Banner SureCross DX80 Gateway Network Manual
  1. Manuals
  2. Brands
  3. Banner Manuals
  4. Gateway
  5. SureCross DX80
  6. Network manual

Banner SureCross DX80 Gateway Network Manual

Wireless i/o
Hide thumbs Also See for SureCross DX80 Gateway:
Table of Contents

Advertisement

Quick Links

Download this manual
SureCross Wireless I/O Network Manual
rev. I 10/25/2012
132607

Advertisement

Table of Contents
loading

Related Manuals for Banner SureCross DX80 Gateway

Summary of Contents for Banner SureCross DX80 Gateway

  • Page 1 SureCross Wireless I/O Network Manual rev. I 10/25/2012 132607...

  • Page 2: Table Of Contents

    Contents Contents The SureCross® DX80 Wireless Network ....................6 SureCross® DX80 Gateways and Nodes ........................... 6 SureCross® DX80 GatewayPro ............................6 DX83 Ethernet Bridge Overview ............................7 Host Systems ..................................7 What is FlexPower®? ................................7 SureCross User Configuration Tool .............................8 Features ..............................9 DX80 Gateway and Node Components ..........................9 DX80 Gateway and Node Wiring Chamber...
  • Page 3 Gateway Link Failure ..............................48 Node Link Failure ..............................49 Units Defined ..................................50 Interpreting Register Values in the Banner Wireless System ................... 52 Setting up the Wireless Network Using the Rotary Dials ....................55 Setting Up the Wireless Network ..........................55 Applying Power to the Gateway or Node ........................
  • Page 4 Contents Analog Inputs, Temperature Sensors ........................71 Analog Inputs, QT50U Long-Range Ultrasonic Sensor .................... 71 Analog Outputs .................................71 Analog Outputs, Three-Wire Sensors ........................71 Analog Outputs, Drive Motor Controllers ........................72 SureCross Power Solutions ........................73 10 to 30V dc Power ................................
  • Page 5 FCC Certification, 900 MHz, 1 Watt Radios ........................102 FCC Certification, 2.4GHz ............................... 103 Certified For Use in the Following Countries ........................104 Exporting SureCross Radios ............................106 Warnings ..............................107 Antenna Installation ................................ 107 Banner Engineering Corp Limited Warranty ........................107 Contact Us ..................................107...

  • Page 6: The Surecross® Dx80 Wireless Network

    SureCross Wireless I/O Network Manual The SureCross® DX80 Wireless Network The SureCross® DX80 wireless I/O network provides reliable monitoring without the burden of wiring or conduit installation. The Sure- Cross wireless network can operate independently or in conjunction with a host system, PLC, and/or PC software. Each wireless network system consists of one Gateway and one or more Nodes.

  • Page 7: Dx83 Ethernet Bridge Overview

    What is FlexPower®? Banner’s FlexPower® technology supplies a true wireless solution by allowing the device to operate using either 10 to 30V dc, 3.6V lithium D cell batteries, or solar power. This unique power management system can operate a FlexPower Node and an optimized sensing device for up to five years on a single lithium D cell.

  • Page 8: Surecross User Configuration Tool

    The UCT requires a special USB to RS-485 (model number BWA-HW-006) converter cable to pass information between your computer and the Gateway. Download the most recent revisions of the UCT software from Banner Engi- neering's website: http://www.bannerengineering.com/wireless. www.bannerengineering.com - tel: 763-544-3164...

  • Page 9: Features

    Features The following feature callouts refer to the DX80 Gateway and Node models, the GatewayPro, and the DX83 Ethernet Bridge. The wiring diagrams include information for connection power and sensors using the 5-pin Euro-style connect, the terminal wiring board, and the Industrial Ethernet connection on the DX83 and GatewayPro.

  • Page 10: Dx80 Gatewaypro

    SureCross Wireless I/O Network Manual 1. Housing. The rugged, industrial DX80 housing meets IEC IP67 standards. 2. Mounting hold, #10/M5 clearance. Mounting Holes accept metric M5 or UNC/UNF #10 hardware -- DIN rail mount adapter bracket avail- able. 3. Wiring terminal strip. The 16 spring-clip type wiring terminals accept wire sizes: AWG 12-28 or 2.5 sq mm.

  • Page 11: Wiring Diagrams

    SureCross Wireless I/O Network Manual Industrial ethernet port, female. Housing. The rugged, industrial DX80 housing meets IEC IP67 stand- ards. Mounting hold, #10/M5 clearance. Mounting Holes accept metric M5 or UNC/UNF #10 hardware -- DIN rail mount adapter bracket availa- ble.

  • Page 12: Dx80

    SureCross Wireless I/O Network Manual DX80...C Wiring Wiring power to the DX80...C models varies depending the power requirements of the model. Terminal Label Gateway, DX85 * 10 to 30V dc Powered Nodes Battery Powered Nodes ** 10 to 30V dc 10 to 30V dc Tx/+ RS485 / D1 / B / +...
  • Page 13 SureCross Wireless I/O Network Manual Single-click Button 1 to advance through menu DINFO FCTRY SITE DVCFG DERR Factory Info Site Survey Device Config Device Error Device Info New Error ERROR Detected Single-click Single-click Single-click Button 2 Button 2 Button 2 AUTO AUTO AUTO...
  • Page 14 SureCross Wireless I/O Network Manual Press and hold Button 1 from any top level menu to power down the Node. Press and hold Button 1 from power down mode to enter RUN mode. Single-click Button 1 to advance through menu DINFO FCTRY DVCFG...

