Cattron North America MK User Manual User Instructions

Laird Controls North America Inc. User Instructions

User Instructions

R02/2000 CATTRON® Section 1, Page 1 Section 1 Section 2 – Product Data & SpecificationsFunctional Description.The CATTRON® Metal Keypad (MK) Series remote controller is a lightweight palm sized, extremelyrugged customizable radio control unit for use with any CATTRON® Portable Radio Remote Control(PRRC) System. CATTRON® MK series controllers are offered in four family configurations: EZ(Easy), CS (Crane Specific), AT (Advanced Technology) and UN (Universal).In all four CATTRON® families of MK series controllers, operational security is advanced to itsmaximum by the use of a removable stainless steel, electronic i-Key which, when installed to thecontroller, defines and enables the appropriate operating parameters. When the i-Key is removed, thecontroller is totally disabled.The keypad unit and electronics are contained in an extreme duty, water resistant and dust proofaluminum housing which has armorized rubber end-caps for switch protection and high impactresistance. Consequently, the MK series keypad controller is able to withstand levels of impactpreviously unattainable by any other portable remote controllers, without the need for carrying cases orprotective rubber housings. The MK controller housing is ergonomically designed with curved bottomand rubber side grips to allow comfortable handling. The i-Key is mounted in a receptacle locatedwithin the confines of the armorized rubber ‘bumper’ that surrounds the top end-cap. SeparateON/OFF (green) and STOP (red) switches are also located next to the removable i-Key. A completelysealed elastomer keypad on the controller front face contains large pushbuttons that are coated withclear epoxy for additional durability. Each pushbutton is identified by a label that clearly indicates thespecific function for that particular key. When pressed, each pushbutton actuates a function switchinside the controller and may be of single-step or two-step operation. Also, when pressed, eachpushbutton has a distinct limit of travel, thus providing an enhanced tactile feel that is noticed by theoperator.All commands from CATTRON® MK controllers respond within milliseconds of pressing apushbutton and are absolute functions; that is, a positive ON command is sent when the button ispressed, and a positive OFF command is sent when the same button is released. Additionally, amainline ON command is sent when power is turned on and anytime a controller function pushbuttonis pressed. Within the MK controller, a microprocessor performs self–diagnostics, interpretspushbutton and switch commands, and controls the radio transmitter.CATTRON® MK controllers are available in single and dual-pressure models. Single-pressure modelsoffer 4, 8, or 12 pushbutton functions (simultaneous, any combination), while dual-pressure modelsoffer 6, 12, or 16 operator commanded functions (simultaneous, any combination). In addition, dual-pressure models provide 2-speed operation and variable frequency drive (VFD) operation with a single
RSection 1, Page 2 02/2000 CATTRON®pushbutton. All CATTRON® MK series controllers normally send on/off commands that activateprogrammed functions at the CATTRON® receiver/decoder.
R02/2000 CATTRON® Section 1, Page 3Functional Description, continued.CATTRON® MK controllers are equipped with an internal antenna and the typical operating(transmitter) range is in excess of 500 feet (160+ meters). It should be understood that operating rangevaries with environmental conditions. Should the transmitter go out of operating range, all motionswill cease.As previously mentioned, operational security is maximized by the need to use a stainless steelelectronic i-Key for controller operation. However, there is an additional and very significantoperational advantage of the CATTRON® i-Key concept. It is that individual system address,operating frequency and keypad configuration may be permanently stored in the i-Key, depending onthe type of MK controller supplied. Therefore, CATTRON® MK series controllers belonging to thesame family at a user location can be identical - only the i-Keys are different. To simplify, each i-Keyis color coded and labeled for an individual control system family, thus, any CATTRON® MKcontroller will run any CATTRON® receiver/decoder belonging to the same family as long as thecorrect i-Key is used. As the result, this unique operating concept reduces the need for specific spareremote controllers. Our unique family of MK Series controllers is identified on the next page.All CATTRON® MK series controllers are powered by disposable 3-Volt alkaline or re-chargeable Ni-Cad battery packs. In normal operation, a green LED ‘flashes’ with each function command messageand a ‘beep’ is sounded when a key is pressed. When the battery voltage becomes low, a separateyellow LED flashes, alerting the operator that the battery pack needs to be replaced or re-charged soon.Battery packs are easily and quickly replaced without the need for tools by turning two knurledthumbscrews and removing the battery cover-plate located within the confines of the armorized rubberbottom end-cap. The battery pack makes positive contact without snaps or plugs and has no wires tobreak; simply drop it in, and replace the battery cover-plate.Ni-Cad battery packs can be re-charged ‘in-situ’ and do not need to be removed from the controllerhousing. To enable such battery charging to be carried out, an optional ‘standard rate’ (10-hour)battery charger is available for all CATTRON® MK series controllers. One end of this charger isconnected to a standard 120VAC outlet, the other plugs into a covered socket located on the curvedunderside of the controller. A ‘rapid rate’ (1-hour) battery charger is available on request.A belt loop strap is available for all CATTRON® MK series controllers. This is quickly and simplyinstalled to a ‘D’-ring located on the curved underside of the controller. Also, an optional shouldercarrying strap is available on request.
