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Cattron MP96 Series User Manual

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

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  • Page 1 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 68C-MP96/48-RD-EN...
  • Page 2 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

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Contents Operation and Maintenance Instructions ......................8 Important Notices ............................8 List of Technical Abbreviations .........................9 Glossary of Graphical Symbols ......................10 Introduction................................ 11 How to Use This Manual........................11 Safety Summary ..............................12 Warnings ..............................
  • Page 4 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 Installation .................................
  • Page 5 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 5.7.3 Log-Utility ..........................62 Installation of the MP96 Datalog Analysis and Utility Prorgam ............. 62 Operating Instructions ............................65 General ..............................65 Remote Control Operation – General Equipment ................. 65 Remote Control Operation – Electric Overhead Traveling (EOT) Crane ..........66 Operator ‘Pitch and Catch’...
  • Page 6 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 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 Replacement Parts and Accessories ........................ 95 Replacement Parts ..........................95 Accessories ............................
  • Page 7 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Remote Controlled Crane Under Repair ....................... 119 Condition of the Remote Controlled Crane ....................120 68C-MP96/48-RD-EN Version 006...

  • Page 8: Operation And Maintenance Instructions

    Operation and Maintenance Instructions 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.

  • Page 9: List Of Technical Abbreviations

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual List of Technical Abbreviations The following abbreviations (acronyms) are frequently used in Cattron Remote Control Technology and may be used in this manual: Alternating Current Metal Keypad Advanced Technology Mainline Advanced Technology Standard NEMA National Electrical Manufacturer’s...

  • Page 10: Glossary Of Graphical Symbols

    User Manual 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.

  • Page 11: Introduction

    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.

  • Page 12: Safety Summary

    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.
  • Page 13 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 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.

  • Page 14: Cautions

    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.

  • Page 15: General

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 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.

  • Page 16: Functional Description

    All Cattron MP96 systems allow for up to 65,534 unique addresses for each RF channel. Typical systems use one of 126 addresses.

  • Page 17: Functional Description

    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. 68C-MP96/48-RD-EN...

  • Page 18: Principle Of Operation

    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. Principle of Operation Referring to Figure 2, the target receiver/decoder is controlled by a remote controller.

  • Page 19: System Functions

    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.

  • Page 20: Fault-Tolerant Operation

    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.

  • Page 21: System Initialization

    After completing the power-on tests, the decoder looks for a properly addressed message from the controller. When a message is received with a valid system address and proper BCH (Data Integrity Character), the Cattron MP96 system decoder quickly tests the operability of the two OPR output relays.

  • Page 22: System Status Display

    Installation section of this manual. 4.5.9 Serial Communication Ports The Cattron MP96 system decoder is available with two RS-232 ports (COM 1 and COM 3) and an isolated RS-485 port (COM 2). ® The two RS232 ports are bi-directional and are used for Datalog download via a Microsoft Windows compatible PC or laptop.
  • Page 23 Equipment Specific Engineered Log (Custom Events): This custom-engineered log is defined by Cattron engineers based on specific information provided by the user. This log will store data (using customer terminology) and specialized states based on user needs. Up to ten of these logs can be identified for creation by the Cattron engineer based on customer needs.

  • Page 24: Downloading, Viewing And Printing The Datalog

    (LPT1). The data will be in an ASCII format. Any standard parallel printer should work (printers are available from Cattron at an additional cost). Local PC Download: The datalog can also be downloaded, viewed, sorted and printed from an external...

  • Page 25: Crane Bridge (Long Travel) Braking

    Cattron offers the brake package in several models for use with many different crane power sources, including 110, 220, 440 VAC and 250 VDC. Any model of Cattron PRC, as well as a pendant or other brand of remote control, can control brake operation.

  • Page 26: R1Hn Receiver Board

    R1HN Receiver Board This is a 16-channel, UHF-synthesized RF receiver. The receiver incorporates a microcomputer and uses Digital Signal Processing (DSP) techniques to selectively recover digital messages using Cattron protocol. The R1HN receiver has LED indicators for the following: •...

