Fomotech Alpha 604A, Operations & Parts Manual

Page 1: ...i 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: ...e List 13 5 OUTPUT CONTACT DIAGRAMS 5 1 Alpha 604 Models 14 5 2 Alpha 607 Models 14 5 3 Alpha 608 Models 15 5 4 Alpha 612 Models 17 6 SYSTEM CONFIGURATIONS 6 1 How to Set ID Codes 22 6 2 Transmitter RF Channel Setting 22 7 RECEIVER SETTING 7 1 How to Set Receiver ID Codes 22 7 2 Receiver RF Channel Settings 23 7 3 Receiver Function Settings 24 7 3 1 α604 607 608 Receiver Function Settings 24 7 3 2...

Page 3: ...2 10 BATTERY CHARGER 10 1 Charger Operation 37 10 2 Battery Charger LED Status Light 39 11 TROUBLE SHOOTING 39 12 SYSTEM SPECIFICATION 40 13 PARTS LIST 42 ...

Page 4: ...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 pushbuttons daily Should any damage that could inhibit the proper operation of the transmitter be found the unit should be immediately removed from service 7 Check the transmitter voltage whenever it is operated Place th...

Page 5: ...single speed pushbuttons 2 Alpha 604B 4 double speed pushbuttons STOP POWER STOP POWER Alpha 604A Alpha 604B 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 ...

Page 6: ...button Alpha 607A Alpha 607B Alpha 607AT Alpha 607BT Alpha 608A Alpha 608B Alpha 608AT Alpha 608BT 2 3 Alpha 612 Models 1 Alpha 612A 12 one speed pushbuttons 2 Alpha 612B 11 one speed pushbuttons I II select pushbutton 3 Alpha 612C 1 6 two speed 6 one speed pushbuttons 4 Alpha 612C 2 8 two speed 4 one speed pushbuttons 5 Alpha 612D 10 two speed 2 one speed pushbuttons 6 Alpha 612E 1 6 two speed 5 ...

Page 7: ...8 Alpha 612 Fig 1 Transmitter Front View Fig 2 Transmitter encoder board and induction charging board Fig 3 Transmitter Internal Assembly 1 Internal antenna 2 Status LED display 3 Battery contact 4 Transmitter induction charging port 5 Programming port 6 Function dip switch 7 JP2 setting pin 8 JP1 setting pin ...

Page 8: ...status green 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 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 Supplied voltage 2 Wiring diagram 6 System serial number 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: ...utton 1 and 2 fuse 5 0A 11 MAIN fuse 5 0A 12 Contact output seat CN3 13 Low voltage LV fuse 5 0A 14 Contact output seat CN4 15 Pushbutton 3 and 4 fuse 5 0A 16 AC power input seat CN2 17 Cable gland output cable Power module Including transformer or full voltage module Please refer to 4 3 α604 α608 α612 Receiver Power Fuse List Please refer to page 36 for system status LED display information 1 Spa...

Page 11: ...er input seat CN2 8 Internal Antenna 9 System Status LED display 10 External antenna port 11 ID code dip switch 12 RF channel dip switch 13 Contact relay LED display 14 Pushbutton 1and 2 fuse 5 0A 15 Contact output seat CN3 16 MAIN contact fuse 5 0A 17 Pushbutton 3 and 4 fuse 5 0A 18 Pushbutton 5 and 6 fuse 5 0A 19 Contact output seat CN4 20 LV AUX fuse 5 0A 21 Cable gland output cable Power modul...

Page 12: ... 2 1 1 A Al lp ph ha a 6 61 12 2 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: ...ction dip switch 18 Voltage selector seat 8 Pushbutton 3 and 4 relay fuse 5 0A 19 MAIN relay fuse 5 0A 9 Pushbutton 5 and 6 relay fuse 5 0A 20 Pushbutton A4 relay fuse 5 0A 10 Pushbutton A1and A2 relay fuse 5 0A 21 Primary power fuse 1 0A AC110V up only 11 Pushbutton A3 relay fuse 5 0A 22 Low voltage LV relay fuse 5 0A POWER AC Power Source Indicator on AC input power supplied off No AC input powe...

Page 14: ... 12 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 α608 FF1 3A 1A 2A F1 3A 2A 0 5A 1A α612 FF1 3A 1A F1 3A 2A 0 8A ...

Page 15: ...GE TROLLEY HOIST FILTER Anti vibration spring must be grounded POWER MAIN F6 5A F1 F5 5A LV AUX1 BRIDGE F4 5A TROLLEY F3 5A COM4 17 L2 X2 L1 X1 GRN YEL COM5 MAIN 22 FF1 21 20 18 19 AUX1 NC N S2 COM3 E W2 COM2 15 16 14 13 LV N1 10 11 12 S1 9 8 COM1 D1 3 5 6 7 W1 E1 4 D2 HOIST F2 5A 2 1 U2 U1 FOM TECH PB1 PB2 PB4 PB3 PB5 PB6 PB8 PB7 5 5 O OU UT TP PU UT T C CO ON NT TA AC CT T D DI IA AG GR RA AM MS...

