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Cattron Excalibur OCU User Manual

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Excalibur
OCU
User Manual
Part # 9M02-7573-A001-EN

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  • Page 1 ™ Excalibur User Manual Part # 9M02-7573-A001-EN...

  • Page 2: Revision History

    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 means Cattron Holdings, Inc.

  • Page 3: Table Of Contents

    Excalibur User Manual Contents Safety Instructions ..................................5 1.1 Warnings ................................5 System Description ..................................7 General ......................................8 3.1 Radio Transmission ............................8 3.1.1 Continuous Transmission ........................... 8 3.1.2 Radio Interference.............................. 8 3.2 Telegram Security .............................. 8 3.2.1 Frame Type ................................ 8 3.2.2 System Address ..............................
  • Page 4 Excalibur User Manual 7.10 Free RF Channel Scan Feature ........................29 7.10.1 RF Channel Change in Scan Mode ......................... 30 Hoist Selection ................................... 31 8.1 Configurable Parameters ..........................31 8.2 Storing the Last Selection Via the Electronic Selection Switch ................ 31 8.3 The Electronic Selection Switch Sequence ......................

  • Page 5: Safety Instructions

    WARNING Only personnel trained and authorized by Cattron, or personnel under the direct guidance of Cattron technical staff and while using the appropriate tools, are authorized to carry out board level maintenance of the equipment. Component level repair by personnel other than Cattron technical staff is strictly forbidden.
  • Page 6 Although Cattron and its subsidiaries do not specify the position of the operator when controlling the equipment, we are aware that some users are instructed and trained by their employer to ride the equipment in a safe manner.

  • Page 7: System Description

    OCUs and MCUs are possible. Additionally, different types of MCUs are available and can be paired with the Excalibur OCU. MCU types can be any of the CattronControl™ range including the CT24-09, CT24-17 Relay MCUs, the CCM12 CANopen, the J1939 MCU and the MMCU4 which can be configured with other BUS-based interfaces such as Ethernet/IP, PROFINET, etc., plus relays and Analog and Digital inputs and outputs.

  • Page 8: General

    Excalibur User Manual General With an OCU and a matching MCU, a machine such as a crane or vehicle can be remotely radio controlled, avoiding the need for a wired connection between the human interface and the controlled device. Several different control elements are integrated into the OCU housing so commands to the device securely encode into a radio transmission.

  • Page 9: Crc

    Excalibur User Manual 3.2.3 CRC The telegram is checked for integrity using a 16-bit CRC. Frames containing a mismatched CRC will be rejected. 3.2.4 Frame Counter Each message has an 8-bit embedded frame counter that changes on every data frame. This prevents frozen data and malicious hacking.

  • Page 10: Standard Operator Control Unit (Ocu)

    User Manual Standard Operator Control Unit (OCU) The Excalibur OCU is a lightweight, palm-sized, extremely rugged customizable controller. Each OCU is designed to meet a specific control application. Two housing sizes are available that may be equipped with 6, 8, 10 or 12 pushbuttons.
  • Page 11 Excalibur User Manual Both steps of each individual pushbutton can operate different functions. Typically, the first step controls a direction or function and the second step controls a speed increment, although it is possible with a step-less drive to use the second step as accelerate, the first step as hold speed, and the released state as decelerate. Any function is active only if the respective pushbutton is pressed.

  • Page 12: Safe-T-Stop Version

    Figure 3: Safe-T-Stop OCU General Information The Excalibur OCU is globally compliant when supplied with an appropriate radio module – additional certifications may be required for some regions; details are available on request. It has been designed with the latest generation dual-channel electronics and exceeds the Safety Related Systems requirements for ISO13849 Category 3 PLd.
  • Page 13 Excalibur User Manual In North America, the Excalibur is compliant with both FCC Part 15 and Industry Canada RSS-210 standards. No United States of America FCC or Industry Canada license is required for operation of FCC Part 15 or RSS-210 OCUs.

  • Page 14: Operating Instructions

    Excalibur User Manual Operating Instructions OCU First Use The battery pack must be fully charged before using the system for the first time. Charging the battery pack can take up to 3 hours. OCU Battery Pack – Removal and Replacement Referring to Figure 4, the Battery Pack is located on the back of the OCU.

  • Page 15: Battery Charging

    User Manual WARNING The battery charging unit is designed for use with Cattron Nickel Metal Hydride (Ni-MH) battery packs. Other battery packs may explode when charged with this device. Failure to comply with this warning will void our warranty and may result in serious injury or death to personnel and damage to equipment.

  • Page 16: Transkeys

    Excalibur User Manual If the battery voltage is far below normal, the charger will cut the fast charge current and go to trickle charge mode. The LED will then indicate “error” by a flickering green and orange light. If the power source input voltage is turned off, the charger will reset. When the power source is turned on again, a new charge cycle will start.

