Alvarado WATCHMAN User manual

Alvarado Manufacturing Company, Inc.
12660 Colony Street, Chino, CA 91710
Telephone: [phone]
Fax: [phone]
[email protected]
www.alvaradomfg.com
PID1244R6-2
Installation Instructions
WATCHMAN
Collision Avoidance System

WATCHMAN Installation Instructions
Page 2 For Assistance: [email protected] [phone] Created on: 06/26/2015
PID1244R6-2 ©Alvarado Mfg. Co., Inc.
WARNING
• Use only skilled individuals to install and service the Watchman. Read these instructions carefully before
beginning.
• Follow a proper maintenance schedule using skilled individuals.
• A 105dB alarm may trigger repeatedly during installation. Use hearing protection during installation.
• Do not drape, hang, or lean any objects from the Watchman.
• Do not continue to use the Watchman if it has been damaged or is functioning incorrectly.
• Do not modify or alter the Watchman.
• Only use Alvarado parts when repairing or maintaining the Watchman.
SAVE THESE INSTRUCTIONS
After installation, the installer is responsible for providing the owner or site manager with these instructions.
Safety Precautions
Contents
The following symbols are used throughout the manual to highlight important information and potential risks when
installing, servicing or using the Watchman.
WARNING This symbol is used in this manual to warn installers and operators of potential harm. Please read
these instructions very carefully.
CAUTION This symbol is used in this manual to designate potential conditions that may pose a risk to
pedestrians, personnel, property and equipment. Please read these instructions very carefully.
NOTE This symbol is used in this manual to designate useful information for the installer and operator.
Please read these instructions.
This symbol is used in this manual to warn installers and other personnel of high noise levels.
Safety Icons
Contents. ......................................................................................................................................................................... 2
Safety Icons..................................................................................................................................................................... 2
Safety Precautions. ......................................................................................................................................................... 2
Function........................................................................................................................................................................... 3
Parts List.......................................................................................................................................................................... 3
Additional Required Items (Not Included)........................................................................................................................ 3
Installation Steps. ............................................................................................................................................................ 3
Tools Required................................................................................................................................................................. 3
Installation Instructions.................................................................................................................................................... 4
Battery Installation. ................................................................................................................................................... 4
Placement and Mounting. ......................................................................................................................................... 4
AC Power Connection............................................................................................................................................... 5
Dry Contact Output Connection (Optional). .............................................................................................................. 6
Functions Check.............................................................................................................................................................. 6
Operation......................................................................................................................................................................... 6
Low-Battery Alert....................................................................................................................................................... 6
Alarm Duration Setting.............................................................................................................................................. 7
Cleaning and Maintenance.............................................................................................................................................. 7
CE Declaration of Conformity. ......................................................................................................................................... 8
Revision History............................................................................................................................................................... 9
ORIGINAL INSTRUCTIONS
HIGH NOISE
LEVELS

WATCHMAN Installation Instructions
Created on: 06/26/2015 For Assistance: [email protected] [phone] Page 3
©Alvarado Mfg. Co., Inc. PID1244R6-2
Installation Steps
• Level
• Tape Measure
• 5/32" Allen Wrench
• Ferrule Crimper
• Wire Cutters
• Screwdriver (Varies)
• Ladder
• Suspension Hardware (the following is recommended):
- Eye Bolts [Qty 2]
- 5/16" x 9" Turnbuckles [Qty 2]
- 3/32" Uncoated Cable [Length dependent on installation]
- 3/32" Aluminum Ferrules [Qty 8]
• C Cell Batteries [Qty 8] (Battery-powered models only)
Make sure that none of these parts are missing and/or damaged before beginning installation. If there are parts missing
and/or damaged, please stop the installation and contact Alvarado.
The Watchman serves as a visual and audio deterrent that warns forklift drivers and management of potential collisions
between forklifts and xtures before they happen. The Watchman installs in front of overhead doors, racking or virtually
any xture in a factory or warehouse. Impact with the Watchman tube triggers a loud alarm and ashing red lights. This
warns the forklift driver to stop immediately and alerts management of the incident.
Battery-Powered Models
1. Battery Installation
2. Placement and Mounting
3. Functions Check
AC-Powered Models
1. Placement and Mounting
2. AC Power Cord Connection
3. Dry Contact Output Connection (Optional)
4. Functions Check
Parts List
Function
For questions, please contact Alvarado at [phone], Monday – Friday 6:30am to 4:30 PST.
Please read this manual completely before installing or operating the product.
Watchman Unit (8' or 10')
[Qty 1]
• 50' AC Power Cord [Qty 1]
• Power Supply [Qty 1]
• Screw Terminal Connector [Qty 1]
Tools Required
Additional Required Items (Not Included)
AC Power Models (Only)

