Cattron MKU OCU User manual

A
MKU OCU
User Manual

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MKU OCU
User Manual
Revision History
VERSION
DATE
NOTES
1.0
6/20/2019
Initial Release
Any information furnished by Cattron™ and its agents is believed to be accurate and reliable. All specifications are subject to change without notice.
Responsibility for the use and application of Cattronproductsrestswith the end user since Cattronand its agentscannot be aware of all potential
uses.Cattronmakesnowarrantiesastonon-infringementnorastothefitness, merchantability,orsustainabilityofanyCattronproductsforany
specificorgeneraluses.CattronHoldings,Inc.,oranyofitsaffiliatesoragentsshallnotbeliableforincidental or consequentialdamagesofany
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 trademarks of Cattron Holdings, Inc. Other marks may be the property of third parties. Nothing
hereinprovidesalicenseunderanyCattronoranythirdpartyintellectualpropertyright.

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Contents
1. Important Notes...................................................................................................................................................5
2. Warnings and Cautions.......................................................................................................................................6
3. System Description .............................................................................................................................................9
4. General............................................................................................................................................................. 10
4.1 Radio Transmission................................................................................................................................. 10
4.1.1 Continuous Transmission.................................................................................................................... 10
4.1.2 Radio Interference ............................................................................................................................... 10
4.2 Telegram Security.................................................................................................................................... 10
4.2.1 Frame Type.......................................................................................................................................... 10
4.2.2 System Address................................................................................................................................... 10
4.2.3 CRC..................................................................................................................................................... 10
4.2.4 Frame Counter..................................................................................................................................... 11
4.3 System Parameters ................................................................................................................................. 11
5. Operator Control Unit (OCU)............................................................................................................................ 12
5.1 General Information................................................................................................................................. 14
6. Preparing the OCU for Operation..................................................................................................................... 16
6.1 Changing TransKeys............................................................................................................................... 16
6.2 Controls and Indicators............................................................................................................................ 16
7. OCU Operation................................................................................................................................................. 18
7.1 OCU Battery Pack ................................................................................................................................... 18
7.2 Changing the Battery Pack...................................................................................................................... 18
7.3 Charging the Battery Pack....................................................................................................................... 18
7.4 Conditioning / Charger Use ..................................................................................................................... 19
7.5 Trickle Charger Use................................................................................................................................. 20
7.6 Alkaline Battery Adapter.......................................................................................................................... 21
8. Operating the OCU........................................................................................................................................... 22
8.1 If the Stop switch verification at Startup is enabled................................................................................. 22
8.2 If the Stop switch verification at Startup is disabled ................................................................................ 23
9. Maintenance Instructions ................................................................................................................................. 24
9.1 Preventative Maintenance....................................................................................................................... 24
9.2 Cleaning the OCU.................................................................................................................................... 24
9.3 Functional Check..................................................................................................................................... 24
10. Changing the RF Channel............................................................................................................................ 25
11. RF Channel Change Option ......................................................................................................................... 26

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11.1 Working Principle..................................................................................................................................... 26
11.2 Activating Programming Mode ................................................................................................................ 27
12. CE Declaration of Conformity ....................................................................................................................... 32
Appendix I: Spare Parts and Accessories............................................................................................................... 33
Appendix II: Technical Data..................................................................................................................................... 34
OCU Technical Specifications ............................................................................................................................. 34
Appendix III: System Configurations ....................................................................................................................... 35
MKU System Identifier ......................................................................................................................................... 35
MKU System Configurations................................................................................................................................ 35
Appendix IV: System Fault / Status Messages ....................................................................................................... 40
OCU Fault / Status Messages ............................................................................................................................. 40
MCU Fault / Status Messages ............................................................................................................................. 40
Appendix V: RF Compliance and Operating Frequency Selection ......................................................................... 41

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1. Important Notes
Information to the User regarding FCC Compliance:
Changes or modifications not expressly approved by the manufacturer could void the user's authority to operate
the equipment.
This Class A digital apparatus complies with Industry-Canada ICES-003 standards.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this
device may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation.
Note: This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference. This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause
harmful interference, in which case the user will be required to correct the interference at their own
expense.
This manual is Confidential and Proprietary to Cattron. The entire document including any or all of the information
contained therein is not to be reproduced, disclosed, or used in whole or in part for any purpose without prior
written authorization from Cattron.

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2. Warnings and Cautions
WARNING
More than one remote control system may be used at, around, or nearby your operating facility.
Therefore, before inserting a TransKey into an OCU, you must insure the correct coded TransKey
is selected for the desired equipment to be operated.
If the wrong TransKey is inserted into an OCU, 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 a horn or lamp and observing that the respective function on the
targeted crane or machine responds.
Failure to implement the above may result in serious injury or death to personnel and damage to
equipment.
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
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.

