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GECMA Components GmbH

MANUAL EXMOD-1-2-3 EX-MODULE BASE STATION REV 1.6 EN.DOC 19.12.08 N.B - 1 -

Operating Manual ExMod -1-2-3

Ex-Module

Base station e.g. for BCSi / Data transmission module

Doc.Nr.:60000321



List of Contents

List of Contents.....................................................................................................2

Introduction ..........................................................................................................2

ExMod-1-2-3 models available.......................................................................3

Technical Data .....................................................................................................5

Certificates.............................................................................................................6

Programming of ExMod-RF10/RF100-2-3....................................................7

Assembly .............................................................................................................10

Connections details...........................................................................................11

Terminal Connections ......................................................................................20

Safety Instructions.............................................................................................22

General Instructions.........................................................................................23

Drawings and certifications............................................................................23

Introduction

The ExMod are designed as base station for cable and RF barcode scanner. Depending on the variant it contains intrinsically safe power supplies, barriers, a charging circuit, a Bluetooth interface and various data transmission interfaces. Furthermore the ExMod designed as data transmission module to transmit data from a device (e.g. Cardreader) located in hazardous area to the safe area. Depending on the variant it contains intrinsically safe power supplies, barriers and various data transmission interfaces. The data of devices can be transmitted via serial interfaces (Ex-i and/or Ex-e): (RS232i / RS232e) or (RS422i / RS422e). Depending on the interface type selected (e.g. RS422e) distances up to 1000m (3300ft) are possible between the ExMod and appropriated devices in safe area. If necessary the signals can be converted via appropriated devices (not included) in safe area. For RS422e signals we recommend as appropriate devices e.g. the RS422/USB converter type Expert EX9531. The connections are realized via Ex e connection box and via Ex i interfaces. All versions of the ExMod are for use in hazardous areas Zone 1[0], Zone 21[20], EPL Gb[Ga], EPL Db[Da]



ExMod-1-2-3 models available

Various models of ExModExModExModExMod----1111----2222----3333 can be supplied: The first parameter -1- will define the form of the input data of Ex-Module. It will contain the radio frequency Bluetooth module or will contain an intrinsically safe serial input interface with a power of 5V or 12V.

The second parameter -2- will define the form of the outputs signals of ExMod: RS232i-RS232e or RS422i/RS422e.

The third parameter -3- will define the supply input power of ExMod: AC/DC or DC/DC.

----1111 = RF10:RF10:RF10:RF10: Base station with Bluetooth radio frequency module (10mW).

In this variant we receive datas transmitted by any Bluetooth module. The integrated Bluetooth module in ExMod send these data via a serial interface, RS232 or RS422. This variant also contains: - Intrinsically safe charging interface for a battery. - Intrinsically safe interface for external antenna. - Intrinsically safe RESET button/interface for Bluetooth module.

RF100:RF100:RF100:RF100: Base station with Bluetooth radio frequency module (100mW).

In this variant we receive datas transmitted by any Bluetooth module. The integrated Bluetooth module in ExMod send these data via a serial interface, RS232 or RS422. This variant also contains: - Intrinsically safe charging interface for a battery. - Intrinsically safe interface for external antenna. - Intrinsically safe RESET button/interface for Bluetooth module.

5V HP:5V HP:5V HP:5V HP: Data transmission module contains an interface which provide an intrinsically safe

RS232 interface with 5V Ex ia high power interface.

5V LP:5V LP:5V LP:5V LP: Data transmission module contains an interface which provide an intrinsically safe RS232 interface with 5V Ex ia low power interface.

12V HP12V HP12V HP12V HP: Data transmission module contains an interface which provide an intrinsically safe

RS232 interface with 12V Ex ia high power interface. ---- 2 = 2 = 2 = 2 = RS232:RS232:RS232:RS232: The output signals of ExMod are realized via a serial RS232 interface.

In this case the ExMod contains two outputs: an intrinsically safe (Ex i) serial interface RS232i and an increased safety (Ex-e) serial interface RS232e (use one interface only!).

RS422RS422RS422RS422i:i:i:i: The output signals of ExMod are realized via serial intrinsically safe signals (EX i)

RS422i.

RS4RS4RS4RS422e:22e:22e:22e: The output signals of ExMod are realized via serial increased safe signals (EX e) RS422e.

