hELLA MINING - Norco Inc

hELLA MININGCATALOGUE

5th Edition

Technology with Vision

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 +61 3 9581 9333 F +61 3 9585 2654 E [email protected] W www.hellamining.com

Go to www.hellamining.com for

Comprehensive information about all HELLA Mining products

New HELLA Mining products

Contact details for all international offices of HELLA Mining

Downloadable catalogues and publications

www.hellamining.com

The illustrations, information and specifications presented and referred to in this catalogue were correct at the date of publication. 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.

© 2013 HELLA Australia Pty Ltd. All rights reserved. Publication date February 2013.

1CONTENTS

Contents

ContentsAlphabetical

2 About HELLA Mining

3 Applications Engineering

4 Case history – rosebel Mine

5 What’s new

6 How to read this catalogue

WORK LIGHTS8 As 5000LEd®

10 Power Beam 3000

11 Power Beam 1000

11 Compact LEd Work Light

12 Megabeam

12 Module 70 LEd

13 LEd Task Lights

14 duraLEd® 1000 Lumen


16 As500®FF Xenon

18 As500®FF Halogen

19 Modul 70 Halogen

20 WL200 Halogen

A8 As 5000LEd®

66 AC/dC Transformers

16 As500®FF Xenon


B41 Battery Master Lockout

switches

C49 CargoLEd®

68 Circuit Breakers


67 Compact LEd

rocker switches

D61 double Crimp Connectors

46 dT Connectors

60 dT Connectors

EMERGENCYBEACONS 22 durarAy3®

23 K-LEd® Mining

24 UltrarAy® dual

25 UltrarAy®-r Twin

26 UltrarAy®-r “rotating”

27 UltrarAy®

28 NaviLEd® M

29 OptirAy®

30 OptirAy® E

31 duraLEd® M High intensity

32 PulserAy® KLX

32 PulserAy® E67

SIGNAL LAMPS34 duraLed® rCL

35 duraLEd® M Combi

36 duraLEd® sAE & ECE

37 duraLEd® MsiP

37 LEd daytime

running Lamp

38 duraLEd® M Marker



35 duraLEd® M Combi


38 duraLEd® M Marker

37 duraLEd® MsiP

34 duraLed® rCL


22 durarAy3®

E48 EuroLEd® Touch M

58 EziPAK® service Kits

G71 Globes H1, H2

72 Globes H3

73 Globes H4

74 Globes H7, H9, H11

75 Globes Xenon

ACCESSORIES40 LEd Buggy Whip

41 Battery Master Lockout

switches

42 screened Extension Cables

43 remote Jump start

Terminals

43 Weatherproof relay

43 self-Amalgamating Tape

43 Nitto Tape

44 NumiLEd®

45 NumiLEd® Pro

46 dT Connectors

INTERIOR LIGHTS48 EuroLEd® Touch M

49 CargoLEd®

50 MiniThinLEd®

H56 Handy Box® service Kits

63 Heat shrink sleeving

K23 K-LEd® Mining

L40 LEd Buggy Whip

37 LEd daytime running

Lamp

62 LEd Fuses

67 LEd Pilot Lamps

13 LEd Task Lamps

M69 MagCode Power Outlet

systems

12 Megabeam

50 MiniThinLEd®

19 Modul 70 Halogen

12 Module 70 LEd

52 MotoVOX® Horns

HORNS & ALARMS52 MotoVOX® Horns

53 retroVOX® Alarms

54 retroVOX® Broadband

Alarm

SERVICE TOOLS56 Handy Box® service Kits


60 dT Connectors

61 double Crimp Connectors

62 LEd Fuses


64 super seal Connectors

ELECTRICAL66 AC/dC Transformers

67 Compact LEd

rocker switches

67 LEd Pilot Lamps

67 Power Connectors

68 Circuit Breakers

69 MagCode Power Outlet

systems

N28 NaviLEd® M

43 Nitto Tape

44 NumiLEd®

45 NumiLEd® Pro

O29 OptirAy®

30 OptirAy® E

P11 Power Beam 1000

10 Power Beam 3000

67 Power Connectors

32 PulserAy® E67

32 PulserAy® KLX

R43 remote Jump start

Terminals


54 retroVOX® Broadband

Alarm

GLOBES71 Globes H1, H2

72 Globes H3

73 Globes H4

74 Globes H7, H9, H11

75 Globes Xenon

TECHNICAL78 General information

79 What is LEd Technology?

80 What is Xenon lighting?

81 HELLA Work Light systems

82 MustAdd® Filter technology

83 iP Codes

PARTS INDEX84 Part Number index

S42 screened Extension Cables

43 self-Amalgamating Tape


U27 UltrarAy®

24 UltrarAy® dual



W43 Weatherproof relay

20 WL200 Halogen

X75 Xenon Globes

2 hELLA MINING

The HELLA Mining Centre of Excellence was created in Australia ten years ago to design, develop and manufacture fixed and mobile lighting products specifically for the mining industry. HELLA uses its research, engineering and logistic expertise to produce lighting products that are designed to world class standards that can be used in mining applications all over the world.The research behind the product selection is based upon data collected from mining equipment in use in many different regions and applications. This data was utilised to set performance parameters as a baseline criteria for survival in a mining application. These parameters are used in testing our products in house before we can be confident to release them to mining field trials and later for general release to the mining industry. This process is vastly different to most of our competitors that will pass on products designed for other target segments and “offered for trial” to mining companies with little idea of the outcome.The product sale is also very different to our competitors as only HELLA Mining offer mining companies a free of charge engineered application service. This service offers the end user information on the product, aiming angles and actual lighting performance prior to any purchase that includes safety as a key area of concern. This service highlights to the customer that HELLA Mining are the mining professionals for lighting and assists our customers with another value proposition to their mining purchase.An area of concern to mining companies with global shareholders is safety and environment. Any negative concerns from ongoing environmental or safety issues can clearly affect the share price of these multinational firms and therefore there is a major focus on HsE (Health, safety and the Environment). HELLA Mining has advanced lighting technology that meets the criteria for enhanced safety as vision plays a vital part in an environment that operates 24 hours a day and has large mobile machinery capable of destruction on a grand scale and a highly mobile road network.HELLA Mining products meet the needs of mining companies around the world. The concept of Technology With Vision highlights the fact that we exceed our customer’s expectations by producing quality products that fulfil the requirements for the harshest industry on earth in an efficient, advanced and professional manner that offers real technology with vision.HELLA Australia is equipped with highly advanced production and distribution facilities.HELLA Australia has 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 valueHELLA 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 (1) year warranty which covers faults in material or workmanship only and provided that the product is used for its intended purpose except for globes, ballasts, fuses and sealed beams, which are on fitment. All HELLA Mining LEd products are covered by a five (5) year warranty on light output, excluding environmental and physical damage.

Important NoteOnly 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. Please ensure local reguations and requirements are met.

PROJECT ARGON: CHARTING THE EXTREMESdeveloping lighting equipment to go the distance in mines requires a deep understanding of their operating systems and specific environmental conditions.At HELLA, we don’t guess, we measure. HELLA Australia’s PrOJECT ArGON collects and researches 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.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.

About HELLA Mining

3hELLA MINING

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 positively input into 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-focused, 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

4 hELLA MINING CASE STUDY

IAMGOLD Rosebel mine boosts safety with HELLA lampsCase study

iAMGOLd’s “rosebel” mine is located in a remote area of suriname, with an attributable production in 2012 expected to be between 360,000 and 380,000 ounces. Gold was first discovered in the rosebel area in 1879. since its discovery, the land has been both publicly and privately owned and operated. A Mineral Agreement between Golden star, Grassalco and the Government of suriname, was granted in 1994 and a final Feasibility study was completed in August 2002.

Commercial production commenced in February 2004 and iAMGOLd acquired rosebel as part of its acquisition of Cambior in late 2006.

IAMGOLD’s Commitment to Safety, Accountability and People – The Installation of two HELLA High-Intensity Gas Discharge lights (HID - Xenon) Flood, mounted on Sandvik™ drills:

A workforce should always be committed towards ZErO harm. Looking at challenges in order to improve our day to day operations and mitigate risks is an ongoing battle but one we can win.

in April 2011, during a regular pit tour a safety officer and the general foreman observed that the lightning intensity around the 13 sandvik™ drills could be improved, especially in the dust hood areas where the drill offsiders must perform operational tasks such as changing drill bits, sampling and guiding the operators during night shift.

A pilot test was done on the 010-215 drill and the results were excellent.

Two of the standard halogen lights were replaced with High-intensity Gas discharge Lights (Hid - Xenon). One light was mounted on the top of the cabin and another one next to the dust hood.

The benefit of these High-intensity Gas discharge Lights (Hid - Xenon) is that they increase the lighting intensity and distribution around the drill and also the visibility for the driller and the drill offsider in the dust hood area. The improved levels of lighting significantly reduce the risks of accidents associated with the work conducted by the drill offsiders in the dust hood area.

AFTER

BEFORE

5hELLA MINING

HELLA Mining products are covered by a one (1) year warranty which covers faults in material or workmanship only and provided that the product is used for its intended purpose except for globes, ballasts, fuses and sealed beams, which are on fitment. All HELLA Mining LEd products are covered by a five (5) year warranty on light output, excluding environmental and physical damage.

AS 5000LED®

Heavy duty LEd Work Light – Page 8 5000 Lumens state of the art heavy duty work light range, tailored to mining requirements.

Power Beam 3000LEd Work LightPage 10 3100 Lumens from a compact high-powered, low wattage illuminating source.

Compact LED Work LightMultivolt™ 9-64V dCPage 11 Very cost-competitive compact, lightweight LEd task light for close range illumination.

WL200Halogen Work LightPage 20All the performance and reliability you expect from a HELLA halogen work light, in a compact, low cost package.

DuraRAY3®LEd rotating BeaconPage 22 The third generation of this award winning beacon ushers in a new era of innovation in mining beacons.

Handy Box®service KitsPage 56 New handy range of kits combine technical and economic demands without compromising quality.

AC/DC Electronic TransformersPage 66 For mains low voltage applications such as LEd lighting, and meeting the vigorous demands of mining.

K-LED® MiningLEd rotating & Flashing BeaconPage 23 A new benchmark in mining beacons, with benchmark CisPr25 Class 5 EMi footprint.

UltraRAY®-R Dualdual Colour LEd BeaconsPage 24 New dual colour beacons eliminate the need for multiple lamps where different colour warnings are required.

DuraLed®-RCLrear Combination LampPage 34 Compact “Fit-and-Forget” lamp

using the latest technology.

What’s new in this catalogue

hELLA MINING6

24 HELLA MINING EMERGENCY BEACONS

UltraRAY®

-R DualDual Colour LED Warning Beacon

Either of the UltraRAY®Dual’s colours can be run on its own or both can display sequentially– and a rotating or flashing pattern can be hard-wired or controlled by an in-cabin switch. UltraRAY® beacons are extremely robust, tolerant to severe vibration levels and very compact in design. A high impact and shock resistant, polycarbonate lens is 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. They are maintenance free with no moving parts or fragile globes.UltraRAY® Dual 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® Dual 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.

New UltraRAY® Dual warning beacons eliminate the need for multiple lamps where different colour warnings are required. They output high visibility dual colours and can be used as signal lights to indicate current states of equipment (e.g. amber/red beacon – red: vehicle has stopped, amber: vehicle is in motion).

PRODUCT fEATURESDual colour beacon allowing flashing or rotating patternCan run one colour only or both colours intermittentlySwitching between colours and patterns by hardwiring or by the use of a toggle switchC-tick compliant,EMC compliant to CISPR25 Class 2Direct mounting

Impact resistant polycarbonate lensPrecision fresnel opticsPowder coated cast alloy baseDirect, pipe mount or magnetic installation optionsfully encapsulated electronicsDouble insulated supply cableO-ring sealsHigh efficiency long life LEDUnique Helioshield™ ambient light suppression improves daylight visibility

SPECIfICATIONSMultivolt™ 12 –30V DCPower 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 IP6K5Shock resistant to 200G

SPARE PARTS9.HM450WLENS White PC Lens

HM400PIPE Pipe Mount Kit9.HM450fLX flexiMount Adapter

IP6K5 200G 12 to 24 V DC

20WMAX.LED

BARE WIRE

0.9KgMULTIVOLT

SAECOMPLIANT

132

130

3 x Ø4equispacedon PCD130

4 x Ø4equispacedon PCD 178

136

187

120°

120°

132

130



136

187

120°

120°

l Amber /l Red Direct Mount HM450ARDIRl Green / l Red Direct Mount HM450GRDIR

HM450GRDIR UltraRAY®Lamp Dual Colour GREEN/RED

HM450ARDIR UltraRAY®Lamp Dual Colour AMBER/RED

Optic appears clear until illuminated

HELLA Mining Part Numbers

Product Features

Product description

Page number

Product section

Product dimensions

spare parts or options

specifications

Product feature symbols (see above for key)

How to read this catalogueKey to symbols:

Multivolt™

MustAdd® Filters

drACO® dampening

MultiFLAsH®

HELLA Product Features

DRACO

MULTIFLASH

MULTIVOLT

MUSTADD

Standards Compliance:

Electrical Compliance

Public road trafficcompliance type

ECE APPROVED

Protection/Hazard Ratings:

iP rating

Transient spike protection

rated shock resistance

IP6K

200G

Electrical:

rated voltage

Power consumption/load

24V

3W

Configuration:

Lamp type

Connection type

Mass1.4Kg

DT

H3

WOrK LiGHTs8 As 5000LEd®

10 Power Beam 3000

11 Power Beam 1000


12 MegaBeam

12 Module 70 LEd

13 LEd Task Light

14 duraLEd® 1000

14 duraLEd® Magnetic Base

15 duraLEd®700

16 As500®FF Xenon


19 Modul 70 Halogen

20 WL200 Halogen

8 hELLA MINING WORK LIGhTS

HELLA has developed As 5000LEd® – the next generation of LEd work light, one specifically designed for the rigours of the mining environment.By utilising the latest technology and materials, HELLA has achieved a new level of performance for LEd lighting, without sacrificing those qualities essential to the mining environment.As 5000LEd® is a match for the extreme environmental conditions encountered in mining, and succeeds where many competitors have failed.24 High Power LEds deliver over 5000 Lumens of light exactly where it is required, through highly developed optics available in two variations. The As 5000LEd® boasts an efficient 60 Watts power consumption, giving it a luminous efficacy close to 100 Lumens/ Watt.As 5000LEd® operates on reduced power mode below 11.6V to prevent battery drain on mobile equipment when lights are on but the engine is not running. HELLA has taken advantage of long underground mining experience in the development of heavy duty work lights, with an integrated dimming function in As 5000LEd, suitable for vehicle passing and efficient above ground daylight operation.The dimming function reduces light output to around 50% and can be controlled by the activation of a second active wire via a switch or other means.The advanced electronics of the luminaire ensure stable operation in a wide range of electrical supply conditions. The lamp is protected from reverse polarity input and short circuit faults. As 5000LEd® is designed to operate at the extreme range of temperatures often encountered in underground and surface mining, from –40° to +50° Celsius. integrated thermal protection ensures longevity of the electrical components at the most extreme temperatures.

