Hella Mining Catalogue 4th Edition - Industrial and Bearing ...

Hella

Mining Catalogue

4th Edition

Hella Australia Pty Ltd ABN 77 006 256 524

54 – 76 Southern Road Mentone Victoria Australia 3194 PO Box 89 Mentone Victoria Australia 3194

P 03 9581 9333 F 03 9585 2654 E [email protected] W www.hella.com/mining

Customer Service: P 03 9581 9299 F 03 9583 1838 P Techline 1800 061729 E [email protected]

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.

© 2010 Hella Australia Pty Ltd. All rights reserved. Release Date November 2010

International Regions

AfricaHella Automotive South Africa (Pty) Ltd1 Fitzpatrick StreetUitenhageSouth Africa 6232Phone: +27 (0)11-538-7530

AsiaHella Asia Singapore Pte LtdRegional Headquarters Asia PacificIndependent Aftermarket2 International Business Park#02 – 15 The StrategySingapore 609930DID: +65 6854 7343

USA Hella Mining LLC1250 Lamollie HwySuite 414Elko Nevada 89801Fax: (775) 738-7450Phone: (775) 738-7441

Canada Hella, Inc. 201 Kelly Drive Peachtree City, GA 30269 Phone: (770) 626-2209 Fax: (770) 631-7575

Mexico & South AmericaHellamex, S.A. de C.V.Proten No. 50Parque Industrial NaucalpanEstado de Mexico, Mexico C.P. 53489Phone: (52) 55-5321-1300

New Zealand Hella-New Zealand LimitedPO Box 5142781–83 Ben Lomond CrescentPakuranga, Auckland 1706Telephone: (09) 577 0000Fax: (09) 576 2476Internet: www.hella.co.nz

EuropeHella KGaA Hueck & Co.Rixbecker Straße 7559552 Lippstadt/GermanyInternet: www.hella.comTelephone: +49 (0) 29 41/38-0Fax: +49 (0) 29 41/38-71 33

www.hella.com/mining

Expert professional advice from our technical department staffed with qualified personnel

Product availability and new product updates

Customer-specific lighting applications engineering service

Mining Centre of Excellence

Hella Centre of Excellence – Mining 3

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 safetyLower operating costGreater productivityPredictable serviceBetter value

Hella mining products are backed by the renowned global Hella quality guarantee, and service and distribution network.

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.

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.

Project Argon charts the extremesDeveloping 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.

MINING WORK LAMPS

28

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

28

WO

RK L

AMPS

12V H3 24V H3Wide Beam HM1524WB HM1526WBNarrow Beam HM1524NB HM1526NBLong Range HM1524LR HM1526LR

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.

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 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

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

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

Protection Sealed against dust and moisture to IP6K7. Shock resistant to 50G.

Spare Parts:

HM8158 Clear Protective Cover

HM8158AMBER Clear Protective Cover - Amber

9.1533.03 Long Range Insert

9.HMUBHNB Insert – Narrow Optic

9.HUMBHWB Insert – Wide Optic

YC2470 H3 Globe, 24V 70W


UltraBeam FF HalogenWork Lamp – 12/24V

HM8158 HM8158AMBER

112 94

101127

24

84

87 50

Front View, Long Range

Long Range Lens

Narrow Beam

DRACOMUSTADD

IP6K7 50G 12/24V 70W MAX

DT & AMP

0.8KgH3, H9, H11

Hella Mining Part Numbers

Page number

Product section

Product dimensions

Alternative view

Alternative model

Spare parts or options

Product feature symbols (see above for key)

Spare parts or options listing

4 How to read this catalogue

Multivolt™

MustADD®

DRACO®

MultiFLASH®

Key to symbols: Hella Product Features Configuration: Electrical: Protection/Hazard Ratings: Standards Compliance:

Lamp type

Connection type

Mass

Rated voltage

Power consumption/load

IP rating

Transient spike protection

Rated shock resistance

Electrical Compliance

Public road trafficcompliance type

DRACO

MULTIFLASH

MULTIVOLT

MUSTADD ECE APPROVED

IP6K

200G

24V

3W

1.4Kg

DT

H3

5Contents

8 Power Beam 1000 15 DuraLED Magnetic Base 28 UltraBeam FF Halogen

9 Power Beam 2000 16 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

40 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

110 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

62 DuraLED SAE 64 DuraLED M Combi 66 DuraLED Marker

63 DuraLED ECE 65 DuraLED MSIP 67 LED Daytime Running Lamp

84 EuroLED Touch M 86 SpotLED 89 MiniThinLED

85 CargoLED 88 FlexSPOT

92 MotoVOX 94 RetroVOX Compression Driver

93 RetroVOX Self Adjusting 95 RetroVOX Broadband

98 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

120 H1, H2 122 H4 124 Xenon

121 H3 123 H7, H9, H11

126 Technical Information 145 Part Number Index

70 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

WORK LAMPS 6

BEACONS 38

ELECTRICAL 108

SIGNAL LAMPS 60

INTERIOR LIGHTING 82

HORNS & ALARMS 90

SERVICE TOOLS 96

GLOBES 118

TECHNICAL 126

ACCESSORIES 68

Work Lamps

8 Power Beam 1000

9 Power Beam 2000

10 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

Work Lamps7

WO

RK L

AMPS

LED WORK LAMPS

8

WO

RK L

AMPS

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.

As an addition to the Hella LED work lamp range, the Power Beam 1000 has been developed as a compact high-powered illuminating source.

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)

Environment temp -40 to +50°C

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

IP6K7 IP6K9K 200G

9 to 33 V DC

18WLED 0.6 KgMULTI

VOLT

Power Beam 1000LED Work Lamp – Multivolt™ 9-33V DC

Power Beam 1000

LED Work Lamp HMPB100

112

142

62

114.596

Power Beam 1000 LED 2.0m high at 10°

1 LUX 39m

LED WORK LAMPS

9

WO

RK L

AMPSPower Beam 2000

LED Work Lamp – Multivolt™ 9-33V DC

By combining 16 high-powered

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 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.

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.

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.

As an addition to the Hella LED work lamp range, the Power Beam 2000 has been developed as a compact high-powered illuminating source.

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

IP6K7 IP6K9K 200G

9 to 33 V DC

43WLED 1.4KgMULTI

VOLT

Power Beam 2000

LED Work Lamp HMPB200

103114

144.5

107

MINING WORK LAMPS

10

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

10

WO

RK L

AMPS

Solid-state LED light sources enabled the design of a fit-and-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, high-voltage 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.

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.

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


IP5K9K

Multivolt 12V DC to 24V DC

Die cast aluminium body

Multi stage anti-corrosion powder coat

High visibility yellow identification ring

Clear glass lens

High intensity LED light

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

IP6K9 200G 12 to 24 V DC

7W

LEDDT & AMP

0.8KgMULTIVOLT

MegaBeamLED Work Lamp – Multivolt™ 12-24V

MegaBeam

LED Work Lamp HM1539LEDLED Work Lamp DT HM1539LDD

Front View

Clear cover to be ordered separately

Spare Parts & Options


83

111

M10

83

75

WO

RK L

AMPS

MINING WORK LAMPS

11

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

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.

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.

Module 70 LEDWork Lamp – Multivolt™ 12-24V

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

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


IP6K7 200G 12 to 24 V DC

15W

LEDDT 0.4KgMULTI

VOLT

Module 70 LED

LED Work Lamp DT HM70LEDD

HM70PR

Front view

HM70PI

105

52

Ø15-28


HM70PR Pipe mount tube attachment (rotating)

HM70PI Pipe mount tube attachment

9.HM70BR Stainless steel bracket

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.


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 2.0m high at 10°

1 LUX 37m

12

WO

RK L

AMPS

LED TASK LAMPS

136 49

5342

Wide Beam Optic HM1535WB

Narrow Beam Optic HM1535NB

Pencil Beam OpticHM1535PB

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.

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.

LED Task Lamp

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

Fully sealed against dust and high-pressure water jets

Inbuilt thermal management protection

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

Homogenous close range illumination

IP6K7 IP6K9K 9 to 33 V DC

3W

LEDBARE WIRE

0.35KgMULTIVOLT

LED Task Lamp

Narrow Beam HM1535NBPencil Beam HM1535PBWide Beam HM1535WB

13

WO

RK L

AMPS

MINING LED SERVICE LAMPS

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.

DuraLed® 700 LumenWhite LED Service Lamp Multivolt™ 9-33V DC

DuraLed® 700 Lumen White LED Service Lamp

Wide Beam HM15700WBNarrow Beam HM15700NBPencil Beam HM15700PB

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 – 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

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)

100

177

148

31

22

DuraLed 700 Lumen Wide Beam 2.5m high at 0°

5 5

5

4

3

2

1

0

DuraLed 700 Lumen Narrow Beam 2.5m high at 0°

5 5

5

4

3

2

1

0

DuraLed 700 Lumen Pencil Beam 2.5m high at 0°

5 5

5

4

3

2

1

0

IP6K7 200G 9 to 33 V DC

9W

LEDDT & BARE WIRE

0.5KgMULTIVOLT

Pencil Beam model shown

MINING LED SERVICE LAMPS

14

WO

RK L

AMPS

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.

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.

Product features

Industry benchmark highest efficacy - 50 LEDs rated to a total of 1000 lumen per lamp


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 LumenWhite LED Service Lamp Multivolt™ 9-33V DC

IP6K7 200G 9 to 33 V DC

12W

LEDDT & BARE WIRE

0.7KgMULTIVOLT

DuraLed® 1000 Lumen White LED Service Lamp

Wide Beam HM1550WB

DuraLed 1000 Lumen Wide Beam 2.5m high at 0°

5 5

5

4

3

2

1

0

222

193

34

96

15

MINING LED WORK LAMPS

WO

RK L

AMPSDuraLed® Magnetic Base

1000 Lumen Work Lamp – 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 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.

The compact 1 metre extension cable extends the range of the light to 8 metres from the

power source.

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.

Combined with the Hella PowerPAK system, users will have a truly high performance mobile lighting system.

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.

Product features

1m coiled cord with 8-metre extension potential.

1000 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

IP6K7IP6K6 200G

9 to 33 V DC

12WLED 0.8KgMULTI

VOLT

DuraLed® 1000 Lumen Magnetic Base

With DT connector HM1550DTWith 12V MagCode connector HM1550MAG-12With 24V MagCode connector HM1550MAG-24With CIG/DIN plug HM1550CIG

222

193

34

96

Compatible with PowerPAK Portable Power Pack,Part No. HM8600

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

16

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

HID WORK LAMPS

16

WO

RK L

AMPS

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 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 re-use, 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.

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.

AS500® FF XenonHeavy Duty Work Lamp


HM8164 Clear Protective Cover AS500

9.HMAPEDL Pedestal Mounting Bracket Assembly

9.HM151TRN Trunnion Mounting Bracket Assembly

9.HMAWHKD Cable harness kit AS500

9.HM15WB Insert – Wide Optic – AS200/500 GDL

9.HM15NB Insert – Narrow Optic – AS200/500 GDL

9.HM151BAL Multivolt Ballast

XN4000 Globe – Xenarc D2S

AS500® FF Xenon Trunnion Pedestal

Wide Beam Multivolt DT HM1512WB HM1513WBNarrow Beam Multivolt DT HM1512NB HM1513NB

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

O-ring seals

Components tested over a –40ºC to +105ºC temperature range

High efficiency & long life D2S 35W Xenon light


IP6K7K

200G shock resistant ballast

50G shock resistant lamp

CE compliant

Protective clear covers available

Consumable spares interchangeable with Hella AS200FF® Xenon range

Shown with Pedestal Mount

DRACOMUSTADD

IP6K7 50G 12/24V 41W

D2SDT 2.8Kg


175

126

122

170

120

56

135

141

127

202135

19

2672M10

Optional Pedestal Bracket

Trunnion Bracket Shown with Trunnion Bracket

17

WO

RK L

AMPS


AS500 FF Xenon Narrow Beam

30030

30

60

Peak 79 LUX

90 120 150

AS500 FF Xenon Wide Beam

30030

30

60

Peak 120 LUX

90 120 150

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

18

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

MINING WORK LAMPS

18

WO

RK L

AMPS

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 adaptation-related 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.

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.

Product features

Steel-reinforced UV-resistant polymer body


Stainless steel bracket

Draco® suspension


MustADD® filter

Double insulated silicone supply cable with DT connector

Replaceable encapsulated Xenon ballast

O-ring seals

Components tested over a –40ºC to +105ºC temp. range



IP6K7



CE compliant


Consumable spares interchangeable with Hella AS500FF Xenon range



HM8154AMBER Clear protective Cover – Amber

9.HM15WB Insert – Wide Optic – AS200/500 GDL

9.HM15NB Insert – Narrow Optic – AS200/500 GDL


XN4000 Globe – Xenarc D2S

AS200 FF Xenon

Wide Beam Multivolt DT HM1504WBNarrow Beam Multivolt DT HM1504NB

AS200 FF XenonHeavy Duty Work Lamp


DRACOMUSTADD

IP6K7 50G 12/24V 41W

D2SDT 1.8Kg

Front View

276.5

50

15062

54

69.5

160

191

163

19

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

19

WO

RK L

AMPS

AS200 FF Xenon Narrow Beam

30030

30

60

Peak 79 LUX

90 120 150

AS200 FF Xenon Wide Beam

30030

30

60

Peak 120 LUX

90 120 150

20

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

MINING WORK LAMPS

20

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

20

WO

RK L

AMPS

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 adaptation-related 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.

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.

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

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

UltraBeam FF X-PowerPackXenon Work Lamp

UltraBeam FF X-PowerPack Xenon 12V DC 24V DC

Wide Beam Pendant Mount HMUBXHWBD-12V HMUBXHWBD-24VNarrow Beam Pendant Mount HMUBXSWBD-12V HMUBXSWBD-24V

DRACOMUSTADD

IP6K7 200G 12/24V 42W

D1SDT 1.26Kg

IP6K9K


HM8160 Clear Protective Cover (included)

HMXN4001 D1S Xenon Globe

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.


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.

HM8160

112 136

101

143

84

24

87 73

Pedestal Mount

Pendant Mount

21

WO

RK L

AMPS

Wide Beam Optic (not serviceable)

D1S Xenon Globe HMXN4001

Integral Xenon Ballast (non-replaceable)

Stainless Steel Bracket

MINING WORK LAMPS

22

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

22

WO

RK L

AMPS

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 adaptation-related 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 corrosion-resistant 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.)

