Download - Industrial and Bearing Supplies

industrialbearings.com.au

Download - Industrial and Bearing Supplies

Hella

Mining Catalogue

4th Edition


Hella Australia Pty Ltd

ABN 77 006 256 524

54 – 76 Southern Road

Mentone Victoria

Australia 3194

PO Box 89

Mentone Victoria

Australia 3194

P 03 9581 9333

F 03 9585 2654

E mining@ha.hella.com

W www.hella.com/mining

Customer Service:

P 03 9581 9299

F 03 9583 1838

P Techline 1800 061729

E custservice@ha.hella.com

Expert professional

advice from our

technical department

staffed with qualified

personnel

Product availability

and new product

updates

Customer-specific

lighting applications

engineering service

www.hella.com/mining

International Regions

Africa

Hella Automotive

South Africa (Pty) Ltd

1 Fitzpatrick Street

Uitenhage

South Africa 6232

Phone: +27 (0)11-538-7530

Asia

Hella Asia Singapore Pte Ltd

Regional Headquarters

Asia Pacific

Independent Aftermarket

2 International Business Park

#02 – 15

The Strategy

Singapore 609930

DID: +65 6854 7343

USA

Hella Mining LLC

1250 Lamollie Hwy

Suite 414

Elko Nevada 89801

Fax: (775) 738-7450

Phone: (775) 738-7441

Canada

Hella, Inc.

201 Kelly Drive

Peachtree City, GA 30269

Phone: (770) 626-2209

Fax: (770) 631-7575

Mexico & South America

Hellamex, S.A. de C.V.

Proten No. 50

Parque Industrial Naucalpan

Estado de Mexico, Mexico

C.P. 53489

Phone: (52) 55-5321-1300

New Zealand

Hella-New Zealand Limited

PO Box 51427

81–83 Ben Lomond Crescent

Pakuranga, Auckland 1706

Telephone: (09) 577 0000

Fax: (09) 576 2476

Internet: www.hella.co.nz

Europe

Hella KGaA Hueck & Co.

Rixbecker Straße 75

59552 Lippstadt/Germany

Internet: www.hella.com

Telephone: +49 (0) 29 41/38-0

Fax: +49 (0) 29 41/38-71 33

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

printing. However Hella reserves the right, subject to all applicable laws, at any time, at its discretion and without notice,

to discontinue or change the specifications or design of any product referred to herein.

The data and suggested applications are given as a general guide only and users should independently evaluate the

suitability of each product for any particular application.

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


Hella Centre of Excellence – Mining 3

Mining Centre of Excellence

Hella Australia manufactures automotive

lighting equipment, and plastic

mouldings and accessories, and employs

approximately 500 people. Its facility in

Mentone, Victoria, designs, develops and

manufactures a range of lighting products

including headlamps, reflectors, lenses,

signal lamps, interior and exterior lighting,

and auxiliary lamps and mouldings.

Hella products are developed and built using

state-of-the-art technology and are used on some

of the most advanced cars in the world.

The Hella manufacturing plant employs injection

moulding machines, polycarbonate lens moulding

machines, thermoset moulding machines,

automated paint processes, hot foil stamping,

aluminium metallising and lacquering facilities.

The Hella Centre of Excellence – Mining, at Hella Australia

head office in Mentone Victoria, was launched in 2002 to

drive a global mine lighting program focussed on the unique

requirements of mining. The key factors in the Australian location

of this important business are:

Over 1280 mines operate under the most stringent safety

requirements, so Australia is the best place to develop and

prove products for the global mining industry

Hella Australia is equipped with highly advanced production

and distribution facilities

Hella Australia has its own full design and development

facilities that include: NATA registered Photometric

Laboratory, Chemical Analysis Laboratory Facilities,

and some of the most advanced environmental and

physical test simulation facilities available anywhere.

Hella continues to develop, prove and market innovative

products based on worldwide leadership in advanced lighting

technology – to demonstrably improve end user profitability in

mining applications. This is achieved through products that offer:

Greater safety

Lower operating cost

Greater productivity

Predictable service

Better value

Hella mining products are backed by the renowned global Hella

quality guarantee, and service and distribution network.

Project Argon charts the extremes

Developing lighting equipment that will go the distance in

mines requires a very clear understanding of their operating

systems and specific environmental conditions.

At Hella, we don’t guess, we measure.

Hella Australia initiated

ARGON, a research

project to collect

detailed data from a

diverse range of mines

and machines.

A suite of robust

sensors with

integrated data

loggers is mounted on

mining plant and machines to record operating conditions, with

the equipment working as normal.

After the sensors are recovered from the machines, their

data is downloaded for analysis and used as the basis of

product design and test specifications able to match extreme

mining environments.

Statement of Warranty

Hella Mining products are covered by a one year warranty which

covers faults in material or workmanship only and provided that

the product is used for its intended purpose.

Important Note

Only products specifically identified as ECE or SAE compliant

are approved for use on public roads, when installed and

operated as required by local regulation on approved vehicles.

The responsibility for correct selection, fitment and operation to

meet local regulations is that of the vehicle operator.


4 How to read this catalogue

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

MULTI

VOLT

Multivolt

H3

Lamp type

24V

Rated voltage

IP6K

IP rating

Electrical Compliance

MUSTADD

MustADD ®

DT

Connection type

3W

Power consumption/load

Transient spike protection

ECE

APPROVED

Public road traffic

compliance type

DRACO

DRACO ®

1.4Kg

Mass

200G

Rated shock resistance

MULTI

FLASH

MultiFLASH ®

Hella Mining Part Numbers

12V H3

24V H3

Wide Beam HM1524WB HM1526WB

Narrow Beam HM1524NB HM1526NB

Long Range HM1524LR HM1526LR

MINING WORK LAMPS

Page number

Product section

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

28

UltraBeamFF Halogen

Work Lamp – 12/24V

UltraBeam FF Halogen, available with Wide, Narrow

and Long Range Beams, are superior, compact

heavy-duty work lamps for use on mining machinery,

and suitable for both 24V and 12V electrical

systems.

Product dimensions

Alternative view

Alternative model

Spare parts or

options

112 94

101 84

127

24

87 50

Front View, Long Range

Narrow Beam

As part of our ongoing

development the Long Range

addition to the UltraBeam FF

range applies our most recent

advances in free-form (FF) reflector

technology. With a clear lens

and the popular H3 Halogen

globe it’s a compact long range

lamp for applications where the

performance of a Xenon light is not

required.

The very compact optics deliver

excellent lighting under continuous

use in the extreme environmental

conditions encountered in mining

applications. Electrical connection

is via integrated DT connector.

The UltraBeam FF clear lens

long range optical insert is a

modular assembly of a precision

die-cast specular reflector with

integral lamp holder, permanently

assembled to a corrosion resistant

hardened clear glass lens, for high

efficiency and perfect focus. The

new lens long range optical insert

is available as a spare part and

is 100% compatible with older

UltraBeam FF H3 work lamps to

enable simple on site maintenance

and perfect retrofitting.

In common with the all

Hella UltraBeam FF work

lamps, the basic version

of the patented MustADD ®

filter is included so the

optical system remains

virtually dust free over

the product life,

in the adverse

atmospheres

typically encountered

in mining.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant. The

UltraBeam FF features integral

DRACO ® dampers in the bracket

system to reduce the intensity of

shock and vibration.

The UltraBeam FF family is based

on very compact lamp housings

moulded from a highly corrosion

resistant, heavy-duty polymer

body.

A lens retaining ring enables easy

routine service access from the

front, while high temperature O-ring

seals ensure effective sealing.

Long Range Lens

Product features:

Powerful long range

and wide spread

illumination

AMP or DT electrical

connection

Robust polymer body

Stainless steel

mounting bracket

Draco ® suspension

MustADD ® multi

air-filter

Specifications:

Temperature Range

-40°C to +105°C

Mounting

Single bolt with tilt

adjustment for upright,

side or pendant

mounting on horizontal

or vertical surfaces.

Stainless steel bracket

and screws included

Free-form (FF) reflector

for powerful long range

illumination

Components tested

over a –40°C to

+105ºC temperature

range

IP6K7

O-ring seals

Clear protective covers

available

Protection

Sealed against dust

and moisture to IP6K7.

Shock resistant to 50G.

HM8158

HM8158AMBER

Spare parts or

options listing

Product feature

symbols (see above

for key)

MUSTADD

DRACO

H3, H9,

H11

IP6K7 50G 12/24V

DT &

AMP

70W

MAX

0.8Kg

Spare Parts:

HM8158

Clear Protective Cover

HM8158AMBER

Clear Protective Cover

- Amber

9.1533.03

Long Range Insert

9.HMUBHNB Insert –

Narrow Optic

9.HUMBHWB

Insert – Wide Optic

YC2470

H3 Globe, 24V 70W

YC1255

H3 Globe, 12V 55W


Contents

5

WORK LAMPS 6

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

9 Power Beam 2000 16 AS500FF Xenon 30 HydroLUX

10 Megabeam 18 AS200FF Xenon 32 AS200 FF Halogen

11 Module 70 LED 20 UltraBeam FF X-PowerPack 34 Oval 100 FF Halogen

12 LED Task Lamps 22 UltraBeam FF Xenon 36 Module 70 Halogen

13 DuraLED 700 Lumen 24 Oval 100 FF Xenon

14 DuraLED 1000 Lumen 26 AS500FF Halogen

BEACONS 38

40 DuraRAY Phase II 48 OptiRAY 54 DuraLED M High Intensity

42 UltraRAY-R Twin 50 OptiRAY E 56 PulseRAY KLX

44 UltraRAY-R “Rotating” 52 MiniRAY 58 PulseRAY E67

46 UltraRAY 53 NaviLED M

SIGNAL LAMPS 60

62 DuraLED SAE 64 DuraLED M Combi 66 DuraLED Marker

63 DuraLED ECE 65 DuraLED MSIP 67 LED Daytime Running Lamp

ACCESSORIES 68

70 LED Buggy Whip 74 NumiLED 80 Weatherproof Relay

71 Remote Jump Start Terminals 75 NumiLED Pro 80 Self-Amalgamating Tape

71 Battery Master Lockout Switch 76 IR Dual Camera System 81 DT Connectors

72 Screened Extension Cables 77 Quad Screen IR Kit

73 HD Screened Ext. Cables 78 AccuPAX

84 EuroLED Touch M 86 SpotLED 89 MiniThinLED

85 CargoLED 88 FlexSPOT

INTERIOR LIGHTING 82

92 MotoVOX 94 RetroVOX Compression Driver

93 RetroVOX Self Adjusting 95 RetroVOX Broadband

HORNS & ALARMS 90

98 EziPAK DT Connector Kit 102 EziPAK Heat Shrink Kit 106 Super Seal Connector

100 EziPAK Double Crimp Kit 104 EziPAK Intelligent Fuse Kit 107 PowerPAK

SERVICE TOOLS 96

110 AC/DC Transformers 113 LED Pilot Lamps 116 MagCode

111 Power Connectors 114 Heavy Duty Circuit Breakers

112 LED Rocker Switches 115 Thermal Circuit Breakers

ELECTRICAL 108

120 H1, H2 122 H4 124 Xenon

121 H3 123 H7, H9, H11

GLOBES 118

126 Technical Information 145 Part Number Index

TECHNICAL 126


Work Lamps 7

WORK LAMPS

8 Power Beam 1000

9 Power Beam 2000

10 Megabeam

11 Module 70 LED

12 LED Task Lamps

13 DuraLED 700 Lumen

14 DuraLED 1000 Lumen

15 DuraLED Magnetic Base

16 AS500FF Xenon

18 AS200FF Xenon

20 UltraBeam FF X-PowerPack

22 UltraBeam FF Xenon

24 Oval 100 FF Xenon

26 AS500FF Halogen

28 UltraBeam FF Halogen

30 HydroLUX

32 AS200FF Halogen

34 Oval 100 FF Halogen

36 Module 70 Halogen


Power Beam 1000

LED Work Lamp

HMPB100

LED WORK LAMPS

WORK LAMPS

8

Power Beam 1000

LED Work Lamp – Multivolt 9-33V DC

As an addition to the Hella LED work lamp

range, the Power Beam 1000 has been

developed as a compact high-powered

illuminating source.

114.5

142

112

62

96

By combining 6 high-powered

LEDs into a compact fully sealed

die cast housing, the Power Beam

1000 provides a respectable

850 Lumen output to provide

close range illumination where

physical constraints on mining

machinery exist.

A rated operating temperature from

-40 to +50°C and an expected

lifespan of over 130 times that

of a halogen bulb, in addition to

excellent ingress protection, make

the Power Beam 1000 suitable

for the most unforgiving mining

environments.

With a low power consumption of

18 Watts, the lamp places minimal

strain on the vehicle’s electrical

system while the quality electronics

provide Multivolt operation over

a range of voltage levels from

9 to 33V DC. The Power Beam

1000 also

features

reverse

polarity

protection,

and

overheating

protection,

which turns the

light off when the

integrated thermal sensor

is triggered.

The integrated DT Plug allows

simple installation and waterproof

connectivity, and the heavy-duty

stainless steel bracket allows for a

wide variety of mounting options.

The low EMC signature ensures the

lamp does not interfere with any

critical safety equipment such as

radios or other electrical devices.

Product features

Operating voltage:

Multivolt 9-32 V DC

16 high power LEDs

Power consumption:

18 W

Light output 850 lm

Colour temperature

6500°K

Low EMC Signature

(CISPR25 class 5)

Ingress Protection

IP6K7 and IP6K9K

Lifespan up to 130

times of a halogen bulb

Connection: integrated

DT plug

Polarity protected

LED fail bridge

High-temperature

protection

Environment temp

-40 to +50°C

Power Beam 1000 LED 2.0m high at 10°

1 LUX 39m

MULTI

VOLT

LED

0.6 Kg

9 to 33

V DC

18W

IP6K7 IP6K9K 200G


Power Beam 2000

LED Work Lamp

HMPB200

LED WORK LAMPS

Power Beam 2000

LED Work Lamp – Multivolt 9-33V DC

As an addition to the Hella LED work lamp

range, the Power Beam 2000 has been

developed as a compact high-powered

illuminating source.

9

WORK LAMPS

By combining

16 highpowered

LEDs into a

compact fully

sealed die cast

housing, the Power Beam 2000

is able to achieve an outstanding

2200 Lumen output to provide

close range illumination where

physical constraints on mining

machinery exist.

With a low power consumption

of 43 Watts, the lamp places

minimal strain on the vehicle’s

electrical system, while the quality

electronics provide Multivolt

operation over a range of voltage

levels from 9 to 33V DC. The Power

Beam 2000 also features reverse

polarity protection, and overheating

protection, which turns the light off

when the integrated thermal sensor

is triggered.

144.5

114

103

107

Product features

Operating voltage:

Multivolt 9-33 V DC

16 high power LEDs

Power consumption:

43 W

Light output 2200 lm

Colour temperature

6000°K

Low EMC Signature

(CISPR25 class 5)

Environment temp

-40 to +50°C

Die cast aluminium

housing, bracket made

of stainless steel

Ingress Protection

IP6K7 and IP6K9K

Lifespan up to 130

times of a halogen bulb

Connection: integrated

cable

Polarity protected

LED fail bridge

High-temperature

protection

With a rated operating temperature

from -40 to +50°C and an expected

lifespan of over 130 times that

of a halogen bulb, in addition to

excellent ingress protection make

the Power Beam 2000 suitable

for the most unforgiving mining

environments.

The Power Beam 1000 comes

pre-wired with 1.8 metres of

electrical cable, allowing quick

and easy installation.

The low EMC signature (class 5)

ensures the lamp does not interfere

with any critical safety equipment

such as radios.

MULTI

VOLT

LED

1.4Kg

9 to 33

V DC

43W

IP6K7 IP6K9K 200G


MegaBeam

LED Work Lamp

LED Work Lamp DT

HM1539LED

HM1539LDD

MINING WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

10

MegaBeam

LED Work Lamp – Multivolt 12-24V

Hella MegaBeam LED is a compact close range

work lamp for use on special vehicles and mining

machines where high vibration or extreme cold

makes the use of conventional work lamps

impractical. High intensity white LEDs provide low

power illumination in an ultra reliable design.

Front View

Clear cover to be ordered separately

Solid-state LED light sources

enabled the design of a fitand-forget,

completely sealed

and waterproof work lamp that

needs no service. The very long

service life of the MegaBeam

LED, combined with no lighting

loss due to internal dirt build-up,

enables the work lamps to deliver

reliable lighting under extremely

tough operating conditions. Low

power consumption and Multivolt

operation features pioneered by

Hella LED products are integral to

the product design.

Brilliant Free-Form reflector optics,

combined with a clear lens,

optimize the light distribution of

the high intensity white LEDs in

the MegaBeam LED work lamp

to provide homogenous large

area illumination with maximum

efficiency. Maximum service

life and light output of the high

intensity LEDs is ensured through

using the die cast aluminium

body as a massive heat sink; its

ergonomic oval shape creates an

efficient and compact unit, easy to

fit into confined spaces.

Fully encapsulated

Multivolt drive circuitry

delivers consistent

illumination from 12-24V

DC – even under severe

voltage fluctuations and

low battery voltage.

Comprehensive

protection against

reverse polarity, highvoltage

spikes and

over-voltage, ensures

reliable operation.

Safe and reliable electrical

connection is facilitated via a 2m

length of highly flexible double

insulated cable, terminated with

either a DT connector or bare wire

ends.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant.

Product features

Yellow ring marks

product as mining

specification version

Electrical connection:

2m double insulated

cable with bare wire

ends or short length

with DT connector

Stainless steel

mounting bracket

IP5K9K

Multivolt 12V DC to

24V DC

Die cast aluminium

body

Multi stage anticorrosion

powder coat

High visibility yellow

identification ring

source array

Fully sealed “Fit and

Forget” design

Pre-wired with multi

strand double insulated

cable

Spike protected to

+500 volts

Over voltage protected

to +200 volts

Reverse polarity

protected to

-500 volts

Power consumption 7W

200G shock impulse

resistant

-40ºC to +50ºC

temperature range

CE compliant

Clear glass lens

High intensity LED light

Spare Parts & Options

HM8161

Clear Protective Cover

MULTI

VOLT

LED

DT &

AMP

0.8Kg

IP6K9

200G

12 to 24

V DC

7W


Module 70 LED

LED Work Lamp DT

HM70LEDD

MINING WORK LAMPS

Module 70 LED

Work Lamp – Multivolt 12-24V

11

WORK LAMPS

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.

Product features

4 high-performance

LEDs

Warm white light output

(colour temperature

6500°K)

200mm double

insulated cable harness

with DT connector

Low power

consumption

Multivolt 12-24V DC

Specifications

Voltage

Multivolt 12-24V DC

Power Consumption

15W

Mounting

Stainless steel pedestal

bracket for upright, side

or pendant mounting.

Cable

200mm double

insulated cable harness

with DT connector.

High-sheen free-form

(FF) reflector

Aluminium die cast

housing

Modern clear glass lens

Resistant to shock and

vibration

IP6K7 & IP6K9K

Reverse polarity and

over

voltage protected

Stainless steel

mounting bracket

Temperature Range

-40°C to +50°C

Protection

Reverse polarity and

Transient Voltage

Suppressor (TVS).

Fully sealed against

dust and moisture to

IP6K7 and IP6K9K.

Shock resistant to

200G.

Module 70 LED work

lamps utilise advanced

materials in a unitary

design that directly bonds a

cast aluminium free-form (FF)

reflector, clear glass lens and high

temperature polymer housing into

a low mass, efficient and very

compact work lamp. Solid-state

high-performance white LED light

sources enabled the design of a

‘fit & forget’, completely sealed

work lamp that requires no service.

The very long service life of

the Module 70 LED, combined

with no lighting loss due to

internal dirt build-up, enables

the work lamps to deliver reliable

lighting under extremely tough

operating conditions. Low power

consumption and Multivolt

operation features, which have

been pioneered by Hella LED

products, are integral to the

product design.

Brilliant free-form (FF) reflector

optics combined with a clear lens

optimise the light distribution of

the high intensity white LEDs in

the Module 70 LED work lamp

to provide and even illumination

with maximum efficiency, reduced

scatter losses and improved beam

control. Maximum service life and

light output of the high intensity

LEDs is ensured through using

the die cast aluminium body as a

massive heat sink; its ergonomic

Module 70 LED 2.0m high at 10°

shape creates an efficient and

compact unit, easy to fit into

confined spaces.

Module 70 LED work lamps

have been tested to withstand

extremely high levels of vibration

and mechanical shock, and

are highly suitable for use in

applications where extreme cold

and mechanical stress make

other work lamps unsuitable.

The low power consumption and

compact size also renders Module

70 LED work lamps suitable for

use inside confined spaces, with

portable power packs, on new

generation small equipment based

on recreational vehicles, battery

powered vehicles and to illuminate

the equipment bays on site service

vehicles and large machinery.

The Module 70 LED features a

rotating base as standard, which

allows vertical adjustment of +

48° to -115°, and 360° rotation

adjustment. The supplied stainless

steel hardware is non-resonant

and highly corrosion resistant. Safe

and reliable electrical connection

is facilitated via 200mm length of

highly flexible double insulated

cable, terminated with a DT

connector. Optional pipe mount

adaptors with and without rotating

adjustment is available. Additional

variants of the Module 70 LED are

available on special request.

83

111

M10

Front view

HM70PR

Ø15-28

52

105

83

HM70PI

75

Spare Parts & Options

HM70PR

Pipe mount tube

attachment (rotating)

HM70PI

Pipe mount tube

attachment

9.HM70BR

Stainless steel bracket

1 LUX 37m

MULTI

VOLT

IP6K7

LED

200G

DT

12 to 24

V DC

0.4Kg

15W


LED Task Lamp

Narrow Beam

Pencil Beam

Wide Beam

HM1535NB

HM1535PB

HM1535WB

LED TASK LAMPS

WORK LAMPS12

LED Task Lamp

On mine sites visibility is paramount to mine safety.

Hella has just launched a low power LED Task Lamp that

provides extra safety through enhanced visibility, at

a fraction of the power consumption of

halogen or HID light fittings.

136 49

53

42

Hella LED Task Lamps are

designed to provide an illuminating

light source in a compact, low

power draw package for various

applications where low profile

fitting and even illumination is

required. The lights are sealed to

withstand high-pressure washing

and require no maintenance (“fit

and forget”).

The lower power usage and

no-maintenance requirement, make

these lamps a sound investment

in enhanced mine safety. The lens

is manufactured from Swiss made

Grilamid ® Optical Nylon which

provides superior resistance to UV

and to a wide range of chemicals,

as well

as high

impact

strength

enabling

the lamp

to survive the

highly demanding environmental

conditions of today’s mining.

The new Hella Task Lamps are

suitable for upright or pendant

mounting and supplied with

universal stainless steel mounting

brackets. They have multiple

applications, which include area

illumination around and inside

the vehicle.

Product features

Multivolt (9-33V DC)

Equipped with

12 highly efficient LEDs

rated at 240 Lumens

Ultra long life ‘Fit and

Forget’

Low power

consumption


DuraLed ® 700 Lumen White LED Service Lamp

Wide Beam

HM15700WB

Narrow Beam

HM15700NB

Pencil Beam

HM15700PB

MINING LED SERVICE LAMPS

®

DuraLed

Hella has developed a new range of universal,

high intensity and ultra energy efficient

DuraLed ® LED Service Lamps offering the

industry benchmark highest efficacy for a variety

of heavy-duty mine lighting applications.

700 Lumen

White LED Service Lamp Multivolt 9-33V DC

13

WORK LAMPS

Product features

Industry benchmark

highest efficacy – 36

LEDs rated to a total of

700 lumen per lamp

Multivolt 9-33V DC

Power consumption


DuraLed ® 1000 Lumen White LED Service Lamp

Wide Beam

HM1550WB

MINING LED SERVICE LAMPS

WORK LAMPS

14

®

DuraLed

1000 Lumen

White LED Service Lamp Multivolt 9-33V DC

Hella has developed a new range of universal, high intensity

and ultra energy efficient DuraLed ® LED Service

Lamps offering the industry benchmark

highest efficacy for a variety of heavy-duty

mine lighting applications.

222

193

34

96

LED lighting offers a number

of decisive advantages over

conventional globe technology that

are beneficial for mining work area

lighting. The new Mining DuraLed ®

High Efficacy LED Service Lamps

consume as little as 9 watts of

power for minimal strain on both

alternator and battery.

In addition to significantly reduced

current draw, the highly efficient,

low temperature LED circuit design

ensures ultra long service life and

extremely low degradation

of performance.

Equipped with precision optics and

the most powerful LEDs available

to date, DuraLed ® High Efficacy

LED Service Lamps provide

exceptional white light output

and optimum light distribution for

significantly improved work safety

and reduced fatigue.

DuraLed ® High Efficacy LED

Service Lamps also offer superior

functional safety and operating

reliability. Unlike Halogen globes,

LEDs are

resistant to

shock and

vibration

and last a

minimum of

10,000 hours,

eliminating the risk of sudden light

failure during

lamp operation.

The lens is manufactured from

ultra-durable Grilamid ® nylon, a

revolutionary high-performance

clear polyamide developed and

manufactured in Switzerland for

extreme impact, UV, chemical and

stress resistance.

DuraLed ® High Efficacy LED

Service Lamps are fully sealed

against dust and moisture ingress

and available in a range of output

intensities and beam patterns:

narrow, pencil and spread beam, to

suit every individual mine lighting

requirement.

Product features

Industry benchmark

highest efficacy - 50

LEDs rated to a total of

1000 lumen per lamp

Multivolt 9-33V DC

Power consumption

< 12W

Ultra durable Grilamid ®

nylon lens for extreme

impact, UV, chemical

and stress resistance

Efficient, low

temperature LED circuit

design ensures ultra

long

life and low degradation

of performance

Wide beam precision

optic for optimum light

distribution

Intense white light

output provides

enhanced work safety

and reduced fatigue

Pre-wired with 2.5

metres connecting

cable

Reverse polarity, spike

and over voltage

protection

Fully sealed to IP6K6

and IP6K7

Resistant to vibration

and shock

EMC compliant

2-hole surface mount

(screw caps and

mounting bushes

included)

DuraLed 1000 Lumen Wide Beam 2.5m high at 0°

5

4

3

2

1

0

5 5

MULTI

VOLT

LED

DT &

BARE

WIRE

0.7Kg

IP6K7

200G

9 to 33

V DC

12W


DuraLed ® 1000 Lumen Magnetic Base

With DT connector

With 12V MagCode connector

With 24V MagCode connector

With CIG/DIN plug

HM1550DT

HM1550MAG-12

HM1550MAG-24

HM1550CIG

MINING LED WORK LAMPS

®

DuraLed

Magnetic Base

1000 Lumen Work Lamp – Multivolt 9-33V DC

Complementing the DuraLed ® range is

the new heavy duty magnetic base

service lamp which uses ultra powerful

neodymium magnets and a

flexible curly-cord cable.

15

WORK LAMPS

The compact 1 metre

extension cable extends

the range of the light

to 8 metres from the

power source.

222

34

96

Product features

1m coiled cord with

8-metre extension

potential.

1000 Lumen Wide

Beam Multivolt

DuraLed

Ideal for use in

confined spaces, such

as engine bays and

under machines

Low power

consumption


AS500 ® FF Xenon Trunnion Pedestal

Wide Beam Multivolt DT HM1512WB HM1513WB

Narrow Beam Multivolt DT HM1512NB HM1513NB

HID WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

16

®

AS500 FF Xenon

Heavy Duty Work Lamp

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.

Optional

Pedestal

Bracket

Shown with Pedestal Mount

MUSTADD

170

120

56

202

DRACO

IP6K7 50G 12/24V

Trunnion Bracket

D2S

135

141

Clear cover to be ordered separately

DT

41W

126

122

135

19

2.8Kg

26

M10

175

127

Good lighting is essential to create a

safe and productive work area where

machine operators can clearly see

their work environment and identify

hazards in time to take the required

action. The AS500 FF is engineered

to deliver excellent lighting

under continuous use in extreme

environmental conditions.

AS500 FF lamps’ Hella Free-Form

optics deliver a homogenous

spread of light, so operators can

see comfortably for long periods.

Its light distribution ensures there

are no sharp transitions from light

to dark in the operator’s visual field,

to significantly reduce adaptation

related eye fatigue and stress.

72

The optical modules comprise

a precision-moulded specular

reflector, permanently assembled

to a corrosion-resistant hardened

glass refractor lens and machined

lamp holder, ensuring perfect

focus. A choice of wide and narrow

asymmetric beam types is available.

The integrated, patented Hella

MustADD ® filter ensures optimum

optical performance is maintained

over product life in the adverse

atmospheres typically encountered

in mining. (See technical section for

more information.)

35W Xenon gas discharge lighting

systems pioneered by Hella have set

the standard across the world for

optimum visual acuity and comfort

for professional work lamp users.

The integral electronic ballast fitted

to the AS500 FF range is specifically

designed for continuous operation in

mining applications. (See technical

section for more information.)

Safe and reliable electrical

connection is via a short length of

highly flexible double insulated cable,

terminated with DT connectors.

An ergonomic heavyduty

cast aluminium

body with an integral

“non-snag” adjustment

handle is the basis of

all AS500 FF lights. A

robust lens retaining

ring with captive M4

Allen bolts enables rapid

routine service access from the

front, while high temperature O-ring

seals ensure effective sealing. A UV

resistant multi-stage powder coating

process ensures optimal corrosion

protection.

Accurate and stable aiming in

high vibration environments in all

assembly positions is vital. The

AS500 FF offers a range of secure

mounting options for almost any

requirement. The standard trunnion

bracket can be fitted to the body in

six different mounting positions; all

of which locate the axis of rotation

in the centre of gravity to minimize

mechanical stress. Four M6 Allen

bolts in arced slots and fixed pivot

points ensure that the aiming angle

can be locked securely. Secondary

mounting holes in the base of the

AS500 FF enable direct mounting

onto equipment, or the use of an

optional pedestal bracket. The heavy

gauge stainless steel hardware is

non-resonant and highly corrosion

resistant. Integral DRACO ® dampers

eliminate all metal-to-metal contact

between the lamp and bracket

to reduce shock and vibration

transmission. (See technical section

for more information.)

Sustainable use of resources is

ensured through the modular

system design, so users can reuse,

repair, or recycle lights into

new applications. Ballasts can be

replaced. Both beam types and

mounting bracket positions and

options can be changed. Halogen

models can also be upgraded to

Xenon and other future options.

