Operating Instructions
Contents
1. Operating Instructions Control and Distribution Box gt 8150 5 Contents 1 2 1 2 2 Contents 1 LONIENIS en ee eucusssaseas shay seevenisnsaneicanesiesessiuaadennsavingeesseamotueme 2 2 General Information sssini nn 2 3 intended USE sereen eenei lease Eene EEE ETRE E e E E 2 4 General Safety Instructions 4a 3 5 Conformity to Standards sats v eer cossauasaedslase evs sods adssoennen sesetehencden eek vereveevessaaadcuce 3 6 WEIS ONE and Storage serred irinin n aaar a Erea 3 7 Assembling and Dismantling 2 e on esse ee 3 8 TecnmealDala una Renee 4 9 installation Conditions msn en 5 TO IGT ANATIOM ass nee BO earnen ia 7 11 Putting into Semite ee sense euere 11 12 Maintenance Overhaul and Repair ccccccecceccceeseseeeeeeeeseeeeeeeeeeessaeeeeeeeeesaees 12 13 Inspections Maintenance Checklist ccccceeeeeeeeeeeeeeeeeeeensesseeesseeeeeees 13 14 Accessories and Spare Parts une 14 15 DISDOSEN ses sea 14 16 EC Declaration Of Conformity nn nn 15 General Information Manufacturer R STAHL Schaltger te GmbH Am Bahnhof 30 74638 Waldenburg Germany Tel 49 7942 943 0 Fax 49 7942 943 4333 Internet www stahl ex com Operating Instructions Information ID No 202162 815060300030 Publication Code 2011 05 23 BA00 Ill en 01 Subject to alterations Intended Use The control and distribution boxes are explosion protected equipment certified fo2. able lug 4 onto the earth bolt 1 and fasten it by means of the lock washer 5a and hexagon nut 5 Put the external PE cable lug 6 onto the earth bolt 1 and fasten it by means of the lock washer 7a and hexagon nut 7 202162 815060300030 Control and Distribution Box 9 2011 05 23 BA00 IIl en 01 8150 5 Installation PE PA connection for cable cross section of up to 70 mm M8 and 120 mm M10 Assembly 0238 internal external connection connection 12780E00 Insert the earth bolt 1 and the sealing ring 1a into a suitable bore of the enclosure wall 2 and fasten it by means of a hexagon nut 3 gt Put the inner PE cable lug 4 onto the earth bolt 1 and fasten it by means of the lock washer 5a and hexagon nut 5 Put the external PE cable lug 6 onto the earth bolt 1 and fasten it by means of the lock washer 7a and hexagon nut 7 10 7 Wiring Z WARNING If the components are installed incorrectly the explosion protection is not guaranteed The required clearance and creepage distances must be adhered to After connecting the cables fasten the mounting rail or elements properly Internal wiring The following cables can be used for the internal wiring Temperature class Conductor cross section Type or similar types External wiring Lead the connecting cable through the cable entries into the enclosure gt Make sure that the cable diameter mat
3. account that there could be an explosive atmosphere in the vicinity of the equipment 202162 815060300030 2011 05 23 BAQ00 Ill en 01 Control and Distribution Box 13 8150 5 Accessories and Spare Parts Inspection schedule for Ex i Check the following Grade of inspection Detailed Close in Visual in inspec spection spection tion Equipment Circuit and or equipment documentation is appropriate to zone classification Installed equipment corresponds to the equipment specified in documentation only applicable for stationary equipment Category and group of electric circuit and or equipment are correct Temperature class of the equipment is correct Installation is clearly labelled There are no unauthorised modifications There are no visible unauthorised modifications Safety barriers relays and other energy limiting devices correspond to the certified type are installed in accordance with the requirements of the certificate and are securely earthed if necessary Electrical connections are fixed properly gt O oO Printed circuit boards are clean and undamaged Installation Cables are installed in accordance with the documentation Cable screens are earthed in accordance with the documentation No obvious signs of damage on cables and wires Sealing of trunking channels pipes and or conduits is satisfactory Point to point connections are all correct B 1 2 3 4 5 6 Earth continuity is satisfa
