Stahl SolConeX8581/31 User manual

Operating instructions
SolConeX 
Switch Socket, 
125 A
> 8581/31

General Information
2SolConeX Switch Socket, 125 A
8581/31
Contents
1 General Information ...............................................................................................2
1.1 Manufacturer .........................................................................................................2
1.2 Information regarding the operating instructions ...................................................3
1.3 Conformity with standards and regulations ...........................................................3
2 Symbols Used .......................................................................................................3
3 General Safety Notes ............................................................................................3
3.1 Storage of these Operating Instructions ................................................................3
3.2 Modifications and alterations .................................................................................4
3.3 Special Versions ....................................................................................................4
4 Intended Use .........................................................................................................4
5 Technical data .......................................................................................................5
5.1 Arrangement of Contact Sleeves and Terminal Marking .......................................8
6 Transport and storage ...........................................................................................9
7 Installation .............................................................................................................9
7.1 Dimensions / fastening dimensions .......................................................................9
7.2 Installation Conditions ...........................................................................................9
7.3 Opening / Closing the Enclosure .........................................................................11
7.4 Mounting and Operating Position ........................................................................11
7.5 Electrical Connection ...........................................................................................11
7.6 Connection ..........................................................................................................12
8 Auxiliary Contacts ................................................................................................12
8.1 Mounting Auxiliary Contacts ................................................................................13
8.2 Dismounting Auxiliary Contacts ...........................................................................13
8.3 Auxiliary Contacts for Ex i Circuits ......................................................................14
8.4 Mounting the Ex i Cover for the Auxiliary Contacts .............................................14
9 Commissioning ....................................................................................................14
9.1 Padlocking with a Padlock ...................................................................................15
10 Maintenance, Overhaul and Repair .....................................................................15
10.1 Short-circuit in the Main Circuit ...........................................................................15
11 Cleaning ..............................................................................................................15
12 Disposal ...............................................................................................................15
13 Accessories and Spare parts .............................................................................16
1 General Information
1.1 Manufacturer
R. STAHL Schaltgeräte GmbH
Am Bahnhof 30
74638 Waldenburg
Germany
Phone: [phone]
Fax: [phone]
Internet: www.stahl-ex.com
E-Mail:[email protected]

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Symbols Used
3
SolConeX Switch Socket, 125 A 8581/
31
1.2 Information regarding the operating instructions
ID-No.: 205582 / 8581615300
Publication Code: 2014-10-10·BA00·III·en·03
1.3 Conformity with standards and regulations
Conformity with 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 in the download area on the internet page
www.stahl-ex.com.
2 Symbols Used
3 General Safety Notes
3.1 Storage of these Operating Instructions
Read carefully these operating instructions and store them near the installation place. 
For correct operation, please observe all other operating instructions enclosed in this 
delivery and the operating instructions of the equipment to be connected.
Safety Instructions
Non-observance may cause damage to the equipment, serious injuries
or even death.
The safety instructions in this operating instructions and on the device must
be observed!
Warning Symbol
Danger due to explosive atmosphere!
Warning Symbol
Danger due to live parts!
WARNING
Use the devices only for their intended purpose!
We cannot be held liable for damage caused by an incorrect or unauthorized
use or by non-observance of these operating instructions.
Use the device only if it is undamaged and clean.
WARNING
Any unauthorized work on the device is prohibited!
Installation, maintenance, overhaul and repair may only be carried out 
by appropriately authorized and trained personnel.

Intended Use
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SolConeX Switch Socket, 125 A
8581/31
Observe the following information during installation and operation:
Any damage can invalidate the explosion protection
National and local safety regulations
National and local accident prevention regulations
National and local assembly and installation regulations (e.g. IEC/EN 60079-14)
Generally recognized technical regulations
Safety instructions in these operating instructions
Characteristic values and rated operating conditions on the rating and data plates
Additional instruction plates fixed directly to the device
3.2 Modifications and alterations
3.3 Special Versions
For special versions, the actual components included in delivery may differ from the de-
scription given here in the following cases:
Xadditional/different order options
Xmodifications to the versions described here due to the latest technical developments
4 Intended Use
The switch sockets 8581/31 are explosion-protected equipment approved for use in haz-
ardous areas of Zones 1, 2 and 21, 22. They connect portable and fixed electrical equip-
ment as well as cables and circuits in hazardous areas.
WARNING
Alterations and modifications to the device are not permitted.
We shall not accept any liability or warranty obligations for damage resulting
from unauthorized alterations and modifications.

