Stahl 6521/4 Series User manual

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Operating instructions
Additional languages r-stahl.com
EN
Floodlight
Series 6521/4

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Floodlight
Series 6521/4
Contents
1 General Information ............................................................................................3
1.1 Manufacturer .......................................................................................................3
1.2 Information regarding the 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 Warning Notes ....................................................................................................4
2.3 Symbols on the Device .......................................................................................5
3 Safety Notes .......................................................................................................5
3.1 Operating Instructions Storage ...........................................................................5
3.2 Safe Use .............................................................................................................5
3.3 Intended Use .......................................................................................................6
3.4 Modifications and Alterations ..............................................................................6
4 Function and Device Design ...............................................................................6
4.1 Function ..............................................................................................................6
4.2 Device Design .....................................................................................................7
5 Technical Data ....................................................................................................8
6 Transport and Storage ......................................................................................12
7 Mounting and Installation ..................................................................................13
7.1 Dimensions / Fastening Dimensions .................................................................13
7.2 Mounting / Dismounting, Operating Position .....................................................16
7.3 Installation .........................................................................................................16
8 Commissioning .................................................................................................20
9 Operation ..........................................................................................................21
9.1 Troubleshooting ................................................................................................21
10 Maintenance, Overhaul, Repair ........................................................................21
10.1 Maintenance .....................................................................................................22
10.2 Repair ...............................................................................................................24
10.3 Returning the Device ........................................................................................24
11 Cleaning ............................................................................................................25
12 Disposal ............................................................................................................25
13 Accessories and Spare Parts ............................................................................25

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General Information
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Floodlight
Series 6521/4
1 General Information
1.1 Manufacturer
1.2 Information regarding the Operating Instructions
ID-No.: 250341 / 6521615300
Publication Code: 2021-02-22·BA00·III·en·01
The original instructions are the English edition.
They are legally binding in all legal affairs.
1.3 Further Documents
• Data sheet
For documents in additional languages, see r-stahl.com.
1.4 Conformity with Standards and Regulations
See certificates and EU Declaration of Conformity: r-stahl.com.
The device has IECEx approval. For certificate please refer to the IECEx homepage:
http://iecex.iec.ch/
Further national certificates can be downloaded via the following link:
https://r-stahl.com/en/global/support/downloads/.
R. STAHL Schaltgeräte GmbH
Am Bahnhof 30
74638 Waldenburg
Germany
R. STAHL (P) LTD., Plot No. - 5
Malrosapuram Road, Sengundram Indl. Area
Singaperumal Koil, Kancheepuram Dist.,
Tamil Nadu – 603 204, INDIA
Phone:
Fax:
Internet:
E-mail:
[phone]
[phone]
r-stahl.com
[email protected]
Phone:
Fax:
Internet:
E-mail:
[phone]
[phone]
r-stahl.com/en/in
[email protected]

Explanation of the Symbols
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Floodlight
Series 6521/4
2 Explanation of the Symbols
2.1 Symbols in these Operating Instructions
2.2 Warning Notes
Warnings must be observed under all circumstances, in order to minimize the risk due to
construction and operation. The warning notes have the following structure:
• Signalling word: DANGER, WARNING, CAUTION, NOTICE
• Type and source of danger/damage
• Consequences of danger
• Taking countermeasures to avoid the danger or damage
Symbol Meaning
Tips and recommendations on the use of the device
Danger due to explosive atmosphere
Danger due to live components
DANGER
Danger to persons
Non-compliance with the instruction results in severe or fatal injuries to
persons.
WARNING
Danger to persons
Non-compliance with the instruction can result in severe or fatal injuries to
persons.
CAUTION
Danger to persons
Non-compliance with the instruction can result in light injuries to persons.
NOTICE
Avoiding material damage
Non-compliance with the instruction can result in material damage to the device and / or
its environment.

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Safety Notes
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Floodlight
Series 6521/4
2.3 Symbols on the Device
3 Safety Notes
3.1 Operating Instructions Storage
• Read the operating instructions carefully.
• Store the operating instructions at the mounting location of the device.
• Observe applicable documents and operating instructions of the devices to be
connected.
3.2 Safe Use
Before mounting
• Read and observe the safety notes in these operating instructions!
• Ensure that the contents of these operating instructions are fully understood by the
personnel in charge.
• Use the device in accordance with its intended and approved purpose only.
• Always consult R. STAHL Schaltgeräte GmbH if using the device under operating
conditions which are not covered by the technical data.
• We cannot be held liable for damage to the device caused by incorrect or unauthorised
use or non-compliance with these operating instructions.
For assembly and installation
• Observe national assembly and installation regulations (e.g. IEC/EN 60079-14).
• Observe national safety and accident prevention regulations.
• During installation and operation, observe the information (characteristic values and
rated operating conditions) on the type plates and data plates and information signs
located on the device.
• Before installation, make sure that the device is not damaged.
Maintenance, repair, commissioning
• Before commissioning, make sure that the device is not damaged.
• Work on the device, such as installation, maintenance, overhaul, repair, may only be
carried out by appropriately authorised and trained personnel.
• Perform only maintenance work or repair described in these operating instructions.
Symbol Meaning
05594E00
CE marking according to the currently applicable directive.
02198E00
According to marking, device approved for hazardous areas.