Page 16: ...1 E1 4 D2 HOIST F2 5A 2 1 U2 U1 SEL II FOM TECH PB1 PB2 PB4 PB3 PB5 PB6 PB8 PB7 FILTER Anti vibration spring must be grounded POWER MAIN F6 5A F1 F5 5A LV AUX1 BRIDGE F4 5A TROLLEY F3 5A COM4 17 L2 X2 L1 X1 GRN YEL COM5 MAIN 22 FF1 21 20 18 19 AUX1 AUX2 N S2 COM3 E W2 COM2 15 16 14 13 LV N1 10 11 12 S1 9 8 COM1 D1 3 5 6 7 W1 E1 4 D2 HOIST F2 5A 2 1 U2 U1 AUX2 FILTER Anti vibration spring must be g...

Page 17: ... 12 9 8 3 5 6 7 4 F2 5A 2 1 BRIDGE TROLLEY HOIST SEL I SEL I SEL II FILTER Anti vibration spring must be grounded POWER MAIN F6 5A F1 F5 5A SEL II AUX1 BRIDGE F4 5A TROLLEY F3 5A COM4 17 L2 X2 L1 X1 GRN YEL COM5 MAIN 22 FF1 21 20 18 19 AUX1 SEL I N S2 COM3 E W2 COM2 15 16 14 13 SEL II N1 10 11 12 S1 9 8 COM1 D1 3 5 6 7 W1 E1 4 D2 HOIST F2 5A 2 1 U2 U1 SEL I PB8 PB7 PB5 PB6 PB4 PB2 PB1 PB3 STOP POW...

Page 18: ... 17 FOM TECH PB1 PB2 PB4 PB3 PB5 PB6 PB8 PB7 PB9 5 5 4 4 A Al lp ph ha a 6 61 12 2 M Mo od de el ls s Alpha 612A Alpha 612B STOP POWER ...

Page 19: ... 18 FOM TECH PB1 PB2 PB4 PB3 PB5 PB6 PB8 PB7 PB9 FOM TECH PB1 PB2 PB4 PB3 PB5 PB6 PB8 PB7 PB9 Alpha 612C 1 Alpha612C 2 ...

Page 20: ... 19 FOM TECH PB1 PB2 PB4 PB3 PB5 PB6 PB8 PB7 PB9 Alpha 612D Alpha 612E 1 STOP POWER ...

Page 21: ... 20 Alpha 612E 2 STOP POWER ...

Page 22: ...rd and put jumper 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 the ...

Page 23: ...equency 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 60 0...

Page 24: ...ple the ID codes 10010110 1 value adds up must to be 4 7 2 Receiver RF Channel Settings There are 68 sets of user adjustable receiving RF channels that can be set manually via an 8 position dip switch located to the right of the receiving RF module Change the receiving RF channel simply by resetting the 8 position dip switch For the location of the receiving RF module please refer to fig 7 8 and 1...

Page 25: ... time is controlled by the transmitter JP3 1 Refer to JP3 1 of Jumper Set Table on Page 24 25 for α604A B 607A AT B BT 608A B 2 Refer to JP3 2 α608T only on Page 25 for α608AT BT Receiver function settings A 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 5 minutes or...

Page 26: ...l 7 3 2 2 Adjust Jumper setting function by decoder board R Re ec ce ei iv ve er r f fu un nc ct ti io on n s se et tt ti in ng gs s Jumper Set table In plant setting default JP1 Mode 0 Open Transmitter 11th pushbutton AUX start when MAIN relay is off Short Transmitter power switch start when MAIN relay is off JP2 Mode 0 Open No auto shutdown time on Main relay Short The receiver MAIN will be deac...

Page 27: ...IP 6 1 Latching toggle relay contact DIP4 Set at 1 0 Momentary relay contact 612B 7 8 DIP 1 1 Not Interlocked 0 Interlocked 7 DIP 2 1 Latching toggle relay contact 0 Momentary relay contact DIP4 Set at 1 8 DIP 3 1 Latching toggle relay contact DIP4 Set at 1 0 Momentary relay contact 9 DIP 4 1 Latching toggle relay contact 0 Momentary relay contact 612C 1 2 2nd speed DIP 1 1 Both 1st and 2nd speed ...

Page 28: ...ed DIP 2 3 4 0 Momentary relay contact DIP2 3 Must set to 0 all the time In plant set at 0 612E 1 2 2nd speed DIP 1 1 Both 1st and 2nd speed contact relay interlocked when pressed to 2nd speed Both 1st and 2nd speed contact relays activated 0 Both 1st and 2nd speed contact relay activated when pressed to 2nd speed Only 2nd speed contact relay activated 7 8 DIP 2 1 Not Interlocked 0 Interlocked 7 D...