  • Page 27: R3Hnx Transceiver Board

    Factory Preset and Field Programmable Frequencies: In order for the receiver and the controller to communicate, they must be set to the same frequency. Cattron receivers and controllers offer multiple frequency selections for maximum versatility. While the factory preset frequencies should be adequate for most users, there may be conditions where it is necessary to program a frequency.

  • Page 28: Talkback

    R3HNX transceiver board. Up to 16 ON/OFF bits of information can be sent back to the remote controller. These bits originate in the MP96 Series decoder and can be either External Event Inputs or ASO Inputs. The received bits are displayed on the controller using up to 12 light emitting diodes and/or a Liquid Crystal Display (LCD).

  • Page 29: Mp96 Series - Feature Summary

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 4.13 MP96 Series – Feature Summary • Use of three microcomputers for faster message handling and ladder logic programming • Low cost per output • Up to 96 relay outputs including ‘ON/OFF’ (mainlines) •...

  • Page 30: Mp96 Series - Specifications

    -22 F to +150 F (-30 C to +65 C), RH 0 to 95% Non-condensing (Special units are available) Microcomputer Speed 11.059 MHz (Three): Memory Size: Two EPROMs, each with 1 MB of memory (programmed by Cattron) Optional Diagnostic / Two RS232C (DB9 connector) Programming Port: One RS485 (2-position terminal block) 68C-MP96/48-RD-EN...
  • Page 31 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual As part of our ‘continuous improvement’ policy, Cattron reserves the right to change Specifications Note: without notice. 68C-MP96/48-RD-EN Version 006...

  • Page 32: Mp96/Mp48 - Feature Comparison

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 4.15 MP96/MP48 – Feature Comparison The Cattron MP Series of Portable Remote Control Systems is available in two configurations: the MP96 and the MP48. The MP96 represents the top of the Cattron line.
  • Page 33 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Features MP96 MP48 High brightness status display for quick machine fault diagnosis Last 32 trouble event message log Last 90 change message log Snapshot log, transmit data and I/O status triggered by specific event...
  • Page 34 Compact EMI/RFI single unit decoder chassis Plug-in micro-controller E-proms allow quick ‘personality’ changes (reduces changes) Can be controlled by a variety of Cattron Controllers: Keypad, Toggle, Paddle, Joystick, and Pendant Licensed and non-licensed systems available (US, Canada, and Europe) Proportional output available for smoother operation and control ‘Snapshot’...
  • Page 35 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Features MP96 MP48 a standard parallel printer Diagnostic datalog analysis and management software for IBM compatible PC’s available RS485 Serial port for interface to industry standard sensors Parallel Printer Port Remote download of datalog via RF link (PDDCTB)
  • Page 36 Microcomputer Speed: 11.095 MHz Memory Size: Two E-Proms, each with 1 MB of memory (programmed by Cattron) Datalog Memory Size: 64K bytes Optional Diagnostic Port: RS232C (DB25 Connector) or RS422 (MIA Connector) Optional Bus Architecture (serial port) for Profibus, Modbus, etc.

  • Page 37: Installation

    If any additions or corrections are made during the installation, note the changes on the drawings in red ink. Return the marked-up drawings to Cattron after the installation so that final prints may be prepared and issued.

  • Page 38: Disconnect And Outlet

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Using a separate control transformer helps by reducing chances of a power slump if other electrical components connected to it fail. It can also be sized to allow installation of a utility outlet near the receiver/decoder for connection of a light or test equipment.

  • Page 39: Relay Outputs

    This allows the connection of different power sources, AC or DC, to each separate relay. Each output relay is typically solid state but may be electro-mechanical as determined by the Cattron application engineer for a given control voltage requirement. All relay outputs are individually fused at 5 A. Critical and directional outputs have accompanying input sense modules that sense the ‘ON/OFF’...
  • Page 40 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Figure 4: Operate (OPR) Contact Wiring The Operate (OPR) relays are energized for the first time when the receiver/decoder has power applied, the controller is turned on, and a matching address code is sent from the controller via an RF signal to the decoder.