  • Page 15: Run Menu

    SureCross Wireless I/O Network Manual RUN Menu The RUN menu displays the network ID (NID), device name (Gate- Gateway Node way or Node), and the I/O values of the device. When using extended address mode, the network ID (NID) is not used.

  • Page 16: Dinfo (Device Information) Menu

    SureCross Wireless I/O Network Manual DINFO (Device Information) Menu On the Gateway, the DINFO menu displays the device-specific information, such Gateway Node as the device name, the network ID (NID), slave ID, baud rate, and parity. When DINFO DINFO in extended address mode, the DINFO menu also displays the maximum Node Device Info Device Info setting and the extended addressing (XADR), or binding, code used to form the...

  • Page 17: Fctry (Factory) Menu

    SureCross Wireless I/O Network Manual FCTRY (Factory) Menu Gateway Node The FCTRY menu displays the version numbers of various compo- nents within the device, including the radio micro number, the LCD FCTRY FCTRY number, the device’s serial number, the device’s model number, Factory Info Factory #s and the production date.

  • Page 18: Site (Site Survey) Menu

    SureCross Wireless I/O Network Manual SITE (Site Survey) Menu Gateway Access the SITE menu to see the results of a Site Survey conduc- ted with this Gateway. SITE Site Survey The SITE menu displays the device number of the Node the Site Single-click Survey was conducted with as well as the missed, green, yellow, Button 2...

  • Page 19: Dvcfg (Device Configuration) Menu

    SureCross Wireless I/O Network Manual DVCFG (Device Configuration) Menu Gateway DVCFG Device Config Single-click Button 2 Single-click Button 1 to advance through menu (NID) (SLID) (BAUD) (PRTY) (MAXN) (XADR) Timing Extended Addressing Network ID Slave ID Baud Rate Parity Single-click Single-click Single-click Single-click...
  • Page 20 SureCross Wireless I/O Network Manual • Slave ID. The slave ID is an identifying number used for devices within a Modbus system. By default, Gateways are set to Modbus Slave ID 1. When using more than one Modbus slave, assign each slave a unique ID number. Node DVCFG Device Config.

  • Page 21: Derr (Device Error) Menu

    SureCross Wireless I/O Network Manual DERR (Device Error) Menu Gateway Node DERR DERR Device Error Device Error New Error New Error ERROR ERROR Detected Detected Single-click Single-click Button 2 Button 2 Single-click Single-click Button 2 Button 2 Single-click Button 1 Single-click Button 1 to advance through menu NOD XX NOD XX...
  • Page 22 SureCross Wireless I/O Network Manual 65.0 22.2 [2.56”] [0.875”] [0.31”] 30.65 [1.21”] 65.0 80.3 [2.56”] [3.16”] [0.75”] [5”] 7.65 [0.30”] [2.36”] 14.67 [0.578”] 80.8 [3.18”] [4.72”] DX80...C Gateway and Node The DX80...C Gateways and Nodes have the same external and mounting dimensions. 101.6 [4”] 65.0 [2.56”] 7.9 [0.31”]...

  • Page 23: Dx80 Gatewaypro

    SureCross Wireless I/O Network Manual DX80...E Housings 195.9 mm [7.71’’] 148.1 mm [5.83’’] 87.6 mm [3.45’’] 55.9 mm [2.20’’] For 1/4” or M7 bolts 20.1 mm 59.7 mm [0.79’’] [2.35”] DX80 GatewayPro The DX80 GatewayPro has the same external and mounting dimensions as the Gateway and Node, but does not have any side access holes or glands.

  • Page 24: Dx83 Ethernet Bridge

    SureCross Wireless I/O Network Manual DX83 Ethernet Bridge Like the GatewayPro, the DX83 Ethernet Bridge has the same external and mounting dimensions, but no side access holes or glands. 65.0 [2.56’’] [0.31’’] [5.35’’] 65.0 80.3 [2.56’’] [3.16’’] 7.65 [0.30’’] 60.0 [2.36’’] 14.67 [0.578’’]...

  • Page 25: Setting Up Your Wireless Network

    • Non-Performance radios must be set to use Extended Address Mode (DIP switch 1 ON) For more detailed instructions about setting up your wireless network, refer to the Quick Start Guide, Banner document number 128185. For more information about using Performance and non-Performance radios within the same network, refer the technical note titled Mixing Performance Radios and 150 mW Radios in the Same Networklisted on the FAQ/Knowledgebase section of Banner's Wireless Sensor Networks website.

  • Page 26: Applying Power To The Gateway Or Node

    SureCross Wireless I/O Network Manual Applying Power to the Gateway or Node Wire Color Gateway (10 to 30V Node (10 to 30V dc) Node (FlexPower™) brown +10 to 30V dc input 10 to 30V dc white RS485 / D1 / B / + blue dc common (GND) dc common (GND)

  • Page 27: Verify Communications

    SureCross Wireless I/O Network Manual 3. Use both of the Node's rotary dials to assign a valid decimal Node Address (between 01 and 47). The left rotary dial represents the tens digit (0 through 4) and the right dial represents the ones digit (0 through 9) of the Node Address. 4.

