User Manual

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Page 34 Part # 68C-MKU, Edition 01/2007, Version 1.0

1. Insert the correct ‘TransKey’. This coded electronic key sets the unique operating

parameters for a given control system. These parameters include, address code,

operating frequency and function key (pushbutton) configurations. Note that an OCU

will not operate without a ‘TransKey’ installed.

NOTE: If your controller uses the bottom row of keypad switches for ‘ON’,

‘OFF’, and ‘STOP’ functions, proceed directly to step 5 of this

procedure.

2. Set red STOP Switch to ‘RUN’. Pulling this switch upward enables power to be

applied to the OCU. If the switch has been pushed down to the ‘STOP’ position, you

will first have to unlatch the switch knob by rotating in a clockwise direction.

3. Set ON/OFF Switch to ‘ON’. Rotating this switch clockwise applies power to the

OCU. If the multicolor STATUS LED illuminates green and two short beeps are

heard, the OCU is ready for use and a power up message has been sent to the

target MCU. The targeted MCU will respond by energizing the mainline contactor of

your controlled machine.

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 PERSONAL INJURY OR

DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

4. Press a non-motion Function Key (pushbutton) such as a horn or lamp and

observe that the targeted crane or machine responds. The OCU is now fully

operational and transmitting a signal as indicated by the green ‘TRANSMIT’ LED

flashing. Operate the keypad control and auxiliary pushbuttons as required,

remembering that each pushbutton must be maintained in order for the function to

continue to operate. Any or all functions may be operated simultaneously if the

controlled machine permits such operation.

Summary of content (31 pages)

