Operating Manual
Joystick
CHALLENGER Ji
MANUAL JI REV 1.6 EN.DOC
05.01.04
A.J.
1
List of Contents
List of Contents....................................................................................................2
Introduction.........................................................................................................2
Available Challenger Ji models ..........................................................................2
Assembly.............................................................................................................3
Pin Connections..................................................................................................3
Technical Data....................................................................................................4
Safety Instructions................................................................................................5
General Instructions.............................................................................................6
Introduction
The Challenger Joystick (Ji) is an intrinsically safe joystick for the application in zone 0 / zone 22.
The joystick functions electrically contact-less which ensures an almost maintenance and wearfree operation. The applied sensor technology results in a virtually infinitesimal resolution.
Additional to the buttons in the front plate a button can be integrated into the joystick (e.g. JiSW). This button have the same function like the left mouse button.
It serves to control an ASD (Application Supporting Device) e.g. a PC terminal and it has been
designed for the application in an explosion-endangered area.
For the installation in Challenger components the Challenger FMO (display) must feature the
option “2.PD“.
It is equipped with a PS/2 data interface for connection to an intrinsically safe data interface.
CHALLENGER Ji is a Microsoft™-compatible joystick and it is also compatible with the standard
Microsoft™ mouse driver.
Available Challenger Ji models
Various models of Challenger Ji can be supplied:
Ji
Ji-B6
Ji-B12
Ji SW
Ji-B6 SW
Ji-B12 SW
MANUAL JI REV 1.6 EN.DOC
Joystick
Joystick with barrier for max. 6.25V
Joystick with barrier for max. 12.5V
Joystick with Switch
Joystick with barrier for max. 6.25V with Switch
Joystick with barrier for max. 12.5V with Switch
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Assembly
To ensure the international protection IP66 (NEMA 4X) the joystick module has to be installed in
a housing min. certified according to IP65 (with a cut-out of 153mm x 84mm and/or 6“ x 3.3“).
The joystick module is inserted into the housing cut-out with its front side to the exterior and
fastened from the inside via a minimum of four mounting clips which are evenly distributed
over the external circumference of the joystick housing in such a way that the module is tight
fitting.
The electrical connection can be seen in the wiring diagram #10100470 and the license.
Pin Connections
Connection
Significance
K44-1 and/or brown and/or 1
K44-2 and/or white and/or 2
K44-3 and/or yellow and/or 3
K44-4 and/or green and/or 4
Supply circuit +UB
Supply / Data circuit GND
Data
Clock
Please find the pin numbering in the pin identification plate which is attached near the pin.
Details can be found in the wiring diagram #10100470 and the license.
MANUAL JI REV 1.6 EN.DOC
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3
Technical Data
Zone 0
Zone 1
Zone 22
II 1 G EEx ia IIB T4
II 2 G EEx ia IIC T4
II 3 D T60°C IP6X
Ex ia IIB T4
Ex ia IIC T4
Ex T60°C IP6X
Operating temperature:
(10 to 90% rel. humidity, n. c.)
Ta: -20°C ... +60°C
(-4°F to 140°F)
Ta: -40°C ... +70°C
(-40°F to 158°F)
Ta: -25°C ... +60°C
(-13°F to 140°F)
License:
TÜV 04 ATEX 2459
TÜV 04 ATEX 2459
TÜV 04 ATEX 2647X
Housing material:
Sheet steel / aluminum
Housing dimensions:
see drawings
International Protection Encl.:
Front side IP66 (NEMA 4X9 with expert installation.
Connection supply:
Pin K44 2 x (0.5-2.5)mm² rigid / flexible
or connecting line
Connection interface:
Pin K44 2 x (0.5-2.5)mm² rigid / flexible
or connecting line
Storage temperature:
-20 °C - +60°C (-4°F to 140°F), 10 to 90% rel. humidity, n. cond.
International ignition
protection:
Type Ji:
Supply voltage:
Via intrinsically safe supply unit with the technical data:
Umax ≤ 5.5 V, Imin > 14 mA
Cimax 19uF, Li negligible
Type Ji-B6:
Supply voltage:
Via intrinsically safe supply unit with the technical data:
Umax ≤ 6.25 V, Imin > 14 mA
Ci, Li negligible
Type Ji-B12:
Supply voltage:
Via intrinsically safe supply unit with the technical data:
Umax ≤ 12.5 V, Imin > 14 mA
Ci, Li negligible
Technical Data Data
circuit all Ji types:
Via intrinsically safe interface with the technical data:
Uimax ≤ 5.5 V
Uo ≤ 5.5V, Io ≤ 142mA, Po ≤ 105mW
Ci, Li negligible
Material joystick gaiterprotector:
Neoprene
Max. admissible load:
300N
Further details can be found in the license.
