FCC/MELLON OCT 13 1998 REMOTE CONTROL SYSTEM SCARECROW RC 400. INSTRUCTION MANUAL. ( Engels ) This instruction manual must be kept in the vehicle cab.
SCARECROW Industrialization AB FCC / USA This device complies with part 15 of the FCC-rules. Operation is subject to the following two conditions : (1) This device may not cause harmful interference, and (2) this device must accept any interference received , including interference that may cause undesired operation. Warning : Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the users authority to operate the equipment.
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, technical data and specification are subject to change or improvement without prior notice.
1. PREFACE This manual is intended as a complement to the crane / machine instruction book and covers the Scarecrow RC 400 Remote Control System. The Scarecrow RC 400 offers the driver an extremely advanced remote control system with speed, precision and control and with maximum safety. In order to ensure your safety and the safety of your crane / machine you should study and learn these instructions.
2. GENERAL SYSTEM DESCRIPTION. Contents : Page : + General schematic of the Scarecrow RC 400 2.2 « General description of the remote control system 23 « The portable control unit 23 « Battery operation (See also 24 + Man oeuvre levers 25 » Emergency stop panel 2.6 + Changing radio channels ( Due to frequency blocking) 2.6 + Switch panel 2.6 + Micro speed control 2.6 « ON/OFF functions 2.7 + Cable for cable control 2.7 » Op to-fibre cable 2.8 + Electronics 2.9 « Expansion cable (EX) 2.
General system description 2-2 General schematic of the RC 400 : The Remote Control System is comprised of the following components: « Control unit ( for cable or radio control ). « Electronic box. + Crane emergency stop box. + Expansion cable (EX). Cable operation. Control cable ( 3-care ). Radio operation: Radio transmitter, Oty. 2. battery packs, battery charger and radio receiver box.
General system description 2-3 1. GENERAL DESCRIPTION OF THE REMOTE CONTROL SYSTEM. The Scarecrow RC 400 remote control system has been specially developed for hydraulically driven mobile cranes and machinery. The system is a digital remote control system based on an extremely advanced micro-processor technology. Years of exhaustive and demanding testing have shown that the remote control system can cope with the roughest of environments.
General system description 2-4 BATTERY BRACKET = > STOP-SCREWS CABLE FIBER OP TIC CONTACT TOGGLE SWITCH-PLATE CARRYING $TRA® RISE Portable control unit vita battery operation ( radio control or opt fiber cable ). A battery is located in the control unit for radio control and is very simple to change. The battery's effective operation time is about 8 hours on one charge.
General system description 2-5 A brief description is given now of the component parts of the control unit. The control unit is comprised of manometer levers for proportional control, switches for ON/OFF and function changing, micro-operation and emergency stop. ( See separate headings below ). TRANSPLANTATION Tact KAELSTYRANGSKON oP NONABSORBENT CHIPOLATA Man oeuvre levers. The man oeuvre levers give fully variable proportional operation and are sprung loaded to return to zero position, i.e.
General system description 2-6 Emergency stop panel. There is a red emergency stop switch ( STOP ) with a manual twist reset, a push button ( ON/SIGNAL/FREQ. SHIFT ) and a red LED on the control unit’s emergency stop panel. « The control unit is started with the sprung reset push button { ON/SIGNAL/FREQ. SHIFT ) «A warning signal is produced on the crane ( SIGNAL ) by holding the push button down. « The warning signal can be issued at any time during operation.
General system description 2-7 ON/OFF and function changing functions. ON/OFF switches can be used to man oeuvre electrical, hydraulic or pneumatic ON/OFF functions, Examples of functions : + Stopping and starting of the vehicle's motor, throttle lever, beep / signal, change-over valves, function changing for ex. 7th and 8th function. + Enable parallel running of two or more valves at the same time from one man oeuvre fever. « Connection of so called hold function, i.e.
General system description 2-8 4. CABLE FOR OPT FIBER OPERATION (NOTE ! OPTION). For opt fiber control the remote control system is complemented with an opt fiber cable, battery pack and battery charger. This means that light is used to send the control information ( not electrical impulses ). The control unit is connected to the electronic box via a thin opt fiber cable.
