Fomotech Alpha 600XS Series, Operations & Parts Manual

Page 1: ...r ri ie es s I I n n d d u u s s t t r r i i a a l l R R a a d d i i o o R R e e m m o o t t e e C C o o n n t t r r o o l l S S y y s s t t e e m m O Op pe er ra at ti io on n P Pa ar rt ts s M Ma an nu ua al l Fomotech International Corp ...

Page 2: ...OUTPUT CONTACT DIAGRAMS 5 1 Alpha 604 Models Double Output 14 5 2 Alpha 607 Models Double Output 15 5 3 Alpha 608 Models Double Output 17 5 4 Alpha 612 Models Double Output 19 6 SYSTEM CONFIGURATIONS 6 1 How to Set ID Codes 26 6 2 Transmitter RF Channel Setting 27 7 RECEIVER SETTING 7 1 How to Set α604 607 608 612 Receiver ID Codes 27 7 1 1 How to set α604 607 608 612 Receiver ID Codes 27 7 1 2 Ho...

Page 3: ...llation 38 9 2 1 Select the location 38 9 2 2 Commissioning steps 38 9 3 System Testing 39 9 4 Receiver System Status LED Display 39 10 BATTERY CHARGER 10 1 Charger Operation 41 10 2 Battery Charger LED Status Light 42 11 TROUBLE SHOOTING 43 12 SYSTEM SPECIFICATION 44 13 PARTS LIST 46 ...

Page 4: ... etc is closed to the transmitter or receiver as it might cause interference 5 Do not change the IDs on transmitter encoder and receiver decoder boards at will 6 Check the transmitter casing and pushbutton daily Should any damage that could inhibit the proper operation of the transmitter be found the unit should be immediately removed from services 7 Check the transmitter voltage whenever it is op...

Page 5: ...a 604BS 4 double speed pushbuttons Alpha 604AS Alpha 604BS 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 STOP POWER 上 下 西 東 FOM TECH EN ISO 13849 1 2008 PLd STOP POWER 上 下 西 東 FOM TECH EN ISO 13849 1 2008 PLd ...

Page 6: ...ne speed pushbuttons 5 Alpha 612DS 10 two speed 2 one speed pushbuttons 6 Alpha 612E 1S 6 two speed 5 one speed pushbuttons I II select pushbutton 7 Alpha 612E 2S 8 two speed 3 one speed pushbuttons I II select pushbutton For cranes with auxiliary hoist and trolley changeover function Alpha 612C 1S Alpha 612C 2S Alpha 612DS Alpha 612E 1S Alpha 612E 2S Alpha 612AS Alpha 612BS STOP POWER STOP POWER ...

Page 7: ...tter Front View Fig 2 Transmitter encoder board and induction charging board Fig 3 Transmitter Internal Assembly 1 Internal antenna 6 Programming port 2 Transmitting RF module 7 E stop connecting port 3 Status LED display 8 Function dip switch 4 Battery contact 9 JP2 setting pin 5 Transmitter induction charging port 10 JP1 setting pin ...

Page 8: ... red light 3 1 Power input socket AC100 240V 3 2 Power input socket DC12 24V 4 Charger holder optional Please refer to below figure for the installation holes 1 Charging cable 2 Charger charging cable included optional 3 Transmitter shock absorbing rubber 4 Shoulder strap 5 Rechargeable batteries optional Fig 4 Battery Charger Holder ...

Page 9: ... TROLLEY HOIST AUX2 60947 EMS EN ISO 13849 1 2008 PLd 1 2 3 7 8 9 4 5 6 11 10 Fig 5 Front View Fig 6 Back View 1 Receiver enclosure 5 System frequency 9 System serial number 2 Wiring diagram 6 Supplied voltage 10 Anti vibration spring 3 Receiver LED displays 7 System ID code 11 Grounding GND 4 Type model 8 System RF channel A AUX Relay Contact Indicator for Alpha 607A 608B models only M MAIN and 2...

