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MotoCrane RADICAL Operation Manual

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MotoCrane RADICAL Operation Manual v1.2
AUGUST 2022

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Summary of Contents for MotoCrane RADICAL

  • Page 1 MotoCrane RADICAL Operation Manual v1.2 AUGUST 2022...

  • Page 3: Safety Signal Words

    RADICAL. If there are any questions, please contact MotoCrane Support at support@motocrane.com. Keep this Operation Manual near your RADICAL for future reference. Safety Signal Words This manual and the safety labels attached to this equipment utilize signal words that signify safety hazards with different levels of severity. The words are preceded by a triangle signifying that these are safety related.

  • Page 4: Table Of Contents

    Front + Middle Boom Rear Boom + Fairing RADICAL Isolator Setting up RADICAL Setup Process Motor Vehicle Requirements RADICAL Base Speedrail mounting dimensions RADICAL Setup “at a glance” RADICAL Base Setup RADICAL Fulcrum Setup RADICAL Boom + Isolator Setup Attaching Payload & Counterweight...
  • Page 5 Range of Motion Limit Switches (Lift Axis only) System Warnings, Errors, Diagnostics Known Hazards Pre-Flight Checklist Transporting and Traveling With RADICAL Troubleshooting and Maintenance Troubleshooting Maintenance Firmware Update Necessary Items Procedure Environmental Specifications Specifications Revision History...

  • Page 6: Before The First Use

    Before the First Use Do the following before using RADICAL for the first time: 1. Read this Operation Manual 2. Read the Warranty in the Terms of Sale 3. Watch any Video Tutorials at https://motocrane.com/knowledge-base 4. Recommended: Attend MotoCrane Training for in-person demonstration...

  • Page 7: Important Product And Safety Instructions

    IMPORTANT PRODUCT AND SAFETY INSTRUCTIONS Safety MotoCrane RADICAL is not a toy and can cause serious injury, death or damage if not used properly. You must exercise caution during use of the RADICAL to ensure a safe filming environment for everyone. This Operation Manual describes safe operation and should be read in conjunction with the online training videos or additional in-person training.

  • Page 8: Disclaimer And Limitations Of Liability

    You agree that you are responsible for your own conduct and any content created while using RADICAL, and for any consequence thereof. You agree to use this product only for purposes that are proper and in accordance with local laws, regulations or other legal requirements.

  • Page 9: System Overview

    System Overview MotoCrane RADICAL...

  • Page 10: Modules

    Modules Power Supply Unit (PSU)

  • Page 11: Radical Base

    RADICAL Base...

  • Page 12: Radical Fulcrum

    RADICAL Fulcrum Base + Fulcrum Legs...

  • Page 13: Front + Middle Boom

    Front + Middle Boom Rear Boom + Fairing...

  • Page 14: Radical Isolator

    RADICAL Isolator...

  • Page 15: Setting Up Radical

    Minimum Width: 30 inches (762mm) Minimum Length: 45 inches (1143mm) The use of RADICAL on any vehicle not meeting the required criteria may cause serious injury, death or damage. Operator is responsible for ensuring all rigging meets the requirements of the shoot...

  • Page 16: Radical Base Speedrail Mounting Dimensions

    RADICAL Base Speedrail mounting dimensions MotoCrane RADICAL is designed for compatibility with steel 1-½ IPS pipe with an outer diameter of 1.9” (48.3mm) and Schedule 40 wall thickness (.145” or 3.7mm)- often called “Scaff Tube” or “Steel Speedrail”. The RADICAL Base Legs are equipped as standard with Speedrail clamps that may accommodate rail sizes between 48-51mm.

  • Page 17: Radical Setup "At A Glance

    RADICAL Setup “at a glance” RADICAL comes in modules that can be set up piece-by-piece: 1. Provide Speedrail mounting for RADICAL via SSG Kit or custom rigging. 2. Place the RADICAL Base on Speedrail and torque the Speedrail Clamps. 3. Add the RADICAL Fulcrum and torque M12 Bolts.

  • Page 18: Radical Base Setup

    NOTE: MAIN Cable routing can be adjusted 90º by installing “A” Base Legs in the “B” locations on the RADICAL Base, and vice-versa (“B” Base Legs in the “A” location on the RADICAL Base). 3. Prepare the RADICAL Base by opening the 4 Speedrail clamps, securing the moving clamp pieces in the open position using bungee cords: 4.

