Fomotech ALPHA3000MODEL Industrial Radio Remote Control User Manual Manual

Fomotech International Corp. Industrial Radio Remote Control Manual

Exhibit D Users Manual per 2 1033 b3

1 TTAABBLLEE OOFF CCOONNTTEENNTTSS Page 1. INTRODUCTION ....................................................................................................... 2 2. SAFETY INSTRUCTION ............................................................................................. 3 3. TRANSMITTER ILLUSTRATION 3.1 Alpha 3000 External Assembly ......................................................................... 4 3.2 Alpha 3000 Internal Assembly ......................................................................... 5 4. RECEIVER ILLUSTRATION 4.1 External Assembly ............................................................................................... 6 4.2 Alpha 3000 Internal Assembly ......................................................................... 7 5. OUTPUT CONTACT DIAGRAM Alpha 3000 Output Contact ............................................................................. 8 6. SYSTEM CONFIGURATIONS 6.1 Jumper Settings ................................................................................................... 9 6.2 Security ID Code Settings ..................................................................................... 10 6.3 Pushbutton Contact Settings ................................................................................. 11 6.4 Voltage Settings ..................................................................................................... 11 7. RECEIVER INSTALLATION 7.1 Preparation For Installation ................................................................................... 12 7.2 Step By Step Installation ....................................................................................... 12 7.3 System Testing ....................................................................................................... 13 8. TRANSMITTER OPERATION ................................................................................... 14 9. TROUBLE SHOOTING ............................................................................................... 15 10. SYSTEM SPECIFICATION ......................................................................................... 16 11. PARTS LIST ................................................................................................................. 17
2 11.. IINNTTRROODDUUCCTTIIOONN The Alpha 3000 System is a highly reliable industrial radio remote control system. The versatile features of the Alpha 3000 system permit its use in many different remote control applications that required 3-step control. The system can be used to control factory cranes, multiple hoists, trolleys, mining equipment, building construction equipment, automatic control systems, and many others. The Alpha 3000 Radio Remote Control System incorporates numerous redundant safety circuits that guaranty maximum security and ensure the system is resistant to outside interference. The major features of the Alpha 3000 system are as follow: * The system uses advanced microprocessors with highly evolved software that has redundant error checking and correcting capabilities to ensure 100% error-free transmission, decoding, and control of all output relays. This highly evolved software includes CRC (cyclical redundancy check codes) and Hamming Codes (error recovery). * To insure maximum operating safety, the Alpha 3000 system incorporates numerous safety features. Some of these built-in safety features include transmitter pushbutton self-diagnosing, transmitter low-voltage detection and warning, receiver self-diagnosing, and MAIN deactivation when the system is in sleep mode. * The transmitter encoder and receiver decoder both utilize advanced microprocessor control. The availability of 65,536 sets of unique ID codes will ensure that only commands from the matching control transmitter can be carried out without any interference from other radio systems. * For added safety, the system also incorporates special Safety MAIN Relay. If the Safety MAIN Relay is defective (fails to open or close during operation), it will signal the system to shut down immediately to avoid the possibility of any accidents occurring. * Water-resistant transmitter and receiver enclosures. The Alpha 3000 Radio Remote Control System consists of a water-resistant handheld transmitter and receiver. The transmitter casing is molded using industrial strength composite materials which are impervious to dust, water, oil, acids, alkaline, heat and sunlight as well as being resistant to deformation due to long term use in harsh environments. The industry’s best 3-step pushbuttons are also constructed from industrial strength composite materials with a minimum of up to one million press cycles. For power savings, the transmitter is designed with an ultra high efficiency power saving circuit that requires only four “AA” size alkaline batteries for more than 200 hours of continuos operation between replacements.
