Stahl EXLUX 6409/4 Series User manual

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Operating instructions
Additional languages www.r-stahl.com
EN
Emergency Luminaire with LED
Series EXLUX 6409/4

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Emergency Luminaire with LED
Series EXLUX 6409/4
Contents
1 General Information ............................................................................................3
1.1 Manufacturer .......................................................................................................3
1.2 Information regarding the operating instructions .................................................3
1.3 Further documents ..............................................................................................3
1.4 Conformity with standards and regulations .........................................................3
2 Explanation of the symbols .................................................................................4
2.1 Symbols in these operating instructions .............................................................4
2.2 Warning notes .....................................................................................................4
2.3 Symbols on the device ........................................................................................5
3 Safety notes ........................................................................................................5
3.1 Operating instructions storage ............................................................................5
3.2 Safe use ..............................................................................................................5
3.3 Intended Use .......................................................................................................6
3.4 Modifications and alterations ..............................................................................6
4 Function and device design ................................................................................6
4.1 Function ..............................................................................................................6
4.2 Device design .....................................................................................................7
5 Technical data .....................................................................................................9
6 Engineering .......................................................................................................13
6.1 Mains operation ................................................................................................13
6.2 Emergency light blocking ..................................................................................14
7 Transport and storage .......................................................................................16
7.1 General .............................................................................................................16
7.2 Batteries ............................................................................................................16
8 Mounting and installation ..................................................................................16
8.1 Dimensions / fastening dimensions ..................................................................17
8.2 Mounting / dismounting, operating position ......................................................19
8.3 Installation .........................................................................................................22
9 Commissioning .................................................................................................27
10 Operation ..........................................................................................................28
10.1 Operating Modes ..............................................................................................28
10.2 Functional and rated operating time test ...........................................................29
10.3 Indications .........................................................................................................29
10.4 Troubleshooting ................................................................................................30
11 Maintenance, Overhaul, Repair ........................................................................31
11.1 Maintenance .....................................................................................................31
11.2 Repair ...............................................................................................................35
11.3 Returning the device .........................................................................................35
12 Cleaning ............................................................................................................35
13 Disposal ............................................................................................................36
14 Accessories and Spare parts ...........................................................................36

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General Information
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Emergency Luminaire with LED
Series EXLUX 6409/4
1 General Information
1.1 Manufacturer
1.2 Information regarding the operating instructions
ID-No.: 266665 / 640960300140
Publication Code: 2018-11-09·BA00·III·en·00
The original instructions are the English edition.
They are legally binding in all legal affairs.
1.3 Further documents
• Data sheet
For documents in additional languages, see www.r-stahl.com.
1.4 Conformity with standards and regulations
See certificates and EU Declaration of Conformity: www.r-stahl.com.
The device has IECEx approval. For certificate please refer to the IECEx homepage:
http://iecex.iec.ch/
Further national certificates can be downloaded via the following link:
https://r-stahl.com/en/global/products/support/downloads/.
R. STAHL Schaltgeräte GmbH
Am Bahnhof 30
74638 Waldenburg
Germany
R. STAHL (P) LTD., Plot No. - 5
Malrosapuram Road, Sengundram Indl. Area
Singaperumal Koil, Kancheepuram Dist.,
Tamil Nadu – 603 204, INDIA
Phone:
Fax:
Internet:
E-mail:
[phone]
[phone]
www.r-stahl.com
[email protected]
Phone:
Fax:
Internet:
E-mail:
[phone]
[phone]
www.rstahl.net
[email protected]
R. STAHL Schaltgeräte GmbH
Business Unit Lighting & Signalling
Nordstr. 10
99427 Weimar
Germany
Phone:
Fax:
Internet:
E-mail:
[phone]
[phone]
www.r-stahl.com
[email protected]

Explanation of the symbols
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Emergency Luminaire with LED
Series EXLUX 6409/4
2 Explanation of the symbols
2.1 Symbols in these operating instructions
2.2 Warning notes
Warnings must be observed under all circumstances, in order to minimize the risk due to
construction and operation. The warning notes have the following structure:
• Signalling word: DANGER, WARNING, CAUTION, NOTICE
• Type and source of danger/damage
• Consequences of danger
• Taking countermeasures to avoid the danger or damage
Symbol Meaning
Tips and recommendations on the use of the device
Danger due to explosive atmosphere
Danger due to live components
DANGER
Danger to persons
Non-compliance with the instruction results in severe or fatal injuries to
persons.
WARNING
Danger to persons
Non-compliance with the instruction can result in severe or fatal injuries to
persons.
CAUTION
Danger to persons
Non-compliance with the instruction can result in light injuries to persons.
NOTICE
Avoiding material damage
Non-compliance with the instruction can result in material damage to the device and / or
its environment.

