Scanreco RC400 G2B User manual

Document number
S071
Revision
C
Date
2011-10-17
Document type
Manual
SERVICE MANUAL
Remote Control
System RC400 G2B/G3B

Contents
1General..........................................................................................................3
1.1 Synopsis 3
1.2 Distribution 3
1.3 Terminology 4
1.4 Applicable products 4
1.5 Productidentication5
2 Preface..........................................................................................................6
2.1 General information 6
3 General system description.........................................................................7
3.1 General description 7
3.2 Schematic overview of Scanreco RC-400 G2B 8
3.3 Schematic overview of Scanreco RC400 G3B 9
4 Getting started............................................................................................10
4.1 PortableControlUnitdenition 10
4.2 CentralUnitG2Bdenition 11
4.3 CentralUnitG3Bdenition    12
4.4 Cable or radio communication 13
4.5 Cable connection schematics 13
5 Inputs & Outputs........................................................................................14
5.1 Analogue functions 14
5.2 Portable Control Unit MAXI digital inputs 16
5.3 Portable Control Unit MINI digital inputs 17
5.4 Digital functions 18
5.5 Terminal schematics for current controlled Central Unit G2B 19
5.6 Terminal schematics for voltage controlled Central Unit G2B 20
5.7 Terminal schematics for Central Unit G2B CAN interface 21
5.8 Connection schematics for Central Unit G3B 22
6 Operational indications.............................................................................23
6.1 Central Unit status and operational indications 23
6.2 Central Unit LED-display 24
6.3 Portable Control Unit status indications 25
7 Error code indications...............................................................................26
7.1 General description 26
7.2 Central Unit error codes 26
7.3 Portable Control Unit error codes 29
8 Radio...........................................................................................................30
8.1 General description 30
8.2 Determining radio quality 30
8.3 Radio channel / Frequency 30
8.4 Range 30
9 Diagnostics mode......................................................................................31
9.1 General description 31
9.2 Activating diagnostics mode 31
9.3 Table / Diagnostics data 32
10 Online Programming mode........................................................................35
10.1 General description 35
10.2 Activating online programming mode 36
10.3 Table / Programming options 37
11 Portable Control Unit self test mode........................................................40
11.1 General description 40
11.2 Activating PCU Test Mode 40
12 ID-code programming.................................................................................41
12.1 General description 41
12.2 Procedure 41
13 G2B Standard cable kits............................................................................42
13.1 General description 42
13.2 Standard supply cable kits 43
13.3 Standard valve cable kits for Sauer-Danfoss PVG-32 44
13.4 Standard valve cable kits for HAWE 45
13.5 Standard valve cable kits for PWM solenoids 46
Document type Document number PageRev
Service Manual S071 C 2 of 46

Attribute Information
Document type Manual
Title Remote Control System RC400 G2B / G3B
Subtitle Service Manual
Document number S071
Filename S071
Revision C
Revision date 2011-10-17
Revision Date Name Note
A 2010-10-29 Scanreco AB First release
B 2011-08-14 Scanreco AB G3B Central Unit added
Major changes in document
C 2011-10-17 Scanreco AB G2B Standard Cable kit chapter added
Minor changes in document
Name Rule
Internal Only within own organization
Document information
Revision history
1 General
Synopsis
Scanreco Remote Control System RC400 G2B/G3B Service Manual
This service manual is intended as a complement to the Remote Control System RC400 G2B
Instructionmanualandcoversmorein-depthinformationsurroundingserviceandfaultnd-
ings on the systems.
1.1
1.2 Distribution
Document type Document number PageRev
Service Manual S071 B 3 of 46

Abbreviation Description
n/a Not applicable
PWM Pulse Width Modulation
PCU Portable Control Unit
CU Central Unit
LED Light Emitting Diode
ST Status LED
DV Dump Valve
Item no: Description Program version
3010 G2B Central Unit PWM EU 4.10
3011 G2B Central Unit PWM NAFTA 4.10
2010 G2B Central Unit Danfoss EU 2.14
2011 G2B Central Unit Danfoss NAFTA 2.14
1602 G3B Central Unit Type 1 EU 1.00
1603 G3B Central Unit Type 1 NAFTA 1.00
1604 G3B Central Unit Type 2 EU 1.00
1605 G3B Central Unit Type 2 NAFTA 1.00
n/a* G2B Portable Control Unit Maxi Linear 1.07
n/a* G2B Portable Control Unit Maxi Joystick 1.07
n/a* G2B Portable Control Unit Mini Linear 1.07
n/a* G2B Portable Control Unit Mini Joystick 1.07
1.4 Applicable products
This document is applicable on the below declared products and program versions.
1.3 Terminology
*DuetothevarietyofcongurationsavailableforthePortableControlUnits,itemnumbersarenot
declared;onlytheavailablePortableControlUnitplatformtypesaredeclared,formoredetailed
information refer to customer part list where available.
Document type Document number PageRev
Service Manual S071 C 4 of 46

