MSA ML-3 Manuale utente

cap lamp system

instructions

PITTSBURGH, PENNSYLVANIA,U.S.A.15230

Manufactured by

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 RESPON-

SIBILITY 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.

WARNING

The warranties made by MSA with respect to the product are voided if the

product is not installed, used, and serviced in accordance with the instruc-

tions in this manual. We encourage our customers to write or call for a

demonstration of this equipment prior to use or for any additional informa-

tion relative to use or repairs. Call 1-800-MSA-2222 during regular working

hours, or 1-800-MSA-5555 after working hours or during emergencies.

TAL 991 (L) Rev. 0 © MSA 1999 Prnt. Spec. 10000005389(S) 10011346

Doc. 10000004394

ML-3

1011346 9/7/99 12:40 PM Page 3

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.

1. An adequate mine lighting pro-

gram must include assessment

of mine lighting requirements,

integration of appropriate MSHA

regulation, selection of proper

equipment, and instruction and

training in use, inspection and

maintenance of equipment. (See

MSHA regulations, Title 30 CFR,

Part 19).

2. The cap lamp system will per-

form as designed only if used

and maintained according to the

manufacturer’s instructions.

Supervisors and users must

read and understand these

instructions before trying to use

or service this product. We

encourage our customers to

write or call their MSA distribu-

tor or call MSA Customer

Service for information on this

product before using it. To reach

the nearest MSA office, call 1-

800-MSA-2222 during normal

business hours, or 1-800-MSA-

5555 after hours or during emer-

gencies.

3. This cap lamp may be used only

after proper instructions and

training of its use.

4. Do not alter, modify, or substi-

tute any components without

the approval of MSA. Such alter-

ations will void the MSHA

approval for use in a hazardous

atmosphere.

5. Inspect the cap lamp and bat-

tery after each use and maintain

them according to MSA’s

instructions. Repairs must be

made by properly trained per-

sonnel only.

6. Follow MSA’s instructions for

first time and routine cap lamp

use. The battery must not be left

“on charge” indefinitely, (see

Storing Idle Batteries section).

Doing so may cause internal

gases to vent, which may lead

to accumulation of combustible

gases in the lamp room, dam-

age to the battery, or reduced

service life.

Failure to follow the above can

result in serious personal injury or

death.

GENERAL DESCRIPTION

The ML-3 Cap Lamp System consists

of cap mounted headpiece powered

by a Luminator®(lead-acid) battery.

The basis of the headpiece in which

some of the internal connections are

integral. A selector switch is incorpo-

rated, which can switch on either the

large main bulb or the small secondary

bulb. The main bulb is held in the

reflector in a focussed position by a

screwed boss form which a lead con-

nects to one of the cable termination

points. The small bulb holder is posi-

tioned at the top of the headpiece,

being connected internally to the cable

termination. The reflector fits over the

small bulb and has a rubber gasket

around the rim to seal against the

headpiece lens.

The battery covers are made of metal

or plastic. When the metal cover is

positioned on the top of the battery, it

2TAL 997 (L) Rev. 0 - 100113469

WARNING

TABLE OF CONTENTS

IMPORTANT .......................................................................2

GENERAL DESCRIPTION..................................................2

Remote Power Connections...........................................3

PREPARATION FOR USE...................................................3

Battery Charging.............................................................3

Storage of Batteries........................................................3

Filling Battery..................................................................3

Using the Remote Power Connection............................3

CAP LAMP SYSTEM..........................................................4

Replacing Battery (Metal Cover).....................................4

Removing Cable Wires from Battery..............................4

Replacing Battery Cover (Metal).....................................4

Replacing Battery (Plastic Cover)...................................4

USING ML-3 CAP LAMP SYSTEM....................................5

Repairing the Headpiece................................................5

REPLACING BULBS ..........................................................6

Removing the Bezel Ring ...............................................6

Replacing Main Bulb.......................................................6

Replacing Small Bulb .....................................................6

Reassembling the Bezel Ring.........................................6

Replacing the Reflector ..................................................6

TROUBLESHOOTING ........................................................7

ML-3 Cap Lamp System

1011346 9/7/99 11:43 AM Page 2

Preparing for Use

is further secured by a lock device

which fits at the end opposite to the

angle clamp. The lock device fits over

the end of the cover, and is secured in

position by a slotted screw. After the

screw is tightened, it can be filled with

wax to detect any unauthorized per-

son tampering with the battery.

