aci 2002 User manual

Remote Control Systems
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200 Series 400 Series 500 Series
REMOTE CONTROL SYSTEMS
OPERATION MANUAL

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TABLE OF CONTENTS
1.0 WARRANTY .............................................................................................................................................................. 4
2.0 SAFETY PRECAUTIONS........................................................................................................................................... 5
2.1 Safety Alert Symbols...................................................................................................................................... 5
2.2 Operating Precautions ................................................................................................................................... 6
2.2.1 Attention ......................................................................................................................................... 6
2.2.2 Precautions (500 Series)................................................................................................................. 6
2.2.3 Emergency Procedures (500 Series)............................................................................................... 6
3.0 GENERAL OPERATION (500 SERIES)..................................................................................................................... 7
3.1 Transmitter Configuration .............................................................................................................................. 7
3.1.1 Model 5008AB................................................................................................................................ 8
3.1.2 Model 50011AB.............................................................................................................................. 9
3.2 General Operation ........................................................................................................................................10
3.3 Special Functions Operation.........................................................................................................................10
3.3.1 Power-On Operations ...................................................................................................................10
3.3.2 Acceleration Operation ..................................................................................................................11
3.3.3 Inching Operation..........................................................................................................................11
4.0 FUNCTION SETTINGS (DEFINED BY CUSTOMER) .............................................................................................. 12
4.1 Pushbutton Function Setting:........................................................................................................................12
5.0 CORRESPONDENCE BETWEEN PUSHBUTTON AND RELAY OUTPUT (500 SERIES) ....................................... 16
6.0 ID-CODE REMOTE SETTING (500 SERIES) .......................................................................................................... 18
7.0 RECEIVER VOLTAGE SELECTION (500 SERIES) ................................................................................................. 20
7.1 Switch the plug to choose voltage ................................................................................................................20
8.0 BOARD LAYOUTS .................................................................................................................................................. 21
8.1 Transmitter PC Board Layout (200 & 400 Series) ..........................................................................................21
8.2 Receiver PC Board Layouts (200 & 400 Series).............................................................................................22
8.3 Independent COM Line.................................................................................................................................25
9.0 FREQUENCY CHANGE (200, 400, & 500 SERIES) ................................................................................................ 26
9.1 Procedures...................................................................................................................................................26
9.2 VHF Band Conversion Table.........................................................................................................................28
9.3 UHF Band Conversion Table ........................................................................................................................29
9.4 Changing RO/START N.O. (normally open) INTO N.C. (normally closed)......................................................30
10.0 TROUBLESHOOTING........................................................................................................................................... 31
11.0 WIRING DIAGRAMS ............................................................................................................................................. 32
12.0 DIMENSIONS & SPECIFICATIONS...................................................................................................................... 34
12.1 Dimensions.................................................................................................................................................34
12.1.1 500 Series: Model 5008 ...............................................................................................................34
12.1.2 500 Series: Model 50011 .............................................................................................................35

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12.1.3 200 Series Receiver.....................................................................................................................36
12.1.4 400 Series Receiver.....................................................................................................................37
12.2 Specifications .............................................................................................................................................38
12.2.1 200 Series ...................................................................................................................................38
12.2.2 400 Series ...................................................................................................................................39
12.2.3 500 Series ...................................................................................................................................40

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1.0 WARRANTY
Every product is thoroughly inspected and tested before it is shipped from the factory. If any problem develops within
one year, return the product prepaid to the factory. If an inspection reveals that the problem is caused by defective
workmanship or material, repairs will be made without charge and the product will be returned with the shipping prepaid.
Excluded Items
This warranty does not cover:
 Deterioration caused by normal wear, abuse, chemical or abrasive actions, improper
maintenance or excessive heat.
 Problems resulting from repairs, modifications, or alterations made by people other
than factory or ACI representatives.
 If the product has been abused or damaged due to an accident.
 If repair parts or accessories other than ACI equipment are used on the product; they
are warranted only to the extent that they are warranted by the manufacturer of said
parts or accessories.
Remarks
EXCEPT AS STATED HERE, ACI MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES
FOR A PARTICULAR PURPOSE.
Alterations or modifications of equipment and use of non-factory repair
parts can lead to dangerous operation and injury.
To avoid injury:
DO NOT alter or modify equipment.
DO NOT use equipment to lift, support or otherwise transport people.
DO NOT suspend unattended loads over people.

