Raytec WARRIOR 24 User manual

910-D-00042 Rev A
Floodlight Range Installation Guide
This installation guide provides instructions for installing the Infra-Red and
White-Light WARRIOR series of industrial floodlights.
Text in Bold is specific for emergency variants
Overview
1 Safety Instructions
2 Installation
3 Maintenance
4 Technical Specification
5 Trouble Shooting
Important information
The WARRIOR series of industrial floodlights are specialist devices, for use in
industrial operating environments.
The units must be installed in accordance with these instructions 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 Raytec for immediate assistance and advice.

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1. Safety instructions
1. Read this leaflet carefully before commencing to install the WARRIOR 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, mains supply and the ambient temperature present is suitable for
the unit being installed.
3. If the WARRIOR unit is to be installed in areas of high vibration, please consult with Raytec.
4. Externally the WARRIOR 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 WARRIOR unit will be
installed in.
5. WARRIOR units are designed to withstand marine environments and are tested in accordance with
IEC60068-2-52. However if the WARRIOR 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 side of floodlight to ascertain type of threaded cable entry on the luminaire. Select
suitably certified 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 20°C 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
Replace any cracked protective shield
Order SPX-BKT-GL from Raytec Ltd

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2. Installation
Mounting WARRIOR 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. Raytec
recommend using M8 Marine Grade A4 Stainless Steel fixings (not supplied)
WARRIOR 24 (Emergency Variant Shown)

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WARRIOR 48
291
150
215
STANDARD EMERGENCY
2. The WARRIOR 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 WARRIOR 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 WARRIOR housing and the
mounting bracket. The unit must be aligned first before securing the bracket,
and bolts tightened to 15Nm. On WARRIOR 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.
50
100
150
504
376
12.5
25

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Typical wiring diagram –standard luminaires
Typical wiring diagram –emergency luminaires

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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 (switched 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 WARRIOR floodlights have terminal blocks suitable for looping 4mm2 cable,
only one cable should be connected to each terminal block connection.
8. Emergency WARRIOR 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 WARRIOR units are maintained in accordance with local
standards.
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 WARRIOR 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, WARRIOR unit and old LED assemblies should be
carried out in accordance with national regulations.

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4. Technical Specification
WARRIOR 24 WARRIOR 48
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

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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
FL12
FL24
FL48
B
10A
11
5
2
B
16A
17
8
4
B
20A
25
12
8
B
25A
35
17
8
C
10A
24
12
6
C
16A
34
17
8
C
20A
49
24
12
C
25A
58
29
14

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Raytec Global (excluding Americas)
Tel: [phone]
[e-mail]
Raytec Ltd.
Unit 15 Wansbeck Business Park, Rotary Parkway
Ashington, Northumberland, NE63 8QW, United Kingdom
raytecled.com
Raytec Americas
Tel: [phone]
[e-mail]
Raytec Systems Inc.
800-300 Terry Fox Drive, Ottawa, Ontario
2K 0E3, Canada