REAC RCB11 User manual

www.reac.se
USER MANUAL
RCB11 & RCB12
REAC CONTROL BOX

www.reac.se
About REAC
REAC is passionate about helping people in their daily lives, and by providing a wide range of advanced
power solutions suitable for many different applications, we hope to make people's lives a little bit easier.
Our aim is to offer our clients an excellent service, backed up by experience and know-how in the
application of advanced motion systems.
REAC's power solutions contain compact and strong electrical actuators, lift and tilt systems, control units
and hand controls. We know that our customers have different needs and therefore our products are
designed to be customized according to their application’s specific requirements.
We are confident to say that we can solve a wide range of motion problems, so please challenge us!
Contact information
REAC AB
Forsbrogatan 4
662 34 Åmål
Sweden
Phone: [phone]
Email: [e-mail]
Web: www.reac.se

www.reac.se
Table of Contents
1INTRODUCTION ..................................................................................................................................... 1
1.1 DOCUMENTATION......................................................................................................................... 1
1.2 SYMBOLS .................................................................................................................................... 1
1.3 ABBREVIATIONS ........................................................................................................................... 1
2PRODUCT DESCRIPTION ..................................................................................................................... 2
2.1 OVERVIEW................................................................................................................................... 2
2.2 SYSTEM AND COMPATIBILITY......................................................................................................... 2
2.3 CONNECTORS.............................................................................................................................. 4
2.4 POWER SUPPLY ........................................................................................................................... 7
2.5 SAFETY FUNCTIONS ..................................................................................................................... 9
3GETTING STARTED............................................................................................................................. 10
3.1 BEFORE FIRST USE..................................................................................................................... 10
3.2 CONNECTING THE CONTROL BOX ................................................................................................ 10
4RST10 TOOLBOX................................................................................................................................. 11
4.2 RCB11 AND RCB12 PARAMETERS ............................................................................................. 12
4.3 CONNECT CONTROL UNIT VIA USB ADAPTER ............................................................................... 15
4.4 FURTHER READING..................................................................................................................... 21
5MAINTENANCE .................................................................................................................................... 22
5.1 SERVICE INTERVALS................................................................................................................... 22
5.2 CLEANING AND DISINFECTION ..................................................................................................... 22
6TROUBLE SHOOTING ......................................................................................................................... 23
6.1 REPAIRS.................................................................................................................................... 25
7TECHNICAL DATA............................................................................................................................... 26
7.1 BASIC CHARACTERISTICS............................................................................................................ 26
7.2 ENVIRONMENTAL CONDITIONS..................................................................................................... 26
7.3 FUNCTIONAL FEATURES.............................................................................................................. 27
7.4 CONTROL INTERFACE OPTIONS ................................................................................................... 27
7.5 POWER OPTIONS........................................................................................................................ 28
7.6 WARRANTY................................................................................................................................ 29
7.7 WASTE DISPOSAL....................................................................................................................... 29
8LABELING ............................................................................................................................................ 30

1
1 Introduction
1.1 Documentation
This manual describes the control systems RCB11 and RCB12
The following related documentation is also available:
•RCB11 data sheet
•RHC10 data sheet
•RCB12 data sheet
•General Features in RST10
•RPP10 data sheet
1.2 Symbols
The following symbols will be used in this document:
Failure to comply with these instructions may result in accidents involving personal injury.
Failing to follow these instructions can result in the product being damaged or destroyed.
Useful tips, recommendations and information for efficient, trouble-free use.
1.3 Abbreviations
FSI – Flexible (digital) Switch Inputs
RCB – REAC Control Box
RHC – REAC Hand Control
RPP – REAC Power Pack
VPI – Versatile Power Interface

2
2 Product description
2.1 Overview
•RCB11 is a 2 channel control box
•RCB12 is a 4 channel control box.
2.2 System and compatibility
A REAC control system consists of a control box, a power source, a hand control, and one or several
actuators.
2.2.1 RCB11
•RCB11 can be combined with RPP10 (REAC Power Pack), RHC10 (REAC Hand Control) and
any REAC actuator.
RCB11 enables you to use a generic digital switch in addtion to a handcontrol for multiple
functionalities.
RPP10
RCB11
RHC10
Generic digital switches
RE3000
RE25

3
2.2.2 RCB12
•RCB12 can be combined with RPP10 (REAC Power Pack), RHC10 (REAC Hand Control) and
any REAC actuator.
RPP10
RHC12
RHC10
Generic digital switches
RE3000
RE25
RE3000
RE25
RCB12

