Fomotech ALPHA600SERIES Remote Control User Manual

Fomotech International Corp. Remote Control

User manual

- 1 - 1. SSAAFFEETTYY IINNSSTTRRUUCCTTIIOONN The Alpha 608 is 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 608 will enhance safety, productivity and efficiency in the workplace. The following procedures should be strictly followed: 1. Do not change the IDs on transmitter encoder and receiver decoder boards at will. 2. 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. 3. Check the transmitter voltage whenever it is operated. 4. 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. 5. 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. 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 waist belt 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. FCC 15.21: “Changes or modifications are not expressly approved by the manufacturer could void the user’s authority to operate the equipment.” “Operations is subject to the following two conditions: (1) this device may cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.”
- 2 - 2. PPUUSSHHBBUUTTTTOONN CCOONNFFIIGGUURRAATTIIOONN 2.1 Alpha 607 & 608 Models α607A -- (7) single speed pushbuttons α607B -- (6) double speed pushbuttons + (1) single speed pushbuttons α607AT -- (6) single speed pushbuttons + (1) single speed pushbutton + (1) selector pushbutton α607BT -- (6) double speed pushbuttons + (1) single speed pushbutton + (1) selector pushbutton α608A -- (8) single speed pushbuttons α608B -- (6) double speed pushbuttons + (2) single speed pushbuttons (Alpha 607A) (Alpha 607B) (Alpha 607AT) (Alpha 607BT) (Alpha 608A) (Alpha 608B)
- 3 - 33.. TTRRAANNSSMMIITTTTEERR OOUUTTLLIINNEE 3.1 TRANSMITTER OUTLINE Size：189mm X 68mm X 30mm (Fig.1) Transmitter Outline 3.2 TRANSMITTER INTERNAL ASSEMBLY (1) Internal antenna (2) Status LED display (3) Battery contact (4) AUX micro-button connector* (5) Programming port (6) ID code dip-switch (7) JP2 setting pin (8) JP1 setting pin (Fig.2) Front View (Fig.3) Back View
- 4 - 3.3 TX INTERNAL MODULE – encoder board 3.4 Transmitter shoulder strap (1) Shock-absorbing rubber (2) Shoulder strap (Fig.4) Encoder board (1)(2)
- 5 - 44.. RREECCEEIIVVEERR OOUUTTLLIINNEE 44..11 EExxtteerrnnaall AAsssseemmbbllyy SIZE：300mm X 230mm X 86mm ACSQMAWSNEUDACSQMAS/ N:FREQ:MOD:VOLT:CH.ID:FILTERAnti-vibration springmust be groundedPOWERMAIN F65AF1F5 5ALV/AUX1COM417L2(X2)L1(X1)GRN/YELCOM5MAIN22FF121201819AUX1AUX2NCCOM3NCCOM2151614 LVN1S1COM1D1W1E1NCNCU1F4 5AF3 5A131011129835674F2 5A21BRIDGETROLLEYHOIST/AUX2 (Fig.7) Front View (Fig.8) Back View
- 6 - 44..22 IInntteerrnnaall AAsssseemmbbllyy (Fig. 9) 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 27 for system status LED display information. FUSEFUSEFUSE1284111012131415171891620FUSEFUSEFUSE356719