An advanced non-stick surface coating prevents dirt build-up on the light and is resistant to acidic minerals and salts. The coating is bonded to the housing and will not peel or flake. The light can be high pressure cleaned.

A high impact resistant Grilamid® lens protects the luminaire from damage, and is UV stable.

A colour temperature of 5700°K mimics daylight and ensures a high colour-rendering index, critical for performing work functions.

The double insulated silicon sheath high temperature cable provides a high quality electrical interface with the supply system. A heavy-duty cable gland provides strain resistance for the cable under extreme vibration.

A specially designed driver board ensures advanced thermal management drawing the heat away from the LEds.

HELLA maintains its high standards in electrical certification with the As 5000LEd® LEd work light, with approvals for CE, C-Tick Compliance, CisPr25 Class 2 and isO13766-2006 for earth moving machinery.

HELLA is proud to introduce into its state of the art LEd work light range – the As 5000LEd, a high output, compact and highly versatile heavy-duty work light for use on mining machinery, and suitable for dC electrical systems.

PrOdUCT FEATUrEsOver 5000 Lumen measured outputdC Voltage model suitable for 9-33V with reduced power low voltage operation 6–11.6VdCdraco® suspension combined with Heavy duty 316 stainless steel bracketWide beam (close range) and narrow beam (long range) models availabledouble insulated silicone supply cable with dT connector

Fully sealed LEd requires no servicingswitchable dimming function version availableNon-stick and easy to clean surface coatingHigh impact Grilamid® nylon lenssuitable for operation in –40C° to +50°C environmentsHeavy duty cable gland offers bend protection

AS 5000LED®

Heavy duty LEd Work Light

DRACO IP6K9K 200G 12/24V 60WLED DT 2.6Kg

168 13

0

204

161

168

168 13

0

204

161

168

020

20

2.5m high at 5°

0 15030 60 90 12020

20

AS 5000LED Narrow Beam

020

20

2.5m high at 5°

0 15030 60 90 12020

20

AS 5000LED Wide Beam

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.

Part No’s. Close range Long range9-33V dC HM1500WB HM1500NB9-33V dC dimmable HM1500WBD HM1500NBD

PIN A+

PIN B–

PIN CDIM

TRIGGER

dT configuration

9hELLA MINING WORK LIGhTS

Unde

rgro

und

Min

ing

Fixe

d Pl

ant

surfa

ce M

inin

g

Mai

ns V

olta

ge

Mob

ile E

quip

men

t

As 5000LEds installed on a d11

10 hELLA MINING WORK LAMPS

110

144

109.9

130

hELLA MINING WORK LIGhTS

Power Beam 3000LEd Work Light – Multivolt™ 9-33V dC

By combining 16 high-powered LEds into a compact fully sealed die cast housing, the Power Beam 3000 achieves an outstanding 3100 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 life span of over 130 times that of a halogen bulb, in addition to excellent ingress protection make the Power Beam 3000 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 3000 also features reverse polarity protection, and overheating protection, which turns the light off when the integrated thermal sensor is triggered. The Power Beam 3000 comes pre-wired with a 150mm high temperature resistant pigtail loom with pre-connected 2 pin dT plug, for quick, 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 3000 has been developed as a compact high-powered illuminating source.

PrOdUCT FEATUrEsOperating voltage: Multivolt™ 9-33 V dC16 high power LEds Power consumption: 43 W Light output 3100 lm Colour temperature 5700°K High impact Grilamid® nylon lensLow EMC signature (CisPr25 class 5) Environment temp -40 to +50°C

die cast aluminium housing, bracket made of stainless steelingress Protection iP6K7 and iP6K9K Life span up to 130 times of a halogen bulb 200G shock testedConnection: Pigtail loom with high temp silicone cable and 2 pin dTPolarity protected LEd fail bridge High-temperature protection

Power Beam 3000 Close range HMPB300WBPower Beam 3000 Long range HMPB300NB

IP6K7 IP6K9K 200G9 to 33 V DC

43WLED 1.4KgMULTI

VOLT

Power Beam 3000 LED 2.5m high at 10°

dT configuration

11hELLA MINING WORK LAMPShELLA MINING WORK LIGhTS

Combining 6 high-powered LEds in a compact, fully sealed die cast housing, Power Beam 1000 provides 850 Lumen output for close range illumination.A rated operating temperature from -40 to +50°C and an expected life span of over 130 times that of a halogen bulb, plus excellent ingress protection, make it 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 from 9 to 33V dC. it also features reverse polarity protection, and overheating

protection 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.

A very cost-competitive LEd task light – its features include iP68 approval, flylead and a soft diffuse light pattern (wide beam pattern). Typical applications include general area lighting around machine walkways, stairs, engine bays, forklifts and cargo trays on a light vehicle fleet. The Multivoltage range makes this

versatile product useful in many different applications. The Compact LEd Work Light comes fitted with bare wires for multiple applications.

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

The Compact LEd Work Light is a lightweight close range light designed for general illumination in areas where physical restraints in mounting locations exist.

PrOdUCT FEATUrEsMultivolt™ 9-32 V dC6 high power LEds Power consumption 18 W Light output 850 lm Colour temperature 6500°K PMMA LensLow EMC signature (CisPr25 class 5)

Environment temp -40 to +50°C iP6K7 and iP6K9K Lasts up to 130 x halogen bulb 200G shock testedConnection – integrated dT plugPolarity protected LEd fail bridge High-temperature protection

sPArE PArTs9.1551LEd.06 dT Pigtail Loom, 2 metres9.1517.08 Universal Pedestal Mounting Bracket

sPArE PArTs9.1537.08 Universal Magnetic Mounting Bracket

PrOdUCT FEATUrEs900 lumen output per lamp (gross lumen) Multivolt range 9V dC to 64V dC Only 0.6A current consumption at 12V dC impact resistant polycarbonate lens

die-cast aluminium housing iP 68 rated integrated multiple lamp linking systemOperating temperature -40ºC to + 60ºC. stainless steel mounting bracket

IP6K7 IP6K9K 200G9 to 33 V DC

18WLED 0.6 KgMULTI

VOLT

Power Beam 1000LEd Work Light – Multivolt™ 9-33V dC

Compact LED Work LightLEd Work Light – Multivolt™ 9-64V dC

LEd Work Light HMPB100

LEd Work Light HM1590WB

112

142

62

114.596

6257.4

82.3

27.6

Power Beam 1000 LED 2.0m high at 10°

1 LUX 39m

IP689 to 64 V DC 6WLED 0.33 KgMULTI

VOLT 200G

12 hELLA MINING WORK LAMPS

Unitary design bonding a cast aluminium free-form (FF) reflector, clear glass lens and high-temp polymer housing into a light, efficient, very compact lamp. High-performance white LEd for ‘fit & forget’, sealed lamp requiring no service. A very long service life and no lighting loss due to internal dirt build-up gives reliable lighting under extreme conditions. Low power consumption and Multivolt™ operation. Free-form (FF) reflector optics with a clear lens optimise light distribution for even illumination with maximum efficiency. The die cast aluminium body is a massive heat sink; it fits easily into confined spaces.Withstands extremely high levels of vibration and mechanical shock, and

suitable for extreme cold or mechanical stress where other work lamps are unsuitable. Low power consumption and compactness also makes it suitable inside confined spaces, with portable power packs, on new generation small equipment based on recreational vehicles, battery powered vehicles and to illuminate equipment bays, onsite service vehicles and large machinery.standard rotating base – allows vertical adjustment of + 48° to -115°, and 360° rotation. stainless steel bracket is non-resonant and corrosion resistant. Optional pipe mount adaptors with/without rotating adjustment available. Additional variants available on 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 Light – Multivolt™ 12-24V

Completely sealed waterproof LEd work lamp that is fit-and-forget. Very long service life combined with no lighting loss due to internal dirt build-up, means reliable lighting under extreme conditions. Low power consumption and Multivolt™ operation. Free-Form optics and a clear lens optimise light distribution of the high intensity white LEds to give homogenous, efficient large area illumination. The die cast aluminium body is a massive heat sink, giving maximum service life and LEd output. The efficient compact unit fits confined spaces.

Fully encapsulated Multivolt™ circuitry delivers consistent illumination from 12-24V dC – even with severe voltage fluctuations and low battery voltage. Protection against reverse polarity, high-voltage spikes and over-voltage.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.

PrOdUCT FEATUrEs2m double insulated cable with bare wire ends or short length with dT connector stainless steel bracket iP5K9K Multivolt™ 12V dC to 24V dC die cast aluminium bodyAnti-corrosion powder coat Clear glass lens

Fully sealed “Fit and Forget” spike protected to +500 voltsOvervoltage protected to +200Vreverse polarity protected -500VPower consumption 7W200G shock impulse resistant-40ºC to +50ºC temp rangeCE compliant

IP5K9K 200G 12 to 24 V DC

7WLED

DT 0.8KgMULTIVOLT

MegaBeamLEd Work Light – Multivolt™ 12-24V

LEd Work Light HM1539LEDLEd Work Light dT HM1539LDD

LEd Work Light dT HM70LEDD

Clear cover to be ordered separately

sPArE PArTs & OPTiONsHM8161 Clear Protective Cover

PrOdUCT FEATUrEsWarm white light (6500°K)200mm double insulated cable harness with dT connectorPower Consumption 15WMultivolt™ 12-24V dCHigh-sheen free-form reflectorAluminium die cast housingModern clear glass lensresists shock and vibrationTemp range -40°C to +50°Cshock resistant to 200G

reverse polarity and Transient Voltage suppressor (TVs)Fully sealed against dust and moisture to iP6K7 and iP6K9K. stainless steel pedestal bracket for upright, side or pendant mounting

IP6K7 200G 12 to 24 V DC

15WLED

DT 0.4KgMULTIVOLT

HM70Pr HM70Pi10

552

Ø15-28

sPArE PArTs & OPTiONsHM70Pr Pipe mount tube attachment (rotating)HM70Pi Pipe mount tube9.HM70Br st. steel bracket

hELLA MINING WORK LIGhTS

83

111

M10

83

75

136 49

5342

Narrow Beam Optic HM1535NB

Pencil Beam OpticHM1535PB

Wide Beam Optic HM1535WB


HELLA compact, low power LEd Task Lights suit various applications where low profile fitting and even illumination is required. The lights are sealed to withstand high-pressure washing and are fit and forget. Their low power usage and no-maintenance make these lamps a sound investment in mine safety. The lens is manufactured from Grilamid® Optical Nylon which provides superior

resistance to UV and a wide range of chemicals. High impact strength enables the lamp to survive demanding mining conditions.They suit upright or pendant mounting and are supplied with universal stainless steel mounting brackets. Applications 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 Light that provides extra safety through enhanced visibility, at a fraction of the power consumption of halogen or Hid light fittings.

LED Task Light

PrOdUCT FEATUrEsMultivolt™ (9-33V dC)12 highly efficient LEds rated at 240 LumensUltra long life ‘Fit and Forget’<3 Watts power consumptionFully sealed against dust and high-pressure water jetsinbuilt thermal management protection

stainless steel universal mounting bracketPolarity protectedspike & overvoltage protectionLong term UV resistantPre-wired with 2.5 metres of 2 x 0.75mm² automotive cableHomogenous close range illumination

IP6K7 IP6K9K 9 to 33 V DC

3WLED

BARE WIRE

0.35KgMULTIVOLT

Narrow Beam HM1535NBPencil Beam HM1535PBWide Beam HM1535WB


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 Lights 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 Lights provide exceptional white light output and optimum light distribution for significantly improved work safety and reduced fatigue.

duraLed® High Efficacy LEd service Lights 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 Lights 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 Lights offering the industry benchmark highest efficacy for a variety of heavy-duty mine lighting applications.

PrOdUCT FEATUrEsindustry benchmark highest efficacy - 50 LEds rated to a total of 1000 lumen per lampMultivolt™ 9-33V dCPower consumption < 12WUltra durable Grilamid® nylon lens for extreme impact, UV, chemical and stress resistanceEfficient, low temperature LEd circuit design ensures ultra long life and low degradation of performanceWide beam precision optic for optimum light distribution

intense white light output provides enhanced work safety and reduced fatiguePre-wired with 2.5 metres connecting cablereverse polarity, spike and over voltage protectionFully sealed to iP6K6 and iP6K7resistant to vibration and shockEMC compliant2-hole surface mount (screw caps and mounting bushes included)

DuraLed® 1000 LumenWhite LED Service Light Multivolt™ 9-33V DC

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 Light 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 DuraLed® Magnetic Base Service Light which uses ultra powerful neodymium magnets and a flexible curly-cord cable.

IP6K7 200G 9 to 33 V DC

12WLED 0.7KgMULTI

VOLT

Wide Beam HM1550WBMagnetic Base dT connector HM1550DTMagnetic Base 12V MagCode connector HM1550MAG-12Magnetic Base 24V MagCode connector HM1550MAG-24Magnetic Base CiG/diN plug HM1550CIG

DuraLed 1000 Lumen Wide Beam 2.5m high at 0°

5 5

5

4

3

2

1

0

222

193

34

96

PrOdUCT FEATUrEs – MAGNETiC BAsE MOdEL1m 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 machinesLow power consumption <12 Watt

sPECiFiCATiONs – MAGNETiC BAsE MOdELMultivolt™ 9-33V dCPower Consumption <12W per lamp

Universal mounting via neodymium magnetsreverse polarity, spike and over voltage protection. sealed against dust and water ingress to iP6K6, iP6K7


HELLA has developed a new range of universal, high intensity and ultra energy efficient duraLed® LEd service Lights offering the industry benchmark highest efficacy for a variety of heavy-duty mine lighting applications.

