SureCross Wireless I/O Networks Instruction Manual Original Instructions 132607 Rev.
SureCross Wireless I/O Networks Contents 1 The SureCross® Performance Wireless Network 1.1 1.2 1.3 1.4 1.5 1.6 2 Features 2.1 2.2 2.3 2.4 2.5 ............................................................. 5 SureCross® Performance Gateways and Nodes ............................................................................. 5 SureCross® Performance GatewayPro .......................................................................................... 5 DX83 Ethernet Bridge Overview .......................
SureCross Wireless I/O Networks 5.5 Setting the Maximum System Devices ........................................................................................43 5.6 Storage Mode and Sleep Mode ................................................................................................. 43 5.7 Modbus Communication Parameters ...........................................................................................43 5.7.1 Setting the Slave ID on a DX80 Gateway ..........................................
SureCross Wireless I/O Networks 9.3.3 Replacing the Battery (DX99...D Models) 10 Troubleshooting ......................................................................... 77 ..........................................................................................................79 10.1 Startup Problems ...................................................................................................................79 10.2 LED Message Codes ..............................................................
SureCross Wireless I/O Networks 1 The SureCross® Performance Wireless Network The SureCross® Performance wireless I/O network provides reliable monitoring without wiring or conduit installation. The SureCross wireless network operates independently or in conjunction with a host system, PLC, and/or PC software. Node FlexPower Node with integrated battery Gateway Node Each wireless network system consists of one Gateway and one or more Nodes.
SureCross Wireless I/O Networks Power Connect a DX83 Ethernet Bridge to a host system using the industrial Ethernet connection on the DX83. To connect the DX83 directly to the host system without using an Ethernet switchbox/hub, some host systems may require a crossover cable. Ethernet cable (crossover cable when connecting to a computer; straight cable when connecting to a hub or switch box) By default, the DX83 is configured to use Modbus/TCP.
SureCross Wireless I/O Networks DX81: Single battery supply module DX81H: Single battery supply module designed specifically to power the DX99 Intrinsically Safe devices with polycarbonate housings DX81P6: Six-pack battery supply module BWA-SOLAR-001: Solar supply; includes solar panel, rechargeable batteries, and controller. 1.6 SureCross User Configuration Tool The User Configuration Tool (UCT) software runs on any Windows machine and uses a converter cable to connect your Gateway to the computer.
SureCross Wireless I/O Networks 2 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. 2.1 DX80 Gateway and Node Components The DX80 Gateway and Node use the same housing and include the same physical features. 1 2 3 4 5 6 7 1.
SureCross Wireless I/O Networks 1 2 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 available. 3 4 5 3. Wiring terminal strip. The 16 spring-clip type wiring terminals accept wire sizes: AWG 12-28 or 2.5 sq mm. 4. Port, PG-7 gland or blank. The PG-7 threaded ports can accept provided cable glands or blanks. 5. Ribbon connector.
SureCross Wireless I/O Networks 1 2 3 1. Industrial ethernet port, female. 2. Housing. The rugged, industrial DX80 housing meets IEC IP67 standards. 3. Mounting hold, #10/M5 clearance. Mounting Holes accept metric M5 or UNC/UNF #10 hardware -- DIN rail mount adapter bracket available. 4. 5-Pin M12 Euro-style quick-disconnect serial port 4 2.5 Wiring Diagrams Use the following drawings to correctly wire power and I/O to the SureCross Wireless radio devices.
SureCross Wireless I/O Networks 2.5.3 DX80...C Wiring Wiring power to the DX80...C models varies depending the power requirements of the model. Connecting dc power to the communication pins (Tx/Rx) causes permanent damage. For FlexPower devices, do not apply more than 5.5 V to the B+ terminal.
SureCross Wireless I/O Networks DX80...C Gateways and Nodes 101.6 [4”] 65.0 [2.56”] 7.9 [0.31”] 65.0 [2.56”] 45.7 [1.8”] 80.3 [3.16”] 7.65 [0.30”] 80.8 [3.18”] 60 [2.36”] 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 [0.79’’] 59.7 mm [2.
SureCross Wireless I/O Networks 2.6.2 GatewayPro 65.0 [2.56’’] 7.9 [0.31’’] 65.0 [2.56’’] 80.3 [3.16’’] 136 [5.35’’] 7.65 [0.30’’] 60 [2.36’’] 14.67 [0.578’’] 80.8 [3.18’’] 2.6.3 DX83 Ethernet Bridge 65.0 [2.56’’] 7.9 [0.31’’] 65.0 [2.56’’] 136 [5.35’’] 80.3 [3.16’’] 7.65 [0.30’’] 60.0 [2.36’’] 14.67 [0.578’’] 80.8 [3.
SureCross Wireless I/O Networks 3 Setting Up Your Wireless Network To set up and install your wireless network, follow these steps. Disconnect the power from your SureCross devices. 1. Configure the DIP switches of all devices. For DIP switch configurations, refer to the product's datasheet. 2. Connect the sensors to the SureCross devices. For available I/O, refer to the product's datasheet. 3. Apply power to all devices. On the Gateway, LED 1 is solid green.
SureCross Wireless I/O Networks 3.3 Applying Power to the Gateway or Node 2 3 5 4 1 Wire Color Gateway (10–30V dc) Node (10–30V dc) 1 brown 10–30V dc input 10–30V dc 2 white RS485 / D1 / B / + 3 blue dc common (GND) 4 black RS485 / D0 / A / - 5 gray Comms gnd dc common (GND) Node (FlexPower) dc common (GND) 3.6–5.5V dc* * Do not apply more than 5.5V dc to the gray wire. 1. Apply power to the Gateway by connecting the 10–30V dc cable as shown.
