ATEX Worklite Instructions
Contents
1. Wolf ATEX Rechargeable Worklite Range Operation and Maintenance Instructions Please Retain Read Before Use EC Declaration of Conformity The Wolf ATEX Worklite meets all relevant provisions of the 94 9 EC Explosive Atmospheres ATEX Equipment Directive by virtue of the issued EC type examination certificate demonstrating compliance with all relevant harmonised standards and essential health and safety requirements The Wolf ATEX Worklite is a self contained portable Worklight with a durable construction of stainless steel and anodised aluminium enclosures The Worklite is powered by a sealed lead acid battery available in two sizes and supplying arrays of 6 or 12 High Power LEDs The Worklite range is approved as Group II Category 2 equipment for use in zone 1 amp 2 potentially explosive gases vapours mists and dusts where the T4 temperature class 135 C maximum surface temperature permits Approval Codes Certification Il2 GD Ex e ib mb IIC T4 Ex tD A21 IP65 T135 C EC Type examination certificate SIRA07ATEX3027 Notified Baseefa 2001 Ltd Body Rockhead Business Park Staden Lane Buxton SK17 9JN UK Notified body number 1180 Harmonised standards applied EN60079 0 2006 EN60079 0 2004 EN60079 7 2007 EN60079 7 2003 EN60079 1 1 2007 EN50020 2002 EN61241 0 2006 EN61241 0 2004 EN61241 1 2004 EN60079 18 2004 Ingress protection level IP65 to EN60529 1992 Wolf Worklites are certified compliant with t2. connected and the enclosure lid replaced ensuring no cables are snagged or obstructing the sealing edge when the lid is in position Torque Setting Top Bottom Plate retaining Screws x12 3 2Nm Torque Setting Lens Clamp Screws x4 3 2Nm Torque Setting Cable Gland Locknut 18Nm Spare Parts List ioe W 200 3xAntistaticLensGuardsinBag CALLE G W 201 Cable and Gland Assembly AUL W 202 Battery Foam Kit 18Ah Battery WL 70 amp WL 80 W 203 Fuse Kit 5A amp Encapsulated 1A ALL W 204 Battery Foam Kit 33Ah Battery WL85 W 205 IndexPlungerKit CAL W 206 Head Pivot BoltsandWasherKit AL W 208 4x Enclosure Lid Screws W 415 W 209 Lens Glass Lens Seal amp O ring kit W 210 Head Seal and set of Screws ALL W 212 Lens Glass Lens Seal amp O ring kit WL 70 O ALL W70 O W 213 Charge Socket with Base Seals amp Screws ALL O AE W 300 Battery Enclosure Lid Seal ALL W 440 Switch Assembly with wires connector ALL LED Board Replacement Requires disassembly of the head and disconnection of battery i Follow Glass Lens Replacement steps i to iii above to remove the lens ii Loosen and remove the screws W 404 retaining the LED board Remove the two right hand lens screws completely and now remove the six W 414 screws retaining the lamp bottom plate iii The LED board lower plate clamping plate and connector block can now al
3. lid ensuring o seal is in place fit and tighten iv re connect the 3 way connector re fit any removed packing foam and replace lid as per enclosure lid removal instructions above Torque Setting Switch Locknut 0 57Nm Charge Socket Assembly Replacement Requires removal of enclosure lid see above i Lift circuit block assembly from enclosure to gain access to terminal block ii Disconnect charger socket wires Yellow and Violet from the terminal block iii Unscrew Charge Cap and move to one side iv Remove the three screws retaining the charge socket base from the underside of the lid v The old base can now be lifted out and replacement fitted in the reverse order of the above ensuring that the o rings are in place and in good condition vi Connect the Yellow and Violet charge socket wires in to the terminal block as shown in Fig 6 Indicator Replacement Requires removal of enclosure lid see above i Disconnect the indicator LED connector ii Using a spanner remove locknut and pull the indicator housing through the lid iii grip the lower part of the LED holder and unscrew the housing from the assembly iv the LED can now be released through the underside of the lid Assembly is the reversal of removal take care not to twist or stress the cable while screwing the lower part of the indicator to the housing and ensure o seals are in place v connect 2 way connector and assemble as above Glass Lens Repl
