Cattron MP96 Series User manual

Cattron™
MP96/48 Series
Portable Remote Control
Systems
User Manual
68C-MP96/48-RD-EN

Cattron™ MP96/48 Series Portable Remote Control Systems
User Manual
2
68C-MP96/48-RD-EN
Version 006
Revision History
VERSION
DATE
NOTES
005
03-2009
006
04-2020
Document rebranded and contact information updated
Any information furnished by Cattron™ and its agents is believed to be accurate and reliable. All specifications are subject to change without notice.
Responsibility for the use and application of Cattronproductsrestswith the end user since Cattronand its agentscannot be aware of all potential
uses.Cattronmakesnowarrantiesastonon-infringementnorastothefitness, merchantability,orsustainabilityofanyCattronproductsforany
specificorgeneraluses.CattronHoldings,Inc.,oranyofitsaffiliatesoragentsshallnotbeliableforincidental or consequentialdamagesofany
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. or one or more subsidiaries of Cattron Holdings, Inc. Cattron™, corresponding logos,
and other marks are trademarks or registered trademarks of Cattron Holdings, Inc. Other marks may be the property of third parties. Nothing
hereinprovidesalicenseunderanyCattronoranythirdpartyintellectualpropertyright.

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Contents
1 Operation and Maintenance Instructions.............................................................................................................8
1.1 Important Notices......................................................................................................................................8
1.2 List of Technical Abbreviations.................................................................................................................9
1.3 Glossary of Graphical Symbols ............................................................................................................. 10
2 Introduction........................................................................................................................................................ 11
2.1 How to Use This Manual........................................................................................................................ 11
3 Safety Summary................................................................................................................................................ 12
Warnings.............................................................................................................................................. 12
Cautions............................................................................................................................................... 14
General................................................................................................................................................. 15
4 Functional Description....................................................................................................................................... 16
4.1 Introduction............................................................................................................................................ 16
4.2 Component Identification....................................................................................................................... 16
4.3 Functional Description........................................................................................................................... 17
4.4 Principle of Operation............................................................................................................................ 18
4.5 System Functions .................................................................................................................................. 19
4.5.1 Fault-Tolerant Operation .......................................................................................................... 20
4.5.2 Protocol..................................................................................................................................... 20
4.5.3 Decoder Circuit Board .............................................................................................................. 20
4.5.4 Multiple Microcomputers........................................................................................................... 20
4.5.5 System Initialization.................................................................................................................. 21
4.5.6 Multiple Watchdog Circuits (Hardware and Software).............................................................. 21
4.5.7 Automatic Safety Override (ASO)............................................................................................. 21
4.5.8 System Status Display.............................................................................................................. 22
4.5.9 Serial Communication Ports..................................................................................................... 22
4.6 Standard Datalog Feature ..................................................................................................................... 22
4.6.1 Downloading, Viewing and Printing the Datalog ...................................................................... 24
4.7 Portable Remote Controller Overview................................................................................................... 24
4.8 Crane Bridge (Long Travel) Braking...................................................................................................... 25
4.9 Radio Frequency (RF) Receiver Options .............................................................................................. 25
4.9.1 R1HN Receiver Board.............................................................................................................. 26
4.9.2 R2HN Receiver Board with Liquid Crystal Display (LCD) ........................................................ 26

