Siemens Simatic 6DL2804-1 Series Assembly instructions

SIMATIC
Distributed I/O
Distributed I/O device
6DL2804-1xxxx & 6DL2804-2xxxx
Hardware Installation Manual
07/2017
A5E42025214-AA
Security information 1
Safety information 2
Purpose of this
documentation 3
Description 4
Mounting 5
Maintenance and servicing 6
Technical specifications 7
Ground points in the
enclosure 8
Dimension drawings 9
ESD Guidelines 10
Service & Support 11

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E42025214-AA
Ⓟ 07/2017 Subject to change
Copyright © Siemens AG 2017.
All rights reserved

Table of contents
1 Security information......................................................................................................................................5
2Safety information.........................................................................................................................................7
2.1 General information..................................................................................................................7
2.2 Laws and directives..................................................................................................................7
2.3 Qualified personnel..................................................................................................................7
2.4 Measures.................................................................................................................................8
3Purpose of this documentation.....................................................................................................................9
4Description..................................................................................................................................................11
4.1 Overview................................................................................................................................11
4.2 Area of application.................................................................................................................11
4.3 Product features.....................................................................................................................12
4.4 Structure of the type designation...........................................................................................12
4.5 Design of enclosure...............................................................................................................14
4.6 Details of the enclosure..........................................................................................................17
5 Mounting.....................................................................................................................................................19
5.1 Transport and storage............................................................................................................19
5.2 Mounting the enclosure..........................................................................................................20
5.3 Installing the enclosure outdoors...........................................................................................22
5.4 Optional installation components...........................................................................................22
5.5 Use of I/O device at temperatures down to -40 °C.................................................................23
6 Maintenance and servicing.........................................................................................................................27
7 Technical specifications..............................................................................................................................29
8 Ground points in the enclosure...................................................................................................................33
9 Dimension drawings...................................................................................................................................35
9.1 Installation: ET200iSP components.......................................................................................35
9.2 Installation: Heating................................................................................................................37
9.3 Installation: FO conductor......................................................................................................38
10 ESD Guidelines..........................................................................................................................................39
11 Service & Support.......................................................................................................................................41
Index...........................................................................................................................................................45
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Table of contents
Distributed I/O device 6DL2804-1xxxx & 6DL2804-2xxxx
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Security information 1
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines, and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens’ products and solutions only form one element of such a concept.
Customer is responsible to prevent unauthorized access to its plants, systems, machines and
networks. Systems, machines and components should only be connected to the enterprise
network or the internet if and to the extent necessary and with appropriate security measures
(e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into
account. For more information about industrial security, please visit:
http://www.siemens.com/industrialsecurity.
Siemens’ products and solutions undergo continuous development to make them more secure.
Siemens strongly recommends to apply product updates as soon as available and to always
use the latest product versions. Use of product versions that are no longer supported, and
failure to apply latest updates may increase customer’s exposure to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed under
http://www.siemens.com/industrialsecurity.
Distributed I/O device 6DL2804-1xxxx & 6DL2804-2xxxx
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Security information
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Safety information 2
2.1 General information
This device left the factory in a perfect state with regard to safety. To maintain this status and
to ensure safe operation of the device, note and follow the instructions and warnings in this
manual.
2.2 Laws and directives
Observe the provisions of the test certification valid for your country.
Electrical connection in potentially explosive atmospheres
When making electrical connections, observe the national regulations and laws for hazardous
areas valid for your country. In Germany, for example, the following apply:
● Ordinance on Industrial Safety and Health
● Standard relating to the installation of electrical systems in hazardous areas DIN EN
60079-14 (previously VDE 0165, T1)
2.3 Qualified personnel
Qualified personnel are people who are familiar with the installation, mounting, commissioning,
and operation of the product. These people have the following qualifications:
● They are authorized, trained or instructed in operating and maintaining devices and systems
according to the safety regulations for electrical circuits, high pressures and aggressive as
well as dangerous media.
● For devices intended for use in explosive atmospheres: They are authorized, trained, or
instructed in working on electrical circuits for systems in potentially explosive atmospheres.
● They are trained or instructed in maintenance and use of appropriate safety equipment
according to the safety regulations.
● They should be trained in first aid.
