Scanreco RC400TR02FH433 Radio transceiver module User Manual

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Document ID	1211126
Application ID	4qkfNZQWIl/3A1JOjq14xg==
Document Description	User manual
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Permanent Confidential	No
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Document Type	User Manual
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Date Submitted	2009-12-09 00:00:00
Date Available	2009-12-09 00:00:00
Creation Date	2001-05-23 10:23:14
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Document Lastmod	2001-05-23 10:23:16
Document Title	User manual

REMOTE CONTROL SYSTEM .
( Engels“ ) _
SCANRECO RC 400.
FCC/MELLDN OCT 131998
INSTRUCTIONMANUAL.
SCA RECO Industrielektronik AB
FCC / USA
This device complies with part 15 of the FCC-rules. Operation is subject to the
following two conditions :
(1) This device may not cause harmful interference, and (2) this device must accept
any interference received , including interference that may cause undesired
operation.
Warning : Changes or modifications to this unit not expressly approved by the
party responsible for compliance could void the user's authority to
operate the equipment.
Postal address Telephone +46 8 744 02 20 VAT nr SE556245004801
Box 471441 Arsta Skolgrfind 22 Telefax +46 8 744 01 95 Org. nr 556245 - 0048
5-100 74 STOCKHOLM / SWEDEN E-mail scanreco@scanreco.se
|/|\
CONTENTS.
1.
PREFACE.
GENERAL SYSTEM DESCRIPTION.
SAFETY REGULATIONS AND OPERATING
INSTRUCTIONS.
INSTALLATION INSTRUCTIONS.
FAULT FINDING.
SPARE PARTS.
OPTION : REGULATIONS AND AUTHORITIES,
TYPE APPROVAL CERTIFICATES.
PROGRAMMING PARAMETERS AND SETTINGS.
ACCESSORIES / OPTIONS.
Dcsngn, cqmpmcm, technichal data and specmcanon am subject in change or improve-mm wnhum prior nmioc. The nm of 1m: mun].
or any pan thereof, may not be reproducrd or transmitted in any form or by any means. elecuonic or mechanical includmg photocopymg,
mmmmg. smug: m an mformanun mmsvnl syslem, or nlhcrwise. whom |hc pfimmncn pznmssion of Scmreco AB, Sweden.
Chaplets 6, 7, 8 and 9 are abbmwamd versions
1. PREFACE
This manual is intended as a complement to the crane / machine instruction book and
covers the Scanreco RC 400 Remote Control System.
The Scanreco RC 400 offers the driver an extremely advanced remote control system
with speed, precision and control and with maximum safety.
In order to ensure your safety and the safety of your crane / machine you should study
and learn these instructions. This will enable you to more quickly familiarise yourself
with your new remote control system and how best to utilise it,
For the crane fixer :
Pause for a while and give yourself extra time to read chapters :
”Chapter 2, General system description" , "Chapter 3. Safety regulations and Operating
instructions".
For the installer :
Pause for a while and give yourself extra time to read chapters :
”Chapter 4. Installation instructions " and "Inspection / Installation documents".
0 Remotely controlled cranes mayo—lily be operated by qualified personnel. The driver
M be aware of the contents of chapter 3 "Safety regulations and Operating
instructions" before operation is started ! Serious accidents can occur if these
instructions are not followed !
- To protect the portable control unit from damage and also for safety reasons, the
control unit must be kept in a locked cab.
- Follow the instructions given in the crane handbook regarding moving the crane
from its parking position, the best arm positioning while loads are being handled and
parking of the crane.
- Due to the unlimited variety of cranes, machines, objects, vehicles and equipment
on which the remote control system (RC 400) are used, and the numerous standards
which are frequently the subject of varying interpretation, it is impossible for
Scanreco AB ISwedens, personnel to provide expert advice regarding the suitability
ofa given RC 400 remote control for a specific application.
It's the purchaser's responsibility to determine the suitability of any Scanreco RC
400 product for an intented application, and to insure that it is installed and guarded
in accordance with all country, federal, state, local, and private safety and health
regulation, codes, standards and Scanreco's recommendation ( This manual).
If the Scanreco RC 400 will he used in a safety critical application, the customer -/
driver must undertake appropriate testing and evaluation to prevent injury to the
ultimate user. Scanreco AB, Sweden does not take responce for any damage or injurie.
Unauthorized tampering with Scanreco RC 400 automatically invalidates guarantee 1
2. GENERAL SYSTEM DESCRIPTION.
Contents : Page :
a General schematic of the Scanreco RC 400 2.2
- General description of the remote control system 2.3
o The portable control unit 2.3
- Battery operation (See also 2.1] - 2.12) 2.4
- Manoeuvre levers 2.5
. Emergency stop panel 2.6
0 Changing radio channels ( Due to frequency blocking) 2.6
. Switch panel 2.6
. Micro - speed control 2.6
a ON/OFF functions 2.7
- Cable for cable control 2.7
- Opto-fibre cable 2.8
- Electranicbux 2.9
- Expansion cable (EX) 2.10
- Crane emergencystop box 2.10
- Battery pack 2.11
- Battery charger and battery charging 2.12
- Radio control 2.13
. Radio transmitter 2.14
. Radio receiver box 2.15
- Option : Duplex-communication with display to give 2.16 - 2.19
current weight loading, moment etc.
General system description 2 , 2
General schematic of the RC 400 :
The Remote Control System is comprised of the following components:
- Control unit (for cable or radin control ).
. Electronicbox.
- Crane emergency stop box.
. Expansion cable ( EX).
- Cable operation Control cable ( 3-oore ),
- Radio operation: Radio transmitter, Q0“. 2. battery packx, battery charger and radio
receiver box.
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General system description 2 — 3
1. GENERAL DESCRIPTION OF THE REMOTE CONTROL SYSTEM.
The Scanreco RC 400 remote control system has been specially developed for hydraulically
driven mobile cranes and machinery. The System is a digital remote control system based on
an extremely advanced micro-processor technologyr Years of exhaustive and demanding
testing have shown that the remote control system can cope with the roughest of environ»
ments.
The remote control system is tested and approved for use in, amongst others, power stations,
with a sky lift for personnel, close to work areas using blasting , on oil platforms, military
establishments or other areas with explosive environments The system is protected against
electromagnetic and radio frequency radiation and can be installed onto all hydraulic valve
types ( voltage, current, pulse width, or protocol steered ) found on the market.
In its basic form the remote control system is comprised of a portable control unit with
manoeuvre levers for proportional control and switches for ON/OFF functions, an electronic-
box with connection cable for driving proportional electro-hydraulic slide controllers.
Digitally coded control information (lever deflection and switch position) is sent from the
control unit via electric cable, opto fibre cable or via radio to the electronicbox,
The control unit and electronicbox translate the magnitude and direction of the manouevre
lever deflections and switch positions to corresponding valve function speed and direction and
thus crane movement.
2. PORTABLE CONTROL UNIT 1 for cable, opto fibre cable, and radio operation 1.
General description of the portable control unit.
The portable control unit is impact and weather resistant and is light weight and compact.
Controls are available for 3, 4, 5 or 6 manoeuvre functions The manoeuvre levers are fully
proportional and have spring return to the zero position. i.e. a "dead—man‘s-handle”. The
control unit has an emergency stop function which will immediately stop all movement .
All manoeuvre levers are protected with a protective frame against unintentional activation
and against mechanical damage. The control unit has multi-step micro-speed operation as
standard enabling instantaneous temporary reduction of speed and it can also be equipped
with a large number of switches for ON/OFF functions. A LED and sound signal are used to
indicate such things as operating and battery status and for a simple and diagnostic fault
finding. ( See picture of control unit).
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General system description 2 - 4
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Portable control unit with battery operation ( radio control oropto fibre cable ).
A battery is located in the control unit for radio control and is very simple to change
- The battery’s effective operation time is about 8 hours on one charge.
- When the battery is approaching time for charging, the control unitbeegs three ( 3 ) times
as a warning and at the same time the LED starts to blink on the control unit,
0 The battery m be used until the LED goes out, after which it can be changed.
If the battery capacity is too LOW the control unit cannot be activated.
. The battery capacity and operational performance is reduced in extremely cold conditions.
( The battery is automatically charged during operation by cable control ).
c In order to reduce battery loading and for safety reasons, the control unit is turned off
automatically, after the unit has been idle for more than approximatelyfifl ( 5 ) minutes.
General system description 2 - 5
A brief description is given now of the component parts of the control unit.
The control unit is comprised of manouevre levers for proportional control, switches for
ON/OFF and function changing, micro—operation and emergency stop. ( See separate headings
below ).
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Manoeuvre levers.
The manoeuvre levers give fully variable proportional operation and are sprung loaded to
return to zero position, i.ei "deadvman’s—handle". When the manoeuvre levers are moved from
zero position the respective hydraulic function starts to operate slowly and increases in speed
as the lever is moved further from zero position and vice versa as the lever is moved back
towards zero position. If any levers are not included for a particular installation, a cover plate
can be mounted for the unused lever locations.
( See also trtle ” Micro-speed Control " ).
For safety reason: all manoeuvre lever: M be in they zero/neutral positionr for a start-up 10 be made If any
lever is not in its sew /neu{ralpusilion during start-up the control unit will blmk and beep the same number of
times as the number ufrhe lever ta indicate which manoeuvre lever isfuulty. The cumml unit can be used but the
faulty lever will be locked and disengaged. (For example ifi/ beep: and blinkrfive (5) Inner, it i: the 51h [ever
from the LEFT which isfaul/y or giving the problem signal).
