REAC RCB15 User manual

www.reac.se
USER MANUAL CONTROL BOX
RCB15, RCB20 & RCB25

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
boxes 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: [email protected]
Web: www.reac.se

www.reac.se
Table of Content
1INTRODUCTION..................................................................................................................................... 1
1.1 ABOUT THIS MANUAL .................................................................................................................... 1
1.2 SYMBOLS .................................................................................................................................... 1
1.3 PRODUCT OVERVIEW.................................................................................................................... 1
2TECHNICAL DATA................................................................................................................................. 2
2.1 SYSTEM AND COMPATIBILITY......................................................................................................... 2
2.2 BASIC CHARACTERISTICS.............................................................................................................. 2
2.3 ENVIRONMENTAL CONDITIONS....................................................................................................... 3
2.4 FUNCTIONAL FEATURES................................................................................................................ 4
2.5 OPERATING INSTRUCTIONS........................................................................................................... 5
2.6 BATTERIES .................................................................................................................................. 6
2.7 CONNECTORS.............................................................................................................................. 8
3PC TOOLS .............................................................................................................................................. 9
3.1 INTRODUCTION............................................................................................................................. 9
3.2 GET STARTED.............................................................................................................................. 9
3.3 SETUP CONNECTION TO CONTROL BOX........................................................................................ 11
3.4 USING RST10........................................................................................................................... 12
3.5 USING RUT10........................................................................................................................... 20
3.6 FURTHER READING..................................................................................................................... 23
4SAFETY ................................................................................................................................................ 24
4.1 EMERGENCY LOWERING AND LIFTING .......................................................................................... 24
4.2 EMERGENCY STOP..................................................................................................................... 24
4.3 DUTY CYCLE PROTECTION .......................................................................................................... 24
4.4 OVER CURRENT ......................................................................................................................... 24
4.5 INTERNAL ERRORS ..................................................................................................................... 24
4.6 BATTERY VENTILATION ............................................................................................................... 25
5MAINTENANCE.................................................................................................................................... 26
5.1 SERVICE INTERVALS................................................................................................................... 26
5.2 CHARGING OF BATTERIES........................................................................................................... 27
5.3 CLEANING AND DISINFECTION ..................................................................................................... 27
5.4 WASTE DISPOSAL....................................................................................................................... 28
5.5 WARRANTY................................................................................................................................ 29
5.6 REPAIRS.................................................................................................................................... 29
5.7 TROUBLESHOOTING ................................................................................................................... 30
5.8 ACCESSORIES............................................................................................................................ 33
6LABELING ............................................................................................................................................ 34
7COMPLYING STANDARDS................................................................................................................. 37

1
1 Introduction
1.1 About this manual
The aim with this user manual is to describe the control systems RCB15, RCB20 and RCB25 with focus
on:
Working principle descriptions
Safety
Maintenance
Troubleshooting
Next to this manual the following documentation is available:
RCB15 data sheet
REC25 data sheet
RCB20 data sheet
RUT10 data sheet
RCB25 data sheet
RST10 data sheet
RHC15 data sheet
General Features in RST10
REC20 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 Product overview
REAC has three variants of control boxes, which each one together with a RCH15 hand control forms a
control system intended to be used in patient handling systems. The three boxes have different features
and functions:
RCB15: is a basic 2 channel control box designed to handle one lift actuator and one leg spread actuator.
RCB20: is a control box with up to 3 actuator channels and detachable lead batteries.
RCB25: is a light weight control box with a slim design. It can handle up to 3 actuator channels and has
detachable lithium batteries. Will be launched Q3 2017.

2
2 Technical data
2.1 System and compatibility
All three variants can be combined with one RE7000 actuator (intended for lift function), one RE2000
(intended for leg spread) and a hand control. RCB20 and RCB25 have a 3rd additional actuator output,
which can be used with for example an RE2000.
2.2 Basic characteristics
RCB15
RCB20
RCB25
Output voltage
24V DC
24V DC
24V DC
No of actuator channels
2
3
3
IP-class
IP24
IP26
IP26
Battery type
Lead
Lead
Lithium
Cycles/charge
80
80
150
Charge time
6 h
6 h
3 h
Weight
3 kg
3,5 kg
2 kg
Flammability rating
UL94 V-0
UL94 V-0
UL94 V-0
Color
RAL 9016
RAL 9016
RAL 9016
Expected service life
8 years1
8 years1
8 years1
1
Provided that service schedule described in the user manuals are followed
Figure 1. System and compatibility