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CAUTION
Cattron MKU battery conditioners and external charging units are designed for use with Cattron Ni-
Cad battery packs only.
Battery packs must be removed or disconnected from battery conditioners/external charging units
within 48 hours of achieving the fully charged state.
Failure to comply with these CAUTIONs may result in equipment and/or battery damage and will
void our warranty.

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3. System Description
A Cattron Portable Remote Control (PRC) system offers the safety and dependability required for industrial
control applications such as overhead cranes, conveyors, machines, etc.
A remote control system enables an operator to be in the safest and most efficient position for each and every
operation, thereby reducing accidents with associated injury or material damage and simultaneously boosting
efficiency and productivity.
Each system typically includes one Operator Control Unit (OCU) and one Machine Control Unit (MCU), but other
combinations of OCUs and MCUs are possible.
Additionally, different types of MCUs are available and can be paired with the OCU. The MCU types can be any of
the CattronControl range, including the CT24-09, CT24-17 Relay MCUs, the CCM12 CANopen, the J1939 MCU
and the MMCU4 which can be configured with other BUS-based interfaces such as Ethernet/IP, PROFINET, etc.,
plus relays and Analog and Digital inputs and outputs. Talkback (optional) to LEDs on the OCU can be made from
either the CCM12 or MMCU4 MCUs.
Basically, the OCU transmits secure data to the MCU where it is decoded and drives the machine interface
(relays, etc.); hence the machine is under the direct control of the OCU.
The OCU is supplied with both Standard System Packages and also with Custom Engineered Systems. This
provides a great deal of flexibility to make the solution fit exactly the client’s needs.
A wide range of optional features are also available for CattronControl systems, including Infra-Red and RF Start-
up and range control options, Multi User control options, etc. More details are available on request.

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4. General
With an OCU and a matching MCU, a machine such as a crane or vehicle can be remotely radio controlled,
avoiding the need for a wired connection between the human interface and the controlled device. A number of
different control elements are integrated into the OCU housing so that commands to the device are securely
encoded into a radio transmission. The MCU is then able to receive this transmission, securely decode these
commands and provide suitable interfaces to drive the machine.
4.1 Radio Transmission
The transmission between the OCU and MCU is performed by means of radio communication. With regard to the
actual radio frequency that is used, there are several radio frequency bands available.
A specific RF frequency band and channel will often have been selected prior to delivery of the system.
Depending on the frequency band, a certain number of RF channels are available.
The OCU and MCU must operate on the same RF channel in order to be able to communicate.
4.1.1 Continuous Transmission
Typically, transmission is continuous and the MCU uses this as part of the information required to maintain the
safety relays in an active state. If the MCU does not receive a valid telegram in this mode for a certain period of
time (defined as PNH-Time), then it automatically turns off; i.e., safety relays and command relays open.
Depending on the application, the PNH-Time varies from 0.5 s to 2.0 s.
In order to ensure optimum communication between the OCU and the MCU, the OCU should ideally be operated
with line-of-sight transmission to the MCU antenna at all times. Avoid total shielding of the signal path by metallic
and other solid obstructions.
In some cases, the MCU may be configured to operate safely in the absence of an RF signal, much as a safety
PLC will do. Such applications are strictly defined.
4.1.2 Radio Interference
Signals from other RF-emitting sources might interfere with the radio communication between the OCU and MCU.
If the radio link is affected by these sources, changing the RF channel or even the RF band might be necessary.
4.2 Telegram Security
The transmitted telegram contains several security features, as follows:
4.2.1 Frame Type
Each message has an 8 bit message type identifier that is unique to the equipment in use.
4.2.2 System Address
Your remote control system uses a 24 bit addressing scheme, where each OCU/MCU pair shares a common,
unique system address. This system address is contained in every telegram sent by the OCU and is checked by
the MCU every time an RF signal is received. The MCU processes a command only when the address in the
telegram and the address stored in the MCU match. This is a safety measure to ensure that the MCU will act only
upon its assigned OCU.
4.2.3 CRC
The telegram is checked for integrity by the use of a 16 bit CRC. Frames containing a mismatched CRC will be
rejected.

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4.2.4 Frame Counter
Each message has an 8 bit embedded frame counter that changes on every data frame. This prevents frozen
data and data frame hacking.
4.3 System Parameters
The system parameters, including the system address and the selected RF channel, are set by programming the
TransKey. The TransKey is a removable radio frequency identification device (RFID) located inside the OCU and
MCU. It is programmed by the manufacturer.
Note: Please refer to the separate 'Configuration Data' documents for the specific system parameter settings
for your system.