Function and Device Design
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Floodlight
Series 6521/4
3.3 Intended Use
The luminaire is equipment
• for lighting areas, work spaces and objects
• can be used indoors and outdoors
• for stationary mounting
• for use in Zones 21, 2, 22 and in the safe area
3.4 Modifications and Alterations
4 Function and Device Design
4.1 Function
Application range
The floodlight 6521/4 is equipment used for lighting areas, work equipment and objects.
It can be used indoors and outdoors.
DANGER
Explosion hazard due to modifications and alterations to the device!
Non-compliance results in severe or fatal injuries.
• Do not modify or alter the device.
No liability or warranty for damage resulting from modifications and
alterations.
DANGER
Explosion hazard due to improper use!
Non-compliance results in severe or fatal injuries.
• Use the device only in accordance with the operating conditions
described in these operating instructions.
• Use the device only for the intended purpose specified in these
operating instructions.

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Function and Device Design
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Floodlight
Series 6521/4
4.2 Device Design
17215E00
1 Luminaire enclosure 4 Mounting bracket
2 Cable gland 5 Lamp holder
3 Opening for restricted
breathing test
6 Connection terminal

Technical Data
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Floodlight
Series 6521/4
5 Technical Data
Explosion Protection
Global (IECEx)
Gas and dust IECEx TUR 10.0014
Ex nR IIC T1) Gc
Ex tb IIIC T1) IP66 Db
Europe (ATEX)
Gas TÜV 11 ATEX 7008
E II 3G Ex nR IIC T1) Gc
Dust TÜV 10 ATEX 7875
E II 2D Ex tb IIIC T1) °C IP66 Db
1)
Certifications and certificates
Certificates IECEx, ATEX, India (PESO)
Temperature class
at Ta =
To max.
at Ta =
Type Lamp Power 40 °C 50 °C 40 °C 50 °C
6521/41 QT ( 150 W T3 T3 156 °C 166 °C
QT ( 250 W T2 T2 202 °C 212 °C
HIT / HST ( 70 W T4 T3 121 °C 131 °C
HIT ( 150 W T3 – 165 °C –
6521/42 QT ( 500 W T3 T3 180 °C 190 °C
HST ( 150 W T4 T3 130 °C 140 °C
HIT / HST ( 250 W T3 T3 156 °C 166 °C
6521/43 QT ( 500 W T3 T3 147 °C 157 °C
QT ( 1000 W T2 T2 230 °C 240 °C
HIT / HST ( 250 W T4 T3 125 °C 135 °C
HIT / HST ( 400 W T3 T3 160 °C 170 °C
HST ( 600 W T3 T2 190 °C 200 °C
QT = Haloge lamps
HIT = Metal halide lamps
HST = High-pressure sodium lamps

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Technical Data
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Floodlight
Series 6521/4
Technical Data
Electrical data
Rated operational
voltage
220 to 240 V AC / DC ±6%; 0, 50, 60 Hz
230 V AC ±6%; 50 Hz
240 V AC ±6%; 50 Hz
Power Type
Rated operating current Inrush current Power factor
500 W QT 2.17 A 2.17 A 1
1000 W QT 4.35 A 4.35 A 1
compensated uncompensated
Power Type
Rated operating current Inrush current Power factor Rated operating current Inrush current Power factor
70 W HST / HIT 0.38 A 0.50 A 0.96 1.00 A 1.30 A 0.37
150 W HST / HIT 0.79 A 1.50 A 0.95 1.80 A 2.70 A 0.40
250 W HST / HIT 1.30 A 2.00 A 0.92 3.00 A 4.20 A 0.40
400 W HST / HIT 2.10 A 2.50 A 0.91 4.45 A 6.00 A 0.43
600 W HST 2.95 A 3.80 A 0.92 6.20 A 8.50 A 0.44
compensated uncompensated
Power Type
Rated operating current Inrush current Power factor Rated operating current Inrush current Power factor
70 W HST / HIT 0.36 A 0.50 A 0.97 1.00 A 1.30 A 0.37
150 W HST / HIT 0.76 A 1.50 A 0.96 1.80 A 2.70 A 0.40
250 W HST / HIT 1.23 A 2.00 A 0.94 3.00 A 4.20 A 0.40
400 W HST / HIT 2.00 A 2.50 A 0.92 4.45 A 6.00 A 0.43
600 W HST 2.80 A 3.80 A 0.93 6.20 A 8.50 A 0.44

