FCC ID: LZ6ALPHA612SERIES Industrial Remote Control

TTAABBLLEE OOFF CCOONNTTEENNTTSS Page 1. SAFETY INSTRUCTION ............................................................................................. 2 2. PUSHBUTTON CONFIGURATION 2.1 2.2 Alpha 607 & 608 Models ..................................................................................... 3 Alpha 612 Models ............................................................................................... 4 3. TRANSMITTER OUTLINE 3.1.1 Alpha 607 & 608 Models ..................................................................................... 3.1.2 Alpha 612 Models

............................................................................................. 3.2 Alpha 607/608/612 Spare Parts ...................................................................... 4. RECEIVER OUTLINE 4.1 Alpha 607 & 608 Models Internal Assembly ....................................................... 4.2 Alpha 612 Models Internal Assembly ................................................................... 5. OUTPUT CONTACT DIAGRAMS 5.2 Alpha 607 Models ................................................................................................. 12-13 5.3 Alpha 608 Models ................................................................................................. 14 5.4 Alpha 612 Models ................................................................................................. 15-19 6. SYSTEM CONFIGURATIONS 6.1 How to Set ID Codes ............................................................................................. 6.2 Transmitter RF Channel Setting ............................................................................. 22 23 5-6 6-7 8 8-9 10-11 7. RECEIVER SETTING 7.1 How to Set Receiver ID Codes .............................................................................. 24 7.2 Receiver RF Channel Setting

.............................................................................. 25 7.3 Receiver Function Setting

.............................................................................. 25 7.4 Frequency (RF) Channels Table .............................................................................. 29 8. TRANSMITTER OPERATION & STATUS LIGHT 8.1 Transmitter Operating Steps 8.2 Transmitter Status light

.............................................................................. 31

.............................................................................. 32 9. RECEIVER INSTALLATION 9.1 Preparation For Installation ................................................................................... 33 33 9.2 Step-By-Step Installation ....................................................................................... 34 9.3 System Testing ....................................................................................................... 9.4 Receiver System Status LED Display..................................................................... 35 10. TROUBLE SHOOTING................................................................................................. 37 11. SYSTEM SPECIFICATION ........................................................................................ 38 12. PARTS LIST ................................................................................................................. 39

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1. SSAAFFEETTYY IINNSSTTRRUUCCTTIIOONN The Alpha 600 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 600 series will enhance safety, productivity and efficiency in the workplace. The following procedures should be strictly followed:

1. The transmitter is equipped with a specialized battery charger. Only two AA Ni-MH rechargeable batteries are allowed to be used in the transmitter. Please note the polarity of the batteries. Do not use other types of battery to prevent any accident Do not change the IDs on transmitter encoder and receiver decoder boards at will. 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. 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. 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. 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. Ensure the waist belt is worn at all time during operation to avoid accidental damage to the transmitter. Rotate the power switch to OFF position when the transmitter is not operated temporarily or the operation is finished. Any repair or adjustment should be proceeding by repair technician for radio remote controls. The operator should not change any electrical parts at will. 2. 3. 4. 5. 6. 7. 8. 9. 10. Changes or modifications are not expressly approved by the manufacturer could void the user's authority to operate the equipment. This device complies with EMC Directive 89/336/EEC, Low Voltage Directive 76/23/EEC and R&TTE Directive 1995/5/EEC.This product has been approved for upper directives and covers the following countries : Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, The Netherlands, UK, Iceland, Norway, Switzerland, Turkey & Romania. 2 2. PPUUSSHHBBUUTTTTOONN CCOONNFFIIGGUURRAATTIIOONN 2.1 Alpha 607 & 608 Models 1. 607A 2. 607B 3. 607AT 4. 607BT 5. 608A 6. 608B

(7) single speed pushbuttons

(6) double speed pushbuttons + (1) single speed pushbuttons

(6) single speed pushbuttons + (1) SELECT I/II pushbutton

(6) double speed pushbuttons + (1) SELECT I/II pushbutton

(8) single speed pushbuttons

(6) double speed pushbuttons + (2) single speed pushbuttons

(Alpha 607B) (Alpha 607AT) (Alpha 607BT)