RSection 1, Page 4 02/2000 CATTRON®Specifications.Case Material:Extreme duty, water resistant and dust proof aluminum housing.Approximate weight:1.4lbs. / 634 grams (including battery pack).Dimensions:8.0" x 3.0" x 2.0" (20.0cm x 7.6cm x 5.1cm).Environmental:Consult CATTRON® factory for a wide range of environmental solutions.EZ CS ATMKEZ(Greeni-Key)MKCS(Bluei-Key)MKUN(Any colori-Key)MKAT(Silveri-Key)
R02/2000 CATTRON® Section 1, Page 5Specifications, continued.Maximum Functions:Single-pressure MK models:4, 8, 12 (simultaneous, any combination) operator commands.Dual-pressure MK models:6, 12, 16 (simultaneous, any combination) operator commands.Auxiliary functions can be added for either model:i.e., trolley/hoist select, crane select (with i-Key only), etc.Switch options:4, 8, or 12 pushbuttons, single or dual pressure.Switch type:Sealed silicon elastomer keypad, dust, water, oil, acid resistant elastomer padwith ‘tactile feel’, clear epoxy coated pushbuttons.Battery life (continuous operation):3 Volt alkaline battery pack (standard) or re-chargeable Ni-Cad battery pack(optional). In USA, Canada and non EU countries, battery life is:- Ni-Cadpack – 65 hours, Alkaline pack – 150 hours. In EU countries, battery life is:-Ni-Cad pack – 40 hours, Alkaline pack – 95 hours.Transmit indicator:Green LED flashes with every transmission.Low battery indication:Yellow LED flashes for low battery, low battery alert signal beeps every 10 seconds.Battery charging:Internal Ni-Cad battery charging. Optional ‘standard rate’ (10 hour) or ‘rapidrate’ (1-hour) battery chargers available.Audio speaker:For function pushbutton ‘click’ and low battery indication.Transmitter frequency:425-447MHz (M) or 447-473MHz (H).
RSection 1, Page 6 02/2000 CATTRON®Overview – Cattron® Radio Remote Control Systems.Figure 1-1 below shows a simplified block diagram of a typical CATTRON® radio remote controlsystem. Refer to this figure and the following paragraphs for a functional description of the remotecontrol system.The target receiver/decoder is controlled by the MK controller. Provided the correct coded i-Key isinserted into the keypad controller, the controller sends signals to the receiver/decoder using a UHFradio link. The signal is picked up by the antenna and passed on to the receiver. If the signal is thecorrect frequency and passes all required data tests, the signal is passed on to the decoder.The decoder compares the address code of the signal to its own address code. If the signal’s addresscode does not match its address code, it is ignored and a message is displayed on a system statusdisplay located in the receiver/decoder unit. If the address code is correct, the decoder processes themessage and energizes and de-energizes the appropriate control, directional output, second speed andauxiliary function relays located within the control system.An Automatic Safety Override (ASO) function continually monitors the state of any safety directionalrelay output (i.e. Forward/Reverse). If a monitored relay electrically fails closed without a commandfrom the controller, the ASO circuit logic de-energizes the master output relay (OPR).During operation, the microprocessor on the decoder board resets multiple watchdog timer circuitswhenever valid messages are received and decoded. If the microprocessor fails to reset the watchdogtimers, the timer circuits shut down and de-activate all relay outputs. The decoder microprocessorrequires continuously valid transmitted signals to be received and decoded or all relay output functionswill be de-activated unless programmed otherwise.Figure 1-1. Typical Radio Remote Control System, simplified block diagramCONTROLLERADDRESSADDRESSFREQANTENNAFREQRECEIVER DECODER12 VDCPOWERSUPPLYWATCHDOGTIMER115 VAC50-60 HZDIRECTIONALOUTPUT RELAYSSECOND SPEED ANDAUXILIARY FUNCTIONOUTPUT RELAYSMACHINEWIRINGASO
