Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
SureCross™ wireless from the most reliable name in sensing.
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
Process
Contents
SureCross Sensing Unplugged™ 4
SureCross Advantages6
System Overview8
Factory
Agriculture and Water
Trac
Process Control and Monitoring10
Factory Automation12
Agriculture and Water Management14
Trac Monitoring and Control16
Commercial and Consumer Monitoring18
SureCross Options20
SureCross Conguration21
SureCross Congured Kits22
SureCross Gateway and Node Models23
SureCross Accessories24
SureCross Antenna Options26
SureCross Specications
and Dimensions27
Commercial
2
When the world thinks of sensors, it thinks of Banner.
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
With more than 17,000 photoelectric, ultrasonic and vision
sensors, and safety products available worldwide, Banner is the
most innovative, most experienced name in sensors. For simple to
complex applications, Banner has more sensor solutions than any
other manufacturer.
The innovation leader with more than 40 years of sensor
development and application expertise, Banner understands the
challenges of sensing in manufacturing and process industries.
Banner has more than 3,000 factory and eld representatives
worldwide, as well as the largest force of application engineers in
the industry who solve thousands of the most challenging
applications every year.
iKnow
Key
Glossary
Wireless Terms
FHSS - Frequency Hopping Spread
Spectrum. A method for generating
spread spectrum transmissions
where the signal is switched
between dierent frequency
channels in a pseudorandom
sequence known by both the
transmitter and the receiver pair.
FHSS is useful for sending small,
redundant packets of data in a high
interference environment.
FlexPower™ systems allow for a true
wireless solution as the Node can be
powered by line power (10-30V dc),
solar panels, or battery power (3.6-
5.5V dc). A SureCross™ FlexPower
battery module and unique power
management system runs the
Node and a device for up to ve
years, depending upon the power
requirements of the device. Battery
life is application specic.
RF - Radio Frequency. Electromagnetic signals in the radio band.
Rx/Tx - Receive. Transmit.
TDMA - Time Division Multiple
Access. A wireless network
communication architecture that
provides a given slot of time for each
device on the network. Provides
guaranteed opportunity for each
device to transmit to the gateway.
3
Introducing SureCross™. Sensing unplugged™.
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
A New Wireless Horizon from the
Most Reliable Name in Sensors.
To satisfy the performance demands for reliable
sensing and actuation, Banner has reinvented wireless.
The SureCross™ Wireless Network is the rst wireless
platform built from the ground up for industry—
featuring proprietary RF design, power management
with battery and solar options, and a host of low-power
sensors designed to deliver robust remote monitoring
and control capabilities.
With SureCross, Banner’s comprehensive sensor
capabilities are extended through wireless connectivity,
often to locations and applications never before
possible. Plant and process visibility becomes
panoramic. Orphaned monitoring resources are
integrated into existing control systems. Assets are
unlocked. Vast new monitoring and actuating
capabilities can be easily created. SureCross provides
the means to fulll the promise of comprehensive,
facility-wide integrated management.
Add Monitoring. Add Control.
Where You Need it Most.
The exibility of the SureCross network
lets you add a host of monitoring and control
capabilities across widespread areas and to
inaccessible areas, and enhances existing
control and data acquisition systems without
new conduit, wiring runs and associated labor
and downtime. Consolidate comprehensive
system status at a single location using
multiple SureCross networks, delivering
single or multiple eld measurements
interfaced to your control room PC,
PLC or DCS system. The SureCross
wireless network is as powerful as
your imagination.
NODE
1
SENSOR
NODE
6
SENSORS
FlexPower
MODULE
SENSORS
NODE
8
SERIAL
INTERFACE
PRIMARY
GATEWAY
4
900MHz
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
Easy to Apply Wireless Modules Go Where Other Systems Can’t.
The Banner SureCross Wireless System is a radio device network with integrated I/O
that can operate in extreme environments while eliminating the need for costly wiring
runs. The most basic SureCross network includes a Gateway system controller and one or
more Nodes that monitor and/or control I/O in remote locations. Nodes are easily deployed
throughout a facility, for gathering data to be concentrated at the Gateway. Installation is
fast and easy with exible mounting and power options. Nodes can be either line-powered
(10 to 30V dc) or FlexPowered with multi-year battery life providing power for communications
and to external sensors.
The Gateway can act as a master device in a star topology autonomously controlling
input to output mapping, or a Modbus Slave in a host control system using RS-485 Modbus
RTU. To relay mapped I/O longer distances, a Gateway can be positioned between two
Nodes to increase transmission range of the network.
SureCross is distinctly superior to conventional wireless networks, facilitating sensing
and actuation on the same network. Not to mention its ability to transmit the status of
each I/O point and continuously monitor the health of each Node’s operational status and
signal integrity.
NODE
12
SENSORS
2.4GHz
SureCross oers easy, reliable
communication between
disparate products and
processes in a single scalable
and unied platform.
• Access hard-to-reach
locations; install where
wiring and conduit are not
practical
• Accommodates digital and
analog I/O in a single unit
• Integrates with existing
process or control networks
• Easy to retrot, expand and
relocate as needed
• 900 MHz and 2.4 GHz
models accommodate
worldwide communication
standards
• Reliable and secure
Frequency Hopping Spread
Spectrum (FHSS) protocol
• Bidirectional Rx/Tx
communications between
Gateway and Nodes
• Mobile, scalable and exible
• Easy plug-and-play
deployment
• Rugged IP67/NEMA 6 design
• FlexPower™ supply options
including battery and solar
NODE
13
SENSORS
FlexPower
MODULE
5
6
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
SureCross™. Purpose-built by Banner.
