Itowa It3r22 User manual

User's manual

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MARI22EN - Rev.1 - 12/2020

Receiver IT3R22

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Receiver IT3R22

USER'S MANUAL

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ANY REPRODUCTION OF ALL OR PART OF THIS MANUAL IS STRICTLY FORBIDDEN

WITHOUT PRIOR WRITTEN PERMISSION FROM ITOWA.

OTHERWISE, ITOWA RESERVES THE RIGHT TO TAKE SUCH ACTION AS IT DEEMS

APPROPRIATE UNDER CURRENT LEGISLATION.

ITOWA RESERVES THE RIGHT TO MODIFY THIS MANUAL WITHOUT PRIOR NOTICE.

Receiver IT3R22

USER'S MANUAL

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INDEX:

1. INTRODUCTION 4

1.1. GCFI VERSION 4

2. GENERAL TERMS AND CONDITIONS FOR THE CORRECT USE OF THE RECEIVER 4

3. DESCRIPTION OF THE RECEIVER 5

3.1. GENERAL DESCRIPTION 5

3.1.1. STANDARD RECEIVER 6

4. TECHNICAL FEATURES 7

4.1. GENERAL CHARACTERISTICS 7

5. INSTALLATION AND START-UP 9

5.1. INSTALLATION OF THE RECEIVER 9

5.1.1. STANDARD FIXING OF THE RECEIVER 9

5.1.2. MAGNETIC FIXING OF THE RECEIVER (OPTIONAL) 10

5.1.3. DISMOUNTING WITH MAGNETIC SUPPORT 11

5.2. CONNECTION 11

5.3. START-UP 15

6. RECEIVER MAINTENANCE 16

7. WORKING CHANNEL DISPLAY 17

7.1. DISPLAY OF THE EQUIPMENT CODE 17

7.2. DISPLAY OF THE WORKING CHANNEL 18

8. SCANNING 19

8.1. AUTOMATIC SCANNING 19

8.2. MANUAL SCAN 19

9. CHANGE OF WORKING FREQUENCY (NOT VALID FOR GCFI VERSIONS) 20

10. LED INFORMATION 21

11. POSSIBLE INCIDENTS AND SOLUTIONS 23

12. RECYCLING 25

12.1. PACKAGING 25

Receiver IT3R22

USER'S MANUAL

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1. INTRODUCTION

The manual you have in your hands is a guide to the correct use of the ITOWA IT3R22 multi-frequency

receiver.

This receiver, together with the associated remote control, is specially designed to be controlled remotely,

without cables, and to act directly on electromechanically driven machinery.

The radio signals used employ FM frequency modulation and FFSK coding. The most advanced

technology and state-of-the-art microprocessors have been used in the electronic design.

In order to avoid undesired manoeuvres, the receiver is equipped with various safety mechanisms, which

will be described in the following chapters. Any auto-detection of anomalies blocks the execution of

manoeuvres.

The receiver operates in the UHF band on frequencies between 433.050 and 434.775 MHz (UN 30 and

32 of the C.N.A.F.), or between 868.000 and 870.000 MHz (UN 39 of the C.N.A.F.) as prescribed by the I-

ETS 300 220 telecommunications regulations.

Contact Itowa for other certificates.

1.1. GCFI VERSION

The GCFI (Intelligent Frequency Change Management) version is equipped with an intelligent system that

allows it to change to unoccupied frequencies in a random and automatic way, thus avoiding interference

that could cause continuous stops during operation.

ATTENTION!: EVERYTHING IN THIS MANUAL RELATED TO THE CHANGE OF

FREQUENCY AND WORKING CHANNEL IS NOT VALID FOR THE GCFI VERSION.

2. GENERAL TERMS AND CONDITIONS FOR THE CORRECT USE OF

THE RECEIVER

In order to have the maximum security in the handling of the receiver, the operator must follow the rules

described in this manual.

When carrying out any manoeuvre on the machine, the operator must be located in a place where he has

a view of the manoeuvre being carried out at all times. If this is not possible, the operator must be located

in a place that allows him to see the maximum possible maneuver and in the hidden places he must use

an assistant. Never carry out a manoeuvre that may have an uncontrolled part.

When the operator finishes his work on the receiver, he must lock the EMERGENCY STOP BUTTON of

the transmitter and must take care not to leave the control of the machine accessible to unauthorised

personnel.

