installation, operating & maintenance sheet

Installation, Operating & Maintenance Sheet

Terminal Boxes for I.S. Circuits

> 8150/2

Contents

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Terminal Boxes for I.S. Circuits8150/2

1 Contents

1 Contents ................................................................................................................22 General Information ...............................................................................................23 Application .............................................................................................................24 Safety Instructions .................................................................................................35 Technical Data ......................................................................................................46 Transport and Storage ..........................................................................................47 Installation ..............................................................................................................48 Wiring ....................................................................................................................69 Commissioning ......................................................................................................710 Maintenance...........................................................................................................711 Accessories and Spare Parts ................................................................................712 Disposal .................................................................................................................8

2 General Information

2.1 ManufacturerR. STAHL, INC.9001 Knight RoadHouston, TX 77054

Tel.: +1 800 782 4357Fax: +1 713 792 9301Internet: www.rstahl.com

2.2 Information regarding this Installation, Operation and Maintenance Sheet ID-No.: 212728 / 815060300180Publication Code: 2011-11-18·IO00·III·en·01Subject to alterations.

2.3 DisclaimerThe 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.

212728 / 8150603001802011-11-18·IO00·III·en·01

Safety Instructions

3Terminal Boxes for I.S. Circuits8150/2

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 hardwareThe following entry hardware can be used to insert cables and conduits into enclosures:

X increased safety „e“ conduit hubs Series 8166/11-0.-NE (see section 11.1) orX for 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 holesIf 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.

WARNINGInstallation 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 mountingMounting brackets are provided with the enclosures which will accept up to 1/4″ (6 mm ) screws.

7.2 Opening the enclosureFully loosen the cover screws using a screwdriver. Do not remove the captive screws from the cover.

7.3 Electrical installationThere 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

WARNINGThe enclosures should not be powder coated in the field because this would change the surface resistance.

WARNINGFor 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


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 AWGOne 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 terminalsIt 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 coverBefore 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

212728 / 8150603001802011-11-18·IO00·III·en·01

Commissioning


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 CleaningUse only a solvent-free household detergent added to the cleaning water.

10.2 Repairs and maintenanceOnly authorized and trained personnel should perform repairs and maintenance work on hazardous location equipment.

The following details must be checked during maintenance:

X Cables are held securely in place by the entry hardware.X Damage to the enclosure, cover gaskets and terminals.

11 Accessories and Spare Parts

11.1 Conduit hub with „Increased Safety“ ground terminal

WARNINGAll 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.: (800) 782-4357 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 10510 29 5715 21 4220 9 21 4725 11 2430 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.




16 14 12 10 8 6 4510 32 6415 24 4820 11 24 5325 13 2730 17 3835 10 2440 17 4445 11 2850 7 2060 11 3065 8 2070 17

Enclosure 8150/1-0176-0176-091…

Current Amps

Wire size AWG










16 14 12 10 8 6 4510 34 6815 26 5120 11 25 5625 14 2930 18 4035 11 2540 18 4745 12 2950 8 2160 12 3265 9 2470 18

Enclosure 8150/1-0236-0176-091…

Current Amps

Wire size AWG










16 14 12 10 8 6 4510 45 8915 34 6720 15 33 7425 18 3830 24 5335 15 3340 23 6245 16 3850 11 2860 16 4265 11 3170 24

Enclosure 8150/1-0236-0176-150…

Current Amps

Wire size AWG









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 8150/1-0300-0200-150... Enclosure size in mm (inches), W x H x D: 300 x 200 x 150 (11.8 x 7.9 x 5.9)

16 14 12 10 8 6 4510 48 9515 36 7120 16 35 7925 19 4030 25 5735 16 3640 25 6645 17 4150 11 3060 17 4565 12 3370 26

Enclosure 8150/1-0300-0200-150…

Current Amps

Wire size AWG









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 8150/1-0360-0176-091... Enclosure size in mm (inches), W x H x D: 360 x 176.5 x 91 (14.2 x 6.9 x 3.6)

16 14 12 10 8 6 4 3 2 1510 36 7115 27 5320 12 26 5925 14 3030 19 4235 11 2740 18 4945 13 3150 8 2260 12 3365 9 25 6270 19 3580 12 20 4285 10 16 3090 13 23

