Fomotech ALPHA504SERIES Industrial Remote Control System User Manual Manual

Fomotech International Corp. Industrial Remote Control System Manual

manual

1 TABLE OF CONTENTS Page 1. INTRODUCTION ....................................................................................................... 2 2. SAFETY INSTRUCTION ............................................................................................. 3 3. PUSHBUTTON CONFIGURATION 3.1 Alpha 500/520 ....................................................................................................... 4 3.2 Alpha 540/560 ....................................................................................................... 5 3.3 Alpha 540T/560T "Select" Settings ……............................................................. 6 3.4 FCC ID Labels and Numbers ............................................................................... 6 4. TRANSMITTER OUTLINE 4.1 Alpha 500/520 ....................................................................................................... 7 4.2 Alpha 540/560 ....................................................................................................... 8 5. RECEIVER OUTLINE 5.1 Alpha 500/520/540/560 ......................................................................................... 9 5.2 Alpha 500/520 Internal Assembly ......................................................................... 10 5.3 Alpha 540/560 Internal Assembly ......................................................................... 11 6. OUTPUT CONTACT DIAGRAM 6.1 Alpha 500/520 Wiring Diagrams .......................................................................... 12 6.2 Alpha 540 Wiring Diagrams ................................................................................. 13 6.3 Alpha 560 Wiring Diagrams ................................................................................. 14 7. SYSTEM SETTING CONFIGURATION ................................................................... 15~16 8. RECEIVER INSTALLATION 8.1 Preparation For Installation ................................................................................... 17 8.2 Step By Step Installation ....................................................................................... 17 8.3 System Testing ....................................................................................................... 18 9. TRANSMITTER OPERATION ................................................................................... 19-20 10. TROUBLE SHOOTING ............................................................................................... 21 11. SYSTEM SPECIFICATION ......................................................................................... 22-23 12. PARTS LIST ................................................................................................................. 24
2 1. INTRODUCTION The Alpha 500 series are highly reliable industrial remote control systems. The versatile features of the Alpha 500 series permit its use in many different remote control applications. They can be used to control cranes, hoists, trolleys, mining equipment, building construction equipment, automatic control systems, and many others. The Alpha 500 series radio 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 500 series are as follow: * The system uses advanced microprocessors which utilizes highly evolved software that have redundant error checking and correcting capabilities to ensure 100 % error-free transmission, decoding, and control of the output relays. These highly evolved software include CRC (Cyclic Redundancy Check codes) and Hamming Codes. * To insure maximum operating safety, the Alpha 500 series incorporate many safety features. Some of these safety features include receiver self-diagnosing, transmitter pushbutton self-diagnosing, transmitter low voltage detection/warning, transmitter/receiver auto shutdown after 1 minute of transmitter low voltage warning, and receiver MAIN deactivation during transmitter non-usage (programmable from 0~30 minutes). * The encoder/decoder system utilizes advanced microprocessor. The availability of 32,768 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. A special programmable integrated circuit is used to insure the unit can not simultaneously command conflicting movements. * Full SMT design for system stability. The Alpha 500 series radio control system consists of a transmitter handheld, a receiver unit, and a six-foot (2-meter) output cable. The transmitter casing is molded using an industrial strength composite material which is impervious to dust, water, oil, acids, alkaline, heat, sunlight, and as well as being resistant to deformation due to long term use in harsh environments. The pushbuttons are also constructed from industrial strength composite material with a minimum of up to one million cycles. For power saving, the transmitter unit uses special high efficiency power saving circuits that requires only two “AA” alkaline batteries (UM-3).
3 2. SAFETY INSTRUCTION The Alpha 500 systems are relatively simple to use. However, it is very important to observe the proper safety procedures during operation. When use properly the Alpha 500 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 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 two "AA" alkaline batteries should be replaced. 3. The emergency stop pushbutton (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 pushbutton immediately. Then turned the power “off” from the main power source of the equipment. 5. The power switch should be turned “off” after use and should never left the power “on” when the unit is unattended. 6. Do not use the same RF channel and ID code as any other unit in use at the same facility. 7. Ensure the wrist strap is worn at all time during operation to avoid accidental dropping. 8. Never operate a crane or equipment with two (2) transmitter units at the same time with same RF channel and ID code.
