Document No: 9100-127-1716-00 Rev E January, 2014 LINEAR LED fixture for Hazardous areas. LSD3C4MEP Self-contained Battery Backup Version Operating Instructions Important Information: This apparatus is suitable for use in Class I, Division 2, Groups A, B, C, D, and Class II, Division 2, Groups: F and G, T4, -20°C ≤Tamb≤ 50°C or unclassified locations. These instructions contain important safety information, read and follow them carefully. Dialight will not accept any responsibility for injury, damage or loss which may occur due to incorrect installation, operation or maintenance. IMPORTANT SAFEGAURDS READ AND FOLLOW ALL SAFETY INSTRUCTIONS • Do NOT let power supply cords touch hot • The installation, operation and maintenance must be carried out by an electrician suitably trained in hazardous areas. • The technical data indicated on the LED fixture surfaces • Do NOT mount near gas or electric heaters • Use CAUTION when servicing batteries. are to be observed. • Changes of the design and modifications to the LED fixture are not permitted. • Repairs must only be carried out by a qualified electrician with hazardous area knowledge. and at heights where it will not be subjected to tampering by unauthorized personnel. • Only genuine Dialight replacement parts must be The use of accessory equipment not • Battery acid can cause burns to skin and eyes. If acid is spilled on skin or in eyes, flush acid with fresh water and contact physician immediately • • Equipment should be mounted in locations recommended by the manufacturer may cause an unsafe condition. • Do NOT use this equipment for other than used when unforeseen repairs are required. during installation. • Do not keep these operating instructions inside the LED fixture during operation. • Do not open the LED fixture when energized. • Wait 10 minutes before opening after de- intended use. SAVE THESE INSTRUCTIONS!! Observe the national safety rules and regulations energizing the LED fixture. Dialight – LED Solutions for Industrial and Hazardous Applications Tel: 732-919-3119 – Fax: 732-751-5778 – www.dialight.com SAVE THESE INSTRUCTIONS!! Figure 1. Dimensions in inches [mm] Electrical Connection Color Code Electrical Connections Do not remove the battery housing unless the battery is being replaced. Remove only the wiring side housing. L1 = LIVE / BLACK N = NEUTRAL / WHITE E = GROUND / GREEN The A/C connection is a permanent live feed. It powers the main normal mode operation, battery charger and is used to activate emergency mode. Batteries come with factory fitted connections that should be not removed during installing or replacing. Single Luminaire Electrical Connections: Connect the black (live) wire to the 5 position lever connector with the black wire. Connect the white (neutral) wire to the 5 position lever connector with the white wires. Wire nut the ground with the ground lead wire at the end in the wiring housing area. Feed thru Electrical Connections: Disconnect power. Strip the black and white wires supplied under the smaller cover to 3/8” and add them to their respective lever connectors. The incoming power will now be connected through the lever connectors. Remove the 3/4 NPT plug at the end near the battery housing to access the opposite (outgoing) end of those wires. Wires must now be connected to the associated, adjoining, fixture. See figure 1. ONLY SINGLE CABLES TO BE USED ON EACH CONNECTION. Dialight – LED Solutions for Industrial and Hazardous Applications Tel: 732-919-3119 – Fax: 732-751-5778 – www.dialight.com Contents Supplied with Luminaire:- Electrical Connection Data:- 1 x LINEAR Luminaire 2 x Certified Blanking Plugs 1 x Dust Plug (used for shipping purpose only) Mounting Brackets (optional) When wire nuts are used for installing they need to be sized to fit the rated wire. No more than 3 wires should be in any wire nut connection. NOTE: Certified Blanking Plugs must be moved to unused ports ELECTRICAL SPECIFICATIONS Rated Input Voltage: Rated Input Current:Typ Rated Input Current:Typ Rated Input Current:Typ 100-277VAC 50/60Hz 380mA at 230Vac 690mA at 120Vac 340mA at 277Vac Operating Temp: -20°C to +50°C MECHANICAL SPECIFICATIONS Housing Material: Copper free Aluminum. Housing Colour: Light Gray, RAL: 7040 Dimensions: see Figure.1 Lens Material: Clear Polycarbonate Suitable for Wet Locations Cable Entries: 3 OFF NPT3/4 Class I, Division 2, Groups A, B, C, D, and Class II, Division 2, Groups: F and G, T4, -20°C ≤Tamb≤ 50°C or unclassified locations. Tightening Torques See mounting instructions Ingress Protection: IP66 NOTE: Only the battery compartment cover