Chalmit Industrial Lighting

INDUSTRIAL
INDUSTRIAL
LIGHTING
PRODUCT GUIDE
10
PROTECTA
SURFACE-MOUNTED FLUORESCENT
The Protecta is a robust GRP fluorescent with high IP rating
designed for use in the most arduous marine environments.
It is constructed from a GRP body and quick-release GRP clamp bar
which secures the hinged clear polycarbonate diffuser. All of the
control gear is mounted onto the reflector/gear-tray which is fitted
to the body. Ease of access to the lamps ensures that installation
and maintenance times are kept to a minimum.
Amongst the available options is a small bayonet lampholder for an
emergency tungsten lamp or a red running light which is for night
vision purposes. Both operate from a separate supply.
ATEX Categories 2 & 3 (Zones 1 & 2) hazardous area versions are
available which are commonly used on FPSO’s and FSO’s.
(Refer to Chalmit hazardous area catalogue)
STANDARD SPECIFICATION
Ingress Protection: IP66/67 to EN 60529
Enclosure: GRP body with clear polycarbonate diffuser and brass suspension points
Entries: 4 x M20 cable entries through gland plates (2 each end)
Internal Wiring: Heat resistant wiring up to 105 0C max
Termination: 3 core 6mm2 max conductors with looping and through wiring.
Reflector/Gear-tray: White polyester painted zinc coated steel
Mounting: Two M8 brass inserts on rear of body
Control Gear: Switch start copper/iron control gear and PFC capacitor
Relamping: Via quick-release diffuser clamp and hinged diffuser
Electrical Supply: 230V 50Hz (always state V/Hz when ordering)
STANDARD PRODUCT RANGE

Catalogue No. Wattage (W) Lamp Type Lampholder Weight
PRGI/118/BI 1x18W T8 Fluorescent G13 6 Kgs
PRGI/218/BI 2x18W T8 Fluorescent G13 6.1 Kgs
* Stainless steel body versions are available also. Their catalogue nos. commence PRSI.
OPTIONS - Suffix to Catalogue No.

/--- Specific voltage - Copper/iron ballasts : 110,120,220,240,254(18W Models) 220,240,254(36W Models)
- High frequency ballasts : 120 to 277
- dc supplies : 12, 24, 110 (18W Models) 12, 24 (36W Models)
/60 60Hz (copper/iron ballasts only)
/ES Electronic start (copper/ iron ballasts only)
/HF High frequency ballast. 220-240V 50/60Hz as standard.
/EL Extra live termination (Compatible with 4-core switched emergency models)
/DC dc supply voltage
/MF Mains fuse
/3P 3 phase termination facility (not available if looping is required)
11
ACCESSORIES (Ordered separately) CATALOGUE ORDER CODE
18W Wall mounting outreach bracket (for use with SPRO4-0003) NPRO4-0008
Pole mounting bracket assembly kit SPRO4-0003
Offset ceiling bracket assembly kit SPRO4-0002
IOM - Protecta Safe Area Fluorescent Luminaire
Issue 04
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Protecta Safe Area Fluorescent Luminaire
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.
MODEL SIZE DIMENSION 'A' DIMENSION 'B'

2x18/20W 742 400
2x36/40W 1352 700
210 DIMENSION 'B' - M8 FIXING CENTRES

147
TWO M20x1.5p DIMENSION 'A' - OVERALL

CABLE ENTRIES THRO'
GLAND PLATES AS NON-EMERGENCY MODELS AND
STANDARD AT EITHER EMERGENCY MODELS WITH INTERNAL BATTERY PACK
END OF THE BODY
IOMPROTS Issue 04 April 00

1
0.0 Specification
Type Of Protection N/A

Area Classification Non-Hazardous
Standard BS EN 60598 Pt 1
Temperature Range T amb 50ºC
Ingress Protection IP66/67 to BS EN 60529
CE Mark The CE marking of this product applies to "The Electrical Equipment (Safety) Regulations
1994" and "The Electromagnetic Compatibility Regulations 1992.
[This legislation is the equivalent in UK law of EC directives 73/23EEC and 89/336/EEC,
respectively].
1.0 Introduction - Protecta Safe Area Fluorescent Luminaire
The Protecta Safe Area fluorescent luminaires are surface mounted or suspended, utilising the two tapped holes on
base of body, with the facility of an integral battery back-up for emergency use. Normal operation is mains supply
two lamps on, switching to one lamp on battery back-up, local switching of the mains lamps, the emergency lamp
only being energised on mains failure. Emergency duration: to BS EN 60598 2.22, as per order. They are mainly
used in harsh environments, and are constructed using a corrosion resistant glass reinforced polyester body
attached to an injection moulded polycarbonate diffuser by hinges and a special clamp. The control gear and
lampholders are mounted on a removable tray which for maintenance has hanging straps.
Note : Ratings using copper/iron switch start control gear are as indicated in TABLE 0.
2.0 Storage
Luminaires and control gear boxes are to be stored in cool dry conditions preventing ingress of moisture and
condensation. Any specific instructions concerning emergency luminaires must be complied with.
3.0 Installation and Safety
3.1 General
There are no health hazards associated with this product whilst in normal use. However, care should be exercised
during the following operations.
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 information in this leaflet is correct at the time of publication. The company reserves the right to make
specification changes as required.
3.2 Tools
12mm, 8mm and 4mm flat blade screwdriver.
Suitable spanners for installing cable glands.
Pliers, knife, wire strippers/cutters.
3.3 Electrical Supplies and Control Gear

The supply voltage and frequency should be specified when ordering. A maximum voltage variation of +6%/-6% on
the nominal is expected. Luminaires should not be operated continuously at more than +6%/-10% of the rated
supply voltage of the control gear or tapping. Care is needed connecting to the nominal 230V UK public

2
supply. The user must determine the actual underlying site supply and purchase or adjust accordingly. Normally,
luminaires for 230V and 240V, 50Hz rating and which use a conventional copper/iron choke, are supplied with a
tap.
If the equipment is located in high or low voltage sections of the system, an appropriate voltage tap should be
selected, but care must be taken to log or mark the equipment so that the tapping is re-set if the equipment is re-
located. If in doubt, tappings should be set on the high side.
Luminaires fitted with electronic control gear are suitable for a rated supply between 220 and 240V, 47-63Hz, and
for higher voltages to order. The safety limits are +10% of this. The supply would normally be expected to lie
within +/-6% of rated. The lamp supply is regulated, therefore the light output over the range is substantially
unchanged.
Some luminaires are available for operation on dc and 110/130V and 277V ac. Operation from dc should be
checked with the Technical Department before ordering. Electronic gear has integrated power factor correction to
>0.95.
Warning : Luminaires are assessed and/or tested for EMC requirements. This is based on the
disposition of entry cables and, where appropriate, through wiring arrangements as supplied or
specified. Users must take care not to introduce wiring into parts of the apparatus materially
different to that which could be reasonably inferred from the disposition of fixed supply
terminals and specified through wiring.
3.4 Lamps
Lamps are bi-pin fluorescent tubes having the following ratings, 18W and 36W (T8) 26mm diameter tubes.
3.5 Mounting
Luminaires should be installed where access for maintenance is practical and in accordance with any lighting
design information provided for the installation.
3.6 Cable Connection
3.6.1 Cables
The temperature conditions of the supply cable entry point are such that 70ºC (ordinary PVC) cable can be used.
On models where there is no fixed through wiring supplied by Chalmit, but where there is a looping facility on the
gear tray, any supply wiring passing through the body must either have a rating of 130ºC or have sleeving fitted
which has a 130ºC rating. 300/500V cable ratings are adequate and no special internal construction is necessary.
Where MCB's are used, the type with the higher short time tripping current ratio used for motor starting and lighting
should be specified. The standard maximum looping size is 2.5mm² with options of 4mm² through wiring. An
internal earth tag can be fitted to the cable gland.
3.6.2 Cable Glands

Cable glands when installed should maintain the desired IP rating of the enclosure.
3.7 Electrical Connections

Luminaires are available for looping and through wiring. The through rating is 16A. Terminals for 4mm² and 6mm²
are available. State which on order. If work is to be done on any luminaire which has already been connected to
the electrical system, it must be isolated from the system. The diffuser cover is swung down and removed if
convenient by swivelling back as far as possible and the reflector tray is then slid out after releasing the locking
screws. This gives access to the mains terminals. Luminaires with terminal blocks have L N E, where appropriate.
3.7.1 Installation of HF and Emergency

Following the mounting of the apparatus and the connection of the supply cable the unit cannot be insulation
tested. When the unit is ready for operation the mains and the battery connections must be made, the unit is

3
supplied with the battery disconnected. After commissioning the unit can be shut down for a long period without
loss of function.
3.8 Servicing and Operation
3.8.1 Opening and Closing the Cover

The procedure for opening the cover is as follows:
Insert the tool into one of the slots in the clamping bar with the end of the tool located into the outer flange of the
body as a fulcrum point, a wide blade screwdriver is recommended. Gently lever the tool away from the diffuser,
the clamping bar will begin to open. Insert the tool in the other clamping bar slot and gently lever away from the
diffuser, the clamping bar will open and the cover will be retained by the hinge. Should difficulty be experienced,
reinsert the tool in the first slot and repeat the procedure.
The procedure for closing and securing the cover is as follows :
Ensure the hinge mechanism is clear of any obstruction and then swing the diffuser into the closed position.
Support the diffuser in position whilst pushing the clamp bar over the edge of the diffuser. Apply even pressure at
both ends of the bar and press the bar over centre.
3.8.2 Removal and Replacement of Clamping Bar (if required)

Open the luminaire as above and remove the diffuser or let it swing down. Press the clamping bar towards the
closed position, tip forward beyond the closed position and the clamping bar will be released from the body. To
replace the clamping bar, put in position on the body with the front edge pointing as far inwards as it will go. Click
the bar outwards and bring back to the normal closed position. The clamping bar should then be secured in
position, open the clamping bar fully by using hand or screwdriver pressure (avoid damaging the gasket), the
clamping bar is then ready to accept the normal closure of the diffuser.
3.8.3 Releasing the Reflector/Gear Tray

Loosen the four fixing screws retaining the reflector/gear tray and slide over keyhole slots. The tray will hang on the
retaining cords without stressing the wiring between body and tray. Replace in reverse order.
3.8.4 Fitting lamps

The bi-pin lamps are fitted in rotating lampholders. The lamp should be pushed firmly down into the lampholder and
rotated 90º. If the lamp does not rotate check that it is completely positioned into the lampholder. There will be a
slight click when the lampholder reaches the 90º position. Before inserting bi-pin lamps ensure the lamp pins are
not slack in the end cap.
3.8.5 Commissioning
Energise the mains and check that both lamps light when the supply is energised.
3.9 Inspection and Maintenance

On battery models, we recommend that the battery duration is checked periodically.
Important : Isolate the mains supply and disconnect the battery terminal before carrying out any work.
3.9.1 Replacement of Electronic Ballast and Invertor Unit (Where Fitted)

The electronic ballast and invertor contain no replaceable parts. Should it be found necessary to replace these
parts, the following procedure should be adopted:
Ensure that the luminaire is isolated from both mains and battery supplies, otherwise a risk of shock may occur.
Disconnect the leads on the ballast at the terminal block. Undo the ballast securing screws and washers and
withdraw the ballast from the gear body. Replace in reverse order. Replacement of the invertor is identical.
3.9.2 Routine Examination

The luminaire must be de-energised before opening. Individual organisations will have their own procedures. What
follows are guidelines based on our experience :

4
1 Ensure lamps are lit when energised by mains supply.

2 Visually check diffuser cover for damage, this should only be cleaned using a damp cloth to avoid static, and
only use recommended detergents for polycarbonate. If the polycarbonate is discoloured or damaged a new
diffuser cover must be fitted.
3 When de-energised and left to cool, there should be no significant sign of internal moisture. If there are any
signs of water ingress, the luminaire should be opened up, dried and any likely ingress points eliminated by re-
gasketting or other replacements.
4 Check cable gland for tightness and nip up if required.
5 Check any external and internal earths.
6 Check all terminations are firmly screwed down, tighten if necessary.
7 Check clips visually for any damage and replace, if necessary.
8 If it has been suspected that the luminaire has suffered mechanical damage, a stringent workshop check on
all components should be made. All components can be removed from the luminaire for inspection.
4.0 Electrical Fault Finding and Replacement

The supply must be isolated before opening the luminaire.
Any live fault finding must be done by a competent electrician and, if carried out with luminaire in place, under a
permit to work.
The control gear can be tested for continuity of connections with a low voltage tester.
If lamps go out repeatedly, and replacement lamps do not work or expected life is reduced, the control gear should
be returned for replacement/testing.
On re-assembly all faulty/damaged wiring should be replaced and connections checked. If an electronic starter is
fitted it will cut out if lamps are defective. Ordinary starters will blink continuously.
5.0 Disposal of Material

The unit is made from combustible 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.
5.1 Lamps
Fluorescent lamps in modest quantities are not "special waste". They should be broken up in a container to avoid
injury. Avoid inhaling dust.
Important : Do not incinerate lamps.
5.2 Battery Disposal

Nickel cadmium batteries are defined as 'controlled waste' under the hazardous waste regulations and disposer
needs to observe a 'duty of care'.
Batteries can be returned to the manufacturers for re-cycling. They must be stored and transported safely and any
necessary pollution control forms completed prior to transportation. Take care to fully discharge batteries before
transporting, or otherwise ensure that there can be no release of stored energy in transit. For further details refer to
our Technical Department.

5
0.0 Tables 0
Table 0 Ratings – Copper/Iron Switch Start Control Gear Refer to Section : 1.0
No. off Lamp Lamp Circuit Power PFC Line

Lamp Watts Type Consumption µf Current
Watts
1 18 Series 24.3 4 0.16
2 18 Parallel 48.6 6 0.32
2 18 Series 42.0 4 0.23
1 36 Series 42.0 4 0.23
2 36 Parallel 84.0 8 0.46
Note: For information on high frequency ballasts contact the Technical Department.

6
Chalmit Lighting 388 Hillington Road, Glasgow G52 4BL, Scotland

A Division of Hubbell Lighting Limited
Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704
Email : info@chalmit.com
Website : www.chalmit.com
Registered Office Ronald Close, Woburn Road Industrial Estate

Kempson, Bedford. MK42 7SH.
Registered No. 3650461
Note Chalmit Lighting reserve the right to amend

characteristics of our products and all data is for
guidance only.
Chalmit Lighting is a leading supplier of Hazardous Area and Marine Lighting products.

7

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12
PROTECTA E
EMERGENCY FLUORESCENT
The Protecta E is a robust GRP fluorescent with high IP Rating
designed for use in the most arduous marine environments.
It is constructed from a GRP body and quick-release GRP clamp bar
which secures the hinged clear polycarbonate diffuser. All of the
control gear is mounted onto the reflector/gear-tray which is fitted to
the body. Ease of access to the lamps ensures that installation and
maintenance times are kept to a minimum.
The Protecta E comes complete with integral 3-hour Ni-Cad battery back
up. The incoming mains supply to the luminaire has the facility to have two
live supplies : continuous live(Lc) which supplies constant power to the
battery and switched live(Ls)which is for external switching,allowing the
luminaire to be locally switched off without the emergency battery pack
unintentionally operating the lamps. If external switching is not required Lc
and Ls are made common at the mains terminal block.
ATEX Categories 2 & 3 (Zones 1 & 2) hazardous area versions are
available which are commonly used on FPSO’s and FSO’s.
Enclosure: GRP body with clear polycarbonate diffuser and brass suspension points
Entries: 4 x M20 cable entries through gland plates (2 each end)
Termination: 3 or 4 core 6mm2 max conductors with looping and through wiring.
Reflector/Gear-tray: White polyester painted zinc coated steel
Mounting: Two M8 brass inserts on rear of body
Control Gear: 18W Models - High frequency ballast & inverter c/w battery pack
36W Models - Copper/iron ballast c/w battery pack
Relamping: Via quick-release diffuser clamp and hinged diffuser
Electrical Supply: 18W Models - 220-240V 50/60Hz
36W Models - 230V 50Hz (always state V/Hz when ordering)

PRGI/118/BI/EM 1x18W T8 Fluorescent G13 8.1 Kgs
* Stainless steel body versions are available also. Their catalogue nos. commence PRSI.
OPTIONS - Suffix to Catalogue No

/--- Specific voltage - Copper/iron ballasts : 220,240,254(36W Models only)
/NM Non-maintained (single lamp models only)
/MF Mains fuse
/3P 3 phase termination facility (not available if through wiring is required)
13
Offset ceiling bracket assembly kit SPRO4-0002
48
STERLING
SURFACE-MOUNTED FLUORESCENT INTERIOR
The Sterling is a quality and cost effective single and twin
fluorescent range with GRP bodies and polycarbonate diffusers which
are secured with stainless steel clips allowing rapid access for
installation and maintenance. The Sterling range is available
in 18W, 36W and 58W T8 Fluorescents as either emergency or
non-emergency models. Emergency models have their own
integral Ni-Cad battery pack. For night vision purposes there is the
option of a red running light which operates from a separate supply.
ATEX Category 3(Zone2) hazardous area versions are available.

Ingress Protection: IP65 to EN 60529
Enclosure: GRP body and clear polycarbonate diffuser
Entries: 2xØ20mm clearance holes(one either end)
Termination: 3 core 4mm2 max conductors (4 core on emergency models)
Relector/Gear-tray: White polyester painted zinc coated steel
Mounting: Through Ø8mm clearance holes. Sealing washers are provided.
Control Gear: Switch start copper/iron control gear and PFC capacitor
Relamping: Via diffuser
Battery duration: 3 Hours (emergency models)
STGI/118/BI 1x18W T8 Fluorescent G13 2.2 Kgs
STGI/136/BI 1x36W T8 Fluorescent G13 3 Kgs
STGI/158/BI 1x58W T8 Fluorescent G13 4 Kgs
STGI/118/BI/EM 1x18W T8 Fluorescent G13 4.0 Kgs
i) Maintained emergency single lamp models are in twin lamp bodies.
ii) 18W Emergency models are available with a high frequency ballast only.