- 3333 = ACACACAC: Supplied with 100VAC…230VAC (±10%), 50…60 Hz

DC24:DC24:DC24:DC24: Supplied with 20-30 VDC



Example: Example: Example: Example: ExExExExModModModMod ––––RFRFRFRF100100100100----RS485RS485RS485RS485iiii----ACACACAC = ExModule (base station) with integrated 100mW Bluetooth

module, output data as RS485i (intrinsically safe serial interface), supplied with 100VAC…230VAC

Model nameModel nameModel nameModel name DescriptionDescriptionDescriptionDescription

1 ExMod-RF 10-RS422i-3 Base station with integrated 10mW Bluetooth module and RS422 Ex ia output interface

2 ExMod-RF 10-RS422e-3 Base station with integrated 10mW Bluetooth module and RS422 Ex e output interface

3 ExMod-RF 10-RS232-3 Base station with integrated 10mW Bluetooth module and RS232 Ex ia output interface and RS232 Ex e output interface

4 ExMod-RF 100-RS422i-3 Base station with integrated 100mW Bluetooth module and RS422 Ex ia output interface

5 ExMod-RF 100-RS422e-3 Base station with integrated 100mW Bluetooth module and RS422 Ex e output interface

6 ExMod-RF 100-RS232-3 Base station with integrated 100mW Bluetooth module and RS232 Ex ia output interface and RS232 Ex e output interface

7 ExMod-5V LP-RS422i-3 Data transmission module with RS232 Ex ia input interface with 5V Ex ia low power interface and RS422 Ex ia output interface

8 ExMod-5V HP-RS422i-3 Data transmission module with RS232 Ex ia input interface with 5V Ex ia high power interface and RS422 Ex ia output interface

9 ExMod-12V HP-RS422i-3 Data transmission module with RS232 Ex ia input interface with 12V Ex ia high power interface and RS422 Ex ia output interface

10 ExMod-5V LP-RS422e-3 Data transmission module with RS232 Ex ia input interface with 5V Ex ia low power interface and RS422 Ex e output interface

11 ExMod-5V HP-RS422e-3 Data transmission module with RS232 Ex ia input interface with 5V Ex ia high power interface and RS422 Ex e output interface

12 ExMod-12V HP-RS422e-3 Data transmission module with RS232 Ex ia input interface with 12V Ex ia high power interface and RS422 Ex e output interface

13 ExMod-5V LP-RS232-3 Data transmission module with RS232 Ex ia input interface with 5V Ex ia low power interface and RS232 Ex ia output interface and RS232 Ex e output interface

14 ExMod-5V HP-RS232-3 Data transmission module with RS232 Ex ia input interface with 5V Ex ia high power interface and RS232 Ex ia output interface and RS232 Ex e output interface

15 ExMod-12V HP-RS232-3 Data transmission module with RS232 Ex ia input interface with 12V Ex ia high power interface and RS232 Ex ia output interface and RS232 Ex e output interface



Technical Data

For all ExMod versions:For all ExMod versions:For all ExMod versions:For all ExMod versions:

Housing type: Stainless steel 1.4301 / AISI 304 (or on request)

Ingress protection: IP64

Operating temperature range: -20°C to +60°C (-4°F to 140°F), 15 to 95% rel. humidity, n. cond.

Storage temperature: -20 °C - +70°C (-4°F to 158°F), 15 to 85% rel. humidity, n. cond.

Hazardous areas: Zone 1[0], Zone 21[20], EPL Gb[Ga], EPL Db[Da] (refer certificates)

Dimensions: 321 mm x 125 mm x 47 mm (12,65” x 4,92” x 1,85” ), refer to attached drawings

Weight: typ. 4.7kg (10,4 lb), depending on variant

Power consumption: typ. 10W / max. 15W (typ. 34BTU / max. 51BTU)

Classification of install. and use: stationary

Interfaces: refer chapter “Connection details”

Data Interfaces: RS232, typ. settings 9600bps, 8 data, 1 stop, no parity, no flow control

For ExModFor ExModFor ExModFor ExMod----RF10RF10RF10RF10----2222----3 and 3 and 3 and 3 and ExModExModExModExMod----RF100RF100RF100RF100----2222----3 versions:3 versions:3 versions:3 versions:

Connection: provide wireless RS232 interface via Bluetooth 1.2 (2,4GHz) specification (transparent RS232 Interface), Class 2 for ExMod-RF10-2-3, Class 1 for ExMod-RF100-2-3

RF distances: max. 10m for ExMod-RF10-2-3 (open field) max. 100m for ExMod-RF100-2-3 (open field) Local conditions can affect the RF distances.

Radiated power: max. 2W

Antenna: External antenna Ex ia (via interface X83), 50Ω impedance, connector SMA standard, extension via appropriated 50Ω coax cable only, max. cable length 1m (3,3ft), use antenna/cable combination whose gain/loss result are max. 2 dBi at external antenna connector X83. Use appropriate pre-mounted antenna/cable approved by Gecma Components GmbH only!

