Stahl 8150/ User manual

Installation, Operating & Maintenance Sheet
Terminal Boxes 
for I.S. Circuits
> 8150/2 

Contents
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1 Contents
1 Contents ................................................................................................................2
2 General Information ...............................................................................................2
3 Application .............................................................................................................2
4 Safety Instructions .................................................................................................3
5 Technical Data ......................................................................................................4
6 Transport and Storage ..........................................................................................4
7 Installation ..............................................................................................................4
8 Wiring ....................................................................................................................6
9 Commissioning ......................................................................................................7
10 Maintenance...........................................................................................................7
11 Accessories and Spare Parts ................................................................................7
12 Disposal .................................................................................................................8
2 General Information
2.1 Manufacturer
R. STAHL, INC.
9001 Knight Road
Houston, TX 77054
Tel.: [phone]
Fax: [phone]
Internet: www.rstahl.com
2.2 Information regarding this Installation, Operation and Maintenance Sheet
ID-No.: 212728 / 815060300180
Publication Code: 2011-11-18·IO00·III·en·01
Subject to alterations.
2.3 Disclaimer
The nature of these instructions is only informative and does not cover all of the details,
variations or combinations in which this equipment may be used, stored, delivered,
installed, safely operated and maintained.
Since conditions of use of the product are outside of the care, custody and control of 
R. STAHL, INC., the purchaser should determine the suitability of the product for his 
intended use, and assumes all risk and liability whatsoever in connection therewith.
Technical information and illustrations are not binding and subject to change 
without notice.
3 Application
The terminal boxes are intended for use in hazardous (classified) locations to connect
intrinsically safe circuits and are only for fixed mounting.

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Safety Instructions
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4 Safety Instructions
The terminal boxes must be used only for their intended purpose. Incorrect usage 
invalidates our warranty provision. Any modifications need to done within the guidelines 
given in this documentation.
These terminal boxes are installed with blue terminals which clearly identify the I.S.
circuits in order to prevent unintentional interference with non-intrinsically safe circuits 
during testing and service.
CAUTION:
No conduit seals are required. Exception see NEC 504-70
Use wiring methods for the location with the associate cable glands or conduit hubs.
Reference NEC, NFPA 70 Article 504-20.
Keep enclosures clean and undamaged while in service.
4.1 Entry hardware
The following entry hardware can be used to insert cables and conduits into enclosures:
Xincreased safety „e“ conduit hubs Series 8166/11-0.-NE (see section 11.1) or
Xfor cable installation any listed cable gland for hazardous (classified) location
To close up unused openings, use listed close-up plugs. (see section 11.2)
4.2 Additional entry holes
If additional entry holes are required, e.g. for installing additional cable glands, 
breather glands, conduit hubs or close-up plugs, the following has to be considered:
Additional through holes can be punched.
While punching please make sure that the surfaces remain even.
When determining the position of the through holes, please consider the correct
clearances.
Choose the applicable through-hole diameter.
Ensure gaskets are not damaged.
WARNING
Installation and maintenance of this product should only be performed by skilled 
and experienced personnel in accordance with the National Electrical Code 
(NFPA 70 - NEC) or the Canadian Electrical Code (CEC), respectively, and 
applicable local code regulations.

Technical Data
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5 Technical Data
6 Transport and Storage
Transport and storage are only permitted in the original packing.
On versions with hinges secure the cover prior to transport.
7 Installation
7.1 Enclosure mounting
Mounting brackets are provided with the enclosures which will accept up to 1/4″(6 mm )
screws.
7.2 Opening the enclosure
Fully loosen the cover screws using a screwdriver. 
Do not remove the captive screws from the cover.
7.3 Electrical installation
There are two types of installation methods: Conduit installation or cable installation.
If the enclosure is complete with factory installed entry hardware proceed to section 8.
If the enclosure does not include entry hardware, select the appropriate hubs or cable
glands from section 11 and install them as follows.
7.4 Installation of approved conduit hubs or cable glands
The enclosures make it necessary for the metal cable glands or conduit hubs to be
bonded to the ground system. This can be accomplished by installing them either by one
of the following methods.
Explosion protection refer to enclosure nameplate
Certificates refer to enclosure nameplate
Material
Enclosure - stainless steel AISI 304 (V1.4301) or AISI 316L (V1.4404) brush finished
Gasket Silicone, foamed
Degree of protection IP66
WARNING
The enclosures should not be powder coated in the field because this would change the 
surface resistance.
WARNING
For field-installed openings, use a hand punch or pneumatic type punch. Always wear
safety glasses and protective clothing when working.

