PowerBox Systems Digi-Switch User manual

Instruction Manual
Digiswitch
SmArtswitch

2PowerBox-Systems − World Leaders in RC Power Supply Systems
Dear customer,
We are delighted that you have decided to purchase the PowerBox DigiSwitch or
SmartSwitch from our range.
We hope you have many hours of pleasure and great success with your new power
supply.
1. PRODUCT DESCRIPTION
The DigiSwitch or SmartSwitch is an excellent choice for any application where
there is no space for mechanical switches and heavy batteries.
In conjunction with modern LiPo or LiFePo battery technology, the DigiSwitch or
SmartSwitch represents an effective weight-saving measure, and also provides
additional security with its integral voltage monitor and electronic switch, which is
both totally reliable and vibration-resistant.
The DigiSwitch reduces the input voltage to 5.9 V (optionally 5.3 V), and therefore
supplies the correct voltage for standard 6 V servos.
The SmartSwitch is ideal for all applications where security has top priority, but
voltage regulation is not required. The micro-controller by which the On / Off swit-
ching system is controlled makes the SmartSwitch the perfect substitute for a
mechanical switch.
The SmartSwitch does not feature an integral voltage regulator, and passes on the
full input voltage to the consumer unit 1 : 1.
The on / off switching process is initiated by pressing the push-button twice. The
micro-controller monitors the sequence, and turns the electronic switch on or off
if the procedure is valid. This eliminates any danger of operating the switch acci-

www.powerbox-systems.com 3
dentally, and produces a connection which is resistant to vibration. The switch is
a latching type, i.e. it stores the last switched state. This means that the system
always remains switched on even if there is a brief interruption in the circuit at the
battery end.
DigiSwitch applications:
- Small to medium-sized xed-wing model aircraft with up to ve standard-sized
servos
- F3A models
- Model gliders with up to eight servos, depending on servo size and model size
- Model helicopters - electric or glow-powered - with rotor diameters up to 1.30 m
and tted with up to ve servos
- RC model cars and boats
- Petrol engine ignition systems which are approved for a maximum input voltage
of 6 V
SmartSwitch applications:
- Small to medium-sized xed-wing model aircraft with up to eight standard-sized
servos
- F3A models
- Model gliders with up to ten servos, depending on servo size and model size
- Model helicopters - electric or glow-powered - with rotor diameters up to 1.60 m
and tted with up to seven servos
- RC model cars and boats
- Petrol engine ignition systems which are approved for a maximum input voltage
of 8.4 V
In the following sections we do not differentiate between the DigiSwitch and
SmartSwitch, since the method of operating the two units is identical.

4PowerBox-Systems − World Leaders in RC Power Supply Systems
2. FIRST USE, OPERATING THE SWITCH
2.1. CONNECTIONS
Connect a battery of your choice to the battery input, taking care to maintain cor-
rect polarity. This can be a 4S (SmartSwitch only) or 5S NiCd / NiMH battery, a 2S
(7.4 V) LiPo / Li-Ion or a 2S (6.6 V) LiFePo pack.
By default the voltage monitor is set up to work with a LiPo battery.
We recommend that you use the LiPo or LiFePo battery packs which we manu-
facture. All PowerBox batteries are equipped with appropriate electronic monitor
and security circuits, balancer and integral charger. All our batteries are supplied
complete with a practical mounting frame of the correct size.
CAUTION: connecting the battery with reversed polarity will instantly ruin the in-
tegral linear regulator!
2.2. SWITCHING ON AND OFF
The Digi- and SmartSwitch features a single button, and is therefore particularly
user-friendly; this button is even employed to set the battery type to be used. The
button transmits the switching signal to the electronic switch, but has nothing to
do with the actual process of switching the current.
The unit is switched on by pressing the sensor button (0.5 sec.), and holding it pres-
sed in until the LED glows orange. Release the button briey, then press it a second
time. The LED now glows green, and the unit is switched on.