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5. Operator Control Unit (OCU)
The OCU is a lightweight, palm-sized, extremely rugged customizable controller for use with any CattronControl
series MCU.
Each OCU is designed to meet a specific control application. Two standard OCU options are available: one with a
toggle select switch on the end cap and one without this switch.
Each pushbutton may have its specific control function identified from a sheet of self-adhesive labels that is
provided for this purpose.
Referring to Figure 1, advanced operational security and configurability are made possible by the use of a
removable RFID 'TransKey' which, when installed in the OCU, defines and enables the appropriate operating
parameters such as frequency and address. A label with the ID address is affixed to each TransKey.
Figure 1: OCU removable TransKey
Note: The OCU and MCU TransKeys must not be swapped. The OCU TransKey is black. The MCU
TransKey is yellow. Swapping TransKeys will result in OCU/MCU fault indications and the system will
not go into operation.
Referring to Figure 2, the keypad unit and electronics are contained in an IP65-rated aluminum housing which has
tough, protective rubber end-caps for switch protection and high impact resistance.
The TransKey is placed into a slot within the confines of the rubber ‘bumper’ that surrounds the top end-cap.
Separate ON/OFF and STOP switches are located next to the TransKey.
A sealed elastomer keypad on the OCU front face contains large pushbuttons (function keys), which are coated
with clear epoxy for additional durability. Each pushbutton is labeled for a specific function. Pushbuttons are two-
step (i.e., dual pressure) operation.
Both steps of each individual pushbutton can operate different functions. Typically the first step controls a
direction or function and the second step controls a speed increment. However, it is possible with a step-less
drive to use the second step as accelerate, the first step as hold speed and the released state as decelerate.
Any function is active only as long as the respective pushbutton is pressed. When the pushbutton is released, the
function stops automatically.
The ‘STATUS’ LED (located in the center of the row of LED lights) indicates the operational mode and any error
messages.
1. MKU Controller
2. Removable
TransKey

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The LEDs located on either side of the ‘STATUS’ LED indicate either selection information or optional Talkback
information.
Figure 2: MKU OCU
MKU dual pressure keypad OCUs normally send ON/OFF commands that activate programmed functions at the
target Cattron MCU.
All MKU OCUs are powered by a rechargeable Ni-Cad or disposable 3-volt alkaline battery packs.
In normal operation, the ‘STATUS’ LED flashes green with each function command message and a beep is
sounded when a key is pressed.
When the battery voltage becomes low, the ‘STATUS’ LED flashes red and a beep sounds every ten seconds to
alert the operator that the battery pack needs to be replaced or re-charged.
The ‘STATUS’ LED can illuminate in a series of red blinking sequences to indicate a specific OCU fault, as
discussed in Appendix IV.
A belt loop strap is provided with all Cattron MKU OCUs. This is quickly and simply installed to a ‘D’-ring located
on the curved underside of the controller. Referring to Figure 3, an optional shoulder-carrying strap is available on
request.
1. STATUS LED
2. ON/OFF Switch
3. TransKey
4. Stop Switch
5. Pushbutton
(function key)

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Figure 3: Optional shoulder-carrying strap
5.1 General Information
The MKU OCU is globally compliant when supplied with an appropriate radio module –additional certifications
may be required for some regions; details are available on request. It has been designed with the latest
generation dual-channel electronics and exceeds the Safety Related Systems requirements for ISO13849
Category 3 PLd.
MKU OCUs are equipped with an internal antenna and the typical operating range is in excess of 300 ft (92 m),
for uninterrupted line-of-sight operation. It should be understood that operating range varies with environmental
conditions. Should the OCU go out of operating range, all motion of the crane or controlled machine will cease.
MKU OCUs have been approved to comply with the RF standards applicable to the region or country of use.
In North America, the MKU is compliant with both FCC Part 15 and Industry Canada RSS-210 standards. No
United States of America FCC or Industry Canada license is required for operation of FCC Part 15 or RSS-210
OCUs. These non-licensed OCUs are approved for use in the 902-928 MHz frequency band. See Appendix V for
additional details.
Other frequency bands are available and may require an operating license.