DuraLed® 700 LumenWhite LEd service Light Multivolt™ 9-33V dC

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 Lights 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 Lights provide exceptional white light output and optimum light distribution for significantly improved work safety and reduced fatigue.

duraLed® High Efficacy LEd service Lights 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 Lights 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 FEATUrEsindustry benchmark highest efficacy – 36 LEds rated to a total of 700 lumen per lampMultivolt™ 9-33V dCPower consumption <9WUltra durable Grilamid® nylon lens for extreme impact, UV, chemical and stress resistanceEfficient, low temperature LEd circuit design ensures ultra long life and low degradation of performanceAvailable with wide, narrow and pencil beam precision optics offering a variety of beam patterns

intense white light output provides enhanced work safety and reduced fatiguePre-wired with 2.5 metres connecting cablereverse polarity, spike and over voltage protectionFully sealed to iP6K6 and iP6K7resistant to vibration and shockEMC compliant2-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

Narrow Beam HM15700NBPencil Beam HM15700PBWide Beam HM15700WB

IP6K7 200G 9 to 33 V DC

9WBARE WIRE 0.5KgMULTI

VOLT

Pencil Beam model shown


Good lighting is essential for 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 delivers excellent lighting under continuous use in extreme conditions. 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, 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 for 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.)35W Xenon gas discharge lighting systems pioneered by HELLA have set the standard across the globe 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, reliable electrical connection is via short length of highly flexible double insulated cable, terminated with dT connectors.

The ergonomic heavy-duty cast aluminium body has an integral “non-snag” adjustment handle. A robust lens retaining ring with captive M4 Allen bolts enables rapid routine service access from the front, and high temperature O-ring seals ensure effective sealing. UV resistant multi-stage powder coating provides optimal corrosion protection. Accurate, stable aiming in high vibration environments in all assembly positions is vital. A range of secure mounting options meets 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 the aiming angle can be locked securely. secondary mounting holes in the base enable direct mounting, 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. Beam types and bracket positions and options can be changed. Halogen models can 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 Light

sPArE PArTs & OPTiONsHM8164 Clear Protective Cover As5009.HMAPEdL Pedestal Mounting Bracket Assembly9.HM15TrN Trunnion Mounting Bracket Assembly9.HMAWHKd Cable harness kit As500

9.HM15WB insert – Wide Optic – As200/500 GdL9.HM15NB insert – Narrow Optic – As200/500 GdL9.HM15BAL Multivolt™ Ballast XN4000 Globe – Xenarc d2s

Trunnion Pedestal

Wide Beam Multivolt™ dT HM1512WB HM1513WBNarrow Beam Multivolt™ dT HM1512NB HM1513NB

PrOdUCT FEATUrEsModular die cast aluminium alloy bodyintegral “non-snag” handleMultiple mounting options with aiming anglesstainless steel trunnion bracket with quad bolt fastening draco® suspension Free-Form wide and narrow beam opticsMustAdd® filter Captive Allen boltsdouble insulated silicone supply cable with dT plugreplaceable encapsulated ballast

O-ring sealsComponents tested over a –40ºC to +105ºC temperature rangeHigh efficiency & long life d2s 35W Xenon lightMultivolt™ 8-32V dCiP6K7K200G shock resistant ballast50G shock resistant lampCE compliantProtective clear covers availableConsumable spares interchangeable with HELLA As200®FF Xenon range

shown with Pedestal Mount

DRACOMUSTADD IP6K7 50G 12/24V 41WD2S

DT 2.8Kg


175

126

122

170

120

56

135

141

127

202135

19

2672M10

Optional Pedestal BracketTrunnion Bracket

shown with Trunnion Bracket


Optional Pedestal Bracket

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

MultiVolt™ Ballast


Trunnion Pedestal

Wide Beam dT HM1510WB HM1511WBNarrow Beam dT HM1510NB HM1511NB

DRACOMUSTADD IP6K7 50G 12/24V 70WH3

DT 2.2Kg

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

shown with Trunnion Bracket

sPArE PArTs & OPTiONsHM8164 Clear Protective Cover As5009.HMAPEdL Pedestal Mounting Bracket Assembly9.HM15TrN Trunnion Mounting Bracket Assembly

9.HMAWHKd Cable harness kit As5009.HMAsHWB insert – Wide Optic – As200/500 H39.HMAsHNB insert – Narrow Optic – As200/500 H3yC2470 Globe – H3 24VyC1255LL Globe – H3 12V

PrOdUCT FEATUrEsModular die cast aluminium alloy bodyintegral “non-snag” handleMultiple mounting optionsstainless steel trunnion bracket with quad bolt fastening draco® suspension Free-Form wide and narrow beam opticsMustAdd® filter Captive Allen boltsdouble insulated silicone supply cable with dT plug

O-ring sealsComponents tested over –40ºC to +105ºC temperature rangeH3 Halogen 70W 24V suppliedCan fit H3 Halogen 55W 12VHigh efficiency & long life d2s 35W Xenon light12V dC & 24V dC optionsiP6K7K200G shock resistant lampProtective clear covers availableConsumable spares interchangeable with HELLA As200FF® Xenon range


175

126

122

170

120

56

135

141

127

202135

19

2672M10

Optional Pedestal Bracket

Trunnion Bracket

Good lighting is essential for a safe, productive work area where operators can clearly see their work environment and identify hazards in time. The As500® FF is engineered to deliver excellent lighting under continuous use in extreme environmental conditions. 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, 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. 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. 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 Light

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

shown with Pedestal Mount


The unitary design directly bonds a cast aluminium Free-Form reflector, lamp holder, clear glass lens and high temperature polymer housing into a low mass, efficient, 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 the new generation of high performance Halogen globes, the H9 (12V only) model is excellent 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 page 3 for 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. The stainless steel bracket is non-resonant and highly corrosion resistant.safe, reliable electrical connection is 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 FEATUrEsFree-Form opticsClear lens “brilliant” appearancedie cast aluminium reflectorTool-less globe accessimpact resistant housing50G shock resistant lamprOHs compliant

Electrical connection: 200mm double insulated cable harness, terminated with dT connector; other terminations available on special request stainless steel bracket iP5K9K H9 12V 65W globe included H3 24V 70W globe included

IP5K9 50G 12/24V 70WmaxH3, H9

DT 0.5KgMULTIVOLT

Modul 70 HalogenWork Light

HM70Pr

9.HM70WH

HM70PisPArE PArTs & OPTiONsHM70Pr Pipe mount tube attachment for rotating HM70Pi Pipe mount tube attachment9.HM70WH Wiring harness H9, 2m

9.HM70Br Bracket stainless steel Modul 709.HM70dC dust Cap H3 CF1265 Globe H9 – 12VyC2470 Globe H3 – 24V

12V H9 24V H3

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

H3 H9

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

12V H9 Halogen Globe

24V H3 Halogen Globe


Close range 12V HM1528WB-12Close range 24V HM1528WB-24

IP6K9K 50G 12/24V55W/12V70W/24VH3

DT 0.76Kg

PrOdUCT FEATUrEsUV resistant polymer bodyGlass lensstainless steel bracketFree-Form wide beam opticsMembrane breather elementdouble insulated

Built in dT connectorO-ring seals in the backComponents tested over a –40ºC to +50ºC temperature rangeH3 Halogen 70W 24V and H3 Halogen 55W 12V availableiP6K9K

sPArE PArTsyC2470 Globe – H3 24VyC1255LL Globe – H3 12V

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 WL200 is engineered to deliver excellent lighting in the extreme environmental conditions encountered in mining applications. WL200 lights 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, 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. HELLA integrated a membrane breather element into the WL200 to ensure the optical system remains virtually dust free over the product’s life in the adverse atmospheres typically encountered in mining. safe and reliable electrical connection is facilitated via a dT connector built into the housing. WL200 lights use a highly corrosion resistant, heavy-duty, UV-resistant polymer body. A dust and water proof plug in the rear enables easy routine service access from the rear while high temperature O-ring seals ensure effective sealing.

WL200 Halogen is a low cost, compact and highly versatile heavy-duty work light for use on mining machinery; suitable for 24V and 12V electrical systems. The work lamp features a robust nylon housing with a strong glass lens, a built in dT plug and is available in 12V H3 55W or 24V H3 70W.

WL200

Halogen Work Light

dT configuration

2121

22 durarAy3®

23 K-LEd® Mining

24 UltrarAy®-r dual



27 UltrarAy®

28 NaviLEd® M

29 OptirAy®

30 OptirAy® E


32 PulserAy® KLX

32 PulserAy® E67

EMErGENCy BEACONs

22 hELLA MINING EMERGENCY BEACONS

Their cast alloy construction and the impact and chemical resistant Xylex lens enables durarAy3® beacons to survive much larger crush or impact loads than conventional optical beacons. durarAy3® 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 durarAy3® LEd warning beacons build on an award winning design with the addition of a new intelligent electronic control system combined with the latest generation of higher output LEds. Higher EMC standard CisPr25 Class 3 certification improves safety and reliability with other electrical devices. A new advanced non-stick surface coating developed specifically for HELLA

Mining products actively prevents dirt build-up on the beacon and is resistant to acidic minerals and salts. The coating is bonded to the housing and will not peel or flake. The Multivolt™ system allows for installation on machines that may have varying voltage outputs due to engine load. Light output from the high-emitting LEds is not affected by this varying supply, with a range of 9-33V dC. The increased light output from the latest generation of LEds ensures safety is not compromised. By combining a cast aluminium housing with the latest generation Xylex® lenses, the durarAy3® is assured excellent long term resistance against cleaning chemicals, UV and impact damage for increased durability and long service life. durarAy3® beacons are fully sealed ‘Fit and Forget’ products that can be submerged and high-pressure washed from any direction. Product features Multivolt™ 9-33V dC.

HELLA’s new durarAy3® ultra durable LEd warning beacons usher in a new era of innovation, building on the award winning design of their predecessors. durarAy3® beacons are designed for mining and construction applications where the cost of equipment downtime is large and safety is paramount.

PrOdUCT FEATUrEsHigh impact resistant Xylex® lens system Heavy-duty cast alloy base and cap for increased mechanical strength and vibration resistance Advanced self cleaning surface coating for optimal corrosion and UV protection.isO 13766-2006 As/NZs CisPr25 Class 3Flame retardant to UL94HB

sealed to iP6K9K and pre-wired to prevent ingress of dirt and moisture 200G shock resistantLow EMC signatureLow current drawself-diagnostic electronics for protection against transient voltage spikes and reverse polarity LEd function colour variants available (Amber, red)

sPArE PArTs9.HM9386.02 installation Kit

IP6K9K 200G 9 to 33 V DC

33WMAXLED DTMULTI

VOLT

DuraRAY3®

LEd rotating Beacon

132.5

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

Amber direct Mount HM9500ADIR

red direct Mount HM9500RDIR

HM9500Adir

Amber - illuminated

HM9500rdir

Top view

23hELLA MINING EMERGENCY BEACONS

Designed by HELLA, K-LED® Mining’s unsurpassed EMI footprint meets the highest possible standard (CISPR25 Class 5). Wherever beacons risk interference with radio communications, K-LED® Mining is the solution of choice. K-LEd® Mining can be mounted directly next to radio communication systems and there will be no disturbance from the beacon. Even though the beacon is ‘whisper quiet’ its 20 high power LEds provide high light output for best visibility. its automatic day/night sensor adjusts brightness to avoid glare discomfort

at night – and with ECE and sAE compliance (amber and red) the product is suitable for road vehicles as well. The spec is ‘Made for Mining’. Before launch the K-LEd® Mining had to pass the tough HELLA Mining specification including 200g drop test (10,000 cycles) and high load dump tests – ensuring this becomes a ‘fit and forget’ beacon for the end user. With its low profile of 87.6mm, K-LEd® Mining is ideal for light bars and all applications where height is critical. Mounting options are direct, magnetic and pole mounting, for maximum versatility.

New K-LEd® Mining is the new benchmark in the world of low profile mining beacons. This state of the art beacon is designed for smaller mobile vehicles to suit modern styling requirements.

PrOdUCT FEATUrEsMultivolt™ 9-33V dCLow profile beacon: height only 87.6mmMounting parameters compliant to durarAy® and UltrarAy® seriesAmber and red ECE and sAE compliant: ECE r65 TA2, ECE r65 Tr2, sAE J 845 Class 120 high power LEdsimpact resistant polycarbonate lensVery high efficiency componentsFlashing or rotating pattern

High EMC resistance: meets CisPr25 class 5High Load dump protection (TVs) ensures long service lifereverse polarity protectionLight sensor for day/night detectioniP 67shock tested to 200gTemperature range -40°C to 60°Cyellow powder coated housingimproved corrosion resistance – coating strongly resists flaking compared to other brands

IP67 200G 9 to 33 V DC

33WMAXLED DTMULTI

VOLT

K-LED® MiningLEd Warning Beacon – Amber

Amber direct Mount HM9600ADIR

Amber Magnet Mount HM9600AMAG

Amber Pole Mount HM9600APIP

3 threaded hole M5, depth 14mm

120° (x3)

120° (x3)

48°ø6

r24ø150 ±0.5

ø130 ±0.

5

ø146

ø164.7

ø169.3

connection cable 3x1mm2

20 1450

49.5

80

87.6


UltraRAY®-R Dualdual Colour LEd Warning Beacon

Either of the UltrarAy®-r dual’s colours can be run on its own or both can display sequentially – and a rotating or flashing pattern can be hard-wired or controlled by an in-cabin switch. UltrarAy®-r dual beacons are extremely robust, tolerant to severe vibration levels and very compact in design. A high impact and shock resistant, polycarbonate lens is 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. They are maintenance free with no moving parts or fragile globes.UltrarAy®-r dual 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 dual 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®-r dual 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.

New UltrarAy®-r dual warning beacons eliminate the need for multiple lamps where different colour warnings are required. They output high visibility dual colours and can be used as signal lights to indicate current states of equipment (e.g. amber/red beacon – red: vehicle has stopped, amber: vehicle is in motion).

