Banner SureCross DX80 User manual

Preliminary Information
Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 1 of 18 www.sensonix.com •763.519.7042
RF by
DX80 Gateway Installation & Operation Manual
•Operates in 902-928MHz ISM
Spectrum
•FHSS operation
•RF configurations – up to 150 mw
•External antenna connection
•RS232 / RS485
•2 Analog In (4-20ma)
•2 Analog Out (4-20ma)
•2 Digital In
•2 Digital Out
•10-30v DC
•LCD, Control buttons, LED
indicators
•Stand alone operation
•DX80 - NEMA 6, IP67 enclosure
The gateway and endpoint nodes communicate over multiple wireless channels within the 902-928MHz
ISM Spectrum. Different configurations of internal & external antennas and different RF power options
allow you to customize the wireless range from a few feet to > 10000’. The implementation of FHSS
methodology allows for reliable communications even in harsh industrial environments. The gateway
station and endpoint nodes communicate with acknowledge handshaking to verify reception of data. Error
checking is also performed to validate the data transmission.
The Gateway and Endpoint node communications always collect signal strength information. The
collected data can help gauge the strength and performance of the wireless signals. The received signal
strength can be adjusted by various parameters such as the TX power settings and Receiver Sensitivity
Modes. Hardware configurations can also impact the signal strength, such as internal / external antenna and
antenna placement.
Features

Preliminary Information
Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 2 of 18 www.sensonix.com •763.519.7042
1 Mechanical
Low Profile DX80 enclosure, a two connector model is shown. A DX80 gateway unit
in a single connector model is also available
All DX80 mechanical enclosures
Model # Description Euro Connectors High
Profile Low Profile
LPGW1 Line Powered Gateway 1 female, 1 male X
LPGW2 Line Powered Gateway 1 male, 8 pin X
LPEN1 Line Powered Endpoint Node 1 female, 1 male X
BPDEN1 Battery Powered Endpoint Node 1 male, 8 pin X
BPMIEN1 Battery Powered Endpoint Node 1 female connector X
BPTMPEN1 Battery, RTD Endpoint Node 2 female connectors X
BPTMPEN2 Battery, Thermocouple Endpoint Node 1 female connector X
BPMG1 Battery, Magnetic Endpoint Node No connectors X

Preliminary Information
Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 3 of 18 www.sensonix.com •763.519.7042
Junction Box
Junction box models – euro connectors, glands,
Euro-style connector or glands?
Mounting holes
Wiring diagram
PC Board with Terminals to identify connection.

Preliminary Information
Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 4 of 18 www.sensonix.com •763.519.7042
Thermocouple &
Compensation
Thermistor
DX80 Battery
powered TC
endpoint node
123456
2
Serial
Interface
Third
Party
PLC
DX80 Line
powered
gateway
24Vdc
power
supply
123456
Junction Box
QT50
DX80 Battery
powered
endpoint node
Digital sensors
for tank hi/lo
123456
1
Junction Box
2 Mounting & Electrical Connections
2.1 Placement
A wireless network can be hindered by radio interference as well has obstructions in the path of the
receiver and transmitter. When planning for the best location to install the wireless gateway or endpoint
node, it is best to be able to monitor the signal strength relative to the positions of the devices. A built in
diagnostic called ‘site survey’ continuously monitors signal strength and displays the information on the
gateway front panel LCD. Use this diagnostic tool to confirm signal quality before fixing devices for
permanent installation. (Refer to the
section on Front Panel Operation.)
Avoid placement of the wireless
units in extreme temperatures, high
vibration and high shock areas. The
DX80 is IP67 compliant and designed for
all types of environments but continued
exposure to harsh environments will
shorten the product life.
Although the DX80 devices are
considered maintenance free, try to avoid
installation in an unserviceable location.
Only place the DX80 devices in
ambient operating temperatures of -40°C
to 85°C.
2.2 External Antenna
For optimal RF communications the
external antenna should be vertically
mounted. A clear line of sight between
gateway and nodes is ideal.
Only Banner approved external
antenna should be connected to DX80 devices. Unsuitable antenna may void the user’s authority to operate
the equipment. The approved antennas are listed in the accessory section.
2.3 Mounting hardware requirements
DX80 devices have four #10 screw holes used for mounting the device vertically or horizontally. The
screws should not be tightened more that XX ft/lbs.
Keep in mind sufficient clearances for the external antenna, euro-style connectors and for viewing the
LCD display. The bottom unit dimensions are supplied in the mechanical section of this document.
2.4 Mounting accessories
DIN rail mounting hardware
Antenna mounting hardware, cables

