(EEE = Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) Installation and Operation Instructions Manufacturer: SAVVY Telematic Systems AG Grabenstrasse 9 CH-8200 Schaffhausen Phone +41 52 633 46 00 Fax +41 52 624 44 41 www.savv -telematics. com Commercial Register No.: CHE-47 1.742.100 VAT ID No.: DE295426820 2020 by SAVVY Telematic Systems AG Version V1.10 03.02.2020 page 1 of 25 EEM instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 4.4 Optional design for the SenseGateway-ExR-DMS 1.2 Special conditions... 2 Internal Functions 24 IEEE 802.15.4 radio interface 2.2 Internal temperature sensors 2.3 Internal reed switch............ 2.4 Independent power supply. 3 External Connections, Explosion-proof Data, and Assembly 3.1 Connection for passive Ex reed switch 3.2 n for Ex pressure sensor.. 3.3 Connections for Ex temperature sensors 3.4 External connections for optional SenseGateway-ExR-DMS strain gauge SAVVY LoadCel Ex 3.5. System diagram for the external sensors . 8 3.6 Grounding and connection to chassis 3.7 Assembly and installation. 4 Environmental Conditions and Combustibility 5 Requirements for Standards 6 Mechanical Dimensions.......... 6.1 Type label, identification, and warning note 6.2 Construction interior view 7 Replacing the Battery . 7.1 Internal battery data. 8 Cable Glands and Fasteners 9 Pressure Equalization Membrane ver 21 10 Fastening with Screws. 10.1 Attachment with a welding adapter 11 12 13 FCC and ISED related statements 2020 by SAVY Telematic Systems AG www.savvy-telematics.com Version V1.10 03.02.2020 page 2 of 25
("EEE Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) Blank page 2020 by SAWY Telematic Systems AG Version V1.10 03.02.2020 page 3 of 25
[EE Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 1 Device Overview The SAVVY SenseGateway-ExR is a sensor gateway which can connect with an Ex pressure sensor and a maximum of three Ex temperature sensors or Ex switches. The gateway communicates wirelessly with the telematics device SAVVY CargoTrac-ExR according to the IEEE802.15.4 standard, which transmits the measurement data to a portal via the Internet. Integrated into the gateway is a primary battery that ensures an autonomous running time of up to 10 years, depending on the operating profile. Two internal temperature sensors detect the ambient and operating temperature. In addition, a reed switch can detect external changes via a magnet (e.g. opening the door, removing the gateway, triggering, etc.). The SAVVY SenseGateway-ExR impresses with its ultra-low power consumption and meets all current environmental guidelines, today and in the future. The SAVVY SenseGateway-ExR is fully configurable for any function via the Internet-
based software SAVVY Synergy and can therefore exactly replicate all customer and system requirements. The main areas of use are in rail freight, tank container, and intermodal traffic. Types of protection:
11 1G Ex ia IIC T4 Ga IL 1D Ex ia IIIC T135C Da ATEX Certificate number: KIWA19ATEX0032X IECEx Certificate number: PTZ17.0003X Ex ia IC T4 Ga Ex ia IIIC T135C Da 2020 by SAVVY Telematic Systems AG Version V1.10 03.02.2020 page 4 of 25 EEEEEEE Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 1.1 Optional design for the SenseGateway-ExR-DMS Instead of a pressure sensor, a passive DMS (strain gauge) SAVVY LoadCell-Ex can be connected to the SenseGateway-ExR DMS. Thus, loading conditions or structural changes can be measured. For this version, it is not possible to connect a pressure sensor. 1.2 Special conditions 1) Extended temperature range -30C < Tamb $ +60C. 2) The housing must not be opened in potentially explosive atmospheres. 3) Integration into the equipotential bonding occurs from the installation. 4) These operating instructions are to be observed. 5) Refer to the operating instructions for electrical and mechanical data. 6) Unused cable glands must be closed by the blind plugs provided by the manufacturer.