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
While wireless monitoring is far from new, Industry has had to wait patiently for robust
bidirectional network devices that oer a feature set designed specically to meet the demands of
manufacturing, processing and challenging commercial applications.
The wait is over.
Banner designed and built the SureCross network using over 40 years of application expertise and
sensor innovation. Unlike other wireless devices, Banner started with the high-performance needs of
Industry and developed a system that meets those needs. The result is a superior network with exclusive
features, engineered and built by the sensor experts trusted worldwide.
Proprietary Radio
Communications
Advanced
Power
Management
Reliable
Response
Communications
Integrity Assured
In industrial applications, there can be no compromise for truly robust, secure
communication that ensures system operational integrity. That’s why Banner built its
own RF model based on essential sensing requirements with bidirectional Rx/Tx
communication capabilities.
True wireless operation means integrated power not only for communications, but
also for operating the attached sensor. Banner developed an innovative FlexPower™
solution that oers years of continuous operation. Innovation in wireless power
management combines ideally with Banner’s ability to design advanced sensors that
consume less power. SureCross also accommodates DC line, battery or solar power for
complete application exibility.
SureCross represents a quantum leap in wireless capabilities with deterministic
response—a system that lets you define actions and system responses to
communication interruptions or failures. Each SureCross device features a bidirectional
transceiver to fully acknowledge data transmission. The Gateway directs Nodes in the
network to respond with specic actions to a communication failure by driving userdened outputs to a default condition. Once the RF link is re-established, the network
automatically returns to normal operation.
SureCross uses a Frequency Hopping Spread Spectrum (FHSS) transmission
method to minimize radio interference, ensuring that the message gets
through and providing integral security. Time Division Multiple Access (TDMA)
slots provide guaranteed bandwidth to each connected Node. Polling and Site
Survey capabilities ensure communication integrity. SureCross oers both 900 MHz
and 2.4 GHz models, allowing you to deploy advanced wireless capabilities
anywhere in the world.
All-in-One
Packaged Solution
with Plug-and-Play
Connectivity
Versatile
Congurations
Gateways and Nodes are rugged, completely integrated and packaged solutions designed
for mounting exibility, extreme durability and plug-and-play installation. Wiring terminals
are readily accessible without removal from mounting. The compact housings come
equipped with quick-disconnect connectors for power and communication, four cable
glands and a large threaded 1/2-inch NPT port for added exibility.
Congure your SureCross wireless network with Gateway and Node components set to
your specications. Or choose SureCross Kits that are congured for a number of common
applications. Either way, Banner can help you select the exact components, tailor your
solution, or help you choose a kit that delivers the performance you need. Banner
Application Engineers are available to provide SureCross congurations that integrate
seamlessly into your legacy systems and solve your most demanding applications.
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
Robust. Reliable. Secure.
The SureCross network uses a Frequency
Hopping Spread Spectrum (FHSS) methodology in
either the 900 MHz frequency band or 2.4 GHz
frequency band. FHSS architecture periodically
“hops” in a random sequence from frequency to
frequency. This technique not only prevents
interference from competing RF signals, it also
enhances security. Multiple user-selectable hop
codes are easily congured by setting the Network
ID using a convenient rotary switch. FHSS innovation
also enables multiple SureCross networks to coexist
within range of one another.
To further ensure reliable communications,
SureCross uses Cyclical Redundancy Checking (CRC)
of both data message acknowledgement and data
error checking to verify message receipt and data
integrity. If the Gateway does not accurately
receive a data packet, the Node resends that
packet until a transmission is successful. Finally,
communication is enhanced through TDMA,
ensuring each Node a time slot for transmission.
A)
B)
C)
D)
E)
F)
(G
(H
(I
(J
(K
GATEWAY
Tests Signal Integrity Locally.
Every SureCross network includes an embedded Site Survey
feature. The Site Survey which is conducted between the Gateway
and each Node, is a fast, simple and reliable way to ensure that
every device is installed for optimal RF performance. Signal results
are displayed in a red, green, yellow and missed format. Identied
using a ashing LED of the corresponding color and an alpha
character on the LCD screen, green, yellow and red indicate
successful data transmission. No ashing LED and an M on the
LCD indicates a missed packet has occurred and the data was not
received successfully on the rst transmission. The message is
resent until it is received successfully.
Green = Excellent
Yellow = Good
Red = Marginal
Missed = Data not received on the rst transmission
8
Engineered Simplicity.
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
A) External Antenna Interface—external exible
antennas rotate for mounting and positioning
versatility; optional internal and remote, standard
and high-gain antennas available
B) Network Identity and Device Address Rotary
Switches—easy-to-set and change; with
screw-on cover
C) Menu and Conguration Access Push Buttons—
click through menu-driven conguration
D) LED Status Indicators—give real-time feedback of RF
link status, serial communication activity and error state
E) LCD Display—six-character display provides run
mode user information and shows enabled I/O
point status; lets user conduct Site Survey, assign
network ID and modify other conguration
parameters locally without a PC or external
software interfaces
F) Internal Wiring Terminal—
16 spring-clip type terminals
(AWG 12-28); are accessible
without removal from mount
1
G)
/2-inch NPT Threaded Port—accepts large cables for
exible wiring options or glands; plug provided
H) IEC IP67; NEMA 6 Rated Housing—ensures reliable,
long-lasting performance in rugged environments
I) Four PG-7 Gland Ports—threaded ports accept
provided cable glands or blanks
J) Versatile Mounting—#10/M5 hardware included with
optional DIN-rail mount adapter
K) 5-Pin M12 Euro-style Quick-Disconnect Fitting—
simplies installation with industry-standard
connectors
A)
B)
C)
D)
E)
F)
(G
(H
(I
(J
(K
NODE
FlexPower™ SYSTEMS
Predictable. Reliable. Repeatable.