4 3. PUSHBUTTON CONFIGURATION 3.1 Alpha 500/520 Models 1. Alpha 500 : Up to 2 motions, single-speed pushbuttons, EMS Stop. 2. Alpha 520 : Up to 2 motions, dual-speed pushbuttons, EMS Stop. (Alpha 500) (Alpha 520) Below are many types of pushbutton configuration that are also available upon request. Interlocked (can also be set to non-interlocked). ON OFF STOP STOPON OFF
5 3.2 Alpha 540/560 Models 1. Alpha 540S : Up to 3 motions, single-speed pushbuttons, EMS Stop. 2. Alpha 540A : Up to 3 motions, single-speed pushbuttons, AUX, EMS Stop. 3. Alpha 540T : Up to 5 motions, single-speed pushbuttons, “Select” pushbutton for auxiliary hoist and/or trolley, EMS Stop. 4. Alpha 560S : Up to 3 motions, dual-speed pushbuttons, EMS Stop. 5. Alpha 560A : Up to 3 motions, dual-speed pushbuttons, AUX, EMS Stop. 6. Alpha 560T : Up to 5 motions, dual-speed pushbuttons, “Select” pushbutton for auxiliary hoist and/or trolley, EMS Stop. (Alpha 540S) (Alpha 540A) (Alpha 540T) (Alpha 560S) (Alpha 560A) (Alpha 560T)
6 3.3 Alpha 540T/560T “Select” Pushbutton Function For Crane system with main and auxiliary hoist, press “Select” pushbutton in sequence to choose between the two hoists. 1) Power "on"  LED-I lit  Main hoist active. 2) Press “Select”  LED-II lit  Auxiliary hoist active. 3) Press “Select”  LED-I & LED-II lit  Both main and auxiliary hoist active with duplicate movements. 4) Press “Select” again  LED I lit  Back to main hoist active. 3.4 FCC ID Labels and Numbers FCC ID: XXXALPHA504SERIES FOMOTECH INTERNATIONAL CORP. 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 received, including interference that may cause undesired operation. FCC ID: XXXALPHA506SERIES FOMOTECH INTERNATIONAL CORP. 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 received, including interference that may cause undesired operation.
7 4. TRANSMITTER OUTLINE 4.1 Alpha 500/520 (Fig. 1) Front View (Fig. 2) Back View (Fig. 3) Front View (Fig. 4) Back view 1) Transmitter enclosure 8) Pushbutton # 3 15) TX quartz crystal 2) Power switch (ON/OFF) 9) System information 16) Programming port 3) Pushbutton #2 10) Battery cover/FCC ID 17) ID code dip-switch 4) Pushbutton #4 11) Battery screws 5) Strap ring 12) Antenna 6) Emergency stop (EMS) 13) Status LED display 7) Pushbutton #1 14) Battery contact 1234567891011ON OFF STOP121314151617
8 4.2 Alpha 540/560 (Fig. 5) Front View (Fig. 6) Back View (Fig. 7) Front View (Fig. 8) Back View 1) Transmitter enclosure 9) Emergency stop (EMS) 17) Antenna 2) Power switch (ON/OFF) 10) Pushbutton #1 18) Status LED display 3) Pushbutton #2 11) Pushbutton #3 19) Battery contact 4) Pushbutton #4 12) Pushbutton #5 20) TX quartz crystals 5) Pushbutton #6 13) Select/AUX pushbutton** 21) Select/AUX 6) Main hoist and/or trolley* 14) System information connector port** 7) Auxiliary hoist and/or trolley* 15) Battery screws 22) Programming port 8) Strap ring 16) Battery cover/FCC ID 23) ID code dip-switch * For Alpha 540T/560T models only. ** For Alpha 540/560 A and T models only. On12347 568
9 5. RECEIVER OUTLINE 5.1 All Models (Fig. 9) Front View (Fig. 10) Back View 1) Receiver enclosure 6) Serial number (S/N) 2) Wiring diagram 7) Security code (ID) 3) Contact relay LED displays* 8) Frequency channel (CH) 4) Model (MOD) 9) Supplied voltage (VOLT) 5) Frequency (FREQ) 10) Anti-vibration spring 11) Grounding (GND) * A ~ AUX (Alpha 540A/560A) and “Select” (Alpha 540T/560T) Indicator. * M ~ MAIN and 2nd Speed Indicator. Green "ON"  MAIN activated. Red "ON"  2nd speed activated (Alpha 560 models only). * SQ ~ RF Frequency Signal Indicator (Red). "ON"  Signals received (ON  0.1 second and OFF  0.1 second). "OFF"  No frequency signals received. * AC ~ Power Source Indicator.
