OLDHAM GT CAP LAMP SYSTEM The Powerful Choice INSTRUCTION MANUAL WARNING This manual, including the warnings and cautions inside, must be read and followed carefully by all persons who use or maintain this product, including those who have any responsibility involving its selection, application, service, or repair. This cap lamp system will perform as designed only if used and maintained according to the instructions, otherwise it could fail to perform as designed and persons who rely on this product could sustain serious personal injury or death. 1
GT / GTL CAP LAMP SYSTEM Important TABLE OF CONTENTS General description Preparation for use Battery charging Storage of batteries Filling battery Cap lamp system Replacing battery Removing cable from battery Replacing battery cover Using GT cap lamp system Repairing the headpiece Replacing bulbs Removing the bezel ring Replacing main bulb Replacing secondary bulb Replacing the reflector Replacing the cable Reassembling the bezel ring GT diagram Item list Expanded Component Diagram Troubleshooting Certification, equipment marking and instructions for compliance with ATEX standards:- Use of Equipment p5 p7 p8 p9 p10 p11 p5 p5 p5 p6 p6 p6 2
IMPORTANT Pay close attention to Warnings and Cautions in this manual. A WARNING describes a condition that may cause severe personal injury or death if allowed to happen. A CAUTION describes a condition that may cause moderate injury or property damage if allowed to happen. GENERAL DESCRIPTION The GT cap lamp system consists of a cap mounted headpiece powered by a (lead-acid) battery. The basis of the headpiece in which some of the internal connections are integral is as follows. A selector switch is incorporated, which can switch on either the large main bulb or the small secondary bulb. The main bulb is held in the reflector in a focused position by a screwed bush from which a lead connects to one of the cable termination points. The small bulb holder is positioned at the top of the headpiece, being connected internally to the cable termination. The reflector fits over the small bulb and has a rubber gasket around the rim to seal against the headpiece lens. The cap lamp is designed to operate at full brilliance for a minimum of an 8-10 hour shift, with reserve energy if needed. At the end of each shift the battery is recharged in a single or multiple station charging unit. Battery charging connection is made through the headpiece. The T5 battery has a transparent case with moulded-in electrolyte level indicators below the filling ports; the T6 is maintenance free and has no facility for topping up electrolyte levels. PREPARING THE GT CAP LAMP FOR FIRST TIME USE Battery charging Every battery must be charged before it is used for the first time. 1. Allow the battery to remain on charge for 24 hours. 2. Top off each cell with distilled water if necessary (see filling battery). Never fill over top of fill line. Note: Batteries which do not perform satisfactorily should be removed from service and cyclecharged for 16 hours and discharged 8 hours. Repeat several times until battery responds. If battery does not respond after three or four cycles, it should be replaced. Never discharge completely! 3. After weekly shifts, the battery should be placed on the charger following the instructions included with the charger, and left to charge the remainder of the weekend. 4. If cap lamp needs cleaning, use a mild detergent and wipe. Do not submerge in water. Storage of batteries All stored batteries with acid should be boost charged for 24 hours every 3 months, and immediately before being placed into regular service. Recommended storage temperature: 0 o C to 27 o C. Filling battery (Type T5 only) The electrolyte level should be maintained between the two lines below the filling and venting hole i.e. slightly above the top of the battery plate. Normally topping up should not be necessary more often than once every 4-6 weeks, and should always be carried out when the battery is fully charged. Only distilled or deionised water should be used in topping off. WARNING The electrolyte level of all batteries should be checked weekly, after the battery is charged (T5 battery only). Add water only when battery is fully charged. If the battery is overtopped, there is a possibility that electrolyte may leak out under certain conditions. 3
Topping up 1. Fill the plastic bottle (P/N M651901) with distilled or deionised water only. 2. Insert the nozzle of the filling tube into the small hole provided in the battery window and squeeze the bottle gently. 3. Fill until the electrolyte level is level with the bottom one of the two scribed lines below the cell window. The battery may have to be tilted back slightly to allow the water to flow. 4. Repeat this procedure in adjacent battery cell. CAUTION The electrolyte is corrosive and can cause burns. Take proper precautions to avoid skin and eye contact. CAP LAMP SYSTEM Replacing battery (Plastic cover) 1. Remove the two M4 button head socket screws from the two clamp holding the cover. Removing cable from battery 1. Loosen nuts from each terminal of battery (do not lose the nuts). 2. Lift each lead from battery terminal. Replacing battery cover 1. Attach cable (leads) to battery 2. Connect red cable to positive battery terminal. 3. Connect black cable to negative battery terminal to ensure correct polarity. 