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 SureCross® products with other products and some example network configurations using the User Configuration Tool (UCT) or the MultiHop Configuration Tool (MHCT).

Finding Information • Network and Data Security • Product Specific Questions • Device Parameters • Wiring • Configuration Examples • MultiHop Radios

General Information for the SureCross® Product Line

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

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

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 SureCross the ability to carry only I/O data signals between Nodes and Gateways.

Product Specific Questions

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 4-20 mA Sensors with 0-20 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 (0–10V dc). All values stored in Modbus registers are unsigned numbers, except for temperature readings. Temperature readings are stored as signed numbers (two's complement).

SureCross® 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 SureCross 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 30V 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 SureCross 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.

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 0-20mA sensor on a 0-20mA analog output.

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

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.

Setting the baud rate to 2400 on your MultiHop radios.

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.

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