SureCross DX80 Gateway

Configurable Gateway with 0 to 20mA analog inputs and outputs

The SureCross® wireless system is a radio frequency network with integrated I/O that can operate in
most environments and eliminate the need for wiring runs. Wireless networks are formed around a
Gateway, which acts as the wireless network master device, and one or more Nodes.
• Wireless industrial I/O device with four 0 to 20 mA analog inputs and four 0 to 20 mA analog out-
puts
• 10 to 30V dc power input
• DIP switches for user configuration
IP67 Base • Modbus serial interface
2.4 GHz
• Site Survey analyzes the network’s signal strength and reliability and displays the results on the
Gateway's LCD
• Frequency Hopping Spread Spectrum (FHSS) technology and Time Division Multiple Access
(TDMA) control architecture ensure reliable data delivery within the unlicensed Industrial, Scientific,
and Medical (ISM) band
IP20 Base • Transceivers provide bidirectional communication between the Gateway and Node, including fully
900 MHz
acknowledged data transmission
For additional information, up- • Lost RF links are detected and relevant outputs set to user-defined conditions
dated documentation, and ac- • The DX80...C models are certified for use in Class I, Division 2, Group A, B, C, D; Zone 2 (Catego-
cessories, refer to Banner En- ry 3G) Hazardous Locations when properly installed in accordance with the National Electrical
gineering's website, www.ban- Code, the Canadian Electrical Code, or applicable local codes/regulations (see Specifications)
nerengineering.com/surecross.

Models Frequency Environmental Rating I/O

DX80G9M6S0P0M4M4 900 MHz ISM Band
IP67, NEMA 6
DX80G2M6S0P0M4M4 2.4 GHz ISM Band
Inputs: Four 0 to 20 mA analog
DX80G9M6S0P0M4M4C 900 MHz ISM Band IP20, NEMA 1 Outputs: Four 0 to 20 mA analog
Class I, Division 2, Group A, B, C, D Hazard-
DX80G2M6S0P0M4M4C 2.4 GHz ISM Band ous Locations (see Specifications)

Internal antenna models are also available, but are not UL Listed. For more information, contact your local Banner Engineering Corp.
representative.

WARNING: Not To Be Used for Personnel Protection

Never use this device as a sensing device for personnel protection. Doing so could lead to serious
injury or death. This device does not include the self-checking redundant circuitry necessary to allow its
use in personnel safety applications. A sensor failure or malfunction can cause either an energized or de-
energized sensor output condition.

The SureCross® DX80 Wireless Network

The SureCross® DX80 wireless I/O network provides reliable moni-
toring without wiring or conduit installation. The SureCross wireless
network operates independently or in conjunction with a host system,
PLC, and/or PC software.
FlexPower Node
Node
Each wireless network system consists of one Gateway and one or
and Battery Supply Module
Gateway
more Nodes. Devices ship with factory-defined discrete, analog, or a
mix of discrete and analog inputs and outputs.
The SureCross® DX80 network is a deterministic system—the net-
work identifies when the radio signal is lost and drives relevant out-
Node

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puts to user-defined conditions. After the radio signal is reacquired,

the network returns to normal operation.

SureCross® DX80 Gateways and Nodes

A Gateway is the master device within each radio network. Every wireless network must have one Gateway, which schedules communi-
cation traffic and controls the I/O configuration for the network, and one or more Nodes. Similar to how a gateway device on a wired
network acts as a “portal” between networks, the SureCross Gateway acts as the portal between the wireless network and the host
controller. When the Gateway, using its Modbus RTU RS-485 connection, is a Modbus slave to a Modbus RTU host controller, the wire-
less network may contain up to 47 Nodes in a single wireless network. The Gateway holds the Modbus registers of all wireless devices
within the network.
A Node is a wireless network end-point device used to provide sensing capability in a remote area or factory. The Node collects data
from sensors and communicates the data back to the Gateway. Nodes are available in a wide variety of power or input/output options.
SureCross User Configuration Tool
The User Configuration Tool (UCT) offers an easy way to link I/O points in your wire-
less network, view I/O register values graphically, and set system communication pa-
rameters when a host system is not part of the wireless network.
The UCT requires a special USB to RS-485 (model number BWA-UCT-900 for 1 Watt
radios, BWA-HW-006 can be used for all other radios) converter cable to pass infor-
mation between your computer and the Gateway. Download the most recent revi-
sions of the UCT software from Banner Engineering's website: http://www.banneren-
gineering.com/wireless.

