Cattron North America MKU915A User Manual
Part # 68C-MKU, Edition 01/2007, Version 1.0
IMPORTANT NOTICES
US and Canadian non-licensed 900 MHz Operator Control Units (OCUs) have been factory
(software) pre-programmed to transmit data to the Machine Control Unit (MCU) until the OCU’s
power is switched ‘OFF’. This pre-programming cannot be changed by yourselves.
The 'TransKey' that accompanies your OCU and MCU has been pre-programmed with certain
system operating parameters before leaving our factory. Such 'TransKey' parameters will
include a specific address and operating frequency; however, CATTRON® strongly advises
you to check that our pre-configured address and frequency is not duplicated in other remote
control equipment located at, or around, your operating facility.
Unless customer technicians have received formal maintenance training from CATTRON
maintenance philosophy is that inoperative OCUs and MCUs be returned as complete units to
our workshops for repair. This is because systems are customized at our factory for a
particular application, thus it is highly unlikely that two systems (or the components therein) will
be the same.
Before returning a Unity product to CATTRON® for repair, the original 'TransKey' supplied with
the unit should be removed and retained for use with your spare unit.
®
, our
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 his/her own expense.
This manual is Confidential and Proprietary to CATTRON® Group International. 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 of
®
CATTRON
Group International.
This manual has been prepared by Stuart C. Banks MSTC (USA), MISTC (UK)
CATTRON
®
Group International Technical Writer/illustrator.
Part # 68C-MKU, Edition 01/2007, Version 1.0 Page 1
This page intentionally left blank
Page 2 Part # 68C-MKU, Edition 01/2007, Version 1.0
Table of Contents
1. SAFETY INSTRUCTIONS .................................................................................................5
1.1 WARNINGS and CAUTIONS ........................................................................................5
1.2 GENERAL .................................................................................................................... 7
2. PRODUCT DATA & SPECIFICATIONS ............................................................................ 9
2.1 SYSTEM FEATURES ...................................................................................................9
2.2 OPERATOR CONTROL UNIT (OCU) ...........................................................................9
2.3 MACHINE CONTROL UNIT (MCU) ............................................................................13
2.4 MKU SYSTEM SPECIFICATIONS .............................................................................. 15
2.5 MKU MODEL CONFIGURATIONS .............................................................................18
2.6 MKU to MKEZ/MKCS Cross Reference Chart .............................................................18
3 SAFETY CONSIDERATIONS ..........................................................................................19
3.1 STANDARD SAFETY & SECURITY FEATURES .......................................................19
3.2 PERMANENT OCU ‘TRANSKEY’ ............................................................................... 20
4 INSTALLATION ............................................................................................................... 21
4.1 CHOOSING A MOUNTING LOCATION ......................................................................21
4.2 WIRING CONNECTIONS ............................................................................................23
5 INTERFACE CONNECTIONS .........................................................................................25
5.1 SAFETY INTERFACE UNIT ........................................................................................ 25
5.2 THE CONTROLLED MACHINE ..................................................................................27
5.3 CONTROL TRANSFORMER ......................................................................................27
5.4 TRANSFER SWITCH .................................................................................................. 27
5.5 RELAY OUTPUTS ......................................................................................................28
5.6 MAINLINE CIRCUIT ....................................................................................................29
Part # 68C-MKU, Edition 01/2007, Version 1.0 Page 3
6 OPERATING INSTRUCTIONS ........................................................................................31
6.1 CHANGING ‘TRANSKEYS’ ........................................................................................31
6.2 CONTROLS AND INDICATORS .................................................................................31
6.3 OCU OPERATION ...................................................................................................... 32
6.4 CHANGING THE BATTERY PACK ............................................................................37
6.5 CHARGING THE BATTERY PACK ............................................................................38
6.6 CONDITIONING THE BATTERY PACK .....................................................................39
6.7 ALKALINE BATTERY ADAPTER ...............................................................................42
7 MAINTENANCE INSTRUCTIONS ..................................................................................43
7.1 PREVENTIVE MAINTENANCE ..................................................................................43
7.2 TRANSMITTER FAULT MESSAGES ......................................................................... 43
7.3 RECEIVER FAULT MESSAGES ................................................................................ 45
8 ACCESSORIES AND CONSUMABLE ITEMS ...............................................................48
8.1 ACCESSORIES/CONSUMABLE ITEMS - ILLUSTRATIONS .....................................49
APPENDIX ‘A’ – OCU CHANNEL CHANGING OPTION .......................................................55
A.1 ACTIVATING THE PROGRAMMING MODE ..............................................................55
A.2 SELECTING THE RF CHANNEL ................................................................................56
A.3 RE-ACTIVATING THE TRANSKEY RF CHANNEL ....................................................57
APPENDIX ‘B’ – INTERFACING TO SAFETY CRITICAL MAINTAINED BI-STABLE
CIRCUITS ...............................................................................................................................59
B.1 EXAMPLE CIRCUIT DIAGRAM - MAGNET ...............................................................59
B.2 EXAMPLE CIRCUIT DIAGRAM - GRAB .....................................................................60
B.3 EXAMPLE CIRCUIT DIAGRAM - VACUUM ............................................................... 61
Page 4 Part # 68C-MKU, Edition 01/2007, Version 1.0
1. SAFETY INSTRUCTIONS
1.1 WARNINGS and CAUTIONS
WARNING and CAUTION statements have been 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 will apply each time the related step is repeated. Before starting any task, the
WARNINGS or CAUTIONS included in the text for the task shall be reviewed and understood.
All WARNINGS and CAUTIONS appearing in this manual are included below.
