3RCI+ Service Manual Covering both Standard and SpaceGuard Systems

Transcription

1 3RCI+ Service Manual Covering both Standard and SpaceGuard Systems v1.07

2 Change History Issue Date Changes Job V1.0 05/07/2016 New issue for V9 3RCI+ V /09/2016 Modified the standard system layout. V /10/2016 Added basic system layout. Modified I/O module connection table and diagram to include Dual Axle Unlock connections. V /11/2017 Update to new part numbering V /02/2016 Update to signal quest gen 3 sensors V /05/2018 Update to error codes V /06/2018 Added Z-Boom inputs to the module connection tables V /07/2018 Added Speed Sensor calibration procedure 2 GKD Technik Ltd

3 Contents Change History Introduction Regular Maintenance Maintenance timetable GKD 3RCI+ Product Options Hardware Description System layouts General Component Wiring Components Component Description Component Replacement 3RCI+ Test Function Menus Ignition Timer Off relay Module Connection Tables Power Wiring To Modules Slew Speed output logic and SpaceGuard Page no Safety Relay 34 Axle Safe to Unlock Relay SpaceGuard and Safety Mismatch Speed Sensor Calibration Data Upload/download Error codes and error diagnosis Information Messages GKD Technik Ltd

4 Introduction The GKD 3RCI+ is a modular rated capacity system designed to be easily maintained in the field. This manual provides information for the service engineer to identify common faults and instruction on how to replace the faulty component. The manual provides a description of each component, its location, mounting detail and replacement procedure. WARNING: THE EQUIPMENT DESCRIBED WITHIN THIS MANUAL IS ELECTRICAL EQUIPMENT WHICH INTERFACES TO AN ELECTRO-MECHANICAL MACHINE. THERE ARE ELECTRICAL, MECHANICAL AND HYDRAULIC HAZARDS PRESENT. ENSURE THAT WORK IS CARRIED OUT ON THE MACHINE ONLY BY FULLY COMPETENT PERSONNEL. Regular Maintenance Regular maintenance of the GKD rated capacity indicator is restricted to visual inspection only. Electrical performances checked on a switch on and the indicator will warn the operator of a fault. Maintenance Timetable Daily - Visual inspection of pressure sensors, angle sensors and their cable connections. Operation of test button to sound alarm. Weekly - Inspection of all cabling to angle sensors, pressure transducer Yearly - Full inspection of crane to confirm fitness for use. GKD 3RCI+ Product Options The GKD 3RCI+ is available as a standard system, using a single gravity referenced angle sensor to monitor each boom position, and as a SpaceGuard system, which is equipped with dual angle sensors on each boom, and on slew and cant / gradient sensing, plus dual processing to enable use of the machine under live overhead cables and / or adjacent to live traffic. 4 GKD Technik Ltd

5 Hardware Description System Architecture The new Version 9 3RCI+ system was introduced by GKD in 2016 to comply with the new RiS-1530-Iss6 specification. The 3RCI+ system typically consists of a colour touchscreen display mounted in the machine cab, three modules mounted on the upper structure of the machine, and one module mounted on the machine undercarriage. The modules on the upper structure are identified as the I/O module (module 5), the Output module (module 1), and the Slew module (module 9). The module installed to the undercarriage is identified as the Undercarriage module (module 11). Some machines may be fitted with the 3RCI+ SpaceGuard variant of the system, SpaceGuard systems have one further module installed to the upper structure, identified as a SpaceGuard module (module 2). Some non - SpaceGuard equipped machines, such as Colmar, may make use of a SpaceGuard module to provide additional inputs or outputs to the system, such as additional counterweight position switches. SpaceGuard The 3RCI+ SpaceGuard system has been designed to comply with Network Rail Remit MLD-R003 for Movement Limiting Devices, and can be certified to work Adjacent Line Open (ALO) and under Live Overhead cables (OLE). SpaceGuard uses dual sensing and dual processing on all moving components to confirm correct operation of all critical sensors and system components. As part of the design, when a slew limit or a virtual wall has been set on the 3RCI+ system, slew speed of the machine is slowed down to no more than 2 m/s measured at the bucket pin at full reach, and as a limit is approached the SpaceGuard system will apply the slew motion cut early and asses the stop position, then allow further movement at 1 m/s up to the limit. Boom operations are slowed as a height limit or virtual wall is approached. 5 GKD Technik Ltd

6 System Layout 6 GKD Technik Ltd

7 System Layout continued... 7 GKD Technik Ltd

8 System Layout continued... 8 GKD Technik Ltd

9 General Component Wiring The 3RCI+ system is CAN based and uses a four core M12 cable to daisy chain sensors and modules together. However, to facilitate the installation the CAN bus may be branched. The system also utilizes industry standard Deutsch connectors for modules which are field serviceable. Inter-module connections are made using standard M12 connectors. Cable looms can be provided, if required, to ensure a plug and play installation. Power connections Power connections to the system should be made in two ways: To each individual module, via the Deutsch connectors, to provide power for outputs and any I/O that is required. Via the CAN bus, to power the Display, Sensors and the Modules. The CAN bus connections use M12 connectors. The connections are as follows: CAN Lo +Ve Supply 0V (Ground) CAN High CAN Bus M12 Connector Pin 1 - Brown Pin 2 - White Pin 3 - Blue Pin 4 - Black NOTE: Pressure transducers, Pressure Switches and Proximity Switches do not use the same wiring as the CAN bus. Where these are being connected, the following applies: +Ve Supply Signal 2 0V (Ground) Signal 1 M12 Proximity Switch Pin 1 - Brown Pin 2 - N/C Pin 3 - Blue Pin 4 - Black M12 Pressure Switch Pin 1 - Brown Pin 2 - N/C Pin 3 - Blue Pin 4 - Black Single Pressure Transducer Pin 1 - Brown Pin 2 - N/C Pin 3 - Blue Pin 4 - Black Dual Pressure Transducer Pin 1 - Brown Pin 2 - White Pin 3 - Blue Pin 4 - Black 9 GKD Technik Ltd