Setting Up Your Wireless Network

To set up and install your wireless network, follow these steps:

1. Configure the DIP switches of all devices.

2. Connect the sensors to the SureCross devices.
3. Apply power to all devices.
4. Form the wireless network by binding the Nodes to the Gateway. If the binding instructions are not included in the datasheet, refer to
the product manual for binding instructions.
5. Observe the LED behavior to verify the devices are communicating with each other.
6. Conduct a site survey between the Gateway and Nodes. If the site survey instructions are not included in this datasheet, refer to the
product manual for detailed site survey instructions.
7. Install your wireless sensor network components. If installation instructions are not included in this datasheet, refer to the product
manual for detailed installation instructions.

For additional information, including installation and setup, weatherproofing, device menu maps, troubleshooting, and a list of accesso-
ries, refer to one of the following product manuals.
• SureCross Quick Start Guide: Banner part number 128185
• SureCross Wireless I/O Network Manual: 132607
• Web Configurator Manual (used with "Pro" and DX83 models): 134421
• Host Configuration Manual 132114
Configuring the DIP Switches
Before making any changes to the DIP switch positions, disconnect the power. DIP switch changes will not be recognized if power isn't
cycled to the device.
For parameters not set via DIP switches, use the User Configuration Tool (UCT) to make configuration changes. For parameters set
using the DIP switches, the DIP switch positions override any changes made using the User Configuration Tool.
Accessing the Internal DIP Switches
To access the internal DIP switches, follow these steps:

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SureCross DX80 Gateway

1. Unscrew the four screws that mount the cover to the bottom housing.
2. Remove the cover from the housing without damaging the ribbon cable or the pins the cable plugs into.
3. Gently unplug the ribbon cable from the board mounted into the bottom housing.
4. Remove the black cover plate from the bottom of the device's cover.
The DIP switches are located behind the rotary dials.

After making the necessary changes to the DIP switches, place the black cover plate back into position and
gently push into place. Plug the ribbon cable in after verifying that the blocked hole lines up with the missing
pin. Mount the cover back onto the housing.

DIP Switch Settings

Switches
Device Settings 1 2 3 4 5 6 7 8
Rotary switch address mode OFF*
Extended address mode ON
Modbus or UCT configured (overrides DIP OFF*
switches 3-8)
DIP switch configured ON
Link loss output: zero OFF* OFF*
Link loss output: one OFF ON
Link loss output: hold last state ON OFF
Link loss output: user configuration ON ON
0–20 mA scale (Not used on 0–10V I/O models.) OFF*
4–20 mA scale (Not used on 0–10V I/O models.) ON

* Default configuration
Address Mode
The SureCross wireless devices may use one of two types of addressing modes: rotary dial addressing or extended addressing. In
rotary dial address mode, the left rotary dial establishes the network ID and the right rotary dial sets the device ID. The wireless network
is restricted to a maximum of 16 devices.
Extended address mode uses a security code to "bind" Nodes to a specific Gateway. Bound Nodes can only send and receive informa-
tion from the Gateway to which they are bound. In extended address mode, wireless networks may contain up to 48 radio devices. For
more information on extended address mode, refer to the SureCross™ Wireless I/O Network product manual.
The device ships in rotary dial address mode by default, with the DIP switch in the OFF position. To use extended address mode, change
the DIP switch to the ON position.
Analog Input and Output Scale
Use the DIP switch to select which current scale to use for all the device's analog inputs and outputs: 0 to 20 mA or 4 to 20 mA. 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. This DIP switch
is used only on the 0 to 20 mA models, not the 0 to 10V models.
Link Loss Outputs
The SureCross DX80 wireless devices use a deterministic radio link time-out method to address RF link interruption or failure. When a
radio link fails, all pertinent wired outputs are sent to defined states until the link is recovered, ensuring that disruptions in the communica-
tions link result in predictable system behavior.

