Vetter SmartFork FrontCam ATEX User manual

Operating instructions
EN
SmartFork® FrontCam ATEX
for use in the Ex zone - BVS 20 ATEX E 108 X
Read the instructions prior to performing any
task!
U163-952
Keep for future use!

SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X
2
EN

This operating instruction (hereinafter referred to as “manual”) contains fundamental
safety instructions for handling the VETTER SmartFork® FrontCam (hereinafter also
referred to as “SmartFork®” or “assistance system”, if explicitly referring to the camera
application). Incorrect use of the SmartFork® can result in serious injuries and even death
due to the considerable dead weight and deployment in potentially explosive atmos-
pheres. For this reason, this manual and especially the safety information contained
therein must be read by the competent industrial truck driver prior to assembly, commis-
sioning and maintenance. The manual must always be available at the operation site of
the SmartFork® (generally on the industrial truck).
Always observe the information in the industrial truck operating instruction and the oper-
ating instruction for the fork carrier used to ensure safe handling of the SmartFork®.
Illustrations in this manual are for basic understanding and may deviate from the actual
design.
Address VETTER Industrie GmbH
Carl-Benz-Strasse 45
57299 Burbach
GERMANY
Phone [phone]
Email [email protected]
Internet www.smartfork.com
About this
manual
Customer
service
Supplemental directives
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 3

TABLE OF CONTENTS
1SMARTFORK® OVERVIEW 6
1.1 Range of application 6
1.2 SmartFork® FrontCam, camera function 7
1.3 EC declaration of conformity 8
1.4 EU type examination 9
2 SAFETY 12
2.1 Symbols in this manual 12
2.2 Applicable documents 12
2.3 Intended use 13
2.4 Operator obligations 16
2.5 Dangers when handling the SmartFork®17
2.6 Safety markings 21
2.7 Personnel requirements 23
2.7.1 Qualifications 23
2.7.2 Unauthorised persons 24
2.7.3 Training 24
2.8 Personal protective equipment 25
2.9 Protection of the environment and disposal 26
3 STRUCTURE 27
3.1 Structure of the basic fork arm 27
3.2 Suspension 28
3.3 Image and signal output devices 29
3.4 Cabling 29
4 ASSEMBLY 30
4.1 Installing the SmartFork® on the fork carrier 30
4.2 Installing and connecting the monitor 32
4.3 Establishing cable connections 33
5 OPERATION 34
5.1 SmartFork® FrontCam 35
5.2 Adjusting the distance between the fork arms 36
6 MAINTENANCE 38
6.1 Maintenance intervals 38
6.2 Maintenance activities 38
6.2.1 Daily visual inspection by the driver 39
6.2.2 Checking the fork arms and suspension system 40
6.2.3 Checking electronics 41
6.2.4 Wear check 41
6.2.5 Checking the locking device 42
6.2.6 Cleaning the fork arm 42
6.2.7 Replacing the fork arm 43
6.2.8 Replacing the application 45
Table of contents
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X
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EN

6.2.9 Spare parts 47
6.3 After completion of maintenance work 47
7 TROUBLESHOOTING 49
8 TECHNICAL DATA 50
9 INDEX 51
Table of contents
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 5

1 SmartFork® overview
1.1 Range of application
The SmartFork® is used to lift, transport and put down loads or goods on pallets that are
intended for transport by fork lift truck or another form of industrial truck approved for use
in potentially explosive atmospheres.
The use of the assistance system allows the position of the load before lifting and the
area directly in front of the SmartFork® to be detected more quickly and efficiently.
The SmartFork® is approved in accordance with EU type examination certificate
BVS 20 ATEX E 108 X for gas explosion protection and dust explosion protection.
Permissible Ex zones:
nEx II 2G Ex h db IIB T5 Gb
nEx II 2D Ex h tb IIIB T95°C Db
The SmartFork® may be used in potentially explosive atmospheres with flammable
gases, vapours, mists and dusts in accordance with EU type examination certificate BVS
20 ATEX E 108 X.
DANGER!
Danger to life from use in non-designated Ex zones!
The SmartFork® may only be used in its designated potentially explosive
atmosphere. Use of the SmartFork® in a non-designated potentially
explosive atmosphere or on a non-approved carrier vehicle can result in
serious injuries or even death.
– Only use the SmartFork® within a temperature range of
-20 °C to +50 °C.
– The SmartFork® may only be used with the approved carrier vehicle in
the potentially explosive atmosphere approved for the carrier vehicle.
Always observe the information in the industrial truck operating
instruction and the operating instruction for the fork carrier.
The use of the SmartFork® outside explosion-proof areas is permitted.
Permissible
Ex zones
SmartFork® overview
Range of application
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X
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1.2 SmartFork® FrontCam, camera function
Fig. 1: SmartFork® FrontCam
The targeting of the load and insertion of the SmartFork® underneath the load is moni-
tored by the direct transmission to the monitor. When a raised load obstructs the view, the
area in front of the fork tips is visible on the monitor.
SmartFork® overview
SmartFork® FrontCam, camera function
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 7