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Installation
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7.4.1 Enclosures with flange plates
Enclosures with flange plates utilizing through holes in the flange plate and standard 
locknuts. Flange plates must be connected to the internal grounding system using 
jumper wires.
7.4.2 Enclosures without flange plates
Enclosures without flange plates using a hole “through the enclosure“ with an 
“increased safety“ grounding locknut.
These locknuts must be bonded between each other and to the grounding system using
jumper wires.
After the entry hardware is installed, connect the appropriate conduit or cable.
14800E00
1 MC-HL cable
2 threaded 
entry component
3 gasket
4 ground wire
5 ground connection
6 standard locknut
7 flange plate with 
through hole
8 “O“ ring
9 cable gland or hazardous
location hub 8166/11
14801E00
1 conduit
2 “O“ ring
3 set screw
4 “increased safety“
grounding terminal
5 ground wire
6 “increased safety“
grounding locknut
7 enclosure with 
through hole
8 hazardous location hub
8166/11 or cable gland
All unused enclosure openings must be closed using approved close-up
plugs with standard locknuts. (see section 11.2)

Wiring
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8 Wiring
IMPORTANT: When connecting conductors:
Strip the wire so that the insulation covers the wire up to the terminal.
Make sure that all wires are connected to the correct terminals.
8.1 P04 bar for solid or stranded wire 16-10 AWG
One or two conductors can be terminated as shown. When connecting two conductors
under the same terminal, it is mandatory that both conductors be identical. They must
both be solid or stranded, and must be the same size and type. It is important to torque
all terminal screws, including unused ones to 18 lb-in.
8.2 Jumpers on terminals
It is good practice to allow only one conductor on either side of the terminal. Should more 
termination points be required the terminals need to be jumpered with appropriate 
jumpers from the same manufacturer as the terminals. Jumper connections are inserted
into the center recessed areas of the appropriate terminal blocks and fastened to the 
current bar.
Partitions provide visual separation between groups of terminal blocks in an assembly.
Partitions are also required to provide electrical separation between adjacent jumper 
connections. An end plate can also be used to provide the electrical separation at 
jumper connections.
End Plates. The open side of each terminal block must be completely covered by an 
end plate or a partition.
8.3 Closing the enclosure cover
Before closing the cover, ensure that:
The cover, gasket and mating surface is clear of debris.
The cover is oriented correctly.
Place the cover on the enclosure and then tighten all screws to 40 lb-in (4.5 Nm) torque.
14269E00
1 Torque 18 lb-in
10 mm / 0.39 "
1

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Commissioning
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9 Commissioning
Before commissioning into service
Make sure that the device is not damaged.
Make sure that the device is installed correctly.
Make sure that the connections have been correctly made.
Remove any foreign objects from the device.
Check the tightening torques.
Check if all covers and partitions on live parts are in place and have been fixed.
10 Maintenance
10.1 Cleaning
Use only a solvent-free household detergent added to the cleaning water.
10.2 Repairs and maintenance
Only authorized and trained personnel should perform repairs and maintenance work on
hazardous location equipment.
The following details must be checked during maintenance:
XCables are held securely in place by the entry hardware.
XDamage to the enclosure, cover gaskets and terminals.
11 Accessories and Spare Parts
11.1 Conduit hub with „Increased Safety“ ground terminal
WARNING
All unused enclosure openings must be closed using approved close-up plugs with
standard locknuts. (see section 11.2)
WARNING
Use only the following accessories in order to maintain the environmental ratings.
14795E00
Size Ordering Code
1/2″8166/11-01-NE
3/4″8166/11-02-NE
1″8166/11-03-NE
1-1/4″8166/11-04-NE
1-1/2″8166/11-05-NE
2″8166/11-06-NE

