Cattron CT24 Series User manual

CT24-9, CT24-17 and
CT24-32 MCU
User Manual
9M02-7608-A001-EN

CT24 MCU
User Manual
2
9M02-7608-A001-EN
Version 2.0
Revision History
VERSION
DATE
NOTES
1.0
05/2016
Initial Release
2.0
09/2019
Rebranded to Cattron
Added CT24-9-ASO
Any information furnished by Cattron™ and its agents is believed to be accurate and reliable. All specifications are subject to change without notice.
Responsibilityfortheuseandapplication ofCattronproductsrestswiththeendusersinceCattronanditsagentscannotbeawareofallpotentialuses.
Cattron makes no warranties as to non-infringement nor as to the fitness, merchantability, or sustainability of any Cattron products for any
specificor generaluses.CattronHoldings,Inc.,oranyofitsaffiliatesoragentsshallnotbeliableforincidental or consequentialdamagesof any
kind. All Cattron products are sold pursuant to the Terms and Conditions of Sale, a copy of which will be furnished upon request. When used as a
tradename herein, Cattron means Cattron Holdings, Inc. or one or more subsidiaries of Cattron Holdings, Inc. Cattron™, corresponding logos,
and other marks are trademarks or registered trademarksofCattronHoldings,Inc.Othermarksmaybethepropertyofthirdparties.Nothingherein
providesalicenseunderanyCattronoranythirdpartyintellectualpropertyright.

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Contents
1. Introduction...................................................................................................................................................................................6
Terminology .......................................................................................................................................................6
2. Warnings and Cautions ..............................................................................................................................................................7
2.1 General Safety Information................................................................................................................................9
2.2 Intended Use....................................................................................................................................................10
2.3 Improper Use ...................................................................................................................................................10
2.4 Safety Instructions for Assembly/Disassembly ................................................................................................10
2.5 Operation of OCUs and MCUs with Identical System Address........................................................................10
3. General .......................................................................................................................................................................................11
3.1 Radio Transmission .........................................................................................................................................11
3.1.1 Continuous Transmission.............................................................................................................................11
3.1.2 Radio Interference........................................................................................................................................11
3.2 Telegram Security............................................................................................................................................11
3.2.1 Frame Type..................................................................................................................................................11
3.2.2 System Address...........................................................................................................................................11
3.2.3 CRC .............................................................................................................................................................11
3.2.4 Frame Counter.............................................................................................................................................12
3.5 System Parameters..........................................................................................................................................12
4. CT24 MCU Overview................................................................................................................................................................13
4.1 Description.......................................................................................................................................................14
4.1.1 Optional 9-36 VDC Input MCU.....................................................................................................................20
5. Installation...................................................................................................................................................................................21
5.1 General ............................................................................................................................................................21
5.2 Mounting ..........................................................................................................................................................21
5.2.1 Choosing a Mounting Location.....................................................................................................................21
5.3 Interface...........................................................................................................................................................25
5.4 Interface Wiring................................................................................................................................................25
5.5 Safety Critical Interfaces..................................................................................................................................25
5.6 Power and Control Cables Interface ................................................................................................................25
5.7 Determination of Correct Control Circuit Wire Gauge......................................................................................26
5.7.1 For High Duty Cycle Applications.................................................................................................................27
5.7.2 For Low Duty Cycle Applications .................................................................................................................27
5.8 Examples of Wire Sizing..................................................................................................................................28
5.8.1 Low Duty Application (Typical Crane)..........................................................................................................28
5.8.2 High Duty Application (Crane with Multi Select or Machine)........................................................................28
5.8.3 High Duty Maximum Current Application .....................................................................................................28