  • Page 17: Ocu Switch-On Procedure

    Excalibur User Manual OCU Switch-On Procedure The correct function of the two switches under the Stop switch must be verified each time the OCU is turned on, to guarantee its ability to operate (at least one switch) and turn off the OCU on demand. Referring to Figure 6 below, switch ON the OCU as follows: Fully press the ON/HORN pushbutton once.
  • Page 18 Excalibur User Manual 1. Fully depress the ON/HORN pushbutton to the second stage and observe that the horn on the targeted crane or machine responds. 2. Now that the system is active, you can operate the OCU control pushbuttons as required. Any or all functions may be operated simultaneously if the controlled machine permits such operation.

  • Page 19: Ocu Maintenance

    User Manual OCU Maintenance Unless customer technicians have received formal maintenance training from Cattron, the safe and approved maintenance philosophy is that inoperative OCUs and MCUs be returned as complete units to our workshops for repair. This ensures that safety and reliability are maintained at the required level.

  • Page 20: Operating Frequency Selection

    Excalibur User Manual Operating Frequency Selection In order to ensure interference-free operation of a radio control system, it may be necessary to change the RF channel preset in the factory for transmission and reception by the system. Changing the RF channel can become necessary due to interference or the fact that a specific RF channel is already in use.

  • Page 21: Changing The Rf Channel

    Excalibur User Manual Changing the RF Channel With this method of changing the RF channel, starting from the current channel which is indicated by the four LEDs, the channel can be changed in the sequence shown in the tables below to a specific channel in the respective frequency band or cluster.

  • Page 22: Cancelling Rf Channel Selection

    Excalibur User Manual Note: Inserting a new TransKey having a different address than the one stored in the OCU and turning ON the OCU activates the RF channel that is pre-configured in the new TransKey. The OCU then starts transmitting on this new RF channel. Cancelling RF channel Selection While the OCU is in Programming Mode, pressing the STOP button anywhere in the sequence cancels the RF channel selected, exits the programming mode and switches off the OCU.
  • Page 23 Excalibur User Manual Table 2: RF Channel Color Code Table for 902-928 MHz RF Module Cluster Channel Freq LED Color 903.0 904.2 green 905.4 orange 906.6 907.8 909.0 green 918.6 orange green 919.8 921.0 green 922.2 green green green 923.4 orange 903.2 orange...
  • Page 24 Excalibur User Manual Table 2: RF Channel Color Code Table for 902-928 MHz RF Module, continued Cluster Channel Freq LED Color 909.6 green orange green 919.2 green 920.4 green green 921.6 green green green green 922.8 green orange 924.0 green orange 903.8 green...
  • Page 25 Excalibur User Manual Table 3: RF Channel Color Code Table for 433 MHz Band LED Color Channel Frequency 433.0775 433.1025 green 433.1275 orange 433.1525 433.1775 433.2025 green 433.2275 orange 433.2525 green 433.2775 green 433.3025 green green 433.3275 green orange 433.3525 orange 433.3775 orange...
  • Page 26 Excalibur User Manual Table 3: RF Channel Color Code Table for 433 MHz Band, continued LED Color Channel Frequency 434.0525 green green 434.0775 green green 434.1025 green green green 434.1275 green green orange 434.1525 green orange 434.1775 green orange 434.2025 green orange green...
  • Page 27 Excalibur User Manual Table 4: RF Channel Color Code Table for 869 MHz Wide Band LED Color Channel Frequency 869.850 869.800 869.900 green 869.535 orange 686.300 * This channel should not be used if existing systems are already operating on channels 1 and/or 2 and are in close proximity. Table 5: RF Channel Color Code Table for 869 MHz Narrow Band LED Color Channel...
  • Page 28 Excalibur User Manual Table 6: RF Channel Color Code Table for 418 MHz Band LED COLOR Channel Frequency 418.9500 green green 418.9750 green orange 419.0000 orange 419.0250 orange 419.0500 orange green 419.0750 orange orange 419.1000 419.1250 419.1500 green 419.1750 orange 419.2000 419.2250 419.2500...

  • Page 29: Field Strength Indicator

    Excalibur User Manual Field Strength Indicator Note: This feature is NOT available for 869 MHz wide band RF modules. While the OCU is in Programming Mode, it is possible to determine whether there are other OCUs or sources of interference on the selected RF channel and how strong that signal is (i.e., its field strength). The level of the signal can either be displayed via the ‘STATUS’...

  • Page 30: Rf Channel Change In Scan Mode

    Excalibur User Manual the lowest interference field strength is displayed as the channel suggestion. This RF channel suggestion can be accepted or the next channel proposal on the list can be selected. 7.10.1 RF Channel Change in Scan Mode While the OCU is in programming mode, pressing the scan button, 2nd stage, creates a list of RF channels where no or little noise field strength has been measured.

  • Page 31: Hoist Selection

    Excalibur User Manual Hoist Selection Configurable Parameters The following parameters are configurable: • Activation/deactivation of changing to different hoists • Storage/no storage of the change to different hoists • The hoists change sequence and output via sequence selection 0-13 Storing the Last Selection Via the Electronic Selection Switch Storing the last selection via the electronic selection switch and reloading this selection on switching the OCU on is preset in the Transkey.

