Part # 68C-MKU, Edition 01/2007, Version 1.
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.
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Table of Contents 1. SAFETY INSTRUCTIONS .................................................................................................5 1.1 WARNINGS and CAUTIONS ........................................................................................5 1.2 GENERAL .................................................................................................................... 7 2. PRODUCT DATA & SPECIFICATIONS ............................................................................9 2.
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 ..........
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.
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.
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.
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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® ‘Unity’ electronics platform.
Figure 1. OCU Removable 'TransKey' NOTE: OCU and MCU TransKeys must not be swapped. The OCU (transmitter) TransKey is black. The MCU (receiver) TransKey is yellow. Swapping TransKeys will result in OCU/MCU fault indications and the system will not go into operation. Referring to Figure 2 opposite, the keypad unit and electronics are contained in an extreme duty, water and dust resistant, aluminum housing which has armorized rubber end-caps for switch protection and high impact resistance.
Figure 2. MKU OCU MKU dual pressure keypad OCUs offer 6, 12, or 16 operator commanded functions (simultaneous, any combination). In addition, these OCUs can provide 2-speed operation and variable frequency drive (VFD) operation. All CATTRON® MKU OCUs normally send ON/OFF commands that activate programmed functions at the target CATTRON® Machine Control Unit. MKU OCUs are equipped with an internal antenna and the typical operating (transmitter) range is in excess of 300 feet (92+ meters) line of sight.
Four Multicolor Function Output LEDs above the top row of function keys indicate when a controller motion command has been activated at the target machine. These LEDs may also be used to identify a frequency channel number when the Channel Programming Option (see Appendix ‘A’) has been incorporated with the controller.
2.3 MACHINE CONTROL UNIT (MCU) Referring to Figure 4 below, the MCU’s receiving and decoding hardware, along with the relay interface, is housed within an IP 65 water resistant enclosure. Figure 4. Typical MCU Component Layout Part # 68C-MKU, Edition 01/2007, Version 1.
The output interface to the controlled machine is handled by relays rated for heavy duty resistive and inductive industrial loads (up to 7 A / 250 VAC). Each relay has a ‘Status’ LED that illuminates when the relay is energized. Individual relay outputs are routed to the controlled equipment via a terminal strip. When a fault condition is detected, the Operate (OPR) relay and all outputs are disabled.
Table 1. MCU SystemStatus LEDs LED DESCRIPTION 1. Power On Illuminates orange when the MCU 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.
Battery type: 3-volt Alkaline Battery Pack (standard). 2.4-volt re-chargeable Ni-Cad Battery Pack (optional). 3-volt Alkaline Battery Adapter for use with quantity 2 ‘AAA’ size Alkaline batteries only (optional). Battery life: Battery Type Constant Transmission Alkaline Battery Pack, Part # 60C-0060A. 2500 mAh 73 hours Ni-Cad Battery Pack, Part # 60C-0060N. 1100 mAh 32 hours Qty. 2 AAA Alkaline Batteries in Adapter, Part # 60C-0062.
MCU: Receiver series: CT24 Frequency range: 902 to 928 MHz Transmission speed: 4.
2.5 MKU MODEL CONFIGURATIONS 2.6 MKU to MKEZ/MKCS Cross Reference Chart Page 18 Part # 68C-MKU, Edition 01/2007, Version 1.
3 SAFETY CONSIDERATIONS CATTRON® believes that to safely operate any remotely controlled equipment, the overall system needs to be configured so that movement or operation of the equipment will take place only when the device is commanded to move or operate. For example; overhead cranes must be equipped with a braking system which can only be released when an electrical signal is sent to the motor. Removal of electrical power or loss of the radio transmitted signal results in application of the brakes.
Redundant Self-Checking Dual Processor Architecture: Both the OCU and the MCU incorporate one Master processor and one Slave (checker) processor. On the OCU, these dual processors monitor the output commands from the pushbuttons. On the MCU, these dual processors monitor the input commands to the relay coils. 3.2 PERMANENT OCU ‘TRANSKEY’ When the ‘TransKey’ is removed, the OCU is totally disabled.
