Raytec WARRIOR User manual

High Power Luminaire Range -
Installation Guide
SPI
This installation guide provides instructions for installing the WARRIOR HP
Highbay/ Floodlight series of industrial floodlights.
Overview
1Safety Instructions
2Installation
3Maintenance
4Technical Specification
5Trouble Shooting
The WARRIOR HP series of industrial floodlights/highbay are for use only in
industrial environments.
The units must be installed by suitably qualified personnel.
If you have any queries about the installation or the certification of the unit –
please contact Raytec for immediate assistance and advice.
Important information
1050-M-00052 Rev C

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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 label 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; Zone 1 and Zone 2 Hazardous areas.
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 label of product to ascertain type of threaded cable entry on the luminaire. Select suitable 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. The light source contained in this luminaire shall only be replaced by the manufacturer or his service agent
or a similar qualified person.
Replace any cracked protective shield
Order SPX-BKT-HPFL-RL from Raytec Ltd
!
Install in a well
ventilated area
Do not continually
stare at lamp
Isolate mains before
removing cover
1.5m

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151
215
350
536 639
173
200
12
30
12
2. Installation
Mounting WARRIOR Unit
1. For good engineering practice a minimum of 2 fixing points must be used,
the fixing points must be suitable for the conditions of use.
2. The line diagrams below are for guidance only - units may be mounted in any
orientation.
Mounting HP WARRIOR Unit – Floodlight Application
151
215
350
536 639
173
200
12
30
12

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Americas Tel: [phone]
151
215
350
536 639
173
200
12
30
12
Mounting WARRIOR Unit – Highbay Application
422 (16.6")
353 (13.9")
536 (21.1")
457 (18")
13
(0.51")
33 (1.3")
172 (6.8")

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LED DRIVER #1
Ex 'd' Enclosure
Ex 'e' Junction Box
LED+
LED-
N
L
DA
DA
LED1+ LED1-
L
E
N
DA
DA
LED2+
LED2-
Ex 'em' Enclosure
Ex d
Assembly
LED DRIVER #2
LED+
LED-
N
L
DA
DA
LED2+ LED2-
LED1+
LED1-
EQUI
EQUI
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
L
E
N
DA
DA
LED2+
LED2-
LED1-
LED1+
Typical wiring diagram
1. Wire the Mains cable into the terminal block. Provision has been made
for this and identified as the E (Earth), L (Live), Ls (Live switched) 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 Ls
terminals on a standard unit are not electrically connected but allows them
to be used on the same circuits as emergency floodlights.
2. Installer should earth the unit separately – an internal and external earth
point are provided as standard.
3. Connect wires to mains supply.
4. If the unit is opened for any reason, disconnect mains.
5. All WARRIOR floodlights/highbay have terminal blocks suitable for looping
4mm2 cable, only one cable should be connected to each terminal block
connection.
6. To use DALI/Dimming interface, connect the DALI terminals on the terminal
block ensuring the correct polarity of DA+ and DA-.
E: Earth
N: Neutral
L1: Live

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3. Maintenance
1. It is essential that all WARRIOR units are maintained in accordance with
national 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 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 remove the cover to get access to the power supply.
Remove the power supply from the mains terminals then remove LED red
and black wires.
5. Disposal of packaging, WARRIOR units and old LED assemblies/power
supplies should be carried out in accordance with national regulations.

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120W version 300W version
Input Voltage 150-264V AC/DC or 110-264V AC/DC
see certification nameplate on product
Input Current (230Vac, full load) 0.52A 1.4A
Consumption 120W 300W
Power Factor (230Vac, full load) >0.97
Mains Frequency 50/60Hz
Inrush Current (Ipeak @50%) 53A, ∆t < 300µs 60A, ∆t < 300µs
Total Harmonic Distortion
(230Vac, full load) ≤3%
IP Rating IP66
Weight (std) 22Kg 23Kg
Dimensions See previous pages for line diagrams
4. Technical Specication

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Inrush Current Typical Curve
Twidth
Ipeak
Max number of fittings allowed per MCB
MCB Type Rating SPZ/SPX-HP10K
(120W Version)
SPZ/SPX-HP15K
(180W Version)
SPZ/SPX-HP20K
(240W Version)
SPZ/SPX-HP25K
(300W Version)
B 10A 4 3 2 1
B 16A 10 6 4 3
B 20A 12 7 5 4
B 25A 15 10 7 6
C 10A 8 5 4 3
C 16A 16 8 6 5
C 20A 20 10 8 6
C 25A 26 16 13 9

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4.1 DALI Wiring Instructions
Cross section in mm2
Maximum cable length L in m
25°C 50°C 75°C
0.14 31 28 26
0.50 112 102 93
0.75 168 153 140
1.00 224 204 187
1.50 300 300 281
2.00 300 300 300
2.50 300 300 300
Table below shows the maximum cable length L between two units. Cable lengths
of more than 300m are not recommended. The maximum allowed voltage drop on
DALI bus system is 2,0V.
*IP66 150-264V AC/DC

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5. Troubleshooting
1. Ensure the two LED boards are correctly wired to terminal block. Red to Red
: Black to Black – paired cables
2. Ensure Mains input is correctly connected.
3. Ensure Mains Input is turned on at the source.
4. 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.

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