Page 10: ...p switch 11 RF channel dip switch 12 Contact relay LED display 13 Pushbutton 1 and 2 fuse 5 0A 14 MAIN fuse 5 0A 15 Contact output seat CN3 16 Low voltage LV fuse 5 0A 17 Contact output seat CN4 18 Pushbutton 3 and 4 fuse 5 0A 19 AC power input seat CN2 20 Cable gland output cable Power module Including transformer or full voltage module Please refer to 4 3 α604 α608 α612 Receiver Power Fuse List ...

Page 11: ... Antenna 10 System Status LED display 11 External antenna port 12 ID code dip switch 13 RF channel dip switch 14 Contact relay LED display 15 Pushbutton 1and 2 fuse 5 0A 16 Contact output seat CN3 17 MAIN contact fuse 5 0A 18 Pushbutton 3 and 4 fuse 5 0A 19 Pushbutton 5 and 6 fuse 5 0A 20 Contact output seat CN4 21 LV AUX fuse 5 0A 22 Cable gland output cable Power module Including transformer or ...

Page 12: ...Al lp ph ha a 6 61 12 2 M Mo od de el ls s E Ex xt te er rn na al l A As ss se em mb bl ly y SIZE 300mm X 230mm X 86mm Fig 9 External Parts Assembly 1 Transparent top cover 3 Mounting bracket with shock absorbers 2 Light gray colored base 4 Cable gland Cord grip ...

Page 13: ...lay fuse F3 5 0A 22 MAIN relay fuse F6 5 0A 10 Pushbutton 5 and 6 relay fuse F3 5 0A 23 Pushbutton A4 relay fuse F8 5 0A 11 Pushbutton A1and A2 relay fuse F5 5 0A 24 Primary power fuse see below 4 3 12 Pushbutton A3 relay fuse F7 5 0A 25 Power port CN2 13 Pushbutton 1 and 2 relay fuse F2 5 0A 26 Low voltage LV relay fuse F9 5 0A POWER AC Power Source Indicator on AC input power supplied off No AC ...

Page 14: ...2 R Re ec ce ei iv ve er r P Po ow we er r F Fu us se e L Li is st t Type Parts No Voltage DC12V 24V AC24 AC36 48V AC100 120 V AC220 240 V AC380 440 V AC100 240V Full Voltage α604 α607 α608 FF1 3A 1A 2A F1 3A 2A 0 5A 1A α612 FF2 2A 2A FF1 3A 1A F1 3A 2A 0 8A ...

Page 15: ... AG GR RA AM MS S 5 5 1 1 A Al lp ph ha a 6 60 04 4 M Mo od de el ls s M MA AI IN N R Re el la ay y D Du ua al l O Ou ut tp pu ut t Relay Description MAIN 1 MAIN relay 1 MAIN 2 MAIN relay 2 U1 U 1 speed U2 U 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed EW2 E W 2 spped LV Transmitter low voltage ...

Page 16: ...de el ls s M MA AI IN N R Re el la ay y D Du ua al l O Ou ut tp pu ut t Relay Description U1 U 1 speed U2 U 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E W2 E W 2 speed N1 N 1 speed S1 S 1 speed N S2 N S 2 speed LV Transmitter low voltage AUX1 AUX1 MAIN 1 MAIN relay 1 MAIN 2 MAIN relay 2 ...

Page 17: ...S N Relay Description U1 U 1 speed U2 U 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E W2 E W 2 speed N1 N 1 speed S1 S 1 speed N S2 N S 2 speed LV Transmitter low voltage SEL I SELECT I SEL II SELECT II MAIN 1 MAIN relay 1 MAIN 2 MAIN relay 2 ...

Page 18: ... ls s M MA AI IN N R Re el la ay y D Du ua al l O Ou ut tp pu ut t Relay Description U1 U 1 speed U2 U 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E W2 E W 2 speed N1 N 1 speed S1 S 1 speed N S2 N S 2 speed LV Transmitter low voltage AUX1 AUX1 AUX2 AUX2 MAIN 1 MAIN relay 1 MAIN 2 MAIN relay 2 ...

Page 19: ...U D W E S N Relay Description U1 U 1 speed U2 U 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E W2 E W 2 speed N1 N 1 speed S1 S 1 speed N S2 N S 2 speed SEL II SELECT II AUX1 AUX1 SEL I SELECT I MAIN 1 MAIN relay 1 MAIN 2 MAIN relay 2 ...