  • Page 28: Conducting A Site Survey Using The Menu System

    SureCross Wireless I/O Network Manual Conducting a Site Survey Using the Menu System Follow these steps to initiate a Site Survey using the Gateway’s buttons and menu system. 1. Remove the rotary dial access cover. 2. To check the status of Node 1, change the Gateway’s right rotary dial to 1. The Gateway is now enabled to read the status of Node 1;...

  • Page 29: Interpreting The Site Survey Results

    SureCross Wireless I/O Network Manual When Site Survey runs, the accumulated results are stored in the Gateway’s I/O 7 and I/O 8 holding registers. The LEDs on the both the Gateway and the Node’s front panel display the signal strength for the wireless RF link. The quality of the communications link is indica- ted by: •...

  • Page 30: Site Survey Troubleshooting

    SureCross™ devices. Higher gain antennas will focus the energy of the radio signal in a specific direction and extend the signal’s range. Using data radios is another option to consider when trying to extend the range of a radio network. For more information on data radios, please refer to Banner’s white paper on range extension. Site Survey Troubleshooting Some tips and tricks about improving radio signal reception may improve the site survey results.

  • Page 31: Installing Your Surecross® Radios

    Installing Your SureCross® Radios The following are some recommendations for installing your wireless network components. Mounting SureCross Devices Outdoors Use a Secondary Enclosure For most outdoor applications, we recommend installing your SureCross devices inside a secondary enclosure. For a list of available enclosures, refer to the Accessories list.

  • Page 32: Watertight Glands And Npt Ports

    Remove Moisture and Condensation If condensation is present in any device, add a small desiccant packet to the inside of the radio. To help vent the radios, Banner also sells a vented plug (model number BWA-HW-031) for the 1/2" NPT port of the SureCross radios.

  • Page 33: Installation Quick Tips

    Gateways and Nodes and select locations without obstruc- tions in the path. For more information about antennas, please refer to the Antenna Basics reference guide, Banner document p/n 132113. Increase the Height of the Antennas Position the external antenna vertically for optimal RF communication.

  • Page 34: Be Aware Of Seasonal Changes

    For more detailed information about how antennas work and how to install them, refer to Antenna Basics, Banner document 132113 (also included as a chapter within the product manual).

  • Page 35: Weatherproof Remote Antenna Installations

    I/O Isolation. When connecting analog and discrete I/O to external equipment such as VFDs (Variable Frequency Drives), it may be appropriate to install interposing relays and/or loop isolation devices to protect the DX80 unit from transients, noise, and ground plane interference originating from devices or the environment. Contact Banner Engineering Corp. for more information. Weatherproof Remote Antenna Installations Prevent water damage to the cable and connections by sealing the connections with rubber splicing tape and electrical tape.

  • Page 36: Antenna Installation

    SureCross Wireless I/O Network Manual Antenna Installation Always install and properly ground a qualified surge suppressor when installing a remote antenna system. Remote antenna configura- tions installed without surge suppressors invalidate the manufacturer's warranty. Always keep the ground wire as short as possible and make all ground connections to a single-point ground system to ensure no ground loops are created.
  • Page 37 SureCross Wireless I/O Network Manual This configuration may be used either inside or outside the building, though a Yagi antenna is usually used in outdoors applications while an omni-directional antenna may be used either inside or outside a building. 5, 6 7, 8 Model Number Description...

  • Page 38: Mounting N-Type Antennas Remotely

    SureCross Wireless I/O Network Manual Model Number Description BWA-EF14128 Fiberglass enclosure, 14”x 12” x 8” BWA-PA1412 Internal panel, 14” x 12” DX81 DX81 FlexPower Battery Supply Module DX81P6 DX81P6 FlexPower Battery Supply 6-Pack * This example image depicts a DX80 radio with a 10-30V dc power supply. The example installation may also work with the DX70 radios or MultiHop radios.
  • Page 39 SureCross Wireless I/O Network Manual Model Number Description BWC-4MNFN15 LMR400 Cable, N-Male to N-Female, 15 Meters BWC-4MNFN30 LMR400 Cable, N-Male to N-Female, 30 Meters BWC-LFNBMN-DC Surge Suppressor, Bulkhead, N-Type, 900 MHz/2.4 GHz, dc-Blocking BWC-1MRSMN05 LMR200 Cable, RP-SMA to N-Male, 0.5 Meters BWC-1MRSMN2 LMR200 Cable, RP-SMA to N-Male, 2 Meters DIN-35-105...

  • Page 40: Advanced Setup Instructions And Additional Information

    SureCross Wireless I/O Network Manual Advanced Setup Instructions and Additional Information Refer to the following sections for advanced setup instructions or additional information on Banner's SureCross wireless technology and its uses. Web-based Configuration The DX80 wireless systems are configured using an Ethernet network connection and a common Web page browser. An Ethernet con- nection can be established from a DX80 GatewayPro or from a DX83 Ethernet Bridge serially connected to the DX80 Gateway.

  • Page 41: Accessing The Web-Based Configuration Screens

    The factory default IP address for the DX83 Ethernet Bridge or DX80 GatewayPro devices is: 192.168.0.1 To change the default IP address, set up the host PC with an IP address different from the Ethernet Bridge or Gateway Pro IP addresses. (Refer to Banner docu- ment 133116 for detailed instructions on setting up the host computer’s network IP address.) For example, change the PC host IP ad-...

