Operating Instructions - Stahl
Contents
1. 80 mm 3 1 hm ipo mm 0 2 FUN Ls d 65mm 65S am L 4 1 iom N Y l Be Em NE Si AH ALB gat 4 4 Att N la AE ne al 9j YZ E g A DX ob E 5 5 mm E 5 ON oly j i NS TT 5 5 mm Compact 8040 11 8040 12 80 mm 80 mm r mm m 6 8m 445 5 mm EE 4 1 5 5 mm SET y 4 BE N j T E l NES Ades LN B vE DE H t il B i mF Eg wu ES E QW d J dy mm i Ho 8040 64 8040 33 UP em i mj E Ay i B a5 mE H t MZ 5 j 0 2 dI i 8040 54 80 406 10 30 0 3 8040606300 S BA 8040 en 02 15 06 2007 3 1 80 mm CU m en 0 2 5 5 mm al ai nj y 2 A E Aj B KE RE ji aes 26 N Je EN g on a Ary E D 0 2 Q TT j 5 5 mm 8040 22 3 1 80 mm 7mm en 0 2 43 1 5 5 mm 11 mm J E i On P B KE vE pE aE on eu a i 0 2 5 5mm 4 8040 42 3 15 80mm 2 76 2m 70mm 5 5mm A io E NS A5 I E Pri co E C i A B le wE EE E Q5 yo E A 8040 73 84 94 Control and signal station 8040 October 132. T Instructions CenSig Control and signal station 6040 Contents 1 2 1 2 2 2 3 Contents 1 Soil 2 2 CAS CTS TAT OUT OU MT Om 2 3 Sale MA SHOCHONS esacsiereansnmmneseaetaneartaensetinesiuetaasnnraninseyanhcamansnaeenoronrsearsanaetiausimnentors 3 4 Conformity to standards 2 00 ecececcccesececeeeeeaeeeeeceececeueeeceeeeeseeessueceseuseeeeeeesneesaneees 3 5 FONCION X 3 6 TEEMAGA e 4 7 LA S m 6 8 H AN AON EE EE E A A EEEE 7 9 SEE eri nro oe T E A E N E E 8 10 Repairs and Maintenance ccccccccecceecceseeceeeceeecaeeceueesaeesaeeseeeceuessaeeaeeeseeesanesaas 9 11 Accessories and spare parts cece ceeeccceeceeceeeeeceeeeceeeeesseeeeseeeeseeeeeeseseeseueeesaeeeesees 10 12 DIPOST E E E E EE 10 13 Type Examination Certificate Page 1 cc cccccccecesseeeeseeeeeseeeesaeeesseneeeseeeeeees 11 14 Declaration of conformity lessen nnns 12 15 Installation Operation amp Maintenance Sheet eeeeeeeeeeeeeeee 13 General Information Manufacturer R STAHL Schaltger te GmbH Am Bahnhof 30 D 74638 Waldenburg Telephone 49 7942 943 0 Fax 49 7942 943 4333 Internet www stahl de Information about the Operating Instructions ID NO 8040606300 Publication
3. 2006 15
4. Code S BA 8040 en 02 1 5 06 2007 We reserve the right to make technical changes without notice Purpose of these instructions Working in hazardous areas the safety of personnel and plant depends on complying with all relevant safety regulations Assembly and maintenance staff working on installations therefore have a particular responsibility They require precise knowledge of the applicable standards and regulations These instructions give a brief summary of the most important safety measures They supplement the corresponding regulations which the staff responsible must study 8040606300 Control and signal station 8040 S BA 8040 en 02 15 06 2007 Safety instructions 3 Safety instructions Use the station only for its intended purpose Incorrect or impermissible use or non compliance with these instructions invalidates our warranty provision No changes to the station impairing its explosion protection are permitted Mount the station only if it is clean and undamaged Observe the following when using the station National safety regulations National accident prevention regulations gt National installation regulations e g IEC 60079 14 Generally recognized technical regulations Safety guidelines in these operating instructions Characteristic values and rated operating conditions on the rating and data plates gt Additional instruction plates on the station Any damage can invalidate the Ex protec
5. 00 p D 04581E00 D 04580E00 ConSig 8040 11 ConSig 8040 12 ConSig 8040 13 97 o4584460 M 25 a mm min max M20 25 31 27 33 Additional dimensions for cable glands Series 8161 Flange b mm Brass 16 04579E00 04583E00 Plastic 16 04585E00 ConSig 8040 23 ConSig 8040 11 Additional dimensions for flanges and ConSig 8040 12 combination C8 When explosion protected electrical equipment is exposed to the weather it is advisable to provide a protective cover or wall CS8 iTransport and storage are only permitted in the original packing 6 Control and signal station 8040 8040606300 S BA 8040 en 02 15 06 2007 Installation 8 Installation To avoid moisture and dirt collecting inside the control