/--- Specific voltage - Copper/iron ballasts : 110,120,220,240,254(18W Models ) 220,240,254(36W & 58W Models)
- High frequency ballasts : 120 to 277 (18W & 36W)
- dc supplies : 12, 24, 110 (18W Models) 12, 24 (36W Models)
/EL Extra live termination (Compatible with 4-core switched emergency models)
/DC dc supply voltage
/NM Non maintained emergency (single lamp bodies only)
/MF Mains fuse
/TW Through wiring (36W & 58W models only)
/3P 3 phase termination facility (not available if looping is required)
49
Offset ceiling bracket assembly kit
IOM - Sterling Safe Area Fluorescent Luminaire
Issue 01

Sterling Safe Area Fluorescent Luminaire
as a guide only.
IOMSTGI Issue 01 May 00

1
0.0 Specification
Area Classification Non-Hazardous (Industrial)

Standard BS EN 60598-1 : 1997
Ingress Protection IP65 to BS EN 60529
1994" and "The Electromagnetic Compatibility Regulations 1992”.
respectively].
1.0 Introduction - Sterling Safe Area Fluorescent Luminaire

The Sterling Safe Area fluorescent luminaires are surface mounted or suspended, utilising the 2 holes on base of
body. They are mainly used in harsh environments, and are constructed using a corrosion resistant glass
reinforced polyester body or a stainless steel body attached to an injection moulded polycarbonate diffuser by self-
retaining stainless steel toggle clips. The control gear and lampholders are mounted on a removable tray, which for
maintenance has hanging straps.
Note : Ratings for the GRP body non-emergency versions are outlined in TABLE 0.
Ratings for Metal Body Non-Emergency versions are outlined in TABLE 1.
Ratings for Emergency versions are outlined in TABLE 2.
2.0 Storage
condensation.
Any specific instructions concerning emergency luminaires must be complied with.
3.1 General
during the following operations. Installation should be carried out in accordance with the local area code of
practice, whichever is appropriate.
3.2 Tools
Screwdriver flat blade 12mm and 3mm. Suitable spanners for installing glands.
3.3 Electrical Supplies

supply voltage of the control gear or tapping. Care is needed connecting to the nominal 230V UK public
supply. The user must determine the actual underlying site supply and purchase or adjust accordingly. Normally
luminaires for 230V and 240V, 50Hz rating are supplied with a tap.

2
3.4 Lamps
Lamps are bi-pin fluorescent tubes having the following ratings, 18W, 36W, 58W (T8) 26mm diameter tubes.
3.5 Mounting
On mounting the luminaire by using the 11mm ∅ holes, it is the responsibility of the user to ensure that an
adequate seal is made to maintain the desired IP rating with a minimum of IP54. Washers are provided. Other
mountings are available on request.
3.6 Cable Connection
3.6.1 Cables
The temperature conditions of the supply cable entry point are such that 70ºC (ordinary PVC) cable can be used in
most luminaire models. On models where there is no fixed through wiring supplied by Chalmit but where there is a
looping facility on the gear tray, any supply wiring passing through the body must either have a rating of 130ºC or
have sleeving fitted which has a 130ºC rating. 300/500 volts cable ratings are adequate and no special internal
construction is necessary. Where MCB's are used, the type with the higher short time tripping current ratio used
for motor starting and lighting should be specified. The standard maximum looping size is 2.5mm² with options of
4mm² through wiring. An internal earth tag can be fitted to the cable gland.
3.6.2 Cable Glands

Cable glands when installed should maintain the minimum IP65 rating of the enclosure. The cable gland should
adequately secure the cable in the unit. Sealing plugs for unused entries should be similarly rated and fitted. Two
21mm ∅ holes are provided, suitable for M20 x 1.5 glands, supplied with travelling plugs only. It is the
responsibility of the user to ensure that an adequate seal between the gland body and the apparatus is maintained.
Tapped entries are available on the stainless steel bodies.
3.7 Cabling
Access for cabling is via diffuser cover, care is to be taken as there is no suspension of diffuser cover. The diffuser
clips are undone and the diffuser laid aside. The gear tray is dropped down after rotating the turnbuckles or sliding
the screws in the keyholes. The tray can be removed by undoing the spring clips on the suspension cables. The
cable glands should be fitted with suitable washers to maintain the desired IP rating. Any earth tag connections
should be fitted. The connecting terminals are identified and the conductors should be bared back so that they
make full contact in the terminals, but the bare conductor should not be more that 1mm beyond the terminal.
Unused terminal screws should be tightened. The cores must be identified by polarity and connected in
accordance with the terminal markings. Before re-fitting the cover, a final check on the correctness of connections
should be made.
Where switched operation is required on the emergency, remove the link and connect line and switched line
separately.
3.7.1 Fitting Lamps

Before opening the diffuser cover ensure that the luminaire is isolated from mains supply. Access for re-lamping is
via diffuser cover, care is to be taken as there is no suspension of diffuser cover. Make sure that the correct lamp
is selected. The lampholders are tombstone type, place the lamp in the lampholder and rotate 90º in lampholder.
When inserting new lamps ensure the pins and lampholder connection is centralised. Replace diffuser cover and
snap clips into place.

3
The emergency unit has no battery isolating arrangement, so if the lamp is replaced with the battery charged, take
care not to touch the lamp cap or pins when removing or refitting the lamp.

1 Ensure lamps are lit when energised by mains supply.

2 Visually check diffuser cover for damage, this should only be cleaned using a damp cloth to avoid static, and
only use recommended detergents for polycarbonate. If the polycarbonate is discoloured or damaged, a new
diffuser cover must be fitted.
3 When de-energised and left to cool, there should be no significant sign of internal moisture. If there are any
signs of water ingress, the luminaire should be opened up, dried and any likely ingress points eliminated by re-
gasketting or other replacements.
7 Check clips visually for any damage, and replace if necessary.

Any live fault finding must be done by a competent electrician and, if carried out with the luminaire in place, under a
permit to work.
As the control gear is copper and iron, the fitting can be tested for continuity of connections.
If lamps go out repeatedly, and replacement lamps do not work or expected life is reduced, the control gear should
be returned for replacement/testing.
On re-assembly, all faulty/damaged wiring should be replaced and connections checked. The electronic starter will
cut out if lamps are defective.
3.9.1 Battery Check and Replacement

The battery is contained in a tube which is sealed. The battery is detached at the plug and socket. Remove the
two clamps to release the battery. Re-assembly is in reverse order.
Important : Take care not to short the leads together as this can cause a fire.
The emergency duration is 3 hours for all wattages. This will gradually degrade. The battery must be replaced
when the duration is not acceptable.
If the electronic unit is healthy, the fuse is intact and the lamp sound, there should always be a little duration which
will reoccur after a short period of recharging. The unit should be checked by a substitution.
Take care to fully discharge batteries before transporting, or otherwise ensure that there can be no release of stored
energy in transit.

The unit is made from combustible 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
complied with.

4
4.1 Lamps

Nickel cadmium batteries are defined as 'controlled waste' under the hazardous waste regulations and disposer
transporting or otherwise ensure that there can be no release of stored energy in transit. For further details refer to
Technical Department.
5.0 MCB Ratings

MCB's allow the use of reduced cable sizes for the supply. The capacitance current is 0.076A per µF at 240V,
50Hz, this may be multiplied by 25 for 250 microseconds for calculation purposes.
Note : MCB ratings are outlined in TABLE 3.

5
0.0 Tables 0/1/2/3
Table 0 Ratings - GRP Body Non-Emergency Versions Refer to Section : 1.0
Model Lamps Voltage Range Circuit Type
STGI/158 1 x 58W T8
STGI/258 2 x 58W T8 220/240V, 50Hz PARALLEL
STGI/136 1 x 36W T8 220/254V, 60Hz
STGI/236 2 x 36W T8
STGI/118 1 x 18W T8
STGI/218
STGI/218 2 x 18W T8
Series
Table 1 Ratings - Metal Body Non-Emergency Versions Refer to Section : 1.0
Model Lamps Voltage Range Circuit Type
STSI/158 1 x 58W T8
STSI/258 2 x 58W T8 220/240V, 50Hz Parallel
STSI/136 1 x 36W T8 220/254V, 60Hz
STSI/236 2 x 36W T8
STSI/118 1 x 18W T8
STSI/218 2 x 18W T8
Series
Table 2 Ratings - Emergency Versions Refer to Section : 1.0
Model Lamps Circuit Type
STGI/258/EM 2 x 58W T8
STGI/236/EM 2 x 36W T8 Parallel

6
Table 3 MCB Ratings Refer to Section : 5.0
Number Lamp Lamp Power PFC Line Consumption Emergency

Of Lamps Watts Circuit Consumption µF Current Watts During Line
Type Watts Charging Current
Power
1 18 Parallel 24.3 4 0.16 --- ---

2 18 Parallel 48.6 6 0.32 --- ---
2 18 Series 42.0 4 0.23 --- ---
1 36 Parallel 42.0 4 0.23 46.0 0.23
2 36 Parallel 84.0 8 0.46 88.0 0.46
1 58 Parallel 66.5 6 0.34 70.5 0.34
2 58 Parallel 133 10 0.68 137.0 0.68

7

Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704


guidance only.

8

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50
ACCLAIM
RECESSED FLUORESCENT INTERIOR
The Acclaim range of fluorescent luminaires is available in both 18W
and 36W twin T8 emergency and non-emergency fluorescents.
The mounting and cover details are flexible to allow the luminaire to
be recessed into a variety of marine ceilings including fire resistant
ceilings up to Solas B15 rating. Emergency models have their own
integral Ni-Cad battery pack.
IP23 is the standard IP rating but there is the option of a higher IP
rating of IP54 if required.
ATEX Category 2 (Zone 1) hazardous area versions are available.
APPLICATIONS: Suitable for accommodation areas, corridors, and

public areas.
Enclosure: White polyester painted zintec body and frame. Clear polycarbonate diffuser
Entries: 4xØ20mm clearance holes(supplied plugged)
Internal Wiring: Stranded, heat resistant wiring up to 105 0C max
Termination: 3 core 4mm2 max conductors (4 core on emergency models)
Reflector/gear-tray: White polyester painted zinc coated steel
Mounting: Swing out side arms (also suitable for drop rod mounting through Ø9mm holes )
Control Gear: High Frequency control gear
Relamping: Via front cover, secured by pan head screws
Battery duration: 3 Hours (emergency models)

ACLI/218/BI 2x18W T8 Fluorescent G13 16 Kgs
ACLI/236/BI 2x36W T8 Fluorescent G13 23 Kgs
ACLI/218/BI/EM 2x18W T8 Fluorescent G13 19 Kgs
ACLI/236/BI/EM 2x36W T8 Fluorescent G13 27 Kgs
18W Emergency models are available with a high frequency ballast only.

/--- Specific voltage - Copper/iron ballasts : 110,120,220,240,254(18W ) 220,240,254(36W)
/ES Electronic start (copper/iron ballasts only)
/MF Mains fuse
/TW Through wiring
/M25 M25 Entries
/IP54 IP54
/LG Low glare louvres
/PD Prismatic diffuser
51
IOM - Acclaim II Safe Area Recessible Fluorescent Luminaire
Issue 02

Acclaim Safe Area Recessible Fluorescent
as a guide only.
720 CRS (18W)

1335 CRS (36W)
2 OFF 21ø HOLES
145
25
750 (18W)
1365 (36W)
EL
D
E O
O
CTNL
R D N
Y O
CO- CLA
AST M T
EA U
UTATNP
SE
IOI CWC
I L
S
NH TH O OL
AZ TH
A VE
A
R NT
S
D
275
208
22.5
IOMACSAF Issue 02 April 00

1
IOM – Acclaim II Safe Area Recessible Fluorescent Luminaire
0.0 Specification

Standard BS EN 60598:1993
Certificate T5 Tamb 40ºC
Emergency Duration BS EN 60598 2.22 ( As per order)
Ingress Protection IP23 to BS EN 60529:1992 (P54 To Order)
respectively].
1.0 Introduction - ACCLAIM II Safe Area Recessible Fluorescent Luminaire
The Acclaim II Safe Area series is a recessible fluorescent luminaire with the facility of an integral battery back up
for emergency use. The luminaire can be constructed to interface with fire resistant ceiling systems to maintain a
B15 SOLAS fire rating, care must be taken to maintain this classification. When insulated refer to Chalmit for
Tamb ratings, as it affects life and battery performance. Normal operation is mains supply two lamps on, switching
to one lamp on battery back up, local switching of the mains lamps, the emergency lamp only being energised on
mains failure.
Important : This range is available in a number of similar but distinctly different versions. Care must be taken
to use the correct instructions and spares, if in doubt contact Sales or Technical Department.
2.0 Storage
Luminaires are to be stored in cool dry conditions preventing ingress of moisture and condensation.
3.1 General
during the following operations.
Installation should be carried out in accordance with any applicable code of practice or regulations and fitting of
specified insulating material is to be adhered too where a specific fire resistance rating is required. In the UK, the
requirements of the "Health & Safety at Work Act 1974" and "Electricity at Work Regulations 1989" must be met.
The luminaires are Class 1 and should be effectively earthed.
Application details on the rating plate must be verified against the requirements before installation.
3.2 Tools
12mm, 8mm and 4mm flat blade screwdriver.

2
Luminaires fitted with electronic control gear are suitable for a rated supply between 220 and 240V, 47-63Hz, and
for higher voltages to order. The safety limits are +10% of this. The supply would normally be expected to lie within
+/-6% of rated. The lamp supply is regulated, therefore the light output over the range is substantially unchanged.
Some luminaires are available for operation on dc and 110/130V and 277V ac. Operation from dc should be
checked with the Technical Department before ordering. Electronic gear has integrated power factor correction to
>0.95.
Warning : Electronic control gear is assessed and/or tested for EMC requirements. This is based on the
disposition of entry cables and, where appropriate, through wiring arrangements as supplied or specified. Users
must take care not to introduce wiring into parts of the apparatus materially different to that which could be
reasonably inferred from the disposition of fixed supply terminals and specified through wiring.
For luminaires fitted with conventional control gear, the supply voltage and frequency should be specified when
ordering. The safety limits are +10%. Care is needed connecting to the nominal 230V UK public supply. The
user must determine the actual underlying site supply and purchase or adjust accordingly. Normally luminaires for
230V and 240V, 50Hz rating are supplied with a tap.
3.4 Lamps
Lamps are bi-pin fluorescent and can have the ratings 18W, 36W (T8) 26mm or 20W, 40W (T12) 38mm tubes. The
bi-pin lampholder accommodates lamps to IEC81 with G13 cap.
3.5 Mounting
design information provided for the installation. Where the luminaire is to be part of the ceiling construction, for
aesthetic reasons, care is to be taken to ensure that the spacing and height specified by ceiling type is met.
When mounting of ceiling support channels, via side arms, they must be secured onto channels by fixing screws.
When B15 fire rating is a requirement, all conditions stated by the ceiling manufacturer and Chalmit must be met.
3.6 Cabling and Cable Glands
3.6.1 Cables
all luminaires. 300/500 volts ratings are adequate. The selection of the cable size will be suitable for the fuse
rating, which applies to the circuit on the supply side of the control gear. The standard maximum looping size is
6mm2 with options of 2.5mm2 or 4mm2 through wiring. An external M6 earth stud is fitted adjacent to the cable
gland.
3.6.2 Cable Glands

Cable glands for entry into enclosures when fitted with any gland to body sealing method and the supply cable,
must reliably maintain the IP rating of the enclosure. Two 21mm diameter holes are provided suitable for 20mm
entries, one with a plug and seal suitable for permanent use, the other has a travelling plug. M20 entries are
standard, other sizes are available on request. The clearance holes are powder coated so if required arrangements
must be made to earth cable glands, kits are available and an external earth point is fitted as standard.
3.7 Electrical Connections

Access for the cabling is via removal of front cover and lamp tray. The front cover is secured using 4/10 off M5
captive screws, care to be taken as there is no suspension arrangement on this and the lampholder tray is secured
by M5 screws and keyhole slots with suspension, allowing the tray to swing down, giving access to terminal
blocks. Install the conductors in the appropriate terminals. Take care not to cut the conductor insulation
excessively, 1mm of bare conductor outside the terminal throat is a maximum. Unused terminal screws should be

3
tightened. Before re-fitting the lampholder tray and front cover, the cores/cable should be neatly tucked away and a
final check made on correct connections. If switched operation is used, the bridge is removed or the common live
connection separated.
3.8 Installation
Following the mounting of the apparatus and the connection of the supply cable the unit cannot be insulation
tested. When the unit is ready for operation the mains and the battery connections must be made, the unit is
supplied with the battery disconnected. After commissioning, the unit can be shut down for a long period without
loss of function.
3.9 Fitting Lamps

Before opening the front cover ensure that the luminaire is isolated from the mains supply. Access for re-lamping
is via the front cover, care is to be taken as there is no suspension of the cover. Make sure that the correct lamp is
selected.