PrOdUCT FEATUrEsdual colour beacon allowing flashing or rotating patternCan run one colour only or both colours intermittentlyswitching between colours and patterns by hardwiring or by the use of a toggle switchC-tick compliant,EMC compliant to CisPr25 Class 2direct mounting

impact resistant polycarbonate lensPrecision Fresnel opticsPowder coated cast alloy basedirect, pipe mount or magnetic installation optionsFully encapsulated electronicsdouble insulated supply cableO-ring sealsHigh efficiency long life LEdUnique Helioshield™ ambient light suppression improves daylight visibility

sPECiFiCATiONsMultivolt™ 12 –30V dCPower 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 iP6K5shock resistant to 200G

sPArE PArTs9.HM450WLENs White PC Lens

HM400PiPE Pipe Mount Kit9.HM450FLX FlexiMount Adapter

IP6K5 200G 12 to 24 V DC

20WMAX.LED

BARE WIRE

0.9KgMULTIVOLT

SAECOMPLIANT

132

130



136

187

120°

120°

132

130



136

187

120°

120°

l Amber /l red direct Mount HM450ARDIRl Green / l red direct Mount HM450GRDIR

HM450Grdir UltrarAy®Lamp dual Colour GrEEN/rEd

HM450Ardir UltrarAy®Lamp dual Colour AMBEr/rEd

Optic appears clear until illuminatedThis high output LED beacon can run one colour at a time

or both colours intermittently


The UltrarAy®-r Twin LEd features either a rotating or flashing pattern easily selectable by grounding the function wire, so users can 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 operating temperature and demand on electrical systems. 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 optimised 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.

The new UltrarAy®-r Twin LEd beacon has been developed for increased visibility in bright sunlight with more than double the luminous intensity of the original UltrarAy®.

PrOdUCT FEATUrEsCertified sAE J845 Class 1 red & amberAvailable in amber, red, blue, green and whiteUser selectable output (rotate or quad flash patterns) Automatic daylight detectionimpact resistant smooth polycarbonate lensPrecision Fresnel opticsPowder coated cast alloy base

direct, pipe mount or magnetic installation optionsLow current draw EMC compliant to CisPr25 Class 2Fully encapsulated electronicsOverheat, reverse polarity and short circuit protectionHigh efficiency, long life LEd light requires 10 Amp fuse

sPECiFiCATiONsMultivolt™ 12 –30V dCPower consumption 50W averageFrequency rotating: 80 cycles/min Flash: 72 fpm (quad)Temperature range –20°C to +50°C


sPArE PArTs9.HM450ALENs Amber PC Lens9.HM450rLENs red PC Lens9.HM450BLENs Blue PC Lens

9.HM450GLENs Green PC Lens9.HM450WLENs White PC LensHM400PiPE Pipe Mount Kit9.HM450FLX FlexiMount Adapter

UltraRAY®-R TWINLEd Warning Beacon

IP6K5 200G 12 to 24 V DC

50WAVERAGELED

BARE WIRE

0.9KgMULTIVOLT

SAECOMPLIANT

132

130



136

187

120°

120°

132

130



136

187

120°

120°

direct Mount Magnetic Mount

l Amber HM500ADIR HM500AMAGl red HM500RDIR HM500RMAGl Blue HM500BDIR HM500BMAGl Green HM500GDIR HM500GMAGl White HM500WDIR HM500WMAG

HM500AFLX UltrarAy-r TWiN including vibration-proof pole mount adapter

Amber red Blue Green 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 optimised to deliver high visibility warning signals in the dusty conditions of surface mining operations – day and night. UltrarAy®-r beacons feature user-selectable ‘rotating’ or quad flash patterns.

PrOdUCT FEATUrEsUser selectable ‘rotating’ or quad flash patterns*sAEJ845 Class i (red and amber)impact resistant polycarbonate lensPrecision Fresnel opticsPowder coated cast alloy basedirect, pipe mount or magnetic installation optionsLow current draw

Fully encapsulated electronicsOverheat, reverse polarity and short circuit protectionEMC compliant to CisPr25 Class 2double insulated supply cableO-ring sealsHigh efficiency, long life LEd lightUnique Helioshield™ ambient light suppression improves daylight visibility * Preset to ‘rotating’ pattern

sPECiFiCATiONsMultivolt™ 12 –30V dCPower consumption 20W max.Frequency rotating: 80 cycles/min Flash: 72 fpm (quad)Temperature range –20°C to +50°C


sPArE PArTs9.HM450ALENs Amber PC Lens9.HM450rLENs red PC Lens9.HM450BLENs Blue PC Lens

9.HM450GLENs Green PC Lens9.HM450WLENs White PC LensHM400PiPE Pipe Mount Kit9.HM450FLX FlexiMount Adapter

UltraRAY®-R “Rotating”LEd Warning Beacon

IP6K5 200G 12 to 24 V DC

20WMAX.LED

BARE WIRE

0.9KgMULTIVOLT

SAECOMPLIANT

132

130



136

187

120°

120°

132

130



136

187

120°

120°

HM450AFLX UltrarAy-r including vibration proof pole-mount adapter




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. 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 to special order.

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 optimised for continuous use applications on mining equipment, for highly effective warning efficiency in daylight on surface operations in the extreme environmental conditions encountered in mining.

PrOdUCT FEATUrEssAE J845 Class 1 red & amberAvailable in amber, red, blue, green and whiteUser selectable flash patterns (4)Automatic daylight detection impact resistant smooth polycarbonate lensClear precision Fresnel opticsCast alloy basedirect, pipe mount or magnetic installation optionsMultivolt™ 12 –30V dCLow current draw

Fully encapsulated electronics1.5kg mass200G shock impulse resistantOverheat, reverse polarity and short circuit protectiondouble insulated supply cable with dT or AMP plugO-ring sealsTested over a –20ºC to +50ºC temperature rangeHigh efficiency, long life LEd lightiP6K5200G shock resistant

sPArE PArTs9.HM400LENs Clear LensHM400PiPE Pipe Mount Kit9.HM450FLX FlexiMount Adapter

UltraRAY®

LEd Warning Beacon

IP6K5 200G 12 to 24 V DC

20WMAX.LED

BARE WIRE

0.9KgMULTIVOLT

SAECOMPLIANT

132

130



136

187

120°

120°

132

130



136

187

120°

120°

HM400AFLX UltrarAy including vibration proof pole-mount adapter





NaviLED® 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 ergonomic, user-friendly design 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 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.

The HELLA NaviLEd® M range of surface mount LEd signal lamps is designed to provide all-round visibility. it is targeted for mining production equipment where coloured signal lamps provide operational status and identification information.

PrOdUCT FEATUrEs‘Flashing’ or ‘steady On’ signal lightFlash rate 100 fpm (approx)High visibility yellow, impact-resistant acrylic baseClear UV and chemical resistant modified acrylic lensFunction colours coded into lens capsAmber, red, blue, green and white functions available3km minimum visible distancesingle high intensity LEd light source sealed unit pre-wired with multi strand double insulated cable

Multivolt™ 9-33V dC spike protected to +500 voltsOver voltage protected to +200 voltsreverse polarity protected to -500 voltsLow power consumption (2W)sealed to iP6K6 and iP6K7 to withstand temporary immersion and high pressure washing200G shock testedTested over a –40ºC to +70ºC temperature rangeExternal elements manufactured from flame retardant polymers rated UL94 HB

IP6K7 200G 9 to 33 V DC

2WLED

DT 0.5KgMULTIVOLT

9083

red on Blue on Green on White onAmber on

Optic appears clear until illuminated in all lamps

With 2.5m cable bare wire

l Amber HM290ADIRl red HM290RDIRl Blue HM290BDIRl Green HM290GDIRl White HM290WDIR


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 & white) to suit all applications. They can be installed with 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 FEATUrEssAE J845 (Class 1 red, Class 2 amber)Available in amber, red, blue, green and white16 user selectable flash patternsAutomatic daylight detection impact resistant smooth polycarbonate lensClear precision Fresnel opticsdirect, pipe mount or magnetic installation optionsBattery pack option

Multivolt™ 12-30V dCLow current draw (1 Amp)200G shock impulse resistantOverheat, reverse polarity and short circuit protectiondouble insulated supply cable O-ring sealsTested over a –20ºC to +50ºC temperature rangeHigh efficiency, long life LEd lightiP6K5200G shock resistant spares interchangeable with HELLA OptirAy® E range

sPArE PArTs9.HM360LENs Clear LensHM360PiPE Pipe Mount Kit

9.HM300FLX FlexiMount Adapter

OptiRAY®

LEd Warning Beacon

optiray

140

113

106

optiray

140

113

106

Battery pack

IP6K5 200G 12 to 30 V DC

12WMAXLED

BARE WIRE

0.5KgMULTIVOLT

SAECOMPLIANT

HM360AFLX OptirAy® includingvibration proof pole-mount adapter



Battery Pack Magnetic Battery Pack

l Amber HM360ABP HM360BPMAGl red HM360RBPl Blue HM360BBPMAG

Amber on Green onred on Blue on White on

30

Amber on Green onred on Blue on White on

hELLA MINING EMERGENCY BEACONS

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 FEATUrEssAE J845 (Class 1 red, Class 2 amber)Available in amber, red, blue, green and whiteimpact resistant smooth polycarbonate lensClear precision Fresnel opticsdirect, pipe mount or magnetic installation optionsMultivolt™ 12-30V dCLow current draw 1 AmpFully encapsulated electronics0.5kg mass200G shock impulse resistant

Overheat, reverse polarity and short circuit protectiondouble insulated supply cable with dT or AMP plugO-ring sealsTested over a –20ºC to +50ºC temperature rangeHigh efficiency, long life LEd lightiP6K5200G shock resistant spares interchangeable with HELLA OptirAy® rangedouble Flash, 80FPM

sPArE PArTs9.HM360LENs Clear LensHM360PiPE Pipe Mount Kit

9.HM300FLX FlexiMount Adapter

IP6K5 200G 12 to 30 V DC

12WMAXLED

BARE WIRE

0.5KgMULTIVOLT

OptiRAY®

ELEd Warning Beacon

optiray

140

113

106

optiray

140

113

106

HM300AFLX OptirAy-E includingvibration proof pole-mount adapter




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 Grilamid® nylon 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.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 FEATUrEsAvailable in amber, red, blue, green and whiteUser selectable flash patterns High impact Grilamid® nylon lensClear precision micro opticsMultivolt™ 9-33V dCLow power < 10W Fully sealed “fit and forget” design0.5kg mass200G shock impulse resistant

Overheat, reverse polarity and short circuit protectiondouble insulated supply cable with dT plug or bare wireTested over a –40ºC to +70ºC temperature rangeHigh efficiency, long life LEd lightiP6K7KUL94 flame retardant rated external partsspares interchangeable with HELLA duraLed® range

sPArE PArTs9.HMdLM001 Cover Kit yellow

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

IP6K7 200G 9 to 33 V DC

9WLED

DT & BARE WIRE

0.5KgMULTIVOLT

MULTIFLASH

With 2.5m cable bare wire

With 250mm cable & dT plug

l Amber HM95903710 HM95903710Dl red HM95903700 HM95903700Dl Blue HM95903760 HM95903760Dl Green HM95903780 HM95903780Dl White HM95903790 HM95903790D

Amber illuminated

Blue illuminated

red illuminated

White illuminated

Green illuminated


reliable, unambiguous, highly visible optical warning signals create a safe work area. The smooth outer polycarbonate amber lens with a precision clear Fresnel optic internal lens reduces dirt build-up. The die cast aluminium base is a heat sink for the drive circuitry. Electronics are encapsulated to protect against shock damage and ingress of moisture or atmospheric contaminants. Thread-on lens and captive O-ring seal gives rapid service access. The field replaceable Xenon flash tube with clip-in base ensures correct polarity. dip switches select double/quad flash plus high/low flash intensity. reverse voltage, high voltage spikes and

over-voltage protected. Base suits standard 6” (150mm) diameter mounting pattern used in North America, or threaded pole.

PulserAy® KLX Xenon strobe fulfils the demands of sAE standards. it is designed for heavy duty use on 24V and 12V mining machinery.

PrOdUCT FEATUrEsHeavy cast alloy baseimpact resistant smooth polycarbonate lensClear Fresnel opticsVoltage Nominal 12V – 24V dCVoltage Operating 9V – 32V dC reverse polarity, voltage spike & surge protectionField selectable double/quad flash & high/low flash intensitysAE J1318 Class 2 compliant

sAE J575 compliant–40ºC to +50ºC temp rangeiP6K650G shock resistant

sPArE PArTs9.HMX7500.01 Lens inner - Fresnel9.HMX7500.02 Amber outer LensHMWGA220 GuardrAy® Protective CageXN6750 Xenon E67 Flash Tube

PulseRAY® KLXHeavy duty Xenon Warning Beacon

174.8

165

174.8

165

Front View

HMWGA220 (optional both for PulserAy® KLX and E67 models)

IP6K6 50G 12/24V 60WXENON BARE WIRE

1.1Kg SAECOMPLIANT

ECECOMPLIANT

Amber HMX7500A

reliable, unambiguous, highly visible optical warning signals create a safe work area. Polycarbonate amber lens with precision Fresnel optic. die cast aluminium base is a heat sink for the circuitry. Electronics are encapsulated to protect against shock damage and ingress of moisture or contaminants. Thread-on lens and captive O-ring seal for rapid access. Field replaceable Xenon flash tube with clip-in base ensures correct polarity. Fault diagnosis through the i.beam LEd status indicator visible through the lens. selection of double or quad flash is by simply

reversing polarity. Comprehensive protection against voltage spikes and over-voltage ensures reliable operation. Base finished in high visibility yellow UV resistant multi-stage powder coating, for optimal corrosion protection. The Base suits the standard 6” (150mm) diameter mounting pattern used in North America as well as a threaded pole.