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4.9.3 R3HNX Transceiver Board....................................................................................................... 27
4.10 TALKBACK® ......................................................................................................................................... 28
4.11 MP96G2 Decoder Board –Field Programmable Memory (EEPROM) ................................................. 28
4.12 Proportional Systems............................................................................................................................. 28
4.13 MP96 Series –Feature Summary ......................................................................................................... 29
4.14 MP96 Series –Specifications................................................................................................................ 30
4.15 MP96/MP48 –Feature Comparison...................................................................................................... 32
5 Installation......................................................................................................................................................... 37
5.1 Pre-installation Checks.......................................................................................................................... 37
5.2 Interface Connections............................................................................................................................ 37
5.2.1 Introduction............................................................................................................................... 37
5.2.2 The Controlled Machine ........................................................................................................... 37
5.2.3 Control Transformer.................................................................................................................. 37
5.2.4 Disconnect and Outlet .............................................................................................................. 38
5.2.5 Transfer Switch......................................................................................................................... 38
5.2.6 Relay Outputs........................................................................................................................... 39
5.2.7 R/C Snubbing ........................................................................................................................... 39
5.2.8 Mainline Circuit (Operate and Reset Relays)........................................................................... 39
5.2.9 Attenuator ................................................................................................................................. 41
5.3 Installation.............................................................................................................................................. 41
5.3.1 Getting Started.......................................................................................................................... 41
5.3.2 Choosing a Mounting Location................................................................................................. 41
5.3.3 Wire Routing............................................................................................................................. 42
5.3.4 Remote Antenna Location........................................................................................................ 43
5.3.5 Triple Diversity Antenna ........................................................................................................... 44
5.3.6 Direct DC Wiring Option ........................................................................................................... 44
5.4 Preset Frequency Selections –Model R1HN Receiver Only................................................................ 46
5.5 Post Installation Checks ........................................................................................................................ 47
5.5.1 System Status Display and LED Indicators.............................................................................. 47
5.5.2 Normal Operating Display ........................................................................................................ 48
5.6 System Checkout................................................................................................................................... 51
5.7 Data Collection and Review Options..................................................................................................... 60
5.7.1 Standard Datalog Feature ........................................................................................................ 60
5.7.2 Portable Data Download –Controller Talkback (PDDCTB) Unit.............................................. 60

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5.7.3 Log-Utility.................................................................................................................................. 62
5.8 Installation of the MP96 Datalog Analysis and Utility Prorgam ............................................................. 62
6 Operating Instructions....................................................................................................................................... 65
6.1 General.................................................................................................................................................. 65
6.2 Remote Control Operation –General Equipment ................................................................................. 65
6.3 Remote Control Operation –Electric Overhead Traveling (EOT) Crane .............................................. 66
6.4 Operator ‘Pitch and Catch’ (Optional).................................................................................................... 68
6.4.1 Crane Remote Control Using Pitch and Catch......................................................................... 68
7 Maintenance...................................................................................................................................................... 70
7.1 General.................................................................................................................................................. 70
7.2 Corrective Maintenance......................................................................................................................... 70
7.3 Preventive Maintenance ........................................................................................................................ 71
7.4 Typical Additional Checks...................................................................................................................... 71
7.4.1 Primary Power Supply.............................................................................................................. 71
7.4.2 Fuses........................................................................................................................................ 71
7.4.3 Fuse Holders ............................................................................................................................ 71
7.4.4 Unit Assemblies........................................................................................................................ 71
7.4.5 Antenna System ....................................................................................................................... 72
7.4.6 Netting ...................................................................................................................................... 72
7.5 Adjustments........................................................................................................................................... 72
7.6 Troubleshooting..................................................................................................................................... 73
7.7 System Status Display Codes ............................................................................................................... 76
7.8 Displayed System Bulletins ................................................................................................................... 77
7.9 Logged Bulletins .................................................................................................................................... 79
7.9.1 Standard Logged System Event Bulletins................................................................................ 79
7.9.2 Standard Logged System Received Message Bulletin ............................................................ 82
7.9.3 Logged ASO FAULT Bulletins.................................................................................................. 83
7.9.4 Logged ASO LOOP FAULT Bulletins....................................................................................... 84
7.9.5 Special Engineered Bulletins.................................................................................................... 84
7.10 Receiver/Decoder Repair ...................................................................................................................... 84
7.10.1 Replacing the Electronics Chassis (Gold Box)......................................................................... 84
7.10.2 Relay Replacement .................................................................................................................. 86
7.10.3 Relay Interface Board Replacement......................................................................................... 86
7.10.4 Receiver Replacement ............................................................................................................. 87