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5.9 Connection of Wires to Interface Connectors ..................................................................................................28
5.9.1 Interface Connectors....................................................................................................................................28
5.9.2 Overview ......................................................................................................................................................28
5.9.3 Spring Clamp Type Inserting a Wire............................................................................................................29
5.9.4 Spring Clamp Type Removing a Wire..........................................................................................................29
5.9.5 Terminal Specifications................................................................................................................................29
5.9.6 Ferrule Types...............................................................................................................................................29
6. MCU Connections .....................................................................................................................................................................32
6.1 CT24-9-ASO Compatibility with CT24-9............................................................................................................33
6.1 Conduit.............................................................................................................................................................36
6.2 The Controller Machine....................................................................................................................................37
6.3 Control Transformer.........................................................................................................................................37
6.4 Relay Outputs ..................................................................................................................................................37
6.5 Mainline Circuit.................................................................................................................................................37
6.6 Transfer Switch................................................................................................................................................39
6.7 Antenna............................................................................................................................................................40
7. Optional System Features........................................................................................................................................................42
7.1 OCU Automatic Turn-Off..................................................................................................................................42
7.2 Motion Enable Features...................................................................................................................................42
7.2.1 Push To Operate (PTO)...............................................................................................................................42
7.2.2 Push To Enable (PTE) .................................................................................................................................42
7.2.3 Double Jog Enable (DJE) (LRC OCUs only)................................................................................................43
7.2.4 Vigilance.......................................................................................................................................................43
7.3 IR Link..............................................................................................................................................................44
7.3.1 Feature and Benefits....................................................................................................................................44
7.3.2 Features Options..........................................................................................................................................44
7.4 RF Range Control............................................................................................................................................46
7.4.1 Feature and Benefits....................................................................................................................................46
7.4.2 Feature Options ...........................................................................................................................................47
7.4.3 Operating Modes..........................................................................................................................................47
7.4.4 Notes on the Differences between IR and RF Close Start...........................................................................48
7.5 Delayed Shutoff (LRC OCUs only)...................................................................................................................48
7.6 User Authorization............................................................................................................................................49
7.7 Multi Address Capability (MAC).......................................................................................................................49
7.7.1 REQUEST Function.....................................................................................................................................50
7.7.2 RELEASE Function......................................................................................................................................50
7.8 Sub Address Capability....................................................................................................................................50
7.8.1 T-SAC TransKeys ........................................................................................................................................50

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7.8.2 B-SAC..........................................................................................................................................................50
7.9 TDMA...............................................................................................................................................................51
7.10 Frequency Scanning........................................................................................................................................51
7.11 SymmetryLock™..............................................................................................................................................51
7.11.1 Key Value Statements .............................................................................................................................52
7.12 Multi-MCU Talkback.........................................................................................................................................52
7.13 Talkback and LCD Display Resolution.............................................................................................................52
Appendix: Error Codes.....................................................................................................................................................................53
CE Declaration of Conformity..........................................................................................................................................................54

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1. Introduction
This manual includes general information concerning the operation of the radio remote Machine Control Unit
(MCU) series CT24. The information is of a general nature and does not include system-specific data. System-
specific data is provided in the technical documentation accompanying the delivery of the system.
For information pertaining to the matching Operator Control Unit (OCU), please refer to the separate OCU user
manual.
Terminology
The following represents important acronyms and long form names used in this document:
•OCU –Operator Control Unit, historically referred to as a transmitter
•MCU –Machine Control Unit, historically referred to as a receiver
•ASO –Automatic Safety Override; in this context, a fully automatic system shutdown made possible by
the use of safety relays on motion output relays to detect a welded or closed contact when it should be
open
•N/O –SPST Normally Open, Form A
•N/C –SPDT Normally Closed, Form C (BBM)