Receiver IT3R22

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3. DESCRIPTION OF THE RECEIVER

3.1. GENERAL DESCRIPTION

The reception unit is composed of a watertight plastic housing (IP65) inside which the various electronic

systems for receiving orders and activating/deactivating the appropriate relays for each machine

operation are located.

This model of receiver, thanks to its robust design, can be used in a multitude of applications, both

indoors and outdoors.

The receiver assembly can be divided into three blocks (Fig. 3 1), UHF receiver, control circuit and relay

circuit.

Fig. 3-1. Block diagram of the receiver

In the case of the GCFI version the block diagram is shown in the figure below:

Fig. 3-2. Block diagram of the receiver (GCFI)

The signal received by the antenna is injected into the receiver, which supplies the microprocessor with a

low-frequency signal in FFSK code. The control module checks that the information received is free of

errors, and then issues the appropriate commands to activate the appropriate relay.

In the case of models incorporating the GCFI version, the receiver

becomes a transceiver in order to establish two-way communication

with the transmitter.

In the event of a malfunction of the equipment, specific control

circuits are in charge of deactivating the receiver's working

manoeuvres.

For extra safety all monitoring circuits are duplicated.

Fig. 3-3. Receiver IT3R22

UHF

RECEIVER

CONTROL

CIRCUIT

TO SWITCHING

CONTACTORS

RELAY

CIRCUIT

TRANSCEIVER

CONTROL

CIRCUIT

TO SWITCHING

CONTACTORS

RELAY

CIRCUIT

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3.1.1. STANDARD RECEIVER

In case you need to remove the controller card follow these instructions:

Lift the tab (1).1) Remove the controller.2)

Fig. 3-4. Details of the tab

Fig. 3-5. Details of the receiver

Receiver

Controller

Tab

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4. TECHNICAL FEATURES

4.1. GENERAL CHARACTERISTICS

System:

MULTI-FREQUENCY

Frequency:

ISM-BAND

Order response time:

<50 ms

Active emergency time:

<50 ms

Passive emergency time:

1600 ms

Range of action:

100 meters

Temperature range:

From -20 to 70 ºC

Frequency bands:

434.050 to 434.775 MHz

868.000 to 870.000 MHz

I-ETS 300 220

Sensitivity:

0,3 µV

Image frequency rejection:

> 65 dB (TBD in GCFI versions)

Protection against intermodulation:

> 65 dB (TBD in GCFI versions)

Rejection to adjacent channel:

> 65 dB (TBD in GCFI versions)

Available manoeuvres:

22 RELAYS + 2 SAFETY STOP RELAYS

Up to 30 relays + 2 stop relays (optional)

Up to 18 +2 relays and 8 analogue outputs (optional)

Up to 22+2 relays and 6 analogue outputs (optional)

Up to 25+2 relays and 3 analogue outputs (optional)

Maximum relay switching

capacity:

Resistive load:

Inductive load (cosØ=0,4):

Maximum operating voltage:

Minimum permissible load:

8 A at 250 Vac or 30 Vdc

3 A at 250 Vac or 4 A a 30 Vdc

440 Vac, 125 Vdc

10 mA a 5 Vdc

Number of switches:

Resistive load:

Inductive load (cosØ=0.4):

105manoeuvres 8 A at 250 Vac

or 30 Vdc

105manoeuvres 3 A at 250 Vac

or 30 Vdc

Power supply:

(according to model)

48 Vac / 115 Vac / 230 Vac (-20% +15%) according to

EN 60047-5-1

24 Vac / 48 Vdc (-20% +15%) according to EN 60047-5-1

24 Vdc (-20% +15%) according to EN 60047-5-1

12 Vdc (-20% +15%) according to EN 60047-5-1

Max. Consumption:

200 mA (230 Vac)

500 mA (115 Vac)

900 mA (48 Vac)

1000 mA (48 Vdc)

1700 mA (24 Vac)

2000 mA (24 Vdc)

4000 mA (12 Vdc)

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Fuses:

Emergency stop manoeuvre : 8 A

Connection:

Via 48-pin Itowa connector

Dimensions:

External

374 x 274 x 126 mm

Fixation:

Bichromated steel 3 mm

Mounting: By bolts or magnetic (optional)

Weight:

With fixation

4,20 kg

Protection:

IP 65

Security level:

Category 4 - SIL3 / PLe according to EN ISO 13849

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5. INSTALLATION AND START-UP

5.1. INSTALLATION OF THE RECEIVER

The receiver should be located in an easily accessible area so that it can be easily handled. The antenna

should be pointing towards the ground and in a protected place to avoid shocks.

