4
INSTALLATION INSTRUCTIONS FOR LOW PROFILE
CONVERSION KITS
COMMISSIONING AND ROUTINE TESTING
When you have completed the conversion, fill in the date of
commissioning in the space provided on the battery label.
The conversion invalidates any certification (e.g. kitemark/CE
safety mark), therefore all markings must be removed.
Note: it is the installer's responsibility to ensure the requirements
of the CE marking, LV and EMC directives are met.
Every month: Interrupt the unswitched live feed for a short
period to ensure that the emergency circuit is working.
OVERVIEW
Every 6 months: Three hour systems should be operated for at
least 1 hour and one hour systems for at least 15 minutes.
After 3 years then annually: The emergency circuit should
be operated for the full specified duration.
Conversion kits allow your existing fitting to provide up to 1
hour of emergency lighting in the event of a power failure.
They are easily installed within the existing fitting or in
specially designed external mounting enclosures.
BATTERIES
It normally takes 10 to 20 minutes charge to provide 1 minute
of discharge power from the battery.
Always use the approved high temperature Nickel Cadmium
batteries and store them between 0 and 25ºC.
The batteries should be replaced when the rated duration is no
longer achieved.
Warning: when disposing of batteries, do not pierce, incinerate
or short circuit them. The approved batteries contain cadmium
and must be disposed of correctly.
There are kits available for most types of four pin fluorescent
lamps, except those with an integral starter or ballast. If you are
in doubt as to which kit you require, our sales department will
be pleased to advise you.
PREPARATION
Before starting a conversion the light fitting must be removed
to a suitable working area away from unqualified personnel. It
is a false economy to do otherwise and you might contravene
current legislation. Check that the lamp which is to be used is
within the lamp power range as specified on the Convertalite
module.
You should have the following equipment to hand:
!
Standard electrical installation hand tools (screwdrivers,
pliers, wire strippers etc.).
! A multimeter.
!
Drills or sheet metal punches to provide holes to mount the
new components.
! An earth resistance and electrical strength measuring set
(maximum voltage 1500V AC).
! A thermocouple & meter or temperature sensitive labels
covering 45°C to 125°C.
! A thermometer to measure the ambient temperature.
! A variac for thermal testing.
To avoid wasting time or money and to comply with current
legislation it is important to take a few moments to plan your
conversion and to follow the instructions given in this leaflet.
It is also recommended that you follow the requirements of
EN598-1, EN598-2.22 and EN55015.
The replacement battery part number is on the battery label.
In most cases, installation of a conversion kit will invalidate the
manufacturers guarantee and it is the responsibility of the
installer to comply with the CE marking, low voltage and EMC
directives. Should this be of concern, please contact our sales
department who will be able to advise on our fitting service.
TECHNICAL SPECIFICATIONS
Lamp Size
Diameter
Watts
TLD18
TLD36
TLD58
TLD70
TLD100
mm
600
1200
1500
1800
2400
PLS7
PLS11
PLL18
PLL24
PLL36
PLL40
PLL55
2D10
2D16
2D28
2D38
PLC10
PLC18
PLC26
-
T8
T8
T8
T8
T8
2G7
2G7
2G11
2G11
2G11
2G11
2G11
GR10q
GR10q
GR10q
GR10q
G24q
G24q
G24q
BQH1
BALLAST
LUMEN
FACTOR
0.20
0.20
0.28
0.20
0.30
0.26
0.18
0.20
-
CQH1
BALLAST
LUMEN
FACTOR
0.32
0.20
0.12
0.24
0.26
0.20
0.46
0.26
0.20
0.32
0.26
If a previously installed light fitting is to be converted, any
components showing signs of degradation should be replaced.
It is also recommended that all internal wiring should be
renewed using high temperature (90ºC) PVC cable or the
type originally specified if it has a higher rating.
COMPONENT LAYOUT GUIDELINES
Mains input voltage: 230 V +6% / -10%, 50 Hz
Power consumption: max. 5 VA, cos phi 0,96 ind.
Recharge period: 24 hours
The conversion kits are best installed inside the light fitting,
usually requiring the repositioning of existing components
(i.e. ballast, starter and PFC capacitors).When installing inside
the fitting:-
Space & temperature restrictions may require remote mounting of
the batteries or the complete conversion kit in a special enclosure.
If this is necessary, it is not as important to take into account the
component temperatures but you should note the following:-
Charge indicator: red LED with cable 1 m
!
System mode: maintained or non-maintained
Normal light output (maintained mode): full rated output of
lamp / ballast combination
!
!
!
Dimensions L x W x H: 216 x 39 x 30 mm
Fixing centers of module: 203 - 208 mm
!
Do not obstruct cable entries, mounting facilities, lighting
controllers or covers.
Do not locate the batteries or capacitor near excessive heat
sources, e.g. ballast's and lamp ends.
The module should be placed as close as possible to the
ballast to keep wires short, while being far enough away to
prevent overheating.
Ensure your layout doesn't interfere with the essential
safety features of the fitting such as shrouding,earthing etc.
!
!
!
The cable to the fully remote enclosure must not exceed 2m.
If mounted more than 1m from the light fitting, the remote
enclosure must be connected using fire proof cable.
Battery leads must be as short as possible, and the total
resistance of the battery lead must not exceed 0.5 ohms.
The LED indicator should be mounted within the light fitting or
remote enclosure where is it clearly visible during normal
operation (mounting requires 6.5 mm hole).
