Cooper Crouse Hinds EVLS HAZARD-GARD Explosion proof Lamp Installation and Maintenance

EVLS HAZARD-GARD Explosion proof Lamp

The selection of lighting equipment is directly related to personnel life and facility safety in hazardous environments such as petrochemicals, offshore platforms, mineral mining, and heavy industry where explosive gases or dust exist. Crouse Hinds, as a globally renowned explosion-proof electrical brand under Eaton, has designed its EVLS HAZARD-GARD series of lighting fixtures specifically to meet the most demanding lighting needs in hazardous areas. This article is based on the official installation and maintenance manual (IF1505), providing a comprehensive analysis of the application scope, safety regulations, installation steps, and maintenance requirements of this series of lamps.

Applicable regions and certification standards

The EVLS HAZARD-GARD series explosion-proof lighting fixtures are suitable for the following hazardous areas (compliant with the National Electrical Code NEC and the Canadian Electrical Code CEC):

Class I, Division 1, Groups B (with GB suffix), C&D: Suitable for places where flammable gases or vapors are present.

Class I, Zone 1, Group IIB+H2 (with GB suffix): Complies with the International Electrotechnical Commission's zoning standards.

Class II, Class III, and coexisting environments: suitable for places with combustible dust, fibers, or fluff.

Damp and Marine Environment: Certified by UL1598 (Damp Environment) and UL1598A (Marine Environment), the protection level reaches Type 4X and IP66, which can resist water spray, corrosion, salt spray, and harsh weather.

The nameplate of the lamp indicates specific classification information, maximum ambient temperature, and corresponding temperature code (T-Code). Users must verify before installation to ensure that the working temperature of the lamp does not exceed the ignition point of hazardous gases.

Safety Warning and General Requirements

To ensure explosion-proof performance and personal safety, the manual repeatedly emphasizes the following core warnings:

Installation and maintenance personnel: must be certified electricians who strictly follow local electrical regulations for operation.

Power off operation: Before installation or maintenance, it is necessary to ensure that the power supply has been cut off.

Grounding requirements: The lighting fixtures must be reliably grounded through a grounding conductor, and it is strictly prohibited to use isolated hangers as grounding connections.

**Lamp cooling * *: Before replacing the lamp, ensure that it is completely cooled to prevent burns.

Explosion risk:

The power supply voltage must be consistent with the rated voltage of the lamp.

The working temperature shall not exceed the ignition temperature of hazardous gases.

The ambient temperature shall not exceed the nominal value on the nameplate.

The installation angle must ensure that the lamp base is facing upwards and deviates from the vertical direction by no more than 25 degrees.

All sealing gaskets must be clean and intact.

The type and power of lamp specified on the nameplate must be used.

The power must be turned off before turning on the lighting fixtures, and they must be kept tightly closed during operation.

Detailed installation steps

1. Preparation for installing modules

All installation module threads must be coated with Crouse Hinds HTL grease to prevent biting.

Determine the temperature level of the power supply wire based on the installation module nameplate.

2. External sealing requirements (key explosion-proof measures)

To prevent explosive gases from entering the lamp through the conduit, it is necessary to seal it within a specified distance. The sealing distances corresponding to different installation methods are as follows (Table 1):

Installation module type Group C&D Group B

EVSP lifting 10 ft (3 m) 18 in (45 cm)

EVSC Ceiling 5 ft (1.5 m) 18 in (45 cm)

EVSJ column mounted 10 ft (3 m) 18 in (45 cm)

EVSW Wall Mounted 10 ft (3 m) 18 in (45 cm)

EVSB Cabin Wall Installation Not Applicable Not Applicable

EVSA+EVMP lifting 18 in (45 cm) 18 in (45 cm)

EVSA+EV Ceiling Ceiling 18 in (45 cm) 18 in (45 cm)

EVSA+EVMJ column installation 18 in (45 cm) 18 in (45 cm)

EVSA+EV Wall Bracket Wall Mounted 18 in (45 cm) 18 in (45 cm)

EVSA+EVJ Cabin Wall Installation Not Applicable Not Applicable

3. Operation of various types of installation modules

Pendant: Screw the Pendant module into the conduit and tighten it with a wrench, tightening the locking screw to a torque of 40 lb in.

Column mounted module (Stanchion): Thread specification 1-1/2 NPT, apply lubricating grease and tighten with locking screw torque of 40 lb in.

Ceiling module: Use four 5/16 inch fasteners (not provided) to secure the module to the structure. After the conduit is screwed in, the unused conduit opening needs to be closed with the provided conduit plug.

