Operating Instructions
Contents
1. intrinsically safe against non intrinsically safe then the insulation voltage value is at least 1500 V double the sum of the rated operational voltage of intrinsically safe circuits plus 1000 V amp The conductors of intrinsically safe or non intrinsically safe circuits are protected by an earthed shield Control Panels and Distribution Systems 134784 8125612300 8125 5 8125 8 2013 01 18 BA00 III en 05 Installation Terminal block in the Ex e enclosure e Pay attention to the test certificate of the terminals Only one conductor may be connected to each terminal Terminal bridging is only permitted if original flameproof accessories have been used Equip with the necessary partitions as needed For additional protection against splaying use crimped terminal sleeves or cable lugs The cross section of the anti splay protection must meet the conductor cross section 8 2 External wiring Guide the connecting cable together with the complete external insulation through the cable entry into the enclosure Please ensure that the cable diameter and the terminal cross section on the cable entry are identical Tighten the hexagon nut of the cable guide Make sure that the tightness of the enclosure and the strain relief protection of the connection points is guaranteed To determine the tightening torques please consult the operating instructions of the individual components La2. Control Panels and Distribution Systems 134784 8125612300 8125 5 8125 8 2013 01 18 BA00 III en 05 3 1 3 2 General Safety Information General Safety Information Safety Instructions for Assembly and Operating Personnel The operating instructions contain basic safety instructions which are to be observed during installation operation and maintenance Non observance can lead to endangerment of persons plant and the environment Z WARNING Risk due to unauthorised work being performed on the device gt Risk of injury and damage to equipment Assembly installation commissioning operation and maintenance must only be performed by personnel who are both authorised and suitably trained for this purpose Before assembly commissioning Read through the operating instructions Give adequate training to the assembly and operating personnel Ensure that the contents of the operating instructions are fully understood by the personnel in charge The national installation and assembly regulations e g IEC EN 60079 14 apply If you have questions Contact the manufacturer When operating the device Ensure the operating instructions are made available on location at all times Observe safety instructions Observe national safety and accident prevention regulations Only run the device according to its performance data gt Servicing maintenance work or repairs which are no
3. Operating Instructions Control Panels and Distribution Systems gt 8125 5 Control Panel and Distribution System gt 8125 8 Terminal Compartment Contents 1 2 1 2 2 2 3 Contents 1 LONIENIS er ee ee ae EEE air Fenaaa 2 2 General lHiormalon ass 2 3 General Safety IMMOMMAUON rescsevcaneeerseddenescede vere eccesccemcebeseereveceedeaensesstvesseegesaseseses 3 4 Designated Use esse 4 5 Technical DaB een ansehe 5 6 Transport Storage and Disposal u see ne rnnt rtrtreeenneen 6 7 PS RTM esse aeg ee ee ee 7 8 NEN Seesen 8 9 COMMISSIONING ses eieiei padaran E ES EEEE EErEE e Eaa S EE Ep epaia 13 10 Maintenance nee ein 14 11 Accessories and Spare Parts sauna sahen ee anna 17 General Information Manufacturer R STAHL Schaltger te GmbH Am Bahnhof 30 74638 Waldenburg Germany Phone 49 7942 943 0 Fax 49 7942 943 4333 Internet www stahl ex com Information regarding the Operating Instructions ID No 134784 8125612300 Publication Code 2013 01 18 BA00 IIl en 05 We reserve the right to make technical changes without notice Symbols Used gt Action request Describes actions to be carried out by the user gt Reaction sign Describes the results or the reactions to the actions taken Bullet Commentary sign describes the notes and recommendations Warning sign Danger due to an explosive atmosphere x ee Warning sign A Danger from energised parts
