LED QUALITY FORROAD SWEEPERS

www.hella.com/municipal

INTRODUCTION

Quality has a name: HELLAMany providers promise high quality – and HELLA is no exception. What sets us apart from the others is that we deliver what we promise. After all, for us quality is not merely an expectation, we also make it happen. That's why we stake our name and reputation on this – and we have set ourselves the ambitious standard of ensuring a consistently high product quality in every respect.

We do this by defining ambitious quality criteria which apply throughout the entire manufacturing process. We also carry out testing procedures that go far beyond the prescribed standards. This is because, as far as we are concerned, quality is ultimately the basis for customer satisfaction.

One LED is not the same as any otherWith LEDs, you are investing in high-quality technology that pays off due to significantly reduced follow-on costs and a longer fault-free service life. This is most clearly demonstrated by the rapid increase in popularity of LEDs. However, certain important factors must be taken into account – note the information provided in the info fields.

Our Rota beacon directly draws your attention to these.

INTRODUCTION

TABLE OF CONTENTS

Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

HELLA is quality – you can count on that . . . . . . . . . . .4HELLA quality: A comparison . . . . . . . . . . . . . . . . . . . . .6Halogen lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8LED lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Why choose HELLA? . . . . . . . . . . . . . . . . . . . . . . . . . . 10LED technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Thermal management . . . . . . . . . . . . . . . . . . . . . . . . . 12Which beacons are approved for use on roads? – Directive ECE-R65 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Beacon lighting technology . . . . . . . . . . . . . . . . . . . . . 16Electromagnetic compatibility ECE-R10 . . . . . . . . . . 19

LED products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

LED products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20LED beacons / LED front flashers . . . . . . . . . . . . . . . 21LED work lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2290 mm LED modules . . . . . . . . . . . . . . . . . . . . . . . . . . 24LED daytime running lights . . . . . . . . . . . . . . . . . . . . . 25LED rear combination lamps . . . . . . . . . . . . . . . . . . . 26LED licence plate lights . . . . . . . . . . . . . . . . . . . . . . . . 27

Municipal fleet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Online tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Find the right product with ease . . . . . . . . . . . . . . . . . 32HELLA can give you the advice you needIntensive, personal support is the foundation of all customer relations at HELLA. This is precisely where we combine the advantages of a medium-sized company with the characteristics of a global player: Precise organisation, flexibility and short delivery times combined with a well established network of subsidiaries as well as professional logistics.

This range is rounded off by our comprehensive service offering with technical customer service, attractive sales support, availability of spare parts and 24 h access to operating instructions online.

If you any questions or need any further details, please get in touch.

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4 | 5QUALITY

HELLA has set itself the ambitious standard of ensuring consistently high product quality in every respect. This is achieved by defining quality criteria and checking every detail using carefully-selected methods throughout the entire manufacturing process. Production quality is ensured by parallel quality monitoring and testing.

Quality products from HELLA are subject to different test procedures in accordance with HELLA standard 67101. These test procedures are conducted by the HELLA test laboratory in Lippstadt, Germany.

HELLA IS QUALITY – YOU CAN COUNT ON THAT

Freezing conditions down to - 40°C and at full power up to + 100°C, also rapid temperature fluctuations, condensation and decondensation tests at air humidities up to max. 95%.

HELLA LED products withstand rapid temperature fluctuations and changes in air humidity.

Environmental conditions such as rain, splash water, hose water and spray are simulated in splash water booths.

HELLA LED products are splash-proof.

Heat, moisture and cold test

Splash water test

First-class quality by convictionHELLA provides a long-term guarantee that its products work perfectly and is committed to achieving customer satisfaction in the spare parts, accessories and light sources areas.

As the long-established company from Lippstadt is a partner to the automotive industry, HELLA products are manufactured precisely according to the specified tolerances in each case. This, combined with the use of sophisticated test procedures during product development, means that you can depend on HELLA products in any situation.

You will find further information on the HELLA quality criteria at: www.hella.com/quality

Before HELLA products are brought onto the market, they undergo rigorous testing:

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Simulation of cleaning in a car wash with extremely high water pressure of up to 120 bar and water temperatures up to + 85°C.

HELLA LED products can be cleaned using a high-pressure cleaner without a problem.

Intensive tests guarantee dust tightness, even with the tiniest of dust particles.

HELLA LED products are exceptionally tight to protect sensitive components from dust.

During this test, our products are exposed to powerful vibrations and impacts.

HELLA LED products offer guaranteed high resistance to vibrations.

Underwater pressure testing at depths of up to 6 m guarantees the leak tightness of our products.