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.

Product features

UV resistant polymer body


Draco® suspension

Free-Form beam optics

MustADD® filter

DT plug

Replaceable encapsulated Xenon ballast

O-ring seals



8-32V DC operationIP6K5K



CE compliant


UltraBeam FF XenonHeavy Duty Work Lamp – 24V DC

UltraBeam FF Xenon 8-32V DC

Wide Beam DT Plug HM1522WB



HM8157AMBER Amber Protective Cover

9.HMUBXWB Reflector & Optic Insert


DRACOMUSTADD

IP6K5 50G 12/24V 41W

D2SDT 2.0Kg

Front View

112

24

140

350

101127

84

120

93

24

43

112

24

140

350

101127

84

120

93

24

43


23

WO

RK L

AMPS

2.5m high at 5°

0 20 40 6030

30

UltraBeam FF Xenon Wide Beam

24

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

MINING WORK LAMPS

24

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

24

WO

RK L

AMPS

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 adaptation-related 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.

OVAL100 FF Xenon is a low profile, heavy-duty work lamp for use on mining machinery, suitable for 24V and 12V electrical systems.

Product features

UV-resistant polymer body

Low profile Oval shape


Draco® suspension


MustADD® filter


Replaceable Xenon ballast

O-ring seals



12V DC & 24V DC options

IP65


CE compliant

OVAL 100 FF XenonHeavy Duty Work Lamp – 24V DC

OVAL 100 FF Xenon

Wide Beam DT HMPVX35WBDNarrow Beam DT HMPVX35NBD


9.HMPUXWB Insert – Wide Optic – GDL

9.HMPUXNB Insert – Narrow Optic – GDL

9.HMPUXB24 Ballast – OVAL100 FF

HMXN4001 Globe – Xenarc D1S

DRACOMUSTADD

IP65 50G 12/24V 41W

D1SDT 1.5Kg

Front View

192mm

160mm 135mm

25

WO

RK L

AMPS

Peak 84 Lux

Peak ★82 Lux 2.5m high at 5°

0 20 40 6030

30

Oval 100FF Xenon Narrow Beam 2.5m high at 5°

0 20 40 6030

30

Oval 100FF Xenon Wide Beam

26

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

HALOGEN WORK LAMPS

AS500® FF Halogen H3 Trunnion Pedestal

Wide Beam DT HM1510WB HM1511WBNarrow Beam DT HM1510NB HM1511NB

DRACOMUSTADD

IP6K7 50G 12/24V 70W

H3DT 2.2Kg

26

WO

RK L

AMPS

Shown with Pedestal Mount

Shown with Trunnion Bracket


HM8164 Clear Protective Cover AS500

9.HMAPEDL Pedestal Mounting Bracket Assembly

9.HM151TRN Trunnion Mounting Bracket Assembly

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

Product features

Modular die cast aluminium alloy body


Multiple mounting options

Stainless steel trunnion bracket with quad bolt fastening

Draco® suspension


MustADD® filter

Captive Allen bolts


O-ring seals


H3 Halogen 70W 24V supplied

H3 Halogen 55W 12V can be fitted


12V DC & 24V DC options

IP6K7K



Consumable spares interchangeable with Hella AS200FF® Xenon range


175

126

122

170

120

56

135

141

127

202135

19

2672M10


Trunnion Bracket

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 re-use, 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.

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.

AS500® FF HalogenHeavy Duty Work Lamp

27

WO

RK L

AMPS


Peak 79 Lux

Peak ★120 Lux

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

Trunnion Bracket

0 10020 40 60 8020

20

2.5m high at 5° AS500 FF Halogen Narrow Beam

0 10020 40 60 8020

20

2.5m high at 5° AS500 FF Halogen Wide Beam

MINING WORK LAMPS

28

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

28

WO

RK L

AMPS

UltraBeam FF Halogen 24V H3Wide Beam HM1526WBNarrow Beam HM1526NBLong Range HM1526LR

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.

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 features:

Powerful long range and wide spread illumination

DT electrical connection

Robust polymer body


Draco® suspension

MustADD® multi air-filter

Free-form (FF) reflector for powerful long range illumination


IP6K7

Clear protective covers available



Specifications:


Mounting Single bolt with tilt adjustment for upright, side or pendant mounting on horizontal or vertical surfaces. Stainless steel bracket and screws included

Protection Sealed against dust and moisture to IP6K7. Shock resistant to 50G.

Spare Parts:


HM8158AMBER Clear Protective Cover - Amber

9.1533.03 Insert – Long Range Optic

9.HMUBHNB Insert – Narrow Optic

9.HMUBHWB Insert – Wide Optic


YC1255LL H3 Globe, 12V 55W

UltraBeam FF HalogenWork Lamp – 12/24V

HM8158 HM8158AMBER

112 94

101127

24

84

87 50

Front View, Long Range

Long Range Lens

Narrow Beam

DRACOMUSTADD

IP6K7 50G 12/24V 70W MAX

DT 0.8KgH3, H9, H11

29

WO

RK L

AMPS

UltraBeam FF Long Range 2.5m high at 5°

0 10020 40 60 8020

20

1 LUX 68m

UltraBeam FF Wide 2.5m high at 5°

0 20 40 6030

30

PEAK 42 LUX

UltraBeam FF Narrow 2.5m high at 5°

0 20 40 6030

30

PEAK 44 LUX

Peak ★44 Lux

Long Range Optic

Narrow Beam Optic

MINING WORK LAMPS

30

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

GHydroLUX® Submersible Driving Lamp 12/24V

Mining Yellow H3 Spread Beam HM1358Mining Yellow H1 Pencil Beam HM1374DMining Yellow H1 Spread Beam HM1375D

Mining Yellow H4 RHD Driving Beam HM1002Mining Yellow H4 LHD Driving Beam HM1002ECE

HydroLUX®

Submersible Driving Lamp 12/24V

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)

IP6K9K


ECE and SAE compliant options

Right and left hand traffic options


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.

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.Clear cover to be ordered separately

Shown with H3 Insert

HM1002 (with H4 Insert)

185 145

198

MUSTADD

IP6K9K 50G 12/24V 100WMAX

ECE/ADR

compliant

H1, H3, H4

BARE WIRE

3.2Kg

30

WO

RK L

AMPS


8151 Clear Protective Cover

HM9.1374.08 Mounting Bracket Assembly

HM9.1374HD.01 Pencil Beam Insert Assembly (H1 Version)

HM9.1375HD.01 Spread Beam Insert Assembly (H1 Version)

9.HM1002ECE.01 Insert HM1002ECE (LHD, H4 ECE Version)

9.HM1002.01 Insert HM1002 (RHD, H4 Version)

9.HM1385.05 Insert HM1358 (H3 Version)

31

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

Note: Spread Beam Lamp is ECE compliant with 12V/55W or 24V/70W globe.

Front View

Pencil Beam Recorded with single lamp. Distance in metres.

Spread Beam Recorded with single lamp. Distance in metres.

1 LUX .5 LUX

31

WO

RK L

AMPS

32

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

MINING WORK LAMPS

32

WO

RK L

AMPS AS200 FF Halogen

Heavy Duty Work Lamp – 12/24V

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 adaptation-related 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.)


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.

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.

Product features

AUV resistant polymer body



Draco® suspension


MustADD® filter

Double insulated silicone supply cable with DT or AMP plug

O-ring seals




IP6K5K



Consumable spares interchangeable with Hella AS500 FF Halogen range

AS200 FF Halogen with AMP plug with DT Plug

Wide Beam HMASH70WBA HMASH70WBDNarrow Beam HMASH70NBA HMASH70NBD

DRACOMUSTADD

IP6K5 50G 12/24V 70W

H3DT & AMP

0.8Kg

137

160 160

Front View


HM8156 Clear Protective Cover AS200 H3

HM8156 AMBER Amber Protective Cover AS200 H3

9.HM15WB Insert – Wide Optic

9.HM15NB Insert – Narrow Optic

YC2470 Globe – H3 24V

YC1255LL Globe – H3 12V

33

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

33

WO

RK L

AMPS

0 10020 40 60 8020

20

2.5m high at 5° AS200 FF Halogen Narrow Beam

0 10020 40 60 8020

20

2.5m high at 5° AS200 FF Halogen Wide Beam

34

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

MINING WORK LAMPS

34

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

34

WO

RK L

AMPS

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 Hella-pioneered 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.)


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.

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.

Product features

UV resistant polymer body

Low profile Oval shape

Individual lamp switching


Draco® suspension


MustADD® filter

Double insulated silicone supply cable with DT or AMP plug

O-ring seals



IP6K5K



OVAL 100 FF HalogenDouble Beam Work Lamp – 24V DC



HM8159AMBER Amber Protective Cover

9.HMPU2NB Insert – Narrow Optic – OVAL100 DB

9.HMPU2WB Insert – Wide Optic – OVAL100 WB

YC2470 Globe H3 – 24V

YC1255LL Globe H3 – 12V

DRACOMUSTADD

IP6K5K 50G 12/24V 70W

H3DT & AMP

1.0Kg

Oval 100 FF Halogen Double Beam with AMP plug with DT Plug

Wide Beam HMPV270WBA HMPV270WBDNarrow Beam HMPV270NBA HMPV270NBD

Wide Beam model

Narrow Beam model – front view


35

WO

RK L

AMPS

Peak 45 Lux

Peak ★50 Lux

0 10020 40 60 8030

30

2.5m high at 5° Oval 100 FF Halogen Narrow Beam

0 10020 40 60 8030

30

2.5m high at 5° Oval 100 FF Halogen Wide Beam

MINING WORK LAMPS

36

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

36

WO

RK L

AMPS

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.

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.)

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.

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.

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.

Product features


Clear lens “brilliant” appearance

Die cast aluminium reflector

Tool less globe access

Impact resistant housing


ROHS compliant

Yellow mounting bracket denotes product as mining specification version

Electrical connection: 200mm double insulated cable harness, terminated with DT connector; other terminations available on special request


IP5K9K

H9 12V 65W Halogen globe included

H3 24V 70W Halogen globe included

IP5K9 50G 12/24V 70Wmax

H3, H9DT 0.5KgMULTI

VOLT

Modul 70 HalogenWork Lamp

HM70PR

9.HM70WH

Front view

HM70PI


HM70PR Pipe mount tube attachment for rotating

HM70PI Pipe mount tube attachment

9.HM70WH Wiring harness H9, 2m

9.HM70BR Bracket Stainless steel Modul 70

9.HM70DC Dust Cap H3 Modul 70

CF1265 Globe H9 – 12V

YC2470 Globe H3 – 24V

Modul 70 Halogen 12V H9 24V H3

Wide Beam HM70H9WB-12V HM70H3WB-24VNarrow Beam HM70H9NB-12V HM70H3NB-24V

H3

H9

37

WO

RK L

AMPS

12V H9 Halogen Globe

24V H3 Halogen Globe

Peak ★84 Lux

Peak ★82 Lux

0 10020 40 60 8020

20

2.5m high at 5° Modul 70 Halogen Narrow Beam

0 10020 40 60 8020

20

Modul 70 Halogen Narrow Beam H9 12V

0 10020 40 60 8020

20

Modul 70 Halogen Narrow Beam

0 10020 40 60 8020

20

2.5m high at 5° Modul 70 Halogen Narrow Beam H3 24V

0 10020 40 60 8020

20

2.5m high at 5° Modul 70 Halogen Wide Beam H9 12V

0 10020 40 60 8020

20

2.5m high at 5° Modul 70 Halogen Wide Beam H3 24V

Beacons

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

39

BEAC

ON

SBeacons

LED BEACONS

40

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

40

BEAC

ON

SDuraRAY® Phase II LED Warning Beacons

l Amber LEDl 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 HM9400AMB2G3 LED Disks HM9400YEL3A HM9400YEL3R HM9400YEL3G HM9400AMB3A HM9400AMB3R HM9400AMB3G4 LED Disks HM9400YEL4A HM9400YEL4R HM9400YEL4G HM9400AMB4A HM9400AMB4R HM9400AMB4G

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 close-up 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 ISO13766-2006 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 long-term 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.

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.

Product features


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 13766-2006

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.HM9386.02 Installation Kit

IP6K7 200G 9 to 33 V DC

33WMAX

LEDDT & BARE WIRE

MULTIVOLT

DuraRAY® Phase IILED Warning Beacons

111.5

130.6

132.5

130.6

153.5

130.6

159

169

25mm Pipe Thread

3 x M4 equispacedon PCD Ø107

3 x M4 equispacedon PCD Ø130

3 x Ø6 equispacedon PCD Ø150

3 LED Disks

2 LED Disks

4 LED Disks

41

BEAC

ON

S

Bottom View

Yellow Housing Amber Housing

Top View

Amber Function Colour

Red Function Colour

Green Function Colour

HM500AFLX UltraRAY-R TWIN includingvibration proof pole-mount adapter

MINING WARNING BEACONS

42

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

42

BEAC

ON

SUltraRAY®-R TWIN LED Warning Beacon l Amber l Red l Blue l Green l White

Direct Mount HM500ADIR HM500RDIR HM500BDIR HM500GDIR HM500WDIRMagnetic Mount HM500AMAG HM500RMAG HM500BMAG HM500GMAG HM500WMAG

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.

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®.

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

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

Specifications

Voltage Multivolt™ 12 –30V DC

Power consumption 50W average

Frequency Rotating: 80 cycles/min Flash: 72 fpm (quad)

Temperature Range –20°C to +50°C

Lead Length 2 metres (double-insulated cable)

Protection Overheat, reverse polarity and short circuit protected.

Sealed against dust and moisture to IP6K5

Shock resistant to 200G

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

IP6K5 200G 12 to 24 V DC

50WAVERAGE

LEDBARE WIRE

0.9KgMULTIVOLT

UltraRAY®-R TWINLED Warning Beacon

SAECOMPLIANT

132

130

3 x Ø4equispacedon PCD130

4 x Ø4equispacedon PCD 178

136

187

120°

120°

Amber

Red

Blue

Green

White

43

BEAC

ON

S

Polycarbonate lens with Helioshield™

Cast alloy base

Rubber vibration insulator


UltraRAY®-R LED Warning Beacon l Amber l Red l Blue l Green l 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.