Depending on the Luminator battery

used, the cap lamp is designed to

operate at full brilliance for a minimum

of an 8-10 hour shift, with reserve

energy if needed. At the end of each

shift the battery is recharged in a sin-

gle- or multiple-station charging unit.

The Luminator Power Cell (13 AH) is

designed to operate at cycle routines

of 8-10 hours discharge/16-14 hour

recharge 5 days/week (max). If the

routines are increased, the Luminator

Power Cell Plus (16 AH) is recom-

mended. Battery charging connection

is made through the headpiece. Each

battery has a transparent case with

molded-in electrolyte level indicators

below the filling ports.

Remote Power Connections

(only available with plastic cover)

The Remote Power Connection allows

the Cap Lamp to be used as a power

source for an external remote device

while still operating as a light source.

MSHA regulation permits this configu-

ration as long as the external remote

device current requirement does not

exceed 275 milliamps.

If using the Remote with the ML-3

Cap Lamp, the Luminator Power Cell

Plus 16 AH battery is recommended,

due to higher battery demands.

However, the Luminator Power Cell 13

AH has been approved.

PREPARING THE ML-3 CAP LAMP

FOR FIRST TIME USE

Battery Charging

Every battery must be charged before

it is used for the first time.

1. Allow the battery to remain on

charge for 24 hours.

2. Top off each cell with distilled water

if necessary (see Filling Battery).

Never fill over top of fill line.

Note

Batteries which do not perform satis-

factorily, should be removed from

service and cycled - charged 16

hours, discharged 8 hours. Repeat

several times until battery responds. If

battery does not respond after three

or four cycles, it should be replaced.

3. After weekly shifts, the battery

should be placed on the charger

following the instructions included

with the charger, and left to charge

the remainder of the weekend.

4. If cap lamp needs cleaning, use a

mild detergent and wipe. Do not

submerge in water.

Storage of Batteries

All stored batteries with acid should

be boost charged for 24 hours every 3

months, and immediately before being

placed into regular service.

Recommended storage temperatures

32˚F to 80˚F.

Filling Battery

The electrolyte level should be main-

tained between the two lines below

the filling and venting hole i.e. slightly

above the top of the battery plate.

Normally topping up should not be

necessary more often than once every

4-6 weeks, and should always be car-

ried out when the battery is fully

charged. Only distilled or deionized

water should be used in topping off.

The electrolyte level of all batteries

should be checked once each

week, and after battery is charged.

Water only when battery is fully

charged. If the battery is over-

topped, there is a possibility that

electrolyte may leak out under cer-

tain conditions.

1. Fill the plastic bottle of the MSA

Filling Device (P/N 69422 or

469773) with distilled water only,

and place it at a convenient loca-

tion close to the batteries to be

watered.

2. Insert the nozzle or needle of the

Filling Tube into the small hole pro-

vided in the battery window.

Depending on the style of filling

device, squeeze the bottle or the

bottle handle.

3. Fill until the electrolyte level is

centered between the two scribed

lines below the cell window. The

battery may have to be tilted back

slightly to allow the water to flow.

4. Repeat this procedure in adjacent

battery cell.

The Electrolyte is corrosive and can

cause burns. Take proper precau-

tions to avoid skin and eye contact.

Contact MSA for battery Materials

Safety Data Sheet (MSDS). Phone

1-800-MSA-2222.

USING THE REMOTE POWER

CONNECTION

Note

If using the Remote Power Connec-

tions with the ML-3 Cap Lamp, the

Luminator Power Cell Plus 16 AH bat-

tery is recommended, due to higher

battery demands. However, the

Luminator Power Cell 13 AH has been

approved.

1. To access the battery power for

an external remote device, remove

the connector cover located on

the top of the battery. Keep the

cover for later use.

