EATON Hazard Gard Linear LED EM XPLA Series LED Fixtures Instruction Manual

Hazard Gard Linear LED EM XPLA Series LED Fixtures
Instruction Manual

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

APPLICATION

Linear LED EM emergency luminaires are suitable for use in the following hazardous (classified) locations as defined by the National Electrical Code (NEC®):
NEC/CEC

• Class I, Division 1, Groups C, D
• Class I, Zone 1, Group IIB
• Class II, Division 1, Groups E, F, G
• Class III
• Wet location, IP66, Type 4X

These luminaire housings shall be used with UL Listed Eaton’s Crouse-Hinds Series hazardous locations luminaire fitting mounting means, Cat. Nos. PM Kit 1.25, PM Kit 1.5, PM Kit 2.0, ZP1050MTK, ZP1057MTK, PM Kit 1.25P, PM Kit 1.5P, PM Kit 2.0P, ZP1050MTKP, ZP1057MTKP.
The assembled luminaire shall be installed in accordance with the National Electric Code NFPA70, and 46CFR111.75-15 and 46CFR112.
The emergency luminaire is intended to be installed with CG-256 (issued by the American Bureau of Shipping and Coast Guard).
Refer to the emergency luminaire nameplate for specific classification information, maximum ambient temperature suitability and corresponding operating temperature (T-code).
Linear LED emergency luminaire construction is designed for use indoors and outdoors in marine and wet locations, where moisture, dirt, corrosion, vibration and rough usage may be present.
INPUT VOLTAGE:

• UNV1: 100-277 VAC 50/60 Hz

STORAGE ENVIRONMENT:
The XPLA Luminaire and accessories must be stored in an ambient from -20°C to +40°C. Store in a dry location.

IMPORTANT SAFEGUARDS

– READ AND FOLLOW ALL SAFETY INSTRUCTIONS

When using electrical equipment, basic safety precautions should always be followed, including the following:
IMPORTANT
Emergency lighting system should be installed, inspected, operated and maintained by qualified and competent personnel.
WARNING
To avoid personal injury, electric shock, explosion or equipment failure:

• Do not use this equipment for other than intended use.
• Make sure the supply voltage is the same as the equipment voltage.
• Do not install where the marked operating temperatures exceed the ignition temperature of the hazardous atmosphere.
• Do not operate in ambient temperatures above those indicated on the equipment nameplate.
• Use proper supply wiring as specified on the equipment nameplate.
• Electrical power must be turned OFF before and during installation and maintenance. Keep tightly closed when in operation.
• In hazardous areas, install and seal all equipment in accordance with the National Electrical Code articles pertaining to hazardous (classified) locations, plus any other applicable codes.
• Install only wiring systems with an equipment grounding conductor (which may be the conduit system).
• Ensure area to be free of hazardous atmospheres before and during installation and maintenance.
• Do not use accessory equipment not recommended by the manufacturer.
• All gasket seals must be clean and undamaged.
• Use only replacement parts from Eaton’s Crouse-Hinds Division.

WARNING
To avoid personal injury, explosion or equipment failure:

• Equipment should be mounted in locations and at heights where it will not readily be subjected to tampering by unauthorized personnel.
• Do not mount near heat-producing equipment.
• Explosion hazard: this luminaire is provided with a factory installed emergency lighting battery pack. Do not disconnect equipment unless area is known to be non-hazardous.

CAUTION
To avoid personal injury or damage to the equipment, it is strongly suggested to use two (2) qualified tradespeople to install the equipment. To avoid burning hands, make sure the luminaire is cool when performing maintenance.
WARNING
To prevent ignition of Groups C and D atmospheres, conduit runs must have a sealing fitting connection within 6 inches (152mm) of the equipment.

SAVE THESE INSTRUCTIONS

Figure 1. EM Fixture Overall Dimensions

INSTALLATION

Maximum mounting height: 15 ft. for XPLA2 EM and XPLA4 EM.