4. Tighten cable leads down with terminal nuts (do not over tighten). 5. Replace fuse. 6. Turn battery so the vent holes are facing you. 7. Replace the battery cover. Note: Ensure that the cable leads lie properly on the battery top without being trapped or pinched. USING THE GT CAP LAMP SYSTEM The GT headpiece is made up of the lamphousing which contains the following parts: - Bezel (ring) - Lens (glass) - Gasket - Reflector - Main bulb - Secondary bulb The on-off switch knob is located on the headpiece. To operate the lamp: 1. Turn the switch knob clockwise to main bulb or anti-clockwise to secondary bulb. 2. Un-clip the clamps and lift cover to one side. 3. Remove fuse. 2. After use turn the switch knob until both bulbs are off. Repairing the headpiece Only the small insulated screwdriver (P/N M201042) should be used as this allows the screws to be secured tightly enough without fear of a short-circuit or other damage. 1. The switch should be placed in the off position and the battery fuse removed (see section cap lamp system) before disassembly of the headpiece. When reassembling the headpiece, ensure that the sealing channel is correctly fitted around the reflector. 2. The reflector is located by two projections which fit either side of the pin that rests against the envelope of the pilot bulb. 3. The bezel ring should be screwed down firmly while holding the glass firmly down with your thumb. 4
4. The lock pin placed so that it fits into one of the recesses of the bezel ring and firmly screwed tight. The lock screw can be sealed with wax if applicable. WARNING It is essential that all contacts in the headpiece are tight, so that no electrical resistance is incurred which might increase the time necessary to obtain an efficient charge or possibly reduce the light output of the lamp. In order to obtain the maximum light possible, the outside of the lens glass should be cleaned thoroughly. Replacing the main bulb 1. Lift reflector out of housing, making sure not to break the bush connection. 2. Unscrew reflector from bush by holding bush and unscrewing reflector. REPLACING BULBS (MAIN AND SECONDARY BULB) Removing the Bezel ring 1. Remove wax seal (if applicable) from lock screw. 2. Unscrew lock screw by using special allen key P/N M237642 3. Remove main bulb. 4. Place the new main bulb in the reflector. 5. Hold the bush and screw the reflector onto it. 3. Unscrew and remove bezel ring from headpiece housing. 4. Remove glass (lens) and reflector with sealing channel from headpiece housing. Note: Inspect all parts for cracks or other damage. Replacing secondary bulb 1. Remove bezel ring (use Remove bezel ring procedures). 2. Remove reflector from headpiece housing. 3. Unscrew secondary bulb from side socket assembly of headpiece housing. 4. Thread the new secondary bulb into the socket assembly (do not overtighten). 5
5. Place the hole in the reflector over the secondary bulb. 6. Reassemble the glass (lens) and bezel to the headpiece assembly. Replacing Cable 1. Remove the cable from the battery terminals. 2. Cut the cable tie which secures the cable under the battery cover, and gently pull the cable out of the battery cover gland. 3. Unscrew the battery collar / cable outlet gland from the headpiece. 4. Remove the bezel ring (see removing the bezel ring ) and glass from the headpiece. 5. Use the spring screwdriver to remove the screws holding the cable terminals inside the headpiece, and gently pull the cable out of the side aperture. Replacing the reflector 1. Remove the bezel ring and lens. 2. Remove the reflector from main bulb bush connection. 3. Remove gasket around reflector. Note: Take care to note the correct polarity of the cable so that reassembly is correctly achieved, and the battery is not reverse charged. 6. To replace the cable reverse the above procedure. Note:- Always remember to refit the cable outlet gland over the cable before commencing reassembly. Reassembling the bezel ring When the lens is in position over the reflector, the bezel ring is locked in position by a hex headed lock screw that fits into a countersunk hole and then enters one of the slots in the bezel ring. 4. Place the gasket around the new reflector. Ensure the gasket is in place all the way around reflector. 5. Thread the reflector onto the bush connection. 6. Reassemble the lens and bezel ring (see Reassembling of bezel ring). The countersunk hole enclosing the lock pin can be filled with wax if desired. 6
GT DIAGRAM ITEM LIST M200101. Headpiece shell M201121. Bezel ring M200131. Glass lens M200411. Sealing channel M203827. Reflector M200323. Small bulb socket M259130. Main bulb 4V 48 Lumen Halogen ** M200130. Small bulb 4V 0.46A M200383. Prefocus reflector Bush and connection M203456. Cable 1.59m M455101. Plastic protection shoe ** dependant upon lamp type and temperature classification M204983 Headpiece Contact Kit G type only Large bulb/switch connection Small bulb/switch connection assembly Switch connection 3/16 B HD screw M204583 Switch Knob Kit G type only Switch knob Switch knob sealing washer Switch blade Switch blade cowl Grub Screw M204883 Positive Charging Screw Kit G type only Positive contact sealing washer Charging contact screw Large bulb socket block Large bulb socket screw M205083 Cable Terminal Spares Kit - D and G type Cable grip Sealing collar Small terminal tag Large terminal tag Terminal sleeving red Terminal