Stahl FL60 Series User manual

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Operating instructions
Additional languages www.r-stahl.com
EN
Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60

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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
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 Modifications and alterations ..............................................................................6
4 Function and device design ................................................................................6
4.1 Function ..............................................................................................................6
5 Technical data .....................................................................................................7
6 Transport and storage .........................................................................................9
7 Mounting and installation ..................................................................................10
7.1 Dimensions / fastening dimensions ..................................................................10
7.2 Mounting / dismounting, operating position ......................................................10
7.3 Installation .........................................................................................................15
8 Commissioning .................................................................................................16
9 Operation ..........................................................................................................16
9.1 Troubleshooting ................................................................................................16
10 Maintenance, overhaul, repair ..........................................................................17
10.1 Maintenance .....................................................................................................17
10.2 Repair ...............................................................................................................18
10.3 Returning the device .........................................................................................18
11 Cleaning ............................................................................................................18
12 Disposal ............................................................................................................19
13 Accessories and spare parts ............................................................................19

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General information
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
1 General information
1.1 Manufacturer
1.2 Information regarding the operating instructions
ID-No.: 223845 / FL6060300010
Publication Code: 2018-04-13·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 www.r-stahl.com.
1.4 Conformity with standards and regulations
See certificates and EU Declaration of Conformity: www.r-stahl.com.
The device has IECEx approval. For certificate please refer to the IECEx homepage:
http://iecex.iec.ch/
R. STAHL Schaltgeräte GmbH
Business Unit Lighting & Signalling
Nordstr. 10
99427 Weimar
Germany
R. STAHL Schaltgeräte GmbH
Am Bahnhof 30
74638 Waldenburg
Germany
Phone:
Fax:
Internet:
E-mail:
[phone]
[phone]
www.r-stahl.com
[email protected]
Phone:
Fax:
Internet:
E-mail:
[phone]
[phone]
www.r-stahl.com
[email protected]

Explanation of the symbols
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
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
= Strobe
= Earth
= Telephone initiate
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.

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Safety notes
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
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.
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 current applicable directive.
02198E00
According to marking, device certified for hazardous areas.
15649E00
Input
15648E00
Output

Function and device design
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
3.3 Modifications and alterations
4 Function and device design
4.1 Function
The explosion proof visual signal series FL60 provides a flashing visual signal intended
to alert, warn or draw attention to an event. It has been designed for use in hazardous
and/or harsh environments. In hazardous areas the devices have explosion protection
for ATEX / IECEx zones 1 + 2 for gas and 21 + 22 for dust. The device is suitable for
Gas groups IIB or IIB + H2, Dust group IIIC. UL certified variants offer protection to
Class 1 Division 1 Gas groups BDC, Class II Division I Gas groups EFG.
The device is not intended for continuos use.
The life of the xenon flash tube is guaranteed for the following number of flashes:
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 according to the operating conditions described in
these operating instructions.
Variant Number of flashes
5 J 2 million
10 J 5 million
20 J 4 million

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Technical data
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
5 Technical data
Explosion Protection
Global (IECEx)
Gas and dust
Europe (ATEX)
Gas and dust
North America (cULus listed)
Gas and dust
IIB+H2 IECEx BAS 05.0087X
IIB IECEx BAS 05.0086X
IIB+H2, IIB IEC 60079-0: 2011 / IEC 60079-1: 2007-04 / IEC 60079-31: 2008
IIB+H2 Ex d IIB+H2 T4 Gb (Ta = -20 … +60°C)
Ex tb IIIC T135°C Db IP 66 (Ta = -20 … +60 °C)
Ex d IIB+H2 T6 Gb (Ta = -20 … +40 °C)
Ex tb IIIC T85°C Db IP 66 (Ta = -20 … +40 °C)
IIB Ex d IIB T4 Gb (Ta = -35 … +60 °C)
Ex tb IIIC T135°C Db IP 66 (Ta = -35 … +60 °C)
Ex d IIB T6 Gb (Ta = -35 … +40 °C)
Ex tb IIIC T85°C Db IP 66 (Ta = -35 … +40 °C)
IIB+H2 Baseefa02ATEX0222X
IIB Baseefa02ATEX0212X
IIB+H2, IIB EN 60079-0: 2009 / EN 60079-1: 2007 / EN 60079-31: 2009
IIB+H2 EII 2 G Ex d IIB+H2 T4 Gb (Ta = -20 … +60 °C)
EII 2 D Ex tb IIIC T135°C Db IP 66 (Ta = -20 … +60 °C)
EII 2 G Ex d IIB+H2 T6 Gb (Ta = -20 … +40 °C)
EII 2 D Ex tb IIIC T85°C Db IP 66 (Ta = -20 … +40 °C)
IIB EII 2 G Ex d IIB T4 Gb (Ta = -35 … +60 °C)
EII 2 D Ex tb IIIC T135°C Db IP 66 (Ta = -35 … +60 °C)
EII 2 G Ex d IIB T6 Gb (Ta = -35 … +40 °C)
EII 2 D Ex tb IIIC T85°C Db IP 66 (Ta = -35 … +40 °C)
IIB+H2, IIB E168831
IIB+H2, IIB USL: UL 60079-0 / UL 60079-1 / UL 1203 / UL 1638
CNL: CSA C22.2 No. 30-M1986 / CSA C22.2 No. 25-M1966 /
CSA E60079-0-7 / CSA E60079-1
IIB+H2 CLASS I, DIVISION 1, GROUPS B, C and D, T4;
CLASS II, DIVISION 1, GROUPS E, F and G;
CLASS III
CLASS I, ZONE 1 AEx d IIB+H2 T4
CLASS I, ZONE 1 Ex d IIB+H2 T4
Operating temperature -25 ... +66 °C
Visual signal appliance private mode
IIB CLASS I, DIVISION 1, GROUPS C and D, T4;
CLASS II, DIVISION 1, GROUPS E, F and G;
CLASS III
CLASS I, ZONE 1 AEx d IIB T4
CLASS I, ZONE 1 Ex d IIB T4
Operating temperature -35 ... +66 °C
Visual signal appliance private mode

