SynergEX Panelboards Installation & Maintenance Information IF 1659 Panelboards for Hazardous Locations

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SynergEX Panelboards

Panelboards for Hazardous Locations

Installation & Maintenance Information

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

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.

To avoid dangerous overheating, do not use aluminum wiring. Use copper wire only.

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

Dimensional Drawings :

SynergEX Panelboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

Certificate of Conformity enclosed separately.

12 Circuit

24 Circuit

42 Circuit

37.40”

(950mm)

37.40”

(950mm)

37.40”

(950mm)

74.80”

(1900mm)

11.81” (300mm)

11.81” (300mm)

30.51” (775mm)

11.81” (300mm)

11.81” (300mm)

IF 1659

IF 1659 • 04/13

60 Circuit

Copyright © 2013, Cooper Industries, Inc.

Figure 1. Dimension Drawings

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

For USL

For CNL

Rated Voltage

Rated Current

Maximum Number of Breakers (Single Pole)

Size A

Size B

Size C

Size D

Connectors

Cable Entries

Terminal Cross-section

Incoming Wires

Outgoing Wires

Enclosure Material

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

Class I, Division 2, Groups A, B, C, D; Class II, Division 1, Groups E, F, G, Extb IIIC T100°C Db to 600VAC / 60 Hz

Max. 225A

Size A (12 cct)

Size B (24 cct)

Size C (42 cct)

Size D (60 cct)

Up to 40°C up to 100A up to 150A up to 225A up to 225A

40°C to 55°C up to 85A up to 125A up to 190A 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

Insulation Class to EN/IEC 61140 I

IP66 (standard version); Type 4X

12

24

42

60

Quantity - acc. to number of breakers (poles)

Acc. to customer’s specification and as certified

Max. AWG 4/0 / 120mm 2

75°C

75°C

Stainless steel

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 )

Connectors grck 16 grck 35 grck 50 grck 70 grck 120

Min.

14

10

6

4

4

Cross Section/AWG

Solid

Max.

4

4

4

-

-

Min.

4

4

4

4

4

Stranded

Max.

6

2

0

2/0

4/0

Number of

Connectors

1

1

1

1

1 d/ mm / inch

5.0 / 0.2

5.0 / 0.2

5.0 / 0.2

5.0 / 0.2

5.0 / 0.2

a/ mm / inch

25.5 / 1.0

26.5 / 1.0

26.5 / 1.0

28.0 / 1.1

29.0 / 1.2

b/ mm / inch

26.5 / 0.5

31.5 / 1.2

35.0 / 1.4

39.0 / 1.5

46.0 / 1.8

c/ mm / inch

12.0 / 0.5

16.0 / 0.6

16.0 / 0.6

20.0 / 0.7

23.0 / 0.8

Test Torque/

N-m

3

10

20

20

33

IF 1659 • 04/13 Copyright © 2013, Cooper Industries, Inc.

Page 2

1.2.2 Rated Current of Connectors/Wires

Ambient

Temperature

Range

Rated Current of Busbar

Cross-section of Cables

40°C 225A

14

15A

12

20A

10

30A

1.2.3 Clearance and Creepage Dimensions of Busbar System

Minimum Spacing Through Air “A” between phases

Minimum Spacing Through Air “B” between phases and ground

Minimum Spacing Over Surface “C” between opposition phases

Minimum Spacing Over Surface “D” between phases and ground

120V/240V 277V/480V

>= 19.0mm

>= 25.0mm

>= 12.5mm

>= 12.5mm

>= 31.0mm

>= 50.0mm

>= 31.0mm

>= 50.0mm

8

40A

6

50A

4

60A

0

100A

Max. Rated Current of Connecting Cables

2/0

150A

4/0

225A

Cross Section / AWG

Stranded

Connectors Min.

grck 16 grck 35 grck 50 grck 70 grck 120

14

10

6

4

4

Max.

6

2

0

2/0

4/0

22

22

25

Stripping

Length

16

18

Figure 3. Stripping Length

1.2.4 Connection Busbar System

1 Phase

120/240V

3 Phase

277/480V

IF 1659 • 04/13 Copyright © 2013, Cooper Industries, Inc.

Page 3

Figure 4. Contact Arrangement/

Circuit Breaker

Figure 5. Contact Arrangement/

Additional Devices

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

For USL

For CNL

Ambient Temperature Range:

Class I, Zone 1

Class I, Division 2, Groups A, B, C, D

Zone 1

Class I, Division 2, Groups A, B, C, D

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

1.3.1 Mechanical Data

Terminal Cross Section:

Main Terminal Module Size 1-3

Current

Aux. Terminals

Quantity Terminals for the Module Size:

Main Terminals

Aux. Terminals

Test Torques:

Main Contacts

Aux. Contacts

Mounting Screws

Enclosure Material

1

2

15A or less AWG 14

20A

25A

AWG 12

AWG 10

30A

40A

1

AWG 10

AWG 8

AWG 14

2

2

3

3.5 N-m

1.0 N-m

2.5 N-m

Polyamide

Stripping Length

3

4

11mm / 0.4”

11mm / 0.4”

11mm / 0.4”

11mm / 0.4”

11mm / 0.4”

11mm / 0.4”

3

1.3.2 277/480V Circuit Breakers

Rated Voltage

Rated Current

Types

Main contact

Main contact

1-pole to 277/480VAC; 60 Hz

10A-40A

GHG 623 1101 R...

