Turbolite Instructions - Wolf Safety Lamp Company
Contents
1. X TY Led mii i Jmm aw SN Z A384 j 105 E A 110 A 113 A85 A 106 _ lt a f oF o 2 aD eu e wr Fe D aie s A 86 A 22 A 22K CA 22GEN A 77 p M v CA 118s A 16 AE AP UE 2077 N i A19 nN y ONT NSSSSSSSSSSSNRNNNSNNNSNNSNNNS WA i CA 168 2 1 CA24 A 57m_ matt A 57p OR polished EXTERNAL FEATURES MAY CHANGE WITHOUT NOTICE Wolf Turbolite Types A TL44 and A TL45 Operation and Maintenance Instructions Introduction The Wolf Turbolites are 250 Watt Tungsten Halogen compressed air operated safety lamps Type 44 is fitted with a polycarbonate Bay Light head for general illumination the end user must check head material is suitable for the atmosphere the Turbolite will be used in Type 45 has a Reflector Head with either a Matt or Polished reflector providing wide angle or concentrated levels of floodlighting They are certified by BASEEFA Ex 78209X to Special Protection SFA 3009 for safe use in Zone 1 and Zone 2 Hazardous Areas with a Temperature Classification T4 This covers safe use in up2. Guard A 163 is screwed firmly down and locked as previously described Lubrication NOTE Any dust grit or dirt in the compressed air can contaminate the grease and bearings causing severe damage The bearings and grease must be clean to prevent damage appropriate air line filters must be used in dusty environments The magneto type Bearings require a medium grade non emulsifying grease which should be applied after 1000 hours running time Grease nipples are not fitted Access to the Bearings requires removing just the three Fastening Screws A 18 in the Housing Cover A 21 Should the Housing Cover resist removal then the edge of the rim should be tapped with a mallet at several points to free the joint The Rotor Assembly A 85 can then be lifted out of the open Generator Housing This will require either a pair of pliers or the aid of Key A 146 on Nut for Rotor Shaft A smear of grease can then be applied to the caged Bearings on each end of the Rotor Shaft and the races situated in the Generator Housing and Housing Cover respectively Before replacing the Rotor Assembly make sure that no small ferrous objects have been attracted to the Magnet Care must be taken when replacing the Assembly to avoid fingers becoming trapped between the Turbine Wheel and the Generator Housing as the Magnet is attracted to the Stator Replacing Bearings Remove Nut for Rotor Shaft A 37 on the Rotor Assembly Washer A 101 Bearing A 40 Turbine W
3. Lockscrew A 74 Replacing Cleaning Glass Disc Type A TL45 THE REFLECTOR HEAD OF THE WOLF TURBOLITE LAMP IS A PRESSURISED ENCLOSURE The lens ring A 24 retains the glass disc A 140 15mm To remove unfasten the four high tensile Stainless Steel Fastening Screws A 18 The Glass Disc is mounted inside the Grooved Rubber Washer A 139 the Reflector sits in the Reflector Head These items can be removed for cleaning replacement The Grooved Rubber Washer in particular should be inspected for any damage as this provides a pressurised seal on both faces of the Reflector Head enclosure When re assembling ensure that this Washer is evenly fitted on both faces of the Glass Disc Place reflector in reflector head before the lens and seal Refastening of this assembly into the Reflector Head must follow normal good practice in fastening down a flanged joint the four Screws A 18 should be fastening down evenly and only tightened sufficiently to make an airtight seal INCORRECT FASTENING OF THESE SCREWS CAN CAUSE The toughened Glass Disc to shatter e The Grooved Rubber seal to become damaged e Weakening of the Fastening Screws e Stripping of the threads in the Reflector Head Replacing Cleaning Ball Glass Type A TL44 After cleaning replacement as necessary the Ball Glass A 19 together with Grooved Rubber Washer A 158 is fitted in the Generator Housing recess first followed by Metal Washer A 16 then the lock Screw Ring
4. to T4 range of explosive gases and vapours as listed in IEC 60079 20 Quality Assurance Standards to ISO 9001 2008 apply to manufacture assembly and final inspection and testing of all lamp units Wolf Turbolites are certified compliant with the 89 336 EEC EMC Directive Operating Instructions The operating pressure of the Wolf Turbolite is between 4 5 and 8 bar The pressure regulator of the lamp unit compensates for the above range of input pressures as well as fluctuations in airline pressures WARNING DIRT OR MOISTURE FROM UNFILTERED AIR WILL DEPOSIT ON THE INSIDE OF THE GLASS DISC OR BALL GLASS REDUCING LIGHT OUTPUT IN A HAZARDOUS AREA SHUT OFF AIR SUPPLY AND WAIT TWO MINUTES BEFORE DISMANTLING THE LAMP THE REFLECTOR HEAD AND BALL GLASS OF THE LAMPS ARE PRESSURISED ENCLOSURES DO NOT COVER OR OBSCURE LIGHT TRANSMITTING PARTS POLYCARBONATE BAY LIGHT CHECK ATMOSPHERE IN EX AREA Maintenance of Wolf Turbolite The maintenance and repair of Wolf Turbolite lamps should only be undertaken by trained or qualified electrical fitters or engineers Lamps should be cleaned and tested every three months if in regular use and every six months where use is less frequent As a guide reference may be made to BS EN 60079 14 1997 IEC 60079 14 1996 Electrical Apparatus for Explosive Gas Atmospheres Electrical Installations in Hazardous Areas BS EN 60079 17 1997 IEC 60079 17 1996 Inspection and Maintena
