Stahl 8150/1 Series User manual

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Operating Instructions
Additional Languages Www.stahl-ex.com
En
Terminal Box
Series 8150/1,
Series 8150/2
– Save For Future Use! –

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Terminal Box
Series 8150/1, Series 8150/2
Contents
1 General Information ............................................................................................3
1.1 Manufacturer .......................................................................................................3
1.2 About these operating instructions ......................................................................3
1.3 Further documents ..............................................................................................3
1.4 Conformity with standards and regulations .........................................................3
2 Explanation of the symbols .................................................................................4
2.1 Symbols in these operating instructions .............................................................4
2.2 Symbols on the device ........................................................................................4
3 Safety ..................................................................................................................4
3.1 Intended Use .......................................................................................................4
3.2 Personnel qualification ........................................................................................4
3.3 Residual risks ......................................................................................................5
4 Transport and storage .........................................................................................7
5 Product selection, project engineering and modification .....................................7
5.1 Additional through holes in flange plates ............................................................8
5.2 Additional through holes in the enclosure ...........................................................9
5.3 External attached components (cable entries, stopping plugs, breathers) .......11
5.4 Internal built-in components (conductors, terminals, fuses) ..............................12
6 Mounting and installation ..................................................................................15
6.1 Mounting/dismounting, operating position ........................................................15
6.2 Installation .........................................................................................................16
7 Commissioning .................................................................................................19
8 Maintenance, overhaul, repair ..........................................................................19
8.1 Maintenance .....................................................................................................19
8.2 Maintenance .....................................................................................................19
8.3 Repair ...............................................................................................................19
9 Returning the device .........................................................................................20
10 Cleaning ............................................................................................................20
11 Disposal ............................................................................................................20
12 Accessories and Spare parts ...........................................................................20
13 Annex A ............................................................................................................21
13.1 Technical data ...................................................................................................21
14 Annex B ............................................................................................................23
14.1 Dimensions / fastening dimensions ..................................................................23

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General Information
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Terminal Box
Series 8150/1, Series 8150/2
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]
1.2 About these operating instructions
Read these operating instructions, especially the safety notes, carefully before use.
Observe all other applicable documents (see also "Further documents" section).
Keep the operating instructions throughout the service life of the device.
Make the operating instructions accessible to operating and maintenance personnel
at all times.
Pass the operating instructions on to each subsequent owner or user of the device.
Update the operating instructions every time you receive an amendment to them
from R. STAHL.
ID-No.: 202161 / 815060300020
Publication Code: 2016-12-13·BA00·III·en·05
The original instructions are the German edition.
They are legally binding in all legal affairs.
1.3 Further documents
• Data sheet
• EU Type Examination Certificate
For documents in additional languages, see www.stahl-ex.com.
1.4 Conformity with standards and regulations
• Certificates and EU Declaration of Conformity: www.stahl-ex.com.
• The device has IECEx approval. See IECEx homepage: http://iecex.iec.ch/

Explanation of the symbols
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Terminal Box
Series 8150/1, Series 8150/2
2 Explanation of the symbols
2.1 Symbols in these operating instructions
2.2 Symbols on the device
3 Safety
The device has been manufactured to the state of the art while observing recognised
safety-related rules. When using the device, it is nevertheless possible for hazards to occur
to life and limb of the user or third parties or for the device, environment or material assets
to be compromised.
Use the device only
- if it is not damaged
- as intended, while remaining aware of safety and dangers
- in accordance with these operating instructions.
3.1 Intended Use
The terminal box 8150 is used to distribute electric energy and / or electric signals in
hazardous areas. It is explosion-protected equipment approved for use in hazardous areas
of Zones 1 and 2 as well as 21 and 22.
The terminal box is manufactured in various sizes and can be combined to create larger
distribution units.
Intended use includes observing these operating instructions and the other applicable
documents, e.g. the data sheet.
All other use of the terminal box is not intended.
3.2 Personnel qualification
Qualified specialist personnel are required to perform the tasks described in these operating
instructions. This primarily applies to work in the following areas:
• Product selection, project engi-
Symbol Meaning
Tip for making work easier
DANGER! Dangerous situation which can result in fatal or severe injuries
causing permanent damage if the safety measures are not
complied with.
WARNING! Dangerous situation which can result in severe injuries
if the safety measures are not complied with.
CAUTION! Dangerous situation which can result in minor injuries
if the safety measures are not complied with.
NOTICE! Dangerous situation which can result in material damage
if the safety measures are not complied with.
Symbol Meaning
16338E00
Notified body in accordance with ATEX directive for monitoring
the manufacturer's quality control system.
02198E00
According to marking, device certified for hazardous areas.