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 SureCross DX80 Gateway

Following a radio link time-out, all outputs linked to the Node in question are set to de-energize (discrete outputs to zero, analog outputs
to 0 mA or 4 mA), energize (discrete outputs to one, analog outputs to 20 mA), or to hold the last stable state/value. Use the DIP switches
to select the link loss output state.
Modbus/User Configuration Tool (UCT) or DIP Switch Configured
In Modbus/UCT Configured mode, the device parameters are changed using the User Configuration Tool (UCT) or a Modbus command.
All DIP switch positions are ignored. In DIP Switch Configured mode, use the DIP switches to configure the parameters listed in the table.
Wiring Your SureCross® Device
Use the following wiring diagrams to first wire the sensors and then apply power to the SureCross devices.
5-pin Euro-Style Hookup
Wiring the 5-pin Euro-style connector depends on the model and power requirements of the device. Connecting dc power to the commu-
nication pins will cause permanent damage.

Wire No. Wire Color Description

2 1 Brown 10 to 30V dc
2 White RS485 / D1 / B / +
3 1 3 Blue dc common (GND)
5
4 Black RS485 / D0 / A / –
4
5 Gray Comms Gnd

DX80...C Wiring
Wiring power to the DX80...C models varies depending the power requirements of the model. Connecting dc power to the communication
pins (Tx/Rx) will cause permanent damage. For FlexPower devices, do not apply more than 5.5V to the gray wire.

Terminal Label Gateway, DX85 10 to 30V dc Powered Nodes Battery Powered Nodes
V+ 10 to 30V dc 10 to 30V dc
Tx/+ RS485 / D1 / B / +
V- dc common (GND) dc common (GND) dc common (GND)
Rx/- RS485 / D0 / A / -
B+ 3.6 to 5.5V dc

Terminal Blocks
Connecting dc power to the communication pins will cause permanent damage. Do not exceed analog input ratings for analog inputs.
Only connect sensor outputs to analog inputs.

IP67 Housings IP20 Housings

AIx or Ax. Analog IN x.
AOx. Analog OUT x.
PWR

PWR

AI1 AO1
AI2 AO2
GND GND
CMx. Serial interface connection. For non-serial in-
CM4 CM2 AI3 AO3
AI4 AO4 terface models, do not make any wiring connections
CM3 CM1
V- V+ to these terminals.
AO4 AI4
V- V+
AO3 AI3 V+ Tx/+ GND. Ground/dc common connection.
Rx/-
AO2 AI2 V- PWR. Power, 10 to 30V dc power connection.
AO1 AI1 V- V+
RX/-. Serial comms line
TX/+. Serial comms line
V+. Power, 10 to 30V dc power connection.
V-. Ground/dc common connection.

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SureCross DX80 Gateway

Wiring Diagrams for Analog Inputs

Connecting dc power to the communication pins will cause permanent damage. Do not exceed analog input ratings for analog inputs.
Only connect sensor outputs to analog inputs.
Analog Input Wiring (10 to 30V dc Pow- Analog Input Wiring (4–20mA, 2-Wire, Analog Input Wiring (4–20mA, 2-Wire,
er) Externally Powered Sensors) Switch Powered Sensors)

PWR AIx SPx

10-30V dc external power + −
sensor +
AIx AIx −
+ −
sensor GND + −
sensor
dc common
GND GND
dc common dc common

(Only possible in models with switch power

(SPx) outputs)

Wiring Diagrams for Analog Outputs

Connecting dc power to the communication pins will cause permanent damage. Do not exceed analog input ratings for analog inputs.
Only connect sensor outputs to analog inputs.

Analog Output Wiring

PWR
10-30V dc
AOx
sensor
GND
dc common

LED Behavior for the Gateways

After powering up and binding the Gateway and its Nodes, verify all devices are communicating properly. When testing communication
between the Gateway and Node, all radios and antennas should be at least two meters apart or the communications may fail.

LED 1 LED 2 Gateway Status

(solid green) Power ON

Device Error
(flashing red) (flashing red)
Modbus Communication Active
(flashing yellow)
Modbus Communication Error
(flashing red)

For Gateway and Ethernet Bridge systems, active Modbus communication refers to the communication between the Gateway and the
Ethernet Bridge. For GatewayPro systems, the Modbus communication LEDs refer to the communication internal to the GatewayPro. For
Gateway only systems, the Modbus communication LEDs refer to the communication between the Gateway and its host system (if appli-
cable).

