INSTALLATION MANUAL RCS PLUS
Contents
1. INSTALLATION MANUAL RCS PLUS 18 6 12 Removing possible air out of the hydraulic system J z i Lift the fork to maximum height for two times to remove al possible air out of the hydraulic system L u mm CI 613 Adjusting the position of the flow adjustment valve sil s ia 2x 7 d TEA t p ee y Se Tad Z f s d ES 2 ri N y 1 Remove the protection cap WA of the flow adjustment valve B 4 p Fall A 2 Unlock the counter nut of the flow adjustment valve S19 INSTALLATION MANUAL RCS PLUS 19 614 Checking if the system functions correctly L x a Start up the indicator E Press the on off key Activate lt 0 5sec a test weighing c by pressing f gt the gt key ki om The forks should go down INSTALLATION MANUAL RCS PLUS BOTTOM VIE open close2. j 1 Let _ 1x A P_02 is the Graduation step bas E P i d ma d A graduation step of 2 is standard l for trucks with a capacitv up to 2500 TRUCK CAPACITY GRADUATION STEP 100 2500 2 2600 5000 5 5100 10000 10 L MET 5 E l EXAMPLE 2 If the truck capacitv is 5000 change the value for P 02 into 5 INSTALLATION MANUAL RCS PLUS 32 m MI NET PP alld 3 2 6 2X es DIEN c FLI a E y 1 E ml dl ME I d T BI ni E rf m c c z P_05 is the Weighing capacity system INSTALLATION MANUAL RCS PLUS 33 34 ILI EJ E E om yo EA r Ea q ED E Ei MIX EUN x FILI EJ N EJ lt 14 I E i j 30 E 3 l l n b 14
3. INSTALLATION MANUAL RCS PLUS 28 IE IMI 1299 d Ad 2 sec x A J C gm 302 iex 3 7 ngu Y pm E 1 pal A 2 lt 0 5 sec M1 l A B 32 d U B AS a 200 al Irt PEN HU r Lr HE i CJ frm fr lt a 85 b CH UY f AP 4 1 8 15 20 cm M1 Li E ff Z INSTALLATION MANUAL RCS PLUS 29 S Press the on off key twice to restart the indicator d 2x Loe INSTALLATION MANUAL RCS PLUS 30 8 8 1 Parameter settings Entering the parameter menu MET INSTALLATION MANUAL RCS PLUS 31 8 2 Changing the parameters
4. DE p Eis INSTALLATION MANUAL RCS PLUS 23 7 3 Preparing for calibration o t Calibration weight M1 2 3 of the truck s lifting capacity EXAMPLE 1 2 2t truck gt M1 1500 x mmm fe ESI Fam 7 7 1 X y min 10 C max 40 15 105 i TT INSTALLATION MANUAL RCS PLUS 24 Working temperature of the forklift truck 74 90 sl l ff i e 0 5 sec M1 l ji cm U Pm Yr TEN JIET iL mi n IL e s 6 8 15 20 Mi Repeat this cycle for 2 minutes INSTALLATION MANUAL RCS PLUS 25 7 5 Zero calibration Start up the indicator Press the on off kev Wi gt
5. 16 18 INSTALLATION MANUAL RCS PLUS Ea x x Lo e e i 1 i 13 A T 3 A BC l gv os S xn sa 025558 aosgS LO N lt lt S S lt O x gt 8 3 Leaving the parameter menu and saving changes g une 2 sec Le e INSTALLATION MANUAL RCS PLUS 35 8 4 Default parameter settings Parameter 40 Function Settings Default Printer option 1 2 5 10 20 50 100 2 2 W full scale Printing units 1 kg ton Auto shut off time 1 99 min 0 always on in 0 loadcell 6 6 wires approved 1 10 x Resolution 2 ADC COUNTS Databits comport Parity comport 1 0 standard remote 1 standard with printer comport LF on off PC protocol 1 1 send CR and LF 1 normally closed 2 normally open 0 0 Measurement interval for weighing Delay interval for weighing 0 1 5 sec Threshold value 200 200 00 5000 Reset to default parameter settings calibration will be deleted Low battery auto switch off 0 not active 1 1 2 minutes after lo ba 1 active message
