Fomotech ALPHA510SERIES Industrial Remote Control User Manual Manual

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Document ID	154322
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Document Description	Exhibit D Users manual per 2 1033 b4
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Document Type	User Manual
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Date Submitted	2001-06-12 00:00:00
Date Available	2001-06-08 00:00:00
Creation Date	0000-00-00 00:00:00
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Document Lastmod	0000-00-00 00:00:00
Document Title	Manual.PDF
Document Creator	Microsoft Word
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TABLE OF CONTENTS
Page
1. INTRODUCTION
The Alpha 580 is highly reliable industrial remote control system. The versatile features of the
Alpha 580 permit its use in many different remote control applications. The system can be used
to control cranes, hoists, trolleys, mining equipment, building construction equipment,
automatic control systems, and many others.
The Alpha 580 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 580 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, and transmitter/receiver auto
shutdown after 1 minute of transmitter low voltage warning.
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 580 radio control system consists of a transmitter handheld, and a receiver unit. 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 580 system is relatively simple to use. However, it is very important to observe the
proper safety procedures during operation. When use properly the Alpha 580 system 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 “o ff ” after use and should never left the power “o n ”
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
The Alpha 580 model can be configured from 3 to 5 motions with 2-speed pushbuttons and an
emergency stop button (EMS).
(Fig. 1) Pushbutton Placements
RES
2-Speed pushbuttons which can be used for the 4th motion or for any other
functions.
AUX
2-Speed pushbuttons which can be used for the 5th motion or for any other
functions.
4. TRANSMITTER OUTLINE
4.1 External View
(Fig. 2) Front
View
1)
2)
3)
4)
5)
6)
7)
Transmitter enclosure
Power switch (ON/OFF)
Pushbutton #2
Pushbutton #4
Pushbutton #6
Pushbutton #8 (A2)
Pushbutton #10 (A4)
8)
9)
10)
11)
12)
13)
14)
Emergency Stop (EMS)
Pushbutton #1
Pushbutton #3
Pushbuttons #5
Pushbutton #7 (A1)
Pushbutton #9 (A3)
System Information
15) Battery Screws
16) Batter Cover/FCC ID
4.2 Internal View
(Fig. 4)
View
Front
17)
18)
19)
TX Module/Antenna
Battery Contact
TX Quartz Crystal
20) Auxiliary Connector
21) Programming Port
22) ID Code Dip-Switch
(Fig. 5
5. RECEIVER OUTLINE
12
13
14
15
16
17
10
18
19
11
(Fig. 6) Receiver Internal Assembly
1)
2)
3)
4)
5)
6)
7)
Power LED Display
SQ Led Display
System Status LED Display
Relay COM LED Display
Programming Port
Jumper Settings
Function Settings
8) E/W Fuse
9) N/S Fuse
10) A1/A2 Fuse
11) A3 Fuse
12) RX Module
13) ID Code Dip-Switch
14) Secondary Power Fuse
15)
16)
17)
18)
19)
Voltage Selector
MAIN Fuse
A4 Fuse
Primary Power Fuse
L/V Fuse
1
(Fig. 7) Receiver External Assembly
1)
2)
Transparent top cover
Light-gray colored base
3)
4)
Mounting bracket with shock absorbers
Cable gland (PG-29)
POWER ~ AC Power Source Indicator “On"
AC input power supplied.
“Off”
No AC input power.
SQ ~ RF Signal Indicator "On"
RF signals received.
"Off"
No RF signals received.
RELAY_COM ~ DC Power Source to Relays “On”
DC power to relays.
“Off” No DC power to relays.
STATUS ~ Receiver System Status LED Display
Please refer to page 14.
6. OUTPUT CONTACT DIAGRAM
NC
No connection
7. SYSTEM SETTING CONFIGURATION
7.1 Jumper Settings (JP3)
JP7
JP6
JP5
JP4
JP3
JP2
JP1
Manufacture settings.
Open
Low voltage warning only; receiver MAIN will not be deactivated.
Short
After one minute of low voltage warning, the transmitter power and
the receiver MAIN will be deactivated. (see note B)
JP3
Note A:
JP1, JP2, JP4, JP5, JP6, and JP7 not applicable for the Alpha 580 model.
Note B:
If transmitter low voltage occurs during operation, other than transmitter itself will display visual
warning, 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.
JP3
Short
System On Work in Progress
JP3
Open
System On Work in Progress
Transmitter Low
LV Warning
Voltage Occurs
Change Batteries
within 1 Minute
YES
Work Resumes
NO
Transmitter and Receiver MAIN Deactivated.
Transmitter Low
LV Warning
Voltage Occurs
Change Batteries
within 1 Minute
YES
Work Resumes
NO
Only Transmitter Unit Deactivated.
7.2 Security ID Code Setting
The ID code dip-switch is located on the back side of the encoder board (refer to Fig. 5 on page
6) and the decoder/relay board (refer to Fig. 6 on page 7).
Example : ID code
10010110
Top location : “1”
Bottom location : “0”
10
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.
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
setting is correct for this voltage.
