A4K Technical Manual_(080528)

8/6/2019 A4K Technical Manual_(080528)

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1．．．． INDEX ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 1

2．．．． INSTRUCTION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 3

3．．．． SAFETY INSTRUCTION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 4

4．．．． INTRODUCTION ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 5~14

4.1 SYSTEM TYPES．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 5~6

4.1.1 8-PUSHBUTTON TYPES．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

5

4.1.2 12-PUSHBUTTON TYPES．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

6

4.2 TRANSMITTER INSTRUCTION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 7~11

4.2.1 TRANSMITTER OUTLINE．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

7

4.2.2 TRANSMITTER EXTERNAL OUTLINE．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

7

4.2.3 TRANSMITTER EXPLOSION VIEW．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

84.2.4 TRANSMITTER INTERIOR DESCRIPTIONS

．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

9~10

4.2.5 HOW TO CHANGE SELECT SWITCH/ PUSHBUTTON．．．．．．．．．．．．．．．．．．．．．．．．．．

10

4.2.6 (1) RECHARGEABLE BATTERY (2) BATTERY CHARGER (3) SHOULDER STRAP．．．．

10

4.2.7 RECHARGEABLE BATTERY OUTPUT CONTACT DIAGRAM．．．．．．．．．．．．．．．．．．．．．．．

10

4.2.8 BATTERY CHARGER EXTERNAL DESCRIPTIONS．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

11

4.3 RECEIVER INSTRUCTION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 12~14

4.3.1 RECEIVER OUTLINE．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

12

4.3.2 RECEIVER EXTERNAL DESCRIPTION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

12

4.3.3 RECEIVER EXPLOSION VIEW．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

12

4.3.4 (1) RX MODULE CARD (2) DECODER CARD (3) RELAY CARD (4) POWER SUPPLY CARD 13~14

5．．．． SYSTEM CONFIGURATIONS．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 15~22

5.1 SECURITY ID CODE SETTINGS．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

15

5.2 FREQUENCY (RF) CHANNEL SETTINGS．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 15

5.3 TRANSMITTER/ RECEIVER FUNCTION SETTING (REFER SOFTWARE MANUAL)．

16

5.4 JUMPER SETTING – J1, J2．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

．

16

5.5 HOW TO CHANGE PUSHBUTTON (IMPORTANT)．．．．．．．．．．．．．．．．．．．．．．．．．

165.6 OPTIONAL FEATURE: INFRARED STARTUP

．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

17

5.6.1 INFRARED STARTUP ACCRESSORIES．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

17

5.6.2 SET “INFRARED STARTUP” TO CHIP CARDS．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 17

5.7 TANDEM (DUAL MASTER) MODE．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 18

5.8 PITCH AND CATCH MODE．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

18

5.9 1R2T PROTECTION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 18

5.10 TRANSMITTER CHANNEL IS SELECTABLE．．．．．．．．．．．．．．．．．．．．． 19~20

5.11 FREQUENCY (RF) CHANNEL TABLE: 433MHz．．．．．．．．．．．．．．．．．．．．

215.12 FREQUENCY (RF) CHANNEL TABLE: 173/301/350/418/447/480MHz ．．．．．．．．． 22



6．．．． TRANSMITTER OPERATION．．．．．．．．．．．．．．．．．．．．．．．．． 23~24

6.1 TRANSMITER OPERATION ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 23

6.2 TRANSMITTER LED DISPLAY & TROUBLE SHOOTING．．．．．．．．．．．．．．．．．．．．．．．．．

23~246.3 TRANSMITTER MAINTENANCE．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 24

7．．．． RECEIVER INSTALLATION ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 25`27

7.1 PREPARATION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

25

7.2 STEP-BY-STEP INSTALLATION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

26

7.3 RECEIVER LED DISPLAY & TROUBLE SHOOTING．．．．．．．．．．．．．．．．．．．．．．．．．．．．

27

8．．．． BATTERY CHARGING & BATTERY STATUS LED DISPLAY．．．．．．．．．．．． 28~29

8.1 BATTERY CHARGING ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 28

8.2 BATTERY STATUS LED DISPLAY & TROUBLE SHOOTING．．．．．．．．．．．．．．．．．．．．．． 29

9．．．． TROUBLE SHOOTING ．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 30

10．．．．SYSTEM SPECIFICATION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 31

10.1 TRANSMITTER SPECIFICATION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

31

10.2 RECEVIER SPECIFICATION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 31

10.3 BATTERY CHARGER SPECIFICATION．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．

31

11．．．．PARTS LIST ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 32



2. INSTRUCTION

The Alpha 4000 series are highly durable, reliable and safe industrial radio remote control systems. The versatile

features of the Alpha 4000 series permit their use in many different remote control applications. The systems

can be used to control factory cranes, monorail systems, multiple hoists, trolleys, mining equipment, building

construction equipment, automatic control systems, and many others.

The system incorporates numerous safety circuits that guaranty maximum security and ensure the system is

resistant to outside interference. The major features of the Alpha 4000 series are as follow:

1. Alpha 4000 series has the automatic shut-off function, when encountering strong radio interference, and

when the transmitter/operator is out of receiving range. The receiver will start the automatic shutdown

function in 0.55 seconds.

2. The system is equipped with highly evolved software that has redundant error checking and correcting

capabilities to ensure 100% error-free transmission, decoding, and control of all output relays. This highly

evolved software includes CRC (Cyclical Redundancy Check) and Hamming Codes (Error Recovery)

programming.

3. The transmitter encoder and receiver decoder both utilize advanced microprocessor control. The availability

of 65,536 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.