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Safety
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Terminal Box
Series 8150/1, Series 8150/2
neering and modification
• Mounting/dismounting the device
• Installation
• Commissioning
• Maintenance, repair, cleaning
Specialists who perform these tasks must have a level of knowledge that complies with
the relevant national standards and regulations.
Additional knowledge is required for activities in hazardous areas! R. Stahl recommends
a level of knowledge described in the following standards:
•IEC/EN 60079-14 (Electrical installations design, selection and erection)
•IEC/EN 60079-17 (Inspection and maintenance of electrical installations)
•IEC/EN 60079-19 (Equipment repair, overhaul and reclamation)
3.3 Residual risks
3.3.1 Explosion hazard
An explosion hazard cannot be entirely ruled out in hazardous areas despite the device
having a state-of-the-art design.
Perform all work steps in hazardous areas with the utmost care at all times!
Possible moments of danger (residual risks) can be categorised according to the following
causes:
Mechanical damage
The device can be pressed or scratched during transport, mounting or commissioning,
causing it to no longer be leak-tight. Such damage can, for example, render the device's
explosion protection partially or fully ineffective. This can result in explosions causing fatal
or severe injuries to persons.
Observe the weight and the maximum load-bearing capacity of the device;
see specifications on the packaging.
Transport the device only in the original packaging or in equivalent packaging.
Use transporting or lifting equipment which is suitable for the size and weight of the device
and can reliably carry the weight of the device.
Check the packaging and the device for damage. Report any damage to R. STAHL
immediately.
Store the device in the original packaging in a dry (no condensation) and stable position
which is safe from vibrations.
Do not damage the enclosure, built-in components or seals during mounting.
Excessive heat-up or electrostatic charge

Safety
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Terminal Box
Series 8150/1, Series 8150/2
Subsequently modifying the device, operating it outside of permitted conditions or cleaning it
improperly can cause it to heat up severely or to become electrostatically charged, resulting
in it producing sparks. This can result in explosions causing fatal or severe injuries
to persons.
Operate the device only within the prescribed operating conditions (see the type plate
and the "Technical data" chapter).
Devices which have a polyester powder coating must not be installed in areas containing
severely charge-producing processes.
Do not paint the device. Consult with R. STAHL before mending flaws such as scratches.
Comply with the area specification of EN IEC 60079-0 when fitting additional plastic
adhesive plates.
Clean the device only with a damp cloth.
Impairment of IP protection
When installed properly and completely, the device will have the required IP degree of
protection. Making structural changes to the device or mounting it improperly can impair
its IP protection. This can result in explosions causing fatal or severe injuries to persons.
Fit plates (on the outside) only without drilling any additional holes.
Only drill holes for cable glands exactly according to the instructions in the "Product
selection, project engineering and modification" and "Mounting" chapters of these
operating instructions. Consult with R: STAHL first if there are any discrepancies or
uncertainties.
Mount the device only in the prescribed mounting position. More detailed explanations
of this can be found in the "Mounting" chapter.
Improper installation, commissioning, maintenance or cleaning
Basic work such as installation, commissioning, maintenance or cleaning of the device must
be performed only in accordance with the valid national regulations of the country of use and
only by qualified persons. Otherwise the explosion protection can be rendered ineffective.
This can result in explosions causing fatal or severe injuries to persons.
Have mounting, installation, commissioning and maintenance performed only by qualified
and authorised persons (see section 3.2.).
Perform modifications to the device only in accordance with these operating instructions.
Have the modifications inspected and approved by R. STAHL or an inspection authority
(3rd party inspection).
Perform maintenance and repairs on the device only using original spare parts and after
consultation with R. STAHL.
Gently clean the device only with a damp cloth and without scratching, abrasive or
aggressive cleaning agents or solutions.
Never clean the device with a strong water jet, e.g. using a high-pressure washer!

