G0002EC: ATX GUIDE FOR INSTRUMENT AND JUNCTION BOXES

G0002E/C - English version 1 www.egsatx.com

ATX Guide for Instrumentation and Junction boxes

Ex e increased safetyEx i intrinsic safety

Gas zones 1 & 2 Dust zones 21 & 22

Available on request or on our website www.egsatx.com


In order to reply more effectively to your own specifications and with respect to the certification requirements for the materials concerned, ATX now offers youthe opportunity to drill and equip, yourself, Junction Boxes for Increased safetyand dust environments. Gain freedom and flexibility : produce your equipment when you want, as youwant, whilst conforming to current standard requirementsGain in terms of time : define yourself your own solutions without the need of an intermediary.From now on with ATX you have the following choices:

Standard pre-drilled boxes ready for use, see the ATX catalogueBoxes drilled by ATX in accordance with your requirementsBoxes drilled by yourself, using this guide

Your only concern is to be effective.

With this guide, ATX provides our know-how and experience for your disposal.

CONTENTS

1) General points page 03

2) Define the number of terminals page 05

3) Define the number of cable entries page 08

4) Location of cable entries page 09

Appendix A page 11

5) Drilling page 12

6) ATX requirements page 14


1) General points

The first step is to choose the material for your boxes in relation to your environment : aluminium, polyester, or stainless steel. The next step is to choose the size of your boxes.To make your choice easy, ATX suggests a method which takes all parameters into account including connecting cross-sections, current being carried, permitted terminals, the number of cable entries, and of course the requirements of European standards.

European standards :In order to satisfy the requirements in European standards EN 60079-0 et EN 60079-7, increased safety boxes (Ex e II) should be used respecting the maximum certified dissipation power (Pw) of each box.This dissipated power is related to a given temperature class, from T6 to T1. The maximum allowable number of terminals in each box is then determined by the connected cross-section and by the intensity carried in each circuit. The calculation of the total dissipated power is taking into account the dissipated power of the internal wiring.

ATEX certified terminals from different manufacturers can be used providing electrical data (rated Voltage and Intensity) is within conformance

Intrinsic safety:There is no need for intrinsic safety junction boxes to have Ex marking and can be used in zone 0 (only ia)

and zones 1&2 (ia or ib)

Rules to respect:a) Terminals colour: When there is a risk of confusion between several type of terminals inside the box:IS terminals must be identified with light blue colour.

b) Clearance distances between IS and NIS.Without partition With partition

c) Creepage distances

d) IS components marked IS or [IS] :The IS components are intrinsically sure, the [IS] components are associated materials which cannot be installed in an area of high risk. They can however be installed in flameproof boxes, as long as the following conditions are respected:

- Ex ia or ib components with or without resin, installed in a d box do not require explosion testing if they are alone in the enclosure, however if they are placed with other NIS components, then an explosion test is required.- Ex [ia] or [ib] components encapsulated in resin can be installed in a d box without further explosion testing, however if the same components are not encapsulated an explosion test is required.

To be earthed if metallic partition

3mm regards to metalic parts (rails, walls, etc..)

6mm between two terminals with different polarity


Polyester version

150215200CAP40095983CAe1095953150320200CAP50095984CAe2095954150425200CAP60095985CAe3095955

95230110CAP30095982PCe3095952

95120110CAP10095980PCe1095950

150575200CAP70095986CAe4095956

95170110CAP20095981PCe2095951

DWHTypePart Nos.TypePart Nos.

External Dimensions (en mm)

Zones 21 & 22Zones 1 & 2 et 21 & 22

Aluminium version

130215205CAP40095993CAe1095963130320205CAP50095994CAe2095964130425205CAP60095995CAe3095965

95230110CAP30095992PCe3095962

95110110CAP10095990PCe1095960

190480380------CAe5095966

95170110CAP20095991PCe2095961

DWHTypePart Nos.Type

Part Nos.