(Alpha 607A)

(Alpha 608A) (Alpha 608B)

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2.2 Alpha 612 Models 1. Alpha 612A 2. Alpha 612B 3. Alpha 612C-1 4. Alpha 612C-2 5. Alpha 612D 6. Alpha 612E-1 7. Alpha 612E-1

(12) one-speed pushbuttons

(11) one-speed pushbuttons + I/II select pushbutton*

(6) two- speed + (6) one-speed pushbuttons

(8) two-speed + (4) one-speed pushbuttons

(10) two-speed + (2) one-speed pushbuttons

(6) two-speed + (5) one-speed pushbuttons + I/II select pushbutton*

(8) two-speed + (3) one-speed pushbuttons + I/II select pushbutton*

* For cranes with auxiliary hoist and trolley (changeover function). POWER STOP POWER STOP POWER STOP POWER STOP 612A 612B 612C-1 612C-2 612D 612E-1 612E-2

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33.. TTRRAANNSSMMIITTTTEERR OOUUTTLLIINNEE 3.1 Transmitter Outline 3.1.1 Alpha 608 3.1.2.1 SIZE: 189mm X 68mm X 30mm

(Fig.1) Transmitter Outline 3.1.2.2 TX INTERNAL MODULE encoder board

(Fig.4) Encoder board

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3.1.2.3 TRANSMITTER INTERNAL ASSEMBLY

(1) Internal antenna

(2) Status LED display

(3) Battery contact

(5) Programming port

(6) ID code dip-switch

(7) JP2 setting pin

(8) JP1 setting pin

(Fig.2) Front View (Fig.3) Back View 3.1.3 Alpha 612 3.1.3.1 SIZE: 235mm X 68mm X 30mm

(Fig.1) Transmitter Outline

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3.1.3.2 TX INTERNAL MODULE Encoder Board 3.1.3.3 TRANSMITTER INTERNAL ASSEMBLY

(1) Internal antenna

(2) Status LED display

(3) Battery contact

(5) Programming port

(6) ID code dip-switch

(7) JP2 setting pin

(8) JP1 setting pin

(Fig.2) Front View (Fig.3) Back View

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3.2 Alpha 604/607/608/612 Spare Parts 44.. RREECCEEIIVVEERR OOUUTTLLIINNEE

(3) Transmitter shock-absorbing rubber

(4) Shoulder strap 44..11 AAllpphhaa 660077//660088 44..11..11 EExxtteerrnnaall AAsssseemmbbllyy SIZE310mm X 134mm X 72mm U D E W N S A M SQ AC A M SQ AC U1 NC D1 NC COM1 E1 W1 NC COM2 N1 S1 NC COM3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LV 15 16 17 18 19 20 21 22 AUX1 AUX2 COM4 MAIN COM5 L1(X1) L2(X2) GRN/YEL HOIST F2 5A TROLLEY F3 5A BRIDGE F4 5A LV/AUX1

/AUX2 F5 5A MAIN F6 5A POWER F1 FF1 I F L T E R Anti-vibration spring must be grounded MOD:

FREQ:

S/ N:

I D:

CH. VOLT:

(Fig.7) Front View

(Fig.8) Back View

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44..11..22 AAllpphhaa 660088 IInntteerrnnaall AAsssseemmbbllyy

(Fig. 9) Internal Parts Assembly F U S E F U S E 7 8 9 10 11 12 13 14 15 16 17 18 19 20 F U S E 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 1 2 3 4 5 6

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E S U F 44..22 AAllpphhaa 661122 44..22..11 EExxtteerrnnaall AAsssseemmbbllyy SIZE300mm X 230mm X 86mm

(Fig. 17) External Parts Assembly 1) 2) Transparent top cover Light-gray colored base 3) Mounting bracket with shock absorbers 4) Cable gland / Cord grip

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44..22..22 AAllpphhaa 661122 IInntteerrnnaall AAsssseemmbbllyy 1 2 3 4 5 6 7 8 9 10 11 12

(Fig. 18) Internal Parts Assembly 13 14 15 16 17 18 19 20 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)

*** 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. Blinking at transmitter power off Other radio interference. POWER ~ AC Power Source Indicator "on" AC input power supplied. 22) Low-voltage (LV) relay fuse (5.0A)

"off" No DC power to relays.

