TABLE OF CONTENTS Page INTRODUCTION 1. 2. SAFETY INSTRUCTION 3. PUSHBUTTON CONFIGURATION
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............................................................................................. 3 3.1 Alpha 500/520 3.2 Alpha 540/560 3.3 Alpha 540T/560T "Select" Settings 3.4 FCC ID Labels and Numbers
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............................................................................... 6 4. TRANSMITTER OUTLINE 4.1 Alpha 500/520 4.2 Alpha 540/560
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....................................................................................................... 8 5. RECEIVER OUTLINE 5.1 Alpha 500/520/540/560 5.2 Alpha 500/520 Internal Assembly 5.3 Alpha 540/560 Internal Assembly
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......................................................................... 11 6. OUTPUT CONTACT DIAGRAM 6.1 Alpha 500/520 Wiring Diagrams .......................................................................... 6.2 Alpha 540 Wiring Diagrams 6.3 Alpha 560 Wiring Diagrams 12
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................................................................................. 14 7. SYSTEM SETTING CONFIGURATION 8. RECEIVER INSTALLATION
................................................................... 15~16 8.1 Preparation For Installation 8.2 Step By Step Installation 8.3 System Testing
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....................................................................................................... 18 9. TRANSMITTER OPERATION 10. TROUBLE SHOOTING 11. SYSTEM SPECIFICATION 12. PARTS LIST
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................................................................................................................. 24 1 1. INTRODUCTION The Alpha 500 series are highly reliable industrial remote control systems. The versatile features of the Alpha 500 series permit its use in many different remote control applications. They can be used to control cranes, hoists, trolleys, mining equipment, building construction equipment, automatic control systems, and many others. The Alpha 500 series radio control 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 which utilizes highly evolved software that have redundant error checking and correcting capabilities to ensure 100 % error -free transmission, decoding, and control of the output relays. These highly evolved software include CRC (Cyclic Redundancy Check codes) and Hamming Codes.
* To insure maximum operating safety, the Alpha 500 series incorporate many safety features. Some of these safety features include receiver self-diagnosing, transmitter pushbutton self-diagnosing, transmitter low voltage detection/warning, transmitter/receiver auto shutdown after 1 minute of transmitter low voltage warning, and receiver MAIN deactivation during transmitter non-usage (programmable from 0~30 minutes).
The encoder/decoder system utilizes advanced microprocessor. The availability of 32,768 sets of unique ID codes will ensure that only commands from the matching control transmitter can be carried out without any interference from other radio systems. A special programmable integrated circuit is used to insure the unit can not simultaneously command conflicting movements. Full SMT design for system stability. The Alpha 500 series radio control system consists of a transmitter handheld, a receiver unit, and a six-foot (2-meter) output cable. The transmitter casing is molded using an industrial strength composite material which is impervious to dust, water, oil, acids, alkaline, heat, sunlight, and as well as being resistant to deformation due to long term use in harsh environments. The pushbuttons are also constructed from industrial strength composite material with a minimum of up to one million cycles. For power saving, the transmitter unit uses special high efficiency power saving circuits that requires only two AA alkaline batteries (UM-3). 2 2. SAFETY INSTRUCTION The Alpha 500 systems are relatively simple to use. However, it is very important to observe the proper safety procedures during operation. When use properly the Alpha 500 systems will enhance productivity and efficiency in the workplace. The following instructions should be strictly followed:
1. Make a daily check of the transmitter casing and pushbuttons. Should it appear that anything could inhibit the proper operation of the transmitter unit, it should be immediately removed from service. 2. The transmitter voltage should be checked on a daily basis. If the voltage is low, the two
"AA" alkaline batteries should be replaced. 3. The emergency stop pushbutton (EMS) should be checked at the beginning of each shift to ensure they are in the proper working order. 4. In the event of an emergency, activate the emergency stop pushbutton immediately. Then turned the power off from the main power source of the equipment. 5. The power switch should be turned off after use and should never left the power on when the unit is unattended. 6. Do not use the same RF channel and ID code as any other unit in use at the same facility. 7. Ensure the wrist strap is worn at all time during operation to avoid accidental dropping. 8. Never operate a crane or equipment with two (2) transmitter units at the same time with same RF channel and ID code. 3 3. PUSHBUTTON CONFIGURATION 3.1 Alpha 500/520 Models 1. Alpha 500 2. Alpha 520
: Up to 2 motions, single-speed pushbuttons, EMS Stop.