10 Components Identification Display The display unit utilizes an LCD touch-screen panel to provide information to the operator and to control the system. There are two warning lights and a machine controller s key switch fitted to the display. Modules Each module is contained in a standard weatherproof enclosure. The modules may have additional external connections for input/output monitoring. Gravity Angle Sensors There are now 2 types of gravity angle sensor. Both are mounted in the same way but they each work slightly differently. The angle sensors are fitted to each moving part of the excavator arm. All of the angle sensors are interconnected via CAN bus and are wired in series (daisy-chain). Pressure Transducer Two pressure sensors are utilized to monitor the hydraulic pressure in the lift rams. The pressure reading directly relates to the load lifted by the machine. Each sensor measures up to 400 bar pressure. 10 GKD Technik Ltd

11 Components continued... Identification continued... Alarm An audible alarms is installed to the machine to provide warning to the operator and personnel within the working envelope of the machine. Some systems are now fitted with multiple alarms connected in parallel to meet minimum sound warning levels. Proximity Switches The slew sensing can be measured in two ways. The most common method utilizes two proximity switches which count the teeth on the slew gear of the excavator. A third proximity sensor is installed to detect when the machine is in a predetermined reference position (normally zero degrees or facing over the floating axle). Rotary Encoder The second method utilizes a rotary encoder. The teeth method is usually accurate to less than 2 degrees whilst the encoder method is accurate to a tenth of a degree. 11 GKD Technik Ltd

12 Component Description Modules A module consists of a translucent yellow plastic enclosure containing a printed circuit board, with two 12 pin Deutsch connectors located at one end, and either one or two M12 screw 4 pin connectors located at the other end. Each module has a specific function, and they are not interchangeable. The module is typically located on the machine at a position convenient to make the connections associated with that module, for instance the Slew module, which has inputs from the slew tooth counting sensors and pressure transducers, is likely to be located close to the stub boom base of the machine, and the Output module, which has outputs to the hydraulic solenoid valves and controls the hydraulic motion cuts, may be located adjacent to the solenoid valve bank. Most installers/converters will group all the modules together in one location. The modules are connected together on a CAN bus network, with the CAN bus connection being made via an M12mm 4 pin connector located on each module. The electronic circuits within the module are powered through the CAN lead, however any powered outputs from the module (sensor power supplies, solenoid valve outputs, lamps etc.) are powered from a separate, fused power supply fed into the module through one or both of the two 12 way Deutsch connectors on the module. All module inputs and outputs are PNP - in other words, all inputs and switched outputs are + volts. Each module features a series of green LEDs which are lit to indicate CAN communication and the status of any inputs or outputs associated with the module. Module Identification The modules provide all of the input and output connection to the RCI. There are four modules in total (five for a SpaceGuard system, or where additional I/O is required for complex machines). The modules are identified as: MOD 1 - Output Module MOD 2 - SpaceGuard Module (SpaceGuard Systems, or where additional I/O is needed) MOD 5 - I/O module (also known as Input Module) MOD 9 - Slew Module MOD 11 - Undercarriage Module 12 GKD Technik Ltd

13 Component Description continued... Cant and Gradient sensor The primary Cant and Gradient sensor is integrated into the Undercarriage module, typically located on the machine undercarriage. Systems certified under RIS1530 issue 4 and above have a second, independent cant and gradient sensor installed alongside the undercarriage module. Undercarriage Module The undercarriage module is located on the base machine adjacent to the slew lock mechanism and the slew ring. It is fitted using two M6 bolts. The undercarriage module is powered from the CAN M12 connector, and has two 12-way deutsch connectors. Inclinometer based sensors The GRAVITY2 angle sensor measures the angle of a boom referenced against gravity, and is securely mounted on the boom to be measured. The sensor has a 12mm connector at each end, one male and one female. Both are CAN bus connectors, and the CAN communication lead passes through the sensor and on to the next sensor in the chain. The final sensor in the chain is usually the Dipper angle sensor, and the CAN bus circuit is completed by fitting a AN terminating resistor into the free 12mm connector on the end of the dipper sensor. SignalQuest Sensors The new v9 system now utilises a gyroscopic angle sensor for the primary means of angular measurement. These are highly accurate but do not require any additional mounting bracketry. 13 GKD Technik Ltd

14 Component Description continued... Pressure Sensors The pressure transducers used are Dual sensors, with two completely separate pressure transducers located inside the same housing, and with dual outputs through the M12 connector cable. The double sensor function provides dual redundancy to the RCI, with the two separate sensor outputs being checked against each other to monitor correct sensor function. Two pressure transducers are installed, one measuring the pressure in the Full side of the hydraulic lift cylinders, and one in the Rod side. The full side transducer measures the lift pressure induced by the load on the end of the hook. The rod side pressure transducer is used to measure the hydraulic circuit back pressure to allow calculation of the true full side pressure due to the load alone. The pressure transducers are wired back to the Slew module Slew Sensors The usual method of monitoring slew angle is by using a pair of slew proximity switches detecting the passing of teeth on the slew gear, or possibly by detecting the passing of a series of reference teeth on an external ring secured to the outside of the slew ring. The proximity switches are mounted 3-6mm away from the teeth being counted. The distance separating the two tooth counting sensors is important, as a pattern of tooth counts must be generated by the two sensors in order to establish the direction of slew. The correct pattern can be observed as shown to the right, using the green LEDs on the Slew module identified as input 1 and input 2. The associated input LED should light up as the tooth is detected by the proximity switch. Failure to detect teeth according to this pattern will result in failure to count slew. Slew Reset When the machine slews over 0 of slew (generally over the oscillating axle end) a third proximity switch should be triggered momentarily as it passes over a target fixed to the undercarriage of the machine. This reset switch is used to reference the slew count to 0 each time the machine slews over the reference point. 14 GKD Technik Ltd