stations electrical installation must be carried out in a clean and dry environment The enclosure may only be opend to carry out installation work and must be carefully closed again following completion of the work Mains connection The conductors must be carefully connected The conductor insulation must reach to the terminal The conductor itself must not be damaged nicked when removing the insulation Ensure that the maximum permissible conductor temperatures are not exceeded by suitable selection of cables and means of running them CS8 When terminal sleeves are fitted they must be gas tight and applied with a suitable to
6. al capacity 12 22 AWG or 2 5 mme tightened to 18 in lbs or 2 N m 4 Directions for Installation 4 1 4 2 Mounting the Enclosure Using a common screwdriver remove the four cover screws Install the enclosure securely using 10 to 1 4 or M5 to M6 mounting screws through holes are provided in the box Mounting dimensions are as shown on page 3 Electrical Installation There are two types of installation methods Conduit installation and cable installation When conduit is used the control station s were ordered and delivered with a 3 4 conduit hubs When MC HL cable is used the control station comes with internal ground plates with NPT threads into which the appropriate cable connec tors with sealing rings have to be fitted October 13 2006 Control and signal station 8040 13 Installation Operation amp Maintenance Sheet R STAHL INC 45 Northwestern Drive Salem NH 03079 4809 Tel 800 782 4357 FAX 603 870 9290 E mail sales 9 rstahl com Website www rstahl com 4 3 Installations of Cable Connectors 4 3 1 When field installing connectors use the pro vided conductive ground metal plates 4 3 2 Align the ground plate inside the enclosure so that the threaded hole is centered with the hole in the enclosure 4 3 3 Insert the connector through the sealing ring and screw the connector into the ground plate inside the enclosure 4 3 4 Tighten the connector so that the sealing ring i
7. ass plate for earthing metal cable glands sides C and D threaded holes M 20 x 1 5 05633E00 8040007550 0 042 threaded hole M 25 x 1 5 8040008550 0 037 Combination adaptor set for combining 2 enclosures 8040806290 0 019 Attention Lower enclosure requires tapped hole M 25 in side C top o5616600 Upper enclosure requires tapped hole M 25 in side D below 12 Disposal Observe the national standard for refuse disposal 10 Control and signal station 8040 8040606300 S BA 8040 en 02 15 06 2007 Type Examination Certificate Page 1 13 Type Examination Certificate Page 1 Physikalisch Technische Bundesanstalt PIB Braunschweig und Berlin 1 EC TYPE EXAMINATION CERTIFICATE Translation 2 Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Directive 94 9 EC 3 EC type examination Certificate Number PTB 01 ATEX 1105 4 Equipment Control and indicator module type 8040 b Manufacturer R STAHL Schaltger te GmbH 6 Address Am Bahnhof 30 D 74638 Waldenburg W rtt Germany 7 This equipment and any acceptable variation thereto are specified in the schedule to this certificate and the documents therein referred to 8 The Physikalisch Technische Bundesanstalt notified body No 0102 in accordance with Article 9 of the Council Directive 94 9 EC of 23 March 1994 certifies that this equipment has been found to comply with th
8. aunschweig 8040606300 Control and signal station 11 S BA 8040 en 02 15 06 2007 8040 Declaration of conformity 14 Declaration of conformity TXV 03 99 Papier chlortrei 12 EG Konformit tserkl rung EC Declaration Of Conformity CE D claration De Conformit PTB 01 ATEX 1105 Wir we nous R STAHL Schaltger te GmbH Am Bahnhof 30 D 74638 Waldenburg erkl ren in alleiniger Verantwortung da das Produkt Befehis und Meldegerat hereby declare in our sole responsibility that the product Control and signal station Type 8040 d clarons de notre seule responsabilit que le produit Postes de commande et de signalisation Type 8040 auf das sich diese Erkl rung bezieht mit der den folgenden Norm en oder normativen Dokumenten bereinstimmt which is the subject of this declaration is in conformity with the following standard s or normative documents auquel cette d claration se rapporte est conforme aux norme s ou aux documents normatifs suivants Bestimmungen der Richtlinie terms of the directive prescription de la directive 94 9 EG Ger te und Schutzsysteme zur bestimmungsgem ften Verwen dung in explosionsgef hrdeten Bereichen 94 9 EC Equipment and protective systems intended for use in potentially explosive atmospheres 94 9 CE Appareils et syst mes de protection destin s tr utilis s en atmosph res explosibles 89 336 EWG Elektromagn
