Stahl 6525 Series User manual

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Operating instructions
Additional languages www.stahl-ex.com
EN
Floodlight LED
Series 6525

General Information
2Floodlight LED
Series 6525
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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 Explanation of the symbols .................................................................................3
2.1 Symbols in these operating instructions .............................................................3
2.2 Warning notes .....................................................................................................3
2.3 Symbols on the device ........................................................................................4
3 Safety notes ........................................................................................................4
3.1 Operating instructions storage ............................................................................4
3.2 Safe use ..............................................................................................................5
3.3 Intended Use .......................................................................................................5
3.4 Modifications and alterations ..............................................................................5
4 Function and device design ................................................................................5
4.1 Function ..............................................................................................................5
4.2 Device design .....................................................................................................6
5 Technical data .....................................................................................................7
6 Transport and storage .......................................................................................10
7 Mounting and installation ..................................................................................10
7.1 Dimensions / fastening dimensions ..................................................................10
7.2 Mounting / dismounting, operating position ......................................................12
7.3 Installation .........................................................................................................12
8 Commissioning .................................................................................................16
9 Maintenance and repair ....................................................................................17
9.1 Maintenance .....................................................................................................17
9.2 Repair ...............................................................................................................19
9.3 Returning the device .........................................................................................19
10 Disposal ............................................................................................................20
11 Accessories and Spare parts ...........................................................................20
1 General Information
1.1 Manufacturer
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]
www.stahl-ex.com
[email protected]
Phone:
Fax:
Internet:
E-mail:
[phone]
[phone]
www.rstahl.net
[email protected]

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Explanation of the symbols
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Floodlight LED
Series 6525
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1.2 Information regarding the operating instructions
ID-No.: 244627 / 652560300010
Publication Code: 2017-07-13·BA00·III·en·03
The original instructions are the English edition.
They are legally binding in all legal affairs.
1.3 Conformity with standards and regulations
See certificates and EU Declaration of Conformity: www.stahl-ex.com.
The device has IECEx approval. See IECEx homepage: http://iecex.iec.ch/
Further national certificates can be downloaded via the following link:
http://www.r-stahl.com/downloads/certificates.html.
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
General danger
Danger due to explosive atmosphere
Danger due to energised parts
Risk of damage to the eyes caused by optical radiation

Safety notes
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Floodlight LED
Series 6525
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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.
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.
Symbol Meaning
05594E00
CE marking according to the currently applicable directive.
02198E00
According to marking, device approved for hazardous areas.

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Function and device design
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Floodlight LED
Series 6525
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3.2 Safe use
• Read and observe the safety notes in these operating instructions!
• Observe characteristic values and rated operating conditions on the rating and data
plates!
• Observe additional information plates on the device!
• Use the device in accordance with its intended and approved purpose only!
• We cannot be held liable for damage caused by incorrect or unauthorized use or by
non-compliance with these operating instructions.
• Before installation and commissioning, make sure that the device is not damaged!
• Work on the device (installation, maintenance, overhaul, repair) may only be carried
out by appropriately authorized and trained personnel.
3.3 Intended Use
The LED floodlight 6525 is equipment
• for stationary mounting
• for use in Zones 21, 2, 22 and in the safe area
• can be used indoors and outdoors
• for lighting areas, work spaces and objects
3.4 Modifications and alterations
4 Function and device design
4.1 Function
• for lighting areas, work spaces and objects
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.
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.

Function and device design
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4.2 Device design
17562E00
1 - Mounting bracket 7 - Seal
2 - Enclosure cover 8 - Luminaire glass cover
3 - LED-Driver 1 9 - Mounting screws
4 - LEDs 10 - LED-Driver 2 (only for 210 W version)
5 - Luminaire enclosure 11 - Cable glands
6 - Heat sink (only for 210 W version) 12 - Connection terminal

