GECMA CHALLENGER 15 Inch User manual

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 1
Operating and Installation Instructions
Remote PC Terminals
CHALLENGER 15”
CHALLENGER 18”

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 2
General reference
Please read these instructions carefully before installing this device.
The CHALLENGER 15/18 and the associated power supply units 15-PSU and 18-PSU for the
CHALLENGER 15 and CHALLENGER 18 respectively may only be installed or deinstalled by
qualified personnel.
The information in the Certificate of Conformity should be fully adhered to.
If you have any questions or suggestions please contact your local representative or us
directly:
 Gecma Components GmbH Gecma International Ltd
Heisenbergstraße 26 – 40 Meridian House, Roe Street
D-50169 Kerpen Congleton, CW12 1PG
Germany United Kingdom
Tel.: [phone] / 69960 [phone]
Fax: [phone] / 69 96 99 [phone]
mailto:[email protected]
 http://www.gecma.com
Technical Developments
The manufacturer reserves the right to modify technical data without notice.
Version-/Revisiondata:
OSD Version: R1 und R2
This manual is valid for CHALLENGER 15-2 and CHALLENGER 18.
(CHALLENGER 15-2 corresponds to the second Generation of CHALLENGER 15.
In the following text it will be referred to as the CHALLENGER 15.)
Warning!

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 3
Repairs, Dangerous chemicals
A note detailing the fault must always accompany equipment sent to
GeCmaComponentsGmbH or any of their agents for repair.
The following procedures must be carried out before a unit is sent back for repair:
 Remove all residues that may be present. Pay special attention to the gasket grooves and
crevices where residue may collect. Please ensure that precautions have been taken to
remove all traces of substances that may represent a health risk before returning the
device.
 Costs of disposal of materials or injury of personnel (acid burns etc.) arising due to the
equipment not being cleaned properly will be charged to the owner of the equipment.
Trademarks:
AT, IBM and PS/2, are registered trademarks of the International Business Machines
Corporation.
Microsoft, Windows and Windows NT are registered trademarks of the Microsoft Corporation.
If any other trademarks are used in the text and pictures of this manual they are herewith
acknowledged as the trademarks of the owner.

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 4
Contents
General reference...........................................................................................................................................2
Contents ..........................................................................................................................................................4
Introduction......................................................................................................................................................5
Application ......................................................................................................................................................6
Operating principle.......................................................................................................................................... 6
Design of the 15-PSU/18-PSU ............................................................................................................................7
Design of the CHALLENGER 15 - FMO display module....................................................................................8
Design of the CHALLENGER 18 - FMO display module..................................................................................10
Design of the CHALLENGER KB keyboard ......................................................................................................12
Design of the CHALLENGER M mouse module..............................................................................................14
Design of the CHALLENGER TB trackball module ...........................................................................................15
Design of the CHALLENGER MTD....................................................................................................................16
Design of the TCV2 data transmission card...................................................................................................17
Design of the PSU2 power supply unit ............................................................................................................19
Design of the 19” rack (optional) ...................................................................................................................20
Software for the TCV2 and KB ........................................................................................................................21
Installation ......................................................................................................................................................22
General installation requirements ............................................................................................................ 22
Installing the terminal................................................................................................................................ 22
Installing the 15-PSU or 18-PSU.................................................................................................................. 22
Installation of CHALLENGER PC Terminals Supplied in Pre-wired Enclosures........................................... 23
Earthing between the STF or EBF Stands and the FH or FHP Enclosure.................................................... 24
Complete Wiring Details ................................................................................................................................25
Operation and adjustment of the display ....................................................................................................32
Options ..........................................................................................................................................................33
Technical data ..............................................................................................................................................34

