652560300010 03 en - r. stahl...tips and recommendations on the use of the device general danger...

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Operating instructionsAdditional languages www.stahl-ex.com

EN

Floodlight LED

Series 6525

General Information

2 Floodlight LEDSeries 6525


Contents1 General Information ............................................................................................21.1 Manufacturer .......................................................................................................21.2 Information regarding the operating instructions .................................................31.3 Conformity with standards and regulations .........................................................32 Explanation of the symbols .................................................................................32.1 Symbols in these operating instructions .............................................................32.2 Warning notes .....................................................................................................32.3 Symbols on the device ........................................................................................43 Safety notes ........................................................................................................43.1 Operating instructions storage ............................................................................43.2 Safe use ..............................................................................................................53.3 Intended Use .......................................................................................................53.4 Modifications and alterations ..............................................................................54 Function and device design ................................................................................54.1 Function ..............................................................................................................54.2 Device design .....................................................................................................65 Technical data .....................................................................................................76 Transport and storage .......................................................................................107 Mounting and installation ..................................................................................107.1 Dimensions / fastening dimensions ..................................................................107.2 Mounting / dismounting, operating position ......................................................127.3 Installation .........................................................................................................128 Commissioning .................................................................................................169 Maintenance and repair ....................................................................................179.1 Maintenance .....................................................................................................179.2 Repair ...............................................................................................................199.3 Returning the device .........................................................................................1910 Disposal ............................................................................................................2011 Accessories and Spare parts ...........................................................................20

1 General Information

1.1 Manufacturer

R. Stahl Schaltgeräte GmbHAm Bahnhof 3074638 WaldenburgGermany

R. STAHL (P) LTD., Plot No. - 5Malrosapuram Road, Sengundram Indl. AreaSingaperumal Koil, Kancheepuram Dist.,Tamil Nadu – 603 204, INDIA

Phone:Fax:Internet:E-mail:

+49 7942 943-0+49 7942 [email protected]

Phone:Fax:Internet:E-mail:

+91 44-30 600 600+91 44-30 600 [email protected]

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Explanation of the symbols

3Floodlight LEDSeries 6525


1.2 Information regarding the operating instructionsID-No.: 244627 / 652560300010Publication Code: 2017-07-13·BA00·III·en·03

The original instructions are the English edition.They are legally binding in all legal affairs.

1.3 Conformity with standards and regulationsSee certificates and EU Declaration of Conformity: www.stahl-ex.com.The device has IECEx approval. See IECEx homepage: http://iecex.iec.ch/Further national certificates can be downloaded via the following link: http://www.r-stahl.com/downloads/certificates.html.

2 Explanation of the symbols

2.1 Symbols in these operating instructions

2.2 Warning notesWarnings 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

Risk of damage to the eyes caused by optical radiation

Safety notes

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Floodlight LEDSeries 6525


2.3 Symbols on the device

3 Safety notes

3.1 Operating instructions storage• Read the operating instructions carefully.• Store the operating instructions at the mounting location of the device.• Observe applicable documents and operating instructions of the devices to be

connected.

DANGERDanger to personsNon-compliance with the instruction results in severe or fatal injuries to persons.

WARNINGDanger to personsNon-compliance with the instruction can result in severe or fatal injuries to persons.

CAUTIONDanger to personsNon-compliance with the instruction can result in light injuries to persons.

NOTICEAvoiding material damageNon-compliance with the instruction can result in material damage to the device and / or its environment.

Symbol Meaning

05594E00

CE marking according to the currently applicable directive.

02198E00

According to marking, device approved for hazardous areas.

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Function and device design



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 UseThe LED floodlight 6525 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

4 Function and device design

4.1 Function• for lighting areas, work spaces and objects

DANGERExplosion hazard due to modifications and alterations to the device! Non-compliance results in severe or fatal injuries.

• Do not modify or alter the device.

DANGERExplosion hazard due to improper use!Non-compliance results in severe or fatal injuries.

• Use the device only in accordance with the operating conditions described in these operating instructions.

• Use the device only for the intended purpose specified in these operating instructions.

