FCC ID: LZ6ALPHA580SERIES Industrial Remote Control

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 4.2 Alpha 540 & 560 Models 4.3 Alpha 580 Models 5. RECEIVER OUTLINE

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............................................................................................... 9 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 7. SYSTEM CONFIGURATIONS 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

..................................................................................... ............................................................................ 21~22 7.1 How to Set Jumper Functions 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 7.6 Frequency (RF) Channel Table ............................................................................. ............................................................................ 24~25 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 ................................................................................... 10. TROUBLE SHOOTING ............................................................................................... 32 33 11. SYSTEM SPECIFICATION ......................................................................................... 12. PARTS LIST ................................................................................................................. 34~35 29~31 1 11.. 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.

2 22.. 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."

3 33.. PPUUSSHHBBUUTTTTOONN CCOONNFFIIGGUURRAATTIIOONN 33..11 AAllpphhaa 550000 && 552200 MMooddeellss 1. Alpha 500 : (4) one-speed pushbuttons. 2. Alpha 520 : (4) two-speed pushbuttons. ON OFF STOP ON OFF STOP

(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). 4 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) 5 33..33 AAllpphhaa 558800 MMooddeellss

: (9) one-speed pushbuttons + (1) SELECT I/II pushbutton.*

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 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 7. Alpha 580E 8. Alpha 580F

* For cranes with auxiliary hoist and trolley (changeover function).

: (10) two-speed pushbuttons + (1) AUX micro-button.

: (6) two-speed + (3) one-speed pushbuttons + (1) SELECT I/II pushbutton.*

: (8) two-speed + (1) one-speed pushbutton + (1) SELECT I/II pushbutton.*

(Alpha 580A-2)

(Alpha 580A-1)

(Alpha 580B)

(Alpha 580C-1)

(Alpha 580C-2)

(Alpha 580D)

(Alpha 580E)

(Alpha 580F) 6 44.. TTRRAANNSSMMIITTTTEERR OOUUTTLLIINNEE 44..11 AAllpphhaa 550000 && 552200 MMooddeellss 1 2 3 4 ON OFF STOP 5 6 7 8 9 10

(Fig. 1) Front View

(Fig. 2) Back View 11 17

(Fig. 3) Front View 14 1) Transmitter enclosure 2) Power switch (ON/OFF) 3) Pushbutton #2 ( / Down ) 4) Pushbutton #4 ( / West) 5) Wrist strap attachment 6) Emergency stop (EMS) 7) Pushbutton #1 ( / Up) 16 O n 1 2 3 4 5 6 7 8 15

(Fig. 4) Back View 8) Pushbutton # 3 ( / East) 15) Programming port 9) System information 16) ID code dip-switch 17) Transmitting RF Board 10) Battery cover 11) Battery cover screws 12) Internal antenna 13) Status LED display 14) Battery contact 7 44..22 AAllpphhaa 554400 && 556600 MMooddeellss

(Fig. 5) Front View

(Fig. 6) Back View O n 1 2 3 4 5 6 7 8

(Fig.7) Front View (Fig. 8) Back View Transmitter enclosure Power switch (ON/OFF) Pushbutton #2 ( / Down) Pushbutton #4 ( / West) Pushbutton #6 ( / South) 1) 2) 3) 4) 5) 6) Wrist strap attachment 7) Emergency stop (EMS) 15) Status LED display 8) Pushbutton #1 ( / Up) 9) Pushbutton #3 ( / East) 16) Battery contact 10) Pushbutton #5 ( / North) 17) AUX micro-button connector*

11) System information 12) Battery cover screws 13) Battery cover 14) Internal antenna 18) Programming port 19) ID code dip-switch 20) Transmitting RF board

* For Alpha 540A and Alpha 560A models only. 8 44..33 AAllpphhaa 558800 MMooddeellss 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