SureCross FlexPower options create a truly wireless sensing
system. Users can choose from battery, solar or line power
options. Ecient power management technology enables the
FlexPower battery system to briey step up the switch power
voltage to activate a sensor device. Once activated, the input
reads the sensor then the switch power shuts o to prolong
battery life—up to 5 years. The actuation voltage, time on and
sample are congurable parameters, with voltage up to
24V dc. These unprecedented capabilities provide a reliable
solution for remote power and hard-to-access locations.
FlexPower™ BATTERY CONSERVATION
CYCLE ON
MULTI-YEAR
BATTERY LIFE
CYCLE OFF
POWER CONSUMPTION
0V
123 45
0
TIME
6. . .
FlexPower SUPPLY
9
Enhancing monitoring or control in legacy process environments is now simple
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
and aordable. Banner SureCross™ Nodes and Gateways can be easily deployed
wherever additional monitoring is desired, without hardwiring and conduit.
Control capabilities featuring Banner sensors and a wide range of industrial
communication protocols can also be added.
10
The Versatile, Robust Wireless Network
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
Designed for Process Applications.
Process Control and Monitoring
Monitoring and control in processing applications are limited only by
imagination. From tank levels to line pressure, from temperature to voltage—
anywhere along the line, the versatile SureCross™ Wireless Network can be deployed,
scaled and redeployed. Adding new Nodes or establishing multiple networks
within the same environment is turnkey. Bidirectional transmission with reliable
performance capabilities make SureCross the rst robust wireless network suited for
a host of process applications.
The SureCross Wireless Network features a congurable default output condition
that denes what happens if the system loses the RF signal. This unique network
characteristic lets you dene how all outputs on the network respond to a communication
interruption or failure. The network can automatically return to normal operational
status as the RF link is re-established.
A SureCross Gateway can be positioned as a repeater to increase the transmission
range. Data can be consolidated and monitored from a central location, enhancing
production decision-making and response.
Wireless Monitoring Retrot in a Pre-Certied Facility
New regulations in a pharmaceutical production facility stipulate the
liquid level of all uids must be closely monitored and logged. SureCross
Nodes with FlexPower™ and Banner U-GAGE® QT50U analog sensors
quickly and easily facilitate this monitoring requirement without new
construction and hardwiring.
Applications
EXAMPLE APPLICATIONS
Motor Temperature Monitoring and Control
Monitoring motor temperature in a high-friction application is controlled by
a line-powered SureCross Node and a Banner T-GAGE® temperature sensor.
The SureCross Gateway transmits operational conditions to the plant control
room using a digital output related to temperature setpoints within the
sensor. The motor is powered down or up based on these temperatures.
Monitoring of Rotating Equipment
The SureCross wireless network eliminates complexities associated with
data acquisition from rotating and moving machinery such as a rotating
kiln. Crucial temperature data is acquired using a thermocouple and
transmitted from the FlexPowered SureCross Nodes to a remote Gateway
in the plant’s control center. Excessive heat triggers an alarm. Data is
always concentrated in the same location for processing or analysis, and
physical risks to personnel are eliminated.
Remote and Tank Farm Monitoring
Monitoring levels, pressure, ow rates or temperatures from dicult-toaccess platforms, towers and large tank farms has historically been a
signicant challenge. Today, FlexPowered SureCross Wireless Nodes
equipped with low-powered sensors can monitor and acquire data
remotely, overcoming logistical hurdles and eliminating risk to personnel.
11
Factory Automation
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
Applications
EXAMPLE APPLICATIONS
The Gateway to Error-Proong Manufacturing.
The Banner Wireless Network is the cost-eective
key to making existing manufacturing facilities and
process tasks align with ecient lean production
principles. Hosts of Wireless Nodes can be deployed
across the production oor to add new remote
monitoring and control capabilities to existing
machinery, as well as to implement systems that
optimize inventory, reduce errors and minimize waste.
At the heart of lean production is the ability to
make small changes and renements. Lean is not a
single solution, but a combination of small steps that contribute to continuous
improvement. The versatile Banner Wireless Network oers the ability to quickly
implement, move, change, expand and rene processes as your needs change.
Where new wiring for power or communications is impractical, a Banner Wireless
Network can be implemented with battery-driven FlexPower™ Nodes that provide
both power for connected or integrated sensors, as well as communication to a
remote Gateway. Now entire error-proong and monitoring systems become portable
for redeployment at will, and installing sensors in locations and on equipment is now
possible where never before.
Banner Wireless Nodes and Gateways reliably orchestrate Banner EZ-LIGHT™
pick-to-light sensing systems to virtually eliminate human error from parts picking
and assembly processes. Wireless parts-call automation keeps line inventories
replenished and saves oor space. Manufacturing, assembly, kitting and verication
processes run more eciently with greatly reduced errors.
Rotating Equipment Monitoring
Battery-powered Banner Wireless Nodes remotely transmit data without hardwired power
cables to monitor and control rotating machines while eliminating costly and cumbersome
slip rings.
Automated Parts Call
Remote, self-contained push buttons attached to Banner Wireless Nodes can be placed at
assembly line workstations to signal a Wireless Gateway-equipped automated guided vehicle
(AGV) for replenishment of assembly parts.
