Grayhill WM09STDB0001 Users Guide

Thunderbird Radio

Product Guide v0.64 (Preliminary)

Bulletin #1033

For Grayhill Part Numbers:

On the Internet: http://www.grayhilloem.ccom

OEM RF Unit - WM09STDB-0001

CF Card – WM09STDB-0002

561 Hillgrove Avenue

LaGrange, IL 60525

Phone: [phone]

Fax: [phone]

E-mail: [e-mail]

EZCom Thunderbird Radio – Product Guide v0.64

Copyright © 2004 Grayhill, Inc. All rights reserved.

The information supplied in this manual is believed to be reliable and accurate at the time of its publication. Grayhill, Inc. assumes no
responsibility for any errors, omissions, or suitability of its products for a particular application.

Warranty

EZCom Thunderbird radios from Grayhill, Inc., (the “Product”) are warranted against defects in materials and workmanship under normal
use, for a period of 1 year from the date of purchase. This warranty does not apply to units that have been abused or stressed beyond the
published environmental and electrical specifications. In the event of a product failure due to materials or workmanship, Grayhill will repair
or replace the defective product. This warranty is limited to the original purchase price of the unit and does not cover installation, labor or
any other contingent costs. For warranty service, return the defective product to Grayhill, shipping prepaid, for prompt repair or replacement.
The foregoing sets forth the full extent of Grayhill’s warranties regard the Product. Repair or replacement at Grayhill’s option is the
exclusive remedy.

THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND GRAYHILL SPECIFICALLY
DISCLAIMS ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL
GRAYHILL, ITS SUPPLIERS OR LICENSORS BE LIABLE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE
PRODUCT, FOR ANY LOSS OF USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS,
OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE
PRODUCT, TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW. SOME STATES DO NOT ALLOW THE EXCLUSION
OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES. THEREFORE, THE FOREGOING EXCLUSIONS MAY
NOT APPLY IN ALL CASES.

This warranty provides specific legal rights. Other rights which vary from state to state may also apply.

Ordering Guide

All programs and files on the CD included with this Product are protected by copyright. Grayhill, Inc. authorizes duplication of the contained
programs and files as necessary for use by the licensee; however, general distribution of these programs and/or files is strictly forbidden
without prior written consent from Grayhill, Inc.

EZCom Thunderbird OEM RF Module WM09STDB-0001
EZCom Thunderbird CF Card WM09STDB-0002
Standard Interface Board WLYY4097-1
AC Power Supply for Interface Board WL-PWR-9V
Product CD (contains Test File and Product Guide PDF) WL-WRD
Evaluation Kit - 2 RF Modules, 2 Standard Interface Boards, 2 DB-9 Cables, 2 AC Adapters, 2 Whip Antennas, 1 CD WLYY4098-1

For antenna options other than a whip antenna, contact Grayhill for the currently available antenna/coax choices.

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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EZCom Thunderbird Radio – Product Guide v0.64

Contents

EZCom Thunderbird Introduction............................................................................................ 5

Application Use .......................................................................................................................................5

RF Module Features................................................................................................................................. 5

Electrical and Mechanical Interfaces......................................................................................... 6

Connectors and Pinouts............................................................................................................................ 6

Antennas ..................................................................................................................................................9

Mechanical Interface..............................................................................................................................10

RF Module Mechanical Drawings .........................................................................................................10

RF Module 3-D Models .........................................................................................................................11

Standard Interface Board ......................................................................................................... 11

Setting the J5 Jumper ............................................................................................................................. 11

Connectors and Pinouts.......................................................................................................................... 12

Interface Board Mechanical Drawings...................................................................................................12

Interface Board 3-D Models...................................................................................................................13

Serial Interface.......................................................................................................................................13

Configuration ............................................................................................................................. 14

AT Commands.......................................................................................................................................14

Binary Commands..................................................................................................................................15

Operation.................................................................................................................................... 17

Standby Mode ........................................................................................................................................ 17

Transmit Mode....................................................................................................................................... 17

Receive Mode ........................................................................................................................................18

Low-Power Modes................................................................................................................................. 18

Networking ................................................................................................................................. 19

Vendor Identification Numbers..............................................................................................................20

Subnet IDs..............................................................................................................................................20

Radio Group Numbers ...........................................................................................................................20

Radio Addresses.....................................................................................................................................21

Radio Address Masks.............................................................................................................................22

Using the EZCom Thunderbird Evaluation Kit ..................................................................... 22

Evaluation Kit Contents.........................................................................................................................22

Evaluation Test Requirements ...............................................................................................................22

Assembly Instructions............................................................................................................................ 22

