Wolf ATEX TURBOLITE A-TL44C Instruction Manual

OPERATION & MAINTENANCE INSTRUCTIONS
ATEX
TURBOLITE
A-TL44C
A-TL45C
WOLF SAFETY LAMP COMPANY
Saxon Road Works, Shefeld, S8 0YA, England
Tel: [phone]
E-mail: [e-mail]
Website: www.wolfsafety.com
• Ideal for task lighting in
hazardous marine and tank
cleaning applications.
• ATEX, UKEX and IECEx
approved for Zone 1,2, 21 and 22
potentially explosive gas and dust
atmospheres.
• Uniquely powered by a supply of
compressed air.
• Compact and lightweight design.
• Up to 9,000 lumens light output
at source.
• Robust and durable nickel plated
aluminium construction.
• IP66 ingress protection rating
when running.
• Toughened glass lens/ball glass.
Wolf ATEX Turbolite Features
0598
A-1022 - Issue 3
DF559
Authorised Representative (EU)2019R1020:
Authorised Representative Service, 77 Camden Street Lower, Dublin, D02 XE80, Ireland
1180

Wolf ATEX Turbolite – A-TL44C and A-TL45C
Operation and Maintenance Instructions
Please Retain - Read Before Use
EU Declaration of Conformity
The Wolf ATEX Turbolites A-TL44C and A-TL45C meet
all relevant provisions of the 2014/34/EU Explosive
Atmospheres (ATEX Equipment) Directive by virtue
of the issued EU type examination certicate,
demonstrating compliance with all relevant
harmonised standards and essential health and safety
requirements.
The Wolf ATEX Turbolite is powered with compressed
air that, once regulated, drives the turbine wheel
tted to the shaft. The magnet, also tted to the shaft,
rotates within windings, generating electricity and
powering a 24v 250watt tungsten halogen bulb. The
A-TL44C Baylight provides all round illumination; the
A-TL45C Floodlight gives directional illumination. Both
A-TL44C and A-TL45C models are constructed from
nickel plated aluminium.
The Wolf ATEX Turbolite is approved as Group II,
Category 2 equipment for use in zone 1, 2, 21 & 22
potentially explosive gases, vapours, mists and dusts
where the T4 temperature class/135°C maximum
surface temperature permits. Note, additional
accessories are required for use in zone 21 & 22.
Certication/Approval Codes:
Ex sb IIC T4 Gb
Ex sb IIIC T135ºC Db (refer to special conditions for safe use)
A-TL44C Ta = -15°C to +55°C
A-TL45C Ta = -20°C to +55°C
EU Type examination certicate: CML 22ATEX9542X
Notied Body:
Notied Body Number: 0598
Harmonised standard: EN IEC 60079-0:2018 and
applied standard IEC 60079-33:2012
Ingress protection level:
IP66 (when running) to EN60529:1992.
IP40 (when not running, keep protected from ingress of
water/dust).
The Wolf ATEX Turbolite is compliant with the
2011/65/EU RoHS Directive to the harmonised standard
EN IEC 63000:2018.
This declaration is issued under the sole responsibility
of Wolf Safety Lamp Company.
Alex Jackson – Managing Director,
Wolf Safety Lamp Company Ltd.,
Shefeld, S8 0YA.
Dated: 01 December 2023
II 2 G D
SGS FIMKO OY, PO Box 30 (Särkiniementie 3),
00211, Helsinki, Finland. IECEx Scheme Certification
Certicate Number: IECEx CML 22.0083X
Ex sb IIC T4 Gb
Ex sb IIIC T135ºC Db (refer to special conditions for safe use)
A-TL44C Ta = -15°C to +55°C
A-TL45C Ta = -20°C to +55°C
Ingress protection level:
IP66 (when running) to EN60529:1992
IP40 (when not running, keep protected from ingress of water/dust)
IEC Standards applied: IEC60079-0:2017, IEC60079-33:2012
IMPORTANT: SPECIAL CONDITIONS FOR SAFE USE (X)
1. This equipment shall only be supplied with air from
a clean, dry source that is free from contamination with
hazardous gas, dust or bres.
