Alpha 3000 Industrial Radio Remote Control System Operation & Parts Manual Williams Wireless, LLC 13101 Eckles Road, Plymouth, Michigan 48170 Phone: (734) 416 5520 Fax: (734) 416 1907 E - m a i l : williamsyrless@aol.
TA B L E O F C O N T E N T S Page 1. 2. 3. INTRODUCTION ....................................................................................................... SAFETY INSTRUCTION ............................................................................................. TRANSMITTER ILLUSTRATION 3.1 Alpha 3000F Models External Assembly ............................................................. 3.2 Alpha 3000F Models Internal Assembly ............................................................. 3.
1 . I N TR O D U C T I O N The Alpha 3000 series are highly durable, reliable, and safe industrial radio remote control system. The versatile features of the Alpha 3000 series permit their usage in many different radio remote control applications that required 1-step to 3-step pushbutton controls. The system can be used to control tower cranes, factory cranes, monorail systems, multiple hoists, trolleys, mining equipment, building construction equipment, automatic control systems, and many others.
2 . S AF E T Y I N S TR U C T I O N The Alpha 3000 system is relatively simple to use, however, it is very important to observe the proper safety procedures before, during, and after operation. When used properly our Alpha 3000 series remote controls will enhance safety, productivity and efficiency in the workplace. The following procedures should be strictly followed: 1. Check the transmitter casing and pushbuttons daily.
3 . T R A N S M I T T E R I L L U S TR AT I O N 3.1 Alpha 3000F Models External Assembly 1 15 2 3 8 4 9 5 10 6 11 START AUX 7 12 6 1 13 17 14 (Transmitter Front View) 1. 2. 3. 4. 5. 6. 7. 8. (Transmitter Back View) Transmitter Unit Status LED Display* Spare Power Key Pushbutton #2 (Down) Pushbutton #4 (West) Pushbutton #6 (South) Emergency Stop Button (EMS) Power Key Switch 9. 10. 11. 12. 13. 14. 15. 16. 17.
3.2 Alpha 3000F Models Internal A s s e m b l y 1 5 2 6 3 9 1 23 4 5 6 7 8 8 7 10 11 4 (PCB Front View) 1. 2. 3. 4. 5. (PCB Back View) Status LED Display RF-to-Encoder Board Connector 1, 2 or 3-Step Pushbuttons Emergency Stop Button (EMS) Power ON/OFF Micro-Switch 6. 7. 8. 9. 10. 11.
3.3 Alpha 3000D Models External Assembly 1 9 1 2 3 10 4 D U 11 5 W E 12 6 S N 13 7 14 8 15 9 16 0 2 17 1 2 18 (Transmitter Front View) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. (Transmitter Back View) Transmitter Unit Status LED Display* Spare Power Key Pushbutton #2 (Down) Pushbutton #4 (West) Pushbutton #6 (South) Pushbutton #8 (AUX) Pushbutton #10 (AUX) Emergency Stop Button (EMS) Power Key Switch 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
3.4 Alpha 3000D Models Internal A s s e m b l y 1 5 2 6 3 9 7 1 23 4 5 6 7 8 8 10 11 4 (PCB Front View) 1. 2. 3. 4. 5. (PCB Back View) Status LED Display RF Board to Encoder Board Connector 1, 2 or 3-Step Pushbuttons Emergency Stop Button (EMS) Power ON/OFF Micro-Switch 6. 7. 8. 9. 10. 11.
4 . R E C E I V E R I L L U S TR AT I O N 4.1 E x t e r n a l A s s e m b l y ( A l l M o d e l s ) 5 1 2 3 4 6 7 (Alpha 3000 Models Receiver External View) 1. 2. 3. Antenna Mount Receiver Enclosure Key Lock 4. 5. 6. 7.
4.2 Alpha 3000F Models Internal A s s e m b l y 1 2 3 4 0 1 5 6 7 1 2 1 8 U1 D1 U2 + D2 U3 + D3 E1 W1 E2 + W2 E3 + W3 N1 S1 N2 + S2 3 1 N3 + S3 4 1 9 Z1 ID ~ ~ 1 5 6 1 (Alpha 3000F Models Receiver Internal View) 1. 2. 3. 4. 5. 6. 7. 8. * Antenna Seat Receiving RF Module Decoder Module Decoder Module Power Display Receiver Status LED Display* SQ Status LED Display* Power (AC) LED Display Upper Relay Board 9. 10. 11. 12. 13. 14. 15. 16.
