Nemalux RF Series User manual
Floodlight Range Installation Guide
Zone 1 variant CML13ATEX3007 or IEC Ex CML14.0001 or CML 21UKEX3099
Zone 2 variant CML17ATEX4231 or IEC Ex CML 17.0135 or CML 21UKEX4106
This installation guide provides instructions for installing the RF series of
explosion protected floodlights.
Text in Bold is specific for emergency variants
Overview
1 Safety Instructions
2Installation
3Maintenance
4 Technical Specication
5Trouble Shooting
Important information
The RF series of explosion protected floodlights are specialist devices, certified for use
in specific operating environments.
The units must be installed in accordance with these instructions, must be correctly
certified for the specific operating environment and must be installed by suitably
qualified personnel.
Emergency floodlights will require the fuse to be reconnected upon installation
and the floodlight subjected to three 24 hour charge/discharge cycles to bring
the battery up to peak capacity.
If you have any queries about the installation or the certification of the unit – please
contact Nemalux for immediate assistance and advice.
RF Series
rev. A-21
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1. Safety instructions
1. Read this leaflet carefully before commencing to install the RF unit and retain it for
future use. Installation can only be carried out by suitably qualified personnel.
2. Check the certification and “T” rating to ensure that the mains supply and the
ambient temperature present is suitable for the unit being installed.
3. If the RF unit is to be installed in areas of high vibration, please consult with
Nemalux.
4. Externally the RF unit housing is constructed from marine grade aluminium, and
toughened glass, stainless steel brackets/fasteners and silicone gaskets, internally
there are many non metallic components. The end user must ensure that these
materials are suitable for the environment the RF unit will be installed in; Zone 1
and Zone 2 Hazardous areas.
5. Check certification nameplate on side of floodlight to ascertain type of threaded
cable entry on the luminaire. Select suitably certified ATEX/IEC Ex /UKEX cable glands
and stopper plugs, these must be parallel thread, have a minium of 5 full thread
engagement and be of a medium/fine tolerance to ISO965-1 and ISO965-
3. The cable entry devices selected must maintain the IP rating of the luminaire
6. The incoming mains cable should not exceed a temperature rise of 20°C above the
ambient conditions; select suitable cable.
7. When the unit is installed correctly and in accordance with these installation
instructions it will not harm humans or animals.
8. Before installing emergency luminaires please check the last charge date of the
battery. This is shown on the external product packaging and also on the battery
label, alternatively consult date shown on the declaration at the back of this
leaflet. If the last charge date was in excess of 3 months (if stored at 5°C to 25°C) or
1 month (if stored outside this range) from date of installation, please consult
Nemalux document 0010-D-00001 Battery Handling Guide
!
Install in a well
ventilated area
Do not continually
stare at lamp
Isolate mains before
removing cover
1.5m
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2. Installation
Mounting RF Unit
1. To meet the requirements of certification a MINIMUM of 2 fixing points must
be used, the fixing points must be suitable for the conditions of use. Nemalux
recommend using M8 Marine Grade A4 Stainless Steel fixings (not supplied)
RF Series 12 Floodlight
RF Series 24 (Emergency Variant Shown)
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RF 48
2. The RF floodlight and the mounting bracket is supplied together as a unit.
The bolts in the side of the housing shall be removed and used to secure the
bracket to the RF housing, the bracket can be attached in the top or bottom
position depending on the mounting application, where possible the cable glands
should be kept to the bottom of the floodlight. It is very important that the red
fibre washers are fitted between the RF housing and the mounting bracket. The
unit must be aligned first before securing the bracket, and bolts tightened to
15Nm. On RF 24 and 48 units a locking screw is provided to lock the luminaire at
various angles, which should be tightened to 4Nm. The unit can be mounted
horizontally or vertically allowing the unit to point up/down or left/right.
