Products / Process Lights / EPL-100
EPL-100 Installation, Operation & Maintenance
LumaStar™ LED Illuminator — Bulletin J500.32 / J500.33 (ATEX)
Download Original Bulletins
Clark-Reliance Bulletins J500.32 (FM/CSA) and J500.33 (ATEX)
Storage and Handling
The Jerguson LED Explosion Proof Illuminator meets or exceeds all applicable specifications when shipped from the factory.
All units should be inspected upon receipt to ensure that no damage has been incurred during transit. If there has been damage, a claim should be filed with the carrier immediately. Units should be stored in an area protected from the elements and corrosive fumes, in a secure manner where they can neither fall nor be struck by other objects.
Care should be taken to protect the window and the end connections from damage. Avoid placing any objects directly on the light at any time.
Components
There are three main components that make up the LED illuminator:
Light Strip
LED array circuit board in 4", 6", 8", 10", or 12" lengths. Constructed of aluminum, stainless steel, glass, and silicone.
Power Supply
Explosion-proof enclosure housing the AC/DC converter. Available in 120 VAC or 240 VAC (FM/CSA) and 115 VAC or 230 VAC (ATEX).
Connecting Cable
Connects the light strip to the power supply. Extension cables available for remote mounting up to 72 ft (22 M) / 15 M (ATEX).
Note: Questions regarding acceptable applications should be directed to The Clark-Reliance Corporation or Northeast Controls Inc.
Bracket Mounting Instructions
Identify your bracket type before proceeding. Confirm the bracket style matches the instructions below. This adjustable assembly is appropriate for any gauge with a cover width not exceeding 4.375 inches (111 mm).
Clip-Style Bracket (Bulletin J500.32.A1 / J500.33.A1)
Align the LumaStar assembly with the rear (side with bolt heads) of the gauge. Loosen bracket thumb nuts and adjust the position of the brackets to line up with their respective bolts on the gauge. Tighten the thumb nuts to secure in place. When possible, use the 2nd set of bolts from the edge of the cover plate.
Align one side of the brackets so that the clip of the brackets is gripping around the side of the gauge. Roll the entire assembly over until it is flush with the rear flat of the gauge and press until the bracket clips have locked into place.
Cable-Style Bracket (Bulletin J500.32.A2)
Check to make sure brackets are properly assembled on the illuminator. The cable should be fed through the stud protruding from behind the illuminator, locking in the bracket. One end of the cable should be crimped into an oval for pulling leverage and the other should be crimped securely around a thumb nut.
Press the LumaStar assembly against the rear of the gauge, aligning the bracket cutouts over the gauge bolt heads. Align the brackets with the 2nd set of bolts in from each end of the gage, when possible.
While holding the top bracket in place, grab the thumb nut end of the cable, wrap around the entire gauge and thread onto the stud until the bracket is secure. When wrapping the cable around the gauge, make sure to feed the cable above the bolt. Snug the cable and secure the thumb nut, but do not fully tighten at this time.
Align the bottom bracket, using the 2nd bolt if possible. Wrap the thumb nut end of the cable around the entire gauge and begin to thread. Pull the cable loop as tight as possible and fully tighten the thumb nut. The lower bracket should now be tight and secure.
After the lower bracket has been tightened, go back to the top bracket and loosen the thumb nut enough to allow the cable to slide through freely. Pull the cable as tight as possible, and fully tighten the thumb nut.
The LumaStar is now properly installed. Feel free to tuck any excess cable inside itself or allow it to hang freely.
Electrical Installation
Caution: All lights are tagged with the service conditions for that particular unit. These specifications are located on the Jerguson tag on the power supply housing. Do not use or refer to specifications listed on the red label on the power supply housing — they are specifications for generic use. Review the ratings prior to installation and again prior to start-up to ensure proper operation in the installed environment. Should there be any doubt as to the applicability of a unit for the installed environment, consult the factory before placing the unit into service.
Note: All installation steps should be performed by a qualified technician and should be executed in accordance with all applicable national and local codes.
The light and power supply should be checked to ensure that they contain no foreign matter, and that the end connections are clean, undamaged, and in line with existing conduit.
Refer to Section 03 (Bracket Mounting Instructions) and mount the LumaStar assembly to the gauge.
CAUTION — Before working with the power supply, verify that the area is free of flammables and the AC power circuit is off. Open the cover of the power supply housing. Insert the AC Line wires into the housing and connect to the "AC IN" terminal block. A ground screw is located inside the enclosure if required.
CAUTION: The DC output is pre-wired. If this connection is removed during installation, reconnect the "AC IN" and "DC OUT" to the proper positions. Failure to do so will result in permanent damage to the power supply.
IMPORTANT: The customer must have a "sealing fitting" in the conduit supplying power to the light's power supply within 18" of the power supply (FM/CSA units). Any additional components must be installed prior to the customer's sealing fitting.
If the cable will not reach the power supply, contact your local representative for the required extension cable.
Replace the cover on the power supply housing.
Switch "ON" the power supply, making sure the Illuminator is functioning properly with all LEDs illuminated.
If the LEDs do not illuminate, remove the cover on the power supply once the power has been turned on. An LED will be lit if it is wired correctly. See Figure 1, Detail "A" in the original bulletin.
