eltherm ELAK-Ex-R Owner's manual

eltherm GmbH
Ernst-Heinkel-Strasse 6 -10
57299 Burbach, Germany
P.: [phone]
F.: [phone]
[email protected]
QAA 090
www.eltherm.com
ELAK-Ex-R
OPERATION
MANUAL
Installation and Operation

CONTENT
Topic Page
DESCRIPTION & TECHNICAL DATA 4
Description 4
Model Views 4
Certication 4
Standards 4
Marking 4
Technical Data 5
Cable Glands 5
Terminals 5
Model Overview 6
INSTALLATION 10
Safety Instructions 10
Receipt of the Goods 10
Strorage 10
Recommended Tools 10
Preparation of Wall Mounting 10
Assembly Instructions 10
Open the Enclosure 11
Attach the Enclosure 11
Connect the Trace Heater / PT100 11
Close the Enclosure 12
Check After Installation 12
Operation & Maintenance 12
Marking (by Customer) 13
Notes 13

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3
Operation instructions
Ex – Junction boxes ELAK-Ex-R
QAA 090
Revision 6
Proviso
We reserve the right to make technical changes. Changes, errors or misprints shall not form the basis for any claim to compen-
sation for damages. Comply with the applicable and currently valid standards and regulations for safety-related components
and systems.
eltherm GmbH
Ernst-Heinkel-Str. 6-10
57299 Burbach
T.: [phone]
F.: [phone]
[email protected]
Document:
88643040X8007X Operation Manual ELAK-
Ex-R (QAA90) EN
Installation and operation
ELAK-Ex-R
Autor: Peter Schmidt Date: 29.02.2020
Revision: 6Detlef Matthes Date: 19.01.2022
NOTE
Important information and instructions for safe, effective and
environmentally compatible usage.
i
ATTENTION
Refers to a potentially dangerous situation. If it is not prevented,
there is a risk of danger or malfunction.
WARNING
Refers to a dangerous situation. If it is not prevented there is risk
of injury or at least a high risk of material damage.
DANGER
Refers to an extremely dangerous situation. If it is not prevented
there is risk of death or at least a high risk of serious injuries.
Contact us: [phone] •[email protected]
The WEEE logo indicates that this product should not be disposed of with other waste.
For more information on the disposal and recovery of waste electrical and electronic equipment (WEEE) and
collection points, please contact your local waste disposal company or the manufacturer from whom you
purchased the product.
IMPORTANT INFORMATION FOR STORAGE
For proper and safe use of the ELAK-Ex-R connection boxes, please follow these instructions.
Please keep these instructions for future reference (e.g. in the system documentation).
IMPORTANT DISPOSAL INFORMATION

4
125 mm
Ø 154.5 mm
Ø 6.5 mm
ATEX II 2G Ex eb IIC T6 Gb
II 2D Ex tb IIIC T 85°C Db
IEC-Ex Ex eb IIC T6 Gb
Ex tb III C T85°C Db
DESCRIPTION & TECHNICAL DATA
The innovative junction box (ELAK-Ex-R) is suitable for use in hazardous areas and offers the user many advantages. For example,
due to the shape of the box, the inserted cable only needs to be bent slightly, which protects against mechanical stress and
damage. A safety gland prevents unauthorized opening of the junction box, or unintentional sliding of the cover (special tool
included).
Additional fastening options for marking labels enable reliable identification of heating circuits in complex systems and allow
customer-specific markings.
MODEL VIEWS
DESCRIPTION
EN 60079-0:2012 + A11:2013, IEC 60079-0 Ed. 6
EN 60079-7:2015, IEC 60079-7 Ed. 5
EN 60079-31:2014, IEC 60079-31 Ed. 2
MARKING
EXPLOSION PROTECTION
CERTIFICATION
STANDARDS
IBExU 08 ATEX 1113 X
IECEx IBE 16.0001 X

