Cattron MKU OCU User manual

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MKU OCU
User Manual

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9M02-7641-A003-EN
Version 1.0
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.