~S 2020 by SAVVY Telematic Systems AG www.savvy-telematics.com Version V1.10 03.02.2020 page 5 of 25 Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 2 Internal Functions 2.1 IEEE 802.15.4 radio interface Feature Standard IEEE 802.15.4 Protocol SAVVY / TIS ready Frequency spectrum 2,405 - 2,475 MHz Transmitted power Tx Up to 18 dBm Reception sensitivity Rx -111 dBm Network topology Mesh, star, tree Number of channels 15 Configuration and FW updates via the Yes air interface 2.2 Internal temperature sensors Feature Type PT1000 Class B (F0.3) Temperature range -55C to 175C 2.3 Internal reed switch Feature Type Magnetic reed switch Operating threshold 15-40AT 2.4 Independent power supply SenseGateway-ExR has an integrated battery cell, which ensures a long and maintenance-free service life. Data about the battery is shown in Fig 7.1 Internal battery data. 2020 by SAVVY Telematic Systems AG
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[EEA Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 3 External Connections, Explosion-proof Data, and Assembly As an operator, you are obliged to comply with all legal requirements, test intervals, operating regulations, etc. The following values are not exceeded by the sum of all external sensors incl. cables:
Co <50 uF Lo <30 UH Uo $3.9 VDC lo $62.8 mA Po $245 mW For application examples and calculations see: 3.5 Circuit diagram of the external sensors. Note that external sensors may only be used in the intended Ex zones. The SenseGateway-ExR may be used in Zone 0, 1, 2, 20, 21, and 22. The installation does not require any protective barriers because all of the circuits are intrinsically safe. If external sensors are used that are not approved for Zone 0 or 20, the SenseGateway-ExR may also only be used in the zone where the corresponding sensor has been approved. Example 1: If a reed switch with protection type Il 26D Ex mb II T6 is connected, the SenseGateway-ExR may be used in zone 1, 2, 21, or 22. Example 2: If a pressure sensor with protection type II 1G Ex ia IIB T4 Ga is connected, the SenseGateway-ExR may be used in zone 0, 1, or 2. Example 3: If a temperature sensor with protection type Il 1G Ex ia IC T6 Gb / 11 1D Ex ia IIIC T60C Da is connected, the SenseGateway-ExR may be used in all zones. 2020 by SAWY Telematic Systems AG www.savvy-telematics.com Version V1.10 03.02.2020 page 7 of 25 Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 3.1. Connection for passive Ex reed switch E.g. StandexMeder MK08-1A75-500W Type of protection: Il 2GD Ex mb II T6 A maximum of three reed switches can be connected. Instead of reed switches, temperature sensors can also be connected; any combination of both types of sensors is also possible. Feature Connection type Screw terminal PIN1-2 / 6-7 / 7-8 PIN 1,6,8 V+
PIN 2,7 V-
Uo $3.9 VDC Po $15 mW lo $3.9 mA Ri 21 kO Co (Sum of all sensors) <50 uF Lo (Sum of all sensors) $30 UH Type Normal Open Insulation resistance min. (NO) 3 MO External diameter cable 4.6-5.0 mm 2020 by SAVY Telematic Systems AG Version V1.10 03.02.2020 page 8 of 25 EEEEEEN Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 3.2 Connection for Ex pressure sensor E.g. AST4400 Type of protection: Il 1G Ex ia IIB T4 Ga Feature Connection type Screw terminal PIN 3-4-5 PIN 3 V+
PIN 4 V-
Pin 5 Signal Uo $3.9 VDC Po $154 mW lo $39.4 mA Co (Sum of all sensors) <50 uF Lo (Sum of all sensors) $30 uH Ri (Signal) 210 kO Ri(V+) 21000 External diameter cable 4.6-5.0 mm 2020 by SAVVY Telematic Systems AG www.savvy-telematics. Version V1.10 03.02.2020 page 9 of 25 SEn) Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 3.3 Connections for Ex temperature sensors e.g. Jumo 90.2821.8496 Type of protection: Il 1G Ex ia IIC T6 Gb / Il 1D Ex ia IIIC T60 C Da A total of three temperature sensors can be connected. Instead of reed switches, temperature sensors can also be connected. Any combination of both types of sensors is also possible. Feature Connection type Screw terminal PIN1-2 / 6-7 / 7-8 PIN 1,6,8 V+
PIN 2,7 V-
