Chalmit Protecta Series Manual

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INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Protecta – (LED) Luminaires (Industrial).
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.
MODEL SIZE DIMENSION ‘A’ DIMENSION ‘B’
02L 742 400
04L 742 400
07L 1352 700

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0.0 Specification
Type Of Protection N/A
Standards EN 60598-1, EN 60598-2-22
Area Classification Industrial, (Non- Hazardous)
Ambient -25°C to +45°C
Ingress Protection IP66/67 to EN 60529
CE Mark 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”. [This legislation is the equivalent in UK law of EU
directives 2014/35/EU, 2014/30/EU, 2012/19/EU respectively].
M Poutney Technical Manager
Luminaire is supplied with Battery plug/Socket disconnected, just prior to switching
power on, connect battery plug and socket.
1.0 Introduction - Protecta Safe Area LED Luminaire
The Protecta Safe Area LED Luminaires are surface mounted or suspended, utilising the two tapped holes on
base of body, with the facility of an integral battery back-up for emergency use. Normal operation is mains supply
LEDS full on, switching to reduced LED power on battery back-up, local switching of the mains LEDS, the
emergency output only being energised on mains failure. Emergency duration: to BS EN 60598 2.22, as per
order. They are mainly used in harsh environments and are constructed using a corrosion resistant glass
reinforced polyester body attached to an injection moulded polycarbonate diffuser by hinges and a special clamp.
The control gear and LED strips are mounted on a removable tray which for maintenance has hanging straps.
2.0 Storage
Luminaires and control gear boxes are to be stored in cool dry conditions preventing ingress of moisture and
condensation. Any specific instructions concerning emergency Luminaires must be complied with.
Battery packs in storage should be cycled charged/discharged/charged every 9 months, as per instructions
below. Always disconnect battery plug and socket for storage.
Any specific instructions concerning emergency luminaires must be complied with.
(Warning: Battery packs not cycled and stored for a year may not be recoverable)
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.
In the UK the requirements of the 'Health and Safety at Work Act' must be met.
Handling and electrical work associated with this product to be in accordance with the 'Manual Handling
Operations Regulations' and 'Electricity at Work Regulations, 1989'. Your attention is drawn to the paragraphs (i)
'Electrical Supplies', (ii) 'Electrical Fault Finding and Replacement' and (iii) 'Inspection and Maintenance'. The
luminaires are Class 1 and should be effectively earthed.
The information in this leaflet is correct at the time of publication. The company reserves the right to make
specification changes as required.
3.2 Tools
12mm, 5mm and 3mm flat blade screwdriver. Pozi number 2 screwdriver
Suitable spanners for installing cable glands. Pliers, knife, wire strippers/cutters.
3.3 Electrical Supplies and Control Gear
Luminaires fitted with electronic control gear are suitable for a rated supply from 120- 277Vac 50-60Hz,
127-300V dc for standard fitting and 220-240V 50/60Hz for emergency. The safety limits are +10% of this. The
supply would normally be expected to lie within +/-6% of rated. The LED supply is regulated, therefore the light
output over the range is substantially unchanged.
Electronic gear has integrated power factor correction to >0.90.