SureCross Wireless I/O Networks 5. Exit binding mode on the Gateway. • • • If you have a two-button Gateway, single-click either button. If you have a one-button Gateway, single-click the button. If you have a Gateway with no buttons, change the Gateway's rotary dials to a valid Network ID. Valid Network IDs are 01 through 32, in decimal, established using the rotary dials. The left dial may be set to 0, 1, 2, or 3.
SureCross Wireless I/O Networks 3.7 Conducting a Site Survey (Gateway and Nodes) A Site Survey, also known as a Radio Signal Strength Indication (RSSI), analyzes the radio communications link between the Gateway and any Node within the network by analyzing the radio signal strength of received data packets and reporting the number of missed packets that required a retry. Perform a Site Survey before permanently installing the radio network to ensure reliable communication.
SureCross Wireless I/O Networks 7. Change the Gateway's right rotary dial to conduct a Site Survey with another Node and repeat steps 2 through 6. 8. To end the Site Survey, double-click button 2. 9. Change the Gateway's right rotary dial back to 0. The LCD displays the device readings for the Gateway. 10. Double-click button 2 to move back to the top level menu. 11. Single-click button 1 to return to RUN mode. 12.
SureCross Wireless I/O Networks 3.7.3 Site Survey Troubleshooting Some tips and tricks about improving radio signal reception may improve the site survey results.
SureCross Wireless I/O Networks The Gateway device also displays the Site Survey results on the LCD. For one transmit and receive interval, the Gateway saves the lowest signal strength. The LCD and Modbus registers contain the results of the last 100 samples. The totals are a running tally of the last 100 samples and are continuously updated.
SureCross Wireless I/O Networks 4 Installing Your SureCross® Radios The following are some recommendations for installing your wireless network components. 4.1 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. Point Away From Direct Sunlight.
SureCross Wireless I/O Networks 2. Manually thread the plug into the housing port until reaching some resistance. 3. Using a 9/16-inch crescent wrench, turn the plug until all the plug’s threads are engaged by the housing port or until the resistance doubles. Do not over-tighten as this will damage the SureCross unit. These threads are tapered and will create a waterproof seal without over-tightening. 4.2 Other Installation Requirements 4.
SureCross 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.
SureCross Wireless I/O Networks 1 1. Antenna mounted remotely from the radio device. 2. Coaxial cable 3. Surge suppressor 4. Ground wire to a single-point ground system 2 3 4 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.
SureCross Wireless I/O Networks 4.4.3 Mount a Dome Antenna to the Enclosure Use a -D dome antenna when mounting an antenna directly to the outside of the enclosure. 1. Dome antenna 2. DIN rail and DIN rail bracket 3. Enclosure The -D dome antennas come with an 18-inch RP-SMA extension cable connected to the antenna. Use this extension cable to connect the antenna directly to the radio. 1 To mount, drill a hole in the enclosure and insert the antenna.
SureCross Wireless I/O Networks 4.4.4 Use an N-Type, Pole-Mounted Antenna This antenna mounts remotely from the box, with the SureCross device mounted inside the box. Ground the surge suppressor and antenna. 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. 2 3 1 4 5, 6 8, 9 7 1. N-type Yagi antenna 2. N-Type to N-Type antenna cable 3. Surge suppressor 4. RP-SMA to N-Type male antenna cable 5 and 6.
SureCross Wireless I/O Networks Omni-Directional Fiberglass Antennas with N-Type Female Connections Models BWA-9O6-A BWA-2O8-A BWA-2O6-A Frequency Description 900 MHz 2.4 GHz BWA-9O6-AS BWA-9O8-AS 900 MHz List Price 6 dBd, Fiberglass, 71.5 inches $355 8.5 dBi, Fiberglass, 24 inches $200 6 dBi, Fiberglass, 16 inches (shown) $125 6 dBi, Fiberglass, 23.6 inches (1.3 inch dia.) $120 8 dBi, Fiberglass, 63 inches (1.5 inch dia.
SureCross Wireless I/O Networks 5 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. 5.1 DX80 Menu Structure The Gateways and Nodes each have their own menu structure and options. 5.1 DX80 Gateway Set-up Menu When power is applied, the DX80 begins running.
SureCross Wireless I/O Networks 5.1 DX80 Node Set-up Menu When power is applied, the DX80 begins running. The display screen auto loops through the RUN menu and communication begins between the Gateway and Node(s). Auto looping through the RUN menu is the normal operating mode for all devices on the wireless network. From the RUN Menu (or any menu), single-click button 1 to advance through the top-level menus.
SureCross Wireless I/O Networks OFF 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 AUTO DISPLAY LOOP Single-click Button 1 Single-click Button 1 Single-click Button 1 NID XX (DEV) (DEV) (DEV) NOD XX NOD XX I/O XX (NAME) (RADIO 0.00 NODE XX MICRO) ON/OFF KIT V 00.
SureCross 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. Gateway Node *RUN *RUN AUTO DISPLAY LOOP adjust the rotary switches to survey the selected Node Single-click Single-click Button 1 Button 1 AUTO DISPLAY LOOP Single-click Button 1 On the Gateway, the I/O displayed may be the I/O of the Gateway or of a selected Node.