Type PT1000 Uo $3.9 VDC Po 315 mW lo $3.9 mA Ri 21 kO Co (Sum of all sensors) <50 uF Lo (Sum of all sensors) $30 uH External diameter cable 4.6-5.0 mm 2020 by SAWY Telematic Systems AG Version V1.10 03.02.2020 page 10 of 25 ariel Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 3.4 External connections for optional SenseGateway-ExR-DMS strain gauge SAVVY LoadCell-Ex Weighing sensor SAVVY LoadCell-Ex Type of protection: Ex Il 1G ia IIC T6 Ga/ Ex Il 1D ia IIIC T85C Da Terminal Color PIN 1 (PT1000+) Green PIN 2 (V-) Yellow PIN 3 (DMS- Signal) White PIN 4 (DMS+ Signal) Grey PIN 5 (V+) Brown PIN 6 (PT1000+) -
PIN 7 (V-) -
PIN 8 (PT1000+ / DIN) -
Uo <3.9V Po < 61mW lo < 15.6mA Co (Sum of all sensors) <= 50uF Lo (Sum of all sensors) < 30uH External diameter cable 4.6 5.0mm 2020 by SAVY Telematic Systems AG
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AST4400 Zindschutzart: {I 1G Ex ia 1B T4 Ga Uo 3.9V / Po 154mW / lo 39.4mA. i O.4uF / Li 0.SuH 1 Reed-Switch Ui 400V / Pi 10W / li 25mA /|Ci 0.4pF / Li 0.7uH StandexMeder MK08-1A75-SOOW Zindschutzart: Il 2GD Ex mb Il TE Uo 3.9V / Po 15mW / lo 3.9mA Verschlusszapfen SenseGateway-ExR TotalCo=0.401uF<50uF 4 Total Lo = 4.2UuH < 30uHY UM BoUBI|dWOD JO} UOT}EIND}eo ay} se ||OM se yosuas ainyesedwia} & JO UOOSUUOD ay} ajdluexe Ue se SIOSUAS [eUJO}X9 OU} OJ WesBeIp WayshS "Ee cl
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[EEN Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 3.6 Grounding and connection to chassis The device does not require a fixed connection to the ground. All electrical signals and intrinsic circuits are separated from the ground and insulated. The nature of the housing and the sensor cables ensures that electrostatic charging cannot take place. The bottom plate can be grounded by the construction of the transport container
(railway car, intermodal tank, container, etc.) and by the assembly of the device with screwing or welding. Likewise, the metal housing of a sensor can be grounded by its assembly, depending on the construction. The relevant directives according to 1999/92/EC (ATEX137) and the standard IEC 60079-14 Ed 5.0 (design, selection, and erection of electrical installations) must be observed in all cases. 3.7 Assembly and installation When assembling, ensure that the flat gasket rests completely on the base plate and is aligned by the threaded bolts. In addition, the following shall be ensured:
e The plug with the screw terminals for the external sensors is fully inserted and locked. e The battery plug is fully inserted and locked. e Check all cable glands for correct seating and 6Nm tightening torque (see image and description on the next page). e The outside diameters of the cables may be between 4.6 and 5.0 mm. e Do not allow single wires to be pinched between the seal and the housing. e All seven housing screws must be tightened with a torque of 2.5 Nm. e Unused cable glands must be provided with a plug and sealed (general delivery condition). 2020 by SAVVY Telematic Systems AG www.savvy-telematics.com Version V1.10 03.02.2020 page 13 of 25
@EEEEZN Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) In order to achieve a sufficient tightening torque and to prevent the connection cable from being disconnected later, the cable gland is to be attached using a 12 mm wrench, and the screwed connection must be tightened using a torque wrench:
The tightening torque is 6 Nm. You can check this with the help of a suitable torque wrench to be certain:
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aa) Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 4 Environmental Conditions and Combustibility Permissible temperature range ATEX /
IECEx (without external sensors)
-30C < T amps +60C Range of temperature range for normal
-40C < Tamp S$ +85C operation (without external sensors) Relative humidity operation 95%
IP protection class with pressure equalizing element according to IEC / 67 EN60529 Vibration, shock. Service life according to EN60068-2-6 and EN61373 5-200 Hz, 50m/*?, Cat.1B Flammability of the housing according to UL94 and IEC/DIN EN 60695-11-10 and