General system description 2-9 5. ELECTRONIC BOX. The electronic box is manufactured in aluminum and is provided with attachments and contacts for connection to the portable control unit, radio receiver box and ON/OFF functions. There are also connections and contacts for supply voltage, elector-hydraulic converter valves, slide controls and dump valve.
General system description 2-10 6. EX-CABLE (EX). A thin and flexible 7-core cable can be connected to the electronic box for outgoing Dysfunctions, for in-going signal handling e.g. overload and lift reduction functions and for serial communications if more than one electronic box is used in so called tandem operation. The cable has a circular type contact (Am phenol / Churchman) at one end.
General system description 2-11 8. BATTERY PACK. The battery pack is impact and weather resistant and is located in the battery holder in the portable control unit . The battery pack is rechargeable and of Nickel Cadmium (Ni Cd) type. The battery pack is protected against short circuits. The terminal voltage of a newly charged battery should be (unloaded VDC. Note. Battery packs supplied since 1 January 1993 have three ( 3) terminal connections.
General system description 2-12 9. BATTERY CHARGER / D BATTERY CHARGING. The battery charger must be mounted in a vibration free area inside the cab or indoors and be protected against damp and temperature variations. + The normal charging time for an empty uncharged battery, is approximately 12-14 hours. + The battery charger should be connected directly to the vehicle battery to enable charging during idle time.
General system description 2-13 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 battery pack, battery charger and radio receiver box. { See also sections “Battery pack", "Battery charger" and " Control unit for battery operation”) 11. RADIO TRANSMITTER.
General system description 2-14 12. RADIO RECEIVER BOX. The radio receiver box is manufactured in aluminum and is provided with attachments, well proven antenna and a connector for connection to the electronics box. Since the radio receiver box can be subjected to a very tough environment, the box is encapsulated for protection against damp, heat, cold, dust, vibration and corrosive environments.
3. SAFETY REGULATIONS AND OPERATING INSTRUCTIONS. These instructions cover, among st 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.
w no Safety regulations and operating instructions 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 man oeuvre levers and switches. 6. . For remote control; Place the electronic box power switch into REMOTE. For manual/emergency operation: Place the electronic power switch into MANUAL.
4. INSTALLATION INSTRUCTIONS. Contents : Page : + General schematic of the RC 400 / During welding, 4.2 = Locating the electronics and radio receiver box. 4.3 « Mounting recommendations for the radio receiver box. 4.4 « Connection of Sanford elector-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.
Installation instructions 4-2 Installation instructions for Scarecrow RC 400 remote control system . When the Scarecrow RC 400 is installed an electrically controlled dump valve must, for reasons of safety, always be connected between the man oeuvre valve and the tank . This means that during an emergency stop man oeuvre the dump valve will be without power and will transfer the pump flow directly to the tank thus making the crane entirely without hydraulic pressure.
Installation instructions 4-3 Installation and mounting instructions. Electronic box : Important: The electronic box must be mounted in accordance with the recommendations given below! To ensure the longest possible life for the electronic box and its cables, the electronic must always be mounted so that the valve contacts are located facing downwards. The electronic box must not be mounted so that the cables face upwards.
Installation instructions 4-4 Mounting of the radio receiver box. « The connection cable ( marked RA ) for the radio receiver box is approximately 2 meters long which is the maximum mounting distance from the electronic box. « For optimum radio communications the radio receiver box should be located as high and free as possible. An antenna screened and surrounded by fixed objects will considerably impair radio reception. « The antenna pin must not touch any metal object.
Installation instructions 4-35 2. Select a suitable location for the electronic box on the vehicle / crane. « The contact for the cable control cable, switches for MANUAL/ 6 / REMOTE and LED for operational status must be located where they are easy to see and reach. Check that the electronic box cable contacts ( cable control, ON/OFF, and radio receiver box connection contacts ) arc located protected from external damage.
4. Installation instructions 4-6 Next install any ON/OFF functions required. The ON/OFF cable is marked EX and should be connected to the "ON-OFF" contact on the electronic box. « Normal ON/OFF function usage is to drive a signal / beep function, throttle lever, changeover valves, motor start/stop etc. See connection recommendations for the starting of a motor ! Each ON/OFF function can drive a maximum of 1.2 Ampere, « The output function is disconnected automatically if loaded by more than 1.2 Amp., i.e.