Appendix A. EZCom Thunderbird CF.................................................................................... 26

CF Interface ...........................................................................................................................................26

RF Connector and Antennas ..................................................................................................................26

PDA Support..........................................................................................................................................26

Configuring a Terminal Connection.......................................................................................................26

Opening a Terminal Connection ............................................................................................................27

Configuring the Thunderbird CF............................................................................................................27

Testing Thunderbird CF Data Transfer..................................................................................................27

Appendix B. Specifications........................................................................................................28

Appendix C. Agency Certification............................................................................................29

FCC Notices........................................................................................................................................... 29

OEM Labeling Requirements.................................................................................................................29

Appendix D. Mechanical Drawings.......................................................................................... 30

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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EZCom Thunderbird Radio – Product Guide v0.64

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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EZCom Thunderbird Introduction

EZCom Thunderbird Radio – Product Guide v0.64

Grayhill’s EZCom Thunderbird radio is a frequency-hopping wireless module that transfers
standard asynchronous
available in two formats:

• The Thunderbird – for host devices that have an available serial port

• The Thunderbird CF – for Windows CE handheld devices

Small in size and easily integrated into existing hardware, both Thunderbirds operate in the 900
MHz ISM frequency band and offer data rates up to 19200 bps, and ranges up to 24 miles
outdoors and 1800 feet indoors. The Thunderbird’s Frequency Hopping Spread Spectrum
(FHSS) technology achieves exceptionally secure data communication, resistant to noise and
interference.

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serial data streams over-the-air between host devices. The data radio is

Application Use

Wireless communications solve many otherwise impossible industrial and commercial
communications problems. Radio waves can transport data over long distances, through the heat
of blast furnaces and the cold temperatures that often prevail at outdoor installations. The
standard Thunderbird provides RF communications for fixed needs, such as manufacturing
control and security, business, and environmental monitoring. The Thunderbird CF allows
mobile personnel and portable equipment to communicate wirelessly.

Note: The standard Thunderbird’s functionality is covered in the first part of this manual.
Appendix A presents a brief description of the Thunderbird CF, and refers the reader to prior
sections when functionality is shared with the standard Thunderbird.

RF Module Features

Receiver Sensitivity: 10-6 BER, –105 dBm

Transmit Power: 160 mW (22 ± 2 dBm)

Frequency: 902-928 MHz for the standard module; 902-921 MHz for the anti-pager module

RF Range: Indoor/Urban – up to 1800 feet; Outdoor Line-Of-Sight – up to 24 miles

Serial Port: The module incorporates a 3.3V CMOS serial port for easy CPU interfacing.

Selectable Serial Data Rates: 2400, 4800, 9600, 19200, 38400, and 57600 bps

Signal Levels: 8 digital I/O with 5V-tolerant 3.3V CMOS signal levels; 3 additional digital I/O

that double as 12-bit A/D inputs

The module communicates directly with any UART interfaced host device through its serial
port, or with any RS-232 interfaced host device via the optional Grayhill standard interface
board.

Note: The RF module can provide simple, built-in I/O functions via its standard 100 mil. pitch
interface header, with no separate controller needed. Contact Grayhill for more information.

1

If a synchronous serial interface is required, please contact the EZCom Thunderbird project manager.

2

Upon request, Grayhill can supply an anti-pager RF module with a custom SAW filter designed to suppress the impact of pager and cell phone systems when

the Thunderbird is deployed very close to pager or cell transmitters.

2

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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EZCom Thunderbird Radio – Product Guide v0.64

Electrical and Mechanical Interfaces

The EZCom Thunderbird uses commonly available connectors and fasteners, and has been
otherwise optimized for easy integration into other systems.

Connectors and Pinouts

The Thunderbird RF module incorporates two connectors: the RF connector and the main
interface connector, as shown in Figure 1 below.

RF

Connector

Main

Interface

Connector

Figure 1. Thunderbird Connectors

Main Interface Connector

The RF module connects to a host device via a 2 x 11, 0.100" pitch male header with 0.025"
square posts. The connector supplies power and I/O, and also is the means whereby a UART­interfaced device can connect directly to the module. The header is gold-flashed for lower
contact resistance.

The outer row of pins (A1 – A11) on the main interface connector performs basic radio
functionality. The inner row of pins (B1 – B11) provides RS-485/422 support; customized
versions can provide analog inputs and digital I/O. See Table 1 and Figure 2 on page 7 for more
information.

