unit.
INSTRUCTIONS FOR THE CORRECT AND
SAFE USE OF THE EQUIPMENT
Operation of this equipment must be undertaken only by qualified persons
who have previously read the Operating Instructions and who are fully
aware of Safety at Work regulations as laid down by law.
Installation of the equipment on the side of the machine to be operated
must be carried out by qualified technical personnel who are well versed in
the technical specifications of the radio control unit and of the machine to
be operated and who are also qualified to carry out installation in the
correct manner according to the guidelines.
The manufacturer of this equipment cannot be held responsible for any
damage to persons or things caused by:
•misuse or improper operation of the equipment
•errors in cabling or wrong electrical connections
•tampering with the equipment
•modifications made to the radio control unit
•use of non original replacement parts
•failure to properly maintain equipment
•failure to replace worn, damaged or defective parts
•operating the equipment while bypassing proper safety regulations, or
otherwise altering the original intended function of the equipment
This equipment functions using radio signals. It is able to operate the
machinery to which it is connected even in the presence of objects that
impede visibility from the machinery, for example: walls, metal or wood
panelling, machinery, tools, buildings, vehicles, etc.
Activating the radio control unit
•Position yourself with the transmitter unit so that you have complete
and totally un-obscured vision of the machine to be operated.
•Never stand under suspended loads.
•Keep proper footing and balance at all times.
•pay attention to the control identification labels next to each pushbutton
or joystick.
•do not activate any buttons or joysticks if you don’t know exactly what
its function is.
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
Transmitter unit BRICK 09K BRICK 09
Transmitter unit BRICK 10K or 12K BRICK 10 or 12
Transmitter unit PAIL
Figure 1
GREEN LED
(ON)
PUSHBUTTON
START
EMERGENCY
STOP
PUSHBUTTON
SWITCHING
ON KEY
GREEN
LED (ON)
RED LED
(BATT)
EMERGENCY STOP
PUSHBUTTON and
POWER ON
SWITCHING ON
KEY (Optional)
AUXILLARY
and START
WITHOUT KEY: with STOP
BUTTON for IGNITION, POWER
OFF & EMERGENCY
WITHOUT KEY: with STOP
BUTTON for IGNITION, POWER
OFF & EMERGENCY
PUSHBUTTON
START
SWITCHING ON
KEY & START
RED LED
(BATT)
PUSHBUTTON
START
4REMdevice® - ITALY

Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
Start up
Model with key: Turn the key clockwise for ¼ of a turn.
Model without key: Turn the STOP button to disengage.
Check that the green led (ON) flashes (once only), this shows that the
unit is switched on (see Fig. 1).
Activation
Press the START pushbutton or turn the key to START depending on the
model. The switching on of the unit is indicated by the flashing of the
green led with a timing of 1 second. If, however, the transmitter unit
beeps and the red led comes on, check that neither the red emergency
pushbutton nor any other pushbuttons have been pressed.
If the receiver unit is ready you will hear the warning sound from the
machine to be operated (installation obligatory).
Operation of radio control unit
Press the pushbuttons or move the command joysticks to carry out the
function required. Note that the pushbuttons of the BRICK keypad are
double step: increasing the pressure on the pushbutton makes a second
contact while is normally assigned to the increase in speed of rotation of
the electric motor or else to the increased opening of a hydraulic valve in
the machine.
In the event of any difficulties experienced in controlling the machine
(either for mechanical or electrical reasons, and not those dependent on
the will of the operator) immediately press the red stop pushbutton and
switch off the transmitter unit by turning the key.
The BRICK radio control unit with keypad is equipped with an automatic
inter-blocking of conflicting or incompatible operating manoeuvres: for
example Up/Down, Turn to left/Turn to right, etc.
Periodically check the working order of the red emergency stop
pushbutton, the switching on key and of all the other functions described
in this booklet.
Never leave the transmitter unit switched on, even for short durations.
At the end of use, before putting the transmitter unit away, press the red
STOP pushbutton and turn the key to the OFF position.
Do not leave the transmitter unit unattended with the switching on key
inserted. Keep the transmitter unit in a safe place that is not accessible to
unauthorised persons. Never allow unqualified persons access to the
transmitter unit.
