EXTRONICS iWAP107 Wireless Enclosure System User Manual

EXTRONICS iWAP107 Wireless Enclosure System

Introduction

The iWAP107 is an ATEX and IECEx approved Zone 1 Access Point Enclosure with intrinsically safe RF outputs; it is designed to allow the deployment of wireless networks in hazardous areas. The concept allows installation of equipment from leading WLAN vendors such as Cisco, Aruba, Aeroscout and Motorola. Each type of Access Point or RF transmitting device is rigorously checked and tested by Extronics to ensure conformity to the latest standards. This means that the user may select the vendor of their choice when extending a WLAN to hazardous areas. However equipment not previously approved will require assessment to determine its suitability.
The intrinsically safe RF outputs of the iWAP107 allows users to choose any antenna for use with their wireless hardware e.g. Extronics iANT200 range of high quality rugged outdoor antennas. Any antennas not listed in the Extronics range must be assessed by the user to ensure they meet the requirements for installation of non-electrical equipment in hazardous areas. Up to eight antennas can be utilized, allowing the MIMO functionality of the latest 802.11n/ac compatible wireless access points to be implemented, providing optimum coverage and maximum data throughput on Chemical Plants, Oil Refineries or Oil & Gas Platforms. Optional features include surge arrestors for lightning suppression in outdoor installations and single mode or multimode fibre optic inputs to allow for extended Ethernet link distance.

Safety Information and Notes

Storage of this Manual
Keep this user manual safe and in the vicinity of the device. All persons required to work on or with the device should be advised on where the manual is stored. 2.2 Special Conditions for Safe Use

ATEX/IECEx

1. Contact Extronics for information on the dimensions of the flameproof joints.
2. The RF output is only to be connected to an antenna suitable for the hazardous location; refer to associated RF galvanic isolator iSOLATE500 equipment certificate IECEx BAS 13.0064X / Baseefa13ATEX0112X, and associated instructions.
3. If the RF output connector is not intended to be connected to a cable and/or antenna, the output connector must be capped.

List of Notes
The notes supplied in this chapter provide information on the following.

• Warning!
  • Possible hazard to life or health.
• Caution
  • Possible damage to property.
• Important
  • Possible damage to enclosure, device or associated equipment.
• Information
  • Notes on the optimum use of the device

Warning! Installation of the iWAP107 must be performed in accordance with IEC 60079-14 and IEC 60079-25. Maintenance and inspection must be performed in accordance with IEC 60079-17.
Warning! Installation of the iWAP107 is only to be performed by skilled electricians and instructed personnel in accordance with national legislation.
Warning! The iWAP107 contains INTRINSICALLY SAFE circuits.
Warning! The iWAP107 contains INTRINSICALLY SAFE circuits.
Warning! The iWAP107 Intrinsically Safe RF output ports are located in the positions shown in Section 3.3. Only antennas in accordance with Section 3.11 may be connected to these ports. Refer to Section 3.12 for antenna installation requirements.
Warning! The iWAP107 MUST be earthed. Refer to Section [earthing] for details.
Warning! The iWAP107 must NOT be installed in hazardous areas requiring Category 1, M1 or M2 equipment.
Warning! Although antennas connected to the Intrinsically Safe RF outputs of the iWAP107 may be installed in hazardous areas requiring Category 1 equipment, the iWAP107 flameproof enclosure must NOT be installed in these environments.
Warning! The iWAP107 flameproof enclosure must NOT be opened when an explosive gas or dust atmosphere is present, or when the equipment is energized.
Warning! The iWAP107 flameproof enclosure lid must be secured only with the bolts supplied, and these must be tightened to the correct torque value. See Section 3.2.2 for details. Contact Extronics for spare bolts.
Warning! The iWAP107 flameproof enclosure must only be fitted with suitably approved cable entry devices. See Section 3.3 for details.
Warning! Do not exceed the RF Threshold Power for the equipment group in which the iWAP107 and its antennas are to be installed; it must be controlled in accordance with IEC 60079- 0, and must not exceed the following levels:

• IIC – 2W (+33dBm)
• IIB – 3.5W (+35.4dBm)
• IIA – 6W (+37.7dBm)
• III – 6W (+37.7dBm)