Zones 21 & 22

Zones 1 & 2 et 21 & 22

316L stainless steel version

95180180JBe30097002

95120120JBe1009700095180120JBe20097001

DWHTypePart Nos.


Zones 1 & 2 et 21 & 22


CableSection Pas / Pitch

Qt 12 11I max 15A 16A

Qt 10 9 8 7I max 20A 22A 24A 25 A

Qt 7I max 32A

Bornes / terminals Quantit de bornes admissiblesQuantity of terminals permitted

2.5 mm 5,1

4 mm 6,1

6 mm 7,9

2.5 mm

4 mm

6 mm

PCe1 - 110 x 120 x 95 mm (Polyester et Aluminium)


Qt 22 21 19 17I max 13A 14A 15A 16A

Qt 18 16 15 14 13 12I max 19A 20A 21A 22A 23A 25A

Qt 14 13 12 11I max 27A 29A 30A 32A

Qt 5 * * rail vertical / on vertical rail onlyI max 50A

Quantity of terminals permitted

2.5 mm

Quantit de bornes admissibles

7,9

Bornes / terminals

10 mm 9,9

5,1

4 mm 6,1

6 mm


2.5 mm

4 mm

6 mm

10 mm


Qt 33 30 28 26 21I max 12A 13A 14A 15A 16A

Qt 28 26 24 22 20 19 17 16 15 14I max 16A 17A 18A 19A 20A 21A 22A 23A 24A 25A

Qt 21 20 19 18 17 16 15 14 13I max 24A 25A 26A 27A 28A 29A 30A 31A 32A

Qt 5 * * rail vertical / on vertical rail onlyI max 50A

Quantit de bornes admissiblesQuantity of terminals permitted

Bornes / terminals

10 mm 9,9

6 mm 7,9

2.5 mm 5,1

4 mm 6,1


2.5 mm

4 mm

6 mm

10 mm

a) Terminal block with same cross-section terminals

Junction boxes used for instrumentation applications have very low current being carried, therefore there is no risk of overheating whatever the number of terminals inside the box.In other cases, the following tables allow you to define your junction box depending on the number of terminals and the maximum authorized current being carried. Note: One terminal block (1 rail) per box.

Terminal dimensions coming fromWeidmuller manufacturer WDU type

Temperature class:

T6 for Ta = 40C

T5 for 40C < Ta = +55C


Qt 28 25 22 20I max 13A 14A 15A 16A

Qt 24 22 19 16 14 13I max 17A 18A 20A 22A 24A 25A

Qt 18 17 15 13 12I max 25A 26A 28A 30A 32A

Qt 14 12 10 9 8 7I max 31,5A 35A 40A 45A 48A 50A

Qt 9 8 7 6 5 4I max 15A 28A 38A 49A 61A 63A

Qt 9 8 6I max 60A 67A 80A

Qt 9 8 6 5I max 71,5A 79A 99A 100A

35 mm 1625 mm

35 mm

10 mm 9,9 10 mm

16 mm 11,9 16 mm

4 mm 6,1 4 mm

6 mm 7,9 6 mm

Bornes / terminals

2.5 mm 5,1 2.5 mm

Quantit de bornes admissiblesQuantity of terminals permitted

CAe1 200 x 215 x 150 mm (Polyester) / 205 x 215 x 130 mm (Aluminium)

2) Define the number of terminals



Qt 50 45 39 34 30 26 21I max 9,2A 10A 11A 12A 13A 14A 16A

Qt 41 35 29 20 17 14I max 12,5A 14A 16A 20A 22A 25A

Qt 32 28 21 16 13I max 18,5A 20A 24A 28A 32A

Qt 25 21 15 11 9 8I max 21A 25A 32A 40A 45A 50A

Qt 12 11 10 9 8 7 6 5I max 9A 19A 27A 35A 42A 50A 59A 63A

Qt 15 10 8 7I max 40,7A 61A 73A 80A

Qt 15 10 8 6I max 48A 72A 86A 100A

16 mm 11,9 16 mm

35 mm 1625 mm

35 mm

6 mm 7,9 6 mm

10 mm 9,9 10 mm

2.5 mm 5,1 2.5 mm

4 mm 6,1 4 mm

CAe2 200 x 320 x 150 mm (Polyester) / 205 x 320 x 130 mm (Aluminium)Bornes / terminals Quantit de bornes admissibles



