Gifas-electric RoadLED 50m User manual

RoadLED 50m
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RoadLED 50m
Manual
VERSION
MODIFICATIONS
1.0
First edition
1.1
Editorial changes

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Table of contents
1General information................................................................................................................3
1.1 Marking concept for hazards and hints ............................................................................ 3
1.2 Responsibilities of the operator........................................................................................3
2Introduction ............................................................................................................................4
2.1 Installation conditions product RoadLED .........................................................................4
2.2 Storage............................................................................................................................4
2.3 Disposal of the device .....................................................................................................4
3Technical Data ........................................................................................................................5
3.1 Technical Data cable reel ................................................................................................5
3.1.1 Dimensions cable reel......................................................................................... 5
3.2 Technical Data light module ............................................................................................6
3.2.1 Dimensions light module .....................................................................................6
3.3 Technical Data Accu........................................................................................................ 7
4Set up cable reel components ...............................................................................................8
4.1 Cable reel components.................................................................................................... 8
4.2 Light module components................................................................................................9
4.2.1 Light module 1-15 ..............................................................................................10
4.2.2 Last light module................................................................................................ 10
5Reparation / replacing light module .................................................................................... 11
5.1 Reparation light module 1-15......................................................................................... 11
5.2 Repair of the last light module (cable end)..................................................................... 14
5.3 Repair of a section..................................................... Fehler! Textmarke nicht definiert.
6Maintenance and debugging ...............................................................................................18
6.1 Inspection and maintenance plan .................................................................................. 18
6.2 Description of the inspection and maintenance plan...................................................... 18
6.3 Troubleshooting / Measures for fault elimination............................................................ 18
7Service ..................................................................................................................................20
7.1 Service addresses......................................................................................................... 20
7.2 Imprint ...........................................................................................................................20

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1 General information
1.1 Marking concept for hazards and hints
Hazard
Hazardous situation which will cause serious injury or even death if it is not prevented.
Caution
Hazardous situation which could cause slight to moderate injury if it is not prevented.
Hint
Indicates information which does not concern personal injury, e.g. hints in respect of material damage.
Protective measures
Increase safety by applying a protective measure.
1.2 Responsibilities of the operator
-Make sure that this document is always kept in a safe place in a legible form together with the product.
-Read these instructions carefully before first start-up of the product.
-This product has been developed and produced exclusively for the use indicated in these documents.
Every other use, which is not mentioned explicitly, could affect the intactness of the product and/or
could constitute a source of danger.
-The manufacturer rejects any liability for damage which has been caused by incorrect or non-intended
use of the product.
-In countries, which do not belong to the European Community, the national legal reference regulations
as well as the standards and regulations applicable in these countries have to be observed for warranty
of a corresponding safety level.
-The installation has to be carried out according to the applicable regulations.
-The manufacturer assumes no liability for inexpert execution of installation as well as deformations
which may occur during operation.
-The electric power supply has to be switched off before executing any action on the installation.
-Exclusively original parts of the manufacturer shall be used for maintenance. Maintenance work may
be carried out by qualified staff only.
-All procedures which are not explicitly mentioned by the manufacturer in the instructions are not per-
mitted.
-The packing material must not be stored within the reach of children as it could be a potential source
of danger.

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2 Introduction
To ensure proper installation, the following steps and notes must be complied with under all circum- stances.
Only this way can it be ensured that the product will work to complete satisfaction.
Hint
Read all instructions before starting installation. Our sales department will be happy to answer any questions
you may have.
2.1 Installation conditions product RoadLED
The RoaLED has been designed for outdoor application. Occasional immersion in shallow water (e.g. puddles)
for a period of max. 8 hours is no problem for the light modules.
The luminaire modules can be driven over with a maximum wheel load of 3.5 t without damaging the housing.
2.2 Storage
No additional measures are required for storage. Ensure that the modules are protected from damage when
packing them.
Ensure that the RoadLED is switched off and the battery is sufficiently charged (min. 50 – max. 80% of the
overall capacity) during storage, in order to protect the battery from discharge. If the RoadLED is stored for a
lengthy period, the charging condition must be checked at regular intervals. The self-discharge of 1% per
month is extremely low, but highly dependent on temperature. Lithium-ion batteries should be recharged
every 3 to 4 months to prevent deep discharge. The battery should always be recharged to min. 60% of the
overall capacity after every use!
The storage temperature must be between -10°C to +25°C, in order to ensure a long battery lifetime.
2.3 Disposal of the device
This product must not be thrown in the garbage.
In accordance with official local and national regulations, this product is to be recycled
appropriately.
European directive 2012/19/EU; waste electrical and electronic equipment (WEEE).