IMPORTANT:
These conversion modules are suitable only for use with the 4pin versions of the lamps listed here, and can NOT be used with
other (amalgam) lamps such as TL5 (T 5) and PLT (Dulux T).
Convertalitegrbsl-v9
15-03-2006
3
2
MAIN INPUT / BATTERY INPUT AND LED CONNECTIONS
GENERAL WIRING GUIDELINES
! Mains wiring must exit fitting from nearest entry/exit point.
! Keep all cables 40mm away from the lamps. This distance
is less important if separated by an earthed metal reflector.
! Lamp wires should be segregated from the mains, battery
and LED wiring. Ideally, a distance of 40 mm is needed
between the lamp wires and other wires.
! If lamp wiring has to be crossed with mains, battery or
LED wiring, it must do so at right angles.
Refer to the diagrams below for typical wiring connections and
observe the following guidelines:
! Always use high temperature 90°C PVC cable (or a higher
grade as originally used in the light fitting).
! All metal work within an earthed fitting MUST be securely
earthed, including reflectors and louvres.
! Keep cables as short as possible, especially Electronic
Ballast
‘Hot’ wires (shown as shortest on ballast diagram).
! Connect the red battery wire to the '+' terminal on the
module and the black battery wire to '-/W'.
! Connect the yellow LED wire to the terminal marked ‘Y’,
and the white LED wire to the terminal marked ‘-/W’.
! Connect the mains neutral to terminal 'N' and connect the
unswitched live to terminal 'L’.
! Connect the switched live supply to the 'L2 IN' terminal on
the module and connect the 'L2 OUT' terminal on the
module to the live terminal of the ballast.
! Ensure the light fitting is securely earthed.
Note: Make sure that the terminals on the module cannot be touched
when changing the lamp or starter by shrouding them with earthed
metal or thermoplastic insulation.
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BATTERY NEG LEAD (BLACK)
AND LED LEAD (WHITE)
USE THE SAME TERMINAL
MAX CABLE DIA. :-2.50mm
LAMP GEAR CONVERSION - TYPICAL WIRING CONNECTIONS
TESTING THE CONVERSION
Carry out the tests below to check that all components are
operating within their prescribed temperature limits.
1. Carry out electrical tests to check safety and operation.
2. Attach thermo-couples or temperature sensitive labels to all
main components (listed in table below).
3. Mount the fitting as it would normally be installed and as
close to its maximum ambient temperature as possible.
4. Apply maximum mains voltage (e.g. 230V+10%)
to switched and unswitched supplies for 30 hours.
5. Switch off and check that the fitting operates on emergency
for its specified duration ( 1 hour).
6. Examine the temperature labels or record maximum
temperatures from thermo-couple readings and compare
with table below.
7. The maximum recorded temperatures must be either below.
component (if marked). If the ambient temperature during
testing was different to the maximum ambient rating add
the difference to the recorded temperature.
Choose the lamp to be used as emergency lamp.
Lamp
Cut the four wires of this lamp.
Lamp
Connect the eight wire ends according to the numbers to the right side of the unit.
8
1
7
2
3
6
4
5
+
_
Battery pos (red)
Y
Led (yellow)
L1
Unswitched live 230V/50Hz
N
Battery neg (black) / Led (white)
Unswitched neutral
L2 in
Switched live in 230V/50Hz
L2 out Switched live out
TEMP TEST POINTS
Lamp
CONVERTALITE
CQH1
Duration 1 hour
Battery type
4,8 V 4 Ah NiCd
Lamp: 18 - 58W
Max. temperature
75 C at test points
Tube
WARNING: MAXIMUM
VOLTAGE 1.5KV
See instruction
leaflet
1
2
3
4
5
6
7
8
2
Component
Ballast
Capacitor
Battery
Convertalite module
External parts of light fitting
that may be touched
External parts designed to
be gripped
PVC cables
90°C rated PVC cables
Thermoplastics
Max. Operating Temp °C
85 (95 if paper interleaved)
50
54
50
70 (or 85 if not metal)
60 (or 75 if not metal)
70
90
If all the component temperatures are within their ratings, you
can convert the rest of the fittings in the same way (providing
they are of the same type). Conversion module temperature
range 'Ta': 0°C - 40°C.
Electrical Tests
Earth Continuity:- Test earth resistance between the earth
terminal and all metal parts exposed during normal use
or when changing the lamp. Resistance must be less than
0.5 ohms at 10 Amps.
Electrical strength:- Test the electrical strength between the
neutral and live terminals bonded together and the earth
terminal. Use a test voltage of 1500V AC(50/60Hz) and ensure
there is no breakdown. Do not use a Megga after installation as
the components may be damaged. Use a suitable flash test with
an output of up to 1500V.
Testing an Installed Fitting
1. Connect mains voltage to the unswitched live supply and
ensure that the LED is lit.
2. Connect mains voltage to the switched and unswitched live
supplies and check that the lamp lights correctly.
3. Apply mains supply to the unswitched live for a minimum
of 10 minutes. Disconnect the supply and check that the
emergency lamp lights.(LED not lit.)
4. It is recommended that a full duration test is carried out
by applying the mains supply for 24 hours and ensuring
The emergency lamp operates for the specified duration.
If any of the above tests fail, repeat them after a full 24 hour
recharge period and then restore the supply and check the LED
indication to make sure the battery is charging.