  • Page 42: Changing The Ip Address

    SureCross Wireless I/O Network Manual 2. Click on any tab at the top of page to log into the configuration software. 3. Enter system as the user name and admin as the password. After making your changes and saving the file, close the browser to log out of the configuration system. Changing the IP Address Use the page tabs at the top of the page to select the hierarchical path: System >...

  • Page 43: Manually Choosing An Extended Address Code - Gateway

    SureCross Wireless I/O Network Manual Rotary Switch Mode Extended Address Mode Menus There are more menu options in extended address mode. Rotary Dials The left rotary dial sets the Network ID and the right On the Gateway, both rotary dials, while in the (NID) dial sets the Device ID/Address.

  • Page 44: Manually Choosing An Extended Address (Binding) Code - Node

    SureCross Wireless I/O Network Manual The Gateway LCD displays the entered value for confirmation by showing CONFRM XADR, then repeating back your value. 13. Single click button 2 to save the code and exit the XADR menu. When entering the extended address code, the digits auto fill with whatever position the rotary switch is currently in. For example, after entering the 00 part of the extended address code 002245, the third digit auto fills with a 0 until the rotary dial is rotated to 2.

  • Page 45: Automatic Binding Using The Menu Navigation

    SureCross Wireless I/O Network Manual The Gateway's LCD displays (NID) 3. Single click button 2. Enters the (NID) menu option. 4. Using both rotary dials on the front of the Gateway, select a Network ID. The left rotary dial acts as the left digit and the right rotary dial acts as the right digit of the Network ID.

  • Page 46: Setting The Maximum System Nodes

    SureCross Wireless I/O Network Manual The Node enters binding mode. The Node's LCD displays NETWRK BINDNG. When the Node is bound, the LEDs are both solid red for a few seconds. The Node cycles its power, then enters RUN mode. 15.

  • Page 47: Setting The Baud Rate

    SureCross Wireless I/O Network Manual To change the Slave ID on the Gateway, follow these steps. 1. Single click button 1 to advance between menus. Stop when you reach the DVCFG menu. 2. Press button 2 once at the *DVCFG menu to enter the Device Configuration menu. 3.

  • Page 48: Default Output Conditions

    SureCross Wireless I/O Network Manual To avoid losing the network connection between the Gateway and Nodes, reset the rotary switches back to their appropriate values before leaving the *DVCFG sub-menus. If the Gateway and Nodes lose their connection, the network may take up to 20 seconds to re-synchronize.

  • Page 49: Node Link Failure

    SureCross Wireless I/O Network Manual The Polling Interval defines how often the Gateway communicates with each Node to verify the RF link is operating. The Gateway incre- ments a Node’s missed message count if a Node does not immediately report back from a polling request. If a Node’s missed message count exceeds the ‘Maximum Missed Message Count,’...

  • Page 50: Units Defined

    SureCross Wireless I/O Network Manual Clearing a lost RF link error does not restore communications. Banner recommends determining and resolving the cause of the RF link error, then allowing the system to auto-recover the lost communications. In the sample system shown, the communication link between the Gateway and Node 1 has failed. Node 1 must have its ‘Node Link Failure’...
  • Page 51 SureCross Wireless I/O Network Manual Units Description Definition Temp °C (Low Celsuis, low resolution. To measure a greater temperature range, use the low resolution unit. In low resolu- Res) tion mode, temperature = (Modbus register value) ÷ 2. LCD: 0000.0C Temp °F (Low Fahrenheit, low resolution.

  • Page 52: Interpreting Register Values In The Banner Wireless System

    4 to 20 mA. LCD: 4.00mA–20.00mA Interpreting Register Values in the Banner Wireless System The units conversion table defines the type and range of values for each type of I/O.
  • Page 53 SureCross Wireless I/O Network Manual Holding Register I/O Range Representation Input Type Data Conversion Description Min. Max. Min. Max. 16-bit T30UF 0 mm 65535 mm 65535 None; stored as millimeter val- Unsigned Humidity 0% RH 100% RH 10000 (Reg Value) ÷ 100 = Relative Unsigned Humidity (RH) Temperature Measurements:...
  • Page 54 SureCross Wireless I/O Network Manual Mapping Unit Types Using signed or unsigned value types allows the user to generically map any input to any output. The signed and unsigned values read the null and span parameters to create the linear translation between one scale and another. The output type is set to mA or V. Output = (Fullscale/Span)(InputValue −...

  • Page 55: Setting Up The Wireless Network Using The Rotary Dials

    Setting up the Wireless Network Using the Rotary Dials Follow these steps to set up your wireless network using the rotary dials instead of using extended addressing mode. Banner recom- mends using Extended Addressing Mode, but some older products may only recognize Rotary Dial Address Mode.
  • Page 56 SureCross Wireless I/O Network Manual 2. On the first Node (device address = 1), set the right rotary dial to 1. Do not change the Device ID for preconfigured kits as this would affect the factory mapping of the I/O. 3.

  • Page 57: Applying Power To The Gateway Or Node

    SureCross Wireless I/O Network Manual Apply power to the Gateway The LCD displays the text shown. While Channel Search Mode runs, LED 1 is solid START red and LED 2 flashes yellow. CHANNL SEARCH MODE The device tests Network ID 2 for availability and counts down from one minute, zero SEARCH seconds.

  • Page 58: Verify Communications

    SureCross Wireless I/O Network Manual Verify Communications After powering up and binding the Gateway and its Nodes, verify all devices are communicating properly. Verify LED 1 is green. Until communication is established with the Gateway, the Node’s LED 2 flashes red. When communication is established, the Node’s LED 1 flashes green.