Technical data
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
Certifications and certificates
Certificates IECEx, ATEX, Brazil (INMETRO), India (PESO), Kazakhstan (TR),
Russia (TR), Taiwan (ITRI), USA & Canada (cULus),
Belarus (TR)
Functional safety (IEC 61508)
Test report SIL 1 IEC61508-2:2010
Technical Data
Technical data
Product weight 5.08 kg
Electrical data
Rated operational
voltage
24 V DC, 48 V DC, 115 V AC and 230 V AC operational parameters + or -10 %
Rated operational
current
Mechanical data
Material
Enclosure aluminium, seawater resistant
Lens cover polycarbonate
Fixings stainless steel
Cable entries 2 cable entries, equipped with stopping plug (1x) and dust cap (1x)
UL devices: equipped with M20 / 1/2 ’’ adapters (2x)
Degree of protection IP66 – IEC 60529
NEMA 4X – UL 50
Operating temperature range
Variant dependant see Explosion protection
Explosion Protection
24 V DC 5 J 220 mA
10 J 500 mA
20 J 1100 mA
48 V DC 5 J 135 mA
10 J 300 mA
20 J 560 mA
115 V AC 5 J 90 mA
10 J 105 mA
20 J 260 mA
230 V AC 5 J 45 mA
10 J 53 mA
20 J 107 mA

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Transport and storage
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
For further technical data, see www.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.
Luminous characteristics
Effective candela
Candela seconds
Flash energy 5, 10 or 20 J
Flash rate 60 FPM
Technical Data
5 J
Clear lens 46 cd
Yellow lens 42 cd
Amber lens 28 cd
Red lens 14 cd
Blue lens 13 cd
Green lens 10 cd
Magenta lens N/A
10 J
Clear lens 127 cd
20 J
Clear lens 265 cd
5 J 9.3 lumens Clear lens
10 J 25 lumens Clear lens
20 J 53 lumens Clear lens

Mounting and installation
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
7 Mounting and installation
7.1 Dimensions / fastening dimensions
7.2 Mounting / dismounting, operating position
• Select a suitable location with regard to the area to be covered by the FL60.
• The surface should be flat in the area of the fixings (see chapter Dimensions /
Fastening Dimensions) and the material suitable to carry the weight of the FL60.
Dimensional Drawings (All Dimensions in mm [inches]) – Subject to Alterations
18381E00
DANGER
Risk of explosion!
Risk of injuries and material damage!
• Terminal sleeves are fitted, they must be gas-tight and applied with a
suitable tool.

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Mounting and installation
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
7.2.1 Installation conditions for electrical connection
7.2.2 Access to the PCB
DANGER
Risk of explosion!
Risk of injuries and material damage!
• Only cable glands with a corresponding certificate may be used.
They must be flameproof (Ex d), suitable for the type of cable used
and fulfil the requirements of IEC/EN 60079-14.
• Cable entry temperature may exceed 70 °C.
• To ensure the required ingress protection, installation of the cable gland
must be performed in accordance with the manufacturer's instructions.
• For unused enclosure holes use Ex d stopping plugs, for unused cable
glands Ex d plugs. Make sure that these components have an
appropriate approval and fulfil the requirements of IEC/EN 60079-14.
• All threaded cable entries to be fitted with an appropriately certified
component and the thread sealed with a suitable non-setting thread
sealant to maintain IP 66 rating.
DANGER
Danger due to energised parts!
Non-compliance results in severe or fatal injuries.
• Before opening and dismounting the device, disconnect it from the
power supply.
• Secure the device against unauthorized switching.
16439E00
• Remove cheese head screws x 4
• Carefully lift end cap
• Lift PCB to expose terminals for
connection (see wiring diagrams
for details)
• Remove protective flash tube cover
4
5
1
2
3