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.

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


Low current draw



Double insulated supply cable

O-ring seals


Unique Helioshield™ ambient light suppression improves daylight visibility

* Preset to ‘rotating’ pattern

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

Lead Length 2 metres (double-insulated cable)

Protection Overheat, reverse polarity and short circuit protected.

Sealed against dust and moisture to IP6K5

Shock resistant to 200G

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



IP6K5 200G 12 to 24 V DC

20WMAX.

LEDBARE WIRE

0.9KgMULTIVOLT

UltraRAY®-R “Rotating”

LED Warning Beacon

SAECOMPLIANT

132

130



136

187

120°

120°

Amber

Red

Blue

Green

White

44

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

44

BEAC

ON

S

HM450AFLX UltraRAY-R includingvibration proof pole-mount adapter

45

BEAC

ON

S

Polycarbonate lens with Helioshield™

Cast alloy base


MINING WARNNG BEACONS

UltraRAY® LED Warning Beacon l Amber l Red l Blue l Green l White


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.

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.

Product features

SAE J845 Class 1 red & amber


User selectable flash patterns (4)



Clear precision Fresnel optics

Cast alloy base


Multivolt 12 –30V DC

Low current draw


1.5kg mass



Double insulated supply cable with DT or AMP plug

O-ring seals

Tested over a –20ºC to +50ºC temperature range


IP6K5


Spare Parts

9.HM400LENS Clear Lens



IP6K5 200G 12 to 24 V DC

20WMAX.

LEDBARE WIRE

0.9KgMULTIVOLT

UltraRAY®

LED Warning Beacon

SAECOMPLIANT

132

130



136

187

120°

120°

Amber

Red

Blue

Green

White

46

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

46

BEAC

ON

S

HM400AFLX UltraRAY includingvibration proof pole-mount adapter

47

BEAC

ON

S

Polycarbonate lens

Cast alloy base



48

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

48

BEAC

ON

SOptiRAY® LED Warning Beacon l Amber l Red l Blue l Green l White

Direct Mount HM360ADIR HM360RDIR HM360BDIR HM360GDIR HM360WDIRMagnetic Mount HM360AMAG HM360RMAG HM360BMAG HM360GMAG HM360WMAGBattery Pack HM360ABP HM360RBPMagnetic Battery Pack HM360ABPMAG HM360BBPMAG

OptiRAY LED beacons offer multiple, user-selectable flash patterns, including a rotating beam, 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 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.

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.

Product features

SAE J845 (Class 1 red, Class 2 amber)


User selectable flash patterns (16)





Battery pack option

Multivolt 12 – 30V DC

Low current draw (1Amp)



Double insulated supply cable

O-ring seals



IP6K5


Spares interchangeable with Hella OptiRAY E range

Spare Parts




IP6K5 200G 12 to 30 V DC

12WMAX

LEDBARE WIRE

0.5KgMULTIVOLT

OptiRAY®

LED Warning Beacon

White on

Amber on

Green on

Red on

Blue on

optiray

140

113

106

Battery pack

SAECOMPLIANT

HM360AFLX OptiRAY includingvibration proof pole-mount adapter

49

BEAC

ON

S


IP6K7 200G 9 to 31 V DC

6W

LEDDT 0.5KgMULTI

VOLT

OptiRAY® E LED Warning Beacon l Amber l Red l Blue l Green l White


50

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

50

BEAC

ON

S

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.

Hella OptiRAY® E LED warning beacons are designed for heavy duty use on mining equipment and service vehicles where complex functionality is not required.

Product features

SAE J845 (Class 1 red, Class 2 amber)





Multivolt 12 – 30V DC

Low current draw 1AMP


0.5kg mass



Double insulated supply cable with DT or AMP plug

O-ring seals



IP6K5


Spares interchangeable with Hella OptiRAY range

Double Flash, 80FPM

Spare Parts




IP6K5 200G 12 to 30 V DC

12WMAX

LEDBARE WIRE

0.5KgMULTIVOLT

OptiRAY® ELED Warning Beacon

White on

Amber on

Green on

Red on

Blue on

optiray

140

113

106

SAECOMPLIANT

HM300AFLX OptiRAY-E includingvibration proof pole-mount adapter

51

BEAC

ON

S


52

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

52

BEAC

ON

S

IP6K5 200G 12 to 30 V DC

12W MAX

LEDBARE WIRE

0.9KgMULTIVOLT

MiniRAY® LED Warning Beacon l Amber l Red l Blue l Green l White

Direct Mount HM180ADIR HM180RDIR HM180BDIR HM180GDIR HM180WDIRMagnetic Mount HM180AMAG HM180RMAG HM180BMAG HM180GMAG HM180WMAGBattery Pack HM180ABP HM180RBP HM180GBP

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).

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.

Product features


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.

MiniRAY®

LED Warning Beacon

Spare Parts


miniray

113

161 140.5

30

130

Battery pack

Red on

Blue on

Green on

White on

Amber on

Designed to identify machine type (colour) and direction of travel (beam pattern).

Side viewFront view Rear view

53

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

MINING SIGNAL LAMPS

53

BEAC

ON

SNaviLED® MWarning Beacon

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 user-friendly 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 over-voltage 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.

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


Spike protected to +500 volts

Over voltage protected to +200 volts


Low power consumption (2W)

Sealed to IP6K6 and IP6K7 to withstand temporary immersion and high pressure washing

200G shock tested


External elements manufactured from flame retardant polymers rated UL94 HB

IP6K7 200G 9 to 33 V DC

2W

LEDDT 0.5KgMULTI

VOLT

NaviLED® M Surface Mount l Amber l Red l Blue l Green l White

Signal Lamp Yellow Housing HM980910621 HM980910421 HM980910721 HM980910221 HM980910021

FLASHING

9083

Amber Illuminated

Blue Illuminated

Red Illuminated

White Illuminated

Green Illuminated

Optic appears clear until illuminated in all lamps

54

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G


54

BEAC

ON

SDuraLed® M High Intensity Warning Beacon l Amber l Red l Blue l Green l White

Narrow Beam Bare Wire HM95903710 HM95903700 HM95903760 HM95903780 HM95903790Narrow Beam DT Plug HM95903710D HM95903700D HM95903760D HM95903780D HM95903790D

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 short-term 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.

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.

Product features


User selectable flash patterns

Impact resistant smooth Xylex lens

Clear precision micro optics


Low power < 10W

Fully sealed “fit and forget” design

0.5kg mass



Double insulated supply cable with DT plug or bare wire



IP6K7K

UL94 flame retardant rated external parts

Spares interchangeable with Hella DuraLed range

Spare Parts

9.HMDLM001 Cover Kit Yellow

IP6K7 200G 9 to 33 V DC

9W

LEDDT & BARE WIRE

0.5KgMULTIVOLT

DuraLed® M High IntensityWarning Beacon

1 second

0123456789

10

Flas

h P

atte

rns

250 ms 500 ms 750 ms

MultiFLASH®

100

177

148

31

22

Amber Illuminated

Blue Illuminated

Red Illuminated

White Illuminated

Green Illuminated

MULTIFLASH

55

BEAC

ON

S

10m

5m4.0m

4.0m

0.8m0.8m

0m

5m

10m30m25m20m15m10m5m

0.0lx

1.0lx

2.5lx

5.0lx

7.5lx

10.0lx

0.0lx

1.3lx

3.0lx

6.0lx

9.0lx

12.0lx

0.0lx

0.8lx

2.5lx

5.0lx

7.5lx

10.0lx

0.0lx

0.3lx

2.5lx

5.0lx

7.5lx

10.0lxBeam Widthand Height

DuraLED Blue 95906070DuraLED Green 95906090

DuraLED Red 95906080DuraLED Amber 95907080

Average Beam Illuminance

Optic appears clear until illuminated in all lamps

Maximum Intensity 500 cd400 cd300 cd100 cd

80%

60%

40%

20%

-90.0° -72.0° -54.0° -36.0° -18.0° 0.0°

DuraLED Red 95906080DuraLED Amber 95907080DuraLED Green 95906090DuraLED Blue 95906070

18.0° 36.0° 54.0° 72.0° 90.0°


56

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

56

BEAC

ON

S

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.

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.

Product features

Heavy cast alloy base



Voltage nominal: 12V – 24V DC

Voltage operating: 9V – 32V DC

Field selectable double or quad flash

Field selectable high/low flash intensity

10 Joules @ 80 FPM

16 Joules @ 65 FPM

Reverse polarity, voltage spike & surge protection

Mounting: 150mm PCD from above and 30mm SPT from below.

SAE J1318 Class 2 compliant

SAE J575 compliant


IP6K6


Suitable for use with GuardRAY protective cage

Consumable spares interchangeable with PulseRAY E67 beacons

PulseRAY® KLXHeavy Duty Xenon Warning Beacon

Spare Parts

9.HMX7500.01 Lens KLX inner - Fresnel

9.HMX7500.02 Lens KLX outer – Amber

HMWGA220 GuardRAY® Protective Cage

XN6750 Globe – Xenon E67 Flash Tube

174.8

165

Front View

HMWGA220 (optional)

IP6K6 50G 12/24V 60W

XENON BARE WIRE

1.1Kg SAECOMPLIANT

ECECOMPLIANT

PulseRAY® KLX

Heavy Duty Xenon Warning Beacon Amber HMX7500A

57

BEAC

ON

S

58

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G

58

BEAC

ON

S


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 thread-on 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.

PulseRAY® E67 Xenon strobe warning beacons are designed for heavy duty use on mining machinery; suitable for 24V and 12V electrical systems.

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

10 Joules @ 80 FPM

16 Joules @ 65 FPM

Reverse polarity, voltage spike & surge protection

Mounting: 150mm PCD from above and 30mm SPT from below


IP6K6


SAE J1318 Class 2 compliant

SAE J575 compliant

Suitable for use with GuardRAY protective cage

Consumable spares interchangeable with PulseRAY KLX beacons

PulseRAY® E67Heavy Duty Xenon Warning Beacon 12/24V DC

PulseRAY®E67 l Amber l Red l Blue l Green l Clear

Heavy Duty Xenon Strobe 12/24V DC HMX6750A HMX6750R HMX6750B HMX6750G HMX6750C

Spare Parts

9.1602.01 E67 Lens - Amber

9.1601.01 E67 Lens - Red

9.1600.01 E67 Lens - Blue

9.1603.01 E67 Lens - Green

9.1604.01 E67 Lens - Clear

HMWGA160 GuardRAY® Protective Cage

XN6750 Globe - Xenon E67 Flash Tube

9.1600.06 Lens Clear Dust Cover

IP6K6 50G 12/24V 60W

XENON BARE WIRE

1.2Kg SAECOMPLIANT

Amber Lens

121

4.8

1656.5

Blue Lens

Red Lens

Clear Lens

Green Lens

HMWGA160 (optional)

59

BEAC

ON

S

Signal Lamps

62 DuraLED SAE

63 DuraLED ECE

64 DuraLED M Combi

65 DuraLED MSIP

66 DuraLED Marker

67 LED Daytime Running Lamp

61

SIGN

AL L

AMPSSignal Lamps

62

SIGN

AL L

AMPS

MINING SIGNAL LAMPS

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.

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.

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).

DuraLed® SAESignal Lamps

DuraLed® SAE Signal Lamp

Stop/Tail Rear Turn Signal (Red) HM060321Rear Turn Signal/Indicator HM070321

HM060321

HM070321

100

177

148

31

22

IP6K7 200G 9 to 33 V DC

5W

LEDDT& BARE WIRE

0.4KgMULTIVOLT

SAE COMPLIANT

63

SIGN

AL L

AMPS

MINING SIGNAL LAMPS

DuraLed® ECE Signal Lamp

Stop/Tail Signal (Red Illuminated) HM060621Rear Turn Signal (Amber Illuminated) HM070621

IP6K7 200G 9 to 31 V DC

2Wto 9W

LEDDT& BARE WIRE

0.4KgMULTIVOLT

ECE APPROVED

DuraLed® ECESignal Lamps

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.

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

(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.

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 dirt-collecting cavities.

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.

Product features

Easy Installation

Variety of surface mount options

Ultra wide angle optics for enhanced side visibility

Ultra low power consumption


ECE Approval

Fully sealed against dust and moisture

100

177

148

31

22

HM060621 (Red Illuminated)

HM070621 (Amber Illuminated)

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:

HM060621 (Red) E13 020533 e4 020889

HM070621 (Amber) E13 010363 e4 020904

MINING SIGNAL LAMPS

64

SIGN

AL L

AMPS

DuraLed® M Combination

Signal Lamp Bare Wire HM2379Signal Lamp DT HM2379D

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 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 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.

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.

Product features




Low power < 10W


0.5kg mass



Double insulated supply cable with DT plug or tinned wire



IP6K7K


ADR, ECE and SABS compliant


CE compliant

Spare Parts

9.HMDLM001 Cover Kit Yellow (Pack of 4)

DuraLed® MCombination Signal Lamp

222

193

34

96

Optic appears clear until illuminated (off)

Tail lamp function displayed

Stop lamp function displayed

Indicator function displayed

All functions displayed (on)

IP6K7 200G 8 to 28 V DC

9W

LEDDT& BARE WIRE

0.7KgMULTIVOLT

ADR/ECE/SABS

COMPLIANT

MINING SIGNAL LAMPS

65

SIGN

AL L

AMPS

DuraLed® MSIP Signal Lamp

Red/Green HM95905030

DuraLed® MSIPSignal Lamp

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.

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.

Product features




Low power < 10W


0.5kg mass



Double insulated supply cable with DT plug or tinned wire



IP6K7K


ROHS compliant


Spare Parts

9.HMDLM001 Cover Kit Yellow (Pack of 4)

IP6K7 200G 8 to 28 V DC

9W

LEDDT& BARE WIRE

0.7KgMULTIVOLT

ADR/ECE/SABS

COMPLIANT

222

193

34

96

Optic appears clear until illuminated (off)

Red illuminated shown

Green illuminated shown

Red & green illuminated shown

66

SIGN

AL L

AMPS

MINING SIGNAL LAMPS

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.

DuraLed® M “Fit and Forget” robust waterproof clearance marker and inspection lamps utilise the latest LED technology specifically for heavy duty applications.

DuraLed® MMarker Lamps

Product features

-40°C to +70°C.


