Oldham DLi User manual

1 September 2016 – Iss. 1
WARNING
This manual, including the warnings and cautions inside, must be read and followed carefully by all
persons who use or maintain this product, including those who have any responsibility involving its
selection, application, service, or repair.
This cap lamp system will perform as designed only if used and maintained according to the
instructions, otherwise it could fail to perform as designed and persons who rely on this product could
sustain serious personal injury or death.
DLi CORDLESS
CAPLAMP SYSTEM
NO COMPROMISE
INSTRUCTION
MANUAL
Ex I M1 Ex ia
I
Ma EN60079
-
35
-
1 Ta = 0
o
C to +40
o
C

2 September 2016 – Iss. 1
DLi Cordless Caplamp
TABLE OF CONTENTS
Important p3
General description p3
Using the DLi caplamp system p3
Preparation for use p3
Preparing the DLi caplamp for first use p3
Battery charging p4
Storage p4
Use and operation p4
Operating the lamp p4
Recharging the lamp p4
Multi-stage chargers p5
Watchdog timer cut-out p5
Recharging via USB charger p5
Repairing the DLi caplamp p6
Operating the lamp p6
Replacing battery and LEDs p6
Replaceable parts p6
Lens glass & Bezel ring p6
Cap clip p6
Button switch p6
Attaching the Lanyard p6
Attaching the lanyard p6
DLi caplamp tools & Spare Parts p8
Replacement parts p8
DLi layout drawing p8
Troubleshooting p9
Use of Equipment p10
Certification, equipment marking and instructions for
compliance with ATEX standards. p10
Use of equipment / certification conditions p11
Contact address & details p11

3 September 2016 – Iss. 1
IMPORTANT
Pay close attention to Warnings and Cautions in this manual.
A WARNING describes a condition that may cause severe personal injury or death if
allowed to happen.
A CAUTION describes a condition that may cause moderate injury or property damage
if allowed to happen.
GENERAL DESCRIPTION
The DLi cordless caplamp consists of cap mounted headpiece with a self-contained
lithium-ion battery and is designed to operate at full brilliance for 10-12 hours from a
fully charged condition, with reserve energy if extended operation is required for 60-
100 minutes. At the end of the working shift, the battery can be recharged using an
approved EnerSys charger. Charging time from fully discharged is 10-12 hours.
The lamp is operated by an intelligent software based system. Operation of the button
will give various lighting patterns dependent on the software fitted. As the battery
voltage falls, the light output will be reduced in order to increase operating time.
The DLi is based on Lithium-ion battery technology and utilises three state of the art
LEDs to give an optimal lighting pattern. The caplamp consists of an outer
polycarbonate shell, switch, cap clip, glass face and charge connections. Charging is
achieved via the two charge points on the rear of the lamp adjacent to the cap clip.
When the lamp is inserted into the charge point the charger begins the charge cycle
until the lamp is completely charged. The charging base prevents the lamp from being
inserted incorrectly
 USING THE DLi CAP LAMP SYSTEM
The DLi caplamp is made up of the lamp-housing which contains the following parts:
- Bezel (ring)
- Lens (glass)
- Gasket
- Reflectors
- Main LED (focus)
- Main LED (wide angle)
- Pilot/auxiliary LED
- Circuit board and switch
- Battery & control circuit
The on-off-on switch button is located on the headpiece. Depressing the button
operates the LEDs through a menu of performance types.
Preparing the DLi Cordless lamp time for first use:
The DLi Caplamp contains battery protection circuitry that shuts the caplamp down in
the event that the battery reaches a low level; this is done to protect the lithium-ion
cells. When this occurs the Caplamp requires a re-initialisation charge:
1. Place the lamp on the charger. The lamp should flash once in the first 10 seconds
and then begin a charge cycle in the following 10 seconds.

4 September 2016 – Iss. 1
2. If the lamp fails to start the charge cycle, briefly connect a 9 volt battery to the
charge points with the positive of the battery to the marked positive connection on
the lamp. The caplamp should flash once when the battery is connected. Then connect
the battery to the charger to begin a full charge cycle.
(reverse connecting the 9 volt battery will not damage the lamp).
NOTE: THE BATTERY IS TRANSPORTED IN A PARTIALLY CHARGED
CONDITION – EVERY LAMP MUST BE FULLY CHARGED BEFORE FIRST USE.
 Battery charging
1. Every lamp should be charged for 12-24 hours before first use.
2. After a working shift, the battery should be placed on the charger, following the
instructions included with the charger, and left to charge. The charger
automatically switches off when the battery is completely charged.
 Storage of lamp
The lamp can be stored for up to 6 months from receipt. All lamps should be given a
24-hour boost charge at 6-monthly intervals until use, where they should again be
fully charged before being placed into regular service.
Recommended storage temperature: 0oC to 27oC.
WARNING: The lamp should only be charged on EnerSys approved chargers.
For charger information and how to convert existing chargers software and charging
contacts to charge-cradle, please consult the Caplamp Charger Manual.
OPERATION
The lamp is turned on and operated by pressing the button on the side of the lamp.
While the exact operation will vary depending on application, the standard lighting
sequence operation will follow this pattern;
1. Lamp turns on 2. Normal working light 3. Boost Light 4. Lamp turns off.
As the battery voltage declines, the intelligent software will reduce the power to the
LED Lights in order to increase operating time. If light output falls, the lamp should be
placed on charge as soon as possible.
Recharging the DLi Caplamp
There is a multi-stage charging system for DLi caplamp batteries. Each lamp position
has its own microprocessor controlled PCB with LED indicators to show mode of
charge and battery charge condition. A 5.0v USB system is also available. Both are
described in the following section.

