CROUSE-HINDS GHG 434 Explosion Protected Control Units Instruction Manual

Operating instructions Explosion-protected control units
GHG 432 and GHG 434

GHG 430 7001 P0001 D/GB/F (M)

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Technical data

1.1 Control unit assemblies

EU-Type Examination Certificate: Marking acc. to 2014/34/EU and standard:

EN 60079-0|  II 2 G Ex eb IIC / IIB+H2  / IIB  T6/T5  Gb
|  II 2 D Ex tb IIIC  T80 °C Db
IECEx type examination certificate: Category of application:
IEC60079-0| IECEx BVS 22.0029X
Ex eb IIC / IIB+H2  / IIB    T6/T5  Gb
Ex tb IIIC T80 °C Db

• = The marking is supplemented or expanded depending on the Ex components used or the housing accessories used (e.g. db, mb, ia, ib, ….)

Ambient temperature range and
perm.storage temperature in original packing::| -20 °C … +40 °C   (catalogue version)
Approved ambient temperature range:
(Deviating temperatures possible with special versions.)| -40 °C … +55 °C

Rated Current / temperature

Rated current| Cross section| Dust protection| T amb ≤ +40 °C| +40 °C ≤ Tamb ≤ +55 °C
---|---|---|---|---
6 A
10 A
16 A| 1.5 mm²| T80°C| T6
T6
n/a| T6
T5  (T6 bis Tamb=+54°C)
n/a
6 A
10 A
16 A| 2.5 mm²| T80°C| T6
T6
T6| T6
T6
T6/T5*1
6 A
10 A
16 A| 4 mm²| T80°C| T6
T6
T6| T6
T6
T6

*1 only with suitable KLE and cables with an extended service temperature range

plug)
suitable cables and test torques of the pressure screw
Cabel entry:| | M12| M16| M20| M25| M32
---|---|---|---|---|---|---
seal 1+2+3
(Ø mm / Nm)| min.
max.(1)| | | | 8.0 / 1.5
10.0 / 2.0|
seal 1+2
(Ø mm / Nm)| min.
max.(1)| |  5.5 / 1.0
7.0 / 1.0| 7.0 / 1.5
9.0 / 1.4| 10.0 / 2.3
13.0 / 2.6| 14.0 / 3.0
17.0 / 4.0
seal 1
(Ø mm / Nm)| min.
max.(1)| 5.0 / 0.8
7.0 / 1.0|  7.0 / 1.0
10.0 / 1.4|  9.5 / 1.0
13.0 / 1.7| 13.5 / 1.3
17.5 / 2.3| 17.5 / 1.5
21.0 / 1.3
Test torque for screw in thread cable entry (Nm)| 1. 2| 3.3| 2.7| 3.0| 5.0

(1) The tests of clamping ranges and torque values were performed with metal mandrel. The clamping range can vary by using cables with different manufacturing tolerances and material properties. Please use a suitable combination of seals in the intermediate area, so that the cap nut can be tightened in future maintenance work on the cable entry.

Empty weight:
Control unit GHG 432 Control unit GHG 434| approx.  0.47 kg
approx.  0.70 kg
---|---
Test torques:|
Cover screws| 2.00 Nm
Enclosure material:
Identification letter “Mat.: A”
Identification letter “Mat.: B” and “Mat.: C”| impact resistant polyamide < 109 Ω impact resistant polyamide > 109 Ω

1.2 Actuator, switch and potentiometer general

Ex db eb IIC/IIB/IIB+H2 Gb
| I M 2 Ex db eb I Mb
IECEx type examination certificate:| IECEx IBE 14.0005U
Category of application|
standard of series IEC 60079:| Ex db eb IIC/IIB/IIB+H2 Gb
| Ex db eb I Mb
Ambient temperature range:

| II 2 G … IIC| -55 °C| +55 °C
| II 2 G … IIB| -60 °C| +55 °C
| II 2 G … IIB+H2| -55 °C| +55 °C
Operating temperature:
| II 2 G … IIC| -55 °C …| +80 °C
| II 2 G … IIB| -60 °C …| +80 °C
| I 2 G … IIB+H2| -55 °C …| +80 °C

1.2.1 Actuator GHG41.11..R….; 2 pole for push button, Mushroom head p.b., switch and Key-operated pushbutton
1.2.2 Actuator GHG41.11..R….; 4 pole for push button, Mushroom head p.b., switch and Key-operated pushbutton

V / 0,5 A
with gold-tipped contacts:| max. 400 mA
Supply terminal:| | 1x / 2x 0.5 – 2.5 mm²;
| | 1 x 4.0 mm² single wire
Test torques:| | 2.5 Nm
Weight:| 2 pole| approx. 0.15 kg
| 4 pole| approx. 0.35 kg