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 SureCross DX80 Gateway

Modbus Register Table

I/O Modbus Holding Register I/O Type Units I/O Range Holding Register Rep- Terminal
resentation Block Labels
Gateway / Any Node Min. Max. Min. (Dec.) Max.
DX85 (Dec.)
1 1 1 + (Node# × 16) Analog IN 1 mA / V 0.0 20.0 / 10.0 0 65535 AI1
2 2 2 + (Node# × 16) Analog IN 2 mA / V 0.0 20.0 / 10.0 0 65535 AI2
3 3 3 + (Node# × 16) Analog IN 3 mA / V 0.0 20.0 / 10.0 0 65535 AI3
4 4 4 + (Node# × 16) Analog IN 4 mA / V 0.0 20.0 / 10.0 0 65535 AI4
...
7 7 7 + (Node# × 16) Reserved
8 8 8 + (Node# × 16) Device Message
9 9 9 + (Node# × 16) Analog OUT 1 mA / V 0.0 20.0 / 10.0 0 65535 AO1
10 10 10 + (Node# × 16) Analog OUT 2 mA / V 0.0 20.0 / 10.0 0 65535 AO2
11 11 11 + (Node# × 16) Analog OUT 3 mA / V 0.0 20.0 / 10.0 0 65535 AO3
12 12 12 + (Node# × 16) Analog OUT 4 mA / V 0.0 20.0 / 10.0 0 65535 AO4
...
15 15 15 + (Node# × 16) Control Message
16 16 16 + (Node# × 16) Reserved

Specifications
Radio and General
Range Power
900 MHz: Up to 4.8 kilometers (3 miles) Requirements: +10 to 30V dc (Outside the USA: +12 to
2.4 GHz: Up to 3.2 kilometers (2 miles) 24V dc, ±10%). (See UL section below for any applica-
Transmit Power ble UL specifications)
900 MHz: 21 dBm (150 mW) conducted Consumption: Less than 1.4 W (60 mA) at 24V dc
2.4 GHz: 18 dBm (65 mW) conducted, less than or Housing
equal to 20 dBm (100 mW) EIRP Polycarbonate housing and rotary dial cover; polyester
900 MHz Compliance (150 mW Radios) labels; EDPM rubber cover gasket; nitrile rubber, non-
FCC ID TGUDX80 - This device complies with FCC sulphur cured button covers
Part 15, Subpart C, 15.247 Weight: 0.26 kg (0.57 lbs)
IC: 7044A-DX8009 Mounting: #10 or M5 (SS M5 hardware included)
2.4 GHz Compliance Max. Tightening Torque: 0.56 N·m (5 lbf·in)
FCC ID UE300DX80-2400 - This device complies with Antenna Connection
FCC Part 15, Subpart C, 15.247 Ext. Reverse Polarity SMA, 50 Ohms
ETSI/EN: In accordance with EN 300 328: V1.7.1 Max Tightening Torque: 0.45 N·m (4 lbf·in)
(2006-05) Interface
IC: 7044A-DX8024 Indicators: Two bi-color LEDs
Spread Spectrum Technology Buttons: Two
FHSS (Frequency Hopping Spread Spectrum) Display: Six character LCD
Link Timeout Wiring Access
Gateway: Configurable Four PG-7, One 1/2-inch NPT, One 5-pin Euro-style
Node: Defined by Gateway male connector

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SureCross DX80 Gateway

Radio and General

Radio range is with the 2 dB antenna that ships with the product. For European applications, power the DX80 from a Limited Power
High-gain antennas are available, but the range depends on the Source as defined in EN 60950-1.
environment and line of sight. To determine the range of your wire-
less network, perform a Site Survey.

Inputs and Outputs

Analog Inputs Analog Outputs
Rating: 24 mA Update Rate: 125 milliseconds
Impedance: 100 Ohms Accuracy: 0.1% of full scale +0.01% per °C
Sample Rate: 62.5 milliseconds Resolution: 12-bit
Report Rate: 1 second or On Change of State (1% To verify the analog input's impedance, use an Ohm meter to
change in value) measure the resistance between the analog input terminal (AIx)
Accuracy: 0.1% of full scale +0.01% per °C and the ground (GND) terminal.
Resolution: 12-bit

