Setting Up Your Wireless Network

SureCross DX80 Gateway
puts to user-defined conditions. After the radio signal is reacquired,
the network returns to normal operation.
SureCross® DX80 Gateways and Nodes
A Gateway is the master device within each radio network. Every wireless network must have one Gateway, which schedules communication traffic and controls the I/O configuration for the network, and one or more Nodes. Similar to how a gateway device on a wired
network acts as a “portal” between networks, the SureCross Gateway acts as the portal between the wireless network and the host
controller. When the Gateway, using its Modbus RTU RS-485 connection, is a Modbus slave to a Modbus RTU host controller, the wireless network may contain up to 47 Nodes in a single wireless network. The Gateway holds the Modbus registers of all wireless devices
within the network.
A Node is a wireless network end-point device used to provide sensing capability in a remote area or factory. The Node collects data
from sensors and communicates the data back to the Gateway. Nodes are available in a wide variety of power or input/output options.
SureCross User Configuration Tool
The User Configuration Tool (UCT) offers an easy way to link I/O points in your wireless network, view I/O register values graphically, and set system communication parameters when a host system is not part of the wireless network.
The UCT requires a special USB to RS-485 (model number BWA-UCT-900 for 1 Watt
radios, BWA-HW-006 can be used for all other radios) converter cable to pass information between your computer and the Gateway. Download the most recent revisions of the UCT software from Banner Engineering's website: http://www.bannerengineering.com/wireless.
Setting Up Your Wireless Network
To set up and install your wireless network, follow these steps:
1.
2.
3.
4.
Configure the DIP switches of all devices.
Connect the sensors to the SureCross devices.
Apply power to all devices.
Form the wireless network by binding the Nodes to the Gateway. If the binding instructions are not included in the datasheet, refer to
the product manual for binding instructions.
5. Observe the LED behavior to verify the devices are communicating with each other.
6. Conduct a site survey between the Gateway and Nodes. If the site survey instructions are not included in this datasheet, refer to the
product manual for detailed site survey instructions.
7. Install your wireless sensor network components. If installation instructions are not included in this datasheet, refer to the product
manual for detailed installation instructions.
For additional information, including installation and setup, weatherproofing, device menu maps, troubleshooting, and a list of accessories, refer to one of the following product manuals.
•
•
•
•
SureCross Quick Start Guide: Banner part number 128185
SureCross Wireless I/O Network Manual: 132607
Web Configurator Manual (used with "Pro" and DX83 models): 134421
Host Configuration Manual 132114
Configuring the DIP Switches
Before making any changes to the DIP switch positions, disconnect the power. DIP switch changes will not be recognized if power isn't
cycled to the device.
For parameters not set via DIP switches, use the User Configuration Tool (UCT) to make configuration changes. For parameters set
using the DIP switches, the DIP switch positions override any changes made using the User Configuration Tool.
Accessing the Internal DIP Switches
To access the internal DIP switches, follow these steps:
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P/N 132158 Rev. H
SureCross DX80 Gateway
1.
2.
3.
4.
Unscrew the four screws that mount the cover to the bottom housing.
Remove the cover from the housing without damaging the ribbon cable or the pins the cable plugs into.
Gently unplug the ribbon cable from the board mounted into the bottom housing.
Remove the black cover plate from the bottom of the device's cover.
The DIP switches are located behind the rotary dials.
After making the necessary changes to the DIP switches, place the black cover plate back into position and
gently push into place. Plug the ribbon cable in after verifying that the blocked hole lines up with the missing
pin. Mount the cover back onto the housing.
DIP Switch Settings
Switches
Device Settings
4
5
Link loss output: zero
OFF*
OFF*
Link loss output: one
OFF
ON
Link loss output: hold last state
ON
OFF
Link loss output: user configuration
ON
ON
Rotary switch address mode
Extended address mode
Modbus or UCT configured (overrides DIP
switches 3-8)
DIP switch configured
1
2
3
6
7
8
OFF*
ON
OFF*
ON
Inputs sourcing (PNP)
OFF*
Inputs sinking (NPN)
ON
* Default configuration
Address Mode
The SureCross wireless devices may use one of two types of addressing modes: rotary dial addressing or extended addressing. In
rotary dial address mode, the left rotary dial establishes the network ID and the right rotary dial sets the device ID. The wireless network
is restricted to a maximum of 16 devices.
