PWM Signal

CAN:3

Digital pulses
CAN:3
+

Digital signals/24 V output

CAN:4
1
2

0
3
4
5
6

9
8
7

ESC
L=0

RCS

RI GCO NTROL SYSTEM

900M
hz
DEC
188 T
10A
1
10A

7
4
1

A
2
3 5A
4

K4A
5 5A
6 5A

9
6
3

B
0-
7
8 5A
9

7
4
1

A
10 5A
11 5A
12
13 5A

K19 7A
9
6
3

B
14 5A
15
16 5A
17

7
4
1

A
5A
18

X-INPUT
19 5A
190

Y-OUT PUT
20
3A

K 197B
21

B
22

9
6
3
5A
23

P LC B AS E UNIT
24 3A

A
24

7
4
1
CAN:3
3A
24
24
24

K 198
25

9
6
3

B
25
25
25
25
0Mh

C
25
25

D
25

BA

C
26

U NI T

P ower
z
27
28

D
P LC EX P.
29

C
30
31

D
B
32
33
34 401

U NI T

P ower
402
35
36 403
404

P LC EX P.
37
37 405
40
406
37
407
60 38 408
61 38
409
62 38 410

U NI T

Pow er
63 38
411
64 39 412

PL C EX P.
65 39 413
66 40 414
67 40 415
68 40 416
69 40 417 K1 05
40 418
70
71 40 419
420
72 41 K3 65
73 42

RS232
421
422
74 43
44 423
75 K3 66
1
00 45
1
00 46

N510
1
00 47
1
00 48
K3 67
1
00 49 0
9 0
9
1
00 50 1
9 1
9
1
00 50
K3 76
1
00 50 2
9 2
9
1
00 50
50 K3 30 K3 77
1
00
1
00 50
1
00 50
1
00 50 K3 64 A K5B
1
00 50
1
00 50
1
00 51 K36 4B K2 00
1
00 52
1
00 53
1
00 54 K3 04
1
00 55 K32 4
56

U2

U1
U1

LED
RS 232
ROC RRC rig

PWM Signal

J1939/CAN:2
Digitala signals
Radio Fault Finding on a
Basics

Radio is the wireless transmission of signals, by modulation of electromagnetic waves with

frequencies below those of visible light.

Electromagnetic radiation travels by means of oscillating electromagnetic fields that pass through the
air and the vacuum of space. It does not require a medium of transport. Information is carried by
systematically changing (modulating) some property of the radiated waves, such as their amplitude or
their frequency. When radio waves pass an electrical conductor, the oscillating fields induce an
alternating current in the conductor. This can be detected and transformed into sound or other signals
that carry information.

All basic radio systems consist of four (4) basic components.

Transmitter - The unit which takes the input from the user through the gimbals or sticks,
encodes it, and sends it to the aircraft.

Receiver - The unit that receives the signal, decodes it, and routes it to the appropriate servo.

Servos - The device that converts the decoded signal to mechanical force to operate a control
surface.

Batteries - The device that provides power for the other devices to operate.

Source:
1. Radio, available: http://en.wikipedia.org
2. The basic radio system, available http://www.srcfa.ca/Beginners/radio_system.htm
Radio transmitter
The radio transmitter communicates with the receiver via a radio link, 1880-1900 MHz or 900 MHz.
The radio protocol includes function instructions for the rig. The protocol also includes unique system
addresses (codes) that are allocated to the specific radio system. This prevents the system from being
controlled from other radio transmitters. The system addresses are stored in a code key. In case of
disruption/malfunction or special authorization requirements, the system can be controlled via a
control cable between the transmitter and receiver. The transmitter is in such a case supplied with
power by the cable and can therefore be used without batteries.

The radio transmitter comprises: Four

proportional control levers which are fed
with 2 V. The signals from the control +

L=0
levers range from 0 V (neutral) to 2 V
(end position). The signals are converted
by the receiver (R232 protocol) to a
value between 0-255, where 0 is neutral 5
4

and 255 maximum actuation. 2

3
6

8
1

The potentiometers in the control levers 0 9

have direction switches. The direction

switch is closed when entering at least
10% of the sector. When the direction
switch is closed, lamp S12 comes on (see
under receiver).

Switches and buttons - work in the same way as ON/OFF switches and work with 0V/5V. When the
switch/button is activated, the signal is 0 V (passive signal) and 5 V when it is not activate.

Winch potentiometer - supplied with 2 V.

Active stop - switches off the electrical supply to the transmitter, which switches off the rig.
Note: This only applies if the rig has contact with the radio transmitter.