  • Page 41: Attenuator

    If any additions or corrections are made during the installation, note the changes on the drawings in red ink. Return the marked-up drawings to Cattron after the installation so that final prints may be prepared and issued. 5.3.2 Choosing a Mounting Location When selecting a location to install the receiver/decoder, there are a few items to consider.

  • Page 42: Wire Routing

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual The enclosure should be mounted in the desired location using the four mounting holes provided – do not weld the enclosure in position. 5.3.3 Wire Routing When two conductors are placed close to each other, electric current in one conductor will induce electric fields in the other (especially if they are physically parallel).

  • Page 43: Remote Antenna Location

    If the 20 ft cable supplied with the remote antenna mounting kit is too long, simply coil the excess cable and hang it securely out of the way of any moving equipment. If the 20 ft cable is not long enough, contact Cattron at www.cattron.com/contact...

  • Page 44: Triple Diversity Antenna

    5.3.6 Direct DC Wiring Option Cattron MP Series receiver/decoders equipped for AC power may be powered directly from a properly filtered 13.8 VDC power source. This capability is normally used when the receiver/decoder is installed on a moving vehicle such as a forklift truck, dump truck or automated vehicle.
  • Page 45 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 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.

  • Page 46: Preset Frequency Selections - Model R1Hn Receiver Only

    In order for the receiver and the controller to communicate, they must be set to the same operating frequency and address. Cattron MP Series receivers offer several factory preconfigured frequency selections for maximum versatility. While the original factory setting should be adequate for most users, there may be conditions where it is necessary to change the operating frequency.

  • Page 47: Post Installation Checks

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 3. Using a small screwdriver, rotate the selector switch to the desired position. 4. Replace the lid on the Gold Box. 5. Restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the Gold Box.

  • Page 48: Normal Operating Display

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Figure 10: System Status Display and LED Indicators 5.5.2 Normal Operating Display The system status display provides useful information to the operator and technician. This information is displayed after the Power On Self Test (POST). The display consists of two lines of text with up to 24 characters on each line.
  • Page 49 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Referring to Figure 12, the normal operating display is divided into several areas of information as follows: Figure 12: Normal Operating Display (Default Screen) Line 1: Referring to Figure 12, display Line 1 contains four areas of information: Micro-processor Communication Status area displays a rotating bar.
  • Page 50 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual At certain times during operation, the address values shown on Line 2 will change temporarily (for approximately one second) to indicate specific activities or conditions of the system. In the example shown in Figure 12, the ‘A:...

  • Page 51: System Checkout

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Description When illuminated, the red OPR1 LED indicates that the OPR1 relay has OPR1 (decoder board) been shut down. When illuminated, the red OPR2 LED indicates that the OPR2 relay has OPR2 (decoder board) been shut down.
  • Page 52 ‘ON’ as the corresponding timer expires. d. The decoder board System Status Display initiates a sequence of opening user information bulletins that describe the decoder’s main features, including Cattron telephone numbers for use if technical assistance is needed. Engineering information is also displayed.
  • Page 53 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual c. Code Plug Value and Valid Addresses [CP: - - ]: The decoder address code plug is read by the microcomputers and its hexadecimal value is displayed in the upper right corner of the display, for ‘CP:...
  • Page 54 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Note: When setting the Real Time Clock in the following steps, other menu options will be displayed. These functions will be more obvious once the basic controls are familiar to the user.
  • Page 55 Note: Since Cattron MP Series receiver/decoders are capable of multiple outputs from one switch command (for example, a hoist matrix), ensure all outputs switch ‘ON’ or ‘OFF’ exactly as programmed.
  • Page 56 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Figure 15: Input and Output Relay Interface Boards – Locations Check the Watchdog Timers: Press and hold one function on the controller. While holding the function, turn off power to the controller using the ON/OFF switch. All function outputs must de-energize within one second and the mainline OPR1 and six main outputs should de-energize within two seconds.
  • Page 57 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual restore operation of the system, set the STOP switch on the controller to the ‘RUN’ position and cycle power to the controller by setting the ON/OFF switch to ‘OFF’ and then ‘ON’.
  • Page 58 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual a. When installed on the controller, set the system STOP switch to ‘STOP’ and the ON/OFF switch to ‘OFF’. This will completely isolate the controller. b. Ensure power is removed from the crane or machine motors. This is normally done by opening the disconnects for the motors at the motor control panels.
  • Page 59 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual e. Remove the Test Jumper and press the Reset PushButton on the decoder to clear the fault. Apply power to the controller (set to ‘ON’). OPR1, OPR2 and the programmed main relays (M1-M6) should energize.