Product features

Modular die cast

aluminium alloy body

Integral “non-snag”

handle

Multiple mounting

options with aiming

angles

Stainless steel trunnion

bracket with quad bolt

fastening

Draco ® suspension

Free-Form wide and

narrow beam optics

MustADD ® filter

Captive Allen bolts

Double insulated

silicone supply cable

with DT plug

Replaceable

encapsulated ballast

Spare Parts & Options

HM8164

Clear Protective Cover

AS500

9.HMAPEDL

Pedestal Mounting

Bracket Assembly

9.HM151TRN

Trunnion Mounting

Bracket Assembly

9.HMAWHKD

Cable harness kit AS500

Shown with

Trunnion Bracket

O-ring seals

Components tested

over a –40ºC to

+105ºC temperature

range

High efficiency & long

life D2S 35W Xenon

light

Multivolt 8-32V DC

IP6K7K

200G shock resistant

ballast

50G shock resistant

lamp

CE compliant

Protective clear covers

available

Consumable spares

interchangeable with

Hella AS200FF ® Xenon

range

9.HM15WB

Insert – Wide Optic –

AS200/500 GDL

9.HM15NB

Insert – Narrow Optic –

AS200/500 GDL

9.HM151BAL

Multivolt Ballast

XN4000

Globe – Xenarc D2S


17

WORK LAMPS

Optional

Pedestal

Bracket

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

AS500 FF Xenon Narrow Beam

AS500 FF Xenon Wide Beam

30

Peak 79 LUX

30

Peak 120 LUX

30

0

30

60

90 120 150

30

0

30

60

90 120 150


AS200 FF Xenon

Wide Beam Multivolt DT

Narrow Beam Multivolt DT

HM1504WB

HM1504NB

MINING WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

18

AS200FF Xenon

Heavy Duty Work Lamp

AS200 FF Xenon is a compact and highly

versatile, heavy-duty work lamp for use on

mining machinery; suitable for 24V and 12V

electrical systems.

160

163

50

191

62

54

6.5

69.5

27

Front View

Clear cover to be ordered separately

150

Good lighting is essential to create

a safe and productive work area

where machine operators can

clearly see their work environment

and identify any hazards in time

to take the required action.

The AS200 FF is engineered to

deliver excellent lighting in the

extreme environmental conditions

encountered in mining applications.

AS200 FF lamps employ Hella

Free-Form optics to deliver

an homogenous spread of

light enabling operators to see

comfortably for long periods of

time. The light distribution of the

beam ensures an absence of sharp

transitions from light to dark in

the operator’s visual field, thus

significantly reducing adaptationrelated

eye fatigue and stress.

The optical modules comprise

of a precision-moulded specular

reflector, permanently assembled

to a corrosion-resistant hardened

glass refractor lens and machined

lamp holder, ensuring perfect

focus of each unit. A choice of

wide and narrow asymmetric beam

types is available to suit different

applications. (See technical section

for more information on Hella’s

applications engineering service.)

Hella integrated a basic version

of the patented MustADD ® filter

into the AS200 FF to ensure the

optical system remains virtually

dust free over the product’s life

in the adverse atmospheres

typically encountered in mining.

(See technical section for more

information.)

35W Xenon gas discharge lighting

systems pioneered by Hella have

set the standard across the world

for delivering

optimum visual

acuity and comfort

to professional work

lamp users. The integral

electronic ballast fitted

to the AS200 FF

range is specifically

designed for continuous

operation in mining applications.

(See technical section for more

information.)

Safe and reliable electrical

connection is facilitated via a short

length of highly flexible double

insulated cable, terminated with DT

connectors.

AS200 FF lights use a highly

corrosion-resistant, heavy-duty

steel reinforced, UV resistant

polymer body, featuring an integral

non-snag handle for adjustment

and handling. A lens-retaining

ring enables easy routine service

access from the front, while high

temperature O-ring seals ensure

effective sealing.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant.

The AS200 FF features integral

DRACO ® dampers in the bracket

system to reduce the intensity of

shock and vibration communicated

to the light. (See technical section

for more information.)

Sustainable use of resources and

high ownership value is ensured

through the modular system

design, enabling AS200 FF users

to repair, or recycle their lights into

new applications. Ballasts can be

replaced, and beam-spread types

can be changed.

Product features

Steel-reinforced UVresistant

polymer body

Integral “non-snag”

handle

Stainless steel bracket

Draco ® suspension

Free-Form wide and

narrow beam optics

MustADD ® filter

Double insulated

silicone supply cable

with DT connector

Replaceable

encapsulated Xenon

ballast

O-ring seals

Spare Parts & Options

HM8154

Clear Protective Cover

HM8154AMBER

Clear protective Cover

– Amber

9.HM15WB

Insert – Wide Optic –

AS200/500 GDL

Components tested

over a –40ºC to

+105ºC temp. range

High efficiency & long

life D2S 35W Xenon

light

Multivolt 8-32V DC

IP6K7

200G shock resistant

ballast

50G shock resistant

lamp

CE compliant

Protective clear covers

available

Consumable spares

interchangeable with

Hella AS500FF Xenon

range

9.HM15NB

Insert – Narrow Optic –

AS200/500 GDL

9.HM151BAL

Multivolt Ballast

XN4000

Globe – Xenarc D2S

MUSTADD

DRACO

D2S

DT

1.8Kg

IP6K7 50G 12/24V

41W


19

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

30

AS200 FF Xenon Narrow Beam

Peak 79 LUX

30

AS200 FF Xenon Wide Beam

Peak 120 LUX

30

0

30

60

90 120 150

30

0

30

60

90 120 150


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

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

Narrow Beam Pendant Mount HMUBXSWBD-12V HMUBXSWBD-24V

MINING WORK LAMPS

MOBILE WORK LAMPS

EQUIPMENT

LIGHTING

20

UltraBeam FF X-PowerPack

Xenon Work Lamp

UltraBeam FF X-PowerPack is a very compact,

heavy-duty Xenon work lamp for use on small

mining machinery. It is suitable for 24V and 12V

electrical systems.

112 136

101 84

143

24

87 73

Pedestal Mount

Pendant Mount

HM8160

Good lighting is essential to create

a safe and productive work area

where machine operators can

clearly see their work environment

and identify any hazards in time to

take the required action. The 35W

Xenon discharge lighting systems

pioneered by Hella have set the

standard across the world for

delivering excellent visual acuity

and comfort to professional work

lamp users.

Hella Free-Form optics enables

the very compact UltraBeam

FF X-PowerPack to deliver a

homogenous spread of light,

enabling operators to see

comfortably for long periods of

time. The light distribution of the

beam ensures an absence of sharp

transitions from light to dark in

the operator’s visual field, thus

significantly reducing adaptationrelated

eye fatigue and stress.

The optical module comprises of

a precision Free Form reflector,

permanently assembled to a

corrosion resistant hardened glass

lens and machined lamp holder,

ensuring high efficiency and

perfect focus of each unit after

lamp changes.

The UltraBeam FF X-PowerPack is

constructed around a new ballast

module for applications where

space is at a premium. The integral

electronic ballast used by the

UltraBeam FF

X-PowerPack is a

“clean sheet” design

optimized for continuous

operation in mining applications,

with particular attention paid to

limit the impact of Electromagnetic

interference.

Hella integrated a basic version

of the patented MustADD ®

filter into the UltraBeamFF

X-PowerPack to ensure

the optical system remains

virtually dust free over product

life in the adverse atmospheres

typically encountered

in mining.

The optical assembly of the very

compact lamp housing is moulded

from a highly corrosion-resistant

heavy-duty UV resistant polymer;

the rear body and ballast housing

is die cast aluminium ensuring

optimal heat dissipation.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant.

Integral DRACO ® dampers in

the bracket system reduce the

intensity of shock and vibration

communicated to the light. The

UltraBeam FF X-PowerPack is

available in both pedestal mount

and pendant mount configurations.

Product features

In-built 5th generation

electronic ballast with

aluminium heatsink

Compact design

Fast, easy installation

High-sheen free-form

(FF) reflector

High efficiency D1S

35W Xenon Globe

Hardened glass lens

Wide Beam Optics

Specifications

Voltage

12 and 24V DC options

Power Consumption

35W Globe (42W total)

Mounting

Stainless steel pedestal

bracket for 4-point

mount and additional

stainless steel mounting

foot for single bolt mount

included.

Cable

Pre-wired with 0.2 metre

sheathed cable and

DT plug.

Supplied with stainless

steel pedestal bracket

and additional

mounting foot

Compatible with

existing UltraBeamFF

mounting brackets

12V DC and 24V DC

variants

IP6K7 and IP6K9K

200g shock resistant

(ballast/housing)

Clear protective cover

included

Temperature Range

-40°C to +80°C

Protection

Fully sealed against dust

and moisture to IP6K9K.

Shock resistant to 200G

(ballast/housing) and

30g (lamp).

EMC Approval

EMC Class 5 according

to CISPR25 for

absolutely

disturbance free

radio and wireless

transmission.

MUSTADD DRACO

DT

D1S

IP6K7 IP6K9K 200G 12/24V

1.26Kg

42W

Spare Parts & Options

HM8160

Clear Protective Cover

(included)

HMXN4001

D1S Xenon Globe


21

WORK LAMPS

Integral Xenon Ballast

(non-replaceable)

D1S Xenon Globe

HMXN4001

Stainless Steel Bracket

Wide Beam Optic

(not serviceable)


UltraBeam FF Xenon 8-32V DC

Wide Beam DT Plug

HM1522WB

MINING WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

22

UltraBeam FFXenon

Heavy Duty Work Lamp – 24V DC

UltraBeam FF Xenon is a superior, compact,

heavy-duty work lamp for use on mining

machinery. It is suitable for 12 to 24V

electrical systems.

101 84

127

24

112

350

93

24

101 84

140

Front View

Clear cover to be ordered separately

43

140

120

The UltraBeam FF utilizes an

350

93

43

externally 24 located ballast to enable

the use of Xenon lighting where

space is at a premium.

Good lighting is essential to 120 create

a safe and productive work area

where machine operators can

clearly see their work environment

and identify any hazards in time to

take the required action.

Hella Free-Form optics enables

the very compact UltraBeam

FF lamps employed to deliver

an homogenous spread of

light, enabling operators to see

comfortably for long periods of

time. The light distribution of the

beam ensures an absence of sharp

transitions from light to dark in

the operator’s visual field, thus

significantly reducing adaptationrelated

eye fatigue and stress.

The optical modules comprise

of a precision die cast specular

reflector, permanently assembled

to a corrosion-resistant hardened

glass refractor lens and machined

lamp holder, ensuring high

efficiency and perfect focus of

each unit.

Hella integrated a basic version

of the patented MustADD ® filter

into the UltraBeam FF to ensure

the optical system remains

virtually dust free over product

life in the adverse atmospheres

typically encountered in mining.

(See technical section for more

information.)

35W Xenon discharge

lighting systems

pioneered by Hella have

set the standard across

the world for delivering

excellent visual acuity and

comfort to professional

work lamp users. The

integral electronic

ballast used by

the UltraBeam FF is

designed specifically for

continuous operation in mining

applications. Safe and reliable

electrical connection between the

ballast and lamp housing is via

a short length of highly flexible

double insulated high voltage

cable, with a permanently fixed

safety lamp socket. (See technical

section for more information.)

The very compact lamp housing is

moulded from a highly corrosionresistant

heavy-duty, UV resistant

polymer body. A lens-retaining

ring enables easy routine service

access from the front, while high

temperature O-ring seals ensure

effective sealing.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant. The

UltraBeam FF features integral

DRACO ® dampers in the bracket

system to reduce the intensity of

shock and vibration communicated

to the light. (See technical section

for more information.)

Product features

UV resistant polymer

body

Stainless steel bracket

Draco ® suspension

Free-Form beam optics

MustADD ® filter

DT plug

Replaceable

encapsulated Xenon

ballast

O-ring seals

Components tested

over a –40ºC to

+105ºC temperature

range

Spare Parts & Options

HM8157

Clear Protective Cover

HM8157AMBER

Amber Protective Cover

High efficiency & long

life D2S 35W Xenon

light

8-32V DC

operationIP6K5K

200G shock resistant

ballast

50G shock resistant

lamp

CE compliant

Protective clear covers

available

9.HMUBXWB

Reflector & Optic Insert

9.HM151BAL

Multivolt Ballast

MUSTADD

DRACO

D2S

DT

2.0Kg

IP6K5 50G 12/24V

41W


23

WORK LAMPS

30

UltraBeam FF Xenon Wide Beam 2.5m high at 5°

30

0 20 40 60


OVAL 100 FF Xenon

Wide Beam DT

Narrow Beam DT

HMPVX35WBD

HMPVX35NBD

MINING WORK LAMPS

MOBILE WORK LAMPS

EQUIPMENT

LIGHTING

24

OVAL 100 FF Xenon

Heavy Duty Work Lamp – 24V DC

OVAL100 FF Xenon is a low profile,

heavy-duty work lamp for use on mining

machinery, suitable for 24V and 12V

electrical systems.

192mm

Front View

160mm

135mm

Good lighting is essential to create

a safe and productive work area

where machine operators can

clearly see their work environment

and identify any hazards in time

to take the required action. The

OVAL100 FF is engineered to

deliver excellent lighting in the

extreme environmental conditions

encountered in mining applications.

OVAL100 FF lamps employ Hella

Free-Form optics to deliver an

homogenous spread of light,

enabling operators to see

comfortably for long periods of

time. The light distribution of the

beam ensures an absence of sharp

transitions from light to dark in

the operator’s visual field, thus

significantly reducing adaptationrelated

eye fatigue and stress.

The optical modules comprise

of a precision-moulded specular

reflector, permanently assembled

to a corrosion-resistant hardened

glass refractor lens and machined

lamp holder, ensuring perfect

focus of each unit. A choice of

wide and narrow asymmetric beam

types is available to suit different

applications.

Hella integrated a basic version

of the patented MustADD ® filter

into the OVAL100 FF to ensure the

optical system remains virtually

dust free over the product’s life

in the adverse atmospheres

typically encountered in mining.

(See technical section for more

information.)

35W Xenon gas discharge lighting

systems pioneered by Hella, have

set the standard across the world

for delivering optimum visual

acuity and comfort to professional

work lamp users. The compact

electronic

ballast fitted

internally to the

OVAL100 FF range

operates a D1S

lamp with integral

ignitor.

Safe and reliable

electrical connection

is facilitated via a short

length of highly flexible double

insulated cable, terminated with

either DT or AMP connectors; other

connector options can be supplied

as special orders.

OVAL100 FF lights use a highly

corrosion-resistant, heavy-duty,

UV-resistant polymer body with a

lens-retaining ring to enable easy

routine service access from the

front, while high temperature O-ring

seals ensure effective sealing.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant.

OVAL100 FF features integral

DRACO ® dampers in the bracket

system to reduce the intensity of

shock and vibration communicated

to the light. (See technical section

for more information.)

Sustainable use of resources and

high ownership value is ensured

through the modular system

design, enabling OVAL100 FF

users to repair, or recycle their

lights into new applications.

Ballasts can be replaced or

exchanged to suit different supply

voltage values and beam-spread

types can be changed.

Product features

UV-resistant polymer

body

Low profile Oval shape

Stainless steel bracket

Draco ® suspension

Free-Form wide and

narrow beam optics

MustADD ® filter

Double insulated

silicone supply cable

with DT plug

Replaceable Xenon

ballast

Spare Parts & Options

9.HMPUXWB

Insert – Wide Optic

– GDL

9.HMPUXNB

Insert – Narrow Optic

– GDL

O-ring seals

Components tested

over a –40°C to

+105ºC temperature

range

High efficiency & long

life D1S 35W Xenon

light

12V DC & 24V DC

options

IP65

50G shock resistant

lamp

CE compliant

9.HMPUXB24

Ballast – OVAL100 FF

HMXN4001

Globe – Xenarc D1S

MUSTADD

DRACO

D1S

DT

1.5Kg

IP65 50G 12/24V

41W


25

WORK LAMPS

Peak

Peak ★

Oval 100FF 84 Lux Xenon Narrow Beam 2.5m high at 5°

Oval 100FF Xenon 82 Lux Wide Beam 2.5m high at 5°

30

30

30

0 20 40 60

30

0 20 40 60


AS500 ® FF Halogen H3 Trunnion Pedestal

Wide Beam DT HM1510WB HM1511WB

Narrow Beam DT HM1510NB HM1511NB

HALOGEN WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

26

AS500

®

FF Halogen

Heavy Duty Work Lamp

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.

Optional

Pedestal

Bracket

Shown with Pedestal Mount

Clear cover to be ordered separately

MUSTADD

170

120

56

202

DRACO

H3

IP6K7 50G 12/24V

Trunnion Bracket

135

141

DT

70W

126

122

135

19

2.2Kg

26

M10

175

127

Good lighting is essential to create a

safe and productive work area where

machine operators can clearly see

their work environment and identify

hazards in time to take the required

action. The AS500 FF is engineered

to deliver excellent lighting

under continuous use in extreme

environmental conditions.

AS500 FF lamps’ Hella Free-Form

optics deliver a homogenous

spread of light, so operators can

see comfortably for long periods.

Its light distribution ensures there

are no sharp transitions from light

to dark in the operator’s visual field,

to significantly reduce adaptation

related eye fatigue and stress.

72

The optical modules comprise

a precision-moulded specular

reflector, permanently assembled

to a corrosion-resistant hardened

glass refractor lens and machined

lamp holder, ensuring perfect

focus. A choice of wide and narrow

asymmetric beam types is available.

The integrated, patented Hella

MustADD ® filter ensures optimum

optical performance is maintained

over product life in the adverse

atmospheres typically encountered

in mining. (See technical section for

more information.)

Safe and reliable electrical

connection is via a short length of

highly flexible double insulated cable,

terminated with DT connectors.

An ergonomic heavy-duty cast

aluminium body with an integral

“non-snag” adjustment handle is

the basis of all AS500 FF lights. A

robust lens retaining ring with captive

M4 Allen bolts enables rapid routine

service access from the front, while

high temperature O-ring seals ensure

effective sealing. A UV

resistant multi-stage

powder coating process

ensures optimal

corrosion protection.

Accurate and stable

aiming in high vibration

environments in all

assembly positions is vital.

The AS500 FF offers a range of

secure mounting options for almost

any requirement. The standard

trunnion bracket can be fitted to

the body in six different mounting

positions; all of which locate the axis

of rotation in the centre of gravity to

minimize mechanical stress. Four

M6 Allen bolts in arced slots and

fixed pivot points ensure that the

aiming angle can be locked securely.

Secondary mounting holes in the

base of the AS500 FF enable direct

mounting onto equipment, or the use

of an optional pedestal bracket. The

heavy gauge stainless steel hardware

is non-resonant and highly corrosion

resistant. Integral DRACO ® dampers

eliminate all metal-to-metal contact

between the lamp and bracket

to reduce shock and vibration

transmission. (See technical section

for more information.)

Sustainable use of resources is

ensured through the modular

system design, so users can reuse,

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.

Product features

Modular die cast

aluminium alloy body

Integral “non-snag”

handle

Multiple mounting

options

Stainless steel trunnion

bracket with quad bolt

fastening

Draco ® suspension

Free-Form wide and

narrow beam optics

MustADD ® filter

Captive Allen bolts

Double insulated

silicone supply cable

with DT plug

O-ring seals

Spare Parts & Options

HM8164

Clear Protective Cover

AS500

9.HMAPEDL

Pedestal Mounting

Bracket Assembly

9.HM151TRN

Trunnion Mounting

Bracket Assembly

Shown with

Trunnion Bracket

Components tested

over a –40ºC to

+105ºC temperature

range

H3 Halogen 70W 24V

supplied

H3 Halogen 55W 12V

can be fitted

High efficiency & long

life D2S 35W Xenon

light

12V DC & 24V DC

options

IP6K7K

200G shock resistant

lamp

Protective clear covers

available

Consumable spares

interchangeable with

Hella AS200FF ® Xenon

range

9.HMAWHKD

Cable harness kit

AS500

9.HM15WB

Insert – Wide Optic –

AS200/500 H3

9.HM15NB

Insert – Narrow Optic

– AS200/500 H3

YC2470

Globe – H3 24V

YC1255LL

Globe – H3 12V


27

WORK LAMPS

Optional

Pedestal

Bracket

Trunnion Bracket

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

20

AS500 FF Halogen Narrow Beam

2.5m high at 5°

20

AS500 FF Halogen Wide Beam

2.5m high at 5°

Peak

79 Lux

Peak ★

120 Lux

20

0 20 40 60 80

100

20

0 20 40 60 80

100


UltraBeam FF Halogen

Wide Beam

Narrow Beam

Long Range

24V H3

HM1526WB

HM1526NB

HM1526LR

MINING WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

28

UltraBeamFF Halogen

Work Lamp – 12/24V

UltraBeam FF Halogen, available with Wide, Narrow

and Long Range Beams, are superior, compact

heavy-duty work lamps for use on mining machinery,

and suitable for both 24V and 12V electrical

systems.

112 94

101 84

127

24

87 50

Front View, Long Range

Narrow Beam

As part of our ongoing

development the Long Range

addition to the UltraBeam FF

range applies our most recent

advances in free-form (FF) reflector

technology. With a clear lens

and the popular H3 Halogen

globe it’s a compact long range

lamp for applications where the

performance of a Xenon light is not

required.

The very compact optics deliver

excellent lighting under continuous

use in the extreme environmental

conditions encountered in mining

applications. Electrical connection

is via integrated DT connector.

The UltraBeam FF clear lens

long range optical insert is a

modular assembly of a precision

die-cast specular reflector with

integral lamp holder, permanently

assembled to a corrosion resistant

hardened clear glass lens, for high

efficiency and perfect focus. The

new lens long range optical insert

is available as a spare part and

is 100% compatible with older

UltraBeam FF H3 work lamps to

enable simple on site maintenance

and perfect retrofitting.

In common with the all

Hella UltraBeam FF work

lamps, the basic version

of the patented MustADD ®

filter is included so the

optical system remains

virtually dust free over

the product life,

in the adverse

atmospheres

typically encountered

in mining.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant. The

UltraBeam FF features integral

DRACO ® dampers in the bracket

system to reduce the intensity of

shock and vibration.

The UltraBeam FF family is based

on very compact lamp housings

moulded from a highly corrosion

resistant, heavy-duty polymer

body.

A lens retaining ring enables easy

routine service access from the

front, while high temperature O-ring

seals ensure effective sealing.

Long Range Lens

Product features:

Powerful long range

and wide spread

illumination

DT electrical

connection

Robust polymer body

Stainless steel

mounting bracket

Draco ® suspension

MustADD ® multi

air-filter

Specifications:

Temperature Range

-40°C to +105°C

Mounting

Single bolt with tilt

adjustment for upright,

side or pendant

mounting on horizontal

or vertical surfaces.

Stainless steel bracket

and screws included

Free-form (FF) reflector

for powerful long range

illumination

Components tested

over a –40°C to

+105ºC temperature

range

IP6K7

Clear protective covers

available

H3 Halogen 70W 24V

supplied

H3 Halogen 55W 12V

can be fitted

Protection

Sealed against dust

and moisture to IP6K7.

Shock resistant to 50G.

HM8158

HM8158AMBER

MUSTADD

DRACO

H3, H9,

H11

IP6K7 50G 12/24V

DT

70W

MAX

0.8Kg

Spare Parts:

HM8158

Clear Protective Cover

HM8158AMBER

Clear Protective Cover

- Amber

9.1533.03

Insert – Long Range

Optic

9.HMUBHNB

Insert – Narrow Optic

9.HMUBHWB

Insert – Wide Optic

YC2470

H3 Globe, 24V 70W

YC1255LL

H3 Globe, 12V 55W


29

WORK LAMPS

Narrow Beam Optic

Long Range Optic

UltraBeam FF Long Range 2.5m high at 5°

20

Peak ★

44 Lux

1 LUX 68m

20

0 20 40 60 80

100

UltraBeam FF Narrow 2.5m high at 5°

30

UltraBeam FF Wide 2.5m high at 5°

30

PEAK 44 LUX

PEAK 42 LUX

30

0 20 40 60

30

0 20 40 60


HydroLUX ® Submersible Driving Lamp 12/24V

Mining Yellow H3 Spread Beam HM1358

Mining Yellow H1 Pencil Beam HM1374D

Mining Yellow H1 Spread Beam HM1375D

Mining Yellow H4 RHD Driving Beam

Mining Yellow H4 LHD Driving Beam

HM1002

HM1002ECE

MINING WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

30

®

HydroLUX

Submersible Driving Lamp 12/24V

HydroLUX ® ultra-heavy duty submersible driving

lamps feature advanced engineering, focused

on the requirements of mining and emergency

vehicles that operate on and off public roads.

Suitable for 24V and 12V electrical systems.

185 145

Shown with H3 Insert

HM1002 (with H4 Insert)

Clear cover to be ordered separately

MUSTADD

H1, H3,

H4

BARE

WIRE

3.2Kg

198

Good lighting is essential to create

a safe and productive illumination

of the road, enabling drivers

to clearly see and identify any

hazards in time to take the required

action. The HydroLUX is not only

engineered to deliver excellent

lighting but also to withstand

regular submersion or continuous

under water operation, as well

as the extreme environmental

conditions encountered in mining

applications.

Hella’s patented isobaric system

prevents water ingress into the

optical module, whilst enabling

easy service access and reliable

long-term operation of the seals

under mining conditions. To ensure

correct operation of the isobaric

system and perfect focus, each

optical module unit comprises

a precision-moulded specular

reflector, with integral lamp

holder permanently assembled

to a corrosion resistant hardened

clear lens seated into a die cast

alloy frame. Each HydroLUX is

individually pressure tested and

certified. (See technical section for

more information.)

HydroLUX lamps are available with

Free-Form spread and pencil beam

auxiliary driving beam distribution

types, in addition to a wide range

of ECE and SAE approved high/

low beam versions for use as

headlamps in left and right hand

public road traffic.

All HydroLUX optical modules

feature a fully integrated, patented

Hella MustADD ® filter to ensure

that optimum optical performance

is maintained over the product’s

life in the adverse atmospheres

typically encountered in mining.

(See technical section for more

information.)

An ergonomic,

heavy-duty

cast aluminium

body with an

integral “non-snag”

adjustment handle

is the basis of all

HydroLUX lights. A

robust lens retaining

ring with captive M4 Allen

bolts enables rapid routine

service access from the front,

while high temperature O-ring

seals ensure effective sealing. A

UV resistant multi-stage powder

coating process ensures optimal

corrosion protection.

Accurate and stable aiming in

a high vibration environment is

a vital aspect of safe and legal

road lighting. The non-resonant

and corrosion resistant cast alloy

bracket fitted to the body shape

minimizes mechanical stress,

and a rubber damper between

the lamp and bracket eliminates

metal-to-metal contact to reduce

the intensity of shock and vibration

communicated to the light. Two M6

Allen bolts ensures that the critical

vertical aiming can be locked

securely, and a M8 bolt in the

base enables direct mounting onto

equipment.

Safe and reliable electrical

connection is facilitated via a 2m

length of highly flexible double

insulated cable, factory sealed

into the body, eliminating the

requirement for water-proof

connections at the lamp. Other

connector options can be supplied

as special orders.

Product features

Wide selection of optics

available

Die cast alloy body and

bracket

MustADD ® filter

Double insulated

silicone supply cable

O-ring seals

H1, H3 and H4 versions

available

Suitable for 12V or 24V

globes (24V supplied)

Spare Parts & Options

8151

Clear Protective Cover

HM9.1374.08

Mounting Bracket

Assembly

HM9.1374HD.01

Pencil Beam Insert

Assembly (H1 Version)

IP6K9K

50G shock resistant

lamp

ECE and SAE compliant

options

Right and left hand

traffic options

Protective clear covers

available

HM9.1375HD.01

Spread Beam Insert

Assembly (H1 Version)

9.HM1002ECE.01

Insert HM1002ECE (LHD,

H4 ECE Version)

9.HM1002.01

Insert HM1002 (RHD, H4

Version)

9.HM1385.05

Insert HM1358 (H3

Version)

IP6K9K 50G 12/24V 100W

MAX

ECE/

ADR

compliant


31

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

Note: Spread Beam Lamp is

ECE compliant with

12V/55W or 24V/70W globe.

Pencil Beam Recorded with single lamp. Distance in metres.

1 LUX .5 LUX

Spread Beam Recorded with single lamp. Distance in metres.

Front View


AS200 FF Halogen with AMP plug with DT Plug

Wide Beam HMASH70WBA HMASH70WBD

Narrow Beam HMASH70NBA HMASH70NBD

MINING WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

32

AS200FF Halogen

Heavy Duty Work Lamp – 12/24V

AS200 FF Halogen is a compact and highly

versatile heavy-duty work lamp for use on

mining machinery; suitable for 24V and

12V electrical systems.

137

Front View

160 160

Good lighting is essential to create

a safe and productive work area

where machine operators can

clearly see their work environment

and identify any hazards in time

to take the required action.

The AS200 FF is engineered to

deliver excellent lighting in the

extreme environmental conditions

encountered in mining applications.

AS200 FF lamps employ Hella

Free-Form optics to deliver an

homogenous spread of light,

enabling operators to see

comfortably for long periods of

time. The light distribution of the

beam ensures an absence of sharp

transitions from light to dark in

the operator’s visual field, thus

significantly reducing adaptationrelated

eye fatigue and stress.

The optical modules comprise

of a precision-moulded specular

reflector, permanently assembled

to a corrosion-resistant hardened

glass refractor lens and lamp

holder, ensuring perfect focus

of each unit. A choice of wide

and narrow asymmetric beam

types is available to suit different

applications. (See technical section

for more information on Hella’s

applications engineering service.)

Hella integrated a basic version

of the patented MustADD ® filter

into the AS200 FF to ensure the

optical system remains virtually

dust free over the product’s life

in the adverse atmospheres

typically encountered in mining.

(See technical section for more

information.)

Safe and

reliable electrical

connection is

facilitated via a

short length of

highly flexible double

insulated cable,

terminated with

either DT or AMP

connectors; other

connector options can

be supplied as

special orders.

AS200 FF lights use a highly

corrosion resistant heavy-duty,

steel reinforced, UV-resistant

polymer body, featuring an integral

non-snag handle for adjustment

and handling. A lens-retaining

ring enables easy routine service

access from the front while high

temperature O-ring seals ensure

effective sealing.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant.

The AS200 FF features integral

DRACO ® dampers in the bracket

system to reduce the intensity of

shock and vibration communicated

to the light. (See technical section

for more information.)

Sustainable use of resources and

high ownership value is ensured

through the modular system

design, enabling AS200 FF users

to repair, or recycle their lights into

new applications. Ballasts can

be replaced or exchanged to suit

different supply voltage values and

beam-spread types can

be changed.

Product features

AUV resistant polymer

body

Integral “non-snag”

handle

Stainless steel bracket

Draco ® suspension

Free-Form wide and

narrow beam optics

MustADD ® filter

Double insulated

silicone supply cable

with DT or AMP plug

O-ring seals

Spare Parts & Options

HM8156

Clear Protective Cover

AS200 H3

HM8156 AMBER

Amber Protective

Cover AS200 H3

Components tested

over a –40ºC to

+105ºC temperature

range

H3 Halogen 70W 24V

supplied

H3 Halogen 55W 12V

can be fitted

IP6K5K

50G shock resistant

lamp

Protective clear covers

available

Consumable spares

interchangeable

with Hella AS500 FF

Halogen range

9.HM15WB

Insert – Wide Optic

9.HM15NB

Insert – Narrow Optic

YC2470

Globe – H3 24V

YC1255LL

Globe – H3 12V

MUSTADD

DRACO

H3

DT &

AMP

0.8Kg

IP6K5 50G 12/24V

70W


33

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

20

AS200 FF Halogen Narrow Beam

2.5m high at 5°

20

AS200 FF Halogen Wide Beam

2.5m high at 5°

20

0 20 40 60 80

100

20

0 20 40 60 80

100


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

Wide Beam HMPV270WBA HMPV270WBD

Narrow Beam HMPV270NBA HMPV270NBD

MINING WORK LAMPS

MOBILE WORK LAMPS

EQUIPMENT

LIGHTING

34

OVAL 100 FF Halogen

Double Beam Work Lamp – 24V DC

OVAL100 FF Halogen is a low profile twin beam,

heavy-duty work lamp for use on mining machinery.

