Banner Sure Cross DX80 User manual

Sure Cross®DX80 Performance Wireless
I/O Networks
Instruction Manual
Original Instructions
132607 Rev. R
27 July 2022
©Banner Engineering Corp. All rights reserved
132607

Contents
1 Sure Cross® DX80 Performance Wireless Networks ................................................................................................. 4
1.1 Gateways and Nodes .......................................................................................................................................................................4
1.2 Host Controller Systems .................................................................................................................................................................. 5
1.3 What is FlexPower®? .......................................................................................................................................................................5
1.4 Sure Cross® DX80 Performance Configuration Software ................................................................................................................6
2 Features ..........................................................................................................................................................................7
2.1 DX80 Gateway and Node Components ...........................................................................................................................................7
2.2 DX80 Gateway and Node Wiring Chamber ..................................................................................................................................... 8
2.3 Dimensions ...................................................................................................................................................................................... 8
2.3.1 Gateways and Nodes ............................................................................................................................................................... 8
2.3.2 DX80...C Gateways and Nodes ................................................................................................................................................9
2.3.3 DX80...E Housings ................................................................................................................................................................... 9
3 Setting Up Your Wireless Network ............................................................................................................................10
3.1 Mixing Performance and Non-Performance (150 mW) Radios in the Same Network .................................................................. 10
3.2 Apply Power to the Gateway or Node ............................................................................................................................................11
3.2.1 DX80...C Wiring ......................................................................................................................................................................11
3.2.2 4-pin M12 D-Coded Industrial Ethernet Wiring .......................................................................................................................12
3.3 Bind Radios to Form Networks ..................................................................................................................................................... 12
3.4 LED Behavior for the Gateways and Nodes .................................................................................................................................. 13
3.5 Conducting a Site Survey (Gateway and Nodes) ...........................................................................................................................13
3.5.1 Conduct a Site Survey Using the Menu System .....................................................................................................................14
3.5.2 Conduct a Site Survey from a Gateway Board Model ........................................................................................................... 14
3.5.3 Conduct a Site Survey Using Modbus Commands ................................................................................................................ 15
3.5.4 Conduct a Site Survey from the DXM .....................................................................................................................................16
3.5.5 Interpreting the Site Survey Results ....................................................................................................................................... 16
3.5.6 Improving Your Site Survey Results .......................................................................................................................................17
4 Installing Your Sure Cross® Radios ......................................................................................................................... 19
4.1 Mounting Sure Cross Devices Outdoors .......................................................................................................................................19
4.1.1 Watertight Glands and NPT Ports .......................................................................................................................................... 19
4.2 Other Installation Requirements ....................................................................................................................................................20
4.3 Installation Quick Tips ...................................................................................................................................................................20
4.3.1 Create a Clear Communication Path ......................................................................................................................................20
4.3.2 Increase the Height of the Antennas ...................................................................................................................................... 20
4.3.3 Collocated Radios .................................................................................................................................................................. 21
4.3.4 Be Aware of Seasonal Changes .............................................................................................................................................21
4.4 Installing a Basic Remote Antenna ................................................................................................................................................ 21
4.4.1 Weatherproof Remote Antenna Installations ..........................................................................................................................22
4.4.2 Installing Remote Antennas ....................................................................................................................................................23
4.4.3 Mount a Dome Antenna to the Enclosure ...............................................................................................................................23
4.4.4 Use an N-Type, Pole-Mounted Antenna .................................................................................................................................24
5 Advanced Setup Options ............................................................................................................................................ 26
5.1 DX80 Menu Structure .....................................................................................................................................................................26
5.1.1 RUN Menu ..............................................................................................................................................................................28
5.1.2 DINFO (Device Information) Menu ......................................................................................................................................... 28
5.1.3 FCTRY (Factory) Menu .......................................................................................................................................................... 28
5.1.4 SITE (Site Survey) Menu ........................................................................................................................................................29
5.1.5 DVCFG (Device Configuration) Menu .................................................................................................................................... 30
5.1.6 DERR (Device Error) Menu .................................................................................................................................................... 32
5.2 Binding Mode: What does it do? ................................................................................................................................................... 32
5.2.1 Automatic Binding Using the Menu Navigation ...................................................................................................................... 32
5.2.2 Bind Radios Using Modbus Commands ................................................................................................................................33
5.3 Setting the Network ID in Extended Addressing Mode .................................................................................................................. 34
5.4 Manually Assign a Binding Code to a Gateway ............................................................................................................................. 34
5.5 Manually Assign a Binding Code to a Node ...................................................................................................................................35
5.6 Setting the Maximum System Devices ...........................................................................................................................................35
5.7 Storage and Sleep Modes .............................................................................................................................................................35
5.8 Modbus Holding Registers .............................................................................................................................................................36
5.9 Modbus Communication Parameters .............................................................................................................................................36
5.9.1 Set the Slave ID on a DX80 Gateway .................................................................................................................................... 37
5.9.2 Set the Baud Rate .................................................................................................................................................................. 37
5.9.3 Set the Parity .......................................................................................................................................................................... 37
5.10 Default Output Conditions ............................................................................................................................................................38
5.10.1 Host Link Failure ...................................................................................................................................................................38
5.10.2 Gateway Link Failure ............................................................................................................................................................38
Sure Cross® DX80 Performance Wireless I/O Networks