Page 20: ... IN N R Re el la ay y D Du ua al l O Ou ut tp pu ut t Relay Description Relay Description U1 U 1 speed D1 D 1 speed E1 E 1 speed W1 W 1 speed MAIN 2 MAIN relay 2 MAIN 1 MAIN relay 1 N1 N 1 speed S1 S 1 speed A1 1 A1 1 speed A2 1 A2 1 speed A3 1 A3 1 speed A4 1 A4 1 speed LV Transmitter low voltage RES 1 RES 1 RES 2 RES 2 Alpha 612AS ...

Page 21: ...cription Relay Description U1 U 1 speed D1 D 1 speed E1 E 1 speed W1 W 1 speed MAIN 2 MAIN relay 2 MAIN 1 MAIN relay 1 N1 N 1 speed S1 S 1 speed A1 1 A1 1 speed A2 1 A2 1 speed A3 1 A3 1 speed I SELECT I II SELECT II LV Transmitter low voltage RES 1 RES 1 RES 2 RES 2 Alpha 612BS ...

Page 22: ... U1 U 1 speed U2 U 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E2 W2 E W 2 speed MAIN 2 MAIN relay 2 MAIN 1 MAIN relay 1 N1 N 1 speed S1 S 1 speed N2 S2 N S 2 speed A1 1 A1 1 speed A2 1 A2 1 speed A3 1 A3 1 speed A4 1 A4 1 speed LV Transmitter low voltage RES 1 RES 1 RES 2 RES 2 Alpha 612C 1S ...

Page 23: ...d U2 U 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E2 W2 E W 2 speed MAIN 2 MAIN relay 2 MAIN 1 MAIN relay 1 N1 N 1 speed S1 S 1 speed N2 S2 N S 2 speed A1 1 A1 1 speed A2 1 A2 1 speed A1 2 A2 2 A1 A2 2 speed A3 1 A3 1 speed A4 1 A4 1 speed LV Transmitter low voltage RES 1 RES 1 RES 2 RES 2 Alpha 612C 2S ...

Page 24: ...D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E2 W2 E W 2 speed MAIN 2 MAIN relay 2 MAIN 1 MAIN relay 1 N1 N 1 speed S1 S 1 speed N2 S2 N S 2 speed A1 1 A1 1 speed A2 1 A2 1 speed A1 2 A2 2 A1 A2 2 speed A3 1 A3 1 speed A3 2 A3 2 speed A4 1 A4 1 speed A4 2 A4 2 speed LV Transmitter low voltage RES 1 RES 1 RES 2 RES2 Alpha 612DS ...

Page 25: ...1 speed U2 U 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E2 W2 E W 2 speed MAIN 2 MAIN relay 2 MAIN 1 MAIN relay 1 N1 N 1 speed S1 S 1 speed N2 S2 N S 2 speed A1 1 A1 1 speed A2 1 A2 1 speed A3 1 A3 1 speed I SELECT I II SELECT II LV Transmitter low voltage RES 1 RES 1 RES 2 RES 2 Alpha 612E 1S ...

Page 26: ... 2 speed D1 D 1 speed D2 D 2 speed E1 E 1 speed W1 W 1 speed E2 W2 E W 2 speed MAIN 2 MAIN relay 2 MAIN 1 MAIN relay 1 N1 N 1 speed S1 S 1 speed N2 S2 N S 2 speed A1 1 A1 1 speed A2 1 A2 1 speed A1 2 A2 2 A1 A2 2 speed A3 1 A3 1 speed I SELECT I II SELECT II LV Transmitter low voltage RES 1 RES 1 RES 2 RES 2 Alpha 612E 2S ...

Page 27: ... and put short boot on the 1st and 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 th...