1.2.3 Potentiometer GHG41.16..R….;

1.3 Signallamp GHG417 1805 R….;

Marking acc. to 2014/34/EU
and standard of series EN 60079:|  II 2 G Ex db eb IIC Gb
 II 2 G Ex db ia IIC Gb
IECEx type examination certificate:| IECEx IBE 13.0031U
Category of application
standard of series IEC 60079:| Ex db eb IIC Gb
Ex db ia IIC Gb
Permissible operating temperature range:| -55 °C … +80 °C
Max. service temperature| +80 °C
(Other temperatures possible with special versions)| 1111
Rated voltage /Rated current:| 1111
e increased safety (Ex db eb)| 20 V … 254 V AC/DC 4 … 15 mA
e increased safety (Ex db eb)| 12 V … 24 V AC/DC max. 24 mA
i intrinsically safe version (Ex db ia)| 10 V … 30 V DC max. 38.7 mA
Ex-i Datas: U i| 30 V
I i| 100 mA
Ci| 0
Li| 0
Pi| 750 mW
Supply terminal:| 1x / 2x 0.5 – 2.5 mm²;   1 x 4.0 mm² solid
Test torques:| 2.5 Nm
Weight:| approx. 0.15 kg

Dimensions of actuator elements 1.4 AM45 / AM72 measuring instrument GHG410 98..(1)R….

Marking acc. to 2014/34/EU
(1) and standard of series EN 60079:
Moving iron 01 = VM 45
08 = VM 72
02 = AM 45
09 = AM 72| II 2 G Ex eb mb IIC Gb
II 2 G Ex eb IIC Gb / Ex eb mb IIC Gb
(1) Moving coil 20 = AM 45
21 = AM 72| II 2 G Ex ib IIC Gb
IECEx type examination certificate:| IECEx BVS 14.0082U
Category of application to
(1) standard of series IEC 60079:
Moving iron 01 = VM 45
08 = VM 72
02 = AM 45
09 = AM 72| Ex eb mb IIC Gb
Ex eb IIC Gb / Ex eb mb IIC Gb
(1)
Moving coil 20 = AM 4521 = AM 72| Ex ib IIC Gb
Operating temperature:| -55 °C …+80 °C
Perm. ambient temperature packing:| -55 °C … +80 °C
Degree of protection to EN/IEC 60529:| IP 66 (installed condition)
Rated voltage:| to max. 500 V
| | Moving iron| Moving coil
---|---|---|---
Measuring accuracy:| | class 2.5| class 1.5
Overload range:| | 10  fold – 25 sec.| 10  fold -5 sec.
| | 25 fold –  4 sec.|
| | 50 fold – 1 sec.|
| | telltale  1:1.5|
Special versions with 1:2; 1:5; 1:6 and 1:8 are possible for c.t.-versions
Measuring range:| AM:| n / 1A; 5 A; 10 A| 0  – 20 mA
| | 0  – 16 A / 25 A  direct| 4  – 24 mA
| VM45:| 6 – 250 V|
| VM72:| 6 – 500 V|
Power consumption:| | |
| VM45:| 0.91 – 1.76 VA|
| VM72:| 0.91 – 2.65 VA|
Coil:| | | 26.5 turns
Internal resistance:| | | 2.5 Ohm +- 30%
Li:| | | max. 0.1 mH
Ci:| | | max. 0.1 nF
Ui:| | | max. 30 V
Ii:| | | max. 150 mA
Supply terminals:| | 1x / 2 x 1.5 – 2.5 mm²| fine- / multi wire
| | 1 x 4.0 mm²| solid wire
Test torques:| | 2.5 Nm|
Weight:| AM/VM 45:| appox. 0.35 Kg|
| AM/VM 72:| approx. 0.40 Kg|

Dimensions in mm
X = fixing dimensions 1.5 Ex 23 control switch; GHG238 ….R….

IIB Gb
 II 2 G Ex db eb IIC Gb
 II 2 G Ex db ia/ib IIB Gb
 II 2 G Ex db ia/ib IIC Gb
 II 2 G Ex db eb I Mb
IECEx type examination certificate:|  IECEx BVS 13.0108U
Category of application
standard of series IEC 60079:| Ex db eb IIB Gb
Ex db eb IIC Gb
Ex db ia/ib IIB Gb
Ex db ia/ib IIC Gb
Ex db eb I Mb
Operating temperature:  (IIB)| -60 °C … +80 °C
 (IIC)| -55 °C … +80 °C
Tested ambient temperature range:  (IIB)| -60 °C … +55 °C
 (IIC)| -55 °C … +55 °C
Degree of protection to EN/IEC 60529:| IP 66 (installed condition)
Rated voltage:| to max.500 V
Rated current:| 10:00 AM
Switching capacity acc. to AC 15 (EN 60947-5-1):| 230 V / 6.0 A 400 V / 6,0 A
Switching capacity acc. to DC 13 (EN 60947-5-1):| 24 V / 6.0 A 230 V / 0,4 A
Perm. short-circuit back-up fuse:| 16 A/gG to 500 V
Design with gold-tipped contacts:| to max. 400 mA
Supply terminals:| 1x / 2x 0.5 – 2.5 mm²;
Test torques supply terminals:| 2.0 Nm
Weight:| 1 level 2 levels
| approx.  0.20 kg approx.  0.35 kg