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
Automatic Switching OFF
If the setting is activated (factory settings) the keypad will automatically
switch itself off after approximately 4 minutes of inactivity. To resume
press the START pushbutton.
Locking and unlocking the PAIL Transmitter
It is possible to lock the use
of the PAIL transmitter model
without a key in the following
manner:
a) start up the transmitter
by turning and
disengaging the STOP
button.
b) press the Joystics 1 and 2
on the arrows direction
and the START button,
then release.
If an attempt is made to activate the transmitter after this operation the
two red and green led lights will flash and the transmitter will emit an
acoustic sound.
To unlock the transmitter repeat the above sequence.
Locking and unlocking the keypad
It is possible to lock the use of the BRICK transmitter
model without a key in the following manner:
c) start up the transmitter by turning and
disengaging the STOP button.
d) press the following pushbuttons at the same
time: 7, 8, 9 and the START button, then
release.
If an attempt is made to activate the transmitter
after this operation the two red and green led lights
will flash and the transmitter will emit an acoustic
sound.
To unlock the BRICK transmitter repeat the above
sequence.
START
STOP
1 2
0/1
STOP
START
7
9
START
8
Figure 2
Figure 3
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
Charging the batteries
The radio control unit’s batteries are inside the transmitter equipment
and are charged using a unique method based on electromagnetic
induction without the need for metal electrical contacts or connection
cables. When the batteries are at a low level there is a warning signal of
three short tones and the red led flashes.
After the first warning signal, the radio control unit will operate perfectly
for up to further 60 minutes.
WARNING !
The battery charger supplied with the system must be kept
in a safe dry place, out of direct sunlight and protected from
the rain. It must be connected to the electrical mains so
that the plug is always accessible.
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
TRANSMITTER
UNIT PAIL
Figure 4
RECHARGE UNIT
CONTACT-LESS
RED LED
(BATT)
LED
(ON)
RED LED
(BATT)
TRANSMITTER
UNIT BRICK
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
The led (ON) on the battery charger (see Fig. 4) indicates the correct
electricity feed.
To charge the batteries, switch off the transmitter unit by turning the key
to the OFF position and place the unit onto the battery charger housing,
taking care that the jutting out part in the middle of the battery charger
is properly inserted into the slot on the bottom of the transmitter unit, as
indicated by the double arrow in Figure 4.
The transmitter unit has an automatic cut off switch that activates when
the transmitter unit is placed onto the battery charger.
The flashing red led (BATT) on the transmitter unit indicates that the
batteries are being charged correctly.
Charging is controlled electronically: the charging time required is
recognised automatically.
When the batteries are completely recharged the red led (BATT) on the
transmitter unit becomes permanently lit.
With new and completely charged batteries the transmitter unit can be
operated for approximately 35 hours (of continuous use).
It is necessary to charge the batteries just once a week
(eg, at the weekend).
The electronic checking of the state of the charging process means it is
possible to leave the equipment on the battery charger for long periods
without causing any adverse affect to the battery.
It is normal for the jutting out part of the recharger and the
corresponding slot of the transmitter unit to become warm during the
charging process.
If the batteries are completely uncharged just place the transmitter unit
on the battery charger for 30 minutes in order to guarantee one working
day’s operation of the radio control unit.
DO NOT attempt to open the battery charger to carry out repairs: in the
event of a unit failure either contact an authorised agent or REMdevice
directly.
When not being used, unplug the recharging unit.
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
CORRECT INSTALLATION OF THE
EQUIPMENT
The installation of the radio control unit must only be undertaken by
qualified competent persons who have been authorised to carry out its
correct installation according to the instructions and who will assume
total responsibility for any possible injury to persons or damaged to
things caused by errors in the wiring of the receiver, of any non
observance of safety regulations, use of unsuitable materials for the
installation of the receiver and the lack of or incomplete testing of the
equipment following installation.
Wiring of the RxDIN-CL receiver unit
Model with sealed casing for external installation at the machinery’s
electric panel.
REM device
RADIO CONTROL EQUIPMENT
RUBY-BOX RECEIVER
®
!
90 mm
260 mm
The casing containing the receiver module must be fixed in a position
easily accessible for maintenance and repair.
Do not position the receiver within metallic structures that could shield or
compromise the reception of the radio signals (ie: boxes, cupboards,
girders, tubing, wire fencing, etc).