2. Slide the remote power device’s

connector onto the connector on

top of the battery until it stops.

3TAL 997 (L) Rev. 0 - 100113469

WARNING

CAUTION

Fill

Lines

1011346 9/7/99 11:43 AM Page 3

Cap Lamp System

3. At end of shift, or when finished

using the external device, remove

the external connection from the

battery top and reinstall the cover.

Place the battery on charge as

described in the Routine Battery

Maintenance section.

4. Refer to Illustrated Parts List for

replacement components.

CAP LAMP SYSTEM

Replacing Battery (Metal Cover)

1. To remove battery cover, remove

the wax seal (if applicable) from

the lock screw hole.

2. Remove locking clamp hex screws

with allen key.

3. Remove locking clamp.

4. Lift up locking clamp end of cover

and slide cover back and off battery.

Removing Cable Wires from Battery

1. Loosen cable clamp screws from

each terminal of battery. (Do not

lose the cable clamp screws.)

2. Lift each cablewire (lead) from bat-

tery terminal.

Replacing Battery Cover (Metal)

1. Attach cable wire (leads) to battery.

2. Connect brown conductor to posi-

tive battery pole.

3. Connect blue conductor to nega-

tive battery pole to ensure correct

polarity.

4. Tighten cable clamp screws with a

flat blade screwdriver. (Do not

overtighten.)

5. Turn battery so the vent holes are

facing you.

6. Place the battery cover end with

the rim to the left of the battery

vent holes.

Note

Ensure that the cable leads lie proper-

ly on the battery top without being

trapped or pinched.

7. Press down on the battery cover.

8. Place the lock clamp and screw

over the battery cover, with the

tab on top of the battery cover.

Note

The battery cover should be tested

immediately after reassembly on to the

battery, and at prescribed intervals, to

determine that there is no electrical

leakage beneath them. This is best

done with a 0 to 6 voltmeter (200 ohms

per volt). The test can be carried out on

the frame with the charge switched on,

by putting the voltmeter positive lead to

the positive spring contact on the

charging frame, and the voltmeter neg-

ative lead to the battery cover. This will

reveal a ‘negative’ leakage to the bat-

tery cover. Reversing the leads, and

putting the voltmeter negative on to the

charging frame negative key, will reveal

any ‘positive’ leakage. If either of these

faults are found, the cover should be

removed and the fault rectified.

9. Tighten the hex screw of lock-

clamp, add wax seal if applicable.

(do not overtighten).

Replacing Battery (Plastic Cover)

1. Remove the battery cover.

a. Use a 5/16” allen wrench to

remove the screws from the

cover clamps. Remove the

clamps from the battery case.

b. Lift the battery cover off the

battery. Each end will have an

adapter clip behind the cover

clamp. Keep these for further

use.

c. Loosen cable clamp screws

from each terminal of battery.

(Do not lose the cable clamp

screws.)

d. Lift each cable wire (lead) from

battery terminal.

Installing New Battery

1. Connect red conductor to positive

battery pole and black conductor

TAL 997 (L) Rev. 0 - 100113469

1011346 9/7/99 11:43 AM Page 4

ML-3 Repair

to negative battery pole to insure

correct polarity.

2. Tighten cable clamp screws with a

flat blade screwdriver. (Do not

overtighten.)

Reinstalling the Battery Cover

1. Check both ends of the battery for

the adapter clips.

Replace the battery cover. It must

fit squarely on top of the battery.

Slide a cover clamp on each end

of the battery and cover.

Note

The mounting hole in each clamp is

slightly off-center. Install the clamp so

that the hole is below center.

2. Install the two screws and tighten,

using the 5/64” allen wrench. (Do

not overtighten.)

USING ML-3 CAP LAMP SYSTEM

The ML-3 headpiece is made up of

the lamp-housing, which contains the

following parts:

— Bezel (ring)

— Lens

— Gasket

— Reflector

— Main Bulb

— Secondary Bulb

The on-off switch knob is located on

the headpiece. To operate the lamp:

1. Turn the switch knob clockwise to

main bulb or counterclockwise to

secondary bulb.

2. After use, turn the switch knob

until both bulbs are off.

