1. Control valve 2. Electric activations 3. RCL Controller 4. Dump valve 5. Electronic box 6. Remote Control Box. System - IRC

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1 System - IRC 1. Control valve 2. Electric activations 3. RCL Controller 4. Dump valve 5. Electronic box 6. Remote Control Box 1

2 System, IRC Electronic Transmission of Signals - Radio Remote Control During crane operation, the control levers on the remote control box are operated. Digitally coded control information is thus sent via radio signals to the electronic box. In the electronic box, the radio signals are converted to two types of signals, which are sent on to the following units: 1. An electric analogue voltage for the electric activations of the valve block 2. Digital CAN Bus signals to the RCL 5100 / 5200 controller Re.: item 1 When operating a control lever in the direction towards the operator, an analogue voltage of between 6 and 12 volts is transmitted to an electric activation. In the electric activation this analogue voltage controls small hydraulic solenoid valves. These solenoid valves control a hydraulic oil pressure, which activates the control levers of the valve block downwards. When operating a control lever in the direction away from the operator, an analogue voltage of between 12 and 18 volts is transmitted to the electric activation. This activates the control levers of the valve block upwards. The control levers on the valve block move at the same speed and in the same direction as the control levers on the remote control box. The signal from a control lever is analogue, i.e. the more it is operated towards the extreme position, the more the voltage for the electric activation is altered and thus the speed of the function in question. 2

3 System, IRC Re.: item 2 When operating a control lever on the remote control box, it transmits radio signals to the electronic box. In a CAN Bus unit in the electronic box, the radio signals are transformed to digital CAN Bus signals which are sent on to the RCL 5100 / 5200 controller. The CAN Bus circuit in the RCL controller receives these digital signals but it also transmits digital control information back to the electronic box. When the crane is remote controlled there is constant communication between the electronic box and the RCL controller, by transmission of digital CAN Bus signals back and forth. Communication from the electronic box to the RCL The electronic box constantly monitors that the coded radio communication is proceeding normally. If everything is OK, signals are sent to the RCL controller informing that the crane is allowed to be operated. If there is any interference in the radio communication and missing signal to the RCL controller, the controller no longer transmits voltage to the dump valve. The hydraulic oil flows to tank and the crane does not move. Communication from the RCL to the electronic box The RCL controller constantly monitors crane operation sending information about this to the electronic box. I.e. a signal is transmitted when the electronic box is to reduce the speed of the crane during HDL-operation. During HDL-operation, the analogue voltage to the electric activations is reduced, thus limiting the movement of the lever on the valve block. The voltage range is reduced from the usual volts to for example volts, while the complete control range of the control lever is maintained. 3

4 System, IRC Hydraulic Transmission of Signals - Radio Remote Control When operating a control lever, proportional analogue voltage is transmitted from the electronic box to the electric activation. In the electric activation this analogue voltage is transformed into a pulsemodulated voltage (pulse) to the four small hydraulic solenoid valves (1.,2.,3., and 4). These solenoid valves control a hydraulic oil pressure to one end or the other of the spool. If the oil pressure is led to the end of the spool, which is closest to the control lever, the spool is moved upwards thus pulling down the lever. If the oil pressure is led to the end of the spool, which is furthest away from the control lever, the spool is moved downwards thus pulling up the lever. Depending on whether the oil from the hydraulic pump is to flow to the A-port or the B-port, the four solenoid valves are activated in a certain combination. Please see table. Analogue voltage Solenoid valve [volt] Direction of the control lever Oil flows form port 12 6 Pulse ON OFF Pulse Neutral down B OFF Pulse Pulse ON Neutral up A E.g. 14 OFF ON OFF ON Holding position A Neutral OFF OFF OFF OFF Neutral, movable A and B closed When activating a stop button, no control current is sent to the electric activations. It is thus possible to operate the control levers, but the dump valve is open, and the crane is not moving. 4

5 SERVICE INFORMATION IN GENERAL Danfoss PVG 32 Changes Side: Page: 1 (2) Seite: Dato: Date: Datum: In connection with IMT introducing two new Can Bus controlled radio control systems (IRC and Scanreco-IRC) on January 2001, the following changes have been made on the Danfoss PVG 32 control valve: 1. New type of high performance electric activations on all crane functions 2. No spool sensors 3. Open centre spool in the slewing section 4. Changed port-relief valves for grab and rotator functions 5. Stay bolts of improved steel quality Re.: item 1 The new electric activations are more compact and have changed socket and plug of the AMP type (previously a Hirchmann plug). Electric activation Electric activation AMP-plug incl. cable (24 volt) (12 volt) Part no Remove the plug by pushing the red plastic lock upwards (pos. 1), and then pull the plug out. When mounting, push in the socket over the plug of the electric activation (pos. 3), and then push the red plastic lock (pos. 4) downwards. All crane and extra valve functions have the new type of high performance electric activations, which operate very precise and fast. I.e. you obtain and improved operation of extension, grab and rotator functions, which previously were fitted with medium performance electric activations.

6 SERVICE INFORMATION IN GENERAL Danfoss PVG 32 Changes Side: Page: 2 (2) Seite: Dato: Date: Datum: Re. item 2 Spool sensors are no longer mounted on the PVG 32 control valve. Instead of a signal from spool sensors, there is in connection with the IRC system an activation signal in the A or B direction from the IRC- electronic box. Re.: item 3 An open centre spool is mounted in the valve section for the slewing movement (previously it was a closed centre spool). To ensure a softer braking when slewing the crane, a double load holding valve is mounted in the hydraulic system for the slewing movement in connection with the PVG 32 control valve. Re.: item 4 In the valve sections for grab and rotator, port-relief valves with a higher pressure setting have been mounted. In the grab section it is 2 x 250 bar and in the rotator section it is 2 x 190 bar port-relief valves. This change has been made to meet with increased requirements to hydraulic working pressure for crane equipment. Re.: item 5 The hydraulic working pressure for cranes is increased, which makes heavier demands on the control valve. Therefore the PVG 32 control valve sections are tightened together by stay bolts made of hightensile steel. Cable references