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7.10.5 Decoder Replacement.............................................................................................................. 89
7.10.6 Code Plug Replacement........................................................................................................... 91
7.10.7 EPROM Replacement .............................................................................................................. 93
7.10.8 Power Supply Module Replacement ........................................................................................ 93
8 Replacement Parts and Accessories................................................................................................................ 95
8.1 Replacement Parts................................................................................................................................ 95
8.2 Accessories ........................................................................................................................................... 95
8.2.1 Two-step Electro-Hydraulic Brake Package............................................................................. 95
8.2.2 Transfer Switch Schematic....................................................................................................... 96
9 Technical Support ............................................................................................................................................. 97
Appendix I –R2HN Receiver................................................................................................................................... 98
Introduction...................................................................................................................................................... 98
Additional Safety Feature ................................................................................................................................ 99
Close Start Setup ............................................................................................................................................ 99
Range Limit Setup......................................................................................................................................... 104
Range Extend Setup ..................................................................................................................................... 107
Scanner Setup............................................................................................................................................... 108
Attenuator Setup............................................................................................................................................ 109
Factory Preset and Field Programmable Frequencies.................................................................................. 110
Factory Preset (Default) Frequencies................................................................................................ 110
Field Programmable Frequencies...................................................................................................... 111
Appendix II –Recommended Safety Rules for Portable Remote Controlled (PRC) Cranes................................ 114
Preface .......................................................................................................................................................... 114
Operator Safety Basics.................................................................................................................................. 114
Area Inspection .................................................................................................................................. 114
Crane Inspection (Mechanical and Structural)................................................................................... 114
Operational Safety Check.................................................................................................................. 115
Persons Authorized to Operate Remote Controlled Cranes ......................................................................... 115
Training Checklist for Operators of Remote Controlled Cranes.................................................................... 116
Operating Area for the Remote Controlled Crane......................................................................................... 116
Hand-held Portable Remote Controller ......................................................................................................... 116
Operating the Remote Controlled Crane....................................................................................................... 117
Boarding the Remote Controlled Crane ........................................................................................................ 118
On Board the Remote Controlled Crane ....................................................................................................... 118

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Remote Controlled Crane Under Repair ....................................................................................................... 119
Condition of the Remote Controlled Crane ................................................................................................... 120

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1 Operation and Maintenance Instructions
1.1 Important Notices
This manual covers both the Cattron Multi Processor (MP) 96 and 48 Series Portable Remote Control (PRC)
Systems, including auxiliary function kits and accessories. System installation information is also included. In
cases where more than one system is provided, it is advisable to mark the controlled equipment number on the
manual cover to avoid confusion.
Your new PRC system has been preconfigured to operate on a specific address and frequency before leaving our
factory. Thus, the address and frequency of the system controller is factory set to operate its corresponding MP
Series receiver/decoder.
Upon installation, Cattronstrongly advises you to check that our preconfigured address and frequency is not
duplicated in other Cattron remote control equipment located at or around your operating facility.
This equipment is firmware based, including encoder, decoder, transmitter and receiver. Any duplication of
operating firmware without written consent of Cattron is prohibited. All firmware, product listings, assembly files
and this manual are protected by U.S. Copyright Laws.
As part of our continuous improvement policy, Cattronreserves the right to change specifications without notice.

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1.2 List of Technical Abbreviations
The following abbreviations (acronyms) are frequently used in Cattron Remote Control Technology and may be
used in this manual:
AC
Alternating Current
MK
Metal Keypad
AT
Advanced Technology
ML
Mainline
ATS
Advanced Technology Standard
NEMA
National Electrical Manufacturer’s
Association
ASO
Automatic Safety Override
Ni-Cad
Nickel Cadmium
BCH
Bose-Chaudhuri-Hocquenghem
(data error detection routines)
OPR
Operate
CS
Crane Specific
PRC
Portable Remote Control
DC
Direct Current
PTO
Push-to-Operate
DOC
Department of Communication
RF
Radio Frequency
DP
Dual Pressure
RFI
Radio Frequency Interference
EDP
Electronic Data Processing
RSSI
Receive Signal Strength Indication
EEPROM
Electrically Erasable
Programmable Read Only
Memory
RST
Reset Relay
EMI
Electro-Magnetic Interference
SP
Single Pressure
EPROM
Erasable Programmable Read
Only Memory
SYNC
Synchronization
FCC
Federal Communications
Commission
TP
Test Point
GND
Ground
TS
Transfer Switch
I/O
Input/Output
VAC
Volts Alternating Current
LCD
Liquid Crystal Display
VDC
Volts Direct Current
LED
Light Emitting Diode
VFD
Variable Frequency Drive