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3 Technical Data
3.1 Technical Data cable reel
Housing material:
halogen-free hard rubber reel body, safety insulated
Frame material:
Solid tubular steel frame, black powder coated
Protection category:
IP54
Protection class:
II
Operating temperature range:
-20°C to +50°C
Total weight:
11.4kg (with LED cable harness)
Dimensions:
350 x 299 x 487mm (L x W x H)
Guarantee:
According to General Conditions of Sale and Delivery
3.1.1 Dimensions cable reel

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3.2 Technical Data light module
Housing material:
Polycarbonate Lexan 164 R
Housing surface:
Transparent
Sealing material:
TPV Santoprene
Protection category:
IP67
Protection class:
III
Over-mobile, load capacity:
3.5t (wheel pressure)
Operating temperature range:
-20°C to +50°C
Weight:
36g
Dimensions:
52,3 x 35,3 x 23mm (L x W x H)
LED Type:
Osram SideLED LY A67F / Osram TopLED LY E67F
LED number per light module:
4x Side LED / 1x Top LED / 1x Bottom LED
LED color:
yellow
3.2.1 Dimensions light module

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3.3 Technical Data Accu
Accu Type:
Li-Ion Accu
Battery design:
5S5P 11000mAh
Cell type:
RH18650 / 3,7V 2200mAh
Nominal accu voltage:
18.5V
Li-Ion Accu capacity:
11000mAh / 203,5Wh
Charging time for full charge 230VAC:
6h
Charging time for full charge 12-24VDC:
6h
Operating time continuous light:
21h
Operating time flash 1 Hz:
ca. 42h
Operating time running light:
ca. 110h
Lifetime:
700-1000 cycles > 80% of the initial capacity at 20°C
Operating temperature range:
-10°C to +50°C
Charging temperature range:
0°C to +40°C
Storage temperature:
-10°C to +25°C storage during max. 3 months without reloading

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4 Set up cable reel components
4.1 Cable reel components
1. Capacity display with 5 LEDs is used to indicate the battery capacity. 1 LED corresponds to 20% of
the battery capacity. The display is started with by pressing the button (5) >2s. The LEDs go out auto-
matically after 5 sec.
•LED red: battery capacity 0-20%
•LED orange 1: battery capacity 21-40%
•LED orange 2: battery capacity 41-60%
•LED green 1: battery capacity 61-80%
•LED green 1: battery capacity 81-100%
2. Fuse: Serves as a protective device for the electric power supply in the event of default.
3. Charger/mains connection: The connection is used to charge the integrated battery with 12-24VDC or
with 230VAC mains voltage. In addition, an optional power supply Art. No. 860946 can be inserted at
the connection. This allows the RoadLED to be operated with a mains supply. Continuous operation
is thereby made possible.
4. Main switch On/Off. Used to switch on the RoadLED. The last function is saved and executed when
the unit is switched on again. (The switch must be in the OFF position to charge the battery.)

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5. Function selection button/Pattern: The button is used to call stored functions. The following functions
have been implemented:
1. Continuous lighting
2. Blinking
3. Flashing
4. Running light from cable reel to cable end
5. Running light from cable end to cable reel
6. Running light from cable reel to cable end and back
6. One press of the button corresponds to one function. Pressing the button again starts a new function.
The battery capacity is displayed if the button is held down for more than 2 seconds.
7. Rotary controller for setting the speed of the running lights, blinking frequency and flash duration in 10
steps. The following speeds and frequencies are possible:
Blinking: 0.5 – 5Hz
Flashing: flash impuls from 10 – 100ms / Pause 800ms
Running light: 50 -150km/h

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4.2 Light module components
4.2.1 Light module 1-15
4.2.2 Last light module
Head screw PAN
3x10mm Torx T10
Item no.
219244
Upper housing part
Item no. 222633
Cable 4x1.0mm2
Item no. 219289
Lower housing part
Item no.
222634
Light module
Item no. 227847
Head screw PAN
2.2x5mm Torx T10
Item no.
219326
Upper housing part
Item no.
222633
Head screw PAN
3x10mm Torx T10
Item no.
219244
Cable 4x1.0mm2
Item no. 219289
Head screw PAN
2.2x5mm Torx T10
Item no.
219326
Light module
Item no. 227847
Lower housing part
Item no.
222634
Jumper
Item no.
227847
Locking pin
Item no. 860928

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5 Reparation / replacing light module
In principle, the following components can be exchanged upon request with consideration given to the ESD
protection measures:
•Upper housing part with sealing
•Lower housing part with sealing
•Light modules
However, it is advisable to replace the entire light module (item no. 860837).
ESD protection measures
Sensitive electrical or electronic parts, components and devices can be damaged or even destroyed by an
electrostatic discharge in the immediate vicinity. An electrostatic discharge can come from people or be
caused through handling ESD-sensitive components. Electrically conductive products which conform to
DIN EN 61340-5-1: Protection of electronic devices from electrostatic phenomena are essential in electro-
nic environments to prevent an electrostatic discharge.
5.1 Reparation light module 1-15
1. Open the housing of the defective
module
Loosen the 4 housing screws with a Torx T6
screwdriver and remove the upper housing
part.
2. Remove the strands from the
electronics
Remove the strands from the self cutting
terminals.
Use a tool to pull the strands
upwards.
Remove the old light module.