4. The system also utilizes advanced microprocessor control (watch dog) for data comparison and

crosschecking between the two decoding microprocessors. When fault are detected via this central

microprocessor, for maximum safety, the entire system will be shutdown immediately to avoid possibility of

any accidents occurring.

5. The Alpha 4000 series is equipped with numerous self-diagnosing functions:

MODE 1 (safe mode): If user in 40 seconds has not operated the transmitter, the transmitter will

automatic shutdown (multiple options by 40 second ~ 60 minutes, also may transmission

continuously and not close power source).

MODE 0 (power-saving model): Any has not operated the transmitter. The transmitter will automatic

shutdown for saving the power.

Alpha 4000 series includes one receiver, transmitter and battery charger. The major features as follows:

1. The transmitter casings are molded using industrial strength composite materials which are impervious to

dust, water, oil, acids, alkaline, heat and sunlight as well as being resistant to deformation due to long term

use in harsh environments. The pushbuttons are also constructed from industrial strength composite

materials with minimum of up to one million press cycles.2. Sensor-type battery charging. Metal and open type contact of battery charger provides water-proof and

strong construction of transmitter that fits every kind of environment. It also enables transmitter to charge

simply by putting it on battery charger.

3. The receiver manufactured by metal material to avoid strong radio interference and protect the internal

circuits.

4. Receiver internal circuits and modules are replaceable, such as RX modules card, decoder card, output relay

card and power supply card.

5. The system utilizes PLL synthesized RF transmission. It allows the user to select from 20 sets of frequency

channels best suited for the environment. The frequency channel is selected via simple dip-switch settings

inside the transmitter and receiver unit. 6. The transmitter and receiver both can be designed function at chip card.

7. Base on the system type selected, you may create all kinds of combination with the software to fit

different working environment.



3. SAFETY INSTRUCTION

The following instructions should be strictly followed:

1. Make a daily check of the transmitter casing, pushbuttons and pushbutton rubber boot.Should it appear that anything could inhibit the proper operation of the transmitter unit, it

should be immediately removed from service.

2. Do not heat the battery or throw it into a fire. Do not touch the gold marking, for instance,

chip card, relay board, RX module and decoder board socket.

3. The transmitter voltage should be checked on a daily basis. If the voltage is low, the battery

pack should be recharged or replaced.

4. The emergency stop button (EMS) should be checked at the beginning of each shift to ensure

they are in the proper working order.

5. In the event of an emergency, push down the emergency stop button immediately to

deactivate the receiver main relay. Then turned the power “off” from the main power source

of the equipment.

6. The transmitter power key should be pulled “off” after each use and should never leave the

transmitter in the power “on” position when the unit is unattended.

7. Never operate a crane or equipment with two (2) transmitter units at the same time with

same frequency channel and ID code.

8. Do not use the same frequency channel and ID code as any other unit in use at the same

facility or within distance of 300 meters.

9. Ensure the waist belt and the shoulder strap is worn at all time during operation to avoid

accidental damages to the transmitter box.

10. When the transmitters and receivers should be repaired or adjustment. Refer all servicing to

qualified service personal. (Do not change parts like transistors, quartz… by yourselves.)



4. INTRODUCTIONS

4.1 System Types

4.1.1 8-pushbutton types：

** Selector switch: 2-stage or 3-stage selector switch

( 1 ) 4008-1 : 8 single speed pushbuttons

( 2 ) 4008-1S : 7 single speed pushbuttons + 1 selector switch

( 3 ) 4008-2 : 8 double speed pushbuttons

( 4 ) 4008-3 : 6 double speed pushbuttons + 2 single speed pushbuttons

( 5 ) 4008-3S : 6 double speed pushbuttons + 1 single speed pushbutton + 1 selector switch

4008-3S4008-34008-24008-1S4008-1



4.1.2 12-pushbutton types：

** Selector switch: 2-stage or 3-stage selector switch

4 0 1 2 - 1 4 0 1 2 - 1 S 4 0 1 2 - 2 4 0 1 2 - 3 4 0 1 2 - 4 4 0 1 2 - 3 S 4 0 1 2 - 2 S 4 0 1 2 - 5

( 1 ) 4012-1 : 12 single speed pushbuttons

( 2 ) 4012-1S : 11 single speed pushbuttons + 1 selector switch


( 4 ) 4012-2S : 6 double speed pushbuttons + 5 single speed pushbuttons + 1 selector switch


( 6 ) 4012-3S : 8 double speed pushbuttons + 3 single speed pushbuttons + 1 selector switch


( 8 ) 4012-5 : 12 double speed pushbuttons



4.2 Transmitter Instruction

4.2.1 Transmitter Outline

8 pushbuttons: 231mm × 65mm × 52mm 12 pushbuttons: 272mm × 65mm × 52mm

(Fig. 1) Transmitter Top / Bottom View

4.2.2 Transmitter External Descriptions

1. On / Off switch

2. Function key

3. Emergency stop button (EMS)

4. Status LED display

5. Shoulder strap holder

6. Selector switch

7. Anti-hit rubber

8. Lithium battery

9. Battery charging slot

10. Battery charging fixed position

11. System information

(Fig. 2) Transmitter External Views

8

9

1 0

1

6

1 1

7

2

4

3

5

8

1 1

9

1 0

1

6

7

2

3

5

4



4.2.3 Transmitter Explosion View

(Fig. 3) 12-pushbutton type transmitter explosion view

(Fig.4) 8-pushbutton type transmitter explosion view



4.2.4 Transmitter Interior Descriptions

(Fig. 5) (1) Recharging chip card (2) Encoder Board (3) TX module (4) LED card (5) 3-stage select switch board

