EATON GHG411.81 Explosion Protected Control Stations Instruction Manual

EATON GHG411.81 Explosion Protected Control Stations

Product Information

• Product Name: Explosion-protected control units GHG 411 and GHG 412
• Manufacturer: CROUSE-HINDS
• Model Numbers: GHG 411 and GHG 412
• Contents: Potentiometer socket, Drucktaster socket, Technical data, Control unit assemblies, Actuator and potentiometer

Technical Specifications:

• Bemessungsspannung (Rated voltage): up to max 690 V
• Bemessungsstrom (Rated current): max 16 A
• Umgebungstemperaturbereich (Operating temperature range): see table
• Schutzart nach EN/IEC 60529 (Degree of protection according to EN/IEC 60529): IP 65 with Doppeldrucktaster
• Schutzklasse nach EN/IEC 61140 (Protection class according to EN/IEC 61140): see table

Product Usage Instructions

Potentiometer Socket
The potentiometer socket is a component used in the control units GHG 411 and GHG 412. It is used to connect and control potentiometers.

Drucktaster Socket
The Drucktaster socket is another component used in the control units GHG 411 and GHG 412. It is used to connect and control Drucktasters.

Technical Data
The technical data provides information about the rated voltage, rated current, operating temperature range, degree of protection, and protection class of the control units GHG 411 and GHG 412. Refer to the user manual for detailed specifications.

Control Unit Assemblies
The control unit assemblies are the main components of the GHG 411 and GHG 412 control units. They consist of various parts including actuators and potentiometers. These assemblies are responsible for controlling and operating the devices connected to the control units.

Actuator and Potentiometer
The actuator and potentiometer are components used in the GHG 411 and GHG 412 control units. The actuator is used to activate or deactivate specific functions, while the potentiometer is used to adjust and control parameters.

For more detailed instructions on installation, wiring, and usage of the GHG 411 and GHG 412 control units, please refer to thecomplete user manual.

Technical data

Control unit assemblies

Actuator and potentiometer generally GHG41

Actuator GHG41.11..R….; 2 pole for
push button, Mushroom head p.b., switch and Key-operated pushbutton

Actuator GHG41.11..R….; 4 pole for
push button, Mushroom head p.b., switch and Key-operated pushbutton

Contact arrangement
Actuator GHG41.11..R….; 1 x 4 pole

Actuator GHG41.11..R….; 2 x 2 pole

Potentiometer

• Rated voltage: up to 250 V
• Rating: 1 W
• Turning range: 270°
• Scale: 0 – 100%
• Supply terminal/Test torques: 2 x 1.0 – 2.5 mm² 1 x 4.0 mm² single wire
• Test torques: 2.5 Nm
• Weight: approx. 0.15 kg

Signal lamp

AM45 / AM72 measuring Instrument

VM45 / VM72 measuring instrument:

Dimension for actuator elements

Terminal block

Principles

Caution
This symbol warns of a possible failure. Failure to observe this caution may result in the total failure of the device or the system or plant to which it is connected.

Special conditions
This symbol shows Highlights for safe use in accordance to EU-Type-Examination Certificate/ IEC Ex-Certificate of Conformity.

Safety instructions

Target group:
For skilled electricians and qualified personnel in accordance with national legislation, including the relevant standards and, where applicable, in acc. with IEC/EN 60079-14 on electrical apparatus for explosive atmospheres.

• The control units GHG 411 and GHG 412 are not suitable for zone 0 and Zone 20 hazardous areas.
• The temperature class and type of protection stated on the appara-tus shall be observed.
• Modifications or changes to the control units are not permitted. They shall be used for their intended purpose and shall be in a perfect and clean state.
• The requirements of the IEC/EN 60079-31 regarding excessive dust deposits and temperature to be considered from the user.
• Only original Cooper Crouse-Hinds / EATON parts may be used as replacements and for repairs.
• Repairs that affect the explosion protection may only be carried out by Cooper Crouse-Hinds / EATON or by a qualified electrician in compliance with the respective national regulations.
• Prior to being put into operation, the control units shall be checked in accordance with the instructions as per section 6.
• The national safety rules and regulations for the prevention of accidents, as well as the safety instructions included in these operating instructions, that, like this text, are set in italics, shall be observed!!

Conformity with standards

The apparatus is conform to the standards specified in the EC-Declaration of conformity, enclosed separately
References to standards and directives in these operating instructions always relate to the latest version Other additions (eg details relating to the year) shall be observed

Field of application

The control units are intended for use in potentially explosive atmospheres in zones 1, 2 as well as in Zones 21 and 22 in accordance with
IEC/EN 60079-10-1 and IEC/EN 60079-10-2?
The enclosure materials used, including any external metal parts, are high quality materials that ensure a corrosion resistance and resistance to chemical substances according to the requirements for use in a ”normal industrial atmosphere”

• impact resistant polyamide
• special steel AISI 316 L

The GHG 411 and GHG 412 control units were made from material “B” (impact- resistant polyamide > 109 Ω) from the production period 01/2012
In case of use in an extremely aggressive atmosphere, please refer to manufacturer

