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CT24 MCU

User Manual

20

9M02-7608-A001-EN
Version 2.0

Referring to

, an additional processor status LED indicator is mounted on the MCU processor board and

may be viewed by removing the MCU front cover. This LED blinks orange if the receiver does not detect a
transmitter and green if valid messages are received. In addition, if the second processor detects a fault, this LED
blinks red.

Figure 7: MCU Status and Fault LEDs

4.1.1 Optional 9-36 VDC Input MCU

An optional 9-36 VDC input MCU, Part Number 1MCU-7608-A103, is available. This MCU is identical to the
standard MCU except that the power supply on the relay board is changed.

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Summary of Contents for CT24 Series

Page 1: ...CT24 9 CT24 17 and CT24 32 MCU User Manual 9M02 7608 A001 EN ...

Page 2: ... as to the fitness merchantability or sustainability of any Cattron products for any specific or general uses Cattron Holdings Inc or any of its affiliates or agents shall not be liable for incidental or consequential damages of any 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 ...

Page 3: ...11 3 2 3 CRC 11 3 2 4 Frame Counter 12 3 5 System Parameters 12 4 CT24 MCU Overview 13 4 1 Description 14 4 1 1 Optional 9 36 VDC Input MCU 20 5 Installation 21 5 1 General 21 5 2 Mounting 21 5 2 1 Choosing a Mounting Location 21 5 3 Interface 25 5 4 Interface Wiring 25 5 5 Safety Critical Interfaces 25 5 6 Power and Control Cables Interface 25 5 7 Determination of Correct Control Circuit Wire Gau...

Page 4: ...nsfer Switch 39 6 7 Antenna 40 7 Optional System Features 42 7 1 OCU Automatic Turn Off 42 7 2 Motion Enable Features 42 7 2 1 Push To Operate PTO 42 7 2 2 Push To Enable PTE 42 7 2 3 Double Jog Enable DJE LRC OCUs only 43 7 2 4 Vigilance 43 7 3 IR Link 44 7 3 1 Feature and Benefits 44 7 3 2 Features Options 44 7 4 RF Range Control 46 7 4 1 Feature and Benefits 46 7 4 2 Feature Options 47 7 4 3 Op...

Page 5: ...ersion 2 0 7 8 2 B SAC 50 7 9 TDMA 51 7 10 Frequency Scanning 51 7 11 SymmetryLock 51 7 11 1 Key Value Statements 52 7 12 Multi MCU Talkback 52 7 13 Talkback and LCD Display Resolution 52 Appendix Error Codes 53 CE Declaration of Conformity 54 ...

Page 6: ...taining to the matching Operator Control Unit OCU please refer to the separate OCU user manual Terminology The following represents important acronyms and long form names used in this document OCU Operator Control Unit historically referred to as a transmitter MCU Machine Control Unit historically referred to as a receiver ASO Automatic Safety Override in this context a fully automatic system shut...

Page 7: ...ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT WARNING MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT AROUND OR NEARBY YOUR OPERATING FACILITY THEREFORE BEFORE INSERTING A TRANSKEY YOU MUST INSURE THE CORRECT CODED TRANSKEY IS SELECTED FOR THE DESIRED EQUIPMENT TO BE OPERATED IF THE WRONG TRANSKEY IS INSERTED OTHER REMOTE CONTROLLED EQUIPMENT LOCATED ...

Page 8: ...PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR REMOTE CONTROL SYSTEM 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 EXHIBITIN...

Page 9: ...witched off and the relevant master switches also switched off WARNING Observe the statutory regulations and directives applicable for the intended purpose e g Accident prevention regulations Safety rules and directives Standards Generally applicable statutory and other binding regulations for accident prevention and environmental protection and general safety and health requirements Keep the oper...

Page 10: ...ause physical damage to the product or the environment 2 4 Safety Instructions for Assembly Disassembly Only trained and qualified persons may perform installation maintenance work Note Ensure suitable transient protection devices are fitted to controlled electrical relays or valves Ensure correct wiring of the crane s main contactor and the manual radio transfer switch Isolate the system from the...

Page 11: ...ly turns off i e safety relays and command relays open Depending on the application the time varies from 0 5 s to 2 0 s In order to ensure optimum communication between the OCU and the MCU ideally operate the OCU with line of sight to the MCU antenna at all times Avoid total shielding of the signal path by metallic and other solid obstructions In some configurations the MCU may be configured to op...

Page 12: ... hacking 3 5 System Parameters The system parameters including the system address and the selected RF channel are set by programming the TransKey This is a removable radio frequency identification device RFID located inside the OCU and MCU It is programmed by the manufacturer Note Please refer to the separate Configuration Data documents for the specific system parameter settings of your system ...