Rated Switching Capacity

Non-ambient Compensated Temperature

Component Size

Weight

2-pole

3-pole ca.

GHG 623 2101 R...

GHG 623 3101 R...

10kA

25°C

1

0.60 kg

1-pole*

Tripping characteristic of circuit breaker, see last page.

*Circuit breakers with additional devices are built into larger component enclosures.

2

0.90 kg

2-pole*

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 to 120/240VAC; 60 Hz

10A to 40A

GHG 623 1001 R...

GHG 623 2001 R...

10kA

40°C

1

0.90 kg ca.

1-pole*

Tripping characteristic of circuit breaker, see last page.

*Circuit breakers with additional devices are built into larger component enclosures in bigger size.

2

1.20 kg

2-pole*

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

1.3.4 Aux./Signal Contact

Rated Voltage

Rated Current

Minimum Switching Capacity

Copyright © 2013, Cooper Industries, Inc.

to 230VAC

2A

5 mA at 24V

277VAC

2A

3

1.20 kg

3-pole*

480VAC

1A

Page 4

2. SAFETY INSTRUCTIONS

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.

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 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

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

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, 12 th Ed., 2009

UL50, 12 th Ed., 2007

UL50E, 1 st Ed., 2007

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.

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.

WARNING

The data according to Sections 3 and 4 shall be taken into account during use.

WARNING

Applications other than those described are not permissible without a written declaration of consent from the manufacturer.

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

The sole responsibility with respect to the suitable and proper use of these panels lies with the operator.

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.

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.

IF 1659 • 04/13

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.

Copyright © 2013, Cooper Industries, Inc.

Page 5

SynergEX Panelboards must not be left near heat sources.

The correct position of the openings for power supply access must be checked before installation.

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.

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.

WARNING

The insulation shall reach to the terminal (see Figure 8). The conductor itself must not be damaged.

Cross Section / AWG

Stranded

Connectors Min.

grck 16 grck 35 grck 50 grck 70 grck 120

14

10

6

4

4

Max.

6

2

0

2/0

4/0

Stripping

Length

16

18

22

22

25

Figure 6. Locking Devices

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.

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).

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 Busbar System

The maximum rated current of the busbar system, specified in the Technical Data, have to be observed.

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.

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.

Figure 10. High Torque Screw ø 6mm

Test Torque 2.8 N-m

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.

Overtightening can impair the degree of protection.

6.6.1 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 11.

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.

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 50mm 2 .

WARNING

Metal flanges, metal plates, and metal cable entries shall be included in the equipotential earth connection.

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).

6.8 Closing Apparatus

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

X 0.98” (25mm)

5.20” (132mm)

4.49” (114mm)

4.02” (102mm)

X 1.69” (43mm)

5.20” (132mm)

4.49” (114mm)

4.02” (102mm)

1.42” (36mm)

X 2.40” (61mm)

5.20” (132mm)

4.49” (114mm)

4.02” (102mm)

2.13” (54mm)

2.83” (72mm)

X 1.69” (43mm)

5.20” (132mm)

4.49” (114mm)

4.02” (102mm)

X 2.40” (61mm)

5.20” (132mm)

4.49” (114mm)

4.02” (102mm)

2.13” (54mm)

X 3.82” (97mm)

5.20” (132mm)

4.49” (114mm)

4.02” (102mm)

2.83” (72mm)

IF 1659 • 04/13

4.25” (108mm)

Copyright © 2013, Cooper Industries, Inc.

Page 9

10.1 Tripping Characteristic of Breakers

K - Characteristic

277/480V 10-25A 277/480V 30-40A

10.2 Derating Table for Breakers

120/240VAC

25

30

35

40

In (A)

10

15

20

277/480VAC

0

13.0

19.5

26.0

30.0

36.0

42.0

48.0

In (A)

10

15

20

25

30

35

40

-40

13.2

21.2

26.5

33.1

-

-

-

-30

12.7

20.4

25.5

31.9

-

-

-

10

12.6

18.9

25.2

29.3

35.1

41.0

46.8

Ambient Temperature T (°C)

20

11.8

30

11.0

17.7

23.6

16.5

22.0

28.0

33.6

39.2

44.8

27.0

32.4

37.8

43.2

40

10.0

15.0

20.0

25.0

30.0

35.0

40.0

-20

12.2

19.6

24.5

30.6

36.9

44.0

49.4

50

9.0

13.5

18.0

24.3

29.1

34.0

38.8

-10

11.7

18.8

23.5

29.3

36.0

42.6

48.4

Ambient Temperature T (°C)

0 10

11.2

17.9

22.4

28.0

10.6

17.0

21.2

26.5

35.0

41.2

46.9

33.9

39.7

45.3

20

10.0

16.0

20.0

25.0

32.7

38.2

43.6

120/240V 10-40A

30

9.4

15.0

18.7

23.4

31.4

36.6

41.9

40

8.7

13.9

17.3

21.7

30.0

35.0

40.0

50

7.9

12.6

15.8

19.8

28.5

33.3

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

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