4. and Distribution Box 202162 815060300030 8150 5 2011 05 23 BA00 IIl en 01 10 Installation Installation A WARNING If the components are installed incorrectly the explosion protection is not guaranteed Observe the enclosed documents such as wiring diagrams When installing additional components make sure that these components have an EC Type Examination Certificate or IECEx Certificate of Conformity When performing this type of device modification the rating and data plates must be adapted correspondingly 10 1 Opening and closing the enclosure For the versions with screw on cover loosen the screws on the enclosure cover If available observe the cover lock at the rotary actuator amp Rotary actuators installed on the cover may optionally have a cover lock In this case the cover can only be removed or closed in one certain position Open and remove the enclosure cover carefully To close the enclosure cover proceed in the reverse order Observe the specified tightening torque 10 2 Cable Entries Z WARNING The cable entries must be installed according to the manufacturer specifications The following cable entries can be used to insert cables and conductors into enclosures X plastic or metal cable glands for permanently installed cable conductors X plastic or metal cable glands with strain relief for conductors that are not permanen
5. are sous sa seule responsabilit dass das Produkt Steuer und Verteilerkasten that the product Control and Distribution box que le produit Equipement de commande et de d rivation Typ en type s type s 8150 75 Hr Hr kkk ner mit den Anforderungen der folgenden Richtlinien und Normen bereinstimmt is in conformity with the requirements of the following directives and standards est conforme aux exigences des directives et des normes suivantes 94 9 EG ATEX Richtlinie EN 60079 0 2012 94 9 EC ATEX Directive EN 60079 1 2007 94 9 CE Directive ATEX EN 60079 5 2007 EN 60079 7 2007 EN 60079 11 2012 EN 60079 18 2010 EN 60079 28 2007 EN 60079 31 2009 Kennzeichnung marking marquage ll 2 G Ex d e ia ia Ga ib ib ma mb op pr op is q ie x TIA IB IIC T6 T5 T4 Gb CE 0158 Il 2 D Ex tb IIIC IP66 T80 C T95 C T130 C Db EG Baumusterpr fbescheinigung PTB 09 ATEX 1109 EC Type Examination Certificate Physikalisch Technische Bundesanstalt Attestation d examen CE de type Bundesallee 100 38116 Braunschweig Germany Produktnormen nach Niederspannungsrichtlinie EN 61439 1 2011 Product standards according to Low Voltage Directive EN 61 439 2 201 4 Normes des produit pour la Directive Basse Tension 2004 108 EG EMV Richtlinie 2004 108 EC EMC Directive 2004 108 CE Directive CEM EN 61439 1 2011 EN 61439 2 2011 Waldenburg 2014 11 07 LAY iV Js 2 i o iV Ort und Datum Werner Forstner J P Riic
6. ches the clamping cross section of the cable entries Tighten the hexagon nut of the cable entries Make sure that the tightness of the enclosure and the strain relief protection at the connection points are provided For tightening torques refer to the operating instructions of the components Control and Distribution Box 202162 815060300030 8150 5 2011 05 23 BA00 IIl en 01 11 Putting into Service Lay the cables in the connection chamber in such a way that X The minimum permissible bending radii for the respective conductor cross section must not be less than the specified minimum X the conductor insulation is not damaged because of sharp edged or movable metal parts Connect electrically Open the enclosure Lay the connecting cables in such a way that the minimum permissible bending radii are less than the specified minimum Connect the protective conductor Remove loose metal particles pollution and traces of moisture Close the enclosure carefully after completing the work Run insulation test according to IEC EN 61439 1 After completing the electric installation the following operations must be performed Fastening of the protection against accidental contact gt Setting of the tripping devices to the nominal value Visual inspection for the presence of loose metal particles soiling and traces of moisture Putting into Service Z WARNING The devices must be operate