MANUAL JI REV 1.6 EN.DOC
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A.J.
4
Safety Instructions
General 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.
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.
Assembly
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.
The device is only to be connected in a de-energized condition.
The intrinsically safe line system with supply and signal lines has to be effected in such a way that no error must be
considered between the individual circuits, see IEC 600-79-14, 12.2.2.8.
If a joystick for use in a dust atmosphere is to be replaced, the device and/or the housing, in which the
joystick 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).
Operation
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 joystick 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.
MANUAL JI REV 1.6 EN.DOC
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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.
Should you have any questions or suggestions please feel free to contact us any time:
GeCma 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:info@gecma.com
http://www.gecma.com
Technical progress
The manufacturer reserves the right to adjust all technical data without special
announcement according to the technical progress.
Repair 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 (cauterisation, etc.) will be charged to the proprietor of the device.
Used trademarks
AT, IBM and PS/2 are registered trademarks of the International Business Machines Corporation.
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.
MANUAL JI REV 1.6 EN.DOC
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A.J.
6
Translation
Translation
TÜV CERT
(13)
EC Design Test Certificate
(1)
(2)
Devices and safety systems for use in accordance with regulations in areas at risk from
explosion – guideline 94/9/EC
(3)
EC design test certificate number:
(14)
(15)
Description of the equipment:
Behind the front plate the electronic components are protected with a housing of at least IP 20.
The protection from front is IP65.
Is a higher enclosureprotection necessary the unit have to be mountet in a suitable hausing.
(4)
Device:
Challenger Joystick Typ Ji
(5)
Manufacturer: Gecma Components GmbH
(6)
Address:
(7)
The construction of this device and the different permitted version are specified in the
appendix to this design test certificate.
(8)
The TÜV NORD CERT GmbH & Co.KG, TÜV CERT certification agency, certifies - as
appointed office no. 0032 in accordance with the guideline of the council of the European
Community of 23rd March 1994 (94/9/EC) – the fulfilment of fundamental safety and health
requirements for the design and manufacture of devices and safety systems for correct use in
areas at risk from explosion, in accordance with Appendix II of the guideline.
The results of the test are set out in the confidential test report no. 04 YEX 551344.
The connection can be made via a premanufactured terminal strip or K44 connection. The
maximum cablelength is 50m. Refer following text.
In the frontplate can be mountet, beside the joysticklever, up to three buttons.
Heisenbergstr. 26-40
D 50169 Kerpen
The permitted ambient temperature range for each type can be found in the following table:
Category
1
2
The basic safety and health requirements are met by conformity with
EN 50014:1997 + A1 + A1 EN 50020:2002 EN 1127:1997 EN 50284:1999
(10)
If there is an “X” sign behind the certification number, special conditions for the safe use of the
device in the appendix to certificate are referred to.
(11)
This EC design test certificate only relates to the design and testing of the specified device in
accordance with guideline 94/9/EC. Further requirements of these guidelines apply for the
manufacturing and the bringing into circulation of this device. These requirements are not
covered by this certificate.
(12)
The marking of the device must contain the following information:
II 1 G EEx ia IIB T4 and
II 2 G EEx ib IIC T4, resp.
TÜV NORD CERT GmbH & Co. KG
TÜV CERT certification body
Am TÜV 1
D-30519 Hannover
Phone: 0511 986-1470
Fax: 0511-986-2555
EC Type Test Certificate No. TÜV 04 ATEX 2459
The Challenger Joystick (Ji) is an intriniscally safe operating device, e.g. for controlling a
pointer on a display.
TÜV 04 ATEX 2459
(9)
Annex
Hannover, 15.04.2004
sd./- illegible
The Head
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
Ambient Temperature Range
-20°C to 60°C
-40°C to 70°C
Electrical Data
Type Ji
Supply Current Circuit
(Terminals K44-1 or cable brown or 1;
K44-2 or cable white or 2)
In explosion protection type intrinsically
safety EEx ia IIC/IIB
Only for connection to certified intrinsically
safe circuits
Ui = 5.5 V
Uo = 5,5 V
Io = Ii of datacircuit but ” 77mA
Po= Pi of datacircuit but ” 105mW
Characteristic curve: linear
Ci = 19uF
The effective internal inductance are
negligibly small.
Interface circuit
(Data: Terminals K44-3 or cable yellow
or 3
Clock: Terminal K44-4 or cable green
or 4)
In explosion protection type intrinsically
safety EEx ia IIC/IIB
Only for connection to certified intrinsically
safe circuits
Ui = 5.5 V
Uo = 5,5 V
Io = 142mA (dynamic)
Io = Ii of supplycircuit but ” 50mA (static) each
circuit
Po = Pi of supplycircuit but ” 105mW
Characteristic curve: linear
Ci = 19uF
The effective internal inductance are
negligibly small.
