Gifas TorchLED Ex User manual

TorchLED Ex
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TorchLED Ex
Manual
VERSION
CHANGES
1.0
First edition
1.1
Editorial changes

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Contents
1General information................................................................................................................4
1.1 Marking concept for hazards and hints............................................................................4
2General information................................................................................................................5
2.1 Product marking ..............................................................................................................5
2.2 Special conditions for safe use........................................................................................5
2.3 Risk.................................................................................................................................6
2.4 Application areas.............................................................................................................6
2.5 Product characteristics and features................................................................................6
2.6 Scope of delivery.............................................................................................................7
2.7 TorchLED Ex technical data............................................................................................7
2.8 Charging station technical data .......................................................................................8
2.9 TorchLED Ex / universal charging station dimensions.....................................................9
2.10 Responsibilities of the operator......................................................................................10
2.11 Storage / cleaning .........................................................................................................10
2.12 Disposing of the device .................................................................................................10
3Installation ............................................................................................................................11
3.1 General .........................................................................................................................11
3.2 Environmental ...............................................................................................................11
3.3 Electrostatic discharge ..................................................................................................11
3.4 Charging of the TorchLED Ex........................................................................................12
3.5 Battery pack ..................................................................................................................12
4Functional overview.............................................................................................................13
4.1 Symbol explanations .....................................................................................................13
4.2 Operating the basic functions ........................................................................................13
4.3 Charge status display....................................................................................................14
4.4 Emergency light function ...............................................................................................14
5Service and troubleshooting ...............................................................................................15
5.1 Batteries........................................................................................................................15
5.2 Inspection and maintenance..........................................................................................16
5.3 Troubleshooting.............................................................................................................16
5.4 Repair............................................................................................................................16
6EU-Declaration of Conformity..............................................................................................17
7Service ..................................................................................................................................18

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7.1 Service addresses.........................................................................................................18
7.2 Imprint...........................................................................................................................18

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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.
-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 General information
2.1 Product marking
The following labels are attached to the explosion-safe TorchLED Ex:
The TorchLED Ex is CE marked according to European ATEX directive 2014/34/EU:
II 2 G Ex ib IIC T4 Gb
II 2 D Ex ib IIIC T140°C Db
This means the TorchLED Ex is designed for use in industrial applications and it fulfils the requirements of
product category 2 for use in hazardous areas due to the presence of explosive mixtures of gases, mists,
vapors or dust in air. The TorchLED Ex is suitable for use in hazardous areas classified as zone 1, 21, 2 and
22. The applied method of protection is Intrinsic Safety and gas group IIC and dust group IIIC are applicable.
The temperature class with regard to the ignition of gas is T4. The maximum surface temperature with respect
to the ignition of dust is 140 °C.
Compliance with the Essential Health and Safety requirements has been assured by compliance with EN
60079-0:2012 / A11:2013 (General requirements) and EN 60079-11:2012 (Intrinsic safety).
The ambient / operational temperature is -20 °C < Ta < +45 °C.
The ATEX certificate number is KIWA 16ATEX0046X. The X behind the certificate number indicates that spe-
cial conditions for safe use as given below are applicable.
2.2 Special conditions for safe use
-Charging of the TorchLED Ex in an hazardous area is not allowed
-Only the following original Gifas Electric TorchLED Ex universal chargers are allowed:
TorchLED Ex universal battery charger 230 VAC, Gifas article No. 860443
TorchLED Ex universal battery charger 12 - 48 VDC, Gifas article No. 860444
The maximum prospective short circuit current at the connection point of the universal charger
to the power source shall be ≤ 300 A.
Figur 2: Inside label
Figur 1: Outside label

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2.3 Risk
Attention
The bundled light can damage the eyes under certain circumstances.
Protective measures
Do not look directly at the LED from a short distance without taking the necessary protective measures. Pro-
tective goggles with tinted lenses are recommended as a protective measure.
2.4 Application areas
The TorchLED Ex is a modern work and inspection light with a wide range of use:
-Work and inspection light for maintenance purposes
-Field lamp for civil protection or the military
-Private use
Thanks to state-of-the-art LED technology, the TorchLED Ex is extremely energy-efficient.
Indication
The TorchLED Ex universal charging station is suitable for installation on construction materials of normal
flammability. The TorchLED Ex operating temperature range is -20 °C to 45 °C.
2.5 Product characteristics and features
The basic characteristics and advantages of the TorchLED Ex are:
-robust housing with elastomer-encapsulated grips
-slip-resistant
-impact-resistant
-free-standing
-compact design
-low weight
-attachment strap
-clip for carrying strap
-various operation modes
-memory function = last setting is retained
-gold-plated charging pint

