Operating Instructions - exim.byexim.by/stahl/i8264.pdf · recommend the use of type 8162 breather glands from R. STAHL Schaltgeräte GmbH. The insta llation of the breather glands

Operating Instructions

Controller and Distribution in Flameproof Encapsulation

> 8264/5 Controller

Contents

1 Contents

1 Contents ................................................................................................................22 General Information ...............................................................................................23 General Safety Information ...................................................................................34 Designated Use .....................................................................................................45 Technical Data ......................................................................................................46 Transport, Storage and Disposal ...........................................................................67 Assembly ...............................................................................................................68 Installation .............................................................................................................79 Commissioning ....................................................................................................1110 Maintenance and Servicing .................................................................................1211 Accessories and Spare Parts .............................................................................1212 Type Examination Certificate (Page 1) ................................................................1313 Declaration of Conformity ....................................................................................14

2 General Information

2.1 ManufacturerR. STAHL Schaltgeräte GmbHAm Bahnhof 30D-74638 Waldenburg

Telephone: +49 7942 943-0Fax: +49 7942 943-4333Internet: www.stahl.de

2.2 Information regarding the Operating InstructionsID NO.: 8264605300Publication Code: S-BA-8264/5-00-en-01/11/2007We reserve the right to make technical changes without notice.

2.3 Symbols UsedA call to take action: Describes the actions to be carried out by the user.Reaction sign: Describes the results or the reactions to the actions taken.

X Checklist signCommentary sign: Describes the notes and recommendations.Warning sign: Danger from energised parts!

Warning sign: Danger due to an explosive atmosphere!

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Controller and Distribution in Flameproof Encapsulation 8264/5 Controller

General Safety Information

3 General Safety Information

3.1 Safety Instructions for Assembly and Operating PersonnelThe operating instructions contain basic safety instructions which are to be observed during installation, operation and maintenance and servicing. Non-observance will endanger persons, plant and the environment.

Before mounting/operating: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.Servicing/maintenance work or repairs which are not 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.

3.2 WarningsWarnings are sub-divided in these operating instructions according to the following scheme:

They are always identified by the signalling word “WARNING“ and sometimes also have a symbol which is specific to the danger involved.

WARNINGRisk due to unauthorised work being performed on the device!

Risk of injury and damage to equipment.Mounting, installation, commissioning and servicing work must only be performed by personnel who are both authorised and suitably trained for this purpose.

WARNINGThe type and source of the danger!

Possible consequences.Measures for avoiding the danger.

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3Controller and Distribution in Flameproof Encapsulation 8264/5 Controller

Designated Use

3.3 Conformity to StandardsThe controllers 8264 comply with the following standards and directives:

X Directive 94/9/ECX IEC 60079-0:2004, IEC 60079-1:2007, IEC 60079-7:2006, IEC 60079-11:1999,

IEC 61241-0:2004, IEC 61241-1:2004X EN 60079-0:2006, EN 60079-1:2007, EN 60079-7:2007, EN 50020:1994,

EN 61241-0:2006, EN 61241-1:2004

4 Designated Use

The controllers can be installed as components in Ex e control systems. A typical application is to install circuit breakers to protect motors in lighting and heating circuit distributors.

For direct cable entry into the enclosures flameproof cable entry glands or threaded holes to the conduit connection can be used. For indirect cable entry connection enclosures, which comply with increased safety type of protection, are used, e.g. series 8146 and 8125 enclosures.

5 Technical Data

WARNINGOnly use the device for its intended purpose!

Otherwise, the manufacturer’s liability and warranty expire.Only use the device under the operating conditions described in the operating instructions.The device must only be used in areas subject to explosion hazards according to these operating instructions.

Explosion protection

Gas explosion protection (ATEX)

E II 2G Ex d IIB T.*E II 3G Ex d IIB T.*E II 2G Ex d IIB + H2 T.* (on request)E II 3G Ex d IIB + H2 T.* (on request)* T4, T5, T6 depending on component

Gas explosion protection (IECEx)

Ex d. IIB T.*Ex d. IIB +H2 T.* (on request)* T4, T5, T6 depending on component

Dust explosion protection (ATEX)

E II 2D Ex tD A21 IP6x T80 °C, T95 °C or T130 °C

Dust explosion protection (IECEx)