It is suitable for 24V and 12V electrical systems.

Narrow Beam model – front view

Clear cover to be ordered separately

The OVAL100 FF is engineered

to deliver excellent lighting in the

extreme environmental conditions

encountered in mining applications.

OVAL100 FF lights employ an

advanced version of the Hellapioneered

twin beam Free-Form

optics to deliver an homogenous

spread of light, enabling people to

see comfortably for long periods

of time. The light distribution of

the beam is engineered to ensure

minimum light spill and an absence

of sharp transitions from light

to dark in the operator’s visual

field, thus significantly reducing

adaptation-related eye fatigue

and stress.

The twin beam optical modules

comprise of a high precision

cast alloy specular reflector,

permanently assembled to a

corrosion-resistant hardened glass

refractor lens and lamp holder,

ensuring perfect focus of each

unit. A choice of wide and narrow

asymmetric beam types is available

to suit different applications.

(See technical section for more

information on Hella’s applications

engineering service.)

Hella integrated a basic version

of the patented MustADD ® filter

into the OVAL100 FF to ensure

the optical system remains

virtually dust free over product

life in the adverse atmospheres

typically encountered in mining.

(See technical section for more

information.)

Safe and

reliable

electrical

connection is

facilitated via a

short length of highly

flexible double insulated

cable, terminated with

either DT or AMP

connectors; other

connector options can

be supplied as

special orders.

OVAL100 FF lights use a highly

corrosion-resistant, heavy-duty,

UV-resistant polymer body, with a

lens-retaining ring to enable easy

routine service access from the

front, while high temperature O-ring

seals ensure effective sealing.

The supplied stainless steel

mounting hardware is non-resonant

and highly corrosion resistant.

The OVAL 100 FF features integral

DRACO ® dampers in the bracket

system to reduce the intensity of

shock and vibration communicated

to the light. (See technical section

for more information.)

Sustainable use of resources and

high ownership value is ensured

through the modular system

design, enabling OVAL100 FF

users to repair, or recycle their

lights into new applications.

Ballasts can be replaced or

exchanged to suit different supply

voltage values and beam-spread

types can be changed.

Product features

UV resistant polymer

body

Low profile Oval shape

Individual lamp

switching

Stainless steel bracket

Draco ® suspension

Free-Form wide and

narrow beam optics

MustADD ® filter

Spare Parts & Options

HM8159

Clear Protective Cover

HM8159AMBER

Amber Protective Cover

9.HMPU2NB

Insert – Narrow Optic –

OVAL100 DB

Wide Beam model

Double insulated

silicone supply cable

with DT or AMP plug

O-ring seals

H3 Halogen 70W 24V

supplied

H3 Halogen 55W 12V

can be fitted

IP6K5K

50G shock resistant

lamp

Protective clear covers

available

9.HMPU2WB

Insert – Wide Optic –

OVAL100 WB

YC2470

Globe H3 – 24V

YC1255LL

Globe H3 – 12V

MUSTADD

DRACO

H3

DT &

AMP

1.0Kg

IP6K5K 50G 12/24V

70W


35

WORK LAMPS

30

Peak ★

Oval 10050 FF Lux Halogen Narrow Beam

2.5m high at 5°

30

Peak

Oval 100 FF Halogen 45 Wide Lux Beam

2.5m high at 5°

30

0 20 40 60 80

100

30

0 20 40 60 80

100


Modul 70 Halogen 12V H9 24V H3

Wide Beam HM70H9WB-12V HM70H3WB-24V

Narrow Beam HM70H9NB-12V HM70H3NB-24V

MINING WORK LAMPS

MOBILE WORK LAMPS EQUIPMENT

LIGHTING

36

Modul 70 Halogen

Work Lamp

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.

Modul 70 utilizes advanced Hella

production and materials in a

unitary design that directly bonds a

cast aluminium Free-Form reflector,

lamp holder, clear glass lens and

high temperature polymer housing

into a low mass, efficient and very

compact work lamp.

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.

Front view

H3

H9

The brilliant Free-Form optics and

clear lens of the Modul 70 reduce

scatter losses and improve beam

control. Designed specifically for

use with the new generation of high

performance Halogen globes, the

H9 (12V only) model is excellent

for applications where high levels

of light may be required for short

periods but the cost of Xenon

cannot be justified. H3 variants of

the Modul 70 are also available

for less demanding applications.

A choice of wide and narrow

asymmetric beam types is available

to suit different applications.

(See technical section for more

information on Hella’s applications

engineering service.)

A rotating base in addition to

the elevation allows vertical

adjustment of + 48° to -115°,

and 360° rotation adjustment. The

supplied stainless steel hardware is

non-resonant and highly corrosion

resistant.

Safe and reliable electrical

connection is facilitated via a

200mm length of highly flexible

double insulated cable, terminated

with a DT connector. Other

connector options can be supplied

as special orders.

Additional variants of the Modul 70

are available on special request.

Product features

Free-Form wide and

narrow beam optics

Clear lens “brilliant”

appearance

Die cast aluminium

reflector

Tool less globe access

Impact resistant

housing

50G shock resistant

lamp

ROHS compliant

Electrical connection:

200mm double

insulated cable

harness, terminated

with DT connector;

other terminations

available on special

request

Stainless steel

mounting bracket

IP5K9K

H9 12V 65W Halogen

globe included

H3 24V 70W Halogen

globe included

HM70PR

HM70PI

Yellow mounting

bracket denotes

product as mining

specification version

9.HM70WH

Spare Parts & Options

HM70PR

Pipe mount tube

attachment for rotating

HM70PI

Pipe mount tube

attachment

9.HM70BR

Bracket Stainless steel

Modul 70

9.HM70DC

Dust Cap H3 Modul 70

CF1265

Globe H9 – 12V

9.HM70WH

Wiring harness H9, 2m

YC2470

Globe H3 – 24V

MULTI

VOLT

H3, H9

DT

0.5Kg

IP5K9

50G

12/24V 70W

max


12V H9

Halogen Globe

37

WORK LAMPS

24V H3

Halogen Globe

Peak ★

84 Lux

Peak ★

82 Lux

Modul 70 Halogen Narrow Beam H9 12V

20

2.5m high at 5°

20

Modul 70 Halogen Wide Beam H9 12V

2.5m high at 5°

20

0 20 40 60 80

100

20

0 20 40 60 80

100

Modul 70 Halogen Narrow Beam H3 24V

20

2.5m high at 5°

20

Modul 70 Halogen Wide Beam H3 24V

2.5m high at 5°

20

0 20 40 60 80

100

20

0 20 40 60 80

100


39

BEACONSBeacons

40 DuraRAY Phase II

42 UltraRAY-R Twin

44 UltraRAY-R “Rotating”

46 UltraRAY

48 OptiRAY

50 OptiRAY E

52 MiniRAY

53 NaviLED M

54 DuraLED M High Intensity

56 PulseRAY KLX

58 PulseRAY E67


DuraRAY ® Phase II

LED Warning Beacons

l Amber LED

l Yellow Base

l Red LED

l Yellow Base

l Green LED

l Yellow Base

l Amber LED

l Amber Base

l Red LED

l Amber Base

l Green LED

l Amber Base

2 LED Disks HM9400YEL2A HM9400YEL2R HM9400YEL2G HM9400AMB2A HM9400AMB2R HM9400AMB2G

3 LED Disks HM9400YEL3A HM9400YEL3R HM9400YEL3G HM9400AMB3A HM9400AMB3R HM9400AMB3G

4 LED Disks HM9400YEL4A HM9400YEL4R HM9400YEL4G HM9400AMB4A HM9400AMB4R HM9400AMB4G

LED BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

40

®

DuraRAY

LED Warning Beacons

Phase II

Hella DuraRAY ® II ultra durable LED warning

beacons improve on the award winning design

of its predecessor. DuraRAY ® II beacons are

designed for mining and construction applications

where the cost of equipment down time is large

and safety is paramount.

130.6

130.6

153.5

132.5

159

3 x Ø6

equispaced

on PCD Ø150

3 x M4

equispaced

on PCD Ø107

3 x M4

equispaced

on PCD Ø130

25mm Pipe Thread

169

130.6

111.5

2 LED Disks

3 LED Disks

4 LED Disks

The cast alloy construction and

modular lens design enables

DuraRAY ® II beacons to survive

much larger crush or impact

loads than conventional optical

beacons. DuraRAY ® II beacons

offer excellent beam control to

ensure very good penetration of

fog and dust without blinding the

operator through back scatter,

whilst delivering high observability

from a distance with minimal closeup

glare.

Solid state LED beacons are

gaining popularity due to their

zero maintenance and long

service life over conventional

rotating beacons, particularly

in harsh mining conditions. The

new range of DuraRAY ® II LED

warning beacons build on an

award winning design with the

addition of a new electronic control

system, combined with higher

output LEDs, and further user

customisation within the range.

Higher EMC standard ISO13766-

2006 certification improves safety

and reliability with other electrical

devices. Coloured secondary

reflectors were added to ensure

easy identification of LED function

colour when the beacon is in ‘off’

mode.

Using an advanced control system

gives users the option to select

from a flashing

or rotating LED

beam pattern by

simply changing

the polarity of

the two wires.

The Multivolt

system allows

for installation on

electrical machines that

may have varying outputs due

to the load on the engine.

The light output from the high

emitting LEDs is not affected by

this varying supply, with a range

of 9-33 Volts DC.

The increased light output from

the LEDs combined with multiple

layers of LEDs delivers a high

degree of redundancy in the

optical system to ensure safety

is not compromised under partial

failure or obscuring conditions.

Utilising ceramic coated aluminium

reflectors and durable XYLEX ®

lenses provides excellent longterm

resistance against cleaning

chemicals, UV and impact damage

for increased durability and long

service life.

DuraRAY ® II beacons are fully

sealed ‘fit and forget’ products

that can be submerged and

high-pressure washed from any

direction.

Product features

Multivolt 9-33V DC

New electronics offer

both ‘rotating’ and

flashing functionality

Modular system of

circular LED discs for

intense, 360˚ visible

light output

Brilliant clear, high

impact resistant

XYLEX ® lens system

Heavy-duty cast alloy

base and cap for

increased mechanical

strength and vibration

resistance

Multi-stage paint

coating for optimal

corrosion and UV

protection

ISO 13766-2006

Flame retardant to

UL94HB

Fully sealed and

pre-wired to prevent

ingress of dirt and

moisture

200G shock resistant

Low EMC signature

Low current draw

Self-diagnostic

electronics for

protection against

transient voltage spikes

and reverse polarity

LED Function colour

variants available

(Amber, Green, Red)

Spare Parts

9.HM9386.02

Installation Kit

MULTI

VOLT

LED

DT &

BARE

WIRE

IP6K7

200G

9 to 33

V DC

33W

MAX


41

BEACONS

Top View

Bottom View

Yellow Housing

Amber Housing

Amber Function

Colour

Red Function

Colour

Green Function

Colour


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

Direct Mount HM500ADIR HM500RDIR HM500BDIR HM500GDIR HM500WDIR

Magnetic Mount HM500AMAG HM500RMAG HM500BMAG HM500GMAG HM500WMAG

MINING WARNING BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

42

®

UltraRAY -R TWIN

LED Warning Beacon

As an addition to the Hella LED beacon range, a new

Twin LED beacon has been developed for increased

visibility in bright sunlight with more than double the

luminous intensity of the original UltraRAY ® .

132

120°

3 x Ø4

equispaced

on PCD 130

136

187

130

120°

Amber

4 x Ø4

equispaced

on PCD 178

Red

Blue

Green

The UltraRAY ® -R Twin LED features

either a rotating or flashing pattern

easily selectable by grounding the

function wire, allowing users to

change the flashing pattern with an

in-cabin switch, removing the need

to open the unit.

It is extremely robust, tolerant to

severe vibration levels and very

compact in design. Equipped with

a high impact and shock resistant

polycarbonate lens bolted to a

heavy-duty cast alloy base, it

is sealed by a neoprene O-ring

against dust and water ingress.

The UltraRAY ® -R Twin LED warning

beacon is maintenance free with

no moving parts or fragile globes.

LED beacons are highly efficient,

delivering up to a 70% energy

saving over conventional beacons.

This greatly reduces both operating

temperature and demand on the

vehicle’s electrical system.

Maximum service life and light

output of the high intensity LEDs

is ensured by integrating the heat

sinks into the cast alloy base.

The Multivolt control module

encapsulated directly into the base

also protects the UltraRAY ® -R Twin

against damage from overheating,

reverse polarity and short circuits.

(See technical

section for more

Multivolt

information.)

The

UltraRAY ® -R

Twin LED

warning beacon

is optimized for

continuous use applications

on mining equipment, to ensure

highly effective warning efficiency

in daylight on surface operations

in the extreme environmental

conditions encountered in mining

applications.

The UltraRAY ® -R Twin LED also

features a patented Helio ® shield,

which protects the beacon’s

internal components from UV

damage. The UltraRAY ® -R Twin

LED beacon is available in five LED

signal colours (amber, red, blue,

green and white) to suit all signal

applications. Installation is possible

with either the standard direct

mount, or an optional magnetic

mount or pipe mounting kit.

Product features

Certified SAE J845

Class 1 red & amber

Available in amber, red,

blue, green and white

User selectable output

(rotate or quad flash

patterns)

Automatic daylight

detection

Impact resistant

smooth polycarbonate

lens

Precision Fresnel optics

Powdercoated cast

alloy base

Specifications

Voltage

Multivolt 12 –30V DC

Power consumption

50W average

Frequency

Rotating: 80 cycles/min

Flash: 72 fpm (quad)

Direct, pipe mount or

magnetic installation

options

Low current draw

EMC Tested

Fully encapsulated

electronics

Overheat, reverse

polarity and short

circuit protection

High efficiency, long life

LED light

Requires 10 Amp fuse

Lead Length

2 metres (doubleinsulated

cable)

Protection

Overheat, reverse

polarity and short

circuit protected.

Sealed against dust

and moisture to IP6K5

White

Temperature Range

–20°C to +50°C

Shock resistant to

200G

MULTI

VOLT

IP6K5

LED

200G

BARE

WIRE

0.9Kg

12 to 24

V DC

SAE

COMPLIANT

50W

AVERAGE

HM500AFLX UltraRAY-R TWIN including

vibration proof pole-mount adapter

Spare Parts

9.HM450ALENS

Amber PC Lens

9.HM450RLENS

Red PC Lens

9.HM450BLENS

Blue PC Lens

9.HM450GLENS

Green PC Lens

9.HM450WLENS

White PC Lens

HM400PIPE

Pipe Mount Kit

9.HM450FLX

FlexiMount Adapter


43

BEACONS

Polycarbonate lens

with Helioshield

Cast alloy base

Rubber vibration insulator


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

Direct Mount HM450ADIR HM450RDIR HM450BDIR HM450GDIR HM450WDIR

Magnetic Mount HM450AMAG HM450RMAG HM450BMAG HM450GMAG HM450WMAG

MINING WARNING BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

44

UltraRAY

®-R “ Rotating ”

LED Warning Beacon

UltraRAY ® -R LED warning beacons are optimized

to deliver high visibility warning signals in the

dusty conditions encountered on surface mining

operations – day and night. The new UltraRAY ® -R

beacons feature user-selectable ‘rotating’ or quad

flash patterns.

132

120°

3 x Ø4

equispaced

on PCD 130

136

187

130

120°

Amber

4 x Ø4

equispaced

on PCD 178

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.

Product features

User selectable

‘rotating’ or quad

flash patterns*

SAEJ845 Class I (red

and amber)

Impact resistant

polycarbonate lens

Precision Fresnel optics

Powdercoated cast

alloy base

Direct, pipe mount or

magnetic installation

options

Low current draw

Specifications

Voltage

Multivolt 12 –30V DC

Power consumption

20W max.

Frequency

Rotating: 80 cycles/min

Flash: 72 fpm (quad)

Temperature Range

–20°C to +50°C

Fully encapsulated

electronics

Overheat, reverse

polarity and short

circuit protection

Double insulated supply

cable

O-ring seals

High efficiency, long life

LED light

Unique Helioshield

ambient light

suppression improves

daylight visibility

* Preset to ‘rotating’

pattern

Lead Length

2 metres (doubleinsulated

cable)

Protection

Overheat, reverse

polarity and short

circuit protected.

Sealed against dust

and moisture to IP6K5

Shock resistant to

200G

MULTI

VOLT

IP6K5

LED

200G

BARE

WIRE

0.9Kg

12 to 24

V DC

SAE

COMPLIANT

20W

MAX.

HM450AFLX UltraRAY-R including

vibration proof pole-mount adapter

Spare Parts

9.HM450ALENS

Amber PC Lens

9.HM450RLENS

Red PC Lens

9.HM450BLENS

Blue PC Lens

9.HM450GLENS

Green PC Lens

9.HM450WLENS

White PC Lens

HM400PIPE

Pipe Mount Kit

9.HM450FLX

FlexiMount Adapter


45

BEACONS

Polycarbonate lens

with Helioshield

Cast alloy base

Rubber vibration insulator


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

Direct Mount HM400ADIR HM400RDIR HM400BDIR HM400GDIR HM400WDIR

Magnetic Mount HM400AMAG HM400RMAG HM400BMAG HM400GMAG HM400WMAG

MINING WARNNG BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

46

®

UltraRAY

LED Warning Beacon

UltraRAY ® LED warning beacons are optimized for

continuous use applications on mining equipment,

to ensure highly effective warning efficiency in

daylight on surface operations in the extreme

environmental conditions encountered in

mining applications.

132

120°

3 x Ø4

equispaced

on PCD 130

136

187

130

120°

Amber

4 x Ø4

equispaced

on PCD 178

Red

Blue

Green

UltraRAY LED beacons offer

multiple, user-selectable flash

patterns to suit a large variety

of applications. Additional user

selectable features include a

battery saver mode to alert users if

the equipment power supply drops

below normal operating voltage

levels to conserve power, as well

as a daylight sensing that can

automatically adjust the intensity of

the beacon to ambient light levels.

A reverse gear circuit allows the

flash pattern to be changed to alert

staff of the travel direction of the

equipment. The desired operational

mode can be selected by simply

changing the DIP switch settings

on the circuit board.

UltraRAY beacons are extremely

robust, tolerant to severe vibration

levels and very compact in design.

Each beacon is equipped with a

high impact and shock- resistant,

clear polycarbonate lens bolted

to a heavy-duty cast alloy base,

sealed by a neoprene O-ring

against dust and water ingress. A

UV resistant multi-stage powder

coating process ensures optimal

corrosion protection.

Unlike Xenon flash strobes,

UltraRAY LED beacons are

maintenance free and extremely

power efficient, which greatly

reduces both operating

temperature and demand on

the vehicle’s

electrical

system.

Maximum

service life

and light

output of the

high intensity

LEDs is ensured

through integrating the

heat sinks into the cast alloy

base. The Multivolt control module

encapsulated directly into the base

also protects the UltraRAY against

damage from overheating, reverse

polarity and short circuits. (See

technical section for more Multivolt

information.)

Safe and reliable electrical

connection is facilitated via a highly

flexible double insulated cable

sealed into the base, terminated as

a short length with a DT connector

or 2m cable with bare wire ends.

Other connector options can be

supplied as special orders.

UltraRAY beacons are available

in five LED signal colours (amber,

red, blue, green and white) to suit

all signal applications. Installation

is possible with either the standard

direct mount or an optional pipe

mounting kit. Temporary use

applications are best served with

the magnetic mount version,

complete with a pre wired cable

and power plug.

Product features

SAE J845 Class 1 red

& amber

Available in amber, red,

blue, green and white

User selectable flash

patterns (4)

Automatic daylight

detection

Impact resistant

smooth polycarbonate

lens

Clear precision Fresnel

optics

Cast alloy base

Direct, pipe mount or

magnetic installation

options

Multivolt 12 –30V DC

Low current draw

Fully encapsulated

electronics

1.5kg mass

200G shock impulse

resistant

Overheat, reverse

polarity and short

circuit protection

Double insulated supply

cable with DT or AMP

plug

O-ring seals

Tested over a –20ºC

to +50ºC temperature

range

High efficiency, long life

LED light

IP6K5

200G shock resistant

Spare Parts

White

9.HM400LENS

Clear Lens

HM400PIPE

Pipe Mount Kit

9.HM450FLX

FlexiMount Adapter

MULTI

VOLT

LED

BARE

WIRE

0.9Kg

SAE

COMPLIANT

HM400AFLX UltraRAY including

vibration proof pole-mount adapter

IP6K5

200G

12 to 24

V DC

20W

MAX.


47

BEACONS

Polycarbonate lens

Cast alloy base

Rubber vibration insulator


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

Direct Mount HM360ADIR HM360RDIR HM360BDIR HM360GDIR HM360WDIR

Magnetic Mount HM360AMAG HM360RMAG HM360BMAG HM360GMAG HM360WMAG

Battery Pack HM360ABP HM360RBP

Magnetic Battery Pack HM360ABPMAG HM360BBPMAG

MINING WARNING BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

48

®

OptiRAY

LED Warning Beacon

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.

113

optiray

106

140

Amber on

Red on

Blue on

Green on

White on

OptiRAY LED beacons offer

multiple, user-selectable flash

patterns, including a rotating

beam, to suit a large variety of

applications. Additional userselectable

features include a

battery saver mode to alert users if

the equipment power supply drops

below normal operating voltage

levels to conserve power, as well

as daylight sensing that can switch

the beacon off during daylight

hours or automatically adjusts the

intensity of the beacon to ambient

light levels. The desired operational

mode can be selected by simply

changing the DIP switch settings

on the circuit board.

OptiRAY beacons are extremely

robust, tolerant to severe vibration

levels and very compact in design.

Each beacon is equipped with a

high impact and shock resistant,

clear polycarbonate lens, and

a rugged, UV damage resistant

fibreglass nylon composite base for

increased mechanical strength and

maximum durability. A neoprene

O-ring seals the assembly against

dust and water. The OptiRAY is well

suited to corrosive environments

where metal products should not

be used.

Unlike Xenon flash strobes,

OptiRAY LED beacons are

maintenance free and extremely

power efficient. Each beacon

draws a maximum of only 1 Amp

at 12V, which greatly reduces

both operating temperature

and demand on the

vehicle’s electrical

system. Maximum

service life and light

output of the high

intensity LEDs is ensured

through using internal

aluminium heat sinks. The

Multivolt control module also

protects the OptiRAY against

damage from overheating, reverse

polarity and short circuits. (See

technical section for more Multivolt

information.)

Safe and reliable electrical

connection is facilitated via a

highly flexible double insulated

cable sealed into the base. Other

connector options can be supplied

as special orders.

OptiRAY beacons are available

in five LED signal colours (amber,

red, blue, green and white) to suit

all signal applications. The beacon

can be installed with either the

standard direct mount or optional

pipe mounting kit; temporary

use applications are best served

with the magnetic mount version,

complete with pre wired cable

and plug. A self-contained version

with battery power supply is also

available for independent use.

Product features

SAE J845 (Class 1 red,

Class 2 amber)

Available in amber, red,

blue, green and white

User selectable flash

patterns (16)

Automatic daylight

detection

Impact resistant

smooth polycarbonate

lens

Clear precision Fresnel

optics

Direct, pipe mount or

magnetic installation

options

Battery pack option

Multivolt 12 – 30V DC

Low current draw

(1Amp)

Spare Parts

9.HM360LENS

Clear Lens

200G shock impulse

resistant

Overheat, reverse

polarity and short

circuit protection

Double insulated supply

cable

O-ring seals

Tested over a –20ºC

to +50ºC temperature

range

High efficiency, long life

LED light

IP6K5

200G shock resistant

Spares interchangeable

with Hella OptiRAY E

range

9.HM300FLX

FlexiMount Adapter

HM360PIPE

Pipe Mount Kit

MULTI

VOLT

LED

BARE

WIRE

0.5Kg

SAE

COMPLIANT

IP6K5

200G

12 to 30

V DC

12W

MAX

HM360AFLX OptiRAY including

vibration proof pole-mount adapter

Battery pack


49

BEACONS


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

Direct Mount HM300ADIR HM300RDIR HM300BDIR HM300GDIR HM300WDIR

Magnetic Mount HM300AMAG HM300RMAG HM300BMAG HM300GMAG HM300WMAG

MINING WARNING BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

50

®

OptiRAY E

LED Warning Beacon

Hella OptiRAY ® E LED warning beacons are designed

for heavy duty use on mining equipment and service

vehicles where complex functionality is not required.

113

optiray

106

140

Amber on

Red on

Blue on

Green on

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.

Product features

SAE J845 (Class 1 red,

Class 2 amber)

Available in amber, red,

blue, green and white

Impact resistant

smooth polycarbonate

lens

Clear precision Fresnel

optics

Direct, pipe mount or

magnetic installation

options

Multivolt 12 – 30V DC

Low current draw

1AMP

Fully encapsulated

electronics

Overheat, reverse

polarity and short

circuit protection

Double insulated supply

cable with DT or AMP

plug

O-ring seals

Tested over a –20ºC

to +50ºC temperature

range

High efficiency, long life

LED light

IP6K5

200G shock resistant

Spares interchangeable

with Hella OptiRAY

range

Double Flash, 80FPM

0.5kg mass

200G shock impulse

resistant

White on

HM300AFLX OptiRAY-E including

vibration proof pole-mount adapter

Spare Parts

9.HM360LENS

Clear Lens

HM360PIPE

Pipe Mount Kit

9.HM300FLX

FlexiMount Adapter

MULTI

VOLT

LED

DT BARE

WIRE

0.5Kg

SAE

COMPLIANT

IP6K5 IP6K7

200G

12 9 to 31 30

V DC

12W 6W

MAX


51

BEACONS


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

Direct Mount HM180ADIR HM180RDIR HM180BDIR HM180GDIR HM180WDIR

Magnetic Mount HM180AMAG HM180RMAG HM180BMAG HM180GMAG HM180WMAG

Battery Pack HM180ABP HM180RBP HM180GBP

MINING WARNING BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

52

®

MiniRAY

LED Warning Beacon

From the unique, virtually indestructible triangular design and

sealed polycarbonate lens, to its superior, long lasting LED

illumination and ultra low current draw, Hella MiniRAY ® LED

Warning Beacons offer outstanding lighting performance and

maximum durability for a vast range of applications where

highly directional optical warning signals are required.

161 140.5

113

miniray

Amber on

Red on

Blue on

Green on

White on

Battery pack

30

130

Utilising a high-intensity LED

lighting system incorporated into a

triangular, solid-state circuit board,

MiniRAY beacons produce high

intensity, axially symmetrical cones

of light to both front and rear of

the machine ensuring high visibility

along the axis of travel, whilst a

low intensity beam to either side

effectively reduces dangerous

glare to machine operators caused

by light reflecting from adjacent

structures or the warning

beacon itself.

MiniRAY beacons have been

specifically designed to protect

machinery operating underground

or in other areas where both

machine type (identified by LED

colour) and direction of travel are

essential indicators to identify

potential dangers.

MiniRAY beacons produce

different light source patterns to

the front and rear of the vehicle

identifying the direction of travel

and effectively reducing the risk

of collisions in poor visibility

conditions. In addition, MiniRAY

beacons provide 3 user-selectable

power levels to suit specific mine

requirements along with a selection

of flash patterns, which can be

linked to the operating mode of

the machinery, making changes in

equipment travel direction

highly visible.

Each MiniRAY beacon is resistant

to prolonged vehicle vibration and

sealed against damaging ingress of

moisture and dust for increased

durability and long service

life. The unique triangular

design deflects direct

impact and reliably

protects against damage

caused by falling rocks,

vehicles, hand tools or

construction debris,

whilst rounded corners

minimize the risk of personal

injury

when working in

confined spaces.

MiniRAY LED beacons require only

very little power, which allows them

to operate day and night, even

when the machinery is turned off.

And when they do run off truck

batteries or other field equipment,

they will operate for days without

draining the battery cells, making

them a cost-effective and reliable

lighting solution for any type

machinery from large earth moving

vehicles to smaller equipment

such as welders, generators

and compressors. And, unlike

Xenon flash tubes, LEDs produce

very little radio interference and

light pulses that do not disturb

lasertesting equipment.

MiniRAY LED beacons are available

in 5 different function colours

(amber, red, green, blue and white)

and offer a variety of mounting

options to suit every installation

requirement including direct

mount, magnetic base, battery box

(selfpowered).

Product features

Multivolt 12-30V DC

Multiple flash patterns

with over-ride function

to link flash patterns

to vehicle’s direction

of travel

Front and rear

identifiable beam

patterns

Unique asymmetrical

light output directing

high power beams

along the travel axis

and low power beams

across the travel axis

Three different power

settings allowing the

user to select between

maximum intensity and

minimum power draw

Solid-state, vibration

resistant circuit

board sealed in

clear, weatherproof

polycarbonate case

for optimum impact

resistance and long

service life

Triangular design

deflects direct impact

and protects against

damage from falling

rocks, vehicles, hand

tools and construction

debris

Versatile power

supply specifications

(permanent installation

or self-powered battery

pack operation or from

a coiled flexible supply

cable)

Modular base system

enables direct mount,

magnetic mount and a

battery pack mount

Low EMC signature.

Side view

Designed to

identify machine

type (colour) and

direction of travel

(beam pattern).

Front view

Rear view

Spare Parts

9.HM180LENS

Clear Lens

MULTI

VOLT

LED

BARE

WIRE

0.9Kg

IP6K5

200G

12 to 30

V DC

12W

MAX


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

Signal Lamp Yellow Housing HM980910621 HM980910421 HM980910721 HM980910221 HM980910021

MINING SIGNAL LAMPS

FLASHING

®

NaviLED

M

Warning Beacon

53

BEACONS MOBILE EQUIPMENT

LIGHTING

Hella NaviLED ® M is a range of surface mount LED signal

lamps, specifically designed to provide all-round visibility.

NaviLED M is targeted for use on mining production

equipment where coloured signal lamps are required to

provide operational status and identification information.

Product features

‘Flashing’ or ‘Steady

On’ signal light

Flash rate 100 fpm

(approx)

High visibility yellow,

impact-resistant acrylic

base

Clear UV and chemical

resistant modified

acrylic lens

Function colours coded

into lens caps

Amber, red, blue, green

and white functions

available

Minimum visible

distance of 3 km

Single high intensity

LED light source

Sealed unit pre-wired

with multi strand

double insulated cable

Multivolt 9-33V DC

Spike protected to

+500 volts

Over voltage protected

to +200 volts

Reverse polarity

protected to -500 volts

Low power

consumption (2W)

Sealed to IP6K6 and

IP6K7 to withstand

temporary immersion

and high pressure

washing

200G shock tested

Tested over a –40ºC

to +70ºC temperature

range

External elements

manufactured

from flame retardant

polymers rated UL94

HB

As a new feature all

NaviLED ® M LED signal

lamps now offer a

single flashing signal

light in addition to the

standard ‘steady on’

signal light function.

The additional flashing

function provides optimum

warning efficiency and renders

the lamp suitable for use as a fault

indication device. The preferred

signal function is selected by

simply reversing the wiring polarity.