Function and device design

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4.2 Device design

17562E00

1 - Mounting bracket 7 - Seal2 - Enclosure cover 8 - Luminaire glass cover3 - LED-Driver 1 9 - Mounting screws4 - LEDs 10 - LED-Driver 2 (only for 210 W version)5 - Luminaire enclosure 11 - Cable glands6 - Heat sink (only for 210 W version) 12 - Connection terminal

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Technical data



5 Technical data

Explosion ProtectionGlobal (IECEx)

Gas and dust IECEx EPS 15.0032Ex nR op is IIC T6 ... T5 GcEx tb IIIC T80°C ... T95°C Db

Europe (ATEX)Gas and dust EPS 15 ATEX 1 991

E II 3 G Ex nR op is IIC T6 ... T5 GcE II 2D Ex tb IIIC T80°C ... T95°C Db

Certifications and certificatesCertificates IECEx, ATEX, India (PESO)

Technical DataElectrical data

Electronic balastRated voltage 220 ... 240 V, 50/60 HzVoltage range 198 ... 264 V, 50/60 HzCurrent consumption

Inrush current

Power factor > 0.95

at ambient temperature Temperature class6525/11..-....-....-... -50 °C < Tamb < +55 °C T5 / T95 °C

6525/11..-21..-....-... -50 °C < Tamb < +50 °C T6 / T80 °C

6525/11..-42..-....-... -50 °C < Tamb < +45 °C T6 / T80 °C

6525/11..-2: 0.54 A6525/11..-4: 0.94 A

6525/11..-21(120 W Version)

6525/11..-42(210 W Version)

Ipeak (measured at 50 % Ipeak)

58 A; ãt = 360 ms 116 A; ãt = 360 ms

max. light fittings per circuit breakerType B 10 A 4 2Type B 16 A 9 4Type B 25 A 20 10

Technical data

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THD ≤ 10 %Luminous characteristics

Values apply to Ta = +25 °C.

Decrease of luminous flux at Ta

19597E00

Ambient conditionsOperating temperature range

-50 ... +55 °C*

* Note: Possible to operate the luminaire at -50°C, provided the luminaire is switched on at -30°C.

Storage temperature -30 ... +75 °C

Technical Data

6525/11..-2 6525/11..-4Power consumption [W] 120 210Colour rendering [CRI] ) 70 ) 70

Colour temperature [K] 5,700 5,700wide beamLuminous flux [lm] 12,860 21,026Luminaire efficiency [lm/W] 107 100medium beamLuminous flux [lm] 11,155 18,361Luminaire efficiency [lm/W] 94 88narrow beamLuminous flux [lm] 12,081 19,979Luminaire efficiency [lm/W] 101 96

100 %

85 %

70 %

55 %

40 %

25 %30 °C 35 °C 40 °C 45 °C 50 °C 55 °C 60 °C

115 %

120 W Version

210 W Version

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Technical data



Alternative material:Enclosure:• stainless steel SS304 (1.4301 or V2A) single powder-coated• stainless steel SS316L (1.4404 or V4A) without powder coatingBracket:• stainless steel SS304 (1.4301 or V2A) without powder-coated

Service life

Mechanical dataDegree of protection IP66Protection class I (with internal PE connection)Impact strength (IK code)

IK10 (IEC 62262)

MaterialEnclosure

Colour Colour white, similar to RAL 9010Seal Foamed silicone in luminaire coverLamp cover Toughened glassBracket Sheet steel, single powder-coated

orStainless steel SS316L (1.4404 or V4A) without powder coating

Luminaire locking Screw Mounting / Installation

Cable entry 1x cable glands Series 81611x cable glands Series 8161 with red stopping plug1x stopping plugs Series 8290

Connection

Loop in/loop out max. 12 A

Technical Data

Ta ( 40 °C Ta at 45 °C Ta at 55 °C

L70B10C10 100,000 h 80,000 h 60,000 h

LxByCz

At the end of the service life:- Luminous flux decreases by “x” percent.- up to "y" percent of all luminaires fall below "x"- up to "z" percent of all luminaires break down completely

6525/....-....-....-.11 Sheet steel, powder-coated6525/....-....-....-.42 Stainless steel SS316L (1.4404 or V4A), with double

powder coating (offshore coating)

Standard: Spring clamp terminals 0.5 ... 4 mm2 solid / strandedStripping length: 10 ... 11 mm

Optional: Spring clamp terminals 0.5 ... 6 mm2 solid / strandedStripping length: 13 ... 15 mm

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.