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Safety notes
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Emergency Luminaire with LED
Series EXLUX 6409/4
2.3 Symbols on the device
3 Safety notes
3.1 Operating instructions storage
• Read the operating instructions carefully.
• Store the operating instructions at the mounting location of the device.
• Observe applicable documents and operating instructions of the devices to be
connected.
3.2 Safe use
Before mounting
• Read and observe the safety notes in these operating instructions!
• Ensure that the contents of these operating instructions are fully understood by the
personnel in charge.
• Use the device in accordance with its intended and approved purpose only.
• Always consult R. STAHL Schaltgeräte GmbH if using the device under operating
conditions which are not covered by the technical data.
• We cannot be held liable for damage to the device caused by incorrect or unauthorised
use or non-compliance with these operating instructions.
For assembly and installation
• Observe national assembly and installation regulations (e.g. IEC/EN 60079-14).
• Observe national safety and accident prevention regulations.
• During installation and operation, observe the information (characteristic values and
rated operating conditions) on the type plates and data plates and information signs
located on the device.
• Before installation, make sure that the device is not damaged.
Maintenance, repair, commissioning
• Before commissioning, make sure that the device is not damaged.
• Work on the device, such as installation, maintenance, overhaul, repair, may only be
carried out by appropriately authorised and trained personnel.
• Perform only maintenance work or repair described in these operating instructions.
Symbol Meaning
05594E00
CE marking according to the currently applicable directive.
02198E00
According to marking, device approved for hazardous areas.

Function and device design
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Emergency Luminaire with LED
Series EXLUX 6409/4
3.3 Intended Use
The luminaire 6409/4 is equipment
• for lighting areas, work spaces and objects
• for emergency lighting in case of power failure.
• can be used indoors and outdoors
• for stationary mounting
• for use in Zones 21, 2, 22 and in the safe area
3.4 Modifications and alterations
4 Function and device design
4.1 Function
Application range
The luminaire 6409/4 is equipment used for lighting areas, work equipment and objects.
It can be used indoors or outdoors and is suitable for emergency lighting in case of power
failure.
The luminaire is approved for use in hazardous areas of Zones 2, 21 and 22.
Mode of operation
A weekly functional test has been permanently integrated. An annual rated operating time
test can be deactivated and activated.
When opened using a central lock, the luminaire switches off automatically (optional).
The operating hours can be determined and the luminaire can be dimmed and switched
via an optional DALI interface.
DANGER
Explosion hazard due to modifications and alterations to the device!
Non-compliance results in severe or fatal injuries.
• Do not modify or alter the device.
No liability or warranty for damage resulting from modifications and
alterations.
DANGER
Explosion hazard due to improper use!
Non-compliance results in severe or fatal injuries.
• Use the device only in accordance with the operating conditions
described in these operating instructions.
• Use the device only for the intended purpose specified in these
operating instructions.

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Function and device design
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Emergency Luminaire with LED
Series EXLUX 6409/4
4.2 Device design
20292E00
1 Translucent cover 5 Connection terminal
2 Control gear 6 Mounting plate (bottom side)
3 Battery 7 Luminaire enclosure
4 Cable entry 8 Battery enclosure

Function and device design
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Emergency Luminaire with LED
Series EXLUX 6409/4
20293E00
9 LED indicator 11 LED PCB
10 Mounting plate (top side) 12 Diffuser
10 11 12
9