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Technical data
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Floodlight LED
Series 6525
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5 Technical data
Explosion Protection
Global (IECEx)
Gas and dust IECEx EPS 15.0032
Ex nR op is IIC T6 ... T5 Gc
Ex tb IIIC T80°C ... T95°C Db
Europe (ATEX)
Gas and dust EPS 15 ATEX 1 991
E II 3 G Ex nR op is IIC T6 ... T5 Gc
E II 2D Ex tb IIIC T80°C ... T95°C Db
Certifications and certificates
Certificates IECEx, ATEX, India (PESO)
Technical Data
Electrical data
Electronic balast
Rated voltage 220 ... 240 V, 50/60 Hz
Voltage range 198 ... 264 V, 50/60 Hz
Current
consumption
Inrush current
Power factor > 0.95
at ambient temperature Temperature class
6525/11..-....-....-... -50 °C < Tamb < +55 °C T5 / T95 °C
6525/11..-21..-....-... -50 °C < Tamb < +50 °C T6 / T80 °C
6525/11..-42..-....-... -50 °C < Tamb < +45 °C T6 / T80 °C
6525/11..-2: 0.54 A
6525/11..-4: 0.94 A
6525/11..-21
(120 W Version)
6525/11..-42
(210 W Version)
Ipeak
(measured at 50 % Ipeak)
58 A; ãt = 360 ms116 A; ãt = 360 ms
max. light fittings per circuit breaker
Type B 10 A 4 2
Type B 16 A 9 4
Type B 25 A 20 10

Technical data
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Series 6525
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THD ≤ 10 %
Luminous characteristics
Values apply to Ta = +25 °C.
Decrease of luminous flux at Ta
19597E00
Ambient conditions
Operating
temperature range
-50 ... +55 °C*
* Note: Possible to operate the luminaire at -50°C, provided the luminaire is
switched on at -30°C.
Storage temperature -30 ... +75 °C
Technical Data
6525/11..-2 6525/11..-4
Power consumption [W] 120 210
Colour rendering [CRI] ) 70 ) 70
Colour temperature [K] 5,700 5,700
wide beam
Luminous flux [lm] 12,860 21,026
Luminaire efficiency [lm/W] 107 100
medium beam
Luminous flux [lm] 11,155 18,361
Luminaire efficiency [lm/W] 94 88
narrow beam
Luminous flux [lm] 12,081 19,979
Luminaire efficiency [lm/W] 101 96
100 %
85 %
70 %
55 %
40 %
25 % 30 °C 35 °C 40 °C 45 °C 50 °C 55 °C 60 °C
115 %
120 W Version
210 W Version

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Technical data
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Floodlight LED
Series 6525
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Alternative material:
Enclosure:
• stainless steel SS304 (1.4301 or V2A) single powder-coated
• stainless steel SS316L (1.4404 or V4A) without powder coating
Bracket:
• stainless steel SS304 (1.4301 or V2A) without powder-coated
Service life
Mechanical data
Degree of protection IP66
Protection class I (with internal PE connection)
Impact strength
(IK code)
IK10 (IEC 62262)
Material
Enclosure
Colour Colour white, similar to RAL 9010
Seal Foamed silicone in luminaire cover
Lamp cover Toughened glass
Bracket Sheet steel, single powder-coated
or
Stainless steel SS316L (1.4404 or V4A) without powder coating
Luminaire locking Screw
Mounting / Installation
Cable entry 1x cable glands Series 8161
1x cable glands Series 8161 with red stopping plug
1x stopping plugs Series 8290
Connection
Loop in/loop out max. 12 A
Technical Data
Ta ( 40 °C Ta at 45 °C Ta at 55 °C
L70B10C10 100,000 h 80,000 h 60,000 h
LxByCz
At the end of the service life:
- Luminous flux decreases by “x” percent.
- up to "y" percent of all luminaires fall below "x"
- up to "z" percent of all luminaires break down completely
6525/....-....-....-.11 Sheet steel, powder-coated
6525/....-....-....-.42 Stainless steel SS316L (1.4404 or V4A), with double
powder coating (offshore coating)
Standard: Spring clamp terminals 0.5 ... 4 mm2 solid / stranded
Stripping length: 10 ... 11 mm
Optional: Spring clamp terminals 0.5 ... 6 mm2 solid / stranded
Stripping length: 13 ... 15 mm

Transport and storage
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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.
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 Alterations
17559E00
17560E00
Floodlight Series 6525
with cooling element
(Version 210 W)
Floodlight Series 6525
without cooling element
(Version 120 W)
400 15,75[]
600 23,62[]
89,50 3,52[]
131,90 5,19[]
400 15,75[]
600 23,62[]
89,50 3,52[]