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3. Dismantle the electronics
Loose the 2 screws with a Torx T6 screwdriver
and remove the electronics.
4. Remove the electronics
Remove the electronics. Consider the ESD pro-
tection measures.
5. Transfer the DIP switch settings
Transfer the DIP switch from the old module to
the new module
If a switch is moved to the right, the respective
address is interpreted as 0. If a switch is moved
to the left, the respective address is interpreted
as 1.
If a configuration is no longer recognisable, the
setting can be taken from the following table
The light module with address 1 is located at
the beginning of the cable reel. The light mo-
dule with address 16 is located at the end of the
cable.
Example: The address of the light module
should be set to address 15. According to the
table in section 6. DIP switch no. 1, 2, 3 and 4
must be in position 1 and DIP switch no. 5 in
position 0.
Adresse RoadLED
Position DIP-
Switch
DIP Switch Nr.
5
4
3
2
1
Adresse 1
0
0
0
0
0
Adresse 2
0
0
0
0
1
Adresse 3
0
0
0
1
0
Adresse 4
0
0
0
1
1
Adresse 5
0
0
1
0
0
Adresse 6
0
0
1
0
1
Adresse 7
0
0
1
1
0
Adresse 8
0
0
1
1
1
Adresse 9
0
1
0
0
0
Adresse 10
0
1
0
0
1
Adresse 11
0
1
0
1
0
Adresse 12
0
1
0
1
1
Adresse 13
0
1
1
0
0
Adresse 14
0
1
1
0
1
Adresse 15
0
1
1
1
0
Adresse 16
0
1
1
1
1

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6. Mounting the electronics
Use a Torx T6 screwdriver to attach the elec-
tronics with 2x 2.2x5mm screws. Make sure
that the connection terminals are at the top. The
max. tightening torque is 0.4Nm
7. Mounting the new LED module
Lay the cable over the module
If necessary, remove 33mm of cable insulation,
so that the cable cores are exposed.
The insulation of the cable cores are labelled
No. 1-4. Place the strands in the self cutting
terminals as shown in the illustration.
Press the cable cores into the self cutting ter-
minals with the caps. The caps must be remo-
ved afterwards.
cable sheath flush
with inside of housing

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1. Mount the upper housing part
Use a Torx T10 screwdriver to mount the up-
per part of the housing with 4x 3x10mm
screws. The max. tightening torque is 1.5Nm.
5.2 Repair of the last light module (cable end)
1. Open the housing of the defective
module
Loosen the 4 housing screws with a Torx T6
screwdriver and remove the upper part.
Dismantle the locking pin and set it aside
2. Remove the strands from the
electronics
Remove the strands from the self cutting
terminals.
Use a tool to pull the strands
upwards.
Remove the old light module.

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3. Dismantle the electronics
Loosen the screws with a Torx T6 screwdriver
and remove the electronics.
4. Remove the electronics
Remove the electronics. Consider the ESD pro-
tection measures.
5. Set the jumper
If the light module at the end of the cable is
replaced, the jumper must be inserted as
shown above.
The jumper serves as a
terminating resistor and prevents reflections in
the cable.
6. Transfer the DIP switch settings
Transfer the DIP switch from the old module to
the new module
If a switch is moved to the right, the respective
address is interpreted as 0. If a switch is moved
to the left, the respective address is interpreted
as 1.
If a configuration is no longer recognisable, the
setting can be taken from the following table
The light module with address 1 is located at
the beginning of the cable reel. The light mo-
dule with address 16 is located at the end of the
cable.
Example: The address of the light module
should be set to address 16. According to the
table in section 6. DIP switch no. 1, 2, 3 and 4
must be in position 1 and DIP switch no. 5 in
position 0.
Adresse RoadLED
Position DIP-
Switch
DIP Switch Nr.
5
4
3
2
1
Adresse 1
0
0
0
0
0
Adresse 2
0
0
0
0
1
Adresse 3
0
0
0
1
0
Adresse 4
0
0
0
1
1
Adresse 5
0
0
1
0
0
Adresse 6
0
0
1
0
1
Adresse 7
0
0
1
1
0
Adresse 8
0
0
1
1
1
Adresse 9
0
1
0
0
0
Adresse 10
0
1
0
0
1
Adresse 11
0
1
0
1
0
Adresse 12
0
1
0
1
1
Adresse 13
0
1
1
0
0
Adresse 14
0
1
1
0
1
Adresse 15
0
1
1
1
0
Adresse 16
0
1
1
1
1