Installation instructions 4-7 Connection schematic for ON/OFF functions. Switch EX cable No. : Function / description : 10N No: 1 Continuous full working throttle. 1 Center No: Idle. | OFF No: 1 Automatic connection of full throttle. 1 20N No: 2 Start vehicle motor. 2 2 OFF No: 3 Stop vehicle motor. 30ON No: 4 RPM + or HOLS ON 3 OFF No: 3 RPM or HOLS OFF ON/SIGNAL No: 7 Signal / Beep / or Overload reset. +24 VDC (1.
Installation instructions 4-8 Connection of motor start / start lock : « To protect the starter motor against unintentional re-start attempts after the vehicle motor has already started, it is recommended that an electric “start lock” is connected in after the motor start signal from the electronic box, EX cable pin 2 ( See connection example below able to find out if the vehicle motor is already started, a signal can be taken, for example, from the generator.
Installation instructions 4-9 Connection schematic for Scarecrow RC 400. Control unit : Electronic box : Left lever, [A,1B Contact Ni ( Valve contact, No: 1). Right lever, 6A, 6B Contact No: 6 ( Valve contact, No: 6). ( Example : Swing, inner boom, outer boom, extension, accessory, rotatory ). CABLE IDENTIFICATION TO POWER SUPPLY TO DUMP VALVE [EMERGENCY 2 STOP VALVE CONTACTS AND CONNECTIONS TO: PRINTING + ELECTRIC-HYDRAULIC CONVERTERS Option / extra (for 7th and 8th proportional functions ).
Installation instructions 4-10 9. BATTERY CHARGER AND BATTERY CHAGRIN The battery charger must be mounted in a vibration free location inside the cab or indoors to give protection against damp and temperature variations. « The normal charge time for an empty discharged battery is approx. 12-14 hours. « The battery charger should be connected directly to the vehicle's battery to enable idle time to be utilized for charging.
Installation instructions 4-11 Changing the direction of crane movement. The description which follows describes how to change the direction of movement if the crane moves in a different direction to that desired. Example: After installation and test operation it is found for example that the 3rd and Sth lever movements operate in the opposite direction to that desired. See the example below for how to change the 3rd and 5th lever movements.
Installation instructions 4-12 General technical data : For dimensions, see chapter 2 "General system description”. Portable control unit: Battery pack : 72VDC. Control unit effective operating time © Approx. 8 hours per charge. Weight: 1.6 kg ( without battery pack and radio transmitter). Weight: 1.9 kg ( with battery pack and radio transmitter). Electronics: Supply voltage ( See order): +24 VDC ( +-20% / max. 5% V peak to peak ). Max. over-voltage : Approx. 33 VDC ( Fuse blows ).
5. FAULT FINDING. The crane driver should check the following before calling the service workshop. Page : « Functional system / LED indication on Electronic box. 5.2 » Always check this! 5.3 « Error messages on the electronic box / actions. 5.4 « Electrical connection schematic for electronic box cables. 5.5 + Electronic box with lid removed. 5.6 The service workshop can check the following before Scarecrow AB, Sweden is contacted. Page : + Whale system not functioning ( In depth fault finding ). 5.
Fault finding 5-2 INDICATIONS WITH FUNCTIONING SYSTEM. The following LED must be lit on a functioning system : ( For other LED combinations and indications , see next A. Portable control unit turned off , the following LED light : « "REMOTE" mode: ( POWER LED lit and LED No 4 must blink ). so "MANUAL" mode: ( Only DV ). B. Portable control unit activated , the following LED light : ( The red LEI} on the control unit must be lit continuously ). .
Fault finding 5-3 Always check this ! Always check this : o Is there +24 VDC, 4-20 %, max. 5 %Peak to peak supply to the system? Measure at the crane emergency stop switch (unloaded and loaded ). See also page 4-6 1! » Are the electronic box fuses whole, i.e. + 16 Amp. ( Plus ) and 30 Amp. { Ground ) ? Open electronic box lid and check. . Does cable control function ? «Does the crane work manually, i.e. with the electronics power supply switch in "MANUAL" position ? + Place switch into " REMOTE " position.