1.6 Terminal block

1.7 Intrinsically safe circuits:

Safe galvanic isolation from all other circuits and earth

X = fixing dimensions

Safety instructions

Target group:
For skilled electricians and suitable qualified, instructed 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 432 and GHG 434. are not suited for use in Zone0 and Zone 20.
The requirements of the IEC/EN 60079-31 regarding excessive dust deposits and temperature to be considered from the user.
The temperature class and type of protection stated on the apparatus 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.
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 control units are conform to the standards specified in the Declaration of conformity, enclosed separately.
References to standards and directives in these operating instructions always relate to the latest version. Other additions (e.g. details relating tothe year) shall be observed.

Field of application

The control units are intended for use in potentially explosive atmospheres in zones 1, 2 and zones 21, 22 in accordance withIEC/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.
In case of use in an extremely aggressive atmosphere, please refer to manufacturer.

Application / Properties

The control units GHG 432 and 434 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”
Where required, the bases are fitted with 0.6W resistors, fine-wire fuses and diodes (max. power dissipation 1 W).
The electrical limiting values that are decisive for the 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® pages 12 and 13). The contact chamber of the gold-tipped version is marked with the letter “G” or colourcoded.
To ensure a safe and reliable disconnection, the normally closed contacts are designed as compulsory opening contacts.
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).
Ex 23 control switch actuator elements shall be provided with a drilled hole, Ø 5.5 mm, at the respective position on the switch collar and can then be padlocked as described above.
Fig. 1:
The measuring instruments AM 72 and AM 45 are used for the local indication of electrical values. See “Technical data” for details of measuring mechanism, accuracy and connection.
With measuring instruments for c.t. 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).
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 recognize 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(e.g. Betr.Si.V, 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 units may result in the invalidation of the guarantee.
6.1 Mounting
The control units GHG 43. 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) and shall not damage the hole (e.g. use of a washer).
The apparatus shall be fixed diagonally with a minimum of 2 screws.
If the screws are overtightened, the apparatus may be damaged.
Fig. 3:
The control units GHG 432 and GHG 434 are suited for mounting on Cooper Crouse-Hinds / EATON apparatus holders by means of self-cutting screws.
See the respective mounting instructions.
6.2 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 the 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.
To maintain the explosion protection, conductors shall be connectedwith 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 apparatus is open, it is necessary to ensure (disconnect voltage supply) that no voltage is carried over into the connected intrinsically safe circuits.
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.
If, to facilitate wiring, the built-in components (AM 72 and AM 45 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 72 andAM 45), pull the hooks outwards to release them.
Switching at the switch shaft of the switch contact block Ex 23 when the enclosure is open is not permitted. (to ensure that the switch can be closed again correctly).
Warning: the engaging positions of the built-in components shall matches the notches on the rail!
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.
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.
6.3 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.
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 (see Technical Data).
The relevant mounting directives for cables entries being used shall be observed.
Intrinsically safe circuits shall be fed through cable entries that are colour-coded (light blue).
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; ADL), 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.
**6.4 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
  6.5 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 and that the enclosure cover for the respective base is being used.
  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.
  6.6 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 ope- ration, 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 intoconsideration for the evaluation of the gas group of the built-in components.
  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 (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, (e.g. intactness of the flameproof components, theenclosure, the seals and cable entries), the switch mechanism function ofthe 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 compo nents 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 6.2 ”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.
Eaton is dedicated to ensuring that reliable, efficient and safe power is available when it’s needed most. With unparalleled knowledge of electrical power management across industries, experts at Eaton deliver customized, integrated solutions to solve our customers’ most critical challenges.
Our focus is on delivering the right solution for the application.
But, decision makers demand more than just innovative products.
They turn to Eaton for an unwavering commitment to personal support that makes customer success a top priority.
For more information, visit www.eaton.com/electrical.
Changes to the products, to the information contained in this document, and to prices are reserved; so are errors and omissions.
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Cooper Crouse-Hinds GmbH
Neuer Weg-Nord 49
69412 Eberbach
E-Mail: Info-Ex@Eaton.com
www.crouse-hinds.de
© 2022 Eaton
All Rights Reserved
Printed in Germany
Publication No.
GHG 430 7001 P0001 D/GB/F (M) /
Auflage / 41.2022 / MS
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