COOLON MC22-XXX-12 Machine Light Emergency Kit Instructions

COOLON MC22-XXX-12 Machine Light Emergency Kit

Product Information

The Machine Light Emergency Kit is a portable emergency lighting solution designed for mobile plant applications. It includes an Extra Low Voltage Emergency Power Pack (ELV EMP) that provides a minimum of 10 minutes of emergency lighting at a maximum load of 100W. The dimensions of the ELV EMP are 280mm (length) x 160mm (width) x 102.4mm (height). The kit also includes a G104 JunctionBox with dimensions of 481mm (length) x 58mm (width) x 64mm (height).

Technical Specifications

• Product Name: Machine Light Emergency Kit
• Model: MC22-XXX-12
• Emergency Lighting Duration: Minimum 10 minutes at maximum load of 100W

Installation Instructions for MC22-XXX-12

1. Remove the 4x socket head screws to separate the base and the main assembly.
2. Secure the base to the mounting surface.
3. Place the main assembly onto the base and secure using the 4x socket head screws.
4. Your Machine Light is now ready to be connected!

Installation Instructions for EMP-724-036AL-ELV

1. Bolt the ELV EMP to a flat surface.
2. Connect power to the 24VDC terminal block from a source that only loses power in case of an emergency.
3. If attaching to a pole, use the U-Bolt Pole Mounting Plate for AL036 Enclosure (ACC-PMB-XXXX-PL100-GAL) available separately.
4. Mount the splitting junction box central to the emergency luminaires and ensure the emergency loom can reach the EMP.
5. Connect the luminaires to the respective terminal in the junction box.
6. Connect the emergency loom to the EMP enclosure.
7. The ELV EMP system is now ready for commissioning.

Emergency Pack Operating Modes

The ELV EMP allows only non-maintained operation. The emergency luminaires will energize in emergency operation when power is lost.

Commissioning Test

To test the emergency pack operation:

1. Connect the EMP to power. The Red Indicator LED on the lid willilluminate to indicate power presence.
2. If the Indicator LED is flashing, check that the batteryisolation switch is in the ON position. If it’s still flashing, refer to the EMP TROUBLESHOOTING section for further details.
3. Press the TEST BUTTON on the lid to simulate a power outage. The Red Indicator LED will stop.

DIMENSIONS

KIT INCLUDES:

• Machine Light LED luminaires 12V
• Junction box
• Emergency luminaire connection loom
• ELV emergency pack
• Machine Light DT extension looms

MC22-XXX-12

Technical Specifications

• Voltage In
• 12 – 16 VDC
• Power
• 20W @ 13.5 VDC

G104 Junction Box

Extra Low Voltage Emergency Power Pack (ELV EMP)

Technical Specifications

• Voltage In
• 20 – 30 VDC
• Power
• 30W

NOTE

• The Coolon ELV EMP is designed for mobile plant applications.
• The ELV EMP provides minimum of 10 minutes emergency lighting at maximum load of 100W

ATTENTION:
ELV EMP must be installed in the upright position Pole Mounting Kits are available designed for mountingproducts on a variety of poles used in the industry.
For more information visit: http://www.coolon.com.au/ind-acc-pdf.

WIRING DIAGRAM

INSTALLATION INSTRUCTIONS

MC22-XXX-12

Step 1
Remove the 4x socket head screws to separate the base and the main assembly.

Step 2
Secure base to the mounting surface.

Step 3
Place main assembly onto the base and secure using 4x socket head screws from Step 1.

Step 4
Your Machine Light is now ready to be connected!

Step 1
Bolt the ELV EMP to a flat surface.

If attaching to a pole, use the U-Bolt Pole Mounting Plate for AL036 Enclosure (ACC-PMB-XXXX-PL100-GAL) available separately. Download the document below for more information: http://www.coolon.com.au/mounting-acc-pdf.

Step 2
Connect power to the 24VDC terminal block.
NOTE: The 24VDC supply is to be provided from a source which only loses power in case of an emergency.

Step 3
Mount the splitting junction box central to the emergency luminaires. Ensure the emergency loom can reach the EMP.

Step 4
Connect the luminaires to the respective terminal in the junction box.

Step 5
Connect the emergency loom to the EMP enclosure. The ELV EMP system is now ready for commissioning.

Battery Details

• Unit only designed to operate using either LEAD CRYSTAL® or VRLA batteries.
• Recommended battery listed below. Contact Coolon for replacement batteries.