The sealed casing containing the receiver module must be installed with
the multipolar cable inlet pointing downwards to stop any water getting
into the unit (see Fig. 5).
CABLE INLET
Figure 5
Receiver
CL Rubybox
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
It is advisable to further protect the casing further using non-metallic
material.
Fix the casing using the assembly KIT provided. The hole sizes are
shown in Figure 5.
Never make holes in the casing. Make sure the casing is properly fixed
by using only suitable safe means.
For any further information or advice regarding the correct
installation and starting up of the equipment contact REMdevice.
WARNING: DO NOT remove the receiver module from its sealed
casing in order to install it inside the machine’s electric panel.
To ensure the safe and correct wiring of the receiver use multipolar
cabling and plug of the same kind used for the cabled keypad provided
with the machine.
Use metal wire heads to clamp the conductors, then connect to the
terminals of the receiver and check they are properly tightened.
To facilitate wiring it is possible to take out the receiver module from the
casing by unhooking the DIN support bracket by lifting the lower tab (see
Figure 6).
Check that there is a suitable isolating device. Using a voltmeter, check
there is suitable current to the electric panel for the receiver module.
Information regarding the electrical current required can be found under
the TECHNICAL SPECIFICATIONS (it is also shown on the adhesive label
located on top of the clamps). The position of the phase and neutral or
positive and negative wires does not matter.
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
Information regarding the receiver’s joysticks’ relay contacts is included in
TECHNICAL SPECIFICATIONS.
Electrical current supply is confirmed by the continuous ON led located on
the receiver module.
The connection between the radio control unit and the machine’s electric
panel must be completed so that if the radio control unit loses contact
with the machine, control can be taken over using the cabled keypad.
The multiple control of a machine using both the radio control unit and
cabled keypad at the same time is NOT permitted. Pay special attention
to the connection of the EMERGENCY STOP circuit by following the
machine’s original electric diagram to wire it up in the correct way.
FREQUENCY CHANGE
PLL LED
FUNCTION CHANGE
RELAY
STOP
FUSE
POWER
SUPPLY
FUSE
RxDIN
RECEIVER
UNIT
LINK LED
ON LED
DIN BRACKET
SERIAL NUMBER
CABLE
ANTENNA
LOWER TAB
PLUG
Figure 6
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
LAYOUT OF COMMAND PUSHBUTTONS for the BRICK
TRANSMITTER
BRICK 09,10,12 K BRICK 09,10,12
PR9
PR11
PR15
PR17
PR21
PR23
PR25
PR27
PR10
PR11
(PR12)
PR16
PR17
(PR18)
PR22
PR23
(PR24)
PR26
PR14
(PR27)
STOP
0/1
(START)
PR5
PR6 START (PR7)
PR8
0/1
STOP
(START)
PR9
PR11
PR15
PR17
PR21
PR23
PR25
PR27
PR10
PR11
(PR12)
PR16
PR17
(PR18)
PR22
PR23
(PR24)
PR26
PR14
(PR27)
PR5
PR6 START (PR7)
PR8
(PR27) (PR14) (PR27) (PR14)
Model with Start up key -Model without Start up key
The model with A/B operation arranged in two relays with fixed selection
PR19 for A and PR13 for B. controlled by the PR25 and PR26 push
buttons. On the BRICK 12 model the push button PR27 and PR14 are on
the sixth line of push button only.
Figure 7
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
The various models differ regarding the number of commands available
and the position of the START.
The commands shown in bracket are available as alternatives in some
models instead of that indicated immediately above them.
For each command PR .. a corresponding relay on the receiver is
assigned.
PAIL TRANSMITTER FULL COMMAND LAYOUT
PR13
PR22
0/1
PR26
PR23
PR21
PR8
PR7
PR26
PR23
PR15
PR25
PR17
PR16
PR25
PR17
PR10
PR5
PR11
PR9
PR5
PR11
START
PR24
PR19
PR18
PR24
PR6
PR6
PR27
PR13
PR13
PR14
PR27
PR14
PR12
Note: Both the transmitter BRICK transmitter PAIL have the function of
the commands shown on the plates direct on the product or supplied. If
were used different labels or plates the symbols must strictly observe the
functions and movements of the machine and must comply with the rules
in force.
