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Custom Wireless Control Adaptation & Integration

We adapt our standard RF products to your site.

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An opened crane transmitter with a custom key layout and an added relay card.

Overview

The problem in the field. A catalog remote rarely fits the machine exactly: the number of functions differs, one button is expected to give two speeds, the signal type the PLC expects (NO/NC, pulse/continuous, analog) doesn't match, steel structures and distance cut the range, and several systems on the same site interfere with each other. With imported products, the manufacturer won't make small changes and the supplier can't customize; the customer "makes do" with extra relays and timers inside the panel. The result: safety risk, maintenance confusion and an undocumented system.

The Elmes solution. A site survey produces the function list and the panel interface, and a range pre-test is carried out. Most needs are solved by configuration: channel/function map, pulse/continuous mode, interlocks, timeout and safe state, address/ID. Where needed, a custom variant is built: membrane/keypad layout, channel count, analog input (potentiometer, joystick, 4–20 mA), custom enclosure, PLC interface (relay, RS485/Modbus). Range is solved with antennas and repeaters; interference-free operation on the same site is ensured by an addressing plan. Installation, SAT and training come from Elmes; the wiring diagram and settings document are delivered.

The result. A wireless control/transfer system that fits the machine exactly, is documented and has service behind it; no temporary fixes are left inside the panel.

CriterionImported catalog remoteGeneral electronics shopElmes
Function/channel changesNone or limitedExtra relays in the panelAt firmware and keypad level
Analog / joystick / 4–20 mAIf a model existsDifficultYes (analog data transmitter base)
PLC interfaceRelayRelayRelay / RS485-Modbus / pulse
Range problemsUp to the vendorTrial and errorPre-test, antennas and repeaters
Documentation (diagram, settings)CatalogNonePer project
Service / spare partsImporter—Local, Ankara
An opened crane transmitter with a custom key layout and an extra relay card, with a cyan schematic behind.
Concept

Features

  • Channel/function map: button → output mapping, pulse/continuous, mutual interlock (forward/reverse), two-speed, E-Stop priority.
  • Analog and joystick transfer: potentiometer, joystick, 4–20 mA / 0–10 V; based on the Wireless Analog & Digital Data Transmitter, with analog outputs on the receiver.
  • PLC interface options: dry-contact relay, RS485/Modbus RTU.
  • Custom keypad/membrane and enclosure: customer logo/labels, IP65 enclosure, belt/neck strap, fixed-panel version.
  • Range solutions: antenna selection (omni/Yagi/J-pole, Industrial RF Antenna Series), height/placement, repeaters; verified with a site pre-test.
  • Multiple systems on one site: address/ID and channel plan; the number of systems that can run without interference is given in the relevant product's specifications.
  • Safe-state settings: communication-loss timeout and output behavior (drop/hold) are set per project.
  • Migration from legacy systems: compatible spare or additional devices for sites running existing 433 MHz systems.
  • Parallel operation with the existing wired control: receiver outputs can be wired in parallel with the existing button circuit; a diagram is provided.
  • TargetPulse counter input: an additional PLC interface option via an I/O carrier board.
  • TargetOverload protection (option): wireless load-cell module, shared with the Wireless Crane Control System.
  • TargetLoRa for long range: in the new series, LoRa communication based on the Elmes Module Series.

Service scope

Indicative durations and pricing depend on project scope; final figures are set in the quotation.

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

Service scope
Scope
  • Site survey and range pre-test
  • Channel/function map and settings
  • Custom keypad/membrane, enclosure, labels
  • Custom firmware profile
  • PLC/panel interface (relay, RS485/Modbus, analog)
  • Antenna/repeater plan
  • Installation, SAT, training
  • Wiring diagram and settings document
Out of scope
Process

Site survey → adaptation → production/configuration → workshop test → installation → SAT/training → service.

Typical duration
Indicative
  • Total: 1–6 weeks
  • Survey: 1–3 days
  • Configuration: 1–2 weeks
  • Custom variant: 2–6 weeks
  • Installation: 1–5 days
Deliverables
  • Adapted transmitter and receiver (channel/function map, custom firmware profile)
  • Custom keypad/membrane, enclosure and labels where needed
  • Range pre-test results and antenna/repeater plan
  • Wiring diagram
  • Settings document
  • Installation, SAT and operator training
What we need from you
  • Machine/panel diagram and PLC I/O list
  • Function list (what each button does, interlocks, speeds)
  • Site access with an electrician on hand
  • Safety requirements (E-Stop, target PL)
  • Mounting location and power supply (AC/DC)
  • Information on other RF systems on site
Team & tools

Team: RF/embedded engineer, field technician.