: Up to 2 motions, dual-speed pushbuttons, EMS Stop. ON OFF STOP ON OFF STOP
(Alpha 500)
(Alpha 520) Below are many types of pushbutton configuration that are also available upon request. Interlocked (can also be set to non-interlocked). 4 3.2 Alpha 540/560 Models
: Up to 3 motions, single-speed pushbuttons, EMS Stop. 1. Alpha 540S 2. Alpha 540A : Up to 3 motions, single-speed pushbuttons, AUX, EMS Stop. 3. Alpha 540T 4. Alpha 560S 5. Alpha 560A : Up to 3 motions, dual-speed pushbuttons, AUX, EMS Stop. 6. Alpha 560T
: Up to 5 motions, single-speed pushbuttons, Select pushbutton for auxiliary hoist and/or trolley, EMS Stop.
: Up to 3 motions, dual-speed pushbuttons, EMS Stop.
: Up to 5 motions, dual-speed pushbuttons, Select pushbutton for auxiliary hoist and/or trolley, EMS Stop.
(Alpha 540S)
(Alpha 540A)
(Alpha 540T)
(Alpha 560S)
(Alpha 560A)
(Alpha 560T) 5 3.3 Alpha 540T/560T Select Pushbutton Function For Crane system with main and auxiliary hoist, press Select pushbutton in sequence to choose between the two hoists. 1) Power "on" LED-I lit Main hoist active. 2) Press Select LED-II lit Auxiliary hoist active. 3) Press Select LED-I & LED-II lit Both main and auxiliary hoist active with 4) Press Select again LED I lit Back to main hoist active. duplicate movements. 3.4 FCC ID Labels and Numbers FCC ID: XXXALPHA504SERIES FOMOTECH INTERNATIONAL CORP. This Device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference and (2) this device must accept any interference received, including interference that may cause undesired operation. FCC ID: XXXALPHA506SERIES FOMOTECH INTERNATIONAL CORP. This Device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference and (2) this device must accept any interference received, including interference that may cause undesired operation. 6 4. TRANSMITTER OUTLINE 4.1 Alpha 500/520 1 2 3 4 ON OFF STOP 5 6 7 8 9 10 11
(Fig. 1) Front View
(Fig. 2) Back View 12 13 14 15 16 17
(Fig. 3) Front View
(Fig. 4) Back view 1) Transmitter enclosure 2) Power switch (ON/OFF) 3) Pushbutton #2 4) Pushbutton #4 5) Strap ring 6) Emergency stop (EMS) 7) Pushbutton #1 8) Pushbutton # 3 9) System information 10) Battery cover/FCC ID 11) Battery screws 12) Antenna 13) Status LED display 14) Battery contact 15) TX quartz crystal 16) Programming port 17) ID code dip-switch 7 4.2 Alpha 540/560
(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 1) Transmitter enclosure 2) Power switch (ON/OFF) 3) Pushbutton #2 4) Pushbutton #4 5) Pushbutton #6 6) Main hoist and/or trolley*
7) Auxiliary hoist and/or trolley*
8) Strap ring 9) Emergency stop (EMS) 10) Pushbutton #1 11) Pushbutton #3 12) Pushbutton #5 13) Select/AUX pushbutton**
14) System information 15) Battery screws 16) Battery cover/FCC ID 17) Antenna 18) Status LED display 19) Battery contact 20) TX quartz crystals 21) Select/AUX connector port**
22) Programming port 23) ID code dip-switch
* For Alpha 540T/560T models only.