Figure 8
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
PR 5
PR 6
PR 7
PR 8
PR 12
PR 13
PR 14
PR 18
PR 19
PR 24
PR 25
PR 26
PR 27
LAMP
PR 5
STOP
START
CLAXON
PR 9
PR 8
PR 7 nc
PR 7 na
PR 6
PR 10
PR 11
PR 12
PR 13
PR 14
PR 15
PR 16
PR 17
PR 18
PR 19
PR 21
PR 22
PR 23
PR 24
PR 25
PR 26 na
PR 26 nc
PR 27
ALIM.
ALIM.
STOP
START
PR 9
PR 10
PR 11
PR 15
PR 16
PR 17
PR 21
PR 22
PR 23
COMANDI COMUNI
CLAXON
LAMP
RECEIVER’S CONNECTION LAYOUT – COMPLETED VERSION
Terminals
COMMANDS
Terminals
COMMON
Figure 9
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
25
1
3
4
RL7
RELAYS
25
1
3
4
RL15
RELAYS
25
1
3
4
RL14
RELAYS
25
1
3
4
RL5
RELAYS
25
1
3
4
RL4
RELAYS
25
1
3
4
RL8
RELAYS
25
1
3
4
RL9
RELAYS
25
1
3
4
RL10
RELAYS
25
1
3
4
RL11
RELAYS
25
1
3
4
RL12
RELAYS
25
1
3
4
RL13
RELAYS
25
1
3
4
RL6
RELAYS
LAMP
LAMP LA MP COM
RE0-OUT
PR5 PR5 COM
RE1-OUT
PR6 COM
PR6
RE2-OUT
PR7 NA PR7 COM
RB3-OUT
PR8 PR8 COM
RE4-OUT
PR9 PR9 COM
RE3-OUT
PR10 PR10 COM
RE5-OUT
PR11 PR11 COM
RE6-OUT
PR12 PR12 COM
RE7-OUT
PR13 PR13 COM
RF0-OUT
PR15 PR15 COM
PR7 NC
RB25-OUT
PR14 PR14 COM
D1
C1
220uF 100V
IN V-
IN V+ OUT V-
OUT V+
D2
+12
IN2 Power Supply
O1 Power Supply
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- ITALY

Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
1 2
3 4
5 6
7 8
910
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
33 34
JP2
Connettore Decodifica e Ricezione
MARCIA-OUT
RG3-OUT RG2-OUT
RG1-OUT RG0-OUT
RE0-OUT
ARRESTO/S
RF6-OUT
RF0-OUT
RF2-OUT RF1-OUT RF3-OUT
RF4-OUT RF5-OUT
RE2-OUT RE3-OUT
RE4-OUT RE5-OUT
RE6-OUT RE7-OUT
RE1-OUT
IN1 Power Supply
O1 Power Supply
ALARM-OUT
RB0-OUT
RB25-OUT RB3-OUT
LAMPEG
2
1
4
5
3
7
8
6
RL3
RELAYD
21
4
5
3
7
8
6
RL1
Alarm
25
1
3
4
RL18
RELAYS
25
1
3
4
RL22
RELAYS
25
1
3
4
RL23
RELAYS
25
1
3
4
RL27
RELAYS
25
1
3
4
RL16
RELAYS
25
1
3
4
RL19
RELAYS
25
1
3
4
RL21
RELAYS
25
1
3
4
RL24
RELAYS
25
1
3
4
RL25
RELAYS
25
1
3
4
RL26
RELAYS
25
1
3
4
RL17
RELAYS
+12
ALARM-OUT
+12B
+12B
MARCIA-OUT
MARC MA RC COM
CLAX CLAX COM
RF1-OUT
PR16 PR16 COM
RF2-OUT
PR17 PR17 COM
RF3-OUT
PR18 PR18 COM
RF4-OUT
PR19 PR19 COM
RG0-OUT
PR21 PR21 COM
RG1-OUT
PR22 PR22 COM
RG2-OUT
PR23 PR23 COM
RG3-OUT
PR24 PR24 COM
RF5-OUT
PR25 PR25 COM
RF6-OUT
PR26 NA PR26 COM
RB0-OUT
PR27 PR27 COM
PR26 NC
2
1
4
5
3
7
8
6
RL2
STOP
+12B
ARRESTO/S
STOP
21
4
5
3
7
8
6
RL28
STOP
C2
100uF 16V
C3
100uF 16V
+12B
4A 250V STOP-COM
STOP-FUSE
STOP-COM
STOP-FUSE
NOTA: negli schemi soprasonoindicati tutti i comandi (PR) possibili
ATTENZIONE: nel radiocomandosonodisponibili solamentei comandi (PR) richiesti
NOTE: all possible commands (PR) are shown on the above diagrams
WARNING: only the requested commands (PR) are available on the radio control
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Morsettiera
COMUNI
IN1 Power Supply
IN2 Power Supply
STOP COM
MARC COM
CLAX COM
LAMP COM
PR5 COM
PR6 COM
PR7 COM
PR8 COM
PR9 COM
PR10 COM
PR11 COM
PR12 COM
PR13 COM
PR15 COM
PR14 COM
PR16 COM
PR17 COM
PR18 COM
PR19 COM
PR21 COM
PR22 COM
PR23 COM
PR24 COM
PR25 COM
PR26 COM
PR27 COM
STOP
MARC
CLAX
LAMP
PR5
PR6
PR7na
PR8
PR9
PR10
PR11
PR12
PR13
PR15
PR7nc
PR14
PR16
PR17
PR18
PR19
PR21
PR22
PR23
PR24
PR25
PR26na
PR27
PR26nc
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
Morsettiera
COMANDI