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1.3 Glossary of Graphical Symbols
Some or all of the following graphical symbols may be found on your Cattron Portable Remote Controller. These
symbols are intended to: (1) convey information independently of language, and (2) identify operator controls and
functions.
LOW
BATTERY
ALARM/HORN
RESET
STEP LESS
PUSH BUTTON
2-STEP PUSH
BUTTON
3-STEP PUSHBUTTON
ACTUATE ONLY
DURING OPERATION
RECEIVE
TRANSMITTX
RX ROTARY SELECTOR
SWITCH
‘ON’ / ‘OFF’ SWITCH
‘STOP’ SWITCH
ELECTRONIC ‘i-KEY’
AC
A+B

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2 Introduction
2.1 How to Use This Manual
Because no two MP PRC applications are exactly the same, this manual contains generic Installation, Operating
Instructions and Maintenance procedures applicable to the MP96/48 Series of Cattron Portable Remote Control
(PRC) Systems.
The Cattron MP Series Portable Remote Control Systems are available in two configurations: the MP96 and the
MP48. The MP96 represents the top of the Cattron line. The MP48 Series offers the same dependability required
for operating machinery in harsh, industrial environments as the MP96, but with fewer features.
The bulk of the information in this manual applies to both the MP96 and the MP48. However, as stated above, the
MP48 is equipped with fewer features than the MP96. Therefore, we have provided a “MP96/MP48 –Feature
Comparison”of both products later in this manual.
ATTENTION
We emphasize that safety considerations are paramount when using portable remote controllers.
Accordingly, read the Safety Summary in its entirety. Also, for your consideration and possible
adoption, Appendix II –Recommended Safety Rules for Portable Remote Controlled (PRC)
CRANES are provided in Appendix II –RECOMMENDED SAFETY RULES FOR
PORTABLE REMOTE CONTROLLED (PRC) CRANES of this manual.
!