A. ZP1057MTK Back/Ceiling Mount

1. Select a durable, corrosion-resistant mounting surface capable of supporting the fixture’s 37.5 lb. (17 kg.) weight and cantilevered mass (as applicable).
2. Make sure the power is disconnected before installing the fixture.
3. For back mount, use the bracket as a template, mark and drill holes into the mounting surface and use supplied 5/16” bolts (see Figure 2).
4. Fixture is now ready for mounting.
5. It is strongly suggested to use two (2) qualified tradespeople to proceed with the final mounting of the fixture. This is recommended to avoid any personal injury or damage to the fixture.
6. Place the four (4) 5/16” bolts through the mounting plate and tighten evenly to the support structure. Minimum torque 138 in.-lbs. (15.6 N-m).
7. Slide the fixture into the mount bracket, engaging the flange on the top of the fixture and position it near the center. For final positioning, adjust approximately as shown in Figure 2.
8. Tighten the four (4) 1/4” set screws on the slide bracket until they bottom. Torque to 78 in.-lbs. (8.8 N-m). Figure 2. ZP1057MTK Back Mount Installation

B. ZP1050MTK Swivel Mount

1. Select a durable, corrosion-resistant mounting surface capable of supporting the fixture’s 37.5 lb. (17 kg.) weight and cantilevered mass (as applicable).

2. Make sure the power is disconnected before installing the fixture.

3. Mark and drill holes for fastening swivel brackets. Use two (2) 3/8” bolts (not supplied) at center to center measurements. Swivel bracket spacing is adjustable, but it is required to keep them at least 24” (610mm) apart.

4. Fixture is now ready for mounting. It is strongly suggested to use two (2) qualified tradespeople to proceed with the final mounting of the fixture. This is recommended to avoid any personal injury or damage to the fixture.

5. Slide the fixture into the mount brackets, engaging the flange on the top of the fixture and position it near the center.
   WARNING
   To avoid personal injury or equipment damage, do not let the fixture hang or flex on one bracket at a time.

6. Tighten the two (2) 1/4” set screws on each slide bracket until they bottom (see Figure 4). Torque to 78 in.-lbs. (8.8 N-m).

7. Adjust the position of the fixture to the desired angle and tighten the two (2) 5/16” pivot bolts. Torque to 138 in.-lbs. (15.6 N-m).

8. Tighten the two (2) 1/4” pivot locking nuts at the adjustment slots to 78 in.-lbs. (8.8 N-m).

C. PM KIT – POLE MOUNT

1. Select a durable, corrosion-resistant mounting surface capable of supporting the fixture’s 37.5 lb. (17 kg.) weight and cantilevered mass (as applicable).
2. Make sure the power is disconnected before installing the fixture.
3. Verify that the clamp (see Figure 6) internal diameter is consistent with the diameter of the pole prior to installation. Clamps are available in 1.65” (42mm), 2.00” (51mm) and 2.36” (60mm) sizes.
4. Pole mount bracket spacing is adjustable, but it is required to keep them at least 24” (610mm) apart.
5. Slide the two (2) pole mount brackets onto the fixture, engaging the flange on the top of the fixture.
6. Tighten the two (2) 1/4” set screws on each slide bracket until they bottom (see Figure 6). Torque to 78 in.-lbs. (8.8 N-m).
7. Remove the two (2) 5/16” screws, lock washers and nuts on each clamp and remove the upper clamp halves.
8. Fixture is now ready for mounting. It is strongly suggested to use two (2) qualified tradespeople to proceed with the final mounting of the fixture. This is recommended to avoid any personal injury or damage to the fixture.
9. Lift fixture into position such that the pole fits into the lower clamp halves.
10. Install the two (2) upper clamp halves and the 5/16” screws, lock washers and nuts on each clamp.
11. Tighten the nuts on the 5/16” screws evenly using a back and forth sequence. Torque to 138 in.-lbs. (15.6 N-m).

| Dimension (inches)
---|---
Configuration| A| B| C| D
PM Kit 2.0 (trade size 2”)| 4.331| 3.543| 2.36| 1.693
PM Kit 1.5 (trade size 1 – 1/2”)| 3.74| 2.953| 2.00| 1.535
PM Kit 1.25 (trade size 1 – 1/14”)| 3.386| 2.598| 1.65| 1.378

SECONDARY SUPPORT
If using secondary support, attach one end of the support cable to a corner eyelet provided on the fixture housing and secure the other end to a fixed support. Use a minimum of two (2) support cables per emergency luminaire, securing at least one to each end of the emergency luminaire housing.