100 9 16 29110 11 19115 9 16125 12

Enclosure 8150/1-0360-0176-091…

Current Amps

Wire size AWG









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 8150/1-0360-0176-150... Enclosure size in mm (inches), W x H x D: 360 x 176.5 x 150 (14.2 x 6.9 x 5.9)

16 14 12 10 8 6 4 3 2 1 1/0 2/0510 46 9115 35 6820 15 34 7525 18 3930 24 5435 15 3440 24 6345 16 3950 11 2860 16 4365 12 32 8070 25 4480 16 26 5485 12 21 3890 17 30

100 11 20 38110 14 25 84115 12 21 44125 15 28150 13 25175 13

Enclosure 8150/1-0360-0176-150…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1510 49 9815 37 7320 17 36 8025 20 4130 26 5835 16 3740 25 6745 17 4250 12 3060 17 4665 12 34 8570 27 4780 17 28 5885 13 23 4190 19 32

100 12 22 40110 15 27115 12 22125 16

Current Amps

Enclosure 8150/1-0360-0360-091…Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250510 60 11915 45 8920 20 44 9825 24 5030 31 7135 19 4540 31 8245 21 5150 14 3760 21 5665 15 42 10470 32 5880 21 34 7085 16 28 5090 23 39

100 15 26 49110 18 33 109115 15 27 58125 20 37150 17 33175 16 34200 18 40225 21 40

Enclosure 8150/1-0360-0360-150…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250510 68 13315 51 10020 23 49 11025 27 5730 35 7935 22 5040 35 9245 24 5750 16 4260 23 6365 17 47 11770 36 6580 23 38 7985 18 31 5690 25 44

100 17 30 55110 21 37 123115 17 31 65125 22 41150 19 37175 19 38200 20 45225 24 45

Enclosure 8150/1-0360-0360-190…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250510 75 14815 56 11020 25 54 12225 30 6330 39 8835 24 5640 38 10245 27 6450 18 4660 26 7065 19 52 12970 40 7280 26 43 8785 20 35 6290 28 49

100 19 33 62110 23 41 136115 19 34 72125 25 46150 21 41175 21 42200 22 50225 26 50

Enclosure 8150/1-0360-0360-230…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1510 58 11515 43 8620 20 42 9525 23 4930 30 6835 19 4340 30 7945 21 4950 14 3660 20 5465 15 40 10070 31 5680 20 33 6885 16 27 4890 22 38

100 14 25 48110 18 31115 15 26125 19

Enclosure 8150/1-0400-0300-150…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250510 73 14315 54 10720 25 53 11825 29 6130 38 8535 24 5440 37 9945 26 6250 17 4560 25 6865 19 50 12570 39 7080 25 41 8585 20 34 6090 27 47

100 18 32 60110 22 39 132115 18 33 70125 24 44150 21 40175 20 40200 21 48225 25 49

Current Amps

Enclosure 8150/1-0400-0300-230…Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250510 64 12615 48 9420 22 46 10425 26 5330 33 7535 21 4740 33 8745 23 5450 15 3960 22 5965 16 44 11070 34 6180 22 36 7585 17 29 5390 24 41

100 16 28 52110 19 35 116115 16 29 61125 21 39150 18 35175 17 36200 19 42225 22 43

Enclosure 8150/1-0400-0400-150…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250510 79 15515 59 11620 27 57 12825 31 6630 41 9235 26 5840 40 10745 28 6750 19 4860 27 7365 20 54 13670 42 7680 27 45 9285 21 36 6590 30 51

100 20 35 65110 24 43 143115 20 36 76125 26 48150 22 43175 22 44200 23 52225 27 53

Enclosure 8150/1-0400-0400-230…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 400 500 600510 70 13815 52 10320 24 51 11425 28 5830 37 8235 23 5240 36 9545 25 5950 17 4360 24 6565 18 48 12070 38 6780 24 40 8285 19 32 5890 26 45

100 17 31 57110 21 38 127115 18 32 67125 23 42150 20 38175 19 39200 21 46225 24 47250 25 62300350380 38400

Enclosure 8150/1-0400-0600-150…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 400 500 600510 84 16615 63 12420 29 61 13725 34 7130 44 9935 27 6240 43 11545 30 7250 20 5260 29 7865 22 58 14570 46 8180 29 48 9885 23 39 6990 32 55