Qt 70 59 51 44 38 29 23I max 8A 9A 10A 11A 12A 14A 16A

Qt 59 56 33 23 19 15I max 10,5A 11A 16A 20A 22A 25A

Qt 45 44 37 32 22 16 14I max 15,9A 16A 18A 20A 25A 30A 32A

Qt 36 31 23 18 10 9I max 17A 20A 26A 32A 45A 50A

Qt 16 15 14 13 11 10 8 6I max 6A 14A 20A 25A 35A 40A 52A 63A

Qt 22 17 13 12 10 8I max 31,4A 43A 56A 60A 69A 80A

Qt 22 17 13 12 10 7I max 37A 50A 63A 70A 80A 100A

16 mm 11,9 16 mm

35 mm 1625 mm

35 mm

6 mm 7,9 6 mm

10 mm 9,9 10 mm

2.5 mm 5,1 2.5 mm

4 mm 6,1 4 mm

CAe3 200 x 425 x 150 mm (Polyester) / 205 x 425 x 130 mm (Aluminium)Bornes / terminals Quantit de bornes admissibles



Qt 100 87 72 61 51 38 29 23I max 6,3A 7A 8A 9A 10A 12A 14A 16A

Qt 83 75 66 33 22 15I max 8,3A 9A 10A 16A 20A 25A

Qt 64 55 46 32 23 18 14I max 12,6A 14A 16A 20A 24A 28A 32A

Qt 51 42 34 28 22 18 13 9I max 12,2A 16A 20A 24A 28A 32A 40A 50A

Qt 20 19 18 17 15 12 10 6I max 4A 11A 15A 19A 26A 37A 46A 63A

Qt 31 27 23 19 14 10 9 8I max 21,8A 28A 34A 42A 55A 70A 75A 80A

Qt 31 27 23 19 14 10 9 7I max 25,7A 32A 40A 50A 63A 80A 89A 100A

16 mm 11,9 16 mm

35 mm 1625 mm

35 mm

6 mm 7,9 6 mm

10 mm 9,9 10 mm

2.5 mm 5,1 2.5 mm

4 mm 6,1 4 mm

CAe4 200 x 575 x 150 mm (Polyester)Bornes / terminals Quantit de bornes admissibles



Qt 64 55 49 43 38I max 12A 13A 14A 15A 16A

Qt 54 45 38 32 25I max 16,2A 18A 20A 22A 25A

Qt 41 39 34 30 26 23I max 23,5A 24A 26A 28A 30A 32A

Qt 33 30 28 25 22 20 17 15I max 30.3A 32A 34A 36A 40A 42A 46A 50A

Qt 27 26 25 24 22 20 15 11I max 9.7A 10A 16A 20A 26A 32A 47A 63A

Qt 20 17 15 13I max 60A 68A 74A 80A

Qt 20 17 14 12I max 71A 80A 90A 100A

16 mm 11,9 16 mm

35 mm 1625 mm

35 mm

6 mm 7,9 6 mm

10 mm 9,9 10 mm

2.5 mm 5,1 2.5 mm

4 mm 6,1 4 mm

CAe5 480 x 380 x 190 mm (Aluminium)Bornes / terminals Quantit de bornes admissibles