4. acement Requires partial disassembly of the head See fig 4 i Loosen and remove the six screws W 414 retaining the lamp TOP plate ii Partially loosen off the four lens clamp screws W 421 until the lens is free to move iii Carefully slide the old lens upwards and out and replace with new lens and seal Ensure seal fits squarely around the new lens after insertion iv Gradually tighten each of the four W 421 lens screws v re fit top plate ensuring that the seal edge follows the edge of the plate and that the holes align and that no dirt particles are present on the sealing edge Tighten all six circuit block from the enclosure if necessary iv Remove the locknut and completely remove the cable assembly from the Worklite v Fitting is the reverse of the above fit the cable gland in to enclosure lid and lamp head bottom plate ensuring that the gland seal is external and the shakeproof washer and locknuts are internal vi Connect the new cable to the head connector block No 1 brown to White No 2 blue to Black and re install the LED board lens clamp plate and bottom plate as per the instructions above vii In the battery enclosure connect the wires in to the connector block No 1 brown to White No 2 blue to Black vili Re Screws connect any disconnected switch or indicator cables and replace the circuit block if necessary When all wire connections are checked and the head has been re assembled the battery can now be
5. ead and disconnection of battery i Follow steps i to ili from LED Board Replacement ii Disconnect terminal block from cable assembly and using a spanner remove the cable gland locknut and remove the cable gland from the bottom plate iii Disconnect the cable from the terminal block tilt the battery enclosure top plate to expose the cable gland locknut If necessary disconnect the switch and indicator lift the W 475 Issue 5 Fig 6 Control circuit 5 Amp charge fuse Charge socket il i Control circuit Lamp Co contro Potted 1A output fuse gt lt DO NOT REMOVE FROM TERMINAL BLOCK Battery Battery e Disconnect battery before maintenance to any of the Worklite circuit For re assembly ensure all foam blocks are correctly inserted as per fig 2 fig 3 and re fit lid A short charge with charger WL 150 will be required each time a battery is re connected before the lamp will light WARNING e USE ONLY WOLF CHARGERS WITH THESE PRODUCTS e USE ONLY GENUINE WOLF REPLACEMENT PARTS e LAMP MUST NOT BE USED WITHOUT BATTERY SPACERS AND PACKING CORRECTLY IN POSITION e LAMP MUST NOT BE USED WITHOUT CHARGE CAP FITTED The Wolf Safety Lamp Co Ltd has a policy of continuous product improvement Changes in design details may be made without prior notice Wolf Safety Lamp Company Saxon Road Works Sheffield S8 OYA Tel 44 114 255 1051 Fax 44 114 255 7988 E mail info wolf sa
6. fety co uk Website www wolf safety co uk
7. he 2004 108 EC EMC Directive The product is CE marked showing compliance with all relevant EC Directives Alex Jackson Managing Director Wolf Safety Lamp Company Ltd Use of the Wolf Worklite First Use Read Instruction Manual Remove protective switch cap and charge fully before first use A damaged Worklite should be repaired in accordance with these instructions before being put back into service Repair work may ONLY be carried out by qualified technicians using components supplied by Wolf and fitted in accordance with these instructions Worklite Models TABLE 1 Battery Lamp High Pwr Low Pwr Charge Duration Duration Duration WL 85 12V 33 Ah_ 12 LED 1020 Im WL 80 12V18Ah_ 12 LED 1020 Im WL 70 12V18Ah 6 LED 510 Im Use of the Wolf Worklite Inspect the following before each use e Battery box lid must be closed and the four retaining screws tightened e Charge socket cover must be in place and tightened by hand This is a certification requirement to maintain IP65 e Cable should have no tears splits or signs of separation from glands e f damage is visible to any seals or the glass lens the part must be replaced Caution when handling Precautions should be taken when lifting and carrying heavy objects Following extended use The lamp head can get hot Do not cover head fins Do not stare directly into the beam as damage to the eye may occur W 475 Issue 5 Disposable Lenses Anti sta