- 7 - 55.. OOUUTTPPUUTT CCOONNTTAACCTT DDIIAAGGRRAAMMSS 55..11 AAllpphhaa 660077 MMooddeellss Alpha 607A Alpha 607B FILTERAnti-vibration springmust be groundedPOWERMAIN F65AF1F5 5ALV/AUX1COM417L2(X2)L1(X1)GRN/YELCOM5MAIN22FF121201819AUX1NCNCCOM3NCCOM2151614 LVN1S1COM1D1W1E1NCNCU1F4 5AF3 5A131011129835674F2 5A21BRIDGETROLLEYHOISTFILTERAnti-vibration springmust be groundedPOWERMAIN F65AF1F5 5ALV/AUX1BRIDGEF4 5ATROLLEYF3 5ACOM417L2(X2)L1(X1)GRN/YELCOM5MAIN22FF121201819AUX1NCN/S2COM3E/W2COM215161413 LVN1101112 S198COM1D13567W1E14D2HOISTF2 5A 21U2U1
- 8 -FILTERAnti-vibration springmust be groundedPOWERMAIN F65AF1F5 5ALV/SEL-ICOM417L2(X2)L1(X1)GRN/YELCOM5MAIN22FF121201819SEL-ISEL-IINCCOM3NCCOM2151614 LVN1S1COM1D1W1E1NCNCU1F4 5AF3 5A131011129835674F2 5A21BRIDGETROLLEYHOIST/SEL-II Alpha 607AT Alpha 607BT FILTERAnti-vibration springmust be groundedPOWERMAIN F65AF1F5 5ALV/SEL-IBRIDGEF4 5ATROLLEYF3 5ACOM417L2(X2)L1(X1)GRN/YELCOM5MAIN22FF121201819SEL-ISEL-IIN/S2COM3E/W2COM215161413 LVN1101112 S198COM1D13567W1E14D2HOISTF2 5A 21U2U1/SEL-II
- 9 - 55..22 AAllpphhaa 660088 MMooddeellss Alpha 608A Alpha 608B FILTERAnti-vibration springmust be groundedPOWERMAIN F65AF1F5 5ALV/AUX1COM417L2(X2)L1(X1)GRN/YELCOM5MAIN22FF121201819AUX1AUX2NCCOM3NCCOM2151614 LVN1S1COM1D1W1E1NCNCU1F4 5AF3 5A131011129835674F2 5A21BRIDGETROLLEYHOIST/AUX2FILTERAnti-vibration springmust be groundedPOWERMAIN F65AF1F5 5ALV/AUX1BRIDGEF4 5ATROLLEYF3 5ACOM417L2(X2)L1(X1)GRN/YELCOM5MAIN22FF121201819AUX1AUX2N/S2COM3E/W2COM215161413 LVN1101112 S198COM1D13567W1E14D2HOISTF2 5A 21U2U1/AUX2
- 10 - 66.. TTRRAANNSSMMIITTTTEERR SSEETTTTIINNGGSS 66..11 HHooww ttoo SSeett IIDD CCooddeess 6.1.1 Set by programming tool 6.1.2 Set by encoder board JP1, 1st / 2nd pin and dip-switch Setting Steps: (1) Rotate the transmitter power to OFF position (2) Disassemble shock-absorbing rubber (3) Put the transmitter pushbutton downward and disassemble transmitter bottom casing. (4) Set ID code with dip-switch and put short boot on 1st / 2nd pin of JP1. (5) Make sure the batteries are installed properly. (6) Rotate the transmitter power switch to ON position. (7) Green status LED ON for 0.1 sec, OFF for 0.1 sec, flash for 1 sec. (5 times) (8) Green status LED steady ON indicates the setting is completed. If the LED status light is changed to red, the setting is failed. Please repeat the above setting steps until the setting is successful. (9) After setting is completed and successful, remove short boot on 1, 2 pin of JP1. (10) Rotate transmitter power switch to OFF position. 編碼板 (Fig. 10) Back view (Fig. 11) Position of dip-switch & jumpers Top slot ON Æ “1”; bottom slot Æ “0”. The setting above is 00000011.