HELLA LED products are tight.

High-pressure cleaner test

Vibration test

Immersion and pressure tightness test

Dust test

DID YOU KNOW?

➔ The heat and cold tests last up to 48 hours. ➔ The leak tightness of products is tested by carrying

out intermittent and splash water tests at pressures up to 5 bar, and a spray water test at a pressure of up to 10 bar.

➔ During the vibration test, all products are tested for up to 24 hours when in operation.

➔ An overpressure test up to 1.6 bar is performed in an immersion tank.

6 | 7QUALITY

Thermal management

The thermal management of HELLA work lights is thoroughly calculated: The heat of the LEDs is evenly distributed and deflected via the housing. If there is a risk of overheating, individual LEDs are automatically dimmed.

Without thermal management, LEDs can very quickly overheat. This makes their service life drop dramatically. Hot spots can deform the entire electronics board, soldering connections can break, causing the complete headlight to fail.

Electromagnetic compatibility (EMC)

The LED arrangement in HELLA's work lights and the construction of the reflector ensure that no interference occurs from magnetic fields.

LED headlights that are not correctly shielded produce strong electro-magnetic fields which interfere with the electronic system, radio and GPS.

Reverse polarity

HELLA work lights are protected against reverse polarity. If they are wrongly connected, they will not be damaged.

If a wrongly connected headlight is not protected against reverse polarity, the electronics will be completed destroyed when switched on.

Surface coating

High quality coatings protect the aluminum components of HELLA work lights from salt and chemicals and therefore from corrosion.

Corrosion can ruin the seal on headlights. In the worst case, water can penetrate and destroy the electronics.

HELLA QUALITY: A COMPARISON

HELLA quality advantages

Where others save

Attempting to save in the wrong place costs more in the end as inferior headlights provide less power and often fail.

Electrostatic discharge (ESD)

Before HELLA employees are allowed to enter the LED production area, they have to be statically discharged to ensure that no components can be damaged by charging.

Static discharge caused by damaged electronic components can make entire headlights unusable. There is a threat of expensive downtime.

Where others are cutting back, HELLA is investing in outstanding quality. Here you can see an example of work lights which demonstrates why the cheaper offers from low-cost suppliers can in the long run turn out to be the expensive choice.

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Quality of the LEDs

Only LEDs that have undergone strict tests are used in HELLA's work lights. The selection guarantees the extremely long service life of the LEDs of up to 60,000 hours.

Resorting to untested, cheap LEDs introduces the risk of a shortened service life and malfunction. Then LED technology cannot be used to its full advantage.

Adhesion

The work lights at HELLA are hermetically sealed by high-accuracy glue-dispensing robots. This guarantees that the lens is glued at an optimal angle for the optimum luminous efficiency which has been precisely calculated.

Inferior headlights are often glued manually. An irregular adhesive bed can lead to the lens angle, and thus the luminous efficiency, not being ideal. If the lens is no longer tight or becomes detached, water can penetrate and make the headlight unusable.

Lens material

The lens of HELLA work lights, which is 100% suitable for daily use, consists of a high quality, impact and scratch-proof plastic. The light emitted remains homogenous, even after colliding with a branch or anything similar. HELLA uses high-quality lens materials to ensure clear vision and maximise light output at all times.

Lenses made of inferior plastic can break and scratch easily. Each scratch leads to undesired light refraction - the more scratches, the more irregular the illumination is. Low-cost materials are not only unable to withstand mechanical impacts, they can also start to turn a yellowish colour when exposed to more intense UV insolation. This leads to a deterioration in the lighting performance.

Light distribution via the reflector system

The reflectors of HELLA work lights are calculated in such a way to ensure that the working area is evenly illuminated and the light optimally used.

Work lights with an unsuitable light control system illuminate the working area unevenly and waste a large part of the light. Brighter spots distract your eyes, making other details difficult to see.

Road sweeper with halogen lighting. The vehicle is equipped with three halogen work lights (H3) to illuminate the front and right sides. The halogen work lights (H3) are exceptionally rugged, powerful and produce homogenous illumination. However, if you compare the two images, you can clearly see the difference between halogen and LED work lights - the light colour.

QUALITY

Halogen bulbs tend to generate less bright light with an obvious yellow cast. With a halogen light, it is quite difficult to detect the cut-off line due to the colour temperature (2,500° Kelvin). The energy consumption of a halogen work light is around 70 watts. This is 22 watts with a comparable LED work light.

