Fomotech ALPHA600SERIES Remote Control User Manual

Fomotech International Corp. Remote Control

User manual

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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.”
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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)
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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)
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SIZE：300mm X 230mm X 86mm
AC
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S/ N:
FREQ:
MOD:
VOLT:
CH.
ID:
FILTER
Anti-vibration spring
must be grounded
POWER
MAIN
F6
5A
F1
F5 5A
LV/AUX1
COM417
L2(X2)
L1(X1)
GRN/YEL
COM5
MAIN
22
FF1
21
20
18
19
AUX1
AUX2
NC
COM3
NC
COM2
15
16
14 LV
N1
S1
COM1
D1
W1
E1
NC
NC
U1
F4 5A
F3 5A
13
10
11
12
9
8
3
5
6
7
4
F2 5A
2
1
BRIDGE
TROLLEY
HOIST
/AUX2
(Fig.7) Front View (Fig.8) Back View
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(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.
FUSE
FUSE
FUSE
1
2
8
4
11
10
12
13
14
15
17
18
9
16
20
FUSE
FUSE
FUSE
3
5
6
7
19
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Alpha 607A Alpha 607B
FILTER
Anti-vibration spring
must be grounded
POWER
MAIN
F6
5A
F1
F5 5A
LV/AUX1
COM4
17
L2(X2)
L1(X1)
GRN/YEL
COM5
MAIN
22
FF1
21
20
18
19
AUX1
NC
NC
COM3
NC
COM2
15
16
14 LV
N1
S1
COM1
D1
W1
E1
NC
NC
U1
F4 5A
F3 5A
13
10
11
12
9
8
3
5
6
7
4
F2 5A
2
1
BRIDGE
TROLLEY
HOIST
FILTER
Anti-vibration spring
must be grounded
POWER
MAIN
F6
5A
F1
F5 5A
LV/AUX1
BRIDGE
F4 5A
TROLLEY
F3 5A
COM4
17
L2(X2)
L1(X1)
GRN/YEL
COM5
MAIN
22
FF1
21
20
18
19
AUX1
NC
N/S2
COM3
E/W2
COM2
15
16
14
13 LV
N1
10
11
12 S1
9
8
COM1
D1
3
5
6
7W1
E1
4D2
HOIST
F2 5A 2
1U2
U1
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FILTER
Anti-vibration spring
must be grounded
POWER
MAIN
F6
5A
F1
F5 5A
LV/SEL-I
COM4
17
L2(X2)
L1(X1)
GRN/YEL
COM5
MAIN
22
FF1
21
20
18
19
SEL-I
SEL-II
NC
COM3
NC
COM2
15
16
14 LV
N1
S1
COM1
D1
W1
E1
NC
NC
U1
F4 5A
F3 5A
13
10
11
12
9
8
3
5
6
7
4
F2 5A
2
1
BRIDGE
TROLLEY
HOIST
/SEL-II
Alpha 607AT Alpha 607BT
FILTER
Anti-vibration spring
must be grounded
POWER
MAIN
F6
5A
F1
F5 5A
LV/SEL-I
BRIDGE
F4 5A
TROLLEY
F3 5A
COM4
17
L2(X2)
L1(X1)
GRN/YEL
COM5
MAIN
22
FF1
21
20
18
19
SEL-I
SEL-II
N/S2
COM3
E/W2
COM2
15
16
14
13 LV
N1
10
11
12 S1
9
8
COM1
D1
3
5
6
7W1
E1
4D2
HOIST
F2 5A 2
1U2
U1
/SEL-II
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Alpha 608A Alpha 608B
FILTER
Anti-vibration spring
must be grounded
POWER
MAIN
F6
5A
F1
F5 5A
LV/AUX1
COM4
17
L2(X2)
L1(X1)
GRN/YEL
COM5
MAIN
22
FF1
21
20
18
19
AUX1
AUX2
NC
COM3
NC
COM2
15
16
14 LV
N1
S1
COM1
D1
W1
E1
NC
NC
U1
F4 5A
F3 5A
13
10
11
12
9
8
3
5
6
7
4
F2 5A
2
1
BRIDGE
TROLLEY
HOIST
/AUX2
FILTER
Anti-vibration spring
must be grounded
POWER
MAIN
F6
5A
F1
F5 5A
LV/AUX1
BRIDGE
F4 5A
TROLLEY
F3 5A
COM4
17
L2(X2)
L1(X1)
GRN/YEL
COM5
MAIN
22
FF1
21
20
18
19
AUX1
AUX2
N/S2
COM3
E/W2
COM2
15
16
14
13 LV
N1
10
11
12 S1
9
8
COM1
D1
3
5
6
7W1
E1
4D2
HOIST
F2 5A 2
1U2
U1
/AUX2
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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.
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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
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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 -
FUSE
JP1 OPEN→JUMP
SHORT→JUMP
AC
DIP-SW
U
JP3
JP2
JP4
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)
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Band 433MHz Dip-Switch Setting Channel
433.075 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
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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 rules
Red 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 pressed
MODE 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_1.9sec
12 Normal operation Press pushbutton Green light flash ON_0.1/OFF_1.9
sec
Power status
light
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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.
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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 -
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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 -
1
12
2.
.
S
SY
YS
ST
TE
EM
M
S
SP
PE
EC
CI
IF
FI
IC
CA
AT
TI
IO
ON
N
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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