LED-Lamp
 Flashes rapidly green when the transmitter is searching for contact with the receiver (DECT
system only).
 Flashes at medium speed with the transmitter is in PWM adjustment mode.
 Flashes slowly green when communication is OK.
 Flashes irregularly green in case of an internal short circuit on the SI2 circuit.
 Flashes red when battery voltage is low.
Radio receiver
The receiver converts the radio waves to two types of signal: PWM signal (Pulse Width Modulation)
and RS232 data protocol.

The PWM signal is an analogue output signal that drives the proportional hydraulic valves (functions
controlled by two control levers, the tramming controls and winch potentiometer). The receiver has 15
active channels for PWM signals. Each channel can be individually adjusted to ensure the correct
speed of movement. Min (crawling speed) and max (fast speed) can be adjusted separately. The
adjustment range is 0-1500 mA. In general, the valves start to react at 200-300 mA and reach their end
positions at 400-600 mA. Read more under the section “Adjustment via the transmitter (radio)”.

LED on receiver:
 The amber lamp lights when the receiver is fed with voltage.
 The red lamp lights if communication between the transmitter and receiver is faulty.
 The first green lamp SI1(3) lights when communication between the transmitter and receiver is
working. Also, the red lamp goes out.
 The second green lamp SI2 (4) lights when a PWM channel is high, i.e. proportional functions are
activated.

The RS232 protocol is converted by the PLC to digital output signal (ON/OFF signals) (see next page).

RS232 COM Bom lift Drillfeed backward

Feed swing right 11 3 K365 K376 K377 Rapid feed backward
Bom sink Drillfeed forward
Feed swing left 12 4 K365 K376 K377 Rapid feed forward

Winch force 13 5 Bomswing right

14 6 Bomswing left

Tramming backward - Left 15 7 Boom extension in

1. POWER ON
2. NORECEPT.
Tramming forward - Left 16 8 Boom extension out
3. SYST. ON
4.PWM ON

Tramming backward - Right 17 9 Feed tilt in

Tramming forward - Right 18 10 Feed tilt out

DECT 1880-1900MhZ

L=0

4 5
6
3
2 7

1 8

0 9
PLC
The new PLC base unit has enhanced capacity and can handle data protocols. Just as previous
generations of PLC, the unit only handles 24 V digital input/output signals. All digital functions
(On/Off) generate signals using the RS232 data protocol. The RS232 protocol is based on the
functions that are active on the radio transmitter. The protocol includes instructions that are processed
by the PLC with directions to activate the outputs. The logic for the PLC is stored in an EEPROM
(program).

Pump 3 Positioning/winch(Y187) 26 22 Winch activation (S172)

I/O module X2:04 Remote 25 21 Safety stop (Reciever output)
Low RPM diesel (K324) 24 20 Compressor load (S180)
Reduced flushing (Y116) 23 17 Pre-heating (S131)
Full flushing (Y115) 22 16 Key in start position (S139)
DCT hatch open(Y253) 21 15 Key in ignition position (S139)
I/O module X4:15 14 Rapid feed stop backward 2(B127)
Percussion active (Y101A) 20 13 Rapid feed stop backward (B126)
Low percussion(Y101B) 17 12 Rapid feed stop forward (B122)
DCT Clean 3 (Y251C) 16 7 Carousel index stop CW (B183)
DCT Clean 2 (Y251B) 15 6 Carousel index stop CCW (B182)
DCT Clean 1 (Y251A) 14 5 Winch protection (S464)
Carousel rotation CCW (Y303A) 13 4 Drillstop (I/O module X3:07)
Carousel rotation CW (Y303B) 12 3 Arm to carousel (B118)
Arm to carousel (Y301A) 11 2 Radio remote control (S130B)
Thread greasing (K449) 1
Flow switch (B142)
Arm to drillcentre (Y301B) 10 0
Rotation pressure (B134)
Loose grip (Y306) 7
Open rod grip (Y300) 6
Engine start (K5B) 5
Stop forward (Y183A) 4
Stop backward (Y183B) 3
Anti-jamming (Y109) 2
ECG Pump (Y107) ECG Relä 1
ECL Pump (Y106) ECL Relä 0

Output Y Input X

RS232 COM

All multi/tramming controls with proportional movement produce a PWM output from the receiver.
The proportional functions for boom lowering, drill feed and rapid feed are activated in the same lever
sector. Each lever sector that produces a PWM signal has its own output channel on the receiver.
When the various functions use the same output channel (3,4) the signal is guided by relays K365,
K376 and K377 to the correct electrical valve. The PLC outputs Y64-67, 76-77 and 104 control the
PWM relays. (See figure on next page.)