3 22.. SSAAFFEETTYY IINNSSTTRRUUCCTTIIOONN The Alpha 3000 system is relatively simple to use, however, it is very important to observe the proper safety procedures before, during, and after operation. When used properly our Alpha 3000 radio remote controls will enhance safety, productivity and efficiency in the workplace. The following procedures should be strictly followed: 1. Check the transmitter casing and pushbuttons daily. Should any damage that could inhibit the proper operation of the transmitter be found the unit should be immediately removed from service. 2. The transmitter voltage should be checked on a daily basis. If the voltage is low (red status light blinking, refer to section 8 on page 14), the four “AA” alkaline batteries should be replaced. 3. The red mushroom type emergency stop button (EMS) should be checked at the beginning of each shift to ensure it is in proper working order and the Stop command is being received. 4. In the event of an emergency, depress the emergency stop button (EMS) immediately to disengage the receiver MAIN and the transmitter power. Then turned the power “off” from the main power source to the crane or equipment. 5. The transmitter power key switch should be pulled “off” after each use and should never leave the transmitter in the power “on” position when the unit is unattended. 6. Do not use the same channel and ID code as any other system in use at the same facility or within 600 feet. 7. Ensure the shoulder strap is worn at all time during operation to avoid accidental damage to the transmitter. 8. Never operate a crane or equipment with two transmitter units at the same time with the same channel and ID code. FCC ID: LZ6ALPHA3000MODEL This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions; (1) this device may not cause harmful interference, and (2) this device must accept any interference receiv ed, including interference that may cause undesired operations.
4 124567891011121314151617333.. TTRRAANNSSMMIITTTTEERR IILLLLUUSSTTRRAATTIIOONN 33..11 AAllpphhaa 33000000 EExxtteerrnnaall AAsssseemmbbllyy (Front Few) (Back View) 1. Transmitter Unit 9. Pushbutton #1 (Up) 2. Status LED Display* 10. Pushbutton #3 (East) 3. Spare Power Key Switch 11. Pushbutton #5 (North) 4. Pushbutton #2 (Down) 12. START/AUX Pushbutton 5. Pushbutton #4 (West) 13. System Information 6. Pushbutton #6 (South) 14. Shoulder Strap Ring 7. Emergency Stop (EMS) 15. FCC/IC Label 8. Power Key Switch 16. Battery Cover 17. Warning Label * Please refer to page14 for Transmitter Status LED information
5 33..22 AAllpphhaa 33000000 IInntteerrnnaall AAsssseemmbbllyy (Front View) (Back View) (RF Board) 1. Status LED Display 6. Battery Power Connector 2. RF-to-Encoder Board Connector 7. ID Code Dip-switch 3. 3-Speed Pushbuttons 8. Antenna 4. Emergency Stop Button (EMS) 9. Transmitting RF Board 5. Power ON/OFF Micro-Switch 10. Quartz Crystal 56714381092
6 562314744.. RREECCEEIIVVEERR IILLLLUUSSTTRRAATTIIOONN 44..11 EExxtteerrnnaall AAsssseemmbbllyy 1. Antenna mount 4. External Grounding Hole 2. Receiver Enclosure 5. Shock Absorber 3. Key Lock 6. System Information 7. Cable Gland / Cord Grip
7 Z1 ~123891011IDS1N1 N3+S3N2+S2W1E1U3+D3U2+D2D1U1 E2+W2 E3+W3~71213141516654 44..22 AAllpphhaa 33000000 IInntteerrnnaall AAsssseemmbbllyy 1. Antenna Seat 9. Bottom Relay Board 2. Receiving RF Module 10. Power Transformer 3. Decoder Module 11. Input Voltage Selector Seat 4. Decoder Module Power Display 12. Contact Relay LED Display 5. Receiver Status LED Display* 13. Terminal Block 6. SQ Status LED Display* 14. Power Fuses (1.0A) 7. Power (AC) LED Display 15. AC Power Input 8. Upper Relay Board 16. MAIN Safety Contact Relay * Please refer to page 15 for Receiver and SQ display information
8 U1 D1 U2+D2 U3+D3 E1 W1 E2+W2 E3+W3 N1 S1 N2+S2 N3+S3MAINZ1UPPER RELAY BOARDBOTTOM RELAY BOARDID5. OUTPUT CONTACT DIAGRAM AAllpphhaa 33000000 OOuuttppuutt CCoonnttaacctt Note: Z1 represents START/AUX output contact. Terminal Block and Common Shorting Pin Assembly Common shorting pin illustrated above can be used rather than “daisy chaining” wiring for the common.
