RETRO XP i3 User manual
RETRO XP
i3
-400 Lumen, High Power LED Lighting System
for
Oldham,
Speleo-Technic and CEAG Mining Style caplamps -User Manual v3.0
READ
all
the
instructions
first
and
make
yourself
familiar
with
the
operation
of
the
Retro
XP
and
the
installation
procedure
Introduction:
Us
ing
the
latest LED
and
electroni
cs
technology,
this
LED retro fit provides
400
lumens
of
light output
with
only
3.0
to
3.7
Watts
of
input
powe
r (a
standard 3
Walt
(!o/V)
Oldham
bulb
prov
ides
48
lurnens).
The
beam
has
an
11
•spot
,wi
th
optional
13
,
30
and
40•
deffusers, which
gives
an excellent
spread
of
l
ight
, illuminating a
much
wider
area.
The
hue
of
the light
is
much closer
to
day
light,without the yellow tinge
bulbs
produce
making
it
much
brighter.
The
light
oulput
stays constant throughoutthe battery life.
The
Retro
XP
also
has
a
small
L
ED
that
is
always
on
when
the un
it
is
turned on, th
is
LED
is
indepe
nd
ent
to
the main
ones
and offers a backup lig
ht
should the main ones fail.
The
Retro
XP
runs from battery p
acks
giving 1.3
to
6.0V
DC
output
with
reverse batteryconnection protection
so
itwill
work
with almost any cell
combination
and
will provide light output
when
norm
al
bulbs will
not
even illuminate. Full performance
can
be achieved from voltages
2.3V
and
above.
DO
NO
T
USE
with
5
cell
NiCAD/NiMH
packs
or
6V
Sealed
Lead
Acid
batteries
as
damage
will
occur.
The
Retro
XP
uses
two
of
the brightest
LED'
s available (Cree
XP
-
G2
R5's). There
are
3
modes
:
701m
·pilot
,
1851m
·nor
mal activities),
and
4001m
·very
bright. A
low
battery
Is
Indicated
by
the
LED's
flashing.
The
Retro XP provides full performance with
2·,
3, 4 cell NiCADI NiMHD
or
2, 3, 4 cellAlkaline,
3.7V
Li-ion and
4V
L
ead
Acid
battery packs.
It
will also
work
with single cell
NiCAD
I Ni
MHD'
s I Alkaline batteries
at
reduced lig
ht
output
.•
With
new
cells that
do
not drop
below
2.3V
under load.
Installation
In
Oldham Cap
Lamps:
1. Before proceeding
make
sure
your battery
is
fully charged and
that
the
existing
ma
in and
pilot
bulbs are working. Disconnect
the
caplamp from
the
batteryto avoid
fu
s
ing
the battery pack.
All
screw connections
that
are
made
must
be
firm and tight. A small flat
blade screwdriver will
be
required. Installation s
hou
ld
take
under
10
minutes.
2.
Unscrew
the bezel from the c:aplamp housing and
tak
e
ou
t the glasswindow. Take
cu
l lhe reflector
and
main
bulb assembly.
Unscrew
the
screw, which fastens
the
wire
that
is
connectedto
the
reflector
lo
the
main
body
of
the
cap lamp.
3.
Unscrew
the
pilo
t
bulb
and
remove
the
pilot
bulb
holder
by
unscrewing
its
two
mounting
screws
.
Unscrew
the
screw for the contact
of
the
main
bulb
and
remove
the
contact see fig
1.
4.
The polarity
of
lhe
terminals inside
th
e
cap
lamp needs
to
be
determined.
The
positive isthe connector block,
wtiich correlates
with
the
external charging contact; a
brown
or
red-sleeved
wire
should
be
connected
to
this.
FIGt
The negative connection
is
to
the
screw
where
the
blue
or
black sleeved wire connectsto, see fig 1
(for
Speleo-
Technic cap lamps see fig 5). To confirm polarity, take
the
Retro
XP
and touch
th
e red wire
to
the
positive
connector
block
and
the
green
wire
to
the negative
screw-
the
Retro
XP
should
light up.
If
it
does
no
t lig
ht
reverse
the
connection.
Make
sure the ·
correct
low
battery link is
inst
alled; see Operation-
Part
4.
5.
The
Retro
XP
can
now
be
connected. Connect
the
RED
wire
so
l
der
tag
from the
Retr
o
XP
to
the
pos
itive
connectorblock u
si
ng
the
same
screw
that
connected the wire from the old main
bulb
body.
Keep
i
ts
orientation
as
shown In
fi
g 2.
After
this, connect
the
GREEN
wire soldertag from the Retro
XP
to
the
contact
screw for
th
e pilot
bulb
-to
do
this
you
will
need
lo
unscrew
this screw
and
then place the solder tag
underneath ii. Keep Its orientation
as
shown in fig 2.
Make
sure
that
the
contact metal strip s
tay
s in place. It is
importa
nt
to
keep the orientat
ions
of
the Retro
XP
wires
as
shown in fig 2 so
thal
the Retro
XP
heatsink
(mounted
on
the back
of
lhe
PCB)
can fit into
the
caplamp cavity.
6.
Tu
rn
the
caplamp switch on,
and
the
Retro XP should switch
on
.
Switch
it
off
and
then
proceed
to
place
the
Retro
XP
into the caplarnp.
To
do
this the battery
inpu
t cable wires
may
need
to
be squashed
and
compacted
down
depending on
how
much
excess
there is, do
this
gently.