WIRING THE LIGHTING FIXTURE

WARNING
To reduce the risk of ignition of hazardous atmospheres, keep cover tightly closed during operation.

1. Open the threaded wiring access cover (see Figure 7) and allow the cover to hang by the lanyard. All components in the emergency luminaire are pre-wired so only input power needs to be connected in the fixture to the lead wires (or terminals) per the wiring diagram (see Figure 9) using methods that comply with all applicable codes. Terminate the equipment grounding conductor (green) first, the common (white) next, and finally, the line voltage (black) last. Tighten all electrical connections.
   Note – Standard openings are 3/4” NPT.

2. If employing the dimming function of the charger driver board: The driver housing must be removed. Use only listed 0-10 VDC lighting controls. Ensure controls are rated for the areas in which they are being installed. Follow manufacturer’s installation instructions and applicable wiring methods as required by NEC/CEC. Ensure the power to the lighting control and the LED fixture are disconnected. Wire the dimming control signal wires per Figure 9. Locate the dimming control signal input wires (orange and black). Using wire rated for minimum of 75°C for ambient temperatures not exceeding 40°C, connect the positive lead from the lighting control unit to the orange lead, then connect the ground lead of the lighting control unit to the black lead wire of the charger driver board. Remove the optional control jumper on the charger driver board (see Battery Replacement Instructions). If the dimming control voltage is set too low, some flickering of the LEDs may occur. If this happens, raise the minimum value of the analog dimming voltage.

3. The battery circuit connector is shipped disconnected. Locate the single contact connector (plug and socket) on the red wires and make the connection.

4. Re-install the threaded access cover. Ensure gasket is seated and clean of debris.
   ( CAUTION: When replacing cover, make sure that there are no protruding wires or connectors that would obstruct the status indicator.

5. Refer to schematic for wiring. Only three (3) conductors maximum are allowed through each entry hub.

Note: To ensure the full battery function, newly installed luminaires with emergency backup must have a minimum of 72 hours charging.

WIRING INSTALLATION CHECKLIST

1. Verify sufficient HTL Lubricant is on conduit entries (recommend approximately 1/8″ bead around the first thread) and that all unused conduit entries on the driver housing are closed with lubricated plugs (see Figure 8).
2. Verify conduit is installed for at least five (5) full threads into the driver housing conduit entries.
3. Verify listed conduit sealing fitting is listed for at least Class I, Groups C, D and Class II, Groups E, F, G hazardous locations, such as Eaton’s Crouse-Hinds series EYS, and located within 6 inches of the luminaire conduit opening as marked on the nameplate.
4. Verify installed conduit plugs are torqued to 42-52 ft.-lbs. (57-71 N-m) for 3/4″ plug.
5. Verify supply wires are connected to luminaire wire leads per wiring diagrams.
6. Verify all electrical connections are tightened.
7. Verify all wires are safely and neatly inside access cover and not on top of status indicator. Re-attach access cap to fixture housing.
8. Verify access cover is tight and cover is in contact with fixture housing.

MAINTENANCE GENERAL

1. Perform visual, electrical and mechanical inspections on a regular basis. The environment and frequency of use should determine this. However, it is recommended that checks be made at least once a year. We recommend an Electrical Preventive Maintenance Program as described in the National Fire Protection Association Bulletin NFPA No. 70B: Recommended Practice For Electrical Equipment Maintenance (www.nfpa.org).
2. The lens should be cleaned periodically to ensure continued lighting performance. To clean, wipe the lens with a clean, damp cloth. If this is not sufficient, use a mild soap or a liquid cleaner such as Collinite NCF or Duco #7. Do not use an abrasive, strong alkaline, or acid cleaner. Damage may result.
3. Visually check for undue heating evidenced by discoloration of wires or other components, damaged parts or leakage evidenced by water or corrosion in the interior. Replace all worn, damaged or malfunctioning components, and clean gasket seals before putting the luminaire back into service.
4. Electrically check to make sure that all connections are clean and tight. Mechanically check that all parts are properly assembled.
5. Check and re-torque all mounting hardware.
6. To prevent heat build-up, remove dust from the LED housing using a soft brush or air pressure.
7. Ensure that the environment is safe before opening enclosure.
8. Ensure power is removed before conducting any service work, such as removing or installing batteries and replacing any components.

