Scanreco RC400 G2B Service Manual Download Page 1

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Document number

S071

Revision

Date

2011-10-17

Document type

Manual

SERVICE MANUAL

Remote Control

System RC400 G2B/G3B

Summary of Contents for RC400 G2B

Page 1: ...Document number S071 Revision C Date 2011 10 17 Document type Manual SERVICE MANUAL Remote Control System RC400 G2B G3B ...

Page 2: ...rational 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 3...

Page 3: ...7 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 ser...

Page 4: ...05 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 configurations available for...

Page 5: ... serial number for verification 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 specifications in order to determine system product configuration Document type Document number Page Rev Service Manual S071 C 5 of 46 ...

Page 6: ...rchaser 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...

Page 7: ...e 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 deflection and switch position is sent from the...

Page 8: ...y cables digital outputs 1 8 Cable 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 7 Supply Cable Kit See chapter 13 for standard available types Dump valve output 8 Valve Cable Kit See chapter 13 for standard available types Document type Document number Page Rev Service Manu...

Page 9: ...y Charger 10 30 VDC 1 4 Battery cassette NiMH 7 2 VDC 2 5 Manoeuvre 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 Page Rev Service Manual S071 C 9 of 46 ...

Page 10: ...rted 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 Page Rev Service Manual S071 C 10of46 ...

Page 11: ...n 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 first then green when in contact with PCU MANUAL MODE System by pass Manual operation LED DV wi...

Page 12: ...ating 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 Page Rev Service Manual S071 C 12of46 ...

Page 13: ...e connector Portable Control Unit Pin assignments Central Unit G2B G3B Pin Assignments 1 1 1 2 3 4 2 2 3 3 4 4 5 5 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 W...

Page 14: ...MAXI Joystick MINI Linear and MINI Joy stick are by default assigned an analogue output on the Central Unit below figures declares the standard assignments PCU MAXI Linear standard assignments PCU MAXI Joystick standard assignments 1A 2A 2B 1B 3A 3B 4A 4B 5A 5B 6A 7A 8A 6B 7B 8B Document type Document number Page Rev Service Manual S071 C 14 of 46 ...

Page 15: ...I Linear standard assignments PCU MINI Joystick standard assignments 1A 1B 1A 2A 2A 5A 3A 3B 5B 6B 4B 4A 6A 2B 2B 1B 3A 3B 4A 4B 5A 5B 6A 6B Document type Document number Page Rev Service Manual S071 C 15of 46 ...

Page 16: ...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 Dig...

Page 17: ... 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 ...

Page 18: ...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 Digi...

Page 19: ...DC 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 ...

Page 20: ... 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 ...

Page 21: ...l specification for fur ther information The Central Unit G2B is not equipped with a specific STOP loop connection if needed a digital output are in such cases assigned if more info is required refer to system technical specification If required a terminator resistor can be installed between points 4 5 the resistor value needs to be defined by the system installer 5 CAN L 4 CAN H 3 GND 2 CAN L 1 C...

Page 22: ...Connection Pin no Colour Function 1 Brown DV2 2 White LOOP1_OUT 3 Blue LOOP1_IN 4 Black LOOP2_OUT 5 Grey LOOP2_IN Cable C 3 meters 5 pole male M12 connector 5 pole male M12 connector 5 pole female M12 connector A B 5 8 Connection schematics for Central Unit G3B The Central Unit G3B is equipped with either 2 or 3 circular M12 5 pole connectors check item no The drawing below declares Pin assignment...

Page 23: ...d operator controlled functions and is then triggered by an event the type of indication will be declared for each event further in this document 6 1 Central Unit status and operational indications The Central Unit G2B is equipped with 2 individual positions where status and operational indications can be read the external LEDs STATUS and DV provides basic limited information whilst the LED displa...

Page 24: ... radio frequency locked on channel 6 Communication link via radio frequency locked on channel 7 Communication link via radio frequency locked on channel 9 Communication link via radio frequency locked on channel 10 Communication link via radio frequency locked on channel 11 Communication link via radio frequency locked on channel 12 Communication link via radio frequency locked on channel 13 Radio...