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 5
Introduction
The CHALLENGER 15/18 is an Visualisation and Operator Terminal. It consists of the following
main components: the CHALLENGER 15/18-FMO display module, the CHALLENGER KB
keyboard and CHALLENGER TB Trackball, plus the 15-PSU or 18-PSU power supply unit and the
associated CHALLENGER TCV2 data transmission card. The transmission card transmits data
from the PC to the CHALLENGER Terminal. Distances of up to 600m and 400 m can be
covered by the 15 and 18 respectively.
The TCV2 transmission card is connected directly to the PC. It is connected to the VGA
graphics card for the RGB signal and the PS2 connectors for the keyboard and mouse signals.
IBM compatible PC’s must be used for trouble free operation. No special driver software is
required nor do any system specific graphics cards need to be installed in the PC.
The transmission of the display, keyboard and mouse data is made by the TCV2 card via a
screened twisted pair cable with 4 pairs to the CHALLENGER 15/18-FMO display module.
Built into the CHALLENGER 15/18-FMO display module is the receiver electronics as well as the
connector blocks for the keyboard and mouse/tracker ball. Power for the CHALLENGER 15/18-
FMO display module is supplied by the 15-PSU or 18-PSU power supply unit.
The following variants are available:
Device Version
CHALLENGER 15-FMO Panel-mounted monitor
CHALLENGER 18-FMO Panel-mounted monitor
CHALLENGER KB Panel-mounted keyboard
CHALLENGER-KMU Panel-mounted keyboard and mouse
CHALLENGER TB Trackball
CHALLENGER M Mouse
CHALLENGER MTD Mouse / trackball decoder
CHALLENGER 15-FH-DMK Field housing with display, mouse and keyboard
CHALLENGER 15-FH-DTK Field housing with display, trackball and keyboard
CHALLENGER 15-FH-D Field housing with display
CHALLENGER 15-FH-DT Field housing with display and trackball
CHALLENGER 15-FH-DK Field housing with display and keyboard
CHALLENGER 15-FH-DM Field housing with display and mouse
CHALLENGER 18-FH-DMK Field housing with display, mouse and keyboard
CHALLENGER 18-FH-DTK Field housing with display, trackball and keyboard
CHALLENGER 18-FH-D Field housing with display
CHALLENGER 18-FH-DT Field Housing with display and trackball
CHALLENGER 18-FH-DK Field housing with display and keyboard
CHALLENGER 18-FH-DM Field housing with display and mouse
CHALLENGER TCV2 19“ Euro card cartridge consisting of:
Data transmission card with optional connections for local
monitor, keyboard and mouse
PSU2 Power supply unit for the TCV2 19” rack
15-PSU Power supply for the CHALLENGER 15-FMO
18-PSU Power supply for the CHALLENGER 18-FMO

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 6
Application
The CHALLENGER 15 and 18 can be employed in all areas of industry where PC functionality is
required in the plant in harsh environments.
CHALLENGER 15:
It can be connected to any IBM compatible PC running software with an XGA resolution
(768 x 1024 pixels, True Colour 32 bit)
CHALLENGER 18:
It can be connected to any IBM compatible PC running software with an SXGA resolution
(1280 x 1024 pixels, True Colour 32 bit)
Operating principle
The VGA screen data and keyboard and mouse/tracker ball data are fed into the TCV2,
where they are combined and converted into conditioned signals. The PSU2 (for 100V…240V
AC) is required to supply the TCV2.
No special graphics card is needed, although we recommend that only good quality cards
are used otherwise picture quality may suffer. The data cable connection should not be wired
via junction boxes.
The electronics in the TCV2 cassette and the CHALLENGER 15/18 FMO allow the PC terminal to
be mounted 600m or more (400m in the case of the 18) from the actual PC CPU (at
distances of 400m or more the resolution and the display refresh rate must be reduced).

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 7
Design of the 15-PSU/18-PSU
The power supply unit 15-PSU or 18-PSU provides two electrically isolated power supply circuits
for the CHALLENGER 15 or CHALLENGER 18. The 15-PSU or 18-PSU has a voltage output of 12V
and a factory pre-set power limitation.
Please refer to the drawing of the 15-PSU or 18-PSU in the appendix for details.
POWER SUPPLIES 12V:
Input Voltage: 100-240V AC (optional 24VDC)
OutputVoltage: 10,8–13,2VDC
Power: 2x30W
InputFrequency: 50-60Hz
Operation Temperature: 0°C – 50°C
The Input-Voltage is connected as the following table to the Terminals labelled “INPUT“. The
supply with Input-Voltage for several modules is achieved by connecting them in parallel.
Input-Voltage: Connection:
INPUT L (L) 100-240V AC (optional +24VDC)
INPUT N (N) 100-240V AC (optional 0VDC)
For 15/18-PSU will be used two modules.
The Power for the CHALLENGER 15/18 is connected as the following table to the Terminals
labelled “OUTPUT”:
Preferred
cable-No.
Output Circuit
Terminals:
Terminal block
K1: Connection:
Cable1 2 OUTPUT 1 V- K1(11) & K3(2) Supply circuit
PS 3 & PS 8 (0 V)
Cable1 1 OUTPUT 1 V+ K1(12) & K3(1) Supply circuit
PS 3 & PS 8 (+12 V)
Cable2 2 OUTPUT 2 V- K1(3+15) & K2(2) Supply circuit
PS 1 & PS 6 & PS 7 (0 V)
Cable2 1 OUTPUT 2 V+ K1(4+16) & K2(1) Supply circuit
PS 1 & PS 6 & PS 7 (+12 V)
Warning!

