User Manual - Fork Alert
Contents
1. Generally the height of the roof of a forklift is approximately 2m 6 8 and recommendations for mounting the IR receivers are based on this height If the IR Transmitter is fitted to the roof of a forklift with a height significantly greater or smaller than 2m 6 8 adjust the heights accordingly or contact Global 7 Group for further recommendations The IR receiver can be mounted above or beside doorways from a height starting at 2 8m 9 11 through to 4 8m 15 9 Figure 3 3 IR BEACON lf there is a need for the receiver to be mounted at the rear of the forklift and the driver s body and head will occlude the transmitter signal there may be a need to relocate the receivers to guarantee detection of the forklift Ideally more than one receiver should be used per zone to provide alternate angles and thus increase the likelihood of detection Figure 3 4 IR RECEIVER Page 9 of 28 Fork Alert System 3 6 INTERNAL TIMER FUNCTION AND ADJUSTMENT Introduction to the Receiver Timer Function From Version 5 receivers are incorporated with an internal trim potentiometer for adjustment of the on time for the one shot output timer included in the receiver circuitry In earlier versions of Fork Alert this timing function was included in the Zone Controller using adjustable timer relays for each zone The current system uses the receiver timer function instead to perform the same function with no timers required i2. on Test the operation of the system and check that the timing delay for the respective receiver zone is correct Remove the out of service sign s and advise the appropriate site personnel that the system is operational INTERNAL RECEIVER DETECTION RANGE ADJUSTMENT Warning This adjustment should only be undertaken by competent technicians authorised to maintain the Fork Alert system and who have adequate knowledge of the system and this manual to undertake this work safely This adjustment requires that 24V DC power normally supplied via cable from the controller or from another appropriate test source to the receiver is maintained during the receiver adjustment procedure Incorrect adjustment and testing of the detection range may cause the system to not detect the presence of a transmitter correctly and therefore all care shall be taken to ensure that these adjustments are made and confirmed correctly Figure 3 6 Range Adjustment VR1 VR2 Page 11 of 28 Fork Alert System Referring to figure 3 6 Follow all local site procedures In this case 24V power from the controller to the receiver will need to be maintained e Carefully remove the 6 receiver face plate retaining screws being fully aware that the receiver is still energised by 24V from the controller through the connecting cable Do not twist or pull on the internal cable connector or short the terminals to the case etc Locate a powered tr
3. critical locations It is the responsibility of users to decide what level of safety redundancy is required for any hazard zone These increased redundancy features include system enhancements such as battery based uninterruptible power supplies to overcome mains supply failure the use of dual receivers dual beacons and dual warning lights in critical locations etc Please discuss these options with Global 7 Group or your local distributor It is the client s responsibility to Ensure that the system configuration and level of redundancy installed is appropriate for the application This includes the possible consideration of 2 or more transmitters per plant item 2 or more chained receivers in a zone an uninterruptible power supply for the zone controller and warning lights the use of dual warning lights etc Ensure that any system is inspected for proper operation regularly as well as continuously monitored by forklift operators and any malfunctions are picked up quickly and rectified properly Be fully aware that the output warning light globe has a finite life typically 2000 hours and that regular inspection procedures and globe replacement preventative maintenance is required Global 7 Group recommends the use of two red warning lights in all installations so that if one globe fails in operation the other will still provide a warning signal until the blown globe is replaced An out of service sign must be placed on the la
4. delay Relay Output selection switch Normally Open NO Normally Closed NC Detection range adjustment 3 3 SPECIFICATIONS POWER CONSUMPTION No load SIZE 130W x 175H x 130D mm 5 4 W x 6 11 H x5 4 D inch OPERATING TEMPERATURE SENSITIVITY Nominal detection range 0 10m 0 33 Peak Wavelength Ap 870nm Nominal Detection Angle Orx 75 Page 7 of 28 Fork Alert System 3 4 ELECTRICAL INSTALLATION Installation of the receiver is performed by following these steps 1 Mount the Receiver case at a recommended height ii Connect the power supply and relay contacts to the Zone Controller or Door Controller lil Check that the power supply is powering the Receiver iv Stimulate receiver with a Fork Alert coded infrared and check for the relay output to switch v Check range of detection with a coded infrared source The following diagram illustrates the electrical connections to the Receiver Figure 3 1 NOTES e CABLE TYPE 4 CORE SHIELDED 16 0 20 S2352 HCG304 OV AND SHIELDING WIRE ARE CONNECTED TOGETHER BOOT LACED TOGETHER jenn 4 WAY PHOENIX CONNECTOR BRASS SHIELD RECEIVER CABLE INTERNAL CONNECTOR WIRING 3 9 PHYSICAL INSTALLATION The Receiver is mounted around the doorway or area of required detection aimed at the typical approach path of a forklift An illustration of this is shown below Figure 3 2 Page 8 of 28 Fork Alert System
5. existing door automation system Will it only work for vehicles fitted with your transmitter beacon Yes it acts as a low level security system in that automated doors will not open for a vehicle without an Global 7 Group transmitter fitted Page 23 of 28 Fork Alert System Appendix 1 Spares env Dou te FA RBB 9 1 ForkAlert Transmitter Beacon Blue For Gas Petrol Forklifts 12VDC 24VDC FA RBB 6 1 For Electric Forklifts 36VDC 48VDC FA MBB 6 1 Magnetic Base for Transmitter beacon ForkAlert Receivers Includes multi angle mount FA HHA 32 1 Hand Held Activator FA PFS 31 1 LED Pictorial Forklift Sign Steel enclosure FA PFS 31 2 240V version FA MSC 22 1 Message Sign CORFLUTE FA MSC 22 1 Message Signs POLY FA WLR 1 7 1 Warning Light Red High intensity 240V rotating beacon FA WLA 17 2 Amber FA WLG 17 3 green FA WSR 18 1 Roshni Siren 240VAC User Programmable Tones Volume Control S2789 Halogen Globe for Warning Light FA BBAS 40 1 Replacement base kit for Beacon note replacement of base unit requires some soldering FAS BLTF 33 1 Replacement Belts for Transmitter Beacon FLAT FAS BLTR 34 1 Replacement Belts for Transmitter Beacon ROUND older models Page 24 of 28 Fork Alert System APPENDIX 2 LIMITATIONS AND CONDITIONS OF SALE Global 7 Group supplies this equipment on the sole basis that the user fully understands that it is intended to supplement ra