Repairing the Headpiece

Only the small insulated screwdriver

should be used, as this allows the

screws to be secured tightly enough

without fear of a short circuit or other

damage. The switch should be placed

in the off position. If a bulb is being

replaced it should be tested in the

headpiece before final reassembly to

verify that it will light. When reassem-

bling the headpiece, it would be

ensured that the gasket is correctly fit-

ted around the reflector. The location of

the reflector is by two projections which

fit either side of the pin that rests

against the envelope of the pilot bulb.

The bezel ring should be screwed down

firmly and the lock pin placed so that it

fits into one of the recesses of the bezel

ring and firmly screwed tight. The coun-

tersunk hole in the locking boss can be

filled with the special sealing wax.

It is essential that all contacts in

the headpiece are tight, so that no

resistance is developed which

might increase the time necessary

to obtain an efficient charge or

might reduce the light output of the

lamp. In order to obtain the maxi-

mum light possible, the outside of

the lens glass should be cleaned

thoroughly.

The headpiece may be supplied

with a 1.0A main bulb, or with a

0.75A. Both bulbs are interchange-

able.

REPLACING BULBS (MAIN AND

SECONDARY PILOT BULB)

Removing the Bezel Ring

1. Remove wax seal (if applicable)

from lock screw.

2. Unscrew and back out lock screw

by using special allen key.

3. Unscrew and remove bezel ring

from headpiece housing.

4. Remove glass (lens) and reflector

with sealing channel from head-

piece housing.

Note

Inspect all parts for cracks or other

damage.

Replacing the Main Bulb

1. Lift reflector out of housing, mak-

ing sure not to break the bushing

connection.

5TAL 997 (L) Rev. 0 - 100113469

WARNING

1011346 9/7/99 11:43 AM Page 5

ML-3 Repair

2. Unscrew reflector from bushing by

holding bushing and unscrewing

reflector.

3. Remove main bulb.

4. Place the new main bulb through

the reflector.

5. Hold the bushing and screw the

reflector onto the bushing. (Do not

overtighten.)

Replacing Secondary Bulb

1. Remove bezel ring (use Remove

Bezel Ring procedures).

2. Remove reflector from headpiece

housing.

3. Unscrew secondary bulb from

side socket assembly of head-

piece housing.

4. Thread the new secondary bulb

into the socket assembly. (Do not

overtighten.)

5. Place the hole in the reflector over

the secondary bulb.

6. Reassemble the glass (lens) and

bezel to the headpiece assembly.

Reassembling the Bezel Ring

When the lens is in position over the

reflector, bezel ring is screwed firmly

in place. The bezel ring is locked in

position by a hex headed lock screw

that fits into a countersunk hole and

then enters one of the slots in the

bezel ring. The countersunk hole

enclosing the lock pin can be filled

with wax if desired.

Replacing the Reflector

1. Remove the bezel ring and lens.

2. Remove the reflector from main

bulb bushing.

3. Remove gasket around reflector.

4. Place the gasket around the new

reflector. Ensure the gasket is in

place all the way around reflector.

5. Thread the reflector onto the

bushing.

6. Reassemble the lens and bezel

ring (see Reassembling of Bezel

Ring).

TAL 997 (L) Rev. 0 - 100113469

1011346 9/7/99 11:44 AM Page 6

1 Lamp Housing..................................

2 Bezel Ring ........................10014213

3 Glass Lens........................10014214

21 Sealing Channel................10014216

22 Reflector...........................10014210

26 Small Bulb Socket

31 Main Bulb 4V 1.0A ...........10014215

Halogen ............................................

