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