Fomotech ALPHA580SERIES Industrial Remote Control User Manual TITAN RV4 2 ODD M1 301MHZ GR

Fomotech International Corp. Industrial Remote Control TITAN RV4 2 ODD M1 301MHZ GR

User Manual

1 TTAABBLLEE OOFF CCOONNTTEENNTTSS Page 1. INTRODUCTION ....................................................................................................... 2 2. SAFETY INSTRUCTION ............................................................................................. 3 3. PUSHBUTTON CONFIGURATION 3.1 Alpha 500 & 520 Models ..................................................................................... 4 3.2 Alpha 540 & 560 Models ..................................................................................... 5 3.3 Alpha 580 Models ............................................................................................... 6 4. TRANSMITTER OUTLINE 4.1 Alpha 500 & 520 Models ..................................................................................... 7 4.2 Alpha 540 & 560 Models ..................................................................................... 8 4.3 Alpha 580 Models ............................................................................................... 9 5. RECEIVER OUTLINE 5.1 Alpha 500 ~ 560 Models External Assembly ....................................................... 10 5.2 Alpha 500 & 520 Models Internal Assembly ....................................................... 11 5.3 Alpha 540 & 560 Models Internal Assembly ....................................................... 12 5.4 Alpha 580 Models External Assembly ................................................................. 13 5.5 Alpha 580 Models Internal Assembly ................................................................. 14 6. OUTPUT CONTACT DIAGRAMS 6.1 Alpha 500 & 520 Models ..................................................................................... 15 6.2 Alpha 540 Models ................................................................................................. 16 6.3 Alpha 560 Models ................................................................................................. 17 6.4 Alpha 580 Models ................................................................................................. 18~20 7. SYSTEM CONFIGURATIONS 7.1 How to Set Jumper Functions ............................................................................. 21~22 7.2 How to Set ID Codes ............................................................................................. 22 7.3 Receiver RF Channel Setting ............................................................................. 23 7.4 How to Remove the Transmitter RF Board ......................................................... 23 7.5 Alpha 580 Pushbutton Function Settings ............................................................. 24~25 7.6 Frequency (RF) Channel Table ............................................................................. 26 8. RECEIVER INSTALLATION 8.1 Preparation For Installation ................................................................................... 27 8.2 Step-By-Step Installation ....................................................................................... 27 8.3 System Testing ....................................................................................................... 28 9. TRANSMITTER OPERATION ................................................................................... 29~31 10. TROUBLE SHOOTING ............................................................................................... 32 11. SYSTEM SPECIFICATION ......................................................................................... 33 12. PARTS LIST ................................................................................................................. 34~35
211.. IINNTTRROODDUUCCTTIIOONN The Alpha 500 series are highly durable, reliable and safe industrial radio remote control systems. The versatile features of the Alpha 500 series permit their use in many different remote control applications. The systems can be used to control factory cranes, monorail systems, multiple hoists, trolleys, mining equipment, building construction equipment, automatic control systems, and many others. The 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 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 Code) and Hamming Codes (Error Recovery) programming. * To insure maximum operating safety, the Alpha 500 series incorporates numerous important safety features. Some of these built in safety features include transmitter pushbutton self-diagnosing during initial startup, transmitter low-voltage detection and visual warning with additional output for external warning light connection (LV relay), receiver self-diagnosing, MAIN deactivation during transmitter low-voltage, when system is in sleep mode, when system encountering strong RF interference, and when the transmitter is out of the receiving range. * The transmitter encoder and receiver decoder both utilize advanced microprocessor control. The availability of 32,768 sets of unique ID codes + 30 distinct RF channels 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 type of safety MAIN contact relay or relays. If the safety MAIN relay becomes defective (fails to open or close during operation or not responding to a “stop” command), it will signal the system to shut down immediately to avoid the possibility of any accidents occurring. * 30 sets of user-adjustable receiving RF channels plus special designed removable transmitting RF board for easy channel replacement and service maintenance. * Waterproofed transmitter and receiver enclosures, including the battery compartment. The Alpha 500 series radio remote control systems consist of water-resistant IP-66 transmitters and IP-65 / IP-66 receivers. All receiver s are equipped with a 2-meter pre-wired output cable (Alpha 500 ~ 560 models). The transmitter casings are 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 pushbuttons are also constructed from industrial strength composite materials with minimum of up to one million press cycles. For battery power savings, the transmitter is designed and manufactured with a special ultra-efficiency power-saving circuit that requires only two “AA” size alkaline batteries for more than 150 hours of continuous operation.
322.. SSAAFFEETTYY IINNSSTTRRUUCCTTIIOONN The Alpha 500 series are relatively simple to use, however, it is very important to observe the proper safety procedures before, during, and after operation. When used properly, the Alpha 500 series 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 or completely off), the two “AA” alkaline batteries should be replaced. 3. The red 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 by the receiver. 4. In the event of an emergency press down the EMS button will immediately deactivates the receiver MAIN relay and the transmitter power. Then turned the power “off” from the main power source to the crane or equipment. 5. The transmitter power switch should be turned off after each use and should never be left in the “power on” state when the unit is unattended. 6. Do not use the same RF channel and ID code as any other system in use at the same facility or within 300-meter distance. 7. Ensure the wrist strap (Alpha 500 ~ 560 models) or the waist belt (Alpha 580 models) is worn at all time during operation to avoid accidental damage to the transmitter. 8. Never operate a crane or equipment with two transmitters at the same time with the same RF channel and ID code, as it will cause radio interference. Caution! Improper Storage of your Spare Transmitter is a Safety Hazard! During the initial installation of your remote control system the spare (second) transmitter should be tested to confirm that it is functioning properly and then the batteries must be removed and the transmitter stored in a secured place. Failure to follow this safety procedure can result in the inadvertent operation of your crane or hoist by unauthorized personnel resulting in serious injury or death! 15.21 ¡§Changes or modifications are not expressly approved by the manufacturer could void the user's authority to operate the equipment.¡¨ "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."