100 21 37 69110 26 46 153115 21 38 81125 28 51150 24 46175 23 47200 25 56225 29 56250 30 75300350380 46400

Enclosure 8150/1-0400-0600-230…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250510 80 15815 60 11820 27 58 13025 32 6730 42 9435 26 5940 41 10945 29 6850 19 4960 28 7565 20 55 13870 43 7780 28 46 9485 22 37 6690 30 52

100 20 35 66110 25 43 145115 20 37 77125 26 49150 23 44175 22 45200 24 53225 28 54

Enclosure 8150/1-0550-0360-230…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 400 500 600510 70 13815 52 10320 24 51 11425 28 5830 37 8235 23 5240 36 9545 25 5950 17 4360 24 6565 18 48 12070 38 6780 24 40 8285 19 32 5890 26 45

100 17 31 57110 21 38 127115 18 32 67125 23 42150 20 38175 19 39200 21 46225 24 47250 25 62300350380 38400

Enclosure 8150/1-0600-0400-150…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 400 500 600510 84 16615 63 12420 29 61 13725 34 7130 44 9935 27 6240 43 11545 30 7250 20 5260 29 7865 22 58 14570 46 8180 29 48 9885 23 39 6990 32 55

100 21 37 69110 26 46 153115 21 38 81125 28 51150 24 46175 23 47200 25 56225 29 56250 30 75300350380 46400

Enclosure 8150/1-0600-0400-230…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0510 82 16215 62 12120 28 60 13425 33 6930 43 9635 27 6140 42 11245 29 7050 20 5160 29 7765 21 57 14270 44 7980 28 47 9685 22 38 6890 31 53

100 21 36 68110 25 45 149115 21 38 79125 27 50150 23175200225250300350380400

Wire size AWGEnclosure 8150/1-0600-0600-150…

Current Amps










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 400 500 600510 97 19115 73 14320 33 71 15825 39 8130 51 11435 32 7240 50 13245 35 8250 23 6060 34 9065 25 67 16770 52 9380 33 55 11385 26 45 8090 37 63

100 24 43 80110 30 53 176115 25 44 93125 32 59150 28 53175 27 54200 29 64225 34 65250 35 86300350380 53400

Enclosure 8150/1-0600-0600-230…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0510 57 11315 43 8420 19 42 9325 23 4830 30 6735 19 4240 29 7845 20 4950 13 3560 20 5365 15 40 9970 31 5580 20 33 6785 15 26 4790 22 37

100 14 25 47110 17 31 104115 14 26 55125 19 35150 16

Enclosure 8150/1-0727-0360-091…

Current Amps

Wire size AWG









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 8150/1-0727-0360-150... Enclosure size in mm (inches), W x H x D: 727x 360 x 150 (28.6 x 14.2 x 5.9)

16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 400 500 600510 68 13415 51 10020 23 49 11025 27 5730 35 7935 22 5040 35 9245 24 5750 16 4260 23 6365 17 47 11770 36 6580 23 38 7985 18 31 5690 26 44

100 17 30 56110 21 37 123115 17 31 65125 22 41150 19 37175 19 38200 20 45225 24 45250 24 60300350380 37400

Enclosure 8150/1-0727-0360-150…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 400 500 600510 75 14715 56 11020 25 54 12125 30 6230 39 8735 24 5540 38 10145 27 6350 18 4660 26 6965 19 52 12970 40 7280 26 42 8785 20 34 6190 28 48

100 19 33 61110 23 40 135115 19 34 72125 25 45150 21 41175 20 42200 22 49225 26 50250 27 66300350380 41400

Enclosure 8150/1-0727-0360-190…

Current Amps

Wire size AWG










16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 400 500 600510 94 18515 70 13820 32 68 15325 38 7930 49 11035 31 7040 48 12845 34 8050 22 5860 33 8765 24 65 16270 51 9080 32 54 11085 26 43 7790 36 61

100 24 41 77110 29 51 171115 24 43 90125 31 57150 27 51175 26 52200 28 62225 33 63250 34 84300350380 52400

Enclosure 8150/1-0787-0480-230…

Current Amps

Wire size AWG







installation, operating & maintenance sheet

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