9. ble from Fa R STAHL Schaltger te GmbH Bd recommend the use of type 8290 stopping plugs for unused holes and 8040606300 S BA 8040 en 02 15 06 2007 8 Control and signal station 8040 Repairs and Maintenance 10 Repairs and Maintenance N WARNING Do not open enclosure when supply is switched on Do not open when intrinsically safe circuits are energised Exception Enclosures with intrinsically safe and non intrinsically safe circuits with the notice Non intrinsically safe circuits protected by IP 30 cover may be opened when supplied with power Repairs and maintenance work on the control stations may only be carried out by appro priately authorized and trained personnel N WARNING Observe the relevant national regulations in the country of use Cts Ifaflameproof device is damaged absolutely no repair or maintenance work is allowed Please replace the device For the purpose of maintenance work the length of time between periodic checks shall be so set that any system faults likely to arise are found promptly The maximum interval between checks is three years Note the following when establishing the interval between checks the ambient conditions installed in the open wind rain sunlight etc the operating conditions utilisation of system operator errors manufacturers instructions in technical documentation mechanical and electrical life of switchgear big changes in the wh
10. e Essential Health and Safety Requirements relating to the design and construction of equipment and protective systems intended for use in potentially explosive atmospheres given in Annex ll to the Directive The examination and test results are recorded in the confidential report PTB Ex 01 11181 9 Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN 50014 1997 A1 A2 EN 50017 1998 EN 50018 2000 EN 50019 2000 EN 50020 1994 EN 50028 1987 10 If the sign X is placed after the certificate number it indicates that the equipment is subject to special conditions for safe use specified in the schedule to this certificate 11 This EC type examination Certificate relates only to the design and construction of the specified equipment in accordance with Directive 94 9 EC Further requirements of this Directive apply to the manufacture and supply of this equipment 12 The marking of the equipment shall include the following li2G EExedqm la ib ia ib Il HA HB IIC T6 T5 or T4 i Braunschweig October 1 2001 sheet 1 3 EC type examination Certificates without signature and official stamp shali not be valid The certificates may be circulated only without alteration Extracts or alterations are subject to approval by the Physikalisch Technische Bundesanstalt In case of dispute the German text shall prevail Physikalisch Technische Bundesanstalt Bundesallee 100 D 38116 Br
11. etische Vertraglichkeit 89 336 EEC Electromagnetic compatibility 89 336 CEE Compatibilit lectromagn tique Waldenburg 14 02 2002 Titel und oder Nr sowie Ausgabedatum der Norm title and or No and date of issue of the standard titre et ou No ainsi que date d mission des normes EN 50014 1997 A1 A2 EN 50019 2000 EN 50017 1998 EN 50020 1994 EN 50018 2000 EN 50028 1987 EN 60947 1 1999 EN 60439 1 1999 Ort und Datum Leiter Marketing und Entwicklung Piace and date Head of Marketing and Development Head of quality management dept lieu et date Directeur Marketing et D velopprment Chef du dept assurance de qualit Control and signal station 8040 8040606300 S BA 8040 en 02 15 06 2007 15 R STAHL INC 9001 Knight Road Houston TX 77054 Tel 800 