(Fig.6) TX module、

LED display、

Encoder board、

Recharging chip card、

3-stage select switch board internal description

1 0

1 3

1 2

1 1

1 4

2 0

1 9

2 1

S

H

1

1 5

1 6

4

5

3

9

2

1

1 6

1 9

1 5

2 1

2 0

S

H

1

4

5

2 3

1 8

8

6

7

1 7

2 8

2 7

1 7

8

1 8

6

7

2 2

2 4

2 5

2 6



1. TX module RF channel dip-switch 2. TX quartz crystal frequency capacitor

3. TX module connector 4. Emergency Stop micro switch

5. One-speed, two-speed pushbuttons 6. Start micro switch

7. Induction power board to encoder board connector 8. Transmitter power micro switch

9. LED4 10. LED3

11. Status LED 12. LED2

13. LED1 14. LED connector

15. LED connector port 16. Function select dip-switch

17. Center CPU connector port 18. 3-stage Select switch board to encoder board connector

19. TX module connector port 20. ID code dip-switch

21. SH1 22. Encoder board to induction power board connector

23. J1, J2 jumper 24. Chip card holder

25. Battery terminal 26. Induction circuit

27. Select switch board to select board wire 28. Encoder board to 3-stage select switch board connector

4.2.5 How to Change Select Switch/ Pushbutton

1. Refer to 4.1 for transmitter types. And remove transmitter and receiver chip cards. (Note: When

change pushbutton to select switch type, you should insert 3-stage select switchboard, refer to Fig. 5).

2. Then solder SH1 short circuit for canceling original setting (Refer to Fig.6 for SH1 position).

3. Reset transmitter and receiver chip cards by programming tool. Then re-insert to transmitter and

receiver.

4.2.6 Rechargeable Battery、Battery Charger and Shoulder Strap Outline

(1)

(2) (3) (4) (5)

(Fig. 7) (1) Cable (2) Battery Charger (3) Rechargeable Battery (4) Adapter (5) Shoulder Strap Outline

4.2.7 Rechargeable Battery Output Contact Diagram

(Fig.8)



4.2.8 Battery Charger External Descriptions & Explosion View

(Fig. 9) Battery Charger External Descriptions

1. Battery charger 2. Power LED display

3. Battery charger LED display 4. Transmitter charger LED display

5. Transmitter charger mounting contact 6. Transmitter charger contact

7. Transmitter charger slot cleaning tool 8. Battery charger mounting hole

9. Battery charger cover 10. Power socket DC12~24V(Inside: the “+“pole. Outside: the “-“ pole)

(Fig.10) Charger Explosion View

_+



4.3 Receiver Introduction

4.3.1 Receiver Outline

300mm × 171mm × 115mm

(Antenna and Plug-in Socket Excluded)

(Fig. 11) Receiver Outline

4.3.2 Receiver External Descriptions

1. Antenna

2. Antenna port

3. AC power display

4. SQ Status Display

5. Status display6. Main relay display

7. System information plate

8. Shock absorber*4

9. Cable gland*2

10. RX module card

11. Output relay card I

12. Output relay card II

13. Output relay card III

14. Output relay card IV

15. Decoder card

16. Power supply card

(Fig.12) Receiver External View

(Fig.13) Receiver Explosion View



4.3.4 (1) RX Module Card (2) Decoder Card (3) Output Relay Card (4) Power Supply Card

(Fig.14)

(Fig.15) RX module

1. Rx module shielding plate holder 2. Antenna port

3. Main relay LED display 4. Status LED display

5. SQ LED display 6. Power LED display

7. RF channel dip-switch 8. Infrared RX module connector

9. RX module card-to-motherboard connector 10. RX module shielding plate



(2) Decoder Board

1. Decoder shielding plate

2. Function select dip-switch

3. ID code dip-switch

4. Chip card holder

5. Chip card J1 & J2 socket

6. Power DC12V input connector

7. Spare power DC12V output connector

8. Main contact relay fuse 5A/250V

9. Main relay connector

10.Relay board contactor port IV

11. Relay board contactor port III

12. Relay board contactor port II

13. Relay board contactor port I

14. RX module connector port (圖十六

)解碼板

(Fig.16) Decoder Board

(3) Relay Board

1. Relay LED display

2. Relay output contact connector port

3. Contact relay holder

4. Contact relays

5. Relay LED display

6. Relay card-to-motherboard connector

(Fig.17) Relay Board

(4) Power Supply Card

1. Power supply board holder

2. Power DC12V2A output connector

3. Power input connector

4. Fuse slot

(Fig.18) Power supply module



5. SYSTEM CONFIGURATIONS

5.1 Security ID Code Settings

Transmitter ID code can be readjusted via an 8-position dip-switch located on the encoder

board. Receiver ID code also can be readjusted via an 8-position dip-switch located on the

chip card of the decoder card. (Refer to Fig.9)

Example: ID code→ 10010110

Top location: “1”

Bottom location: “0”

(Fig.19) Dip Switch

5.2 Frequency (RF) Channel Settings

Both transmitter and receiver frequency channel can be readjusted via an 8-position

dip-switch located on the TX module and RX module. (Refer to Fig.10). Please note

only when the 8-posttion dip-switch→ “000000”, frequency channel can be readjusted

by the chip card.