HALOGEN LIGHTING

2 x halogen work lights (H3)

The same road sweeper, however fitted with HELLA LED work lights. During the conversion, a total of three LED work lights were installed: one to illuminate the side and two more to illuminate the front. The Q90 LED work light is pressure-cleaner proof (IP 6K9K/IP 68), has an extremely robust housing and features innovative thermal management. This ensures that the LEDs do not overheat, thus allowing a longer service life to be attained.

HELLA has a specifically developed and calculated reflector concept for every LED work light to homogenously distribute the light beams in the work area.

This is often more important that a high lumen number because only homogenous illumination ensures that you have light where you really need it. As described in the image before, you can clearly distinguish between the brightness of halogen and LED. Due to the daylight-like colour temperature of LED light at 5,700° Kelvin, it is significantly more pleasant for the human eye and therefore leads to better quality work at night. Furthermore, the image perfectly demonstrates the greatly optimised illumination of the work area thanks to HELLA LED work lights.

LED LIGHTING

3 x LED work lights, Q90 LED

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10 | 11QUALITY

WHY CHOOSE HELLA?

HELLA LED lights satisfy the highest expectations. They have been developed and produced according to the strictest quality standards. HELLA ensures they are suitable for daily use by carrying out a series of simulation tests under the toughest conditions to test them to their limits:Long-term reliability tests were carried out during which the products were exposed to stress factors such as temperature, moisture and current feed, and they subsequently obtained the internationally recognised AECQ qualification.

But this norm is not sufficient for HELLA. The LEDs are therefore subjected to thousands of hours of additional stress and service life testing. That is why, in addition to the visual features, the electrical and thermal features are decisive for HELLA.

10 | 11

Everyone is talking about LED technology and it is the buzzword in the area of lighting technology. The advantages and disadvantages clearly demonstrate which type of applications LED products are most suitable for.

LED TECHNOLOGY

YOUR ADVANTAGES

➔ Extremely sturdy ➔ High potential savings ➔ Optimum warning effectiveness ➔ Low power consumption

HELLA quality advantages

Extremely long service lifeHigh-quality components, complex technology and no movable components (no mechanical wear).

No downtimes or assembly times LEDs with an extremely long service life often last the lifetime of the vehicle (maintenance-free).

Outstanding functional safetyHELLA LED products must meet the highest quality requirements before being approved for the market.

Highly resistant to vibrationLEDs consist of few fixed components and are therefore considerably more resistant to vibrations than xenon for example.

High energy efficiencyTop performance with low power consumption. The energy required to operate LED products is considerably lower than halogen or xenon – which makes them ideal for continuous operation.

Highly effective warningOptimum lighting performance during the day and at night.

Modern designModern design due to compact LEDs.

Low life cycle costsLong service life, maintenance-free and high degree of energy efficiency ensure much lower life cycle costs compared with xenon or halogen products.

Multi-voltageWide range of applications possible without having to consider voltage fluctuations.

Small increase in temperatureThe thermal management has been optimised in order to remove heat and achieve the maximum performance and service life of the LED.

High potential savingsSystematic use of HELLA LED lighting not only reduces fuel consumption, it also reduces the cost of materials and labour, and also the repair hours. For details, refer to pages 28 to 31.

12 | 13QUALITY

THERMAL MANAGEMENT

The service life of a LED heavily depends on its temperature and the applied current. If the LEDs overheat (usually because the input currents are too high), their service life will be drastically reduced. Effective thermal management is therefore extremely important.

HELLA uses state-of-the-art simulation programs to precisely calculate the heat flow. The task of the developer is to protect the LED from overheating and to ensure heat is removed reliably and efficiently.

Why use thermal management? ➔ The basis for effective uniform lighting ➔ Keeps the LEDs within the optimum temperature range ➔ Increases the service life of the product ➔ Reduces the risk of failure

Most important components ➔ Cooling fins incorporated into headlamp casing ➔ High-quality LEDs (automotive standard) ➔ Thermosensors for temperature monitoring ➔ Heat-dissipating substances (film, paste, …)

INSUFFICIENT THERMAL MANAGEMENT

Hot spots cause the components to expand at different rates which normally leads to failure.

Disadvantages: ➔ Mechanical stress on the circuit board ➔ The adhesive bond on components breaks ➔ Breaks in soldering points ➔ Cracks in the circuit board ➔ Result: Short circuit

The heat on the PCB is not being sufficiently dissipated by the heat sink, i.e. there is a risk of the LEDs overheating. If they are damaged they could cause a failure.