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Transport and storage
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Terminal Box
Series 8150/1, Series 8150/2
3.3.2 Risk of injury
Falling devices or components
The heavy device or components can fall during transport and mounting, causing severe
injury to persons in the form of bruises and contusions.
Use transporting and lifting equipment suitable for the size and weight of the device
when transporting and mounting it.
Observe the weight and the maximum load-bearing capacity of the device;
see specifications on the packaging.
Use suitable mounting hardware for mounting.
Electric shock
During electric installation, operation and maintenance, there will at times be high voltages
present at the device. Persons coming into contact with electric lines carrying excessively
high voltage can suffer severe electric shocks and consequently injuries.
Operate the device only on equipment with the internal voltage specified in the "Technical
data" chapter.
Connect electric circuits only to suitable terminals.
4 Transport and storage
Transport and store the device carefully and in accordance with the safety notes
(see chapter 3).
5 Product selection, project engineering and modification
DANGER! Explosion due to damaged seal in devices with enclosure hinges!
Non-compliance results in fatal or severe injuries.
Devices with enclosure hinges must be transported only with a transport lock.
DANGER! Explosion due to subsequent, complete painting of the device!
Non-compliance results in fatal or severe injuries.
Do not paint the device.
Consult with R. STAHL before mending flaws such as scratches.
DANGER! Explosion due to defective sealing of the device!
Non-compliance results in fatal or severe injuries.
Fit plates (on the outside) only without drilling any additional holes.
Only drill additional holes exactly in accordance with the instructions in the
"Mounting" chapter. Consult with R. STAHL first if there are any discrepancies
or uncertainties.
Equip the enclosure only with equipment (e.g. cable entries, stopping plugs,
drain and breather valves) that is verifiably approved for use in hazardous areas.
Examples: EU Type Examination Certificate or IECEx Certificate of Conformity
Seal unused cable entries with certified plugs (red).
Seal all open drilled holes by means of suitable equipment.

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Terminal Box
Series 8150/1, Series 8150/2
When complying with the installation conditions and specifications on the type plate:
Check whether enough cable entries are provided. Drill additional holes if necessary;
see sections 5.1 to 5.2.
Equip terminals and, if necessary, mount built-in components; see section 5.4.
The methods mainly considered for modification are subsequently machining or equipping
the terminal box. In this case, the following possibilities are available:
• Additional through holes on the flange plate, either by R. STAHL or by the customer
(section 5.1)
• Additional through holes in the enclosure, either by R. STAHL or by the customer
(section 5.2)
• External attached components either by R. STAHL or by the customer (section 5.3)
• Internal built-in components either by R. STAHL or by the customer (section 5.4)
5.1 Additional through holes in flange plates
5.1.1 Creation of additional drilled holes and through holes by R. STAHL
Forward the following information to R. STAHL:
-Type
- Data sheet
- Quantity, manufacturers and approvals of the components that are to be installed.
R. STAHL
• will check whether the components, drilled hole diameters, quantity and position
correspond with the approval
• will create the drilled holes and through holes
• will mount the components
• will update the order documentation
• will carry out a routine test
• will, if necessary, fit a new type plate if the technical data has changed,
e.g. due to the components that are to be additionally installed.
Work that has been carried out single-handedly must be inspected and approved in
accordance with national regulations. Otherwise it must be inspected and approved
by R. STAHL or an inspection authority (3rd party inspection) (section 3.3.1). R. STAHL
can do this on request and for appropriate remuneration. No additional inspection and
approval is required if the work is carried out by R. STAHL.