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3 Safety Summary
All WARNING and CAUTION statements used in this manual are included in this section. These statements are
applicable to all operating and maintenance procedures, practices or conditions considered essential to the
protection of personnel (WARNING) or equipment and property (CAUTION). A WARNING and/or CAUTION will
apply each time the related step is repeated. Before starting any task, the WARNINGS and/or CAUTIONS should
be reviewed and understood.
Warnings
WARNING
FAILURE TO COMPLY WITH ANY OF THE WARNINGS IN THIS MANUAL MAY RESULT IN
SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
WARNING
CATTRON MAKES EVERY EFFORT TO ENSURE THE ADDRESS AND FREQUENCY ASSIGNED
TO YOUR NEW PRC SYSTEM IS NOT DUPLICATED BASED UPON RECORDS WHICH ONLY
INDICATE THE ADDRESS AND FREQUENCY OF ALL PAST PRC SYSTEMS AS SHIPPED FROM
OUR FACILITY TO YOURS.
THEREFORE, IT SHOULD BE FULLY UNDERSTOOD THAT:
1) WHEN A PRC SYSTEM HAS LEFT OUR FACTORY, CATTRON HAS NO CONTROL OVER ANY
ADDRESSES AND FREQUENCIES SUBSEQUENTLY ASSIGNED AND PROGRAMMED BY YOU
OR BY OTHERS, EITHER NOW OR IN THE FUTURE.
2) CATTRON HAS NO CONTROL OVER THE ADDRESS AND FREQUENCY ASSIGNMENTS OF
ANY OTHER PRC SYSTEM(S) THAT MAY BE IN OPERATION IN CLOSE PROXIMITY TO YOUR
FACILITY.
CONSEQUENTLY, AND PURSUANT TO THE ABOVE STATEMENTS, CATTRON SHALL NOT BE
HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE ARISING
FROM DUPLICATED ADDRESSES AND FREQUENCIES OF REMOTE CONTROL SYSTEMS.
WARNING
FAILURE TO PROPERLY SELECT ADDRESS AND FREQUENCY MAY RESULT IN THE
UNINTENTIONAL OPERATION OF OTHER MACHINERY. DO NOT DUPLICATE ADDRESS
ASSIGNMENT.
WARNING
ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED
EQUIPMENT (I.E., CRANES) MUST HAVE A BRAKE INSTALLED.
THE REMOTE CONTROL OPERATE (OPR) RELAYS MUST BE CONNECTED TO THE MAINLINE
SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY
OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SHUT
DOWN THE CONTROLLED EQUIPMENT AND/OR SET THE EQUIPMENT BRAKE.
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WARNING
MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND OR NEARBY
YOUR OPERATING FACILITY. THEREFORE, IF THE WRONG ADDRESS AND OPERATING
FREQUENCY IS PROGRAMMED INTO A REMOTE CONTROLLER, OTHER EQUIPMENT
LOCATED AT, AROUND OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL.
FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN THE UNDESIRED OPERATION OF
OTHER EQUIPMENT.
WARNING
AFTER CHANGING AN ADDRESS OR FREQUENCY SELECTOR SWITCH, YOU MUST FIRST
ENSURE THE TARGETED MACHINE IS UNDER REMOTE CONTROL BEFORE OPERATING ANY
MOTION FUNCTION SWITCH. THIS MAY BE ACCOMPLISHED BY OPERATING A NON-MOTION
FUNCTION SWITCH ON THE REMOTE CONTROLLER SUCH AS A HORN OR LIGHT.
FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN THE UNDESIRED OPERATION OF
OTHER EQUIPMENT.
WARNING
ON CAB AND REMOTE OPERATED CRANES OR CARRIERS, AN AUDIBLE OR VISUAL
WARNING MEANS SHALL BE PROVIDED. IN ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO
OR VISUAL ALARM INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS.
WARNING
WHEN INSTALLED TO YOUR CONTROLLER, NEVER DISABLE THE PUSH-TO-OPERATE (PTO)
BAR SWITCH.
WARNING
DE-ENERGIZE AND TAG OUT ALL SOURCES OF ELECTRICAL POWER BEFORE CARRYING
OUT TOUCH TESTS ON EQUIPMENT. FAILURE TO PROPERLY DE-ENERGIZE EQUIPMENT
MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK.
WARNING
HIGH VOLTAGE MAY BE PRESENT ON RELAY OUTPUT TERMINALS. EXERCISE CAUTION
WHEN WORKING NEAR THE RELAY OUTPUT BOARDS. FAILURE TO OBSERVE THIS
WARNING MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK.
WARNING
REMOVE POWER FROM THE CRANE OR MACHINE MOTORS BEFORE PERFORMING ASO
TESTS. THESE TESTS REQUIRE THE ENERGIZING OF THE OUTPUT RELAYS USING
JUMPERS. ENERGIZING THE RELAYS WHILE POWER IS APPLIED TO THE SYSTEM MOTORS
MAY RESULT IN UNDESIRED MOVEMENT OF THE CRANE OR MACHINE. IN ADDITION,
DAMAGE TO THE CIRCUIT BOARDS MAY RESULT IF THE TEST JUMPER CONTACTS THE
WRONG COMPONENT.
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WARNING
THE USE OF UNAPPROVED COMPONENTS OR ACCESSORIES IN THE SYSTEMS SOLD BY
CATTRON 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 EXHIBITING
OBSERVABLE DAMAGE OR DEFECT.
USE OF NON-CONFORMING PARTS, ASSEMBLIES AND ACCESSORIES MAY LEAD TO INJURY
OR DEATH.
WARNING
THE REMOTE CONTROL SYSTEM YOU HAVE PURCHASED IS DESIGNED TO STOP IN A SAFE
MODE UNDER A VARIETY OF CONDITIONS. SOME EXAMPLES OF THESE CONDITIONS ARE
EXCESSIVE RADIO SIGNAL INTERFERENCE, LOSS OF BATTERY AND/OR ELECTRIC POWER,
FAILURE OF CERTAIN COMPONENTS, OPERATION BEYOND SIGNAL RANGE AND OTHERS.
ALTHOUGH CATTRON DOES 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. IT IS
IMPERATIVE THAT YOU ARE PREPARED FOR AN UNPLANNED STOP OF THE EQUIPMENT AT
ANY TIME AND DO NOT PLACE YOURSELF OR OTHERS IN A POSITION WHERE THIS
SITUATION MAY CAUSE YOU TO FALL FROM THE EQUIPMENT.
FAILURE TO USE CAUTION MAY LEAD TO INJURY OR DEATH.
Cautions
CAUTION
ON 12 VDC APPLICATIONS, INCOMING POWER MUST HAVE A 1 AMP SLOW-BLOW FUSE IN
LINE WITH THE POSITIVE LEAD NEAR THE BATTERY OR POWER SOURCE.
ENSURE THE PROPER DC VOLTAGE IS CONNECTED TO THE RECEIVER/DECODER.
OBSERVE PROPER POLARITY WHEN MAKING ALL CONNECTIONS.
FAILURE TO COMPLY WITH THESE CAUTIONS WILL RESULT IN VEHICLE AND EQUIPMENT
DAMAGE.
CAUTION
ELECTROSTATIC SENSITIVE DEVICES SUCH AS EPROMS ARE PRESENT ON CIRCUIT
BOARDS. USE AN ANTI-STATIC MAT AND PERSONAL GROUNDING STRAP (WRIST) FOR ALL
MAINTENANCE PROCEDURES INVOLVING CIRCUIT BOARDS AND ELECTROSTATIC
SENSITIVE DEVICES.
FAILURE TO COMPLY WITH THIS CAUTION MAY RESULT IN EQUIPMENT DAMAGE AND WILL
VOID OUR WARRANTY.
CAUTION
EPROMS ARE ELECTROSTATIC SENSITIVE DEVICES. USE AN ANTI-STATIC MAT AND
PERSONAL GROUNDING STRAP (WRIST) WHEN REPLACING OR INSTALLING EPROMS.
FAILURE TO COMPLY WITH THIS CAUTION MAY RESULT IN EQUIPMENT DAMAGE AND WILL
VOID OUR WARRANTY.
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General
ATTENTION
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.
Do not replace components or make adjustments inside the equipment with the electric power supply turned on.
Under certain conditions, danger may exist even when the power control is in the off position due to charges
retained by capacitors. To avoid injuries, always remove power, discharge and ground a circuit before touching it.
Adhere to all lock out/tag out requirements.
DO NOT SERVICE OR ADJUST ALONE. Whenever possible, do not attempt internal service or adjustment of
equipment unless another person capable of rendering aid and resuscitation is present.
FINGER RINGS/JEWELRY. Finger rings have caused many serious injuries. Remove rings, watches and other
metallic objects which may cause shock or burn hazards.
SOLDERING/DESOLDERING. Avoid breathing fumes generated by soldering/desoldering. Perform all operations
in a ventilated area. Eye protection is required.
CLEANING SOLVENTS. Some cleaners and solvents have adverse effects on skin, eyes, respiratory tract and
internal organs. These adverse effects range from discomfort to serious injury and death, depending on the
material and degree of exposure. Observe manufacturers’ warning labels and contact your immediate supervisor
if in any doubt.
Remember…. the persons reading these instructions and operating the remote
control system are primarily responsible for their own health and safety.
!

