Victor VL71 Operation Manual

VL71 IOM IECEx ATEX Issue 02 May 08 1 Issue 02 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Victor: VL71 FLOODLIGHT (IECEx) (ATEX) Important : Please read these instructions carefully before installing or maintaining this equipment. Good electrical practices should be followed at all times and this data should be used As a guide only.

VL71 IOM IECEx ATEX Issue 02 May 08 2 0.0 Specification Type Of Protection Ex nR (restricted breathing enclosure), Ex nA (non-sparking). Protection Standards (IEC) EN 60079-0, (IEC) EN 60079-15, (IEC) EN 61241-0, (IEC) EN 61241-1. ATEX Equipment Classification Group II Category 3 G Group II Category 3 D Area Classification Zone 2 areas to (IEC) EN 60079-10 and installation to (IEC) EN 60079-14 Zone 22 areas to (IEC) EN 61241-10 and installation to (IEC) EN 61241-14. Certificate EC Type Examination Certificate Baseefa07ATEX0119X IECEx Certificate IECEx BAS07.0025X Equipment Coding Ex nR II T3 Ex tD A22 IP6* T**ºC (Refer to table 0) Ex nA II T3 Ex tD A22 IP6* T**ºC Ingress Protection IP66 and IP67 to BS EN 60529 CE Mark The CE marking of this product applies to "The Electrical Equipment (Safety) Regulations 1994", ‘’The Electromagnetic Compatibility Regulations 1992", the “Waste Electrical and Electronic Equipment Regulations 2006” and the "Equipment and Protective Systems intended for use in Explosive Atmospheres Regulations 1996". [This legislation is the equivalent in UK law of EC directives 73/23EEC, 89/336/EEC, 2002/96/EC and 94/9/EC respectively]. ATEX Declaration The Equipment is declared to meet the provisions of the ATEX directive (94/9/EC) by reason of the EC Type Examination and compliance with the Essential Health and Safety Requirements. I MacLeod Technical Manager 1.0 Introduction – VL71 nR FLOODLIGHT. The VL71 Floodlight is designed for all round lighting applications. It is suitable for use with tubular discharge lamps and single ended tungsten halogen lamps. A gear box is used with the low voltage range of 400w HID versions. The floodlight is restricted in its mounting position. The beam of the floodlight may be aimed at any angle but the control gear must always be mounted on or below the axis of rotation of the floodlight. The floodlight is designed to be safe in normal operation. The floodlight should not be used in conditions where there are environmental, vibration or shock conditions above the normal for fixed installations. The gaskets should not be exposed to hydrocarbons in liquid or high concentration vapour states. The floodlight is suitable for applications where category 3 apparatus is used. The application is for ignitable gas and dust atmospheres. The floodlight is not suitable for portable applications. Note : Lamp ranges and temperature ratings are outlined in TABLE 0. 2.0 Storage Luminaires and control gear boxes are to be stored in cool dry conditions preventing ingress of moisture and condensation. 3.0 Installation and Safety 3.1 General There is no health hazards associated with this product whilst in normal use. However, care should be exercised during the following operations. Installation should be carried out in accordance with (IECEx) EN 60079-14 or the local hazardous area code of practice, whichever is appropriate. In the UK the requirements of the 'Health and Safety at Work Act' must be met.