Page 13: ...quirements This MCU can be operated with one or more operator control units OCUs Basically in its most simple form the OCU is a radio transmitter and the MCU is a radio receiver A radio frequency RF receiver decoder and relay interface contained in the MCU is under the direct control of the operator with the OCU The CT24 MCU is supplied in three different size enclosures the smaller CT24 9 the med...

Page 14: ...9 only has a single fuse If the OCU is communicating with the MCU and the machine Mainline Contactor fails to energize these fuses should be checked for continuity Just like the OCU MCUs use a removable TransKey to define and enable the appropriate operating parameters Note OCU and MCU TransKeys must not be swapped The OCU transmitter TransKey is black The MCU receiver TransKey is yellow Swapping ...

Page 15: ... The following items are identified in Figure 2 1 Status LEDs on micro board 2 TransKey inserted in slot inside enclosure 3 Seven N O function relays 4 Terminal main input voltage 5 Fuse main input 6 Removable terminal strip for function relays 7 Fuse for main contactor safety relays 8 Terminal strip for main contactor safety relays 9 Two main contactor safety relays 10 Two C O function relays ...

Page 16: ... N O safety relays and two C O safety relays The following items are identified in Figure 3 1 Five N O function relays 2 Two N O function safety relays 3 Two C O function safety relays 4 Main contactor safety relays 5 Fuses for main contactor safety relays 6 Terminals for main contactor safety relays NB If you are replacing a CT24 9 relay board with a CT24 9 ASO relay board it will be necessary to...

Page 17: ... CT24 17 MCU The following items are identified in Figure 4 1 Transkey 2 Status LEDs 3 Terminal main input voltage 4 Fuse main input 5 Function relay plug in terminal strips 6 Fuses for main contactor safety relays 7 Terminal strip for main contactor safety relays ...

Page 18: ...nal HAN style connector shown fitted The following items are identified in Figure 5 1 Status LEDs 2 TransKey 3 Terminal main voltage 4 Fuse mains 5 Removable terminal strips for function relays 6 Fuses for main contactor safety relays 7 Terminal strip for main contactor safety relays ...

Page 19: ...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 safety relays are energized Illuminates orange if valid data from the OCU is received and the safety relays are de energized Illuminates red if data from another OCU with invali...

Page 20: ...ED blinks orange if the receiver does not detect a transmitter and green if valid messages are received In addition if the second processor detects a fault this LED blinks red Figure 7 MCU Status and Fault LEDs 4 1 1 Optional 9 36 VDC Input MCU An optional 9 36 VDC input MCU Part Number 1MCU 7608 A103 is available This MCU is identical to the standard MCU except that the power supply on the relay ...

Page 21: ...d within a secondary enclosure Select a location to minimize any possible interference from RF sources such as motors Ideally the MCU enclosure should be installed as close as practical to the controlled machine s electrical cabinet All wiring entering the enclosure must be terminated inside the enclosure Note Do not install any pass through wiring To prevent interference on signal lines do not in...

Page 22: ...CT24 MCU User Manual 22 9M02 7608 A001 EN Version 2 0 Figure 8 CT24 9 and CT24 17 MCU Enclosure Mounting Dimensions Drawings ...

Page 23: ...CT24 MCU User Manual 23 9M02 7608 A001 EN Version 2 0 Figure 9 CT24 9 and CT24 17 MCU Enclosure Mounting Drilling Drawings ...

Page 24: ...CT24 MCU User Manual 24 9M02 7608 A001 EN Version 2 0 Figure 10 CT24 32 MCU Enclosure Mounting Drilling Drawings ...

Page 25: ...NS 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 REMOTE CONTROL SYSTEM When safety critical bistable maintained functions i e electro magnetic circuits vacuum circuits grab pump m...

Page 26: ...evice being controlled Where the voltage exceeds that mentioned above of 30 VAC or 42 2 VDC the wire should not be less than 24 AWG or 0 2 mm2 in order to comply with International Electrical Safety Standards Rules defining wire gauge are many and depend on factors such as temperature wire bundling number of loaded wire pairs duty cycle of output function etc In order to simplify the process the f...

Page 27: ...CT24 MCU User Manual 27 9M02 7608 A001 EN Version 2 0 Table 2 are based on cable with insulation rated at 105ºC ...

Page 28: ... 265 C3 Bundled Cables 0 55 for 10 pairs worse than CSA 22 2 14 at 0 7 D1 Duty Cycle Correction 1 265 25 for a standard Crane AWG mm2 CSA 22 2 14 3 col 5 Wire Capacity 14 AWG 2 08 15 00 8 25 8 25 10 44 16 AWG 1 31 9 00 4 95 4 95 6 26 18 AWG 0 823 6 00 3 30 3 30 4 17 20 AWG 0 518 4 00 2 20 2 20 2 78 22 AWG 0 326 3 00 1 65 1 65 2 09 24 AWG 0 205 2 00 1 10 1 10 1 39 4 Bundled Cables 7 24 0 7 5 7 1 Fo...