SureCross Wireless I/O Networks 5.1.2 DINFO (Device Information) Menu The DINFO menu displays some device-specific information. Gateway Node *DINFO Device Info *DINFO Device Info AUTO DISPLAY LOOP Single-click Button 1 (DEV) GATEWY AUTO DISPLAY LOOP Single-click Button 1 On the Node, the DINFO menu displays the device type including the Node address, the device name, and the network ID (NID). When using extended address (binding) mode, the network ID value is no longer used by the devices.
SureCross Wireless I/O Networks 5.1.3 FCTRY (Factory) Menu The FCTRY menu displays the version numbers of various components within the device, including the radio micro number, the LCD number, the device’s serial number, the device’s model number, and the production date. Gateway Node *FCTRY Factory Info *FCTRY Factory #s AUTO DISPLAY LOOP Single-click Button 1 (DEV) GATEWY (RADIO MICRO) V 00.0 A (LCD MICRO) V 00.
SureCross Wireless I/O Networks 5.1.4 SITE (Site Survey) Menu The SITE menu displays the results of a Site Survey conducted with this Gateway. Gateway *SiteSITE Survey Double-click Button 2 Single-click Button 2 The SITE menu displays the device number of the Node the Site Survey was conducted with as well as the missed, green, yellow, and red received packet count. The SITE menu is only available on the Gateways.
SureCross 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).
SureCross Wireless I/O Networks Node *DVCFG Device Config.
SureCross Wireless I/O Networks On the Gateway use the DERR menu to clear, disable, or ignore error messages generated by devices within the network. The Node number that generated the error and the error code (EC) display onscreen. Single-click button 1 to advance through the menu of CLEAR (clear this particular instance of the error from the system), DISABL (disable this particular error from appearing from this specific Node), and IGNORE (ignore this error but do not remove it from the system).
SureCross Wireless I/O Networks 1. Ethernet crossover cable using the Modbus/TCP or EtherNet/IP™ communication protocol 1 Host 2. Industrial Ethernet connection 3. GatewayPro 2 3 5.2 Example Layout #3 This example system layout may also be configured using the web pages. Instead of using a GatewayPro to connect to the host system, a Gateway and Ethernet Bridge is used to achieve the same function. In this configuration, the Gateway is Modbus Slave 1. 1.
SureCross Wireless I/O Networks 1. Open a Web browser and log into the Ethernet Bridge or GatewayPro by typing the IP address in the browser location window: http://192.168.0.1. The Web home page for the Ethernet Bridge or GatewayPro displays. 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. 5.2.
SureCross Wireless I/O Networks 5.3 Binding Mode: What does it do? Binding Nodes to a Gateway ensures the Nodes only exchange data with the Gateway they are bound to. After a Gateway enters binding mode, the Gateway automatically generates and transmits a unique extended addressing (XADR), or binding, code to all Nodes within range that are also in binding mode. The extended addressing (binding) code defines the network, and all radios within a network must use the same code.
SureCross Wireless I/O Networks Rotary Switch Mode Nodes in Network Extended Address Mode A maximum of 15 Nodes can be used in the wireless A maximum of 47 Nodes (48 total devices) can be network used in the wireless network. 5.4.1 Manually Choosing an Extended Address Code - Gateway Manually choosing the extended address code is useful when replacing components of an existing wireless network.
SureCross Wireless I/O Networks 9. Single click button 2 to enter the extended address code entry step. The LCD shows SET XADR 000000. 10. Use the right rotary switch to begin setting the extended address code. Digit selection begins with the left most digit. After selecting the first digit, single click button 1 to advance right to the next digit. All six digits must be filled, even if it is with leading zeros. For example, to use 2245 as the code, enter 002245 into the device. 11.
SureCross Wireless I/O Networks 6. Single click button 2 to enter XADR mode. When the display reads (AUTO), single click button 2 again to begin the automatic binding mode. The LEDs flash alternately when the Gateway is in binding mode. Any Node entering binding mode will bind to this Gateway. The Gateway's LCD displays NETWRK BINDNG. 7. On the Node: remove the top cover. 8. Move DIP switch 1 to the ON position. Extended address mode is activated using DIP switch 1. 9. Apply power to the Node.
SureCross Wireless I/O Networks Parameter Default Value Description Slave ID 1 Baud Rate 19200 Defines communication data rate (19.2, 38.4, or 9.6 kbps) between the Gateway and the Host through the serial interface. Parity None Defines serial parity (none, even, or odd) between Gateway and Host. Defines the slave number (01–99) for the serial Modbus RTU protocol. When operating more than one network with a Modbus Master device, change the Slave IDs. 5.7.
SureCross Wireless I/O Networks 5. Double-click Gateway push button 2 to return to the Device Configuration (*DVCFG) menu. 6. Click Gateway push button 1 until reaching the *RUN menu option. 5.8 Default Output Conditions The timeout structure of the SureCross wireless network sets relevant outputs to user-defined conditions when radio or host communications fail. If the timeout features are enabled, the outputs are set to default states or the last known state before the error.
SureCross Wireless I/O Networks Host System Node 1 Gateway Node 2 In the sample system shown, the communication link between the Gateway and Node 1 has failed. Node 2 must have its Gateway Link Failure flag set to allow any outputs linked to Node 1 to be set to the defined default state when the communication link between Node 1 and the Gateway fails. 5.8.3 Node Link Failure A Node Link Failure is determined by the polling interval/rate or the out-of-sync timing.
