Hella. Mining Catalogue. 4th Edition

Transcription

1 Hella Mining Catalogue 4th Edition

2 Hella Australia Pty Ltd ABN Southern Road Mentone Victoria Australia 3194 PO Box 89 Mentone Victoria Australia 3194 P F E mining@ha.hella.com W Customer Service: P F P Techline E custservice@ha.hella.com Expert professional advice from our technical department staffed with qualified personnel Product availability and new product updates Customer-specific lighting applications engineering service International Regions Africa Hella Automotive South Africa (Pty) Ltd 1 Fitzpatrick Street Uitenhage South Africa 6232 Phone: +27 (0) Asia Hella Asia Singapore Pte Ltd Regional Headquarters Asia Pacific Independent Aftermarket 2 International Business Park #02 15 The Strategy Singapore DID: USA Hella Mining LLC 1250 Lamollie Hwy Suite 414 Elko Nevada Fax: (775) Phone: (775) Canada Hella, Inc. 201 Kelly Drive Peachtree City, GA Phone: (770) Fax: (770) Mexico & South America Hellamex, S.A. de C.V. Proten No. 50 Parque Industrial Naucalpan Estado de Mexico, Mexico C.P Phone: (52) New Zealand Hella-New Zealand Limited PO Box Ben Lomond Crescent Pakuranga, Auckland 1706 Telephone: (09) Fax: (09) Internet: Europe Hella KGaA Hueck & Co. Rixbecker Straße Lippstadt/Germany Internet: Telephone: +49 (0) 29 41/38-0 Fax: +49 (0) 29 41/ The illustrations, information and specifications presented and referred to in this catalogue were correct at the date of printing. However Hella reserves the right, subject to all applicable laws, at any time, at its discretion and without notice, to discontinue or change the specifications or design of any product referred to herein. The data and suggested applications are given as a general guide only and users should independently evaluate the suitability of each product for any particular application Hella Australia Pty Ltd. All rights reserved. Release Date November 2010

3 Hella Centre of Excellence Mining 3 Mining Centre of Excellence Hella Australia manufactures automotive lighting equipment, and plastic mouldings and accessories, and employs approximately 500 people. Its facility in Mentone, Victoria, designs, develops and manufactures a range of lighting products including headlamps, reflectors, lenses, signal lamps, interior and exterior lighting, and auxiliary lamps and mouldings. Hella products are developed and built using state-of-the-art technology and are used on some of the most advanced cars in the world. The Hella manufacturing plant employs injection moulding machines, polycarbonate lens moulding machines, thermoset moulding machines, automated paint processes, hot foil stamping, aluminium metallising and lacquering facilities. The Hella Centre of Excellence Mining, at Hella Australia head office in Mentone Victoria, was launched in 2002 to drive a global mine lighting program focussed on the unique requirements of mining. The key factors in the Australian location of this important business are: Over 1280 mines operate under the most stringent safety requirements, so Australia is the best place to develop and prove products for the global mining industry Hella Australia is equipped with highly advanced production and distribution facilities Hella Australia has its own full design and development facilities that include: NATA registered Photometric Laboratory, Chemical Analysis Laboratory Facilities, and some of the most advanced environmental and physical test simulation facilities available anywhere. Hella continues to develop, prove and market innovative products based on worldwide leadership in advanced lighting technology to demonstrably improve end user profitability in mining applications. This is achieved through products that offer: Greater safety Lower operating cost Greater productivity Predictable service Better value Hella mining products are backed by the renowned global Hella quality guarantee, and service and distribution network. Project Argon charts the extremes Developing lighting equipment that will go the distance in mines requires a very clear understanding of their operating systems and specific environmental conditions. At Hella, we don t guess, we measure. Hella Australia initiated ARGON, a research project to collect detailed data from a diverse range of mines and machines. A suite of robust sensors with integrated data loggers is mounted on mining plant and machines to record operating conditions, with the equipment working as normal. After the sensors are recovered from the machines, their data is downloaded for analysis and used as the basis of product design and test specifications able to match extreme mining environments. Statement of Warranty Hella Mining products are covered by a one year warranty which covers faults in material or workmanship only and provided that the product is used for its intended purpose. Important Note Only products specifically identified as ECE or SAE compliant are approved for use on public roads, when installed and operated as required by local regulation on approved vehicles. The responsibility for correct selection, fitment and operation to meet local regulations is that of the vehicle operator.

4 4 How to read this catalogue Key to symbols: Hella Product Features Configuration: Electrical: Protection/Hazard Ratings: Standards Compliance: MULTI VOLT Multivolt H3 Lamp type 24V Rated voltage IP6K IP rating Electrical Compliance MUSTADD MustADD DT Connection type 3W Power consumption/load Transient spike protection ECE APPROVED Public road traffic compliance type DRACO DRACO 1.4Kg Mass 200G Rated shock resistance MULTI FLASH MultiFLASH Hella Mining Part Numbers 12V H3 24V H3 Wide Beam HM1524WB HM1526WB Narrow Beam HM1524NB HM1526NB Long Range HM1524LR HM1526LR MINING WORK LAMPS Page number Product section MOBILE WORK LAMPS EQUIPMENT LIGHTING 28 UltraBeam FF Halogen Work Lamp 12/24V UltraBeam FF Halogen, available with Wide, Narrow and Long Range Beams, are superior, compact heavy-duty work lamps for use on mining machinery, and suitable for both 24V and 12V electrical systems. Product dimensions Alternative view Alternative model Spare parts or options Front View, Long Range Narrow Beam As part of our ongoing development the Long Range addition to the UltraBeam FF range applies our most recent advances in free-form (FF) reflector technology. With a clear lens and the popular H3 Halogen globe it s a compact long range lamp for applications where the performance of a Xenon light is not required. The very compact optics deliver excellent lighting under continuous use in the extreme environmental conditions encountered in mining applications. Electrical connection is via integrated DT connector. The UltraBeam FF clear lens long range optical insert is a modular assembly of a precision die-cast specular reflector with integral lamp holder, permanently assembled to a corrosion resistant hardened clear glass lens, for high efficiency and perfect focus. The new lens long range optical insert is available as a spare part and is 100% compatible with older UltraBeam FF H3 work lamps to enable simple on site maintenance and perfect retrofitting. In common with the all Hella UltraBeam FF work lamps, the basic version of the patented MustADD filter is included so the optical system remains virtually dust free over the product life, in the adverse atmospheres typically encountered in mining. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. The UltraBeam FF features integral DRACO dampers in the bracket system to reduce the intensity of shock and vibration. The UltraBeam FF family is based on very compact lamp housings moulded from a highly corrosion resistant, heavy-duty polymer body. A lens retaining ring enables easy routine service access from the front, while high temperature O-ring seals ensure effective sealing. Long Range Lens Product features: Powerful long range and wide spread illumination AMP or DT electrical connection Robust polymer body Stainless steel mounting bracket Draco suspension MustADD multi air-filter Specifications: Temperature Range -40 C to +105 C Mounting Single bolt with tilt adjustment for upright, side or pendant mounting on horizontal or vertical surfaces. Stainless steel bracket and screws included Free-form (FF) reflector for powerful long range illumination Components tested over a 40 C to +105ºC temperature range IP6K7 O-ring seals Clear protective covers available Protection Sealed against dust and moisture to IP6K7. Shock resistant to 50G. HM8158 HM8158AMBER Spare parts or options listing Product feature symbols (see above for key) MUSTADD DRACO H3, H9, H11 IP6K7 50G 12/24V DT & AMP 70W MAX 0.8Kg Spare Parts: HM8158 Clear Protective Cover HM8158AMBER Clear Protective Cover - Amber Long Range Insert 9.HMUBHNB Insert Narrow Optic 9.HUMBHWB Insert Wide Optic YC2470 H3 Globe, 24V 70W YC1255 H3 Globe, 12V 55W

5 Contents 5 WORK LAMPS 6 8 Power Beam DuraLED Magnetic Base 28 UltraBeam FF Halogen 9 Power Beam AS500FF Xenon 30 HydroLUX 10 Megabeam 18 AS200FF Xenon 32 AS200 FF Halogen 11 Module 70 LED 20 UltraBeam FF X-PowerPack 34 Oval 100 FF Halogen 12 LED Task Lamps 22 UltraBeam FF Xenon 36 Module 70 Halogen 13 DuraLED 700 Lumen 24 Oval 100 FF Xenon 14 DuraLED 1000 Lumen 26 AS500FF Halogen BEACONS DuraRAY Phase II 48 OptiRAY 54 DuraLED M High Intensity 42 UltraRAY-R Twin 50 OptiRAY E 56 PulseRAY KLX 44 UltraRAY-R Rotating 52 MiniRAY 58 PulseRAY E67 46 UltraRAY 53 NaviLED M SIGNAL LAMPS DuraLED SAE 64 DuraLED M Combi 66 DuraLED Marker 63 DuraLED ECE 65 DuraLED MSIP 67 LED Daytime Running Lamp ACCESSORIES LED Buggy Whip 74 NumiLED 80 Weatherproof Relay 71 Remote Jump Start Terminals 75 NumiLED Pro 80 Self-Amalgamating Tape 71 Battery Master Lockout Switch 76 IR Dual Camera System 81 DT Connectors 72 Screened Extension Cables 77 Quad Screen IR Kit 73 HD Screened Ext. Cables 78 AccuPAX 84 EuroLED Touch M 86 SpotLED 89 MiniThinLED 85 CargoLED 88 FlexSPOT INTERIOR LIGHTING MotoVOX 94 RetroVOX Compression Driver 93 RetroVOX Self Adjusting 95 RetroVOX Broadband HORNS & ALARMS EziPAK DT Connector Kit 102 EziPAK Heat Shrink Kit 106 Super Seal Connector 100 EziPAK Double Crimp Kit 104 EziPAK Intelligent Fuse Kit 107 PowerPAK SERVICE TOOLS AC/DC Transformers 113 LED Pilot Lamps 116 MagCode 111 Power Connectors 114 Heavy Duty Circuit Breakers 112 LED Rocker Switches 115 Thermal Circuit Breakers ELECTRICAL H1, H2 122 H4 124 Xenon 121 H3 123 H7, H9, H11 GLOBES Technical Information 145 Part Number Index TECHNICAL 126

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7 Work Lamps 7 WORK LAMPS 8 Power Beam Power Beam Megabeam 11 Module 70 LED 12 LED Task Lamps 13 DuraLED 700 Lumen 14 DuraLED 1000 Lumen 15 DuraLED Magnetic Base 16 AS500FF Xenon 18 AS200FF Xenon 20 UltraBeam FF X-PowerPack 22 UltraBeam FF Xenon 24 Oval 100 FF Xenon 26 AS500FF Halogen 28 UltraBeam FF Halogen 30 HydroLUX 32 AS200FF Halogen 34 Oval 100 FF Halogen 36 Module 70 Halogen

8 Power Beam 1000 LED Work Lamp HMPB100 LED WORK LAMPS WORK LAMPS 8 Power Beam 1000 LED Work Lamp Multivolt 9-33V DC As an addition to the Hella LED work lamp range, the Power Beam 1000 has been developed as a compact high-powered illuminating source By combining 6 high-powered LEDs into a compact fully sealed die cast housing, the Power Beam 1000 provides a respectable 850 Lumen output to provide close range illumination where physical constraints on mining machinery exist. A rated operating temperature from -40 to +50 C and an expected lifespan of over 130 times that of a halogen bulb, in addition to excellent ingress protection, make the Power Beam 1000 suitable for the most unforgiving mining environments. With a low power consumption of 18 Watts, the lamp places minimal strain on the vehicle s electrical system while the quality electronics provide Multivolt operation over a range of voltage levels from 9 to 33V DC. The Power Beam 1000 also features reverse polarity protection, and overheating protection, which turns the light off when the integrated thermal sensor is triggered. The integrated DT Plug allows simple installation and waterproof connectivity, and the heavy-duty stainless steel bracket allows for a wide variety of mounting options. The low EMC signature ensures the lamp does not interfere with any critical safety equipment such as radios or other electrical devices. Product features Operating voltage: Multivolt 9-32 V DC 16 high power LEDs Power consumption: 18 W Light output 850 lm Colour temperature 6500 K Low EMC Signature (CISPR25 class 5) Ingress Protection IP6K7 and IP6K9K Lifespan up to 130 times of a halogen bulb Connection: integrated DT plug Polarity protected LED fail bridge High-temperature protection Environment temp -40 to +50 C Power Beam 1000 LED 2.0m high at 10 1 LUX 39m MULTI VOLT LED 0.6 Kg 9 to 33 V DC 18W IP6K7 IP6K9K 200G

9 Power Beam 2000 LED Work Lamp HMPB200 LED WORK LAMPS Power Beam 2000 LED Work Lamp Multivolt 9-33V DC As an addition to the Hella LED work lamp range, the Power Beam 2000 has been developed as a compact high-powered illuminating source. 9 WORK LAMPS By combining 16 highpowered LEDs into a compact fully sealed die cast housing, the Power Beam 2000 is able to achieve an outstanding 2200 Lumen output to provide close range illumination where physical constraints on mining machinery exist. With a low power consumption of 43 Watts, the lamp places minimal strain on the vehicle s electrical system, while the quality electronics provide Multivolt operation over a range of voltage levels from 9 to 33V DC. The Power Beam 2000 also features reverse polarity protection, and overheating protection, which turns the light off when the integrated thermal sensor is triggered Product features Operating voltage: Multivolt 9-33 V DC 16 high power LEDs Power consumption: 43 W Light output 2200 lm Colour temperature 6000 K Low EMC Signature (CISPR25 class 5) Environment temp -40 to +50 C Die cast aluminium housing, bracket made of stainless steel Ingress Protection IP6K7 and IP6K9K Lifespan up to 130 times of a halogen bulb Connection: integrated cable Polarity protected LED fail bridge High-temperature protection With a rated operating temperature from -40 to +50 C and an expected lifespan of over 130 times that of a halogen bulb, in addition to excellent ingress protection make the Power Beam 2000 suitable for the most unforgiving mining environments. The Power Beam 1000 comes pre-wired with 1.8 metres of electrical cable, allowing quick and easy installation. The low EMC signature (class 5) ensures the lamp does not interfere with any critical safety equipment such as radios. MULTI VOLT LED 1.4Kg 9 to 33 V DC 43W IP6K7 IP6K9K 200G

10 MegaBeam LED Work Lamp LED Work Lamp DT HM1539LED HM1539LDD MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 10 MegaBeam LED Work Lamp Multivolt 12-24V Hella MegaBeam LED is a compact close range work lamp for use on special vehicles and mining machines where high vibration or extreme cold makes the use of conventional work lamps impractical. High intensity white LEDs provide low power illumination in an ultra reliable design. Front View Clear cover to be ordered separately Solid-state LED light sources enabled the design of a fitand-forget, completely sealed and waterproof work lamp that needs no service. The very long service life of the MegaBeam LED, combined with no lighting loss due to internal dirt build-up, enables the work lamps to deliver reliable lighting under extremely tough operating conditions. Low power consumption and Multivolt operation features pioneered by Hella LED products are integral to the product design. Brilliant Free-Form reflector optics, combined with a clear lens, optimize the light distribution of the high intensity white LEDs in the MegaBeam LED work lamp to provide homogenous large area illumination with maximum efficiency. Maximum service life and light output of the high intensity LEDs is ensured through using the die cast aluminium body as a massive heat sink; its ergonomic oval shape creates an efficient and compact unit, easy to fit into confined spaces. Fully encapsulated Multivolt drive circuitry delivers consistent illumination from 12-24V DC even under severe voltage fluctuations and low battery voltage. Comprehensive protection against reverse polarity, highvoltage spikes and over-voltage, ensures reliable operation. Safe and reliable electrical connection is facilitated via a 2m length of highly flexible double insulated cable, terminated with either a DT connector or bare wire ends. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. Product features Yellow ring marks product as mining specification version Electrical connection: 2m double insulated cable with bare wire ends or short length with DT connector Stainless steel mounting bracket IP5K9K Multivolt 12V DC to 24V DC Die cast aluminium body Multi stage anticorrosion powder coat High visibility yellow identification ring source array Fully sealed Fit and Forget design Pre-wired with multi strand double insulated cable Spike protected to +500 volts Over voltage protected to +200 volts Reverse polarity protected to -500 volts Power consumption 7W 200G shock impulse resistant -40ºC to +50ºC temperature range CE compliant Clear glass lens High intensity LED light Spare Parts & Options HM8161 Clear Protective Cover MULTI VOLT LED DT & AMP 0.8Kg IP6K9 200G 12 to 24 V DC 7W

11 Module 70 LED LED Work Lamp DT HM70LEDD MINING WORK LAMPS Module 70 LED Work Lamp Multivolt 12-24V 11 WORK LAMPS Module 70 LED is an ultra compact LED work lamp for use on mining support function vehicles or in applications where mounting space is limited. The lamp provides uniform close-range illumination with 12V or 24V electrical systems. High intensity white LEDs provide energy efficient illumination in an ultra reliable design. Product features 4 high-performance LEDs Warm white light output (colour temperature 6500 K) 200mm double insulated cable harness with DT connector Low power consumption Multivolt 12-24V DC Specifications Voltage Multivolt 12-24V DC Power Consumption 15W Mounting Stainless steel pedestal bracket for upright, side or pendant mounting. Cable 200mm double insulated cable harness with DT connector. High-sheen free-form (FF) reflector Aluminium die cast housing Modern clear glass lens Resistant to shock and vibration IP6K7 & IP6K9K Reverse polarity and over voltage protected Stainless steel mounting bracket Temperature Range -40 C to +50 C Protection Reverse polarity and Transient Voltage Suppressor (TVS). Fully sealed against dust and moisture to IP6K7 and IP6K9K. Shock resistant to 200G. Module 70 LED work lamps utilise advanced materials in a unitary design that directly bonds a cast aluminium free-form (FF) reflector, clear glass lens and high temperature polymer housing into a low mass, efficient and very compact work lamp. Solid-state high-performance white LED light sources enabled the design of a fit & forget, completely sealed work lamp that requires no service. The very long service life of the Module 70 LED, combined with no lighting loss due to internal dirt build-up, enables the work lamps to deliver reliable lighting under extremely tough operating conditions. Low power consumption and Multivolt operation features, which have been pioneered by Hella LED products, are integral to the product design. Brilliant free-form (FF) reflector optics combined with a clear lens optimise the light distribution of the high intensity white LEDs in the Module 70 LED work lamp to provide and even illumination with maximum efficiency, reduced scatter losses and improved beam control. Maximum service life and light output of the high intensity LEDs is ensured through using the die cast aluminium body as a massive heat sink; its ergonomic Module 70 LED 2.0m high at 10 shape creates an efficient and compact unit, easy to fit into confined spaces. Module 70 LED work lamps have been tested to withstand extremely high levels of vibration and mechanical shock, and are highly suitable for use in applications where extreme cold and mechanical stress make other work lamps unsuitable. The low power consumption and compact size also renders Module 70 LED work lamps suitable for use inside confined spaces, with portable power packs, on new generation small equipment based on recreational vehicles, battery powered vehicles and to illuminate the equipment bays on site service vehicles and large machinery. The Module 70 LED features a rotating base as standard, which allows vertical adjustment of + 48 to -115, and 360 rotation adjustment. The supplied stainless steel hardware is non-resonant and highly corrosion resistant. Safe and reliable electrical connection is facilitated via 200mm length of highly flexible double insulated cable, terminated with a DT connector. Optional pipe mount adaptors with and without rotating adjustment is available. Additional variants of the Module 70 LED are available on special request M10 Front view HM70PR Ø HM70PI 75 Spare Parts & Options HM70PR Pipe mount tube attachment (rotating) HM70PI Pipe mount tube attachment 9.HM70BR Stainless steel bracket 1 LUX 37m MULTI VOLT IP6K7 LED 200G DT 12 to 24 V DC 0.4Kg 15W

12 LED Task Lamp Narrow Beam Pencil Beam Wide Beam HM1535NB HM1535PB HM1535WB LED TASK LAMPS WORK LAMPS12 LED Task Lamp On mine sites visibility is paramount to mine safety. Hella has just launched a low power LED Task Lamp that provides extra safety through enhanced visibility, at a fraction of the power consumption of halogen or HID light fittings Hella LED Task Lamps are designed to provide an illuminating light source in a compact, low power draw package for various applications where low profile fitting and even illumination is required. The lights are sealed to withstand high-pressure washing and require no maintenance ( fit and forget ). The lower power usage and no-maintenance requirement, make these lamps a sound investment in enhanced mine safety. The lens is manufactured from Swiss made Grilamid Optical Nylon which provides superior resistance to UV and to a wide range of chemicals, as well as high impact strength enabling the lamp to survive the highly demanding environmental conditions of today s mining. The new Hella Task Lamps are suitable for upright or pendant mounting and supplied with universal stainless steel mounting brackets. They have multiple applications, which include area illumination around and inside the vehicle. Product features Multivolt (9-33V DC) Equipped with 12 highly efficient LEDs rated at 240 Lumens Ultra long life Fit and Forget Low power consumption <3 Watts Stainless steel universal mounting bracket Polarity protected Spike and overvoltage protection Long term UV resistant Pre-wired with 2.5 metres of 2 x 0.75mm² automotive cable Fully sealed against dust and high-pressure water jets Homogenous close range illumination Inbuilt thermal management protection Narrow Beam Optic HM1535NB Pencil Beam Optic HM1535PB Wide Beam Optic HM1535WB MULTI VOLT LED BARE WIRE 0.35Kg IP6K7 IP6K9K 9 to 33 V DC 3W

13 DuraLed 700 Lumen White LED Service Lamp Wide Beam HM15700WB Narrow Beam HM15700NB Pencil Beam HM15700PB MINING LED SERVICE LAMPS DuraLed Hella has developed a new range of universal, high intensity and ultra energy efficient DuraLed LED Service Lamps offering the industry benchmark highest efficacy for a variety of heavy-duty mine lighting applications. 700 Lumen White LED Service Lamp Multivolt 9-33V DC 13 WORK LAMPS Product features Industry benchmark highest efficacy 36 LEDs rated to a total of 700 lumen per lamp Multivolt 9-33V DC Power consumption <9W Ultra durable Grilamid nylon lens for extreme impact, UV, chemical and stress resistance Efficient, low temperature LED circuit design ensures ultra long life and low degradation of performance Available with wide, narrow and pencil beam precision optics offering a variety of beam patterns Pencil Beam model shown Intense white light output provides enhanced work safety and reduced fatigue Pre-wired with 2.5 metres connecting cable Reverse polarity, spike and over voltage protection Fully sealed to IP6K6 and IP6K7 Resistant to vibration and shock EMC compliant 2-hole surface mount (screw caps & mounting bushes included) LED lighting offers a number of decisive advantages over conventional globe technology that are beneficial for mining work area lighting. The new Mining DuraLed High Efficacy LED Service Lamps consume as little as 9 watts of power for minimal strain on both alternator and battery. In addition to significantly reduced current draw, the highly efficient, low temperature LED circuit design ensures ultra long service life and extremely low degradation of performance. Equipped with precision optics and the most powerful LEDs available to date, DuraLed High Efficacy LED Service Lamps provide exceptional white light output and optimum light distribution for significantly improved work safety and reduced fatigue. DuraLed High Efficacy LED Service Lamps also offer superior functional safety and operating reliability. Unlike Halogen globes, LEDs are resistant to shock and vibration and last a minimum of 10,000 hours, eliminating the risk of sudden light failure during lamp operation. The lens is manufactured from ultra-durable Grilamid nylon, a revolutionary high-performance clear polyamide developed and manufactured in Switzerland for extreme impact, UV, chemical and stress resistance. DuraLed High Efficacy LED Service Lamps are fully sealed against dust and moisture ingress and available in a range of output intensities and beam patterns: narrow, pencil and spread beam, to suit every individual mine lighting requirement DuraLed 700 Lumen Wide Beam 2.5m high at 0 DuraLed 700 Lumen Narrow Beam 2.5m high at 0 DuraLed 700 Lumen Pencil Beam 2.5m high at MULTI VOLT LED DT & BARE WIRE 0.5Kg IP6K7 200G 9 to 33 V DC 9W

14 DuraLed 1000 Lumen White LED Service Lamp Wide Beam HM1550WB MINING LED SERVICE LAMPS WORK LAMPS 14 DuraLed 1000 Lumen White LED Service Lamp Multivolt 9-33V DC Hella has developed a new range of universal, high intensity and ultra energy efficient DuraLed LED Service Lamps offering the industry benchmark highest efficacy for a variety of heavy-duty mine lighting applications LED lighting offers a number of decisive advantages over conventional globe technology that are beneficial for mining work area lighting. The new Mining DuraLed High Efficacy LED Service Lamps consume as little as 9 watts of power for minimal strain on both alternator and battery. In addition to significantly reduced current draw, the highly efficient, low temperature LED circuit design ensures ultra long service life and extremely low degradation of performance. Equipped with precision optics and the most powerful LEDs available to date, DuraLed High Efficacy LED Service Lamps provide exceptional white light output and optimum light distribution for significantly improved work safety and reduced fatigue. DuraLed High Efficacy LED Service Lamps also offer superior functional safety and operating reliability. Unlike Halogen globes, LEDs are resistant to shock and vibration and last a minimum of 10,000 hours, eliminating the risk of sudden light failure during lamp operation. The lens is manufactured from ultra-durable Grilamid nylon, a revolutionary high-performance clear polyamide developed and manufactured in Switzerland for extreme impact, UV, chemical and stress resistance. DuraLed High Efficacy LED Service Lamps are fully sealed against dust and moisture ingress and available in a range of output intensities and beam patterns: narrow, pencil and spread beam, to suit every individual mine lighting requirement. Product features Industry benchmark highest efficacy - 50 LEDs rated to a total of 1000 lumen per lamp Multivolt 9-33V DC Power consumption < 12W Ultra durable Grilamid nylon lens for extreme impact, UV, chemical and stress resistance Efficient, low temperature LED circuit design ensures ultra long life and low degradation of performance Wide beam precision optic for optimum light distribution Intense white light output provides enhanced work safety and reduced fatigue Pre-wired with 2.5 metres connecting cable Reverse polarity, spike and over voltage protection Fully sealed to IP6K6 and IP6K7 Resistant to vibration and shock EMC compliant 2-hole surface mount (screw caps and mounting bushes included) DuraLed 1000 Lumen Wide Beam 2.5m high at MULTI VOLT LED DT & BARE WIRE 0.7Kg IP6K7 200G 9 to 33 V DC 12W

15 DuraLed 1000 Lumen Magnetic Base With DT connector With 12V MagCode connector With 24V MagCode connector With CIG/DIN plug HM1550DT HM1550MAG-12 HM1550MAG-24 HM1550CIG MINING LED WORK LAMPS DuraLed Magnetic Base 1000 Lumen Work Lamp Multivolt 9-33V DC Complementing the DuraLed range is the new heavy duty magnetic base service lamp which uses ultra powerful neodymium magnets and a flexible curly-cord cable. 15 WORK LAMPS The compact 1 metre extension cable extends the range of the light to 8 metres from the power source Product features 1m coiled cord with 8-metre extension potential Lumen Wide Beam Multivolt DuraLed Ideal for use in confined spaces, such as engine bays and under machines Low power consumption <12 watt Multivolt 9 33V DC The high output LEDs provide excellent uniform illumination whilst the low power consumption of the LEDs reduces the drain on the vehicle s electrical system. The 1000 Lumen wide beam light output provides exceptional illumination in areas where permanent mains power is unsuitable. The magnets combined have a huge holding potential of 44kg, making the light resistant to heavy knocks and vibration. The unit is sealed making it resistant to moisture and dust damage. The quality electronics allow stable light output over varying power sources from 9 to 33V DC. 193 Specifications Voltage Multivolt 9-33V DC Power Consumption <12W per lamp Mounting Universal mounting via neodymium magnets Protection Reverse polarity, spike and over voltage protection. Sealed against dust and water ingress to IP6K6, IP6K7 The light is quick and easy to install, making it an excellent temporary maintenance or service lamp. The magnets simply snap the light to any metallic surface and the lamp can be powered from a variety of terminations. The Work Lamp comes in four connection options, cigarette lighter, DIN plug, 12 volt MagCode or 24 volt MagCode to meet the needs of a range of users and applications. Combined with the Hella PowerPAK system, users will have a truly high performance mobile lighting system. Compatible with PowerPAK Portable Power Pack, Part No. HM8600 MULTI VOLT LED 0.8Kg 9 to 33 V DC 12W IP6K6 IP6K7 200G