When
insertingthe Retro
XP
into place apply gentle
pressure
to
lh
e
pressure
points
ind
icat
ed
in fig 3.
Do
not
press
or
touch the reflectors and
do
not
use
excessive force. Once inserted,
gently
fold a
nd
position
the
Retro
XP
wires
as
shown
in fig 3 making
sure
nothing
is
trapped. Turn
the
lamp
on
again
and
t
es
t i
ts
operation. If
the
Retro
XP
does
not
sitevenly in
the
cap
lamp,
try
adjusti
ng
the position
of
the
positive
and
negative connections
of
the
power leads from the battery cable inside t
he
cap
lamp.
Hot
melt glue can also
be
used
to
place
the
Retro
XP
if
needed
.
7. Once the Retro
XP
is
inserted the
new
'O' ring supplied m
ust
be
placed into
the
bezel.
Take
t
he
bezel
and
insert
the
glass
wi
ndow
, then press in the '
0'
ring see fig 4.
Screw
the
bezel
back
onto
the
cap
lamp
and
make
sure
ii
is
a secure fit. If
the
Retro XP is
mounted
slightly higherthan it should
be
(this
may
occur
on
older
models
of
cap lamp) take care in
how
far
you
screw
the
bezel
down
so
as
nol to
over
stress
the Retro
XP
PCB.
lnstanatlon In Speleo-Technic Cap/amps:
1. Before proceeding
make
sure
your battery is fully charged and
that
the existing main
and
pi
lot bulbs are
work
ing
.•
All screwconnections
that
are
made must be firm
and
tight. A small
flat
blade screwdriverwill be required.
2.
Unscrew
the bezel from
the
caplamp
housing and
take
out
the
glass
window.
Remove
the
reflector,
ma
in
bulb
and
pilotbulb.
3. Remove the screws,
which
hold
th
e bulb mounting plate, and take the plate out. Note that there
may
be
one
or
two screws
ho
l
ding
lhe
pl
ate.
When
you remove
the
plate
the
brown or red-sleeved wire will also
be
disconnected.
Connect
U1is
wire back into
the
same
position with
one
of
the screws into
lhe
connector block see fig 5.
Unscrew
the
main
bu
lb
screw
and
r
emove
the
contact. Continue on from Oldham installation instruct
io
ns
part
4.
Operation:
1.
Turning
On
and
Off: turn the caplamp switch until the light comes on. Turn the caplamp switch until the light turns off.
2.
~ode
Chan~ing:
whilst the lamp is on, turn the caplamp switch on and off very quickly; this
must
be done in under 1 second.
The
light output will
increase noticeably. The difference between modes is very noticeable so no indication is required. Mode
1-
701m,
Mode
2-
185/m, Mode
3-
4001m.
When
in
Mode
3, changing
mode
will revert back to Mode
1.
Note that when you turn the lamp off permanently, up on turning it back on it
will revert to the last setting it
was
used in.
Be
aware
that
operating
the
Retro
XP
in
Mode
1
still
provides
an
excellent
level
of
light.
3.
OverHeating: if running in Mode 3 (highest setting) in certain conditions the Retro
XP
can over heat. The Retro
XP
in this case will reduce its
output to
Mode
2 and stays there until the whole unit has cooled down. When this happens it will flash quickly 3 times. Note that you cannot
change mode when overheated. Once cooled down. it will flash quickly 3 times again and return to Mode 3. The Retro XP
has
been built to fit into
caplamps that
w~re
.never designed for LED's, heat dissipation.is a problem when used in warm environments
or
in underground locations were
the temperature
1s
higher
than would be expected. In these cases over heating can occur and the cooling cycle will implement
to
account for this.
The unit cannot be damaged by over heating, as the maximum temperature is limited.
4.
Low
Battery:
if
a series
of
10 quick flashes occurs. this indicates
that the battery is low.
It
is recommended that you turn the lamp to
Mode 1 - the lowest setting to avoid draining the batteries
excessively and possibly damaging them, also this will give you the
maximum run time for
the
energy left. The series
of
quick flashes
will repeat every 10 minutes. There is a 3
Way
link labelled
SK1
on
the PCB, this enables very accurate low battery indication, as the
Retro XP knows by this
what
battery you are using with it. Make
sure that the link(s) are set up correctly to avoid false alarms.
-No
of
Cells I Battery Type
3.GV
Li-ion I 4V Oldham
1 Cell NiCD I NiMH I ALK
2 Cells
N1CD
I NiMH I ALK
3 Cells NiCD I NiMH I ALK
4 Cells NiCD I NiMH I ALK
Low
Battery
Vollaae
3.5V
1.2V
2.2V
3.3V
4 4V
Link 1 Link 2 Link 3
OUT' OUT
OUT
IN
OUT OUT
OUT
IN
OUT
IN IN
OUT
OUT OUT
IN
5.
Estimating
Lamp
Run
Time:
listed below are the estimated run times
of
the Retro XP when used with some
of
the common battery combinations.
·'"
·~~'~::l~~
lf
~~non
standard
tia~~ery
pack
is used. it is possible to calculate
tn~estimated
run
tiq.i·4~~
the Retro XP in hours
by
dividing the
lbattery.p~c~~paci!YJir\~mp
Hours by the input current taken by
'/:
th~.,e,~~.·.':f~lr
\h~
':"~~~
it is used in.
•
i.
ql-.
t
!';-
.....
~··
.• :ft.
'ff.~:~
,;\¥.
'.or:~~mp
