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LITEPAK 1.

0 CAP LAMP MAINTENANCE MANUAL

Confidential

By Shem CK Banda (Industrial Engineer) & Kwena E Manaka (Product Manager)

LITEPAK 1.0 CAP LAMP MAINTENANCE MANUAL


The Litepak cap lamp is designed, amongst other applications, for all underground mining, emergency services, security services and maintenance services. To maintain the Litepaks high standard of performance at all times, it is important to take good care of the Litepak and the following strategies will ensure this.

1.
1.1.

NEW LITEPAK 1.0 CAPLAMP On receiving a new Litepak, make sure that the Litepak has all the main components shown in fig. 1 (Main components of the Litepak 1.0 cap lamp). Turn the Litepak on (according to section 2.1.1 of this document) to verify the Litepak is in working condition. Put the Litepak on the charger and make sure the battery accepts charge. This may not be necessary if there is a charge in the battery. Charge the battery for at least 12 hours before use. If any of the above fails, refer to section 4 of this document for repair and corrective actions or return the unit to the distributor or manufacturer.

1.2.

1.3.

1.4. 1.5.

Headpiece Switch knob Cap hook

Battery top cover

Lens

Battery Bezel ring Cable


Fig. 1: Main components of the Litepak 1.0 cap lamp

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2.

WORKING WITH THE LITEPAK 1.0 CAP LAMP

Make sure all first-time users of the Litepak go through and understand the basic operation of the Litepak outlined in section 2.1 below. 2.1 2.1.1 Basic Operation of the Litepak. Switching the Litepak On/Off, ref fig. 2 (Switching direction of the Litepak 1.0 cap lamp). The Litepak has a half circle operational switch. Turning the switch in the clockwise direction as shown in the figure will switch the Litepak on. Turning the switch in the anticlockwise direction will switch the Litepak off. NB: Under no circumstance should the switch be forced to turn a full circle in either direction as this will result in damaging the switch. Handling the Litepak The Litepak should be carried with due care. Avoid carrying the Litepak by its cable or hitting the battery or head piece against or with hard surfaces as this may result in damaging the unit. The Litepak should be turned ON only when it is necessary to do so. Working with the Litepak 1.0 cap lamp on shift. On issuing the Litepak for a shift, make sure: i) The Litepak is in good working condition. ii) The battery was fully charged as specified in section 3 of this document. 2.3.2 When receiving the Litepak from shift: i) ii) iii) iv) Check the Litepak to ensure it is in working condition. Litepaks that are in working condition should be charged as specified in section 3 of this document. Faulty Litepaks should be repaired as specified in sections 5 and 6 of this document. Dirty Litepaks from shift should be cleaned as specified in section 4 of this document.

2.1.2

2.2 2.3 2.3.1

Off

On

Fig. 2: Switching direction of the Litepak 1.0 cap lamp

3.
3.1

CHARGING THE LITEPAK 1.0 CAP LAMP New Litepaks and Litepaks that are in working condition returning from shift should be charged for at least 12 hours before their next issue. When charging the Litepak: i) Make sure that the Litepak is placed in the correct charging position on the charging rack.

3.2

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ii) The charging contacts, both on the charging rack and Litepak should not be blocked by any insulating material. 3.3 Any universal charge rack that supplies between 5 Vdc and 6 Vdc at up to 1 Amp per point is suitable for charging the Litepak.

4.
4.1

CLEANING THE LITEPAK 1.0 CAP LAMP Dirty Litepaks returning from the shift should be cleaned with a clean soft cloth before placing them on the charge rack for charging. Avoid any cleaning method that may lead to scratching of the lens or reflectors. No solvents should be used for cleaning any part of the Litepak.

4.2 4.3

5.

ASSEMBLING THE LITEPAK CAP LAMP

As mentioned in the disassembling of the Litepak cap lamp, the final assembly of the Litepak involves putting together four sub assemblies namely: Battery, Cable and Battery top cover sub assembly, Headpiece sub assembly and the Lens and reflector sub assembly. The following procedures will detail how to first build these sub assemblies and finally, the final assembly when building the Litepak cap lamp.