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

Spare Parts

9.HMDLM002 Marker Housing Yellow (Pack of 4)

DuraLed® M l WhiteInspection Point

l l Red/Amber Side Marker

l RedMarker

l AmberCabin Marker

l AmberMarker

Marker Lamp Bare Wire HM2054 HM2053PC HM2307 HM2026 HM2051Marker Lamp DT HM2054D HM2053PCD HM2307D HM2026D HM2051D

IP6K7 200G 8 to 28 V DC

1W

LEDDT& BARE WIRE

0.4KgMULTIVOLT

ADR/ECE

COMPLIANT

60

28.5

32

38

White Inspection Point Lamp

Red Marker Lamp (SAE/ECE compliant)

Amber Cabin Marker Lamp

Amber Marker Lamp (SAE/ECE compliant)

Red/Amber Side Marker Lamp (not ECE compliant)

Marker Lamps displayed in OFF and ON modes. Optics on marker ;amps appear clear until illuminated.

HM2051 HM2307

67

SIGN

AL L

AMPS

DAYTIME RUNNING LAMPS

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.

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

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).

LED Daytime Running Lamp

LED Daytime Running Lamp

2 Lamp Kit HM1535DRL

136 49

5342

Kit contains two lamps

IP6K7 IP6K9K 9 to 33 V DC

2W

LEDBARE WIRE

0.72KgMULTIVOLT

ADR COMPLIANT

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

69

ACCE

SSO

RIESAccessories

LED BUGGY WHIPS

IP6K7 200G 12V 1W

LEDDT 0.5KgMULTI

VOLT

ACCE

SSO

RIES

70

LED Buggy Whip

1.2 metre HM46122.0 metre HM46203.0 metre HM4630

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.HM46FX Replacement Reflective Cross Flag

9.HM46MS Medium Spring

9.HM46GL LED Globe

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.

LED Buggy Whip

Snap On/Off Quick Release

9.HM46FX

9.HM46MP

9.HM46MS

71

ACCE

SSO

RIES

TERMINALS & SWITCHES

Battery Master Lockout Switch

HM7592B

Technical information:

Removes risk of terminal crossing

High Impact ABS Plastic

Zinc Coated Terminals

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.

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.


Waterproof and Dustproof to IP67

Tested to 200G shock for 10 000 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.

Remote Jump Start Terminals

Battery Master Lockout Switch

Remote Jump Start Terminals

HM7546J

78

63 6345

69.1

60.3

135.6

10

11.4

SCREENED CABLES

ACCE

SSO

RIES

72

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

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 3199.

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 build-up 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.

Screened Extension Cables

10A Socket

15A Socket

Braid is earthed when cord is in use

Screened Extension Cables with 10A Plug/Socket

10m HMEC1010AU

15m HMEC1510AU

20m HMEC2010AU

25m HMEC2510AUScreened Extension Cables with 15A Plug/Socket

20m HMEC2015AU

30m HMEC3015AU

40m HMEC4015AU

SCREENED CABLES

73

ACCE

SSO

RIES

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

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 build-up within the product.

Hella Heavy Duty Screened Extension Cables are approved to Australian and New Zealand standards AS/NZS 3191/3120/3112 and 3199.

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.

Heavy Duty Screened Extension Cables

10A Socket

15A Socket

Braid is earthed when cord is in use

Screened Extension Cables with 10A Plug/Socket

20m HMIC2010AUScreened Extension Cables with 15A Plug/Socket

20m HMIC2015AUScreened Extension Cables with 20A Plug/Socket

30m HMIC3020AU

20A Socket

IP66

MINING SIGNAL LAMPS

74

ACCE

SSO

RIES

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.

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.

Product features

Improves safety & visibility

Low maintenance

Low energy consumption

Long service life

Expandable fleet numbers

Easy to assemble

Excellent performance in hot, cold and wet environments

Fully sealed against dust and moisture to IP6K7

Durable PMMA lens

Robust ABS and PC housing

Spare Parts

9.HMTN001 NumiLED® 8-Way Distribution Board

9.HMTN002 NumiLED® Connection Cable - Single, 2m

9.HMTN003 NumiLED® Connection Cable - Triple, 2m

9.HMTN004 NumiLED® Vibration Mounting Kit

HM4960SA DT Connector Kit - Male (pack of 10)

IP6K7 200G 24V DC 60W MAX

LEDDT 5.0KgMULTI

VOLT

NumiLED®

Number Boards

NumiLED® Kits – Small (396mm)Set of 10 small LED modules, 24V DC HMTNM6605Single number housing, stainless steel HMTNM6606Single number housing, black HMTNM6607Triple number housing, stainless steel HMTNM6608Triple number housing, black HMTNM6609

NumiLED® Kits – Large (720mm)Set of 10 large LED modules, 24V DC HMTND2156Housing, stainless steel HMTND2157Housing, black HMTND2158

247

396

Small Board Single

720

396

Small Board Triple

400

720

Large Board Single

MINING SIGNAL LAMPS

75

ACCE

SSO

RIESNumiLED® Pro

Number Boards

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.

NumiLED® PRO number boards are even more versatile featuring the advanced programmable power board with internal memory function.

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

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)

IP6K7 200G 24V DC 60W MAX

LEDDT 5.0KgMULTI

VOLT

NumiLED® Pro Boards – Small (396mm)Single number board, stainless steel HMTNM6612Single number board, black HMTNM6613Triple number board, stainless steel HMTNM6610Triple number board, black HMTNM6611

NumiLED® Pro Boards – Large (720mm)Board, stainless steel HMTND2159Board, black HMTND2160

247

396

Small Board Single

720

396

Small Board Triple

Large Board Single

Distribution Board (Rear View)

Vibration Damping (Detail)

Programming dongle

400

720

MINING REVERSING CAMERA KIT

ACCE

SSO

RIES

76

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

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, F2.0

110° diagonal lens angle

Ingress protected to IP68


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

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.

Colour 5.6 inch Monitor, Infra-red Camera, 20m Cable, 12-24V

HM5700KITColour 7.0 inch Monitor, Infra-red Camera, 20m Cable, 12-24V

HM5701KIT

Infra-red Dual Camera System

9.HM5700 5.6" Monitor

9.HM5701 7.0" Monitor

9.HM5703 Connection Cable

MINING REVERSING CAMERA KIT

77

ACCE

SSO

RIES

Technical Specifications – Quad Monitor:

LCD Display 16:9 7”

Multivolt™ system 12V DC or 24V DC supply


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)

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 custom-made 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 Input Infra-red Camera System

Spare Parts:

9.HM5702 Infra-red Reverse Camera

9.HM5703 Connection cable, 20m

9.HM5801 Colour Multiscreen Monitor 17.8cm (7.0”)

9.HM5802 Steel Camera Guard

Quad Screen IR Camera Kit Monitor, Infra-red Camera, 20m Cable, 12-24V

HM5800KIT

9.HM5703 Connection Cable

9.HM5801 7" Monitor

9.HM5802 Steel Camera Guard

MASTER SWITCH

ACCE

SSO

RIES

78


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)

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 2809.2 and European ADR 2005.

In addition to the rollover sensor, optional equipment includes lock-out guards, switches and cable harnesses to facilitate easy installation of the AccuPAX unit.

Battery Master Switch 12V

HM4660ABattery Master Switch 24V

HM4660B

AccuPAX® Battery Master Switch

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 1-0967325-kit)

HM4660SWF Push Button Switch, 2 pin (use connector 1-0967325-kit)

HM4660LOC Lockable Cover, Stainless Steel

HM4660KTB 7 Pin DIN Connector with 5M Harness

HM4660KTC 7 Pin DIN Connector with 700mm Harness

HM4660A

118

127

168

104

130

HM4660A

118

127

168

104

130

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

MASTER SWITCH

79

ACCE

SSO

RIES

HM4660SWA Latching Push On / Twist Off Switch - Double Pole, IP65

HM4660LOC Lockable Stainless Steel Cover

HM4660SWD Momentary Push Button Switch - Single Pole with Guard, IP65

HM4660ROD iROS Roll-over Protection Device

WEATHERPROOF KIT, LOOM TAPE

ACCE

SSO

RIES

80

Self-Amalgamating Tape

12V Weatherproof Changeover Relay and Connector Assembly Kit

12V Kit

HMWPR001

Self-Amalgamating Tape

HMAT85

56.5mm

35mm

8787a

30

86 85

86 85 87 87a30

12V ISO mini relay and connector assembly kit: 1 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 3.00mm2 2 x Small barrel pull to seat terminal 6.3mm width suits cable size 1.00 - 2.00mm2

Voltage 10 -16V DC

Operating Range Temp -40°C to +125°C

Contact current rating NO 35A / NC 20A

Coil Resistance @ 23°C 70-90 Ohms

Transient Suppressor Resistor 680 Ohms

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 0.5mm, tensile strength at break 12 N/cm

Breakdown Voltage 34 kV/mm

Elongation 600%

Service Temperature -35˚C to +130˚C

CONNECTORS

81

ACCE

SSO

RIESDT Connectors

HM8275 DT Connector Crimping Tool

DT Connectors

Environmentally sealed connectors rated -55°C to +125°C. Supplied complete with removable, solid copper crimp contacts (1.0 – 2.0mm2) and secondary locks. All contacts rated 13A.

Qty. in pack

2 Pole DT Connector Set 1 HM4960

2 Pole DT Connector Half-Set* 10 HM4960FM








Spare Parts

Small I.D. plug contact to suit cable 0.5 – 1.0mm2 9.HM4960.01

Small I.D. socket contact to suit cable 0.5 – 1.0mm2 9.HM4960.02

Large I.D. plug contact to suit cable 1.0 – 2.0mm2 9.HM4960.03

Large I.D. socket contact to suit cable 1.0 – 2.0mm2 9.HM4960.04

Sealing plug 9.HM4960.05

* Half-Set = female socket with male contacts.

DT Connector Crimping Tool

Specially dsigned crimping tool with multiple jaws for even crimp of DT Terminals

HM8275

HM4960

HM4961

HM4962

HM4963

HM4964

HM4965

Interior Lighting

84 EuroLED Touch M

85 CargoLED

86 SpotLED

88 FlexSPOT

89 MiniThinLED

83

INTE

RIO

R LI

GHTI

NG

Interior Lighting

MINING INtERIOR LAMPS

84

INTE

RIO

R LI

GHTI

NG

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


Ultra low power consumption

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

IP6K7 200G 9 to 33 V DC

5W

LEDDT & BARE WIRE

0.3KgMULTIVOLT

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).

EuroLED® Touch MInterior Lamp – Multivolt™ 9-33V DC

130

130110

30

30

13

Cable Exit

Red On

White On

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.

Spare Parts

8HG959952022 EuroLED® Mounting Spacer

Mounting Spacer – designed to suit all EuroLED® interior lamps. Enables easy surface mount with side cable exit

EuroLED® Touch M Interior Lamp

with 2.5m cable HM959950211with 0.5m cable and DT plug HM959950221

85

INTE

RIO

R LI

GHTI

NG

MINING INTERIOR LAMPS

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.

CargoLED®

Heavy Duty Interior Lamp Multivolt™ 9-31V DC

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 over-voltage 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.

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


-40ºC – +60ºC


ADR 2006 (hazardous goods transport) compliant

IP6K9 200G 9 to 31 V DC

6W

LEDDT 0.5KgMULTI

VOLT

CargoLED®

Heavy Duty Interior Lamp HM227HD

Shown lit

86

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G


86

INTE

RIO

R LI

GHTI

NG

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.

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.

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


Power consumption: 3W

Fully sealed to IP6K9K (optical unit) to withstand temporary immersion and high pressure washing


-40ºC – +60ºC


ADR 2006 (hazardous goods transport) compliant

IP6K7 200G 9 to 31 V DC

3W

LEDDT 0.3KgMULTI

VOLT

SpotLED®

Fixed & Adjustable Interior Lamps Multivolt™ 9-31V DC

Adjustable Model (20°), shown with white LED illuminated, and white cover

Fixed Model, shown with Red Ambient Ring illuminated, and white cover

SpotLED®

Screw Mount, DTl White Cover l White Cover

l Red Ambient Ringl Yellow Cover l Yellow Cover

l Red Ambient Ringl Black Cover l Black Cover

l Red Ambient Ring

Fixed HM680FNW HM680FRW HM680FNY HM680FRY HM680FNB HM680FRBAdjustable HM680ANW HM680ARW HM680ANY HM680ARY HM680ANB HM680ARB

Spare Parts

9.HMDLM002 Marker Housing Yellow (Pack of 4)

Fixed Model

Adjustable Model

Optional Yellow Cover

Optional Black Cover

Optional White Cover

Adjustable model shown

87

INTE

RIO

R LI

GHTI

NG


88

INTE

RIO

R LI

GHTI

NG

FlexSPOT® LED Interior Lamp l White Shroud l Yellow Shroud

150mm flexible arm HM720150W HM720150Y400mm flexible arm HM720400W HM720400Y

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.

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.

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


Power consumption: 2.5W

Sealed to IP53 protects active electronics and optics against splashed liquid


-40ºC to +60ºC


EC, ROHS and ADR 2006 (hazardous goods transport) compliant

IP53 200G 9 to 31 V DC

2W

LEDBARE WIRE

0.4KgMULTIVOLT

FlexSPOT®

LED Interior Lamp Multivolt™ 9-31V DC

MO

BILE

EQ

UIPM

ENT

LIGH

TIN

G


89

INTE

RIO

R LI

GHTI

NG

MiniThinLED® Interior Lamp l Red l White l Blue l Green

24V DC HM6605RD-24V HM6605WD-24V HM6603BD-24V HM6603GD-24V12V DC HM6605RD-12V HM6605WD-12V HM6603BD-12V HM6603GD-12V

MiniThinLED®

Interior Lamp

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.

MiniThinLED® lamps are robust low profile multi-use LED lamps ideal for general

applications such as insteps, ambient and storage lights.