-20 UL94 V-0 Flammability of the housing according to EN45545-2 HL1, HL2, HL3 for R22, R23, R24, R26 Salt spray Min. 96h Specific surface resistivity
<1011 Q at (30+5)% relative humidity UV light-fastness for outdoor use UL746C Impact strength EN60079-0 21 kg from 0.7 m 5 Requirements for Standards Norm IEC 60079-0 (Ed.6.0), IEC 60079-11 eee (Ed.6.0) ATEX EN60079-0:2013, EN60079-11:2012 RED (2014/53/EU) EN 301489-1 V2.1.1:2017-02, EN 301489-17 V3.1.1:2017-02, EN 300328 V2.1.1:2016-11 Protection provided by Enclosure EN 60529+A1+A2: 2013 Environmental Temperature and Humidity EN 60068-2-1, EN 60068-2-38, EN 60068-2-2 Sinus, Shock, and Random Vibration Test EN 61373, EN 60068-2-6 EMC Railway EN 50155:2007, EN 50121-3-2:2015 2020 by SAWY Telematic Systems AG www.savvy-telematics.com Version V1.10 03.02.2020 page 16 of 25 i Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 6 Mechanical Dimensions Weight About 1.2 kg Dimensions L x W x H 165 x 105 x 46 mm (incl. Cable Glands, excl. Cable) Housing material per 1SO1874 PA 66 + PA6, MFHR, 14-110N, GF 30 FR (40) Color RAL7035 light gray Base plate Stainless steel 1.4301 2020 by SAVY Telematic Systems AG Version V1.10 03.02.2020 page 17 of 25
[EEN Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 6.1. Type label, identification, and warning note The following important information is provided on the housing:
1) ATEX identification (can deviate from this picture). 2) Serial number and MAC address, readable and as a QR code.
SAVVY Telematic Systems AG Grabenstrasse 9 CH-8200 Schaffhausen
=3.9V 11 1G Exia IIC T4 Ga IAD Ex ia IIIC T135C Da PTZ1GATEXO008X
-30C $ Ta $ +60C U:
cE SenseGateway-ExR
! Read manual before installation !
2872 3) The housing must not be opened in potentially explosive atmospheres. 4) Manufacturer's address, temperature range, electrical data, EU type-
examination certificate number. IECEx PTZ 17.0003 X Ex ia llC T4 Ga Ex ia IIIC T135C Da IP67 FCC ID: 2ATWF-SGWEXRDMS f =_. we (5) 5) IECEx, FCC, ISED Label Location Info 2020 by SAWY Telematic Systems AG Version V1.10 03.02.2020 page 18 of 25
[EEE Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 6.2 Construction interior view maa | _RTD or Reed RTD or Reed
(Optional Strain Gage) View with removed housing base. 2020 by SAVVY Telematic Systems AG Version V1.10 03.02.2020 page 19 of 25 EEEE Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 7 Replacing the Battery The battery may only be replaced by an original battery from the manufacturer. The replacement is never to be carried out in a potentially explosive atmosphere; corresponding warnings can be found on the device and in the operating instructions. The risk of confusion with a third-party battery is excluded since the manufacturer, type, nominal values, and the plug must be clearly identified. When replacing the battery, note that the switch's lock must be released and re-
locked for the new battery:
BATTERY REPLACEMENT ONTY WITH ORIGINAL ARTICLE No 1060
$11-0205-10-77 Open lock
7.1 Internal battery data Article Number 1060 / 1090 Nominal voltage 3.6 VDC solos: open circuit 3.9 VDC Capacity 19 Ah Battery housing D-cell Diameter max. 33.6 mm Length max. 60 mm Weight 97 g Type LiSOCI2 (lithium thionyl chloride) Connector plug Product-specific 2020 by SAWY Telematic Systems AG Version V1.10 03.02.2020 page 20 of 25
(2 Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 8 Cable Glands and Fasteners Cable fasteners made of rustproof steel A2 with an IP67 degree of protection anda temperature range of -40C to +100C are used for the cable ducts. Unused ducts are sealed using a plug. 9 Pressure Equalization Membrane During the device's intended application, large pressure differences can occur due to rapid temperature fluctuations. Therefore, a pressure relief membrane is provided to prevent possible penetration by moisture. In addition, this membrane allows the emission of moisture, which has entered via diffusion, for example. The pressure compensation membrane has an IP68 degree of protection and is designed for a temperature range of -40C to +150C.