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4 Functional Description
4.1 Introduction
Cattron MP Series Portable Remote Control (PRC) systems offer the security, reliability and flexibility required for
harsh industrial control applications, coupled with the speed of either three high performance microcomputers
(MP96 Series) and two high performance microcomputers (MP48 Series). While the MP96 Portable Remote
Control System represents the top of the Cattron line, the MP48 Series PRC System offers the same security,
reliability and dependability required for operating machinery in harsh industrial environments, but with fewer
features.
All MP systems are individually custom-designed for a specific application at our Cattron facility. No two PRC
system applications will be identical.
A single board receiver is under the direct control of a variety of lightweight, hand-held style control transmitters.
Received signals are routed to a single board decoder that contains three microcomputers (control,secondary,
and data). Although each microcomputer is programmed for separate tasks, all three microcomputers
communicate with each other when necessary, providing a high degree of ‘back-up’.
Taking the MP96 system as an example, the control microcomputer receives incoming data that has been
processed by the receiver. It decodes the incoming data, checking for all the correct addresses, data and error
check bytes.
The secondary microcomputer receives the same data as the control microcomputer and independently decodes
the data, making a separate validity check.
The data microcomputer stores event data in a log with date and time stamp information for download or display.
All Cattron MP96 systems allow for up to 65,534 unique addresses for each RF channel. Typical systems use one
of 126 addresses.
4.2 Component Identification
Figure 1 identifies the major components of a typical MP Series receiver/decoder. Note that the system illustrated
is a generic configuration as normally provided for crane remote control applications. While the electronics
chassis (containing the power supply, receiver and decoder boards) is common to all MP Series systems, there
may be some physical differences between the illustrated system and your actual system. Notably, such
differences may be in the type or size of the NEMA/IP enclosure, and the quantity, location and configuration of
the relay output boards and hardware contained within.