7 Mounting and installation

7.1 Dimensions / fastening dimensions

DANGERExplosion 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

17559E00

17560E00

Floodlight Series 6525with cooling element(Version 210 W)

Floodlight Series 6525without cooling element(Version 120 W)

400 15,75[ ]

600

23,6

2[

]

89,50 3,52[ ]

131,90 5,19[ ] 400 15,75[ ]

60

0

23

,62

[]

89,50 3,52[ ]

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Mounting and installation



17561E00

Mounting bracket

18258E00 18257EE00

Floodlight Series 6525 with ring boltswith cooling element(Version 210 W)

Floodlight Series 6525 with ring boltswithout cooling element(Version 120 W)

Dimensional Drawings (All Dimensions in mm [inches]) - Subject to Alterations

60

[2,3

6]

3 x 13Ø

[3 x 0,51]Ø

405 [15,94]

380 [14,9

6]

445 [17,52]

250[9,84]

20 [0,79]

3 [0,1

2]

R 20 [R 0,79]

363 [14,2

9]

363 [1,3

8]

8,50Ø

[Ø 0,33]

13 x 8,50Ø

[13 x 0,33]Ø


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7.2 Mounting / dismounting, operating position

• suitable for use indoors and outdoors• designed for wall, ceiling, pole mounting with bracket• max torque value between bracket and floodlight 10 Nm• pendant mounting using ring eyes (M6).

7.3 Installation

7.3.1 Opening and Closing of the Enclosure

DANGERExplosion 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).

CAUTIONRisk of damage to the eyes caused by optical radiation!Minor injuries are possible!

• The minimum distance for the narrow beam version between the luminaire and the viewer's eyes must be 8.23 m.

DANGERRisk of electric shock due to improper opening!Non-compliance results in severe or fatal injuries.

• Open luminaires without switch only in de-energized state (see information plate on the lock)!

NOTICEDanger due to electrostatic discharge.Electronic components can be destroyed if touched.

• Do not touch the LED-PCBs!

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Opening the luminaire• (1) loosen the four mounting screws.• (2) carefully open the enclosure cover.• (3) open the enclosure cover fully.

Closing the luminaire• (4) liften the enclosure cover.• (5) carefully close the enclosure cover.• (6) securely tighten the four screws (torque value 5 Nm).

17990E00

17991E00

3

4

5

6


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7.3.2 Cable entries

Cable glands and stopping plugs must be approved for the following types of protection:a) restricted breathing (nR) and dust (IIIC)b) increased safety (e)

Please observe the following, if cable glands and stopping plugs are used, but not provided by R. STAHL Schaltgeräte GmbH:• Permissible cable diameter range, torques, temperature range of use• IP level of protection, at least IP 65 or according to details on rating plate• Operating instructions of the cable glands and stopping plugsadditionally, observe the following for cable glands and stopping plugs of the type of protection "increased safety" (e):• valid EC type examination certificate and • confirmation of the manufacturer for the combination of the cable and screw

connection

WARNINGNot approved cable glands and stopping plugs.Explosion protection is impaired!

• Only use separately certified cable glands and stopping plugs.

Recommendation:Use of cable glands and stopping plugs supplied by R. STAHL Schaltgeräte GmbH.

• see data sheet on our homepage www.stahl-ex.com.

DANGERExplosion hazard if breathers are used!Accidents or fatal injury are almost certain to happen!

• Do not use breathers.

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7.3.3 Electrical connectionsElectrical connectionObserve the maximum clamping possibility of the connecting terminals (see chapter "Technical data").

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.Connection terminals

Standard: Spring clamp terminals 0.5 to 4 mm2

(rigid and flexible)Stripping length: 10 ... 11 mm

Optional: Spring clamp terminals 0.5 to 6 mm2

(rigid and flexible)Stripping length: 13 ... 15 mm

5-pole 5-pole

15516E00

16526E00

LegendL1, L2, L3 = phase (3-pole: L1; 5-pole: L1, L2, L3)N = neutral conductorPE = protective conductor

NL

1L

2L

3

L3

L2

L1

N

Commissioning

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8 Commissioning

Before commissioning, ensure the following:• Check the mounting and installation.• Inspect enclosure for damage.• If necessary, remove foreign bodies.• If necessary, clean the connection chamber.• Check if the conductors have been inserted correctly.• Check if all screws and nuts have been tightened firmly.• Check whether all the cable entries and stopping plugs have been tightened firmly.• Check if all conductors have been clamped firmly.• Check if the line voltage and the rated operational voltage are consistent.• Check if the permissible conductor diameter for the corresponding cable entries have

been used.• Check if the device is closed according to regulations.• Check whether the bracket mounting & cover mounting screws are tightened with

proper torque.

