Banner Wireless Network User Manual

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SureCross™ wireless from the most reliable name in sensing.
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Contents
SureCross Sensing Unplugged™ 4
SureCross Advantages 6
System Overview 8
Factory
Agriculture and Water
Trac
Process Control and Monitoring 10
Factory Automation 12
Agriculture and Water Management 14
Trac Monitoring and Control 16
Commercial and Consumer Monitoring 18
SureCross Options 20
SureCross Conguration 21
SureCross Congured Kits 22
SureCross Gateway and Node Models 23
SureCross Accessories 24
SureCross Antenna Options 26
SureCross Specications and Dimensions 27
Commercial
2
When the world thinks of sensors, it thinks of Banner.
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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 dierent 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 specic.
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™.
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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 fulll 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
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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 oers easy, reliable communication between disparate products and processes in a single scalable and unied 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 retrot, 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
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SureCross™. Purpose-built by Banner.
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While wireless monitoring is far from new, Industry has had to wait patiently for robust bidirectional network devices that oer a feature set designed specically 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 oers 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 specic actions to a communication failure by driving user­dened 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 oers 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
Congurations
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.
Congure your SureCross wireless network with Gateway and Node components set to your specications. Or choose SureCross Kits that are congured 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 congurations that integrate seamlessly into your legacy systems and solve your most demanding applications.
7
SureCross™. Powerful Capabilities. Sophisticated Functionality.
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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 congured 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. Identied 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.
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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 Conguration Access Push Buttons—
click through menu-driven conguration
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 conguration 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—
simplies 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. Ecient power management technology enables the FlexPower battery system to briey 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 congurable 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
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and aordable. 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
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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 congurable default output condition that denes what happens if the system loses the RF signal. This unique network characteristic lets you dene 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 Retrot in a Pre-Certied 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 dicult-to­access platforms, towers and large tank farms has historically been a signicant 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
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Applications
EXAMPLE APPLICATIONS
The Gateway to Error-Proong Manufacturing.
The Banner Wireless Network is the cost-eective key to making existing manufacturing facilities and process tasks align with ecient 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 renements. Lean is not a single solution, but a combination of small steps that contribute to continuous improvement. The versatile Banner Wireless Network oers the ability to quickly implement, move, change, expand and rene 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-proong 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 verication processes run more eciently 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-Proong 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 Eector
To eliminate frequent and unpredictable slip rings or ex cable failure on robotic arms, a SureCross Wireless Node with FlexPower Module monitors the end eector. Two NAMUR proximity sensors, each powered by the FlexPower Module, are characterized for power draw, allowing predictable, scheduled replacement of the battery.
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Wireless Conveyor Monitoring. Banner Wireless Nodes with optional FlexPower™
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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.
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Agriculture and Water Management
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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 notications, 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 suered
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 oer 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 congurable default output condition can provide the predictable response needed for critical control applications. With congurable 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.
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EXAMPLE APPLICATIONS
Applications
Environmental Temperature and Humidity Monitoring
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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
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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 ecient transfers.
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Trac Monitoring and Control
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A More Dependable and Rugged Sensing Solution for the Demands of Trac Management.
Applications
Conventional embedded solutions for trac management and control, such as fragile inductive loop detection (ILD) systems, are signicantly prone to failure. High failure rates associated with ILD systems not only create inaccurate data that can lead to inecient trac management, but make frequent and dicult 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 trac 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-trac doors and detecting vehicles at drive-thru systems and turn lanes. This dedicated solution—developed specically for wireless presence sensing—simplies in-ground installation and oers 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 workow and loading dock trac 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.
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To monitor and control access of secure or supply areas, Banner SureCross™ provides turnkey wireless solutions. Highly
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reliable security and response systems are easily retrotted into existing facilities to monitor access and control entry, providing alarms or notications 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 oer a complete, modular system that you can apply and move as needed to dierent 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 eciency 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 oces. 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.
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Commercial and Consumer Monitoring
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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 ecient 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 oce.
Retail Trac Analysis
To understand trac 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 trac and optimal store layout, this versatile system provides data to the Gateway located in the management oces.
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.
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SureCross™ Gateway and Node Possibilities
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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)
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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™ Congured Kits.
