NIGHTSTICK XPR-5561GC Intrinsically Safe Rechargeable ATEX Cap Lamp Instruction Manual

: June 6, 2024
: NIGHTSTICK

Table of Contents

THE XPR-5561GC IS APPROVED FOR USE
WARNINGS – INTRINSICALLY SAFE
SPECIAL INSTRUCTIONS FOR INTRINSIC SAFETY
CAUTION
CHARGING THE LIGHT
OPERATION
WARRANTY
Documents / Resources
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)

Instruction Manual
XPR-5561GC

THE XPR-5561GC IS APPROVED FOR USE

Bayco Products, Inc.
640 S. Sanden Blvd., Wylie, TX 75098
Model XPR-5561 Permissible Cap Lamp Assembly

APPROVAL No. 19-A160003-1
TESTED FOR INTRINSIC SAFETY IN METHANE-AIR MIXTURES ONLY
WARNINGS:

Only to be charged on the surface, or underground in accordance with the applicable regulations pertaining to battery-charging stations (reference 30 CFR 75.340) with a Bayco Products, Inc. Model 5560-CHGR2.
Do not open in areas where permissibility is required.

Ex ia FLASHLIGHT FOR USE IN HAZARDOUS LOCATIONS UL listed for use with Bayco Li-ion Battery Pack 5560-BATT NIGHTSTICK XPR-5561GC Intrinsically Safe
Rechargeable ATEX Cap Lamp - FIGURE 1

WARNING: Do not charge the battery in a hazardous location
WARNING: Do not replace the battery when an explosive atmosphere is present

WARNINGS – INTRINSICALLY SAFE

Warning: To prevent ignition of a hazardous atmosphere, the XPR-5561GC must only be charged in an area known to be non-hazardous.
Warning: Use only the approved Nightstick 5560-BATT Lithium-ion rechargeable battery pack.
Warning: To prevent ignition of a hazardous atmosphere, do not open the battery compartment or attempt to exchange the battery pack while in the hazardous environment. This task must ONLY be performed in an area known to be non-hazardous.
Warning: Open the battery compartment on the XPR-5561GC and replace the approved Nightstick 5560-BATT Lithium-ion rechargeable battery pack in fresh air only. To maintain IP rating, torque battery compartment screws to 3.5 in-lb.
Warning: replacement of the Lithium-ion rechargeable battery pack must be performed by a qualified technician only.
Warning: Substitution of components may impair intrinsic safety.

SPECIAL INSTRUCTIONS FOR INTRINSIC SAFETY

For personal safety, always confirm the rating of any known hazardous or potentially hazardous location where the XPR-5561GC is to be used.

CAUTION

Rechargeable Lithium-ion batteries must be used and charged properly. Improper use can result in serious injury, fire, or death.
Do not leave the battery in direct sunlight or use or store the battery inside cars in hot weather.
Do not expose the battery to water or saltwater, or allow the battery to get wet.
Do not store the battery with metallic objects that may cause a short circuit.
Immediately discontinue use of the battery if the battery emits an unusual smell, feels hot, changes color, changes shape or appears abnormal in any way.
Keep out of the reach of children.

CHARGING THE LIGHT

CHARGER INPUT: 12 VDC Max
WARNING: Use only the supplied 5560-CHGR2 Charger & approved Nightstick Lithium-ion Rechargeable Battery Pack.

The time required to charge the 5561 is conditional on the remaining charge left in the Lithium-ion Rechargeable Battery Pack at the time of charging. The maximum charge time required is approximately 6 hours.
Fully charge the 5561 before the first use, or if the 5561 has been unused for several months.
When the 5561 is properly seated in the charger, the LED Charge Indicator light will turn solid RED indicating that the Lithium-ion Rechargeable Battery Pack is charging. The Lithium-ion Rechargeable Battery Pack is fully charged when the LED Charge Indicator light turns GREEN.
The Lithium-ion Rechargeable Battery Pack does not have any Recharge Memory Effect; therefore placing the 5561 in the charger prior to full depletion of the battery does not adversely affect the battery life. The 5561 can be kept in the charger indefinitely without any negative impact on the battery or the battery life.