MANUFACTURER

• Betta Batteries

MODEL

• 6-CNFJ-7.2

CAPACITY

• 12V, 7.2Ah / 20HR

Emergency Pack Operating Modes

NON-MAINTAINED
Emergency use only.
The ELV EMP allows only non-maintained operation. The emergency luminaires willenergise in emergency operation, i.e: when power is lost.

Commissioning Test

• Energise the ELV EMP and turn the battery isolation switch ON.
• Once energised allow up to 10 seconds for the ELV EMP controller to go through the self-test procedure.
• Batteries are labelled with their last charge date. If the batteries have not been used more than 3 months, they have to cycle 2–3 times to restore their capacity.
• A typical cycle includes a 16 hour charge followed by a complete discharge.
• The ELV EMP will provide a minimum 10 minutes of emergency lighting when using a maximum load of 100W.

Emergency Pack Operation

1. Once the EMP is connected to power the Red Indicator LED on the lid will illuminate to indicate power presence.
   • If the Indicator LED is flashing, check that the battery isolation switch is in the “ON” position.
   • If the battery isolation switch is in the “ON” position and the Red Indicator LED is still flashing, see the EMP TROUBLESHOOTING section for further details.
2. Pressing the “TEST BUTTON” on the lid will disconnect the power simulating a power outage. The Red Indicator LED will stop illuminating and the EMP will operate in emergency mode if the battery isolation switch is in the “ON” position.
3. Critical system fault is indicated by the flashing Red Indicator LED during power presence.See the EMP TROUBLESHOOTING section for further details.

Emergency Pack Troubleshooting

On-board processor monitors the state of the EMP modules and periodically checks the batteries. Internal operations and fault conditions are signalled by on-board LEDs. Critical Fault will cause external Indicator LED to flash.

Error Code: RED LEDs (Internal Fault Indicator)
Error Code: Internal RED Fault indicator LEDs used for internal diagnostics. LEDs indicate internal faults using binary codes.
Error Code: In the event external Indicator LED is flashing, information about the internal LED status may help diagnostic and fault rectification on- site. Contact COOLON support (support@coolon.com.au) for guidance.
Charger 2: GREEN LEDs (Operating Mode Indicator)
Charger 1: POWER LED will illuminate when mains is present.
Power: CHARGER 1 and CHARGER 2 LEDs flash during charge and stay ON once the individual respective batteries are fully charged.

Battery Replacement Procedure

1. Isolate power supplied to the EMP.

2. Put battery isolation switch to “OFF” position.

3. Disconnect the spade terminals from the batteries.
   NOTE: Do not use any conductive material to remove the terminal connector.

4. Loosen the top then the bottom battery housing keeping the captivescrews within the housings.

5. Remove the batteries and insert new batteries.
   NOTE: Fit the rubber battery tray to the new batteries before installation. The spade terminals connector must fit snug on the terminal – if theterminal connection is loose compress the connector slightly to ensure a sturdy connection.

6. Tighten the bottom then the top battery housing. The batteries should sit snug with the battery housing flat on the base.

7. Carefully connect respective spade terminals observing battery polarity.
   NOTE: Black wire always connects to negative terminal of the battery. Battery wiring diagram is provided on the right.

Storage Shelf Life

The ELV EMP has a storage shelf life of up to 12 months when stored at a temperature of 20±5°C. Storage temperatures outside of 20±5°C but within the prescribed unit operating temperature limit will result in a decreased product shelf life of up to 6 months.
If the ELV EMP cannot be commissioned (put into in-service operation) within the prescribed shelf life then it should be put through a charge cycle (see below).
Following a charge cycle, the unit can be stored for a further period appropriate to the storage temperature. Failure to comply with the above requirements may result in irreparable damage to the battery since such a state would permanently alter the battery chemistry, this type of failure is not covered by warranty. The charge cycle procedure is as follows:

1. Connect the unit to mains supply, Control line connection does not need to be made, just A, N, E
2. Turn the battery isolation switch to the ON (connected) position
3. Energise the unit and allow to charge for 16 hours (a red indicator should be observed, the indicator should not flash)
4. De-energise the unit and disconnect mains supply
5. Turn the battery isolation switch to the OFF (disconnected) position
6. Pack the unit for storage

• support@coolon.com.au
• aus. 1300 287 533
• intl. +613 8681 3633
• www.coolon.com.au.
• www.coolon.com.au.

Product must be installed by a suitably qualified person. All documentation is subject to change without notice. Refer to our website for the latest information.

References

• Coolon LED Lighting Products - Melbourne, Australia | Coolon LED Lighting

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