CustomPITLAMP modules provide a seamless retrofit to Oldham or CEAG mining lamps. No physical modification to the lamp unit is necessary, and typically the only tool required is a small flat blade screwdriver. CustomPITLAMP modules are fitted using the existing rubber seal and glass front window to retain the integrity of the lamp.
CustomPITLAMP PL modules have 3 wires to connect. One red wire (+ve) and two black wires (-ve). The black rubber bezel seal (recovered from original reflector) should be fited to outside edge of module. A small flat blade screwdriver is required to connect the 3 wires within the headset.
The red wire is connected directly to the positive supply from the battery. The connection is invariably made at the common connection block inside of the headset. In this example the positive feed from the battery is 'brown' (but could equally be 'red'). The two black wires are connected to the output sides of the two position switch as shown (The switch is on the left). The input side of the switch is fed by the negative from the battery, in this example 'blue' (could be 'black').
Note - the module is designed such that the two LED are switched independently, and operate separately. The two LED circuits should not be wired together. Wiring the two circuits together is beyond the operational scope of the module.
Take care to ensure that the connections, in particular the positive connections at the bottom of the photo, are orientated so that they are not in physical contact with the aluminium module (as illustrated above). Otherwise you will potentially create a short circuit and fry your battery pack.
The vast majority of mining lamps arrangements are wired up with the negative battery connection going to switch, and the positive to a common terminal within the headset. PL modules are configured for this. Very occasionally we come across a mining lamp headset that is wired up the opposite way around. In this scenario it will be necessary to swap the battery inputs around. This can be done by swapping wires in headset (the blue and brown in this example) or swapping polarity somewhere else in system, e.g at the battery pack.
Once positve and negative connections have been made, test module is working (by powering up). Input should not exceed 6.0 volts (do not use with Speleo Technics FX5, Kirby kidney pack or any 5 cell arrangement as fully charged voltage of such arrangements is in excess of 6.0 volts). If module does not immediately work, then stop and check that you have correct polarity. PL modules are polarity protected so it is unlikely that you will cause damage.
Once tested and operating, disconnect battery and insert module into headset (flood LED at the top), ensuring that wiring does not interfere with switch operation, and refit glass window and bezel. Holding glass window in place with thumb, and applying pressure while fitting will help, as there is no mechanism to prevent rotation of the CustomPITLAMP Module. At this stage it is worth considering how to achieve a degree of water resistance from your lamp. Greasing the rubber seal is good practice.
In this example (an Oldham headset), the original pilot bulb holder that would have been at the top of the photo has been removed. This is not essential but can be considered good practice as it improves fitting access. Similarly, for CEAG (Including Speleo Technics) headsets it is preferable to completely remove the redundant internal metal bridge that holds the original bulbs.
Fitting a CustomPITLAMP Module also provides an excellent opporunity to examine the condition of the switch. Dirty contacts should be cleaned and greased, and flattened contacts could be gently bent back into shape. If they are badly corroded, replacement should be considered. If the switch is stiff in operation, it is recommended that it is dismantled, cleaned and greased.