sleeving black Terminal tag (headpiece end) M454071V M454371V T5 Battery T6 Battery M204683 D and G Lock Contact Spares kit Lock spring Lock barrel Lock contact Lock contact screw Lock contact sealing washer M204783 D and G Cap-clip Spares kit Cap clip Cap clip screw Cap clip nut Cap head lock pin M455045 Plastic Battery Cover (complete) Clip for standard cover Screw for plastic cover Cable gland Cable tie M614830 TOOL KIT Small tools and spares kit for D and G type lamps comprising:- Cable outlet gland key Allen Key for headpiece lock pin Insulated screwdriver Spring screwdriver Spanner for T5 battery terminal nuts Spanner for L16 Battery terminal nuts Topping up bottle (for T5 battery only) Spanner for D -type switch Two OCBL battery fuses Note: Only certain replacement items above may be purchased individually. All others, as noted above, must be purchased in kit form as this ensures that other associated parts are also available for replacement at the same time. 7
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TROUBLESHOOTING PROBLEM CAUSE Bulb glows dimly, flickers or fails 1. Low battery capacity: a. Observe the electrolyte level in the cell windows and make certain level is between the two scribed lines on the cell windows. b. Continuous use of battery that has not been fully charged will cause it to lose its capacity. This may be corrected by cycling the battery several times (discharge 8 hours and recharge 16 hours). Repeat this procedure 3 times. If battery does not respond, replace with a new one. c. Battery not charged. 2. Loose connections a. Gently wiggle or pry each connection on top of the battery to make sure it is tight and working properly. b. Check the cables for broken conductors by twisting or pulling it at various points along its length. c. Check the headpiece terminals and the electrical connections inside the headpiece in the same manner as those on the battery. d. Make sure the bulb is secure and making good contact. e. If the light flickers or dims when any of the preceding items are being checked, that item should be repaired or replaced. 3. Electrolyte level a. Check at least once each month to see that the electrolyte level is between the two scribed lines on the cell window. Battery not holding a charge during shift a. Make sure charger output is correct. Battery capacity a. Check charger. b. Check electrolyte level after charge c. Make sure connections between headpiece and battery are good. d. Make sure that charging rack connections are good. e. Make sure stored batteries are boost charged before placing into service. b. Check battery connections. IMPORTANT: ALWAYS RECHARGE THE LAMP AFTER USE. 9
Certification, equipment marking and instructions for compliance with ATEX standards:- The GT range of cap lamps are certified for use in Mines (Group I) and Surface (Group II) areas where a potentially explosive atmosphere may exist. The lamps are suitable for M2 (Mining) and Group II 2 applications. Certification codes are:- ATEX: IECEx: SIRA 02ATEX3175 SIRA 02Y2207 Mining Group I: - EEx I (Ta = 0C to + 40C) Surface Group II: - EEx II (Ta = 0C to + 40C) Warning the correct main bulb must be fitted to ensure the correct temperature classification. Bulb Type Part Number Description Temperature Classification B2 M259130 Prefocus Halogen Bulb 4.1v48L T2 B2 M259530 Prefocus Halogen Bulb 4v 1.5A T2 B3 M259230 Prefocus Halogen Bulb 4v 0.75A T3 B4 M201230 Prefocus Krypton Bulb 4v 1A T4 Lamp Type Reference:- The lamps can be assembled in a variety of combinations to satisfy customer requirements. The assembly combination is stated on the certification label and this combination should not be changed without consultation of Enersys Ltd., Swinton, Manchester UK. The type code sequence is as below:- 1 2 3 4 Lamptop type Bulb type Battery Cover type Battery type G Standard B2 P Plastic Cover T5 16Ah Low Maintenance GH i.s. power Take off B3 L Hand Lamp T6 16Ah Maintenance Free B4 C Communication Cover R Remote Take Off 1 2 3 4 Sample type code: - G B2 P T5 10
Use of equipment:- The user must ensure that the lamp supplied meets the safety standard required for the Zoned area:- 1. This equipment must only be used in a Category M2 or 2 /3 zone. This equipment is not suitable for a Category M1 or 1 zone. 2. Check the temperature classification and ensure the correct main bulb is fitted. 3. Check that the operating temperature range is in the range 20C to +40C for Mining and 0C to +40C for surface application. 4. The lamp must not be disassembled in a hazardous area. 5. The lamp must not be charged in a hazardous area. 6. The cap light and battery casings are manufactured from polycarbonate and ABS with nitrile rubber seals. The performance of these materials, with respect to attack by aggressive substances that may be present in the hazardous area, shall be taken into account before the equipment is used. 7. Plastic surfaces may cause propagating brush discharges. Propagating brush discharges are caused by non-conducting fluid flow over a non-conducting plastic surface. The cap lights shall not be used in areas where a high fluid flow over the plastic surfaces may occur (for example in the case of a ruptured process pipe or compressed air pipe). EnerSys Rake Lane, Clifton Junction, Swinton Manchester M27 8LR UK hawker.mining@uk.enersys.com tel: +44 (0)161 727 3950 fax: +44 (0)161 727 3949 April 2008 11