  • Page 60: Data Collection And Review Options

    An additional RF link between the MP96 receiver/decoder and the controller • A customized controller incorporating a PDDCTB unit and TALKBACK ® • The PC-based Datalog Analysis and Utility Program (Part Number CPA-0326) If you require further details on this option, contact Cattron at www.cattron.com/contact. 68C-MP96/48-RD-EN Version 006...
  • Page 61 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 68C-MP96/48-RD-EN Version 006...

  • Page 62: Log-Utility

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 5.7.3 Log-Utility The display contains a selectable menu that allows access to the following data via the three pushbuttons located on the decoder board. Having completed the System Checkout detailed above, it is assumed that you are familiar with how to move about the system status display using the three manual control pushbuttons PB2, and PB4.
  • Page 63 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual PASSWORD: This is needed to execute most functions within the program. The default password is set to ‘master’ (all lower case letters). The system administrator will use the master password, giving him/her access to all of the program’s functions.
  • Page 64 The Datalog Analysis and Utility Program (Part Number CPA-0326) consists of three different components: the program itself, available on 3 1/2" diskette, the cable for serial interface and an adapter. When ordering the program, please specify what parts you require. If further assistance is needed, please contact Cattron at www.cattron.com/contact.

  • Page 65: Operating Instructions

    (1) on the front page of the manual supplied with the controller, and (2) on a serial tag located inside the battery door. The address and frequency of the MP96 Series receiver/decoder is recorded (1) on the front page of the manual supplied with the portable remote control system, and (2) on a label located on the outside of the electronics chassis (i.e., Gold Box)

  • Page 66: Remote Control Operation - Electric Overhead Traveling (Eot) Crane

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual b. Set the controller’s Power ON/OFF Switch(es) to the ‘ON’ position. When transmitting with a good battery, two short ‘beeps’ will be heard immediately after the Power ON/OFF Switch is set to ‘ON’...
  • Page 67 (1) on the front page of the manual supplied with the controller, and (2) on a serial tag located inside the battery door. The address and frequency of the MP96 Series receiver/decoder is recorded (1) on the front page of the manual supplied with the portable remote control system, and (2) on a label located on the outside of the electronics chassis (i.e., Gold Box)

  • Page 68: Operator 'Pitch And Catch' (Optional)

    These functions are normally identified during initial discussions between customer operators, customer management and Cattron application engineers. Once it has been agreed: (1) which functions are to be transferred, (2) which functions are to be controlled by the primary controller only, and (3) which functions that will remain with the secondary controller, your remote control system is custom engineered to provide these operational requirements.
  • Page 69 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual taken control of the crane. It should be noted that Operator ‘A’ remains in control even if Operator ‘B’ switches his or her controller power to ‘ON’ and attempts to control the crane – control access is denied to Operator ‘B’...

  • Page 70: Maintenance

    Reconnect all wires to the same location from which they were removed Note: Microprocessor devices, as used in Cattron PRC systems, use programmable EPROMs for program storage. Proper part numbers, version numbers and, in some cases, revision numbers must be used when installing spare circuit boards.

  • Page 71: Preventive Maintenance

    Inoperative systems are normally repaired by circuit board substitution. If possible, the entire EMI/RFI shielded electronic chassis (the ‘Gold Box’) should be returned to Cattron for testing and repair. Make sure all optional jumpers are properly configured and the proper address code and frequency are set prior to applying power.

  • Page 72: Antenna System

    Carrier Detect LED will turn on. If the carrier signal contains data and a Q-Sync pulse as would be the case if the signal had been transmitted from a Cattron controller, the receiver’s orange Data LED and yellow Q-Sync LED would also turn on.

