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Technical Notes and Job Aids

Banner Engineering Corp. is committed to providing detailed technical content and educational material about our industrial wireless I/O network devices.

The following technical notes include instructions about integrating Sure Cross® products with other products and some example network configurations using the User Configuration Tool (UCT) or the MultiHop Configuration Tool (MHCT).

Finding InformationNetwork and Data SecurityProduct Specific QuestionsDevice ParametersWiringConfiguration ExamplesMultiHop Radios

General Information for the Sure Cross® Product Line

Wireless Glossary of Terms. Defines many basic radio and Banner® Sure Cross® terminology used in product documentation.

Certified Countries List. Banner Engineering maintains a list of all countries certified to use the Sure Cross radio products.

Using Sure Cross Radios with Existing Wi-Fi Networks. Will Banner’s wireless systems work with your existing 802.11 (Wi-Fi) network? Yes, it will work exceptionally well. Read this technical note for more information about using the Sure Cross radios with existing wireless networks.

Network and Data Security

Data Security. Using a proprietary protocol provides a higher level of data security than open protocols. Proprietary systems are more difficult to hack than an open standard. Banner Engineering Corp. developed a communication method that gives Sure Cross the ability to carry only I/O data signals between Nodes and Gateways.

Product Specific Questions and Answers

Power Solutions and Battery Life. Lists some sensors that have been evaluated for use with the FlexPower® Nodes. However, the sample and report rates used in your network configuration will affect the battery life. The slower the sample and report rates, the longer the battery will last. Depending on the sensor and configuration of your devices, your battery or battery pack can last anywhere from several months to more than 10 years.

Using 4 to 20 mA Sensors with 0 to 20 mA Analog I/O. When using a 4-20 mA sensor with a 0-20 mA input, the sensor uses the 4-20 mA section of the total range. Using a 4-20 mA with a 0-20 mA input allows you to determine when you have an error condition with the sensor. A normal input reading between 4 and 20 mA indicates a functioning sensor whereas a value below 4 mA indicates an error condition, such as a broken wire or loose connection.

Monitoring DX80 System Health. Described the differences between polling mode and heartbeat mode on the DX80 radios.

Mixing Performance Radios and DX80 Radios in the Same Network. To comply with federal regulations, the 150 mW radios and 1 Watt radios communicate differently. For this reason, to use Performance radios and DX80 radios in the same network, the Performance radios must operate in 250 mW mode, not 1 Watt mode. All Performance models offer the ability to select between 250 mW and 1 Watt operation using the DIP switches.

Interpreting Register Values. The units conversion table defines the type and range of values for each type of I/O. The wireless devices have many different units of measure for inputs including: milliamp (mA), voltage (V), temperature (°C or °F), humidity (RH), or a raw 16-bit or 32-bit value. Outputs can be either current (4–20 mA, 0–20 mA) or voltage (0–10 V dc). All values stored in Modbus registers are unsigned numbers, except for temperature readings. Temperature readings are stored as signed numbers (two's complement).

Materials List. Lists the materials used in the Sure Cross product line.

Sure Cross Device Parameters

Hysteresis and threshold work together to define the on and off points of an analog input.

Sample, report, and polling rates establish how often sensors, Nodes, and Gateways communicate with each other. These settings directly affect how long a battery-powered system can operate.

Thermocouples and RTDs measure temperature differently and are appropriate for different applications.

Monitor host timeouts. On a DX80 wireless network, there are two basic timeouts to monitor: radio link timeouts between the Gateway and its Nodes, and host timeouts between the host system and the DX83 or GatewayPro. This technical note describes how to use the Server Timeout parameter in the DX83/GatewayPro.

Extend the warm-up time. Follow these instructions to extend the warm-up time for switch powered sensors.

Wiring Issues

Using Dual Power Supplies. Common examples of this configuration include powering a FlexPower Gateway or Data Radio using the Sure Cross Solar Supply and using a DX81 or DX81P6 as a backup battery supply (in addition to the rechargeable battery pack that is already part of the solar power assembly). Another common example involves using a PS24DX 10 to 30 V dc power supply and a DX81 Battery Module as a battery backup.

