ATEX light fittings: how to cut installation costs?
Engineers who have spent over a decade designing lighting installations in the largest chemical, energy, and offshore facilities know the strengths and weaknesses of luminaires from various manufacturers. It was their guidelines that helped us create Ex luminaires that combine reasonable pricing with the potential for cost savings in installation materials, labor, and subsequent energy consumption.
Key factors affecting installation costs
The aforementioned extensive experience working in industrial facilities has clearly shown that selecting the right luminaires has a significant impact on three key aspects that can greatly increase installation costs. Here’s why:
- Cost of ATEX lamps: ATEX lamps intended for use in explosion hazard zones are 2-3 times more expensive than standard industrial luminaires. Choosing optimal luminaires can significantly reduce the number of lamps needed to illuminate a given area.
- Installation costs in explosion hazard zones: Installations in these zones require the use of more expensive ATEX junction boxes. Luminaires that do not require these boxes are cheaper to install, both in terms of material costs and faster installation times.
- Emergency and primary lighting: In many cases, primary lighting luminaires also serve as emergency lighting, requiring the use of non-flammable and therefore more expensive cables. Luminaires that reduce the need for power cables lower the overall installation cost.
Additionally, some industries require the use of stainless steel installation materials, which increases the cost of boxes, trays, and other components. Reducing or eliminating these elements also contributes to reducing installation costs.
ATEX OptiLine Series: the design behind the luminaire
Considering the above factors, we designed the ATEX OptiLine series luminaire in such a way as to:
Reduce Component Costs
- Reduce the number of luminaires in the lighting installation,
- Eliminate junction boxes,
- Minimize cable lengths,
- Reduce the length of trays and other mounting materials.
Reduce Installation Time
- Elimination of Loose Parts: the use of a hinged cover and internal mounting plate, integrated clips with the cover, and non-loose screws.
- Ease of Connection: providing ample internal space for easy electrical connections.
- Reduction of Mounting Components: reducing the number of components requiring assembly, such as boxes, trays, hangers.
- Use of Cable Glands in Two Sizes: introducing cable glands in two sizes (M20 and M25), which provides greater flexibility in using different types and thicknesses of cables, including non-flammable cables, from various manufacturers.
What to consider when choosing an Ex luminaire: example of OptiLine
Below, we present the key features of the ATEX OptiLine lighting fixture that contribute to reducing the costs of installing primary and emergency lighting in industrial settings. These features simplify the design, installation, and subsequent electrical testing processes of the fixtures.
Lenses that add to flexibility
The Ex OptiLine fixtures allow the use of lenses to change the direction of emitted light, an innovative solution that offers great flexibility while using standard mounting brackets.
How it works?
In typical fixtures, changing the light direction requires the use of special brackets, which increases investment costs. The ATEX OptiLine lighting fixture can be mounted using standard brackets, and the light direction can be changed by applying one of 22 available lenses mounted under the cover directly on the LED module.
For example, this solution works very well when it is necessary to illuminate safety switches, fire extinguishers, or valves, or when mounting fixtures at an increased height. The latter solution allows the OptiLine to be used as a High-Bay fixture, meaning it does not require special constructions to lower the mounting point.
Benefits of using light concentrating lenses
- Lower installation costs: eliminating the need for High-Bay fixtures and additional structures leads to significant cost reductions in installation.
- Ease of use and maintenance: using a single type of lighting fixture throughout the space simplifies their installation and subsequent use and maintenance, increasing efficiency and work convenience.
More cable glands in the fixture
Optimized fixture housings often do not allow for the installation of more cable glands. This, in turn, limits the possibilities of connecting them into larger systems. Moreover, some fixtures allow for the installation of only one M20 gland or, worse, have a factory-installed power cable that must be connected to the power supply or other fixtures via a junction box. All of this unnecessarily complicates and increases installation costs.
Flexibility in mounting cable glands
The Ex OptiLine lighting fixture can accommodate up to four M20 or M25 cable glands (two on each side). This solution, combined with through cables and two electrical connectors placed at both ends of the fixture, allows for easy connection into larger systems without the need for expensive Ex junction boxes. Additionally, this approach reduces the consumption of power cables and cable trays, translating into lower overall installation costs.