Banner oers a large number of SureCross wireless kits that are congured 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, congurable Gateways and Nodes can be set to solve your most challenging remote sensing scenarios. Conguration allows the assembly of wireless networks using the exact SureCross components required.
Modify
Alter Presets
Expand Conguration
FlexPower™ Settings
Custom Solution
ENGINEERED APPLICATIONS
SureCross™ Congured 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 dierent 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 Frequency Icon* Gateway I/O Node 1 I/O Node 2 I/O Node 3 I/O Node 4 I/O Data Sheet
DX80K9M6DP1
DX80K2M6DP1
DX80K9M6DP4
DX80K2M6DP4
Model Number Frequency Icon* Gateway I/ O Node 1 I/O Node 2 I/O Data Sheet
DX80K9M6MP1
DX80K2M6MP1
DX80K9M6MP2
DX80K9M6MP2
Model Number Frequency Icon* Gateway I/O Node 1 I/O Notes Data 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
G N
G N
G
G
NNN
N
NNN
N
G N
G N
G NN
G NN
G N
G N
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
G N
G N
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 congurable 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 Number Frequency I/O Antenna Data Sheet
DX80G9M6W4P4
DX80G9M6S4P4
DX80G2M6W4P4
DX80G2M6S4P4
DX80G9M6W2P2M2M2
DX80G9M6S2P2M2M2
DX80G2M6W2P2M2M2
DX80G2M6S2P2M2M2
Model Number Frequency I/O Antenna Data Sheet
DX80N9X6W4P4
DX80N9X6S4P4
DX80N2X6W4P4
DX80N2X6S4P4
DX80N9X6W2P2M2M2
DX80N9X6S2P2M2M2
DX80N2X6W2P2M2M2
DX80N2X6S2P2M2M2
Model Number Frequency I/O Notes Antenna 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 Number Frequency I/O Antenna Data 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
900 MHz
(3 Thermocouple*
2.4 GHz
900 MHz
2.4 GHz
900 MHz
2.4 GHz
900 MHz
2.4 GHz Internal
& 1 Thermistor)
(sinking)(NMOS)
(Internal sensor, internal battery, multi-year life)
Temperature
4 IN
Discrete
2 IN & 2 OUT
Discrete
2 IN & 2 OUT
(sinking)(NMOS)
Temperature
4 IN
(3 wire RTD**)
Analog
4 IN
(0-20 mA)
M-GAGE™
Internal
External
Internal
External
Internal
External
Internal
External
Internal
External
Internal
External
Internal
131297
131597
131762
131598
Flex
Nodes
FlexPower Supply
More information online at bannerengineering.com
23
SureCross™ Accessories
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 Number Supply Voltage Description Sensing Mode Range Output 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 Number Construction Connection LED Function Inputs Data 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
Ultrasonic 200 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
PNP 121902
70137
69943
DX81
DX85
EZAC
Flex
Power
Supplies
AC Power Supply Options
Expandable Remote I/O
Model Number Voltage Supplied Description Connection Housing Data Sheet
DX81
DX121
**Replacement lithium primary battery model number is BWA-BATT-001
Model Number Voltage Supplied Description Connection Housing Data Sheet
SPS101Q
SPS101SQ
EZAC-E-QE5-QS5
PS24W
Model Number I/O Functionality Description Housing Data 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 QD IP67
Sensor Connection:
5-pin Euro QD
AC Power Connection:
5-pin Mini QD
5-pin Euro QD
IP67
IP54 66959
IP65 120321
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
Quick-Disconnect (QD) Cables and Cordsets
4-Pin Euro-Style Cables
5-Pin Euro-Style Cables
5-Pin Euro-Style Cordsets
Double Ended
5-Pin Mini-Style Cables
Model Number Style Length Used With
MQDC-406
MQDC-415
MQDC1-506.5
MQDC1-506
MQDC1-515
DEE2R-51D
DEE2R-53D
DEE2R-515D
MBCC-506
MBCC-512
MBCC-530
Hardware
Mounting Hardware
Model Number Description
BWA-HW-001
BWA-HW-002
Female Straight/
Unterminated
Female Straight/
Unterminated
