Flameproof LED Headlight & WorkLight for Underground Mine Vehicles

1. ROOBUCK
“BUCKLITE”
Flameproof LED Headlight
& WorkLight for
Underground Mine Vehicles

2. ROOBUCK COMPANY AT A GLANCE

3. ROOBUCK | BUCKLITE > RBLA1
• Roobuck announces the release of the “BUCKLITE” (TRUCK LIGHT). A “State of the
art" LED headlight/worklight, specifically designed for Underground Coal Mines
and other potentially explosive environments such as Oil & Gas and Dust
applications.
• The BUCKLITE is a radically different light specifically designed to replace the
dangerously hot Halogen Lights currently used globally in Underground Coal
mining; and is currently under a MSHA approval process.

4. ROOBUCK | BUCKLITE > RBLA1
• The BUCKLITE has a brass enclosure and a wide range of power inputs 1235Volts
DC in flameproof. The Ex Certification by TestSafe Australia will satisfy both IECEX
and MSHA requirements, allowing immediate adoption by the global
Underground Coal Mining Industry.
• The BUCKLITE is designed for the most rigorous mining environments. Roobuck
applied its expertise in LED light mining equipment and explosion-proof
technologies to create this headlight.

5. CONSTRUCTION DESIGN PRINCIPLES
The BUCKLITE is a heavy-duty, flameproof, bronze-
encased, highly efficient and enhanced LED
headlight that will transform vehicle, machine, and
operational lighting. It is purpose designed to
withstand the most demanding harsh underground
coal mining environments.
It features a heavy duty brass enclosure, IP66 ingress
protection, advanced temperature control and high
light output with 24 high efficient CREE LED lights. A
thick Pyrex glass in a high Impact resistance is
permanently assembled.
The internal temperature is constantly monitored by
temperature sensors and the power will be reduced
whenever the temperature exceeds the specified
level and therefore the room temperature of the
enclosure is reliably maintained.

6. CONSTRUCTION DESIGN PRINCIPLES Contd.
The Light uses 12 LEDs are in a forward direction
and 12 LEDs are in dim structure pointing toward
the ground to avoid glare to incoming personnel.
The light is suitable for all types of underground
Mines.
LEDs have a long lifetime plus an encapsulated
structure so they never need any service e.g. bulb
replacement. A warm white colour makes it close to
natural light in a high colour rendering index;
although other white light indexes can be selected.
The low energy draw of the CREE LEDs, together
with constant monitoring by temperature sensors
have made this possible. Power is reduced whenever
temperatures exceed specified levels, so the low
temperature of the enclosure is strictly maintained.

7. EXPLODED VIEW

8. Features & Benefits
The Bucklite (Truck Light) is a heavy – duty flame proof bronze -
encased, highly efficient and enhanced LED headlight that will
transform vehicle, machine, and operational lighting; having been
designed to withstand the most demanding, harsh underground coal
and hardrock mining environments.
The low energy draw of the CREE LEDs together with constant
monitoring by temperature sensors have made this possible. Power is
reduced whenever temperatures exceed specified levels, so the low
temperature of the enclosure is strictly maintained. Group features in
logical categories, using one slide per category.

9. Construction
A 10 kg Cast LG2 Bronze
Housing with IP66 ingress
protection provides a robust
outercasing for the Bucklite.
A 12.7 mm thick x80 mm
diameter clear Lexan
polycarbonate disc is silicone
sealed in to front position.
Lens module with 24 crystal
lens reflectors amplifies and
directs 24 white LEDs in the
forward direction, and a
further12 red LEDs, without
lens reflectors, provide
redtaillights when operating
in reverse direction.
Sealed front and rear with
Viton O-rings for water ingress
protection.
Powder-coated mild steel
mounting bracket,designed to
bend and absorb most heavy
impact blows.
Removable rear cap ensures
clearly visible check and easy
Ex-d cable connection.
Two Ex-d cable glands allows
a daisy chain configuration.

10. OPERATION
There is two operating modes: 1. HeadlightMode 2. Tail-lightMode.
Different LEDs are powered up in two modes. Tail-light Mode is designed for reversing and
the LEDs are in low power and red in colour. Connecting the power cable as marked on the
terminal sets the Bucklite in the Headlight Mode. Simply reversing the polarity of the power
can set it into Tail-lightMode. Two mode switching can be achieved by wiring in the vehicle.

11. MAINTENANCE
• Regular inspections are critical for the safe use of the Bucklite.
• The inspection schedule is set out by standard AS/NZS2290. 1–Table1in 3.2.3 (Mobileequipment). Corresponding local standards are highly
recommended for users outside Australia.
• Daily External Inspections should check:
1.any damage on the enclosure, lens, cable gland and cable, mounting
2.correct operation and sufficient illumination and;
3.correct operation of the switch for mode switching
• Six monthly Internal Inspections can be conducted after opening the Rear Cap, as instructedin the installation. Check the conditions of terminal and
cable connection, any water or duct ingress and any burning mark.
• Long term overhauls should include complete conformity verifications. Overhauls and repairing can only be conducted by a registered workshop
accredited by the IECEx Scheme.
• The Design Risk Assessment and Onsite Risk Assessment by users can be used as an important reference.

12. THE CENTRAL LIGHT UNIT (CLU)
• The CLU (Central Light Unit) is the significant invention within this product. All functions are integrated into this
single part. The main frame is an Aluminium Cylinder. The circuity is encapsulated into the Aluminium Cylinder. The
Aluminium-core LED circuit board is situated on the top of the tube.
• The terminal for cable connection is mounted on the back. The CLU can be taken off from the front of the BUCKLITE
by removing the cover. The replaceable feature of the CLU makes service, turnaround time and upgrade easier; and
also significantly increases the lifetime of the product.

13. Operating Specifications
Voltage Input: 12-35 VDC
Power Consumption: 30 Watts
Luminous Flux: > 3,000 Lm
Colour Temperature: 2,600K - 4,300K
LED Life-time: > 50,000 Hours!
Enclosure Material: LG2 Bronze
Weight: 9 Kgs
Ingress Protection: IP66
Ambient Temperature: -20oC to +40oC

14. INSTALLATION STEPS
a) Remove installed headlight/s from
the machine, including mounting
bracket, in accordance with the
nominated procedure, and lay aside in
a safe work area.
b) Attach the Bucklite bracket onto
the machine and tension down.
c) Taking the Bucklite, remove the
Rear Cap by undoing the 2 x M10 Cap
screws.
d) Connect the 2 wires of a cable
leading into the rear of the BUCKLITE,
and then connect another cable
leading to the next headlamp for a
daisy chain connection. (Only if it is a
daisy chain connection).
e) If bonding and/or an earth
connection is required; there is an
earth/bonding screw hole in M4x8mm
on back of the Rear Cap besides the
plate. If earth or/and boding
connection is required, fit with zinc
plated star washer and nickel plated
brass screw.
f) Mount the Bucklite onto the new
bracket, mount the Rear cap, set
correct angle and tighten down. g)
Test the operation in both Headlight
mode and Tail-Light mode.

15. ROOBUCK CONTACT
DETAILS
HEAD OFFICE
ADDRESS: 6/20 WEST ST, BROOKVALE, NSW, 2100,
AUSTRALIA
TEL: (02) 9938 1550 FAX: (02) 9939 8532
EMAIL: INFO@ROOBUCK.COM.AU
WEB: WWW.ROOBUCK.COM.AU