4.3 Alpha 3000D Models Internal A s s e m b l y 1 2 3 4 0 1 5 6 7 1 2 1 8 U1 D1 U2 + D2 U3 + D3 E1 W1 E2 + W2 E3 + W3 N1 S1 N2 + S2 3 1 N3 + S3 4 1 9 AU2 + AD2 AU3 + AD3 X1 Y1 X2+Y2 (X2) X3 +Y3 (Y2) Z1 ID ~ ~ 1 5 6 1 (Alpha 3000D Models Receiver Internal View) 1. 2. 3. 4. 5. 6. 7. 8. Antenna Seat Receiving RF Module Decoder Module Decoder Module Power Display Receiver Status LED Display* SQ Status LED Display* Power (AC) LED Display Upper Relay Board 9. 10. 11. 12. 13. 14. 15.
5. OUTPUT CONTACT DIAGRAM 5.1 Alpha 3000F2 Output Contact K13 K14 K15 U1 D1 U2 + D2 E1 W1 E2 + W2 J1 5 N1 S1 N2 + S2 UPPER RELAY BOARD Z1 RES ID MAIN AC BOTTOM RELAY BOARD Note: Z1 output contact represents the 7th pushbutton on the transmitter (START/AUX), which can be used for lights, horn, or other types of applications (refer to section 6.5 on page 21).
5.2 U1 Alpha 3000F3 Output Contact D1 U2 + D2 U3 + D3 E1 W1 E2 + W2 E3 + W3 N1 S1 N2 + S2 N3 + S3 UPPER RELAY BOARD Z1 RES ID MAIN BOTTOM RELAY BOARD Note: Z1 output contact represents the 7th pushbutton on the transmitter (START/AUX), which can be used for lights, horn, or other types of applications (refer to section 6.5 on page 21). Terminal Block and Common Shorting Pin Assembly Common shorting pin illustrated above can be used rather than “daisy chaining” wiring for the common.
5.3 U1 Alpha 3000D2 Output Contact D1 U2 + D2 E1 W1 E2 + W2 N1 S1 N2 + S2 UPPER RELAY BOARD AU1 AD1 AU2 + AD2 X1 Y1 Z1 X2+Y2 RES MAIN ID BOTTOM RELAY BOARD Note A: Note B: Note C: AU & AD output contacts represent the 7th and 8t h pushbuttons on the transmitter (AUX_& AUX_), which can be used for the auxiliary hoist motion or other types of applications (refer to section 6.5 on page 21).
5.4 U1 Alpha 3000D3 Output Contact D1 U2 + D2 U3 + D3 E1 W1 E2 + W2 E3 + W3 N1 S1 N2 + S2 N3 + S3 UPPER RELAY BOARD AU1 AD1 AU2 + AD2 AU3 + AD3 X1 Y1 X2+Y2 (X2) X3+Y3 (Y2) Z1 RES MAIN ID BOTTOM RELAY BOARD Note A: Note B: Note C: AU & AD output contacts represent the 7th and 8t h pushbuttons on the transmitter (AUX_& AUX_), which can be used for the auxiliary hoist motion or other types of applications (refer to section 6.5 on page 21).
5.5 U1 Alpha 3000D2-A Output Contact D1 U2 + D2 E1 W1 E2 + W2 N1 S1 N2 + S2 UPPER RELAY BOARD AU1 AD1 X1 Y1 Z1 RES MAIN ID BOTTOM RELAY BOARD Note A: Note B: Note C: AU & AD output contacts represent the 7th and 8th pushbuttons on the transmitter (AUX_& AUX_), which can be used for the auxiliary hoist motion or other types of applications (refer to section 6.5 on page 21).
5.6 U1 Alpha 3000D3-A Output Contact D1 U2 + D2 U3 + D3 E1 W1 E2 + W2 E3 + W3 N1 S1 N2 + S2 N3 + S3 UPPER RELAY BOARD AU1 AD1 X1 Y1 Z1 RES MAIN ID BOTTOM RELAY BOARD Note A: Note B: Note C: AU & AD output contacts represent the 7th and 8th pushbuttons on the transmitter (AUX_& AUX_), which can be used for the auxiliary hoist motion or other types of applications (refer to section 6.5 on page 21).
6 . S Y S T E M C O N F I G U R AT I O N S 6.1 J u m p er S e t t i n g s There are numerous functions that can be set via jumpers located inside the decoder module. Please see the diagram and chart below on how to set these functions. Manufacture Setting Open After inserting the transmitter power key at system startup, or after EMS reset, press and hold START/AUX to activate the receiver MAIN relay. Short Insert the transmitter power key will immediately activates the receiver MAIN relay.