15 Component Description continued... Slew Encoder The primary method of monitoring slew on a SpaceGuard machine is by Rotary Encoder. The Encoder is an absolute sensor - it does not require referencing. It is generally fitted to the top of the slip ring carrying power and signals between the upper and lower machine structures, and is connected to the CAN bus. It can be fitted to the upper or lower structure of the machine. Where slew errors are experienced with a rotary encoder, the most likely cause is mechanical slippage on the drive to the slip ring shaft. Resetting the slew position where errors occur is done from within the Calibration menu. 15 GKD Technik Ltd

16 Component Description continued... SpaceGuard and Slew / Angle checking SpaceGuard systems utilise one bank of angle sensors, plus the rotary encoder for slew monitoring, to calculate the position in space of the lift point (usually the bucket pin) and then apply the data from tipping charts within the system calibration to calculate the machine lift capacity in that particular position. The second bank of angle sensors, plus the tooth counting slew sensors, are used to derive a secondary calculation of the lift point position, which is compared to the calculated position from the primary sensors. If the two systems give different results, a SAFETY MISMATCH warning is given on the 3RCI+ display and the machine hydraulics are motion cut. An override function is provided on the display when the motion cuts are applied, this should be used to recover the machine to a safe position. Overload / Trailer Breakaway Alarm Connection Alarms supplied by GKD Technik have a small circuit board located in the alarm enclosure. This circuit board has two sets of three connection terminals, and it s function is to translate the +V outputs from the I/O module to 0V signals used by the sounder to provide separate overload and trailer breakaway alarm tones. Connect the +V Tipping alarm output from the I/O module to terminal A or SI, the +V Trailer Breakaway alarm output to terminal B or SC and a 0V connection to terminal C or 0V on connector CN1. Connector CN2 is used to take the outputs back out of the alarm enclosure and on to the next alarm enclosure. Each alarm should be connected in the same way. 16 GKD Technik Ltd

17 Component Replacement Display Turn off the power to the RCI system. Remove the CAN bus cable from the connector on the rear of the display by unscrewing the outer collar. Undo the adjustment screw on the mount taking care to support the display until it may be removed from the mounting jaw. Replace the display in the reverse sequence. Reconnect the CAN bus cable to the connector taking care not to use undue force. IF REQUIRED: Switch on the system and access the service menu ( MODE SERVICE PASSWORD). Insert the GKD program backup memory stick into the USB socket at the base of the display and copy the calibration files to the display. Modules Turn off the power to the machine and disconnect the two 12 way Deutsch connectors from the module. Remove the 12mm CAN bus connector, and if fitted, the Override key switch connectors. The module may now be removed, and replaced as required. DO NOT DISCONNECT OR RECONNECT MODULES TO THE CAN BUS WITH POWER APPLIED. NOTE - UNDERCARRIAGE MODULE: THE UNDERCARRIAGE MODULE CONTAINS THE MACHINE PRIMARY CANT AND GRADIENT SENSOR. DISTURBING THE MOUNTING OF THE UNDERCARRIAGE MODULE IS LIKELY TO RESULT IN THE NEED TO RECALIBRATE CANT AND GRADIENT. Angle Sensor Turn off the power to the RCI system. Remove the CAN bus cables (x2) from the faulty angle sensor connector. Undo the mounting nuts to remove the sensor, taking a note of the orientation of the sensor. Replacement is the opposite of the above procedure. Turn on the system and access the status inputs menu (MODE STATUS). Move the linkage to the calibration position as defined below. The reference line for each component is a line drawn between the main linkage pins. Stub boom - vertical or 90. This may be achieved by using a plum-bob attached to the upper pin. Dipper- vertical or -90. Use the same method as for the Stub boom. Fore boom - horizontal or 0. This is achieved by stretching a line between the pins and using a spirit level to check. Check that the relevant angle sensor is showing 0, 90 or -90 as appropriate. If necessary loosen the fixing bolts on the angle sensor and adjust as required. Re-tighten the bolts. 17 GKD Technik Ltd

18 Component Replacement continued... Angle Sensor - Gravity type continued... Replacement of cables simply involves the disconnection of the CAN connectors at each angle sensor while the system is switched off and replacement with the appropriate length replacement. Pressure Transducer and cable Support the excavator front-end equipment on the ground (note it is usual to have the dipper in a vertical position to allow access to the pressure transducer). Relieve any residual pressure in the system by operating the boom down control immediately after the engine stops. Switch off the RCI system. Remove the connector from the rear of the pressure transducer. Place a container to catch any spillage of hydraulic fluids under the lift ram adjacent to the cab. Carefully undo the hydraulic fitting below the Cat pressure switch. CAUTION: HIGH HYDRAULIC PRESSURE MAY BE PRESENT. WEAR SUITABLE PROTECTIVE CLOTHING AND EYE PROTECTION. Allow any residual pressure to release prior to removing the pressure transducer. The GKD pressure transducer may now be unscrewed from the hydraulic fitting and replaced. Re-fitting is the reverse of removal. Reconnect the cable. Re-start the excavator and lift the front-end equipment off the support. Check for leaks. Slew reset sensor Slew the machine to allow easy access to the sensor located adjacent to the slew locking pin on the upper-carriage. Switch off the machine and separate the connector for the reset sensor. Release the sensor by undoing the U-bolt fixing. Replacement is the reverse of removal. Adjust the gap between the reset marker and the sensor by use of sensor fixing nuts. Reconnect cable and power on system. 18 GKD Technik Ltd

