Scanreco RC400 User manual

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REMOTE CONTROL SYSTEM
SCANRECO RC 400.
INSTRUCTION MANUAL.
( EngelskVer 2 ) This instruction manual must be kept in the vehicle cab.

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CONTENTS.
1.PREFACE.
2.GENERAL SYSTEM DESCRIPTION.
3.SAFETY REGULATIONS AND OPERATING
INSTRUCTIONS.
4.INSTALLATION INSTRUCTIONS.
5.FAULT FINDING.
6.SPARE PARTS.
7.OPTION : REGULATIONS AND AUTHORITIES,
TYPE APPROVAL CERTIFICATES.
8.PROGRAMMING PARAMETERS AND SETTINGS.
9.ACCESSORIES / OPTIONS.
Design, equipment, technichal data and specification are subject to change or improvement without prior notice. The text of this manual,
or anypart thereof, maynot be reproduced or transmitted in anyform or byanymeans, electronic or mechanical including photocopying,
recording, storage in an information retrieval system, or otherwise, without the prior written permission of Scanreco AB, Sweden.
Chapters 6, 7, 8 and 9 are abbreviated versions.

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1. PREFACE
This manual is intended as a complement to the crane / machine instruction book and
covers the Scanreco RC 400 Remote Control System.
The Scanreco RC 400 offers the driver an extremely advanced remote control system
with speed, precision and control and with maximumsafety.
In order to ensure your safety and the safety of your crane / machine you should study
and learn these instructions. This will enable you to more quickly familiarise yourself
with your new remote control systemand how best to utilise it.
For the crane driver :
Pause for a while and give yourself extra time to read chapters :
"Chapter 2. General system description" , "Chapter 3. Safetyregulations and Operating
instructions".
For the installer :
Pause for a while and give yourself extra time to read chapters :
"Chapter 4. Installation instructions " and "Inspection / Installation documents".
·Remotely controlled cranes may only be operated by qualified personnel. The driver
must be aware of the contents of chapter 3 "Safety regulations and Operating
instructions" before operation is started ! Serious accidents can occur if these
instructions are not followed !
·To protect the portable control unit fromdamage and also for safety reasons, the
control unit must be kept in a locked cab.
·Follow the instructions given in the crane handbook regarding moving the crane
fromits parking position, the best armpositioning while loads are being handled and
parking of the crane.
·Due to the unlimited variety of cranes, machines, objects, vehicles and equipment
on which the remote control system( RC 400 ) are used, and the numerous standards
which are frequently the subject of varying interpretation, it is impossible for
Scanreco AB / Swedens, personnel to provide expert advice regarding the suitability
of a given RC 400 remote control for a specific application.
It s the purchaser s responsibility to determine the suitability of any Scanreco RC
400 product for an intented application, and to insure that it is installed and guarded
in accordance with all country, federal, state, local, and private safety and health
regulation, codes, standards and Scanreco s recommendation ( This manual ).
If the Scanreco RC 400 will be used in a safety critical application, the customer -/
driver must undertake appropriate testing and evaluation to prevent injury to the
ultimate user. Scanreco AB, Sweden does not take responce for any damage or injurie.
·Unauthorized tampering with Scanreco RC 400 automatically invalidates guarantee !

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2. GENERAL SYSTEM DESCRIPTION.
Contents :Page :
·General schematic of the Scanreco RC 4002.2
·General description of the remote control system2.3
·The portable control unit2.3
·Battery operation ( See also 2.11 - 2.12 )2.4
·Manoeuvre levers2.5
·Emergency stop panel2.6
·Changing radio channels ( Due to frequency blocking )2.6
·Switch panel2.6
·Micro - speed control2.6
·ON/OFF functions2.7
·Cable for cable control 2.7
·Opto-fibre cable2.8
·Electronicbox2.9
·Expansion cable (EX) 2.10
·Crane emergencystop box2.10
·Battery pack2.11
·Battery charger and battery charging2.12
·Radio control2.13
·Radio transmitter2.14
·Radio receiver box2.15
·Option : Duplex-communication with display to give2.16 - 2.19
current weight loading, moment etc.