6. hazardous gas or dust area where gas or dust area where there is an explosion hazard Note General advice or assistance in determining equipment locations or configurations given by Global 7 Group staff is of a general nature only and intended to assist users to locate the items of equipment for satisfactory technical operation This does not and is not in any way whatsoever intended to imply that Global 7 Group accepts responsibility for the final layout or effectiveness of the installation for any or all operational conditions Page 26 of 28 Fork Alert System APPENDIX 3 SIGN OFF SHEET FORK ALERT CUSTOMER SIGN OFF SHEET Customer Original Global 7 Group Job No Installed Address Customer Position contact name Areas Being installed Date No of No of No of Customer Name Description Installed Controllers Receivers warning Initials No of Transmitters Total No of Forklifts installed by this equipped with installer Transmitters in this site The customer endorses that they have inspected the installation and tested the operation of the Fork Alert system in all areas The customer also endorses that work carried out is to the standard required and covers the areas or zones stated above to the customers satisfaction Further modifications to the system after this date other than under warranty conditions will be subject to charges Customer contact Customer name Sign off Fork Alert System Fo
7. installer must supply cable glands conduit and other mounting accessories and install as per wiring standards All holes must be de burred and affixed with glands and conduit fittings for the mains entry and the switched mains cabling exits to the warning systems Glands and conduit fittings should be sized for a minimum of 14mm 2 diameter cable and a minimum of 16mm conduit fittings The cable entry and exit locations must be made in the lower face of the enclosure in the designated zone as shown in the following diagram Care must be taken to ensure no damage occurs to the circuit board or components during drilling of gland and conduit holes af an 30mm All holes must be within white region Conduit mounting holes should be on dashed centre line Figure 4 5 Conduit entry and exit holes must be drilled to be on the centreline shown and the holes must entirely lie within the rectangle Note that the allowable drilling rectangle does not extend to the left hand end as far as there is an internal bracket welded on the inner face Page 17 of 28 Fork Alert System 5 MAINTENANCE 5 1 MAINTENANCE OVERVIEW Regular monthly inspections should be made of all external plant and equipment to ensure they are not physically damaged or covered with dirt and grime Office based equipment should be inspected at least every 3 months 5 2 TRANSMITTER The transmitter must be powered down before any internal maintenanc
8. the set maximum range setting Conduct a final check of the receiver plug fully inserted into the socket and the receiver case earthing connector correctly fitted to the spade lug welded to the lower receiver case Carefully replace the receiver and face plate assembly into the lower receiver case and refit and tighten the six cover retaining screws e Ensure that the angle of the receiver is set correctly for that receiver location e Test the range setting is correct for that receiver by checking the maximum triggering range with the beacon from various angles e When correct operation of the system is confirmed re instate the system to service remove the out of service signs and advise the appropriate site personnel that the system is operational Page 12 of 28 Fork Alert System 4 ZONE CONTROLLER The Zone Controller is used primarily when the system is utilised as a warning system It is an isolated switching device combined with an onboard power supply When triggered by the receivers the Zone Controllers relays activate and switch mains voltages to screw terminal outputs within the enclosure These outputs are used to power warning systems such as alarms flashing lights etc 4 1 OPERATION The Zone Controller serves the following purposes e Supplies 24VDC to each external receiver e Contains 24VDC relay coil outputs switched by NO Normally Open contacts from the receivers When the receiver is po
9. FITS 1 7 EXAMPLE 2 TRANSMITTER 2 1 OPERATION 2 2 VERSIONS 2 3 SPECIFICATIONS 2 4 ELECTRICAL INSTALLATION 2 5 PHYSICAL INSTALLATION 3 RECEIVER 3 1 OPERATION 3 2 VERSION 3 3 SPECIFICATIONS 3 4 ELECTRICAL INSTALLATION 3 5 PHYSICAL INSTALLATION 3 6 INTERNAL TIMER FUNCTION AND ADJUSTMENT 3 7 INTERNAL RECEIVER DETECTION RANGE ADJUSTMENT 4 ZONE CONTROLLER 4 1 OPERATION 4 2 VERSIONS 4 3 SPECIFICATIONS 4 4 ELECTRICAL INSTALLATION 4 5 PHYSICAL INSTALLATION 5 MAINTENANCE 5 1 MAINTENANCE OVERVIEW 5 2 TRANSMITTER 5 3 RECEIVERS 5 4 ZONE CONTROLLER 8 PERIPHERALS 5 5 PART REPLACEMENT 5 6 TROUBLESHOOTING 5 7 OPERATIONAL AND MAINTENANCE PRECAUTIONS 5 8 SAFETY PRECAUTIONS 5 9 SYSTEM SIGN OFF 5 10 FORK ALERT FREQUENTLY ASKED QUESTIONS APPENDIX 1 SPARES APPENDIX 2 LIMITATIONS AND CONDITIONS OF SALE APPENDIX 3 SIGN OFF SHEET COCO NNN N DOUBS A CO CO ND Fork Alert System 1 INTRODUCTION Fork Alert is a Vehicle Proximity Detection System that utilises patented Sweepscan technology Its unique combination of the following features provides many benefits in comparison with alternative vehicle sensor technologies Wide 10metre 32 10 radius detection zone early triggering 360 omni directional triggering detection from any angle orientation e Specific triggering range accurate and consistent detection zone Definable detection zone controlling triggering to th
10. ForkAlert e Fork Alert System User Manual C CE Fork Alert System Copyright Global 7 Group Pty Ltd 2006 2014 All rights reserved Reproduction transfer distribution or storage of part or all of the contents in this document in any form without the prior written consent of Global 7 Group Pty Ltd is prohibited Fork Alert is a registered trademark of Imatek Group Pty Ltd Global 7 Group Pty Ltd is the exclusive worldwide manufacturer of Fork Alert systems Global 7 Group Pty Ltd operates a policy of continuous development Global 7 Group Pty Ltd reserves the right to make changes and improvements to any of the products described in this document without prior notice Global 7 Group Pty Ltd assumes no responsibility for any errors that may appear in this document nor does it make expressed or implied warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Global 7 Group Pty Ltd shall not be liable for incidental or consequential damages in connection with or arising out of the furnishing performance or use of this document and the material it describes The availability of particular accessories may vary by region Fork Alert System 1 INTRODUCTION 1 1 BASIC OPERATING PRINCIPLE 1 2 APPLICATION AUTOMATED PEDESTRIAN WARNING SYSTEM 1 3 BENEFITS 1 5 APPLICATIONS DOOR AUTOMATION 1 6 BENE
11. ansmitter beacon at a suitable height and at the maximum range that the receiver is to be set to away from the receiver Ensure that the beacon to be used to trigger the receiver has a clean lens and is in working order by testing it with other receivers If in any doubt use a new beacon e The Range is factory pre set to 10 meters increase from this range is not recommended Over range may result in false triggering and incorrect operation of the system If adjustment is necessary the range setting should be adjusted in the location that the device will be used in i e outdoors in daylight or indoors If a receiver range is set up for a particular range indoors and then the receiver is mounted outdoors the effective range may be less or vice versa Using a small bladed screwdriver carefully turn trimmer VR2 to your desired range setting as a rough guide 5 to 8 meters is a good choice e lf further adjustment is required use trimmer VR1 to fine tune your range Again using a small bladed screwdriver adjust the Variable Range Adjustment VR1 as shown in figure 3 6 to the point where the detection is just at the point of being on and off with slight movements of the adjustment When this point is determined move the adjustment ever so slightly further clockwise to ensure reliable triggering by the beacon at this maximum range The maximum triggering range is then set The receiver should trigger at all beacon distances equal to or less than