7. conductor types are used There is no visible damage to cables and wires Sealing of trunking channels pipes and or conduits is okay Sealing devices and terminal sleeves are correctly filled The conduit system and the interface with mixed system are not damaged Earth connections including any supplementary potential equalisations are satisfactory for example connections are properly fixed and conductor cross sections are sufficient Physical inspection Visual inspection Fault loop impedance TN systems or earthing resistance IT systems is sufficient Insulation resistance is sufficient Automatic electrical protective devices respond within the allowed limit values Automatic electrical protective devices are set correctly auto reset not possible Special operating conditions if applicable are observed Cables and or wires not in use are correctly terminated Obstructions adjacent to flameproof joints are in accordance with IEC 60079 14 x XxX X X KK KK Installations with variable voltage frequency are in accordance with documentation Environmental effects Equipment is adequately protected against corrosion weather vibration and other adver se factors No undue accumulation of dust or dirt Electrical insulation is clean and dry NOTE 1 General Equipment with both types of protection d and e is checked using a combination of both columns NOTE 2 Item B7 and B8 When using electrical test equipment take into
8. ctor nicking when removing the insulation When removing the insulation make sure that the conductor insulation reaches right up to the clamping points Select suitable cables to be used and appropriate way of leading them to ensure that the maximum permitted conductor temperature and the maximum permitted surface temperature is not exceeded The permitted ambient temperature at the built in devices and components must not be exceeded 10 6 Earth connection A protective conductor is always required The external protective conductor connection is designed for cable lugs The cable must run near to the enclosure All blank non live metal parts have to be included into the protective conductor system regardless of the rated operational voltage Neutral conductors are considered to be live conductors They have to be installed accordingly Inactive metal parts are insulated acc to EN 61439 1 IEC 61641 and are not connected to earth c The data for potential equalization PA potential earth PE in intrinsically safe circuits are given in the documentation of the associated equipment PE PA connection for cable cross section of up to 25mm Assembly 0245 internal external connection connection 07855E00 Insert the earth bolt 1 and the sealing ring 1a into a suitable bore of the enclosure wall 2 and fasten it by means of a hexagon nut 3 Put the inner PE c
9. ctory for example the connections are fixed properly and the conductor cross sections are sufficient Earth connection maintain the type of protection The intrinsically safe circuit is isolated from the earth or grounded at one point only refer to documentation Separation is maintained between intrinsically safe and non intrinsically safe circuits in common distribution boxes or relay cubicles If applicable short circuit protection of the power supply is in accordance with the documentation Special operating conditions if applicable are observed Cables and or wires not in use are correctly terminated Ambient conditions Equipment is adequately protected against corrosion weather vibration and other adverse factors No undue accumulation of dust and dirt 14 Accessories and Spare Parts Z WARNING Use only original R STAHL accessories and spare parts When installing additional components ensure that these components have an EC Type Examination Certificate or IECEx Certificate of Conformity 15 Disposal The national waste disposal regulations have to be observed 14 Control and Distribution Box 202162 815060300030 8150 5 2011 05 23 BA00 IIl en 01 EG Konformitatserklarung EC Declaration of Conformity D claration de Conformit CE R STAHL Schaltger te GmbH Am Bahnhof 30 74638 Waldenburg Germany erklart in alleiniger Verantwortung declares in its sole responsibility d cl
10. d only in completely closed enclosures amp For unused enclosure holes use R STAHL stopping plugs for example Series 8290 for unused cable entries use R STAHL plugs e g Series 8161 Before putting into service Make sure that the device is not damaged Make sure that the device is installed correctly Remove any foreign objects from the device Check the tightening torques Check if all covers and partitions on live parts are in place and have been fixed Back up fuse Secure the system by means of the specified electric back up fuse Ensure sufficient short circuit current at the mains connection connection point for reliable triggering of the fuse 202162 815060300030 Control and Distribution Box 11 2011 05 23 BA00 IIl en 01 8150 5 Maintenance Overhaul and Repair 12 Maintenance Overhaul and Repair A WARNING Do not open when live Do not open when non intrinsically safe circuits are live Exception Devices with intrinsically and non intrinsically safe circuits marked with NON INTRINSICALLY SAFE CIRCUITS PROTECTED BY INTERNAL IP30 COVER may be opened while energized The following details must be checked during maintenance X Cables are held securely in place by the clamping points X Compliance with the permitted temperatures acc to IEC EN 60079 et seqq X Damage to the enclosure and sealing gaskets 12 Control and Distributi