Mounting and installation
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
7.2.3 Reassembly of enclosure
Inserting the PCB
For correct positioning of the PCB there are 2 grooves in the enclosure.
Depending on the version, insert the PCB in the corresponding groove!
• With the electrical lines connected, carefully lower the PCB back into the correct
position in the enclosure.
• Ensure the flash tube is clearly visible and centrally located in the glass dome.
• Slowly and carefully, the end cap must be inserted squarely into the enclosure.
Do not use force.
• Replace cheese-head screws M5 x 16 (see information below) and tighten the screws
with a tightening torque of 3 Nm.
18814E00 18813E00
• FL60/./D50/./..
• FL60/./F50/./..
• FL60/./D100/./..
• FL60/./D200/./..
• FL60/./F100/./..
• FL60/./F200/./..
• FL60/./L50/./..
• FL60/./L100/./..
• FL60/./L200/./..
• FL60/./N50/./..
• FL60/./N100/./..
• FL60/./N200/./..
• Carefully assemble the device to ensure that the degree of protection
is IP 66.
• The cheese-head screws are delivered with Nyltite seals
(see the "Connection" section above).
• Check the Nyltite seals for damage before the installation.
• Tighten cheese-head screws with a torque of 3 Nm.
• Use the Nyltite seal a maximum of five times with the tightening torque.

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Mounting and installation
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
7.2.4 Electrical connection
Key Components
15748E00
16440E00 16441E00
Key components FL60 DC (5J) Key components FL60 AC
16443E00
Key components FL60 DC, AC
(10J, 20J)
Legend
1 = Terminal blocks
1
1
1
10J
20J

Mounting and installation
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
Cable Connection
Interconnection of devices parallel
Up to 10 devices with common supplies may be connected as a single system loop.
Circuit diagrams
DC versions
AC versions
• Approximately 20 cm (8 Inch) tails are required inside the enclosure
for connection to the terminals on the PCB. This is especially important
for installation using solid core cable.
• The terminals accept wires of 2.5 mm2 or 14 to 18 AWG.
18418E00 18419E00
18420E00
FL60 DC 5 J FL60 DC 5 J
telephone initiate
FL60 DC 10/20 J
18415E00
18417E00
18416E00
FL60 AC 5 J FL60 AC 5 J
telephone initiate
FL60 AC10/20 J
= Strobe
= Earth
= Telephone initiate

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Mounting and installation
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
7.2.5 Earth connection
• 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.
7.3 Installation
15265E00
WARNING
Danger of electric shock due to energised parts!
Non-compliance can result in severe or fatal injuries.
• All connections and wiring must be disconnected from the power supply.
• Secure the connections against unauthorized switching.
DANGER
Risk of explosion!
Risk of injuries and material damage!
• Operate the device only if it is not damaged.
• If the thread is damaged, the device must be replaced immediately.
• Take extreme care when handling the device and internal components.
• Particular care is needed when accessing the PCB for installation.
• Exposed joint surfaces must be protected and not have contact with
dust or dirt, or be knocked against any object.
• The end flanges must be fitted squarely and on no account is force to be
used.
• The flange must not be hammered, levered with a metal instrument or
the fixing screws used to pull down the flange.
• With care and patience, it will be found that the flange enters the body
without difficulty.
• Install the device only in a clean and dry operating environment.
Check the following:
• Do you have the correct device to satisfy the system specification?
• Are the gas group and temperature range of the product suitable for the
intended application?
• Is the supply voltage correct?
• Is the strobe the correct colour?
• Is a suitable mounting location available?

Commissioning
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
8 Commissioning
Before commissioning, ensure the following:
• No components are damaged.
• The device has been installed according to regulations.
• There are no foreign bodies inside the device.
• All screws and nuts have been firmly tightened.
• The prescribed tightening torques have been observed.
• Connection has been made correctly.
9 Operation
The device is used to warn and alert by means
• of a visual signal.
9.1 Troubleshooting
If an error occurs please re-visit the earlier sections of this document.
If the error cannot be eliminated using the mentioned procedures:
• Contact R. STAHL Schaltgeräte GmbH.
For fast processing, have the following information ready:
• Type and serial number
• Purchase information
• Error description
• Intended use (in particular input / output wiring)
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.

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Maintenance, overhaul, repair
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
10 Maintenance, overhaul, repair
10.1 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.
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.

Cleaning
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
10.2 Repair
10.3 Returning the device
• Only return or package the devices after consulting R. STAHL!
Contact the responsible representative from R. STAHL.
R. STAHL's customer service is available to handle returns if repair or service is required.
• Contact customer service personally.
or
• Go to the www.r-stahl.com website.
• Under "Support" > "RMA form", select "Request RMA slip".
• Fill out the form and send it.
Confirmation will be sent. R. STAHL's customer service will contact you.
You will receive an RMA slip after speaking with customer service.
• Send the device along with the RMA slip in the packaging to
R. STAHL Schaltgeräte GmbH (refer to Section 1.1 for the address).
11 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.
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.

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Disposal
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Explosion Proof Visual Signal -
5, 10 or 20 Joule
Series FL60
12 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.
13 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.r-stahl.com.