Technical Data
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Floodlight
Series 6521/4
208 V AC ±6%; 60 Hz
220 V AC ±6%; 60 Hz
240 V AC ±6%; 60 Hz
Technical Data
compensated uncompensated
Power Type
Rated operating current Inrush current Power factor Rated operating current Inrush current Power factor
70 W HST / HIT 0.39 A 0.50 A 0.92 1.00 A 1.30 A 0.37
150 W HST / HIT 0.80 A 1.50 A 0.94 1.80 A 2.70 A 0.42
400 W HIT 1.90 A 2.50 A 0.97 4.20 A 5.80 A 0.44
400 W HST 2.30 A 2.80 A 0.96 4.45 A 6.00 A 0.44
compensated uncompensated
Power Type
Rated operating current Inrush current Power factor Rated operating current Inrush current Power factor
70 W HST / HIT 0.36 A 0.50 A 0.95 1.00 A 1.30 A 0.37
150 W HST / HIT 0.75 A 1.50 A 0.96 1.80 A 2.70 A 0.42
250 W HST / HIT 1.50 A 2.00 A 0.90 3.00 A 4.20 A 0.40
400 W HIT 1.80 A 2.40 A 0.98 4.20 A 5.80 A 0.44
400 W HST 2.20 A 2.70 A 0.98 4.45 A 6.00 A 0.44
600 W HST 2.95 A 3.80 A 0.96 6.20 A 8.50 A 0.46
compensated uncompensated
Power Type
Rated operating current Inrush current Power factor Rated operating current Inrush current Power factor
70 W HST / HIT 0.33 A 0.50 A 0.97 1.00 A 1.30 A 0.37
150 W HST / HIT 0.68 A 1.50 A 0.97 1.80 A 2.70 A 0.42
250 W HST / HIT 1.35 A 2.00 A 0.91 3.00 A 4.20 A 0.40
400 W HIT 1.60 A 2.30 A 0.97 4.20 A 5.80 A 0.44
400 W HST 2.00 A 2.60 A 0.98 4.45 A 6.00 A 0.44

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Technical Data
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Floodlight
Series 6521/4
Inrush current maximum number of light fittings per miniature circuit breaker:
Protection class I (with internal and external PE connection)
Ambient conditions
Ambient temperature -40 to +40 °C / +50 °C (observe the temperature class)
-50 to +40 °C / +50 °C (QT lamps, observe the temperature class)
Technical Data
compensated
Type QT QT HIT / HST HST
500 W 1000 W 70 W 150 W 250 W 400 W 600 W
B10A 4285321
B16A 73138532
B20A 941610642
B25A 11 5 20 12 8 5 3
C10A 42127532
C16A 731811742
C20A 941314953
C25A 115 2917117 4
uncompensated
Type HIT / HST HST
70 W 150 W 250 W 400 W 600 W
B10A 5211--
B16A 84211
B20A 95322
B25A 126422
C10A 74211
C16A 116321
C20A 147432
C25A 179542

Transport and Storage
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Floodlight
Series 6521/4
For further technical data, see r-stahl.com.
6 Transport and Storage
• Transport and store the device only in the original packaging.
• Store the device in a dry place (no condensation) and vibration-free.
• Do not drop the device.
Mechanical data
Degree of protection IP66 to EN 60598
Impact strength
(IK code)
IK10 (IEC 62262)
Material
Enclosure
Window Safety glass; resistant to thermal shocks
Seal Silicone
Reflector Aluminium, anodised
Luminaire locking Pan head screw, M6, stainless steel
Hinged enclosure cover
Mounting / Installation
Operating position Horizontal lamp axis
Cable entry
Standard 1 x M20 x 1.5 cable gland, clamping area Ø 4 to 13 mm
1 x M20 x 1.5 stopping plug
1 x M20 x 1.5 cable gland (with blind plugs – as test holes)
Special specific costumer order possible
Connection 3-pole (L1, N, PE)
Spring clamp terminals
Standard: 0.5 to 4 mm2 (solid and finely stranded)
Optional: 0.5 to 6 mm2 (solid and finely stranded)
(2 free clamping units per pole available)
Mounting U-shaped holding bracket made of stainless steel, continuously swivelable
around the rotary axis of the flood lights.
Technical Data
6521/4...-...-...-1-...-.. Sheet steel powder coated RAL 7032 (pebble-grey)
6521/4...-...-...-3-...-.. Stainless steel 1.4301 (V2A)
6521/4...-...-...-4-...-.. Stainless steel 1.4404 (V4A)