** For Alpha 540/560 A and T models only. 8 5. RECEIVER OUTLINE 5.1 All Models
(Fig. 9) Front View 1) Receiver enclosure 2) Wiring diagram 3) Contact relay LED displays*
4) Model (MOD) 5) Frequency (FREQ)
(Fig. 10) Back View Serial number (S/N) Security code (ID) Frequency channel (CH) Supplied voltage (VOLT) 6) 7) 8) 9) 10) Anti-vibration spring 11) Grounding (GND)
~ AUX (Alpha 540A/560A) and Select (Alpha 540T/560T) Indicator.
* A
* M ~ MAIN and 2nd Speed Indicator.
Green "ON" MAIN activated. Red "ON"
SQ ~ RF Frequency Signal Indicator (Red).
2nd speed activated (Alpha 560 models only).
* AC ~
"ON" Signals received (ON 0.1 second and OFF 0.1 second).
"OFF" No frequency signals received. Power Source Indicator. 9 5.2 Alpha 500/520 Internal Assembly F U S E E S U F FUSE E S U F FUSE
(Fig. 11) Internal Parts Assembly ID code dip-switch 1) RX module 2) Power fuse (AC) 3) Spare fuses & jumpers 4) 5) Contact relay LED displays 6) MAIN fuse 7) Pushbutton #1 and #2 fuse 8) Contact output seat (CN3) 9) Low voltage warning fuse (LV) 10) Pushbutton #3 and #4 fuse 11) AC power input seat (CN2) 12) Output cable mouth 13) Reserved output cable mouth 14) System status LED display 10 5.3 Alpha 540/560 Internal Assembly F U S E F U S E E S U F FUSE E S U F F U S E
(Fig. 12) Internal Parts Assembly 1) RX module 2) Power fuse (AC) 3) Contact output (CN3, CN4) 4) Reserved contact output (CN5) 5) AC power connector (CN2) 6) Antenna 7) System status LED display 8) ID code dip-switch 9) Contact relay LED displays 10) MAIN contact fuse 11) Pushbutton #1 and #2 fuse 12) Pushbutton #3 and #4 fuse 13) Pushbutton #5 and #6 fuse 14) Low voltage fuse (Alpha 540S/560S) 15) Spare fuse & jumpers 16) Output cable mouth 17) Reserved output cable mouth LV/AUX fuse (Alpha 540A/560A) SELECT fuse (Alpha 540T/560T) 11 6. OUTPUT CONTACT DIAGRAM 6.1 Alpha 500/520 Wiring Diagram MAIN 5A U/D 5A E/W 5A LV 5A NC NC NC NC NC NC MAIN 5A U/D 5A E/W 5A LV 5A NC NC NC POWER 1A POWER 1A
(Alpha 500) (Alpha 520) NC No connection 12 6.2 Alpha 540 Wiring Diagrams MAIN 5A U/D 5A E/W 5A LV,AUX 5A N/S 5A NC NC NC NC NC MAIN 5A U/D 5A E/W 5A LV,AUX 5A N/S 5A NC NC MAIN 5A U/D 5A E/W 5A LV,AUX 5A N/S 5A NC NC POWER 1A POWER 1A POWER 1A
(Alpha 540A)
(Alpha 540T) NC No connection
(Alpha 540S) 13 6.3 Alpha 560 Wiring Diagrams MAIN 5A U/D 5A E/W 5A LV,AUX 5A N/S 5A MAIN 5A U/D 5A E/W 5A LV,AUX 5A N/S 5A POWER 1A POWER 1A
(Alpha 560A)
(Alpha 560T) MAIN 5A U/D 5A E/W 5A LV,AUX 5A N/S 5A NC POWER 1A NC No connection
(Alpha 560S) 14 7. SYSTEM SETTING CONFIGURATION How To Set Jumper Functions OPENJUMP SHORTJUMP Manufacture settings. JP1 JP2 JP3 JP4 Open Short Open Short Open Short Open Short
* T models do not have LV relay output for external connection. Manufacture preset for all Alpha 540A/T and 560A/T models Press the AUX/SELECT button to activate all transmitter key functions and the receiver MAIN after transmitter power on and After EMS reset Manufacture preset for all Alpha 500/520/540S/560S models Turn on the power switch to activate all transmitter key functions and the receiver MAIN. After EMS reset, turn the transmitter power switch off and then on again to activate all transmitter key functions and the receiver MAIN. Receiver MAIN stays "on constantly. After 5 minutes of transmitter non-usage (pushbuttons not pressed), receiver MAIN will be deactivated. (see note A) After 1 minute of low voltage warning, only the transmitter power will be deactivated. After 1 minute of low voltage warning, both the transmitter power and the receiver MAIN will be deactivated. (see note B) AUX in normal key function (for Alpha 540A/560A only). AUX in toggled key function (for Alpha 540A/560A only). Note A MAIN shut-off time during system non-operation can be set from 0~30 minutes via external programmer;
