SureCross DX81 FlexPower Supplies
FlexPower supplies provide a reliable solution for remote power and hard-to-access locations.
- FlexPower battery modules supply power to FlexPower Nodes. The DX81 module uses one lithium primary battery.
- FlexPower batteries feature efficient power management technology.
- The battery provides brief switchpower voltage to activate a sensing device.
- Once activated, the input reads the sensor, and then the switchpower shuts off to prolong battery life—up to 5 years.
- The actuation voltage, time on and sample are configurable parameters, with voltage up to 24V dc.
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Monitoring Environmental Conditions
A semiconductor fab needs to monitor temperature, relative humidity, and oxygen levels at multiple points within their processing plant, along a 2 kilometer long process piping system. They require a solution that monitors temperature, relative humidity, and oxygen levels, provides a location for the monitoring points, and collects all data to a central point and interfaces with their SCADA system. The solution needs to create an efficient, safe work environment for all employees. With over 2 kilometers of underground tunnel piping systems, installing cable to each monitoring location is cost prohibitive.
Motor Condition Monitoring for Predictive Maintenance
FlexPower Nodes equipped with thermocouple or RTD sensors were mounted near the monitored motors. The sensor data is sent to a Gateway installed in a central control location. The temperature set point can be established to meet the applications requirements and then provide a discrete output from the Gateway. When predetermined temperature levels are detected, the red light of a stack light connected to a Gateway lights up, alerting personnel that maintenance is required.
Thermal Remediation Temperature Measurement
The EPA has placed restrictions on the use of many fumigants citing a correlation between their use and ozone depletion. As an alternative, a large-scale flour mill performs three to four thermal remediations per year to eradicate flour beetles. The temperature inside the mill is brought up to 122° F (50° C). This is done gradually to minimize equipment and building strain caused by heat expansion.
Valve Temperature Monitoring at a Steam Power Plant
To allow for quicker, more frequent, and more efficient scanning of target valve population tailpipe temperatures, a series of FlexPower Thermocouple Nodes and FlexPower Battery Supply Modules are installed. Temperature measurements of the valves and pipes are measured and wirelessly transmitted to a DXM100 Wireless Controller mounted in a central location. The DXM100 gathers the data and transfers the data to a SCADA system that monitors and graphically displays the temperature data.
Monitoring Rotating Kiln Temperatures
The SureCross Wireless Sensor 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 or RTD and transmitted from the FlexPower Nodes to a remote Gateway in the plant's control center. Data is always concentrated in the same location for processing or analysis, and manual data collection and physical risks to personnel are eliminated. Temperature data is logged and anal
Level Monitoring On Rotary Filler System
Banner’s Sure Cross wireless system can easily transmit temperature, pressure and fill levels to a local PLCs. The wireless system will seamlessly alert operators if bottling is occurring below the desired fill level. This helps prevent errors and leads to greater consistency in bottled beverages. Consistent fill levels mean no recalls—and no wasted products. Using a wireless system also eliminates the need for slip rings on the rotary filler, which in turn reduces maintenance costs.
Day Tank Level Monitoring
Using a wireless level monitoring system, day tank fill levels are now monitored continuously so that materials are maintained at a specific quantity. Because these tanks are slowly filled or depleted, ultrasonic sensors can be used to measure the tank levels without false readings or tank wall interference. With a SureCross Wireless Network, FlexPower™ Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a T30UF ultrasonic analog level sensor to operate for years on a single DX81 battery power supply. Remotely located tank sensor readings can be forwarded to a host system for data tracking, sending e-mail alerts, or to trigger specific events, such as refilling the tank. Tank resources are only filled when necessary to maintain customer-defined levels. Time is no longer wasted performing routine refills on tanks that did not need to be refilled.
Wireless Water Treatment Monitoring in Unsafe or Harsh Conditions
In most waste water installations, the locations are not wired for power or data transfers. With a SureCross Wireless Network, FlexPower Nodes are deployed at each holding unit without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with an ultrasonic analog level sensor to operate for years on a single DX81 battery power supply.