Page 25: ...ro step 5 active Note that these LEDs are used also for error code alarms and operator controlled functions and are then triggered by an event the type of indication will be declared for each event further in this document The Portable Control Unit uses 2 LEDs to indicate operational status the Portable Control Unit is also equipped with an internal buzzer that emits sounds and alarms when require...

Page 26: ...tatus and indicate the appropriate error code via the LED display the Central Unit will then reset to operational mode if possible Below example flowchart on behaviour This fault sequence will take an approximately 6 seconds The external LED STATUS will flash rapidly in red colour declaring that an error has been detected for more detailed information the LED display must be monitored or error cod...

Page 27: ...on Remove terminal connector and reset system 02 03 Safety switch error Safety switch output read back error incorrect voltage High instead of Low System will self reset Remove all terminal connectors and reset system 02 04 Safety switch error Safety switch output read back error incorrect voltage Low instead of High System will self reset Remove all terminal connectors and reset system 03 00 Ille...

Page 28: ...N controller 08 03 CAN physical layer error Bad communication transmission System will self reset Check CAN connections Check other nodes on bus and reset system 08 04 CAN PDO length exceeded PDO length is to long System will self reset Reset system re initiate via CAN controller 08 05 CAN PDO length error PDO length is too short System will self reset Reset system re initiate via CAN controller 0...

Page 29: ...0 VDC System will self reset Check power supply and supply connections 98 n a Undefined PCU error Undefined error in PCU Diagnose PCU via TEST MODE 99 n a Undefined CU error Undefined error in CU System will self reset Remove all terminal connectors Check power supply and supply connections Reset system 7 2 1 Error codes continued Indications Meaning 1 Analogue input 1 not at zero position during ...

Page 30: ...mined by the external status LED and or the first 7 segment on the LED display during radio communication When an optimal communication is acquired the external Status LED will be fixed green and the Central Unit LED display will indicate 1x x being dependent on program setting Short interruptions and losses of data packages will be indicated by irregular flashes of these indicators an increasing ...

Page 31: ...N direc tion 15 times or until the Central Units LED display indicates D i 0 0 5 Diagnostics mode is now active The diagnostics mode consist of 8 different menus that can be toggled using the on button once a menu is entered the current values for that specific parameter is presented in the LED display To exit diagnostics mode press Stop button on Portable Control Unit 9 Diagnostics mode If activa...

Page 32: ...r is actuated display responds by indicating related output for 1 second In example 1 A 2 A 3 A 4 A 5 A 6 A 7 A 8 A 1 b 2 b 3 b 4 b 5 b 6 b 7 b 8 b Followed by the current value in correspondance to lever angle 1 99 h i h i indicating that 100 velocity is achieved Position LED Indication Meaning D i 0 0 Default position D i 0 1 Analogue output status D i 0 2 Digital output status D i 0 3 Digital I...

Page 33: ...registered by the Central Unit refer to chapter 7 for error code information The LED display will toggle the logged error codes continuously Hold Micro toggle in LEFT position for 5 seconds E r C L is displayed in the LED display Error Clear Release and press Micro toggle once more to LEFT position to confirm Central Unit error code logg is cleared An error code clear is suitable to conduct after ...

Page 34: ...its program is presented in two sequences continuously repeated In example Press On button eight times from position D i 0 0 D i 0 8 is displayed followed by the current firmware version V n n n The current version of the Portable Control Units program is presented in two sequences con tinuously repeated 9 3 5 Position 5 Program save Press On button five times from position D i 0 0 D i 0 5 is disp...

Page 35: ... changes caused by this The system has 4 levels of authorisation Authorisation level 1 Installer Change direction of analogue movement Authorisation level 2 Well trained installer well trained service personnel Change direction of analogue outputs A B Change start speeds for analogue outputs Change stop speeds for analogue outputs Change micro speed for analogue outputs Change ramp speeds for anal...

Page 36: ... the Central Units LED display indicates P o 0 0 5 Online programming mode is now active The online programming mode consist of 15 different menu s that can be toggled using the On button once a menu is entered the Central Units LED dis play will indicate the current parameter value of any actuated analogue output MICRO ON left will decrease the value and MICRO OFF right will increase the value To...

