Zalux 52-1458/Z Explosion Proof LED Luminaire OREX 2 Ex type User Manual

: June 9, 2024
: zalux

52-1458/Z Explosion Proof LED Luminaire OREX 2 Ex type

USER’S MANUAL
Explosion-proof LED luminaire
OREX 2 Ex type
No. 52-1458/Z
(ZxEx210031000202r3)

January 2022

ZALUX, S.A.
Avenida Manuel Rodríguez Ayuso, 114. Centro Empresarial Miralbueno. Planta 1a, Local P-2, 50012, Zaragoza, Spain | +34 976 46 22 00 |
info@zalux.com | www.zalux.com

User’s manual
OREX 2 Ex luminaire
No. 52-1458/Z (ZxEx210031000202r3)
Revision 1 Page 2

1. Introduction

The subject of this manual is an explosion-proof, energy-saving lighting fitting, type OREX 2 Ex, up to 270W, equipped with LED diodes of high luminous efficiency.

1.1. Intended use

The OREX 2 Ex luminaire is designed to illuminate:
– industrial halls and spaces classified as zones 2, gases, vapors and mists of flammable liquids,
– auxiliary rooms with high dustiness with the possibility of water splashes, i.e. boiler houses, hydro nodes, baths, garages, shelters, open and closed warehouses,
– workstation process lines, among others: chemical, petroleum, petrochemical, gas, wood,
mining, construction and food loose materials,
– rooms with increased temperature.

1.2. Functional properties

The wide power range allows the luminaire to be used in high, medium and low buildings. Optional additional increase in energy efficiency possible by external control via 1-10.

2. Design

The OREX 2 Ex luminaire consists of the following elements:
– body – aluminum alloy,
– pressure ring – aluminum alloy,
– tempered glass,
– LED light module,
– power supply with an integrated 3×1.0mm2 power cord (length 300mm),
– luminous flux adjustment via 1-10V according to versions,
– mounting eyelet,

Optionally, the luminaire can be:
– equipped with a connection chamber (ICB variant) with two openings for inserting power cables. The holes are equipped with M20, M25 cable gland or can be blind,
– equipped with an industrial power supply (IPS variant),
– adapted to work at elevated temperatures (HT variant),
– led driver is separated from the light unit (SD variant).

3. Technical data

Technical parameters

Parameter name

|

Value (unit)

Supply voltage

|

90-305 VAC 140-250 VDC 50-60/0Hz

Power

|

40-270W* ±10%

Power factor

|

PF ≥ 0.95**

ATEX marking

|

II 3G Ex ec op is IIC T5..T4 Gc

IECEx marking

|

Ex ec op is IIC T5..T4 Gc

EU-type examination certificate number

|

OBAC 21 ATEX 0135X

IECEx Certificate number

|

IECEx OBAC 21.0003X

Standards

|

EN IEC 60079-0:2018; EN 60079-7:2015+A1:2018

EN 60079-28:2015 EN 60079-31:2014

Source of light

|

ultra-bright LED lights

Color temperature

|

4000K ±10% as an option 3000K, 5000K, 6500K ±10%

Protection class

|

I

Degree of protection

|

IP 66/67***

|

IK 10

Ambient temperature range

|

in accordance with the table, point 8.2 – special conditions of use

Weight

|

6,5 kg – for version 40-160W

9,5 kg – for version 180-270W

External dimensions

|

Ø390×145 mm – for version 40-160W

Ø460×150 mm – for version 180-270W

CRT

|

80 (other on request) ±10%

* According to the table of execution types – point 3.1

** At 230VAC and 160W power

*** When using a cable gland with a lower IP, the degree of protection of the entire luminaire is re duced – see pt. 8.2

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User’s manual

OREX 2 Ex luminaire

No. 52-1458/Z (ZxEx210031000202r3)

3.1. Version types

Type designation:

Diffuser

type

|

Luminaire

size

|

Lighting flux

|

CRT + CCT

|

Electronic driver type

|

Cable gland type and size

(only for ICB version)

|

Additional

information

---|---|---|---|---|---|---

None: standard glass

G1: milky glass

G..: other glass on request

|

39: Ø390 mm (max 160 W)