6. RAVAS INSTALLATION MANUAL RCS PLUS Rev 25 09 08 INSTALLATION MANUAL RCS PLUS PLEASE RETAIN THESE ASSEMBLY INSTRUCTIONS FOR FUTURE REFERENCE If you have any queries concerning the duration and terms of the guarantee please contact your supplier We would also refer you to our General Sale and Supply Conditions which are available on request The manufacturer accepts no liability for any damage or injury caused by failure to follow these instructions or from negligent operation or assembly even if this is not expressly stated in this instruction manual In light of our policy of continuous improvement it is possible that details of the product may differ from those described in this manual For this reason these instructions should only be treated as guidelines for the installation of the relevant product This manual has been compiled with all due care but the manufacturer cannot be held responsible for any errors or the consequences thereof All rights are reserved and no part of this manual may be reproduced in any way INSTALLATION MANUAL RCS PLUS 2 Table of contents pag 1 Introduction 4 2 Warnings amp safety measures 4 3 Overview of components 5 4 Exploded view 8 parts list 7 5 Before the installation 9 5 1 Capacity of the forklift truck 9 5 2 Maximum pressure in the hydraulic system 9 5 3 Battery voltage of the forklift truck 9 5 4 Making the system pressure free 9 5 5 Conditio
7. 1 sec e 1 TEN l D ndd po emm mL i The display should show 0 AdJ gt If TARE is shown N press the on off key 1x once escape ja ben l Lift the empty forks up to the reference height E INSTALLATION MANUAL RCS PLUS 26 m EJ im ji sore AR EL EE D el JI 6 8 15 20 27 INSTALLATION MANUAL RCS PLUS 7 6 Span calibration MET _ V Ed sm gt I E lt 12 sec FI FI Fi fi ie ILI ILI ILI 0 1 d ie 1 x Change 0000 into the value for M1 1 1 1500 mi mi es PET il l n ii lu _ sr IL U T T ET d ET y rs n 77 1x e 5x x a L 8500 E 1
8. F lt gt IP65 INSTALLATION MANUAL RCS PLUS 10 6 Installation 6 1 Connecting the threaded joints to the hvdraulic block USA oniv l i 2 f Lr i 6 2 Installing the hydraulic block wa bw d Aff 3 110 mm Wa N IN 4 9 inch INSTALLATION MANUAL RCS PLUS 11 6 3 Installing the T piece Type A 1 centre cylinder Mount a T piece in the pressure line of the truck close to the cvlinder to make the split point for the RCS plus Tvpe B 2 side cvlinders Mount a T piece in the pressure line of the truck close to both cvlinders to make the split point for the RCS plus INSTALLATION MANUAL RCS PLUS 12 6 4 Short hvdraulic line from the T piece to the inlet of the hvdraulic block INSTALLATION MANUAL RCS PLUS 13 6 5 Hvdraulic line from the outlet of the hvdraulic block to the return line of the truck B Connect with the A Connect directiv to existing main return the oil reservoir line after the oil filter pA Do not place an oil if installed filter in the return line of the RCS PLUS INSTALLATION MANUAL RCS PLUS 14 6 6 Position of the indicator The indicator should be easv to reach and read out l
9. La 4 M Pen ee If not open the flow adjustment valve by turning the adjustment nipple counter clockwise INSTALLATION MANUAL RCS PLUS 21 7 Calibration 7 1 Tuning the lowering speed of the forks Start up the indicator Press the on off key i 32 80 cm mn Lift the empty forks up to the reference height lt 0 5 sec The forks should go down with a constant speed The downwards movement should be in between 6 8 inch or 15 20cm Also check it with loaded forks If needed adjust the position of the flow adjustment valve steps 7 10 INSTALLATION MANUAL RCS PLUS 22 11 S19 Remove the protection cap of the flow adjustment valve e open close 4 519 Unlock the counter nut of the flow adjustment valve 14 519 TI When OK lock the counter nut of the flow adjustment valve and mount the protection cap 7 2 Marking the reference height 90