Wall mounted module: secured with four 3/8-inch fasteners, conduit screwed in, not plugged with openings.

Bulkhead module: also secured with four 3/8-inch fasteners, with conduit screwed in.

4. Wiring steps

Unscrew two chrome plated screws and remove the wiring terminal block from the installation module.

Introduce the wires introduced on site into the module.

Connect the terminal block wires to the power cord according to the wiring diagram:

Connect the grounding wire to the green grounding wire in the module. If there is no independent grounding conductor in the system, the module grounding wire needs to be terminated or removed.

Connect the non grounded power cord to the black wire of the terminal block.

Connect the other power cord to the red wire on the terminal block.

All electrical connections must be securely fastened.

Reinstall the wiring terminal block back into the module and secure it.

The default factory voltage is 277V (unless otherwise ordered). If other voltages are required, disconnect the 277V ballast lead from the black factory connector, connect the lead with the required voltage, and seal the 277V lead with a crimping terminal.

5. Lamp installation and reflector/protective cover installation

Before installing the lamp, ensure its cooling and confirm that the type, power, and nameplate are consistent.

After installing the lamp, apply a small amount of HTL grease on the thread, screw the globe component into the ballast housing until it fits tightly against the O-ring, and tighten the screw.

Fully screw the lighting fixture into the installation module and tighten the screw with a torque of 40 lb in.

To install reflectors (RA725 corner or RD725 dome):

Remove the three screws from the globe casing.

Align the reflector with the housing hole.

Re tighten the screw.

If a protective cover needs to be installed at the same time, a reflector must be installed first.

To install a protective cover (P515 wire type or EV502 cast type):

Loosen the three fixing screws of the globe casing.

Wire type: Slide the protective cover ring under the screw head and tighten the screw.

Casting shape: Align the shield ring hole with the screw, rotate the shield to insert the screw head into the groove, and tighten the screw.

6. Power on

After completing all installation steps, the power can be turned on.

Lamp replacement and maintenance

Lamp replacement steps:

Disconnect the power and allow the light fixture to cool completely.

Loosen the screws that secure the globe component, unscrew the globe component, and remove the old lamp. If the globe is difficult to rotate, a straight screwdriver can be inserted into the lifting slot to pry it loose (see Figure 9).

Clean and inspect according to maintenance requirements.

Install new lamps of the same model, size, and power, and tighten them.

Thoroughly clean or replace the sealing gasket.

Apply a small amount of HTL grease on the threads, unscrew the globe component back into the ballast housing until it fits tightly against the O-ring, and tighten the screws.

Daily maintenance suggestions:

Regular inspection: Based on the environment and frequency of use, it is recommended to conduct a comprehensive inspection at least once a year, including visual inspection, electrical and mechanical inspection. A preventive maintenance plan can be established by referring to NFPA 70B Recommended Practice for Electrical Equipment Maintenance.

Cleaning: Regularly clean the globe, reflector, and protective cover to ensure lighting effectiveness. Wipe with a clean damp cloth. For stubborn stains, use neutral soap or liquid cleaners such as Collinite NCF and Duco # 7. It is strictly prohibited to use abrasives, strong alkalis or acid cleaners to avoid damage.

Electrical inspection: Check if the contact ring on the wiring terminal block of the installation module is conducting well. If there is surface contamination, gently polish it. Ensure that all connection points are clean and securely fastened.

Visual inspection: Check for signs of overheating (such as discoloration of wires or components), component damage, internal water ingress, or corrosion. If there are any damaged parts, they need to be replaced and the sealing surface cleaned before being put into use.

Mechanical inspection: Ensure that all components are assembled correctly.

On site assembly of lighting fixtures structure

The complete EVLS HAZARD-GARD lighting fixture consists of the following parts:

Lamp shell of ballast (including globe component)

Installation module (with multiple options such as lifting, ceiling mounting, column mounting, wall mounting, cabin wall mounting, etc.)

Optional: protective cover, reflector

Overview of Technical Parameters (50-175 W)

Light source type: High pressure sodium lamp (HPS) or metal halide lamp (MH)

**Lamp Base * *: Medium Base

Voltage options: 120, 208, 220, 240, 277, 480 V and multiple taps, etc

Protection level: Type 4X, IP66

Applicable environment: Class I, Div. 1, Groups B/C/D; Class I, Zone 1, Group IIB+H2； Class II/III； Ocean/Wet Place

Installation posture: Lamp base facing upwards, deviation from vertical ≤ 25 °