Error-Proong Manufacturing
Applying lean manufacturing principles in existing assembly facilities is easily and economically
facilitated by Banner EZ-LIGHT operator indicator lights and pick-to-light systems applied across
a Banner Wireless Network.
Robot End Eector
To eliminate frequent and unpredictable slip rings or ex cable failure on robotic arms, a
SureCross Wireless Node with FlexPower Module monitors the end eector. Two NAMUR
proximity sensors, each powered by the FlexPower Module, are characterized for power draw,
allowing predictable, scheduled replacement of the battery.
12
Wireless Conveyor Monitoring. Banner Wireless Nodes with optional FlexPower™
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
and low-power Banner sensors combine to create a portable monitoring system
that instantly integrates into a legacy overhead conveyor without new hardwiring.
Nodes travel with the product, providing remote monitoring and control using
the Wireless Gateway.
13
Agriculture and Water Management
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
Monitoring operational status
in critical systems such as barn
ventilation or temperature control
equipment can prevent loss of
livestock or spoilage of other
resources that can occur within
minutes of a power loss. A
SureCross™ Wireless Node
equipped with FlexPower™
and a ow sensor is isolated
from the power grid to
monitor system status, issue
alarms and notications,
and/or to trigger backup
power systems to restore
environmental conditions.
Remote and Field-Based Monitoring is Now a Reality.
Field-based agribusiness and water management applications have long suered
from the inability to monitor operational status, levels, temperature and other crucial
information. Now the convergence of the powerful SureCross™ Wireless Network and the
longevity of SureCross FlexPower™ supplies provide easy-to-apply solutions to the toughest
monitoring challenges.
A host of SureCross antennas, power options, connectivity solutions and a complete range of
sensors oer capabilities never before available. Solutions can be easily integrated within, or provide
output to, existing operations and management software.
Banner has taken the robust RF performance and bidirectional Rx/Tx communication capabilities of
SureCross to deliver the rst practical, wireless network for monitoring and control. FHSS communication
protocol plus fully-acknowledged data transfer provide unprecedented communications reliability, but
only Banner’s congurable default output condition can provide the predictable response needed for critical
control applications. With congurable default output conditions, your system’s response to wireless signal
interruption is in your control, allowing an actuator, valve or similar device to engage, disengage or hold—
returning the system to a known status and/or triggering other system events
until transmission integrity is re-established.
Rugged IP67 SureCross Nodes are built to perform in the most severe
environments and outdoor locations, including agricultural and agribusiness
applications. Temperature extremes, dust, moisture and remote locations
demand rugged, self-contained monitoring solutions. And SureCross solutions
are built to handle it. Continuous, reliable monitoring of resources, status,
temperature, ow, levels and more help to optimize ag-based operations and
maximize yields while reducing losses and waste.
14
EXAMPLE APPLICATIONS
Applications
Environmental Temperature and Humidity Monitoring
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
SureCross™ Wireless Nodes equipped with FlexPower™ and a
thermocouple or RTD can be easily implemented for monitoring
optimal barn temperature ranges or dairy bulk tank temperatures,
triggering a setpoint alarm if the acceptable range is exceeded.
Specialized Nodes can accommodate temperature and humidity
sensors for monitoring and alarm output on one device.
Air Flow/Ventilation Monitoring
The ventilation system is monitored with a ow meter attached
to a Flex Node. An alarm is sent if the system fails, enabling the
sta to take action in the case of a lightning strike or other
unpredictable events that can lead to the loss of livestock.
Ethanol Plant Water Monitoring
Ethanol processing facilities can
use millions of gallons of water
per day. SureCross Wireless
Nodes equipped with FlexPower
and pressure sensors can precisely
monitor critical water holding tank levels, sending
data to a SureCross Gateway and Banner EZ-LIGHT™
status indicator in a remote control center location.
Municipal Water Monitoring
Monitoring multiple data points including ll level, pH,
conductivity and ow—often from varied locations in a large
water treatment plant—can be a challenge. With four analog
inputs, a single SureCross Node can easily centralize and
transmit critical monitoring information.
15
Rail Transport Car Positioning
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
M-GAGE™ Wireless Sensor Nodes embedded into tracks signal the arrival and
facilitate positioning of hoppers, tank and freight cars for loading and unloading.
EZ-LIGHT™ signals indicate rail car position to optimally align cars to spouts,
elevators and nozzles for more ecient transfers.
16
Trac Monitoring and Control
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
A More Dependable and Rugged Sensing Solution for the Demands
of Trac Management.
Applications
Conventional embedded solutions for trac management
and control, such as fragile inductive loop detection (ILD) systems,
are signicantly prone to failure. High failure rates associated with
ILD systems not only create inaccurate data that can lead to
inecient trac management, but make frequent and dicult
replacement of in-pavement inductive loops and weakened
pavement integrity a harsh reality.
Banner SureCross™ Wireless Networking greatly improves the
performance and reliability of embedded trac management and
control sensors. By doing away with the fragile inductive loop,
installation, service and operational life are exponentially increased.
Instead, ILDs are replaced by a wireless Banner M-GAGE™ sensor and integrated
FlexPower™ battery supply, encapsulated in a rugged IP67 SureCross Node housing.
The M-GAGE vehicle detection sensor is a passive, non-contact magnetic receiver that
reliably detects 3-dimensional changes in the Earth’s natural magnetic eld caused by
the presence of large ferrous objects.
The SureCross Wireless M-GAGE sensor replaces inductive loop systems and can
be used in applications such as car wash entry/exit, opening and closing high-trac
doors and detecting vehicles at drive-thru systems and turn lanes. This dedicated
solution—developed specically for wireless presence sensing—simplies in-ground
installation and oers quick and easy access for battery replacement after up to ten
years of trouble-free operation.