(Fig. 9) Front View

(Fig. 10) Back View 19 20 21 25 24 22 23

(Fig. 11) Front View (Fig. 12) Back View 1) Transmitter enclosure 2) External antenna port 3) Power switch (ON/OFF) 4) Pushbutton #2 ( / Down) 5) Pushbutton #4 ( / West) 6) Pushbutton #6 ( / South) 7) Pushbutton #8 (A2) 8) Pushbutton #10 (A4) 17) Battery cover screws 18) Battery cover 19) Internal antenna 20) Status LED display 9) Waist belt attachment 10) Emergency stop (EMS) Pushbutton #1 ( / Up) 11) Pushbutton #3 ( / East) 12) 13) Pushbutton #5 ( / North) 21) Battery contact Pushbutton #7 (A1) 14) Pushbutton #9 (A3) 15) 16) System information 22) AUX micro-button connector*

23) Programming port 24) ID code dip-switch 25) Transmitting RF board

* For optional AUX micro-button or buttons. 9 55.. RREECCEEIIVVEERR OOUUTTLLIINNEE 55..11 AAllpphhaa 550000 ~~ 556600 MMooddeellss EExxtteerrnnaall AAsssseemmbbllyy U D E W N S A M SQ AC A M SQ AC MAIN 5A U/D 5A E/W 5A LV,AUX 5A N/S 5A AC220V 50/60HZ POWER 1A Anti-vibration spring must be grounded 4 5 6 1 2 3 7 8 9 10 11

(Fig. 13) Front View

(Fig. 14) Back View 1) Receiver enclosure 2) Wiring diagram 3) Receiver LED displays*

4) Type model 5) System frequency 6) System serial number 7) System ID code 8) System RF channel 9) Supplied voltage 10) Anti-vibration spring 11) Grounding (GND) AUX Relay Contact Indicator (for Alpha 540A/560A models only).

A

* M ~ MAIN and 2nd Speed Relay Contact Indicator.

SQ ~

2nd speed activated (for Alpha 560S/A models only). Green "on" MAIN activated (All models). Red "on"

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. Power Source Indicator (red) "on" AC input power supplied.

"off" No AC input power.

* AC ~

10 55..22 AAllpphhaa 550000 && 552200 MMooddeellss IInntteerrnnaall AAsssseemmbbllyy

(Fig. 15) Internal Parts Assembly ID code dip-switch 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) 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 2 3 1 2 3 4 11 4 5 6 7 8 9 10 11 12 13 14 15 16 F U S E FUSE FUSE E S U F F U S E 1) Spare fuse & jumper compartment 2) Spare Jumper slots 3) Spare fuse slots 4) Receiver top casing 55..33 AAllpphhaa 554400 && 556600 MMooddeellss IInntteerrnnaall AAsssseemmbbllyy 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.

(Fig. 16) Internal Parts Assembly 7 8 9 10 11 12 13 14 15 16 17 18 19 20 F U S E FUSE FUSE F U S E F U S E E S U F 1) Spare fuse & jumper compartment 2) Spare Jumper slots 3) Spare fuse slots 4) Receiver top casing 1 2 3 4 5 6 1 2 3 4 12 55..44 AAllpphhaa 558800 MMooddeellss EExxtteerrnnaall AAsssseemmbbllyy 1 2 3 4

(Fig. 17) External Parts Assembly Transparent top cover Light-gray colored base 3) Mounting bracket with shock absorbers 4) Cable gland / Cord grip 1) 2) 13 55..55 AAllpphhaa 558800 MMooddeellss IInntteerrnnaall AAsssseemmbbllyy 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

(Fig. 18) Internal Parts Assembly 12) Pushbutton #1 and #2 relay fuse (5.0A) 13) Receiving RF module 14) External antenna port 15) RF channel dip-switch 16) ID code dip-switch 17) Secondary power fuse (0.8A) 18) Voltage selector seat 19) MAIN relay fuse (5.0A) 20) Pushbutton A4 relay fuse (5.0A) 1) Power LED display*

2) SQ LED display**

3) Status LED display****

4) DC power relay LED display***

5) Programming port 6) Jumper settings 7) Function dip-switch 8) Pushbutton #3 and #4 relay fuse (5.0A) 9) Pushbutton #5 and #6 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)

Blinking at transmitter power off Other radio interference.

*** RELAY_COM ~ DC Power Source to Relays "on" DC power to relays.

**** STATUS ~ Receiver System Status LED Display Please refer to page 32.

"off" No AC input power. SQ ~ RF Signal Indicator "on" RF signal detected and received.

