SynergEX Panelboards. Installation & Maintenance Information IF Panelboards for Hazardous Locations SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

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1 SynergEX Panelboards Panelboards for Hazardous Locations Installation & Maintenance Information IF 1659 SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE CAUTION Read these operating instructions and all other information sheets before wiring and use (300mm) Do not alter this product in any way. Doing so may lead to serious injury or death. To avoid dangerous overheating, do not use aluminum wiring. Use copper wire only (950mm) To avoid electrical shock, electrical power must be OFF before and during installation, inspection, and maintenance. Observe the national safety rules and regulations (775mm) TABLE OF CONTENTS Dimensional Drawings: SynergEX Panelboards Breakers Circuit (300mm) 1. Technical Data Complete Distribution Technical Data Busbar System Busbar System Connectors Rated Current of Connectors/Wires Clearance and Creepage Dimensions of Busbar System Connection Busbar System Hazardous Location Technical Data for Breakers Mechanical Data /480V Circuit Breakers /240V Circuit Breakers Aux./Signal Contact Safety Instructions Conformity with Standards Field of Application Application/Properties Installation Transport/Storage Before Installation Transport Mounting/Installation Opening SynergEX Panelboards Electrical Connection General Busbar System Electrical Connection Busbar System Busbar Connectors Cable Entries, Blanking Plugs Drilling for Additional Cable Entries Flanges, Metal Plates, and External Earth Connection Closing Apparatus Putting Into Operation Maintenance/Servicing Repairs/Modifications Disposal/Recycling Dimensional Drawings, Breakers Tripping Characteristic Derating Table for Breakers Certificate of Conformity enclosed separately. 24 Circuit 42 Circuit (950mm) (950mm) (1900mm) (1280mm) (300mm) (1600mm) (1100mm) (300mm) 60 Circuit Figure 1. Dimension Drawings IF /13 Copyright 2013, Cooper Industries, Inc. Page 1

2 1. TECHNICAL DATA 1.1 Complete Distribution Master Contract Explosion Category: -20 C or -20 C to -40 C with heater For USL AEx de IIC T4 For CNL Ex de IIC T4; Ex tb IIIC T100 C Db Certifications and Compliances: Class I, Zones 1 & 2 For USL Zone 1 & 2 For CNL Rated Voltage to 600VAC / 60 Hz 1.2 Technical Data Busbar System Class I, Division 2, Groups A, B, C, D; Class II, Division 1, Groups E, F, G Class I, Division 2, Groups A, B, C, D; Class II, Division 1, Groups E, F, G, Extb IIIC T100 C Db Rated Current Max. 225A Up to 40 C 40 C to 55 C Size A (12 cct) up to 100A up to 85A Size B (24 cct) up to 150A up to 125A Size C (42 cct) up to 225A up to 190A Size D (60 cct) up to 225A up to 190A Ambient Temperature -40 C to +55 C (varies with configuration) Perm. Storage Temperature in Original Packing -40 C to +55 C Degree of Protection to EN/IEC IP66 (standard version); Type 4X Insulation Class to EN/IEC I Maximum Number of Breakers (Single Pole) Size A 12 Size B 24 Size C 42 Size D 60 Connectors Quantity - acc. to number of breakers (poles) Cable Entries Acc. to customer s specification and as certified Terminal Cross-section Max. AWG 4/0 / 120mm 2 Incoming Wires 75 C Outgoing Wires 75 C Enclosure Material Stainless steel -20 C to -40 C without heater AEx de IIB T4 Ex de IIB T4; Ex tb IIIC T100 C Db Busbar Rail System Rated Voltage Rated Current Rated Short Time Current Rated Short Circuit Current Support Spacing for Is to 10kA Test Torques: Fixing Screws Busbar System 1 x 12mm x 5mm 600V / 60 Hz 225A (40 C) 4kA 10kA 300mm 2.5 N-m Figure 2. Connectors Busbar System Connectors (phase X/Y/Z, neutral N, ground ) Cross Section/AWG Solid Stranded Number of d/ a/ b/ c/ Test Torque/ Connectors Min. Max. Min. Max. Connectors mm / inch mm / inch mm / inch mm / inch N-m grck / / / / grck / / / / grck / / / / grck / / / / / grck / / / / / IF /13 Copyright 2013, Cooper Industries, Inc. Page 2