Tools: RF channel/interference scanner, programming and serial-communication test tools, spectrum analyzer/SWR meter, antenna kit; keypad/membrane and enclosure supplier.

Pricing model
Indicative
  • Standard product price + fixed adaptation fee
  • Custom variant: NRE + per unit
  • Installation: per day + travel
  • Multiple sites: unit price per site
Warranty & maintenance

The product warranty remains valid for the adapted product (details on the relevant product page). Service and spare parts from Ankara; batteries are consumables.

Target warranty
Target
  • Adaptation workmanship: 12 months
  • Spare parts: 5 years

Applications

  • Cranes and lifting equipment
  • Concrete pumps and construction machinery
  • Horizontal / vertical conveying
  • Door and barrier control
  • Pump and valve control
  • Analog / joystick transfer
  • Well-tank level links
  • In-plant calling
  • Wireless PLC I/O expansion
  • Wireless bridging of RS485 devices

Adaptations are built on Elmes's standard RF products: Wireless Crane Control System, Wireless Machine Start & Control, Wireless Analog & Digital Data Transmitter, Wireless Well & Tank Control System, Wireless Digital I/O Link — 8 Channels and Wireless RS485 Modem. If a new RF product is needed, the work runs under Contract Electronic Product Development; if a panel has to be built, it is planned together with SCADA & Industrial Automation.

Compliance & documentation

Contract and IP. We work with a quote and order confirmation; larger jobs get a statement of work (SOW). The adapted firmware profile and keypad design stay with Elmes and the customer receives the right to use the device; customer-specific enclosure/label designs belong to the customer. Machine drawings and panel information are kept confidential; use in our portfolio requires permission.

Radio. Elmes RF products operate in the 433 MHz ISM band, within ETSI EN 300 220 limits and in bands that comply with the BTK short-range device regulation; 868 MHz is planned only as an option in the new series. No adaptations to non-standard frequencies or power levels are made.

  • CE / RED — Elmes RF products
    At self-declaration level; product-specific status on the respective product pages.
    Self-declared
  • CE / RED accredited lab certificate
    Target
  • Machine safety — EN ISO 13849, EN 60204-32 (cranes)
    The machine builder's responsibility; Elmes provides the E-Stop and safe-state-on-communication-loss functions in the receiver.
    Out of scope
  • Performance level (PL) rating for the wireless control
    To be published once documented at product level.
    Target
  • EN 60204-1 — receiver panel connection
    Made according to the standard's principles; a wiring diagram is delivered.
    Self-declared

References

Some of the organizations using this product family.

  • DANONE
  • ASAŞ
  • Sistek
  • Hidropol
  • Ademsan
  • Opal
  • BM İnşaat
  • ARTEK
  • ENV-EX
  • Treysan
  • Tok Grup Mühendislik
  • Adel Elektrik Otomasyon
  • Tekel Binası

Frequently asked questions

Your catalog remote doesn't quite fit our machine; what can you do?

We adapt the channel/function map, button layout, enclosure and PLC interface. Most needs are met by configuration within 1–2 weeks; a custom keypad/enclosure takes 2–6 weeks (indicative).

Will several systems on the same site interfere?

No; each system is separated by its address/ID and channel plan. The number of supported systems is given in the relevant product's specifications and is checked with a channel/interference scan during installation.

What does the machine do if the transmitter is dropped or the battery dies?

When the receiver stops getting commands, it goes to a safe state after a defined time (on cranes, a stop). E-Stop is the priority channel. This behavior is tested during SAT.

Does it work alongside our existing wired control?

Yes; the receiver outputs can be wired in parallel with the existing button circuit, and a diagram is provided.

What if the range isn't enough?

It's solved with antennas (omni/Yagi/J-pole), placement and repeaters; a pre-test is done during the survey. The new series targets longer range with LoRa.

How does it communicate with a PLC?

Via dry-contact relays (standard), RS485/Modbus RTU (variant) or analog outputs.

Do you adapt systems for a single machine too?

Yes; configuration adaptations are done even for one device. Custom keypads/enclosures are priced by quantity.

Can we do the installation ourselves?

Yes, using the wiring diagram and settings document. We recommend that Elmes carries out the range and safe-state tests; remote support is available.

What about warranty and service?

The product warranty remains valid for the adapted product; a 12-month warranty on adaptation workmanship is the target. Service and spare parts are provided from Ankara.

Let's talk about your project

Our engineering team replies within 24 hours.

Request a quote +90 (312) 395 85 86

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