Chalmit lighting Micronex 70W HPS Manual

I-MICN-01.doc Issue 06 Mar10 1
IOM – MICRONEX - ZONE 2 FLOODLIGHT (ATEX, Ex n)
Issue 06
Micronex - Floodlight Luminaires
ATEX, Ex n
INSTALLATION
,
OPERATION AND MAINTENANCE INSTRUCTIONS
Important: Please read these instructions carefully before installing or maintaining this equipment.
Good electrical practices should be followed at all times and this data should be used
as a guide only.
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I-MICN-01.doc Issue 06 Mar10 2
IOM – MICRONEX - ZONE 2 FLOODLIGHT (ATEX, Ex n)
Type(s) of Protection Ex nR (Non-Sparking) (Restricted Breathing)
Protection Standard EN 50021
Area of Application Zone 2 areas to BS EN 60079-10 and installation to BS EN 60079-14
ATEX Equipment
Classification
Group II Category 3 G
Equipment Coding II 3 G Ex nR II T3 Tamb 40ºC
Certificate Type Examination EECS BAS98ATEX3054
Ingress Protection IP66 and IP67 to BS EN 60529
CE Mark
Declaration of
compliance with
standards
The CE marking of this product applies to "The Electrical Equipment (Safety)
Regulations 2006", "The Electromagnetic Compatibility Regulations 2004", the “Waste
Electrical and Electronic Equipment Regulations 2006” and the "Equipment and
Protective Systems intended for use in Explosive Atmospheres Regulations 1996".
[This legislation is the equivalent in UK law of EC directives 2006/95/EC, 2004/108/EC
and 2002/96/EC respectively].
The Equipment is declared to meet the provisions of the ATEX directive (94/9/EC) by
reason of the EC Type Examination and compliance with the Essential Health and
Safety Requirements.
I MacLeod Technical Manager
SPECIAL CONDITIONS FOR SAFE USE
None
1.0 Introduction - Micronex Floodlight
The type of protection is Ex nR using a restricted breathing enclosure.
Note: The maximum ambient and surface temperature ratings are as indicated in TABLE 0.
2.0 Application
The luminaire is designed to be safe in normal operation.
The luminaire should not be used in conditions where there are environmental, vibration or shock conditions
above the normal expected levels for fixed installations.
The gaskets should not be exposed to hydrocarbons in liquid or high concentration vapour states.
The body material is made from marine grade aluminium, copper free (BS1490 LM6), powder coated.
The luminaire is suitable for applications where Category 3 apparatus can be used. The application is for
ignitable gas atmospheres. The type examination does not address suitability for dusts or portable applications.
Table 1 Maximum Ambient and Surface Temperature Rating
Wattage Lamp Ambient Temp T Rating Cable Rating
Cable Rise
70W SON/TS, MBI/TS 40ºC T3 75oC 30oC
Table 2 Starting and Running Currents
Lamp Start A Run A PFC µF
70W HPS 0.55 0.40 10
70W MBI 0.55 0.40 10

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IOM – MICRONEX - ZONE 2 FLOODLIGHT (ATEX, Ex n)
Table 3 Fuse Ratings
Number of Lamps
Lamp Type
1 2 3 4 5 6
70W HPS 4A 4A 4A 6A 6A 10A
70W MBI 4A 4A 4A 6A 6A 10A
Table 4 Weight and Windage
Type Weight
Windage
MICRONEX HPS/MBI 5.1kg 0.08m2
Power factor ≥0.85
EMC EN 55015
Terminals 6mm² as standard, through wiring and looping has current limit of 16A.
Tamb Storage -40°C to +80°C
Storage Luminaires should be stored in cool dry conditions preventing ingress of moisture and
condensation
Lamps Lamps suitable for RX7 lampholders in accordance with EN 60838
Fuse and Refer to tables 2 and 3 for starting and running currents and fuse ratings. Also refer to
section
MCB ratings 5 for information regarding inrush current.

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IOM – MICRONEX - ZONE 2 FLOODLIGHT (ATEX, Ex n)
Suitable spanners for installing
cable glands, 3mm and 5mm
flat blade screwdriver and a M6
Allen key.
3.0 Installation and Safety
3.1 General
There are no health hazards
associated with this product
whilst in normal use. However,
care should be exercised during
the following operations.
Installation should be carried
out in accordance with BS
EN60079-14 or the local
hazardous area code of
practice, whichever is
appropriate.
Pliers, knife, wire
strippers/cutters.
3.3 Electrical Supplies
The luminaires are Class 1 and
should be effectively earthed.
Certification details on the
rating plate must be verified
against the application
requirements before
installation. The information in
this leaflet is correct at the time
of publication. The company
reserves the right to make
specification changes as
required.
The supply voltage and
frequency should be specified
when ordering a maximum
voltage variation of +6%/-6% on
the nominal is expected. (The
safety limit for T rating is
+10%). Luminaires should not
be operated continuously at
more than +6%/-10% of the
rated supply voltage of the
control gear or tapping. The
user must determine the actual
underlying site supply and
purchase or adjust accordingly.
Care must be taken if
connecting to the nominal
230V UK Public Supply. In
some cases, the luminaires
have multi-tapped control gear
which can be set to a range of
voltages. The tappings are
shown on the control gear and
the limits are shown on the
rating plate. If the equipment is
located in high or low voltage
sections of the system, an
appropriate voltage tap should
be selected to obtain the best
lamp performance, but care
must be taken to log or mark
the equipment so that the
tapping is re-set if the
equipment is relocated. If in
doubt, tappings should be set
on the high side. 10V Max.
drop is desirable for HPS and
required for MBI. All circuits
use S.I.P. (superimposed
pulse) ignitors. This means that
there are only two connections
to the choke so tap selection is
obvious. Where supply
conditions include significant
harmonics the PFC can be
omitted.
Where shore or construction
site supplies are used, which
are different to the service
location supplies, tappings
should be re-set. If not, advice
on the effect of these temporary
3.2 Tools
A cross head screwdriver blade
to open the cover.