433.. PPUUSSHHBBUUTTTTOONN CCOONNFFIIGGUURRAATTIIOONN 33..11 AAllpphhaa 550000 && 552200 MMooddeellss 1. Alpha 500 : (4) one-speed pushbuttons. 2. Alpha 520 : (4) two-speed pushbuttons. (Alpha 500) (Alpha 520) Below are some of many types of pushbutton configurations that are also available, please contact your dealer for more details. Interlocked (Can also be set to non-interlocked via an external programmer unit). ON OFF STOP STOPON OFF
5 33..22 AAllpphhaa 554400 && 556600 MMooddeellss 1. Alpha 540S : (6) one-speed pushbuttons. 2. Alpha 540A : (6) one-speed pushbuttons + (1) AUX micro-button. 3. Alpha 560S : (6) two-speed pushbuttons. 4. Alpha 560A : (6) two-speed pushbuttons + (1) AUX micro-button. (Alpha 540S) (Alpha 540A) (Alpha 560S) (Alpha 560A)
6 33..33 AAllpphhaa 558800 MMooddeellss 1. Alpha 580A-1 : (10) one-speed pushbuttons (labeled as 3 motions). 2. Alpha 580A-2 : (10) one-speed pushbuttons (labeled as 4 motions). 3. Alpha 580B : (9) one-speed pushbuttons + (1) SELECT I/II pushbutton.* 4. Alpha 580C-1 : (6) two-speed + (4) one-speed pushbuttons. 5. Alpha 580C-2 : (8) two-speed + (2) one-speed pushbuttons. 6. Alpha 580D : (10) two-speed pushbuttons + (1) AUX micro-button. 7. Alpha 580E : (6) two-speed + (3) one-speed pushbuttons + (1) SELECT I/II pushbutton.* 8. Alpha 580F : (8) two-speed + (1) one-speed pushbutton + (1) SELECT I/II pushbutton.* * For cranes with auxiliary hoist and trolley (changeover function). (Alpha 580A-1) (Alpha 580A-2) (Alpha 580B) (Alpha 580C-1) (Alpha 580C-2) (Alpha 580D) (Alpha 580E) (Alpha 580F)
7141516On123475681744.. TTRRAANNSSMMIITTTTEERR OOUUTTLLIINNEE 44..11 AAllpphhaa 550000 && 552200 MMooddeellss (Fig. 1) Front View (Fig. 2) Back View (Fig. 3) Front View (Fig. 4) Back View 1) Transmitter enclosure 8) Pushbutton # 3 (→ / East) 15) Programming port 2) Power switch (ON/OFF) 9) System information 16) ID code dip-switch 3) Pushbutton #2 (↓ / Down ) 10) Battery cover 17) Transmitting RF Board 4) Pushbutton #4 (← / West) 11) Battery cover screws 5) Wrist strap attachment 12) Internal antenna 6) Emergency stop (EMS) 13) Status LED display 7) Pushbutton #1 (↑ / Up) 14) Battery contact 1234567891011ON OFF STOP
8On12347568 44..22 AAllpphhaa 554400 && 556600 MMooddeellss (Fig. 5) Front View (Fig. 6) Back View (Fig.7) Front View (Fig. 8) Back View 1) Transmitter enclosure 8) Pushbutton #1 (↑ / Up) 15) Status LED display 2) Power switch (ON/OFF) 9) Pushbutton #3 (→ / East) 16) Battery contact 3) Pushbutton #2 (↓ / Down) 10) Pushbutton #5 (↗ / North) 17) AUX micro-button connector* 4) Pushbutton #4 (← / West) 11) System information 18) Programming port 5) Pushbutton #6 (↙ / South) 12) Battery cover screws 19) ID code dip-switch 6) Wrist strap attachment 13) Battery cover 20) Transmitting RF board 7) Emergency stop (EMS) 14) Internal antenna * For Alpha 540A and Alpha 560A models only.
91234567810171816911121314152021 2223242519 44..33 AAllpphhaa 558800 MMooddeellss (Fig. 9) Front View (Fig. 10) Back View (Fig. 11) Front View (Fig. 12) Back View 1) Transmitter enclosure 9) Waist belt attachment 17) Battery cover screws 2) External antenna port 10) Emergency stop (EMS) 18) Battery cover 3) Power switch (ON/OFF) 11) Pushbutton #1 (↑ / Up) 19) Internal antenna 4) Pushbutton #2 (↓ / Down) 12) Pushbutton #3 (→ / East) 20) Status LED display 5) Pushbutton #4 (← / West) 13) Pushbutton #5 (↗ / North) 21) Battery contact 6) Pushbutton #6 (↙ / South) 14) Pushbutton #7 (A1) 22) AUX micro-button connector* 7) Pushbutton #8 (A2) 15) Pushbutton #9 (A3) 23) Programming port 8) Pushbutton #10 (A4) 16) System information 24) ID code dip-switch 25) Transmitting RF board * For optional AUX micro-button or buttons.