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5
Operation instructions
Ex – Junction boxes ELAK-Ex-R
QAA 090
Revision 6
Contact us: [phone] •[email protected]
Nominal voltage (max.) 550 V AC
Nominal current max 24 A (see terminals)
Ambient temperature - 45 °C up to +50 °C
Nominal cross-section* Power cable max. 6 mm² (ELAK-Ex-R8 max. 2.5 mm²)
Material Polyamid, glass fiber reinforced, black
Cable glands / blind plugs Polyamid
Dimmensions (ca.) Ø 154,5 mm, Height 125 mm
Protection level IP 65
Impact strength 7 Joule
Installation Type Wall mounting
Weight ca. 0,7 kg
* Connection cross-section (solid or ne-stranded without wire end sleeve); terminals heating cable max. 4 mm² (AWG11);
Terminals temperature sensor max. 2.5 mm² (AWG 13)
TECHNICAL DATA
Size Clamping range Wrench size Torques
Thread Screw
[mm] [mm] [Nm]
M16 4 - 7 15 2,5 2 - 1,65
M20 5,5 - 13 24 3,75 3,5 - 2,5
M25 8 - 17 29 5 5 - 3
CABLE GLANDS
Nominal cross-section Wire cross-section Current
[mm²] [mm]² [A]
1.5 0,5 - 2,5 15
2,5 0,5 - 4,0 21
4,0 0,5 - 6,0 24
TERMINALS
DANGER
SPECIAL CONDITIONS according to Type Ex certificate
The ambient temperature range, depending on the cable glands used, is specified from -45°C or -40°C (Type R. steel 8161/5 &
steel 8161/6) to +50°C.

6
1
2
3
6
5
4
PE PE1 2 3
L1 L2 L3
ELAK-Ex-R2
1 2
3
4 5
ELAK-Ex-R1
PE PE1
L1 L2 L3
ELAK-Ex-R2
PE PE
PE
1 2 3
L1 L2 L3
Pos. Type Quantity Clamp-
range
1 Blind plug M20x1.5 1 -
2 Cable gland M25x1.5 1 9-13/12-17
mm
3 Blind plug M16x1.5 1 -
4 Cable gland M16x1.5 2 4 - 10 mm
5 Protective earth terminal 2 6 mm²
6 Feed through-terminal 3 6 mm²
0X80072 two-phase 0X80072 three-phase
ELAK-Ex-R2 (0X80072)
2 Phase or star point for connection ELKM-AG-**
Pos. Type Quantity Clamp-
range
1 Blind plug M20x1.5 1 -
2 Blind plug M25x1.5 1 -
3 Cable gland M16x1.5 3 4 - 10 mm
4 Feed through-terminal 1 6 mm²
5 Protective earth terminal 1 6 mm²
ELAK-Ex-R1 (0X80071)
Star point for connection ELKM-AG-**
MODELL OVERVIEW
Terminal for earthing or electrical protection

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7
1 2
3
5
6
1
6
5
3
2
4
ϑ
1N1
ELAK-Ex-R4 EL-CT
PE PE1 2 3
PE L N
4
ϑ
1N1
ELAK-Ex-R5 EL-CT
PE PE1 2 3
PE L N
Operation instructions
Ex – Junction boxes ELAK-Ex-R
QAA 090
Revision 6
Contact us: [phone] •[email protected]
ELAK-Ex-R4 (0X80074)
Connection of 1 ELKM-AG-** + EL-CT
Pos. Type Quantity Clamp-
range
1 Cable gland M20x1.5 1 9 - 12 mm
2 Cable gland M25x1.5 1 9-13/12-17 mm
3 Cable gland M25x1.5 1 9-13/12-17 mm
4 Cable gland M20x1.5 1 9 - 12 mm
5 Protective conductor terminal 2 6 mm²
6 4 Wire Through clamp 3 6 mm²
Pos. Type Quantity Clamp-
range
1 Cable gland M20x1.5 1 7 - 12 mm
2 Cable gland M25x1.5 1 9-13/12-17 mm
3 Cable gland M16x1.5 1 4 - 10 mm
4 Borehole M20 1 -
5 Protective conductor terminal 2 6 mm²
6 Through clamp 3 6 mm²
ELAK-Ex-R5 (0X80075)
Connection of 1 ELSR + EL-CT
Terminal for earthing or electrical protection