EXAMPLE APPLICATIONS
Automated Car Wash Detection
Vehicle presence is detected by an in-ground embedded M-GAGE Wireless
Sensor Node that activates the automated car wash system to power up
and trigger the entry door. The payment system and the car wash remain
in a low-power consumption standby mode until a customer arrives. It also
eliminates the inevitability of complex and costly inductive loop repair.
Loading Dock Occupancy Monitoring
For optimum workow and loading dock trac management, it’s
essential for dock workers to know of arrivals immediately. M-GAGE
Wireless Sensor Nodes mounted on each loading bay signal the arrival of
vehicles by illuminating remotely mounted Banner EZ-LIGHT™ indicators
that are visible throughout the facility. Supervisors can also be alerted to
arrivals using their PC or PDA. Workers assemble quicker at the appropriate
dock, cargo security and facility access are greatly enhanced and docks
are freed-up faster. Best of all, no through-wall wiring installation is
required to implement the system.
Parking Kiosk Access and Control
An embedded M-GAGE Wireless Sensor Node detects approaching
vehicles to activate automated parking control systems, payment kiosks
and automated access control barriers.
Train Yard Marshalling
Rugged IP67 M-GAGE Wireless Sensor Nodes embedded at various points
in tracks can be used for accurate remote monitoring of train car location
and marshalling. As cars pass from one sensor to another at changeover
locations, track controls can be activated to handle switching of
subsequent cars.
17
To monitor and control access of secure or supply areas, Banner SureCross™ provides turnkey wireless solutions. Highly
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
reliable security and response systems are easily retrotted into existing facilities to monitor access and control entry,
providing alarms or notications if doors are opened or left unclosed, or if emergency exits have been opened.
Modular Monitoring Capabilities.
Whether facility-wide or with a single-node, the SureCross™ Wireless Network
facilitates adding capabilities for monitoring, security and essential control with ease,
low cost and little-to-no disruption of existing systems. Easy-to-apply SureCross
Wireless Kits oer a complete, modular system that you can apply and move as
needed to dierent locations and for diverse applications. FlexPower™ battery options
create a completely portable system that is sensing unplugged. Systems can be
expanded as needed, and networks can be combined or divided as needs change.
Continuous, reliable facilities monitoring—whether for security, operational
eciency or condition—ensures smooth operation 24/7/365. Rudimentary security
and access challenges can be quickly addressed with any number of photoelectric
proximity sensors, contact closures, switches and detection sensors that, when
connected to a Node, can communicate wirelessly to the
Gateway in facility control centers or security oces.
Alarms and signal output to switches can trigger desired
responses within larger integrated systems. With the
SureCross Wireless Network, monitoring capabilities and
responses can be embedded wherever needed.
18
Commercial and Consumer Monitoring
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
EXAMPLE APPLICATIONS
Applications
Energy Monitoring/Management
A rooftop HVAC system can be activated based on facility requirements through a Wireless Gateway
located inside a facility’s physical plant. With this monitoring system, industry managers identify
opportunities where their facility could be more energy ecient and conserve plant resources.
Security/Access Monitoring
To monitor and control the entry to storage rooms in the back of a large facility, a proximity
sensor is used with a FlexPower Node. When the door is opened or closed an EZ-LIGHT™
connected to the Gateway signals the main oce.
Retail Trac Analysis
To understand trac ow and consumer habits in a retail environment, a SureCross FlexPower
Node and a Banner MINI-BEAM® sensor provide a discrete, peel-and-stick monitoring and
counting solution. Moved about the location to assess retail trac and optimal store layout, this
versatile system provides data to the Gateway located in the management oces.
Refrigeration System Temperature Monitoring
A SureCross FlexPower Node used with an RTD ensures an optimal temperature is maintained
within large cold chain storage systems for refrigeration, walk-in coolers, freezers or standard
grocery cases. The remote Gateway is located o the oor and issues an alarm to management
personnel if the temperature exceeds acceptable limits.
19
SureCross™ Gateway and Node Possibilities
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
• I/O can be tailored to accommodate up to 12 functions per device.
• Open design supports inputs from sensors and devices from Banner and other manufacturers.
• Multiple network and protocol options make it easy to link to industrial host systems.
• FlexPower™ devices enable sensing solutions never before possible.
What type of sensors
need to be wireless?
SureCross works with:
• Photoelectric
• Ultrasonic
• Inductive
• Capacitive
• Contact Closures
• Thermocouple
• Pressure
• Thermistor
• Distance
• RTD
• Level
• Flow
Do you use
Serial Comms?
SureCross supports:
• Modbus RTU RS-485
• Modbus RTU RS-232
• Modbus TCP/IP
• EtherNet/IP
How much I/O?
SureCross can provide:
• Up to 4 Analog IN
(current, voltage)
• Up to 8 Discrete IN
(sinking, sourcing)
• Up to 4 Analog OUT
(current, voltage)
• Up to 8 Discrete OUT
(sinking, sourcing)
20
More information online at bannerengineering.com
What types of power
are available?
SureCross power options:
• 10 to 30V dc
• AC options
• FlexPower supply options:
-FlexPower Battery Modules
-FlexPower Solar Modules
SureCross™ Configuration: Engineered Your Way
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
• Configured Kits are only a starting point; add Nodes through the configurable Gateway to
expand an application solution.
• Custom setup of I/O function, timing and network health monitoring is handled through a
configurable Gateway.
APPLICATION
SureCross™ Congured Kits.