9 JUMP66.. SSYYSSTTEEMM CCOONNFFIIGGUURRAATTIIOONNSS 66..11 JJuummppeerr SSeettttiinnggss There are numerous functions that can be set via jumpers located inside the decoder module. Please see the diagram and chart below on how to set these functions. Manufacture Setting Open After inserting the transmitter power key switch, or after EMS reset, press START/AUX pushbutton to activate the receiver MAIN. JP1 Short Insert the transmitter power key switch will immediately activates the receiver MAIN. After EMS reset, re-insert the power key switch to reactivate the receiver MAIN. Open After 5 minutes of transmitter non-usage the receiver MAIN will be deactivated (sleep mode). JP2 Short Sleep mode deactivated with receiver MAIN stays on constantly. Open Pushbutton 1 ~ 6 interlocked. JP3 Short Pushbutton 1 ~ 6 non-interlocked with single speed contact. Open No acceleration delay from 1st through 3rd speed. JP4 Short Acceleration delay for up to 1 second from 1st through 3rd speed. Note: Every time when you change jumper settings you must first turn the receiver power “off” and then turn it back “on” after setting so that they can be stored in memory.
10 JP1 JP1 Open Insert the transmitter power key switch Press START/AUX Receiver MAIN activated or After EMS reset Press START/AUX Receiver MAIN activated JP1 Short Insert the transmitter power key switch Receiver MAIN activated or After EMS reset Re-insert the transmitter power key switch Receiver MAIN activated JP2 JP2 Open After 5 minutes of transmitter non -usage Receiver MAIN deactivated JP2 Short Receiver MAIN stays “on” constantly until the main power source of the system is turn “off” JP3 JP3 Open Pushbutton 1 ~ 6 interlocked JP3 Short Pushbutton 1 ~ 6 non-interlocked with single speed contact JP4 JP4 Open No acceleration delay from 1st through 3rd speed JP4 Short 1st speed depressed After 1 second 1st speed contact relay engaged 2nd speed depressed After 1 second 2nd speed contact relay engaged 3rd speed depressed After 1 second 3rd speed contact relay engaged 66..22 SSeeccuurriittyy IIDD CCooddee SSeettttiinnggss The ID code dip-switch is located on the backside of the encoder board (refer to item #7 on page 5) and on the top of the decoder module (see below). Example : ID code ? 10001100 Top Location ? “1” Bottom Location ? “0”
11 IDDIP SWITCH 66..33 PPuusshhbbuuttttoonn CCoonnttaacctt SSeettttiinnggss The START/AUX pushbutton can be set either to normal or latching contact. This function that can be set via an 8-position dip-switch located inside the decoder module (please refer to the diagram below). By adjusting the dip setting either to the top or bottom slot will change the contact form of the pushbutton (please refer to the chart below). Pus hbuttons are numbered from right-to-left and from top-to-bottom. Top position ? “1” Bottom position ? “0” Alpha 3000 DIP1 ? “0” ? Pushbutton 7 (START/AUX) with normal momentary contact “1” ? Pushbutton 7 (START/AUX) with toggle / latching contact 66..44 VVoollttaaggee SSeettttiinnggss There are four different voltage settings available inside the Alpha 3000 receiver enclosure (bottom relay board), please select one that corresponds to the main power source of the crane or equipment. Input Voltage Range Accepted: 1) AC 110V ? From AC 100V ~ AC 120V 2) AC 220V ? From AC 220V ~ AC 240V 3) AC 380V ? From AC 380V ~ AC 400V 4) AC 415V ? From AC 415V ~ AC 440V
12 77.. RREECCEEIIVVEERR IINNSSTTAALLLLAATTIIOONN 77..11 PPrreeppaarraattiioonn FFoorr IInnssttaallllaattiioonn 1. Required Tools: (1) Flat Head Screwdriver (-) (2) Phillips Head Screwdriver (+) (3) Multi-Meter (4) Open End Wrench (5) Power Drill with 10.5mm ~ 11mm Drill-Bit 2. Check to ensure that your receiver is not set to the same channel and ID code as any other systems in operation at the same facility within 600 feet. 3. Prior to installation, make sure that the crane or equipment itself is working properly. 4. Use a multi-meter to check the voltage source available and ensure that the receiver voltage setting matches your power source. 5. Prior to installation, switch “off” the main power source to the crane or equipment. 77..22 SStteepp BByy SStteepp IInnssttaallllaattiioonn 1. The location selected should have the antenna visible from all areas where the transmitter is to be used. 2. The location selected should not be exposed to high levels of electrical noise. 3. Ensure the selected location has adequate space to accommodate the receiver enclosure. 4. Make sure the receiver unit is in upright position (vertical). 5. The distance between the antenna and the control panel should be as far apart as possible. 6. Drill two holes on the control panel (10.5mm). Refer to diagrams next page. 7. Tightened the bolt nuts provided. 8. Ensure AC ground is connected to the power input terminal block, otherwise chassis ground should be connect to the chassis ground connection hole on the receiver enclosure (refer to item #4 on page 6). 9. For system wiring, please refer to the output contact diagram on page 8. 10. Ensure all wiring is correct and safely secured and all screws are fastened.