R02/2000 CATTRON® Section 1, Page 7MK AT Series Keypad Controllers – Availability Options.The various configurations available for the CATTRON® Advanced Technology (AT) family of MKSeries Controllers are summarized below:NOTE: This MK Controller is custom built for your remote controlapplication. When ordering any replacement part, providethe following information: (1) the model and revision numberlocated on the serial tag underneath the controller, and (2) thecontrol system ID and serial number located on the i-Keylabel tag.MK (AT Family) Remote Controllers - model summary chart.MODEL PART NUMBER (Suffix Codes: DP = Dual Pressure. DS = Display. +2 = additional function keys. S = Switch)KM16DPKM12DPKM06DPKM04KM08KM12KM12+2KM12DSKM12SLEGEND-= NOT AVAILABLE1= NUMBER SUPPLIED+= ACCESSORY111111111Frequency Band Range From 425-447MHz (M) or 447-473MHz (H)--11-----4 Function Buttons-1--1----8 Function Buttons1----111112 Function Buttons111111111Power On/Off Switch (green)111111111Internal Antenna111111111System Stop (red)-------1-Liquid Crystal Display111111111Belt Loop Carrying Strap, 2" Black Nylon, Part Number 42C-0066+++++++++Shoulder Carrying Strap, Part Number 42C-0057111111111Alkaline Battery Pack, Part Number 60C-0060A+++++++++Ni-Cad Rechargeable Battery Pack, Part Number 60C-0060N+++++++++Ni-Cad Standard Rate (10-hr) Battery Charger, Part Number 70C-0001+++++++++Ni-Cad Rapid Rate (1-hr) Battery Charger, Part Number 70C-0002END OF SECTION
RSection 1, Page 8 02/2000 CATTRON®Section 2 – Safety InformationSafety Considerations.CATTRON® believes that to safely operate any remotely controlled equipment, the overall systemneeds to be configured so that movement or operation of the equipment will take place only when thedevice is commanded to move or operate. For example; overhead cranes must be equipped with abraking system which can only be released when an electrical signal is sent to the motor. Removal ofelectrical power or loss of the radio transmitted signal results in application of the brakes. This isaccomplished when a CATTRON® Electro-Hydraulic brake package is installed – contact the factoryfor details.In keeping with this philosophy - NO COMMAND, NO MOVEMENT - CATTRON® has designedyour radio remote control system with the following safety and security features.Standard Safety & Security Features.i-Key: Operational security is advanced to its maximum by the use of aremovable stainless steel, electronic, i-Key which, when installed to the MKcontroller, defines and enables the operating parameters. When the i-Key isremoved, the controller is totally disabled.Unique address code: Each MK controller and receiver/decoder pair isconfigured with a unique address code so that the equipment will respond only tothe controller whose address code matches that of the decoder.Intelligent digital message protocol: CATTRON® remote control systemsutilize a unique message protocol for industrial control applications rather thanthe customary Electronic Data Processing (EDP) type of message format.Green ON/OFF power switch: The MK controller is provided with a greenpower ON/OFF switch that must be set to ‘ON’ in order to send commands to thereceiver/decoder. If the power switch is set to ‘OFF’, the decoder will remove allcommands from the controlled machinery, stopping all movement.Red System STOP Switch: Operating the red STOP switch while the MKcontroller is turned on will repeatedly send a burst of stop commands to alloutputs including the mainline control relay (OPR).Operate relay (OPR): The operate (OPR) output relay shall be wired to control auser-provided electro-magnetic power contactor. The electro-magnetic contactoropens and closes the main electrical supply circuit(s) to the controlled device.Automatic Safety Override: The Automatic Safety Override (ASO) functioncontinually monitors all selected decoder directional relays and safety relatedoutputs. If any monitored relay closes without command from the MK controller,the Operate (OPR) Relay immediately de-energizes. This prevents any movementof the controlled machine without command from the controller.
