IOM – VANGUARD BULKHEAD (INDUSTRIAL)

Vanguard VL20i

Industrial Bulkhead Luminaires

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

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.

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IOM – VANGUARD BULKHEAD (INDUSTRIAL)

Type Of Protection N/A

Area of application Non Hazardous

Standard

Certificate

Ingress Protection

BS EN 600598

N/A

IP66 and IP67 to BS EN60529

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 [This legislation is the equivalent in UK law of EC directives 2006/95/EC, 2004/108/EC and 2002/96/EC respectively].

1.0 Introduction – Vanguard Bulkhead

This installation leaflet describes the Vanguard Industrial range bulkhead luminaires. The Vanguard is manufactured from painted corrosion resistant aluminium alloy with a toughened glass dome and silicone rubber gaskets. The lamp chamber and the integral control gear are contained within an IP65 enclosure. The lamp cap is E27. Refer to the following tables for ratings and ambient limitations.

2.0 Application

The luminaire 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.

3.0 Installation and Safety

3.1 General

There are no health hazards associated with this product whilst in normal use. In the UK the requirements of the

'Health and Safety at Work Act' must be met. 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 luminaires are Class 1 and should be effectively earthed. The luminaires are quite heavy and suitable means of handling on installation must be provided.

3.2 Tools

Strap wrench, 3mm and 5mm flat blade screwdriver.

Pliers, knife, wire strippers/cutters.

A spanner suitable for fitting cable glands.

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 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.

In some cases, the luminaires have multi-tapped control gear which can be set to a range of typical voltages.

Note that ballasts are not dual frequency. 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 to obtain the best lamp performance, but care must be taken to log or mark the equipment so that the tapping is re-set if the equipment is relocated. If in doubt, tappings should be set on the high side. 10V Max. drop is desirable for HPS and required for MBI.

All circuits use S.I.P. (superimposed pulse) ignitors. This means that there are only two connections to the choke, so tap selection is obvious. Where supply conditions include significant harmonics, the PFC can be omitted.

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Where shore or construction site supplies are used, which are different to the service location supplies, the tappings should be re-set. If not, advice on the effect of these temporary supplies should be sought from the

Technical Department.

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 millisecs; 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 inrush current can be calculated where circuit conditions are known. The nominal capacitor current will probably be the determining factor, 0.076A per µF at 240V, 50Hz (adjust for other supply volts by multiplication, x 6/5 for 60Hz). For HBC fuses use 1.5 x normal capacitor current. All calculations must satisfy wiring regulations.

3.3.2 Lamps

The discharge lamps used are of a standardised type. There is no preference between make or colour. The

Vanguard uses Elipitical HPS and HPS compatible MBI lamps and eliptical MBF lamps. Note that the use of diffuse elliptical lamps may affect photometric performance. Care must be taken to fit the correct new and replacement lamp in order to preserve the control gear and obtain the designed photometric performance. The lamp type is shown on the rating plate. 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 to control gear.

The above information is current at the time of preparation. The development of lamps and control gear is ongoing and detailed advice on lamp performance can be obtained from the lamp supplier or from Chalmit.

Important: HPS and MBI circuits should not be energised without a lamp fitted.

HPS and MBI lamps with internal ignitors must not be used.

3.4 Mounting

Luminaires should be installed where access for maintenance is practical and in accordance with any lighting design information provided for the installation. The luminaire is designed to operate at any angle except with glass upwards. The wall mounting or ceiling mounting arrangements should be secured with lock washers or self-locking nuts and bolts

3.5 Fitting the Glass

Care must be taken when fitting the Glass, as the gasket is part of this assembly.

The following steps must be taken:

The gasket should be placed onto body and the gasket should be between glass and cover front.

The gasket should not be twisted at any point.

3.6 Cabling and Cable Glands

3.6.1 Cables

The cable entry temperatures are given as the rise over the maximum rated ambient temperature. This allows the user to adjust the cable specification for actual site maximum temperature. The standard conductor section is 4mm² max. All models are suitable for looping. Standard 300/500V cable is suitable.

Cable glands for entry into the enclosures when fitted with any gland to body sealing method and supply cable, must reliably maintain the IP rating of the enclosure. Nylon washers are provided with the unit to seal between the gland body and the luminaire. The cable glands must be to the appropriate European Standard for industrial cable entries and cable entry devices. Plastic cable glands can be used. Where brass cable glands are used nickel plating should be used.

