BANNER DX80N2X6S-P8-KR SureCross Performance Series Industrial Wireless Gateway and Nodes Instructions

SureCross Performance Node

Configurable Node with up to 12 sourcing discrete inputs or outputs

The SureCross® wireless system is a radio frequency network with integrated I/O that can operate in most environments and eliminate the need for wiring runs. Wireless networks are formed around a Gateway, which acts as the wireless network master device, and one or more Nodes.

• Wireless industrial I/O device with up to 12 sourcing discrete inputs or outputs. The default configuration is set to 6 inputs and 6 outputs (without bit-packing).
• Selectable transmit power levels of 250 mW or 1 Watt for 900 MHz models and 65 mW for 2.4 GHz models
• 10 to 30V dc power input
• DIP switches for user configuration
• Frequency Hopping Spread Spectrum (FHSS) technology and Time Division Multiple Access (TDMA) control architectures ensure reliable data delivery within the unlicensed  Industrial, Scientific, and Medical (ISM) band
• Transceivers provide bidirectional communication between the Gateway and Node, in- cluding fully acknowledged data transmission
• Lost RF links are detected and relevant outputs set to user-defined conditions For additional information, updated documentation, and accessories, refer to Banner engineering’s website, www.banner-engineering.com/surecross.

12 PNP outputs (for a total of 12 I/O)
(Default configuration is 6 IN and 6 OUT, without bit-packing)

DX80…C (IP20; NEMA 1) models are also available. To order this model with IP20 housing, add a C to the end of the model number: DX80N9X6S-P8C.

**WARNING:** Not To Be Used for Personnel Protection
Never use this device as a sensing device for personnel protection. Doing so could lead to serious injury or death. This device does not include the self- checking redundant circuitry necessary to allow its use in personnel safety applications. A sensor failure or malfunction can cause either an energized or de-energized sensor output condition.

CAUTION: Never Operate 1 Watt Radios Without Antennas
To avoid damaging the radio circuitry, never power up SureCross Performance or SureCross MultiHop (1Watt) radios without an antenna.

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 pa- 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.banneren-gineering.com/wireless.

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.

2. Connect the sensors to the SureCross devices.

3. Apply power to all devices.
   On the Gateway, LED 1 is solid green. On the Node, LED 2 flashes red to indicate there is no radio link to the Gateway.

4. 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.
   On the Gateway, LED 1 is solid green. On the Node, LED 1 flash green to indicate it is communicating with the Gateway.

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 accesso-Aries, 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:

1. Unscrew the four screws that mount the cover to the bottom housing.
2. Remove the cover from the housing without damaging the ribbon cable or the pins the cable plugs into.
3. Gently unplug the ribbon cable from the board mounted into the bottom housing.
4. 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 it 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| 1| 2| 3| 4| 5| 6| 7| 8
Transmit power level: 1 Watt (30 dBm)| OFF| | | | | | |
Transmit power level: 250 mW (24 dBm), DX80 corn- compatibility mode| ON| | | | | | |
Modbus or UCT configured (overrides switches 5-8)| | OFF| | | | | |

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SureCross Performance Node

Switches

Device Settings| 1| 2| 3| 4| 5| 6| 7| 8
DIP switch configured (Uses 5-8 for I/O configuration)| | ON| | | | | |
12 inputs. 0 outputs| | | | | OFF| OFF| OFF| OFF
11 inputs. 1 output| | | | | OFF| OFF| OFF| ON
10 inputs. 2 outputs| | | | | OFF| OFF| ON| OFF
9 inputs, 3 outputs| | | | | OFF| OFF| ON| ON
8 inputs, 4 outputs| | | | | OFF| ON| OFF| OFF
7 inputs, 5 outputs| | | | | OFF| ON| OFF| ON
6 inputs, 6 outputs| | | | | OFF| ON| ON| OFF
5 inputs, 7 outputs| | | | | OFF| ON| ON| ON
4 inputs, 8 outputs| | | | | ON| OFF| OFF| OFF
3 inputs, 9 outputs| | | | | ON| OFF| OFF| ON
2 inputs, 10 outputs| | | | | ON| OFF| ON| OFF
1 input, 11 outputs| | | | | ON| OFF| ON| ON
0 inputs, 12 outputs| | | | | ON| ON| OFF| OFF
6 inputs, 6 outputs (non-bit-packed)| | | | | ON| ON| OFF| ON
8 bit-packed inputs. 4 non-bit-packed outputs| | | | | ON| ON| ON| OFF
4 non-bit-packed inputs. 8 bit-packed outputs| | | | | ON| ON| ON| ON

