Fomotech A4000SERIES Industrial Crane Remote Controler User Manual A4K 01 06 255 266 1

Fomotech International Corp. Industrial Crane Remote Controler A4K 01 06 255 266 1

Manual

- 1 -  TTAABBLLEE OOFF CCOONNTTEENNTTSS 1 3 SAFETY INSTRUCTION   2 4 INTRODUCTION     3~8 4.1 SYSTEM TYPES 3 4.1.1 8-PUSHBUTTON TYPES 3~4 4.1.2 12-PUSHBUTTON TYPES 4~5 4.1.3 CUSTOM-MADE TYPES  5 4.2 TRANSMITTER INSTRUCTION 5 4.2.1 TRANSMITTER OUTLINE 5 4.2.2 RECEIVER EXTERIOR DESCRIPTION 6 4.2.3 (1) ENCODER BOARD (2) TX MODULE (3) RECHARGE SHIP CARD 6 4.2.4 (1) RECHARGEABLE BATTERY (2) BATTERY CHARGER (3) SHOULDER STRAP  7 4.3 RECEIVER INSTRUCTION 7 4.3.1 RECEIVER OUTLINE 7 4.3.2 RECEIVER EXTERIOR OUTLINE 7 4.3.3 RECEIVER MOUNTING DIMENSION 8 4.3.4 (1) RX MODULE CARD (2) DECODER CARD (3) RELAY CARD (4) POWER SUPPLY CARD 8~9 4.4 BATTERY CHARGER INTRODUCTION  4.5 OUTPUT WIRING DIAGRAM 9 5 SYSTEM SETTINGS  10~11 5.1 TRANSMITTER ID CODE SETTINGS 10 5.2 TRANSMITTER FREQUENCY CHANNEL SETTINGS 10 5.3 TRANSMITTER FUNCTION SETTINGS  10 5.4 FREQUENCY CHANNEL TABLE 10 5.5 RECEIVER FUNCTION SETTINGS 11 6 RECEIVER INSTALLATION   12~13 6.1 RECEIVER LED DISPLAY  12 6.2 PREPARATION 12 6.3 STEP-BY-STEP INSTALLATION 13 7 TRANSMITTER INSTALLATION    14 7.1 STEP-BY-STEP INSTALLATION  14 7.2 TRANSMITTER LED DISPLAY  14 8 BATTERY CHARGING      15 9 TROUBLE SHOOTING            15 10SYSTEM SPECIFICATION  16 10.1 TRANSMITTER SPECIFICATION 16 10.2 RECEVIER SPECIFICATION 16 11PARTS LIST          17 
- 2 - 3. SAFETY INSTRUCTION The Twister 2X system is relatively simple to use. However, it is very important to observe the proper safety procedures before, during, and after operation. When use properly the Twister 2X systems will enhance productivity and efficiency in the workplace. The following instructions should be strictly followed: 1. Make a daily check of the transmitter casing, joysticks and pushbuttons. Should it appear that anything could inhibit the proper operation of the transmitter unit, it should be immediately removed from service. 2. The transmitter voltage should be checked on a daily basis. If the voltage is low, the battery pack should be recharged or replaced (refer to page 23 for battery power status LED display). 3. The emergency stop button (EMS) should be checked at the beginning of each shift to ensure they are in the proper working order. 4. In the event of an emergency, activate the emergency stop button immediately by pressing the red EMS button down. This will immediately disconnect the transmitter power and receiver MAIN relays. Then turned the power “off” from the main power source of the equipment. 5. The transmitter power key, which is located on the right side of the transmitter box, should be turned “off” after each use and should never left the power key in “on” position when the unit is unattended. 6. Do not use the same frequency channel and ID code as any other unit in use at the same facility or within distance of 300 meters. 7. Ensure the waist belt and the shoulder strap is worn at all time during operation to avoid accidental damages to the transmitter box. 8. Never operate a crane or equipment with two (2) transmitter units at the same time with same frequency channel and ID code. 