Connect NAMUR sensors. Refer to this technical note to learn how to use NAMUR sensors with Banner's Sure Cross radios and how to configure the radios.

Create a DX80-to-RS485 cable. Download these instructions to learn how to connect a DX80 device to a Red Lion G3 HMI.

Use an EZ-AC Power Supply. Download these instructions to learn how to use an EZ-AC to power a DX80.

Wire a DX80...C Gateway to a DX85...C Modbus RTU Remote I/O device.

Wire a DX80...C Gateway to use the UCT cable.

Wire a DX80...C FlexPower Node to the DX81 FlexPower Battery Supply Module.

Connect a MultiHop radio to a PLC using RS-232 and a DB9 connection. This technical note shows which splitter cable to use to connect a MultiHop radio to a PLC.

Connect MultiHop radios to a variety of other devices.

Using a Solar Power System to Power any 4–20 mA Loop or Modbus Transmitter. This technical note details how to use the solar assembly to power a MultiHop radio and sensor.

Configuration Examples

Changing the IP Address in Windows. Instructions on how to change your computer's IP address for several versions of Microsoft Windows.

Setting a K-type thermocouple Node input to trigger a discrete output on the Gateway when the thermocouple temperature rises above 120° F using the User Configuration Tool (UCT) and extended control messages.

Converting a counter frequency to an analog output on a DX80 Gateway using the UCT.

Mapping a Node's Lost Link message to an output on a Gateway to trigger an alarm or light using the UCT.

Mapping temperature inputs to analog outouts using the UCT's Null and Span parameters.

Mapping one input to two outputs using the UCT.

Mapping DX85 I/O to a Node using the UCT.

Configuring a DX80 Gateway and DX85 Modbus RTU Remote I/O device as a Modbus master using the UCT.

Allen-Bradley Signed vs Unsigned Workaround. Converting the GatewayPro’s 16-bit unsigned integer to a 16-bit signed integer using Allen-Bradley’s Control Logix®.

DX80 Sample on Demand.

Mapping one input to another input. using the UCT and extended logic.

Configuring a flash pattern for an EZ-LIGHT using the UCT.

Customizing a mapped alarm state using the User Configuration Tool (UCT).

Mapping Multiple 12 I/O Nodes to the 12 I/O Gateway technical note explains how to use the 12 I/O devices with the custom configuration options and gives a detailed example of how this works.

Mapping 12 I/O Inputs to Multiple 12 I/O Outputs also explains how to use the 12 I/O devices (Performance P7 and P8 models) with the User Configuration Tool.

Enabling host timeout error conditions. If the host system and Gateway do not interact within an established time, it is considered a host communication timeout error and all outputs will be set to a user defined default state.

Configuring for continous switch power or Host controlled switch power. Switch power outputs on a DX80 device are variable power supply outputs that can be used to power external devices. The switch power outputs are typically used in short bursts to turn on a sensor, sample the sensor output, and turn off the sensor, which is accomplished by the DX80 device running from a 3.6 volt battery and specific timing parameters. Some applications want to control the switched power outputs from the host or would like to always have the switched power output active.

Convering an Analog OUT to 0-20mA. Using something other than a 0-20 mA sensor on a 0-20 mA analog output.

Converting an Analog IN to 0-20mA. Using something other than a 0-20 mA sensor on a 0-20 mA analog input.

Manually assigning extended address (binding) codes to Gateways and Nodes. This is particularly useful when you are replacing a Gateway or Node in an existing network and do not want to distrupt the performance of the network.

Programming a GatewayPro Using the UCT. This technical note shows you how to use the UCT to configure your network when you are using a GatewayPro by removing some jumpers. After using the UCT, you must return the jumpers back to their original position.

Windows 7 and the User Configuration Tool. Some computer systems running Microsoft Windows 7 may not run the User Configuration Tool if the user is not configured with administrator rights on the computer system.

Bit Packing Information into Registers. Bit packing involves using a single register, or range of contiguous registers, to represent multiple I/O values, instead of using a single register for each I/O value. Several of the newer Sure Cross models use bit packing to store discrete data.

Using the DX99 Radar Boost Model’s Switch Power. The DX99N...D5 model features two 4–20mA inputs, one discrete NPN input, one 3-wire RTD input, and a switch power connection. The switch power control uses a unique algorithm to optimize the functionality and power use of the DX99, allowing the DX99 to efficiently power external sensors.

