StreamLight FIRE VULCAN User manual

TABLE OF CONTENTS
PREFACE...................................................................................................……… -2-
TROUBLESHOOTING DIAGRAM..............................................................……… -3-
GENERAL NOTES......................................................................................………-4-
SECTION I, REMOVING/REPLACING THE FACECAP ..........................………..-5-
SECTION II, TESTING/REPLACING THE LAMP .....................……….................-6-
SECTION III, TESTING THE VULCAN BATTERY......................……………........-8-
SECTION IV, TESTING/REPLACING THE SWITCH/PCB ASSEMBLY..……......-12-
SECTION V, TESTING/REPAIRING THE CHARGER SYSTEM........….…………-22-
SECTION VI, THE BODY…………………………………………………………...…-29-
VULCAN REPLACEMENT PARTS AND DIAGRAM..................….....………........-30-
VULCAN SWITCH/PCB SCHEMATIC………………………………………………..-31-
VULCAN CHARGE RACK PCB SCHEMATIC……………..………………………..-32-
FIRE VULCAN TROUBLESHOOTING DIAGRAM.....................................……….-34-
FIRE VULCAN GENERAL NOTES.............................................................……….35-
TESTING/REPLACING THE SWITCH/PCB ASSEMBLY..…….................….....…-36-
FIRE VULCAN REPLACEMENT PARTS AND DIAGRAM..................….…..…….-42-
FIRE VULCAN SWITCH SCHEMATIC……………………………………….……….-43-
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VULCAN SERVICE MANUAL
PREFACE
The purpose of this manual is to provide the information needed to service the Streamlight
Vulcan flashlight system.
This manual is dated (see front cover). Additions, deletions and changes to this manual
will display a later date.
A set of tools including a Phillips screwdriver, a #3 Tri-Wing driver, a 5/16” wrench,
needlenose pliers, a 15 ohm/10 Watt resistor, and a multimeter are required to service the
Vulcan.
Lamp may be changed without special tools.
For additional information and/or assistance contact:
STREAMLIGHT, INC.
Repair Department
30 Eagleville Road
Eagleville, Pa. 19403
Phone [phone]
Phone [phone]
FAX [phone]
7:00 a.m. - 5:00 p.m. EST
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Note:A known Good Vulcan and Charge Rack will help to determine if the problem lies with the suspect Vulcan or the Charge Rack.
With no Vulcan in the suspect Charge Rack, and power applied, there should be no LED lighted. With a good Vulcan in the suspect Charge Rack, and power applied, either the Red or the Green LED should be lighted; if not, the problem is most likely with the Charge Rack.
When a suspect Vulcan is discharged for several minutes and placed in a known good Charge Rack, if the Red LED does not light, the problem is most likely with the Vulcan. Detailed testing instructions can be found in Section V on Page 18.
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GENERAL NOTES
Troubleshooting Note
A troubleshooting diagram is provided (page 3) to help enable a repair technician to isolate
and repair electrical problems which can arise. The diagram describes a condition and
suggests the underlying cause. Repair procedures are provided in the chapters indicated
in the solution blocks. The troubleshooting procedure does not attempt to isolate individual
components. Instead it suggests replacement of modules or assemblies such as the
printed circuit board, the battery, etc. Occasionally problems may arise which are not
included in the troubleshooting procedure. In these cases a thorough physical inspection
may reveal a broken wire, cracked or damaged printed circuit board (PCB), or some other
mechanical damage which results in an apparent electrical problem. If the problem
remains elusive the Vulcan and all of its available components (including the charge rack
and plug-in wall transformer) should be returned to Streamlight for factory service.
Charge Contacts
The charge contacts located on the Vulcan and the charge rack must be kept clean. If the
charge rack contacts become dirty they can become stuck in the down position and fail to
make proper contact, resulting in the Vulcan not receiving a proper charge. If the contacts
become dirty they can be cleaned with a mild non-corrosive cleaner (WD-40). In extreme
cases, fouling can be removed by using a pencil eraser. Be careful not to remove the
protective plated surface of the charge contacts.