12. case mounting position remove the six cover screws on the receiver and lift the face plate and receiver module clear of the enclosure body Locate the timer adjustment pot with the receiver board oriented as shown above Do not disturb the two range adjustments to the right of the timer adjuster The timer is factory set to approximately 2 3 seconds Using a small screwdriver carefully adjust the timer to the desired delay holding the board as shown in the diagram anti clockwise is shorter on time clockwise is longer on time There are guide marks shown for 0 5 and 10 seconds maximum Do not adjust the timer to less than 1 second or the output warning device may respond directly to the pulse from the transmitter as it rotates In this case rather than being continuously on as required for the time the transmitter is in detection range the output device may pulse on and off during the detection time Carefully check that the green plug is fully inserted in its socket and that the earthing lead is connected to the spade terminal on the lower case Carefully refit the receiver board and face plate assembly back into the lower enclosure Refit and tighten the six cover retaining screws to ensure that dust and water can not enter the enclosure Check the receiver adjustable mount is in the correct position If the mount has been moved readjust and test the correct triggering operation of the receiver Switch the controller back to
13. d correctly through each zone Forklift operators should be instructed to take immediate action if any problems with the system 8 If the system is taken out of service or a malfunction identified a sign should be attached nearby immediately 9 Forklift drivers should be instructed to make the following checks daily during their shifts to ensure the Fork Alert system is functioning correctly e Range Check Ensure the transmitter and receivers have a consistent range of activation Although sunlight and synthetic light may marginally affect the detection range of the system any significant change in range should be reported to the appropriate maintenance department or Global 7 Group e Alarm Check Ensure that the alarms or doors are triggered every time a forklift approaches the receiver e Belt Check Ensure the Transmitters reflective mirror is rotating beneath the lens cover lf the mirror is not rotating the drive belt may need replacing Contact Global 7 Group or your nearest distributor for replacement belts Page 21 of 28 Fork Alert System 5 8 SAFETY PRECAUTIONS WARNING The Fork Alert transmitter is a Class 1 infrared emitter e The transmitter outputs a bright infrared rotating beam which is invisible to the human eye The infrared beam originates from six 6 solid state IRED emitters located in the transmitter turntable centre under the revolving mirror Under normal operating conditions t
14. driver e Improved security as the system is activated only from designated mobile plants preventing entry by unwanted vehicles e Environmentally friendly the system is energy efficient as it is only activated by the designated mobile plants not susceptible to false triggering by other movements e lt is site specific as the system is activated within a defined zone which eliminates false triggering from outside the zone A 10 metre 32 10 radius range provides early detection of the designated forklift allowing enough time for the door to open for the entering forklift Activated only by Global 7 Group coded transmitters ensuring the system is immune to radio frequency interference from drives motors etc The system is flexible and can be applied to indoor and or outdoor situations un affected by sunlight 1 7 EXAMPLE LEGEND IR RECEIVER RANGE INFRARED RECEIVER FORKLIFT AUTOMATIC DOOR TRANSMITTER PEDESTRIAN WALKWAY PEDESTRIAN Figure 1 3 Example Application to activate a door The site layout schematic in Figure 1 3 illustrates an automatic door that will open for designated forklifts but not for any pedestrians Typically the Receiver is mounted above the door to provide a wide detection zone that allow
15. e immediate environment Does not make use of Radio Frequency technology not subject to interference Indoor and outdoor functionality suitable to most environments Modular design for easy installation low cost low impact 1 1 BASIC OPERATING PRINCIPLE The principle of the Sweepscan technology is the remote detection of a coded infrared signal from a transmitter attached to a forklift or other vehicle The signal sensor called a Receiver has an accurately adjustable range and a wide detection zone which is easily configured for specific applications The Transmitter which is designed for most types of forklifts or other vehicle transmits the invisible signal 360 around the forklift or other vehicle ensuring that the forklift or other vehicle will be detected regardless of its orientation or direction relative to any Receiver Figure 1 1 Basic Operating Principle otating IR Signal TRANSMITTER Beacon RECEIVER sensor 1 2 APPLICATION AUTOMATED PEDESTRIAN WARNING SYSTEM The Fork Alert system s major application is to warn pedestrians of the presence of forklifts or other vehicle It can be used to supplement existing safety measures by providing an additional automatic warning for pedestrians when a piece of mobile plant i e forklift is within a specified location For example where a machine might be approaching a doorway or blind corner and is obscured from the pedestrian s view Global 7 Group off
16. e work is performed on it e g lens removal for belt replacement Maintenance shall be carried out by suitably trained personnel and care shall be exercised to avoid staring into the LED emitters when the cover or mirror is removed Despite their output being invisible the six infrared emitting diodes shall be regarded for added safety during maintenance as being a high intensity light source The transmitter belt should be inspected at 3 monthly intervals If it shows signs of deterioration cracking wear etc it should be replaced with a new one 5 3 RECEIVERS The optical windows on the Receivers should be clean and not have a build up of dust and grime Clean using a water based detergent and wash and dry off A visual inspection of all seals and gland entries should show no signs of deterioration or moisture entry Replace as required 5 4 ZONE CONTROLLER 8 PERIPHERALS The standard warning light globe in the red warning light has a rated life of 2000 hours of operation A periodic replacement schedule should be worked out on the basis of typical usage versus globe life and implemented on site The use of two warning lights operating in parallel is highly recommended to provide redundancy until maintenance is performed The use of non water based chemical washes may adversely affect equipment enclosures If in doubt about compatibility please contact Global 7 Group 5 5 PART REPLACEMENT In the event of component failure or t
