Download Installation and Maintenance Sheet

SynergEX Panelboards
Panelboards for Hazardous Locations
Installation & Maintenance Information
IF 1659
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
11.81”
(300mm)
CAUTION
Read these operating instructions and all other information sheets before wiring and use.
WARNING
Do not alter this product in any way. Doing so may lead to serious injury or death.
37.40”
(950mm)
To avoid dangerous overheating, do not use aluminum wiring. Use copper wire only.
30.51”
(775mm)
To avoid electrical shock, electrical power must be “OFF” before and during installation, inspection,
and maintenance.
Observe the national safety rules and regulations.
TABLE OF CONTENTS
12 Circuit
43.31”
(1100mm)
37.40”
(950mm)
11.81”
(300mm)
24 Circuit
37.40”
(950mm)
62.99”
(1600mm)
42 Circuit
11.81”
(300mm)
1. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Complete Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Technical Data Busbar System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Busbar System Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Rated Current of Connectors/Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.3 Clearance and Creepage Dimensions of Busbar System . . . . . . . . . . . . . . . . . . . . 3
1.2.4 Connection Busbar System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Hazardous Location Technical Data for Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1 Mechanical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2 277/480V Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.3 120/240V Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.4 Aux./Signal Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Conformity with Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Field of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Application/Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.1 Transport/Storage Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.1.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.2 Mounting/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.3 Opening SynergEX Panelboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.4 Electrical Connection General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.5 Busbar System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.5.1 Electrical Connection Busbar System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.5.2 Busbar Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.6 Cable Entries, Blanking Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.6.1 Drilling for Additional Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.7 Flanges, Metal Plates, and External Earth Connection . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.8 Closing Apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.9 Putting Into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. Maintenance/Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8. Repairs/Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9. Disposal/Recycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10. Dimensional Drawings, Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10.1 Tripping Characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10.2 Derating Table for Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
11.81”
(300mm)
Dimensional Drawings:
SynergEX Panelboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
74.80”
(1900mm)
50.39”
(1280mm)
Certificate of Conformity enclosed separately.
60 Circuit
Figure 1. Dimension Drawings
IF 1659 • 04/13
Copyright© 2013, Cooper Industries, Inc.
Page 1
1. TECHNICAL DATA
1.1 Complete Distribution
Master Contract
Explosion Category:
For USL
For CNL
Certifications and Compliances:
240 700
-20°C or -20°C to -40°C with heater
AEx de IIC T4
Ex de IIC T4; Ex tb IIIC T100°C Db
-20°C to -40°C without heater
AEx de IIB T4
Ex de IIB T4; Ex tb IIIC T100°C Db
Class I, Zones 1 & 2
Class I, Division 2, Groups A, B, C, D; Class II, Division 1, Groups E, F, G
Zone 1 & 2
For CNL
Class I, Division 2, Groups A, B, C, D; Class II, Division 1, Groups E, F, G, Extb IIIC T100°C Db
Rated Voltage
to 600VAC / 60 Hz
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 60529
IP66 (standard version); Type 4X
Insulation Class to EN/IEC 61140
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 / 120mm2
Incoming Wires
75°C
Outgoing Wires
75°C
Enclosure Material
Stainless steel
For USL
1.2 Technical Data Busbar System
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
1.2.1 Busbar System Connectors (phase X/Y/Z, neutral N, ground
)
Cross Section/AWG
Solid
Stranded
Connectors
Min.
Max.
Min.
Max.
Number of
Connectors
d/
mm / inch
a/
mm / inch
b/
mm / inch
c/
mm / inch
grck 16
14
4
4
6
1
5.0 / 0.2
25.5 / 1.0
26.5 / 0.5
12.0 / 0.5
3
grck 35
10
4
4
2
1
5.0 / 0.2
26.5 / 1.0
31.5 / 1.2
16.0 / 0.6
10
grck 50
6
4
4
0
1
5.0 / 0.2
26.5 / 1.0
35.0 / 1.4
16.0 / 0.6
20
grck 70
4
-
4
2/0
1
5.0 / 0.2
28.0 / 1.1
39.0 / 1.5
20.0 / 0.7
20
grck 120
4
-
4
4/0
1
5.0 / 0.2
29.0 / 1.2
46.0 / 1.8
23.0 / 0.8
33
IF 1659 • 04/13
Copyright© 2013, Cooper Industries, Inc.