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Floodlight
Series 6521/4
7 Mounting and Installation
7.1 Dimensions / Fastening Dimensions
DANGER
Explosion hazard due to incorrect installation of the device!
Non-compliance results in severe or fatal injuries.
• Carry out installation strictly according to the instructions and national
safety and accident prevention regulations to maintain the explosion
protection.
• Select and install the electrical device so that explosion protection is not
affected due to external influences, i.e. pressure conditions, chemical,
mechanical, thermal and electric impact such as vibration, humidity and
corrosion (see IEC/EN 60079-14).
• The device must only be installed by trained qualified personnel who is
familiar with the relevant standards.
Dimensional drawings (all dimensions in mm [inches]) – Subject to modification
22455E00 22456E00
Size 1 – Pole mounting Size 2 – Pole mounting
22457E00
Size 3 – Pole mounting
ØØ50 / 60
[ 1,97 / 2,36]
ØØ
340 [13,39] 180 [7,09]
140,50
[5,53]
375 [14,76]
ØØ50 / 60
[ 1,97 / 2,36]
ØØ
471 [18,54] 215 [8,46]
189,50
[7,46]
509 [20,04]
587 [23,11]
ØØ 50 / 60
[ 1,97 / 2,36]
ØØ
559 [22,01]
237 [9,33]
215 [8,46]

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Floodlight
Series 6521/4
22464E00
Mounting plate for pole mounting Ø 50
22461E00
Clamp for pole mounting Ø 50
Dimensional drawings (all dimensions in mm [inches]) – Subject to modification
3 x 9 Ø
[3 x 0,35] Ø
150 [5,91]
200 [7,87]
250 [9,84]
360 [14,17]
450 [17,72]
100 [3,94]
162 [6,38]
4 x 9 Ø
[4 x 0,35] Ø
7 x 13 Ø
[7 x 0,51] Ø
3 x 9 Ø
[3 x 0,35] Ø
85,50 [3,37]
[1,57]
40
35 [1,38]
R 25,50 [R 1,00]
R 35 [R 1,38]
500 [19,69]
[0,12]
3
[0,14]
3,50
100 [3,94]
112 [4,41]
41,50
[1,63]
35
[1,38]
R 25,50
[R 1,00]
112 [4,41]
[0,87]
22
[0,14]
3,50
50,50
[1,99]
[0,12]
3
40 [1,57]
85,50 [3,37]
2 x 9 Ø
[2 x 0,35] Ø

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Floodlight
Series 6521/4
22465E00
Mounting plate for pole mounting Ø 60
22462E00
Clamp for pole mounting Ø 60
Dimensional drawings (all dimensions in mm [inches]) – Subject to modification
3 x 9 Ø
[3 x 0,35] Ø
150 [5,91]
200 [7,87]
250 [9,84]
360 [14,17]
450 [17,72]
100 [3,94]
162 [6,38]
4 x 9 Ø
[4 x 0,35] Ø
7 x 13 Ø
[7 x 0,51] Ø
3 x 9 Ø
[3 x 0,35] Ø
95,50 [3,76]
[1,57]
40
35 [1,38]
R 30,30 [R 1,19]
R 35 [R 1,38]
500 [19,69]
[0,12]
3
[0,14]
3,50
100 [3,94]
112 [4,41]
46,80
[1,84]
35
[1,38]
R 30,30
[R 1,19]
122 [4,80]
[1,06]
26,80
[0,14]
3,50
[0,12]
3
60,20
[2,37]
40 [1,57]
95,50 [3,76]
2 x 9Ø
[2 x 0,35]Ø

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Floodlight
Series 6521/4
7.2 Mounting / Dismounting, Operating Position
The mounting position of the floodlight is optional. The luminaire axis must be horizontal.
7.3 Installation
7.3.1 Opening and Closing of the Enclosure
DANGER
Explosion hazard due to inadmissible heating!
Non-compliance results in severe or fatal injuries.
• Avoid external heat sources and/or direct sunlight (risk of change of
temperature class or change of maximum permissible surface
temperature).
• Do not exceed the maximum ambient temperature due to external heat
sources (premature failure of equipment).
DANGER
Risk of electric shock due to improper opening!
Non-compliance results in severe or fatal injuries.
• Open luminaires without switch only in de-energized state
(see information plate on the lock)!
17216E00
Opening:
• Loosen the M6 (allen key 5) cover
screws.
• Open the cover.
Closing:
• Close the cover.
• Firmly tighten the cover screws
(tightening torque 2.5 Nm).