  • Page 73: Troubleshooting

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Figure 18: Squelch Adjustment Troubleshooting Table 3 is arranged in a simple problem/cause/correction format. The possible faults are arranged in order from most likely to least likely. Always read the system status display for error codes or displayed system bulletins that may describe the fault cause in detail, as well as any instructions for repair.
  • Page 74 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Problem Cause Correction Decoder Wrong controller or Ensure the correct controller is being used for this system. completes wrong controller When installed, ensure the STOP switch on the controller is in “power on”...
  • Page 75 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Problem Cause Correction ™ Unit works up Antenna damaged or Note: The unit may be working correctly if Range Limiting close but fails at not installed properly in use. longer ranges Inspect the antenna for any damage, including shorts, opens and improper grounds.

  • Page 76: System Status Display Codes

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Problem Cause Correction Error code The system status Refer to the System Status Display Codes below for a displayed on display shows an error complete description of all error codes. Correct any faulty...

  • Page 77: Displayed System Bulletins

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Displayed System Bulletins Displayed system bulletins are messages generated by operating conditions within the MP96 system. During operational use, the standard operating display format illustrated in Figure 19 will be shown unless a system bulletin is present with a higher priority.
  • Page 78 ADDRESS [XX]* ASO FAULT [xxxxxxx] INPUT ON ASO LOOP FAULT [xxxxxxx] INPUT OFF * where [XX] = address letter; e.g., 1A, 3C Note: [xxxxxxx] is the label assigned to the module by the Cattron Application Engineering Department. 68C-MP96/48-RD-EN Version 006...

  • Page 79: Logged Bulletins

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Note: There are 48 possible ASO FAULT and ASO LOOP FAULT logs, depending on the application. There are ten possible custom engineered logs. These logs may or may not be included in the LAST 32 LOG.
  • Page 80 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Display Line 1 Display Line 2 DECODER OFFLINE MOTOR WD OUTS DISABLED XMITTER IS ONLINE ADDRESS A XMITTER IS OFFLINE ADDRESS A XMITTER IS ONLINE ADDRESS B XMITTER IS OFFLINE ADDRESS B...
  • Page 81 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Display Line 1 Display Line 2 [MAIN5] OUTPUT OFF [MAIN5] OUTPUTS DISABLED [MAIN6] OUTPUT ON [MAIN6] OUTPUTS ENABLED [MAIN6] OUTPUT OFF [MAIN6] OUTPUTS DISABLED HARDWARE WATCHDOG TEST [OPR1] OUTPUT HARDWARE WATCHDOG TEST...

  • Page 82: Standard Logged System Received Message Bulletin

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Display Line 1 Display Line 2 RF TEST MODE HAS BEEN ACTIVATED SUPERIO CHIP FAILED INIT READ #1 (VALUE NOT 0x88) SUPERIO CHIP FAILED INIT READ #2 (VALUE NOT 0x00) SUPERIO CHIP FAILED INIT...

  • Page 83: Logged Aso Fault Bulletins

    – refer to the section on Displayed System Bulletins. Application specific ASO FAULT Bulletin descriptions are chosen by Cattron when engineering your control system. These descriptions are substituted for the xxx’s shown below. ASO FAULT [xxxxxxx] INPUT ON (when)

  • Page 84: Logged Aso Loop Fault Bulletins

    Replacing the Electronics Chassis, or ‘Gold Box’, with a spare unit is the easiest and fastest way of correcting problems with the receiver/decoder. The Gold Box can then be returned to Cattron for repair. This is the recommended method of repair when the technician has not been trained on repairing Cattron receiver/decoders.
  • Page 85 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 6. Disconnect the ribbon cables connecting the Gold Box to the relay interface boards. 7. Loosen the four nuts securing the Gold Box to the cover of the receiver/decoder and withdraw the Gold Box from the receiver/decoder.

  • Page 86: Relay Replacement

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 7.10.2 Relay Replacement Referring back to Figure 21, replace a relay as follows: 1. Open the cover of the receiver/decoder enclosure. 2. Remove power from the receiver/decoder by turning off the circuit breaker located on the bottom of the ‘Gold Box’.