- 3 - 4. INTRODUCTIONS           4.1.1 8-pushbutton types 4008-1: 8 single speed pushbuttons 4008-1S: 7 single speed pushbuttons + 1 selector switch 4008-2: 8 double speed pushbuttons 4008-3: 6 double speed pushbuttons + 2 single speed pushbuttons 4008-3S: 6 double speed pushbuttons + 1 single speed pushbutton + 1 selector switch                              
- 4 - 4.1.2 12-pushbutton types 4012-1: 12 single speed pushbuttons 4012-1S: 11 single speed pushbuttons + 1 selector switch 4012-2: 6 double speed pushbuttons + 6 single speed pushbuttons 4012-2S: 6 double speed pushbuttons + 5 single speed pushbuttons + 1 selector switch 4012-3: 8 double speed pushbuttons + 4 single speed pushbuttons 4012-3S: 8 double speed pushbuttons + 3 single speed pushbuttons + 1 selector switch 4012-4: 10 double speed pushbuttons + 2 single speed pushbuttons                                            
- 5 - 4.2 Transmitter Outline 4.2.1 Transmitter External Descriptions 12 pushbuttons: 272mm × 65mm × 52mm 8 pushbuttons: 231mm × 65mm × 52mm (Fig. 1) Transmitter Top / Bottom View 1. On / Off switch 2. function key 3. Emergency Stop Button (EMS) 4. Status LED Display 5. Shoulder Strap holder 6. Selector Switch 7. Anti-hit rubber 8. Lithium battery 9. Battery charging slot 10 Battery charging fixing hole  (Fig. 2) Transmitter Exterior Views 
- 6 - 4.2.3 Encoder Board, TX Module, Recharging chip card and Rechargeable Battery Descriptions: (Fig. 3) Encoder Board, RF Module, Power Card Descriptions 1.Transmitting channel dip-switch 5. Start Switch 9.LED Display cable port 13.Transmitting RF module cable port 17.Chip Card Holder 2. Adjustable capacitor for PLL frequency compensation 6. One/Two speed pushbutton 10.AUX dip-switch 14. ID code dip-switch 18.Battery pack contact spring 3.Transmitting RF module cable 7. Emergency Stop Pushbutton (EMS) 11.Micro-Processor Programming Port 15.Battery charging board to encoder board cable port 19.Battery charging wiring loop holder 4.Port of Encoder board to battery charging board port 8. Power Switch(ON/OFF) 12.Extra 2 aux. pushbuttons and selector switch cable connector 16.Chip card special setting port (Fig. 4) Encoder Board, TX Module and Power Card Interior Descriptions 
- 7 -   4.2.4 Battery Charger Exterior Descriptions 1. Lithium charging holder 2. Power Status LED 3. Low Battery Charging Status LED 4. Transmitter Charging Status LED 5. Transmitter Charging Fixing Pole 6. Transmitter Charging Pole 7. Cleaning Tool for Charging Hole 8. Battery Charger Fixing Holes 9. Lithium Battery Cover 10 Power Socket 11.Anti-Slippery Pads (Fig. 2) Battery Charger Exterior Descriptions 
- 7 - 4.2.4 Rechargeable BatteryBattery Charger and Shoulder Strap Outline (Fig. 5) Rechargeable BatteryBattery Charger and Shoulder Strap Outline 4.3 Receiver Introductions 4.3.1 Receiver Outline 300mm × 171mm × 115mm (Antenna and Plug-in Socket Excluded)(Fig. 6) Receiver Outline 4.3.2 Receiver Exterior Descriptions: 1. Antenna 2. Antenna holder 3. Receiver power source indicator 4. Receiver RF signal indicator 5. Receiver status indicator 6. Receiver main indicator 7. Model / Specification label 8. Anti-vibration fixing pole*4 9. cable gland*2 10.RX module card 11.Output relay card I 12.Output relay card II 13.Output relay card III 14.Output relay card IV 15.Decoder card 16.Power supply card              (Fig.7) Receiver External Descriptions
- 8 - 4.3.3 Receiver Mounting Dimension (fig.8) Receiver Mounting Dimension 4.3.4 (1) RX Module Card (2) Decoder Card (3) Output Relay Card (4) Power Supply Card (fig.9) (1) RX Module 1. RX module card fixing holder 2. Antenna port 3. Receiver main indicator 4. Receiver status indicator 5. Receiver signal indicator 6. Receiver power source indicator 7. RX module edge connector 8. RX module shielding plate (Fig. 10) RX module
- 9 - (2) Decoder card (Fig. 11) 1. Decoder card shielding plate 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.RX module edge connector 13. (Fig. 11) Decoder card (3) Relay card (Fig.12) 1. Relay light pipe LED 2. Relay contact 3. Relay fixing holder 4. Relay 5. Relay indicator 6. Relay card edge connector (Fig. 12) Relay card (4) Power board (Fig. 13) 1. Power board aluminum holder 2. 3. 4. 4.4 Output Wiring diagram (Fig. 13) Power Board Enclosed inside receiver enclosure lid
- 10 - 5. SYSTEM SETTINGS 5.1 Transmitter ID Code Settings Transmitter ID code are set via an 8-position dip-switch located on the encoder board (refer to fig.3 on page 6) Example: ID code → 10010110 Top location: “1” (fig.14) dip switch Bottom location: “0”     Transmitter Frequency Channel Settings The transmitter frequency channel is also set via an 8-position dip-switch located on the encoder board (refer to fig.3 on page 6) Example: frequency 433.075MHZ/channel 01(00000001) (fig.15) frequency dip switch Top location: “1” Bottom location: “0” 5.3 Transmitter Function Settings: Not yet available.