On battery models, we recommend that the battery duration is checked periodically.
4.1 Replacement of Electronic Ballast and Invertor Unit (Where Fitted)

The electronic ballast and invertor contain no replaceable parts. Should it be found necessary to replace these
parts, the following procedure should be adopted:
Ensure that the luminaire is isolated from both mains and battery supplies, otherwise a risk of shock may occur.
Disconnect the leads on the ballast at the terminal block. Undo the ballast securing screws and washers and
withdraw the ballast from the gear body. Replace in reverse order. Replacement of the invertor is identical.
Important : Isolate the mains supply and disconnect the battery terminal before carrying out any work.
4.2 Routine Examination

1 Ensure lamps are lit when energised by mains supply and emergency lamp on battery pack.
2 Visually check cover front for damage, this should only be cleaned using a damp cloth, to avoid static, and
only use recommended detergents for polycarbonates. If the polycarbonate is discoloured or damaged, a
new cover assembly must be fitted. Additional prismatic diffuser or louvres should be cleaned with a dry
cloth. If damaged, they should be replaced.
3 When de-energised and left to cool, there should be no significant sign of internal moisture. If there are
any signs of water ingress, the luminaire should be opened up, dried and any likely ingress points
eliminated by re-gasketting or other replacements.
7 Check battery securing screws are tight, when fitted.
8 Check cover screw washers for wear and tightness of screws.

4

The unit is made from combustible materials. The control gear contains plastic parts. All electrical components
and the diffuser 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.
5.1 Lamps

Nickel cadmium batteries are defined as 'controlled waste' under the hazardous waste regulations and the disposer
transporting or otherwise ensure that there can be no release of stored energy in transit. For further details refer to
our Technical Department.

5

6

7

Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704


guidance only.

8

9
14
800 SERIES
STAINLESS STEEL FLOODLIGHTS DECK & EXTERIOR
The 800 series is a floodlight range specifically designed for hostile
marine environments. Constructed from 316S31 marine grade
stainless steel, the range is fitted with internal control gear and can
be quickly relamped by removing the toughened glass front cover via
the specially designed front cover clamps. There is the option of a
remote gear box for all HPS and metal halide lamp models although
for certain models this is standard. Other options include M25 cable
entries, auxiliary tungsten halogen lamp, looping, narrow beam
reflector and timed cut-out ignitor. For high vibration applications
there is the option of a strengthened mounting arrangement for added
safety.
ATEX Category 3 (Zone 2) hazardous area versions are available
which are commonly used on FPSO’s and FSO’s
Enclosure: Marine grade 316S31 stainless steel construction
Entries: 2 x M20 cable entries
Internal Wiring: Flexible wiring, silicone insulated, heat resistant up to 180 0C
Termination: 3 core 4mm2 max conductors
Reflector: Wide beam high purity anodised aluminium
Mounting: Adjustable stirrup bracket
Control Gear: Internal (with remote option using control gear box)
Relamping: Via front cover (c/w safety chains) and quick release clips
Electrical Supply: 220,230,240,254V 50Hz for SON-T & MBI-T lamp models
250V Max ac/dc for tungsten halogen lamps
(always state V/Hz when ordering)
844I/070/HS 70 HPS E27 12 Kgs
854I/100/HS 100 HPS E40 18 Kgs
854I/150/MS 150 HPS/Metal halide E40 18 Kgs
854I/400/MS* 400 HPS/Metal halide E40 17 Kgs
854I/500/TH 500 Single ended T/Halogen E40 16.5 Kgs
864I/600/HS* 600 HPS E40 21 Kgs
864I/2x4/MS* 2x400 HPS/Metal halide E40 17 Kgs
* require 501/502 series external control gear box
The following models are for 120V, 50Hz unless stated.

864I/150/MS/120** 150 HPS/Metal halide E40 18 Kgs
864I/250/MS/120** 250 HPS/Metal halide E40 19 Kgs
864I/400/MS/120*** 400 HPS/Metal halide E40 17 Kgs
** Internal control gear & transformer *** Supplied c/w remote gear-box. Details on request.

/--- Specific voltage (200,210)
/60 60Hz
/M25 2xM25 Entries
/AL Auxiliary tungsten halogen lamp
/N Narrow beam reflector
/TI Timed cut out ignitor
/ST Strengthened mounting arrangement.
15
844 Pole mounting bracket assembly (inc fixings) S8444-0002
844 Wire guard (Ordered with luminaire) S8444-0005
844 Anti-glare shield (Ordered with luminaire) S8444-0001
IOM – 844I, 854I & 864I Floodlights
Issue 00

800 Series Stainless Steel Floodlight
as a guide only.
A E
D
B
2 OFF M20 CABLE ENTRIES

C C
3 HOLES ø13 (854, 864)
3 HOLES ø12 (844)
DIMENSIONS 844I 854I 864I

70/100W 150/250/400W 400/600W
A 308 415 465
B 443 630 640
C 75 150 150
D 348 490 500
E 175 185 190
F 175 260 260
IOM800i Issue 00 April 00 1

0.0 Specification
Area of Application Non-hazardous

Standard BS4533 Section 102.1 : 1990, Section 102.5 : 1990
Ingress Protection IP66/67 to BS EN 60529: 1992
respectively].
1.0 Introduction – 800 Series Stainless Steel Floodlight

The type 844I, 854I and 864I floodlights are manufactured in marine grade 316 stainless steel and are designed for
use in marine or hostile environments. The maximum recommended operating ambient (tamb) is 40ºC for indoors
or still air and 50ºC for outdoors or where situated in free moving air.
Note : All the floodlights in this series are suitable for tubular lamps only.
The range of models is outlined in TABLE 0.
2.0 Storage
3.1 General
Installation must be made in accordance with good electrical procedure and local codes of practice. In the UK the
requirements of the “Health and Safety at Work Act” and “The Electricity at Work Act” must be met. The
luminaires are Class 1 and should be effectively earthed. The luminaires are heavy and suitable handling
equipment must be employed during installation.
3.2 Tools
Suitable spanners for installing cable glands, 3mm and 5mm flat blade screwdriver.

the nominal is expected. In some cases, the luminaires have multi-tapped control gear which can be set to a range
of 50 and 60Hz voltages.
The tappings are shown on the control gear and the limits are shown on the rating plate. If the equipment is
located in the high or low voltage sections of the system, an appropriate voltage tap should be selected, 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 advised for MBI. All the HPS and MBI circuits use SIP (superimposed
pulse) ignitors. This means that there are only two connections to the choke making the tap selection obvious.
Where shore or construction site supplies are different to the service locations supplies used, tappings should be
re-set . If not, advice on the affect of these temporary supplies should be sought from the Chalmit Technical
Department.
IOM800i Issue 00 April 00

2
3.4 Mounting
Luminaries should be installed where access for maintenance is practical and in accordance with any lighting
design information provided for the installation. The foot mounting or rear mounting arrangements should be
secured with lock washers or self-locking nuts and bolts. The luminaire should be mounted with the lamp axis
horizontal. Any aiming angle may be used. The luminaire should not be mounted with the gear positioned above
the lamp if at all possible.
Note: The weights of the various models are indicated in TABLE 0.
3.5 Lamps
The high pressure sodium lamps are of a standardised type. There is no preference between make or colour. The
844I model has an E27 lampholder, the 854I and 864I models have an E40 lampholder.
MBI lamps are not standardised in the 250W and 400W range. For MBI the 3.0A 250W lamp and the 4.2A 400W
lamp is used.
Only tubular lamps should be used. Both specular (plain) and dispersive (mottled) reflectors are available for all
luminaires and should be specified when ordering.
Anti-glare shields are available for all types but must be ordered with the equipment, as the fixings are not
standard. Care must be taken to fit the correct lamp in order to obtain the designed photometric performance.
HPS and MBI lamps should be replaced shortly after they do not light. The indication of the end of life for HPS
lamps is “cycling”, where the lamps 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 becoming diodes with possible detrimental effects to control gear. The above information is current at time
of printing. The development of lamps and control gear is ongoing and detailed advice on lamp performance can be
obtained from the lamp supplier or from Chamlit. HPS and MBI circuits should not be energised without a lamp
fitted. HPS and MBI lamps with internal ignitors must not be used.

all the standard range luminaires. The maximum looping size is 2.5mm² with 6mm² single entry as standard. Two
entry points capable of accepting 20mm ∅ glands are standard. It is the responsibility of the user to ensure that
the correct cable size and fuse rating are used.
Cable glands where installed should maintain the IP rating of the luminaire and if using metal glands, should be of
suitable material or suitably protected to meet any prevailing environmental conditions. Plastic glands may be
used except in cases where the earth is provided by means of the cable armour in which case a suitable metal
gland should be employed. Care should be taken to ensure that a good contact is made between the gland and
the body of the luminaire.
It is the responsibility of the user to ensure that an adequate seal is made between the gland and the body to
maintain the IP rating.
3.7 Cabling and Fitting Lamps

Access for cabling and fitting lamps is by removing the front cover. Before removing the cover on any occasion,
check that the cover support chain is sound.
The cover is released by undoing the two toggle clips using a screwdriver or a peg through the hole in the clip.
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.
Lamps must be of the correct type and firmly screwed into place. The cover is replaced and the toggle clips
snapped over.

3

Routine 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 maintenance. Individual organisations will have their own procedures.
What follows are guidelines based on Chalmit’s experience :
1 Ensure the lamp is lit when energised and that the lampglass 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 re-gasketting.
3 Check all cable glands for tightness and nip up if necessary.
4 Check all cover toggle clips for tightness. If they appear slack, re-set by bending the angle
between the long sides of the clips until they require firm pressure to lock into place.
5 Clean the lampglass.

Control gear will not normally go open circuit unless it has first overheated; the signs of this are obvious, being
severe discoloration of the paint of the gear and cracks in any exposed insulation. Similarly, a bad contact at the
lamp cap will usually result in discoloration as a sign of overheating.
Any fault finding must be carried out by a competent electrician. With HPS 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 will be unusual not to have other parts available to perform a substitution fault finding routine and this is the
normal procedure. 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.
4.0 Overhaul
The unit is largely made of material which are very corrosion resistant. This allows the unit to be completely
stripped, mechanically cleaned, then re-built with new electrical parts as required. The internal wiring is 1.0mm²
flexible, silicone rubber insulated. If the cover gasket has deteriorated by softening or permanent set, a new cover
assembly should be fitted. As an alternative, replacement gasket strip can be obtained from CHALMIT but to fit
this, care is needed. The old gasket should be removed and remaining adhesive scrapped off with a chisel type
blade.
New strips are cut full length on the short sides and neatly butted on the long sides. The gasket pieces are fixed in
place and the butt joint sealed with silicone R.T.V. The cover assembly is left unclipped on top of a body with a
sheet of thin polythene between it and the body to avoid adhesion. After a few hours the cover is removed and
allowed to cure in free air for 24 hours.
5.0 Fuse Ratings

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 25x 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 MCBs with a wide range of

4
characteristics, the individual engineer can make a better judgement of what is required. The normal capacitor
current will probably be the determining factor 0.076A per µF at 240V, 50Hz (adjust for other volts by multiplication,
x 6/5 for 60Hz). For HBC fuses use 1.5 x normal capacitor current.
All calculations must satisfy wiring regulations.
Note : Starting and running currents for 240V, 50Hz are as indicated in TABLE 1.
A conventional matrix for HBC fuses is outlined in TABLE 2.

The unit is made chiefly from inert 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 the electrical components may give off noxious fumes if incinerated. Care
must be taken to render these fumes harmless or avoid inhalation. Any local regulations concerning disposal must
be complied with.
6.1 Lamps
Discharge lamps in modest quantities are not "special waste". The outer envelope should be broken in the
container to avoid injury.
This applies to the UK, there may be other regulations on disposal operating in other countries.

5
0.0 Tables 0/1/2
Table 0 Ratings Refer to Section : 1.0
Model Lamp Type Weight

kg
844I 70W SON/T & MBI-T 10
100W SON/T 21
150W SON/T 22
854I
250W SON/T & MBI-T 23
400W SON/T* 20
400W SON/T & MBI-T 26
864I
600W SON/T* 23
* Ignitor only fitted. Remote gear box required.
Table 1 Starting and Running Currents Refer to Section : 5.0
Lamp Start A Run A Capacitance Circuit Power (W)

µF
70W HPS 0.55 0.4 10 80
100W HPS 1.0 0.56 10 117
150W HPS 1.45 0.8 20 175
250W HPS 2.35 1.3 30 285
400W HPS 4.0 2.2 40 445
600W HPS 5.6 3.1 60 645
150W MBI 1.6 0.8 20 175
250W MBI 2.7 1.35 30 285
400W MBI 4.0 2.2 40 445
Table 2 Fuse Ratings Refer to Section : 5.0

6
Lamp Wattage Number of Lamps
1 2 3 4 5 6
70W 4A 4A 4A 4A 4A 4A
100W 4A 4A 6A 10A 10A 10A
150W 4A 6A 10A 10A 16A 16A
250W 10A 16A 16A 20A 20A 20A
400W 16A 20A 20A 25A 25A 32A
600W 16A 20A 25A 32A 32A 40A
Note : Minimum Power Correction Factor : 0.85

7

Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704
Email : email@chalmit.com


guidance only.

8

9
24
NEXXUS
HEAVY DUTY BULKHEAD DECK & EXTERIOR
The Nexxus bulkhead luminaire is suitable for H.I.D, incandescent
and compact fluorescent lamps. Its construction consists of a
black-painted marine grade die cast aluminium LM6 alloy body
with a heat resistant prismatic glass cover, silicone rubber sealing
gasket and stainless steel fixings.
The Nexxus bulkhead offers a compact and versatile solution in
many applications especially those with high levels of dirt and/or
moisture. They are simple to install,easy to maintain and durable.

APPLICATIONS: Ships decks, car decks, walkways,

ports & harbours
Enclosure: Epoxy painted aluminium alloy LM6 body with prismatic glass lens,
silicone rubber gasket and stainless steel fixings
Entries: 3 x M20 cable entries
Termination: 3 core 6mm2 max conductors with looping or through wiring.
Reflector: High purity anodised aluminium
Mounting: 4 x Ø7mm clearance holes in body fixing channel.
Control Gear: Internal copper/iron ballast with ignitor and PFC capacitors (H.I.D lamp models)
Relamping: Via front glass cover secured by four stainless steel screws
Electrical Supply: 220-240V 50Hz (50W HPS lamp model)
220/230/240/254V 50Hz (70W & 80W models)
240V 50Hz (CFL models) 250V Max ac/dc (GLS lamp model)

NEXI/050/HS 50 HPS E27 6.5 Kgs
NEXI/070/MS 70 HPS/Metal halide E27 7 Kgs
NEXI/080/MV 80 MBFU E27 6.5 Kgs
NEXI/113/CF 1x13W CFL G24 5.5 Kgs
NEXI/213/CF 2x13W CFL G24 6 Kgs
NEXI/200/GL 200W GLS E27 5 Kgs

/--- Specific voltage (208,254)
/60 60Hz
/TI Timed cut out ignitor
/MF Mains fuse
25
Wire Guard Kit (inc.fixings) SNEX1-0001
IOM - Nexxus Industrial Bulkhead
Luminaire
Issue 00

Nexxus Industrial Bulkhead Luminaire
as a guide only.
297
204
4 HOLES DIA 7
190
178
87
168
IOMNEXIND Issue 00 June 02 1

Luminaire
0.0 Specification
Standard BS EN 60598
Ingress Protection IP66 and IP67 to BS EN 60529
CE Mark The CE marking of this product applies to “The Electrical Equipment (Safety)
Regulations 1994” and “The Electromagnetic Compatibility Regulations 1992”.
1.0 Introduction - Nexxus Industrial Bulkhead Luminaire
1.1 Application
The luminaire should not be used 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.
2.0 Storage
condensation.
3.1 General
during the following operations. In the UK, the requirements of the 'Health and Safety at Work Act' must be met.
The luminaires are quite heavy and suitable means of handling on installation must be provided.
Details on the rating plate must be verified against the application requirements before installation. The information
in this leaflet is correct at the time of publication. The company reserves the right to make specification changes
as required.
3.2 Tools
3mm and 5mm flat blade screwdriver.

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 for T rating 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. Care must be taken if connecting to the
nominal 230V UK public supply. In some cases, the luminaires have multi-tapped control gear which can be set
to a range of 50 and 60 Hz voltages. 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 below the actual tapping 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. Where shore or construction site
supplies are used, which are different to the service location supplies, tappings should be re-set. If not, advice on
the effect of these temporary supplies should be sought from the Technical Department.
3.4 Lamps

Luminaire
The discharge lamps used are of a standardised type. There is no preference between make or colour. The
compact fluorescent lamps are of the four pin type. The compact fluorescent lamps use G24q type caps, which
vary with lamp wattage and are secured with a retaining bracket. Philips lamps must be used to obtain a correct
fit. Care must be taken to fit the correct new and replacement lamps in order to preserve the certification
conditions 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.
3.5 Mounting
design information provided for the installation. The rear mounting arrangements should be secured with lock
washers or self-locking nuts and bolts. Any mounting attitude may be used.
3.5.1 Weights
Note : Weights for the various types are outlined in Table 3.
3.6.1 Cables
The terminals are suitable for standard conductor section up to 6mm² max. All models are suitable for looping.
Standard 300/500V cable is suitable.
Note: Through wiring when used, is subject to a maximum current of 16A.
3.6.2 Cable Glands

Cable glands and sealing plugs when installed must maintain the ingress protection rating of the enclosure. Rubber
sealing washers and steel compression washers are provided with the unit to seal between the gland body and the
luminaire. The body torque value is 12Nm. The user must ensure that the assembly fulfils the above requirement.
Entries suitable for M20 cable glands are standard.
3.6.3 Cable Gland Types

Refer to the cable gland manufacturers catalogue for information with regard to compatibility with cable types.
Refer also to Chalmit for the assessment of other suitable types, these will be covered by a manufacturers
declaration.