DANGERExplosion hazard due to incorrect installation!Non-compliance results in severe or fatal injuries.

• Check the device for proper installation before commissioning.• Comply with national regulations.

DANGERExplosion hazard due to incorrect installation!Non-compliance results in severe or fatal injuries.

• Carry out the restricted breathing test prior to first commissioning. (See chapter "Restricted breathing test")

NOTICEMalfunction or device damage caused by condensation.Non-compliance can result in material damage!

• operate the luminaire continuously or periodically over extended periods of time.• avoid thermal bridges.

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Maintenance and repair



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.

WARNINGRisk 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.

• To be carried out as per EN60079-17 and as per EN60079-19.

DANGERExplosion hazard due to hot built-in components!Accidents or fatal injury are almost certain to happen!

• Only open the enclosure in switched-off state.• The device must be allowed to cool down for at least 15 minutes before

opening it.

NOTICEDanger due to electrostatic discharge.Electronic components can be destroyed if touched.

• Do not touch the LED-PCBs!

Observe the relevant national regulations in the country of use.

Check Measuresthe 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.


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• Restricted breathing of enclosure (see chapter "Restricted breathing test").

9.1.1 Restricted breathing testThe luminaire is equipped with a test device for restricted breathing.Restricted breathing must be checked after installation and during regular maintenance acc. to IEC/EN 60079-15.

Inspection according to IEC/EN 60079-15, para. 23.2.3.2.1.1

In order to test restricted breathing (pressure test), the luminaire is equipped with a cable entry with red stopping plugs.• Remove the red stopping plug.

Check Measures

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.

If the restricted breathing test has failed, take the device out of operation!

NOTICEMoisture inside the light fittingcan result in damage to electric and electronic components.

• Remove moisture with a cloth!• Determine the source and eliminate the cause!• Avoid condensation and thermal bridges!

WARNINGRestricted breathing is not guaranteed any longer!Explosion protection is impaired!

• After replacing seals or enclosure components carry out the restricted breathing test acc. to IEC/EN 60079-15, para. 23.2.3.2.1.1.

RecommendationCheck the luminaire by using the handheld testing instrument for restricted breathing from R. Stahl Schaltgeräte GmbH (see data sheet).

The test should only be carried out at constant temperature conditions.

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• Insert the hose of the test device into the cable entry for testing restricted breathing.• Hand-tighten the cable entry.• Use the hand pump to create a vacuum of 0.3 kPa (3 mbar).The test has been passed if after 90 seconds a vacuum of at least 0.15 kPa (1.5 mbar) is still present in the luminaire.After inspection:• Remove the hose of the test device for testing restricted breathing from the

cable entry.• Close the luminaire using the red stopping plug.

Alternative pressure and time specifications:

9.1.2 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.

9.2 Repair

9.3 Returning the deviceUse the "Service form" to return the device if repair or service is required. On the internet site "www.stahl-ex.com" under "Downloads > Customer service":• Download the service form.• Fill out the service form.• Send the device along with the service form in the original packaging to

R. STAHL Schaltgeräte GmbH.

Alternative 1 Alternative 2Vacuum at start of test 3.0 kPa (30 mbar) 0.3 kPa (3 mbar)Test duration 14 seconds 14 secondsVacuum after testing 2.7 kPa (27 mbar) 0.27 kPa (2.7 mbar)

If the luminaire is only marked with the type of protection for dust (IIIC), the cable entries and stopping plugs do not need to meet the requirements for restricted breathing (nR).

DANGERExplosion 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.

Disposal

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10 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.

11 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.stahl-ex.com.

652560300010 03 en - r. stahl...tips and recommendations on the use of the device general danger...

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