• Default configuration
  For the 6 IN/6 OUT non-bit-packed configuration, the discrete INs use I/O points 1 through 6 and the discrete OUTs use I/O points 9 through 14. For the 8 bit-packed IN/4  non-bit-packed OUT configuration, all discrete INs use I/O point 1 and the discrete OUTs use I/O points 9 through 12. For the 4 non-bit- packed IN/8 bit-packed output configuration, the discrete INs use I/O points 1 through 4 and all bit-packed outputs use I/O point 9.

Modbus/UCT Configured or DIP Switch Configured for I/O Configuration
In the OFF position, this device is configured for six discrete inputs and six discrete outputs (non-bit packed) for products built after May 2011. For products built before May  2011, this default position configures the device for 12 inputs and zero outputs (bit packed). In the OFF position, users can send commands directly from the host system to the devices to select custom I/O configuration. Users may also use the User Configuration Tool (UCT) to write custom configuration In the ON position, use DIP switches 5  through 8 to select one of the pre-programmed discrete I/O configurations shown in the DIP Switch Settings table.

Transmit Power Levels
The 900 MHz radios can be operated at 1 watt (30 dBm) or 250 mW (24 dBm). While the radios operate in 1 Watt mode, they cannot communicate with 150 mW DX80 radio devices. To communicate with the 150 mW radio models, operate this radio in 250 mW mode. For 2.4 GHz radios, this DIP switch is disabled. The transmit power for 2.4 GHz is fixed at about 100 mW EIRP (18 dBm), making the 2.4 GHz Performance models automatically compatible with the DX80 2.4 GHz models.
User-Defined Configuration of Discrete I/O on the 12 I/O Devices
The 12 I/O devices can be configured into any combination of 12 discrete inputs or outputs. Inputs are stored in a bit packed form in I/O point 1, device register 1. Outputs  are stored in a bit packed form in I/O point 9, device register 9. (See Modbus Register Block table on the previous page.)
Defining Inputs and Outputs
To define which of the 12 I/O points are inputs, adjust the bit field stored as I/O 1’s threshold parameter [15:0]. Set bit 0 of the 16-bit parameter data word to define I/O 1 as an input, set bit 1 to define I/O 2 as an input, et cetera. Each bit position of the parameter is associated with an I/O point. In the example below, the first five I/O points are defined as inputs.

Input Parameter| Bit 15| 14| 13| 12| 11| 10| 09| 08| 07| 06| 05| 104| 03| 02| 01| 00
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
Input Point #| | | | | 12| 11| 10| 9| 8| 7| 6| 5| 4| 3| 2| 1
Parameter| | | | | 0| 0| 0| 0| 0| 0| 0| 1| 1| 1| 1| 1
Data| | | | | | | | | | | | | | | |

Define outputs the same way by adjusting the bit field stored in I/O 9’s threshold parameter [15:0]. Verify the bit pattern for outputs does not overlap the input pattern. In the example below, I/O points 6-12 are set as outputs.

Input Parameter| Bit 15| 14| 13| 12| 11| 10| 09| 08| 07                11| 06| 05| 04| 03| 02| 01| 00
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
Input Point #| | | | | 12| 11| 10| 9| 8| 7| 6| 5| 4| 3| 2| 1
Parameter Data| | | | | 1| 1| 1| 1| 1| 1| 1| 0| 0| 0| 0| 0

For inputs, the first I/O point selected as input is placed in bit position 0 in register 1. The second input point is in bit position 1, et cetera. Likewise, for outputs, the first  I/O point selected as output is placed in bit position 0 in register 9, the second input point is in bit position 2. The bit-packed values are stored in the right-justified format.