Portable Control Unit MINI
Portable Control Unit MAXI
Central Unit G3B
Central Unit G2B
1.5 Product identication
AllSCANRECOProductsarelabeledwithproductpartnumberandserialnumberforverication.
Below illustrations shows where these numbers can be located.
Alwayscheckandverifyproductitem-andserialno.beforeanytypeofserviceiscommisioned,
refertocustomerpartslistandsystem-/producttechnicalspecicationsinordertodetermine
system-/productconguration.
Document type Document number PageRev
Service Manual S071 C 5 of 46

2.1 General information
•Remotelycontrolledcranesmayonlybeoperatedbyqualiedpersonnel.The
driver must be aware of the contents of chapter 4 “Safety regulations and
Operating instructions” available in the Intruction Manual before operation is started.
Serious accidents may occur if these instructions are not followed.
•Toprotecttheportablecontrolunitfromdamageandforsafetyreasons,the
control unit must be kept in a locked cabin
•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areused,andthenumerous
standardswhicharefrequentlythesubjectofvaryinginterpretation,itis
impossible for the personnel at Scanreco to provide expert advice regarding
thesuitabilityofagivenremotecontrolforaspecicapplication.Itisthe
responsibility of the purchaser to determine the suitability of any Scanreco
remote control product for an intended 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
recommendation (this manual). If the Scanreco RC 400 G2B/G3B will be used in a
safetycriticalapplication,thecustomer/drivermustundertakeappropriate
testing and evaluation to prevent injury to the ultimate user. Scanreco does
not take responsibility for any damage or injury.
•UnauthorizedtamperingwithaScanrecoremotecontrolsystemautomaticallyinvalidates
guarantee.
This manual is intended as a complement to the crane / machine instruction book
and covers the Scanreco RC 400 G2B/G3B Remote Control System.
The Scanreco RC 400 G2B/G3B offers the driver an extremely advanced remote control
systemwithspeed,precision,controland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 quickly familiarise yourself
with your new remote control system and how to utilise it.
2 Preface
Document type Document number PageRev
Service Manual S071 C 6 of 46

3.1 General description of Scanreco RC-400 G2B/G3B
The Scanreco RC 400 G2B/G3B remote control system has been especially developed for
hydraulically driven mobile cranes and machinery. The system is a digital remote
control system based on an extremely advanced microprocessor technology. Years of
exhaustive and demanding testing have shown that the remote control system can
cope with the roughest of environments.
The system is protected against electromagnetic and radio frequency radiation and
canbeinstalledontomost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,a
central unit with connection cable for driving proportional electro-hydraulic slide
controllers.
Digitallycodedcontrolinformation(leverdeectionandswitchposition)issentfrom
the control unit via electric cable or via radio to the central unit. The control unit and
centralunittranslatethemagnitudeanddirectionofthemanoeuvreleverdeections
andswitchpositionstocorrespondingvalvefunction,speedanddirectionandthus
crane movement.
3 General system description
Document type Document number PageRev
Service Manual S071 C 7 of 46

No Description Qty
1Portable Control unit (PCU) 1
2Central unit G2B (CU) 1
3Battery Charger (10 - 30 VDC) 1
4Battery cassette (NiMH 7.2 VDC) 2
5Manoeuvre cable (10 meters) 1
6Emergency stop box (Optional) 1
7Cable kit supply cables + digital outputs 1
8Cable kit valves cables (analogue outputs) 1
3.2 Schematic overview of Scanreco RC-400 G2B
1
4
2
3
5
Below illustrations shows a typical system consistory for the G2B system
2A
6
7Supply Cable Kit
See chapter 13 for standard available
types
Dump valve output 8Valve Cable Kit
See chapter 13 for standard available
types
Document type Document number PageRev
Service Manual S071 C 8 of 46