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Floodlight
Series 6521/4
7.3.2 Electrical Connections
Electrical connection
Observe the maximum clamping possibility of the connection terminals
(see chapter "Technical data").
Observe the following when connecting to the electrical connection:
• Clamping must be carried out precisely.
• Do not clamp any part of the conductor insulation.
• Do not mix up the conductors.
• Observe the technical regulations when connecting the conductor.
• Clamp the conductor firmly.
Connection terminals
Clamping range:
Standard: 0.5 to 4 mm2
Optional: 0.5 to 6 mm2
Stripping length:
Standard: 10 to 11 mm
Optional: 13 to 15 mm
Standard:
21968E00
N
L1
L1
N
3-pole
L1 = phase
N = neutral conductor
PE = protective
conductor

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Floodlight
Series 6521/4
Loop in/loop out wiring of the mains connection
Loop in/loop out wiring with max. 12 A possible
21967E00
• Insert the cable.
17217E00
• Connect the conductor to the spring
clamp terminal.
• Check that the cable is clamped
properly.
• The unit must be connected to a good quality earth.
• The internal Earth connection is the primary point.
The external connection is for a supplementary bonding connection
and is used where local code or authorities permit or require such
connection.

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Floodlight
Series 6521/4
7.3.3 Cable Entries
The standard luminaire is delivered with 3 lead-in holes, 1 cable glands and
1 stopping plug.
Tightening torques for components from R. STAHL Schaltgeräte GmbH
Luminaires with installed cable entries and stopping plugs from
R. STAHL Schaltgeräte GmbH must be tightened using the following values:
Luminaires with cable entries and stopping plugs which are not supplied by
R. STAHL Schaltgeräte GmbH
Please observe the following:
• the required dust resistance!
• the required type of protection!
• the required temperature resistance!
• the IP degree of protection according to the rating plate!
• the operating instructions of the cable entries and stopping plugs!
• the required tightening torques!
• the range of the permissible cable diameter!
• Insert the metal cable entries and/or stopping plugs into the PE!
Tightening torque
Connection thread Pressure screw
Cable entry
8161
M20 x 1.5 2.3 Nm 1.5 Nm
M25 x 1.5 3.0 Nm 2.0 Nm
Stopping plugs
8290
M20 x 1.5 1.0 Nm –
M25 x 1.5 1.5 Nm –
DANGER
Explosion hazard due to impermissible cable entries and stopping plugs!
Non-compliance results in severe or fatal injuries.
• Only use separately certified cable glands and stopping plugs which
have been tested and certified according to Directive 2014/34/EU
(ATEX) or IECEx (CoC) and which comply with the standard version
stated in the certificate of the luminaire.
Cable glands and stopping plugs must be approved for the following types of
protection:
a) restricted breathing (nR) and dust (IIIC)
b) increased safety (e)

Commissioning
20 250341 / 6521615300
2021-02-22·BA00·III·en·01
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Floodlight
Series 6521/4
8 Commissioning
Before commissioning, ensure the following:
• Check the mounting and installation.
• Inspect enclosure for damage.
• If necessary, remove foreign bodies.
• If necessary, clean the connection chamber.
• Check if the conductors have been inserted correctly.
• Check if all screws and nuts have been tightened firmly.
• Check if all drilled holes are closed.
• Check whether all the cable entries and stopping plugs have been tightened firmly.
• Check if all conductors have been clamped firmly.
• Check if the line voltage and the rated operational voltage are consistent.
• Check if the permissible conductor diameter for the corresponding cable entries have
been used.
• Check if the device is closed according to regulations.
DANGER
Explosion hazard due to incorrect installation!
Non-compliance results in severe or fatal injuries.
• Check the device for proper installation before commissioning.
• Comply with national regulations.
DANGER
Explosion hazard due to incorrect installation!
Non-compliance results in severe or fatal injuries.
• Carry out the restricted breathing test prior to first commissioning.
(See chapter "Restricted breathing test")
NOTICE
Malfunction or device damage caused by condensation.
Non-compliance can result in material damage!
• operate the luminaire continuously or periodically over extended periods of time.
• avoid thermal bridges.