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Technical data
5
SolConeX Switch Socket, 125 A 8581/
31
5 Technical data
Version 8581/31
Explosion protection
Gas and dust Ex d e IIC T6 (Ta = -30 ...+40 °C)
Ex d e IIC T5 (Ta = -30 ...+45 °C)
Versions with auxiliary contacts for Ex i circuits:
Ex d e [ib] IIC T6 (Ta = -30 ...+40 °C)
Ex d e [ib] IIC T5 (Ta = -30 ...+45 °C)
Ex tD A21 IP66 T65 °C (Ta = -30 ... +40 °C)
Ex tD A21 IP66 T75 °C (Ta = -30 ... +45 °C)
Versions with auxiliary contacts for Ex i circuits:
Ex tD A21 [ib] IP66 T65 °C (Ta = -30 ... +40 °C)
Ex tD A21 [ib] IP66 T75 °C (Ta = -30 ... +45 °C)
Europe (ATEX)
Gas and dust E II 2 G Ex d e IIC T6 (Ta = - 30 ...+ 40 °C)
E II 2 G Ex d e IIC T5 (Ta = - 30 ...+ 45 °C)
Versions with auxiliary contacts for Ex i circuits:
E II 2 G Ex d e [ib] IIC T6 (Ta = - 30 ...+ 40 °C)
E II 2 G Ex d e [ib] IIC T5 (Ta = - 30 ...+ 45 °C)
E II 2 D Ex tD A21 IP66 T65°C (Ta = - 30 ... + 40 °C)
E II 2 D Ex tD A21 IP66 T75°C (Ta = - 30 ... + 45 °C)
Versions with auxiliary contacts for Ex i circuits:
E II 2 D Ex tD A21 [ib] IP66 T65 °C (Ta = - 30 ... + 40 °C)
E II 2 D Ex tD A21 [ib] IP66 T75 °C (Ta = - 30 ... + 45 °C)
Certificates
IECEx IECEx PTB 06.0034
Europe (ATEX) PTB 01 ATEX 1161
Ambient temperature see explosion protection data -45 C° on request (internal lubrication using silicone grease)
Assignment of temperature class / ambient temperature / rated operational voltage / rated
connection cross-section
Valid for the following versions: 208705_V02; 208738_V02; 212169_V02
Interlocked switch 3 pole switch with isolating characteristics
1 auxiliary contact (ON - delayed, OFF - advanced)
Switching handle padlockable in position 0 and I
Rated operational voltage max. 690 V
Rated operational current max. 125 A
Rated insulation voltage max. 690 V
Temperature class Rated operational
current
Rated connection cross-section
T6 T5 Socket Plug
(+ 45 °C 125 A 70 mm250 mm2
(+ 40 °C (+ 55 °C 110 A
(+ 45 °C (+ 60 °C 100 A
(+ 40 °C 125 A 50 to 70 mm235 mm2
Use only heat-resistant
cables )85 °C, e.g.,
Type NSSHÖU!
(+ 45 °C 115 A
(+ 40 °C (+ 55 °C 100 A 50 to 70 mm235 mm2