Extended address mode uses a security code to "bind" Nodes to a specific Gateway. Bound Nodes can only send and receive information from the Gateway to which they are bound. In extended address mode, wireless networks may contain up to 48 radio devices. For
more information on extended address mode, refer to the SureCross™ Wireless I/O Network product manual.
The device ships in rotary dial address mode by default, with the DIP switch in the OFF position. To use extended address mode, change
the DIP switch to the ON position.
Discrete Input Type
Select the type of discrete input sensors to use with this device: sourcing (PNP) sensors or sinking (NPN) sensors.
Link Loss Outputs
The SureCross DX80 wireless devices use a deterministic radio link time-out method to address RF link interruption or failure. When a
radio link fails, all pertinent wired outputs are sent to defined states until the link is recovered, ensuring that disruptions in the communications link result in predictable system behavior.
Following a radio link time-out, all outputs linked to the Node in question are set to de-energize (discrete outputs to zero, analog outputs
to 0 mA or 4 mA), energize (discrete outputs to one, analog outputs to 20 mA), or to hold the last stable state/value. Use the DIP switches
to select the link loss output state.
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SureCross DX80 Gateway
Modbus/User Configuration Tool (UCT) or DIP Switch Configured
In Modbus/UCT Configured mode, the device parameters are changed using the User Configuration Tool (UCT) or a Modbus command.
All DIP switch positions are ignored. In DIP Switch Configured mode, use the DIP switches to configure the parameters listed in the table.
Wiring Your SureCross® Device
Use the following wiring diagrams to first wire the sensors and then apply power to the SureCross devices.
5-pin Euro-Style Hookup
Wiring the 5-pin Euro-style connector depends on the model and power requirements of the device. Connecting dc power to the communication pins will cause permanent damage.
Wire No.
2
3
5
1
4
Wire Color
Description
1
Brown
10 to 30V dc
2
White
RS485 / D1 / B / +
3
Blue
dc common (GND)
4
Black
RS485 / D0 / A / –
5
Gray
Comms Gnd
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) will cause permanent damage. For FlexPower devices, do not apply more than 5.5V to the gray wire.
Terminal Label Gateway, DX85
10 to 30V dc Powered Nodes
V+
10 to 30V dc
Tx/+
RS485 / D1 / B / +
V-
dc common (GND)
Rx/-
RS485 / D0 / A / -
Battery Powered Nodes
10 to 30V dc
dc common (GND)
B+
dc common (GND)
3.6 to 5.5V dc
Terminal Blocks
IP67 Housing
IP20 Housing
DO8 PWR
DO7 GND
DO6 PWR
DO5 GND
DO4 DI4
DO3 DI3
DO2 DI2
DO1 DI1
DI1
DI2
DI3
DI4
DO7
DO8
V+
VV-
DO1
DO2
DO3
DO4
DO5
DO6
Tx/+
Rx/V+
DIx. Discrete IN x.
DOx. Discrete OUT x.
GND. Ground/dc common connection.
PWR. Power, 10 to 30V dc power connection.
RX/-. Serial comms line
TX/+. Serial comms line
V+. Power, 10 to 30V dc power connection.
V-. Ground/dc common connection.
Wiring Diagrams for Discrete Inputs
Connecting dc power to the communication pins will cause permanent damage. For the DX8x...C models, PWR in the wiring diagram
refers to V+ on the wiring board and GND in the wiring diagram refers to V- on the wiring board.
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SureCross DX80 Gateway
Discrete Input Wiring for PNP Sensors
Discrete Input Wiring for NPN Sensors
PWR
10-30V dc
DIx
DIx
GND
dc common
Wiring Diagrams for Discrete Outputs
Connecting dc power to the communication pins will cause permanent damage. For the DX8x...C models, PWR in the wiring diagram
refers to V+ on the wiring board and GND in the wiring diagram refers to V- on the wiring board.
Discrete Output Wiring (PNP)
PWR
10-30V dc
DOx
Load
GND
dc common
LED Behavior for the Gateways
After powering up and binding the Gateway and its Nodes, verify all devices are communicating properly. When testing communication
between the Gateway and Node, all radios and antennas should be at least two meters apart or the communications may fail.
LED 1
LED 2
Gateway Status
Power ON
(solid green)
(flashing red)
Device Error
(flashing red)
Modbus Communication Active
(flashing yellow)
Modbus Communication Error
(flashing red)
For Gateway and Ethernet Bridge systems, active Modbus communication refers to the communication between the Gateway and the
Ethernet Bridge. For GatewayPro systems, the Modbus communication LEDs refer to the communication internal to the GatewayPro. For
Gateway only systems, the Modbus communication LEDs refer to the communication between the Gateway and its host system (if applicable).