Fault finding 5-4 Error messages / Actions. Simple error messages can be read with the help of the LED on the electronics. LED 1-4 are used to give error messages. The first LED (No.1) always blinks with errors and then a combination of lights is shown on LED 1-4, REMOTE] OFF L ‘When the control unit is activated and the electronic switch is in " REMOTE " position do any of these LED combinations exist 7 Error message : Error source / Reason : Action : LED 1, pause and then LED 2. ON/OFF function.
Fault finding 5-5 Error messages / Actions. Simple error messages can be read with the help of the LED on the electronics. LED 1-4 are used to give error messages. The first LED (No.1) always blinks with errors and then a combination of lights is shown on LED 1-4. (REMOTE) OFF 1 MANUAL ‘When the control unit is activated and the electronics switch is in * REMOTE position do any of these LED combinations exist ? Error message ; Error source / Reason : Action : LED 1, pause and then LED 2. ON/OFF function.
Fault finding 5-6 Connection schematic for electronic box with ready-made cables for Sanford elector-hydraulic boxes : POEM or PEEVE. Incoming supply voltage: +24 VDC max. 5% Peak to peak } Regulation range: 5,8 182 V (+ A124,0V) Neutral position: + 120 VDC (+ At1240V) Incoming supply voltage: Dump valve : 2 Incoming : Ground / 0 VDC. 2: Ground, dump valve. t incoming : + 24 VDC ( See above } 1: Plus drive, dump valve. Movement 1. { Scorecard's cable and cable number in valve cetacean ).
Fault finding Connection schematic for electronic box for proportional coils / elector-hydraulic slides. Incoming supply voltage: +24 VDC, 20% max. bespeak to peak Cable numbering in electronics / Cabling ; Incoming supply voltage: Dump valve : 2 Incoming : Ground / 0 VDC. 2: Ground, dump valve 1 Incoming : + 24 VDC ( Sec above ) 1: Plus drive, dump valve. Movements 1A and 1B. 2 1A, Ground 1 1A, Current signal { PW, 2 1B, Ground. i IB , Current signal ( PWM ). Movements 2A and 2B. 2A. Ground.
TTT rT TTT CIO Fault finding 5-8 Electronics box with lid removed. DIODE Z1 ~~ 2 (TWO) PIECES FUSE HOLDERS WITH FUSES TT ROSIE Cm « Plus fuse: +10 Amp. (Red) / ( Standard car type fuse). » Minus fuse: 30 Amp. ( Green )/ ( Standard car type fuse).
Fault finding 5-9 1. WHOLE SYSTEM NON-FUNCTIONAL. The MANUAL OFF 7 REMOTE switch on the electronic box can be used fo select between manual operation and cable or radio control. RO3085 1.A. Electronic box. REMOTE position: No functions work and the electronic POWER LED not lit MANUAL position: No functions work and the electronic box DV LED not lit. LAL Is the vehicle's ignition or power outlet switched on ? 1.AZ. Is the crane emergency stop button pulled up ? 1.A3.
Fault finding 5-10 1.C. Portable control unit and electronic box. Whole system non-functional, but: Control unit red LED lit, electronics POWER LED lit and LED 4 blinking. 1.C1. During radio control: Test using cable control ( control cable }. If it works with the cable, there is probably a fault in the radio transmitter, radio receiver box or in their connections. { Does the radio control unit match this electronics i.c. same ID code 7) 1.C3.
Fault finding 5-11 LE. Portable control unit. The control unit beeps and the red LED blinks when pressed. ( cable or radio control ). { Electronics switch MANUAL / OFF / REMOTE mus be in REMOTE position, the POWER LED must be hr and LED 4 must blink ). For safety reasons all man oeuvre levers must be in the zero / neutral position in order for a sitar to be made.
Fault finding 5-12 2. SOME PROPORTIONAL MOVEMENTS MISSING. The whole system works, but a particular proportional movement is missing, REMOTE] CABLE ' 4 {OFF . Ee) Nl [MANUAL 1H QOOOCO000 RI3C85 LED indication: DIR. A: Man oeuvre lever in A-direction activated and moved. The intensity of the LED will increase with increased lever displacement. The LED is commoner and summed, i.e. only one man oeuvre lever at a time can be maneuvered in A-direction for a check to be made DIR.