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55.. OOUUTTPPUUTT CCOONNTTAACCTT DDIIAAGGRRAAMMSS 55..11 AAllpphhaa 660077 MMooddeellss

((Alpha 607A)

(Alpha 607B) 1 2 3 4 5 6 7 8 9 10 U1 NC D1 NC COM1 E1 W1 NC COM2 N1 11 S1 12 NC 13 COM3 14 LV 15 AUX1 16 NC 17 COM4 18 MAIN 19 COM5 HOIST F2 5A TROLLEY F3 5A BRIDGE F4 5A LV/AUX1 F5 5A MAIN F6 5A POWER U1 U2 1 2 3 D1 4 D2 5 6 E1 7 W1 8 9 10 N1 COM1 E/W2 COM2 11 S1 12 N/S2 13 COM3 14 LV 15 AUX1 16 NC 17 COM4 18 MAIN 19 COM5 HOIST F2 5A TROLLEY F3 5A BRIDGE F4 5A LV/AUX1 F5 5A MAIN F6 5A POWER FF1 F1 F I L T E R 20 21 22 L1(X1) L2(X2) GRN/YEL FF1 F1 F I L T E R 20 21 22 L1(X1) L2(X2) GRN/YEL Anti-vibration spring must be grounded Anti-vibration spring must be grounded

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((Alpha 607AT)

(Alpha 607BT) HOIST F2 5A TROLLEY F3 5A BRIDGE F4 5A LV/SEL-I

/SEL-II F5 5A MAIN F6 5A POWER FF1 F1 F I L T E R 1 2 3 4 5 6 7 8 9 10 U1 NC D1 NC COM1 E1 W1 NC COM2 N1 11 S1 12 NC 13 COM3 14 LV 15 SEL-I 16 SEL-II 17 COM4 18 MAIN 19 COM5 20 21 22 L1(X1) L2(X2) GRN/YEL HOIST F2 5A TROLLEY F3 5A BRIDGE F4 5A LV/SEL-I

/SEL-II F5 5A MAIN F6 5A POWER FF1 F1 F I L T E R U1 U2 1 2 3 D1 4 D2 5 6 E1 7 W1 8 9 10 N1 COM1 E/W2 COM2 11 S1 12 N/S2 13 COM3 14 LV 15 SEL-I 16 SEL-II 17 COM4 18 MAIN 19 COM5 20 21 22 L1(X1) L2(X2) GRN/YEL Anti-vibration spring must be grounded Anti-vibration spring must be grounded

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55..22 AAllpphhaa 660088 MMooddeellss

((Alpha 608A)

(Alpha 608B) 1 2 3 4 5 6 7 8 9 10 U1 NC D1 NC COM1 E1 W1 NC COM2 N1 11 S1 12 NC 13 COM3 14 LV 15 AUX1 16 AUX2 17 COM4 18 MAIN 19 COM5 HOIST F2 5A TROLLEY F3 5A BRIDGE F4 5A LV/AUX1

/AUX2 F5 5A MAIN F6 5A POWER U1 U2 1 2 3 D1 4 D2 5 6 E1 7 W1 8 9 10 N1 COM1 E/W2 COM2 11 S1 12 N/S2 13 COM3 14 LV 15 AUX1 16 AUX2 17 COM4 18 MAIN 19 COM5 HOIST F2 5A TROLLEY F3 5A BRIDGE F4 5A LV/AUX1

/AUX2 F5 5A MAIN F6 5A POWER FF1 F1 F I L T E R 20 21 22 L1(X1) L2(X2) GRN/YEL FF1 F1 F I L T E R 20 21 22 L1(X1) L2(X2) GRN/YEL Anti-vibration spring must be grounded Anti-vibration spring must be grounded

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55..33 AAllpphhaa 661122 MMooddeellss

(Alpha 612A) same as Alpha 580A+2

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(Alpha 612B) same as Alpha 580B+2

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(Alpha 612C-1) same as Alpha 580C-1+2

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(Alpha 612C-2) same as Alpha 580C-2+2

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(Alpha 612D) same as Alpha 580D+2

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(Alpha 612E-1) same as Alpha 580E-1+2

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(Alpha 612E-2) same as Alpha 580E-2+2

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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.