Note: RHS arm movements, carousel rotation, gripper claw opening, rotation, percussion/flushing air
and threading/unthreading are controlled by multi lever sectors but the signal type is a digital 24 V
PLC output.

LED on PLC: When the PLC receives data from the receiver, the lamp flashes red.
PLC/Receiver
Pump 3 positioning/winch (Y187) 26
I/O module X2:04 Remote 25
Low RPM Diesel (K324) 24
Flush air reduced (Y116) 23
Flush air full (Y115) 22
DCT hatch open (Y253) 21
I/O module X4:15 22 Winch enable (S172)
Impact on (Y101A) 20 21 Remote safety stop (Receiver output)
Impact low (Y101B) 17 20 Compressor load (S180)
DCT Clean 3 (Y251C) 16 17 Preheating (S131)
DCT Clean 2 (Y251B) 15 16 Start key in start position (S139)
DCT Clean 1 (Y251A) 14 15 Start key in ignition position (S139)
Carousel rotation CW (Y303A) 13 14 Rpd feed stop reduced speed upper (B127)
Carousel rotation CCW (Y303B) 12 13 Rpd feed stop uncoupled (B126)
Arm to carousel (Y301A) 11 12 Rpd feed stop reduced speed lower (B122)
Thread greasing (K449) 7 Carousel stop from the gripper (B183)
Arm to drill centrum (Y301B) 10 6 Carousel stop to the gripper (B182)
Loose rod grip (Y306) 7 5 Winch protection (S464)
Open rod grip (Y300) 6 4 Drill stop (I/O Module X3:07)
Engine start (K5B) 5 3 Arm to carousel (B118)
Stop forward (Y183A) 4 2 Remote (S130B)
Stop backward(Y183B) 3 1 Flow switch (B142)
Anti-jamming (Y109) 2 0 Rotation pressure (B134)
ECG Pump (Y107) ECG Relay 1
ECL Pump (Y106) ECL Relay 0
Output Y Input X

Coupling thread (Y149B) 47

Rotation right (Y102B) 45 46 Drill feed forward (Y104)
Track oscillation float (Y473) 43 44 Rotation left (Y102A)
Track oscillation R backwards (Y420A) 41 42 Track oscillation right forward (Y420B)

Hydraulic jack out (Y410B) 36 37 Track oscillation left backward (Y419A)

Tramming main, high speed (Y122) 34 40 Track oscillation left forward (Y419B)
Preheating (Y120) 32 35 Hydraulic jack in (Y410A)
Engine enable (K330) 30 33 Tramming main flow (Y121)
31 Warning sign (H185)

Winch control valve (K304) 104 105 Zero set (K105)

Winch in (Y208A) 102 103 Winch out (Y208B)
Winch force variable on (Y215) 100 101 Winch brake release (Y209)
106 I/O module X2:10 Display view toggle
PLC Expension unit 3:1
Watermist manual (Y112B) 71 77 PWM Rapid feed (K377)
Sleeve retainer (Y309) 73 I/O module X4:04
Watermist automatic (Y112A) 70 75 Compressor load (Y210)
76 PWM Rapid feed (K376)

I/O module X4:18

Support upper closed (K366A) 63 64 PWM signal enable (K364A-B)
Support lower closed (Y350B) 61 66 PWM signal enable (K366)
I/O module X4:17 67 PWM signal enable (K367)
Support upper open (Y361A) 62 65 PWM signal enable (K365)
Suppoer lower open (Y350A) 60
PWM signal enable (K364A-B) 64
PLC Expension unit 2:1
Hood down (Y357B) 56 57 DCT on (Y250)
Feed extension in (Y405A) 52 55 Hood up (Y375A)
I/O module X4:16 51 Feed extention out (Y405B)
Coupling unthread (Y419A) 50

PWM
OUTPUTS

L=0

4 5
6
3

900MHZ/Dect 1880-1900MHZ
2 7

1 8

0 9
Radio system
The radio transmitter communicates with the receiver via a radio link (DECT 1880-1900 MHz or
900 MHz). RS 232 serial communication links the receiver and PLC. Logic for digital signals (24 V
ON/OFF signal) is processed by the PLC based on the RS 232 protocol from the receiver.
PWM signals for proportional functions are processed by the PWM card in the receiver. The
digital/PWM signals are linked to the electric valves via the distribution boxes.

Conditions for activation of radio system:

Tx→ Rx→ PLC in→ PLC out→ Function
S139 (ignition pos.) K4A aktivated PLC(energized)
S130B activated - PLC/X2-On (10 sec countdown begins)
S169 activated Radio receiver PLC/X21-On PLC/Y25-On X2:04→
24V/On RRC On

Note: S169 must be activated within 10 seconds to establish a communication link between the
transmitter and PLC.