4 INSTALLATION 4.1 CHOOSING A MOUNTING LOCATION There are a few items to consider when selecting a location to install the MCU enclosure. First, the MCU enclosure must be installed in a location that allows easy access for maintenance and service. Adequate clearance must be allowed to remove the cover for access. The location must also provide adequate RF reception range and a clear ‘line of sight’ to the transmitter. Select a location to minimize any possible interference from RF sources such as motors.
Figure 7. MCU enclosure mounting footprint drawings Page 22 Part # 68C-MKU, Edition 01/2007, Version 1.
4.2 WIRING CONNECTIONS Figures 8 and 9 below show the respective terminal strip connections within the 9 MCU and 12-17 MCU enclosures. The actual wiring configuration depends on; (1) the type of MCU Enclosure, and (2) the work/configuration sheet supplied with your system. Figure 8. 9 MCU enclosure wiring connections Part # 68C-MKU, Edition 01/2007, Version 1.
Figure 9. 12-17 MCU enclosure wiring connections Page 24 Part # 68C-MKU, Edition 01/2007, Version 1.
5 INTERFACE CONNECTIONS Before installing the remote control system, you are advised to prepare an electrical wiring diagram that defines all electrical interface connections between the system and the equipment being controlled. Before installing the remote control system, we advise you to first read the following topics of discussion (Paragraphs 5.1 thru 5.6). At the same time, you should locate and refer to the example mainline drawing provided in Figure 10 overleaf. 5.
Figure 10. Example mainline drawing Page 26 Part # 68C-MKU, Edition 01/2007, Version 1.
5.2 THE CONTROLLED MACHINE The machine you are interfacing to may consist of single or multiple contactor panels, single or multiple manual controls, and single or multiple control transformers etc. Notice that there is no common connection between relay output contacts, allowing control of different power sources and combinations of AC and DC power. Application of the normally open relay contacts is similar to wiring that is required for any control switch, such as a pendant.
Figure 11. Typical transfer switch wiring When switching the transfer switch between remote and manual control, observe the following precautions: • Do not transfer control of a crane with a load lifted. Always set down all loads prior to changing the position of the transfer switch. • If the crane is equipped with a magnet, it shall be set in the drop position prior to changing the position of the transfer switch. • Set (push down) the red STOP switch on the MKU controller to ‘STOP’.
5.6 MAINLINE CIRCUIT Referring to Figure 12 below, the Operate (OPR) relay K0-M AND K0-S outputs are special. They should always be connected to the mainline (ML) contactor. If a fault were to occur, the ‘OPR’ relays, which control the mainline contactor, would safely bring the equipment to a stop. This makes the use of a mainline contactor mandatory for safe operation of this equipment. Figure 12.
Referring to Figure 13 below, an auxiliary function may be used as a Reset (RST) output that will only be effective when the Operate (OPR) relays have been closed. Figure 13. OPR contact and RST wiring Momentary closure of the Reset (RST) relay picks up the mainline (ML) contactor, which is maintained under control of the OPR relays. Thus, power is supplied to the controlled device. If OPR opens, the mainline contactor releases, removing power from the controlled device and stopping all motion.
6 OPERATING INSTRUCTIONS NOTE: During normal operation, all interfaces with the system are through the OCU. MCUs require no operator action as these units have been designed to operate completely unattended. 6.1 CHANGING ‘TRANSKEYS’ Due to the flexible ‘TransKey’ concept, it is not uncommon for one OCU controller to be used to control multiple cranes or machines.
With the correct color coded ‘TransKey’ inserted into the OCU, setting both the STOP and ON/OFF switches to their respective ‘RUN’ and ‘ON’ positions will apply power to the OCU. NOTE: Some MKU controllers use the bottom row of keypad switches to switch the unit ‘ON’ and ‘OFF’. Immediately after power has been applied to the transmitter, if a good battery is installed, the multicolor STATUS LED should momentarily illuminate red, followed by orange, then ‘flash’ green. Two short beeps will also be heard.
If the DP button is depressed to its first level, first speed is achieved and maintained as long as the button remains at that level of depression. If the button is depressed to its second level, second speed is achieved. If the operator releases pressure and allows the button to return to the first level, first speed is again achieved. Moving directly from ‘OFF’ to the second level of depression can command second speed if sufficient pressure is applied.