1055.. RREECCEEIIVVEERR OOUUTTLLIINNEE 55..11 AAllpphhaa 550000 ~~ 556600 MMooddeellss EExxtteerrnnaall AAsssseemmbbllyy (Fig. 13) Front View (Fig. 14) Back View 1) Receiver enclosure 5) System frequency 9) Supplied voltage 2) Wiring diagram 6) System serial number 10) Anti-vibration spring 3) Receiver LED displays* 7) System ID code 11) Grounding (GND) 4) Type model 8) System RF channel * A ~ AUX Relay Contact Indicator (for Alpha 540A/560A models only). * M ~ MAIN and 2nd Speed Relay Contact Indicator. Green "on" → MAIN activated (All models). Red "on" → 2nd speed activated (for Alpha 560S/A models only). * SQ ~ RF Signal Indicator (Red). "on" → RF signal detected and received. "off" → No RF signal detected or received. Blinking at transmitter power "off" → Other radio interference. * AC ~ Power Source Indicator (red) "on" → AC input power supplied. "off" → No AC input power. 1APOWERAC220V 50/60HZmust be groundedAnti-vibration s pring5AN/S5A5A5ALV,AUXE/WMAINU/D5AACSQMAWSNEUDACSQMA4567982311011
111234 55..22 AAllpphhaa 550000 && 552200 MMooddeellss IInntteerrnnaall AAsssseemmbbllyy (Fig. 15) Internal Parts Assembly 1) Receiving RF module 2) Secondary power AC fuse (0.50A) 3) Primary power AC fuse (1.0A) 4) System status LED display* 5) External antenna port 6) ID code dip-switch 7) RF channel dip-switch 8) Contact relay LED display 9) Pushbutton #1 and #2 fuse (5.0A) 10) MAIN fuse (5.0A) 11) Contact output seat (CN3) 12) Low-voltage (LV) fuse (5.0A) 13) Contact output seat (CN4) 14) Pushbutton #3 and #4 fuse (5.0A) 15) AC power input seat (CN2) 16) Cable gland & output cable * Please refer to page 32 for system status LED display information. 1) Spare fuse & jumper compartment 2) Spare Jumper slots 3) Spare fuse slots 4) Receiver top casing 37689101112141551316FUSEFUSEFUSEFUSEFUSE124
121234 55..33 AAllpphhaa 554400 && 556600 MMooddeellss IInntteerrnnaall AAsssseemmbbllyy (Fig. 16) Internal Parts Assembly 1) Receiving RF module 2) External programming port 3) Secondary power AC fuse (0.50A) 4) Contact output seat (CN8) 5) Primary power AC fuse (1.0A) 6) AC power input seat (CN2) 7) Internal Antenna 8) System Status LED display* 9) External antenna port 10) ID code dip-switch 11) RF channel dip-switch 12) Contact relay LED display 13) Pushbutton #1and #2 fuse (5.0A) 14) Contact output seat (CN3) 15) MAIN contact fuse (5.0A) 16) Pushbutton #3 and #4 fuse (5.0A) 17) Pushbutton #5 and #6 fuse (5.0A) 18) Contact output seat (CN4) 19) LV & AUX fuse (5.0A) 20) Cable gland & output cable * Please refer to page 32 for system status LED display information. 1) Spare fuse & jumper compartment 2) Spare Jumper slots 3) Spare fuse slots 4) Receiver top casing 3567194111012131415171891620FUSEFUSEFUSEFUSEFUSEFUSE128
131234 55..44 AAllpphhaa 558800 MMooddeellss EExxtteerrnnaall AAsssseemmbbllyy (Fig. 17) External Parts Assembly 1) Transparent top cover 3) Mounting bracket with shock absorbers 2) Light-gray colored base 4) Cable gland / Cord grip
141720191816145101197861342131512 55..55 AAllpphhaa 558800 MMooddeellss IInntteerrnnaall AAsssseemmbbllyy (Fig. 18) Internal Parts Assembly 1) Power LED display* 12) Pushbutton #1 and #2 relay fuse (5.0A) 2) SQ LED display** 13) Receiving RF module 3) Status LED display**** 14) External antenna port 4) DC power relay LED display*** 15) RF channel dip-switch 5) Programming port 16) ID code dip-switch 6) Jumper settings 17) Secondary power fuse (0.8A) 7) Function dip-switch 18) Voltage selector seat 8) Pushbutton #3 and #4 relay fuse (5.0A) 19) MAIN relay fuse (5.0A) 9) Pushbutton #5 and #6 relay fuse (5.0A) 20) Pushbutton A4 relay fuse (5.0A) 10) Pushbutton A1and A2 relay fuse (5.0A) 21) Primary power fuse (1.0A) 11) Pushbutton A3 relay fuse (5.0A) 22) Low-voltage (LV) relay fuse (5.0A) * POWER ~ AC Power Source Indicator "on" → AC input power supplied. "off" → No AC input power. ** SQ ~ RF Signal Indicator "on" → RF signal detected and received. "off" → No RF signal detected or received. Blinking at transmitter power “off” → Other radio interference. *** 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 32.