Bluetooth type setting: RS232 interface, individual bounding programmable, connectable, discoverable

Bluetooth PIN: 0000

General/input interfaces: Charging Interface Ex ia (interface X82) External antenna interface for BT-module Ex ia (interface X83) Reset button/interface for BT-module Ex ia (interface X88)

Output interfaces: refer to details for ExMod-1-RS232-3, ExMod-1-RS422i-3 and ExMod-1-RS422e-3



For ExModFor ExModFor ExModFor ExMod----5V 5V 5V 5V HHHHPPPP----2222----3,3,3,3, ExMod ExMod ExMod ExMod----5V 5V 5V 5V LLLLPPPP----2222----3 3 3 3 and ExModand ExModand ExModand ExMod----12V HP12V HP12V HP12V HP----2222----3 versions3 versions3 versions3 versions::::

General/input interfaces: 5V HP Power Interface Ex ia (interface X81) for ExMod-5V HP-2-3 or 5V LP Power Interface Ex ia (interface X81) for ExMod-5V LP-2-3 or 12V HP Power Interface Ex ia (interface X81) for ExMod-12V HP-2-3. Serial data Interface Ex ia (interface X81)

Output interfaces: refer to details for ExMod-1-RS232-3, ExMod-1-RS422i-3 and ExMod-1-RS422e-3

For ExModFor ExModFor ExModFor ExMod----1111----RS232RS232RS232RS232----3, ExMod3, ExMod3, ExMod3, ExMod----1111----RS422iRS422iRS422iRS422i----3 and ExMod3 and ExMod3 and ExMod3 and ExMod----1111----RS422eRS422eRS422eRS422e----3 versions:3 versions:3 versions:3 versions:

General/input interfaces: refer to details for ExMod-RF10-2-3 and ExMod-RF100-2-3 versions and ExMod-5V HP-2-3, ExMod-5V LP-2-3 and ExMod-12V HP-2-3 versions

Output interfaces: RS232 Ex ia output interface and RS232 Ex e output interface for ExMod-1-RS232-3 or RS422 Ex ia output interface for ExMod-1-RS422i-3 or RS422 Ex e output interface for ExMod-1-RS422e-3

For ExModFor ExModFor ExModFor ExMod----1111----2222----AC AC AC AC and ExModand ExModand ExModand ExMod----1111----2222----DC24 DC24 DC24 DC24 versions:versions:versions:versions:

Supply: for AC: 100VAC…230VAC (±10%), 50… 60 Hz / 1A

for DC24: 20-30 VDC / 1A

Certificates

ATEX certification of ExModATEX certification of ExModATEX certification of ExModATEX certification of ExMod----1111----2222----3:3:3:3: Zone 1 [0] / EPL Gb [Ga]Zone 1 [0] / EPL Gb [Ga]Zone 1 [0] / EPL Gb [Ga]Zone 1 [0] / EPL Gb [Ga] Zone 21 [20] / EPL Zone 21 [20] / EPL Zone 21 [20] / EPL Zone 21 [20] / EPL DDDDb [b [b [b [DDDDa]a]a]a] ATEX ignition protection Ex II 2(1)G Ex e q [ia IIC] T4

Gb Ex II 2(1)D Ex tD [iaD] A21 IP64 T130°C

Operating temperature (10% to 90% rel. humidity, n.c)

Ta: -20°C … +60°C (-4°F to 140°F)

Ta: -20°C … +60°C (-4°F to 140°F)

ATEX certification TÜV 08 ATEX 7639 X TÜV 08 ATEX 7639 X IECEx certification of ExModIECEx certification of ExModIECEx certification of ExModIECEx certification of ExMod----1111----2222----3:3:3:3: (in certificationprocess) Zone 1 [0] / EPLZone 1 [0] / EPLZone 1 [0] / EPLZone 1 [0] / EPL Gb [Ga] Gb [Ga] Gb [Ga] Gb [Ga] Zone 21 [20] / Zone 21 [20] / Zone 21 [20] / Zone 21 [20] / EPL Db [Da]EPL Db [Da]EPL Db [Da]EPL Db [Da] IECEx ignition protection Ex e q [ia IIC] T4 Gb Ex tD [iaD] A21 I64 T130°C

Operating temperature (10% to 90% rel. humidity, n.c)

Ta: -20°C … +60°C (-4°F to 140°F)

Ta: -20°C … +60°C (-4°F to 140°F)

IECEx certification IECEx TUR 08. XXXX X IECEx TUR 08. XXXX X

FurtherFurtherFurtherFurther details can be found in the attached license. details can be found in the attached license. details can be found in the attached license. details can be found in the attached license.



Programming of ExMod-RF10/RF100-2-3

The ExMod-RF10/RF100-2-3 pre programmed by Gecma.

The standard setting are the automatic connection to the accessory barcodescanner BCSi-RF10/RF100.

In this case the BT-connection of the ExMod-RF10/RF100 connect automatically to the BCSi-RF10/RF100

with the BT-adress listed in the test certificate.