5.1

Procedures to build Litepak cap lamp sub assemblies.

Tools Required: 1.5 mm Allen key driver 2 mm Allen key driver Forked screwdriver 4.5 X 75 engineers screwdriver Long nose pliers Tab connector crimper YYT11 Cable crimping tool 18 mm gland spanner

The Litepak battery comes as a sealed unit and no one is allowed to tamper with it. If you have a problem with the battery, contact the supplier. 5.1.1 Procedures to assemble the Lens and reflectors sub assembly i) Place the front and back o-rings in their designed grooves on the large reflector by hand as shown.

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ii) With the small reflector facing inside of the large reflector, place the lens on top of the front o-ring.

The lens should fit snugly in its designed space of the big reflector. Make sure the front o-ring were not dislocated from its designed groove. NB: The Lens and reflectors sub assembly has been assembled.

5.1.2

Procedure to assemble the Cable and battery top cover sub assembly i) Using the Tab connector crimper YYT11, crimp the crimp lugs on all four the wire ends as shown.

ii) Slip the securing bush over one end of the cable as shown. This will be the headpiece side

iii) Place the cable wire clamp about 10mm from the sheath edge and clamp it with the cable clamping tool as shown

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iv) Insert the grommet in the top cover bush by squeezing it through the hole as shown

v) Insert the other end of the cable into the grommet and pull the cable through the cover bush as shown. You may need to apply a lubricant e.g. soapy water on the cable to easy the pulling. This will be the battery side.

vi) Inset the cable through the top cover hole and screw the bush into the top cover as shown.

vii) Place the cable wire clamp about 10mm from the sheath end and clamp it with the cable clamping tool as shown

viii) Pull back the cable until the cable wire clamp is seated against the top cover guides as shown

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ix) On the battery side place the black sleeving over the black wire and the red sleeving over the red wire as shown.

NB: The Cable and battery top cover sub assembly has been assembled.

5.1.3

Procedure to assemble the headpiece i) Place the switch negative contact plate and switch lower contact plate in their designed position in the headpiece housing as shown

ii) Add the switch upper contact plate on top of the switch lower contact plate as shown.

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iii) Place two M3 brass washers on the upper contact plate and make sure the holes align. Threading these parts over a guide like an Allen key aids the assembly process. iv) Place the PCB in the headpiece housing as shown

v) Secure the PCB, two brass washers, upper switch contact plate and lower switch contact plate to the headpiece housing with M3 screw (PCB Screw) as shown

vi) Place the charge socket block in its place and secure it with two screws as shown

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vii) Place a steel washer and neoprene washer onto the charge contact screw as shown

viii) Tighten the charge contact to the socket block through the hole from the outside of the headpiece housing

ix) Place the switch shaft o-ring on the switch shaft as shown.

x) Using long nose pliers, place the switch block in position as shown.

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xi) Push the switch shaft in from the outside and secure it to the switch block with a grub screw as shown. Loctite 222 should be used to secure the grub screw.

xii) Place the charge contact barrel and the charge contact rubber in their respective positions at the back of the headpiece housing as shown.

xiii) Place the cap hook in position. Using the forked screw drivers, secure the cap hook to the headpiece housing with a cap hook screw from one side, a lock washer and a nut on the other side as shown.

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NB: The Headpiece has been assembled.

5.2

Procedures to fully assemble the Litepak

Tools Required: Triangular nut driver 12 mm gland spanner 5.5 mm nut driver Forked Screw driver Long nose pliers 5.2.1. Procedures to assemble the cable to the headpiece i) Place the cable entry o-ring seal on the cable as shown

ii) Insert the cable (headpiece end) into the headpiece Take care to ensure the o-ring seals perfectly at the cable entry into the headpiece. iii) Using the 12mm gland spanner, secure the cable to the headpiece with the cable grand

iv) Place the terminals on their respective screws on the PCB (red to positive and black to negative)

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v) Place a lock washer on each of the terminals and secure the terminals with an M3 nut as shown.