Application / Properties

• The control units GHG 411 and 412 are intended for the local control of electrical installations in potentially explosive atmospheres
• The units are fitted with built-in components according to the respective application Specially marked special versions of the control units can be used in ”intrinsically safe circuits”
• The electrical limiting values that are decisive for intrinsic safety shall be observed.
• The version with gold-tipped contacts is suited for switching extra-low voltage circuits Special attention shall be paid to the maximum current load (see technical data)
• The contact chamber of the gold-tipped version is marked with the letter ”G” or colour-coded
• To ensure a safe and reliable disconnection, the normally closed contacts are designed as compulsory opening contacts
• Where required, the bases are fitted with 0?6 W resistors, fine-wire fuses and diodes (max power dissipation 1 W)
• The measuring instruments AM/VM72 and AM/VM45 are used for the local indication of electrical values See ”Technical Data” for details of measuring mechanism, accuracy and connection Fig 1:  With measuring instruments AM/VM72 and AM/VM45 for connection n/1A (Fig 1, item 2) the interchangeable scales can be exchanged via a flap on the upper part of the measuring instrument (Fig 1, item 1)
• When the switch collar of small control switches is cut out at the respective locking position, they can be padlocked (padlock shackle Ø up to 5 mm) Fig 2:
• The 4 pole pushbutton contact can be added with the standard CCH actuators
• If the 4 pole pushbutton contact is added with an Emergency STOP Mushroom-head pushbutton actuator, then you have to use the actuators with CCH order number GHG 410 1437R
• This actuators can be recognized by the red thrust washer and black inserting sign
• 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 Messrs. Cooper Crouse-Hinds / EATON.
• During operation the instructions stated in section 7 of the operating instructions shall be observed.
• The sole responsibility with respect to the suitability and proper use of the control switches with regard to the basic requirements of these instructions (see technical data) lies with the operator.

Installation

The relevant national regulations (eg BetrSiV, the equipment safety law for Germany) and the generally recognized rules of engineering apply for the installation and operation IEC/EN 60079-14
The improper installation and operation of control switches may result in the invalidation of the guarantee.

Mounting

• The control units GHG 411 can be mounted without opening the enclosure.
• When the control units are mounted directly onto the wall, they shall rest evenly only on the fastening points provided for this purpose.
• The screw chosen shall fit the fixing hole (see dimensional drawings, page 10) and shall not damage the hole (eg use of a washer)
• The apparatus shall be fixed diagonally with a minimum of 2 screws a If the screws are overtightened, the apparatus may be damaged. Fig 3:
• The control units GHG 411 and GHG 412 are suited for mounting on Cooper Crouse-Hinds / EATON apparatus holders by means of self-cutting screws See the respective mounting instructions.
• The control units GHG 412 can be mounted in the flange openings provided for this purpose.
• Here special attention shall be paid to an even sealing surface and the perfect condition of the seal that is foamed into the enclosure cover of the control unit.
• The control unit is mounted in the flange opening by means of fixing lugs that engage behind the flange opening.
• These are actuated by turning the 2 fixing screws on the front of the enclosure cover clockwise.

Opening apparatus / Electrical connection

• Before opening the apparatus, it is necessary to ensure that there is no voltage or to take suitable protective measures.
• The electrical connection of may only be carried out by specialists (IEC/EN 60079-14).
• The properly bared conductors of cables shall be connected with due regard to the respective regulations.
• If multi- or fine-wire connection cables are used, the wire ends shall be handled according to the applicable national and international regulations (eg use of multicore cable ends).
• To maintain explosion protection, conductors shall be connected with special care.The insulation shall reach up to the terminal. The conductor itself shall not be damaged..
• In the case of mixed Ex-e / Ex-i installations, the required minimum clearances shall be maintained (see, for example,
• IEC/EN 60079-11). When the apparatus is open, it is necessary to ensure (disconnect the voltage supply) that no voltage is carried over into the connected intrinsically safe circuits.
• The installation instructions for intrinsically safe electrical apparatus shall be observed.
• It is necessary to ensure that the permissible external capacitance and inductance of the special intrinsically safe circuits are not exceeded.
• The minimum and maximum conductor cross sections that can be connected shall be observed (see technical data)
• All screws and/or nuts of connection terminals, including those not in use, shall be tightened down securely.
• The standard terminals are designed for the direct connection of conductors with copper wires.
• The circuit diagram of the built-in components is shown on the components or attached to them, or it is shown in the operating instructions.
  • In the case of building up the electrical equipment in the “protective insulation” version, appropriate sticker ( ) GHG 905 1002 P0005 can be requested by the manufacturer
  • If the inserted terminal rail is not equipped completely with line-up terminals, the terminal rail must be included in the equipotential earth connection also
  • If, to facilitate wiring, the built-in components (AM/VM72 and AM/VM45 measuring instruments, pushbutton contact block, signal lamp bases, control switch contact blocks, potentiometer bases, etc?) are snapped off the rail on the bottom of the
  • enclosure, the components shall be snapped back properly into the same notch on the rail.
  • To snap off components (including the measuring instruments AM/VM72 and AM/VM45), pull the hooks outwards to release them.
  • To ensure that the apparatus closes correctly, switching at the switch shaft of the switches insert is not permitted when the apparatus is open.
  • Warning: the engaging positions of the built-in components shall matches the notches on the rail!