Page 29: ...ty Application Crane with Multi Select or Machine For a multi select set of five outputs continuous The common wire may be carrying 200 W 5X40 at 48 VAC for a current of 4 A Therefore 16 AWG might be used Each select output might be 0 83 A 40 48 so 24 AWG would be fine 5 8 3 High Duty Maximum Current Application For multiple outputs running 5 A loads continuous Common carrying up to two relay load...

Page 30: ...locks TYPE ALL EXCEPT ANALOG ANALOG WIRE RANGE AWG Spring clamp ASP046 series ASP044 series 0 459 mm2 to 1 5 mm2 24 to 16 Screw 249 series n a 0 459 mm2 to 2 5 mm2 24 to 13 5 9 6 Ferrule Types Ferrules can support wires sizes from 12 to 24 AWG Both single wire and dual double wire ferrules are available as shown in the following figures Figure 13 Single Wire Ferrules Figure 14 Dual Wire Ferrules 1...

Page 31: ... X X 14 X 1 16 1 1 18 1 1 20 2 2 22 2 2 24 2 2 Note The use of ferrules is recommended with spring clamp terminals The spring block terminals are suitable for a wire range of 24 AWG 0 2 mm2 to 16 AWG 1 31 mm2 If you are using two wires in the same terminal then the limit is 20 AWG 0 518 mm2 per wire If larger wires up to 14 AWG or 2 5 mm are required then screw terminals can be substituted or ferr...

Page 32: ...YPE ALL EXCEPT ANALOG ANALOG WIRE RANGE AWG Spring clamp ASP046 series ASP044 series 0 08 mm2 to 1 5 mm2 28 to 16 Table 7 Terminal Blocks Screw Type TYPE ALL EXCEPT ANALOG ANALOG WIRE RANGE AWG Screw 249 series n a 0 08 mm2 to 2 5 mm2 28 to 12 Screw n a 369 series 0 08 mm2 to 1 5 mm2 28 to 16 ...

Page 33: ... 0 6 MCU Connections The following pages show the respective terminal strip connections within the MCU enclosure The actual wiring to the machine depends on the specific configuration sheet supplied with your system Figure 15 CT24 9 Relays and Terminals ...

Page 34: ...y using safety relays on K6 through K9 and that the Main Contactor relays K0 M and K0 S have separate fuses and terminal strips When replacing a CT24 9 board with a CT24 9 ASO board it will be necessary to link J1A N O terminal to J1B C terminal and to take the J1 C terminal and J2 NC terminal to the machine main contactor control circuit as the CT24 9 only has one terminal pair see Figure 14 ...

Page 35: ...CT24 MCU User Manual 35 9M02 7608 A001 EN Version 2 0 Figure 16 CT24 17 Relays and Terminals ...

Page 36: ... 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 K32 K31 K30 K29 Power Module J6 J5 F2 F6 K34 K33 F3 1 2 3 4 5 6 7 8 9 10 11 12 J8 1 2 3 4 5 6 7 8 9 10 11 12 J9 1 2 3 4 5 6 7 8 9 10 11 12 J10 1 2 3 4 5 6 7 8 9 10 11 12 J11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 J3 J7 1 2 3 4 J4 1 2 BLK WHT 90 265 Vac Input 1 GRN 1 CPU Board J18 ...

Page 37: ...to the Conduit Grounding Kit and secured using the Lock Nut and the Binding Screw Both the incoming Protective Earth PE wire and a wire from the MCU PE terminal must be connected and securely fastened to the Protective Earth Clamp Use a Conduit Grounding Kit as recommended by the conduit manufacturer that has an appropriate National Approval A typical example would be an RACO type 1264 that carrie...

Page 38: ...ent 6 4 Relay Outputs Each output relay has at least one normally open NO contact which is available for wiring at the relay board terminal block TB These contacts are rated for up to 5 0 A at 110 240 VAC or 30 VDC Each output relay is completely independent of all other relays There are no common connections between any output contacts This allows the connection of different power sources AC and ...

Page 39: ...CT24 MCU User Manual 39 9M02 7608 A001 EN Version 2 0 Figure 20 Example Mainline Drawing ...

Page 40: ...tching the OCU to ON energizes the mainline contactor Once the mainline is energized a continuously repeated valid signal must be received for function outputs to engage If this signal is interrupted for any reason all function outputs will switch off Figure 19 Basic Safety Relay Contact Wiring 6 6 Transfer Switch A Transfer Switch Type HM254 73 Part Number 452031 provides an easy way to switch th...

Page 41: ...ansfer 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 Press the STOP button on the OCU and temporarily remov...