R02/2000 CATTRON® Section 1, Page 9Standard Safety & Security Features, continued.Data Error Checking: All communications from the MK controller to thereceiver/decoder contain error-checking information (BCH data error detectionroutines). The entire data command packet must pass error detection tests beforebeing processed.Typical method of operation (incorporating above safety features).Using a radio controlled overhead crane as an example:`WARNINGS:1. ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTORINSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES)HAVE A BRAKE INSTALLED.2. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BECONNECTED TO THE MAINLINE SO THAT STOP COMMANDSOR FAULT CONDITIONS MONITORED BY AUTOMATICSAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZETHE MAINLINE CONTACTOR AND SET THE EQUIPMENTBRAKE.3. ALL EQUIPMENT SHALL HAVE AUDIO AND VISUAL ALARMINDICATIONS MEETING GOVERNMENTAL REQUIREMENTS.4. MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USEDAT, AROUND, OR NEARBY YOUR OPERATING FACILITY.THEREFORE, BEFORE INSERTING AN ‘i-KEY’ INTO AN MKCONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-KEY’ IS SELECTED FOR THE DESIRED EQUIPMENT TO BEOPERATED.5. IF THE WRONG ‘i-KEY’ IS INSERTED INTO AN MKCONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND,OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL.FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAYRESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH INTURN COULD RESULT IN PERSONAL INJURY OR DEATH TOPERSONNEL AND DAMAGE TO EQUIPMENTThe Operate (OPR) relay(s) is energized for the first time when:The red STOP and green ON/OFF switches on the MK Controller are pulled out inthe proper sequence (red, then green), the correct coded i-Key is installed, and thetarget receiver/decoder has power applied. With all these conditions satisfied, amatching address code is sent by way of RF signal from the MK controller to thedecoder.
RSection 1, Page 10 02/2000 CATTRON®Typical method of operation, continued.The OPR relay is wired to the mainline (ML) contactor on the crane. Once the mainline is energized, acontinuously repeated valid signal must be received for function outputs to engage. If this signal isinterrupted for any reason, all function outputs will turn off unless programmed otherwise.Figure 2-1 below shows an Operate (OPR) contact wired directly to the mainline (ML) contactor.Provided the red STOP switch on the MK Controller is pulled out and the correct coded i-Key isinstalled, setting the green ON/OFF power switch on the MK controller to ‘ON’ will energize themainline contactor.An auxiliary function may be used as a Reset (RST) output that will only be effective when theOperate (OPR) relay has been closed. Momentary closure of the Reset (RST) relay picks up themainline (ML) contactor, which is maintained under control of the OPR. Thus, power is supplied tothe controlled device. If OPR opens, the mainline contactor releases, removing power from thecontrolled device and stopping all motion.Figure 2-1. Operate (OPR) contact wiringOPR 120VRC5.0ATBL1 MLMLMANUALDISCONNECTL2L3LL1LL2LL3TOMOTORRECEIVER/DECODER EXISTING CONTROLS
R02/2000 CATTRON® Section 1, Page 11Typical method of operation, continued.Figure 2-2 below shows the Operate (OPR) relay and optional Reset (RST) relay wired to control amainline contactor. This configuration requires the operator to activate the reset function on thecontroller after he/she has turned the unit on. Once reset, the ML contactor stays energized until OPRde-energizes.Figure 2-2. Operate (OPR) contactor and Reset Relay (RST) wiringOPR 120VRSTRRCC5.0A5.0ATBL1 MLML MLMANUALDISCONNECTL2L3LL1LL2LL3TOMOTORRECEIVER/DECODER EXISTING CONTROLSIn addition to being energized by the presence of a signal from the controller, OPR is undersupervision of the Automatic Safety Override (ASO) circuit. The ASO circuit disables the OPR(shutting down the controlled machinery) if an ASO circuit monitored output relay is active when nocorresponding command is being received from the controller. In this event, no action is required bythe operator to stop the equipment. The ASO safety circuitry will stop motion automatically withoutany operator command when a monitored output relay fault is detected.