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)

IP69 200G 12/24 V DC

3W

LEDBARE WIRE

0.1Kg

5 LED Red

5 LED White

3 LED Blue

3 LED Green

Alarms & Horns

92 MotoVOX

93 RetroVOX Self Adjusting

94 RetroVOX Compression Driver

95 RetroVOX Broadband

91

ALAR

MS

& H

ORN

S

Alarms & Horns

REVERSING ALARMS

ALAR

MS

& H

ORN

S 92 MotoVOX® Compact 117dB Horn

MotoVOX® Forward 117dB Horn

MotoVOX® Compact 107dB Horn

MotoVOX® 117dB Compact Horn

HMFH312P

MotoVOX® FH117 117dB Horn

HMFH117P

MotoVOX® FH107 107dB Horn

HMFH107P

+�

- 77

95128

127mm

183.1mm

78mm

81mm

118mm

92mm81mm

127mm

183.1mm

78mm

81mm

118mm

92mm81mm

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 117 @ 1.2m

Approval SAE J1105 Sept 89, Type K. U.L. recognised for electric vehicles and fork lifts.

Electronic forward horn is designed to be used where a high-decibel rugged horn is necessary.

Voltage 12-24V DC

Decibel 117 @ 1.2m

Approval SAE J1105 Sept 89, Type J @ 24V systems SAE J1105 Sept 89, Type K @ 12V systems

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 107 @ 1.2m

Approval SAE J1105 Sept 89, Type L

REVERSING ALARMS

93

ALAR

MS

& H

ORN

S

RA917 Self Adjusting 112dB Alarm

HMRA917E

RetroVOX® Self Adjusting Reversing Alarm

RetroVOX® Ultra Heavy Duty Reversing Alarm

RA112 Ultra Heavy Duty 112dB Alarm

HMRA112P

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.

Voltage 12- 24V DC

Decibel 87 - 112 @ 1.2m

Approval SAE J994 Type D

163

102

1804.4 78

3.08

1024.0

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, 112 @ 1.2m

Approval SAE J994 Types A, B & C

REVERSING ALARMS

ALAR

MS

& H

ORN

S 94 RetroVOX® Compression Driver Reversing Alarm (Manual)

RetroVOX® Compression Driver Reversing Alarm (Automatic)

RetroVOX® Compression Driver 112dB Alarm (Manual)

HMRA603P

RetroVOX® Compression Driver 112dB Alarm (Automatic)

HMRA611P

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.

Voltage 12-24V DC (reverse polarity protected)

Decibel 117dB @ 1.2m, 97/107/112dB @1.2m, manual adjustment

Approval SAE J994 class A/B/C

101152

178

81

HMRA603P

101152

178

81

HMRA603P

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.


Decibel 87-112dB @1.2m, automatic adjustment to SAE J994 requirement

Approval SAE J994 classes A-D

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.


Decibel 87-112dB @1.2m

Approval SAE J994 class A-D EC, E11

95

152

173

155

80

RetroVOX Broadband 112dB Alarm (Manual)

HMRA107B

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

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

55

76

4591

Voltage 12-24V DC

Current Max. 0.5 Amps

Decibel 87 @ 1m

Approval SAE J994 Class E 11 CE & EMC Approved

ALARMS

95

ALAR

MS

& H

ORN

S

RetroVOX® Compact Broadband 87dB Alarm

RetroVOX® Broadband 87-112dB Reversing Alarm

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

97

SERV

ICE

TOO

LSService Tools

CONNECTOR KITS

SERV

ICE

TOO

LS 98

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-by-step 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.

EziPAK® DT Connector Kit

HM8277

HM8275

HM8285

HM8283

EziPAK® DT Connector Kit (389 Pieces)(See list of included components next page)

EziPAK® DT Connector Kit (incl. Crimping Tool HM8276) HM8283

Accessories

Universal DT Contact Crimping Tool HM8275

DT Contact Crimping Tool 0.5 - 1.0mm HM8277

EziPAK® Double Drawer Storage Module (empty) HM8285

EziPAK® Single Divisional Carry Case (empty) HM8286

CONNECTOR KITS

99

SERV

ICE

TOO

LS

HM8276

9.HM4950 9.HM4951

9.HM4940 9.HM4941

9.HM4942 9.HM4943

9.HM4944 9.HM4945

9.HM4946 9.HM4947

9.HM4948 9.HM4949

9.HM4952 9.HM49539.HM4954 9.HM4955 9.HM4956

9.HM4957 9.HM4958 9.HM4959

DT Connectors (included in EziPAK® DT Connector Kit)

Qty in pack

2-Way Male DT Connector (incl. wedge) 15 9.HM4940

2-Way Female DT Connector (incl. wedge) 15 9.HM4941











3-Way Round Male HDT Connector 5 9.HM4952

3-Way Round Female HDT Connector 5 9.HM4953

Male DT Connector Pin 100 9.HM4954

Female DT Connector Socket 100 9.HM4955

Connector Sealing Plug 50 9.HM4956

Service Tools (included in EziPAK® DT Connector Kit)

DT Contact Crimping Tool 1.0 - 2.0mm 1 HM8276

DT Contact Removal Tool 1.0 - 2.0mm 3 9.HM4957

DT Contact Removal Tool 0.5 - 1.0mm 3 9.HM4958

DT Connector Wedge Removal Tool 1 9.HM4959

CONNECTOR KITS

SERV

ICE

TOO

LS 100


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.

EziPAK® Double Crimp Connector Kit

HM8285

HM8284

EziPAK® Double Crimp Connector Kit (3,652 Pieces)(See list of included components next page)

EziPAK® Double Crimp Connector Kit HM8284

AccessoriesEziPAK® Double Drawer Storage Module (empty) HM8285


CONNECTOR KITS

101

SERV

ICE

TOO

LS

Double Crimp Connectors (included in EziPAK® Double Crimp Connector Kit)

Qty in pack

Push-On Female Terminal - Red, 6.3mm 200 9.HM8500

Push-On Female Terminal - Blue, 6.3mm 200 9.HM8501

Push-On Female Terminal - Yellow, 6.3mm 150 9.HM8502

Push-On Female Terminal - Yellow, 9.5mm 100 9.HM8503

Fully Insulated Female Blade Terminal - Red, 6.3mm 200 9.HM8504

Fully Insulated Female Blade Terminal - Blue, 6.3mm 200 9.HM8505

Push-On 2-Way Male/Female Terminal - Blue, 6.3mm 200 9.HM8511

Male Blade Terminal - Red, 6.3mm 200 9.HM8513

Male Blade Terminal - Blue, 6.3mm 200 9.HM8514

Single Male Bullet Connector - Red 200 9.HM8520

Single Male Bullet Connector - Blue 200 9.HM8521

Single Female Bullet Connector - Red 200 9.HM8522

Single Female Bullet Connector - Blue 200 9.HM8523

Cable Connector - Red 200 9.HM8530

Cable Connector - Blue 200 9.HM8531

Cable Connector - Yellow 100 9.HM8532

Eye Terminal - Red, 5.0mm 200 9.HM8541

Eye Terminal - Blue, 5.0mm 2009.HM8543

Eye Terminal - Yellow, 9.5mm 200 9.HM8548

Eye Terminal - Yellow, 5.0mm 100 9.HM8549

Crimping Tool (included in EziPAK® Double Crimp Connector Kit)

Ratchet Crimping Tool 1 8273

8273

9.HM8504 9.HM8505

9.HM8511 9.HM8513

9.HM8521 9.HM8522

9.HM8523 9.HM8530

9.HM85329.HM8531

9.HM8548 9.HM8549

9.HM8541 9.HM8543

9.HM85209.HM8514

9.HM8500 9.HM8501

9.HM8502 9.HM8503

REPAIR KITS

SERV

ICE

TOO

LS 102


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 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-to-cable 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.


HM8285

HM8287

EziPAK® Heat Shrink Harness Repair Kit (270Pieces)(See list of included components next page)

EziPAK® Heat Shrink Harness Repair Kit HM8287



EziPAK® Heat Shrink Harness Repair Kit

REPAIR KITS

103

SERV

ICE

TOO

LS

Heat Shrink Sleeving (included in EziPAK® Heat Shrink Harness Repair Kit)

Qty in pack

Adhesive Lined Heat Shrink Sleeving 3.2mm 35 9.HM4960






Solder Sleeve – Clear, 1.7mm 25 9.HM4966

Solder Sleeve – Red, 2.7mm 25 9.HM4967

Solder Sleeve – Blue, 4.5mm 25 9.HM4968

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)

Battery powered soldering iron 1 HM8288

Flameless gas heat gun 1 HM8289

Lead Free Solder in Cartridge 1 9.HM4971

Insulation Tape – Black, 19mm x 20m Lead Free 10 9.HM4972

HM8289

9.HM4971 9.HM4972

HM8288

9.HM4970

9.HM4969

9.HM4968

9.HM4967

9.HM4966

9.HM4965

9.HM4964

9.HM4963

9.HM4962

9.HM4961

9.HM4960

FUSE KITS

SERV

ICE

TOO

LS 104


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 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.


HM8285

HM8290

EziPAK® Intelligent Fuse Kit (556 Pieces)(See list of included components next page)

EziPAK® Intelligent Fuse Kit HM8290



EziPAK® Intelligent Fuse Kit

LED glows if fuse blows, for instant identification

FUSE KITS

105

SERV

ICE

TOO

LS

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.HM4993

9.HM4993

9.HM4977 9.HM4978

9.HM4979 9.HM4980

9.HM4983 9.HM4984

9.HM4985 9.HM4986

9.HM49889.HM4987

9.HM4991 9.HM4992

9.HM4989 9.HM4990

9.HM49829.HM4981

9.HM4973 9.HM4974

9.HM4975 9.HM4976

CONNECTORS

SERV

ICE

TOO

LS 106 Super Seal Connectors

Super Seal Connector Kit

5 of each Super Seal connector plug and socket 100 x Plug terminals, Part No. 9.HM4980.02 100 x Socket terminals, Part No. 9.HM4980.04 100 x Yellow con ductor seals, Part No. 9.HM4980.06 100 x Red cavity plugs, Part No. 9.HM4980.09

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 HM4980.01/02/04/05/06/07/09.

Qty. in pack

1 Pole Super Seal Plug 4 HM4981-P

1 Pole Super Seal Socket 4 HM4981-S











Spare Parts Qty. in pack

Plug terminals to suit cable 0.35 – 0.50mm2 50 9.HM4980.01

Plug terminals to suit cable 0.75 – 1.50mm2 50 9.HM4980.02

Socket terminals to suit cable 0.35 – 0.50mm2 50 9.HM4980.03

Socket terminals to suit cable 0.75 – 1.50mm2 50 9.HM4980.04

Green seal to suit cable insulation 1.4 – 1.7mm dia. 50 9.HM4980.05

Yellow seal to suit cable insulation 1.8 – 2.4mm dia. 50 9.HM4980.06

Red seal to suit cable insulation 2.5 – 3.3mm dia. 50 9.HM4980.07

Red cavity plug 50 9.HM4980.09

Super Seal Connector Crimping Tool

Crimping tool designed for use with Super Seal connector terminals.

HM8298

HM4981-P HM4982-P HM4983-P

HM4981-S HM4982-S HM4983-S

HM4984-P HM4985-P HM4986-P

HM4984-S HM4985-S HM4986-S

9.HM4980.05 9.HM4980.06 9.HM4980.07

HM8298 Super Seal Connector Crimping Tool

Socket TerminalPlug Terminal

HM4980 Super Seal Connector Kit

POWER PACK

107

SERV

ICE

TOO

LS

Compatible with DuraLed® Work Lamp, Magnetic Base,Part No. HM1550MAG12Part No. HM1550CIG

12V DC

15A Max Mag

Code CIG DIN

PowerPAKPortable Power Pack

Spare Parts:

9.HM8600B Replacement battery

9.HM8600C Charging cable to suit vehicle

9.HM4985 15A LED Blade Fuses (30 Pack)

PowerPAK Portable Emergency Unit

HM8600

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

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.

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

109

ELEC

TRIC

ALElectrical

ELECTRONIC TRANSFORMERS

ELEC

TRIC

AL

110 AC/DC Electronic Transformers

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

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.

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

Technical Specifications

240V AC – 12V DC

20VA HM1220AC60VA HM1260AC240V AC – 24V DC

20VA HM2420AC60VA HM2460AC

IP67 200G

POWER CONNECTORS

111

ELEC

TRIC

AL

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).

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 HM50AND



Connector Kit, 75A 6AWG, black HMPS75S

Connector Kit, 75A 6AWG, green HMPS75G

Connector Kit, 75A 6AWG, red HMPS75R

Connector Kit, 75A 6AWG, blue HMPS75B

Power Connectors

LED ROCKER SWITCHES

ELEC

TRIC

AL

112 Compact LED Rocker Switches

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 Mounting opening 20mm dia.

Panels Suitable for panels up to 2.5mm thick.

Protection Weatherproof (from front)

Voltage 12 or 24V DC LED included (non-replaceable).

Maximum Load 10A at 12V DC 5A at 24V DC

25 11.58.3

14

20

25 11.58.3

14

20

Amber

Red

Blue

Green

LED Rocker Switches 24V DC

Amber Illuminated HM4400ARed Illuminated HM4400RBlue Illuminated HM4400BGreen Illuminated HM4400GLED Rocker Switches 12V DC

Amber Illuminated HM4400A-12VRed Illuminated HM4400R-12VBlue Illuminated HM4400B-12VGreen Illuminated HM4400G-12V

12/24VDC

LED PILOT LAMPS

113

ELEC

TRIC

AL

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 Lamps

Mounting Mounting opening 22mm dia.

For Panels Up to 38mm thick

Protection IP65

Voltage 12V / 24V AC/DC Other voltages available upon request

2716

51.5 30

13 42.6

Red

Green

Amber

White

Blue

LED Pilot Lamp, 12V AC/DC

Red, Super Bright 2716

Green 2717

Amber, Super Bright 2718

White 2719

Blue, Super Bright 2720

LED Pilot Lamp, 24V AC/DC

Red, Super Bright 2716-24V

Green 2717-24V

Amber, Super Bright 2718-24V

White 2719-24V

Blue, Super Bright 2720-24V

LED Pilot Lamp, 24V

Green, Super Bright HM2717-24V

White, Super Bright HM2719-24V

CIRCUIT BREAKERS

ELEC

TRIC

AL

114

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.

Heavy Duty Circuit Breakers

Panel Mount Circuit Breakers

Thermal Overcurrent Circuit Breakers

Automotive circuit breaker, plug in mounting, manual release with locking tangs for vibration resistance.