  • Page 19: Radical Fulcrum Setup

    Base to the Fulcrum. Identify the “Fulcrum Front” and “Fulcrum Rear” sides of the Base and Fulcrum. See illustration below: Make sure the safety pin (Labeled “Remove Before Flight”) is installed in the RADICAL Fulcrum before attempting to lift and mount it to the RADICAL Base.
  • Page 20 4. With a partner, hoist the RADICAL Fulcrum onto the RADICAL Base Pedestal. Slide the Fulcrum if necessary to locate the bolt holes. Install the Fulcrum to the RADICAL Base using M12 Split lock washer and M12 bolts. Applying appropriate torque to the...
  • Page 21 5. Slide the RADICAL Base + Fulcrum so that the Pedestal is centered side-to-side. 6. Tighten the clamps by applying adequate torque to M12 wing nut to safely secure the Speedrail within the clamp Make sure the safety pin (Labeled “Remove Before Flight”) is removed from the RADICAL...

  • Page 22: Radical Boom + Isolator Setup

    3. Install the x6 M12 fasteners into the mounting holes with adequate torque to safely secure the Rear Boom to the fulcrum. Do not hang on RADICAL. Only apply force on Lock knobs, spanners, and boom tools in a rotational direction. Hanging on RADICAL can cause damage.
  • Page 23 6. Install the Fairing over the x3 M12 mounting studs so that the head of the studs are seated firmly within the x3 slots of the fairing. 7. Tighten the mounting studs with adequate torque to safely secure the Fairing 8.
  • Page 24 Isolator to the Front Boom IF YOU ARE INSTALLING THE HEAVYLIFT KIT, COMPLETE HEAVYLIFT SETUP AS DESCRIBED WITHIN THE HEAVYLIFT OPERATION MANUAL (FOUND ON THE MOTOCRANE KNOWLEDGE BASE) BEFORE PROCEEDING.

  • Page 25: Attaching Payload & Counterweight

    CW and secure the CW Preload with the CW Lock Knobs. Maximum allowable Counterweight Pre-load without payload attached to the RADICAL Isolator is 100lbs/45.5kg! 12. Remove the x4 M6 Bolts from the RADICAL Isolator Head Adapter, and remove it.

  • Page 26: Radical Isolator Tuning

    14. Mount the Payload (35lbs MAX unless using Heavylift Upgrade Kit) onto the RADICAL Isolator so that the Head Adapter can be fastened to the Isolator using the x4 M6 Fasteners. Install Safety Pin.
  • Page 27 ● If the head does not reach the neutral hanging position, the damping should be decreased (it is too hard/stiff) ● If the head swings past the neutral hanging position, the damping should be increased (it is too loose/soft). ● If the head reaches the neutral hanging position and does not swing past, the damping is correct.

  • Page 28: Motocrane Power Supply Unit (Psu) Setup

    MotoCrane Power Supply Unit (PSU) Setup 1. Prepare the 48V power source by confirming that it is terminated with the mating Gray Anderson SB50 Connector. DOUBLE CHECK PROPER POLARITY! See 48V Power Guide [LINK] 2. With the PSU System (SYS) Power Switch in the “OFF” position, connect the 48V power source to the Main Power Input cable.
  • Page 29 Power Input cable. Connect the ACC Power Input cable to the ACC power in (PWR IN). 4. Connect the MotoCrane Controller Cable to the COM port on the PSU, then to the COM port on the MotoCrane Controller. Make sure the Controller has the DISARM/E-Stop engaged (pressed down).
  • Page 30 6. Connect the shorter MAIN Cable from the MAIN Port on the RADICAL Base to the MAIN Port on the Fulcrum. 7. If supplying accessory power, connect the appropriate ACC Power Adapter cable from the ACC Port on the RADICAL Base, to the appropriate port on the...
  • Page 31 8. The MotoCrane PSU MAIN and ACC Power Switches can now be turned on.

  • Page 32: Command Console Setup

    NOTE: Carefully read through the COMMAND Console Operation Manual (available at www.motocrane.com/knowledge-base) for a complete understanding of all Controller features, menus and submenus. Serious injury and/or death can occur from irresponsible use of RADICAL. Always start with slow, controlled operation of RADICAL before attempting arm moves at speed.

  • Page 33: Operation And Tuning

    ACC COM has 6 available conductors, and can be used for signal connections such as controlling a stabilized head like the Shotover G1 via hardwired connection, instead of wirelessly. Inputs for ACC COM / PWR on the RADICAL PSU (above) and outputs on the RADICAL Base(below)

  • Page 34: Control Modes

    Control Modes RADICAL can be operated in several different modes of operation for both the Swing and Lift Axis. These modes of operation are described below, with specific notes listed where differences between the Swing and Lift axis exist. SETUP Mode Typically used when the modules are unloaded, without booms or payload, or for a bench test.

  • Page 35: Ins Mode (Lift Axis Only)

    99% of applications. INS Mode (Lift Axis Only) Recommended default mode for the Lift Axis on RADICAL units equipped with the INS 2 upgrade. Full range of motion absolute Limits are available in this mode. In INS mode, the control command from the user is translated into a desired change in angular position of the Axis (the “target”...