WATCHMAN Installation Instructions
Page 4 For Assistance: [email protected] [phone] Created on: 06/26/2015
PID1244R6-2 ©Alvarado Mfg. Co., Inc.
Adhere to the following placement guidelines:
• Verify the structural integrity of the object(s), i.e. joists, to which the Watchman will be suspended.
• To provide enough warning time to avert a collision, the Watchman must be placed at a sufcient distance in front
of the object being protected to allow the forklift driver sufcient time to react and stop after Watchman activation.
What a sufcient distance is depends on the application where the Watchman is being used. Relevant factors
include the object being protected, the trafc pattern of the facility, available hanging space, and forklift operating
speeds. For applications where the Watchman will be placed in front of a roll-up door, locating the Watchman a
minimum of 4' in front of the door is generally an appropriate distance.
• Place the bottom of Watchman's tube a minimum of 2" below the object or surface being protected.
• Ensure the suspension cable angles are between 90° and 135° [Figure 3].
Battery installation is only applicable to battery-
powered models. For AC-powered models, skip to
the Placement and Mounting section below.
1. Remove the packaging from both end caps.
2. Locate the master side end cap on the opposite end of the
Watchman decal [Figure 3]. Using a 5/32" Allen wrench,
remove the screw securing the end cap to the tube.
3. Remove the end cap. Locate the thumb screw on the plastic
bar used to keep the battery packs in place [Figure 1].
4. Loosen the thumb screw and swing the plastic bar to the
side to gain access to battery packs [Figure 2].
5. Disconnect the (2) battery pack connectors and slide out the
battery packs from the end cap [Figure 2].
6. Insert (8) C cell batteries into the battery packs, ensuring
correct battery polarity. Make sure batteries are fully
inserted into the battery packs.
7. Return the battery packs to the end cap and reconnect the
(2) battery connectors. Swing the plastic bar back into place
and tighten the thumb screw.
8. Using a 5/32" Allen wrench, reinstall the end cap.
Installation Instructions
Battery Installation
NOTE Fig. 1
Fig. 2
CAUTION
9V Connectors
Thumb Screw
Fig. 3
Left End Cap
(Master Side)
135° 135°
90° 90°
Watchman Decal
Right End Cap
(Slave Side)
Placement and Mounting

WATCHMAN Installation Instructions
Created on: 06/26/2015 For Assistance: [email protected] [phone] Page 5
©Alvarado Mfg. Co., Inc. PID1244R6-2
Once the Watchman's placement has been determined:
1. Install eye bolts to the object(s) to which the Watchman will be suspended (joist, girder, etc).
2. Using ferrules and a ferrule crimper, secure suspension cables to the eye bolts [Figure 4].
3. Install (1) turnbuckle per suspension cable using ferrules and a ferrule crimper [Figure 5].
4. Attach suspension cables from the turnbuckles to the Watchman's eye bolts using ferrules and a ferrule crimper.
5. Using a level, check horizontal alignment of the Watchman. Adjust the height of the Watchman as needed using
the turnbuckles.
Placement and Mounting (cont.)
AC Power Connection
AC power connection is applicable to AC-powered
models only. When connecting AC power, make
sure no batteries are installed.
1. Locate the AC power cord at the master side end cap
on the opposite end of the Watchman decal
[Figure 3].
2. Run the AC power cord up along the suspension
cable and swag it over to an adjacent wall. Make sure
there is sufcient cord slack to allow the Watchman to
move laterally in the case of a collision event
[Figure 6].
3. Obtain the included AC power supply and screw
terminal connector. Locate the RED and BLACK
wires of the AC power cord. Using an appropriate
screwdriver, connect the RED wire to the (+) terminal,
and the BLACK wire the (–) terminal on the screw
terminal connector.
4. Plug the power supply into a 120 VAC power outlet,
and to the screw terminal connector.
NOTE
NOTE
NOTE
There are many methods of mounting the Watchman. The following instructions assume that the recommended
suspension hardware is being used. Instructions on the use of other suspension hardware and methods are outside
the scope of this manual.
NOTE
The AC power cord is 50' in length.
The WHITE and GREEN wires bundled with the
AC power wires are used for dry contact output
(see next page). If you are not going to use the dry
contact output, ensure wires remain insulated.
Fig. 6
Swag
Swagging the AC power cord
allows the Watchman to move
freely back and forth without
excessive strain on the cord.
Wall
Fig. 4 Fig. 5