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Technical data
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Emergency Luminaire with LED
Series EXLUX 6409/4
5 Technical data
Explosion Protection
Global (IECEx)
Gas and dust IECEx IBE 16.0047
Ex db ec IIC T4 Gc
Ex tc IIIC T100°C Dc
Ex tb op is IIIC T100°C Db
Europe (ATEX)
Gas and dust IBExU 16 ATEX 1233
E II 3 G Ex db ec IIC T4 Gc
E II 3 D Ex tc IIIC T100°C Dc
E II 2 D Ex tb op is IIIC T100°C Db
Certifications and certificates
Certificates IECEx, ATEX
Technical Data
Electrical data
Rated operational
voltage
AC: 110 to 230 V ±10 %; 50 to 60 Hz
Rated operational
current
Power factor
Rated insulation
voltage
250 V
THD Size 2: < 15 %
Size 4: < 8 %
Inrush current Ipeak = 63 A; Δt = 115 ms
maximum number of luminaires per miniature circuit breaker at 230 V:
Size 2 Size 4
At nominal voltage 110 V 230 V 110 V 230 V
During stand-by
switching mode
< 0.08 A < 0.08 A < 0.08 A < 0.08 A
In continuous mode 0.24 A 0.13 A 0.43 A 0.21 A
Size 2 Size 4
At nominal voltage 110 V 230 V 110 V 230 V
) 0.98 ) 0.90 ) 0.99 ) 0.95
Type 10 A 16 A 20 A 25 A
B7111417
C11 19 23 29
K23 38 47 59

Technical data
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Emergency Luminaire with LED
Series EXLUX 6409/4
Degree of protection IP66 / IP67 (IEC 60598)
IP64 if a breather is used
Protection class I (with internal PE connection)
Impact strength
(IK code)
IK10 (IEC 62262)
Luminous characteristics
Colour rendering Ra ) 80
Colour temperature 4,000 K, 5,000 K or 6,500 K depending on the variant
Luminous flux
Values apply to Ta = +25 °C.
Luminous flux
decrease
at ambient temperature
20340E00
A: Size 2; 230 V 50 Hz
B: Size 4; 230 V 50 Hz
C: Size 2; 110 V AC 60 Hz
D: Size 4; 110 V AC 60 Hz
Technical Data
Size 2 Size 4
Power consumption [W] 25 45
Diffuser with without with without
Luminous flux [lm] 2,910 3,230 5,810 6,460
Luminaire efficacy [lm/W] 116 129 129 144
100 %
90 %
80 %
70 %
60 %
50 % 30 °C 35 °C 40 °C 45 °C 50 °C 55 °C 60 °C
A
D
C
T
a
ɸ
L
B

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Technical data
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Emergency Luminaire with LED
Series EXLUX 6409/4
Ambient conditions
Ambient temperature
(1) Rated operating time during emergency light operation
is guaranteed within an ambient temperature range of -5 to +50 °C.
This also applies to charging and discharging of the battery. The rated
operatzing time might be reduced if used outside this temperature range.
(2) Battery service life
is guaranteed within an ambient temperature range of -30 to +50 °C
according to IEC/EN 60598-2-22.
Service life
LED Life Time L90B50: 100,000 h
LxBy
At the end of the service life:
• Luminous flux decline to "x" percent
• Up to "y" percent of all luminaires fall below "x"
Mechanical data
Material
Enclosure
Enclosure polyester resin, glass fibre reinforced
Colour Grey colour, similar to RAL 7035
Seal Silicone seal, foamed into the translucent cover
Translucent cover Polycarbonate
Luminaire locking Central lock for M8 / A/F 13 box spanner;
the translucent cover can be swivelled on its hinge
Mounting / Installation
Cable glands
Connection Spring clamp terminals
Standard: 6-pole: L1, L2, L3, L, N, PE
with DALI: 8-pole: L1, L2, L3, N, PE, D1, D2
Clamping range:
1 x 1.5 to 6 mm2 (solid / finely stranded)
(2 free clamping units per pole available)
Technical Data
without through wiring -30 to +60 °C (1, 2)
IN through wiring ( 10 A -30 to +55 °C (1, 2)
IN through wiring ( 16 A -30 to +50 °C (1)
Standard luminaire
Plastic: 2 x M25 x 1.5 cable entries 8161 and
2 x M25 x 1.5 stopping plugs 8290 (enclosed)
Metal: 2 x metal plates M20 x 1.5 connected by
means of PE for metal cable entries
Attention: cable entries must be ordered separately
Special
version:
max. 4 drilled holes for M20, M25, NPSM ½’’
max. 2 drilled holes for NPT ¾"
Metal cable glands: M20 x 1.5, M25 x 1.5; earthing metal cable
entries using metal plates