31 Main Bulb 4V 0.75A .........10014212

Halogen (not shown)

32 Small Bulb 4V 0.46A.........10014217

33 Prefocus Reflector

Bush & Connection...........10014222

124 Cable ................................10014218

27 Large Bulb/Switch Connection

Assembly

28 Small Bulb/Switch Connection

Assembly

29 Switch Connection

30 3/16” B HD Screw

16 Positive Contact Sealing Washer

5 Switch Knob

6 Switch Knob Sealing Washer

7 Switch Blade

8 Switch Blade Cowl

9 Grub Screw

16 Positive Contact Sealing Washer

19 Charging Contact Screw

24 Large Bulb Socket Block

25 Large Bulb Socket Screw

14 Lock Spring

15 Lock Barrel

17 Lock Contact

18 Lock Contact Screw

23 Lock Contact Sealing Washer

10 Cap Clip

11 Cap Clip Screw

12 Cap Clip Nut

13 Spring Washer Steel

131 Battery Cover Assembly (Metal)

132 Cable Gland

135 Lock Clamp & Bush Assembly

137 Battery Lock Screw

138 Insulating Pad PVC

139 Battery Top Gasket

140 Blank Number Check

141 Flat Head Rivet

142 Cable Lock

122 Allen Key for Lock Pin

155 Allen Key for Battery Cover Lock

130 Key for Cable Gland

Screwdriver (not shown)

Headpiece Contact Kit 10014519

Switch Knob Kit 10014515

Charging Screw Kit 10014517

Lock Contact Kit 10014516

Cap Clip Kit 10014518

Battery Cover Kit (Metal) 10014220

Tool Kit 10014219

Item List

TAL 997 (L) Rev. 0 - 100113469

ML-3 Diagram

15 14

1011

182317122

130

13 12

16 19

138

124

132

135

141 131 137

140 155

139

142

Note: Only certain replacement items above may be purchased individually. All others, as

noted, must be purchased in kit form.

1011346 9/7/99 2:05 PM Page 5

Troubleshooting

PROBLEM CAUSE

Bulb glows dimly, flickers or fails 1. Low battery capacity

a. Observe the electrolyte level in the cell windows and make certain level is

between the two scribed lines on the cell windows.

b. Continuous use of battery that has not been fully charged will cause it to

lose its capacity. This may be corrected by cycling the battery several times

(discharge 8 hours and recharge 16 hours). Repeat this procedure 3 times. If

battery does not respond, replace with a new one.

c. Battery not charged.

2. Loose connections

a. Gently wiggle or pry each connection on top of the battery to make sure it

is tight and working properly.

b. Check the cables for broken conductors by twisting or pulling it at various

points along its length.

c. Check the headpiece terminals and the electrical connections inside the

headpiece in the same manner as those on the battery.

d. Make sure the bulb is secure and making good contact.

e. If the light flickers or dims when any of the preceding items are being

checked, that item should be repaired or replaced.

f. If battery appears warm on charge, this is normal and is not necessarily an

indication that anything is wrong with the battery.

3. Electrolyte Level

a. Check at least once each week to see that the electrolyte level is between

the two scribed lines on the cell window.

Battery not holding a charge a. Make sure charger output is correct.

during shift b. Check electrolyte level after charge.

c. Make sure connections between headpiece and battery are good; charging

rack connections are good.

d. Make sure stored batteries are boost charged before placing into service.

Battery Capacity: a. 13 AH battery recommended for 8-10 hour discharge/16-14 hour

Loses charge during weekly use charge, 5 days a week. Use the 16 AH Luminator battery for greater cycle

routines.

b. Check charger.

c. Check battery connections.

ML-3 Repair

9TAL 997 (L) Rev. 0 - 100113469

1011346 9/7/99 11:44 AM Page 9

The Following Assemblies have Battery with Acid and 13 Amps

Complete Cap Lamp Headpiece and Cover

Assembly Number Assembly Main Bulb Amp Battery Cover

10010590 10010624 1.0 Stainless Steel

10010592 10010625 .75 Stainless Steel

10010594 10010626 1.0 Plastic

10010596 10010627 .75 Plastic

10010598 10010628 1.0 Plastic w/Remote

10010610 10010629 .75 Plastic w/Remote

The Following Assemblies have Battery with Acid and 16 Amps

10010612 10010624 1.0 Stainless Steel

10010614 10010625 .75 Stainless Steel

10010616 10010626 1.0 Plastic

10010618 10010627 .75 Plastic

10010620 10010628 1.0 Plastic w/Remote

10010622 10010629 .75 Plastic w/Remote

1011346 9/7/99 11:44 AM Page 10

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