- 11 - 66..22 TTrraannssmmiitttteerr CChhaannnneell SSeettttiinnggss Transmitter channel setting (select the channel you would like to operate. No exceed to channel limit) 6.2.1 Set by programming tool 6.2.2 Set by encoder board 2nd & 3rd pin of JP1 and dip-switch When setting frequency on TX board JP1, put short boot on 2nd & 3rd pin of JP1. Change the frequency needed by changing the dip-switch setting. Repeat the previous steps to set frequency. (Note: set the dip-switch from the 4th digit) Example：Set channel as 03→(00011) → Correct setting
- 12 - 77.. RREECCEEIIVVEERR SSEETTTTIINNGGSS 77..11 HHooww ttoo SSeett RReecceeiivveerr IIDD CCooddeess Top slot Æ “1” Bottom slot Æ “0” ID DIP-SW Set the ID codes needed on the decoder board dip-switch. For example: the ID codes set above Æ 10000111. 7.2 Receiver RF Channel Setting There are 20 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. Top slot Æ“1＂; bottom slot Æ“0＂ For example：the channel dip-switch set above Æ 00101, channel 05. 12345
- 13 -FUSEJP1 OPEN→JUMPSHORT→JUMPACDIP-SWUJP3JP2JP4 7.3 Receiver Function Setting 7.3.1 Set by programming tool 7.3.2 Adjust Jumper setting function by decoder board α608 function can be changed simply by adjusting Jumper setting. Please refer to Jumper Set Table as below. Receiver function setting: A. Select any pushbutton or ON/OFF power switch to start the system. The MAIN relay will be activated when system is started. (after the receiver power is started and emergency stop button is elevated) B. The MAIN relay auto shutdown time can be set as 3 minutes or depends on customer’s single request. (Remark 1) C. When transmitter voltage is low, relays for the receiver MAIN and LV (Remark 1) will be auto shutdown after one minute. (Fig. 12) Alpha 607, 608 models Jumper Set table: in-plant setting (default). JP1 Open Power key to activate relay MAIN relay (After turning “on” the transmitter power and pressing the emergency Stop button) Open No auto shutdown time on Main relay JP2 Short The receiver MAIN will be deactivated after consecutive 5 minutes of standby time. Open No auto shutdown time on MAIN and LV relays JP3 Short After one minute of transmitter LV, the MAIN and LV relays will be deactivated. Open 7th AUX: “Normal” pushbutton setting JP4 Short 7th AUX: “Togglel” pushbutton setting ※ Open → no Jumper Short → put Jumper Remark 1：The setting of auto shutdown time can be done by manufacturer or distributor. Setting range: 0~30 minutes. (In-plant setting: 3 minutes) Remark 2：When the transmitter voltage is low, LV relay will be activated and siren or lights will be ON. (one second of interval)
- 14 - 77..44 FFrreeqquueennccyy ((RRFF)) CChhaannnneellss TTaabbllee Band 433MHz Dip-Switch Setting Channel433.075 MHz 00000001 01 433.100 MHz 00000010 02 433.125 MHz 00000011 03 433.150 MHz 00000100 04 433.175 MHz 00000101 05 433.200 MHz 00000110 06 433.225 MHz 00000111 07 433.250 MHz 00001000 08 433.275 MHz 00001001 09 433.300 MHz 00001010 10 433.825 MHz 00001011 11 433.850 MHz 00001100 12 433.875 MHz 00001101 13 433.900 MHz 00001110 14 433.925 MHz 00001111 15 433.950 MHz 00010000 16 433.975 MHz 00010001 17 434.000 MHz 00010010 18 434.025 MHz 00010011 19 434.050 MHz 00010100 20 434.075 MHz 00010101 21 434.100 MHz 00010110 22 434.125 MHz 00010111 23 434.150 MHz 00011000 24 434.175 MHz 00011001 25 434.200 MHz 00011010 26 434.225 MHz 00011011 27 434.250 MHz 00011100 28 434.275 MHz 00011101 29 434.300 MHz 00011110 30
- 15 - 88.. TTRRAANNSSMMIITTTTEERR OOPPEERRAATTIIOONN && SSTTAATTUUSS LLIIGGHHTT 8.1 Transmitter Operating Steps 1. Make sure the two “AA” NiMH rechargeable batteries are installed correctly. Please note the polarity of the batteries. 