Access for cabling and fitting lamps is by removing the front cover. The cover is released by unscrewing the four
screws using a screwdriver. 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. Lamps must be of the correct type and firmly screwed into place. The cover is replaced
and the screws tightened down.
3.7.1 Fused Terminal Blocks

When a fused terminal block has been fitted, 2.5mm² cable maximum and single entry only, no looping.

Luminaire
Visual inspection should be carried out at a minimum of 12 monthly intervals and more frequently if conditions are

The equipment must be de-energised before opening. Individual organisations will have their own procedures.
What follows are guidelines based on our experience :
1. Ensure the lamp is lit when energised and that the lampglass 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 re-gasketting.
3. Check the cable gland for tightness and nip up if necessary.
4. Check all cover screws for tightness and nip up if necessary.
5. Clean the lampglass.
6. When relamping, check that the cover gasket has not softened or become excessively deformed. If in doubt,
replace ( See Section 4.0 ).

In most instances, the faults are simple, namely loose or broken connections, unserviceable lamps or open circuit
control gear. Control gear will not normally go open circuit unless it has first over-heated; the signs of this are
obvious, being severe discoloration of the paint on the gear and cracks in any exposed insulation. Similarly, a bad
contact at the lamp cap will usually result in discoloration as a sign of overheating. 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 will
be unusual to have no other parts available to perform a substitution fault finding routine and this is the normal
procedure. 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.
3.9.1 Thermal Protector

Thermal protectors may be included. If the lamp goes on and off over a timescale of several minutes, this could 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 ( See Section 3.4 ).
4.0 Overhaul
The unit is largely made of materials that are very corrosion resistant. This allows the unit to be completely
stripped, cleaned, 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 and lamp details. The seal is between the glass and the base. The glass is retained in the
cover frame by stainless steel clips. If the sealing gasket has deteriorated by softening or permanent set, a new
sealing gasket should be fitted, which can be obtained from Chalmit. To fit this, care is needed, the old gasket
should be removed and remaining adhesive scraped off. The gasket is fixed in place to the body with a small
amount of silicone RTV.
5.0 Fuse Ratings

to PFC capacitors which can be up to 25 x the rated capacitor current and last 1-2 millisecs; lamp starting current
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.

Luminaire
Note: Starting and running currents for 240V, 50Hz are as indicated in Table 1.

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
complied with.
6.1 Lamps
Incandescent lamps, fluorescent lamps and discharge lamps in modest quantities are not "special waste". The
outer envelope should be broken in a container to avoid possible injury from fragmentation. This applies to the UK,
there may be other regulations on disposal operating in other countries.
0.0 Tables 0/1/2/3

Luminaire
Table 0 Range
Wattage Lamp Lamp Cap
50W SON E27

70W SON, MBI E27
100W SON/E, MBI E27 / E40
80W MBFU E27
160W MBTF E27
100W GLS E27
150W GLS E27
200W GLS E27
13W CFL-DE G24q-1
2 x 13W CFL-DE G24q-1
18W CFL-DE G24q-2
26W CFL-DE G24q-3
Lamp Start A Run A PFC µF
50W HPS 0.35 0.28 10

70W HPS 0.55 0.40 10
70W MBI 0.55 0.40 10
80W MBF 0.50 0.43 8
Lamp Number of Lamps
1 2 3 4 5 6
50W HPS 4A 4A 4A 6A 6A 10A

70W HPS 4A 4A 4A 6A 6A 10A
70W MBI 4A 4A 4A 6A 6A 10A
80W MBF 4A 4A 4A 6A 6A 10A
Table 3 Weights Refer to Section : 3.5.1
Lamp Type Weight
HPS/MBI 7.5kg
CFL-DE 7.0kg
GLS/ MBTF 5.2kg
MBFU 6.3kg

Luminaire

Luminaire

Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704
Email : Info@chalmit.com


guidance only.

34
ECLIPSE JUNIOR
WELLGLASS
The Eclipse Junior is a lightweight wellglass range suitable for
discharge lamps up to 100W and GLS lamps up to 150W which offer
a compact lighting solution where all round lighting is needed in
positions having limited space and access. They have a lightweight
corrosion resistant die cast aluminium alloy hinged body and lid
with a lamp glass which is unscrewed for quick access when
relamping. Direct ceiling-mounted is standard but stanchion-
mounted and wall-mounted versions are available on request

APPLICATIONS: Engine rooms.
Enclosure: Die cast aluminium alloy body with glass lens.
Silicone rubber gasket. Stainless steel fasteners.
Entries: 2 x M20 Cable Entries
Termination: 3 core 6mm2 max conductors with looping.
Mounting: Ceiling mounted as standard
Control Gear: Internal copper/iron ballast with ignitor and PFC capacitor (H.I.D lamp models)
Relamping: Via screwed lamp glass.
Electrical Supply: 220/230/240/254V 50Hz (70W & 80W models)
220/230/240V 50Hz (50W & 125W models)
250V Max ac/dc (GLS lamp model)

ECJI/050/HS 50 HPS E27 5.5 Kgs
ECJI/070/MS 70 HPS/Metal halide E27 6 Kgs
ECJI/080/MV 80 MBFU E27 6 Kgs
ECJI/125/MV 125 MBFU E27 6.5 Kgs
ECJI/150/GLS 150 GLS E27 5 Kgs

/--- Specific voltage (220,230,254,260)
/60 60Hz
/W Wall-mounted version
/ST Stanchion mounted version
35
Cast guard (except 125W model) CECJ7-0003
IOM - Eclipse Junior Safe Area Wellglass
Issue 00

Eclipse Junior Safe Area Wellglass
as a guide only.
245
ENTRY POSITION ENTRY POSITION
310
Ø7 FIXING HOLES
280
300
IOMECLJS Issue 00 January 00

1
0.0 Specification
Standard BS EN 60598
respectively].
1.0 Introduction - Eclipse Junior Safe Area Wellglass
A lightweight wellglass luminaire suitable for use in hostile, industrial environments, available with various mounting
arrangements to ease access and maintenance of the control gear enclosure and assist when installing or
maintaining in high or difficult areas. The enclosure is painted aluminium with a fluted glass globe lens or optional
prismatic glass refractor. All screws and bracketry are manufactured from stainless steel or corrosion resistant
aluminium.
Note: The range of lamp options available are as indicated in TABLE 0.
1.1 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.
2.0 Storage
condensation.
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.
Certification details on the rating plate must be verified against the application requirements before installation. The
information in this leaflet is correct at the time of publication. The company reserves the right to make specification
changes as required.
3.2 Tools
A flat blade screwdriver to open the end cover.
Strap wrench to tighten/loosen the diffuser.
3mm and 5mm flat blade screwdriver. Pliers, knife, wire and strippers/cutters.
A spanner suitable for fitting cable glands.

The supply voltage and frequency should be specified when ordering, a maximum voltage variation of +6%/-6% on
supply voltage of the control gear or tapping. The user must determine the actual underlying site supply voltage
and purchase or adjust accordingly. Care must be taken if connecting to the nominal 230V UK public supply.
In some cases, the luminaires have multi-tapped control gear that can be set to a range of 50 and 60Hz voltages.

2
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. 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.
Where shore or construction site supplies are used, which are different to the service location supplies, tappings
should be re-set. If not, advice on the effect of these temporary supplies should be sought from the Technical
Department.
3.4 Lamps
The discharge lamps used are of a standardised type. There is no preference between make or colour. The
Eclipse Junior uses tubular HPS and HPS compatible MBI lamps, elliptical MBF lamps, GLS and compact
fluorescent lamps. Note that the use of diffuse elliptical lamps will alter the photometric performance of the
luminaries. Care must be taken to fit the correct new and replacement lamps in order to preserve 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 ( See Section 3.9.1 ).
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.
3.5 Mounting
design information provided for the installation. The wall mounting or ceiling mounting arrangements should be
secured with lock washers or self-locking nuts and bolts. The pole mounting version must be mounted so as to
maintain the IP rating.
3.5.1 Weights and Windages
Note : Weights and Windages for the various types are outlined in TABLE 3.
3.6.1 Cables
The standard conductor section is 6mm² max. The pendant and pole mounts are not suitable for looping. Standard
300/500V cable is suitable.
3.6.2 Cable Glands

Where brass cable glands are used in a corrosive environment, cadmium or nickel plating should be used. Sealing
plugs for unused entries should be similarly rated and fitted. Entries suitable for M20 cable glands are standard.
Entries suitable for M25, 3/4” or 1” NPT are available to special order.

Before fitting lamps or opening the luminaire, the luminaire must be de-energised and isolated from the supply.
Access for cabling is by removing the mounting adapter. The end cover is released by undoing the screw using a
flat blade screwdriver. 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 connections check. The cover is replaced and the screws tightened down.

3
The lamp is replaced by removing the diffuser. Lamps must be of the correct type and firmly screwed into place.

Visual inspection should be carried out at suitable 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.
1 Ensure the lamp is lit when energised and that the lampglass 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 re-
gasketting.
3 Check the cable gland for tightness and nip up if necessary.

In most instances, the faults are simple, namely loose or broken connections, unserviceable lamps or open circuit
control gear. Control gear will not normally go open circuit unless it has first over-heated; the signs of this are
obvious, being severe discoloration of the paint on the gear and cracks in any exposed insulation. Similarly, a bad
contact at the lamp cap will usually result in discoloration as a sign of overheating.
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 will be unusual to have no other parts available to perform a substitution fault finding
routine and this is the normal procedure. 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.
3.9.1 Thermal Protector

Thermal protectors may be included in the ballast. If the lamp goes on and off over a timescale of several minutes,
this could 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 ( See Section 3.4 ).
4.0 Overhaul
The unit is largely made of materials that are very corrosion resistant. This allows the unit to be completely
stripped, cleaned, 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 seal at the end cover is held within a groove by silicone R.T.V. If
the gaskets have deteriorated by softening or permanent set, new gaskets should be fitted, which can be obtained
from Chalmit. To fit the mounting adapter gasket, the old gasket should be removed and remaining adhesive
scraped off. The gasket is fixed in place with silicone R.T.V. to the body. The end cover is then tightened down.
5.0 Fuse Ratings

to PFC capacitors can be up to 25 x the rated capacitor current and lasts 1-2 millisecs; lamp starting current
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.

4
Note : Starting and running currents for 240V, 50Hz are outlined in TABLE 1.
and synthetic resins. All electrical components and the body parts may give off noxious fumes if incinerated. Take
complied with.
6.1 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. This applies to the UK, there may be other regulations on disposal
operating in other countries.

5
Table 0 Range Refer to Section : 1.0
Wattage Lamp Lamp

Cap
50W SON/T E27
70W SON/T, MBI/T E27
80W MBF E27
100W SON/T, MBI/T E27
125W MBF E27
100W GLS E27
150W GLS E27
13W CFL-DE G24q
18W CFL-DE G24q
26W CFL-DE G24q
Lamp Start A Run A PFC µF
50W HPS 0.35 0.28 10

70W HPS 0.55 0.4 10
70W MBI 0.55 0.4 10
80W MBF 0.5 0.43 8
100W HPS 1 0.56 10
100W MBI 1 0.56 10
125W MBF 1 0.66 10
Note : Minimum power factor correction: 0.85
1 2 3 4 5 6
50W 4A 4A 4A 6A 6A 10A
70W 4A 4A 4A 6A 6A 10A
80W 4A 4A 4A 4A 6A 10A
100W 4A 4A 6A 10A 10A 10A
125W 4A 6A 6A 10A 10A 10A
Table 3 Weights and Windages Refer to Section : 3.5.1
Type
SON/T, MBI/T MBF GLS CFL-DE
Weight 6.4kg 5.7kg 4.8kg 5.5kg

6
Windage 0.15m2 0.15m2 0.15m2 0.15m2

7

Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704


guidance only.

8

9
22
DEXLUX
STAINLESS STEEL FLOODLIGHTS DECK & EXTERIOR
The Dexlux floodlight range is constructed from 316S31 marine
grade stainless steel and is designed for hostile marine
environments. They are available with a wide range of both
tungsten halogen lamps.
In addition to being compact and lightweight, there are a

number of additional options such as anti-vibration damper
assembly, anti-glare shield and wire guard making the Dexlux an
extremely popular marine floodlight range
APPLICATIONS: Ships decks, ports and harbours
Enclosure: 316S31 marine grade stainless steel body with toughened glass window,
silicone rubber gasket and GRP terminal box.
Entries: 1 x 20mm clearance hole in junction box.
Mounting: Stirrup bracket
Control Gear: N/A for tungsten halogen models.
Relamping: Via front cover and quick release clips.

Electrical Supply: 250V Max ac/dc

DEXI/200/TH 200 Tungsten-Halogen R7s 5 Kgs
DEXI/500/TH 500 Tungsten-Halogen R7s 6.5 Kgs
DEXI/1000/TH 1000 Tungsten-Halogen R7s 9 Kgs
OPTIONS - Suffix to Catalogue No

/M25 25mm cable entry
23
Anti-vibration damper S8000-0001
Pole-mounting bracket assembly (inc. fixings) S8134-0002
Anti-glare shield (ordered with luminaire) S8134-0001
IOM - DEXLUX Tungsten Halogen Floodlight
Issue 00

DEXLUX Tungsten Halogen Floodlight
as a guide only.
IOMDEXLUX Issue 00 May 00

1
0.0 Specification
Area Classification Non-Hazardous (Industrial)

Standard BS4533 Section 102.1 : 1990, Section 102.5 : 1990
Construction Marine Grade Stainless Steel Body with toughened safety glass
Lamp Type Linear Tungsten Halogen
Ingress Protection IP67 to BS EN 60529 : 1992
respectively].
1.0 Introduction - DEXLUX Tungsten Halogen Floodlight

The Dexlux series is a compact, stainless steel marine floodlight range suitable for a variety of linear tungsten
halogen lamps.
2.0 Storage
3.1 General
Installation should be carried out in accordance with statutory regulations in force in that area. In the UK the
requirements of the “Health & Safety at Work Act and the Electricity at Work Act” should be met. The floodlights
are Class 1 and should be effectively earthed. Lamps should be disposed of carefully.
3.2 Tools
Suitable spanners for installing cable glands, 3mm and 5mm flat blade screwdriver.

The floodlights may be used with a variety of voltages or supply frequencies but care must be taken to ensure the
correct lamp is chosen to suit the supply. The lamp should not be operated over 106% rated voltage except under
abnormal conditions. Using a lamp not suited to the supply voltage will have a serious effect on the lamp life and
may lead to overheating of components within the floodlight. Tungsten halogen lamps are voltage sensitive and the
nominal lamp life will be significantly reduced when the voltage goes above the nominal value. Similarly, light
output will reduce below the nominal voltage.
Tungsten halogen lamps can fail to short circuit, so cables must be adequately fuse protected. Inrush current can
be ten times the nominal, so surge resistant fuses are needed.
3.4 Mounting
Luminaries should be installed where access for maintenance is practical and in accordance with any lighting
design information provided for the installation. This will usually consist of mounting points and aiming angles. The
luminaire should be mounted using the bracket(s) supplied and secured using shakeproof washers or self-locking
nuts and bolts. If mounting the lamp in anything other than the horizontal axis, then the lamp manufacturer should
be consulted to ensure that this is permissible.

all the standard range luminaires with terminal boxes. The maximum looping size is 2.5mm² with 6mm² single
entry as standard. One single 20mm gland entry is supplied as standard and the facility exists to drill other entry
points in the terminal box. Care must be taken to ensure any additional holes line up with the earth continuity strip
within the terminal box. It is the responsibility of the installer to ensure that the correct cable size and fuse rating
are used.
Cable glands where installed should maintain the IP67 rating of the enclosure and if using metal cable glands,
should be of suitable material or suitably protected to meet any prevailing environmental conditions. Plastic glands
may be used except in cases where the earth is provided by means of the cable armour, in which a suitable metal
IOMDEXLUX Issue 00 May 00 2

gland should be employed. In this case, care should be taken to ensure correct contact is made between the
gland and earth continuity strip inside the terminal box.
It is the responsibility of the user to ensure that an adequate seal is made between the gland and the terminal box.

Access for fitting lamps is by removing the front cover. The DEXI/200 model also allows access to the lamp
holders, which have three different mounting positions to facilitate different lamp lengths. The reflector will also have
to be removed to allow this modification and this is achieved by removing the central screw.
The cover is removed by undoing the two toggle clips using a screwdriver or a rod through the hole in clip to lever it
off. Care should be taken to ensure that fingers do not touch the glass tube of the lamp as this could reduce the
lamp life. On completion, the cover is replaced and the toggle clamps snapped into position.
Access for cabling is via the terminal box cover, which is removed by undoing the four cover screws. Install the
conductors in the appropriate terminals. Take care not to cut back the insulation on the conductors excessively,
1mm bare conductor showing outside the terminal is a maximum. Any unused terminal should be fully tightened.
Finally replace the cover, checking the gasket before tightening the screws.