2. When this equipment is used in the presence of
combustible dust, the air outlet shall be tted with
additional hose so that it is piped to a safe area instead of
venting into the hazardous area.
3. The hoses that are tted to this equipment shall be
anti-static with a resistance between 104 Ω and 108 Ω.
UK Declaration of Conformity
The Wolf ATEX Turbolites A-TL44C and A-TL45C meet
all the statutory requirements of the Equipment and
Protective Systems Intended for Use in Potentially
Explosive Atmospheres Regulations 2016, UKSI 2016/1107
as amended by UKSI 2019/696 by virtue of the issued
UKEX type examination certicate, demonstrating
compliance with all relevant designated standards and
essential health and safety requirements.
Certication/Approval Code:
Ex sb IIC T4 Gb
Ex sb IIIC T135ºC Db (refer to special conditions for safe use)
A-TL44C Ta = -15°C to +55°C
A-TL45C Ta = -20°C to +55°C
UK Type examination certicate: CML 22UKEX9543X
Approved Body:
Approval body number: 1180
Designated standard: EN IEC 60079-0:2018 and applied
standard IEC 60079-33:2012.
The Wolf ATEX Turbolite is compliant with the Restriction
of the Use of Certain Hazardous Substances in Electrical
and Electronic Equipment Regulations 2012, UKSI
2012/3032 to the harmonised standard EN IEC 63000:2018.
This declaration is issued under the sole responsibility of
Wolf Safety Lamp Company.
Alex Jackson – Managing Director,
Wolf Safety Lamp Company Ltd.,
Shefeld, S8 0YA.
Dated: 01 December 2023
SGS Baseefa Ltd, Rockhead Business Park,
Staden Lane, Buxton, SK17 9RZ, UK.
II 2 G D
1 10
TECHNICAL DATA A-TL44C A-TL45C
Power Source Type Compressed Air Driven Turbo-Alternator Generator
Input Pressure Range 5-8 Bar
Consumption 0.75m³ / min.
Light Source Part Number A-129 (6,000lm, supplied as standard) / A-159 (9,000lm, alternative)
Type Halogen Filled Filament Bulb
Voltage 24V
Wattage 250W
Lumen Output 6,000lm / 9,000lm
Life 2,000hrs / 200hrs
Beam Type 360° Illumination 25° Flood
Lens Lens Ball Glass / Plastic Dome Toughened Glass
Enclosure Nickel Plated Aluminium
Ingress Protection IP66 when running*
IP40 when not running
Weight 4.4kg 5.3kg
Gas Temperature Class T4
Dust Surface Temperature T135°C
Lower Ambient Temp Limit -15°C -20°C
Upper Ambient Temp Limit 55°C
Wolf Safety Lamp Co. reserves the right to change technical specications without prior notice.
*Once pressurised, lamp may be used underwater. When using under water always start lamp
before submersing and ensure lamp is running until removed from water. Remote exhaust can be
used above water surface to eliminate bubbles. Depth of use limitations to be considered regarding
water pressure.
Disposal of Waste Material:
Disposal of packaging, parts and end of life products should be carried out in accordance with
applicable regulations.
The Wolf Safety Lamp Co. Ltd has a policy of continuous product improvement. Changes in design
details may be made without prior notice. Prices and design are subject to alteration without
notice. All products sold are subject to our conditions of sale. A copy of these instructions with any
relevant revisions can be found at www.wolfsafety.com.

Wolf ATEX Turbolite – A-TL44C and A-TL45C Operating Instructions
The Wolf ATEX Turbolite is a compressed air driven lamp. The operating pressure must be between
5 and 8 bar (70 to 120 psi). The ideal running and setting pressure is 5.5 bar (80 psi).
The pressure regulator on the lamp compensates for uctuations in airline pressures. Every
Turbolite Airlamp, as supplied, can be connected to a 12.5mm (1/2”) bore hose, a 3/4” BSP male
thread, or a 3/4” BSP female thread.
The supply hose must be anti-static to BS2050 and should be connected to earth at the supply end.