Example: Frequency channel 01 (100000) / Frequency 433.075MHZ

Top location: “1”

Bottom location: “0”

(Fig. 20) Frequency Dip Switch



5.3 Transmitter / Receiver Function Setting (Please Refer Software Manual)

5.4 Jumper Setting- J1, J2

J1 Use transmitter/receiver without the Chip Card

Insert short pin into J1 jumper, the transmitter/ receiver

can be used without the chip card. When use the

transmitter/ receiver by chip card, the J1 short pin must

removed.

J2 Copy a Chip Card (Fig. 21)

Insert short pin into J2 jumper and replace a new chip card. Turn on the power source, CPU will

write data in the new chip card. When the 5 LED status display green (on), remove J2 short pin.

5.5 HOW TO CHANGE PUSHBUTTON

HOW TO CHANGE 1-SPEED TO 2-SPEED ( OR 2-SPEED TO 1-SPEED) PUSHBUTTON

5.5.1 HARDWARE

1-1. Refer 4.1 for System Types

1-2. Short encoder board SH1, then change one-speed to two-speed pushbutton. Re-program transmitter

and receiver chip cards form one-speed to two-speed. (Refer below for encoder board SH1)

Note: 1. Selector switch can’t be changed to pushbutton.

2. Selector switch can’t be change position.

3. When the setting of chip card is 8-pushbutton types, the chip card can’t be used in

12-pushbutton types transmitter/ receiver. Opposite, when the setting of chip card is

12-pushbutton system types, the chip card can’t be used in 8-pushbutton types hardware.

5.5.2 SOFTWARE

2-1. When change pushbutton for 2-speed to 1-speed pushbutton, in order to cancel 2-speed protection

function, you have to change the setting of chip card.

2-2. Remove transmitter and receiver chip cards.

2-3. Change the setting form 2-speed to 1-speed pushbutton of both transmitter and receiver chip cards

(The settings of transmitter chip card and receiver chip card have to both the same)

2-4. Insert re-programmed chip cards into transmitter and receiver.

J1

J2

J1 J2



5.6 Optional Feature: Infrared Startup

(Fig. 22)

5.6.1 Infrared Startup Accessories:

1-1. Transmitter infrared LED sensor (refer to Fig.22)

1-2. Infrared receiving module (refer to Fig.22): If the ID code of the transmitter unit is altered via8-pin dip-switch setting inside the transmitter (refer to Fig.6), you must then also change

the ID code in the receiver (refer to page 14).

1-3. Infrared receiving module input connector (refer to Fig.22):

(1) GND (2) DC+8V (3) Infrared receiving module

5.6.2 Set “Infrared Startup” to chip card (refer to chapter 5.7 of software function setting manual).

If the system is equipped with “Infrared Startup” function, the operator then can only activate

the receiver MAIN relay within 100-meter linear distance from the location of the receiver or

the receiving infrared module. Point the infrared LED sensor located on the front of thetransmitter towards the infrared receiving module.

★ How to cancel “ Infrared Start” function

Insert pin both into (1) GND and (3) Infrared receiving module or remove Infrared receiving module

input connector (refer to Fig.22). Or reset transmitter and receiver chip cards without “Infrared start”

function.

Infrared receiving module

Transmitter infrared LED sensor

(Infrared receiving module connector



5.7 Tandem (Dual Master) Mode

This mode allows two operators controlling two crane systems independently or one operator

controlling two crane systems simultaneously. (Crane I, Crane II, Crane I+II)

To operate in Tandem mode, please keep rotating the power switch to START position and

depressing Tandem button to select I, II or I+II, you may refer the LED status. Then release E-stop

switch → rotate the power to START again to operate the equipment. Note that the Tandem

pushbutton can only be set on the 7th

single-speed pushbutton for Alpha 4008 and 11th

single-speed

pushbutton for Alpha 4012. The two transmitters operated in Tandem mode should have different

channels and identical ID. It is only available under Mode 1. Please refer to below for LED status of

Tandem mode operation.

5.8 Pitch and Catch Mode

This mode allows two operators controlling one crane system from opposite ends of a long or cross

travel.

To operate in Pitch and Catch Mode, please depress the Release pushbutton and then rotate the

power switch to START position and release. The power of the receiver will be off (main relay will

be deactivated). Then, either turn on Transmitter 1 or Transmitter 2, the transmitter which be turned

on (activate main relay of the receiver) first will control the Crane.

Note that the Release pushbutton can only be set on the 7th

single-speed pushbutton for Alpha 4008

and 11th

single-speed pushbutton for Alpha 4012. The two transmitters operated in Pitch and Catch

mode should have different channels and same identical ID. It is only available under Mode 1.

5.9 1R2T Protection

Two transmitters to one receiver. For safety purpose, only one transmitter can control the receiver at

a time.

How to switch Transmitter 1/ Transmitter 2 to control the receiver in 1R2T protection

function:When the transmitter that controls the receiver is low-battery / depress emergency stop

button / rotate the power switch to OFF position. The main relay of receiver will be deactivated.

Then, either turn on Transmitter 1 again or turn on Transmitter 2, the transmitter which be turned on

first will control the receiver.

Note that the two transmitters operated in 1R2T Protection shall have same channels and identical

ID.

Crane I

Crane II

Crane I+II

: LED position 1: Red Light (LED position 2: Green Light)

: LED position 2: Red Light (LED position 1: Green Light)

: LED position 1 & 2: Red Light



5.10 Transmitter Channel is Selectable

Operate a 3-step automatic return momentary selector switch to select transmitter channel.

Transmitter Channel is selectable function can be set on the 7th

single speed pushbutton on

8-pushbutton system types, 11th

single speed pushbutton on 12-pushbutton and 12+2-pushbutton

system types.