46: Ø460 mm

|

60: 6000 for 40W

90: 9000 for 60W

120: 12000 for 80W

150: 15000 for 100W

180: 18000 for 120W

210: 21000 for 140 W

225: 22500 for 150 W

240: 24000 for 160W

270: 27000 for 180W

300: 30000 for 200W

330: 33000 for 220W

360: 36000 for 240W

390: 39000 for 260W

405: 40500 for 270 W

Tolerance ± 10%

|

840: CRI 80 and 4000K

850: CRI 80 and 5000K

Other on

request

|

P: service con

nector

ETDD: Digital

diming DALI

PDA: service con nector and digital dimming DALI

10V: analog dim ing 1-10V

P10V: service connector and analog dimming 1- 10V

ET: power cord

|

CG: plastic cable gland

NiCG: nickel-plated

brass cable

BCG: brass cable gland

ACG: cable gland for armored cable

H: housing with a hole for cable gland

Standard size cable/hole M20 and one cable

gland. Other size and quantity of cable gland on request.

|

Painting:

RAL.. type

IPS: external industrial

power supply equipped with integrated

connected

cable (in

creased ser

vice live)

SD: power

supply assem bly and light

ing assembly separated,

connected

with cable

(max 160W)

ICB: version with industrial power supply and connec

tion box (max 160W)

… other on

request

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User’s manual

OREX 2 Ex luminaire

No. 52-1458/Z (ZxEx210031000202r3)

HT versions – adapted to work at elevated temperatures:

Diffuser

type

|

Luminaire

size

|

Lighting flux

|

CRT + CCT

|

Electronic driver type

|

Cable gland type and size

(only for ICBHT ver sion)

|

Additional

information

---|---|---|---|---|---|---

None:

standard

glass

G1: milky

glass

G..: other

glass on

request

|

39: Ø390 mm

|

60: 6000 for 40W

90: 9000 for 60W

120: 12000 for 80W

Tolerance ± 10%

|

840: CRI 80 and 4000K

850: CRI 80 and 5000K

Other on

request

|

P: service con

nector

ETDD: Digital

diming DALI

PDA: service con nector and digital dimming DALI

10V: analog dim ing 1-10V

P10V: service

connector and

analog dimming 1- 10V

ET: power cord

|

CG: plastic cable gland

NiCG: nickel-plated

brass cable

BCG: brass cable gland

ACG: cable gland for armored cable

H: housing with a hole for cable gland

Standard size cable/hole M20 and one cable

gland. Other size and quantity of cable gland on request.

|

Painting:

RAL.. type

HT: industrial power supply with an addi

tional heat

sink

SDHT: power supply assem bly and light

ing assembly separated,

connected

with cable

ICBHT: ver

sion with in

dustrial power supply and

connection

box

… other on

request

Additional accessories:

Accessories

Lighting system

|

Mounting accessories

|

Others

None – no reflector;

R –symmetrical reflector;

AR – asymmetrical reflector;

WG – steel mesh;

… – other on request;

|

None – single eyebolt;

WM – wall mount;

ST – pipe mount;

WU – universal mounting;

NA – luminaire without mounting accesso ries

.. – other on request;

|

JB.. – junction box;

CR –power cords with an Ex connect or;

… – other on request;

Examples of type designation:

• OREX 2 Ex 39 90-840 P – OREX 2 Ex, 40 W power, 4000K CRI80 LED matrix and with diagnostic connector.

• OREX 2 Ex G1 39 150-930 P10V 2NiCG20 ICB AR WM – OREX 2 Ex milk glass

100W fitting, 4000K CRI 80 LED matrix. Equipped with a diagnostic connector with analog

1-10V dimming, with an integrated connection chamber with two cable glands made of

nickel-plated brass, size M20. Additional accessories asymmetrical reflector and wall mount.

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No. 52-1458/Z (ZxEx210031000202r3)

3.2. Advantages of the luminaire

− robust and compact design,

− quick, simple and easy installation,

− high resistance to a corrosive industrial environment,

− very high luminous efficacy,

− high-quality power supply unit and LEDs,

− UV-resistant.

4. Operation, service and use

Turning on the power causes the luminaire to light up automatically. The variants equipped with a control connector (DIMMING) have the option of adjusting the output power in the range from 10% to 100% of the nominal power.

5. Installation, mounting, disassembling

Note!

The equipment should be installed taking into consideration all recommendations given in this manual and should be carried out by a fitter, professional installer with necessary knowledge, tools and qualifications.

Electrical installation

For standard and IPS versions, the luminaire is equipped with a three-core power cable (L, N, PE). The PE protective conductor (grounding) is internally connected to the metal body. Optionally, a cable for brightness control (dimming) is led out of the luminaire. All cables should be connected in an appropriate manner, compliant with ATEX requirements, and with the appropriate IP degree, not less than IP 54. The brightness control cables (dimming) are not protected with an intrinsically safe structure, therefore, if they are not used, they must be properly secured (e.g. in a Ex junction box with reinforced construction joints or through a dedicated end cap). Cable connections must be made securely so that they cannot become disconnected or loosened spontaneously.