3 1.2.2 Rated Current of Connectors/Wires Ambient Temperature Range Rated Current of Busbar 40 C 225A Cross-section of Cables Max. Rated Current of Connecting Cables /0 4/0 15A 20A 30A 40A 50A 60A 100A 150A 225A Clearance and Creepage Dimensions of Busbar System 120V/240V 277V/480V Minimum Spacing Through Air A between phases >= 19.0mm >= 25.0mm Minimum Spacing Through Air B between phases and ground >= 12.5mm >= 12.5mm Minimum Spacing Over Surface C between opposition phases >= 31.0mm >= 50.0mm Minimum Spacing Over Surface D between phases and ground >= 31.0mm >= 50.0mm Cross Section / AWG Connectors Stranded Min. Max. Stripping Length grck grck grck grck /0 22 grck /0 25 Figure 3. Stripping Length Connection Busbar System 1 Phase 120/240V 3 Phase 277/480V IF /13 Copyright 2013, Cooper Industries, Inc. Page 3

4 1.3 Hazardous Location Technical Data for Breakers Master Contract Explosion Category: For USL AEx de IIB/IIC For CNL Ex de IIB/IIC Certifications and Compliances: Class I, Zone 1 For USL Class I, Division 2, Groups A, B, C, D Zone 1 For CNL Class I, Division 2, Groups A, B, C, D Ambient Temperature Range: IIC: -20 C to +55 C (GHG62-1/2/3/4...R...) IIB: -45 C to +55 C (GHG62-1/2...R...) Permissible Service Temperature Range: IIC: -20 C to +110 C (GHG62-1/2/3/4...R...) IIB: -45 C to +110 C (GHG62-1/2...R...) Other temperatures possible with special versions. Perm. Ambient Temperature in Original Packing -45 C to 60 C Figure 4. Contact Arrangement/ Circuit Breaker Mechanical Data Terminal Cross Section: Stripping Length Main Terminal Module Size 1-3 Current 15A or less AWG 14 11mm / A AWG 12 11mm / A AWG 10 11mm / A AWG 10 11mm / A AWG 8 11mm / 0.4 Aux. Terminals AWG 14 11mm / 0.4 Quantity Terminals for the Module Size: Main Terminals Aux. Terminals Test Torques: Main Contacts 3.5 N-m Aux. Contacts 1.0 N-m Mounting Screws 2.5 N-m Enclosure Material Polyamide /480V Circuit Breakers Figure 5. Contact Arrangement/ Additional Devices Rated Voltage Main contact to 277/480VAC; 60 Hz Rated Current Main contact 10A-40A Types 1-pole GHG R... 2-pole GHG R... 3-pole GHG R... Rated Switching Capacity 10kA Non-ambient Compensated Temperature 25 C Component Size Weight ca kg 0.90 kg 1.20 kg 1-pole* 2-pole* 3-pole* Tripping characteristic of circuit breaker, see last page. *Circuit breakers with additional devices are built into larger component enclosures /240V Circuit Breakers Rated Voltage Main contact to 120/240VAC; 60 Hz Rated Current Main contact 10A to 40A Types 1-pole GHG R... 2-pole GHG R... Rated Switching Capacity 10kA Non-ambient Compensated Temperature 40 C Component Size 1 2 Weight ca kg 1.20 kg 1-pole* 2-pole* Tripping characteristic of circuit breaker, see last page. *Circuit breakers with additional devices are built into larger component enclosures in bigger size Aux./Signal Contact The technical data relates to standard built-in apparatus. If other built-in apparatus is used, the technical data sheets or the data on the type label shall be observed. Rated Voltage to 230VAC 277VAC 480VAC Rated Current 2A 2A 1A Minimum Switching Capacity 5 ma at 24V IF /13 Copyright 2013, Cooper Industries, Inc. Page 4