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General schematic of the RC 400 :
The Remote Control Systemis comprised of the following components:
·Control unit ( for cable or radio control ).
·Electronicbox.
·Crane emergency stop box.
·Expansion cable ( EX ).
- Cable operation: Control cable (3-core ).
- Radio operation: Radio transmitter, Qty. 2. battery packs, battery charger and radio
receiver box.

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1. GENERAL DESCRIPTION OFTHE REMOTE CONTROL SYSTEM.
The Scanreco RC 400 remote control system has been speciallydeveloped for hydraulically
driven mobile cranes and machinery. The system is a digital remote control system based on
an extremelyadvanced micro-processor technology. Years of exhaustive and demanding
testinghave shown that the remote control system can cope with the roughest of environ-
ments.
The remote control system is tested and approved for use in, amongst others, power stations,
with a skylift for personnel, close to work areas usingblasting, on oil platforms, military
establishments or other areas with explosive environments. The system is protected against
electromagnetic and radio frequencyradiation and can be installed onto all hydraulic valve
types ( voltage, current, pulse width, or protocol steered ) found on the market.
In its basic form the remote control system is comprised of a portable control unit with
manoeuvre levers for proportional control and switches for ON/OFF functions, an electronic-
boxwith connection cable for drivingproportional electro-hydraulic slide controllers.
Digitallycoded control information (lever deflection and switch position) is sent from the
control unit via electric cable, opto fibre cable or via radio to the electronicbox. The control
unit and electronicboxtranslate the magnitude and direction of the manouevre lever deflect-
ions and switch positions to correspondingvalve function speed and direction and thus crane
movement.
2. PORTABLE CONTROL UNIT ( for cable, opto fibre cable, and radio operation ).
General description of the portable control unit.
The portable control unit is impact and weather resistant and is light weight and compact.
Controls are available for 4, 5, 6, 7 or 8 manoeuvre functions. The manoeuvre levers are fully
proportional and have springreturn to the zero position, i.e. a "dead-man's-handle". The
control unit has an emergencystop function which will immediatelystop all movement .
All manoeuvre levers are protected with a protective frame against unintentional activation
and against mechanical damage. The control unit has multi-step micro-speed operation as
standard enablinginstantaneous temporaryreduction of speed and it can also be equipped
with a large number of switches for ON/OFF functions. A LED and sound signal are used to
indicate such things as operatingand batterystatus and for a simple and diagnostic fault
finding. ( See picture of control unit ).

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Portable control unit with battery operation ( radio control or opto fibre cable ).
A batteryis located in the control unit for radio control and is verysimple to change.
·The battery's effective operation time is about 8 hours on one charge.
·When the batteryis approachingtime for charging, the control unit beeps three ( 3 ) times
as a warningand at the same time the LED starts to blink on the control unit.
·The batterymust be used until the LED goes out, after which it can be changed.
If the batterycapacityis too LOW the control unit cannot be activated.
·The batterycapacityand operational performance is reduced in extremelycold conditions.
( The batteryis automaticallycharged duringoperation bycable control ).
·In order to reduce batteryloadingand for safetyreasons, the control unit is turned off
automatically, after the unit has been idle for more than approximatelyfive ( 5 ) minutes.

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A brief description is given now of the component parts of the control unit.
The control unit is comprised of manouevre levers for proportional control, switches for
ON/OFF and function changing, micro-operation and emergencystop. ( See separate headings
below).
Manoeuvre levers.
The manoeuvre levers give fullyvariable proportional operation and are sprungloaded to
return to zero position, i.e. "dead-man's-handle". When the manoeuvre levers are moved from
zero position the respective hydraulic function starts to operate slowlyand increases in speed
as the lever is moved further from zero position and vice versa as the lever is moved back
towards zero position. If anylevers are not included for a particular installation, a cover plate
can be mounted for the unused lever locations.
( See also title "Micro-speed control ").
For safety reasons all manoeuvre levers must be in their zero/neutral positions for a start-up to be made. If any
lever is not in its zero / neutral position during start-up, the control unit will blink and beep the same number of
times as the number of the lever to indicate which manoeuvre lever is faulty. The control unit can be used but the
faulty lever will be locked and disengaged. ( For example if it beeps and blinks five (5) times, it is the 5th lever
from the LEFT which is faulty or giving the problem signal ).