Technical data
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Emergency Luminaire with LED
Series EXLUX 6409/4
For further technical data, see www.r-stahl.com.
Through wiring
Assembly
Control gear
Emergency light
mode
In case of power failure the LEDs are supplied by the battery
Rated operating time at optimal ambient temperature of the battery:
Switchover voltage From mains to battery operation at U < 0.83 x UN
From battery to mains operation at U > 0.88 x UN
Battery set
Version NiCd battery, gas-tight
Operating voltage 6 V
Capacity 7 Ah
Replacing the
battery set
When opening the battery enclosure, the connection between the battery
and the control gear is disconnected by means of a switch.
The battery set can be replaced after disconnecting the plug-in contacts.
Optional
DALI-connection DALI interface in accordance with IEC 62386-207:2009-08
Breather Breather 8162/1 from R.STAHL Schaltgeräte GmbH
The breather guarantees compliance with degree of protection IP64
in all mounting positions. The breather may not be used in atmospheres
with corrosive gasses.
Technical Data
Standard
luminaire
with
Luminaries are equipped with internal through wiring.
Connection of ingoing and outgoing leads on
opposite sites is possible.
Terminals: See Tech. data
Wiring cross section of the supply line connection:
2.5 mm2 for max. 16 A
(Observe service temperature)
Optional without
On the connection side, there are 2 bores M25 x 1.5
for cable entries for ingoing and outgoing wiring of the
connection line
(ingoing and outgoing leads on one side).
Standard luminaire
Standard: 2 x M8 insert nuts in the enclosure
Special: Mounting grooves in the enclosure for use of fastening
and ceiling rails for variable luminaire mounting
(variable mounting distances for luminaires
L = 700 mm: 320 to 480 mm;
L = 1310 mm; 670 to 930 mm)
Battery
capacity
Rated operating
time
Emergency light output
Size 2 Size 4
7 Ah 1.5 h 65 % 35 %
3.0 h 35 % 20 %

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Engineering
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Emergency Luminaire with LED
Series EXLUX 6409/4
6 Engineering
6.1 Mains operation
6.1.1 Stand-by operation
• The light fitting is switched off.
6.1.2 Continuous operation
• The light fitting is switched on.
6.1.3 Normal lighting operation
• The light fitting is operated by normal lighting.
16397E00
16398E00
16399E00
PE
N
L1
L´ PE N L1 L2 L3
PE
N
L1
L´ PE N L1 L2 L3
PE
N
L1
L´ PE N L1 L2 L3

Engineering
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Emergency Luminaire with LED
Series EXLUX 6409/4
6.2 Emergency light blocking
A remote switch for emergency light blocking can be connected to terminals
„Remote-switch“ of the control gear.
6.2.1 Connection version remote switch
The remote switch is directly connected to the control gear.
The following connection versions are possible:
Point-to-point connection
19192E00
Remote switch is closed Remote switch is opened
Power supply
operation
Switching on the luminaire
depending on operation mode
Switching on the luminaire
depending on operation mode
Power failure Emergency light function No emergency light function
18474E00

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Engineering
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Emergency Luminaire with LED
Series EXLUX 6409/4
Linear connection
The following conductor specifications must be observed during connection.
18473E00
Point-to-point connection Linear connection
maximum conductor length
x 1 500 m 100 m
x 2 50 m
x 3 500 m
maximum number of light fittings 50 30
Cable cross section 1.5 mm21.5 mm2

Transport and storage
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Emergency Luminaire with LED
Series EXLUX 6409/4
7 Transport and storage
7.1 General
• Transport and store the device only in the original packaging.
• Store the device in a dry place (no condensation) and vibration-free.
• Do not drop the device.
7.2 Batteries
• Do not transport together with other materials.
• Do not transport in explosive dust atmosphere.
• Handle with care.
• Store protected from fire, sources of dust, harmful gases and liquids.
• Store in a dry and cool location.
Recommendation:
• Store battery at an ambient temperature of +5 to +25 °C and a relative humidity of
65 ±5 %. The storage period is reduced of up to one month if stored outside this
temperature range.
8 Mounting and installation
NOTICE
Risk of deep battery discharge due to exceeded storage!
Non-compliance can result in material damage!
• The battery should be charged within 26 weeks from date of production by
means of operating the luminaire.
DANGER
Explosion hazard due to incorrect installation of the device!
Non-compliance results in severe or fatal injuries.
• Carry out installation strictly according to the instructions and national
safety and accident prevention regulations to maintain the explosion
protection.
• Select and install the electrical device so that explosion protection is not
affected due to external influences, i.e. pressure conditions, chemical,
mechanical, thermal and electric impact such as vibration, humidity and
corrosion (see IEC/EN 60079-14).
• The device must only be installed by trained qualified personnel who is
familiar with the relevant standards.
NOTICE
Malfunction or device damage caused by condensation.
Non-compliance can result in material damage!
• operate the luminaire continuously or periodically over extended periods of time.
• avoid thermal bridges.