13 77..33 SSyysstteemm TTeessttiinngg 1. Connect the power source to the receiver and test the MAIN relay output (EMS button) and observe that it properly opens and closes the main line. 2. Test the operation of each function to ensure it corresponds to the transmitter direction labels and/or the pendant it is replacing. 3. Test the limit switches on the crane and verify that they are working properly. 4. If your new remote control is replacing an existing pendant make sure it is completely disconnected to prevent unwanted control commands. 5. If your new remote control is replacing an existing pendant make sure the pushbutton is stored in a safe location where it will not interfere with remote operation.
14 UD8.. TTRRAANNSSMMIITTTTEERR OOPPEERRAATTIIOONN 1. Batteries _ Make sure the four “AA” alkaline batteries are installed correctly, the labels on the battery holder will tell you which side is “up” and which side is “down”. Use 2000mA alkaline type batteries for optimum operating time between replacements. 2. Start Up _ Insert the power key switch located on the top right hand side of the transmitter unit (refer to diagram below). The Status LED on the face of the transmitter will display a green light (type -1 below) for up to 2 seconds when the power key switch is inserted. Do make sure the red EMS pushbutton is in elevated position when the transmitter power key is inserted, by pulling it upward. Then depress the START/AUX pushbutton to activate the receiver MAIN (depending on JP1 setting on page 9). When the pushbuttons are depressed, the transmitter status LED will display a blinking green light (type-2 below) telling you that the command signals are being transmitted to the receiver. After 5 minutes of transmitter non-usage (pushbuttons not depressed), the receiver MAIN will be automatically deactivated (depending on JP2 setting on page 9). To resume work, just depress the START/AUX pushbuttons. 3. Status Light Display (refer to item #2 on page 4). TYPE LED DISPLAY INDICATION 1 Green “on” ? 2.0 seconds System power “on” 2 Green “on” ? 0.1 second “off” ? 2.0 seconds Pushbutton depressed with signal transmitted 3 Red “on” ? 0.1 second “off” ? 2.0 seconds Transmitter low -voltage warning 4 2 fast red blinks followed by 2 seconds “off” Pushbutton contact jammed or locked 5 Red “on” ? 0.5 second “off” ? 0.5 second Emergency Stop Button activated (depressed) 4. EMS & Restarting _ In case of an emergency, depressing the Red EMS pushbutton will immediately deactivates the receiver MAIN contact relay. When EMS is activated, the Status LED will display a red blinking lights that is “on” ? 0.5 second and “off” ? 0.5 second (refer to the chart above). To reactivate the system, just pull up the EMS pushbutton and depress START/AUX (depending on JP1 setting on page 9). 5. Interlocking Pushbuttons _ The top three sets of motions (the first 6 pushbuttons) are interlocked to its self so no conflicting commands can take place for safety purpose. For example, depressing the hoist “UP” and “DOWN” pushbutton simultaneously will result in no command being sent.