1.3 EC declaration of conformity
VETTER Industrie GmbH, as the manufacturer, hereby declares that the products listed
below comply with the standards and guidelines listed below.
Name: - SmartFork Frontcam ATEX
Solid stainless steel fork arm with camera built into the fork tip for use in
potentially explosive atmospheres.
Model: - 150701800WGXSFR-001 S.-Nr. 1 - 24
Ex zone
marking:
- II 2G Ex h db IIB T5 Gb
II 2D Ex h tb IIIB T95°C Db
This declaration is void if a change is made to the aforementioned equipment. The
authorised agent for compiling the technical documentation is the signatory.
The subject of the declaration described above complies with the relevant EU harmonisa-
tion legislation.
Applied national standards and guidelines:
2014/34/EU Annex II - Legislation covering equipment and protective systems
intended for use in potentially explosive atmospheres
2006/42/EC - Machinery Directive
DIN EN 1755:2016 - Industrial Trucks - Safety requirements and verification - Sup-
plementary requirements for operation in potentially explosive
atmospheres
EN ISO 80079-36:2016 - Non-electrical equipment for explosive atmospheres - Basic
method and requirements
EN ISO 80079-37:2016 - Non-electrical type of protection “h”
EN IEC 60079-0:2018 - Explosive atmospheres – Equipment – General requirements
EN 60079-1:2014 - Explosive atmospheres – Equipment protection by flameproof
enclosures “d”
EN 60079-31:2014 - Explosive atmospheres - Equipment dust ignition protection by
enclosure enclosure “t”
Notified body: - DEKRA Testing and Certification GmbH (0158)
EU type examination certificate: - BVS 20 ATEX E 108 X
DEKRA Testing and Certification GmbH (0158), the notified body, was involved in the pro-
duction control and has confirmed conformity with the type for the aforementioned serial
numbers
BVS 21 ATEX ZQ 163-01
VETTER Industrie GmbH
Carl-Benz-Strasse 45
57299 Burbach/Germany
Gunther Grindel (Technical Director)
SmartFork® overview
EC declaration of conformity
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X
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1.4 EU type examination
SmartFork® overview
EU type examination
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 9

SmartFork® overview
EU type examination
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X
10
EN

SmartFork® overview
EU type examination
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 11

2 Safety
2.1 Symbols in this manual
Safety instructions are indicated by symbols in this manual. The safety instructions are
initiated by signal words that indicate the degree of the danger.
DANGER!
This combination of symbol and signal word indicates an imminently dan-
gerous situation which, if not avoided, will result in death or serious injury.
WARNING!
This combination of symbol and signal word indicates a potentially dan-
gerous situation which, if not avoided, could result in death or serious
injury.
CAUTION!
This combination of symbol and signal word indicates a potentially dan-
gerous situation which, if not avoided, could result in slight or minor inju-
ries.
NOTICE!
This combination of symbol and signal word indicates a potentially dan-
gerous situation which, if not avoided, could result in damage to property.
ENVIRONMENT!
This combination of symbol and signal word indicates potential dangers
to the environment.
This symbol highlights useful tips and recommendations as well as infor-
mation designed to ensure efficient and smooth operation.
2.2 Applicable documents
In addition to this manual, also observe the documentation of the other components and
machines used, as well as operator-specific requirements:
nOperating instruction for the industrial truck
nOperating instruction for the mounted fork carrier
Safety instruc-
tions
Tips and rec-
ommenda-
tions
Safety
Applicable documents
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X
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nOperating instructions for the operator
nOperating manual for the display units used (monitors, displays)
nOperating manual for the mast connector used (e.g. mast cable)
2.3 Intended use
The SmartFork® is intended exclusively for the transport of loads in potentially explosive
atmospheres. The use of the assistance system serves merely to assist the driver when
lifting, transporting and setting down loads. It does not in any way replace the safety obli-
gation and duty of care when handling the SmartFork® nor does it provide protection
against incorrect use. The SmartFork® may only be used on approved industrial trucks
with compatible fork carriers in the potentially explosive atmospheres approved for the
carrier vehicle.
The use of the SmartFork® outside explosion-proof areas is permitted.
Safety
Intended use
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 13