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Figure 1: MP Series Receiver/Decoder Component Layout (Crane Variant)
4.3 Functional Description
Referring to Figure 1 above, the receiving and decoding hardware, along with the relay interface board, is housed
within a NEMA 12 (IP65) or other optional enclosure. The decoder has a system status display to show system
status and act as central reference point. The output interface is handled by solid state plug-in relays rated for
heavy-duty resistive and inductive industrial loads. Each output function relay has two screw terminals, an output
fuse and an LED indicator. The output contact of each critical and directional output relay is also monitored by the
decoder, which is used to sense and verify each of these relay outputs. Upon detection of a fault condition, the
Motor Main Relays or Operate (OPR) relays and all relay outputs are disabled. This is the Automatic Safety
Override (ASO) function, a safety feature found on all Cattron Portable Remote Control systems.

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Table 1 provides details about several of the components identified in Figure 1.
Table 1: Receiver/Decoder Components
Component
Description
Electronics chassis
(Gold Box)
The enclosure, commonly known as the ‘Gold Box’ due to its gold anodized coating,
contains the receiver and decoder circuit boards along with the power supply for the
entire receiver/decoder. For ease of repair, the entire Gold Box can be quickly swapped
out with a spare and returned to Cattron for repair.
Relay output board(s)
The relay output board(s) provide a common connection point for all user connections
to the output relays. The MP96 system has provision for up to 96 relay outputs and up
to 48 inputs, depending on system requirements.
Receiver
The receiver contains the electronic circuits that perform the radio reception functions.
Several LEDs mounted on the receiver circuit board indicate the status of the radio
communications link with the controller.
Decoder
The decoder contains the electronic circuits and microcomputers that control system
functions. This includes checking the address of incoming signals, interpreting the
controller’s commands and controlling the status of the output relays.
Antenna
The connected antenna provides radio reception for the receiver/decoder. Three
antennas may be installed in a ‘triple diversity antenna configuration’.
Power supply module
The power supply module inside the Gold Box provides all required power for the
receiver/decoder. This module also contains an over voltage/under voltage board with
factory pre-programmed setpoints. The power supply module requires 115 VAC at
50-60 Hz.
The receiver/decoder can also be supplied directly with 12 VDC nominal (13.5 VDC).
Other AC or DC supply voltages are available upon request. Contact Cattron at
www.cattron.com/contact.
4.4 Principle of Operation
Referring to Figure 2, the target receiver/decoder is controlled by a remote controller. Provided the correct
address and frequency is programmed into the controller, the controller transmits signals to the receiver/decoder
using a radio link. The signal is picked up by the antenna and passed on to the receiver. If the received signal is
the correct frequency and passes all required data tests, the signal is passed on to the decoder.
The decoder compares the address code of the signal with its own programmed address code. If the signal’s
address code does not match the decoder’s address code, it is ignored and a message is displayed on a system
status display located in the receiver/decoder unit. If the address code is correct, the decoder processes the
message and energizes and de-energizes the appropriate relays.

