Vetter SmartFork FrontCam ATEX Operating Instructions Manual Download

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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:

Operating instruction for the industrial truck

Operating 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

Summary of Contents for SmartFork FrontCam ATEX

Page 1: ...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 ...

Page 2: ...SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X 2 EN ...

Page 3: ...nt 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 bas...

Page 4: ...asic 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 activit...

Page 5: ...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 ...

Page 6: ...ith 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 ...

Page 7: ... 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 ...

Page 8: ...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 Explosiv...

Page 9: ...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 ...

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

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

Page 12: ...t 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 smoo...

Page 13: ...ist 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 Smar...

Page 14: ...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 Trans...

Page 15: ...he 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 por...

Page 16: ...k 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 n The 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 re...

Page 17: ...wn 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 lo...

Page 18: ... 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...

Page 19: ...ing 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 dea...

Page 20: ...nts 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 f...

Page 21: ...ore beginning the activity 2 6 Safety markings The hard stamping identifies via the article number it contains the version of the SmartFork upon delivery SmartForks without a marking must not be put into opera tion The SmartFork hard stamping is on the back of the fork at the side Fig 2 NOTICE The use of the SmartFork without the prescribed markings is considered incorrect use Fig 2 Hard stamping ...

Page 22: ... vehicle The ATEX type plate provides information about the intended deployment environment for the SmartFork upon delivery and is located on the fork back underneath the hard stamping The ATEX type plate contains specifications for the equipment group equipment cate gory hazard type type of potentially explosive atmosphere and maximum temperature value For further details see Ä Further informatio...

Page 23: ...is regard The driver of industrial trucks is familiar with the use of all variants of the SmartFork and the associated dangers Electrician Due to their specialist training knowledge and experience as well as knowledge of the relevant norms and regulations the electrician is capable of carrying out work on elec trical systems and independently recognising and avoiding possible dangers The electrici...

Page 24: ... occupation related regulations governing the usage location must be observed 2 7 2 Unauthorised persons WARNING Risk to life for unauthorised persons due to hazards in the danger and working zone Unauthorised persons who do not meet the requirements described here will not be familiar with the dangers in the working zone Therefore unau thorised persons face the risk of serious injury or death Una...

Page 25: ...oads and from bumping against fixed objects Protective clothing Protective clothing is tight fitting workwear with low tensile strength short sleeves and without any protruding parts Protective gloves Protective gloves are used to protect hands from friction abrasions punctures and deeper injuries They also offer protection in the event of contact with hot surfaces Protective work clothing Protect...

Page 26: ...eased into the environment take suitable measures immediately If in doubt notify the competent municipal authorities of the damage and inquire about suitable measures to be taken The following environmentally hazardous substances are used Electronic components may contain recyclable components and components that could damage the environment Have electronic components recycled or disposed of by au...

Page 27: ...ront camera 9 Taper 10 Mounting slot for cable guide sealed with adhesive 11 Blade length L measurement from inner side of back to the fork tip 12 Inner heel 13 Wear zone 14 Lower hook 15 ATEX compliant connector plug 16 Upper hook 14 16 Suspension 17 Back height 18 Locking pin 19 Spring 20 Lever 21 Roll pin 22 Alternative shaft suspension Structure Structure of the basic fork arm EN SmartFork Fro...

Page 28: ...lock can be ensured by the locking device on the upper hook Observe the rele vant operating instruction for the fork carrier installed on the industrial truck The attachment dimensions for the SmartFork can be requested from customer service Ä Customer service on page 3 upon stating the order number on the hard stamping NOTICE Providing equipotential bonding Potential differences can result in die...

Page 29: ... 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 Never shorten the connection cable Protect the cable connections from damage Do not guide cables over sharp edges always secure the cable routing Adhere to the prescribed main...

Page 30: ...mbly of the SmartFork on the fork carrier in the following order 1 Prepare the lifting device for large loads e g indoor crane and lifting straps The work is to be carried out by 2 people 2 Move the fork carrier to the vertical position and move it to a height that allows for safe and comfortable assembly of the fork arm 3 Remove the locking screw on the assembly side of the fork carrier Fig 6 Sma...