PrOdUCT FEATUrEsHeavy cast alloy baseimpact resistant polycarbonate lensVoltage nominal: 12V – 24V dCVoltage operating: 9V – 32V dC Field selectable double or quad flashi.beam™ Monitorreverse polarity, voltage spike & surge protection–40°C to +50ºC temp rangeiP6K650G shock resistant lampsAE J1318 Class 2 compliant

sAE J575 compliantConsumables interchangeable with PulserAy KLX beacons

sPArE PArTs9.1602.01 E67 Lens - Amber9.1601.01 E67 Lens - red9.1600.01 E67 Lens - Blue9.1603.01 E67 Lens - Green9.1604.01 E67 Lens - ClearHMWGA160 GuardrAy® Protective CageXN6750 Globe - Xenon E67 Flash Tube9.1600.06 Lens Clear dust Cover

PulseRAY® E67Heavy duty Xenon Warning Beacon 12/24V dC

IP6K6 50G 12/24V 60WXENON BARE WIRE

1.2Kg SAECOMPLIANT

121

4.8

1656.5

Amber Lens Blue Lensred Lens Clear LensGreen Lens

l Amber HME6750Al red HME6750Rl Blue HME6750B

l Green HME6750Gl Clear HME6750C

34 duraLed® rCL

35 duraLEd® M


37 duraLEd® MsiP

37 LEd daytime running Lamp

38 duraLEd® Marker

siGNAL LAMPs

34 hELLA MINING SIGNAL LAMPS

Optic appears clear until illuminated (off)

Tail lamp function displayed

stop lamp function displayed

reversing lamp function displayed

indicator function displayed

duraLed® rCL Part No. HM2380dT (with integrated dT) shown

signal Lamp – Bare Wire HM2380signal Lamp – Wired with dT HM2380Dsignal Lamp – integrated dT HM2380DT

222

193

34

96

The high impact shock resistant clear Grilamid® lens is bonded to a rugged, UV damage-resistant composite base for maximum strength and durability, with no lighting loss due to internal dirt build-up. They also suit wet/corrosive environments and tolerate short-term immersion. Unlike normal signal lamps, duraLed® products are maintenance free and extremely power efficient, greatly reducing operating temperature and demand on electrical systems. internal heat sinks ensure maximum service life and light output. The integral Multivolt™ control module also protects the

duraLed® rCL against damage from overheating, reversed polarity and short circuits.safe and reliable electrical connection is facilitated via 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 options to order.The advanced, clear micro optic lenses prevent the hazardous occurrence of “ghost” signals from 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.

A compact “Fit and Forget” stop/tail/indicator/reverse combination signal lamp utilising the latest LEd technology, engineered for ultra heavy-duty mining applications and service vehicles. Extremely robust and fully sealed, they tolerate severe vibration levels.

PrOdUCT FEATUrEsimpact resistant smooth Grilamid® lensClear precision micro opticsMultivolt™ 8-28V dCLow power <10W Fully sealed “fit and forget” 0.6kg mass200G shock impulse resistantOverheat, reverse polarity and short circuit protection

double insulated supply cable with dT plug (6 pin) or tinned wire–40ºC to +70ºC rangeHigh efficiency, long life iP6K6K and iP6K7KUL94 flame retardant rated external partsAdr compliant spares interchangeable with HELLA duraLed® rangeCE compliant

DuraLed®

RCLrear Combination Lamp, Multivolt™ 8-28V dC

IP6K5 200G 12 to 24 V DC

20WMAX.LED 0.9KgMULTI

VOLTDT& BARE WIRE

ADR/ECE/SABS

COMPLIANT

35

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, shock resistant clear Grilamid® nylon lens is permanently bonded to a rugged, UV damage-resistant composite base for mechanical strength and maximum durability. HELLA engineered duraLEd® M Combi lamps to ensure very long service life and no light loss due to internal dirt build-up; they are also well suited to wet and corrosive environments and tolerate short-term immersion. Unlike normal signal lamps, duraLEd® products are maintenance free and extremely power efficient, which greatly reduces both operating temperature and demand on electrical systems.

Maximum service life and light output of the high intensity LEds is ensured by internal heat sinks. The integral Multivolt™ control module protects the duraLEd® M against damage from overheating, reversed polarity and short circuits. safe and reliable electrical connection is facilitated via 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.Advanced, clear micro optic lenses 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 FEATUrEsHigh impact Grilamid® nylon lensClear precision micro opticsMultivolt™ 8-28V dCLow power < 10W Fully sealed “fit and forget” design0.5kg mass200G shock impulse resistantOverheat, reverse polarity and short circuit protectiondouble insulated supply cable with dT plug or tinned wire

Tested over a –40ºC to +70ºC temperature rangeHigh efficiency, long life LEd lightiP6K7KUL94 flame retardant rated external partsAdr, ECE and sABs compliantspares interchangeable with HELLA duraLEd® rangeCE compliant

sPArE PArTs9.HMdLM001 Cover Kit yellow (Pack of 4)

DuraLed® MCombination signal Lamp

222

193

34

96


Tail lamp function displayed

stop lamp function displayed

indicator function displayed

All functions displayed (on)

IP6K7 200G 8 to 28 V DC

9WLED

DT& BARE WIRE

0.7KgMULTIVOLT

ADR/ECE/SABS

COMPLIANT

Rear of truck and trailer havesame lighting requirements

hELLA MINING SIGNAL LAMPS

36 hELLA MINING SIGNAL 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. 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 or ECE regulations. The material used for ECE compliant part numbers is a new generation of acrylics while the sAE versions feature a durable PC lens. Both materials have 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® 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. Their LEd technology means low maintenance, low current draw and ultra long service life.

PrOdUCT FEATUrEsEasy installationVariety of surface mount optionsUltra wide optics for enhanced visibilitysAE lens: PolycarbonateECE lens: High impact PMMA AcrylicLow power consumption and Multivolt™ circuitry for maximum light output

Multivolt™9 - 33V dCsAE compliant (Part No’s. HM060321 and HM070321)ECE Approval (Part No’s. HM060221 and HM070221)iP6K6 (Protection against dust and high pressure water jets)iP6K7 (Protection against temporary water immersion).

DuraLed® SAE and ECEsignal Lamps

HM060321 HM070321

100

177

148

31

22

2Wto 9WIP6K7 200G 9 to 33

V DCLEDDT& BARE WIRE

0.4KgMULTIVOLT

SAE COMPLIANT

HM060621 (red illuminated) HM070621 (Amber illuminated)

sPECiFiCATiONsVoltage Multivolt™ 9-33V dCPower Consumption:rear direction indicator 9W rear Position Lamp 2WPark Lamp 2Wstop Lamp 9WProtection:reverse Polarity Protection5.0kW 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 020889HM070621 (Amber) E13 010363 e4 020904

duraLed® sAE stop/Tail rear Turn signal (red) HM060321duraLed® sAE rear Turn signal/indicator HM070321duraLed® ECE stop/Tail signal (red illuminated) HM060621duraLed® ECE rear Turn signal (Amber illuminated) HM070621

37

red/Green HM95905030

DuraLed® MSIPsignal Lamp

duraLed® MsiP lamps are extremely robust, fully sealed truly “fit and forget”, tolerant to severe vibration and very compact. A clear Grilamid® nylon lens is high impact and shock resistant, and bonded to a rugged, UV damage resistant composite base for strength and durability. They are engineered for very long service life and no lighting loss due to internal dirt build-up; they also suit wet and corrosive environments and tolerate short-term immersion. Unlike normal signal lamps, duraLed® is maintenance free and power efficient. This reduces both operating temperature and demand on electrical systems. internal heat sinks ensure maximum service life and output of

the high intensity LEds. The integral Multivolt™ control module protects the duraLed® MsiP against damage from overheating, reverse polarity and short circuits. safe and reliable electrical connection is facilitated via highly flexible double insulated cable, sealed into the base and terminated with tinned wire ends. Other connector options are available 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 installation on almost any surface.

duraLed® MsiPs (Mine safety indicator Panel) offer both red and green LEd signals in one compact housing, engineered for ultra heavy-duty applications where safety is important, such as underground transport equipment sharing space with foot traffic.

PrOdUCT FEATUrEsHigh impact Grilamid® nylon lensClear precision micro opticsMultivolt™ 8-28V dCLow power < 10W Fully sealed “fit and forget” 0.5kg mass200G shock impulse resistantOverheat, reverse polarity and

short circuit protectiondouble insulated supply cable with dT plug or tinned wire–40ºC to +70ºC temp rangeiP6K7KUL94 flame retardant rated external partsrOHs compliantspares interchangeable with HELLA duraLEd® range

sPArE PArTs9.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


red illuminated shown

Green illuminated shown

red & green illuminated shown


This low power LEd drL provides extra safety through enhanced visibility, at a fraction of the power consumption of conventional headlights. designed to significantly improve vehicle visibility on site, they are sealed, fit and forget, and are Adr approved for road use, giving them the versatility for multiple applications. With lower power usage and zero maintenance, these lamps are a sound investment in enhanced mine safety. The lens is manufactured from Grilamid®

Optical Nylon which provides superior resistance to UV and to a wide range of chemicals, and high impact strength, enabling the lamp to survive the highly demanding conditions of mining.The HELLA LEd daytime running Lamp (drL) is suitable for upright or pendant mounting and supplied with universal stainless steel mounting brackets. LEd drLs also have other applications such as area illumination around the vehicle.

PrOdUCT FEATUrEsMultivolt™ (9-33V dC)12 high efficiency LEdsUltra long life ‘Fit and Forget’< 2 Watts power consumption Fully sealed against dust and high-pressure water jetsOver-temperature protections/s universal bracket

Polarity protectedspike & overvoltage protectionLong term UV resistantPre-wired with 2.5 metres of 3 x 0.75mm² automotive cableHomogenous close range illuminationAdr/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

136 49

5342

IP6K7 IP6K9K 9 to 33 V DC

2WLED

BARE WIRE

0.72KgMULTIVOLT

ADR COMPLIANT

2 Lamp Kit HM1535DRL

Kit contains two lamps

38 HELLA MINING WORK LAMPS

duraLEd® M clearance and marker lamps are heavy duty injection moulded in UV resistant polymers that offer high resistance to corrosion and attack from a range of aggressive elements commonly found in mining, industrial and chemical plants (refer to the technical section for detailed information). These polymers offer high levels of protection against impact damage and exhibit 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 their fitment 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.200G shock resistant sealed to iP6K6 & iP6K7 to withstand temporary immersion and high pressure washingMultivolt™ 8 - 28V dC Up to 60% less current draw than comparable globe lampsUltrafast response timeTransient spike protectionreverse 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 PArTs9.HMdLM002 Marker Housing yellow (Pack of 4)

IP6K7 200G 8 to 28 V DC

1WLED

DT& 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 lamps appear clear until illuminated.


Marker Lamp Bare Wire Marker Lamp dT

l White inspection Point HM2054 HM2054Dl l red/Amber side Marker HM2053PC HM2053PCDl red Marker HM2307 HM2307Dl Amber Cabin Marker HM2026 HM2026Dl Amber Marker HM2051 HM2051D

HM2051

HM2307

Rear of truck and trailer havesame lighting requirements

ACCEssOriEs40 LEd Buggy Whips

41 Battery Master Lockout switches

42 screened Extension Cables

43 remote Jump start Terminals

43 Weatherproof Changeover relay

46 self Amalgamating Tape

43 Nitto Tape

44 NumiLEd®

45 NumiLEd® Pro

46 dT Connectors

IP6K7 200G 12V 1WLED

DT 0.5KgMULTIVOLT

40 hELLA MINING ACCESSORIES

sPArE PArTs:9.HM46MP Male Pin Connector for Quick release9.HM46FX replacement reflective Cross Flag

9.HM46Ms Medium spring9.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 fibreglass 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 Whips

snap On/Off Quick release

illuminated LEd tip

9.HM46FX

9.HM46MP

9.HM46MS

1.2 metre HM46122.0 metre HM46203.0 metre HM4630

TECHNiCAL sPECiFiCATiONs:Light source: Quality LEds in BA9 bulb holderVoltage 12VPower Consumption < 1W

Length: 1.2 metres, 2.0 metres or 3.0 metresMounting: integrated mounting bolt on base with snap on/off quick-release shaft for quick and easy installation

3m 2m 1.2m

dT configuration

41hELLA MINING ACCESSORIES

HELLA Mining has released four new variants of mining battery lockout switches. Battery lockout switches provide a reliable power disconnection and safety cutoff that protects the vehicle against tampering, theft and battery drain. it also protects personnel from electrical hazards during service operations.The 4 Pole HM7591s allows isolation of both positive and negative sides from the battery, or isolation of 2 circuits with only one switch.

TyPiCAL APPLiCATiONs: Any mobile machinery or dC fixed applications that require lockout / tag-out procedures for maintenance. red colour code is typically employed for battery, the yellow colour code typically for ignition.

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.

PrOdUCT FEATUrEs125 Amps at 6-36V dC Continuous (HM7591s)300 Amps at 6-36V dC Continuous (HM7590r/y)Operating Temp -40°C to +29°Csilver Environment Contact surfacesBrass Electrical Contact surfaces45 degree switch Travel

UL Listedsuits panel thickness up to 6.5mm

ACCEssOriEs & sPArE PArTs:9.HM759rEd red Lockout Cover 9.HM759yEL yellow Lockout Cover Compatible with existing HELLA Automotive spare Part No’s. 4645, 4646, 4647

TECHNiCAL iNFOrMATiON:Waterproof and dustproof to iP67Tested to 200G shock for 10 000 cyclessealed design allows switch to be mounted in the best location regardless of environmentLarge red handle makes it easy to operate with gloved handsComposite-engineered polymer housing that will not corrode.300A continuous current rating at 12V and 250A at 24VTemperature operating range -40°C to + 85°C

divider on base prevents accidental shorting of battery cablesEasy to read designations on bezel and 90° switch travel make it easy to identify switch position.

Battery Master Lockout Switches

Battery Master Lockout Switches

69.1

60.3

135.6

10

11.4

Lockout switch, red Handle HM7592BLockout switch, yellow Handle HM7592Y

2 Pole & Field Terminals switch, red Handle HM7590R2 Pole & Field Terminals switch, yellow Handle HM7590Y4 Pole switch, s/s Handle HM7591S

HM7592y

HM7592B

HM7590r Lockout switch red 2 Pole & Field Terminals

9.HM759yELyellow Lockout Cover 9MK

9.HM759rEdred Lockout Cover 9MK

HM7590y Lockout switch yellow, 2 Pole & Field Terminals 9MK

HM7591s switch 4 Pole


PrOdUCT FEATUrEs:Triple insulated cableTinned copper braided shield earthed for additional protectionExtra soft flex to avoid tanglesHeavy-duty strain reliefsFully encapsulated plugs and socketsApproved to Australian and New Zealand standards As/NZs 3191/3120/3112 and 9199reduced electromagnetic interferenceNo corrosion of conductors from moisture in cables, plugs or socketsPlug and socket impact tested to 100 Joule

Cable impact tested to iK10 (20 Joule)2.5mm² conductors on all screened extension cables2.5mm² conductors on all screened extension cables

FEATUrEs OF HEAVy dUTy EXTENsiON CABLEs.Neon safety light fitted in socketiP66 rated protection on plug/socket connection when assembled correctlyiP66 cover designed to suit other major brands of manufacturers

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. The Heavy duty version of screened Extension Cables also provide additional protection against wet and dusty environments.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.