WARNING:
ALL TRACKED EQUIPMENT (I.E. CRANES) HAVE A BRAKE INSTALLED.
THE REMOTE CONTROL OPERATE (OPR) 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.
ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND
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
UNINTENED 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 NONMOTION 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 PERSONAL INJURY OR
DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
Part # 68C-MKU, Edition 01/2007, Version 1.0 Page 5
WARNING:
UNLESS SPECIFIED, MKU PORTABLE REMOTE CONTROL SYSTEMS ARE NOT
DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE
MAINTAINED FUNCTIONS, (i.e., magnet circuits, vacuum circuits, grab, pump
motors, fire supression, etc.).
A PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE MAINTAINED
FUNCTIONS SHALL BE INSTALLED, IDEALLY USING A CATTRON® RELAY
INTERFACE UNIT, PART # RI004NE.
ALTERNATIVELY, EXAMPLE CIRCUIT DIAGRAMS ARE PROVIDED IN APPENDIX
‘B’ OF THIS MANUAL TO ENABLE YOU TO PROPERLY INTERFACE YOUR
REMOTE CONTROL SYSTEM WITH SAFETY CRITICAL BI-STABLE MAINTAINED
FUNCTIONS BEFORE OPERATIONAL USE.
SHOULD CATTRON® MKU SYSTEMS BE INADVERTENTLY CONFIGURED TO
INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE 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 PORTABLE REMOTE
CONTROL SYSTEM.
CAUTIONS:
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.
CAUTION:
CATTRON® MKU Battery Adapters are designed for use with non re-chargeable
‘AAA’ size Alkaline Batteries only. Carbon/Zinc, Lithium, or Ni-Cad Batteries are
not to be used with this adapter. Damage to batteries will occur if this adapter is
used for battery charging.
Page 6 Part # 68C-MKU, Edition 01/2007, Version 1.0
1.2 GENERAL
The following are general safety precautions that are not related to any specific procedure and
therefore do not appear elsewhere in this manual. These are general safety precautions and
instructions that people must understand and apply during many phases of operation and
maintenance to ensure personal safety and health and the protection of your company
property.
KEEP AWAY FROM LIVE CIRCUITS. Maintenance personnel must observe all safety
requirements at all times. Do not replace components or make adjustments inside the
equipment with the electrical supply turned on. Under certain conditions, danger may exist
even when the power control is in the off position due to charges retained by capacitors. To
avoid injuries, always remove power, discharge and ground a circuit before touching it.
Adhere to all lock out/tag requirements.
INTERNAL SERVICE AND/OR ADJUSTMENTS. Whenever possible, do not attempt internal
service or adjustment of equipment unless another person capable of rendering aid and
resuscitation is present.
FINGER RINGS/JEWELRY. Finger rings have caused many serious injuries. Remove rings,
watches and other metallic objects that may cause shock or burn hazards.
SOLDERING/DE-SOLDERING. Avoid breathing fumes generated by soldering/de-soldering.
Perform all operations in a ventilated area. Eye protection is required.
CLEANING SOLVENTS. Some cleaners and solvents have adverse effects on skin, eyes,
respiratory tract and internal organs. These adverse effects range from discomfort to serious
injury and death, depending on the material and degree of exposure. Observe manufacturers’
warning labels and contact your immediate supervisor if in any doubt.
Remember…. the person now reading these instructions is primarily responsible for his
or her own health and safety.
Part # 68C-MKU, Edition 01/2007, Version 1.0 Page 7
This page intentionally left blank
Page 8 Part # 68C-MKU, Edition 01/2007, Version 1.0
2. PRODUCT DATA & SPECIFICATIONS
CATTRON® Unity Portable Remote Control (PRC) systems offer the safety and dependability
required for industrial control applications with reversing motor control such as overhead
cranes, conveyors, etc. Each system includes an Operator Control Unit (radio transmitter) and
a Machine Control Unit (radio receiver) which are based on the CATTRON
platform. Unity PRC systems are custom engineered at our factory for your controlled
machine and are designed to go straight on the job with no FCC or Industry Canada
license required.
The Unity PRC system described in this manual incorporates high-performance
microprocessors with a minimum number of components in their design. An RF receiver,
decoder and relay interface contained in the Machine Control Unit is under the direct control of
a lightweight, hand-held Metal Keypad Operator Control Unit. Different system configurations
are available so that we can recommend the best one for your application.
2.1 SYSTEM FEATURES
• Sturdy, lightweight transmitters with integrated fall protection
• Synthesized two, three, four, or five motor control, plus mainline ON/OFF
® ‘
Unity’ electronics
• Ergonomic design
• High availability and operating safety through use of quality components
• High message security, >16 million addresses
• Average response time of less than 70 mS
• 5 Multi-function LEDs for status and error indication, acoustic low voltage alarm
• Power-on self diagnostics
• Increased safety through Multiple transmission coverage, Hamming distance d ≥ 6,
dual-processor system with Master/slave-technology
• Dual Stop circuit
• Pre-programmed system frequency, address, and operating parameters of radio control
transmitters and receivers using ‘TransKeys’
®
• Proven CATTRON
reliability
2.2 OPERATOR CONTROL UNIT (OCU)
The CATTRON
®
MK Unity Series OCU is a lightweight palm sized, extremely rugged
customizable radio control transmitter for use with any CATTRON® Unity based PRC System.
Referring to Figure 1 overleaf, operational security is advanced to its maximum by the use of a
removable 'TransKey' which, when installed to the OCU, defines and enables the appropriate
operating parameters. A non-removable 'TransKey' option is available for situations where
interchangeability of OCU s is not required.
Part # 68C-MKU, Edition 01/2007, Version 1.0 Page 9
Loading...