See Section 3.10.1 for an example of how to calculate the RF Threshold Power

Warning! The iWAP107 must not be modified in any way.
Warning! There are no user-serviceable parts below the top plate of the iWAP107 – see Section 3.5 for details. Always refer service enquiries to Extronics.
Warning! Hazardous voltages are present within the iWAP107 enclosure.
Warning! Hot surfaces may be present within the iWAP107 enclosure – observe the warning labels fitted
Warning! Optical radiation hazards may be present within the iWAP107 enclosure – observe the warning labels fitted.
Warning! The iWAP107 may weigh up to 70Kg. Exercise care when handling and mounting.
Warning! DO NOT lift the iWAP107 using the threaded entries, N-typ RF connectors or door bolts. Lift only using suitably approved slings, fitted by suitably qualified personnel
Important Ensure that NO TOOLS come into contact with the flamepath of the enclosure, as this may cause irreparable damage an render the unit unsafe
Important Always re-apply a thin layer of Loctite 8104 or Loxeal GS silicone grease to the enclosure flame paths whenever the iWAP107 flameproof enclosure is opened. This is required to maintain the IP rating of the enclosure
Important Do not exceed the power supply parameters specified on the iWAP107 external rating plate
Important Only replace the fuse with the same value and type indicatedon the internal fuse identification label
Important Ensure that only the correct fibre transceiver format/power is connected to the iWAP107. Damage to the iWAP107 fibre interface or customer equipment may occur if the wrong format/excessive optical power is used.

Installation

Mounting

Warning! The iWAP107 stainless steel enclosure weighs approximately70Kg. Exercise care when handling, and use suitable mounting points and structures. Mount the enclosure ONLY using the mounting points shown.
Warning! DO NOT lift the iWAP107 using the threaded entries, N-typ RF connectors or door bolts. Lift only using suitably approvedslings, fitted by suitably qualified personnel.

Opening and Closing the Enclosure

Important Ensure that NO TOOLS come into contact with the flamepath of the enclosure, as this may cause irreparable damage and render the unit unsafe.
Warning! The iWAP107 flameproof enclosure must NOT be opened when an explosive gas or dust atmosphere is present, or when the equipment is energized.
Warning! The iWAP107 flameproof enclosure lid must be secured only with the bolts supplied, and these must be tightened to the correct torque value. Contact Extronics for spare bolts.
Important Always re-apply a thin layer of Loctite 8104 or Loxeal GS9 silicone grease to the enclosure flame paths whenever the iWAP107 flameproof enclosure is opened. This is required to maintain the IP rating of the enclosure

Opening the Enclosure

The flamepaths of the iWAP107 enclosure are supplied with grease applied to protect them. This can make the enclosure lid difficult to open as the grease can cause it to stick. Therefore Extronics recommend the use of a double suction lifter. This tool is available from hardware and builders supply stores. Extronics recommend using a lifter that has a working load of 50kg minimum and approximate dimensions 300mm x 120mm

• Remove all bolts, using a wrench with an 8mm hex head. Store the bolts carefully to avoid damage or loss.
• Attach the suction lifter as per the instructions provided with the lifter and release the door.

Closing the Enclosure

• Check that the correct grease (Loctite 8104 or Loxeal GS9) has been applied to the flame-path, and that it is free of damage.
• Check all bolts are the correct type and free from damage.
• Re-insert the bolts and hand-tighten only.
• Using a torque wrench fitted with an 8mm hex head, tighten the bolts in opposite corners of the box, then work around the box. Use the following maximum torque.

Lid Bolt Torques

Cable Entries

Warning! The iWAP107 flameproof enclosure must only be fitted with suitably approved cable entry devices.
Warning! The iWAP107 protective plastic transport caps fitted to al threaded cable entries MUST be replaced with suitably certified cable glands or stopping plugs before installation in a hazardous area.
Warning! Any iSOLATE-CT RF connector transits fitted to the iWAP107 must NOT be loosened or removed by the user under any circumstances, as their flameproof protection may b damaged by this.

