ROTOTILT ICS User manual

2020-11-20
Control System - ICS
2200450_ 7913
Volvo EW 160E, 180E & 220E
EWR150E & 170E
Translation of the Original Instructions _EN

2020-11-20
ICS Control System
Translation of
EC Declaration of incorporation of partly completed machinery
In accordance with Machinery Directive 2006/42/EC. Appendix II B
Manufacturer
Rototilt Group AB
Box 56
SE-922 21 Vindeln
SWEDEN
declare under our sole responsibility that the following product:
Product:
Qualied to compile the technical documentation in accordance with annex 7A:
Niklas Bjuhr
VP Engineering, Rototilt Group AB
Place and date: Vindeln, Sweden
Name and signature of authorized person:
a) complies with the following essential health and safety requirements:
1.1.3, 1.2, 1.7.4,
in, the European Parliament and European Council Machinery Directive 2006/42/EC of 17 May,
2006.
b) is manufactured in accordance with other applicable directives such as:
Directive 2014/30/EU of The European Parliament and Of The Council of 26 February 2014 on
the harmonisation of the laws of the Member States relating to electromagnetic compatibility
c) is manufactured in accordance with the following harmonized standards:
SS-EN ISO 12100:2010, SS-EN ISO 13849-1:2016, as well as applicable parts
of SS-EN 474-1:2006+A5:2018 and SS-EN 474-5:2006+A3:2013.
Anders Jonsson
CEO, Rototilt Group AB
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5
23
1
64
7
EN English
Overview
The product described in the document consists of components for the ICS control system. The overviews
show standard equipment and options.
Refer to the gures and lists below as well as on the following pages.
ICS control system
ICS control system consists of the
following components:
1. Harness, boom
Contact (SecureLock, machine
coupler)
2. Display
Switch for tool replacement.
Cab control unit, CCU
3. Handles with controls to operate
Rototilt® functions and base machine
functions are ordered separately
4. Valve block
Electric swivel
5. Rototilt®control unit, TCU
Zero-position sensor. (ICS sensor,
ICS SecureLock)
Frequency sensor. (ICS sensor,
ICS SecureLock)
6. Connection to the base machine
control unit.
7. Locking cylinder sensor.
(ICS SecureLock)
LED lighting. (ICS SecureLock)
!
IMPORTANT - Read the Instructions for Use for
the control system, tiltrotator and base
machine before starting work. Pay
particular attention to the safety instructions.
!
IMPORTANT - Pressurising the Rototilt®hydraulic
system means that the quick coupler
locking function will be pressurised.
Handle
The handles are equipped with switches
and rollers to control Rototilt® and base
machine functions.
The handle functions are congured as
described on the sticker.
Also see display
!
IMPORTANT - The base machine’s factor-installed
handles have been replaced with handles
adapted for ICS.
Carefully check the changed functions, for both the
base machine and Rototilt®.
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Pulsating
Light /
Blinkande
ljus
xed Light/
fast ljus
IMPORTANT
Always pressurize
ROTOTILT®
to activate the
locking cylinder
after a tool change
P
TCU
CCU
Sound / Ljud
Light / Ljus
Power
CAN-bus
Internal
Error
LED INDICATIONS
OK Error
EN English
Switch, quick coupler locking
function
The quick coupler locking function switch
is interlocked. This prevents accidental
activation of the quick coupler locking
function.
Control unit
The control units have three LEDs:
green, orange and red. When the system
is working correctly, all LEDs light and
with no ashing.
When a malfunction occurs the relevant
LED begins ashing.
PWR (green) shows whether the unit is
powered up.
CAN (orange) shows whether communi-
cations with CAN bus are working.
SYS (red) shows whether the unit’s inter-
nal components are working correctly.
The control units are not interchangeable.
Cab control unit, CCU
The control unit receives signals from the
handles and switches.
The control unit sends signals to the
valve block shunt and tiltrotator via CAN
bus.
