Airturbo Instructions - Wolf Safety Lamp Company
Contents
1. Wolf Wolf Safety Lamp Company WOLF AIRTURBO LAMPS Nos A 0444 and A 0445 OPERATION AND MAINTENANCE INSTRUCTIONS A134 A 34 A 30 a 28 A 116 a SSS SSSI Nate 5 7 maim pet NS TIL Goi e aa ra pal 3 NES FTES E A 89 A 90 LD WF a Se A 1315 A 58 A 59 Yas an A 88 A 7 A 87 LEE SENT A 52 NENA IN me E WES EXTERNAL FEATURES MAY CHANGE WITHOUT NOTICE Wolf Airturbo Lamps Nos A 0444 and A 0445 Operation and Maintenance Instructions Introduction The Wolf Airturbos are 55 Watt Tungsten Halogen compressed air operated safety lamps No A 0444 is fitted with a polycarbonate Bay Light head for general illumination the end user must check head material is suitable for the atmosphere the Airturbo will be used in A 0445 has a Reflector Head with either a Matt or Polished Reflector providing wide angle or concentrated levels of lighting They are certified by BASEEFA Ex 78209X to Special Protection SFA 3009 for safe use in Zone 1 and Zone 2 Hazardous Areas with a Temperature Classification T6 This covers safe use in up to T6 range of explosive gases and vapours as listed in Code of Practice BS 5345 Part 1 1989 Quality Assurance Standards to ISO 9000 2000 apply to manufacture assembly and final inspection and testing of all lamp units Operating Instructions The operating pressure of the Wolf Airturbo is between 4 5 and 8 ba2. 0445 To gain access to the Bulb the Reflector Head Assembly A 56a is unlocked by releasing Lockscrew A 74 which allows it to be unscrewed from the Generator Housing Remove together the Metal Washer A 16 Rubber Washer A17a and the Air Inlet Reflector A 130 Fit the Spare Bulb in the Bulbholder A 49 and replace other parts in the reverse order these parts will be clamped in position when the reflector head is screwed back onto the Generator Housing Ensure Lockscrew A 74 is refastened Care should be taken when fitting the Bulb to ensure that the flange of the Air Inlet Reflector does not make contact with the Generator Housing This could only happen with lamps made before June 1971 The date of manufacture is on the Approval plate If with the bulb in place there is contact a new air inlet reflector should be fitted A 0444 Lockscrew Ring Guard A 163 for Ball Glass is removed from the Generator Housing and the Bulb replaced in much the same manner except that Rubber Washer A 17a is not fitted or required in this instance When replacing the Reflector Head Bay Light Head screw down with only sufficient torque to seal the pressurised enclosure The seals are internal by way of A 131 Grooved Rubber Washer for Ball Glass or Rubber Washer A 17 lt for Reflector Head Ensure Metal Washer A 16 is uppermost on the Rubber Washer before re fitting either type of Head In both cases refasten Lockscrew A 74 Replacing Cleaning Glass Dis
3. 183 Portable A C Voltmeter A 183 A 42 Rotor Complete A 42 A 184 _ Filter Automatic Drain Unit 6 Lamps A 184 A 48 Long Screw for Bulbholder A 48 A 186 Ultra High Efficiency Two Stage Filter A 186 A 49 Bulbholder A 49 Automatic Drain Unit 6 Lamps A 51 Contact Plate complete A 51 A 189 Screwed handle Set amp Test Device A 189 A 52 Insulating Bush 2 A 52 A 200 Setting amp Testing Device complete A 200 A 53 Connecting Screw 2 A 53 A 300 Folding Tripod Stand A 300 A 54 Stator Winding A 54 A 55GEN Complete Airturbo Generator A 55GEN A 55K Generator Housing Complete A 55K A 55s Generator Housing only A 55s Reflector Head A 56 Reflector Head Assembly A 56A Matt Reflector A 57M Polished Reflector A 57P Lock Washer for Bridle 2 A 72 Lock Screw for Rfl Hd Guard A 74 Substitute Obsolete OBS Parts Airlamp Wing Nut retaining clip 2 A 86 No 4 Washer for Bridle Bolt No 10 Washer for Connecting Screw 2 A 87 No 10 Bridle Bolt Nut for Connecting Screw 2 A 88 No 20s Stainless Steel Fastening Screws Pressure Regulating Piston only A 89 No 27 Lockscrew for Piston Chamber Rubber Seal for Piston A 90 35s Housing Cover Screw for Bearing Race in A 55s 2 A 94 No 65 Spring Washer for No 20s Air Regulating Plate A 97 Collar for Lockscrew Piston Chamber A 98 Pre December 1986 parts still available for Wolf Airturbo Lamp No A 0445 0445 U M Guard Ring for 10mm Glass Disc Glass Disc 10mm toughened Nylon Lock Pellett Lock Scre