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2. Warnings and Cautions
WARNING and CAUTION statements are strategically placed throughout all text prior to operating or
maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING),
or equipment and property (CAUTION). A WARNING and CAUTION applies each time the related step repeats.
Before starting any task, review and understand the WARNINGS or CAUTIONS included in the text. All
WARNINGS and CAUTIONS appearing in this manual are included below.
WARNING
ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL
TRACKED EQUIPMENT (I.E., CRANES) MUST HAVE A BRAKE INSTALLED.
THE REMOTE CONTROL SAFETY RELAYS MUST BE CONNECTED TO THE MAINLINE SO
THAT STOP COMMANDS WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE
EQUIPMENT BRAKE.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR
DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
WARNING
MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND, OR NEARBY
YOUR OPERATING FACILITY. THEREFORE, BEFORE INSERTING A 'TRANSKEY', YOU MUST
INSURE THE CORRECT CODED 'TRANSKEY' IS SELECTED FOR THE DESIRED EQUIPMENT
TO BE OPERATED.
IF THE WRONG 'TRANSKEY' IS INSERTED, OTHER REMOTE CONTROLLED EQUIPMENT
LOCATED AT, AROUND, OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN UNINTENDED
OPERATION OF REMOTE CONTROLLED EQUIPMENT WHICH IN TURN COULD RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
WARNING
BEFORE ATTEMPTING TO USE THE REMOTE CONTROL SYSTEM, VERIFY THE TARGET
CRANE OR MACHINE YOU WISH TO OPERATE IS UNDER THE DIRECT COMMAND OF
YOUR OCU. THIS IS ACCOMPLISHED BY OPERATING A NON-MOTION OCU FUNCTION
SUCH AS THE HORN AND OBSERVING THAT THE HORN SOUNDS ON THE TARGETED
CRANE OR MACHINE.
FAILURE TO IMPLEMENT THE ABOVE MAY RESULT IN SERIOUS INJURY OR DEATH TO
PERSONNEL AND DAMAGE TO EQUIPMENT.
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WARNING
UNLESS SPECIFIED, REMOTE CONTROL SYSTEMS ARE NOT DESIGNED TO INTERFACE
DIRECTLY TO SAFETY CRITICAL BISTABLE MAINTAINED FUNCTIONS (i.e., magnetic circuits,
vacuum circuits, grab, pump motors, fire suppression, etc.).
A PROPER INTERFACE TO SAFETY CRITICAL BISTABLE MAINTAINED FUNCTIONS SHALL
BE INSTALLED, IDEALLY USING A RELAY INTERFACE UNIT.
SHOULD CATTRON SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE
DIRECTLY WITH SAFETY CRITICAL BISTABLE MAINTAINED FUNCTIONS AT YOUR
OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY OR DEATH TO
PERSONNEL MAY RESULT.
IT MUST BE FULLY UNDERSTOOD THAT CATTRON WILL NOT BE HELD LIABLE FOR
PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE
FROM IMPROPER CONFIGURATION OF YOUR REMOTE CONTROL SYSTEM.
WARNING
THE USE OF UNAPPROVED COMPONENTS OR ACCESSORIES IN THE SYSTEMS SOLD BY
CATTRON AND ITS SUBSIDIARIES IS STRICTLY PROHIBITED. UNAPPROVED
COMPONENTS ARE DEFINED AS ANY COMPONENT NOT INSPECTED AND SOLD BY
CATTRON. THIS ALSO INCLUDES ANY COMPONENT MODIFIED FROM ITS INTENDED USE
AND/OR ANY COMPONENT EXHIBITING OBSERVABLE DAMAGE OR DEFECT.
USE OF NON-CONFORMING PARTS, ASSEMBLIES AND ACCESSORIES MAY LEAD TO
INJURY OR DEATH.
WARNING
ONLY PERSONEL TRAINED AND AUTHORIZED BY CATTRON, OR PERSONEL UNDER THE
DIRECT GUIDANCE OF CATTRON TECHNICAL STAFF AND WHILE USING THE
APROPRIATE TOOLS, ARE AUTHORIZED TO CARRY OUT BOARD LEVEL MAINTENANCE
OF THE CT24 MCU.
COMPONENT LEVEL REPAIR BY PERSONEL OTHER THAN CATTRON TECHNICAL STAFF
IS STRICTLY FORBIDDEN.
USE OF NON-CONFORMING PARTS, ASSEMBLIES AND ACCESSORIES MAY LEAD TO
INJURY OR DEATH.
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WARNING
THE REMOTE CONTROL SYSTEM YOU HAVE PURCHASED IS DESIGNED TO STOP IN A
SAFE MODE UNDER A VARIETY OF CONDITIONS. SOME EXAMPLES OF THESE
CONDITIONS ARE EXCESSIVE RADIO SIGNAL INTERFERENCE, LOSS OF BATTERY
AND/OR ELECTRICAL POWER, FAILURE OF CERTAIN COMPONENTS, OPERATION
BEYOND SIGNAL RANGE AND OTHERS. ALTHOUGH CATTRON AND ITS SUBSIDIARIES DO
NOT SPECIFY THE POSITION OF THE OPERATOR WHEN CONTROLLING THE EQUIPMENT,
WE ARE AWARE THAT SOME USERS ARE INSTRUCTED AND TRAINED BY THEIR
EMPLOYER TO RIDE THE EQUIPMENT IN A SAFE MANNER. IT IS IMPERATIVE THAT YOU
ARE PREPARED FOR AN UNPLANNED STOP OF THE EQUIPMENT AT ANY TIME AND DO
NOT PLACE YOURSELF OR OTHERS IN A POSITION WHERE THIS SITUATION MAY CAUSE
YOU TO FALL FROM THE EQUIPMENT. FAILURE TO USE CAUTION MAY LEAD TO INJURY
OR DEATH.
2.1 General Safety Information