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IOM – MICRONEX - ZONE 2 FLOODLIGHT (ATEX, Ex n)
supplies should be sought from
the Technical Department.
3.4 Lamps
The Micronex uses double
ended HPS and MBI lamps and
are of a standardised type, with
no preference between make or
colour. All have RX7 caps.
Care must be taken to fit the
correct new and replacement
lamp in order to preserve the
certification conditions and
obtain the designed
photometric performance. The
lamp type is shown on the
rating plate.Lamps should be
replaced shortly after they do
not light. One indication of the
end of life for HPS lamps is
'cycling', where the lamp goes
out then re-ignites after a
minute or so interval. If
discharge luminaires are
burned continuously, they
should be switched off
occasionally to allow old lamps
to fail to re-ignite, rather than
possibly become diodes with
detrimental effects to control
gear.
The above information is
current at the time of
preparation. The development
of lamps and control gear is
ongoing and detailed advice on
lamp performance can be
obtained from the lamp supplier
or from Chalmit.
Note: HPS and MBI
circuits should not be energised
without a lamp fitted. HPS and
MBI lamps with internal
ignitors must not be used.
3.5 Mounting
Luminaires should be installed
where access for maintenance
is practical and in accordance
with any lighting design
information provided for the
installation. The stirrup
mounting arrangements should
be secured with lock washers
or self-locking nuts and bolts.
There are clearance holes for
M10 bolts. The luminaire
should be mounted with the
lamp axis horizontal.
3.5.1 Weights and
Windages
The weights and windages for
the various floodlight types are
outlined in TABLE 4.
3.6 Cabling and Cable
Glands
3.6.1 Cables
The cable entry temperatures
are given as the rise over the
maximum rated ambient. This
allows the user to adjust the
cable specification for the
actual site maximum
temperature. The terminals are
suitable for standard conductor
section up to 6mm² max. All
models are suitable for looping.
Standard 300/500V cable is
suitable. The cable makeup
must be suitable to ensure the
obtaining of a restricted
breathing enclosure when the
cable gland assembly is fitted.
It is strongly advisable to use a
high quality and well filled cable
with direct entry into restricted
breathing luminaires.
3.6.2 Cable Glands
Cable glands and sealing plugs
when installed must maintain
the restricted breathing
enclosure. Entries suitable for
M20 cable glands are standard.
To maintain the restricted
breathing properties of the
enclosure a suitable cable
gland such as a Hawke
501/453/RAC type should be
installed or a cable gland
satisfying the following
requirements:
The cable gland must
satisfy the requirements for
en 60079-0 and must
maintain an ingress rating
of at least IP65.
The certified cable gland is
to be a compression type
gland where the cable
sheath is evenly
compressed when
tightened or an Ex d
stuffing type or a punched
seal type.
To enable a reliable seal at
the cable entry face a
neoprene or silicone
rubber washer and a
stainless steel washer are
provided for each entry
and must be fitted.
3.7 Cabling and Fitting
Lamps
Access for cabling and fitting
lamps is by removing the front
cover. The cover is released by
undoing the two screws using a
screwdriver. Reselect the
voltage tappings if necessary.
Install the conductors in the
appropriate terminals. Take
care not to cut back the
insulation excessively, 1mm
bare conductor outside the
terminal is a maximum. Any
unused terminal should be fully
tightened.
When the cabling is complete,
make a final tightness and
connection check.
Lamps must be of the correct
type and correctly in place. The
cover is replaced and the
screws tightened down.
3.8 Inspection and
Maintenance
Visual inspection should be
carried out at a minimum of 12
monthly intervals and more
frequently if conditions are
severe. The time between
lamp changes could be very
infrequent and this is too long a
period without inspection.
3.8.1 Routine Examination
(a) The equipment must be de-
energised before opening.
Individual organisations will
have their own procedures.
What follows are guidelines
based on BS EN 60079-17 and
on our experience :
1. Ensure the lamp is lit
when energised and