WATCHMAN Installation Instructions
Page 6 For Assistance: [email protected] [phone] Created on: 06/26/2015
PID1244R6-2 ©Alvarado Mfg. Co., Inc.
The Watchman's bidirectional shock sensors are designed to detect collisions to the front and back of the ABS tube
[Figure 7]. When a collision occurs, an audible alarm will sound and both red lights will ash for approximately (4)
seconds.
Under normal usage, fresh batteries will last approximately 1.5 - 2 years. When the batteries are in need of
replacement, the Watchman will begin to chirp once every (5) minutes.
Due to operational variables, it is not possible to calculate how long the Watchman will operate after the low-battery
alert begins. For this reason, batteries should be replaced promptly after the low-battery alert begins to sound.
Operation
Fig. 7
Collision Detection Zone
Low-Battery Alert
NOTE
The alarm duration can be set to 4 or 8 seconds. The factory default setting for alarm duration is 4 seconds.
Refer to the instructions below for changing the alarm duration setting.
To perform a functions check:
1. Strike the front face of the tube with a hard object such as a broom handle. The alarm should sound and both
lights should ash.
2. Repeat with the other side of the tube.
Functions Check
HIGH NOISE
LEVELS
Dry Contact Output Connection (Optional)
The dry contact output enables the Watchman to activate another device such as an external light, alarm, or counter,
during a collision event. The output provides a 100ms dry contact.
1. Connect the WHITE and GREEN wires to the dry contact terminals on your external device.
NOTE
The contacts have a maximum current rating of 500mA.

WATCHMAN Installation Instructions
Created on: 06/26/2015 For Assistance: [email protected] [phone] Page 7
©Alvarado Mfg. Co., Inc. PID1244R6-2
Cleaning and Maintenance
Use and all-purpose cleaner and damp cloth to clean the Watchman unit.
Perform the following maintenance steps on a quarterly basis:
• Check all suspension hardware (including the Watchman's eye bolts). Tighten or replace if necessary.
• Inspect the ABS tube and end caps for cracks or other damage if there has been a collision.
• Replace the batteries (if applicable).
• Perform the functions check as described on page 6.
Alarm Duration Setting
To change the alarm duration setting:
1. Using a right-angle #2 Phillips screwdriver, remove
the metal lens cap guard.
2. Using a #10 torx wrench, remove the red lens cap.
3. Locate the SW1 switch. Set the switch to 4 SEC or
8 SEC [Figure 8].
4. Replace the red lens cap.
5. Replace lens cap guard.
Tools Required:
• Right-Angle #2 Phillips Screwdriver
• #10 Torx Wrench Fig. 8

WATCHMAN Installation Instructions
Page 8 For Assistance: [email protected] [phone] Created on: 06/26/2015
PID1244R6-2 ©Alvarado Mfg. Co., Inc.
CE Declaration of Conformity

WATCHMAN Installation Instructions
Created on: 06/26/2015 For Assistance: [email protected] [phone] Page 9
©Alvarado Mfg. Co., Inc. PID1244R6-2
Revision Date Author Description
6-0 11/18/13 A. Flores CE compliance. Imported to new layout.
6-1 04/29/15 A. Flores Updated parts list. Low-Battery Alert operational status.
6-2 06/26/15 A. Flores Changed AC Power Cord length from 30' to 50'.
Revision History

Alvarado Manufacturing Company, Inc.
12660 Colony Street, Chino, CA 91710
Telephone: [phone]
Fax: [phone]
[email protected]
www.alvaradomfg.com
© 2013 Alvarado Manufacturing Company, Inc.
This work may not be reproduced, published or redistributed, in whole or in part, without the express prior written permission of Alvarado.