Qt 21 21 17 15 14 12 11 10 9I max 16A 8.7A 10A 11A 12A 13A 14A 15A 16A

Qt 18 16 18 16 15 14 12 10 8 6I max 23A 25A 11A 12A 13A 14A 15.5A 18A 20A 25A

Qt 13 13 12 11 10 9 8 7 5I max 32A 18A 19A 20A 22A 23A 25A 27A 32A

Qt 11 9 11 10 9 8 7 6 5 3I max 44A 50A 14.5A 18A 21A 24A 28A 32A 38A 50A

10 mm

2.5 mm

4 mm

6 mm

Bornes / terminalsTa= + 55C

Quantity of terminals permittedTa= + 70C

JBe30 180 x 180 x 95 mm (Acier Inoxydable 316L)Quantit de bornes admissibles

10 mm 9,9

2.5 mm 5,1

4 mm 6,1

6 mm 7,9

b) Terminal block with different cross-section terminals:

The total length of your terminal block mustnt exceed the dimension L.

If intensity values given in the previous tables didnt match your application you must use the calculation method defined in appendix A (page 11).

In case of Terminal block with different cross-section terminals you must use the calculation method defined in appendix A (page 11).


Qt 21 21 20 17 15 14 11 9 7I max 16A 6.5A 7A 8A 9A 10A 12A 13.8A 16A

Qt 18 17 18 17 16 14 12 10 8 4I max 24A 25A 7.7A 8A 9A 10.5A 12A 15A 17.5A 25A

Qt 13 13 12 11 10 9 8 6 4I max 32A 14.5A 15A 17A 18A 20A 21.5A 26A 32A

4 mm 6,1 4 mm

6 mm 7,9 6 mm

Ta= + 55C Ta= + 70C

2.5 mm 5,1 2.5 mm

JBe20 120 x 180 x 95 mm (Acier Inoxydable 316L)Quantit de bornes admissibles

Bornes / terminals Quantity of terminals permitted

Cable

Section Pas / Pitch

Qt 10 9 8 7 6 5 4 3I max 5.7A 6A 7A 9A 10A 12A 14A 16A

Qt 8 7 6 5 4 3 3I max 7A 9A 11A 13A 16A 20A 25 A

Qt 6 5 4 3 2I max 13.7A 16A 21A 25A 32A

6 mm 7,9 6 mm 632A

4 mm 6,1 4 mm8

25 A

Ta= + 55C Ta= + 70C

2.5 mm 5,1 2.5 mm10

16A

JBe10 120 x 120 x 95 mm (Acier Inoxydable 316L)

Quantit de bornes admissiblesBornes / terminals Quantity of terminals permitted

2,5 4 6 10 16Pas / Pitch (mm) 5,1 6,1 7,9 9,9 11,9Cable (mm) 2,5 4 6 10 16 25 35I max (A) 16 25 32 50 63 80 100

3516

Bornes / TerminalsSection (mm) / Capacity (mm)

Type PCe1 PCe2 PCe3 CAe1 CAe2 CAe3 CAe4 CAe5 JBe10 JBe20 JBe30L (mm) 62 112 172 147 255 360 510 330 51 110 110

Max. Authorized dissipated power.(W)

6 11 16 17 22 29 36 36 6 11 16


Choice of the boxes

These tables allow you to identify the box when taking into account the permitted number of cable entries per face.

Aluminium boxes

316L stainless steel boxes

Example Polyester box Part no. 095954 side A: number of module is 18 thereforethere are several possible configurations such as 18 x 1 module or 9 x 2 modules, or 6 x 3 modules, or 7 x 2 modules + 1 x 4 modules, etc

Polyester boxes

3) Define the number of cable entries

PG11 1

PG13 1

PG16 1

PG21 2

PG29 3

PG36 4

PG48 6

Cable entryElectrical thread

Number of modules

M20 1

M25 1

M32 1

M40 2

M50 3

Cable entryMetric thread

Number of modules

* Module: theoretical space of cable entry

A B C D

2 2 2 2 110 120 95 095950 PCe1 095980 CAP10

3 2 3 2 110 170 95 095951 PCe2 095981 CAP20

4 2 4 2 110 230 95 095952 PCe3 095982 CAP30

11 8 11 8 200 215 150 095953 CAe1 095983 CAP40

18 8 18 8 200 320 150 095954 CAe2 095984 CAP50

26 8 26 8 200 425 150 095955 CAe3 095985 CAP60

38 8 38 8 200 575 150 095956 CAe4 095986 CAP70

H W D Part No. Type Part No. Type

Allowable numberof modules per side

External Dimensions(mm)