If the LED in the power supply is not lit, check the power source and the connection before continuing.
ATEX Units — Additional Caution
Incorrectly wiring the AC input to the DC output will cause permanent damage to the power supply and result in the ignition of hazardous atmospheres. ATEX units use a stainless steel I.S. connector and aluminum conduit sealing device. Electrical connection is ½" FNPT.
Operation
The LED illuminator can run continuously. The operating life of LED lights exceeds 100,000 hours under normal conditions.
Routine Maintenance
Keep the window on the front of the light clean using commercial glass cleaners, such as Windex® or similar. Never use harsh abrasives, wire brushes, metal scrapers, or any material that could scratch the window. The window may be cleaned while the unit is in operation.
The light may be removed while the unit is in operation during inspection or maintenance of the customer's gage glass. The Illuminator may also be disconnected from the power supply, if desired. Disconnect the cord at the supplied screw connector adjacent to the power supply. The plant power going to the power supply does not need to be disconnected.
Fuse Replacement
This power supply is fused for AC protection. In the event of a large voltage surge, the fuse may release, causing no output voltage.
Replacement Fuse
Clark-Reliance P/N E-F-DIN-F400MA — 400 mA 5×20 mm DIN Fuse
Loosen the cover locking screw and open the cover of the power supply housing.
Remove and replace the bad fuse. Refer to Figure 1 in the original bulletin for fuse location.
Replacing the Power Supply
Loosen the cover locking screw and open the cover of the power supply housing. Disconnect AC power in and remove AC wires from the enclosure.
Remove the assembly from the gage and relocate to the desired work area.
Disconnect the power cable between the power supply and the light bar assembly.
Trim gasket material at the top end cap to match the slot opening and slide out the bracket and mounting hardware.
Loosen the power supply screws and slide the power supply off the light bar assembly.
Slide the new power supply onto the light bar assembly.
Insert the bracket and mounting hardware for the top bracket back into the slot.
Securely tighten the power supply screws and the top bracket screw.
Install the power cord between the power supply and the light strip, making sure connectors are fully connected.
Specifications
FM / CSA Units (Bulletin J500.32)
| Power Supply | 120 or 240 VAC @ 50–60 Hz |
| Power Consumption | < 750 mA @ 120 VAC / < 375 mA @ 240 VAC |
| Estimated Life | 100,000 Hours (continuous) |
| Agency Approvals | FM Approved, CSA — Class I, Div. I, Grps. B, C & D; Class II, Div I, Grps. E, F & G |
| Wire Size | Min 18 AWG / Max 12 AWG |
| Max Distance (supply to light) | 72 feet (22 M) |
| Ambient Temperature | −40°F (−40°C) to 170°F (77°C) |
| Electrical Connection | ¾" FNPT |
ATEX Units (Bulletin J500.33)
| Power Supply | 115 or 230 VAC @ 50–60 Hz |
| Power Consumption | < 750 mA @ 115 VAC / < 375 mA @ 230 VAC |
| Estimated Life | 100,000 Hours (continuous) |
| Agency Approvals | ATEX Approved — Explosion Protected |
| Wire Size | Min 1 mm² / Max 2.5 mm² |
| Max Distance (supply to light) | 15 M |
| Ambient Temperature | −40°C to 77°C |
| Electrical Connection | ½" FNPT |
Replacement Parts & Ordering Information
FM / CSA Spare Parts
| Item | Part Number | Description |
|---|---|---|
| 1 | S23293 | 120 VAC Power Supply Board/Bracket Sub-Assembly |
| 2 | S23294 | 240 VAC Power Supply Board/Bracket Sub-Assembly |
| 3 | S23213 | 120 VAC Power Supply with Explosion Proof Enclosure (Includes All Items) |
| 4 | S23295 | 240 VAC Power Supply with Explosion Proof Enclosure (Includes All Items) |
| 5 | E-F-DIN-F400MA | Fuse — 400 mA |
| 6 | V205696 | 5 Ft (2.5 M) Extension Power Cord, For Remote Mounting |
| 7 | S23174-4 | LED Array Circuit Board, 4" |
| 8 | S23174-6 | LED Array Circuit Board, 6" |
| 9 | S23174-8 | LED Array Circuit Board, 8" |
| 10 | S23174-10 | LED Array Circuit Board, 10" |
| 11 | S23174-12 | LED Array Circuit Board, 12" |
ATEX Spare Parts
| Item | Part Number | Description |
|---|---|---|
| 1 | S24287-115V | 115 VAC ATEX Power Supply Board/Bracket Sub-Assembly |
| 2 | S24287-230V | 230 VAC ATEX Power Supply Board/Bracket Sub-Assembly |
| 3 | S24196-EPL-115V | 115 VAC ATEX Power Supply with Enclosure (Includes All Items) |
| 4 | S24196-EPL-230V | 230 VAC ATEX Power Supply with Enclosure (Includes All Items) |
| 5 | E-F-DIN-F400MA | 400 mA 5×20 mm DIN Fuse |
Order Replacement Parts
Contact Northeast Controls to order EPL-100 spare parts and accessories.
EPL-100 Technical Support
1-201-419-6111 · [email protected]
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