Page 28: ... frequency needed by changing the dip switch setting Repeat the previous steps to set another frequency Example Set channel as 03 00000011 Correct setting 7 7 R RE EC CE EI IV VE ER R S SE ET TT TI IN NG GS S 7 7 1 1 H Ho ow w t to o s se et t α α6 60 04 4 6 60 07 7 6 60 08 8 6 61 12 2 R Re ec ce ei iv ve er r I ID D C Co od de es s 7 7 1 1 1 1 H Ho ow w t to o s se et t α α6 60 04 4 6 60 07 7 6 6...

Page 29: ...8 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 7 1 1 2 2 H Ho ow w t to o s se et t α α6 61 12 2 R Re ec ce ei iv ve er r I ID D C Co od de e Please refer to Fig 18 Internal Part...

Page 30: ...1 of Jumper Set Table on Page 41 42 for α604AS BS 607AS ATS BS BTS and 608AS BS 2 Refer to JP3 2 α608T only on Page 42 for α608ATS BTS 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 depen...

Page 31: ...l Remark 3 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 the memory 7 3 2 α612 Receiver Function Setting 7 3 2 1 Set by programming tool Input from programming port CN3 and CN5 The data of CN3 and CN5 have to be identical 7 3 2 2 Adjust Jumper setting function on decoder board R Re ec ce ei i...

Page 32: ...ed 0 Interlocked 7 8 DIP 3 1 Latching toggle relay contact DIP2 must be set at 1 0 Momentary relay contact 9 10 DIP 4 1 Not Interlocked 0 Interlocked 9 DIP 5 1 Latching toggle relay contact DIP4 must be set at 1 0 Momentary relay contact 10 DIP 6 1 Latching toggle relay contact 0 Momentary relay contact 612BS 7 8 DIP 1 1 Not Interlocked 0 Interlocked 7 DIP 2 1 Latching toggle relay contact 0 Momen...

Page 33: ...ed separately 0 Two contact relays activated When 2nd speed contact relay is activated 1st speed contact relay is activated at the same time 612E 1S 7 8 DIP 2 1 Not Interlocked 0 Interlocked 7 DIP 3 1 Latching toggle relay contact DIP2 must be set at 1 0 Momentary relay contact 8 DIP 4 1 Latching toggle relay contact 0 Momentary relay contact 612 AS C 1S C 2S DS 11 DIP 7 1 Latching toggle relay co...

Page 34: ...emove the Y terminal from the other end of the wire the n screw the position originally with Y terminal tightly 2 2 Select the voltage needed base on the label of the transformer Unscrew the position selected put the Y terminal into the position selected and screw it tightly Transformer type no K 2367 Position AC 110V AC 100V AC 125V Position AC 240V AC 200V AC 240V Transformer type no K 2368 Posi...

Page 35: ...MHz 00001110 14 434 750 MHz 00110000 48 433 925 MHz 00001111 15 434 775 MHz 00110001 49 433 950 MHz 00010000 16 433 325 MHz 00110010 50 433 975 MHz 00010001 17 433 350 MHz 00110011 51 434 000 MHz 00010010 18 433 375 MHz 00110100 52 434 025 MHz 00010011 19 433 400 MHz 00110101 53 434 050 MHz 00010100 20 433 425 MHz 00110110 54 434 075 MHz 00010101 21 433 450 MHz 00110111 55 434 100 MHz 00010110 22 ...

Page 36: ...indicates the transmitter with batteries needs to be recharged For battery charging or replacement please refer to instruction next page 3 When any function pushbutton is depressed the transmitter Status LED displays a green blinking light that is on 0 1 second and off 1 9 seconds If the voltage is low the transmitter red Status LED will be on 0 1 second and off 1 9 seconds this indicates the tran...

Page 37: ... lower than 2 2V when transmitter is operated the LV code will be 1 and low voltage status light will be shown For standard version the transmitter will stop sending signals when voltage is lower than 2 0V for EN ISO 13849 1 version the transmitter will stop sending signals when voltage is lower than 1 8 STOP POWER STOP POWER STOP press lock emergency stop STOP Elevate clockwise reset Turn on the ...