Routine inspection should be carried out at a minimum of 12 monthly intervals and more frequently if conditions are

With Tungsten Halogen lamps the faults are normally of a relatively simple nature, namely loose or broken
connections or unserviceable lamps.
Any fault finding must be carried out by a competent electrician and should spares be required, these can be
obtained direct from Chalmit.
4.0 Overhaul
The unit is largely made up of materials which are very corrosion resistant. This allows the unit to be completely
stripped, mechanically cleaned, then rebuilt with new electrical parts as required. The internal wiring is 1.0mm
flexible, silicone rubber insulated. A high temperature sleeve is fitted to both lamp holder cables. All the spares
required are available. Please state the model number, lamp and reflector details. The seal at the cover is between
the glass and the body. The glass is retained in the cover frame by silicone R.T.V. adhesive. If the cover gasket
has deteriorated by softening or permanent set, a new cover assembly should be fitted.
As an alternative, replacement gasket strip can be obtained from Chalmit but to fit this, care is needed. The old
gasket should be removed and remaining adhesive scraped off with a chisel type blade.
New strips are cut full length on the short sides and neatly butted on the long sides. The gasket pieces are fixed in
place and the butt joint sealed with silicone R.T.V. The cover assembly is left unclipped on top of a body with a
sheet of thin polythene between it and the body to avoid adhesion. After a few hours the cover is removed and
allowed to cure in free air for 24 hours. The assembly should be tested for air tightness on a test body before being
fitted to an overhaul unit.
5.0 Fuse Ratings

Information regarding fuse/mcb ratings should be obtained from the lamp manufacturer of the protective device
employed. If using mcb’s, care must be taken to ensure that the correct type is used to take into account the
inrush current of the lamp. It is the responsibility of the installer to ensure that the installation is suitably protected.
6.0 Disposal of Materials

The unit is chiefly made from inert incombustible materials.
All the electrical components may give off noxious fumes if incinerated. Lamps must not be incinerated. Care
must be taken to render these fumes harmless or avoid inhalation. Any local regulations concerning disposal must
be complied with.
6.1 Lamps
Incandescent lamps and discharge lamps in modest quantities are not "special waste". The outer envelope should
be broken in the container to avoid injury.


Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704


guidance only.

16
503
FLOODLIGHT DECK & EXTERIOR
The 503 is a high power floodlight designed for the most arduous marine
environments. It is suitable for 600W and 1000W HPS lamps and
tungsten halogen lamps up to 2000W. For HPS lamp models,
the control gear is housed in a separate control gear box. When
required,the ignitor can be mounted in a box on the floodlight allowing
control gear to be situated further from the floodlight and eliminating
the need for expensive high voltage cable between the floodlight and
control gear box.
The 503 has a robust, corrosion resistant, low pressure die cast LM6
aluminium alloy enclosure (a PTFE protective coating can be applied if
required) with a toughened glass window and silicone sealing.
The use of the 503 will give extremely high levels of illumination from
a small number of floodlights, greatly reducing installation and
maintenance costs.
Zone 2 ExN versions are available
APPLICATIONS: Ships decks and holds, ports and harbours

Enclosure: Marine grade aluminium LM6 alloy body with toughened
glass window, silicone rubber gasket
Entries: 1 x M20 cable entry
Mounting: Foot mounted
Control Gear: Refer to 502 control gear box for models with HPS lamps.
Relamping: Via end cover secured by stainless steel screws
Electrical Supply: 250V Max ac/dc for tungsten halogen lamps
For models with HPS lamps see 502 control gear box V/Hz range.

503I/600/HS 600 HPS E40 25 Kgs
503I/1000/HS 1000 HPS E40 25 Kgs
503I/2000/TH 2000 Single ended T/Halogen E40 25 Kgs
503I/2x4/MS 2x400 HPS/Metal halide E40 27 Kgs

/IG Integral leg mounted ignitor
/P PTFE Coating
17
Pole-mounting bracket S2000-0007
Swinging jib bracket S2000-0019
Anti-glare shield S5030-0007
Wire Guard S5030-0008
IOM - 503 Industrial
High Wattage Floodlight
Issue 00

503 High Wattage Floodlight
as a guide only.
251 616
652
297
73 CRS 435 CRS

IGNITOR BOX
ø16
OPTIONAL
M20 CABLE ENTRY
WEIGHT ALUMINIUM LM6 GUNMETAL LG2

25kg 73kg
2
WINDAGE AREA: 0.22m
IOM503INDIND Issue 00 December 00

1
IOM - 503 Industrial High Wattage Floodlight
0.0 Specification
Area Classification Non Hazardous

Standard BS4533 Section 102.1
Ingress Protection IP66 and IP67 to BS EN 60529
1994" and "The Electromagnetic Compatibility Regulations 1992".
[This legislation is the equivalent in UK law of EC directives 73/23EEC, 89/336/EEC and
94/9/EC respectively].
1.0 Introduction - 503 High Wattage Floodlight

The 503 series of Industrial floodlights are designed for area lighting applications. The maximum ambient
temperature is as shown. The unit is used in conjunction with a 500 series control gear box or 700 series control
gear box.
Note : Lamp ranges and ambient temperature ratings are as indicated in TABLE 0.
2.0 Storage
condensation.
3.0.1 General
during the following operations. Installation should be carried out in accordance with good electrical procedure and
local code of practices.
Handling and electrical work associated with this product to be in accordance with the ‘Manual Handling Operations
3.1 Special conditions for Installation.
3.1.1 Special conditions for safe use

1 The method of cable entry shall be such as to retain the ingress protection properties of the luminaire. In
particular, if conduit entry is used, a stopper gland shall be inserted in the conduit.
2 Mercury vapour lamps shall be used only in conjunction with ballasts complying with BS 4782 or other
appropriate specification.
3 High pressure sodium lamps shall be used only in conjunction with ballasts which limit the power input to a
lamp to its rated value, when operating at the rated supply voltage. The ignitor circuit shall not produce a
pulse voltage in excess of 4.5kV peak.
IOM503IND IND Issue 00 December 00

2
Note: Unless authoritative information to the contrary is available from the manufacturer of a
particular lamp, it must be assumed that the use of a lamp with an internal ignitor will infringe
this requirement.
4 For luminaires fitted with high pressure mercury vapour lamps or tungsten halogen lamps, the cable from
the luminaire to the adjacent leg mounted junction box or the control gear box shall be suitable for 150ºC
(Silicone Rubber or better).
5 For luminaires fitted with high pressure sodium lamps, the cable from the luminaire to the adjacent leg
mounted junction box or the control gear box shall be suitable for 120ºC and shall comply with one of the
following :
a) Glass braided cores (300/500V grade to Table 10 of BS 6500), formed in a 3-core cable with an outer
sheath selected from Table 8 in BS 6500.
b) 450/750V grade cable to Table 8 in BS 6500 but with the thickness of the outer sheath increased to
approximately 1½ times the value given in the table.
6 With the exception of Item 5a), the cores of the incoming cable shall be sleeved with the glass braided
sleeving provided by the manufacturer.
Note : The cable standards quoted are now obsolete or superseded by later editions. We can interpret
the cable requirements as 150ºC or 120ºC, as appropriate. For HPS luminaires, the cable carrying
the ignition pulse should be 600/1000V rating. The Chalmit Type 4891 cable meets all
requirements.
3.2 Tools
3mm and 5mm flat blade screwdriver.
14mm and 15mm A/F spanners.

The discharge lamp luminaires are supplied from separate 500/700 series control gear boxes. The installation and
operating instructions for these boxes are dealt with in a separate leaflet.
The supply voltage and frequency should be specified for the control gear box when ordering. The Tungsten
Halogen luminaires are suitable for lamps in the range 220/240V ac and dc. The correct lamp for the supply must
be used. Incandescent lamps must be selected for the supply voltage. Running at over the rated supply voltage
will reduce life and at greater than +10% will compromise the fitting. A maximum voltage variation of +/-6% on the
nominal is expected. (The safety limit for operation 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. Care is needed in connecting to the nominal
230V UK public supply.
In some cases, the control gear boxes have multi-tap control gear which can be set to a range of 50 and 60Hz
cycle voltages. The tappings are shown on the control gear and the limits are shown on the rating plate. If, the
equipment is located in a high or low voltage section 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 tappings can
be reset if the equipment is re-located. If in doubt, tappings should be set on the high side.
For Tungsten Halogen sources, the voltage drop calculation will be made to cover the voltage drop from the main
supply point. For the MBF lamp the distance from the control gear box to the luminaire does not have a practical
limit. The total voltage drop of supply and connection cable should not exceed the values given.
In the case of the HPS lamp the normal maximum distance from the control gear box to the luminaire is 3 metres.
If a greater distance is necessary for operational reasons, the model with the ignitor box attached to the foot
mounting bracket of the luminaire should be ordered. In this case, a control gear box without an ignitor is ordered

3
to supply the luminaire. A calculation can then be made to cover the voltage drop between the control gear box
and the luminaire. 20V maximum nominal drop is acceptable for Tungsten-Halogen and MBF lamps, 10V
maximum drop is desirable for HPS. The lamp power will be reduced. In all cases, the calculation is made on the
lamp current, not the corrected circuit current.
The HPS circuit uses a SIP (superimposed pulse) ignitor. This means there are only two connections to the choke
and the tap selection is obvious.
When the construction site supply is different to that of the service location, the tappings should be re-set. If not,
advice on the effect of these temporary supplies should be sought from the Technical Department.
3.4 Lamps
The lamps are of a standardised type and there is no preference between make and colour. When fitting lamps, a
check should be made that the lamp steady assembly does not become solid before the access cover has been
fully bolted down. There may be some variation in length on the 1000W SON/T lamps available. In the later
models, the length variation is catered for by a lamp steady using a spacer. This spacer can be put either on the
stem or inside the steady cup to allow for a 2mm shift in the steady spring compression range. The assembly is
available for retrofit for older models.
Care must be taken to fit the correct lamp in order that it will operate properly, maintain the certification conditions
and obtain the design photometric performance.
HPS 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 and then re-ignites after a minute or so interval. If discharge luminaires are
burnt continuously, they should be switched off occasionally. This allows old lamps to fail to re-ignite, reducing the
possibility of them becoming diodes with detrimental effects to the control gear.
HPS lamps and Mercury lamps will have a half life (50% mortality) of up to 24,000 hours but in the case of MBF
lamps, the lumen output will by then have decreased to 50% or less. The lumen output of HPS lamps remains
substantially constant during the life of the luminaire.
The above information is current at the time of preparation. The development of lamps and control gear is ongoing
and detailed advice on the lamp performance can be obtained from the lamp supplier.
Note : HPS circuits should not be energised without the lamp fitted.
HPS lamps with internal ignitors must not be used.
3.5 Mounting
design information provided for the installation. This will usually consist of aiming points and aiming angles. The
foot mounting brackets should be secured with lock washers or self-locking nuts and bolts.
3.6.1 Cables
The temperature conditions at the supply cable point are such that high temperature cable must be used in all the
luminaires. This is referred to in the special conditions for safe use. In the case of HPS luminaires, the cable
between the luminaire and the ignitor must be able to withstand the starting impulse (wherever located). Chalmit
Type 4891 cable meets the requirements of the application. The cable make-up must be suitable to ensure the
maintaining of the restricted breathing enclosure when the cable gland assembly is fitted.
3.6.2 Cable Glands

Cable glands and sealing plugs when installed must maintain the ingress protection of the enclosure. Rubber
sealing washers and steel compression washers are provided with the unit. The user must ensure that the
assembly fulfils the above requirement.
Cable entries suitable for M20 cable glands are standard.

4

Access for cabling is via the top hat shaped cover which carries the lampholder. The cable assembly is screwed
into the cover after it has been removed from the luminaire. The lampholder assembly is slackened to allow
access. The ignitor output goes to the lampholder centre contact, marked L at the terminal D at the ignitor

Visual inspection should be carried out at suitable intervals, 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.
What follows are guidelines based on Chalmit’s own experience:-
1 Ensure that the lamp is lit when energised and that the lampglass is not damaged.
2 When de-energised and left to cool, there should be no significant sign of internal moisture. I f there are
signs of water ingress, the luminaire should be opened up, dried out, and any likely ingress points
eliminated by re-gasketting. With the type of construction used in the 503, anything other than slight
condensation should be very rare.
3 Check the cable gland for tightness and nip up if necessary.
4 Check any external earthing connections.
5 Check the access cover and lamp housing screws for tightness and nip up if necessary. Torque 16Nm.
If the covers are removed it is good practice to replace the gasket.
6 Check the silicone sealant used to secure the lampglass. If it has become seriously discoloured or very
soft, the luminaire will need to be returned to Chalmit for re-glazing. The material used for glazing has a
long life and in normal applications would not be expected to deteriorate. Direct contamination with
hydrocarbon oils could cause degradation.
7 Check that the lamp glass retaining clamps are in place and secure. (The purpose of these clamps is to
reduce the load on the lamp glass caused by internal pressure build up from the high temperature of the
light sources).
8 Clean the lamp glass.
9 When re-lamping, the incoming and lampholder terminals should be checked for signs of overheating and
the terminals tightened up.

With Mercury and Tungsten Halogen lamps the faults are simple, namely loose or broken connections,
unserviceable lamps or open circuit control gear. Control gear will not normally go open circuit unless it has first
overheated; signs of this are obvious, being severe discoloration of the paint on the gear and cracks in any exposed
insulation. Similarly, a bad contact at the lamp cap will usually result in discoloration as a sign of overheating.
permit to work. With HPS 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" flicker effect on the lamp and a
buzzing sound from the ignitor. It will be unusual to have no other parts available to perform a substitution fault
finding routine and this is the normal procedure. Before re-assembling, all connections should be re-checked and
any damaged cable replaced. The supply must be isolated.
4.0 Overhaul
The unit is largely made of materials, which are very corrosion resistant. Overhaul consists of cleaning and
replacement of gaskets where necessary. All the spares required are available from Chalmit. Please state the
model number and lamp type. No unauthorised modifications should be made.
5.0 Fuse Ratings

5
The following remarks concern HID lamp circuits at the input side of the control gear box. The output side of the
control gear box carries the lamp current, not the circuit current. The lamp current is shown in Table 1. This value
should be used for any calculations of voltage drop between the control box and luminaire. Where the ignitor for
HPS is contained in the control gear box, the cable also carries the starting pulse. The choke acts as a current
limiter, therefore there is no means of protecting against a line to neutral fault on the electrical circuit beyond the
choke. Extra care must therefore be taken to ensure sound cable installations. The fuse ratings for HID lamp
circuits need to take into account 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 normal capacitor
current will probably be the determining factor, 0.076A per µF at 240V, 50Hz (adjust for other volts by
multiplication,x6/5 for 60Hz). For HBC fuses use 1.5 x normal capacitor current. For T/Hal inrush, use 8 x rated
current. All calculations must satisfy wiring regulations.
Note : Starting and running currents for 240V, 50Hz. are as indicated in TABLE 1.

and synthetic resins. All electrical components and the body parts may give off noxious fumes if incinerated. Take
complied with.
6.1 Lamps
Note : Do not incinerate lamps.

6
0.0 Tables 0/1
Table 0 Lamp Ranges and Ambient Temperature Ratings Refer to Section : 1.0
Lamp Ambient Rating
600W SON/T T amb 60ºC

1000W SON/T T amb 40ºC
1000W MBI T amb 40ºC
2000W MBI T amb 40ºC
700W MBF T amb 40ºC
2000W T/HAL T amb 40ºC
Lamp Lamp A Start A Run A Capacitance

µF
600W SON/T 6.2 5.6 3.1 60
1000W SON/T 10.6 6.9 5.0 100
1000W MBI 10.6 6.9 5.0 100

2000W MBI 16.5 15.8 9.9 100
2000W MBI 10.3 8.9 5.6 30
Cross Phase
700W MBF 5.4 5.6 3.5 30
2kW T/HAL 8.33 approx. x6 8.33 N/A

7

Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704


guidance only.

8

9
18
501 & 502

CONTROL GEAR BOXES DECK & EXTERIOR
The 501 & 502 Control Gear Boxes house the lamp control gear.
If required, transformers can be fitted for 110V & 120V supplies.
The control gear box allows easy access to the control gear
allowing the floodlight to be situated in difficult to reach locations.
Both of these control gear boxes are constructed from 316S31
marine grade stainless steel and are suitable for both indoor and
outdoor applications where rugged, corrosion resistant construction
and reliability are essential.
Cable entry is through 20mm clearance holes as standard or
alternatively through tapped cable entry pads. The 501 & 502 are
most commonly used for floodlights such as the 503 & 800 Series.
Zone 2 ExN versions are available.

Enclosure: 316S31 marine grade stainless steel construction
Entries: 3 x 20mm clearance holes
Mounting: Base mounting straps
Control Gear: Internal copper/iron multi-tapped ballast and PFC capacitors
(Ignitor not fitted on standard models)
Electrical Supply: 220,230,240,254V 50Hz

Catalogue No. Lamp Wattage (W) Lamp Type Weight
501I/150/MS 150 HPS/Metal halide 14 Kgs
501I/600/MS 600 HPS 19 Kgs
502I/2x4/MS 2x400 HPS/Metal halide 28 Kgs
502I/1000/HS 1000 HPS 32 Kgs
The following models are for 120V,50Hz. For 60Hz further suffix Catalogue No. by /60.
Catalogue No. Lamp Wattage (W) Lamp Type Weight

502I/150/MS/120 150 HPS/Metal halide 21.5 Kgs
502I/600/HS/120 600 HPS 36.5 Kgs

/60 60Hz supply.
/M25 3x25mm entries
/IG Integral ignitor
/LO Looping
/NC No capacitors
/TE Tapped cable entry plate
19
ACCESSORIES (Ordered separately CATALOGUE ORDER CODE
IOM – 500 Industrial Series Control Gear Box
Issue 00

500 Industrial Series Control Gearbox
as a guide only.
A
B
3-OFF M20
CABLE ENTRIES
C
E
ø16
G
BOX TYPE A B C D E F G
500 460 381 159 203 229 152 171
501 502 381 235 279 305 152 171
502 569 476 283 343 381 174 190
IOM500IND Issue 00 December 00

1
IOM - 500 Industrial Series Control Gear Box
0.0 Specification
Area Classification Non Hazardous

Standard BS4662 : 1970
Ingress Protection IP66 and IP67 to BS EN 60529 (IEC 529)
1994" and "The Electromagnetic Compatibility Regulations 1992".
[This legislation is the equivalent in UK law of EC directives 73/23EEC, 89/336/EEC and
94/9/EC respectively].
1.0 Introduction – 500 Industrial Series Control Gearbox

The 500 Industrial Series of control gear boxes is usually used to power the 400 and 503 series Industrial
luminaires. The boxes are fabricated from stainless steel and contain control gear or transformers as appropriate.
They are also available without an ignitor in order to be able to power the luminaires with close coupled ignitor units.
Note : Lamp ranges and temperature ratings are as indicated in TABLE 0.
2.0 Storage
condensation.
3.1 General
during the following operations. Installation should be carried out in accordance with good electrical procedures
and local code of practices.
3.1.1 Special Conditions Of Use

These special conditions should be read in conjunction with those for the associated luminaire :
1 For use with high pressure sodium lamps, the inter-connecting cable between the control gear box and the
luminaire shall be suitable for the duty with the high voltage lamp striking pulse of up to 4.5kV. Subject to
other limitations that may be imposed by a particular luminaire, the following cables may be regarded as
suitable :
(a) Glass braided cores (300/500V grade to table 10 of BS6500), formed in a 3-core cable with an outer
sheath selected from table 8 in BS6500.
(b) 450/750V grade cable to table 8 in BS6500, but with the thickness of the outer sheathing increased to
approximately 1½ times the value given in the table.
2 The control gear box should not be used with luminaires which incorporate high pressure sodium lamps
with internal ignitors.

