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Banner Sure Cross DX80 Instruction Manual

Performance wireless i/o networks
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®
Sure Cross
DX80 Performance Wireless
I/O Networks
Instruction Manual
Original Instructions
132607 Rev. R
27 July 2022
©
Banner Engineering Corp. All rights reserved
132607

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  • Page 1 ® Sure Cross DX80 Performance Wireless I/O Networks Instruction Manual Original Instructions 132607 Rev. R 27 July 2022 © Banner Engineering Corp. All rights reserved 132607...

  • Page 2: Table Of Contents

    ® Sure Cross DX80 Performance Wireless I/O Networks Contents ® 1 Sure Cross DX80 Performance Wireless Networks ....................4 1.1 Gateways and Nodes ..................................4 1.2 Host Controller Systems .................................. 5 ® 1.3 What is FlexPower ..................................5 ® 1.4 Sure Cross DX80 Performance Configuration Software ........................6 2 Features...
  • Page 3 ................................. 39 5.11 Defining the Units ..................................39 5.11.1 Input Units .................................... 40 5.11.2 Output Units ..................................40 5.11.3 Interpreting Register Values in the Banner Wireless System ....................41 5.11.4 Signed Numbers ..................................42 5.11.5 Mapping Unit Types ................................42 6 Product Support and Maintenance ...........................

  • Page 4: Sure Cross ® Dx80 Performance Wireless Networks

    ® Sure Cross DX80 Performance Wireless I/O Networks ® 1 Sure Cross DX80 Performance Wireless Networks ® The Sure Cross DX80 Performance wireless I/O network provides reliable monitoring without wiring or conduit installation. The network operates 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, and devices ship with factory-defined discrete, analog, or a mix of discrete and analog inputs and outputs.

  • Page 5: Host Controller Systems

    1.3 What is FlexPower Banner’s FlexPower technology supplies a true wireless solution by allowing the device to operate using either 10 to 30 V dc, 3.6 V 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 6: Sure Cross ® Dx80 Performance Configuration Software

    Use a USB to RS-485 adapter cable to connect a standalone DX80 Gateway to the computer. For DXM Controllers with an internal DX80 radio, connect a computer to the DXM Controller using the supplied USB or Ethernet connection. Download the most recent revisions of the configuration software from Banner Engineering's website: https:// www.bannerengineering.com/us/en/products/wireless-sensor-networks/reference-library/software.html.

  • Page 7: Features

    ® Sure Cross DX80 Performance Wireless I/O Networks 2 Features The following feature callouts refer to the DX80 Gateway and Node models. The wiring diagrams include information for connection power and sensors using the 5-pin M12 connector, the terminal wiring board, and any other applicable connection.

  • Page 8: Dx80 Gateway And Node Wiring Chamber

    ® Sure Cross DX80 Performance Wireless I/O Networks 2.2 DX80 Gateway and Node Wiring Chamber The DX80 Gateway and Node use the same housing and terminal block for wiring. Figure 5. Wiring chamber of the Performance Gateway and Node 1. Housing—The rugged, industrial DX80 housing meets IEC IP67 standards. 2.

  • Page 9: Dx80

    ® Sure Cross DX80 Performance Wireless I/O Networks 2.3.2 DX80...C Gateways and Nodes All measurements are listed in millimeters, unless noted otherwise. Figure 7. Dimensions for the C housing models 101.6 [4”] 65.0 [2.56”] 7.9 [0.31”] 80.3 [3.16”] 65.0 80.8 45.7 [2.56”] [3.18”]...

  • Page 10: Setting Up Your Wireless Network

    • DXM Instruction Manuals (DXM100-Bx: 190037 and DXM150-Bx: 190038) Figure 9. Performance radio network with Gateway and Nodes Sure Cross DX80 Node (150 mW radio) Sure Cross DX80 Gateway (150 mW radio) Sure Cross DX99 Node Sure Cross Performance Node...

  • Page 11: Apply Power To The Gateway Or Node

    ® Sure Cross DX80 Performance Wireless I/O Networks Figure 10. Performance radio network with a DXM and Nodes Sure Cross DX80 Node (150 mW radio) Enter Back Sure Cross DXM Controller (in 250 mW mode) Sure Cross Performance Node (in 250 mW mode) 3.2 Apply Power to the Gateway or Node...

  • Page 12: 4-Pin M12 D-Coded Industrial Ethernet Wiring

    ® Sure Cross DX80 Performance Wireless I/O Networks Terminal Label Gateway and DX85 10 V DC to 30 V DC Powered Nodes Battery-Powered Nodes 3.6 V DC to 5.5 V DC 3.2.2 4-pin M12 D-Coded Industrial Ethernet Wiring Use the 4-pin M12 D-Coded industrial Ethernet connection to connect the radio network to an Ethernet-based host system. Table 3: 4-pin wiring for the D-coded Ethernet connector 4-pin Industrial Ethernet Connector (female) Wire Color...