8. id again taking care not to snag any cables To replace battery remove foam and spacers which surround the circuit slide battery forward to release top spacer and lift battery out taking care not to short the battery terminals on enclosure flange or metal tools Re assembly is the reverse of above See diagram for foam spacer positions and orientations Inspect all wire connections connect battery terminals Re connect vent pipe W 475 Issue 5 Battery Replacement WL 80 amp WL 70 To replace W 218 18Ah battery in WL 80 amp WL 70 Unscrew the two terminal block retaining screws A to remove terminal block and remove cross piece retaining screws at B The circuit block C foam block D and foam side piece E can now be removed in that order Disconnect vent pipe at F by pressing on the blue ring of the fitting while pulling on the pipe The Worklite box can now be tipped on to it s side so the battery stands upright and the top of the battery can be pulled forward and removed from the box Disconnect battery wires and replace battery Re fitting is the reverse of the above Ensure vent pipe is connected to fitting under flange Fig 3 Component Replacement Procedures Applies to all Models Switch Replacement Requires removal of enclosure lid see above i Disconnect the switch connector ii Using a spanner remove switch locknut and push switch through lid iii Place new switch in
9. l be separated from the head Take care not to damage the LED lenses when handling iv the LED board can now be disconnected from the connector block and the new LED board connected White to No 1 or brown Black to No 2 or blue v feed the LED board up in to the head and ensure that the thermal interface sheet W 428 for WL 85 and WL 80 or W 429 for WL70 is in position with holes aligned Insert and tighten screws W 404 and line up the lens clamp threaded holes with the screws Partially tighten Fit bottom plate and tighten the six screws vi Re assemble as per iii iv and v from Glass Lens Replacement See Fig 5 Note THERMAL GASKET MUST ALWAYS BE USED Torque Setting LED PCB Screws x4 2 5Nm Control Circuit Replacement Requires removal of enclosure lid see above Disconnect the Battery ii At the terminal block disconnect Lamp Output wires identified as 1 and 2 or blue brown and Yellow and Violet charge socket and also the two connectors to the switch and the indicator LED The circuit block can now be removed and the new Circuit fitted see Fig 6 for connections Always connect the battery last Torque Setting Terminal Block Screws 0 5Nm Description Battery Pt Circuit Spare No Pt No WL 85 12V 35 Ah 12 LED W 235 W 494 WL 80 12V 18 Ah 12 LED W 218 W 534 WL 70 12V 18 Ah 6 LED W 218 W 495 Cable Replacement ONLY USE GENUINE WOLF REPLACEMENT PARTS Requires disassembly of the h
10. merse Charging Use only the WL 150 Worklite Charger The charge socket cover must first be removed before the charger plug can be connected The Worklite indicator will show flashing Red and Green at all times when connected to a charger The WL 150 Charger was updated in Q4 2012 check the part number on the charger label before referring to the LED status description below Both chargers are compatible with all versions of the Worklite Charger Status LEDs Part No AC 0412A Pre Q4 2012 RED Mains power connected and charger is switched ON ORANGE Charging Cooling fan on fast speed GREEN Fully Charged Cooling fan on slow speed The charger continues to supply a trickle charge and can be left in this mode on standby Charger Status LEDs Part No 31AC0412A A03 Post Q4 2012 RED Mains power connected and charger is switched ON ORANGE Charging Cooling fan on fast speed GREEN Fully Charged Cooling fan on slow speed The charger continues to supply a trickle charge and can be left in this mode on standby This version of the WL 150 has a system to detect when the battery in the Worklite has reached the end of its life and cannot be charged At the end of the normal charging period if the RED LED is OFF and the other LED is ORANGE or GREEN then the battery in the Worklite must be replaced To ensure the ingress protection level is maintained The charge socket cover MUST be re fitted to the cha