1566.. OOUUTTPPUUTT CCOONNTTAACCTT DDIIAAGGRRAAMMSS 66..11 AAllpphhaa 550000 && 552200 MMooddeellss (Alpha 500) (Alpha 520) POWERLV5AE/W5AU/D5AMAIN5APOWERLV5AE/W5AU/D5AMAIN5A
16 66..22 AAllpphhaa 554400 MMooddeellss (Alpha 540S) (Alpha 540A) POWER5A5ALV,AUXE/WMAINU/D5A5AN/SPOWER5A5ALV,AUXE/WMAINU/D5A5AN/S
17 66..33 AAllpphhaa 556600 MMooddeellss (Alpha 560S) (Alpha 560A) POWER5A5ALV,AUXE/WMAINU/D5A5AN/SPOWER5A5ALV,AUXE/WMAINU/D5A5AN/S
18 66..44 AAllpphhaa 558800 MMooddeellss (Alpha 580A-1) & (Alpha 580A-2) Note: The output contact diagram for both Alpha 580A-1 and Alpha 580A-2 models are identical, the only difference is the transmitter pushbutton labeling. (Alpha 580B)
19 (Alpha 580C-1) & (Alpha 580C-2) Note: For Alpha 580C-1 model, please disregard “A1.2 + 2.2” terminal output. (Alpha 580D)
20 (Alpha 580E) (Alpha 580F)
21JP1JP2JP3JP4JP5JP6JP777.. SSYYSSTTEEMM CCOONNFFIIGGUURRAATTIIOONNSS 77..11 HHooww TToo SSeett JJuummppeerr FFuunnccttiioonnss (Fig. 19) Alpha 500 ~ 560 Models (Fig. 20) Alpha 580 Models Manufacture Settings Open For Alpha 580 models only 1. After turning “on” the transmitter power, press START/AUX pushbutton to activate the receiver MAIN. 2. After EMS Reset, press START/AUX pushbutton to activate the receiver MAIN. JP1 Short For all models 1. Turning “on” the transmitter power will activate the receiver MAIN. 2. Resetting the EMS will activate the receiver MAIN. Open Reserved JP2 Short Reserved Open For all models After 1 minute of transmitter low-voltage warning, the transmitter power will be deactivated. JP3 Short For all models After 1minute of transmitter low-voltage warning, the transmitter power “and” the receiver MAIN will be deactivated. (refer to note A below) Open For Alpha 540A & 560A models AUX button with normal momentary relay contact. JP4 Short For Alpha 540A & 560A models AUX button with latching relay contact. Note A: If transmitter low-voltage condition occurs during operation the transmitter handset itself will display a visual warning by blinking the status light red. Furthermore, the transmitter will also send out a special low-voltage command signal to the receiver to activate its internal low-voltage (LV) warning relay. By connecting a horn, siren or lights to the LV relay output the operator can be notified of a transmitter low-voltage condition. The LV relay will open and close at one-second intervals for up to a minute warning the operator of the low-voltage condition. To insure maximum safety, both the transmitter power and the receiver MAIN will be deactivated (depending on JP3 settings) Note B: Every time when you change jumper settings you must first turn the receiver power “off” and then turn it back “on” so that the new settings can be stored in memory. FUSEJP1 OPEN→JUMPSHORT→JUMPACDIP-SWUJP3JP2JP4
22 JP-1 Setting (for Alpha 580 models only) JP1 Open Power “On” Press START/AUX pushbutton Receiver MAIN activated OR Reset EMS button Press START/AUX pushbutton Receiver MAIN activated JP4 Short Power “On” Receiver MAIN activated OR Reset EMS button Receiver MAIN activated JP-3 Setting (for all models) YES Work resumes JP3 Open Power “On” Work in progress Transmitter low-voltage condition occursLV warningReplace batteries within 1 minute NO Transmitter unit will be deactivatedYES Work resumes JP3 Short Power “On” Work in progress Transmitter low-voltage condition occursLV warningReplace batteries within 1 minuteNO The transmitter power and the receiver MAIN will be deactivated JP-4 Settings (for Alpha 540A & 560A models only) JP4 Open AUX button with normal momentary relay contact JP4 Short AUX button with latching/toggled relay contact 77..22 HHooww ttoo SSeett IIDD CCooddeess The ID code dip-switch is located on the backside of the transmitter encoder board and on the topside of the receiver decoder/relay board (refer to section 3~5). When you change the ID code of the system please make sure that the “1” value adds up to be an “odd” number (see below). Example : ID code → 10001100 → “1” x 3 = 3 → Odd number → Correct setting Top slot → “1” Bottom slot → “0” NNoottee:: DDeeppeennddiinngg oonn aarreeaa,, mmooddeellss iinn ssoommee ccoouunnttrriieess mmaayy hhaavvee ““EEvveenn”” nnuummbbeerreedd IIDD ccooddee.. PPlleeaassee cchheecckk tthhee IIDD ccooddee iinnffoorrmmaattiioonn llooccaatteedd oonn tthhee bbaacckkssiiddee ooff tthhee ttrraannssmmiitttteerr hhaannddsseett oorr oonn tthhee ffaaccee ccoovveerr ooff tthhee rreecceeiivveerr uunniitt ffoorr ccoorrrreecctt IIDD ccooddee sseettttiinngg ((oodddd oorr eevveenn))..