Cable Entries and Connections for iWAP107-C-37-AC-SG-2450- 4S-N-0-N stainless steel enclosure
The iWAP107-C-37-AC-SG-2450-4S-N-0-N stainless steel enclosure is supplied with entries and connectors as shown in Figure 3.

• Connections A-D are INTRINSICALLY SAFE outputs providing galvanically isolated RF signals (see Section 16 for details), carried on conventional 50Ω impedance N-type female connections. The N-type connections are the front part of the iSOLATE-CT devices which transit through the flameproof wall of the iWAP107022 enclosure, and are approved as part of the iWAP107 ATEX/IECEx certification. The designators A-D correspond with the RF port assignments of the Cisco AIR-CAP2602E-Z-K9 access point installed in the flameproof enclosure.
• Entries D and E are M20 x 1.5 – 6H threaded Ex d entries. Entry D is for the power supply, entry E for the data connection

Earthing

Warning! The iWAP107 MUST be earthed. It must be connected to the plant earth system using at least one of the external bonding points, using a minimum 4mm2 conductor. The earth cable must be installed in accordance with the requirements of IEC 60079-14.
Warning! The iWAP107 enclosure door earth bond must not be removed.
Warning! The iWAP107 internal power input connector has an earth connection, which must be terminated to the protective earth conductor of the incoming power supply

Location of iWAP107 stainless steel enclosure external earth bond points
There is an M5 threaded earth bond point on each of the 4 enclosure feet.

Location of iWAP107 aluminium enclosure external earth bond points

Electrical Installation

Important Do not exceed the power supply parameters specified on the iWAP107 external rating plate.
Important Only replace the fuse with the same value and type indicated on the internal fuse identification label.

__

A

| __

Fuse Holder

| Contains 1 active fuse and 1

spare. Not fitted on POE version. See Section 3.7

__

B

| __

Power input

| Mains (L,N,E) or DC (+,-,E)

input, dependent on product configuration. Not fitted on POE version. See Section

3.6 for details.

__

__

C

| __

__

Fibre input

| This can be single mode or multimode fibre, or replaced by a blanking plate, depending on product

options. See Section 3.9.3 for details

__

__

D

| __

__

CAT5E input

| This 10/100/1000 Base T CAT5E data connection. It may also be replaced by a blanking plate, depending

on product options. See Section 3.9.1 for details

__

E

| __

Console port

| This is a serial console port for Cisco Access Points. See

3.9.4 for details.

__

F

| __

Fibre splice tray

| This is a 12-way fibre splice tray, only fitted when the fibre option is selected.

Power supply
Important The iWAP107 may be powered from a number of different ower sources, depending on its configuration. Refer to the rating plate of the unit supplied for details.

The mains power connection is made with a 2-part screw-terminal connector (supplied), the plug part is Phoenix Contact 1804917, and spare plugs can also be supplied by Extronics. It has a minimum tightening torque of 0.5Nm, a maximum of 0.6Nm, and requires a 3.5mm x 0.6mm slotted screwdriver.

Wire Type| Minimum Cross Sectional Area| Maximum Cross Sectional Area
---|---|---
Single Solid Core| 0.2mm2| 4mm2
Single Stranded Wire| 0.2mm2| 4mm2
Single Stranded Wire, With Ferrule With/Without Sleeve| 0.25mm2| 4mm2
2 Solid Conductors With

Same Cross Section

| 0.2mm2| 2mm2
2 Stranded Conductors With Same Cross Section| 0.2mm2| 1.5mm2
2 Stranded Conductors With Same Cross Section, With Ferrules Without Sleeves|

0.25mm2

|

1.5mm2

Fusing

Fuse Ratings

Important Only replace the fuse with the correct type, having established the reason for the fuse blowing.
The iWAP107 is fitted with a single fuse on the Live circuit, of either a 1A or 2A, depending its configuration. The fuse requirement for the specific model supplied is written on the top plate next to the fuse holder.
The iWAP107 contains surge suppression and filtering devices which may cause the fuse to blow if the unit is subjected to power surges or transients. Replacement fuses should be either 1 or 2A Time-lag 20mm x 5mm HRC Fuses, rated at 250VAC, 1500A Interrupt Rating, for example Littelfuse 0215001.MXP or 0215002.MXP.