If necessary, rearrange the terminal wires so that they do not impede the switch operation, interfere with the LEDs or impede the further assembly of the reflectors. NB: The cable has been assembled to the headpiece.

5.2.2.

Procedures to assemble the battery to the cable and headpiece i) Place the battery o-ring seal in its designed groove as shown.

ii) Place the wire terminals on their respective screws on the battery (red to positive and black to negative) iii) Place a lock washer on each of the terminals and secure the terminals with an M3 nut as shown.

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iv) Place the name plate in its designed groove on the battery top cover and close the battery with the top cover v) Using forked screw drivers, secure the top cover to the battery with the special screws as shown.

NB The battery has been assembled to the cable and headpiece. 5.2.3. Procedures to assemble the Lens and reflectors sub assembly to the headpiece i) Place the Lens and reflector sub assembly on top of the headpiece as shown

Make sure the reflector aligns with the cable entrance ii) Tighten the bezel onto the headpiece, while pressing down firmly onto the middle of the lens so that the lens and reflector assembly DOES NOT ROTATE as you tighten the bezel.

iii) Clean the lens from all finger marks

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iv) Insert the bezel lock screw. Using the triangular socket driver, tighten the bezel lock screw

NB: the Lens and reflectors sub assembly has been assembled to the headpiece and the Litepak cap lamp is now fully assembled.

6.

DISASSEMBLING THE LITEPAK CAP LAMP

The final assembly of the Litepak involves putting together four sub assemblies namely: Battery, Cable and battery top cover sub assembly, headpiece sub assembly and the lens and reflector sub assembly. The following procedures will detail how to first disassemble a fully built Litepak into these four subassemblies and then, how to further disassemble the sub assemblies (if required) into individual spare parts. 6.1 Procedures to disassemble the fully built Litepak cap lamp Into the four sub assemblies:

Tools Required: Triangular nut driver 12mm gland spanner 5.5mm nut driver Forked Screw driver Long nose pliers 6.1.1 Procedures to disassemble the battery from the fully built Litepak cap lamp: i) Using the forked screw driver, unscrew the battery top cover securing screws as shown

ii) Carefully pull the battery and the battery top cover apart just enough to secure a working space to unscrew the positive and negative battery terminals securing nuts iii) Using the 5.5mm nut driver, unscrew the battery terminals securing nuts as shown

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Battery o-ring

iv) Remove the lock washers v) Remove the positive and negative battery terminals form their respective terminal screws vi) Remove the battery o-ring NB: The battery has been successfully disassembled

6.1.2

Procedures to disassemble the Lens and reflectors sub assembly from the fully built Litepak cap lamp i) Using the triangular nut driver, unscrew the bezel lock pin as shown

ii) Unscrew the bezel ring whilst simultaneously pressing down on the lens as shown

NB: When unscrewing the bezel ring, make sure the lens does not rotate together with the bezel ring as this may damage the internal module iii) Carefully remove the Reflectors and lens sub assembly from the headpiece housing NB: The Lens and reflectors sub assembly has been successfully removed

6.1.3

Procedure To disassemble the Cable and battery top cover and headpiece sub assemblies

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(This procedure must always follow procedure number 6.1.1 i.e. the battery must always be disconnected first before carrying out any work in the headpiece. Failure to do so will result in damaging the PCB) i) Unscrew the positive and negative terminal securing nuts using the 5.5mm nut driver as shown.

ii) Remove the spring washers lying on top of the terminals iii) Using the long nose priers, remove the positive and negative terminals form their respective terminal screws iv) Unscrew the cable securing bush using the 12mm gland spanner as shown.

v) Carefully pull the cable out of the head piece. There is an o-ring at the cable entrance of the head piece which must be removed if it was not pulled out together with the cable NB. The headpiece and cable and battery top cover sub assemblies have been successfully disassembled