SureCross Wireless I/O Networks Units 1 Description 4 to 20 mA Definition Analog unit. Modbus register contents are scaled such that 0 represents 4 mA and 65535 represents 20 mA. LCD: 4.00mA–20.00mA 2 0 to 20 mA Default analog input unit. Modbus register contents are scaled such that 0 represents 0 mA and 65535 represents 20 mA. LCD: 0.00mA–20.00mA 3 Discrete (ON/ OFF) 4 Default discrete input unit. LCD: ON/OFF 0 to 10 V Analog input using 0 to 10 V instead of current.
SureCross Wireless I/O Networks Units 2 Description 0 to 20 mA Definition Default analog input unit. Modbus register contents are scaled such that 0 represents 0 mA and 65535 represents 20 mA. LCD: 0.00mA–20.00mA 3 Discrete (ON/ OFF) 4 Default discrete unit. LCD: ON/OFF 0 to 10 V Analog unit using 0 to 10 V instead of current. Modbus register contents are scaled such that 0 represents (Volts) 0 V and 65535 represents 10 V. LCD: 0.00V–10.
SureCross Wireless I/O Networks 5.9.1 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. The wireless devices have many different units of measure for inputs including: milliamp (mA), voltage (V), temperature (°C or °F), humidity (RH), or a raw 16-bit or 32-bit value. Outputs can be either current (4 to 20 mA, 0 to 20 mA) or voltage (0 to 10 V dc).
SureCross Wireless I/O Networks Register Value Converted Decimal Calculated Temperature Two's Complement Value Decimal Value 0000 0000 0000 0101 5 5 0.25 0000 0000 0000 0100 4 4 0.20 0000 0000 0000 0011 3 3 0.15 0000 0000 0000 0010 2 2 0.10 0000 0000 0000 0001 1 1 0.05 0000 0000 0000 0000 0 0 0 1111 1111 1111 1111 65535 -1 -0.05 1111 1111 1111 1110 65534 -2 -0.10 1111 1111 1111 1101 65533 -3 -0.15 1111 1111 1111 1100 65532 -4 -.
SureCross Wireless I/O Networks With an input distance reading of 1560 mm, the output value will be: Output = (Fullscale ÷ Span)(InValue − Null) + Offset (Fullscale ÷ Span) = 10 ÷ 1800 = 0.00555 (Value − Null ) = 1560 − 200 = 1360 Offset = 0 Output = 0.00555 × 1360 + 0 = 7.54 V Alarm Conditions. The standard alarm conditions are as follows: Unsigned Alarm = 0xFFFF Signed Alarm = 0x7FFF If special alarm conditions are needed, consult the factory for details. 5.
SureCross Wireless I/O Networks After setting both the Network ID and Device Address for all devices, re-install the rotary dial access covers, referring to the Installation section for IP67 instructions. A successful radio link is identified by a blinking green LED 1 on each Node. 5.10.4 Setting Up Channel Search Mode A Gateway runs Channel Search Mode on power up or when the Gateway’s Network ID is changed. Before beginning, apply power to the Gateway.
SureCross Wireless I/O Networks Apply power to the Gateway The LCD displays the text shown. While Channel Search Mode runs, LED 1 is solid red and LED 2 flashes yellow. START CHANNL SEARCH MODE The device tests Network ID 2 for availability and counts down from one minute, zero seconds.
SureCross Wireless I/O Networks 6 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 systems and host-connected systems. DX83 Ethernet Bridge DX80 Gateway, 900 MHz DX80DR9M-H MultiHop Radio 6.1 Stand-Alone Systems 6.1.
SureCross Wireless I/O Networks 6.1.2 Gateway with Multiple Nodes (DX80) In this configuration, the Gateway is the master of the wireless network. Configure this network using the User Configuration Tool (UCT) and RS-485 to USB adapter cable. The UCT is used to map inputs and outputs between Nodes and Gateways. 2 1 2 2 Item Model No. Description 1 DX80G... DX80 or DX80 Performance Gateway 2 DX80N...
SureCross Wireless I/O Networks 6.1.3 Gateway Configured as a Modbus Master This example network uses the Gateway as master of the wireless network and master of the Modbus network. This configuration is used when the I/O capacity of the Gateway is exceeded. The Gateway is configured with a table of mapping entries that allow the DX85 Modbus RTU Remote I/O devices (as Modbus slaves) to be mapped to the wireless Nodes.
SureCross Wireless I/O Networks 6.2 Modbus RTU 6.2.1 Modbus RTU Host Controlled Operation A simple host-connected system uses an RS-485 serial cable to connect the Gateway 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. The wireless network is a Modbus slave. In this configuration, the wireless network collects I/O data and sends it back to a Modbus host system.
SureCross Wireless I/O Networks 6.2.2 Modbus RTU with Multiple Slave Devices In the example host controlled configuration, the Gateway is a Modbus slave to the host system, but remains the master of the wireless network. The Gateway is connected directly to the host system using an RS-485 serial cable. This system may also connect DX85 Modbus RTU Remote I/O devices to the serial cable to expand the available I/O.
SureCross Wireless I/O Networks 6.2.3 Modbus RTU with Multiple Slave Devices - Layout 2 In this example host controlled configuration, the Gateway is a Modbus slave to the host system, but remains the master of the wireless network. The Gateway is connected directly to the host system using a fieldbus connection. This system also connects DX85 Modbus RTU Remote I/O devices and a third-party Modbus slave device to the serial bus to expand the available I/O.