Conditions for deactivation of radio system:

Alt Tx→ Rx→ PLC in→ PLC out→ Function
1 S169 deactivated Radio receiver PLC/X21-Off PLC/Y25-Off X2:04→
24V/Off RRC Off
2 S132 activated Radio receiver PLC/X21-Off PLC/Y25-Off X2:04→
24V/Off RRC Off
3 If the emergency stop signal between the radio receiver and PLC is broken for more than 1
second.(Dect) 0.5 sek.(900Mhz) → RRC Off
4 If the RS232 protocol between the receiver and PLC is broken for more than 2 seconds.
→ RRC Off

Conditions for automatic off function:

Tx→ Rx→ PLC in→ PLC out→ Function
S130 (positioning/tramming) RS232 RS232 PLC/Y17-Off Y101B Off
10 seconds without activity - - PLC/Y64-Off K364A, B Off
- - PLC/Y65-Off K365 Off
- - PLC/Y66-Off K366 Off
- - PLC/Y67-Off K367 Off
- - PLC/Y33-Off Y121 Off
Note: PLC begins the countdown when no functions are activated on the radio.

Resetting the automatic off function:

Tx→ Rx→ PLC in→ PLC out→ Function
S186 activated RS232 RS232 PLC/Y64-On K364A, B On
RS232 RS232 PLC/Y65-On K365 On
RS232 RS232 PLC/Y66-On K366 On
RS232 RS232 PLC/Y67-On K367 On
RS232 RS232 PLC/Y33-On Y121 On*
* When S130 is in positioning/tramming mode.
Note: When automatically shutting down the radio, the relays that are connected to the valve spools
are deactivated. Digital functions such as RHS, drill steel support etc are blocked through the PLC.
Adjustments via the transmitter (radio)
PWM signals can be adjusted using a special battery for the transmitter (radio). The battery has two
push-buttons: (+) to increase the signal and (-) to decrease the signal.

Conditions for adjustment:

 Activate the radio system by pressing both push-buttons. When the radio system is in adjustment
mode, the LED on the transmitter flashes more rapidly.

Conditions for PWM signal (crawling/creeping)

 Move to the sector where the movement begins (10% of the sector is a so-called dead zone).
 Press + or - until the desired crawling speed is attained.

Conditions for PWM signal (rapid):

 Move to the end position for the sector.
 Press + or - until the desired rapid speed for the function is attained.

Note: The relationship between the min and max speed is linear. It is therefore vital to find the very
beginning of the sector (min speed).
No function on Remote Control
Check the LED indicator on Tx
+
If LED starts blinking slowly, then fuse for battery power is broken.
If no light (no power supply), check emergency stop, Still no light, connect the
battery, battery holder connection, key switch communication cable
Still no light, check If no light, check fuse for Rx.
power supply LED
on Rx

L=0

4 5 RS232 COM
If there is light, check power supply via cable.
If the cable is OK, contact factory.
6
3
2 7

1 8

0 9

1. POWER ON
2. NORECEPT.
3. SYST. ON
4. PWM ON

Check power supply If no light, check fuse for Rx.

For DECT system only. If LED is flashing rapidly (2 Hz) LED on Rx
If problem remains,
RS232 COM
If there is light, check
i.e. The 2nd red
antenna installation
LED still ON
1. POWER ON
2. NORECEPT.
3. SYST. ON
4. PWM ON

If system starts working, (i.e. goes out. Then it is failure with

Connect the communication cable,
the DECT/HF module. Try another Tx, and fix the old one by
check LEDs on Rx & functions on
changing out the DECT/HF module.
remote control
If problem remains, change the DECT/HF module in Rx.

Check power supply If no light, check fuse for Rx.

For 900 system only. If LED on Tx is flashing as all LED on Rx
functions are normal, but there is no response from
If problem remains,
the rig.
RS232 COM

If there is light, check

i.e. The 2nd red
antenna installation
LED still ON
1. POWER ON
2. NORECEPT.
3. SYST. ON
4. PWM ON

Radio trouble shooting guide

No proportional functions available (no response from joysticks & paddles)

If the LED is blinking at a irregular speed Confirm joystick/paddle in neutral position, then re-start system.
Check the LED indicator on Tx (3 fast... pause... 3 fast)
If problem remains, open the remote control and disconnect the analogue
joysticks & paddles one by one, re-start the system every time a joystick/paddle is disconneted.
Keep doing until LED on Tx goes back to normal blinking. Then repare or replace the defected joystick/paddle.
+

L=0

1
3

0
4 5
6

9
8 See instruction “Change of Z-joystick” to remove the contacts.