Ex tD A21 IP6x T80 °C, T95 °C or T130 °C

Certificates KEMA 01 ATEX 2145

IECEx certification IECEx KEM 07.0051

Rated operational voltage Ue max. 11 kV, AC/DC

Rated operational current Ie max. 1250 A

Terminals max. 300 mm2

Type of protection Gas: IP 54Dust: IP 6X

Enclosure Aluminium (AlSi 7Mg) (saltwater-proof according to EN 13890) or stainless steel (S5316L)

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Technical Data

Ambient temperature range standard: -20 ... +40 °Con request: -20 ... +50 °Cwith explosion protection Ex d IIB + H2: -20 °C ... +50 °C (on request)

Power dissipation

Weight

Dimension Drawings (all dimensions in mm) - subject to alterations

10294E00

06815E00

Ta = 40 °C Ta = 50 °C

Empty enclosure T6 T5 T4 T6 T5 T4

8264/.112 55 W 80 W 170 W 34 W 54 W 125 W

8264/.212 75 W 120 W 235 W 47 W 81 W 173 W

8264/.222 115 W 160 W 320 W 71 W 108 W 236 W

8264/.223 125 W 190 W 370 W 78 W 129 W 273 W

8264/.323 160 W 240 W 465 W 99 W 163 W 343 W

8264/.333 200 W 300 W 565 W 116 W 190 W 417 W

8264/.933 301 W 447 W 810 W 207 W 355 W 598 W

8264/.993 347 W 520 W 933 W 248 W 405 W 826 W

Empty enclosure Enclosure Enclosure cover

Empty enclosure Enclosure Enclosure cover

8264/.112-2 23 kg 9 kg 8264/.112-3 9 kg 3 kg

8264/.212-2 38 kg 14 kg 8264/.212-3 16 kg 4 kg

8264/.222-2 59 kg 23 kg 8264/.222-3 21 kg 6 kg

8264/.223-2 42 kg 23 kg 8264/.223-3 26 kg 6 kg

8264/.323-2 79 kg 31 kg 8264/.323-3 31 kg 11 kg

8264/.333-2 97 kg 43 kg 8264/.333-3 38 kg 14 kg

8264/.933-2 118 kg 67 kg 8264/.933-3 58 kg 32 kg

8264/.993-2 175 kg 95 kg 8264/.993-3 99 kg 51 kg

A B C

8264/.112 235 235 270

8264/.212 360 235 270

8264/.222 360 360 270

8264/.323 480 360 340

8264/.333 480 480 340

8264/.933 730 480 340

8264/.993 730 730 340

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Transport, Storage and Disposal

6 Transport, Storage and Disposal

TransportShock-free in its original carton, do not drop, handle carefully.

StorageStore in a dry place in its original packing.

DisposalEnsure environmentally friendly disposal of all components according to legal regulations.

7 Assembly

Place the Ex d enclosure on the mounting rail and connect it with M12 screws (pay attention to the weight, see chapter "Technical Data").

Ex e connection chamber:

If deployed outdoors / where exposure to the elements is the case, it is recommended to provide the explosion-protected electrical equipment with a protective cover or wall.

To prevent condensation from forming inside the connection chambers, we recommend the use of type 8162 breather glands from R. STAHL Schaltgeräte GmbH. The installation of the breather glands reduces the level of protection afforded as per IEC 60529.The degree of protection is IP 66 if installed vertically, with the breather gland at the bottom and IP 64 if installed in any other way.

WARNINGDanger through not approved cable glands!

If a not approved cable entry gland is used, explosion protection can no longer be guaranteed.Only use cable entry glands, which are approved of for the required type of protection.

WARNINGDanger through open holes or unused cable entries on the Ex e connection enclosure!

Explosion protection is no longer guaranteed if holes or cable entries in the Ex e connection enclosure are left open.Open holes must be sealed in line with the certification for the controller with the appropriate separate stopping plugs.

WARNINGDanger from excessive weight!

Use suitable lifting tool.Secure to prevent from toppling.

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Installation

8 Installation

WARNINGInstallation may only be performed by qualified personnel!

Installation work may only be performed by authorised personnel suitably trained for this purpose.Follow all applicable national regulations of the country of use.

WARNINGIncorrectly installed components!

Explosion protection cannot be guaranteed any more if the components are incorrectly installed.If crimped wire ends are used, these must be gas-tight and attached using an appropriate tool.

WARNINGUse of cable glands without cable strain-reliefs!

Explosion protection cannot be guaranteed any more if cable glands are installed without cable strain-reliefs in the vicinity of loosely laid cables and leads.Securely lay cabling and leads.If installation is to to take place in areas with loosely laid cables, only use cable glands that are approved for this application.