Voltage Rating 12 - 28V DC

Current Ratings 3–25A. (30A upon request)

Typical Life / Contact Rating

6,000 operations at 1 x IN 3,000 operations at 2 x IN ≤ 20A 1,000 operations at 2 x IN ≤ 25A

Interrupting Capacity Icn

3...15A 200A 20...25A 400A

Note Replaces standard blade fuses

Threadneck panel mounting, with optional push/push switch actuation.

Voltage Rating 250V AC / 12-28V DC

Current Ratings 0.05...25A

Typical Life/Contact Rating 5,000 operations at 2 x IN

Interrupting Capacity Icn 0.05...2.5A 8 x IN 3...5A 20 x IN 6...12A 200 x A 13...25A 400 x A

Approvals VDE, CSA, UL, Semko, SEV, LRoS, BV

Automotive circuit breaker, standard fuseblock mounting with manual release option (-H2)

Voltage Rating 12 - 28V DC

Current Ratings 6–25A. (30A upon request)

Typical Life / Contact Rating 300 operations at ≤ 50A

Interrupting Capacity Icn ≥ 3 operations @ ≤ 150A ≥ 1 operation @ ≤ 2000A

Note Replaces standard blade fuses

1606.4

18.9

160 6

24 .945

29

46.522.510.4

Thermal Overcurrent Circuit Breakers

6A - Max. 28V DC 87308A - Max. 28V DC 873110A - Max. 28V DC 873215A - Max. 28V DC 873320A - Max. 28V DC 873425A - Max. 28V DC 8735

Heavy Duty Circuit Breakers

3A - Max. 28V DC 87366A - Max. 28V DC 873710A - Max. 28V DC 873815A - Max. 28V DC 873920A - Max. 28V DC 874025A - Max. 28V DC 8741

Panel Mount Circuit Breakers

10A - Max. 28V DC 874220A - Max. 28V DC 874325A - Max. 28V DC 874430A - Max. 28V DC 874535A - Max. 28V DC 8746

CIRCUIT BREAKERS

115

ELEC

TRIC

AL

Single pole, miniaturised, aircraft-style 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

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.

Thermal Circuit Breakers

Voltage Rating 115V AC / 12-28 V DC

Typical Life 20,000 operations mechanical or, 10,000 operations at IN (≤ 25A) 5,000 operations at IN (30 + 35A)

Ambient Temperature -55°C to +125°C (-67°C to +257°F)

Insulation co-ordination (IEC 60664 & 60664A)

Rated impulse withstand voltage 1.5kV

Pollution degree 3

Dielectric Strength (IEC 60664 & 60664A)

Test Voltage Operating area AC 1,500V Main to aux. circuit AC 1,500V

Interrupting Capacity Icn

AC 115V (400 Hz) ≤4A 1,000A 5A 2,000A 7.5 to 35A 2,500A

DC 28V 1 to 25A 6,000A 30 + 35A 4,000A

Vibration 15g (70 - 2000Hz) - Sinus 16.4 grams - Random

Acceleration 17g

Shock 75g

Explosion to VG 95210, sheet 10/MIL - STD-202, meth. 109

.486

.34312.35

8.7

.55013.97

.2526.4

.0260.65

31 1.22

M12x1

8.4

.331

12.8.504

8.5.335

16.2

.638

min 4.6

min.18

1

10

.394

3.2 +3

+.006

+5

.123

12.5

+0.2

+.00

8.4

92

9.5+

0.2

+.00

8.3

74

.429

.3398.6

10.9

.0410.8

.42914.8

.3037.7

18.9

31 1.22

M12x1

8.4

.331

12.8.504

8.5.335

16.2

.638

min 4.6

min.18

1

10

.394

3.2 +3

+.006

+5

.123

12.5

+0.2

+.00

8.4

92

9.5+

0.2

+.00

8.3

74

31 1.22

M12x1

8.4

.331

12.8.504

8.5.335

16.2

.638

min 4.6

min.18

1

10

.394

3.2 +3

+.006

+5

.123

12.5

+0.2

+.00

8.4

92

9.5+

0.2

+.00

8.3

74

Thermal Circuit Breakers

3A - Max. 28V DC HMET483.035A - Max. 28V DC HMET483.057.5A - Max. 28V DC HMET483.0710A - Max. 28V DC HMET483.1015A - Max. 28V DC HMET483.1520A - Max. 28V DC HMET483.2025A - Max. 28V DC HMET483.2530A - Max. 28V DC HMET483.3035A - Max. 28V DC HMET483.35

Spare Parts:

HMET307.01 ID collar Black

HMET307.02 ID collar White

HMET307.03 ID collar Red

HMET307.04 ID collar Green

HMET307.05 ID collar Blue

HMET307.51 Safety lock-out collar Red

HMET200.08 IP66 safety cover Clear

HMET307.01

HMET307.01

HMET307.01

HMET307.01

HMET307.01

HMET307.01

HMET307.01

HMET307.01

POWER OUTLET SYSTEMS

ELEC

TRIC

AL

116

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

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.

MagCode Power System

Power System 12V HMPS12VKITPower Port 12V HMPS12VPTPower Clip 12V HMPS12VCPPower System 24V HMPS24VKITPower Port 24V HMPS24VPTPower Clip 24V HMPS24VCP

MagCode Power System Plus

Power System 12V HMPS12VPROKITPower Port 12V HMPS12PROVPTPower Clip 12V HMPS12PROVCPPower System 24V HMPS24PROVKITPower Port 24V HMPS24PROVPTPower Clip 24V HMPS24PROVCP

MagCode Power Port Cap HMPSPCAP

MagCodePower Outlet Systems

Power Port

Power Clip

Specifications: MagCode Power System MagCode Power System PlusLocking 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 2.5mm2 2.5mm2

Mounting Opening 28mm dia. (M28) 28mm dia. (M28)

Rated Voltage 12V / 24V DC 12V / 24V DCMax. 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/s2 5Hz - 200Hz, 8.5m/s2

Shock Resistance 3 axes, 3,000 shocks, 3 axes, 3,000 shocks, 11ms, 30g 11ms, 30gProtection 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 42Duty Cycles Without load > 10,000 cycles > 10,000 cycles At 25A 4,000 cycles 4,000 cycles

HMPSPCAP. Stylish protective cover to suit all MagCode Power Ports. Snap shut cap provides reliable protection from the elements.

POWER OUTLET SYSTEMS

117

ELEC

TRIC

AL

MagCode Power System

MagCode Power System Plus

Incoming

current

Pole without

Current

Incoming

current

Pole under

Current

Open System (1)

Closed System (2)

Incoming

current

Pole without

CurrentOpen System (1)

Incoming

current

Pole without

Current

Incoming

current

Pole under

Current

Closed System (2)

Locked System (3)

Colour code: l Permanent magnets l Plate with permanent magnets l Voltageless l Under current

Globes

120 H1

120 H2

121 H3

122 H4

123 H7

123 H9

123 H11

124 Xenon

119

GLO

BESGlobes

HALOGEN GLOBES

GLO

BES

120 H1 Globes

H2 Globes

Part No. Voltage Wattage Base ADR 51/00 Category

UV Cut

H1 PREMIUM XENON HALOGEN - PLUS 50

CX1255BL 12 55 P14.5s H1 •

H1 PREMIUM XENON HALOGEN - COOL BLUE

CB1255BL 12 55 P14.5s H1 •


UV Cut

Rated Life Long Life / Standard

H1 HALOGEN LONG LIFE

C1255LL 12 55 P14.5s H1 • 1250 400

H1 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE

C2470LTS 24 70 P14.5s H1 • 1200 650


UV Cut

H1 HALOGEN HIGH PERFORMANCE

C12100 12 100 P14.5s - •

C24100 24 100 P14.5s - •

HALOGEN

C2470 24 70 P14.5s H1 •

39

10

24

CB1255BLdia

Xenon Cool Blue

Xenon Plus 50


UV Cut


CD12100 12 100 X511 - •

CD24100 24 100 X511 - •

HALOGEN

CD1255 12 55 X511 H2 •

CD2470 24 70 X511 H2 •

9

29

CD12100BLdia

Halogen Premium Long Life Halogen

HALOGEN GLOBES

121

GLO

BES


UV Cut


YCX1255BL 12 55 PK22s H3 •


YCP1255BL 12 55 PK22s H3 •


YCB1255BL 12 55 PK22s H3 •


UV Cut

Rated Life Long Life / Standard


YC1255LL 12 55 PK22s H3 • 1500 450


YC2470LTS 24 70 PK22s H3 • 1200 650


UV Cut


YC12100 12 100 PK22s - •

YC24100 24 100 PK22s - •

HALOGEN

YC2470 24 70 PK22s H3 •

11

30.5

YC12100BLdia

Xenon Plus 30

Long Life Halogen

Halogen

Premium Long Life Halogen

H3 Globes

H4 Halogen Globes

HALOGEN GLOBES

GLO

BES

122


UV Cut

Rated Life Tc Long Life / Standard


XD1260/55LL 12 60/55 P43t H4 • 1500 700

XD2475/70LL 24 75/70 P43t H4 • 1500 700


XD2475/70LTS 24 75/70 P43t H4 • 1400 700


UV Cut


XD12100/55 12 100/55 P43t - •

XD12100/90 12 100/90 P43t - •

XD24100/90 24 100/90 P43t - •

H4 HALOGEN

XD1260/55 12 60/55 P43t H4 •

XD2475/70 24 75/70 P43t H4 •


UV Cut


XDX1260/55BL 12 60/55 P43t H4 •


XDB1260/55BL 12 60/55 P43t H4 •

14

78.5

44

XD1260/55dia

14

78.5

44

XD1260/55dia

Xenon Cool Blue

Xenon Plus 50

H4 Premium Xenon Globes

HALOGEN GLOBES

123

GLO

BES


UV Cut

Rated Life TcLong Life / Standard


CA1255LL 12 55 PX26d H7 • 930 550


CA2470LTS 24 70 Px26d H7 • 1000 500

11

42

15

CA1255dia


UV Cut

H9 HALOGEN

CF1265 12 65 PGJ 19-5 H9 •

11

40

46

CG1255


UV Cut

H11 HALOGEN

CG1255 12 55 PGJ 19-2 H11 •

CG2470 24 70 PGJ 19-2 H11 •

11

40

46

CF1265


UV Cut

H7 HALOGEN

CA1255X 12 55 PX26d H7 •

CA2470 24 70 PX26d H7 •

H7 Globes

H9 Globes

H11 Globes

XENON GAS DISCHARGE

GLO

BES

124 Xenon Gas Discharge Lamps

Xenon Gas Discharge Flash Tube

Part No. Type Voltage Wattage Base ADR 51/00 Category

UV Cut

HMXN4001 D1S 85 35 PK32d-2 D1S •

XN4000 D2S 85 35 P32d-2 D2S •

HMXN4YEL D2S 85 35 P32d-2 D2S •

Description Xenon Gas Discharge globes for driving and work lamps.

Comparison D1S/D2S

Rated Wattage 35W

Luminous Flux 3200lm

Luminous Efficacy 91Im/W

Colour Temperature 4250°K

Average Luminance 6500*cd/cm2

Lamp Life B3 1500h Tc 3000h

Filament/arc length 4.2mm

Note 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.

25

9

75

XN4000dia XN4000D2S/R/C

HMXN4YELD2S

43

9

82

HMXN4001D1S


UV Cut

Xenon gas discharge globes suitable for emergency flasher, revolving and/or strobe lamps

XN6750 12-24 - Circuit Board Plug-In - -

43mm

49mm

15mmNote: Use this lamp for PulseRAY Xenon strobe warning beacons.

HMXN4YELYellow D2S Xenon Globe

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.

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

127

TECH

NIC

ALTechnical

TECH

NIC

AL

128 General Information

Luminous EfficacyUnit 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

1

0.1

10

100

1000683 lm/W = Theoretical limit for monochrome green light (555nm)

199lm/W = Theoretical limit for "white" light (380–780nm)Low Pressure Sodium LampsHigh Pressure Sodium LampsFluorescent, Metal Halide, Yellow Compact, Xenarc Lamps

Tungsten-Halogen Lamps

High Pressure Mercury Vapour Lamps

Special Light Bulbs Xenon Lamps,Mercury Tungsten Blended Lamps

General Lighting Service Lamps

lm/W

Carbon Thread Incandescent Lamps

Glow Lamps, Electroluminiscent Plate

Paraffin Lamp

Candle

High Intensity white LED

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.

50000 1000

visible light

Tungsten filament windingtemperatures Tfor 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)

w

wave length unit of measure nm

2000 3000 4000

1

2

3

4IR radiation

UV

- rad

iatio

n

Tw 2800˚C

Tw 2600˚C

Tw 2400˚C

ref

L eλ

Colour RenderingDepending 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.

Luminous efficacies of various light sources

The main properties of an incandescent lamp, namely its luminous efficacy and life, are influenced largely by the filament temperature.

Relative Spectral Power Distribution Of Incandescent Lamps

Operating principle of an Incandescent LampThe 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.

Tungsten-Halogen LampsTungsten-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.

Lamp life

Light output

Lamp life

65% = 40 000% life

75% = 10 000% life

75% = 3600% life

85% = 1000% life

90% = 600% life

95% = 190% life

80% = 1700% life

200

250

150

100

50

070 80 90 100 110 120 130 %

Light output

Lamp power

Lamp power

%

Halogen CycleA 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.

Tungsten Halogenide

Halogen cycle

Halogen CycleAs 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.

Tungsten Halogenide

Halogen cycle

Tungsten Halogenide

Halogen cycle

129

TECH

NIC

AL

TECH

NIC

AL

130 High Intensity Discharge (HID) Lamp Operation

Metal Halide (MH)LampsMetal 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 4.0–5.0kV peak for a cold start with the lamps requiring a cooling period of between 10–15 minutes before they will re-ignite. Certain lamps are capable of hot re-ignition, 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) LampsHigh 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.

What is Xenon lighting technology? 131

TECH

NIC

AL

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 (day-light) 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.

