Nemalux RB Series User manual

RB Series
RB Bulkhead Range - Installation Guide
Zone 1 variant CML 13ATEX3007, IEC Ex CML14.0001 & CML21UKEX3099
Zone 2 variant CML 17ATEX4231, IEC Ex CML17.0135 & CML21UKEX4106
This installation guide provides instructions for installing the White-Light RB series of explosion
protected bulkheads.
Text in italics is specific for emergency variants.
Overview
1Safety Instructions
2Installation
3Maintenance
4 TechnicalSpecication
5Declaration of Conformity
Important information
The RB series of explosion protected bulkheads 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.
If you have any queries about the installation or the certification of the unit – please contact
Nemalux for immediate assistance and advice.
rev. A-21
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1. Safety instructions
1. Read this leaflet carefully before commencing to install the RB Bulkhead unit
and retain it for future use. Installation can only be carried out by suitably
qualified personnel.
2. Check the certification nameplate attached to the luminaire to ensure that
the hazardous zone, mains supply, ambient temperature present and ‘T’ rating are
suitable for the environment the unit is being installed in.
3. If the RB unit is to be installed in areas of high vibration, please consult with
Nemalux.
4. Externally the RB 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 RB unit will be
installed in; Zone 1 and Zone 2 Hazardous areas.
5. Check certification nameplate on side of bulkhead 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 minimum
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 24°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 RB 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 recommends
using M6 Marine Grade A4 Stainless Steel fixings (not supplied).
121
104
302
288
204
220 182
240
220
168
70
20
17
3
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2. The RB Bulkhead is supplied as standard with the mounting brackets as shown
on the above diagram, other mounting methods/brackets available – please
contact Nemalux.
RB Bulkhead Standard/Emergency Variant
3. Installer should earth the unit separately – an internal and external earth point
are provided as standard
4. Connect wires to mains supply.
5. If the unit is opened for any reason, disconnect mains – On emergency
luminaires there may be more than one mains supply
6. All RB bulkheads have terminal blocks suitable for looping 4mm2 cable,
only one cable should be connected to each terminal block connection
Wire the Mains cable into the terminal block. Provision has been made for this and
identified as the E (Earth), L1 (Live switched), L2 (Live permanent) 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 are not
electrically connected but allows them to be used on the same circuits as emergency
bulkheads.
NEL1 L2
EARTHTOSCREW
PSU
WHITE/RED
WHITE
BLUE
BROWN
GREEN
TO LED's
Typical wiring diagram - Standard Variants
Typical wiring diagram - Emergency Variants
NEL1 L2
EARTHTOSCREW
PSU
WHITE/RED
WHITE
BLUE
BROWN
GREEN
TO LED's
BATTERY
RED
RED
BLACK
BLACK
FUSE
GREY
REMOVE LINK IF 4-CORE
CABLE USED
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•Commissioning Cycle
•Function test
•Self-test
A tri-colour LED indicator displays the light fitting status. The indication colours are
shown in table 1.
a. Commissioning Cycle
•Starts automatically after 24 hours of uninterrupted charging.
•3 charge/discharge cycles to optimise battery’s full capacity.
•Battery is charged for 24 hours before each discharge cycle.
•No need for manual commissioning
b. Function Test
•Carried out every 7 days.
•Checks the function of the battery, lamp and power supply.
•Lasts for few minutes only.
RB Intelligent Emergency Operation Guide
Operation
The light fitting will carry out the following function automatically after installation:
7. The battery fuse located within the Bulkhead housing on emergency variants is
disconnected after final manufacturing testing. When installing the bulkhead
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.
(Unless an ‘EMX’ intelligent emergency variant – see notes below)
8. 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
9. During emergency operation the light output and duration will be determined by
the variant purchased
10. 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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Notes
•The luminaire will switch off momentarily (<0.5sec) during the transition
between a test and normal operation.
•If a test was interrupted by a mains failure, the test will be halted, and the unit
will enter emergency mode. Once the mains supply is back, the unit will allow
24 hours to recharge the battery before continuing the tests.
•The self-test is carried out at a random time to eliminate the possibility of having
more than one unit undergoing the test at the same time.
LED indication
c. Self-test
•Carried out at a random time every 3 month.
•Checks the battery’s capacity and lamp’s condition.