Technical data
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SolConeX Switch Socket, 125 A
8581/31
Switching capacity acc. to IEC/EN 60947-3:
1) 1 contact
2) 2 contacts connected in series
3) 3 contacts connected in series
Short-circuit protection
Without thermal protection max. 125 A gG acc. to IEC/EN 60269-2
With thermal protection max. 160 A gG acc. to IEC/EN 60269-2
Connection cross-section
Single conductor
connection 35 ... 150 mm2 (AWG 2/0 ... 300 kcmil) stranded
50 ... 150 mm2 (AWG 1/0 ... 300 kcmil) finely stranded
Multiple conductor
connection 2 x 35 mm2 ... 2 x 50 mm2 (2 x AWG 2 ... 2 x AWG 1/0)
Only conductors of the same cross-section are permissible!
Connect PE terminal using cable lugs and assembly kit only (see "Accessories and Spare Parts"
Assembly kit Cable lugs, art. no. 211465)
Service life
electrical 20,000 operating cycles
Mechanical 100,000 operating cycles
Tightening torque
Main contacts 25 ... 30 Nm
Cover screws 4.5 Nm
Cable gland 1 x M63 x 1.5
(lateral positioning acc. to order possible)
Clamping range 31 ... 48 mm
Stopping plug 1 x M25 x 1.5, 1 x M63 x 1.5
Enclosure material polyester, glass fibre reinforced
Degree of protection IP66 acc. to IEC/EN 60529
Auxiliary contacts
Standard version 8080/1-1: 1 NC contact + 1 NO contact in left installation slot
NO contact ON delayed
NO contact OFF leading (> 20 ms before opening of the main contacts)
NC contacts synchronizing
Possible auxiliary contacts max. 2 auxiliary contact blocks of type 8080/1 (slow-action contacts)
8080/1-1: 1 NC contact / 1 NO contact
NO contact ON delayed 1)
NO contact OFF advanced (> 20 ms before opening of the main contacts) 1)
NC contact synchronising
8080/1-3: 2 NC contacts 2)
8080/1-4: 2 NO contacts 2)
1) only in the left installation slot, synchronising in the right installation slot
2) synchronising in all installation slots
Rated operational voltage 250 V AC / DC
400 V AC, for equal potential of both contacts
500 V AC, when 1 NC + 1 NO and the same potential of both contacts is used
Rated operational current max. 6 A
Short-circuit protection 10 A, tripping characteristic gG acc. to IEC/EN 60269-1
Connection cross-section 1.5 ... 2.5 mm2 (AWG 16 ... 14) solid / finely stranded
Tightening torque 0.4 Nm
AC-3 DC-23 DC-1
690 V, 125 A 220 V, 125 A3) 220 V, 125 A3)
120 V, 125 A2) 120 V, 125 A2)
60 V, 125 A1) 60 V, 125 A1)

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Transport and storage
7
SolConeX Switch Socket, 125 A 8581/
31
5.1 Arrangement of Contact Sleeves and Terminal Marking
Arrangement of contact sleeves and terminal marking:
The example shows the 6 o'clock position
Colour code and arrangement of the earth contact sleeve, relative to the polarizing slot, for different voltages and frequen-
cies according to IEC/EN 60309-2
1) Mainly for ship installations
2) Only for refrigerated containers (according to ISO standards)
3) Not standardized but recommended preferred position
4) Colour code in accordance with voltage colour code
6 Transport and storage
Transport and storage are only permitted in the original packaging.
The devices must be stored in a dry place and vibration-free.
06556E00 06555E00
3 P + PE
8581/31-4..
3P + N + PE
8581/31-5..
No. of poles Frequency Rated operational voltage Colour code Earth contact sleeve
position
3 P + PE
8581/31-4..
50 and 60 Hz 100 ... 130 V yellow 4 h
200 ... 250 V blue 9 h
380 ... 415 V red 6 h
60 Hz 440 ... 460 V 1) red 11 h
50 and 60 Hz 480 ... 500 V black 7 h
600 ... 690 V black 5 h
after isolating transformer 4) 12 h
50 Hz
60 Hz
380 V
440 V 2) red 3 h
100 ... 300 Hz > 50 V green 10 h 3)
> 300 ... 500 Hz > 50 V green 2 h
3P + N + PE
8581/31-5..
50 and 60 Hz 57 / 100 ... 75 / 130 V yellow 4 h
120 / 208 ... 144 / 250 V blue 9 h
200 / 346 ... 240 / 415 V red 6 h
277 / 480 ... 288 / 500 V black 7 h
347 / 600 ... 400 / 690 V black 5 h
60 Hz 250 / 440 ... 265 / 460 V 1) red 11 h
50 Hz 220 / 380 V 2) red 3 h
60 Hz 250 / 440 V 2)
100 ... 300 Hz > 50 V green 10 h 3)
> 300 ... 500 Hz > 50 V green 2 h
Any no. of poles All nominal operating voltages and/or frequencies not covered by other arrange-
ments.
1 h