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General system description 2 - 6
Emergency stop panel.
There is a red emergency stop switch (STOP) with a manual twist reset, a push button
( ONISIGNAL/FREQ. SHIFT ) and a red LED on the control unit’s emergency stop panel,
- The control unit is started with the sprung reset push button (ON/SIGNAL/FREQ. SHIFT )
. A warning signal is produced on the crane (SIGNAL) by holding the push button down.
. The warning signal can be issued at any time during operation
- All movement of the crane is stopped if the emergency stop is activated on the control
unit. The red LED indicates operating and battery status.
EMERGENCYSTOPJLME
EMERGENCYSTOP
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Switch panel ( Micro-speed, ON/OFF and function change functions ).
The control unit can be equipped with different switch panels, depending upon the particular
installation.
There is a switch for micro-speed operation, i.e. speed control, as standard on all switch
panels, Switch panels are equipped with different types and combinations of switches for
ON/OFF manoeuvring or for function changing.
Alternative One switch can be used to designate tha/ levers n ill give ON/OF F functions (functinn changing).
Micro — Speed control ( reduction of speed ).
This return sprung switch can be used to reduce the operating speed in fig ( 5 ) steps from
100% to 6070, 50%, 40%, 30% and 20% speed by limiting the hydraulic steering. The
regulation of the function‘s speed is still made over the entire lever stroke and with retained
resolution.
- With impulses from the sprung loaded toggle switch to the left, towards ON, speed
reduction can be produced from 100% to 60%, 50%. 40%, 30% and 20% steering,
- Movement of the switch to the right, towards OFF. will produce 100% steering once
again ( See also next item ).
. For safety reasons, a return to 100% steering can only be made if all manoeuvre levers are
in their zero positions.
- NOTE !! If the emergency stop is pressed on the control unit, the control unit will restart
from the normal position, i.e. lOO% steering.
(As visible acknowledgement that micro operation is relected. the control unit': red LED will light/or along
period and then extinguish fur a shortperma', this sequence then betng repeated. Do not mistake lhl: for
”low battery capacity” )
General system description 2 — 7
ON/OFF and function changing functions.
ON/OFF switches can be used to manoeuvre electrical, hydraulic or pneumatic ON/OFF
functions.
Examples of functions :
. Stopping and starting of the vehicle’s motor, throttle lever, beep / signal, change—over
valves, function changing for ex, 7th and 8th function.
- Enable parallel running of two or more valves at the same time from one manoeuvre lever.
- Connection of so called hold function, i.e. "lock" 21 function at a specific speed, after
which the speed is kept constant without the lever having to be held ( for example
hydraulically driven drills ) etc. This can be compared to the speed control in a private car.
Make sure that you always know which functions are connected for ON/OFF manoeuvring.
Alternative One swrlch can be used to designate that levers will give eitherpropwiiunnl or ON/OFFfuncrians
(function changing }
3. CABLE FOR CABLE CONTROL electrical 3-core .
The control unit is connected to the electronicbox via a thin and flexible 3-core cable. The
cable has round contacts (Amphenol / Hirchmarin) at each end.
The cable feeds the digital coded control information from the control unit to the electronic
box. The cable is available in standard lengths of 10 , 15 , 25 , 50 and 100 metres.
With cable (antral, the xmndard cable length supplied is 15 merres
A 10 metre conrrol cable is xuppli'ed with 0pm or radio control, for emergency operation
(I =Supply , 2 =Data , Ground= Ground/Minus , 3 =Na connection ).
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General system description 2 - 8
4. CABLE FOR OPTO FIBRE OPERATION ( NOTE ! OPTlO 1
For opto fibre control the remote control system is complemented with an opto fibre cable,
battery pack and battery charger. This means thatm is used to send the control information
( not electrical impulses ).
The control unit is connected to the electronicbox via a thin opto fibre cable. The cable has
circular type contacts (Ampehenol / Hirchmann) at each end and the opto fibre electronics is
built in and integrated into the contacts,
Oplofibre cable is used in those cases where the use ufrradilional control cable is n_at allowed. This can be
during work under or near m electrical power lines or ground cables where Contact orflash-over between
control unit and crane could be fatal
With upm fibre cable lhe central unit and eleclronicbox (crane / vehicle) are my electrically connected, Le. are
totally isolated and galvanically separated
(Radio cumml gives the Same personnel prolecliun )
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General system description 2 - 9
5. ELECTRONICBOX.
The electronicbox is manufactured in aluminium and is provided with attachments and contacts
for connection to the portable control unit, radio receiver box and ON/OFF functions. There are
also connections and contacts for supply voltage, electro-hydraulic converter valves, slide
controls and dump valve. Since the electronicbox can be exposed to very tough environments,
the box is encapsulated to give protection from damp, heat, cold, dust, vibration and corrosive
environments.
The electronicbox has short circuit proof inputs and outputs and has protection against polarity
reversal, over-voltage and large incoming voltage transients and EMC / RF. Connection of the
electronicbox can therefore be made without risk of damage. The electronicbox is delivered for
supply voltages of +12 / +24 VDC ( +I- 20 % ) with negative ground. There are two standard car
type fuses located inside the electronicbox.
Plus fuse: +10 Amp. and minus fuse: , 30 Amp.
A transformer for standard mains voltages can also be used to pthdc the electronicbox with supply voltage.
Primary voltage: 110, 115, 220240, 380, 440 VAC and secondary voltage + 12 / +24 VDC ( +l- lO%).
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There are LEDs on the electronicbox to indicate operating status etc : See also page : 5—2 H!
POWER: Indicates supply voltage to the electronichox ( foggleswitch in REMOTE position ),
DV: Dump-Valve activated.
ON/OFF: ON/OFF function activated. flie LED is commoned and summed i e. only one switch at a time can
be activated from the control unit to enable control.
DIR. A: Manoeuvre lever A-direction activated and moved . The intensity of the light from LED—A increases
with increased lever angle. The LED is commoned and summed. i.e. only one manoeuvre lever at a time can be
manoeuvred in the A~dtrection to enable control.
DIR. B: Manoeuvre lever B»direction activated and moved , The intensity ofthe light from LED-B increases
with increased lever angle, The LED is commoned and summed, Le, only one manoeuvre lever at a time can be
manoeuvred, m the BAdrrection to enable control.
Doc.nr : 6611-007
General system description 2 - 10
6. EX-CABLE ( EX 1.
A thin and flexible 7-core cable can be connected to the electronicbox for outgoing ON/OFF-
functions, for in-going signal handling e.g. overload and lift reduction functions and for serial
communications if more than one electronicbox is used in so called tandem operation. The
cable has a circular type contact (Amphenol (Hirchmann) at one end.
( The EX—cable IS marked With the letters EX and should be connected [0 the ON/OFF conncclor on Ihe
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7. CRANE EMERGENCY STOP BOX/
The crane emergency stop box is a separate unit for fixed mounting on the vehicle. The crane
emergency stop box must be connected between the vehicle battery and the electronicbox.
- When an emergency stop is activated the main power supply to the entire remote control
system is disconnected
- The crane emergency stop must be suitably located and easily accessible.
- Before operation is started, the driver must inform all fellow-workers about the emergency
stop function and its location.
thh the eloctronicbox switch in MANUAL position and an electric dump valve, the emergency Slop
function is also available during manual hand lever operation.
( See also chapter 5, "Safety regulations and Operating instructions" ).
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General system description 2 - ll
8. BATTERY PACK.
The battery pack is impact and weather resistant and is located in the battery holder in the
portable control unit . The battery pack is rechargeable and ofNickelgadmium (NiCd) type.
The battery pack is protected against short circuits, The terminal voltage of a newly charged
battery should be ( unloaded ) ca 7.0 - 9.0 VDC.
Note.
Battery packs supplied since 1 January 1993 have three ( 3 ) terminal connections. The centre
terminal is used for Scanreco’s quick charger ( option ).
The battery pack is fully compatible with all battery packs previously supplied,
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~ The effective operational capacity of the battery is approximately 8 hours per charger
- When the battery is approaching time for recharging, the control unit beeps THREE ( 3 )
TIMES as a waming and at the same time the LED starts to blink on the control unit. See
next item.
- The battery must be used until the LED goes out, after which it can be changed.
If the battery capacity is too LOW the control unit cannot be activated.
- The battery capacity and operational performance is reduced in extremely cold conditions.
(The battery is automatically charged during operation by cable control ).
- In order to reduce battery loading and for safety reasons. the control unit istumed off
automatically, after the unit has been idle for more than approximately/M ( 5 ) minutes.
General system description 2 — 12
9. BATTERY CHARGER AND BATTERY CHARGI G.
The battery charger must be mounted in a vibration free area inside the cab or indoors and be
protected against damp and temperature variations.
- The normal charging time for an empty uncharged battery. is approximately 12-14 hours
- The battery charger should be connected directly to the vehicle battery to enable charging
during idle time,
a The batter charger is constructed so that no damage will occur from long continuous
charging.
- The supply voltage to the battery charger should be +1 1 VDC to +30 VDC.
There are two indicating LEDs on the hatteg charger:
- RED LED (POWER) : indicates supply power available ( i.e. from the vehicle battery ).
- GREEN LED (CHARGING) : indicates that charging is taking place.