782 4357 FAX 713 792 9301 E mail sales Q rstahl com Website www rstahl com Series 8040 Non Metallic Control and Signaling Stations Please read this entire document before beginning any work Consig 1 Safety Instructions Installation and maintenance of these control station should only be performed by qualified personnel in accordance with the National Electrical Code NFPA 70 or the Canadian Electrical Code CEC and any local regulations which relate to hazardous classi fied locations CAUTION Disconnect power supply before installing or serv icing these control stations Operate only undamaged devices with observa
12. icates Rated working voltage Display range Version Certificates Rated working voltage Version Certificates Rated working voltage Rated operating characteristics referred to service category Version Certificates Rated working voltage Rated working current Ambient temperature at Temperature class Version Certificates Rated isolation voltage 8040606300 S BA 8040 en 02 15 06 2007 Type 8010 Indicating lamp PTB 01 ATEX 1160 U 20 V 254 V Exe max 15 mA Ex i max 150 mA 0 Hz 60 Hz 20 C 55 C at T6 Exi 20 TC 60 C at TA Ex e Type 8405 Ammeter PTB 01 ATEX 2158 U max 690 V corresponds to measuring range to DIN 43701 Type 8208 Control unit PTB 01 ATEX 1066 U max 500 V Type 8082 Contact block PTB 00 ATEX 1031 U max 500 V Service category AC 15 Rated operating voltage 400 V Rated operating current max 6 A Breaking capacity max 1000 VA Service category DC 13 Rated operating voltage 110 V Rated operating current max 6 A Breaking capacity max 110 W Type 8008 Control switch PTB 00 ATEX 1111 U 690 V 5 96 AC 1 220 V DC 1 max 750 V max 16 A T6 at 16 A max 40 C T5 at 16 A max 55 C T4 at 16 A max 60 C Type 8453 Control unit PTB 01 ATEX 1067 U max 550 V Control and signal station 8040 Technical data Fitting 7 Fitting Dimension drawings all dimensions in mm subject to alterations 72 80 72 80 04582E
13. its 8040606300 Control and signal station 7 S BA 8040 en 02 15 06 2007 ca 8040 Commissioning The only exception to this is the use of cables in which the cores of the intrinsically sate or the non intrinsically safe circuit are surrounded by an earthed screen The pre conditions for the separation between parts to be connected for intrinsically safe and non intrinsically safe circuits are a distance of 50 mm around an insulating 1 mm thick or earthed metal 0 45 mm thick isolating plate or an isolating plate which is separated from enclosure walls by a distance of lt 1 5 mm 9 Commissioning N WARNING Please convince yourself before operation that the enclosure is completely without damage Before commissioning ensure that the control station has been installed according to the directions gt the control station is not damaged there are no foreign bodies inside the control station connections have been made correctly the cables have been made correctly all screws and nuts are fully tightened the cable glands and stopping plugs are securely tightened unused cable entries are sealed with plugs certified to Directive 94 9 EC and unused holes are sealed by stopping plugs certified to Directive 94 9 EC N WARNING Excessive tightening of cable glands and stopping plugs can impair the degree of protection type 8161 stopping plugs for unused cable entries Both are availa
14. ivery installation safe operation and maintenance Since conditions of use of the product are outside of the care custody and control of the manufacturer the pur chaser should determine the suitability of the product for his intended use and assumes all risk and liability what soever in connection therewith Fiberglass Reinforced Polyester FRP enclosure Ground Plale with Terminals and set screw Conduit Hub or Cable Gland Entry 316 SST Cover Screws Consig Qual Push Button Actuator October 13 2006 8040606300 S BA 8040 en 02 15 06 2007 R STAHL INC 9001 Knight Road Houston TX 77054 E mail sales Q rstahl com Website www rstahl com Tel 800 782 4357 FAX 713 792 9301 Installation Operation amp Maintenance Sheet INSTALLATION OPERATION amp MAINTENANCE SHEET 2 8 72 mm 2 8 72 mm 43 1 11 mm