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Terminal Box
Series 8150/1, Series 8150/2
5.1.2 Ascertaining the usable area for cable entries in flange plates
18104E00
Collision frame and earth connection of flange plate
Select a space/area for the cable entry on the flange plate anywhere inside the collision
frame (see thin line in figure). Ensure that screw connections made later do not go beyond
this collision frame.
Observe the following conditions when doing so:
Leave enough distance to the circumferential seal (min. 2 mm) (see detail in figure).
Leave enough distance to the earth connection (min. 10 mm) (see bottom of figure).
5.1.3 Creation of additional drilled holes and through holes by the customer
Modify the device carefully and only in accordance with the safety notes (see chapter 3).
Calculate the usable area, see section 5.1.2.
Create additional through holes by lasing or punching (drilling, hole cutting).
Ensure that the surfaces remain flat during punching and cutting.
Determine the core hole diameter for threads. Do not use an NPT thread!
When determining the through holes, observe the mounting distances.
Adjust the hole diameters to the dimensions of the built-in parts or their seals.
The use of built-in components with flat seal (gasket) is preferred.
Observe section 5.3 "Built-in components" when subsequently equipping components!
5.2 Additional through holes in the enclosure
5.2.1 Creation of additional drilled holes and through holes by R. STAHL
Give the following information to R. STAHL:
-Enclosure side
-Type
- Data sheet
- Quantity, manufacturers and approvals of the components that are to be installed.
Terminal boxes which the customer wants delivered without drilled holes are generally
marked as empty enclosures (marking in accordance with EN IEC 60079-7 and
EN IEC 60079-0, as incomplete equipment "U" inside the enclosure).
2 [0,08]
10 [0,39]
2 [0,08]

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Terminal Box
Series 8150/1, Series 8150/2
R. STAHL
• will check whether the components, drilled hole diameters, quantity and position
correspond with the approval
• will create the drilled holes and through holes
• will mount the components
• will update the order documentation
• will carry out a routine test
• will, if necessary, fit a new type plate if the technical data has changed,
e.g. due to the components that are to be additionally installed.
5.2.2 Calculate the usable area for cable entries in the enclosure
The calculation is performed in three steps:
Calculate the total usable area
Calculate the required area for cable entries
Calculate the remaining usable area.
1.) Calculate the total usable area
The total usable area for installation is calculated as follows:
(Length of the inner enclosure wall - 2 x 10 mm*) x (Height of the inner enclosure wall - 2 x 10 mm*)
*2 x 10 mm = circumferential rim of the inner enclosure wall
2.) Calculate the required area for cable entries
Multiply the quantity of desired cable entries by the space requirement values of the
appropriate type from the following table.
Important: The area for the cable entries must be smaller than the total usable area.
Otherwise a larger enclosure must be chosen.
Important for the following calculation:
Measure the dimensions on the plane surface inside of the enclosure
(not on the outside of the enclosure)
Consider additional space required for blind rivet nuts. The space requirement for
the built-in part is determined using the width across corners of the cable entry plus
additional space for the tool.
Cable entry thread diameter
( 12 mm ( 16 mm ( 20 mm ( 25 mm ( 32 mm ( 40 mm ( 50 mm ( 63 mm
Required
space for
each
piece
315 mm2495 mm2685 mm2990 mm21560 mm22420 mm23425 mm25160 mm2