16 AS500 FF Xenon Trunnion Pedestal Wide Beam Multivolt DT HM1512WB HM1513WB Narrow Beam Multivolt DT HM1512NB HM1513NB HID WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 16 AS500 FF Xenon Heavy Duty Work Lamp AS500 FF Xenon is a compact and highly versatile, ultra heavy-duty work lamp for use on mining machinery, suitable for 24V and 12V electrical systems. Optional Pedestal Bracket Shown with Pedestal Mount MUSTADD DRACO IP6K7 50G 12/24V Trunnion Bracket D2S Clear cover to be ordered separately DT 41W Kg 175 Good lighting is essential to create a safe and productive work area where machine operators can clearly see their work environment and identify hazards in time to take the required action. The AS500 FF is engineered to deliver excellent lighting under continuous use in extreme environmental conditions. AS500 FF lamps Hella Free-Form optics deliver a homogenous spread of light, so operators can see comfortably for long periods. Its light distribution ensures there are no sharp transitions from light to dark in the operator s visual field, to significantly reduce adaptation related eye fatigue and stress. The optical modules comprise a precision-moulded specular reflector, permanently assembled to a corrosion-resistant hardened glass refractor lens and machined lamp holder, ensuring perfect focus. A choice of wide and narrow asymmetric beam types is available. The integrated, patented Hella MustADD filter ensures optimum optical performance is maintained over product life in the adverse atmospheres typically encountered in mining. (See technical section for more information.) 35W Xenon gas discharge lighting systems pioneered by Hella have set the standard across the world for optimum visual acuity and comfort for professional work lamp users. The integral electronic ballast fitted to the AS500 FF range is specifically designed for continuous operation in mining applications. (See technical section for more information.) Safe and reliable electrical connection is via a short length of highly flexible double insulated cable, terminated with DT connectors. An ergonomic heavyduty cast aluminium body with an integral non-snag adjustment handle is the basis of all AS500 FF lights. A robust lens retaining ring with captive M4 Allen bolts enables rapid routine service access from the front, while high temperature O-ring seals ensure effective sealing. A UV resistant multi-stage powder coating process ensures optimal corrosion protection. Accurate and stable aiming in high vibration environments in all assembly positions is vital. The AS500 FF offers a range of secure mounting options for almost any requirement. The standard trunnion bracket can be fitted to the body in six different mounting positions; all of which locate the axis of rotation in the centre of gravity to minimize mechanical stress. Four M6 Allen bolts in arced slots and fixed pivot points ensure that the aiming angle can be locked securely. Secondary mounting holes in the base of the AS500 FF enable direct mounting onto equipment, or the use of an optional pedestal bracket. The heavy gauge stainless steel hardware is non-resonant and highly corrosion resistant. Integral DRACO dampers eliminate all metal-to-metal contact between the lamp and bracket to reduce shock and vibration transmission. (See technical section for more information.) Sustainable use of resources is ensured through the modular system design, so users can reuse, repair, or recycle lights into new applications. Ballasts can be replaced. Both beam types and mounting bracket positions and options can be changed. Halogen models can also be upgraded to Xenon and other future options. Product features Modular die cast aluminium alloy body Integral non-snag handle Multiple mounting options with aiming angles Stainless steel trunnion bracket with quad bolt fastening Draco suspension Free-Form wide and narrow beam optics MustADD filter Captive Allen bolts Double insulated silicone supply cable with DT plug Replaceable encapsulated ballast Spare Parts & Options HM8164 Clear Protective Cover AS500 9.HMAPEDL Pedestal Mounting Bracket Assembly 9.HM151TRN Trunnion Mounting Bracket Assembly 9.HMAWHKD Cable harness kit AS500 Shown with Trunnion Bracket O-ring seals Components tested over a 40ºC to +105ºC temperature range High efficiency & long life D2S 35W Xenon light Multivolt 8-32V DC IP6K7K 200G shock resistant ballast 50G shock resistant lamp CE compliant Protective clear covers available Consumable spares interchangeable with Hella AS200FF Xenon range 9.HM15WB Insert Wide Optic AS200/500 GDL 9.HM15NB Insert Narrow Optic AS200/500 GDL 9.HM151BAL Multivolt Ballast XN4000 Globe Xenarc D2S

17 17 WORK LAMPS Optional Pedestal Bracket Multi-adjustable trunnion bracket ensures accurate and stable aiming in a high vibration environment in all assembly positions. Bracket locates the axis of rotation in the centre of gravity AS500 FF Xenon Narrow Beam AS500 FF Xenon Wide Beam 30 Peak 79 LUX 30 Peak 120 LUX

18 AS200 FF Xenon Wide Beam Multivolt DT Narrow Beam Multivolt DT HM1504WB HM1504NB MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 18 AS200 FF Xenon Heavy Duty Work Lamp AS200 FF Xenon is a compact and highly versatile, heavy-duty work lamp for use on mining machinery; suitable for 24V and 12V electrical systems Front View Clear cover to be ordered separately 150 Good lighting is essential to create a safe and productive work area where machine operators can clearly see their work environment and identify any hazards in time to take the required action. The AS200 FF is engineered to deliver excellent lighting in the extreme environmental conditions encountered in mining applications. AS200 FF lamps employ Hella Free-Form optics to deliver an homogenous spread of light enabling operators to see comfortably for long periods of time. The light distribution of the beam ensures an absence of sharp transitions from light to dark in the operator s visual field, thus significantly reducing adaptationrelated eye fatigue and stress. The optical modules comprise of a precision-moulded specular reflector, permanently assembled to a corrosion-resistant hardened glass refractor lens and machined lamp holder, ensuring perfect focus of each unit. A choice of wide and narrow asymmetric beam types is available to suit different applications. (See technical section for more information on Hella s applications engineering service.) Hella integrated a basic version of the patented MustADD filter into the AS200 FF to ensure the optical system remains virtually dust free over the product s life in the adverse atmospheres typically encountered in mining. (See technical section for more information.) 35W Xenon gas discharge lighting systems pioneered by Hella have set the standard across the world for delivering optimum visual acuity and comfort to professional work lamp users. The integral electronic ballast fitted to the AS200 FF range is specifically designed for continuous operation in mining applications. (See technical section for more information.) Safe and reliable electrical connection is facilitated via a short length of highly flexible double insulated cable, terminated with DT connectors. AS200 FF lights use a highly corrosion-resistant, heavy-duty steel reinforced, UV resistant polymer body, featuring an integral non-snag handle for adjustment and handling. A lens-retaining ring enables easy routine service access from the front, while high temperature O-ring seals ensure effective sealing. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. The AS200 FF features integral DRACO dampers in the bracket system to reduce the intensity of shock and vibration communicated to the light. (See technical section for more information.) Sustainable use of resources and high ownership value is ensured through the modular system design, enabling AS200 FF users to repair, or recycle their lights into new applications. Ballasts can be replaced, and beam-spread types can be changed. Product features Steel-reinforced UVresistant polymer body Integral non-snag handle Stainless steel bracket Draco suspension Free-Form wide and narrow beam optics MustADD filter Double insulated silicone supply cable with DT connector Replaceable encapsulated Xenon ballast O-ring seals Spare Parts & Options HM8154 Clear Protective Cover HM8154AMBER Clear protective Cover Amber 9.HM15WB Insert Wide Optic AS200/500 GDL Components tested over a 40ºC to +105ºC temp. range High efficiency & long life D2S 35W Xenon light Multivolt 8-32V DC IP6K7 200G shock resistant ballast 50G shock resistant lamp CE compliant Protective clear covers available Consumable spares interchangeable with Hella AS500FF Xenon range 9.HM15NB Insert Narrow Optic AS200/500 GDL 9.HM151BAL Multivolt Ballast XN4000 Globe Xenarc D2S MUSTADD DRACO D2S DT 1.8Kg IP6K7 50G 12/24V 41W

19 19 MOBILE WORK LAMPS EQUIPMENT LIGHTING 30 AS200 FF Xenon Narrow Beam Peak 79 LUX 30 AS200 FF Xenon Wide Beam Peak 120 LUX

20 UltraBeam FF X-PowerPack Xenon 12V DC 24V DC Wide Beam Pendant Mount HMUBXHWBD-12V HMUBXHWBD-24V Narrow Beam Pendant Mount HMUBXSWBD-12V HMUBXSWBD-24V MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 20 UltraBeam FF X-PowerPack Xenon Work Lamp UltraBeam FF X-PowerPack is a very compact, heavy-duty Xenon work lamp for use on small mining machinery. It is suitable for 24V and 12V electrical systems Pedestal Mount Pendant Mount HM8160 Good lighting is essential to create a safe and productive work area where machine operators can clearly see their work environment and identify any hazards in time to take the required action. The 35W Xenon discharge lighting systems pioneered by Hella have set the standard across the world for delivering excellent visual acuity and comfort to professional work lamp users. Hella Free-Form optics enables the very compact UltraBeam FF X-PowerPack to deliver a homogenous spread of light, enabling operators to see comfortably for long periods of time. The light distribution of the beam ensures an absence of sharp transitions from light to dark in the operator s visual field, thus significantly reducing adaptationrelated eye fatigue and stress. The optical module comprises of a precision Free Form reflector, permanently assembled to a corrosion resistant hardened glass lens and machined lamp holder, ensuring high efficiency and perfect focus of each unit after lamp changes. The UltraBeam FF X-PowerPack is constructed around a new ballast module for applications where space is at a premium. The integral electronic ballast used by the UltraBeam FF X-PowerPack is a clean sheet design optimized for continuous operation in mining applications, with particular attention paid to limit the impact of Electromagnetic interference. Hella integrated a basic version of the patented MustADD filter into the UltraBeamFF X-PowerPack to ensure the optical system remains virtually dust free over product life in the adverse atmospheres typically encountered in mining. The optical assembly of the very compact lamp housing is moulded from a highly corrosion-resistant heavy-duty UV resistant polymer; the rear body and ballast housing is die cast aluminium ensuring optimal heat dissipation. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. Integral DRACO dampers in the bracket system reduce the intensity of shock and vibration communicated to the light. The UltraBeam FF X-PowerPack is available in both pedestal mount and pendant mount configurations. Product features In-built 5th generation electronic ballast with aluminium heatsink Compact design Fast, easy installation High-sheen free-form (FF) reflector High efficiency D1S 35W Xenon Globe Hardened glass lens Wide Beam Optics Specifications Voltage 12 and 24V DC options Power Consumption 35W Globe (42W total) Mounting Stainless steel pedestal bracket for 4-point mount and additional stainless steel mounting foot for single bolt mount included. Cable Pre-wired with 0.2 metre sheathed cable and DT plug. Supplied with stainless steel pedestal bracket and additional mounting foot Compatible with existing UltraBeamFF mounting brackets 12V DC and 24V DC variants IP6K7 and IP6K9K 200g shock resistant (ballast/housing) Clear protective cover included Temperature Range -40 C to +80 C Protection Fully sealed against dust and moisture to IP6K9K. Shock resistant to 200G (ballast/housing) and 30g (lamp). EMC Approval EMC Class 5 according to CISPR25 for absolutely disturbance free radio and wireless transmission. MUSTADD DRACO DT D1S IP6K7 IP6K9K 200G 12/24V 1.26Kg 42W Spare Parts & Options HM8160 Clear Protective Cover (included) HMXN4001 D1S Xenon Globe

21 21 WORK LAMPS Integral Xenon Ballast (non-replaceable) D1S Xenon Globe HMXN4001 Stainless Steel Bracket Wide Beam Optic (not serviceable)

22 UltraBeam FF Xenon 8-32V DC Wide Beam DT Plug HM1522WB MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 22 UltraBeam FF Xenon Heavy Duty Work Lamp 24V DC UltraBeam FF Xenon is a superior, compact, heavy-duty work lamp for use on mining machinery. It is suitable for 12 to 24V electrical systems Front View Clear cover to be ordered separately The UltraBeam FF utilizes an externally located ballast to enable the use of Xenon lighting where space is at a premium. Good lighting is essential to create a safe and productive work area where machine operators can clearly see their work environment and identify any hazards in time to take the required action. Hella Free-Form optics enables the very compact UltraBeam FF lamps employed to deliver an homogenous spread of light, enabling operators to see comfortably for long periods of time. The light distribution of the beam ensures an absence of sharp transitions from light to dark in the operator s visual field, thus significantly reducing adaptationrelated eye fatigue and stress. The optical modules comprise of a precision die cast specular reflector, permanently assembled to a corrosion-resistant hardened glass refractor lens and machined lamp holder, ensuring high efficiency and perfect focus of each unit. Hella integrated a basic version of the patented MustADD filter into the UltraBeam FF to ensure the optical system remains virtually dust free over product life in the adverse atmospheres typically encountered in mining. (See technical section for more information.) 35W Xenon discharge lighting systems pioneered by Hella have set the standard across the world for delivering excellent visual acuity and comfort to professional work lamp users. The integral electronic ballast used by the UltraBeam FF is designed specifically for continuous operation in mining applications. Safe and reliable electrical connection between the ballast and lamp housing is via a short length of highly flexible double insulated high voltage cable, with a permanently fixed safety lamp socket. (See technical section for more information.) The very compact lamp housing is moulded from a highly corrosionresistant heavy-duty, UV resistant polymer body. A lens-retaining ring enables easy routine service access from the front, while high temperature O-ring seals ensure effective sealing. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. The UltraBeam FF features integral DRACO dampers in the bracket system to reduce the intensity of shock and vibration communicated to the light. (See technical section for more information.) Product features UV resistant polymer body Stainless steel bracket Draco suspension Free-Form beam optics MustADD filter DT plug Replaceable encapsulated Xenon ballast O-ring seals Components tested over a 40ºC to +105ºC temperature range Spare Parts & Options HM8157 Clear Protective Cover HM8157AMBER Amber Protective Cover High efficiency & long life D2S 35W Xenon light 8-32V DC operationip6k5k 200G shock resistant ballast 50G shock resistant lamp CE compliant Protective clear covers available 9.HMUBXWB Reflector & Optic Insert 9.HM151BAL Multivolt Ballast MUSTADD DRACO D2S DT 2.0Kg IP6K5 50G 12/24V 41W

23 23 WORK LAMPS 30 UltraBeam FF Xenon Wide Beam 2.5m high at

24 OVAL 100 FF Xenon Wide Beam DT Narrow Beam DT HMPVX35WBD HMPVX35NBD MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 24 OVAL 100 FF Xenon Heavy Duty Work Lamp 24V DC OVAL100 FF Xenon is a low profile, heavy-duty work lamp for use on mining machinery, suitable for 24V and 12V electrical systems. 192mm Front View 160mm 135mm Good lighting is essential to create a safe and productive work area where machine operators can clearly see their work environment and identify any hazards in time to take the required action. The OVAL100 FF is engineered to deliver excellent lighting in the extreme environmental conditions encountered in mining applications. OVAL100 FF lamps employ Hella Free-Form optics to deliver an homogenous spread of light, enabling operators to see comfortably for long periods of time. The light distribution of the beam ensures an absence of sharp transitions from light to dark in the operator s visual field, thus significantly reducing adaptationrelated eye fatigue and stress. The optical modules comprise of a precision-moulded specular reflector, permanently assembled to a corrosion-resistant hardened glass refractor lens and machined lamp holder, ensuring perfect focus of each unit. A choice of wide and narrow asymmetric beam types is available to suit different applications. Hella integrated a basic version of the patented MustADD filter into the OVAL100 FF to ensure the optical system remains virtually dust free over the product s life in the adverse atmospheres typically encountered in mining. (See technical section for more information.) 35W Xenon gas discharge lighting systems pioneered by Hella, have set the standard across the world for delivering optimum visual acuity and comfort to professional work lamp users. The compact electronic ballast fitted internally to the OVAL100 FF range operates a D1S lamp with integral ignitor. Safe and reliable electrical connection is facilitated via a short length of highly flexible double insulated cable, terminated with either DT or AMP connectors; other connector options can be supplied as special orders. OVAL100 FF lights use a highly corrosion-resistant, heavy-duty, UV-resistant polymer body with a lens-retaining ring to enable easy routine service access from the front, while high temperature O-ring seals ensure effective sealing. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. OVAL100 FF features integral DRACO dampers in the bracket system to reduce the intensity of shock and vibration communicated to the light. (See technical section for more information.) Sustainable use of resources and high ownership value is ensured through the modular system design, enabling OVAL100 FF users to repair, or recycle their lights into new applications. Ballasts can be replaced or exchanged to suit different supply voltage values and beam-spread types can be changed. Product features UV-resistant polymer body Low profile Oval shape Stainless steel bracket Draco suspension Free-Form wide and narrow beam optics MustADD filter Double insulated silicone supply cable with DT plug Replaceable Xenon ballast Spare Parts & Options 9.HMPUXWB Insert Wide Optic GDL 9.HMPUXNB Insert Narrow Optic GDL O-ring seals Components tested over a 40 C to +105ºC temperature range High efficiency & long life D1S 35W Xenon light 12V DC & 24V DC options IP65 50G shock resistant lamp CE compliant 9.HMPUXB24 Ballast OVAL100 FF HMXN4001 Globe Xenarc D1S MUSTADD DRACO D1S DT 1.5Kg IP65 50G 12/24V 41W

25 25 WORK LAMPS Peak Peak Oval 100FF 84 Lux Xenon Narrow Beam 2.5m high at 5 Oval 100FF Xenon 82 Lux Wide Beam 2.5m high at

26 AS500 FF Halogen H3 Trunnion Pedestal Wide Beam DT HM1510WB HM1511WB Narrow Beam DT HM1510NB HM1511NB HALOGEN WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 26 AS500 FF Halogen Heavy Duty Work Lamp AS500 FF Xenon is a compact and highly versatile, ultra heavy-duty work lamp for use on mining machinery, suitable for 24V and 12V electrical systems. Optional Pedestal Bracket Shown with Pedestal Mount MUSTADD Clear cover to be ordered separately DRACO H3 IP6K7 50G 12/24V Trunnion Bracket DT 70W Kg 175 Good lighting is essential to create a safe and productive work area where machine operators can clearly see their work environment and identify hazards in time to take the required action. The AS500 FF is engineered to deliver excellent lighting under continuous use in extreme environmental conditions. AS500 FF lamps Hella Free-Form optics deliver a homogenous spread of light, so operators can see comfortably for long periods. Its light distribution ensures there are no sharp transitions from light to dark in the operator s visual field, to significantly reduce adaptation related eye fatigue and stress. The optical modules comprise a precision-moulded specular reflector, permanently assembled to a corrosion-resistant hardened glass refractor lens and machined lamp holder, ensuring perfect focus. A choice of wide and narrow asymmetric beam types is available. The integrated, patented Hella MustADD filter ensures optimum optical performance is maintained over product life in the adverse atmospheres typically encountered in mining. (See technical section for more information.) Safe and reliable electrical connection is via a short length of highly flexible double insulated cable, terminated with DT connectors. An ergonomic heavy-duty cast aluminium body with an integral non-snag adjustment handle is the basis of all AS500 FF lights. A robust lens retaining ring with captive M4 Allen bolts enables rapid routine service access from the front, while high temperature O-ring seals ensure effective sealing. A UV resistant multi-stage powder coating process ensures optimal corrosion protection. Accurate and stable aiming in high vibration environments in all assembly positions is vital. The AS500 FF offers a range of secure mounting options for almost any requirement. The standard trunnion bracket can be fitted to the body in six different mounting positions; all of which locate the axis of rotation in the centre of gravity to minimize mechanical stress. Four M6 Allen bolts in arced slots and fixed pivot points ensure that the aiming angle can be locked securely. Secondary mounting holes in the base of the AS500 FF enable direct mounting onto equipment, or the use of an optional pedestal bracket. The heavy gauge stainless steel hardware is non-resonant and highly corrosion resistant. Integral DRACO dampers eliminate all metal-to-metal contact between the lamp and bracket to reduce shock and vibration transmission. (See technical section for more information.) Sustainable use of resources is ensured through the modular system design, so users can reuse, repair, or recycle lights into new applications. Ballasts can be replaced or exchanged to suit different voltages. Both beam types and mounting bracket positions and options can be changed. Halogen models can also be upgraded to Xenon and other future options. Product features Modular die cast aluminium alloy body Integral non-snag handle Multiple mounting options Stainless steel trunnion bracket with quad bolt fastening Draco suspension Free-Form wide and narrow beam optics MustADD filter Captive Allen bolts Double insulated silicone supply cable with DT plug O-ring seals Spare Parts & Options HM8164 Clear Protective Cover AS500 9.HMAPEDL Pedestal Mounting Bracket Assembly 9.HM151TRN Trunnion Mounting Bracket Assembly Shown with Trunnion Bracket Components tested over a 40ºC to +105ºC temperature range H3 Halogen 70W 24V supplied H3 Halogen 55W 12V can be fitted High efficiency & long life D2S 35W Xenon light 12V DC & 24V DC options IP6K7K 200G shock resistant lamp Protective clear covers available Consumable spares interchangeable with Hella AS200FF Xenon range 9.HMAWHKD Cable harness kit AS500 9.HM15WB Insert Wide Optic AS200/500 H3 9.HM15NB Insert Narrow Optic AS200/500 H3 YC2470 Globe H3 24V YC1255LL Globe H3 12V

27 27 WORK LAMPS Optional Pedestal Bracket Trunnion Bracket Multi-adjustable trunnion bracket ensures accurate and stable aiming in a high vibration environment in all assembly positions. Bracket locates the axis of rotation in the centre of gravity 20 AS500 FF Halogen Narrow Beam 2.5m high at 5 20 AS500 FF Halogen Wide Beam 2.5m high at 5 Peak 79 Lux Peak 120 Lux

28 UltraBeam FF Halogen Wide Beam Narrow Beam Long Range 24V H3 HM1526WB HM1526NB HM1526LR MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 28 UltraBeam FF Halogen Work Lamp 12/24V UltraBeam FF Halogen, available with Wide, Narrow and Long Range Beams, are superior, compact heavy-duty work lamps for use on mining machinery, and suitable for both 24V and 12V electrical systems Front View, Long Range Narrow Beam As part of our ongoing development the Long Range addition to the UltraBeam FF range applies our most recent advances in free-form (FF) reflector technology. With a clear lens and the popular H3 Halogen globe it s a compact long range lamp for applications where the performance of a Xenon light is not required. The very compact optics deliver excellent lighting under continuous use in the extreme environmental conditions encountered in mining applications. Electrical connection is via integrated DT connector. The UltraBeam FF clear lens long range optical insert is a modular assembly of a precision die-cast specular reflector with integral lamp holder, permanently assembled to a corrosion resistant hardened clear glass lens, for high efficiency and perfect focus. The new lens long range optical insert is available as a spare part and is 100% compatible with older UltraBeam FF H3 work lamps to enable simple on site maintenance and perfect retrofitting. In common with the all Hella UltraBeam FF work lamps, the basic version of the patented MustADD filter is included so the optical system remains virtually dust free over the product life, in the adverse atmospheres typically encountered in mining. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. The UltraBeam FF features integral DRACO dampers in the bracket system to reduce the intensity of shock and vibration. The UltraBeam FF family is based on very compact lamp housings moulded from a highly corrosion resistant, heavy-duty polymer body. A lens retaining ring enables easy routine service access from the front, while high temperature O-ring seals ensure effective sealing. Long Range Lens Product features: Powerful long range and wide spread illumination DT electrical connection Robust polymer body Stainless steel mounting bracket Draco suspension MustADD multi air-filter Specifications: Temperature Range -40 C to +105 C Mounting Single bolt with tilt adjustment for upright, side or pendant mounting on horizontal or vertical surfaces. Stainless steel bracket and screws included Free-form (FF) reflector for powerful long range illumination Components tested over a 40 C to +105ºC temperature range IP6K7 Clear protective covers available H3 Halogen 70W 24V supplied H3 Halogen 55W 12V can be fitted Protection Sealed against dust and moisture to IP6K7. Shock resistant to 50G. HM8158 HM8158AMBER MUSTADD DRACO H3, H9, H11 IP6K7 50G 12/24V DT 70W MAX 0.8Kg Spare Parts: HM8158 Clear Protective Cover HM8158AMBER Clear Protective Cover - Amber Insert Long Range Optic 9.HMUBHNB Insert Narrow Optic 9.HMUBHWB Insert Wide Optic YC2470 H3 Globe, 24V 70W YC1255LL H3 Globe, 12V 55W

29 29 WORK LAMPS Narrow Beam Optic Long Range Optic UltraBeam FF Long Range 2.5m high at 5 20 Peak 44 Lux 1 LUX 68m UltraBeam FF Narrow 2.5m high at 5 30 UltraBeam FF Wide 2.5m high at 5 30 PEAK 44 LUX PEAK 42 LUX

30 HydroLUX Submersible Driving Lamp 12/24V Mining Yellow H3 Spread Beam HM1358 Mining Yellow H1 Pencil Beam HM1374D Mining Yellow H1 Spread Beam HM1375D Mining Yellow H4 RHD Driving Beam Mining Yellow H4 LHD Driving Beam HM1002 HM1002ECE MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 30 HydroLUX Submersible Driving Lamp 12/24V HydroLUX ultra-heavy duty submersible driving lamps feature advanced engineering, focused on the requirements of mining and emergency vehicles that operate on and off public roads. Suitable for 24V and 12V electrical systems Shown with H3 Insert HM1002 (with H4 Insert) Clear cover to be ordered separately MUSTADD H1, H3, H4 BARE WIRE 3.2Kg 198 Good lighting is essential to create a safe and productive illumination of the road, enabling drivers to clearly see and identify any hazards in time to take the required action. The HydroLUX is not only engineered to deliver excellent lighting but also to withstand regular submersion or continuous under water operation, as well as the extreme environmental conditions encountered in mining applications. Hella s patented isobaric system prevents water ingress into the optical module, whilst enabling easy service access and reliable long-term operation of the seals under mining conditions. To ensure correct operation of the isobaric system and perfect focus, each optical module unit comprises a precision-moulded specular reflector, with integral lamp holder permanently assembled to a corrosion resistant hardened clear lens seated into a die cast alloy frame. Each HydroLUX is individually pressure tested and certified. (See technical section for more information.) HydroLUX lamps are available with Free-Form spread and pencil beam auxiliary driving beam distribution types, in addition to a wide range of ECE and SAE approved high/ low beam versions for use as headlamps in left and right hand public road traffic. All HydroLUX optical modules feature a fully integrated, patented Hella MustADD filter to ensure that optimum optical performance is maintained over the product s life in the adverse atmospheres typically encountered in mining. (See technical section for more information.) An ergonomic, heavy-duty cast aluminium body with an integral non-snag adjustment handle is the basis of all HydroLUX lights. A robust lens retaining ring with captive M4 Allen bolts enables rapid routine service access from the front, while high temperature O-ring seals ensure effective sealing. A UV resistant multi-stage powder coating process ensures optimal corrosion protection. Accurate and stable aiming in a high vibration environment is a vital aspect of safe and legal road lighting. The non-resonant and corrosion resistant cast alloy bracket fitted to the body shape minimizes mechanical stress, and a rubber damper between the lamp and bracket eliminates metal-to-metal contact to reduce the intensity of shock and vibration communicated to the light. Two M6 Allen bolts ensures that the critical vertical aiming can be locked securely, and a M8 bolt in the base enables direct mounting onto equipment. Safe and reliable electrical connection is facilitated via a 2m length of highly flexible double insulated cable, factory sealed into the body, eliminating the requirement for water-proof connections at the lamp. Other connector options can be supplied as special orders. Product features Wide selection of optics available Die cast alloy body and bracket MustADD filter Double insulated silicone supply cable O-ring seals H1, H3 and H4 versions available Suitable for 12V or 24V globes (24V supplied) Spare Parts & Options 8151 Clear Protective Cover HM Mounting Bracket Assembly HM9.1374HD.01 Pencil Beam Insert Assembly (H1 Version) IP6K9K 50G shock resistant lamp ECE and SAE compliant options Right and left hand traffic options Protective clear covers available HM9.1375HD.01 Spread Beam Insert Assembly (H1 Version) 9.HM1002ECE.01 Insert HM1002ECE (LHD, H4 ECE Version) 9.HM Insert HM1002 (RHD, H4 Version) 9.HM Insert HM1358 (H3 Version) IP6K9K 50G 12/24V 100W MAX ECE/ ADR compliant

31 31 MOBILE WORK LAMPS EQUIPMENT LIGHTING Note: Spread Beam Lamp is ECE compliant with 12V/55W or 24V/70W globe. Pencil Beam Recorded with single lamp. Distance in metres. 1 LUX.5 LUX Spread Beam Recorded with single lamp. Distance in metres. Front View