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IOM – MICRONEX - ZONE 2 FLOODLIGHT (ATEX, Ex n)
that the lampglass is
not damaged.
2. When de-energised
and left to cool there
should be no significant
sign of internal
moisture. If there are
signs of water
ingress, the luminaire
should be opened up,
dried out, and any likely
ingress points
eliminated by
re-gasketting.
3. Check the cable gland
for tightness and nip up
if necessary.
4. Check the tightness of
the cover screws and
nip up if necessary.
5. Clean the lampglass.
(b) When relamping, check that
the cover gasket has not
softened or become
excessively deformed, if in
doubt replace (see Section 4.0).
3.9 Electrical Fault
Finding and Replacement
The supply must be isolated
before opening the luminaire.
In most instances the faults are
simple, namely loose or broken
connections, unserviceable
lamps or open circuit control
gear. Control gear will not
normally go open circuit unless
it has first over-heated; the
signs of this are obvious, being
severe discoloration of the paint
on the gear and cracks in any
exposed insulation. Similarly, a
bad contact at the lamp cap will
usually result in discoloration as
a sign of overheating.
Any fault finding must be done
by a competent electrician and,
if carried out with the luminaire
in place, under a permit to
work. With HPS and MBI, the
ignitor can become faulty. If the
lamp is fitted, the choke has
continuity and the connections
are good and correct they
should produce an "attempt to
start" effect in the lamp and a
buzzing sound from the ignitor.
It will be unusual to have no
other parts available to perform
a substitution fault finding
routine and this is the normal
procedure. Before re-
assembling, all connections
should be checked and any
damaged cable replaced. The
ignition connection to the
lampholder is sleeved with H.T.
sleeving and this must be kept
in place.
3.9.1 Thermal Protector
Thermal protectors are
included. If the lamp goes on
and off over a timescale of
several minutes, this could be
the thermal protector operating.
The causes are defective
lamps/diode effects, gross over
voltage or the choke beginning
to fail and this should be
investigated directly. See also
Section 3.4.
4.0 Overhaul
The unit is largely made of
materials which are very
corrosion resistant. This allows
the unit to be completely
stripped, cleaned, then re-built
with new electrical parts as
required. The internal wiring is
1.0mm² flexible, silicone rubber
insulated. An H.T. sleeve is
fitted to the ignitor cable. All the
spares required are available.
Please state the model number,
lamp details.
The seal at the cover is
between the glass and the
frame. The glass is retained in
the cover frame by silicone
R.T.V. adhesive.
If the cover gasket has
deteriorated by softening or
permanent set, a new cover
gasket should be fitted. Which
can be obtained from Chalmit.
To fit this, care is needed, the
old gasket should be removed
and remaining adhesive
scraped off. The gasket is fixed
in place and joined with silicone
R.T.V. to the body. The cover
is tightened down and the
assembly should be tested for
air tightness prior to installation.
5.0 Fuse Ratings
The fuse ratings for HID lamp
circuits need to take account of
three components of circuit
current. Current inrush to PFC
capacitors which can be up to
25 x the rated capacitor current
and last 1-2 millisecs; lamp
starting current including steady
capacitor current which
together may decline from up to
200% of normal at 10 seconds
after switch-on to normal after 4
minutes; rectification effects
caused by asymmetrical
cathode heating for a few
seconds after starting, this
effect is random and very
variable. With the availability of
MCB's with a wide range of
characteristics, the individual
engineer can make a better
judgement of what is required.
Use MCB's suitable for inrush
currents to reduce ratings. The
inrush current can be calculated
where circuit conditions are
known. The nominal capacitor
current will probably be the
determining factor, 0.076A per
µF at 240V, 50Hz (adjust for
other supply volts by
multiplication, x 6/5 for 60Hz).
For HBC fuses use 1.5 x
normal capacitor current. All
calculations must satisfy wiring
regulations.
6.0 Disposal of Material
The unit is mostly made from
incombustible materials. The
capacitor is of the dry film type
and does not contain PCB's.
The control gear contains
plastic parts and polyester
resin. The ignitor contains
electronic components and
synthetic resins. All electrical
components and the body parts
may give off noxious fumes if

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IOM – MICRONEX - ZONE 2 FLOODLIGHT (ATEX, Ex n)
incinerated. Take care to
render these fumes harmless or
avoid inhalation. Any local
regulations concerning disposal
must be complied with. Any
disposal must satisfy the
requirements of the WEEE
directive [2002/96/EC] and
therefore must not be treated
as commercial waste. The unit
is mainly made from
incombustible materials. The
control gear contains plastic,
resin and electronic
components. All electrical
components may give off
noxious fumes if incinerated.
6.1 Lamps
Discharge lamps in modest
quantities are not "special
waste". The outer envelope
should be broken in a container
to avoid possible injury from
fragmentation, avoid inhaling
dust.
This applies to the UK, there
may be other regulations on
disposal operating in other
countries.
Note: Do not incinerate
lamps.
To comply with the Waste Electrical and Electronic Equipment directive 2002/96/EC the
apparatus cannot be classified as commercial waste and as such must be disposed of or
recycled in such a manner as to reduce the environmental impact.