OPERATION

The XPR-5561GC is controlled by 2 Switches and has 6 separate lighting modes:

High-brightness Spotlight
Low-brightness Spotlight
Spotlight Beacon
High-brightness Floodlight
Survival-mode Floodlight
Dual-Light (both the Spotlight and Floodlight on at the same time)

Spotlight Modes
To activate the spotlight, press and release the spotlight switch. The default mode will be low-brightness. Press the spotlight switch a second time to activate the high-brightness mode. To activate the spotlight beacon press and hold the spotlight button until the beacon turns on. Press the spotlight switch a third time to turn the light off.

Floodlight Modes
To activate the floodlight, press and release the floodlight switch. The default mode will be high-brightness. To select the survival mode, press the floodlight switch a second time. Press the floodlight switch a third time to turn the light off.

Dual-Light Mode
Dual-Light mode allows the user to turn on both the spotlight and the floodlight at the same time. The dual-Light mode can be activated by simply pressing the spotlight switch and then the floodlight switch. If the 5561 already has the spotlight or the floodlight on (regardless of what brightness mode that light is in), pressing the switch for the light that is NOT on, will activate Dual-Light mode. The user can leave Dual-Light mode and go back to either spotlight or floodlight mode simply by pressing the switch for the mode that they wish to turn off. To turn both lights off, simply press each of the switches independently.

Low Battery Warning
The XPR-5561GC has a Low Battery Warning feature. Once the battery charge falls below 2.9V, the Spotlight LED will blink once every minute while the light is on regardless of which of the 5 modes the 5561 is in at the time. The Spotlight LED will continue to flash until the battery is fully depleted or until the 5561 is recharged to have a remaining charge capacity greater than 2.9V. This warning feature is an indication that the 5561 should be charged as soon as is possible. If the 5561 is off, no such warning will take place.

THE XPR-5561GC FITS ON ANY HARD HAT THAT HAS A HARD HAT LAMP BRACKET ATTACHED:
Nightstick NS-HMC9 Headlamp Bracket Mounting Instructions

Ensure mounting surface is clean and oil-free (use alcohol wipe if needed)
Prior to installing, determine the mounting location that allows the headlamp to fully tilt without interfering with the helmet brim.
Remove adhesive backing.
Firmly press bracket into place up for 30 seconds with flat side facing up (see image).
While supporting mount, slide headlamp clip into bracket slot. (Note: adhesive reaches peak strength in 24 hours)

to attach to the HARD HAT lamp bracket
Slide the clip on the back of the XPR-5561GC into the slot on the top edge of the Hard Hat Lamp Bracket and press down firmly until the clip is fully engaged into the bracket.
to remove from the Hard hat lamp bracket
Grasp the XPR-5561GC and pull up until the clip slides out of the Hard Hat Lamp Bracket.

WARRANTY

LIMITED LIFETIME WARRANTY
Bayco Products, Inc. warrants this product to be free from defects in workmanship and materials for the original purchaser’s lifetime. The Limited Lifetime Warranty includes LEDs, housing, and lenses. Rechargeable batteries, chargers, switches, electronics, and included accessories are warranted for a period of two years with proof of purchase. Normal wear and failures which are caused by accidents, misuse, abuse, faulty installation, and lightning damage are excluded.
We will repair or replace this product should we determine it to be defective. This is the only warranty, expressed or implied, including any warranty of merchantability or fitness for a particular purpose.
For a complete copy of the warranty, go to www.baycoproducts.com/bayco- productsupport/warranties. Retain your receipt for proof of purchase.

EU Declaration of Conformity (DoC)
XPR-5561G, XPR-5561GC

Company name: Bayco Products.
Postal address: 640 Sanden Blvd.
Postcode and City: 75098
Wylie, Texas USA
Declare that the DoC is issued under our sole responsibility and belongs to the following product:
Apparatus model/Product: XPR-5561G, XPR-5561GC
Type: Cap Lamp
ATEX Directive 2014/34/EU

The following harmonized standards and technical specifications have been applied: Evaluated to the following safety standards by Underwriters Laboratories (U.L.):
EN 60079-0:2012/A11:2013 EN 60079-11:2012 (ia) EN 50303:2000
These Products are fully compliant and do not contain the restricted substances above levels noted in EU RoHS.
Certificate No. DEMKO 17 ATEX 1826 Rev. 0

Name James Conner Engineer
Form F-900-001 Rev-A
Date of issue: 2/11/2020
Bayco Products, Inc. • 640 South Sanden Blvd. • Wylie, TX 75098 • USA • 1-800-233-2155 • 1-469-326-9400 • www.nightstick.com
INS-XPR-5561GC-DL-21