There is a buzzer in the CCU that sounds
to attract the operator’s attention if the
quick coupler locking function is open or
in the event of a fault.
Rototilt® control unit, TCU
The control unit receives signals from
the cab control unit, and from sensors in
Rototilt®.
Rototilt® control unit sends signals to
valves and LED lamp.
There is a sensor in the Rototilt® control
unit that detects the tilt angle.
!
IMPORTANT - The control units have a similar
appearance but the content di󰀨ers. They
are not interchangeable.
!
WARNING! A problem has occurred if the buzzer
sounds without activating the quick coupler
locking function switch. The display shows
information about the current problem.
Display
Settings, calibration and activation of
certain functions are made via the display
and its keys.
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X Hydraulics
Handle Functions
* Index Finger Side
Axle Lock
Signal Horn
Outriggers/Blade*
CDC*
Pulse Function*
Hold/Shift*
Rotation
Powerboost
Direction F/N/R
Floating Boom
Short Cut
Grapple/Extra*
Tilt
Decal Volvo
Control Unit -
Excavator
EN English
Machine control
Machine control regulates the oil ow to
the hydraulic circuit for extra equipment
on the base machine. Movement of
the rollers in the handles a󰀨ects the oil
ow in the machine's main valve via the
control unit.
The system has two di󰀨erent functions:
Rototilt® control
When the 8-pole connector on the stick is
connected, a ow is regulated parallel to
the valves on Rototilt ® and the hydraulic
ow is adjusted to this.
The ow runs in one direction only.
Regulation of extra hydraulics
When the base machine is run without
Rototilt ®, the control can be used to
regulate the oil ow in the machine circuit
for extra hydraulics.
The ow can be regulated in both
directions.
In this mode, the extra/grapple roller
regulates X1.
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Planeringsskopa, rotation 360°
Rotation, 360° Rotation, 360°
Planeringsskopa, tilt 40°
Tilt, 40°
Tilt, 40°
Left Handle
1. Rotation, clockwise
2. Rotation, anti-clockwise
Right Handle
3. Tilt, right cylinder extension
4. Tilt, left cylinder extension
4
3
2
1
4
3
2
1
EN English
!
IMPORTANT - When using Rototilt® the base machine/
excavator pedals must not be used to further increase the
oil ow, as this can result in serious damage to Rototilt®.
Operating Rototilt®
The ICS control system permits tilt,
rotation, grapple and an extra function to
be used in parallel and to be regulated
proportionally.
ICS works in parallel with any pedals on
the base machine/excavator. When using
Rototilt® the base machine/excavator’s
pedals must not be used to regulate the
oil ow.
A calibrated ICS system provides each
system with its optimal ow. The Rototilt®
can be seriously damaged if the pedals
on the base machine/excavator are used
to further increase the ow.
Carefully check the positions and
functions of the switches.
The appearance and placement of
switches may vary depending on the
base machine/excavator and handle.
The selected function opens the
equivalent directional valve on Rototilt®.
Activate the ICS control
system
The system is activated when the base
machine/excavator is in the ignition
position.
Speed
The speed of all functions can be
adjusted.
The adjustment is made via Display,
Speed settings menu.
The speed can be adjusted in general
for all functions. The speed can also be
adjusted separately for each individual
function.
Operation
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Pulse function
#1 #2
TILT
HOLD
#2EXTRA2#1
Hold function
PULSE
Hold-to-Run
0,5 s
EN English
Pulsating function
The ICS control system can produce a
pulsating, shaking function to spread
material out of a tilting bucket, for
example.
Press the Pulse switch, then adjust the
speed with the roller for the tilt function.
Non-variable hydraulic flow, Extra 2
The ow can be locked using the Hold
switch when the intended level is reached
with roller for Extra 2. Press and hold the
switch for 0.5 seconds.
The next time the switch is pressed for
the hold function, the function and ow
stop.
!
IMPORTANT - The base machine’s factory-installed
handles have been replaced with handles adapted for
ICS. Carefully check the changed functions, for both the
base machine and Rototilt®.