A fuse»holder ( bayonet type ) is located next to the connecting cable and contains a glass fuse
3 Amp, (quick), size 5 x 20 mm .
Polarilyfar the connecting cable: + Blue and - Brown
The battery charger current withoul battery pack is' =10 - 20 mA.
The battery charger current M battery pack is. =150 - 140 mA.
The terminal voltage at the battery charger terminal: is approximately the same a: the vehtcle buttery voltage.
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Defective / non-functioning battery charger:
If the driver is using cable control and the battery pack is in place in the control unit, the
battery will be charged automatically. See also below.
Battery charging via cable control, for ex. over night : (Charging time LT approx. 12-14 ham).
Place the battery pack in the control unit (emergency stop depressed) and connect the cable
between the control unit and the electronicbox (emergency stop on the crane activated).
The electronicbox must be in Remote : (Pawer, and LED No. 4 M blink) Battery charging is
now taking place !
Doc.nr : 6611-007
General system description 2 A 13
10. RADIO CONTROL See "11, Rad“ transmitter" and "12. Radio rec ' r box"
For radio control operation the remote control system is complemented with a radio
transmitter. a battery pack, battery charger and radio receiver box.
(See also xecrian: "Barlerypack", ”Ballery charger” and " Control um"! for balmy opera/ion“).
11. RADIO TRANSMITTER.
The radio transmitter card ( which is encapsulated and has a well proven built-in antenna) is
mounted onto the control unit electronics card ( HTX 402 ). The radio transmitter is connected
via a pin strip, to the electronics card and is screwed down using four fixing spacers. When
the radio transmitter is connected to the electronics card ( HTX 402 ). a unique identity code is
added automatically to the digitally coded control information. The radio transmitter is
approved in accordance with European radio standards I-ETS 300 220 and I—ETS 300 683.
The driver can make an immediate radio channel change by using control unit push button
”ON/SIGNAL/FREQSHIFT”. The radio channel change can be made at any time during
operation. The radio transmitter operates in the 405 - 490 Mhz band.
For the mobile market 12 ( twelve ) radio channels in the ISM band (433 too-434.700 a 25kHz )
are available for use.
No special licence is required by the user for the frequencies for which the radio transmitter is
approved.
Changing the radio channel : A double press of the (FREQ. SHIFT) push button Will make the system
execute an immediate radio channel changer Press the button w quickly and the red LED should blink and the
control unit should beep once to confirm that a radio channel change has been made A radio channel change can
be made at any time during operation, The system has twelve (12) radio channels as standard .
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General system description 2 - 14
12. RADIO RECEIVER BOX.
The radio receiver box is manufactured in aluminium and is provided with attachments, well
proven antenna and a connector for connection to the electronics box. Since the radio receiver
box can be subjected to a very tough environment, the box is encapsulated for protection
against damp, heat, cold, dust, vibration and corrosive environments. A green LED on the
radio receiver box indicates supply voltage ( the radio receiver box receivers its supply voltage
from the electronicbox ),
When the radio receiver box is connected to the electronicbox. a unique identity code is
automatically added to the digitally coded control information.
The radio receiver box is approved in accordance with European radio standards I-ETS 300
220 and I-ETS 300 683. With the use of the control unit push button "ON/SIGNAL/FREQ SHIFT"
the driver can make a direct change of radio channel. A radio channel change can be made at
any time during operation. The radio receiver box operates in the 405 - 490 Mhz band.
12 (twelve ) radio channels are available in the I.S.M band (431100434700 5 25kl-lz ) for
mobile operation.
No special licence is required for the user for the frequencies for which the radio receiver box
is approved.
( The connecting table/or the radio receiver box IS marked With the Ienerr RA and should be connected to
contuc/ RADIO an the electronlcbox).
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3. SAFETY REGULATIONS AND OPERATING
INSTRUCTIONS.
These instructions cover, amongst other things, those special regulations which apply for
remotely controlled cranes ( cable or radio ). The driverm be aware of the contents of
these safety regulations.
Remote controlled cranes may o_nly be operated by trained personnel. The portable control
unit must never be passed over to any person who has not received trai ing for remote
controlled cranes. If these instructions are not followed, serious accidents can occur!
W 1
. Check that the control unit matches the crane / vehicle which he is to operate
- Aquaint himself with the symbols and positions for operating functions and directions.
- Check the emergency stop function and general remote control system operation daily .
- During operation, walk or stand at a suitable distance from the crane to be able to get a
good view of the operation. No unauthorised persons may be within the crane’s working
area.
. Be aware that it is forbidden to convey loads over himself or fellow workers.
Release all manoeuvre levers (dead-man‘s-handIes) if crane movement control is lost
and then immediately press the emergency stops on the control unit and on the crane.
0 The emergency stop on the control unit should always be in the depressed position
whenever the unit is not in use. This applies even for short stoppages, for example, if the
driver wishes to move.
0 After a completed run, press the emergency stop on the control unit and on the crane. The
control unit must be kept out of reach of unauthorised persons.
- Always report equipment faults or shortcomings to the person responsible for the crane.
- Check that none of the safety devices have been altered or removed.
- Refer to the current regulations / instructions regarding ”Persannelhfiing with cranes ",
"Overloading/overload protection ", " Visible signaLr during the operation afcranes " and "The location
o/cmnes close to airpaer and high—tension power lines".
. Be aware of any other pertinent regulations and of any local regulations which may
apply. These are to be found in the relevant safety regulations regarding crane transport.
Be aware of the contents in "OPERATING INSTRUCTIONS” and the handling and method
of working of the remote control system, See next page “ Operating instructions " 1
Safety regulations and operating instructions 3 - 2
OPERATING INSTRUCTIONS.
Before operation, the driver MUST make himself aware of the contents in the
"SAFETY REGULATIONS" for remotely controlled cranes. The driver must be
aware of the function ofall manoeuvre levers and switches.
1, For remote control: Place the electronicbox power switch into REMOTE.
For manual/emergency operation: Place the electronicbox power switch into MANUAL
(Power is now only supplied to the dump valve and the crane’sfunctions can be
manoeuvred directly from the valve ’s hand levers).
Twist up the emergency stop switches on the crane and on the control unit.
Cable operation: Connect the control cable between the control unit and the electronics
box ( crane ).
Radio operation: Place a newly charged battery in the control unit‘s battery holder,
3. Press ONISIGNAL/FREQi-SHIFT. and the red LED will light continuously
4. The crane is now ready for operation. The driver must be aware of all manoeuvre lever and
switch functions before operation is started.
St To switch off or to activate the emergency stop the emergency stop switches on the control
unit and crane should be pressed down. The emergency stop on the control unit should
always be in the depressed position whenever the unit is not in use. This applies even for
short stoppages, for example, if the driver wishes to move
6, To ensure a long life for the control unit and for reasons of safety, the control unitmust be
kept locked in the cab.( The comm] mm should be regularly wiped off with a damp cloth for example Jr
4. INSTALLATION INSTRUCTIONS.
Contents : Page :
- General schematic of the RC 400 / Duringm 4.2
- Locating the electronicbox and radio receiver box. 4.3
- Mounting recommendations for the radio receiver box. 4.4
- Connection ofDanfoss electro-hydraulic valve and dump valve. 4.5
. Connection of proportional magnets and dump valve. 4.5
- Connection of supply voltage and ON/OFF functions. 4.6
- Connection schematic for ON/OFF functions (see also page 4.6). 4.7
- Connection schematic for start of vehicle motor and start lock. 4.8
- Connection schematic for valve contacts to Dant‘oss valves. 4.9
- Connection schematic for battery charger. 4.10
. Changing crane direction ( lf crane movement reversed to that desired). 4.11
When installing remote control on vessels/boats ( marine cranes ).
- Grounding of electronicbox and radio receiver box. 4.4 - 4.5
Technical data :
- Portable control unit, electronicbox and radio receiver box 4.15
Installation instmctions 4 - 2
Installation instructions for Scanreco RC 400 remote
control system .
When the Scanreco RC 400 is installed an electrically controlled dum valve must, for
reasons of safety, always be connected between the manoeuvre valve and the tank . This
means that during an emergency stop manoeuvre the dump valve will be without power
and will transfer the pump flow directly to the tank thus making the crane entirely
without hydraulic pressure.
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Welding.
It is sometimes necessary to weld a truck/machine. During welding the system’s electrical
connections must a ways be disconnected from other equipment, ie. power supply cables ( +
and - ), all valve contacts, the EX cable and radio receiver box contact must be disconnected,
1. Before installation is started, it is recommended that a test run is made of the existing crane
system (movement and functions) in order to discover existing faults or operational
disturbances in the crane, hydraulic valves or other functions. Note these and notify
the customer if any faults are found.
Installation instructions 4 — 3
Installation and mounting instructions.
Electronicbox :
Important: The electronicbox M be mounted in accordance with the recommendations
given below! To ensure the longest possible life for the electronicbox and its cables, the
electronicbox must always be mounted so that the valve contacts are located facing
downwards. The electronicbox must not be mounted so that the cables face upwards The
reason for this is to hinder water from running via the cables towards the electronicbox.
( The cables on the electronicbox are thus Lot subjected to long periods of accumulated water, damp, salt etc. ).
The electroniebox should be mounted in a vibration free location and not close to strong heat
sources ( for example exhaust pipes etcr ). See also page 4.5 - 4.6 !
OK OK WRONG
Radio receiver box :
Important: The radio receiver box M be mounted in accordance with the recommendations
below!