RSection 1, Page 12 02/2000 CATTRON®Radio Control Operator’s Duties – General Equipment.The following procedures provide general guidelines for radio control operation of equipment andshould not be used as a substitute for your plant operating procedures.1. Before operating equipment, carry out the following:`WARNINGS:1. ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTORINSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES)HAVE A BRAKE INSTALLED.2. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BECONNECTED TO THE MAINLINE SO THAT STOP COMMANDSOR FAULT CONDITIONS MONITORED BY AUTOMATICSAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZETHE MAINLINE CONTACTOR AND SET THE EQUIPMENTBRAKE.3. ALL EQUIPMENT SHALL HAVE AUDIO AND VISUAL ALARMINDICATIONS MEETING GOVERNMENTAL REQUIREMENTS.4. MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USEDAT, AROUND, OR NEARBY YOUR OPERATING FACILITY.THEREFORE, BEFORE INSERTING AN ‘i-KEY’ INTO AN MKCONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-KEY’ IS SELECTED FOR THE DESIRED EQUIPMENT TO BEOPERATED.5. IF THE WRONG ‘i-KEY’ IS INSERTED INTO AN MKCONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND,OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL.FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAYRESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH INTURN COULD RESULT IN PERSONAL INJURY OR DEATH TOPERSONNEL AND DAMAGE TO EQUIPMENTa. Install the correct coded i-Key for the desired equipment to be operated. If the wrongcoded i-Key is installed to the MK controller, the target equipment will not operate.However; other equipment located at, around, or nearby your facility may becomeoperational.
R02/2000 CATTRON® Section 1, Page 13Radio Control Operator’s Duties – General Equipment, continued.b. Set (pull out) MK controller red STOP switch to ‘RUN’ and set (pull out) greenON/OFF power switch to ‘ON’. When transmitting with a good battery, two short‘beeps’ will be heard immediately after the ON/OFF power switch is set to ‘ON’ andthe green TRANSMIT LED will ‘flash’ rhythmically. When the battery starts to golow, the yellow LOW BATTERY LED will ‘flash’ continuously, which means youshould change or re-charge the battery pack (refer to Battery Pack in Section 4 of thismanual for instructions on how to replace a battery pack).c. When installed, depress ALARM/RESET pushbutton on MK controller (this isnormally an optional function that sounds the equipment alarm and resets the mainpower contactor).d. Check each function independently to be sure that equipment is responding correctly.e. Where a limit switch is provided, you should check the limit switch at the beginning ofeach shift as defined by your plant operating procedures.f. Check range limiting if used.g. Check STOP operationh. Check brake operation.2. You must report all defective or missing safety equipment, mechanical or electrical defects toyour supervisor without delay. Do not continue operation until fully repaired.3. If anyone is in the path of equipment travel, stop and sound the alarm before proceeding.4. Persons operating this equipment shall not use a limit stop as a utility stopping device.5 When leaving the equipment area for any reason, set (push down) the MK controller red STOPswitch to ‘STOP’ and set (push down) the green ON/OFF power switch to ‘OFF’. Remove thei-Key from the MK controller and keep it on your person.6. Do not allow any unauthorized person to operate the MK controller.7. Do not operate the MK controller at a distance where the equipment and all surrounding objectsare not visible.8. Do not attempt to override any of the safety features built into the Radio Control System.9. If for any reason you or anyone has to board the radio controlled equipment, set (push down) theMK controller red STOP switch to ‘STOP’ and set (push down) the green ON/OFF power switchto ‘OFF’. Remove the i-Key from the MK controller and keep it on your person.
