SureCross Wireless Application Note

Monitoring Level and Pressure in a Rotary Filler

Benefits
Wirelessly transmit level and pressure data from a rotary filler to eliminate
cables and slip rings
Process data sent to a control cabinet automatically triggers an inflow
pump to replenish the rotary filler
The DX81P6 Battery Module supplies power to the radio and the sensors
used to gather data for more than one year

Application
A bottling plant monitors the level and pressure inside each rotary filler to
accurately determine when to activate the inflow into the filler tank.
Wireless data acquisition solutions offer an alternative to masses of unreliable
cables and expensive slip rings.

Solution
To wirelessly monitor and report level and pressure, each filler is equipped with
a FlexPower Node and DX81P6 6-pack battery supply. The FlexPower Node Wireless data acquisition solutions
has two 0 to 20 mA analog inputs and the battery pack supplies power to the
Node and sensors for more than a year. and on-board battery power offer
an alternative to masses of cables
A level probe and pressure transmitter were characterized for current draw and
connected to the FlexPower Nodes on the tanks. and slip rings.
The FlexPower Nodes send the signals back to a Gateway equipped with four 0
to 20 mA outputs. The Gateway is mounted near the rotary filler inflow controls
and regulates when the pumps are activated.

Results
Using a wireless system eliminates costly slip rings and reduces required
maintenance to once per year (battery replacement).
The wireless solution also significantly reduces filler downtime, increasing
overall production efficiency.

Please contact your local Banner Engineering representative

or go to BannerEngineering.com/WirelessApplications for more
information about this application
p/n 156263
Banner Engineering Corp. 9714 Tenth Ave. No., Minneapolis, MN USA 55441 Phone: 763.544.3164 www.bannerengineering.com Email: sensors@bannerengineering.com
Gateway at Pump Control Cabinet Gateway
Model Description Qty
DX80G9M60P0M4M4C DX80 Gateway in an IP20 housing, 4 analog IN, 4 analog OUT 1
(900 MHz)
Requires 1030V power. Ships with power cable, 2 dB Omni
antenna, mounting hardware.
BWA-HW-006 Modbus 485 to USB converter cable, use this cable to map I/O 1
between the Gateway and Nodes
SMBDX80DIN DIN-rail mounting bracket for radio and/or power supply (optional) 2
DIN-35-105 DIN-rail section, 105mm long, 35mm design (optional) 2
Control panel cabinet for
BWA-EF1086 Fiberglass enclosure, 10 x 8 x 6 (optional) 1
tank inflow
BWA-PA108 Enclosure subpanel, aluminum (optional) 1

tank

FlexPower Node on Rotary Filler

Model Description Qty
DX80N9X2S2P2M2 DX80 FlexPower Node in an IP67 housing, 2 discrete IN, 2 discrete 1
(900 MHz) OUT, 2 020 mA analog IN
Ships with power cable, 2 dB Omni antenna, mounting hardware.
DX81P6 DX81P6 FlexPower 6-Pack Battery Supply Module 1
LT12E-R16-S20LI0- Turck 12 R16 Level Probe with 420 mA output, 2 flange mount, 1
EX-B1140/3A retentive probe, and 3A sanitary rating
RKV 40-2 Turck 2M cordset for Level Probe with SS coupling nut 1
PT100-PSIG-13- Turck 100 psi Pressure Transmitter with 1 1/2 sanitary flange mount 1
LI3-H1131/S1604 and diaphragm, 420 mA output
RK 4T-2/S618 Turck 2M shielded cordset for Pressure Transmitter 1

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Banner Engineering Corp. 9714 Tenth Ave. No., Minneapolis, MN USA 55441 Phone: 763.544.3164 www.bannerengineering.com Email: sensors@bannerengineering.com