19 Component Replacement continued... Slew proximity sensors The slew sensors are typically located beneath an inspection plate at the boom foot. Support the excavator front-end equipment on the ground ensuring that the stub-boom is as vertical as possible to provide access to the inspection plate. Undo the two fixing bolts and carefully remove the inspection plate and brackets. Wipe away excess grease. Measure and note the distance that the sensor protrudes in front of the fixing bracket. Remove the sensor by disconnecting the connector and undoing the fixing nuts. Fit the new sensor and adjust the fixing nuts to position the sensor so that the protrusion is the same as that measured for the faulty sensor. Refit the connector. Refit the inspection plate and tighten the bolts. Undercarriage Module Switch off the RCI. Release the 12mm CAN connector and the multi-way connectors from the Undercarriage module. Replacement is the reverse of removal. Note that the cant and gradient should be checked for accuracy after the Undercarriage sensor has been disturbed, it may be necessary to adjust the cant and gradient settings within the calibration of the 3RCI+. WARNING - DISTURB THE CASE POSITION ONLY IF ABSOLUTELY NECESSARY! Override Key Switch The supplied external override key switch must be connected to the M12 connector (internal thread) on the Output module, and also to the SpaceGuard module if fitted. TAKE CARE THAT ONLY THE OVERRIDE KEY SWITCH IS CONNECTED TO THESE INPUTS, THE OVERRIDE KEY SWITCH CIRCUIT IS LOW VOLTAGE AND CONNECTING ANY POWERED CIRCUIT (INCLUDING THE GKD CAN BUS CIRCUIT) TO THE OVERRIDE INPUTS ON THE OUTPUT AND SPACEGUARD MODULES WILL DAMAGE THE MODULES. ALL FOUR WIRES IN THE KEY SWITCH CABLE ARE USED, IF THE CABLE IS CUT OR JOINED, ALL FOUR COLOURED WIRES NEED TO BE RECONNECTED. 3RCI+ Standard systems - On a standard 3RCI+ system, the override key switch is only connected to the Output module via the M12 connector (internal thread). 3RCI+ SpaceGuard systems - On a 3RCI+ SpaceGuard system, the override key switch cable is connected to both the Output module and SpaceGuard modules. 19 GKD Technik Ltd

20 3RCI+ Test Function Menus The 3RCI+ incorporates a Test section, accessed through the display, which may assist in diagnosis of faults. The Test function is accessed from the TEST page via the Menu button. Alarm Test button An Alarm test sequence may be started by pressing Alarm Test located within the Test page Pressing Alarm Test will trigger a cycle where the 3RCI+ will turn on each alarm and warning lamp one by one for about 2 seconds each. The warning lamps will include the roof mounted Blue lamp, the Red and White window mounted status lamps (if fitted), and the Amber and Red LEDs within the 3R- CI+ display. The alarms sounded are Sounder 1 (Tipping Alarm) and Sounder 2 (Trailer Breakaway alarm). Test button The Test button provides access to features that will enable an engineer to test all of the inputs, outputs and angle sensors fitted on the machine. To enter this test screen, a pass code is required. This will be given to engineers that attend the GKD training course for this product. Please contact GKD Technik for further information. Please DO NOT distribute this pass code to operators. Once inside the Test screen, the options shown in the figure opposite will typically be available. 20 GKD Technik Ltd

21 3RCI+ Test Function Menus continued... Angle Inputs shows the status and values of all angle sensors, including the Cant and Gradient sensors, and the Full side and Return side pressure transducers, and the slew position. Boom angles are configured so that 0 degrees is straight ahead, level with the horizon. Booms facing up (such as the Stub Boom) will have an angle in + degrees, booms facing down (dipper, for instance) will usually have an angle in - degrees, with -90 being vertically down. Boom angles are measured between the end pin centres. The CANT/GRAD tab shows the angles from the CANT/GRAD sensors, typically the Undercarriage Module. The Inputs button provides access to test all of the inputs on the system. Each button, shown here, will open a window to allow you to check these inputs. Typically, this can be used to check the axle lock input or slew inputs. The Outputs button provides access to test all of the outputs on the system. Each button, shown here, will open a window and allow each output to be selected to test its function. Typically, this can be used for testing the motion cuts via the MOD1 button. 21 GKD Technik Ltd

22 Ignition Timer Off relay Ignition Timer Off relay This relay is now included with every system and must be fitted to prevent the system switching off as soon as the ignition is switched off. The purpose of this is to prevent data loss during system start up. This relay will come preset to turn off after 30 seconds so it will just need to be installed as follows: Pin 87 Pin 15 Pin 31 Connection to vehicle chassis Pin 30 Main positive feed from Battery Module connection table - colour key The following pages detail the connections to the modules, and are colour coded as follows: Colour Orange Required for all installations to comply with RIS1530 issue 6. Green Required for all typical installations Blue Required for SpaceGuard installations to comply with MLD-R003 and 1530 issue 6. No colour Optional, may be required depending on configuration and application. 22 GKD Technik Ltd

23 Module Connection Tables Output Module Solenoid valves are controlled directly from the Output Module. The Solenoid outputs of the Output Module are each capable of sourcing a continuous 2A current. When installing valves check the solenoid coil current consumption. If the current consumption exceeds the limits then intermediate relays should be installed. The following table shows the solenoid function and connections. Grey Black Function 1 O/P 1 allow slew LEFT Slew left motion cut 2 O/P 2 allow slew RIGHT Slew right motion cut 3 O/P 3 allow stub UP Stub boom up motion cut 4 O/P 4 allow stub DOWN Stub boom down motion cut 5 O/P 6 allow fore DOWN Fore boom down motion cut 6 O/P 8 allow dipper IN Dipper in motion cut 7 O/P 7 allow dipper OUT Dipper out motion cut 8 O/P 5 allow fore UP Fore boom up motion cut 9 Watchdog IN Safety watchdog relay in (required for SpaceGuard and 1530-iss 6) 10 POS +24V supply IN Switched by ignition and protected by a 15A Fuse 11 POS +24V supply IN Switched by ignition and protected by a 15A Fuse 12 0V IN To vehicle chassis ground 1 O/P 15 SpaceGuard Inactive +V out when SpaceGuard system is not active 2 O/P 13 Offset cut LEFT OPTION - Offset boom left motion cut 3 Watchdog OUT Safety watchdog relay out (required for SpaceGuard and 1530-iss 6) 4 POS +24V supply IN Switched by ignition and protected by a 15A Fuse 5 POS +24V supply IN Switched by ignition and protected by a 15A Fuse 6 0V IN to vehicle chassis ground 7 O/P 9 allow bucket IN / Jib DOWN OPTION - Bucket in / Jib Down motion cut 8 O/P 10 allow bucket OUT / Jib UP OPTION - Bucket out / Jib Up motion cut 9 O/P 11 travel allow +V out when travel is allowed 10 O/P 12 steering unlock OPTION - Allows steering to unlock 11 O/P 14 offset cut RIGHT OPTION - Offset boom right motion cut 12 O/P 16 slew brake +V out to release slew brake (required for SpaceGuard and 1530-iss 6) 23 GKD Technik Ltd