15. ol Connecting cables to fitted devices with screw terminals Where fitted devices have screw terminals 1 or 2 cables may be connected to a single terminal If the conductors are single strand both must have the same cross section and be of the same material Cables may be connected without any special preparation Connecting cables to fitted devices with screwless terminals contact block connections shown as example 05565E00 05886E00 Intrinsically safe circuits Only insulated cables whose test voltage is at least AC 500 V and whose quality is at least HO5 may be used for intrinsically safe circuits The diameter of individual conductors may not be less than 0 1 mm This also applies to the individual wires of multi strand cables With regard to the insulation and separation of terminals and cables it should be noted that the insulation test voltage is derived from the sum of the rated operating voltages of intrinsically safe and non intrinsically safe circuits In the case of intrinsically safe against earth then the insulation voltage value is at least 500 V or double the value of the intrinsically safe circuit rated operating voltage In the case of intrinsically safe against non intrinsically safe then the insulation voltage value is at least 1500 V or double the rated operating voltage plus 1000 V Cables for Ex i circuits must be run at least 8 mm away from the cables of other intrinsically safe circu
16. ole system e g change of zone allocation N WARNING Checks should be by sight adjacent or detailed depending on local conditions If faults are found during these checks which affect the explosion protection then the system must be taken out of service until the faults have been cleared The following points must be checked during maintenance clamping screws holding the cables are securely seated compliance with permitted temperatures to EN 60079 0 cracks in plastic enclosures damage to the gaskets 8040606300 Control and signal station 9 S BA 8040 en 02 15 06 2007 ca 8040 Accessories and spare parts 11 Accessories and spare parts N WARNING Use only original spare parts as well as original accessories made by R STAHL Schalt ger te GmbH Designation Illustration Description Ordering Code Weight kg Plant indentification LATOTOR ZY plain 8040001850 0 032 label oseoscoo fOr fitting to enclosures 8040 plasic paper label Flange in brass to fit in factory only on sides C and D Hole sizes acc to specification 8040812490 0 280 up to M 20 x 1 5 2 threaded holes are possible 05626E00 with thread 1 x M 25 x 1 5 8040813490 with threads 2 x M 20 x 1 5 8040816490 Flange in plastic to fit in factory only on sides C and D threads acc to specification 8040815490 0 900 05625E00 with threads 2 x M 20 x 1 5 8040823490 0 148 with threads 2 x M 25 x 1 5 8040817490 0 900 Br
17. s pressed evenly against the enclosure 4 3 5 Tighten the set screw on the metal plate to prevent the connector from loosening 4 3 6 n case of through wiring the two ground plates need to be bonded with jumper wire since the FRP enclosures are non metallic 5 Approved Connector Hardware MC TEK Cable Connectors and Sealing Rings MCR Series Connector Sealing Ring Ordering Code Ordering Code MCRO050 NCS1 3 4 MCRO075 NCS2 Non metallic NPT Close up Plugs Size Ordering Code PD E 4 0 29 00 PD E 4 0 30 00 SEALING RING METAL PLATE WITH CUN a THREADED HOLE royale nu Mie ENCLOSURE WALL A 80 406 10 30 0 14 Control and signal station 8040 INSTALLATION OPERATION amp MAINTENANCE SHEET Connect conductors to the component termi nals capacity 12 AWG or 2 5 mm Conductor insulation must reach to the termi nals Tighten all terminals to 18 in Ib includ ing those unused and secure components on mounting rail Perform a continuity check Replace the enclosure cover ensuring alignment between actuators and internal components Actuate the switch and or pushbuttons to check for free operation Energize the supply circuit and test the system Note The nature of these instructions is only informative and does not cover all of the details variations or combina tions in which this equipment may be used its storage del