Female Straight/
Male Straight
Female Straight/
Unterminated
Replacement mounting hardware packet
Replacement access hardware pack (5 plugs & 4 glands)
2 m
5 m
0.5 m
2 m
5 m
0.3 m
1 m
2.4 m
2 m
4 m
9 m
• MINI-BEAM
• EZ-LIGHT™
• DX80
• DX85
• DX81
• DX121
FlexPower™ Module
• Expandable I/O Module
• AC Power Supplies
Cordsets
Banner oers the most
®
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 eciency, 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 MHz 2.4 GHz
Up to 4.8 kilometers (3 miles)* Up to 3.2 kilometers (2 miles)*
902 - 928 MHz ISM band 2.4 - 2.4835 GHz ISM band
21 dBm conducted 18 dBm conducted, b 20 dBm EIRP
FHSS (Frequency Hopping Spread Spectrum) FHSS (Frequency Hopping Spread Spectrum)
Ext. reverse polarity SMA - 50 7 Ext. reverse polarity SMA - 50 7
0.45 N/m (4 in/lbf) 0.45 N/m (4 in/lbf)
NEMA 6 / IEC IP67**
-40 to +85° C (electronics); -20 to +80° C (LCD)
95% max. relative (non-condensing)
IEC 68-2-6 and IEC 68-2-7 Shock: 30g, 11 milliseconds half sine wave, 18 shocks Vibration: 0.5 mm p-p, 10 - 60 Hz
Compliance
Dimension Drawings
900 MHz Models
2.4 GHz Models
Gateway
FCC ID TGUDX80 - This device complies with FCC Part 15, Subpart C, 15.247
FCC ID UE300DX80-2400 - This device complies with FCC Part 15, Subpart C, 15.247 ETSI/EN: In accordance with EN 300 328: V1.7.1 (2006-05)
Node
60.0 mm
Detailed Dimensions
127.0 mm
127.0 mm
80.8 mm
80.8 mm
60.0 mm
More information online at bannerengineering.com
27
Banner Engineering Corp., 9714 Tenth Avenue North, Minneapolis, MN 55441 U.S.A.
Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: (800) 670-4183 ● www.stevenengineering.com
Phone 763.544.3164 Fax 763.544.3213 bannerengineering.com email: sensors@bannerengineering.com
1.888.3.SENSOR (1.888.373.6767)
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:
• Choose Use the following IP Address
• Change the IP Address to 192.168.0.2
• Change the Subnet Mask to 255.255.255.0
• Click OK
©2007 Banner Engineering Corp. • 9714 Tenth Avenue North • Minneapolis, MN 55441 USA
763.544.3164 • Fax 763.544.3213 • Toll Free 1.888.3.SENSOR (1.888.373.6767) • www.bannerengineering.com/training
. . .
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 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:
• Choose Use the following IP Address
• Change the IP Address to 192.168.0.2
• Change the Subnet Mask to 255.255.255.0
• Click OK
©2007 Banner Engineering Corp. • 9714 Tenth Avenue North • Minneapolis, MN 55441 USA
763.544.3164 • Fax 763.544.3213 • Toll Free 1.888.3.SENSOR (1.888.373.6767) • www.bannerengineering.com/training
. . .
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 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
©2007 Banner Engineering Corp. • 9714 Tenth Avenue North • Minneapolis, MN 55441 USA
763.544.3164 • Fax 763.544.3213 • Toll Free 1.888.3.SENSOR (1.888.373.6767) • www.bannerengineering.com/training
• Choose Specifiy an IP Address
• Change the IP Address to 192.168.0.2
• Change the Subnet Mask to 255.255.255.0
• Click OK
. . .
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 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 Properties NOTE: 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.
©2007 Banner Engineering Corp. • 9714 Tenth Avenue North • Minneapolis, MN 55441 USA
763.544.3164 • Fax 763.544.3213 • Toll Free 1.888.3.SENSOR (1.888.373.6767) • www.bannerengineering.com/training
Write down the existing address of your PC before changing it:
. . .
• Choose Specify an IP Address
• Change the IP Address to 192.168.0.2
• Change the Subnet Mask to 255.255.255.0
• Click OK
• Reboot the PC
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