Raytec RAYMAX WARRIOR User manual

illuminators installation guide
LUX WARRIORMAX and
This installation guide provides instructions for installing the RAYMAX Infra-Red and
RAYLUX White-Light WARRIOR series of explosion protected illuminators.
1. Safety Instructions
2. Installation
3. Maintenance
4. Technical Specification
5. Trouble Shooting
Version 4.0
Important information
• TheWARRIORseriesofexplosionprotectedilluminatorsarespecialistdevices,
certified for use in specific operating environments.
• Theunitsmustbeinstalledinaccordwiththeseinstructions,mustbecorrectly
certiedforthespecicoperatingenvironmentandmustbeinstalledbysuitably
qualified personnel.
• Ifyouhaveanyqueriesabouttheinstallationorthecerticationoftheunit–please
contactRaytecforimmediateassistanceandadvice.
Overview

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1.Safetyinstructions
1. ReadthisleaetcarefullybeforecommencingtoinstalltheWARRIORunitandretainit
forfutureuse.Installationcanonlybecarriedoutbysuitablyqualiedpersonnel.
2. Checkthecertication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Raytec.
4. The WARRIOR unit housing is constructed from marine grade aluminium and
polycarbonate. The end user must ensure that these materials are suitable for the
atmospheretheWARRIORunitwillbeinstalledin;Zone1andZone2Hazardousareas.
5. The incoming mains cable should not exceed a temperature rise of 61˚C above
theambientconditions;selectsuitablecableandcablegland.You must use ATEX
approvedcableandglandse.g.M25,foradviceonsuitableglandsandcablesplease
contactRaytec
Specicationssubjecttochangewithoutnotice.
Installationtobecarriedoutbysuitabletrainedandqualiedpersonnel.
!
Isolatemainsbefore
removing cover
Installinawell
ventilated area
Donotcontinually
stare at lamp
1.5m

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2. Installation
Mount WARRIOR Unit
1. TomeettherequirementsofcerticationaMINIMUMof2xingpointsmustbeused,
thexing/xingpointsmustbesuitablefortheconditionsofuse.
2. Theunitmayhavebeensuppliedwithanintegratedphotocell.Careshouldbetaken
whenpositioningtheunittoensurethesensorisnotshielded,isnotpointingdirectly
atanotherlightsourceandismonitoringthegeneral,prevailinglightconditions.
3. TheWARRIORilluminator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.Itisveryimportantthattheredbrewashersarettedbetween
theWARRIORhousingandthemountingbracket.Theunitmustbealignedrstbefore
securingthebracket.Theunitcanbemountedhorizontallyorverticallyallowingthe
unittopointup/downorleft/right.
267
R30
120
R15
5 x
HOLES 9
30
100
281
250
245 202
2 x M20 ENTRIES
COMPLETE WITH
IEC Ex APPROVED
STOPPER PLUGS
EXTERNAL
EARTH/GROUND
POINT
135

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Power Connections
1 2 3 4 5 6 7 8 9 10 11 12
Terminal Loop
(colour may vary)
MAINS
INPUT
MAINS
LOOPING
OUTPUT
(OPTIONAL)
LAMPS (LED)
OUTPUTS
(OPTIONAL)
PHOTOCELL
INPUT
(OPTIONAL)
Terminal Pins
Wiring Label
Terminal
Cable Crimp
(colour may vary)
Terminal
Block
Weidmüller
WHITEWHITE WHITEWHITE
BLACKBLACK BLACK
BLACK
RED
RED
RED
RED
BLUE
BLUE BLUE
BROWN
BROWN BROWN
GREEN/YELLOW
GREEN/YELLOW
GREEN/YELLOW GREEN/YELLOW
Photocell Black
(-ve)
Red
(+ve) N L E
WiretheMainscableintotheterminalblock.Provisionhasbeenmadeforthisandidentied
astheE(Earth/Ground),L(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.
4. Installershouldearth/groundtheunitseparately.
5. Connectwirestomainssupply;
Blue=Neutral
 Brown=Live
 Green/Yellow=Earth/Ground
6. Iftheunitisopenedforanyreason,disconnectmains.
For 24V version only – Must not be used on a Centre Tapped Earth Transformer
power supply

