T&D TL-9054T3 Operation And Maintenance Instruction

Toplite Portable Searchlight
TL-9050T3 Spotlight & TL-9055T3 Floodlight
Operation and Maintenance Instructions
Certification
Code: EEx e m ib IIC T3 Certification: BASEEFA No. Ex 92 C 3405
Use of Toplite Searchlight in Hazardous Areas
The Toplite TL-9050T3 Spotlight and TL-9055T3 Floodlight are for use in potentially explosive gases, vapours and mists, zones 1
and 2. Applicable standards: EN50014:1977, EN50019:1977, EN50020:1977, EN50028:1987. The Toplite is not approved for use in
zone 0.
Users should consult BS 5345:Part 1:1989 or IEC 79-10 'Code of practice for the selection, installation and maintenance of electrical
apparatus for use in potentially explosive atmospheres', or national equivalent.
o o
Permissible hazardous area ambient: -20 C to +40 C.
Copies of the Toplite Approval Certificate are available on request.
Ingress protection for the Toplite Handheld Searchlight: IP67 to EN60529:1992.
Heavily soiled lamps must not be immersed in water or exposed to high pressure jets for cleaning.
The Toplite body is anti-static.
The Toplite is CE marked in compliance with the EMC directive, a declaration of conformity is available on request.
Lamps must not be charged or opened in hazardous areas. Charging and maintenance must be carried out in a safe area.
A damaged lamp should be withdrawn, examined and repaired before being put back into service. Maintenance and repair must be
carried out by a competent technician or electrician, familiar with certified electrical apparatus, in accordance with these maintenance
instructions and using factory supplied spare parts only. Modifications to the Toplite are not permitted.
Operation
To use. Charge lamp before use. Switch operation positions:
Mode of Operation. The Toplite control circuit assembly manages the operation and charging of the lamp, it also shows available
battery duration by coloured indicator state. At the end of a discharge, the lamp will automatically switch down to walk-out mode and run
for approximately 10 minutes before automatic cut-off. The indication cycle is shown below:
Discharge Indication Sequence
mode of use
indicator state
TL-9050T3 (50 watt)
high power
30 mins
green
main discharge
amber 30 mins
walk-out mode red ** 10 mins approx.
Total duration 70 mins
** Note: On reaching red state, lamp automatically switches to low power and pulses every 15 seconds
Discharge times may vary with the age of the battery
Charging
To Charge the Toplite. Only charge the Toplite T3 with the specified Toplite T3 Charger. Plug the charger into a mains socket.
Remove the charging socket protective cover at the rear of the handle on the Toplite body. Insert the charging plug into the socket, the
charge indicator on the Toplite will start to flash to confirm charging. If the indicator does not start to flash, either the charging plug is not
correctly fitted or the Toplite is already charged. Replace charging socket protective cover after charging.
Toplite State of Charge Indicator. To ensure correct calibration of the state of charge indicator, users are advised that once in every 20
charge/discharge cycles, the Toplite should be fully discharged, past the walk-out mode, until it automatically cuts-off.
Toplite Power Failure Mode. The Toplite can be charged with the operation switch in the on position, but the lamp will not illuminate. If
power to the charger is then interrupted (i.e. if mains power fails) the Toplite will automatically illuminate.
Toplite Over-Temperature Warning. The Toplite has a thermal sensor built into the battery pack, fitted to protect against excessive
heat rise during charging or discharging of the battery. In the unlikely event that the battery does exceed temperature limits, the Toplite
system will shut down and the indicator will scroll through the three colour states. Allow the Toplite battery to cool for 30 minutes and
resume use. If over-temperature problems persist, contact the supplier or manufacturer.
Battery Care
To ensure maximum capacity from the battery it is advisable to fully discharge and recharge twice every six months.
up:- high power middle:- off down:- low power
TL-9050T3 & TL9055T3
duration of colour state (approximate)
TL-9055T3 (35 watt)
low power high power low power
60 mins 45 mins 90 mins
60 mins 45 mins 90 mins
10 mins approx.
130 mins 100 mins 190 mins
Toplite Chargers
TL-9054T3 (EU lead in, lead out) and TL-9056T3 (UK lead in, lead out)
The Chargers are either 'plug-top' or 'lead in, lead out' style, for use on mains AC voltages of 230 Volts at 50-60Hz. Charging is fully
automatic and takes approximately 16 hours, after which it steps down to a trickle charge state, allowing the lamp to be left on charge
continuously. The Chargers are CE marked in compliance with the Low Voltage Directive and the EMC Directive, a declaration of
conformity is available on request. The Toplite TL-9050T3 and TL-9055T3 Lamps must only be charged with the specified Toplite
Charger in a non-hazardous area. Do not use the Toplite Charger with any other type of rechargeable system.