(Fig. 10) Back view Top slot ON 1; bottom slot 0. The setting above is 00000011.

(Fig. 11) Position of dip-switch & jumpers

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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) ExampleSet channel as 03(00000011) Correct setting

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77.. RREECCEEIIVVEERR SSEETTTTIINNGGSS 77..11 HHooww ttoo SSeett 660077//660088//661122 RReecceeiivveerr IIDD CCooddeess 77..11..11 HHooww ttoo SSeett 660077//660088 RReecceeiivveerr IIDD CCooddee Top slot 1 Bottom slot 0 ID DIP-SW Set the ID codes needed on the decoder board dip-switch. For example: the ID codes set above 10000111. 77..11..22 HHooww ttoo sseett 661122 RReecceeiivveerr IIDD CCooddee Please refer Fig. 18 receiver internal parts assembly (Page 17) for ID code 8-position dip-switch to set receiver ID code. Top slot 1; bottom slot 0 Set the ID codes needed on the decoder board dip-switch. For example: the ID codes 10010110 1 value adds up must to be 4 1 2 3 4 5 6 7 8

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7.2 Receiver RF Channel Setting There are 68 sets of user-adjustable receiving RF channels that can be set manually via a 8-position dip-switch located to the right of the receiving RF module. Change the receiving RF channel simply by resetting these 8-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 1; bottom slot 0 For examplethe channel dip-switch set above 00000101, channel 05. 8 7 5 6 3 4 2 1 Channel Dip-Switch Settings Part Number:BRXN-433 CH.401 00000001 CH.424 00011000 CH.447 00101111 CH.402 00000010 CH.425 00011001 CH.448 00110000 CH.403 00000011 CH.426 00011010 CH.449 00110001 CH.404 00000100 CH.427 00011011 CH.450 00110010 CH.405 00000101 CH.428 00011100 CH.451 00110011 CH.406 00000110 CH.429 00011101 CH.452 00110100 CH.407 00000111 CH.430 00011110 CH.453 00110101 CH.408 00001000 CH.431 00011111 CH.454 00110110 CH.409 00001001 CH.432 00100000 CH.455 00110111 CH.410 00001010 CH.433 00100001 CH.456 00111000 CH.411 00001011 CH.434 00100010 CH.457 00111001 CH.412 00001100 CH.435 00100011 CH.458 00111010 CH.413 00001101 CH.436 00100100 CH.459 00111011 CH.414 00001110 CH.437 00100101 CH.460 00111100 CH.415 00001111 CH.438 00100110 CH.461 00111101 CH.416 00010000 CH.439 00100111 CH.462 00111110 CH.417 00010001 CH.440 00101000 CH.463 00111111 CH.418 00010010 CH.441 00101001 CH.464 01000000 CH.419 00010011 CH.442 00101010 CH.465 01000001 CH.420 00010100 CH.443 00101011 CH.466 01000010 CH.421 00010101 CH.444 00101100 CH.467 01000011 CH.422 00010110 CH.445 00101101 CH.468 01000100 CH.423 00010111 CH.446 00101110 7.3 Receiver Function Setting 7.3.1 607/608 Receiver Function Setting 7.3.1.1 Set by programming tool 7.3.1.2. Adjust Jumper setting function by decoder board 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 customers 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. JP1 JP2 JP3 JP4 DIP-SW OPENJUMP U AC SHORTJUMP F U S E