Page 37: ...ent Available values 0 or 1 Normal or reversed direction When actuating a lever joystick the LED display will indicate which output that is active and its cor responding direction Example 1 b 0 1 meaning reversed direction is enabled for output 1 For individual adjustment of start speed Available values Values ranging from 1 100 When activating a lever joystick the LED display will indicate which ...

Page 38: ...eed 10 3 9 Position 09 Micro speed SET2 For individual adjustment of 1st step micro speed Available values Values ranging from 1 100 When activating a lever joystick the LED display will indicate which output that is active and its corresponding 1st step micros speed 10 3 5 Position 05 Start ramp SET1 For individual adjustment of start ramp Available values Values ranging from 0 100 0 No ramp dela...

Page 39: ...ed Available values Values ranging from 1 100 When activating a lever joystick the LED display will indicate which output that is active and its corresponding start speed For individual adjustment of stop speed Available values Values ranging from 1 00 When activating a lever joystick the LED display will indicate which output that is active and its corresponding stop speed For individual adjustme...

Page 40: ...s until the Power LED is distinguished approx 10 times 4 Portable Control Unit Self Test Mode is now active Each time a switch is activated manoeuvred the control unit should beep Each time a manoeuvre lever is activated manoeuvred a beep signal should be heard from the Portable Control Unit which increases in sound intensity along with lever displacement The control unit beeps with a continuous t...

Page 41: ...the deactivate 6 When ID programming is completed remove the cable control insert battery pack and test run the system application with radio control If the initial short beep is followed by one long beep the Central Unit LED display indication bL and Portable Control Unit then deactivates the ID programming has been rejected check below for further info Note Via cable control option you can easil...

Page 42: ...s coils Typically two sets of cable kits are required one for power supply and digital functions and one for analogue functions see below illustration 1 Left side Supply Cable kit for power supply and digital functions 2 Right side Valve Cable kit for analouge functions Document type Document number Page Rev Service Manual S071 C 42of46 ...

Page 43: ... chapter 5 7 for assignments Power supply See chapter 5 5 5 6 for assignments DV Dump Valve output Hirchmann GDM3009 1 DV 2 DV Cable specification Cable Lenght Wires x Dim 2 5 meters 2 x 2 5mm DV 2 meters 2 x 1 0mm EX1 3 meters 11 x 0 5mm EX2 3 meters 10 x 0 5mm EX3 3 meters 5 x 0 5mm EX4 3 meters 5 x 0 5mm Girder cable alignment 2 2 2 2 2 2 2 13 2 Standard Supply cable kits For connection of powe...

Page 44: ...cation Cable Lenght Wires x Dim 1 8 2 meters 3 x 0 5mm 4 3 1 MODULE SUPPLY 1 MODULE SUPPLY 1 1 2 2 3 3 2 3 GND 3 GND 1 2 REGULATED SUPPLY 2 REGULATED SUPPLY WIRE WIRE Girder cable alignment 13 3 Standard valve cable kits for Sauer Danfoss PVG 32 For connection of analogue functions for Sauer Danfoss PVG 32 module Central Unit type 2010 2011 Document type Document number Page Rev Service Manual S07...

Page 45: ...mann GDM3009 1 2 3 Cable specification Cable Lenght Wires x Dim 1 8 2 meters 3 x 0 5mm 1 PWM A 3 PWM B 2 PWM WIRE Girder cable alignment 1 2 3 13 3 Standard valve cable kits for HAWE For connection of analogue functions for HAWE module Central Unit type 3010 3011 Document type Document number Page Rev Service Manual S071 C 45of46 ...

Page 46: ... 4A 4B 2A 2B 5A 5B 3A 3B 6A 6B 7A 7B 8A 8B CONNECTOR AMP JPT 2 pol CONNECTOR Hirchmann GDM3009 1 2 Cable specification Cable Lenght Wires x Dim 1 8 A B 2 meters 2 x 0 5mm 2 PWM 2 PWM 1 PWM 1 PWM WIRE WIRE Girder cable alignment 2 1 1 1 2 2 13 3 Standard valve cable kits for PWM solenoids For connection of analogue functions for PWM solenoids Central Unit type 3010 3011 Document type Document numbe...

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