The highly ergonomic and userfriendly

design ensures that the

NaviLED M has no sharp edges

or protruding fasteners when

installed. Hella engineers NaviLED

M lamps to ensure a very long

service life with no lighting loss

due to internal dirt build-up;

they are very well suited to wet

and corrosive environments and

tolerate short-term immersion.

Excellent durability of the housing

and active LED electronics, as well

as long term impact, chemical and

UV damage resistance in the highly

corrosive and abrasive mining

environment, is ensured through

meticulous testing and selection of

materials and assembly processes.

NaviLED M signal lamps have

undergone extensive ‘test to

destruction’ programs to ensure

product reliability meets Hella

Mining requirements.

Advanced Multivolt circuitry

pioneered by Hella which provides

reverse polarity, spike and overvoltage

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.

83

Amber

Illuminated

Red

Illuminated

Blue

Illuminated

Green

Illuminated

White

Illuminated

90

Optic appears clear until illuminated in all lamps

MULTI

VOLT

LED

DT

0.5Kg

IP6K7

200G

9 to 33

V DC

2W


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

Narrow Beam Bare Wire HM95903710 HM95903700 HM95903760 HM95903780 HM95903790

Narrow Beam DT Plug HM95903710D HM95903700D HM95903760D HM95903780D HM95903790D

MINING WARNING BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

54

®

DuraLed

Warning Beacon

M High Intensity

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.

100

177

148

Amber

Illuminated

Red

Illuminated

Blue

Illuminated

Green

Illuminated

White

Illuminated

31

22

Hella MultiFlash LED beacons

offer multiple, user-selectable flash

patterns to suit a large variety

of applications. The desired

operational mode can be selected

by simply changing the settings

via the power cable. No external

control systems are required.

DuraLed M beacons are extremely

robust, fully sealed truly “fit and

forget” products, tolerant to severe

vibration levels and very compact

in design. A high impact and

shock resistant clear Xylex lens is

permanently bonded to a rugged,

UV damage-resistant composite

base for increased mechanical

strength and maximum durability.

Hella engineered DuraLed M lamps

to ensure a very long service life

and no lighting loss due to internal

dirt build-up; they are also very

well suited to wet and corrosive

environments and tolerate shortterm

immersion. (See technical

section for more Xylex information.)

Unlike Xenon flash strobes,

DuraLed M LED beacons

are maintenance free and

extremely power efficient which

greatly reduces both operating

temperature and demand on

the vehicle’s electrical system.

Maximum service life and light

output of the high intensity LEDs

is ensured through using internal

heat sinks. The integral Multivolt

and MultiFlash control module also

protects the DuraLed M against

damage from overheat, reverse

polarity and short circuits. (See

technical section for more Multivolt

information.)

Safe and reliable electrical

connection is facilitated via a highly

flexible double insulated cable

sealed into

the base,

terminated

as a short

length with a

DT connector

or 2m cable with

tinned wire ends. Other connector

options can be supplied as special

orders.

DuraLed M MultiFlash beacons

are equipped with advanced clear

micro optic lenses to prevent the

hazardous occurrence of “ghost”

signals by internally reflected light

from other sources. Five LED signal

colours are available (amber, red,

blue, green and white) to suit all

signal applications.

The smooth ergonomic design

and very low profile (under 35mm)

allows DuraLed M units to be

installed on almost any surface.

Specially designed nylon bushes

prevent stress fractures developing

in the base, by distributing the

fasting bolt load over a large

surface of the base without

transferring any torque. Tamper

proof screw covers securely

lock the product into place and

simplify cleaning by eliminating dirt

collecting cavities.

Flash Patterns

0

1

2

3

4

5

6

7

8

9

10

MultiFLASH ®

Product features

Available in amber, red,

blue, green and white

User selectable flash

patterns

Impact resistant

smooth Xylex lens

Clear precision micro

optics

Multivolt 9-33V DC

Low power < 10W

Fully sealed “fit and

forget” design

0.5kg mass

200G shock impulse

resistant

Spare Parts

9.HMDLM001

Cover Kit Yellow

1 second

Overheat, reverse

polarity and short

circuit protection

Double insulated supply

cable with DT plug or

bare wire

Tested over a –40ºC

to +70ºC temperature

range

High efficiency, long life

LED light

IP6K7K

UL94 flame retardant

rated external parts

Spares interchangeable

with Hella DuraLed

range

MULTI

VOLT

MULTI

FLASH

LED

DT &

BARE

WIRE

0.5Kg

250 ms 500 ms 750 ms

IP6K7

200G

9 to 33

V DC

9W


55

BEACONS

Optic appears clear

until illuminated in

all lamps

DuraLED Blue 95906070 DuraLED Red 95906080

DuraLED Green 95906090 DuraLED Amber 95907080

10.0lx 10.0lx 12.0lx 10.0lx

Average Beam

Illuminance

7.5lx 7.5lx 9.0lx 7.5lx

10m

5m

Beam Width

and Height

4.0m

80%

60%

5.0lx

5.0lx

6.0lx

5.0lx

0.8m

0m

0.8m

40%

20%

2.5lx

2.5lx

3.0lx

2.5lx

5m

4.0m

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

18.0° 36.0° 54.0° 72.0° 90.0°

0.3lx

0.0lx

0.8lx

0.0lx

1.3lx

0.0lx

1.0lx

0.0lx

5m

10m

15m

20m

25m

10m

30m

Maximum Intensity

DuraLED Red 95906080 500 cd

DuraLED Amber 95907080 400 cd

DuraLED Green 95906090 300 cd

DuraLED Blue 95906070 100 cd


PulseRAY ® KLX

Heavy Duty Xenon Warning Beacon Amber

HMX7500A

MINING WARNING BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

56

®

PulseRAY

KLX

Heavy Duty Xenon Warning Beacon

PulseRAY ® KLX Xenon strobe warning beacons

are specifically developed to fulfill the demands of

markets with SAE standards. The beacon is designed

for heavy duty use on mining machinery; suitable for

24V and 12V electrical systems.

Front View

174.8

165

Reliable, unambiguous and highly

visible optical warning signals

are essential to create a safe

and productive work area where

machine operators can clearly see

and identify any hazards in their

work environment at the correct

time to take the required action.

The PulseRAY KLX is engineered

to deliver intense high visibility

signals under continuous use in the

extreme environmental conditions

encountered in mining applications.

PulseRAY KLX beacons combine a

smooth outer polycarbonate amber

lens in the classic Hella shape, with

a high clear precision Fresnel optic

internal lens, reducing dirt build-up

compared to textured lenses and

delivering significant improvements

in long term light output and beam

control under actual operating

conditions. (Other lens colours

available as special order.)

Extended service life, and

maximum light output of the

PulseRAY is ensured by using the

die cast aluminium base as heat

sink for the Multivolt drive circuitry.

The electronics are encapsulated

as protection against shock

damage and ingress of moisture or

other atmospheric contaminants.

Rapid service access to

the PulseRAY is enabled

by its thread-on lens

and captive O-ring

seal, while the

field replaceable

Xenon flash tube

with clip-in base

ensures correct

polarity. User

selection between

double or quad flash

as well as high or low flash

intensity is done by setting DIP

switches when fitting the PulseRAY.

Comprehensive protection

is provided against reverse

voltage, high voltage spikes and

over-voltage.

The heavy-duty cast alloy base,

finished in high visibility yellow

UV resistant multi-stage powder

coating process, ensures optimal

corrosion protection. The PulseRAY

KLX base suits the standard 6”

(150mm) diameter mounting

pattern used in North America, as

well as a threaded pole.

Product features

Heavy cast alloy base

Impact resistant

smooth polycarbonate

lens

Clear precision Fresnel

optics

Voltage nominal: 12V –

24V DC

Voltage operating: 9V –

32V DC

Field selectable double

or quad flash

Field selectable high/

low flash intensity

10 Joules @ 80 FPM

16 Joules @ 65 FPM

Mounting: 150mm PCD

from above and 30mm

SPT from below.

SAE J1318 Class 2

compliant

SAE J575 compliant

Components tested

over a –40ºC to +50ºC

temperature range

IP6K6

50G shock resistant

lamp

Suitable for use with

GuardRAY protective

cage

Consumable spares

interchangeable with

PulseRAY E67 beacons

Reverse polarity,

voltage spike & surge

protection

XENON

BARE

WIRE

1.1Kg

SAE

COMPLIANT

ECE

COMPLIANT

HMWGA220 (optional)

Spare Parts

9.HMX7500.01

Lens KLX inner -

Fresnel

9.HMX7500.02

Lens KLX outer –

Amber

HMWGA220

GuardRAY ® Protective

Cage

XN6750

Globe – Xenon E67

Flash Tube

IP6K6

50G

12/24V 60W


57

BEACONS


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

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

MINING WARNING BEACONS

MOBILE BEACONS EQUIPMENT

LIGHTING

58

®

PulseRAY

E67

Heavy Duty Xenon Warning Beacon 12/24V DC

PulseRAY ® E67 Xenon strobe warning beacons are

designed for heavy duty use on mining machinery;

suitable for 24V and 12V electrical systems.

121

4.8

165

6.5

Amber Lens

Red Lens

Blue Lens

Green Lens

Reliable, unambiguous and highly

visible optical warning signals

are essential to create a safe

and productive work area where

machine operators can clearly see

and identify any hazards in their

work environment at the correct

time to take the required action.

The PulseRAY E67 is engineered

to deliver intense high visibility

signals under continuous use in the

extreme environmental conditions

encountered in mining applications.

PulseRAY E67 beacons feature

an impact resistant polycarbonate

lens with Fresnel optics.

Extended service life, and

maximum light output of the

PulseRAY is ensured by using the

die cast aluminium base as a heat

sink for the Multivolt drive circuitry.

The electronics is encapsulated as

protection against shock damage

and ingress of moisture or other

atmospheric contaminants.

Rapid service access to the

PulseRAY is enabled by its threadon

lens and captive O-ring seal,

while the field replaceable Xenon

flash tube with clip-in

base ensures correct

polarity. Reliable fault

diagnosis of the

lamp is facilitated

through the i.beam

LED status indicator

visible through

the outer lens. (See

technical section for more

information.)

Selection between double or quad

flash operation of the PulseRAY is

done by simply reversing operating

polarity. Comprehensive protection

provided against high voltage

spikes and over-voltage ensures

reliable operation.

The heavy duty cast alloy base

finished in high visibility yellow

UV resistant multi-stage powder

coating process, ensures optimal

corrosion protection. The PulseRAY

E67 base suits the standard 6”

(150mm) diameter mounting

pattern used in North America as

well as a threaded pole.

Product features

Heavy cast alloy base

Impact resistant

polycarbonate lens

Voltage nominal: 12V –

24V DC

Voltage operating: 9V –

32V DC

Field selectable double

or quad flash

i.beam Monitor

10 Joules @ 80 FPM

16 Joules @ 65 FPM

Reverse polarity,

voltage spike & surge

protection

Mounting: 150mm PCD

from above and 30mm

SPT from below

Components tested

over a –40°C to +50ºC

temperature range

IP6K6

50G shock resistant

lamp

SAE J1318 Class 2

compliant

SAE J575 compliant

Suitable for use with

GuardRAY protective

cage

Consumable spares

interchangeable with

PulseRAY KLX beacons

Clear Lens

HMWGA160 (optional)

Spare Parts

9.1602.01

E67 Lens - Amber

9.1601.01

E67 Lens - Red

9.1600.01

E67 Lens - Blue

9.1603.01

E67 Lens - Green

HMWGA160

GuardRAY ® Protective

Cage

XN6750

Globe - Xenon E67

Flash Tube

9.1600.06

Lens Clear Dust Cover

XENON

BARE

WIRE

1.2Kg

SAE

COMPLIANT

9.1604.01

E67 Lens - Clear

IP6K6

50G

12/24V 60W


59

BEACONS


Signal Lamps

61

SIGNAL LAMPS

62 DuraLED SAE

63 DuraLED ECE

64 DuraLED M Combi

65 DuraLED MSIP

66 DuraLED Marker

67 LED Daytime Running Lamp


DuraLed ® SAE Signal Lamp

Stop/Tail Rear Turn Signal (Red)

Rear Turn Signal/Indicator

HM060321

HM070321

MINING SIGNAL LAMPS

SIGNAL LAMPS

62

®

DuraLed

Signal Lamps

SAE

Hella’s DuraLed ® lamps include models which are

ECE approved, and SAE compliant. They suit

a variety of vehicle applications and are easy

to fit and durable. The lamps incorporate the

latest in LED technology for low maintenance

requirements, low current draw and ultra long

service life.

100

HM060321

177

148

31

22

DuraLed lamps feature unique

designs with shallow shapes

and concealed mounting screws

for enhanced protection against

damage. All lamps are pre-wired

with multi-core sheathed cable,

fully sealed against dust and

moisture to International Protection

Standards IP6K6 and IP6K7, and

are compliant with current SAE

regulations.

The material used for these part

numbers is a new generation of

acrylics which has a high tolerance

to chemicals and washing fluids

as well as an enhanced impact

resistance. This suits vehicles

frequently washed with standard

automotive chemicals.

DuraLed SAE Signal Lamps feature

low power consumption and

Multivolt circuitry, ensuring full

light output from 9 to 33 volts (8

to 28 volts for the Marker Lamp).

The lamps are fully

sealed against

dust and moisture

and may be

mounted vertically

or horizontally

(2-hole surface mount

and mounting bushes supplied).

Multivolt for optimum brightness

at input voltage from 9 to 33 volts

with 9W power consumption.

Reverse polarity protection

and 5.0kW Transient Voltage

Suppressor (TVS). Made to IP6K6

(Protection against dust and high

pressure water jets) and IP6K7

(Protection against temporary

water immersion) standards.

Standard lamp comes with 2.5m

of cable.

Product features

Easy installation

Variety of surface

mount options

Ultra wide optics for

enhanced visibility

Low power

consumption and

Multivolt circuitry for

maximum light output

Multivolt9 - 33V DC

SAE compliant

IP6K6 (Protection

against dust and high

pressure water jets)

IP6K7 (Protection

against temporary

water immersion).

HM070321

MULTI

VOLT

LED

DT&

BARE

WIRE

0.4Kg

SAE

COMPLIANT

IP6K7

200G

9 to 33

V DC

5W


DuraLed ® ECE Signal Lamp

Stop/Tail Signal (Red Illuminated)

Rear Turn Signal (Amber Illuminated)

HM060621

HM070621

MINING SIGNAL LAMPS

®

DuraLed

Hella DuraLed ® ECE lamps are high quality, long lasting

mining signal lamps that are ECE approved. They suit

a variety of vehicle applications and are easy to fit and

durable. They incorporate the latest in LED technology

for low maintenance requirements, low current draw

and ultra long service life.

ECE

Signal Lamps

63

SIGNAL LAMPS

Product features

Easy Installation

Variety of surface

mount options

Ultra wide angle optics

for enhanced side

visibility

Ultra low power

consumption

Multivolt 9-33V DC

ECE Approval

Fully sealed against

dust and moisture

DuraLed ® lamps are

extremely robust,

fully sealed truly “fit

and forget” products,

tolerant to severe vibration levels

and very compact in design with

concealed mounting screws for

enhanced protection against

damage.

All lamps are pre-wired with

multi-core sheathed cable, fully

sealed against dust and moisture

to International Protection

Standards IP6K6 and IP6K7, and

are compliant with current SAE

regulations.

(maximum 9 Watts) for minimal

strain on a vehicle’s electrical

system.

The high quality circuitry features

reverse polarity protection

and 5.0kW Transient Voltage

Suppressor (TVS).

Lamps are sealed to IP6K6

(protection against dust and high

pressure water jets) and IP6K7

(protection against temporary

water immersion) standards.

They come pre-wired with

integrated DT plug for easy

installation.

100

177

148

31

22

Specifications

Voltage

Multivolt 9-33V DC

Power Consumption:

Rear Direction

Indicator 9W

Rear Position

Lamp 2W

Park Lamp 2W

Stop Lamp 9W

Protection:

Reverse Polarity

Protection

5.0kW Transient

Voltage Suppressor

(TVS)

Protection Codes:

IP6K6 (protection

against dust and high

pressure water jets)

IP6K7 (protection

against temporary

water immersion)

Approvals:

HM060621 (Red)

E13 020533

e4 020889

HM070621 (Amber)

E13 010363

e4 020904

The material used for these lights

includes a new generation of

acrylics which has a high tolerance

to chemicals and washing fluids

as well as an enhanced impact

resistance. This suits vehicles

frequently washed with highly

corrosive mining chemicals.

DuraLed ® SAE Signal Lamps

feature low power consumption

and Multivolt circuitry, ensuring

full light output from 9 to 33 volts.

The lamps are fully sealed against

dust and moisture and may be

mounted vertically or horizontally

(2-hole surface mount and

mounting bushes supplied).

LED technology ensures the lamps

have ultra-low power consumption

DuraLed ® lamps are equipped

with advanced clear micro optic

lenses to prevent the hazardous

occurrence of “ghost” signals by

internally reflected light from other

sources.

The smooth ergonomic design

and very low profile (under 35mm)

allows DuraLed ® units to be

installed on almost any surface.

Specially designed nylon bushes

prevent stress fractures developing

in the base, by distributing the

fastening bolt load over a large

surface area of the base without

transferring any torque. Tamper

proof screw covers securely lock

the product into place and simplify

cleaning by eliminating dirtcollecting

cavities.

HM060621 (Red Illuminated)

HM070621 (Amber Illuminated)

MULTI

VOLT

LED

DT&

BARE

WIRE

0.4Kg

ECE

APPROVED

IP6K7

200G

9 to 31

V DC

2W

to 9W


DuraLed ® M Combination

Signal Lamp Bare Wire

Signal Lamp DT

HM2379

HM2379D

MINING SIGNAL LAMPS

SIGNAL LAMPS

64

®

DuraLed

M

Combination Signal Lamp

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.

222

193

34

96

Optic appears

clear until

illuminated (off)

Tail lamp

function

displayed

Stop lamp

function

displayed

DuraLed M Combi lamps are

extremely robust, fully sealed truly

“fit and forget” products, tolerant

to severe vibration levels and very

compact in design. A high impact

and shock resistant clear Xylex

lens is permanently bonded to

a rugged, UV damage-resistant

composite base for increased

mechanical strength and maximum

durability. Hella engineered

DuraLed M Combi lamps to

ensure a very long service life and

no lighting loss due to internal

dirt build-up; they are also very

well suited to wet and corrosive

environments and tolerate shortterm

immersion. (See technical

section for more Xylex information.)

Unlike normal signal lamps,

DuraLed products are maintenance

free and extremely power efficient,

which greatly reduces both

operating temperature and demand

on the vehicle’s electrical system.

Maximum service life and light

output of the high intensity LEDs

is ensured by using internal heat

sinks. The integral Multivolt control

module

also

protects

the DuraLed M against damage

from overheating, reversed

polarity and short circuits. (See

technical section for more Multivolt

information.)

Safe and reliable electrical

connection is facilitated via a highly

flexible double insulated cable

sealed into the base, terminated as

a short length with a DT connector

or 2m cable with tinned wire ends.

Other connector options can be

supplied as special orders.

DuraLed M Combi lamps are

equipped with advanced, clear

micro optic lenses to prevent the

hazardous occurrence of “ghost”

signals by internally reflected light

from other sources.

The smooth ergonomic design

and very low profile (under 35mm)

allows DuraLed units to be installed

on almost any surface.

Product features

Impact resistant

smooth Xylex lens

Clear precision micro

optics

Multivolt 8-28V DC

Low power < 10W

Fully sealed “fit and

forget” design

0.5kg mass

200G shock impulse

resistant

Overheat, reverse

polarity and short

circuit protection

Double insulated supply

cable with DT plug or

tinned wire

Spare Parts

9.HMDLM001

Cover Kit Yellow

(Pack of 4)

Tested over a –40ºC

to +70ºC temperature

range

High efficiency, long life

LED light

IP6K7K

UL94 flame retardant

rated external parts

ADR, ECE and SABS

compliant

Spares interchangeable

with Hella DuraLed

range

CE compliant

Indicator

function

displayed

All functions

displayed (on)

MULTI

VOLT

LED

DT&

BARE

WIRE

0.7Kg

ADR/

ECE/

SABS

COMPLIANT

IP6K7

200G

8 to 28

V DC

9W


DuraLed ® MSIP Signal Lamp

Red/Green

HM95905030

MINING SIGNAL LAMPS

®

DuraLed

DuraLed ® MSIPs (Mine Safety Indicator Panel)

are LED signal lamps offering both red and green

signals in one compact housing, engineered

specifically for ultra heavy-duty applications where

safety is important, such as on underground

transport equipment sharing space with foot traffic.

MSIP

Signal Lamp

65

SIGNAL LAMPS

Product features

Impact resistant

smooth Xylex lens

Clear precision micro

optics

Multivolt 8-28V DC

Low power < 10W

Fully sealed “fit and

forget” design

0.5kg mass

200G shock impulse

resistant

Overheat, reverse

polarity and short

circuit protection

Spare Parts

9.HMDLM001

Cover Kit Yellow

(Pack of 4)

Double insulated supply

cable with DT plug or

tinned wire

Tested over a –40ºC

to +70ºC temperature

range

High efficiency, long life

LED light

IP6K7K

UL94 flame retardant

rated external parts

ROHS compliant

Spares interchangeable

with Hella DuraLed

range

DuraLed

MSIP

lamps are

extremely

robust, fully sealed truly “fit and

forget” products, tolerant to severe

vibration levels and very compact

in design. A high impact and

shock resistant, clear Xylex lens is

permanently bonded to a rugged,

UV damage resistant composite

base for increased mechanical

strength and maximum durability.

Hella engineered DuraLed MSIP

lamps to ensure a very long

service life and no lighting loss

due to internal dirt build-up; they

are also very well suited to wet

and corrosive environments and

tolerate short-term immersion. (See

technical section for more Xylex

information.)

Unlike normal signal lamps,

DuraLed products are maintenance

free and extremely power

efficient, which greatly reduces

both operating temperature and

demand on the vehicle’s electrical

system. Maximum service life and

light output of the high intensity

LEDs is ensured through using

internal heat sinks. The integral

Multivolt control module also

protects the DuraLed MSIP against

damage from overheating, reverse

polarity and short circuits. (See

technical section for more Multivolt

information.)

Safe and reliable electrical

connection is facilitated via a

highly flexible double insulated

cable, sealed into the base and

terminated with tinned wire ends.

Other connector options can be

supplied as special orders.

DuraLed MSIP lamps are equipped

with advanced clear micro optic

lenses to prevent the hazardous

occurrence of “ghost” signals by

internally reflected light from other

sources.

The smooth ergonomic design

and very low profile (under 35mm)

allows DuraLed units to be installed

on almost any surface.

222

193

34

96

Optic appears

clear until

illuminated (off)

Red

illuminated

shown

Green

illuminated

shown

Red & green

illuminated

shown

MULTI

VOLT

LED

DT&

BARE

WIRE

0.7Kg

ADR/

ECE/

SABS

COMPLIANT

IP6K7

200G

8 to 28

V DC

9W


DuraLed ® M

l White

Inspection Point

l l Red/Amber

Side Marker

l Red

Marker

l Amber

Cabin Marker

l Amber

Marker

Marker Lamp Bare Wire HM2054 HM2053PC HM2307 HM2026 HM2051

Marker Lamp DT HM2054D HM2053PCD HM2307D HM2026D HM2051D

MINING SIGNAL LAMPS

SIGNAL LAMPS

66

®

DuraLed

Marker Lamps

M

DuraLed ® M “Fit and Forget” robust waterproof clearance

marker and inspection lamps utilise the latest LED

technology specifically for heavy duty applications.

32

38

60

28.5

White Inspection

Point Lamp

Red/Amber

Side

Marker Lamp

(not ECE

compliant)

Red Marker

Lamp

(SAE/ECE

compliant)

The DuraLed M clearance and

marker lamps are heavy duty

injection moulded units in UV

resistant polymers that offer a

high resistance to corrosion and

attack from a range of aggressive

elements commonly found in

mining, industrial and chemical

plants (Please refer to the technical

section for detailed information).

The polymers used also offer high

levels of protection against impact

damage whilst exhibiting a large

degree of self-damping vibration

protection.

DuraLed M signal lamps feature

the Hella pioneered Multivolt

system that ensures the same

ultra bright light output at supply

voltages between 8V DC and

28V DC, eliminating the problems

associated with voltage drop and

allowing the fitment of the same

products on plant and machinery

with 12V DC or 24V DC electrical

systems.

All DuraLed M products are

fully sealed and pre-wired to

cope with temporary immersion

and high pressure cleaning. To

enable easy integration into most

mining machine wiring harnesses,

DuraLed M products are supplied

optional with DT Plug.

Product features

-40°C to +70°C.

200G shock resistant

Sealed to IP6K6 &

IP6K7 to withstand

temporary immersion

and high pressure

washing

Multivolt 8 - 28V DC

Up to 60% less current

draw than comparable

globe lamps

Ultrafast response time

Transient spike

protection

Reverse polarity

protection

Sealed unit pre-wired

with multi-core double

insulated wire

Available with DT Plugs

or bare wire ends

ADR & ECE compliant

approved for road use

High visibility yellow

mounting base

Polycarbonate lens

material rated UL94

5VB

PMMA lens material

rated UL94 HB

Mounting base material

rated UL94 UB

Amber Cabin

Marker Lamp

Amber

Marker Lamp

(SAE/ECE

compliant)

Marker Lamps displayed in OFF and ON modes.

Optics on marker ;amps appear clear until illuminated.

Spare Parts

9.HMDLM002

Marker Housing Yellow

(Pack of 4)

HM2051

HM2307

MULTI

VOLT

LED

DT&

BARE

WIRE

0.4Kg

ADR/

ECE

COMPLIANT

IP6K7

200G

8 to 28

V DC

1W


LED Daytime Running Lamp

2 Lamp Kit HM1535DRL

DAYTIME RUNNING LAMPS

LED Daytime Running Lamp

67

SIGNAL LAMPS

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).

Product features

Multivolt (9-33V DC)

Equipped with 12

highly

efficient LEDs

Ultra long life ‘Fit and

Forget’

Low power

consumption

< 2 Watts

Fully sealed against

dust and high-pressure

water jets

Inbuilt overtemperature

protection

Stainless steel

universal

mounting bracket

Polarity protected

Spike and overvoltage

protection

Long term UV resistant

Pre-wired with 2.5

metres of 3 x 0.75mm²

automotive cable

Homogenous close

range illumination

ADR/ECE: ADR 76/00

Hella has just launched a low

power LED Daytime Running Lamp

that provides extra safety through

enhanced visibility, at a fraction

of the power consumption of

conventional headlights.

Hella LED Daytime Running Lamps

(DRLs) are designed to significantly

improve vehicle visibility on site.

These lights are sealed and require

no maintenance (“fit and forget”)

and are ADR approved for road

use, giving the lights the versatility

to suit multiple applications.

With lower power usage and a

zero maintenance requirement,

make these lamps a sound

investment into enhanced mine

safety. The lens is manufactured

from Swiss made Grilamid ® Optical

Nylon which provides superior

resistance to UV and to a

wide range of chemicals, as well

as high impact strength, enabling

the lamp to survive the highly

demanding environmental

conditions of today’s mining.

The new Hella LED Daytime

Running Lamp (DRL) is suitable for

upright or pendant mounting and

supplied with universal stainless

steel mounting brackets. LED DRLs

have multiple applications, which

include area illumination around

the vehicle.

53

136 49

42

Kit contains two lamps

MULTI

VOLT

LED

BARE

WIRE

0.72Kg

IP6K7 IP6K9K

9 to 33

V DC

2W

ADR

COMPLIANT


Accessories

69

ACCESSORIES

70 LED Buggy Whip

71 Remote Jump Start Terminals

Battery Master Lockout Switch

72 Screened Extension Cables

73 Heavy Duty Screened

Extension Cables

74 NumiLED

75 NumiLED Pro

76 IR Dual Camera System

77 Quad Screen IR Kit

78 AccuPAX

80 Weatherproof Relay

Self-Amalgamating Tape

81 DT Connectors


LED BUGGY WHIPS

ACCESSORIES

70

LED Buggy Whip

LED Buggy Whip

1.2 metre HM4612

2.0 metre HM4620

3.0 metre HM4630

MULTI

VOLT

IP6K7

LED

200G

DT

0.5Kg

12V

1W

To meet safety regulations, mine

sites often require light vehicles

to display high visibility safety

flags to

improve visibility for drivers of

heavy machinery. Mounting onto

the bumper bars of light vehicles,

these give vehicles an extra layer

of protection.

During night and poor visibility

levels the operation of light

vehicles generally requires the

use of rotating safety beacons to

improve visibility. However in mine

sites where the topological surface

contains large dips and hills, these

may not be adequate.

By combining a bright LED with a

long reflective safety flag, drivers

of light vehicles can ensure they

are always in the line of sight of

heavy machinery.

The LED module puts negligible

load on the vehicles electrical

system (less than 1W), the

shaft is constructed from a high

quality fiberglass rod, sealing

the electrical components from

weather damage. The flag mounts

to the vehicle via a quality quick

release latch allowing the flag to

be taken down when the vehicle

is off site. The cable is terminated

with a DT plug, allowing quick

removal whilst sealing the electrics

from environmental damage.

The flag contains reflective UV

resistant material and the nylon

material repels the high levels of

dirt and dust often encountered in

mine sites.

9.HM46FX

Technical Specifications:

Light source

Quality LEDs in BA9 bulb

holder

Voltage 12V

Power Consumption

< 1W

Length

1.2 metres, 2.0 metres or

3.0 metres

Mounting

Integrated mounting

bolt on base with snap

on/off quick-release

shaft for quick and

easy installation

Spare Parts:

9.HM46MP

Male Pin Connector for Quick

Release

9.HM46MS

Medium Spring

9.HM46GL

LED Globe

9.HM46MP

9.HM46MS

9.HM46FX

Replacement Reflective Cross

Flag

Snap On/Off Quick Release


TERMINALS & SWITCHES

Remote Jump Start Terminals

71

ACCESSORIES

Heavy duty, high capacity

jump-start connectors for

vehicles and equipment.

Ideal for use where access

to terminals is restricted

or dangerous. Eliminates

the chance of cross polarity

connections through the

specially shaped plug. Reduces

chance of sparking and possible

ignition of flammable materials.

Features high impact ABS

plastic housing/insulator.

Zinc coated terminals.

Easy to mount and connect,

supplied with washers and M12

Nyloc Nuts.

Remote Jump Start Terminals

HM7546J

78

63 45

63

Technical information:

Removes risk of terminal

crossing

High Impact ABS Plastic

Zinc Coated Terminals

Battery Master Lockout Switch

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.

Battery Master Lockout Switch

HM7592B

69.1

10

Technical information:

Waterproof and Dustproof

to IP67

Tested to 200G shock for 10

000 cycles.

Sealed design allows switch

to be mounted in the best

location regardless of

environment.

Large red handle makes it

easy to operate with gloved

hands.

Composite-engineered

polymer housing that will not

corrode.

300A continuous current

rating at 12V and 250A at

24V

Temperature operating range

-40°C to + 85°C.

Divider on base prevents

accidental shorting of battery

cables.