4
2.3 Connectors
2.3.1 RCB11 connectors
The connector front can as an option be equipped with an overlay to simplify connector mounting. The
overlay can be customized to fit a certain application.
Overlay example and the placement of the connectors:
2.3.2 RCB12 connectors

5
2.3.3 Connector Description
VPI Connector
VPI (Versatile Power Interface) is a connector for batteries, main supply or other external power.
Actuator Connector
Any REAC actuator1can be used with the RCB11, if equipped with a 6.5 mm phono connector.
To achieve full IP-protection the connector needs to be equipped with O-rings. The actuator connector can
also be equipped with color markings to simplify correct mounting.
Hand Control Connector
REAC Hand Control RHC10 can be used together with the RCB11. As standard equipped with a 6.5 mm
phono connector. To achieve full IP-protection the connector needs to be equipped with O-rings. The
actuator connector can also be equipped with color markings to simplify correct mounting.
FSI Connector2
The FSI (Flexible digital Switch Input) connector is an interface for reading generic digital switches using a
3.5 mm phone connector, for applications where the hand control is not preferred.
Different control interfaces can be used, but they need to be individually configured. During evaluation and
try out this can easily be done by using RST10 PC-tool (see section 4). For serial production a pre-
calibrated software can be ordered from REAC.
The FSI connector can be equipped with color markings to simplify correct mounting.
All cables are eqipped with O-rings, without the O-rings the IP protection will be lost.
Actuator connectors and the hand control connector are of the same type. Make sure that
the connectors are correctly plugged. Color coding of cables and control box is available as
an option.
If digital switches are used, it is recommended to use switches that have normally open
polarity, to get a "hold-to-run" behavior. Also, normally open switches will consume less
power, compared to normally closed.
To simplify assembly of the O-rings put some grease on them (standard Vaseline is ok).
1Except RE7000 which has a special interface.
2This is only available on RCB11 Premium, to connect digital switches to RCB12 the digital input adapter, RHC12, needs to be used
as a gateway.

6
2.3.4 Connecting VPI
The VPI connector is keyed and must be inserted according to the image below. Make sure the part of the
connector that forms a straight line is facing the straight line on the control box connector.
RCB11 VPI jack
RPP10 VPI jack
Please make sure that the cable is firmly attached to the unit chassis with e.g. cable ties or similar to avoid
unintended detachment.
Forcing the VPI connector in to the RCB11 the wrong way can damage the control box
electronics and cause malfunction.
If the cable between the control box and the battery has been disconnected the procedure
for internally connecting the battery has to be done again. The battery will be internally
disconnected even if the cable is reattached. See section 2.5.2 for more information.
Make sure that the side of the cable
connector forming a straight line is
inserted towards the knob on the VPI
connector jack.

7
2.4 Power supply
RPP10
•RPP103can be used together with either RCB11 or RCB12.
•RPP10 is the Pb battery pack which both RCB11 and RCB12 are matched to by default.
2.4.1 Power connector
RCB11 and RCB12 both have to be connected to some external power source, via the VPI-connector,
since they do not have any built-in battery. As long as the power source supports the VPI interface, it can
be connected.
The VPI-interface supports the following types of power sources:
•A Pb matched battery pack
•A smart battery pack
•Some other third party power source.
RCB11 premium and RCB12 premium are able to automatically detect which type of power source that
has been attached.
RCB11 premium and RCB12 premium are needs to be setup for handling a certain power source
correctly. By default they are both setup expecting a Pb matched battery pack.
See section 2.3 for connection instructions.
2.4.2 Battery data retrieval
Depending on the type of power source used, battery data such as current charge level and other
information is retrieved in different ways:
•A Pb battery pack is not able to provide any data regarding battery characteristics and charge
level. The state charge of a matched Pb battery pack needs to be analyzed by the control unit,
by using assumptions about the battery pack that has to be stored in the control unit, and
therefor the control unit and battery pack has to be matched to work properly.
•A smart battery pack is able to provide all data regarding characteristics and charge level.
•In the case of using some third party power source, which is unmonitored by the control unit,
the control unit will not be able to get any data regarding characteristics and charge level, nor be
able to analyze the power source in any way. Therefore, no charge level indicator will be
available in this case.
Only RCB11 premium has support for getting data from a smart battery pack.
2.4.3 Presenting charge level
Battery charge level, if available, can be presented to the user in two ways:
•By using RCB11 or RCB12 equipped with an RHC10 hand control. The standard RHC10 has
a battery level indicator as default. When the low battery indicator LED is flashing, the battery
level is low and charging is recommended.
•By using RCB11 Premium or RCB12 Premium with sound warnings enabled. Equipped with a
speaker, which can give an audible feedback when the battery has reached a low battery level,
and a movement is requested.
3Further information regarding RPP10 can be found in the RPP10 Data Sheet or in the User Manual for RPP10, which can be
downloaded from REAC webpage.