4. Ex components used max 630 A depending on the type of terminal and Ex components used max 240 mm depending on the type of terminal and Ex components used the enclosures are supplied without flanges in the standard version Depending on the order the enclosures can be fitted on one or more sides with flanges flange material galvanised sheet steel or stainless steel IP66 depending on the installed equipment 60 100 C depending on the installed equipment Control Panels and Distribution Systems 5 8125 5 8125 8 Transport Storage and Disposal Dimensional drawings all dimensions in mm subject to alterations A 55 10 9 04554E00 04555E00 04556E00 8125 04 8125 05 8125 06 oof 04560E00 ais Additional dimension for flange 360 al 320 RAN 04557E00 04558E00 8125 07 8125 08 Height of enclosure h Enclosure 91mm 150mm 190 mm 230 mm He 8125 1 8125 3 8125 5 8125 6 E 8125 04 X A 8125 05 X 8125 06 X x 8125 07 X x ss _ ii il p 8125 08 X x x x Ln 687 8125 09 X x x 72 ig X can be supplied 0455900 8125 09 6 Transport Storage and Disposal Transport Shock free in its original carton do not drop handle carefully Storage Store in a dry
5. in accordance with documentation Control Panels and Distribution Systems 15 8125 5 8125 8 Maintenance Ambient conditions Equipment is adequately protected against corrosion weather vibration and other adverse factors No undue accumulation of dust and dirt Electrical insulation is clean and dry NOTE 1 General information Equipment having the types of protection d and e is checked using a combination of both columns NOTE 2 Items B7 and B8 When using electrical test equipment take into account that there could be an explosive atmosphere in the vicinity of the equipment Inspection schedule for Ex i Please check the following gt o Ook WN AQ 16 Equipment Circuit and or equipment documentation is appropriate to zone classification Installed equipment corresponds to the equipment specified in the documentation only applicable for stationary equipment Category and group of the electric circuit and or the 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 approved type are installed in accordance with the certifications and are securely earthed if necessary Electrical connections are fixed properly Printed circuit boards are clean and undamaged Installation Cables a
6. to the specified tightening torque Type Tightening torque Nm Screw type 8125 4 5 Cheese head screws M6 x 28 Back up fuse Protect the system using the given electrical back up fuse Make sure that there is sufficient short circuit current on the mains connection for tripping the fuse Internal wiring Cables Z WARNING For internal wiring use only type of wires specified in the table Temperature classes with different conductor types Type Temperature class Conductor cross section H07G T5 HO5V2 T6 gt 1 mm Cu or similar types A WARNING routed incorrectly Incorrectly routed cables in the Ex e enclosure gt Explosion protection cannot be guaranteed any more if the wires are Strictly adhere to the required creepage distances and clearances Mounting rails or elements must be fastened properly Loosen the mounting rails or elements for connecting the cables correctly After connecting the conductors fasten the mounting rails or elements properly 134784 8125612300 Control Panels and Distribution Systems 9 2013 01 18 BA00 IIl en 05 8125 5 8125 8 Installation 10 Intrinsically safe circuits A WARNING A Danger due to incorrectly dimensioned cables and wires gt Risk of severe injuries Use only insulated cables and wires whose test voltage is minimum 500 V AC and whose m
7. 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 sealing is satisfactory Fracture proof encapsulation and hermetically sealed devices are undamaged Restricted breathing enclosure is satisfactory Motor fans have sufficient clearance to enclosure and or covers Breathing and draining devices are satisfactory Installation Appropriate cable and conductor types are used There is no obvious damage to cables Sealing of trunking ducts pipes and or conduits is satisfactory Sealing devices and terminal sleeves are correctly filled Integrity of conduit system and interface with mixed system is maintained Earth connections including any supplementary equipotential bonding are satisfactory for example connections are properly fixed and the cross sections of the conductors are sufficient Physical check Visual check Fault loop impedance TN systems or earthing resistance IT systems is satisfactory Insulation resistance is satisfactory 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 not in use are correctly terminated Obstructions adjacent to flameproof joints are in accordance with IEC 60079 14 Variable voltage frequency installation