In compliance with Royal Decree 171/2004 on the Coordination of Business Activities, you are reminded

that you must guarantee the safety conditions for the maintenance of the machine in question, especially

in terms of its accessibility and transit areas to the points where the operator must carry out his work.

ATTENTION!: IT IS VERY IMPORTANT TO CLOSE THE COVER OF THE RECEIVER

CORRECTLY IN ORDER TO ENSURE THAT IT IS WATERTIGHT, AS THE ENTRY OF

WATER CAN SPOIL IT. THE WARRANTY DOES NOT COVER FAULTS RESULTING

FROM IMPROPER CLOSING OF THE COVER.

Whenever the installation allows it, the antenna should be free of metal shields to achieve a better radio

link and avoid communication cuts.

Itowa is not responsible for improper installation.

5.1.1. STANDARD FIXING OF THE RECEIVER

Applicable only in Spain

Fig. 5-1. Standard fixation

Receiver IT3R22

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Mount the fixation on a stable, robust support of proportionate measures to this fixation.1) Place the fixation in vertical position using if necessary the alternative holes to the two central ones2)

shown in figure 5-2.

Tighten the bolts sufficiently to support the weight of the device without deforming the mounting.

Take special care when the support is an angle instead of a tube.

Thread the DIN 6921 M6 screws (4) into the fixation, leaving space for the device's fixing ears to enter

(as shown in detail in figure 5-2).

Once the fixing assembly has been fitted to the machine, slide the receiver along its guides until it3)

stops.

Finally, tighten the DIN 6921 M6 screws with a No. 10 open-end spanner.4)

ATTENTION!: THE RECEIVER CLAMPING ASSEMBLY (METAL PARTS) MUST BE

FIRMLY FIXED BEFORE ANCHORING THE RECEIVER BODY.

5.1.2. MAGNETIC FIXING OF THE RECEIVER (OPTIONAL)

Fig. 5-2. Magnetic fixation

Thread the DIN 6921 of M6 screws (3) into the fixation, leaving space for the fixation ears of the1) device to enter, as shown in detail (4).

Place the magnetic fixation (2) in a place on the metal structure of the machine (1) which MUST BE2) AT LEAST 4 MM THICK and where the four magnets make contact with the surface, in flatness.

Once the fixing assembly has been fitted to the machine (5), slide the receiver along its guides until it3) stops (6).

Finally, tighten the DIN 6921 of M6 screws (7) with an open-end spanner No. 10.4)

ATTENTION!: ONCE INSTALLED, CHECK THAT THE EQUIPMENT IS FIRMLY

ANCHORED AND THAT IT DOES NOT SLIP.

Receiver IT3R22

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5.1.3. DISMOUNTING WITH MAGNETIC SUPPORT

Fig. 5-3. Steps for dismantling the receiver with magnetic holder

Due to the magnetic force of the magnets, the following instructions should be followed when uninstalling

the device:

Loosen the DIN 6921 M6 screws (1) with a No. 10 open-end spanner.1) Remove the receiver (2).2) Lever with a flat screwdriver between the metal structure of the machine and the magnetic3) attachment (3).

5.2. CONNECTION

It is recommended to connect the equipment with a standardised multi-cable hose such as the cable

switchboard. This hose should be connected to the equipment at one end, while at the other end a multi-

pin connector should be fitted, identical to the one used by the machine for interconnection with a cable

switchboard. This allows the remote control or the cable control to be interchanged simply by connecting

or disconnecting the hose.

ATTENTION!: THE HORN RELAY MUST NOT BE CONNECTED TO CONTROL ANY

OTHER OPERATION UNLESS OTHERWISE INDICATED.

The conductor of the switching common must be of adequate diameter, it must not exceed 2.5 mm Ø or

be less than 1.5 mm Ø, and you should not place two cables of 0.75 mm Ø each. Under no

circumstances may the switching common conductor be smaller than the diameter of the switching

conductors.