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. Insert the correct ‘TransKey’. This coded electronic key sets the unique operating parameters for a given control system. These parameters include, address code, operating frequency and function key (pushbutton) configurations. Note that an OCU will not operate without a ‘TransKey’ installed. NOTE: If your controller uses the bottom row of keypad switches for ‘ON’, ‘OFF’, and ‘STOP’ functions, proceed directly to step 5 of this procedure. 2. Set red STOP Switch to ‘RUN’.
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NOTES: A system STOP may be initiated at any time during the control function by pushing the red STOP switch downwards. It should be further noted that in “pitch and catch” control operations where two OCUs are used, only the OCU that sets the ‘STOP’ condition will re-set the ‘RUN’ condition. When all control functions have been completed, we recommend you initiate a system STOP (push red STOP switch down) before setting the ON/OFF switch to the ‘OFF’ position. 5.
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Figure 15. Alternative MKU Controller - Power-up using bottom row keypad switches Page 36 Part # 68C-MKU, Edition 01/2007, Version 1.
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6.4 CHANGING THE BATTERY PACK Referring to Figure 16 below, remove the battery pack as follows: a. Lay MKU controller (1) face down. b. Release two knurled thumbscrews (2) and withdraw cover-plate (3). c. Withdraw battery pack (4) from battery compartment (5). Figure 16. Battery Pack, removal and replacement Referring to Figure 16 above, replace the battery pack as follows: a. Position battery pack (4) with the four contact strips facing down and forwards.
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6.5 CHARGING THE BATTERY PACK NOTES: Do not re-charge the battery pack until the OCU’s LED indicates ‘low battery’. A CATTRON® External Battery Charging Unit (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 a period of 10 hours from a 110-120 VAC mains supply. Standard rate chargers include a yellow LED to indicate charge mode.
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Figure 17. External Ni-Cad Battery Pack Charging NI-CAD BATTERY PACK ONLY PART # 60C-0060N CHARGING JACK FROM BATTERY CHARGER 6.6 CONDITIONING THE BATTERY PACK A ‘state of the art’ CATTRON® Battery Conditioner (Part # 70C-0002) is available for use with Ni-Cad battery packs only. The Battery Conditioner automatically conditions the battery pack by first discharging it at 750mA for 1.5 hours before applying a rapid charge for 1.2 hours.
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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.
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Figure 18. Battery Pack Conditioning – interconnection details Part # 68C-MKU, Edition 01/2007, Version 1.
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6.7 ALKALINE BATTERY ADAPTER 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. Referring to Figure 19 below, a CATTRON® Battery Adapter is available which will accept two ‘AAA’ size Alkaline 1.5-volt batteries only. It should be noted that when using ‘AAA’ size Alkaline 1.
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7 MAINTENANCE INSTRUCTIONS Unless customer technicians have received formal maintenance training from CATTRON®, our maintenance philosophy is that inoperative OCUs and MCUs be returned as complete units to our workshops for repair. This is because each system has been customized at our factory for a particular application, thus it is highly unlikely that two control systems will be the same.
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Table 2. OCU Fault Messages - multicolor STATUS LED LED Indication Fault Action 2-flashes TransKey missing Plug in the Transkey 3-flashes TransKey cannot be read Check the Transkey configuration* 4-flashes Fault in the low-voltage test during switch-on Switch the OCU off then on again.
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7.3 RECEIVER FAULT MESSAGES The MCU has five externally visible LED indicators that display the current system status to the operator. Referring to Figure 20 below and Table 3 overleaf, these are: Figure 20. MCU System Status LEDs Part # 68C-MKU, Edition 01/2007, Version 1.
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Table 3. MCU External Status LEDs LED Description 1. Power On Illuminates orange when the MCU receiver has voltage 2. Scan Mode Flashes red/orange in Scan Mode Not used when system is configured for fixed frequency 3. RF Reception Illuminates green when valid data from the OCU is received and both OPR relays are energized Illuminates orange if valid data from the OCU is received and the OPR relays are de-energized Illuminates red if data from another OCU (with invalid address) is received 4.
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The PROCESSOR FAULT LED blinks orange if the receiver does not detect a transmitter, and green when valid RF Transmissions are received. If the processor detects a fault, it will signal this by blinking in red. Refer to Table 4 below for the blink sequence and the corresponding fault messages. Note that any repairs or replacements should only be made by CATTRON® trained technicians. Table 4.
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8 ACCESSORIES AND CONSUMABLE ITEMS Contact CATTRON® sales department for availability and pricing of the following accessories and consumable items. These items are itemized in Table 5 below and illustrated on the following pages. Table 5. Optional Accessories Item # Part Number Order Item Description Quantity 1 60C-0060A 1 Battery pack, alkaline, non-rechargeable, 3-volt, 2,500 mAH 2 60C-0060N 1 Battery pack, Ni-Cad, re-chargeable, 2.
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8.1 ACCESSORIES/CONSUMABLE ITEMS - ILLUSTRATIONS White color Item 1. Battery pack, alkaline, non-rechargeable, 3-volt, 2,500 mAH – Part # 60C-0060A Yellow color Item 2. Battery pack, Ni-Cad, re-chargeable, 2.4-volt, 1,100 mAH – Part # 60C-0060N Part # 68C-MKU, Edition 01/2007, Version 1.
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BELT LOOP STRAP Item 3. Carrying strap, belt, loop, 2", nylon, black - Part # 42C-0066 Item 4. Battery Charger, Ni-Cad, standard charge (10-hour), 110 VAC - Part # 70C-0001 Page 50 Part # 68C-MKU, Edition 01/2007, Version 1.
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BATTERY PACK CONDITIONER MULTI-VOLTAGE ADAPTER Item 5. Battery Conditioner, 100-240 VAC input, complete with multi-voltage adapter - Part # 70C-0002 SHOULDER CARRYING STRAP Item 6. Carrying strap, shoulder - Part # 42C-0057 Part # 68C-MKU, Edition 01/2007, Version 1.
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NI-CAD BATTERY PACK ONLY PART # 60C-0060N CHARGING JACK FROM BATTERY CHARGER Item 7. External Battery Charging Unit (used with items 2, 4, & 5 above) - Part # 70C-0003 BATTERY ADAPTER, 3 VOLT (QUANTITY 2 x ‘AAA’ SIZE) USE ‘AAA’ ALKALINE BATTERIES ONLY Item 8. Battery Adapter for Quantity 2 x ‘AAA’ Alkaline Batteries - Part # 60C-0062 Page 52 Part # 68C-MKU, Edition 01/2007, Version 1.
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Item 9. Standard Label Kit, English Text - Part # 54C-0088A Part # 68C-MKU, Edition 01/2007, Version 1.
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Item 10. Special Label Kit, English Text - Part # 54C-0088SPA Page 54 Part # 68C-MKU, Edition 01/2007, Version 1.
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APPENDIX ‘A’ – OCU CHANNEL CHANGING OPTION Occasionally, a change of RF channel may be necessary due to radio interference or the fact that the factory pre-programmed RF channel is already in use. This is normally accomplished by reprogramming the TransKey (external programming). However, some OCUs are equipped with a Channel Changing Option that allows the operator to change the RF channel using the OCU keypad.
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Figure A-1. RF Programming Mode Pushbuttons and LEDs A.2 SELECTING THE RF CHANNEL Pressing the first level of the UP and DOWN buttons selects the next higher or next lower RF channel respectively. Alternatively, holding down the second level initiates a fast run (approx. 0.3 seconds per channel) in order to set the system to the desired RF channel (see example Table A-1, above).
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A.3 RE-ACTIVATING THE TRANSKEY RF CHANNEL Pressing the first level of the Field Strength Channel Pushbutton and the ‘ON’ Pushbutton reactivates the RF channel originally configured in the TransKey (basic configuration). This action exits the programming mode and switches off the OCU. When the OCU is switched on again, it will transmit on the RF Channel stored in the TransKey Part # 68C-MKU, Edition 01/2007, Version 1.
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APPENDIX ‘B’ – INTERFACING TO SAFETY CRITICAL MAINTAINED BISTABLE CIRCUITS B.1 EXAMPLE CIRCUIT DIAGRAM - MAGNET Part # 68C-MKU, Edition 01/2007, Version 1.
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B.2 EXAMPLE CIRCUIT DIAGRAM - GRAB Page 60 Part # 68C-MKU, Edition 01/2007, Version 1.
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B.3 EXAMPLE CIRCUIT DIAGRAM - VACUUM Part # 68C-MKU, Edition 01/2007, Version 1.
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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.