Input Param- ter| Bit 15| 14| 13| 12| 11| 10| 09| 08| 07      1| 106| 05| 04| 03| 02| 01| 00
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
Input Point #| | | | | 0| 0| 0| 0| 0| 0| 0| INS| IN 4| IN 3| IN 2| IN 1
Parameter Data| | | | | 0| 0| 0| 0| 0| OUT

7

| OUT

6

| OUT

5

| OUT

4

| OUT

3

| OUT

2

| OUT

1

Defining Inputs and Outputs Using the UCT
To configure either a Gateway or Node, select the Gateway or specific Node from the dropdown list. To configure a DX85 Remote I/O model set the DX85’s Slave ID to 01, and select the Gateway from the dropdown list.
To define which of the 12 I/O points are inputs for the selected device, adjust the threshold parameter for I/O point 1. Set bit 0 of the 16-bit parameter data word to define  I/O 1 as an input, set bit 1 to define I/O 2 as an input, et cetera. Each bit position of the parameter is associated with an I/O point. In the example below, the first five I/O points are defined as inputs (0000 0001 1111 = 0x001F = 0031). To define which of the 12 I/O points are outputs for the selected device, adjust the threshold parameter for I/O point 9. In the example below, bits 11 through 5 are used to set seven outputs (1111 1110 0000 = 0x0FE0 = 4064)

Mixing Performance and Non-Performance Radios in the Same Network
To comply with federal regulations, the 150 mW radios and 1 Watt radios communicate differently. To mix Performance radios with non-Performance radios:
• Performance radios must operate in 250 mW mode, not 1 Watt mode (DIP switch 1 ON)
• 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 to the technical note titled Mixing Performance Radios and 150  mW Radios in the Same Network listed on the FAQ/Knowledgebase section of Banner’s Wireless Sensor Networks website.

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 Wiring (Nodes)
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. For FlexPower devices, do not apply more than 5.5V to the gray wire.

| Wire No.| Wire Color| 10 to 30V dc Powered Nodes| Battery Powered Nodes
---|---|---|---|---
| 1
2
3
4
5| Brown
White
Blue
Black
Gray| 10 to 30V dc
dc common (GND)| dc common (GND)
3.6 to 5.5V dc

Terminal Blocks and Wiring (12 Sourcing I/O Models)

IP67 Wiring Board (-P8 Models)

|

IP20 Wiring Board (-P8C Models)

---|---
IOx. Input or output (depending on configuration)
GND. Ground/dc common connection.
PWR. Power, 10 to 30V dc power connection.| RX/-. Serial comms line for Gateways and DX85s only. No con-section for Nodes.
TX/+. Serial comms line for Gateways and DX85s only. No connection for Nodes
V+. Power, 10 to 30V dc power connection.
V-. Ground/dc common connection.

When using the DIP switches to configure the input and output selection, wire the inputs beginning with IO1. After all, inputs are wired, begin using the remaining IOx as outputs. For example, if you are using 10 inputs and 2 outputs, use terminals IO1 through 10 for the inputs and terminals IO 11 and 12 for the outputs.
For the default configuration of 6 IN and 6 OUT, use IO 1 through 6 to wire the inputs and IO 7 through 12 to wire the outputs.

Discrete Input Wiring for PNP Sensors Discrete Output Wiring (PNP)
The Dix and DOx of these wiring diagrams correspond to the IOx on the terminal block.

DX80…C Wiring
Wiring power to the DX80…C models varies depending on 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 5.5V to the B+ terminal.

Terminal Label| Gateway, DX85| 10 to 30V dc Powered Nodes| Battery Powered Nodes
---|---|---|---
V+
Tx/+
V-
Rx/-
B+| 10 to 30V dc
RS485 / D1 / B / +
dc common (GND)
RS485 / D0 / A / –| 10 to 30V dc
dc common (GND)| dc common (GND)
3.6 to 5.5V dc

LED Behavior for the Nodes
After powering up and binding the Gateway and its Nodes, verify all devices are communicating properly. A Node will not sample its inputs until it is communicating with its  Gateway. When testing communication between the Gateway and Node, all radios and antennas should be at least two meters apart or the communications may fail.

(flashing green)

(flashing red)

| (flashing red)
(flashing red, 1 per 3 sec)| Radio Link Ok
Device Error
No Radio Link

Modbus Register Table

I      10

litilliii

| I Modbus Holding Register| I/O Type| 110 Range| Holding Register 1 Representation| Terminal Block
Labels
---|---|---|---|---|---
Gateway or
DX85| Any Node| | | Min.
Value| Max.
Value| I   Min.