AddiTiONAL FEATUrEs OF HEAVy dUTy sCrEENEd EXTENsiON CABLEs

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.

The electrical conductors and screen are welded to the connector pins to minimise contact resistance and the risk of separation between the plug and cables.

The earthed screen provides significantly improved suppression of electro magnetic fields radiated by the cable, and provides additional protection for 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.

Screened Extension Cables

screened Extension Cable (above)

Heavy duty (right)

Braid is earthed when cord is in use

Screened Extension Cables with 10A Plug/Socket

10m HMEC1010AU15m HMEC1510AU20m HMEC2010AU25m HMEC2510AUScreened Extension Cables with 15A Plug/Socket

20m HMEC2015AU30m HMEC3015AU40m HMEC4015AU

HEAVY DUTY Screened Extension Cables with 10A Plug/Socket

20m HMIC2010AUHEAVY DUTY Screened Extension Cables with 15A Plug/Socket

20m HMIC2015AUHEAVY DUTY Screened Extension Cables with 20A Plug/Socket

30m HMIC3020AU

10A socket 15A socket 20A socket Us socket

IP66

hELLA MINING ACCESSORIES

ADVANCED SAFETY

self-Amalgamating Tape HMAT85

Nitto Tape

Nitto Tape (roll of 18) 9.HM4972

Self-Amalgamating Tape

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

PrOdUCT FEATUrEssuperb electrical insulation – no deterioration in insulating characteristics Minimal flagging makes reliable wiring work possible

Outstanding cut-ability, can be torn by hand Excellent freeze resistance – no degradation in adhesive force even at -10°C, so fit is reliable Exceptional initial adhesion.

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.

43

12V Kit HMWPR00124V Kit HMWPR002

PrOdUCT FEATUrEsdustproof iP54 to iEC 529 with mounting bracketWeight 35gNominal Voltage 12V or 24VTerminals tin plated isO 8092-1Ambient

shock resistance: 20Gdrop Test: 1 Metre onto concrete maxFlammability: Exceeds UL94-HBOverload current: 240A for 1 second, 140A for 5 seconds, 80A for 40 seconds, 54A for 1800 seconds.

Weatherproof Changeover Relay & Connector Assembly Kits

56.5mm

35mm

12V Kit 24V KitVoltage range 10 -16V dC 20 -28V dCOperating range Temp -40°C to +155°C -40°C to +155°CContact Current rating NO 35A / NC 20A NO 40A / NC 30ACoil resistance @ 23°C 70-90 Ohms 360 OhmsTransient suppressor resistor 680 Ohms 2700 Ohms

TECHNiCAL iNFOrMATiON:removes risk of terminal crossing High impact ABs PlasticZinc 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 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.Also available: Mounting Bracket, Protective Cover/Cap, or a Kit containing the terminal, bracket and cover.

Remote Jump Start Terminals

78

63 6345

Terminal HM7546JTerminal Kit HM7546KITTerminal Bracket HM7546BTerminal Cap HM7546C Terminal

KitTerminal Bracket

Terminal Cap


12V Kit (Green seal)


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 and 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.

Where situational awareness is essential, NumiLEd® modular robust illuminated identification panels provide essential visibility. Typical applications are: id numbers for mining haul trucks and shovels, process tanks and conveyor transfer stations.

PrOdUCT FEATUrEsimproves safety & visibilityLow maintenanceLow energy consumptionLong service lifeExpandable fleet numbersEasy to assemble

Excellent performance in hot, cold and wet environmentsFully sealed against dust and moisture to iP6K7durable PMMA lensrobust ABs and PC housing

sPArE PArTs9.HMTN001 NumiLEd® 8-Way distribution Board9.HMTN002 NumiLEd® Connection Cable - single, 2m

9.HMTN003 NumiLEd® Connection Cable - Triple, 2m9.HMTN004 NumiLEd® Vibration Mounting KitHM4960sA dT Connector Kit - Male (pack of 10)

IP6K7 200G 24V DC 60W MAXLED

DT 5.0KgMULTIVOLT

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


45HELLA MINING WORK LAMPS

NumiLED® ProNumber 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 unauthorised 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 FEATUrEsimproves safety & visibilityPre-assembled and fitted with all required LEd modules Programmable power distribution board with internal memory functionintegrated front mounted MagCode® programming portsupplied with special MagCode® programming dongle to change charactersreverse polarity and voltage spike protected

Low maintenanceLong service lifeExpandable fleet numberssate of the art designLow energy consumption (max. 20W per digit)Excellent performance in hot, cold and wet environmentsFully sealed against dust and moisture to iP6K7durable PMMA lensrobust ABs and PC housing

sPArE PArTs9.HMTN002 NumiLEd® Connection Cable - single, 2m9.HMTN003 NumiLEd® Connection Cable - Triple, 2m9.HMTN004 NumiLEd® Vibration Mounting Kit9.HMTN005 NumiLEd® PrO Programming dongle

9.HMTN006 NumiLEd® PrO Programmable PCBHM4960sA 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 MAXLED

DT 5.0KgMULTIVOLT

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


46 HELLA MINING WORK LAMPShELLA MINING ACCESSORIES

DT ConnectorsAccessories

HM8275 dT Connector Crimping Tool

DT ConnectorsEnvironmentally 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 HM49602 Pole dT Connector Half-set* 10 HM4960FM3 Pole dT Connector set 1 HM49613 Pole dT Connector Half-set* 10 HM4961FM4 Pole dT Connector set 1 HM49626 Pole dT Connector set 1 HM49636 Pole dT Connector Half-set* 10 HM4963FM8 Pole dT Connector set 1 HM496412 Pole dT Connector set 1 HM4965

* Half-set = female socket with male contacts.

DT Connector Crimping Toolspecially designed crimping tool with multiple jaws for even crimp of dT Terminals HM8275

dT Crimping Tool 0.5 – 4.00 HM8277

HM4960

HM4961

HM4962

HM4963

HM4964

HM4965 HM8277 dT Contact Crimping Tool 0.5 - 4.0mm

iNTEriOr LiGHTiNG48 EuroLEd® Touch M

49 CargoLEd®

50 MiniThinLEd®

48 hELLA MINING INTERIOR LAMPS

EuroLEd® Touch interior lamps are equipped with high-performance LEds – a single white LEd in the centre plus multiple red LEds arranged in a circular pattern – and highly advanced lens optics providing uniform light distribution without glare for optimum efficiency and increased safety. Multivolt™ electronics ensure consistent brightness at any input between 9 and 33V dC, even with 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 colour and regulate light intensity to suit individual cabin lighting requirements. When the finger is held on either switch pad for longer than two seconds, the lamp automatically cycles through four dimming stages until the finger is released. The integrated memory function ensures the lamp turns on at the 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 FEATUrEsdual colour LEd lightingintegral, touch sensitive switchingdimming function with memoryMultivolt™ 9-33V dCUltra low power consumption

shock and vibration resistanceOver voltage, reverse polarity and transient spike circuit protectionLow EMC signatureiP 6K6 6K7 completely sealed against dust and moisture

IP6K7 200G 9 to 33 V DC

5WLED

DT & BARE WIRE

0.3KgMULTIVOLT

Harnessing the durability and power saving benefits of advanced LEd technology, EuroLEd® Touch interior lamps offer dual colour LEd light output of white light for general interior illumination and red light to help maintain night vision (see below).

EuroLED® Touch Mdual Colour interior Lamp – Multivolt™ 9-33V dC

130

130110

30

30

13

Cable Exit

red OnWhite On

red Light and Night VisionThe eye has 2 types of receptors: rods and cones. Rods are

responsible for our daytime and colour vision and have increased sensitivity towards the red band of the visible spectrum. Cones are responsible for night vision capability and have increased sensitivity towards the blue band of the visible spectrum. So, red light helps night vision as it does not affect the sensitivity of the cones.

sPArE PArTs8HG959952022 EuroLEd® Mounting spacer

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

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

49

HELLA CargoLEd® is an advanced interior light designed with particular attention to visual comfort when operators need high quality light for visually intensive tasks over extended periods, in environments unsuited to 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 to 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 reliability. 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 FEATUrEsAluminium core body for optimal thermal performance of LEdsClear UV and chemical resistant modified acrylic lensLarge optical system for high light outputLow luminance indirect design ensures low glare High intensity LEd light source array sealed unit pre-wired with multi strand double insulated cableAvailable with dT plugs Multivolt™ 9-31V dC spike protected to +500 volts

Over voltage protected to +200 voltsreverse polarity protected to -500 voltsPower consumption: 6Wsealed to iP6K9 to withstand temporary immersion and high pressure washing when installedsurface mount accessories available200G shock impulse resistant-40ºC – +60ºCExternal elements manufactured from flame retardant polymers rated UL94 HBAdr 2006 (hazardous goods transport) compliant

IP6K9 200G 9 to 31 V DC

6WLED

DT 0.5KgMULTIVOLT

Heavy duty interior Lamp HM227HD

CargoLEd® on

hELLA MINING INTERIOR LAMPS

50 hELLA MINING INTERIOR LAMPS

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 FEATUrEsApproximately 136 x 30 x 11mm12V or 24V versionsVarious colour possibilitiesstate of the art designEasy flush mounting screw versionExcellent durability “Fit and Forget”

Low energy consumption 1.2W – 2.8WExcellent performance in heavy, cold and wet environmentsWater resistant iP69Performance temperature range -40 to +60CQuality materials: PMMA (Lens) and ABs+PC (Housing)

IP69 200G 12/24 V DC

3WLED

BARE WIRE

0.1Kg

5 LEd red

5 LEd White

3 LEd Blue

3 LEd Green

12V dC 24V dC

l red HM6605RD-12V HM6605RD-24Vl Blue HM6603BD-12V HM6603BD-24Vl Green HM6603GD-12V HM6603GD-24Vl White HM6605WD-12V HM6605WD-24V

ALArMs & HOrNs52 MotoVOX® Horns


54 retroVOX® Broadband Alarms

52

MotoVOX® Compact 117dB Horn

MotoVOX® Forward 117dB Horn

MotoVOX® Compact 107dB Horn

HMFH312P

HMFH117P

HMFH107P

+

- 77

95128

127mm

183.1mm

78mm

81mm

118mm

92mm

81mm

127mm

183.1mm

78mm

81mm

118mm

92mm

81mm

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

hELLA MINING ALARMS

53

HMRA917E

RetroVOX® Self Adjusting Reversing Alarm

RetroVOX®Ultra Heavy Duty Reversing 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

180

78

102

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

hELLA MINING ALARMS


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.

Voltage 12-24V dC (reverse polarity protected)

decibel 87-112dB @1.2m

Approval sAE J994 class A-d EC, E11

95

152

173

155

80

PrOdUCT FEATUrEs:ingress Protected to iP68 (waterproof)solid-state, spark-free electronics

Epoxy-sealed against mud, water and vibrationCan 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 localised 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.

HMRA087B

HMRA107B

55

76

4591

Voltage 12-24V dC

Current Max. 0.5 Amps

decibel 87 @ 1m

Approval sAE J994 Class E 11 CE & EMC Approved

RetroVOX® Compact Broadband 87dB Alarm

RetroVOX® Broadband 87-112dB Reversing Alarm

hELLA MINING ALARMS

What is a broadband alarm?White sound is the safest and yet quietest type of reverse alarm on the market. The distinct “ssh ssh” sound is less irritating than tonal beeping alarms, so it prevents workers from becoming desensitised to the warning. The sound emitted is directional and therefore instantly locatable, enabling pedestrians to work out exactly which vehicle is moving and in which direction, allowing them to move to safety. The wide spectrum of frequencies created, helps to detect the sound easier than narrow band tonal alarms. White sound reversing alarms work effectively at lower decibel ratings containing the sound only in the danger area.

sErViCE TOOLs56 Handy Box® service Kits


60 dT Connectors

62 double Crimp Connectors

63 LEd Fuses



56 hELLA MINING SERVICE TOOLS

The new range of HELLA Handy Box® service kits satisfies technical and economic demands without compromising quality. The kit is comprehensive and yet small enough to fit into service vehicles. it can easily be carried onsite for service.Assortment kits slide and lock into the Handy Box®, which is stackable.Handy Boxes® are manufactured from lightweight, durable polypropylene, and contain comprehensive assortments of dT connectors, blade fuses, standard heat shrink and crimp terminals.All parts in the kits are available as spares, allowing restocking whenever required.

Handy Box® DT Connector Kit(258 Pieces)

Handy Box® Heat Shrink Kit(576 Pieces)

Handy Box® Service Kits

Handy Box® dT Connector Kit (incl. Crimping Tool HM8277) HM8292

Handy Box® Heat shrink Kit (Heat shrink not adhesive lined) HM8293

Handy Box® Service Kit

Handy Box®® Complete set: Carry case complete with all four Handy Box® kits – dT Connector kit, Blade Fuse Kit, Heat shrink Kit, and Crimp Terminal Kit

HM8291

Handy Box® Carry Case (empty), storage room for four assortment kits HM8296

The dT connector kit to service the popular dEUTsCH connectors is the first module of the range to be released. The Handy Box® kit is supplied with the most popular dEUTsCH connectors plus the essential tools to make and repair these connections.

The Heat shrink Kit contains various diameters and lengths of heat shrink in different colours.

replacement Parts for Handy Box® Heat shrink Kit:

Part No. description

9.HM4810 Heat shrink Tubing 3 Colors 1,2...5 9MJ9.HM4811 Heat shrink Tubing BK/Tr 1,2...50 9MJ9.HM4812 Heat shrink Tubing 3-COLOr 1,6...50 9MJ9.HM4813 Heat shrink Tubing BK/Tr 1,6...50 9MJ9.HM4814 Heat shrink Tubing 3-COLOr 2,4...50 9MJ9.HM4815 1Heat shrink Tubing BK/Tr 2,4...50 9MJ9.HM4816 Heat shrink Tubing 3-COLOr 3,2...50 9MJ9.HM4817 Heat shrink Tubing BK/Tr 3,2...50 9MJ9.HM4818 Heat shrink Tubing 5-COLOr 4,8-100 9MJ9.HM4819 Heat shrink Tubing 5-COLOr 6,2-100 9MJ9.HM4820 Heat shrink Tubing BK/Tr 9,5-100 9MJ9.HM4821 Heat shrink Tubing 5-COLOr 4,8-200 9MJ9.HM4822 Heat shrink Tubing BK 9,5/12,7-200 9MJ

replacement Parts for Handy Box® dT Connector Kit:


9.HM4940G 2 Pin dT Plug set (Pack of 10)

9.HM4941G 2 Pin dT receptacle set (Pack of 10)9.HM4942G 3 Pin dT Plug set (Pack of 10)9.HM4943G 3 Pin dT receptacle set (Pack of 10)9.HM4946G 6 Pin dT Plug set (Pack of 8)9.HM4947G 6 Pin dT receptacle set (Pack of 8)

57hELLA MINING SERVICE TOOLS

Features all the popular amperage and blade fuse sizes. The range of blade fuses comprises of mini fuses, standard fuses and maxi fuses. The kit also comes complete with a fuse puller which is also a universal voltage tester with test LEd. it is adjustable to all sizes of fuse terminal as per the kit offering.