★ Transmitter shall have a 3-step automatic return momentary selector switch.

Start “Transmitter Channel is Selectable” function and identify Start channel and End channel

on transmitter chip card. When transmitter is operated in this function, receiver will

AUTOSCAN new channel.

★ Operate in “Transmitter Channel is Selectable” function, do not depress any pushbutton androtate the 3-stage momentary selector switch follow Step 1 to Step5 in one second. Then the

transmitter stop transmitting and after transmitter displays start-up LED, you can start to select

channel.

★ Rotating the 3-stage momentary selector switch form middle→ left to decrease one number of

channel, rotate the 3-stage momentary selector switch form middle→ right position to increase

one number of channel.

For example: If channel range is set form 01 to 20 and the channel in use is 05. Rotate the

selector switch form middle to left position, the channel will be change to 04. In opposite, rotate

form middle to right position, the channel will be change to 06.

For example: If channel range is set form 01 to 20 and the channel in use is 01. Rotate the

selector switch form middle to left position, the channel change to 20. In opposite, if the

channel in use is 20, rotate the selector switch form middle to right position, the channel will

be change to 01.

★ The status of transmitter channel shows pervious setting, not in-plant setting.

★ Channel number under 10 Green LED is displayed. Channel number over 10, Red LED and

Green LED are displayed alternately. Digit in tens of channel number display Red LED, digit inones of channel number display Green LED (Please refer Table One)

★ Transmitter channel between 1 ~ 9, LED display a constant green light.

- + . .

Step 1

- + . .

Step 3

- + . .

Step 4

- + . .

Step 5

- + . .

Step 2



Transmitter Channel LED Display

Red LED Green LED

Digit

in

Tens

1 2 3 4

Digit

in

Ones

1 2 3 4

10 BLINK 1LIGHT/

BLINK

20 BLINK 2LIGHT/

BLINK

30 BLINK 3LIGHT/

BLINK

40 BLINK 4LIGHT/

BLINK

50 BLINK BLINK 5LIGHT/

BLINK

LIGHT/

BLINK


BLINK

LIGHT/

BLINK


BLINK

LIGHT/

BLINK

80 BLINK BLINK BLINK 8LIGHT/

BLINK

LIGHT/

BLINK

LIGHT/

BLINK

90 BLINK BLINK BLINK 9LIGHT/ BLINK

LIGHT/ BLINK

LIGHT/ BLINK

For example：

CH 1→ Transmitter Status LED 1 displays a green blinking light.CH 8→ Transmitter Status LED 1 & 3 & 4 display green blinking lights.（1＋3＋4＝8）

CH 14→ Transmitter Status LED 1 displays a red blinking light, LED 4 display a green

blinking light.

CH 20→ Transmitter Status LED 2 displays a red blinking light.CH 33→ Transmitter Status LED 3 displays red & green LED blinking lights alternately.



5.11 Frequency (RF) Channel Table: 433M/ 25K

FREQUENCYDIP-SWITCH

SETTINGCHANNEL FREQUENCY

DIP-SWITCH

SETTINGCHANNEL

433.075 MHz 000001 01 434.450 MHz 100100 36

433.100 MHz 000010 02 434.475 MHz 100101 37

433.125 MHz 000011 03 434.500 MHz 100110 38

433.150 MHz 000100 04 434.525 MHz 100111 39

433.175 MHz 000101 05 434.550 MHz 101000 40

433.200 MHz 000110 06 434.575 MHz 101001 41

433.225 MHz 000111 07 434.600 MHz 101010 42

433.250 MHz 001000 08 434.625 MHz 101011 43

433.275 MHz 001001 09 434.650 MHz 101100 44

433.300 MHz 001010 10 434.675 MHz 101101 45433.825 MHz 001011 11 434.700 MHz 101110 46

433.850 MHz 001100 12 434.725 MHz 101111 47

433.875 MHz 001101 13 434.750 MHz 110000 48

433.900 MHz 001110 14 434.775 MHz 110001 49

433.925 MHz 001111 15 434.800 MHz 110010 50

433.950 MHz 010000 16 434.825 MHz 110011 51

433.975 MHz 010001 17 434.850 MHz 110100 52

434.000 MHz 010010 18 434.875 MHz 110101 53

434.025 MHz 010011 19 434.900 MHz 110110 54

434.050 MHz 010100 20 434.925 MHz 110111 55

434.075 MHz 010101 21 434.950 MHz 111000 56

434.100 MHz 010110 22 434.975 MHz 111001 57

434.125 MHz 010111 23 435.000 MHz 111010 58

434.150 MHz 011000 24 435.025 MHz 111011 59

434.175 MHz 011001 25 435.050 MHz 111100 60

434.200 MHz 011010 26 435.075 MHz 111101 61

434.225 MHz 011011 27 435.100 MHz 111110 62

434.250 MHz 011100 28 435.125 MHz 111111 63

434.275 MHz 011101 29

434.300 MHz 011110 30

434.325 MHz 011111 31

434.350 MHz 100000 32

434.375 MHz 100001 33

434.400 MHz 100010 34

434.425 MHz 100011 35



5.12 Frequency (RF) Channel Table: 173/301/350/418/447/480M

FREQUENCY /

CHANNEL801~831 701~710 601~630 201~233 101~114 01~20

CH 418M/25k 447M/12.5k 480M/25k 301M/25k 173M/12.5k 350M/25k

01 418.950 447.8750 480.0500 301.1050 173.6250 350.2250

02 418.975 447.8875 480.0750 301.1300 173.6375 350.2500

03 419.000 447.9000 480.1000 301.1550 173.6500 350.2750

04 419.025 447.9125 480.1250 301.1800 173.6625 350.3000

05 419.050 447.9250 480.1500 301.2050 173.6750 350.3250.