6.2

Procedures for further disassembling of the Litepak cap lamp sub assemblies:

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Tools Required: 1.5 mm Allan key driver 2 mm Allan key driver Forked screwdriver 4.5 X 75 engineers screwdriver Long nose pliers Knife Cable crimping tool 18 mm gland spanner You are not allowed at any point to disassemble the battery. If you have any problem with the battery, please refer it to the supplier 6.2.1. Procedures to disassemble the Lens and reflectors sub assembly i) Use your finger tips as shown to remove the lens and the small reflector from the large reflector.

ii) Remove the front and back o-rings from the large reflector by hand NB: The lens and reflectors sub assembly has been disassembled into its spare parts. 6.2.2. Procedure to disassemble the Cable and battery top cover sub assembly i) Remove the number plate from the top cover as shown

ii) Remove the black sleeving from the black terminal wire and the red sleeving from the red terminal wire. iii) Unscrew the top cover cable securing bush using the 18 mm gland spanner as shown

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iv) Pull the top cover cable bush together with the grommet up the cable for a distance of +/- 10cm as shown.

NB: You may need to apply lubricant e.g. soapy water on the cable to easy the pulling. v) Pull the cable from the inside of the top cover enough to give you sufficient working space vi) Loosen and pull off the cable wire clamps from the cable using pliers as shown

vii) Pull the cable out of the top cover as shown

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viii) Pull the top cover cable bush together with the grommet from the cable. You may need to apply lubricant e.g. soapy water on the cable to easy the pulling. ix) Remove the grommet from the top cover cable bush by squeezing it out of the top cover cable bush hole.

NB: The Cable and battery top cover sub assembly has been disassembled into its spare parts

6.2.3.

Procedures to disassemble the headpiece i) With the switch in the ON position, unscrew the switch screw using a 1.5 mm Allan key driver as shown

ii) Pull out the switch knob from the head piece.

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There is an o-ring at the switch knob entrance from the outside of the head piece which must be removed if it was not pulled out together with the switch knob iii) Using the long nose pliers, take out the switch block from the head piece as shown.

iv) Unscrew the charge contact screw using a 2 mm Allan key driver as shown

There are two washers (one neoprene and one steel) at the charge contact screw entrance from the outside of the head piece which must be removed if they were not pulled out together with the charge contact screw v) Unscrew the Socket block securing screws using a 4.5 X 75 engineers screwdriver as shown

vi) Remove the socket block from the head piece

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vii) Using a 4.5 X 75 engineers screwdriver, unscrew the PCB screw as show.

viii) All components inside the head piece (PCB, lower switch contact plate, upper switch contact plate, the negative switch contact plate and the two brass washers) are loose and can be removed. ix) Whilst holding the cap hook screw, use a forked screw driver to unscrew the cap hook nut as shown.

x) A lock washer and the cap hook will fall off once the screw is pulled out. xi) Remove the charge contact barrel and charge contact rubber using a long nose pliers. NB: The headpiece has been disassembled into its spare parts

7.
7.1. 7.2.

TROUBLESHOOTING The table below outlines the troubleshooting process if problems are encountered with the Litepak. Important: Only suitably qualified and certified persons as per Section 9 of this document may repair the Litepak. Possible Cause The battery was not charged Damaged cable Loose connections Solution/s Charge the battery Replace the cable Tighten all loose connections

Problem Caplamp does not give light

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Poor quality light

Battery does not accept charge

Battery power does not last a shift after a full charging cycle

Loose/non functional switch Problem with LED PCB Dirty lens Damaged/ scratched lens Dirty reflector/s Damaged reflector/s Reflector o-rings out of position Loose battery connections Worn out or damaged cable Worn out charging key Damaged charging circuit on the headpiece PCB Poor charging e.g. charging rack does not conform Blocked charging contacts Damaged LED driver circuit on the headpiece PCB Battery past its life expectancy