ATTENTION!: THE CONNECTION MUST BE MADE IN SUCH A WAY THAT WHEN THE

MAIN SWITCH IS TURNED OFF, THE RECEIVER IS ALSO TURNED OFF.

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For further details on the connection, please refer to the relay output sheet provided with the receiver.

The standard receiver internally allows the selection of three different voltages (230 Vac, 115 Vac, or 48

Vac). For other models, we have receivers that are supplied with a single voltage of 24 Vac/dc or 12

Vac/dc.

ATTENTION!: CHECK THAT THE VOLTAGE SELECTION IS AS DESIRED BEFORE

APPLYING VOLTAGE TO THE EQUIPMENT. ALL RECEIVERS WITH STANDARD

CONFIGURATIONS ARE DELIVERED FROM THE FACTORY WITH THE VOLTAGE

PRE-SELECTED AT 230 VAC BUT, AS A PRECAUTION, IT IS ADVISABLE TO CHECK

THAT THE SELECTION IS CORRECT.

ATTENTION!: AS A SAFETY MEASURE IT IS ESSENTIAL TO ENSURE AN EARTH

CONNECTION VIA THE CORRESPONDING PIN OF THE CONNECTOR.

The connection will be made through the terminal block that is screwed to the inside of the receiver's

cover:

Fig. 5-4. Numbered terminals for the connection of the receiver.

SELECTOR

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The connection of the operations associated with the relays and the power supply are indicated in the

following table:

ATTENTION!: IF THE STOP MANOEUVRE DOES NOT REQUIRE INDEPENDENT CONTACTS, A

JUMPER MUST BE MADE BETWEEN TERMINALS 43 AND 45, AND THE MANOEUVRE MUST BE

CONNECTED TO TERMINALS 41 AND 47.

Itowa is not responsible for improper installation.

Selectable supply voltage on the receiver board

CONNECTOR PIN

RELAY

MANOEUVRE

AUX.1

TRAVELLING

NORTH

TRAVELLING

SOUTH

2nd

TRAVELLING

LOWER

RAISE

2nd HOISTING

3rd HOISTING

SLEWING

RIGHT

SLEWING

LEFT

2nd SLEWING

4th HOISTING

FREE

CONNECTOR PIN

RELAY

MANOEUVRE

4th TROLLEY

3rd SLEWING

4th SLEWING

SLEW

BRAKE

TROLLEY

BACKWARD

TROLLEY

FORWARD

2nd TROLLEY

3rd TROLLEY

HORN

START

STOP 1

STOP 2

(1)

Fig. 5-5. Connection of standard receiver relays and associated manoeuvres for a tower crane

as an example. The specific document for relay and/or analogue output is supplied with the

receiver.

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In models with optional relay and/or analogue output controls, the device internally incorporates one of

the following expansion modules. The connection of the controls associated to each one of them is

indicated in the specific documentation delivered with the device.

For the adjustment of the analogue outputs, please refer to the corresponding appendix.

Fig. 5-6. Expansion module with 8 relay outputs.

Fig. 5-7. Expansion module with 3 relay outputs

and 3 analogue outputs

Fig. 5-8. Expansion module with 8 analogue outputs.

Receiver IT3R22

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5.3. START-UP

Once the receiver has been installed and connected, the LEDs on the front of the machine will light up

sequentially when the main switch is activated. The functionality of each LED varies depending on the

state of the receiver, but in this case they only indicate a check of the receiver.

The following steps will be carried out with the remote control associated to the receiver:

Insert a charged battery into the remote control, unlock the STOP button and press the START1)

button.

The receiver will start operating by activating the receiver's start and stop relays, and the general2) contactor will be interlocked. The LEDs of the remote control and receiver will start blinking and the

LED S1 of the receiver will be activated indicating that the radio control unit is in working mode.

From this moment on, the operation of any button will trigger the corresponding manoeuvre. The3) selected manoeuvre will remain active as long as the button is pressed.

Whenever there is a change in the status of one or more relays, the LED S2 on the receiver (relay4) LED) will blink rapidly. If there is no change, the LED will remain off

To keep the radio channel free and prevent the operator from accidentally leaving the machine running

when not in use, the remote control has been fitted with an automatic stop system. If no action is taken,

this system reacts after 180 seconds (configurable) by sending a stop sequence to the receiver, which will

make the machine stop.