Prior to installation, switch “off”the main power source to the equipment.
3.
4.
5.
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 4 holes on the control panel (10.5mm).
7. Tightened the 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 9.
10. Ensure all wiring is correct and safely secured and all screws are fastened.
11
2 5 5 mm
4 - O 10.5
2 7 8 mm
8.3 System Testing
1.
2.
3.
4.
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.
Ensure the receiver MAIN can be properly controlled by the remote control.
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.
12
9. TRANSMITTER OPERATION
1.
Make sure the two alkaline batteries are installed correctly. Do make sure to use alkaline
type batteries for longer operating time between battery replacements. Rechargeable
batteries can also be used (1,600mA or higher recommended).
2.
Turn “o n ”the power switch located on the top left hand corner of the transmitter unit (refer
to diagram below). The Status LED on the face of the transmitter will display a green light
for up to two seconds when the power switch is turned “o n ”. Make sure the red EMS
pushbutton is elevated (on), by twisting it 1/4 turn clockwise.
If the Status LED displays a red blinking light with on 0.1 second and off 2.0 seconds
or no light at all, this indicates that the two “A A ” batteries in the transmitter must be
replaced. If the Status LED light is blinking red, on 2.0 seconds and off 0.1 second, it
means that the transmitter unit is locked due to a jammed (closed) or defective pushbutton
contact. This important safety feature is designed to prevent any unexpected crane
movement at system start-up caused by a defective or jammed (closed) pushbutton contact.
After turning “o n ”the transmitter unit, the system will go into self-diagnosing procedure.
After 0.5 second, the transmitter key functions and receiver MAIN will be activated.
3.
In case of an emergency, press down the red EMS button will immediately deactivates the
receiver MAIN contact relay. To reset the EMS function and restart the system, just turn
the red EMS button clockwise to enable the red button to elevate to its non-active position.
4.
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
13
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
Ensure the correct transmitter is in
Transmitter does not Transmitter and the receiver are
use. The labels on the receiver and
not on the same RF channel (SQ
communicate to
the transmitter will identify the RF
lamp not lit) or ID code.
receiver.
channel and ID code in use.
Turn “on”the transmitter and with
EMS in its elevated position. If
Transmitter does not
Low or no transmitting power the status LED shows blinking red
communicate to
from the transmitter unit.
light or no light at all, then turn the
receiver.
power “off”and replace the two
alkaline AA batteries.
No power to the
Ensure power input to the receiver
receiver (AC power Blown fuse or no input power unit is correct. If power indicator
connection.
indicator on the
(AC) is still not lit, please check
receiver unit not lit).
the receiver for any burned fuse.
Please refer to section 6 and 7 to
Receiver configuration is not set
Outputs do not
ensure receiver is correctly wired
properly or output wiring is
operate correctly.
and configured for your
incorrect.
application.
Receiver System Status LED Display (please refer to Fig. 6 on page 7).
TYPE
LED INDICATION
(Red)
REASON
Constant red light.
EEPROM error, manufacture reprogramming
required.
ON
OFF
Incorrect ID code, please readjust accordingly.
1.0 second
1.0 second
Dim or no light.
Under-voltage, check the main power supply.
ON
OFF
2.0 seconds
0.1 second
System error, manufacture reprogramming required.
ON
OFF
0.1 second
2.0 seconds
System normal with transmitter pushbutton either in
neutral or in transmitter power “off”position.
6.
ON
OFF
0.1 second
0.1second
System normal with transmitter pushbutton in
non-neutral position (pressed).
14
11. SYSTEM SPECIFICATION
Transmitter Unit
Frequency Range
Transmitting Range
Hamming Distance
Channel Spacing
Frequency Control
Frequency Drift
Frequency Deviation
Spurious Emission
Transmitting Power
Emission
Antenna Impedance
Enclosure
Source Voltage
Current Drain
Operating Temp.
Dimension
Weight
433 MHz
150 feet
25KHz
Quartz Crystals
< 5ppm @ -20 ~ +70
< 1ppm @ 25
- 50dB
~.1mW
F1D
50 ohms
IP-66
3.0 VDC (“AA”alkaline batteries X 2)
10 ~ 20 mA
-20 ~ +70
213mm X 86mm X 33mm
290g (include batteries)
15
Receiver Unit
Frequency Range
Channel Spacing
Hamming Distance
Frequency Control
Frequency Drift
Frequency Deviation
Sensitivity
Antenna Impedance
Data Decoder Reference
Responding Time
Enclosure
Source Voltage
Power Consumption
Operating Temp.
Output Contact Rating
Dimension
Weight
433 MHz
25KHz
Quartz Crystals
< 5ppm @ -20 ~ +70
< 1ppm @ 25
0.4 V
50 ohms
Quartz Crystals
40mS (Normal)
IP-65
110 VAC, 50/60 Hz.
11VA
-20 ~ +70
250V @ 10A
300mm X 230mm X 86mm
3,400g (Include shock absorbers)
16

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Creator                         : Microsoft Word
Create Date                     : Wednesday, May 23, 2001 6:52:45 AM
Title                           : Manual.PDF
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