VL71 IOM IECEx ATEX Issue 02 May 08 3 Handling and electrical work associated with this product to be in accordance with the 'Manual Handling Operations Regulations' and 'Electricity at Work Regulations, 1989'. Your attention is drawn to the paragraphs (i) 'Electrical Supplies', (ii) 'Electrical Fault Finding and Replacement' and (iii) 'Inspection and Maintenance'. The floodlights are Class 1 and should be effectively earthed. The luminaires are quite heavy and suitable means of handling on installation must be provided. Certification details on the rating plate must be verified against the application requirements before installation. The information in this leaflet is correct at the time of publication. The company reserves the right to make specification changes as required. 3.1.1 Use in Combustible Dust Atmospheres Where the equipment is used in ignitable dust atmospheres reference must be made to the selection and installation standards in order that the equipment is used correctly. In particular this applies to the de-rating of surface temperature for use where dust clouds may be present. Dust layers should not be allowed to accumulate on the fitting surface and good housekeeping is required for safe operation. Dust in layers has the potential to form ignitable clouds and to burn at lower temperatures. Refer to EN 61241-14 for additional details of selection, installation and maintenance. 3.1.2 Hybrid Mixtures – Gas plus Dust. Where Hybrid mixtures exist as defined in EN 1127 as a potentially explosive atmosphere, consideration should be given to verifying that the maximum surface temperature of the luminaire is below the ignition temperature of the hybrid mixture. 3.1.3 Floodlight Orientation in the presence of combustible dust. The luminaire was tested in accordance with (IECEx) EN 61241-1, (IECEx) EN 61241-0 practice A. As the build up of the dust layer can never be guaranteed not to occur, the luminaire must not be mounted in an orientation where the dust could lie on the glass. The temperature on the glass is the hottest point on the luminaire and any obstruction of the radiation from the luminaire would cause the surface temperature to increase. 3.2 Tools A cross head screwdriver blade to open hinged cover. 3mm and 5mm flat blade screwdriver. Suitable spanners for installing cable glands. Pliers, knife, wire strippers/cutters. 3.3 Electrical Supplies The supply voltage and frequency should be specified when ordering. A maximum voltage variation of +6%/-6% on the nominal is expected. (The safety limit for T rating is +10%). Luminaires should not be operated continuously at more than +6%/-10% of the rated supply voltage of the control gear or tapping. The user must determine the actual underlying site supply and purchase or adjust accordingly. Care must be taken in connecting to the nominal 230V UK public supply. In most cases, the luminaire has multi-tapped control gear which can be set to a range of voltages on 50 or 60Hz cycles. The tappings are shown on the control gear and the limits are shown on the rating plate. If the equipment is located in high or low voltage sections of the system, an appropriate voltage tap should be selected, but care must be taken to log or mark the equipment so that the tapping is re-set if the equipment is re-located. If in doubt, tappings should be set on the high side, 10V max. drop is desirable for HPS. The light output will be reduced. The HPS circuits use S.I.P ignitors and the circuit diagram will indicate the choke connections. Where MBI/Metal Halide lamps are used, the tapping must be set accurately for best performance. Where shore or construction site supplies are used, different to the service supplies, tappings should be re-set. If not, advice on the effect of these temporary supplies should be sought from the Technical Department. Where adverse system conditions occur, luminaires can be supplied without PFC. The circuit current will then be the lamp current. The circuit power does not change. Tungsten Halogen lamps must be selected for the supply voltage. Running at over the rated supply voltage will reduce life and at greater than +10% will compromise the T rating.

VL71 IOM IECEx ATEX Issue 02 May 08 4 3.4 Lamps The lamps used in this range are of a standardised type, and there is no preference between makes, or in the case of HPS colour. Due to the need to control photometric performance and certification conditions, and avoid incorrect lamps being fitted, the type of lamp and size is specified on the rating plate. If mixed installations are used, care must be taken to ensure that the correct lamp is fitted on installation and replacement. HPS and MBI lamps should be replaced shortly after they do not light. One indication of the end of life for HPS lamps is 'cycling' where the lamp goes out then re-ignites after a minute or so interval. If discharge luminaires are burned continuously they should be switched off occasionally, to allow old lamps to fail to re-ignite rather than possibly become diodes with detrimental effects on control gear. The above information is current at the time of publication. The development of lamps and control gear is ongoing and detailed advice on lamp performance can be obtained from the Technical Department or the lamp supplier. HPS and MBI circuits should not be energised without a lamp fitted. HPS lamps without an internal ignitor should be used. The current HPS control gear is incompatible with internal ignitor lamps. 3.5 Mounting Floodlights should be installed where access for maintenance is practical and in accordance with any lighting design information provided for the installation. This will usually consist of aiming points and aiming angles. Mounting arrangements should be secured with lock washers or self-locking nuts and bolts. 3.6 Cabling and Cable Glands 3.6.1 Cable Glands Cable glands and sealing plugs when installed must maintain the properties of the restricted breathing enclosure. Rubber sealing washers and steel compression washers are provided with the unit. The installer and user take responsibility for the selection of cables, cable glands and seals. The product is certified for ATEX and to comply with the certification for installation and use within the EU, cable glands and sealing plugs must have ATEX component approval. For installation outside the EU, suitable cable glands in accordance with (IECEx) EN 60079-0 will meet the technical requirements. The cable and gland assembly when installed must maintain the IP66/67 rating of the floodlight. The cable gland must withstand an impact value of 7Nm where the risk of mechanical damage is high or 4Nm where the risk of mechanical damage is low. Sealing plugs must be similarly rated and a tool must be used for their removal. Where the cable is not reliably clamped externally to the apparatus, the cable gland must clamp the cable against a pull in Newtons of 20 x the cable OD in mm for non-armoured cable and 80 x the cable OD for armoured cable. Where brass cable glands are used in a corrosive environment cadmium or nickel plating should be used. Two tapped cable entries are provided, one with a plug and seal suitable for permanent use, the other has a travelling plug. M20 x 1.5 entries are standard, other sizes are available on request. A Hawke 501/453/RAC would be suitable for the above. 3.6.2 Cable At maximum rated ambient temperature refer to rating table for minimum cable temperature rating. The luminaire is also rated with the temperature rise at the cable entry. This allows the user to adjust the cable spec. for an actual T amb lower than that for which the luminaire is certified. The standard looping conductor size is 6mm². Internal and external earth points are provided. Standard 300/500V rated cable is suitable. The cable make-up must be suitable to ensure the maintaining of the restricted breathing enclosure when the cable gland assembly is fitted. The selection of cable size will be suitable for the fuse rating. Some guidance on this is given below. When MCB's are used, the type with the higher inrush current resistance, as used for motor starting and lighting, should be specified. 3.6.3 Cable Connection The cable connections are made by removing the front cover. Before removing front cover check that the support chain is sound. The cover is released by undoing the six toggle clamps, using a screwdriver or suitable metal rod. The reflector is