5.10.3 Node Link Failure ................................................................................................................................................................. 39
5.11 Defining the Units .........................................................................................................................................................................39
5.11.1 Input Units ............................................................................................................................................................................ 40
5.11.2 Output Units .........................................................................................................................................................................40
5.11.3 Interpreting Register Values in the Banner Wireless System ...............................................................................................41
5.11.4 Signed Numbers ..................................................................................................................................................................42
5.11.5 Mapping Unit Types .............................................................................................................................................................42
6 Product Support and Maintenance ........................................................................................................................... 44
6.1 DX80 Performance Documentation .............................................................................................................................................. 44
6.2 Troubleshooting ............................................................................................................................................................................. 44
6.2.1 Startup Problems ....................................................................................................................................................................44
6.2.2 LED Message Codes ..............................................................................................................................................................45
6.2.3 LCD Message Codes ............................................................................................................................................................. 45
6.2.4 Inputs and Outputs ................................................................................................................................................................. 47
6.2.5 Radio Link Time-Out and Recovery (Non-Host Connected Systems) ....................................................................................47
6.3 Maintenance ...................................................................................................................................................................................48
6.3.1 Replacing the Main Body Gasket ........................................................................................................................................... 48
6.3.2 Replacing the Rotary Dial Access Cover ................................................................................................................................48
6.3.3 Install or Replace the Battery for a DX81 Model .................................................................................................................... 49
6.3.4 Install or Replace the Battery for a DX80 Integrated Battery Model .......................................................................................50
6.3.5 Install or Replace the Battery (DX99...D Models) ..................................................................................................................50
6.4 Sure Cross® Radio Certifications ...................................................................................................................................................51
6.4.1 FCC Part 15 Class A ............................................................................................................................................................. 51
6.4.2 Industry Canada .................................................................................................................................................................... 51
6.4.3 FCC and ISED Certification, 900 MHz, 1 Watt Radios ...........................................................................................................51
6.4.4 FCC and ISED Certification, 2.4GHz ......................................................................................................................................52
6.4.5 Exporting Sure Cross® Radios ............................................................................................................................................... 53
6.4.6 International Certifications for Sure Cross® Radios ............................................................................................................... 53
6.5 Contact Us ..................................................................................................................................................................................... 54
6.6 Warnings ........................................................................................................................................................................................54
6.7 Banner Engineering Corp Limited Warranty ................................................................................................................................. 55
Sure Cross® DX80 Performance Wireless I/O Networks

1 Sure Cross®DX80 Performance Wireless Networks
The Sure Cross® DX80 Performance wireless I/O network provides reliable monitoring without wiring or conduit installation.
The network operates independently or in conjunction with a host system, PLC, and/or PC software. Each wireless network
system consists of one Gateway and one or more Nodes, and devices ship with factory-defined discrete, analog, or a mix of
discrete and analog inputs and outputs.
The Sure Cross® DX80 Performance network is a deterministic system—the network identifies when the radio signal is lost
and drives relevant outputs to user-defined conditions. After the radio signal is reacquired, the network returns to normal
operation.
Figure 1. Sure Cross® DX80 Performance wireless network
Node
Gateway
Node
Node
1.1 Gateways and Nodes
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.
A Gateway is the master device within each radio network. Similar to how a gateway device on a wired network acts as a
“portal” between networks, the Sure Cross 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.
Figure 2. Gateways and Nodes
Node
Gateway
Node
Node
Sure Cross® DX80 Performance Wireless I/O Networks
4 www.bannerengineering.com - Tel: + 1 888 373 6767