3
2.3 Environmental conditions
RCB15
RCB20
RCB25
Operating
Ambient temperature
0 °C to +40 °C
0 °C to +40 °C
0 °C to +40 °C
Relative humidity
15% to 90%
15% to 90%
15% to 90%
Atmospheric pressure
700 to 1060 hPa
700 to 1060 hPa
700 to 1060 hPa
Storage
Ambient temperature
-25 °C to +50 °C
-25 °C to +50 °C
-25 °C to +45 °C
Relative humidity
15% to 90%
15% to 90%
15% to 90%
Atmospheric pressure
700 to 1060 hPa
700 to 1060 hPa
700 to 1060 hPa
Using the the products outside theire specified limits may lead to subsequent malfunction or
personal injury

4
2.4 Functional features
RCB15
RCB20
RCB25
Emergency stop button



Button for lifting on control box panel



Button for lowering on control box panel



Buttons for leg spread on control box panel


Low battery sound alarm



Deep discharge protection



Battery charging indicator



Detachable batteries


Internal charger



External charger


USB interface


Service reminder tracking



Service tool (RST10)


Tracking tool (RUT10)


Duty cycle protection



Adjustable soft start- and stop ramps (via RST10)


Adjustable current limits (via RST10)


Two speed operation2



Energy regeneration3



Fast battery charging

2
Only available together with RHC15
3
Together with RE7000 actuator

5
2.5 Operating instructions
The normal way to interface with the system is via the hand control. All three versions are compatible with
REAC hand control RHC15, which is a hand control adapted for patient handling applications.
RHC15 has as default a 2-speed operation for the lift operation and buttons for leg spread. RHC15 can be
customized to fit certain application’s unique needs, but as standard the RHC15 patient lift version has the
following features and design:
Figure 2. Hand control description

6
If the hand control for some reason is out of order or for some other reason not practical to use, the
system can also be maneuvered via a control panel on the control box. The control panels differ a bit
between the variants, where RCB20 and RCB25 have some additional functions compared to RCB15.
These panels can also be customized to fit a certain application. Standard panels have the following
features and design:
2.6 Batteries
RCB15, RCB20 have lead batteries and RCB25 has a lithium battery. All three are equipped with an
internal charger. It is recommended to charge the batteries regularly to prolong the life of the batteries. It is
recommended to charge the batteries before first use.
All variants are equipped with a speaker, which will give a warning sound when the batteries reach a low
battery level and a movement is performed. The system can also be equipped with a RHC15 hand control,
which has a battery level indicator as default.
The system is designed to be able to complete one full lifting cycle with maximum load (according to EN
ISO 10535:2006) after the warning is given. It is however recommended to charge the batteries as soon
as possible after the warning signal is heard or the low battery LED is flashing.
In the unlikely event of battery acid leakage and you get it in your eyes or on your skin -
rinse thoroughly with lots of water and contact your local healthcare for further consultation.
When the battery level is critically low all operations will be aborted to protect the batteries
All three variants of the RCB controls are equipped with a feature to handle regenerative
energy from the actuators4to the batteries. This makes it possible to use actuators with very
good efficiency, which in turn gives an improved time between charging
4
Currently only available together with RE7000
Figure 3. Control panel description

7
2.6.1 Detachable batteries
RCB20 and RCB25 have a detachable battery pack, which can easily be removed when it’s time for
charging or change to another battery pack.
Figure 4. Detachable battery
By pressing the release latch (A), holding the handle (B) and pulling the battery half upwards to detach the
batteries.
The removable batteries are not interchangeable between RCB20 and RCB25. They use different battery
types, having different specifications. Therefor a mechanical protection will make sure there is no mix up
between the two battery types (marked with red circles in the figure below).
Figure 5. Battery keying
The battery must be mounted while charging, if failing to do so will expose the charger poles
to the user and touching them can be unpleasant.
The battery keying must not be manipulated with. Wrong battery type will cause malfunction.

8
2.7 Connectors
Connector placement - The figure below shows the placement of the connectors:
Figure 6. RCB15 connector placement
Figure 7. RCB20 and RCB25 connector placement
Only a charger cable provided by REAC is allowed to be used in this system. If another
cable is used IP protection can not be assured.
All cables (except USB cable) 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.
Wrongly mounted connectors will not cause any harm, but the system will not work properly.
To reduce the risk to mixup actuator connectors, the actuators can be customize with RCB-
connectors, which will serve as identifiers and the control system will only accept an actuator
with no ID or the correct ID in that jack.
Any USB (type A to type B) cable can be used.
To simplify assembly of the O-rings put some grease on them (standard Vaseline is OK).

