RF & Wireless Systems · Hardware

Wireless Crane Control System

Name: Wireless Crane Control System
Brand: Elmes

TXI-VK200 / RXO-RT207-27D-6AN

Encrypted RF link, millions of operations in the field.

TXI-VK200 handheld crane transmitter: orange body, mushroom emergency stop, 7-segment display and 8 two-speed arrow keys

Overview

The problem in the field. On overhead cranes, a pendant control ties the operator to the area under the load and to the line of travel; festoon cable systems suffer from breaks, crushing and connection faults, and every fault means a production stop. Imported wireless remotes come with a fixed button layout, special functions (analog speed, extra relays, interlocks) cannot be added, and service is abroad. When several cranes work in the same plant, remotes triggering each other is a safety risk.

The solution. The Elmes crane control system carries commands from a handheld or belt-pack transmitter to the receiver in encrypted RF packets; the receiver's relay contacts connect directly to the contactors or drives. Every system has a unique ID, so transmitters with a different ID cannot affect the receiver. The emergency stop command is processed with priority; if the link drops or the battery runs out, the receiver releases its relays to a safe state. The operator controls the load from wherever they see it best.

Customization. 6–32 channels, two-speed buttons, joystick/analog speed, analog 0/4–20 mA and 0–10 V outputs (up to a receiver with 27 digital + 6 analog outputs), latch/momentary selection and reverse-button protection are configured per application. For non-crane machines such as concrete pumps, horizontal lifts and doors/barriers, the same hardware is offered as Wireless Machine Start & Control.

In a factory hall, an operator controls a load on the overhead crane with the TXI-VK200 transmitter in a gloved hand — In use

Crane control family: 8-channel handheld, 32-channel belt-pack, new N3 series with OLED and the RXO-RT207 DIN-rail receiver — Product family

Features

Emergency stop (E-Stop): mushroom button on the transmitter; a priority command that opens all relays on the receiver.
Two-speed buttons: low/high speed with a two-stage press.
Analog / joystick control: analog or digital joystick; 0/4–20 mA and 0–10 V analog transfer; 6 analog outputs on the receiver.
Latch / momentary selection: latching or hold-to-run operation per channel.
Pilot relay and reverse-button protection: opposite-direction interlock; forward and reverse cannot run at the same time.
On/off lock: key-switch or code-protected start.
Automatic signal cut-off on low battery plus charge/transmit LEDs.
OLED display: optional.
Multiple transmitters: more than one remote can be paired to the same receiver.
TargetOn-screen status: RSSI, battery and active channel display.
TargetSingle active remote lock: with multiple transmitters, a hand-over protocol keeps only one remote in control at a time.
TargetDual-channel E-Stop path: separate safety relay with monitoring and an EN ISO 13850 button.
TargetAutomatic channel switching: keeps the link alive by changing channels in noisy environments.
TargetDual battery: a spare battery for uninterrupted operation.
TargetOverload protection module: a wireless load-cell transmitter that locks the hoist channel when the load limit is exceeded.
TargetMotion detection: automatic stop via accelerometer if the transmitter is dropped or turned over.
TargetFunctional safety: EN ISO 13849-1 PL d / IEC 62061 SIL 2 for the E-Stop path.

System components

System components
Model code	Component	Description	Request a quote
TXI-VK200	Handheld / belt-pack transmitter	6, 8, 10, 16, 24 or 32 channels; emergency stop; two-speed button and joystick options	Request a quote: TXI-VK200
RXO-RT207-27D-6AN	Receiver	Up to 27 digital + 6 analog outputs; relay contacts wired to contactors/drives	Request a quote: RXO-RT207-27D-6AN

Specifications

Values marked “Target” are design targets, next-generation values or chip-vendor data; they are updated as measurement and certification are completed.