Handy Box® Blade Fuse Kit HM8294

Handy Box® Blade Fuse Kit(475 Pieces)

The professional double crimp connector kit is supplied with the most popular terminals and connectors as well as a HELLA special Crimping Tool for insulated Crimp Terminals.

Handy Box® Crimp Terminal Kit HM8295

Handy Box® Crimp Terminal Kit(401 Pieces)

replacement Parts for Handy Box® Blade Fuse Kit:


9.HM4823 Flat Fuse insert 2A 8Js




9.HM4827 Flat Fuse insert 7,5A 8Js







9.HM4834 Fuse-Link 3A 8Js


9.HM4836 Flat Fuse insert 5A Fivefold 8Js

9.HM4837 Flat Fuse insert 7,5A 8Js


9.HM4839 Fuse-Link 8Js



9.HM4842 Fuse insert 30A 8Js


replacement Parts for Handy Box® Crimp Terminal Kit:


9.HM4844 Cable shoe 4-1 8KW

9.HM4845 Cable shoe 5-1 8KW

9.HM4846 Flat receptacle Female 8KW

9.HM4847 Flat Terminal 6,3 8KW

9.HM4848 round Plug 4 8KW

9.HM4849 Cable shoe 5-2,5 8KW

9.HM4850 Flat receptacle Female 6,3 8KW



9.HM4853 Cable Lug shoe 6-2,5 574-99 8KW 8KW

9.HM4854 Joint Connector 8KW



9.HM4857 Circular socket d4 8KW

9.HM4858 Flat Terminal (Female) receptacle 8KW

9.HM4859 Flat Terminal (Female) receptacle 8KW

9.HM4860 Cable shoe 8KW

9.HM4861 Cable shoe 8KW

9.HM4862 CLUTCH 8KW

9.HM4863 Connector, insulating splice 8KV

9.HM4864 Crimping Tool 8PE


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.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(389 Pieces)

EziPAK® Service Kits

HM8277

HM8275

HM8285 double drawer storage Module

HM8286 single divisional Carry Case

HM8283

HM8284

EziPAK® dT Connector Kit (incl. Crimping Tool HM8277) HM8283

Accessories

Universal dT Contact Crimping Tool HM8275

dT Contact Crimping Tool 0.5 - 4.0mm HM8277EziPAK® double drawer storage Module (empty) HM8285EziPAK® single divisional Carry Case (empty) HM8286

EziPAK® Double Crimp Connector Kit(3,652 Pieces)

EziPAK® double Crimp Connector Kit HM8284

AccessoriesEziPAK® double drawer storage Module (empty) HM8285EziPAK® single divisional Carry Case (empty) HM8286

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.

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.


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.

HM8290

EziPAK® intelligent Fuse Kit HM8290


EziPAK® Intelligent Fuse Kit(556 Pieces)

LEd glows if fuse blows, for instant identification

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.

HM8287

EziPAK® Heat shrink Harness repair Kit HM8287


EziPAK® Heat Shrink Harness Repair Kit(270 Pieces)


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.HM4953

9.HM4954 9.HM4955 9.HM4956

9.HM4957 9.HM4958 9.HM4959

DT Connectors (included in EziPAK® DT Connector Kit) Qty in pack Part No

2-Way Plug dT Connector (incl. wedge) 15 9.HM4940

2-Way receptacle dT Connector (incl. wedge) 15 9.HM4941











3-Way round Plug HdT Connector 5 9.HM4952

3-Way round receptacle HdT Connector 5 9.HM4953

Plug dT Connector Pin 100 9.HM4954

receptacle dT Connector socket 100 9.HM4955

Connector sealing Plug 50 9.HM4956

Service Tools

dT Contact Crimping Tool 0.5-4.0mm 1 HM8277

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

dT Connector crimping Tool 1 HM8275

DT Connectorsincluded in EziPAK® dT Connector Kit

HM8275 dT Connector Crimping Tool

HM8277 dT Contact Crimping Tool 0.5 - 4.0mm


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

Qty in pack Part No.

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 200 9.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

Double Crimp Connectorsincluded in EziPAK® double Crimp Connector Kit


LED Fuses(included in EziPAK® Intelligent Fuse Kit)

Qty in pack Part No

Mini Blade Fuse - 3A, Violet 30 9.HM4973Mini Blade Fuse - 5A, Tan 30 9.HM4974Mini Blade Fuse - 7.5A, Brown 30 9.HM4975Mini Blade Fuse - 10A, red 30 9.HM4976Mini Blade Fuse - 15A, Blue 30 9.HM4977Mini Blade Fuse - 20A, yellow 30 9.HM4978Mini Blade Fuse - 25A, Natural 30 9.HM4979Mini Blade Fuse - 30A, Green 30 9.HM4980Blade Fuse - 3A, Violet 30 9.HM4981Blade Fuse - 5A, Tan 30 9.HM4982Blade Fuse - 7.5A, Brown 30 9.HM4983Blade Fuse - 10A, red 30 9.HM4984Blade Fuse - 15A, Blue 30 9.HM4985Blade Fuse - 20A, yellow 30 9.HM4986Blade Fuse - 25A, Natural 30 9.HM4987Blade Fuse - 30A, Green 30 9.HM4988Blade Fuse - 40A, Amber 30 9.HM4989Maxi Blade Fuse - 20A, yellow 15 9.HM4990Maxi Blade Fuse - 30A, Green 15 9.HM4991Maxi 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

LED Fusesincluded in EziPAK® intelligent Fuse Kit


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

Qty in pack Part No.

Adhesive Lined Heat shrink sleeving 3.2mm 35 9.HM4960Adhesive Lined Heat shrink sleeving 6.4mm 35 9.HM4961Adhesive Lined Heat shrink sleeving 9.5mm 35 9.HM4962Adhesive Lined Heat shrink sleeving 12.7mm 20 9.HM4963Adhesive Lined Heat shrink sleeving 19.1mm 10 9.HM4964Adhesive Lined Heat shrink sleeving 25.4mm 6 9.HM4965solder sleeve – Clear, 1.7mm 25 9.HM4966solder sleeve – red, 2.7mm 25 9.HM4967solder sleeve – Blue, 4.5mm 25 9.HM4968solder sleeve – yellow, 6.0mm 25 9.HM4969solder sleeve – Grey, 7.0mm 25 9.HM4970

Service Tools (included in EziPAK® Double Crimp Connector Kit)

Battery powered soldering iron 1 HM8288Flameless gas heat gun 1 HM8289Lead Free solder in Cartridge 1 9.HM4971insulation Tape – Black, 19mm x 20m Lead Free 10 9.HM4972

HM8289

9.HM4971 9.HM4972

HM82889.HM4970

9.HM4969

9.HM4968

9.HM4967

9.HM4966

9.HM4965

9.HM4964

9.HM4963

9.HM4962

9.HM4961

9.HM4960

Heat Shrink Sleevingincluded in EziPAK® Heath shrink Harness repair Kit


Super Seal ConnectorsKit and Parts

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 conductor seals, Part No. 9.HM4980.06 100 x red cavity plugs, Part No. 9.HM4980.09

HM4980

Super Seal ConnectorsWaterproof (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-P1 Pole super seal socket 4 HM4981-S2 Pole super seal Plug 4 HM4982-P2 Pole super seal socket 4 HM4982-S3 Pole super seal Plug 3 HM4983-P3 Pole super seal socket 3 HM4983-S4 Pole super seal Plug 3 HM4984-P4 Pole super seal socket 3 HM4984-S5 Pole super seal Plug 2 HM4985-P5 Pole super seal socket 2 HM4985-S6 Pole super seal Plug 2 HM4986-P6 Pole super seal socket 2 HM4986-S

Spare Parts Qty. in pack

Plug terminals to suit cable 0.35 – 0.50mm2 50 9.HM4980.01Plug terminals to suit cable 0.75 – 1.50mm2 50 9.HM4980.02socket terminals to suit cable 0.35 – 0.50mm2 50 9.HM4980.03socket terminals to suit cable 0.75 – 1.50mm2 50 9.HM4980.04Green seal to suit cable insulation 1.4 – 1.7mm dia. 50 9.HM4980.05yellow seal to suit cable insulation 1.8 – 2.4mm dia. 50 9.HM4980.06red seal to suit cable insulation 2.5 – 3.3mm dia. 50 9.HM4980.07red cavity plug 50 9.HM4980.09

Super Seal Connector Crimping ToolCrimping 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

ELECTriCAL66 AC/dC Transformers

67 Compact LEd rocker switches

67 LEd Pilot Lamps

67 Power Connectors

68 Circuit Breakers

69 MagCode Power Outlet systems

66 hELLA MINING ELECTRICAL

AC/DC Electronic Transformers

PrOdUCT FEATUrEs:Full range AC input short circuit protectionOver current protectionOver voltage protectionFully isolated plastic case

Pre-wired, no assembly requiredCompact sizesuitable 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.They 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 12Volts, in either a 20 or 60 watt power

supply or in 24Volts in 20, 60, 100, or 320 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. The bigger transformers especially, are suitable for high performance luminaires such as As5000 – and convert these products into AC luminaires.

HM1220AC HM1260AC HM2420AC HM2460AC HM24100AC HM24320AC

dC Voltage 12V 12V 24V 24V 24V 24V

rated Current 1.67A 5A 0.84A 2.5A 4A 13.3A

rated Power 20W 60W 20.2W 60W 96W 320W

ripple 120mVp-p 120mVp-p 150mVp-p 150mVp-p 150mVp-p 150mVp-p

Voltage Tolerance 5% 5% 5% 5% 3% 1%

setup, rise Time (230V AC) 500ms, 20ms 500ms, 30ms 500ms, 20ms 500ms, 30ms 1200ms, 80ms 2500ms, 80ms

Hold Up Time (230V AC) 50ms 50ms 50ms 50ms 60ms 15ms

Voltage range 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC 90 ~ 305V AC

Frequency range 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz

Efficiency 81% 83% 83% 86% 88.50% 94%

AC Current (230V AC) 0.35A 1A 0.35A 1A 0.45A 1.65A

Max inrush Current (230V AC) 70A 60A 70A 60A 40A 75A

Leakage Current (230V AC) 0.25mA 0.25mA 0.25mA 0.25mA <0.75mA <0.75mA

Over Current 110 to 150% 110 to 150% 110 to 150% 110 to 150% 95 to 102% 95 to 108%

Over Voltage 13.8 to 16V 13.8 to 16.2V 28 to 32V 27.6 to 32.4V 27 to 34V 27 to 33V

Operating Temperature (°C) -30 to +70º C -30 to +70º C -30 to +70º C -30 to +70º C -40 ~ +70°C -40 ~ +70°C

Vibration 200G 200G 200G 200G 200G 200G

ingress Protection iP67 iP67 iP67 iP67 iP67 iP67

TECHNiCAL sPECiFiCATiONs

110-240V AC – 12V DC

20VA HM1220AC60VA HM1260AC110-240V AC – 24V DC

20VA HM2420AC60VA HM2460AC100VA HM24100AC320VA HM24320AC

IP67 200G

durarAy3® As 5000LEd® duraLEd® 1000

suitable for use with dC luminaires

67hELLA MINING ELECTRICAL

PrOdUCT FEATUrEs:Easy installation, reducing costsUltra durable, reducing replacement costsHigh current capacity suits a broad range of product applicationsQuick connection saving time spent on servicingAccept varied cable sizes, reducing inventoryGenderless – reduces fitment errors

One-way fitment ensures correct polarity connection every time2 pole housingsilver-plated copper contactsrated to 600 V AC or dCHM50ANd: 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, suitable for mining and industrial applications where durability, ease of connection and release, and reliable connection are of paramount importance. Manufactured 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.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.

Connector Kit ANd, 50A 6AWG HM50ANDConnector Kit ANd, 175A 6AWG HM175ANDConnector Kit ANd, 50A 6AWG HM350ANDConnector Kit, 75A 6AWG, black HMPS75SConnector Kit, 75A 6AWG, green HMPS75GConnector Kit, 75A 6AWG, red HMPS75RConnector Kit, 75A 6AWG, blue HMPS75B

Power Connectors

Compact LED Rocker SwitchesCompact, 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.

PrOdUCT FEATUrEsMounting opening 20mm dia.suitable for panels up to 2.5mm thick.Protection – Weatherproof (from front)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

12V DC 24V DC

Amber illuminated HM4400A-12V HM4400Ared illuminated HM4400R-12V HM4400RBlue illuminated HM4400B-12V HM4400BGreen illuminated HM4400G-12V HM4400G

12/24VDC

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.

PrOdUCT FEATUrEsMounting opening 22mm dia.For panels up to 38mm thickiP65 ProtectionVoltage 12V/24V AC/dC Other voltages available upon request

LED Pilot Lamps

2716

51.5 30

13 42.6

red Green Amber White Blue

12V AC/DC 24V AC/DC

red, super Bright 2716 2716-24VGreen 2717 2717-24VAmber, super Bright 2718 2718-24VWhite 2719 2719-24VBlue, super Bright 2720 2720-24V

24V

Green, super Bright HM2717-24V

68 hELLA MINING ELECTRICAL

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

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

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

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

69hELLA MINING ELECTRICAL

PrOdUCT FEATUrEs:stable connection100% short-circuit-proofEasy to installMinimal mounting depth (port)Up to 25A current loaddust and water resistantEasy to clean

Novel coded system to avoid 12V and 24V products

AddiTiONAL FEATUrEs – POWEr sysTEM PLUs:suitable for high current loadsGreater 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, to deliver 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 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 automatic switching does not occur before the outside contact is secure, to eliminate problems associated with arcing.They are dust and water resistant, easy to clean and suitable for straightforward retrofitting a vast range of applications. Advanced technology and superior design makes them 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 HMPSPRO12VKITPower Port 12V HMPSPRO12VPTPower Clip 12V HMPSPRO12VCPPower system 24V HMPSPRO24VKITPower Port 24V HMPSPRO24VPTPower Clip 24V HMPSPRO24VCP

MagCode Power Port Cap HMPSPCAP

MagCodePower Outlet systems

Power Port

Power Clip

Specifications: MagCode Power System MagCode Power System Plus

Locking 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 dC

Max. 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, 30g

Protection 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 42

duty Cycles Without load > 10,000 cycles > 10,000 cycles At 25A 4,000 cycles 4,000 cycles

HMPsPCAP. Protective cover suits all MagCode Power Ports. snap shut cap provides reliable protection from the elements.