  • Page 13: Led Behavior For The Gateways And Nodes

    ® Sure Cross DX80 Performance Wireless I/O Networks The Node automatically exits binding mode, cycles its power, then enters RUN mode. 4. For DXM models, click BACK to exit binding for that specific Node address. 5. Repeat steps 2 through 4 for all Nodes that will communicate to this Gateway. 6.

  • Page 14: Conduct A Site Survey Using The Menu System

    ® Sure Cross DX80 Performance Wireless I/O Networks 3.5.1 Conduct a Site Survey Using the Menu System Initiate a Site Survey using the Gateway’s buttons and menu system. 1. Remove the Gateway's rotary dial access cover. 2. Set the Gateway's rotary dials to the desired Node number. For example, to check the status of Node 1, set the Gateway's left rotary dial to 0 and the right rotary dial to 1.

  • Page 15: Conduct A Site Survey Using Modbus Commands

    ® Sure Cross DX80 Performance Wireless I/O Networks 1. Set the Gateway's rotary dials to the Node address you'd like to conduct a Site Survey with. For example, to analyze the signal strength between this Gateway and Node 02, rotate the left rotary dial to 0 and the right rotary dial to 2.

  • Page 16: Conduct A Site Survey From The Dxm

    If you find poor signal quality, common solutions include moving the DXM to a more central location relative to the Nodes or using higher-gain antennas on the DXM. Contact your local Banner Engineering representative for assistance. 3.5.5 Interpreting the Site Survey Results Site Survey results are listed as a percentage of data packets received and indicate the signal strength of the received signal.

  • Page 17: Improving Your Site Survey Results

    The lack of signals may also be due to the distance between the Gateway (master radio) and Nodes (remote radio). If this is the case, please contact Banner Engineering for further assistance. We also recommend installing the antenna(s) remotely at a higher position. Additional antenna cables are available from Banner Engineering if needed.
  • Page 18 ® Sure Cross DX80 Performance Wireless I/O Networks • BWC-4MNFN30 (30 meters long) Requires a surge suppression device (model BWC-PRC827-DC) if the antenna is external to a building, connected to other electronics, or elevated. BWA-9O8-AS (8 dBi OMNI antenna with Type N cable connector)—Antenna for very strong antenna performance increase. Requires a RP-SMA to Type N converter cable (model BWC-1MRSMN05).

  • Page 19: Installing Your Sure Cross ® Radios

    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-inch NPT port of the Sure Cross radios.

  • Page 20: Other Installation Requirements

    To achieve the best radio performance, carefully consider the installation locations for the Gateways and Nodes and select locations without obstructions in the path. For more information about antennas, please refer to the Antenna Basics reference guide, Banner document p/n 132113. 4.3.2 Increase the Height of the Antennas Position the external antenna vertically for optimal radio communication.

  • Page 21: Collocated Radios

    ® Sure Cross DX80 Performance Wireless I/O Networks 4.3.3 Collocated Radios When the radio network’s master device is located too close to another radio device, communications between all devices is interrupted. For this reason, always assign a unique Network ID to your wireless networks. The Network ID (NID) is a unique identifier you assign to each wireless network to minimizes the chances of two collocated networks interfering with each other.

  • Page 22: 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.

  • Page 23: Installing Remote Antennas

    ® Sure Cross DX80 Performance Wireless I/O Networks Figure 22. Use electrical tape to prevent UV damage Step 3: Protect the rubber splicing tape from UV damage by tightly wrapping electrical tape on top of the rubber splicing tape. The electrical tape should completely cover the rubber splicing tape and overlap the rubber tape by one inch on each side of the connection.

  • Page 24: Use An N-Type, Pole-Mounted Antenna

    ® Sure Cross DX80 Performance Wireless I/O Networks Table 10: Omni-directional dome antenna with RP-SMA male connection Omni-Directional Dome Antenna with RP-SMA Male Connection BWA-9O2-D • Dome antenna, 2 dBi, 18-inch cable, 900 MHz • RP-SMA Box Mount • Datasheet: b_3145121 BWA-2O2-D •...
  • Page 25 ® Sure Cross DX80 Performance Wireless I/O Networks Directional (Yagi) Antennas with an N-Type Female Connection BWA-9Y10-A • 10 dBd, 6.8 × 24 inches Outdoor, 900 MHz • Datasheet: b_3145130 Table 12: Omni-directional fiberglass antennas with N-type female connections Omni-Directional Fiberglass Antennas with N-Type Female Connections BWA-9O6-A •...