  • Page 32: Hoists And Enable Selection Buttons For The 10 And 12 Button Ocus

    Excalibur User Manual Hoists and Enable Selection Buttons for the 10 and 12 Button OCUs The buttons for switching to a different hoist are shown in the diagram and charts below. S67- 10 Button OCU Lifting gear sequence 0 – 5 S69 –...
  • Page 33 Excalibur User Manual 10 BUTTON OCU FUNCTION PUSHBUTTON HOIST PRESS NOTES RELAY PRESS LEFT 1 LEFT 2 RIGHT 1 RIGHT 2 LEFT RIGHT SEQUENCE SEQUENTIAL A-B-BOTH SEQUENTIAL A-BOTH-B SEQUENTIAL A-B-A INDEPENDENT BUTTON SELECTION ON-OFF INDEPENDENT BUTTON SELECTION, ON-OFF, ONLY ONE HOIST AT A TIME RIGHT BUTTON MUST BE DEPRESSED AS AN ENABLE INDEPENDENT BUTTON...
  • Page 34 Excalibur User Manual 12 BUTTON OCU FUNCTION PUSHBUTTON HOIST PRESS NOTES RELAY PRESS LEFT 1 LEFT 2 RIGHT 1 RIGHT 2 LEFT RIGHT SEQUENCE SEQUENTIAL A-B-BOTH SEQUENTIAL A-BOTH-B SEQUENTIAL A-B-A INDEPENDENT BUTTON SELECTION ON-OFF INDEPENDENT BUTTON SELECTION, ON-OFF, ONLY ONE HOIST AT A TIME RIGHT BUTTON MUST BE DEPRESSED AS AN ENABLE INDEPENDENT BUTTON...

  • Page 35: Crane Selection

    Excalibur User Manual Crane Selection This optional feature is also known as Multi Access Control (MAC). Multi-Address Capability allows up to 15 MCUs to be controlled by up to seven OCUs. The selection and de-selection process is described below. Figure 11: Button assignment on Excalibur controllers 9.1 General Operating Notes Depending on the system type, up to 15 MCUs can be controlled, either individually or in groups, by up to seven OCUs;...

  • Page 36: Operation Following A Request

    Excalibur User Manual • Keep the Request button pressed until the status indicator on the crane indicates the desired status. (** = This function is configuration-dependent. If "automatic release" is configured, the MCUs are released automatically as soon as the position of the MCU selection switch is changed) 9.3.1 Operation Following a REQUEST Once one or more cranes have been requested, it is then possible to switch between the various available combinations of cranes by altering the position of the electronic selection switch on the OCU.
  • Page 37 Excalibur User Manual Figure 12: Multi control mode Figure 13: Single control mode 9M02-7573-A001-EN Version 3.0...

  • Page 38: Operating Notes

    Excalibur User Manual 9.7 Operating Notes 9.7.1 Stop Command Issuing a Stop command on an OCU affects all MCUs that are switched on and assigned to that OCU. 9.7.2 MCU Behavior When Switched On When the power supply of a MCU is switched on, the MCU is initially not assigned to an OCU. 9.7.3 Behavior of the Safety Relays The safety relays are only activated when an OCU requests one or more cranes.

  • Page 39: Compliance

    User Manual 10. Compliance CE Declaration of Conformity Hereby Cattron declares that the radio equipment is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address: www.cattron.com RF Compliance Information to the User regarding FCC Compliance: •...

  • Page 40: Appendix I: Technical Specifications

    Excalibur User Manual Appendix I: Technical Specifications OCU Technical Specifications OCU DATA DESCRIPTION OCU SERIES CT24 Excalibur FREQUENCY RANGE 902-928 MHz, 433-434 MHz, 868-869 MHz, 447-473 MHz and others OPERATION RANGE 300 ft line-of-sight typical TRANSMISSION SPEED 20 kb/s POWER OUTPUT 1mW or 10mW typical ANTENNA Internal...

  • Page 41: Appendix Ii: System Fault/Status Messages

    ‘STATUS’ LED will illuminate red and signal this with a series of blinks. Refer to the following table for the blink sequence and the corresponding fault messages. Note that any repairs or replacements should be made only by Cattron trained technicians. OCU STATUS LED...

  • Page 42: Appendix Iii: Configuration Sheets

    Excalibur User Manual Appendix III: Configuration Sheets Example Configuration Sheet for System Model 983127 9M02-7573-A001-EN Version 3.0...

  • Page 43: Example Configuration Sheet For System Model 983128

    Excalibur User Manual Example Configuration Sheet for System Model 983128 9M02-7573-A001-EN Version 3.0...

  • Page 44: Example Configuration Sheet For System Model 983129

    Excalibur User Manual Example Configuration Sheet for System Model 983129 9M02-7573-A001-EN Version 3.0...

  • Page 45: Example Configuration Sheet For System Model 983130

    Excalibur User Manual Example Configuration Sheet for System Model 983130 9M02-7573-A001-EN Version 3.0...
  • Page 46 Due to continuous product improvement, the 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 9M02-7573-A001-EN Version 3.0...

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