Changing Fuse
See Figure 8 for access to Fuse. The fuse holder also carries a spare fuse for convenience.

External Overcurrent Protection
The iWAP107 should be installed on a circuit with a double-pole circuit breaker of amaximum of 25A. This is the maximum current rating of the smallest internal chassis earth bond in accordance with EN60950-1 2.6.3.3. Refer to Extronics if it becomes necessary to exceed this rating.

Data Connections

Copper Ethernet

Information Check that the line speed of the switch port to which the iWAP107 is connected matches the iWAP107 por configuration, otherwise communication may not be established

If Copper Ethernet is specified, this will be terminated in a standard CAT5E RJ45 Socket on the front plate of the iWAP107, Position D in Figure 6. Typically the interface will be an IEEE 10/100/1000BaseT format, but this is dependent on the access point installed.
Terminate the RJ45 plug as follows (EIA 568B standard):

Power-Over-Ethernet (POE)
If Power-Over-Ethernet (POE) is used, the format will depend on the access point installed in the iWAP107. Ensure that the correct Power Sourcing Equipment (PSE) is used. Connect the RJ45 cable per Section 3.9.1.

Optical Fibre

Warning! Optical radiation hazards may be present within the iWAP107 enclosure – observe the warning labels fitted.
Important Ensure that only the correct fibre transceiver format/power is connected to the iWAP107. Damage to the iWAP107 fibre interface or customer equipment may occur if the wrong format/excessive optical power is used.

The iWAP107 optical fibre format may be any of the following, refer to product option code #4 for details. Other optical formats are available on request.

Option #4| Fibre Format| Connection| Transmitter Power| Receiver Sensitivity| Max Receiver Input

Without Damage

| Wavelength| Typical Range
---|---|---|---|---|---|---|---
F| 100Base

-FX

| LC Duplex Multimode 62/125µm or

50/125µm

| -14 to -20dBm (62/125µm)

-14 to – 23.5dBm (50/125µm)

| -31dBm| -8dBm| 1310nm| 2km
S| 100Base

-FX

| LC Duplex Single Mode 9/125 µm| -8 to -15dBm| -34dBm| 0dBm| 1310nm| 30km
FG| 1000Bas e-FX| LC Duplex Multimode 62/125µm or 50/125µm| -1 to -9dBm (62/125µm)

-1 to – 9dBm (50/125µm)

| -19dBm| -1dBm| 1310nm| 2km (62/125µm) 1km (50/125µm)
SG| 1000Bas e-FX| LC Duplex Single Mode 9/125 µm| -3 to -9.5dBm| -20dBm| -3dBm| 1310nm| 10km

Console Port
The console port is a standard Cisco RS232 configuration port on an RJ45 socket. The port for Cisco Access Points is 9600 Baud, 8 Data Bits, No Parity, 1 Stop Bit. Other vendors may use different formats.

Table 5: Cisco console port wiring

Intrinsically Safe RF Outputs

Warning! The iWAP107 Intrinsically Safe RF output ports are located in the positions shown in Section 3.3. Only antennas in accordance with Section 3.11 may be connected to these ports. Refer to Section 3.12 for antenna installation requirements.
Warning! Although antennas connected to the Intrinsically Safe RF outputs of the iWAP107 may be installed in a hazardous areas requiring Category 1 equipment, the iWAP107 flameproof enclosure must NOT be installed in these environments.
Warning! Do not exceed the RF Threshold Power for the equipment group in which the iWAP107 and its antennas are to be installed; it must be controlled in accordance with IEC 60079-0, and must not exceed the following levels:

• IIC – 2W (+33dBm)
• IIB – 3.5W (+35.4dBm)
• IIA – 6W (+37.7dBm)
• III – 6W (+37.7dBm)

The RF outputs of the iWAP107 are approved as:

• Ex ia IIC Ga
• Ex ia IIIC Da
• Um = 253Vr.m.s

Refer to Figure 4 for location of Intrinsically Safe RF outputs of iWAP107-C-37-AC-SG-2450-4S-N-0-N

Example of RF threshold power calculation
The following example shows how the RF threshold power may be calculated:
Maximum transmitter output power (from transmitter datasheet) = 20dBm (100mW) Coaxial cable loss = 2dB
Antenna gain = 5dBi
Threshold power = 20dBm – 2dB + 5dBi
Threshold power = 23dBm (200mW)

Antenna Requirements
Antennas connected to the iWAP107 Intrinsically Safe RF outputs must be assessed as ‘simple apparatus’ in accordance with IEC 60079-11. Antennas supplied by Extronics for use with the iWAP107 already meet these requirements. It is possible to assess other antennas for this purpose, contact Extronics for details.