Page 31: ...ower hooks of the SmartFork enclose the pro file of the fork carrier 7 Repeat the procedure for the second SmartFork Carry out assembly from the other side of the fork carrier 8 Align both fork arms evenly to the centre of the fork carrier at the requisite width 9 Lock both fork arms by closing the lever inside the locking grooves 10 Fit the locking screw on the fork carrier again 11 Connect the S...

Page 32: ...n the SmartFork and the industrial truck 1 NOTICE Insufficient stability due to incorrect borehole size If the borehole is too big this can impair the stability of the fork arm Make the borehole on the back of the fork at the side in an area roughly 50 mm below the fork head In doing so ensure that the borehole for the screw connection for equipotential bonding does not exceed thread size M6 2 Cut...

Page 33: ...fault current by the electrical components by means of suitable technical devices in order to prevent damage to the assistance system Always ensure the permissible supply voltage of 12 24 V DC with power consumption of max 0 5 W Fig 8 Plug connector of type GHG57 Establish the plug connection between the SmartFork plug connector of type GHG57 ATEX certified Fig 8 and the cable connection for the l...

Page 34: ...uipotential bonding between the SmartFork and the indus trial truck 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 If people or objects in the danger zone are not detected there is a risk of serious accidents The SmartFork FrontCam application is merely an assistance system Always adhere to the general ...

Page 35: ...pplied by the ignition of the industrial truck ð The camera monitor can be switched on 2 Switch on the camera monitor Other controls are not available ð The area directly in front of the fork tips is displayed on the camera monitor 3 Move the fork arms in front of the load to be lifted 4 Additionally monitor and control the lifting of the load on the camera monitor 5 During transport use the Smart...

Page 36: ...ng groove on the fork carrier 3 Lever open position 1 Raise the SmartFork up from the ground 2 Open the SmartFork locking device To do so put the lever Fig 10 1 of the locking device vertically upwards Fig 10 3 3 WARNING Risk of hands and other body parts being crushed when moving Grasp the SmartFork at the head and fork blade and carefully move it to the side on the fork carrier with appropriate ...

Page 37: ... the SmartFork To do so flip the lever again 6 Check that the SmartFork is locked into the locking groove Fig 10 2 If this is not the case move the SmartFork horizontally until the lock engages Operation Adjusting the distance between the fork arms EN SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X 37 ...

Page 38: ... the SmartFork FrontCam no later than 2 years after the last replacement Service specialist If necessary Cleaning Ä Chapter 6 2 6 Cleaning the fork arm on page 42 Driver of industrial trucks Replace the fork arms Ä Chapter 6 2 7 Replacing the fork arm on page 43 Driver of industrial trucks Depending on operating time wear and use the operator can independently choose a much shorter interval 6 2 Ma...

Page 39: ...y clouded or damaged The SmartFork FrontCam application must be securely installed in the fork arm The cables in the SmartFork must be firmly adhered in place Fill worn adhesive solely with approved SikaTack Drive adhesive and leave it to harden for at least 60 minutes n Check the fork arm locking device for functionality The SmartFork must be engaged in the designated locking groove Fig 10 2 The ...

Page 40: ...acturer accordingly in this regard Ä Chapter 6 2 9 Spare parts on page 47 The polycarbonate sheets all stainless steel covers including their screw connec tions and seals must be seated securely and free of damage n Safety markings must be complete and legible 6 2 2 Checking the fork arms and suspension system Personnel n Service specialist Protective equipment n Industrial safety helmet n Protect...

Page 41: ...he electronic components to ensure an ATEX com pliant plug connection Plugs must be plugged in securely and be free of play Retighten loose plug connections Replace the plug connection if this is not possible n Check the cables for damage cracks or kinks Take the fork arm out of service imme diately if the cables are damaged Note the instructions for repair Ä Chapter 6 2 8 Replacing the applicatio...

Page 42: ...ing device is jamming check it for dirt and deformation and if in doubt replace it n Check the integrity of the locking device Fig 4 18 21 Replace the following compo nents immediately If the locking device is incomplete immediately ban further use of the VETTER SmartFork Commissioning may only be carried out after a successful repair n Remove any dirt from the locking device 6 2 6 Cleaning the fo...