(Fig. 12) Alpha 607, 608 models

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Jumper Set table: in-plant setting (default). JP1 JP2 JP3 JP4 Open Open Short Open Short Open Short Power key to activate relay MAIN relay (After turning on the transmitter power and pressing the emergency Stop button) No auto shutdown time on Main relay The receiver MAIN will be deactivated after consecutive 5 minutes of standby time. No auto shutdown time on MAIN and LV relays After one minute of transmitter LV, the MAIN and LV relays will be deactivated. 7th AUX: Normal pushbutton setting 7th AUX: Toggle pushbutton setting Open no Jumper Short put Jumper Remark 1The setting of auto shutdown time can be done by manufacturer or distributor. Setting range: 0~30 minutes. (In-plant setting: 5 minutes) Remark 2When the transmitter voltage is low, LV relay will be activated and siren or lights will be ON. (one second of interval) Remark 3Every 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. 7.3.2 612 Receiver Function Setting 7.3.2.1 Set by programming tool 7.3.2.2. Adjust Jumper setting function by decoder board RReecceeiivveerr ffuunnccttiioonn sseettttiinngg::

Jumper Set table: In-plant setting (default). JP1 JP2 JP3 Open Open Short Open Short Power key to activate relay MAIN relay (After turning on the transmitter power and pressing the emergency stop button) No auto shutdown time on Main relay The receiver MAIN will be deactivated after consecutive 5 minutes of standby time. No auto shutdown time on MAIN and LV relays After one minute of transmitter LV, the MAIN and LV relays will be deactivated. Open No jumper Short Put Jumper Remark 1The setting of auto shutdown time can be done by manufacturer or distributor. Setting range: 0~30 minutes. (In-plant setting: 5 minutes) Remark 2When the transmitter voltage is low, LV relay will be activated and siren or lights will be ON. (One second of interval) Remark 3Every 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.

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7.3.3 Alpha 612 Models Dip-Switch Function Table Model Pushbutton Dip-Switch Setting Description 1 & 2 3 & 4 5 & 6 DIP 1 7 & 8 DIP 2 1 Not Interlocked 0 Interlocked 1 Not Interlocked 0 Interlocked 7 & 8 DIP 3 1 Latching/toggle relay contact 0 Momentary relay contact DIP2 Set at 1 9 & 10 DIP 4 1 Not Interlocked 0 Interlocked 9 10 DIP 5 DIP 6 1 Latching/toggle relay contact 0 Momentary relay contact 1 Latching/toggle relay contact 0 Momentary relay contact DIP4 Set at 1 DIP4 Set at 1 7 & 8 DIP 1 7 8 9 DIP 2 DIP 3 DIP 4 1 Not Interlocked 0 Interlocked 1 Latching/toggle relay contact 0 Momentary relay contact DIP4 Set at 1 1 Latching/toggle relay contact 0 Momentary relay contact 1 Latching/toggle relay contact 0 Momentary relay contact 1 0 Both 1st and 2nd speed contact relay interlocked when pressed to 2nd speed Both 1st and 2nd speed contact relay activated when pressed to 2nd speed DIP4 Set at 1 Both 1st and 2nd speed contact relays activated Only 2nd speed contact relay activated 612C 1 & 2

(2nd speed) DIP 1

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612A 612B 612B DIP 2,3 00 Momentary relay contact 9 DIP 2,3 01 Latching/toggle relay contact DIP 2,3 10 Activate the 3rd speed 1 Latching/toggle relay contact 10 DIP 4 1 & 2

(2nd speed) DIP 1 612D 0 Momentary relay contact 1 0 Both 1st and 2nd speed contact relay interlocked when pressed to 2nd speed Both 1st and 2nd speed contact relay activated when pressed to 2nd speed

DIP 2,3,4 0 Momentary relay contact 1 & 2

(2nd speed) DIP 1 1 0 Both 1st and 2nd speed contact relay interlocked when pressed to 2nd speed Both 1st and 2nd speed contact relay activated when pressed to 2nd speed Both 1st and 2nd speed contact relays activated Only 2nd speed contact relay activated DIP2&3 Must set to 0 all the time