32 AS200 FF Halogen with AMP plug with DT Plug Wide Beam HMASH70WBA HMASH70WBD Narrow Beam HMASH70NBA HMASH70NBD MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 32 AS200 FF Halogen Heavy Duty Work Lamp 12/24V AS200 FF Halogen is a compact and highly versatile heavy-duty work lamp for use on mining machinery; suitable for 24V and 12V electrical systems. 137 Front View Good lighting is essential to create a safe and productive work area where machine operators can clearly see their work environment and identify any hazards in time to take the required action. The AS200 FF is engineered to deliver excellent lighting in the extreme environmental conditions encountered in mining applications. AS200 FF lamps employ Hella Free-Form optics to deliver an homogenous spread of light, enabling operators to see comfortably for long periods of time. The light distribution of the beam ensures an absence of sharp transitions from light to dark in the operator s visual field, thus significantly reducing adaptationrelated eye fatigue and stress. The optical modules comprise of a precision-moulded specular reflector, permanently assembled to a corrosion-resistant hardened glass refractor lens and lamp holder, ensuring perfect focus of each unit. A choice of wide and narrow asymmetric beam types is available to suit different applications. (See technical section for more information on Hella s applications engineering service.) Hella integrated a basic version of the patented MustADD filter into the AS200 FF to ensure the optical system remains virtually dust free over the product s life in the adverse atmospheres typically encountered in mining. (See technical section for more information.) Safe and reliable electrical connection is facilitated via a short length of highly flexible double insulated cable, terminated with either DT or AMP connectors; other connector options can be supplied as special orders. AS200 FF lights use a highly corrosion resistant heavy-duty, steel reinforced, UV-resistant polymer body, featuring an integral non-snag handle for adjustment and handling. A lens-retaining ring enables easy routine service access from the front while high temperature O-ring seals ensure effective sealing. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. The AS200 FF features integral DRACO dampers in the bracket system to reduce the intensity of shock and vibration communicated to the light. (See technical section for more information.) Sustainable use of resources and high ownership value is ensured through the modular system design, enabling AS200 FF users to repair, or recycle their lights into new applications. Ballasts can be replaced or exchanged to suit different supply voltage values and beam-spread types can be changed. Product features AUV resistant polymer body Integral non-snag handle Stainless steel bracket Draco suspension Free-Form wide and narrow beam optics MustADD filter Double insulated silicone supply cable with DT or AMP plug O-ring seals Spare Parts & Options HM8156 Clear Protective Cover AS200 H3 HM8156 AMBER Amber Protective Cover AS200 H3 Components tested over a 40ºC to +105ºC temperature range H3 Halogen 70W 24V supplied H3 Halogen 55W 12V can be fitted IP6K5K 50G shock resistant lamp Protective clear covers available Consumable spares interchangeable with Hella AS500 FF Halogen range 9.HM15WB Insert Wide Optic 9.HM15NB Insert Narrow Optic YC2470 Globe H3 24V YC1255LL Globe H3 12V MUSTADD DRACO H3 DT & AMP 0.8Kg IP6K5 50G 12/24V 70W

33 33 MOBILE WORK LAMPS EQUIPMENT LIGHTING 20 AS200 FF Halogen Narrow Beam 2.5m high at 5 20 AS200 FF Halogen Wide Beam 2.5m high at

34 Oval 100 FF Halogen Double Beam with AMP plug with DT Plug Wide Beam HMPV270WBA HMPV270WBD Narrow Beam HMPV270NBA HMPV270NBD MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 34 OVAL 100 FF Halogen Double Beam Work Lamp 24V DC OVAL100 FF Halogen is a low profile twin beam, heavy-duty work lamp for use on mining machinery. It is suitable for 24V and 12V electrical systems. Narrow Beam model front view Clear cover to be ordered separately The OVAL100 FF is engineered to deliver excellent lighting in the extreme environmental conditions encountered in mining applications. OVAL100 FF lights employ an advanced version of the Hellapioneered twin beam Free-Form optics to deliver an homogenous spread of light, enabling people to see comfortably for long periods of time. The light distribution of the beam is engineered to ensure minimum light spill and an absence of sharp transitions from light to dark in the operator s visual field, thus significantly reducing adaptation-related eye fatigue and stress. The twin beam optical modules comprise of a high precision cast alloy specular reflector, permanently assembled to a corrosion-resistant hardened glass refractor lens and lamp holder, ensuring perfect focus of each unit. A choice of wide and narrow asymmetric beam types is available to suit different applications. (See technical section for more information on Hella s applications engineering service.) Hella integrated a basic version of the patented MustADD filter into the OVAL100 FF to ensure the optical system remains virtually dust free over product life in the adverse atmospheres typically encountered in mining. (See technical section for more information.) Safe and reliable electrical connection is facilitated via a short length of highly flexible double insulated cable, terminated with either DT or AMP connectors; other connector options can be supplied as special orders. OVAL100 FF lights use a highly corrosion-resistant, heavy-duty, UV-resistant polymer body, with a lens-retaining ring to enable easy routine service access from the front, while high temperature O-ring seals ensure effective sealing. The supplied stainless steel mounting hardware is non-resonant and highly corrosion resistant. The OVAL 100 FF features integral DRACO dampers in the bracket system to reduce the intensity of shock and vibration communicated to the light. (See technical section for more information.) Sustainable use of resources and high ownership value is ensured through the modular system design, enabling OVAL100 FF users to repair, or recycle their lights into new applications. Ballasts can be replaced or exchanged to suit different supply voltage values and beam-spread types can be changed. Product features UV resistant polymer body Low profile Oval shape Individual lamp switching Stainless steel bracket Draco suspension Free-Form wide and narrow beam optics MustADD filter Spare Parts & Options HM8159 Clear Protective Cover HM8159AMBER Amber Protective Cover 9.HMPU2NB Insert Narrow Optic OVAL100 DB Wide Beam model Double insulated silicone supply cable with DT or AMP plug O-ring seals H3 Halogen 70W 24V supplied H3 Halogen 55W 12V can be fitted IP6K5K 50G shock resistant lamp Protective clear covers available 9.HMPU2WB Insert Wide Optic OVAL100 WB YC2470 Globe H3 24V YC1255LL Globe H3 12V MUSTADD DRACO H3 DT & AMP 1.0Kg IP6K5K 50G 12/24V 70W

35 35 WORK LAMPS 30 Peak Oval FF Lux Halogen Narrow Beam 2.5m high at 5 30 Peak Oval 100 FF Halogen 45 Wide Lux Beam 2.5m high at

36 Modul 70 Halogen 12V H9 24V H3 Wide Beam HM70H9WB-12V HM70H3WB-24V Narrow Beam HM70H9NB-12V HM70H3NB-24V MINING WORK LAMPS MOBILE WORK LAMPS EQUIPMENT LIGHTING 36 Modul 70 Halogen Work Lamp Hella Modul 70 is an ultra-compact Halogen work lamp for use on mining support function vehicles or in applications where space is very limited. The lamp provides close-range illumination or long-range illumination with 12V or 24V electrical systems. Modul 70 utilizes advanced Hella production and materials in a unitary design that directly bonds a cast aluminium Free-Form reflector, lamp holder, clear glass lens and high temperature polymer housing into a low mass, efficient and very compact work lamp. Direct access to the globe without the use of a tool enables rapid routine service access. High temperature O-ring seals integral to the H9 globe, and a protective rubber cap for H3 variants, ensure effective sealing. Front view H3 H9 The brilliant Free-Form optics and clear lens of the Modul 70 reduce scatter losses and improve beam control. Designed specifically for use with the new generation of high performance Halogen globes, the H9 (12V only) model is excellent for applications where high levels of light may be required for short periods but the cost of Xenon cannot be justified. H3 variants of the Modul 70 are also available for less demanding applications. A choice of wide and narrow asymmetric beam types is available to suit different applications. (See technical section for more information on Hella s applications engineering service.) A rotating base in addition to the elevation allows vertical adjustment of + 48 to -115, and 360 rotation adjustment. The supplied stainless steel hardware is non-resonant and highly corrosion resistant. Safe and reliable electrical connection is facilitated via a 200mm length of highly flexible double insulated cable, terminated with a DT connector. Other connector options can be supplied as special orders. Additional variants of the Modul 70 are available on special request. Product features Free-Form wide and narrow beam optics Clear lens brilliant appearance Die cast aluminium reflector Tool less globe access Impact resistant housing 50G shock resistant lamp ROHS compliant Electrical connection: 200mm double insulated cable harness, terminated with DT connector; other terminations available on special request Stainless steel mounting bracket IP5K9K H9 12V 65W Halogen globe included H3 24V 70W Halogen globe included HM70PR HM70PI Yellow mounting bracket denotes product as mining specification version 9.HM70WH Spare Parts & Options HM70PR Pipe mount tube attachment for rotating HM70PI Pipe mount tube attachment 9.HM70BR Bracket Stainless steel Modul 70 9.HM70DC Dust Cap H3 Modul 70 CF1265 Globe H9 12V 9.HM70WH Wiring harness H9, 2m YC2470 Globe H3 24V MULTI VOLT H3, H9 DT 0.5Kg IP5K9 50G 12/24V 70W max

37 12V H9 Halogen Globe 37 WORK LAMPS 24V H3 Halogen Globe Peak 84 Lux Peak 82 Lux Modul 70 Halogen Narrow Beam H9 12V m high at 5 20 Modul 70 Halogen Wide Beam H9 12V 2.5m high at Modul 70 Halogen Narrow Beam H3 24V m high at 5 20 Modul 70 Halogen Wide Beam H3 24V 2.5m high at

38

39 39 BEACONSBeacons 40 DuraRAY Phase II 42 UltraRAY-R Twin 44 UltraRAY-R Rotating 46 UltraRAY 48 OptiRAY 50 OptiRAY E 52 MiniRAY 53 NaviLED M 54 DuraLED M High Intensity 56 PulseRAY KLX 58 PulseRAY E67

40 DuraRAY Phase II LED Warning Beacons l Amber LED l Yellow Base l Red LED l Yellow Base l Green LED l Yellow Base l Amber LED l Amber Base l Red LED l Amber Base l Green LED l Amber Base 2 LED Disks HM9400YEL2A HM9400YEL2R HM9400YEL2G HM9400AMB2A HM9400AMB2R HM9400AMB2G 3 LED Disks HM9400YEL3A HM9400YEL3R HM9400YEL3G HM9400AMB3A HM9400AMB3R HM9400AMB3G 4 LED Disks HM9400YEL4A HM9400YEL4R HM9400YEL4G HM9400AMB4A HM9400AMB4R HM9400AMB4G LED BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 40 DuraRAY LED Warning Beacons Phase II Hella DuraRAY II ultra durable LED warning beacons improve on the award winning design of its predecessor. DuraRAY II beacons are designed for mining and construction applications where the cost of equipment down time is large and safety is paramount x Ø6 equispaced on PCD Ø150 3 x M4 equispaced on PCD Ø107 3 x M4 equispaced on PCD Ø130 25mm Pipe Thread LED Disks 3 LED Disks 4 LED Disks The cast alloy construction and modular lens design enables DuraRAY II beacons to survive much larger crush or impact loads than conventional optical beacons. DuraRAY II beacons offer excellent beam control to ensure very good penetration of fog and dust without blinding the operator through back scatter, whilst delivering high observability from a distance with minimal closeup glare. Solid state LED beacons are gaining popularity due to their zero maintenance and long service life over conventional rotating beacons, particularly in harsh mining conditions. The new range of DuraRAY II LED warning beacons build on an award winning design with the addition of a new electronic control system, combined with higher output LEDs, and further user customisation within the range. Higher EMC standard ISO certification improves safety and reliability with other electrical devices. Coloured secondary reflectors were added to ensure easy identification of LED function colour when the beacon is in off mode. Using an advanced control system gives users the option to select from a flashing or rotating LED beam pattern by simply changing the polarity of the two wires. The Multivolt system allows for installation on electrical machines that may have varying outputs due to the load on the engine. The light output from the high emitting LEDs is not affected by this varying supply, with a range of 9-33 Volts DC. The increased light output from the LEDs combined with multiple layers of LEDs delivers a high degree of redundancy in the optical system to ensure safety is not compromised under partial failure or obscuring conditions. Utilising ceramic coated aluminium reflectors and durable XYLEX lenses provides excellent longterm resistance against cleaning chemicals, UV and impact damage for increased durability and long service life. DuraRAY II beacons are fully sealed fit and forget products that can be submerged and high-pressure washed from any direction. Product features Multivolt 9-33V DC New electronics offer both rotating and flashing functionality Modular system of circular LED discs for intense, 360 visible light output Brilliant clear, high impact resistant XYLEX lens system Heavy-duty cast alloy base and cap for increased mechanical strength and vibration resistance Multi-stage paint coating for optimal corrosion and UV protection ISO Flame retardant to UL94HB Fully sealed and pre-wired to prevent ingress of dirt and moisture 200G shock resistant Low EMC signature Low current draw Self-diagnostic electronics for protection against transient voltage spikes and reverse polarity LED Function colour variants available (Amber, Green, Red) Spare Parts 9.HM Installation Kit MULTI VOLT LED DT & BARE WIRE IP6K7 200G 9 to 33 V DC 33W MAX

41 41 BEACONS Top View Bottom View Yellow Housing Amber Housing Amber Function Colour Red Function Colour Green Function Colour

42 UltraRAY -R TWIN LED Warning Beacon l Amber l Red l Blue l Green l White Direct Mount HM500ADIR HM500RDIR HM500BDIR HM500GDIR HM500WDIR Magnetic Mount HM500AMAG HM500RMAG HM500BMAG HM500GMAG HM500WMAG MINING WARNING BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 42 UltraRAY -R TWIN LED Warning Beacon As an addition to the Hella LED beacon range, a new Twin LED beacon has been developed for increased visibility in bright sunlight with more than double the luminous intensity of the original UltraRAY x Ø4 equispaced on PCD Amber Red Blue Green The UltraRAY -R Twin LED features either a rotating or flashing pattern easily selectable by grounding the function wire, allowing users to change the flashing pattern with an in-cabin switch, removing the need to open the unit. It is extremely robust, tolerant to severe vibration levels and very compact in design. Equipped with a high impact and shock resistant polycarbonate lens bolted to a heavy-duty cast alloy base, it is sealed by a neoprene O-ring against dust and water ingress. The UltraRAY -R Twin LED warning beacon is maintenance free with no moving parts or fragile globes. LED beacons are highly efficient, delivering up to a 70% energy saving over conventional beacons. This greatly reduces both operating temperature and demand on the vehicle s electrical system. Maximum service life and light output of the high intensity LEDs is ensured by integrating the heat sinks into the cast alloy base. The Multivolt control module encapsulated directly into the base also protects the UltraRAY -R Twin against damage from overheating, reverse polarity and short circuits. (See technical section for more Multivolt information.) The UltraRAY -R Twin LED warning beacon is optimized for continuous use applications on mining equipment, to ensure highly effective warning efficiency in daylight on surface operations in the extreme environmental conditions encountered in mining applications. The UltraRAY -R Twin LED also features a patented Helio shield, which protects the beacon s internal components from UV damage. The UltraRAY -R Twin LED beacon is available in five LED signal colours (amber, red, blue, green and white) to suit all signal applications. Installation is possible with either the standard direct mount, or an optional magnetic mount or pipe mounting kit. Product features Certified SAE J845 Class 1 red & amber Available in amber, red, blue, green and white User selectable output (rotate or quad flash patterns) Automatic daylight detection Impact resistant smooth polycarbonate lens Precision Fresnel optics Powdercoated cast alloy base Specifications Voltage Multivolt 12 30V DC Power consumption 50W average Frequency Rotating: 80 cycles/min Flash: 72 fpm (quad) Direct, pipe mount or magnetic installation options Low current draw EMC Tested Fully encapsulated electronics Overheat, reverse polarity and short circuit protection High efficiency, long life LED light Requires 10 Amp fuse Lead Length 2 metres (doubleinsulated cable) Protection Overheat, reverse polarity and short circuit protected. Sealed against dust and moisture to IP6K5 White Temperature Range 20 C to +50 C Shock resistant to 200G MULTI VOLT IP6K5 LED 200G BARE WIRE 0.9Kg 12 to 24 V DC SAE COMPLIANT 50W AVERAGE HM500AFLX UltraRAY-R TWIN including vibration proof pole-mount adapter Spare Parts 9.HM450ALENS Amber PC Lens 9.HM450RLENS Red PC Lens 9.HM450BLENS Blue PC Lens 9.HM450GLENS Green PC Lens 9.HM450WLENS White PC Lens HM400PIPE Pipe Mount Kit 9.HM450FLX FlexiMount Adapter

43 43 BEACONS Polycarbonate lens with Helioshield Cast alloy base Rubber vibration insulator

44 UltraRAY -R LED Warning Beacon l Amber l Red l Blue l Green l White Direct Mount HM450ADIR HM450RDIR HM450BDIR HM450GDIR HM450WDIR Magnetic Mount HM450AMAG HM450RMAG HM450BMAG HM450GMAG HM450WMAG MINING WARNING BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 44 UltraRAY -R Rotating LED Warning Beacon UltraRAY -R LED warning beacons are optimized to deliver high visibility warning signals in the dusty conditions encountered on surface mining operations day and night. The new UltraRAY -R beacons feature user-selectable rotating or quad flash patterns x Ø4 equispaced on PCD Amber Red Blue Green White UltraRAY beacons are extremely robust, tolerant to severe vibration levels and very compact in design. Each beacon is equipped with a high impact and shock resistant, polycarbonate lens bolted to a heavy-duty cast alloy base, sealed by a neoprene O-ring against dust and water ingress. The UV resistant multi-stage powder coating process ensures optimal corrosion protection. UltraRAY LED warning beacons are maintenance free with no moving parts or fragile globes. UltraRAY -R rotating beacons incorporate the unique Hella Helioshield technology developed specifically for warning beacons used on mine sites to significantly increase the signal contrast against bright-sky or snow backgrounds and reduce the occurrence of phantom signals in direct sunlight. All UltraRAY -R LED beacons are highly energy efficient delivering up to 70% energy saving over conventional beacons, which greatly reduces both operating temperature and demand on the vehicle s electrical system. Maximum service life and light output of the high intensity LEDs is ensured through integrating the heat sinks into the cast alloy base. The Multivolt control module encapsulated directly into the base ensures full light intensity independent of supply voltage and protects the beacon against damage from overheating, reverse polarity and short circuits. Safe and reliable electrical connection is facilitated via a highly flexible double- insulated cable sealed into the base, terminated with bare wire ends. Other connector options can be supplied as special orders. UltraRAY beacons are available in five LED signal colours (amber, red, blue, green and white) to suit all signal applications. Installation is possible with either the standard direct mount or an optional pipe mounting kit. Temporary use applications are best served with the magnetic mount version, complete with a pre-wired cable and power plug. Product features User selectable rotating or quad flash patterns* SAEJ845 Class I (red and amber) Impact resistant polycarbonate lens Precision Fresnel optics Powdercoated cast alloy base Direct, pipe mount or magnetic installation options Low current draw Specifications Voltage Multivolt 12 30V DC Power consumption 20W max. Frequency Rotating: 80 cycles/min Flash: 72 fpm (quad) Temperature Range 20 C to +50 C Fully encapsulated electronics Overheat, reverse polarity and short circuit protection Double insulated supply cable O-ring seals High efficiency, long life LED light Unique Helioshield ambient light suppression improves daylight visibility * Preset to rotating pattern Lead Length 2 metres (doubleinsulated cable) Protection Overheat, reverse polarity and short circuit protected. Sealed against dust and moisture to IP6K5 Shock resistant to 200G MULTI VOLT IP6K5 LED 200G BARE WIRE 0.9Kg 12 to 24 V DC SAE COMPLIANT 20W MAX. HM450AFLX UltraRAY-R including vibration proof pole-mount adapter Spare Parts 9.HM450ALENS Amber PC Lens 9.HM450RLENS Red PC Lens 9.HM450BLENS Blue PC Lens 9.HM450GLENS Green PC Lens 9.HM450WLENS White PC Lens HM400PIPE Pipe Mount Kit 9.HM450FLX FlexiMount Adapter

45 45 BEACONS Polycarbonate lens with Helioshield Cast alloy base Rubber vibration insulator

46 UltraRAY LED Warning Beacon l Amber l Red l Blue l Green l White Direct Mount HM400ADIR HM400RDIR HM400BDIR HM400GDIR HM400WDIR Magnetic Mount HM400AMAG HM400RMAG HM400BMAG HM400GMAG HM400WMAG MINING WARNNG BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 46 UltraRAY LED Warning Beacon UltraRAY LED warning beacons are optimized for continuous use applications on mining equipment, to ensure highly effective warning efficiency in daylight on surface operations in the extreme environmental conditions encountered in mining applications x Ø4 equispaced on PCD Amber Red Blue Green UltraRAY LED beacons offer multiple, user-selectable flash patterns to suit a large variety of applications. Additional user selectable features include a battery saver mode to alert users if the equipment power supply drops below normal operating voltage levels to conserve power, as well as a daylight sensing that can automatically adjust the intensity of the beacon to ambient light levels. A reverse gear circuit allows the flash pattern to be changed to alert staff of the travel direction of the equipment. The desired operational mode can be selected by simply changing the DIP switch settings on the circuit board. UltraRAY beacons are extremely robust, tolerant to severe vibration levels and very compact in design. Each beacon is equipped with a high impact and shock- resistant, clear polycarbonate lens bolted to a heavy-duty cast alloy base, sealed by a neoprene O-ring against dust and water ingress. A UV resistant multi-stage powder coating process ensures optimal corrosion protection. Unlike Xenon flash strobes, UltraRAY LED beacons are maintenance free and extremely power efficient, which greatly reduces both operating temperature and demand on the vehicle s electrical system. Maximum service life and light output of the high intensity LEDs is ensured through integrating the heat sinks into the cast alloy base. The Multivolt control module encapsulated directly into the base also protects the UltraRAY against damage from overheating, reverse polarity and short circuits. (See technical section for more Multivolt information.) Safe and reliable electrical connection is facilitated via a highly flexible double insulated cable sealed into the base, terminated as a short length with a DT connector or 2m cable with bare wire ends. Other connector options can be supplied as special orders. UltraRAY beacons are available in five LED signal colours (amber, red, blue, green and white) to suit all signal applications. Installation is possible with either the standard direct mount or an optional pipe mounting kit. Temporary use applications are best served with the magnetic mount version, complete with a pre wired cable and power plug. Product features SAE J845 Class 1 red & amber Available in amber, red, blue, green and white User selectable flash patterns (4) Automatic daylight detection Impact resistant smooth polycarbonate lens Clear precision Fresnel optics Cast alloy base Direct, pipe mount or magnetic installation options Multivolt 12 30V DC Low current draw Fully encapsulated electronics 1.5kg mass 200G shock impulse resistant Overheat, reverse polarity and short circuit protection Double insulated supply cable with DT or AMP plug O-ring seals Tested over a 20ºC to +50ºC temperature range High efficiency, long life LED light IP6K5 200G shock resistant Spare Parts White 9.HM400LENS Clear Lens HM400PIPE Pipe Mount Kit 9.HM450FLX FlexiMount Adapter MULTI VOLT LED BARE WIRE 0.9Kg SAE COMPLIANT HM400AFLX UltraRAY including vibration proof pole-mount adapter IP6K5 200G 12 to 24 V DC 20W MAX.

47 47 BEACONS Polycarbonate lens Cast alloy base Rubber vibration insulator

48 OptiRAY LED Warning Beacon l Amber l Red l Blue l Green l White Direct Mount HM360ADIR HM360RDIR HM360BDIR HM360GDIR HM360WDIR Magnetic Mount HM360AMAG HM360RMAG HM360BMAG HM360GMAG HM360WMAG Battery Pack HM360ABP HM360RBP Magnetic Battery Pack HM360ABPMAG HM360BBPMAG MINING WARNING BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 48 OptiRAY LED Warning Beacon OptiRAY LED warning beacons are versatile lights designed for heavy duty use on mining equipment and service vehicles that need light output matched to the ambient lighting, for optimum warning efficiency day or night, surface or underground Amber on Red on Blue on Green on White on OptiRAY LED beacons offer multiple, user-selectable flash patterns, including a rotating beam, to suit a large variety of applications. Additional userselectable features include a battery saver mode to alert users if the equipment power supply drops below normal operating voltage levels to conserve power, as well as daylight sensing that can switch the beacon off during daylight hours or automatically adjusts the intensity of the beacon to ambient light levels. The desired operational mode can be selected by simply changing the DIP switch settings on the circuit board. OptiRAY beacons are extremely robust, tolerant to severe vibration levels and very compact in design. Each beacon is equipped with a high impact and shock resistant, clear polycarbonate lens, and a rugged, UV damage resistant fibreglass nylon composite base for increased mechanical strength and maximum durability. A neoprene O-ring seals the assembly against dust and water. The OptiRAY is well suited to corrosive environments where metal products should not be used. Unlike Xenon flash strobes, OptiRAY LED beacons are maintenance free and extremely power efficient. Each beacon draws a maximum of only 1 Amp at 12V, which greatly reduces both operating temperature and demand on the vehicle s electrical system. Maximum service life and light output of the high intensity LEDs is ensured through using internal aluminium heat sinks. The Multivolt control module also protects the OptiRAY against damage from overheating, reverse polarity and short circuits. (See technical section for more Multivolt information.) Safe and reliable electrical connection is facilitated via a highly flexible double insulated cable sealed into the base. Other connector options can be supplied as special orders. OptiRAY beacons are available in five LED signal colours (amber, red, blue, green and white) to suit all signal applications. The beacon can be installed with either the standard direct mount or optional pipe mounting kit; temporary use applications are best served with the magnetic mount version, complete with pre wired cable and plug. A self-contained version with battery power supply is also available for independent use. Product features SAE J845 (Class 1 red, Class 2 amber) Available in amber, red, blue, green and white User selectable flash patterns (16) Automatic daylight detection Impact resistant smooth polycarbonate lens Clear precision Fresnel optics Direct, pipe mount or magnetic installation options Battery pack option Multivolt 12 30V DC Low current draw (1Amp) Spare Parts 9.HM360LENS Clear Lens 200G shock impulse resistant Overheat, reverse polarity and short circuit protection Double insulated supply cable O-ring seals Tested over a 20ºC to +50ºC temperature range High efficiency, long life LED light IP6K5 200G shock resistant Spares interchangeable with Hella OptiRAY E range 9.HM300FLX FlexiMount Adapter HM360PIPE Pipe Mount Kit MULTI VOLT LED BARE WIRE 0.5Kg SAE COMPLIANT IP6K5 200G 12 to 30 V DC 12W MAX HM360AFLX OptiRAY including vibration proof pole-mount adapter Battery pack

49 49 BEACONS

50 OptiRAY E LED Warning Beacon l Amber l Red l Blue l Green l White Direct Mount HM300ADIR HM300RDIR HM300BDIR HM300GDIR HM300WDIR Magnetic Mount HM300AMAG HM300RMAG HM300BMAG HM300GMAG HM300WMAG MINING WARNING BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 50 OptiRAY E LED Warning Beacon Hella OptiRAY E LED warning beacons are designed for heavy duty use on mining equipment and service vehicles where complex functionality is not required Amber on Red on Blue on Green on OptiRAY E beacons are engineered to the same high standard as the full-featured OptiRAY products, but including only the essential features enables the benefits of LED products to be extended into a significantly wider range of applications. OptiRAY E beacons are extremely robust, tolerant to severe vibration levels and very compact in design. Each beacon is equipped with a high impact and shock resistant, clear polycarbonate lens and a rugged, UV damage resistant fibreglass nylon composite base for increased mechanical strength and maximum durability. A neoprene O-ring seals the assembly against dust and water. The OptiRAY E is well suited to corrosive environments where metal products should not be used. Unlike Xenon flash strobes, OptiRAY E LED beacons are maintenance-free and extremely power efficient. Each beacon draws a maximum of only 1 AMP at 12V, which greatly reduces both operating temperature and demand on the vehicle s electrical system. Maximum service life and light output of the high intensity LEDs is ensured through using internal aluminium heat sinks. The Multivolt control module also protects the OptiRAY E against damage from overheating, reverse polarity and short circuits. (See technical section for more Multivolt information.) Safe and reliable electrical connection is facilitated via a highly flexible double insulated cable sealed into the base, terminated as a short length with a DT connector or 2m cable with bare wire ends. Other connector options can be supplied as special orders. OptiRAY E beacons are available in five LED signal colours (amber, red, blue, green and white) to suit all signal applications. Installation is possible with either the standard direct mount or optional pipe mounting kit; temporary use applications are best served with the magnetic mount version, complete with a pre wired cable and power plug. Product features SAE J845 (Class 1 red, Class 2 amber) Available in amber, red, blue, green and white Impact resistant smooth polycarbonate lens Clear precision Fresnel optics Direct, pipe mount or magnetic installation options Multivolt 12 30V DC Low current draw 1AMP Fully encapsulated electronics Overheat, reverse polarity and short circuit protection Double insulated supply cable with DT or AMP plug O-ring seals Tested over a 20ºC to +50ºC temperature range High efficiency, long life LED light IP6K5 200G shock resistant Spares interchangeable with Hella OptiRAY range Double Flash, 80FPM 0.5kg mass 200G shock impulse resistant White on HM300AFLX OptiRAY-E including vibration proof pole-mount adapter Spare Parts 9.HM360LENS Clear Lens HM360PIPE Pipe Mount Kit 9.HM300FLX FlexiMount Adapter MULTI VOLT LED DT BARE WIRE 0.5Kg SAE COMPLIANT IP6K5 IP6K7 200G 12 9 to V DC 12W 6W MAX

