Cooper Lighting and Security issued a recall notice in August 2004 following the identification of a fault affecting 8, 8.4 and 16uF capacitors used in the manufacture of some Crompton light fittings. Following extensive research into the nature and scope of the fault, site based evidence and analysis of capacitor returns statistics it has become evident that a review of the recall notice is appropriate.

This safety warning notice supersedes the recall notice of August 2004.

Warning

We need to bring to your attention that a fault may develop in capacitors used in certain light fittings manufactured by Cooper Lighting and Security ltd in Crompton brand, JSB brand and in distributors' own brands.

The fault is not apparent during testing but appears after use. The fault can appear as a loss of capacitance, capacitors running hot, deformation of the capacitor case, smoking or in certain circumstances, the capacitor catching fire.

The incidence of capacitors catching fire is very low, but because of the risk attached to fire, this issue needs to be taken very seriously.

The majority of light fittings are constructed from metal, which encloses the capacitor. In the event of a capacitor fire, laboratory research and site based evidence has shown that the metal body contains the fire. It should be stressed that this only applies when the light fittings are correctly installed and are not attached to surfaces that promote the spread of fire or in flammable atmospheres (where specifically designed fittings should be used anyway).

Light fittings that have a Tpb rated plastic diffuser and no metal surface segregating the capacitor from the diffuser (for example recessed modular fittings), do represent a potential risk of the fire spreading beyond the capacitor. Light fittings that have a plastic housing also represent a (lower) potential fire risk in that the plastic housing may melt and expose the mounting surface.

Capacitors at risk

Analysis of capacitor returns has shown that the capacitors at risk are from a series of specific production batches during the period April 2003 to June 2004. All of the capacitors at risk are branded DNA and are of type LPPT.

Fittings at risk

The following fittings have been identified as having a capacitor which could lead to a building fire:

• Modulay fitted with Tpb prismatic diffusers
• Moduspec fitted with Tpb diffusers
• Moduseal fitted with Tpa diffusers
• Varsity (but not Varsity School or Varsity Hospital)
• Dulcet
• Iona
• Fairlite - where the fitting is mounted on a flammable surface that will support the spread of fire.

If a capacitor should fail in a fitting not identified in the above list it does not represent a safety risk.

Remedial Action

At the time of the initial recall Cooper Lighting and Security changed to an alternative capacitor supplier, froze and reworked stock in the supply chain to minimise the potential impact of the fault as a precautionary measure.

Stockists were contacted and asked to inspect their stocks and where appropriate return them for inspection and rework.

The recall generated a list of sites where suspect fittings had been installed. Almost all of these sites have now been investigated, visited and inspected and where appropriate the capacitors have been changed.

Some customers identified in the initial recall have not responded to warning notices, a final warning letter was sent requesting a response by the end of 2005 to allow the fittings to be traced and capacitors at risk replaced. This exercise is now complete.

A small quantity of additional fittings have been identified as possibly at risk, hence the reason for this issue of the safety warning notice. These are primarily three lamp 36w recessed modular fittings with plastic diffusers, Iona and JSB Fairlite. These are being traced through the distribution chain. Any fittings identified will be investigated and where appropriate the capacitors will be changed free of charge. The closing date for notification to Cooper Lighting and Security for this free service is 31st March 2006.

Cooper Lighting and Security ltd have taken a highly responsible stance since issuing the original recall notice in August 2004 and continue with that approach with this warning notice. Every effort has been made to trace suspect product and we have financed the changing of suspect product on site. In order to support our customers who discover a suspect product after 31st March 2006 we will not finance the checking of capacitors on site but will offer free of charge replacement capacitors on request.

Contact Details

The following help line has been set up to deal with issues relating to this Capacitor Safety Warning Notice.

Telephone: 01302 303999 or Fax: 01302 303349

Cooper Lighting and Security apologise for any inconvenience caused to its customers.