For the ICB variant, the luminaire is equipped with an additional integrated connection chamber. This enables the connection of through-flow, end-of-line power or simultaneous connection to the luminaire of a power line and a dimming line through cable glands placed on the top cover. The list of cable glands approved for use in the luminaire in point 8.2.

For the SD variant, as for the standard versions, the power supply is equipped with a three wire power cable (L, N, PE) and an optional brightness control cable. The electrical installation is analogous. The power supply unit and the lighting unit are separated and connected by a 10m long power cord (others on request). It is permissible to shorten the cable. It is suggested to carry out this operation from the side of the lighting unit, inside which the terminal strip is built-in. On the side of the power supply, the connection cable is terminated with a fast connector.

Due to the explosion-proof design, it is not allowed to switch on the power supply unit when the lighting assembly unit is disconnected

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OREX 2 Ex luminaire

No. 52-1458/Z (ZxEx210031000202r3)

Luminaire diagram

Standard and IPS version: Version with an additional chamber connection terminal (ICB):

Mechanical assembly

For standard variants, IPS and ICB, the luminaire should be mounted using the provided mounting eye, which should be screwed into the housing and properly secured against loosening with the use of a spring washer and a side locking screw. There are also additional accessories available for mounting the luminaire, e.g. to a wall, on a pipe / mast.

If mounting accessory is disassembled for transport, at the assembly stage, fix it using the included screws and spring washers.

For the SD variant, the lighting unit should be mounted in the same way as for the ICB vari ant. It is suggested that the power supply unit should be mounted in a place with the lowest possible available temperature and low exposure to mechanical damage.

It is possible to order the luminaire without mounting accessories, then proper mounting of the luminaire should be ensured. The elements used for mounting the luminaires (adapters, lugs) should be properly secured against loosening, eg with thread glue, spring washers, self-locking nuts, etc. Fastening the luminaire should take the entire load so that the power cable is not stressed.

In the case of installation in the vicinity of machines or devices that may cause excessive heating of the luminaire, the use of additional thermal shields should be considered. Using the luminaire in a place exposed to direct sunlight may cause excessive heating of the luminaire, which may reduce its lifetime and even damage it. It is recommended that the luminaire installed in such places is turned off during the day.

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User’s manual

OREX 2 Ex luminaire

No. 52-1458/Z (ZxEx210031000202r3)

6. Maintenance and repairs

Observe the laws and regulations in your country when using the lamp.

During periodic inspections, check:

The housing is not mechanically damaged
Check the housing for ingress of water and dust into the housing.
Condition of the paint coating, especially when using a C5 category paint coating (on request)
Correctness of choking of supply cables in cable glands for ICB and SD variants
For the ICB and SD variants, the correct fastening of the wires in the terminal strip
For the SD variant, the technical condition of the fast connector connecting the power supply unit with the lighting unit In the event of heavy soiling, the luminaire should be cleaned with a damp cloth.

In the case of using a luminaire with a special paint coating in category C5, a coating control plan should be introduced in accordance with EN ISO 12944-8. The control plan is adapted to the specific operating conditions of the luminaire. It should contain a description of the control tasks and the scope of the work performed. The coating corrosion assessment should be made on the basis of the ISO 4628 standard. Failure to follow the above procedure may result in the loss of the paint coat ing warranty.

The lifetime of the light source depends on the ambient temperature of the luminaire and its power. During operation, LEDs gradually reduce their luminous flux – this is a natural process, characteristic of all white LEDs. The degree of LED wear does not affect the luminaire’s operational safety.

Due to the explosion-proof design, service repairs may only be performed by the manufacturer’s service or an authorized unit with appropriate service documentation.

Before opening the fitting, disconnect the power supply.

For the ICB version, before opening the connection chamber, disconnect the power supply and wait for min. 30 minutes.

If the luminaire is dirty, clean it with a damp cloth only.

When replacing the power supply unit, pay special attention to the correct electrical connection with the LED matrix

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No. 52-1458/Z (ZxEx210031000202r3)

7. Transport and storage

7.1. Transport

The originally packed devices should be transported using covered means of transport. The packaging should be secured against shifting and sudden shocks. Devices should be transported at a temperature not lower than -20°C and not higher than +50°C.

7.2. Storage

The equipment should be stored in closed areas at a temperature not lower than -20°C and not higher than +50°C and away from heaters.