TECH

NIC

AL

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

Colour 840 LUMILUX®

Cool White

Metal Halide (MH) Lamps

HQI®.../N Daylight HQI®-TS.../WDL Warm White

Xenon spectral power distribution V(λ) Human vision photopic sensitivity (day light adapted) V’(λ) Human vision scotopic sensitivity (night adapted)

Rel

ativ

e em

issi

on a

nd s

ensi

tivity

wave length unit of measure nm

The spectrum of light produced by Xenon lamps is optimised tomaximize visual performance of people with dark adapted vision

300,0 400,0 500,0 600,0 700,0 800,0

Xenon Gas Discharge (XGD) LampsHigh Pressure Sodium (HPS) Lamps

VIALOX®

133

TECH

NIC

AL

Special features of Hella HID ballasts:• very short magnetic paths• transverse laminations with no stray field

junctions• short heat paths• winding insulation Class H materials• 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

100% final testing• continuity• winding short circuit• core to coil high voltage

test• operating values

Maintenance-Free Long Service Life BallastsThe 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.

Ignitors and Ballasts

HID Ignitors and BallastsThe 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 60926 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.

Ignitor Temperature RiseBecause 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.

L

Ballast HV

N

C

B La

IGN

N

Precise lamp management through digital technologyThe 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.

TECH

NIC

AL

134 Ignitors and Ballasts

Capacitor QualityAssured 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 61049 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.

Power factor in Fluorescent and HID CircuitsFor 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.

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.

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.

BallastLampL

C

S

N

Figure 1 Figure 2

Capacitors 135

TECH

NIC

AL

Voltage RegulationThe secondary voltage of a transformer changes with the load, therefore, for multi-lamp 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 sideAnother 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.

Safety Extra Low Voltage (SELV) Lighting Recommendations

Principles of operation of the Safety Isolating TransformerA 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 lifeBecause 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.

TECH

NIC

AL

136 Transformers

Safety Extra Low Voltage (SELV) Lighting Recommendations (continued)

Protection and ApprovalIt 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 60742.

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.

ImmunityA 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 61547.

EmissionThe limits for emission as per EN 61000-3-2 are maintained by high-quality filter circuits.

Electromagnetic CompatibilityHarmonics from non-linear loads cause distortions in the mains supply. The special circuit design fulfils the requirements of EN 61000-3-2.

RFI ProtectionThe sophisticated filtering system of electronic transformers TE ensures compliance with EN 55015 and VDE 0875-151

HarmonicsThe requirements of the EMS Directive 89/336/EEC are fulfilled by observance of the standards for emission and immunity.

Disposal of incandescent lampsIncandescent 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 lampsSmall 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 gearHella 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.

Hella products comply with the RoHS regulations passed by the EC on electronic waste

137

TECH

NIC

AL

Electronic Safety Isolating Transformers for Low Voltage Lamps

Disposal of old lamps and control gear

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 benefitsLED 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 technologyUnlike 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 designThe 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.

®

TECH

NIC

AL

138 LED Technology

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 TechnologyHella’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) LampThe 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.

Hella Work Lamp systems 139

TECH

NIC

AL

Paraboloid lamp Free-Form (FF) lamp

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.

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

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.

Vibr

atio

n

— Input

— DRACO® output

— Std output

— Difference (DRACO®-Std)

Time

TECH

NIC

AL

140 DRACO® vibration damping systems

Xenon Gas Discharge (XGD) work lamps

Instead of a coiled filament, a light arc is the light source in Xenon lamps. The bulb, which is only the size of a cherry stone, is filled with Xenon gas and metal salts. In order to ignite the Xenon bulb, an extremely high voltage of approximately 20,000 volts is required.

This is provided by an electronic ballast: 12V or 24V and direct current is transformed into 20,000V alternating current.

At temperatures of around 5000˚C, a light arc is created. With a power consumption of a mere 35 watts, this generates 2.5 times the light flux of an Halogen globe of the same power or equivalent to a 100W Halogen globe.

The current generation of control units is only half the size of and approximately one third lighter than the first and second generation.

The ignition electronics can now be completely integrated into the control unit. As a result of these control units, the lamp’s light is almost independent of voltage fluctuations in the vehicle electrical system, as the electronics operate the Xenon globes at constant output.

Operational duty cycles in mining are some of the most demanding and are normally combined with intensive switching cycles, dust-loaded air, corrosive atmospheres and often high levels of humidity.

Equipment designed for less demanding environments will not maintain their claimed lighting performance for a long period when used in mining. Hella designs fully sealed LED “fit and forget” lights whenever possible for mining applications. Where “fit and forget” is not practical, the reality of mining operational demands is taken into account. Due to their heavy usage loads, mining lights must be designed to allow for far more globe changes than are required elsewhere, and they must

be fitted with seals that will function under less than perfect conditions.

To overcome the problems encountered in practice with semi-perfect seals, Hella mining work lamps incorporate sophisticated breathing paths and air filters. This ensures that a low-resistance route is always available for air to enter and leave the luminaire; eliminating pressure gradients across seals and the consequence of unpredictable leakage behaviour. It is essential that these aspects are thoroughly integrated at the design stage.

Hella’s patented MustADD® breathing system chemically

cleans and dehydrates the air drawn into the lamp every time it is switched off, resulting in significantly extended product life. The combined particulate, chemical and de-hydrating barrier effectively reduces corrosive damage and allows AS500 FF® work lamps to operate repeatedly in harsh environments for extended periods.

MustADD® air filters remove dust particles to sub-micron level from the air and minimise airborne moisture, ensuring optimum light performance is maintained in corrosive environments.

Heavily contaminated air typical in mining environments rapidly deteriorates the

operational performance of most air filter systems. The MustADD® system is designed to substantially regenerate itself through two actions:

Action 1When switched on, the active components in the system rapidly heat up and impart some heat to the air inside the assembly. This heating action increases the internal air pressure and lowers the relative humidity simultaneously; thereby forcing the vented air to re-absorb moisture from the desiccant as it is expelled from the light.

Action 2The vigorous vibration of the equipment to which the work lamp is mounted, mechanically cleans accumulated particulate matter from the membrane. The physical structure of the micro-porous membrane is specified so that the particulates are stopped on the surface and not trapped within the filter medium.

MustADD systems of various levels of sophistication are implemented across the Hella mining product range, to deliver optimum value according to the product’s intended application. Even the least sophisticated implementation, using only the particulate barrier, delivers remarkable results due to the fact that the same design methods and specialised materials are used, regardless of product.

MechanicalFiltration

(3 micron)Chemical

Scrub

Dehydration

Light Source

ReflectorEnvironment

Lens

Seal

What is Xenon light?

MustADD® Filter Technology

141

TECH

NIC

AL

Chemical Material Investigated A

lum

iniu

m

Fib

reg

lass

Acr

ylic

Po

lyca

rbo

nate

Sta

inle

ss S

teel

Accumulator Acid N R R L L

Acetic Acid up to 5% L R R R R

Acetic Acid up to 15% N R R R R

Acetone R N N N R

Alcohol up to 30% L R R R R

Alcohol concentrate R N N R R

Ammonia 25% R L R L R

Aniline R N N N R

Aromatic Hydrocarbons R L R S R

Benzine R N N L R

Carbon Dioxide R R R R R

Carbon Monoxide R R R R R

Carbon Tetrachloride L L L R R

Caustic Soda 2% N L R N R

Caustic Soda 10% N N R N R

Chloroform R N N N L

Common Salt L R R L R

Crude Oil R R R S R

Diesel Oil R R R L R

Dioxane R N N R

Ether R L N N R

Ethyl Acetate R N N R R

Glycerine R R R L R

Glycol R R R R R

Hydrobromic Acid N N L N

Hydrocarbons R L L S R

Hydrochloric Acid 5% N R R R N


Chemical Material Investigated A

lum

iniu

m

Fib

reg

lass

Acr

ylic

Po

lyca

rbo

nate

Sta

inle

ss S

teel


Hydrogen Peroxide over 40% R N L N R

Hydrogen Sulphide R R R R R

Ketones R N N R R

Lyso R N N N R

Metal Salts and their aqueous solutions

N R R R L

Methanol R L N L R

Methylene Chloride L N N N R

Milk of Lime N R R L R

Nitric Acid 5% N R R R R

Nitric Acid 30% N L L L L

Nitric Acid concentrate N N N N R

Petrol R R R R R

Petroleum Ether R R R R R

Phenol L N N N R

Pyridine R N N R R

Sea Water L R R R R

Soap Suds L R R S R

Soda N R R R L

Sulphuric Acid 5% N R R R N

Sulphuric Acid 30% N R R R N

Sulphuric Acid concentrate N N N L N

Sulphurous Acid 5% L L R N L

Synthetic detergent N R R R R

Turpentine R R R R R

Water up to 70° C R R R R R

Xylene R N N N R

Ambient temperature 20° C

R ResistantL Resistant within limits

N Not resistantS Resistant when saturated, resistant within

limits when saturated.

TECH

NIC

AL

142 Tables for Chemical Resistance

PolycarbonatePolycarbonate is soluble in a number of technical solvents. Good solvents include: methylene chloride, ethylene chloride, trichloroethane, tetrachloroethane, chloroform, m-cresol and pyridine.

Comparatively poor solvents for polycarbonate include: deoxane,

tetrahydrofuran, cyclohexanone and dimethylformamide.

Examples of swelling agents are: benzene, chlorobenzene, tetralin, acetone, ethyl acetate, acetonitrile and carbon tetrachloride.

Polycarbonate is resistant to mineral acids, even in high concentrations, many organic

acids, oxidising and reducing agents, neutral and acid salt solutions, many greases, waxes and oils, saturated, aliphatic and cycloaliphatic hydrocarbons and alcohols, with the exception of methyl alcohol.

Polycarbonate is chemically degraded by aqueous or alcoholic alkaline solutions, ammonia gas and its solutions and also by amines.

Chemicalsacetaldehyde N

acetic acid up to 10% R

acetone N

acrylonitrile N

ammonia N

ammonium hydroxide solution N

ammoniym sulphate, saturated solution in water

R

benzene N

benzoic acid N

borax, saturated solution in water R

bromine N

butylene glycol R

calcium hypochlorite R

carbon dioxide, moist R

caustic potash N

caustic soda N

chlorinated lime solution 2% in water R

chlorine gas, dry L

chlorine gas, moist N

chromic acid, 20% in water R

coal gas R

cresol N

dibutyl phthalate (plasticiser) N

diethylene glycol R

dioxane N

ethanol R

ether N

ethyl alcohol 96% pure R

ethylene chloride N

ethylene glycol R

formalin 10% R

formic acid 30% L

glycol R

heptane R

hydrochloric acid, conc. N

hydrochloric acid 20% R

hydrogen sulphide R

ligroin (hydrocarbon mixture) R

methane R

methanol N

methylmethacrylate N

nitric acid 10% R

nitric acid 20% N

nitrous fumes, dry N

ozone R

petroleum ether (hydrocarbon mixture) L

petroleum spirit (for dry cleaning, free of aromatics)

R

phenol N

potassium cyanide N

potassium permanganate, 10% in water

R

potassium sulphate, saturated solution in water

R

propionic acid 20% R

sodium bicarbonate, saturated solution in water

R

sodium chloride, saturated solution in water

R

sulphur dioxide L

sulphuric acid, conc. N

sulphuric acid 50% R

toluene N

trichloroethylene N

Disinfectantscarbolic acid N

hydrogen peroxide R

iodine, tincture L

perhydrol R

Pharmaceuticals, Cosmeticslanolin R

nail varnish remover N

Foodstuffs, drinks and tobaccoallspice N

coffee R

edible oil R

fruit juices R

glucose R

linseed oil R

nutmeg N

sugar solution, saturated R

vegetable juices R

vegetable oil R

Detergents, rinsing and cleaningagents

Ajax® R

Persil® L

Pril® R

silicone oil emulsion R

soft soap R

tuba carpet shampoo conc. L

Technical oils and greasesBaysilone® fluids (silicone fluids) R

brake fluid (ATE) N

camphor oil N

diesel oil L

fish liver oil R

hydraulic fluid (Vac HLP 16) R

paraffin oil R

silicone oil R

turpentine substitute R

varnish L

Adhesives and sealants Cellux® adhesive films R

glazier’s putty R

insulating tape R

rubber (free of plasticiser) R

Polishes and anti-static agentsDelu® anti-static solution R

Perspex polish 3® R

Plexiklar® R

Polifac® grinding paste R

Inksmultimarker (Faber Castell) L

pelican royal blue 4001 R

Miscellaneousbattery acid R

chrome oxide green (grinding paste) R

cleaning petrol R

coal gas R

exhaust fumes, acidic R

kerosene, (aviation fuel) N

motor fuel, high octane N

motor fuel, ordinary L

grade

polyethylene R

polymeric plasticisers L

tannic acid N

thinners N

white spirit N

R Resistant L Resistant within limits N Not resistant

This information and technical data advice, whether verbal, in writing or through trials, is given in good faith without warranty. This also applies where proprietary rights of third parties are involved.

This advice does not release you from the obligation to check its validity.

Chemical Resistance Table (Standard Polycarbonate) 143

TECH

NIC

AL

The specification of a degree of protection for protection against access and foreign object includes all lower degrees of protection.

The degrees of protection 1 to 6K for protection against water include all the lower degrees of protection. Due to different physical affects, this does not automatically have to apply to water protection grades 7, 8 and 9K.

IP 2 K 3 K C M

Code letters (Ingress Protection)

First characteristic numeral (numerals 0 to 6 or letter X)

Second characteristic numeral (numerals 0 to 8 or letter X)

Additional letter (optional) (letters A, B, C, D)

Supplementary letter (optional) (letters M, S) (letter K)

Ingress Protection: Overview of the Elements of the IP Code

Element Numeral/ Letter

Meaning for the protection of electrical equipment

Meaning for the protection of persons

First characteristic numeral/ supplementary letter 0

12345K6K

Against the ingress of solid foreign objects (including dust):not protectedwith Ø ≥ 50mmwith Ø ≥ 50mmwith Ø ≥ 50mmwith Ø ≥ 50mmdust-protecteddust-tight

Against access to hazardous parts(unless described by extra letters): not protectedwith back of handwith fingerwith toolwith wirewith wirewith wire

Second characteristic numeral/ supplementary letter

012344K566K789K

Against the ingress of water:Not protectedVertical drippingDripping (inclined 15°)SprayingSplashingSame with increased pressureJettingPowerful jettingSame at increased pressureTemporary immersionContinuous immersionHigh-pressure/steam jet cleaning

Additional letter(optional)

ABC D

Meaning for the protection of electrical equipment

Against access to hazardous parts (unless described by first characteristic numeral):with back of handwith fingerwith toolwith wire

Supplementary letter(optional)

M

S

K

Movement of moving parts during water testStandstill of moving partsduring water testSpecifically for the electrical equipment in road vehicles

TECH

NIC

AL

144 Construction and meaning of the IP (Ingress Protection) Code

The Hella Centre of Excellence – Mining provides an Applications Engineering lighting design service for Hella Mining customers. The aim of this unique service is to reduce risk to end users and OEMs of implementing an inappropriate lighting design, enabling all stakeholders to evaluate, comment and change the design prior to implementation.