Fault finding 5-13 2.C When maneuvering is started with the “faulty” man oeuvre lever, movement stops. 2.C1. A short circuit, overload or other fault exists between the electronic box valve cable and valve contact or in the elector-hydraulic slide control. 2.C1. Change the faulty valve contact on the elector-hydraulic slide control to a working function. If the man oeuvre lever now works there is a short circuit or other fault in the hydroelectrically slide control.
Fault finding 5-14 3. CERTAIN ON/OFF FUNCTIONS MISSING. ON/OFF: ON/OFF function activated. The LED is commoner and summed, ie. only one switch at a time can be activated from the control unit for the check to be made. REMOTE OFF [MANUAL liz peer / —— 1 R93C85 3. An ON/OFF LED does not light when a certain switch is activated on the portable control unit. Test of the portable control unit: 3.A1. First check the control unit and its switches. The test is best made in the control unit's “TEST-MODE".
Fault finding 5-15 PORTABLE CONTROL UNIT TEST-MODE . Functional description. To simplify service and faultfinding, the portable control unit can be put into internal TEST MODE. This means that the service man can easily control the control unit's switches and man oeuvre levers, without the need to open the control unit. When each switch or man oeuvre lever is activated / maneuvered the control unit gives a “beep signal” to confirm that the function is working.
Fault finding 5-16 RC 400 which only works with cable, not with radio. A. Changing radio transmitter or radio receiver box. Test first by changing the radio receiver box (i.e. the unit located on the crane). 1. Changing the radio receiver box. Do not unscrew the entire radio receiver box, but do as follows : A. Unscrew and remove contact : "RADIO" from the electronic box. B. Test by connecting the contact to the "new" radio receiver box. C. Test run the system with radio control. D.
Fault finding 5-17 Repair of control cable. General : The control unit is connected to the electronic box via a thin and flexible 3-core cable. The cable has circular type connection contacts (Am phenol / Churchman) at each end. Final control : Ohm measure the cable's contacts for check of continuity. ( Rec. area : min. 0.5 mm?) Connections in the contact : 1 = Supply 2 = Data L = Ground/Minus 3 = Not connected.
Fault finding 5-18 Programming of radio identity codes. Do as follows : 1. Remove the battery pack from the control unit. Test run the system with cable control. 2. Leave the cable control connected between the control unit and the electronic box. 3. Press the emergency stop on the control unit and then on the crane. The red LED on the control unit must be off, and all LED on the electronic box must also be off 1! 4. Twist up the emergency stop on the crane and then on the control unit. 5.
6. SPARE PARTS. RC 400 SPARE PARTS AND SPARE PARTS LIST Introduction. The RC 400 remote control system is constructed using a number of standardized basic components which enables a minimum of spare parts stocks. No adjustments are required after the changing of system parts. This means quick, simple and effective service. The spare parts list is divided into 10 ten } main groups. The order number, part description and required quantity must always be given when spare parts are ordered.
8. PROGRAMMING PARAMETERS AND SETTINGS. General descriptive The Scarecrow RC 400 offers considerable possibilities for system constructors of hydraulically driven mobile cranes and machines. The program in the control system is very comprehensive. flexible and has many adaptation possibilities for specific applications. The control system offers simple programming of a number of functions which can easily be turned on or off or altered during operation.
Programming parameters and settings Individual delayed start and stop movements ( ramp functions acceleration and retardation ). Ramp functions give soft start and stop movements which protects the crane / machine against overloading during careless maneuvering. Start delay, i.c. this is the time required for the man oeuvre valve slide to reach its final position from the time the man oeuvre lever has left its neutral position. The time can be set individually to between 0 and 5 seconds for A and B ports.
Programming parameters and settings 8 3 Changing the direction of movement of the crane. This describes how changes in direction of movement are made if the crane moves in the opposite direction to that desired, Example: After installation and test operation it is found that the 3rd and 5th lever movements operate in the opposite direction to that desired. See the example below for how to change the 3rd and Sth lever movements. DO AS FOLLOWS! I. Remove the battery pack.