9
3 PC tools
3.1 Introduction
RCB20 and RCB25 have an USB-interface to easily connect to the REAC Service Toolbox (RST10)
and/or REAC Usage Tracking Tool (RUT10).
RST10 is a toolbox for maintenance and service. It can be used to control configurable settings such as
individual current limits and start- and stop ramps, to perform common service tasks, and to monitor
system behavior. Engineers might find it useful when evaluating application solutions. Service technicians
can use the tool for regular maintenance tasks as well as for some in field troubleshooting.
In addition to RST10 REAC also provides RUT10, which is a usage tracking tool, aimed for administrators
and managers who want to look up information relevant for evaluation and optimization usage of their lifts.
The tool has a user-friendly interface showing basic summaries of lift usage, battery level and additional
info, and is intended to be useful also for non-tech personnel. It also has the ability to export usage data,
which can be analyzed in other tools, for example in Microsoft Excel®.
3.2 Get started
The PC tools are acquired from REAC sales. For more information see chapter 5.8.
System requirements are stated in the technical datasheet for each PC tool.
PC tools from REAC can be run in two modes:
Portable version: Run directly from a USB memory or similar
5
.
Installed version: Installed on the PC. An icon will show up in the start menu and/or as a program
icon on the desktop.
To run the portable version double click on the file called “portable” and it will start up, ready to use.
5
For single use situations or when there are restrictions or limitations in installation rights on the computer.

10
To install double click on the file called “setup” and a guide will start to take you thru the process. If no
special requirements, the suggested setting are best left as they are. Click “Next”, “Install” and “Finish”.
After installing, it shall be possible to find a new program launcher in the programs menu:

11
And on the desktop:
Or directly on the hard drive, where it has been installed:
To start the installed program, select the program in the program start menu, or double click on the
program icon on the desktop, or double click on the program in the programs folder on the hard disk.
3.3 Setup connection to control box
A regular USB cable (A-B type) is used between the USB connector in the control box and your PC.
The cable shall be inserted into the USB jack connector, see chapter 2.7.
When connecting a control box to a PC for the first time, the PC needs to get and install drivers to be able
to handle the new control box. It is recommended to be connected to the Internet while doing this, then it
all will be made automatically.
This will take a while, in meantime the system will inform that it is working, using some symbol and/or
some messages down here:

12
When the driver installation is done, a message will be shown that the device is ready to use.
If not connected to Internet while doing this, or if something goes wrong ask your IT support.
3.4 Using RST10
REAC Service Toolbox (RST10), as the name suggests, is a toolbox consisting of several different tools.
In this user manual, all aspects of all the various tools will not be covered. Instead this section will focus
on tasks most relevant to users of RCB20 and RCB25.
All chapters below, describing tasks, assumes that the program has been installed and/or run as
described in chapter 3.2. It also assumes that a connection to a control box is set up according to chapter
3.3 and that a connection to the system is established as described in chapter 3.4.1.
3.4.1 General
When starting RST10 it will only show a gray blank space. No connection is made automatically. In order
to connect to a system, press the “Maintain” button, or choose “System” – “Maintain…” in the program
menu.
Then select the correct com port. If connecting to a new system for the first time, it will most likely be the
last com port available. Then click “Next”.

13
Now all status registers, parameters and log items will be retrieved, from all units in the system. When
done, it will be presented like this.
In the small area to the left, one icon for each detected unit is listed. There is also an icon for the
aggregated log, common for all units. Cstands for the control box. H stands for the hand control.
The larger area to the right is for viewing different tools. In the example above, a viewer for the control box
(C icon), have been double clicked, and opened up in the area to the right, showing its groups of status
registers and parameters.