(In-plant set at 0) Both 1st and 2nd speed contact relays activated Only 2nd speed contact relay activated 612E 7 & 8 DIP 2 1 Not Interlocked 0 Interlocked 7 DIP 3 1 Latching/toggle relay contact 0 Momentary relay contact DIP2 Set at 1 612 A/B/C/D/E 11 DIP 7 12 DIP 8 1 Latching/toggle relay contact 0 Momentary relay contact 1 Latching/toggle relay contact 0 Momentary relay contact In-plant all set at 0

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77..44 FFrreeqquueennccyy ((RRFF)) CChhaannnneellss TTaabbllee FREQUENCY 433.075 MHz 433.100 MHz 433.125 MHz 433.150 MHz 433.175 MHz 433.200 MHz 433.225 MHz 433.250 MHz 433.275 MHz 433.300 MHz 433.825 MHz 433.850 MHz 433.875 MHz 433.900 MHz 433.925 MHz 433.950 MHz 433.975 MHz 434.000 MHz 434.025 MHz 434.050 MHz 434.075 MHz 434.100 MHz 434.125 MHz 434.150 MHz 434.175 MHz 434.200 MHz 434.225 MHz 434.250 MHz 434.275 MHz 434.300 MHz 434.325 MHz 434.350 MHz 434.375 MHz DIP-SWITCH SETTING CHANNEL 00000001 00000010 00000011 00000100 00000101 00000110 00000111 00001000 00001001 00001010 00001011 00001100 00001101 00001110 00001111 00010000 00010001 00010010 00010011 00010100 00010101 00010110 00010111 00011000 00011001 00011010 00011011 00011100 00011101 00011110 00011111 00100000 00100001 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

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FREQUENCY 434.400 MHz 434.425 MHz 434.450 MHz 434.475 MHz 434.500 MHz 434.525 MHz 434.550 MHz 434.575 MHz 434.600 MHz 434.625 MHz 434.650 MHz 434.675 MHz 434.700 MHz 434.725 MHz 434.750 MHz 434.775 MHz 433.325 MHz 433.350 MHz 433.375 MHz 433.400 MHz 433.425 MHz 433.450 MHz 433.475 MHz 433.500 MHz 433.525 MHz 433.550 MHz 433.575 MHz 433.600 MHz 433.625 MHz 433.650 MHz 433.675 MHz 433.700 MHz 433.725 MHz 433.750 MHz 433.775 MHz DIP-SWITCH SETTING CHANNEL 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 00100010 00100011 00100100 00100101 00100110 00100111 00101000 00101001 00101010 00101011 00101100 00101101 00101110 00101111 00110000 00110001 00110010 00110011 00110100 00110101 00110110 00110111 00111000 00111001 00111010 00111011 00111100 00111101 00111110 00111111 01000000 01000001 01000010 01000011 01000100

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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 0.1 second and off 1.9 seconds, or no light at all, this indicates the transmitter with batteries needs to be recharged. 3. When any function pushbutton is depressed, the transmitter Status LED displays a red blinking light that is on 0.1 second and off 1.9 seconds. If the voltage is low, the transmitter Status LED will be on0.1 second and off1.9 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. 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. The transmitter Status LED will be blinking on0.5 second and off0.5 second for 30 seconds (Mode 0). Then turn off the transmitter power. 5. 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. 6. Note that the transmitter cannot be hit by outer force, so that malfunction can be prevented. 7. 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. 8. 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. 9. 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.

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Power status light 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 Charging Place transmitter into charger Red light ON Power on when voltage is low BATT<2.2V Red light flash ON_0.1/OFF_1.9 sec

(until power off) Setting failed or invalided Set data by using JUMPER & dip-switch without following rules Red light ON_0.1/OFF_0.1 sec Setting completed JP1 or JP2 inserted Green light ON until power off. EEPROM ID error RF module abnormal ID even number error Pushbutton locked Normal power on EEPROM ID code does not match CPU PLL UNLOCK Setting error Power on pushbutton connected BATT>=2.2V and all the pushbuttons are not depressed STOP status STOP button is pressed Red light ON until power off Red light ON_0.1/OFF_0.1 sec Red light ON_1/OFF_1 sec Red light ON_1.9/OFF_0.1 sec (until power off) All the lights ON_2 sec MODE 0: Red light ON_0.5/ OFF_ 0.5sec, flash 30sec. MODE 1: all the lights OFF Red light flash ON_0.1/OFF_1.9sec Low voltage during operation Normal operation BATT<2.2V and press pushbutton Press pushbutton Green light flash ON_0.1/OFF_1.9 sec 1 2 3 4 5 6 7 8 9 10 11 12

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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 with10.5mm 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 equipments 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.