06 419.075 447.9375 480.1750 301.2300 173.6875 350.3500

07 419.100 447.9500 480.2000 301.2550 173.7000 350.3750

08 419.125 447.9625 480.2250 301.2800 173.7125 350.4000

09 419.150 447.9750 480.2500 301.3050 173.7250 350.4250

10 419.175 447.9875 480.2750 301.3300 173.7375 350.4500

11 419.200 480.3000 301.3550 173.7500 350.4750

12 419.225 480.3250 301.3800 173.7625 350.5000

13 419.250 480.3500 301.4050 173.7750 350.5250

14 419.275 480.3750 301.4300 173.7875 350.5000

15 419.300 480.4000 301.4550 350.5750

16 419.325 480.4250 301.4800 350.6000

17 419.350 480.4500 301.5050 350.6250

18 419.375 480.4750 301.5300 350.6500

19 419.400 480.5000 301.5550 350.6750

20 419.425 480.5250 301.5800 350.7000

21 419.450 480.5500 301.6050

22 419.475 480.5750 301.6300

24 419.525 480.6250 301.6800

25 419.550 480.6500 301.7050

26 419.575 480.6750 301.7300

27 419.600 480.7000 301.7550

28 419.625 480.7250 301.7800

29 419.650 480.7500 301.8050

30 419.675 480.7750 301.8300

31 419.700 301.8550

32 301.8800

33 301.9050



6. TRANSMITTER OPERATION

6.1 Transmitter Operation

★ Make sure that the red emergency stop button (EMS) is elevated before the transmitter power is turned on.

1. Rotate the power switch: (Off) → (On) → (Start) to turn on the transmitter. The transmitter can be used

after the “power on” LED status display normally finished. Do not press any pushbutton when turn on the

transmitter.

6.2 Transmitter LED Display

1. Transmitter LED Display

(Fig. 23) Transmitter LED display

2. Transmitter Status LED Display & Trouble Shooting:

LED STATUS DISPLAY REASON SOLUTION

Green (on) → 0.1 sec.

(off ) → 0.9 sec. Standby ---

0.2 sec. per step:

Red (S)→

(2+S+3)→

(1+2+S+3+4)→

Green (S)→

(2+S+3)→

(1+2+S+3+4)

Transmitter power “on” ---

Green (on)→

0.1 second

(off )→

0.1 secondTransmitter active ---

Refer to Battery Power LED DisplayCharging ---

8 blinks: Red (on) → 0.1 sec.

(off)→

0.3 sec.CPU I/O error Repair encoder board

2 blinks: Red (on)→

0.1 sec.(off)

→ 0.3 sec.

Low battery power or out of battery

Charging transmitter or changefull-battery


0.1 sec.

(off)→

0.3 sec.EEPROM error Repair encoder board


0.1 sec.

(off)→

0.3 sec.Chip card defective Reset chip card


0.1 sec.

(off)→

0.3 sec.TX module defective Repair TX module


0.1 sec.

(off)→

0.3 sec.Jammed or defective

pushbutton

1. Do not press pushbutton when

turn on the transmitter.

2. Replace pushbutton

Red (on)→

0.1 second

(off )→

0.9 second

Transmitter low-voltage

warning

Charging transmitter or change

battery



N

Note: POS = Power Off Stop: When set the power switch to (Off) position, it will transmit “Stop” codes.

6.3 Transmitter LED Display

(Fig. 24)

LED STATUS DISPLAY REASON SOLUTION

5 blinks: Red (on) → 0.1 sec.

(off)→

0.3 sec.

No Chip card is inserted

- Insert programmed chip card or

refer to 1.

- Chip card defective:

1. Insert short pin into J1, the

transmitter can be used without

chip card. When use by chip card,

J1 must removed.

2. Replace new and programmedchip card.

Insert short pin into J2 jumper and

replace a new chip card. Then turn

on the power source, CPU will

copy data on the chip card. When

all five LED status display green(on), remove J2 pin.

Emergency stop or POS function

started (refer to note)---

Red (on)→

0.1 second

(off )→

0.1 second

Emergency stop with pressing

pushbuttonor pushbuttons jammed

---

0.5 sec. per step:

Green (1)→

(1+2)→

(1+2+S)→

(1+2+S+3)→

(1+2+S+3+4)

Update the chip card ---

0.5 sec. per step:

Green (4) → (3+4) → (S+3+4) →

(2+S+3+4) → (1+2+S+3+4)

Copy CPU data to chip card

1. All LED will display green (on)

when write data in chip card is

finished. Then remove J2 pin, the

transmitter can be used.

2. Any LED will display red (on)

when write data in chip card is

defective. Turn off the transmitterand try again or change new chip

card.

Check transmitter outline:A. Check the transmitter enclosure and pushbutton rubber boot. If damaged, enclosure and

pushbutton rubber boot should be replaced.B. Always keep the battery terminals clean.

C. Check if there is ample batter charge: Turn the transmitter on and check if the LED displays

“S” blinking green.

3. Loading the battery: Remove the battery cover screws which on the back of transmitter and load

the battery.



7. RECEIVER INSTALLATION

7.1 Preparation for Installation

2. Receiver Mounting Dimension

(Fig.25) Receiver Mounting Dimension

3. Ensure receiver is not set to the same frequency channel and ID code as any other units in

use at the same facility or within distance of 300 meters.