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2.0 SAFETY PRECAUTIONS
2.1 Safety Alert Symbols
Throughout this manual are steps and procedures that can prevent hazardous situations, the following symbols are used
to identify the degree or level of hazard seriousness.
DANGER, WARNING AND CAUTION NOTICE
Symbol
Description
Danger
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury and
property damage.
Warning
Indicates an imminently hazardous situation which, if not
avoided, could result in death or serious injury and
property damage.
Caution
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury or
property damage.
Notice
Notifies people of installation, operation or maintenance
information which is important but not directly hazard
related.
Failure to read and comply with any of the limitations noted in this manual can result in serious bodily
injury or death, and/or property damage.

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2.2 Operating Precautions
2.2.1 Attention
1. Due to the complex nature of equipment, it is necessary to read the entire manual before installation.
2. Never allow any unauthorized personnel to dismantle equipment as this may cause equipment damage.
3. The equipment has been stringently tested for quality assurance before delivery from factory. However, it must
not be used in extremely dangerous situations or where damage may result.
4. After operation, switch off crane main power as well as receiver unit and remove rotary key from transmitter unit.
5. Keep the transmitter in a safe place when not in use to avoid any unintentional operation.
6. The crane should be equipped with a main power relay, limit switch, and other safety devices required.
7. Do not use this device during an electrical storm or where there are conditions of high electrical interference.
8. Always check transmitter batteries and receiver input power condition before operation.
9. The installation and maintenance service is allowed only when the crane and receiver power are off to avoid
electrical shock.
10. The contents of the manual may be ammended by the manufacturer without notice.
11. The specification and function is subject to change without notice by manufacturer.
2.2.2 Precautions (500 Series)
1. Press EMS button and switch off main power of crane and receiver after operation. Then, remove transmitter
rotary key and keep in a safe place.
2. The following may cause receiver response delay and you should stop operation immediately when these
situations occur.
a. Beyond operating range.
b. During severe radio interference.
3. Remove transmitter batteries when not in use for a long period of time.
4. To extend product life, please follow the standard operating procedure and maintain system regularly.
2.2.3 Emergency Procedures (500 Series)
In case of emergency, please follow the procedure below:
5. Press EMS button and stop operation.
6. Switch rotary key to “OFF” position and remove it from transmitter unit.
7. Switch off crane main power.
8. Contact the authorized distributor for further assistance.

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3.0 GENERAL OPERATION (500 SERIES)
3.1 Transmitter Configuration
1. Antenna
2. Emergency Stop
3. LED indicator
4. Motor Pushbutton
5. Auxiliary Pushbutton R1-R4
6. F1 Pushbutton
7. Start Pushbutton
8. Battery Cover
9. Rotary Key Switch
10. Security Key

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3.1.1 Model 5008AB

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3.1.2 Model 50011AB

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3.2 General Operation
1. Install two (2) new AA-size alkaline batteries in the battery box of MODEL 50011, then insert into battery case
of transmitter; or battery chamber of 5008, and screw in transmitter's bottom cover. Make sure the "+" and "-
"directions are correct.
2. Insert security key in the "OFF" position.
3. Turn on the power according to the "Power-On Modes ". Note: LED indicator will flash red if proper
procedures are not followed.
4. Operate transmitter by pressing each pushbutton.
5. After operation, perform the following procedures in sequence:
(1) Press EMS mushroom,
(2) Rotate security key or rotary key switch counterclockwise to the " OFF " position,
(3) remove key and keep it in a safe place, (4) remove batteries if not to be used for a long period of
time.
3.3 Special Functions Operation
3.3.1 Power-On Operations
Power-On means that the Main-Relay on the receiver will switch on as soon as the transmitter sends a signal
and then the receiver will be on standby for continuous control. There are 2 options for "Power-On Mode":
1. Any Pushbutton Power-On Mode
a. Rotate "EMS" mushroom clockwise 45°and pull out.
b. Turn security key clockwise to "ON" position for 50011; Rotary key switch clockwise to "ON" for
5008.
c. Press any pushbutton on the transmitter. This will turn on the power as well as execute the
function of pushbutton.
2. " START' ' Pushbutton Power-On Mode
a. Rotate "EMS" mushroom clockwise 45° and pull out.
b. Turn security key clockwise to "ON" position for 50011; Rotary key switch clockwise to "ON" for
5008.
c. Press "START" pushbutton on the transmitter to turn on power for 50011; Continue to turn rotary key
switch to "START" position to turn on power for 5008 (the rotary key switch will return to "ON"
position automatically after being released .