11. entry plus space requirement for the used tool Calculation of the usable area Usable area minus the area which is required for the built in parts The following chart shows an example of the space requirements for R STAHL cable entries Cable entry thread diameter lt mm lt 12mm lt 16 mm lt 20 mm lt 25 mm lt 32 mm lt 40mm lt 50 mm lt 63 mm Space 315mm 495 mm 685 mm 990 mm 1560 mm 2420 mm 3425 mm 5160 mm requirement per pc Calculation example X Dimensions of enclosure inner wall 297 mm Side D x 122 mm Side C X Desired cable entries M25 15 pc M32 7 pc Usable area 297 mm 2x10 mm x 122 mm 2x10 mm 28254 mm 2x10 mm circumferential rim of enclosure inner wall Required area for cable entries Qty Type Area 15 pe M20 15x 685 mm 10275 mm 7 pe M32 7x 1560 mm 10920 mm 21195 mm required area for cable entries 28254 mm usable area 7059 mm remaining usable area The area for the cable entries must be smaller than the calculated usable area If this is not the case a larger enclosure must be chosen Control and Distribution Box 202162 815060300030 8150 5 2011 05 23 BA00 IIl en 01 Installation 10 5 Electrical connection Z WARNING Observe the data of the terminal manufacturer for example the tightening torque The conductor must be carefully connected Do not damage the condu
12. ia ib ma mb q IIA IIB IIC T6 T5 T4 Gb amp Il 2 D Ex tb IIIC IP66 T130 C T95 C T80 C Db Ex d e ia ib ia ib ma mb q IIA IIB IIC T6 T5 T4 Gb Ex tb IIIC IP66 T130 C T95 C T80 C Db PTB 09 ATEX 1109 IECEx PTB 09 0049 max 1100 V AC DC depending on explosion protected components used max 630 A depending on explosion protected components used 300 mm depending on explosion protected components used 60 85 C depending on explosion protected components used IP66 acc to IEC EN 60529 depending on the built in components used 8150 5 2 stainless steel 1 4301 AISI 304 brush finished 8150 5 3 stainless steel 1 4404 AISI 316L brush finished Silicone foamed sheet steel galvanized min 2mm 3mm In the standard version the enclosures are supplied without flanges Depending on order requirements the enclosures can be installed on one or more sides with flanges flange material sheet steel zinc galvanised or stainless steel with captive M6 stainless steel combo head screws with cover hinges 4 5Nm M8 blind rivet nut 1x at the outside of the enclosure M8 rivet nut 1x on mounting plate M6 bolt 1x additionally on enclosures with cover hinges A WARNING Powder coated enclosures must not be used in areas where intense electrostatic charging may occur 202162 815060300030 2011 05 23 BA00 IIl en 01 4 Control and Distr
13. ibution Box 8150 5 2011 05 23 BA00 IIl en 01 Installation Conditions Installation Conditions Clearance and creepage distances When installing components the clearance and creepage distances between the individual components as well as between the components and the enclosure wall must be sufficiently dimensioned The creepage distances between the components must be tested and observed acc to the guidelines of the relevant operating instructions The clearance distances dependent on the rated operational voltage of the fitted terminals must be complied with On all devices the distance between enclosure cover and connection screws of the built in components have to be observed with the conductor connected minimum the values of the required creepage distances e g gt 14 mm at 1100 V Distance between connection parts for intrinsically safe and non intrinsically safe circuits Partitions used to separate connection terminals shall extend to within 1 5 mm of the enclosure walls or alternatively shall provide a minimum distance of 50 mm between the bare conducting parts of the connection terminals when measured in any direction around the partition The minimum thickness of metal partitions must be 0 45 mm They must be earthed and have sufficient strength and stiffness to ensure that they might not be damaged during connection work Furthermore the metal partitions must be equipped with appropriate current carryi