Sealing plugs for unused entries should be similarly rated and fitted.

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Entries suitable for M20 cable glands are standard. Entries suitable for M25 are available to special order.

3.7 Cabling and Fitting Lamps

Access for cabling is via the front cover, using a flat blade screwdriver, unscrew the 4 screws. Reselect the voltage tappings if necessary. Install the conductors in the appropriate terminals. Take care not to cut back the insulation excessively, 1mm bare conductor outside the terminal is a maximum. Any unused terminal should be fully tightened.

When the cabling is complete make a final tightness and connection check. The cover is replaced and the screws tightened down.

Before fitting lamps or opening the luminaire, the luminaire must be de-energised and isolated from the supply.

The lamp is replaced by removing the front cover as above, ensuring screws are fully tightened on refitting cover front.

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. The time between lamp changes could be very infrequent and this is too long a period without inspection.

The equipment must be de-energised before opening. Individual organisations will have their own procedures:-

1 Ensure the lamp is lit when energised and that the glass globe 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 regasketting.

3 Check the cable gland for tightness.

4 Check the tightness of the cover screws.

5 Clean the glass.

6 When re-lamping, check that gasket has not been dammaged or become excessively deformed. If in doubt, replace (See Section 3.9).

The supply must be isolated before opening the luminaire.

In most instances, the faults are simple, namely loose or broken connections, unserviceable lamps or open circuit control gear. 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, 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 in the lamp and a buzzing sound from the ignitor. It is good practice to have substitution parts available for fault finding. Before re-assembling, all connections should be checked and any damaged cable replaced. The ignition connection to the lampholder is sleeved with H.T. sleeving and this must be kept in place.

Thermal protectors are included. If the lamp goes on and off over a timescale of several minutes, this may 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.

3.9 Overhaul

The unit is largely made of materials that are very corrosion resistant. This allows the unit to be completely stripped, cleaned, and then re-built with new electrical parts as required. The internal wiring is 1.0mm² flexible, silicone rubber insulated. An H.T. sleeve is fitted to the ignitor cable. All the spares required are available.

Please state the model number, lamp and optical details.

The glass gasket is similarly held in place by the front cover and the glass.

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If the gaskets have deteriorated by softening or permanent set, new gaskets should be fitted, which can be obtained from Victor. To fit the gasket, the old gasket should be removed. The gasket is fixed in place between glass and front cover.

4 Disposal of Material

The unit is mostly made from incombustible materials. The capacitor is of the dry film type and does not contain

PCB's. The control gear contains plastic parts and polyester resin. The ignitor contains electronic components and synthetic resins. All electrical components and the body parts may give off noxious fumes if incinerated.

Take care to render these fumes harmless or avoid inhalation. Any local regulations concerning disposal must be complied with. 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 mainly made from incombustible materials. The control gear contains plastic, resin and electronic components. All electrical components may give off noxious fumes if incinerated.

5 Lamps

Discharge lamps in modest quantities are not "special waste". The outer envelope should be broken in a container to avoid possible injury from fragmentation Any local regulations concerning disposal must be complied with.

Important: Do not incinerate lamps.

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.

Total circuit watts:

TECHNICAL DATA

150W GLS =150W 80W MBFU = 87W

50 W MBFU = 58W

70W SON = 82W

50W SON = 60W current at switch on:

(for < 1ms) correction capacitor

50 W MBFU = 0.32A or 0.62A without power factor correction capacitor

70W SON = 0.55A or 1.0A without power factor correction capacitor

50W SON = 0.35A or 0.77A without power factor correction capacitor

Power factor correction is better than 0.85 if a capacitor is fitted when needed.

The luminaire is made from aluminium (body) and glass (lens).

The user must ensure that these materials are suitable for the atmosphere the luminaire will be installed in. (N.B some variants have gunmetal bodies)

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Power factor

T amb

Storage

Storage

≥ 0.85

EMC EN

Terminals 4mm² as standard, looping has current limit of 16A.

-40°C to +80°C

Luminaires should be stored in cool dry conditions preventing ingress of moisture and condensation

Lamps

Fuse and

MCB ratings

Tubular lamps with an E27 or E40 cap in accordance with EN 6023

Refer to table 2 for starting and running currents and fuse ratings. Also refer to section

3.3.1 for information regarding inrush current.

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