Stahl 8146/1 User manual

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Operating instructions
Additional languages www.stahl-ex.com
EN
Terminal Boxes
Series 8146/1,
Series 8146/2
– Save for future use! –

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Terminal Boxes
Series 8146/1, Series 8146/2
Contents
1 General Information ............................................................................................3
1.1 Manufacturer .......................................................................................................3
1.2 About these 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 Symbols on the Device .......................................................................................4
3 Safety ..................................................................................................................5
3.1 Intended Use .......................................................................................................5
3.2 Personnel Qualification .......................................................................................5
3.3 Residual Risks ....................................................................................................6
4 Transport and Storage ........................................................................................8
5 Product Selection, Project Engineering and Modification ...................................8
5.1 Additional Through Holes in Flange Plates .........................................................9
5.2 Additional Through Holes in the Enclosure with
an internal Brass or Flange Plate ......................................................................10
5.3 External Attached Components
(Cable Entries, Stopping Plugs, Breathers) ......................................................13
5.4 Internal Built-In Components
(Conductors, Terminals, Fuses) ........................................................................14
6 Mounting and Installation ..................................................................................17
6.1 Mounting / Dismounting, Operating Position .....................................................17
6.2 Installation .........................................................................................................18
7 Commissioning .................................................................................................21
8 Maintenance and Repair ...................................................................................21
8.1 Maintenance .....................................................................................................21
8.2 Maintenance .....................................................................................................21
8.3 Repair ...............................................................................................................21
9 Returning the Device ........................................................................................21
10 Cleaning ............................................................................................................22
11 Disposal ............................................................................................................22
12 Accessories and Spare Parts ...........................................................................22
13 Annex A ............................................................................................................23
13.1 Technical Data ..................................................................................................23
14 Annex B ............................................................................................................26
14.1 Dimensions / Fastening Dimensions .................................................................26

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General Information
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Terminal Boxes
Series 8146/1, Series 8146/2
1 General Information
1.1 Manufacturer
R. STAHL Schaltgeräte GmbH
Am Bahnhof 30
74638 Waldenburg
Germany
Phone: [phone]
Fax: [phone]
Internet: www.stahl-ex.com
E-Mail: [e-mail]
1.2 About these Operating Instructions
Read these operating instructions, especially the safety notes, carefully before use.
Observe all other applicable documents (see also section 1.3).
Keep the operating instructions throughout the service life of the device.
Make the operating instructions accessible to operating and maintenance personnel at all
times.
Pass the operating instructions on to each subsequent owner or user of the device.
Update the operating instructions every time you receive an amendment to them from
R. STAHL.
ID-No.: 137189 / 8146619300
Publication Code: 2016-11-10·BA00·III·en·06
The original instructions are the German edition.
They are legally binding in all legal affairs.
1.3 Further Documents
• Data sheet
• EU Type Examination Certificate
For documents in additional languages, see www.stahl-ex.com.
1.4 Conformity with Standards and Regulations
• Certificates and EU Declaration of Conformity: www.stahl-ex.com.
• The device has IECEx approval. See IECEx homepage: http://iecex.iec.ch/

Explanation of the Symbols
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Terminal Boxes
Series 8146/1, Series 8146/2
2 Explanation of the Symbols
2.1 Symbols in these Operating Instructions
2.2 Symbols on the Device
Symbol Meaning
Tip for making work easier
DANGER! Dangerous situation which can result in fatal or severe injuries
causing permanent damage if the safety measures are not
complied with.
WARNING! Dangerous situation which can result in severe injuries if the
safety measures are not complied with.
CAUTION! Dangerous situation which can result in minor injuries if the
safety measures are not complied with.
NOTICE! Dangerous situation which can result in material damage if the
safety measures are not complied with.
Symbol Meaning
05594E00
CE marking according to the currently applicable directive.
02198E00
According to marking, device certified for hazardous areas.

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Safety
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Terminal Boxes
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3 Safety
The device has been manufactured to the state of the art while observing recognised
safety-related rules. When using the device, it is nevertheless possible for hazards to occur
to life and limb of the user or third parties or for the device, environment or material assets to
be compromised.
Use the device only
- if it is not damaged
- as intended, while remaining aware of safety and dangers
- in accordance with these operating instructions.
3.1 Intended Use
The terminal boxes 8146/1 and /2 are used to distribute electric energy and / or electric
signals in hazardous areas. They are explosion-protected equipment certified for use in
hazardous areas of Zones 1, 2, 21 and 22.
The terminal boxes are manufactured in various sizes and can be combined to create larger
distribution units. They must be installed so they are stationary.
Intended use includes observing these operating instructions and the other applicable
documents, e.g. the data sheet. Any other use of the terminal boxes is not intended.
3.2 Personnel Qualification
Qualified specialist personnel are required to perform the activities described in these
operating instructions. This primarily applies to work in the following areas:
• Product selection, project engineering and modification
• Mounting/dismounting the device
• Installation
• Commissioning
• Maintenance, repair, cleaning
Specialists who perform these tasks must have a level of knowledge that meets applicable
national standards and regulations.
Additional knowledge is required for tasks in hazardous areas! R. STAHL recommends
having a level of knowledge equal to that described in the following standards:
•IEC/EN 60079-14 (Electrical installations design, selection and erection)
•IEC/EN 60079-17 (Inspection and maintenance of electrical installations)
•IEC/EN 60079-19 (Equipment repair, overhaul and reclamation)