10 5.2 Alpha 500/520 Internal Assembly (Fig. 11) Internal Parts Assembly 1) RX module 8) Contact output seat (CN3) 2) Power fuse (AC) 9) Low voltage warning fuse (LV) 3) Spare fuses & jumpers 10) Pushbutton #3 and #4 fuse 4) ID code dip-switch 11) AC power input seat (CN2) 5) Contact relay LED displays 12) Output cable mouth 6) MAIN fuse 13) Reserved output cable mouth 7) Pushbutton #1 and #2 fuse 14) System status LED display FUSEFUSEFUSEFUSEFUSE
11 5.3 Alpha 540/560 Internal Assembly (Fig. 12) Internal Parts Assembly 1) RX module 10) MAIN contact fuse 2) Power fuse (AC) 11) Pushbutton #1 and #2 fuse 3) Contact output (CN3, CN4) 12) Pushbutton #3 and #4 fuse 4) Reserved contact output (CN5) 13) Pushbutton #5 and #6 fuse 5) AC power connector (CN2) 14) Low voltage fuse (Alpha 540S/560S) 6) Antenna LV/AUX fuse (Alpha 540A/560A) 7) System status LED display SELECT fuse (Alpha 540T/560T) 8) ID code dip-switch 15) Spare fuse & jumpers 9) Contact relay LED displays 16) Output cable mouth 17) Reserved output cable mouth FUSEFUSEFUSEFUSEFUSEFUSE
126. OUTPUT CONTACT DIAGRAM 6.1 Alpha 500/520 Wiring Diagram (Alpha 500) (Alpha 520) NC  No connection POWER1ALV5AE/W5AU/D5AMAIN5ANCNCNCPOWER1ALV5AE/W5AU/D5AMAIN5ANCNCNCNCNCNC
13 6.2 Alpha 540 Wiring Diagrams (Alpha 540S) (Alpha 540A) (Alpha 540T) NC  No connection NC1APOWER5AE/W5AN/SLV,AUX5ANCU/D5AMAIN5ANCNCNCNC1APOWER5AE/W5AN/SLV,AUX5ANCU/D5AMAIN5ANC1APOWER5AE/W5AN/SLV,AUX5ANCU/D5AMAIN5A
14 6.3 Alpha 560 Wiring Diagrams (Alpha 560S) (Alpha 560A) (Alpha 560T) NC  No connection 1APOWER5AN/S5A5A5ALV,AUXE/WMAINU/D5A1APOWER5AN/S5A5A5ALV,AUXE/WMAINU/D5A1APOWER5AE/W5AN/SLV,AUX5AU/D5AMAIN5ANC
157. SYSTEM SETTING CONFIGURATION How To Set Jumper Functions Manufacture settings. * T models do not have LV relay output for external connection. Open Manufacture preset for all Alpha 540A/T and 560A/T models Press the AUX/SELECT button to activate all transmitter key functions and the receiver MAIN after transmitter power “on” and After EMS reset JP1 Short Manufacture preset for all Alpha 500/520/540S/560S models Turn “on” the power switch to activate all transmitter key functions and the receiver MAIN. After EMS reset, turn the transmitter power switch “off” and then “on” again to activate all transmitter key functions and the receiver MAIN. Open Receiver MAIN stays "on” constantly. JP2 Short After 5 minutes of transmitter non-usage (pushbuttons not pressed), receiver MAIN will be deactivated. (see note A) Open After 1 minute of low voltage warning, only the transmitter power will be deactivated. JP3 Short After 1 minute of low voltage warning, both the transmitter power and the receiver MAIN will be deactivated. (see note B) Open AUX in normal key function (for Alpha 540A/560A only). JP4 Short AUX in toggled key function (for Alpha 540A/560A only). Note A MAIN shut-off time during system non-operation can be set from 0~30 minutes via external programmer; manufacture preset at five (5) minutes. To resume operation after five minutes, just press any pushbutton to reactivate the receiver MAIN. Note B: If