www.powerbox-systems.com 5
The procedure for switching off is identical: press the sensor button (0.5 sec.) and
hold it pressed in until the LED glows orange. Release the button briey before pres-
sing it a second time: the LED now goes out, and the unit is switched off.
This two-stage switching procedure eliminates the danger of switching the system
on or off accidentally.
If the LED glows orange or red instead of green when you switch the unit on, then:
- the battery connected to the unit is at or only partially charged
- the unit is set up for the wrong type of battery.
2.3. SETTING THE BATTERY TYPE
If you wish to use a 4s/5s NiCd or NiMH battery, or a 2s LiFePo pack, it is essential
to set the voltage monitor to match your choice, otherwise the LED with ash red
constantly. Please note, however, that the setting has absolutely no effect on the
actual switching process or the voltage regulation system.
This is the procedure for setting up the unit to suit the different battery types:
DigiSwitch:
- Connect the battery, and switch on the DigiSwitch
- Now hold the button pressed in, and watch the LED
- The LED will glow red, then go out again after a while
- Pause, hold the button pressed in again
- The LED ashes green once. If you release the button now, you have selected
the 2s LiPo battery type
- Pause, hold the button pressed in again

6PowerBox-Systems − World Leaders in RC Power Supply Systems
- The LED ashes green twice. If you release the button now, you have selected
the 5s NiCd/ NiMH battery type
- Pause, hold the button pressed in again
- The LED ashes green three times. If you release the button now, you have selec-
ted the 2s LiFePo battery type
SmartSwitch:
- Connect the battery, and switch on the SmartSwitch
- Now hold the button pressed in, and watch the LED
- The LED will glow red, then go out again after a while
- Pause, hold the button pressed in again
- The LED ashes green once. If you release the button now, you have selected
the 2s LiPo battery type
- Pause, hold the button pressed in again
- The LED ashes green twice. If you release the button now, you have selected
the 5s NiCd/ NiMH battery type
- Pause, hold the button pressed in again
- The LED ashes green three times. If you release the button now, you have selec-
ted the 4s NiCd/ NiMH battery type
- Pause, hold the button pressed in again
- The LED ashes green four times. If you release the button now, you have selected
the 2s LiFePo battery type
This procedure does take a few seconds, but is designed to prevent the user setting
the wrong battery type accidentally. In any case it only has to be carried out once
when you switch battery types; the setting is stored permanently in the micro-con-
troller.

www.powerbox-systems.com 7
2.4. VOLTAGE MONITOR
The Digi- or SmartSwitch not only regulates the operating voltage of your RC sys-
tem, it also monitors the battery connected to it.
The tri-colour LED, which you have already used to conrm the unit’s power-on
status, also informs you of the voltage of your battery by changing colour. The
four stages are reected by the colours green, orange, red and ashing red. Before
you launch your model, you should always switch the RC system on and move the
sticks around briey: this gives you the chance to check whether the system is “in
the green” while the battery is actually under load. The coloured LED also acts as
a warning if the battery is too small to cope with the servos in your model, or if the
battery cables are of inadequate cross-sectional area.
2.5. INSTALLATION
Please don’t throw away the internal packaging, as it includes a cutting template for
marking out the switch opening in or on the model.
Although the product is well protected against the effects of vibration, you should
still install it in a part of the fuselage where vibration levels are low.
The GRP fuselage sides of a powered model aircraft are not suitable for mounting a
switch - regardless of type - because they always tend to oscillate and vibrate. You
can eliminate this problem by tting a doubler made of 2.5 or 3 mm plywood: cut a
plate 2 to 3 cm larger all round than the switch cut-out, and glue it to the inside of
the fuselage at the appropriate point before sawing out the switch opening.
The plywood plate helps to absorb vibration, and also provides sufcient material
for several turns of the switch retaining screws to “grip”.

8PowerBox-Systems − World Leaders in RC Power Supply Systems
3. OPERATING NOTES
If the battery is left connected to the Digi- or SmartSwitch when it is switched
off, the microprocessor goes into stand-by mode; in this state it draws a minimal
idle current of around 5.0 μμA, which is far lower than the self-discharge rate of any
rechargeable battery.
Nevertheless, it is good practice to disconnect the battery from the unit if you know
you will not be ying the model for a protracted period.
We are frequently asked this question: how much current can the DigiSwitch or
SmartSwitch handle? Here is a comprehensive explanation:
DigiSwitch:
The capacity of the PowerBox DigiSwitch (1 - 3 A) is limited by the performance of
the regulator when cooled efciently, rather than by the switching capacity of the
DigiSwitch. To obtain good cooling and ensure high performance, one of the he-
at-sinks of the DigiSwitch is attached to the outside of the unit. This part is normal-
ly installed on the model’s fuselage side, where it receives a constant ow of coo-
ling air when the model is ying. The internal silver-coloured heat-sink is soldered to
the regulator circuit board due to its greater ability to withstand high temperatures.
The maximum current-handling capacity of the electronic components is 12 A; this
means that the unit can cope with brief peak loads up to this level without problem.
If the DigiSwitch is operated on a 5S NiCd or a 2S LiFePo battery, the maximum
regulator capacity is higher because of the lower voltage level of these cells.
If you nd that the DigiSwitch heats up to an uncomfortable level (above 60°C) in