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Terminal Box
Series 8150/1, Series 8150/2
3.) Calculate the remaining usable area
Subtract the required area for cable entries from the total usable area.
5.2.3 Creation of additional drilled holes and through holes by the customer
Modify the device carefully and only in accordance with the safety notes (see chapter 3).
Calculate the usable area for built-in components, see sections 5.1.2 and 5.2.2.
Create additional through holes by lasing or punching (drilling, hole cutting). When doing
so, maintain a distance of min. 10 mm to the rim of the enclosure
(see figure).
18105E00
Ensure that the surfaces remain flat during punching and cutting.
When determining the through holes, observe the mounting distances.
Adjust the hole diameters to the dimensions of the built-in parts or their seals.
The use of built-in components with flat seal (gasket) is preferred.
Observe section 6.3 "Cable entries, stopping plugs, breathers" when subsequently
equipping components!
5.3 External attached components (cable entries, stopping plugs, breathers)
Calculation example:
Starting conditions:
• Dimensions of inner enclosure wall: 297 mm (Side D) x 122 mm (Side C)
• Desired cable entries: M20 (15 pc), M32 (7 pc)
Calculate the total usable area:
(297 mm - 2 x 10 mm*) x (122 mm - 2 x 10 mm*)
= 28254 mm2
Calculate the required area for cable entries and remaining usable area:
Quantity Type Area
15 pieces M20 15 x 685 mm210275 mm2
7 pieces M32 7 x 1560 mm210920 mm2
21195 mm2required area for cable entries
28254 mm2usable area
7059 mm2remaining usable area
Drilled holes and through holes are generally already equipped with the components
intended for the application ex-factory.
If customers intend to carry out equipping themselves, a dust and transport protection
is applied to the openings in the enclosure (adhesive tape with a warning note or plastic
caps) ex-factory.
10 [0,39]

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Terminal Box
Series 8150/1, Series 8150/2
5.3.1 Fitting of attached components by R. STAHL
Give the following information to R. STAHL:
-Type
- Data sheet
- Quantity, manufacturers and approvals of the components that are to be attached.
R. STAHL
• will check whether the components, quantity and position correspond with the approval
• will mount the components
• will update the order documentation
• will carry out a routine test
• will, if necessary, fit a new type plate if the technical data has changed,
e.g. due to the components that are to be additionally attached.
5.3.2 Fitting of attached components by the customer
Select material
It is advisable to use the following materials when equipping the terminal box:
Cable entry
• for electric lines which are permanently installed: Plastic or metal cable entries for electric
lines which are permanently installed
• for electric lines which are not permanently installed: Plastic or metal cable entries with
strain relief.
Closing of unused entries
• Plastic or metal stopping plugs.
Drainage and pressure equalisation (prevention of the vacuum effect)
• Plastic or metal drain and breather valves.
Equip the device carefully and in accordance with the safety notes (see chapter 3).
Observe the specifications on the type plate of the device for the selection and operating
temperature of the components and seals.
Calculate the usable area for attached components; see sections 5.1.2 and 5.2.2.
Adjust the hole diameters of drilled holes to the dimensions of the built-in parts or
their seals!
The use of attached components with flat seal (gasket) is preferred.
5.4 Internal built-in components (conductors, terminals, fuses)
Ascertain the maximum number of conductors
Heat develops in every terminal box due to contact resistances at the terminals and
the cables installed in the enclosure. In order to ensure that the maximum temperatures
of a terminal box are not exceeded, care should be taken that the current load of
the circuits installed in the terminal box does not exceed certain values!

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Terminal Box
Series 8150/1, Series 8150/2
5.4.1 Ascertain the number of conductors using the table from the EU Type Examination Certificate
Refer to the specifications in the EU Type Examination Certificate for the maximum
permitted number of conductors – in relation to the current load and conductor
cross-section.
Taking enclosure 8150/1-0250-0180-120 as an example: The maximum permitted number
of conductors can be ascertained using the following table.
12543E00
*) Current, **) conductor cross-section
Explanations of the table:
Each inserted conductor and each internal connection conductor must be selected.
Jumpers and protective conductors are not considered as conductors.
Noncritical (light area of the table)
The light area is noncritical in terms of heating up the enclosure. Circuits classified as being
in this area can be incorporated in the enclosure in any number.
Critical (inscribed area of the table)
The inscribed area of the table shows the maximum permissible number of conductors
considering the cross-section of the conductor and the continuous current loading.
When using this table, simultaneous factors and load factors may be accounted for.
Mixed arrangements with circuits of different cross-sections and currents are possible;
in this case the proportion of the loading from the individual circuits should be allowed for.
If a terminal box is fully loaded according to the critical area of the inscribed part of the table,
then any number of circuits from the noncritical, light area may be added.
8150/1-0250-0180-120
[A]*
[mm²]**
1,5
20
16
10
6
25
35
50
63
80
100
125
160
200
225
250
315
400
500
63
21
42
163
9
24
47
11
26 51
720 50
316 41
519 68
721 76
920
820
718
56 15 48
2919
411 24
2714
3928
5
2,5 4610 16 25 3535 50 70 95 120 150 185 240 300