5 2. SAFETY INSTRUCTIONS For installation only by a qualified electrician in accordance with the National Electric Code, the Canadian Electric Code, applicable local codes, and these instructions. SynergEX Panelboards are not suitable for Zone 0 or Zone 20 hazardous areas. The temperature class and explosion group marked on the distributions shall be observed. The permissible ambient temperature, the terminal cross-section, and the self-heating of the apparatus, which is mainly caused by the power dissipation, are to be observed to ensure that the temperature class stated on the type label of the apparatus is maintained. (Test criterion for the selfheating is an overload of 10%). The apparatus shall be used for the intended purpose and shall be in a perfect and clean state. Check to see that the rating label on the device is correct for the installation. Only original parts from the manufacturer may be used as replacements and for repairs. Repairs that affect the explosion protection may only be carried out by Cooper Crouse-Hinds / CEAG or by a qualified electrician in compliance with the respective national regulations. Modifications to the distributions or design changes are not permitted. Prior to being put into operation, the distributions shall be checked in accordance with the instructions given in Section 6. Before initial operation, any foreign matter shall be removed from the distribution enclosures. Before opening the enclosure dead front, it is necessary to ensure that the distributions are isolated from the voltage supply or take the appropriate protective measures. The minimum terminal cross-sections of the flameproof components shall be observed during connection in accordance with CSA C22.2 No. 29 / UL67. Maximum continuous load on all circuit breakers (including main and subfeeder breakers) not to exceed 80% of rating. The national safety rules and regulations for the prevention of accidents, as well as the safety instructions included in these operating instructions, shall be observed. 3. CONFORMITY WITH STANDARDS SynergEX Panelboards have been designed, manufactured, and tested according to the following standards: CSA C CSA C (R2003) CSA C CSA C CSA C22.2 No M85 CSA C22.2 No CSA C22.2 No. 213-M1987 CAN/CSA C22.2 No :11 CAN/CSA C22.2 No : 11 CAN/CSA C22.2 No :12 CAN/CSA C22.2 No :12 4. FIELD OF APPLICATION ANSI/ISA ( ): 2009 ANSI/ISA ( ): 2009 ANSI/ISA ( ): 2008 ANSI/ISA ( ): 2009 UL67, 12 th Ed., 2009 UL50, 12 th Ed., 2007 UL50E, 1 st Ed., 2007 The distributions are suitable for use in hazardous areas in Class I, Division 2; Class II, Division 1; Zone 1; Zone 2; Zone 21; or Zone 22 in accordance with IEC , CAN/CSA The materials used for the enclosures, including the exterior metal parts, are high quality materials that ensure an appropriate corrosion protection and resistance to chemical substances according to the requirements for use in a normal industrial atmosphere : - Stainless steel AISI 316L - Stainless steel AISI Safety glass In case of use in an extremely aggressive atmosphere, please refer to manufacturer. 5. APPLICATION/PROPERTIES SynergEX Panelboards are used for distributing electric power (e.g. main, lighting, heating, control and intrinsically safe circuits, etc.). (See Technical Data for temperature classes, explosion groups, and permissible ambient temperatures). The function of MCB circuit breakers and ELCBs (RCDs) with circuit breakers shall be checked after several short circuits. An ELCB (RCD) does not prevent the sensation caused by an electric shock, but it limits the duration of the current flow through the human body to such a short time that the probability of a fatal effect is reduced to a negligible amount. Once the cause for the tripping of the ELCB (RCD) has been eliminated, it is reset by switching the toggle to the ON position. Details of the electric contacts are given on the base of the component or in these operating instructions. If not specified in these operating instructions, information on the safe use of third-party products shall be requested from the respective manufacturer of the equipment. 6. INSTALLATION The relevant national regulations and the generally recognized rules of engineering apply for the installation and operation. 6.1 Transport/Storage Before Installation SynergEX Panelboards shall be inspected on receipt to verify that they are complete and undamaged. If the delivery is not complete, an inventory shall be drawn up immediately together with the transport company. Any damages shall be documented accordingly. To store, SynergEX Panelboards shall be placed on a clean, dry, and flat surface, whereby the position shall be maintained. SynergEX Panelboards shall be protected against adverse weather conditions Transport To transport SynergEX Panelboards, use the suitable transport aids that are put at your disposal. Depending on the size of the SynergEX Panelboards, a transport beam might have to be used. 6.2 Mounting/Installation The data according to Sections 3 and 4 shall be taken into account during use. Applications other than those described are not permissible without a written declaration of consent from the manufacturer. During operation, the instructions stated in Section 7 of the operating instructions shall be observed. These operating instructions also apply as instructions for the replacement or addition to individual flameproof components. The sole responsibility with respect to the suitable and proper use of these panels lies with the operator. The mounting and installation of SynergEX Panelboards must only be carried out by skilled electricians. SynergEX Panelboards can be mounted without opening the cover. When SynergEX Panelboards are mounted directly onto the wall, they shall rest evenly only on the fastening points provided for this purpose, and they shall be fixed in such a way that they cannot twist or turn. The screws used shall match the fixing holes (see dimension drawings) and must not damage the openings (e.g. use of washers). All fixing points shall be used when screwing SynergEX Panelboards to the wall or floor. Excessive tightening can result in damage to SynergEX Panelboards. IF /13 Copyright 2013, Cooper Industries, Inc. Page 5