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7. Mounting the electronics
Use a Torx T6 screwdriver to attach the elec-
tronics with 2x 2.2x5mm screws. Make sure
that the connection terminals are at the top. The
max. tightening torque is 0.4Nm
8. Mounting the new LED module
Lay the cable over the module
If necessary, remove 19mm of cable insulation,
so that the cable cores are exposed.
The insulation of the cable cores are labelled
No. 1-4. Place the strands in the self cutting
terminals as shown in the illustration.
Press the cable cores into the self cutting ter-
minals with the caps. The caps must be remo-
ved afterwards.
cable sheath flush
with inside of housing

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9. Mount the locking pin
Mounting position as shown in the illustration.
10. Mount the upper housing part
Use a Torx T10 screwdriver to mount the upper
part of the housing with 4x 3x10mm screws.
The max. tightening torque is 1.5Nm.
5.3 Repair of a cable section
If a section of a cable is damaged, it can be re-
placed with a new cable. Remove 17mm of
cable insulation.

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6 Maintenance and debugging
6.1 Inspection and maintenance plan
Work to be carried out
Time period/frequency
Function test
In accordance with the country-specific provisions/as
required
Cleaning
If required and according to the degree of dirt
6.2 Description of the inspection and maintenance plan
All functions of the RoadLED must be maintained and, if need be, executed by professionally trained person-
nel, in accordance with the regulations, standards and rules of the respective country.
6.3 Troubleshooting / Measures for fault elimination
Fault / error message
Possible cause
Remedy
LED modules do not light up
-Battery discharged
-Fuse defective
-Interrupted cable
-Light module defective
-Control unit defective
-Charge battery
-Replace defective fuse
-Check cable and replace damaged sec-
tion if necessary.
-Replace the electronics of the light mo-
dule.
-
Contact the manufacturer GIFAS or
have it checked by a qualified electri-
cian on site.
-if required, send in the complete unit.
LED module flickers
-Light module connection
may not be tight
-Cable break
-Contact the manufacturer GIFAS or
have it checked by a qualified electri-
cian on site
-If required, send in the light module.
Battery is not being charged
-Charger not correctly
connected
-Charging cable defective
-Plug and socket connec-
tions defective
-
Temperature too high or
too low
-
Battery defective
-Check charging cable for correct con-
nection.
-Check charging cable for damage
-Change charging environment or select
cooler or warmer location
-Battery capacity indication defective
-Send to GIFAS for repair
Battery is not being fully
charged -
Battery life too
short
-Ageing of the battery and
decrease of the max.
capacity
-Battery not fully charged
-Send to GIFAS for battery change.
-Recharge the battery and charge it oc-
casionally using the battery capacity in-
dication monitoring.
Damage to cable drum
-Send to GIFAS for repair

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Hint
The RoadLED and its components may only be replaced by the manufacturer or a service technician appointed
by the manufacturer or a comparable qualified person.
Subject to technical changes and errors.
These operating instructions are the property of GIFAS ELECTRIC GmbH and may not be copied, translated,
transferred, duplicated or passed on to third parties, either in whole or in part, without the prior written permis-
sion of GIFAS ELECTRIC GmbH.

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7 Service
7.1 Service addresses
GIFAS ELECTRIC GmbH
GIFAS
-ELECTRIC S.r.l
GIFAS ELECTRIC GmbH
GIFAS
-ELECTRIC GmbH
Borsigstra
sse 9
Via dei Filaracci 45
Strass
2
Dietrichstrasse 2
Piano del Quercione
Postfach 275
D
-41469 Neuss
I
-55054 Massarosa (LU)
A
-5301 Eugendorf
CH
-9424 Rheineck
[phone] [phone] [phone] [phone]
[phone] [phone] [phone] [phone]
www.gifas.de www.gifas.it www.gifas.at www.gifas.ch
[e-mail] inf[email protected] [e-mail] inf[email protected]
7.2 Imprint
GIFAS-ELECTRIC GmbH
CH-9424 Rheineck
www.gifas.ch
Technical changes and errors reserved.
These installation instructions are the property of GIFAS-ELECTRIC GmbH and may not be copied, tran-
slated, transferred, duplicated or passed on to third parties without the previous written consent of GIFAS-
ELECTRIC.