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3.3.2 Acceleration Operation
1. For 50011 : The "START" pushbutton is acceleration pushbutton.
2. For 5008: The "START" key is the acceleration key.
3. When a motion is in the second speed, quick touch of acceleration pushbutton will accelerate the speed.
Repeated touch of acceleration pushbutton will increase the speed. Note: When accelerating, the motion
pushbutton must be depressed and held in the second speed. If motion pushbutton is released , there will
be no acceleration and speed will return to zero.
3.3.3 Inching Operation
1. "Start" pushbutton is set for "inching" function.
2. Press and hold inching pushbutton .
3. Press any motion pushbutton to perform the inching motion. Note: The other pushbutton of transmitter
must be released before pressing the inching pus hbutton.

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4.0 FUNCTION SETTINGS (DEFINED BY CUSTOMER)
4.1 Pushbutton Function Setting:
UP/DOWN, NORTH/SOUTH, EAST/WEST,R1/R2, R3/R4 Pushbutton Function Setting
Item
Title
Content
Description
1
Button Function
1. Normal/Normal
2. Toggle/Toggle
3. No/Off
4. Normal/Toggle
5. Dual Motor(1)/Dual Motor (1)
6. Dual Motor(2)/Dual Motor (2)
7. 3 Speed Accel. / 3 Speed Accel.
8. Digital Accel. / Digital Accel.
9. Normal/Dual Motor(1)
10. Normal/Dual Motor(2 )
11. Toggle/Dual Motor (1)
12. Toggle/Dual Motor (2)
13. Toggle/3 Speed Accel.
14. Synthesis/Synthesis
NOTE: 500 Series Model
5008
Up/Down Pushbuttons are for full
functions, the rest are for Normal,
Toggle, On, Off only.
Normal: The relative relay is "ON" when the
Pushbutton is pressed and held.
The relative relay is "OFF" when the Pushbutton is
released.
Toggle: Press the Pushbutton and release once for
"ON", re-press and release for "OFF"
ON & OFF: Two relative Pushbuttons are set to
respectively control the same relay. If a Push- button
set as "ON" is pressed and released, the
relay remains conductive. At this time, the other
Pushbutton can't change the situation of this relay
except the Pushbutton set as "OFF".
Dual Motor(1): When Pushbutton is released from
2nd speed and back to 1st, the 1st speed relay is
activated again til the Pushbutton is totally released.
Dual Motor(2): When Pushbutton is released
from 2nd speed and back to 1st, the 1st speed relay
is not activated but bypassed.
3 Speed Accel.: Use "START" to accelerate to
3 Speed
Digital Accel.: Use "START" to accelerate to 4
Speed
Synthesis: Three relays used for two dual- speed
motions, the fourth relay works as
independent "TOGGLE" ON and OFF function
when two Pushbuttons pressed simultaneously and
again.
2
Acceleration
Delay
0-4.0 seconds
This function is used to set the time interval between
acceleration relays (i.e. conduction delayed time of
acceleration delay. It is suitable for accelerative
operation to prevent the crane from running at a higher
speed to damage the motor.
3
EMS Control
1. Control by EMS
2. Bypass EMS
Control by EMS means the corresponding relay of
function Pushbutton is controlled by EMS
mushroom or emergency stop signal. Bypass EMS
means the corresponding relay
of function Pushbutton will not be controlledby
EMS mushroom or emergency stop signal.
4
Interlock
Function
1. Interlock Delay
0-2 seconds
2. Non-Interlocked
Interlock: If it is dangerous or improper to
operation two motions at the same time, select
"INTERLOCK". Delay time means the time interval
before next motion is valid.
Non-Interlocked: If two motions are safe or
irrelevant to operate at the same time, select
"NON-INTERLOCKED".