Zones 1 --> 2et 21 --> 22

Zones21 --> 22

A B C D

2 2 2 2 110 110 95 095960 PCe1 095980 CAP10

3 2 3 2 110 170 95 095961 PCe2 095981 CAP20

4 2 4 2 110 230 95 095962 PCe3 095982 CAP30

11 8 11 7 205 215 130 095963 CAe1 095983 CAP40

17 8 17 7 205 320 130 095964 CAe2 095984 CAP50

26 8 26 7 205 425 130 095965 CAe3 095985 CAP60

34 25 34 25 380 480 190 095966 CAe5 --- ---

H W D Part No. Type Part No. Type



Zones 1 --> 2et 21 --> 22

Zones21 --> 22

A B C D

5 5 5 5 120 120 95 097000 JBe10

9 5 9 5 120 180 95 097001 JBe20

9 9 9 9 180 180 95 097002 JBe30

H W D Part No. Type



Zones 1 --> 2et 21 --> 22


Rf. Type Rf. Type Rf. Type Rf. Type

095950 PCe1 095980 CAP10 095960 PCe1 095980 CAP10

Polyester Aluminium

Zones 1 & 2et 21 & 22

Zones21 & 22

Zones 1 & 2et 21 & 22

Zones21 & 22

E F G Rf. Type Rf. Type

150 133 174 095953 CAe1 095983 CAP40

255 238 279 095954 CAe2 095984 CAP50

360 343 384 095955 CAe3 095985 CAP60

Polyester

Dimensions (mm)Zones 1 & 2et 21 & 22

Zones21 & 22

Rf. Type Rf. Type

095956 CAe4 095986 CAP70

Polyester

Zones 1 & 2et 21 & 22

Zones21 & 22

E F Rf. Type Rf. Type Rf. Type Rf. Type

116 134 095951 PCe2 095981 CAP20 095961 PCe2 095981 CAP20

176 194 095952 PCe3 095982 CAP30 095962 PCe3 095982 CAP30

Polyester Aluminium

Zones 1 & 2et 21 & 22

Zones21 & 22

Zones21 & 22

Dimensions (mm)

Zones 1 & 2et 21 & 22

4) Location of cable entries


Rf. Type

095966 CAe5

Aluminium

Zones 1 & 2et 21 & 22

E F G Rf. Type Rf. Type

150 133 174 095963 CAe1 095983 CAP40

250 238 275 095964 CAe2 095984 CAP50

355 343 380 095965 CAe3 095985 CAP60

Aluminium

Dimensions (mm)Zones 1 & 2et 21 & 22

Zones21 & 22

E F G H Part No. Type

110 80 80 110 097000 JBe10

170 140 80 110 097001 JBe20

170 140 140 170 097002 JBe30

316L St/Steel

Dimensions (mm) Zones 1 & 2et 21 & 22


Polyester, Aluminium and 316L St/Steel boxes

Check if the calculated power P is less than or equalto maximum allowed dissipated power of the box.

Dissipated power calculation:

N : Number of same cross-section terminalPc: Dissipated power of the cable connected to the terminal

I: Intensity (A)Pc = R x I R: Rsistance of cable (ohms)

Pb: Dissipated power of the terminal

Pb: terminal dissipated power

P = [ N x P1 ] + [ N x P1 ] + [ N x P1 ] + . [ N x P1 ]

2,5mm terminal 4mm terminal 6mm terminal .. 70mmterminal

P1: Dissipated power of terminal and cable = Pb + Pc

Appendix A

R: Rsistance of cable (ohms)