BATTERY REPLACEMENT INSTRUCTIONS

1. Only Eaton’s Crouse-Hinds series XPLA EM BATTERY PACK is acceptable as a replacement battery.

2. Area must be free of hazardous gas or vapors. Be sure to de-energize the luminaire before performing any maintenance.

3. Battery replacement requires removal of the driver housing (see Figure 11).

4. Open the threaded wiring access cover (see Figure 10) and allow the cover to hang by the lanyard.

5. Disconnect the battery circuit connector (red wire).

6. Disconnect the input wires (line in, neutral and ground).

7. Disconnect the conduit or fittings from the driver housing entries.

8. Remove the luminaire from the hazardous area.

9. Remove the twenty-four (24) socket head cap screws and lock washers from the driver housing using a 5mm hex wrench or bit.

10. Ensure all driver housing screws have been removed.

11. Remove the driver housing.
    Note: Keep the housing close to the luminaire body to avoid strain on the attached wire harness (see Figure 11).

12. Disconnect the connectors from the charger/driver board from battery #1 and battery #2, respectively (see Figure 12).

13. Cut the wire ties on each wire tie mount on the two (2) battery hold-down clamps.

14. Remove the four (4) screws that secure each battery pack hold-down clamp and remove the old battery packs. Replace with new battery packs supplied by Eaton’s Crouse-Hinds Division.

15. Secure each hold-down clamp with four (4) screws and tighten to 5 in.lbs. (0.6 N-m).

16. After replacing the battery packs, connect both battery pack connectors to the board connectors (the battery packs can be connected to either connector).

17. Bundle the battery leads neatly (see Figure 12) and secure them to the wire tie mounts using the wire ties supplied in the EM battery kit.

18. Re-install the driver housing, ensuring no wires are being pinched between the driver housing and the luminaire housing.

19. Re-install the twenty-four (24) socket head cap screws and lock washers from the driver housing using a 5mm hex wrench or bit.

20. Replace any damaged or missing housing screws. Use only alloy steel M6-1.5 x 20mm screws.

21. Tighten housing screws in a criss-cross pattern and torque to 45 in.-lbs.

22. Reconnect the conduit or fittings to the driver housing entries.

23. Reconnect input wires per wiring diagrams.

24. Reconnect the battery circuit connector (red wire).

25. Re-install threaded access cover (see “Wiring the Lighting Fixture”).

LED STATUS BLINK CODES

System operating as expected
1 _
(1 blink every two seconds)| System normal, battery charging| No action required
System operating as expected
3
(Three rapid blinks, then a pause, and then three quick blinks again)| LED load current too low or not present
Control select jumper not installed| Check connections to fixture
Install jumper on “Optional Control” terminals if not using dimming
If analog dimming is used, control voltage may be low enough which may cause this error to be set, this is normal
If not using dimming, and jumper is installed, circuit board may be bad
4
(Four rapid blinks, then a pause, and then four quick blinks again)| Battery voltage error| Check battery connections
Ensure fixture has been provided adequate time for battery charging (up to 72 hours for a new battery)
If the error persists after charging, batteries may be defective
5
(Five rapid blinks, then a pause, and then five quick blinks again)| Battery voltage equalization error| Battery packs may not be receiving charge equally; check connections between packs and circuit board
Red sense wire may have become disconnected
6 ** **
(Six rapid blinks, then a pause, and then six quick blinks again)| Battery charging current error| Check battery connections or replace circuit board

Only one LED blink code will be displayed at one time in order to avoid confusion. The priority will follow the order in the table above.
The LED loads can flicker when analog dimming is used and the control voltage is set to a low level. Keep in mind that this is normal and different loads will have the possibility of flicker at different voltage levels.
It is recommended to replace the batteries every 3 years. It is recommended that the equipment be tested regularly in accordance with local codes.