Banner oers a large number of SureCross
wireless kits that are congured with
everything you need to solve many
common applications quickly and easily.
Preset functionality makes the network
easy to deploy and operate.
SureCross™ Unlimited Solutions.
Whatever the demands of your application,
congurable Gateways and Nodes can be set
to solve your most challenging remote sensing
scenarios. Conguration allows the assembly
of wireless networks using the exact SureCross
components required.
Modify
Alter Presets
Expand Conguration
FlexPower™ Settings
Custom Solution
ENGINEERED APPLICATIONS
SureCross™ Congured Kit
This application employs two NAMUR proximity sensors that interface with the FlexPower Node. Based on the power consumptive properties of
the sensors and the required sample interval of 250 milliseconds it was calculated that the DX81 FlexPower supply would last one year. Banner is
continuously building a library of characterized sensors from dierent manufacturers to make FlexPower solutions plug-and-play.
Cable Method
Robot Work Cell
Control Panel
To Robot’s
Sensors
Junction Box
18'
More information online at bannerengineering.com
SureCross™ Method
Robot Work Cell
To Robot’s
Sensors
Junction Box
DX81
Battery Box
DX80 NODE
Control Panel
DX80 GATEWAY
21
SureCross™ Plug-and-Play: Configured Kits
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
• One box houses the preset Gateway, Node(s), accessories and hardware to get you up and running quickly.
• The Gateway is configured to independently control I/O mapping for all devices within the kit.
• Network traits are preset to provide discrete I/O on change of state and periodic reporting of analog I/O.
Discrete
Analog &
Discrete
Flex
Power
Systems
†
Model Number FrequencyIcon*Gateway I/ONode 1 I/O Node 2 I/O Node 3 I/O Node 4 I/O Data Sheet
DX80K9M6DP1
DX80K2M6DP1
DX80K9M6DP4
DX80K2M6DP4
Model Number FrequencyIcon*Gateway I/ ONode 1 I/ONode 2 I/OData Sheet
†
DX80K9M6MP1
DX80K2M6MP1
DX80K9M6MP2
DX80K9M6MP2
™
Model Number FrequencyIcon*Gateway I/ONode 1 I/ONotesData Sheet
DX80K9M3PE1
DX80K2M3PE1
900 MHz
2.4 GHz
900 MHz
2.4 GHz
900 MHz
2.4 GHz
900 MHz
2.4 GHz
900 MHz
2.4 GHz
GN
GN
G
G
NNN
N
NNN
N
GN
GN
GNN
GNN
GN
GN
Discrete
4 IN & 4 OUT
Discrete
4 IN & 4 OUT
Modbus Enabled
Discrete
2 IN & 2 OUT
Analog
2 IN & 2 OUT
Discrete
2 IN & 2 OUT
Modbus Enabled
Analog
2 IN & 2 OUT
Discrete
2 OUT
(sinking)
Discrete
4 IN & 4 OUT
Discrete
1 IN & 1 OUT
2 IN & 2 OUT
2 IN & 2 OUT
1 IN & 1 OUT
1 IN & 1 OUT
(FlexPower™ supply
configured for MINI-BEAM)
Discrete
1 IN & 1 OUT
Discrete
Analog
Discrete
Analog
Discrete
1 IN
1 IN
(passive)
Discrete
1 IN & 1 OUT
DX81
included; provides power
for
1 IN & 1 OUT
Discrete
1 IN & 1 OUT
Analog
1 IN & 1 OUT
Flex
Power supply
Flex
Power Node and
MINI-BEAM
Discrete
129306
129308
129312
129313
129318
Discrete
DX80K9M3GE1
DX80K2M3GE1
* = Gateway = Node † = Discrete outputs are sourcing unless otherwise noted. Analog outputs are 0-20 mA.
G
ENGINEERED APPLICATIONS
SureCross™ Unlimited Solutions
900 MHz
2.4 GHz
N
GN
GN
Discrete
Modbus Enabled
2 OUT
(sinking)
Analog
2 OUT
(0-20 mA)
2 IN (passive)
Analog
1 IN
Flex
Power supply
(1
configured to provide 15V for
500 ms every 15 minutes)
1 IN
(passive)
Flex
Power supply
DX81
included; provides power
Flex
Power Node and
for
one analog sensor
129320
This application employs a congurable Gateway, a FlexPower Node and a 10 to 30V dc Node. The Gateway provides two functions: rst to
determine the appropriate valve control actuation and second, to extend transmission range for the application up to 6 miles. The FlexPower
Node is located in a remote location without access to power and cycles periodically to collect ow data for media. Based on this data, the
Gateway dictates the open and close action of the valve to the output on the 10 to 30V dc Node, which is located on the valve.
Flow
Sensor
OFF
To
Control
Valv e
DX80
Node
3 miles
DX80
Gateway
3 miles
DX80
Node
DX81
Battery
Module
10-30V DC
22
More information online at bannerengineering.com
10-30V DC
SureCross™ Gateway and Node Models
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
• A network consists of one Gateway and one or more Nodes that operate in the same frequency band.
• Each Network accommodates one Gateway and any combination of Nodes shown in the table below.
• Input-to-output mapping is controlled by a configured Gateway or supported through serial communication.
• Multiple antenna options available; internal antenna recommended for ranges less than 500 ft, external antennas enable ranges up to 3 miles.