24 Module Connection Tables continued... Output Module continued Use the following diagram as a reference when adding connections. 24 GKD Technik Ltd

25 Module Connection Tables continued... Slew Module - Also includes the pressure sensor inputs. The three Slew Sensor proximity switches are connected to this module as per the table below. Use only the supplied pressure sensor WIKA MHS-1 with this module. The signals (4-20mA) and power to the pressure sensors are supplied by this module. This power SHOULD NOT be used for any other use as it can only provide approx. 500mA. Please see the table below for the full set of connections. Grey Black Function 1 Full side pressure 1 Pressure sensor input 1 full side (4-20 ma) 2 Full side pressure 2 Pressure sensor input 2 full side (4-20 ma) 3 I/P 5 Swivel boom 2 / Z-Boom input 3 OPTION - 2nd input to detect swivel boom straight, SpaceGuard applications For Z-BOOM, this is input 3. 4 I/P 2 slew proximity switch 2 Slew tooth count proximity switch 2 input 5 NOT USED Not used on 3RCI+ 6 I/P 9 Swivel boom input / capacity reduction / Z-Boom input 2 OPTION - 1st input to detect swivel boom straight, also reduces capacity to programmed value. For Z-BOOM, this is input 2. 7 I/P 3 Slew Reference switch Slew reference proximity switch input 8 I/P 7 Slew left detect Pilot line slew left pressure switch input 9 I/P 6 Slew right detect Pilot line slew right pressure switch input 10 I/P 1 slew proximity switch 1 Proximity switch input, tooth count sensor 1 11 POS +24V supply OUT Pressure sensor +V out 12 0V OUT Pressure sensor 0V out 1 NOT USED Not used on 3RCI+ 2 NOT USED Not used on 3RCI+ 3 NOT USED Not used on 3RCI+ 4 POS +24V supply IN Switched by ignition and protected by a 15A Fuse 5 POS +24V supply OUT Pressure sensor +V out 6 0V OUT Pressure sensor 0V out 7 Rod side pressure 1 Pressure sensor input 1 rod side (4-20 ma) 8 Rod side pressure 2 Pressure sensor input 2 rod side (4-20 ma) 9 POS +24V supply IN Switched by ignition and protected by a 15A Fuse 10 NOT USED Not used on 3RCI+ 11 NOT USED Not used on 3RCI+ 12 0V IN 0V input, connect to chassis (ground) 25 GKD Technik Ltd

26 Module Connection Tables continued... Slew Module continued... Use the following diagram as a reference when adding connections. 26 GKD Technik Ltd

27 Module Connection Tables continued... Input/output Module - also known as input module Please see the table below for the full set of connections. Grey Black Function 1 NOT USED Not used on 3RCI+ 2 I/P 2 Front Rail Axle lock Input from front rail axle lock switch 3 I/P 3 Engine on Input +V when engine running - typically from alternator D+ connection 4 I/P 4 LUL duty OPTION - switch to LUL duty setting 5 I/P 5 Rear Rail Axle Lock Input from rear rail axle lock switch 6 I/P 6 Travel REV Sense reverse travel - to switch rail lighting on undercarriage 7 I/P 7 Low Rail OPTION - for high / low rail machines to switch rail mode 8 I/P 8 Inhibit booms / slew OPTION - motion cut all booms and slew movement 9 I/P 9 Counterweight retracted 2 / Road Axle Lock / Z-Boom input 4 OPTION - for COLMAR - second input to confirm counterweight retracted For TWIN UNLOCK, this is the Road Axle Input. For Z-BOOM, this is input I/P 10 Front Rail Axle lock feedback Feedback loop to confirm front rail axle lock status, MUST BE FITTED FOR ISSUE 6 11 Power in +V ignition switched Switched by ignition and protected by a 15A Fuse 12 Chassis earth 0V 0V connection to vehicle chassis 1 O/P 7 Limit set ON when a virtual wall or slew limit is active AND foreman key switch in locked position 2 O/P 5 Front Rail Axle safe to unlock To relay, prevents axle unlock when unsafe to do so 3 4 I/P 11 Rear Rail Axle lock feedback or Counterweight retracted 1 / Z-Boom input 1 I/P 12 Road Axle lock feedback or Counterweight extended Feedback loop to confirm rear rail axle lock status, MUST BE FITTED FOR ISSUE 6. For COLMAR - first input to confirm counterweight retracted. For Z-BOOM, this is input 1. Feedback loop to confirm road axle lock status, MUST BE FITTED FOR ISSUE 6. For COLMAR - input when counterweight is fully extended 5 Power in +V ignition switched Switched by ignition and protected by a 15A Fuse 6 Power in +V ignition switched Switched by ignition and protected by a 15A Fuse 7 O/P 1 Rail lights To switch off road lighting when in rail duties 8 O/P 2 Blue beacon Powers blue beacon on cab when in lift duties 9 O/P 3 Rear Rail Axle Safe to Unlock or Turret Slew beacon For certain machines, this output is connected to a relay which prevents the unlock of the rear rail axle, when unsafe to do so. For COLMAR this output controls the Turret Slew Warning Beacon. 10 O/P 4 Road Axle Safe to Unlock or White beacon For certain machines, this output is connected to a relay which prevents the unlock of the road axle, when unsafe to do so. Standard Option - for white beacon in cab window when in lifting mode 11 O/P 6 Overload alarm Output to overload alarms 12 O/P 8 Breakaway alarm Output to trailer breakaway alarms 27 GKD Technik Ltd