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2.4 Measures
In the interest of safety, observe the following precautionary measures:
WARNING
Type of protection "Flameproof enclosure d"
Devices with "pressure-resistant encapsulation" protection may only be opened when the
power has been disconnected.
Type of protection "Intrinsic safety i"
"Intrinsically-safe" devices lose their certification as soon as they are operated on circuits
which do not correspond with the test certification valid in your country.
Type of protection "Increased safety e"
Devices with the type of protection "Increased safety" must not produce sparks or electric
arcs during operation under normal conditions. Electrical equipment and parts must not
exceed a rated voltage of 11 kV.
Type of protection "Mold encapsulation m"
Devices with the type of protection "Mold encapsulation" are potted in casting compound.
Type of protection "By means of enclosure t"
Devices with the type of protection "By means of enclosure" prevent the penetration of dust
or reduce it to a harmless level. Explosive equipment can be installed. The temperature on
the housing must not ignite the surrounding atmosphere.
WARNING
Use in environments with aggressive and dangerous media
The device can be operated both at high pressure and with aggressive and hazardous media.
Therefore, improper use of this device may lead to serious injury and or considerable damage
to property. Above all, it must be noted when the device was in use and is to be exchanged.
CAUTION
Electrostatic sensitive devices
This device contains electrostatic sensitive devices. ESD devices can be destroyed by
voltages well below the threshold of human perception. These static voltages develop when
you touch a component or electrical connection of a device without having discharged the
static charges present on your body. The damage to a module as a result of overvoltage
cannot usually be detected immediately. It may only become apparent after a long period of
operation.
Safety information
2.4 Measures
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Purpose of this documentation 3
This manual contains all the information that you will require to install and use the device.
It is intended for persons who install the device mechanically, connect it electrically, set
parameters and commission it, as well as for service and maintenance technicians.
Distributed I/O device 6DL2804-1xxxx & 6DL2804-2xxxx
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Purpose of this documentation
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Description 4
4.1 Overview
The device is used as a control, switching and distribution unit in hazardous areas (gas: Zones
1, 2; dust: 21, 22; mining: M2). The product satisfies the requirements of the following standards
● EN/IEC 60079-0 General requirements
● EN/IEC 60079-7 Enhanced safety
● EN/ICE 60079-31 Protection by means of enclosure
The device consists of the wall-mounted enclosure and the components installed in it, for each
of which there are separate certificates.
The device is also identified by the standards of the installed components. The supplied ATEX
certificate applies to the device and to the components installed by the manufacturer.
4.2 Area of application
● The wall-mounted enclosures are suitable for installation and operation of distributed I/O,
such as ET 200iSP, in the following hazardous areas:
– Device group I (mining, M2)
– Device group II (Zones 1 + 2 gas, and Zones 21 + 22 dust)
● The device consists of the wall-mounted enclosure (6DL2804-0xxxx) and the installed
electronic components.
● The device has been tested and certified for use in these hazardous areas.
Note
Product information on the Internet
You will find further information on installing and connecting the electronic components, for
example in:
● ET 200iSP manual (A5E00247482)
● Principles of explosion protection manual (6ES7398-8RA00-8BA0)
This information is available on the Internet on the Siemens home page.
● Only open the enclosure in Zones 21 and 22 if no ignitable dust atmosphere is present.
● The device is identified depending on:
– The installed components
– Use for the following hazardous areas: gas, dust or mining
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4.3 Product features
The device consists of a separately certified wall-mounted enclosure (6DL2804-0xxxx). The
enclosure is made of stainless steel and is intended for wall mounting.