1.2 Host Controller Systems
Host controller systems collect I/O data for logging, controlling other devices, or performing calculations.
Host controller systems can contain up to 47 Nodes (when using Extended Addressing Mode) within a single network. Inputs
from Nodes within the network are transmitted to the Gateway, which communicates the information to a host system for
processing. Although the Gateway is the master device within the radio network, it may be a slave to the Modbus network.
1.3 What is FlexPower®?
Banner’s FlexPower technology supplies a true wireless solution by allowing the device to operate using either 10 to 30 V dc,
3.6 V lithium D cell batteries, or solar power. This unique power management system can operate a FlexPower Node and an
optimized sensing device for up to five years on a single lithium D cell.
• FlexPower Nodes may be powered from 10 to 30 V dc and use an external battery supply module to provide a battery
back-up solution.
• When a FlexPower Node receives 10 to 30 V dc, it operates like a standard 10 to 30 V dc Node.
• Good applications for FlexPower devices operating from batteries include sensors that require no or very little power,
including dry contacts, RTDs, and thermocouples.
The following FlexPower options are available:
• DX81-LITH, a single battery supply module;
• DX81P6, a 6-pack of lithium batteries;
• DX81H, a single battery supply module designed specifically to power the DX99 Intrinsically Safe devices with
polycarbonate housings; and
• BWA-SOLAR PANEL 3W, 5W, or 20W, solar panel assemblies.
DX81-LITH: 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 PANEL 3W, BWA-SOLAR
PANEL 5W, or BWA-SOLAR PANEL
20W: Includes 3 W, 5 W, or 20 W solar
panel.
Order the solar controller (model BWA-
Solar CNTRL-12V) separately when you
are not using the solar panel with a DXM
Wireless Controller. For more information
about solar power solutions, see Sure
Cross® Solar Solutions.
Sure Cross® DX80 Performance Wireless I/O Networks
www.bannerengineering.com - Tel: + 1 888 373 6767 5

1.4 Sure Cross®DX80 Performance Configuration Software
The configuration software offers an easy way to link I/O points in your wireless network, view I/O register values, and set
system communication parameters when a host system is not part of the wireless network. The software runs on any
computer with the Windows Vista, Windows 7, Windows 8, or Windows 10 operating system.
Figure 3. Device Configuration screen
Use a USB to RS-485 adapter cable to connect a standalone DX80 Gateway to the computer. For DXM Controllers with an
internal DX80 radio, connect a computer to the DXM Controller using the supplied USB or Ethernet connection. Download
the most recent revisions of the configuration software from Banner Engineering's website: https://
www.bannerengineering.com/us/en/products/wireless-sensor-networks/reference-library/software.html.
The USB to RS-485 adapter cable is not required for the DXM Controller. For standalone DX80 Gateway devices use:
• USB to RS-485 adapter cable model BWA-UCT-900 for 1 Watt radios
• USB to RS-485 adapter cable model BWA-HW-006 for all other radios
Sure Cross® DX80 Performance Wireless I/O Networks
6 www.bannerengineering.com - Tel: + 1 888 373 6767