Cable entries (KLE); blanking plugs

• Generally, only certified cable entries and blanking plugs may be used. Flexible cables shall be used with trumpet-shaped cable glands or other suitable entries with additional pull relief.
• The relevant mounting directives for cables entries being used shall be observed?
• When using cable entries with a degree of protection that is lower than the IP protection of the apparatus, the degree of IP protection for the complete unit is reduced?
• Intrinsically safe circuits shall be fed through cable entries that are colour-coded (light blue)?
• When using cable entries for fixed cables it is necessary to ensure that no inadmissible high mechanical stress is applied to the cable entry or its seal?
• In order to ensure the minimum degree of protection, any unused entry holes shall be sealed with certified blanking plugs?
• When fitting cable entries, care has to be taken that the sealing inserts are suitable for the cable diameter? In the case of sealing inserts that are cut out, it is necessary to ensure that the insert is properly adapted to the cable diameter?
• In order to ensure the required minimum degree of protection, the cable entries shall be tightened down securely?

Overtightening can impair the degree of protection.

Warning: When tightening the cap nut of the metal cable entry (e.g. type ADE; CMDEL), a suitable tool shall be used to safeguard the gland against twisting.
Any unused metric Cooper Crouse-Hinds / EATON cable entries shall be sealed with the blanking plug certified for these metric cable entries?

**Flange and metal plates ***
If flange plates have to be dismantled, (e?g? to drill entry holes), when replacing the plates, in order to maintain the minimum degree of protection, it is necessary to ensure that the flange plate and the fixing clamp fit correctly?

• PE conductors fed from outside shall be connected to the PE terminal provided on the flange. the maximum terminal cross section is 6 mm².
• Warning: Metal flanges, metal plates and metal glands shall be incorporated in the potential equalization.
• not yet certified for category II D

Closing apparatus /Cover closure

• When fitting the enclosure cover onto the base, it is necessary to ensure that the actuator elements correspond correctly with the built-in components, care shall be taken to ensure that the switch shaft of the switch insert engages correctly in the carrier hole of the switch handle and that the enclosure cover for the respective base is being used.
• The switch handle shall be in the position it had when the apparatus was opened.
• Any foreign matter shall be removed from the apparatus.
• To ensure the required minimum degree of protection, the cover screws shall be tightened down.
• Overtightening may impair the degree of protection.

Putting into operation
Before putting the apparatus 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 apparatus and of the built-in components (measuring instruments, signal lamps, pushbuttons, etc) shall be checked in accordance with these operating instructions and other applicable regulations
The zero setting of the measuring instrument needle shall be checked before putting it into operation If necessary, the measuring instrument needle shall be set to zero using the adjustment screw
The gas group (IIB or IIC) of the intrinsically safe circuit shall be taken into consideration for the evaluation of the gas group of the built-in compo- nents
a The improper operation of control units may result in the invalidation of the guarantee.

Maintenance / Servicing

• The valid national regulations for the servicing/maintenance of electrical apparatus for use in potentially explosive atmospheres shall be observed (e.g. IEC/EN 60079-17).
• Prior to opening the enclosure, it is necessary to ensure that the voltage supply has been isolated or to take suitable protective measures.
• Working with live circuits is permissible for intrinsically safe circuits
• The necessary intervals between servicing depend upon the specific application and shall be stipulated by the operator according to the respective operating conditions
• During servicing, above all, the parts on which the explosion protection depend and function, (eg intactness of the flameproof components, the enclosure, the seals and cable entries), the switch mechanism function of the control switch, efficacyof the gaskets and the cable entries and tight fit of all screws 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.

Cleaning:

Apparatus marked “Mat.: B” or “Mat.: C” on the type lable have to be cleaned as follows:
Because of the risk of an electrostatic charge, the junction boxes shall only be cleaned with a damp, non fibrous cloth or sponge!

Repairs / Overhaul / Modification

Only original Cooper Crouse-Hinds / EATON parts shall be used for carrying out repairs.

• In the event of damage to the flameproof encapsulation, replacement of these components is mandatory. In case of doubt, the respective apparatus shall be sent to Cooper Crouse-Hinds / EATON for repair.
• Repairs that affect the explosion protection may only be carried out by Cooper Crouse-Hinds / EATON or by a qualified electrician in compliance with the respective national regulations (IEC/EN 60079-19).
  Apparatus modifications or design changes are not permitted; excepted from this is the fitting of additional cable entries within the scope of the apparatus approvals or acc? to the instructions given by the manufacturer?
  When replacing individual built-in components (pushbuttons, etc) section 62 ”Opening apparatus / Electrical connection” shall be observed?

Disposal / Recycling

When the apparatus is disposed of, the respective national regulations on waste disposal will have to be observed. In case of disposal you can obtain additional information from your Cooper Crouse-Hinds /EATON branch. Subject to modifications or supplement of the product range.

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