"off" No RF signal detected or received. POWER ~ AC Power Source Indicator "on" AC input power supplied. 22) Low-voltage (LV) relay fuse (5.0A)

"off" No DC power to relays. 14 66.. OOUUTTPPUUTT CCOONNTTAACCTT DDIIAAGGRRAAMMSS

(Alpha 520) MAIN 5A U/D 5A E/W 5A LV 5A POWER

(Alpha 500) E/W 5A U/D 5A MAIN 5A 66..11 AAllpphhaa 550000 && 552200 MMooddeellss POWER LV 5A 15 66..22 AAllpphhaa 554400 MMooddeellss

(Alpha 540S)

(Alpha 540A) MAIN 5A MAIN 5A U/D 5A E/W 5A LV,AUX N/S 5A U/D 5A E/W 5A LV,AUX N/S 5A POWER POWER 16 66..33 AAllpphhaa 556600 MMooddeellss

(Alpha 560S)

(Alpha 560A) MAIN 5A U/D 5A E/W 5A LV,AUX N/S 5A MAIN 5A U/D 5A E/W 5A LV,AUX N/S 5A POWER POWER 17 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) 18

(Alpha 580C-1)

(Alpha 580C-2)

Note: For Alpha 580C-1 model, please disregard A1.2 + 2.2 terminal output.

(Alpha 580D) 19

(Alpha 580E)

(Alpha 580F) 20 77.. SSYYSSTTEEMM CCOONNFFIIGGUURRAATTIIOONNSS 77..11 HHooww TToo SSeett JJuummppeerr FFuunnccttiioonnss JP1 JP2 JP3 JP4 DIP-SW U OPENJUMP SHORTJUMP J P 1 J P 2 J P 3 J P 4 J P 5 J P 6 J P 7 F U S E AC

(Fig. 19) Alpha 500 ~ 560 Models

(Fig. 20) Alpha 580 Models Manufacture Settings JP1 JP2 JP3 JP4 Open Short Open Short Open Short Open Short 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. 1. Turning on the transmitter power will activate the receiver MAIN. 2. Resetting the EMS will activate the receiver MAIN. For all models Reserved Reserved After 1 minute of transmitter low-voltage warning, the transmitter For all models power will be deactivated. After 1minute of transmitter low-voltage warning, the transmitter power and the receiver MAIN will be deactivated. (refer to note A below) For all models For Alpha 540A & 560A models AUX button with normal momentary relay contact. 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. 21 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) JP3 Open Power On Work in progress Transmitter low-voltage condition occurs LV warning Replace batteries within 1 minute YES Work resumes NO Transmitter unit will be deactivated JP3 Short Power On Work in progress Transmitter low-voltage condition occurs LV warning Replace batteries within 1 minute YES NO Work resumes The transmitter power and the receiver MAIN will be deactivated JP-4 Settings (for Alpha 540A & 560A models only) JP4 Open JP4 Short AUX button with normal momentary relay contact 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)).. 22 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. 1 2 3 4 5 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). 23 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). Example:

DIP-1 DIP-2 DIP-3 DIP-4 DIP-5 DIP-6 0 1 1 0 0 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 Alpha 580B 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) 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 24 Alpha 580 models dip-switch function table (continued) Alpha 580C-1

Alpha 580C-2 Alpha 580D Alpha 580E 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 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 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 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) 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. 25 77..66 FFrreeqquueennccyy ((RRFF)) CChhaannnneellss TTaabbllee FREQUENCY DIP-SWITCH SETTING RF CHANNEL 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 301.105 MHz 301.130 MHz 301.155 MHz 301.180 MHz 301.205 MHz 301.230 MHz 301.255 MHz 301.280 MHz 301.305 MHz 301.330 MHz 301.355 MHz 301.380 MHz 301.405 MHz 301.430 MHz 301.455 MHz 301.480 MHz 301.505 MHz 301.530 MHz 301.555 MHz 301.580 MHz 301.605 MHz 301.630 MHz 301.655 MHz 301.680 MHz 301.705 MHz 301.730 MHz 301.755 MHz 301.780 MHz 301.805 MHz 301.830 MHz 00001 00010 00011 00100 00101 00110 00111 01000 01001 01010 01011 01100 01101 01110 01111 10000 10001 10010 10011 10100 10101 10110 10111 11000 11001 11010 11011 11100 11101 11110 26 88.. 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. Prior to installation, make sure that the crane or equipment itself is working properly. 3. 4. Use a multi-meter to check the voltage source available and ensure the receiver voltage setting matches your power source. Prior to installation, switch off the main power source to the crane or equipment. 5. 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 6.