51 51 BEACONS

52 MiniRAY LED Warning Beacon l Amber l Red l Blue l Green l White Direct Mount HM180ADIR HM180RDIR HM180BDIR HM180GDIR HM180WDIR Magnetic Mount HM180AMAG HM180RMAG HM180BMAG HM180GMAG HM180WMAG Battery Pack HM180ABP HM180RBP HM180GBP MINING WARNING BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 52 MiniRAY LED Warning Beacon From the unique, virtually indestructible triangular design and sealed polycarbonate lens, to its superior, long lasting LED illumination and ultra low current draw, Hella MiniRAY LED Warning Beacons offer outstanding lighting performance and maximum durability for a vast range of applications where highly directional optical warning signals are required Amber on Red on Blue on Green on White on Battery pack Utilising a high-intensity LED lighting system incorporated into a triangular, solid-state circuit board, MiniRAY beacons produce high intensity, axially symmetrical cones of light to both front and rear of the machine ensuring high visibility along the axis of travel, whilst a low intensity beam to either side effectively reduces dangerous glare to machine operators caused by light reflecting from adjacent structures or the warning beacon itself. MiniRAY beacons have been specifically designed to protect machinery operating underground or in other areas where both machine type (identified by LED colour) and direction of travel are essential indicators to identify potential dangers. MiniRAY beacons produce different light source patterns to the front and rear of the vehicle identifying the direction of travel and effectively reducing the risk of collisions in poor visibility conditions. In addition, MiniRAY beacons provide 3 user-selectable power levels to suit specific mine requirements along with a selection of flash patterns, which can be linked to the operating mode of the machinery, making changes in equipment travel direction highly visible. Each MiniRAY beacon is resistant to prolonged vehicle vibration and sealed against damaging ingress of moisture and dust for increased durability and long service life. The unique triangular design deflects direct impact and reliably protects against damage caused by falling rocks, vehicles, hand tools or construction debris, whilst rounded corners minimize the risk of personal injury when working in confined spaces. MiniRAY LED beacons require only very little power, which allows them to operate day and night, even when the machinery is turned off. And when they do run off truck batteries or other field equipment, they will operate for days without draining the battery cells, making them a cost-effective and reliable lighting solution for any type machinery from large earth moving vehicles to smaller equipment such as welders, generators and compressors. And, unlike Xenon flash tubes, LEDs produce very little radio interference and light pulses that do not disturb lasertesting equipment. MiniRAY LED beacons are available in 5 different function colours (amber, red, green, blue and white) and offer a variety of mounting options to suit every installation requirement including direct mount, magnetic base, battery box (selfpowered). Product features Multivolt 12-30V DC Multiple flash patterns with over-ride function to link flash patterns to vehicle s direction of travel Front and rear identifiable beam patterns Unique asymmetrical light output directing high power beams along the travel axis and low power beams across the travel axis Three different power settings allowing the user to select between maximum intensity and minimum power draw Solid-state, vibration resistant circuit board sealed in clear, weatherproof polycarbonate case for optimum impact resistance and long service life Triangular design deflects direct impact and protects against damage from falling rocks, vehicles, hand tools and construction debris Versatile power supply specifications (permanent installation or self-powered battery pack operation or from a coiled flexible supply cable) Modular base system enables direct mount, magnetic mount and a battery pack mount Low EMC signature. Side view Designed to identify machine type (colour) and direction of travel (beam pattern). Front view Rear view Spare Parts 9.HM180LENS Clear Lens MULTI VOLT LED BARE WIRE 0.9Kg IP6K5 200G 12 to 30 V DC 12W MAX

53 NaviLED M Surface Mount l Amber l Red l Blue l Green l White Signal Lamp Yellow Housing HM HM HM HM HM MINING SIGNAL LAMPS FLASHING NaviLED M Warning Beacon 53 BEACONS MOBILE EQUIPMENT LIGHTING Hella NaviLED M is a range of surface mount LED signal lamps, specifically designed to provide all-round visibility. NaviLED M is targeted for use on mining production equipment where coloured signal lamps are required to provide operational status and identification information. Product features Flashing or Steady On signal light Flash rate 100 fpm (approx) High visibility yellow, impact-resistant acrylic base Clear UV and chemical resistant modified acrylic lens Function colours coded into lens caps Amber, red, blue, green and white functions available Minimum visible distance of 3 km Single high intensity LED light source Sealed unit pre-wired with multi strand double insulated cable Multivolt 9-33V DC Spike protected to +500 volts Over voltage protected to +200 volts Reverse polarity protected to -500 volts Low power consumption (2W) Sealed to IP6K6 and IP6K7 to withstand temporary immersion and high pressure washing 200G shock tested Tested over a 40ºC to +70ºC temperature range External elements manufactured from flame retardant polymers rated UL94 HB As a new feature all NaviLED M LED signal lamps now offer a single flashing signal light in addition to the standard steady on signal light function. The additional flashing function provides optimum warning efficiency and renders the lamp suitable for use as a fault indication device. The preferred signal function is selected by simply reversing the wiring polarity. The highly ergonomic and userfriendly design ensures that the NaviLED M has no sharp edges or protruding fasteners when installed. Hella engineers NaviLED M lamps to ensure a very long service life with no lighting loss due to internal dirt build-up; they are very well suited to wet and corrosive environments and tolerate short-term immersion. Excellent durability of the housing and active LED electronics, as well as long term impact, chemical and UV damage resistance in the highly corrosive and abrasive mining environment, is ensured through meticulous testing and selection of materials and assembly processes. NaviLED M signal lamps have undergone extensive test to destruction programs to ensure product reliability meets Hella Mining requirements. Advanced Multivolt circuitry pioneered by Hella which provides reverse polarity, spike and overvoltage protection for long life and reliable operation of the LED, is sealed into the base. The lamps deliver consistent illumination from 9-33V (See technical section for additional information.) NaviLED M lamps are available in five LED signal colours (amber, red, blue, green and white). Maximum service life and light output of the high intensity LED light source is ensured through an integral aluminium heat sink. A multi component refractor system delivers controlled rotationally symmetrical light distribution with minimal losses. The smooth self-cleaning exterior lens can be re-polished if required, with no detrimental effect on light-output or chemical resistance. Safe and reliable electrical connection is facilitated via a short length double insulated multi core cable. Other connector options can be supplied as special orders. 83 Amber Illuminated Red Illuminated Blue Illuminated Green Illuminated White Illuminated 90 Optic appears clear until illuminated in all lamps MULTI VOLT LED DT 0.5Kg IP6K7 200G 9 to 33 V DC 2W

54 DuraLed M High Intensity Warning Beacon l Amber l Red l Blue l Green l White Narrow Beam Bare Wire HM HM HM HM HM Narrow Beam DT Plug HM D HM D HM D HM D HM D MINING WARNING BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 54 DuraLed Warning Beacon M High Intensity DuraLed M MultiFlash are versatile high intensity LED optical warning beacon lights designed for heavy duty installation on mining equipment and service vehicles in applications where roof-mounted warning beacons may not be desirable or sufficient Amber Illuminated Red Illuminated Blue Illuminated Green Illuminated White Illuminated Hella MultiFlash LED beacons offer multiple, user-selectable flash patterns to suit a large variety of applications. The desired operational mode can be selected by simply changing the settings via the power cable. No external control systems are required. DuraLed M beacons are extremely robust, fully sealed truly fit and forget products, tolerant to severe vibration levels and very compact in design. A high impact and shock resistant clear Xylex lens is permanently bonded to a rugged, UV damage-resistant composite base for increased mechanical strength and maximum durability. Hella engineered DuraLed M lamps to ensure a very long service life and no lighting loss due to internal dirt build-up; they are also very well suited to wet and corrosive environments and tolerate shortterm immersion. (See technical section for more Xylex information.) Unlike Xenon flash strobes, DuraLed M LED beacons are maintenance free and extremely power efficient which greatly reduces both operating temperature and demand on the vehicle s electrical system. Maximum service life and light output of the high intensity LEDs is ensured through using internal heat sinks. The integral Multivolt and MultiFlash control module also protects the DuraLed M against damage from overheat, reverse polarity and short circuits. (See technical section for more Multivolt information.) Safe and reliable electrical connection is facilitated via a highly flexible double insulated cable sealed into the base, terminated as a short length with a DT connector or 2m cable with tinned wire ends. Other connector options can be supplied as special orders. DuraLed M MultiFlash beacons are equipped with advanced clear micro optic lenses to prevent the hazardous occurrence of ghost signals by internally reflected light from other sources. Five LED signal colours are available (amber, red, blue, green and white) to suit all signal applications. The smooth ergonomic design and very low profile (under 35mm) allows DuraLed M units to be installed on almost any surface. Specially designed nylon bushes prevent stress fractures developing in the base, by distributing the fasting bolt load over a large surface of the base without transferring any torque. Tamper proof screw covers securely lock the product into place and simplify cleaning by eliminating dirt collecting cavities. Flash Patterns MultiFLASH Product features Available in amber, red, blue, green and white User selectable flash patterns Impact resistant smooth Xylex lens Clear precision micro optics Multivolt 9-33V DC Low power < 10W Fully sealed fit and forget design 0.5kg mass 200G shock impulse resistant Spare Parts 9.HMDLM001 Cover Kit Yellow 1 second Overheat, reverse polarity and short circuit protection Double insulated supply cable with DT plug or bare wire Tested over a 40ºC to +70ºC temperature range High efficiency, long life LED light IP6K7K UL94 flame retardant rated external parts Spares interchangeable with Hella DuraLed range MULTI VOLT MULTI FLASH LED DT & BARE WIRE 0.5Kg 250 ms 500 ms 750 ms IP6K7 200G 9 to 33 V DC 9W

55 55 BEACONS Optic appears clear until illuminated in all lamps DuraLED Blue DuraLED Red DuraLED Green DuraLED Amber lx 10.0lx 12.0lx 10.0lx Average Beam Illuminance 7.5lx 7.5lx 9.0lx 7.5lx 10m 5m Beam Width and Height 4.0m 80% 60% 5.0lx 5.0lx 6.0lx 5.0lx 0.8m 0m 0.8m 40% 20% 2.5lx 2.5lx 3.0lx 2.5lx 5m 4.0m lx 0.0lx 0.8lx 0.0lx 1.3lx 0.0lx 1.0lx 0.0lx 5m 10m 15m 20m 25m 10m 30m Maximum Intensity DuraLED Red cd DuraLED Amber cd DuraLED Green cd DuraLED Blue cd

56 PulseRAY KLX Heavy Duty Xenon Warning Beacon Amber HMX7500A MINING WARNING BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 56 PulseRAY KLX Heavy Duty Xenon Warning Beacon PulseRAY KLX Xenon strobe warning beacons are specifically developed to fulfill the demands of markets with SAE standards. The beacon is designed for heavy duty use on mining machinery; suitable for 24V and 12V electrical systems. Front View Reliable, unambiguous and highly visible optical warning signals are essential to create a safe and productive work area where machine operators can clearly see and identify any hazards in their work environment at the correct time to take the required action. The PulseRAY KLX is engineered to deliver intense high visibility signals under continuous use in the extreme environmental conditions encountered in mining applications. PulseRAY KLX beacons combine a smooth outer polycarbonate amber lens in the classic Hella shape, with a high clear precision Fresnel optic internal lens, reducing dirt build-up compared to textured lenses and delivering significant improvements in long term light output and beam control under actual operating conditions. (Other lens colours available as special order.) Extended service life, and maximum light output of the PulseRAY is ensured by using the die cast aluminium base as heat sink for the Multivolt drive circuitry. The electronics are encapsulated as protection against shock damage and ingress of moisture or other atmospheric contaminants. Rapid service access to the PulseRAY is enabled by its thread-on lens and captive O-ring seal, while the field replaceable Xenon flash tube with clip-in base ensures correct polarity. User selection between double or quad flash as well as high or low flash intensity is done by setting DIP switches when fitting the PulseRAY. Comprehensive protection is provided against reverse voltage, high voltage spikes and over-voltage. The heavy-duty cast alloy base, finished in high visibility yellow UV resistant multi-stage powder coating process, ensures optimal corrosion protection. The PulseRAY KLX base suits the standard 6 (150mm) diameter mounting pattern used in North America, as well as a threaded pole. Product features Heavy cast alloy base Impact resistant smooth polycarbonate lens Clear precision Fresnel optics Voltage nominal: 12V 24V DC Voltage operating: 9V 32V DC Field selectable double or quad flash Field selectable high/ low flash intensity FPM FPM Mounting: 150mm PCD from above and 30mm SPT from below. SAE J1318 Class 2 compliant SAE J575 compliant Components tested over a 40ºC to +50ºC temperature range IP6K6 50G shock resistant lamp Suitable for use with GuardRAY protective cage Consumable spares interchangeable with PulseRAY E67 beacons Reverse polarity, voltage spike & surge protection XENON BARE WIRE 1.1Kg SAE COMPLIANT ECE COMPLIANT HMWGA220 (optional) Spare Parts 9.HMX Lens KLX inner - Fresnel 9.HMX Lens KLX outer Amber HMWGA220 GuardRAY Protective Cage XN6750 Globe Xenon E67 Flash Tube IP6K6 50G 12/24V 60W

57 57 BEACONS

58 PulseRAY E67 l Amber l Red l Blue l Green l Clear Heavy Duty Xenon Strobe 12/24V DC HMX6750A HMX6750R HMX6750B HMX6750G HMX6750C MINING WARNING BEACONS MOBILE BEACONS EQUIPMENT LIGHTING 58 PulseRAY E67 Heavy Duty Xenon Warning Beacon 12/24V DC PulseRAY E67 Xenon strobe warning beacons are designed for heavy duty use on mining machinery; suitable for 24V and 12V electrical systems Amber Lens Red Lens Blue Lens Green Lens Reliable, unambiguous and highly visible optical warning signals are essential to create a safe and productive work area where machine operators can clearly see and identify any hazards in their work environment at the correct time to take the required action. The PulseRAY E67 is engineered to deliver intense high visibility signals under continuous use in the extreme environmental conditions encountered in mining applications. PulseRAY E67 beacons feature an impact resistant polycarbonate lens with Fresnel optics. Extended service life, and maximum light output of the PulseRAY is ensured by using the die cast aluminium base as a heat sink for the Multivolt drive circuitry. The electronics is encapsulated as protection against shock damage and ingress of moisture or other atmospheric contaminants. Rapid service access to the PulseRAY is enabled by its threadon lens and captive O-ring seal, while the field replaceable Xenon flash tube with clip-in base ensures correct polarity. Reliable fault diagnosis of the lamp is facilitated through the i.beam LED status indicator visible through the outer lens. (See technical section for more information.) Selection between double or quad flash operation of the PulseRAY is done by simply reversing operating polarity. Comprehensive protection provided against high voltage spikes and over-voltage ensures reliable operation. The heavy duty cast alloy base finished in high visibility yellow UV resistant multi-stage powder coating process, ensures optimal corrosion protection. The PulseRAY E67 base suits the standard 6 (150mm) diameter mounting pattern used in North America as well as a threaded pole. Product features Heavy cast alloy base Impact resistant polycarbonate lens Voltage nominal: 12V 24V DC Voltage operating: 9V 32V DC Field selectable double or quad flash i.beam Monitor FPM FPM Reverse polarity, voltage spike & surge protection Mounting: 150mm PCD from above and 30mm SPT from below Components tested over a 40 C to +50ºC temperature range IP6K6 50G shock resistant lamp SAE J1318 Class 2 compliant SAE J575 compliant Suitable for use with GuardRAY protective cage Consumable spares interchangeable with PulseRAY KLX beacons Clear Lens HMWGA160 (optional) Spare Parts E67 Lens - Amber E67 Lens - Red E67 Lens - Blue E67 Lens - Green HMWGA160 GuardRAY Protective Cage XN6750 Globe - Xenon E67 Flash Tube Lens Clear Dust Cover XENON BARE WIRE 1.2Kg SAE COMPLIANT E67 Lens - Clear IP6K6 50G 12/24V 60W

59 59 BEACONS

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61 Signal Lamps 61 SIGNAL LAMPS 62 DuraLED SAE 63 DuraLED ECE 64 DuraLED M Combi 65 DuraLED MSIP 66 DuraLED Marker 67 LED Daytime Running Lamp

62 DuraLed SAE Signal Lamp Stop/Tail Rear Turn Signal (Red) Rear Turn Signal/Indicator HM HM MINING SIGNAL LAMPS SIGNAL LAMPS 62 DuraLed Signal Lamps SAE Hella s DuraLed lamps include models which are ECE approved, and SAE compliant. They suit a variety of vehicle applications and are easy to fit and durable. The lamps incorporate the latest in LED technology for low maintenance requirements, low current draw and ultra long service life. 100 HM DuraLed lamps feature unique designs with shallow shapes and concealed mounting screws for enhanced protection against damage. All lamps are pre-wired with multi-core sheathed cable, fully sealed against dust and moisture to International Protection Standards IP6K6 and IP6K7, and are compliant with current SAE regulations. The material used for these part numbers is a new generation of acrylics which has a high tolerance to chemicals and washing fluids as well as an enhanced impact resistance. This suits vehicles frequently washed with standard automotive chemicals. DuraLed SAE Signal Lamps feature low power consumption and Multivolt circuitry, ensuring full light output from 9 to 33 volts (8 to 28 volts for the Marker Lamp). The lamps are fully sealed against dust and moisture and may be mounted vertically or horizontally (2-hole surface mount and mounting bushes supplied). Multivolt for optimum brightness at input voltage from 9 to 33 volts with 9W power consumption. Reverse polarity protection and 5.0kW Transient Voltage Suppressor (TVS). Made to IP6K6 (Protection against dust and high pressure water jets) and IP6K7 (Protection against temporary water immersion) standards. Standard lamp comes with 2.5m of cable. Product features Easy installation Variety of surface mount options Ultra wide optics for enhanced visibility Low power consumption and Multivolt circuitry for maximum light output Multivolt 9-33V DC SAE compliant IP6K6 (Protection against dust and high pressure water jets) IP6K7 (Protection against temporary water immersion). HM MULTI VOLT LED DT& BARE WIRE 0.4Kg SAE COMPLIANT IP6K7 200G 9 to 33 V DC 5W

63 DuraLed ECE Signal Lamp Stop/Tail Signal (Red Illuminated) Rear Turn Signal (Amber Illuminated) HM HM MINING SIGNAL LAMPS DuraLed Hella DuraLed ECE lamps are high quality, long lasting mining signal lamps that are ECE approved. They suit a variety of vehicle applications and are easy to fit and durable. They incorporate the latest in LED technology for low maintenance requirements, low current draw and ultra long service life. ECE Signal Lamps 63 SIGNAL LAMPS Product features Easy Installation Variety of surface mount options Ultra wide angle optics for enhanced side visibility Ultra low power consumption Multivolt 9-33V DC ECE Approval Fully sealed against dust and moisture DuraLed lamps are extremely robust, fully sealed truly fit and forget products, tolerant to severe vibration levels and very compact in design with concealed mounting screws for enhanced protection against damage. All lamps are pre-wired with multi-core sheathed cable, fully sealed against dust and moisture to International Protection Standards IP6K6 and IP6K7, and are compliant with current SAE regulations. (maximum 9 Watts) for minimal strain on a vehicle s electrical system. The high quality circuitry features reverse polarity protection and 5.0kW Transient Voltage Suppressor (TVS). Lamps are sealed to IP6K6 (protection against dust and high pressure water jets) and IP6K7 (protection against temporary water immersion) standards. They come pre-wired with integrated DT plug for easy installation Specifications Voltage Multivolt 9-33V DC Power Consumption: Rear Direction Indicator 9W Rear Position Lamp 2W Park Lamp 2W Stop Lamp 9W Protection: Reverse Polarity Protection 5.0kW Transient Voltage Suppressor (TVS) Protection Codes: IP6K6 (protection against dust and high pressure water jets) IP6K7 (protection against temporary water immersion) Approvals: HM (Red) E e HM (Amber) E e The material used for these lights includes a new generation of acrylics which has a high tolerance to chemicals and washing fluids as well as an enhanced impact resistance. This suits vehicles frequently washed with highly corrosive mining chemicals. DuraLed SAE Signal Lamps feature low power consumption and Multivolt circuitry, ensuring full light output from 9 to 33 volts. The lamps are fully sealed against dust and moisture and may be mounted vertically or horizontally (2-hole surface mount and mounting bushes supplied). LED technology ensures the lamps have ultra-low power consumption DuraLed lamps are equipped with advanced clear micro optic lenses to prevent the hazardous occurrence of ghost signals by internally reflected light from other sources. The smooth ergonomic design and very low profile (under 35mm) allows DuraLed units to be installed on almost any surface. Specially designed nylon bushes prevent stress fractures developing in the base, by distributing the fastening bolt load over a large surface area of the base without transferring any torque. Tamper proof screw covers securely lock the product into place and simplify cleaning by eliminating dirtcollecting cavities. HM (Red Illuminated) HM (Amber Illuminated) MULTI VOLT LED DT& BARE WIRE 0.4Kg ECE APPROVED IP6K7 200G 9 to 31 V DC 2W to 9W

64 DuraLed M Combination Signal Lamp Bare Wire Signal Lamp DT HM2379 HM2379D MINING SIGNAL LAMPS SIGNAL LAMPS 64 DuraLed M Combination Signal Lamp DuraLed M Combi are Fit and Forget stop/tail/indicator combination signal lamps, utilising the latest LED technology, and engineered specifically for ultra heavy-duty applications on mining equipment and service vehicles Optic appears clear until illuminated (off) Tail lamp function displayed Stop lamp function displayed DuraLed M Combi lamps are extremely robust, fully sealed truly fit and forget products, tolerant to severe vibration levels and very compact in design. A high impact and shock resistant clear Xylex lens is permanently bonded to a rugged, UV damage-resistant composite base for increased mechanical strength and maximum durability. Hella engineered DuraLed M Combi lamps to ensure a very long service life and no lighting loss due to internal dirt build-up; they are also very well suited to wet and corrosive environments and tolerate shortterm immersion. (See technical section for more Xylex information.) Unlike normal signal lamps, DuraLed products are maintenance free and extremely power efficient, which greatly reduces both operating temperature and demand on the vehicle s electrical system. Maximum service life and light output of the high intensity LEDs is ensured by using internal heat sinks. The integral Multivolt control module also protects the DuraLed M against damage from overheating, reversed polarity and short circuits. (See technical section for more Multivolt information.) Safe and reliable electrical connection is facilitated via a highly flexible double insulated cable sealed into the base, terminated as a short length with a DT connector or 2m cable with tinned wire ends. Other connector options can be supplied as special orders. DuraLed M Combi lamps are equipped with advanced, clear micro optic lenses to prevent the hazardous occurrence of ghost signals by internally reflected light from other sources. The smooth ergonomic design and very low profile (under 35mm) allows DuraLed units to be installed on almost any surface. Product features Impact resistant smooth Xylex lens Clear precision micro optics Multivolt 8-28V DC Low power < 10W Fully sealed fit and forget design 0.5kg mass 200G shock impulse resistant Overheat, reverse polarity and short circuit protection Double insulated supply cable with DT plug or tinned wire Spare Parts 9.HMDLM001 Cover Kit Yellow (Pack of 4) Tested over a 40ºC to +70ºC temperature range High efficiency, long life LED light IP6K7K UL94 flame retardant rated external parts ADR, ECE and SABS compliant Spares interchangeable with Hella DuraLed range CE compliant Indicator function displayed All functions displayed (on) MULTI VOLT LED DT& BARE WIRE 0.7Kg ADR/ ECE/ SABS COMPLIANT IP6K7 200G 8 to 28 V DC 9W

65 DuraLed MSIP Signal Lamp Red/Green HM MINING SIGNAL LAMPS DuraLed DuraLed MSIPs (Mine Safety Indicator Panel) are LED signal lamps offering both red and green signals in one compact housing, engineered specifically for ultra heavy-duty applications where safety is important, such as on underground transport equipment sharing space with foot traffic. MSIP Signal Lamp 65 SIGNAL LAMPS Product features Impact resistant smooth Xylex lens Clear precision micro optics Multivolt 8-28V DC Low power < 10W Fully sealed fit and forget design 0.5kg mass 200G shock impulse resistant Overheat, reverse polarity and short circuit protection Spare Parts 9.HMDLM001 Cover Kit Yellow (Pack of 4) Double insulated supply cable with DT plug or tinned wire Tested over a 40ºC to +70ºC temperature range High efficiency, long life LED light IP6K7K UL94 flame retardant rated external parts ROHS compliant Spares interchangeable with Hella DuraLed range DuraLed MSIP lamps are extremely robust, fully sealed truly fit and forget products, tolerant to severe vibration levels and very compact in design. A high impact and shock resistant, clear Xylex lens is permanently bonded to a rugged, UV damage resistant composite base for increased mechanical strength and maximum durability. Hella engineered DuraLed MSIP lamps to ensure a very long service life and no lighting loss due to internal dirt build-up; they are also very well suited to wet and corrosive environments and tolerate short-term immersion. (See technical section for more Xylex information.) Unlike normal signal lamps, DuraLed products are maintenance free and extremely power efficient, which greatly reduces both operating temperature and demand on the vehicle s electrical system. Maximum service life and light output of the high intensity LEDs is ensured through using internal heat sinks. The integral Multivolt control module also protects the DuraLed MSIP against damage from overheating, reverse polarity and short circuits. (See technical section for more Multivolt information.) Safe and reliable electrical connection is facilitated via a highly flexible double insulated cable, sealed into the base and terminated with tinned wire ends. Other connector options can be supplied as special orders. DuraLed MSIP lamps are equipped with advanced clear micro optic lenses to prevent the hazardous occurrence of ghost signals by internally reflected light from other sources. The smooth ergonomic design and very low profile (under 35mm) allows DuraLed units to be installed on almost any surface Optic appears clear until illuminated (off) Red illuminated shown Green illuminated shown Red & green illuminated shown MULTI VOLT LED DT& BARE WIRE 0.7Kg ADR/ ECE/ SABS COMPLIANT IP6K7 200G 8 to 28 V DC 9W

66 DuraLed M l White Inspection Point l l Red/Amber Side Marker l Red Marker l Amber Cabin Marker l Amber Marker Marker Lamp Bare Wire HM2054 HM2053PC HM2307 HM2026 HM2051 Marker Lamp DT HM2054D HM2053PCD HM2307D HM2026D HM2051D MINING SIGNAL LAMPS SIGNAL LAMPS 66 DuraLed Marker Lamps M DuraLed M Fit and Forget robust waterproof clearance marker and inspection lamps utilise the latest LED technology specifically for heavy duty applications White Inspection Point Lamp Red/Amber Side Marker Lamp (not ECE compliant) Red Marker Lamp (SAE/ECE compliant) The DuraLed M clearance and marker lamps are heavy duty injection moulded units in UV resistant polymers that offer a high resistance to corrosion and attack from a range of aggressive elements commonly found in mining, industrial and chemical plants (Please refer to the technical section for detailed information). The polymers used also offer high levels of protection against impact damage whilst exhibiting a large degree of self-damping vibration protection. DuraLed M signal lamps feature the Hella pioneered Multivolt system that ensures the same ultra bright light output at supply voltages between 8V DC and 28V DC, eliminating the problems associated with voltage drop and allowing the fitment of the same products on plant and machinery with 12V DC or 24V DC electrical systems. All DuraLed M products are fully sealed and pre-wired to cope with temporary immersion and high pressure cleaning. To enable easy integration into most mining machine wiring harnesses, DuraLed M products are supplied optional with DT Plug. Product features -40 C to +70 C. 200G shock resistant Sealed to IP6K6 & IP6K7 to withstand temporary immersion and high pressure washing Multivolt 8-28V DC Up to 60% less current draw than comparable globe lamps Ultrafast response time Transient spike protection Reverse polarity protection Sealed unit pre-wired with multi-core double insulated wire Available with DT Plugs or bare wire ends ADR & ECE compliant approved for road use High visibility yellow mounting base Polycarbonate lens material rated UL94 5VB PMMA lens material rated UL94 HB Mounting base material rated UL94 UB Amber Cabin Marker Lamp Amber Marker Lamp (SAE/ECE compliant) Marker Lamps displayed in OFF and ON modes. Optics on marker ;amps appear clear until illuminated. Spare Parts 9.HMDLM002 Marker Housing Yellow (Pack of 4) HM2051 HM2307 MULTI VOLT LED DT& BARE WIRE 0.4Kg ADR/ ECE COMPLIANT IP6K7 200G 8 to 28 V DC 1W