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2.6 Scope of delivery
2.7 TorchLED Ex technical data
Power supply:
3,7 V Lithium Polymer battery, 1.440 mAh
Charging time full battery capacity:
approx. 5 h
Light duration 2 LEDs:
approx. 3,5 h (see chapter 3 for further information)
Light:
2 Power-LED weiss à 3 W
Luminous flux 2 LEDs:
175 lm
LED charge status display:
green
Light color:
cool white, 5.700 K
LED service life:
> 50,000 h
Degree of protection:
IP54 (closed housing)
Protection class:
III
Temperature range:
-use: -20 °C to +45 °C
-charge: 0 °C to +40 °C
Dimensions (W x H x D):
68 x 115.4 x 35 mm
Figur 3: TorchLE Ex
Figur 4: charging station

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2.8 Charging station technical data
Operating voltage:
100 - 240 VAC 50/60 Hz
12 - 48 VDC
Charging characteristics:
6,2 V, 320 mA (TorchLED Ex)
9,1 V, 780 mA (non-Ex TorchLED reversed polarity)
Housing:
ABS
Weight:
160 g
Degree of protection:
IP44
Protection class:
II
Contacts:
spring steel, gold-plated
Temperature range:
0 °C to +40 °C
Dimensions (W x H x D):
86.6 x 79.6 x 44mm
Installation type:
installation against the wall
Indication
When the batteries have been completely drained, there will briefly be no display when the light is being re-
charged in the charging station, even though it is actually charging!
The display appears as soon as the batteries are charged over the threshold voltage; this is not a malfunction
of the TorchLED Ex or the charging unit.
The temperature range for charging the batteries is 0 °C to 40 °C. The batteries must not be charged at tem-
peratures outside this range.
Figur 5: Spotlight beam characteristics

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2.9 TorchLED Ex / universal charging station dimensions
Figur 6: TorchLED Ex dimensions
Figur 7: Universal charger dimensions

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2.10 Responsibilities of the operator
1. Ensure that this document is always in a legible form and stored with the device.
2. Read this instruction manual carefully and thoroughly before operating the device for the first time.
3. This product has been developed and manufactured exclusively for the application specified within
this document. Any application not explicitly stated in this document could damage the integrity of the
product and/or be a source of danger.
4. The manufacturer will reject any liability for damage caused by any improper use of the product.
5. Countries that are not part of the European Community must observe national legal regulations, as
well as any other valid standards and provisions, in order to guarantee a corresponding level of safety.
6. The installation of the TorchLED Ex charging station must be carried out in accordance with the appli-
cable regulations.
7. The manufacturer will not accept any liability in the event of incorrect installation or any deformations
that may occur as a result.
8. The electric power supply must be switched off before any interventions on the TorchLED Ex charging
station.
9. Only original parts from the manufacturer may be used for maintenance. Only qualified personnel may
carry out maintenance work on the TorchLED Ex torch light.
10. Any procedure that is not explicitly included in the instructions by the manufacturer is not permitted.
11. The packaging material must not be kept within the reach of children; this is a potential source of
danger.
Indication
If the TorchLED Ex is used in harsh or hazardous environments, the housing must be kept close to avoid
damage and malfunctions.
It should also be ensured that the TorchLED Ex charging station is used in a place protected from humidity
and wetness.
2.11 Storage / cleaning
No additional measures are required for storage. Ensure that the packaging will not be damaged. Whensoiled,
clean the light with a cleaning cloth. Do not use scouring / abrasive agents or solvents!
2.12 Disposing 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 appropri-
ately.
European directive 2012/19/EU; waste electrical and electronic equipment (WEEE).