WARNINGDanger through damaged surface!

If surfaces are damaged, it can no longer be guaranteed that the joint is flameproof.Handle the enclosure cover with care when putting it down and placing it on the enclosure.If the enclosure cover or the enclosure has a damaged surface, replace the respective part immediately.

WARNINGDanger from use of non-approved cable entry glands!

If non-approved cable glands are used, explosion protection can no longer be guaranteed.When selecting or replacing cable entry glands, refer to the component documentation for the type and size of thread.

WARNINGDanger from an excessively heavy enclosure cover!

When opening, take into consideration that the enclosure cover is very heavy (see chapter "Technical Data").Use suitable lifting tool.Attach a suitable hinge as necessary (see catalogue).

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Installation

Opening and closing the enclosure cover

Unfasten the screws on the enclosure.Open and remove the enclosure cover carefully (pay attention to the weight, see chapter "Technical Data").To close the enclosure cover, repeat the steps in reverse order.Use the specified tightening torque.

Mains connection

The conductors must be carefully connected.The conductor insulation must reach to the terminal.The conductor itself must not be damaged.Ensure that the maximum permissible conductor temperatures are not exceeded by suitable selection of cables and means of running them.Please refer to the terminal details in the technical data.

8.1 Internal wiringWires

Temperature class in case of various wire types

Type Tightening torque [Nm] Screw type8264/.112-. 8264/.212-. 8264/.222-. 8264/.223-. 8264/.323-. 8264/.333-. 8264/.933-3 8264/.993-3

20 Cheese-head screws M10 x 30 A4-70 as per ISO 4762

8264/.933-2 8264/.993-2

32 Cheese-head screws M12 x 30 A4-80 as per ISO 4762

WARNINGUse only cables of the type specified in the table for internal cabling.

Type Temperature class Conductor sizeH07G-K T5

) 0.5 mm2, CuH07V-K T6H05V-K T6LIY T6NSGAFÖU T5or comparable types

WARNINGIncorrectly routed cables in the Ex “e“ chamber!

Explosion protection can no longer be guaranteed if the cables are routed incorrectly.Strictly adhere to the required creepage distances and air gaps.Mouting rails or elements must be tightened correctly.

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Installation

I.S. circuits

Insulation test voltage

When considering insulation and isolation of terminals and cabling, please bear in mind that the insulation test voltage is calculated from the sum of the rated operating voltages of intrinsically safe circuits.

“Intrinsically safe against earth“

In the case “intrinsically safe against earth“ results in an insulation voltage value of at least 500 V (otherwise, use double the value of the rated operating voltages of intrinsically safe circuits).

“Intrinsically safe against non intrinsically safe“

In the case “intrinsically safe against non intrinsically safe“ results in an insulation voltage value of at least 1500 V (otherwise, use double the sum of the rated operating voltages of intrinsically safe circuits plus 1000 V).

Line-up terminal Ex “e“ connection chamber

WARNINGDanger through incorrectly dimensioned cables and wires!

Risk of serious injury.Only insulated cables and wires, whose test voltage is 500 V AC or above and whose minimum quality conforms with H05, must be used.The diameter of the individual conductors must not be less than 0.1 mm.The diameter of the individual wires of stranded conductors must not be less than 0.1 mm.

WARNINGDanger through incorrectly routed cables and wires!

Danger of short circuits.Wires and cables must be a minimum distance of 8 mm to wires and cables of other intrinsically safe circuits. Exception: The cores of intrinsically safe or non-intrinsically safe circuits are protected by a grounded shield.

A distance of 50 mm or creepage distance around an insulating () 1mm) or grounded metallic () 0.45 mm) separating plate must be provided between the connection points of intrinsically safe and non-intrinsically safe circuits.A separating plate, which reaches within ( 1.5 mm to the wall of the enclosure, must be provided between the connection points of intrinsically safe and non-intrinsically safe circuits.

Pay attention to the test certificate of the terminals.Only one cable is to be connected per clamping point. Terminal bridging is only permitted if original I.S. accessories have been used.Equip with the necessary partition plates as needed.For additional protection against splaying use crimped wire ends or cable lugs.The cross-sectional area of the splay protection must meet the wire cross section.

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Installation

8.2 External wiringLead the connection cabling with intact external insulation jackets through the cable entries into the connection chamber.

Please ensure that the wire cross section agrees with the specifications of the cable gland.