The radio receiver box must be mounted in a vibration free location and not close to strong
sources of heat ( for example exhaust pipes etc. ). See next page !
OK WRONG WRONG
Installation instructions 4 - 4
Mounting of the radio receiver box.
. The connection cable (marked RA ) for the radio receiver box is approximately 2 metres
long which is the maximum mounting distance from the electronicbox.
- For optimum radio communications the radio receiver box should be located as high and
frfi as possible, An antenna screened and surrounded by fixed objects will considerably
impair radio reception
- The antenna pin must not touch any metal object. The radio receiver box should be
mounted horizontally with the antenna pin sticking vertically up. ( See instructions f).
- The radio receiver box should be mounted in a vibration free location and not be
subjected to strong sources of heat ( for example exhaust pipes etc. ).
Control units and electronicboxes with the same serial number have been programmed with a unique "identity
code" when delivered, i.e. they do not need to have their identity codes programmed. See section "Identity code
programming" ifthis is not the case.
NOTE! Marine cranes : The casing of the radio receiver box is grounded and connected to supply voltage
earth. In those special cases where a galvanically isolated earth is required ( for ex. marine use ). the radio
receiver's boxmust be mounted on rubber siand—offslhushes to obtain a galvanically isolated earth,
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Installation instructions 4 - 5
2. Select a suitable location for the electronicbox on the vehicle / crane.
a The contact for the cable control cable, switches for MANUAL/ 0 / REMOTE and LEDs
for operational status must be located where they are easy to see and reach. Check that
the electronicbox cable contacts ( cable control, ON/OFF, and radio receiver box
connection contacts ) are located so as to be protected from external damage.
0 If the electronicbox is to be mounted in any other manner, the connections and contacts
must n_ot face upwards ! This is to hinder long-term accumulations of water, damp and
corrosive salt in the cables, connections and contacts.
NOTE! Marine cranes : The casing of the electromcbox is grounded and connected to supply voltage earth. In
those special cases Where a galvanically isolated eanh is required ( for ex. marine use ), the radio receiver’s box
must be mounted on rubber stand-offs/bushes to obtain a galvanically isolated earth.
3. Connect the electronicbox valve contacts, as per the schematic in which each valve group
and function can be seen. A valve gasket is mounted under each valve contact and to
prevent future operational disturbances, a weatherproof grease / silicon should be applied
between the valve contact and the manoeuvre valve.
- The valve contacts for the electro—hydraulic slide controller are marked and numbered
1 2 3 up to 8.
(The control unit's Icfl manoeuvre [ever I = valve contact I).
(The control unit”: n‘ghf manoeuvre lever 6 : valve Contact 6 )»
~ The valve contacts for the dump valve are marked M. ( Max. output drive max JAM.)
( Thefimction is automatically cut of/ifluaded by more than 2Amp.. t' e the output tr not damaged ).
- All cable and valve contacts must remain in place even for valve contacts which are not
used. Unused valve contacts should be carefully sea ed with grease and electrical tape
( to keep damp out which could cause operational disturbances / alarms ).
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Installation instructions 4 - 6
4. Next install any ON/OFF functions required. The ON/OFF cable is marked EX and should
be connected to the "ON—OFF" contact on the electronicbox.
- Non'nal ON/OFF function usage is to drive a signal lbeep function, throttle lever,
changeover valves, motor start/stop etc. See connection recommendations for the
starting of a motor !
Each ON/OFF function can drive a maximum of 1.2 Amperer
. The output function is disconnected automatically if loaded by more than 1.2 Amp., i.e.
the drive output is not damaged.
( For higher output drive an auxiliary relay can be mounted. See connection schematic
for starting of vehicle motor ).
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5, Connect the power supply cables via the crane emergency stop box to the electronicbox +
supply voltage + and — to ground.
Cable number : 1 (+24 VDC , +/-2l]% , max. 5% V peak to peak) Marked: +
Cable number : 2 (0 VDC/GROUND ) * Marked: -
*Check that the same earth potential exists he!“ een the Scanreco earth cable (No. 2 ) and the vehicle's
battery minus during max. loading ( Let there is not a potential drop [difference as a result of poor
earthing or the cable cross sectional area being insufficient).
Standard car type fuses are located inside the electronicbox. (Plusfuse' 10 Amp. and minusfure.
30 Amp Automatic [user may NOT be used in the electronicbox ).
Use supply cable with the correct dimension (min. 1.5-2.5 mm1 ), so that the cable
bushings in the crane emergency stop box seal properly. Make sure that all cable terminals
are well tightened.
For back end mounted cranes : Use supply cable of min. 2.5 —5.0 mm2 ! l !
Use plenty of grease in the emergency stop breaker and its screws and the supply cable.
Connect power from the vehicle battery via the vehicle‘s ignition switch or power outlet.
Mg l Volvo trucks which break main power on the earth side ( not the plus side ) :
Make very sure that the electronicbox earth is connected correctly, i.e. that the earth for the electronicbox
is also disconnected !!
Installation instructions
Connection schematic for ON/OFF functions.
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Function / descri tion :
No: 1 Continuous full working throttle.
Automatic connection of full throttle. 1
Stop vehicle motor.
HPLS ON
HPLS OFF
S itch EX cable
1 ON
1 Centre No: - Idle.
1 OFF No: 1
2 ON No: 2 Start vehicle motor. 2
2 OFF N0: 3
3 ON N0: 4 RPM +
3 OFF No: 5 RPM -
ON/SIGNAL N0: 7
Signal / Beep / or Overload reset.
4-7
+ 24 VDC ( 1.2 Amp ) is provided on each respective line on the EX cable after the respective
ON/OFF function is activated from the control unit.
Note. An auxiliary relay is not normally required for ON/OFF functions except for starting of the vehicle motor.
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. Automatic throttle control, i.e. throttle opening occurs at the same time that a manoeuvre is started with one
of the levers, The throttle opening has a shut-down delay, i.e. it stays up for ca 6 seconds after the latest lever
movement.
Installation instructions 4 — 8
Connection of motor start / start lock :
- To protect the starter motor against unintentional re-start attempts after the vehicle motor
has already started, it is recommended that an electric "start lock" is connected in after the
motor start signal from the electronicbox, EX cable pin 2 ( See connection example
below )i
a To be able to find out if the vehicle motor is already started, a signal can be taken, for
example, from the generator. In this way the crane drivercannot activate the starter motor
by mistake.
- Before connection, consult the truck manufacturer, customer and inspector !
Start lock / Protection relay. Help relay.
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a When an Impulse is received from the portable control urtil, +24 VDC is generated (EX no 2) ml the start
lock relay, to the starter motor. When the motor hat started, the start lock relay receives a val/age uh pin 86
from the generator and the relay 1: pulled
- lfa new activation is made and art impulse is generated from the portable control unit the voltage will not
reach the rtarter molar, rmce the start lock relay is activated, t’.e. a start nanvrepeal lock.
- Generator connection ’ D+ Thu is only an example Before connecttng, contact the truck manufacturer 1
Flying Jib / Extending jib :
During the manoeuvring of for example a jib / tool or reversing valve from the control unit the
manual switch / breaker must always be activated. This is so that manual manoeuvring can be
made if any fault should occur in the remote control system.
Installation instructions 4 f 9
Connection schematic for Scanreco RC 400.
Control unit : Electronicbox :
Left lever, 1A, 1B Contact No: 1 (Valve contact, No: 1 ).
Right lever, 6A, 63 Contact No: 6 (Valve contact, No: 6).
( Example : Swing, inner boom, outer boom, extension, accessory, rotator ).
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Option / extra ( for 7th and 8th proportional functions ).
Change function 5 to 7 = Valve contact 7 ( Electronicbox ).
Change function 6 to 8 = Valve contact 8 ( Electronicbox 1.
(Change by using switch 4 , OFF = 5th and 61h functions , ON = 7th and 8th functions).
The location of the change functions lever l - 6 , to 7- 8 , can be selected freely at delivery.
Installation instructions 4 - 10
9. BATTERY CHARGER AND BATTERY CHARGING.
The battery charger must be mounted in a vibration free location inside the cab or indoors to
give protection against damp and temperature variations.
. The normal charge time for an empty discharged battery is approx. 12-14 hours.
- The battery charger should be connected directly to the vehicle's battery to enable idle time
to be utilised for charging
o The battery charger is constructed so that the battery packs will not be damaged by long
continuous charging.
. The supply voltage for the battery charger should be +1 1 VDC to +30 VDC.
There are two light emitting diodes gLEDs] on the batten charger :
- A RED LED (POWER) : indicates supply voltage present ( i.e. from the vehicle battery ).
. A GREEN LED (CHARGING) : indicates that charging is taking place.
A fuse-holder ( bayonet type ) is located next to the power cable with a glass fuse
3 Amp. ( quick ), with size S x 20 mm.
Polarity for connection cable + Blue and — Brown
Battery charger current withow batterypack IS.’ =10 - 20 mA
Battery charger current with battery pack it =130 - 140 mA
Terminal voltage at battery charger terminal: is appt‘m‘imalely the same as the vehicle Supply voltage
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With defective / nun-functioning battery charger:
If the driver is using cable control and the battery pack is located in the control unit, the
battery will be charged automatically. See also below.
Battery charging via cable control, e.g. over night : (Charging time is approx 12-14 hours).
Place the battery pack into the control unit (emergency stop depressed) and connect the cable
between the control unit and the electronicbox (crane's emergency stop rwisied up).
