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SureCross™ DX80 Quick Start Guide

A setup guide for the SureCross™ DX80 wireless systems

WARNING…

Not to be used for personnel protection

Never use these products for personnel protection. Doing so could lead to serious injury or death.

These products do NOT include the self-checking redundant circuitry necessary to allow their use in personnel safety applications.

A failure or malfunction can cause either an energized or de-energized product output condition. Consult your current Banner Safety

Products catalog for safety products that meet OSHA, ANSI, and IEC standards for personnel protection.

Printed in USA 04/07 P/N 128185 Rev B

Introducing the SureCross™ DX80 Wireless System

The SureCross™ DX80 wireless system provides reliable monitoring without the burden

of wiring or conduit installation, and can operate independently or in conjunction with a

PLC and/or PC software.

The SureCross DX80 network is a deterministic system—the network identifies when

the radio signal is lost and drives relevant outputs to user-defined conditions. Once the

radio signal is reacquired, the network returns to normal operation.

Each wireless system consists of one Gateway and one or more Nodes that ship with

factory predefined inputs and outputs. Devices may be all discrete I/O, mixed discrete

and analog I/O, and FlexPower™.

A Gateway device acts as the master device within each radio network system. The

Gateway initiates communication and reporting with the Nodes.

A radio network contains only one Gateway, but can contain many Nodes. Each Node

device can be connected to a sensor or output device and reports I/O status to the

Gateway.

A Gateway and Node can be arranged to extend the range of the network or to avoid

obstacles in the transmission path. The Gateway receives a transmission from one

Node and forwards it to another Node positioned to avoid the obstacle.

Host-connected systems can contain up to 15 nodes within a single network and may

be all discrete or a mix of discrete and analog I/O. Host-connected systems allow for

logic and calculations to be applied to the I/O. Inputs from Nodes within the network

are transmitted to the Gateway, which communicates the information to a host device

for processing. While the Gateway is the master device within the radio network, the

Gateway is a slave to the Modbus network.

FlexPower devices allow for a true wireless solution as the Node can be powered

by line power (10 to 30V dc) or battery power (3.6 to 5.5V dc). A SureCross DX81

battery pack and unique power management system runs the Node and a device for

up to five years, depending upon the power requirements of the device. Battery life is

application specific. Contact Banner Engineering’s application engineers for a battery

life calculation for your specific application.

Overview ................................................1

Features and Components .....................2

Menu System .........................................4

QuickStart

Step 1: Set NID & Device Address

Step 2: Apply Power (Gateway) .....

Step 3: Apply power (Node) ...........

Step 4: Verify Communications ......

Step 5: Site Survey ........................

Step 6: Installation .......................

Maintenance/Parts Replacement .........13

Host Network .......................................15

Product Dimensions .............................17

Troubleshooting ...................................18

Accessories..........................................20

Agency Certifications ...........................21

FCC Certification..................................22

Table of Contents

Summary of content (24 pages)