- 11 - 5.4 Frequency Channel Table FREQUENCY DIP-SWITCH SETTING CHANNEL 433.075 MHz 00000001 01 433.100 MHz 00000010 02 433.125 MHz 00000011 03 433.150 MHz 00000100 04 433.175 MHz 00000101 05 433.200 MHz 00000110 06 433.225 MHz 00000111 07 433.250 MHz 00001000 08 433.275 MHz 00001001 09 433.300 MHz 00001010 10 433.825 MHz 00001011 11 433.850 MHz 00001100 12 433.875 MHz 00001101 13 433.900 MHz 00001110 14 433.925 MHz 00001111 15 433.950 MHz 00010000 16 433.975 MHz 00010001 17 434.000 MHz 00010010 18 434.025 MHz 00010011 19 434.050 MHz 00010100 20 
- 12 - 6 RECEIVER INSTALLATION 6.1 Receiver Status LED Displays Receiver Status LED Display (Fig 17) Receiver Status LED Display 1. Receiver Power Display 3. Receiver Status Display 2. Receiver SQ Status Display 4. Receiver MAIN Display 2. Receiver Central CPU Status LED Display LED INDICATION REASON Slow Blinks (Green) Standby Fast Blinks (Green) Transmitted signals received Fast Blinks (Red) MAIN contact relays jammed or defective 3 Fast Blinks (Red) RX module defective 4 Fast Blinks (Red) EEPROM error 5 Fast Blinks (Red) Incorrect transmitted ID code 6 Fast Blinks (Red) Incorrect system type Slow Blinks (Green) Standby 6.2 Preparation 1. Required Tools: (1) Flat Head Screwdriver (-) (6) Power Drill with φ10.5  ~φ11  Drill-Bit (2) 5mm Wrench X 6 (7) Long nose plier (3) Multi-Meters (8) Cutter plier (4) Box end wrench or 14  Wrench X 2 (5) Power Drill (9) Output Cables (φ12.5 ~φ19.5 ) and wiring materials 2. Ensure receiver is not set to the same frequency channel and ID code as any other units in use at the same facility or within distance of 300 meters. 3. Prior to installation, make sure that the crane system itself is working properly. 4. Use the multi-meter to check the voltage source available and ensure receiver voltage setting is correct for this voltage. 5. Prior to installation, switch off the main power source to the equipment. 