  • Page 36: Relative Limits

    Limits Relative Limits Relative Limits are used in STANDARD mode. Relative means that the Limit is relative to the absolute encoder on the respective module (Base or Fulcrum). For example, a relative Lower Limit of -12 degrees on the Lift Axis means that the relative angle between the Fulcrum and the Base will not exceed -12 degrees.

  • Page 37: System Protections

    In order to protect against circuit board failures and over-current/over-temperature related problems, RADICAL has a stall detection mechanism that cuts off the flow of power to the motor if the level of current has been too high for too long. It is a measure of intensity, and has been tested to ensure it cuts off power before the stall causes a risk to the system.

  • Page 38: Range Of Motion Limit Switches (Lift Axis Only)

    Limits. System Warnings, Errors, Diagnostics RADICAL, just like other MotoCrane products, has a full suite of system monitoring metrics, in addition to Warnings and Errors, which notify the operator in the event that something requires attention. See the “Troubleshooting and Maintenance” section of this manual for...

  • Page 39: Known Hazards

    Known Hazards The following list represents a list of known hazards that exist when operating RADICAL. This is not exhaustive, but represents some common hazards to watch out for. Your vehicle. Set limits and familiarize yourself with the acceleration and ▪...

  • Page 40: Pre-Flight Checklist

    Pre-Flight Checklist Before taking RADICAL on the road, go through this pre-flight checklist. Pre-Flight Checklist Action Check Base leg clamps Torqued Fasteners around base legs Torqued Fasteners around fulcrum legs Torqued X-brace fasteners Torqued Fulcrum Safety Pin (“Remove Before Flight”)

  • Page 41: Transporting And Traveling With Radical

    (level, and aligned longitudinally with the car.) 3. With the DISARM/E-stop button still released, adjust SPEED to “0” for both axes. This is so that any accidental joystick inputs will not cause RADICAL to move during rigging.

  • Page 42: Troubleshooting And Maintenance

    Troubleshooting and Maintenance Troubleshooting Please use the RADICAL Troubleshooting Guide for field diagnosis of any issues. The latest version can be found at www.motocrane.com/knowledge-base. Maintenance RADICAL needs maintenance to keep it running smoothly. This includes cleaning after use and lubricating or replacing moving elements. Please see the table below or contact support@motocrane.com...
  • Page 43 Required grease: Base Type: Lithium Group No: Grade 2 Over-lubrication can result in internal seal failure and may cause permanent equipment damage. We recommend contacting support@motocrane.com to confirm that your unit needs re-lubrication before proceeding.

  • Page 44: Firmware Update

    STM32CubeProgrammer tool from the Knowledge Base. 2. Set up RADICAL as usual, but keep the System Power turned OFF. Note - the booms do not need to be installed for this. 3. Remove the USB cover from the RADICAL Cortex module using a 2mm hex key.
  • Page 45 5. Gently hold the small push-button next to the USB port (for example, by using the same 2mm hex key) while someone turns ON the SYSTEM POWER on the RADICAL PSU. The button must be pressed BEFORE the SYSTEM POWER is turned ON. The small-push button may be released after the COMMAND Console boots up (usually takes around 4-5 seconds).
  • Page 46 7. Click on “Connect”. 8. Select “Erasing & Programming”...
  • Page 47 9. Select all sectors by clicking on the check box shown below 10. Click on “Erase selected sectors” and wait for the procedure to complete successfully (usually less than one minute)
  • Page 48 11. Click on “Browse” and select the CORTEX firmware file that you downloaded or were provided 12. Click on “Start Programming” (note that the “Verify programming” and “Run after programming” check-boxes can be checked or unchecked - it does not matter, but “skip flash erase before programming”...
  • Page 49 13. Confirm the update was successful. 14. Power cycle the system for new firmware to load properly and confirm there are no active errors. 15. Replace the USB cover on the RADICAL Cortex.

  • Page 50: Environmental Specifications

    Exterior RADICAL modules are weather resistant. The Controller and Power Supply Unit go inside the vehicle and are not weather resistant. After using RADICAL in wet or dusty conditions, wipe all components down with a soft dry cloth. Do not spray any cleaning liquids inside components of RADICAL that are not water resistant.

  • Page 51: Specifications

    Max Controlled Speeds: <6 sec 360º Swing, <2sec -35 to +35º Lift Weather: IP65 (Can be sprayed with low pressure water from all directions) Electrical Control: Wired CAN-BUS control via MotoCrane COMMAND Console PSU Main Power Input: 48VDC (45V-60VDC MAX), 50A Peak (3kW PEAK) PSU Accessory Power Input: 5V-60VDC, 20A MAX...

  • Page 52: Revision History

    MotoCrane Technical Support support@motocrane.com This content is subject to change. Download the latest version from: www.motocrane.com/knowledge-base If you have any questions about this document, please contact MotoCrane, LLC by sending an email to contact@motocrane.com. ©2022 MotoCrane, LLC. All rights reserved.

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