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Warning: Luminaires are assessed and/or tested for EMC requirements. This is based on the disposition
of entry cables and, where appropriate, through wiring arrangements as supplied or specified.
Users must take care not to introduce wiring into parts of the apparatus materially different to that
which could be reasonably inferred from the disposition of fixed supply terminals and specified wiring.
3.4 Light Emitting Diodes (LED)
LED’s are supplied in either 02L, 04L or 07L options with the colour temperature of 4000K or 5000K.
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 standard suspension is via two M8 tapped holes in brass
bushes in the top of the body, the recommended torque for the fixing bolts is 10-15Nm. (at 400mm centres for
02L and 04L and 700mm centres for the 07L model). The brass bushes and lock nuts should not be removed
during installation. Various adaptors, pole clamps and suspension brackets are available to order. The 02L and
04L models are available with integral side entry for 42 mm diameter poles (non- emergency only).
3.6 Cable Connection
3.6.1 Cables
The temperature conditions of the supply cable entry point are such that 70ºC (ordinary PVC) cable can be used.
300/500V cable ratings are adequate and no special internal construction is necessary. Where MCB's are used,
the type with the higher short time tripping current ratio used for motor starting and lighting should be specified.
The standard maximum looping size is 2.5mm² with options of 4mm² through wiring
3.6.2 Cable Glands
Cable glands when installed should maintain the desired IP rating of the enclosure.
3.7 Electrical Connections
Luminaires are available for looping and through wiring. The through rating is 16A. Terminals for 4mm² and
6mm² are available. State which on order. If work is to be done on any Luminaire which has already been
connected to the electrical system, it must be isolated from the system. The diffuser cover is swung down and
removed if convenient by swivelling back as far as possible and the reflector tray is then slid out after releasing
the locking screws. This gives access to the mains terminals. Standard fitting mains terminal blocks have L N E,
where appropriate.
Mains terminal blocks on the emergency luminaires are marked Lc Ls N Earth.
Switching the voltage on the Ls connection enables the luminaire to be switched on and off without the
emergency function being activated. The Ls connection is insulated from Lc and has a signal function only
drawing a very small current.
The emergency units can be connected as switched or un-switched as standard, an non-maintained units on
request. The switching facility is to allow the luminaire to be switched off whilst still charging the battery. Where
switching is required, the un-switched line (Lc) is connected to the continuous mains supply. A link is fitted during
assembly between Lc and switched line (Ls); this is removed for the switch-able mode. If the link is removed and
Ls not supplied, the unit will only operate on emergency.
3.7.1 Installation of HF and Emergency
Following the mounting of the apparatus and the connection of the supply cable the unit cannot be insulation
tested. When the unit is ready for operation the mains and the battery connections must be made, the unit is
supplied with the battery disconnected. After commissioning the unit can be shut down for a long period without
loss of function. However with emergency versions the battery should be disconnected to ensure battery life is
maintained.
3.8 Servicing and Operation
3.8.1 Opening and Closing the Cover
The procedure for opening the cover is as follows:
Insert the tool into one of the slots in the clamping bar with the end of the tool located into the outer flange of the
body as a fulcrum point, a wide blade screwdriver is recommended. Gently lever the tool away from the diffuser,

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the clamping bar will begin to open. Insert the tool in the other clamping bar slot and gently lever away from the
diffuser the clamping bar will open and the cover will be retained by the hinge. Should difficulty be experienced
reinsert the tool in the first slot and repeat the procedure.
The procedure for closing and securing the cover is as follows:
Ensure the hinge mechanism is clear of any obstruction and then swing the diffuser into the closed position.
Support the diffuser in position whilst pushing the clamp bar over the edge of the diffuser. Apply even pressure
at both ends of the bar and press the bar over centre.
3.8.2 Removal and Replacement of Clamping Bar (if required)
Open the luminaire as above and remove the diffuser or let it swing down. Press the clamping bar towards the
closed position, tip forward beyond the closed position and the clamping bar will be released from the body. To
replace the clamping bar, put in position on the body with the front edge pointing as far inwards as it will go. Click
the bar outwards and bring back to the normal closed position. The clamping bar should then be secured in
position, open the clamping bar fully by using hand or screwdriver pressure (avoid damaging the gasket), the
clamping bar is then ready to accept the normal closure of the diffuser.
3.8.3 Releasing the LED Tray / Gear Tray
Loosen the four fixing screws retaining the LED / Gear tray and slide over keyhole slots. The tray will hang on the
retaining cords without stressing the wiring between body and tray. Replace in reverse order.
3.8.4 Retro Fitting Lamps to LED’s
Before opening the front cover ensure that the luminaire is isolated from the mains supply. Access for retro fitting
is via the front cover, care is to be taken as there is limited suspension of the cover. Make sure that the correct
ESD protection is taken during LED replacement to avoid electric discharge to the PCB.
3.8.5 Commissioning
Energise the mains and check that LED’s light when the supply is energised.
Emergency luminaires are supplied with the Battery plug/Socket disconnected. Just prior to switching power on,
connect battery plug and socket.
Emergency luminaires will require battery packs to be cycled to obtain the full duration/capacity of the Ni-Cd
battery cells. It is recommended that the unit is charged for a minimum period of 24 hours, then permitted to
discharge via emergency operation (power OFF), and then charged again for a minimum period of 24 hours.
If checking battery duration at this time it may be necessary to repeat the cycle to obtain the full 3 hour duration.
3.8.6 Post Commissioning Storage
It is assumed that during commissioning the battery plug and socket are connected.
If the power is to be removed after commissioning for a period of time, our recommendations, along with
guidance from the battery manufacturer, are:
 Up to 6 months – No action required. Mains power can be reapplied during this time and the battery will
accept a charge.
 6 to 12 months – Disconnect battery plug and socket to maintain charge in the battery.
Before re-connection of mains power re-connect the battery plug and socket. Mains power can be
reapplied and the battery will accept a charge.
 Longer than 12 months – Disconnect battery plug and socket. Approximately every 6 months carry out a
charging/discharging cycle, 24 hours charging followed by 3 hour discharge and another 24 hour charge,
then isolate power and disconnect battery plug & socket. This is to avoid deep discharge of cells, which
is caused by a trickle discharge or by long term storage. This could lead to the cells not accepting a
charge from the inverter or not achieving full expected duration.
 If the battery is to be checked separately, it should be charged using a constant current charger at
200/400mA for 30/15 hours for the 4Ah. Discharge measurement is not easy as the current is
proportional to the voltage for resistance loads, so it has to be averaged. Discharge the battery at 1 to
2A and multiply current by time. Do not discharge below 1 volt per cell, which is 5V. The capacity should
be 75% or more of normal.

