1. SSAAFFEETTYY IINNSSTTRRUUCCTTIIOONN The Alpha 608 is relatively simple to use, however, it is very important to observe the proper safety procedures before, during, and after operation. When used properly, the Alpha 608 will enhance safety, productivity and efficiency in the workplace. Do not change the IDs on transmitter encoder and receiver decoder boards at will. The following procedures should be strictly followed:
1. 2. Check the transmitter casing and pushbuttons daily. Should any damage that could inhibit the proper operation of the transmitter be found the unit should be immediately removed from service. Check the transmitter voltage whenever it is operated. 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. 3. 4. 5. In the event of an emergency press down the EMS button will immediately deactivates the receiver MAIN relay and the transmitter power. Then turned the power off from the main power source to the crane or equipment. 6. Do not use the same RF channel and ID code as any other system in use at the same facility or within 300-meter distance. 7. 8. Ensure the waist belt is worn at all time during operation to avoid accidental damage to the transmitter. Never operate a crane or equipment with two transmitters at the same time with the same RF channel and ID code, as it will cause radio interference. FCC 15.21: Changes or modifications are not expressly approved by the manufacturer could void the users authority to operate the equipment. Operations is subject to the following two conditions: (1) this device may cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.
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2. PPUUSSHHBBUUTTTTOONN CCOONNFFIIGGUURRAATTIIOONN 2.1 Alpha 607 & 608 Models 607A --
607B --
607AT --
607BT --
608A --
608B --
(7) single speed pushbuttons
(6) double speed pushbuttons + (1) single speed pushbuttons
(6) single speed pushbuttons + (1) single speed pushbutton + (1) selector pushbutton
(6) double speed pushbuttons + (1) single speed pushbutton + (1) selector 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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33.. TTRRAANNSSMMIITTTTEERR OOUUTTLLIINNEE 3.1 TRANSMITTER OUTLINE Size189mm X 68mm X 30mm
(Fig.1) Transmitter Outline 3.2 TRANSMITTER INTERNAL ASSEMBLY
(1) Internal antenna
(2) Status LED display
(3) Battery contact
(4) AUX micro-button connector*
(5) Programming port
(6) ID code dip-switch
(7) JP2 setting pin
(8) JP1 setting pin
(Fig.2) Front View (Fig.3) Back View
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3.3 TX INTERNAL MODULE encoder board
(Fig.4) Encoder board 3.4 Transmitter shoulder strap
(1)
(2)
(1) Shock-absorbing rubber
(2) Shoulder strap
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44.. RREECCEEIIVVEERR OOUUTTLLIINNEE 44..11 EExxtteerrnnaall AAsssseemmbbllyy SIZE300mm X 230mm X 86mm 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 F4 5A BRIDGE LV/AUX1
/AUX2 F5 5A MAIN F6 5A POWER F1 FF1 F I 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..22 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 Receiving RF module 1) 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*
External antenna port 9) 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 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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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(00011) Correct setting
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77.. RREECCEEIIVVEERR SSEETTTTIINNGGSS 77..11 HHooww ttoo SSeett RReecceeiivveerr IIDD CCooddeess 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. 7.2 Receiver RF Channel Setting There are 20 sets of user-adjustable receiving RF channels that can be set manually via a 5-position dip-switch located to the right of the receiving RF module. Change the receiving RF channel simply by resetting these 5-position dip-switch. For the location of the receiving RF module, please refer to fig. 15, 16, and 18 on page 11, 12, and 14. 1 2 3 4 5 Top slot 1; bottom slot 0 For examplethe channel dip-switch set above 00101, channel 05.
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7.3 Receiver Function Setting 7.3.1 Set by programming tool 7.3.2 Adjust Jumper setting function by decoder board 608 function can be changed simply by adjusting Jumper setting. Please refer to Jumper Set Table as below. Receiver function setting:
A. Select any pushbutton or ON/OFF power switch to start the system. The MAIN relay will be activated when system is started. (after the receiver power is started and emergency stop button is elevated) B. The MAIN relay auto shutdown time can be set as 3 minutes or depends on 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 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: Togglel 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: 3 minutes) Remark 2When the transmitter voltage is low, LV relay will be activated and siren or lights will be ON. (one second of interval)
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77..44 FFrreeqquueennccyy ((RRFF)) CChhaannnneellss TTaabbllee Band 433MHz 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 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 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
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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. For battery charging or replacement, please refer to instruction next page. When any function pushbutton is depressed, the transmitter Status LED displays a red blinking light that is on 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. 3. EMS & Restarting _ In case of an emergency, press down the red emergency stop button (EMS) will immediately deactivates the transmitter and receiver MAIN relay. The transmitter Status LED will be blinking on0.5 second and off0.5 second for 30 seconds (Mode 0). Then turn off the transmitter power. 4. The emergency stop button is a right-rotate momentary spring-return type. To turn on the transmitter and activate the MAIN relay, please elevate the emergency stop button again and rotate the transmitter power key to ON position. 5. Note that the transmitter cannot be hit by outer forces, so that malfunction can be prevented. 6. The operating temperature is -10 ~ +50. Avoid operating the transmitter in high temperature workshop. If operating temperature is higher than 50,the auto shutdown protection installed inside CPU will shut down the transmitter and deactivate the MAIN relay. 7. To operation normally, the battery power has to be over 2.2V. If the voltage is lower than 2.2V, the system cannot be started and low voltage will be showed until the MAIN is completely shutdown. 8. If the power voltage is lowered than 2.2V when transmitter is operated, the LV code will be 1 and low voltage status light will be shown. The transmitter will stop sending signals when voltage is lower than 2.0V.
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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 Power on when voltage is low Solution BATT<2.2V LED Indication Red light flash ON_0.1/OFF_1.9 sec
(until power_off) Setting failed invalided Setting completed EEPROM ID error RF module abnormal ID even number error Pushbutton locked Normal power_on or Set data by using JUMPER & dip-switch without following rules Red light ON_0.1/OFF_0.1 sec JP1 or JP2 inserted Green light ON until power_off. EEPROM ID code does not match CPU 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) PLL UNLOCK Setting error power_on pushbutton connected BATT>=2.2V and all the pushbuttons are not depressed 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 Green light flash ON_0.1/OFF_1.9 sec STOP status STOP button is pressed voltage Low operation during BATT<2.2V and press pushbutton Normal operation Press pushbutton
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2 3 4 5 6 7 8 9 10 11 12 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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(Fig. 13) Alpha 607, 608 models
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9.4 Receiver system Status LED Display LED status light F U S E 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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1111.. TTRROOUUBBLLEE SSHHOOOOTTIINNGG Should the operator find the equipment not operating normally, please check the chart below for simple trouble shooting tips. PROBLEM POSSIBLE REASON SOLUTION Transmitter does not communicate with the receiver. Transmitter and the receiver are not on the same RF channel
(SQ lamp not lit) or ID code. 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. 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. Transmitter does not communicate with the receiver. Transmitter is turned on with the EMS activated (pressed down). Please refer to section 6 and 7 to ensure receiver is correctly wired and configured for your application. Elevate the EMS first and then turn the power switch off and then on again.
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1122.. 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) 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)
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 285g (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 1,625g (include output cable)
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