-telematics.com 2020 by SAVVY Telematic Systems AG Version V1.10 03.02.2020 page 21 of 25 EEEEZ Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 10 Fastening with Screws Various types of fastening are available. The bottom plate of the unit can be screwed directly onto a flat surface using three M6 safety screws. Possible small irregularities are compensated for by the spacer bushing in the floor plate. The hole pattern of the SenseGateway-ExR base plate is as follows:
10 145 201 a 753 202 165 Pay attention to a flat surface and mounting!
Unevenness can have a negative effect on the seal and thus prevent both warranty and use in potentially explosive atmospheres. T4Ga JECEx PTZ 17.0003 X |
_ Flat and even surface Flat and even surface 2020 by SAVVY Telematic Systems AG Version V1.10 03.02.2020 page 22 of 25
(EEEEE Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 10.1 Attachment with a welding adapter A further possibility is attaching it by means of a welding adapter, which is first welded to the object. Then the device is screwed onto the welding adapter with three M6 safety screws. 165 10, 145 204 TOP 5 a 5 oO Bs 9 E Fal EF 5 a BOTTOM
a 4x Losereravur, muss deuttich sichtbar sein Depending on the project requirements, the welding adapter is available in various materials, such as DD11, $235, or 1.4301. When using the welding adapter, it must be mounted on grounded metal parts. 2020 by SAVVY Telematic Systems AG Version V1.10 03.02.2020 page 23 of 25
(EEEZH Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 11 Storage and Decommissioning 11.1 Storage The SenseGateway-ExR is delivered in such a way that it can be stored easily over a longer period of time. The internal battery consumes very little or no energy during storage. Make sure that storage takes place at an ambient temperature of +10C to
+30C and that humidity is below 60% rH. 11.2 Decommissioning and disposal The SenseGateway-ExR may not be dismantled and taken out of operation in potentially explosive atmospheres. The internal battery must not be removed in potentially explosive atmospheres. When the unit is taken out of service, the device and the mounting devices can be disposed of separately. The mounting devices are made of steel or stainless steel and can accordingly be recycled as scrap metal. The whole device can be handed over to an appropriate collection point for electronic waste or returned to the following address:
For Germany/EU: SAVVY Telematic Systems AG Goods receiving c/o LogConnect AG Zollstrasse 5 DE-78239 Rielasingen For Switzerland: SAVVY Telematic Systems AG Grabenstrasse 9 CH-8200 Schaffhausen Thank you for ensuring proper disposal. 2020 by SAVVY Telematic Systems AG www.savvy-telematics.com Version V1.10 03.02.2020 page 24 of 25 EEEE Instructions for Installing and Operating the SAVVY SenseGateway-ExR-(DMS) 12 Certificate of Conformity Contact us or check online at https://www.iecex.com/
13 FCC and ISED related statements Changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:
(1) this device may not cause harmful interference, and
(2) this device must accept any interference received, including interference that may cause undesired operation. This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with a minimum distance of 20 cm between the radiator and any human body. This device contains licence-exempt transmitter(s)/receiver(s) that comply with Innovation, Science and Economic Development Canadas licence-exempt RSS(s). Operation is subject to the following two conditions:
1. This device may not cause interference. 2. This device must accept any interference, including interference that may cause undesired operation of the device. Lmetteur/rcepteur exempt de licence contenu dans le prsent appareil est conforme aux CNR d'Innovation, Sciences et Dveloppement conomique Canada applicables aux appareils radio exempts de licence. Lexploitation est autorise aux deux conditions suivantes :
1. Lappareil ne doit pas produire de brouillage;
2. Lappareil doit accepter tout brouillage radiolectrique subi, mme si le brouillage est susceptible den compromettre le fonctionnement. This equipment complies with IC RSS-102 radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with a minimum distance of 20 cm between the radiator and any human body. 2020 by SAVVY Telematic Systems AG Version V1.10 03.02.2020 page 25 of 25