Banner Wireless Network User Manual

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● 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: [phone] ● www.stevenengineering.com

Process

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.

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● 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 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™.

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● 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 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

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● 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 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

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● www.stevenengineering.com

SureCross™. Purpose-built by Banner.

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● www.stevenengineering.com

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.

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● 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 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.

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● 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 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

Courtesy of Steven Engineering, Inc. ● 230 Ryan Way, South San Francisco, CA 94080-6370 ● General Inquiries: [phone] ● www.stevenengineering.com

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