RSection 1, Page 14 02/2000 CATTRON®Radio Control Operator’s Duties – E.O.T. Crane.The following procedures provide general guidelines for radio control operation of a crane and shouldnot be used as a substitute for your plant operating procedures.1. Before lifting any loads, carry out the following:`WARNINGS:1. ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTORINSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES)HAVE A BRAKE INSTALLED.2. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BECONNECTED TO THE MAINLINE SO THAT STOP COMMANDSOR FAULT CONDITIONS MONITORED BY AUTOMATICSAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZETHE MAINLINE CONTACTOR AND SET THE EQUIPMENTBRAKE.3. ALL EQUIPMENT SHALL HAVE AUDIO AND VISUAL ALARMINDICATIONS MEETING GOVERNMENTAL REQUIREMENTS.4. MORE THAN ONE REMOTE CONTROL SYSTEM MAY BEUSED AT, AROUND, OR NEARBY YOUR OPERATINGFACILITY. THEREFORE, BEFORE INSERTING AN ‘i-KEY’INTO AN MK CONTROLLER, YOU MUST INSURE THECORRECT CODED ‘i-KEY’ IS SELECTED FOR THE DESIREDEQUIPMENT TO BE OPERATED.5. IF THE WRONG ‘i-KEY’ IS INSERTED INTO AN MKCONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND,OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL.FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAYRESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH INTURN COULD RESULT IN PERSONAL INJURY OR DEATH TOPERSONNEL AND DAMAGE TO EQUIPMENTa. Install the correct coded i-Key for the desired equipment to be operated. If the wrongcoded i-Key is installed to the MK controller, the target equipment will not operate.However; other equipment located at, around, or nearby your facility may becomeoperational.
R02/2000 CATTRON® Section 1, Page 15Radio Control Operator’s Duties – E.O.T. Crane, continued.b. Set (pull out) MK controller red STOP switch to ‘RUN’ and set (pull out) green ON/OFFpower switch to ‘ON’. When transmitting with a good battery, two short ‘beeps’ will beheard immediately after the ON/OFF power switch is set to ‘ON’ and the greenTRANSMIT LED will ‘flash’ rhythmically. When the battery starts to go low, the yellowLOW BATTERY LED will ‘flash’ continuously, which means you should change or re-charge the battery pack (refer to Battery Pack in Section 4 of this manual for instructionson how to replace a battery pack).c. When installed, depress ALARM/RESET pushbutton on MK controller (this isnormally an optional function that sounds the alarm and resets the main powercontactor).d. Check each function independently to be sure that equipment is responding correctly.e. Where a limit switch is provided, you should check the limit switch at the beginning ofeach shift as defined by your plant operating procedures.f. Check range limiting if used.g. Check STOP operation.h. Check Brake operation2. You must report all defective or missing safety equipment, mechanical or electrical defects toyour supervisor without delay. Do not continue operation until fully repaired.3. When raising or lowering a load, proceed slowly and make certain the load is under control.4. When lifting maximum load, you should test the brakes by raising the load a few inches fromthe floor. If the brakes will not hold, the load shall be immediately lowered and not moveduntil brakes are adjusted or repaired.5. Center the Trolley directly over the load before starting to hoist.6. Take slack out of chains or slings gradually and make sure hands and other objects are clearbefore making the lift.7. Keep all parts of the body away from the lifts. Also, do not stand under a lift.8. Do not make a lift or move the equipment if anyone is in a position to be injured.9. Load should not be carried over workmen's heads.10. If anyone is in the path of travel, stop and sound the alarm before proceeding.