5. Wolf Turbolite Types A TL44 and A TL45 Parts List Type A TL44 Type A TL45 Type A TL44 Type A TL45 Part No Description Part No Part No Description Part No BAYLIGHT FLOODLIGHT A 6 Screw for Air Inlet Plate 6 A 6 A 105 Air Inlet Plate 3 A 105 A 7 Screw for Stator 3 A 7 A 106 OQ Ring Seal for Air Inlet Plate 3 A 106 A 8 Wing Nut for Bridle Bolt 2 A 8 A 109 Air Regulating Plate A 109 A 11 Bridle Bolt for Wing Nut 2 A 11 A 110 Piston Complete A 110 A 13s Bridle with Safety Hook A 113 Piston Spacer A 113 A 16 Metal Washer A 114 Spring for Piston Silver Passivated A 114 A 18 Stainless Steel Fastening Screws A 115 Diaphragm A 115 3 TL44 7 TL45 A 116 Lockscrew for Piston Chamber A 116 A 19 Ball Glass A 118s Bulbholder complete A 118s A 21 Housing Cover A 129 Bulb 24v 250w Tungsten Halogen A 129 A 22K Generator Housing Complete A 133 Connecting Tube A 133 A 22 Generator Housing only A 134 Overthrow Nut A 134 A 22GEN Generator Housing Assy Grooved Rubber Washer 15mm A 139 Reflector Head Glass Disc 15mm toughened A 140 Reflector Head Assembly Grooved Rubber Washer Lens Ring Bulb 24v 250w Tungsten Halogen A 159 Lock Nut for Regulating Screw High Output Regulating Screw Lockscrew Ring Guard Air Filter Sieve Wing Nut Retaining Clip 2 Connecting Piece Waved Spring Washer for Bearing 2 Nut for Rotor Shaft Turbine Wheel Ball Bearing with Race 2 Rotor Shaft Insulating Bush 2 Tools and Accessories for us
6. ady for resetting the pressure regulator and hence the generator electrical output Setting Generator Voltage Output A clean dry air supply of suitable pressure should be coupled up to the Lamps As Regulating Screw A 29 is screwed in using Pressure Regulating Keys A 68 the air supply will start to drive the turbine Progressively as more air is supplied the turbine generates more electrical power Finally the point will be reached where the bulb output starts to oscillate The Triac device in the Alternator Circuit at this point switches power from the Bulb to the Resistance Coil and back to the Bulb in slow cycles The regulating Screw should then be turned out slowly until the oscillation stops A further half to full turn anti clockwise will provide the correct Generator output of 24 volts The Regulating Screw should then be locked with Lock Nut A 28 The Lockscrew A 116 together with Collar A 98 should be replaced in the end of the Piston Chamber to prevent any unauthorised tampering NOTE The Triac is designed to trigger at 27 volts and as well as a means of setting the Generator output it is also a bulb failure open circuit protection device preventing over speed of the Rotor in these circumstances Replacing Bulbholder Assembly Since January 1993 the new type Bulbholder has been fitted to all Turbolites and incorporates a proprietary ceramic bi pin holder and the whole unit is sealed in production but is otherwise a d
7. e with Wolf Turbolite Lamps Tools A 68 Pair of Pressure Regulating Keys A 146 Key for Nut No A 37 A 170 Hexagon Key for A 18 3 16 A F A 171 Hexagon Key for A 74 2 5m m A F Screw for Stator Terminal 2 Stator Winding Reflector Matt Reflector Polished Lock Washer for Bridle 2 Lock Screw for Rfl Hd Guard O Ring Seal for Reflector Head Magnet Accessories A 178 Lubricant 400 gram tube A 178 A 179 Antistatic Hose bore 18 3m 607 A 179 A 180 Antistatic Hose bore 36 6m 120 A 180 A 181 Stainless Steel Hose Clips A 181 A 184 Filter Automatic Drain Unit 2 Lamps A 184 A 186 Ultra High Efficiency Two Stage Filter A 186 Nut for Stator Terminal 2 Automatic Drain Unit 2 Lamps Collar for Lockscrew A 300 Folding Tripod Stand A 300 Washer for Rotor Shaft Nut Rotor Spacer Rotor Assembly Washer for Stator Terminal 2 WOLF SAFETY LAMP COMPANY Saxon Road Works Sheffield S8 OYA England Tel 44 114 255 1051 Fax 44 114 255 7988 SS Wolf E mail info wolf safety co uk Website www wolf safety co uk ISO 9001 Wolf Safety Lamp Company AL 92 Issue 4 MMD 5 11 K Wolf Wolf Safety Lamp Company WOLF URBOLITE Types A TLA4 and A TL45 OPERATION AND MAINTENANCE INSTRUCTIONS 8 134 A 83 A 115 A 114 A 28 A 98 i T T Cn 7 133 34 109 A 29 er T z 94 A 37 f ED xx SS NEM DEP V S CS