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Start/F1 Pushbutton Function Setting
Item
Title
Content
Description
1
Button Function
START
F1
Inching: "Inching" means that once the Push-
button is pressed, relative relay will be activated
within a certain period of time to operate a short
but precise movement. Press and hold inching
Pushbutton and then press motion Pushbutton to
perform the inching motion.
Acceleration: When the motion is at the
2nd speed, quick pushing on acceleration
Pushbutton will accumulate one speed each
time and the relative relay will turn on accord-
ingly. When accelerating, the motion Pushbutton
must be pressed and held in the 2nd speed. If
motion Pushbutton is released, there will be no
acceleration and the speed will return to zero.
1. Normal
2. Toggle
3. Inching/
Accel.
1. Normal
2. Toggle
3. Dual Motor (1)
4. Dual Motor (2)
2
EMS Control
1. Control by EMS
2. Bypass EMS
Control by EMS means the corresponding relay
of function Pushbutton is controlled by EMS
mushroom or emergency stop signal.
Bypass EMS means the corresponding relay of
function Pushbutton will not be controlled by EMS
mushroom or emergency stop signal.
3
Inching
0.1 -4.0 seconds
Select the time interval of each inching motion.
4
Acceleration
Delay
0-4.0 seconds
Select the time interval for each acceleration.

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Transmitter Function Setting
Item
Title
Content
Description
1
POWER-ON
Mode
1. Any Pushbutton
2. START Pushbutton
Any Pushbutton: When mushroom is released
and security or rotary key is at "ON" position, the
receiver will be "POWER-ON"by pressing any
Pushbutton on transmitter.
START Pushbutton: When mushroom is released
and security or rotary key is at "ON" position, the
receive will be "POWER-ON" only by pressing
"START" Pushbutton on transmitter.
2
Transmit Mode
1. Non-Continuous
2. Continuous 15 seconds-
30 seconds OFF
3. Continuous Never OFF
Non-Continuous: Once the receiver is "POWER-
ON", the transmitter will transmit signal only when
Pushbutton is pressed. This mode can save the
power of transmitter.
Continuous Due Time OFF: Transmitter will
transmit signal continuously during "POWER-
ON" and stop sending signal if no Pushbutton is
pressed within selected timeframe.
Continuous Never OFF:Transmitter will keep
sending signal unless turned off manually.
3
Auto Off
1. Enable
2. Disable
Enable: When Transmit Mode is set for
continuous, it will send an EMS signal to "POWER-
OFF" the receiver if it is set to auto off in a certain
timeframe.
Disable: Disable the function to send EMS signal
to receiver before the transmitter is off.
4
Normal OP LED
1. ON
2. ON Every 1 -4 seconds
3. OFF
ON: LED indicator will glow with green color when
transmitter is transmitting. It still works for warning
and fault indication with first priority.
ON Every 1 - 4 seconds: LED indicator is flashing
with green color every 1 -4 seconds.
OFF: LED indicator will not work during normal
operation in order to save power. But, it is still
available for warning and fault indication.
5
Powersaving
1. Enable
2. Disable
Enable: By using firmware to control frequency
transmission cycle period, thus to reduce power
consumption of transmitter. Simultaneously, the
operating distance will be decreased when the
"POWERSAVING" mode is enabled.
Disable: Disable this function.
6
Remote Setting
1. Enable
2. Disable
Enable: Allow the transmitter to do ID-Code
remote setting.
Disable: Not allow ID-Code remote setting on
transmitter.