17. ers additional components for this application These include e A Zone Controller to power the Receivers and switch mains power to wiring devices and e Warning Devices such as warning lights and audible alarms Page 1 of 28 Fork Alert System 1 3 BENEFITS Benefits of the Fork Alert system for warning pedestrians include Improves Occupational Health and Safety through earlier and more visible notification to pedestrians of approaching vehicles Supplements normal driver warnings with automatic early warning systems around blind corners through doorways etc e Visible warning systems overcome the problems associated with noisy factories or busy warehouses Reduces the risk of pedestrian death or injury Reduces the likelihood of operations being disrupted by an accident Predictable range and coverage that can extend as far as necessary through a chained receiver system e Line of sight characteristics of infrared allowing system to adapt to specific site layout e Range remains unaffected by nearby metal plant or equipment unlike radio frequency systems provided the infrared beams have line of sight Straightforward and quick to install by any authorized electrical contractor Modular for future expansion Note Global 7 Group Pty Ltd supplies the Fork Alert system on the sole basis that the user fully understands it is intended to supplement rather than replace industry safety procedures and reg
18. h another zone to determine if this is the case Zone Controller red LED is not lit Check there is mains power to the Zone Controller Remove Zone Controller cover and check circuit breaker isolate power and check output fuses Check the 1A fuse in the top RH corner of the Zone Controller Ifa multimeter is available check that there is 24V across this fuse Page 19 of 28 Fork Alert System SYMPTOM ACTION System does not operate at The system is designed to operate outdoors at around 10m 32 10 expected range and indoors at around 15m 49 3 ft lf range is too short check the potentiometer in the receiver removal of front cover is necessary and adjust clockwise as necessary NOTE if wound too far it may cause unwanted triggering due to sunlight interference Check that the Transmitter beacons are operating at two revolutions per second and that the lens and mirror are clean Check that the receiver is still pointing in the appropriate direction and is not misaligned Output device warning light is Check each receiver within that zone and ensure that the cable to it activating without forklift in area has not been damaged Check each Receiver to see if the Red LED indicates it has power lf more than one receiver connected to each zone check the wiring IS correct Check Jumper settings If necessary remove additional receivers and have only one connected to determine if this is the problem i Ensure that the potent
19. he transmitter outputs a rotating fan shaped beam in the direction of the polished mirror surface as it rotates If this output was visible it would appear as a brief flash each time the polished mirror surface passes the viewing point e The transmitter output is classified as Class 1 non hazardous optically safe under all normal viewing conditions according to AS NZS 2211 1 1997 compatible with IEC 825 1 1993 e Internal maintenance of the transmitter such as belt replacement shall only be conducted when the transmitter is de energised so that the infrared source is first shut down e Under no circumstances shall any maintenance or other personnel be permitted to stare into the mirror face if it is stationary or into the IRED emitters at close range with the mirror removed Maintenance shall only be carried out by suitably trained personnel who are aware of these requirements Warning it is not possible to tell if the IRED emitters are on or off by simply looking at them They do not emit any visible indication at all that they are on WARNING Hazardous voltages are present in parts of this equipment e Incorrect installation or repair methods can cause injury or death e Only properly trained technical staff should install and maintain this equipment e Never work on energised equipment unless properly trained and authorised by a responsible authority e Do not attempt to adjust or repair mains powered equ
20. her malfunction incorrect operation will result Page 4 of 28 Fork Alert System 2 3 SPECIFICATIONS DESCRIPTION SPECIFICATION INPUT DC12 24V or DC36 48V check transmitter label OUTPUT Infrared Emission Peak Wavelength A 870nm Nominal Output Angle 6tx 15 to 45 OPTICAL SAFETY Class 1 Non hazardous infrared emitter according to AS NZS 2211 1 1997 compatible with IEC 825 1 Observe recommended precautions during maintenance with covers removed Do not stare into the infrared emitters or stationary mirror CURRENT Approximately 0 25A SIZE 130Wx175Hx130D mm 5 4 W x 6 11 H x5 4 D inch WEIGHT 500g 1lbs 20z OPERATING 0 to 45 Celsius 82 to 113 F TEMPERATURE STORAGE 0 to 45 Celsius 82 to 113 F TEMPERATURE 2 4 ELECTRICAL INSTALLATION First confirm that you have a transmitter of the correct voltage rating for the particular forklift that it is to be fitted to Typically gas petrol forklifts require a 12 24V DC transmitter and electric forklifts a 36 48V DC transmitter However this may vary and must be confirmed before installation Secondly confirm that the particular forklift is not used in designated hazardous areas where there is a requirement for approved electrical equipment for explosive atmospheres Do not fit the Fork Alert transmitter to this type of forklift as the Fork Alert system has not been approved for use in explosive areas requiring specially tested and ap
21. important differences compared to the older version 4 3 SPECIFICATIONS DESCRIPTION SPECIFICATIONS INPUT AC 100 240V 47 63Hz OUTPUT DC24V 0 625A to power receivers only AC 100 240V 47 63Hz 3A for powering warning lights sirens etc POWER CONSUMPTION No lt 1W Load SIZE 200 x 300 x 100 mm 7 10 x 11 10 x 311 inch WEIGHT 4 0 kg 8lb130z INGRESS PROTECTION IP 64 HOSE PROOF OPERATING TEMPERATURE 0 to 45 Celsius 32 to 113 F Page 13 of 28 Fork Alert System STORAGE TEMPERATURE 15 to 60 Celsius 5 to 108 F 4 4 ELECTRICAL INSTALLATION The Zone Controller requires a 100VAC 240VAC mains supply which powers an internal 24VDC power supply for the IR receivers The zone controller also contains relays that switch the 100 VAC 240VAC in order to power the external sirens and beacons The maximum current ratings for these outputs are as follows 100 240V AC maximum total output current 3A 24 V DC absolute maximum total output current 0 625A Note that each external receiver draws 0 072A 72 mA The maximum number of receivers that should be driven by this controller is six 6 The total current draw from the 24V output for 6 receivers is 6 x 0 072 0 432 A Receivers can be daisy chained without the need for cable to run from each receiver back to the controller This is simply a matter of connecting the receiver supply lines in parallel and the relay li