6 SynergEX Panelboards must not be left near heat sources. The correct position of the openings for power supply access must be checked before installation. The connections for the incoming and outgoing leads of the busbar systems shall be fitted in such a way that the current load of the copper rails is distributed evenly. 6.3 Opening SynergEX Panelboards Use the relevant key for the locking device (see Figure 6). To maintain the explosion protection, conductors shall be connected with special care. The insulation shall reach to the terminal (see Figure 8). The conductor itself must not be damaged. Cross Section / AWG Connectors Stranded Min. Max. Stripping Length grck grck grck grck /0 22 grck /0 25 Figure 8. Stripping Length The minimum and maximum connectable conductor cross-sections are to be observed. All screws and/or nuts of the connection terminals, including those not in use, shall be tightened down securely. The circuit diagram for the built-in components is either shown on the components, or in the operating instructions. In the case of wired SynergEX Panelboards, the connection diagram included with the apparatus is to be observed. Figure 6. Locking Devices If a flameproof component is disassembled before it is connected to the electric power supply, it is necessary to ensure that the components are put back into the distribution enclosure correctly. Overtightening can damage the enclosure or impair the sealing effect. After opening the lid of the SynergEX Panelboard, you can open the protective covers by unscrewing the screws (see Figure 7). Before opening the dead front in the SynergEX Panelboard, it is necessary to ensure that the SynergEX Panelboard is isolated from the voltage supply or to take suitable protective measures. 6.5 Busbar System The maximum rated current of the busbar system, specified in the Technical Data, have to be observed Electrical Connection Busbar System The electrical connection of the apparatus may only be carried out by skilled staff. In order to maintain the mode of protection, special care shall be taken when connecting the conductors. The minimum and maximum connectable conductor cross-sections are to be observed (see Table 1.2.1). Figure 7. Protective Cover, Open 6.4 Electrical Connection General The electrical connection of the apparatus may only be carried out by trained staff. The properly bared conductors of cables shall be connected with due regard to the respective regulations. The incoming and outgoing wires shall be identified as sized for 75C. IF /13 Copyright 2013, Cooper Industries, Inc. Page 6

7 6.5.2 Busbar Connectors When positioning the connectors, the required clearances D in Figure ( Connection Busbar System ) shall be observed. The possible combinations of connectors and terminal cross-sections can be seen in Table Place the connectors and wiring as shown in Figures 8 and ( Connection Busbar System ). The stripping of the cable depends on the used busbar terminal. The stripped wire should not protrude above the busbar terminal. The insulation must reach up to the terminal (see Figure 8). The busbar terminal attract at least with the test torque specified in Table Excessive tightening will damage the threads. Figure 10. High Torque Screw ø 6mm Test Torque 2.8 N-m Before putting the apparatus into operation, the tests specified in the individual national regulations shall be performed. Improper validation and operation can lead to loss of warranty. 6.6 Cable Entries (KLE); Blanking Plugs Generally only certified cable entries and blanking plugs may be used. The relevant mounting directives for the built-in cable entries shall be observed. When using cable entries for the connection to or into the apparatus, where applicable, the relevant special conditions for safe use given in the individual certificates shall be considered. In order to ensure the minimum degree of protection, any unused entry holes shall be sealed with certified blanking plugs. Overtightening can impair the degree of protection Drilling for Additional Cable Entries Additional holes for cable entries can be drilled into the metal flange. Observe the dimensions of drilling surface, shown in Figure Flanges, Metal Plates, and External Earth Connection If flange plates have to be removed, in order to maintain the minimum protection category, attention shall be paid to the proper fit of the flange plates when remounting them (see Figure 9). Figure 11. Drilling Surface of Metal Flanges Flange plates for SynergEX Panelboards shall be fitted in such a way that the IP protection is maintained. Pay attention to the proper fit of the sealing. Ground conductors fed from outside are to be connected to the ground terminal provided on the SynergEX Panelboard enclosure. The maximum cross-section is 50mm 2. Metal flanges, metal plates, and metal cable entries shall be included in the equipotential earth connection. 6.8 Closing Apparatus Any foreign matter shall be removed from the SynergEX Panelboard. To ensure the minimum protection category, the lids of SynergEX Panelboards shall be closed correctly. 6.9 Putting Into Operation Before putting SynergEX Panelboards into operation, the tests specified in the individual national regulations shall be performed. In addition to this, before being put into operation, the correct functioning of the SynergEX Panelboards and of the built-in components shall be checked in accordance with these operating instructions and other applicable regulations. The incorrect installation and operation of SynergEX Panelboards can result in the invalidation of the guarantee. Figure 9. Cable Entries/Flanges To fix the flange plates, use the high torque screws (ø 6mm, length 6mm) (see Figure 10). Please observe the respective torques given in Figure 10. IF /13 Copyright 2013, Cooper Industries, Inc. Page 7