transmitter lo w voltage occurs during operation, other than transmitter itself will display visual warnings, it will also send out a low voltage signal to the receiver to activate its external low voltage warning device. By connecting a horn, buzzer, or siren to the LV-relay output will ensure that the operator will clearly notice the low voltage warning even in hard to see or hear environments. After one minute of low voltage warning, to insure maximum safety, both the transmitter power and the receiver MAIN will be deactivated. For proper battery replacement, you must first turn “off” the transmitter power, replace the batteries, and then turn the power switch back “on” again to reactivate the transmitter and the receiver unit. OPEN¡÷JUMPSHORT¡÷JUMP
16 JP1 (Manufacture preset for the Alpha 500/520/540S/540A/560S/560A models) * Reset Power Switch  Turn the transmitter power switch “off” and then “on” again. JP1 (For the Alpha 540T/560T models - Manufacture preset at JP1-Open) * Reset Power Switch  Turn the transmitter power switch “off” and then “on” again. JP2 * Programmable from 1~30 minutes via external programmer. JP3 JP4 (For Alpha 540A/560A models only) JP4Short Aux-Togglefunction JP4Open Aux-NormalfunctionJP1ShortTransmitterOnMAINActivatedMAINActivatedPressEMSMAINDeactivatedResetEMSReset"Power Switch"JP1ShortTransmitterOnMAINActivatedPressEMSMAINDeactivatedResetEMSReset"Power Switch"MAINActivatedJP1Open TransmitterOn MAINActivated PressEMS MAINDeactivated ResetEMS Press AnyPushbutton MAINActivatedJP2Short 5 minutes of non-transmissionof commands MAINDeactivatedJP3Short SystemON Work inProgressTransmitterLow VoltageOccursLVWarning MAINDeactivatedChangeBatteries within1 minuteYesNoNotApplicableJP1Open
17 8. RECEIVER INSTALLATION 8.1 Preparation For Installation 1. Required Tools: (1) Flat Head Screwdriver (-) (2) Phillips Head Screwdriver (+) (3) Multi-Meter (4) 14mm Wrench x 2 (5) 10.5mm Drill-Bit 2. Ensure receiver is not set to the same channel and ID code as any other units in operation at the same facility. 3. Prior to installation, make sure the equipment 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. 8.2 Step By Step Installation 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 (see diagram next page). 6. Drill a hole on the control panel (10.5mm) 7. Tightened the two bolt nuts provided. 8. If the control panel has a plastic surface, extended grounding wire should be used. 9. For system wiring, please refer to the output contact diagram on page 12~14 or on the receiver enclosure. 10. Ensure all wiring is correct and safely secured and all screws are fastened.
18 8.3 System Testing 1. Connect the power source to the receiver and test the operation of each function to ensure it operates in the same manner as the pendant controller. 2. Ensure the receiver MAIN can be properly controlled by the remote control. 3. Ensure the limit switches on the equipment that limit all travels are working properly. 4. Ensure the pendant controller is located in a safe location where it would not interfere with remote operation.