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Series 6525
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17561E00
Mounting bracket
18258E00 18257EE00
Floodlight Series 6525 with ring bolts
with cooling element
(Version 210 W)
Floodlight Series 6525 with ring bolts
without cooling element
(Version 120 W)
Dimensional Drawings (All Dimensions in mm [inches]) - Subject to Alterations
60 [2,36]
3 x 13Ø
[3 x 0,51]Ø
405 [15,94]
380 [14,96]
445 [17,52]
250[9,84]
20 [0,79]
3 [0,12]
R 20 [R 0,79]
363 [14,29]
363 [1,38]
8,50Ø
[Ø0,33]
13 x 8,50Ø
[13 x 0,33]Ø

Mounting and installation
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7.2 Mounting / dismounting, operating position
• suitable for use indoors and outdoors
• designed for wall, ceiling, pole mounting with bracket
• max torque value between bracket and floodlight 10 Nm
• pendant mounting using ring eyes (M6).
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).
CAUTION
Risk of damage to the eyes caused by optical radiation!
Minor injuries are possible!
• The minimum distance for the narrow beam version between the
luminaire and the viewer's eyes must be 8.23 m.
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)!
NOTICE
Danger due to electrostatic discharge.
Electronic components can be destroyed if touched.
• Do not touch the LED-PCBs!

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Opening the luminaire
• (1) loosen the four mounting screws.
• (2) carefully open the enclosure cover.
• (3) open the enclosure cover fully.
Closing the luminaire
• (4) liften the enclosure cover.
• (5) carefully close the enclosure cover.
• (6) securely tighten the four screws (torque value 5 Nm).
17990E00
17991E00
3
4
5
6

Mounting and installation
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7.3.2 Cable entries
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)
Please observe the following, if cable glands and stopping plugs are used, but not
provided by R. STAHL Schaltgeräte GmbH:
• Permissible cable diameter range, torques, temperature range of use
• IP level of protection, at least IP 65 or according to details on rating plate
• Operating instructions of the cable glands and stopping plugs
additionally, observe the following for cable glands and stopping plugs of the type of
protection "increased safety" (e):
• valid EC type examination certificate and
• confirmation of the manufacturer for the combination of the cable and screw
connection
WARNING
Not approved cable glands and stopping plugs.
Explosion protection is impaired!
• Only use separately certified cable glands and stopping plugs.
Recommendation:
Use of cable glands and stopping plugs supplied by
R. STAHL Schaltgeräte GmbH.
• see data sheet on our homepage www.stahl-ex.com.
DANGER
Explosion hazard if breathers are used!
Accidents or fatal injury are almost certain to happen!
• Do not use breathers.

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7.3.3 Electrical connections
Electrical connection
Observe the maximum clamping possibility of the connecting terminals (see chapter
"Technical data").
Note:
• Clamping must be carried out precisely!
• Do not clamp any part of the conductor insulation!
• Do not interchange the conductors!
• Observe the technical regulations when connecting the conductor!
• Clamp the conductor firmly.
Connection terminals
Standard:
Spring clamp terminals 0.5 to 4 mm2
(rigid and flexible)
Stripping length: 10 ... 11 mm
Optional:
Spring clamp terminals 0.5 to 6 mm2
(rigid and flexible)
Stripping length: 13 ... 15 mm
5-pole 5-pole
15516E00
16526E00
Legend
L1, L2, L3 = phase (3-pole: L1; 5-pole: L1, L2, L3)
N = neutral conductor
PE = protective conductor
N
L1
L2
L3
L3L2L1
N

Commissioning
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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 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.
• Check whether the bracket mounting & cover mounting screws are tightened with
proper torque.
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.