Installation
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SolConeX Switch Socket, 125 A
8581/31
7 Installation
7.1 Dimensions / fastening dimensions
7.2 Installation Conditions
Dimensional drawings (all dimensions in mm) - subject to alterations
10339E00 10340E00
8581/31-...
CES 125 A switch socket
8581/12-...
SolConeX 125 A plug
WARNING
Risk of electric shock!
Before opening the device, disconnect it from the power supply.
WARNING
Use approved components only!
For unused enclosure holes, use R. STAHL stopping plugs, for unused cable
entries, use R. STAHL plugs.
Make sure that these components have appropriate approval and meet the re-
quirements of IEC/EN.
NOTICE
When open, the switch cogwheel may not be switched, since the switching
function is not guaranteed with a wrong cogwheel position.
8581/12-4...
125 A 
3 P + ¿
8581/12-5...
125 A 
3 P + N + ¿
A 310.5 310.5
B 96.0 96.0
C 82.0 82.0
D 125 125

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Installation
9
SolConeX Switch Socket, 125 A 8581/
31
7.3 Opening / Closing the Enclosure
To open the enclosure
Loosen the cover screws.
Open the cover including the rotary handle.
To close the enclosure
Close the cover including the rotary handle.
Tighten the cover screws to the specified torque (4.5 Nm).
7.4 Mounting and Operating Position
When mounting, make sure that
the hinged cover is at the bottom, the connection chamber is on top
the device is fixed in a vertical installation position to a plane wall using three screws
(d6 ... 8 mm) and suitable washers
all screws and nuts have been firmly tightened.
7.5 Electrical Connection
The information given in chapter "Technical Data" must be observed.
The conductor connection must be made with particular care.
The conductor insulation must reach up to the clamping points.
Do not damage the conductor (nicking) when removing the insulation.
Select suitable cables to be used and appropriate way of installing them to ensure that
the maximum permitted conductor temperatures and the maximum permitted surface
temperature are not exceeded.
NOTICE
When explosion protected equipment is exposed to the weather, it is advis-
able to provide a protective cover or wall.
The elongated holes allow vertical and horizontal adjustment during mount-
ing.
NOTICE
A protective conductor is always required.

Auxiliary Contacts
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SolConeX Switch Socket, 125 A
8581/31
7.6 Connection
Open the connecting chamber cover.
Strip the insulation from the cable ends.
Push the cable through the cable gland into the connection chamber.
Clamp stripped cable ends under the corresponding clamping point.
While clamping, ensure that the stripped cable ends are fully underneath the clamping
plate.
Make sure that the clamping points are strain-relieved.
Tighten the union nut of the cable gland, place the connection chamber cover carefully
on top and tighten it.
8 Auxiliary Contacts
Standard versions are delivered with an auxiliary contact (8080/1-1: 1 NC contact and 1
NO contact) in the left installation slot.
A maximum of 2 Type 8080/1 auxiliary contacts can be used.
The switching function of the auxiliary contact depends on the installation slot used, see
chapter "Technical Data".
Auxiliary contacts in Ex i circuits
If the auxiliary contacts of Type 8080/1 are used in Ex i circuits, they must be provided
with a cover (art. no. 168855).
WARNING
Ensure correct conductor connection!
Observe the maximum connection cross-sections, please refer to chapter
"Technical Data".
In case of multiple conductor connection, connect PE terminal using cable
lugs and assembly kit only (art. no. 211465)
In case of multiple conductor connection, only connectors of the same type
and the same cross-section and material may be used.
NOTICE
Metal cable glands are included in the earthing measures.
09290T00
a [mm] b [mm] max. [mm2]
Main contacts 380 20 50
Auxiliary contacts 380 10 2.5