4. Prior to installation, make sure that the crane or equipment itself is working properly.

5. Use the multi-meter to check the voltage source available and ensure the receiver voltage

setting matches your power source. Prior to installation, switch off the main power source

to the crane or equipment.

1. Required Tools:(1) Flat Head Screwdriver (-) (6) Power Drill with φ10.5 ㎜ ~φ11 ㎜ Drill-Bit

(2) 5mm Wrench X 6 (7) Long nose pliers

(3) Multi-Meters (8) Cutter pliers

(4) Box end wrench or 14㎜

Wrench X 2

(5) Power Drill

(9) Output Cables (φ12.5㎜

~φ19.5㎜

) and wiring materials



7.2 Step-by-Step Receiver Installation

1. Select a suitable location to mount the receiver.

2. As much as possible, the location selected should be has the antenna visible from all area

s where the transmitter is to be used.

3. The location selected should not be exposed to high levels of electric noise.

4. Ensure the selected location has adequate space to accommodate the receiver enclosure.

5. The distance between the antenna and the control panel should be as far as possible.

6. Drill four holes on the control panel (10.50mm)

7. Tighten all screws provided.

8. Ensure AC ground is connected to the power input terminal block otherwise chassis groun

d should be connected to the chassis ground connection hole on the receiver enclosure.

9. Ensure all wiring is correct and safely secured and all screws are fastened.

(Fig. 26) Receiver mounting size



7.3 Receiver Status LED Displays

1. Receiver Status LED Display

(Fig 27) Receiver Status LED Display

2. Receiver Central CPU Status LED Display

LED INDICATION REASON SOLUTION

Constant (Green)Transmitted signals detected and

received.---

Fast Blinks (Green/ Red) Transmitter power (on) step incorrect

Blinks (Green) → 0.1 sec. Transmitted signal decoded. ---

Green (On)→

0.1 sec.

(Off)→

0.8 sec.

Decoder on standby

(No transmitted signals detected)---

2 Fast Blinks (Red) Incorrect transmitted ID code

Check transmitter’s ID code if same to

receiver.

3 Fast Blinks (Red)Main contact relay jammed or

defectiveReplace main contact relay

4 Fast Blinks (Red) RX module defective Repair RX module

5 Fast Blinks (Red) Chip card defective

Insert programmed chip card or refer to 1.

- Chip card defective:

1. Insert short pin into J1, the

transmitter can be used without chip

card. When use by chip card, J1 must

removed.

2. Replace new and programmed chip

card. Insert short pin into J2 jumperand replace

Insert replace a new chip card. Then

turn on the power source, CPU will

copy data on the chip card. When all

LED status display green (on), remove

J2 pin.

6 Fast Blinks (Red) Chip card data error Reset chip card by programming tool

7 Fast Blinks (Red) EEPORM error Repair decoder board

8 Fast Blinks (Red) System fault Repair decoder board

POWER LED DISPLAY STATUS ---

No light display Under-voltage ( voltage < 10.5V) Turn off and check the voltage source

Blinks (Red)→

0.1 sec. Over-voltage (voltage > 16V) Turn off and check the voltage source

1. Receiver Power Display 3. Receiver Status Display

2. Receiver SQ Status Display 4. Receiver MAIN Relay Display



8. BATTERYCHARGING &LED DISPALY

8.1 Battery Charging

1. Connect the power cord of the charger to the AC100 ~240V power outlet. Refer to page 7 Fig.4.

2. Insert spare battery pack to the Lithium charging holder of the charger. Refer to 8.2 for battery charger

status power LED display.

3. Turn off transmitter. Then adjust the transmitter to the charging fixing pole of the charger and fully insert

to the charging pole. Refer to 8.2 for battery charger status power LED display.

3

-

M

3

(Fig.28)

Insert battery pack to charger Insert transmitter to charger

(Fig.29)

21

12



8.2 Battery Status LED Display

(Fig. 30)

LED Status Display Reason/ Solution

1 Green (on) Normal-voltage

2 No LED display Under-voltage

Power LED

3 Green blink → 0.1 second Over-voltage

1 No LED display Standby

2 Red (on) Charging

3Red (on)

→ 0.1 sec., (off)

→ 0.3 sec.

Blink every 2 sec.Battery over-charging

4 Red (on) → 1.9 sec., (off) → 0.1 sec. Warm-up

5 No LED display Under-voltage

Battery charger

LED

6 Green (on) Charging is completed

1 Under-voltage

2No LED display

Standby

3 Red (on) → 1.9 sec., (off) → 0.1 sec. Warm-up

4 Red (on) Charging

5 Green (on) Charging is completed

6Red (on) 0.1 sec.

→ (off) 0.3 sec.

Blink twiceHigh circuit temperature.

7 Red (on)→

0.1 sec. Once Overtime charging

Transmittercharger LED

8Red (on) 0.1 sec. → (off) 0.3 sec.

Blink three timesCircuit defective

9.R e d ( o n ) 0.1 sec. → (off) 0.3 sec.

Blink four times

Remove battery before charging iscompleted.



9. TROUBLE SHOOTING

Should the operator find the equipment not operating normally, please check the chart below for simple trouble

shooting tip.

PROBLEM POSSIBLE REASON SOLUTION

Transmitter does not communicate

to receiver.

Transmitter and the receiver arenot on the same RF channel

(SQ not lit) or ID code.

Ensure the correct transmitter is inuse. The labels on the receiver and

the transmitter will identify the RF

channel and ID code in use.

Transmitter does not communicate

to receiver.

Low or no transmitting power

from the transmitter unit.