Gateways
10 to 30V dc
LinePowered
Nodes
10 to 30V dc
Flex
Power
Nodes with
Switched
Power
Outputs
FlexPower
Supply
Model NumberFrequencyI/OAntennaData Sheet
DX80G9M6W4P4
DX80G9M6S4P4
DX80G2M6W4P4
DX80G2M6S4P4
DX80G9M6W2P2M2M2
DX80G9M6S2P2M2M2
DX80G2M6W2P2M2M2
DX80G2M6S2P2M2M2
Model NumberFrequencyI/OAntennaData Sheet
DX80N9X6W4P4
DX80N9X6S4P4
DX80N2X6W4P4
DX80N2X6S4P4
DX80N9X6W2P2M2M2
DX80N9X6S2P2M2M2
DX80N2X6W2P2M2M2
DX80N2X6S2P2M2M2
™
Model NumberFrequencyI/ONotesAntenna Data Sheet
DX80N9X2W2N2M2X
DX80N9X2S2N2M2X
DX80N2X2W2N2M2X
DX80N2X2S2N2M2X
900 MHz
2.4 GHz
900 MHz
2.4 GHz
900 MHz
2.4 GHz
900 MHz
2.4 GHz
900 MHz
2.4 GHz
4 IN & 4 OUT
(sourcing)(sourcing)
Discrete
Modbus Enabled
2 IN & 2 OUT
(sourcing)(sourcing)
4 IN & 4 OUT
(sourcing)(sourcing)
Discrete
2 IN & 2 OUT
(sourcing)(sourcing)
Discrete
2 IN & 2 OUT
(sinking)(NMOS)
Discrete
Analog
2 IN & 2 OUT
(0-20 mA)(0-20 mA)
Discrete
Analog
2 IN & 2 OUT
(0-20 mA)(0-20 mA)
Analog
2 IN
(0-20 mA)
FlexPower supply
Internal
External
Internal
External
Internal
External
Internal
External
Internal
External
Internal
External
Internal
External
Internal
External
Configurable
switched power
outputs provide
sensor actuation
voltage up to
24V dc from the
Internal
External
Internal
External
131291
131292
131293
131295
131296
Power
™
Model NumberFrequencyI/OAntennaData Sheet
DX80N9X2W2N2T
DX80N9X2S2N2T
DX80N2X2W2N2T
DX80N2X2S2N2T
DX80N9X2W0P0R
DX80N9X2S0P0R
DX80N2X2W0P0R
DX80N2X2S0P0R
DX80N9X2W2N2M4
DX80N9X2S2N2M4
DX80N2X2W2N2M4
DX80N2X2S2N2M4
DX80N9X2S0P0Z0
DX80N2X2S0P0Z0
* Thermocouple units default to J-type. Other types configurable
** RTD units default to 3-wire 100 Ohm. Other types configurable
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
QT50U
MINI-BEAM
M18
T30
K50L
K80L
Sensors
Optimized for
use with
FlexPower™
Systems
EZ-LIGHT
Indicators
Multi-Color,
7-f unc tio n
Model NumberSupply VoltageDescriptionSensing ModeRangeOutput Type Connection Data Sheet*
Other Colors
Available
Selectable:
0 to 10V dc or
4 to 20 mA
Bipolar
NPN/PNP
Bipolar
NPN/PNP
QT50ULBQ6-75390
SM312LPQD-76885
SM312DQD-75904
* Data sheets are for standard product, contact factory for additional supporting literature.
™
Model NumberConstructionConnectionLED FunctionInputsData Sheet
M18GRY2PQ
T30GRY2PQ
K50LGRY2PQ
K80LGRY2PQ
FlexPower™
MINI-BEAM
18 mm mount
Nickel-plated brass
30 mm mount
Thermoplastic polyester
30 mm mount
Thermoplastic polyester
Flat or DIN mount
Thermoplastic polyester
®
U-GAGE
Ultrasonic200 mm - 8 m
P
®
Photoelectric
4-pin Euro QD
POLAR RETRO
DIFFUSE
3 m
380 mm
Choose Red, Yellow
or Green ON, flashing
or alternating
5-pin
Euro QD
4-pin
Euro QD
4-pin
Euro QD
PNP121902
70137
69943
DX81
DX85
EZAC
Flex
Power
Supplies
AC Power
Supply
Options
Expandable
Remote I/O
™
Model NumberVoltage SuppliedDescriptionConnectionHousingData Sheet
DX81
DX121
**Replacement lithium primary battery model number is BWA-BATT-001
Model NumberVoltage SuppliedDescriptionConnectionHousingData Sheet
SPS101Q
SPS101SQ
EZAC-E-QE5-QS5
PS24W
Model NumberI/O FunctionalityDescriptionHousingData Sheet
DX85-4P4M2M2
DX85-6P6
FlexPower Battery
Module to supply
FlexPower Node
12V dc @ 120 mA max
24V dc @ 700 mA
24V dc @ 500 mA
2 Analog IN, 2 Analog OUT (0-20 mA);
4 Discrete IN (sourcing),
4 Discrete OUT (sourcing)
6 Discrete IN (sourcing),
6 Discrete OUT (sourcing)
Module driven by one lithium primary battery**
Module driven by six lithium primary batteries**131628
Converts 105 - 130V ac, 60 Hz to 12V dc
(SPST e/m Relay Output)
Converts 105 - 130V ac, 60 Hz to 12V dc
(Optically Isolated SPST Solid-state Output)
Converts 100 - 230V ac to 24V dc
(no output)
Converts 100 - 240V ac to 24V dc
North America (wall plug)
Modbus RTU Slave
Expansion I/O Modules;
used to expand Gateway
I/O capacity
5-pin Euro QDIP67
Sensor Connection:
5-pin Euro QD
AC Power Connection:
5-pin Mini QD
5-pin Euro QD
IP67
IP5466959
IP65120321
Non-
industrial
(not sealed)
131629
131599
131596
–
24
18
More information online at bannerengineering.com
SureCross™ Accessories
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
complete and integrated
line of sensing products.