Safety
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Terminal Boxes
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3.3 Residual Risks
3.3.1 Explosion Hazard
An explosion hazard cannot be entirely ruled out in hazardous areas despite the device
having a state-of-the-art design.
Perform all work steps in hazardous areas with the utmost care at all times!
Possible moments of danger (residual risks) can be categorised according to the following
causes:
Mechanical damage
The device can be pressed or scratched during transport, mounting or commissioning,
causing it to no longer be leak-tight. Such damage can, for example, render the device's
explosion protection partially or fully ineffective. This can result in explosions causing fatal or
severe injuries to persons.
Observe the weight and the maximum load-bearing capacity of the device;
see specifications on the packaging.
Transport the device only in the original packaging or in equivalent packaging.
Use transporting or lifting equipment which is suitable for the size and weight of the device
and can reliably carry the weight of the device.
Check the packaging and the device for damage. Report any damage to R. STAHL
immediately.
Store the device in the original packaging in a dry (no condensation) and stable position
which is safe from vibrations.
Do not damage the enclosure, built-in components or seals during mounting.
Excessive heating or electrostatic charge
Subsequently modifying the device, operating it outside of permitted conditions or failing to
clean it properly can cause it to heat up excessively or to become electrostatically charged,
causing it to produce sparks. This can result in explosions causing fatal or severe injuries to
persons.
Operate the device only within the prescribed operating conditions
(see the type plate and the "Technical data" chapter).
Only allow the manufacturer to paint the device and have this company coat it with special,
conductive paint.
Equip devices used outdoors in the elements with a protective roof or wall.
Regularly inspect the device for a material change (plastic). If any changes are identified,
test or replace the device.
Do not paint the device. Have all repairs performed by the manufacturer.
Comply with the area specification of EN IEC 60079-0 when fitting additional plastic
adhesive labels.
Clean the device only with a damp cloth.

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Safety
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Terminal Boxes
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Impairment of IP protection
When installed properly and completely, the device will have the required IP degree of
protection. Making structural changes to the device or mounting it improperly can impair its
IP protection. This can result in explosions causing fatal or severe injuries to persons.
Only apply labels (on the outside) without drilling any additional holes.
Only drill holes for cable glands exactly according to the instructions in the
"Product selection, project engineering and modification" and "Mounting" chapters of
these operating instructions. Consult with R: STAHL first if there are any discrepancies or
uncertainties.
Mount the device only in the prescribed mounting position. More detailed explanations of
this can be found in the "Mounting" chapter.
Improper installation, commissioning, maintenance or cleaning
Basic work such as installation, commissioning, maintenance or cleaning of the device must
be performed only in accordance with the valid national regulations of the country of use and
only by qualified persons. Otherwise the explosion protection can be rendered ineffective.
This can result in explosions causing fatal or severe injuries to persons.
Have mounting, installation, commissioning and maintenance performed only by qualified
and authorised persons (see section 3.2).
Only make changes to the device in accordance with the instructions in these operating
instructions. Have R. STAHL or a test body (3rd party inspection) carry out acceptance.
Perform maintenance and repairs on the device only using original spare parts and after
consultation with R. STAHL.
Gently clean the device only with a damp cloth and without scratching, abrasive or
aggressive cleaning agents or solutions.
Never clean the device with a strong water jet, e.g. using a high-pressure washer!
3.3.2 Risk of Injury
Falling devices or components
The heavy device or components can fall during transport and mounting, causing severe
injury to persons in the form of bruises and contusions.
Use transporting and lifting equipment suitable for the size and weight of the device when
transporting and mounting it.
Observe the weight and the maximum load-bearing capacity of the device;
see specifications on the packaging.
Use suitable mounting hardware for mounting.
Electric shock
During electric installation, operation and maintenance, there will at times be high voltages
present at the device. Persons coming into contact with electric lines carrying excessively
high voltage can suffer severe electric shocks and consequently injuries.
Operate the device only on equipment with the internal voltage specified in the
"Technical data" chapter.
Connect electric circuits only to suitable terminals.