Tighten/replace the switch Repair/replace the LED PCB Clean the lens Replace the lens Clean the reflector/s Replace the reflector/s Replace the reflector o-rings Tighten the battery connections Replace the cable Replace the charging key Replace the PCB Make sure the rack conforms to point 3.3 of this document. Clear the charging contacts. Replace the PCB Replace the battery

8.
8.1

REPAIRING THE LITEPARK 1.0 CAP LAMP Only people with technical abilities as specified in section 7 of this document should be given the responsibility to repair the Litepak. For any electrical work on headpiece terminals, the battery terminals should be disconnected first. Failure to do so may result in short circuits and permanent damage to the unit. For any repairs involving the opening of the headpiece, the reflector o-ring seals, both front and rear should be replaced and seated properly. Go through the trouble shooting process outlined in section 5 of this document before opening/disconnecting the Litepak or its parts. This can be bypassed if the fault is obvious e.g. replacing a damaged cable. Procedure to replace a damaged/scratched reflector or lens i) Disassemble the lens/reflector sub assembly from the unit as in procedure 6.1.2. points i) to iii) ii) Further disassemble the lens/reflector sub assembly as in procedure 6.2.1 points i) and ii) iii) Using the new reflector or lens and new o-rings, assemble the lens/reflector sub assembly as in procedure 5.1.1 points i) and ii) iv) Reassemble the lens and reflector sub assembly to the unit as in procedure 5.2.3 pints i) to iv)

8.2

8.3

8.4

8.5

8.6

Procedure to replace a worn out or faulty battery i) Disassemble the finished/faulty battery from the entire unit as in procedure 6.1.1 points i) to v) ii) Using the new battery and new battery O-ring seal, reassemble the battery to the unit as in procedure 5.2.2 points i) to v)

8.7

Procedure to replace a faulty switch shaft or switch block i) ii) iii) iv) v) Disassemble the Lens and reflector sub assembly from the entire unit as in procedure 6.1.2 pints i) to iii) Further disassemble the Lens and reflector sub assembly as in procedure 6.2.1 points i) and ii) Using the old reflector and lens, with new o-rings, assemble the Lens and reflector sub assembly as in procedure 5.1.1 points i) and ii) Disassemble the switch from the headpiece as in procedure 6.2.3 points i) to iii) Using the new switch arm or switch block together with a new switch shaft o-ring, reassemble the switch to the headpiece as in procedure 5.1.3 points ix) to xi)

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vi) Reassemble the Lens and reflector sub assembly to the unit as in procedure 5.2.3 pints i) to iv) 8.8 Procedure to replace the charge contact screw i) Disassemble the Lens and reflector sub assembly from the unit as in procedure 6.1.2 pints i) to iii) ii) Further disassemble the Lens and reflector sub assembly as in procedure 6.2.1 points i) and ii) iii) Using the old reflector and lens, with new o-rings, assemble the Lens and reflector sub assembly as in procedure 5.1.1 points i) and ii) iv) Disassemble the charge contact screw from the headpiece as in procedure 6.2.3 point iv) v) Reassemble the new charge contact screw with a new neoprene washer to the headpiece as in procedure 5.1.3 points vii) to viii) vi) Reassemble the Lens and reflector sub assembly to the unit as in procedure 5.2.3 pints i) to iv)

8.9

Procedure to replace a PCB, switch contact plates (negative, lower and upper) and headpiece housing Disconnect the battery as in procedure 6.1.3 points i) to vi) Disassemble the Lens and reflector sub assembly from the unit as in procedure 6.1.2 pints i) to iii) Further disassemble the Lens and reflector sub assembly as in procedure 6.2.1 points i) and ii) Using the old reflector and lens, with new o-rings, assemble the Lens and reflector sub assembly as in procedure 5.1.1 points i) and ii) v) Disconnect and remove the cable as in procedure 6.1.3 points i) to v) vi) Disassemble the headpiece as in procedure 6.2.3 points i) to viii) vii) Discard all old o-rings and use new o-rings, reassemble the headpiece with the replaced part/s as in procedure 5.1.3 point i) to xi) viii) Using new o-ring, put back the cable and reconnect the terminals as in procedure 5.2.1 points i) to v) ix) Using a new o-ring, reconnect the battery as in procedure 5.2.2 points i) to v) x) Reassemble the Lens and reflector sub assembly to the unit as in procedure 5.2.3 pints i) to iv) i) ii) iii) iv)