67 LED Daytime Running Lamp 2 Lamp Kit HM1535DRL DAYTIME RUNNING LAMPS LED Daytime Running Lamp 67 SIGNAL LAMPS On mine site safety is paramount. On most sites the use of headlights on vehicles is mandatory at all times, however dipped beam headlights are less visible during daylight hours than dedicated Daytime Running Lamps (DRLs). Product features Multivolt (9-33V DC) Equipped with 12 highly efficient LEDs Ultra long life Fit and Forget Low power consumption < 2 Watts Fully sealed against dust and high-pressure water jets Inbuilt overtemperature protection Stainless steel universal mounting bracket Polarity protected Spike and overvoltage protection Long term UV resistant Pre-wired with 2.5 metres of 3 x 0.75mm² automotive cable Homogenous close range illumination ADR/ECE: ADR 76/00 Hella has just launched a low power LED Daytime Running Lamp that provides extra safety through enhanced visibility, at a fraction of the power consumption of conventional headlights. Hella LED Daytime Running Lamps (DRLs) are designed to significantly improve vehicle visibility on site. These lights are sealed and require no maintenance ( fit and forget ) and are ADR approved for road use, giving the lights the versatility to suit multiple applications. With lower power usage and a zero maintenance requirement, make these lamps a sound investment into enhanced mine safety. The lens is manufactured from Swiss made Grilamid Optical Nylon which provides superior resistance to UV and to a wide range of chemicals, as well as high impact strength, enabling the lamp to survive the highly demanding environmental conditions of today s mining. The new Hella LED Daytime Running Lamp (DRL) is suitable for upright or pendant mounting and supplied with universal stainless steel mounting brackets. LED DRLs have multiple applications, which include area illumination around the vehicle Kit contains two lamps MULTI VOLT LED BARE WIRE 0.72Kg IP6K7 IP6K9K 9 to 33 V DC 2W ADR COMPLIANT

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69 Accessories 69 ACCESSORIES 70 LED Buggy Whip 71 Remote Jump Start Terminals Battery Master Lockout Switch 72 Screened Extension Cables 73 Heavy Duty Screened Extension Cables 74 NumiLED 75 NumiLED Pro 76 IR Dual Camera System 77 Quad Screen IR Kit 78 AccuPAX 80 Weatherproof Relay Self-Amalgamating Tape 81 DT Connectors

70 LED BUGGY WHIPS ACCESSORIES 70 LED Buggy Whip LED Buggy Whip 1.2 metre HM metre HM metre HM4630 MULTI VOLT IP6K7 LED 200G DT 0.5Kg 12V 1W To meet safety regulations, mine sites often require light vehicles to display high visibility safety flags to improve visibility for drivers of heavy machinery. Mounting onto the bumper bars of light vehicles, these give vehicles an extra layer of protection. During night and poor visibility levels the operation of light vehicles generally requires the use of rotating safety beacons to improve visibility. However in mine sites where the topological surface contains large dips and hills, these may not be adequate. By combining a bright LED with a long reflective safety flag, drivers of light vehicles can ensure they are always in the line of sight of heavy machinery. The LED module puts negligible load on the vehicles electrical system (less than 1W), the shaft is constructed from a high quality fiberglass rod, sealing the electrical components from weather damage. The flag mounts to the vehicle via a quality quick release latch allowing the flag to be taken down when the vehicle is off site. The cable is terminated with a DT plug, allowing quick removal whilst sealing the electrics from environmental damage. The flag contains reflective UV resistant material and the nylon material repels the high levels of dirt and dust often encountered in mine sites. 9.HM46FX Technical Specifications: Light source Quality LEDs in BA9 bulb holder Voltage 12V Power Consumption < 1W Length 1.2 metres, 2.0 metres or 3.0 metres Mounting Integrated mounting bolt on base with snap on/off quick-release shaft for quick and easy installation Spare Parts: 9.HM46MP Male Pin Connector for Quick Release 9.HM46MS Medium Spring 9.HM46GL LED Globe 9.HM46MP 9.HM46MS 9.HM46FX Replacement Reflective Cross Flag Snap On/Off Quick Release

71 TERMINALS & SWITCHES Remote Jump Start Terminals 71 ACCESSORIES Heavy duty, high capacity jump-start connectors for vehicles and equipment. Ideal for use where access to terminals is restricted or dangerous. Eliminates the chance of cross polarity connections through the specially shaped plug. Reduces chance of sparking and possible ignition of flammable materials. Features high impact ABS plastic housing/insulator. Zinc coated terminals. Easy to mount and connect, supplied with washers and M12 Nyloc Nuts. Remote Jump Start Terminals HM7546J Technical information: Removes risk of terminal crossing High Impact ABS Plastic Zinc Coated Terminals Battery Master Lockout Switch As a further extension to the accessories range Hella has developed a heavy-duty 2-pole lockable battery lock out switch. The Battery lockout switch provides a reliable power disconnection and safety cut-off that protects the vehicle against tampering, theft and battery drain. It also protects service personnel from electrical hazards during service operations. Battery Master Lockout Switch HM7592B Technical information: Waterproof and Dustproof to IP67 Tested to 200G shock for cycles. Sealed design allows switch to be mounted in the best location regardless of environment. Large red handle makes it easy to operate with gloved hands. Composite-engineered polymer housing that will not corrode. 300A continuous current rating at 12V and 250A at 24V Temperature operating range -40 C to + 85 C. Divider on base prevents accidental shorting of battery cables. Easy to read designations on bezel and 90 switch travel make it easy to identify switch position

72 SCREENED CABLES ACCESSORIES 72 Screened Extension Cables Screened Extension Cables with 10A Plug/Socket 10m HMEC1010AU 15m HMEC1510AU 20m HMEC2010AU 25m HMEC2510AU Screened Extension Cables with 15A Plug/Socket 20m HMEC2015AU 30m HMEC3015AU 40m HMEC4015AU Braid is earthed when cord is in use 10A Socket 15A Socket Electrical safety is an important aspect in the overall Occupation Health and Safety environment, and there is increasing awareness that passive elements like cables and extension cords form a key link in the safety system. Permanently installed power cables are protected from mechanical damage by conduit, cable trays and steel wire armour. Extension cords are not so protected. This lower degree of protection is even more obviously an anomaly when it is considered that the extension cords used in construction and maintenance are not only more likely to be damaged mechanically than the permanent cables but also in much closer proximity to people. Hella Screened Extension Cables are specifically designed to improve safety in a mining and general industry environment by offering a more durable and safer product for tradespeople to use. Hella Screened Extension Cables are approved to Australian and New Zealand standards AS/NZS 3191/3120/3112 and Hella Screened Extension Cables offer superior protection with a durable protective UV resistant outer sheath made from PVC that is designed to withstand the general wear and tear of electrical cables in workshop and field applications. Hella screened cables also incorporate clear moulded plug and socket ends for greater protection of the user and the internal conductors by ensuring there is no separation of the plug and cables. These moulded plugs and sockets also prevent moisture ingress to minimise corrosion and ensure a much longer service life. Hella Screened Extension Cables utilise a tinned braided copper screen for maximum flexibility and electromagnetic suppression of the extension cable. This makes for easy use for the operator in daily applications and avoids time-consuming cable tangles. This protective copper braid offers greater protection against damage to the cable and is also connected to the earth pin on each end of the extension cable ensuring that a residual current device is activated immediately if a catastrophic failure occurs. The copper conductor cores used in all Hella Screened Extension Cables have a cross sectional area of 2.5mm². This is to ensure minimum voltage drop over the length of the cable and longer life due to the reduction of heat buildup within the product. Utilising a flexible and safer screened extension cable is a must for every mine, quarry and general industry and is recommended by mining department safety officials as a matter of course. Hella Screened Extension Cables are available in various length and current options to suit every application. Product Features: Triple insulated cable Tinned copper braided shield is earthed for additional protection Extra soft flex to avoid tangles Heavy-duty strain reliefs Fully encapsulated plugs and sockets Approved to Australian and New Zealand standards AS/ NZS 3191/3120/3112 and 9199 Reduced electromagnetic interference No corrosion of conductors from moisture in cables, plugs or sockets Plug and socket impact tested to 100 Joule Cable impact tested to IK10 (20 Joule) 2.5mm² conductors on all screened extension cables

73 SCREENED CABLES Heavy Duty Screened Extension Cables 73 ACCESSORIES Electrical safety is an important aspect in the overall Occupational Health and Safety environment, and there is increasing awareness that passive elements like cables and extension cords form a key link in the safety system. Permanently installed power cables are protected from mechanical damage by conduit, cable trays and steel wire armour. Extension cords are not so protected. This lower degree of protection is an obvious anomaly extension cords used in construction and maintenance are not only more likely to be damaged mechanically than permanent cables but also in much closer proximity to people. Hella Heavy Duty Screened Extension Cables are designed specifically for ease of use and to improve electrical safety in the mining and construction industries by offering a more durable, safer product for tradespeople to use in wet and dusty environments. The electrical plug and socket are protected against water and dust ingress to IP66 by a proprietary cover system that mates with the majority industry standard screw covers industrial electrical outlets used in Australia and New Zealand. Hella Heavy Duty Screened Extension Cable insulation and connectors are moulded using clear protective UV resistant PVC outer sheath enabling users and inspectors to rapidly and reliably visually identity the condition of all the safety features of cables brought onto the site or used in the workshop. A neon lamp indicating if power is present in the cable is incorporated in the socket of all Hella Heavy Duty Screened Extension cables enabling users to immediately identify live circuits, and aid testing. Extended service life and greater user safety is ensured by reducing moisture ingress into the extension cable itself through the use of clear moulded plug and socket ends ensuring a perfect seal and stress transfer between the electrical connectors and the cable itself. The electrical conductors and screen are welded to the connector pins to minimize contact resistance and the risk of separation between the plug and cables. Hella Screened Extension Cables utilise a braided tinned copper screen for maximum flexibility across a wide range temperature range, and avoids time-consuming cable tangles. The earthed screen provides significantly improved suppression of electro magnetic fields radiated by the cable, and provides additional protection fro equipment connected to the cables against induced currents. As the first contact caused by mechanical damage to the cable is to the earthed screen it ensures that a residual current device is activated immediately. The copper conductor cores used in all Hella Screened Extension Cables have a cross sectional area of 2.5mm². This is to ensure minimum voltage drop over the length of the cable and longer life due to the reduction of heat buildup within the product. Hella Heavy Duty Screened Extension Cables are approved to Australian and New Zealand standards AS/NZS 3191/3120/3112 and Utilising a flexible and safer screened extension cable with IP66 rating or better ingress protection is a must for every mine, quarry and general industry and is recommended by mining department safety officials as a matter of course. Hella Heavy Duty Screened Extension Cables are available in various length and current options to suit every application. Screened Extension Cables with 10A Plug/Socket 20m HMIC2010AU Screened Extension Cables with 15A Plug/Socket 20m HMIC2015AU Screened Extension Cables with 20A Plug/Socket 30m HMIC3020AU IP66 Braid is earthed when cord is in use 10A Socket 15A Socket 20A Socket Product Features: Triple insulated cable Tinned copper braided shield earthed for additional protection Extra soft flex to avoid tangles Heavy-duty strain reliefs Fully encapsulated plugs and sockets Approved to Australian and New Zealand standards AS/ NZS 3191/3120/3112 and 9199 Reduced electromagnetic interference No corrosion of conductors from moisture in cables, plugs or sockets Neon safety light fitted in socket IP66 rated protection on plug/socket connection when assembled correctly IP66 cover designed to suit other major brands of manufacturers 2.5mm² conductors on all screened extension cables

74 NumiLED Kits Small (396mm) Set of 10 small LED modules, 24V DC Single number housing, stainless steel Single number housing, black Triple number housing, stainless steel Triple number housing, black HMTNM6605 HMTNM6606 HMTNM6607 HMTNM6608 HMTNM6609 NumiLED Kits Large (720mm) Set of 10 large LED modules, 24V DC Housing, stainless steel Housing, black HMTND2156 HMTND2157 HMTND2158 MINING SIGNAL LAMPS ACCESSORIES 74 NumiLED Number Boards NumiLED is a modular system of robust illuminated identification panels developed for use in work environments where situational awareness forms the basis of safe operation, and where visibility is often very poor. Typical applications are: identification numbers for mining haul trucks and shovels, process tanks and conveyor transfer stations Small Board Single 720 Small Board Triple Large Board Single 396 The very high levels of dirt in mining and many industrial applications render retro-reflective and normal high contrast signage ineffective within a short period. The NumiLED system overcomes these challenges through the combination of advanced optical engineering and the best high intensity LED technology available. NumiLED panels provide clear, legible identification for instances up to one kilometre. Each NumiLED unit consists of a robust housing equipped with an array of high intensity LED modules arranged to display an alphanumeric character of choice. Hella engineered every aspect of the NumiLED system to withstand the corrosion, vibration and generally hostile operational environment for extended periods. Designed to indefinitely retain its full integrity after maintenance, repairs can be made quickly without any requirement for specialised tools or skills. The active LED modules are custom versions of proven fit & forget Hella products adapted to suit this application. The LED modules are fully sealed and pre-wired with double insulated cabling and keyed DT connectors to eliminate malfunctions due to water ingress, corrosion or user errors. Cognisant of the operating environment, the NumiLED system is designed to allow any one LED module to be damaged without impairing the function of the whole unit. Individual LED modules can be added, removed and replaced at any time, allowing users to re-use or repair, or recycle NumiLED units into new applications. To ensure long term reliability and maintainability, the power distribution and control of the LED modules is implemented as a weatherproof distribution module with keyed DT sockets affixed to the rear of the NumiLED housing. The power module is based on an ultra heavy-duty military grade dual layer gold plated PCB incorporating fault finding diagnostics as well as the programming control system in the NumiLED PRO versions. NumiLED housings are precision fabricated from heavy gauge grade 304 stainless plates. A corrosion and UV resistant black semi gloss powder coat or natural finishes are standard options. The NumiLED housing is supplied complete with power module, prepared fixing and mounting holes, with the larger cabling holes fitted with high quality rubber grommets to prevent cable chafing. In addition, each NumiLED housing is equipped with four high quality vibration dampers to isolate the NumiLED number board from the vibration generated by the machine it is mounted to. Product features Improves safety & visibility Low maintenance Low energy consumption Long service life Expandable fleet numbers Easy to assemble Spare Parts 9.HMTN001 NumiLED 8-Way Distribution Board 9.HMTN002 NumiLED Connection Cable - Single, 2m Excellent performance in hot, cold and wet environments Fully sealed against dust and moisture to IP6K7 Durable PMMA lens Robust ABS and PC housing 9.HMTN003 NumiLED Connection Cable - Triple, 2m 9.HMTN004 NumiLED Vibration Mounting Kit HM4960SA DT Connector Kit - Male (pack of 10) MULTI VOLT LED DT 5.0Kg IP6K7 200G 24V DC 60W MAX

75 NumiLED Pro Boards Small (396mm) Single number board, stainless steel Single number board, black Triple number board, stainless steel Triple number board, black HMTNM6612 HMTNM6613 HMTNM6610 HMTNM6611 NumiLED Pro Boards Large (720mm) Board, stainless steel Board, black HMTND2159 HMTND2160 MINING SIGNAL LAMPS NumiLED NumiLED PRO number boards are even more versatile featuring the advanced programmable power board with internal memory function. Pro Number Boards 75 ACCESSORIES Programming dongle Product features Improves safety & visibility Pre-assembled and fitted with all required LED modules Programmable power distribution board with internal memory function Integrated front mounted MagCode programming port Supplied with special MagCode programming dongle to change characters Reverse polarity and voltage spike protected Low maintenance Long service life Expandable fleet numbers Sate of the art design Low energy consumption (max. 20W per digit) Excellent performance in hot, cold and wet environments Fully sealed against dust and moisture to IP6K7 Durable PMMA lens Robust ABS and PC housing While the standard NumiLED Kit consists of empty housings and packs of LED modules that the end user assembles to create the desired digits, the programmable NumiLED PRO boards are supplied fully assembled with all seven LED modules. The required digit is selected by simply using the supplied dongle on the special integrated MagCode programming port. The NumiLED PRO board will cycle through all possible digits and stop when the socket is removed. The internal memory function ensures that the selected digit is displayed every time power is supplied and will continue to do so even if a damaged LED module is replaced. The NumiLED PRO board can be re-programmed at any time using the same process. To prevent unauthorized tampering with the displayed digits, the front mounted programming port mechanically disconnects the electrical connection when the dongle is removed, which itself incorporates encrypted data that the power module must validate prior to responding to any programming inputs. To suit different equipment types, mounting preferences and visibility distance requirements found on mines, Hella offers NumiLED boards in two sizes. While the large (720mm tall) housing is supplied as single digits only for ease of handling, the smaller (396mm tall) housing is available in both single and triple digit versions. The standard NumiLED LED colour is red, but users can obtain different coloured LED modules for applications where different equipment types are identified through their colour as special orders Small Board Single 720 Small Board Triple Large Board Single 396 Spare Parts 9.HMTN002 NumiLED Connection Cable - Single, 2m 9.HMTN003 NumiLED Connection Cable - Triple, 2m 9.HMTN004 NumiLED Vibration Mounting Kit 9.HMTN005 NumiLED PRO Programming Dongle 9.HMTN006 NumiLED PRO Programmable PCB HM4960SA DT Connector Kit - Male (pack of 10) HMTNM6605 Small LED Modules, 24V DC (pack of 10) HMTNM2156 Large LED Modules, 24V DC (pack of 10) Vibration Damping (Detail) Distribution Board (Rear View) MULTI VOLT IP6K7 LED 200G DT 5.0Kg 24V DC 60W MAX

76 MINING REVERSING CAMERA KIT ACCESSORIES 76 Infra-red Dual Camera System Colour 5.6 inch Monitor, Infra-red Camera, 20m Cable, 12-24V HM5700KIT Colour 7.0 inch Monitor, Infra-red Camera, 20m Cable, 12-24V HM5701KIT Spare Parts: 9.HM5700 Colour 5.6 Monitor 9.HM5701 Colour 7.0 Monitor 9.HM5702 Infra-red Reverse Camera 9.HM5703 Connection cable, 20m Visibility around vehicles on mine sites can be an issue, particularly on large machinery. Hella has introduced a highly durable LED Infra-red system with the ability for customized setup based on the application. The Infra-red camera enables greater visibility by penetrating harsh dusty environments with minimal backscatter. The option of a compact 5.6 monitor or larger 7.0 screen enables site operators to greatly improve safety. The unit has a low power burden on the system of less than 5W for monitor and less than 2W for camera and is powered by a Multivolt system, allowing safe operation during fluctuation in the vehicle voltage level between 9 and 32V. The camera also includes audio pickup with built in speaker in the monitor for additional safety. Other features include highly durable splash proof screen with automatic day/night dimming function and manual brightness, contrast, colour and volume control as well as true and mirror image display modes for camera mounting flexibility. The highly durable LED Infra-red Camera is constructed from aluminum alloy and has been designed to withstand heavy vibration as well as damage from harsh environments, dust and moisture often encountered on mine sites. Equipped with 18 high-quality Infra-red LEDs for excellent night vision up to 12 metres. The system features a small physical footprint for versatile mounting and overall weight of only 380 grams (including mounting bracket). Designed and tested to withstand a temperature range of -10 C to +65 C. 9.HM " Monitor Technical Specifications 5.6 inch and 7.0 inch Monitor: LCD Display Multivolt system 12V or 24V DC supply Low power consumption < 5W Built-in speaker Adjustable brightness, contrast, colour and volume control Auto day/night dimming function True/Mirror image selection on monitor Camera switching on monitor Auto trigger function for optional second camera Operating temperature range -15 C to +65 C Signal system PAL/NTSC Auto 9.HM " Monitor Technical Specifications Infra-red Camera: Robust aluminium alloy 18pcs IR LEDs for improved night vision (10-12 metres) 1/4 image size Focal length of lens 2.6mm, F diagonal lens angle Ingress protected to IP68 Low power consumption < 2W Compact size (82 x 73 x 58mm) Light weight of only 380g (including mounting bracket) Camera activation by means of reverse gear selection Operating temperature range -30 C to +65 C 9.HM5703 Connection Cable

77 MINING REVERSING CAMERA KIT Quad Screen Input Infra-red Camera System 77 ACCESSORIES To complement Hella s visual display systems a quad screen system capable of up to 4 camera inputs has been developed. The system is designed for large mining machinery such as loaders and excavators where drivers require viewpoints from multiple angles. Offering the flexibility of displaying one, two, three, or even four camera views, the system caters for the largest of mining machinery in many applications. The monitor is rugged enough for mining use, with an aluminium alloy housing providing ingress protection to IP65. With a weight of only 800 grams, the monitor has a small physical footprint in the driver s cabin. The monitor has the ability to automatically adjust the display mode according to the number of camera inputs detected. Other features include an automatic day/night dimming function, along with manual brightness, contrast, colour and volume control as well as independent true and mirror image display modes for each camera, offering further mounting flexibility. The seven inbuilt languages allow the system to be used in many different countries by a wide range of operators. Also now available is a custommade heavy-duty steel camera guard, designed to protect the infra-red camera from damage and vandalism. The kit is designed to withstand heavy vibration as well as damage from dust, moisture and the harsh environments often encountered on mine sites. The quality electronics provide reverse polarity and high and low voltage protection. Kit contains monitor bracket, roll of silicon tape, 1.5m loom cable, sun visor, 20m extension cable and IR camera. Quad Screen IR Camera Kit Monitor, Infra-red Camera, 20m Cable, 12-24V HM5800KIT Spare Parts: 9.HM5702 Infra-red Reverse Camera 9.HM5703 Connection cable, 20m 9.HM5801 7" Monitor 9.HM5801 Colour Multiscreen Monitor 17.8cm (7.0 ) 9.HM5802 Steel Camera Guard Technical Specifications Quad Monitor: LCD Display 16:9 7 Multivolt system 12V DC or 24V DC supply Low power consumption < 5W Built-in speaker Adjustable brightness, contrast, colour and volume control Auto day/night dimming function Brightness 350 cd/m² Resolution 336,960 pixels True/Mirror image selection on monitor Camera switching on monitor Auto trigger function for optional second camera Operating temperature range 20 C to +70 C Signal system PAL/NTSC Auto Dimensions 200(L)*76(W)*138.5(D) 9.HM5802 Steel Camera Guard 9.HM5703 Connection Cable

78 MASTER SWITCH ACCESSORIES 78 AccuPAX Battery Master Switch Battery Master Switch 12V HM4660A Battery Master Switch 24V HM4660B Spare Parts: HM4660ROD iros Roll-over Protection Device HM4660SWA Latching Push On / Twist Off Switch - Double Pole, IP65 HM4660SWB Latching Push On / Twist Off Switch - Double Pole with Guard, IP65 HM4660SWC Momentary Push Button Switch - Single Pole, IP65 HM4660SWD Momentary Push Button Switch - Single Pole with Guard, IP65 HM4660SWE Rotary On / Off Switch, 4 pin, with Lid (use connector kit) HM4660SWF Push Button Switch, 2 pin (use connector kit) HM4660LOC Lockable Cover, Stainless Steel HM4660KTB 7 Pin DIN Connector with 5M Harness HM4660KTC 7 Pin DIN Connector with 700mm Harness AccuPAX is an intelligent 2-pole, bi-stable, electro-mechanical battery master switch with mechanical locking. It is approved for hazardous goods transport. It incorporates a micro controller to monitor and operate several safety functions, that is unavailable on older style battery isolator switches, and is suitable for 12V and 24V systems. Its prime function is to disconnect and isolate the main battery positive and negative circuits of the vehicle or engine plant to render it safe and/or inoperable. It may be wired and operated directly at the control panel on the switch face to replace existing products. Significantly more sophisticated control systems can be implented, with multiple safety isolators located in the cabin or elsewhere at desired locations around the vehicle. AccuPAX can also be activated by an external trigger like a roll-over sensor. In normal situations, AccuPAX will step through a pre-programmed shut-down sequence, ensuring the safe disconnection of onboard engine management systems to avoid data corruption. Incorporated in this sequence is an alternator field isolation procedure to prevent damage to the alternator, battery and electrical system due to voltage surges. In emergency shut down situations, such as a rollover, AccuPAX disconnects all power immediately via the emergency shut down switch, or the optional rollover detection device. AccuPAX constantly monitors system voltage and disconnects the battery if system voltage falls below the user selected safety level, to prevent damage to the electrical system. The AccuPAX complies with Australian Standards AS and European ADR In addition to the rollover sensor, optional equipment includes lock-out guards, switches and cable harnesses to facilitate easy installation of the AccuPAX unit Technical information: Ex & CE Certified Compliant with ADR 2005 Compliant with AS 2809 (Draft) Field isolation for North American vehicles D+ shutdown for European vehicles Delayed ECM shutdown to prevent re-programming Direct plug in iros roll over device works with all other roll over devices (optional equipment - not supplied) Roll over simulation test with status light Luminous On/ Off/ Roll Over push button switches Robust IP65 rated enclosure Stainless Steel mounting bracket (Lucas SSB interchangeable) Low battery voltages disconnect Lockable cover (optional equipment not supplied) Switch Rating: HM4660A HM4660B Operating Voltage 9 to 15 Volts 18 to 30 Volts Current Rating 300A continuous 300A continuous Max Current 5 Sec 2500A 2500A Max Current 30 Sec 600A 600A Field Isolation Circuit 10A max 10A max Optional Low Voltage Monitoring <11.4V ± 0.3V (60 sec delay) <22.5V ± 0.3V (60 sec delay) Low Voltage Disconnect <9.5V (60 sec delay) <18V (60 sec delay) External Trigger 10mA 10mA Roll Over 1A 1A Current Draw OFF Mode 150mA (red LED illumination) 150mA (red LED illumination) Auxiliary Relay # 1 10A 10A Auxiliary Relay # 2 for ECM Delay 0.5A 0.3A

79 MASTER SWITCH 79 ACCESSORIES HM4660LOC Lockable Stainless Steel Cover HM4660SWA Latching Push On / Twist Off Switch - Double Pole, IP65 HM4660SWD Momentary Push Button Switch - Single Pole with Guard, IP65 HM4660ROD iros Roll-over Protection Device

80 WEATHERPROOF KIT, LOOM TAPE ACCESSORIES 80 12V Weatherproof Changeover Relay and Connector Assembly Kit 12V Kit 12V ISO mini relay and connector assembly kit: HMWPR a x ISO-style 12 volt c/cover relay 1 x Connector body with seals for pull to seat terminals 3 x Large barrel pull to seat terminal 6.3mm width suits cable size 3.00mm 2 2 x Small barrel pull to seat terminal 6.3mm width suits cable size mm 2 30 Voltage 10-16V DC a Operating Range Temp -40 C to +125 C 35mm Contact current rating NO 35A / NC 20A Coil 23 C Transient Suppressor Resistor Ohms 680 Ohms 56.5mm Self-Amalgamating Tape Self-Amalgamating Tape HMAT85 Polyethylene self-amalgamating loom tape ideal for waterproof sealing of electrical connections, temporary repair and sealing of plumbing joints. Also suitable for emergency repair of radiators, engine hoses and auto electrics. Easy to unwind and resistant to water, ozone, UV and a wide range of chemicals including alkalis, hydraulic fluids and vegetable oils. Tape Thickness Breakdown Voltage 0.5mm, tensile strength at break 12 N/cm 34 kv/mm Elongation 600% Service Temperature -35 C to +130 C

81 CONNECTORS DT Connectors 81 ACCESSORIES DT Connectors Environmentally sealed connectors rated -55 C to +125 C. Supplied complete with removable, solid copper crimp contacts ( mm 2 ) and secondary locks. All contacts rated 13A. HM4960 HM4961 Qty. in pack 2 Pole DT Connector Set 1 HM Pole DT Connector Half-Set* 10 HM4960FM 3 Pole DT Connector Set 1 HM Pole DT Connector Half-Set* 10 HM4961FM 4 Pole DT Connector Set 1 HM Pole DT Connector Set 1 HM Pole DT Connector Half-Set* 10 HM4963FM 8 Pole DT Connector Set 1 HM Pole DT Connector Set 1 HM4965 HM4962 HM4963 Spare Parts Small I.D. plug contact to suit cable mm 2 Small I.D. socket contact to suit cable mm 2 Large I.D. plug contact to suit cable mm 2 Large I.D. socket contact to suit cable mm 2 Sealing plug 9.HM HM HM HM HM * Half-Set = female socket with male contacts. HM4964 DT Connector Crimping Tool Specially dsigned crimping tool with multiple jaws for even crimp of DT Terminals HM8275 HM4965 HM8275 DT Connector Crimping Tool

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83 Interior Lighting 83 INTERIOR LIGHTING 84 EuroLED Touch M 85 CargoLED 86 SpotLED 88 FlexSPOT 89 MiniThinLED