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In Europe and other regions, the operating frequency will typically be in the 433-434 MHz license exempt band;
again, other licensed and unlicensed frequency bands are available.
Battery packs are easily and quickly replaced without the need for tools by turning two knurled thumbscrews and
removing the battery cover-plate located within the confines of the bottom end-cap. The battery pack makes
positive contact without snaps or plugs and has no wires to break –simply drop it in and replace the battery
cover-plate.
A battery charger, battery conditioner, ‘AAA’ size battery adapter, and an external battery charging unit are
available on request. Refer to the accessories/consumable items in Appendix I of this manual for details and part
numbers.
In normal operation, a ‘STATUS’ LED (located centrally) flashes green at 1.25 second intervals. When the battery
voltage becomes low, the ‘STATUS’ LED flashes red at one second intervals to alert the operator that the battery
pack needs to be replaced or re-charged. The ‘STATUS’ LED will also illuminate in a series of red blinking
sequences to indicate a specific OCU fault –refer to Appendix IV for a table of OCU Fault/Status Messages.
In some remote control applications, four function LEDs located to the right and left of the ‘STATUS’ LED may be
configured to indicate when an OCU function command has been activated at the target machine, or to provide
status indication of the machine state, via Talkback.

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6. Preparing the OCU for Operation
6.1 Changing TransKeys
WARNING
More than one remote control system may be used at, around, or nearby your operating facility.
Therefore, before inserting a TransKey into an OCU, you must insure the correct coded TransKey
is selected for the desired equipment to be operated.
If the wrong TransKey is inserted into an OCU, 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.
Due to the flexible TransKey concept, it is not uncommon for one OCU to be used to control multiple cranes or
machines. Each crane or machine will be provided with a unique pair of TransKeys having the same address.
This pair of TransKeys must be inserted into their respective OCU and MCU locations before carrying out remote
control operations.
A permanent TransKey retainer is also supplied with your OCU. Installing this item as shown in Figure 4 will
securely retain the TransKey within the OCU top end-cap.
Cattron strongly emphasizes that installing the permanent TransKey retainer is entirely at the operator’s
discretion. An operator should be aware that securely retaining the TransKey within the OCU top end-cap will not
prevent unauthorized operation of the controller or its target machinery.
Therefore, when not in authorized use, Cattron recommends that an OCU having a permanently retained
TransKey be held in a suitable cabinet under lock and key.
1. Permanent TransKey
retainer (Part # 3BRA-
7598-A001)
2. Retaining screws (Part
# 03C-0142)
3. TransKey
4. Removable TransKey
retainer (Part # 3BRA-
7598-A101)
5. TransKey
6.2 Controls and
Figure 4: Permanent and removable TransKey retainers

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Indicators
Referring to Figure 5, the OCU is a lightweight hand-held unit with twelve pushbuttons (function keys) on a single
keypad, plus a rotary ON/OFF switch and a push/pull STOP switch.
The OCU may be hand carried, held by a belt loop strap or worn with an optional shoulder-carrying strap. The
OCU is powered by a disposable (alkaline) or rechargeable (Ni-Cad) battery pack.
Figure 5: Operator controls and indicators
Note: An optional toggle switch may be fitted between the ON/OFF switch and STOP switch.
With the correct color-coded TransKey inserted into the OCU, setting both the STOP and ON/OFF switches to
their respective ‘OFF’ and ‘ON’ positions will apply power to the OCU.
Immediately after power has been applied to the OCU, if a good battery is installed, the ‘STATUS’ LED should
momentarily illuminate red, followed by orange, then ‘flash’ green. Two short beeps will also be heard. In addition,
any time a pushbutton (function key) is pressed, a beep will be heard and the ‘STATUS’ LED will ‘flash’ green
during a radio transmission.
When the battery voltage becomes low, the ‘STATUS’ LED will ‘flash’ red and a beep will be heard once every ten
seconds to alert the operator to change or re-charge the battery pack.
When the ON/OFF switch is set to the ‘OFF’ position, power is removed from the OCU causing all control
functions to cease. Setting (pushing down) the red STOP switch to ‘STOP’ before setting the ON/OFF switch to
‘OFF’ immediately sends a stop command to the MCU.
Referring to Figure 5 above, all active function key (pushbutton) commands are identified using labels placed next
to each pushbutton. When a pushbutton is depressed, the OCU transmits the corresponding command (as
labeled). All pushbutton operations are momentary and must be maintained by the operator. Releasing the
pushbutton will send an ‘OFF’ command that de-energizes the corresponding output function.
1. STATUS LED
2. ON/OFF Switch
3. TransKey
4. Stop Switch
5. Pushbutton
(function key)