manufacture preset at five (5) minutes. To resume operation after five minutes, just press any pushbutton to reactivate the receiver MAIN. Note B:
If transmitter lo w voltage occurs during operation, other than transmitter itself will display visual warnings, it will also send out a low voltage signal to the receiver to activate its external low voltage warning device. By connecting a horn, buzzer, or siren to the LV-relay output will ensure that the operator will clearly notice the low voltage warning even in hard to see or hear environments. After one minute of low voltage warning, to insure maximum safety, both the transmitter power and the receiver MAIN will be deactivated. For proper battery replacement, you must first turn off the transmitter power, replace the batteries, and then turn the power switch back on again to reactivate the transmitter and the receiver unit. 15 JP1 (Manufacture preset for the Alpha 500/520/540S/540A/560S/560A models) JP1 Short Transmitter Deactivated Reset EMS Press EMS Activated MAIN MAIN On Reset
"Power Switch"
MAIN Activated
* Reset Power Switch Turn the transmitter power switch off and then on again. JP1 Open Not Applicable JP1 (For the Alpha 540T/560T models - Manufacture preset at JP1-Open) JP1 Short Transmitter On MAIN Activated Press EMS MAIN Deactivated Reset EMS Reset
"Power Switch"
MAIN Activated
* Reset Power Switch Turn the transmitter power switch off and then on again. Transmitter On MAIN Activated Press EMS MAIN Deactivated Reset EMS Press Any Pushbutton MAIN Activated JP1 Open JP2 JP2 Short 5 minutes of non-transmission of commands MAIN Deactivated
* Programmable from 1~30 minutes via external programmer. JP3 JP3 Short System ON Work in Progress Transmitter Low Voltage Occurs LV Warning Change Batteries within 1 minute No MAIN Deactivated Yes JP4 (For Alpha 540A/560A models only) JP4 Short Aux-Toggle function JP4 Open Aux-Normal function 16 8. RECEIVER INSTALLATION 8.1 Preparation For Installation 1. Required Tools:
(1) Flat Head Screwdriver (-)
(2) Phillips Head Screwdriver (+)
(3) Multi-Meter
(4) 14mm Wrench x 2
(5) 10.5mm Drill-Bit 2. Ensure receiver is not set to the same channel and ID code as any other units in operation at the same facility. 3. Prior to installation, make sure the equipment itself is working properly. 4. Use the multi-meter to check the voltage source available and ensure receiver voltage setting is correct for this voltage. 5. Prior to installation, switch off the main power source to the equipment. 8.2 Step By Step Installation 1. 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. 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 (see diagram next page). 6. Drill a hole on the control panel (10.5mm) 7. Tightened the two bolt nuts provided. 8. 9. For system wiring, please refer to the output contact diagram on page 12~14 or on the If the control panel has a plastic surface, extended grounding wire should be used. receiver enclosure. 10. Ensure all wiring is correct and safely secured and all screws are fastened. 17 8.3 System Testing 1. Connect the power source to the receiver and test the operation of each function to ensure it operates in the same manner as the pendant controller. 2. Ensure the receiver MAIN can be properly controlled by the remote control. 3. Ensure the limit switches on the equipment that limit all travels are working properly. 4. Ensure the pendant controller is located in a safe location where it would not interfere with remote operation. 