Modbus Register Table
When your wireless network does not include a host system, the four input/eight output Node must be mapped to the eight input/four
output Gateway.
I/O
Point
Modbus Holding Register
Gateway/
DX85
Any Node
1
1
1 + (Node# × 16)
2
2
3
4
I/O Type
I/O Range
Holding Register Representation
Terminal
Block Labels
Min.
Max.
Min. (Dec.)
Max. (Dec.)
Discrete IN 1
0
1
0
1
DI1
2 + (Node# × 16)
Discrete IN 2
0
1
0
1
DI2
3
3 + (Node# × 16)
Discrete IN 3
0
1
0
1
DI3
4
4 + (Node# × 16)
Discrete IN 4
0
1
0
1
DI4
...
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SureCross DX80 Gateway
I/O
Point
Modbus Holding Register
I/O Type
I/O Range
Gateway/
DX85
Any Node
7
7
7 + (Node# × 16)
Reserved
8
8
8 + (Node# × 16)
Device Message
9
9
9 + (Node# × 16)
Discrete OUT 1–8
Holding Register Representation
Min.
Max.
Min. (Dec.)
Max. (Dec.)
0
**
0
255
Terminal
Block Labels
DO1
...
15
15
15 + (Node# × 16)
Control Message
16
16
16 + (Node# × 16)
Reserved
The lower eight bits of the 16-bit unsigned register
represent each of the eight digital outputs. Therefore, if all outputs are OFF (0) the register contains 0x0000; if all outputs are ON (1) the register
contains 0x00FF (255).
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
Output 1
Output 8
Output 2
Specifications
Radio and General
Range
Power
900 MHz: Up to 4.8 kilometers (3 miles)
Requirements: +10 to 30V dc (Outside the USA: +12 to
24V dc, ±10%). (See UL section below for any applica2.4 GHz: Up to 3.2 kilometers (2 miles)
ble UL specifications)
Transmit Power
Consumption: Less than 1.4 W (60 mA) at 24V dc
900 MHz: 21 dBm (150 mW) conducted
Housing
2.4 GHz: 18 dBm (65 mW) conducted, less than or
Polycarbonate housing and rotary dial cover; polyester
equal to 20 dBm (100 mW) EIRP
labels; EDPM rubber cover gasket; nitrile rubber, non900 MHz Compliance (150 mW Radios)
sulphur cured button covers
FCC ID TGUDX80 - This device complies with FCC
Weight: 0.26 kg (0.57 lbs)
Part 15, Subpart C, 15.247
Mounting: #10 or M5 (SS M5 hardware included)
IC: 7044A-DX8009
Max.
Tightening Torque: 0.56 N·m (5 lbf·in)
2.4 GHz Compliance
Antenna Connection
FCC ID UE300DX80-2400 - This device complies with
Ext. Reverse Polarity SMA, 50 Ohms
FCC Part 15, Subpart C, 15.247
Max Tightening Torque: 0.45 N·m (4 lbf·in)
ETSI/EN: In accordance with EN 300 328: V1.7.1
(2006-05)
Interface
IC: 7044A-DX8024
Indicators: Two bi-color LEDs
Spread Spectrum Technology
Buttons: Two
FHSS (Frequency Hopping Spread Spectrum)
Display: Six character LCD
Link Timeout
Wiring Access
Gateway: Configurable
Four PG-7, One 1/2-inch NPT, One 5-pin Euro-style
male connector
Node: Defined by Gateway
Radio range is with the 2 dB antenna that ships with the product. For European applications, power the DX80 from a Limited Power
Source as defined in EN 60950-1.
High-gain antennas are available, but the range depends on the
environment and line of sight. To determine the range of your wireless network, perform a Site Survey.