NNNNormally no additional settings necessary!ormally no additional settings necessary!ormally no additional settings necessary!ormally no additional settings necessary! Programming options of the ExMod-RF10/RF100-2-3: 1) You can scan a list of available BT devices in the range of this ExMod-RF10/RF100-2-3

2) You can program the bounding list and order of automatic connection to BT devices (defined by the BT- address)

3) You can reset to factory defaults For programming you have to enter the configurationmode of the ExMod-RF10/RF100-2-3: Connect the ExMod-RF10/RF100-2-3 via a appropriated serial Interface to a PC. Open a appropriated terminal/communication software (e.g. Hyperterminal at Windows) and connect to your serial interface with the parameter 9600/8/1/no parity. Press the hidden reset button X88 at the ExMod-RF10/RF100-2-3 near the antenna connection with a small appropriated item. Alternative you can connect a button to the intrinsically safe interface X88 pin 2 and pin 3. After pressing reset button or after power up the ExMod-RF10/RF100-2-3 will show you the message in Hyperteminal: +++ Press <CR>,<CR>,<ESC>,<ESC> to enter BlueRS+ configurator +++

Now you have to press the ““““enterenterenterenter”””” button two times and then the button two times and then the button two times and then the button two times and then the ““““ESCESCESCESC”””” butto butto butto button two timesn two timesn two timesn two times within 1 secondwithin 1 secondwithin 1 secondwithin 1 second after shown this message. After successfully operation you´ll see the message with internal firmware information: BG2a00 V1.207.4 Feb 11 2008 15:30:05 #

The “#” identify that you are in the programming mode (during programming mode no other operation possible). All follow commands you have to enter behind the “#”. You can program as much commands as you want. Please note that you have to save and exitsave and exitsave and exitsave and exit the programming with the commands: save exit

All settings/changings valid after save and exit only.



List of available BT devicesList of available BT devicesList of available BT devicesList of available BT devices To get a list of available BT-devices in the range of this ExMod-RF10/RF100 you have to enter: binq 2 (Please note the space character before the “2”)

Now you´ll get a list with all available BT-devices. This will take some seconds. Below you´ll find a list with samples: starting inquiry..... d01: 0009DD504A43 0x00010C -064 d02:B 001E3B7977EE 0x001F00 -073 d03: 00802508B9E3 0x001F00 -038 d04: 001E3B7976EE 0x000202 -078 starting name/service discovery..... d01: 0009DD504A43 0x00010C -064 Dell PC d02:B 00802508B9E3 0x001F00 -073 GECMA BCSi-RF100 SN:086724 d03: 00802508B9E3 0x001F00 -038 GECMA BCSi-RF100 SN:086725 d04: 001E3B7976EE 0x000202 -078 NOKIA N73

A short description: After “starting inquiry.....” the ExMod-RF10/RF100 list all found devices. After “starting name/service discovery.....” you´ll find additional information. D02: list the device number. Here device “D02”

B list that this device bounded already. Means in this case it´s not possible to connect to this device.

00802508B9E3 list the BT adress (in this case 00802508B9E3)

0x001F00 list the BT device type (in this case a uncategorized or serial device)

-073 list the signal strength (as lower the value as better the connection)

GECMA BCSi-RF100 SN:086724 list the BT device name



Programming the Programming the Programming the Programming the bounding list and bounding list and bounding list and bounding list and order of automatic connectionorder of automatic connectionorder of automatic connectionorder of automatic connection You can list up to 3 devices which are automatically connected when inside the RF range of the ExMod-RF10/RF100. The ExMod-RF10/RF100 follow the list of order for the connection. Means when he find device 1 (BT-address 1) he connect automatically to device 1. The other devices not connected. When device 1 not available (or leave the RF range) the ExMod-RF10/RF100 connect automatically to the next available listed device. And so on for the other programmed devices. The ExMod-RF10/RF100 allow one connection at same time. Bounding exclusively to device 1 only possible when device 1 listed only and no entry for device 2 and device 3. Programming device 1: Brad=00802508B9E3 (“00802508B9E3” are a sample for the BT-adress)

Programming device 2: Brad2=00802508B9E4 (“00802508B9E4” are a sample for the BT-adress)

Programming device 3: Brad3=00802508B9E5 (“00802508B9E5” are a sample for the BT-adress)

In top shown sample the ExMod-RF10/RF100 connect to BT address “00802508B9E3”automatically. When this BT address “00802508B9E3” not available (or leave the RF range) the ExMod-RF10/RF100 connect automatically to BT address “00802508B9E4” and so on. When you want to connect to one BT device (e.g. BCSi-RF10/RF100) exclusively you have to enter device 1 only. Don´t enter any other adress to device 2 or device 3 or enter the address “000000000000”. You can show the current status of the particular device list by enter Brad for device 1 or Brad2 for device 2 or Brad3 for device 3

You can delete each particular device by enter the address “000000000000”. Example to delete device 3: Brad3=000000000000