The electronicbox in Remote : (Power. and LED No 4 M blink). Battery charging is now taking
place i
Installation instructions 4 — 11
Changing the direction of crane movement.
The description which follows describes how to change the direction of movement if the
crane moves in a different direction to that desired.
Example:
After installation and test operation it is found for example that the 3rd and 5th lever move?
ments operate in the opposite direction to that desired. See the example below for how to
change the 3rd and 5th lever movements.
DO AS FOLLOWS!
1.
Remove the battery pack. Connect the cable between the control unit and electronicbox
and test run the crane. Then press the emergency stop on the control unit and emergency
stop on the crane.
. Twist up the emergency stop on the control unit and on the crane.
. Press the control unit's ON/SIGNAL/FREQ.-Sl—IIF1' button.
(The red LED should light continuously).
Press spring return switch MICRO in veg quick succession to the RIGHT in the OFF
direction to produce impulses until the control unit gives a long beep signal. Wait approx.
12 seconds for a new long beep signal then continue with item 5.
Note 1. The red LED will be extinguished each time the control unit gives a beep signal.
Note. 2. If you do not receive the first long beep signal, start again from item 1 and execute items 3. and 4.
quicker. Items 3. and 4. must be executed within max. 5 seconds.
. Now press ON/SIGNAL/FREQ.-Sl-IIFT once.
( The control unit’s built-m beeper wtll give a short beep once every 5 seconds It) confirm that the item:
above have been done correctly [forty other beep signals are heard you must restartfi'om item I again 1.
Now you can easily change the crane direction, see item 6.
Now you can operate the crane. Move the 3rd manoeuvre lever ( which is operating in the
opposite direction to that desired ) away from zero position until the crane just starts to
move and hold it there then give switch MICRO an impulse to the LEFT in the ON
direction. The crane will now change direction and continue with the same selected speed,
in the opposite direction. Do the same with the 5th manoeuvre lever.
Move the 5th manoeuvre lever (which is operating in the opposite direction to that which is
desired) away from zero position until the crane just starts to move and hold it there and
give toggle switch MICRO an impulse to the LEFT in the ON direction.
The crane will now immediately change direction and continue with the same selected
speed in the opposite direction. ( If a direction change has been made earlier/or a particular lever. do
(he same as above but give toggle switch MICRO an impulse to the RIGHT, in the OFF direction).
Operate and check that all crane movement is now in the desired direction.
, Press the emergency stop on the portable control unit. Programming is now completed and
the crane is operating in the directions YOU decided in item 6. If you are not satisfied with
any direction/directions, repeat these. See item 1.
Installation instructions 4 - 12
General technical data :
For dimensions, see chapter 2 - ”General system description ”.
Portable control unit:
Battery pack : 7.2 VDC.
Control unit effective operating time : Approx. 8 hours per charge.
Weight : I.6 kg ( without battery pack and radio transmitter).
Weight: 1.9 kg ( m battery pack and radio transmitter).
Electronicbox:
Supply voltage (See order) : + 24 VDC( +/- 20 % / max. 5% V peak to peak ).
Max. over-voltage : Approx. 33 VDC ( Fuse blows ).
Proportional functions : l - 8 double operating proportional functions.
Dump valve drive : Max. 20 Ampere ( short circuit proof ).
ON/OFF drive : Max. 1,2 Ampere ( short circuit proof ).
Regulation signal disconnected with: Supply voltage + 24 VDC at 15 - 17 VDC.
Current consumption at Idle: 60 mA (Without radio receiver box ),
140 mA (With radio receiver box ).
Total current consumption : See Danfoss catalogue for PVEO, PVEM, PVEH-cunenl
consumption 1
Sum all current consumption, i c. all PVEM/PVEH.
ONIOFF functions, dump valve etc.
Fuses in electronics box : Plus : + 10 Amp. ( Standard car fuse / Red ).
Ground : - 30 Amp. ( Standard car fuse/Green ).
Battery charger :
Battery charger current consumption without battery pack is : z 10 - 20 mA.
Battery charger current consumption with battery pack is : = 130 - 140 mA.
Terminal voltage at battery charger terminals is : z Vehicle supply voltage.
Fuse 1 Glass fuse 3 Ampere ( quick ), with size 5 x 20 mm.
Location : The fuse holder ( bayonet type ) is to be found beside the connection cable.
5. FAULT FINDING.
The crane driver should check the following before calling the service
workshop.
Page :
o Functional system / LEDs indication on Electronicbox. 5.2
- Always check this l 5.3
. Error messages on the electronicbox / actions. 5.4
- Electrical connection schematic for electronicbox cables. 5.5
o Electroniebox with lid removed. 5.6
The service workshop can check the following before Scanreco AB,
Sweden is contacted.
Page :
. Whole system not functioning ( In depth fault finding ). 5.7
- Control unit red lamp M continuously. 5.8 -
A Some proportional functions missing. 5.10 -
. Some ON/OFF functions missing. 5.12
- Test mode for control unit (Internal tests) 5.13 -
- Cable control works but not radio. 5.14
- Repair of control cable. 5.15
- Programming of 1D code (Only authorised workshops). 5.16
Fault finding 5 » 2
INDICATIONS WITH FUNCTIONING
SYSTEM.
The following LEDs must be lit on a functioning system :
(For other LED combinations and indications , see next page/pages! ! ).
A. Portable control unit turned off, the following LEDs light :
"REMOTE" mode : ( POWER LED lit and LED No 4 must blink).
. "MANUAL" mode: ( Only DV ).
B. Portable control unit activated , the following LEDs light :
( The red LED on the control unit must be lit continuously ).
- "REMOTE" mode: ( With radio operation : POWER, DV* , 2 , 3 ).
- ”REMOTE" mode: ( With cable operation : POWER, DV*, 2 , 3 , 4).
DV" . When remote control is activated, the dump valve is also activated If the manoeuvre levers
remain in the neutral Qositt‘on for more than approx. I second, the dump valve will automati—
cally be deactivated (tie. the oil is dumped to the tank)
Later when one ofthe manoeuvre levers leave: the neutralposition, the dump valve will be
reactivated at the same time.
( All manoeuvre levers and ON/OFF functions must be in the neutral position, he not
activated. During operation by radio , the GREEN LED on the radio receiver box
must be lit ).
nm a, . Am i nm
Fault finding 5 - 3
Always check this !
Always check th '
- Is there + 24 VDC, +/- 20 %, max. 5 %Vpeflk to peak supply to the system? Measure at the
crane emergency stop switch (unloaded and loaded ). See also page 4-6 H!
. Are the electronicbox fuses whole, Le. +10 Amp. (Plus) and - 30 Amp. (Ground) 7
Open clectronicbox lid and check.
- Does cable control function 7
- Does the crane work manually, i.e. with the electronicbox power supply switch in
"MANUAL" position ?
- Place switch into " REMOTE " position.
- Unscrew and remove the EX cable from the electronicbox.
. Remove valve contact DV from the dump valve.
- Remove valve contacts Nos. 1 to 8.
. Answer item 2.
2. When all these contacts are removed, which LEDs are lit on the electronicbox '.’
The following LEDs are lit:
Fault finding 5 - 4
Error messages / Actions.
Simple error messages can he read with the help of the LEDs on the electronicbox. LEDs
1 - 4 are used to give error messages. The first LED (No.1) always ' ks w' h errors and
then a combination of lights is shown on LEDs 1 - 4 .
When the control unit is activated and the electronicbox switch is in " REMOTE "
position do any of these LED combinations exist 7
Error message : Error source / Reason : Action :
LED I, pause and then LED 2 ON/OFF function, lOver—loadf“ Unscrew EX cable,
LED 1, pause and then LEDs 2 and 4, Dump-Valve ( short circuit ). Remove valve contact DV.
LED I, pause and then LEDs 2 and 3. Danfoss electro-hydraulic unit Remove valve contacts 1-8.
(short circuit)
LED I, pause and then LEDs 3 and 4 Danfoss-regulator signal invalid action Remove valve contacts 1-8.
LED I, pause and then LEDs 1 and 4 Error supervision in PVEH activated, Remove valve contacts 1—8,
* Load drawn by one of the ON/OFF outputs on the EX cable 15 more than 1.2 Amp. Check connection and
magnetic winding.
Another combination is lit :
Electronicbox type and ser. no. :
Control unit type and ser. no. :
(A gpe label is located on the control uni], electronicbox and radio receiver box).
Fault finding 5 - 5
Error messages / Actions.
Simple error messages can be read with the help ofthe LEDs on the electronicbox. Him
1 — 4 are used to give error messages. The first LED (No.1) always blinks with errors and
then a combination oflights is shown on LEDs 1 - 4 .
When the control unit is activated and the electronicbox switch is in " REMOTE “
position do any of these LED combinations exist ?
Error message : Error source / Reason : Action :
LED 1, pause and then LED 2. ON/OFF function. / Over load.‘ Unscrew EX cable.
LED I. pause and then LEDs 2 and 4. Dump valve ( short circuit ). Remove valve Contact DV.
LED 1. pause and then LEDs 2 and 3. Electro-hydrauhcvalve / coil Remove Valve contacts 1—8.
(short circuit).
* Load drawn by one of the ON/OFF outputs on the EX cable is more than 1.2 Amp. Check connection and
magnetic winding.
Another combination is lit:
Electronicbox type and ser. no. :
Control unit type and ser. no. :
(A type label is located on (he control umn electronicbox and radio receiver box)
Fault finding 5 - 6
Connection schematic for electronicbox with ready-made cables for
Danfoss electro-hydraulic boxes : PVEM or PVEH.