10. 6 7 Installing the indicator INSTALLATION MANUAL RCS PLUS 15 6 8 Connecting the sensor cable INSTALLATION MANUAL RCS PLUS 16 6 9 Connecting the cables for the electric valve and sensor 6 10 Connecting the power supply cable EU US 3 15A fuse in 12 Brown Red the 12 V wire Z Cy N If needed install NS AW a net filter I NS If needed install a DC DC supply from power converter Output 12VDC Not needed when the indicator is supplied with an integrated 3A power converter or regulator If so the label CONVERTER INSIDE or REGULATOR INSIDE must be sticked onto the indicator and power cable INSTALLATION MANUAL RCS PLUS 17 6 11 Connecting the svstem wires see electrical diagram o o o o U E B oo a Woo l 000 00 m 55 5 E i
11. Software version indicator N im KIO INSTALLATION MANUAL RCS PLUS 36 9 Attachments 9 1 Connecting the svstem wires and printer wires If the RCS PLUS is equipped with a printer connect the wires of the power supply and the printer with indicator board as shown in the wiring drawing below o un Wn blue brown brown INSTALLATION MANUAL RCS PLUS 37
12. e hvdraulic block in the hvdraulic svstem of the forklift truck is carried out bv vour official forklift dealer Type A 1 center cylinder 5 4 Indicator High pressure 1 Z Low pressure Oil filter Hydraulic 00 block RCS PLUS i fi Hvdraulic Pump Oil reservoir f U valve block LP Connection return INSTALLATION MANUAL RCS PLUS 5 Tvpe B 2 side cvlinders CE 5 Indicator t m High pressure gt Low pressure t t Oil filter Hvdraulic J block RCS PLUS Hydraulic valve block Pump Oil reservoir i Connection return INSTALLATION MANUAL RCS PLUS 6 Exploded view amp parts list 4 7 16 7 INSTALLATION MANUAL RCS PLUS Position Designation Quantity Supplier 1 Bracket indicator 1 RAVAS 2 Indicator 1 RAVAS 3 12V power calbe 1 RAVAS 4 Hydraulic block 1 RAVAS 5 Flow adjustment valve protection cap 1 RAVAS 6 Sensor cable 1 RAVAS 7 Oil pressure sensor 1 RAVAS 8 Electric valve 1 RAVAS 9 Control cable plug 1 RAVAS 10 Plug 2 RAVAS 11 Thread adaptor G3 8 G3 4 2 NPTF 2 RAVAS USA only 12 Elbow coupling G3 8 G3 4 2 Material handling dealer 13 Washer 2 Material handling dealer 14 Hexagonal bolt 2 Material handling dealer 15 Hydraulic hose or pipe pressu
13. heir lowest position and make the hydraulic system pressure free by tilting the mast forwards Be sure the chain is slack Option 2 Lift the forks and position them on top of a supporting surface Make the hydraulic system pressure free by lowering the lifting cylinder into its lowest position Be sure the chain is slack l INSTALLATION MANUAL RCS PLUS 9 5 5 The condition of mechanical components of the forklift truck After installation of the RCS PLUS svstem on the forklift truck the truck is part of the weighing svstem In particular the mechanical parts of the forklift truck such as the mast mast roles and bearings will influence the accuracv of the weightings For this reason it is important that these components are in good condition no local wear in the mast of the fork lift truck clean the system good lubrication of the mast and chains regular maintenance so that the condition of the system is constant when lifting and decreasing the forks no whistling and cracking sounds from the mast 909 1 1 r H D LI OK L 6 M1 LH fi l u 10 40 15 F 105
14. n of mechanical components of the forklift truck 10 6 Installation 11 6 1 Connecting the threaded joints to the hydraulic block 11 6 2 Installing the hydraulic block 11 6 3 Installing the T piece 12 6 4 Short hydraulic line from the T piece to the inlet of the hydraulic block 13 6 5 Hydraulic line from the outlet of the hydraulic block to the return line of the truck 14 6 6 Position of the indicator 15 6 7 Installing the indicator 15 6 8 Connecting the sensor cable 16 6 9 Connecting the cables for the electric valve and sensor 17 6 10 Connecting the power supply cable 17 6 11 Connecting the system wires 18 6 12 Removing possible air