2. Status lights_To operate the transmitter, please rotate the power key on the top-left corner clockwise to “on” position. The status LED (green and red) will be steady “on” for 2 seconds and then “off”. If the transmitter Status LED displays a red blinking light that is “on” Æ 0.1 second and “off” Æ 1.9 seconds, or no light at all, this indicates the transmitter with batteries needs to be recharged. For battery charging or replacement, please refer to instruction next page. When any function pushbutton is depressed, the transmitter Status LED displays a red blinking light that is “on”Æ 0.1 second and “off”Æ 1.9 seconds. If the voltage is low, the transmitter Status LED will be “on”Æ0.1 second and “off”Æ1.9 seconds, this indicates the transmitter with batteries needs to be recharged. Continuous operation will cause the transmitter battery power exhausting and cannot operate at all. 3. EMS & Restarting _ In case of an emergency, press down the red emergency stop button (EMS) will immediately deactivates the transmitter and receiver MAIN relay. The transmitter Status LED will be blinking “on”Æ0.5 second and “off”Æ0.5 second for 30 seconds (Mode 0). Then turn off the transmitter power. 4. The emergency stop button is a right-rotate momentary spring-return type. To turn on the transmitter and activate the MAIN relay, please elevate the emergency stop button again and rotate the transmitter power key to “ON” position. 5. Note that the transmitter cannot be hit by outer forces, so that malfunction can be prevented. 6. The operating temperature is -10 ~ +50℃. Avoid operating the transmitter in high temperature workshop. If operating temperature is higher than 50℃,the auto shutdown protection installed inside CPU will shut down the transmitter and deactivate the MAIN relay. 7. To operation normally, the battery power has to be over 2.2V. If the voltage is lower than 2.2V, the system cannot be started and low voltage will be showed until the MAIN is completely shutdown. 8. If the power voltage is lowered than 2.2V when transmitter is operated, the LV code will be “1” and low voltage status light will be shown. The transmitter will stop sending signals when voltage is lower than 2.0V.
- 16 - STOP: press → lock (emergency stop) STOP: Elevate clockwise → reset (Turn on the transmitter at any time) 8.2 Transmitter Status Light Type Status Solution LED Indication 2 Power on when voltage is low BATT<2.2V Red light flash ON_0.1/OFF_1.9 sec (until power_off) 3 Setting failed or invalided Set data by using JUMPER & dip-switch without following rulesRed light ON_0.1/OFF_0.1 sec 4 Setting completed JP1 or JP2 inserted Green light ON until power_off. 5 EEPROM ID error EEPROM ID code does not match CPU Red light ON until power_off 6 RF module abnormal PLL UNLOCK Red light ON_0.1/OFF_0.1 sec 7 ID even number error Setting error Red light ON_1/OFF_1 sec 8 Pushbutton locked power_on pushbutton connected Red light ON_1.9/OFF_0.1 sec (until power_off) 9 Normal power_on BATT>=2.2V and all the pushbuttons are not depressed All the lights ON_2 sec 10 STOP status STOP button is pressedMODE 0: Red light ON_0.5/ OFF_ 0.5sec, flash 30sec. MODE 1: all the lights OFF 11 Low voltage during operation BATT<2.2V and press pushbutton Red light flash ON_0.1/OFF_1.9sec12 Normal operation Press pushbutton Green light flash ON_0.1/OFF_1.9sec Power status light
- 17 - 99.. RREECCEEIIVVEERR IINNSSTTAALLLLAATTIIOONN 99..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 withφ10.5mm 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. 99..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 the fig. on page 22). 6. If a crane or equipment’s runway is longer than 100 meters, an external antenna should be added. The Alpha 608 receiver housing has provisions for an external factory installed antenna available as an option, contact your dealer for price and delivery. 7. Drill a hole 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 4. 11. Ensure all wiring is correct and safely secured and all screws are fastened.
- 18 - (Fig. 13) Alpha 607, 608 models
- 19 - 9.4 Receiver system Status LED Display FUSE Receiver system Status LED Display 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. LED status light
- 20 - 1111.. 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.
- 21 - 1122.. SSYYSSTTEEMM SSPPEECCIIFFIICCAATTIIOONN Transmitter Unit Frequency Range : 433 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 (607~608 Models) : 172mm x 68mm x 33mm Weight (607~608 Models) : 285g (include batteries) Receiver Unit Frequency Range : 433 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 (607~608 Models) : 310mm x 134mm x 72mm Weight (607~608 Models) : 1,625g (include output cable)

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