Incoming supply voltage: + 24 VDC ( +I- 20% . mait, 5‘7szeak to peak)
Regulation range: 5,8 — 182 V (+ At 24.0 V ) Neutral position: + 12.0 VDC (+ At 24,0V)
Incoming supply voltaget Dump valve :
2 Incoming : Ground I 0 VDC. 2: Ground, dump valve.
1 Incoming : + 24 VDC ( See above) 1: Plus drive. dump valve,
Movement 1. (Scanreco's cable and cable number in valve Contact ).
1 Outgoing supply voltage for PVEM or PVEH I Danfoss pin No: 1.
l Regulated voltage for PVEM or PVEH / Danfuss pin No: 2.
Yellow/green Outgoing ground ( 0 VDC ) for PVEM or PVEH/ Danfoss pm No: Ground.
3 Option (Error supervision I’VEH ) / Dun/0:3 pin No 3
Movemenl 2. ( Scanreco's cable and cable number in valve contact).
1 Outgomg supply voltage for PVEM or PVEH / Danfoss pin NO‘ 1.
2 Regulated voltage for PVEM or PVEH / Danfoss pin No: 2
Yellow/green Outgoing around ( 0 VDC ) for PVEM or PVEH I Danfoss pin No: Ground.
3 Option (Etror Jupé'rvtxtbrt PVEH) / Danfim pm No 5.
Movement 3. (Scanreco's cable and cable number in valve cantnct ).
l Outgoing supply voltage for PVEM or PVEH I Danfoss pin No: 1,
2 Regulated voltage for PVEM or PVEHI Danfoss pm No: 2.
Yellow/green Outgoing ground ( 0 VDC ) for PVEM or PVEH I Danfoss pin No: Ground.
3 Option (Error supervision PVEH) / Dart/0.“ pin No 3
Movement 4. (Scanreco's cable and cable number in valve contact).
1 Outgoing supply voltage for PVEM or PVEl-l I Dantoss pin No: 1.
2 Regulated voltage for PVEM or PVEH I Danfoss pin No: 2.
Yellow/green Outgoing ground ( 0 VDC ) for PVEM or PVEH/ Danfoss pm No: Ground.
3 Option (Error supervision FVEH) / Dun/0:5 pin No. 3.
Movement 5. ( Scanreco's cable and cable number in valve contact).
1 Outgoing supply voltage for PVEM or PVEH I Danfoss pin No: 1.
2 Regulated voltage for PVEM or PVEH / Dan(oss pin No: 2.
Yellow/green Outgoing ground ( 0 VDC ) for PVEM or PVEi-l/ Danfnss pin No: Ground
3 Option (Error supervision PVEH) / Danfus: pin Na‘ 3.
Movement 6i (Scanreco's cable and cable number in valve contact).
1 Outgoing supply voltage for PVEM or PVEH I Danfoss pin No: 1.
2 Regulated voltage for PVEM or PVEH I Danfoss pm No: 2.
Yellow/green Outgoing ground ( 0 VDC ) for PVEM or PVEH I Danfoss pin No. Ground,
3 Option ( Error xupzrvisiori PVEH) / Dan/0:5 pin Na. 3.
Movement 7. (Scanreco's cable and cable number in valve Contact ).
l Outgoing supply voltage for PVEM or PVEH/Danfoss pm No: 1.
2 Regulated voltage for PVEM or PVEH I Danfoss pin No: 2.
Yellow/green Outgoing ground ( 0 VDC ) for PVEM or PVEH I Danfoss pin No: Ground.
3 Option (Error supervision PVEH) / Danfuss pin Na: 3
Movement 8. ( Scanreco's cable and cable number in valve contact).
1 Outgoing supply voltage for PVEM or PVEH I Danfoss pin No: 1
2 Regulated Voltage for PVEM or PVEH I Danfoss pin No: 2.
Yellow/green Outgoing ground ( 0 VDC ) for PVEM or PVEH I Dant’oss pin No: Ground.
3 Option (Error supervision PVEH) / Dan/ass pm N0. 3,
Fault finding 5 » 7
Connection schematic for electronicbox for proportional coils /
electro-hydraulic slides.
Incoming sugply voltage: + 24 VDC , +/» 20% max 5%Vpeak to peak
Cable numbering in electroniebox / Cabling:
Incoming supply voltage: Dump valve :
2 incoming : Ground I 0 VDC. 2: Ground. dump valve.
1 Incoming : + 24 VDC ( See above) I. Plus drive, dump valve.
Movements 1A and 1B.
2 1A , Ground.
1 1A , Current signal ( PWM ).
2 IB » Ground,
1B ,Currenl signal ( PWM ),
Movements 2A and 2B.
2 2A , Ground.
l 2A , Current signal ( PWM ).
2 28 , Ground
1 2B , Current signal ( PWM ).
Movements 3A and 3B.
2 3A ,Ground,
I 3A , Currenl Signal ( PWM ).
2 3B , Ground.
I 313 ,Currem signal ( PWM ).
Movements 4A and 4B.
2 4A , Ground
1 4A , Current signal ( PWM ).
2 AB , Ground.
1 4B , Current signal ( PWM ).
Movements 5A and SB.
2 5A , Ground
1 5A , Current signal ( PWM ).
2 5B . Ground
1 SB , Current signal ( PWM ).
Movements 6A and GB.
2 6A , Ground.
1 6A , Current Signal ( PWM ).
2 6B ,Ground.
1 6B ,Currenl Signal ( PWM ).
( PWM = Pulse Width Modulated )
Fault finding 5 — 8
Electronics box with lid removed.
DiODE 21
2 (TWO) PIECES
FUSEHOLDERS
WITH FUSES
fifififififififififi
R93311E
- Plus fuse: +10 Amp. (Red) / (Standard car type fuse).
- Minus fuse: - 30 Amp. (Green )/ (Standard car type fuse).
Fault finding 5 - 9
1. WHOLE SYSTEM N FUNCTIONAL.
__—___———_
The MANUAL/ OFF/ REMOTE switch on lhe eIec/ronicbox can be used to select between manual operation
and cable or radio control
R93085
1.A. Electronicbox.
REMOTE position: No functions work and the electronicbox POWER LED not lit
MANUAL position: No functions work and the electronicbox DV LED not lit
1.A1. Is the vehicle’s ignition or power outlet switched on ?
1.A2. Is the crane emergency stop button pulled up 7
1.A3. Is switch MANUAL l OFF / REMOTE in the OFF position 7
1.A4. Check the power supply cables to the electronicbox. cable connections to the crane
emergency stop switch and the two fuses in the electronicbox (See item 1 A5).
1.A5. The Electronicbox fuses are accessible after the lid has been removed and are standard
car type.
PLUS {use 10 Amp (Red) , The fuse holder is marked: + 10A.
MINUS fuse 30 Amp. (Green) , The fuse holder is marked: - 30 A.
(Blownfilses should nor be replaced more rhan one (I) rime without the short Circull having been located If the
MINUS/GROUNDfilse has blown make a careful check oflhe vehicle and electronicbox ground connections).
1.A6. Remove the connectors to the ON/OFF functions and radio receiver box.
1.A7. The electronicbox is probably faulty. Contact the service Workshop, retailer or
Scanreco. Sweden for recommended action.
LB. Electronicbox.
MANUAL position: No functions work and the DV LED on the electronicbox is liL
(The crane cannot be manoeuvred manually ).
1.B1. Check the electronicbox dump valve cable (DV) and valve contact.
( Oxide, break or bad contact 7 ).
LBZ. Dump valve coil faulty.
1.133. Dump valve hydraulic / mechanical function faulty.
LB4. Fault in crane's hydraulics / mechanics.
Fault finding 5 - 10
LC. Portable control unit and electronicbox.
Whole system non-functional, but:
Control unit red LED lit, electroniebox POWER LED lit and LED 4 blinking.
1.C1.During radio control: Test using cable control ( control cable ).
If it works with the cable, there is probably a fault in the radio transmitter, radio receiver
box or in their connections. (Does the radio control unit match this electronicbox i.e. same
ID code 7 )
1.C3. During cable control control cable ):
Probably a fault in the control cable. Check the cable connections/contacts.
1.C4. Change and try a new control cable.
LCS. Change and try a new control unit.
1.C6. Change and try a new electronicbox.
1.D. Portable control unit.
The red LED on the control unit does not light when the 0N/SIGNALIFREQ.—SHIFT switch is
pressed.
( cable or radio control ),
( The electronicbox switch MANUAL / OF F / REMOTE mart be in REMOTE past/inn, with POWER LED lit
and LED 4 blinking),
l.D1. Twist up the emergency stop switches on the portable control unit and on the crane.
LDZ. Radio control: Change the battery pack, check the condition of the batteries, check
the battery charger, check the battery holder’s terminals. Test with cable control.
Cable control: Check the cable control cable and its connection/contacts (breaks,
intermittent contacts, shorts circuits).
1.D3. Unscrew the emergency switch panel and any extra switch panels.
1.04. Check the connections to the battery, battery pack and control cable and all other
connections to the control unit’s electronics card. Check the emergency stop switch,
emergency stop switch contact block Check the 0N/SIGNALIFREQ.-SHIFT push
button (Breaks 7 Check continuity of the push button). Check the LED.
l.D5. Radio control: Remove the radio transmitter card ( short circuits / high current
consumption 7),
1.D6. Remove all manoeuvre levers ( abnormally high current consumption 7 ).