Wireless Tank Level Analysis in Unsafe or Harsh Conditions
Banner’s SureCross DX99 wireless FlexPower Nodes offer Class I, II, and III, Division 1 and Zone 0 certifications for installations requiring Intrinsically Safe operation. With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a pressure sensor to operate for years on a single DX81 battery power supply.
Wireless Tank Farm Monitoring in Unsafe or Harsh Conditions
With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a pressure sensor to operate for years on a single DX81 battery power supply.
Tank Farm Monitoring
With a Sure Cross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with an ultrasonic analog level sensor to operate for years on a single DX81 battery power supply. A DX80 FlexPower Node offers a combination of discrete and analog I/O in a single package, eliminating the need for time-consuming manual data collection.
Water Tower Level Monitoring and Pump Control
A submersible pressure sensor and float switches connected to a FlexPower™ Node provide constant monitoring of water tower levels and wirelessly transmits data to a Gateway mounted near the pumps.
Landfill Leachate and Ground Well Monitoring
A single FlexPower™ Node equipped with a counter input and submersible pressure sensor/transmitter can be used to reliably monitor both the leachate level and the pump. The submersible pressure transmitter monitors the leachate level while the counter counts pump strokes used to remove that leachate.
Waste Water Management in a Land-fill Site
After careful consideration of several systems, the operators of the landfill determined that the Banner Wireless system was the only solution that could meet all imposed standards and seamlessly co-exist with other devices already in place at their site. With the help of integrator Wilson Mohr, they were able to create a system that could take data from below ground and make it accessible at the desk of the end user. One battery powered Node at the top of each well powers the radio and the ultrasonic analog level sensor. Each Node is equipped with a specialized low-power 4-20 mA analog level sensor and one 10-30V dc powered Gateway controls the system. The Data Radio and Modbus master controller module enhance portability of data and an omni-directional antenna extends the range of Gateway-Node communication up and over the hill and across the landfill site. Cutting-edge power management capabilities and an internal battery eliminate long haul cabling and create a greatly-reduced cost of installation. The wireless devices also have built-in diagnostic properties that send out alarms prior to complete shutdown, minimizing down time. They are also completely scalable and can adapt as the operators fill in and create new wells.
Shopping Center Directs Vehicles to Available Parking
Reduce vehicle congestion, wireless monitoring
Monitoring Power Use to Avoid Peak Use Charges
A Sure Cross DX80 wireless system can be installed to make the system work better. The DX80 Node accepts a signal from the PLC operating the smart power system that shows which capacitors are being used. The signals are transmitted to a DX80 Gateway installed in a visible location. The Gateway uses EZ-LIGHT Tower Lights to indicate which capacitors are being used and an alarm to notify personnel when energy use drifts outside the desired range.
Landfill Methane Reclamation and Flare Stack Monitoring
To meet governmental regulations, landfill managers need to accurately monitor methane gas production, removal, venting, and burning. To accurately determine methane production levels and flow, a pressure transducer can detect both pressure and vacuum present within the methane production system.
Calling an AGV for Parts
DX80 SureCross Wireless products are a great way to communicate with automated guide vehicles in a wide variety of industries. Remote, self-contained push buttons attached to SureCross Wireless Nodes can be placed at assembly line workstations. When a specific part is needed, the push buttons can be activated and a signal sent to a Wireless Gateway-equipped AGV for replenishment of parts.
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Security/Access Monitoring with a Wireless Network
A door to a secured storage room is equipped with a proximity sensor. When the door opens, the sensor transmits the data through a FlexPower Node to a Gateway, which illuminates an EZ-LIGHT indicator light in the main office.
Monitoring Customer Traffic
To understand traffic flow and consumer habits in a retail environment, a SureCross FlexPower Node and a Banner MINI-BEAM sensor provide a discreet, peel-and-stick monitoring and counting solution.