8
When the low battery feedback is activated a few strokes remains, how many depends on the application
and the level can be configured by using the RST10 tool (see section 4.4.10).
The charge level can also be read using RST10 tool. For information about this see 4.4.9 .
Charge level is only available when using a matched Pb battery or when using a premium
control unit with a smart battery pack. If using some other third party power source, or using
a basic control unit with a smart battery pack, charge level is not applicable.
2.4.4 Battery disconnect
Purpose
To protect power packs from deep discharge and damaged battery cells, the control unit is equipped with
a battery disconnect feature which make it possible for the control unit to disconnect itself from the power
pack, completely, to increase storage time. While disconnected, the storage time of a complete system will
be equal to the storage
First use
When the control unit has been connected to the external battery with the cable it is still internally
disconnected due to the built-in battery disconnect functionality. When the system is ready for first use
the battery needs to be internally connected.
Reconnect
To reconnect the battery, plug in the standard 24 V charger delivered with the battery pack.
Wait approximately 5 seconds and then unplug the charger. The battery is now connected. The general
recommendation is to keep the charger connected until fully charged.
Automatic internal battery disconnect
To prevent deep discharge and protect batteries on the field or during long transports the battery is
automatically disconnected at critical low battery level or after 18 days of standby. This time can be
configured by using RST10.
Request disconnect using PC tool
It is possible to manually disconnect the battery internally, via the HC bus connector, and the PC tool
RST10 (section 4.3.11)
Request disconnect using charge connector
It is also possible to manually disconnect the battery internally, via the charger connector, not having to
unplug any other connectors. To disconnect the battery this way, plug in a 9 V power source to the
charger input. Wait minimum 5 seconds and maximum 10 seconds before unplugging alternatively, if a
REAC hand control (e.g. RHC10) is connected, wait for all LEDs to flash before unplugging. All LEDs
flashing is a confirmation from the control unit that the battery has been disconnected.
Requirements of 9 V power source
•Output connector: 5.5 mm x 2.1 mm barrel jack with positive center
•Output voltage: 6-10 V DC (e.g. a 9 V battery can be used)
•Output current: minimum 50 mA, maximum 800 mA (fused or current limited)

9
2.5 Safety functions
2.5.1 Duty cycle
To prevent the actuator motors from overheating, the REAC control systems have a built-in supervision
and protection feature. There are three limits used to determine if the user shall be warned or if the
operation should stop.
The following limits can be configured per actuator channel:
•Warning limit.
•No acceleration allowed limit (ongoing movement continues at current or lower speed, no new
movement can start).
•No movement allowed limit.
The duty cycle limits can be configured by using RST10, see section 4.2.5.
2.5.2 Disabled motor activation while charging
If the charger is connected motor activation is prevented by the control unit (RCB11 and RCB12). The
reason is that the charger is not intended to run a motor and doing so might cause EMC disturbance from
the charger.
2.5.3 Overcurrent
Over current is a limit that is used to detect if the actuator is overloaded, runs into any obstacle or reaches
an end limit (if limit switches are not used). Current peaks above the set current limit is cut after 250 ms, or
immediately at 2 A over current level.
It is possible to configure individual current limits for all channels via the RST10, see section 4.2.4.
2.5.4 Internal errors
If an internal error is detected, the operation turns off for one channel only or for all channels, depending
on the type of error. The alert indicator LED on the hand control lights up.
Errors are automatically cleared after 10 seconds and the operation turns on again. If the error still
remains, the channel/channels will be turned off again and no operation will be possible.