WARNING!
Risk of injury from incorrect use!
Incorrect use of the SmartFork® can lead to life-threatening situations
(e.g. ignition of flammable substances in an explosive atmosphere) and
serious injuries.
– Never use the SmartFork® in a potentially explosive atmosphere if
said atmosphere is not stated on the safety marking.
– Prior to use, always ensure that the SmartFork® is undamaged and
carries no electric charge (equipotential bonding intact).
– Never neglect the general requirements for safety and due diligence. If
in doubt, personally ensure that there are no people or obstacles in the
danger zone of the industrial truck.
– Never install the SmartFork® on a fork carrier that is incompatible with
the Ex zone fork arm supplied. Observe the relevant operating instruc-
tion for the fork carrier installed on the industrial truck.
– Never use the SmartFork® at temperatures outside the temperature
range of -20 °C to +50 °C.
– Never use load carriers made of sparking material.
– Never use the SmartFork® if it is dirty, greasy or covered in ice.
– Never use the SmartFork® as a reversible fork arm.
– Never use the SmartFork® for demolition work.
– Never use the SmartFork® on a rotary device or pallet handler.
– Never use the SmartFork® to lift or transport living creatures, espe-
cially people. Transport in so-called workman baskets in conjunction
with the SmartFork® is also not permitted.
– Never perform assembly or disassembly of the SmartFork® inside
potentially explosive atmospheres.
– Never allow insufficiently qualified persons to carry out maintenance or
troubleshooting work.
– Never skip a maintenance interval.
– Never independently modify the SmartFork®.
– Never use the SmartFork® without the locking device engaged.
– Never operate the SmartFork® without safety markings.
– Never allow unauthorised persons access to the industrial truck.
Incorrect use
of a general
nature
Safety
Intended use
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X
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WARNING!
Risk of injury when lifting and setting down the load!
Incorrect use of the SmartFork® when lifting and setting down the load
can lead to life-threatening situations (e.g. ignition of flammable sub-
stances in an explosive atmosphere) and serious injuries.
– Never exceed the maximum load capacity of both SmartForks® used.
– Contact between the SmartFork® and objects other than the load or
load carrier (pallet) is not permitted.
– When driving in and out of the load carrier and for movements through
which the SmartFork® could come in contact with the ground, never
move faster than 0.8 m/s in order to prevent frictional heat being an
ignition source.
– Never pick up loads using only the tip area of the SmartFork®.
– Never subject the SmartFork® to lateral forces. It is not permitted to
drive into or out of the pallet/load at an angle, or to push the pallet/load
from the side.
– Never drop loads onto the SmartFork®.
– Never use the SmartForks® separately or load them unequally.
WARNING!
Risk of injury when transporting loads!
Incorrect use of the SmartFork® when transporting loads can lead to life-
threatening situations (e.g. ignition of flammable substances in an explo-
sive atmosphere) and serious injuries.
– Never allow the SmartFork® to scrape along the ground during trans-
port. Drive mode with the fork arms lowered as far as the ground is for-
bidden. Anticipate the lowering and bending of the SmartFork® when
loaded and position the fork arms at the appropriate height during
transport.
– Only use the SmartFork® for road transport with an approved warning
system (e.g. warning bars) as per the road traffic regulations (when
unloaded).
– Always use suitable intermediate layers when transporting sparking
materials without a load carrier.
– Never transport molten materials.
Risk of injury
during lifting
and setting
down
Risk of injury
during trans-
port
Safety
Intended use
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 15