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2 5 5 mm 4 - O10.5 2 7 8 mm

(Fig. 21) Alpha 604, 607, 608 Models 2 5 5 mm 4 - O10.5 2 7 8 mm

(Fig. 22) Alpha 612 Models 99..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).

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9.4 Receiver system Status LED Display F U S E LED status light Receiver system Status LED Display 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.

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9.4.1 Alpha 612 Receiver System Status LED Display Led Indication ON Power LED display OFF ON OFF BLINK ON OFF SQ, Status LED display Relay LED display Reason Solution Normal-voltage Under-voltage Transmitted signals detected and received No transmitting signal detected 1.Transmitter standby Turn on the transmitter 2.Interference Turn off the transmitter Normal operation Receiver defective Repair decoder board

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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. 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.

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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 (607~608 Models) Weight (607~608 Models)

(612 Models)

(612 Models) 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 (607~608 Models) Weight (607~608 Models)

(612 Models)

(612 Models)

433 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 172mm x 68mm x 33mm 235mm x 68mm x 30mm 300g (include batteries) 350g (include batteries) 433 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 236mm x 80mm 2,000g (include output cable) 3,400g (include output cable)

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1122.. PPAARRTTSS LLIISSTT Transmitter 1. Encoder board (Alpha 607A) Encoder board (Alpha 607B) Encoder board (Alpha 607AT) Encoder board (Alpha 607BT) Encoder board (Alpha 608A) Encoder board (Alpha 608B) 2. Transmitter enclosure (A607 & Alpha 608) 3. Battery cover 4. 2-step pushbutton 1-step pushbutton 5. Pushbutton rubber fixing holder 6. Pushbutton rubber boot (Alpha 607 & 608) 7. Transmitter shock-absorbing rubber (Alpha 607 & 608) 8. Transmitter vinyl protective cover (Alpha 607 & 608) 9.EMS pushbutton 10. EMS red cap (all models) 11. A600 waist strap 12. Rechargeable battery 13. A600 pushbutton direction label Receiver 1. Decoder board (Alpha 607A) Decoder board (Alpha 607B) Decoder board (Alpha 607AT) Decoder board (Alpha 607BT) Decoder board (Alpha 608A) Decoder board (Alpha 608B) 2. 433MHz receiver RF module (All models) 3. Receiver enclosure (Alpha 607, 608) 4. Receiver mounting spring (Alpha 607, 608) 5. Regular Output Contact Relay-blue (All Models) 6. Safety MAIN Contact Relay-DC12V (All Models) 7. Transformer (12/24VDC Alpha 600-608) Transformer (24VAC Alpha 600-608) Transformer (48VAC Alpha 600-608) Transformer (110/120VAC Alpha 600-608) Transformer (220/230VAC Alpha 600-608) Transformer (380VAC Alpha 600-608) Transformer (220/230VAC Alpha 600-608)

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Part No. BEN607A BEN607B BEN607AT BEN607BT BEN608A BEN608B BCT607 BC600 B50001 B50002 BCH608 PRB02 SAR02 VPC02 B50003 EMS01 WS01 RCB01 DL01 BDE607A BDE607B BDE607AT BDE607BT BDE608A BDE608B BRX433 BCR607 RMS600 BDE607BT BDE608A T24VDC T24VAC T48VAC T120VAC T230VAC T380VAC T230VAC 8. 2-meter Output Cable with 5 Common Circuits Cable (24C*2m V3.5, Alpha 607, 608) OC607 9. Optional External 433 MHz Antenna (All Models) ANT433