23 77..33 RReecceeiivveerr RRFF CChhaannnneell SSeettttiinngg There are 30 sets of user-adjustable receiving RF channels that can be set manually via a 5-position dip-switch located to the right of the receiving RF module. Change the receiving RF channel simply by resetting these 5-position dip-switch. For the location of the receiving RF module, please refer to fig. 15, 16, and 18 on page 11, 12, and 14. Example: For the above dip-switch setting (00101) counting from dip-position #1 through #5, the above RF channel would be “205”, which also represents frequency “301.205 MHz”. Please refer to the frequency (RF) channel table on page 26 or the CHANNEL → DIP label located on the receiving RF module itself. 77..44 HHooww ttoo RReemmoovvee tthhee TTrraannssmmiittttiinngg RRFF BBooaarrdd The transmitter RF channel can be easily replaced or exchanged simply by replacing the small removable RF board located atop the transmitter encoder board. The small RF board can be easily removed by unscrewing the two small bolts that secured the RF board and the encoder board together (refer to the diagram below). Please keep in mind that the RF channel of the transmitter must be identical to the receiver. If the RF channel for both transmitter and receiver are different, please readjust accordingly (refer to section 7.3 above). 12345
24 77..55 AAllpphhaa 558800 MMooddeellss PPuusshhbbuuttttoonn FFuunnccttiioonn SSeettttiinnggss Numerous Alpha 580 models’ pushbutton contact relay settings can be set via an 8-position dip-switch located on the receiver decoder/relay board (refer to fig. 18 on page 14). DIP-1 → “0” Example: DIP-2 → “1” DIP-3 → “1” DIP-4 → “0” DIP-5 → “0” DIP-6 → “0” Top slot represents “1” value and lower slot represents “0” value. Alpha 580 models dip-switch function table Alpha 580A-1 & Alpha 580A-2 DIP1 → “0” → pushbutton 1&2, 3&4, 5&6 interlocked “1” → pushbutton 1&2, 3&4, 5&6 not interlocked DIP2 → “0” → pushbuttons 7&8 interlocked “1” → pushbutton 7&8 not interlocked DIP3 → “0” → pushbutton 7&8 with momentary relay contact (DIP2 set at “1”) “1” → pushbutton 7&8 with latching/toggled relay contact (DIP2 set at “1”) DIP4 → “0” → pushbutton 9&10 interlocked “1” → pushbutton 9&10 not interlocked DIP5 → “0” → pushbutton 9 with momentary relay contact (DIP4 set at “1”) “1” → pushbutton 9 with latching/toggled relay contact (DIP4 set at “1”) DIP6 → “0” → 10th pushbutton with momentary relay contact (DIP4 set at “1”) “1” → 10th pushbutton with latching/toggled relay contact (DIP4 set at “1”) Alpha 580B DIP1 → “0” → pushbutton 7&8 interlocked “1” → pushbutton 7&8 not interlocked DIP2 → “0” → pushbuttons 7 with momentary relay contact (DIP1 set at “1”) “1” → pushbutton 7 with latching/toggled relay contact (DIP1 set at “1”) DIP3 → “0” → pushbutton 8 with momentary relay contact (DIP1 set at “1”) “1” → pushbutton 8 with latching/toggled relay contact (DIP1 set at “1”) DIP4 → “0” → pushbutton 9 with momentary relay contact “1” → pushbutton 9 with latching/toggled relay contact
25 Alpha 580 models dip-switch function table (continued) Alpha 580C-1 & Alpha 580C-2 DIP1 → “0” → pushbutton 1&2 with both 1st and 2nd speed contact relay activated when pressed to 2nd speed (refer to note A) “1” → pushbutton 1&2 with both 1st and 2nd speed contact relay interlocked when pressed to 2nd speed (refer to note B) DIP2&3 → “00” → pushbuttons 9 with momentary relay contact “01” → pushbutton 9 with latching/toggled relay contact “10” → pushbutton 9 with 3rd speed function (refer to note C) DIP4 → “0” → pushbutton 10 with momentary relay contact “1” → pushbutton 10 with latching/toggled relay contact Alpha 580D DIP1 → “0” → pushbutton 1&2 with both 1st and 2nd speed contact relay activated when pressed to 2nd speed (refer to note A) “1” → pushbutton 1&2 with both 1st and 2nd speed contact relay interlocked when pressed to 2nd speed (refer to note B) DIP2 & DIP3 must set to “0” at all time Alpha 580E DIP1 → “0” → pushbutton 1&2 with both 1st and 2nd speed contact relay activated when pressed to 2nd speed (refer to note A) “1” → pushbutton 1&2 with both 1st and 2nd speed contact relay interlocked when pressed to 2nd speed (refer to note B) DIP2 → “0” → pushbuttons 7&8 interlocked “1” → pushbutton 7&8 not interlocked DIP3 → “0” → pushbutton 7 with momentary relay contact (DIP2 set at “1”) “1” → pushbutton 7 with latching/toggled relay contact (DIP2 set at “1”) DIP4 → “0” → pushbutton 8 with momentary relay contact (DIP2 set at “1”) “1” → pushbutton 8 with latching/toggled relay contact (DIP2 set at “1”) DIP5&6 → “00” → pushbutton 9 with momentary relay contact “01” → pushbutton 9 with latching/toggled relay contact “10” → pushbutton 9 with 3rd speed function (refer to note C) Alpha 580F DIP1 → “0” → pushbutton 1&2 with both 1st and 2nd speed contact relay activated when pressed to 2nd speed (refer to note A) “1” → pushbutton 1&2 with both 1st and 2nd speed contact relay interlocked when pressed to 2nd speed (refer to note B) DIP2&3 → “00” → pushbutton 9 with momentary relay contact “01” → pushbutton 9 with latching/toggled relay contact “10” → pushbutton 9 with 3rd speed function (refer to note C) Note A: This setting is ideal for majority of the crane systems (manufacture preset). When pressed to 2nd speed for the hoist motion, the 1st speed contact relay will remain engaged (closed) along with the 2nd speed contact relay. Note B: This setting is ideal for crane system with dual-motor hoist. When pressed to 2nd speed for the hoist motion, the 1st speed contact relay will be disengaged (open), with only the 2nd speed contact relay engaged (closed). Note C: During operation, when a particular command pushbutton is in the 2nd speed position (pushbutton fully pressed), pressing the 10th pushbutton once will activate the 3rd speed contact relay. If the operator presses the 10th pushbutton again, the command pushbutton currently in use will return to the 2nd speed position.