- 13 - 6.3 Step-by-Step Receiver Installation 1. Decide system wiring first for cable arrangement. If cable gland is used, please stuff those cable glands which are not used. (All the cable glands are stuffed prior to the shipment.) 2. Select a suitable wiring location: (1) The location selected should have the antenna visible from all areas where the receiver is fixed. (2) Select the location which is far from high voltage wiring or equipment, e.g. motor, relay…etc. (3) The location selected should not be blocked. Coaxial cable is suggested to be used to move the location of antenna if needed. (4) Please refer to Fig. 18 Receiver Mounting Size for the selection of better installing location. 3. Please refer to Fig. 18 Anti-Vibration Spring Location. Drill 4 fixing holes (11mm). * Note: The higher the receiver, the better. 4. Tighten 4 screws provided on receiver. 5. Power cable has to be connected to AC position and ground cable has to be connected to GND position. It is also acceptable to connect ground cable to screw fixing hole on receiver. 6. Ensure all wiring is correct and safely secured and all screws are fastened. (Fig. 18) Receiver mounting size
- 14 - 7. TRANSMITTER INSTALLATION                         1. Transmitter LED Display (Fig 19) Transmitter LED Display (1) Battery Power LED Display: green light for having enough power, read light for insufficient power. (2) Transmitter Status LED Display: green light for normal status, red light for abnormal status. 3. Transmitter Status LED Display: STATUS DISPLAY REASON No Light Displayed Transmitter in sleep mode with receiver MAIN relay deactivated Slow Blinks (Green) Transmitter on standby Fast Blinks (Green) Transmitter active Constant Red Light Jammed or defective pushbutton, switch or joystick contacts Fast Blinks (Red) The contact point currently in use is operative (refer to note A) 3 Fast Blinks (Red) PLL TX module defective 4 Fast Blinks (Red) EEPROM error Note A: When there is a defective or jammed pushbutton, switch or joystick contacts, the transmitter status LED will display a constant red light without flashes. To find out which contact is defective or jammed, activate each pushbuttons, switches or joysticks a step at a time by holding at each position for up to 2 seconds. If a flashing red light (blinks rapidly) is displayed at a specific position, it means that the contact point for that particular position is operative. If the lights remained constantly red at a certain position, then it means that this position’s contact is either jammed or defective. The main purpose of function is to let the user realize which contact on the transmitter is not working properly and required service immediately.
- 15 - 4. Transmitter Battery Power LED Display POWER DISPLAY REASON Constant Green Battery level normal Slow blinking Red 1. Low battery power (1st warning) 2. Battery below average. Replace battery immediately. Fast blinking Red 1. Low battery power (2nd warning) 2. Transmitter unit will stop transmitting at anytime Constant Red 1. Low battery power (3rd warning) 2. Transmitter power and receiver MAIN relay deactivated 
- 16 -     BATTERY CHARGING1. Plug in the power cord and the power indicator will light up. 2. When a battery pack is inserted, the green charging light will blink to indicate charging is taking place at the current moment. 3. If discharging of battery pack is desire, press the “DISCHARGE” button. (Discharged voltage about 30mA) At discharging mode, the green blinking light will now turned into a constant red light indicating that the battery pack is now being discharged. If you want to cancel the discharge, just press “DISCHARGE” button again. 4. When discharging is completed, the charger will automatically switch to the charging mode where the green blinking light will reappear again. 5. The charging time for a 600mA NiCd battery pack is approximately 3 ~ 6 hours. As for the 1450mA NiMH battery pack, the charging time is approximately 7 ~ 9 hours. 6. When charging is completed, a constant green light will appear to indicate that the battery pack is fully charged. (Battery tepid is normal) 7. When the battery pack is at 90% charged state, trickle charging will take over to ensure the longevity of the battery pack and as well as to ensure the battery pack is 100% charged. 8. When the battery pack’s temperature exceeds 50 , the charger will go into protective mode and charging will be discontinued. 9. To prolong the life of the battery pack, it is recommended that the battery pack be fully discharged prior to every re-charging. Order Status Display Reason LED Display Status 1 Charge Hang the transmitter on the charger Refer to (charger LED display) 2 CPU I/O error Set the 47k ground resistor on CPU I/O button open. Red light ON_0.1 sec./OFF_0.3 sec. 8 times, OFF_0.8 sec. 3 2nd warning Lithium battery 2.8V or regular 2.4V turns all the power off Red light ON_0.1 sec./OFF_0.3 sec. twice, OFF_0.8 sec. 4 EEPROM fails EEPROM data write-in fail Red light ON_0.1 sec./OFF_0.3 sec. 7 times, OFF_0.8 sec. 5 Chip card fails (not inserted) No chip card or write-in error Red light ON_0.1 sec./OFF_0.3 sec. 5 times, OFF_0.8 sec. 6 Chip card data error Chip card data does not match data in CRC 8. System type is not identical. Red light ON_0.1 sec./OFF_0.3 sec. 6 times, OFF_0.8 sec. 7 TX module fails RF module error tested by encoder Red light ON_0.1 sec./OFF_0.3 sec. 4 times, OFF_0.8 sec. 8 Pushbuttons locked Power on when part of the pushbuttons are connected Red light ON_0.1 sec./OFF_0.3 sec. 3 times, OFF_0.8 sec.