15 99.. TTRROOUUBBLLEE SSHHOOOOTTIINNGG 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 communicate to receiver. Transmitter and the receiver are not on the same RF channel (SQ not lit) or ID code. Ensure the correct transmitter is in use. The labels on the receiver and the transmitter will identify the RF channel and ID code in use. Transmitter does not communicate to receiver. Low or no transmitting power from the transmitter unit. Turn on the transmitter and with EMS elevated. If the status LED shows blinking red lights or no lights, then turn the power off and replace the four batteries. No power to the receiver. Blown fuse or no input power connection. Ensure power input to the receiver unit is correct. If power indicator (AC) is not lit, please check the receiver for any open fuse. Outputs do not operate correctly. Receiver configuration and output wiring is not set properly. Please refer to section 5 and 6 to ensure receiver is correctly wired and configured for your application. Receiver Status LED Display (refer to item #5 on page 7) TYPE LED INDICATION PROBLEM AND SOLUTION 1 3 fast blinks followed by OFF ? 2.0 seconds Defective MAIN contact relay. 2 2 fast blinks followed by OFF ? 2.0 seconds Incorrect ID code setting. 3 ON ? 0.1 second OFF ? 2.0 seconds Decoder on standby. 4 ON ? 0.1 second OFF ? 0.1 second Transmitted signal decoded. SQ Status LED Display (refer to item #6 on page 7) TYPE LED INDICATION PROBLEM AND SOLUTION 1 ON ? 0.1 second OFF ? 0.1 second Transmitted signal received by the receiver. 2 Blinking when pushbuttons are not depressed. Other radio interference.
16 1100.. SSYYSSTTEEMM SSPPEECCIIFFIICCAATTIIOONN Transmitter Unit Frequency Range : 301MHz Transmitting Range : 150 feet Hamming Distance : ?6 Channel Spacing : 25KHz Frequency Control : Quartz Crystals Frequency Drift : < 5ppm @-4? ~ 158? Frequency Deviation : < 1ppm @ 77? Spurious Emission : -50dB Transmitting Power : 0.1mW Emission : F1D Antenna Impedance : 50 ohms Enclosure : IP -66 Source Voltage : DC 6.0V Current Drain : 8mA @ 6V Operating Temp. : -4? ~ 158? Dimension : 23cm x 7.8cm x 4.7cm Weight (include batteries) : 21oz Receiver Unit Frequency Range : 301MHz Modulation : Narrow Band FM Frequency Control : Quartz Crystals Frequency Drift : < 5ppm @ -4? ~ 158? Frequency Deviation : < 1ppm @ 77? Sensitivity : -118dBm Antenna Impedance : 50ohms Data Decoder Reference : Quartz Crystals Responding Time : 64~100mS Enclosure : IP -66 Standard Source Voltage : AC 120V/220V/380V/415V @ 50/60 Hz. Power Consumption : 11VA Operating Temp. : -4? ~ 158? Output Contact Rating : 250V @ 10A Dimension : 42.5cm x 24.5cm x 13cm Weight (include antenna) : 17.68lb
17 1111.. PPAARRTTSS LLIISSTT 1. Transmitting RF Board TX-2005 2. Encoder Board EN-3000 3. Receiving RF Module RX-3000 4. Decoder Module DE-3000 5. Upper Rely Board RY-3000 6. Bottom Relay Board RY-3001 7. Transmitter Casing TC-3000 8. Receiver Enclosure RC-3000 9. Receiver Antenna (301MHz) ANT-301 10. Transformer (AC-110V/220V/380V/415V) SSB-1726 (AC-115V/208V/230V/460V) SSB-2213 11. 1-Step Pushbutton (Optional) PB-3001 2-Step Pushbutton (Optional) PB-3002 3-Step Pushbutton (Standard) PB-3003 12. Emergency Stop Button EMS-3000 13. Emergency Stop Red Cap RD-3000 14. Pushbutton Rubber Boot RB-3000 15. Pushbutton Compass Label DL-3000 16. Transmitter Power Key + Strap TK-3000 17. Receiver Panel Key RK-3000 18. Transmitter Battery Holder BH-3000 19. Transmitter Battery Cover BC-3000 20. Terminal Block TB-3000 21. Common Shorting Pin SP-3000 22. Cable Gland / Cord Grip CG-3000 23. Shock Absorber SA-3000 24. Transmitter Shoulder Strap SS-3000 25. Protective Vinyl Covering PC-3000

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