(Dec.)

| Max.
(Dec.)
1| 1| 1+ (Node# x 16)| Bit-Packed Discrete IN| 0| 1| 0| 1| 101 to 1012
2| 2| 2 + (Node# x 16)| Non-Bit-Packed Discrete IN (depend­ing on DIP switch configuration)| | | | |
3| 3| 3 + (Node# x 16)| | | | |
4| 4| 4 + (Node# x 16)| | | | |
5| 5| 5 + (Node# x 16)| | | | |
6| 6| 6 + (Node# x 16)| | | | |
7| 7| 7 + (Node# x 16)| Reserved| | | | |
8| 8| 8 + (Node# x 16)| Device Message| | | | |
9| 9| 9 + (Node# x 16)| Bit-Packed Discrete OUT| 0| 1| 0| 1| 101 to 1012
10| 10| 10 + (Node# x 16)| Non-Bit-Packed Discrete OUT (de­pending on DIP switch configuration)| | | | |
11| 11| 11 + (Node# x 16)| | | | |
12| 12| 12 + (Node# x 16)| | | | |
13| 13| 13 + (Node# x 16)| | | | |
14| 14| 14 + (Node# x 16)| | | | |
15| 15| 15 + (Node# x 16)| Control Message| | | | |
16| 16| 16 + (Node# x 16)| Reserved| | | | |

Specifications

Range
900 MHz (1 Watt): Up to 9.6 kilometers (6 miles)2.4 GHz: Up to 3.2 kilometers (2 miles)
Transmit Power
900 MHz (1 Watt): 30 dBm (1 W) conducted (up to 36 dBm EIRP)
2.4 GHz: 18 dBm (65 mW) conducted, less than or equal to 20 dBm (100 mW) EIRP
900 MHz Compliance (1 Watt Radios)
FCC ID UE3RM1809: This device complies with FCC
Part 15, Subpart C, 15.247
IC: 7044A-RM1809| **Power*
Requirements: +10 to 30V dc (Outside the USA: +12 to
24V dc, ±10%). (See UL section below for any applica-
by UL specifications)
900 MHz Consumption: Maximum current draw is <40
mA and typical current draw is <30 mA at 24V dc. (2.4
GHz consumption is less.)
Radio| General
---|---
2.4 GHz Compliance
FCC ID UE300DX80-2400 – This device complies with
FCC Part 15, Subpart C, 15.247
ETSI/EN: In accordance with EN 300 328: V1.7.1
(2006-05)
IC: 7044A-DX8024
Spread Spectrum Technology
FHSS (Frequency Hopping Spread Spectrum)
Link Timeout
Gateway: Configurable via User Configuration Tool
(UCT) software
Node: Defined by Gateway
The radio range is with the 2 dB antenna that ships with the product.
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.| Housing
Polycarbonate housing and rotary dial cover; polyester labels; EDPM rubber cover gasket; nitrile rubber, non-sulfur cured button covers
Weight: 0.26 kg (0.57 lbs)
Mounting: #10 or M5 (SS M5 hardware included)
Max. Tightening Torque: 0.56 N·m (5 lbf·in)
Antenna Connection
Ext. Reverse Polarity SMA, 50 Ohms
Max Tightening Torque: 0.45 N·m (4 lbf·in)
Interface
Indicators: Two bi-color LEDs
Buttons: Two
Display: Six character LCD
Wiring Access
DX80 models: Four PG-7, One 1/2-inch NPT, One 5-
pin Euro-style male connector
DX80…C models: External terminals
For European applications, power the DX80 from a Limited Power
Source as defined in EN 60950-1.
Inputs| Outputs
---|---
Discrete Inputs
Rating: 3 mA max current at 30V dc
Sample Rate: 62.5 milliseconds
Report Rate: On change of state
ON Condition (PNP): Greater than 8V
OFF Condition (PNP): Less than 5V| Discrete Outputs
Update Rate: Up to 62.5 milliseconds
ON Condition (PNP): Supply minus 2V
OFF Condition (PNP): 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
Environmental|
---|---
Rating
DX80 models:IEC IP67; NEMA 6; (See UL section be-
low for any applicable UL specifications)
DX80…C models: IEC IP20; NEMA 1
Conditions**
Operating Temperature: −40 to +85 °C (Electronics);−20 to +80 °C (LCD)
Operating Humidity: 95% max. relative (non-condensing)
Radiated Immunity: 10 V/m, 80-2700 MHz (EN61000-6-2)| 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

Operating the devices at the maximum operating conditions for extended periods can shorten the life of the device.
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)

• 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 radiofrequency 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 destina- on the 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 the misuse, abuse, or 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, WHICH- ER 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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