10
3 Getting started
3.1 Before first use
Before using the RPP10 for the first time, you should charge the battery for 24 hours. This to ensure full
charge and to prolong the lifetime of the battery.
To charge the battery the first time, do the following:
1. Connect the RPP10 to a control box, see section 3.2.
2. Connect the battery charger to the RPP10 charger jack and to a wall socket.
3. Check that the LED on the charger is red, indicating charging.
4. Keep the charger connected for 24 hours. Make sure RCB11 is connected to the RPP10 at all
time during charging.
3.2 Connecting the control box
You connect the control box to the VPI connector on the RPP10. For the RCB11, a VPI cable is needed.
The RCB12 control box has a fixed VPI cable. If an extension is needed, an additional VPI cable can be
connected.
The VPI connector is keyed and must be inserted according to the image below. Make sure the part of the
connector that forms a straight line is facing the straight line on the RPP10 connector.
To connect the control box to the RPP10, do the following:
1. RCB11: Connect the VPI cable to the VPI connector on the control box.
2. Connect the VPI cable to the VPI connector on the RPP10. When battery has been disconnected
from the RCB11, it requires to be woken up from battery disconnect mode, by connecting the
charger for a couple of seconds. Even though the battery is fully charged.

11
4 RST10 toolbox
The REAC Service Toolbox RST10 is a Windows software consisting of several maintenance and service
tools. The RST10 can be used to configure settings, evaluate application solutions, perform service tasks,
and monitor system behavior.
For installation and connection instructions, see section 3.2.
4.1.1 User interface
1. This area displays icons for each detected unit and a log:
a. Log aggregated log for all units
b. GUSB adapter (gateway)
c. Ccontrol box
d. Hhand control
To select a unit, double-click the icon.
2. This area displays groups of status registers and parameters for the selected unit.
a. To expand a group, click the plus sign.
b. To collapse a group, click the minus sign.
.
2
1

12
This image shows status registers and parameters in an expanded group.
1. Status registers are values that only can be read/viewed.
2. Parameters are values that can be changed. Parameters have a colon sign in front of the value.
To change a parameter, do the following:
1. Click the parameter value.
2. Enter a new value.
3. Press Enter. The new parameter value becomes effective immediately.
4.2 RCB11 and RCB12 parameters
To view and change the RCB11 and RCB12 parameters, select the Cicon and expand the groups.
The configurable parameters are available in the following groups:
•DC out 1-4, one group per actuator channel
•Operation
•Usage
4.2.1 Soft start and soft stop
The soft start and soft stop parameters are used to adjust the start and stop ramps of the motor.
The parameters are set in time (ms). The time is between 0 to 100% PWM. Simply explained it works
more like a ramp speed setting, rather than an actual time setting. If a movement at 50% PWM is
demanded, that PWM level will be reached in half the time.
The Soft start and Soft stop parameters are available in the DC out groups.
4.2.2 Gain
If an actuator is considered to run too fast, either because it is built that way or as a result of the
mechanics around it, the speed can be limited by using the gain parameter. This can be needed, for
example, if the load is “helping” the actuator in one direction.
There is one parameter in each direction: Gain forward and Gain backward. The gain parameters are set
in % of the full pass-through of the signal.
The Gain forward and Gain backward parameters are available in the DC out groups.
Parameters related to a channel will become effective after the next movement on that
channel.
Even if the parameter is called “gain”, this is not about amplification of the signal.
The maximum gain is the neutral 100%, meaning that it is only possible to reduce the signal.
2
1

13
4.2.3 Reverse orientation
The reverse orientation parameter is used to compensate for crossed motor cables, a gearbox that alters
the direction, or similar.
0 means regular orientation. 1 means reversed orientation.
The Reverse orientation parameter is available in the DC out groups.
4.2.4 Current limits
Overcurrent is a limit that is used to detect if the actuator is overloaded, runs into any obstacle, or reaches
an end limit (if limit switches are not used). The movement will be stopped if the motor current is above the
set limit for 250 ms. If the motor current is 2 A above the set limit, the movement will stop immediately.
There is one current limit parameter in each direction: Max current forward and Max current backward.
The parameters are set in mA.
The Max current forward and Max current backward parameters are available in the DC out groups.
4.2.5 Duty cycle
To prevent the actuator motors from overheating, the REAC control systems have a built-in supervision
and protection feature. There are three levels used to determine if the user shall be warned or if the
operation should stop. In the control box, this is realized as a percentage out of a total time.
The following levels can be configured per actuator channel:
•ED warning level: At this level, the alert LED on the hand control will light up when the motor is
running.
•ED no start level: At this level, the motor will not start anymore, until after “cool down”. An already
started movement will continue at current or lower speed.
•ED stop level: At this level, the motor will stop immediately. The motor will stop even in the middle
of a movement.
The parameters are set in percentage of time using a motor, within a certain period (duty cycle). Most
REAC actuators have a specified duty cycle of 2 minutes run, followed by 18 minutes of rest; in total 20
minutes.
The duty cycle parameters are available in the DC out groups.
4.2.6 Regular input throttle
It is possible to control the reaction speed for the regular buttons on the hand control.
Using a button on the hand control will result in a request to start a movement at a certain throttle level.
This level, one for each channel, is set by the regular input throttle parameters.
The parameters are set in percentage of full throttle input signal.
The regular input throttle parameters are available in the Operation group.
The regular input throttle parameter is only intended for control of the button speed.
To adjust for different actuators and mechanical factors, the gain parameters should be
used, see section 4.2.2.