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SureCross DX80 Gateway
Inputs and Outputs
Discrete Inputs
Rating: 3 mA max current at 30V dc
Sample Rate: 62.5 milliseconds
Report Rate: On change of state
Discrete Input ON Condition
PNP: Greater than 8V
NPN: Less than 0.7V
Discrete Input OFF Condition
PNP: Less than 5V
NPN: Greater than 2V or open
Discrete Outputs
Update Rate: 125 milliseconds
ON Condition: Supply minus 2V
OFF Condition: Less than 2V
Output State Following Timeout: OFF
Discrete Output Rating (PNP)
100 mA max current at 30V dc
ON-State Saturation: Less than 3V at 100 mA
OFF-state Leakage: Less than 10 μA
Communication and Environmental
Hardware (RS-485)
Interface: 2-wire half-duplex RS-485
Baud rates: 9.6k, 19.2k (default), or 38.4k
Data format: 8 data bits, no parity, 1 stop bit
Protocol
Modbus RTU
Shock and Vibration
IEC 68-2-6 and IEC 68-2-7
Shock: 30g, 11 millisecond half sine wave, 18 shocks
Vibration: 0.5 mm p-p, 10 to 60 Hz
Rating
DX80 Models:IEC IP67; NEMA 6; (See UL section below for any applicable UL specifications)
DX80...C Models: IEC IP20; NEMA 1 (In a suitable enclosure: Class I, Division 2, Group A, B, C, D; T4 −40
to 80 °C)
Operating Environment
Temperature: −40 to +85 °C (Electronics); −20 to +80
°C (LCD)
Humidity: 95% max. relative (non-condensing)
Radiated Immunity: 10 V/m, 80-2700 MHz
(EN61000-6-2)
Refer to the SureCross DX80 Wireless I/O Network Product Manual (p/n 132607) for installation and waterproofing instructions. Operating the devices at the maximum operating conditions for extended periods can shorten the life of the device.
Certifications
DX8x...C (External Wiring Terminal Models)
CSA: Class I, Division 2, Groups A, B, C, D
(Ex/A Ex nA II T4); Certificate: 1921239
UL Listing
Maximum ambient temperature: 70 °C
Mounting instructions: See document 132607
Power rating: 10 to 30V dc, UL Class 2
Enclosure environmental rating: UL Type 1
LCIE/ATEX: Zone 2 (II 3G / Ex nA IIC); Certificate: LCIE 10 ATEX 1012 X
Included with Model
The following items ship with the DX80 radios.
• BWA-HW-002: DX80 Access Hardware Kit, containing four PG-7 plastic threaded plugs, four PG-7 nylon gland fittings, four PG-7 hex
nuts, one 1/2-inch NPT plug, and one 1/2-inch nylon gland fitting. (Not included with IP20 DX80...C models)
• BWA-HW-001: Mounting Hardware Kit, containing four M5-0.8 x 25mm SS screws, four M5-0.8 x 16mm SS screws, four M5-0.8mm
SS hex nuts, and four #8-32 x 3/4" SS bolts
• BWA-HW-003: PTFE tape
• BWA-9O2-C (900 MHz) or BWA-2O2-C (2.4 GHz): Antenna, 2 dBd Omni, Rubber Swivel RP-SMA Male. (Not included with Internal
antenna models)
• Quick Start Guide (128185 for DX80 Gateways or 152653 for MultiHop models)
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SureCross DX80 Gateway
• MQDC1-506: 5-Euro (single ended) straight cable, 2m (Not included with FlexPower devices)
• BWA-HW-011: IP20 Screw Terminal Headers (2 pack) (Included only with the IP20 DX80...C models)
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. No surge suppressor can absorb all lightning strikes; do
not touch the SureCross® device or any equipment connected to the SureCross device during a thunderstorm.
Exporting SureCross Radios. It is our intent to fully comply with all national and regional regulations regarding radio frequency emissions. Customers who want to re-export this product to a country other than that to which it was sold must ensure the device is approved in the destination country. A list of approved countries appears in the Radio Certifications section of the product manual. The SureCross wireless products were
certified for use in these countries using the antenna that ships with the product. When using other antennas, verify you are not exceeding the transmit
power levels allowed by local governing agencies. Consult with Banner Engineering Corp. if the destination country is not on this list.
Violating Warnings. The manufacturer does not take responsibility for the violation of any warning listed in this document. Make no modifications to
this product; any modifications to this product not expressly approved by Banner Engineering could void the user’s authority to operate the product.
All specifications published in this document are subject to change; Banner reserves the right to modify product specifications or to update documentation at any time. For the most recent version of any documentation, refer to: www.bannerengineering.com. © 2006-2013 Banner Engineering
Corp. All rights reserved.
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. This warranty does not cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED (INCLUDING, WITHOUT LIMITATION,
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE,
COURSE OF DEALING OR TRADE USAGE.
This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP.
BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT, WHETHER ARISING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY, NEGLIGENCE, OR OTHERWISE.
Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any obligations or liabilities relating to any product
previously manufactured by Banner Engineering Corp.
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