1.D7. The control unit's electronics card is probably defective.
1.D8. Contact the service workshop, distributor or Scanrcco, Sweden.
Fault finding 5 -11
LE. Portable control unit.
The control unit beeps and the red LED blinks when 0NISIGNALIFREQ.—SHIF1‘ pressed.
( cable or radio control ).
(Electronicbux xwilch MANUAL /0FF/REMOTE must be in REMOTEPDSHIDYL [he POWER LED must be
[it and LED 4 must blink).
For safety reaxahs all manoeuvre levers must be in the sen) / neutral position in order far a start 10 be made If
any manoeuvre lever is no! in the zero / neutral past/ion during start—up. the control unit will beep and blink the
same number afrime: as the number nj’lhe non-zeroed manoeuvre lever in arder m indicate which manoeuvre
lever is (mum/ed or in error The control unit can be med but lhefauliy lever will be locked and disconnected
(For examplefive (5) beeps and blink: which indicates that fhe 5th leverfi‘um rhe LEFT isfaulry ur moved/rum
58777},
LEI. Change the manoeuvre lever which is indicated as faultyi Check that the manoeuvre
lever is connected to the electronic card in the control unit via the pin / socket strip.
Use care during the assembly.
If the fault is not fixed see item 1.E2,
LEZ. Change the electronic card in the control unit.
Fault finding 5 - 12
2. SOME PROPORTIONAL MOVEMENTS MISSING.
The whole system works, but a particular proportional movement is missing.
REMO
Orr _
MANUAL 1 1:2
RQEOBS
MM
DIR . Manoeuvre lever in A»dircction activated and moved. The intensity of the LED will increase with
increased lever displacement. The LED is commoned and summed, i.e. only one manoeuvre lever at a time can
he manoeuvred in A—direction for a check to be made.
DIR. B: Manoeuvre lever in B-direction activated and moved, The intensity of the LED will increase with
mcreased lever displacement. The LED is commoned and summed, i,e, only one manoeuvre lever at a time can
be manoeuvred in B-direction for a check to be made.
2A. DIR. A / DIR. B LEDs not lit, during manoeuvre of a certain prop. function from the
control unit.
Z.AI. Change the manoeuvre lever, i.e. change the "non working" manoeuvre lever to a
working function If the fault moves on the control unit the manoeuvre lever is faulty.
1. Change the manoeuvre lever,
2. Change the electronic card in the control unit.
3. Change the electronicbox.
Z.A2. The function can also be tested with the "TEST-MODE".
2.3. DIR. A or 0111.8 LEDs m during manoeuvring from control unit but:
A particular valve movement does not function.
2.131. Check the cable and valve contact between the electronicbox and the electro—
hydraulic slide control.
2.132. Change the faulty Valve contact on the electro-hydraulic slide control to a working
function, If the function now works, then the fault was in the previous electro-
hydraulic slide control
Change the electro-hydraulic slide control/valve section.
2.33. Change the electronicbox.
Fault finding 5 - 13
2.C When manoeuvring is started with the “faulty” manoeuvre lever, movement stops.
2.C1. A shon circuit, overload or other fault exists between the electronicbox valve cable
and valve contact or in the electro—hydraulic slide control,
2.Cl. Change the faulty valve contact on the electro-hydraulic slide control to a working
function.
If the manoeuvre lever now works there is a short circuit or other fault in the electro—
hydraulic slide control.
Change the electro-hydraulic slide controlr
If it still doesn’t work - see item 2.C2.
2.C2, Check the cable and valve contacts between the electronicbox and the slide control,
(Check the cable for damage, oxide etc. ).
2.C3. Repair / fix / clean / grease any damage [0 the cable or valve contact.
2.C4. Change the electronicboxr
Fault finding 5 — 14
3. CERTAIN ON/OFF FUNCTIONS MISSING.
ON/OFF: ON/OFF function activated. The LED is Commoned and summed. i.e. only one switch at a time can
be activated from the control unit for the check to be made.
REMOTE
err ,
MANUAL “
v _
R93085
3. An ON/OFF LED does not light when a certain switch is activated on the portable
control unit.
Test of the portable control unit:
3.A1. First check the control unit and its switches. The test is best made in the control unit’s
"TEST-MODE". (See section ”TEST-MODE”).
"TEST-MODE” selected: The control unit beeps when the "faulty" switch is activated, (Le.
switch and control unit OK) - go on to section 3.A24
3.A2. ”TEST—MODE" selected: The control unit does not beep when the "faulty" switch is
activated.
Check the cable connections to the switch in the control unit.
Change the switch panel.
Change the electronic card in the control unit.
Test of electronicbox:
3.A3. Remove the ON/OFF cable ( Ex ) connection from the electronics box. If the fault
disappears see section 3,A4. If the fault remains there is a short circuit in the
electronicbox ON/OFF contact or in its cable connections.
3.A4. Short circuit in the electronicbox ON/OFF cable ( EX ) or in its connections (Measure
continuity).
Repair break, short circuit or change ON/OFF cable. ( EX ).
3.A5. ON/OFP function’s current consumption exceeded (Max, 1.2 Amp. / function).
3.A6. Short circuit in the manoeuvred function (electromagnet / coil / motor / relay etc, ).
3.A7. Electronicbox drive stage faulty, change electronicbox.
3.13 ONIOFF LED lights during activation, but function on crane not activated.
3.B1. Check the electronicbox ON/OFF cable (EX) and its connections (Measure continuity).
3.32. Check the electronicbox ON/OFF contact ( Ex ) and its connections in the box.
3.B3. Check the manoeuvred function’s connections and its function.
Fault finding 5 ~ 15
PORTABLE CONTROL UNIT TEST-MODE .
Functional description.
To simplify service and faultfinding, the portable control unit can be put into internal TEST-
MODE.
This means that the service man can easily control the control unit's switches and manoeuvre
levers, without the need to open the control unit.
When each switch or manoeuvre lever is activated / manoeuvred the control unit gives a
"beep - signal" to confirm that the function is working.
When "TEST - MODE" is selected M transfer of proportional, ON/OFF, or dump valve
functions is made to the electronicbox.
mum in iiltlltiHHiHlllmiiii HHIIIHmunminullllii‘i mllmlimm u rm
Do as follows :
1. Press emergency stop on the control unit.
Twist up the emergency stop on the control unit and press ON lSIGNAL/FREQ.-SHIFT.
3. Then press ON / SIGNAL/FREQ-Smn ten ( 10) times is quick succession.
(This can be done either by cable or radio control).
4. The control unit's red LED should blink quickly.
( If the LED is lit continuously, restart from item 1 ).
5. The control unit TEST— MODE is now selected - see item or
6. Each time a switch is activated / manoeuvred the control unit should beep.
( If a particular switch does not beep, there must be a fault in the switch or in the control
unit’s electronic card ).
7. Each time a manoeuvre lever is activated / manoeuvred a beep signal should be heard from
the control unit which increases in I‘sound intensity” with lever displacement. The control
unit beeps with a continuous tone when the manoeuvre lever is manoeuvred to maximum
This gives a confirmation that the control unit‘s levers have been manoeuvred fully lmax,
( If a certain manoeuvre lever does not beep there is a fault in the manoeuvre lever, pin /
socket contact or in the control unit’s electronic card ).
8. When testing of the control unit is completed, press down the emergency stop on the
control unit. The control unit will now function normally.
Fault finding 5 - 16
RC 400 which only works with cable, not with radio.
A. Changing radio transmitter or radio receiver box.
Test first by changing the radio receiver box ( i.e. the unit located on the crane).
1. Changing the radio receiver hox.
Do not unscrew the entire radio receiver box but do as follows :
A. Unscrew and remove contact : "RADIO” from the electronicbox.
B. Test by connecting the contact to the "nfl" radio receiver box.
C. Test run the system with radio control,
D. If it still does not work, see item 2.
E. Screw back the contact from the "g" radio receiver box.
F. M but the radio transmitter is probably defective, see item 2 !
Note. If the GREEN LED does not light on both radio receiver boxes, there is probably a fault
in the electronicbox radio contact or inside the electronicbox. Contact Scanreco,
Sweden in this case.
2. Changing the radio transmitter ( Le. inside the portable control unit).
A. Unscrew the 2 (two) screws on each short side on the under-sidet ie. a total of 4 ( four )
screws.
Pull the over and under sections carefully apart.
B. Unscrew the radio transmitter ( total of 4 screws) and replace it with an exchange unit.
To avoid intermittent contact/functional disturbances from the radio transmitter, the
mounting screws for the ”new" radio transmitter must be well tightened !!
C. Replace the upper and lower halves, replace the screws and then test run.
If the radio units still does not work contact Scanreco AB, Sweden.
Doc.nr : 6611-007
Fault finding 5 » 17
Repair of control cable.
General :
The control unit is connected to the electronicbox via a thin and flexible 3—core cable, The
cable has circular type connection contacts (Amphenol / Hirchmann) at each and
Final control : Ohm measure the cable’s contacts for check of continuity.
(Rec. area I min 0.5 mm”
Connections in the cgntac; :
l = Supply
2 = Data
J. = Ground/Minus
3 A Not connected
Connecting :
fl : Q :
Ground 41» Ground
1 4:1
2 4:2
K1 K2
1 JORD
2 3
Fault finding 5 ~ 18
Programming of radio identity codes.