•Performs self-recovery for the battery if not at peak capacity.
•Is carried out at 100% load
•Discharges only 2/3 of the battery’s capacity.
LED Indication Condition
Blinking amber Commissioning
Static Amber Function Test
Self-test
Blinking Red
Battery defective/Fuse blown
PSU error
Battery not at peak capacity
Light engine failure
No light Emergency mode activated
Static Green Battery charged and PSU OK
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3. Maintenance
1. It is essential that all RB Bulkhead 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 RB Bulkhead from the mains supply and allow to cool before
carrying out any maintenance work.
•For Emergency variants, battery must be isolated/ connected when a
hazardous environment is NOT present prior to carrying out any maintenance
work.
4. In the unlikely event of a number of LED’s failing, the light engine assembly must
be replaced. This is achieved by loosening front cover bolts, disconnecting the
white LED cables to power supply, remove four M6 bolts from rear of light engine
and pull the light engine assembly clear. Re fitting a light engine is a reversal of
the above procedure.
5. The unit has one independent power supply, in the event that the 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, then the power supply
can then be removed. Fitting a new power supply is a reversal of the above
procedure.
6. Disposal of packaging, RB unit and old LED assemblies should be carried out in
accordance with national regulations.
PROTECTION/CERTIFICATION
CML13ATEX3007,IECExCML14.0001&CML21UKEX3099II 2 GD Ex eb mb
IIC T4 Gb
Ta-52°Cto+55°C(standardvariants)
II 2 GD Ex eb mb IIC T4 Gb
Ta-20°Cto+46°C(emergencyvariants)
ExtbIIICT98°CDb
IP66&IP67Ta=-52°Cto+55°C
110V-254VACor18-48VAC/18-69VDC
CML17ATEX4231,IECExCML17.0135&CML21UKEX4106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tcIIICT98°CDc
IP66&IP67Ta=-50°Cto+55°C
110V-254VACor18-48VAC/18-69VDC
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4. Technical Specification
RB-2-STD RB-2-EM
Input Voltage 110-254V AC
Input Current (230Vac, full load) 0.15A 0.16A
Consumption 34W 37W
Power Factor (230Vac, full load) >0.97
Mains Frequency 50/60Hz
Inrush Current (Ipeak @50%) 20A, ∆t < 300µs
Total Harmonic Distortion (230Vac, full load) <10%
IP Rating IP66/67
Weight (std) 5Kg 6Kg
Dimensions See previous pages for line diagrams
ATEX and IECEx and UKEX Rating See above
Twidth
Inrush Current Typical Curve
Ipeak
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Max number of fittings allowed
per MCB (Based on 230V)
MCB Type Rating RB-2-STD RB-2-EM
B 10A 11 10
B 16A 17 15
B 20A 25 22
B 25A 35 32
C 10A 24 20
C 16A 34 28
C 20A 49 44
C 25A 58 55
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Declaration Of Conformity
With The Atex Directive 2014/34/EU
& UK Directive SI 2016 NO. 1107 (as amended)
The RB 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 the ATEX directive 2014/34/EU of 20th April
2016 and the UK directive SI 2016 No. 1107 (as amended)
Manufacturer
Description
of Equipment
Certification
Body
Certificate
Numbers
Equipment
Marking
Raytec Ltd
Unit 15, Wansbeck Business Park
Rotary Parkway
Ashington
Northumberland
NE63 8QW
United Kingdom
RB/Spartan range of bulkhead luminaires – 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 Gb
Ta -52oC to +55oC (standard variants)
II 2 GD Ex eb mb IIC T4 Gb
Ta -20oC to +46oC (emergency variants)
Ex tb IIIC T98°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 tc IIIC T98°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 60079-7 : 2015 + A1 : 2018
EN 60079-31 : 2014
EN 60079-0 : 2018
EN 60079-18 : 2015 + A1 : 2017
EN 60079-1:2014
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Andalso2014/35/EU-LowVoltageDirective,2014/30/EU-EMCDirective
Signed
Name Barry Thompson
Position Director
Dated
Serial number

1018 - 72nd Ave NE | Calgary, AB, Canada T2E 8V9
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W: www.nemalux.com
Industrial LED Lighting designed to solve
harsh and hazardous lighting challenges.
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