and the power supply cover located on the top side of the fixture should be removed for battery replacements and initial wiring installation. Dialight – LED Solutions for Industrial and Hazardous Applications Tel: 732-919-3119 – Fax: 732-751-5778 – www.dialight.com Conformity with Standards This equipment conforms to the standards specified in the ATM. It has been designed, manufactured and tested in accordance with UL844/UL8750. Equipment Application This lighting equipment is intended for use in Class1 Div2 and Class2 Div2 or unclassified locations. The product can be used inside or outside to illuminate areas with potentially explosive atmosphere. This fixture is a sustained battery backup light. All LEDs are illuminated when the fixture is operating under normal A/C power. The internal 3.6V 10Ah battery pack provides a minimum 3 hour emergency duration (reduced light output). Installation Remove the Wiring Side Cover to attach incoming power. Connect incoming power as described on page 2 under “Electrical Connections”. Ensure that the o-rings are properly seated in the grooves and wires are not pinched. Reattach the Cover using the screws previously removed. Tighten all screws to 15 in/lbs (1.75NewtonM’s). Restore power and verify operation. NOTE: For Pendant mounting; The center dust cap should be removed and disposed of. The Certified blanking plugs located on the ends of the power supply enclosure are factory installed but should be verified for tightness before finishing the installation. Questions in regards to installation should be directed to your local sales rep or Dialight.com. Refer to line drawing for further information: Ensure that the mains voltage supply is disconnected before connecting the luminaire. Install the equipment in accordance with the manufacturer’s instructions as well as any other applicable electric codes. Option 2. Ceiling or Flat Wall Mounting Always transport and store the equipment in its original packaging and keep in a dry location. Remove the Wiring Side Cover to attach incoming power. Connect incoming power as described on page 2 under “Electrical Connections”. Ensure that the o-rings are properly seated in the grooves and wires are not pinched. Reattach the Cover using the screws previously removed. Tighten all screws to 15 in/lbs (1.75NewtonM’s). Restore power and verify operation. When unpacking check for any cracks or damage in the housing, lens and gasket seal, if in doubt do not install! Contact your local sales rep or Dialight. The improper installation, operation and maintenance of these luminaires may result in the invalidation of the warrantee. Mounting Luminaire There are 2 mounting options for this luminaire, depending which mounting accessories were supplied on purchase (See Luminaire Mounting Options). Option1. Conduit Mounting Conduit thru Mount Installation Steps: Assemble the mounting brackets to the luminaire with the screws supplied in the optional mounting bracket kit. NOTE: For Option 2 mounting; the center dust cap should be removed and disposed of. The Certified blanking plugs located on the ends of the power supply enclosure are factory installed but should be verified for tightness before finishing the installation. Questions in regards to installation should be directed to your local sales rep or Dialight.com. Refer to line drawing for further information: Conduit Pendant Mount Installation Steps: For maximum long term reliability and light output, the light must be installed in free air. The Linear fixture design incorporates an over-temperature control circuit that reduces input power should internal temperatures reach a maximum level. In this event, light output may be reduced. The Linear fixture is threaded for 3/4” NPT, at the center and each end of the Power Supply Housing, in order to be assembled to conduit. Attach conduit as shown in. Use conductive pipe sealant for all fittings and conduit. Warning: If there is moisture present or chance of it in the conduit system than necessary precautions should be taken by the installer to prevent the moisture from entering thru the cable or conduit and entering the fixture. Failure to comply with the above could void factory warranties. Fixture is factory wired for both Pendant and Through wiring. For maximum long term reliability and light output, the light must be installed in free air. The Linear fixture design incorporates an over-temperature control circuit that reduces input power should internal temperatures reach a maximum level. In this event, light output may be reduced. The Linear fixture is threaded for 