Luminell D0054 RLX Cx EX Zone1 LED Flood Light User Manual
- June 6, 2024
- Luminell
Table of Contents
D0054 Gel Filled Connection Box Manual
GENERAL
The Connection Box Gel Kit is designed to benefit the customer and is to be
used with compatible Luminell lights both in hazardous and non-hazardous
areas.
Use of the Connection Box Gel Kit reduces the need for regular inspections of
Luminell’s hazardous area explosion-proof lights, especially beneficial if
lights are mounted in hard-to-reach places. It presents the potential for cost
reductions, increased operational efficiency, and safety. The gel in the
Connection Box Gel Kit fills the connection box and displaces the air inside
of it.
This solution can also be used with Luminell’s compatible non-hazardous area
lights. Poor quality cables, the reuse of old cables or cable glands, or the
incorrect installation of either can greatly increase the risk for water
ingress through cable or cable glands over time. Application of the Connection
Box Gel Kit eliminates the risk of this happening and ensures a maintenance-
free light solution.
It does not change/affect the Ex protection method for compatible hazardous
area models but provides similar characteristics as the Ex m encapsulated
protection method.
The warranty of the floodlight is not reduced nor is it extended when using
this product. The expected lifetime of the product will not be reduced but
rather prolonged as it eliminates the risk of water ingress as mentioned
above.
By using the Connection Box Gel Kit, the installer must acknowledge and follow
these instructions, in order to keep the certificate valid and the product
functional. These instructions are to be followed in addition to those in the
User Manual which comes with the product.
COMPATIBLE LIGHTS
Compatible lights are listed in the Luminell Product Finder
(https://luminell.com/product-numbers-public/)
- RLX DxZ1.21 with a S/N higher than Dx0268 (production date from July 2019)
2. RLX DxZ2.21
3. Lights marked with “Compatible with Luminell Gel kit” on the back cover.
BOX CONTENTS
- L0559 Gel bag 600ml L0558 DO NOT OPEN – Metal tag 70-72 Ø6 Engraved
- L0552 Gel Filled Connection Box Manual
- Spare bolts and washers for back cover
1x M6x20 DIN 912 A4 and 1x B6 DIN 127 A4
TECHNICAL SPECIFICATIONS
4.1 TEMPERATURE
The viscosity of the gel is temperature-dependent. It gets thick, harder to
mix, and pour at lower temperatures.
Application temperature:| +5 to +40°C (0 to +5°C is possible but not
recommended. +10 to +40°C is ideal)
---|---
Storage temperature:| 0 to +40°C
Operating temperature:| Same as floodlight temp. range.
- Pro Tip:
Keep the gel bag warm inside your coverall or jacket until you are ready to use it.
4.2 STORAGE
Store dry and frost-free. Store user manual and MSDS close to the bag.
PROCEDURE
The mechanical and electrical installation of the floodlight must be done
correctly. Not following this procedure may void the certificate. Read the
entire procedure before starting the process.
1. Verify that you are filling a compatible light. See 2 Compatible lights
2. Ensure all cables, cable glands and wires are installed properly. Use at
least 2,5mm² or AWG14 wire cores to avoid harmful temperature rise.
3. Tilt the floodlight so that the connection box is horizontal. The back cover can be hung on the bolt on the cooling rib on the right-hand side.
4. The gel time is limited to 1 hour. We recommend preparing the floodlight before mixing. Mix the gel by removing the black clamp and squeeze the bag carefully by hand for at least 1 minute. Pour the mixture into the connection box immediately after mixing. The spare gel is calculated in the bag to be used as a curing sample. Note mixing time, product S/N and product tag on the bag and keep it to check if the excess gel is cured.
5. Fill the connection box. up to 1-3mm from the gasket surface. Use the step just below the gasket surface inside the terminal box as leveling line to make sure there is sufficient gel. Make sure that the floodlight is tilted horizontally so that the gel covers the terminals and cable glands. Air bubbles will occur; these are only cosmetic and will not affect the safety of the product. Blowing hot air on the surface will burst the bubbles.
6. Fasten the metal tag to the back cover bolts. This is intended as a
barrier for the installer so that unnecessary opening of the connection box is
avoided.
Angle/point the floodlight according to the light plan. Wait 2 hours before
turning on the floodlight.
7. Check to cure sample after 4 hours. Visual inspection is possible after
the installation, but not recommended. The back cover will adhere to the gel,
and force must be applied to open it. Opening several times may cause extra
degradation on the sealing. 8. If possible, attach this manual to the
maintenance tag routine or folder to avoid unnecessarily
opening of the connection box.
MAINTENANCE
Maintenance is not relevant or needed. The solution is made to last the entire lifetime of the Luminell floodlight. If possible, attach this manual to the maintenance tag routine or folder to avoid unnecessary opening of the connection box. See RLX Ex Maintenance Program for a suggested maintenance program for Ex products.
- After the floodlight has been filled with gel the floodlight cannot be disconnected and reused. The gel will fill and seal the inside of the terminals and a safe connection cannot be ensured.
- The gel is soft and re-enterable. The cable can be reused if the part exposed to the gel is cut off, thus getting clean wire cores for the next connection.
- A thin crust is formed on the surface due to oxidation. Limit the opening of the terminal box to a minimum.
- The gel turns hazelnut brown when cured and will darken over time.
Luminal Norway AS
Doc. Nr.: D0054 Gel Filled connection box manual v1.5