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7. OCU Operation
7.1 OCU Battery Pack
If using rechargeable batteries, they must be fully charged before using the remote control system for the first
time. Note that charging the battery pack can take up to three hours for a fast charger (Part # 70C-0002) and over
10 hours for a trickle charger (Part # 70C-0001).
We recommend that the battery packs be discharged completely from time to time to preserve their capacity.
7.2 Changing the Battery Pack
Referring to Figure 6, remove the battery pack as follows:
1. Lay the OCU (5) face down.
2. Release the two knurled thumbscrews (2) and withdraw the cover-plate (1).
3. Withdraw the battery pack (3) from the battery compartment (4).
Figure 6: Battery pack removal and replacement
Replace the battery pack as follows:
1. Position the battery pack (3) with the four contact strips facing down and forwards. Install the battery pack (3)
by pushing it fully inside the battery compartment (4).
2. Install the cover-plate (1) and secure it by evenly hand tightening the two knurled thumbscrews (2). Do not
over-tighten –a snug fit is all that is necessary.
7.3 Charging the Battery Pack
Note: Do not re-charge the battery pack until the OCU LED indicates ‘low battery’.
Note: A Cattron external battery charging adapter (Part # 70C-0003) will be required for battery charging or
conditioning.
A Cattron ‘Standard’ Battery Charger (Part # 70C-0001) enables a Ni-Cad battery pack to be charged within 10
hours.
A Cattron Battery Conditioner/Charger (Part # 70C-0002) is also available. For details, refer to Section 7.4 below.
1. Cover Plate
2. Knurled
Thumbscrew (2)
3. Battery Pack
4. Battery
Compartment
5. OCU

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CAUTION
Cattron MKU battery conditioners and external charging units are designed for use with Cattron Ni-
Cad battery packs only.
Battery packs must be removed or disconnected from battery conditioners/external charging units
within 48 hours of achieving the fully charged state.
Failure to comply with these CAUTIONs may result in equipment and/or battery damage and will
void our warranty.
Inserting battery into adapter and initiating charging
To charge a Ni-Cad battery pack, refer to Figure 7. Connect the Cattron battery charger to the power source by
inserting the charging jack into the external battery charging adapter socket. Drop the battery pack into the battery
charging adapter, ensuring the battery pack contacts are positioned as shown. When the Ni-Cad battery pack is
properly installed, the appropriate LED(s) on the charging unit will show the current status (refer to the appropriate
tables for the charger in use below).
Figure 7: Ni-Cad battery pack charging adapter
7.4 Conditioning / Charger Use
The Cattron Battery Conditioner/Charger (Part # 70C-0002) is available for use with Ni-Cad battery packs only.
The conditioner/charger automatically conditions the battery pack by first discharging it at 750mA for 1.5 hours
before applying a rapid charge for 1.2 hours. The unit incorporates end-of-charge detection circuitry to accurately
sense when the battery pack is fully charged. When this condition has been detected, the conditioner/charger
switches to a ‘trickle’ charge mode that keeps the battery pack fully charged and ready to use for up to 48 hours.
To prevent damage to the battery pack, it should be removed from the conditioner/charger within 48 hours of
achieving a fully charged state.
The Cattron battery conditioner/charger incorporates an LED that indicates status as follows:
•Amber Color –indicates the battery pack is being discharged.
•Red Color –indicates the battery pack is being charged at a rapid rate.
•Green Color –indicates the battery pack is fully charged and that a ‘trickle’ charge is being applied to
maintain the fully charged state. The battery pack is ready for use and should be removed from the
conditioner within 48 hours.
1. Charging jack
from battery
charger
2. Ni-Cad battery
pack only (Part
# 60C-0060N)

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The battery conditioner/charger includes a VAC adaptor that enables the unit to operate from power supply
voltages between 100 and 240 VAC @ 50/60 kHz. Referring to Figure 8, this adaptor is connected as shown.
Similarly, when connecting the battery conditioner to the external battery charging unit, refer to Figure 9 for the
appropriate connections.
Figure 8: Battery pack conditioning / charging unit –interconnection details
Figure 9: Battery pack conditioning / charging unit to adapter –interconnection details
7.5 Trickle Charger Use
The Cattron Battery Trickle Charger (Part # 70C-0001) is available for use only with Ni-Cad battery packs and a
power supply of 120V 60Hz.
1. Output jack from
VAC adapter
2. 18 VDC input
socket
3. Output to
external
charging unit
4. Battery
conditioner (Part
# 70C-0002)
5. VAC power
adapter
6. VAC outlet
1. Battery charging
adapter (Part #
70C-0003)
2. Charging jack
3. STATUS LED
4. Battery
conditioner (Part
# 70C-0002)
5. Ni-Cad battery
pack (Part #
60C-0060N)