3/4” NPT, at the center and each end of the Power Supply Housing, in order to be assembled to conduit. Use conductive pipe sealant for all fittings and conduit. WARNING :If there is moisture present or chance of it in the conduit system than necessary precautions should be taken by the installer to prevent the moisture from entering thru the cable or conduit and entering the fixture. Failure to comply with the above could void factory warranties. Fixture is factory wired for both Pendant and Through wiring Dialight – LED Solutions for Industrial and Hazardous Applications Tel: 732-919-3119 – Fax: 732-751-5778 – www.dialight.com Opening the Luminaire Do not over tighten as the protection rating may be compromised. Always refer to gland manufacturers data for torque settings. ATTENTION: WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS. AVERTISSEMENT - RISQUE D'EXPLOSION AVANT DE DECONNECTER L'EQUIPEMENT, COUPER LE COURANT OU S'ASSURER QUE L'EMPLACEMENT EST DESIGNE NON DANGEREUX. Wait 10 minutes after disconnection before opening. Unscrew the battery compartment to gain access to the batteries and wiring. On a new fixture, the battery will have been disconnected, and be in an unknown state of charge. Do not drop or use batteries that appear to have been damaged. Connections supplied on the battery must be used and should not be replaced. NOTE: Shorting of the battery will result in a unsafe condition and could cause the battery to explode. Special Conditions for Safe Use Suitably certified cable entries must be used which include a sealing washer to maintain the IP66/67 rating of the enclosure. The glands must be suitable for use within an operating temperature range of -40°C to +80°C. The gland must be suitable for Class1 Div2 or Class2 Div2 installations to maintain protection, the entry thread shall also be suitably sealed to maintain the ingress protection rating of the fixture. When used with steel basket weave armour or braided (screened) cable the basket weave armour or braid is unable to carry the cable load without fracture therefore the cable must be clamped and cleated to prevent pulling on the cable being transmitted to the cable terminations. Electrical Connection Electrical Connection When connecting the conductors extra care should be taken in order to maintain the hazardous protection. The insulation of the conductors shall reach up to the Lever Connectors. The conductor itself shall not be damaged. The connectible minimum and maximum conductor cross sections shall be observed (see electrical connection data). The L1 connection is a permanent live feed. It powers the main normal mode operation, battery charger and is used to activate battery backup mode. In sustained operating mode a single live feed is connected to L1. All LEDs are illuminated. Cable Entries and Cables IMPORTANT: The cable glands used with this fixture must be certified to the Class1 Div2 requirements. The cable used must be suitable for the site application and/or the site requirements. When assembling the cable entries for the mains connection, always observe the manufacturer’s specifications for the glands used. Unused cable entries must be closed and sealed by a certified blanking plug. Note: This fixture is supplied with one dust cap and two certified blanking plug. Battery Upon completion of electrical wiring and testing, be sure to reconnect the battery by mating together to the 2 pole plug and socket. Closing the LED Luminaire Remove any foreign bodies from the fixture Pay attention when fitting the covers to the enclosure, make sure the seals are clean and undamaged. Do not allow any cables to become trapped between the cover and the housing Tighten all screws evenly (see table) The cable entries should be securely tightened to ensure that the minimum protection rating is achieved. The cable entry should be rated to minimum of IP66 to maintain the protection level of the fixture. Dialight – LED Solutions for Industrial and Hazardous Applications Tel: 732-919-3119 – Fax: 732-751-5778 – www.dialight.com Wait at least 10 minutes before opening the LED luminaire after de-energising. Taking into operation Prior to operating, check the luminaire for its correct installation in compliance with these operating instructions and other applicable regulations. Attention: Only fully certified equipment may be put into operation. Improper installation and operation of this luminaire may invalidate the warranty. Upon applying power, confirm the operation of battery circuits by observing the green status LED located under the lens cover. The green status LED will light only if - The battery is connected - The battery is charging and within acceptable voltage limits If the green Status LED is not lit with power applied to the L1 feed, disconnect power and rectify any faults. The battery pack should be replaced every 3 years for continued reliable operation. To replace the battery: 1) Disconnect the mains power – Battery Backup mode will operate. 