Page 38: ... more than 2 seconds Blinking red light green light ON_0 1 OFF_0 1 second 14 Normal operation Press pushbutton Green light flash ON_0 1 OFF_1 9 sec 9 9 R RE EC CE EI IV VE ER R I IN NS ST TA AL LL LA AT TI IO ON N 9 9 1 1 P Pr re ep pa ar ra at ti io on n f fo or r I In ns st ta al ll la at ti io on n 1 Required Tools for Receiver Installation 1 Flat Head Screwdriver 2 Phillips Head Screwdriver 3 ...

Page 39: ...hen the antenna position has to be higher than the control box as Fig 14 α612 Drill four holes dia 10 5mm base on the position of the receiver shock absorbers Fig 15 9 2 2 Commissioning steps 1 Decide the wiring type and cable If the cable gland is used for the cable please use the enclosed rubber cork to seal the cable gland without cable 2 For system wiring please refer to the output contact dia...

Page 40: ...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 to...

Page 41: ...utral or in transmitter power off position 6 ON 0 1 second OFF 0 1second System normal with transmitter pushbutton in non neutral position pushbutton depressed Note Please refer to section 7 1 on page 27 for correct ID code setting 9 9 4 4 1 1 A Al lp ph ha a 6 61 12 2 R Re ec ce ei iv ve er r S Sy ys st te em m S St ta at tu us s L LE ED D D Di is sp pl la ay y Led Indication Reason Solution Powe...

Page 42: ...A size 2 rechargeable batteries Charging can be completed in 5 hours Set the power switch on the OFF position whenever transmitter is not operated Press E STOP button and slide in the transmitter into the charger to charge The transmitter is suggested to be charged whenever it is not operated The power switch should be rotated to OFF position while charging otherwise charging cannot be proceeded T...

Page 43: ...ted in a shorter time than usual To charge normally please take out the transmitter from charger and insert it into charger again Please change the two rechargeable batteries from the transmitter battery compartment at the same time to charge or discharge completely Charger power LED green Charging Charging completed Charging failed POWER Slide in transmitter into battery charger transmitter vinyl...

Page 44: ...tter 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 th...

Page 45: ...Operating Temperature 10 60 80 high temperature protection Transmitting Power Consumption 20mA 3 5V Various from encoding mode and transmitting power Continue Operating Time consecutive 100hrs batteries full 2000mA Band 433MHz Transmitting Power 1mW LV Voltage 2 2V 1 8V Frequency Range 433 MHz Transmitting Power 0 1 mW 10mW Frequency Control VTCXO PLL Frequency Deviation 1ppm 25 Spurious Emission ...

Page 46: ...e α604 607 608 DC12V 24V AC48V AC380V Full voltage module AC100 240V 50 60Hz α612 DC12V 24V AC25 36 42 50V AC110V 240V AC380 460V 50 60Hz Power Consumption α604 8 Watt α607 8 10 Watt α612 15 Watt Operating Temperature 10 70 Output Contact Rating 250V 10A Dimension 604 Models 310mm x 134mm x 72mm 607 608 Models 310mm x 134mm x 72mm 612 Models 300mm x 230mm x 86mm Weight 604 Models 1 625g include ou...

Page 47: ...hbutton B50002 6 EMS red cap All models EMSN01 7 EMS pushbutton mechanism All models red cap included B50004 8 Pushbutton rubber boot fixing holder Alpha 604 BFH604 Pushbutton rubber boot fixing holder Alpha 607 608 BFH607 608 Pushbutton rubber boot fixing holder Alpha 612 BFH612 9 Pushbutton rubber boot Alpha 604 PRB01 Pushbutton rubber boot Alpha 607 608 PRB02 Pushbutton rubber boot Alpha 612 PR...

Page 48: ...612 T24VDC Transformer 48VAC Alpha 600 608 T48VAC Transformer 110VAC Alpha 600 608 T110VAC Transformer 220VAC Alpha 600 608 T220VAC Transformer 230VAC Alpha 600 608 T230VAC Transformer 240VAC Alpha 600 608 T240VAC Transformer 380VAC Alpha 600 608 T380VAC Transformer 25 36 42 50VAC Alpha 612 T25 36 42 50VAC Transformer 110 240VAC Alpha 612 T110 240VAC Transformer 380 460VAC Alpha 612 T380 460VAC 8 ...