Disposal
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11.2 NPT close-up plugs „Increased Safety“
11.3 Cable gland locknuts with „Increased Safety“ ground terminal
11.4 MC/TEK cable glands
12 Disposal
The national and local waste disposal regulations have to be observed.
12295E00
Size Ordering Code
1/2″PD-E-4-0-29-00
3/4″PD-E-4-0-30-00
1″PD-E-4-0-31-00
1-1/4″PD-E-4-0-32-00
1-1/2″PD-E-4-0-33-00
2″PD-E-4-0-34-00
14797E00
Size Ordering Code
1/2″8166/11-01-E
3/4″8166/11-02-E
1″8166/11-03-E
1-1/4″8166/11-04-E
1-1/2″8166/11-05-E
2″8166/11-06-E
14796E00
Size Ordering Code
1/2″TMC050A
3/4″TMC075A
1″TMC100A
1-1/4″TMC125A
1-1/2″TMC150A
2″TMC20SA or TMC200A

R. STAHL INC. 9001 Knight Road Houston, TX 77054 Tel.: [phone] www.rstahl.com
Electrical Capacity Table
In hazardous (classified) areas, heat produced by current in the wire inside an enclosure is a concern. Therefore, the continuous current of each current carrying
conductor, the quantity and the size of the conductors inside a terminal enclosure need to be limited.
Type 8150/1-0176-0116-091...
Enclosure size in mm (inches), W x H x D: 176.5 x 116.5 x 91 (6.9 x 4.6 x 3.6)
16 14 12 10
5
10 29 57
15 21 42
20 921 47
25 11 24
30 15
Enclosure 8150/1-0176-0116-091…
Current
Amps
Wire size AWG
How to use the electrical capacity tables:
In the white area of the electrical capacity table, the permitted numbers of the current carrying conductors inside the enclosure are indicated
(in and out counts as two wires) depending on wire size and continuous current.
In the shaded area of the electrical capacity table, additional conductors/terminals are permitted up to space limit of the enclosure.
In the area with dark diagonal lines, no conductors are permitted.
Jumper links and ground wires can be neglected, in calculating the number of wires. These can be added whenever necessary.
Mixed circuits of different wire sizes and current values are possible by applying the table values proportionally.
Please refer to section 9.3.1 of 8150/1 Installation, Operating & Maintenance Sheet for more information.

R. STAHL INC. 9001 Knight Road Houston, TX 77054 Tel.: [phone] www.rstahl.com
Electrical Capacity Table
In hazardous (classified) areas, heat produced by current in the wire inside an enclosure is a concern. Therefore, the continuous current of each current carrying
conductor, the quantity and the size of the conductors inside a terminal enclosure need to be limited.
Type 8150/1-0176-0176-091...
Enclosure size in mm (inches), W x H x D: 176.5 x 176.5 x 91 (6.9 x 6.9 x 3.6)
16 14 12 10 864
5
10 32 64
15 24 48
20 11 24 53
25 13 27
30 17 38
35 10 24
40 17 44
45 11 28
50 720
60 11 30
65 820
70 17
Enclosure 8150/1-0176-0176-091…
Current
Amps
Wire size AWG
How to use the electrical capacity tables:
In the white area of the electrical capacity table, the permitted numbers of the current carrying conductors inside the enclosure are indicated
(in and out counts as two wires) depending on wire size and continuous current.
In the shaded area of the electrical capacity table, additional conductors/terminals are permitted up to space limit of the enclosure.
In the area with dark diagonal lines, no conductors are permitted.
Jumper links and ground wires can be neglected, in calculating the number of wires. These can be added whenever necessary.
Mixed circuits of different wire sizes and current values are possible by applying the table values proportionally.
Please refer to section 9.3.1 of 8150/1 Installation, Operating & Maintenance Sheet for more information.