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3 Installation
3.1 General
The TorchLED Ex is a microcontroller controlled Intrinsically Safe light.
Components:
-Main board with 2 power LEDs + one signal LED where the PCB acts as the heat sink.
-Battery board which contains 2 Li-Po cells connected in parallel and which provides the charging cir-
cuitry, battery protector and Intrinsically Safe current and power limiter circuits. The battery pack is not
user replaceable. Charging only occurs in the safe area.
The TorchLED Ex is only chargeable from the universal charger that contains protective circuitry and has been
assessed in accordance with EN-IEC-60079-11.
3.2 Environmental
Always follow local regulations and at least IEC60079-14 (Explosive atmospheres - Part 14: Electrical instal-
lations design, selection and erection) or other local codes of practice.
Charging may only take place in the safe area using the Gifas universal charger. Use of any other charger will
invalidate the Intrinsically Safe protection of the TorchLED Ex. The universal charger may only be used in-
doors, in a clean and dry location.
The allowed temperature range during charging must be 0 ºC ... +40 ºC.
Discharging and storage may be any Zone 1 or Zone 21 or safer location in accordance with the marking and
IEC60079-14, in particular with the rated ambient temperature range Ta.
The TorchLED Ex may not be allowed to build up dust, appropriate sanitary measures need to be taken to
prevent this.
Even though the TorchLED Ex may be allowed to be used at temperatures below 0 ºC , please be aware that
the battery capacity may be substantially reduced, possibly even by 50%.
When the TorchLED Ex battery is completely empty it is highly recommended to remove it from the hazardous
area and to place the TorchLED Ex in the universal charger as soon as possible.
It should also be noted that protective circuits in the TorchLED Ex remain active at all time, even when the
device appears to be turned off. These circuits will slowly drain the TorchLED Ex until battery protection circuits
completely shut off the battery.
3.3 Electrostatic discharge
The TorchLED Ex surface has examined to be safe when there is a risk of electrostatic discharges during the
intended use.
Care must be taken not to use the TorchLED Ex in an environment with a prolific charge generating mechanism
that can affect the TorchLED Ex.
Examples where not to use the TorchLED Ex:
-Areas where a pneumatic transfer of powders occur.
-Areas where charge spraying in a powder coating process occurs.

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3.4 Charging of the TorchLED Ex
The TorchLED Ex is only chargeable from the Gifas universal charger that contains protective circuitry and
has been assessed in accordance with EN-IEC-60079-11.
-Observe an ambient temperature 0 ºC < Ta < +40 ºC during charging
-The TorchLED standby time exceeds 1 year, but it is highly recommend to check the battery at regular
intervals as draining the battery below 2V will cause permanent degradation of the cells and reduce
battery life.
-When the TorchLED has been automatically shut down due to a low battery voltage (2.8V) it should
be recharged as soon as possible, as further self-discharge of the cells below 2V will cause permanent
degradation of the cells and reduce battery life.
-Reviving LiPo cells that have been discharged below 2V is not recommended and will void your war-
ranty. When in doubt contact your reseller.
-The universal charger can be powered from 12V-48VDC batteries and provides the required protected
voltage to the charger circuit on the Battery board.
-The universal charger can also be powered from a 230V mains adapter that provides a SELV (double
isolated) DC voltage according to IEC-61558-2-6 or IEC-61010-1 of less than 50V.
-Do not attempt to charge the TorchLED Ex from an ordinary TorchLED charger.
-The universal charger is able to detect either a non-Ex TorchLED or a TorchLED Ex by the presence
of a magnet and delivers the required voltage and polarity.
-In the hazardous area the charging contacts are protected by Intrinsically Safe circuits to prevent ig-
nition capability. It is recommended to not unnecessarily touch these contacts to prevent electrostatic
discharges that might damage the charging circuitry.
-Internally the battery pack is permanently connected to the TorchLED Ex main board. Do not touch
any of the circuits. Do not disassemble. The battery pack is not user replaceable.
3.5 Battery pack
The battery pack of the TorchLED Ex should be able to receive 1.000 charges. At this time the capacity may
be reduced by 20% of the original capacity. As other factors can further reduce battery capacity it is recom-
mended to have the battery pack replaced when noticeable capacity reduction has occurred.

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4 Functional overview
4.1 Symbol explanations
Button functions
Symbol
Function
Symbol
On / off
Tapping: Switches the light on and off
The memory function becomes active each time
the light is switched on (last selected setting).
Function selection
or dimming
Quick actuation:
Function selection:
Broad light, focused light or full light
Long actuation while switched-on:
Dimming
Light functions
Main function
Function
Light duration at 20 °C
1 x Power LED
Broad or focused light (full power)
approx. 7 h
Broad or focused light (dimmed)
> 48 h
2 x Power LED
Full power
approx. 3,5 h
Dimmed
> 24 h
4.2 Operating the basic functions
Switching the light on:
A quick actuation of switches on the light according to the
most last setting.
Lighting mode selection:
A quick actuation of switches the operating mode.
Dimming:
A one-time long actuation of reduces the brightness of the
light. Another long actuation of increases the brightness of the
light.