18 9. TRANSMITTER OPERATION 1. Make sure the (2) alkaline batteries are installed correctly. Do make sure to use alkaline type batteries for longer operating time between battery replacements. 2. Turn on the power switch located on the top left hand corner of the transmitter unit (see diagram next page). Immediately after turning on the transmitter unit, the status LED indicator located at the center of the power switch will display a green light for up to 1.5 seconds, do make sure that the red EMS pushbutton is in its elevated position. If the status LED displays a red blinking light (ON 0.1 second and OFF 2.0 seconds) or no light at all, then you must replace a set of new batteries before operation. If the red blinking light is ON 2.0 seconds and OFF 0.1 second, the transmitter unit will deactivates itself (locked) due to a jammed or defected pushbutton contact. This important safety feature is designed to prevent unexpected crane movement at system start up caused by a defected pushbutton contact. After transmitter self-diagnosing procedure is completed without any problems detected
(within 1 second), all transmitter key functions and the receiver MAIN will be activated. 3. Alpha 540T/560T model When the transmitter unit is turned on to begin work, the LED-I will light up to indicate only the main hoist and/or trolley is activated. If you want to activate the auxiliary hoist and/or trolley, press the "Select" pushbutton, and the LED display will now switched from LED-I to LED-II to indicate that only the auxiliary hoist and/or trolley is activated. Press "Select" again to have both main and auxiliary hoist and/or trolley activated at the same time (both LED-I and LED-II lit). To switch back to the main hoist and/or trolley activation, just press the "Select" pushbutton once again. (please refer to section 3.3 on page 6) Every time when the transmitter unit is turned off and then on again, the "Select "
setting will resets itself to LED-I (back to main hoist and/or trolley active) 4. Alpha 540T/560T model "Select" setting can not be changed while other command pushbuttons are in use (command pushbuttons pressed). To insure maximum safety,
"select" settings (I, II, I&II) can only be changed when all command pushbuttons are in their neutral position (command pushbuttons not pressed). 19 5. In case of an emergency, press down the red EMS pushbutton will immediately deactivates the receiver MAIN. When the EMS pushbutton is activated, the status LED on the transmitter unit will display a red blinking light to indicate EMS activation (ON 0.5 second and OFF 0.5 second). To reactivate the system again, turn the EMS pushbutton clockwise so that the red cap will elevate to its non-active position. Then turn the transmitter power switch off and then on again to activate all transmitte r key functions and the receiver MAIN. As for the Alpha 540T and 560T models, to reactivate the system after EMS reset, just press any command pushbutton (please refer to JP1 setting on page 15 and 16). 6. Please note that conflicted movements are inte rlocked to one another for safety purpose. Pressing conflicted commands at the same time will result in a non-transmission. LED DISPLAY 20 10. TROUBLE SHOOTING Should the operator find the equipment not operating normally, please check the chart below for simple trouble shooting steps. SYMPTOM REASON SOLUTION Transmitter does not communicate to 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 to receiver. No power to the receiver (AC power indicator on the receiver unit not lit). Outputs do not operate correctly. Low or no transmitting power from the transmitter unit. Blown fuse or no input power connection. Receiver configuration is not set properly or output wiring is incorrect. Turn on the transmitter and with EMS in its elevated position. 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. Ensure power input to the receiver unit is correct. If power indicator