RSection 1, Page 16 02/2000 CATTRON®Radio Control Operator’s Duties – E.O.T. Crane, continued.11. Do not drag slings, chains, etc. along the floor.12. Persons operating this equipment shall not use a limit stop as a utility stopping device.13. Bumping other cranes or run-away stops is prohibited.14. When moving the equipment to the loading point, be sure that hook block, attachment, orcables will not fall on the adjacent equipment.15. When leaving the crane area for any reason, be sure slings or chains are raised and set (pushdown) the MK controller red STOP switch to ‘STOP’. Set (push down) the green ON/OFFpower switch to ‘OFF’. Remove the i-Key from the MK controller and keep it on your person.16. Do not allow any unauthorized person to operate the MK controller.17. Do not operate the MK controller at a distance where the crane and all surrounding objects arenot visible.18. Do not attempt to override any of the safety features built into the Radio Control System.19. If for any reason you or anyone has to board a radio controlled crane, set (push down) the MKcontroller red STOP switch to ‘STOP’ and set (push down) the green ON/OFF power switch to‘OFF’. Remove the i-Key from the MK controller and keep it on your person.END OF SECTION
R02/2000 CATTRON® Section 1, Page 17Section 3 – Operating InstructionsControls and Indicators.The standard MK Series Controller is a lightweight hand-held unit with up to twelve pushbuttons(function keys) on a single keypad, plus a pull/push ON/OFF switch and a push/pull STOP switch.The color coded i-Key sets the operating parameters for your control system and has been pre-configured at our factory. Your MK series controller has been custom engineered to duplicate all thecontrol functions normally found on the equipment being controlled and may contain basic controlfunctions as well as some auxiliary functions, depending on system application. The controller may behand carried, held by a belt loop strap or an optional shoulder carrying strap. The keypad controller ispowered by a disposable (Alkaline), or rechargeable (Ni-Cad), battery pack.Referring to Figure 3-1 below, all MK Series Controllers have the following Controls and Indicators:Figure 3-1. Operator controls and indicators
RSection 1, Page 18 02/2000 CATTRON®Controls and Indicators, continued.Referring to Figure 3-1, above, with the correct color coded ‘i-Key’ inserted into the MK controller,pulling both the STOP and ON/OFF switches to their respective ‘RUN’ and ‘ON’ positions will applypower to the transmitter. When transmitting with a good battery, two short ‘beeps’ will be heardimmediately after the ON/OFF power switch is set to ‘ON’ and the green TRANSMIT LED will‘flash’ rhythmically. In addition, any time a pushbutton (function key) is pressed, the greenTRANSMIT LED will ‘flash’ during each radio transmission.When the battery energy starts to go low, the yellow LOW BATTERY LED will ‘flash’ continuously,signaling the operator to change or re-charge the battery pack (refer to Battery Pack in Section 4 ofthis manual for instructions on how to replace a battery pack). When the ON/OFF switch is set(pushed) to the ‘OFF’ position, all control functions will cease.All active Function Key (pushbutton) commands are identified using labels placed next to eachpushbutton. When a pushbutton is depressed, the controller transmits the corresponding command (aslabeled). 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 outputfunction. The controller stops sending commands five seconds after the last pushbutton is released. A‘beep’ will be heard each time a button is pressed or released.Setting (pushing down) the red STOP switch to ‘STOP’ immediately sends a burst of stop commandsto the receiver/decoder unit. Immediately after the stop commands have been sent, the transmitterwithin the keypad controller switches OFF. STOP commands will automatically be repeated for oneminute or until the green ON/OFF switch is set (pushed) to the ‘OFF’ position.Battery Charging (optional).When installed, the re-chargeable Ni-Cad battery pack can be re-charged ‘in-situ’ and does not need tobe removed from the Keypad Controller housing. In this unit, it is not recommended to re-chargethe battery until the yellow LED flashes continuously.Figure 3-2. Battery ChargingMK Series ControllerChargerJack
R02/2000 CATTRON® Section 1, Page 19Battery Charging, continued.To re-charge the Battery, refer to Figure 3-2 above, and connect the transformer end of the batterycharger to a standard 120VAC outlet. Position the Keypad Controller face down, open out the hingedcover protecting the charging socket and insert the charger jack. Using the standard rate batterycharger, a fully discharged Ni-Cad battery pack will take approximately 10 hours to fully charge.Using the rapid rate battery charger, a fully discharged Ni-Cad battery pack will take approximately 1hour to fully charge.Operating Procedure – single pressure keypad controller.Note that all single pressure function keys are clearly marked with single arrows on the face of thepushbutton.`WARNINGS:6. ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTORINSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES)HAVE A BRAKE INSTALLED.7. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BECONNECTED TO THE MAINLINE SO THAT STOP COMMANDSOR FAULT CONDITIONS MONITORED BY AUTOMATICSAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZETHE MAINLINE CONTACTOR AND SET THE EQUIPMENTBRAKE.8. ALL EQUIPMENT SHALL HAVE AUDIO AND VISUAL ALARMINDICATIONS MEETING GOVERNMENTAL REQUIREMENTS.9. MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USEDAT, AROUND, OR NEARBY YOUR OPERATING FACILITY.THEREFORE, BEFORE INSERTING AN ‘i-KEY’ INTO AN MKCONTROLLER, YOU MUST INSURE THE CORRECT CODED ‘i-KEY’ IS SELECTED FOR THE DESIRED EQUIPMENT TO BEOPERATED.5. IF THE WRONG ‘i-KEY’ IS INSERTED INTO AN MKCONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND,OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL.FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAYRESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH INTURN COULD RESULT IN PERSONAL INJURY OR DEATH TOPERSONNEL AND DAMAGE TO EQUIPMENT