8
1
6 5
3
2
4
PE
ELAK-Ex-R8
ELTF-PT.15
PE5 6 7 81 2 3 4
RT RT
WS
RT RT
WS
1 2
3
65
4
ELAK-Ex-R7
PEL N
PE1 2 PE
ELTF-PT.15
Connection of 1 or 2 ELTF-PT.15 [Ex ib]
Pos. Type Quan-
tity Clamp-
range
1 Blind plug M20x1.5 blue 1 -
2 Cable gland M25x1.5 blue 1 9 - 17 mm
3 Blind plug M16x1.5 blue 1 -
4 Cable gland M16x1.5 blue 2 6 - 10 mm
5 Protective earth terminal 2 2,5 mm²
6 Feed through-terminal 8 2,5 mm²
ELAK-Ex-R8i (0X80078IB)
Connection of one or two [ib] PT100 Temperature sensor
ELAK-Ex-R7 (0X80077)
Connection of 1 up to 3 ELSR
Pos. Type Quan-
tity Clamp-
range
1
Blind plug M20x1.5 1 -
2 Blind plug M25x1.5 1 -
3
Borehole M20 1 -
4
Cable gland M25x1.5 2 9-13/12-17 mm
5 Protective earth terminal 2 4 mm²
6 Feed through-terminal 2 4 mm²
Terminal for earthing or electrical protection

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9
1
6 5
3
2
4
PE
ELAK-Ex-R8
ELTF-PTEx.1 ELTF-PTEx.1
PE5 6 7 81 2 3 4
RT/BL
RT
WS/BL
WS
RT/BL
RT
WS/BL
WS
PE
ELAK-Ex-R8
ELTF-PTEx.3 ELTF-PTEx.3
PE5 6 7 81 2 3 4
RT RT
WS
RT RT
WS
ELTF-PTEx.4
PE
ELAK-Ex-R8
PE5 6 7 81 2 3 4
RT RT
WS
BL
BL
GR
PE
ELAK-Ex-R8
ELTF-PTEx.2 ELTF-PTEx.2
PE5 6 7 81 2 3 4
RT/BL
RT
WS/BL
WS
RT/BL
RT
WS/BL
WS
Operation instructions
Ex – Junction boxes ELAK-Ex-R
QAA 090
Revision 6
Contact us: [phone] •[email protected]
ELAK-Ex-R8 (0X80078)
Connection of one or two PT100 temperature sensors
Pos. Type Quan-
tity Clamp-
range
1 Blind plug M20x1.5 1 -
2
Cable gland M25x1.5 1 9 - 17 mm
3 Blind plug M16x1.5 1 -
4
Cable gland M16x1.5 2 6 - 10 mm
5
Protective conductor terminal 2 2,5 mm²
6 Through clamp 8 2,5 mm²
Connection of one or two ELTF-PTEx.1
Connection of 1 or 2 ELTF-PTEx.2
Connection of 1 or 2 ELTF-PTEx.3
Connection of 1 ELTF-PTEx.4 (Double-PT100)
Terminal for earthing or electrical protection

10
2
95 mm
124 mm
Ø 6.5 mm
ATTENTION
• The following steps should only be carried out by
persons trained in handling explosive equipment.
• Strict compliance with the relevant safety regulations in
potentially explosive atmospheres is a requirement for
the safety of persons, plants and equipment.
• The persons entrusted with the planning, installation
and maintenance bear a special responsibility and must
therefore be thoroughly familiar with the applicable
regulations.
• These instructions are intended for this group of people
and contain all the important information required for
the safe handling of the ELAK-Ex-R junction boxes.
• The instructions must be kept together with the system
documentation for later use and must be kept and be
available during the entire service life of the product.
SAFETY INSTRUCTIONS
RECEIPT OF THE GOODS
On receipt of the goods, check the junction boxes and the
accessories and compare the type information with the infor-
mation on the delivery note to ensure that the correct mate-
rial has been delivered.
STORAGE
Storage should be in a dry, clean place at an ambient
temperature from 0°C to 50°C.
INSTALLATION
RECOMMENDED TOOLS
PREPARATION OF WALL MOUNTING
Drill two Ø 8 mm holes (see drilling diagram) and insert the
appropriate dowels into the holes. Use screws with a max.
diameter of 6 mm to fasten the enclosure.
ASSEMBLY INSTRUCTIONS
ATTENTION
• In the version with borehole Ø 42 mm, mounting only
with mounting bracket „eltherm Ex-It“ according to the
QAA-073.
• When selecting the mounting location, take into ac-
count the degree of mechanical danger to the junction
box and the cable entries as well as the permissible am-
bient temperature.
• Ensure that the surface on which the junction box is
mounted is capable of bearing loads.
• Cables inserted into the junction box must be laid firmly
and secured against being pulled out of the cable entry
(e.g. by a cable clamp).
• Unused clamping points must be tightened.
• All cable entries, reducers and blind plugs may only be
used in conjunction with threaded connection seals, O-
rings or moulded sealing elements and must be separa-
tely tested and approved for type of protection „e“ or „t“
with EPL Gb or Db.
• Seals in the cable entries must not be exchanged or ne-
sted.
• Threaded boreholes can be reduced in size. However,