Test Torque/
N-m
Page 2
1.2.2 Rated Current of Connectors/Wires
Ambient
Temperature
Range
40°C
Rated Current
of Busbar
Cross-section of Cables
Max. Rated Current of Connecting Cables
225A
14
12
10
8
6
4
0
2/0
4/0
15A
20A
30A
40A
50A
60A
100A
150A
225A
1.2.3 Clearance and Creepage Dimensions of Busbar System
Minimum Spacing Through Air
Minimum Spacing Through Air
Minimum Spacing Over Surface
Minimum Spacing Over Surface
“A” between phases
“B” between phases and ground
“C” between opposition phases
“D” between phases and ground
Cross Section / AWG
120V/240V
277V/480V
>= 19.0mm
>= 12.5mm
>= 31.0mm
>= 31.0mm
>= 25.0mm
>= 12.5mm
>= 50.0mm
>= 50.0mm
Stranded
Connectors Min.
Max.
Stripping
Length
grck 16
14
6
16
grck 35
10
2
18
grck 50
6
0
22
grck 70
4
2/0
22
grck 120
4
4/0
25
Figure 3. Stripping Length
1.2.4 Connection Busbar System
1 Phase
120/240V
IF 1659 • 04/13
3 Phase
277/480V
Copyright© 2013, Cooper Industries, Inc.
Page 3
1.3 Hazardous Location Technical Data for Breakers
Master Contract
Explosion Category:
For USL
For CNL
Certifications and Compliances:
240 700
AEx de IIB/IIC
Ex de IIB/IIC
Class I, Zone 1
Class I, Division 2, Groups A, B, C, D
Zone 1
Class I, Division 2, Groups A, B, C, D
For USL
For CNL
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
Figure 4. Contact Arrangement/
Circuit Breaker
-45°C to 60°C
1.3.1 Mechanical Data
Terminal Cross Section:
Main Terminal Module Size 1-3
Current
Stripping Length
15A or less
20A
25A
30A
40A
Aux. Terminals
Quantity Terminals for the Module Size:
Main Terminals
Aux. Terminals
Test Torques:
Main Contacts
Aux. Contacts
Mounting Screws
Enclosure Material
AWG 14
AWG 12
AWG 10
AWG 10
AWG 8
AWG 14
2
2
3
1
1
2
11mm / 0.4”
11mm / 0.4”
11mm / 0.4”
11mm / 0.4”
11mm / 0.4”
11mm / 0.4”
3
3
4
3.5 N-m
1.0 N-m
2.5 N-m
Polyamide
1.3.2 277/480V Circuit Breakers
Figure 5. Contact Arrangement/
Additional Devices
Rated Voltage
Rated Current
Types
Main contact
Main contact
1-pole
2-pole
3-pole
Rated Switching Capacity
Non-ambient Compensated Temperature
Component Size
Weight
ca.
to 277/480VAC; 60 Hz
10A-40A
GHG 623 1101 R...
GHG 623 2101 R...
GHG 623 3101 R...
10kA
25°C
1
0.60 kg
2
0.90 kg
3
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.
1.3.3 120/240V Circuit Breakers
Rated Voltage
Rated Current
Types
Rated Switching Capacity
Non-ambient Compensated Temperature
Component Size
Weight
Main contact
Main contact
1-pole
2-pole
ca.
to 120/240VAC; 60 Hz
10A to 40A
GHG 623 1001 R...
GHG 623 2001 R...
10kA
40°C
1
0.90 kg
2
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.
1.3.4 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.