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Terminal Box
Series 8150/1, Series 8150/2
Dangerous (dark area of the table)
Terminal boxes which are designed according to this area require an additional
temperature-rise test.
Example calculation (general):
Ensure that operating temperatures – in particular low ones – of the terminal box and
the selected electric lines match.
5.4.2 Additional terminals
Fitting of additional terminals by R. STAHL
Forward the following information to R. STAHL:
-Type
- Manufacturer
- Data sheet
- Quantity
-Enclosure size
R. STAHL
• will check whether the terminal type, quantity, cross-section and current load correspond
with the approval
• will check whether the enclosure size, drilled holes and through holes are sufficient
• will install the terminals
• will, if necessary, create required drilled holes and fit required cable entries
• will update the order documentation
• will carry out a routine test
• will, if necessary, fit a new type plate if the technical data, such as current or conductor
cross-section, has changed.
Fitting of additional terminals by the customer
Modify the device carefully and only in accordance with the safety notes (see chapter 3).
Ascertain additional terminal points, terminal type, quantity, cross-section and current
load.
Check whether type plate data is changed as a result of subsequently equipping
(cross-section, voltage, current, etc.).
Check whether enough space and fastening options are available for equipping.
Cross-section [mm2]Current [A] No. of conductors Proportion
2.5 16 10 (of 30) = 33 %
16 50 12 (of 48) = 25 %
25 63 36 (of 90) = 40 %
= 98 % < 100 %
Subsequently equipping is not permitted if the installation conditions are not complied
with!

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5.4.3 Fuses
When fitting fuses, the ambient temperature values for the following temperature classes
apply:
When fitting fuses, the ambient temperature values for areas with dust explosion hazard
for the following max. permissible surface temperatures apply:
6 Mounting and installation
6.1 Mounting/dismounting, operating position
Mount the device carefully and only in accordance with the safety notes (see chapter 3).
Read through the following installation conditions and assembly instructions carefully and
follow them precisely.
6.1.1 Operating position
Mount the device using the mounting straps. Refer to the dimensional drawing for
the dimensions of the mounting holes.
14282E00
Installing, modifying or retrofitting fuses is only permitted to be performed by R. STAHL!
Fuse current value Temperature class
( 4 A T6
> 4 A ... ( 5 A T5
> 5 A ... ( 6.3 A T4
Fuse current value Ambient temperature
(Ta)
Max. permissible
surface temperature
( 4 A ( 40 °C T80°C
( 4 A ( 56 °C T95°C
( 5 A ( 46 °C T95°C
( 6.3 A ( 70 °C T130°C
DANGER! Explosion due to incorrect mounting position!
Non-compliance results in fatal or severe injuries.
Mount the device only on the floor or wall, not overhead or in a free-standing
position.
Mount the device torsion-free only on a level surface.
25
7 [0,28]
18 [0,71]
26 [1,02]
20
Xø [ø 0,28]7
[0,98]
[0,79]