28 Module Connection Tables continued... Input/Output Module continued... Use the following diagram as a reference when adding connections. 28 GKD Technik Ltd

29 Module Connection Tables continued... Undercarriage Module The undercarriage module controls the rail lights and drive interlock and receives status inputs from stabilizers and other services such as the trailer breakaway input. Note the rear rail bogie up input will also control the road/rail duty on the system. Grey Black Function 1 I/P Speed pulse PNP proximity input for speed, needed to switch rail lights on undercarriage 2 I/P Speed direction OPTION - to provide direction of travel, 2nd speed sensor 3 I/P Stab rear left DOWN OPTION - Stabiliser input 4 I/P Rail front bogie DOWN Front DOWN rail gear input - REQUIRED FOR ISSUE 6 5 I/P Emergency Stop Logs input only, no action taken by RCI 6 I/P Rail rear bogie DOWN Rear DOWN rail gear input - REQUIRED FOR ISSUE 6 7 I/P Rail rear bogie UP Rear UP rail gear input - REQUIRED FOR ISSUE 6 8 I/P Stab front right DOWN OPTION - Stabiliser input 9 I/P Rail front bogie UP Front UP rail gear input - REQUIRED FOR ISSUE 6 10 I/P Stab rear right DOWN OPTION - Stabiliser input to 24v Supply in Switched by ignition and protected by a 15A Fuse 12 GND 0V 0V to chassis 1 O/P Rear red rail lights Rail lights output +V 2 O/P Front red rail lights Rail lights output +V 3 I/P Stabiliser stowed OPTION - Stabiliser input - loop all stabiliser stowed switches to this i/p 4 I/P Stab front left DOWN OPTION - Stabiliser input 5 12 to 24v Supply in Switched by ignition and protected by a 15A Fuse 6 12 to 24v Supply in Switched by ignition and protected by a 15A Fuse 7 I/P Air pressure Air pressure (brakes) input - alarm and drive cut when no pressure 8 I/P Breakaway alarm Trailer breakaway input, alarm when triggered. Hydraulic flow switch 9 NOT USED Not used on 3RCI+ 10 O/P Drive interlock OPTION - +V output to interlock solenoid 11 O/P Front white rail lights Rail lights output +V 12 O/P Rear white rail lights Rail lights output +V 29 GKD Technik Ltd

30 Module Connection Tables continued... Undercarriage Module continued... Use the following diagram as a reference when adding connections. 30 GKD Technik Ltd

31 Module Connection Tables continued... SpaceGuard Module Where fitted, the SpaceGuard module interfaces to the CAN bus and the override switch via M12 connectors. The M12 connectors are male and female to ensure incorrect connection is not possible. Grey Black Service (allowed) Function 1 O/P 1 Slew fast Allows slew speed of 2m/s when active 2 O/P 2 Stub boom fast Allows fast stub boom speed when active 3 O/P 3 Fore boom fast Allows fast fore boom speed when active 4 O/P 4 Dipper fast Allows fast dipper speed when active 5 O/P 6 Safety Relay Secondary machine cut if limit exceeded - REQUIRED FOR ISSUE 6 6 O/P 7 Turret Lock OPTION - COLMAR - Allow turret unlocking pin 7 O/P 8 Track Twist OPTION - COLMAR - Allow full speed when active 8 O/P 5 Slew fastest Allows slew speed to maximum when active 9 I/P Watchdog In Safety watchdog relay in to 24v Supply in Switched by ignition and protected by a 15A Fuse to 24v Supply in Switched by ignition and protected by a 15A Fuse 12 GND 0V 0V to chassis 1 O/P 15 Jib/Bucket DOWN Fast OPTION - COLMAR - Allow full speed of jib/bucket down when active 2 O/P 13 C/W Retract OPTION - COLMAR - Allow counterweight retract 3 O/P Watchdog Out Safety watchdog relay out 4 12 to 24v Supply in Switched by ignition and protected by a 15A Fuse 5 12 to 24v Supply in Switched by ignition and protected by a 15A Fuse 6 GND 0V 0V to chassis 7 O/P 9 Dipper Retract OPTION - COLMAR - Allow dipper extension in 8 O/P 10 Dipper Extend OPTION - COLMAR - Allow dipper extension out 9 O/P 11 Jib Retract OPTION - COLMAR - Allow jib extension in 10 O/P 12 Jib Extend OPTION - COLMAR - Allow jib extension out 11 O/P 14 C/W Extend OPTION - COLMAR - Allow counterweight extend 12 O/P 16 Jib/Bucket UP Fast OPTION - COLMAR - Allow full speed of jib/bucket up when active 31 GKD Technik Ltd

32 Module Connection Tables continued... SpaceGuard Module continued... Use the following diagram as a reference when adding connections. 32 GKD Technik Ltd

