Samcon SKDP03-T Installation instructions manual

Cable Kit SKDP03-T
10 M
Mounting instructions

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 2 von 12
Inhaltsverzeichnis
1Content of the Cable Kit SKDP03-T ........................................................................3
2Installing and wiring (connection to ExTB-3).........................................................3
2.1 Customization of the cable connection................................................................4
2.2 Insertion into Ex-e ...............................................................................................6
2.3 Connecting the cable to the clamps ....................................................................6
3Mounting the barrier gland (insertion into Ex-d) ...................................................7
3.1 Components of the barrier gland.........................................................................7
3.2 Configuration of the connection...........................................................................7
3.3 Kneading.............................................................................................................8
3.4 Adhesive bonding (Loctite)..................................................................................8
4Connecting the RJ 45 plug (Ex-d or non-ex)..........................................................9
5Connecting the power channel (24VDC) ..............................................................10
6Support / contact....................................................................................................10
7Notes .......................................................................................................................11
Table of Figures
Figure 1.1 –Content of the Cable Kit SKDP03-T ..............................................................3
Figure 2.1 –Cable cross section.......................................................................................4
Figure 2.2 –Stripped cable and bare shielding .................................................................4
Figure 2.3 –Blank shielding wire and shielding braid........................................................4
Figure 2.4 –Shrinking tube over twisted shielding braid ...................................................5
Figure 2.5 –Customized cable..........................................................................................5
Figure 2.6 –Connection in the terminal box......................................................................6
Figure 3.1 –Components of the barrier gland...................................................................7
Figure 3.2 –Configure the connection for the barrier gland ..............................................7
Figure 3.3 –Kneading of the barrier gland ........................................................................8
Figure 3.4 –Glued-areas...................................................................................................8
Figure 4.1 –Connecting the RJ 45 plug............................................................................9
Figure 4.2 –Completed cable with a RJ 45 plug...............................................................9
Revision history
Product: Cable Kit SKDP03-T 10 M
Title: Cable Kit SKDP03-T 10 M Mounting instructions
Doc. -Id. CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx
Autor: Eva Schneider
Datum: May 9, 2018
Rev.- Index
Datum
Name
Comment
Approved by
EX Officer
0
May 9th, 2018
E.Schneider
Compilation of the document

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 3 von 12
1 Content of the Cable Kit SKDP03-T
Figure 1.1 –Content of the Cable Kit SKDP03-T
2 Installing and wiring (connection to ExTB-3)
The following chapter describes the configuration of the cable, how to insert it into the
terminal box ExTB-3 and how to connect it.
Attention!
The electrical connection of the equipment must be executed by quali-
fied personnel only!
Attention!
Please observe the national regulations regarding security, installa-
tion, and accident prevention (e.g. IEC 60079-14)!
Attention!
When stripping the isolation, no inner cores must be damaged!
(a)
(b)
(c)
(d)
10 m SKDP03-T System Cable
Digital (a)
1 x cable gland with compound
(b)
5 ml Loctite threadlock (c)
1 x CAT6 RJ45 industrial plug
pro (5.5 –10.5 mm) (d)
40 cm shrinking tube yellow-
green (e)
10 cm shrinking tube black (e)
8 x wire-end ferrules (e)
1 x documentation
(e)

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2.1 Customization of the cable connection
Looking at the digital system cable’s cross section, the following elements are visible:
Figure 2.1 –Cable cross section
Remove 10 cm of the wire’s outer sheath (green jacket) (1) without damaging the wires.
Then cut off the white filling threads (2) and remove the white foil around the network ca-
bles (7) so that the shield is uncovered. In a next step, separate the shield by pulling out
the data elements (8) from the copper wire shielding (4) (see figure 2.2).
Figure 2.2 –Stripped cable and bare shielding
Cut off the five filling threads and the plastic foil. Make sure that the blank shielding wire
(5) is not removed. Twist this blank wire with the shielding (4) as shown below.
Figure 2.3 –Blank shielding wire and shielding braid
Blank shielding wire
Outer sheath (jacket) (1)
Filling threads (2)
Power elements (3)
Copper wire shielding (4)
Blank shielding wire (5)
Shielding foil (6)
Isolation foil (7)
Data elements (8)
(7)
(2)
(1)
(4)
(3)
Shielding wire + Shielding braid

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 5 von 12
Cut the yellow-green shrinking tube to match the length of the shielding braid. Now
shrink-fit the shrinking tube by using a hot air blower.
Figure 2.4 –Shrinking tube over twisted shielding braid
After this, put the black shrinking tube over all cables and the shielding and shrink it.
Remove approx. 1 cm of the foil (6) at the top of the 4 twisted pairs (8). Untwist them to
match this length and cut off the ends with a wire stripper. Squeeze the wire end ferrules
onto the 3 power cables the grounding cable.
Figure 2.5 –Customized cable
(6)
(8)
(3)