Page 42: ...uitable gland for the co axial cable to exit and connect to the antenna connector on the MCU 7 Conduit shall not be connected directly to the MCU enclosure as there is no provision for grounding it within the MCU Figure 21 Remote Antenna Parts If you have ordered an optional remote antenna there will be a connector for the antenna cable at the top of receiver enclosure 1 Install the antenna at a l...

Page 43: ...ns can be hard to maintain and can cause operator fatigue Bars and pads can be easier to maintain but are difficult to implement in many controller designs 7 2 2 Push To Enable PTE In a PTE system there is a means of activation that only needs to be depressed momentarily before a lever joystick or button is activated for the motions to operate The enable actuator may take the form of a button in t...

Page 44: ... LED outputs to create the following sequence of colors Green Joysticks disabled Red Joysticks enabled Orange During initial enabling sequence Pros Easy to use Protects against accidental activation before the motion is enabled Cons Once activated if an additional lever is accidentally deflected protection will require removal of the deflecting mechanism or pressing the Stop button 7 2 4 Vigilance...

Page 45: ...serious injuries or death to personnel An operator picks up the wrong controller fails to verify the identity of the crane and while thinking it is not working a crane behind him is moving which hits an adjacent crane with a suspended press die that then swings into the press and is irreversibly damaged When a system is configured to control functionality by the presence of a specific IR transmitt...

Page 46: ...e 22 IR Close Start Note The controller will only start when inside the IR zone 10 Ton Press IR Emitter CRUSH ZONE Safe Zone Figure 23 IR Function Enable Note The controller only operates the machine when it is inside the IR zone IR START CONE About 40 degrees ...

Page 47: ...r picks up a controller and moves the controls around unaware that it is actually operating a crane with consequentially dangerous results An employee is working on a controller in a workshop and has not isolated the crane supply the crane moves around causing material damage and narrowly misses causing serious injuries or death to personnel An operator picks up the wrong controller fails to verif...

Page 48: ...ge Bluetooth wireless technology link that is temporarily connected to the MCU A Class 1 Bluetooth Dongle may also need to be fitted to the PC to increase the range beyond that which is built in to the Bluetooth device 7 4 3 Operating Modes There are three operating modes as described below It is possible to select only a single mode or a combination of Close Start and Range Limit or Range Limit a...

Page 49: ...he following ways IR requires the addition of one or more IR transmitters and receivers on the machine and the OCU RF uses the radios already being used for the data transmission so it is inherently simpler and may cost less RF is not directional but IR is very directional and requires the OCU to be well aligned with a clear line of sight before a CS is possible while RF only requires a general al...

Page 50: ...reads the card and compares the ID card to a list of predefined users If the card is current the OCU sends a signal to the MCU that the user is authorized and enables control 7 7 Multi Address Capability MAC MAC is an optional feature and allows up to 15 MCUs to be controlled by up to seven OCUs Some simple examples are below each MCU is equipped with a number of lights outputs to indicate the cur...

Page 51: ...ase 7 8 Sub Address Capability This optional feature is available for the LRC L OCU and the MMCU4 or CT24 MCUs It allows one LRC OCU to have secure and simultaneous selection of up to four from a larger number of MCUs by the insertion into the OCU of a number of RFID keys With this feature there is no possibility that any two OCUs can attempt to select the same MCU at the same time An example of u...

Page 52: ...bjects that are too large for a single crane the wing of an aircraft or the carriage of a rail car are both good examples If the cranes being used do not move together in symmetry there is a risk of the load being dropped with consequential damaging to the load surrounding equipment and personnel Traditionally tandem crane operations have required additional systems to be fitted to form a safety i...

Page 53: ... the LCD Backlight control the status LEDs activate Haptic Vibration or audible alerts etc The information could be obtained from many different types of devices such as Load Scales Positional Sensors Overload Sensors Confirmation of State Warning State Process Data Instructions for operators 7 13 Talkback and LCD Display Resolution Talkback is an optional feature Talkback may be directed to LEDs ...

Page 54: ...on for repair 6 flashes not used 7 flashes Fault with RF module Replace the RF module 8 flashes General system error Send to Cattron for repair 9 flashes Relay control voltage is too low Send to Cattron for repair 10 flashes Hardware fault Send to Cattron for repair 11 12 flashes not used 13 flashes Slave CAN controller cross monitor error Make sure both master and slave CAN interfaces are properl...

Page 55: ...al 55 9M02 7608 A001 EN Version 2 0 CE Declaration of Conformity Hereby Cattron declares that the radio equipment is in compliance with Directive 2014 53 EU View the EU Declaration of Conformity document www cattron com ...

Page 56: ...e information provided in this document is subject to change without notice Cattron Support For remote and communication control systems support parts and repair or technical support visit us online at www cattron com contact Cattron North America Inc 655 N River Rd NW Suite A Warren OH 44483 ...

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