  • Page 87: Receiver Replacement

    EPROM before replacing the receiver board. If the existing EPROM part number does not match the EPROM part number on the replacement receiver board, contact Cattron at www.cattron.com/contact. Referring to Figure 22, replace the receiver circuit board as follows: 1.
  • Page 88 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 12. Install the lid on the Gold Box and secure by tightening the four captive screws. 13. Restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the Gold Box.

  • Page 89: Decoder Replacement

    Note and record the part numbers on the labels of both EPROMs before replacing the decoder board. If the existing EPROM part numbers do not match those on the replacement decoder board, contact Cattron at www.cattron.com/contact. When swapping out or installing an EPROM, refer to the EPROM Replacement procedure found later in this manual.
  • Page 90 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 11. To replace the code plug, turn off the power to the receiver/decoder. Remove the code plug by pulling straight up and away from the board. Remove the code plug from the old decoder circuit board in the same fashion.

  • Page 91: Code Plug Replacement

    The code assigned to the receiver/decoder at the factory is found on a label placed on the side of the ‘Gold Box’. A code plug installed on the decoder circuit board sets the code. Cattron sets the code of all receiver/decoders before they leave the factory.
  • Page 92 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Figure 24: Code Plug Settings 68C-MP96/48-RD-EN Version 006...

  • Page 93: Eprom Replacement

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 7.10.7 EPROM Replacement 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.
  • Page 94 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 10. Connect the power input plug to the main power supply. 11. Restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the Gold Box. 12. Close the cover of the receiver/decoder.

  • Page 95: Replacement Parts And Accessories

    110, 220, and 440 VAC and 250 VDC. Any model of Cattron PRC, as well as a pendant or other brand of remote control, can control brake operation.

  • Page 96: Transfer Switch Schematic

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual The Cattron Two-Step Electro-Hydraulic Brake Package provides safety for the crane system. When properly installed, the brake package will not allow operation of the crane unless sufficient brake pressure exists to stop the crane in case of an emergency.

  • Page 97: Technical Support

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Technical Support For remote and communication control systems support, parts and repair, or technical support, visit us online at: www.cattron.com/contact. 68C-MP96/48-RD-EN Version 006...

  • Page 98: Appendix I - R2Hn Receiver

    Close Start • Range Limit • Range Extend • Scanner (optional) – may require ‘Gold Box’ modifications, contact Cattron at www.cattron.com/contact • Attenuator • Field Programmable Frequency Selection Close Start, Range Limit and Range Extend require the use of a Triple Diversity Antenna system. When installing a triple diversity antenna system, we recommend that you physically tag each antenna and its associated line kit with a number (1, 2 and 3) and permanently record its individual location on the controlled machine.

  • Page 99: Additional Safety Feature

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Additional Safety Feature As an additional safety measure, we have recently implemented a ‘Power-up/Neutral’ feature on all MP96 systems. To accomplish this, the R2HN Receiver has been factory programmed to clamp the data being sent to the decoder when the operator moves out of range with ‘Range Limiting’...
  • Page 100 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual before setting the Close Start options, and (2) observe the RF signal strength indication on the LCD display while setting the desired close start parameters using the two control pushbuttons on the receiver.
  • Page 101 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Figure 27: Close Start Ranges 68C-MP96/48-RD-EN Version 006...
  • Page 102 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual To set the Close Start option, proceed as follows: 1. Determine the length of time the operator can be ‘off the air’ before he or she is required to satisfy the Close Start ‘unlock’...
  • Page 103 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 9. Press either of the two display control pushbuttons on the receiver to set the required timeout value on the LCD display. This value may be set anywhere between 0.1 and 15 minutes in 0.1 minute increments.

  • Page 104: Range Limit Setup

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual After making any changes to the Close Start options above, test the system for proper operation. Have an operator take the controller to the desired distance to unlock Close Start. Set the controller power to ‘ON’ and operate a switch/pushbutton function that will not cause any movement of the controlled machine, such as a horn, siren or light.
  • Page 105 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Observe the Transmit LED on the controller which should flash green when the controller is transmitting. Confirm that the green Carrier Detect LED on the receiver circuit board also flashes. This indicates that the receiver is receiving a RF signal from the transmitter.
  • Page 106 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 8. Momentarily press and release both display control buttons until the following message appears on the display: RANGE LIMIT -dBm RSSI-120 SET OFF The example display above shows the controller’s Receive Signal Strength Indication (RSSI) value at...