The Hella team combines decades of lighting expertise across many countries and industries with the most sophisticated software. However, our most valuable asset is ongoing consultation combined with extensive practical on-site mining experience, enabling us to understand the unique visual and environmental requirements of the mining industry.

We are fully aware of the wide and sometimes conflicting range of operational requirements, covering the need for greater equipment, operator and maintenance personnel safety, lowered cost of ownership and maintenance, increased productivity requirements and the

need for a predictable service life.

We use appropriate, proven technologies and methods to provide the mining operation with an engineering-based, application-focussed, customised solution. The system design not only complies with the relevant occupational health and safety regulations, but also with real life maintenance and operational needs.

Hella lighting designs typically include; aiming and orientation angles, number and type of luminaires, part numbers, spare parts, illumination level achieved and appropriate standards referenced. Our service extends to both fixed and mobile plant lighting designs. The final design is contained in a clear and concise document that can be

presented to all relevant stakeholders, ready to be integrated into on site maintenance documentation systems.

Our experience in Applications Engineering allows us to create lighting designs in a short time frame and with limited information.

Applications Engineering 145

TECH

NIC

AL

2 PAGE 2716 1132717 1132718 1132719 1132720 1132716-24V 1132717-24V 1132718-24V 1132719-24V 1132720-24V 113

8 PAGE 8151 308273 1018730 1148731 1148732 1148733 1148734 1148735 1148736 1148737 1148738 1148739 1148740 1148741 1148742 1148743 1148744 1148745 1148746 1148HG959952022 84

9 PAGE

9.1533.03 289.1600.01 589.1600.06 589.1601.01 589.1602.01 589.1603.01 589.1604.01 58

9.HM PAGE

9.HM1002.01 309.HM1002ECE.01 309.HM1385.05 309.HM151BAL 169.HM151TRN 169.HM15NB 169.HM15WB 169.HM180LENS 529.HM300FLX 489.HM360LENS 489.HM400LENS 469.HM450ALENS 469.HM450BLENS 469.HM450FLX 429.HM450GLENS 469.HM450RLENS 469.HM450WLENS 469.HM46FX 709.HM46GL 709.HM46MP 709.HM46MS 70

9.HM4940 999.HM4941 999.HM4942 999.HM4943 999.HM4944 999.HM4945 999.HM4946 999.HM4947 999.HM4948 999.HM4949 999.HM4950 999.HM4951 999.HM4952 999.HM4953 999.HM4954 999.HM4955 999.HM4956 999.HM4957 999.HM4958 999.HM4959 999.HM4960 1039.HM4960.01 819.HM4960.02 819.HM4960.03 819.HM4960.04 819.HM4960.05 819.HM4961 1039.HM4962 1039.HM4963 1039.HM4964 1039.HM4965 1039.HM4966 1039.HM4967 1039.HM4968 1039.HM4969 1039.HM4970 1039.HM4971 1039.HM4972 1039.HM4973 1059.HM4974 1059.HM4975 1059.HM4976 1059.HM4977 1059.HM4978 1059.HM4979 1059.HM4980 1059.HM4980.01 1069.HM4980.02 1069.HM4980.03 1069.HM4980.04 1069.HM4980.05 1069.HM4980.06 1069.HM4980.07 1069.HM4980.09 1069.HM4981 1059.HM4982 1059.HM4983 1059.HM4984 1059.HM4985 1059.HM4986 1059.HM4987 1059.HM4988 1059.HM4989 1059.HM4990 1059.HM4991 1059.HM4992 105

9.HM4993 1059.HM5700 769.HM5701 769.HM5702 769.HM5703 769.HM5801 779.HM5802 779.HM70BR 119.HM70BR 369.HM70DC 369.HM70WH 369.HM8500 1019.HM8501 1019.HM8502 1019.HM8503 1019.HM8504 1019.HM8505 1019.HM8511 1019.HM8513 1019.HM8514 1019.HM8520 1019.HM8521 1019.HM8522 1019.HM8523 1019.HM8530 1019.HM8531 1019.HM8532 1019.HM8541 1019.HM8543 1019.HM8548 1019.HM8549 1019.HM8600B 1079.HM8600C 1079.HM9386.02 409.HMAPEDL 169.HMAWHKD 169.HMDLM001 549.HMDLM001 649.HMDLM002 669.HMDLM002 869.HMPU2NB 349.HMPU2WB 349.HMPUXB24 249.HMPUXNB 249.HMPUXWB 249.HMTN001 749.HMTN002 749.HMTN003 749.HMTN004 749.HMTN005 759.HMTN006 759.HMUBHWB 289.HMUBHNB 289.HMX7500.01 569.HMX7500.02 56

C PAGE

C12100 120C1255LL 120C24100 120C2470 120C2470LTS 120CA1255LL 123CA1255X 123CA2470 123CA2470LTS 123

CB1255BL 120CD12100 120CD1255 120CD24100 120CD2470 120CF1265 123CG1255 123CG2470 123CX1255BL 120

HM0 PAGE

HM060321 62HM060621 63HM070321 62HM070621 63

HM1 PAGE

HM1002 30HM1002ECE 30HM1220AC 110HM1260AC 110HM1358 30HM1374D 30HM1375D 30HM1504NB 18HM1504WB 18HM1510NB 26HM1510WB 26HM1511NB 26HM1511WB 26HM1512NB 16HM1512WB 16HM1513NB 16HM1513WB 16HM1522WB 22HM1526LR 28HM1526NB 28HM1526WB 28HM1535DRL 67HM1535NB 12HM1535PB 12HM1535WB 12HM1539LDD 10HM1539LED 10HM1550CIG 15HM1550DT 15HM1550MAG-12 15HM1550MAG-24 15HM1550WB 14HM15700NB 13HM15700PB 13HM15700WB 13HM175AND 111HM180ABP 52HM180ADIR 52HM180AMAG 52HM180BDIR 52HM180BMAG 52HM180GBP 52HM180GDIR 52HM180GMAG 52HM180RBP 52HM180RDIR 52HM180RMAG 52HM180WDIR 52HM180WMAG 52

HM2 PAGE

HM2026 66HM2026D 66HM2051 66HM2051D 66HM2053PC 66HM2053PCD 66HM2054 66HM2054D 66HM227HD 85HM2307 66HM2307D 66HM2379 64HM2379D 64HM2420AC 110HM2460AC 110HM2717-24V 113HM2719-24V 113

HM3 PAGE

HM300ADIR 50HM300AFLX 50HM300AMAG 50HM300BDIR 50HM300BMAG 50HM300GDIR 50HM300GMAG 50HM300RDIR 50HM300RMAG 50HM300WDIR 50HM300WMAG 50HM350AND 111HM360ABP 48HM360ABPMAG 48HM360ADIR 48HM360AMAG 48HM360BBPMAG 48HM360BDIR 48HM360BMAG 48HM360FLX 48HM360GDIR 48HM360GMAG 48HM360PIPE 48HM360RBP 48HM360RDIR 48HM360RMAG 48HM360WDIR 48HM360WMAG 48

HM4 PAGE

HM400ADIR 46HM400AFLX 46HM400AMAG 46HM400BDIR 46HM400BMAG 46HM400GDIR 46HM400GMAG 46HM400PIPE 46HM400RDIR 46HM400RMAG 46HM400WDIR 46HM400WMAG 46HM4400A 112HM4400A-12V 112HM4400B 112

146 Part Number Index

HM4400B-12V 112HM4400G 112HM4400G-12V 112HM4400R 112HM4400R-12V 112HM450ADIR 44HM450AFLX 44HM450AMAG 44HM450BDIR 44HM450BMAG 44HM450GDIR 44HM450GMAG 44HM450RDIR 44HM450RMAG 44HM450WDIR 44HM450WMAG 44HM4612 70HM4620 70HM4630 70HM4660A 78HM4660B 78HM4660KTB7 78HM4660KTC7 78HM4660LOC 78HM4660ROD 78HM4660SWA 78HM4660SWB 78HM4660SWC 78HM4660SWD 78HM4660SWE 78HM4660SWF 78HM4960 81HM4960FM 81HM4960SA 74HM4961 81HM4961FM 81HM4962 81HM4963 81HM4963FM 81HM4964 81HM4965 81HM4980 106HM4981-P 106HM4981-S 106HM4982-P 106HM4982-S 106HM4983-P 106HM4983-S 106HM4984-P 106HM4984-S 106HM4985-P 106HM4985-S 106HM4986-P 106HM4986-S 106

HM5 PAGE

HM500ADIR 42HM500AFLX 42HM500AMAG 42HM500BDIR 42HM500BMAG 42HM500GDIR 42HM500GMAG 42HM500RDIR 42HM500RMAG 42

HM500WDIR 42HM500WMAG 42HM50AND 111HM5700KIT 76HM5701KIT 76HM5800KIT 77

HM6 PAGE

HM6603BD-12V 89HM6603BD-24V 89HM6603GD-12V 89HM6603GD-24V 89HM6605RD-12V 89HM6605RD-24V 89HM6605WD-12V 89HM6605WD-24V 89HM680ANB 86HM680ANW 86HM680ANY 86HM680ARB 86HM680ARW 86HM680ARY 86HM680FNB 86HM680FNW 86HM680FNY 86HM680FRB 86HM680FRW 86HM680FRY 86

HM7 PAGE

HM70H3NB-24V 36HM70H3WB-24V 36HM70H9NB-12V 36HM70H9WB-12V 36HM70LEDD 11HM70PI 11HM70PI 36HM70PR 11HM70PR 36HM720150W 88HM720150Y 88HM720400W 88HM720400Y 88HM7546J 71HM7592B 71

HM8 PAGE

HM8154 18HM8154AMBER 18HM8156 32HM8156AMBER 32HM8158 28HM8158AMBER 28HM8159 34HM8159AMBER 34HM8160 20HM8161 10HM8164 16HM8275 81HM8275 98HM8276 98HM8277 98HM8283 98HM8284 100

HM8285 98HM8286 98HM8287 102HM8288 103HM8289 103HM8290 104HM8298 106HM8600 107

HM9 PAGE

HM9.1374.08 30HM9.1374HD.01 30HM9.1375HD.01 30HM9400AMB2A 40HM9400AMB2G 40HM9400AMB2R 40HM9400AMB3A 40HM9400AMB3G 40HM9400AMB3R 40HM9400AMB4A 40HM9400AMB4G 40HM9400AMB4R 40HM9400YEL2A 40HM9400YEL2G 40HM9400YEL2R 40HM9400YEL3A 40HM9400YEL3G 40HM9400YEL3R 40HM9400YEL4A 40HM9400YEL4G 40HM9400YEL4R 40HM95903700 54HM95903700D 54HM95903710 54HM95903710D 54HM95903760 54HM95903760D 54HM95903780 54HM95903780D 54HM95903790 54HM95903790D 54HM95905030 65HM959950211 84HM959950221 84HM980910021 53HM980910221 53HM980910421 53HM980910621 53HM980910721 53

HMA PAGE

HMASH70NBA 32HMASH70NBD 32HMASH70WBA 32HMASH70WBD 32HMAT85 80

HME PAGE

HMEC1010AU 72HMEC1510AU 72HMEC2010AU 72HMEC2015AU 72HMEC2510AU 72HMEC3015AU 72

HMEC4015AU 72HMET200.08 115HMET307.01 115HMET307.02 115HMET307.03 115HMET307.04 115HMET307.05 115HMET307.51 115HMET483.03 115HMET483.05 115HMET483.07 115HMET483.10 115HMET483.15 115HMET483.20 115HMET483.25 115HMET483.30 115HMET483.35 115

HMF PAGE

HMFH107P 92HMFH117P 92HMFH312P 92

HMI PAGE

HMIC2010AU 73HMIC2015AU 73HMIC3020AU 73

HMP PAGE

HMPB100 8HMPB200 9HMPS12PROVCP 116HMPS12PROVPT 116HMPS12VCP 116HMPS12VKIT 116HMPS12VPROKIT 116HMPS12VPT 116HMPS24PROVCP 116HMPS24PROVKIT 116HMPS24PROVPT 116HMPS24VCP 116HMPS24VKIT 116HMPS24VPT 116HMPS75B 111HMPS75G 111HMPS75R 111HMPS75S 111HMPSPCAP 116HMPV270NBA 34HMPV270NBD 34HMPV270WBA 34HMPV270WBD 34HMPVX35NBD 24HMPVX35WBD 24

HMR PAGE

HMRA087B 95HMRA107B 95HMRA112P 93HMRA603P 94HMRA611P 94HMRA917E 93

HMT PAGE

HMTND2156 74HMTND2157 74HMTND2158 74HMTND2159 75HMTND2160 75HMTNM6605 74HMTNM6606 74HMTNM6607 74HMTNM6608 74HMTNM6609 74HMTNM6610 75HMTNM6611 75HMTNM6612 75HMTNM6613 75

HMU PAGE

HMUBXHWBD-12V 20HMUBXHWBD-24V 20HMUBXSWBD-12V 20HMUBXSWBD-24V 20

HMW PAGE

HMWGA160 58HMWGA220 56HMWPR001 80

HMX PAGE

HMX6750A 58HMX6750B 58HMX6750C 58HMX6750G 58HMX6750R 58HMX7500A 56HMXN4001 20HMXN4001 24HMXN4001 124HMXN4YEL 124

X PAGE

XD12100/55 122XD12100/90 122XD1260/55 122XD1260/55LL 122XD24100/90 122XD2475/70 122XD2475/70LL 122XD2475/70LTS 122XDB1260/55BL 122XDX1260/55BL 122XN4000 124XN6750 124

Y PAGE

YC12100 121YC1255LL 121YC24100 121YC2470 121YC2470LTS 121YCB1255BL 121YCP1255BL 121YCX1255BL 121

147

www.hella.com/mining

Hella Mining Catalogue 4th Edition - Industrial and Bearing ...

Documents

Transcript of Hella Mining Catalogue 4th Edition - Industrial and Bearing ...