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3.9 Inspection and Maintenance
On battery models, we recommend that the battery duration is checked periodically.
Important: Isolate the mains supply and disconnect the battery terminal before carrying out any work.
3.9.1 Replacement of Electronic Ballast and EM convertor Unit (Where Fitted)
The electronic ballast and EM convertor contain no replaceable parts. Should it be found necessary to replace
these parts, the following procedure should be adopted:
Ensure that the Luminaire is isolated from both mains and battery supplies, otherwise a risk of shock may occur.
Disconnect the leads on the ballast at the terminal block. Undo the ballast securing screws and washers and
withdraw the ballast from the gear body. Replace in reverse order. Replacement of the EM convertor is identical.
3.9.2 Routine Examination
The Luminaire must be de-energised before opening. Individual organisations will have their own procedures.
What follows are guidelines based on our experience :
1 Ensure LED’s are lit when energised by mains supply.
2 Visually check diffuser cover for damage, this should only be cleaned using a damp cloth to avoid static, and
only use recommended detergents for polycarbonate. If the polycarbonate is discoloured or damaged a new
diffuser cover must be fitted.
3 When de-energised and left to cool, there should be no significant sign of internal moisture. If there are any
signs of water ingress, the Luminaire should be opened up, dried and any likely ingress points eliminated by
re-gasketting or other replacements.
4 Check cable gland for tightness and nip up if required.
5 Check any external and internal earths.
6 Check all terminations are firmly screwed down, tighten if necessary.
7 Check clips visually for any damage and replace, if necessary.
8 If it has been suspected that the Luminaire has suffered mechanical damage, a stringent workshop check on
all components should be made. All components can be removed from the Luminaire for inspection.
4.0 Electrical Fault Finding and Replacement
The supply must be isolated before opening the Luminaire.
Any live fault finding must be done by a competent electrician and, if carried out with Luminaire in place, under a
permit to work.
The control gear can be tested for continuity of connections with a low voltage tester.
If LED’s go out repeatedly, and replacement components do not work or expected life is reduced, the control
gear should be returned for replacement / testing.
On re-assembly all faulty / damaged wiring should be replaced and connections checked.
5.0 Disposal of Material
The unit is made from combustible materials. The control gear contains plastic parts and polyester resin. All
electrical components and the body parts may give off noxious fumes if 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 [2012/19/EU] and therefore must not be treated as
commercial waste. The unit is mainly made from incombustible materials.
5.1 LED’s
LED’s in modest quantities are not "special waste". They should be broken up in a container to avoid injury.
Avoid inhaling dust.
5.2 Battery Disposal
Nickel cadmium batteries are defined as 'controlled waste' under the hazardous waste regulations and disposer
needs to observe a 'duty of care'.
Batteries can be returned to the manufacturers for re-cycling. They must be stored and transported safely and
any necessary pollution control forms completed prior to transportation. Take care to fully discharge batteries
before transporting, or otherwise ensure that there can be no release of stored energy in transit. For further
details refer to our Technical Department.