Sufficiently tighten the hexagon nut of the cable gland so that the seal of the connection chamber as well as the strain relief at the connection point are adequate. To determine the tightening torques, please consult the operating instructions of the individual components.

Arrange the connection cables in the connection chamber in such a way that:

The minimum permissible bending radii for the respective wire cross section are not violated.No mechanical damage to the conductor insulation rubbing against sharp-edged metal parts results.

Connection terminals

Tighten the screws of the connection terminals in accordance with the specified connection torques.

WARNINGIncorrect installation!

Risk of serious injury.Please observe the thread sizes specified in the equipment documentation for the cable inlet glands.The connection cables must conform with the applicable regulations and be of the cross sectional area required. The diameter must coincide with the cable entry gland data.By suitable selection of the cables used and the type of routing, it must be ensured that the maximum permissible conductor temperature is not exceeded.The permissible ambient temperature around the intrinsically safe units and components must not be exceeded.When stripping insulation, it must be ensured that the conductor insulation reaches right up to the terminal clamps.The conductor must not be damaged when stripping insulation.The switchgear combination must only be installed in a dry, clean environment.

Dimension of screws M3 M4 M5 M6 M8 M10Connection torque [Nm]

0.8 2.0 3.5 5.0 10.0 17.0

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Commissioning

Protective earth conductor

06817E00

When using the external earthing connection terminal, connect the PE conductor to the enclosure (1) with a cable lug (2). After the cable lug use a washer (3) and secure the screw (5) with a screw locking (4) to prevent it from coming loose.Regardless of the operating voltage, connect all bare, non-energised metal parts to earth / grounding system.The external protective earthing conductor is designed to be fitted with a cable lug. The cable must be laid snugly against the enclosure so that a entanglement of the cabling is prevented.

Connecting to the mains

Open the enclosure.Lead the connection cabling with intact external insulation jackets through the cable entries into the connection chamber.Arrange the connection cables in the connection chamber in such a way that the minimum permissible bending radii are not exceeded.In all cases, connect the protective earth conductor.If applicable, remove loose metal particles, dirt and traces of moisture from the connection chamber.Carefully close the enclosure after concluding the connection work.Carry out an insulation test in accordance with IEC/EN 60439-1.

9 Commissioning

Before commissioning

Make sure that the unit is not damaged.Make sure that the unit ist installed correctly.Remove any foreign object from the unit and clean the connection chamber.Check that cable entry glands and plugs are tightly fitted.Check that screws and nuts are tightly fitted.Insprect the cable entry gland for damage.Check the tightening torque of the screws.

Information regarding potential equalisation (cabling) (PA), protective earth systems (PE) and intrinsic safety circuits can be found in the documentation accompanying the devices being built in.

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Maintenance and Servicing

10 Maintenance and Servicing

10.1 Regular Maintenance WorkConsult the relevant regulations (e.g. IEC/EN 60079-17) to determine the type and extent of inspections.The length of time between periodic checks shall be so set that any system faults likely to arise are found promptly.

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 EN 60079-0.X Make sure the device is used according to its designated use

10.2 CleaningX Clean with a cloth, brush, vacuum cleaner or similar items.

11 Accessories and Spare Parts

WARNINGDanger from energised parts!

Risk of the most severe injuries occuring.Before any maintenance work commences, disconnect the device from the power supply.Secure the device against unauthorised activation.

WARNINGRisk due to unauthorised work being performed on the device!

There is a risk of injury and damage to equipment. Mounting, 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 flat joint do not comply with tables 1 or 2 from standard IEC/EN 60079-1. Contact the manufacturer before starting to work on the joint surfaces.

WARNINGShort circuit in the circuit

After multiple short circuits, the flameproof encapsulation is no longer guaranteed.After a short circuit, check the functionality of the device.Replace the entire device if needed.

WARNINGUse of non-approved accessories and replacement parts!

The manufacturer’s liability and rights to make claims under warranty will be invalidated.Only use original accessories and original spare parts manufactured by R. STAHL.

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Type Examination Certificate (Page 1)

12 Type Examination Certificate (Page 1)

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Declaration of Conformity

13 Declaration of Conformity

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8264605300S-BA-8264/5-00-en-01/11/2007

Documents

Operating Instructions - exim.byexim.by/stahl/i8264.pdf · recommend the use of type 8162 breather glands from R. STAHL Schaltgeräte GmbH. The insta llation of the breather glands