14. ing voltage of intrinsically safe and non intrinsically safe circuits In the case of intrinsically safe to earth there is a minimum insulation voltage value of 500 V otherwise double the rated operating voltage of intrinsically safe circuits In the case of intrinsically safe to non intrinsically safe there is a minimum insulation voltage value of 1500 V or double the rated operating voltage plus 1000 V Clearance and creepage distances of intrinsically safe components The clearance and creepage distances between the blank conductive parts of connection terminals of separated intrinsically safe circuits to earthed or potential free conductive parts must be equal or larger than the values of IEC EN 60079 11 table 5 If separated intrinsically safe circuits have to be considered the safety distance between the blank conductive parts of the outer connections must be as follows minimum 6 mm between the separated intrinsically safe circuits gt minimum 3 mm to the earthed parts if a possible connection to earth has not been considered in the safety analysis Terminal blocks in Ex e enclosure X Terminal bridging is only permitted if original explosion protected accessories are used X The partitions required for this purpose must be retrofitted if necessary X For additional splice protection use core end sleeves or cable lugs The cross section of the splice protection must match the conductor cross section 6 Control
15. kgauer Place and date Leiter Zertifizierung Schaltgerate Leiter Qualitatsmanagement Lieu et date Head of Certification Switchgear Director Quality Management Chef de Certification Appareillage Directeur Assurance de Qualit F 4174 601 01 2011 STMZ 815060020030 02 EC Declaration Of Conformity 16 Control and Distribution Box 202162 815060300030 8150 5 2011 05 23 BA00 IIl en 01
16. ng capacity in order to prevent a burn out or disconnection of the earth connection The minimum thickness of nonmetallic insulating partitions must be 0 9 mm They must have an appropriate comparative tracking index CTI and must be supported in such a way that no deformation can occur When fuses gt 4 A are used care must be taken to ensure that no inadmissible heating at the terminals of intrinsically safe ciruits can occur C Note for manufacture and operation The installation of the equipment with type of protection intrinsic safety Ex i must be carried out in such a way that the distances as well as the clearance and creepage distances between intrinsically safe and non intrinsically safe circuits according to IEC EN 60079 14 are observed Covers for combinations of non intrinsically safe and intrinsically safe circuits All live parts which are not acc to Ex i protection must be equipped with an inner cover which meets a minimum degree of IP30 protection when the equipment is opened 202162 815060300030 Control and Distribution Box 5 8150 5 Installation Conditions Intrinsically safe circuits In intrinsically safe circuits only insulated cables and conductors with a test voltage of at least 500 V AC and a minimum quality of HO5 are permitted Relating to insulation and separation of terminals and cables it has to be observed that the insulation test voltage is the sum of the rated operat
17. nsport and storage are only permitted in the original packing 7 Assembling and Dismantling C lfthe explosion protected equipment is exposed to the weather it is advisable to provide a protective cover or wall amp Dimensions and weight data as well as the location of fastening points are given in the enclosed mechanical assembly drawings amp Toavoid condensation inside of the enclosure it is recommended to install a R STAHL breather Type 8162 Depending on the installation location the degree of protection decreases according to IEC EN 60529 For any installation position the degree of protection is IP64 if the breather is installed downwards it is IP66 202162 815060300030 Control and Distribution Box 3 2011 05 23 BA00 IIl en 01 8150 5 Technical Data 8 Technical Data Marking Europe ATEX Gas explosion protection Dust explosion protection IECEx Gas explosion protection Dust explosion protection Certificates Europe ATEX IECEx Electrical data Rated operational voltage Rated operational current Rated cross section Ambient conditions Ambient temperature Mechanical data Degree of protection Material Enclosure Sealing gasket Mounting plate Wall thickness Enclosure cover Mounting plate Flanges Standard Option Cover fixing Standard Option Cover screws tightening torque Earth connection amp Il 2 G Ex d e ia ib