VL71 IOM IECEx ATEX Issue 02 May 08 5 removed by releasing four screws. The baffle plate is removed by undoing 2 x M5 nuts at the base. Reselect the voltage tapping if necessary. No 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 bootlace ferrule. Leads connected to the terminals shall be insulated for the appropriate voltage and this insulation shall extend to within 1mm of the metal of the terminal throat. All terminal screws, used and unused, shall be tightened down to between 1.2 Nm and 2 Nm. The cover is replaced and the toggle clamps snapped back over. 3.7 Fitting Lamps Make sure the correct lamp is selected, access for fitting lamps is gained through the lampglass cover, as above. The lamp should be firmly screwed into place. 3.8 Inspection and Maintenance Visual inspection should be carried out at a minimum of 12 monthly intervals and more frequently if conditions are severe, refer to (IECEx) EN 60079-17. The time between lamp changes could be very infrequent and this is too long a period without inspection. 3.8.1 Routine Examination The equipment must be de-energised before opening and note taken of the rated opening delay periods alternatively the nameplate may read ‘do not open when an explosive gas atmosphere is present’. Individual organisations will have their own procedures. What follows are guidelines based on (IECEx) EN 60079-17 and on our experience: 1 Ensure the lamp is lit when energised and that the lampglass is not damaged. 2 When de-energised and left to cool there should be no significant sign of internal moisture. If there are signs of water ingress, the luminaire should be opened up, dried out, and any likely ingress points eliminated by re-gasketting, re- greasing or other replacement. 3 Check the cable gland for tightness and tighten if necessary. 4 Check any external earthing. 5 Examine the glass for any signs of damage. Clean glass. 6 When relamping, check that the cover gasket has not softened or become excessively deformed, if in doubt replace (see section 4.0 ). Important : Where spares are needed, these must be replaced with manufacturers parts. No modifications should be made without the knowledge and approval of the manufacturer. 3.9 Electrical Fault Finding and Replacement The supply must be isolated before opening the luminaire. Control gear will not normally go open circuit unless it has overheated first and the signs of this are obvious, being severe discoloration of the paint on the gear and cracks in any exposed insulation. Similarly, a bad contact at the lamp cap will usually result in signs of overheating. Any fault finding must be done by a competent electrician and, if carried out with the luminaire in place, under a permit to work. With HPS and MBI lamps the ignitor can become faulty. If the lamp is fitted, the choke has continuity and the connections are good and correct, they should produce an 'attempt to start' effect and a buzzing sound from the ignitor. It will be unusual to have no other parts available to perform a substitution fault finding routine and this is the normal procedure. Before re- assembling, all connections should be checked and any damaged cable replaced. The ignition connection to the lampholder is sleeved with a high temperature silicone sleeve and this must be kept in place. 3.9.1 Thermal Protector Thermal protectors are included. If the lamp goes on and off over a timescale of several minutes, this could be the thermal protector operating. The causes are defective lamps/diode effects, gross over voltage or the choke beginning to fail and this should be investigated directly. Also see section 3.4.