2
Note : The standards quoted above are now obsolete or replaced by later editions. Reference should
be made to the cable requirements of the associated luminaires. The requirements apply to the
outgoing cable; the feed cable is not specified and can be ordinary PVC or better. Type 4891
cable meets the requirement to supply the luminaire.
3.2 Tools
3mm and 5mm flat blade screwdriver, 13mm and 10mm A/F sockets.

supply voltage of the control gear or tapping. Care must be taken connecting to the nominal 230V UK public
supply. The user must determine the actual underlying site supply and purchase or adjust accordingly. In most
cases, control gear boxes have multi-tap control gear which can be set to a range of 50 and 60Hz voltages. 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, but care should be taken
to log or mark the equipment so that the tapping can be reset if the equipment is relocated. If in doubt, tappings
should be set on the high side. 20V max. nominal drop is acceptable for mercury vapour and tungsten halogen
sources, 10V max. drop is desirable for HPS. The light output will be reduced. The total supply and
interconnecting cable drop should not exceed the values given.
All the HPS circuits use S.I.P. (superimposed pulse) ignitors. This means that there are only two connections to
the choke, making the tap selection obvious. Where shore or construction site supplies are used, which are
different to the service supplies, tappings should be reset. If not, advice on the effect of these temporary supplies
should be sought from the Technical Department.
Important : Circuits must not be energised without the lamp fitted. Lamps must be replaced shortly after
they fail to light.
Incandescent lamps must be selected for the supply voltage. Running at over the rated supply voltage will reduce
life and at greater than +10% will compromise the operation of the luminaire/control gear.
3.4 Luminaires
Care must be taken to ensure that the lamp used in the associated luminaire corresponds to the control gear used.
HPS control gear boxes should not be energised with an unlamped luminaire connected. HPS lamps with
internal ignitors must not be used. If the control gear box for 150W to 400W HPS luminaires is more than 16
metres from the luminaire, a luminaire with integral or close coupled ignitor is needed. Where "Plus" high output
lamps are used, a close coupled ignitor is needed. For 70W and 1000W HPS the maximum distance is 2 metres.
3.5 Mounting
The box should be firmly attached to the structure in a position where access can be gained to install cables and
carry out routine maintenance. Any mounting attitude can be used.
3.6.1 Cables
The output cable must meet the requirements of the associated luminaire. This means that the cable make up
must be suitable for maintaining the ingress protection of the enclosure of the luminaire when used in conjunction
with the appropriate cable gland.

3
3.6.2 Cable Glands

The cable glands when installed should maintain the IP rating of the enclosure with a minimum of IP54. The cable
gland should adequately secure the cable in the unit, unless provision is made to restrain the cable by other
means. It is the responsibility of the user to ensure an adequate seal between the gland body and the apparatus.
Versions of the box are available for single entry and twin entry to loop 4mm2 cable. Versions suitable for looping
6mm2 cable are available to special order. The looping requirements should be specified when ordering. Clearance
holes for M20 or M25 cable glands are standard. Versions with tapped internal pads are available to special order.
3.6.3 Installation
1 Undo the hexagon nuts securing the hinged lid. The rating plate is fixed to the lid. If the lid is removed to
facilitate cabling, take care not to mix it up with lids from other boxes which may have different ratings.
2 Re-select the voltage tappings if necessary.
3 Install the cable glands and cables. If the supplied rubber sealing washer is used, the large stainless steel
washer must also be used. The rubber washer can be inside or outside the box.
4 Install the conductors in the appropriate terminals. Take care not to cut back the insulation excessively,
1mm bare conductor outside the terminal throat is a maximum.
5 Any unused terminals should be fully tightened.
6 Check for correct connections and replace the lid.
7 Tighten the lid to the recommended tightening torque (2 lb.ft/2.7Nm). Do not overtighten and distort the lid.

Individual organisations will have their own procedures for inspection and maintenance. What follows are guidelines
based on Chalmit’s own experience.
Maintenance work and fault finding must be performed by competent personnel under an appropriate permit to work
and with the apparatus isolated.
Frequency of maintenance will depend on experience and operating conditions.
Before opening, the box must be electrically isolated.
1 Ensure the control gear box is operating the associated luminaire correctly. If the luminaire is not operated
correctly with a serviceable lamp, check the control gear box first for signs of bad connections or
overheating. If the box is in good condition and the choke has continuity, check the fault finding procedure
for the luminaire. Refer to the luminaire instructions.
2 Open the box. Check for any signs of water ingress. If there is, determine the entry point if possible.
Replace the cable gland sealing washers or box lid gasket as appropriate (see below). Clean up and dry
out the box before re-energising.
3 Check terminals for tightness and any sign of overheating. Replace the terminals where necessary. If the
choke has overheated, it will be badly discoloured. A d.c. resistance check compared with a spare unit will
give confirmation of any internal shorting.
4 The capacitors should be checked visually and if intact, and not corroded, should be satisfactory. The only
likely fault with shunt capacitors is that the capacitance gradually reduces in the self-healing type or that
the fuse blows. Capacitors can be disconnected and given a capacitance check. If capacitance has been
lost and is a critical factor in the circuit design, consideration will need to be given to further investigation
and the replacement of the capacitors. In those cases where the capacitors are used in conjunction with
step-up transformers, the power factor correction is critical as the transformers will draw excess current and
overheat if the secondary is uncorrected. If installations using transformers are seen to be "cycling", that
is, going on and off, this can be due to the thermal trip in the transformer operating. If the luminaires on
the circuit are apparently working normally, an investigation into the capacitance should be made.
5 Check the lid gasket and if there are signs that the gasket is not making a good joint, replace it (see below).
6 Check that the cable glands are tight and nip up if necessary.
7 Refit the lid and re-tighten the nuts to the recommended torque. A dab of grease on the thread is
recommended.

4
8 Check that the rating label is readable and secure. Refit using silicone sealant or other suitable adhesive
if necessary.
9 Re-energise and check for correct luminaire operation. Any spare parts needed must be obtained from the
manufacturer and unauthorised modifications must not be made. If a lid gasket needs to be replaced, obtain a
spare from Chalmit. Remove the old gasket and scrape off any adhesive. The gasket is self-adhesive, remove
the self-adhesive backing, put the gasket in place squarely and smooth down.

permit to work. With mercury and T-H lamps the faults are simple, loose or broken connections, unserviceable
lamps or open circuit control gear. Control gear will not normally go open circuit unless it has overheated first and
the signs of this are obvious, being severe discolouration of the paint on the gear and cracks in any exposed
insulation. Similarly, a bad contact at the lamp cap will result in signs of overheating. With HPS lamps the ignitor
can become faulty. If the lamp is fitted and the choke has continuity and the connections are good and correct,
they should produce an "attempt to start" flicker effect and a buzzing sound from the ignitor. It will be unusual to
have no other parts available to perform a substitution fault finding routine and this is the normal procedure. Some
boxes have fuses fitted and these should be checked. The supply must be isolated.
3.9 Fuse Ratings

seconds after starting, this effect is random and very variable.
current will probably be the determining factor 0.076A per µF at 50Hz (adjust for other volts my multiplication, x 6/5
for 60Hz). For HBC fuses use 1.5 x normal capacitor current. All calculations must satisfy wiring regulations.
Note : Starting and running currents for 240V, 50Hz are indicated in TABLE 1.

The unit mostly contains incombustible materials. The capacitor is of the dry film type and does not contain
and synthetic resins. All electrical components 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.
4.1 Lamps
be broken in the container to avoid injury. This applies to the UK, there may be other regulations on disposal
operating in other countries.

5

0.0 Tables 0/1/2
Table 0 Lamp Ranges and Temperature Ratings Refer to Section : 1.0
Model Lamps Transformer Ambient Rating
80W MBFU
500 125W MBFU 500VA Auto T amb 40ºC
250W MBFU
400W MBFU
501 70W HPS
150W HPS 1250VA
250W HPS
400W HPS
700W MBFU
502 1000W HPS
1000W MBI T amb 35°C
2000W MBI
Up to 400W HPS or
MBFU
500VA Auto T amb 40°C
Lamp Lamp A Start A Run A Capacitance µF Circuit Power (W)
70W HPS 1.0 0.55 0.4 10 80

150W HPS 1.8 1.45 0.8 20 175
250W HPS 3.0 2.35 1.3 30 285
400W HPS 4.6 4.0 2.2 40 445
1000W 10.6 6.9 5.0 100 1100
HPS/MBI
2000W MBI 16.5 15.8 9.9 100 2105
2000W MBI 10.3 8.9 5.6 30 2085
Cross Phase
80W MBF 0.8 0.7 0.4 8 88
125W MBF 1.2 1.7 0.66 10 145
250W MBF 2.13 2.8 1.4 15 280
400W MBF 3.25 4.4 2.2 20 430
700W MBF 5.4 5.6 3.5 30 740
Note : The lamp current is that between the control box and the luminaire.
Start and run currents are corrected.
Minimum power correction factor: 0.85.

6

1 2 3 4 5 6
150W HPS 4A 6A 10A 10A 16A 16A
250W HPS 10A 16A 16A 20A 20A 20A
400W HPS 16A 20A 20A 25A 25A 32A
1000W HPS/MBI 20A 25A - - - -
2000W MBI 25A - - - - -
2000W MBI 20A - - - - -
Cross Phase
700W MBF 16A 20A 25A 32A 32A 40A

7

Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704


guidance only.

8

9
20
469
FLOODLIGHT DECK & EXTERIOR
The 469 is a tungsten halogen floodlight for lamps up
to 1000W. It has a robust, corrosion resistant marine grade
aluminium LM6 alloy enclosure with a toughened glass front cover
and stainless steel fasteners, making it ideal for hostile marine
environments
APPLICATIONS: Ships decks, holds, ports and harbours
Enclosure: Marine grade aluminium LM6 alloy body with
toughened glass window, silicone rubber gasket
Entries: 1 x M20 cable entry
Mounting: Foot mounted
Control Gear: N/A
Relamping: Via front glass cover assembly secured by stainless steel screws

469I/1000/TH 300/500/1000 Single ended T/Hal E40 10 Kgs

/M25 M25 Cable Entry
/PM Pole mounted
/P PTFE Coated
21
Anti glare shield S4000-0002
Wire Guard E0850-0002
Swinging Jib Assembly S2000-0019
IOM - 400 Series Floodlight
Issue 00

400 Series Industrial Floodlight
as a guide only.
M20 TAPPED ENTRY
457 200 73 - 86
CHALMIT
273
95
57
ø 16 48 - 64
203
260 WEIGHT ALUMINIUM LM6 GUNMETAL LG2

10Kg 30Kg
2
WINDAGE AREA: 0.14m
IOM400IND Issue 00 Rev 0 June 02 1

0.0 Specification
Area Classification Industrial (Safe Area)

Standard BS EN 60598-1
Ingress Protection IP66 and IP67 to BS EN60529(IEC 529)
1994" and "The Electromagnetic Compatibility Regulations 1992", it does not apply to the
"Equipment and Protective Systems intended for use in Explosive Atmospheres
Regulations 1996". [This legislation is the equivalent in UK law of EC directives
73/23EEC, 89/336/EEC and 94/9/EC respectively].
1.0 Introduction - 400 Series Floodlight

The 400 series of floodlights comprises a range of luminaires for high pressure sodium, mercury vapour and
tungsten halogen lamps. The luminaires, other than the tungsten halogen and 70W high pressure sodium types,
are supplied from separate gear boxes in the 500 series.
Note : While the range is comprehensive there are also some special options available, adding to
those outlined in TABLE 0.
Versions of the 484 and 486 150W/400W are also available with the ignitor in a box on the rear of the luminaire.
This arrangement allows the use of a remote control gear box, without ignitor, mounted at long distances from the
luminaire. For other HPS luminaires in the range supplied by 500 Series boxes with ignitors, the maximum
distance allowed is 16 metres (but see note in section 5.4 Lamps). The 70W HPS luminaire has internal control
gear.
2.0 Storage
Luminaires and control are to be stored in cool dry conditions preventing ingress of moisture and condensation.
3.1 General
during the following operations. Installation should be carried out in accordance with the local area code of practice
and fitting of specified insulating material to be adhered to where a specific fire resistance rating is required.
The luminaires are quite heavy, especially in gunmetal version and suitable means of handling on installation must
be provided.
Certification details on the rating plate must be verified against the application requirements before installation.

3.2 Tools
3mm and 5mm flat blade screwdriver, 19mm A/F spanner.
5/16" and 1/4" BSW spanners.

The supply voltage and frequency should be specified when ordering. A maximum voltage variation of +/-6% on
the nominal voltage is expected. (The safety limit for T rating 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. Care must be taken connecting
to the nominal 230V UK public supply. In nearly all cases, the luminaires will be supplied from 500 series
control gear boxes. In most cases, these will have multi-tap control gear which can be set to a range of 50 and 60
Hz voltages. 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, the appropriate voltage tap should be selected
but care must be taken to log or mark the equipment so that the tapping can be reset if the equipment is
relocated. If in doubt the tapping should be set on the high side. 20V max. nominal drop is acceptable for MBF
and Tungsten-Halogen. 10V max. drop is desirable for HPS. The light output will be reduced. The total supply
and interconnecting cable drop should not exceed the values given.
All the HPS circuits use SIP (superimposed pulse) ignitors. This means that there are only two connections to
the choke, making the tap selection obvious.
Where shore or construction site supplies which are different from the service locations supplies are used, the
tapping should be reset. If not, advice on the effect of these temporary supplies should be sought from our
technical department.
The rating nameplates originally specified 250V max. for slave luminaires. Later models have this requirement
modified and limit the luminaire to use with 500 series control gear boxes. This eliminates the artificial nameplate
voltage rating for the slave luminaires. Calculations need to be made for remote operation at a considerable
distance from the control gear box. Voltage drop calculations should be based on the lamp current.
life and at greater than +10% will compromise the T rating.
3.4 Lamps
The high pressure sodium and mercury vapour lamps are of a standardised type. There is no preference between
make or colour. All have E40 caps except for the 70W which is E27. The 484 series use tubular lamps and the
486 series elliptical lamps. HPS "Plus" lamps with higher output are now available but these will not work with
luminaires made before 1990 or with a remote ignitor in the control box. Care must be taken to fit the correct lamp
in order to maintain the certification conditions and obtain the designed photometric performance.
HPS lamps should be replaced shortly after they do not light. The indication for end of life for HPS lamps is
"cycling", when a lamp goes out and 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 possible 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.
Important : HPS circuits should not be energised without a lamp fitted. HPS lamps with internal
ignitors must not be used.
life and at greater than +10% will compromise the T rating.
3.5 Mounting

Luminaires should be installed where access for maintenance is practical and in accordance with the lighting
design information provided for the installation. This will usually consist of aiming points and aiming angles. The
foot mounting arrangement should be secured with lockwashers or self-locking nuts and bolts. The luminaires
should be mounted with the lamp axis horizontal. Any aiming angle may be used. The post fixing brackets are
designed for use on posts or pipes of 17/8" (48 mm) to 2½" (63 mm) dia. The pole mounting bracket arrangement
should be secured with lock washers or self-locking nuts and bolts. The luminaires should be fitted to the post,
the clamping nuts lightly tightened and the luminaire positioned so that the light output is directed towards the area
to be illuminated. When the correct position is obtained, the nuts should be tightened securely to ensure that the
luminaire is fixed correctly to the post. The foot fixing or bulkhead mounting luminaire should be secured by 4
bolts or studs, either ½" BSW (M12) or 5/8" BSW (M16), by using the 4 off 5/8" (16 mm) dia. holes provided on
2¼" (57 mm) x l8¼" (464 mm) centres. By slackening off the nuts on the trunnion brackets, the luminaire can be
rotated in the vertical plane through 300°. When the correct mounting angle is determined, the nuts must be re-
tightened to clamp the luminaire in position.
3.6 Cabling And Cable Glands
3.6.1 Cables
Standard 300/500V cable is suitable. All the luminaires are suitable for single entry of 4mm2 maximum cable only.
The exception is the 70W, which is available with a looping facility.
3.6.2 Cable Glands

Cable glands and sealing plugs when installed must maintain the IP rating of the luminaire. Where appropriate,
rubber sealing washers and steel compression washers are provided with the unit. The user must ensure that the
assembly fulfils the above requirement. Entries for M20 cable glands are standard.
3.7 Cabling And Fitting Lamps

Access for fitting lamps is by removing of front cover. Access for cabling is by the terminal chamber cover. Before
removing the front cover on any occasion, check that the cover support chain is sound. The front cover is released
by undoing the 8 hexagon headed screws. These should be slackened off in turn and then undone fully. Lamps
must be of the correct type and firmly screwed into place. When the lamp has been fitted, the gasket should be
checked and then the cover fitted into place. Initially the bolts are nipped up and then fully tightened using a
diagonal/cross over method. The tightening torque is 16 lb. ft. (22Nm). When fully tightened the gasket should
protrude slightly from the edge of the cover at all points. The gasket should not be greased, the bolt threads may
be re-greased if required during installation or maintenance.
Access for cabling is via the terminal box cover. The screws are loosened and the cover removed. The conductor
ends should be prepared so that the conductors are properly gripped and the bare part of the conductor should not
extend more than 1mm beyond the throat. The connection should be made in accordance with the polarity marked
and any unused terminal screws should be fully tightened. The lid is refitted, ensuring the gasket is correctly
positioned and the screws are then evenly tightened. The tightening torque is 3 lb. ft. (4Nm).