Easy to read designations

on bezel and 90° switch

travel make it easy to identify

switch position.

11.4

60.3

135.6


SCREENED CABLES

ACCESSORIES

72

Screened Extension Cables

Screened Extension Cables

with 10A Plug/Socket

10m

HMEC1010AU

15m

HMEC1510AU

20m

HMEC2010AU

25m

HMEC2510AU

Screened Extension Cables

with 15A Plug/Socket

20m

HMEC2015AU

30m

HMEC3015AU

40m

HMEC4015AU

Braid is earthed when cord is in use

10A Socket

15A Socket

Electrical safety is an important

aspect in the overall Occupation

Health and Safety environment,

and there is increasing awareness

that passive elements like cables

and extension cords form a key

link in the safety system.

Permanently installed power

cables are protected from

mechanical damage by conduit,

cable trays and steel wire armour.

Extension cords are not so

protected. This lower degree of

protection is even more obviously

an anomaly when it is considered

that the extension cords used in

construction and maintenance

are not only more likely to be

damaged mechanically than the

permanent cables but also in

much closer proximity to people.

Hella Screened Extension Cables

are specifically designed to

improve safety in a mining and

general industry environment by

offering a more durable and safer

product for tradespeople to use.

Hella Screened Extension Cables

are approved to Australian and

New Zealand standards AS/NZS

3191/3120/3112 and 3199.

Hella Screened Extension Cables

offer superior protection with a

durable protective UV resistant

outer sheath made from PVC

that is designed to withstand the

general wear and tear

of electrical cables in workshop

and field applications.

Hella screened cables also

incorporate clear moulded plug

and socket ends for greater

protection of the user and

the internal conductors

by ensuring there is no

separation of the plug and

cables. These moulded plugs

and sockets also prevent

moisture ingress to minimise

corrosion and ensure a much

longer service life.

Hella Screened Extension

Cables utilise a tinned braided

copper screen for maximum

flexibility and electromagnetic

suppression of the extension

cable. This makes for easy use for

the operator in daily applications

and avoids time-consuming cable

tangles. This protective copper

braid offers greater protection

against damage to the cable and

is also connected to the earth pin

on each end of the extension cable

ensuring that a residual current

device is activated immediately if a

catastrophic failure occurs.

The copper conductor cores used

in all Hella Screened Extension

Cables have a cross sectional

area of 2.5mm². This is to ensure

minimum voltage drop over the

length of the cable and longer life

due to the reduction of heat buildup

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.

Product Features:

Triple insulated cable

Tinned copper braided shield

is earthed for additional

protection

Extra soft flex to avoid tangles

Heavy-duty strain reliefs

Fully encapsulated plugs and

sockets

Approved to Australian and

New Zealand standards AS/

NZS 3191/3120/3112 and

9199

Reduced electromagnetic

interference

No corrosion of conductors

from moisture in cables,

plugs or sockets

Plug and socket impact

tested to 100 Joule

Cable impact tested to IK10

(20 Joule)

2.5mm² conductors on all

screened extension cables


SCREENED CABLES

Heavy Duty Screened Extension Cables

73

ACCESSORIES

Electrical safety is an

important aspect in the overall

Occupational Health and

Safety environment, and

there is increasing awareness

that passive elements like

cables and extension cords

form a key link in the safety

system.

Permanently installed power

cables are protected from

mechanical damage by conduit, cable

trays and steel wire armour. Extension

cords are not so protected. This lower

degree of protection is an obvious

anomaly – extension cords used in

construction and maintenance are

not only more likely to be damaged

mechanically than permanent cables

but also in much closer proximity to

people.

Hella Heavy Duty Screened Extension

Cables are designed specifically for

ease of use and to improve electrical

safety in the mining and construction

industries by offering a more durable,

safer product for tradespeople to

use in wet and dusty environments.

The electrical plug and socket are

protected against water and dust

ingress to IP66 by a proprietary cover

system that mates with the majority

industry standard screw covers

industrial electrical outlets used in

Australia and New Zealand.

Hella Heavy Duty Screened Extension

Cable insulation and connectors are

moulded using clear protective UV

resistant PVC outer sheath enabling

users and inspectors to rapidly and

reliably visually identity the condition

of all the safety features of cables

brought onto the site or used in the

workshop. A neon lamp indicating

if power is present in the cable is

incorporated in the socket of all Hella

Heavy Duty Screened Extension cables

enabling users to immediately identify

live circuits, and aid testing.

Extended service life and greater user

safety is ensured by reducing moisture

ingress into the extension cable itself

through the use of clear moulded plug

and socket ends ensuring a perfect

seal and stress transfer between the

electrical connectors and the cable

itself. The electrical conductors and

screen are welded to the connector

pins to minimize contact resistance

and the risk of separation between the

plug and cables.

Hella Screened Extension Cables

utilise a braided tinned copper screen

for maximum flexibility across a wide

range temperature range, and avoids

time-consuming cable tangles.

The earthed screen provides

significantly improved suppression

of electro magnetic fields radiated

by the cable, and provides additional

protection fro equipment connected to

the cables against induced currents. As

the first contact caused by mechanical

damage to the cable is to the earthed

screen it ensures that a residual current

device is activated immediately.

The copper conductor cores used in

all Hella Screened Extension Cables

have a cross sectional area of 2.5mm².

This is to ensure minimum voltage drop

over the length of the cable and longer

life due to the reduction of heat buildup

within the product.

Hella Heavy Duty Screened Extension

Cables are approved to Australian

and New Zealand standards AS/NZS

3191/3120/3112 and 3199.

Utilising a flexible and safer screened

extension cable with IP66 rating or

better ingress protection is a must

for every mine, quarry and general

industry and is recommended by

mining department safety officials as a

matter of course.

Hella Heavy Duty Screened Extension

Cables are available in various length

and current options to suit every

application.

Screened Extension Cables

with 10A Plug/Socket

20m

HMIC2010AU

Screened Extension Cables

with 15A Plug/Socket

20m

HMIC2015AU

Screened Extension Cables

with 20A Plug/Socket

30m

HMIC3020AU

IP66

Braid is earthed when cord is in use

10A Socket

15A Socket

20A Socket

Product Features:

Triple insulated cable

Tinned copper braided shield

earthed for additional protection

Extra soft flex to avoid tangles

Heavy-duty strain reliefs

Fully encapsulated plugs and

sockets

Approved to Australian and

New Zealand standards AS/

NZS 3191/3120/3112 and

9199

Reduced electromagnetic

interference

No corrosion of conductors

from moisture in cables,

plugs or sockets

Neon safety light fitted in

socket

IP66 rated protection on

plug/socket connection when

assembled correctly

IP66 cover designed to

suit other major brands of

manufacturers

2.5mm² conductors on all

screened extension cables


NumiLED ® Kits – Small (396mm)

Set of 10 small LED modules, 24V DC

Single number housing, stainless steel

Single number housing, black

Triple number housing, stainless steel

Triple number housing, black

HMTNM6605

HMTNM6606

HMTNM6607

HMTNM6608

HMTNM6609

NumiLED ® Kits – Large (720mm)

Set of 10 large LED modules, 24V DC

Housing, stainless steel

Housing, black

HMTND2156

HMTND2157

HMTND2158

MINING SIGNAL LAMPS

ACCESSORIES

74

®

NumiLED

Number Boards

NumiLED ® is a modular system of robust illuminated

identification panels developed for use in work environments

where situational awareness forms the basis of safe operation,

and where visibility is often very poor. Typical applications are:

identification numbers for mining haul trucks and shovels,

process tanks and conveyor transfer stations.

247

396

Small Board Single

720

Small Board Triple

400

720

Large Board Single

396

The very high levels of dirt in

mining and many industrial

applications render retro-reflective

and normal high contrast signage

ineffective within a short period.

The NumiLED ® system overcomes

these challenges through the

combination of advanced optical

engineering and the best high

intensity LED technology available.

NumiLED ® panels provide

clear, legible identification for

instances up to one kilometre.

Each NumiLED ® unit consists of

a robust housing equipped with

an array of high intensity LED

modules arranged to display

an alphanumeric character of

choice. Hella engineered every

aspect of the NumiLED ® system to

withstand the corrosion, vibration

and generally hostile operational

environment for extended periods.

Designed to indefinitely retain its

full integrity after maintenance,

repairs can be made quickly

without any requirement for

specialised tools or skills.

The active LED modules are

custom versions of proven ‘fit &

forget’ Hella products adapted

to suit this application. The LED

modules are fully sealed and

pre-wired with double insulated

cabling and keyed DT connectors

to eliminate malfunctions due to

water ingress, corrosion or user

errors. Cognisant of the operating

environment, the NumiLED ®

system is designed to allow any

one LED module to be damaged

without impairing the function

of the whole unit. Individual LED

modules can be added, removed

and replaced at any time, allowing

users to re-use or repair, or

recycle NumiLED ® units into new

applications.

To ensure long term reliability

and maintainability, the power

distribution and control of the

LED modules is implemented

as a weatherproof distribution

module with keyed DT sockets

affixed to the rear of the NumiLED ®

housing. The power module is

based on an ultra heavy-duty

military grade dual layer gold

plated PCB incorporating fault

finding diagnostics as well as the

programming control system in the

NumiLED ® PRO versions.

NumiLED ® housings are precision

fabricated from heavy gauge grade

304 stainless plates. A corrosion

and UV resistant black semi gloss

powder coat or natural finishes are

standard options. The NumiLED ®

housing is supplied complete with

power module, prepared fixing

and mounting holes, with the

larger cabling holes fitted with high

quality rubber grommets to prevent

cable chafing. In addition, each

NumiLED ® housing is equipped

with four high quality vibration

dampers to isolate the NumiLED ®

number board from the vibration

generated by the machine it

is mounted to.

Product features

Improves safety &

visibility

Low maintenance

Low energy

consumption

Long service life

Expandable fleet

numbers

Easy to assemble

Spare Parts

9.HMTN001

NumiLED ® 8-Way

Distribution Board

9.HMTN002

NumiLED ® Connection

Cable - Single, 2m

Excellent performance

in hot, cold and wet

environments

Fully sealed against

dust and moisture to

IP6K7

Durable PMMA lens

Robust ABS and PC

housing

9.HMTN003

NumiLED ® Connection

Cable - Triple, 2m

9.HMTN004

NumiLED ® Vibration

Mounting Kit

HM4960SA

DT Connector Kit -

Male (pack of 10)

MULTI

VOLT

LED

DT

5.0Kg

IP6K7

200G

24V DC

60W

MAX


NumiLED ® Pro Boards – Small (396mm)

Single number board, stainless steel

Single number board, black

Triple number board, stainless steel

Triple number board, black

HMTNM6612

HMTNM6613

HMTNM6610

HMTNM6611

NumiLED ® Pro Boards – Large (720mm)

Board, stainless steel

Board, black

HMTND2159

HMTND2160

MINING SIGNAL LAMPS

®

NumiLED

NumiLED ® PRO number boards are even more versatile

featuring the advanced programmable power board with

internal memory function.

Pro

Number Boards

75

ACCESSORIES

Programming

dongle

Product features

Improves safety &

visibility

Pre-assembled and

fitted with all required

LED modules

Programmable power

distribution board

with internal memory

function

Integrated front

mounted MagCode ®

programming port

Supplied with

special MagCode ®

programming dongle to

change characters

Reverse polarity and

voltage spike protected

Low maintenance

Long service life

Expandable fleet

numbers

Sate of the art design

Low energy

consumption

(max. 20W per digit)

Excellent performance

in hot, cold and wet

environments

Fully sealed against

dust and moisture to

IP6K7

Durable PMMA lens

Robust ABS and PC

housing

While the standard NumiLED ® Kit

consists of empty housings and

packs of LED modules that the

end user assembles to create the

desired digits, the programmable

NumiLED ® PRO boards are

supplied fully assembled with all

seven LED modules. The required

digit is selected by simply using

the supplied dongle on the

special integrated MagCode ®

programming port. The NumiLED ®

PRO board will cycle through all

possible digits and stop when the

socket is removed.

The internal memory function

ensures that the selected digit

is displayed every time power is

supplied and will continue to do

so even if a damaged LED module

is replaced. The NumiLED ® PRO

board can be re-programmed at

any time using the same process.

To prevent unauthorized tampering

with the displayed digits, the

front mounted programming port

mechanically disconnects the

electrical connection when the

dongle is removed, which itself

incorporates encrypted data

that the power module must

validate prior to responding to any

programming inputs.

To suit different equipment types,

mounting preferences and visibility

distance requirements found on

mines, Hella offers NumiLED ®

boards in two sizes. While the large

(720mm tall) housing is supplied

as single digits only for ease of

handling, the smaller (396mm tall)

housing is available in both single

and triple digit versions.

The standard NumiLED ® LED

colour is red, but users can obtain

different coloured LED modules

for applications where different

equipment types are identified

through their colour as special

orders.

247

396

Small Board Single

720

Small Board Triple

400

720

Large Board Single

396

Spare Parts

9.HMTN002

NumiLED ® Connection

Cable - Single, 2m

9.HMTN003

NumiLED ® Connection

Cable - Triple, 2m

9.HMTN004

NumiLED ® Vibration

Mounting Kit

9.HMTN005

NumiLED ® PRO

Programming Dongle

9.HMTN006

NumiLED ® PRO

Programmable PCB

HM4960SA

DT Connector Kit -

Male (pack of 10)

HMTNM6605

Small LED Modules,

24V DC (pack of 10)

HMTNM2156

Large LED Modules,

24V DC (pack of 10)

Vibration Damping (Detail)

Distribution Board (Rear View)

MULTI

VOLT

IP6K7

LED

200G

DT

5.0Kg

24V DC

60W

MAX


MINING REVERSING CAMERA KIT

ACCESSORIES

76

Infra-red Dual Camera System

Colour 5.6 inch Monitor, Infra-red

Camera, 20m Cable, 12-24V

HM5700KIT

Colour 7.0 inch Monitor, Infra-red

Camera, 20m Cable, 12-24V

HM5701KIT

Spare Parts:

9.HM5700

Colour 5.6”

Monitor

9.HM5701

Colour 7.0”

Monitor

9.HM5702

Infra-red Reverse

Camera

9.HM5703

Connection cable,

20m

Visibility around vehicles on mine

sites can be an issue, particularly

on large machinery. Hella has

introduced a highly durable LED

Infra-red system with the ability for

customized setup based on the

application.

The Infra-red camera enables

greater visibility by penetrating

harsh dusty environments with

minimal backscatter. The option of

a compact 5.6” monitor or larger

7.0” screen enables site operators

to greatly improve safety.

The unit has a low power burden

on the system of less than 5W

for monitor and less than 2W

for camera and is powered by a

Multivolt system, allowing safe

operation during fluctuation in the

vehicle voltage level between 9

and 32V. The camera also includes

audio pickup with built in speaker

in the monitor for additional safety.

Other features include highly

durable splash proof screen with

automatic day/night dimming

function and manual brightness,

contrast, colour and

volume control as well

as true and mirror image

display modes for camera

mounting flexibility.

The highly durable LED

Infra-red Camera is

constructed from aluminum

alloy and has been designed

to withstand heavy vibration

as well as damage from

harsh environments,

dust and moisture often

encountered on mine sites.

Equipped with 18 high-quality

Infra-red LEDs for excellent night

vision up to 12 metres. The system

features a small physical footprint

for versatile mounting and

overall weight of only 380 grams

(including mounting bracket).

Designed and tested to withstand

a temperature range of -10°C to

+65°C.

9.HM5700 5.6" Monitor

Technical Specifications –

5.6 inch and 7.0 inch

Monitor:

LCD Display

Multivolt system 12V or 24V

DC supply

Low power consumption

< 5W

Built-in speaker

Adjustable brightness,

contrast, colour and volume

control

Auto day/night dimming

function

True/Mirror image selection

on monitor

Camera switching on monitor

Auto trigger function for

optional second camera

Operating temperature range

-15°C to +65°C

Signal system PAL/NTSC Auto

9.HM5701 7.0" Monitor

Technical Specifications –

Infra-red Camera:

Robust aluminium alloy

18pcs IR LEDs for improved

night vision (10-12 metres)

1/4” image size

Focal length of lens 2.6mm,

F2.0

110° diagonal lens angle

Ingress protected to IP68

Low power consumption

< 2W

Compact size (82 x 73 x

58mm)

Light weight of only 380g

(including mounting bracket)

Camera activation by means

of reverse gear selection

Operating temperature range

-30°C to +65°C

9.HM5703 Connection Cable


MINING REVERSING CAMERA KIT

Quad Screen Input Infra-red Camera System

77

ACCESSORIES

To complement

Hella’s visual display

systems a quad screen

system capable of up

to 4 camera inputs has

been developed.

The system is

designed for large

mining machinery

such as loaders

and excavators

where drivers require

viewpoints from multiple angles.

Offering the flexibility of displaying

one, two, three, or even four

camera views, the system caters

for the largest of mining machinery

in many applications.

The monitor is rugged enough for

mining use, with an aluminium

alloy housing providing ingress

protection to IP65. With a weight

of only 800 grams, the monitor has

a small physical footprint in the

driver’s cabin.

The monitor has the ability to

automatically adjust the display

mode according to the number of

camera inputs detected.

Other features include an

automatic day/night dimming

function, along with manual

brightness, contrast, colour

and volume control as well as

independent true and mirror image

display modes for each camera,

offering further mounting flexibility.

The seven inbuilt languages allow

the system to be used in many

different countries by a wide range

of operators.

Also now available is a custommade

heavy-duty steel camera

guard, designed to protect the

infra-red camera from damage and

vandalism.

The kit is designed to withstand

heavy vibration as well as

damage from dust, moisture and

the harsh environments often

encountered on mine sites. The

quality electronics provide reverse

polarity and high and low voltage

protection.

Kit contains monitor bracket, roll

of silicon tape, 1.5m loom cable,

sun visor, 20m extension cable

and IR camera.

Quad Screen IR Camera Kit Monitor,

Infra-red Camera, 20m Cable, 12-24V

HM5800KIT

Spare Parts:

9.HM5702

Infra-red Reverse

Camera

9.HM5703

Connection cable,

20m

9.HM5801 7" Monitor

9.HM5801

Colour Multiscreen

Monitor 17.8cm

(7.0”)

9.HM5802

Steel Camera

Guard

Technical Specifications –

Quad Monitor:

LCD Display 16:9 7”

Multivolt system 12V DC or

24V DC supply

Low power consumption

< 5W

Built-in speaker

Adjustable brightness,

contrast, colour and volume

control

Auto day/night dimming

function

Brightness 350 cd/m²

Resolution 336,960 pixels

True/Mirror image selection

on monitor

Camera switching on monitor

Auto trigger function for

optional second camera

Operating temperature range

–20°C to +70°C

Signal system PAL/NTSC Auto

Dimensions

200(L)*76(W)*138.5(D)

9.HM5802 Steel Camera Guard

9.HM5703 Connection Cable


MASTER SWITCH

ACCESSORIES

78

AccuPAX ®

Battery Master Switch

Battery Master Switch 12V

HM4660A

Battery Master Switch 24V

HM4660B

Spare Parts:

HM4660ROD

iROS Roll-over

Protection Device

HM4660SWA

Latching Push On /

Twist Off Switch -

Double Pole, IP65

HM4660SWB

Latching Push On /

Twist Off Switch -

Double Pole with

Guard, IP65

HM4660SWC

Momentary Push

Button Switch -

Single Pole, IP65

HM4660SWD

Momentary Push

Button Switch -

Single Pole with

Guard, IP65

HM4660SWE

Rotary On / Off

Switch, 4 pin, with

Lid (use connector

1-0967325-kit)

HM4660SWF

Push Button Switch,

2 pin (use connector

1-0967325-kit)

HM4660LOC

Lockable Cover,

Stainless Steel

HM4660KTB 7

Pin DIN Connector

with 5M Harness

HM4660KTC 7

Pin DIN Connector

with 700mm

Harness

AccuPAX ® is an intelligent 2-pole,

bi-stable, electro-mechanical

battery master switch with

mechanical locking. It is approved

for hazardous goods transport. It

incorporates a micro controller to

monitor and operate several safety

functions, that is unavailable on

older style battery isolator switches,

and is suitable for 12V and 24V

systems.

Its prime function is to disconnect

and isolate the main battery positive

and negative circuits of the vehicle

or engine plant to render it safe

and/or inoperable. It may be wired

and operated directly at the control

panel on the switch face to replace

existing products. Significantly

more sophisticated control systems

can be implented, with multiple

safety isolators located in the cabin

or elsewhere at desired locations

around the vehicle. AccuPAX can

also be activated by an external

trigger like a roll-over sensor.

In normal situations, AccuPAX will

step through a pre-programmed

shut-down sequence, ensuring

the safe disconnection of onboard

engine management systems

to avoid data corruption.

Incorporated in this sequence

is an alternator field isolation

procedure to prevent damage

to the alternator, battery and

electrical system due to

voltage surges.

In emergency shut down

situations, such as a rollover,

AccuPAX disconnects all

power immediately via the

emergency shut down

switch, or the optional

rollover detection device.

AccuPAX constantly monitors

system voltage and disconnects the

battery if system voltage falls below

the user selected safety level, to

prevent damage to the electrical

system.

The AccuPAX complies with

Australian Standards AS 2809.2

and European ADR 2005.

In addition to the rollover sensor,

optional equipment includes

lock-out guards, switches and

cable harnesses to facilitate easy

installation of the AccuPAX unit.

168

104

130

Technical information:

Ex & CE Certified

Compliant with ADR 2005

Compliant with AS 2809

(Draft)

Field isolation for North

American vehicles

D+ shutdown for European

vehicles

Delayed ECM shutdown to

prevent re-programming

Direct plug in iROS roll

over device – works with

all other roll over devices

(optional equipment - not

supplied)

Roll over simulation test with

status light

Luminous On/ Off/ Roll Over

push button switches

Robust IP65 rated enclosure

Stainless Steel mounting

bracket (Lucas SSB

interchangeable)

Low battery voltages

disconnect

Lockable cover (optional

equipment – not supplied)

104

Switch Rating: HM4660A HM4660B

Operating Voltage 9 to 15 Volts 18 to 30 Volts

118

Current Rating 300A continuous 300A continuous

127

Max Current 5 Sec 2500A 2500A

130

HM4660A

Max Current 30 Sec 600A 600A

Field Isolation Circuit 10A max 10A max

Optional Low Voltage Monitoring


MASTER SWITCH

79

ACCESSORIES

HM4660LOC Lockable Stainless Steel Cover

HM4660SWA

Latching Push On / Twist Off Switch -

Double Pole, IP65

HM4660SWD

Momentary Push Button Switch -

Single Pole with Guard, IP65

HM4660ROD iROS Roll-over Protection Device


WEATHERPROOF KIT, LOOM TAPE

ACCESSORIES

80

12V Weatherproof Changeover Relay

and Connector Assembly Kit

12V Kit

12V ISO mini relay and connector assembly kit:

HMWPR001

87

87a

86 85

1 x ISO-style 12 volt c/cover relay

1 x Connector body with seals for pull to seat terminals

3 x Large barrel pull to seat terminal 6.3mm width suits

cable size 3.00mm 2

2 x Small barrel pull to seat terminal 6.3mm width suits

cable size 1.00 - 2.00mm 2

30

Voltage

10 -16V DC

30 86 85 87 87a

Operating Range Temp

-40°C to +125°C

35mm

Contact current rating

NO 35A / NC 20A

Coil Resistance @ 23°C

Transient Suppressor Resistor

70-90 Ohms

680 Ohms

56.5mm

Self-Amalgamating Tape

Self-Amalgamating Tape

HMAT85

Polyethylene self-amalgamating loom tape ideal for waterproof sealing of

electrical connections, temporary repair and sealing of plumbing joints.

Also suitable for emergency repair of radiators, engine hoses and auto

electrics. Easy to unwind and resistant to water, ozone, UV and a wide

range of chemicals including alkalis, hydraulic fluids and vegetable oils.

Tape Thickness

Breakdown Voltage

0.5mm, tensile strength at break 12 N/cm

34 kV/mm

Elongation 600%

Service Temperature

-35˚C to +130˚C


CONNECTORS

DT Connectors

81

ACCESSORIES

DT Connectors

Environmentally sealed connectors rated -55°C to

+125°C. Supplied complete with removable, solid

copper crimp contacts (1.0 – 2.0mm 2 ) and secondary

locks. All contacts rated 13A.

HM4960

HM4961

Qty. in

pack

2 Pole DT Connector Set 1 HM4960

2 Pole DT Connector Half-Set* 10 HM4960FM

3 Pole DT Connector Set 1 HM4961

3 Pole DT Connector Half-Set* 10 HM4961FM

4 Pole DT Connector Set 1 HM4962

6 Pole DT Connector Set 1 HM4963

6 Pole DT Connector Half-Set* 10 HM4963FM

8 Pole DT Connector Set 1 HM4964

12 Pole DT Connector Set 1 HM4965

HM4962

HM4963

Spare Parts

Small I.D. plug contact to suit cable 0.5 – 1.0mm 2

Small I.D. socket contact to suit cable 0.5 – 1.0mm 2

Large I.D. plug contact to suit cable 1.0 – 2.0mm 2

Large I.D. socket contact to suit cable 1.0 – 2.0mm 2

Sealing plug

9.HM4960.01

9.HM4960.02

9.HM4960.03

9.HM4960.04

9.HM4960.05

* Half-Set = female socket with male contacts.

HM4964

DT Connector Crimping Tool

Specially dsigned crimping tool with multiple

jaws for even crimp of DT Terminals

HM8275

HM4965

HM8275 DT Connector Crimping Tool


Interior Lighting

83

INTERIOR LIGHTING

84 EuroLED Touch M

85 CargoLED

86 SpotLED

88 FlexSPOT

89 MiniThinLED


EuroLED ® Touch M Interior Lamp

with 2.5m cable

with 0.5m cable and DT plug

HM959950211

HM959950221

MINING INtERIOR LAMPS

INTERIOR LIGHTING

84

®

EuroLED

Touch M

Interior Lamp – Multivolt 9-33V DC

Harnessing the durability and power saving benefits of

advanced single LED technology, EuroLED ® Touch

interior lamps offer long lasting, dual colour LED light

output of white light for general interior illumination

and the additional function of red light to help

maintain night vision (see below).

110

White On

Red On

30

13

Cable Exit

130

30

130

EuroLED Touch interior lamps are

equipped with high-performance

LEDs – a single white LED in the

centre of the lamp plus multiple

red LEDs arranged in a circular

pattern – and highly advanced

lens optics providing a uniform

light distribution without glare for

optimum efficiency and increased

safety. The use of MultivoltTM

electronics ensures a consistent

level of brightness at any input

voltage between 9 and 33V DC,

even when subjected to severe

voltage fluctuations.

Lighting control is made easy

thanks to integral, touch sensitive

switch pads (white pad for white

light, red pad for red light) and a

4-stage dimming function with

memory. All it needs is the touch of

a finger to switch the light colour

and regulate the light intensity

to suit individual cabin lighting

requirements. When the finger is

held on either switch pad for longer

than two seconds, the lamp will

automatically cycle through four

dimming stages until the

finger is released on the

light level required. The

integrated memory function

ensures the lamp turns on at

the light level last selected.

In addition to touch sensitive

switching, EuroLED Touch lamps

are also suitable for synchronised

remote operation from multiple

points using standard On/Off/On

momentary switches.

EuroLED Touch lamps are shock

and vibration resistant and

completely sealed against dust and

moisture to international protection

standards for maximum durability

and increased service life. The

unique rounded and low profile

design allows fitment into narrow

panels, whilst offering distinct

operational and safety benefits.

Compared to common fluorescent

lamps, EuroLED Touch interior

lamps will not interfere with other

electronic equipment and run

completely silent.

Product features

Dual colour LED

lighting

Integral, touch sensitive

switching

Dimming function with

memory

Multivolt 9-33V DC

Ultra low power

consumption

Spare Parts

8HG959952022

EuroLED ® Mounting

Spacer

Shock and vibration

resistance

Over voltage, reverse

polarity and transient

spike circuit protection

Low EMC signature

IP 6K6 6K7 completely

sealed against dust and

moisture

Red Light and Night Vision

The human eye contains two types of receptors,

rods and cones. Both have an increased

sensitivity to frequency bands at different ends of

the visual spectrum. Rods are largely responsible

for our daytime and colour vision and have an increased sensitivity

towards the red band of the visual spectrum. In contrast cones are

responsible for our night vision capability and have an increased

sensitivity towards the blue, shorter wavelength band of the visual

spectrum. For this reason red light helps to preserve our night vision

as it will not affect the sensitivity of the cones.

Mounting Spacer – designed to suit all

EuroLED ® interior lamps. Enables easy

surface mount with side cable exit

MULTI

VOLT

LED

DT &

BARE

WIRE

0.3Kg

IP6K7

200G

9 to 33

V DC

5W


CargoLED ®

Heavy Duty Interior Lamp

HM227HD

MINING INTERIOR LAMPS

®

CargoLED

Heavy Duty Interior Lamp Multivolt 9-31V DC

Hella CargoLED ® is an advanced interior light

designed with particular attention to visual comfort

for applications where operators need high quality

light to perform visually intensive tasks for extended

periods, in operating environments unsuitable for

conventional light sources.

85

INTERIOR LIGHTING

Product features

Aluminium core body

for optimal thermal

performance of LEDs

Clear UV and chemical

resistant modified

acrylic lens

Large optical system

for high light output

Low luminance indirect

design ensures low

glare

High intensity LED light

source array

Sealed unit pre-wired

with multi strand

double insulated cable

Available with DT plugs

Multivolt 9-31V DC

Spike protected to

+500volts

Over voltage protected

to +200volts

Reverse polarity

protected to -500volts

Power consumption:

6W

Sealed to IP6K9 to

withstand temporary

immersion and high

pressure washing when

installed

Surface mount

accessories available

200G shock impulse

resistant

-40ºC – +60ºC

External elements

manufactured from

flame retardant

polymers rated

UL94 HB

ADR 2006 (hazardous

goods transport)

compliant

Traditional vehicle interior

lighting systems do not

deliver the quality of light

required by operators of drill

rigs and other complex plants

who often spend large amounts

work time reading detail maps or

drawings. Concurrently, flat display

panels containing more information

are replacing analogue instruments

in cabins adding to the intensity

and complexity of the visual tasks.

To overcome the limitations of high

susceptibility to physical damage

and poor efficiency inherent in

conventional solutions, Hella

produced the CargoLED. This

unique product combines the best

LED experience with advanced,

glare free, low luminance “indirect”

lighting technology originally

developed for CAD studios. This

highly innovative solution delivers

the visual comfort normally found

in offices into almost any mining

machine cabin.

The low power consumption and

minimal heat output of CargoLED

enables continuous operation in

confined spaces and reduces burn

injury risk.

CargoLED employs a large

“brilliant” Free-Form optical system

and clear lens to provide a large

homogenous area illumination

with maximum efficiency. Hella

engineered CargoLED lamps to

ensure a very long service life and

no lighting loss due to internal dirt

build-up. Maximum service life and

light output of the high intensity

LEDs is ensured through using the

aluminium body as a massive heat

sink. The clear exterior lens can

be re-polished if required, with no

detrimental effect on light-output or

chemical resistance. CargoLED is

unaffected by shock and vibration,

ensuring high reliability. The lamp is

fully sealed and designed for a true

“fit and forget” installation.