Disadvantages: ➔ Low light output ➔ Accelerated wear ➔ Reduced service life ➔ Overheating = downtimes and repair time

12 | 13

Many LED products are impressive due to their powerful light outputs. Many manufacturers also push LEDs to their limits and also far beyond in order to maximise the light outputs. If the operating temperature of LEDs is too high, this has a direct effect on the service life and luminous efficiency of the product. The full potential of the LEDs can then only be exploited if the heat generated is deflected outwards to prevent the LEDs from overheating.

If you want to get the best out of LED technology, thermal management is essential!

LEDS

EXAMPLE OF OPTIMUM THERMAL MANAGEMENT BY HELLA USING A BEACON

Thermosensors for greater safetyHELLA LED products are equipped with thermal management which, assisted by temperature sensors, can actively intervene in the system. These sensors monitor the temperature of the LED and respond immediately. If the system identifies excessively high temperatures, it automatically reduces the input current. During this process, the light output of the headlight is dimmed until the temperature of the LEDs is once again within the optimum range. The LEDs are therefore always operated under perfect conditions. This is the only way to achieve a service life of up to 60,000 hours.

The thermal imaging camera clearly shows how HELLA thermal management works: The high temperatures of the LEDs are distributed uniformly across a large surface area which then transfers this heat to the surroundings.

The dissipation of heat, and therefore the thermal conductivity of the housing in headlights, for example, can be improved by using cooling fins.

HELLA selects heat-conductive materials and arranges components to ensure effective heat flow. Thermal management dissipates heat from the LED. This is why we can guarantee a long service life for our products!

Advantages: ➔ Effective heat flow ➔ Optimum temperature distribution ➔ Long service life ➔ Reliability

QUALITY

WHICH BEACONS ARE APPROVED FOR USE ON ROADS? – DIRECTIVE ECE-R65

A beacon may only be used on public roads if it meets Directive ECE-R65.

ECE-R65 is the European directive for beacons. It specifies the required light values, light distribution and fitting specifications, etc. Can also be viewed at www.unece.org (United Nations Economic Commission for Europe)

MountingThe beacon [warning light] shall be designed in such a way that it cannot be adjusted after it has been fitted correctly to the vehicle (ECE-R65 5.2). The design and fixing method must conform to DIN14620. The beacon itself can have the following designs: A, B1, B2 or C.

The large E-approval mark (here ) shows whether the beacon meets the ECE-R65 directive and therefore has approval.

Design A Design B1 Design B2 Design C

EMC test number TA1 ECE-R65

Inspection tag T 360°

CE CE marking A Amber; B = Blue

Pmax. 9 W = 9 watt power consumption 1 1 = night; 2 = day and night

10 03 6194 ECE-R10 approval TA1 Amber beacon with night level according to ECE-R65

65 00 3397 ECE-R65 approval TA2 Amber beacon with day and night level according to ECE-R65

Positive example:The warning signal can be seen from all directions in a 25 m radius.

Correct

Negative example: The warning signal cannot be seen from all directions in a 25 m radius - this is interrupted in the area of the tow hook. In this case, another warning light needs to be attached to the rear of the vehicle or two beacons attached to the driver's cab.

Incorrect

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QUALITY

BEACON LIGHTING TECHNOLOGY

Inefficient luminous efficiency

Homogenous, large-surface illumination or illumination

➔ Reduced illumination surface ➔ Moderate rise in luminous intensity ➔ Blurred warning effect ➔ Low luminous intensity ➔ Limited luminous efficiency or focusing of light ➔ High scattering losses

➔ Very steep rise in light values ➔ Signal immediately perceivable ➔ High peak values (light values clearly higher than the

statutory requirements) ➔ Optimum luminous efficiency and focusing of light ➔ Best possible luminous efficiency ➔ Optimally directed light

The light values to be obtained are indicated by the effective luminous intensity. An amber beacon must, for example, reach a luminous intensity of 70 cd (effective candela) at night at a vertical angle of + 8°.

A blue beacon in contrast must reach 25 cd at night at a vertical angle of + 4°.

Effective luminous intensity(candela)

Blue Amber Red

0° 50 (night)120 (day)

100 (night)230 (day)

50 (night)120 (day)

4° 25 (night)60 (day) – 25 (night)

60 (day)

8° – 70 (night)170 (day) –

LIGHT VALUES ACCORDING TO ECE-R65

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18 | 19QUALITY

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ELECTROMAGNETIC COMPATIBILITY ECE-R10

What is EMC (ECE-R10)?Electromagnetic compatibility (EMC) is a major quality feature for optical signaling systems and describes two factors: radiated interference and interference immunity. The legal foundations for this are the CISPR 25 as well as the ISO 7637 and 11452.

Interference immunityGuarantees sufficiently high resistance to external electro-magnetic interference.