Visual inspection should be carried out at suitable intervals, frequently if conditions are severe. The time between
lamp changes could be infrequent and this is too long a period without inspection.

The equipment must be de-energised and isolated before opening. Individual organisations will have their own
procedures. What follows are guidelines based on our experience :
1 Ensure the lamp is lit when energised and that the lamp glass is not damaged. Check for superficial damage
to the enclosure.

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 re-
gasketing.
3 Check the tightness of the main cover screws. Torque 22Nm.
4 Check the supply cable for damage and check the cable glands for tightness and nip up if necessary.
5 Examine the sealant holding the lamp glass into the cover. If possible the consistency of the sealant should
be compared with that of a new luminaire. The sealant will become discoloured in time. If the sealant has
become very soft when compared with a new unit and is suffering from serious loss of adhesion to the glass,
the complete cover assembly will need to be replaced. In general the sealing system has a very long life but
users should be aware of possible damage caused by close exposure to hydrocarbon oils.
6 The cover gasket should be checked for softening and if it has become significantly softer than a new unit or
sticky, it should be replaced. It should be noted that the 1000W tungsten halogen luminaire has the red
silicone rubber gasket.
7 The lamp glass should be cleaned. This is particularly important to avoid the accumulation of dirt or dust
causing an increase in the T rating of equipment.
8 If it is thought that the luminaire has suffered mechanical damage, a stringent workshop check should be
carried out.
9 When the cover is removed for re-lamping, the lampholder security and connections should be checked.
Spare parts are available from ourselves, the model number and lamp size should be given when ordering. No
unauthorised modifications should be made.
3.9 Electrical Fault Finding And Replacement

With mercury lamps the faults are simple namely loose or broken connections, un-serviceable lamps or open
circuit control gear. (Control gear faults are also covered in the maintenance procedures for the control gear
boxes).
Control gear will not normally go open circuit unless it has first overheated; the signs of this are being severe
discoloration of the paint on the gear and cracks in any exposed insulation. Similarly a bad contact at the lamp cap
will usually result in discoloration at the site of overheating.
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 lamps the ignitor can become faulty. If the lamp is fitted, the lamp has continuity and the
connections are good and correct, they should produce an "attempt to start" flicker effect in the lamp and a buzzing
sound from the ignitor. It would be unusual to have no other parts available to perform a substitution fault finding
routine and this is the normal procedure. Before reassembling, all connections should be checked and any
damaged cable replaced. The ignition connection to the lampholder issleeved with the HT sleeving and this must
be kept in place. The ignition connection goes to the centre of the lamp cap.
The supply must be isolated.
4.0 Fuse Ratings

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.
current will probably be the determining factor 0.076A per µF at 240V, 50Hz (adjust for other volts by multiplication,
x 6/5 for 60 Hz). For HBC fuses, use 1.5 x normal capacitor current. For T-H inrush, use 8 x rated current. All
calculations must satisfy wiring regulations.

5.0 Disposal Of Materials

and synthetic resins. All electrical components 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.
5.1 Lamps
0.0 Tables 0/1/2

Table Options Refer to Section : 1.0

O
Model Lamp Watts Voltage Range T Rating T amb Max c
484/70 SON/T 70 (210/250V, 50 Hz T6 40

220/270V, 60 Hz)
484/150 SON/T 150 " T3 40
484/250 SON/T 250 " T3 40
484/400 SON/T 400 " T3 40
486/70 SON/E 70 " T6 40
486/150 SON/E 150 " T3 40
486/250 SON/E 250 " T3 40
486/400 SON/E 400 " T3 25
486/250M MBFU 250 " T3 40
486/400M MBFU 400 " T3 25
469/300 T-HAL 300 110/125V ac/dc T3 50
469/500 T-HAL 500 110/125V ac/dc T3 40
220/240V ac/dc
Table 1 Starting And Running Currents Refer to Section : 4.0
Lamp Lamp Circuit Circuit Capacitance µF Circuit Power (W)

Current A Start A Run A
70W HPS 1.0 0.55 0.4 10 80
150W HPS 1.8 1.45 0.8 20 175
250W HPS 3.0 2.35 1.3 30 285
400W HPS 4.6 4.0 2.2 40 445
250W MBF 2.13 2.8 1.4 15 280
400W MBF 3.25 4.4 2.2 20 430
Note : Minimum power correction factor 0.85
Lamp Type Number of Lamps
1 2 3 4 5 6
70W 4A 4A 4A 6A 6A 10A
150W 4A 6A 10A 10A 16A 16A
250W 10A 16A 16A 20A 20A 20A
400W 16A 20A 20A 25A 25A 32A


Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704


guidance only.

32
489
EPDM BULKHEAD
This compact and lightweight EPDM bulkhead range has excellent
vibration resistance making it ideal for use in hostile marine
environments. The 489 is manufactured from EPDM rubber and has
a high impact polycarbonate glass lens to give maximum
protection. The range is suitable for compact fluorescent, H.I.D and
GLS lamps with a recommended maximum continuous
operating ambient temperature of +25°C. Models with GLS lamps
can operate at an ambient temperature as low as -40°C. All control
gear for compact fluorescent models and H.I.D lamp
models is contained within the EPDM enclosure
APPLICATIONS: Ships decks (fishing vessels in particular),

walkways, ports and harbours
Enclosure: EDPM rubber with polycarbonate lens
Entries: 1xM20 cable entry
Termination: 2 core 1.5mm2 conductors (through wiring 2x1mm2)
Mounting: 4x9mm clearance holes on two aluminium mounting straps
Control Gear: Copper and iron control gear (H.I.D & compact fluorescent models)
Relamping: Via stainless steel clamp screw
Electrical Supply: 240V 50Hz (Compact fluorescents)
220-240V 50Hz (H.I.D Lamps) 250V Max ac/dc (GLS model)

489I/113/CF 1x10/13 CFL G24 4.0 Kgs
489I/022/CF 22 Circular fluorescent G10q 4.0 Kgs
489I/050/HS 50 HPS E27 5.0 Kgs
489I/070/MS 70 HPS/Metal halide E27 5.0 Kgs
489I/080/MV 80 MBFU E27 4.6 Kgs
489I/200/GL 200 GLS E27 4.0 Kgs

/LO Looping
/SS Stainless steel mounting straps
33
IOM - 489 EPDM Rubber Bulkhead
Issue 00

489 EPDM Bulkhead Luminaire
as a guide only.
203mm
ø300mm
ø9mm
133mm
362mm
IOM489 Issue 00 April 00 1

0.0 Specification

Standard BS EN 60598/01
Certificate N/A
Material Body EPDM Rubber
Cover Injection Moulded Polycarbonate
Temperature Rating (T amb) 35ºC ceiling mounted, 40ºC wall mounted to -40ºC
(HPS/Tungsten Halogen), -20ºC (MBI/MBF), -10ºC fluorescent
respectively].
1.0 Introduction - 489 Bulkhead

The 489 range is made with EPDM rubber body and polycarbonate cover. The 489H luminaire for portable
applications is class II, the other luminaires are class I and must be effectively earthed. The units suitable for GLS
lamps can use lamps up to 200W rating with a maximum current of 5A. The fixed luminaires have aluminium
mounting brackets as standard, stainless steel can be supplied as an option. Blue and yellow domes are available
for Heli-deck marking purposes.
Note : Lamp ranges are as outlined in TABLE 0.
2.0 General
Installation should be made in accordance with a code of practice where appropriate. In the UK, the requirements
of the 'Health and Safety at Work Act' must be met. Lamps must be disposed of in a safe manner. The luminaires
are (except for the 489H) Class I and should be effectively earthed. Some of the luminaires are heavy and suitable
handling equipment must be provided.
Important : For luminaires with electronic ballasts, the ballast must be disconnected before any High
Voltage ("Megger") test is made.

The supply voltage and frequency should be specified when ordering. A maximum voltage variation +/- 6% on the
nominal is expected. There have been some recent changes in voltage settings and tolerance for nominal supplies
in the UK and Europe and these need to be taken into account. The specification for tappings on the control gear
or lamps should be such that the supply does not exceed 106% of the nominal control gear setting or lamp voltage
for other than abnormal conditions. In some cases, the luminaires have multi-tapped control gear which can be set
to a range of 50 and 60Hz voltages. The tappings are shown on the control gear. If the equipment is located in
high or low voltage sections of the system, an appropriate voltage tap should be selected, but care must be taken
to log or mark the equipment so that the tapping is re-set if the equipment is re-located. If in doubt, tappings
should be set on a high side as this will increase lamp life. All HPS circuits use SIP (superimposed pulse) ignitors.
This means that there are only two connections to the choke making the tap selection obvious. Where shore or
construction site supplies are used, which are different to the service supplies, the tappings should be re-set. If
not, advice on the effect of these temporary supplies should be sought from the Chalmit Technical Department.
2.2 Lamps

The high pressure sodium and mercury lamps are of the standardised type and there is no preference in make or
colour. The luminaires using the PLC 13W lamp with electronic ballasts use the four pin type of lamp.
Care is needed to fit the correct lamp in order to obtain the design photometric performance. HPS lamp should be
replaced shortly after they do not light. The indication of the end of life for HPS lamps is cycling where the lamp
goes out then re-lights after a minute or so. The luminaires are now being fitted with anti-cycling ignitors giving a
total of about 80 seconds of ignition during any switching on cycle, to protect against damage by end of life
conditions. If discharge lamps are burned continuously, they should be switched off occasionally to allow lamps to
fail to re-ignite, rather than possibly become diodes with possible detrimental effects on control gear. The above
information was current at the time of printing. The development of lamps and control gear is on-going and detailed
advice on lamp performance can be obtained from the lamp supplier or from Chalmit. HPS circuits should not be
energised without a lamp fitted. HPS lamps with internal ignitors must not be used.
2.3 Mounting
2.4 Cables
Temperature conditions of the supply cable are such that 70ºC (ordinary PVC) can be used for single entry models.
The standard cable section is 2.5mm² max. All models are suitable for 300/500V cable. If the model with looping
facilities has been ordered and PVC cable is used, insulating sleeving should be added where the through cable is
adjacent to the choke.
2.4.1 Cabling and Fitting Lamps

Access for fitting the lamp is by removing the front cover. The front cover is released by undoing the screw on the
clamping band, when the band is replaced it should only be tightened to the stop. Lamps must be of the correct
type and screwed or placed firmly into the lamp holder. To gain access to the cabling, the reflector is removed. In
the case of fixed luminaires where glands are supplied, the cables should be suitable for making an IP seal in the
gland. Where metal cable glands or plastic cable glands are used with the body having the internal frame to
support the choke, a large washer should be placed on the outside under the cable gland to prevent the glands from
being drawn into the rubber. Where portable luminaires are used, the cable should be of a flexible type with a
minimum rating of 85ºC (CSP/ERR) or similar).
Before cabling, any voltage tap re-selection should be made. The conductor ends should be prepared so that the
conductors are properly gripped and the bare part of the conductor should not extend to more than 1mm beyond
the throat. The connection should be made in accordance with the polarity marking. Any used terminal screws
should be fully tightened. Before replacing the cover, a final check of the connections should be made.

Routine inspection should be carried out at a minimum of 2 years interval and more frequently if conditions are
severe. The time between lamps changes could be very infrequent and this is too long a period without inspection.

The equipment must be de-energised and isolated before maintenance. Individual organisations will have their own
procedures. What follows are guidelines based on Chalmit's experience :
1 Ensure the lamp is lit when energised and that the lampglass is not damaged. Check for superficial damage to
the enclosure.
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.
3 Check the cable gland for tightness and nip up if necessary. Check supply cables for damage.
5 Every three years, or more frequently, depending on experience, the control gear internal connections should be
checked for tightness and any sign of corrosion or overheating. Any suspect components should be replaced.


With mercury vapour lamps the faults are simple, namely loose or broken connections, unserviceable lamps or
open circuit control gear. Control gear will not normally go open circuit unless it has first overheated; the signs of
this are obvious, being severe discoloration of the paint on the gear and cracks in any exposed insulation.
Similarly, bad contact at the lamp cap will usually result in discoloration as a sign of overheating. 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 lamps, 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 the lamp and a buzzing sound from the ignitor. It will
ignition connection to the lampholder is sleeved with HT sleeving and this must be kept in place.
3.3 Overhaul
All the spares required are available. Please state the model number lamp and reflector details when ordering. The
reflectors vary from between the various models.
4.0 Fuse Ratings

switch-on to normal after 4 minutes; rectification effects caused by asymmetrical cathode emission for a few
characteristics, the individual engineer can make a better judgement of what is required.
The normal capacitor current will probably be the determining factor 0.076A per µF at 240V, 50Hz (adjust for other
voltages by multiplication, x 6/5 for 60Hz). For HBC fuses use 1.5 x normal capacitor current.
Tungsten Halogen lamps have high in rush currents of 10 x the nominal current.
A conventional matrix for HBC fuses for HPS is outlined in TABLE 2.

The capacitor is of a dry film type and does not contain PCB's. The control gear contains electronic components
and synthetic resins. All the electrical components and the body and polycarbonate cover will also give off noxious
fumes if incinerated, so care must be taken to render any fumes harmless and avoid inhalation. Any local
regulations concerning disposal must be complied with.
5.1 Lamps
Incandescent lamps, fluorescent lamps and discharge lamps in modest quantities are not "special waste". The
outer envelope should be broken in the container to avoid injury.
0.0 Tables 0/1/2

Table 0 Lamp Ranges Refer to Section : 1.0
Cat. No. Lamps Lamp Holder Weight Voltage

kg
489I/22 22W Fluor. G10q 3.5 240V
489I/200/GL 200W GLS Max. ES 3.2 25, 50, 110, 200, 220, 240V
489I/50/MV 50W MBFU ES 4.6 220, 240V
489I/80/MV 80W MBFU ES 4.6 220, 240V
489I/50/HS 50W SON ES 5.0 220, 240V
489I/70/HS 70W SON ES 5.0 220, 240V
489H 200W GLS Max. ES 3.2 25, 50, 110, 200, 220, 240V
489I/13/CF 13W PLC G24q 3.5 24, 50, 100, 240V
Lamp Start A Run A Capacitance µF Circuit Power (W)
22W Fluor. 0.21 0.14 6 31

50W HPS 0.41 0.3 8 65
70W HPS 0.55 0.4 10 80
13W PLC 0.11 0.11 - 13.6
1 2 3 4 5 6
70W HPS 4A 4A 4A 6A 6A 10A

80W MBF 4A 4A 4A 4A 6A 6A


Telephone : +44 (0)141 882 5555

0700 CHALMIT
Fax : +44 (0)141 883 3704
EMail : email@chalmit.com


guidance only.