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 8
Design of the CHALLENGER 15 - FMO display module
For mechanical details of the CHALLENGER 15-FMO please refer to the drawings in the
appendix.
Technical Data:
Component : CHALLENGER-15-FMO
Resolution : XGA (1024 x 768 pixels)
Lower resolutions are interpolated.
Screen size : 15.1“
Display type : TFT with 16 million colours
Ingress protection : IP66 (NEMA 4x) from front
Front plate : Anodised aluminium
Dimensions : 417 x 340.5 x 70 mm (w x h x d)
Weight : 12 kg
Power supply : 15-PSU
The connections are detailed in the following table.
Preferred
cable-No. Terminal block K1: Connection:
1 Not used
2 Not used
Cable2 2 3 Supply PS6- (0 V)
Cable2 1 4 Supply PS6+ (+12V)
5 Not used
6 Not used
7 Not used
8 Not used
9 Not used
10 Not used
Cable1 2 11 Supply PS3- (0 V)
Cable1 1 12 Supply PS3+ (+12)
13 Not used
14 Not used
Cable2 2 15 Supply PS1- (0 V)
Cable2 1 16 Supply PS1+ (+12)
Preferred
cable-No. Terminal block K2: Connection:
Cable2 1 1 Supply PS7+ (+12)
Cable2 2 2 Supply PS7- (0 V)
3 Not used
Preferred
cable-No. Terminal block K3: Connection:
Cable1 1 1 Supply PS8+ (+12)
Cable1 2 2 Supply PS8- (0 V)
3 Not used

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 9
The data signal is connected to terminal block K5. Only use recommended cable.
Preferred
cable-color Terminal block K5: Connection:
white 1 1. Twisted pair (a)
brown 2 1. Twisted pair (b)
white 3 2. Twisted pair (a)
green 4 2. Twisted pair (b)
white 5 3. Twisted pair (a)
orange 6 3. Twisted pair (b)
Screen 7 Screen
Screen 8 Screen
white 9 4. Twisted pair (a)
blue 10 4. Twisted pair (b)
Preferred
cable-No. Terminal block K4: Connection:
1 1 Keyboard/pointing device data (a)
2 2 Keyboard/pointing device data (b)
3 3 GND
4 4 Backlight-control
5 5 GND
6 6 GND
7 7 Keyboard power supply +5V
8 8 Keyboard power supply 0V
9 9 Pointing device power supply +5V
10 10 Pointing device power supply 0V
Preferred
cable-No. Terminal block K9: Connection:
17 1 Barcode Scanner Power Supply
16 2 Barcode Scanner Power Supply
13 3 OSD keyboard SUB menu
15 4 OSD keyboard UP
14 5 OSD keyboard Down
12 6 OSD keyboard menu
11 7 OSD keyboard GND
The adjustment potentiometers and the four-key keypad are described in “Commissioning“.

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MANUAL CHALL 15_18 EN REV.1.3.NEX.DOC 31.01.07 A.J 10
Design of the CHALLENGER 18 - FMO display module
For mechanical details of the CHALLENGER 18 display module please refer to the drawings in
the appendix.
Technical Data:
Component : CHALLENGER-18-FMO
Resolution : SXGA (1280 x 1024 pixels)
Lower resolutions are interpolated.
Screen size : 19 “
Display type : TFT with 16 million colours
Ingress protection : IP66 (NEMA 4X) from front
Front plate : Anodised aluminium
Dimensions : 505.9 x 427.7 x 80 mm (w x h x d)
Weight : 16 kg
Power supply : 18-PSU
The connections are detailed in the following table.
Preferred
cable-No. Terminal block K1: Connection:
1 Not used
2 Not used
Cable2 2 3 Supply PS6- (0 V)
Cable2 1 4 Supply PS6+ (+12V)
5 Not used
6 Not used
7 Not used
8 Not used
9 Not used
10 Not used
Cable1 2 11 Supply PS3- (0 V)
Cable1 1 12 Supply PS3+ (+12)
13 Not used
14 Not used
Cable2 2 15 Supply PS1- (0 V)
Cable2 1 16 Supply PS1+ (+12)
Preferred
cable-No. Terminal block K2: Connection:
Cable2 1 1 Supply PS7+ (+12)
Cable2 2 2 Supply PS7- (0 V)
3 Not used
Preferred
cable-No. Terminal block K3: Connection:
Cable1 1 1 Supply PS8+ (+12)
Cable1 2 2 Supply PS8- (0 V)
3 Not used