WARNING!
Incorrect use of the assistance systems!
Incorrect use of the SmartFork® FrontCam can lead to life-threatening
situations (e.g. harm to persons) and serious injuries.
– Never use the assistance system as the sole image source for
assessing danger zones. If in doubt, personally ensure that there are
no people or obstacles in the danger zone of the industrial truck.
– Never use the assistance system if the flameproof enclosure is dam-
aged.
– Never use the assistance system in insufficiently illuminated areas or if
visibility is reduced due to mist or dusts.
– Never use the assistance system at temperatures outside the tem-
perature range of -20 °C to +50 °C.
– Never use the assistance system if the polycarbonate lens is dirty,
greasy or covered in ice.
2.4 Operator obligations
The operator is the person who operates the SmartFork® on an industrial truck for indus-
trial or commercial purposes, or who delegates use to a third party and bears the legal
product responsibility during operation for the protection of personnel or third parties.
The SmartFork® is used in the commercial sector. The operator of the SmartFork® is
therefore subject to the legal requirements for occupational safety.
In particular, the following applies:
nThe operator must be aware of the applicable health and safety regulations and in a
risk assessment must determine any additional dangers that could arise from the par-
ticular working conditions at the operation site of the SmartFork®. These must be out-
lined in the form of operating instructions for operation of the SmartFork®.
nThe operator must ensure over the entire operating time that the operating instructions
created by him/her correspond to the current state of the rules and regulations, and
adjust them if necessary.
nThe operator must clearly regulate and specify the responsibilities for assembly, opera-
tion, troubleshooting, maintenance and cleaning.
nThe operator must ensure that all persons that come into contact with the SmartFork®
have read and understood this manual. In addition, he/she must regularly train per-
sonnel and inform them of any dangers.
nThe operator must provide personnel with the required protective equipment and
instruct them that wearing the required protective equipment is mandatory.
In addition, the operator is responsible for ensuring that the SmartFork® is always in a
technically perfect condition. The following therefore applies:
nThe operator of the overall system (industrial truck) must prevent excessive current
consumption (fault current) by means of suitable technical devices.
nThe operator must ensure that the maintenance intervals described in this manual are
adhered to.
Incorrect use
of the assis-
tance system
Operator
Operator obli-
gations
Safety
Operator obligations
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X
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nThe operator must regularly have all safety devices checked for functionality and integ-
rity.
nThe operator must ensure that the polycarbonate lens of the SmartFork® FrontCam is
not exposed to direct sunlight for a prolonged period of time.
2.5 Dangers when handling the SmartFork®
DANGER!
Risk of injury from ignition due to electrostatic discharge!
Friction during e.g. assembly and disassembly or due to the SmartFork®
scraping against the load or ground can lead to electrostatic discharge
and therefore to potential differences. Significant potential differences can
result in dielectric breakdown and discharge as short, high electric cur-
rent. In this regard, there is a danger of flammable substances being
ignited in potentially explosive atmospheres. This could have fatal conse-
quences under certain circumstances.
– Always discharge your own electrostatic charge before touching any
components.
– Always provide equipotential bonding to dissipate the electrical energy
Ä “Establishing equipotential bonding” on page 32.
– Always perform assembly and disassembly of the SmartFork® outside
of Ex zones.
– Always avoid contact with the ground during all movements of the
SmartFork® (driving in/out, manoeuvring and transport). Drive mode
with the fork arms lowered as far as the ground is forbidden. Anticipate
the lowering and bending of the SmartFork® when loaded and position
the fork arms at the appropriate height during transport.
– Prevent friction between the SmartFork® and load at all times.
– Never subject the SmartFork® to lateral forces. It is not permitted to
drive into or out of the pallet/load at an angle, or to push the pallet/load
from the side.
– Fix all cables and cable guides in place adequately to prevent uninten-
tional movement and static charge.
Electrostatic
discharge
Safety
Dangers when handling the SmartFork®
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 17