(refer to fig. 21 and fig. 22 on page 28). If a crane or equipments 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). If the control panel has a plastic surface, extended grounding wire should be used. 8. Tightened the bolt nuts provided. 9. 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. 27

(Fig. 21) Alpha 500 ~ 560 Models 2 5 5 mm 4 - O10.5 2 7 8 mm

(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. 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). 5. 28 99.. TTRRAANNSSMMIITTTTEERR OOPPEERRAATTIIOONN 2. 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. 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 29 3. 4. 5. 6. 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). 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 LED DISPLAY 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). 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. 30 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. 31 1100.. 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. Transmitter does not communicate with the receiver. Low or no transmitting power from the transmitter unit. 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. 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. Outputs do not operate correctly. Receiver configuration is not set properly or output wiring is incorrect. 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. 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 1 2 3 4 5 6 Constant red light. ON 1.0 second OFF 1.0 second Dim or no light. ON 2.0 seconds OFF 0.1 second ON 0.1 second OFF 2.0 seconds ON 0.1 second OFF 0.1second EEPROM error reprogramming required. Incorrect receiver ID code setting (see note below). ID code not matched on both the transmitter and receiver unit, please readjust accordingly. Under-voltage, check the main power-supply. MAIN contact relay jammed or defective. System normal with transmitter pushbutton either in neutral or in transmitter power off position. 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. 32 1111.. SSYYSSTTEEMM SSPPEECCIIFFIICCAATTIIOONN Transmitter Unit

Frequency Range

Transmitting Range

Hamming Distance Channel Spacing

Frequency Control

Frequency Drift Frequency Deviation

Spurious Emission

Transmitting Power

Emission Antenna Impedance

Enclosure Rating

Source Voltage

Current Drain Operating Temperature

Dimension (500~520 Models)

(540~560 Models)

(580 Models) Weight (500~520 Models)

(540~560 Models)

(580 Models) 301 MHz 100 meters 6 25KHz Quartz Crystals

< 5ppm @ -25 ~ +75

< 1ppm @ 25

- 50dB

~1mW F1D 50 ohms IP-66 3.0V (AA alkaline batteries x 2) 10 ~ 18mA

-25 ~ +75 140mm x 68mm x 33mm 173mm x 68mm x 33mm 213mm x 68mm x 33mm 200g (include batteries) 240g (include batteries) 290g (include batteries) Receiver Unit Frequency Range Channel Spacing Hamming Distance Frequency Control Frequency Drift Frequency Deviation Sensitivity Antenna Impedance Data Decoder Reference Responding Time Enclosure Rating Source Voltage Power Consumption Operating Temperature Output Contact Rating Dimension (500~560 Models)

(580 Models) Weight (500~520 Models)

(540~560 Models)

(580 Models)

33 301 MHz 25KHz 6 Synthesizer (PLL)

< 5ppm @ -25 ~ +75

< 1ppm @ 25

-120dBm 50ohms Quartz Crystals 40ms (Normal) IP-65 (Alpha 500~560 Models) IP-66 (Alpha 580 Models) AC 220V ~ 230V @ 50/60 Hz. 11VA