Page 29: ...emove the Y terminal from the other end of the wire then 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 Posit...

Page 30: ...MHz 00110000 48 301 455 MHz 00001111 15 302 305 MHz 00110001 49 301 480 MHz 00010000 16 302 330 MHz 00110010 50 301 505 MHz 00010001 17 302 355 MHz 00110011 51 301 530 MHz 00010010 18 302 380 MHz 00110100 52 301 555 MHz 00010011 19 302 405 MHz 00110101 53 301 580 MHz 00010100 20 302 430 MHz 00110110 54 301 605 MHz 00010101 21 302 455 MHz 00110111 55 301 630 MHz 00010110 22 302 480 MHz 00111000 56 ...

Page 31: ...3 925 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 22 433 475 MHz 00111000 56 434 125 MHz 000101...

Page 32: ... key to off position When the power key is switched from on to off the transmitter will also send a Stop command to the receiver for 3 seconds the red status light flashes 3 times and at the same time deactivate the MAIN relay Shutting Off the Transmitter POS _ Mode 1 To disconnect the transmitter power just turn the power key to off position When the power key is switched from on to off the trans...

Page 33: ...s not match CPU data Constant red light ON until transmitter power shuts off 6 RF module abnormal PLL UNLOCK Red light ON_0 1 OFF_0 1 sec 7 ID even number error Setting error Red light ON_1 OFF_1 sec 8 Pushbutton locked Power on pushbutton connected Red light ON_1 9 OFF_0 1 sec until power off 9 Normal power on BATT 2 2V and all the pushbuttons are not depressed All the lights ON_2 sec 10 STOP sta...

Page 34: ...ps Head Screwdriver 3 Multi Meter 4 14mm Wrench x 2 5 Power Drill withφ10 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 availabl...

Page 35: ...losed rubber cork to seal the cable gland without cable 2 For system wiring please refer to the output contact diagrams from page 13 3 Ensure the selected location has adequate space to accommodate the receiver enclosure 4 Make sure the receiver unit is in upright position vertical NOTE The distance between the antenna and the control panel should be as far apart as possible refer to the fig 14 15...

Page 36: ...ransmitter 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 ...

Page 37: ...mal with transmitter pushbutton either in neutral 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 20 for correct ID code setting Alpha 612 Receiver System Status LED Display Led Indication Reason Solution Power LED display ON Normal voltage OFF Under vo...

Page 38: ...ry charger voltage AC100 240V 50 60Hz power consumption 10W Use Nickel Metal low self discharge Hydride NI MH 2000mA AA size 2 rechargeable batteries Charging can be completed in 3 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 n...

Page 39: ... charger and insert it into charger again to proceed with charging normally If the rechargeable batteries are not used for a longer period of time the charging will be completed 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 at the same time to charge or discharge completely ...

Page 40: ...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 receiv...

Page 41: ... 65 Operating Temperature 10 60 80 high temperature protection Transmitting Power Consumption 30mA 3 5V Various from encoding mode and transmitting power Continue Operating Time consecutive 100hrs batteries full 2000mA Band 301 433MHz Transmitting Power 1mW Frequency Range 301 433 MHz Transmitting Power 0 1 mW 10mW Frequency Control VTCXO PLL Frequency Deviation 1ppm 25 Spurious Emission 50dB Emis...

Page 42: ... 301 433 Frequency Control VTCXO PLL Frequency Drift 5ppm 20 70 Frequency Deviation 1ppm 25 Sensitivity 115dBm Spurious Emission 50dB Antenna Impedance 50 ohms Responding Time 40ms Normal Enclosure Rating IP 65 Source Voltage α604 607 608 DC12V 24V AC48V AC110V AC220V AC230V AC240 AC380V Full voltage module AC100 240V 50 60Hz α612 DC12V 24V AC25 36 42 50V AC110V 240V AC380 460V 50 60Hz Power Consu...

Page 43: ...r vinyl protective cover Alpha 604 VPC01 Transmitter vinyl protective cover Alpha 607 608 VPC02 Transmitter vinyl protective cover Alpha 612 VPC03 11 EMS pushbutton B50003 12 EMS red cap EMS01 13 A600 waist strap WS01 14 Rechargeable battery RCB01 15 A600 pushbutton direction label DL01 Receiver Part No 1 433MHz receiver RF module All models BRX433 2 Decoder board Alpha 604A BDE604A Decoder board ...

Page 44: ...60VAC Alpha 612 T380 460VAC 8 Full voltage module 100 240VAC Alpha 600 608 FV100 240VAC 9 2 meter Output Cable with 5 Common Circuits Cable 24C 2m V3 5 Alpha 607 608 OC607 10 Optional External 433 MHz Antenna All Models ANT433 Charger USB programming parts 1 Charging board CHPCB600 2 Electromagnetic board ELEPCB 3 Charger casing CHC600 4 Charging cable CHCA 5 Charger holder CHH600 6 USB programmin...