199. TRANSMITTER OPERATION 1. Make sure the (2) alkaline batteries are installed correctly. Do make sure to use alkaline type batteries for longer operating time between battery replacements. 2. Turn “on” the power switch located on the top left hand corner of the transmitter unit (see diagram next page). Immediately after turning “on” the transmitter unit, the status LED indicator located at the center of the power switch will display a green light for up to 1.5 seconds, do make sure that the red EMS pushbutton is in its elevated position. If the status LED displays a red blinking light (ON  0.1 second and OFF  2.0 seconds) or no light at all, then you must replace a set of new batteries before operation. If the red blinking light is ON  2.0 seconds and OFF  0.1 second, the transmitter unit will deactivates itself (locked) due to a jammed or defected pushbutton contact. This important safety feature is designed to prevent unexpected crane movement at system start up caused by a defected pushbutton contact. After transmitter self-diagnosing procedure is completed without any problems detected (within 1 second), all transmitter key functions and the receiver MAIN will be activated. 3. Alpha 540T/560T model  When the transmitter unit is turned “on” to begin work, the LED-I will light up to indicate only the main hoist and/or trolley is activated. If you want to activate the auxiliary hoist and/or trolley, press the "Select" pushbutton, and the LED display will now switched from LED-I to LED-II to indicate that only the auxiliary hoist and/or trolley is activated. Press "Select" again to have both main and auxiliary hoist and/or trolley activated at the same time (both LED-I and LED-II lit). To switch back to the main hoist and/or trolley activation, just press the "Select" pushbutton once again. (please refer to section 3.3 on page 6) Every time when the transmitter unit is turned “off” and then “on” again, the "Select " setting will resets itself to LED-I (back to main hoist and/or trolley active) 4. Alpha 540T/560T model  "Select" setting can not be changed while other command pushbuttons are in use (command pushbuttons pressed). To insure maximum safety, "select" settings (I, II, I&II) can only be changed when all command pushbuttons are in their neutral position (command pushbuttons not pressed).
20 5. In case of an emergency, press down the red EMS pushbutton will immediately deactivates the receiver MAIN. When the EMS pushbutton is activated, the status LED on the transmitter unit will display a red blinking light to indicate EMS activation (ON  0.5 second and OFF  0.5 second). To reactivate the system again, turn the EMS pushbutton clockwise so that the red cap will elevate to its non-active position. Then turn the transmitter power switch “off” and then “on” again to activate all transmitte r key functions and the receiver MAIN. As for the Alpha 540T and 560T models, to reactivate the system after EMS reset, just press any command pushbutton (please refer to JP1 setting on page 15 and 16). 6. Please note that conflicted movements are interlocked to one another for safety purpose. Pressing conflicted commands at the same time will result in a non-transmission. LED DISPLAY
2110. TROUBLE SHOOTING Should the operator find the equipment not operating normally, please check the chart below for simple trouble shooting steps. SYMPTOM REASON SOLUTION Transmitter does not communicate to receiver. Transmitter and the receiver are not on the same RF channel (SQ lamp 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 in its elevated position. If the status LED shows blinking red light or no light at all, then turn the power “off” and replace the two alkaline AA batteries. No power to the receiver (AC power indicator on the receiver unit not lit). Blown fuse or no input power connection. Ensure power input to the receiver unit is correct. If power indicator (AC) is still not lit, please check the receiver for any burned fuse. Outputs do not operate correctly. Receiver configuration is not set properly or output wiring is incorrect. Please refer to section 6 and 7 to ensure receiver is correctly wired and configured for your application. Receiver System Status LED Display (please refer to Fig. 11 on page 10). TYPE LED INDICATION (Red) REASON 1 Constant red light. EEPROM error, manufacture reprogramming required. 2 ON  1.0 second OFF  1.0 second Incorrect ID code, please readjust accordingly. 3 Dim or no light. Under-voltage, check the main power supply. 4 ON  2.0 seconds OFF  0.1 second System error, manufacture reprogramming required. 5 ON  0.1 second OFF  2.0 seconds System normal with transmitter pushbutton either in neutral or in transmitter power “off” position. 6. ON  0.1 second OFF  0.1second System normal with transmitter pushbutton in non-neutral position (pressed).