14
To expand a group, press the plus sign in front of the group name, which then changes to a minus sign.
To collapse a group, press the minus sign.
Status registers are values that only can be read/viewed. Parameters are values that can be changed.
To tell status registers and parameters apart, parameters have a small colon in front of the value.
To change a parameter, click on its value, type in a new value, and hit Enter. The value will become
effective immediately.
Parameters belonging to a certain channel will not use new values until the next movement
on that channel.
3.4.2 Soft start and soft stop
When connected to a system, activate the control box view (icon C).
This view contains groups called “DC out”. There is one group for each motor output channel. Under each
of these groups there are two parameters called “Soft start” and “Soft stop”, i.e. one for each channel.
These 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.
3.4.3 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 might need to be limited. If for example the load is “helping” the actuator in
one direction, then this can be limited by using the gain values.
For each channel, there is a pair of gain parameters, one in each direction. These parameters are found in
the “DC Out” groups in the control box view (icon C) and are called “Gain forward” and “Gain backward”.
Gain is set in % of full pass thru of the signal.
The word gain might imply that it is about an amplification of the signal. It is not. The
maximum gain is the neutral 100 %, i.e. it is only possible to reduce the signal.

15
3.4.4 Reverse orientation
If any motor cables are crossed, or any gearbox will alter the direction, or similar, there is a setting for
each motor channel that when enabled will compensate for this and reverse the orientation.
This parameter is found in the control box view (icon C), in the “DC out” groups. The parameter is called
“Reverse orientation”.
0 means regular orientation. 1 means reversed orientation.
3.4.5 Current limits
In the control box view (icon C), in the “DC out” groups parameters for setting the current limit is also
found.
They are called “Max current forward” and “Max current backward” and are set in mA. One in each motor
direction.
Motor movement will be stopped if motor current is above this level for 250 ms, or immediately if motor
current is above this level plus 2000 mA.
3.4.6 Duty cycle
In the control box view (icon C), in the “DC out” groups there are parameters for setting duty cycle limits,
they are also set per channel and are called “ED warning level”, “ED no start level” and “ED stop level”.
They are set in % of time using a motor, within a certain period. The period is usually 20 minutes.
ED warning level, is the level where the alert LED
6
will light up when running.
ED no start level, is the level where the motor will not be possible to start anymore, until
“cool down”. An already started movement can continue at current speed, or lower speed.
ED stop level, is the level where the motor will stop. It will stop immediately, when the level is
reached, even if in the middle of a movement.
3.4.7 Regular input throttle
Using normal speed buttons on the hand control, or on a control box panel (see chapter 2.5), will result in
a request of starting a movement at a certain throttle level. This level, one for each channel, is set by the
Regular input throttle parameters.
In the control box view (icon C) there is a group called “Operation”, which contains all the Regular input
throttle parameters.
Regular input throttle parameters are set in % of full possible throttle input signal from the operator.
6
The alert LED is always available on a REAC standard hand control, RHC15 (see chapter 2.5).

16
On the RHC15 control box panel there are two high speed buttons. These will not be
affected by setting Regular input throttle. The high-speed buttons will always give a request
for 100 % throttle.
The Regular input throttle parameter is only intended to be used to set the regular speed for
regular buttons, relative to full speed. To adjust for different actuators and mechanical
factors the Gain parameters should be used.
3.4.8 Service intervals
RCB20 and RCB25 both have the possibility to set a time based limit, and/or a limit based on
number of lifts.
To adjust service recommendation intervals, and/or to reset the counters go to the control box view (icon
C), and the group called “Lifts”. That group contains the parameter “Lifts service interval” and a parameter
called “Periodical service interval”.
Lifts service interval, can be set to the number of lifts before a service recommendation LED
7
will
light up.
Periodical service interval, can be set to the number of days until a service recommendation LED7
will light up.
To disable these limits, select the value, hit “Delete” and then hit “Enter”. No LED7will light up. When no
value is set, the text “Not set” is shown instead of a value.
Setting service limits must only be done by authorized personnel, since failing to perform
necessary service on the system, may lead to subsequent malfunction or personal injury.
7
The service LED is always available on a REAC standard hand control, RHC15 (see chapter 2.5).

17
To reset the periods, i.e. to start the counters over at 0, a function must be used. Functions can be
reached in three different ways. But the easiest is by right clicking on the C icon, in the area to the left and
select the counter you want to reset.
A confirmation window will pop up:
Resetting counters must only be done by authorized personnel, since failing to perform
necessary service on the system, may lead to subsequent malfunction or personal injury.
For RCB25 it is possible to set limits when it is recommended to replace the battery, this will also be
indicated via the service LED7.
These limits are handled in a similar way, as the other service recommendation limits, but to find them
battery box view (icon B) must be opened. In this view a group called “Service settings”, which contains
parameters called “Replace recommendation capacity” and “Replace recommendation cycles” must be
opened.
It is not possible to reset counters in a battery box. The battery box is not intended to be
serviced, when recommended it should be replaced.