2 Features
The following feature callouts refer to the DX80 Gateway and Node models. The wiring diagrams include information for
connection power and sensors using the 5-pin M12 connector, the terminal wiring board, and any other applicable
connection.
2.1 DX80 Gateway and Node Components
The DX80 Gateway and Node use the same housing and include the same physical features.
Figure 4. Features of the Performance Gateway and Node
1
2
3
4
5
6
7
1. Port, NPT gland, or plug—If unused, install the provided plug into the 1/2 NPT threaded port. Refer to the Installation
section if an IP67 seal is required.
2. Rotary switch 1 (left)—In Rotary Dial Addressing Mode, 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.
Rotary switch 2 (right)—On the Gateway, sets the Gateway’s LCD viewing device address. The Gateway is
predefined as Device Address 0. On the Node, sets the Node’s Device Address (hexidecimal 1 to F). Each Node
within a network must have a unique Node Device Address.
3. Push button 1—Single-click to advance across all top-level DX80 menus. Single-click to move down interactive
menus, once a top-level menu is chosen. Button 1 is also used to wake integrated battery models from the
hibernation mode they ship in.
4. Push button 2—Double-click to select a menu and to enter manual scrolling mode. Double-click to move up one level
at a time.
5. LED 1 and 2—Provide real-time feedback to the user regarding RF link status, serial communications activity, and the
error state.
6. LCD Display—Six-character display provides run mode user information and shows enabled I/O point status. This
display allows the user to conduct a Site Survey (RSSI) and modify other DX80 configuration parameters without the
use of a PC or other external software interfaces. On the Node, after 15 minutes of inactivity, the LCD goes blank.
Press any button to refresh the display.
7. 5-Pin M12 quick-disconnect serial port
Sure Cross® DX80 Performance Wireless I/O Networks
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2.2 DX80 Gateway and Node Wiring Chamber
The DX80 Gateway and Node use the same housing and terminal block for wiring.
Figure 5. Wiring chamber of the Performance Gateway and Node
1
2
3
4
5
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. 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—Ribbon cable connects wiring base to LCD/radio.
2.3 Dimensions
The DX80, DX83, and DX70 models all share the same housing and mounting hole dimensions.
2.3.1 Gateways and Nodes
All measurements are listed in millimeters, unless noted otherwise.
Figure 6. Dimensions for the Performance Gateway and Node
65.0
[2.56”]
65.0
[2.56”]
80.3
[3.16”]
80.8
[3.18”]
60
[2.36”]
120
[4.72”]
127
[5”]
19
[0.75”]
30.65
[1.21”]
22.2
[0.875”]
7.9
[0.31”]
7.65
[0.30”]
14.67
[0.578”]
Sure Cross® DX80 Performance Wireless I/O Networks
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2.3.2 DX80...C Gateways and Nodes
All measurements are listed in millimeters, unless noted otherwise.
Figure 7. Dimensions for the C housing models
7.9 [0.31”]
80.8
[3.18”]
65.0 [2.56”]
80.3
[3.16”]
65.0
[2.56”]
7.65 [0.30”] 60
[2.36”]
45.7
[1.8”]
101.6 [4”]
2.3.3 DX80...E Housings
All measurements are listed in millimeters, unless noted otherwise.
Figure 8. DX80...E Housing
6 mm
[0.24”]
3.2 mm
[0.13”]
167.4 mm
[6.59”]
75.3 mm
[2.96”]
2X 12-14 NPSM
20.1 mm
[0.79”]
87.6 mm
[3.45”]
13.7 mm
[0.54”]
36.2 mm
[1.42”]
148.1 mm
[5.83”]
55.9 mm
[2.20”]
2X Dia 8.3 mm
[0.33”]
Sure Cross® DX80 Performance Wireless I/O Networks
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3 Setting Up Your Wireless Network
To set up and install your wireless network, follow these steps.
1. Disconnect the power from your Sure Cross devices.
2. Configure the DIP switches of all devices. DIP switch configurations are always listed in the product's datasheet.
3. If your device has I/O, connect the sensors to the Sure Cross devices. Available I/O is always listed in the product's
datasheet. If your device does not have I/O, skip this step.
4. Refer to the wiring diagrams to apply power to all devices.
• For housed models, the Gateway's LED 1 is solid green and the Node's LED 2 flashes red to indicate there is no
radio link to the Gateway.
• For board-level models, the Gateway's LED is solid green and the Node's LED flashes red to indicate there is no
radio link to the Gateway.
5. Form the wireless network by binding the Nodes to the Gateway.
6. Observe the LED behavior to verify the devices are communicating with each other.
• For housed models, the Gateway's LED 1 is solid green and the Node's LED 1 flashes green to indicate it is
communicating with the Gateway.
• For board-level models, the Gateway's LED is solid green and the Node's LED flashes green to indicate it is
communicating with the Gateway.
7. Configure any I/O points to use the sensors connected to the Sure Cross devices.
8. Conduct a site survey between the Gateway and Nodes.
9. Install your wireless sensor network components.
3.1 Mixing Performance and Non-Performance (150 mW) Radios in
the Same Network
To comply with federal regulations, the 150 mW radios and 1 Watt radios communicate differently. All Performance models
offer the ability to select between 250 mW and 1 Watt operation using the DIP switches.
To mix Performance radios with non-Performance radios, refer to the product datasheet and:
• Operate Performance radios in 250 mW mode, not 1 Watt mode
• Set non-Performance (150 mW) radios to use Extended Address Mode
The 150 mW, 250 mW, and 1 Watt networks operate when collocated, but verify the antenna separation distance between a
Gateway and Node or between two Gateways is at least 10 feet apart. For more detailed instructions about setting up your
wireless network, refer to the following documents:
• DX80 Performance Quick Start Guide (p/n 128185)
• DX80 Performance Wireless I/O Network Instruction Manual (p/n 132607)
• DXM Quick Start Guide (p/n 191247)
• DXM Instruction Manuals (DXM100-Bx: 190037 and DXM150-Bx: 190038)
Figure 9. Performance radio network with Gateway and Nodes
Sure Cross DX80 Gateway
(150 mW radio)
Sure Cross DX80 Node
(150 mW radio)
Sure Cross Performance Node
(in 250 mW mode)
Sure Cross DX99 Node
(150 mW radio)
Up to 3 miles
Sure Cross® DX80 Performance Wireless I/O Networks
10 www.bannerengineering.com - Tel: + 1 888 373 6767