Reset to facReset to facReset to facReset to factory defaulttory defaulttory defaulttory default To set to factory default please enter follow parameters in the list of order. Please note that after reset to factory default no bounding device programmed! Please program a bounding device for proper function. defa=1 br=4 flc=0 cdtr=0 cmds=8



Assembly

The assembly and the connections of the inputs/outputs cables depend of ExMod-1-2-3 models. For the installation plan of each ExMod-1-2-3 models, please refer to the following attached drawings: # 10101281: Installation plan of ExMod-RF10 or RF100-RS422i-3 # 10101282: Installation plan of ExMod-RF10 or RF100-RS422e-3 # 10101283: Installation plan of ExMod-RF10 or RF100-RS232-3 # 10101284: Installation plan of ExMod-5VHP or 5VLP or 12VHP-2-RS422i # 10101285: Installation plan of ExMod-5VHP or 5VLP or 12VHP-2-RS422e # 10101286: Installation plan of ExMod-5VHP or 5VLP or 12VHP-2-RS232



Connections details

For all Ex ModFor all Ex ModFor all Ex ModFor all Ex Mod----1111----2222----3333:::: Supply voltage in: X80X80X80X80, Terminal 1-2, Increased safety:

Contact 1: +U / L Contact 2: GND / N 2 x (0,2-2,5)mm² / (24AWG-14AWG), single- and multi-strand Strip length 6-7mm (0,26in) Um max. 250V / 1500A Cable gland M16 for round cable, Outer cable diameter 5,5...10mm (0,22“...0,39“) For ExMod-1-2-AC *:

Utyp ≤ 100V…230V (±10%) Ityp ≤ 1A Um ≤ 250V Ik ≤ 1500A For ExMod-1-2-DC24 *:

Utyp ≤ 20V…30V (±10%) Ityp ≤ 1A Um ≤ 250V Ik ≤ 1500A

Supply voltage out: X80X80X80X80, Terminal 3-4, Increased safety: Contact 3: +U / L Contact 4: GND / N 2 x (0,2-2,5)mm² / (24AWG-14AWG), single- and multi-strand Strip length 6-7mm (0,26in) Cable gland M16 for round cable, Outer cable diameter 5,5...10mm (0,22“...0,39“) Output current max. 3A.



For ExModFor ExModFor ExModFor ExMod----RF10 or RF100RF10 or RF100RF10 or RF100RF10 or RF100----2222----3333:::: Charging Interface: X82X82X82X82, Terminal 1-2, Intrinsically safe ia:

Contact 1: +U Contact 2: GND 2 x (0,2-2,5)mm² / (24AWG-14AWG), single- and multi-strand Strip length 6-7mm (0,26in) Cable gland M12 for round cable, Outer cable diameter 4...7mm (0,16“...0,28“) Ui ≤ 10,8 V Ii ≤ not important Pi ≤ 6,6 W Li ≤ negligible Ci ≤ negligible Uo ≤ 10,8 V Io ≤ 553 mA Po ≤ 2,54 W Lo ≤ 20 uH Co ≤ 2 uF Recommended max. cable length 5m (16,4ft) Pay attention to the values listed in corresponding standards.

Antenna interface: X8X8X8X83333----1 to 1 to 1 to 1 to 2222, Intrinsically safe ia:

Contact 1: antenna signal Contact 2: GND connector SMA standard, 50Ω impedance Ui ≤ 5,5 V Ii ≤ not important Pi ≤ 1,2 W Li ≤ 0,05 uH Ci ≤ 45 uF Uo ≤ 5,4 V Io ≤ 300 mA Po ≤ 1,2 W Lo ≤ 1 uH Co ≤ 10 uF Extension via appropriated 50Ω coax cable only, use antenna/cable combination that gain/loss result are max. 2 dBi at external antenna connector X83. Use from Gecma Components GmbH appropriated and approved pre mounted antenna /cable only! Recommended max. cable length 1m (3,3ft). Pay attention to the values listed in corresponding standards.



Reset interface: X88X88X88X88----1111 to to to to 4444, Intrinsically safe ia: Contact 1: NC Contact 2: Res1 Contact 3: Res2 Contact 4: NC Recommended connector: Phoenix MSTB2,5/4-ST-5,08 BU Ui ≤ 5,5 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 5,4 V Io ≤ 168 mA Po ≤ 226 mW Lo ≤ 1 mH Co ≤ 0,5 uF Recommended max. cable length 1000m (3300ft) Pay attention to the values listed in corresponding standards.