8. amp We recommend the use of type 8290 stopping plugs for unused holes and type 8161 plugs for unused cable entries in the enclosure Both are available from R STAHL Schaltgerate GmbH 134784 8125612300 Control Panels and Distribution Systems 13 2013 01 18 BA00 IIl en 05 8125 5 8125 8 Maintenance 10 Maintenance A WARNING Danger from energised parts gt Risk of severe injuries A Before any maintenance work commences disconnect the device from the power supply Secure the device against unauthorised activation 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 A WARNING Risk due to unauthorised work being performed on the device gt Risk of injury and damage to equipment Assembly installation commissioning operation and maintenance must only be performed by personnel who are both authorised and suitably trained for this purpose The dimensions of the flameproof joint do not comply with the tables in the standard IEC EN 60079 1 Contact the manufacturer before starting to work on the joint faces 10 1 Regular Maintenance Work Consult the relevant national regulations e g IEC EN 60079 17 to determine the type and extent of inspections Plan the intervals so that any defects in the equipment which may be anti
9. cipated are promptly detected To check as part of the maintenance schedule X Check that cables and lines are clamped properly X Inspect device for visible damage X Compliance with the permitted temperatures in accordance with IEC EN 60079 0 X Make sure that the device is used according to its designated use 10 2 Cleaning X Clean with a cloth brush vacuum cleaner or similar items 14 Control Panels and Distribution Systems 134784 8125612300 8125 5 8125 8 2013 01 18 BA00 III en 05 Maintenance 10 3 Inspection maintenance checklist Inspection schedule for Ex d e und n D Detailed inspection C Close inspection V Visual inspection Please check the following Type of Type of Type of protectio protectio protectio n d n e nn oo Oa BP ON gt D 134784 8125612300 2013 01 18 BA00 IIl en 05 Equipment Equipment is suitable for the respective zone Equipment group is correct Temperature class of equipment is correct Circuit identification of equipment is correct Circuit identification of equipment is available Enclosure windows and glass to metal sealing and or compounds are satisfactory There are no unauthorised modifications There are no visible unauthorised modifications Screws cable glands direct and indirect and blind plugs are correct complete and tight Physical check Visual check Joint faces are clean and undamaged seals if any are satisfactory Joint widths are
10. e frame system only for enclosures 8125 07 8125 08 and 8125 09 Observe the weight of the enclosure depending on the type and number of fitted components amp To prevent condensation in the enclosure we recommend using a type 8162 breather from R STAHL Schaltgerate GmbH The installation of the breather reduces the type of protection as per IEC 60529 If installed vertically breather at the bottom the type of protection is IP 66 otherwise IP 64 134784 8125612300 Control Panels and Distribution Systems 7 2013 01 18 BA00 IIl en 05 8125 5 8125 8 Installation 8 Installation A WARNING Installation may only be performed by qualified personnel Installation of the devices may only be carried out by appropriately authorised and trained personnel Observe the relevant national regulations in the country of use A WARNING Danger due to non observance of warning signs and instruction plates on the device Read and observe all warning signs and instruction plates attached to the device before starting installation Z WARNING Incorrectly installed components gt Explosion protection cannot be guaranteed any more if the components are incorrectly installed If terminal sleeves are used they must be gas tight and applied with a suitable tool Z WARNING Use of cable entries without strain relief gt Explosion protect
