Nemalux RL Series User manual

Important information
The RL series of explosion protected luminaires 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.
Linear Range - Installation Guide
CML14ATEX3119 & IEC Ex CML 15.0001 & CML21UKEX3105
CML15ATEX4138 & IEC Ex CML15.0068 & CML21UKEX4104
CML16ATEX1130 & IEC Ex CML16.0052 & CML21UKEX1100
This installation guide provides instructions for installing RL series of explosion
protected linear luminaires.
Text in italics is specific for emergency variants.
Overview
1
2
3
4
5
Safety Instructions
Installation
Maintenance
Technical Specification
Declaration of Conformity
RL Series
rev. A-21
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1. Safety instructions
1. Read this leaflet carefully before commencing to install the RL unit and retain it for future use. Installation can only
be carried out by suitably qualified personnel.
2. Check the certification to ensure that the hazardous zone, mains supply, ambient temperature present and ‘T’
rating are is suitable for the environment the unit is being installed in.
3. If the RL unit is to be installed in areas of high vibration, please consult with Nemalux.
4. Externally the RL unit housing is constructed from marine grade aluminium and polycarbonate outer optic, 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 RL unit will be installed in; Zone 1 or Zone 2
Hazardous areas
Plastic components may be cleaned with water containing a small amount of detergent, followed by a clean
water wash. Chemicals/ oils that come into contact with plastic parts may cause stress cracking and premature
component failure.
5. RL units are designed to withstand marine environments and are tested in accordance with IEC60068-
2-52. However if the SPARTAN unit is to be installed in a very high corrosive environment such as coastal and
offshore the following good practice should be followed:
During installing ensure there are no scratches, chips or defects in external paint surface that
would allow ingress of water to bare aluminium. If so touch up with suitable paint
During installation apply an anti corrosive jointing compound to screw threads such as PSU cover
and external earth points.
During installation ensure exterior surface of the product is not in direct contact with a dissimilar
metal such as galvanised steel. If so fit a nylon barrier to prevent galvanic corrosion.
During maintenance regularly wash down external surface of fitting with clean, fresh water to remove any
deposits of mineral salts on the exterior surface.
6. Check certification nameplate on cover of luminaire 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
7. The incoming mains cable should not exceed a temperature rise of 27oC above the ambient conditions; select
suitable cable.
8. When the unit is installed correctly and in accordance with these installation instructions it will not harm humans
or animals.
9. 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 Raytec document 0010-D-00001 Battery
Handling Guide
!
Install in a well
ventilated area Do not continually stare
at lamp
Isolate mains before
removing cover
1.5 m
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2. Installation
Mounting RL 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.
2. The rear of the unit has 3 blind sets of M8/M6 fixing points, a full range of mounting
accessories are available including a range of pole clamps, ceiling mount brackets,
various wall mount brackets, outreach bracket and chain mount eyelets. Please consult
nemalux for further details. The spigot mount version of the product is provided
with a pole mount system and 2xM6 A4 SS Grub Screws for mounting onto
32-43mm diameter poles. Once mounted tighten grub screws to 15Nm.
3. When installing the RL luminaire vertically where possible, the cable glands
should be kept to the bottom of the luminaire.
1370 FOR RL168 EMER
761 FOR RL84 STD AND EMER
1251 FOR RL168 STD
1635 FOR RL168-1500 STD
174
108
400 FOR RL84
700 FOR RL168/RL168-1500
969 FOR RL84 EM
851 FOR RL84
1341 FOR RL168
177
111
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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, an identical terminal block is also available at the other end of the luminaire to allow
the unit to be through wired. The L2 terminals on a standard unit is not electrically connected
but allows them to be used on the same circuits as emergency luminaires.
4. Installer should earth the unit separately – an internal and external earth point are
provided as standard at each end of the luminaire
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
Typical wiring diagram - Emergency Variants
NEL1 L2
EARTHTOSCREW
PSU PSU
WHITE/RED
WHITE
BLUE
BROWN
BLUE
BROWN
GREEN
RED
WHITE
TO LED's
Typical wiring diagram - Standard Variants
NEL1 L2
EARTH TO SCREW
PSU
WHITE/RED
WHITE
BLUE
BROWN
GREEN
TO LED's
BATTERY
RED
RED
BLACK
BLACK
FUSE
GREY
PSU
BLUE
BROWN
RED
WHITE
REMOVE LINK IF 4-CORE CABLE USED
Typical wiring diagram - Standard Variants
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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. If there is a mains failure in this
time the count resets for another 24 hours.
•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.
RL Intelligent Emergency Operation Guide
Operation
The light fitting will carry out the following function automatically after installation:
7. All RL luminaires have terminal blocks suitable for looping 4mm2 cable, only one
cable should be connected to each terminal block connection
8. The battery fuse is located in the compartment that contains the battery, the fuse is