  • Page 59: System Layouts

    System Layouts Because of the flexibility of the DX80 wireless devices, many different configurations using Gateways, Nodes, GatewayPros, Ethernet Bridges, Modbus slave devices, data radios, data radio repeaters, and/or solar powered systems are possible, both as stand-alone sys- tems and host-connected systems. DX83 Ethernet Bridge DX80 Gateway, 900 MHz DX80DR9M-H MultiHop Radio...

  • Page 60: Gateway Configured As A Modbus Master

    SureCross Wireless I/O Network Manual Item Model No. Description DX80G... DX80 Gateway DX80N... DX80 Node 81398 User Configuration Tool (software included on SureCross documentation CD, not shown) BWA-HW-006 RS-485 to USB adapter cable (not shown) Gateway Configured as a Modbus Master This example network uses the DX80 Gateway device as both master of the wireless network as well as the master of the Modbus network.

  • Page 61: Modbus Rtu

    SureCross Wireless I/O Network Manual Item Model No. Description DX80G... DX80 Gateway DX85M... DX85 Modbus RTU Remote I/O DX80N... DX80 Nodes or FlexPower Nodes 81398 User Configuration Tool (software included on SureCross documentation CD, not shown) BWA-HW-006 RS-485 to USB adapter cable (not shown) Modbus RTU rev.

  • Page 62: Modbus Rtu Host Controlled Operation

    SureCross Wireless I/O Network Manual Modbus RTU Host Controlled Operation A simple host-connected system uses an RS485 serial cable to connect the DX80 Gateway device to a host system. The host system may be a PC or a PLC unit. Because the serial cable is used to connect to a host system, the communications protocol used is Modbus RTU.

  • Page 63: Modbus Rtu With Multiple Slave Devices - Layout 2

    SureCross Wireless I/O Network Manual The Gateway is connected directly to the host system using an RS485 serial cable. This system may also connect DX85 Expanded I/O devices to the serial cable to expand the available I/O. The DX80 Gateway and each DX85 connected as shown below are Modbus slave devices to the host system.

  • Page 64: Modbus/Tcp And Ethernet/Ip

    SureCross Wireless I/O Network Manual Item Model No. Description DX80G... DX80 Gateway DX85M... DX85 Modbus RTU Remote I/O Third party Modbus slave device DX80N... Nodes or FlexPower Nodes Modbus/TCP and EtherNet/IP Host Connected - DX80 GatewayPro Connect a DX80 GatewayPro to a host system using the industrial Ethernet connection on the DX80 GatewayPro. www.bannerengineering.com - tel: 763-544-3164 rev.
  • Page 65 SureCross Wireless I/O Network Manual To connect the DX80 GatewayPro directly to the host system, use a crossover cable. By default, the DX80 GatewayPro is a Modbus/TCP or EtherNet/IP™ server. To configure the GatewayPro as a Modbus client device, change the configuration using the configuration Web pages.

  • Page 66: Data Radios

    SureCross Wireless I/O Network Manual Item Model No. Description DX80N... Nodes or FlexPower Nodes BWA-E2M Ethernet Cable, M12 Industrial/RJ45, Straight, 2 m Ethernet hub or switch box * If I/O is needed on the GatewayPro, use DX85 Modbus RTU Remote I/O devices similar to a previous configuration. Data Radios Data Radios Data radios extend the range of the Modbus network while keeping the network addressing system simple.
  • Page 67 SureCross Wireless I/O Network Manual The DX85 shown is a Modbus slave; the data radios extend the range of the Modbus network. Item Model No. Description DX80G... DX80 Gateway (configured as a Modbus master for this example) DX85M... DX85 Modbus RTU Remote I/O (configued as a Modbus slave for this example) DX80DR*M-H MultiHop Data Radio DX80N...

  • Page 68: Sensor Connections

    Sensor Connections The Sensor Connections guide lists most common Banner and non-Banner sensors and how to wire them to the DX80 devices. This reference guide lists typical connections. If you have additional questions about a specific sensor or its connection instructions, please contact Banner Engineering or the manufacturer of the sensor you are using.

  • Page 69: Discrete Inputs, Mini-Beam

    SureCross Wireless I/O Network Manual Discrete Inputs, MINI-BEAM MINI-BEAM MINI-BEAM Two-wire MINI-BEAM sensor using a FlexPower Node and pow- ered using the DX80’s switch power. Discrete Outputs Discrete Outputs Sourcing (PNP) Sinking (NPN) 10-30V dc 10-30V dc Load Load dc common dc common Wiring diagram for a sourcing (PNP) two-wire output load powered Wiring diagram for a sinking (NPN) two-wire output.

  • Page 70: Analog Inputs

    Analog Sensors. For analog sensors, the ground/dc common of the sensor should be connected to the ground of the DX80 device. For best results, Banner recommends that the power source for the sensor and DX80 device is the same. Analog Inputs, Powered using DX80 Terminals...

  • Page 71: Analog Inputs, Temperature Sensors

    SureCross Wireless I/O Network Manual Two-Wire Sensors Three-Wire Sensors Two-wire analog sensor using a FlexPower Node but the sensor is Three-wire analog sensor using a FlexPower Node but the sensor powered externally (not from the DX80 device). is powered externally (not from the DX80 device). Analog Inputs, Temperature Sensors Thermocouple −...