84 EuroLED Touch M Interior Lamp with 2.5m cable with 0.5m cable and DT plug HM HM MINING INtERIOR LAMPS INTERIOR LIGHTING 84 EuroLED Touch M Interior Lamp Multivolt 9-33V DC Harnessing the durability and power saving benefits of advanced single LED technology, EuroLED Touch interior lamps offer long lasting, dual colour LED light output of white light for general interior illumination and the additional function of red light to help maintain night vision (see below). 110 White On Red On Cable Exit EuroLED Touch interior lamps are equipped with high-performance LEDs a single white LED in the centre of the lamp plus multiple red LEDs arranged in a circular pattern and highly advanced lens optics providing a uniform light distribution without glare for optimum efficiency and increased safety. The use of MultivoltTM electronics ensures a consistent level of brightness at any input voltage between 9 and 33V DC, even when subjected to severe voltage fluctuations. Lighting control is made easy thanks to integral, touch sensitive switch pads (white pad for white light, red pad for red light) and a 4-stage dimming function with memory. All it needs is the touch of a finger to switch the light colour and regulate the light intensity to suit individual cabin lighting requirements. When the finger is held on either switch pad for longer than two seconds, the lamp will automatically cycle through four dimming stages until the finger is released on the light level required. The integrated memory function ensures the lamp turns on at the light level last selected. In addition to touch sensitive switching, EuroLED Touch lamps are also suitable for synchronised remote operation from multiple points using standard On/Off/On momentary switches. EuroLED Touch lamps are shock and vibration resistant and completely sealed against dust and moisture to international protection standards for maximum durability and increased service life. The unique rounded and low profile design allows fitment into narrow panels, whilst offering distinct operational and safety benefits. Compared to common fluorescent lamps, EuroLED Touch interior lamps will not interfere with other electronic equipment and run completely silent. Product features Dual colour LED lighting Integral, touch sensitive switching Dimming function with memory Multivolt 9-33V DC Ultra low power consumption Spare Parts 8HG EuroLED Mounting Spacer Shock and vibration resistance Over voltage, reverse polarity and transient spike circuit protection Low EMC signature IP 6K6 6K7 completely sealed against dust and moisture Red Light and Night Vision The human eye contains two types of receptors, rods and cones. Both have an increased sensitivity to frequency bands at different ends of the visual spectrum. Rods are largely responsible for our daytime and colour vision and have an increased sensitivity towards the red band of the visual spectrum. In contrast cones are responsible for our night vision capability and have an increased sensitivity towards the blue, shorter wavelength band of the visual spectrum. For this reason red light helps to preserve our night vision as it will not affect the sensitivity of the cones. Mounting Spacer designed to suit all EuroLED interior lamps. Enables easy surface mount with side cable exit MULTI VOLT LED DT & BARE WIRE 0.3Kg IP6K7 200G 9 to 33 V DC 5W

85 CargoLED Heavy Duty Interior Lamp HM227HD MINING INTERIOR LAMPS CargoLED Heavy Duty Interior Lamp Multivolt 9-31V DC Hella CargoLED is an advanced interior light designed with particular attention to visual comfort for applications where operators need high quality light to perform visually intensive tasks for extended periods, in operating environments unsuitable for conventional light sources. 85 INTERIOR LIGHTING Product features Aluminium core body for optimal thermal performance of LEDs Clear UV and chemical resistant modified acrylic lens Large optical system for high light output Low luminance indirect design ensures low glare High intensity LED light source array Sealed unit pre-wired with multi strand double insulated cable Available with DT plugs Multivolt 9-31V DC Spike protected to +500volts Over voltage protected to +200volts Reverse polarity protected to -500volts Power consumption: 6W Sealed to IP6K9 to withstand temporary immersion and high pressure washing when installed Surface mount accessories available 200G shock impulse resistant -40ºC +60ºC External elements manufactured from flame retardant polymers rated UL94 HB ADR 2006 (hazardous goods transport) compliant Traditional vehicle interior lighting systems do not deliver the quality of light required by operators of drill rigs and other complex plants who often spend large amounts work time reading detail maps or drawings. Concurrently, flat display panels containing more information are replacing analogue instruments in cabins adding to the intensity and complexity of the visual tasks. To overcome the limitations of high susceptibility to physical damage and poor efficiency inherent in conventional solutions, Hella produced the CargoLED. This unique product combines the best LED experience with advanced, glare free, low luminance indirect lighting technology originally developed for CAD studios. This highly innovative solution delivers the visual comfort normally found in offices into almost any mining machine cabin. The low power consumption and minimal heat output of CargoLED enables continuous operation in confined spaces and reduces burn injury risk. CargoLED employs a large brilliant Free-Form optical system and clear lens to provide a large homogenous area illumination with maximum efficiency. Hella engineered CargoLED lamps to ensure a very long service life and no lighting loss due to internal dirt build-up. Maximum service life and light output of the high intensity LEDs is ensured through using the aluminium body as a massive heat sink. The clear exterior lens can be re-polished if required, with no detrimental effect on light-output or chemical resistance. CargoLED is unaffected by shock and vibration, ensuring high reliability. The lamp is fully sealed and designed for a true fit and forget installation. Advanced Multivolt control of the LEDs ensures consistent illumination from 9-31V DC even under severe voltage fluctuations and low battery voltages. This delivers significantly better performance than low-power fluorescent or incandescent interior lights. The circuitry also provides reverse polarity, spike and overvoltage protection for long life and reliable operation. Safe and reliable electrical connection is facilitated via a short length double insulated cable terminated as standard in DT connectors. A thick gasket is supplied to ensure reliable sealing for recessed installation, and an optional surface mount adaptor is available. Shown lit MULTI VOLT LED DT 0.5Kg IP6K9 200G 9 to 31 V DC 6W

86 SpotLED Screw Mount, DT l White Cover l White Cover l Red Ambient Ring l Yellow Cover l Yellow Cover l Red Ambient Ring l Black Cover l Black Cover l Red Ambient Ring Fixed HM680FNW HM680FRW HM680FNY HM680FRY HM680FNB HM680FRB Adjustable HM680ANW HM680ARW HM680ANY HM680ARY HM680ANB HM680ARB MINING INTERIOR LAMPS MOBILE INTERIOR EQUIPMENT LIGHTING LIGHTING 86 SpotLED Fixed & Adjustable Interior Lamps Multivolt 9-31V DC SpotLED lamps are sophisticated LED interior lights designed for applications where there is a requirement for low glare, spill free lighting, with the option to switch from white primary to red ambient light to maintain night vision. Fixed Model Adjustable Model Adjustable Model (20 ), shown with white LED illuminated, and white cover SpotLED interior lights are available in a number of versions: These include fixed or adjustable optical modules either with or without the low level ambient illumination to monitor critical instruments. General illumination is provided by a single high intensity white LED located deep inside a Free-Form reflector with a black sleeve to eliminate direct view of the light source and discomfort glare. A separately switched, low intensity red LED illuminates a circular light CELIS light guide, to provide low intensity ambient illumination for safety and night vision compatability. The low power consumption, combined with minimal heat output in continuous use, and ergonomic, smooth design of SpotLED reduces personal injury risk in confined spaces, while the fit-and-forget completely sealed and waterproof optical units will not suffer lighting loss due to internal dirt build up. Advanced Multivolt drive circuitry, providing reverse polarity, spike and over-voltage protection for long life and reliable operation, is sealed into the optical module. SpotLED lamps deliver consistent illumination from 9-31V DC even under severe voltage fluctuations and low battery voltages. Maximum service life and light output of the high intensity LED light source is ensured through an integral aluminium heat sink. SpotLED lights require external switching systems, and can operate on standard interior light circuits. Safe and reliable electrical connection is facilitated via a short length double insulated multi core cable terminated as standard in DT connectors. The screw cover end caps are available in a range of colours. Ambient light functions in amber, blue, green or white can also be delivered on special order. Product features Available in fixed or adjustable versions 20 degree angle adjustment to each side Low intensity red CELIS ambient light Aluminium heat sink mounted LED Clear polycarbonate lens and CELIS light guide for excellent optical performance and impact resistance Impact resistant, easy to clean ABS housing components Low glare homogenous light distribution High intensity LED light sources Changeable colour side caps Pre-wired with multi strand double insulated cable with DT Multivolt 9-31V DC Reverse polarity protected to -500 volts Power consumption: 3W Fully sealed to IP6K9K (optical unit) to withstand temporary immersion and high pressure washing 200G shock impulse resistant -40ºC +60ºC External elements manufactured from flame retardant polymers rated UL94 HB ADR 2006 (hazardous goods transport) compliant Fixed Model, shown with Red Ambient Ring illuminated, and white cover Spare Parts 9.HMDLM002 Marker Housing Yellow (Pack of 4) MULTI VOLT LED DT 0.3Kg IP6K7 200G 9 to 31 V DC 3W

87 87 INTERIOR LIGHTING Adjustable model shown Optional Yellow Cover Optional Black Cover Optional White Cover

88 FlexSPOT LED Interior Lamp l White Shroud l Yellow Shroud 150mm flexible arm HM720150W HM720150Y 400mm flexible arm HM720400W HM720400Y MINING INTERIOR LAMPS INTERIOR LIGHTING 88 FlexSPOT LED Interior Lamp Multivolt 9-31V DC FlexSPOT LED is a flexible arm LED interior lamp with integral switch, for use in applications where the operating environment is unsuitable for conventional light sources. A new generation of high efficiency white LED light sources enabled the design of a fit-and-forget low power reading light with a very long service life and little heat build-up, enabling continuous use of the FlexSPOT with no danger of over heating or burn injury. FlexSPOT LED is unaffected by shock and vibration and has a high-reliability switch integrated into the lamp head, for ease of use and integration into work environments. Advanced Multivolt circuitry, providing reverse polarity, spike and over-voltage protection for long life and reliable operation of the LED, is sealed into the light. FlexSPOT lamps will deliver consistent illumination from 9-31V DC even under severe voltage fluctuations and low battery voltages. Maximum service life and light output of the high intensity LED light source is ensured by an aluminium heat sink internal to the lamp head. We have tested the SpotLED lamp head to the same exacting standards demanded of Hella Mining LED signal lights. Hella bonded the best quality flexible arm available into the head and mounting bracket to ensure a long, trouble-free life for the FlexSPOT. Safe and reliable electrical connection is facilitated via a short length double insulated cable terminated as standard with bare wire ends. Product features Aluminium heat sink for optimal thermal performance of LEDs UV and chemical resistant modified acrylic lens Impact resistant polycarbonate and ABS housing Integral switch Low glare homogenous light distribution High intensity LED light source Pre-wired with multi strand double insulated cable Available with DT plugs or bare wire ends Multivolt 9-31V DC Reverse polarity protected to -500 volts Power consumption: 2.5W Sealed to IP53 protects active electronics and optics against splashed liquid 200G shock impulse resistant -40ºC to +60ºC External elements manufactured from flame retardant polymers rated UL94 HB EC, ROHS and ADR 2006 (hazardous goods transport) compliant MULTI VOLT LED BARE WIRE 0.4Kg IP53 200G 9 to 31 V DC 2W

89 MiniThinLED Interior Lamp l Red l White l Blue l Green 24V DC HM6605RD-24V HM6605WD-24V HM6603BD-24V HM6603GD-24V 12V DC HM6605RD-12V HM6605WD-12V HM6603BD-12V HM6603GD-12V MINING INTERIOR LAMPS MiniThinLED Interior Lamp 89 MOBILE EQUIPMENT INTERIOR LIGHTING LIGHTING MiniThinLED lamps are robust low profile multi-use LED lamps ideal for general applications such as insteps, ambient and storage lights. MiniThinLED lamps feature an ergonomic and user-friendly design only 11mm high, with no sharp edges when installed. Hella engineered MiniThinLED lamps to ensure a very long service life and no lighting loss due to internal dirt build-up; they are also very well suited to wet and corrosive environments and tolerate short term immersion. Designed for flush mounting, the clear exterior lens can be re-polished if required with no detrimental effect on light-output or chemical resistance. MiniThinLED is fully sealed and unaffected by shock and vibration, ensuring high reliability for a true fit and forget installation. The lamps are available in a range of LED colours (red, blue, green and white) to suit a wide range of applications. Safe and reliable electrical connection is facilitated via a short length double insulated multi core cable terminated with bare wire ends. Product features Approximately 136 x 30 x 11mm 12V or 24V versions Various colour possibilities State of the art design Easy flush mounting screw version Excellent durability Fit and Forget Low energy consumption 1.2W 2.8W Excellent performance in heavy, cold and wet environments Water resistant IP69 Performance temperature range -40 to +60C Quality materials: PMMA (Lens) and ABS+PC (Housing) 5 LED Red 5 LED White 3 LED Blue 3 LED Green LED BARE WIRE 0.1Kg IP69 200G 12/24 V DC 3W

90

91 Alarms & Horns 91 ALARMS & HORNS 92 MotoVOX 93 RetroVOX Self Adjusting 94 RetroVOX Compression Driver 95 RetroVOX Broadband

92 REVERSING ALARMS ALARMS & HORNS 92 MotoVOX Compact 117dB Horn MotoVOX 117dB Compact Horn HMFH312P Solid state electronic horn designed for extremely long life and to replace high maintenance electromechanical horns. This model is designed to meet or exceed all applicable SAE specifications. Used by major OEMs. Voltage 12-24V DC Decibel 1.2m Approval SAE J1105 Sept 89, Type K. U.L. recognised for electric vehicles and fork lifts. MotoVOX Forward 117dB Horn MotoVOX FH dB Horn HMFH117P 183.1mm Electronic forward horn is designed to be used where a high-decibel rugged horn is necessary. Voltage 12-24V DC Decibel 1.2m Approval SAE J1105 Sept 89, Type 24V systems SAE J1105 Sept 89, Type 12V systems 81mm MotoVOX Compact 107dB Horn MotoVOX FH dB Horn HMFH107P Solid state electronic horn designed for extremely long life and to replace high maintenance electromechanical horns. This model is designed to meet or exceed all applicable SAE specifications. Used by major OEMs. Voltage 12-48V DC Decibel 1.2m Approval SAE J1105 Sept 89, Type L 92mm 118mm 81mm

93 REVERSING ALARMS RetroVOX Self Adjusting Reversing Alarm 93 ALARMS & HORNS Steel housing and construction for rugged applications. Integral bracket includes same mounting pattern with OEMs, self adjusting. Suitable for high pressure washing, epoxy encapsulated circuit board protects alarm against moisture and vibration damage. RA917 Self Adjusting 112dB Alarm HMRA917E Voltage 12-24V DC Decibel 1.2m Approval SAE J994 Type D RetroVOX Ultra Heavy Duty Reversing Alarm One of the most rugged adjustable, heavy-duty alarms on the market. These alarms are designed to withstand the most punishing environments. They have #8-32 UNC terminal studs on the back of the unit. Used by major OEMs. Voltage 12-36V DC Decibel 97, 107, 1.2m RA112 Ultra Heavy Duty 112dB Alarm HMRA112P Approval SAE J994 Types A, B & C

94 REVERSING ALARMS ALARMS & HORNS 94 RetroVOX Compression Driver Reversing Alarm (Manual) RetroVOX Compression Driver 112dB Alarm (Manual) HMRA603P New high-efficiency reversing alarms with reduced power draw and significantly better acoustic performance over life. Heavy-duty polymer construction fits popular OEM dimensions. Fully encapsulated spark-free electronics (IP68) allows high pressure water cleaning. 200G shock resistant. 81 Voltage Decibel Approval 12-24V DC (reverse polarity protected) 1.2m, manual adjustment SAE J994 class A/B/C RetroVOX Compression Driver Reversing Alarm (Automatic) RetroVOX Compression Driver 112dB Alarm (Automatic) HMRA611P New high efficiency reversing alarm with reduced power draw and significantly better acoustic performance over life. Heavy-duty polymer construction fits popular OEM dimensions. Fully encapsulated spark-free electronics (IP68) allows high pressure water cleaning. 200G shock resistant. 81 Voltage Decibel Approval 12-24V DC (reverse polarity protected) automatic adjustment to SAE J994 requirement SAE J994 classes A-D

95 ALARMS RetroVOX Compact Broadband 87dB Alarm 95 ALARMS & HORNS Noise Pollution can be an issue for mine sites close to residential areas. Hella have introduced a range of broadband or white noise reversing alarms to prevent miners from having to compromise on safety. By emitting sound over a large range of frequencies, the sound dissipates faster and is localized so that sound doesn t carry. The RetroVOX features a rugged design, which is highly reliable and unaffected by continuous vibration, moisture, heat, cold, sun glare and dirt. RetroVOX Broadband 87dB Alarm HMRA087B Voltage Current Decibel 12-24V DC Max. 0.5 Amps 1m Approval SAE J994 Class E 11 CE & EMC Approved Product Features: Ingress Protected to IP68 (waterproof) Solid-state, spark-free electronics Epoxy-sealed against mud, water and vibration Can be steam-cleaned and pressure-hosed RetroVOX Broadband dB Reversing Alarm Broad band or white noise reversing alarm for applications where normal reversing alarm sounds cause problems. Heavy-duty construction fits popular OEM dimensions. Solid-state fully sealed spark-free electronics (IP68) allows high pressure water cleaning. 200G shock resistant. RetroVOX Broadband 112dB Alarm (Manual) HMRA107B Voltage Decibel Approval 12-24V DC (reverse polarity protected) SAE J994 class A-D EC, E

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97 Service Tools 97 SERVICE TOOLS 98 EziPAK DT Connector Kit 100 EziPAK Double Crimp Kit 102 EziPAK Heat Shrink Kit 104 EziPAK Intelligent Fuse Kit 106 Super Seal Connector 107 PowerPAK

98 CONNECTOR KITS SERVICE TOOLS 98 EziPAK DT Connector Kit EziPAK DT Connector Kit (389 Pieces) (See list of included components next page) EziPAK DT Connector Kit (incl. Crimping Tool HM8276) Accessories Universal DT Contact Crimping Tool HM8283 HM8275 DT Contact Crimping Tool mm HM8277 EziPAK Double Drawer Storage Module (empty) EziPAK Single Divisional Carry Case (empty) HM8285 HM8286 Hella has developed a new range of EziPAK service kits to meet the need of mobile field service technicians maintaining mining machines on site. EziPAK kits are based on many years of practical experience. Each kit is contained in an impact resistant and washable, heavy-duty injection moulded carry case that slides into a self locking modular double storage tray for easy installation into field service vehicles or use as a central storage point in the workshop environment. The DT connector kit to service the popular DEUTSCH connectors is the first module of the range to be released. The EziPAK kit is supplied with the most popular DEUTSCH connectors including the essential tools to make and repair these connections and a highly detailed step-bystep instruction document ensuring that users obtain truly professional results. Each EziPAK kit is supplied with a hard wearing large format visual reference of it s contents, this also contains the re-order information for refill packs of DT consumables, thus enabling customers to maintain the EziPAK service kit indefinitely. Additional tools, empty carry cases and rack modules are also available to allow service teams to create their own customised kits if needed. HM8283 HM8285 HM8275 HM8277

99 CONNECTOR KITS 99 SERVICE TOOLS DT Connectors (included in EziPAK DT Connector Kit) Qty in pack 2-Way Male DT Connector (incl. wedge) 15 9.HM Way Female DT Connector (incl. wedge) 15 9.HM Way Male DT Connector (incl. wedge) 15 9.HM Way Female DT Connector (incl. wedge) 15 9.HM Way Male DT Connector (incl. wedge) 10 9.HM Way Female DT Connector (incl. wedge) 10 9.HM Way Male DT Connector (incl. wedge) 10 9.HM Way Female DT Connector (incl. wedge) 10 9.HM Way Male DT Connector (incl. wedge) 5 9.HM Way Female DT Connector (incl. wedge) 5 9.HM Way Male DT Connector (incl. wedge) 5 9.HM Way Female DT Connector (incl. wedge) 5 9.HM Way Round Male HDT Connector 5 9.HM Way Round Female HDT Connector 5 9.HM4953 Male DT Connector Pin HM4954 Female DT Connector Socket HM4955 Connector Sealing Plug 50 9.HM HM HM HM HM HM HM HM HM4947 Service Tools (included in EziPAK DT Connector Kit) DT Contact Crimping Tool mm 1 HM HM HM4949 DT Contact Removal Tool mm 3 9.HM4957 DT Contact Removal Tool mm 3 9.HM4958 DT Connector Wedge Removal Tool 1 9.HM HM HM HM HM HM HM HM HM HM HM4959 HM8276

100 CONNECTOR KITS SERVICE TOOLS100 EziPAK Double Crimp Connector Kit EziPAK Double Crimp Connector Kit (3,652 Pieces) (See list of included components next page) EziPAK Double Crimp Connector Kit Accessories EziPAK Double Drawer Storage Module (empty) EziPAK Single Divisional Carry Case (empty) HM8284 HM8285 HM8286 Hella has developed a new range of EziPAK service kits to meet the need of mobile field service technicians maintaining mining machines on site. EziPAK kits are based on many years of practical experience. Each kit is contained in an impact resistant and washable, heavy-duty injection moulded carry case that slides into a self locking modular double storage tray for easy installation into field service vehicles or use as a central storage point in the workshop environment. The professional double crimp connector kit is supplied with the most popular terminals and connectors as well as a ratchet crimping tool ensuring that users obtain truly professional results. Each EziPAK kit is supplied with a hard wearing large format visual reference of it s contents, this also contains the re-order information for refill packs of consumables, thus enabling customers to maintain the EziPAK service kit indefinitely. Additional empty carry cases and rack modules are also available to allow service teams to create their own customised kits if needed. HM8284 HM8285

101 CONNECTOR KITS 101 SERVICE TOOLS Double Crimp Connectors (included in EziPAK Double Crimp Connector Kit) Qty in pack Push-On Female Terminal - Red, 6.3mm HM8500 Push-On Female Terminal - Blue, 6.3mm 200 Push-On Female Terminal - Yellow, 6.3mm HM HM HM HM8501 Push-On Female Terminal - Yellow, 9.5mm HM8503 Fully Insulated Female Blade Terminal - Red, 6.3mm HM8504 Fully Insulated Female Blade Terminal - Blue, 6.3mm HM HM HM8503 Push-On 2-Way Male/Female Terminal - Blue, 6.3mm HM8511 Male Blade Terminal - Red, 6.3mm HM8513 Male Blade Terminal - Blue, 6.3mm 200 Single Male Bullet Connector - Red HM HM HM HM8505 Single Male Bullet Connector - Blue HM8521 Single Female Bullet Connector - Red HM8522 Single Female Bullet Connector - Blue 200 Cable Connector - Red HM HM HM HM8513 Cable Connector - Blue HM8531 Cable Connector - Yellow 100 Eye Terminal - Red, 5.0mm HM HM HM HM8520 Eye Terminal - Blue, 5.0mm HM8543 Eye Terminal - Yellow, 9.5mm 200 Eye Terminal - Yellow, 5.0mm HM HM HM HM8522 Crimping Tool (included in EziPAK Double Crimp Connector Kit) Ratchet Crimping Tool HM HM HM HM HM HM HM HM8549

102 REPAIR KITS SERVICE TOOLS102 EziPAK Heat Shrink Harness Repair Kit EziPAK Heat Shrink Harness Repair Kit (270Pieces) (See list of included components next page) EziPAK Heat Shrink Harness Repair Kit Accessories EziPAK Double Drawer Storage Module (empty) EziPAK Single Divisional Carry Case (empty) HM8287 HM8285 HM8286 Hella has developed a new range of EziPAK service kits to meet the need of mobile field service technicians maintaining mining machines on site. EziPAK kits are based on many years of practical experience. Each kit is contained in an impact resistant and washable, heavyduty injection moulded carry case that slides into a self locking modular double storage tray for easy installation into field service vehicles, or use as a central storage point in the workshop environment. The EziPAK kit comprises six of the most popular size heat shrink sleeves as well as five different sized solder sleeves. A battery operated soldering iron and a flameless heat gun are also part of the kit. Hella adhesive-lined, medium-wall heat-shrink sleeving is a versatile, environmentally friendly choice for many commercial and heavy-duty mining applications that require mechanical protection and sealing against moisture and chemical ingress, whilst maintaining flexibility when installed. Typical applications include environmental sealing and protection or irregular shapes, such as wire splices, breakouts and connector-tocable transitions, in demanding industries. Hella heat-shrink sleeving features an outer jacket of radiation-cross linked, flexible, flame-retardant polyolefin. Unlike other typical flame-retardant sleeving, Hella Mining sleeving is free of polybrominated biphenyl oxides (PBBOs). In Europe, these chemicals are classified as environmentally hazardous substances. As the sleeving shrinks, the inner adhesive liner melts and flows to seal and encapsulate components or splices contained within. The adhesive bonds to a wide range of plastics, rubber and metals, including polyethylene, neoprene and steel. With a high shrink ratio of 3:1, only a few sizes of Hella heat-shrink sleeving are needed to cover a wide range of substrate diameters and irregular shapes, enhancing inventory efficiency. Hella heat-shrink sleeving is UL recognized (E35586) and CSA-certified (LR31929) at 125ºC, 600V. Additional empty carry cases and rack modules are also available to allow service teams to create their own customised kits if needed. HM8287 HM8285

103 REPAIR KITS 103 SERVICE TOOLS Heat Shrink Sleeving (included in EziPAK Heat Shrink Harness Repair Kit) Qty in pack Adhesive Lined Heat Shrink Sleeving 3.2mm 35 9.HM4960 Adhesive Lined Heat Shrink Sleeving 6.4mm 35 9.HM4961 Adhesive Lined Heat Shrink Sleeving 9.5mm 35 9.HM4962 Adhesive Lined Heat Shrink Sleeving 12.7mm 20 9.HM4963 Adhesive Lined Heat Shrink Sleeving 19.1mm 10 9.HM HM4965 Adhesive Lined Heat Shrink Sleeving 25.4mm 6 9.HM4965 Solder Sleeve Clear, 1.7mm 25 9.HM4966 Solder Sleeve Red, 2.7mm 25 9.HM4967 Solder Sleeve Blue, 4.5mm 25 9.HM HM4964 Solder Sleeve Yellow, 6.0mm 25 9.HM4969 Solder Sleeve Grey, 7.0mm 25 9.HM4970 Service Tools (included in EziPAK Double Crimp Connector Kit) 9.HM4963 Battery powered soldering iron 1 HM8288 Flameless gas heat gun 1 HM8289 Lead Free Solder in Cartridge 1 9.HM HM4962 Insulation Tape Black, 19mm x 20m Lead Free 10 9.HM HM HM4960 HM HM4970 HM HM HM HM HM HM HM4966

104 FUSE KITS SERVICE TOOLS104 EziPAK Intelligent Fuse Kit EziPAK Intelligent Fuse Kit (556 Pieces) (See list of included components next page) EziPAK Intelligent Fuse Kit Accessories EziPAK Double Drawer Storage Module (empty) EziPAK Single Divisional Carry Case (empty) HM8290 HM8285 HM8286 Hella has developed a new range of EziPAK service kits to meet the need of mobile field service technicians maintaining mining machines on site. EziPAK kits are based on many years of practical experience. Each kit is contained in an impact resistant and washable, heavyduty injection moulded carry case that slides into a self locking modular double storage tray for easy installation into field service vehicles, or use as a central storage point in the workshop environment. The professional Intelligent Fuse Kit features all the popular amperage and blade fuse sizes. The range of blade fuses contained in the EziPAK kit comprises of mini fuses, standard fuses and maxi fuses all equipped with an LED to indicate when a fuse is blown. This aid in visual fault finding and a blown fuse can be recognised in an instant due to the LED indicating the condition of the fuse. When the LED on the fuse is illuminated, this would indicate a blown fuse. The fuses are a direct replacement for standard blade fuses and no modifications are necessary to convert to this system. The Intelligent Fuse Kit also comes complete with a fuse puller and a universal voltage tester. The fuse puller is also a terminal tester with test LED. The terminal tester is adjustable to all sizes of fuse terminal as per the kit offering. Additional empty carry cases and rack modules are also available to allow service teams to create their own customised kits if needed. HM8290 HM8285 LED glows if fuse blows, for instant identification