disconnected after final manufacturing testing. When installing the linear 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)
9. 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
10. During emergency operation the light output and duration will be determined by the
variant purchased
11. Once wiring is complete replace terminal enclosure covers. Ensure gasket is located neatly in
channel and no wires are trapped between cover and body. Tighten screws to 3Nm
12. 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.
c. Self-test
•Carried out at a random time every 3 months.
•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
LED Indication Condition
Static Amber Commissioning in progress
Flashing
Discharge cycle in progress
LED will flash in relevant colour while discharging
Static Red
Battery defective/Fuse blown
PSU error
Battery not at peak capacity
Light engine failure
No light Emergency mode activated
Static Green Commissioning completed
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3. Maintenance
1. It is essential that all RL 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 RL unit 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 removing the outer polycarbonate cover and then
releasing the M3 bolts that hold the LED assembly in place, disconnect the white and
red/white cable to the power supply and pull the light engine PCB clear. Re fitting a
light engine is a reversal of the above procedure.
•For emergency variants, battery must be isolated/ connected when a hazardous
environment is NOT present prior to carrying out any maintenance work.
5. The unit has either 1 or 2 independent power supplies located in the terminal chamber
covers, in the event that a power supply needs to be replaced the terminal chamber cover
should be removed, the cables disconnected and the dog clip can then be detached
from the cover. Fitting a new power supply is a reversal of the above procedure.
6. Disposal of packaging, RL unit and old LED assemblies/power supplies should be carried
out in accordance with national regulations.
Protection Concepts
CML14ATEX3119 or IEC Ex CML15.0001 or CML21UKEX3105
CML15ATEX4138 or IEC Ex CML15.0068 or CML21UKEX4104
CML16ATEX1130 or IEC Ex CML16.0052 or CML21UKEX1100
Standard variants
II 2 GD Ex eb mb IIC T4 Gb Ex
tb IIIC T80°C Db
-40°C to +60°C
Standard variants
II 3 GD Ex ec mc IIC T4 Gc Ex
tc IIIC T80°C Dc
-40°C to +60°C
Standard variants
II 2 D Ex tb IIIC T80°C Db
-40°C to +60°C
Emergency variants
II 2 GD Ex eb mb IIC T4 Gb Ex
tb IIIC T76°C Db
-20°C to +50°C
Emergency variants
II 3 GD Ex ec mc IIC T4 Gc Ex
tc IIIC T75°C Dc
-20°C to +50°C
Emergency variants
II 2 D Ex tb IIIC T76°C Db
-20°C to +50°C
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4. Technical Specification
RL-1-STD RL-1-EM RL-2-STD RL-2-EM
Input Voltage 110-254V AC
Input Current (230Vac, full load) 0.15A 0.3A
Consumption 24W STD 32W EM 49W STD 56W EM
Power Factor (230Vac, full load) >0.95
Mains Frequency 50/60Hz
Inrush Current (Ipeak @50%) 20A, ∆t < 300µs 28A, ∆t < 300µs
Total Harmonic Distortion (230Vac, full load) <10%
IP Rating IP66/67
Weight (std) 6Kg 7Kg 9Kg 10Kg
Dimensions See previous pages for line diagrams
ATEX and IECEx Rating See below
Twidth
Inrush Current Typical Curve
Ipeak
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Max number of fittings allowed per MCB
(Based on 230V)
MCB Type Rating RL-1-STD RL-1-EM RL-2-STD RL-2-EM
B 10A 11 10 5 4
B 16A 17 15 8 7
B 20A 25 22 12 11
B 25A 35 32 16 15
C 10A 24 20 11 10
C 16A 34 28 16 15
C 20A 49 44 23 20
C 25A 58 55 28 25
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Manufacturer
Description
of Equipment
Certification Body
Certificate
numbers
Declaration Of Conformity
With The Atex Directive 2014/34/EU
& UK Directive SI 2016 No. 1107 (as amended)
The RL series luminaire is manufactured by Raytec Ltd. for Nemalux Inc.
Nemalux 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)
CML14ATEX3119 or IEC Ex CML15.0001 or CML21UKEX3105
CML15ATEX4138 or IEC Ex CML15.0068 or CML21UKEX4104
Standard variants
II 2 GD Ex eb mb IIC T4 Gb Ex
tb IIIC T80°C Db
-40°C to +60°C
Standard variants
II 3 GD Ex ec mc IIC T4 Gc Ex
tc IIIC T80°C Dc
-40°C to +60°C
Emergency variants
II 2 GD Ex eb mb IIC T4 Gb Ex
tb IIIC T76°C Db
-20°C to +50°C
Emergency variants
II 3 GD Ex ec mc IIC T4 Gc Ex
tc IIIC T75°C Dc
-20°C to +50°C
10-12
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Raytec Ltd
Unit 15, Wansbeck Business Park
Rotary Parkway
Ashington
Northumberland
NE63 8QW
United Kingdom
Spartan range of linear luminaires – standard and emergency
CML
New Port Road
Ellesmere Port
CH65 4LZ
C M L 1 4 A T E X 3 1 1 9 & I E C E x C M L 1 5 . 0 0 0 1 & C M L 2 1 U K E X 3 1 0 5
CML15ATEX4138 & IEC Ex CML15.0068 & CML21UKEX4104
CML16ATEX1130 & IEC Ex CML16.0052 & CML21UKEX1100
ATEX Quality Assurance Notication CSA BV (2813)
UKCA Quality Assurance Notication CSA UK (0518)

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IP66 & IP67
110V-254V AC or 18-48V AC/18-69V DC
Compliance with the Essential Health and Safety Requirements has been assessed by
reference to the following standards -
EN 60079-0 : 2018
EN 60079-7: 2015+A1:2018
EN 60079-31 : 2014
EN 60079-18:2015+A1:2017
And also 2014/35/EU – Low Voltage Directive, 2014/30/EU – EMC Directive
Signed
Name Barry Thompson
Position Director
Dated
Serial number
CML16ATEX1130 or IEC Ex CML16.0052 or CML21UKEX1100
Standard variants
II 2 D Ex tb IIIC T80°C Db
-40°C to +60°C
Emergency variants
II 2 D Ex tb IIIC T76°C Db
-20°C to +50°C

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Industrial LED Lighting designed to solve
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