Preliminary Information
Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 5 of 18 www.sensonix.com •763.519.7042
2.5 Euro-Style Connectors
The Gateway devices have 8-pin or 12-pin euro-style connectors. The pin numbering and wire color is
identified below. The signal wire to pin number association table identifies all wires for the DX80
Gateway.
2.5.1 8-pin Euro-Style Wiring (models LPGW2, BPDEN1)
Signal to pin association for 8-pin Euro-Style connectors. DX80 Gateway models
DX80 internal 8-pin Euro Style Connector
(male)
* Looking at the pin end
8-Pin Euro-Style Cable
LPGW2 –
Line Powered
Gateway
Internal
Wire
Color
Cable
Wire
Color
Pin
#Euro QD1 male
White White 1
Brown Brown 2 10-30Vdc
Green Green 3 DigitalInput
Yellow Yellow 4 Courtesy Ground
Gray Gray 5 NMOS Output
Red Pink 6
Blue Blue 7 Ground
Violet wire 8 Shield
Euro-Style
Connector

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Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 6 of 18 www.sensonix.com •763.519.7042
2.5.2 12-pin Euro-Style Wiring
Signal to pin association for 12-pin Euro-Style connectors. DX80 Gateway models
Looking at the connection pin end
Internal
Wire Color
Cable
Wire
Color Pin # Euro QD1 female Euro QD2 male
White White 1 -
Brown Brown 2 10-30Vdc Output 10-30Vdc Input
Green Green 3 Analog In1 (4-20mA) RS485 -
Yellow Yellow 4 Analog Out1 (4-20mA) RS485 +
Grey Grey 5 Analog In2 (4-20mA) RS485 Signal Gnd
White/Red Pink 6 Analog Out2 (4-20mA) -
Blue Blue 7 Ground Ground
Red Red 8 - RS232Tx
Orange Orange 9 DigitalIn1 RS232Rx
White/Black Tan 10 DigitalOut1 -
Black Black 11 DigitalIn2 -
Violet Violet 12 DigitalOut 2 -
LPGW1 –
Line Powered Gateway
Euro-Style Connector

Preliminary Information
Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 7 of 18 www.sensonix.com •763.519.7042
2.6 ModBus Communications, RS232 / 485 (model LPGW1)
The gateway interface is controlled using the Modbus RTU protocol. The gateway device operates as
a Modbus slave device with a programmable slave address in the range of 01-99. The serial interface is set
up with factory default parameters of 19.2k baud, one start bit, two stop bits, no flow control and a slave
address of ‘01’.
The following Modbus function codes are supported. For DX80 configuration commands and DX80
user commands refer to the DX80 Interface Protocol document.
Type Function
Code Description
Modbus Cmd 1 0x1 Read Coils, 1 – 2000 contiguous status of coils
Modbus Cmd 2 0x2 Read Discrete Inputs, 1 – 2000 contiguous status of discrete inputs
Modbus Cmd 3 0x3 Read Holding Registers, 1 – 125, contiguous block of holding regs.
Modbus Cmd 4 0x4 Read Input Registers, 1 – 125, contiguous block of input registers
Modbus Cmd 5 0x5 Write Single Coil
Modbus Cmd 6 0x6 Write Single Register
Modbus Cmd 15 0xF Write Multiple Coils, 1 – 0x7B0 force multiple coils, ON or OFF
Modbus Cmd 16 0x10 Write Multiple Registers, 1 – 0x78, contiguous block of registers
The gateway front panel LED’s are used to display information about the Modbus serial
communications.
LED1
•‘GREEN’ when power is applied and the gateway is operational.
•‘RED’ indicates a system error has occurred. Review the LCD display for further
information.
LED2
•‘YELLOW’ signifies a frame reception or sending.
•‘RED’ signals an internal Modbus error has occurred.
•Flashing ‘RED’ indicates a communications fault or configuration error.
The RS485 connections are on the 12-pin euro-style male connector QD2 on the gateway. See the Euro
Connector Diagram section in this manual