VL71 IOM IECEx ATEX Issue 02 May 08 6 4.0 Overhaul The unit is largely made of materials which are very corrosion resistant. This allows the unit to be completely stripped, cleaned then re-built with new electrical components as required. All spares required are available. Please state the model number, lamp and reflector details. The seal at the cover is between the glass and the body. The glass is retained in the cover frame by silicone R.T.V. adhesive. If the cover gasket has deteriorated a new cover assembly should be fitted, which can be obtained from Victor. 4.1 Fuse Ratings The fuse ratings for HID lamp circuits need to take account of three components of circuit current. Current inrush to PFC capacitors which can be up to 25 x the rated capacitor current, and last 1-2 milliseconds. Lamp starting current including steady capacitor current which together may decline from up to 200% of normal at 10 seconds after switch-on to normal after 4 minutes; rectification effects caused by asymmetrical cathode heating for a few seconds after starting, this effect is random and very variable. With the availability of MCB's with a wide range of characteristics, the individual engineer can make a better judgement of what is required. Use MCB's suitable for inrush currents to reduce ratings. The normal capacitor current, will probably be the determining factor, 0.076A per μF at 240V, 50Hz (adjust for other volts by multiplication, x 6/5 for 60Hz). For HBC fuses use 1.5 x normal capacitor current. For GLS inrush use 6 x rated current. All calculations must satisfy wiring regulations. Note : Starting and running currents for 240V, 50Hz are as indicated in TABLE 1. A conventional matrix for HBC fuses is shown in TABLE 2. 5.0 Disposal of Material Any disposal must satisfy the requirements of the WEEE directive [2002/96/EC] and therefore must not be treated as commercial waste. The unit is mostly made from incombustible materials. The control gear contains plastic, polyester resin and electronic components. All electrical components may give off noxious fumes if incinerated. 5.1 Lamps Incandescent lamps and discharge lamps in modest quantities are not "special waste". The outer envelope should be broken in a container to avoid possible injury by fragmentation. This applies to the UK, there may be other regulations on disposal operating in other countries. Important : Do not incinerate lamps. 5.2 To comply with the Waste Electrical and Electronic Equipment directive 2002/96/EC the apparatus cannot be classified as commercial waste and as such must be disposed of or recycled in such a manner as to reduce the environmental impact.

VL71 IOM IECEx ATEX Issue 02 May 08 7 0.0 Tables 0/1/2 Table 0 Lamp Ranges and Temperature Ratings Refer to Section : 1.0 Lamp Wattage Rated Supply T Class T amb ºC Min Ambient ºC Rated Cable ºC Cable Temperature Rise Above Ambient T/HAL 500 220-254V T3 55 70 15 SON/T 400 T3 50 70 20 250 T4 55 70 15 150 T4 60 70 10 MBI/T 400 T3 50 70 20 250 T4 55 70 15 150 220-254V …50/60Hz T4 60 70 10 400 T3 55 80 25 250 T4 55 70 15 SON/T 150 T4 55 70 15 400 T3 55 80 25 250 T4 55 70 15 MBI/T 150 110-120V 50/60Hz T4 55 -50ºC 70 15 Table 1 Starting and Running Currents Refer to section : 4.0 LAMP Lamp A Start A Run A Capacitance μF Circuit Power (W) 150W SON/T 1.8 1.45 0.8 20 175 250W SON/T 3.0 2.35 1.3 30 285 400W SON/T 4.6 4.0 2.2 40 445 150W MBI 1.8 1.6 0.8 20 175 250W MBI 3.0 2.7 1.35 30 285 400W MBI 4.2 4.0 2.2 40 445 Notes: Minimum power factor correction: 0.85. The start and running currents are corrected. Table 2 Fuse Ratings Refer to section : 4.0 Number of Lamps Lamp 1 2 3 4 5 6 150W 4A 6A 10A 10A 16A 16A 250W 10A 16A 16A 20A 20A 20A 400W 16A 20A 20A 25A 25A 32A

VL71 IOM IECEx ATEX Issue 02 May 08 8 Victor Lighting: Victor Lighting PO Box 5571, Glasgow G52 9AH Scotland Telephone : +44 (0)141 810 9644 Fax : +44 (0)141 810 9642 Email : [email protected] Web : www.victor-lighting.com For Technical support, please contact [email protected] Registered Office Mitre House 160 Aldersgate Street, London EC1A 4DD Registered No. 669157 Note Victor Lighting reserve the right to amend characteristics of our products and all data is for guidance only.