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Emergencystop panel.
There is a red emergencystop switch ( STOP ) with a manual twist reset, a push button
( ON/SIGNAL/FREQ. SHIFT ) and a red LED on the control unit's emergencystop panel.
·The control unit is started with the sprungreset push button ( ON/SIGNAL/FREQ. SHIFT )
·A warningsignal is produced on the crane ( SIGNAL ) byholdingthe push button down.
·All movement of the crane is stopped if the emergencystop is activated on the control
unit. The red LED indicates operatingand batterystatus.
Micro - Speed control ( reduction of speed ).
This return sprungswitch can be used to reduce the operatingspeed in five ( 5 ) steps from
100% to 60%, 50%, 40%, 30% and 20% speed bylimitingthe hydraulic steering. The
regulation of the function's speed is still made over the entire lever stroke and with retained
resolution.
·With impulses from the sprungloaded toggle switch to the left, towards ON, speed
reduction can be produced from 100% to 60%, 50%, 40%, 30% and 20% steering.
·Movement of the switch to the right, towards OFF, will produce 100% steeringonce
again ( See also next item ).
·For safetyreasons, a return to 100% steeringcan onlybe made if all manoeuvre levers are
in their zero positions.
·When the green LED is blinking, the Micro-speed function is activated. The number of
blinks indicate the operatingspeed as defined below. If the emergencystop is pressed on
the controller unit, the controller unit will start from the last chosen speed.
Green LED :Indication :
Green LED not lit0 to 100 % speed ( normal speed ).
1 blink everythird second =0 to 60 % speed
2 blink everythird second =0 to 50 % speed
3 blink everythird second =0 to 40 % speed
4 blink everythird second =0 to 30 % speed
5 blink everythird second =0 to 20 % speed

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ON/OFF and function changing functions.
ON/OFF switches can be used to manoeuvre electrical, hydraulic or pneumatic ON/OFF
functions. Examples of functions :
·Stoppingand startingof the vehicle's motor, throttle lever, beep / signal, change-over
valves, function changingfor ex. 9th and 10th function.
·Enable parallel runningof two or more valves at the same time from one manoeuvre lever.
·Connection of so called hold function, i.e. "lock" a function at a specific speed, after
which the speed is kept constant without the lever havingto be held ( for example
hydraulicallydriven drills ) etc. This can be compared to the speed control in a private car.
Make sure that you always know which functions are connected for ON/OFF manoeuvring.
Alternative: One switch can be used to designate that levers will give either proportional or ON/OFF functions
( function changing ).
3. CABLE FOR CABLE CONTROL ( electrical 3-core ).
The control unit is connected to the electronicboxvia a thin and flexible 3-core cable. The
cable has round contacts (Amphenol / Hirchmann) at each end.
The cable feeds the digital coded control information from the control unit to the electronic
box. The cable is available in standard lengths of 10 , 15 , 25 , 50 and 100 metres.
With cable control, the standard cable length supplied is 15 metres .
A 10 metre control cable is supplied with opto or radio control, for emergency operation.
( 1 = Supply , 2 = Data , Ground = Ground/Minus , 3 = No connection ).

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4. CABLE FOR OPTO FIBRE OPERATION ( NOTE ! OPTION ).
For opto fibre control the remote control system is complemented with an opto fibre cable,
batterypack and batterycharger. This means that light is used to send the control information
( not electrical impulses ).
The control unit is connected to the electronicboxvia a thin opto fibre cable. The cable has
circular type contacts (Ampehenol / Hirchmann) at each end and the opto fibre electronics is
built in and integrated into the contacts.
Opto fibre cable is used in those cases where the use of traditional control cable is not allowed. This can be
during work under or near to electrical power lines or ground cables where contact or flash-over between
control unit and crane could be fatal.
With opto fibre cable the control unit and electronicbox ( crane / vehicle ) are not electrically connected, i.e. are
totally isolated and galvanically separated.
( Radio control gives the same personnel protection ).