IF 1659 • 04/13
Rated Voltage
Rated Current
Minimum Switching Capacity
Copyright© 2013, Cooper Industries, Inc.
to 230VAC
2A
5 mA at 24V
277VAC
2A
480VAC
1A
Page 4
2. SAFETY INSTRUCTIONS
5. APPLICATION/PROPERTIES
WARNING
®
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.
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.
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.
WARNING
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.
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.
WARNING
The data according to Sections 3 and 4 shall be taken into account during use.
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.
WARNING
Applications other than those described are not permissible without a written declaration of consent
from the manufacturer.
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.
WARNING
During operation, the instructions stated in Section 7 of the operating instructions shall be observed.
WARNING
These operating instructions also apply as instructions for the replacement or addition to individual
flameproof components.
WARNING
3. CONFORMITY WITH STANDARDS
The sole responsibility with respect to the suitable and proper use of these panels lies with the operator.
SynergEX Panelboards have been designed, manufactured, and tested according to the following
standards:
CSA C22.2 0-10
CSA C22.2 0.5-1982 (R2003)
CSA C22.2 94.1-07
CSA C22.2 94.2-07
CSA C22.2 No. 0.12-M85
CSA C22.2 No. 29-11
CSA C22.2 No. 213-M1987
6. INSTALLATION
ANSI/ISA 60079-0 (12.00.01): 2009
ANSI/ISA 60079-1 (12.00.01): 2009
ANSI/ISA 60079-7 (12.16.01): 2008
ANSI/ISA 60079-31 (12.10.03): 2009
UL67, 12th Ed., 2009
UL50, 12th Ed., 2007
UL50E, 1st Ed., 2007
CAN/CSA C22.2 No. 60079-0:11
CAN/CSA C22.2 No. 60079-1: 11
CAN/CSA C22.2 No. 60079-7:12
CAN/CSA C22.2 No. 60079-31:12
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.
6.1.1 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.
4. FIELD OF APPLICATION
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 IEC60079-10, CAN/CSA 60079-10.
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 304
- Safety glass
In case of use in an extremely aggressive atmosphere, please refer to manufacturer.
6.2 Mounting/Installation
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.
WARNING
Excessive tightening can result in damage to SynergEX Panelboards.
IF 1659 • 04/13
Copyright© 2013, Cooper Industries, Inc.
Page 5
SynergEX Panelboards must not be left near heat sources.
To maintain the explosion protection, conductors shall be connected with special care.
The correct position of the openings for power supply access must be checked before installation.
WARNING
The insulation shall reach to the terminal (see Figure 8). The conductor itself must not be damaged.
WARNING
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.
Cross Section / AWG
Stranded
6.3 Opening SynergEX Panelboards
Use the relevant key for the locking device (see Figure 6).
Connectors Min.
Max.
Stripping
Length
grck 16
14
6
16
grck 35
10
2
18
grck 50
6
0
22
grck 70
4
2/0
22
grck 120
4
4/0
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.
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.
Figure 6. Locking Devices
WARNING
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).
6.5 Busbar System
The maximum rated current of the busbar system, specified in the Technical Data, have to be observed.
WARNING
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.
6.5.1 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
WARNING
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.
WARNING
The incoming and outgoing wires shall be identified as sized for 75C.
IF 1659 • 04/13
Copyright© 2013, Cooper Industries, Inc.
Page 6
6.5.2 Busbar Connectors
When positioning the connectors, the required clearances “D” in Figure 1.2.4 (“Connection Busbar
System”) shall be observed.
The possible combinations of connectors and terminal cross-sections can be seen in Table 1.2.1.
Place the connectors and wiring as shown in Figures 8 and 1.2.4 (“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 1.2.1. 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
WARNING
Generally only certified cable entries and blanking plugs may be used.
WARNING
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.
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.
Overtightening can impair the degree of protection.
WARNING
Ground conductors fed from outside are to be connected to the ground terminal provided on the
SynergEX Panelboard enclosure. The maximum cross-section is 50mm2.
WARNING
6.6.1 Drilling for Additional Cable Entries
Metal flanges, metal plates, and metal cable entries shall be included in the equipotential earth connection.
Additional holes for cable entries can be drilled into the metal flange.