8. Additional information

8.1. CE marking

The CE marking has been affixed under the following regulations:

Explosion-proof equipment – Directive 2014/34/EU (ATEX)

Electromagnetic compatibility – Directive 2014/30/EU (EMC)

Restriction of hazardous substances – Directive 2011/65/EU (RoHS II)

Information on the obtained certificates and standards applied to the equipment evaluation has been specified in the declaration of conformity attached to every copy of the device.

The harmonized standards applied to demonstrate the compliance with the relevant directive are set out in the EU declaration of conformity supplied together with the device.

8.2. Special conditions for safe use

• Due to the risk of electrostatic charge, the luminaire should be cleaned with a damp cloth only.

• The ambient temperature range depends on the temperature class / max. surface tempera ture and the power of the luminaire.

• For the ICB variant, during operation, the maximum operating temperature inside the cable gland depends on the power of the luminaire and the maximum ambient temperature – this should be taken into account when selecting power cables. The exact values for the maximum cable gland temperature can be found in the table below.

• For the ICB variant, the luminaire is available without cable entries (with factory-made holes).

Before installation in the facility, it should be equipped with cable gland and / or plugs that meet the following criteria:

⮚ The cable gland and / or the stopping plug must be listed in table 2 in the ap pendix to the operating manual,

⮚ If you want to use a cable gland and / or a stopping plug that is not included

in Table 2, please contact the manufacturer for a conformity assessment,

⮚ For HT / ICB luminaires, the maximum operating temperature of the groove

must be at least 100 ° C,

⮚ The change of the cable gland type along with its basic parameters should be recorded in table 1 – appendix.

• The ambient temperature range and the temperature class of the OREX 2 Ex luminaire are determined in accordance with the table below:

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User’s manual

OREX 2 Ex luminaire

No. 52-1458/Z (ZxEx210031000202r3)

Luminaire power

[W]

|

The temperature class of the OREX 2 Ex luminaire – standard version, ICB IPS and SD

Ambient temperature range

---|---

-32°C≤Ta≤+45°C

|

-32°C≤Ta≤+50°C

|

-32°C≤Ta≤+55°C

|

-32°C≤Ta≤+60°C

40 – 80

|

T5 / T85°C

|

T5 / T90°C

|

T5 / T95°C

|

T4 / T100°C*****

81 – 120

|

T5 / T85°C

|

T5 / T90°C

|

T5 / T95°C

|

T4 / T100°C*****

121 – 160

|

T5 / T90°C

|

T5 / T95°C

|

T4 / T100°C*****

|

–

161 – 200

|

T5 / T90°C

|

T5 / T95°C

|

T4 / T100°C*****

|

–

201 – 240

|

T5 / T90°C

|

T5 / T95°C

|

T4 / T100°C*****

|

–

241 – 270

|

T5 / T95°C

|

T4 / T100°C*****

|

–

|

–

Luminaire power

[W]

|

Luminaire temperature class OREX 2 Ex – HT version *****

Ambient temperature range

---|---

-32°C≤Ta≤+55°C

|

-32°C≤Ta≤+60°C

|

-32°C≤Ta≤+65°C

|

-32°C≤Ta≤+70°C

|

-32°C≤Ta≤+75°C

40 – 80

|

T5 / T95°C

|

T4 / T100°C

|

T4 / T105°C

|

T4 / T110°C

|

T4 / T115°C

8.3. Basic safety principles

• Before attempting any works related to the equipment, the provisions of this manual should be read thoroughly.

• Follow good engineering practices during the selection of the equipment for a given application, during installation and during operation.

• The device should only be operated by personnel trained for this purpose.

• The safety rules of this type of equipment should be observed.

• Prior to the installation, check whether the marking on the rating plate satisfies requirements for a given application.

• Compliance with the instructions in this manual is a condition for warranty claims.

***** Operating the luminaire at elevated temperature shortens its service life

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No. 52-1458/Z (ZxEx210031000202r3)

8.4. Recycling and disposal

The symbol of a crossed-out waste container that appears on a product indicates that
it is subject to the provisions of European Directive 2012/19/EU (WEEE) and the
Waste Electrical and Electronic Equipment Act (Journal of Laws of 2015, item 1688 as
amended). The worn-out device together with a battery (if included) may not be
disposed of jointly with other waste. The worn-out equipment should be handed to
the manufacturer or to a point collecting discarded electronic and electric equipment to ensure its proper disposal. The requirements for the management and disposal of other waste are specified in the Waste Law (Journal of Laws of 2013, item 21 as amended).
In order to obtain more detailed information on product recycling, please contact the manufacturer, a local government unit, or waste management services. The packaging consists of a cardboard box and a polyurethane foam or cardboard filling.