TEST SWITCH

When the test switch is pressed, the fixture LEDs will flash once and the input 24 volts will be disconnected from the charging system. When the test switch is released, the fixture LEDs will flash once, and the input 24 volt power will be reconnected to the charging system. During the time the test switch is pressed, all of the diagnostic checks will continue to be performed and the charging status LED will be indicating the highest priority error. Pressing the test switch allows the user to verify that the batteries are connected and charged enough to power the fixture. This test switch is to be used in accordance with NFPA 101 Life Safety Code®. The responsibility to carry out the required testing is the responsibility of the user.
PERIODIC TESTING
Article 700 of the National Electrical Code states, “Systems shall be tested periodically on a schedule acceptable to the authority having jurisdiction to assure their maintenance in proper operating condition.” It also states, “A written record shall be kept of such tests and maintenance.”
In the absence of periodic testing requirements by a local authority, the following recommendations from the NFPA 101 (2003) Life Safety Code are strongly recommended:

1. Monthly: Momentarily operate push-to-test switch. Observe that emergency lighting fixtures are on full brightness for the entire test cycle. Record the test on the Maintenance Record Card (provided on page 4).
2. Annually: Shut off AC power at the distribution panel. Verify that the emergency lighting fixtures remain “ON” for a minimum of 1-1/2 hours.
   NOTE: We suggest that this test be continued until the power supply automatically shuts the emergency light(s) off. This will help maintain full battery capacity.
   Record the test on the Maintenance Record Card.
   Allow 144 hours charging time before depending on the battery to operate at full capacity.
   Failure to function properly in either test may indicate the need for battery or lamp replacement.

REPLACEMENT PARTS
Servicing of any parts should be performed by qualified personnel. ONLY use replacement parts and batteries supplied by Eaton’s Crouse-Hinds Division.
Eaton’s Crouse-Hinds series linear LED fixtures are designed to provide years of reliable lighting performance. However, should the need for replacement parts arise, they are available through your authorized Eaton distributor.
Assistance may also be obtained through your local Eaton representative or the Eaton Sales Service Department, 1201 Wolf Street, Syracuse, New York 13208, Phone 866-764-5454.

PAINT SHIELD INSTALLATION INSTRUCTIONS
The optional paint shield can be installed by the customer over the lens of the emergency luminaire to minimize paint overspray accumulation on the light emitting surface.

1. Ensure all previous installation steps have been followed.
2. Locate the shield over the light emitting surface with the open portion facing the luminaire (see Figure 13).
3. Hook one side of the shield over the flange on one side of the luminaire housing.
4. Push on the opposite side of the paint shield to snap it over the flange on the luminaire housing.

MAINTENANCE RECORD
NFPA 101 (2003) REQUIREMENTS
“ A FUNCTIONAL TEST SHALL BE CONDUCTED ON EVERY REQUIRED EMERGENCY LIGHTING SYSTEM AT 30 DAY INTERVALS FOR A MINIMUM OF 30 SECONDS. AN ANNUAL TEST SHALL BE CONDUCTED FOR THE 1-1/2 HOUR DURATION.
EQUIPMENT SHALL BE FULLY OPERATIONAL FOR THE DURATION OF THE TEST. WRITTEN RECORDS OF TESTING SHALL BE KEPT BY THE OWNER FOR INSPECTION BY THE AUTHORITY HAVING JURISDICTION.”

| Duration of Test 1-1/2| | | |
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Date| 30 Sec.| Hour| Other| Battery Replaced| Inspected By| Lamp Replaced (Record Fixture Location)| Notes
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All statements, technical information and recommendations contained herein are based on information and tests we believe to be reliable. The accuracy or completeness thereof are not guaranteed. In accordance with Eaton’s Crouse- Hinds Division’s “Terms and Conditions of Sale,” and since conditions of use are outside our control, the purchaser should determine the suitability of the product for his intended use and assumes all risk and liability whatsoever in connection therewith.

Eaton’s Crouse-Hinds Division
1201 Wolf Street Syracuse, NY 13208
U.S.A.
Copyright© 2022
IF 1905
Revision 2
Revised 07/22
Revised 11/20

References

• nfpa.org
• NFPA | The National Fire Protection Association

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