Continuity between lamp and hose should be checked to ensure there is no risk of static build up.
Quick connect couplings can be insulative. If the coupling being used is insulative, the external
earthing point on the lamp should be used to ground the lamp body to the hose.
9 2
For standard use in gas atmospheres an
exhaust hose is not required. If working in close
proximity to the lamp for long periods of time,
hearing protection is recommended.
GD(gas & dust)
19mm / 3/4”
GD(gas & dust)
19mm / 3/4”
G(gas)
19mm / 3/4”
G(gas)
G(gas)
Use of the Silencer and Remote Exhaust in a Hazardous Gas & Dust or Dust Atmosphere
Use of the Silencer and Remote Exhaust in a Hazardous Gas Atmosphere
g. 1 g. 2
g. 3 g. 4
To operate with reduced noise levels in gas
atmospheres, an exhaust hose may be used
to vent within the explosive atmosphere. When
venting within the explosive atmosphere the
silencer must be tted to the end of the exhaust
hose as shown in g. 2.
To operate in dust atmospheres, an exhaust hose must be used to vent outside of the explosive
atmosphere, so that the exhaust air doesn’t agitate the dust. The exhaust hose silencer is optional
in this arrangement. Fig. 3 shows safe area exhaust with silencer. Fig. 4 shows safe area exhaust
without silencer.
Exhaust hose must be anti-static to BS2050. 19mm (3/4”) bore hose will result in minimal loss of
performance. Ensure exhaust hose does not cause a hazard.
Setting Generator Voltage
A setting and testing device (A-1040) is required to set or check the generator voltage.
23.5V AC
A-69
g. 10
g. 9
1. Fit to the generator, connect the two wires to
the contact spade connectors. See g. 9.
28
27
29
2929
14
2. Fit the reector head (A-TL45C models) or ball
glass and locking dome (A-TL44C models) to the
top of the setting and testing device and run the
lamp at 5.5 bar (80 psi).
3. Remove the regulator lock screw then, using the
pressure regulator key set (A-69), release the lock
nut and adjust the regulating screw. See g. 10.
When required voltage of 23.5 volts is
reached turn the air supply on/off three
times to ensure regulator setting is
stable.
Once the voltage is set and
stable, re-t the regulator
lock nut and lock screw.

Wolf ATEX Turbolite – A-TL44C and A-TL45C
3 8
The 24v 250 watt tungsten halogen bi pin
capsule bulb A-129/A-159, should be handled
with care, the pins are fragile. When the bulb
blows the ATEX Turbolite should be switched off
immediately and removed from service for bulb
replacement.
The bulbholder can be removed by unscrewing
the two securing screws and unscrewing the
wiring contact screws and nuts. The nuts are
accessed from the inside of the generator. On
inspection, check these nuts are torqued to
1.5Nm to ensure a reliable electrical contact and
pressure seal on the insulating bush.
When re-assembling the ATEX Turbolite, ensure
the head is screwed down until it comes to a
stop when the castings contact each other. This
will ensure there is enough compression on the
oodlight head seal or ball glass seal to seal the
pressurised enclosure. Then lock the enclosure
with the lock screw.
Removal/Replacement of the Glass Lens -
Type A-TL45C
The lens ring retains the glass lens. To remove,
unscrew the four fastening screws, using a 6mm
Allen key. The glass lens is mounted inside the
lens seal.
Inspect the lens seal before replacing the lens. If
the seal is damaged it must be replaced.
The fastening screws are high tensile A4
stainless steel specication. IMPORTANT, the
strength of these screws is safety critical, only
use specied spare parts. Incorrect fastening of
these screws can cause:
• The toughened glass lens to shatter
• The lens seal to become damaged
• Weakening of the fastening screws
• Stripping of the threads in the reector head
Inspection and Maintenance
EN IEC 60079-17
1. A damaged ATEX Turbolite should be
withdrawn and repaired in accordance with
these instructions, by trained/qualied
personnel.
2. ATEX Turbolites must be inspected, cleaned
and tested after every 1000 hours of use. Refer
to IEC 60079-17 for guidance on inspection and
maintenance.