SureCross Wireless I/O Networks 6.3 Modbus/TCP and EtherNet/IP 6.3.1 Host Connected - DX80 GatewayPro Connect a GatewayPro to a host system using the GatewayPro's industrial Ethernet connection. To connect the GatewayPro directly to the host system, use a crossover cable. By default, the GatewayPro is a Modbus/TCP or EtherNet/IP™ server. To configure the GatewayPro as a Modbus client device, use the configuration Web pages.
SureCross Wireless I/O Networks 6.4 Data Radios 6.4.1 Data Radios Data radios extend the range of the Modbus network and keep the network addressing system simple. In this basic example, the data radios act as a wire replacement to extend the Modbus network. 2 2 3 4 1 1. 2. 3. 4. 1 Fieldbus connection Data radio Modbus master device Modbus slave device 6.4.
SureCross Wireless I/O Networks 6.4.3 Data Radios with a Gateway as the Modbus Master In this example network, the Gateway is both the master for the radio network and the master for the Modbus network. The DX85 shown is a Modbus slave; the data radios extend the range of the Modbus network. 3 3 5 2 5 1 4 Model No. Description 1 DX80G... DX80 or DX80 Performance Gateway (configured as a Modbus master for this example) 2 DX85M...
SureCross Wireless I/O Networks 7 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. Discrete Sensors. Neither the inputs nor the outputs on the DX80 devices are isolated.
SureCross Wireless I/O Networks 7.1.3 Discrete Inputs, MINI-BEAM MINI-BEAM Discrete IN MINI-BEAM SP1 Two-wire MINI-BEAM sensor using a FlexPower Node and powered using the Node’s switch power. 7.2 Discrete Outputs 7.2.1 Discrete Outputs Sinking (NPN) Sourcing (PNP) PWR PWR 10-30V dc 10-30V dc Discrete OUT Discrete OUT Load Load GND GND dc common dc common Wiring diagram for a sourcing (PNP) two-wire output load powered using the SureCross device terminal block.
SureCross Wireless I/O Networks 7.3.2 Analog Inputs, Powered from Switch Power Two-Wire Sensors Three-Wire Sensors SPx SPx + − Analog IN + sensor + − sensor Analog IN − + − GND GND dc common dc common Two-wire analog sensor or two-wire NAMUR proximity sensor using a FlexPower Node and powered using the Node’s switch power. Three-wire analog sensor using a FlexPower Node and powered using the Node’s switch power. Do not exceed analog input ratings for analog inputs.
SureCross Wireless I/O Networks 7.3.5 Analog Inputs, QT50U Long-Range Ultrasonic Sensor QT50U Ultrasonic Sensor QT50U A1+ Four-wire QT50U sensor, using a FlexPower Node, and powered using the Node’s switch power terminal. The QT50U output is set to 4–20 mA. A1− Do not apply power to the Ax+ connection. (wh) (bk) GND dc common (bu) SP1 sensor power (bn) 7.4 Analog Outputs 7.4.
SureCross Wireless I/O Networks 8 SureCross Power Solutions The SureCross Power Solutions guide lists the various power options for SureCross devices. Also included in this guide is a battery life calculation for some discrete and analog sensors, examples of solar power installations, and brief instructions explaining how to measure your sensor's current draw and calculate the estimated battery life for your installation. 8.
SureCross Wireless I/O Networks Warmup Time Switch Power Voltage 0 Volts Sample point Sample point Sample interval 8.2.2 FlexPower with Integrated Battery A few FlexPower devices operate using a 3.6V lithium D cell battery integrated into the housing. These integrated battery devices: • • • Operate only from the battery and cannot use an external power supply, Are limited in the available I/O because of the limited connectivity, and Can only be powered from the integrated battery. 8.2.
SureCross Wireless I/O Networks 3 Manufacturer Device Model Turck Pressure PT100R-11-L13-H1131 Boost Voltage Warmup Time 10V 10 ms Sample and Report Rates 1 second 2 seconds 4 seconds 16 seconds 64 seconds 5 minutes 15 minutes 1 0.00 0.00 0.00 0.26 0.91 2.61 4.45 2 0.87 1.45 2.15 3.32 3.89 4.25 4.25 3 0.87 1.45 2.15 3.32 3.89 4.25 4.25 Note, battery life calculations are based on the sensor operating 24 hours a day, 365 days a year. 5.0 4.5 4.
SureCross Wireless I/O Networks Sample and Report Rates 62.5 ms 125 ms 250 ms 500 ms 1 second 2 seconds 16 seconds 1 0.97 1.67 2.62 3.74 4.75 5.49 6.28 2 0.20 0.40 0.72 1.27 2.05 2.99 5.07 Note, battery life calculations are based on the sensor operating 24 hours a day, 365 days a year. 7 6 DX81 Battery Life (Years) SM312DQD-78419 5 4 3 2 Bi10U-M30-AP6X-H1141 1 0 62.
SureCross Wireless I/O Networks 4.00 DX81 Battery Life (Years) 3.50 Reading 1 register 3.00 2.50 Reading 3 registers 2.00 1.50 1.00 0.50 0.00 .125 .500 1 4 8 16 64 Sample and Report Rate (sec) These values are estimated based on the current hardware and software configuration and are subject to change without notice. Environmental conditions will also contribute to the battery’s lifespan. Current estimates are based on a battery operating at room temperature.