Freedom of Cable Choice
Compatible with larger M25 cable glands
The ability to use M25 cable glands in the ATEX OptiLine lighting fixtures allows for the use of cables with a larger cross-section. This gives users the freedom to choose cable manufacturers and the possibility of using thicker, non-flammable cables, increasing flexibility in adapting the installation to specific needs.
Reduction of voltage drops
Moreover, thanks to the ability to use cables with a larger cross-section, voltage drops along their length can be reduced. This is especially important in the case of emergency lighting fixtures, where cables must withstand temperatures exceeding 600°C. As a result, lighting systems maintain their efficiency and reliability even in extreme working conditions.
Quick and safe installation
No loose parts
One of the main advantages of ATEX OptiLine fixtures for explosion hazard zones is their thoughtful design, which does not contain loose parts. The lamp cover and internal mounting plate with the LED module are equipped with hinges, eliminating the risk of dropping during installation and electrical testing.
Safe opening and installation
Opening the cover involves releasing metal latches on only one side of the lamp. To comply with the ATEX directive, the manufacturer must ensure that this is only possible with the use of a tool. However, to make this as easy as possible, the latches are designed to be easily opened with a single screwdriver motion. Moreover, they are integrated with the fixture, eliminating the risk of losing them.
If necessary, both the cover and clamps can be completely detached.
Easy access to electrical components
Opening the mounting plate, under which the electrical connectors are located, requires only the rotation of two screws. Thanks to a specially shaped screw head, this can be done by hand or with a screwdriver. Importantly, the screws are secured against falling out (so-called “non-drop screws”).
Increased convenience and safety
This configuration provides convenient and quick access to electrical components, including cable connectors, allowing for quick power connection. You can be sure that no part will accidentally fall during installation. This not only increases convenience by freeing your hands during installation but also enhances your safety. A lost screw during installation could not only contaminate the product being manufactured but also lead to equipment failure or, in extreme cases, pose a risk of generating mechanical sparks that could ignite an explosive atmosphere.
Cover options in LED EX OptiLine fitting
The LED Ex lighting fixtures from the OptiLine series offer a choice of three different covers, adapted to different applications:
- Transparent Cover: Suitable primarily for areas requiring high light output. It is often used outdoors or in large indoor spaces.
- Frosted Cover: Ideal for outdoor use when it is important to reduce glare or in indoor spaces requiring strong yet diffused light.
- Milk Cover: Provides pleasant, diffused light without glare and eye strain, making it the best solution for indoor spaces where workers are frequently or continuously present.
Variable light output in emergency lighting
Each ATEX OptiLine lighting fixture can be individually configured to emit different levels of light output in emergency mode. This feature increases flexibility in designing the lighting system and positively impacts installation costs.
Certificates and safety
OptiLine fixtures are ATEX and IECEx certified, ensuring their safe use in zone 21 and 22 (dust), as well as in zone 2 (gases and liquid vapors) in explosive environments.
Durability and resistance of OptiLine Fixtures
The high impact resistance of the fixtures has been confirmed by tests according to the PN-EN IEC 60079-0 standard. The fixture also has a high IP protection rating of 66/67. These features confirm the solid quality of the housing and cover, ensuring long-lasting and reliable operation.
Key Features of Durability and resistance
- Tests Compliant with PN-EN IEC 60079-0 Standard: The high impact resistance of the fixtures has been confirmed by rigorous tests, ensuring their resistance to impacts and other mechanical damage.
- IP66/67 Protection Rating: The high IP protection rating of 66/67 means that the fixtures are fully protected against dust and powerful water jets, making them ideal for operation in harsh and demanding conditions.
These exceptional features confirm the solid and durable nature of the ATEX OptiLine fixtures, guaranteeing their reliability and longevity in various industrial environments.
Versatility of EX LED OptiLine fittings
Primary and emergency lighting functions
The EX LED lamps from the OptiLine series can serve as both primary and emergency lighting fixtures, eliminating the need to install separate systems for these two functions. Emergency versions are available in two options:
- Ex Emergency Fixture Powered by a Central Battery (OptiLine CBX/CBY Model).
- Ex Emergency Fixture Powered by an Internal Battery (OptiLine A1 Model).
Wide range of light power
Basic ATEX OptiLine lighting fixtures, with emergency lighting capabilities, are available in two lengths (670 and 1276 mm) and offer six power levels: 20, 25, 30, 38, 48, and 58 W. Combined with three different cover transparency options, this provides a wide range of light output from 2,900 to over 10,000 lumens.