!
IMPORTANT -
Carefully check the relevant functions, on the display or
the handle sticker.
i
INFO – The illustration shows a general conguration of
the handle functions. Conrm current settings via the
menu: Handle in display..
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PWR CAN
SYS
EN English
Detaching the tool
Position the tool horizontally, resting on
rm ground, or so that the tool cannot
slide out of the grip when the quick
coupler locks are opened.
!
IMPORTANT - If the tool can fall or change position in
connection with the procedure, there is a risk of damaging
the tool and/or quick coupler.
!
IMPORTANT - It is only possible to open the lock when
the start menu is visible or from the troubleshooting menu.
Operating Rototilt® Quick coupler
Check that the display shows the start
menu. The icon for the quick coupler
locking function is shown above the
green function key.
First press the green function key and
release it.
The buzzer sounds.
Now move the quick coupler locking
function switch to the open position.
The switch is enabled for a period of 10
seconds.
The lock remains open as long as the
switch remains open, but pressurising
is only performed during the preset time
period, 3-12 seconds.
The selected time can be checked on the
display, Menu settings.
The switch must be switched on and then
o󰀨 again to repressurise the hydraulic
cylinder.
See the Instructions for Use for the quick
coupler.
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Indicator Rod - Open
EN English
When Rototilt® is pressurised
hydraulically the quick coupler locking
function is opened. The indication on the
quick coupler shows that the lock is open.
When the quick coupler’s locking wedge/
locking bolts are fully open, the tool can
be detached by slowly retracting the
bucket cylinder.
Return the switch to its original position
to close the lock.
Pressurising is conducted for a preset
time, maximum 12 seconds.The selected
time can be checked on the display,
Menu settings.
The switch must be switched on and then
o󰀨 again to repressurise the hydraulic
cylinder.
A warning is shown on the display if the
quick coupler is in the open position.
The base machine/excavator can be
equipped with di󰀨erent combinations
of quick coupler and machine coupler.
The gure and text on the display are
dependent on the combination.
Both the quick coupler and the machine
coupler are available with and without
electronic monitoring (SecureLock).
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Indicator Rod - Closed
Locking Wedge - Closed
EN English
Attaching tools
Open the quick coupler and check that
the indication shows that the lock is open.
Position the bracket so that its grip
is correctly aligned with the tool’s
attachment frame.
Now slowly pivot the tool by extending
the bucket cylinder.
Adjust with small shaft or boom
movements if necessary.
Return the switch for quick coupler
locking function.
The quick coupler’s locking cylinder
returns to its closed position. The
indication on the display conrms that the
switch is in the locked position.
The indicator on the quick coupler shows
that the quick coupler locking function is
in the locked position.
Inspection of quick coupler locking
function
i
INFO - If the quick coupler locking function is in the
closed position when the attachment is attached, the
switch must be switched on, o󰀨 and on again.
Inspection of the quick coupler
locking function
Even if the indication shows that the
locking wedge has engaged in the locked
position, perform the following test to
check the tool is attached securely:
Push the tool forwards towards the
ground, see the gure to the left.
Operate the bucket in this position,
inwards and outwards, to check that
the locking wedge has locked the tool
correctly.
Rotate the quick coupler and check from
the operator position that the locking
wedge/locking pistons have engaged.
In the event of uncertainty, exit the
machine and conduct a visual check.
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2
1
1 2
3
EN English
Quick coupler with SecureLock
Operate in the same way as the quick
coupler without SecureLock, see above.
When the quick coupler is opened a
warning is given that the locking cylinder
has been retracted and is in the open
position.
When the quick coupler is closed, the
message indicates that the locking
cylinder is extended and is in a securely
locked position.
Inspection of quick coupler locking
function.
A warning text appears on the display if
the tool is not coupled correctly.
If you do not intend to couple a tool, the
warning must be acknowledged.
First press the green function key and
release it.
Now press the OK function key. The
buzzer warning signal stops.