Current system
Frequency	433 MHz ISM band; no frequency licence required
Control channels	6 / 8 / 10 / 16 / 24 / 32
Receiver outputs	Up to 27 digital + 6 analog outputs
Analog signal	0/4–20 mA, 0–10 V
System ID	65,000 unique IDs

Radio (new series)
Frequency band	433.05–434.79 MHz, 8 channels; 868 MHz as an option onlyTarget
RF channels	8 (200 kHz spacing)Target
Output power	+22 dBm, adjustable; within ETSI limitsTarget
Receiver sensitivity	−129 dBm @ SF11/BW125 (chip datasheet)Target
Modulation	LoRa SF7–SF9 (SF7 for low latency)Target
Data rate	~5.5 kbps at SF7Target
Antenna connector	u.FL / SMATarget

Range
Open field	≥ 1000 m (SF7, 2 dBi antenna, 2 m height)Target
Industrial environment	≥ 150 m indoorsTarget

Communication & security
Encryption	AES-128-CCM + counter (replay protection)Target
Addressing	16-bit network ID + 16-bit address + device UIDTarget
Pairing	At the factory and in the field with a service toolTarget
Systems on the same site	≥ 8 independent networks (channel × network ID)Target

Performance & fail-safe
Command latency	≤ 50 msTarget
Fail-safe on link loss	≤ 500 ms, adjustableTarget
Watchdog	Independent hardware watchdog (IWDG)Target

Power
Receiver supply	9–36 VDC; 230 VAC optionTarget
Receiver consumption	Depends on the number of relays
Transmitter battery	Li-ion 3.7 V, replaceable packTarget
Continuous operation	≥ 48 hoursTarget
Charging time	≤ 4 hoursTarget

Inputs / outputs
Relay outputs	8 / 16 relays; dedicated carrier board for the 27 + 6 class; 5 A / 250 VACTarget
Analog outputs	2 (carrier board); 6 with an add-on boardTarget
Communication	RS485 / Modbus RTU optionTarget

Mechanical & environmental
Receiver enclosure	DIN-rail housingTarget
Transmitter housing	Industrial polycarbonateTarget
Ingress protection	IP65 transmitter, IP65 receiver boxTarget
Operating temperature	−20…+60 °C transmitter (battery), −25…+70 °C receiverTarget
Humidity	5–95 %, non-condensingTarget

Warranty & service
Warranty	2 years; repair and spare parts in Ankara
Spare-parts support	5 yearsTarget

Applications

Overhead and gantry cranes
Ceiling cranes
Mobile cranes
Port equipment
Steel mills / foundries (high EMI)
Logistics warehouses
Construction machinery

For non-crane machines (concrete pumps, horizontal lifts, doors/barriers, pump start/stop), the same transmitter and receiver family is described on the Wireless Machine Start & Control page. The existing pendant can stay in place as a backup; the receiver relays connect to the contactor coils in place of the pendant contacts.

Compliance & documentation

The system operates in the 433 MHz ISM band within legal power limits and requires no frequency licence. Product-level documentation is being prepared according to the plan below.

CE – RED 2014/53/EU (EN 300 220-2, EN 301 489-1/-3)
Starting at module level
Target
LVD (EN 62368-1 / EN 61010-1) — 230 VAC receiver
Target
RoHS declaration
Target
EN 13557 — crane controls and control stations
Target
EN ISO 13849-1 PL d / IEC 62061 SIL 2 — E-Stop path
Target
EN ISO 13850 — emergency stop
Target
CE declaration of conformity, user manual and wiring diagram
Target

References

Some of the organizations using this product family.

Sistek
Hidropol
Ademsan
Tekel Binası

Frequently asked questions

How many crane systems can run on the same site without interfering?

Every system has a unique ID (65,000 IDs); transmitters with a different ID cannot affect the receiver. The new series targets at least 8 independent networks through channel and network-ID combinations.

What happens if the transmitter is dropped or the battery runs out?

Commands work on a hold-to-run (momentary) basis; when the button is released or the link is lost, the receiver releases its relays. On low battery the transmitter cuts its signal automatically and the receiver stays in a safe state.

Can it be fitted to a crane that already has a pendant control?

Yes. The receiver relays connect to the contactor coils in place of today's pendant contacts; the pendant can remain as a backup.

How many functions are supported?

Transmitters come with 6, 8, 10, 16, 24 or 32 channels; receivers offer up to 27 digital + 6 analog outputs. Two-speed buttons, joystick and analog speed are optional.

How can the range be extended?

Mount the receiver antenna outside the panel, high up and away from metal, and use a high-gain antenna. The new series targets longer range with repeaters and LoRa modulation.

How does it communicate with a PLC or drive?

Through relay (dry) contacts and analog outputs. The new series targets status read-out over Modbus RTU (RS485).

Is 868 MHz available?

Current products operate at 433 MHz. 868 MHz is planned only as an option in the new series.

What about warranty and service?

2-year warranty; repair and spare parts in Ankara. Channel and button customization is done in-house at Elmes.

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