No Description Qty
1Portable Control unit (PCU) 1
2Central unit G3B (CU) 1
3Battery Charger (10 - 30 VDC) 1
4Battery cassette (NiMH 7.2 VDC) 2
5Manoeuvre cable (10 meters) 1
3.3 Schematic overview of Scanreco RC-400 G3B
1
4
3
5
Below illustrations shows a typical system consistory for the G3B system
2
Document type Document number PageRev
Service Manual S071 C 9 of 46

Micro-toggle
Micro-LED
Stop-button
Power-LED
On-button
Cable port
4.1 Portable Control Unit denition
4 Getting started
The illustrations below aims to delare all entities mentioned in this document.
Insert battery or connect cable connector!
1. Twist up the Stop-button
2. Press the On-button once
- LED-Power will be illuminated RED
Activating the Portable Control Unit
Document type Document number PageRev
Service Manual S071 C10 of 46

R/M-Switch
Status LEDs
LED-display
Cable / Programming port
Terminal connectors
4.2 Central Unit G2B denition
The illustrations below aims to declare all
entities mentioned in this document.
Activating the Central Unit
The Central Unit can be activated in two modes via the R/M switch; REMOTE or MANUAL mode.
InREMOTEmodetheCentralUnitiscontrolledbythePCU,inMANUALmodethesystemsupplies
only the DV-output intended for Dump valve supply; the complete system is by-passed allowing
manual operation of distributor bench (where available).
REMOTE MODE:
Operation via PCU
LED STATUS will be illuminated
redatrstthengreenwhenin
contact with PCU.
MANUAL MODE:
System by-pass / Manual operation
LED DV will be illuminated red.
RemoteManual Off
Document type Document number PageRev
Service Manual S071 C 11 of 46

LED-display
Cable A
Cable C
Cable B
4.3 Central Unit G3B denition
The illustrations below aims to declare all entities mentioned in this document.
Activating the Central Unit G3B
TheCentralUnitG3BissuppliedthruCableAandrequiresexternalpowerswitching,seechapter
5.8 for further info.
The Central Unit G3B exists in 2 different versions; one with 2 cable outputs and one with 3 cable
outputs. Refer to chapter 5.8 for further info.
Document type Document number PageRev
Service Manual S071 C12 of 46

Cable A
Cable C
Cable B
4.4 Cable or radio communication
4.5 Cable connection schematics
Cablecommunicationhashigherprioritythanradiocommunication,ifacablelinkispresent
betweenthePCUandCentralUnitthiswillbedetectedbythesystem,disablingradiocommunica-
tion.
3
3
4
455
22
11
Standard 10m cable connector
Portable Control Unit Pin assignments Central Unit G2B/G3B Pin Assignments
11
1 2 3 4
22
33
44
55
Brown / Data
Brown / Data
White / GND
White / GND
n/a
n/a
Blue / RS 232 TX
Black / RS 232 RX
Grey / Supply output
Grey / Supply output
+_
Battery
Terminal
4-pole main print
card connection
5- pole male
M12 connector
5- pole female
M12 connector
Orange
White
Cable connection
Pin no. Wire color
1 Brown
2 White
3 Blue
4 Black
5 Grey
Document type Document number PageRev
Service Manual S071 C 13 of 46

5 Inputs & Outputs
1A 4A
1B 4B
2A
7B 8A
7A 8B
2B
3A
3B
5A
5B
6B 6A
5.1 Analogue functions
Theanalogueinputsavailableforeachplatform(MAXILinear,MAXIJoystick,MINILinearand
MINIJoystick)arebydefaultassignedananalogueoutputontheCentralUnit,belowgures
declares the standard assignments.
PCU MAXI Linear standard assignments
PCU MAXI Joystick standard assignments
1A 2A
2B1B
3A
3B
4A
4B
5A
5B
6A 7A 8A
6B 7B 8B
Document type Document number PageRev
Service Manual S071 C 14 of 46

PCU MINI Linear standard assignments
PCU MINI Joystick standard assignments
1A
1B 1A
2A
2A 5A 3A
3B5B
6B 4B 4A
6A
2B
2B1B
3A
3B
4A
4B
5A
5B
6A
6B
Document type Document number PageRev
Service Manual S071 C 15 of 46