105 FUSE KITS 105 SERVICE TOOLS LED Fuses (included in EziPAK Intelligent Fuse Kit) Qty in pack Mini Blade Fuse - 3A, Violet 30 9.HM4973 Mini Blade Fuse - 5A, Tan 30 9.HM4974 Mini Blade Fuse - 7.5A, Brown 30 9.HM4975 Mini Blade Fuse - 10A, Red 30 9.HM4976 Mini Blade Fuse - 15A, Blue 30 9.HM4977 Mini Blade Fuse - 20A, Yellow 30 9.HM4978 Mini Blade Fuse - 25A, Natural 30 9.HM4979 Mini Blade Fuse - 30A, Green 30 9.HM4980 Blade Fuse - 3A, Violet 30 9.HM4981 Blade Fuse - 5A, Tan 30 9.HM4982 Blade Fuse - 7.5A, Brown 30 9.HM4983 Blade Fuse - 10A, Red 30 9.HM4984 Blade Fuse - 15A, Blue 30 9.HM4985 Blade Fuse - 20A, Yellow 30 9.HM4986 Blade Fuse - 25A, Natural 30 9.HM4987 Blade Fuse - 30A, Green 30 9.HM4988 Blade Fuse - 40A, Amber 30 9.HM4989 Maxi Blade Fuse - 20A, Yellow 15 9.HM4990 Maxi Blade Fuse - 30A, Green 15 9.HM4991 Maxi Blade Fuse - 40A, Orange 15 9.HM4992 Service Tools (included in EziPAK Intelligent Fuse Kit) LED Fuse Puller/Tester - Yellow 1 9.HM HM HM HM HM HM HM HM HM HM HM HM HM HM HM HM HM HM HM HM HM HM4992

106 CONNECTORS SERVICE TOOLS106 Super Seal Connectors Super Seal Connector Kit 5 of each Super Seal connector plug and socket 100 x Plug terminals, Part No. 9.HM x Socket terminals, Part No. 9.HM x Yellow con ductor seals, Part No. 9.HM x Red cavity plugs, Part No. 9.HM HM4980 Super Seal Connectors Waterproof (IP 67) connectors with secondary locks. Supplied without metal terminals, seals and cavity plugs; these are to be ordered separately under part numbers HM /02/04/05/06/07/09. Qty. in pack 1 Pole Super Seal Plug 4 HM4981-P 1 Pole Super Seal Socket 4 HM4981-S 2 Pole Super Seal Plug 4 HM4982-P 2 Pole Super Seal Socket 4 HM4982-S 3 Pole Super Seal Plug 3 HM4983-P 3 Pole Super Seal Socket 3 HM4983-S 4 Pole Super Seal Plug 3 HM4984-P 4 Pole Super Seal Socket 3 HM4984-S 5 Pole Super Seal Plug 2 HM4985-P 5 Pole Super Seal Socket 2 HM4985-S 6 Pole Super Seal Plug 2 HM4986-P 6 Pole Super Seal Socket 2 HM4986-S HM4980 Super Seal Connector Kit HM4981-P HM4982-P HM4983-P HM4981-S HM4982-S HM4983-S HM4984-P HM4985-P HM4986-P Spare Parts Qty. in pack Plug terminals to suit cable mm HM Plug terminals to suit cable mm HM Socket terminals to suit cable mm HM Socket terminals to suit cable mm HM Green seal to suit cable insulation mm dia HM Yellow seal to suit cable insulation mm dia HM Red seal to suit cable insulation mm dia HM Red cavity plug 50 9.HM HM4984-S HM4985-S HM4986-S Plug Terminal Socket Terminal 9.HM HM HM Super Seal Connector Crimping Tool Crimping tool designed for use with Super Seal connector terminals. HM8298 HM8298 Super Seal Connector Crimping Tool

107 POWER PACK PowerPAK Portable Power Pack 107 SERVICE TOOLS The PowerPAK is designed for portable emergency power to run remote area work lamps, signal beacons or other 12 volt accessories. PowerPAK is a fully integrated battery pack with three different styles of power outlets. PowerPAK is a plug and play user friendly system that is fully integrated into a water resistant lockable carry case and has an internal battery charger that charges off mains power. Alternatively, the PowerPAK can also be recharged from a vehicle 12 volt system. The PowerPAK is a highly mobile and easy to carry power supply, particularly useful for service technicians and mining maintenance personnel operating in remote and isolated locations. The three different style power outlets make the unit suitable for a diverse range of applications in mining, automotive, camping or marine environments. Each power outlet is independently fused to 15 Amps using a quality LED fuse that illuminates when blown, enabling users to visually see which circuit has had a fault. Combining a quality deep cycle marine-grade battery with a water resistant heavy-duty carry case and a truly rugged power supply enables trades people to carry out repairs in the field when 240 volt mains supply is not suitable. The three different power outputs allow for simultaneous operation of 12 volt equipment and lighting. The quality electronics allow the unit to be charged on 12 volt supply through the bi-directional power outputs for charging on the go or via 240 volt mains supply. The Deep cycle 18Ah marine gel battery can be replaced if required, extending the lifetime of the PowerPAK system. PowerPAK Portable Emergency Unit HM V DC 15A Max Spare Parts: Mag Code 9.HM8600B Replacement battery 9.HM8600C Charging cable to suit vehicle CIG DIN 9.HM A LED Blade Fuses (30 Pack) Product Features: 1 MagCode connection 1 Cigarette lighter connection 1 Din plug connection 240 Volt and 12 Volt charge Deep Cycle Marine GEL 12 Volt 18Ah battery Compatible with DuraLed Work Lamp, Magnetic Base, Part No. HM1550MAG12 Part No. HM1550CIG

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109 Electrical 109 ELECTRICAL 110 AC/DC Transformers 111 Power Connectors 112 LED Rocker Switches 113 LED Pilot Lamps 114 Heavy Duty Circuit Breakers 115 Thermal Circuit Breakers 116 MagCode

110 ELECTRONIC TRANSFORMERS ELECTRICAL 110 AC/DC Electronic Transformers 240V AC 12V DC 20VA HM1220AC 60VA HM1260AC 240V AC 24V DC 20VA HM2420AC 60VA HM2460AC IP67 200G On mine sites, quality is critical to the survival of electronic equipment. Hella has introduced a range of electronic converters to increase the potential of low voltage applications, such as LED lighting, where only mains power is available. The converters are fully sealed to IP67 and have endured 200G-shock testing, making them suitable for the vigorous demands of mining. Highly efficient components enable the converters to operate with low heat generation. Units operate from an input voltage of 90 to 264V AC and provide output voltage levels of 12 or 24 Volts, in either a 20 or 60 watt power supply. The units feature an intelligent over current protection system, which recovers automatically once the fault is removed. Pre-wiring removes the need to open the casing, requiring a simple crimp or solder for installation. With a small physical footprint and high environmental specifications, the converters can be installed in the most demanding mining locations. Product Features: Full range AC input Short circuit protection Over current protection Over voltage protection Fully isolated plastic case Pre-wired, no assembly required Compact size Suitable for LED lighting 200G shock tested Technical Specifications HM1220 HM1260 HM2420 HM2460 DC Voltage 12V 12V 24V 24V Rated Current 1.67A 5A 0.84A 2.5A Rated Power 20W 60W 20.2W 60W Ripple 120mVp-p 120mVp-p 150mVp-p 150mVp-p Voltage Tolerance 5% 5% 5% 5% Setup, Rise Time (230V AC) 500ms, 20ms 500ms, 30ms 500ms, 20ms 500ms, 30ms Hold Up Time (230V AC) 50ms 50ms 50ms 50ms Voltage Tolerance 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC Frequency Range 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz Efficiency 81% 83% 83% 86% AC Current (230V AC) 0.35A 1A 0.35A 1A Max Inrush Current (230V AC) 70A 60A 70A 60A Leakage Current (230V AC) 0.25mA 0.25mA 0.25mA 0.25mA Over Current 110 to 150% 110 to 150% 110 to 150% 110 to 150% Over Voltage 13.8 to 16V 13.8 to 16.2V 28 to 32V 27.6 to 32.4V Operating Temperature ( C) -30 to +70º C -30 to +70º C -30 to +70º C -30 to +70º C Vibration 200G 200G 200G 200G Ingress Protection IP67 IP67 IP67 IP67

111 POWER CONNECTORS Power Connectors 111 ELECTRICAL Power Connectors are high current, industry standard connectors. Power Connectors are suitable for mining and industrial applications where durability, ease of connection and release, and reliable connection are of paramount importance. They are available in various sizes relating to their current carrying capacity. Power Connectors are made from polycarbonate resin that meets UL94 V0 requirements. The housings are genderless to help reduce inventory, while still ensuring correct polarity connection. The housings have an integral stainless steel locking spring for improved contact retention and mating force. The colour-coded connector housing designates the suggested application voltage maximum. Hella has selected the grey range, which can manage voltage levels up to 600 Volts (AC or DC). The housings also incorporate mechanical keys to prevent mating with different housings. The contacts are cold-headed and can be crimped or soldered to the cable. They are flat wiping and therefore self-cleaning as they are fitted and removed from other compatible connectors. The contacts can carry high current for a broad range of applications. Power Connectors are suitable for use in most mining and industrial applications, due to their robust construction and ease of fitment. Power Connectors Connector Kit AND, 50A 6AWG Connector Kit AND, 175A 6AWG Connector Kit AND, 50A 6AWG Connector Kit, 75A 6AWG, black Connector Kit, 75A 6AWG, green Connector Kit, 75A 6AWG, red Connector Kit, 75A 6AWG, blue HM50AND HM175AND HM350AND HMPS75S HMPS75G HMPS75R HMPS75B Product Features: Easy to install, reducing installation costs Ultra durable, reducing replacement costs High current capacity suits a broad range of product applications Quick to connect and remove, saving time spent on servicing Products accept varied cable sizes, reducing inventory Genderless connector reduces possibility of fitment errors One-way fitment ensures correct polarity connection every time 2 pole housing Silver-plated copper contacts Rated to 600 V AC or DC HM50AND: 50A, 6-12 AWG wire (B&S cable) HM175AN: 175A, 4-1/0 AWG wire (B&S cable) HM350AND: 275A, 1/0-300 MCM wire (B&S cable).

112 LED ROCKER SWITCHES ELECTRICAL 112 Compact LED Rocker Switches LED Rocker Switches 24V DC Amber Illuminated HM4400A Red Illuminated HM4400R Blue Illuminated HM4400B Green Illuminated HM4400G LED Rocker Switches 12V DC Amber Illuminated HM4400A-12V Red Illuminated HM4400R-12V Blue Illuminated HM4400B-12V Green Illuminated HM4400G-12V Compact, heavy-duty LED illuminated Rocker Switches featuring durable nylon frame and waterproof rubber sealing boot for additional protection in industrial and mining environments. Fitted with push-on terminals and ultra durable LEDs for illumination, removing the need for regular globe replacement. Weatherproof from front if installed correctly. Mounting Panels Protection Voltage Mounting opening 20mm dia. Suitable for panels up to 2.5mm thick. Weatherproof (from front) 12 or 24V DC LED included (non-replaceable). 12/24V DC Maximum Load 10A at 12V DC 5A at 24V DC Amber Red Blue Green

113 LED PILOT LAMPS LED Pilot Lamps 113 ELECTRICAL Heavy-duty multi-chip LED Pilot Lamps featuring shock-resistant one-piece construction for long service life, polycarbonate lens and screws with screw retainer and in-built finger protection. LED Pilot Lamp, 12V AC/DC Red, Super Bright 2716 Green 2717 Amber, Super Bright 2718 White 2719 Mounting For Panels Protection Voltage Mounting opening 22mm dia. Up to 38mm thick IP65 12V / 24V AC/DC Other voltages available upon request Blue, Super Bright 2720 LED Pilot Lamp, 24V AC/DC Red, Super Bright V Green V Amber, Super Bright V White V Blue, Super Bright V LED Pilot Lamp, 24V Green, Super Bright White, Super Bright HM V HM V Red Green Amber White Blue

114 CIRCUIT BREAKERS ELECTRICAL 114 Heavy Duty Circuit Breakers Heavy Duty Circuit Breakers 3A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC Automotive circuit breaker, plug in mounting, manual release with locking tangs for vibration resistance. Voltage Rating Current Ratings Typical Life / Contact Rating Interrupting Capacity Icn Note 12-28V DC 3 25A. (30A upon request) 6,000 operations at 1 x IN 3,000 operations at 2 x IN 20A 1,000 operations at 2 x IN 25A A A 200A 400A Replaces standard blade fuses Panel Mount Circuit Breakers Panel Mount Circuit Breakers 10A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC Threadneck panel mounting, with optional push/push switch actuation. Voltage Rating 250V AC / 12-28V DC Current Ratings A Typical Life/Contact Rating 5,000 operations at 2 x IN Interrupting Capacity Icn A 8 x IN 3...5A 20 x IN A 200 x A A 400 x A Approvals VDE, CSA, UL, Semko, SEV, LRoS, BV Thermal Overcurrent Circuit Breakers Thermal Overcurrent Circuit Breakers 6A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC A - Max. 28V DC Operated simply by the heating effect of current, thermal circuit breakers are some of the most reliable, cost effective protection devices available. They are ideally suited to the protection of a broad range of components and systems motors and transformer windings, printed circuit boards, low voltage power distribution circuits of road vehicles, boats, and battery powered machines. These all require the ability to discriminate between safe switch-on surges or transients, and harmful sustained overloads. They can, for example, withstand large surges arising from lamp loads or motor starting. They also protect against effects of genuine failure such as motor locked rotors. Their characteristics can be matched closely to the ratings of protected components, so wiring and connectors don t need to be oversized. They offer dependable protection, even under low level overcurrent conditions that can t be adequately covered by other methods Automotive circuit breaker, standard fuseblock mounting with manual release option (-H2) Voltage Rating Current Ratings Typical Life / Contact Rating Interrupting Capacity I cn Note 12-28V DC 6 25A. (30A upon request) 300 operations at 50A 3 150A A Replaces standard blade fuses

115 CIRCUIT BREAKERS Thermal Circuit Breakers 115 ELECTRICAL Single pole, miniaturised, aircraftstyle thermal circuit breaker with tease-free, trip-free, snap action mechanism and push/pull on/off manual actuation (M-type TO CBE to EN 60934). An indicator band on the push button clearly shows the tripped/off position. The circuit is threadneck panel Voltage Rating mounted in metric configurations. Advanced two-chamber design contributes to fail-safe operation. Temperature compensation from -55 C to +125 C, with auxiliary contacts, and fully approved for use on a wide range of aircraft and equipment. Full specification ensures suitability for the most demanding applications. 115V AC / V DC Thermal Circuit Breakers 3A - Max. 28V DC HMET A - Max. 28V DC HMET A - Max. 28V DC HMET A - Max. 28V DC HMET A - Max. 28V DC HMET A - Max. 28V DC HMET A - Max. 28V DC HMET A - Max. 28V DC HMET A - Max. 28V DC HMET min 4.6 min Typical Life Ambient Temperature Insulation co-ordination (IEC & 60664A) Dielectric Strength (IEC & 60664A) 20,000 operations mechanical or, 10,000 operations at IN ( 25A) 5,000 operations at IN ( A) -55 C to +125 C (-67 C to +257 F) Rated impulse withstand voltage Pollution degree 3 Test Voltage Operating area AC 1,500V Main to aux. circuit AC 1,500V 1.5kV Spare Parts: HMET ID collar Black HMET ID collar White HMET ID collar Red HMET ID collar Green HMET ID collar Blue HMET Safety lock-out collar Red HMET IP66 safety cover Clear M12x Interrupting Capacity I cn AC 115V (400 Hz) 4A 1,000A 5A 2,000A 7.5 to 35A 2,500A HMET HMET DC 28V 1 to 25A 6,000A A 4,000A Vibration 15g ( Hz) - Sinus 16.4 grams - Random Acceleration 17g HMET HMET Shock 75g HMET HMET Explosion to VG 95210, sheet 10/MIL - STD-202, meth. 109 HMET HMET

116 POWER OUTLET SYSTEMS ELECTRICAL 116 MagCode Power Outlet Systems MagCode Power System Power System 12V HMPS12VKIT Power Port 12V HMPS12VPT Power Clip 12V HMPS12VCP Power System 24V HMPS24VKIT Power Port 24V HMPS24VPT Power Clip 24V HMPS24VCP MagCode Power System Plus Power System 12V HMPS12VPROKIT Power Port 12V HMPS12PROVPT Power Clip 12V HMPS12PROVCP Power System 24V HMPS24PROVKIT Power Port 24V HMPS24PROVPT Power Clip 24V HMPS24PROVCP MagCode Power Port Cap HMPSPCAP MagCode Power Systems are revolutionary power outlet systems for 12 and 24V DC circuits. Unlike conventional connectors, MagCode Power Systems utilise magnetically coded flat contacts, delivering safe power across modular components far superior to the ubiquitous cigarette lighter sockets. Both port (outlet) and clip (connector) feature powerful magnets with integral switching function ensuring a stable connection and safe power supply. Other metal objects or permanent magnets cannot energise the contacts at any time, making the outlet completely safe and 100% short-circuit-proof. MagCode Power System Plus for higher power circuits features an additional mechanical twist lock offering greater security (higher separation forces) and reliable prevention of arcing. The mechanical twist lock ensures that the automatic switching does not occur before the outside contact is securely fastened, thus effectively eliminating problems associated with arcing. MagCode Power Systems are dust and water resistant, easy to clean and suitable for straightforward retrofitting a vast range of applications. Their advanced technology and superior design makes MagCode Power Systems the ideal exterior connector on vehicles under conditions of sustained charging and high current load. They are available in 12V DC and 24V DC variants; the magnets of the two voltage variants are coded differently to avoid mix-ups. Power Clip Power Port HMPSPCAP. Stylish protective cover to suit all MagCode Power Ports. Snap shut cap provides reliable protection from the elements. Key Features: Latest high tech design Stable connection 100% short-circuit-proof Easy to install Minimal mounting depth (port) Up to 25A current load Dust and water resistant Easy to clean Novel coded system to avoid 12V and 24V products Additional Features Power System Plus: Suitable for high current loads Greater security (higher separation forces) No arcing Specifications: MagCode Power System MagCode Power System Plus Locking Mechanism Magnetic connection Magnetic connection plus mechanical twist lock Terminal Power Port 6.3mm flat connectors Cable tails Power Clip Screw terminals Screw terminals Max. Wire Cross Section 2.5mm 2 2.5mm 2 Mounting Opening 28mm dia. (M28) 28mm dia. (M28) Rated Voltage 12V / 24V DC 12V / 24V DC Max. Current Load 25A at +20 C 26A at +20 C 14A at +70 C 25A at +70 C 12A at +85 C 20A at +85 C Vibration Resistance 3 axes, 8h, 3 axes, 8h, 5Hz - 200Hz, 8.5m/s 2 5Hz - 200Hz, 8.5m/s 2 Shock Resistance 3 axes, 3,000 shocks, 3 axes, 3,000 shocks, 11ms, 30g 11ms, 30g Protection Port (front side installed) IP 6K9K IP 6K9K Port (connection side) IP 5K0 IP 5K0 Clip (not connected) IP 40 IP 40 Clip (on port) IP 42 IP 42 Duty Cycles Without load > 10,000 cycles > 10,000 cycles At 25A 4,000 cycles 4,000 cycles

117 POWER OUTLET SYSTEMS 117 ELECTRICAL MagCode Power System Incoming current Incoming current Pole without Current Pole under Current Open System (1) Closed System (2) Colour code: l Permanent magnets l Plate with permanent magnets l Voltageless l Under current Incoming current MagCode Power System Plus Open System (1) Pole without Current Incoming Incoming current current Pole under Closed System (2) Pole without Current Locked System (3) Current

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119 119 GLOBESGlobes 120 H1 120 H2 121 H3 122 H4 123 H7 123 H9 123 H Xenon

120 HALOGEN GLOBES 120 H1 Globes GLOBES 10 Part No. Voltage Wattage Base ADR 51/00 Category UV Cut 39 H1 PREMIUM XENON HALOGEN - PLUS 50 CX1255BL P14.5s H1 H1 PREMIUM XENON HALOGEN - COOL BLUE 24 CB1255BL P14.5s H1 Xenon Plus 50 Xenon Cool Blue Part No. Voltage Wattage Base ADR 51/00 Category UV Cut Rated Life Long Life / Standard H1 HALOGEN LONG LIFE C1255LL P14.5s H H1 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE C2470LTS P14.5s H Part No. Voltage Wattage Base ADR 51/00 Category UV Cut H1 HALOGEN HIGH PERFORMANCE C P14.5s - C P14.5s - HALOGEN C P14.5s H1 Halogen Premium Long Life Halogen H2 Globes 9 Part No. Voltage Wattage Base ADR 51/00 Category UV Cut 29 H2 HALOGEN HIGH PERFORMANCE CD X511 - CD X511 - HALOGEN CD X511 H2 CD X511 H2

121 HALOGEN GLOBES H3 Globes 121 GLOBES Part No. Voltage Wattage Base ADR 51/00 Category UV Cut 11 H3 PREMIUM XENON HALOGEN - PLUS YCX1255BL PK22s H3 Xenon Plus 30 H3 PREMIUM XENON HALOGEN - PLUS 30 YCP1255BL PK22s H3 H3 PREMIUM XENON HALOGEN - COOL BLUE YCB1255BL PK22s H3 Part No. Voltage Wattage Base ADR 51/00 Category UV Cut Rated Life Long Life / Standard Long Life Halogen H3 HALOGEN LONG LIFE YC1255LL PK22s H H3 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE YC2470LTS PK22s H Part No. Voltage Wattage Base ADR 51/00 Category UV Cut H3 HALOGEN HIGH PERFORMANCE Halogen YC PK22s - YC PK22s - HALOGEN YC PK22s H3 Premium Long Life Halogen

122 HALOGEN GLOBES 122 H4 Premium Xenon Globes GLOBES 14 Part No. Voltage Wattage Base ADR 51/00 Category UV Cut 78.5 H4 PREMIUM XENON HALOGEN - PLUS 50 XDX1260/55BL 12 60/55 P43t H4 H4 PREMIUM XENON HALOGEN - COOL BLUE 44 XDB1260/55BL 12 60/55 P43t H4 Xenon Cool Blue Xenon Plus 50 H4 Halogen Globes 14 Part No. Voltage Wattage Base ADR 51/00 Category UV Cut Rated Life T c Long Life / Standard H4 HALOGEN LONG LIFE XD1260/55LL 12 60/55 P43t H XD2475/70LL 24 75/70 P43t H H4 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE XD2475/70LTS 24 75/70 P43t H Part No. Voltage Wattage Base ADR 51/00 Category UV Cut H4 HALOGEN HIGH PERFORMANCE XD12100/ /55 P43t - XD12100/ /90 P43t - XD24100/ /90 P43t - H4 HALOGEN XD1260/ /55 P43t H4 XD2475/ /70 P43t H4

123 HALOGEN GLOBES H7 Globes 123 GLOBES Part No. Voltage Wattage Base ADR 51/00 Category UV Cut Rated Life Tc Long Life / Standard 11 H7 HALOGEN LONG LIFE CA1255LL PX26d H H7 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE CA2470LTS Px26d H Part No. Voltage Wattage Base ADR 51/00 Category UV Cut H7 HALOGEN CA1255X PX26d H7 CA PX26d H7 H9 Globes Part No. Voltage Wattage Base ADR 51/00 Category UV Cut 11 H9 HALOGEN CF PGJ 19-5 H CF1265 H11 Globes Part No. Voltage Wattage Base ADR 51/00 Category UV Cut 11 H11 HALOGEN CG PGJ 19-2 H11 CG PGJ 19-2 H CG1255

124 XENON GAS DISCHARGE 124 Xenon Gas Discharge Lamps GLOBES 9 Description Comparison Xenon Gas Discharge globes for driving and work lamps. D1S/D2S 82 Rated Wattage Luminous Flux Luminous Efficacy 35W 3200lm 91Im/W HMXN4001 D1S Colour Temperature 4250 K Average Luminance 6500*cd/cm 2 43 Lamp Life B3 1500h Tc 3000h 9 Filament/arc length Note 4.2mm Replace Lamps only with same type. D1S lamps must be used in Oval 100FF Xenon work lamps. D2S lamps must be used in all other Xenon work lamps in this catalogue. 75 Part No. Type Voltage Wattage Base ADR 51/00 Category UV Cut HMXN4001 D1S PK32d-2 D1S 25 XN4000 D2S P32d-2 D2S HMXN4YEL D2S P32d-2 D2S XN4000 D2S/R/C HMXN4YEL D2S Xenon Gas Discharge Flash Tube Part No. Voltage Wattage Base ADR 51/00 Category UV Cut 49mm Xenon gas discharge globes suitable for emergency flasher, revolving and/or strobe lamps XN Circuit Board Plug-In mm 43mm Note: Use this lamp for PulseRAY Xenon strobe warning beacons.

125 Engineering Based Solutions: Australian Antarctic Division 125 Due to the high reflectance properties of ice and snow in Antarctica, backscatter was becoming an issue from the white xenon light of the AS500. To overcome this issue an amber version of the AS500 was developed in conjunction with the Australian Antarctic Division, as the colour temperature of the globe eliminated this issue. Hella AS500 Proven lighting for the most unforgiving environments. HMXN4YEL Yellow D2S Xenon Globe

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127 Technical 127 TECHNICAL 128 General Information 130 High Intensity Discharge Lamp Operation 131 What is Xenon lighting technology? 132 Spectral power distribution of fluorescent and discharge lamps 133 Ignitors and ballasts 135 Capacitors 136 Transformers 138 LED technology 139 Hella work lamp systems 140 DRACO vibration damping systems 140 Xenon Gas Discharge work lamps 141 What is Xenon light? 141 MustADD filter technology 142 Chemical resistance tables 144 Ingress Protection 145 Applications Engineering

128 128 General Information TECHNICAL Luminous Efficacy Unit of measurement: lumen per watt [lm/w]: Luminous efficacy indicates the efficiency with which the electrical power consumed is converted into light. The maximum that can be achieved in theory, with all the energy being converted into visible light, is 683 lm/w. In reality, the figures are much lower, between 10 and 150 lm/w. Luminous efficacies of various light sources lm/w = Theoretical limit for monochrome green light (555nm) 199lm/W = Theoretical limit for "white" light ( nm) Low Pressure Sodium Lamps High Pressure Sodium Lamps Fluorescent, Metal Halide, Yellow Compact, Xenarc Lamps High Pressure Mercury Vapour Lamps High Intensity white LED Special Light Bulbs Xenon Lamps, Mercury Tungsten Blended Lamps Tungsten-Halogen Lamps General Lighting Service Lamps Colour Rendering Depending on the location and the purpose, artificial light should enable colours to be perceived correctly, as though being seen by natural daylight. Such assessments are based on the colour rendering properties of a light source, which are expressed in terms of categories of the general colour rendering index, R a. The colour rendering index is a measure of the correspondence between the colour of an object under the light source being measured and its colour under a reference light source. Carbon Thread Incandescent Lamps 1 Glow Lamps, Electroluminiscent Plate Paraffin Lamp lm/w 0.1 Candle Incandescent and Halogen Lamp Operation Incandescent lamps are classic thermal radiators in which electricity flows through a Tungsten wire in an enclosed glass bulb filled with a vacuum or inert gas, heating it to approximately 2600 C to 3000 C and making it glow. Most of the radiation emitted is at the infra-red end of the spectrum. L e λ ref UV - radiation IR radiation Tw 2800 C Tw 2600 C Tungsten filament winding temperatures T w for incandescent lamps 2400 C corresponds to a 15W lamp (vacuum bulb) 2600 C corresponds to a 40W lamp (bulb filled with gas) 2800 C corresponds to a 500W lamp (bulb filled with gas) Tw 2400 C visible light wave length unit of measure nm Relative Spectral Power Distribution Of Incandescent Lamps The main properties of an incandescent lamp, namely its luminous efficacy and life, are influenced largely by the filament temperature.