Slip Ring Replacement with Wireless Solutions
Slip rings are subject to constant movement which in turn leads to continuous maintenance in order to avoid degradation of the rotating electrical connection caused by normal wear and debris. Slip ring failure bring production to a halt, resulting in unexpected and costly downtime. The DX80 wireless radios provide a non-contact solution for transmitting the sensor signals from inside the filler bowl to the control panel. The wireless node located on the rotary filler can be battery powered thus providing power to the sensors for a wire-free installation. The DX80 wireless solution eliminates the need for slip rings, helping to decrease downtime and maintenance.
Retrofit for Robotics
The DX80 Gateway is positioned at the control panel to collect and process data. A DX80 Node, DX81 Battery Module, and I/O block are attached to the robotic arm. The Node allows for data gathering at the robot's end effector and also comes available with an M23 connector. The DX81 Battery Module provides power for both the Node and one external input device. These devices are easily integrated with existing equipment.
Energy Management with a Wireless Network
A Gateway inside a facility’s physical plant monitors energy use and demand. Depending on facility requirements—which change often—the wireless network can activate or shut down a rooftop HVAC system. With this monitoring system, industry managers can identify opportunities to make energy use more efficient and conserve plant resources at their facility.
Rotating Equipment Monitoring
In a number of automotive manufacturing processes, rotary tables are used to index parts into various automatic and manual work stations. In many cases, it is necessary to use sensors to verify that parts are present, properly placed, or correctly processed before indexing. Historically, the solution of using slip rings to allow sensor power and signals to be hardwired to the control system has often proven to be costly and unreliable. An alternative solution that allows more sensor signals to be processed while increasing the reliability is needed.
Monitoring Operator Efficiency in a Printing Facility
A cardboard goods printer struggled with an inability to track machine operators’ efficiency and performance as measured against standard production rates.
Landfill Leachate Pump Cycle Counting
Leachate removal from a landfill well is a primary function to guarantee consistent landfill gas production. Instead of manually collecting the pump count data, wireless technology can be used to save time and eliminate errors.
Presence Detection on Rotating Lathe Turret
Betty Machine chose the SureCross® DX80 FlexPower® wireless network from Banner Engineering. This versatile, highly-scalable solution is built around a Gateway capable of two-way communication with multiple end-point Nodes.
Collecting Snap Samples
To collect snap samples quicker and avoid exposure to wastewater, use wireless technology to automatically collect snap samples and deliver the contents to the collection jug. A small pump installed at the collection site can be activated automatically, and at programmed time intervals, to extract the snap sample. A wireless signal is used to trigger the collection and to confirm a successful collection.
Managing Energy Use at an Amusement Park
Wireless technology was used to control air compressors that powered rides, saving maintenance workers time waiting for air pressure to build up.
Controlling a Room Light Remotely
A Q45 Emitter/Receiver detects when someone steps on the first step and sends a discrete signal to the Gateway to turn the light on. The light switch has a built-in timer that turns the light off after 20 minutes.
Monitoring a Pellet Conveyor
A plastic blown-film extrusion company manufactures wrapping products. With over a ½ mile of various conveyor systems used to carry and mix the pellet medium, the multiple conveyor systems must remain free of blockages and mechanical failures must be detected quickly to reduce costs from wasted material, ruined batches, and costly down time.
Wireless Reduces Downtime
A producer of stainless steel and special alloys supplies billets, blooms and ingots to the metal casting industry. During production, articulating robots are used to handle magnesium billets. Proximity switches located on the end effectors of the robots communicate status information from the grippers to a control panel. Robotic cables had been used to connect the proximity switches to the control panel. Environmental challenges and the motion of the robot compromised the integrity of the cables. Breaks were quite frequent and production had to be halted for repair and replacement, pushing up costs and driving down productivity.