2) Unscrew the battery compartment housing. 3) Disconnect the two pole battery connector. 4) Remove the battery pack 5) Unpack the new battery pack and inspect for damage. 6) Install new battery pack and secure in place 7) Reconnect the battery connector. 8) Re install the compartment ensuring seals are not damaged, and cable or straps are not trapped. 9) Re-energise the circuits and check the green status LED illuminates. Allow 24 hours charging before expecting full emergency duration. Dispose of old batteries in accordance with local regulations. If any unforeseen repairs are required then always observe explosion protection regulations and requirements. In Service, Battery Charging and condition monitoring Inspection When power is applied (initially or after an outage), the battery should be charged for 30 hours. Thereafter, in order to maximize battery life while maintaining emergency capacity, the battery charging operates for 1 minute in every hour. Cable entries must be free from corrosion. The battery is continually monitored for voltage limits and charge current acceptance (during charge pulses). If the mains power supply is interrupted, the fixture will switch to battery Backup mode operation at reduced light output. Expected battery backup mode duration exceeds 3 hours. If, during an battery backup mode cycle, the battery capacity has deteriorated to the point that 3 hours is not achieved, then when power is restored this battery “failure” will be signaled by flashing the green status LED once every 8 seconds. The fault indication will be automatically reset when the battery pack is replaced. Maintenance and Battery Replacement WARNING: WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS. AVERTISSEMENT - RISQUE D'EXPLOSION AVANT DE DECONNECTER L'EQUIPEMENT, COUPER LE COURANT OU S'ASSURER QUE L'EMPLACEMENT EST DESIGNE NON DANGEREUX. Disconnect the power supply to the luminaire before maintenance or repair. Within the scope of the maintenance or inspection routine the following should be included. Status LED must be illuminated and not flashing. Repairs / Overhaul / Modification The relevant national regulations which apply to the maintenance/servicing of electrical apparatus in explosive atmospheres shall be observed. WARNING - EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2. AVERTISSEMENT - RISQUE D'EXPLOSION LA SUBSTITUTIOND E COMPOSANTSP EUTR ENDRE CE MATERIEL INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I, DIVISION 2. Any unforeseen repairs or overhaul may only carried out with genuine Dialight spare parts. Should the luminaire enclosure be damaged, only a replacement will be permitted. In case of doubt, the equipment should be returned to Dialight for inspection/repair. **Modifications to the device or changes of its design are not permitted. This equipment must be operated according to the intended purpose in a perfect and undamaged condition. Dialight – LED Solutions for Industrial and Hazardous Applications Tel: 732-919-3119 – Fax: 732-751-5778 – www.dialight.com Should any unforeseen spares be required then please contact your local sales rep or Dialight for availability. Disposal/Recycling When the apparatus is disposed of, the respective national regulations on waste disposal should be observed. WARNING - EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIV 2. Ordering Spare Parts Replacement Batteries: Models: Use 3.6VDC, 10 Ah NiMH rechargeable battery, Dialight p/n LSXBATREP1, only. WARNING - EXPLOSION HAZARD BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON-HAZARDOUS. AVERTISSEMENT- RISQUED 'EXPLOSIONAFIN D'EVITER TOUT RISQUE D'EXPLOSION, S'ASSURER QUE L'EMPLACEMENT EST DESIGNE NON DANGEREUX AVANT DE CHANGER LA BATTER I E. AVERTISSEMENT - RISQUE D'EXPLOSION LA SUBSTITUTIOND E COMPOSANTSP EUTR ENDRE CE MATERIEL INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I, DIVISION 2. REV. A B ECO No. 9362 12120 DRN CHK WSL AR WSL DW APP DW SB QA RL JP CM JN JN DATE 2/27/13 7/25/13 C D E 12556 12973 15244 WSL GZ WSL GZ WSL GZ SB SB SB RL RL JP JN JN JN 8/15/13 9/5/13 1/6/14 Dialight – LED Solutions for Industrial and Hazardous Applications Tel: 732-919-3119 – Fax: 732-751-5778 – www.dialight.com