3. The use of non-Wolf spare parts and/or
improper tting of spare parts will invalidate
product certication and the manufacturer’s
warranty and may cause an unsafe condition.
If in doubt, contact the Wolf Safety Lamp
Company.
4. Before use in a hazardous dust atmosphere,
lamps must be checked to ensure there is no air
leakage. If a lamp is leaking, check the condition
of all seals and tightness of assembly screws
and threads. Refer to torque settings in g. 6
(page 5-6).
WARNING:
• Pressurised enclosure, inspect lamp in
accordance with these instructions before
operation.
• All maintenance to be carried out in the safe
area.
• Before dismantling the lamp shut off air
supply and wait two minutes.
• Do not cover or obscure light transmitting
parts.
• These lamps are not solidly earthed.
Precautions against the hazards associated
with static electricity should be taken.
• A-TL44C model has a polycarbonate lens,
the end user must ensure suitability of the
atmosphere the lamp will be used in.
Item No. Part No. Spare Part Description
27 A-69 Pair of Pressure Regulating Keys
28 A-1040 Setting and Testing Device
29 A-1045 Remote Exhaust Hose Kit - 36m Exhaust Hose, Hose Tails, Stainless
Steel Exhaust Washer & Silicone Exhaust Washer
30 A-179 Anti-Static Hose 12.5mm Bore 18.3m
31 A-180 Anti-Static Hose 12.5mm Bore 36.6m
32 A-1082 Hose Fitting Kit - Hose Tail, Overthrow Nut & Connecting Piece
33 A-34 Connecting Piece
34 A-146 Key for Nut on Rotor Shaft and Regulator Retainer
35 A-184 Filter / Automatic Drain Valve
36 A-186 High Efciency Filter / Automatic Drain Valve
37 A-190 Filter Stand
38 A-300 1m Folding Tripod Stand - Stainless Steel
Accessories
Head Removal and Bulb/Bulb Holder
Replacement
To gain access to the bulb, release the lock
screw using a 2.5mm Allen key and unscrew
the oodlight head assembly/baylight head
assembly from the generator.
Removal/Replacement of the Ball Glass - Type
A-TL44C
Remove the locking screw and lock ring dome
to access the ball glass. Remove the ball glass
from the seal and t new ball glass in the same
orientation. Refer to g. 7 on page 6.
Inspect the ball glass seal before replacing the
lens. If the seal is damaged it must be replaced.
Regulator Assembly
The regulator adjusts the output voltage of the generator. All the regulator parts are correctly
aligned and secured by the retainer. Do not disturb the regulator unless it ceases to function
correctly. If replacement or cleaning of any parts is necessary, remove the retainer using the forked
end of the A-146 tool. Check the fabric and beaded rim of the diaphragm on the piston assembly
(A-110) for deterioration.
Before re-assembly of the regulator, the lockscrew, lock nut and regulating screw must be
removed from the opposite end of the regulator piston chamber, to release pressure on the
regulator spring.
The regulating screw and lock nut should then be loosely tted just inside the end of the piston
chamber, ready for setting the generator voltage.
Lock Screw
Lock NutPiston Spacer
Regulating Screw
Piston Diaphragm
Piston Spring
Piston Assembly
Air Filter Sieve
Retainer
Air Regulating Plate
g. 8

Wolf ATEX Turbolite – A-TL44C and A-TL45C
7 4
Inspection and replacement of generator
sealed bearings
To remove the rear cover, remove the 3x
fastening screws, using a 5mm Allen key. The
assembled rotor is tted to the rear cover. Do
not prise the rear cover off, attraction of the
magnet will resist removal. Tap the generator
housing with a plastic mallet to aid removal of
the rear cover.
Use tool A-146 (item 34) to hold the rotor shaft
lock collar, while you remove the rotor shaft nut
with a 10mm spanner.
Disassemble the components from the rotor
shaft to get access to the bearing retaining ring
and 3 x pozi-drive bearing retaining ring screws,
which allow the rotor shaft with sealed bearing
to be removed from the rear cover.