To reactivate the transmitter-receiver unit, press the START button.

To activate the emergency stop, simply press the STOP button. This will deactivate the stop relays and

the remote control. In this situation, all the relays that were activated will be deactivated and the initial

message will appear again on the LCD display.

ATTENTION!: REMEMBER THAT ACTIVATING THE STOP BUTTON IS THE SAME AS

STOPPING THE REMOTE CONTROL, WHICH MEANS THAT IT IMMEDIATELY

DEACTIVATES ANY RELAY IN THE RECEIVER THAT WAS ACTIVATED.

When the machine stops, the frequency channel on which the device is working is displayed by the

pulses on the and LEDs of the receiver. A detailed explanation of this display is given in section

¡Error! No se encuentra el origen de la referencia..

Fig. 5-9. Start sequence on the LEDs

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6. RECEIVER MAINTENANCE

The receiver you have purchased is manufactured with top quality materials that ensure perfect

functioning and operation. Like any other machine or equipment, this receiver requires a minimum basic

attention that should be respected. In order to increase the lifetime of your receiver as much as possible,

and to avoid unnecessary repair costs, we recommend that you strictly follow the following maintenance

and preservation tips:

Use the mounting accessories properly and adjust them so that the receiver can be used comfortably

and safely.

Avoid unnecessary impacts.

It’s advisable not to leave the receiver unnecessarily exposed to the sun's rays.

As a general rule, it is advisable to carry out a complete check of the sealing parts that protect the

receiver from bad weather from time to time. This check should be carried out by a Technical Assistance

Service accredited by ITOWA, as poor waterproofing can cause irreparable damage to the equipment.

ATTENTION!: BEFORE ANY MANIPULATION, PROCEED TO DEACTIVATE THE MAIN

SWITCH OF THE MACHINE.

ATTENTION!: ORIGINAL SPARE PARTS MUST BE USED FOR ANY REPAIRS AND

UNDER NO CIRCUMSTANCES MUST THE SAFETY FEATURES OF THE RECEIVER

BE ALTERED.

For the maintenance of the receiver, the following parts shall be checked:

The connection between the receiver and the machine's electrical equipment.

The correct functioning of the active and passive safety circuits.

The correct operation of all LEDs through the start-up test.

The correct fixing of the entire assembly and the correct closing of the cover and cable glands.

If you have an external antenna, check that the connection is clean and free of rust.

To check the operation of the active safety system, simply operate the STOP button on the transmitter

while it is running. The general contactor must fall down immediately.

To check the operation of the passive safety, disconnect the power supply or battery from the transmitter.

The general contactor must fall down after 1.6 seconds.

ATTENTION!: IF ANY ANOMALY IS DETECTED IN THE OPERATION OF THE

RECEIVER, IT MUST BE PUT OUT OF SERVICE IMMEDIATELY.

If you have any questions or doubts, please do not hesitate to contact our Technical Assistance Service

or any of our authorised technicians.

Receiver IT3R22

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7. WORKING CHANNEL DISPLAY

7.1. DISPLAY OF THE EQUIPMENT CODE

If you wish to know the device code, the receiver allows you to display it through a simple sequence of

pulses.

Fig 7-1. Location of the button on the base plate of the receiver.

In order to start the display, the receiver must be in standby mode. Press the button located on the base

plate (see Fig. 7-1) of the receiver for 1 to 2 seconds and, after this pulse, the sequence begins, which

will divide the code into 6 hexadecimal digits. The following table shows the number that will be displayed

by the LEDs according to the character to be expressed:

Hexadecimal

character

Number of pulses

For each of the 6 characters to be displayed, one of the LEDs will be used and this will show as many

pulses as the corresponding character in the code indicates. It begins with S1 with the first character of

the code (most significant digit) and ends with the last character of the code (least significant digit).

To show that the indication of pulses of a character has finished, it will flash (short pulse) all the LEDs,

except for the LED that is being displayed at that time, and this sequence will be repeated continuously.

To display the pulses of the next character, press the button for between 1 and 2 seconds.

The same procedure must be followed for the remaining characters until all 6 characters of the device

code have been displayed, thus returning the receiver to its standby state.