For ExModFor ExModFor ExModFor ExMod----5V HP5V HP5V HP5V HP----2222----3:3:3:3: Power/data interface: X81X81X81X81, Terminal 1-5, Intrinsically safe ia:

5 x (0,2-2,5)mm² / (24AWG-14AWG), single- and multi-strand Strip length 6-7mm (0,26in) Cable gland M12 for round cable, Outer cable diameter 4...7mm (0,16“...0,28“)

When the distance between the supply line (X81-1 and 2) and the data lines (X81-3 to X81-5) complycomplycomplycomply to the clearance / creepage distances in the standard IEC/EN 60079-11: Supply voltage: X81X81X81X81----1 and 21 and 21 and 21 and 2, Intrinsically safe ia:

Contact 1: +Ui Contact 2: GND Ui ≤ 5,5 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 5,4 V Io ≤ 1,43 A Po ≤ 5,7 W Lo ≤ 1uH Co ≤ 65 uF



Data Lines: X81X81X81X81----3 to X813 to X813 to X813 to X81----5555, Intrinsically safe ia: Contact 3: RXD (input) Contact 4: TXD (output) Contact 5: GND Ui ≤ 25 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 5,4 V Io ≤ 12 mA Po ≤ 16 mW Lo ≤ 2 mH Co ≤ 65 uF Recommended max. cable length 5m (16,4ft). Pay attention to the values listed in corresponding standards.

When the distance between the supply line (X81-1 and 2) and the data lines (X81-3 to X81-5) not not not not complycomplycomplycomply to the clearance / creepage distances in the standard IEC/EN 60079-11: Supply voltage / Data: X81X81X81X81----1 to 51 to 51 to 51 to 5, Intrinsically safe ia:

Contact 1: +Ui Contact 2: GND Contact 3: RXD (input) Contact 4: TXD (output) Contact 5: GND Ui ≤ 5,5 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 5,4 V Io ≤ 1,43 A Po ≤ 5,7 W Lo ≤ 1 uH Co ≤ 50 uF Recommended max. cable length 5m (16,4ft). Pay attention to the values listed in corresponding standards.



For ExModFor ExModFor ExModFor ExMod----5V LP5V LP5V LP5V LP----2222----3:3:3:3: Power/data interface: X81X81X81X81, Terminal 1-5, Intrinsically safe ia:



Contact 1: +Ui Contact 2: GND Ui ≤ 5,5 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 5,4 V Io ≤ 424 mA Po ≤ 1,15 W Lo ≤ 1 uH Co ≤ 65 uF





Contact 1: +Ui Contact 2: GND Contact 3: RXD (input) Contact 4: TXD (output) Contact 5: GND Ui ≤ 5,5 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 5,4 V Io ≤ 436 mA Po ≤ 1,1 W Lo ≤ 1 uH Co ≤ 65 uF Recommended max. cable length 5m (16,4ft). Pay attention to the values listed in corresponding standards.

For ExModFor ExModFor ExModFor ExMod----12V HP12V HP12V HP12V HP----2222----3:3:3:3: Power/data interface: X81X81X81X81, Terminal 1-5, Intrinsically safe ia:



Contact 1: +Ui Contact 2: GND Ui ≤ 12,5 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 12,4 V Io ≤ 514 mA Po ≤ 2,37 W Lo ≤ 10 uH Co ≤ 1,2 uF





Contact 1: +Ui Contact 2: GND Contact 3: RXD (input) Contact 4: TXD (output) Contact 5: GND Ui ≤ 12,5 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 12,4 V Io ≤ 526 mA Po ≤ 2,38 mW Lo ≤ 10 uH Co ≤ 1,2 uF Recommended max. cable length 5m (16,4ft). Pay attention to the values listed in corresponding standards.



For ExModFor ExModFor ExModFor ExMod----1111----RS232RS232RS232RS232----3:3:3:3: RS232i Interface: X84X84X84X84, Terminal 1 to 3, Intrinsically safe ia:

Contact 1: RXD (input) Contact 2: TXD (output) Contact 3: GND 3 x (0,2-2,5)mm² / (24AWG-14AWG), single- and multi-strand Strip length 6-7mm (0,26in) Cable gland M12 for round cable, Outer cable diameter 4...7mm (0,16“...0,28“) Ui ≤ 25 V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 5,4 V Io ≤ 12 mA Po ≤ 16 mW Lo ≤ 200 mH Co ≤ 0,5 uF Recommended max. cable length 15m (50ft). Pay attention to the values listed in corresponding standards.

RS232e Interface: X85X85X85X85, Terminal 1 to 3, Increased safety:

Contact 1: RXD (input) Contact 2: TXD (output) Contact 3: GND 3 x (0,2-2,5)mm² / (24AWG-14AWG), single- and multi-strand Um max. 250V / 1500A Cable gland M16 for round cable, Outer cable diameter 5,5...10mm (0,22“...0,39“) Utyp ≤ 30V Ityp ≤ 2A Um ≤ 250V Ik ≤ 1500A Recommended max. cable length 15m (50ft). Pay attention to the values listed in corresponding standards.