Page 43: ...lel to the ground 3 Raise the SmartFork up from the ground by raising the fork carrier until it is no longer in contact with the ground Secure the fork carrier against unintended low ering 4 Disconnect the plug connections between the ATEX compliant plug connection and the associated cables of the lift mast connector 5 Disconnect the screw connection of the equipotential bonding between the fork a...

Page 44: ...st you and push it down from the fork carrier with appropriate force 9 WARNING Risk of injury from falling fork arms Secure the SmartFork against falling immediately after disassembly by setting it down to one side 10 Install the new SmartFork Ä Chapter 4 Assembly on page 30 Maintenance Maintenance activities Replacing the fork arm SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X...

Page 45: ...eal Defective or porous seals make it possible for potential explosion gases to escape from the flameproof enclosure and enter the outside This could result in dangerous situations and serious injuries To ensure that the flameproof enclosure is completely sealed inside the fork arm a new seal must always be inserted after the cover is opened NOTICE Risk of explosion due to damaged covers Damaged c...

Page 46: ...seal Fig 12 7 and O ring Fig 12 2 5 Unscrew both threaded pins Fig 12 6 6 Loosen the cable connection of the FrontCam 7 Pull the FrontCam Fig 12 1 out towards the front 8 Insert the new FrontCam Fig 12 1 and slide it through 9 Establish the cable connection of the FrontCam 10 Insert the threaded pins Fig 12 6 and in doing so fix the FrontCam in place 11 Insert the new side seal Fig 12 7 and new O ...

Page 47: ...ENG 277100 ATEX cover front 5 2 ISO10642 M6x25 A4 Hexagon socket countersunk screws M6 x 25 6 2 ISO4026 M12x16 A4 Threaded pins M12 x 16 7 1 ENG 277072 Seal side 8 1 ENG 277102 ATEX cover side 9 4 ISO10642 M5x25 A4 Hexagon socket countersunk screws M5 x 25 6 3 After completion of maintenance work Personnel n Driver of industrial trucks Protective equipment n Protective work clothing n Industrial h...

Page 48: ...ruck safeguard back in place 5 Remove all tools materials and other equipment from the work area and clean the work area remove any leaked materials such as e g liquids processing materials or similar Maintenance After completion of maintenance work SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X 48 EN ...

Page 49: ...he driver on page 39 2 Check the power supply and ensure that all plug connections are secure Protective sheets must not be dirty or scratched If these measures do not resolve the malfunctions contact your dealer and state the data on the hard stamping Troubleshooting EN SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X 49 ...

Page 50: ...cal data Tab 2 FrontCam pin assignment Pin No Wire Marking 1 Core Signal 2 X X 3 red 12 24 VDC 4 black GND 5 Shield Video Technical data SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X 50 EN ...

Page 51: ... FrontCam 7 FrontCam components 45 FrontCam pin assignment 50 H Hard stamping 21 I Image output devices 29 Incorrect use 13 Intake current 33 L Locking device checking 42 Overview 36 M Maintenance 38 Checking the fork arms 40 Checking the hooks 40 Checking the locking device 42 Electronics check 41 Maintenance activities 38 Maintenance intervals 38 Marking 21 O Operation 34 35 Operator 16 Operator...

Page 52: ...iction 34 Structure 27 Suspension 28 Symbols In the manual 12 on the fork arm 21 T Technical data 50 Troubleshooting 49 Type examination 9 V Visual inspection daily 38 W Wear check 41 Index SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X 52 EN ...

Page 53: ...SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X 53 ...

Page 54: ...SmartFork FrontCam ATEX for use in the Ex zone BVS 20 ATEX E 108 X 54 ...

Page 55: ......

Page 56: ...elopment Deviations and changes are part of our ongoing review and improvement of the product VETTER Industrie GmbH does not accept any respon sibility or liability for errors that arise from the use and application of this document This document including all parts is protected by copyright All rights reserved No part of this document may be copied translated microfilmed or used in any way for pr...

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