8 7. MAINTENANCE/SERVICING The valid regulations IEC for the servicing/maintenance of electrical apparatus for use in potentially explosive atmospheres shall be observed. Prior to opening SynergEX dead front, it is necessary to ensure that the voltage supply has been isolated or to take suitable protective measures. The user is responsible for stipulating the necessary maintenance intervals specific to the application depending on the conditions of use, national directives, and standards. Should the maintenance interval for the function test of an RCD (ELCB) not be defined, the manufacturer of the RCD (ELCB) recommends testing the function by actuating the test button twice yearly. The RCD (ELCB) shall release when the test button is actuated. If this is not the case, the protective function is no longer guaranteed and the RCD (ELCB) shall be replaced. During servicing, above all, the correct working order of parts on which the explosion protection depends (e.g. intactness and efficiency of the flameproof components, the enclosure, the seals, and cable entries shall be checked). If, in the course of servicing, it is ascertained that repairs are necessary, Section 8 of these operating instructions shall be observed. 8. REPAIRS/MODIFICATIONS Only original Cooper Crouse-Hinds / CEAG parts shall be used for carrying out repairs. In the event of damage to the flameproof encapsulation, replacement of the respective components is mandatory. In case of doubt, the respective apparatus shall be sent back to the manufacturer for repair. Repairs that affect the explosion protection may only be carried out by Cooper Crouse-Hinds / CEAG or by a qualified electrician in compliance with the respective national regulations (IEC ). Ex-d components in SynergEX Panelboards may only be replaced by components of the same type (electrical ratings and mechanical size). When replacing these individual built-in components, Section 6.2 ( Opening Apparatus / Electrical Connection ) shall be observed. Apparatus modifications or design changes are not permitted; excluded from this are the fitting of additional cable entries, additional RCD (ELCB), and the installation of connection terminals within the scope of the approvals for the respective apparatus, or according to details laid down by the manufacturer. 9. DISPOSAL/RECYCLING The respective valid national regulations for waste disposal shall be observed when disposing of apparatus. To facilitate recycling of individual parts, parts made of molded plastic shall bear the marking for the type of plastic used. The product range is subject to changes and additions. IF /13 Copyright 2013, Cooper Industries, Inc. Page 8

9 10. DIMENSIONAL DRAWINGS, BREAKERS X 0.98 (25mm) X 1.69 (43mm) 0.22 (ø5.5mm) 0.22 (ø5.5mm) 1.42 (36mm) 2.13 (54mm) X 2.40 (61mm) 0.22 (5.5mm) 2.83 (72mm) X 1.69 (43mm) X 2.40 (61mm) 0.22 (5.5mm) 0.22 (5.5mm) 2.13 (54mm) 2.83 (72mm) X 3.82 (97mm) 0.22 (5.5mm) 4.25 (108mm) IF /13 Copyright 2013, Cooper Industries, Inc. Page 9

10 10.1 Tripping Characteristic of Breakers K - Characteristic 277/480V 10-25A 277/480V 30-40A 120/240V 10-40A 10.2 Derating Table for Breakers 120/240VAC Ambient Temperature T ( C) In (A) /480VAC Ambient Temperature T ( C) In (A) GHG P0001 (-) All statements, technical information and recommendations contained herein are based on information and tests we believe to be reliable. The accuracy or completeness thereof are not guaranteed. In accordance with Crouse-Hinds "Terms and Conditions of Sale," and since conditions of use are outside our control, the purchaser should determine the suitability of the product for his intended use and assumes all risk and liability whatsoever in connection therewith. Cooper Industries Inc. IF 1659 Crouse-Hinds Division Revision 1 PO Box 4999, Syracuse, New York U.S.A. New 04/13 Copyright 2013, Cooper Industries, Inc.