No matter what industry
you’re in—or products you
manufacture—Banner has
the right sensors to automate
your plant, improve overall
eciency, quality and safety.
Choose from thousands of
standard DC sensing products
for line-powered (10 to 30V dc)
applications, or low-power
sensors—ideal for FlexPower
applications. Whatever your
need, we have the correct
sensor to solve your toughest
challenges.
Hardware
Request
Catalog
Bracket
SMBDX80DIN
DIN-rail flat mounting
FlexPower Solar Modules
Create a SureCross network completely
independent of line power with solar panels
and rechargeable batteries.
More information online at bannerengineering.com
FlexPower
Options
25
SureCross™ Antennas & Cabling Options
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
• Choose from a variety of direct and remote-mount and high-gain model options to get the best antenna for your application.
• A complete offering of cables and accessories is available for virtually every SureCross module and antenna location challenge.
High-Gain Yagi
Directional Yagi antenna can greatly
extend the range of any SureCross device.
Antenna
Options
Remote Antenna Cables
Offered in various lengths, low-loss cables can be
used to mount the antenna outside the SureCross
device installation location.
Antenna Adapter Cables
Various cables with many connector types
can be used to interface antennas and other
accessories to SureCross devices.
High-Performance Omni
Provide Omni directional coverage
and can be used to increase the
transmission range of the entire
SureCross network: available in
Direct-Mount
direct- or remote-mount versions.
Lightning Protectors
Safeguard your SureCross
network with simple maintenance
free lightning protection devices.
Remote-Mount
26
More information online at bannerengineering.com
SureCross™ Specifications & Dimensions
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
Product Specifications and Modifications Disclaimer
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. Visit bannerengineering.com for up-to-date product information before ordering.
General
Radio
Environmental
Power
Power Consumption
Mounting
M5 Fasteners – Max. Tightening Torque
Case Material
Weight
Indicators
Switches
Display
External Cable Glands
Cable Glands – Max. Tightening Torque
Range, with Standard 2dB Antenna
Frequency
Transmit Power
Spread Spectrum Technology
Antenna Connector
Antenna – Max. Tightening Torque
* Depending upon the environment and line-of-sight, high gain antennas are available to increase the range.
Environmental Rating
Operating Temperature
Operating Humidity
Shock and Vibration
** Please refer to the SureCross™ DX80 Quick Start Guide, Banner part number 128185, for installation and waterproofing instructions.
+10 - 30V dc or 3.6 - 5.5V dc low power option
< 1.4 W at 24V dc
#10 or M5 (M5 hardware included)
0.56 N/m (5 in/lbf)
Polycarbonate
0.26 kg (0.57 lb.)
Two LED, bi-color
Two push buttons
Six character LCD
Four PG-7 type, one 1/2-inch NPT type
0.56 N/m (5 in/lbf)
900 MHz2.4 GHz
Up to 4.8 kilometers (3 miles)*Up to 3.2 kilometers (2 miles)*
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
PRINTED IN U.S.A. Copyright, 2007 Banner Engineering Corp.
P/N 131620
Supplemental Information
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
SureCross™ DX80 Wireless Devices - Changing IP Address in Windows 2000
Overview: To use Ethernet communication with the DX80 Gateway Pro, configure the IP address of your computer.
Default IP Address:
192.168.0.1
Typical IP Address:
192.168.0.2
Procedure: To change the IP address of a Windows 2000 computer, do the following:
• Click Start > Network and Dial-up Connections > Local Area Connection
43
21
• Click Properties
• Choose Internet Protocols (TCP/IP) and click Properties
• Write down the existing address of your PC before changing it:
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
SureCross™ DX80 Wireless Devices - Changing IP Address in Windows XP
Overview: To use Ethernet communication with the DX80 Gateway Pro, configure the IP address of your computer.
Default IP Address:
192.168.0.1
Typical IP Address:
192.168.0.2
Procedure: To change the IP address of a Windows XP computer, do the following:
1
3
5
• Click Start > Connect To >
Show All Connections
4
• Click Properties
• Choose your
2
• Choose Internet Protocol (TCP/IP) and click Properties
Local Area Connection
• Write down the existing address of your PC before changing it:
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
SureCross™ DX80 Wireless Devices - Changing IP Address in Windows NT
Overview: To use Ethernet communication with the DX80 Gateway Pro, configure the IP address of your computer.
Default IP Address:
192.168.0.1
Typical IP Address:
192.168.0.2
Procedure: To change the IP address of a Windows NT computer, do the following:
1
• Click Start > Settings > Control Panel
3
2
• Double-click the Network icon
4
• Write down the existing address of your PC before changing it:
• Click the Protocols tab > TCP/IP Protocol > Properties
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
SureCross™ DX80 Wireless Devices - Changing IP Address in Windows 95, 98 & ME
Overview: To use Ethernet communication with the DX80 Gateway Pro, configure the IP address of your computer.
Default IP Address:
192.168.0.1
Typical IP Address:
192.168.0.2
Procedure: To change the IP address of a Windows 95, 98, or ME computer, do the following:
• Double-click the Network icon
1
• Click Start > Settings > Control Panel
3
2
4
• Click the IP Address tab
• Scroll down the components list
• Click on your Network Card after TCP/IP
• Click on PropertiesNOTE: There may be more than one TCP/IP component
on the list, so choose one that is similar to the
description of your Network Card.