Return to the start menu using any key.
A visual warning will be shown at
30-second intervals as long as Rototilt®
is running without a tool and remains
visible until any key is pressed again.
Quick coupler QuickChange™
Operation is the same as for the quick
coupler; see above.
When the quick coupler is opened a
warning is given that the locking pistons
has been retracted and that the quick
coupler is in the open position
When closing the coupler, the rst pin (1)
is engaged, followed by pin (2) and nally
the locking bolts (3)..
The quick coupler locking function cannot
be closed until both pins in the attach-
ment frame are positioned correctly.
The position on the quick coupler’s three
sensors are monitored continuously.
All sensors are shown in green on the
display when a tool is coupled correctly.
Perform Inspection of quick coupler
locking function.
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On / Off function
TILT
HOLD
#2#1
Hold function without tiltrotator
PULSE
Hold-to-Run
HOLD
Hold-to-Run
0,5 s
EN English
Detach Rototilt®
Always park the tiltrotator on a stable and
at surface, without tools. Make sure that
Rototilt® cannot tip over.
Disconnect the hydraulic hoses and
harness between the Rototilt® and the
base machine. The tiltrotator is now
detached from the base machine.
If the machine coupler is open while the
harness to the tiltrotator is still connected,
a warning is shown on the display.
Operating extra hydraulics
Detach Rototilt®.
Now select regulation of extra hydraulics
on the display by activating double valve
block shunt. Conrm with the OK function
key.
For return to Rototilt ® control: First
connect the tiltrotator and then connect it
to the base machine.
Now select Rototilt® operation on the
display and conrm the selection with
the green function key and then the OK
function key.
Control of the oil ow in the base
machine’s extra hydraulics circuit can be
performed using a roller or switch. Both
alternatives work in parallel with any
pedals on the base machine.
Roller for the tilt function regulates the
ow in both directions.
Non-variable hydraulic flow
The ow can be locked using the Hold
switch when the intended level is reached
with the roller for tilt. Press and hold the
switch for 0.5 seconds.
The next time the switch is pressed for
the hold function, the function and ow
stop.
On/Off control
Pulse switch starts and closes full ow
in one direction. Hold switch starts and
closes full ow in the other direction.
Activate control with the switch via the
Angles menu. ”On/O󰀨 Double Feeder”
must be conrmed with OK. The function
is only active in this view.
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www.
www.rototilt.com/icssupport
C
A
B
10
D
9
11
4
8
3
7
2
6
1
5
EN English
i
INFO - Prole 0 is reserved for the installer and
cannot be modied by another user.
ICS and ICS Direct are congured during
installation using the display. Operators
can adjust settings on the display and
save them in individual proles. The last
selected prole remains active after start-
up; change if necessary. The installer uses
prole 0.
A. The top bar indicates the current menu
or numbered warnings. Also see alarm
list in the Schematics section.
B. 8 sub-menus are shown on the Start
menu:
1. Angles
2. Speed
3. Brightness
4. Language
5. System information
6. Handle - Functions
7. Troubleshooting
8. Settings
C. Icons are shown on the bottom bar. At
the left edge, the icons indicate which
function or function key activates in the
current view.
The current prole is shown in the right
corner.
D. The display has a total of 8 keys:
9. Three function keys
blue, green & red
10. Four arrow keys
Change values & navigate the
menu
11. One key to conrm (OK).
Unless otherwise stated, make the
changes as follows:
Move the cursor using the arrow keys.
Conrm with OK.
Adjust the values with the arrow keys.
Conrm with OK.
Return to the previous menu or position
using the right function key (red).
Additional information - (?)
When a question mark (?) appears above
the left (blue) function key, additional
information will be shown in the next view.
From the start menu – press the blue key
and a QR code will appear.
Scan the QR code with an appropriate
device. The QR leads to an o󰀩cial website
containing support information.
