Stahl EXLUX 6402/2 Series User manual

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Operating instructions
Additional languages www.stahl-ex.com
EN
Linear Luminaire with LED
Series EXLUX 6402/2

2Linear Luminaire with LED
Series EXLUX 6402/2
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Contents
1 General Information ............................................................................................3
1.1 Manufacturer .......................................................................................................3
1.2 Information regarding the operating instructions .................................................3
1.3 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 .......................................................................................................5
3.4 Modifications and alterations ..............................................................................5
4 Function and device design ................................................................................6
4.1 Function ..............................................................................................................6
4.2 Device design .....................................................................................................6
5 Technical data .....................................................................................................8
6 Transport and storage .......................................................................................11
7 Mounting and installation ..................................................................................12
7.1 Dimensions / fastening dimensions ..................................................................12
7.2 Mounting / dismounting, operating position ......................................................13
7.3 Installation .........................................................................................................16
8 Commissioning .................................................................................................19
9 Maintenance and repair ....................................................................................20
9.1 Maintenance .....................................................................................................20
9.2 Repair ...............................................................................................................21
9.3 Returning the device .........................................................................................21
10 Disposal ............................................................................................................21
11 Accessories and Spare parts ...........................................................................21

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General Information
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1 General Information
1.1 Manufacturer
1.2 Information regarding the operating instructions
ID-No.: 243137 / 640260300020
Publication Code: 2015-12-22·BA00·III·en·05
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 EC Declaration of Conformity: www.stahl-ex.com.
The device has IECEx approval. See IECEx homepage: http://iecex.iec.ch/
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]
R. STAHL Schaltgeräte GmbH
Business Unit Lighting & Signalling
Nordstr. 10
99427 Weimar
Germany
Phone:
Fax:
Inter-
net:
E-mail:
[phone]
[phone]
www.stahl-ex.com
[email protected]

Explanation of the symbols
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2 Explanation of the symbols
2.1 Symbols in these operating instructions
2.2 Warning notes
Warning notes 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/damage
Symbol Meaning
Tips and recommendations on the use of the device
General danger
Danger due to explosive atmosphere
Danger due to energised parts
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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2.3 Symbols on the device
3 Safety notes
3.1 Operating instructions storage
• Read the operating instructions carefully and store them at the mounting location
of the device.
• Observe applicable documents and operating instructions of the devices to be
connected.
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 luminaire 6402/2 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
Symbol Meaning
05594E00
CE marking according to the currently applicable directive.
02198E00
According to marking, device approved for hazardous areas.
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.

Function and device design
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4 Function and device design
4.1 Function
• for lighting areas, work spaces and objects
• switching off the equipment by means of a central lock (optional) when the luminaire
is opened
4.2 Device design
DANGER
Explosion hazard due to improper use!
Non-compliance results in severe or fatal injuries.
• Use the device only according to the operating conditions described in
these operating instructions.
16346E00
4567
123
5

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Function and device design
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16349E00
1 - Connection terminal - mounting plate
(internal wiring)
6 - Luminaire enclosure
2 - Ballast 7 - Mounting plate
3 - Translucent cover 8 - LED PCB
4 - Cable gland 9 - Diffuser (optional / accessories)
5 - Connection terminal - luminaire
(customer wiring)
78 9

Technical data
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5 Technical data
Explosion Protection
Global (IECEx)
Gas and dust IECEx IBE 14.0080X
EX nA d op is IIC T4 Gc
EX tb IIIC T100 °C Db
EX tc IIIC T100 °C Dc
Europe (ATEX)
Dust IBExU14ATEX1292
E II 2 D Ex tb IIIC T100 °C Db
Gas and dust IBExU14ATEXB020 X
E II 3 G Ex nA d op is IIC T4 Gc
E II 3 D Ex tc IIIC T100 °C Dc
Certifications and certificates
Certificates IECEx, ATEX
Technical Data
Electrical data
Ballast AC: 220 ... 240 V ±10 %; 50 ... 60 Hz
DC: 200 ... 250 V ±10 %
Inrush current Ipeak = 53.5 A; Δt = 124.8 ms
maximum number of luminaires per miniature circuit breaker:
Power factor ) 0.93
Degree of protection IP66 / IP67 (IEC 60598)
Protection class I (with internal PE connection)
Impact strength (IK
code)
IK10 (IEC 62262)
Disconnection of the
light
When opening the luminaire
Switch with safety lock (optional); when opening the central lock all poles of the
voltage supply to the ballast are disconnected; contacts of the switching ele-
ment are positive opening, they can only be switched on again when the lumi-
naire trough and the central locking system are closed.
Type 10 A 16 A 20 A 25 A
B8121620
C13 21 27 33