The Red and Green Charge Indicators
The Vulcan charge rack is equipped with two LED’s which light to indicate
the mode that the charging circuit is in. The red LED indicates that the
battery is being charged. The green LED indicates that the charging cycle is
complete and the battery is at maximum capacity.
The LED’s can warn of malfunctions within the charging circuitry. The red
LED should turn “off” completely twelve (12) hours or less after the charge
cycle is initiated and the green LED should turn “on”. If the red LED remains
on for more than 12 hours the charging circuit must be tested and repaired or replaced as
necessary (see section V).
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Charge Contacts

SECTION I
REMOVING/REPLACING THE FACECAP
The facecap of the Vulcan is designed to prevent water from entering and damaging the
flashlight. A proper seal is achieved through the use of two internally mounted O-rings. It
is very important that the facecap be properly reinstalled after it has been removed.
Removal
A. Support the body of the Vulcan. The body should be placed in a bench mounted vise if
one is available with the facecap pointing upwards.
Note: Be sure to protect the body from damage.
B. Grasp the outside of the facecap and turn it counterclockwise until it comes free from
the Vulcan body.
Note: A strap wrench (minimum diameter 5 1/2 inches) will greatly facilitate removal of the
facecap.
Replacement
A. Support the body of the Vulcan as in step one above.
B. Thread the facecap onto the body and tighten the facecap to the point that you cannot
move the lens/reflector within the facecap.
C. Turn the facecap an additional 1/8th turn to insure its water resistance.
D. Inspect the area between the facecap and the lens to be sure that no portion of the
O-ring is showing. If the O-ring is showing remove the facecap and reinstall it as in
steps 1, 2, and 3 above.
O-ring must not
be showing.
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SECTION II
TESTING/REPLACING THE LAMP
A. Remove the facecap from the Vulcan as described in Section I.
B. Carefully lift the lamp/reflector assembly away from the Vulcan body.
C. There are two different styles of bulbs. The single filament bulbs have two leads. Dual
filament bulbs have three leads.
Note:The single and dual filament bulbs are not interchangeable. Follow the instructions
below to test or replace the bulb.
1. Test the bulb.
Dual Filament
Common Lead
Single Filament
a. Unscrew the threaded bulb socket from the reflector.
b. Pull the old bulb straight out from the socket.
c. Use a multimeter in the continuity position.
(1). For single filament (bi-pin) bulbs place a meter lead on each bulb lead (a
beep or continuity indicates a good bulb).
(2). For dual filament bulbs (three pin) first establish the common lead (the
common lead connects with the long filament support visible inside the
bulb). Place one meter lead on the common lead and then test each of
the remaining leads (a beep or continuity indicates a good bulb).
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2. Bulb replacement.
Note:Single and Dual filament bulbs are not interchangeable. A single filament bulb
socket is connected to the circuit board by two wire leads. A dual filament bulb socket is
connected by three wire leads.
Dual Filament Socket Single Filament Socket
a. Replace the bulb by aligning the pins with the holes in the socket and seat the
bulb firmly.
Note:Use care and make sure that the leads are properly aligned when inserting the dual
filament bulb.
b. Wipe off any fingerprints from the bulb with a tissue and alcohol. Any oil left on
the bulb will permanently “smoke” the inside of the reflector.
c. Screw the socket back into the reflector assembly.
d. The socket can be adjusted in the spot reflector assembly.
(1). Turn the Vulcan on and shine it on a wall approximately 10 feet away.
(2). Adjust to the desired focus by screwing the socket inward towards the fully
seated position or outwards until the point where the socket O-ring starts to
leave the surrounding screw shell of the reflector.
Note:The focus should be attained somewhere between the two limits described (try 1/4
turn out from the fully seated position).
D. Place the reflector/lens assembly back into the Vulcan body.
E. Reassemble the Vulcan as shown in Section I.
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SECTION III
TESTING/REPLACING THE BATTERY
Test for Charge Power to the Battery
A. Remove the facecap from the Vulcan as described in Section I.
B. Place a multimeter into the DC Volts position.
C. Place the red meter lead onto the positive (red) battery terminal and the black meter
lead onto the negative (black) battery terminal.