The device is intended for the installation of control and measuring devices such as:
● Distributed I/O systems:
– ET 200iSP for use in Zones 1 and 2 (gas), Zones 21 and 22 (dust), and M2 (mining)
● Modular electro-pneumatic automation system AirLine Ex (type 8650, from the company
Bürkert)
● Buffer stages and safety barriers
● Relays, buffer elements and fuses
● Separate terminals for intrinsically safe and non-intrinsically safe circuits
● Command and signaling devices
● Temperature sensors
● Heating and thermostat
● Lightning protection components
● FO coupler
4.4 Structure of the type designation
The device has type designation:
0SHUPLVVLEOHRSHUDWLQJWHPSHUDWXUHIURPr&SODVWLFWHUPLQDOEODFN 1SHUPLVVLEOHRSHUDWLQJWHPSHUDWXUHIURPr&PHWDOWHUPLQDO 2SHUPLVVLEOHRSHUDWLQJWHPSHUDWXUHIURPr&SODVWLFWHUPLQDOEOXH 6SHUPLVVLEOHRSHUDWLQJWHPSHUDWXUHIURPr&PHWDOWHUPLQDOIRUPLQLQJ ZLWKURZRIWHUPLQDOV ZLWKURZVRIWHUPLQDOV ZLWKURZV0WHUPLQDOV ZLWKURZV0WHUPLQDOV ZLWKURZV0WHUPLQDOV ZLWKURZV0WHUPLQDOV=''LPHQVLRQV[[PP:[+['=('LPHQVLRQV[[PP:[+['=)'LPHQVLRQV[[PP:[+['=*'LPHQVLRQV[[PP:[+['= H..:'LPHQVLRQVPD[[[PP:[+[' $=RQH '=RQH 00LQLQJ0 ,QVWDOODWLRQRIFRPSRQHQWVZLWKRXWHOHFWURSQHXPDWLFV\VWHm
,QVWDOODWLRQRIFRPSRQHQWVZLWKDQHOHFWURSQHXPDWLFV\VWHP%¾UNHUW6DL2804 - xxxxx
Description
4.4 Structure of the type designation
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The enclosure sizes D...G have a cover which pivots upwards by means of gas-filled dampers.
The enclosure sizes H...W have doors with right-hand hinges (close on left).
Description
4.4 Structure of the type designation
Distributed I/O device 6DL2804-1xxxx & 6DL2804-2xxxx
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4.5 Design of enclosure
Standard enclosure 6DL2804-0xD...Gxx



+
%7
①Mounting plate ⑤M20 cable glands
②Drainage/pressure compensation nozzle ⑥M32 cable glands
③Equipotential bonding rail with terminals ⑦M6 grounding screw
④M16 or M20 cable glands ⑧Removable connection to enclosure ground
Figure 4-1 Standard enclosure 6DL2804-0xD...Gxx
W x H x D: See Structure of the type designation (Page 12)
Description
4.5 Design of enclosure
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Standard enclosure 6DL2804-0xH…Wxx
+
%
Figure 4-2 Standard enclosure 6DL2804-0xH...Wxx, view 1
Description
4.5 Design of enclosure
Distributed I/O device 6DL2804-1xxxx & 6DL2804-2xxxx
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


①Mounting plate ⑥M32 cable glands *)
②Drainage/pressure compensation
nozzle
⑦M6 grounding screw
③Equipotential bonding rail with termi‐
nals
⑧Removable connection to enclosure ground
④M16 or M20 cable glands *) ⑨Optional power supply terminals
⑤M20 cable glands *)
*) The size and number of cable glands can be defined specific to the project.
Figure 4-3 Standard enclosure 6DL2804-0xH…Wxx, view 2
Description
4.5 Design of enclosure
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4.6 Details of the enclosure
Degree of protection
The degree of protection depends on the enclosure size and the parts used such as cable
entries, dummy plugs and climate nozzles. The nameplate specifies the degree of protection
for which the enclosure is designed. The minimum degrees of protection are:
● Device group I: IP54/IP55
● Device group II: IP54 to IP66 (Zones 1 + 2)
● Device group II: IP64 to IP66 (Zones 21 + 22)
Operating temperature
The operating temperature range of the enclosure depends on the temperature range of the
parts used, and can differ from the actual operating temperature range:
● -40 °C to +75 °C: only for the enclosure versions 6DL2804-0xxx1
● 0 °C to +75 °C
The nameplate specifies the permissible operating temperature range in each case.
● Prior to installation of components, check the operating temperature range of the complete
setup. The operating temperature range for the complete setup may be limited by the
maximum permissible operating temperature of the components and the dissipated heat
produced in the enclosure.
Climate nozzles provide pressure compensation and drainage in the event of varying climatic
conditions.
● In the case of aggressive environments, check whether use of the enclosure is possible
with the material in question. Delivery of enclosures with appropriate surface protection is
possible for use with aggressive environmental conditions.