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
Page 1 of 3
Page 2 of 3
Translation
Translation
Annex to EC Type Test Certificate No. TÜV 03 ATEX 2459
First Supplement
for
TÜV CERT
EC Design Test Certificate TÜV 04 ATEX 2459
Note the rules for connecting intrinsically safe circuits.
The intrinsically safe circuits are galvanic together connected.
Device:
The Challenger Joystick Typ Ji are suitable for mount and connecting to the under DMT 00
ATEX E 089 X with 1. supplement, certificatet devices Challenger KB, KB-2*, KMU, KMU-2*,
MTD, MTD-2* and under TÜV 03 ATEX 2251 certificatet devices KB-FPi and KB-2D-FPi
instead of Challenger TB and Challenger M.
Becouse of the protectionlevel and category of the in the top listed devices the protectionlevel
of the intrinsically safe circuits are “ib” and category 2 of the complete equipment.
The maximum permitted cablelength are 5m
(16)
The test documents are listed in test report no. 04 YEX 551344.
(17)
Particular requirement:
None
(18)
Fundamental safety and health requirements:
None in addition
Challenger Joystick Typ Ji, Ji-B6 and Ji-B12
Manufacturer: Gecma Components GmbH
Address:
Heisenbergstr. 26-40
D 50169 Kerpen
The Challenger Joystick type Ji will be expanded with the types Ji-B6 and Ji-B12
Additional the mechanical construction modified. Optional a button can be located to the
joysticklever.
Electrical Data
When use in category 1 G the circuits must be protected by
protectionlevel “ia”.
Type Ji
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
Supply Current Circuit
(Terminals K44-1 or cable brown or 1;
K44-2 or cable white or 2)
In explosion protection type intrinsically
safety EEx ia IIC/IIB
Only for connection to certified intrinsically
safe circuits
Ui = 5.5 V
Pi = 0,9 W
Uo = 5,5 V
Io = Ii of datacircuit but ≤ 77mA
Po= Pi of datacircuit but ≤ 105mW
Characteristic curve: linear
Ci = 19uF
The effective internal inductance are
negligibly small.
Interface circuit
(Data: Terminals K44-3 or cable yellow
or 3
Clock: Terminal K44-4 or cable green
or 4)
In explosion protection type intrinsically
safety EEx ia IIC/IIB
Only for connection to certified intrinsically
safe circuits
Ui = 5.5 V
Uo = 5,5 V
Io = Ii of supplycircuit but ≤ 77mA
Po = Pi of supplycircuit but ≤ 105mW
Characteristic curve: linear
The effective internal capacitances and
inductance are negligibly small.
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
Page 3 of 3
Page 1 of 3
Translation
Translation
Annex to 1. supplement of EC Type Test Certificate No. TÜV 03 ATEX 2459
Interface circuit
(Data: Terminals K44-3 or cable yellow
or 3
Clock: Terminal K44-4 or cable green
or 4)
Type Ji-B6
Supply Current Circuit
(Terminals K44-1 or cable brown or 1;
K44-2 or cable white or 2)
In explosion protection type intrinsically
safety EEx ia IIC/IIB
Only for connection to certified intrinsically
safe circuits
Ui = 6,25 V
Uo = 5,5 V
Io = 74 mA (short term)
Io = 38 mA (static)
Po= Pi of datacircuit but ≤ 53mW
Characteristic curve: linear
The effective internal capacitances and
inductance are negligibly small.
In explosion protection type intrinsically
safety EEx ia IIC/IIB
Only for connection to certified intrinsically
safe circuits
Ui = 5.5 V
Uo = 12,5 V
Io = 77 mA (short term)
Io = Ii of supplycircuit but ≤ 21mA (static)
Po = Pi of supplycircuit but ≤ 65mW
Characteristic curve: linear
The effective internal capacitances and
inductance are negligibly small.
Note the rules for connecting intrinsically safe circuits.
The intrinsically safe circuits are galvanic together connected.
Interface circuit
(Data: Terminals K44-3 or cable yellow
or 3
Clock: Terminal K44-4 or cable green
or 4)
In explosion protection type intrinsically
safety EEx ia IIC/IIB
Only for connection to certified intrinsically
safe circuits
Ui = 5.5 V
Uo = 6,25 V
Io = 77 mA (short term)
Io = Ii of supplycircuit but ≤ 43mA (static)
Po = Pi of supplycircuit but ≤ 67mW
Characteristic curve: linear
The effective internal capacitances and
inductance are negligibly small.
All other specifications valid without changes.
The test documents are listed in test report no. 04 YEX 551344-d.