MagCode Power System MagCode Power System Plus

HMXN4yELyellow d2s Xenon Globe

Engineering Based solutions: Australian Antarctic divisiondue 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.

70

HELLA AS500® – Proven lighting for the most unforgiving environments.

GLOBEs71 H1

71 H2

72 H3

73 H4

74 H7

74 H9

74 H11

75 Xenon

72 hELLA MINING GLOBES

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

73


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

hELLA MINING GLOBES

H3 Globes

74


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

hELLA MINING GLOBES

H4 Premium Halogen Globes

75


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

CG1255Part No. Voltage Wattage Base Adr 51/00 Category

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

CA1255 12 55 PX26d H7 •

CA2470 24 70 PX26d H7 •

hELLA MINING GLOBES

H7 Globes

H9 Globes

H11 Globes

76 hELLA MINING GLOBES

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

15mm

Note: Use this lamp for PulseRAY Xenon strobe warning beacons.

TECHNiCAL78 General information

79 What is LEd technology?

80 What is Xenon lighting technology?

81 HELLA work light systems

81 drACO® vibration damping systems

82 MustAdd® filter technology

83 Meaning of the iP (ingress Protection) Code

78 hELLA MINING TEChNICAL INFORMATION

General InformationLuminous 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 Lamps

Fluorescent, 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

79hELLA MINING TEChNICAL INFORMATION

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.

What is LED Technology?

80

What is Xenon lighting technology?

hELLA MINING TEChNICAL INFORMATION

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 specialised 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 (daylight) 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.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.

81

For mining vehicles and production plant, good lighting is essential for activities other than just driving. Haul trucks, shovels, drills, cranes and special purpose vehicles often need separate, pivotable ‘work lamps’ for loading, unloading, and other operations. Using the right 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. select HELLA work lamps that suit the specific task best using LEd, Xenon or Halogen technology. Lights are available with integral handles, dual beam optics and a wide range of mounting options. For complex projects, take advantage of 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 Light systems

Paraboloid lamp

Free-Form (FF) lamp

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 applicationdrACO 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-rigid 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

ation

— input— drACO® output— std output— difference (drACO®-std)

Time

DRACO® vibration damping systems


DRACO

82

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

MustADD® Filter Technology


MUSTADD

83

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

012345K6K

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

Construction and meaning of the IP (Ingress Protection) Code


84 hELLA MINING

2 PAGE

2716 672716-24V 672717 672717-24V 672718 672718-24V 672719 672719-24V 672720 672720-24V 67

8 PAGE

8273 618730 688731 688732 688733 688734 688735 688736 688737 688738 688739 688740 688741 688742 688743 688744 688745 688746 688HG959952022 48

9 PAGE

9.1600.01 329.1600.06 329.1601.01 329.1602.01 329.1603.01 329.1604.01 32

9HM PAGE

9.HM15BAL 169.HM15NB 169.HM15TrN 16, 189.HM15WB 169.HM300FLX 29, 309.HM360LENs 29, 309.HM400LENs 279.HM450ALENs 25, 269.HM450BLENs 25, 269.HM450FLX 24, 25, 26, 279.HM450GLENs 25, 269.HM450rLENs 25, 269.HM450WLENs 24, 25, 269.HM46FX 409.HM46GL 409.HM46MP 409.HM46Ms 409.HM4810 569.HM4811 569.HM4812 569.HM4813 56

9.HM4814 569.HM4815 569.HM4816 569.HM4817 569.HM4818 569.HM4819 569.HM4820 569.HM4821 569.HM4822 569.HM4823 579.HM4824 579.HM4825 579.HM4826 579.HM4827 579.HM4828 579.HM4829 579.HM4830 579.HM4831 579.HM4832 579.HM4833 579.HM4834 579.HM4835 579.HM4836 579.HM4837 579.HM4838 579.HM4839 579.HM4840 579.HM4841 579.HM4842 579.HM4843 579.HM4844 579.HM4845 579.HM4846 579.HM4847 579.HM4848 579.HM4849 579.HM4850 579.HM4851 579.HM4852 579.HM4853 579.HM4854 579.HM4855 579.HM4856 579.HM4857 579.HM4858 579.HM4859 579.HM4860 579.HM4861 579.HM4862 579.HM4863 579.HM4864 579.HM4940 609.HM4940G 569.HM4941 609.HM4941G 569.HM4942 609.HM4942G 569.HM4943 609.HM4943G 569.HM4944 609.HM4945 609.HM4946 609.HM4946G 569.HM4947 609.HM4947G 569.HM4948 609.HM4949 609.HM4950 60

9.HM4951 609.HM4952 609.HM4953 609.HM4954 609.HM4955 609.HM4956 609.HM4957 609.HM4958 609.HM4959 609.HM4960 639.HM4960.01 469.HM4960.02 469.HM4960.03 469.HM4960.04 469.HM4960.05 469.HM4961 639.HM4962 639.HM4963 639.HM4964 639.HM4965 639.HM4966 639.HM4967 639.HM4968 639.HM4969 639.HM4970 639.HM4971 639.HM4972 43, 639.HM4973 629.HM4974 629.HM4975 629.HM4976 629.HM4977 629.HM4978 629.HM4979 629.HM4980 629.HM4980.01 649.HM4980.02 649.HM4980.03 649.HM4980.04 649.HM4980.05 649.HM4980.06 649.HM4980.07 649.HM4980.09 649.HM4981 629.HM4982 629.HM4983 629.HM4984 629.HM4985 629.HM4986 629.HM4987 629.HM4988 629.HM4989 629.HM4990 629.HM4991 629.HM4992 629.HM4993 629.HM70Br 12, 199.HM70dC 199.HM70WH 199.HM759rEd 419.HM759yEL 419.HM8500 619.HM8501 619.HM8502 619.HM8503 619.HM8504 619.HM8505 619.HM8511 61

9.HM8513 619.HM8514 619.HM8520 619.HM8521 619.HM8522 619.HM8523 619.HM8530 619.HM8531 619.HM8532 619.HM8541 619.HM8543 619.HM8548 619.HM8549 619.HM9386.02 229.HMAPEdL 16, 189.HMAsHNB 189.HMAsHWB 189.HMAWHKd 16, 189.HMdLM001 31, 35, 379.HMdLM002 389.HMTN001 449.HMTN002 44, 459.HMTN003 44, 459.HMTN004 44, 459.HMTN005 459.HMTN006 459.HMX7500.01 329.HMX7500.02 32

C PAGE

C12100 71C1255LL 71C24100 71C2470 71C2470LTs 71CA1255 74CA1255LL 74CA2470 74CA2470LTs 74CB1255BL 71Cd12100 71Cd1255 71Cd24100 71Cd2470 71CF1265 19, 74CG1255 74CG2470 74CX1255BL 71

HM0 PAGE

HM060321 36HM060621 36HM070321 36HM070621 36

HM1 PAGE

HM1220AC 66HM1260AC 66HM1500NB 8HM1500NBd 8HM1500WB 8HM1500WBd 8HM1510NB 18HM1510WB 18HM1511NB 18HM1511WB 18HM1512NB 16HM1512WB 16HM1513NB 16HM1513WB 16HM1528WB-12 20HM1528WB-24 20HM1535drL 37HM1535NB 13HM1535PB 13HM1535WB 13HM1539Ldd 12HM1539LEd 12HM1550CiG 14HM1550dT 14HM1550MAG-12 14HM1550MAG-24 14HM1550WB 14HM15700NB 15HM15700PB 15HM15700WB 15HM1590WB 11HM175ANd 67

HM2 PAGE

HM2026 38HM2026d 38HM2051 38HM2051d 38HM2053PC 38HM2053PCd 38HM2054 38HM2054d 38HM227Hd 49HM2307 38HM2307d 38HM2379 35HM2379d 35HM2380 34HM2380d 34HM2380dT 34HM24100AC 66HM2420AC 66HM24320AC 66HM2460AC 66HM2717-24V 67HM290Adir 28HM290Bdir 28HM290Gdir 28H M290rdir 28HM290Wdir 28

Part Number Index

85hELLA MINING

HM3 PAGE

HM300Adir 30HM300AMAG 30HM300Bdir 30HM300BMAG 30HM300Gdir 30HM300GMAG 30HM300rdir 30HM300rMAG 30HM300Wdir 30HM300WMAG 30HM350ANd 67HM360ABP 29HM360Adir 29HM360AMAG 29HM360BBPMAG 29HM360Bdir 29HM360BMAG 29HM360BPMAG 29HM360Gdir 29HM360GMAG 29HM360PiPE 29, 30HM360rBP 29HM360rdir 29HM360rMAG 29HM360Wdir 29HM360WMAG 29

HM4 PAGE

HM400Adir 27HM400AMAG 27HM400Bdir 27HM400BMAG 27HM400Gdir 27HM400GMAG 27HM400PiPE 24, 25, 26, 27HM400rdir 27HM400rMAG 27HM400Wdir 27HM400WMAG 27HM4400A 67HM4400A-12V 67HM4400B 67HM4400B-12V 67HM4400G 67HM4400G-12V 67HM4400r 67HM4400r-12V 67HM450Adir 26HM450AMAG 26HM450Ardir 24HM450Bdir 26HM450BMAG 26HM450Gdir 26HM450GMAG 26HM450Grdir 24HM450rdir 26HM450rMAG 26HM450Wdir 26HM450WMAG 26HM4612 40HM4620 40HM4630 40HM4960 46HM4960FM 46HM4960sA 44, 45

HM4961 46HM4961FM 46HM4962 46HM4963 46HM4963FM 46HM4964 46HM4965 46HM4980 64HM4981-P 64HM4981-s 64HM4982-P 64HM4982-s 64HM4983-P 64HM4983-s 64HM4984-P 64HM4984-s 64HM4985-P 64HM4985-s 64HM4986-P 64HM4986-s 64

HM5 PAGE

HM500Adir 25HM500AMAG 25HM500Bdir 25HM500BMAG 25HM500Gdir 25HM500GMAG 25HM500rdir 25HM500rMAG 25HM500Wdir 25HM500WMAG 25HM50ANd 67

HM6 PAGE

HM6603Bd-12V 50HM6603Bd-24V 50HM6603Gd-12V 50HM6603Gd-24V 50HM6605rd-12V 50HM6605rd-24V 50HM6605Wd-12V 50HM6605Wd-24V 50

HM7 PAGE

HM70H3NB-24V 19HM70H3WB-24V 19HM70H9NB-12V 19HM70H9WB-12V 19HM70LEdd 12HM70Pi 12, 19HM70Pr 12, 19HM7546B 43HM7546C 43HM7546J 43HM7546KiT 43HM7590r 41HM7590y 41HM7591s 41HM7592B 41HM7592y 41

HM8 PAGE

HM8164 16, 18HM8275 46, 58, 60HM8277 46, 58, 60HM8283 58HM8284 58HM8285 59HM8286 58HM8287 59HM8288 63HM8289 63HM8290 59HM8291 56HM8292 56HM8293 56HM8294 57HM8295 57HM8296 56HM8298 64

HM9 PAGE

HM9500Adir 22HM9500rdir 22HM95903700 31HM95903700d 31HM95903710 31HM95903710d 31HM95903760 31HM95903760d 31HM95903780 31HM95903780d 31HM95903790 31HM95903790d 31HM95905030 37HM959950211 48HM959950221 48HM9600Adir 23HM9600AMAG 23HM9600APiP 23

HMA PAGE

HMAT85 43

HME PAGE

HME6750A 32HME6750B 32HME6750C 32HME6750G 32HME6750r 32HMEC1010AU 42HMEC1510AU 42HMEC2010AU 42HMEC2015AU 42HMEC2510AU 42HMEC3015AU 42HMEC4015AU 42

HMF PAGE

HMFH107P 52HMFH117P 52HMFH312P 52

HMI PAGE

HMiC2010AU 42HMiC2015AU 42HMiC3020AU 42HMPB100 11

HMP PAGE

HMPB300NB 10HMPB300WB 10HMPs12VCP 69HMPs12VKiT 69HMPs12VPT 69HMPs24VCP 69HMPs24VKiT 69HMPs24VPT 69HMPs75B 67HMPs75G 67HMPs75r 67HMPs75s 67HMPsPCAP 69HMPsPrO12VCP 69HMPsPrO12VKiT 69HMPsPrO12VPT 69HMPsPrO24VCP 69HMPsPrO24VKiT 69HMPsPrO24VPT 69

HMR PAGE

HMrA087B 54HMrA107B 54HMrA112P 53HMrA917E 53

HMT PAGE

HMTNd2156 44HMTNd2157 44HMTNd2158 44HMTNM2156 45HMTNM6605 44, 45HMTNM6606 44HMTNM6607 44HMTNM6608 44HMTNM6609 44HMTNM6610 45HMTNM6611 45HMTNM6612 45HMTNM6613 45

HMW PAGE

HMWGA160 32HMWGA220 32HMWPr001 43HMWPr002 43

HMX PAGE

HMX7500A 32HMXN4001 75HMXN4yEL 75

X PAGE

Xd12100/55 73Xd12100/90 73Xd1260/55 73Xd1260/55LL 73Xd24100/90 73Xd2475/70 73Xd2475/70LL 73Xd2475/70LTs 73XdB1260/55BL 73XdX1260/55BL 73XN4000 16, 75XN6750 32, 75

Y PAGE

yC12100 72yC1255LL 18, 20, 72yC24100 72yC2470 18, 19, 20, 72yC2470LTs 72yCB1255BL 72yCP1255BL 72yCX1255BL 72

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