Communication and Environmental

Hardware (RS-485) Rating
Interface: 2-wire half-duplex RS-485 DX80 Models:IEC IP67; NEMA 6; (See UL section be-
Baud rates: 9.6k, 19.2k (default), or 38.4k low for any applicable UL specifications)
Data format: 8 data bits, no parity, 1 stop bit DX80...C Models: IEC IP20; NEMA 1 (In a suitable en-
Protocol closure: Class I, Division 2, Group A, B, C, D; T4 −40
Modbus RTU to 80 °C)
Shock and Vibration Operating Environmental
IEC 68-2-6 and IEC 68-2-7 Temperature: −40 to +85 °C (Electronics); −20 to +80
Shock: 30g, 11 millisecond half sine wave, 18 shocks °C (LCD)
Vibration: 0.5 mm p-p, 10 to 60 Hz Humidity: 95% max. relative (non-condensing)
Radiated Immunity: 10 V/m, 80-2700 MHz
(EN61000-6-2)
Refer to the SureCross DX80 Wireless I/O Network Product Man-
ual (p/n 132607) for installation and waterproofing instructions. Op-
erating the devices at the maximum operating conditions for exten-
ded periods can shorten the life of the device.

Certification
DX8x...C (External Wiring Terminal Models) UL Listing
Maximum ambient temperature: 70 °C
CSA: Class I, Division 2, Groups A, B, C, D Mounting instructions: See document 132607
(Ex/A Ex nA II T4); Certificate: 1921239 Power rating: 10 to 30V dc, UL Class 2
Enclosure environmental rating: UL Type 1
LCIE/ATEX: Zone 2 (II 3G / Ex nA IIC); Certifi-
cate: LCIE 10 ATEX 1012 X

Included with Model

The following items ship with the DX80 radios.
• BWA-HW-002: DX80 Access Hardware Kit, containing four PG-7 plastic threaded plugs, four PG-7 nylon gland fittings, four PG-7 hex
nuts, one 1/2-inch NPT plug, and one 1/2-inch nylon gland fitting. (Not included with IP20 DX80...C models)

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 SureCross DX80 Gateway

• BWA-HW-001: Mounting Hardware Kit, containing four M5-0.8 x 25mm SS screws, four M5-0.8 x 16mm SS screws, four M5-0.8mm
SS hex nuts, and four #8-32 x 3/4" SS bolts
• BWA-HW-003: PTFE tape
• BWA-9O2-C (900 MHz) or BWA-2O2-C (2.4 GHz): Antenna, 2 dBd Omni, Rubber Swivel RP-SMA Male. (Not included with Internal
antenna models)
• Quick Start Guide (128185 for DX80 Gateways or 152653 for MultiHop models)
• MQDC1-506: 5-Euro (single ended) straight cable, 2m (Not included with FlexPower devices)
• BWA-HW-011: IP20 Screw Terminal Headers (2 pack) (Included only with the IP20 DX80...C models)

Warnings
Antenna Installations. Install and properly ground a qualified surge suppressor when installing a remote antenna system. Remote antenna
configurations installed without surge suppressors invalidate the manufacturer's warranty. Keep the ground wire as short as possible and make all
ground connections to a single-point ground system to ensure no ground loops are created. No surge suppressor can absorb all lightning strikes; do
not touch the SureCross® device or any equipment connected to the SureCross device during a thunderstorm.
Exporting SureCross Radios. It is our intent to fully comply with all national and regional regulations regarding radio frequency emissions. Custom-
ers who want to re-export this product to a country other than that to which it was sold must ensure the device is approved in the destina-
tion country. A list of approved countries appears in the Radio Certifications section of the product manual. The SureCross wireless products were
certified for use in these countries using the antenna that ships with the product. When using other antennas, verify you are not exceeding the transmit
power levels allowed by local governing agencies. Consult with Banner Engineering Corp. if the destination country is not on this list.
Violating Warnings. The manufacturer does not take responsibility for the violation of any warning listed in this document. Make no modifications to
this product; any modifications to this product not expressly approved by Banner Engineering could void the user’s authority to operate the product.
All specifications published in this document are subject to change; Banner reserves the right to modify product specifications or to update docu-
mentation at any time. For the most recent version of any documentation, refer to: www.bannerengineering.com. © 2006-2013 Banner Engineering
Corp. All rights reserved.

Banner Engineering Corp Limited Warranty

Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following the date of shipment. Banner Engineering
Corp. will repair or replace, free of charge, any product of its manufacture which, at the time it is returned to the factory, is found to have been defective during the
warranty period. This warranty does not cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED (INCLUDING, WITHOUT LIMITATION,
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE,
COURSE OF DEALING OR TRADE USAGE.
This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP.
BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT, WHETH-
ER ARISING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY, NEGLIGENCE, OR OTHERWISE.
Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any obligations or liabilities relating to any product
previously manufactured by Banner Engineering Corp.

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