8.10

Procedure to replace a cable Disconnect the battery as in procedure 6.1.3 points i) to vi) Disassemble the Lens and reflector sub assembly from the unit as in procedure 6.1.2 pints i) to iii) Further disassemble the Lens and reflector sub assembly as in procedure 6.2.1 points i) and ii) Using the old reflector and lens, with new o-rings, assemble the Lens and reflector sub assembly as in procedure 5.1.1 points i) and ii) v) Disconnect and remove the cable as in procedure 6.1.3 points i) to v) vi) Disassemble the headpiece as in procedure 6.2.3 points i) to viii) vii) Remove the battery top cover as in procedure 6.2.2 points ii) to xiii) viii) With the new cable, new crimp lugs and new wire clamps, reassemble the cable as in procedure 5.1.2 points i) to ix) ix) Using a new o-ring, put back the cable and reconnect the terminals as in procedure 5.2.1 points i) to v) x) Using a new o-ring, reconnect the battery as in procedure 5.2.2 points i) to v) xi) Reassemble the lens/reflector sub assembly to the unit as in procedure 5.2.3 pints i) to iv) i) ii) iii) iv)

8.11

Procedure to replace a battery top cover i) Disconnect the battery as in procedure 6.1.3 points i) to vi) ii) Only at the battery top cover side, remove the cable as in procedure 6.2.2 points i) to v) and vii) to xiii)

8.12

Procedure to replace the cap hook or the charge contact barrel i) Disassemble the cap hook and the charge contact barrel as in procedure 6.2.3 points ix) to xi) ii) With the new cap hook or charge contact barrel, reassemble as in procedure 5.1.3 points xii) to xiii)

9.

LITEPAK 1.0 CAP LAMP SERVICING TECHNICIANS

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To maintain the intrinsic safety certification of the Litepak all personnel performing any service or repair on the Litepak have to be trained and certified in maintaining intrinsically safe equipment. There are two levels of certified service technicians for the Litepak depending on the functions they are required to perform. Below are the respective tool requirements and duties they may perform: 9.1 9.1.1. Litepak Service Technician Level 1 Tools Required: i) 2.5 mm Allan key driver ii) 2.0 mm Allen key driver iii) Cable clamp crimping tool iv) 5mm flat screw driver v) 5.5mm nut driver (only particular type) vi) Triangular nut driver vii) 12mm gland spanner viii) 18mm gland spanner ix) Forked screwdriver 9.1.2. Functions Performed: ii) i) Daily cleaning of Cap lamps ii) Check functional life of battery iii) Replace cap lamp cables iv) Replace reflectors or lens v) Replace cap hook vi) Replace lock barrel vii) Replace charge stud viii) Replace number plate ix) Test / Replace batteries x) Sort Cap lamps to be repaired by level 2 technician iii) iv) v) 9.2 9.2.1 Litepak Service Technician Level 2 Tools Required: i) As for level 1 technician Plus ii) Soldering iron iii) Power supply iv) LED module test jig

9.2.2.

Functions Performed: i) As for level 1 technician Plus Test and evaluate LED modules charging functions Test and evaluate LED modules LED functions Repair / Replace headpiece PCB Repair / Replace LED PCB

10.

CERTIFICATION

The Litepak carries the following certifications and approvals: Intrinsically safe Ex ia I/IIC T4 as per SANS/IEC60079-11. SANS1438 (2005) compliant as per test report MS-XPL/07241 South African Department of Minerals and Energy approval number PN75. To maintain its intrinsic safety certification, no modification, alteration or attachment is allowed to be made on the Litepak cap lamp.

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