DANGER!
Risk of injury from ignition due to hot surfaces!
Friction or the SmartFork® scraping against the load or ground, but also
the electrical devices installed (camera), can give rise to the formation of
(frictional) heat. In this regard, there is a danger of flammable substances
being ignited in potentially explosive atmospheres. This could have fatal
consequences under certain circumstances.
– Restrict the intake current for electrical components by means of tech-
nical devices.
– Always avoid contact with the ground during all movements of the
SmartFork® (driving in/out, manoeuvring and transport). Drive mode
with the fork arms lowered as far as the ground is forbidden. Anticipate
the lowering and bending of the SmartFork® when loaded and position
the fork arms at the appropriate height during transport.
– When driving in and out of the load carrier and for movements through
which the SmartFork® could come in contact with the ground, never
move faster than 0.8 m/s in order to prevent frictional heat being an
ignition source.
– Prevent friction between the SmartFork® and load at all times.
– Always pick up and set down the load slowly and carefully.
DANGER!
Risk of injury from ignition due to spark formation!
Mechanical sparking or sparking due to a short-circuit can lead to the
ignition of flammable substances in potentially explosive atmospheres
with fatal consequences under certain circumstances.
– Always avoid contact with the ground during all movements of the
SmartFork® (driving in/out, manoeuvring and transport). Drive mode
with the fork arms lowered as far as the ground is forbidden. Anticipate
the lowering and bending of the SmartFork® when loaded and position
the fork arms at the appropriate height during transport.
– Always perform assembly and disassembly of the SmartFork® outside
of Ex zones.
– Always avoid bumping into objects in drive mode. Always pick up and
set down the load slowly and carefully.
– Prevent friction between the SmartFork® and load at all times.
– Check the camera connection lead for cable damage daily and check
that the plug connection is secure.
Hot surfaces
Spark forma-
tion
Safety
Dangers when handling the SmartFork®
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DANGER!
Risk of injury from ignition due to components coming loose inde-
pendently!
If screw and plug connections (e.g. due to vibrations) come loose inde-
pendently, this can lead to failure of the assistance system and to the for-
mation of an ignition source. In potentially explosive atmospheres, this
can result in serious injuries or even death.
Observe the following points at all times:
– Regularly check the functionality of the lock to ensure there is no unin-
tentional loosening of the plug GHG57.
– Perform a daily visual inspection of the plug connection to ensure it is
secure and free of damage.
– Perform a daily visual inspection of the screw connections to ensure
they are secure.
– Use threadlocker (e.g. Loctite®) to secure the screw connections
against unintentional loosening.
WARNING!
Risk of injury from improper cabling!
Improperly laid cable connections between the power source and the
SmartFork® could be damaged by mechanical influences such as ten-
sion, friction or becoming jammed. Defective cables could cause short
circuits and electronic malfunctions, system failures or cable fires. In
potentially explosive atmospheres, this can result in serious injuries or
even death.
– Electrical connections and cable connections may only be carried out
by an electrician.
– Ensure that the plug connection at the fork head is ATEX-compliant.
– Always lay the cables with enough play (e.g. loops) to avoid mechan-
ical abrasion and loosening.
– Protect the cable connections from damage (Do not guide cables over
sharp edges, always secure the cable routing).
– Adhere to the prescribed maintenance intervals.
Loose compo-
nents
Improper
cable connec-
tion
Safety
Dangers when handling the SmartFork®
EN
SmartFork® FrontCam ATEX for use in the Ex zone - BVS 20 ATEX E 108 X 19

WARNING!
Danger to life from obstructed view!
People and objects under or in front of the raised load are not detected
depending on the position of the SmartFork®. If people or objects in the
danger zone are not detected, there is a risk of serious accidents.
– The SmartFork® is only an assistance system. Always adhere to the
general requirements for safety and due diligence.
– Ensure that there are no people or objects in the danger zone of the
industrial truck.
– If the situation in the transport area is not visible, get out and carry out
a visual inspection or refer to someone who can guide and assist you.
WARNING!
Risk of injury from incorrectly executed work on the SmartFork®!
The load capacity of the SmartFork® depends significantly on a com-
pletely intact structure. Unauthorised modifications such as boreholes for
add-ons, welding work etc. could compromise the load capacity of the
SmartFork® and result in serious accidents from falling loads.
– Never carry out modifications (e.g. boreholes, welding work) on the
SmartFork®.
WARNING!
Risk of injury from tipping or slipping load!
Incorrect lifting of loads could cause the load to tip or slip, ignite due to
spark formation and cause serious injuries.
– Space the fork arms equally from the middle of the vehicle and lock
them in position.
– Take hold of the load with the SmartFork® as far from its centre as
possible.
– Raise the load using its entire length and distribute it evenly on both
SmartForks®.
WARNING!
Risk of injury from slipping load!
If there is moisture, dirt or ice on the lifting surfaces of the SmartFork®,
there is an increased risk of the load slipping. A slipping load could lead
to ignition due to spark formation and cause serious injuries.
– Remove any dirt from the SmartFork® before lifting the load.
– In wet, snowy or icy conditions etc., secure the load with e.g. tension
belts.
General
requirement
for safety
Unauthorised
modification
Incorrect fork
arm spacing
Moisture and
dirt
Safety
Dangers when handling the SmartFork®
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