www.powerbox-systems.com 9
use, then it is a safe assumption that the load connected to it is too great. You can
usually improve the situation by installing the DigiSwitch in a position where the
cooling airow is better, and also by reducing any stiffness in the control surfaces
or mechanical linkages. If none of these measures eliminates the problem, you
should replace the unit with a PowerBox Sensor, as this product is designed for
higher currents. We will be glad to advise you on such matters.
SmartSwitch:
The SmartSwitch requires no cooling in operation. The switching capacity is more
than 20 A, and in practice the limiting factor is the connecting cable.
As already mentioned, the SmartSwitch is not tted with a voltage regulator, and
for this reason it does not constitute a means of operating standard 6 V servos
with LiPo batteries.

10 PowerBox-Systems − World Leaders in RC Power Supply Systems
4. DIMENSIONS

www.powerbox-systems.com 11
5. SET CONTENTS
- DigiSwitch/SmartSwitch
- Retaining screws
- Installation template
- Operating instructions
Order No. 6410: Digiswitch 5,9V JR/JR Connector
Order No. 6420: Digiswitch 5,9V MPX/2xJR Connector
Order No. 6510: SmartSwitch JR/JR Connector
Order No. 6520: SmartSwitch MPX/2xJR Connector
6. SERVICE NOTE
We are anxious to offer good service to our customers, and to this end we have
set up a Support Forum which deals with all queries concerning our products. This
relieves us of a great deal of work, as it eliminates the need to answer frequently
asked questions time and again. At the same it gives you the opportunity to obtain
help quickly all round the clock - even at weekends. All the answers are provided by
the PowerBox Team, guaranteeing that the information is correct.
Please use the Support Forum before you telephone us.
You can nd the forum at the following address:
www.forum.powerbox-systems.com

12 PowerBox-Systems − World Leaders in RC Power Supply Systems
SERVICE ADDRESS
PowerBox-Systems GmbH
Ludwig-Auer-Straße 5
D-86609 Donauwoerth
Germany
7. GUARANTEE CONDITIONS
At PowerBox-Systems we insist on the highest possible quality standards in the
development and manufacture of our products. They are guaranteed “Made in
Germany”!
That is why we are able to grant a 36 month guarantee on our PowerBox Digi-
Switch and SmartSwitch from the initial date of purchase. The guarantee covers
proven material faults, which will be corrected by us at no charge to you. As a
precautionary measure, we are obliged to point out that we reserve the right to
replace the unit if we deem the repair to be economically unviable.
Repairs which our Service department carries out for you do not extend the original
guarantee period.
The guarantee does not cover damage caused by incorrect usage, e.g. reverse
polarity, excessive vibration, excessive voltage, damp, fuel, and short-circuits. The
same applies to defects due to severe wear.
We accept no liability for transit dama-
ge or loss of your shipment. If you wish
to make a claim under guarantee, please
send the device to the following address,
together with proof of purchase and a de-
scription of the defect:

www.powerbox-systems.com 13
8. LIABILITY EXCLUSION
We are not in a position to ensure that you observe our instructions regarding in-
stallation of the PowerBox DigiSwitch or SmartSwitch, full the recommended
conditions when using the unit, or maintain the entire radio control system com-
petently.
For this reason we deny liability for loss, damage or costs which arise due to
the use or operation of the PowerBox DigiSwitch or SmartSwitch, or which are
connected with such use in any way. Regardless of the legal arguments employed,
our obligation to pay compensation is limited to the invoice total of our products
which were involved in the event, insofar as this is deemed legally permissible.
We wish you every success with your new PowerBox DigiSwitch or SmartSwitch.
Donauwoerth, Juli 2019

PowerBox-Systems GmbH
certied according to DIN EN ISO 9001
Ludwig-Auer-Straße 5
D-86609 Donauwoerth
Germany
[phone]
[phone]
www.powerbox-systems.com
07/2019
Digiswitch
SmArtswitch