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Mounting and installation
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Emergency Luminaire with LED
Series EXLUX 6409/4
8.1 Dimensions / fastening dimensions
Dimensional drawings (all dimensions in mm [inches]) – Subject to modification
16127E00
EXLUX 6409/4
Dimensional drawings for assembly parts and accessories (all dimensions in mm [inches])
– Subject to alterations
15778E00 15779E00
Mounting rail
M25 x 1,5
183,5 [7,22]
125
L3
L2
L1
L3
L2
[4,92]
M25 x 1,5
Dimen-
sions
Luminaire
Size 2 Size 4
L1 857 [33.74] 1467 [57.76]
L2 1) 400 [15.75] 800 [31.50]
L3 2) 320 to 480 [12.60 to 18.90] 670 to 930 [26.38 to 36.61]
1) fixed mounting distance
2) variable mounting distance
9
30
9
6,10
ø 8,10
32 [1,26]
12
[, ]0 47
18,50
[, ]0 73
30,50
[, ]1 20
74 [ , ]2 91
86 [ , ]3 39
124 4 88[, ] 11 [ , ]0 43
[0,35]
[1,18].
[ø 0 24,].[ø 0,32] [0,35]
[0,24]
ø 6,10
215 8.46[]
215 [
193 - 198 [7,60 - 7,80]
13 [0,51]

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Emergency Luminaire with LED
Series EXLUX 6409/4
15782E00 15781E00 15783E00
Ring bolt fitted in
insert nut of the
luminaire
Mounting bracket
fitted in
mounting rail
Pipe clamp
fitted in
mounting rail
15780E00 03257E00
Wall mounting bracket
fitted in mounting rail
Bracket for wall mounting
with pipe section
17755E00
Dimensions Luminaire
Size 2 Size 4
L1 1135 [44.69] 1744 [68.66]
L2 390 [15.35] 338 [13.31]
Linear luminaire EXLUX with pole mounting sleeve
Dimensional drawings for assembly parts and accessories (all dimensions in mm [inches])
– Subject to alterations
186 [7,32]
146 [5,75]
200 [7,87]
80
[3,15]
Ø
42
± 0,60
[ 1,65 ]
Ø
± 0,02

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Emergency Luminaire with LED
Series EXLUX 6409/4
8.2 Mounting / dismounting, operating position
Suspension at fixed mounting points
DANGER
Explosion hazard due to electrostatic discharge
Non-complicance results in severe or fatal injuries.
Do not use the luminaire in strong charge generating environments!
The following processes/activities should be avoided:
• accidental friction
• particle currents
DANGER
Explosion hazard due to inadmissible heating!
Non-compliance results in severe or fatal injuries.
• Avoid external heat sources and/or direct sunlight (risk of change of
temperature class or change of maximum permissible surface
temperature).
• Do not exceed the maximum ambient temperature due to external heat
sources (premature failure of equipment).
The luminaire is suitable for wall and ceiling mounting.
In event of wall mounting in outdoor areas, avoid installation with central lock
at top.
The mounting position with upward light emission in outdoor areas is
prohibited.
16324E00
max. screw-in depth 10 mm
L2
Size L2 mm [inch]
2 400 [15.75]
4 800 [31.50]

Mounting and installation
20 266665 / 640960300140
2018-11-09·BA00·III·en·00
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Emergency Luminaire with LED
Series EXLUX 6409/4
Suspension at movable mounting parts
Pole mounting using pole mounting sleeve
16325E00 16326E00
Mounting bracket Top rail
Lateral mounting pockets for variable points of suspension.
When mounting the luminaire using top rails, ensure that the mounting
surface is flat. Otherwise, the enclosure might be mounted in a warped/
twisted way. The result is leakage of the luminaire and difficulties in replacing
the translucent cover.
18483E00
18482E00
L
L4
L
L
L4
L
Size L4 mm [inch] L mm [inch]
2 320 [15.60] 80 [3.15]
4 670 [26.38] 130 [5.12]