14
4.2.7 Low battery warning
The hand control has a low battery LED and the RCB11 and RCB12 Premium has a low battery sound
alarm. The LED starts flashing and the alarm gives a sound when the controlbox has reached a low level.
It is possible to adjust the level for when the low battery warnings will be activated.
The level is set as an absolute value in mAh. This makes it possible to set a level where there are a
certain number of strokes left for a typical application, regardless of power source.
The low battery warning parameter is available in the Operation group.
4.2.8 Service intervals
RCB11 and RCB12 can optionally be used with other either RHC10 or RCH15. RHC15 has a service
interval indication LED. It is possible to adjust the limits for the service indication and to reset the interval
counters. Only authorized personnel is allowed to change the service limits and reset counters.
The service interval limit defines the number of strokes before the service indication LED on the hand
control will light up.
The limit is set per channel using the parameter Strokes service interval X, where X is the channel
number.
To disable the service interval limit, select the value, press Delete, and then press Enter. The text “Not
set” is shown instead of a value. If the limit is disabled, the service indication LED will never light up.
The service interval parameters are available in the Usage group.
4.2.8.1 Reset counter
To reset the service interval counter to 0, do the following:
1. Right-click the Cicon. This displays a menu.
2. To reset the counter for channel X, select Reset strokes since service X.
3. In the Confirmation dialog, select Yes.
1. Select Power disconnect from the menu.
2. In the Confirmation dialog, select Yes.

15
4.3 Connect control unit via USB adapter
4.3.1 USB adapter overview
4.3.2 Connect USB cable
A regular USB cable (A-B type) is used between the USB adapter and the PC. The cable should be
inserted into the USB connector. See section 4.3.1.
When connecting a control unit to a PC for the first time, the PC needs to get and install drivers to be able
to handle the new control unit. It is recommended to be connected to the Internet while doing this, then it
will all be made automatically.
This will take a while, in the meantime the system will inform that it is working on it, by showing
information, usually in the lower left corner of the screen.
When the driver installation is done, a message will be shown that the device is ready to use.
4.3.3 Connect control unit
Between the control unit and the USB adapter a straight 6.35 mm male to male tele plug cable is used. In
the control unit, it shall be inserted in the HC connector, instead of the hand control. On the USB adapter.
There are three identical HC connectors. Either one can be used.

16
4.3.4 Use the hand control
To be able to test and monitor the system live, running actuators from the hand control, while having the
PC connected, the hand control can optionally be inserted via any of the HC connectors on the
USB adapter.
4.3.5 FSI switch inputs
In the control unit view (icon C), in the “FSI switch inputs” group, parameters for matching how the
switches are connected, and for assigning which switches are connected to which functions.
The parameters named “Switch input layout” are used for selecting one of four possible schematics for
how the switches are connected.
Layout 1, “mono” pin layout (default)
Layout 2, normal “stereo” pin layout
Layout 3, alternative, “mono-like” tip common, pin layout
T
S
A
T
R
S
B
A
T
R
S
B
A

17
Layout 4, alternative, ring common, layout
The parameters named “Switch input logic” are used for selecting if switches are normally closed, or
normally open. 0 is normally open. 1 is normally closed.
The parameters named “Switch input role” are used for selecting which feature each switch shall be
connected to. The following table shows which parameter value corresponds to which feature.
Value
Function
(Not set)
Disabled
0
Channel 1 forward
1
Channel 1 backward
2
Channel 2 forward
3
Channel 2 backward
10
On/off
4.3.6 Service intervals
To adjust service recommendation intervals, and/or to reset the counters go to the control unit view (icon
C), and the group called “Usage”. This group contains the parameter “Strokes service interval X”, where X
is the channel number. These parameters can be set to the number of strokes before a service
recommendation LED will light up (available on REAC hand controls).
This must only be performed by authorized personnel.
To disable these limits, select the value, hit “Delete” and then hit “Enter”. No LEDFel! Bokmärket är inte definierat.
will light up then, ever. When no value is set, the text “Not set” is shown instead of a value.
T
R
S
B
A