If at any time during the display process, from start to finish, the receiver receives a command from the

transmitter to start up, the display will end and the receiver will go into operating mode.

For a better understanding of the above process, an example of a code and the result of the display is

proposed.

Receiver IT3R22

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The example code is 01A38E:

The sequence in the example above would be (P1 is the button):

All LEDs are blinking.

Blinking of all LEDs except S1 until P1 is pressed.

1 pulse of S2 and blinking of all LEDs except S2 until P1 is pressed.

10 pulses of S3 and blinking of all LEDs except S3 until P1 is pressed.

3 pulses of S4 and blinking of all LEDs except S4 until P1 is pressed.

8 pulses of S5 and blinking of all LEDs except S5 until P1 is pressed.

14 pulses of S6 and blinking of all LEDs except S6 until P1 is pressed.

Once P1 is pressed, the display of the device code ends.

7.2. DISPLAY OF THE WORKING CHANNEL

It’s important to know the frequency channel you are working on when making a frequency change or

detecting possible interference from other devices on the communication between the transmitter and the

receiver.

To find out the frequency channel of the receiver, you must follow these steps:

Start the receiver by unlocking the transmitter's STOP button and operate the transmitter.

Engage the STOP button to switch the device to the standby mode. The receiver will then indicate the

working channel as follows:

oFirst, the LED will blink as many times as the frequency channel has tens.

oWhen the display of the tens is finished, it will continue, through the led to the display

of the units of the working channel.

If an attempt is made to start the equipment while the channel is being displayed, it will be given

preference, the channel display will stop and the receiver will be started.

Another way to know the frequency channel is at the moment of powering the receiver. After the LED

test, the receiver will indicate the working channel.

When a frequency change is completed, the receiver also displays the new working channel.

Led

Code

Number of pulses in LED

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8. SCANNING

The receiver has some systems for detecting anomalies in the event that other equipment or systems

interfere with the communication between the transmitter and the receiver. These systems include

frequency scanning, which will be used to scan the entire band and find the frequency channels that are

or have been occupied by some other device emitting within the same band.

By finding the channels that are or have been occupied, by deduction, it’s possible to know which ones

are free and, therefore, it’s convenient to configure one of them to avoid these anomalies.

8.1. AUTOMATIC SCANNING

While the equipment is at rest, it polls the free and occupied channels of the entire band. If the scanned

channel is occupied, it will proceed to check if the signal is its own or from another device. If it is

recognised as its own, the working channel will be updated with the new configuration and work will

continue with this new working channel.

If there is no signal on the scanned channel that is recognised as belonging to the device, then it will

simply be recorded whether the channel is occupied or free.

The status of the occupied channel will prevail over the status of the free channel, meaning that as soon

as a channel is found to be occupied it will still be registered as free during a subsequent scan. This

recording will be deleted as soon as the receiver is no longer supplied with power.

8.2. MANUAL SCAN

The manual scan is performed in order to have information about the channels that are not occupied by

radio frequency signals from other devices and to be able to use one of these channels to work without

interference. For this purpose, a scan of all the channels in the band is carried out starting at the moment

the order is given.

To activate this command, the receiver must be in standby mode and the button on the main board must

be pressed for more than 2 seconds. The LEDs will light up sequentially and cyclically with approximately

half a second intervals between each status indicating that the scanning process is taking place, as

shown in the following table:

→

…

Once the scanning process has finished, which lasts about half a minute, the LEDs will stop displaying

this information and the channels that have been detected as unoccupied will be displayed. These

channels are the result of the scan that has just been carried out along with any automatic scans that may

have been performed while the equipment was in a state of rest since it was last restarted (last restart

should be from the last time the receiver was powered up).

The channels will be indicated by pulses of the and LEDs using the same system as for indicating

the working channel. All free channels will be indicated sequentially, separated by a blinking light in which

all the LEDs will light up. The order will be as follows:

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Start with the lowest free channel.1) 11 units will be added for the next channel to be displayed, as long as the band in which you are2) working allows it.

If the result is higher than the maximum number of band channels, the maximum number of band3) channels will be deducted.

If the channel is not free, it does not present it and directly goes to the next one in the same order.4) For a better understanding, an example of result display in the 868MHz band will be shown: