Fomotech ALPHA506SERIES Industrial Remote Control System User Manual Manual
Fomotech International Corp. Industrial Remote Control System Manual
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manual
TABLE OF CONTENTS Page 1. INTRODUCTION ....................................................................................................... 2. 3. SAFETY INSTRUCTION ............................................................................................. PUSHBUTTON CONFIGURATION 3.1 Alpha 500/520 3.2 Alpha 540/560 ....................................................................................................... ....................................................................................................... 3.3 Alpha 540T/560T "Select" Settings ……............................................................. 3.4 FCC ID Labels and Numbers ............................................................................... TRANSMITTER OUTLINE 4.1 Alpha 500/520 ....................................................................................................... 4. 5. 6. 7. 8. 4.2 Alpha 540/560 ....................................................................................................... RECEIVER OUTLINE 5.1 Alpha 500/520/540/560 ......................................................................................... 5.2 Alpha 500/520 Internal Assembly ......................................................................... 10 5.3 Alpha 540/560 Internal Assembly OUTPUT CONTACT DIAGRAM ......................................................................... 11 6.1 Alpha 500/520 Wiring Diagrams .......................................................................... 6.2 Alpha 540 Wiring Diagrams ................................................................................. 12 13 6.3 Alpha 560 Wiring Diagrams ................................................................................. SYSTEM SETTING CONFIGURATION ................................................................... 14 15~16 RECEIVER INSTALLATION 8.1 Preparation For Installation ................................................................................... 17 8.2 Step By Step Installation ....................................................................................... 8.3 System Testing ....................................................................................................... 17 18 9. TRANSMITTER OPERATION ................................................................................... 10. TROUBLE SHOOTING ............................................................................................... 19-20 21 11. SYSTEM SPECIFICATION ......................................................................................... 12. PARTS LIST ................................................................................................................. 22-23 24 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). 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. 3. PUSHBUTTON CONFIGURATION 3.1 Alpha 500/520 Models 1. 2. Alpha 500 Alpha 520 ON OFF : Up to 2 motions, single-speed pushbuttons, EMS Stop. : Up to 2 motions, dual-speed pushbuttons, EMS Stop. STOP ON OFF (Alpha 500) STOP (Alpha 520) Below are many types of pushbutton configuration that are also available upon request. Interlocked (can also be set to non-interlocked). 3.2 Alpha 540/560 Models 1. Alpha 540S 2. Alpha 540A : Up to 3 motions, single-speed pushbuttons, EMS Stop. : 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 5. Alpha 560A : Up to 3 motions, dual-speed pushbuttons, EMS Stop. : 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) 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" 2) Press “Select” 3) Press “Select” LED-I lit Main hoist active. LED-II lit Auxiliary hoist active. LED-I & LED-II lit Both main and auxiliary hoist active with 4) Press “Select” again duplicate movements. Back to main hoist active. LED I lit 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. 4. TRANSMITTER OUTLINE 4.1 Alpha 500/520 ON OFF STOP 11 10 (Fig. 1) Front View (Fig. 2) Back View 12 15 13 17 14 16 (Fig. 3) Front View (Fig. 4) Back view 1) 2) Transmitter enclosure Power switch (ON/OFF) 8) 9) Pushbutton # 3 System information 3) 4) Pushbutton #2 Pushbutton #4 10) Battery cover/FCC ID 11) Battery screws 5) 6) Strap ring Emergency stop (EMS) 12) Antenna 13) Status LED display 7) Pushbutton #1 14) Battery contact 15) TX quartz crystal 16) Programming port 17) ID code dip-switch 4.2 Alpha 540/560 (Fig. 5) Front View (Fig. 6) Back View 2 3 4 5 6 7 8 (Fig. 7) Front View (Fig. 8) Back View 1) Transmitter enclosure 9) Emergency stop (EMS) 2) Power switch (ON/OFF) 3) Pushbutton #2 10) Pushbutton #1 11) Pushbutton #3 18) Status LED display 19) Battery contact 4) Pushbutton #4 5) Pushbutton #6 12) Pushbutton #5 13) Select/AUX pushbutton** 20) TX quartz crystals 21) Select/AUX 6) Main hoist and/or trolley* 7) Auxiliary hoist and/or trolley* 14) System information 15) Battery screws connector port** 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. 17) Antenna 5. RECEIVER OUTLINE 5.1 All Models (Fig. 9) Front View (Fig. 10) Back View 1) Receiver enclosure 2) Wiring diagram 6) 7) Serial number (S/N) Security code (ID) 3) Contact relay LED displays* 4) Model (MOD) 8) 9) Frequency channel (CH) Supplied voltage (VOLT) 5) Frequency (FREQ) 10) 11) Anti-vibration spring Grounding (GND) AUX (Alpha 540A/560A) and “Select” (Alpha 540T/560T) Indicator. MAIN and 2nd Speed Indicator. Green "ON" MAIN activated. SQ ~ Red "ON" 2nd speed activated (Alpha 560 models only). RF Frequency Signal Indicator (Red). "ON" "OFF" AC ~ Signals received (ON 0.1 second and OFF No frequency signals received. Power Source Indicator. 0.1 second). 5.2 Alpha 500/520 Internal Assembly FU SE SE FU SE FU SE FU SE FU (Fig. 11) Internal Parts Assembly 1) RX module 8) 2) 3) Power fuse (AC) Spare fuses & jumpers 9) Low voltage warning fuse (LV) 10) Pushbutton #3 and #4 fuse 4) 5) ID code dip-switch Contact relay LED displays 11) AC power input seat (CN2) 12) Output cable mouth 6) 7) MAIN fuse Pushbutton #1 and #2 fuse 13) Reserved output cable mouth 14) System status LED display 10 Contact output seat (CN3) 5.3 Alpha 540/560 Internal Assembly FU SE FU SE FU SE FUS E FU SE FU SE (Fig. 12) Internal Parts Assembly 1) RX module 2) Power fuse (AC) 10) MAIN contact fuse 11) Pushbutton #1 and #2 fuse 3) Contact output (CN3, CN4) 4) Reserved contact output (CN5) 12) Pushbutton #3 and #4 fuse 13) Pushbutton #5 and #6 fuse 5) AC power connector (CN2) 6) Antenna 14) Low voltage fuse (Alpha 540S/560S) LV/AUX fuse (Alpha 540A/560A) 7) System status LED display 8) ID code dip-switch SELECT fuse (Alpha 540T/560T) 15) Spare fuse & jumpers 9) Contact relay LED displays 16) Output cable mouth 17) Reserved output cable mouth 11 6. OUTPUT CONTACT DIAGRAM 6.1 Alpha 500/520 Wiring Diagram MAIN 5A MAIN 5A NC U/D 5A U/D 5A NC E/W 5A E/W 5A NC LV 5A LV 5A NC NC NC NC NC POWER 1A POWER 1A (Alpha 500) NC NC (Alpha 520) No connection 12 6.2 Alpha 540 Wiring Diagrams MAIN 5A MAIN 5A MAIN 5A U/D 5A U/D 5A NC U/D 5A NC E/W 5A NC LV,AUX 5A N/S 5A E/W 5A NC LV,AUX 5A NC E/W 5A NC LV,AUX 5A N/S 5A NC N/S 5A NC NC POWER 1A POWER 1A (Alpha 540S) NC (Alpha 540A) No connection 13 POWER 1A (Alpha 540T) 6.3 Alpha 560 Wiring Diagrams MAIN 5A MAIN 5A MAIN 5A U/D 5A U/D 5A U/D 5A E/W 5A E/W 5A E/W 5A LV,AUX 5A LV,AUX 5A LV,AUX 5A N/S 5A N/S 5A N/S 5A NC POWER 1A (Alpha 560S) NC POWER 1A (Alpha 560A) No connection 14 POWER 1A (Alpha 560T) 7. SYSTEM SETTING CONFIGURATION How To Set Jumper Functions OPEN¡ ÷JUMP SHORT¡ J ÷UMP Manufacture settings. * T models do not have LV relay output for external connection. Manufacture preset for all Alpha 540A/T and 560A/T models Open Press the AUX/SELECT button to activate all transmitter key functions and the receiver MAIN after transmitter power “on” and After EMS reset Short 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. 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. 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). Short AUX in toggled key function (for Alpha 540A/560A only). JP1 Manufacture preset for all Alpha 500/520/540S/560S models JP2 JP3 JP4 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. 15 JP1 (Manufacture preset for the Alpha 500/520/540S/540A/560S/560A models) JP1 Short Transmitter On * Reset Power Switch JP1 Open MAIN Activated Press EMS MAIN Deactivated Reset EMS Reset "Power Switch" MAIN Activated Reset "Power Switch" MAIN Activated Turn the transmitter power switch “off” and then “on” again. Not Applicable JP1 (For the Alpha 540T/560T models - Manufacture preset at JP1-Open) JP1 Short Transmitter On * Reset Power Switch JP1 Open MAIN Activated Press EMS MAIN Deactivated Reset EMS Turn the transmitter power switch “off” and then “on” again. Transmitter On MAIN Activated Press EMS MAIN Deactivated Reset EMS Press Any Pushbutton MAIN Activated JP2 JP2 Short 5 minutes of non-transmission of commands MAIN Deactivated * Programmable from 1~30 minutes via external programmer. JP3 JP3 Short System ON Work in Progress Transmitter Low Voltage Occurs LV Warning Change Batteries within 1 minut Yes JP4 (For Alpha 540A/560A models only) JP4 Short Aux-Toggle function JP4 Open Aux-Normal function 16 No MAIN Deactivated 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. 4. Prior to installation, make sure the equipment itself is working properly. Use the multi-meter to check the voltage source available and ensure receiver voltage 5. setting is correct for this voltage. 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 2. transmitter is to be used. 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. 5. Make sure the receiver unit is in upright position (vertical). The distance between the antenna and the control panel should be as far apart as 6. possible (see diagram next page). Drill a hole on the control panel (10.5mm) 7. 8. Tightened the two bolt nuts provided. 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. 17 8.3 System Testing 1. Connect the power source to the receiver and test the operation of each function to 2. ensure it operates in the same manner as the pendant controller. Ensure the receiver MAIN can be properly controlled by the remote control. 3. 4. Ensure the limit switches on the equipment that limit all travels are working properly. Ensure the pendant controller is located in a safe location where it would not interfere with remote operation. 18 9. 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). 19 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 inte rlocked to one another for safety purpose. Pressing conflicted commands at the same time will result in a non-transmission. LED DISPLAY 20 10. 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. No power to the receiver (AC power indicator on the receiver unit not lit). Blown fuse or no input power connection. Outputs do not operate correctly. Receiver configuration is not set properly or output wiring is incorrect. 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. 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. 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 Constant red light. EEPROM error, manufacture reprogramming required. ON OFF Incorrect ID code, please readjust accordingly. 6. 1.0 second 1.0 second Dim or no light. ON OFF ON OFF ON OFF 2.0 seconds 0.1 second 0.1 second 2.0 seconds 0.1 second 0.1second Under-voltage, check the main power supply. System error, manufacture reprogramming required. System normal with transmitter pushbutton either in neutral or in transmitter power “off” position. System normal with transmitter pushbutton in non-neutral position (pressed). 21 11. SYSTEM SPECIFICATION Transmitter Unit Frequency Range 301 MHz Transmitting Range Hamming Distance 150 feet Channel Spacing Frequency Control 25KHz Quartz Crystals Frequency Drift Frequency Deviation < 5ppm @ -20 < 1ppm @ 25 Spurious Emission Transmitting Power - 50dB ~1mW Emission Antenna Impedance F1D 50 ohms Enclosure Source Voltage IP-66 3.0 VDC (“AA” alkaline batteries X 2) Current Drain Operating Temp. 10 ~ 20 mA -20 ~ +70 Dimension (Alpha 500/520) Dimension (Alpha 540/560) 134mm X 68mm X 30.5mm 166mm X 67.5mm X 30mm Weight (Alpha 500/520) Weight (Alpha 540/560) 7.05oz. (include batteries) 8.82oz. (include batteries) 22 ~ +70 Receiver Unit Frequency Range 301 MHz Channel Spacing Hamming Distance 25KHz Frequency Control Frequency Drift Quartz Crystals < 5ppm @ -20 ~ +70 Frequency Deviation Sensitivity < 1ppm @ 25 0.4ìV Antenna Impedance Data Decoder Reference 50 ohms Quartz Crystals Responding Time Enclosure 40mS (Normal) IP-65 Source Voltage Power Consumption 48~380 VAC, 50/60 Hz. 11VA Operating Temp. Output Contact Rating -20 ~ +70 250V @ 10A Dimension Weight (Alpha 500/520) 310mm X 134mm X 72mm 57.3oz. (include output cable) Weight (Alpha 540/560) 60oz. (include output cable) 23 12. PARTS LIST 1. TX Module/Encoder Board (Alpha 500) TX Module/Encoder Board (Alpha 520) TX Module/Encoder Board (Alpha 540S) TX Module/Encoder Board (Alpha 540A) TX Module/Encoder Board (Alpha 540T) TX Module/Encoder Board (Alpha 560S) TX Module/Encoder Board (Alpha 560A) TX Module/Encoder Board (Alpha 560T) 2. RX Module (All models) 3. Decoder/Relay Board (Alpha 500) Decoder/Relay Board (Alpha 520) Decoder/Relay Board (Alpha 540S) Decoder/Relay Board (Alpha 540A) Decoder/Relay Board (Alpha 540T) Decoder/Relay Board (Alpha 560S) Decoder/Relay Board (Alpha 560A) Decoder/Relay Board (Alpha 560T) 4. Transmitter Enclosure (Alpha 500/520) Transmitter Enclosure (Alpha 540S/560S) Transmitter Enclosure (Alpha 540A/560A) Transmitter Enclosure (Alpha 540T/560T) 5. Receiver Enclosure (All models) 6. Pushbutton (Dual speed) Pushbutton (Single speed) 7. EMS Red Cap 8. Wrist Strap 9. Pushbutton Rubber Boot 10. Direction labels (All types) 11. Transformer (48 VAC) Transformer (110~120 VAC) Transformer (220~230 VAC) Transformer (380 VAC) 12. Contact Relay 24 BEN50 BEN52 BEN54S BEN54A BEN54T BEN56S BEN56A BEN56T BRX10S BDR50 BDR52 BDR54S BDR54A BDR54T BDR56S BDR56A BDR56T BCT50 BCT54S BCT54A BCT54T BCR50 B50001 B50002 EMS01 WS01 PRB01 DL01 T48V T120V T230V T380V RLY01
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