Banner SureCross DX80 User manual

Printed in USA 05/07 P/N 132607
SureCross™ DX80
Wireless I/O Network
Product Manual

WARRANTY: Banner Engineering Corp. warrants its products to be free from defects for
one year. Banner Engineering Corp. will repair or replace, free of charge, any product of its
manufacture found to be defective at the time it is returned to the factory during the warranty
period. This warranty does not cover damage or liability for the improper application of
Banner products. This warranty is in lieu of any other warranty either expressed or implied.
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.
Banner Engineering Corp., 9714 Tenth Ave. No., Minneapolis, MN USA 55441 • Phone: [phone] • www.bannerengineering.com • Email: [email protected]
P/N 132607
Banner Engineering Corp.
9714 Tenth Ave. No.
Minneapolis, MN USA 55441
Phone: [phone]
www.bannerengineering.com
Email: [email protected]

P/N 132607 3
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
Table of Contents
Introducing the SureCross™ DX80 Wireless System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DX80 Gateway and Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DX80 Gateway Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DX83 Ethernet Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DX80 Gateway and Node Wiring Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DX80 Gateway and Node Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DX80 Gateway Pro Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DX83 Ethernet Bridge Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setup - Wireless Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DX80 Gateway and Gateway Pro Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DX80 Node Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 1 - Set up the Network ID and Device Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Step 2 - Powering the Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 3 - Verify Communications, Gateway and Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 4 - Site Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setup - Ethernet Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Web Page Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Communication Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Ideal Mounting Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Weather-Proofing Glands and Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quick Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting - Wireless. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
RF Link Time-Out and Recovery - Gateway and Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
RF Link Time-Out and Recovery - Host-Connected Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Restoring Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Jumper Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Accessories and Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Agency Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Industry Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FCC Certification - 900 MHz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FCC Certification - 2.4 GHz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Appendix A - Recommended Browsers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Recommended Browsers and System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Browser Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Appendix B - Ethernet Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Appendix C - Additional SureCross™ Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4P/N 132607
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
Introducing the SureCross™ DX80 Wireless System
The SureCross™ DX80 wireless I/O network 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.
Devices may be all discrete I/O, mixed discrete and analog I/O, or FlexPower™. A
Gateway device acts as the master device within each radio network and 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 sensors
or output devices and reports I/O status to the Gateway.
The DX80 Gateway Pro combines, in one DX80 unit, the function of a standard
Gateway with the ability to interface to Ethernet using Modbus/TCP or EtherNet/IP™
protocols. The Gateway Pro has a serial port as well as an industrial Ethernet port.
To achieve the same functionality with a standard Gateway, add a DX83 Ethernet
Bridge to any standard DX80 Gateway device. The DX83 Ethernet Bridge adds the Web
page configuration ability to your system as well as the ability to interface to Ethernet
using Modbus/TCP or EtherNet/IP protocols. A DX83 Ethernet Bridge connected to a
DX80 Gateway functions as a DX80 Gateway Pro while allowing the Gateway to have
I/O points.
For more information on specific components, please refer to the data sheets for the
SureCross devices:
•
Gateways
•
Line-Powered Nodes
•
FlexPower™ Nodes
Additional reference guides are available at www.bannerengineering.com on a variety of
topics, including:
Literature Number Topic
132113 A guide to antenna basics
132114 A guide to using Modbus® with the SureCross products
132033 How to configure I/O parameters using Modbus registers
133601 Samples of SureCross network configurations
133602 Running the Site Survey and interpreting the results

P/N 132607 5
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
Features
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.
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.
Rotary Switch 2 (right) - Gateway: Sets the Gateway’s LCD viewing device address. The Gateway is predefined as Device Address 0.
Node: Sets the Node’s Device Address (hexidecimal 1 to F). Each Node within a network must have a unique Node Device Address.
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.
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.
LED 1 and 2 - Provide real-time feedback to the user regarding RF link status, serial communications activity, and the error state.
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.
5-Pin M12 Euro-style quick-disconnect serial port
Single-click
Button 1
Single-click
Button 1
Double-click
Button 2
Double-click
Button 2
etc.
Single-click
Button 1
etc.
DX80 Gateway and Node
1
2
3
4
5
6
1
2
3
4
5
6
7
7