SureCross Wireless I/O Networks 1. Averaging Fluke Meter 2. DX81 Battery Supply Module 3. DX80 FlexPower Node with MINIBEAM 4. BWA-HW-010 Cable, FlexPower Current Monitoring 8.4 Example Solar Powered Systems For installations without wired power, the solar powered assembly 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.
SureCross Wireless I/O Networks 2 Host System This example system shows a solar power system powering data radios and Gateways, expanding the wireless network far beyond the limits of wired power sources. NID A 5 1 2 NID A 5 1 8 NID 1 2 NID A 7 6 NID 1 Item 6 NID 1 Model No. Description 1 BWA-SOLAR-001 FlexPower Solar Supply, includes panel, solar controller, rechargeable batteries, and mounting materials 2 DX80DR*M-H MultiHop Data Radio, 900 MHz or 2.
SureCross Wireless I/O Networks 1. BWA-SOLAR-001. FlexPower Solar Supply, includes panel, solar controller, rechargeable batteries, and mounting materials. 2. DX80N... DX80 or DX80 Performance FlexPower Node or 10–30V dc Node. 3. Power Splitter Cable, quick disconnect, 5-pin Euro, female trunk, male branches. 2 1 3 8.4.2 Battery Backup Feature The DX81P6 6-Pack Battery Supply Module can operate as a power backup for the FlexPower Solar Supply when the units are connected using the splitter cable..
SureCross Wireless I/O Networks 4 Host System 1 4 1 3 4 2 5 Model No. Description 1 BWA-SOLAR-001 FlexPower Solar Supply, includes panel, solar controller, rechargeable batteries, and mounting materials 2 DX80N... DX80 or DX80 Performance FlexPower Node or 10 to 30 V dc Node 3 DX80G*M2S-P Performance FlexPower Gateway, No I/O 4 DX80DR*M-H MultiHop Data Radio, 900 MHz or 2.4 GHz 5 CSRB-M1250M125.47M125.
SureCross Wireless I/O Networks 9 Maintenance Follow these instructions to perform basic maintenance tasks. 9.1 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: • Fully seated within its channel along the full length of the perimeter, and • Positioned straight within the channel with no twisting, stress, or stretching. 9.
SureCross Wireless I/O Networks 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. The battery may be replaced in explosive gas atmospheres. Replacement battery model number: BWA-BATT-001. For pricing and availability, contact Banner Engineering. 9.3.
SureCross Wireless I/O Networks 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. The battery may be replaced in explosive gas atmospheres. Replacement battery model number: BWA-BATT-001. For pricing and availability, contact Banner Engineering.
SureCross Wireless I/O Networks 10 Troubleshooting The following troubleshooting tips include some basic instructions for common problems. 10.1 Startup Problems The following problems are associated with starting up your radios. The radio won't wake up. While in storage mode, the radio does not operate. All SureCross® radios powered 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 5 seconds.
SureCross Wireless I/O Networks LED 1 LED 2 Definition/Solution Gateway, DX85: Modbus communication error Flashing red For a Gateway system, a Modbus communications error indicates a bad transmission or checksum error between the host and the Gateway device. For a GatewayPro system, a Modbus communications error indicates a communications problem internal to the GatewayPro.
SureCross Wireless I/O Networks 10.3 LCD Message Codes These message codes display on the device's LCD. Message BAD EE EC XX Solution System Error. A system error typically represents a failure of the EE PROM. Contact the factory for replacement. The XX refers to the Modbus register 8 message code shown in Modbus Message Codes for Register 8 on page 81. The LCD displays the message code in decimal; host-controlled systems read the message codes in hex.
SureCross Wireless I/O Networks Message Code [15:8] Data Field [7:0] FE -- Description Modbus register 8 device messages are disabled. The Modbus register 8 clears or disables messages using the Gateway’s Modbus register 15. (Decimal values 65024 through 65279.) 10.4 Inputs and Outputs Some inputs or outputs are not working. Option 1. From the Node, access the menu system and use manual scrolling mode within *RUN to freeze the I/O status on the LCD display for the device in question.
SureCross Wireless I/O Networks OUT 1 = Normal OUT 2 = Normal OUT 1 = Normal OUT 2 = Normal OUT 3 = Normal OUT 4 = Normal Node 1 Gateway OUT 1 = Normal OUT 2 = Normal Node 2 Figure 4. Radio link between the Gateway and Node 1 has recovered.
SureCross Wireless I/O Networks 11 SureCross Accessories 11.1 Accessories The accessories list includes FCC approved antennas, antenna cabling, surge suppressors, power supplies, replacement batteries, enclosures, cables, and other hardware. 11.1.1 Selecting an Enclosure Select the enclosure size based on what you intend to mount inside it. Always select the largest enclosure you can to allow for future expansion. 6 × 6 inch: Fits a single DX80.