26 77..66 FFrreeqquueennccyy ((RRFF)) CChhaannnneellss TTaabbllee FREQUENCY DIP-SWITCH SETTING RF CHANNEL 301.105 MHz 00001 201 301.130 MHz 00010 202 301.155 MHz 00011 203 301.180 MHz 00100 204 301.205 MHz 00101 205 301.230 MHz 00110 206 301.255 MHz 00111 207 301.280 MHz 01000 208 301.305 MHz 01001 209 301.330 MHz 01010 210 301.355 MHz 01011 211 301.380 MHz 01100 212 301.405 MHz 01101 213 301.430 MHz 01110 214 301.455 MHz 01111 215 301.480 MHz 10000 216 301.505 MHz 10001 217 301.530 MHz 10010 218 301.555 MHz 10011 219 301.580 MHz 10100 220 301.605 MHz 10101 221 301.630 MHz 10110 222 301.655 MHz 10111 223 301.680 MHz 11000 224 301.705 MHz 11001 225 301.730 MHz 11010 226 301.755 MHz 11011 227 301.780 MHz 11100 228 301.805 MHz 11101 229 301.830 MHz 11110 230
2788.. RREECCEEIIVVEERR IINNSSTTAALLLLAATTIIOONN 88..11 PPrreeppaarraattiioonn FFoorr IInnssttaallllaattiioonn 1. Required Tools for Receiver Installation: (1) Flat Head Screwdriver (-) (2) Phillips Head Screwdriver (+) (3) Multi-Meter (4) 14mm Wrench x 2 (5) Power Drill with 10.5mm Drill-Bit 2. Check to ensure that your receiver is not set to the same RF channel and ID code as any other systems in operation at the same facility or within 300-meter distance. 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 the receiver voltage setting matches your power source. 5. Prior to installation, switch off the main power source to the crane or equipment. 88..22 SStteepp--BByy--SStteepp IInnssttaallllaattiioonn 1. For better reception, 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. Mounting the receiver next to an unshielded variable frequency control (inverter) may cause minor interference. Always locate the receiver unit as far away from inverter controls as possible. 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 (refer to fig. 21 and fig. 22 on page 28). 6. If a crane or equipment’s runway is longer than 100 meters, an external antenna should be added. The Alpha 500 series’ receiver housing has provisions for an external factory installed antenna available as an option, contact your dealer for price and delivery. 7. Alpha 500 ~ 560 models: Drill a hole on the control panel (10.5mm). Alpha 580 models: Drill 4 holes on the control panel (10.5mm). 8. Tightened the bolt nuts provided. 9. If the control panel has a plastic surface, extended grounding wire should be used. 10. For system wiring, please refer to the output contact diagrams from page 15~20. 11. Ensure all wiring is correct and safely secured and all screws are fastened.
28255mm278mm4- O10.5 (Fig. 21) Alpha 500 ~ 560 Models (Fig. 22) Alpha 580 Models 88..33 SSyysstteemm TTeessttiinngg 1. Connect the power source to the receiver and test the MAIN relay output by pressing the red emergency stop button (EMS) and observe that it properly opens and closes the main line disconnect contactor. 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 hoist and/or crane and verify 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, i. e. snick circuits. 5. If your new remote control is replacing an existing pendant make sure it is stored in a safe location where it will not interfere with remote operation (get torn off).
2999.. TTRRAANNSSMMIITTTTEERR OOPPEERRAATTIIOONN 1. Batteries _ Make sure the two “AA” alkaline batteries are installed correctly. Use 2000mA rated alkaline-type batteries for optimum operating time between replacements. If rechargeable-type batteries are used, for optimum operating time, choose ones rated above 1600mA. 2. Startup Procedure _ There are two types of transmitter power key-switch available for the Alpha 500 series, the standard fixed type (refer to fig. 23) and the optional removable type (refer to fig. 24). Basically both key types operate in the same fashion depending on personal preference and safety regulations. For the below illustrations the optional removable-type power key is used. Elevate the red EMS button by twisting it 1/4 turn clockwise; it will pop up. Then insert the transmitter power key onto the key-switch slot located on the top left-hand corner of transmitter handset (refer to fig. 25). Make sure the black arrow marking on the power key is pointed directly towards the “OFF” marking on the transmitter handset. To turn on the transmitter power, just rotate the power key clockwise to “ON” position. The Status LED located at the center of the power switch will display a green blinking light for up to 40 seconds when the power key is turned to “ON” position. At this time the receiver MAIN relay is also activated. After 40 seconds of inactivity, that is 40 seconds after the last pushbutton is released, the green light will disappear thus temporarily deactivating the transmitter power and the receiver MAIN. Pressing any pushbutton thereafter will close the receiver MAIN and start the timing sequence over again. This important safety feature is designed to ensure that the transmitter handset and the receiver MAIN will be in "power off" position if the operator forgets to turn off the transmitter power, or if the transmitter unit is left unattended in the work area. (Fig. 23) Fixed On/Off key (Fig. 24) Removable On/Off key (Fig. 25) Removable power key installation procedure
30LED DISPLAY 3. Status Lights _ If the transmitter Status LED displays a red blinking light that is “on” → 0.1 second and “off” → 2.0 seconds, or no light at all, this indicates that the two “AA” batteries in the transmitter must be replaced. For battery replacement please refer to instruction next page. If the transmitter Status LED is blinking red, “on” → 2.0 seconds and “off” → 0.1 second, it means that the transmitter handset is locked due to a damaged or closed pushbutton contact. Also possibly the operator is pressing a pushbutton while going through the start up sequence. This important safety feature is designed to prevent any unexpected crane movement at system startup caused by closed or defective pushbutton contacts. If the transmitter Status LED displays a constant red light without flashing, this indicates that the transmitter ID code is set incorrectly (refer to section 7.2 on page 22). 4. EMS & Restarting _ In case of an emergency, press down the red emergency stop button (EMS) will immediately deactivates the transmitter and receiver MAIN relay. To reactivate the system, just turn the EMS button clockwise 1/4 turn so that the red button pops up (refer to fig. 26 below). (Fig. 26) EMS Button 5. Shutting Off the Transmitter _ To disconnect the transmitter power and the receiver MAIN relay, just turn the transmitter power to “OFF” position. When the transmitter power is turned off, the receiver MAIN is also deactivated (open). 6. Models with 3-Stage SELECT Function _ When the transmitter power key is turned “on”, LED-I will light up indicating only the main hoist and/or trolley is activated. To activate the auxiliary hoist and/or trolley, just press the "Select" pushbutton one time, the LED display will switch from LED-I to LED-II, indicating only the auxiliary hoist and/or trolley is activated. Press the "Select" pushbutton again to have both main and auxiliary hoist and/or trolley activated at the same time (both LED-I and LED-II lit). When both LED-I and LED-II are lit, pressing any pushbutton will result in duplicate movement for the main and auxiliary hoist and/or trolley. Example: Both main and auxiliary hoist will go up at the same time when “UP” ( ↑) pushbutton is pressed. To switch back to the main hoist and/or trolley, just press the "Select" pushbutton again. Please note that every time when the transmitter power is turned “off” and then back “on” again, or after EMS reset, the "Select " setting will default back to LED-I with main hoist and/or trolley active.