Advanced Multivolt control of

the LEDs ensures consistent

illumination from 9-31V DC – even

under severe voltage fluctuations

and low battery voltages. This

delivers significantly better

performance than low-power

fluorescent or incandescent interior

lights. The circuitry also provides

reverse polarity, spike and overvoltage

protection for long life and

reliable operation.

Safe and reliable electrical

connection is facilitated via a

short length double insulated

cable terminated as standard in

DT connectors. A thick gasket is

supplied to ensure reliable sealing

for recessed installation, and an

optional surface mount adaptor

is available.

Shown lit

MULTI

VOLT

LED

DT

0.5Kg

IP6K9

200G

9 to 31

V DC

6W


SpotLED ®

Screw Mount, DT

l White Cover

l White Cover

l Red Ambient Ring

l Yellow Cover

l Yellow Cover

l Red Ambient Ring

l Black Cover

l Black Cover

l Red Ambient Ring

Fixed HM680FNW HM680FRW HM680FNY HM680FRY HM680FNB HM680FRB

Adjustable HM680ANW HM680ARW HM680ANY HM680ARY HM680ANB HM680ARB

MINING INTERIOR LAMPS

MOBILE INTERIOR EQUIPMENT LIGHTING

LIGHTING

86

®

SpotLED

Fixed & Adjustable Interior Lamps Multivolt 9-31V DC

SpotLED ® lamps are sophisticated LED interior lights

designed for applications where there is a requirement

for low glare, spill free lighting, with the option to

switch from white primary to red ambient light to

maintain night vision.

Fixed Model

Adjustable Model

Adjustable Model (20°), shown with

white LED illuminated, and white cover

SpotLED interior lights are available

in a number of versions: These

include fixed or adjustable optical

modules either with or without the

low level ambient illumination to

monitor critical instruments.

General illumination is provided by

a single high intensity white LED

located deep inside a Free-Form

reflector with a black sleeve to

eliminate direct view of the light

source and discomfort glare. A

separately switched, low intensity

red LED illuminates a circular

light CELIS light guide, to provide

low intensity ambient illumination

for safety and night vision

compatability.

The low power consumption,

combined with minimal heat output

in continuous use, and ergonomic,

smooth design of SpotLED reduces

personal injury risk in confined

spaces, while the fit-and-forget

completely sealed and waterproof

optical units will not suffer lighting

loss due to internal dirt build up.

Advanced Multivolt drive circuitry,

providing reverse polarity, spike

and over-voltage

protection for long life

and reliable operation,

is sealed into the

optical module. SpotLED

lamps deliver consistent

illumination from 9-31V

DC – even under severe voltage

fluctuations and low battery

voltages. Maximum service life and

light output of the high intensity

LED light source is ensured

through an integral aluminium

heat sink.

SpotLED lights require external

switching systems, and can

operate on standard interior

light circuits.

Safe and reliable electrical

connection is facilitated via a short

length double insulated multi core

cable terminated as standard in

DT connectors.

The screw cover end caps are

available in a range of colours.

Ambient light functions in amber,

blue, green or white can also be

delivered on special order.

Product features

Available in fixed or

adjustable versions

20 degree angle

adjustment to each side

Low intensity red CELIS

ambient light

Aluminium heat sink

mounted LED

Clear polycarbonate

lens and CELIS light

guide for excellent

optical performance

and impact resistance

Impact resistant, easy

to clean ABS housing

components

Low glare homogenous

light distribution

High intensity LED light

sources

Changeable colour side

caps

Pre-wired with multi

strand double insulated

cable with DT

Multivolt 9-31V DC

Reverse polarity

protected to -500 volts

Power consumption:

3W

Fully sealed to IP6K9K

(optical unit) to

withstand temporary

immersion and high

pressure washing

200G shock impulse

resistant

-40ºC – +60ºC

External elements

manufactured from

flame retardant

polymers rated UL94

HB

ADR 2006 (hazardous

goods transport)

compliant

Fixed Model, shown with Red Ambient

Ring illuminated, and white cover

Spare Parts

9.HMDLM002

Marker Housing Yellow

(Pack of 4)

MULTI

VOLT

LED

DT

0.3Kg

IP6K7

200G

9 to 31

V DC

3W


87

INTERIOR LIGHTING

Adjustable model shown

Optional

Yellow

Cover

Optional

Black

Cover

Optional

White

Cover


FlexSPOT ® LED Interior Lamp l White Shroud l Yellow Shroud

150mm flexible arm HM720150W HM720150Y

400mm flexible arm HM720400W HM720400Y

MINING INTERIOR LAMPS

INTERIOR LIGHTING

88

FlexSPOT

®

LED Interior Lamp Multivolt 9-31V DC

FlexSPOT LED ® is a flexible arm LED interior lamp with

integral switch, for use in applications where the operating

environment is unsuitable for conventional light sources.

A new generation of high efficiency

white LED light sources enabled

the design of a fit-and-forget low

power reading light with a very long

service life and little heat build-up,

enabling continuous use of the

FlexSPOT with no danger of over

heating or burn injury.

FlexSPOT LED is unaffected by

shock and vibration and has a

high-reliability switch integrated

into the lamp head, for ease of

use and integration into work

environments. Advanced Multivolt

circuitry, providing reverse polarity,

spike and over-voltage protection

for long life and reliable operation

of the LED, is sealed into the

light. FlexSPOT lamps will deliver

consistent illumination from 9-31V

DC – even under severe voltage

fluctuations and low battery

voltages. Maximum service life and

light output of the high intensity

LED light source is ensured by an

aluminium heat sink internal to the

lamp head.

We have tested the SpotLED

lamp head to the same exacting

standards demanded of Hella

Mining LED signal lights. Hella

bonded the best quality flexible

arm available into the head and

mounting bracket to ensure a

long, trouble-free life for the

FlexSPOT.

Safe and reliable electrical

connection is facilitated via a short

length double insulated cable

terminated as standard with bare

wire ends.

Product features

Aluminium heat sink

for optimal thermal

performance of LEDs

UV and chemical

resistant modified

acrylic lens

Impact resistant

polycarbonate and ABS

housing

Integral switch

Low glare homogenous

light distribution

High intensity LED light

source

Pre-wired with multi

strand double insulated

cable

Available with DT plugs

or bare wire ends

Reverse polarity

protected to

-500 volts

Power consumption:

2.5W

Sealed to IP53 protects

active electronics and

optics against splashed

liquid

200G shock impulse

resistant

-40ºC to +60ºC

External elements

manufactured from

flame retardant

polymers rated

UL94 HB

EC, ROHS and ADR

2006 (hazardous goods

transport) compliant

Multivolt 9-31V DC

MULTI

VOLT

LED

BARE

WIRE

0.4Kg

IP53

200G

9 to 31

V DC

2W


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

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

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

MINING INTERIOR LAMPS

®

MiniThinLED

Interior Lamp

89

MOBILE EQUIPMENT

INTERIOR LIGHTING

LIGHTING

MiniThinLED ® lamps are robust low profile

multi-use LED lamps ideal for general

applications such as insteps, ambient and

storage lights.

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.

Product features

Approximately 136 x

30 x 11mm

12V or 24V versions

Various colour

possibilities

State of the art design

Easy flush mounting

screw version

Excellent durability “Fit

and Forget”

Low energy

consumption 1.2W –

2.8W

Excellent performance

in heavy, cold and wet

environments

Water resistant IP69

Performance

temperature range -40

to +60C

Quality materials:

PMMA (Lens) and

ABS+PC (Housing)

5 LED Red

5 LED White

3 LED Blue

3 LED Green

LED

BARE

WIRE

0.1Kg

IP69

200G

12/24

V DC

3W


Alarms & Horns

91

ALARMS & HORNS

92 MotoVOX

93 RetroVOX Self Adjusting

94 RetroVOX Compression Driver

95 RetroVOX Broadband


REVERSING ALARMS

ALARMS & HORNS

92 MotoVOX

®

Compact 117dB Horn

MotoVOX ® 117dB Compact Horn

HMFH312P

128

95

+

- 77

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.

MotoVOX ®

Forward 117dB Horn

MotoVOX ® FH117 92mm 117dB Horn

HMFH117P

118mm

183.1mm

81mm

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

81mm

127mm

MotoVOX ®

Compact 107dB Horn

78mm

MotoVOX ® FH107 107dB Horn

HMFH107P

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

92mm

118mm

81mm

183.1mm

81mm


REVERSING ALARMS

RetroVOX ®

Self Adjusting Reversing Alarm

93

ALARMS & HORNS

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.

RA917 Self Adjusting 112dB Alarm

HMRA917E

Voltage

12- 24V DC

Decibel 87 - 112 @ 1.2m

Approval

SAE J994 Type D

180

4.4

78

3.08

102

4.0

RetroVOX ®

Ultra Heavy Duty Reversing Alarm

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

RA112 Ultra Heavy Duty 112dB Alarm

HMRA112P

163

102

Approval

SAE J994 Types A, B & C


REVERSING ALARMS

ALARMS & HORNS

94 RetroVOX

®

Compression Driver Reversing Alarm

(Manual)

RetroVOX ® Compression Driver

112dB Alarm (Manual)

HMRA603P

178

152

101

New high-efficiency reversing alarms with reduced power draw

and significantly better acoustic performance over life. Heavy-duty

polymer construction fits popular OEM dimensions. Fully encapsulated

spark-free electronics (IP68) allows high pressure water cleaning.

200G shock resistant.

HMRA603P

81

Voltage

Decibel

Approval

12-24V DC (reverse polarity protected)

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

adjustment

SAE J994 class A/B/C

RetroVOX ®

Compression Driver Reversing Alarm

(Automatic)

RetroVOX ® Compression Driver

112dB Alarm (Automatic)

HMRA611P

178

152

101

New high efficiency reversing alarm with reduced power draw and

significantly better acoustic performance over life. Heavy-duty

polymer construction fits popular OEM dimensions. Fully encapsulated

spark-free electronics (IP68) allows high pressure water cleaning.

200G shock resistant.

HMRA603P

81

Voltage

Decibel

Approval

12-24V DC (reverse polarity protected)

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

requirement

SAE J994 classes A-D


ALARMS

RetroVOX ® Compact Broadband 87dB Alarm

95

ALARMS & HORNS

Noise Pollution can be an issue for mine sites close to residential areas.

Hella have introduced a range of broadband or ‘white noise’ reversing

alarms to prevent miners from having to compromise on safety. By

emitting sound over a large range of frequencies, the sound dissipates

faster and is localized so that sound doesn’t carry. The RetroVOX features

a rugged design, which is highly reliable and unaffected by continuous

vibration, moisture, heat, cold, sun glare and dirt.

RetroVOX Broadband 87dB Alarm

HMRA087B

91

45

76

55

Voltage

Current

Decibel

12-24V DC

Max. 0.5 Amps

87 @ 1m

Approval SAE J994 Class E 11

CE & EMC Approved

Product Features:

Ingress Protected to IP68

(waterproof)

Solid-state, spark-free

electronics

Epoxy-sealed against mud,

water and vibration

Can be steam-cleaned and

pressure-hosed

RetroVOX ®

Broadband 87-112dB Reversing Alarm

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.

RetroVOX Broadband 112dB Alarm

(Manual)

HMRA107B

Voltage

Decibel

Approval

12-24V DC (reverse polarity protected)

87-112dB @1.2m

SAE J994 class A-D EC, E11

95

152

173

80

155


Service Tools

97

SERVICE TOOLS

98 EziPAK DT Connector Kit

100 EziPAK Double Crimp Kit

102 EziPAK Heat Shrink Kit

104 EziPAK Intelligent Fuse Kit

106 Super Seal Connector

107 PowerPAK


CONNECTOR KITS

SERVICE TOOLS

98

EziPAK ®

DT Connector Kit

EziPAK ® DT Connector Kit

(389 Pieces)

(See list of included components next page)

EziPAK ® DT Connector Kit

(incl. Crimping Tool HM8276)

Accessories

Universal DT Contact

Crimping Tool

HM8283

HM8275

DT Contact Crimping Tool

0.5 - 1.0mm HM8277

EziPAK ® Double Drawer

Storage Module (empty)

EziPAK ® Single Divisional

Carry Case (empty)

HM8285

HM8286

Hella has developed a new range

of EziPAK ® service kits to meet

the need of mobile field service

technicians maintaining mining

machines on site.

EziPAK ® kits are based on many

years of practical experience.

Each kit is contained in an

impact resistant and washable,

heavy-duty injection moulded

carry case that slides into a self

locking modular double storage

tray for easy installation into field

service vehicles or use as a central

storage point in the workshop

environment.

The DT connector kit to service the

popular DEUTSCH connectors is

the first module of the range to be

released.

The EziPAK ® kit is supplied with

the most popular DEUTSCH

connectors including the

essential tools to make and

repair these connections and

a highly detailed step-bystep

instruction document

ensuring that users obtain truly

professional results.

Each EziPAK ® kit is supplied

with a hard wearing large format

visual reference of it’s contents,

this also contains the re-order

information for refill packs of

DT consumables, thus enabling

customers to maintain the

EziPAK ® service kit indefinitely.

Additional tools, empty carry

cases and rack modules are

also available to allow service

teams to create their own

customised kits if needed.

HM8283

HM8285

HM8275

HM8277


CONNECTOR KITS

99

SERVICE TOOLS

DT Connectors (included in EziPAK ® DT

Connector Kit)

Qty in

pack

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

9.HM4940

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

3-Way Male DT Connector (incl. wedge) 15

9.HM4942

3-Way Female DT Connector (incl. wedge) 15

9.HM4943

4-Way Male DT Connector (incl. wedge) 10

9.HM4944

4-Way Female DT Connector (incl. wedge) 10

9.HM4945

6-Way Male DT Connector (incl. wedge) 10

9.HM4946

6-Way Female DT Connector (incl. wedge) 10

9.HM4947

8-Way Male DT Connector (incl. wedge) 5

9.HM4948

8-Way Female DT Connector (incl. wedge) 5

9.HM4949

12-Way Male DT Connector (incl. wedge) 5

9.HM4950

12-Way Female DT Connector (incl. wedge) 5

9.HM4951

3-Way Round Male HDT Connector 5

9.HM4952

3-Way Round Female HDT Connector 5

9.HM4953

Male DT Connector Pin 100

9.HM4954

Female DT Connector Socket 100

9.HM4955

Connector Sealing Plug 50

9.HM4956

9.HM4940

9.HM4942

9.HM4944

9.HM4946

9.HM4941

9.HM4943

9.HM4945

9.HM4947

Service Tools (included in EziPAK ® DT

Connector Kit)

DT Contact Crimping Tool 1.0 - 2.0mm 1

HM8276

9.HM4948

9.HM4949

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

9.HM4950

9.HM4951

9.HM4954 9.HM4955 9.HM4956

9.HM4952

9.HM4953

9.HM4957 9.HM4958 9.HM4959

HM8276


CONNECTOR KITS

SERVICE TOOLS100

EziPAK ®

Double Crimp Connector Kit

EziPAK ® Double Crimp

Connector Kit (3,652 Pieces)

(See list of included components next page)

EziPAK ® Double Crimp

Connector Kit

Accessories

EziPAK ® Double Drawer

Storage Module (empty)

EziPAK ® Single Divisional

Carry Case (empty)

HM8284

HM8285

HM8286

Hella has developed a new range

of EziPAK ® service kits to meet

the need of mobile field service

technicians maintaining mining

machines on site.

EziPAK ® kits are based on many

years of practical experience.

Each kit is contained in an

impact resistant and washable,

heavy-duty injection moulded

carry case that slides into a self

locking modular double storage

tray for easy installation into field

service vehicles or use as a central

storage point in the workshop

environment.

The professional double crimp

connector kit is supplied with

the most popular terminals and

connectors as well as a ratchet

crimping tool ensuring that users

obtain truly professional results.

Each EziPAK ® kit is supplied

with a hard wearing large

format visual reference of it’s

contents, this also contains

the re-order information for

refill packs of consumables,

thus enabling customers to

maintain the EziPAK ® service kit

indefinitely.

Additional empty carry cases

and rack modules are also

available to allow service teams

to create their own customised

kits if needed.

HM8284

HM8285


CONNECTOR KITS

101

SERVICE TOOLS

Double Crimp Connectors (included in EziPAK ®

Double Crimp Connector Kit)

Qty in

pack

Push-On Female Terminal - Red, 6.3mm 200

9.HM8500

Push-On Female Terminal - Blue, 6.3mm 200

Push-On Female Terminal - Yellow, 6.3mm 150

9.HM8501

9.HM8502

9.HM8500

9.HM8501

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

9.HM8502

9.HM8503

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

Single Male Bullet Connector - Red 200

9.HM8514

9.HM8520

9.HM8504

9.HM8505

Single Male Bullet Connector - Blue 200

9.HM8521

Single Female Bullet Connector - Red 200

9.HM8522

Single Female Bullet Connector - Blue 200

Cable Connector - Red 200

9.HM8523

9.HM8530

9.HM8511

9.HM8513

Cable Connector - Blue 200

9.HM8531

Cable Connector - Yellow 100

Eye Terminal - Red, 5.0mm 200

9.HM8532

9.HM8541

9.HM8514

9.HM8520

Eye Terminal - Blue, 5.0mm 200

9.HM8543

Eye Terminal - Yellow, 9.5mm 200

Eye Terminal - Yellow, 5.0mm 100

9.HM8548

9.HM8549

9.HM8521

9.HM8522

Crimping Tool (included in

EziPAK ® Double Crimp Connector Kit)

Ratchet Crimping Tool 1

8273

9.HM8523

9.HM8530

9.HM8531

9.HM8532

9.HM8541

9.HM8543

8273

9.HM8548

9.HM8549


REPAIR KITS

SERVICE TOOLS102

EziPAK ®

Heat Shrink Harness Repair Kit

EziPAK ® Heat Shrink Harness

Repair Kit (270Pieces)

(See list of included components next page)

EziPAK ® Heat Shrink Harness

Repair Kit

Accessories

EziPAK ® Double Drawer

Storage Module (empty)

EziPAK ® Single Divisional

Carry Case (empty)

HM8287

HM8285

HM8286

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, heavyduty

injection moulded carry

case that slides into a self locking

modular double storage tray for

easy installation into field service

vehicles, or use as a central

storage point in the workshop

environment.

The EziPAK ® kit comprises six of

the most popular size heat shrink

sleeves as well as five different

sized solder sleeves. A battery

operated soldering iron and a

flameless heat gun are also part

of the kit.

Hella adhesive-lined, medium-wall

heat-shrink sleeving is a versatile,

environmentally friendly choice for

many commercial and heavy-duty

mining applications that require

mechanical protection and sealing

against moisture and chemical

ingress, whilst maintaining

flexibility when installed. Typical

applications include environmental

sealing and protection or irregular

shapes, such as wire splices,

breakouts and connector-tocable

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.

Additional empty carry cases and

rack modules are also available to

allow service teams to create their

own customised kits if needed.

HM8287

HM8285


REPAIR KITS

103

SERVICE TOOLS

Heat Shrink Sleeving (included in

EziPAK ® Heat Shrink Harness Repair Kit)

Qty in

pack

Adhesive Lined Heat Shrink Sleeving 3.2mm 35 9.HM4960

Adhesive Lined Heat Shrink Sleeving 6.4mm 35 9.HM4961

Adhesive Lined Heat Shrink Sleeving 9.5mm 35 9.HM4962

Adhesive Lined Heat Shrink Sleeving 12.7mm 20 9.HM4963

Adhesive Lined Heat Shrink Sleeving 19.1mm 10 9.HM4964

9.HM4965

Adhesive Lined Heat Shrink Sleeving 25.4mm 6 9.HM4965

Solder Sleeve – Clear, 1.7mm 25 9.HM4966

Solder Sleeve – Red, 2.7mm 25 9.HM4967

Solder Sleeve – Blue, 4.5mm 25 9.HM4968

9.HM4964

Solder Sleeve – Yellow, 6.0mm 25 9.HM4969

Solder Sleeve – Grey, 7.0mm 25 9.HM4970

Service Tools (included in

EziPAK ® Double Crimp Connector Kit)

9.HM4963

Battery powered soldering iron 1 HM8288

Flameless gas heat gun 1 HM8289

Lead Free Solder in Cartridge 1 9.HM4971

9.HM4962

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

9.HM4961

9.HM4960

HM8288

9.HM4970

HM8289

9.HM4969

9.HM4968

9.HM4967

9.HM4971

9.HM4972

9.HM4966


FUSE KITS

SERVICE TOOLS104

EziPAK ®

Intelligent Fuse Kit

EziPAK ® Intelligent Fuse Kit

(556 Pieces)

(See list of included components next page)

EziPAK ® Intelligent Fuse Kit

Accessories

EziPAK ® Double Drawer

Storage Module (empty)

EziPAK ® Single Divisional

Carry Case (empty)

HM8290

HM8285

HM8286

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, heavyduty

injection moulded carry

case that slides into a self locking

modular double storage tray for

easy installation into field service

vehicles, or use as a central

storage point in the workshop

environment.

The professional Intelligent

Fuse Kit features all the popular

amperage and blade fuse

sizes. The range of blade fuses

contained in the EziPAK ® kit

comprises of mini fuses, standard

fuses and maxi fuses all equipped

with an LED to indicate when a

fuse is blown.

This aid in visual fault finding and

a blown fuse can be recognised

in an instant due to the LED

indicating the condition of the

fuse. When the LED on the

fuse is illuminated, this would

indicate a blown fuse. The fuses

are a direct replacement for

standard blade fuses and no

modifications are necessary to

convert to this system.

The Intelligent Fuse Kit also

comes complete with a fuse

puller and a universal voltage

tester.

The fuse puller is also a terminal

tester with test LED. The

terminal tester is adjustable to

all sizes of fuse terminal as per

the kit offering.

Additional empty carry cases

and rack modules are also

available to allow service

teams to create their own

customised kits if needed.

HM8290

HM8285

LED glows if fuse blows, for instant identification


FUSE KITS

105

SERVICE TOOLS

LED Fuses

(included in EziPAK ® Intelligent Fuse Kit)

Qty in

pack

Mini Blade Fuse - 3A, Violet 30 9.HM4973

Mini Blade Fuse - 5A, Tan 30 9.HM4974

Mini Blade Fuse - 7.5A, Brown 30 9.HM4975

Mini Blade Fuse - 10A, Red 30 9.HM4976

Mini Blade Fuse - 15A, Blue 30 9.HM4977

Mini Blade Fuse - 20A, Yellow 30 9.HM4978

Mini Blade Fuse - 25A, Natural 30 9.HM4979

Mini Blade Fuse - 30A, Green 30 9.HM4980

Blade Fuse - 3A, Violet 30 9.HM4981

Blade Fuse - 5A, Tan 30 9.HM4982

Blade Fuse - 7.5A, Brown 30 9.HM4983

Blade Fuse - 10A, Red 30 9.HM4984

Blade Fuse - 15A, Blue 30 9.HM4985

Blade Fuse - 20A, Yellow 30 9.HM4986

Blade Fuse - 25A, Natural 30 9.HM4987

Blade Fuse - 30A, Green 30 9.HM4988

Blade Fuse - 40A, Amber 30 9.HM4989

Maxi Blade Fuse - 20A, Yellow 15 9.HM4990

Maxi Blade Fuse - 30A, Green 15 9.HM4991

Maxi Blade Fuse - 40A, Orange 15 9.HM4992

Service Tools

(included in EziPAK ® Intelligent Fuse Kit)

LED Fuse Puller/Tester - Yellow 1 9.HM4993

9.HM4973

9.HM4975

9.HM4977

9.HM4979

9.HM4981

9.HM4983

9.HM4974

9.HM4976

9.HM4978

9.HM4980

9.HM4982

9.HM4984

9.HM4985

9.HM4986

9.HM4987

9.HM4988

9.HM4989

9.HM4990

9.HM4993

9.HM4991

9.HM4992


CONNECTORS

SERVICE TOOLS106 Super Seal Connectors

Super Seal Connector Kit

5 of each Super Seal connector plug and socket

100 x Plug terminals, Part No. 9.HM4980.02

100 x Socket terminals, Part No. 9.HM4980.04

100 x Yellow con ductor seals, Part No. 9.HM4980.06

100 x Red cavity plugs, Part No. 9.HM4980.09

HM4980

Super Seal Connectors

Waterproof (IP 67) connectors with secondary locks.

Supplied without metal terminals, seals and cavity plugs; these are to be

ordered separately under part numbers HM4980.01/02/04/05/06/07/09.

Qty. in

pack

1 Pole Super Seal Plug 4 HM4981-P

1 Pole Super Seal Socket 4 HM4981-S

2 Pole Super Seal Plug 4 HM4982-P

2 Pole Super Seal Socket 4 HM4982-S

3 Pole Super Seal Plug 3 HM4983-P

3 Pole Super Seal Socket 3 HM4983-S

4 Pole Super Seal Plug 3 HM4984-P

4 Pole Super Seal Socket 3 HM4984-S

5 Pole Super Seal Plug 2 HM4985-P

5 Pole Super Seal Socket 2 HM4985-S

6 Pole Super Seal Plug 2 HM4986-P

6 Pole Super Seal Socket 2 HM4986-S

HM4980 Super Seal Connector Kit

HM4981-P HM4982-P HM4983-P

HM4981-S HM4982-S HM4983-S

HM4984-P HM4985-P HM4986-P

Spare Parts

Qty. in

pack

Plug terminals to suit cable 0.35 – 0.50mm 2 50 9.HM4980.01

Plug terminals to suit cable 0.75 – 1.50mm 2 50 9.HM4980.02

Socket terminals to suit cable 0.35 – 0.50mm 2 50 9.HM4980.03

Socket terminals to suit cable 0.75 – 1.50mm 2 50 9.HM4980.04

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

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

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

Red cavity plug 50 9.HM4980.09

HM4984-S HM4985-S HM4986-S

Plug Terminal

Socket Terminal

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

Super Seal Connector Crimping Tool

Crimping tool designed for use with

Super Seal connector terminals.

HM8298

HM8298 Super Seal Connector Crimping Tool


POWER PACK

PowerPAK

Portable Power Pack

107

SERVICE TOOLS

The

PowerPAK

is designed

for portable

emergency

power to run

remote area work

lamps, signal

beacons or other

12 volt accessories.

PowerPAK is a fully integrated

battery pack with three different

styles of power outlets.

PowerPAK is a plug and play

user friendly system that is fully

integrated into a water resistant

lockable carry case and has

an internal battery charger that

charges off mains power.

Alternatively, the PowerPAK can

also be recharged from a vehicle

12 volt system.

The PowerPAK is a highly mobile

and easy to carry power supply,

particularly useful for service

technicians and mining

maintenance personnel operating

in remote and isolated locations.

The three different style power

outlets make the unit suitable for

a diverse range of applications in

mining, automotive, camping or

marine environments.

Each power outlet is independently

fused to 15 Amps using a quality

LED fuse that illuminates when

blown, enabling users to visually

see which circuit has had a fault.

Combining a quality deep cycle

marine-grade battery with a water

resistant heavy-duty carry case

and a truly rugged power supply

enables trades people to carry out

repairs in the field when 240 volt

mains supply is not suitable.

The three different power outputs

allow for simultaneous operation of

12 volt equipment and lighting.

The quality electronics allow the

unit to be charged on 12 volt

supply through the bi-directional

power outputs for charging on the

go or via 240 volt mains supply.

The Deep cycle 18Ah marine gel

battery can be replaced if required,

extending the lifetime of the

PowerPAK system.

PowerPAK Portable

Emergency Unit

HM8600

12V

DC

15A

Max

Spare Parts:

Mag

Code

9.HM8600B

Replacement battery

9.HM8600C

Charging cable to

suit vehicle

CIG

DIN

9.HM4985

15A LED Blade

Fuses

(30 Pack)

Product Features:

1 MagCode connection

1 Cigarette lighter connection

1 Din plug connection

240 Volt and 12 Volt charge

Deep Cycle Marine GEL 12

Volt

18Ah battery

Compatible with DuraLed ® Work Lamp, Magnetic Base,

Part No. HM1550MAG12

Part No. HM1550CIG


Electrical

109

ELECTRICAL

110 AC/DC Transformers

111 Power Connectors

112 LED Rocker Switches

113 LED Pilot Lamps

114 Heavy Duty Circuit Breakers

115 Thermal Circuit Breakers

116 MagCode


ELECTRONIC TRANSFORMERS

ELECTRICAL

110 AC/DC Electronic Transformers

240V AC – 12V DC

20VA HM1220AC

60VA HM1260AC

240V AC – 24V DC

20VA HM2420AC

60VA HM2460AC

IP67 200G

On mine sites, quality is critical

to the survival of electronic

equipment.

Hella has introduced a range of

electronic converters to increase

the potential of low voltage

applications, such as LED lighting,

where only mains power is

available.

The converters are fully sealed

to IP67 and have endured

200G-shock testing, making

them suitable for the vigorous

demands of mining.

Highly efficient components

enable the converters to operate

with low heat generation.

Units operate from an input

voltage of 90 to 264V AC and

provide output

voltage levels of 12

or 24 Volts, in either

a 20 or 60 watt

power supply.

The units feature

an intelligent over

current protection system,

which recovers automatically once

the fault is removed.

Pre-wiring removes the need to

open the casing, requiring a simple

crimp or solder for installation.

With a small physical footprint

and high environmental

specifications, the converters

can be installed in the most

demanding mining locations.

Product Features:

Full range AC input

Short circuit protection

Over current protection

Over voltage protection

Fully isolated plastic case

Pre-wired, no assembly

required

Compact size

Suitable for LED lighting

200G shock tested

Technical Specifications

HM1220 HM1260 HM2420 HM2460

DC Voltage 12V 12V 24V 24V

Rated Current 1.67A 5A 0.84A 2.5A

Rated Power 20W 60W 20.2W 60W

Ripple 120mVp-p 120mVp-p 150mVp-p 150mVp-p

Voltage Tolerance 5% 5% 5% 5%

Setup, Rise Time

(230V AC)

500ms, 20ms 500ms, 30ms 500ms, 20ms 500ms, 30ms

Hold Up Time

(230V AC)

50ms 50ms 50ms 50ms

Voltage Tolerance 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC

Frequency Range 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz

Efficiency 81% 83% 83% 86%

AC Current

(230V AC)

0.35A 1A 0.35A 1A

Max Inrush Current

(230V AC)

70A 60A 70A 60A

Leakage Current

(230V AC)

0.25mA 0.25mA 0.25mA 0.25mA

Over Current 110 to 150% 110 to 150% 110 to 150% 110 to 150%

Over Voltage 13.8 to 16V 13.8 to 16.2V 28 to 32V 27.6 to 32.4V

Operating

Temperature (°C)

-30 to +70º C -30 to +70º C -30 to +70º C -30 to +70º C

Vibration 200G 200G 200G 200G

Ingress Protection IP67 IP67 IP67 IP67


POWER CONNECTORS

Power Connectors

111

ELECTRICAL

Power Connectors are

high current, industry

standard connectors.

Power Connectors

are suitable for mining and

industrial applications where

durability, ease of connection and

release, and reliable connection

are of paramount importance.

They are available in various

sizes relating to their current

carrying capacity.

Power Connectors are made

from polycarbonate resin that

meets UL94 V0 requirements.