If problem still remains when all the joysticks are disconnected.

Inspect all relevent connectors for oxidation/moisture,
clean if necessary.
If signal is low (0V), check the fuse on PWM card
RS232 COM
in Rx, replace the fuse if necessary.
If the LED is blinking normally, and none If lit, check the relevent signal
Check the on PWM output X1/60-75.
of the analogue functions works. If signal is high (24V), this means no electrical load
2nd LED
1. POWER ON
2. NORECEPT.
3. SYST. ON
on Rx due to open relay, open circuit or broken spool.
4. PWM ON

If not lit, failure with the joystick/paddle, change the joystick/paddle.

Radio trouble shooting guide

Specific joystick function / switch failure
RS232 COM If not lit, failure with the joystick, change joystick.
If a joystick does not carry out Check the
If the function shows OK in the trouble shooting program,
its intended function 2nd LED
continue trouble shooting on PLC, relay, hydraulic system.
1. POWER ON
2. NORECEPT.
3. SYST. ON
4. PWM ON
on Rx If lit, connect the RS 232 trouble shooting program.
If the functions shows OFF in the trouble shooting program,
joystick failure, change the joystick.

If the function shows OK in the trouble shooting program,

continue trouble shooting on PLC, relay, hydraulic system.
If a switch is not working If lit, connect the RS 232 trouble shooting program.
If the functions shows OFF in the trouble shooting program,
switch failure, change the switch.

Radio trouble shooting guide

Component location - Transmitter

XYZ joystick,
Potentiometer
transmission covered

Paddles in neutral
position
Fuse for battery power

DECT module/1900 MHz system

HF module 900 MHz system
HF module for
Antenna 900 MHz system

Radio trouble shooting guide

Component location - Receiver
Enlargement

Antenna Reset buttons

HF module

See enlargement S2 PWM +

Bus manager card/module

S1 PWM -
Fuses for Rx power supply

Power supply module/card

Emergency stop card

Relay card/module

Rs232 card/module

PWM card/module

Fuse for PWM card

Radio trouble shooting guide
 Instructions
Change of Z-joystick

Change of Z-joystick “Ver 1”

Clean the transmitter carefully before changing the Z-joystick. 1
Dismantel the 4 pcs screws in the bellow holder, and 2 pcs
screws under the bellow (see yellow arrow pict. 1)
Split the transmitter housing in half (4 screws, allen key 4mm.)

Dismantel cable clamps, 2 screws ( pict.2, yellow arrow)

Disconnect the 2 black connectors, pull back the cable

connector in direction like white arrow pict. 2

For to assembled the new Z-joystick, make the procedure 2

inverse direction.

Make assure that the rubber bellow is properly mounted !

( se page change of rubber bellow )

Change of Z-joystick “Ver 2”

Clean the transmitter carefully before changing the Z-joystick.
3
Split the transmitter housing in half (4 screws, allen key 4 mm.) LEFT RIGHT
Bu5 Bu7 Bu3 Bu1
Dismantel pcb, 6 pcs screws, note: that under the pcb it is Bu6 Bu2
distance between pcb and transparent plastic cover.
( pict.3, screws yellow arrow, pict.5 distance and trans plastic cover, yellow
arrow)

Dismantel band cable holder, (4 pcs screws pict.3 orange arrows)

Release left or right joystick band cable contacts. Disconnect the
3 red connectors from the pcb.
4
Now the joystick and pcb is unattached.
L. = Bu5 L. = Bu7
R. = Bu2 R. = Bu1
Dismantel joystick from upperpart of housing, the 4 pcs screws
in the bellow holder, and 2 pcs screws under the bellow
(Pict 1,. yellow arrow pict. 1) L. = Bu6
R. = Bu3
Assemble the new joystick, explanation of placing of band
cables to pcb. (Pict 4)

Move the distance from old to new joystick. (Pict.4 yellow arrow)
5
For to assembled the new Z-joystick, make the procedure
inverse direction.

Make assure that the rubber bellow is proper monted ! Distance

( se page change of rubber bellow )
Plastic cove

Important: in case of warranty, always return the joystick.

Document always the transmitters ser. No. 735- xxxxxx at the
return delivery note !

Industrial Radio Control AB • Hedvägen 56, S-780 40 Mockfjärd • SWEDEN Radiostyrning

Tel. +46 (0)241-21455 • Fax. +46 (0)241-20855 • e-mail: elg@ircab.se • http://www.ircab.se