Cable and wiring entries (CWE)
● When fitting cables, observe the manufacturer's data on the tightening torques of the cable
and wiring entries.
● Use the tightening torque of the clamping screw when connecting the cables.
● Relieve the tension on the cables outside the enclosure so that the cable gland is not
stressed.
● For additional information and technical specifications, refer the respective manufacturer
documentation, in particular:
– Technical specifications, clamping ranges for cables
– Notes on use, installation, mounting, commissioning and maintenance
Description
4.6 Details of the enclosure
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Note
Use the supplied red dummy plugs to close any cable glands not in use. Only then is it ensured
that the degree of protection is retained.
Equipotential bonding rail
The equipotential bonding rail (10 x 3 mm) with terminals (up to 4 mm²) is used to contact the
cable shields. Alternatively, you can also use other terminals here, e.g. KLBüCo from the
company Weidmüller (not included in the scope of delivery)
Connect the equipotential bonding wire to the bonding terminal (0.75 to 35 mm²).
Short lines connect the equipotential bonding rail to the mounting plate and thus to the
enclosure.
Note
Also observe the installation guidelines in the ET200iSP operating instructions, Section 5.2
"Using ET 200iSP with equipotential bonding".
Wall supports
Screw the wall supports onto the enclosures using M6/M8 screws depending on the enclosure
size. These are included with the enclosure accessories. To secure the enclosure, use 8 mm
diameter screws and lock washers.
Grounding connection
The M6/M8 ground connection screw is used for the PE conductor; use a cable with lug for
this. To prevent the screw from becoming loose, make sure you use the lock washer.
Connecting the grounding cable avoids static charge which is important, in particular, for dust
explosion protection.
Installed components
The enclosure nameplate specifies the parameters within which the installed components can
be used.
Observe the following if you subsequently connect equipment and the required cables on site:
● Read and observe the manufacturer's instructions, especially notes, warnings and
information on special features.
● Electrical equipment as well as combinations of equipment can impair the intrinsic safety
of the circuits as a result of their electrical parameters. Prior to installing equipment, check
that the intrinsic safety of the circuit is still guaranteed.
Description
4.6 Details of the enclosure
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Mounting 5
Note
● When installing control and measuring devices in the Ex enclosure, keep to the instructions
in the relevant product descriptions and the technical specifications in the data sheets.
● All control and measuring devices installed in the enclosure must be separately certified
for the relevant hazardous zone.
● Run the tests prescribed in the relevant national regulations for the installed control and
measuring devices.
Note
● Install and operate the distributed I/O device in hazardous areas according to the
specifications of the EC-type examination certificate according to ATEX and these
operating instructions or the standards and directives valid in your country.
● Assembly, installation, commissioning and maintenance may only be performed by
qualified personnel.
● The devices and installed components must only be used for their intended purpose.
5.1 Transport and storage
Pack and store the enclosure for transport or storage so that there can be no undue strain on
the enclosure, particularly on its top cover. If there is too much strain on the top cover of the
enclosure, this can damage the seal.
Do not place the enclosure on the cable glands fitted in its base, otherwise the glands will be
damaged.
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5.2 Mounting the enclosure
The enclosure is intended for wall mounting and should be secured with the wall supports
supplied with it. Use the following template for the drilling.
PP%
+
Figure 5-1 Drilling template for securing the device
CAUTION
Danger of injury when the enclosure is opened
When opening the enclosure with pivoting cover, the cover is pressed upwards by means of
the pressure of the dampers. When opening, press against the cover with your hand.
Note
● Remember the maximum thermal load on the cables and wiring. The degree of protection
is only ensured when suitable cables and wires are used and correctly installed.
● Note that it is only permitted to connect and disconnect the cables to the power supply
module if the module has been powered down.
● The degree of protection is reduced when the enclosure is mounted vertically.
Procedure
1. To open the enclosure, unlock using a double-bit key (included with the enclosure). Hold
the cover firmly while unlocking to make sure that it does not spring up as a result of the
pressure of the dampers.
2. Mount the wall support (included in the enclosure accessories) to the rear panel of the
enclosure in accordance with Fig. 4-1. Secure the enclosure using 8 mm diameter screws
and lock washers at the location of use.
Mounting
5.2 Mounting the enclosure
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