Configuration - Operator functions
The settings below are open and made from the start menu inputs, allowing all operators to make and save
settings in their specic proles. However, some changes cannot be made by the installer (prole 0).
Display
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PWR CAN
SYS
EN English
Language
(Language)
The language setting is changed via
the menu. The 7 options are: English,
Swedish, Finnish, Norwegian, German,
Danish and French.
Select the ag for the preferred language.
Conrm with OK.
Restarting the control system will apply
the language change.
Settings
Profile
(Settings - Operator prole)
The bottom bar shows the active prole.
Mark the settings in the start menu,
conrm with OK.
1. Specied values for the prole are
changed using the arrow keys.
2. Select operator prole 1-4. The
selection is conrmed with OK.
i
INFO - Prole 0 is reserved for the installer and
cannot be modied by another user.
!
IMPORTANT - It is only possible to open the lock
when the start menu is visible or from the
troubleshooting menu.
Quick coupler
The icon for the quick coupler is shown
in the lower list on the menus Start and
Trouble shooting.
In order to open the quick coupler, the
green function key must rst be pressed
and the released.
The buzzer sounds and the lock
switch can then be regulated during a
10-second period.
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Rotor = normal direction / vanlig riktning
Rotor = inverted direction / omvänd riktning
EN English
Change the direction
The roller direction can be changed:
select the function and conrm with OK.
Shift direction with x/x, middle function
button (green).
A dash above the function shows that it is
inverted. Conrm with OK.
Change the position
The user (prole 1-4) can switch the
position of tilt and rotation.
Switch the position using the left function
button (blue). A warning text will now be
displayed in the menu view.
A larger warning text is also displayed
upon each start-up of the system, and
upon each activation of the shut-o󰀨 lever.
The warning must be conrmed with OK
to activate the tiltrotator’s functions.
The ability to switch positions for the
rotation and tilt functions should be used
as seldom as possible.
Handle
(Functions - Left/Right)
The functions of the rollers and switches
are described in the menu.
Information about handle conguration is
specied in three places: On the decal,
on the display and in the base machine’s/
excavator’s instructions for use.
!
IMPORTANT - The base machine/excavator’s
factory-installed handles have been replaced with
handles adapted to the control system.
Carefully check the changed functions, for both the
base machine/excavator and alternative control.
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*
*Not visible for operator when RPS is installed.
Visas ej i förarprol om RPS är installerat.
EN English
Pulse function, frequency
(Angle - Pulse function Frequency)
Select Frequency and adjust the
frequency of the pulse function.
Pressurising
(Feeder time Coupler)
Select feeder time, quick coupler locking
function, and set the desired value (3-12
sec). The saved value regulates the time
that the quick coupler locking function is
pressurised.
Calibrate angles
In order for the angle display to work
correctly, it must be calibrated with the
right bucket.
Rotate the bucket to the zero position.
Position the bucket bottom at against
the surface.
Now highlight the icon to save (diskette),
using the arrow keys.
Conrm with the OK function key.
Angles
Information about rotation* and tilt
angles is found via the menu and special
functions can also be chosen here.
Pulse function
(Angle - Pulse function)
The pulse function is active when starting
the system, except in those cases when
the hydraulic thumb is activated.
Shake the bucket by pressing and
holding switch 1, left handle depressed,
and at the same time pulling roller B with
the tilt function (default: roller B, right
handle).
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EN English
Automatic Grade Control
Option only available with activated RPS
and established communication with
excavator system.
If the automatic tilt and rotation function
is included in the installed excavation
system, it can be controlled via ICS.
Select the icon for the Angles menu and
then conrm your selection with OK.
Select Auto grade control (AGC) in the
view on the display using the arrow keys.
Conrm your choice with OK.
Activate the function by pressing and
holding the button on the handle. Locate
the function via the handle decal.
The function is only active in this view.
i
INFO -
If RPS is installed, angles are calibrated by an
authorised installation engineer.
Home position*
(Angle - Set position)
Select the set position and press OK to
save the current rotor and tilt positions in
the memory for the next time the system
is started.