8. heel A 38 Magnet A 180 and Rotor Spacer A 102 and finally second Bearing A 40 from the Rotor Shaft A 41 These parts should be cleaned and replaced in reverse order together with new bearings Underneath each of the outer races of the Bearings is fitted a Waved Spring Washer A 36 These ensure the correct loading of the bearings It is important to check that these Waved Spring Washers are in good condition before fitting the new outer Bearing races Air Regulator Assembly All the Air Regulator parts are secured by Connecting Piece A 34 and should not be disturbed unless the Regulator ceases to function correctly The Connecting Piece also serves to align the Air Regulating Plate A 109 the Piston Spacer A 1183 the Piston Complete A 110 fitted with rolling diaphragm and lastly the Spring for Piston A 114 These parts are withdrawn from the front of the piston chamber and should be cleaned and examined for wear and damage and replaced as necessary In particular the fabric and beaded rim of the diaphragm should be checked for damage Before re assembly of the Piston parts the Regulating Screw A 29 and Lock Nut A 28 must be removed from the other end of the piston chamber Hexagon Lock Key A 171 will be needed to remove Lockscrew A 116 and Pair of Pressure Regulating Keys A 68 to remove Regulating Screw and Lock Nut The Regulating Screw A 29 and Lock Nut A 28 should then be loosely fitted just inside the end of the piston chamber re
9. irect substitute for the old one The Triac Control Assembly is integral with the Bulbholder Complete A 118s The Bulbholder is positioned inside the Reflector Head Ball Glass fastened by the two Nuts A 88 on Screw for Stator terminal A 53 which pass through the wall of the Generator Housing These Screws are insulated and sealed by insulating Bushes A 52 and carry the power from the Stator Winding A 54 If removed it is essential to ensure that the Insulating Bushes are in good condition because as well as providing electrical insulation they also provide a pressure seal between the Reflector Head and the Generator Housing Use of Wolf Turbolite in Hazardous Areas The introduction details the Hazardous Area Zones of Use and the Temperature Classification of the Turbolite but users are advised to consult BS EN 60079 14 1997 IEC 60079 14 1996 Electrical Apparatus for Explosive Gas Atmospheres Electrical Installations in Hazardous Areas before operating in a Hazardous Area Conditions of Certification X are that clean dry compressed air must be used to power the lamps through anti static air hose of resistances between connection 10 ohms maximum and 10 ohms minimum to NCB Specification P182 or BS 2050 These lamps are not solidly earthed and when used in Tankers and precautions against the hazards of static electricity in cargo tanks as set out in the International Chamber of Shipping Tanker Safety Act Petrole
10. nce of Electrical Installations in Hazardous Areas The use of incorrect spare parts and the improper fitting of spare parts will invalidate certification and the Manufacturer s Guarantee Full details of maintenance and repair procedures follow If in doubt contact the Company Bulb Changing The 24 Volt 250 Watt Tungsten Halogen Bulb should be handled with care if it becomes misted or dirty it should be cleaned with a soft cloth moistened with methylated spirit TYPE A TL45 To gain access to the Bulb the Reflector Head A 23A is unlocked by releasing Lockscrew A 74 which allows it to be unscrewed from the Generator Housing TYPE A TL44 Lockscrew Ring Guard A 163 for Ball Glass is removed from the Generator Housing in the same manner Care should be taken to avoid damaging the replacement Bulb when locating the pins in the spring loaded contacts of the new type of Bulbholder in use since January 1993 For the old type of Bulbholder the bulb pins are released by slackening screws for contacts and then re tightened so that the bulb pins are firmly clamped by the contacts on each side of the Bulbholder In future Contacts A 122 and A 123 will be the only spares available for the old type Bulbholder When replacing the Reflector Head screw down on to the O ring A 77 with sufficient torque to seal the pressurised enclosure For Type 44 sealing is internal by way of A 158 Grooved Rubber Washer for Ball Glass In both cases refasten
11. um as amended or The Oil Tanker and Terminal Safety Guide 1977 edition should be observed Major changes in design are permitted as Variations of Approvals but may otherwise be made without prior notice
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