33 Power Wiring To Modules 33 GKD Technik Ltd

34 Slew Speed output logic and SpaceGuard The 3RCI+ SpaceGuard system is able to control slew speed in accordance with Network Rail requirements as set out on MLD-R003. The system is able to set the slew speed to one of three states: Full speed (no restriction). 2m/s as measured at the bucket pin at full radius. 1 m/s as measured at the bucket pin at full radius. The three speeds are achieved by the state of the two slew speed outputs, Slew Fast (Output 1) and Slew Fastest (Output 5). These are as follows: Condition No slew limit or virtual wall set Slew limit or virtual wall set, 2m/s speed required Slew limit or virtual wall set, 1m/s speed required Slew Fast - Output 1 (Grey Connector Pin 1) Output high (+V voltage present) Output high (+V voltage present) Output low (no voltage present) Slew Fastest - Output 5 (Grey Connector Pin 8) Output high (+V voltage present) Output low (no voltage present) Output low (no voltage present) Output 6 - Safety Relay There is now the ability to stop all machine movement in the event of a motion cut failure. If the machine has reached a limit, and the system attempts to motion cut but the valve is stuck or faulty, the system will now use Output 6 of the SpaceGuard Module (Grey connector pin 5) to activate a relay that is wired into the Deadman switch in the cab. This will cut all motions to the machine and prevent further unsafe movement. This relay can be overridden in an emergency, please see the following page. The relay, which is the same as the one detailed on page 42 and supplied with every system, is fitted as follows: 34 GKD Technik Ltd

35 Axle Safe To Unlock Relay We now specify and supply a relay to use for the Axle Safe to Unlock output. This relay has an override on it to allow the axles to be unlocked in the event of a complete system failure and machine recovery is required. Relay Wiring Relay Override On the top of the relay, there is a small test button that can be used to override it in the event of an emergency. Please see the pictures to the right for details on how to do this. 35 GKD Technik Ltd

36 SpaceGuard and Safety Mismatch SpaceGuard constantly monitors the status of each angle sensor against it s paired angle sensor on the same articulation. So long as both angle sensors on each of the booms are giving the same results, to within a few degrees, and the Primary and Secondary slew monitoring sensors agree with each other, SpaceGuard allows the 3RCI+ system to work as normal. Should a difference be detected between any pair of sensors, a Safety Mismatch warning will be displayed, the machine will be motion cut and the external alarm will sound. It is probable that the Mismatch only occurs when a limit is set, as SpaceGuard is usually configured so that the SpaceGuard Mismatch checking is active only when a height, slew or virtual wall limit is turned on. In order to determine which sensor is mismatched, it is necessary to use the Test mode on the 3RCI+ display. A six digit code is required for access, please contact GKD for access to this code, which is for engineer use only and is not to be divulged to machine operators. Once inside the Test menu, select the MORE tab and press the TANDEM / SAFETY button. Inside the TANDEM / SAFETY section, select the ANGLES tab at the top of the page. The angles of the Main and Safety sensors for the Stub Boom, the Fore Boom, the Dipper and the Slew are shown on the screen in the Main and Safety columns, with the difference between the Main and Safety sensors for each component being shown in the Diff column. The Limit column shows the maximum difference allowed between any pair of sensors, and the Flag column will show either a 0 or a 1 against each machine component to show whether the component passes or fails the mismatch test, 0 for pass and 1 for fail. 36 GKD Technik Ltd

37 Speed Sensor Calibration To set up the speed sensor it is necessary to travel the machine. A speed measurement tool will be required. A handheld GPS unit with speed readout is sufficient. To calibrate the speed sensor, go to the following page: SERVICE CALIBRATE SENSORS SLEW SENSOR Travel the machine at full speed and when the speed reading on the GPS is stable note the speed whilst simultaneously pressing the Capture button. Stop the machine and then press Measured and enter the speed. The speed should be entered in MPH. Check the speed. If the speed is negative then invert the reverse speed input in the relevant module options. 37 GKD Technik Ltd

38 Data Upload/download Machine data comprises a series of user, executable and data files that are stored in a specific directory on the 3RCI+ display. To change the data, the engineer has to use a GKD download dongle. Without this specific dongle it is not possible to change the data. Steps to upload data are as follows: Insert the USB memory stick containing the new data into the GKD dongle. Ensure the data is in a folder called DATAEXE. Ensure the display is powered up and on the operator screen. Press on the Menu button. Now press on the Service button. Enter your service code and press OK. Insert dongle to connector on the base of the 3RCI+ display. The DATA TRANSFER button should now be available. Press on the DATA TRANSFER button. Now press on the ONLOAD DATA TO 3RCI button. The relevant machine files will now be copied from the USB memory stick onto the Display. When completed, a message will be shown asking you to restart the display. Press Ok and the display will restart with the new machine files. Steps to download data are as follows: Insert the USB memory stick into the GKD dongle. Ensure there is in folder called DATAEXE in the root of the USB memory stick and that it is empty (if it is not empty, any data will be overwritten). Ensure the display is powered up and on the operator screen. Press on the Menu button. Now press on the Service button. Enter your service code and press Ok. Insert dongle to connector on the base of the 3RCI+ display. The DATA TRANSFER button should now be available. Press on the DATA TRANSFER button. Press on the OFFLOAD DATA TO GKD USB DRIVE button. The relevant machine files will be copied off the display and onto the USB Memory Stick. This will also include the Log files so might take a while. When the transfer is complete, a window will appear showing you how many files were successfully copied. At this point you can remove the dongle from the display. 38 GKD Technik Ltd

39 Error codes and error diagnosis Error Message Definition Notes E1 Stabiliser footing lost! Redeploy E2 Boom offset not straight! E4 Axles not locked! E5 Counterweight Mismatch E6 Backwards Stability! E8 Dipper Mismatch! E9 Foreboom Mismatch! E10 Pre-boom mismatch! E11 Height Mismatch! Offset or Swing boom is not detected as straight System requires axles to be locked and detects they are Unlocked COLMAR - counterweight IN detection switches do not match Machine is at risk of becoming backwardly Unstable SPACEGUARD - the two angle sensors that monitor the dipper angle do not agree SPACEGUARD - the two angle sensors that monitor the fore boom angle do not agree SPACEGUARD - the two angle sensors that monitor the primary (stub) boom angle do not agree SPACEGUARD - The height limit calculations between the primary and safety sensor banks indicate a difference outside the permitted tolerance. Position boom in the straight ahead position. Check proximity switches that detect that the boom is straight for correct operation. Lock axles, or check feedback loop from axle lock solenoid (if fitted) Check correct operation of 2 x proximity switches detecting that the counterweight is fully retracted. Return to more stable position by lowering stub boom or slewing back in line. Check the angle sensors monitoring the DIPPER for mechanical damage and correct operation. Check the angle sensors monitoring the FORE BOOM for mechanical damage and correct operation. Check the angle sensors monitoring the STUB BOOM for mechanical damage and correct operation. Check the angle sensors using the TEST menu to determine where the difference lies, and then inspect the angle sensors for mechanical damage or misalignment. E12 Radius Mismatch! SPACEGUARD - The radius calculations between the Primary and safety sensor banks indicate a difference outside the permitted tolerance. Check the angle sensors using the TEST menu to determine where the difference lies, and then inspect the angle sensors for mechanical damage or misalignment. 39 GKD Technik Ltd