2,5 4 6 10 16 25 35

PCe1 0,001466 0,000912 0,000610

PCe2 0,001832 0,001140 0,000762 0,000452

PCe3 0,002290 0,001425 0,000953 0,000565

CAe1 0,002748 0,001710 0,001143 0,000678 0,000426 0,000270 0,000195

CAe2 0,003481 0,002166 0,001448 0,000859 0,000540 0,000342 0,000247

CAe3 0,004305 0,002679 0,001791 0,001062 0,000667 0,000423 0,000306

CAe4 0,005496 0,003420 0,002286 0,001356 0,000852 0,000540 0,000390

CAe5 0,004488 0,002793 0,001867 0,001107 0,000696 0,000441 0,000319

JBe10 0,001740 0,001083 0,000724

JBe20 0,002198 0,001368 0,000914

JBe30 0,002473 0,001539 0,001029 0,000610

Typ

e

Borne (section en mm) / Terminal (capacity mm)

Cross-section (mm) 2,5 4 6 10 16 35

Pb (W) 0.141 0.196 0.194 0.50 1.786 0.903

Type PCe1 PCe2 PCe3 CAe1 CAe2 CAe3 CAe4 CAe5 JBe10 JBe20 JBe30L (mm) 62 112 172 147 255 360 510 330 51 110 110

Max. Allowed dissipated power.(W)

6 11 16 17 22 29 36 36 6 11 16


5) Drilling

How to drill boxes?In order to help you, ATX has created 3 tables which give you drilling distances and also the location for each cable entry.a) The drilling distance and the position of a cable gland and a plug with the same thread.

Electrical thread


b) The drilling distance and the position of a cable gland and a plug with different thread.

Metric thread

Electrical and Metric thread


6) ATX requirements

This chapter contains requirements based on ATXs experience to make successful increased safetyjunction boxes

The thicknesses of boxes can vary depending on their dimensions and material, and this thickness must be known before machining. The following tables show the thicknesses (e) for each boxes.

You can equip polyester boxes with an earthing plate that you can make yourself, for electrical continuity of cable armour.Depending of the thickness of the earthing plate* you can make a combination of clearance holes and/or tapped holes in the box and in the earthing plate.Caution! It is forbidden to have tapped hole on the box and the earthing plate at the same time.Earthing plate performs three functions at the same time : mechanically hold the cable entries in position, earth the cable armour, provide earth continuity.

* From cable entry size electrical thread n36 and metric thread M40, box and earthing plate must have clearance hole and locknut.

Drilling and Machining

Polyester and Aluminium boxes (tapped holespossible)

Thickness of the boxes

316L St/Steel boxes (only clearance holes )

1,5JBe30097002

1,5JBe100970001,5JBe20097001

TypePart Nos.

Wall thickness

(mm)

Zones 1 2 et 21 22

(wallthickness)

(wallthickness)


If the length of the treaded part of the cable entry or plug is less than 10mm, boxes will have to betapped.Caution! Do not forget the locknuts if you are usingclearance holes

Tapped and clearance holes

Polyester and aluminium boxes Locknuts

Clearances holes only, for all types of thread.Caution! Do not forget the locknuts.

316L Stainless steel boxes

Quality of drilling and tapping

Correct Non Correct

Clearance hole

Tapped hole

Drilling and/or tapping must done in order to always guarantee :- Index of protection of the box (IP)- the non bending of the drilled and/or wall

Results to get (see photos below):

Part Nos.

thread


Traceability

Earth stud

Marking

Fixing of the label in order to maintain the box index protection (IP)

Mounting of earth crossing terminal

All ATX equipment comprises a manufacturing number that corresponds to the product supplied, in accordance with article 29.2 in standard EN 60079-0

You should place your own label (containing at least your name and manufacturing number) where it can be seen from outside close to the label, for each customized adaptation for the purposes of product traceability. Note that the manufacturing number may be the same for a series of identical equipment, coming from same batch.

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G0002EC: ATX GUIDE FOR INSTRUMENT AND JUNCTION BOXES

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