PAGE 1
SureCross™ DX80 Quick Start Guide A setup guide for the SureCross™ DX80 wireless systems Introducing the SureCross™ DX80 Wireless System The SureCross™ DX80 wireless system provides reliable monitoring without the burden of wiring or conduit installation, and can operate independently or in conjunction with a PLC and/or PC software. The SureCross DX80 network is a deterministic system—the network identifies when the radio signal is lost and drives relevant outputs to user-defined conditions.
PAGE 2
SureCross™ DX80 Quick Start Guide DX80 Gateway and Node Front Panel Interface 1 2 3 4 5 6 7 Rotary Switches: Used to set Network ID & Device Address 1 Rotary Switch 1 (left) Sets the Network ID (NID) to a hexidecimal value from 0 to F, for a total of 16 Network IDs. A Gateway and its corresponding Nodes must be assigned the same Network ID. 2 Rotary Switch 2 (right) On Gateway: Sets the Gateway’s LCD viewing device address. The Gateway is predefined as Device Address 0.
PAGE 3
SureCross™ DX80 Quick Start Guide DX80 Gateway and Node Wiring Chamber 1 2 3 4 5 6 7 8 NPT Gland, or Plug 1 Port, If unused, install the provided plug into the 1/2 NPT threaded port. Use PTFE tape if an IP67 seal is required. 2 Housing The rugged, industrial DX80 housing meets IEC IP67 standards.
PAGE 4
SureCross™ DX80 Quick Start Guide SureCross™ DX80 Gateway Setup Menu When power is applied, the DX80 immediately begins running. The display screen autoscrolls through the *RUN menu and communication begins between the Gateway and Node(s). Autoscrolling 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.
PAGE 5
SureCross™ DX80 Quick Start Guide SureCross™ DX80 Node Setup Menu When power is applied, the DX80 immediately enters *RUN mode. *RUN mode 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. To return to the top level menus and autoscrolling mode, double-click button 2 twice.*** To enter manual scrolling mode, double-click button 2 at the top level menu.
PAGE 6
SureCross™ DX80 Quick Start Guide Quick Start: STEP 1 > Set Network ID & Device/Node Address The wireless RF network is defined by the Network ID (NID) assigned to the Gateway and its Nodes. Each device within this common network must have a unique Device Address assigned. Network ID (NID) Device Address For factory configured kits, the Network ID and Device Addresses have been assigned. Otherwise, use the Rotary Switches (shown right) to define both the NID and Device Address for each device.
PAGE 7
SureCross™ DX80 Quick Start Guide Quick Start: STEP 2 > Apply Power, Gateway To apply power to the Gateway, connect the 10-30V dc cable as shown. User Action Display/Status Apply power... The LCD display shows the current I/O status of the Gateway. Notes This reading occurs only when power is applied to the Gateway. The Gateway starts in *RUN mode. Displays current Network ID (NID) Gateway Pinout Diagram Device is ... ...
PAGE 8
SureCross™ DX80 Quick Start Guide Quick Start: STEP 4 > Verify Communications, Gateway Verify LED 1 is on and green. Status LED 1 Power ON Green ON System Error Red Flash LED 2 — Red Flash Modbus Communication Active — Yellow Flash Modbus Communication Error — Red Flash > Verify Communications, Node Verify LED 1 is flashing Green and LED 2 is off. Until communication is established with the Gateway, the Node’s LED 2 flashes Red.
PAGE 9
SureCross™ DX80 Quick Start Guide Quick Start: STEP 5 > Site Survey (optional) A site survey analyzes the radio signal between a Gateway and a specified Node and reports the number of data packets missed or received. Perform the Site Survey before permanently installing your network to ensure reliable communication. Use the Gateway to perform a site survey analysis. User Action Notes Display/Status RETURN TO RUN MODE SURVEY READINGS SITE SURVEY MENU Remove Gateway rotary switch access cover.
PAGE 10
SureCross™ DX80 Quick Start Guide Quick Start: STEP 6 > Installation Avoid Direct Sunlight To minimize the damaging effects of ultra-violet radiation, avoid mounting the Gateway or Node facing intense direct sunlight. Ideal Mounting Conditions • Mount the DX80 within a protective enclosure, • Mount the DX80 under an overhang or other source of shade, • Install the DX80 indoors, or • Face the unit north when installing outside.
PAGE 11
SureCross™ DX80 Quick Start Guide Installation - Weather-Proofing Glands and Plugs Watertight Glands and Plugs If the DX80 is mounted outdoors or will be exposed to moisture, dirt, or dust, follow these steps to weatherproof the units. Watertight Glands To make the glands watertight: 1. Wrap four to eight passes of polytetrafluoroethylene (PTFE) tape around the threads as close as possible to the hexagonal body of the gland. 2. Manually thread the gland into the housing hole.
PAGE 12