  • Page 107: Range Extend Setup

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Range Extend Setup The Range Extend option is the opposite of Range Limit and requires the use of the triple diversity antenna system. When Range Limiting is not in use, the receiver can be put into Range Extend mode. When a system with the Range Extend option enabled receives a signal, the signal strength is measured from each antenna.

  • Page 108: Scanner Setup

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Scanner Setup The Optional Scanner function allows the receiver to scan up to 16 frequencies for signals from the controller. This feature can be used in multi-controller applications where the controllers operate on multiple frequencies.

  • Page 109: Attenuator Setup

    RF signals on, or adjacent to, the equipment operating frequency. An external attenuator can be used if a different amount of attenuation is necessary. To obtain an external attenuator for your receiver/decoder, contact Cattron at www.cattron.com/contact. To set the built-in attenuator on the Model R2HN receiver, perform the following procedure: 1.

  • Page 110: Factory Preset And Field Programmable Frequencies

    In order for the receiver and the controller to communicate, they must be set to the same frequency. Cattron receivers and controllers offer multiple frequency selections for maximum versatility. While the factory preset frequencies should be adequate for most users, there may be conditions where it is necessary to program a frequency.

  • Page 111: Field Programmable Frequencies

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 5. Momentarily press and release both display control buttons until the following message appears on the display: FREQUENCY TABLE: FACTORY PGM ROM This indicates that the receiver is currently using the factory programmed frequency table in Read-only Memory (ROM).
  • Page 112 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 7. To select a frequency channel to program, press and release both display control buttons. The display will change to the following: CHANNEL NUMBER FOR FREQ ADJ.#1 This indicates that the frequency for channel one can now be programmed.
  • Page 113 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual 17. As required, set the Gold Box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors. 68C-MP96/48-RD-EN Version 006...

  • Page 114: Appendix Ii - Recommended Safety Rules For Portable Remote Controlled (Prc) Cranes

    Cattron emphasize that the recommendations contained herein are not intended to supersede the rules or regulations of our customers, or the rules and regulations of any applicable local, state, or federal government organizations.

  • Page 115: Operational Safety Check

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual • Check for proper fluid levels and make sure all grease fittings are lubricated to manufacturer recommendations • Check for broken welds and cracks in the bridge structure • Check for wheel damage, broken welds on the frame and drum damage •...

  • Page 116: Training Checklist For Operators Of Remote Controlled Cranes

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Training Checklist for Operators of Remote Controlled Cranes As a minimum, Portable Remote Control Operators shall: • Have knowledge of hazards inherent to crane operation • Have knowledge of safety guidelines for portable remote controlled cranes •...

  • Page 117: Operating The Remote Controlled Crane

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual • When an operator is putting on or taking off the controller by means of its belt loop strap, carrying harness or shoulder strap, the controller shall be switched ‘OFF’ beforehand, using the appropriate ON/OFF switch(es).

  • Page 118: Boarding The Remote Controlled Crane

    Cattron™ MP96/48 Series Portable Remote Control Systems User Manual • The PRC crane operator shall hoist lifts high enough to clear all apparatus and workers below the crane • Plugging shall not be used as a regular means of stopping the crane and should be used for emergency stops only.
  • Page 119 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual • If, during the course of repairs, it becomes necessary to move the crane, it shall be the responsibility of the crew leader to ensure that all personnel located on and within the operational area of the crane are in a safe position, out of harm’s way.
  • Page 120 Cattron™ MP96/48 Series Portable Remote Control Systems User Manual Condition of the Remote Controlled Crane It is recommended that a written report be sent to your supervisor whenever you detect any condition that makes the crane unsafe. Many plants supply printed forms for this purpose. The PRC crane operator shall fill out these forms and turn them in at the end of each shift.
  • Page 121 Cattron Wireless Automation and Control Solutions 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 68C-MP96/48-RD-EN Version 006...

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