28
458
EPDM FLOODLIGHT
This high wattage, weatherproof, robust EPDM floodlight range has
excellent vibration resistance making it ideal for use in hostile
marine environments. The 458 is manufactured from EPDM rubber
with a heavy duty borosilicate front glass and wire guard for
maximum protection. The 458 is suitable for GLS and HPS lamps
with maximum continuous operating ambient temperature
of +25°C. Models with GLS lamps can operate at an ambient
temperature as low as -40°C. A 501 control gear box is required for
models with HPS lamps.

walkways, ports and harbours)
Enclosure: EDPM rubber with borosilicate front glass
Entries: 1x10mm cable entry point complete with cable clamp
Termination: 2 core 1.5mm 2 max conductors
Mounting: Via lifting hook (Portable handlamp version)
Base-mounted or pole-mounted available as alternatives.
Control Gear: N/A
Electrical Supply: 250V Max ac/dc (GLS model). For HPS models see 501 Control Gear Box.
Protection: Class II

458I/150/HS 150 HPS E40 4.2 Kgs
458I/250/HS 250 HPS E40 4.2 Kgs
458I/500/GL 500 GLS E40 4.2 Kgs

/B Base-mounted
/PM Pole-mounted
29
IOM - 458 EPDM Rubber Floodlight
Issue 00

458 EPDM Rubber Floodlight
as a guide only.
0
47
ø292mm
1
ø7
11

0.0 Specification

Certificate N/A
Cover Injection Moulded Polycarbonate or Borosilicate Glass
Temperature Rating (T amb) 30ºC, -40ºC (HPS/Tungsten Halogen), -20ºC (MBI/MBF)
respectively].
1.0 Introduction – 458HG Class II IP65 & 458 IP66 EPDM Rubber Floodlight
The range is made with EPDM rubber body and a polycarbonate or borosilicate glass cover. The 458HG luminaire
for portable applications is class II and the other luminaires are class I and must be effectively earthed. The fixed
luminaires have an aluminium mounting bracket as standard, stainless steel fixing screws, borosilicate glass cover
and guard. The units suitable for GLS and Tungsten Halogen lamps can use lamps up to 500W.
2.0 General
are (except for the 458HG) Class I and should be effectively earthed. Some of the luminaires are heavy and
suitable handling equipment must be provided.
Important : For luminaires with electronic ballasts, the ballast must be disconnected before any High
Voltage ("Megger") test is made.

in the UK and Europe and these need to be taken into account.
The specification for tappings on the control gear or lamps should be such that the supply does not exceed 106%
of the nominal control gear setting or lamp voltage for other than abnormal conditions. In some cases, the
luminaires have multi-tapped control gear which can be set to a range of 50 and 60Hz voltages. The tappings are
shown on the control gear.
selected but care must be taken to log or mark the equipment so that the tapping is re-set if the equipment is re-
located. If in doubt, tappings should be set on the high side as this will increase lamp life. All HPS circuits use
SIP (superimposed pulse) ignitors. This means that there are only two connections to the choke making the tap
selection obvious. Where shore or construction site supplies are used, which are different to the service supplies,
the tappings should be re-set. If not, advice on the effect of these temporary supplies should be sought from the
Chalmit Technical Department.
2.2 Lamps
colour. Care is needed to fit the correct lamp in order to obtain the design photometric performance. HPS lamp

should be replaced shortly after they do not light. The indication of the end of life for HPS lamps is cycling where
the lamp goes out then re-lights after a minute or so. The luminaires are now being fitted with anti-cycling ignitors
giving a total of about 80 seconds of ignition during any switching on cycle to protect against damage by end of life
information was current at the time of printing. The development of lamps and control gear is on going and detailed
2.3 Mounting
2.4 Cables
facilities has been ordered and PVC cable is used insulating sleeving should be added where the through cable is

type and screwed firmly into the lampholder. Access to the cabling is gained by removing the reflector. In the
case of fixed luminaires where glands are supplied, the cables should be suitable for making an IP seal in the
should be fully tightened. Before replacing the cover, a final check of the connections should be made.


the enclosure.

With HPS lamps the ignitor can become faulty. If the lamp is fitted, the choke has continuity and the connections
3.3 Overhaul
4.0 Fuse Ratings

5.0 Disposal Of Material

and synthetic resins. All the electrical components, the EPDM rubber body and polycarbonate cover will also give
off noxious fumes if incinerated, so care must be taken to render any fumes harmless and avoid inhalation. Any
local regulations concerning disposal must be complied with.
5.1 Lamps

0.0 Tables 0/1/2

kg
458I/500/GL 500W GLS Max. E40 4.2 250V Max.
458I/300/TH 300W TH E40 4.2 250V
458I/500/TH 500W TH E40 4.2 120V
458I/150/S 150W SON/T E40 4.2 (Refer to
458I/250/S 250W SON/T E40 4.2 506 control
458I/250/M 250W MBFU E40 4.2 gear box)
458HG Upto 300W GLS E40 4.0 --
Lamp Lamp Current Start A Run A Capacitance µF Circuit Power (W)
70W HPS 1.0 0.55 0.4 10 80

150W HPS 1.8 1.45 0.8 20 175
250W HPS 3.0 2.35 1.3 30 285
250W MBF 2.13 2.80 1.4 1.5 280
1 2 3 4 5 6
70W 4A 4A 4A 6A 6A 10A
150W 4A 6A 10A 10A 16A 16A
250W 10A 16A 16A 20A 20A 20A


Telephone : +44 (0)141 882 5555

0700 CHALMIT
Fax : +44 (0)141 883 3704


guidance only.


30
487
EPDM FLOODLIGHT
This compact, robust and weatherproof EPDM floodlight range has
excellent vibration resistance making it ideal for use in hostile marine
environments. The 487 is manufactured from EPDM rubber with a
toughened front glass and a wire guard for maximum protection.
For submersible operation down to a maximum depth of 18m, an IP68
version is available. The 487 is suitable for GLS lamps up to 200W
with a recommended maximum continuous operating ambient
temperature of +25 °C and minimum temperature as low as -40°C

Ingress Protection: IP54 to EN 60529 (with guard)
Enclosure: EDPM rubber with toughened front glass
Entries: 1x10mm cable entry point complete with cable clamp
Termination: 2 core 1.5mm2 max conductors
Mounting: Via lifting hook ( portable handlamp version )
Base-mounted(as illustrated above) or pole-mounted available as alternatives
Control Gear: N/A
Protection: Class II

487I/200/GL 200 GLS E27 4.2 Kgs

/B Base-mounted
/PM Pole-mounted
/IP67 IP67 (Silicone sealing ring fitted to glass. No guard fitted)
/SP IP68 Submersible version
31
Issue 00

487 EPDM Rubber Floodlight
as a guide only.
m
5m
34
ø178mm
1
ø7
11
IOM487 Issue 00 June 02 1

0.0 Specification

Standard BSEN60598/01
Certificate N/A

Cover Toughened Glass
Temperature Rating T amb) 25ºC, -40ºC (HPS/Tungsten Halogen),

-20ºC (MBI/MBF), -10ºC
Ingress Protection IP65 BS EN60529
1994" and "The Electromagnetic Compatibility Regulations 1992", it does not apply to the
"Equipment and Protective Systems intended for use in Explosive Atmospheres
Regulations 1996". [This legislation is the equivalent in UK law of EC directives
73/23EEC, 89/336/EEC and 94/9/EC respectively].
1.0 Introduction - 487 EPDM Rubber Floodlight

The 487 range is made with EPDM rubber body and toughened glass cover. The 487 H luminaire for portable
applications is class II, the other luminaires are class I and must be effectively earthed. The fixed luminaires have
aluminium mounting brackets as standard, stainless steel can be supplied as an option. The units suitable for
GLS lamps can use lamps up to 200W.
2.0 General
are (except for the 487H) Class I and should be effectively earthed. Some of the luminaires are heavy and suitable
handling equipment must be provided.

in the UK and Europe and these need to be taken into account.
The specification for tappings on the control gear or lamps should be such that the supply does not exceed 106%
of the nominal control gear setting or lamp voltage for other than abnormal conditions. In some cases, the
luminaires have multi-tapped control gear which can be set to a range of 50 and 60Hz voltages. The tappings are
shown on the control gear.
located. If in doubt, tappings should be set on a high side as this will increase lamp life. All HPS circuits use SIP
(superimposed pulse) ignitors. This means that there are only two connections to the choke making the tap
selection obvious. Where shore or construction site supplies are used, which are different to the service supplies,
the tappings should be re-set. If not, advice on the effect of these temporary supplies should be sought from the
Chalmit Technical Department.

2.2 Lamps
colour. The luminaires using the SON/T and MBFU light source require a 506 control gear box.
Care is needed to fit the correct lamp in order to obtain the design photometric performance. HPS lamp should be
replaced shortly after they do not light. The indication of the end of life for HPS lamps is cycling where the lamp
goes out then re-ignites after a minute or so. The luminaires are now being fitted with anti-cycling ignitors giving a
total of about 80 seconds of ignition during any switching on cycle to protect against damage by end of life
information was current at the time of printing. The development of lamps and control gear is on-going and detailed
2.3 Mounting
2.4 Cables
facilities has been ordered and PVC cable is used, insulating sleeving should be added where the through cable is

Access for fitting lamp is by removing the front cover. The front cover is released by undoing the screw on the
type and screwed or placed firmly into the lamp holder. To gain access to the cabling, the reflector is removed. In
the case of fixed luminaires where glands are supplied, the cables should be suitable for making an IP seal in the
should be fully tightened. Before replacing the cover, a final check should be made of the connections.


the enclosure.

5 Every three years, or more frequently, depending on experience, the control gear internal connections should
be checked for tightness and any sign of corrosion or overheating. Any suspect components should be
replaced.

With HPS lamps the ignitor can become faulty. If the lamp is fitted, the choke has continuity and the connections
3.3 Overhaul
3.4 Fuse Ratings

Note : All calculations must satisfy wiring regulations.

Starting and running currents for 240V, 50Hz are as indicated in TABLE 1.
4.0 Disposal Of Material

and synthetic resins. All the electrical components and the body and polycarbonate cover will also give off noxious
fumes if incinerated, so care must be taken to render any fumes harmless and avoid inhalation. Any local
regulations concerning disposal must be complied with.
4.1 Lamps
The lamp manufacturers produce detailed information on the handling and disposal of discharge lamps. It will be
advantageous for the user to obtain copies of this information. For totally enclosed luminaires re-lamped when
isolated and using lamps with outer envelopes, the following are the important points. Break the outer envelope
when inside a container in a ventilated area. Lamps may currently be considered as normal waste. If there are
large quantities there may be local regulations on disposal.



0.0 Tables 0/1/2

kg
487-25-200G/H 25-200W GLS ES/BC 2.0 250V Max
487-60-150PAR 60-120W PAR38 ES 2.0 250V Max
487-200TH 200W T/HAL ES 2.0 250V Max
487-70S 70W SON/T ES 2.0 (Refer to 506
487-80M 80W MBFU ES 2.0 control gear box)
Note : Always state rated supply when ordering gear box.
Table 1 Starting And Running Currents Refer to Section : 3.4
70W HPS 0.55 0.4 10 80

80W MBF 0.5 0.43 8 88
1 2 3 4 5 6
70W SON 4A 4A 4A 6A 6A 10A

80W MBF 4A 4A 4A 4A 6A 6A


Telephone : +44 (0)141 882 5555

Fax : +44 (0)141 883 3704


guidance only.


26
279
EPDM BULKHEAD
This compact and lightweight EPDM bulkhead range has
excellent vibration resistance making it ideal for use in hostile
marine environments. The 279 is manufactured from EPDM rubber
with a high impact polycarbonate lens for maximum protection.
For submersible operation down to a maximum depth of 5m, an IP68
version is available. The 279 is suitable for GLS and compact
fluorescent lamps with maximum continuous operating ambient
temperature of +25 °C. Models with GLS lamps can operate at an
ambient temperature as low as -40°C . All control gear for compact
fluorescent models is contained within the EPDM enclosure.

Enclosure: EDPM rubber with polycarbonate lens
Entries: 2x10mm cable entry points complete with cable clamps
Termination: 2 core 1.5mm2 conductors (through wiring 2x1mm2)
Mounting: Via 4x9mm clearance holes on two stainless steel mounting straps
Control Gear: Copper and iron control gear (compact fluorescent models)
Electrical Supply: 240V, 50Hz (Compact fluorescent) 12V-250V ac/dc (GLS)

279I/107/CF 1x7 PL-S/2P G23 1.0 Kgs
279I/207/CF 2x7 PL-S/2P G23 1.2 Kgs
279I/060/GL 60 GLS E27 0.8 Kgs

/120/60 120V/60Hz supply (1x7W Model only)
/SP Submersible IP68 version
Issue 00

279 EPDM Bulkhead Luminaire
as a guide only.
4-FIXING
HOLES Ø8
Ø200
85
215 140

0.0 Specification

Certificate N/A
Cover Injection Moulded Polycarbonate
Temperature Rating (T amb) 35ºC ceiling mounted, 40ºC wall mounted to -40ºC
(Tungsten Halogen), -10ºC fluorescent
Ingress Protection IP65 BS5490 (IEC 529)
1994" and "The Electromagnetic Compatibility Regulations 1992”.
respectively].
1.0 Introduction - 279 Bulkhead

The 279 range is made with EPDM rubber body and polycarbonate cover. The 279H luminaire for portable
applications is class II, the other luminaires are class I and must be effectively earthed. The units suitable for GLS
lamps can use lamps up to 60W rating with a maximum current of 2.5A. The fixed luminaires have stainless steel
mounting brackets as standard.
2.0 General
are (except for the 279H) Class I and should be effectively earthed.

in the UK and Europe and these need to be taken into account. The specification for tappings on the control gear
or lamps should be such that the supply does not exceed 106% of the nominal control gear setting or lamp voltage
for other than abnormal conditions. In some cases, the luminaires have multi-tapped control gear which can be set
to a range of 50 and 60Hz voltages. The tappings are shown on the control gear. If the equipment is located in
high or low voltage sections of the system, an appropriate voltage tap should be selected, but care must be taken
to log or mark the equipment so that the tapping is re-set if the equipment is re-located. If in doubt, tappings
should be set on a high side as this will increase lamp life. Where shore or construction site supplies are used,
which are different to the service supplies, the tappings should be re-set. If not, advice on the effect of these
temporary supplies should be sought from the CHALMIT Technical Department.

2.2 Lamps
The luminaires using the PL 7W lamp use the two pin lamp version.
Care is needed to fit the correct lamp in order to obtain the design photometric performance. The above information
was current at the time of printing. The development of lamps and control gear is on-going and detailed advice on
lamp performance can be obtained from the lamp supplier or from Chalmit.
2.3 Mounting
2.4 Cables
The standard cable section is 1.0mm² max. All models are suitable for 300/500V cable.
Class I luminaires should have a suitable earth connection made at the mounting straps, either externally or
internally.

type and screwed or placed firmly into the lamp holder. To gain access to the cabling, the reflector is removed
Where portable luminaires are used, the cable should be of a flexible type with a minimum rating of 85ºC
(CSP/ERR) or similar).
The conductor ends should be prepared so that the conductors are properly gripped and the bare part of the
conductor should not extend to more than 1mm beyond the throat. The connection should be made in accordance
with the polarity marking. Any used terminal screws should be fully tightened. Before replacing the cover, a final
check of the connections should be made.


the enclosure.


Control gear will not normally go open circuit unless it has first overheated; the signs of this are obvious, being
severe discoloration of the paint on the gear and cracks in any exposed insulation. Similarly, bad contact at the
lamp cap will usually result in discoloration as a sign of overheating. Any fault finding must be done by a
competent electrician and, if carried out with the luminaire in place, under a permit to work.
Before re-assembling, all connections should be checked and any damaged cable replaced.
3.3 Overhaul
4.0 Fuse Ratings

GLS lamps have high in rush currents of 10 x the nominal current.
judgement of what is required.

The control gear contains electronic components and synthetic resins. All the electrical components and the body
and polycarbonate cover will also give off noxious fumes if incinerated, so care must be taken to render any fumes
harmless and avoid inhalation. Any local regulations concerning disposal must be complied with.
5.1 Lamps
Incandescent lamps and fluorescent lamps in modest quantities are not "special waste". The outer envelope
should be broken in the container to avoid injury.

0.0 Tables 0/1

kg
279I/107/CF 7W Fluor. G23 1.0 220/240V
279I/207/CF 2 x 7W Fluor. G23 1.3 220/240V
279I/060/GL 25 to 60W GLS ES/BC 0.8 25, 50, 110, 200, 220, 240V
7W Fluor. 0.055 0.05 - 12

2 x 7W Fluor. 0.085 0.08 - 18


Telephone : +44 (0)141 882 5555

0700 CHALMIT
Fax : +44 (0)141 883 3704


guidance only.


27

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INDUSTRIAL

STANDARD PRODUCT RANGE

OPTIONS - Suffix to Catalogue No.

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

MODEL SIZE DIMENSION 'A' DIMENSION 'B'

210 DIMENSION 'B' - M8 FIXING CENTRES

TWO M20x1.5p DIMENSION 'A' - OVERALL

IOMPROTS Issue 04 April 00

Type Of Protection N/A

1.0 Introduction - Protecta Safe Area Fluorescent Luminaire

3.0 Installation and Safety

3.3 Electrical Supplies and Control Gear

IOMPROTS Issue 04 April 00

3.6 Cable Connection

3.6.2 Cable Glands

3.7 Electrical Connections

3.7.1 Installation of HF and Emergency

IOMPROTS Issue 04 April 00

3.8.1 Opening and Closing the Cover

3.8.2 Removal and Replacement of Clamping Bar (if required)

3.8.3 Releasing the Reflector/Gear Tray

3.8.4 Fitting lamps

3.9 Inspection and Maintenance

3.9.1 Replacement of Electronic Ballast and Invertor Unit (Where Fitted)

3.9.2 Routine Examination

IOMPROTS Issue 04 April 00

1 Ensure lamps are lit when energised by mains supply.

4.0 Electrical Fault Finding and Replacement

5.0 Disposal of Material

Important : Do not incinerate lamps.

5.2 Battery Disposal

IOMPROTS Issue 04 April 00

No. off Lamp Lamp Circuit Power PFC Line

IOMPROTS Issue 04 April 00

Chalmit Lighting 388 Hillington Road, Glasgow G52 4BL, Scotland

Telephone : +44 (0)141 882 5555

Registered Office Ronald Close, Woburn Road Industrial Estate

Registered No. 3650461

Note Chalmit Lighting reserve the right to amend

IOMPROTS Issue 04 April 00

IOMPROTS Issue 04 April 00

STANDARD PRODUCT RANGE

OPTIONS - Suffix to Catalogue No

ATEX Category 3(Zone2) hazardous area versions are available.

OPTIONS - Suffix to Catalogue No.

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

IOMSTGI Issue 01 May 00

Area Classification Non-Hazardous (Industrial)

1.0 Introduction - Sterling Safe Area Fluorescent Luminaire

3.0 Installation and Safety

3.3 Electrical Supplies

IOMSTGI Issue 01 May 00

3.6 Cable Connection

3.6.2 Cable Glands

3.7.1 Fitting Lamps

IOMSTGI Issue 01 May 00

3.8.1 Routine Examination

1 Ensure lamps are lit when energised by mains supply.

3.9 Electrical Fault Finding and Replacement

3.9.1 Battery Check and Replacement