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6.1.2 Environmental installation conditions
Provide a protective roof or wall if the explosion-protected device is exposed to weather.
Equip explosion-protected electric equipment with a breather and drain valve in order
to prevent the vacuum effect. Observe the correct mounting orientation (bottom) when
doing so. See also section 6.1.1
Do not create any cold bridges (risk of condensation). If necessary, mount the enclosure
with a clearance to reduce condensation in the enclosure to a minimum.
6.2 Installation
16523E00
• Alignment of enclosure depending
on mounting type:
• For vertical mounting:
any alignment
• For horizontal mounting:
cover on top
• Hanging position/overhanging
cover is not permitted!
Operation under difficult conditions, such as on ships or in strong sunlight, requires
additional measures to be taken for correct installation, depending on the place of use.
Further information and instructions on this can be obtained from your regional sales
contact on request.
DANGER! Explosion due to severe heat-up inside the enclosure!
Non-compliance results in fatal or severe injuries.
Ensure that distances between Ex e electric circuits and Ex i electric circuits comply
with standards (EN IEC 60079-11).
Select suitable conductors that do not exceed the permitted heating temperature
within the enclosure.
Pay attention to the specified cross-sections.
Attach the core end sleeves properly.
DANGER! Explosion due to improper installation!
Non-compliance results in fatal or severe injuries.
Install the device carefully and only in accordance with the safety notes (chapter 3).
The installation steps stated below must be carried out very precisely.
The necessary technical details/data on electric installation can be found in the following
documents:
"Technical data" chapter in these operating instructions
Documentation and data sheets provided by the terminal manufacturers
Documentation and data sheets of the installed devices (e.g. for specifications
on equipotential bonding, earthing and intrinsically-safe circuits)
≦ 90°

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Terminal Box
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6.2.1 Conductor Connection
Select suitable conductors that do not exceed the permitted heating temperature within
the enclosure.
Ensure that conductors have the specified cross-sections.
Guide the conductor insulation so that it reaches the terminals.
Do not damage the conductor when stripping the insulation (e.g. by denting it).
Attach the core end sleeves properly.
If the system is equipped with all possible terminals and live conductors, and the maximum
current load has been reached, ensure that the length of a conductor from the screw
connection to the terminal point does not exceed the diagonal planes of the enclosure.
6.2.2 Protective Conductor Connection
Always connect the protective conductor.
Use cable lugs for external protective conductor connection.
Permanently install the protective conductor close to the enclosure.
Connect all uncoated, non-energised metal parts to the protective conductor system.
Neutral conductors have to be installed as live conductors.
6.2.3 Installation Conditions
Installation conditions for creepage distances and clearances
18591E00
I = Minimum distance from the
enclosure in accordance with
EN IEC 60079-7 standard (table)
y = Clearance
X = Factor in accordance with
EN IEC 60079-7 depending on
conductor cross-section
18590E00
X * I = Minimum distance
18592E00
18593E00
m = 50 mm distance between Ex e and
Ex i terminal blocks
c = 8 mm distance between Ex e and
Ex i cable lines
II
II
X I
*
y
I
I
m
c

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Distances, creepage distances and clearances
When installing components the creepage distances and clearances between
the individual components as well as between the components and the enclosure wall
must be sufficiently dimensioned. Observe the values from the EN IEC 66079-7 standard
(table) when doing so.
Check the creepage distances of the components and comply with them in accordance
with the specifications in the respective operating instructions.
The clearance distances, depending on the rated operational voltage of the fitted
terminals, must be complied with.
Observe the distance between the enclosure cover and connection screws of the built-in
components (with the conductor connected): at least the value of the required clearances.
Distance between the connecting units for intrinsically safe and non-intrinsically safe circuits
Mount partitions used to separate connection terminals at least 1.5 mm from the enclosure
walls, or alternatively ensure a minimum distance of 50 mm between the uncoated
conducting parts of the connection terminals (when measured in any direction around
the partition)
Make sure that metallic partitions
• are at least 0.45 mm thick
• are earthed
• are sufficiently strong and rigid
• have sufficient current carrying capacity.
Make sure that non-metallic, insulating partitions
• are at least 0.9 mm thick
• have an appropriate comparative tracking index (CTI)
• are reinforced to prevent deformation.
When using fuses > 4 A, implement additional design measures to prevent impermissible
heat-up at the terminals of the intrinsically safe circuits.
Covers for combinations of non-intrinsically safe and intrinsically safe circuits
Equip all live parts which are not acc. to "Ex i" protection with an inner cover which meets
at least the degree of protection IP30 when the equipment is open.
Intrinsically safe circuits
In intrinsically safe circuits, use only insulated cables and conductors with a test voltage
of at least 500 V AC and a minimum quality of H05.
Calculate the insulation test voltage for the insulation and separation of terminals and
conductors from the sum of the rated operational voltages of intrinsically safe and
non-intrinsically safe circuits.
• In case of "intrinsically safe to earth", there is a minimum rated insulation voltage value
of 500 V (otherwise, double the value of the rated operational voltage of intrinsically safe
circuits).
• In the case of "intrinsically safe to non-intrinsically safe", there is a minimum rated
insulation voltage value of 1500 V (otherwise, double the rated operational voltage plus
1000 V).