  • Page 26: Advanced Setup Options

    Sure Cross DX80 Performance Wireless I/O Networks 5 Advanced Setup Options ® Refer to the following sections for advanced setup instructions or additional information on Banner's Sure Cross wireless technology and its uses. 5.1 DX80 Menu Structure The Gateways and Nodes each have their own menu structure and options.
  • Page 27 ® Sure Cross DX80 Performance Wireless I/O Networks Figure 26. Node menu system 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...

  • Page 28: Run Menu

    ® Sure Cross DX80 Performance Wireless I/O Networks 5.1.1 RUN Menu The RUN menu displays the network ID (NID), device name (Gateway or Node), and the I/O values of the device. Figure 27. RUN menu on the Gateway and Node Gateway Node AUTO...

  • Page 29: Site (Site Survey) Menu

    ® Sure Cross DX80 Performance Wireless I/O Networks If you call Banner Engineering for technical support, having this information available may help diagnose your particular problem. 5.1.4 SITE (Site Survey) Menu The SITE menu displays the results of a Site Survey conducted with this Gateway.

  • Page 30: Dvcfg (Device Configuration) Menu

    ® Sure Cross DX80 Performance Wireless I/O Networks 5.1.5 DVCFG (Device Configuration) Menu On Gateways, the DVCFG menu allows users to set various device-specific parameters, including the network ID (NID), slave ID (SLID), baud rate, and parity. In extended address mode, use this menu to also set the maximum number of radio devices (MAXN) within the network and the extended address binding code (XADR).
  • Page 31 ® Sure Cross DX80 Performance Wireless I/O Networks Network ID The Network ID (NID) is a unique identifier you assign to each wireless network to minimizes the chances of two collocated networks interfering with each other. Assigning different NIDs to different networks improves collocation performance in dense installations.

  • Page 32: Derr (Device Error) Menu

    ® Sure Cross DX80 Performance Wireless I/O Networks 5.1.6 DERR (Device Error) Menu Use the DERR menu to manage device error messages. Figure 33. DERR menu for the Gateway and Node Gateway Node DERR DERR Device Error Device Error New Error New Error ERROR ERROR...

  • Page 33: Bind Radios Using Modbus Commands

    ® Sure Cross DX80 Performance Wireless I/O Networks 9. Apply power to the Node. The Node's LCD displays POWER, then *RUN. 10. On the Node, single click button 1 to advance across the menus, stopping at the DVCFG menu. The Node's LCD displays (DVCFG). 11.

  • Page 34: Setting The Network Id In Extended Addressing Mode

    ® Sure Cross DX80 Performance Wireless I/O Networks 3. Repeat steps 1 and 2 for all Nodes that will communicate to this Gateway. 4. Write 0x0000 (hex) to the Gateway's register 6371 to stop the binding procedure. For more information about using Modbus commands, refer to Host Controller Systems instruction manual (p/n 132114). 5.3 Setting the Network ID in Extended Addressing Mode Use the menu system to set the Network ID when using extended address mode.

  • Page 35: Manually Assign A Binding Code To A Node

    ® Sure Cross DX80 Performance Wireless I/O Networks 10. Single click button 2 when code entry is complete. The Gateway LCD displays the entered value for confirmation by showing CONFRM XADR, then repeating back your value. 11. Single click button 2 to save the code and exit the XADR menu. When entering the binding code, the digits auto fill with whatever position the rotary switch is currently in.

  • Page 36: Modbus Holding Registers

    ® Sure Cross DX80 Performance Wireless I/O Networks remains on for an additional minute after the radio enters storage mode. After a device has entered storage mode, you must wait one minute before waking it. Sleep Mode (applies to both battery and 10–30 V DC powered models)—During normal operation, the Sure Cross radio devices enter sleep mode after 15 minutes of operation.

  • Page 37: Set The Slave Id On A Dx80 Gateway

    ® Sure Cross DX80 Performance Wireless I/O Networks 5.9.1 Set the Slave ID on a DX80 Gateway By default, all Gateways are set to Modbus Slave ID 1. 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.

  • Page 38: Default Output Conditions

    ® Sure Cross DX80 Performance Wireless I/O Networks 7. Double-click Gateway button 2 to return to the Device Configuration (DVCFG) menu. 8. Click Gateway button 1 until reaching the RUN menu option. 5.10 Default Output Conditions The timeout structure of the SureCross wireless network sets relevant outputs to user-defined conditions when radio or host communications fail.

  • Page 39: Node Link Failure

    Gateway can clear the error condition and resume normal operation. The front panel buttons or the Gateway’s register I/O 15 clear error conditions. Clearing a lost radio link error does not restore communications. Banner recommends determining and resolving the cause of the radio link error, then allowing the system to auto-recover the lost communications.

  • Page 40: Input Units

    ® Sure Cross DX80 Performance Wireless I/O Networks 5.11.1 Input Units Table 19: Defining the input units Units Description Definition Displays the raw A/D conversion data with data ranges from 0 to 65535. This units type is Raw A/D hex value typically used only for factory calibration.