11. e only original accessories and original spare parts manufactured by R STAHL Designation Illustration Flanges 05740E00 05738E00 05739E00 Spacer 04901E00 Cover hinges En 05737E00 Mounting kit 09019E00 134784 8125612300 2013 01 18 BA00 IIl en 05 Description Order number Weight kg sheet steel 134216 0 200 stainless steel 135051 0 340 can be mounted on enclosue side 8125 051 C D 8125 061 A B C D 8125 071 A B C D 8125 S71 c D 8125 081 A B C D sheet steel 134245 1 050 stainless steel 135093 1 310 can be mounted on enclosue side 8125 073 C D 8125 083 085 A B C D 8125 093 095 A B C D sheet steel 134274 1 050 stainless steel 135125 0 630 can be mounted on enclosue side 8125 063 A B C D 8125 073 A B 68 mm x 68 mm 136012 0 010 68 mm x 128 mm 135974 0 020 126 mm x 266 mm 136031 0 040 126 mm x 126 mm 136235 0 100 8125 for retrofitting to enclosure Kit consisting of 2 hinges 134943 0 034 3 hinges 134949 0 051 2 mounting kits 134937 0 080 Control Panels and Distribution Systems 17 8125 5 8125 8 EG Konformit tserkl rung EC Declaration of Conformity D claration de Conformite CE R STAHL Schaltger te GmbH Am Bahnhof 30 74638 Waldenburg Germany erkl rt in alleiniger Verantwortung declares in its sole responsibility d clare sous sa seule responsabilit dass das Produkt Steuer und Verteilerkasten that the product Control and Distribution box que
12. gear Director Quality Management Chef de Certification Appareillage Directeur Assurance de Qualit F 4174 601 01 2011 STMZ 8125603020 02
13. inimum quality is HO5 The diameter of one conductor must not be smaller than 0 1 mm The diameter of individual wires of finely stranded conductors must not be smaller than 0 1 mm A WARNING Danger due to incorrectly routed cables and wires gt Risk of short circuit Wires and cables must be at a minimum distance of 8 mm to wires and cables of other intrinsically safe circuits A WARNING A A Danger due to incorrectly routed cables and wires gt Risk of short circuit An isolating plate at a distance of lt 1 5 mm to the enclosure wall must be provided between the connection points of intrinsically safe and non intrinsically safe circuits A distance of 50 mm around an insulating 1 mm thick or earthed metal 0 45 mm thick isolating plate must be provided between the connection points of intrinsically safe and non intrinsically safe circuits Insulation test voltage 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 circuits Intrinsically safe against earth In case of intrinsically safe against earth then the insulation voltage value is at least 500 V or double the value of the rated operational voltage of intrinsically safe circuits Intrinsically safe against non intrinsically safe In case of
14. ion against contact Set nominal values in all release devices Check visually if there are loose metal parts soiling or traces of moisture If any clean and dry the enclosure Please make sure to consult the enclosed documentation such as wiring diagrams or similar Connecting to the mains Open the enclosure gt Lead the connecting cables with intact external insulation jackets through the cable entry Lay the connecting cables so that the minimum permissible bending radii are achieved The protective earth conductor must always be connected Remove loose metal particles dirt and traces of moisture from the terminal compartment if any Carefully close the enclosure after finishing the work Test the insulation in accordance with IEC EN 60439 1 9 Commissioning Before commissioning gt Make sure that the device is not damaged Make sure that the device is installed correctly Remove any foreign object from the device Check that cable entries and stopping plugs are tight Check that screws and nuts are tightly fitted Inspect cable entry for damage Check tightening torques gt Make sure that unused cable entries are sealed with plugs certified according to Directive 94 9 EC and unused holes are sealed by stopping plugs certified according to Directive 94 9 EC Check whether all covers and barriers for live parts are installed and fixed
15. ion cannot be guaranteed any more if cable entries are installed without cable strain relief in the vicinity of loosely laid cables and leads gt Securely lay cables and leads If the cables are laid loosely only use cable entries approved for this application A WARNING Danger due to not approved cable entries gt If a not approved cable entry is used explosion protection can no longer be guaranteed When selecting or replacing cable glands the thread type and size indicated in the component documentation must be observed Use only cable glands approved for the required type of protection DI el e To avoid an accumulation of moisture and dirt inside the combined switch panels the electrical installation has to be executed under clean and dry ambient conditions The enclosures must only be opened during installation works and be closed correctly after completing the work Control Panels and Distribution Systems 134784 8125612300 8125 5 8125 8 2013 01 18 BA00 Ill en 05 8 1 Installation Opening and closing the enclosure cover amp Knob levers attached to the cover may have a cover lock In this case the cover can only be removed or closed in a definite position gt Loosen the screws on the enclosure gt Observe the cover lock on the knob lever if any Open and remove the enclosure cover carefully For closing the cover proceed in reverse order Adhere