Mating Connectors

For the host device, a female 22-pin connector that uses at least two points of contact per pin is
recommended. In high vibration and shock applications, consider using one of the more
expensive 22-pin connectors with 4 points of contact, or else solder the header into your PCB.
Example female 22-pin connectors with 2 points of contact per pin are listed here:

Female 22-Pin Connectors with 2 Points of Contact

Digi-Key PN 15-44-4111-ND Available at Digi-Key, 800-344-4539 or www.digikey.com
Samtec PN CES-111-01-G-D Available at Samtec, 800-726-8329 or www.samtec.com

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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EZCom Thunderbird Radio – Product Guide v0.64

Table 1. J2 Pin Signal Descriptions

Module Pin Signal Name I/O When Active Description

A1 FOUT O* Low Flow Control Out

A2 Power Down I* High When driven high, module powers down.

A3 DO (Data Out) O* N/A

A4 DI (Data In) I N/A

A5 FIN I** Low

A6 RESET I* Low Resets module parameters to defaults

A7 RX O High Receive LED pulses high during RF reception.

Low

A8 TX / PWR O

High

A9 CONFIG I*** Low

A10 VCC I - 4.5-15 VDC ± 5% V regulated

A11 GND - - Ground

* Pin uses a 10K Ω Pull-Up resistor (already installed in the module).

** Pin uses a 10K Ω Pull-Down resistor (already installed in the module).

*** Pin uses a 100K Ω Pull-Up resistor (already installed in the module).

Serial data leaving Thunderbird module

(to host, from over-the-air)

Serial data entering Thunderbird module

(from host, to over-the-air)

Flow Control In /

Binary Command Mode Control

Transmit LED pulses low during transmission.

At power-up, PWR driven high; remains high

Hold low during reboot to enter AT Command

Mode (backup method for command sequence)

Note: When integrating the Thunderbird with a host PC board, ensure all unused lines are left
disconnected (floating).

A

1

F

-

U

O

2

A

W

P

-

A

3

-

D

A

4

-

A

6

A

8

A

9

A

A

T

R

D

O

W

N

A

A

T

U

O

T

D

A

T

A

I

N

A

-

5

I

N

F

-

E

S

R

T

E

A

7

R

X

-

-

/

T

X

W

P

R

-

O

C

N

F

I

G

1

0

V

-

C

C

1

1

G

-

D

N

B

1

-

3

-

6

P

0

-

B4-11 - I/O 0-7

2

Figure 2. Main Interface Connector Pinouts

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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EZCom Thunderbird Radio – Product Guide v0.64

RF Connector

Three types of RF connectors are available:

• Soldered ¼ wave wire antenna

• Reverse Polarity SMA (RP-SMA)

• MMCX

Note: Though usually installed topside, the RF connector can be installed on the underside of
the module. Contact Grayhill to request this installation variation.

Soldered Wire Antenna

If your application is mainly short-range, a soldered wire antenna should be more than sufficient.
The integrated antenna will have poorer range performance than larger antennas or antennas
with better placement, but it is by far the least expensive antenna solution.

Reverse Polarity SMA Connector

The Reverse Polarity SMA connector is the best choice for remotely mounted antennas such as
those placed on equipment boxes. An example of an RP-SMA connection is a Thunderbird
radio mounted inside a NEMA enclosure for protection from the elements (see Figure 3 below),
with a lightning arrestor used as a bulkhead feed-through connecting to an external coax, which
in turn connects to an antenna mounted on a tower.

Antenna

Female

N-Connector

Male

N-Connector

Good

Low-Loss

Coax

NEMA Box

Male N-Connector

Female N-Connector

Male N-Connector

Gasket

¼" Coax Cable

Lightning

Arrestor

Female N-Connector

RP-SMA

Connector

Thunderbird

Figure 3. NEMA Box Connection

The connection inside the box is usually accomplished via a high-quality ¼" diameter coaxial
cable, like the Times LMR-195 or similar, as these coax choices are easier to route inside a box
than the 0.400" or 0.600" diameter coax products commonly used to run up the side of a tower.

For tighter mounting restrictions, an RP-SMA connection can be extended off the PCB with a
soldered coax pig-tail. This kind of connection would use an RG-316, 0.140" diameter coaxial
cable. The RG-316 has a large attenuation factor, so it should not be more than 12" long.

MMCX Connector

The MMCX connector provides a push-on, snap-action connection designed for a very limited
number of insertions. The MMCX connector is best for miniature coaxes most often seen where
very tight spaces and short runs are involved. Example uses for MMCX connections are mobile
and portable applications. An RP-SMA connector can also be used for those applications where
a screw-on connector is required.

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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EZCom Thunderbird Radio – Product Guide v0.64

Antennas

Several common antennas have been pre-qualified for use with the Thunderbird RF module,
including a high-gain patch antenna for directional links and a high-gain, omni-directional
antenna for wide-area coverage.