40 Error codes and error diagnosis Error Message Definition Notes E13 Slew Mismatch! SPACEGUARD - The slew angle calculations between the primary and safety slew sensors indicate a difference outside the permitted tolerance. Slew the machine over the slew reference point (0º of slew) to reset the safety tooth counting sensor count. If problem persists, use the TEST menu to check the primary and safety slew count and determine which is in error. E14 Safety Mismatch! SPACEGUARD - at least one of E15 Mismatched the pairs of angle sensors, or Safety! slew sensors, is not within the permitted tolerance. E16 Safety Board Lost MCU SPACEGUARD - communication between the primary and safety processor boards in the MCU has been lost. Slew the machine over the slew reference point (0º of slew) to reset the safety tooth counting sensor count. If problem persists, use the TEST menu to check the primary and safety slew count, and primary and safety boom angles, and determine which is in error. Check within the MCU for obvious bad connections or water ingress. If no obvious fault found, contact GKD. E20 Slew left into limit! E21 Slew Right into Limit! SPACEGUARD - The pilot line pressure sensor monitoring the slew LEFT driver request indicates that the operator is trying to slew LEFT into a slew or wall limit. SPACEGUARD - The pilot line pressure sensor monitoring the slew RIGHT driver request indicates that the operator is trying to slew RIGHT into a slew or wall limit. If slew LEFT is not being operated, use the TEST menu (External Inputs, Module 9 SLEW, input 7) to check the input from the slew left request for correct operation, check slew LEFT pressure sensor in the slew left pilot line. If slew RIGHT is not being operated, use the TEST menu (External Inputs, Module 9 SLEW, input 6) to check the input from the slew left request for correct operation, check slew RIGHT pressure sensor in the slew left pilot line. 40 GKD Technik Ltd

41 Error codes and error diagnosis Error Message Definition Notes E22 Offset Mismatch! E23 Offset sensor (fore) 0! E24 Offset sensor (fore) 1023! E25 Safety Offset sensor (fore) 0! E26 Safety Offset sensor (fore) 1023! E27 RS Dual over pressure! E28 RS dual pressure mismatch! E29 RS Dual pressure over 20mA! E30 RS Dual under 4mA! E31 RS dual press sensor 0! E32 RS dual press sensor 1023! SPACEGUARD - the two proximity switches detecting that an offset or swing boom is straight do not agree. WELDER - the two offset angle sensors do not agree The main angle sensor monitoring the angle of offset of the fore boom is giving a 0 bit reading The main angle sensor monitoring the angle of offset of the fore boom is giving a 1023 bit reading The safety angle sensor monitoring the angle of offset of the fore boom is giving a 0 bit reading The safety angle sensor monitoring the angle of offset of the fore boom is giving a 1023 bit reading Indicates a detected error or issue with the Rod side pressure transducer, or connection of the rod side pressure transducer to the slew module. Check both proximity switches for correct operation and mechanical damage. WELDER - check the outputs of the two offset angle sensors, check sensors for physical damage. Check the main offset angle sensor for correct operation and connection Check the main offset angle sensor for correct operation and connection Check the safety offset angle sensor for correct operation and connection Check the safety offset angle sensor for correct operation and connection Check Rod side pressure transducer and wiring for correct operation and / or mechanical damage. Replace sensor if necessary. Potentially could be a slew module issue. 41 GKD Technik Ltd

42 Error codes and error diagnosis Error Message Definition Notes E33 RS over Indicates a detected error or Check Rod side pressure transducer and wiring pressure! E34 RS 20mA press sensor over 20mA! issue with the Rod side pressure for correct operation and / or mechanical transducer, or connection of the damage. rod side pressure transducer to E35 RS press sensor below 4mA! E35 RS press sensor the slew module. Where low pressure is indicated, apply pressure to the Replace sensor if necessary. Potentially could be a slew module issue. below 4mA! E36 RS press sensor 0! E37 RS dual press sensor 1023! sensor using the boom hydraulics to check if error is resolved. E38, E39, E40, E41, E42, E43, E44, E45, E46, E47, E48, E49, E50. As pre the above, but from the FULL pressure side of the lift cylinder. As above, Full side pressure transducer. E56 Extn reeler out of range! E57 Boom Ang out of range! Extending dipper - the reeler sensor that monitors extension length is giving an unexpected reading The primary (stub) boom angle sensor detects that the boom has reached an impossible Position Check the reeler sensor for correct operation, mechanical damage or faulty connection. Check the stub boom angle sensor for correct operation, mechanical damage, or faulty connection. E65 MOD1 Op 9-16 fault! E66 Mod1 Op 1-8 fault! E67 MOD1 Op 9-16 no power! E68 Op 9-16 connection! E69 MOD1 Op 1-8 no power! E70 MOD1 Op 1-8 connection! Module 1 (Output module), Check the Deutsch connectors and output multiple outputs are detected as connections to Module 1 (Output module). being disconnected or short circuited, or a problem is Check the power supply connections to the detected with the external Module 1 (Output module). power supply to the module through the Deutsch connectors. 42 GKD Technik Ltd