16. le produit Equipement de commande et de d rivation Typ en type s type s 8125 5 8125 8 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 112 G Ex de ib ia Ga mb q IIA IIB IIC T6 T5 T4 Gb i ER amp 112 D Ex tb IIIC T80 C T95 C T130 C Db IP66 CE 0158 EG Baumusterpr fbescheinigung PTB 01 ATEX 1001 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 2011 Normes des produit pour la Directive Basse Tension 2004 108 EG EMV Richtlinie 2004 108 EC EMC Directive EN 61439 1 2011 2004 108 CE Directive CEM EN 614392 2011 7 _ 9 D A ha Waldenburg 2014 11 04 WV Inu 5 iV I of VW i j _ Ort und Datum Werner F rstner J P R ckgauer j Place and date Leiter Zertifizierung Schaltger te Leiter Qualit tsmanagement Lieu et date Head of Certification Switch
17. ly Inactive metal parts are insulated in accordance with IEC EN 60439 1 and not connected to PE C Please take the details relating to potential equalisation earthing and intrinsically safe circuits from the documentation of the relevant equipment Protective earth conductor for cable cross sections up to 70 mm External connection Internal connection 07855E00 Guide the earth bolt 1 through a suitable hole in the enclosure wall 2 and secure it by means of the hexagon nut 3 Slide the inner PE cable lug 4 onto the earth bolt 1 Secure the PE cable lug by means of lock washer and hexagon nut 5 Slide the outer PE cable lug 6 onto the earth bolt 1 Secure the PE cable lug by means of lock washer and hexagon nut 7 Protective earth conductor for cable cross section up to 35 mm M6 and up to 70 mm M8 External 1 2 3 4 Internal connection N connection KA KI 07873E00 Clamp the outer PE conductor between the plates 2 and fasten it by means of hexagon nuts 1 Clamp the inner PE conductor between the plates 3 and fasten it by means of hexagon nuts 4 12 Control Panels and Distribution Systems 134784 8125612300 2013 01 18 BA00 Ill en 05 8125 5 8125 8 Commissioning The following work is required after finishing electrical installation Attach protect
18. place in its original packaging Disposal Ensure environmentally friendly disposal of all components according to legal regulations 6 Control Panels and Distribution Systems 134784 8125612300 8125 5 8125 8 2013 01 18 BA00 III en 05 Assembly Assembly Z WARNING Danger due to not approved cable entries gt If a not approved cable entry is used explosion protection can no longer be guaranteed Use only cable glands approved for the required type of protection When selecting or using cable glands the thread type and size indicated in the component documentation must be observed A WARNING Danger due to open holes or unused cable entries on the Ex e enclosure gt The explosion protection can no longer be guaranteed if holes or unused cable entries of the Ex e enclosure are left open Open holes must be sealed with separate stopping plugs suitable for this purpose in accordance with the certification of the control panel A WARNING Danger due to excessive weight Use suitable lifting appliances Secure against tipping Install a protective roof or wall if the explosion protected device is mounted outdoors Information regarding mechanical assembly such as location of attachment points dimensions or weight of the combined switch panels can be found in the enclosed assembly drawings Use the included mounting kit for assembly or optionally the frame system 8298 Assembly using th
19. re installed in accordance with the documentation Cable screens are earthed in accordance with the documentation There is no obvious damage to cables Sealing of trunking ducts pipes and or conduits is satisfactory Point to point connections are all correct Earth continuity is satisfactory for example the connections are fixed properly and the conductor cross sections are sufficient Earth connection maintain the integrity of the type of protection The intrinsically safe circuit is isolated from 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 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 Control Panels and Distribution Systems 8125 5 8125 8 Grade of inspection Detailed Close Visual inspectio inspectio inspectio 134784 8125612300 2013 01 18 BA00 III en 05 Accessories and Spare Parts 11 Accessories and Spare Parts A WARNING Use of non approved accessories and spare parts gt The manufacturer s liability and warranty expire Us