Note that on the MAXI platform the Terminals 1 and 2 are mirrored and available on both left and right hand side of the
stop button
5.2 Portable Control Unit MAXI digital inputs
ThedigitalinputsavailableareNOTallbydefaultassignedandigitaloutputontheCentralUnit,
 belowguresonlydeclaresdigitalinputaccess.
No. Type Colour
code
AMP
Pin no.
- Common (GND) Black 1
10 Digital input 33 Pink 2
9 Digital input 06 Grey 3
8 Digital input 02 Brown 4
7 Digital input 32 Purple 5
6 Digital input 05 Orange 6
5 Digital input 31 Black 7
4 Digital input 07 White 8
3 Digital input 04 Blue 9
2 Digital input 03 Green 10
1 Digital input 01 Yellow 11
- Supply output Red 12
No. Type Colour
code
Amp
Pin no.
- Common (GND) Black 1
20 Digital input 36 Pink 2
19 Digital input 35 Grey 3
18 Digital input 34 Brown 4
17 Digital input 37 Purple 5
16 Digital input 08 Orange 6
15 Digital input 09 Black 7
14 Digital input 13 White 8
13 Digital input 12 Blue 9
12 Digital input 11 Green 10
11 Digital input 10 Yellow 11
- Supply output Red 12
1-12 1-12 1-121-12
Terminal 2
Terminal 1
Document type Document number PageRev
Service Manual S071 C 16 of 46

5.3 Portable Control Unit MINI digital inputs
ThedigitalinputsavailableareNOTallbydefaultassignedandigitaloutputontheCentralUnit,
 belowguresonlydeclaresdigitalinputaccess.
No. Type Colour
code
AMP
Pin no.
- Common (GND) Black 1
10 Digital input 33 Pink 2
9 Digital input 06 Grey 3
8 Digital input 02 Brown 4
7 Digital input 32 Purple 5
6 Digital input 05 Orange 6
5 Digital input 31 Black 7
4 Digital input 07 White 8
3 Digital input 04 Blue 9
2 Digital input 03 Green 10
1 Digital input 01 Yellow 11
- Supply output Red 12
No. Type Colour
code
Amp
Pin no.
- Common (GND) Black 1
20 Digital input 36 Pink 2
19 Digital input 35 Grey 3
18 Digital input 34 Brown 4
17 Digital input 37 Purple 5
16 Digital input 08 Orange 6
15 Digital input 09 Black 7
14 Digital input 13 White 8
13 Digital input 12 Blue 9
12 Digital input 11 Green 10
11 Digital input 10 Yellow 11
- Supply output Red 12
Terminal 2Terminal 1
1-12 1-12
Document type Document number PageRev
Service Manual S071 C 17 of 46

5.4 Digital functions
Thedigitalfunctionsutilizedvariesdependingonsystemconguration,upto20digitalfunctions
can be implemented thru left- and/or right switch panels with programmable assignments to up
to 14 digital outputs.
In excess the On-button may also be assigned a digital output.
Below shows PCU platforms standard digital inputs and default Central Unit output assignment
Position Type Central Unit
301 3 way detent
toggle
Digital output 1 / Digital output 1 Parallel with ana-
logue input movement (AutoRPM engine feature)
302 3 way spring
back toggle
Digital output 2 / Digital output 3 (Engine start /
Engine stop)
303 3 way spring
back toggle
Digital output 4 / Digital output 5 (Engine RPM+ /
Engine RPM-)
304/305 2 way detent
toggle
Digital output 6 (Optional)
On-button Push button Digital output 7
301
301
304
305
302
302
303
303
On-button
On-button
PCU MINI Standard assignment
PCU MAXI Standard assignment
Document type Document number PageRev
Service Manual S071 C 18 of 46