4. electrical output Setting Generator Voltage Output Airturbo Setting and Testing Device A 200 will be required for correct setting of the Generator output adjusted by re setting the Air Regulator The Setting and Testing Device is fitted on the Generator in place of the Head and all other associated parts including the Bulb fastened and sealed with Screwed Handle A 189 The Bulb is fitted and fastened by means of a clip in the Bulbholder on top of the Setting and Testing Device and Voltmeter connections are made to the two terminals Couple up and turn on a CLEAN and DRY supply of compressed air to the Lamp checking first that no air is escaping past the Pressure Regulating Piston by sealing the exposed hole with the thumb an escape will be indicated by an increase in Turbine speed and Voltage reading In such circumstances the Rubber Seal for Piston A 90 should be replaced as above with a smear of grease to assist assembly Using the Pair of Pressure Regulating Keys A 68 screw in Regulating Screw A 29 to increase voltage output or screw out to decrease Voltage output When the Voltage output is steady at between 11 5 and 12 0 Volts turn the air supply off and on several times allowing the Turbine to achieve maximum speed each time and make any minor adjustments if necessary Leave the Lamp running for 15 minutes before making any final adjustments to the regulating screw The setting can now be locked with Lock Nut A 28 using the o
5. c A 0445 THE REFLECTOR HEAD OF THE WOLF AIRTURBO LAMP IS A PRESSURISED ENCLOSURE The lens ring A 24 retains the glass disc A 140 15mm To remove unfasten the four high tensile Stainless Steel Fastening Screws A 18 The Glass Disc is mounted inside the Grooved Rubber Washer A 139 The reflector sits in the reflector head These items can be removed for cleaning replacement The Grooved Rubber Washer in particular should be inspected for any damage as this provides a pressurised seal on both faces of the Reflector Head enclosure When re assembling ensure that this Washer is evenly fitted on both faces of the Glass Disc Place reflector in reflector head before the lens with seal Refastening of this assembly into the Reflector Head must follow normal good practice in fastening down a flanged joint the 4 Screws A 18 should be fastened down opposite and evenly only sufficiently to make an airtight seal INCORRECT FASTENING OF THESE SCREWS CAN CAUSE e The toughened Glass Disc to shatter e The Grooved Rubber seal to become damaged e Weakening of the Fastening Screws e Stripping of the threads in the Reflector Head NOTE Lockwashers are no longer fitted with Fastening Screws A 18 Replacing Cleaning Ball Glass A 0444 After cleaning replacement as necessary the Ball Glass A 19 together with Grooved Rubber Washer for Ball Glass A 131 is fitted in the Generator Housing recess first followed by Metal Washer A 16 then
6. der together with new bearings Underneath the outer race of the Bearing in Housing Cover A 21 is fitted a Waved Spring Washer A 36 This ensures the correct loading of the bearings It is important to check that the Waved Spring Washer is in good condition before fitting a new outer Bearing race The other outer Bearing race is a tight fit in the Generator Housing To replace this Bearing race first remove the Lamp Head and then the Rotor Complete A 42 from the Generator Housing Unscrew the two Nuts for Stator Terminal A 88 and push through the two Connecting Screws A 53 These screws are insulated and sealed by Insulating Bushes A 52 and carry the power from the Stator Winding A 54 If removed it is essential to ensure that the Insulating Bushes are in good condition because as well as providing electrical insulation they also provide a pressure seal between the Reflector Head and the Generator Housing The Contact Plate A 51 can then be extracted and the two Screws for Bearing Race A 94 can be removed so that Forked Tool A 147 can be inserted through the holes and used for tapping out the Bearing Race Clean the bearing recess before fitting a new Bearing Race in position The Bearings and races should be lubricated with a smear of grease When replacing the Housing Cover A 21 spring lift will indicate that the Bearings are properly loaded Magnet The A 39 Magnet has a long life but should be kept clean and free from iron fili