20. s are intended for stationary installation as standard Z WARNING Only use the device for its intended purpose gt Otherwise the manufacturer s liability and warranty expire The device may only be used under the operating conditions described in these operating instructions The device may only be used in hazardous areas according to these operating instructions 4 Control Panels and Distribution Systems 134784 8125612300 8125 5 8125 8 2013 01 18 BA00 Ill en 05 5 Technical Data Explosion protection Global IECEx Gas and dust Europe ATEX Gas and dust Material Enclosure Standard Option Seal Cover lock Standard Option Rated voltage Rated current Rated cross section Flanges Standard Option Degree of protection Operating temperature range 134784 8125612300 2013 01 18 BA00 IIl en 05 Technical Data IECEx PTB 06 0079 Ex d e ia ib ia Gb mb q IIA IIB IIC T6 T5 T4 Gb Ex tb IIIC T 80 C T 95 C T 130 C Db PTB 01 ATEX 1001 amp II 2 G Ex de ia ib ia Gb q IIA IIB IIC T6 T5 T4 Gb amp Il 2 D Ex tb IIIC T 80 C T 95 C T 130 C Db IP66 Galvanised sheet steel painted in light grey RAL 7032 Stainless steel 1 4404 AISI 316L electropolished painting possible to order Silicone foam Option Polyurethane foam with captive M6 stainless steel combo head screws with cover hinges max 1100 V AC DC depending on the type of terminal and
21. t described in the operating instructions must not be performed without prior agreement with the manufacturer Any damage may render explosion protection null and void No changes to the device impairing their explosion protection are permitted Install and use the device only if it is undamaged dry and clean Warnings Warnings are sub divided in these operating instructions according to the following scheme Z WARNING Type and source of the danger gt Possible consequences Measures to avoid danger They are always identified by the signalling word WARNING and sometimes also have a symbol which is specific to the danger involved 134784 8125612300 Control Panels and Distribution Systems 3 2013 01 18 BA00 IIl en 05 8125 5 8125 8 Designated Use 3 3 Conformity to Standards The conformity to the standards and regulations is specified in the corresponding certificates and declarations of the manufacturer e g EC Declaration of Conformity These documents are available for download on the internet page www stahl ex com 4 Designated Use The control and distribution boxes as well as the switch and distribution systems 8125 5 combined with their fitted components are used to control switch and transmit electrical energy The terminal compartment enclosures 8125 8 are used as terminal compartments for enclosures of the type of protection d flameproof enclosure All these device
22. y the connecting cables in the terminal compartment so that The minimum permissible bending radii for the respective conductor cross section are achieved Mechanical damage of the conductor isolation rubbing against sharp edged or movable metal parts is avoided A Z WARNING Incorrect installation gt Risk of severe injuries Please observe the thread sizes for the cable entries specified in the equipment documentation The connecting cable should comply with relevant regulations and have the required cross section The diameter must be identical to the data on the cable entry Ensure that the maximum permissible conductor temperatures are not exceeded by suitable selection of cables and means of running them gt The permissible ambient temperature around the intrinsically safe devices and components must not be exceeded When stripping insulation it must be ensured that the conductor insulation reaches right up to the terminals The conductor itself must not be damaged when removing the insulation 134784 8125612300 Control Panels and Distribution Systems 11 2013 01 18 BA00 IIl en 05 8125 5 8125 8 Installation Protective earth conductor Always connect the protective earth conductor Regardless ofthe operating voltage connect all bare non energised metal parts to the protective earth conductor Consider the N conductor as being energised and lay it according
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