5 September 2016 – Iss. 1
The DLi cordless lamp is recharged by connecting it to the power supply cradle as
shown in the following sequence:
1. Position the lamp in the charging cradle (red button facing outward/down)
2. Push down on the lamp to click in place. Charging commences automatically
and can not overcharge from the USB supply.
3. Do not put lamp in upside-down (red button toward the charger).
4. Do not charge with lights switched on.

Multi Stage charge cycle for Oldham Lithium Ion Batteries LED Indication
Stage 0 - Waiting for a battery - Green and Red LEDs off
Stage 1 - Battery on constant current charge - Red LED Only. (14-hour watchdog timer starts)
Stage 2 - Charging with controlled voltage to complete charge - Green and Red LEDs on
Stage 3 - Battery is fully charged - Green LED on with Red flashing every 5 seconds
Stage 4 - A watchdog time-out has occurred before battery was fully.
 Watchdog timer cut-out
If a watchdog time-out occurs;
Check that both charge connections are tight and that charge contacts are clean and
undamaged.
Return to charge and monitor. If time-out occurs again then refer to your nearest
distributor.
Recharging the DLi Caplamp from USB connection
The DLi cordless lamp can also be recharged via connection to a USB power supply
through a computer USB connection, or into a 12v adaptor plug (automotive
connection) as shown below:
1. Connect the USB cable to the cradle.
2. Connect the other end of the cable to the computer USB socket or 12V car plug.
3. Insert the DLi lamp into the charging cradle as described in the previous
section, taking care not to insert upside-down or with lights switched on.
1
2
3
4
1
2
3

6 September 2016 – Iss. 1
NB. The USB connection provides a constant (float) voltage. There is no electronic
control of the recharge process but the lamp should be fully charged after 12 hours.
REPAIRING THE DLi CAP LAMP
The DLi Caplamp contains internal fuses and electronic protection measures and
should be considered as a sealed-for-life product, virtually maintenance free. User
serviceable components in this Caplamp are restricted to the following replaceable
parts:
 Replacing battery & LEDs
The DLi caplamp contains internal fuses and electronic protection measures as an
integral part of the battery. The LEDs are permanently fixed to the LED driver circuit
board. As such, no economical repair or replacement of these two components is
considered possible in this caplamp.
If the LEDs fail to operate or the circuit board is damaged, the lamp must be returned
to an authorised Oldham representative for inspection and analysis.
Replaceable Parts
Lens glass / bezel ring. Held in place by 6 off M3 Screws.
To replace the bezel and glass (one complete component), remove the 6-off M3
screws using the bezel screw Allen key M237642, and then lift off the bezel. Replace,
with a new bezel, taking care to ensure that the logo is at the top of the lamp.
Replace the screws, but do not over tighten. The Bezel should be replaced if the glass
is cracked or damaged - replacement of the glass bezel can improve lighting
performance.
Cap Clip. If the cap clip is damaged it may become difficult to connect the lamp to
the charger or safety helmet. In this case, the cap clip must be replaced (M210445–
cap clip spares kit).
The cap clip is held by an M4 x 25mm screw. Use the bezel screw Allen key M237642
and capclip nut spanner M204842 to remove the screw, and lift the capclip away from
the lamp. Position the replacement capclip around the holding lug, insert the screw
and tighten the nut until adjustment of the capclip angle is sufficient to hold the lamp
in the desired position when placed on the helmet.
NB./ a new lock nut should be used each time in order to prevent loosening of the
capclip.
Button switch: If the button switch fails to operate, the repair must be completed by
an authorised Oldham representative.
 Attaching the lanyard
Local regulations vary from mine to mine, but it is recommended that the user
attaches the lamp or the helmet via a lanyard connection. Users should satisfy
themselves that the lamp is securely attached to the helmet, and that the lamp will
not be lost if the user loses his helmet.

7 September 2016 – Iss. 1
A small hole is provided in the rear of the DLi caplamp for a spring hoop attachment
that make connection of the lanyard possible.
Depending upon local regulations, the user may chose simply to attach the lamp to
the helmet via a lanyard, or the lamp-to-helmet-to-user as indicated in the pictures
below:
Mines may chose and specify their own lanyard preference, but short (helmet
attachment) and long (personal attachment) lanyards are available from Enersys.