Antenna Installation
Antennas approved by Extronics for use with the iWAP107 may either be fitted directly to the RF connectors of the iWAP107, or via a length of coaxial cable.
If antennas are sited remotely from the iWAP107 flameproof enclosure, any metallic parts of the antennas must be isolated from earth by > 500Vr.m.s, to prevent hazardous earth currents from flowing in the coaxial cable .

Figure 10: iWAP107 IS RF Installation Diagram

Intended Purpose Usage

Warning! Maintenance and inspection of the iWAP107 must be performed in accordance with IEC 60079-17.
Important Before setting the units to work, read the technical documentation carefully.
Important The latest version of the technical documentation or the corresponding technical supplements is valid in each case

The iWAP107 is built using modern components and is extremely reliable in operation; however it must only be used for its intended purpose. Please note that the intended purpose also includes compliance with the instructions issued by the manufacturer for installation, setting up and service.
Any other use is regarded as conflicting with the intended purpose. The manufacturer is not liable for any subsequent damage resulting from such inadmissible use. The user bears the sole risk in such cases.

Transportation and Storage
All iWAP107 devices must be so transported and stored that they are not subjected to any excessive mechanical stresses.

Authorized Persons
Only persons trained for the purpose are authorized to handle the iWAP107; they must be familiar with the unit and must be aware of the regulation and provisions required for explosion protection as well as the relevant accident prevention regulations.

Cleaning and Maintenance
The iWAP107 and all its components require no maintenance. All work on the iWAP107 by personnel who are not expressly qualified for such activities will cause the Ex approval and the guarantee to become void.

Cleaning and Maintenance Intervals
The cleaning intervals depend on the environment where the system is installed.

Aggressive substances and environments
The iWAP107 is not designed to come into contact with aggressive substances or environments, please be aware that additional protection may be required.

Exposure to external stresses
The iWAP107 is not designed to be subjected to excessive stresses e.g. vibration, heat, impact. Additional protection is required to protect against these external stresses.
The iWAP107 will require additional protection if it is installed in a location where it may be subjected to damage.

Technical Data

Label Drawing

Where AAA=Supply voltage, BBB=Supply current, CCC=Supply Frequency, DDD=Product option codes, EEE=Notified body number for production, MAC1/MAC2 are the Ethernet MAC addresses of up to 2 devices installed in the unit.

Type Codes

EU Declaration of Conformity

Manual Revision History

THIS DOCUMENT MUST NOT BE MODIFIED WITHOUT PRIOR PERMISSION FROM THE AUTHORISED PERSON

Document Change History
Issue No.| Changed By| Details Of Change| Date| Red Line

PIL

| ECN| Approved by:|
1.0| BTS| Initial Release| 25/04/2014| N/A| N/A| BTS
2.0| BTS| Added Aluminium enclosure details| 29/04/2014| N/A| N/A| BTS
2.1| AJP| Updated type codes and enclosure image| 01/07/2014| N/A| N/A| AJP|
2.2| JR| Released to Winman in PDF Format| 17/04/2015| N/A| N/A| NS|
2.3| SR| Updated EU Declaration of Conformity| 04/07/2016| N/A| 110| NS|
2.4| JR| Update of page 1 image.| 29/07/2016| N/A| 127| JR|
2.5| PR| Update opening the enclosure section 3.2.1| 13/09/2016| N/A| 150| NS|
Notes:|
This document is not to be modified without prior reference to an authorized person.

Web: www.extronics.com

References

• Hazardous Area Solutions | Process Industries | Extronics

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