11. rge socket and tightened beforehand Ensure area around charge socket is free from dirt Do not charge in Hazardous Area Charger operating ambient 10 C to 25 C Charger ingress protection IP20 protect from dirt and moisture Do not cover ventilation slots When charger is not in use disconnect from mains and Worklite The WL 150 Charger is CE marked in compliance with the 2004 108 EC EMC Directive and 73 23 EEC Low Voltage Directive Peak Output Current during charge period 4 0A Peak Output Voltage standby fully charged 14 6V max Voltage on Trickle Charge 13 8V FOR APPROXIMATE CHARGE DISCHARGE DURATIONS SEE TABLE 1 MAINTAINENCE Repair by qualified technicians ONLY Precautions should be taken when handling batteries do not allow terminals to short across any metal parts or objects Connect cables as per Fig 6 Do not allow cables to short or touch battery terminals at any time as this may cause damage to circuit Removal of lamp head Loosen handle bolts W 433 ii Loosen pivot bolts W 411 and whilst supporting the head remove pivot bolts retract the indexer and spread the side plates by approx 5mm lifting the head upwards and backward until it is free and it can then be rested upside down next to the box Avoid pulling on the cable When re fitting lamp head ensure threaded hole in lamp head aligns centrally with spacer washers and hole in frame prior to fully tightening pivot bolts Torq
12. tic lens covers W 200 12 LED Pk 3 can be fitted to protect the Worklite glass lens from damage Press Switch Once ON Full Power Press Switch Again ON Half Power Press Switch Again OFF Operation Battery Level Indication The indicator LED on the enclosure lid will indicate in the sequence as shown in table 2 Actual indication periods may vary as a result of temperature charge cycle battery condition and electrical tolerances When the battery level is very low the red indicator and beam will flash To assess whether a battery needs to be replaced the duration of a full discharge should be compared with table 1 If lt 70 replace the battery TABLE 2 Battery Deep discharge protection The lamp will automatically cut off when the battery reaches a pre determined low voltage A red followed by flashing red indicator and flashing beam will warn of imminent cut off The lamp must be re charged before further use or storage Storage Due to the self discharge characteristics of this type of Lead Acid battery it is imperative that it is charged every SIX months when in storage otherwise permanent loss of capacity might occur Replacement Battery WL 85 12V 33Ah pt no W 235 ONLY WL 80 amp WL 70 12V 18Ah pt no W 218 ONLY Head Angle Adjustment To adjust head angle for your work area retract the indexing plunger and angle lamp head Cleaning Use a mild soap and water and soft brush only Do not im
13. ue Setting Handle x2 10 0 Nm Torque Setting Pivot Bolts x2 6 0 Nm Use Loctite 222 on thread Removal of battery enclosure lid Remove the four retaining screws W 405 and lift and slide the enclosure lid rearward taking care not to pull on any of the connecting wires inside the enclosure Before carrying out any work on cable lamp switch or indicator connections it is important to disconnect the battery first Re fitting lid Ensure the vent pipe is properly fitted to connections and is tucked inside the enclosure Ensure the lid is fitted in the correct orientation and that seal W 300 is in place Ensure that no wires overhang this seal the box edge or the battery top foam or rest directly above the battery terminals when tightening each of the four lid retaining screws W 405 Tighten screws in equal increments to ensure lid lowers evenly Seal W 300 is bonded to the enclosure Torque Setting Battery Enclosure Lid Screws x4 3 0Nm Battery Replacement WL 85 Requires removal of both lamp head and enclosure lid To replace W 235 33Ah battery in a WL 85 First disconnect both wires from Go Fig 1 the battery Disconnect the vent pipe from the fitting under the flange by pressing on the blue ring to release the pipe Remove circuit top foam from under box flange and disconnect vent pipe from under flange Lift the encapsulated circuit block assembly from alongside the battery remove from the box and place next to the l
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