Charging Indication Sequence
Indicator Colour
red flashing
amber flashing
green flashing
green
Charging time for a fully discharged lamp is 16 hours; charging times may vary with the age of the battery
Maintenance
Before working on the Toplite, ensure it is switched 'off'. Work should never be carried out with the switch in the 'on' position or with
the Toplite connected to the Charger.
To open the Toplite. Remove the retaining bolts and lens cover from the front of the lamp. Remove the toughened glass disc and flat
seal. Remove the sealed beam unit; this may be a tight fit in the lamp cavity in the Toplite body moulding. In some cases the side of the
Toplite body can be tapped in order to assist in the removal of the sealed beam unit. Note the orientation of the lamp for refitting. To
replace the sealed beam unit, see instructions below.
To remove the Switch Assembly. Ensure the switch connector is disconnected. Remove the locking nut from the switch bush on the
outside of the lamp. Remove the switch from the inside of the lamp; note orientation for correct refitting.
To remove the State of Charge Indicator. This procedure will almost certainly result in damage to the components, users are strongly
advised not to carry out such work unless it is considered essential. Ensure the indicator connector is disconnected. Remove the locking
nut from the indicator bush on the inside of the Toplite. Pull the indicator housing through from the outside of the lamp. Unscrew the
white LED retainer ensuring that the legs of the LED are not strained. Pull the LED out of the indicator housing. The LED with leads and
connector attached can now be removed through the inside of the Toplite.
To carry out any further work the Chassis must be removed
To remove the Chassis. Remove the two retaining nuts from the front flanges of the Chassis, use a hex key to prevent retaining screws
from turning. Disconnect all connectors and withdraw the Chassis from the Toplite body. When re-assembling, check with diagram to
ensure parts are assembled correctly, check that rubber seal is undamaged.
To replace the Sealed Beam Unit. Loosen the two screws on the terminal block holding the yellow lamp wires. The wires can be
removed and wires from a replacement sealed beam unit fitted and the screws tightened.
To replace the Fuse. Loosen the two screws on the terminal block holding the Fuse. The Fuse can be removed and a replacement
fitted and the screws tightened.
To remove the control circuit assembly. Ensure that all connectors are disconnected and all wires from the terminal block to other
components are removed. CAUTION, prevent the wires from the battery pack touching each other. Cut the tywrap holding the
control circuit assembly in place and remove from the chassis. The refitting is the reverse procedure.
To remove the Battery Pack. Ensure the connector from the battery pack to the control circuit assembly is disconnected. Cut the two
tywraps holding the battery pack into the chassis. Loosen the two screws on the terminal block holding the wires from the battery pack,
withdraw the wires. CAUTION, ensure the wires do not touch. The battery pack can now be removed from the chassis. The refitting
of a new battery pack is the reverse procedure. Ensure the connecting wires are tightly clamped in the terminal block and the tywraps are
replaced.
Note: When the battery pack is disconnected from the control circuit assembly, the system is reset to zero capacity. The Toplite must be
recharged before further use.
The Toplite Battery is a Nickel Cadmium cell system, providing up to 1000 charge and discharge cycles. The pack is specifically
designed to comply with the requirements of electrical equipment for use in potentially explosive atmospheres and must not be replaced
with any non-Wolf component. For optimum performance and safety please observe the following:
Warning:
Charge before first use
Recharge immediately when flat. Recharge every three months when in storage.
Do not incinerate or short circuit. Do not cut, crush or puncture
Dispose of battery via a licensed disposal agency . Do not charge other than from a Wolf Charger
Note: Dangerous goods regulations, hazardous materials regulations, restricted articles regulations
The US Department of Transport, IATA and CAA declare these batteries as 'non-regulated'.
The Wolf Safety Lamp Company have a policy of continuous product review and improvement, changes in design details may be made
without prior notice.
All performance values given have been attained under laboratory conditions, the user must regard these values as approximate.
WWW.CABLEJOINTS.CO.UK
THORNE & DERRICK UK
TEL 0044 191 490 1547 FAX 0044 477 5371
TEL 0044 117 977 4647 FAX 0044 977 5582
WWW.THORNEANDDERRICK.CO.UK
TL-9050T3 & TL9055T3
State of charge (%)
0 - 45
45 - 90
90 - 99
100%