Do as follows :
1. Remove the battery pack from the control unit. Test run the system withcable control.
2. Leave the cable control connected between the control unit and the electronicbox.
3. Press the emergency stop on the control unit and then on the crane.
The red LED on the control unit must he fl, and all LEDs on the electronicbox
must also be of!!!
4. Twist up the emergency stop on the crane and then on the control unit.
5. Press the 0N/SIGNAL/FREQ.-SHIFI‘ button ( the red LED will light) and hold it down for at
least 10 seconds. The control unit will beep in quick succession to confirm that
programming is completed.
6. The programming is completed, remove the cable control, replace the battery pack and test
run the crane with radio control.
7. If this procedure does not work, repeat the programming ( see items 2—6 ). If it still does not
work, contact Scanreco AB, Sweden,
Information.
During cable control, all control units can be used to the crane in question, i.e. during cable
control the radio transmitter and radio receiver box and the identity code is disconnected
automatically.
The battery is charged automatically during cable control.
6. SPARE PART
RC 400 - SPARE PARTS AND SPARE PARTS LIST
Introduction.
The RC 400 remote comm] system is constructed using a number of standardised basic
components which enables a minimum of spare parts stocks. & adjustments are required
after the changing of system parts. This means quick, simple and effective service,
The spare parts list is divided into 10 ( ten ) main groups. The order number, part description
and required quantity must always be given when spare pans are ordered. When ordering
spare pans for a specific type of remote control please state the system model/type number
and serial number ( TYPEi , SerNo. ),
( Model labels are to be found on the control unit, eIecImnicbox and radio receiver box )
Contents:
- Portable Control unit (for cable or radio control).
- Control cable ( electrical 3-core ).
- Control cable (opto fibre cable ).
- Crane emergencystop box.
. Electronicbox.
- Expansion cable ( EX ).
- Radio transmitter.
- Radio receiver box.
- Battery charger.
a Battery pack.
. Accessories / Options.
8. PROGRAMMING PARAMETERS AND
SETTINGS.
E H"
The Scanreco RC 400 offers considerable possibilities for system constructors of hydraulically
driven mobile cranes and machines. The program in the control system is very comprehensive,
flexible and has many adaptation possibilities for specific applications. The control system
offers simple programming of a number of functions which can easily be turned on or off or
altered during operation.
To obtain the best manoeuvre characteristics in the simplest way, all programming /calibr~
ation of manoeuvre characteristics is made during operation ( so called on—line ). All prog-
ramming / calibration is made from the portable control unit. Programming is simple and
does not require tools / instruments or any special knowledge.
(Programming can ofcuurse be also madefrom a PC, terminal).
The control system is furnished with and prepared for 2-way (duplex) communications and for
signal handling of functions such as ramp. parallel, lock, ”dead-man’s", hold, double and
overload / lift reduction etc.
THE SYSTEM HAS 4 LEVELS OF AUTHORISATION:
- Authorisation level 1. (Installer),
- Authorisation level 2. ( Well trained installer, well trained service personnel ).
- Authorisation level 3. ( Well trained crane and valve manufacturer, well trained system
constructor ).
- Authorisation level 4. ( Scanreco AB, Sweden ).
- Authorisation level 1: | Installer 1.
LA To change the direction ofthe crane.
If the crane moves in the opposite direction to that which is desired.
- Authorisation level 2: 1 Well trained installer, well trained service personnel 1.
- 2.A Individual changes to the manoeuvre valve star1 speed for A or B ports.
If the manoeuvre valve’s starting value "dead-band” is to be increased or decreased for A or B port.
- LB Individual speed reduction for A or B ports.
Individual maximum manoeuvre speed reduction for a particular critical function ( e.g.
swing function ). Fully variable speed reduction can be made for manoeuvre valves on the A
or B portst This enables the crane driver to pre-set the maximum oil flow for each individual
function ( A or B port ) as required.
- 2.C Individual changes to micro - speed control for A or B ports.
Due to non-symmetry in certain valves hydraulic system or in the crane / machine the micro
speed can be less well defined. If this is the case the micro-speed final speed can be changed
and adjusted (i.e. for max, lever position) for A or B port for all movements,
Nate: After [he completed odjuslmem afthe micro-speed ,
The remaining micro-Speed’s "reduclion steps ” will be proportional to the railing.
Programming parameters and settings 8 — 2
- 2.D Individual delayed start and stop movements ( ramp functions acceleration and
retardation ).
Ramp functions give soft start and stop movements which protects the crane / machine against
overloading during careless manoeuvring.
Start delay, i.e. this is the time required for the manoeuvre valve slide to reach its final
posttion from the time the manoeuvre lever has left its neutral position. The time can be
set individually to between 0 and 5 seconds for A and B ports. ( See tables below ! )
Stop delay, i.e. this is the time required for the manoeuvre valve slide to come to its neutral
position after the manoeuvre lever has been placed in the neutral position The time can be
set individually to between 0 and 5 seconds for A and B ports. ( See tables below ! )
- Authorisation level 3.
( Only a few of the functions are described here) :
- Individually programmable manoeuvre curves.
The basic characteristics of the manoeuvre curves can be varied extensively. The manoeuvre
curve in relation to the manoeuvre lever can be linear, linear with different curve slopes or
with a break point in the manoeuvre curve The appearance and characteristic of the
manoeuvre curve can be individually installed for each valve section ( A or B port ) for
example for a particular critical function.
- Programming for the 7th and 8th valve movements or for serial tandem operation.
- Double function ( different control characteristics depending upon speed, ramps etc. ).
- Hold function: ( i.e. "lock" a function at a particular speed, after which the speed will be
kept constant without the lever needing to be held ).
- Dead-man's function (can be designed to cater for different safety requirements )4
- Individual or common reduction functions. A reduction or stop can be ordered by external
input signals in critical situations if the crane / machine becomes overloaded or / and
overturns External input signals can also cause reduction of speed of all functions to be
made in the case of insufficient pump capacity. With external input signals, when the crane
driver is working from a sky lift. an automatic reduction/decrease of speed can be made.
With external input signals the control system can always drive the support legs down but
upwards only if the pressure in cylinder is so low that the vehicle is standing firmly, etcr
- Automatic dumping: ( an optional time can be set for automatic dumping/unloading, which
means unnecessary heat generation is avoided and a further increase in safety ).
E.t.c.
The Installer/system designer is responsible for seeing that the RC 400 is used correctly
for all applications and is responsible for any re-programming of the system functions
and the characteristics changes caused by this.
See section 2.D. Ramp timesfor various classes are given in the tables below ( Classes t] to 15) :
( Times can be set, as per the table, for delayed star! and Line movements for A and B port: ).
Cl-ss Ramp tlme tales.) Class Ramp time mu.)
0 O 0 set: S l.() sec
1 0 1 sec. 9 l 2 sec
1 D 2 sec. 10 1.5 sec
3 D 3 sec. ll 1 7 sec
4 u 4 sec 12 2 0 sec
5 D 5 sec. 13 z 5 see
5 Désec. IA 3,55ec
7 0 8 sec. 15 5 0 sec
Programming parameters and settings 8 - 3
Changing the direction of m ment of the crane.
This describes how changes in direction ol‘ movement are made if the crane moves in the
opposite direction to that desired.
Example:
After installation and test operation it is found that the 3rd and 5th lever movements operate in
the opposite direction to that desired. See the example below for how to change the 3rd and
5th lever movements.
D0 AS FOLLOWS!
1, Remove the battery pack. Connect the cable between the control unit and electronicbox and
test run the crane. Then press the emergency stop on the control unit and emergency stop
on the crane.
2. Twist up the emergency stop on the control unit and on the crane.
3. Press the control unit’s ON/SIGNAL/FREQ.~SHIF1‘ button.
(The red LED should light continuously).
4. Produce impulses in very quick succession with spring return switch MICRO to RIGHT in
the OFF direction until the control unit gives a long beep signal. Wait approx. 12 seconds
until the next long beep signal then continue with item 5.
Note 1. The red LED will be extinguished each time the control unit gives a beep signal.
Not 2. If you do not receive the first long beep signal, start again from item 1 and execute items 3. and 4.
quicker. Items 3. and 4. must be executed within max. 5 seconds.
5. Now press ON/SIGNAL/FREQ-SHIFT once.
( The control unit's built-in beeper will give a short beep once every 5 seconds to confirm that the item:
above have been dune correctly. Ifuny other beep signals are heard you must restart from [Ian I again ).
Now you can easily change direction, see item 6,
6. Now you can operate the crane. Move the 3rd control lever ( which is operating in the
opposite direction to that desired ) and give switch MICRO an impulse to the LEFT in the
ON direction.
The crane will now change direction and continue With the same selected speed, in the
opposite direction. Do the same with the 5th manoeuvre lever.
Move the 5th manoeuvre lever (which is operating in the opposite direction to that which is
desired) and give toggle switch MICRO an impulse to the LEFT in the ON direction
The crane will now immediately change direction and continue with the same selected
speed in the opposite direction. ( If a direction change has been made earlier for a particular lever, do
the rame as above but give toggle switch MICRO an impulse to the RIGHT, in the OFF direction)
Operate and check that all crane directions go in the desired direction.
7. Press the emergency stop on the CONTROL UNIT.
Programming is now completed and the crane is operating in the directions YOU decided
in item 6.
( Fur radia operation. remove the cable control and test run the crane).
If you are not satisfied with any direction/directions, repeat these. See item 1.

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