6P/N 132607
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
DX80 Gateway Pro
1
2
3
4
5
6
7
1
7
Industrial Ethernet Port, female
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.
Rotary Switch 2 (right) - Gateway: Sets the Gateway’s LCD viewing device address. The Gateway is predefined as Device Address 0.
Node: Sets the Node’s Device Address (hexidecimal 1 to F). Each Node within a network must have a unique Node Device Address.
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.
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.
LED 1 and 2 - Provide real-time feedback to the user regarding RF link status, serial communications activity, and the error state.
LCD Display - Six-character display provides run mode user information. 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.
5-Pin M12 Euro-style quick-disconnect serial port
Single-click
Button 1
Single-click
Button 1
Double-click
Button 2
Double-click
Button 2
etc.
Single-click
Button 1
etc.
2
3
4
5
6

P/N 132607 7
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
DX83 Ethernet Bridge
1
2
3
4
1
2
3
4
Industrial Ethernet Port, female
Housing - The rugged, industrial DX80 housing meets IEC IP67 standards.
Mounting Hole, #10/M5 Clearance - Mounting Holes accept metric M5 or UNC/UNF #10
hardware -- DIN rail mount adapter bracket available.
5-Pin M12 Euro-style quick-disconnect serial port
Pinouts
No. Color Description
1 Brown 10 to 30V dc Input
2 White RS485 / D1 / B /+
3 Blue dc common
4 Black RS485 / D0 / A / -
5 Gray Comms Gnd
NOTE: Terminal block GND = dc common
5-pin M12 Euro Hookup
No. Color Description
1 White/Orange +Tx
2 White/Blue +Rx
3 Orange -Tx
4 Blue -Rx
Industrial Ethernet Hookup

8P/N 132607
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
DX80 Gateway and Node Wiring Chamber
Housing - The rugged, industrial DX80 housing meets IEC IP67 standards.
Mounting Hole, #10/M5 Clearance - Mounting Holes accept metric M5 or UNC/UNF #10 hardware -- DIN rail mount adapter bracket
available.
Wiring Terminal Strip - The 16 spring-clip type wiring terminals accept wire sizes: AWG 12-28 or 2.5 mm2
Port, PG-7 Gland or Blank - The PG-7 threaded ports can accept provided cable glands or blanks.
Ribbon Connector - Ribbon cable connects wiring base to LCD/radio.
5-Pin M12 Euro-style quick-disconnect fitting
1
2
3
4
5
6
1
6
5
4
3
2
The Gateway Pro has no serviceable parts inside the housing and no wiring chamber. During setup or standard operation, there
should not be a need to open the Gateway Pro.

P/N 132607 9
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
DX80 Gateway and Node Dimensions
65.0 mm
(2.56”)
65.0 mm
(2.56”) 80.3 mm
(3.16”)
80.8 mm
(3.18”)
60 mm
(2.36”)
120 mm
(4.72”)
127 mm
(5”)
19 mm
(0.75”)
30.65 mm
(1.21”)
22.2 mm
(.875”)
7.9 mm
(0.31”)
7.65 mm
(0.30”)
14.67 mm
(0.578”)

10 P/N 132607
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
DX80 Gateway Pro Dimensions
65.0 mm
(2.56”)
65.0 mm
(2.56”)
80.3 mm
(3.16”)
80.8 mm
(3.18”)
60 mm
(2.36”)
136mm
(5.35”)
7.9 mm
(0.31”)
7.65 mm
(0.30”)
14.67 mm
(0.578”)