RETRO XP i3 User Manual

RETRO XP i3 - 400 Lumen, High Power LED Lighting System for Oldham,
Speleo-Technic and CEAG Mining Style caplamps - User Manual v3.0
READ all the instructions first and make yourself familiar with the operation of the Retro XP and the installation procedure
Introduction:
Usi ng the latest LED and electroni cs technology, this LED retro fit provides 400 lumens of light output with only 3.0 to 3.7 Watts of input power (a
standard 3 Walt
(!o/V)
Oldham bulb provides 48 lurnens) . The beam has an 11 •spot, w ith optional 13, 30 and 40• deffusers, which gives an excellent
spread of light, illuminating a much wider area. The hue of the light is much closer to dayl ight, without the yellow tinge bulbs produce making it much
brighter. The light oulput stays constant throughout the battery life. The Retro
XP
also has a small
LED
that is always
on
when the unit is turned on, this
LED is independent to the main ones and offers a backup light should the main ones fail.
The
Retro
XP runs from battery packs giving 1.3 to 6.0V DC output with reverse battery connection protection so
it
will work with almost any cell
combination and will provide light output when normal bulbs will not even illuminate. Full performance can be achieved from voltages 2.3V and above.
DO NOT USE with 5 cell NiCAD/NiMH packs or 6V Sealed Lead Acid batteries as damage will occur.
The Retro XP uses two of the brightest LED's available (Cree XP-G2 R5's). The re are 3 modes: 701m ·pilot, 1851m ·normal activities), and 4001m ·very
bright. A low battery Is Indicated by the LED's flashing.
The Retro XP provides full performance with 2·, 3, 4 cell NiCAD I NiMHD or 2, 3, 4 cell Alkaline, 3.7V Li-ion and 4V Lead Acid battery packs. It will also
work with single cell NiCAD
I
NiMHD's
I
Alkaline batteries at reduced light output.• With new cells that do not drop below 2.3V under load.
Installation In Oldham Cap Lamps:
1. Before proceeding make sure your battery is fully charged and that the existing main and pilot bulbs are working. Disconnect the caplamp from the
battery to avoid fusing the b attery pack. All screw connections that are made must be firm and tight. A small flat
blade screwdriver will be required. Installation should take under 10 minutes.
2. Unscrew the bezel from the c:aplamp housing and take ou t the glass window. Take cul l he reflector and main
bulb assembly. Unscrew the screw, which fastens the wire that is connected to the r eflector lo the main body of
the cap lamp.
3. Unscrew the pilot bulb and remove the pilot bulb holder by unscrewing its two mounting screws. Unscrew the
screw for the contact of the main bulb and remove the contact see fig 1.
4. The polarity of lhe terminals inside the cap lamp needs to be determined. The positive is the connector block,
wtiich correlates with the external charging contact; a brown or red-sleeved wire should be connected to this.
FIGt
The negative connection is to the screw where the blue or black sleeved wire connects to, see fig 1 (for Speleo-
Technic cap lamps see fig 5). To confirm polarity, take the Retro
XP
and touch the red wire to the positive connector block and the green wire to
the negative screw- the Retro
XP
should light up. If it does not light reverse the connection. Make sure the ·
correct low battery link is installed ; see Operation - Part 4.
5. The Retro XP can now be connected. Connect the RED wire solder tag from the Retro XP to the positive
connector block using the same screw that connected the wire from the old main bulb body. Keep its
orientation as shown In fi g 2. After this , connect the GREEN wire solder t ag from the Retro XP to the contact
screw for the pilot bulb - to do this you will need lo unscrew this screw and then place the solder tag
underneath ii. Keep Its orientation as shown in fig 2. Make sure that the contact metal strip stays in place. It is
important to keep th e orienta tions of the Retro XP wires as shown in fig 2 so thal the Retro XP heatsink
(mounted on the back of lhe PCB) can fit into the caplamp cavity.
6. Turn the caplamp switch on, and the Retro XP should switch on. Switch it off
and then proceed to place the Retro XP into the caplarnp. To do this the battery
input cable wires may need to be squashed and compacted down depending on
how
much
excess there is, do this gently. When inserting the Retro XP into place apply gentle
pressure to lhe pressure points indicated in fig 3. Do not press or touch the reflectors and
do not use excessive force. Once i nserted, gently fold and position the Retro
XP
wires as
shown in fig 3 making sure nothing is trapped. Turn the lamp on again and test its
operation. If the Retro
XP
does not
sit
evenly in the cap lamp,
try
adjusting the position of
the positive and negative connections of the power l eads from the battery cable inside the
cap lamp. Hot melt glue can also be used to place the Retro XP if needed.
7 . Once the Retro XP is i nserted the new ' O' ring supplied must be placed into the bezel.
Take the bezel and insert the glass window, then press in the
' 0'
ring see fig 4. Screw the
bezel back onto the cap lamp and make sure ii is a secure fit. If the Retro XP is mounted
slightly higher than it should be (this may occur on older models of cap lamp) take care in how far you screw the bezel
down so as nol to over stress the Retro XP PCB.
lnstanatlon In Speleo-Technic Cap/amps:
1. Before proceeding make sure your battery is fully charged and that th e existing main and pilot bulbs are working .•
All screw connections that are made must be firm and tight. A small flat blade screwdriver will be required.
2. Unscrew the bezel from the caplamp housing and take out the glass window. Remove the reflector, main bulb and
pilot bulb.
3. Remove the screws, which hold the bulb mounting pla te, and take the plate out. Note that the re may be one or
two screws holding lhe plate. When you re move the plate the brown or red-sleeved wire will also be disconnected.
Connect U1is wire back into the same position with one of the screws into lhe connector block see fig 5. Unscrew
the main bulb screw and remove the contact. Continue on from Oldham installation instructions part 4.