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5. ELECTRONICBOX.
The electronicboxis manufactured in aluminium and is provided with attachments and contacts
for connection to the portable control unit, radio receiver boxand ON/OFF functions. There are
also connections and contacts for supplyvoltage, electro-hydraulic converter valves, slide
controls and dump valve. Since the electronicboxcan be exposed to verytough environments,
the boxis encapsulated to give protection from damp, heat, cold, dust, vibration and corrosive
environments.
The electronicboxhas short circuit proof inputs and outputs and has protection against polarity
reversal, over-voltage and large incomingvoltage transients and EMC / RF. Connection of the
electronicboxcan therefore be made without risk of damage. The electronicboxis delivered for
supplyvoltages of +12 / +24 VDC ( +/- 20 % ) with negative ground. There are two standard car
type fuses located inside the electronicbox.
Plus fuse: + 10 Amp. and minus fuse: - 30 Amp.
Atransformer for standard mains voltages can also be used to provide the electronicbox with supplyvoltage.
Primaryvoltage: 110, 115, 220-240, 380, 440 VAC and secondaryvoltage + 12 / +24 VDC ( +/- 10%).
There are LEDs on the electronicboxto indicate operatingstatus e.t.c : See also page : 5-2 !!!
POWER: Indicates supplyvoltage to the electronicbox ( toggleswitch in REMOTE position ).
DV: Dump-Valve activated.
ON/OFF: ON/OFF function activated. The LED is commoned and summed, i.e. onlyone switch at a time can
be activated fromthe control unit to enable control.
DIR. A: Manoeuvre lever A-direction activated and moved . The intensityof the light fromLED-Aincreases
with increased lever angle. The LED is commoned and summed, i.e. onlyone manoeuvre lever at a time
can be manoeuvred in the A-direction to enable control.
DIR. B: Manoeuvre lever B-direction activated and moved . The intensityof the light fromLED-B increases
with increased lever angle. The LED is commoned and summed, i.e. onlyone manoeuvre lever at a time
can be manoeuvred, in the B-direction to enable control.

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6. EX-CABLE ( EX ).
A thin and flexible 7-core cable can be connected to the electronicboxfor outgoingON/OFF-
functions, for in-goingsignal handlinge.g. overload and lift reduction functions and for serial
communications if more than one electronicboxis used in so called tandem operation. The
cable has a circular type contact (Amphenol / Hirchmann) at one end.
( The EX-cable is marked with the letters EX and should be connected to the ON/OFF connector on the
electronicbox ).
7. CRANE EMERGENCY STOPBOX / MAIN EMERGENCY STOP.
The crane emergencystop boxis a separate unit for fixed mountingon the vehicle. The crane
emergencystop boxmust be connected between the vehicle batteryand the electronicbox.
·When an emergencystop is activated the main power supplyto the entire remote control
system is disconnected.
·The crane emergencystop must be suitablylocated and easilyaccessible.
·Before operation is started, the driver must inform all fellow-workers about the emergency
stop function and its location.
With the electronicbox switch in MANUAL position and an electric dump valve, the emergencystop
function is also available during manual hand lever operation.
( See also chapter 5. "Safetyregulations and Operatinginstructions" ).

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8. BATTERY PACK.
The batterypack is impact and weather resistant and is located in the batteryholder in the
portable control unit . The batterypack is rechargeable and of NickelCadmium (NiCd) type.
The batterypack is protected against short circuits. The terminal voltage of a newlycharged
batteryshould be ( unloaded ) ca 7.0 - 9.0 VDC.
Note.
Batterypacks supplied since 1 January1993 have three ( 3 ) terminal connections. The centre
terminal is used for Scanreco s quick charger ( option ).
The batterypack is fullycompatible with all batterypacks previouslysupplied.
·The effective operational capacityof the batteryis approximately8 hours per charge.
·When the batteryis approachingtime for recharging, the control unit beeps THREE ( 3 )
TIMES as a warningand at the same time the LED starts to blink on the control unit. See
next item.
·The batterymust be used until the LED goes out, after which it can be changed.
If the batterycapacityis too LOW the control unit cannot be activated.
·The batterycapacityand operational performance is reduced in extremelycold conditions.
( The batteryis automaticallycharged duringoperation bycable control ).
·In order to reduce batteryloadingand for safetyreasons, the control unit is turned off
automatically, after the unit has been idle for more than approximatelyfive ( 5 ) minutes.