For ExModFor ExModFor ExModFor ExMod----1111----RS422iRS422iRS422iRS422i----3:3:3:3: RS422i Interface: X8X8X8X86666, Terminal 1 to 5, Intrinsically safe ia:

Contact 1: RX- i Contact 2: RX+ i Contact 3: TX- i Contact 4: TX+ i Contact 5: GND 5 x (0,2-2,5)mm² / (24AWG-14AWG), single- and multi-strand Strip length 6-7mm (0,26in) Cable gland M12 for round cable, Outer cable diameter 4...7mm (0,16“...0,28“) Ui ≤ 8,2V Ii ≤ not important Pi ≤ not important Li ≤ negligible Ci ≤ negligible Uo ≤ 5,4 V Io ≤ 64 mA Po ≤ 253 mW Lo ≤ 9 mH Co ≤ 0,5 uF Recommended max. cable length 1000m (3300ft) Pay attention to the values listed in corresponding standards.

RS422e Interface: X8X8X8X87777, Terminal 1 to 5, Increased safety:

Contact 1: RX- e Contact 2: RX+ e Contact 3: TX- e Contact 4: TX+ e Contact 5: GND 5 x (0,2-2,5)mm² / (24AWG-14AWG), single- and multi-strand Um max. 250V / 1500A Cable gland M16 for round cable, Outer cable diameter 5,5...10mm (0,22“...0,39“) Utyp ≤ 30V Ityp ≤ 2A Um ≤ 250V Ik ≤ 1500A Recommended max. cable length 1000m (3300ft) Pay attention to the values listed in corresponding standards.



Terminal Connections

Ex e supply voltage interface X80:

Connection Significance 100-250VAC(max)

AC variant 24VDC variant

X80-1 Supplycircuit

L Supplycircuit +24V DC

X80-2 Supplycircuit

N Supplycircuit 0V DC

X80-3 Outputcircuit

L Outputcircuit +24V DC

X80-4 Outputcircuit

N Outputcircuit 0V DC

X80-5 PE PE X80-6 PE PE

The device are supplied via the Supply circuit. The Output circuit are integrated to supply optional other devices (max. 3A). The Supply circuit and the Output circuit are connected parallel.

Ex i charging interface X82:X82:X82:X82:

ConnectionConnectionConnectionConnection SignificanceSignificanceSignificanceSignificance X82-1 +U X82-2 GND

Ex i serial interface RS232i with power X81X81X81X81::::

ConnectionConnectionConnectionConnection SignificanceSignificanceSignificanceSignificance X81-1 +U X81-2 GND X81-3 RxDi (Input) X81-4 TxDi (Output) X81-5 GND

Ex i serial interface RS232i X84:X84:X84:X84:

ConnectionConnectionConnectionConnection SignificanceSignificanceSignificanceSignificance X84-1 RxDi (Input) X84-2 TxDi (Output) X84-3 GND

Ex e serial interface RS232e X85:X85:X85:X85:

ConnectionConnectionConnectionConnection SignificanceSignificanceSignificanceSignificance X85-1 RxD (Input) X85-2 TxD (Output) X85-3 GND



Ex i interface RS422i X86:X86:X86:X86:

ConnectionConnectionConnectionConnection SignificanceSignificanceSignificanceSignificance X86-1 Rx-i X86-2 Rx+i X86-3 Tx-i X86-4 Tx+i X86-5 GND

Ex e interface RS422e X87:X87:X87:X87:

ConnectionConnectionConnectionConnection SignificanceSignificanceSignificanceSignificance X87-1 Rx-e X87-2 Rx+e X87-3 Tx-e X87-4 Tx+e X87-5 GND

Ex i antenna interface X83:X83:X83:X83:

ConnectionConnectionConnectionConnection SignificanceSignificanceSignificanceSignificance X83-1 Antenna signal X83-2 GND

Ex i Reset interface X88:X88:X88:X88:

ConnectionConnectionConnectionConnection SignificanceSignificanceSignificanceSignificance X88-1 NC X88-2 RES1 X88-3 RES2 X88-4 NC

Further details can be found in attached installation plan drawings of different variants.



Safety Instructions

General Safety InstructionsGeneral Safety InstructionsGeneral Safety InstructionsGeneral Safety Instructions The instructions stated in this chapter are to be followed accurately to ensure a safe and reliable operation.

The license and the special conditions included in it are to be observed.

Follow the national safety regulations and the accident prevention regulations.

The installation is only to be performed by specialists. These specialist must be familiar with the characteristics of explosion-endangered facilities.

Incorrect or inadmissible application as well as non-observance of the instructions of this operating manual make the guarantee void.

For ExMod-RF10/RF100-2-3 only: The BT-modul has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules and with RSS-210 of IndustryCanada as LMO. This device contains transmitter with FCCID: RFR- C11G2, IC ID: 4957A-C11G2. The BT-modul is a qualified design according to the Bluetooth Qualification Program Reference Document (PRD) V2.0. The Qualified Design ID (QDID) is: B012419.

Only use this device for the approved purpose.