RSection 1, Page 20 02/2000 CATTRON®Operating Procedure – single pressure keypad controller,continued.`CAUTION:If the MK Controller is used or left standing in an upright position duringvery wet weather, or in hostile environments where large amounts ofmoisture are present, water will seep into the ‘i-key’ receptacle and stop allcontrol functions. To resume control functions, simply invert and shake thecontroller to remove excess water from the ‘i-key’ receptacle. Ideally, toprevent such occurences, the controller should: (1) never be left standingupright, (2) always be carried by the appropriate belt loop or shoulderstrap, and (3) operated in a near horizontal position during wet weather.1. Insert correct color coded ‘i-Key’. This coded electronic key sets the unique operatingparameters for a given control system. These parameters include, address code, operatingfrequency and function key (pushbutton) configurations. The i-key is simply installed bypressing into its receptacle. Once installed, the i-key may be further secured to the controllerusing the metal stud located behind the rubber bumper. Note the controller will not operatewithout an i-Key installed. However; other equipment located at, around, or nearby yourfacility may become operational.2. Set red STOP Switch to ‘RUN’. Pulling this switch upwards enables power to be applied tothe controller.3. Set green ON/OFF Switch to ‘ON’. Pulling this switch upwards applies power to thecontroller. Two quick ‘beeps’ with the green TRANSMIT LED flashing rhythmically indicatesthe controller is ready for use and a power up message has been sent to the targetreceiver/decoder. The targeted receiver/decoder will respond by energizing the mainlinecontactor of your controlled equipment.4. Press any active Function Key (pushbutton). The MK controller is now fully operational andtransmitting a signal as indicated by the green TRANSMIT LED flashing. Operate the keypadcontrol and auxiliary pushbuttons as required, remembering that each pushbutton must bemaintained in order for the function to continue to operate. Any or all functions may beoperated simultaneously if the controlled machine permits such operation.NOTES: A system STOP may be initiated at any time during the controlfunction by pushing the red STOP switch downwards. It shouldbe further noted that in “pitch and catch” control operationswhere two MK controllers are used, only the controller (i-Key)that sets the ‘STOP’ condition will re-set the ‘RUN’ condition.When all control functions have been completed, we recommendyou initiate a system STOP (push red STOP switch down)before setting (pushing) the green ON/OFF switch to the ‘OFF’position.
R02/2000 CATTRON® Section 1, Page 21Operating Procedure – dual pressure keypad controller.Note that all dual pressure function keys are clearly marked with double arrows on the face of thepushbutton.Your Dual Pressure (DP) function key pushbuttons have been pre-assigned through i-Keyprogramming for two-step operation. In other words, a second output is tied to the second level ofbutton depression. Other than the outputs of dual pressure pushbuttons, functional operation of thekeypad controller is the same as the single pressure controller described above.Operating principle (dual pressure keypad controllers).Typically, Dual Pressure (DP) controllers send one of two output commands to the receiver/decoderfrom a single button. DP buttons are paired to opposite directions of the same output, (i.e., forwardand reverse). These two buttons will control direction and speed relays. The first level of depression oneach button will command the desired direction and first step of movement (two directions = tworelays). The third relay is operated by either button’s second level of depression to the second speedoutput of the controlled equipment. This could be a single relay, or two separate relays assigned for thesecond speed step or for the VFD accelerate output (for the button in use).If the DP button is depressed to its first level, first speed is achieved and maintained as long as thebutton remains at that level of depression. If the button is depressed to its second level, second speed isachieved. If the operator releases pressure and allows the button to return to the first level, first speed isagain achieved.Moving directly from ‘OFF’ to the second level of depression can command second speed if sufficientpressure is applied. For example, one of two DP buttons labeled ‘FORWARD’ and ‘REVERSE’ isused at the first pressure level to command the direction and first speed of the equipment. The secondpressure level of the button in use will command a second speed.END OF SECTION

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