7. ew for Air Inlet Plate 2 A 6 A 116 Lock Screw for Piston Chamber A 116 A 7 Screw for Stator 3 A 7 A 130 Air Inlet Reflector A 130 A 8 Wing Nut 2 A 8 A 131 Grooved Rubber Washer for Ball Glass A 131 A 11 Bridle Bolt 2 A 11 A 133 Connecting Tube A 133 A 13s Bridle with Safety Hook A 13s A 134 Overthrow Nut A 134 A 16 Metal Washer A 16 Grooved Rubber Washer 15mm A 139 Rubber Washer A 17A Glass Disc 15mm toughened A 140 A 18 3 Stainless Steel Fastening Screws A 18 7 A 163 Lockscrew Ring Guard A 19 Ball Glass A 1130 Bulb 12v 55w Tungsten Halogen A 1130 A 21 Housing Cover A 21 Lens Ring A 24 A 26 Air Inlet Plate A 26 A 28 Lock Nut for Regulating Screw A 28 A 29 Regulating Screw A 29 A 68 Pair of Pressure Regulating Keys A 68 A 30 Spring for Piston Gold Passivated A 30 A 146 Key for Nut No A 37 A 146 A 31s Piston Complete A 31s A 147 Forked tool for removing Bearing Race A 147 A 33 Air Filter Sieve A 33 A 170 Hexagon Key for A 18s s A F A 170 A 34 Connecting Piece A 34 A 171 Hexagon Key for A 74 2 5mm A F A 171 Tools and Accessories for use with Wolf Airturbo Lamps Tools A 36 Waved Spring Washer for Bearing 1 A 36 Accessories A 37 Nut for Rotor Shaft A 37 A 178 Lubricant 400 gram tube A 178 A 38 Turbine Wheel A 38 A 179 Antistatic Hose bore 18 3m 60 A 179 A 39 Magnet A 39 A 180 Antistatic Hose bore 36 6m 120 A 180 A 40 Ball Bearing with Race 2 A 40 A 181 Stainless Steel Hose Clips A 181 A 41 Rotor Shaft A 41 A
8. ngs and ferrous objects Magnet style changed Sept 2009 from then on magnet will be marked A 39 The magnet should be a light sliding fit onto the rotor shaft and should never be tapped or hit with a hammer as this can affect the magnetism and may cause sharp pieces to break off Avoid close proximity of any large ferrous objects Air Regulator Assembly All the Air Regulator parts are fastened in position by Connecting Piece A 34 with Air Filter Sieve A 33 and should not be disturbed unless the Regulator ceases to function correctly While ever fastened the Connecting Piece also maintains the alignment of the Air Regulating Plate A 97 Removal of these parts gives access to Pressure Regulating Piston complete A 31s and Spring for Piston A 30 These parts are withdrawn from the front of the piston chamber and should be cleaned and examined for wear and damage and replaced as necessary In particular the lip of Rubber Seal for Piston A 90 should be checked for damage or wear Before re assembly of the Piston parts the Regulating Screw A 29 and Lock Nut A 28 must be removed from the other end of the piston chamber Hexagon Lock Key A 171 will be needed to remove Lockscrew A 116 and Pair of Pressure Regulating Keys A 68 to remove Regulating Screw and Lock Nut The Regulating Screw A 29 and Lock Nut A 28 should then be loosely fitted just inside the end of the piston chamber ready for resetting the pressure regulator and hence the generator
9. r The pressure regulator of the lamp unit compensates for the above range of input pressures as well as fluctuations in airline pressures WARNING DIRT OR MOISTURE FROM UNFILTERED AIR WILL DEPOSIT ON THE INSIDE OF THE GLASS DISC OR BALL GLASS REDUCING LIGHT OUTPUT THE REFLECTOR HEAD AND BALL GLASS OF THE LAMPS ARE PRESSURISED ENCLOSURES DO NOT COVER OR OBSCURE LIGHT TRANSMITTING PARTS POLYCARBONATE BAY LIGHT CHECK ATMOSPHERE IN EX AREA Maintenance of Wolf Airturbos The maintenance and repair of Wolf Airturbo lamps should only be undertaken by trained or qualified electrical fitters or engineers