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Figure 2: Portable Remote Control System –Simplified Block Diagram
An Automatic Safety Override (ASO) function continually monitors the state of all critical and directional relay
outputs. If a critical output relay electrically fails closed without a command from the controller, the ASO circuit
logic de-energizes the Motor Mainline or OPR relays. This prevents any movement of the controlled machine
without command from the controller.
During operation, microcomputers on the decoder board reset multiple watchdog timer circuits whenever valid
messages are received and decoded. If the microcomputers fail to reset the watchdog timers, the timer circuits
shut down and de-activate all relay outputs. The decoder microcomputers require continuously valid transmitted
signals to be received and decoded or all relay output functions will be de-activated unless programmed
otherwise. It should be noted that the mainline control relay (under control of OPR) may be maintained for 10
minutes, depending on system configuration.
4.5 System Functions
With the Cattron MP96, the average response time after a controller function switch is first operated and the
output device is actuated is less than 60 milliseconds. In jogging applications where a function switch is
depressed for the second and consecutive times, the average response time is less than 120 milliseconds.
The Cattron MP96 is a modular system that provides up to 96 ‘ON/OFF’ outputs with as many as 48 digital inputs.
The system is engineered to meet the specific needs of each user. The system capabilities allow for thousands of
optional configurations that reflect the versatility of the Cattron MP96. This gives the operator complete control of
any function of the crane, controlled machine or industrial equipment.
All functions of these systems can be operated simultaneously and/or independently. This creates a more efficient
and flexible system, increasing productivity. There are no confusing ‘do's and don'ts’ to remember when selecting
functions.
With the Cattron MP96 system, all speed steps are under direct operator control. This allows the operator to
judiciously select the appropriate speed for the load and operating conditions.

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Systems can be engineered to allow multiple operators to control one crane on a first-come, first-serve basis –for
example, two to three operators working one piece of equipment using ‘Pitch and Catch’; two operators
simultaneously controlling a single decoder; or one operator with a supervisory control overriding the second
operator with all or selected functions.
A variety of proportional (motion stepless) systems are available for the Cattron MP96 system. The preferred
Cattron standard is Six Motion Stepless. This is a six motion proportional system with a choice of high current, low
current or Pulse Width Modulation (PWM) load drive capabilities. It should be noted that the MP96 series may be
configured for up to 10 Motion Stepless systems, although limited auxiliary functions would be available in such a
configuration. In addition to the ‘volt free’ potentiometer, all ‘stepless’ systems have ‘ON/OFF’ outputs for each
direction (forward/reverse). These models include integral transfer relays for the analog output selection from
manual to remote control. For additional information regarding proportional (stepless) systems, please refer to
Proportional Systems later in this section.
4.5.1 Fault-Tolerant Operation
The MP96 has the ability to detect a failure in the controlled machine and still provide limited, safe, continued
operations.
In addition to the mainline power contactor, various machine functions can be separated and placed in up to six
individual motor groups. This allows the MP96 to ‘shut down’ a failed area of the machine (e.g., trolley) and still
allow operation of other functions (e.g., hoist and bridge).
4.5.2 Protocol
One important safety feature is the use of a unique Cattron intelligent digital message protocol for industrial
control applications rather than the customary Electronic Data Processing (EDP) type of message format. Only
the unique, digital data message generated by a Cattron controller transmitter will be recognized; all others are
rejected. This special protocol is complex and consists of start bits, synchronization, address, command and
error-checking bits. The information must be received and decoded correctly at least twice a second or the
decoder outputs will stop.
4.5.3 Decoder Circuit Board
The decoder is the programmable computer portion of the Cattron MP96 system. It provides simultaneous and
independent output functions according to commands from the correct operator controller.
4.5.4 Multiple Microcomputers
The MP96's single board decoder employs three microcomputers interfaced with various I/O devices for
maintaining safety and integrity of system functions. The first of these is the control microcomputer which is
tasked with all I/O functions and message traffic and is responsible for Operate (OPR) Relay #1 and the motor
group main contactors.
The secondary microcomputer is responsible for the additional verification of the received messages of the
control microcomputer. When a transmitted command message is received by the decoder, it is verified by the
control microcomputer and passed to the secondary microcomputer. Additionally, this same command message
is directly routed to the secondary microcomputer which then independently verifies the proper address and
returns it to the control microcomputer for comparison and final verification. The secondary microcomputer is also
responsible for the OPR #2 operational commands. The two OPRs, in series, control the equipment mainline
contactor.
The third microcomputer is the data microcomputer. It is dedicated to the handling of data processing and storage
for later recall, using the status display and datalog analysis utility program.