31 1) Power "on" → LED-I "lit” → Main hoist and/or trolley activated. 2) Press “Select” button once → LED-II "lit" → Auxiliary hoist and/or trolley activated. 3) Press “Select” button again → both LED-I & II "lit" → Both main and auxiliary hoist and/or trolley activated with duplicate movements. 4) Press “Select” button again → “Select” mode returned to LED-I with only the main hoist and/or trolley activated. 7. Interlocking Pushbuttons _ Each set of motion is interlocked to its self so no conflicting commands can take place. For example, pressing the hoist UP (↑) and DOWN (↓) button simultaneously will result in no command signal being sent. 8. Battery Changing _ To change batteries, just unscrew the battery cover located on the backside of the transmitter handset with a (+) screwdriver. When changing new batteries, make sure that the batteries are installed correctly. The marking inside the battery compartment will tell you which side is positive (+) charge and which side is negative (-). After changing the batteries, make sure all screws are tightened. 9. Transmission Data _ The data of the Alpha 500 series are carried out by the power-saving PCDT method of transmission (Pause Continuous Data Transmission). The duration of each PCDT transmission is set at 40 seconds, with option for 3 minutes (please contact your dealer for more details). During this 40-second PCDT transmission, the transmitter unit will only send out "zero position command" to the receiver if the operator gives no active commands (pushbutton not pressed). If no active commands are given after 40 seconds, that is 40 seconds after the last pushbutton is released, the receiver MAIN will be temporarily deactivated (open). The receiver MAIN can only be reactivated when the receiver unit receives an active command from the transmitter unit by pressing the pushbuttons. Furthermore, if the system encountered strong radio interference or if the transmitter is out of the receiving range during operation, to insure operating safety, the receiver MAIN relay will also be temporarily deactivated.
321100.. 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 with the 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 with the receiver. Low or no transmitting power from the transmitter unit. Turn “on” the transmitter with EMS elevated. 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 the power indicator (AC) is still not lit, please check the receiver for any open 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.Transmitter does not communicate with the receiver. Transmitter is turned on with the EMS activated (pressed down). Elevate the EMS first and then turn the power switch off and then on again. Receiver System Status LED Display (Refer to fig.15/16/18 on page 11/12/14) TYPE LED INDICATION PROBLEM AND SOLUTION EEPROM error – reprogramming required. 1 Constant red light. Incorrect receiver ID code setting (see note below). 2 ON → 1.0 second OFF → 1.0 second ID code not matched on both the transmitter and receiver unit, please readjust accordingly. 3 Dim or no light. Under-voltage, check the main power-supply. 4 ON → 2.0 seconds OFF → 0.1 second MAIN contact relay jammed or defective. 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 (pushbutton depressed). Note: Please refer to section 7.2 on page 22 for correct ID code setting.
331111.. SSYYSSTTEEMM SSPPEECCIIFFIICCAATTIIOONN Transmitter Unit Frequency Range : 301 MHz Transmitting Range : 100 meters Hamming Distance : 6 Channel Spacing : 25KHz Frequency Control : Quartz Crystals Frequency Drift : < 5ppm @ -25℃ ~ +75℃ Frequency Deviation : < 1ppm @ 25℃ Spurious Emission : - 50dB Transmitting Power : ~1mW Emission : F1D Antenna Impedance : 50 ohms Enclosure Rating : IP-66 Source Voltage : 3.0V (“AA” alkaline batteries x 2) Current Drain : 10 ~ 18mA Operating Temperature : -25℃ ~ +75℃ Dimension (500~520 Models) : 140mm x 68mm x 33mm (540~560 Models) : 173mm x 68mm x 33mm (580 Models) : 213mm x 68mm x 33mm Weight (500~520 Models) : 200g (include batteries) (540~560 Models) : 240g (include batteries) (580 Models) : 290g (include batteries) Receiver Unit Frequency Range : 301 MHz Channel Spacing : 25KHz Hamming Distance : 6 Frequency Control : Synthesizer (PLL) Frequency Drift : < 5ppm @ -25℃ ~ +75℃ Frequency Deviation : < 1ppm @ 25℃ Sensitivity : -120dBm Antenna Impedance : 50ohms Data Decoder Reference : Quartz Crystals Responding Time : 40ms (Normal) Enclosure Rating : IP-65 (Alpha 500~560 Models) IP-66 (Alpha 580 Models) Source Voltage : AC 220V ~ 230V @ 50/60 Hz. Power Consumption : 11VA Operating Temperature : -25℃ ~ +75℃ Output Contact Rating : 250V @ 10A Dimension (500~560 Models) : 310mm x 134mm x 72mm (580 Models) : 300mm x 230mm x 86mm Weight (500~520 Models) : 1,625g (include output cable) (540~560 Models) : 1,700g (include output cable) (580 Models) : 3,400g (no output cable)