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 6 von 12
2.2 Insertion into Ex-e
Through the middle cable gland, insert the prepared cable (q.v. chapter 2. 1) into the
terminal box ExTB3.
2.3 Connecting the cable to the clamps
Corresponding to the color code of the already connected camera cable, also the cables
of the cable kit are connected so that the colors match. Please do not untie the twisted
pair network and put the shielding braid as close to the clamps as possible. Tidily strip
the ends of the wires and mount them firmly.
Figure 2.6 –Connection in the terminal box
On YouTube, you will find precise instructions on the cable configuration and the connec-
tion inside the terminal box ExTB3 at: https://www.youtube.com/watch?v=lqd5fsS7MsM

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 7 von 12
3 Mounting the barrier gland (insertion into Ex-d)
3.1 Components of the barrier gland
Figure 3.1 –Components of the barrier gland
3.2 Configuration of the connection
Strip 25 cm off the green jacket (q.v. chapter 2.1, figure 2.1 (1)) and cut off the isolation
foil (7). Please make sure not to damage the individual wires of the connecting cable. Cut
off the white filling threads (2) and remove the foil around the network cables (6). Then
separate the shield and cut off the blank shielding wire (5) and the shielding braid (4) so
that the foil around the cables can be removed. To prepare the twisted pairs (8) for the
kneading screw connection, they need to be untwisted.
Slightly unscrew the red outer seal nut until the cable can be easily inserted into the
screw connection 1 (insert direction: from outer seal nut towards screw connection 1).
The rim of the green sheath must close flush with the screw connection 1. Then tighten
the red outer seal nut enough to hold the cable in position and put the spacer on top.
Figure 3.2 –Configure the connection for the barrier gland
Screw connection 1
Outer
seal nut
(red)
Spacer
Compound Tube
Screw connection 2

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 8 von 12
3.3 Kneading
Put on the supplied protective gloves and mix both components of the two-part expoxy
compound until it is pliable and of an even color (minimum mixing temperature 10°C /
50°F). Untwist the cable cores and apply the compound around them over a length of 40
mm so that there is compound around each individual cable core (zigzag). Now put the
compound tube over the cable and pass the compound tube over the conductors until the
stepped end is fully located with the tube spacer. Remove surplus compound and make
sure that it does not overlap the tube. If required, add more compound into place until the
compound tube is fully filled.
Figure 3.3 –Kneading of the barrier gland
The compound should be flush to the tube. Please let everything dry for at least 24 h and
allow the compound to harden. After the drying period, please check that all cables are
tightly connected with the compound and screw on the screw connection 2 until it comes
to an effective stop.
3.4 Adhesive bonding (Loctite)
Please apply threadlocker (Loctite) generously to all three threads of the barrier gland).
The Loctite is included in the delivery scope.
Figure 3.4 –Glued-areas
For more detailed instructions on how to set up the barrier gland (insertion into Ex-d)
please refer to our YouTube tutorial: https://www.youtube.com/watch?v=U1nap29TEFY

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 9 von 12
4 Connecting the RJ 45 plug (Ex-d or non-ex)
Strip off 25 cm of the cable isolation as described in chapter 3.1. Please make sure not to
damage the isolation foil (7).
The plug is connected according to EIA/TIA-568B (q.v. attached sketch).
The cables of the same color will be put through the applicable opening and then cut off
flush at the front. It is important that the shielding is lead through until it touches the
shielding clamp.
Figure 4.1 –Connecting the RJ 45 plug
With a gripper, press together the plug until it snaps and remove the piece of paper.
Figure 4.2 –Completed cable with a RJ 45 plug
For detailed instructions regarding the connection of the RJ 45 plug please refer to our
YouTube tutorial: https://www.youtube.com/watch?v=LOJ_7drrn4E&feature=youtu.be

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 10 von 12
5 Connecting the power channel (24VDC)
In hazardous areas, the power cable is connected by using a barrier gland. In safe areas,
it is sufficient to use a common cable gland.
Cable distribution: Black +24 VDC
Blue 0 VDC
Green-yellow to earth potential
6 Support / contact
If you have any questions or if you need our support please contact us at:
Mail: [email protected]
Tel.: [phone]
https://www.samcon.eu/en/contact/

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 11 von 12
7 Notes

Doc.-ID: CableKitSKDP03-T_10M_MountingInstructions_rev.00.docx, Seite 12 von 12
Schillerstrasse 17, 35102 Lohra-Altenvers
www.samcon.eu, inf[email protected]
fon: [phone], fax: - 31