18. tion 4 Conformity to standards The station complies with the following standards and regulations Directive 94 9 EC EN 60079 0 EN 60079 7 EN 61241 0 EN 61241 1 gt IEC 60079 0 IEC 60079 1 IEC 60079 11 IEC 60079 18 IEC 60079 7 IEC 61241 0 IEC 61241 1 Type 8040 station is suitable for use in hazardous areas zones 1 2 and 21 22 5 Function Type 8040 control and signal stations are explosion protected equipments for local mounting They are used for control and switching functions in hazardous areas 8040606300 Control and signal station 3 S BA 8040 en 02 15 06 2007 ca 8040 Technical data 6 Technical data Version Explosion protection Gas explosion protection Gas explosion protection IECEx Dust explosion protection Dust explosion protection IECEx Certificates Gas explosion protection Dust explosion protection IECEx certification Rated working voltage Rated working current Operating temperature range Cable entries Max Cross section for connection Terminal tightening torque Flanges Degree of protection Material Housing Gaskets Cover fixing Type 8040 x Il 2 G Ex edqm ia ib ia ib Il IIA IIB IIC T6 T5 or T4 Ex de ia ib ia ib m Il IIA IIB IIC T6 T5 or T4 I 2 D Ex tD A21 IP 65 T 80 C T 95 C T 130 C Ex tD A21 IP65 T 80 C T 95 C PTB 01 ATEX 1105 PTB 01 ATEX 1105 IECEx PTB 06 0025 max 690 V AC depends on components
19. tions of the operating parameters in Section 2 For a Class Zone 1 conduit installation conduit seals are required refer to NEC 505 16 B 1 For any other cable or conduit installation NO seals are required Use only approved wiring methods for the location with the appropriate conduit cable fittings 2 Certification NEC Class Zone 1 amp 2 AEx ed IIC T6 IP66 Class Div 2 Groups ABCD Class Il Div 2 Groups FG Class III Enclosure Type 3 4 4X UL Listed File No E182378 CEC Class Zone 1 amp 2 Ex ed IIC T6 IP66 Class Div 2 Groups ABCD Class Il Div 1 amp 2 Groups EFG Class III Enclosure Type 3 4 4X Certified File No LR99480 26 Il 2 G EEx ed IIC T6 IP66 PTB 01 ATEX 1105 80 406 10 30 0 8040606300 S BA 8040 en 02 15 06 2007 Installation Operation amp Maintenance Sheet Installation Operation amp Maintenance Sheet INSTALLATION OPERATION amp MAINTENANCE SHEET 3 Component Data 3 1 3 2 3 3 3 4 Pilot Light type 8010 12V 254V AC DC 0 60Hz Terminal capacity 12 22 AWG or 2 5 mme tightened to 18 in Ibs or 2 N m Contact Block type 8082 600V 10A max Terminal capacity 12 22 AWG or 2 5 mm tight ened to 18 in lbs or 2 N m Control Switch type 8008 2 0 and 8008 2 1 600V 10A max Terminal capacity 12 22 AWG or 2 5 mm tightened to 18 in Ibs or 2 N m Ammeter type 8405 600V Ampere rating see data on device Termin
20. used 20 C 40 C 50 C 60 C on request Standard 1xM 25x 1 5 cable gland 8161 side below D directly mounted into enclosure wall Special in side C top and or side D below 1 x M 20 x 1 551 x M25 x 1 5 metal cable glands are possible mounting of metal cable glands in metal flange or via metal adapter plate 2 5 mm max 1 2 Nm In standard design the enclosures are without flanges On request they can be fitted with flanges on sides C and D Flanges are available in polyester resin or in brass powder coated dark grey similar to RAL 7024 IP 66 Polyester resin glass fibre reinforced PU foam M 4 cheese head screws imprescriptible stainless steel N WARNING With ambient temperatures 20 C cable entries suitable for low temperatures must be used or the station must be so positioned that the cable entries are mechanically protected The electrical data is affected by the devices fitted Please refer to the individual type and rating plates C8 f cable glands other than those manufactured by Fa R STAHL Schaltgerate GmbH are used then their degree of protection should be noted Control and signal station 8040 8040606300 S BA 8040 en 02 15 06 2007 Technical data of R STAHL devices which can be fitted Version Certificates Rated working voltage Rated working current le Frequency range Ambient temperature at Temperature class Version Certif
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