The housings are genderless

to help reduce inventory,

while still ensuring correct

polarity connection.

The housings have an integral

stainless steel locking spring for

improved contact retention and

mating force. The colour-coded

connector housing designates

the suggested application voltage

maximum. Hella has selected the

grey range, which can manage

voltage levels up to 600 Volts

(AC or DC). The housings also

incorporate mechanical keys

to prevent mating with different

housings.

The contacts are cold-headed

and can be crimped or soldered

to the cable. They are flat wiping

and therefore self-cleaning as

they are fitted and removed from

other compatible connectors. The

contacts can carry high current for

a broad range of applications.

Power Connectors are suitable for

use in most mining and industrial

applications, due to their robust

construction and ease of fitment.

Power Connectors

Connector Kit AND,

50A 6AWG

Connector Kit AND,

175A 6AWG

Connector Kit AND,

50A 6AWG

Connector Kit,

75A 6AWG, black

Connector Kit,

75A 6AWG, green

Connector Kit,

75A 6AWG, red

Connector Kit,

75A 6AWG, blue

HM50AND

HM175AND

HM350AND

HMPS75S

HMPS75G

HMPS75R

HMPS75B

Product Features:

Easy to install, reducing

installation costs

Ultra durable, reducing

replacement costs

High current capacity suits

a broad range of product

applications

Quick to connect and remove,

saving time spent on

servicing

Products accept varied cable

sizes, reducing inventory

Genderless connector

reduces possibility of fitment

errors

One-way fitment ensures

correct polarity connection

every time

2 pole housing

Silver-plated copper contacts

Rated to 600 V AC or DC

HM50AND: 50A, 6-12 AWG

wire (B&S cable)

HM175AN: 175A, 4-1/0 AWG

wire (B&S cable)

HM350AND: 275A, 1/0-300

MCM wire (B&S cable).


LED ROCKER SWITCHES

ELECTRICAL

112 Compact LED Rocker Switches

LED Rocker Switches 24V DC

Amber Illuminated HM4400A

Red Illuminated HM4400R

Blue Illuminated HM4400B

Green Illuminated HM4400G

LED Rocker Switches 12V DC

Amber Illuminated HM4400A-12V

Red Illuminated HM4400R-12V

Blue Illuminated HM4400B-12V

Green Illuminated HM4400G-12V

Compact, heavy-duty LED illuminated Rocker Switches featuring

durable nylon frame and waterproof rubber sealing boot for additional

protection in industrial and mining environments. Fitted with push-on

terminals and ultra durable LEDs for illumination, removing the need for

regular globe replacement. Weatherproof from front if installed correctly.

Mounting

Panels

Protection

Voltage

Mounting opening 20mm dia.

Suitable for panels up to 2.5mm thick.

Weatherproof (from front)

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

12/24V

DC

Maximum Load

10A at 12V DC

5A at 24V DC

25 11.5

14

8.3

20

Amber

25 11.5

14

8.3

Red

20

Blue

Green


LED PILOT LAMPS

LED Pilot Lamps

113

ELECTRICAL

Heavy-duty multi-chip LED Pilot

Lamps featuring shock-resistant

one-piece construction for long

service life, polycarbonate

lens and screws with screw

retainer and in-built finger

protection.

LED Pilot Lamp, 12V AC/DC

Red, Super Bright 2716

Green 2717

Amber, Super Bright 2718

White 2719

Mounting

For Panels

Protection

Voltage

Mounting opening 22mm dia.

Up to 38mm thick

IP65

12V / 24V AC/DC

Other voltages available upon request

Blue, Super Bright 2720

LED Pilot Lamp, 24V AC/DC

Red, Super Bright 2716-24V

Green 2717-24V

Amber, Super Bright 2718-24V

White 2719-24V

Blue, Super Bright 2720-24V

LED Pilot Lamp, 24V

Green, Super Bright

White, Super Bright

HM2717-24V

HM2719-24V

Red

51.5 30

Green

13 42.6

2716

Amber

White

Blue


CIRCUIT BREAKERS

ELECTRICAL

114

Heavy Duty Circuit Breakers

Heavy Duty Circuit Breakers

3A - Max. 28V DC 8736

6A - Max. 28V DC 8737

10A - Max. 28V DC 8738

15A - Max. 28V DC 8739

20A - Max. 28V DC 8740

25A - Max. 28V DC 8741

18.9

6.4

160

Automotive circuit breaker, plug in mounting, manual release with locking

tangs for vibration resistance.

Voltage Rating

Current Ratings

Typical Life /

Contact Rating

Interrupting

Capacity Icn

Note

12 - 28V DC

3–25A. (30A upon request)

6,000 operations at 1 x IN

3,000 operations at 2 x IN ≤ 20A

1,000 operations at 2 x IN ≤ 25A

3...15A

20...25A

200A

400A

Replaces standard blade fuses

Panel Mount Circuit Breakers

Panel Mount Circuit Breakers

10A - Max. 28V DC 8742

20A - Max. 28V DC 8743

25A - Max. 28V DC 8744

30A - Max. 28V DC 8745

35A - Max. 28V DC 8746

29

10.4

46.5

22.5

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

Thermal Overcurrent Circuit Breakers

Thermal Overcurrent Circuit Breakers

6A - Max. 28V DC 8730

8A - Max. 28V DC 8731

10A - Max. 28V DC 8732

15A - Max. 28V DC 8733

20A - Max. 28V DC 8734

25A - Max. 28V DC 8735

160 6

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.

24

.945

Automotive circuit breaker, standard fuseblock mounting with

manual release option (-H2)

Voltage Rating

Current Ratings

Typical Life / Contact Rating

Interrupting Capacity I cn

Note

12 - 28V DC

6–25A. (30A upon request)

300 operations at ≤ 50A

≥ 3 operations @ ≤ 150A

≥ 1 operation @ ≤ 2000A

Replaces standard blade fuses


CIRCUIT BREAKERS

Thermal Circuit Breakers

115

ELECTRICAL

Single pole, miniaturised, aircraftstyle

thermal circuit breaker with

tease-free, trip-free, snap action

mechanism

and push/pull on/off manual

actuation (M-type TO CBE to EN

60934). An indicator band on

the push button clearly shows

the tripped/off position. The

circuit is threadneck panel

Voltage Rating

mounted in metric configurations.

Advanced two-chamber design

contributes to fail-safe operation.

Temperature compensation from

-55°C to +125°C, with auxiliary

contacts, and fully approved for

use on a wide range of aircraft

and equipment. Full specification

ensures suitability for the most

demanding applications.

115V AC / 12-28 V DC

Thermal Circuit Breakers

3A - Max. 28V DC HMET483.03

5A - Max. 28V DC HMET483.05

7.5A - Max. 28V DC HMET483.07

10A - Max. 28V DC HMET483.10

15A - Max. 28V DC HMET483.15

20A - Max. 28V DC HMET483.20

25A - Max. 28V DC HMET483.25

30A - Max. 28V DC HMET483.30

35A - Max. 28V DC HMET483.35

16.2

.638

min 4.6

min.181

10

.394

12.8

.504

31

1.22

M12x1

Typical Life

8.4

.331

Ambient Temperature

Insulation co-ordination

(IEC 60664 & 60664A)

Dielectric Strength (IEC

8.5

60664 & 60664A)

.335

20,000 operations mechanical or,

10,000 operations at IN (≤ 25A)

5,000 operations at IN (30 + 35A)

-55°C to +125°C (-67°C to +257°F)

Rated impulse withstand voltage

Pollution degree 3

Test Voltage

Operating area AC 1,500V

Main to aux. circuit AC 1,500V

1.5kV

Spare Parts:

HMET307.01

ID collar Black

HMET307.02

ID collar White

HMET307.03

ID collar Red

HMET307.04

ID collar Green

HMET307.05

ID collar Blue

HMET307.51

Safety lock-out

collar Red

HMET200.08

IP66 safety cover

Clear

10

94

M12x1

8.4

.331

3.2 +3 +5

.123 +.006

Interrupting

Capacity I cn

9.5 +0.2

.374 +.008

AC 115V (400 Hz)

≤4A 1,000A

5A 2,000A

7.5 to 35A 2,500A

HMET307.01

HMET307.01

12.8

.504

31

1.22

8.5

.335

12.5 +0.2

.492 +.008

DC 28V

1 to 25A 6,000A

30 + 35A 4,000A

Vibration 15g (70 - 2000Hz) -

Sinus 16.4 grams - Random

Acceleration

17g

10

.394

HMET307.01

M12x1

8.4

.331

HMET307.01

Shock

75g

HMET307.01

HMET307.01

3.2 +3 +5

.123 +.006

9.5 +0.2

Explosion to VG 95210, sheet 10/MIL -

STD-202, meth. 109

31

1.22

+.008

.374

16.2

.638

min 4.6

min.181

12.5 +0.2

+.008

.492

7.7

.303

14.8

.429

6.4

.252

13.97

.550

12.8

.504

3.2 +3 +5

.123 +.006

8.5

HMET307.01 .335

9.5 +0.2

.374 +.008

HMET307.01

8.6

.339

10.9

.429

8.7

.343

12.35

.486

18.9

12.5 +0.2

+.008

.492

0.8

.041

0.65

.026


POWER OUTLET SYSTEMS

ELECTRICAL

116

MagCode

Power Outlet Systems

MagCode Power System

Power System 12V HMPS12VKIT

Power Port 12V HMPS12VPT

Power Clip 12V HMPS12VCP

Power System 24V HMPS24VKIT

Power Port 24V HMPS24VPT

Power Clip 24V HMPS24VCP

MagCode Power System Plus

Power System 12V HMPS12VPROKIT

Power Port 12V HMPS12PROVPT

Power Clip 12V HMPS12PROVCP

Power System 24V HMPS24PROVKIT

Power Port 24V HMPS24PROVPT

Power Clip 24V HMPS24PROVCP

MagCode

Power Port Cap

HMPSPCAP

MagCode Power Systems are

revolutionary power outlet systems

for 12 and 24V DC circuits. Unlike

conventional connectors, MagCode

Power Systems utilise magnetically

coded flat contacts, delivering safe

power across modular components

far superior to the ubiquitous

cigarette lighter sockets.

Both port (outlet) and clip

(connector) feature powerful

magnets with integral switching

function ensuring a stable

connection and safe power supply.

Other metal objects or permanent

magnets cannot energise the

contacts at any time, making the

outlet completely safe and 100%

short-circuit-proof.

MagCode Power System Plus

for higher power circuits features

an additional mechanical twist

lock offering greater security

(higher separation forces) and

reliable prevention of arcing. The

mechanical twist lock ensures that

the automatic switching does not

occur before the outside contact is

securely fastened, thus effectively

eliminating problems associated

with arcing.

MagCode Power Systems are dust

and water resistant, easy to clean

and suitable for straightforward

retrofitting a vast range of

applications. Their advanced

technology and superior design

makes MagCode Power Systems

the ideal exterior connector on

vehicles under conditions of

sustained charging and high

current load. They are available

in 12V DC and 24V DC variants;

the magnets of the two voltage

variants are coded differently to

avoid mix-ups.

Power Clip

Power Port

HMPSPCAP. Stylish protective cover to suit

all MagCode Power Ports. Snap shut cap

provides reliable protection from the elements.

Key Features:

Latest high tech design

Stable connection

100% short-circuit-proof

Easy to install

Minimal mounting depth

(port)

Up to 25A current load

Dust and water resistant

Easy to clean

Novel coded system to avoid

12V and 24V products

Additional Features –

Power System Plus:

Suitable for high current

loads

Greater security (higher

separation forces)

No arcing

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 2.5mm 2 2.5mm 2

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/s 2 5Hz - 200Hz, 8.5m/s 2

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


POWER OUTLET SYSTEMS

117

ELECTRICAL

MagCode

Power System

Incoming

current

Incoming

current

Pole without

Current

Pole under

Current

Open System

(1)

Closed System

(2)

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

Incoming

current

MagCode

Power System Plus

Open System

(1)

Pole without

Current

Incoming

Incoming

current

current

Pole under

Closed System

(2)

Pole without

Current

Locked System

(3)

Current


119

GLOBESGlobes

120 H1

120 H2

121 H3

122 H4

123 H7

123 H9

123 H11

124 Xenon


HALOGEN GLOBES

120 H1 Globes

GLOBES

10

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

39

H1 PREMIUM XENON HALOGEN - PLUS 50

CX1255BL 12 55 P14.5s H1 •

H1 PREMIUM XENON HALOGEN - COOL BLUE

24

CB1255BL 12 55 P14.5s H1 •

Xenon

Plus 50

Xenon

Cool Blue

CB1255BLdia

Part No. Voltage Wattage Base ADR 51/00

Category

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

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

H1 HALOGEN HIGH PERFORMANCE

C12100 12 100 P14.5s - •

C24100 24 100 P14.5s - •

HALOGEN

C2470 24 70 P14.5s H1 •

Halogen

Premium Long

Life Halogen

H2 Globes

9

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

29

H2 HALOGEN HIGH PERFORMANCE

CD12100 12 100 X511 - •

CD24100 24 100 X511 - •

HALOGEN

CD1255 12 55 X511 H2 •

CD2470 24 70 X511 H2 •

CD12100BLdia


HALOGEN GLOBES

H3 Globes

121

GLOBES

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

11

H3 PREMIUM XENON HALOGEN - PLUS 50

30.5

Xenon Plus 30

YCX1255BL 12 55 PK22s H3 •

H3 PREMIUM XENON HALOGEN - PLUS 30

YCP1255BL 12 55 PK22s H3 •

H3 PREMIUM XENON HALOGEN - COOL BLUE

YCB1255BL 12 55 PK22s H3 •

YC12100BLdia

Part No. Voltage Wattage Base ADR 51/00

Category

UV

Cut

Rated Life

Long Life / Standard

Long Life Halogen

H3 HALOGEN LONG LIFE

YC1255LL 12 55 PK22s H3 • 1500 450

H3 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE

YC2470LTS 24 70 PK22s H3 • 1200 650

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

H3 HALOGEN HIGH PERFORMANCE

Halogen

YC12100 12 100 PK22s - •

YC24100 24 100 PK22s - •

HALOGEN

YC2470 24 70 PK22s H3 •

Premium Long Life Halogen


HALOGEN GLOBES

122

H4 Premium Xenon Globes

GLOBES

14

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

78.5

H4 PREMIUM XENON HALOGEN - PLUS 50

XDX1260/55BL 12 60/55 P43t H4 •

H4 PREMIUM XENON HALOGEN - COOL BLUE

44

XDB1260/55BL 12 60/55 P43t H4 •

Xenon

Cool Blue

XD1260/55dia

Xenon

Plus 50

H4 Halogen Globes

14

Part No. Voltage Wattage Base ADR 51/00

Category

UV

Cut

Rated Life T c

Long Life / Standard

78.5

44

H4 HALOGEN LONG LIFE

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

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

H4 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE

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

XD1260/55dia

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

H4 HALOGEN HIGH PERFORMANCE

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 •


HALOGEN GLOBES

H7 Globes

123

GLOBES

Part No. Voltage Wattage Base ADR 51/00

Category

UV

Cut

Rated Life Tc

Long Life / Standard

11

H7 HALOGEN LONG LIFE

CA1255LL 12 55 PX26d H7 • 930 550

H7 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE

CA2470LTS 24 70 Px26d H7 • 1000 500

42

15

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

CA1255dia

H7 HALOGEN

CA1255X 12 55 PX26d H7 •

CA2470 24 70 PX26d H7 •

H9 Globes

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

11

H9 HALOGEN

CF1265 12 65 PGJ 19-5 H9 •

46

40

CF1265

H11 Globes

Part No. Voltage Wattage Base ADR 51/00

Category

UV Cut

11

H11 HALOGEN

CG1255 12 55 PGJ 19-2 H11 •

CG2470 24 70 PGJ 19-2 H11 •

46

40

CG1255


XENON GAS DISCHARGE

124 Xenon Gas Discharge Lamps

GLOBES

9

Description

Comparison

Xenon Gas Discharge globes for driving and work lamps.

D1S/D2S

82

Rated Wattage

Luminous Flux

Luminous Efficacy

35W

3200lm

91Im/W

HMXN4001

D1S

Colour Temperature 4250°K

Average Luminance 6500*cd/cm 2

43

Lamp Life B3 1500h

Tc 3000h

9

Filament/arc length

Note

4.2mm

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.

75

Part No. Type Voltage Wattage Base ADR 51/00

Category

UV Cut

HMXN4001 D1S 85 35 PK32d-2 D1S •

25

XN4000 D2S 85 35 P32d-2 D2S •

HMXN4YEL

D2S 85 35 P32d-2 D2S •

XN4000dia

XN4000

D2S/R/C

HMXN4YEL

D2S

Xenon Gas Discharge Flash Tube

Part No. Voltage Wattage Base ADR 51/00

Category

UV

Cut

49mm

Xenon gas discharge globes suitable for

emergency flasher, revolving and/or strobe lamps

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

15mm

43mm

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


Engineering Based Solutions:

Australian Antarctic Division

125

Due to the high reflectance properties of ice and snow in Antarctica,

backscatter was becoming an issue from the white xenon light of the AS500.

To overcome this issue an amber version of the AS500 was developed in

conjunction with the Australian Antarctic Division, as the colour temperature

of the globe eliminated this issue.

Hella AS500 – Proven lighting for the most unforgiving environments.

HMXN4YEL

Yellow D2S Xenon Globe


Technical

127

TECHNICAL

128 General Information

130 High Intensity Discharge Lamp Operation

131 What is Xenon lighting technology

132 Spectral power distribution of fluorescent

and discharge lamps

133 Ignitors and ballasts

135 Capacitors

136 Transformers

138 LED technology

139 Hella work lamp systems

140 DRACO ® vibration damping systems

140 Xenon Gas Discharge work lamps

141 What is Xenon light

141 MustADD ® filter technology

142 Chemical resistance tables

144 Ingress Protection

145 Applications Engineering


128 General Information

TECHNICAL

Luminous Efficacy

Unit 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

1000

100

10

683 lm/W = Theoretical limit for

monochrome green light (555nm)

199lm/W = Theoretical limit for

"white" light (380–780nm)

Low Pressure Sodium Lamps

High Pressure Sodium Lamps

Fluorescent, Metal Halide, Yellow Compact,

Xenarc Lamps

High Pressure Mercury Vapour Lamps

High Intensity white LED

Special Light Bulbs Xenon Lamps,

Mercury Tungsten Blended Lamps

Tungsten-Halogen Lamps

General Lighting Service Lamps

Colour Rendering

Depending 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.

Carbon Thread Incandescent Lamps

1

Glow Lamps, Electroluminiscent Plate

Paraffin Lamp

lm/W

0.1

Candle

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.

L e λ ref

Luminous efficacies of various light sources

4

3

2

1

UV - radiation

IR radiation

Tw 2800˚C

Tw 2600˚C

Tungsten filament winding

temperatures T w

for 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)

Tw 2400˚C

0

1000

2000 3000 4000

5000

visible light

wave length unit of measure nm

Relative Spectral Power Distribution Of Incandescent Lamps

The main properties of an incandescent lamp, namely its luminous efficacy and

life, are influenced largely by the filament temperature.


129

TECHNICAL

Operating principle of an

Incandescent Lamp

The higher the filament temperature, the

higher the luminous efficacy, but the shorter

the lamp life.

A reduction in lamp life is a consequence of

the rapid increase in the rate of vaporization

of the Tungsten atoms as the temperature

rises; this process not only produces a black

coating on the bulb but also ultimately causes

the filament to break.

Blackening of the bulb can be effectively

countered by using as heavy an inert gas

as possible (Argon, Krypton or Xenon) and

ensuring that this gas is at high pressure

to reduce the rate at which the Tungsten

vaporises.

The principal types of incandescent lamp

are: general-purpose lamps, special-purpose

lamps, decorative lamps and incandescent

reflector lamps. The luminous efficacy of

incandescent lamps in the 25 to 1000W range

is between about 9 and 19 lm/W for lamps

with an average life of 1000 hours.

%

250

200

65% = 40 000% life

75% = 10 000% life

75% = 3600% life

80% = 1700% life

85% = 1000% life

90% = 600% life

Tungsten-Halogen Lamps

Tungsten-Halogen lamps operate in the

same way as incandescent lamps and have

a similar design. The small quantities of

Halogens (Bromine, Chlorine, Fluorine and

Iodine) and their compounds added to the

filler gas, almost entirely prevent the bulb

from blackening due to vaporizing Tungsten

atoms within a particular temperature range,

so there is no associated drop in luminous

flux. The bulbs in Tungsten-Halogen lamps

can therefore be made much smaller, which

means the pressure of the filler gas can be

increased and more economical use can

therefore be made of expensive inert gases

like Krypton and Xenon. The life of Tungsten

lamps varies from 50 hours for photographic

studio types, to over 2000 hours for

commercial display lighting types. Automotive

Halogen lamps are generally rated in the 300

hour range.

95% = 190% life

Halogen Cycle

As already mentioned, the main

characteristics of an incandescent lamp,

namely its luminous efficacy and service

life, are determined to a large extent by the

filament temperature. The higher the filament

temperature, the higher the luminous efficacy

but the shorter the life of the lamp.

This reduction in the life of the lamp is a

consequence of the rate at which Tungsten

vaporises from the filament. This rate

increases rapidly with temperature. Not only

does it blacken the inside of the bulb, it

causes the filament ultimately to burn right

through.

This blackening of the bulb can be effectively

countered by adding halogens to the filler

gas to keep the vaporized Tungsten away

from the bulb wall in a cycle process . The

Tungsten that vaporises from the filament

during normal operation drifts towards

the bulb wall by diffusion or convection

in thermal regions (•1 1400°C) where

they disintegrate. Some of the Tungsten is

transported back to the filament, but not

to its original location. The normal Halogen

cycle therefore merely prevents the bulb from

blackening, it does not extend the life of the

lamp. The lamp comes to the end of its life

when the filament breaks at one of its

hot spots.

150

Lamp life

Light output

Tungsten

Halogenide

Lamp power

Halogen cycle

100

Tungsten

Halogenide

Lamp power

Halogen cycle

50

Light output

Tungsten

Lamp life

Halogenide

0

70 80 90 100 110 120 130 %

Halogen cycle

Halogen Cycle

A regenerative cycle would be feasible with Fluorine

but because this Halogen is so corrosive towards

the quartz and hard glass used for the bulb, and

resistant to the Halogen currently used, a satisfactory

solution has not yet been found.


130 High Intensity Discharge (HID) Lamp Operation

TECHNICAL

Metal Halide (MH)Lamps

Metal Halide lamps are high-pressure mercury

lamps with added metal iodides or iodides of

the rare earths – Dysprosium (Dy), Holmium (Ho)

and Thulium (Tm) – and complex compounds of

Caesium (Cs) and Tin Halide (Sn). The Halides

decompose in the core of the discharge arc

and the metals can be excited to emit light

with an intensity and spectral distribution that

depends on the vapour pressure of the metal

halides. The luminous efficacy and the colour

rendering properties of the Mercury discharge

are significantly improved and the gaps in the

mercury spectrum are closed. Metal Halide

(MH) lamps are similar in their construction

to mercury vapour lamps. They are popular

for their excellent colour rendering which is

achieved by the inclusion of rare earth elements

in the discharge tube.

Metal Halide lamps are temperature sensitive,

with optimal operation occurring at 100°C to

180°C ambient temperature. Luminaires should

be designed to provide suitable conditions.

Ballasts must operate lamps from the correct

supply voltage and their impedance should

not vary more than ±3% from the specified

value. The supply voltage should not deviate

for extended periods for more than 3% of the

nominal rated voltage of the ballast, and the

supply frequency should not deviate by more

than ±3%.

Metal Halide lamps require higher voltages for

starting than the usual supply voltages. Various

circuits are used to achieve the required starting

conditions.

Metal Halide lamps require leakage reactance

ballasts, constant wattage auto-transformer

control equipment or series reactor type

ballasts with ignitor. The latter is the most

economical solution, with the constant wattage

circuit being the best for electrical performance.

Electronic control gear for lower wattage MH

lamps is also available

Separate information and data is available for

the Hella range of constant wattage control

equipment.

Most Metal Halide lamps will require an ignitor

to start the discharge in the arc. The ignition

voltage is generally 4.0–5.0kV peak for a cold

start with the lamps requiring a cooling period

of between 10–15 minutes before they will

re-ignite. Certain lamps are capable of hot reignition,

in which case voltages of up to 35kV

peak are required. Some of the higher wattage

2000W and 3500W lamps can require hot,

instant re-strike voltages of up to 60kV peak.

NOTE: Not all makes and/or types of Metal

Halide lamps can be operated on ignitor circuits

– consult the lamp manufacturer or Hella for

information or lamp control gear compatibility.

High Pressure Sodium (HPS)

Lamps

High Pressure Sodium (HPS) lamps can operate

satisfactorily from –30°C to +100°C on series

reactor ballast circuits, but precautions against

increase arc tube voltage, due to thermal back

radiation when mounted in luminaires, should

be considered. Only a typical 10 volt increase

in lamp voltage is tolerable. The lamp power

and discharge tube temperature are highly

dependent upon the lamp voltage. It is therefore

important that the mains voltage does not

exceed 105% of the nominal rated voltage of

the choke for extended periods.

The ballast should exhibit a closely controlled

current/voltage characteristic, to prevent the

lamp from exceeding the maximum power limit

as it ages and the lamp voltage rises.

Standard lamps with standard ignitors

re-ignite after 60 to 90 seconds, requiring 2kV

to 5kV to ignite from a cold start, depending on

the lamp specifications. High pressure sodium

lamps can only be re-ignited hot if they are of

linear double-ended construction because hot

re-strike requires 18kV to 25kV peak starting

pulses.


What is Xenon lighting technology 131

TECHNICAL

Xenon globes use an

electric current passed

through Xenon gas to

produce light, rather

than a filament. Not

only does this method

require minimal electric

current draw compared

to filament lighting, it is

much more robust and

lasts much longer than

the Halogen lamps it is

designed to replace.

Xenon (XGD) lamps are

specialized high pressure

discharge lamps developed

for use in the automotive

industry. Unlike industrial HID

lamp types (MH and HPS) that

require several minutes to warm up

and reach full light output, XGD lamps are

designed to strike immediately and the

associated ballast systems are capable of

restarting them when hot.

The light colour spectrum of XGD lamps is

specifically optimised to provide the best

performance when used in applications

where the user is in a scotopic vision (dark)

adapted condition, whereas most other

lamps are balanced for photopic (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.


TECHNICAL

132 Spectral Power Distribution of

Fluorescent and Discharge Lamps

Visible range from 380 to 780 nm

Vertical scale: 400 nW

1000 Im -10 nm

Fluorescent Lamps

Metal Halide (MH) Lamps

Colour 840 LUMILUX ®

Cool White

HQI ® .../N Daylight

HQI ® -TS.../WDL Warm White

High Pressure Sodium (HPS) Lamps

Xenon Gas Discharge (XGD) Lamps

VIALOX ®

Relative emission and sensitivity

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

wave length unit of measure nm

Xenon spectral power distribution

V(λ) Human vision photopic sensitivity (day light adapted)

V’(λ) Human vision scotopic sensitivity (night adapted)

The spectrum of light produced by Xenon lamps is optimised to

maximize visual performance of people with dark adapted vision


Ignitors and Ballasts

133

TECHNICAL

Maintenance-Free Long

Service Life Ballasts

The choice of insulating materials and

their operating temperatures determine

the ballast life. Hella ballasts use class H

insulation materials which are designed for

temperatures up to 180°C, thus ensuring

maximum service life.

The permitted maximum working temperature

of the winding is designated ‘tw’. The

adherence to this temperature guarantees an

average life of 10 years continuous usage. If

the temperature in application is lower, then

the life is correspondingly higher.

Hella HID ballast windings are designed

and constructed using Class H insulation

materials, the tw130 or in OG models tw150

rated winding ensuring maximum service life.

In normal operation in a 40°C ambient

temperature, probable service life of more

than 50 years could be expected.

The graph below shows the theoretical

service life of an Hella HID ballast. Even

when arduously operated at the maximum

recommended temperature, more than 10

years service life can be expected. Every 10°C

over maximum winding temperature of 130°C

or 150°C halves ballast life. The winding

temperature is the ambient temperature plus

∆t, the temperature rise, which is a function of

ballast power consumption.

The high quality and reliability of insulated

conductors is dependent not only on the

production process, but also on the choice of

raw materials.

Many years of experience, both as a user

and manufacturer of enamelled winding

wire has given Hella the knowledge and

expertise to select the best raw materials from

internationally approved suppliers.

Critical attention is paid to the enamel as the

material utilised to insulate the conductor.

Choice of enamel is a key factor and is

linked both to the enamelling system as well

as the electrical, mechanical and technical

characteristics of the finished product.

Special features of Hella HID ballasts:

100% final testing

• very short magnetic paths

• continuity

• transverse laminations with no stray field • winding short circuit

junctions

• core to coil high voltage

• short heat paths

test

• winding insulation Class H materials

• operating values

• vacuum impregnated core and coil

• long service life

• low power consumption

• tw150 winding temperature rating

• fully automatic production technology with

assured manufacturing procedures and quality


134 Ignitors and Ballasts

TECHNICAL

HID Ignitors and Ballasts

The starting voltage for most High-Intensity

Discharge (HID) lamps, especially metal halide

and high-pressure sodium types, is higher

than the mains voltage.

Ignitors provide the necessary high voltage to

start such lamps.

The high-voltage pulse varies from 1 to 5kV

depending upon the type of the lamp and is

inhibited when the lamp starts.

Hella ignitors are manufactured in

accordance with IEC 60926 and IEC 60927,

the International Standards specifying

performance, general and safety requirements

for starting devices.

Old high-pressure sodium and metal

halide lamps with conventional ignitor

technology often cause visual discomfort and

electromagnetic interference at the end of the

lamp life when the ignitor would repeatedly

strike the lamp, and it would not stabilize

electrically.

This cycling can be a significant irritant and

become a safety risk.

The solution: ‘PulseControl’ from Hella, the

first digital ignitor in the world.

Greater reliability, greater ignition power,

reduced re-strike time and minimum

interference through digital, precise

management of all lamp types without

annoying flashing.

L

N

C

Ballast

HV

BLa N

IGN

Precise lamp management

through digital technology

The patented switching circuit digitally

controls the ignition and automatic tripping

logic functions. PulseControl does not

consider the time of the re-strike period but

the number of attempts made. Because of

this, all lamps are switched off after 3 cycles

regardless of luminaire or lamp type.

Re-strike time reduced by

up to 50%

Depending on the lamp wattage, 4–10 ignition

pulses per half wave will be generated.

As a result of the increased ignition power

and the pulse/break cycle, the re-strike time is

reduced by up to 50%.

Interference reduced by

up to 90%

This 90% reduction in interference time (only

about 30 sec instead of 300 sec), is due to the

reduced re-strike period and the pulse/break

cycle which strikes for 5 seconds then pauses

for 25 seconds.

Ignitor Temperature Rise

Because ignitors have heat-sensitive

elements, their suitability for particular

applications is determined by the rise in the

element’s temperature. When mounting an

ignitor in the luminaire on a control equipment

enclosure, the ambient temperature range of

the application must be considered.

Quality components in Hella ignitors ensure

that they can withstand temperatures from

–30°C to +100°C with a minimum power loss.