Assembly is the reverse of the above; check
correct orientation of all components. Medium
strength thread lock (e.g. Loctite 222) should be
applied to the bearing retaining ring screws and
the outer race of the bottom bearing. Take care
not to contaminate the bearing face with thread
lock.
Sealed bearings must be replaced as a set.
Never re-use the circlip washer and ensure
waved spring washers are tted, as shown in
g. 5.
On inspection and assembly always check the
rotor shaft nut is secure. High strength thread
lock (e.g. Loctite 270) should be used on the
rotor shaft nut.
Before re-tting the rotor assembly to the
generator housing, make sure that no small
ferrous objects have been attracted to the
magnet. When replacing the rotor assembly, the
magnet will be strongly attracted to the stator.
Ensure the sealed bearing locates correctly
into the generator housing; avoid nger traps
between the generator housing and the rear
cover.
For replacement part numbers, refer to spare
parts list on page 7. g. 5
10
34
12
Rotor Assembly
Item No. Part No. Spare Part Description
Parts for A-TL44C & A-TL45C
1A-129 Bulb 24V 250W Tungsten Halogen (6000lm)
2A-159 Bulb 24V 250W Tungsten Halogen, High Output (9000lm)
3 A-TLGEN ATEX Turbolite Generator (for A-TL44C and A-TL45C models)
4 A-1053 Bulbholder
5A-1056 Regulator Service Kit - Piston, Piston Spring, Piston Spacer, Air Regulating
Plate, Air Filter Sieve, Retainer, Regulating Screw, Lock Screw, Locking Nut
6A-33 Air Filter Sieve
7A-110 Piston Assembly
8 A-1058 Air Inlet Kit - Air Inlet Plate (x1), Air Inlet Seal (x1) and Screws (x2)
9 A-1059 Rotor Kit - Includes All Rotor Parts Except Magnet Rotor and Turbine Wheel
10 A-80 Magnet Rotor
11 A-38 Turbine Wheel
12 A-1062 Sealed Bearing (x2), Waved Washer (x2) and Circlip Washer for Rotor Shaft
13 A-1063 Stator Winding and Fixing Screws (x3)
14 A-1064 Exhaust Silencer with Stainless Steel Washer and Silicone Washer
15 A-1065 Contact Assembly - Screw, Nut, Washers, Insulating Bush and Fast On Tab
16 A-1066 Bridle Kit - Bridle, Eyebolt, Carabiner and Fixings
17 LL-1117 Generator Fastening Screw (x1)
18 A-74 Locking Screw
Spare Parts
12
11
9
9
9
Torque 0.5Nm
10mm Spanner
Parts for A-TL44C only
19 A-44H Baylight Head Assembly
20 A-1054 Baylight Seal Kit - Generator Seal, Air Inlet Seals, Stainless Steel Exhaust
Washer, Silicone Exhaust Washer, Ball Glass Seal & Ball Glass Washer
21 A-19 Baylight Ball Glass
Parts for A-TL45C only
22 A-45H Floodlight Head Assembly
23 A-1055 Floodlight Seal Kit - Generator Seal, Air Inlet Seals, Stainless Steel Exhaust
Washer, Silicone Exhaust Washer, Reector Housing Seal and Lens Seal
24 A-1004 Floodlight Glass Lens
25 A-1006 Floodlight Reector
26 A-1010 Reector Housing Fastening Screws
Medium strength thread lock
High strength thread lock

Wolf ATEX Turbolite – A-TL44C and A-TL45C
56
Torque 0.5Nm
Torque 2.5Nm
Torque 2.2Nm
Torque 0.5Nm
Torque
1.5Nm
Torque
2.5Nm
g. 6
g. 7
19
22
20
21
1
2
/
4
13
14
17
24
23
25
23
7
For replacement part numbers, refer to spare parts list on page 7.
20
23
/
20
23
/
5
5
8
32
16
15
15
3
26
20
23
/
33
6
18
Lock Screw
Torque 0.5Nm Max.
18
Torque
2.5Nm
SECTION
21
20
Note orientation of the baylight seal, with larger
internal radius at the top as shown.
Lock Screw
Torque 0.5Nm Max.