Configuring the DX99...D5 Radar Boost Node. Describes how to configure the DX99N9X1S1N0M3X0D5 or DX99N2X1S1N0M3X0D5 Node to work with an Endress + Hauser FMR 245 (4-20 mA) or VEGAPULS 62 (PS62.UXCAE3DANXX) Radar Sensors.

Configuring the DX99...D4 Comms Boost Model to work with a Siemens Model 2100 Digital Level Sensor. This technical note describes how to configure the DX99N9-2100-ASSY and DX99N2-2100-ASSY kits to work with a Siemens Model 2100 Digital Level Sensor.

Changing the Binding Code (XADR) Using Modbus Registers. To change a binding code from a host system, use the Gateway’s Modbus control registers.

Converting a Discrete Input into a Synchronous Counter. Any discrete input can be converted to a synchronous counter, as long as the synchronous counter rate is less than 10 Hz and the pulse width is greater than 62.5 milliseconds.

Entering Binding Mode from a Modbus Host Controller. Includes instructions on how to start binding mode on either a MultiHop radio or a Gateway from your Modbus Host Controller system.

MultiHop Radios

Connecting a MultiHop radio to a PLC using RS-232 and a DB9 Connection. This technical note shows which splitter cable to use to connect a MultiHop radio to a PLC.

Connecting MultiHop radios to a variety of other devices.

Cable Replacement Configuration. A quick, one-page cheat sheet covering how to replace a cable connecting two Modbus devices with two MultiHop radios.

Performing a site survey of the MultiHop radio measures the signal quality between two devices. A site survey can be initiated from the LCD menu on any MultiHop radio or from a host system.

Switch Power Configuration. Switch power can be linked to a specific input or can be configured to supply continuous power to a device.

Configuring for Continuous Power Output. One switch power output can be configured to supply continuous power to a sensor.

Low Power Applications. Changing some default settings optimizes MultiHop radios for low power applications.

Restoring factory defaults to a MultiHop radio by writing to these four registers.

Bootloader screen updates the firmware and EEPROM files and allows you to view the firmware version numbers. Updating the firmware or EEPROM files typically requires that someone from the factory sends you an updated program file.

Route messages while operating in transparent mode by using the Destination Address parameter.

Formational Percentage. Adjust the minimum acceptable site survey link quality (formational percentage) to join to a parent radio. Increase the formation percentage to force slave radios to create a radio link to repeaters instead of the master radio. For long-range applications with weak radio signals, users can decrease the acceptable link strength.

Network Formation Tables. Describes how the MultiHop radios form their networks.

Default Output Conditions. Three default conditions may be used to set outputs to defined default states.

Sample on Demand. Allows a host control system to force selected inputs on a MultiHop radio to immediately sample.

Configure a DX83 Ethernet Bridge as the Modbus Master device to control MultiHop radios.

Mapping a push button input on a DX85 to an EZ-LIGHT output on a MultiHop Radio using the UCT.

Configuring a MultiHop radio to act as a mobile asset creates a MultiHop radio able to join different networks as it travels within range of the networks.

Manually assigning a binding code. Use the buttons and menu system displayed on the LCD to manually assign a binding code to a MultiHop radio.

Configure your host system to detect when a MultiHop radio has lost its radio link with the rest of the MultiHop network.

Disabling sleep mode or adjusting the sleep mode parameters.

Using a Solar Power System to Power any 4–20 mA Loop or Modbus Transmitter. This technical note details how to use the solar assembly to power a MultiHop radio and sensor.

Using the MultiHop Configuration Tool with the MultiHop Etherent Data Radio. The MultiHop Configuration Tool can be used with the Ethernet Data Radios to examine the network topology, conduct a site survey, or adjust parameter settings.

Using Data Radios to Connect an M-GAGE or R-GAGE to the Banner GUI. Learn how to connect your M-GAGE or R-GAGE sensor to the Banner sensor GUI.

Entering Binding Mode from a Modbus Host Controller. Includes instructions on how to start binding mode on either a MultiHop radio or a Gateway from your Modbus Host Controller system.

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