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Technical data
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Luminous characteristics
Luminous flux
Values apply to Ta = +25 °C.
Luminous flux decrease at Ta = +55 °C to 85% of the nominal value.
Ambient conditions
Operating tempera-
ture range
-30 ... +55 °C
Storage -30 ... +75 °C
Service life
Service life
Technical Data
6402/21.2-.5..-..0 6402/22.4-.5..-..0 6402/21.2-.5..-..1 6402/22.4-.5..-..1
Power consumption [W] 28 52 28 52
Colour rendering [Ra] ) 80 ) 80 ) 70 ) 70
Colour temperature [K] 5000 5000 5700 5700
without diffuser
Luminous flux [lm] 2919 5375 3150 5800
Luminaire efficiency [lm/W] 105 103 113 111
Light output ratio [%] 85 85 92 92
with diffuser
Luminous flux [lm] 2558 4670 2760 5040
Luminaire efficiency [lm/W] 92 90 99 97
Light output ratio [%] 75 76 81 82
Ta ( 25 °C Ta ( 45 °C Ta ( 55 °C
L70B10C10 100,000 h 100,000 h 50,000 h
LxByCz
At the end of the service life:
• Luminous flux decrease to "x" percent
• up to "y" percent of all luminaires fall below "x"
• up to "z" percent of all luminaires break down completely

Technical data
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Mechanical data
Material
Enclosure
Material Polyester resin, glass fibre-reinforced
Colour colour grey, similar to RAL 7035
Seal Silicone foam gasket in the lamp cover
Translucent cover Polycarbonate
Luminaire locking Central locking which can be opened/closed using a socket key M8 / wrench
size 13, hinged lamp cover
Mounting / Installation
Cable glands
Connection
Through wiring
Technical Data
Standard luminaire
Plastic: 2 x M25 x 1.5 cable gland 8161 and
2 x M25 x 1.5 stopping plugs 8290 (enclosed)
Metal: 2 x metal plates M20 x 1.5 connected by means of PE for metal
cable entries
Attention: cable entries must be ordered separately
Special: max. 4 bores for M20, M25, NPSM ½’’
max. 2 bores for NPT ¾’’
Metal cable glands: M20 x 1.5, M25 x 1.5; earthing of the metal
cable entries by means of metal plates
Standard: Spring clamp terminals
5-pole: L1, L2, L3, N, PE (with through wiring)
Clamping range: 1 x 0.75 ... 4 mm2 (solid/finely stranded)
(2 free clamping units for each pole available)
Special: Terminal block with covering
5-pole: L1, L2, L3, N, PE
Clamping range: 2x 0.75 ... 6 mm2 (solid);
2 x 0.75 ... 4 mm2 (finely and extra finely stranded)
Standard light
fitting
with
Light fittings are equipped with internal through wiring.
Ingoing and outgoing leads can be connected to the
opposite sides.
Terminals: see techn. data
Wiring cross section: 2.5 mm2 for max. 16 A.
Optional without
On the connection side, there are 2 bores M25 x 1.5 for
cable entries for ingoing and outgoing wiring of the
connection line
(ingoing and outgoing leads on one side).

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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.
Assembly
Technical Data
Standard luminaire
Standard: 2 x M8 insert nuts in the enclosure
Special: Mounting grooves in the enclosure for the use of fastening and
ceiling rails for variable luminaire mounting (variable mounting
distances for luminaires L = 700 mm: 320 ... 480 mm;
L = 1310 mm: 670 ... 930 mm)

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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
15440E00
EXLUX 6402 Standard luminaire
M25 x 1,5 L3 M25 x 1,5
L2
L1b
h1
Dimensions Luminaire
28 W 52 W
L1 700 [27.56] 1310 [51.57]
L2 1) 400 [15.75] 800 [31.50]
L3 2) 320 ... 480
[12.60 ... 18.90]
670 ... 930
[26.38 ... 36.61]
b 184 [7.24] 184 [7.24]
h1 125 [4.92] 125 [4.92]
1) fixed mounting distance
2) variable mounting distance

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7.2 Mounting / dismounting, operating position
Suspension at fixed mounting points
DANGER
Explosion hazard due to electrostatic discharge
Non-complicance results in severe or fatal injuries.
Do not use the luminaire in strong charge generating environments!
The following processes/activities should be avoided:
• accidental friction
• particle currents
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).
The luminaire is suitable for wall and ceiling mounting.
Wall mounting must be performed with the central lock directed downwards.
The mounting position with light emission upwards is not allowed when
mounted outdoors.

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Suspension at moveable assembly parts
Pole mounting
Pole mounting using pipe clamps
15446E00
max. screw-in depth 10 mm [0.39]
15442E00 15447E00
Mounting bracket Top rail
Lateral mounting pockets for variable suspension points.
When mounting the luminaire using top rails, ensure that the mounting
surface is flat. Otherwise, the enclosure might be mounted in a
warped/twisted way. The result is leakage of the luminaire and difficulties in
replacing the translucent cover.
L2
Version L2 mm [inches]
28 W 400 [15.75]
52 W 800 [31.50]
L
L4
L
L4
L
L
Version L4 mm [inches] L mm [inches]
28 W 320 [12.60] 80 [3.15]
52 W 670 [26.38] 130 [5.12]