  • Page 72: Analog Outputs, Drive Motor Controllers

    SureCross Wireless I/O Network Manual Analog Outputs, Drive Motor Controllers AI- Referenced to Ground AI- Not Referenced to Ground Drive/motor drive/motor controllers controller AI− AI− When the AI- can be referenced to ground, use this wiring diagram When the AI- cannot be referenced to ground, use this wiring dia- for drive/motor controllers.

  • Page 73: Surecross Power Solutions

    What is FlexPower®? Banner’s FlexPower® technology supplies a true wireless solution by allowing the device to operate using either 10 to 30V dc, 3.6V lithium D cell batteries, or solar power. This unique power management system can operate a FlexPower Node and an optimized sensing device for up to five years on a single lithium D cell.

  • Page 74: Switch Power (With Flexpower)

    • Are limited in the available I/O because of the limited connectivity, and • Can only be powered from the integrated battery. FlexPower® Solar Supply Banner’s FlexPower® Solar Supply Assembly can be used to power up to two radio devices, including a FlexPower Node, a FlexPower Gateway, or a data radio.

  • Page 75: Battery Life Calculations

    For each sensor characterized, a boost voltage and warmup time was specified. The sample and reports rates were varied to calculate the estimated battery life. For example, a Banner QT50ULBQ6-75390 sensor set to a boost voltage of 15 volts, a warm-up time of 500 milliseconds, and a sample and report rate of 15 minutes, should have a battery life of 4.45 years.

  • Page 76: Discrete Configuration

    For each sensor characterized, a boost voltage and warmup time was specified. The sample and reports rates were varied to calculate the estimated battery life. For example, a Banner Optical sensor, model SM312DQD-78419, set to a boost voltage of 5 volts, a warm-up time of 4 milliseconds, and a sample and report rate of 16 seconds, should have a battery life of just over 6 years.

  • Page 77: Temperature And Humidity Sensor

    Calculating Battery Life To estimate the battery life for a sensor not included in our list, use the configuration and cable shown (Banner cable BWA-HW-010) to measure the current draw of your system. 1. Connect the cable to the FlexPower Node and the battery supply module as shown below. The cable’s male end plugs into the Flex- Power Node and the female end plugs into the battery module.

  • Page 78: Example Solar Powered Systems

    SureCross Wireless I/O Network Manual Item Model No. Description Averaging Fluke Meter DX81 DX81 Battery Supply Module DX80 FlexPower Node with MINI-BEAM BWA-HW-010 Cable, FlexPower Current Monitoring Example Solar Powered Systems For installations without wired power, a solar powered system with an integrated solar controller and rechargeable batteries may be used to power data radios, FlexPower Gateways, or FlexPower Nodes connected to sensors that require more power than a single battery unit can supply.
  • Page 79 SureCross Wireless I/O Network Manual Powering a data radio or data radio repeater with a solar panel allows for the expansion of the wireless network to installations with no reliable power source. The example system shows a solar power system powering data radios and Gateways, expanding the wireless network far beyond the limits of wired power sources.

  • Page 80: Parallel Solar Systems

    SureCross Wireless I/O Network Manual Item Model No. Description BWA-SOLAR-001 FlexPower Solar Supply, includes panel, solar controller, rechargeable batteries, and mounting materials DX80DR*M Data radio, 900MHz or 2.4GHz DX80N9X2S2N2M2 FlexPower Node, 900MHz, Boost Power, 2 discrete IN, 2 NMOS discrete OUT, 2 ana- log IN (2.4GHz also available) QT50U-75390 U-GAGE Long range ultra-sonic sensor, low power consumption...

  • Page 81: Autonomous Process Monitoring With Continuous Sensor Operation

    SureCross Wireless I/O Network Manual Autonomous Process Monitoring with Continuous Sensor Operation A single FlexPower Solar Supply can supply any continuously powered 4–20 mA, two-wire transmitter at 13V and power the DX80 Flex- Power Node for continuous sensor operation. This application requires at least 1.7 hours of sun per day and the battery provides about 10 days of autonomy with a full transmitter signal of 20 mA.
  • Page 82 SureCross Wireless I/O Network Manual Host System Item Model No. Description BWA-SOLAR-001 FlexPower Solar Supply, includes panel, solar controller, rechargeable batteries, and mounting materials DX80N... FlexPower Node or 10 to 30V dc Node DX80G*M2S FlexPower Gateway, No I/O DX80DR*M Data radio, 900MHz or 2.4GHz CSRB-M1250M125.47M125.73 Cable, RS-485, quick disconnect, 5-pin Euro, male trunk, female branches, black* www.bannerengineering.com - tel: 763-544-3164...

  • Page 83: Maintenance

    Maintenance Follow these instructions to perform basic maintenance tasks. Replacing the Main Body Gasket Check the main body gasket every time a SureCross device is opened. Replace the gasket when it is damaged, discolored, or showing signs of wear. The gasket must be: •...

  • Page 84: Battery Replacement

    Do not recharge, crush, disassemble, or expose the contents to water. Replacement battery model number: BWA-BATT-001. For pricing and availability, contact Banner Engineering. DX81P6 FlexPower™ Module Battery Replacement To replace the lithium "D" cell battery pack in the DX81P6 FlexPower™ battery kit, follow these steps.