Long life

Lighting control electronic equipment is

designed to run continuously for a minimum of

80,000 hours when operating at its maximum

temperature. This high level of reliability

can be achieved only by using high-quality

insulation and heat-resistant components.

Very low temperature rise in Hella ignitors

makes them highly reliable components for

use in all lighting control equipment.


Capacitors 135

TECHNICAL

Power factor in Fluorescent and

HID Circuits

For a pure resistive load in an electrical circuit,

the voltage (V) and current (I) are in phase with

each other and the overall power factor (cosΦ)

has a value of unity. It can also be said that

the average power (P) of the resistive circuit is

equal to the apparent power (S), ie. P = V x I.

However, in a pure reactive electrical circuit,

there is no resistive component; the voltage

and current are 90° out of phase, ie. cosΦ = 0.

Electrical circuits containing a combination of

both resistive and reactive elements display

both average power and apparent power

components.

Power factor is therefore the ratio by which

the apparent power is multiplied, in order

to obtain the average power actually being

consumed in the circuit, ie. P = V x I x cosΦ.

For example, a power factor of 0.5 indicates

that the circuit has a reactive component

having a phase angle of +60° or -60°.

In common practice most loads are inductive

and therefore the current lags the voltage

(lagging power factor), whereas a typical

capacitive load has a leading power factor.

Fluorescent and HID lamp circuits have an

inherent low power factor (around 0.4 to

0.5), due to the control gear inductance.

The inductance is in the circuit to limit the

current through the lamp, however, in lighting

installations where many lamps are used,

high input current increases the cost of mains

reticulation.

Raising the power factor by means of the

inclusion of a capacitor (opposite effect to an

inductor) substantially reduces the current

drawn from the mains, giving improvement

in the reticulation efficiency, which in turn

enables a reduction in copper wire size and

transformer sizes (the generating equipment).

Most power distribution authorities have a

requirement of high power factor (HPF) for

lighting installations of generally 0.85 to 0.95

minimum.

Figure 1 Figure 2

A typical discharge lighting circuit without

power factor correction, eg. 400W high

pressure sodium, has a power factor of

approximately 0.4. Figure 1 shows the

relationship of current and voltage in this

application.

This power factor characteristic can be

corrected to approximately 0.9 by adding

a capacitor (leading) to the lagging line

current, to cancel the phase shift. Figure 2

illustrates this.

In common application therefore, by

connecting a capacitor into the lighting circuit,

the power factor can be improved to the

values normally prescribed by the regulatory

authorities so that practically inductance free

operation results.

L

N

C

Ballast

S

Lamp

Capacitor Quality

Assured quality of capacitors is first and

foremost and cannot be compromised. Hella

uses accepted IEC and BSI Standards as the

minimum measure of quality.

Production is integrated with an audited

Quality System that is accredited to AS/NZS

ISO9002 and supported by a technical team

and fully equipped laboratory facilities.

Hella power factor correction lighting

capacitors have been certified by British

Standards Institute to BSEN 61048, and

BSEN 61049 and has ENEC approval (License

no. KM 30180).

These standards provide, thorough quality

checks of materials and capacitance

characteristics, a capacitor that retains its

integrity under the required conditions of

operation.

Quality Test Program

• materials / component inspection

• end spray thickness test

• voltage test

• capacitance tolerance check

• dissipation factor

• physical inspection

• end product batch test

• endurance test

• Assured Quality Systems (ISO9002 series)

• BSI certification

• ENEC approval

• testing of the dielectric materials

• in-line 100% capacitance testing

• new automatic ‘AC’ tester

• stud mounting or alternative clip spring

accessories.


136 Transformers

TECHNICAL

Principles of operation of the

Safety Isolating Transformer

A transformer transfers electrical energy from

one circuit to another through the medium of

a magnetic field. The transformer may step up

the voltage, step it down or deliver energy at

the same voltage.

The safety isolating transformer is one of the

most widely used of all transformers. It is

designed to achieve an accurate voltage ratio

within a specific load range.

There is no direct connection between the

windings. They are only connected by the

intangible lines of magnetic flux in the core. In

some types of circuits the transformers may

have 1:1 ratio.

Long life

Because of the long hours of use, low voltage

transformers have to be designed and built

to a high specification, which involves the

use of quality heat-resistant materials. Class

H insulation materials ensure long service

life, which, according to EN60742, allows a

maximum winding temperature rise of 140°C

at 6% over voltage.

At an actual winding temperature of 130°C,

10 years life can be expected. The graph

above shows the theoretical service life of

a transformer against winding temperature.

Every 10°C over the winding temperature of

130°C, halves the transformer life.

The manufacturing technique used by Hella

is to vacuum impregnate the transformer

with an unsaturated polyester resin. Typical

characteristics are thermal class ‘H’ (180°C

IEC600). Vacuum impregnation improves

quality and longevity because the resin is

drawn into the heart of the core and coil. This

maximises heat transfer and also ensures

silent operation.

Safety Extra Low Voltage (SELV) Lighting Recommendations

Voltage Regulation

The secondary voltage of a transformer

changes with the load, therefore, for multilamp

applications, a transformer with good

voltage regulation must be used. This is

because unloading of the transformer occurs

as lamps burn out, eg: there may be 4 x

50W lamps wired to a 200VA transformer

and if one or two lamps fail, the transformer

regulation may not be able to compensate

for the decrease in load. This will subject

the remaining lamps to an over supply

of secondary voltage. Therefore, it is

recommended that failed lamps always be

replaced.

On a one lamp/one transformer installation,

the regulation of the transformer is not

important as long as the lamp wattage

matches the full load of the transformer. These

small transformers generally have higher

impedance and regulation characteristics.

It follows that the higher impedance limits the

in-rush current on a cold lamp.

The lower in-rush current (or “soft start”) helps

lamp life. Filament evaporation eventually

creates a weak spot on the filament. This

weak spot is effected by in-rush current. As a

result, the one lamp/one transformer system is

beneficial for ferro-magnetic transformers, but

does not apply for correctly rated electronic

transformers.

High current on the

secondary side

Another important consideration in Extra

Low Voltage systems is the impact of high

currents. Circuits must be designed and

cables sized to carry the higher currents. A

12V lamp can draw 20 times more current

than a 240V lamp of the same wattage.

For maximum safety, optimum voltage at the

lamp and consequently lamp performance,

it is preferable to use one (1) ferro-magnetic

transformer per lamp.

On multi-lamp systems, each lamp should be

cabled back to the transformer independently,

particularly as the relatively smaller cables

used would be more practical and easier

to terminate at both the light fitting and

the transformer. In these installations it is

necessary to estimate voltage drop to each

lamp and use the appropriate sized cable

according to each cable run. If each light

fitting in a multi-lamp system individually

wired back to the transformer, then the

possibility of using cable lugs to a common

stud connection should be considered.


137

TECHNICAL

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

Protection and Approval

It is mandatory under the wiring rules that

transformers for remote mounting are housed

in a suitable enclosure and, as a prescribed

item, must be approved by the Statutory

Authority to EN 60742.

The approval number must be clearly marked

on the enclosure. Also, under the wiring rules,

the transformer must be installed in a position

where it is easily accessible for inspection and

maintenance.

The transformer enclosure

and wiring to the light

fitting must have adequate

ventilation. If the wiring and

the transformer enclosure

are covered with insulation

material then substantial

derating and overheating

may occur.

Electronic Safety Isolating Transformers for Low Voltage Lamps

Immunity

A transient mains voltage surge may

occur when inductive loads (e.g. motors

or conventional chokes) are switched off.

TE electronic transformers are protected

against voltage surges and spurious pulses

of any polarity by random phase position

superimposed on the supply voltage, in

accordance with EN 61547.

Emission

The limits for emission as per EN 61000-3-2

are maintained by high-quality filter circuits.

Electromagnetic Compatibility

Harmonics from non-linear loads cause

distortions in the mains supply. The special

circuit design fulfils the requirements of

EN 61000-3-2.

RFI Protection

The sophisticated filtering system of

electronic transformers TE ensures

compliance with EN 55015 and

VDE 0875-151

Harmonics

The requirements of the EMS Directive

89/336/EEC are fulfilled by observance of the

standards for emission and immunity.

Disposal of old lamps and control gear

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

Disposal of incandescent lamps

Incandescent lamps consist of glass and

metal. They do not contain any materials

that will harm the environment so they can

be simply thrown away with the household

refuse. They should not be placed in

containers for recycled glass, however,

because the glass used for these lamps is not

the same as the glass used for bottles.

Tungsten-Halogen lamps contain very small

quantities of halogens and Halogen-hydrogen

compounds, but the amounts are insignificant

(only a few millionths of a gram). Even several

lamps together do not present any risk to

people or the environment. The lamps can

therefore be thrown away with household

waste.

Disposal of discharge lamps

Small quantities of mercury can be found

in most HID fluorescent and compact

fluorescent lamps. These lamps also contain

small quantities of recyclable phosphors

so they should not be placed in household

refuse or recycled glass containers but sent

for proper recycling at community recycling

centres. Low-pressure sodium lamps and

sodium Xenon lamps can be disposed of

without the need for any special action.

Disposal of control gear

Hella ECGs, ballasts, ignitors, capacitors

and other electronic units do not contain

any material that will harm the environment

but they do contain recyclable electronic

components so they should be disposed of

as electronic waste.


138 LED Technology

TECHNICAL

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 benefits

LED 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 technology

Unlike 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

design

The 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.

®


Hella Work Lamp systems 139

TECHNICAL

For mining vehicles and production plant,

good lighting is essential for activities other

than just driving. Haul trucks, shovels, drills,

cranes and other special purpose vehicles

often need separate, pivotable ‘work lamps’

for loading, unloading, and other operations.

Using the right work lamp can make the work

easier and, in most cases, a lot safer. That’s

why Hella, long a pioneer in innovative lighting

technology, offers a wide range of work lamps

designed for specific applications.

Hella Lighting Technology

Hella’s range of work lamps includes long,

short and mid-range lamps, offering close or

wide illumination. You can select Hella work

lamps that suit the specific task best using

Halogen, Xenon or LED technology. Lamps

are available with integral handles, dual beam

optics and a wide range of mounting options.

For complex projects we would suggest you

contact our applications engineering service.

Multivolt

One of the leading advantages of Hella LED

technology is the unique Multivolt circuitry

fitted to most LED products. The system

ensures a uniform level of light intensity and

full light output at any voltage in the range

stated (typically from less than 10V to more

than 28V). Multivolt lamps can be connected

to 12V or 24V automotive electrical systems,

without modification. The light output will not

be adversely affected by the voltage drop

commonly encountered in such systems

on large machines and trailers. In all but

the most compact lights, the Hella Multivolt

system also incorporates sophisticated

over voltage, transient impulse and reverse

voltage protection and thermal management

circuitry to ensure that the LED lamp functions

problem free.

The Paraboloid Lamp

The paraboloid lamp is classic amongst the

lamp systems in use today. It uses a parabolic

reflector and the light source is located at it’s

focal point. The reflector captures the light,

bundles it and radiates it.

The lens ensures that the light is distributed as

required, directing it to pre-specified areas in

front of the lamp. Effective paraboloid lamps

have a large reflector in order to capture a

great deal of light.

The lens must be as vertical as possible

in order to ensure good light refraction.

Reflectors with a long focal length provide

good long-range illumination; those with short

focal lengths collect more light and provide

good short-range illumination.

The Free-Form (FF) Lamp

The 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.

Paraboloid lamp

Free-Form (FF) lamp


140 DRACO

®

vibration damping systems

TECHNICAL

Operational duty cycles in mining are some

of the most demanding, and field research by

Hella has measured shock and vibration levels

of remarkable magnitudes.

Equipment designed for less demanding

environments will fail rapidly when used in

mining, and often when most needed. Our

design aim is to produce equipment that will

function reliably in a continuously shock and

vibration laden environment.

Most types of mine lighting equipment

requires single point mounting to allow

for azimuth and elevation adjustments.

This arrangement concentrates stress and

maximizes overturning moment of inertia

in the light that is mounted. To analyse the

mechanical design effectively and deliver

reliable and predictable results, it is essential

that these aspects are thoroughly integrated

at the design stage; just adding impressive

looking brackets often leads to poorer

performance and progressively

cascading failures.

Hella developed our unique DRACO ® vibration

damping technology to enable us to limit the

vibration passing from the mounting surface

of the mining machine to

the relatively fragile globe

in the light fitting. DRACO

dampening effectively

eliminates resonant

behaviour and is specifically

designed for systems

subject to stochastic

(random) vibration with

a large dynamic range,

like that typically found

on mining machines. We

can adjust the system

parameters to suit each light

and its application

DRACO vibration damping systems consist of

at least two rigid mounting plates separated

by two (or more) flexible compounds of

differing hardness and damping properties,

arranged in parallel in one damper assembly.

This provides a non-ridgid mounting

arrangement between the vibration source

(the mining machine) and load (the light

fitting). Vibration signals are delayed in time,

reduced in amplitude, as well as altered in

spectral composition when some vibration

Vibration

Time

— Input

— DRACO ® output

— Std output

— Difference

(DRACO ® -Std)

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.

Xenon Gas Discharge (XGD) work lamps

What is Xenon lighting technology

Xenon globes use an electric current passed

through Xenon gas to produce light, rather

than a filament. Not only does this method

require minimal electric current draw

compared to filament lighting, it is also very

close to daylight.

As the human eye is designed to see in

daylight, Xenon lighting causes less eye strain

than other globe types, making it a more

convenient and safer night lighting option.

It also reflects road signs and markings

more brightly.

Advantages of Xenon lighting

• Wider (up to three times as large) and more

uniform illumination

• Twice the light of standard Halogen globes,

with less than half the power usage – safer

and more environmentally friendly

• Light colour very similar to daylight –

reduces strain on the eye

• Steady brightness levels even if power

supply varies

• Impact and vibration-resistant light arc

ensures a globe service life five times

longer than standard globes

Xenon Gas Discharge Work Lamps

The Hella XGD models are high-performance,

robust work lamps designed for most extreme

and heavy-duty assignments.

Hella Mining Work Lamp features:

• Improved lens protection through extended

housing

• Custom built Xenon ballast and electronic

circuitry integrated into housing for greater

reliability

• Inbuilt handle for easy aiming

• Integrated AMP plug with connection cable

or DT Plug

• DRACO ® vibration-damping pivot base and

mounting bracket

• Available in 12V DC and 24V DC application

• Special seals

• MUSTADD ® filter.


What is Xenon light

141

TECHNICAL

Instead of a coiled filament, a light arc is the

light source in Xenon lamps. The bulb, which

is only the size of a cherry stone, is filled with

Xenon gas and metal salts. In order to ignite

the Xenon bulb, an extremely high voltage of

approximately 20,000 volts is required.

This is provided by an electronic ballast: 12V

or 24V and direct current is transformed into

20,000V alternating current.

At temperatures of around 5000˚C, a light arc

is created. With a power consumption of a

mere 35 watts, this generates 2.5 times the

light flux of an Halogen globe of the same

power or equivalent to a 100W Halogen globe.

The current generation of control units is only

half the size of and approximately one third

lighter than the first and second generation.

The ignition electronics can now be

completely integrated into the control unit.

As a result of these control units, the lamp’s

light is almost independent of voltage

fluctuations in the vehicle electrical system, as

the electronics operate the Xenon globes at

constant output.

MustADD ® Filter Technology

Environment

Mechanical

Filtration

(3 micron)

Dehydration

Chemical

Scrub

Light

Source

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

Reflector

be fitted with seals that will

function under less than perfect

conditions.

To overcome the problems

encountered in practice with

Seal

semi-perfect seals, Hella

mining work lamps incorporate

sophisticated breathing paths

and air filters. This ensures that

a low-resistance route is always

Lens

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 dehydrating

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 1

When 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 2

The 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.


142 Tables for Chemical Resistance

Aluminium

Fibreglass

Acrylic

Polycarbonate

Chemical Material

Investigated

Accumulator Acid N R R L L

Acetic Acid up to 5% L R R R R

Acetic Acid up to 15% N R R R R

Acetone R N N N R

Alcohol up to 30% L R R R R

Alcohol concentrate R N N R R

Ammonia 25% R L R L R

Aniline R N N N R

Aromatic Hydrocarbons R L R S R

Benzine R N N L R

Carbon Dioxide R R R R R

Carbon Monoxide R R R R R

Carbon Tetrachloride L L L R R

Caustic Soda 2% N L R N R

Caustic Soda 10% N N R N R

Chloroform R N N N L

Common Salt L R R L R

Crude Oil R R R S R

Diesel Oil R R R L R

Dioxane R N N R

Ether R L N N R

Ethyl Acetate R N N R R

Glycerine R R R L R

Glycol R R R R R

Hydrobromic Acid N N L N

Hydrocarbons R L L S R

Hydrochloric Acid 5% N R R R N

Hydrochloric Acid 30% N R R R N

Stainless Steel

Aluminium

TECHNICAL

Fibreglass

Acrylic

Polycarbonate

Chemical Material

Investigated

Hydrochloric Acid 96% N R R R N

Hydrogen Peroxide over 40% R N L N R

Hydrogen Sulphide R R R R R

Ketones R N N R R

Lyso R N N N R

Metal Salts and their

aqueous solutions

Stainless Steel

N R R R L

Methanol R L N L R

Methylene Chloride L N N N R

Milk of Lime N R R L R

Nitric Acid 5% N R R R R

Nitric Acid 30% N L L L L

Nitric Acid concentrate N N N N R

Petrol R R R R R

Petroleum Ether R R R R R

Phenol L N N N R

Pyridine R N N R R

Sea Water L R R R R

Soap Suds L R R S R

Soda N R R R L

Sulphuric Acid 5% N R R R N

Sulphuric Acid 30% N R R R N

Sulphuric Acid concentrate N N N L N

Sulphurous Acid 5% L L R N L

Synthetic detergent N R R R R

Turpentine R R R R R

Water up to 70° C R R R R R

Xylene R N N N R

Ambient temperature 20° C

R Resistant

L Resistant within limits

N

S

Not resistant

Resistant when saturated, resistant within

limits when saturated.


Chemical Resistance Table (Standard Polycarbonate) 143

TECHNICAL

Polycarbonate

Polycarbonate is soluble in a number of

technical solvents. Good solvents include:

methylene chloride, ethylene chloride,

trichloroethane, tetrachloroethane,

chloroform, m-cresol and pyridine.

Comparatively poor solvents for

polycarbonate include: deoxane,

tetrahydrofuran, cyclohexanone and

dimethylformamide.

Examples of swelling agents are:

benzene, chlorobenzene, tetralin, acetone,

ethyl acetate, acetonitrile and carbon

tetrachloride.

Polycarbonate is resistant to mineral acids,

even in high concentrations, many organic

acids, oxidising and reducing agents, neutral

and acid salt solutions, many greases,

waxes and oils, saturated, aliphatic and

cycloaliphatic hydrocarbons and alcohols,

with the exception of methyl alcohol.

Polycarbonate is chemically degraded by

aqueous or alcoholic alkaline solutions,

ammonia gas and its solutions and also

by amines.

Chemicals

acetaldehyde

acetic acid up to 10%

acetone

acrylonitrile

ammonia

ammonium

hydroxide solution

ammoniym sulphate,

saturated solution in

water

benzene

benzoic acid

borax, saturated

solution in water

bromine

butylene glycol

calcium hypochlorite

carbon dioxide, moist

caustic potash

caustic soda

chlorinated lime

solution 2% in water

chlorine gas, dry

chlorine gas, moist

chromic acid, 20%

in water

coal gas

cresol

dibutyl phthalate

(plasticiser)

diethylene glycol

dioxane

ethanol

N

R

N

N

N

N

R

N

N

R

N

R

R

R

N

N

R

L

N

R

R

N

N

R

N

R

ether

ethyl alcohol 96%

pure

ethylene chloride

ethylene glycol

formalin 10%

formic acid 30%

glycol

heptane

hydrochloric acid,

conc.

hydrochloric acid

20%

hydrogen sulphide

ligroin (hydrocarbon

mixture)

methane

methanol

methylmethacrylate

nitric acid 10%

nitric acid 20%

nitrous fumes, dry

ozone

petroleum ether

(hydrocarbon mixture)

petroleum spirit (for

dry cleaning, free of

aromatics)

phenol

potassium cyanide

potassium

permanganate, 10%

in water

potassium sulphate,

saturated solution in

water

N

R

N

R

R

L

R

R

N

R

R

R

R

N

N

R

N

N

R

L

R

N

N

R

R

propionic acid 20% R

sodium bicarbonate,

saturated solution in R

water

sodium chloride,

saturated solution in R

water

sulphur dioxide L

sulphuric acid, conc. N

sulphuric acid 50% R

toluene

N

trichloroethylene N

Disinfectants

carbolic acid N

hydrogen peroxide R

iodine, tincture L

perhydrol

R

Pharmaceuticals,

Cosmetics

lanolin

R

nail varnish remover N

Foodstuffs, drinks

and tobacco

allspice

N

coffee

R

edible oil

R

fruit juices

R

glucose

R

linseed oil

R

nutmeg

N

sugar solution,

saturated

R

vegetable juices R

vegetable oil R

Detergents, rinsing

and cleaning

agents

Ajax ®

R

Persil ®

L

Pril ®

R

silicone oil emulsion R

soft soap

R

tuba carpet

shampoo conc.

L

Technical oils and

greases

Baysilone ® fluids

(silicone fluids)

R

brake fluid (ATE) N

camphor oil

N

diesel oil

L

fish liver oil

R

hydraulic fluid (Vac

HLP 16)

R

paraffin oil

R

silicone oil

R

turpentine substitute R

varnish

L

Adhesives and

sealants

Cellux ® adhesive

films

R

glazier’s putty R

insulating tape R

rubber (free of

plasticiser)

R

Polishes and antistatic

agents

Delu ® anti-static

solution

R

Perspex polish 3 ®

R

Plexiklar ®

R

Polifac ® grinding

paste

R

Inks

multimarker (Faber

Castell)

L

pelican royal blue

4001

R

Miscellaneous

battery acid

R

chrome oxide green

(grinding paste)

R

cleaning petrol R

coal gas

R

exhaust fumes, acidic R

kerosene, (aviation

fuel)

N

motor fuel, high

octane

N

motor fuel, ordinary L

grade

polyethylene R

polymeric plasticisers L

tannic acid

N

thinners

N

white spirit

N

R Resistant L Resistant within limits N Not resistant

This information and technical data advice, whether verbal, in writing or through trials, is given in good faith without warranty.

This also applies where proprietary rights of third parties are involved.

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


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

TECHNICAL

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.

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)

IP 2 K 3 K C M

Ingress Protection: Overview of the Elements of the IP Code

Element

Numeral/

Letter

Meaning for the

protection of electrical equipment

Meaning for the

protection of persons

First characteristic

numeral/ supplementary

letter

0

12345K

6K

Against the ingress of solid

foreign objects (including dust):

not protected

with Ø ≥ 50mm

with Ø ≥ 50mm

with Ø ≥ 50mm

with Ø ≥ 50mm

dust-protected

dust-tight

Against access to hazardous parts

(unless described by extra letters):

not protected

with back of hand

with finger

with tool

with wire

with wire

with wire

Second characteristic

numeral/ supplementary

letter

0

1

2

3

4

4K

5

6

6K

7

8

9K

Against the ingress of water:

Not protected

Vertical dripping

Dripping (inclined 15°)

Spraying

Splashing

Same with increased pressure

Jetting

Powerful jetting

Same at increased pressure

Temporary immersion

Continuous immersion

High-pressure/steam jet cleaning

Additional letter

(optional)

A

B

C

D

Meaning for the protection of electrical

equipment

Against access to hazardous parts

(unless described by first characteristic

numeral):

with back of hand

with finger

with tool

with wire

Supplementary letter

(optional)

M

S

K

Movement of moving parts

during water test

Standstill of moving parts

during water test

Specifically for the electrical equipment

in road vehicles


Applications Engineering 145

TECHNICAL

The Hella Centre of Excellence – Mining

provides an Applications Engineering lighting

design service for Hella Mining customers.

The aim of this unique service is to reduce

risk to end users and OEMs of implementing

an inappropriate lighting design, enabling

all stakeholders to evaluate, comment and

change the design prior to implementation.

The Hella team combines decades of

lighting expertise across many countries

and industries with the most sophisticated

software. However, our most valuable asset

is ongoing consultation combined with

extensive practical on-site mining experience,

enabling us to understand the unique visual

and environmental requirements of the mining

industry.

We are fully aware of the wide and sometimes

conflicting range of operational requirements,

covering the need for greater equipment,

operator and maintenance personnel safety,

lowered cost of ownership and maintenance,

increased productivity requirements and the

need for a predictable

service life.

We use appropriate, proven

technologies and methods to

provide the mining operation

with an engineering-based,

application-focussed,

customised solution. The

system design not only

complies with the relevant

occupational health and

safety regulations, but also

with real life maintenance and

operational needs.

Hella lighting designs

typically include; aiming

and orientation angles, number and type

of luminaires, part numbers, spare parts,

illumination level achieved and appropriate

standards referenced. Our service extends

to both fixed and mobile plant lighting

designs. The final design is contained in a

clear and concise document that can be

presented to all relevant stakeholders, ready

to be integrated into on site maintenance

documentation systems.

Our experience in Applications Engineering

allows us to create lighting designs in a short

time frame and with limited information.


146 Part Number Index

2 PAGE

2716 113

2717 113

2718 113

2719 113

2720 113

2716-24V 113

2717-24V 113

2718-24V 113

2719-24V 113

2720-24V 113

8 PAGE

8151 30

8273 101

8730 114

8731 114

8732 114

8733 114

8734 114

8735 114

8736 114

8737 114

8738 114

8739 114

8740 114

8741 114

8742 114

8743 114

8744 114

8745 114

8746 114

8HG959952022 84

9 PAGE

9.1533.03 28

9.1600.01 58

9.1600.06 58

9.1601.01 58

9.1602.01 58

9.1603.01 58

9.1604.01 58

9.HM

PAGE

9.HM1002.01 30

9.HM1002ECE.01 30

9.HM1385.05 30

9.HM151BAL 16

9.HM151TRN 16

9.HM15NB 16

9.HM15WB 16

9.HM180LENS 52

9.HM300FLX 48

9.HM360LENS 48

9.HM400LENS 46

9.HM450ALENS 46

9.HM450BLENS 46

9.HM450FLX 42

9.HM450GLENS 46

9.HM450RLENS 46

9.HM450WLENS 46

9.HM46FX 70

9.HM46GL 70

9.HM46MP 70

9.HM46MS 70

9.HM4940 99

9.HM4941 99

9.HM4942 99

9.HM4943 99

9.HM4944 99

9.HM4945 99

9.HM4946 99

9.HM4947 99

9.HM4948 99

9.HM4949 99

9.HM4950 99

9.HM4951 99

9.HM4952 99

9.HM4953 99

9.HM4954 99

9.HM4955 99

9.HM4956 99

9.HM4957 99

9.HM4958 99

9.HM4959 99

9.HM4960 103

9.HM4960.01 81

9.HM4960.02 81

9.HM4960.03 81

9.HM4960.04 81

9.HM4960.05 81

9.HM4961 103

9.HM4962 103

9.HM4963 103

9.HM4964 103

9.HM4965 103

9.HM4966 103

9.HM4967 103

9.HM4968 103

9.HM4969 103

9.HM4970 103

9.HM4971 103

9.HM4972 103

9.HM4973 105

9.HM4974 105

9.HM4975 105

9.HM4976 105

9.HM4977 105

9.HM4978 105

9.HM4979 105

9.HM4980 105

9.HM4980.01 106

9.HM4980.02 106

9.HM4980.03 106

9.HM4980.04 106

9.HM4980.05 106

9.HM4980.06 106

9.HM4980.07 106

9.HM4980.09 106

9.HM4981 105

9.HM4982 105

9.HM4983 105

9.HM4984 105

9.HM4985 105

9.HM4986 105

9.HM4987 105

9.HM4988 105

9.HM4989 105

9.HM4990 105

9.HM4991 105

9.HM4992 105

9.HM4993 105

9.HM5700 76

9.HM5701 76

9.HM5702 76

9.HM5703 76

9.HM5801 77

9.HM5802 77

9.HM70BR 11

9.HM70BR 36

9.HM70DC 36

9.HM70WH 36

9.HM8500 101

9.HM8501 101

9.HM8502 101

9.HM8503 101

9.HM8504 101

9.HM8505 101

9.HM8511 101

9.HM8513 101

9.HM8514 101

9.HM8520 101

9.HM8521 101

9.HM8522 101

9.HM8523 101

9.HM8530 101

9.HM8531 101

9.HM8532 101

9.HM8541 101

9.HM8543 101

9.HM8548 101

9.HM8549 101

9.HM8600B 107

9.HM8600C 107

9.HM9386.02 40

9.HMAPEDL 16

9.HMAWHKD 16

9.HMDLM001 54

9.HMDLM001 64

9.HMDLM002 66

9.HMDLM002 86

9.HMPU2NB 34

9.HMPU2WB 34

9.HMPUXB24 24

9.HMPUXNB 24

9.HMPUXWB 24

9.HMTN001 74

9.HMTN002 74

9.HMTN003 74

9.HMTN004 74

9.HMTN005 75

9.HMTN006 75

9.HMUBHWB 28

9.HMUBHNB 28

9.HMX7500.01 56

9.HMX7500.02 56

C

PAGE

C12100 120

C1255LL 120

C24100 120

C2470 120

C2470LTS 120

CA1255LL 123

CA1255X 123

CA2470 123

CA2470LTS 123

CB1255BL 120

CD12100 120

CD1255 120

CD24100 120

CD2470 120

CF1265 123

CG1255 123

CG2470 123

CX1255BL 120

HM0

PAGE

HM060321 62

HM060621 63

HM070321 62

HM070621 63

HM1

PAGE

HM1002 30

HM1002ECE 30

HM1220AC 110

HM1260AC 110

HM1358 30

HM1374D 30

HM1375D 30

HM1504NB 18

HM1504WB 18

HM1510NB 26

HM1510WB 26

HM1511NB 26

HM1511WB 26

HM1512NB 16

HM1512WB 16

HM1513NB 16

HM1513WB 16

HM1522WB 22

HM1526LR 28

HM1526NB 28

HM1526WB 28

HM1535DRL 67

HM1535NB 12

HM1535PB 12

HM1535WB 12

HM1539LDD 10

HM1539LED 10

HM1550CIG 15

HM1550DT 15

HM1550MAG-12 15

HM1550MAG-24 15

HM1550WB 14

HM15700NB 13

HM15700PB 13

HM15700WB 13

HM175AND 111

HM180ABP 52

HM180ADIR 52

HM180AMAG 52

HM180BDIR 52

HM180BMAG 52

HM180GBP 52

HM180GDIR 52

HM180GMAG 52

HM180RBP 52

HM180RDIR 52

HM180RMAG 52

HM180WDIR 52

HM180WMAG 52

HM2

PAGE

HM2026 66

HM2026D 66

HM2051 66

HM2051D 66

HM2053PC 66

HM2053PCD 66

HM2054 66

HM2054D 66

HM227HD 85

HM2307 66

HM2307D 66

HM2379 64

HM2379D 64

HM2420AC 110

HM2460AC 110

HM2717-24V 113