(AC) is still not lit, please check the receiver for any burned fuse. Please refer to section 6 and 7 to ensure receiver is correctly wired and configured for your application. Receiver System Status LED Display (please refer to Fig. 11 on page 10). TYPE LED INDICATION
(Red) REASON 1 2 3 4 5 6. Constant red light. ON 1.0 second OFF 1.0 second EEPROM error, manufacture reprogramming required. Incorrect ID code, please readjust accordingly. Dim or no light. Under-voltage, check the main power supply. ON 2.0 seconds OFF 0.1 second ON 0.1 second OFF 2.0 seconds ON 0.1 second OFF 0.1second System error, manufacture reprogramming required. System normal with transmitter pushbutton either in neutral or in transmitter power off position. System normal with transmitter pushbutton in non-neutral position (pressed). 21 11. SYSTEM SPECIFICATION Transmitter Unit Frequency Range Transmitting Range Hamming Distance Channel Spacing Frequency Control Frequency Drift Frequency Deviation Spurious Emission Transmitting Power Emission Antenna Impedance Enclosure Source Voltage Current Drain Operating Temp. Dimension (Alpha 500/520) Dimension (Alpha 540/560) Weight (Alpha 500/520) Weight (Alpha 540/560)
301 MHz 150 feet 4 25KHz Quartz Crystals
< 5ppm @ -20 ~ +70
< 1ppm @ 25
- 50dB
~1mW F1D 50 ohms IP-66 3.0 VDC (AA alkaline batteries X 2) 10 ~ 20 mA
-20 ~ +70 134mm X 68mm X 30.5mm 166mm X 67.5mm X 30mm 7.05oz. (include batteries) 8.82oz. (include batteries) 22 Receiver Unit Frequency Range Channel Spacing Hamming Distance Frequency Control Frequency Drift Frequency Deviation Sensitivity Antenna Impedance Data Decoder Reference Responding Time Enclosure Source Voltage Power Consumption Operating Temp. Output Contact Rating Dimension Weight (Alpha 500/520) Weight (Alpha 540/560)
301 MHz 25KHz 4 Quartz Crystals
< 5ppm @ -20 ~ +70
< 1ppm @ 25 0.4V 50 ohms Quartz Crystals 40mS (Normal) IP-65 48~380 VAC, 50/60 Hz. 11VA
-20 ~ +70 250V @ 10A 310mm X 134mm X 72mm 57.3oz. (include output cable) 60oz. (include output cable) 23 12. PARTS LIST 1. TX Module/Encoder Board (Alpha 500) TX Module/Encoder Board (Alpha 520) TX Module/Encoder Board (Alpha 540S) TX Module/Encoder Board (Alpha 540A) TX Module/Encoder Board (Alpha 540T) TX Module/Encoder Board (Alpha 560S) TX Module/Encoder Board (Alpha 560A) TX Module/Encoder Board (Alpha 560T) 2. RX Module (All models) 3. Decoder/Relay Board (Alpha 500) Decoder/Relay Board (Alpha 520) Decoder/Relay Board (Alpha 540S) Decoder/Relay Board (Alpha 540A) Decoder/Relay Board (Alpha 540T) Decoder/Relay Board (Alpha 560S) Decoder/Relay Board (Alpha 560A) Decoder/Relay Board (Alpha 560T) 4. Transmitter Enclosure (Alpha 500/520) 5. Receiver Enclosure (All models) 6. Pushbutton (Dual speed) Pushbutton (Single speed) 7. EMS Red Cap 8. Wrist Strap 9. Pushbutton Rubber Boot 10. Direction labels (All types) 11. Transformer (48 VAC) Transmitter Enclosure (Alpha 540S/560S) Transmitter Enclosure (Alpha 540A/560A) Transmitter Enclosure (Alpha 540T/560T) Transformer (110~120 VAC) Transformer (220~230 VAC) Transformer (380 VAC) 12. Contact Relay BEN50 BEN52 BEN54S BEN54A BEN54T BEN56S BEN56A BEN56T BRX10S BDR50 BDR52 BDR54S BDR54A BDR54T BDR56S BDR56A BDR56T BCT50 BCT54S BCT54A BCT54T BCR50 B50001 B50002 EMS01 WS01 PRB01 DL01 T48V T120V T230V T380V RLY01 24