2211. SYSTEM SPECIFICATION Transmitter Unit Frequency Range : 301 MHz Transmitting Range : 150 feet Hamming Distance : 4 Channel Spacing : 25KHz Frequency Control : Quartz Crystals Frequency Drift : < 5ppm @ -20 ~ +70 Frequency Deviation : < 1ppm @ 25 Spurious Emission : - 50dB Transmitting Power : ~1mW Emission : F1D Antenna Impedance : 50 ohms Enclosure : IP-66 Source Voltage : 3.0 VDC (“AA” alkaline batteries X 2) Current Drain : 10 ~ 20 mA Operating Temp. : -20 ~ +70 Dimension (Alpha 500/520) : 134mm X 68mm X 30.5mm Dimension (Alpha 540/560) : 166mm X 67.5mm X 30mm Weight (Alpha 500/520) : 7.05oz. (include batteries) Weight (Alpha 540/560) : 8.82oz. (include batteries)
23 Receiver Unit Frequency Range : 301 MHz Channel Spacing : 25KHz Hamming Distance : 4 Frequency Control : Quartz Crystals Frequency Drift : < 5ppm @ -20 ~ +70 Frequency Deviation : < 1ppm @ 25 Sensitivity : 0.4ìV Antenna Impedance : 50 ohms Data Decoder Reference : Quartz Crystals Responding Time : 40mS (Normal) Enclosure : IP-65 Source Voltage : 48~380 VAC, 50/60 Hz. Power Consumption : 11VA Operating Temp. : -20 ~ +70 Output Contact Rating : 250V @ 10A Dimension : 310mm X 134mm X 72mm Weight (Alpha 500/520) : 57.3oz. (include output cable) Weight (Alpha 540/560) : 60oz. (include output cable)
2412. PARTS LIST 1. TX Module/Encoder Board (Alpha 500) BEN50 TX Module/Encoder Board (Alpha 520) BEN52 TX Module/Encoder Board (Alpha 540S) BEN54S TX Module/Encoder Board (Alpha 540A) BEN54A TX Module/Encoder Board (Alpha 540T) BEN54T TX Module/Encoder Board (Alpha 560S) BEN56S TX Module/Encoder Board (Alpha 560A) BEN56A TX Module/Encoder Board (Alpha 560T) BEN56T 2. RX Module (All models) BRX10S 3. Decoder/Relay Board (Alpha 500) BDR50 Decoder/Relay Board (Alpha 520) BDR52 Decoder/Relay Board (Alpha 540S) BDR54S Decoder/Relay Board (Alpha 540A) BDR54A Decoder/Relay Board (Alpha 540T) BDR54T Decoder/Relay Board (Alpha 560S) BDR56S Decoder/Relay Board (Alpha 560A) BDR56A Decoder/Relay Board (Alpha 560T) BDR56T 4. Transmitter Enclosure (Alpha 500/520) BCT50 Transmitter Enclosure (Alpha 540S/560S) BCT54S Transmitter Enclosure (Alpha 540A/560A) BCT54A Transmitter Enclosure (Alpha 540T/560T) BCT54T 5. Receiver Enclosure (All models) BCR50 6. Pushbutton (Dual speed) B50001 Pushbutton (Single speed) B50002 7. EMS Red Cap EMS01 8. Wrist Strap WS01 9. Pushbutton Rubber Boot PRB01 10. Direction labels (All types) DL01 11. Transformer (48 VAC) T48V Transformer (110~120 VAC) T120V Transformer (220~230 VAC) T230V Transformer (380 VAC) T380V 12. Contact Relay RLY01

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