22. in the zone controller matching that particular zone is on prior to the forklift being in the area The LED should then flicker off when the forklift is detected Remove Zone Controller Lid to do this lf the output device is a warning light check that the globe is not blown Check the fuses adjacent to the relays in the zone controller and replace if blown Remove Zone Controller Lid to do this No LED S are lit on the receiver Check to see if the Zone Controller has power Red LED on front should be lit Check the wiring within the Zone Controller lf more than one receiver is connected to that zone check that the jumper JP is removed for the specific zone Removal of one of the receivers from the terminal block may help to debug the problem Check that the Red LED within the Zone Controller matching that particular zone is on prior to the forklift being in the area The LED should then flicker off when the forklift is detected Both LED s on the receiver are lit Check that the receiver input cable wires are in the correct or flickering without the Forklift sequence in the 4 pin phoenix connector Reversing of the order of being nearby these wires causes this symptom Also check that the correct jumper setting within the Zone Controller matches the configuration of receivers le Jumper removed if more than one receiver connected to a zone There is a very remote possibility that the Jumper connector is damaged Swap it wit
23. iometer within the Receiver is not wound to maximum and the receiver is not outdoors Ensure receiver and Zone Controller are properly grounded as per installation manual From Version 7 receiver Ensure receiver Output Select switch is set to Normally Close NC 5 7 OPERATIONAL AND MAINTENANCE PRECAUTIONS The following operational and maintenance precautions as well as the limitations and Conditions of Sale in Appendix 2 must be followed 1 Electrical safety warning for the mains powered Zone Controller and warning systems e The appliance is not intended for use by young children or infirm persons without supervision e Young children should be supervised to ensure they do not play with the appliance e Where the Zone Controller is powered through a flexible supply cord the Zone Controller is classified as having a Type Y attachment according to AS NZS 3350 1 2002 IEC60335 1 1991 MOD If the power supply cord becomes damaged it must be replaced by the manufacturer the manufacturer s service agent or a similarly qualified person in order to avoid a hazard 2 The infrared transmitter is a Class 1 non hazardous infrared emitter according to AS NZS 2211 1 1997 compatible with IEC 825 1 1993 It is considered eye safe when viewed under all normal operating conditions however the following maintenance instructions must be observed e The transmitter emits a bright infrared rotating beam that is invisible to the human eye I
24. ipment while it is powered if you are alone e It is essential to have a trained person present who can render immediate aid in case of an accident WARNING Before turning off the Fork Alert system warn all pedestrians that the system is not in service 5 9 SYSTEM SIGN OFF Each system must be signed off by a responsible person from the organisation having the Fork Alert system installed The attached sheet appendix 3 can be used extra copies can be made to identify the areas and system specifications and signed off as appropriate Any changes made to the system that differ from the initial installation should have an accompanying sign off form completed and or should be checked by the appropriate Global 7 Group representative Page 22 of 28 Fork Alert System 5 10 FORK ALERT FREQUENTLY ASKED QUESTIONS Can the Fork Alert system cover greater distance than the nominal 10m 33tt Yes the receivers can be chained to give greater coverage i e three receivers could be placed down a corridor to give 30m 98 4ft coverage Can the Fork Alert system be adjusted to cover less distance Yes the receiver s sensitivity can be wound down to shorter distances via a potentiometer in the receiver Who installs the Fork Alert system Electricians can install the system Global 7 Group provides the installation instructions or Global 7 Group can arrange the installation if you prefer Who installs the Infrared Transmitter
25. lable with magnetic base mount pole mount or screw mount Transmitter shape and profile may vary between models Figure 2 3 Beacon Mounting Screw Mount ET The belt drive that rotates the transmitter mirror must be set according to the supply voltage as per the following diagram Always turn the transmitter off before changing the belt or belt settings Figure 2 4 12 36 48 V DC Page 6 of 28 Fork Alert System 3 RECEIVER 3 1 OPERATION Receivers are mounted in strategic positions i e doorways throughout the factory warehouse and detect the presence of the coded Infrared beam from the forklift Transmitter They are connected to either a Zone Controller which converts the forklift sense trigger from the receiver into a suitable output to drive sirens alarms and other warning devices or a Door Controller which triggers the opening and closing of a door The receiver is designed in such a way that the output from the receiver is fail safe That is in the event of power being removed from the receiver receiver failure or cable damage the unit will report the presence of a forklift 3 2 VERSION The Receiver described in this manual is the current production version which is identifiable by its black colour The previous Receivers were white The main additional features of this Receiver are e Internal timer for the off
26. mp immediately if Page 25 of 28 Fork Alert System the Fork Alert system is not operating for any reason Ensure that the warning light operating voltage matches the Zone Controller supply voltage Put in place procedures to continuously ensure that all vehicles that will travel through every Fork Alert detection zone on the site will be equipped with a Fork Alert transmitter beacon This is required to enable each vehicle to trigger the alarms Unequipped vehicles will not sound the warning alarm and therefore whenever it is required that an unequipped vehicle pass through the zone adequate alternative safety precautions must be taken to adequately warn pedestrians of the hazard Warning Unless the detection zone is extended by using extra receivers spaced further out refer below the standard one receiver Fork Alert system is designed for use with mobile plant moving at less than 10 kmph 6 21mph This upper limit is recommended based on the distance that the forklift will travel during one complete rotation of the emitter beam mirror As the beacon mirror rotates at approximately 100 rom 1 7 revs per second then if the mobile plant item eg forklift is moving at 10 kmph 6 21mph it can theoretically move 1 6m 5 25ft the extreme case is the time the plant moves during one full mirror rotation time into the 15m 49 2ft detection zone before the alarm is triggered If the distance the plant can move into the detection zone with o