129 129 TECHNICAL Operating principle of an Incandescent Lamp The higher the filament temperature, the higher the luminous efficacy, but the shorter the lamp life. A reduction in lamp life is a consequence of the rapid increase in the rate of vaporization of the Tungsten atoms as the temperature rises; this process not only produces a black coating on the bulb but also ultimately causes the filament to break. Blackening of the bulb can be effectively countered by using as heavy an inert gas as possible (Argon, Krypton or Xenon) and ensuring that this gas is at high pressure to reduce the rate at which the Tungsten vaporises. The principal types of incandescent lamp are: general-purpose lamps, special-purpose lamps, decorative lamps and incandescent reflector lamps. The luminous efficacy of incandescent lamps in the 25 to 1000W range is between about 9 and 19 lm/w for lamps with an average life of 1000 hours. % % = % life 75% = % life 75% = 3600% life 80% = 1700% life 85% = 1000% life 90% = 600% life Tungsten-Halogen Lamps Tungsten-Halogen lamps operate in the same way as incandescent lamps and have a similar design. The small quantities of Halogens (Bromine, Chlorine, Fluorine and Iodine) and their compounds added to the filler gas, almost entirely prevent the bulb from blackening due to vaporizing Tungsten atoms within a particular temperature range, so there is no associated drop in luminous flux. The bulbs in Tungsten-Halogen lamps can therefore be made much smaller, which means the pressure of the filler gas can be increased and more economical use can therefore be made of expensive inert gases like Krypton and Xenon. The life of Tungsten lamps varies from 50 hours for photographic studio types, to over 2000 hours for commercial display lighting types. Automotive Halogen lamps are generally rated in the 300 hour range. 95% = 190% life Halogen Cycle As already mentioned, the main characteristics of an incandescent lamp, namely its luminous efficacy and service life, are determined to a large extent by the filament temperature. The higher the filament temperature, the higher the luminous efficacy but the shorter the life of the lamp. This reduction in the life of the lamp is a consequence of the rate at which Tungsten vaporises from the filament. This rate increases rapidly with temperature. Not only does it blacken the inside of the bulb, it causes the filament ultimately to burn right through. This blackening of the bulb can be effectively countered by adding halogens to the filler gas to keep the vaporized Tungsten away from the bulb wall in a cycle process. The Tungsten that vaporises from the filament during normal operation drifts towards the bulb wall by diffusion or convection in thermal regions ( 1 <1400 C), where it forms stable Tungsten-Halogen compounds. Thermal currents take these compounds near the hot filament ( 2 >1400 C) where they disintegrate. Some of the Tungsten is transported back to the filament, but not to its original location. The normal Halogen cycle therefore merely prevents the bulb from blackening, it does not extend the life of the lamp. The lamp comes to the end of its life when the filament breaks at one of its hot spots. 150 Lamp life Light output Tungsten Lamp power 100 Halogenide Lamp power Halogen cycle 50 Light output Lamp life % Halogen Cycle A regenerative cycle would be feasible with Fluorine but because this Halogen is so corrosive towards the quartz and hard glass used for the bulb, and resistant to the Halogen currently used, a satisfactory solution has not yet been found.

130 130 High Intensity Discharge (HID) Lamp Operation TECHNICAL Metal Halide (MH)Lamps Metal Halide lamps are high-pressure mercury lamps with added metal iodides or iodides of the rare earths Dysprosium (Dy), Holmium (Ho) and Thulium (Tm) and complex compounds of Caesium (Cs) and Tin Halide (Sn). The Halides decompose in the core of the discharge arc and the metals can be excited to emit light with an intensity and spectral distribution that depends on the vapour pressure of the metal halides. The luminous efficacy and the colour rendering properties of the Mercury discharge are significantly improved and the gaps in the mercury spectrum are closed. Metal Halide (MH) lamps are similar in their construction to mercury vapour lamps. They are popular for their excellent colour rendering which is achieved by the inclusion of rare earth elements in the discharge tube. Metal Halide lamps are temperature sensitive, with optimal operation occurring at 100 C to 180 C ambient temperature. Luminaires should be designed to provide suitable conditions. Ballasts must operate lamps from the correct supply voltage and their impedance should not vary more than ±3% from the specified value. The supply voltage should not deviate for extended periods for more than 3% of the nominal rated voltage of the ballast, and the supply frequency should not deviate by more than ±3%. Metal Halide lamps require higher voltages for starting than the usual supply voltages. Various circuits are used to achieve the required starting conditions. Metal Halide lamps require leakage reactance ballasts, constant wattage auto-transformer control equipment or series reactor type ballasts with ignitor. The latter is the most economical solution, with the constant wattage circuit being the best for electrical performance. Electronic control gear for lower wattage MH lamps is also available Separate information and data is available for the Hella range of constant wattage control equipment. Most Metal Halide lamps will require an ignitor to start the discharge in the arc. The ignition voltage is generally kV peak for a cold start with the lamps requiring a cooling period of between minutes before they will re-ignite. Certain lamps are capable of hot reignition, in which case voltages of up to 35kV peak are required. Some of the higher wattage 2000W and 3500W lamps can require hot, instant re-strike voltages of up to 60kV peak. NOTE: Not all makes and/or types of Metal Halide lamps can be operated on ignitor circuits consult the lamp manufacturer or Hella for information or lamp control gear compatibility. High Pressure Sodium (HPS) Lamps High Pressure Sodium (HPS) lamps can operate satisfactorily from 30 C to +100 C on series reactor ballast circuits, but precautions against increase arc tube voltage, due to thermal back radiation when mounted in luminaires, should be considered. Only a typical 10 volt increase in lamp voltage is tolerable. The lamp power and discharge tube temperature are highly dependent upon the lamp voltage. It is therefore important that the mains voltage does not exceed 105% of the nominal rated voltage of the choke for extended periods. The ballast should exhibit a closely controlled current/voltage characteristic, to prevent the lamp from exceeding the maximum power limit as it ages and the lamp voltage rises. Standard lamps with standard ignitors re-ignite after 60 to 90 seconds, requiring 2kV to 5kV to ignite from a cold start, depending on the lamp specifications. High pressure sodium lamps can only be re-ignited hot if they are of linear double-ended construction because hot re-strike requires 18kV to 25kV peak starting pulses.

131 What is Xenon lighting technology? 131 TECHNICAL Xenon globes use an electric current passed through Xenon gas to produce light, rather than a filament. Not only does this method require minimal electric current draw compared to filament lighting, it is much more robust and lasts much longer than the Halogen lamps it is designed to replace. Xenon (XGD) lamps are specialized high pressure discharge lamps developed for use in the automotive industry. Unlike industrial HID lamp types (MH and HPS) that require several minutes to warm up and reach full light output, XGD lamps are designed to strike immediately and the associated ballast systems are capable of restarting them when hot. The light colour spectrum of XGD lamps is specifically optimised to provide the best performance when used in applications where the user is in a scotopic vision (dark) adapted condition, whereas most other lamps are balanced for photopic (daylight) vision. This is one of the key reasons why Xenon lighting causes less eye strain than other globe types, making it a more convenient and safer night lighting option. It also reflects off road signs and markings more brightly. The XGD technology consists of a very compact quartz glass arc tube discharge vessel, filled with Xenon gas and metal halide salts. In this hybrid system, Xenon gas provides the instant start aspect while the metal halide salts contribute the very high luminous efficacy of a XGD lamp. The arc tube assembly also contains two electrodes that protrude into the gas via special seals, to ensure the system remains hermetically sealed after many switching cycles and despite all the vibration the lamp will be exposed to under normal operating conditions. The arc tube itself is encased in a soda lime glass outer jacket to filter out the ultra-violet generated by the gas discharge. This is of particular importance, considering the widespread use of polycarbonate lenses in automotive lighting. This active part of the XGD lamp is mounted in one of two basic lamp holder types: D1/D3 range contains an integrated ignitor module and suits designs where space efficiency is very important and lamp replacement cost is less important, the D2 range requires an external ignitor (typically integrated into the ballast) and suits high duty cycle systems where lamp replacement occurs on a regular basis.

132 TECHNICAL 132 Spectral Power Distribution of Fluorescent and Discharge Lamps Visible range from 380 to 780 nm Vertical scale: 400 nw 1000 Im -10 nm Fluorescent Lamps Metal Halide (MH) Lamps Colour 840 LUMILUX Cool White HQI.../N Daylight HQI -TS.../WDL Warm White High Pressure Sodium (HPS) Lamps Xenon Gas Discharge (XGD) Lamps VIALOX Relative emission and sensitivity 300,0 400,0 500,0 600,0 700,0 800,0 wave length unit of measure nm Xenon spectral power distribution V(λ) Human vision photopic sensitivity (day light adapted) V (λ) Human vision scotopic sensitivity (night adapted) The spectrum of light produced by Xenon lamps is optimised to maximize visual performance of people with dark adapted vision

133 Ignitors and Ballasts 133 TECHNICAL Maintenance-Free Long Service Life Ballasts The choice of insulating materials and their operating temperatures determine the ballast life. Hella ballasts use class H insulation materials which are designed for temperatures up to 180 C, thus ensuring maximum service life. The permitted maximum working temperature of the winding is designated tw. The adherence to this temperature guarantees an average life of 10 years continuous usage. If the temperature in application is lower, then the life is correspondingly higher. Hella HID ballast windings are designed and constructed using Class H insulation materials, the tw130 or in OG models tw150 rated winding ensuring maximum service life. In normal operation in a 40 C ambient temperature, probable service life of more than 50 years could be expected. The graph below shows the theoretical service life of an Hella HID ballast. Even when arduously operated at the maximum recommended temperature, more than 10 years service life can be expected. Every 10 C over maximum winding temperature of 130 C or 150 C halves ballast life. The winding temperature is the ambient temperature plus t, the temperature rise, which is a function of ballast power consumption. The high quality and reliability of insulated conductors is dependent not only on the production process, but also on the choice of raw materials. Many years of experience, both as a user and manufacturer of enamelled winding wire has given Hella the knowledge and expertise to select the best raw materials from internationally approved suppliers. Critical attention is paid to the enamel as the material utilised to insulate the conductor. Choice of enamel is a key factor and is linked both to the enamelling system as well as the electrical, mechanical and technical characteristics of the finished product. Special features of Hella HID ballasts: 100% final testing very short magnetic paths continuity transverse laminations with no stray field winding short circuit junctions core to coil high voltage short heat paths test winding insulation Class H materials operating values vacuum impregnated core and coil long service life low power consumption tw150 winding temperature rating fully automatic production technology with assured manufacturing procedures and quality

134 134 Ignitors and Ballasts TECHNICAL HID Ignitors and Ballasts The starting voltage for most High-Intensity Discharge (HID) lamps, especially metal halide and high-pressure sodium types, is higher than the mains voltage. Ignitors provide the necessary high voltage to start such lamps. The high-voltage pulse varies from 1 to 5kV depending upon the type of the lamp and is inhibited when the lamp starts. Hella ignitors are manufactured in accordance with IEC and IEC 60927, the International Standards specifying performance, general and safety requirements for starting devices. Old high-pressure sodium and metal halide lamps with conventional ignitor technology often cause visual discomfort and electromagnetic interference at the end of the lamp life when the ignitor would repeatedly strike the lamp, and it would not stabilize electrically. This cycling can be a significant irritant and become a safety risk. The solution: PulseControl from Hella, the first digital ignitor in the world. Greater reliability, greater ignition power, reduced re-strike time and minimum interference through digital, precise management of all lamp types without annoying flashing. L N C Ballast HV BLaN IGN Precise lamp management through digital technology The patented switching circuit digitally controls the ignition and automatic tripping logic functions. PulseControl does not consider the time of the re-strike period but the number of attempts made. Because of this, all lamps are switched off after 3 cycles regardless of luminaire or lamp type. Re-strike time reduced by up to 50% Depending on the lamp wattage, 4 10 ignition pulses per half wave will be generated. As a result of the increased ignition power and the pulse/break cycle, the re-strike time is reduced by up to 50%. Interference reduced by up to 90% This 90% reduction in interference time (only about 30 sec instead of 300 sec), is due to the reduced re-strike period and the pulse/break cycle which strikes for 5 seconds then pauses for 25 seconds. Ignitor Temperature Rise Because ignitors have heat-sensitive elements, their suitability for particular applications is determined by the rise in the element s temperature. When mounting an ignitor in the luminaire on a control equipment enclosure, the ambient temperature range of the application must be considered. Quality components in Hella ignitors ensure that they can withstand temperatures from 30 C to +100 C with a minimum power loss. Long life Lighting control electronic equipment is designed to run continuously for a minimum of 80,000 hours when operating at its maximum temperature. This high level of reliability can be achieved only by using high-quality insulation and heat-resistant components. Very low temperature rise in Hella ignitors makes them highly reliable components for use in all lighting control equipment.

135 Capacitors 135 TECHNICAL Power factor in Fluorescent and HID Circuits For a pure resistive load in an electrical circuit, the voltage (V) and current (I) are in phase with each other and the overall power factor (cosφ) has a value of unity. It can also be said that the average power (P) of the resistive circuit is equal to the apparent power (S), ie. P = V x I. However, in a pure reactive electrical circuit, there is no resistive component; the voltage and current are 90 out of phase, ie. cosφ = 0. Electrical circuits containing a combination of both resistive and reactive elements display both average power and apparent power components. Power factor is therefore the ratio by which the apparent power is multiplied, in order to obtain the average power actually being consumed in the circuit, ie. P = V x I x cosφ. For example, a power factor of 0.5 indicates that the circuit has a reactive component having a phase angle of +60 or -60. In common practice most loads are inductive and therefore the current lags the voltage (lagging power factor), whereas a typical capacitive load has a leading power factor. Fluorescent and HID lamp circuits have an inherent low power factor (around 0.4 to 0.5), due to the control gear inductance. The inductance is in the circuit to limit the current through the lamp, however, in lighting installations where many lamps are used, high input current increases the cost of mains reticulation. Raising the power factor by means of the inclusion of a capacitor (opposite effect to an inductor) substantially reduces the current drawn from the mains, giving improvement in the reticulation efficiency, which in turn enables a reduction in copper wire size and transformer sizes (the generating equipment). Most power distribution authorities have a requirement of high power factor (HPF) for lighting installations of generally 0.85 to 0.95 minimum. Figure 1 Figure 2 A typical discharge lighting circuit without power factor correction, eg. 400W high pressure sodium, has a power factor of approximately 0.4. Figure 1 shows the relationship of current and voltage in this application. This power factor characteristic can be corrected to approximately 0.9 by adding a capacitor (leading) to the lagging line current, to cancel the phase shift. Figure 2 illustrates this. In common application therefore, by connecting a capacitor into the lighting circuit, the power factor can be improved to the values normally prescribed by the regulatory authorities so that practically inductance free operation results. L N C Ballast S Lamp Capacitor Quality Assured quality of capacitors is first and foremost and cannot be compromised. Hella uses accepted IEC and BSI Standards as the minimum measure of quality. Production is integrated with an audited Quality System that is accredited to AS/NZS ISO9002 and supported by a technical team and fully equipped laboratory facilities. Hella power factor correction lighting capacitors have been certified by British Standards Institute to BSEN 61048, and BSEN and has ENEC approval (License no. KM 30180). These standards provide, thorough quality checks of materials and capacitance characteristics, a capacitor that retains its integrity under the required conditions of operation. Quality Test Program materials / component inspection end spray thickness test voltage test capacitance tolerance check dissipation factor physical inspection end product batch test endurance test Assured Quality Systems (ISO9002 series) BSI certification ENEC approval testing of the dielectric materials in-line 100% capacitance testing new automatic AC tester stud mounting or alternative clip spring accessories.

136 136 Transformers TECHNICAL Principles of operation of the Safety Isolating Transformer A transformer transfers electrical energy from one circuit to another through the medium of a magnetic field. The transformer may step up the voltage, step it down or deliver energy at the same voltage. The safety isolating transformer is one of the most widely used of all transformers. It is designed to achieve an accurate voltage ratio within a specific load range. There is no direct connection between the windings. They are only connected by the intangible lines of magnetic flux in the core. In some types of circuits the transformers may have 1:1 ratio. Long life Because of the long hours of use, low voltage transformers have to be designed and built to a high specification, which involves the use of quality heat-resistant materials. Class H insulation materials ensure long service life, which, according to EN60742, allows a maximum winding temperature rise of 140 C at 6% over voltage. At an actual winding temperature of 130 C, 10 years life can be expected. The graph above shows the theoretical service life of a transformer against winding temperature. Every 10 C over the winding temperature of 130 C, halves the transformer life. The manufacturing technique used by Hella is to vacuum impregnate the transformer with an unsaturated polyester resin. Typical characteristics are thermal class H (180 C IEC600). Vacuum impregnation improves quality and longevity because the resin is drawn into the heart of the core and coil. This maximises heat transfer and also ensures silent operation. Safety Extra Low Voltage (SELV) Lighting Recommendations Voltage Regulation The secondary voltage of a transformer changes with the load, therefore, for multilamp applications, a transformer with good voltage regulation must be used. This is because unloading of the transformer occurs as lamps burn out, eg: there may be 4 x 50W lamps wired to a 200VA transformer and if one or two lamps fail, the transformer regulation may not be able to compensate for the decrease in load. This will subject the remaining lamps to an over supply of secondary voltage. Therefore, it is recommended that failed lamps always be replaced. On a one lamp/one transformer installation, the regulation of the transformer is not important as long as the lamp wattage matches the full load of the transformer. These small transformers generally have higher impedance and regulation characteristics. It follows that the higher impedance limits the in-rush current on a cold lamp. The lower in-rush current (or soft start ) helps lamp life. Filament evaporation eventually creates a weak spot on the filament. This weak spot is effected by in-rush current. As a result, the one lamp/one transformer system is beneficial for ferro-magnetic transformers, but does not apply for correctly rated electronic transformers. High current on the secondary side Another important consideration in Extra Low Voltage systems is the impact of high currents. Circuits must be designed and cables sized to carry the higher currents. A 12V lamp can draw 20 times more current than a 240V lamp of the same wattage. For maximum safety, optimum voltage at the lamp and consequently lamp performance, it is preferable to use one (1) ferro-magnetic transformer per lamp. On multi-lamp systems, each lamp should be cabled back to the transformer independently, particularly as the relatively smaller cables used would be more practical and easier to terminate at both the light fitting and the transformer. In these installations it is necessary to estimate voltage drop to each lamp and use the appropriate sized cable according to each cable run. If each light fitting in a multi-lamp system individually wired back to the transformer, then the possibility of using cable lugs to a common stud connection should be considered.

137 137 TECHNICAL Safety Extra Low Voltage (SELV) Lighting Recommendations (continued) Protection and Approval It is mandatory under the wiring rules that transformers for remote mounting are housed in a suitable enclosure and, as a prescribed item, must be approved by the Statutory Authority to EN The approval number must be clearly marked on the enclosure. Also, under the wiring rules, the transformer must be installed in a position where it is easily accessible for inspection and maintenance. The transformer enclosure and wiring to the light fitting must have adequate ventilation. If the wiring and the transformer enclosure are covered with insulation material then substantial derating and overheating may occur. Electronic Safety Isolating Transformers for Low Voltage Lamps Immunity A transient mains voltage surge may occur when inductive loads (e.g. motors or conventional chokes) are switched off. TE electronic transformers are protected against voltage surges and spurious pulses of any polarity by random phase position superimposed on the supply voltage, in accordance with EN Emission The limits for emission as per EN are maintained by high-quality filter circuits. Electromagnetic Compatibility Harmonics from non-linear loads cause distortions in the mains supply. The special circuit design fulfils the requirements of EN RFI Protection The sophisticated filtering system of electronic transformers TE ensures compliance with EN and VDE Harmonics The requirements of the EMS Directive 89/336/EEC are fulfilled by observance of the standards for emission and immunity. Disposal of old lamps and control gear Hella products comply with the RoHS regulations passed by the EC on electronic waste Disposal of incandescent lamps Incandescent lamps consist of glass and metal. They do not contain any materials that will harm the environment so they can be simply thrown away with the household refuse. They should not be placed in containers for recycled glass, however, because the glass used for these lamps is not the same as the glass used for bottles. Tungsten-Halogen lamps contain very small quantities of halogens and Halogen-hydrogen compounds, but the amounts are insignificant (only a few millionths of a gram). Even several lamps together do not present any risk to people or the environment. The lamps can therefore be thrown away with household waste. Disposal of discharge lamps Small quantities of mercury can be found in most HID fluorescent and compact fluorescent lamps. These lamps also contain small quantities of recyclable phosphors so they should not be placed in household refuse or recycled glass containers but sent for proper recycling at community recycling centres. Low-pressure sodium lamps and sodium Xenon lamps can be disposed of without the need for any special action. Disposal of control gear Hella ECGs, ballasts, ignitors, capacitors and other electronic units do not contain any material that will harm the environment but they do contain recyclable electronic components so they should be disposed of as electronic waste.

138 138 LED Technology TECHNICAL An LED (Light Emitting Diode) is a solid state electronic device that consists of several layers of semiconductor material, in contrast to a lamp that consists of a glass envelope and electrodes assembled into a base. The mechanically robust nature and low voltage operation inherent in LED technology makes it attractive to use in many lighting applications. LED benefits LED Technology has enormous benefits for the mining industry, the most obvious being the reduction in maintenance requirements of our fit and forget design principle that reduces vehicle servicing down times, as there are no globes to burn out or holders to corrode. Hella LED lamps are pre-wired for easy installation and manufactured to offer maximum impact resistance and high tolerance to chemicals, salt spray and cleaning fluids. Most of the LED products offered can survive shock impulses of 200G, and operate over a much wider range of ambient temperatures than normal products. LED technology Unlike conventional lamps that produce a broad spectrum of colours (white light), an LED emits light only in a particular single colour. The specific colour is dependent on the semiconductor material system used (AllnGaP and InGaN) and ranges from red through amber, green and blue. Creating a coloured light signal from a conventional globe requires the use of a filter (generally a coloured lens) that absorbs most of the light and passes through only the desired colour spectrum. The filter losses normally range from 30% to 80% depending on the colour and intensity requirements. LED technology eliminates this inefficient process. Hella LED signal and warning lamps operate with up to 60% less current draw than comparable globe lamps. White light from an LED is produced by one of two methods. The most common is a process of luminescence conversion where a blue LED light excites a phosphor to emit yellow light, the mixture resulting in white light. The other process of RGB colour mixing uses individual red, green and blue LEDs and by altering the relative mix of the three primary colours, any other colour including white can be created. The efficiency of white LEDs has risen considerably over the past few years; values of 50 lm/w and more are now being achieved. It is now possible to produce white LED lights that are more efficient than Halogen and incandescent lamps, but still significantly less efficient than gas discharge lamps. The relatively high cost of high-efficiency white LEDs still limits their use to applications where a small amount of light with minimal heat is required, areas where mechanical damage due to shock and vibration destroys other lights, or where the safety of low voltage operation is paramount. LED temperature behaviour The amount of light emitted by an LED reduces as the temperature rises: yellow LEDs are more affected by high temperatures than green and blue LEDs. Loss of output as a result of high temperature reverses when the LED cools down and should not be confused with degradation which happens over a long time or in lamps in which LEDs are operated beyond their design current. LED product design The high efficiency, low power demand that Hella LED lamps are known for is not an automatic result of using LED technology. Many competitor products are no more efficient or durable than conventional lights. Hella invests considerable time and diligence into the four most significant aspects of LED product design, thereby producing award winning, class-leading, innovative products that set new standards and receive worldwide recognition. The most important issue relates to the selection and optimum application of LED devices suited to each task. Like all electronic components, LEDs are mass-produced, with each production batch yielding LEDs that vary enormously in efficiency and colour. As one of the largest global users of high intensity LEDs, Hella has developed sophisticated techniques that enable us to select only the most efficient LEDs that fall within very tight colour specification parameters. The second aspect depends on maximising optical system efficiency. Individual LED devices typically produce a hundred times less light than a conventional light globe. To use the light effectively requires highly meticulous optical system design. The third aspect relates to effective power supply and control circuit designs. LEDs are much more sensitive to heat and electrical issues than conventional lamps. The development of robust, efficient circuits that manage the operation of LEDs is just as important as the optical aspects. Years of experience gained through the production and worldwide use of millions of LED lights, enables Hella to keep delivering innovative and effective solutions to the challenges faced by LED systems. The final aspect is the physical product design. All the mechanical, thermal management and operational environment and production requirements are integrated into a robust product that is expected to remain fully operational under severe cold, heat and humidity, while also being subjected to high levels of vibration. Hella backs up our innovative physical design and assembly processes with a large investment in extensive in-house test and development facilities to prove all of our products meet the demands placed on them in the field.

139 Hella Work Lamp systems 139 TECHNICAL For mining vehicles and production plant, good lighting is essential for activities other than just driving. Haul trucks, shovels, drills, cranes and other special purpose vehicles often need separate, pivotable work lamps for loading, unloading, and other operations. Using the right work lamp can make the work easier and, in most cases, a lot safer. That s why Hella, long a pioneer in innovative lighting technology, offers a wide range of work lamps designed for specific applications. Hella Lighting Technology Hella s range of work lamps includes long, short and mid-range lamps, offering close or wide illumination. You can select Hella work lamps that suit the specific task best using Halogen, Xenon or LED technology. Lamps are available with integral handles, dual beam optics and a wide range of mounting options. For complex projects we would suggest you contact our applications engineering service. Multivolt One of the leading advantages of Hella LED technology is the unique Multivolt circuitry fitted to most LED products. The system ensures a uniform level of light intensity and full light output at any voltage in the range stated (typically from less than 10V to more than 28V). Multivolt lamps can be connected to 12V or 24V automotive electrical systems, without modification. The light output will not be adversely affected by the voltage drop commonly encountered in such systems on large machines and trailers. In all but the most compact lights, the Hella Multivolt system also incorporates sophisticated over voltage, transient impulse and reverse voltage protection and thermal management circuitry to ensure that the LED lamp functions problem free. The Paraboloid Lamp The paraboloid lamp is classic amongst the lamp systems in use today. It uses a parabolic reflector and the light source is located at it s focal point. The reflector captures the light, bundles it and radiates it. The lens ensures that the light is distributed as required, directing it to pre-specified areas in front of the lamp. Effective paraboloid lamps have a large reflector in order to capture a great deal of light. The lens must be as vertical as possible in order to ensure good light refraction. Reflectors with a long focal length provide good long-range illumination; those with short focal lengths collect more light and provide good short-range illumination. The Free-Form (FF) Lamp The FF lamp represents a quantum leap in lamp technology. Its reflector surface no longer corresponds to an even paraboloid. Rather, each point of the reflector surface has an exactly defined function: to collect light, concentrate and direct and distribute it. The reflector alone generates the desired light distribution. The entire light output of an FF lamp is comprised of more than 50,000 spots of light. The entire reflector is effective in Hella Free-Form work lamps. The FF lamp takes the light exactly to where it is supposed to be. The result: brighter, more even illumination of the work area, greater range, and hardly any scatter loss or dazzling. In order to calculate the reflector surface of an FF lamp, extremely powerful electronic computers and high-precision tools and production machines are required. Fractions of a thousandth of a millimetre alter the effectiveness of the entire system. Paraboloid lamp Free-Form (FF) lamp

140 140 DRACO vibration damping systems TECHNICAL Operational duty cycles in mining are some of the most demanding, and field research by Hella has measured shock and vibration levels of remarkable magnitudes. Equipment designed for less demanding environments will fail rapidly when used in mining, and often when most needed. Our design aim is to produce equipment that will function reliably in a continuously shock and vibration laden environment. Most types of mine lighting equipment requires single point mounting to allow for azimuth and elevation adjustments. This arrangement concentrates stress and maximizes overturning moment of inertia in the light that is mounted. To analyse the mechanical design effectively and deliver reliable and predictable results, it is essential that these aspects are thoroughly integrated at the design stage; just adding impressive looking brackets often leads to poorer performance and progressively cascading failures. Hella developed our unique DRACO vibration damping technology to enable us to limit the vibration passing from the mounting surface of the mining machine to the relatively fragile globe in the light fitting. DRACO dampening effectively eliminates resonant behaviour and is specifically designed for systems subject to stochastic (random) vibration with a large dynamic range, like that typically found on mining machines. We can adjust the system parameters to suit each light and its application DRACO vibration damping systems consist of at least two rigid mounting plates separated by two (or more) flexible compounds of differing hardness and damping properties, arranged in parallel in one damper assembly. This provides a non-ridgid mounting arrangement between the vibration source (the mining machine) and load (the light fitting). Vibration signals are delayed in time, reduced in amplitude, as well as altered in spectral composition when some vibration Vibration Time Input DRACO output Std output Difference (DRACO -Std) energy is converted into heat as it passes through each of the flexible compounds. Detail differences between the damping behaviour compound types creates a relative phase shift in the vibration signals exiting each compound. When the two (or more) vibration signals are re-combined in the light fitting, a new vibration signal is created with a compressed dynamic range and lower peak vibration level, reducing the stress in the load (light fitting) significantly. Xenon Gas Discharge (XGD) work lamps What is Xenon lighting technology? Xenon globes use an electric current passed through Xenon gas to produce light, rather than a filament. Not only does this method require minimal electric current draw compared to filament lighting, it is also very close to daylight. As the human eye is designed to see in daylight, Xenon lighting causes less eye strain than other globe types, making it a more convenient and safer night lighting option. It also reflects road signs and markings more brightly. Advantages of Xenon lighting Wider (up to three times as large) and more uniform illumination Twice the light of standard Halogen globes, with less than half the power usage safer and more environmentally friendly Light colour very similar to daylight reduces strain on the eye Steady brightness levels even if power supply varies Impact and vibration-resistant light arc ensures a globe service life five times longer than standard globes Xenon Gas Discharge Work Lamps The Hella XGD models are high-performance, robust work lamps designed for most extreme and heavy-duty assignments. Hella Mining Work Lamp features: Improved lens protection through extended housing Custom built Xenon ballast and electronic circuitry integrated into housing for greater reliability Inbuilt handle for easy aiming Integrated AMP plug with connection cable or DT Plug DRACO vibration-damping pivot base and mounting bracket Available in 12V DC and 24V DC application Special seals MUSTADD filter.