Preliminary Information
Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 8 of 18 www.sensonix.com •763.519.7042
3 Setup & Operation
3.1 DX80 Front Panel
The DX80 front panel picture helps identify
each switch, button and LED. The rotary switches in
the middle of the round window are identified as a
10’s switch (left switch) and a 1’s switch (right
switch). The value for each rotary switch is 0 – 9.
The rotary switches define different parameters
depending upon the current operating state and
whether the device is a gateway or node.
During Run Mode the gateway rotary switches
define the device information to display; the node
switches indicate the node ID number.
During configuration of the Network ID, the
rotary switches indicate the network ID number on
both the gateway and the node.
During configuration of the Modbus slave
number the gateway rotary switches indicate the
Modbus slave number 01-99.
During Site Survey operations the gateway
switches define the node ID number; the node rotary
switches define the node ID number.
The gateway front panel LED’s are used to display information about the Modbus serial
communications
LED1
•‘GREEN’ when power is applied and the gateway is operational.
•‘RED’ indicates a system error has occurred. Review the LCD display for further
information.
LED2
•‘YELLOW’ signifies a frame reception or sending.
•‘RED’ signals an internal Modbus error has occurred.
•Flashing ‘RED’ indicates a communications fault or configuration error.
The gateway LCD panel will display a variety of information about the gateway and wireless system.
3.2 Power on / Power Off
The gateway and nodes can be powered up or powered down with button 1. When the device is
powered down (sleep mode), depress button 1 for 2-3 seconds, the device will activate. Holding down
button1 for 2-3 seconds when the device is active will cause the device to power off. The wireless devices
are not operational when in Sleep Mode.

Preliminary Information
Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 9 of 18 www.sensonix.com •763.519.7042
3.3 Set-up / Configuration
The gateway and nodes must be configured to create a communications link. A properly running
wireless network will be indicated on each endpoint node by LED1 flashing green every second. (The
gateway LED’s monitor the Modbus host link)
Complete the following configuration steps to set up the wireless link.
DC power or Battery power applied to all devices and powered up. (out of sleep mode) (See 4.2 Power
on / Power off)
Gateway Set-up –
•Rotary switches = ‘00’
•Network ID set to a common value for the entire wireless network. The factory default is ‘01’
and will work for most single network installations. (See Setting the Network ID to change
the network ID)
•The Modbus slave number must be set to a unique number compared to other slaves on the
serial host bus. This is only required if using a host interface with the gateway.
Node / Endpoint Set-up –
•Rotary switches = unique number for each node in the wireless network. 01-99, 00 is not valid
•LED1 will blink GREEN every second when a RF communications link is established.
•LED1 will blink RED every 3 seconds when a node is not communicating with the gateway.
*Some endpoint nodes may require up to 20 seconds after power-on to synchronize with the gateway.
3.4 LabView Configuration
Node configuration, Sensor configuration,
System Parameters – dynamic TDMA

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Banner Engineering Corp •Minneapolis, MN USA www.bannerengineering.com •Tel: [phone]
Sensonix Incorporated •Plymouth, MN USA 10 of 18 www.sensonix.com •763.519.7042
3.5 Front Panel Operation
The front panel rotary switches and push button switches control the display information and
configuration of the DX80 devices. The flow diagram below shows the button sequences and operational
flow for what is possible with the DX80 Gateway.
Sleep
Mode
RUN
Run Mode CONFIG
Config
DIAG
Diagnostics sc.1
sc.1
sc1
Site Survey Start
Dev Warn / Err
Name A
Name B
Name C
RF Msg
S/W RF rev high
S/W RF rev low
S/N high
S/N low
Mod high
Mod low
Point 0 status
Point 1 status
Point N status
DEVINF
Device Info
sc.2
S/W Cm rev high
S/W Cm rev low
dc.2
Password
protect,
Rotary Sw
sc.2
Dev Warn / Err
Sys Warn / Err
Password
protect,
Rotary Sw
sc.2
FACTRY
Factory
sc.2 dc.2
sc.1
Rotary switches
define device
Rotary switches
define device
Rotary switches
define device
Production high
Production low
sc.1
dc.2
dc.2
Config Start
RF Baud
Network ID
ModBus Baud
ModBus Slave ID
hold.1
hold.1
hold.1 = press and hold button 1 for 2-3 seconds
sc.1 = single click button 1
sc.2 = single click button 2
dc.2 = double click button 2
From a powered-off state, press and hold button 1 for 2-3 seconds will turn on the Gateway or Node.
From any state, press and hold button 1 for 2-3 seconds will turn off the Gateway or Node. Configuration
steps not fully completed before going into sleep mode will be lost.
3.5.1 Operating States
Sleep Mode – This is the off state for all devices. Sleep mode can be entered or exited by holding
button 1 for 2-3 seconds regardless of the current state. All LED’s will be turned off in this state. (The LCD
display will be turned off for DX80 devices with an LCD display)
Run Mode – (LCD display = ‘RUN’) This is the default operating state for normal operation. Out of
sleep mode the device will transition into run mode. If no buttons changes are detected the gateway will
display device information. The rotary switches on the gateway will define which device information to