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Typical wiring diagram – standard luminaires
Typical wiring diagram – emergency luminaires
WHITE/ REDWHITE/ RED
WHITE/ RED
WHITE/ RED
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3. Open the rear compartment to access terminal block. Wire the Mains cable into
the terminal block. Provision has been made for this and identified as the E
(Earth), L1 (swiched live) and L2 (permanent live) and N (Neutral) terminals. There
are two pairs of contacts for each of these to facilitate a mains cable that can be
looped in and out of the unit. The L2 terminals on a standard unit is not
electrically connected but allows them to be used on the same circuits as
emergency floodlights.
4. Installer should earth the unit separately – an internal and external earth point are
provided as standard.
5. Connect wires to mains supply.
6. If the unit is opened for any reason, disconnect mains – On emergency
luminaires there may be more than one mains supply.
7. All RF floodlights have terminal blocks suitable for looping 4mm2 cable, only one
cable should be connected to each terminal block connection.
8. Emergency RF floodlights may have a single green LED fitted adjacent to the
incoming cable glands, when illuminated the green LED indicates that the
emergency system is healthy.
9. The battery fuse located in the power supply lid on emergency variants is
disconnected after final manufacturing testing. When installing the
floodlight the battery fuse will need to be reconnected and the unit charged
for 24 hours and then discharged (repeated 3 times) to bring the battery up
to peak capacity.
10. If a 4 core cable is used on emergency luminaires – L1, L2, N and E the link
cable at the front of the terminal block between L1 and L2 should be
removed.
11. During emergency operation the light output and duration will be
determined by the variant purchased.
12. Once wiring is complete replace rear cover. Ensure gasket is located neatly
in channel and no wires are trapped between cover and body. Tighten cover
screws to 3Nm.
13. If carrying out Insulation Resistance tests the normal method of insulation testing
is to connect Live and Neutral together and test between this point and Earth to
prevent the risk of damage to the electronic control gear.
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3. Maintenance
1. It is essential that all RF units are maintained in accordance with the requirements
of the EN60079-17 standard: (Electrical apparatus for explosive gas atmospheres –
other than mines).
2. IMPORTANT. No modifications are permitted to the unit, all spare parts must be
purchased from the manufacturer, unauthorized modifications or spare parts will
invalidate certification and make the equipment dangerous.
3. Isolate the RF unit from the mains supply and allow to cool before carrying out
any maintenance work.
4. The unit has 2 independent power supplies, in the event that a power supply
needs to be replaced the cables to the LED and mains terminal block will need to
be disconnected, the four M6 bolts released the power supply can then be
removed. Fitting a new power supply is a reversal of the above procedure.
5. Disposal of packaging, RF unit and old LED assemblies should be carried out in
accordance with national regulations.
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4. Technical Specification
RF-8 RF-17
Input Voltage 110-254V AC or 18-48V AC/18-69V DC or 12V DC
Consumption 68W max 136W max
Consumption
(Emergency variant) 71W max 139W max
Power Factor >0.95
Mains Frequency 50/60Hz
Inrush Current (Ipeak @ 50%) 40A ∆t < 300µs
Total Harmonic Distortion (230Vac full load) <10%
IP Rating IP66/67
Weight Environment Standard - 8kg (17.6lbs)
Emergency - 10Kg (22lbs)
Standard - 16kg (35.2lbs)
Emergency - 20Kg (44lbs)
Weight Environment
(Emergency variant) 11.5kg (25.3lbs) 21kg (46.3lbs)
Dimensions Dimensions See previous pages for line diagrams
ATEX and IECEx and UKEX Rating See below
CML17ATEX4231 or IECEx CML 17.0135 or
CML 21UKEX4106
II 3 GD Ex ec mc IIC T4 Gc
Ta -50°C to +55°C (standard variants)
II 3 GD Ex ec mc IIC T4 Gc
Ta -20°C to +55°C (emergency variants) Ex tb
IIIC T82°C Dc
IP66 & IP67 Ta = -50°C to +55°C
110V-254V AC or 18-48V AC/18-69V DC
Protection/Certification
CML13ATEX3007 or IEC Ex CML14.0001 or
CML 21UKEX3099
II 2 GD Ex eb mb IIC T4/T5 Gb
Ta -52°C to +55°C (standard variants)