Conversions and modifications to the device are inadmissible.

The housing is only to be opened by the company Gecma Components GmbH.

The first two digits of the serial number located at the nameplate identify the year of manufacture.

AssemblyAssemblyAssemblyAssembly

The national assembly and installation regulations are to be observed.

The generally accepted rules of engineering are to be observed.

The entire equipment is to be connected and operated correctly and properly according to the applicable standards, guidelines and installation instructions.

The housing is to be grounded via grounding equipment. Grounding must be effected with a core cross section of at least 4mm².

Shielded cables are recommended for use in combination with this device.

Connect the device only when the Ex e and Ex i circuits are complete de-energized. Do not open the terminal enclosure when the device is powered and live. Ensure the power supply is isolated. The cable diameter has to comply to the specification of the terminals. The outer diameter of the cables has to comply to the specification of the cable glands. Tighten the Cable glands according to the rules. Seal not used cable glands. The cable glands of the Ex e terminal enclosure have to comply to the national standards and have to be interchanged if necessary.

Ensure that between the ExMod-1-2-3 * and the accesoiry devices equipotential bonding has to be established.

The device is only to be connected in a de-energized condition.

Isolate all circuits, wait 2 min. before opening the accessory Ex e CONNECTION BOX!

If the device in a dust atmosphere is to be replaced, the device and/or the housing, in which the device is installed, is to be de-energized first and if necessary cooled according to the regulations. Before opening the device and/or housing and during period in which the device and/or the housing is open, the environment of the device and/or housing has to be kept dust-free to such an extent that no dust can enter the interior of the housing. When installing new components observe that all seals are in a flawless condition and function properly.

Before putting the device into operation make sure that the device has been installed as prescribed and that the device and its wiring are not damaged.

If the power supply of the device is not intrinsically safe, the license will become void and it must not be operated as an intrinsically safe device. If the device was operated intrinsically safely with a low level of international protection (e.g. ib), it must not be operated afterwards in applications for a higher level of international protection (e.g. ia).

Only permanently laid cables may be entered. The use must guarantee suitable clamping

The cable glands, if visible, may be used only in places where they are protected against the influence of mechanical danger.

In the case that the Ex e terminals X80-1 and X80-2 are solely connected the short current protection must be suitable for the diameter of the connected cable. If in addition the power is looped through the Ex-e terminals X80-3 and X80-4 the maximum current must be limited to a value lower or equal than 5A.

The maximum short current at the place of installation must not exceed 1500 A.

OperationOperationOperationOperation

The device is only to be operated in an undamaged and clean condition.

If the device has suffered any damages which might affect the international protection (e.g. cracks, holes or broken components) it must be taken out of service immediately. The device can only be put into operation again after the defect components have been exchanged.

When the device is damaged, do not touch it any longer! Risk of injury!

If the device is to be used in a dust atmosphere dust layers >5mm have to be removed.

In the event of non-observance & non-compliance the stipulated explosion protection cannot be guaranteed and/or the guarantee will become void!

Modifications require the written approval by the company GeCma Components GmbH.



General Instructions

Before starting the assembly read the entire operating manual! In cases of doubt (in the form of mistranslation) the German operating manual is to be applied. We do not assume liability for misprints and errors in this operating manual. The housings shall only be opened by personnel of Gecma Components GmbH. Should you have any questions or suggestions please feel free to contact us any time: GeCma Components GmbHGeCma Components GmbHGeCma Components GmbHGeCma Components GmbH Heisenbergstraße 26 – 40 D-50169 Kerpen Tel.: +49 (0)22 37 / 69 96 0 Fax: +49 (0)22 37 / 69 96 99 mailto:[email protected] http://www.gecma.com Technical progressTechnical progressTechnical progressTechnical progress The manufacturer reserves the right to adjust all technical data without special announcement according to the technical progress. Repair work, hazardous materialRepair work, hazardous materialRepair work, hazardous materialRepair work, hazardous material The description of the respective fault(s) is in any case to be included with the devices which are sent to GeCma Components GmbH for repair. The following measures are to be taken before sending a device in for repair: Please remove the entire adhering medium residue. Pay special attention to sealing grooves and gaps which might contain medium residue. We have to ask you to refrain from sending the device back if it is impossible for you to definitely guarantee that all health-endangering material has completely been removed. Costs which arise due to inadequate cleaning of the device for a potential disposal or for personal injury (cauterization, etc.) will be charged to the proprietor of the device. Used trademarksUsed trademarksUsed trademarksUsed trademarks AT, IBM and PS/2 are registered trademarks of the International Business Machines Corporation. Bluetooth is a registered trademark of Bluetooth SIG, Inc. Microsoft, Windows and Windows NT are registered trademarks of Microsoft Corporation. All other trademarks mentioned and depicted in the text are trademarks of the respective owners and are recognized as registered.

Drawings and certifications

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