TÜV NORD CERT GmbH & Co. KG
TÜV CERT certification body
Am TÜV 1
D-30519 Hannover
Phone: 0511 986-1470
Fax: 0511-986-2555
Hannover, 24.01.2006
sd./- illegible
The Head
Type Ji-B6
Supply Current Circuit
(Terminals K44-1 or cable brown or 1;
K44-2 or cable white or 2)
In explosion protection type intrinsically
safety EEx ia IIC/IIB
Only for connection to certified intrinsically
safe circuits
Ui = 12,5 V
Uo = 5,5 V
Io = 11 mA (short term)
Io = 9 mA (static)
Po= Pi of datacircuit but ≤ 15mW
Characteristic curve: linear
The effective internal capacitances and
inductance are negligibly small.
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
Page 2 of 3
Page 3 of 3
Translation
TÜV CERT
Declaration of conformity
(1)
(2)
Devices and safety systems for use in accordance with regulations in areas at risk from
explosion – guideline 94/9/EC
(3)
EC design test certificate number:
TÜV 04 ATEX 2647 X
(4)
Device:
Challenger Joystick Typ Ji, Ji-B6, Ji-B12
(5)
Manufacturer: Gecma Components GmbH
(6)
Address:
(7)
The construction of this device and the different permitted version are specified in the
appendix to this design test certificate.
(8)
The TÜV NORD CERT GmbH & Co.KG, TÜV CERT certification agency, certifies - as
appointed office no. 0032 in accordance with the guideline of the council of the European
Community of 23rd March 1994 (94/9/EC) – the fulfilment of fundamental safety and health
requirements for the design and manufacture of devices and safety systems for correct use in
areas at risk from explosion, in accordance with Appendix II of the guideline.
The results of the test are set out in the confidential test report no. 04 YEX 551344b.
(9)
The basic safety and health requirements are met by conformity with
Heisenbergstr. 26-40
D 50169 Kerpen
EN 50281-1-1: 1998 +A1 :2002
(10)
If there is an “X” sign behind the certification number, special conditions for the safe use of the
device in the appendix to certificate are referred to.
(11)
This EC design test certificate only relates to the design and testing of the specified device in
accordance with guideline 94/9/EC. Further requirements of these guidelines apply for the
manufacturing and the bringing into circulation of this device. These requirements are not
covered by this certificate.
(12)
The marking of the device must contain the following information:
II 3 D T60°C IP 6X
TÜV NORD CERT GmbH & Co. KG
TÜV CERT certification body
Am TÜV 1
D-30519 Hannover
Phone: 0511 986-1470
Fax: 0511-986-2555
Hannover, 29.10.2004
sd./- illegible
The Head
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
Page 1 of 2
Translation
(13)
First Supplement
for
TÜV CERT
Annex
(14)
(15)
Translation
EC Type Test Certificate No. TÜV 04 ATEX 2647 X
EC Design Test Certificate TÜV 04 ATEX 2647 X
Description of the equipment:
The Challenger Joystick (Ji) is an intriniscally safe operating device, e.g. for controlling a
pointer on a display.
Device:
The electrical connection realized with terminals or with a premounted cable, whereby the
electrical connection normally realized inside the additional enclosure.
Manufacturer: Gecma Components GmbH
In the frontplate can be mountet, beside the joysticklever, up to three buttons.
Address:
The operationtemperature specified to -25°C up to 6 0°C.
Challenger Joystick Typ Ji, Ji-B6 and Ji-B12
Heisenbergstr. 26-40
D 50169 Kerpen
Electrical Data
The Challenger Joystick type Ji, Ji-B6 and Ji-B12 will be produced regarding the new
productiondirectives.
Type Ji
The mechanical construction modified. Optional a button can be located to the joysticklever.
Supply Current Circuit
(Terminals K44-1 or cable brown or 1;
K44-2 or cable white or 2)
To connect to circuits with follow max. values
under normal conditions:
All other specifications valid without changes.
The test documents are listed in test report no. 04 YEX 551344-e.
U = 5,5V for type Ji
U = 6,25V for type Ji-B6
U= 12,5V for type Ji-B12
To connect to circuits with follow max. values
Interface circuit
(Data: Terminals K44-3 or cable yellow under normal conditions:
or 3
Clock: Terminal K44-4 or cable green U = 5,5V
or 4)
TÜV NORD CERT GmbH & Co. KG
TÜV CERT certification body
Am TÜV 1
D-30519 Hannover
Phone: 0511 986-1470
Fax: 0511-986-2555
(16)
The test documents are listed in test report no. 04 YEX 551344b.
(17)
Particular requirement:
The Challenger Joystick must be mounted into a enclosure which fulfill the requirements of
category 3D EN 50281-1-1 as minimum.
(18)
Fundamental safety and health requirements:
None in addition
Hannover, 24.01.2006
sd./- illegible
The Head
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
This certificate must only be circulated without any modification.
Excerpts or changed require the approval of TÜV NORD CERT GmbH & Co. KG
Page 2 of 2
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