Terminals
COMMANDS
Terminals
COMMON
Figure 10
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
Wiring of the receiver unit RxDIN
For internal installation (on DIN bracket) to the machine’s electric panel.
The wiring of this model of receiver must only be carried out by
the manufacturer of the
electric panel.
If the electric panel is made from
metal place the active antenna on
the outside.
Use Ø 16 mm holes for fixing on
the desired side.
Use the cable inlet bolt to lock the
box into position. Figure 11.
Testing the radio control unit
For a RxDIN-CL receiver:
•with the machine to be operated turned off, plug in the receiver’s
multipolar cable in the place of the cabled keypad and make sure
it is locked with the appropriate hooks.
•check that the connection cable between the receiver and the
machine does not get twisted or caught up in mechanical parts
during movement of the machine.
•open the sealed casing to see the led that shows the state of the
receiver.
Switch on the machine to be operated. Always staying in a safe position
out of the range of action, in the event of a wiring error the machine
could accidentally move when switched on.
Check that the ON led is continuously lit (see Fig. 6) indicating electric
current to the receiver module.
Check that the PLL led is flashing (see Fig. 6) indicating the receiver
module’s radio signal is in stand by.
Check the antenna’s SMA connector is tightened.
Switch on the transmitter unit (as shown on Page 5) and check the
continuous LINK led is lit on the receiver (see Fig. 6) indicating the
correct communication between the transmitter and receiver.
CABLE INLET
Ø 16 mm
Figure 11
External Antenna for RxDIN
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Installation, start up and operating manual – version 5.3 Gen.10
Radio control BRICK and PAIL
Check the proper working order of the red emergency stop
mushroom button, the switching on key and of the functions.
Press the red pushbutton (see Fig. 1) and check that the LINK led on the
receiver is off (see Fig. 6) indicating that the radio control unit has been
disactivated.
To resume the testing procedure reset the emergency pushbutton by
turning it approximately a ¼ of a turn until it makes a step, then press
the START button again on the transmitter unit.
Press a pushbutton or move a joystick of the machine assigned to a
manoeuvre and keeping it held down press the STOP pushbutton. The
machine must stop immediately. To continue reset the emergency stop
button.
Once again press a pushbutton or command joystick to carry out a
movement and keep it pressed while turning the key anticlockwise (to the
OFF position). The machine should stop within one second (due to no
radio signal).
After having reactivated the transmitter unit activate one pushbutton or
joystick at a time and check the machine is carrying out the manoeuvres
as indicated by the symbol at its side.
Move away from the receiver and while always watching the machine
carry out the manoeuvres in different work areas to ascertain the full
coverage of the signal.
At the end of testing clearly compile the receiver unit’s wiring diagram
and the Correct Instalment Declaration Certificate.
20 REMdevice®
- ITALY