*Does not apply to ICS Basic.
Save position*
(Angle - Saved position)
Select saved position and press OK.
When switch 1, left handle, is activated,
the rotor and tilt functions move to the
saved, predened positions. Rotation and
tilt movement take place in the direction
that represents the shortest route from
the current position to the saved position.
The function is only active in this view.
*Does not apply to ICS Basic.
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Program version, Cabin Rototilt
11.222.333
Program version, Display Rototilt
11.222.333
Program version, Tiltrotator 01.002.003
Supply voltage Cab 0.0V
Tiltrotator 0.0V
Time 12:42
Date 2016-10-01
Hours counters
Power on 0:08
Rotor 0:00
Tilt 0:00
Grapple 0:00
Extra2 0:00
EN English
Double feeder
The Double feeder mode can be
activated after Rototilt® has been
disengaged.
The function is controlled either with the
tilt function roller or with the pulse switch
and the hold switch.
Activate control with the switch via the
Angles menu.
”On/O󰀨 Double Feeder” must be
conrmed with OK.
See Operation of extra hydraulics.
System Information
Serial number - The tiltrotator’s specic
number, also found on the rating plate.
Software version - Shows the version
number for the software of each unit,
display, CCI and TCU.
Supply Voltage - Power supply to the
control unit and tiltrotator.
Time - Current time. Select the row and
then press the middle function button
(green) to set the time.
In some cases Bat Clock is not
connected, which results in the system
losing the time and date setting.
Date - Current date.
Hours counters - Shows the total hours
of operation for the tiltrotator, and the
total hours of operation for each function.
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Reduced speed indicated
EN English
Reminder service
The system shows a reminder, after
every 8 hours of operation. The reminder
indicates that requisite service must be
carried out.
If the ILS option is specied, the reminder
for the 8-hour interval is automatically
switched o󰀨.
See the Rototilt® Instructions for Use
The system also displays reminders
for other intervals. The oil in the rotor is
changed for the rst time after 500 h, then
once every 1000 hours or once yearly.
Also refer to the tiltrotator’s Instructions for
Use, Maintenance and Technical Data.
!
IMPORTANT - Detailed information about the
actions to be performed at each interval can be
found in the tiltrotator’s Instructions for Use.
Interval: “Daily inspection” and “8th hour of
operating” refer to di󰀨erent service points.
Speed
(Speed)
Both the general speed and the speed
of specic functions are adjusted via the
menu.
Navigate between the functions using the
vertical arrow keys.
Adjust the values of each function using
the horizontal arrow keys. Conrm the
settings with OK.
After a speed reduction is adjusted and
conrmed, this is indicated on the start
menu by a star.
See the gure.
For detailed information, go to
Troubleshooting – input signals.
Speed cannot be adjusted in prole 0.
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Parked
position
Active
hydraulic
thumb
EN English
Brightness
(Brightness)
The display brightness is adjusted with
the arrow keys.
Conrm with OK.
Hydraulic thumb
(Angle - Activate thumb)
If the base machine/excavator is
equipped with a hydraulic thumb on
the stick, the ICS system can prevent
simultaneous use of the tiltrotator and
hydraulic thumb.
The display shows the alternatives under
the Angles menu. If the text is grey
instead of black, the function cannot be
activated.
To activate this function, the tiltrotator’s
rotation position must be at the zero
position; a certain margin of error (<5°) is
allowed.
The angle of the tiltrotator in relation to
the base machine/excavator shaft shall
be 0°. Perform a visual check to ensure
that this is the case.
Select the alternative and conrm with
OK.
As long as the hydraulic thumb is
activated, a warning text is shown on the
display.
Disabling the function must be done
manually. It does not shut down in
connection with system restarts or when
the base machine/excavator ignition is
turned on and o󰀨.
Before disabling the function, the
hydraulic thumb must be returned to the
parked position. Perform a visual check
to ensure that this is the case.
Turn o󰀨 the function with OK.
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