II 2 GD Ex eb mb IIC T6 Gb
Ta -52°C to +48°C
II 2 GD Ex eb mb IIC T4 Gb
Ta -20°C to +55°C (emergency variants) Ex tb
IIIC T82°C Db
IP66 & IP67 Ta = -52°C to +55°C
110V-254 AC or 18-48V AC/18-69V DC
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5. Trouble Shooting
1. Ensure the two LED boards are correctly wired to terminal block.
White to White : White/Red to White/Red
2. Ensure Mains input is correctly connected.
3. Ensure Mains Input is turned on at the source
4. On emergency variants check fuse to ensure it has not blown
5. If LED panel fails to light is it possible to identify if problem is with LED panel or
power supply by swapping LED cables to opposite power supply to help
identify problem.
Max number of fittings allowed per MCB
(Based on 230V)
MCB Type Rating RF-8 RF-17
B 10A 5 2
B 16A 8 4
B 20A 12 8
B 25A 17 8
C 10A 12 6
C 16A 17 8
C 20A 24 12
C 25A 29 14
RF
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Declaration Of Conformity
With The Atex Directive 2014/34/EU
& UK Directive SI 2016 No. 1107 (as amended)
The RF series luminaire is manufactured by Raytec Ltd. for Nemalux Inc.
Raytec Ltd. declares under our sole responsibility that the product(s) listed below
conform with the relevant provisions of directive 2014/34/EU of 20th April 2016 and
UK Directive SI 2016 No. 1107 (as amended)
Manufacturer
Description
of Equipment
Certification
Body
Certificate
Equipment
Marking
Raytec Ltd
Unit 15, Wansbeck Business Park
Rotary Parkway
Ashington
Northumberland, NE63 8QW
United Kingdom
RF Series/Spartan range of floodlights – standard and
emergency
CML
New Port Road
Ellesmere Port, CH65 4LZ
Zone 1 - CML13ATEX3007, IEC Ex CML14.0001 & CML21UKEX3099 Zone
2 - CML17ATEX4231, IEC Ex CML17.0135 & CML21UKEX4106 ATEX
Quality Assurance Notification CSA BV (2813)
UKCA Quality Assurance Notification CSA UK (0518)
II 2 GD Ex eb mb IIC T4/T5 Gb
Ta -52oC to +55oC (standard variants)
II 2 GD Ex eb mb IIC T6 Gb
Ta -52°C to +48oC
II 2 GD Ex eb mb IIC T4 Gb
Ta -20oC to +55oC (emergency variants)
Ex tb IIIC T82°C Db
IP66 & IP67 Ta = -52°C to +55°C
110V-254V AC or 18-48V AC/18-69V DC
II 3 GD Ex ec mc IIC T4 Gc
Ta -50oC to +55oC (standard variants)
II 3 GD Ex ec mc IIC T4 Gc
Ta -20oC to +55oC (emergency variants)
Ex tb IIIC T82°C Dc
IP66 & IP67 Ta = -50°C to +55°C
110V-254V AC or 18-48V AC/18-69V DC
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Compliance with the Essential Health and Safety Requirements has been assessed by
reference to the following harmonised/designated standards -
EN 60079-0 : 2018 EN 60079-7 : 2015 + A1 : 2018
EN 60079-18 : 2015 + A1 : 2017 EN 60079-31 : 2014
EN 60079-1 : 2014
And also 2014/35/EU - Low Voltage Directive, 2014/30/EU - EMC Directive
Signed
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Name Barry Thompson
Position Director
Dated
Serial number
1018 - 72nd Ave NE | Calgary, AB, Canada T2E 8V9
Toll Free: 1-877-NEMALUX / 1-877-636-2589
P: 1.403.242.7475
F: F: 1.403.243.6190
W: www.nemalux.com
Industrial LED Lighting designed to solve
harsh and hazardous lighting challenges.
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