•Persons under the influence of drugs, alcohol and/or other medicine that impairs reaction may not
assemble, disassemble, install, put into operation, repair or operate the product.
•All conversions and modifications of an installation or system must conform to the relevant safety
requirements. Only qualified, trained, authorized personnel may perform work on the equipment, in
accordance with the relevant safety requirements.
•In the event of malfunction and/or visible defects or irregularities, the product must be stopped, switched
off, and the relevant master switches also switched off.
WARNING
Observe the statutory regulations and directives applicable for the intended purpose, e.g.:
•Accident prevention regulations
•Safety rules and directives
•Standards
•Generally applicable statutory and other binding regulations for accident prevention and
environmental protection, and general safety and health requirements.
•Keep the operating manual permanently accessible at the place of product use.
•The personnel assigned to work on/with the product must have read and understood this operating
manual and the safety instructions.
•The safety instructions must, if necessary, be supplemented by the user with instructions concerning the
work organization, work sequences, qualified personnel, etc.
•All repairs made during the warranty period must be carried out by the manufacturer or appointed
authorized service center; failure to comply will invalidate the warranty.
•Only trained personnel may perform maintenance and repair on the product.
•All repairs made should be carried out in a suitably clean static-safe environment, free from contaminants
such as metal filings, water, oil, etc.
•It is the user’s responsibility to ensure that the product always operates in good condition and that all
applicable safety requirements and regulations are observed.
•Product modifications may not be carried out without the consent of the manufacturer.
•Original spare parts from the manufacturer must be used.
•Carry out periodic inspections and/or maintenance either required by law or prescribed in the user manual
within the required intervals.
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2.2 Intended Use
The product must only be used in good condition, by instructed personnel, and subject to compliance with all
applicable safety and accident prevention regulations. Use only for the intended purpose and according to the
instructions contained within this user manual.
2.3 Improper Use
Ensure compliance with equipment ratings and operate only as intended, in particular:
•Only authorized and trained personnel should open the MCU cover and install/maintain
•Ensure all supplies to the equipment are isolated before installation/maintenance
•Check that power supply voltage/frequency data is correct
•Do not misuse or exceed operating specifications
•Ensure daily and periodic maintenance routines are observed
CAUTION
Damage to the device:
The unit is rated at IP65. For environments harsher than this, use an appropriate secondary
enclosure.
Neglecting the above can result in danger for life and limb and/or cause physical damage to the
product or the environment.
2.4 Safety Instructions for Assembly/Disassembly
Only trained and qualified persons may perform installation/maintenance work.
Note: Ensure suitable transient protection devices are fitted to controlled electrical relays or valves. Ensure
correct wiring of the crane’s main contactor and the manual radio transfer switch.
•Isolate the system from the electrical power in accordance with the applicable regulations.
•Observe user-specific regulations.
•Only use suitable tools.
•Secure the installation area.
2.5 Operation of OCUs and MCUs with Identical System Address
To ensure safe operation, OCUs and MCUs are uniquely paired by way of a unique system address. This system
address will only be assigned once by the manufacturer.
CAUTION
Conflict of Addresses:
The user must ensure that the system address is used as designed and intended for a single
system.
The system address is marked on the master TransKey; the OCU and intended MCU address
must match.
In the event of a breach of this undertaking, the user is liable for any resulting damage/loss and
shall indemnify the manufacturer against all third-party liability claims.
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