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Receiver Function Setting
Item
Title
Content
Description
1
Passive Act
1. Relay OFF
2. POWER OFF
Passive Act:The function of this item is used to
set the reaction of receiver when no command
signal is received from transmitter in certain time
(the default time is 0.5 seconds).
Relay OFF means the Main Relay is still "ON" but
the other relays with the "NORMAL:'function are all
de-energized. It is not necessary to re-commence
the procedure of "POWER-ON" again to continue
operating.
POWER OFF means the Main Relay and all of
the other relays with the "NORMAL:' and "Control
by EMS" functions are going to de-energize and
it is essential to re-commence the procedures of
"POWER ON" again to continue operation.
2
Passive Act Tim-
ing
0.1 -4 seconds
The duration working time of receiver between
passive act is activated and the power or relay is
really OFF.
3
Auto-OFF (RX)
1. None-Execute
2. 10 minutes~4 hours
POWER OFF
Enable: When Transmit Mode is set for continu-
ous, it will send an EMS signal to "POWER-OFF"
the receiver if it is set to auto off in a certain time-
frame.
Disable: Disable the function to send EMS signal
to receiver before the transmitter is off.
4
Remote Setting
1. Enable
2. Disable
Enable:AIIow the receiver to do ID-Code remote
setting.
Disable: Not allow ID-Code remote setting on
receiver.

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5.0 CORRESPONDENCE BETWEEN PUSHBUTTON AND RELAY
OUTPUT (500 SERIES)
Note: When pushbutton is released from 2nd speed and back to 1st one, the 1st speed relay is activated again until
the pushbutton is completely released.

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Note: When Up and Down pushbuttons are pressed at the same time, the second relay works as “Toggle”, released
when they are pressed simultaneously again.

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6.0 ID-CODE REMOTE SETTING (500 SERIES)
The use of Copier (500 Series)
1. Insert the six (6) pins of the female plug into the male socket inside the TX or RX of the 500 Series.
2. To copy and save the data from TX or RX, put the magnetic key onto the receptor to connect. To transfer
the saved data from the copier to TX or RX, release the magnetic key from the receptor.
3. Press and release the "1" pushbutton (or 2 or 3) to copy and save the data (when the magnetic key is
on) from TX or RX, after the green indicator light has flashed, the transfer is finished, disconnect the
plug. Complete the same procedure to transfer the data from copier to TX or RX (when magnetic key is
off). Note:
(1) Make sure the power of TX or RX is off when copying.
(2) The copier can copy both function settings and ID-Code, but to pair the crystal is still essential to
match both TX and RX for communicating with each other.
ID-Code Remote Setting (500 Series)
ID-Code remote setting allows you to pair the new TX or RX if one of them is damaged. Using ID-Code remote
setting will allow both the TX and RX to have the same ID-Code.
Please make sure the following conditions are met before ID-Code remote setting:
1. Both TX and RX are of the SAME model and frequency.
2. Place the transmitter as close as possible to the receiver to avoid interference.
3. Turn off the RX power for at least 10 seconds and turn it on again.
ID-Code Remote Setting Instructions
1. Press and hold the transmitter EMS button and "UP" pushbutton.
2. Press "DOWN" pushbutton four (4) times and then release "EMS & UP" push buttons when the red light
on the transmitter is flashing.
3. Start the system as you usually would.

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ID-Code Remote Setting (continued)
ATTENTION:
 In case ID-Code remote setting fails, repeat the instructions above within 4
minutes.
 ID-Code remote setting is available for ID Code only. It will not change
function settings.
 Within the operating distance, all same model systems on the same frequency
will be paired with the transmitter's ID Code.
 A jumper added inside the receiver is necessary to enable the ID-Code remote
setting function.
Model 5008
Model 50011
Jumper to add for ID-
Code remote setting

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7.0 RECEIVER VOLTAGE SELECTION (500 SERIES)
Receiver Voltage Selection
There are two (2) types of power voltages (DC & AC) available for the 500 Series:
1. DC
Type: Input Voltage: 12 ~ 24 VDC Relay Contact: 1OA-36 VDC
2. AC Type: Three (3) different AC transformers: 48/110/220V, 48 / 220/380V,
3. 110/220/380V. Disconnect the AX's power, select the proper voltage and plug in the connector.
7.1 Switch the plug to choose voltage
Transmitter Battery Information
Two (2) AA size alkaline batteries are required for the transmitter. The LED will flash green when the battery
power is sufficient. The LED will flash red when the battery power is low.
Note: The operating distance will become shorter and intermittent when the battery is low (replace with new
batteries when battery power is low).
DO NOT USE RECHARGABLE BATTERIES.