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Clearance and creepage distances of intrinsically safe components
Make sure that the creepage distances and clearances between the uncoated, conductive
parts of connection terminals of separated, intrinsically safe circuits to earthed or
potential-free, conductive parts is equal or greater than the values of EN IEC 60079-11,
Table 5.
For separated, intrinsically safe electric circuits, set up a safe distance between
the uncoated, conductive parts of external connections, which meets the following
requirements:
• minimum 6 mm between the separated, intrinsically safe circuits
• minimum 3 mm to earthed parts if possible connection to earth has not been considered
in the safety analysis.
7 Commissioning
Before commissioning, carry out the following checks:
Check the enclosure for damage.
Check that mounting and installation have been performed correctly. When doing so,
check whether all covers and partitions for live parts have been installed and fastened.
Make sure that all openings/drilled holes in the enclosure are sealed with permissible
components. Dust and transport protection (adhesive tape or plastic caps) fitted at
the factory must be replaced with certified components.
Make sure that seals and sealing systems are clean and undamaged.
If necessary, remove foreign bodies.
If necessary, clean the connection chamber.
Check whether all prescribed tightening torques have been observed.
8 Maintenance, overhaul, repair
Observe the relevant national regulations in the country of use, e.g. EN IEC 60079-14,
EN IEC 60079-17, EN IEC 60079-19.
8.1 Maintenance
Check the following points in addition to the national regulations:
• whether the clamping screws holding the cables are securely seated,
• whether the device enclosure and / or protective enclosure have cracks or other visible
signs of damage,
• compliance with the permitted temperatures,
• whether the nut is securely seated.
8.2 Maintenance
Perform maintenance on the device according to the applicable national regulations
and the safety notes in these operating instructions (chapter 3).
8.3 Repair
Perform repairs to the device only using original spare parts and after consulting with
R. STAHL.

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9 Returning the device
Only return or package the devices after consulting R. STAHL!
Contact the responsible representative at R. STAHL for this.
R. STAHL's customer service is available to handle returns if repair or service is required.
Contact customer service personally.
or
Go to the www.stahl.com website.
Select "Downloads" > Customer service > "RMA Request".
Fill out the form.
Wait for confirmation. R. STAHL's customer service will contact you.
You will receive an RMA slip after speaking with customer service.
Send the device along with the RMA slip in the packaging to R. STAHL Schaltgeräte
GmbH (refer to Section 1.1 for the address).
10 Cleaning
Check the device for damage before and after cleaning it. Take damaged devices out
of operation immediately.
To avoid electrostatic charging, the devices located in hazardous areas may only
be cleaned using a damp cloth.
When cleaning with a damp cloth, use water or mild, non-abrasive, non-scratching
cleaning agents.
Do not use aggressive detergents or solvents.
Never clean the device with a strong water jet, e.g. using a high-pressure washer!
11 Disposal
Observe national and local regulations and statutory regulations regarding disposal.
Separate materials when sending them for recycling.
Ensure environmentally friendly disposal of all components according to the statutory
regulations.
12 Accessories and Spare parts
Only return or package the devices after contacting and consulting R. STAHL!
NOTICE! Malfunction or damage to the device due to the use of non-original components.
Non-compliance can result in material damage.
Use only original accessories and spare parts from R. STAHL Schaltgeräte GmbH
(see data sheet).