8 September 2016 – Iss. 1
DLi Cordless Caplamp, Tools and Spares List
DLi cordless caplamp M263051
Bezel and Glass Assembly M202921
Cap Clip M210344
Cap clip & screw repair kit M210445
Short Lanyard M253343
Long Lanyard M253243
Bezel screw Allen key M237642
Capclip nut spanner M204842
Charger adapter conversion kit M616832

9 September 2016 – Iss. 1
TROUBLESHOOTING
PROBLEM CAUSE & REMEDY
The caplamp will not operate when
removed from the box.
Connect a nine volt battery to the charging
terminals of the caplamp. Then connect the
caplamp to the charger. If the caplamp fails to
charge, return it to your authorised distributor.
Lamp Fails to Light 1. Check Charger
Battery low voltage safety circuit has
operated and charger needs to “wake up”
battery.
(place the lamp on charge to re-activate)
2. Fuse Failure
Consult local representative
Lamp not giving light for a full shift a. Make sure charger output is correct.
b. Check charger functionality (including
connections)
c. Check + battery connections at the back of
the lamp.
d. Make sure the connections between
headpiece and battery are good.
e. Make sure that charging rack connections
are good.
f. Ensure lamp is fully charged before use
The caplamp will not operate in
normal or high power modes but
switches directly into low power.
The battery is almost fully discharged, connect
to the charger.
The Caplamp flashes when placed
on charge but does not start
charging
Connect a nine volt battery to the charging
terminals of the caplamp. Then connect the
caplamp to the charger. If the caplamp fails to
charge, return it to your authorised distributor.
IMPORTANT: LAMP SHOULD BE RECHARGED AFTER EACH USE.

10 September 2016 – Iss. 1
Certification, equipment marking and instructions for compliance with ATEX
standards:-
The DLi range of cap lamps is certified for use in mines where potentially explosive
atmospheres may exist. The lamp is suitable for M1 Mining applications.
Only lamps clearly labelled and marked with the ATEX symbol are to be
used in a hazardous area.
Detail IECEx ATEX
Certificate number:
IECEx SIR 13.0093X
Sira 13ATEX2259X
Certification code:
Ex ia I Ma En60079
-
35
-
1
Ex ia I Ma En60079
-
35
-
1
Other marking:
0518 I M1
Model number:
M263051
Manufacturer’s name:
EnerSys Ltd
Manufacturer’s address:
Manchester M27 8FF UK
Ambient range:
0°C to +40°C
S/n & year of manufacture:
Marked on equipment
Warnings:
Do not charge or open in hazardous location.
Use only correctly rated charger
Entity parameters:
U
m
7.7 VDC I
i
2.55 A

11 September 2016 – Iss. 1
Conditions of Certification and special conditions for safe use
The user must ensure that the lamp supplied meets the safety standard required for
the Zoned area:-
(1) This equipment must only be used in accordance with the certification
approved.
(2) Only an EnerSys approved and assessed charger (incorporating the M657012
Crowbar Circuit with supply voltage not exceeding 26.5v**) should be used for
certification conditions. Certification may be invalid if an incorrect charger is
used. Lamp may function normally with a non-assessed charger. Under no
circumstances should a charging voltage in excess of 7.7 V be applied to the
lamp. (** full specification available upon request)
(3) The lamp should not be charged in a hazardous area.
(4) The lamp should never be disassembled in a hazardous area.
(5) The lamp should only be cleaned with a damp cloth
(6) Only approved and trained personnel should disassemble the lamp.
(7) Lamp is certified for use between 0°C to +40°C.
(8) Plastic surfaces may cause propagating brush discharges. Propagating brush
discharges are caused by non-conducting fluid flow over a non-conducting
plastic surface. The cap lights shall not be used in areas where a high fluid flow
over the plastic surfaces may occur (for example in the case of a ruptured
process pipe or compressed air pipe).
(9) The caplamp is manufactured from polycarbonate and ABS with EPDM rubber
seals. The performance of these materials, with respect to attack by aggressive
substances that may be present in the hazardous area, shall be taken into
account before the equipment is used.
(10) If a charge-generating mechanism is present, an incendive level of charge could
migrate to these metal parts and subsequently discharge to earthed metal.
Precautions are required to ensure that a charge-generating mechanism is
unlikely to be present and/or discharge to earthed metal is improbable.
(11) Under certain extreme circumstances, the exposed plastic of the enclosure and
unearthed metal parts such as the caplamp clip may store ignition-capable level
of electrostatic charge. Therefore the user/installer shall implement precautions
to prevent the build-up of electrostatic charge, e.g. locate the equipment where
a charge-generating mechanism (such as wind-blown dust) is unlikely to be
present, and clean with a damp cloth.
Denchi Power Ltd.
Denchi House, Thurso Business Park,
Thurso, Caithness, KW147XW
URL: www.oldhamcaplamps.com
Email: [email protected]
Tel.: [phone]
September 2016