5.5 Terminal schematics for current controlled Central Unit G2B
The drawing below declares access points for each available input and output both from the inside
terminal (above) and the standard cable kits (below). Standard cable wire number/marking is also
declared.
Position Type Central Unit
301 3 way detent
toggle
Digital output 1 / Digital output 1 Parallel with ana-
logue input movement (AutoRPM engine feature)
302 3 way spring
back toggle
Digital output 2 / Digital output 3 (Engine start /
Engine stop)
303 3 way spring
back toggle
Digital output 4 / Digital output 5 (Engine RPM+ /
Engine RPM-)
304/305 2 way detent
toggle
Digital output 6 (Optional)
On-button Push button Digital output 7 9= Digital output 14 / Serial out
8=
Digital output 13 / Digital input 4
7= Digital output 12
6= Digital output 11
5= GND
4= Digital output 10
3= Digital output 9
2= Digital output 8
1=
Digital output 7
10= GND
EX 2
EX 1
11 Input supply +VDC
10= Digital input 3
9= Digital input 2
8=Digital input 1
1= Digital output 1
3= Digital output 3
2= Digital output 2
4= Digital output 4
5= Digital output 5
6= Digital output 6
7= GND
11 Input supply +VDC
10= Digital input 3
9= Digital input 2
8= Digital input 1
7= GND
6= Digital output 6
5= Digital output 5
4= Digital output 4
3= Digital output 3
2= Digital output 2
1= Digital output 1
1= Supply
1= DV+
2= GND
2= DV-
+/-
DV
1
1
16
17 32
1 = 1A PWM +
17 = 5A PWM +
2 = 1A PWM -
18 = 5A PWM -
3 = 1B PWM +
19 = 5B PWM +
4 = 1B PWM -
20 = 5B PWM -
5 = 2A PWM +
21 = 6A PWM +
6 = 2A PWM -
22 = 6A PWM -
7 = 2B PWM +
23 = 6B PWM +
8 = 2B PWM -
24 = 6B PWM -
9 = 3A PWM +
25 = 7A PWM +
10 = 3A PWM -
26 = 7A PWM -
11 = 3B PWM +
27 = 7B PWM +
12 = 3B PWM -
28 = 7B PWM -
13 = 4A PWM +
29 = 8A PWM +
14 = 4A PWM -
30 = 8A PWM -
15 = 4B PWM +
31 = 8B PWM +
16 = 4B PWM -
32 = 8B PWM -
1= PWM +
2= PWM -
Analogue outputs
1 4
1 A
11
1 B
2 A
2 B
3 A
......
8 B
10= GND
4 = DV-
3 = DV+
2 = GND
1 = + Supply
9= Digital output 14 / Serial out
8=
Digital output 13 / Digital input 4
7= Digital output 12
6= Digital output 11
5= GND
4= Digital output 10
3= Digital output 9
2= Digital output 8
1=
Digital output 7
110
Document type Document number PageRev
Service Manual S071 C 19 of 46

The drawing below declares access points for each available input and output both from the inside
terminal (above) and the standard cable kits (below). Standard cable wire number/marking is also
declared.
5.6 Terminal schematics for voltage controlled Central Unit G2B
EX 1
11 Input supply +VDC
10= Digital input 3
9= Digital input 2
8=Digital input 1
1= Digital output 1
3= Digital output 3
2= Digital output 2
4= Digital output 4
5= Digital output 5
6= Digital output 6
7= GND
11 Input supply +VDC
10= Digital input 310= GND
9= Digital input 2
8= Digital input 1
7= GND
6= Digital output 6
5= Digital output 5
4= Digital output 4
3= Digital output 3
2= Digital output 2
1= Digital output 1
4 = DV-
3 = DV+
2 = GND
1 = + Supply
1= Supply
1= DV+
2= GND
2= DV-
+/-
DV
1
1
16
17 32
1 = 1 Module supply voltage
17 = 5 Module supply voltage
2 = 1 Regulated supply voltage
18 = 5 Regulated supply voltage
3 = 1 GND
19 = 5 GND
4 = 1 Error input (optional)
20 = 5 Error input (optional)
5 = 2 Module supply voltage
21 = 6 Module supply voltage
6 = 2 Regulated supply voltage
22 = 6 Regulated supply voltage
7 = 2 GND
23 = 6 GND
8 = 2 Error input (optional)
24 = 6 Error input (optional)
9 = 3 Module supply voltage
25 = 7 Module supply voltage
10 = 3
Regulated supply voltage
26 = 7 Regulated supply voltage
11 = 3 GND
27 = 7 GND
1 = Module supply voltage
12 = 3 Error input (optional)
28 = 7 Error input (optional)
2 =
Regulated supply voltage
13 = 4 Module supply voltage
29 = 8 Module supply voltage
3 = GND
14 = 4
Regulated supply voltage
30 = 8 Regulated supply voltage
4 = Error input (optional)
15 = 4 GND
31 = 8 GND
16 = 4 Error input (optional)
32 = 8 Error input (optional)
14
11
1
2
3
4
5
....
8
9= Digital output 14 / Serial out
8=
Digital output 13 / Digital input 4
7= Digital output 12
6= Digital output 11
5= GND
4= Digital output 10
3= Digital output 9
2= Digital output 8
1=
Digital output 7
110
9= Digital output 14 / Serial out
8=
Digital output 13 / Digital input 4
7= Digital output 12
6= Digital output 11
5= GND
4= Digital output 10
3= Digital output 9
2= Digital output 8
1=
Digital output 7
10= GND
EX 2
Document type Document number PageRev
Service Manual S071 C 20 of 46