27. n the current version of the Zone Controller PCB Version 1 The receiver typically receives short pulses of modulated infrared signal from a rotating Fork Alert transmitter beacon as it rotates The one shot timer function has been included in the receiver circuitry to change these intermittent detections into a continuous output for a preset time The receiver incorporates an output signal relay which is factory default normally closed when there is a no detection condition This relay out is connected to and operates the respective Zone Controller zone relay via two wires in the 4 core shielded cable between the receiver and the Zone Controller From version 7 a switch is added to select relay output for Normally Close NC or Normally Open NO for Sweepscan Systems where a Zone Controller is not in use The other two wires of the 4 core cable supply 24V DC from the Zone Controller to power the receiver circuit The receiver timer adjustment sets the length of time that the respective Zone Controller zone relay and output warning device will be held in the detected or on condition If the timer is set to 3 seconds and the receiver detects a single brief pulse from the transmitter the output warning devices will operate for 3 seconds If the receiver timer is set to 3 or several seconds and the receiver detects the brief pulses from a rotating beacon which stays within range then the output warning devices will stay on continuously un
28. n the rear metal surface 1 2 3 lt is recommended that the Zone Controller be mounted as close as practicable to the Receivers to reduce the need for longer than necessary cable runs Choose a Suitable dry location where mains power is available or can be provided Ensure that the wall can adequately support the load and that there are no electrical or other cables in the wall at the positions that the mounting holes are to be drilled lf necessary remove or move the circuit breaker or circuit board assembly using a screwdriver or other appropriate tool Carefully release the DIN rail lock tabs holding the circuit breaker and board mount assembly from the DIN mounting rail and move these away from the mounting hole positions Carefully drill the required number of mounting holes in the rear of the case at the locations shown below Use the case as a marking template and mark the wall hole locations in the desired position Ensure that the case is true and level Page 16 of 28 Fork Alert System 7 Install the enclosure using the appropriate fasteners for the particular wall and tighten the screws 8 Re install the circuit breaker and circuit board assembly to the DIN rail by snapping them in Ensure that no swarf is on the boards or other components Clean any loose swarf material from inside the enclosure Figure 4 4 Mounting Hole Placement Guide 4x 7mm diameter spaced as shown gt 20mm T The
29. ne receiver before triggering the alarm is too great for any particular application then the plant upper speed limit in the area shall be reduced accordingly or the use of a chain of two or more detectors receivers be employed see below Note that the system alarm will be triggered rapidly once the emitter beam sweeps over the receiver and a timer in the Receiver will extend the alarm on time to several seconds even if the triggering beam sweeps over the receiver only once momentarily for milliseconds Note that if it is necessary to have a full 15m 49 2ft warning zone at any particular location where the forklifts are moving at higher speeds then two or more up to 6 as required receivers can be chained in series on one zone controller channel zone to extend the range of the detection zone In this case the additional receivers would be placed further away from the first receiver so that the detection zone is extended out and the plant is correspondingly detected earlier WARNING Do not use the Fork Alert system in hazardous gas or dust areas where special intrinsically safe or explosion protected electrical equipment is required to prevent a possible explosion The standard Fork Alert system is not certified for use in hazardous gas or hazardous dust areas where explosion protected or intrinsically safe equipment is required Do not use or allow the standard Fork Alert system to be used in any classified
30. nes in series However the Zone Controller is only capable of supplying a total of six receivers maximum NOTE Do not connect more than six Receivers to one Zone Controller Figure 4 1 Zone Controller Illustration oy oe 1A 2AG C0768 1 3 CH Mains Switching Zone Controller Y Y Amskan PANEL LED 24VDC 0 63A POWER SUPPLY LD ON No forklift LD OFF Forklift Detected JP ON 1 RX Per Zone JP OFF 2 RX Per Zone JP1 JP2 JP3 ZONE 1 ZONE 2 ZONE 3 C pW RXa RXb RXA RXB RXa RXb RXA RXB RXa RXb RXA RXB 424 OV 24 OV 24 OV 24 OV 24 OV 24 OV ZONE 1 ZONE2 ZONE3 A N A N A N AwN DODD DODO DOU ou AN Ar DOOD DODD DOD DDKDDKDD WT Page 14 of 28 Fork Alert System Please refer to Figure 4 1 Terminal A INPUT 100 250VAC ACTIVE Mains Input Terminal N INPUT N INPUT 100 250VAC NEUTRAL Mains 100 250VAC NEUTRAL Mains Input Terminal that has a wire link to the base iia n for earthing Not shown EARTH CHASSIS Terminal Supply to external Power On Status LED Can be set to output 24VDC or PANEL LED dropped via series resistor to operate a LED Default is to drive a 1 7V LED with 20mA Fuse Ft BA 2AG Fuse for Mains supply Receivers Please refer to figures 4 1 4 2 and 4 3 The following is for Zone 1 only onn PS OFF allows connection of an additional IR Receiver to Zone 1 LED LD1 Indica
31. o reduce system downtime Global 7 Group and its authorised distributors can supply selected components of the Fork Alert system The attached appendix lists part numbers and descriptions to assist the end user in selecting the right part Page 18 of 28 Fork Alert System 5 6 TROUBLESHOOTING The Global 7 Group Fork Alert System has been designed to be as rugged as possible Integral to this design is the low rate of equipment failure The following table illustrates the more common situations SYMPTOM ACTION Ensure the vehicle is fitted with a Fork Alert Transmitter beacon blue and that the Red LED is on and mirror is rotating at two revolutions per second Warning light Output device does not operate when forklift is within receiver zone i e within 10m Ensure the Transmitter beacon mounted on the vehicle is of the correct voltage for that vehicle l e 12 24 version for a 12 or 24V vehicle typically Internal Combustion and 36 48V version for 36 or 48V vehicle typically Battery Electric Other voltages will require a custom transmitter Determine that there is a clear line of sight from the transmitter to the receiver Ensure that the receiver has power Red LED is lit on front Check that the green LED on the receiver activates when the forklift is within range if it does there is most likely a problem in the output device or the connection to the zone controller Check that the relevant red LED with
32. ondition are disposed of properly and safely 3 The Zone Controller and attached cabling operate at mains voltage which is inherently dangerous and can cause serious injury or death if strict electrical safety precautions are not observed at all times The circuit board and wiring inside the Zone Controller enclosure carry mains voltages as well as 24VDC WARNING Isolate the power before performing any work on the Fork Alert system 4 Only competent staff having adequate knowledge of the Fork Alert system s proper operations should carry out maintenance and adjustment of the system 5 All vehicles expected to be operating in a Fork Alert zone must be fitted with a Fork Alert transmitter 6 Dust dirt grease paint etc must not be permitted to build up on the transmitter s lens or the front of the receivers The frequency of inspections and cleaning routines will vary depending on local conditions but a regular maintenance procedure should be established Always ensure materials pallets trucks or new installations do not obscure the beam path from the forklifts transmitter to the receiver s 7 Replace damaged system components immediately continuous monitoring program to rapidly detect and rectify system malfunctions that may prevent proper detection of a forklifts presence should be implemented when Fork Alert is commissioned Forklift drivers should be a core part of this program as they can readily check alarms are being triggere