Negative
Terminal
Positive
Terminal
D. Note the voltage.
E. Place the Vulcan into a known good charge rack, and connect it to a power supply.
F. Allow the Vulcan to charge for 5 minutes.
G. Leave the Vulcan charging in the charge rack and re-test the battery as described in
Step C above.
H. The voltage of the battery while charging in the charge rack should be at least .20 Volts
above the voltage noted in Step D above.
1. If the voltage is at least .20 Volts greater than the voltage noted in Step D, proceed
to the Quick Battery Test.
2. If the voltage is less than .20 Volts greater than the voltage noted in Step D, proceed
to Testing the Printed Circuit Board, located in Section IV.
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Quick Battery Test
A. Charge the Vulcan in a known good charge rack for 12 hours, or until the Green LED
lights.
B. Remove the Vulcan from the charge rack.
C. Place a multimeter into the DC Volts position.
D. Place the red meter lead onto the positive (red) battery terminal and the black meter
lead onto the negative (black) battery terminal.
E. The voltage should measure above 6.5 Volts.
F. If the voltage is less than 6.5 Volts, the battery will need to be replaced.
G. If the voltage is 6.5 Volts or greater, place the battery under load by running the Vulcan
with a six-watt bulb for 10 minutes. Leave the Vulcan ‘on’ during the following test.
H. Re-test the battery as described in Step C above.
I. The voltage should measure between 6.0 Volts and 6.4 Volts.
1. If the voltage is less than 6.0 Volts, the battery will need to be replaced.
2. If the voltage is 6.0 Volts or greater, the battery is probably usable. If the customer’s
complaint is short run time, proceed to the run time test below.
Run Time Test
A. Charge the Vulcan in a known good charge rack for 12 hours, or until the Green LED
lights.
B. Remove the Vulcan from the charge rack.
C. Turn the Vulcan ‘on’ and note the run time. Also observe the lamp intensity.
1. Run time is the time from when the Vulcan is turned on to the point where it
becomes no longer usable.
2. Nominal run times and charge times are listed below.
Lamp Option Run Time Charge Time (AC) Charge Time (DC)
3 watt spot 6.75 hrs. 12.0 hrs. 10 hrs.
6 watt spot 3.75 hrs. 12.0 hrs. 10 hrs.
8 watt spot 2.75 hrs. 12.0 hrs. 10 hrs.
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3. Normal intensity and short run time may indicate sulfation.
4. Low intensity and normal run time may indicate shorted cells.
5. Batteries which exhibit signs of sulfation or shorted cells must be replaced.
The sealed lead acid battery in this product is recyclable. At the end of its useful
life, under various state laws, it may be illegal to dispose of this battery in the
municipal solid waste stream. Check with your local solid waste officials for
details in your area for recycling options or proper disposal.
Pb
D. If the Vulcan has normal intensity and normal run time the battery is good.
Removing and Replacing the Vulcan Battery (See pictures on Page 11.)
A. Remove the facecap as described in Section l.
B. Place the Vulcan on a table or bench with the open end facing upwards and with the
handle away from you.
C. Carefully lift the reflector/lens assembly from the body and unscrew it from the lamp
socket.
D. Unscrew the Phillips head screws on each side of the battery clamp and remove the
battery clamp.
E. Carefully disconnect the battery leads. (Use needle-nose pliers if necessary.) Move
the battery leads aside.
F. Move the charge leads aside enough to allow the battery to pass. Do not disconnect
the charge leads.
G. Carefully pull the battery from the Vulcan body.
Note:Always handle the battery with care and do not allow it to become short-circuited. A
short-circuited battery can deliver hundreds of amperes of current, which can start a fire.
H. Install the new battery in the Vulcan.
1. Place the battery, terminal side up, into the Vulcan body. Position the battery with
the negative (black) terminal closest to the Printed Circuit Board, and the positive
(red) terminal closest to the charge contacts.
2. Attach the battery leads to the battery terminals, observing proper polarity.
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