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Table A Series Standard circuit
Refer to Section
:
1.0
No. of
LED strips
Lumens Driver
Current
Power
Consumption
Watts
Line
Current
Inrush
Current/
Duration
02L-1 x 560mm 2296 400mA 16 0.07A 31A (1.7 μs)
04L 2 x 560mm 3526 300mA 24 0.10A 34A(2.3 μs)
07L 2 x 1120mm
6596 600mA 44 0.19A 36A (2.7 μs)
Table B Series Emergency circuit Refer to Section
:
1.0
No. of
LED strips
Lumens Driver
Current
Power
Consumption
Watts
Line
Current
Inrush
Current/
Duration
02L 1 x 560mm 2296 400mA 20 0.10A 31A (1.7 μs)
04L 2 x 560mm 3526 300mA 26 0.12A 31A(1.8 μs)
07L 2 x 1120mm 6596 600mA 48 0.22A 36A (2.7 μs)
6.0 Emergency Self-Test or Battery Monitoring Versions
This version is capable of testing the performance of the emergency Luminaire in accordance with IEC 62034.
Commissioning
After installation of the Luminaire and initial connection of the mains supply will initiate commissioning where the
battery will remain on charge for an uninterrupted 24 hours. At this time the module will conduct a commissioning
test for the full duration.
The 24 hours recharge occurs also if a new battery is connected or the module exits the rest mode condition.
The following automatic commissioning duration test is only performed when a battery is replaced and fully
charged (after 24 hrs) and the interval time is not set to zero, otherwise the system is expected to perform the
testing.
If the mains supply is to be interrupted for more than 7 days, then the battery MUST be disconnected.
Functional test
The time of day and frequency of the 5 seconds function test can be set by the
DALI controller. The default setting is a 5 seconds test on a weekly basis.
Duration test
The time of day and frequency of the duration test can be set by the DALI
controller. The default setting is a duration test conducted every 52 weeks.
To comply with the Waste Electrical and Electronic Equipment directive 2012/19/EU 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.

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LED Indicator - A bi-colour LED indicates the status of the module as follows:
LED Indication Status Comment
Permanent green System OK AC mode
Fast flashing green
(0,1 sec on – 0,1 sec off) Function test underway
Slow flashing green
(1 sec on – 1 sec off) Duration test underway
Red LED on Load failure Open circuit / Short circuit / LED failure
Slow flashing red
(1 sec on – 1 sec off) Battery failure
Battery failed the duration test or function test /
Battery is defect or deep discharged/
Incorrect battery voltage
Fast flashing red
(0,1 sec on – 0,1 sec off) Charging failure Incorrect charging current
Green and red off DC mode Battery operation (emergency mode)

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EU-Declaration of conformity
UE-Déclaration de conformité
EU-Konformitätserklärung
Manufacturer Chalmit Address 388 Hillington Road, Glasgow. G52 4BL Scotland UK
Product Protecta LED Industrial (Standard and Emergency)
Catalogue PR3I/***/**/** Example: PR3I/02L/LE/EM
Area Classification Industrial, (Non- Hazardous)
Ingress Protection IP66/67
Ambient -25°C to +45°C
Terms of the directive: Standard & Date Certified to Standards Date Declared to
2014/30/EU Electromagnetic compatibility
EN 55015 : 2013
2014/30/UE Compatibilité électromagnétique
EN 61547 : 2009
2014/30/EU Elektromagnetische Verträglichkeit
EN 61000-3-2 : 2014
2014/35/EU Low voltage equipment
EN 60598-1 : 2015
2014/35/UE
Équipements électriques à bas voltage EN 60598-2-5 : 2015
2014/35/EU
Niederspannungsgeräte / -systeme EN 60598-2-22 : 2014
EN 60529 : 1992
2012/19/EU Waste of electrical and electronic equipment
2012/19/UE
Déchets d'équipements électriques et électroniques
2012/19/EU
Entsorgung der elektrischen und elektronischen Geräte
/ Systeme
2011/65/EU RoHS II Directive
On behalf of the Chalmit, I declare that, on the date the equipment accompanied by this declaration is placed on the market, the equipment
conforms to all technical and regulatory requirements of the above listed directives.
En tant que représentant du fabricant Chalmit, je déclare qu'à la date où les équipements accompagnant cette déclaration sont mis sur le
marché, ceux-ci sont conformes à toutes les dispositions réglementaires et techniques des directives énumérées ci-dessus.
Hiermit bestätige ich, im Namen von Chalmit, dass am Tag der Lieferung des Produkts/der Produkte zusammen mit dieser Erklärung das
Gerät/die Geräte alle technischen und regulativen Anforderungen der oben aufgeführten Direktiven erfüllt.
Name and Date Mark Poutney 18/07/2019 Technical Manager
Nom et Date Directeur technique
Name und Datum Technischer Leiter
Quality Management System Acreditation: ISO 9001
Système de Management Qualité Accréditation:
Qualitätsmanagementsystem Akkreditierung:
Environmental Management System. ISO 14001
Système de gestion de l'environnement. by/par/durch
Umwelt kontroll system. Loyd's Register
Certificate No./Certificat N°/Zertifikat Nr. LRQ 4005876