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Auxiliary Contacts
11
SolConeX Switch Socket, 125 A 8581/
31
8.1 Mounting Auxiliary Contacts
12435E00
Carefully remove the cover (1) of the installation slot (3) using a screwdriver or a knife.
Carefully insert the auxilary contact (2) into the installation slot until it engages.
Paste the enclosed circuit diagram indicating the respective switching function to the
rating plate of the switch.
8.2 Dismounting Auxiliary Contacts
Introduce the auxiliary contact key (art. no. 201909) with the Stahl logo pointing 
upwards (!) between the auxiliary contact and the switch cover.
Pull out the auxiliary contact along with the auxiliary contact key.
NOTICE
Before mounting an auxiliary contact, the cover (1) must be removed. 
The degree of protection IP20 (finger-safe) remains intact even after 
removing the cover.
15021E00
13
2
CLICK

Commissioning
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SolConeX Switch Socket, 125 A
8581/31
8.3 Auxiliary Contacts for Ex i Circuits
8.4 Mounting the Ex i Cover for the Auxiliary Contacts
12436E00
Attach the cover (4) from the top to the auxiliary contact until the lug engages.
9 Commissioning
The switch socket may only be used fully closed with the connection chamber cover in
place!
The switch socket can only be switched on with inserted plug.
Only Type 8581/12 plugs from R. STAHL may be used.
Make sure that the bayonet lock of the socket is closed when the plug is pulled out.
Before commissioning, ensure that
no components are damaged
the device has been installed according to regulations
there are no foreign bodies inside the device
all screws and nuts have been firmly tightened,
the prescribed tightening torques have been observed
connection has been made correctly.
WARNING
Observe the specified clearance and creepage distances!
For use in Ex i circuits, the auxiliary contacts (Type 8080/1) must be provided
with a cover (art. no. 168855).
The customer is only allowed to install an intrinsically safe auxiliary contact
if no alligator clips are mounted on the two terminals located on the left and
right side of the respective installation slot!
NOTICE
The Ex i cover serves to ensure the required tight string length (50 mm) 
between the connection points of intrinsically safe and non-intrinsically 
safe circuits.
4

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Maintenance, Overhaul and Repair
13
SolConeX Switch Socket, 125 A 8581/
31
9.1 Padlocking with a Padlock
The switch can be padlocked in position 0 and I.
10 Maintenance, Overhaul and Repair
The following details must be checked during maintenance:
Cables are held securely in place
Compliance with the permitted temperatures (according to IEC/EN 60079)
Damage to the enclosure and seals
Check if screws and nuts are tight.
10.1 Short-circuit in the Main Circuit
11 Cleaning
The device may only be cleaned with a damp cloth.
12 Disposal
Observe the national waste disposal regulations.
NOTICE
Switching on and off has to be done swiftly and completely!
Avoid switching positions between 0 and I (ON and OFF)!
WARNING
Risk of electric shock!
Before opening the device, disconnect it from the power supply.
NOTICE
To avoid corrosion, the plug must be pulled regularly.
WARNING
After a short-circuit in the main circuit, the switch must be replaced!
Replace the switch after each short circuit in the main circuit, since with hermet-
ically sealed equipment the state of the switching contacts cannot be checked.

Accessories and Spare parts
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SolConeX Switch Socket, 125 A
8581/31
13 Accessories and Spare parts
WARNING
Use only original R. STAHL accessories and spare parts.
Designation Figure Description Art. no. Weight
kg
Switch insert 8549/1-31L Load and motor switch 168776 4.720
Plastic cable gland
02055E00
239157 0.020
8161/7-M63-4828 239161 0.120
Stopping plug
04840E00
143524 0.007
8290/3-M63 x 1,5 143548 0.030
Auxiliary contact,
series 8080/1
12446E00
2 NC contacts (8080/1-3) 2) 168356 0.026
1 NC contact + 1 NO contact (8080/1-1) 1) 168351 0.026
2 NO contacts (8080/1-4) 2) 168353 0.026
The switching function of the auxiliary contact depends
on the installation slot used.
1) left: delayed (ON), advanced (OFF);
right: synchronising
2) left and right: synchronising
Ex i cover
12451E00
Ex i cover for auxiliary contacts for use in Ex i circuits 168855 0.008
Auxiliary contact key
14151E00
for removing the mounted auxiliary contact 201909 0.035
Assembly kit
Cable lugs
14502E00
for the connection of conductors with cable lugs 211465 0.327
8161/7-M25-1707 50 pieces
8290/3-M25 x 1,5 1 pieces