SureCross Wireless I/O Networks With Clear Covers Models Description List Price BWA-AH664C Enclosure, Polycarbonate, with Clear Cover, 6 × 6 × 4 $100 BWA-AH864C Enclosure, Polycarbonate, with Clear Cover, 8 × 6 × 4 $111 BWA-AH1084C Enclosure, Polycarbonate, with Clear Cover, 10 × 8 × 4 $141 BWA-AH12106C Enclosure, Polycarbonate, with Clear Cover, 12 × 10 × 6 $185 BWA-AH14126C Enclosure, Polycarbonate, with Clear Cover, 14 × 12 × 6 $204 BWA-AH16148C Enclosure, Polycarbonate, with Clear Co
SureCross Wireless I/O Networks Fiberglass Enclosures Models Description List Price BWA-EF14128 Enclosure Fiberglass Hinged 14" × 12" × 8" BWA-EF1086 Enclosure Fiberglass Hinged 10" × 8" × 6" $95 BWA-EF866 Enclosure Fiberglass Hinged 8" × 6" × 6" $85 BWA-PA1412 Panel, 14 × 12 $26 BWA-PA108 Panel, 10 × 8 $22 BWA-PA86 Panel, 8 × 6 $10 BWA-PM12 Pole Mount, 12 inch $73 BWA-PM8 Pole Mount, 8 inch $55 BWA-PM6 Pole Mount, 6 inch $52 $135 11.1.
SureCross Wireless I/O Networks Antennas: Dome Omni-Directional Dome Antennas Models Frequency Description BWA-9O2-D 900 MHz 2 dBi, 18-inch cable BWA-2O2-D 2.4 GHz 2 dBi, 18-inch cable Connection List Price $95 RP-SMA Box Mount 4 $95 Antennas: Other Models BWA-2O5-M Frequency 2.4 GHz Description Connection List Price 5 dBi, Magnetic whip antenna, 12 ft cable RP-SMA Male $80 Antennas: Fiberglass N-Type The following antennas are fiberglass and are typically used outdoors.
SureCross Wireless I/O Networks Antennas: Yagi N-Type The following antennas are yagi (directional) antennas with N-Type connections. Directional (Yagi) Antennas with an N-Type Female Connection Models Frequency BWA-9Y6-A BWA-9Y10-A 900 MHz Description List Price 6.5 dBd, 6.8 × 13 inches Outdoor $135 10 dBd, 6.8 × 24 inches Outdoor $150 Antenna Cables: RP-SMA to RP-SMA Use these cables to connect a radio to a bulkhead surge suppressor or a bulkhead surge suppressor to an RP-SMA antenna.
SureCross Wireless I/O Networks Antenna Cables: N-Type These LMR400 cables are antenna extension cables, connecting an N-type antenna to another N-type antenna cable. These cables are usually used outside the enclosure.
SureCross Wireless I/O Networks FlexPower Supplies and Replacement Batteries Power Supplies Models Description List Price DX81 Battery Supply Module with mounting hardware $100 DX81H Battery Supply Module with mounting hardware, for DX99 polycarbonate housing devices $145 DX81P6 Battery Supply Module, six “D” cells, with mounting hardware $395 BWA-SOLAR-001 FlexPower Solar Supply, includes panel (13 11/16” × 15 3/16”), controller, rechargeable battery pack, mounting hardware $850 Replacement
SureCross Wireless I/O Networks Models Description List Price BWA-RELAY-12V Relay, Blade Style with Base, 12 V $29 BWA-RELAY-24V Relay, Blade Style with Base, 24 V $29 BWA-RH1B-UDC12V Relay, Blade Style, No Base, 12 V (replacement part) $21 BWA-RH1B-UDC24V Relay, Blade Style, No Base, 24 V (replacement part) $21 BWA-SH1B-05 Relay Base Only (replacement part) $13 11.1.5 Brackets and Mounting Options BWA-HW-001 Mounting Hardware Kit List Price Screw, M5-0.8 x 25 mm, SS (4) Screw, M5-0.
SureCross Wireless I/O Networks Brackets List Price SMBDX80QT50 IMAGE HERE Used to connect a QT50U, DX81 FlexPower Battery Supply Module, and DX80 device together $39 BWA-HW-034 • DIN rail clip, black plastic $10 This standard Banner bracket can also be used to remotely mount dome antennas. SMBAMS18RA • Right-angle SMBAMS series bracket with 18 mm hole • Articulation slots for 90+° rotation • 12-ga. (2.6 mm) cold-rolled steel 40 C 48 A $12 B 45 Hole center spacing: A = 26.0, A to B = 13.
SureCross Wireless I/O Networks Models Description List Price DX85M4P4M2M2 DX85 Modbus RTU Remote I/O, 4 Discrete IN, 4 Discrete OUT, 2 Analog IN, 2 Analog OUT (0 to 20 mA) $475 DX85M4P8 DX85 Modbus RTU Remote I/O, 4 Discrete IN, 8 Discrete OUT $475 DX85M8P4 DX85 Modbus RTU Remote I/O, 8 Discrete IN, 4 Discrete OUT $475 DX85M0P0M4M4 DX85 Modbus RTU Remote I/O, 4 Analog IN, 4 Analog OUT (0 to 20 mA) $475 DX85M-P7 DX85 Modbus RTU Remote I/O, Up to 12 sinking inputs or up to 12 NMOS sinking ou
SureCross Wireless I/O Networks Models Description BWA-THERMISTOR-001 BWA-THERMISTOR-002 List Price NTC Thermistor, 2.2 KOhms, +/-0.2%C, blue bead (For models: DX80N9X2S2N2T/C, DX99N9X2S2N0T4X0A0, and DX99N9X1S2N0T4X0D0) NTC Thermistor, 10 KOhms, +/-0.