18. on Box 202162 815060300030 8150 5 2011 05 23 BA00 IIl en 01 Inspections Maintenance Checklist 13 Inspections Maintenance Checklist Inspection schedule for Ex d e und n D Detailed inspection C Close inspection V Visual inspection Check the following Type of Type of Type of protection protection protection g o n Devices Equipment corresponds to EPL zone requirement of the installation site Equipment group is correct Temperature class of the equipment is correct Electric circuit designation of the equipment is correct Electric circuit designation of the equipment is available Enclosure windows and glass to metal seals and or joints are okay There are no unauthorised modifications There are no visible unauthorised modifications OAN DAF WNHY D Screws cable entries direct and indirect and blind plugs are correct complete and tight Physical inspection Visual inspection Joint faces are clean and undamaged seals if any are okay Joint widths are within the allowed limit values Rated value type and arrangement of the lamps are correct Electrical connections are tight and fixed properly Condition of the enclosure seal is okay Fracture proof encapsulation and hermetically sealed devices are undamaged Restricted breathing enclosure is okay Motor fans have sufficient clearance to enclosure and or covers Breathing and draining devices are okay Installation Appropriate cable and
19. r use in hazardous areas of Zones 1 2 and 21 22 They are used together with the built in components to control switch and transfer electrical energy The devices are intended only for fixed mounting Control and Distribution Box 202162 815060300030 8150 5 2011 05 23 BA00 IIl en 01 General Safety Instructions 4 General Safety Instructions The devices must be used only for the permitted purpose Incorrect or impermissible use or non compliance with these instructions invalidates our warranty provision Any altera tions and modifications to the device impairing its explosion protection are not permitted Use the device only if it is undamaged and clean Z WARNING Installation maintenance overhaul and repair may only be carried out by appropriately authorised and trained personnel Observe the following information during installation and operation Any damage can invalidate the explosion protection National safety regulations National accident prevention regulations National installation regulations e g IEC EN 60079 14 Generally recognized technical regulations Safety guidelines in these operating instructions Characteristic values and rated operating conditions on the rating and data plates Additional instruction plates fixed directly to the device 5 Conformity to Standards The relevant standards are listed in the EC Declaration of Conformity 6 Transport and Storage Tra
20. tly installed To seal unused openings X plastic or metal stopping plugs can be used Make sure that these components have an EC Type Examination Certificate respectively an IECEx Certificate of Conformity The IP degree of protection stated on the rating plate has to be observed 10 3 Making of Additional Through Holes If additional through holes are required e g for installing cable entries breathing glands or other parts the following has to be considered Additional through holes can be laser cut or punched While punching please make sure that the surfaces remain even When determining the through holes please consider the installing distances Adjust hole diameter to the dimensions of the built in parts or their seals Do not damage circumferential sealing lips 202162 815060300030 Control and Distribution Box 7 2011 05 23 BA00Ill en 01 8150 5 Installation 10 4 Usable Area for Cable Entries The usable area for cable entry installation is calculated as follows Length of enclosure inner wall 2x10 mm x Height of enclosure inner wall 2x10 mm 2x10 mm circumferential rim of enclosure inner wall Attention gt Take the measurements on the face surface of the enclosure inner wall not on the enclosure outer wall Consider the positions of the blind rivet nuts to avoid damage The required space for the built in part results from The width across corners of the cable
Download Pdf Manuals
Related Search