out of the hydraulic system 19 6 13 Adjusting the position of the flow adjustment valve 19 6 14 Checking if the system functions correctly 20 7 Calibration 22 7 1 Tuning the lowering speed of the forks 22 7 2 Marking the reference height 23 7 3 Preparing for calibration 24 7 4 Working temperature of the forklift truck 25 7 5 Zero calibration 26 7 6 Span calibration 28 8 Parameter settings 31 8 1 Entering the parameter menu 31 8 2 Changing the parameters 32 8 3 Leaving the parameter menu and saving changes 35 8 4 Default parameter settings 36 9 Attachments 37 INSTALLATION MANUAL RCS PLUS 3 1 Introduction This manual describes the assembly of the RCS PLUS Read this manual carefully The installer must be informed of the contents of this manual Follow the contents of the manual preciselv Al
15. re side 1 Material handling dealer 16 T piece 1 Material handling dealer 17 Hydraulic hose or pipe 1 Material handling dealer 18 Hydraulic hose or pipe return side 1 Material handling dealer 19 Netfilter 1 RAVAS 20 DC DC power converter 1 RAVAS Not needed when the indicator is supplied with an integrated 3A power converter or regulator If so the label CONVERTER INSIDE or REGULATOR INSIDE must be sticked onto the indicator and power cable If needed they parts 19 and 20 can be ordered additionally at RAVAS recommended INSTALLATION MANUAL RCS PLUS 8 5 Before the installation Before vou start with the installation check the forklift truck on the following points 5 1 Capacity of the forklift truck The RCS PLUS can be installed on forklift trucks with a capacity of maximum 99 ton 5 2 Maximum pressure in the hydraulic system The RCS PLUS will operate optimally at an oil pressure up to 350 bar 5 3 Battery voltage of the forklift truck The most common voltages for forklift trucks are 12 24 48 and 80 VDC The RCS PLUS operates on 12 VDC In cases where the battery voltage is greater than 12 VDC the system requires a DC DC power converter with an output voltage of 12 VDC 5 4 Making the system pressure free Before installation of the RCS PLUS the hydraulic system of the fork lift truck must be pressure free There are two ways to do this Option 1 Place the forks on the ground in t
16. wavs do things in the correct order This manual should be kept in a drv and safe place In case of damage or loss the user mav request a new copv of the manual from RAVAS 2 Warnings amp safety measures g When installing the RCS PLUS please observe carefully the instructions and guidelines contained in this manual Always perform each step in sequence If any of the instructions are not clear please contact RAVAS READ CAREFULLV The installation of the RCS PLUS should oniv be performed bv an acknowledged electro and hvdraulic technical installer Possible failures to the equipment must be communicated to vour installer The equipment should be checked annuallv bv vour installer ATTENTION Should vou have anv further questions after reading this manual please contact us at RAVAS EUROPE B V Toepadweg 7 Postbus 2023 5300 CA Zaltbommel Nederland Phone 431 0 418 515220 Fax 31 0 418 515320 Internet www ravas com Email info ravas com INSTALLATION MANUAL RCS PLUS 4 3 Overview of components The RCS PLUS weighing system consists of two main components 1 Indicator 2 Hydraulic block The hvdraulic block has been connected on the hvdraulic svstem of the forklift truck The indicator the control panel of the svstem for the driver operates on 12 Volt DC supplv connected on the batterv of the truck The illustation below shows the components in the circuit ltis advised that the installation of th
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