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Maintenance and repair
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9 Maintenance and repair
9.1 Maintenance
• Determine the type and extent of inspections in compliance with the relevant national
regulations.
• Adapt inspection intervals to the operating conditions.
The following tests and measures must be carried out during regular maintenance.
WARNING
Risk of electric shock or malfunctioning of the device due to unauthorized
work!
Non-compliance can result in severe injuries and material damage.
• Work performed on the device must only be carried out by appropriately
authorized and qualified electricians.
• To be carried out as per EN60079-17 and as per EN60079-19.
DANGER
Explosion hazard due to hot built-in components!
Accidents or fatal injury are almost certain to happen!
• Only open the enclosure in switched-off state.
• The device must be allowed to cool down for at least 15 minutes before
opening it.
NOTICE
Danger due to electrostatic discharge.
Electronic components can be destroyed if touched.
• Do not touch the LED-PCBs!
Observe the relevant national regulations in the country of use.
Check Measures
the permissible ambient temperature If exceeding the permissible ambient
temperature or falling below the device
must be taken out of operation.
the enclosure components for formation of
cracks and damage.
Replace the exchangeable enclosure
components. If the enclosure components
are non-exchangeable, the device must be
taken out of operation.
its intended use If the device is not used according to its
intended use, it must be taken out of
operation.
if the conductors are clamped properly clamp loose conductors tightly.
the cables for ageing and damage replace damaged or aged cables.

Maintenance and repair
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• Restricted breathing of enclosure (see chapter "Restricted breathing test").
9.1.1 Restricted breathing test
The luminaire is equipped with a test device for restricted breathing.
Restricted breathing must be checked after installation and during regular maintenance
acc. to IEC/EN 60079-15.
Inspection according to IEC/EN 60079-15, para. 23.2.3.2.1.1
In order to test restricted breathing (pressure test), the luminaire is equipped with a cable
entry with red stopping plugs.
• Remove the red stopping plug.
Check Measures
the seals for ageing and damage replace damaged, aged and porous seals
and completely change enclosure
components with foamed seal.
the inside and outside of the luminaire for
pollution
clean the luminaire.
If the restricted breathing test has failed, take the device out of operation!
NOTICE
Moisture inside the light fitting
can result in damage to electric and electronic components.
• Remove moisture with a cloth!
• Determine the source and eliminate the cause!
• Avoid condensation and thermal bridges!
WARNING
Restricted breathing is not guaranteed any longer!
Explosion protection is impaired!
• After replacing seals or enclosure components carry out the restricted
breathing test acc. to IEC/EN 60079-15, para. 23.2.3.2.1.1.
Recommendation
Check the luminaire by using the handheld testing instrument for restricted
breathing from R. Stahl Schaltgeräte GmbH (see data sheet).
The test should only be carried out at constant temperature conditions.

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• Insert the hose of the test device into the cable entry for testing restricted breathing.
• Hand-tighten the cable entry.
• Use the hand pump to create a vacuum of 0.3 kPa (3 mbar).
The test has been passed if after 90 seconds a vacuum of at least 0.15 kPa (1.5 mbar)
is still present in the luminaire.
After inspection:
• Remove the hose of the test device for testing restricted breathing from the
cable entry.
• Close the luminaire using the red stopping plug.
Alternative pressure and time specifications:
9.1.2 Cleaning
• Clean the device only with a cloth, brush, vacuum cleaner or similar items.
• When cleaning with a damp cloth, use water or mild, non-abrasive, non-scratching
cleaning agents.
• Do not use aggressive detergents or solvents.
9.2 Repair
9.3 Returning the device
Use the "Service form" to return the device if repair or service is required. On the internet
site "www.stahl-ex.com" under "Downloads > Customer service":
• Download the service form.
• Fill out the service form.
• Send the device along with the service form in the original packaging to
R. STAHL Schaltgeräte GmbH.
Alternative 1 Alternative 2
Vacuum at start of test 3.0 kPa (30 mbar) 0.3 kPa (3 mbar)
Test duration 14 seconds 14 seconds
Vacuum after testing 2.7 kPa (27 mbar) 0.27 kPa (2.7 mbar)
If the luminaire is only marked with the type of protection for dust (IIIC), the
cable entries and stopping plugs do not need to meet the requirements for
restricted breathing (nR).
DANGER
Explosion hazard due to improper repair!
Non-compliance results in severe or fatal injuries.
• Repair work on the devices must be performed only by R. STAHL
Schaltgeräte GmbH.

Disposal
20 244627 / 652560300010
2017-07-13·BA00·III·en·03
Floodlight LED
Series 6525
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10 Disposal
• Observe national and local regulations and statutory regulation regarding disposal.
• Separate materials when sending it for recycling.
• Ensure environmentally friendly disposal of all components according to the statutory
regulations.
11 Accessories and Spare parts
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.
For accessories and spare parts, see data sheet on our homepage
www.stahl-ex.com.