- 17 - 9 STOP status or POS activates Depress STOP button or power switch OFF 10 STOP status and function button is depressed Depress STOP button and then function buttons Red light ON_0.1 sec., OFF_0.1 sec. blinks 11 1st warning Lithium battery 3.2V or regular 3.0V Red light ON_0.1 sec., OFF_0.9 sec. blinks 12 Regular power on Normal voltage. Some buttons are not depressed 0.2 sec. red light S→(2+S+3) →(1+2+S+3+4) →green light S→(2+S+3) →(1+2+S+3+4) 13 operating TX board sends signal remittently or continuously Green light ON_0.1 sec., OFF_0.1 sec. blinks 14 Standby status Without sending signals remittently or continuously Green light ON_0.1 sec., OFF_0.9 sec. blinks 15 Chip card updated CRC in chip card changed   CRC   0.5 sec. green light 1→(1+2)→(1+2+S) →(1+2+S+3) →(1+2+S+3+4) 16 Copy data in CPU to chip card JP2 short 0.5 sec. green light 4→(3+4)→(S+3+4) →(2+S+3+4) →(1+2+S+3+4) TROUBLE SHOOTING Should the operator find the equipment not operating normally, please check the chart below for simple trouble shooting tips. PROBLEM POSSIBLE REASON SOLUTION Transmitter does not communicatewith the receiver Use pendant handset to operate but not work Repair crane 1. Transmitter is not turned on 2. Transmitter low battery power 1. Battery and status LED does not lit 2. Turn on the transmitter power. Release EMS button and battery indicator constantly red 1.Turn on the power 2.Replace recharge-able battery No power to the receiver (AC power indicator on the receiver unit not lit) Check if the receiver power board is lit, if not Ensure receiver is correctly wired Receiver fuse burn down Check if receiver fuse is burn down, if so Replace fuse  10.SYSTEM SPECIFICATION
- 18 - Transmitter Unit Frequency Range : PLL 433MHz Transmitting Range: : 70 Meters Continuous Operating Time : 8 Hours Security ID Code : 65,536 sets (16 + 1 bit) Channel Spacing : 25KHz Hamming Distance : D  4 + CRC8 Frequency Control : Quartz Crystals (PLL) Frequency Drift : < 5ppm @ -10 ~ 70 Frequency Deviation : < 1ppm @ 25 Spurious Emission : > 50dBc Transmitting Power : ~1.0mW Emission : F1D Antenna Impedance : 50 ohms Enclosure Rating : IP-66 Source Voltage : 4.2VDC lithium / 1800mA Current Drain : ~20mA@3.7V Operating Temperature : -10 ~ 70 Dimension : 273mm X 65mm X 52mm (12 pushbuttons) 228mm X 65mm X 52mm (8 pushbuttons) Weight : 615g (with 1800mA lithium battery) Note: Longer or shorter transmitting ranges are available upon request.        Receiver Unit
- 19 - Frequency Range : PLL 433 MHz Channel Spacing : 25KHz Hamming Distance : D          Frequency Control : RX module card or synthesizer (PLL) Frequency Drift : < 5ppm @ -10 ~ 70 Frequency Deviation : < 1ppm @ 25 Sensitivity : < -125dBm Antenna Impedance : 50 ohms Data Decoder Reference : Quartz Crystals Responding Time : 50mS ~ 150mS Enclosure Rating : IP-66 Source Voltage : 100 ~ 240VAC @ 50/60 Hz. (standard equipped) Power Consumption : MAX 32W@240VAC 50Hz Operating Temperature : -10 ~ +75 Output Contact Rating : 250V @ 10A Dimension : 300mm X 171mm X 115mm Weight : 4,500g (without the output cable) Note: Other types of source voltages are available upon request. 
- 20 -15.21 “Changes or modifications are not expressly approved by the manufacturer could void the user's authority to operate the equipment. Changes or modifications to the device may void FCC and CE compliance. In frequently used radio links should be tested regularly to protect against undetected interference or fault.” "Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device."

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