SureCross™ DX80 Quick Start Guide Quick Tips Clear Communication Paths A wireless network can be hindered by radio interference and obstructions in the path between a receiver and transmitter. To achieve the best radio performance, carefully consider the installation locations for the Gateways and Nodes. Increase Height of DX80 Units Orient the external antenna vertically for optimal RF communication. If necessary, consider changing the height of the DX80 position to improve reception levels.
PAGE 13
SureCross™ DX80 Quick Start Guide Maintenance and Parts Installation Main Body Gasket Check the main body gasket every time the DX80 is opened. Replace the gasket when it is damaged, discolored, or showing signs of wear. The gasket must be: Main Body Gasket • Fully seated within its channel along the full length of the perimeter, and • Positioned straight within the channel with no twisting, stress, or stretching.
PAGE 14
SureCross™ DX80 Quick Start Guide DX80 Battery Replacement Battery Replacement To replace the lithum “D” cell battery in the DX81 FlexPower battery kit, 1. Remove the four screws mounting the battery pack face plate to the body. 2. Remove the face plate. 3. Remove the discharged battery and replace with a new battery. Verify the battery’s positive and negative terminals align to the positive and negative terminals of the battery holder mounted within the case. 4.
PAGE 15
SureCross™ DX80 Quick Start Guide Host Network - Gateway Setting up the Network and Device IDs, powering up the devices, and conducting the Site Survey for a host-connected network is the same as for the standard DX80 wireless system. All device I/O for the network is accessed using the host/master device. To access the Modbus device, you may first need to configure system-level communication parameters on the DX80 Gateway, in addition to the serial hookups shown below.
PAGE 16
SureCross™ DX80 Quick Start Guide Host Network - Gateway (con’t) Setting the Slave ID, Baud Rate, and Parity Similar to Network ID, the Slave ID, Baud Rate, and Parity parameters can be changed in the Device Configuration (*DVCFG) system menu option. Follow the top level system menu through *DVCFG to the Slave ID (SLID) parameter. The LCD displays an alternating current value and new value for the parameter.
PAGE 17
SureCross™ DX80 Quick Start Guide DX80 Gateway and Node Dimensions 65.0 mm (2.56") 22.2 mm (.875") 7.9 mm (0.31") 30.65 mm (1.21") 65.0 mm (2.56") 19 mm (0.75") 80.3 mm (3.16") 127 mm (5") 7.65 mm (0.30") 60 mm (2.36") 14.67 mm (0.578") 80.8 mm (3.18") 120 mm (4.72") Banner Engineering Corp. • Minneapolis, MN U.S.A. www.bannerengineering.com • Tel: 763.544.
PAGE 18
SureCross™ DX80 Quick Start Guide Troubleshooting RF Link Time-Out and Recovery The SureCross™ DX80 wireless devices employ a deterministic link time-out method to address RF link interruption or failure. As soon as a specific Node/Gateway RF link fails, all pertinent wired outputs are de-energized until the link is recovered (see component data sheet for more information.
PAGE 19
SureCross™ DX80 Quick Start Guide Troubleshooting (con’t) A wireless network can be hindered by radio interference and by obstructions in the path of the receiver and transmitter. To achieve the best radio performance possible, carefully consider the installation locations for Gateways and Nodes. The need for a clear path increases as the transmission distance increases. Use Site Survey (RSSI) to confirm signal quality before fixing devices for permanent installation.
PAGE 20
SureCross™ DX80 Quick Start Guide Troubleshooting (con’t) Problem Description Possible Solutions I/O functionality • Use manual scrolling mode within *RUN to freeze the I/O status on the LCD display for the device in question. Verify that when the input device changes state or changes value, the LCD mirrors the behavior. • Also verify that the LCD on the output side mirrors the linked input’s behavior.
PAGE 21
SureCross™ DX80 Quick Start Guide Agency Certifications Industry Canada This Class A digital apparatus meets all requirements of the Canadian Interference Causing Equipment Regulations. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
PAGE 22
SureCross™ DX80 Quick Start Guide FCC Certification - 900 MHz FCC Certification The DX80 Module complies with Part 15 of the FCC rules and regulations. FCC ID: TGUDX80 This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
PAGE 23
SureCross™ DX80 Quick Start Guide FCC Certification - 2.4 GHz FCC Certification The DX80 Module complies with Part 15 of the FCC rules and regulations. FCC ID: UE300DX80-2400 This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
PAGE 24
CAUTION . . . 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. Contact the Factory for more information. All specifications published in this document are subject to change. Banner reserves the right to modify the specifications of products, prior to their order, without notice. WARRANTY: Banner Engineering Corp. warrants its products to be free from defects for one year.