Turn on the transmitter with EMS

button elevated. If the status LED

displayed a blinking red light or no

lights at all, then turn the power off

and charging or replace

rechargeable battery.

No power to the receiver.Blown fuse or no input power

connection.

Ensure power input to the receiver

unit is correct. If power indicator

(AC) is not lit, please check the

receiver for any open fuse.

Pushbuttons interlocked

The pushbuttons are interlocked to

its self so no conflicting commands

can take place for safety purpose.

For example, pressing the Hoist

“UP” and Hoist “DOWN”

pushbutton simultaneously will

result in no command being sent.

Turn off the transmitter power

source then restart. Do not press

two pushbuttons simultaneously.

The transmitter status LED

displayed a blinking red lights 6

times.

Chip card program incorrect.Refer to software manual and reset

program.

The transmitter status LED

displayed a blinking red lights 5

times.

Chip card un-inserted. Insert chip card.

SQ LED blinking lights when the

transmitter is turned off. Or when

the transmitter is active normally,

the receiver is not active or

reaction delay.

Other radio interference. Change to other frequency.



10. SYSTEM SPECIFICATION

10.1 Transmitter Unit

Frequency Range : PLL 433MHz

Transmitting Range : 70 MetersHamming Distance : D ≧ 6

Channel Spacing : 25 KHz

Frequency Control : Quartz Crystals (PLL)

Frequency Drift : < 5ppm @ -10 ~ 70℃ ℃

Frequency Deviation : < 1ppm @ 25℃

Spurious Emission : > 50dBc

Transmitting Power : ~1 mW

Emission : F1DAntenna Impedance : 50

Enclosure Rating : IP-66

Source Voltage : 4.2VDC lithium / 1800mACurrent Drain : [email protected]

Operating Temperature : -10 ~ 70℃ ℃

Dimension : 273 mm x 65 mm x 52 mm (12 pushbuttons)

228 mm x 65 mm x 5 2mm (8 pushbuttons)

Weight : 610g (with 1800mA lithium battery)

10.2 Receiver Unit

Frequency Range : PLL 433 MHz

Channel Spacing : 25KHzHamming Distance : D 6≧

Frequency Control : RX module card or synthesizer (PLL)

Frequency Drift : < 5ppm @ -10 ~ 70℃ ℃

Frequency Deviation : < 1 ppm @ 25℃

Sensitivity : < -125dBm

Antenna Impedance : 50

Data Decoder Reference : Quartz Crystals (PLL)

Responding Time : 50 ~ 150 ms

Enclosure Rating : IP-66

Source Voltage : 100 ~ 240VAC @ 50/60 Hz.

Power Consumption : MAX 32W@240VAC 50Hz

Operating Temperature : -10 ~ +70℃ ℃

Output Contact Rating : 250V @ 10A

Dimension : 300 mm x 171 mm x 115 mm

Weight : 4,500g

10.3 Charger Unit

Frequency Range : PLL 433 MHz

Power Consumption : DC12 ~ 24V 24W or AC100 ~ 240V 50/60Hz 30W

Operating Temperature/ Humidity : - 20 ~ +40℃ ℃

/ 95%

Charging time : Battery: 3.6 hr (500mA), Transmitter: 2.4 hr

Heating time : To -3℃

Max 30 minutesDimension : 174.5 mm x 122 mm x 55 mm

Weight : 500g


http://slidepdf.com/reader/full/a4k-technical-manual080528 32/32

11. PARTS LIST

11.1 Transmitter Unit1. A4008-3 Transmitter BT4008

A4012-2 Transmitter BT4012

2. A4008 Encoder Board (2-speed) EN4008

A4012 Encoder Board(2-speed) EN4012

3. A4000 433MHz Transmitting RF Board TX40004. Transmitter chip card holder CH4000

5. 1-speed pushbutton PB4001

2-speed pushbutton PB4002

6. 2-stage selector switch SW-2T

3-stage selector switch SW-3T

2-stage selector switch (monentary) SW-3TM

7. Alpha 4008 transmitter upper casing BCTT4008

Alpha 4008 transmitter bottom casing BCTB4008

Alpha 4012 transmitter upper casing BCTT4012

Alpha 4012 transmitter bottom casing BCTB4012

Alpha 4008 transmitter casing TC4008

Alpha 4012 transmitter casing TC4012

8. Pushbutton rubber boot RB4000

9. Emergency stop button EMS500

10. Emergency stop red cap EMS04

11. Chip Card CHIP

12. Lithium battery BAT4000

13. Shoulder strap SS5000

14. Transmitter key + strap (all models) TK4000

15. Transmitter anti-vibration bumper (upper right/bottom right/upper left/bottom left) SB4000 \

11.2 Receiver Unit16. A4008 receiver R4008

A4012 receiver R4012

17. PLL RX Module (All Modules) RX4000

18. Relay board (16R) for Alpha 4008 models RY4001

Relay board (24R) for Alpha 4012 models RY4002

19. Regular Relay 12VDC RR12V

20. Safety Relay 12VDC SR12V

21. 433/419/447MHz Receiver Antenna ANT43322. A4000 Receiver Upper Enclosure RCT4000

A4000 Receiver Bottom Enclosure RCB4000

A4000 Receiver Enclosure (complete) RE4000

23. Shock Absorber SA4000

Decoder board DE4000

Decoder board (Infrared) DE4000

Power supply card (100-240VAC) PS4000

Transformer EV-00029 TEV029

11.3 Battery Charger24. Charger (AC100-240V) BCH4000

Documents

A4K Technical Manual_(080528)