-25 ~ +75 250V @ 10A 310mm x 134mm x 72mm 300mm x 230mm x 86mm 1,625g (include output cable) 1,700g (include output cable) 3,400g (no output cable) 1122.. PPAARRTTSS LLIISSTT 301 MHz Transmitting RF Board (All Models) 1. 2. Encoder Board (Alpha 500) Encoder Board (Alpha 520) Encoder Board (Alpha 540S) Encoder Board (Alpha 540A) Encoder Board (Alpha 560S) Encoder Board (Alpha 560A) Encoder Board (Alpha 580A-1) Encoder Board (Alpha 580A-2) Encoder Board (Alpha 580B) Encoder Board (Alpha 580C-1) Encoder Board (Alpha 580C-2) Encoder Board (Alpha 580D) Encoder Board (Alpha 580E) Encoder Board (Alpha 580F) 301 MHz Receiving RF Module (All Models) Transmitter Enclosure (Alpha 540S & 560S Models) Transmitter Enclosure (Alpha 540A & 560A Models) Transmitter Enclosure (Alpha 580A, C, D Models) Transmitter Enclosure (Alpha 580B, E, F Models) 3. 4. Decoder/Relay Board (Alpha 500) Decoder/Relay Board (Alpha 520) Decoder/Relay Board (Alpha 540S) Decoder/Relay Board (Alpha 540A) Decoder/Relay Board (Alpha 560S) Decoder/Relay Board (Alpha 560A) Decoder/Relay Board (Alpha 580A-1) Decoder/Relay Board (Alpha 580A-2) Decoder/Relay Board (Alpha 580B) Decoder/Relay Board (Alpha 580C-1) Decoder/Relay Board (Alpha 580C-2) Decoder/Relay Board (Alpha 580D) Decoder/Relay Board (Alpha 580E) Decoder/Relay Board (Alpha 580F) 5. Transmitter Enclosure (Alpha 500 & 520 Models) 6. Receiver Enclosure (Alpha 500 & 520 Models) Receiver Enclosure (Alpha 540 & 560 Models) Receiver Enclosure (Alpha 580 Models) 34 BTX301 BEN500 BEN520 BEN540S BEN540A BEN560S BEN560A BEN580A1 BEN580A2 BEN580B BEN580C1 BEN580C2 BEN580D BEN580E BEN580F BRX301 BDR500 BDR520 BDR540S BDR540A BDR560S BDR560A BDR580A1 BDR580A2 BDR580B BDR580C1 BDR580C2 BDR580D BDR580E BDR580F BCT500 BCT560S BCT560A BCT580A BCT580B BCR500 BCR560 BCR580 Waist Belt (Alpha 580 Models) 7. Double-Step Pushbutton (All Models) Single-Step Pushbutton (All Models) 8. EMS Red Cap (All Models) 9. Wrist Strap (Alpha 500 ~ 560 Models) 10. Pushbutton Rubber Boot (Alpha 500 & 520 Models) Pushbutton Rubber Boot (Alpha 540 & 560 Models) Pushbutton Rubber Boot (Alpha 580 Models) 11. Pushbutton Direction labels (All Types) 12. Transformer (12/24VDC Alpha 500 ~ 560 Models) Transformer (24VAC Alpha 500 ~ 560 Models) Transformer (48VAC Alpha 500 ~ 560 Models) Transformer (110/120VAC Alpha 500 ~ 560 Models) Transformer (220/230 VAC Alpha 500 ~ 560 Models) Transformer (380VAC Alpha 500 ~ 560 Models) Transformer (12/24VDC Alpha 580 Models) Transformer (AC 110V~120V / 220V~240V Alpha 580 Models) Transformer (AC 350V~380V / 400V~460V Alpha 580 Models) Transformer (AC 24V/32V/46V/48V Alpha 580 Models) 13. Regular Output Contact Relay (All Models) Safety MAIN Contact Relay (All Models) 14. Protective Vinyl Casing (Alpha 500 ~ 560 Models) Protective Vinyl Casing (Alpha 540 ~ 560 Models) 15. Leather Pouch (Alpha 500 ~ 520 Models) Leather Pouch (Alpha 540 ~ 560 Models) B50001 B50002 EMS01 WS01 WB01 PRB01 PRB02 PRB03 DL01 T24VDC T24VAC T48VAC T120VAC T230VAC T380VAC SSB-2601 SSB-2603 SSB-2604 SSB-2665 RLY01 RLY02 VPC01 VPC02 LP500 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) 18. Optional External 301 MHz Antenna (All Models) 19. BNC Jack for External Antenna Connection (Alpha 500 ~ 560 Models)BNC500 20. BNC Lead Wire for External Antenna Connection 21. 2-meter Coaxial Cable for External Antenna Connection (All Models) 22. Removable Transmitter Power Key (All Models) Receiver Shock Absorbers + Mounting Hardware (Alpha 580 Models) BNC Jack for External Antenna Connection (Alpha 580 Models) BNC580 BLW500 CC500 KEY01 RMS500 RSA580 ANT301 35