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11
Operation instructions
Ex – Junction boxes ELAK-Ex-R
QAA 090
Revision 6
Contact us: [phone] •[email protected]
several reducers must not be reductions must not be
nested.
• Before inserting blind plugs, reducers or conduit entries
into free threaded boreholes, make sure that the threa-
ded borehole is clean and undamaged and that the re-
spective threads fit together.
• After connection, all openings must be closed tightly
(cover, threaded boreholes, cable entries). Use suitable
open-end, ring or socket spanners to tighten the cable
entries. The test torques listed in the chapter „Technical
data“ must be observed.
• ATTENTION: Excessive tightening may impair the IP pro-
tection class!
• The lid of the junction box is designed to mount a iden-
tification plate provided by the customer. Use screws Ø
2.2 x 6 mm for fastening.
2Insert a flat-tip
screwdriver between the
locking arm and the
rear bar and push the
locking arm forward a few
millimetres by turning
the screwdriver
3Turn the headless
screw back with the Al-
len wrench (size 2) until
it is protruding slightly
out of the locking arm
1Tighten the head-
less screw with an Allen
wrench (size 2) until the
locking arm is flush with
the side bars
4Lift the
lid (using the
screwdriver)
5Open the
lid (using the-
screwdriver)
OPEN THE ENCLOSURE
6Fasten the en-
closure on the wall
or on the moun-
ting bracket.
FASTEN THE ENCLOSURE
CONNECT THE TRACE HEATER / PT 100
ATTENTION
• Please observe the respective installation instructions
for the heating cables / sensors to be connected.
• Make sure that all terminals and cable glands are tighte-
ned according to the instructions.
• Before closing the terminal box, carry out the installa-
tion check of the heating cables.

12
1Visual inspection of housing and lid to ensure they are
not damaged. The lid can only be inserted in one position
(locking arms / twist protection recesses have different width).
Move the lid to the appropriate position.
2Attach the lid with the narrower locking arm (without a
headless screw), close the lid and…
3Use the pliers to lock the lid.
CLOSE THE ENCLOSURE CHECK AFTER INSTALLATION
ATTENTION
After completing the installation, the following steps must
be taken:
• Visual inspection of the junction boxes for possible me-
chanical damage.
• Damaged junction boxes must not be put into operation
and must be replaced.
• Check the cover of the junction box and its attachments
(cable entries) for tight fit.
• All threaded openings must be fitted with cable entries
or blind plugs, which must be firmly tightened and tight.
OPERATION & MAINTENANCE
DANGER
• The junction boxes may only be opened (this also in-
cludes loosening cable entries!) in a de-energised state.
disconnected from the power supply.
• Damaged junction boxes must not be put into opera-
tion.
ATTENTION
When operating the junction boxes, the permissible ambient
temperature must be observed.
• The locally applicable safety regulations must be obser-
ved.
• The permissible operating conditions according to
„Technical data“ or labelling (voltage, current, operating
temperature, maximum ambient temperature, IP protec-
tion class) must be observed.
• The cable entries must not be operated in dust explosion
hazardous areas with dust deposits >= 50 mm.
• It is recommended to visually check the integrity and
tight fit of the cable gland and the connected cable at
suitable intervals depending on the installation location
and application.
• If necessary, the cable entries must be retightened, da-
maged junction boxes or cable entries must be replaced
by qualified personnel.
• If repair work is to be carried out on heated system parts,
the junction boxes must be protected against damage.
• After completion of the repair work, the junction box
must be checked again.

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13
70 mm (Ø 2,2 x 6mm)
Operation instructions
Ex – Junction boxes ELAK-Ex-R
QAA 090
Revision 6
Contact us: [phone] •[email protected]
MARKING (made by customer)
NOTE
Customer-side labeling with an identification plate is possib-
le.
• The size of the marking plate must not exceed
2000 mm².
i
NOTES

www.eltherm.com
eltherm GmbH
Headquarters
Ernst-Heinkel-Straße 6 -10
57299 Burbach. Germany
T.: [phone]
F.: [phone]
[email protected]
Contact us: [phone] •[email protected]
8643040X8007X Operation Manual ELAK-Ex-R (QAA90) EN- subject to technical changes without notice.
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