Only Grayhill-approved antennas and cables should be used with this radio. If none of the
antennas listed in the RF Module Approved Antenna Lists (below) meet your needs, Grayhill
can provide or suggest an antenna solution that will be optimal for your application and will
meet FCC requirements.

For optimal antenna operation, it is important that an antenna have an unobstructed line-of-sight.
Radios with ¼ wave wire antennas soldered to their PCBs and no obstructions in their lines-of­sight work much better than radios with more expensive antennas that have obstructions in their
lines-of-sight. An unobstructed line-of-sight means there is no non-gaseous matter with particles
larger than 0.020" diameter between the antennas. Fog and smoke should not pose a problem.

Note: Plastic generally does not cause line-of-sight problems unless the carbon content of the
plastic is high (carbon is usually added for EMC shielding). Some colorants used in plastic­making can also pose line-of-sight problems. Metal, stone and anything that absorbs water is
considered an obstruction.

RF Module Approved Antenna Lists

Table 2. Antennas with 20 cm. Minimum Separation Distance

Antenna Type Manufacturer

Yagi Maxrad BMOY8905 9 WL-ANT-Y9A

Yagi LM BYSS-090-09-01 9 WL-ANT-Y9LA

Patch LM BPAS85-090-08-11SW 8 WL-ANT-P9LA

Patch Maxrad MP8068 8 WLHH1434-1

Omni Maxrad MFB9157 7 WL-ANT-MN7A

Omni Maxrad MFB9153 3 WLHH1230-1

Manufacturer

Part Number

Gain

(dBd)

Grayhill

Part Number

Table 3. Antennas with Smaller Minimum Separation Distances

Antenna Type Manufacturer

PCB Dipole Centurion Revie PRO 0 01HH5222-2 N/A

Whip Maxrad MEXE902 -0.5 WL-ANT-W9MA 3 cm

¼ Wave Integrated

Wire Antenna

Note: To obtain approval of other antennas for use with the EZCom Thunderbird RF module, contact
Grayhill. Grayhill can also supply cables to OEM clients.

Grayhill

Manufacturer

Part Number

Permanent

Antenna Wire

Gain

(dBd)

-3 WM09STDB-0003

Grayhill

Part Number

Min. Separation

Distance

5 cm

!

WARNING: This device has been tested with the antennas listed in Tables 2 and 3 above.

When integrated into OEM products, fixed antennas require installation that prevents end users
from replacing them with non-approved antennas. Antennas not listed in Tables 2 and 3 must
be tested to comply with FCC Section 15.203 (unique antenna connectors) and FCC Section

15.247 (emissions).

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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EZCom Thunderbird Radio – Product Guide v0.64

Mechanical Interface

The Thunderbird was designed to be bolted to a host PCB and has mounting holes for #6 socket
head cap screws for this purpose. You can bolt the radio board itself to a panel or fixture. If you
decide to mount the RF module away from the electrical device to which it connects, plug a
ribbon cable into the main interface connector to bring the signals out. With the right length of
screw standoff, it is possible to capture the ribbon cable connector in such a way that it will not
come off unless the screws holding the PCB to the surface on which it is mounted are removed.
This method secures the cable against vibration.

3.3V CMOS Logic

FOUT

DI (Data In)

Microcontroller

FIN

DI (Data Out)

Thunderbird

Radio

Figure 4. Communications with UART Interfaced Host Devices

Another way to mount the Thunderbird on a host is to connect the module to the Grayhill
interface board via the main interface connector, and then bolt the interface board to the host.
The interface board’s screw holes are larger than those on the Thunderbird PCB, and will
accommodate any standard #6 screw. Use of the interface board also allows for I/O signals to be
brought out on a separate connector from the serial interface. See the Standard Interface Board
section below for more information.

Your RF cabling should be kept as short as practical and secured in such a way that it will not
vibrate and wear the insulation off. To have the cabling pass through the side of a box or case,
use a bulkhead fitting. For fixed systems, the bulkhead fitting should be a lighting arrestor.
Grayhill can provide suitable lightning arrestor kits (Grayhill Part Number WL-ARST-1). The
coax connection to any outside enclosure should be in the bottom of the enclosure to allow for a
drip-loop on the coax.

RF Module Mechanical Drawings

DXF files supplying mechanical drawings of the EZCom Thunderbird RF module are available
at www.grayhilloem.com. See Figure 15 on page 30 for large-scale mechanical drawings of the
standard Thunderbird radio.

© 2004 Grayhill, Inc., Confidential and Proprietary Page

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