Lamps should be cleaned and tested every three months if in regular use and every six months where use is less frequent As a guide reference may be made to BSEN 60079 14 1997 IEC 60079 14 1996 Electrical Apparatus for Explosive Gas Atmospheres Electrical Installations in Hazardous Areas BSEN 60079 17 1997 IEC 60079 17 1996 Inspection and Maintenance of Electrical Installations in Hazardous Areas The use of incorrect spare parts and the improper fitting of spare parts will invalidate certification and the Manufacturer s Guarantee Full details of maintenance and repair procedures follow If in doubt contact the Company Bulb Changing The 12 Volt 55 Watt Tungsten Halogen Bulb should be handled with care if it becomes misted or dirty it should be cleaned with a soft cloth moistened with methylated spirit A
10. the Lockscrew Ring Guard A 163 is screwed firmly down and locked as previously described Lubrication The magneto type Bearings require a medium grade non emulsifying grease which should be applied after 1000 hours running time Grease nipples are no longer fitted to the Generator Housing and Cover as this encouraged over greasing Access to the Bearings requires removing just the three Fastening Screws A 18 in the Housing Cover A 21 Should the Housing Cover resist removal then the edge of the rim should be tapped with a mallet at several points to free the joint The Rotor Complete A 42 can then be lifted out of the open Generator Housing This may require either a pair of pliers or the aid of Key A 146 on Nut for Rotor Shaft A smear of grease can then be applied to the caged Bearings on each end of the Rotor Shaft and in the races situated in the Generator Housing and Housing Cover respectively Before replacing the Rotor Assembly make sure that no small ferrous objects have been attracted to the Magnet Care must be taken when replacing the Assembly to avoid fingers becoming trapped between the Turbine Wheel and the Generator Housing as the Magnet is attracted to the Stator Replacing Bearings Remove Nut for Rotor Shaft A 37 on the Rotor Assembly Washer A 101 first Bearing A 40 Turbine Wheel A 38 Magnet A 39 and finally second Bearing A 40 from the Rotor Shaft A 41 These parts should be cleaned and replaced in reverse or
11. uter sleeve of the Keys and finally replace Lockscrew for Piston Chamber A 116 together with Collar A 98 to secure the setting Use of Wolf Airturbo in Hazardous Areas The introduction details the Hazardous Area Zones of Use and the Temperature Classification of the Airturbo but users are advised to consult BSEN 60079 14 1997 IEC 60079 14 1996 Electrical Apparatus for Explosive Gas Atmospheres Electrical Installations in Hazardous Areas before operating in a Hazardous Area Conditions of Certification are that clean dry compressed air must be used to power the lamps through anti static air hose of resistances between connection 10 ohms maximum and 10 ohms minimum to NCB Specification P182 or BS 2050 These lamps are not solidly earthed and when used in Tankers the precautions against the hazards of static electricity in cargo tanks as set out in the International Chamber of Shipping Tanker Safety Act Petroleum as amended or The Oil Tanker and Terminal Safety Guide 1977 edition should be observed Major changes in design are permitted as Variations of Approvals but may otherwise be made without prior notice Wolf Airturbo Lamps Nos A 0444 and A 0445 Parts List Type A 0444 Type A 0445 Type A 0444 Type A 0445 Part No Description Part No Part No Description Part No A 2 Contact Plunger A 2 A 101 Washer for Rotor Shaft Nut A 101 A 3 Screw for Contact Plunger A 3 A 102 Rotor Spacer A 102 A 6 Scr
12. w with No 75 Grease Nipple Grooved Rubber Washer 10mm WOLF SAFETY LAMP COMPANY Saxon Road Works Sheffield S8 OYA England Tel 44 114 255 1051 Fax 44 114 255 7988 C Wolf 2 E mail info wolf safety co uk Website www wolf safety co uk ISO 9001 Wolf Safety Lamp Company A 91 Issue 6 MMD 2 12 2 K E
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