Transport and Storage
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Terminal Boxes
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4 Transport and Storage
Transport and store the device carefully and in accordance with the safety notes
(see "Safety" section).
5 Product Selection, Project Engineering and Modification
When complying with the installation conditions and specifications on the type plate:
Check whether enough cable entries are provided. Drill additional holes if necessary;
see sections 5.1 to 5.2.
Equip terminals and, if necessary, mount built-in components; see section 5.4.
The methods mainly considered for modification are subsequently machining or equipping
the terminal box. In this case, the following possibilities are available:
• Additional through holes on the flange plate, either by R. STAHL or by the customer
(section 5.1)
• Additional through holes in the enclosure, either by R. STAHL or by the customer
(section 5.2)
• External attached components either by R. STAHL or by the customer (section 5.3)
• Internal built-in components either by R. STAHL or by the customer (section 5.4)
DANGER! Explosion due to subsequent, complete painting of the device!
Non-compliance results in fatal or severe injuries.
Do not paint the device.
Have all repairs performed by the manufacturer.
DANGER! Explosion due to defective sealing of the device!
Non-compliance results in fatal or severe injuries.
Only apply labels (on the outside) without drilling any additional holes.
Only create additional drilled holes specifically in accordance with the instructions
in the "Mounting" chapter. Consult R. STAHL in the event of deviations or
uncertainties.
Equip the enclosure only with equipment (e.g. cable entries, stopping plugs,
drain and breather valves) that is verifiably approved for use in hazardous areas.
Examples: EU Type Examination Certificate or IECEx Certificate of Conformity
Seal any unused cable entries with the stopping plugs approved for the type of
protection.
Seal all open drilled holes by means of suitable equipment.
Acceptance of work performed in-house must be carried out in accordance with national
regulations. Otherwise, you must have R. STAHL or a test body (3rd party inspection)
(section 3.3.1) carry out acceptance. On request, R. STAHL can carry out this work if
offered appropriate remuneration. If the work is carried out by R. STAHL, no additional
acceptance is necessary.

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Product Selection, Project Engineering and Modification
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Terminal Boxes
Series 8146/1, Series 8146/2
5.1 Additional Through Holes in Flange Plates
5.1.1 Creation of Additional Drilled Holes and Through Holes by R. STAHL
Forward the following information to R. STAHL:
-Type
- Data sheet
- Quantity, manufacturers and approvals of the components that are to be installed.
R. STAHL
• will check whether the components, drilled hole diameters, quantity and position
correspond with the approval
• will create the drilled holes and through holes
• will mount the components
• will update the order documentation
• will carry out a routine test
• will, if necessary, fit a new type plate if the technical data has changed,
e.g. due to the components that are to be additionally installed.
5.1.2 Ascertaining the usable Area for Cable Entries in Flange Plates
All dimensions in mm [inches]
18495E00
Collision frame and earth connection of flange plate
Select a space/area for the cable entry on the flange plate anywhere inside the collision
frame (see thin line in figure). Ensure that screw connections made later do not go beyond
this collision frame.
Observe the following conditions when doing so:
Leave enough distance to the circumferential seal (min. 3 mm)
(see detail in figure).
312[0, ]
312[0, ]

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Terminal Boxes
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5.1.3 Creation of Additional Drilled Holes and Through Holes by the Customer
Modify the device carefully and only in accordance with the safety notes
(see "Safety" section).
Calculate the usable area, see section 5.1.2.
Create additional through holes by lasing or punching (drilling, hole cutting).
When punching and cutting, make sure that the outer surfaces of the enclosure remain flat
and undamaged (without cracks).
Determine the core hole diameter for threads. Do not use an NPT thread!
When determining the through holes, observe the mounting distances.
Adjust the hole diameters to the dimensions of the built-in parts or their seals.
ONLY use built-in components with flat seal (gasket).
Observe section 5.3 when subsequently equipping components!
5.2 Additional Through Holes in the Enclosure with an internal Brass or Flange Plate
5.2.1 Creation of Additional Drilled Holes and Through Holes by R. STAHL
Give the following information to R. STAHL:
-Enclosure side
-Type
- Data sheet
- Quantity, manufacturers and approvals of the components that are to be installed.
R. STAHL
• will check whether the components, drilled hole diameters, quantity and position
correspond with the approval
• will create the drilled holes and through holes
• will mount the components
• will update the order documentation
• will carry out a routine test
• will, if necessary, fit a new type plate if the technical data has changed,
e.g. due to the components that are to be additionally installed.
Terminal boxes which the customer wants delivered without drilled holes are generally
marked as empty enclosures with the corresponding type plate (marking in accordance
with EN IEC 60079-7 and EN IEC 60079-0, as incomplete equipment "U" inside the
enclosure).