JP3 JP3 Open Pushbutton 1 through 6 interlocked JP3 Short Pushbutton 1 through 6 non-interlocked with each pushbutton becomes single-speed contact JP4 (F3 & D3 models only) JP4 Open JP4 Short 6.
Due to Alpha 3000 series’ ID code (or address code) is 16-digit long, the first 8 digits are set via the soldering slot and the remaining last 8 digits are set via the dip-switch (total of 16 digits). For the soldering slot, the “SH8” represents the 1st digit of the ID code and “SH15” represents the 8th digit of the ID code. As for the dip-switch, the “1” represents 9th digit of the ID code and the “8” represents the 16th digit of the ID code (last digit).
6.4 Frequency (RF) Channel Table FREQUENCY DIP-SWITCH SETTING RF CHANNEL 301.105 MHz 00001 201 301.130 MHz 00010 202 301.155 MHz 00011 203 301.180 MHz 00100 204 301.205 MHz 00101 205 301.230 MHz 00110 206 301.255 MHz 00111 207 301.280 MHz 01000 208 301.305 MHz 01001 209 301.330 MHz 01010 210 301.355 MHz 01011 211 301.380 MHz 01100 212 301.405 MHz 01101 213 301.430 MHz 01110 214 301.455 MHz 01111 215 301.480 MHz 10000 216 301.505 MHz 10001 217 301.
6.5 Pushbutton Contact Settings There are numerous pushbutton functions that can be programmed via an 8-position dip-switch located on the decoder module (refer to the diagram below). By adjusting each dip setting either to the top or bottom location will change the contact form of the intended pushbutton (refer to the chart below). Transmitter pushbuttons are numbered from right-to-left and then from top-to-bottom.
6.6 V o l t a g e S e t t i n g s There are four different voltage settings available inside the Alpha 3000 receiver located next to the bottom relay board, please select one that corresponds to the main power source of the crane or equipment. Power Transform Available: SSB-2181 _ 48VAC / 220VAC / 0ACV / 460VAC @ 50/60Hz. SSB-1726 _ 110VAC / 220VAC / 380VAC / 415VAC @ 50/60Hz. SSB-2213 _ 115VAC / 208VAC / 230VAC / 460VAC @ 50/60Hz.
7 . R E C E I V E R I N S TA L L AT I O N 7.1 Preparation For Installation 1. Required Tools: (1) Flat Head Screwdriver (-) (2) Phillips Head Screwdriver (+) (3) Multi-Meter (4) Open End Wrench (5) Power Drill with 10.5mm ~ 11mm 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 distance of 900 feet. 3.
7.3 System Testing 1. Connect the power source to the receiver and test the MAIN relay output (EMS button) and observe that it properly opens and closes the main line. 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 crane and verify that they are working properly. 4.
8.. T R A N S M I T T E R O P E R AT I O N 1. Batteries _ Make sure the four “AA” alkaline batteries are installed correctly, the labels on the battery holder will tell you which side is “up” and which side is “down”. Use 2,000mA alkaline type batteries for optimum operating time between replacements. If rechargeable batteries are used, for optimum operating time between replacements, select ones rated 1,600mA or above. 2.
6. Interlocking Pushbuttons _ For both F & D models, the top 3 sets of motions are interlocked to its self so no conflicting commands can take place for safety purpose. For example, pressing the hoist “UP” and “DOWN” pushbutton simultaneously will result in no command being sent (depending on JP3 setting on page 17). 7.
9 . T R O U B L E S H O OT I N G 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 to receiver. Transmitter and the receiver are not on the same RF channel (SQ 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.
1 0 . S Y S T E M S P E C I F I C AT I O N 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 : : : : : : : : : : : : : : : : Weight (include batteries) : 301MHz 300 feet _6 25KHz Quartz Crystals < 5ppm @ -13_ ~ 158_ < 1ppm -50dB ~0.3mW F1D 50 ohms IP-66 DC 6.0V 8mA @ 6V -13_ ~ 158_ 9.
1 1 . PARTS L I S T 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 301MHz. Transmitting RF Board (All Models) Encoder Board (Alpha 3000F2) Encoder Board (Alpha 3000F3) Encoder Board (Alpha 3000D2) Encoder Board (Alpha 3000D3) Encoder Board (Alpha 3000D2-A) Encoder Board (Alpha 3000D3-A) 301MHz.