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Switching the light off:
A quick actuation of when the light is switched on will switch it
off again.
Emergency light:
A three second actuation of and while the light is in the
universal charger toggles the emergency light mode.
4.3 Charge status display
Charge status display:
Emergency light function is on:
battery charging: green status led blinks 1,1 sec on and 0,1 sec off
battery charged: green status led blinks 0,1 sec on and 1,1 sec off
Emergency light function is off:
battery charging: green status led blinks 0,6 sec on and 0,6 sec off
battery charged: green status led is on without blinking.
Batteries:
If the battery charge goes below approx. 20%, this will be the TorchLED Ex signaled by the light blinking twice
which will be repeated every two minutes.
At the same time, the light will enter the energy saving mode and it is dimmed to 25% of its maximum power.
The remaining light duration depends on the mode and dimming level.
The light must be recharged as soon as possible in order to avoid damaging the batteries.
4.4 Emergency light function
If the emergency light function is activated and power-loss occurs during charging of the TorchLED Ex, the
upper (wide) LED of the TorchLED Ex will be switched on at full power.
The energy saving mode will not be activated during emergency light mode; the light will remain at full power
until the batteries are empty.
As soon as power to the TorchLED Ex is restored, the light is turned off again and the charging operation is
continued.
When the emergency light mode is on, the mode key is ignored and the power button can be used to turn the
light off. The emergency light can be switched off by pressing the button .

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5 Service and troubleshooting
5.1 Batteries
In order to guarantee flawless operation, the following rules for the handling of batteries apply:
Self-discharge:
The self-discharge of the unused batteries is very minor. It is not linear and depends on various parameters,
such as temperature, charge status, batteries status etc.
Indication
The batteries should be recharged every 6 months.
Service life:
Up to 1.000 charge cycles are possible if the batteries is well looked-after. The batteries should NEVER be
deep-discharged!
Indication
It is best to recharge the batteries after every use.
Charging:
The batteries are not charged outside the following temperature range: 0°C to 40°C
Indication
Always charge the batteries at room temperature.
Storage:
Temperatures above 40°C and excessive humidity damage batteries.
Indication
Always store batteries at room temperature and keep them dry.
Guarantee:
Batteries are classified as wearing parts. They can be damaged by improper use and as a result, their service
life can be significantly impaired. Because of this, the batteries does not have the same guarantee period as
the device itself.
Indication
Light: 2 years. Batteries: 1 year
Observing the points above will not stop the ageing process, but will slow it down significantly.

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5.2 Inspection and maintenance
The requirements as stated in EN-IEC 60079-17 or other codes of practice valid on the place of installation
apply.
If the TorchLED Ex enclosure or LED window appears cracked, dented, broken or otherwise no longer in good
condition or are very dirty they must be immediately repaired or cleaned.
As the device internal circuits are always on, in case of damage it must be removed from the hazardous area
immediately and may only be restored after the repair has been carried out and approved.
After approximately 1000 charges or when a noticeable capacity reduction occurs it is recommended to have
the battery pack replaced.
The cycle of maintenance depends on the specific conditions of use. As a general guide line for light use a 12
month interval is recommended.
All functions of this light are to be serviced in accordance with the relevant regulations, standards and rules of
the respective country and revised by professionally trained personnel when required.
5.3 Troubleshooting
Fault/error message
Possible cause(s)
Remedy
TorchLED Ex can no longer be
charged
Charging station defec-
tive
Contact GIFAS, replace charging
station if necessary
TorchLED Ex can no longer be
charged, but charging station still
works
Charging electronics or
batteries defective
Contact GIFAS, send back torch
light for repair (replace the batter-
ies)
An LED no longer illuminates
LED defective
Contact GIFAS, send back torch
light for repair
The light illuminates for a short time
only, despite being charged
Batteries are no longer
functional
Contact GIFAS, send back torch
light for repair (replace the batter-
ies)
5.4 Repair
Repair to the TorchLED Ex may only be done by using original parts. It shall be carried out by qualified skilled
workers who have been trained in accordance with EN-IEC 60079-19 or other codes of practice valid on the
place of installation.
Applying of non-original parts may lead to injury to persons and damage to equipment.
If non-original parts are used or repair has been carried out in an incompetent manner the warranties concern-
ing explosion safety no longer apply. Therefore it is necessary to return the equipment to the manufacturer in
cases repair is demanded.

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6 EU-Declaration of Conformity

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7 Service
7.1 Service addresses
7.2 Imprint
GIFAS-ELECTRIC GmbH
CH-9424 Rheineck
www.gifas.ch
Subject to technical modifications; errors excepted.
This manual is the property of GIFAS-ELECTRIC GmbH and may not be copied, translated, transferred, du-
plicated or passed on to third Parties –neither completely nor in part –without prior written permission of
GIFAS-ELECTRIC GmbH.
GIFAS ELECTRIC GmbH
GIFAS-ELECTRIC S.r.l
GIFAS ELECTRIC GmbH
GIFAS-ELECTRIC GmbH
Borsigstrasse 9
Via dei Filaracci 45
Pebering-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]
[email protected]
[email protected]t
[email protected]