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9. BATTERY CHARGER AND BATTERY CHARGING.
The batterycharger must be mounted in a vibration free area inside the cab or indoors and be
protected against damp and temperature variations.
·The normal chargingtime for an emptyuncharged battery, is approximately12-14 hours.
·The batterycharger should be connected directlyto the vehicle batteryto enable charging
duringidle time.
·The batter charger is constructed so that no damage will occur from longcontinuous
charging.
·The supplyvoltage to the batterycharger should be +11 VDC to +30 VDC.
There are two indicating LEDs on the battery charger :
·RED LED (POWER) : indicates supplypower available ( i.e. from the vehicle battery).
·GREEN LED (CHARGING) : indicates that chargingis takingplace.
A fuse-holder ( bayonet type ) is located next to the connectingcable and contains a glass fuse
3 Amp. ( quick ), size 5 x20 mm .
Polarity for the connecting cable: +Blue and - Brown.
The battery charger current without battery pack is:
»
10 - 20 mA.
The battery charger current with battery pack is:
»
130 - 140 mA.
The terminal voltage at the battery charger terminals is approximately the same as the vehicle battery voltage.
Defective / non-functioning battery charger:
If the driver is usingcable control and the batterypack is in place in the control unit, the
batterywill be charged automatically. See also below.
Battery charging via cable control, for ex. over night : (Charging time is approx. 12-14 hours).
Place the batterypack in the control unit (emergency stop depressed) and connect the cable
between the control unit and the electronicbox(emergency stop on the crane activated).
The electronicboxmust be in Remote : (Power, and LED No. 4 should blink). Batterychargingis
now takingplace !

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10. RADIO CONTROL ( See "11. Radio transmitter" and "12. Radio receiver box" ).
For radio control operation the remote control system is complemented with a radio
transmitter, a batterypack, batterycharger and radio receiver box.
( See also sections "Battery pack", "Battery charger"and "Control unit for battery operation").
11. RADIO TRANSMITTER.
The radio transmitter card ( which is encapsulated and has a well proven built-in antenna ) is
mounted onto the control unit electronics card ( HTX 402 ). The radio transmitter is connected
via a pin strip, to the electronics card and is screwed down usingfour fixingspacers. When
the radio transmitter is connected to the electronics card ( HTX 402 ), a unique identitycode is
added automaticallyto the digitallycoded control information. The radio transmitter is
approved in accordance with European radio standards I-ETS 300 220 and I-ETS 300 683.
The driver can make an immediate radio channel change byusingcontrol unit push button
"ON/SIGNAL/FREQ.SHIFT". The radio channel change can be made at anytime during
operation. The radio transmitter operates in the 405 - 490 Mhz band.
For the mobile market 12 ( twelve ) radio channels in the I.S.M band ( 433.100-434.700 á25kHz )
are available for use. ( United Kingdom : 458.500-458.950 MHz a 25kHz ).
No special licence is required bythe user for the frequencies for which the radio transmitter is
approved.
Changing the radio channel : Adouble press of the (FREQ. SHIFT) push button will make the system
execute an immediate radio channel change. Press the button twice quicklyand the red LED should blink and the
control unit should beep once to confirmthat a radio channel change has been made. Aradio channel change can
be made at anytime during operation. The systemhas twelve (12) radio channels as standard .

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12. RADIO RECEIVER BOX.
The radio receiver boxis manufactured in aluminium and is provided with attachments, well
proven antenna and a connector for connection to the electronics box. Since the radio receiver
boxcan be subjected to a verytough environment, the boxis encapsulated for protection
against damp, heat, cold, dust, vibration and corrosive environments. A green LED on the
radio receiver boxindicates supplyvoltage ( the radio receiver boxreceivers its supplyvoltage
from the electronicbox).
When the radio receiver boxis connected to the electronicbox, a unique identitycode is
automaticallyadded to the digitallycoded control information.
The radio receiver boxis approved in accordance with European radio standards I-ETS 300
220 and I-ETS 300 683. With the use of the control unit push button "ON/SIGNAL/FREQ.SHIFT"
the driver can make a direct change of radio channel. A radio channel change can be made at
anytime duringoperation. The radio receiver boxoperates in the 405 - 490 Mhz band.
12 ( twelve ) radio channels are available in the I.S.M band ( 433.100-434.700 á25kHz ) for
mobile operation ( United Kingdom : 458.500-458.950 MHz a 25kHz ).
No special licence is required for the user for the frequencies for which the radio receiver box
is approved.
( The connecting cable for the radio receiver box is marked with the letters RA and should be connected to
contact RADIO on the electronicbox ).

