1. Tools and BoM list

Tools

•  Crimping Tool

Crimping tools are used to deform materials and create connections. To connect wires together or to other connectors, crimping is commonly used in electrical work.

•  Precision Micro Wire Cutter

A wire cutter or cable cutter is a tool that cut wires and cables in a safe manner without damaging the insulation or conductors.

•  Measuring Tape

A Measure Tape is a tool used to measure length.

•  Stripping tool

Wire strippers are portable handheld tools used by workers, especially electricians, to remove the protective coating of electric wires for replacement or repair.

•  Knife

A tool used to cut wires or cables.

•  Soldering Equipment

A durable, permanent connection can be created by joining conductive metal elements with solder. Soldering machines are essential tools for building, modifying, and repairing electronics.

•  Hot air gun

Heat guns are devices that emit a jet of compressed air toward a particular point or surface.

BoM list

• Ferrule

Correct ferrule size must be selected based on the gauge of the wire, as a standard Rheonics uses ferrule with a pin length of 8mm and diameter of 1mm (cross-section 0.5mm2).

•  Solder wire

Solder wires are wires with a low melting point, used to create joints using a soldering iron.

•  Heat shrink tube

Heat shrink tubing is a common element in most electrical installations that protects wires from moisture, dust, abrasion, and sharp objects that might otherwise damage them.

• Ex Sensor Cable

The SRV/SRD sensor is connected to its associated Zener diode barriers by means of a cable that has an 8-pole M12 connector on the sensor end.

The cable and connector selected must be rated for at least the highest ambient temperature at which the sensor will be used.

• M12 connector of the sensor

Connector, Universal, 8-position, halogen-free, shielded, Socket straight M12, A-coded, Insulation displacement connection, knurl material: Zinc die-cast, nickel-plated, external cable diameter 5 mm ... 9.7 mm

• Metal tape

This tape is commonly used to secure duct seams, connections, and joints. Additionally, it has excellent waterproof properties.

End result

Once all the steps are completed we are going to obtain our Ex sensor cable with the following three sections. 

2. Probe side M12 connector preparation

Required tools:

1. Knife

2. Measurement tape

3. M12 Connector

4. Metal tape

• Take the cable and cut the required length for your application. We recommend stripping out the cable sheath at 80mm from the end as a suitable length to prepare the cables for M12 Connector preparation.

• Since the sensor cable has an outer diameter of about 8.5 mm, the cable's shield must be fixed
  with the provided metal tape as shown in the instructions for cable with a diameter over 6 mm. 

• After the cable shield has been fixed, the rest of the shield can be cut at the edge of the tape. Then pass all 8 wires of the cable through the sensor body. Take care not to damage the insulation of the wires. Push the cable completely into the sensor connector to ensure proper contact with the cable shield.

• The connector body has 8 color marked slits in the front. Pull each wire into the slit marked with its
  color as shown in Figure 19.

• Cut the remnant of each wire, so each wire is fixed in the available space.

• Close the sensor connector.

• After the sensor connector has been mounted on the blue sensor cable, it can be connected to the M12
  the connector of the sensor. 

3. SME electronics side sensor cable preparation for EX zener barriers

Requirements:

1. Knife

2. Cutter

• Strip the blue outer cable sheath on a length of 100 mm (4 in.)

Figure 25. Metal shield twisted with heat shrink.

• Crimp a ferrule to the ground cable end.

Figure 26. Ferrule crimped to the ground cable.

•  After the stripping of the cable sheath, carefully loosen and then twist the cable shield. 

• Remove the plastic cover from the colored wires.

Requirements:

1. Soldering machine

2. Solder wire

3. Heat Shrink tube

4. Hot air gun

• Take the twisted cable shield and cover it fully with a heat shrink.

• Take the twisted cable shield and cover it fully with a heat shrink.

Figure 30. Metal shield twisted with heat shrink.

• Crimp a ferrule to the ground cable end.

Figure 31. Ferrule crimped to the ground cable

Requirement:

1. Crimping tool

Your crimping tool should have a nest for inserting the terminal. After inserting in the correct slot, squeeze the crimp tool firmly and release it to get a long-lasting, tight fuse. 

We recommend crimping the ferrules on 4 sides for the connection with the Zener barriers.

• Twist the wire and Crimp them (Crimpers) using the Crimping Tool.

• The green and yellow wires are not used to operate the sensor. They have to be connected to the
  ground together with the shield of the cable. This means that they should be connected to the ground terminals of the Zener barriers.

•  Strip all eight wires on a length of 10 mm and put bootlace ferrules on the ends.

4. Ex zener barriers to SME connection

Next is the connection of the Zener barriers with the SME-DRM, the blue end is used to connect to the sensor that is installed in the hazardous area.

Requirement:

1. Various wires with crimped ends.

2. Zener barriers Z041x2 and Z757.

3. SME-DRM

• Install the SME-DRM and the Zener barriers in a DIN-rail and prepare short wires to be used.

• Next is to have a proper grounding, which could be either the DIN-rail or the ground available in the Zener barriers.

• The wiring should be done the same as the wiring diagram shown in Figure 28 Part A. The end result should be as follow.

5. Ex sensor to zener barrier

Requirement:

1. Ex Sensor cable with crimped ends.

2. Zener barrier Z041 x 2 and Z757

3. SME-DRM

• This step starts with the wiring of each ferrule end with the connection of the Zener barrier, we need to connect each wire to the corresponding terminal in the Zener barrier based on this wiring diagram where the Part B represents the ferrule ends prepared.

• The final result should look like this.

Note:

• Typically SME-DRM is used for connection with EX barriers so both can be mounted inside a cabinet with DIN rails

However, it is also possible to put the EX barriers in another enclosure and connect to the SME-TR or SME-TRD using cable glands. 

• The barrier can also be used in an enclosure and a cable can be connected between barrier and the SME-TR/TRD through cable glands. 

References: 

[1] Crimping Pliers for Wire Ferrules 

[2] Precision Micro Wire Cutter - Cutting Range: 28-14 AWG 

[3] How To Read Measure Tape | Reading A Tape Measure | Measuring Tape Reading 

[4] FD2810WS - Wire Cutting and Stripping Tool - 28AWG to 10AWG
[5] Uline Steel Knife in Stock - ULINE 

[6] SCHOFIC 936D Plus Rework Soldering Station SMD Desoldering Solder Iron Handle ESD Soldering Kit Soldering Machine Soldering Iron Kit Soldering Stand 

[7] RS PRO EOT0202 500°C max Corded Heat Gun, Type C - EuroPlug 

[8] https://www.distrelec.ch/en/bootlace-ferrule-5mm-white-14mm-pack-of-100-pieces-rnd-connect-rnd-465-00566/p/30110345 

[9] RS PRO Wire, 0.71mm Lead solder, 183°C Melting Point 

[10] HellermannTyton Heat Shrink Tubing, Black, Blue, Green/Yellow, Red, White 3mm Sleeve Dia. x 35mm Length 3:1 Ratio 

[11] Productdetails | HELUKABEL 

[12] SACC-M12FS-8QO-0,5 SH - Connector - 1414611 | Phoenix Contact 

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