SureCross Wireless I/O Networks Models Description List Price BWA-E2M Ethernet cable, RSCD RJ45 440, 2 m $41 BWA-E8M Ethernet cable, RSCD RJ45 440, 8 m $71 BWA-EX2M Ethernet cable, crossover, RSCD RJ45CR 440, 2 m $41 Adapter Cables Models Description List Price BWA-HW-006 Adapter cable, USB to RS-485, for use with the User Configuration Tool software (UCT) $132 BWA-UCT-900 (shown) Adapter cable with power, USB to RS-485, for use with the User Configuration Tool software (UCT), supplies p
SureCross Wireless I/O Networks Other Splitter Cables Models Description List Price BWA-DRSPLITTER Splitter cable, DB9 Female (RS232) trunk to 5-pin Euro-style male and female $43 Euro-Style Cordsets - Single Ended Right-angle cordsets are not compatible with the DX70 devices. When facing the Node or Gateway toward you and the quick disconnect connection is facing down, the right-angle cables exit to the right. When using the FlexPower Node with integrated battery, use a double ended cordset.
SureCross Wireless I/O Networks 5-Pin Threaded M12/Euro-Style Cordsets (Double Ended and Less Than 3 m Long) Model Length DEE2R-51D 0.31 m (1 ft) DEE2R-53D 0.91 m (3 ft) Style Dimensions Pinout Female 2 40 Typ. 1 3 4 M12 x 1 ø 14.5 Female Straight/ Male Straight DEE2R-58D 5 Male 44 Typ. 2.44 m (8 ft) 1 2 M12 x 1 ø 14.
SureCross Wireless I/O Networks Cable Glands and Plugs Models Description List Price BWA-HP.5-10 Dummy Hole Plugs, 1/2-inch NPT, 10 pieces BWA-HW-031 Vent Plug, 1/2" NPT, IP67 $50 BWA-CG.5-10 Cable Glands, 1/2-inch NPT, 10 pieces, Cordgrips for cable diameters 0.17’’ to 0.45’’ $32 BWA-CG.5-3X5.6-10 Cable Glands, 1/2-inch NPT, Cordgrip for 3 holes of 2.8 to 5.6 mm diam, 10 Pack $32 BWA-CG.5-2X2.5-10 Cable Glands, 1/2-inch NPT, Cordgrip for 2 holes of 1.2 to 2.5 mm diam, 10 Pack $32 BWA-CG.
SureCross Wireless I/O Networks 12 Radio Certifications Banner's SureCross product line is certified by the FCC, European Union, and many other countries for operation within specific radio frequencies. 12.1 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.
SureCross Wireless I/O Networks Model Number Antenna Type Maximum Gain 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. Type certified antennas 12.2 FCC Certification, 900 MHz, 1 Watt Radios The DX80 Module complies with Part 15 of the FCC rules and regulations. FCC ID: UE3RM1809 This device complies with Part 15 of the FCC Rules.
SureCross Wireless I/O Networks DX80 Module may be used only with Approved Antennas that have been tested with this module. Model Number Antenna Type Maximum Gain Minimum Required Cable/ Connector Loss - Integral Antenna Unity gain 0 BWA-9O1-x Omni, 1/4 wave dipole ≤2 dBi 0 BWA-9O2-C Omni, 1/2 wave dipole, Swivel ≤2 dBi 0 BWA-9O6-A Omni Wideband, Fiberglass Radome ≤8.2 dBi 2.2 dB BWA-9O5-B Omni Base Whip ≤7.2 dBi 1.2 dB BWA-9Y10-A Yagi ≤10 dBi 4 dB 12.3 FCC Certification, 2.
SureCross Wireless I/O Networks 12.3 FCC Approved Antennas WARNING: This equipment is approved only for mobile and base station transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 20 cm from all persons and must not be collocated or operating in conjunction with any other antenna or transmitter. DX80 Module may be used only with Approved Antennas that have been tested with this module.
SureCross Wireless I/O Networks Radio Modules Country 900 MHz (150 mW) 900 MHz (1 Watt) 2.
SureCross Wireless I/O Networks Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le matériel brouiller du Canada. Le present appareil numérique n’emet pas de bruits radioélectriques dépassant les limites applicables aux appareils numeriques de le Classe A préscrites dans le Reglement sur le brouillage radioélectrique édits par le ministere des Communications du Canada. France - In Guyane (French Guiana) and La Réunion (Reunion Island), outdoor use not allowed.
SureCross Wireless I/O Networks 13 Warnings Antenna Installations. Install and properly ground a qualified surge suppressor when installing a remote antenna system. Remote antenna configurations installed without surge suppressors invalidate the manufacturer's warranty. 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.
SureCross Wireless I/O Networks India Address: Banner Engineering India Pune Head Quarters Office No. 1001, 10th Floor Sai Capital, Opp. ICC Senapati Bapat Road Pune 411016, India Phone: +91 (0) 206 640 5624 Website: www.bannerengineering.co.in Email: salesindia@bannerengineering.com Mexico Address: Banner Engineering de Mexico Monterrey Head Office Edificio VAO Av. David Alfaro Siqueiros No.103 Col. Valle Oriente C.P.
Index A antenna remote installation 26 antenna installation remote 23–26 B main body 76 glands and plugs 21 ground 22 ground wire 23–26 I I/O isolation 23–26 input value 49, 50 integrated battery 68 bad EE 81 battery integrated 68 battery life analog sensors 68 discrete sensors 69 measuring 71 temperature sensors 70 battery pack 6, 67, 68 battery replacement DX80 77 DX81 and DX81H 76 baud rate 44 mechanical stress 22 Modbus communication parameters 43, 44 Modbus time-out error code 81 C N certificat