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Additional important information
Note: Torque = Newton Metre (Nm)
7. All WARRIOR units have terminal blocks suitable for 4mm2 live, neutral and earth/
ground.
8. Wheninstallingtheunitthespecialconditionsforsafeuseshouldbeadheredto–
i. Exceptforinternalwiring,notmorethanonesingleormultiplestrandleadshallbe
connected into either side of any terminal, unless multiple conductors have been
joinedinasuitablemanner,e.g.twoconductorsintoasingleinsulatedcrimpedboot
lace ferrule.
ii. Leadsconnectedtotheterminalsshallbeinsulatedfortheappropriatevoltageand
thisinsulationshallextendtowithin1mmofthemetaloftheterminalthroat.
iii. Allterminalscrews,usedandunused,ontheWARRIORterminalblock(typeBkIECEx
SIR05.0035Uterminalblock)shallbetighteneddowntobetween0.5Nmand0.7Nm.
iv. The WARRIOR terminal hey shall only be installed and wired with cable within a
temperature range of -10°C to 80°C.
v. Whencross-connectingcombsareusedontheterminalstherelevantconditionsof
certicationIECExSIR05.0035UandIECExSIR05.0037Ushallbeapplied.
vi. Cableentryholesshallbettedwitheitheranappropriatelycertiedcableglandor
appropriatelycertiedblankingelement.Theseshallprovideandmaintainaminimum
enclosureingressprotectionofIP66orIP67asappropriate.
vii. IntheunlikelyeventofthefailureofanLED,theassemblymustbereplaced;contact
Raytecforassistance.

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4. Technical Specification
Input Voltage 100-254VAC
 24VAC/DCversionavailable
Consumption 60Wmax
Power Factor >0.95
Mains Frequency 50/60Hz
IP Rating 66/67
Weight 6kg
Dimensions 250x165x145mm
ATEX and IECEx Zone1&Zone2:
Rating II2GDExembII
Protection / Certification
IECEx Cert.
ExembIICT4Gb
ExtIIICT103°C
DbIP66/67
Tamb-20°Cto+50°C
ATEX Cert.
II2GD
ExembIICT4Gb
ExtIIICT103°C
DbIP66/67
Ta=-20°Cto+50°C
WARRIOR Specification
3. Maintenance
1. IsolatetheWARRIORunitfromthemainssupplyandallowtocoolbeforecarryingout
anymaintenancework.
2. IntheunlikelyeventofthefailureofanLED,theassemblymustbereplaced;contact
Raytecforassistance.
3. ItisessentialthatallWARRIORunitsaremaintainedinaccordancewiththerequirements
of the EN60079-17standard: (Electrical apparatus for explosive gas atmospheres –
otherthanmines).
4. IMPORTANT. No modications are permitted to the unit, all spare parts must be
purchased from the manufacturer, unauthorized modications or spare parts will
invalidate certification.
5. ELECTROSTATIC CHARGING HAZARD-Plasticcomponentsmaybecleanedwith
watercontainingasmallamountofdetergent,followedbyacleanwaterwash.Surplus
watercanbewipedoffplasticcomponents,buttheyshouldnotbewipedorpolished
withadryclothtoavoidabuild-upofstaticelectricity.
6. Disposalofpackaging,WARRIORunitandoldLEDassembliesshouldbecarriedout
inaccordancewithnationalregulations.

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PART CODES & DISTANCES
RLW-200-10 RAYLUXWarrior,10° White-Light 120m(394ft)
RLW-200-30 RAYLUXWarrior,30° White-Light 65m(213ft)
RLW-200-50 RAYLUXWarrior,50° White-Light 45m(184ft)
5.Troubleshooting
1. EnsurethetwoLEDboardsarecorrectlywiredtoterminalblock.
Red to Red : Black to Black
2. EnsureMainsinputiscorrectlyconnected.
Earth/Ground to Yellow/Green : Live to Brown : Neutral to Blue
3. EnsureMainsInputisturnedonatthesource
PART CODES & DISTANCES
RMW2-200-10 RAYMAXWarrior,10° 850nm 150m(492ft)
RMW2-200-30 RAYMAXWarrior,30° 850nm 80m(262ft)
RMW2-200-50 RAYMAXWarrior,50° 850nm 56m(184ft)
RAYMAX WARRIOR: Infra-Red
RAYLUX WARRIOR: White-Light

8
UK / Europe
T: [phone]
F: [phone]
[e-mail]
Americas (Toll Free)
T: [phone]
[e-mail]
www.rayteccctv.com
WII/11/10.1