  • Page 85: Dx80 Integrated Battery Replacement

    SureCross Wireless I/O Network Manual Replacement battery pack model number: BWA-BATT-002. For pricing and availability, contact Banner Engineering. DX80 Integrated Battery Replacement To replace the lithium "D" cell battery in any integrated housing model, follow these steps. 1. Remove the four screws mounting the face plate to the housing and remove the face plate.
  • Page 86 As with all batteries, these are a fire, explosion, and severe burn hazard. Do not burn or expose them to high temperatures. Do not recharge, crush, disassemble, or expose the contents to water. Replacement battery model number: BWA-BATT-001. For pricing and availability, contact Banner Engineering. www.bannerengineering.com - tel: 763-544-3164...

  • Page 87: Troubleshooting

    Troubleshooting The following troubleshooting tips include some basic instructions for common problems. Startup Problems Problem Solution While in storage mode, the radio does not operate. All SureCross® radios powered Radio won't wake up from an integrated battery ship from the factory in storage mode to conserve the battery. To wake the device, press and hold button 1 for five seconds.
  • Page 88 SureCross Wireless I/O Network Manual LED 1 LED 2 Definition/Solution Flashing yellow Device error. If the LCD also reports BAD EE, contact the factory for replacement. Flashing red Flashing red Gateway, DX85: Modbus communication error For a Gateway system, a Modbus communications error indicates a bad transmis- Flashing red sion or checksum error between the host and the Gateway device.

  • Page 89: Lcd Message Codes

    SureCross Wireless I/O Network Manual LED 1 LED 2 Definition/Solution 2. Check the cables connecting the GatewayPro to the host device. No LED 1 No LED 2 All DX80 devices display “POWER” on the LCD for the first five to ten seconds after applying power.

  • Page 90: Inputs And Outputs

    SureCross Wireless I/O Network Manual code, the higher the priority. For more information about how Site Survey data is stored in registers 7 and 8, refer to the Site Survey section. The following are Modbus message codes, shown in hex, that may appear on the SureCross devices' I/O 8 Modbus register. Device Register 8 (Hex) Message Code Data Field...

  • Page 91: Radio Link Time-Out And Recovery (Non-Host Connected Systems)

    Node/Gateway RF link fails, all pertinent wired outputs are de-energized until the link is recovered (see component data sheet for more information.) Through this process, users of Banner wireless networks can be assured that disruptions in the communications link result in predictable system behavior.

  • Page 92: Accessories

    SureCross Wireless I/O Network Manual Accessories The accessories list includes FCC approved antennas, antenna cabling, surge suppressors, power supplies, replacement batteries, en- closures, cables, and other hardware. Antennas Not to scale Part No. Model No. Description Omni-Directional Antennas 76908 BWA-9O2-C 902-928 MHz, 2 dBi, RP-SMA Male, Rubber swivel (ships with 900 MHz DX80 devices) 17721...

  • Page 93: Dx85 Modbus Rtu Remote I/O Devices

    SureCross Wireless I/O Network Manual DX85 Modbus RTU Remote I/O Devices These remote I/O devices have a Modbus interface and are used to expand the I/O of the Gateway or the Modbus host. DX85 Modbus RTU Remote I/O DX85...C Modbus RTU Remote I/O DX85 Part DX85...C Part No.

  • Page 94: Other Power Supplies

    SureCross Wireless I/O Network Manual Part No. Model No. Description 77674 DX81P6 Battery Supply Module, 6 “D” cells, with mounting hardware 81057 BWA-SOLAR-001 FlexPower Solar Supply, includes panel (13 11/16” x 15 3/16”), controller, rechargeable battery pack, mounting hardware 78261 Lithium “D”...

  • Page 95: Sensors

    SureCross Wireless I/O Network Manual Part No. Model No. Description 77422 PS24W DC Power Supply, 500 mA, 24V dc, Demo kit power supply 74321 EZAC-E-QE5 DC Power Supply, 700 mA, 24V dc, 5-pin Euro-style QD, Hard- wired AC power connection 73466 EZAC-E-QE5-QS5 DC Power Supply, 700 mA, 24V dc, 5-pin Euro-style QD, 5-pin...

  • Page 96: Surge Suppressors

    SureCross Wireless I/O Network Manual Part No. Model No. Description 10406 BWA-THERMIS- NTC Thermistor, 2 KOhms, +/-0.2%C TOR-001 14275 BWA-S612-30-100 NoShok Series 612 Submersible Level Transmitter, model 612-30-1-1- N-100, 0 to 30 psig, 100' cable 14276 BWA-S612-15-100 NoShok Series 612 Submersible Level Transmitter, model 612-15-1-1- N-100, 0 to 15 psig, 100' cable Surge Suppressors Part No.

  • Page 97: Ethernet Cables

    SureCross Wireless I/O Network Manual Part No. Model No. Description 77821 BWC-4MNFN15 LMR400 N Male to N Female, 15M 77822 BWC-4MNFN30 LMR400 N Male to N Female, 30M Ethernet Cables Part No. Model No. Description 77669 BWA-E2M Ethernet cable, RSCD RJ45 440, 2M 78469 BWA-E8M Ethernet cable, RSCD RJ45 440, 8M...