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3. SAFETY REGULATIONS AND OPERATING
INSTRUCTIONS.
These instructions cover, amongst other things, those special regulations which apply for
remotely controlled cranes ( cable or radio ). The driver must be aware of the contents of
these safety regulations.
Remote controlled cranes may only be operated by trained personnel. The portable control
unit must never be passed over to any person who has not received training for remote
controlled cranes. If these instructions are not followed, serious accidents can occur!
THE CRANE DRIVER MUST :
·Check that the control unit matches the crane / vehicle which he is to operate.
·Aquaint himself with the symbols and positions for operatingfunctions and directions.
·Check the emergencystop function and general remote control system operation daily.
·Duringoperation, walk or stand at a suitable distance from the crane to be able to get a
good view of the operation. No unauthorised persons maybe within the crane's working
area.
·Be aware that it is forbidden to conveyloads over himself or fellow workers.
·Release all manoeuvre levers (dead-man's-handles) if crane movement control is lost
and then immediatelypress the emergencystops on the control unit and on the crane.
·The emergencystop on the control unit should always be in the depressed position
whenever the unit is not in use. This applies even for short stoppages, for example, if the
driver wishes to move.
·After a completed run, press the emergencystop on the control unit and on the crane. The
control unit must be kept out of reach of unauthorised persons.
·Always report equipment faults or shortcomings to the person responsible for the crane.
·Check that none of the safetydevices have been altered or removed.
·Refer to the current regulations / instructions regarding"Personnel lifting with cranes ",
"Overloading/overload protection ", "Visible signals during the operation of cranes " and "The location
of cranes close to airports and high-tension power lines".
·Be aware of anyother pertinent regulations and of anylocal regulations which may
apply. These are to be found in the relevant safetyregulations regardingcrane transport.
·Be aware of the contents in "OPERATING INSTRUCTIONS" and the handlingand method
of workingof the remote control system. See next page " Operatinginstructions " !

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OPERATING INSTRUCTIONS.
Before operation, the driver MUST make himself aware of the contents in the
"SAFETY REGULATIONS" for remotely controlled cranes. The driver must be
aware of the function of all manoeuvre levers and switches.
1. For remote control: Place the electronicboxpower switch into REMOTE.
For manual/emergencyoperation: Place the electronicboxpower switch into MANUAL.
(Power is now only supplied to the dump valve and the crane's functions can be
manoeuvred directly from the valve's hand levers).
Twist up the emergencystop switches on the crane and on the control unit.
Cable operation:Connect the control cable between the control unit and the electronics
box( crane ).
Radio operation:Place a newlycharged batteryin the control unit's batteryholder.
3. Press ON/SIGNAL/FREQ.-SHIFT, and the red LED will light continuously.
4. The crane is now readyfor operation. The driver must be aware of all manoeuvre lever and
switch functions before operation is started.
5. To switch off or to activate the emergencystop the emergencystop switches on the control
unit and crane should be pressed down. The emergencystop on the control unit should
always be in the depressed position whenever the unit is not in use. This applies even for
short stoppages, for example, if the driver wishes to move.
6. To ensure a longlife for the control unit and for reasons of safety, the control unit must be
kept locked in the cab.( The control unit should be regularlywiped off with a damp cloth for example ).

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4. INSTALLATION INSTRUCTIONS.
Contents :Page :
·General schematic of the RC 400 / During welding.4.2
·Locating the electronicbox and radio receiver box.4.3
·Mounting recommendations for the radio receiver box.4.4
·Connection of Danfoss electro-hydraulic valve and dump valve.4.5
·Connection of proportional magnets and dump valve.4.5
·Connection of supply voltage and ON/OFF functions. 4.6
·Connection schematic for ON/OFF functions ( see also page 4.6 ).4.7
·Connection schematic for start of vehicle motor and start lock.4.8
·Connection schematic for valve contacts to Danfoss valves.4.9
·Connection schematic for battery charger.4.10
·Changing crane direction ( If crane movement reversed to that desired ).4.11
When installing remote control on vessels/boats ( marine cranes ).
·Grounding of electronicbox and radio receiver box.4.4 - 4.5
Technical data :
·Portable control unit, electronicbox and radio receiver box4.15