341122.. PPAARRTTSS LLIISSTT 1. 301 MHz Transmitting RF Board (All Models) BTX301 2. Encoder Board (Alpha 500) BEN500 Encoder Board (Alpha 520) BEN520 Encoder Board (Alpha 540S) BEN540S Encoder Board (Alpha 540A) BEN540A Encoder Board (Alpha 560S) BEN560S Encoder Board (Alpha 560A) BEN560A Encoder Board (Alpha 580A-1) BEN580A1 Encoder Board (Alpha 580A-2) BEN580A2 Encoder Board (Alpha 580B) BEN580B Encoder Board (Alpha 580C-1) BEN580C1 Encoder Board (Alpha 580C-2) BEN580C2 Encoder Board (Alpha 580D) BEN580D Encoder Board (Alpha 580E) BEN580E Encoder Board (Alpha 580F) BEN580F 3. 301 MHz Receiving RF Module (All Models) BRX301 4. Decoder/Relay Board (Alpha 500) BDR500 Decoder/Relay Board (Alpha 520) BDR520 Decoder/Relay Board (Alpha 540S) BDR540S Decoder/Relay Board (Alpha 540A) BDR540A Decoder/Relay Board (Alpha 560S) BDR560S Decoder/Relay Board (Alpha 560A) BDR560A Decoder/Relay Board (Alpha 580A-1) BDR580A1 Decoder/Relay Board (Alpha 580A-2) BDR580A2 Decoder/Relay Board (Alpha 580B) BDR580B Decoder/Relay Board (Alpha 580C-1) BDR580C1 Decoder/Relay Board (Alpha 580C-2) BDR580C2 Decoder/Relay Board (Alpha 580D) BDR580D Decoder/Relay Board (Alpha 580E) BDR580E Decoder/Relay Board (Alpha 580F) BDR580F 5. Transmitter Enclosure (Alpha 500 & 520 Models) BCT500 Transmitter Enclosure (Alpha 540S & 560S Models) BCT560S Transmitter Enclosure (Alpha 540A & 560A Models) BCT560A Transmitter Enclosure (Alpha 580A, C, D Models) BCT580A Transmitter Enclosure (Alpha 580B, E, F Models) BCT580B 6. Receiver Enclosure (Alpha 500 & 520 Models) BCR500 Receiver Enclosure (Alpha 540 & 560 Models) BCR560 Receiver Enclosure (Alpha 580 Models) BCR580
35 7. Double-Step Pushbutton (All Models) B50001 Single-Step Pushbutton (All Models) B50002 8. EMS Red Cap (All Models) EMS01 9. Wrist Strap (Alpha 500 ~ 560 Models) WS01 Waist Belt (Alpha 580 Models) WB01 10. Pushbutton Rubber Boot (Alpha 500 & 520 Models) PRB01 Pushbutton Rubber Boot (Alpha 540 & 560 Models) PRB02 Pushbutton Rubber Boot (Alpha 580 Models) PRB03 11. Pushbutton Direction labels (All Types) DL01 12. Transformer (12/24VDC – Alpha 500 ~ 560 Models) T24VDC Transformer (24VAC – Alpha 500 ~ 560 Models) T24VAC Transformer (48VAC – Alpha 500 ~ 560 Models) T48VAC Transformer (110/120VAC – Alpha 500 ~ 560 Models) T120VAC Transformer (220/230 VAC – Alpha 500 ~ 560 Models) T230VAC Transformer (380VAC – Alpha 500 ~ 560 Models) T380VAC Transformer (12/24VDC – Alpha 580 Models) SSB-2601 Transformer (AC 110V~120V / 220V~240V – Alpha 580 Models) SSB-2603 Transformer (AC 350V~380V / 400V~460V – Alpha 580 Models) SSB-2604 Transformer (AC 24V/32V/46V/48V – Alpha 580 Models) SSB-2665 13. Regular Output Contact Relay (All Models) RLY01 Safety MAIN Contact Relay (All Models) RLY02 14. Protective Vinyl Casing (Alpha 500 ~ 560 Models) VPC01 Protective Vinyl Casing (Alpha 540 ~ 560 Models) VPC02 15. Leather Pouch (Alpha 500 ~ 520 Models) LP500 Leather Pouch (Alpha 540 ~ 560 Models) LP560 16. 2-meter Output Cable with 1 Common Circuit (Alpha 500 ~ 560 Models) OC500 2-meter Output Cable with 1 Common Circuit (Alpha 540 ~ 560 Models) OC501 2-meter Output Cable with 2 Common Circuits (Alpha 540 ~ 560 Models) OC502 2-meter Output Cable with 3 Common Circuits (Alpha 500 ~ 520 Models) OC503 2-meter Output Cable with 4 Common Circuits (Alpha 540 ~ 560 Models) OC504 17. Receiver Mounting Spring + Hardware (Alpha 500 ~ 560 Models) RMS500 Receiver Shock Absorbers + Mounting Hardware (Alpha 580 Models) RSA580 18. Optional External 301 MHz Antenna (All Models) ANT301 19. BNC Jack for External Antenna Connection (Alpha 500 ~ 560 Models)BNC500 BNC Jack for External Antenna Connection (Alpha 580 Models) BNC580 20. BNC Lead Wire for External Antenna Connection BLW500 21. 2-meter Coaxial Cable for External Antenna Connection (All Models) CC500 22. Removable Transmitter Power Key (All Models) KEY01

Navigation menu