33. proved electrical equipment for explosive atmospheres The Transmitter can be hard wired into the forklift s fuse box or plug directly into the cigarette lighter socket See Figure 2 2 for IR Transmitter Wiring Diagram Alternatively many users prefer to connect the transmitter so that it is un powered whenever the forklift park brake is applied i e the transmitter is only powered when the ignition is on and the park brake is off This type of connection prevents a Fork Alert alarm being generated if the forklift is parked temporarily with both the handbrake on and the ignition left on If this type of connection is used ensure that the switch is correctly adjusted so the forklift cannot be driven with the handbrake only partially on and the transmitter un powered Check with the forklift manufacturer or dealer to confirm the suitability of any installation Page 5 of 28 Fork Alert System WARNING If the transmitter is wired with reverse polarity the rotating mechanism will still spin but the red status light will not be on Do not operate the transmitter if wired incorrectly ensure that the red status light is on Battery optional handbrake switch connection shown disabled with handbrake on 2 5 PHYSICAL INSTALLATION The transmitter must be mounted on the roof of the forklift with no objects blocking the line of sight to the receiver This may require an extension pole for the transmitter The transmitter is avai
34. rkAlert e GLOBAL 7 GROUP PO BOX 7277 Dandenong VIC 3175 Australia PHONE 61 419 566 749 61 419 133 973 FAX 61 384 566 757 Email kenny forkalert net ken forkalert net
35. s forklifts to approach from any direction Page 3 of 28 Fork Alert System 2 TRANSMITTER 2 1 OPERATION The Transmitter is mounted to the roof of the forklift and emits a coded infrared beam in all directions It is coded to eliminate accidental triggering Note that you will not see the Transmitter flashing or emitting any visible light like a standard visible warning light when it is operating as infrared light is invisible to the human eye FORK CALE RT rou m CE Do not expect the transmitter to flash light like a normal forklift beacon The transmitter is an infrared emitter and is classified as eye safe Class 1 non hazardous under all normal viewing conditions according to AS NZS 2211 1 1997 compatible with IEC 825 1 1993 Whilst classified as eye safe it is advisable not to look directly into the Infrared emitter at close range Always assume that the transmitter is emitting invisible infrared signals if the mirror is rotating or if the transmitter is not rotating but powered up Figure 2 1 32 10 Figure 2 1 illustrates the transmission coverage of the beacon 2 2 VERSIONS The beacons are supplied in two different versions each having different input voltage ranges 12 24V DC and 36 48V DC indicated on the transmitter It is important that the correct transmitter be selected to correctly match the operating voltage of the forklift otherwise damage to the transmitter or ot
36. t is not possible to tell if the infrared emitters are functioning correctly by looking at them They will always appear to be off but may in fact be on It is considered best practice and safest to always assume the emitters are operating until it can be clearly ascertained that the device is unpowered e The infrared beam is emitted by six solid state infrared LEDs located in the centre of the transmitter turntable beneath the revolving mirror assembly The LEDs emit upwards and are reflected by the mirror surface Page 20 of 28 Fork Alert System e Under normal operating conditions the transmitter emits a vertical fan shaped beam onto the mirror that rotates through 360 degrees If the beam was visible it would appear as a brief flash each time the mirror rotated past the viewing point e Internal maintenance of the transmitter such as belt replacement shall only be conducted when transmitter is powered down so the infrared source is shut down Refer to section 7 2 3 for correct belt installation instructions e Under no circumstances should any maintenance or other personnel be permitted to stare into the transmitter mirror at close range if the mirror is stationary or into the infrared emitters with the mirror removed These precautions will prevent any potential eye hazard Maintenance should only be performed by suitably trained personnel who are aware of these requirements e Ensure that any beacons no longer in a serviceable c
37. tes Zone 1 has power but is not triggering ee Indicates Zone 1 is active and triggering Assuming there is power on the board FUSE 1A 2AG 1A 2AG Fuse for 24VDC supply to all IR Receivers AC MAINS AM MWE AC MAINS MAINS EARTH CHASSIS Page 15 of 28 Fork Alert System Figure 4 3 Example of the Zone Controller wiring diagram ZONE CONTROLLER 4 Core Shielded 16 0 20 EARTH ON CHASSIS OF ZONE CONTROLLER SHIELD IS CONNECTED TO EARTH TAB ON CHASSIS RXa 24 RXb OV IR RECEIVER WARNING LIGHT Terminal A Active terminal that is supplied when forklift is detected OUTPUT Terminal N Neutral terminal OUTPUT FUSE F2 1A 2AG Fuse for mains output Zone 1 4 5 PHYSICAL INSTALLATION Wall Mounting The enclosure must be wall mounted by adequate screws bolts or dyna bolts through the base of the enclosure at the locations specified below Special care must be taken to ensure that the holes are correctly sited and not closer to any part of the electrical or electronic components within the enclosure The mounting method must be capable of supporting 150 kgs 330lbs110z minimum and the four mounting bolts or dynabolts should each have a shaft thread which is a minimum of 6 35mm diameter 0 28 A flat washer of a minimum of 15mm 0 59 diameter should be used on each bolt thread mating on the inner face of the Zone Controller enclosure in order to adequately spread the load o
38. that goes on the Forklift Electricians can install the units however if you lease your forklifts you should seek advice from the forklift supplier and possibly get them to install it onto their machines Why doesn t the transmitter flash The transmitter sweeps an invisible beam around the forklift The transmitter is purely for the Fork Alert system and does not replace the existing flashing light on the forklift Is the beacon safe for employees to look at Yes the Fork Alert has been tested by ARPANSA Australian Radiation Protection and Nuclear Safety Agency to AS2211 and is classified non hazardous What is a Zone A zone is defined as a detection area that is covered by one or more Receivers activating an individual output circuit What are the Receiver timers for These allow the Receivers to stay active for a predetermined time usually a few seconds after the transmitter signal has not been detected The potentiometer for these timers is found in the receiver lf move premises or change forklifts is the system moveable Yes the Fork Alert system can be relocated to new premises and is easily transferred from one forklift or other vehicle to another provided the transmitter voltage matches the new vehicle If the voltages are different a new transmitter will need to be ordered Can use the Fork Alert system in conjunction with existing In ground loop detectors Yes the system can be easily integrated into your