  • Page 98: Euro-Style Cordsets

    SureCross Wireless I/O Network Manual Part No. Model No. Description 14642 BWA-HW-026 Splitter cable, wall wart for external power split to 5-pin Euro- style male and 5-pin Euro female (to power a M-H at 1 Watt while configuring it through the MHCT) 13250 BWA-DRSPLITTER Splitter cable, DB9 Female (RS232) trunk to 5-pin Euro-style...

  • Page 99: Replacement Parts

    SureCross Wireless I/O Network Manual Part No. Model No. Description 11320 BWA-EF14128 Enclosure Fiberglass Hinged 14"x12"x8" 11321 BWA-EF1086 Enclosure Fiberglass Hinged 10"x8"x6" 11322 BWA-EF866 Enclosure Fiberglass Hinged 8"x6"x6" 11326 BWA-PA1412 Panel, 14 x 12 11327 BWA-PA108 Panel, 10 x 8 11327 BWA-PA86 Panel, 8 x 6...
  • Page 100 SureCross Wireless I/O Network Manual Part No. Model No. Description Items Access cover, rotary, clear plastic (2) 83244 BWA-HW-009 Solar Assembly Hardware Pack Includes brackets, bolts, set screws 79438 BWA-CG.5-10 Cable Glands, 1/2-inch NPT 10 pieces, cordgrips for cable diameters 0.17’’ to 0.45’’...

  • Page 101: Radio Certifications

    Radio Certifications Banner's SureCross product line is certified by the FCC, European Union, and many other countries for operation within specific radio frequencies. FCC Certification, 900MHz The DX80 Module complies with Part 15 of the FCC rules and regulations. FCC ID: TGUDX80 This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

  • Page 102: Fcc Certification, 900 Mhz, 1 Watt Radios

    SureCross Wireless I/O Network Manual Model Number Antenna Type Maximum Gain BWA-9O1-x Omni, 1/4 wave dipole ≤2 dBi BWA-9O2-C Omni, 1/2 wave dipole, Swivel ≤2 dBi BWA-9O6-A Omni Wideband, Fiberglass Radome ≤8.2 dBi BWA-9O5-B Omni Base Whip ≤7.2 dBi BWA-9Y10-A Yagi ≤10 dBi Table 1.

  • Page 103: Fcc Certification, 2.4Ghz

    SureCross Wireless I/O Network Manual Model Number Antenna Type Maximum Gain Minimum Required Cable/Connec- tor Loss Integral Antenna Unity gain BWA-9O1-x Omni, 1/4 wave dipole ≤2 dBi BWA-9O2-C Omni, 1/2 wave dipole, Swivel ≤2 dBi BWA-9O6-A Omni Wideband, Fiberglass Radome ≤8.2 dBi 2.2 dB BWA-9O5-B...

  • Page 104: Certified For Use In The Following Countries

    SureCross Wireless I/O Network Manual Model Number Antenna Type Maximum Gain Integral antenna Unity gain BWA-2O2-C Omni, 1/2 wave dipole, Swivel ≤2 dBi BWA-2O5-C Omni, Collinear, Swivel ≤5 dBi BWA-2O7-C Omni, Coaxial Sleeve, Swivel ≤7 dBi Certified For Use in the Following Countries The SureCross radio devices are approved for use in the following countries.
  • Page 105 SureCross Wireless I/O Network Manual Radio Modules Country 900 MHz (150 mW) 900 MHz (1 Watt) 2.4 GHz (65 mW) Israel Italy Latvia Liechtenstein Lithuania Luxembourg Malta Mexico Netherlands New Zealand Norway Panama Poland Portugal Romania Saudi Arabia (Kingdom of) Singapore Slovakia Slovenia...

  • Page 106: Exporting Surecross Radios

    Additional Statements - 900 MHz This device has been designed to operate with the antennas listed on Banner Engineering’s website and having a maximum gain of 9 dBm. Antennas not included in this list or having a gain greater that 9 dBm are strictly prohibited for use with this device. The required antenna impedance is 50 ohms.

  • Page 107: Warnings

    Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following the date of shipment. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture which, at the time it is returned to the factory, is found to have been defective during the warranty period.
  • Page 108 Banner Engineering Japan Cent-Urban Building 305 3-23-15, Nishi-Nakajima Yodogawa-Ku, Osaka 532-0011 JAPAN, Tel: 81- (0)6-6309-0411, Fax: 81-6-6309-0416, www.bannerengineering.co.jp, mail@bannerengineering.co.jp Banner Engineering Int’l Incorporated Taiwan Rep. Office 8F-2, No. 308, Sec. 1, Neihu Rd. Taipei, Taiwan 114 Tel: +886 (0)2 8751 9966, Fax: +886 2 8751 2966, www.bannerengineering.com.tw, info@bannerengineering.com.tw Banner Engineering India Pune Head Quarters Office, No.
  • Page 109 Index input value 52–54 integrated battery 74 antenna direct installation 36 remote installation 36, 38 antenna installation lightning arrestor 34–36, 38 remote 34–36, 38 link time-out 91 warning 36, 107 weatherproofing 35 mechanical stress 32, 33 bad EE 89 Modbus communication parameters 46 battery integrated 74 battery life...
  • Page 110 Warranty: Banner Engineering Corporation warrants its products to be free from defects for a period of one year. Banner Engineering Corporation will repair or replace, free of charge, any product of its manufacture found to be defective at the time it is returned to the factory during the warranty period.

This manual is also suitable for:

Dx81Dx81p6Surecross dx80 gatewayproDx83tDx81hDx83a

Table of Contents