  • Page 41: Interpreting Register Values In The Banner Wireless System

    4 mA. The span is the entire distance range that is to be associated with 4 to 20 mA. 5.11.3 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 42: Signed Numbers

    ® Sure Cross DX80 Performance Wireless I/O Networks 5.11.4 Signed Numbers Temperature values are stored in Modbus registers as two's complement signed numbers. Using two's complement allows negative numbers to be stored in Modbus registers. Although not technically a sign bit, the most significant bit (MSB) indicates a negative number when the value is set to one (1).
  • Page 43 ® Sure Cross DX80 Performance Wireless I/O Networks Example: Mapping a Temperature Map a temperature input from a Node to a 4 to 20 mA output. The starting temperature is −20 °F and the last temperature will be 50 °F (4 mA = −20 °F, 20 mA = 50 °F). This defines the null as −20 °F and the span as 70. With an input temperature value of −5 °F, the output value will be: Output = (Fullscale ÷...

  • Page 44: Product Support And Maintenance

    ® Sure Cross DX80 Performance Wireless I/O Networks 6 Product Support and Maintenance 6.1 DX80 Performance Documentation For additional information, including installation and configuration, weatherproofing, device menu maps, troubleshooting, and a list of accessories, refer to one of the following product manuals. •...

  • Page 45: Led Message Codes

    ® Sure Cross DX80 Performance Wireless I/O Networks 6.2.2 LED Message Codes Solid or flashing LEDs mean different things depending on whether the device is a Gateway, Node, or DX85 Remote I/O Modbus Slave. Table 25: LED message codes LED 1 LED 2 Definition/Solution Solid green...
  • Page 46 ® Sure Cross DX80 Performance Wireless I/O Networks Message Solution EC XX The XX refers to the Modbus register 8 message code shown in Modbus Message Codes for Register 8 on page 46. The LCD displays the message code in decimal; host-controlled systems read the message codes in hex. DX80 display shows *ERROR: The Gateway uses fully-acknowledged polling to ensure each Node radio link is robust.

  • Page 47: Inputs And Outputs

    When a specific Node/Gateway radio link fails, all pertinent wired outputs are de-energized until the link is recovered (see component datasheet 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 48: Maintenance

    ® Sure Cross DX80 Performance Wireless I/O Networks Figure 38. Radio link between the Gateway and Node 1 has recovered. OUT 1 = Normal OUT 2 = Normal OUT 1 = Normal Node 1 OUT 2 = Normal OUT 3 = Normal OUT 4 = Normal Gateway OUT 1 = Normal...

  • Page 49: Install Or Replace The Battery For A Dx81 Model

    The battery may be replaced in explosive gas atmospheres. For non-hazardous locations, the replacement battery is model BWA-BATT-011. For non- hazardous or hazardous locations, the replacement battery is Xeno model XL-205F, Banner model BWA-BATT-001. For pricing and availability, contact Banner Engineering.

  • Page 50: Install Or Replace The Battery For A Dx80 Integrated Battery Model

    For non-hazardous locations, the replacement battery is model BWA-BATT-011. For non- hazardous or hazardous locations, the replacement battery is Xeno model XL-205F, Banner model BWA-BATT-001. For pricing and availability, contact Banner Engineering. 6.3.5 Install or Replace the Battery (DX99...D Models) WARNING: •...

  • Page 51: Sure Cross ® Radio Certifications

    ® 6.4 Sure Cross Radio Certifications Banner's Sure Cross product line is certified by the FCC, European Union, and many other countries for operation within specific radio frequencies. 6.4.1 FCC Part 15 Class A This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules.

  • Page 52: Fcc And Ised Certification, 2.4Ghz

    ® Sure Cross DX80 Performance Wireless I/O Networks Contains FCC ID: [UE3RM1809 or UE3SX7023EXT] Contains IC: [7044A-RM1809 or 7044A-SX7023EXT] HVIN: [RM1809 or 223150] This device complies with Part 15 of the FCC Rules. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

  • Page 53: Exporting Sure Cross ® Radios

    When using other antennas, verify you are not exceeding the transmit power levels allowed by local governing agencies. This device has been designed to operate with the antennas listed on Banner Engineering’s website and having a maximum gain of 9 dBm.

  • Page 54: Contact Us

    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.

  • Page 55: Banner Engineering Corp Limited Warranty

    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 56 Index antenna increase height 20 forming networks 12 parity 37 installing 21 fullscale 41 polling 47 installing dome 23 installing N-type 24 installing remote 21–24 weatherproofing 22 gasket radio link failure 47 main body 48 radio time-out 45–47 ground 20 RF device time-out 46 ground wire 21–24 bad EE 45, 46...

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