39. ther than replace industry safety procedures and regulations applying to the use of forklifts or other plant The user acknowledges and agrees that as with all electronic equipment of this nature it may be subject to possible malfunction through improper system operation power loss inadequate maintenance accidental damage or component system malfunction It therefore remains the responsibility of the purchaser to ensure that in case of possible malfunction adequate alternative safety procedures are always in place to prevent possible injury or damage Additionally the client accepts that the system operates on line of sight transmission between the plant transmitter and the receivers and that total occlusion or covering of the path by other objects can prevent the warning being given lt is a condition of sale that the user accepts full responsibility for ensuring that the system is satisfactory for its intended purpose according to the specific operational environment Global 7 Group does not accept liability for any consequential loss or damage arising from the use or application of this equipment The detection range coverage implied by this document is approximate only and only after full installation can the operational coverage of the Fork Alert system be determined The effective detection range may decrease by a small percentage as the transmitter equipment ages as this is a typical characteristic of the infrared transmitter diodes This sho
40. til the transmitter beacon leaves the detection zone WARNING The Relay Output NC NO Range and Timer adjustments are provided inside the receiver housing Those adjustments must only be undertaken by competent authorised persons having a thorough understanding of this manual and the operation of the elements of the complete system Incorrect adjustments may affect the correct operation or result in a non operational warning system Careful adjustments and confirmation of correct operation is essential The Relay Output Switch on Normally Open NO condition is for standalone or Sweepscan System where Normally Open signal is required only In a Fork Alert System when the switch is set to Normally Open position the receiver do not operate correctly with the Zone Controller Please ensure the switch is set to factory default Normally Close NC position when used with a Fork Alert Zone Controller Figure 3 5 Select Switch Adjustment Adjustment Default NC VR1 VR2 Note Components and colour may vary Page 10 of 28 Fork Alert System Referring to the figure 3 5 the timer adjustment procedure is as follows 3 Follow any local site procedures Turn the mains power to the controller off There are dangerous voltages inside the controller take extreme care to avoid contacting any components or live parts Place an appropriate sign on the controller to warn others away if necessary Without interfering with the Receiver
41. ulations applying to the use of forklifts or other mobile plant 1 4 EXAMPLE Refer to Figure 1 2 Example Application to warn pedestrians The following site layout schematic details the locations of the components needed to install the Fork Alert system at a blind corner E Pedestrian pr Walkway f Pedestrian Fork Alert Receiver range Warning Light Fork Alert Receiver Fork Alert Transmitter Fork Alert Zone Controller Figure 1 2 Example Application to warn pedestrians Typically the receivers are mounted on one side of a doorway or blind spot to detect an approaching forklift or other vehicle Warning devices are placed in strategic positions to effectively warn pedestrians of the approaching hazard Page 2 of 28 Fork Alert System 1 5 Applications Door Automation The use of Fork Alert to activate automatic doors is another major application of the Fork Alert system With features superior to ground loops PE Beams motion sensors and Radio Frequency RF base systems Fork Alert is extremely effective as an activation sensor for automatic doors In this application no additional components are required The Receivers are powered and interfaced directly to the existing door controller 1 6 BENEFITS The benefits of the Fork Alert system used as a Door opener include e Provides greater efficiency as the system is fully automatic always active no action required by the forklift
42. uld not present a problem in most applications however it is recommended that the range should be checked every 3 months to check for this effect and the transmitter beacon should be replaced if the range is found to be unsatisfactory compared to its original performance Modifications to any of the forklifts and or the site eg addition of equipment or erection of walls shelves etc may adversely affect the performance of the Fork Alert system principally if the signal paths to the receivers are inadvertently blocked Care must be taken not to block the line of site between the forklift beacons and the receivers e g by moving or stationary objects like trucks walls materials or by accidentally painting over the receivers etc Users must be aware that the transmitter beacon is a Class 1 non hazardous infrared emitter which is safe under all normal viewing conditions according to AS NZS 2211 1 1997 compatible with IEC 825 1 1993 Note that the infrared output of the beacon is invisible to the human eye however it should still be regarded as a bright light source when viewed from an unusually close distance eg if work is being performed on or inside the beacon itself Hence it is important that the beacon supply is switched off before any internal maintenance work is conducted with the lens cover removed eg for belt replacement etc Global 7 Group offers and recommends system configurations with increased component redundancy for
43. wered up its internal output contact is closed when a forklift is detected the contact opens and triggers the Zone Controllers relay This design operates as a fail safe feature if the cable between the Zone Controller and a Receiver is cut or damaged the warning alarms will activate Contains relay contacts that switch mains voltages to the output terminals for powering lights sirens and other devices 4 2 VERSIONS The Zone Controller described in this manual is the current production version which is readily identifiable by the printed circuit board layout and identification details which follow This is the second general production version of the Zone Controller and differs from the first in several ways e The current version of the Zone Controller does not contain internal output relay timers e The current version is based on a printed circuit board design the first version was hand wired e The current version requires the use of the Revision 5 or higher receivers which have the zone output timing function and timer adjustments included in the receiver The receiver timer adjustment allows the on time of the zone specific relay output of the Zone Controller to be extended This means that a momentary trigger pulse at the receiver produces a continuous output from the Zone Controller a forklifts Transmitter will create a timed adjustable output from a warning light siren etc e The current version s specifications have
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