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For pipe clamp mounting, use the solution of R. STAHL Schaltgeräte GmbH with
integrated mounting rail providing reliable and stable four-point fixing!
Wall bracket mounting
15455E00
15443E00
Version L4 mm [inches] L mm [inches]
28 W 320 [12.60] 80 [3.15]
52 W 670 [26.38] 130 [5.12]
In case of point suspension using pipe clamps,
R. STAHL Schaltgeräte GmbH does not guarantee the strength and
tightness of the luminaire!
15515E00 15517E00
Version L4 mm [inches] L mm [inches]
28 W 320 [12.60] 80 [3.15]
L4
L
L
L
L4
L
1
0
x
1
5
°

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7.3 Installation
7.3.1 Opening and Closing of the Enclosure
• Remove the closing cap of the central lock.
• Turn the central lock using a socket wrench M8, wrench size 13, by 90° to the left
as far as it will go.
• Swivel down the translucent cover.
• Proceed in reverse order to close.
• The seal of the translucent cover must lie correctly on the sealing edge.
• Push the closing cap onto the central lock opening (dust protection).
52 W 670 [26.38] 130 [5.12]
When mounting the luminaire using top rails, ensure that the mounting sur-
face is flat. Otherwise, the enclosure might be mounted in a warped/twisted
way. The result is leakage of the luminaire and difficulties in replacing the
translucent cover.
For pipe clamp mounting, use the solution of R. STAHL Schaltgeräte GmbH
with integrated mounting rail providing reliable and stable four-point fixing!
In case of point suspension using pipe clamps, R. STAHL Schaltgeräte
GmbH does not guarantee the strength and tightness of the luminaire!
DANGER
Risk of electric shock!
Risk of fatal injuries!
• Luminaires without switch must not be opened when they are supplied
with power (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!
Recommendation
Opening and closing of the luminaire by using a socket wrench from
R. STAHL Schaltgeräte GmbH.
15448E00
15451E00
15436E00
165°
170
90°

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Note:
• Version without switch: Disconnect the luminaire from the power supply and secure
it against being switched on again.
• Version with switch: The luminaire is positively disconnected from the power supply
by actuating the central lock.
• In open end position and with translucent cover swivelled down, a restart lock-out
device prevents the central lock from being actuated.
Please do not use force!
When the translucent cover is closed, the central lock is released.
Opening and closing the reflector plate
7.3.2 Electrical connections
Electrical connection
Observe the maximum clamping possibility of the connecting terminals (see chapter
"Technical data").
For optional screw-type terminals, two conductors per clamping unit can be clamped
(ingoing and outgoing wiring).
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.
• The terminal cover of optional screw-type terminals does not have to be removed
to clamp the conductor!
• Optional screw-type terminals: Firmly tighten screws (tightening torque 2 Nm,
for unused clamping units 0.7 Nm)!
Connection terminals
15512E00
1 Open the reflector plate by
pressing the safety latch.
2 Swivel down the reflector plate.
• When closing, flip up the
reflector plate and snap it into
place.
12

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Through wiring
7.3.3 Cable Entries
The standard luminaire is delivered with 3 lead-in holes, 2 cable glands and
2 stopping plug.
Please observe the tightening torque for luminaires with installed cable glands and
stopping plugs from R. STAHL Schaltgeräte GmbH.
Standard:
Spring clamp terminals
up to 4 mm2
Optional:
Screw-type terminals
up to 4 mm2 finely and
extra finely stranded,
and 6 mm2 solid
Stripping length:
10 ... 11 mm
Stripping length:
10 ... 11 mm
15516E00
15438E00
NOTE
Through wiring with 2.5 mm 2 cross-section for max. 16 A.
Tightening torque
Connection thread Pressure screw
Cable gland 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
N
L1
L2
L3
L3L2L1
N
L1, L2, L3 = Phase
N = Neutral conductor
PE = Protective conductor

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Luminaires with approved cable glands and stopping plugs; not supplied by
R. STAHL Schaltgeräte GmbH
Please note:
• 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 glands and stopping plugs!
• the required tightening torques!
• the range of the permissible cable diameter!
8 Commissioning
Before commissioning, ensure that
• the device has been installed according to regulations.
• the power supply voltage and the rated operational voltage are identical.
• the required cable diameter for cable glands has been used.
• the cable entries and stopping plugs have been securely tightened.
• the cables are correctly connected.
• the connection has been performed correctly.
• all screws and nuts are tightened according to regulations.
• the connection chamber is clean.
• the device is not damaged.
• no foreign bodies are inside the device.
• the device is sealed according to regulations.
• the LED assembly and the diffusor are clean.
M25 x 1.5 1.5 Nm
WARNING
Cable glands and stopping plugs which are not approved.
Explosion protection is impaired!
• Only use separately certified cable glands and stopping plugs.
DANGER
Explosion hazard due to incorrect installation!
Non-compliance results in severe or fatal injuries.
• Check the device for proper installation and function before
commissioning.
• Comply with the national regulations.
NOTE
Condensation
due to specific environmental and operating conditions condensation cannot be avoided
completely.
• operate the luminaire continuously or periodically over extended periods of time!
• avoid thermal bridges!

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.
9.1.1 Cleaning
• Clean the device only with a damp cloth.
• Use water or mild cleaning agents.
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.
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.
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.
NOTE
The luminaire is marked with the warning "Clean with damp cloth only".