Observe the dimensions of drilling surface, shown in Figure 11.
6.8 Closing Apparatus
6.7 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).
WARNING
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.
WARNING
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 1659 • 04/13
Copyright© 2013, Cooper Industries, Inc.
Page 7
7. MAINTENANCE/SERVICING
WARNING
The valid regulations IEC 60079-17 for the servicing/maintenance of electrical apparatus for use in
potentially explosive atmospheres shall be observed.
WARNING
Prior to opening SynergEX dead front, it is necessary to ensure that the voltage supply has been isolated or to take suitable protective measures.
WARNING
The user is responsible for stipulating the necessary maintenance intervals specific to the application depending on the conditions of use, national directives, and standards.
WARNING
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
WARNING
Only original Cooper Crouse-Hinds / CEAG parts shall be used for carrying out repairs.
WARNING
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.
WARNING
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 60079-19).
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 1659 • 04/13
Copyright© 2013, Cooper Industries, Inc.
Page 8
10. DIMENSIONAL DRAWINGS, BREAKERS
5.20” (132mm)
4.49” (114mm)
5.20” (132mm)
4.49” (114mm)
X 1.69” (43mm)
X 0.98” (25mm)
4.02” (102mm)
0.22” (ø5.5mm)
6.97” (177mm)
X 6.54” (166mm)
0.22” (ø5.5mm)
6.97” (177mm)
X 6.54” (166mm)
4.02” (102mm)
2.13” (54mm)
1.42” (36mm)
5.20” (132mm)
4.49” (114mm)
X 2.40” (61mm)
6.97” (177mm)
X 6.54” (166mm)
0.22” (5.5mm)
4.02” (102mm)
2.83” (72mm)
5.20” (132mm)
4.49” (114mm)
5.20” (132mm)
4.49” (114mm)
X 2.40” (61mm)
X 1.69” (43mm)
4.02” (102mm)
0.22” (5.5mm)
6.97” (177mm)
X 6.54” (166mm)
0.22” (5.5mm)
X 6.54” (166mm)
6.97” (177mm)
4.02” (102mm)
2.83” (72mm)
2.13” (54mm)
5.20” (132mm)
4.49” (114mm)
X 3.82” (97mm)
6.97” (177mm)
X 6.54” (166mm)
0.22” (5.5mm)
4.02” (102mm)
4.25” (108mm)
IF 1659 • 04/13
Copyright© 2013, Cooper Industries, Inc.
Page 9
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)
0
10
20
30
40
50
10
13.0
12.6
11.8
11.0
10.0
9.0
15
19.5
18.9
17.7
16.5
15.0
13.5
20
26.0
25.2
23.6
22.0
20.0
18.0
25
30.0
29.3
28.0
27.0
25.0
24.3
30
36.0
35.1
33.6
32.4
30.0
29.1
35
42.0
41.0
39.2
37.8
35.0
34.0
40
48.0
46.8
44.8
43.2
40.0
38.8
277/480VAC
Ambient Temperature T (°C)
In (A)
-40
-30
-20
-10
0
10
20
30
40
50
10
13.2
12.7
12.2
11.7
11.2
10.6
10.0
9.4
8.7
7.9
15
21.2
20.4
19.6
18.8
17.9
17.0
16.0
15.0
13.9
12.6
20
26.5
25.5
24.5
23.5
22.4
21.2
20.0
18.7
17.3
15.8
25
33.1
31.9
30.6
29.3
28.0
26.5
25.0
23.4
21.7
19.8
30
-
-
36.9
36.0
35.0
33.9
32.7
31.4
30.0
28.5
35
-
-
44.0
42.6
41.2
39.7
38.2
36.6
35.0
33.3
40
-
-
49.4
48.4
46.9
45.3
43.6
41.9
40.0
38.0
GHG 680 7001 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.
Crouse-Hinds Division
PO Box 4999, Syracuse, New York 13221 • U.S.A.
Copyright© 2013, Cooper Industries, Inc.
IF 1659
Revision 1
New 04/13