HELLA electronic devices CANNOT cause interference!In Europe, products can only be sold if they comply with EMC directive 2004/108/EC. Manufacturers must declare a product’s conformity by providing a CE mark on the product. HELLA takes compliance with EMC criteria one step further by also obtaining the “E” permit according to ECE regulation 10. This guarantees the interference-free function of the device with the vehicle electric system, thus making the device perfectly suited for use in any vehicle group.

Electromagnetic interactions

Radio/TV

Mobile telephone Sat radio Navigation Telematics fee collection

Entire electrical system

Distance warning radar

Radiated interferenceLimitation of radiated electromagnetic interference to a level that guarantees the interference-free operation of other devices in the environment.

Protective classes standard CISPR 25:CISPR 25 is the standard for classification of emitted interference on a scale of 1 - 5. Products in class 5 must satisfy the most demanding requirements, and are even suitable for installation situations directly next to an aerial. Category 3 satisfies the statutory standards which guarantees adequate protection in standard practice. (HELLA lighting systems satisfy at least category 3, many achieve category 5, and guarantee absolute functional safety in all application situations.)

Only beacons which can have both of these test numbers are approved for use on public roads.

1 2

1 ECE-R65

2 ECE-R10

20 | 21LED PRODUCTS

HELLA offers a comprehensive range of products for municipal emergency vehicles and special vehicles which are perfectly harmonised with the specific operating requirements.

In addition to front and rear combination lamps, our portfolio also includes optical warning systems and beacons, daytime running lights and work lights. We also offer a wide range of interior lighting. The innovative LED technology is extensively used in all products listed – with the familiar benefits such as being maintenance-free and significantly reduced operating costs.

LED PRODUCTS

Product example: KL 7000 LED

Excellent thermal management

Easy cleaning due to a smooth dome

Shell reflectors for optimal luminous efficiency and distribution

High-quality LEDs

Protection from overvoltage/inverse polarity

Ceramics capacitor for extremely long service life

However, the HELLA range does not just comprise classic vehicle lighting: We also have a strong presence in the area of electrics and electronics. Irrespective of whether they are vehicle lighting or electronics solutions, all our products have one thing in common: the outstanding HELLA quality which you can rely on at all times.

KL 7000 LED beaconThe KL 7000 LED is a compact beacon which is available with a rotating or flashing signal. The version for fixed attachment can be mounted from above or below.

Rotating signalMultivolt 10-32 V, fixed attachment 2RL 011 484-001Multivolt 10-32 V, pipe socket fixing 2RL 011 484-011Multivolt 10-32 V, magnetic mounting bracket 2RL 011 484-021Flashing signalMultivolt 10-32 V, fixed attachment 2XD 012 972-001Multivolt 10-32 V, pipe socket fixing 2XD 012 972-011Multivolt 10-32 V, magnetic mounting bracket 2XD 012 972-021

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Rota LED beaconThe Rota LED with rotating or flashing LED light function impresses with its high level of efficiency, its flat and compact design, and rotating LED light function. Due to the shock absorbing rubber foot, it is highly resilient against vibration and thus perfectly suited for challenging applications.

➔ ECE-R65 approved LED beacon with rotating warning signal ➔ High vibration resistance and extremely robust ➔ Extremely efficient

Rotating signalMultivolt 10-32 V, fixed attachment 2RL 010 979-001Multivolt 10-32 V, flexible pipe socket fixing 2RL 010 979-011Multivolt 10-32 V, magnetic mounting bracket 2RL 010 979-021Flashing signalMultivolt 10-32 V, fixed attachment 2XD 012 878-001Multivolt 10-32 V, pipe socket fixing 2XD 012 878-011Multivolt 10-32 V, magnetic mounting bracket 2XD 012 878-021

LED BEACONS / LED FRONT FLASHERS

K-LED 2.0 beaconThe HELLA K-LED 2.0 beacon ensures the best possible warning effect and thus optimum safety as it automatically illuminates 2.3 times brighter during the day than it does at night. It is also the first HELLA beacon where you can choose between rotating or flashing warning signals by pressing a switch or by means of programming. This offers you the right warning signal for any application.

➔ 2 levels (ECE-R65): Beacon with light sensor for automatic switching between day and night mode for ultimate warning effectiveness

➔ Functional safety: The first HELLA beacon to meet the requirements of IP 67 ➔ Extremely robust and highly compact

Multivolt 10-32 V, fixed attachment 2XD 011 557-101Multivolt 10-32 V, airport fixed attachment 2XD 011 557-701Multivolt 10-32 V, pipe socket fixing 2XD 011 557-201Multivolt 10-32 V, magnetic mounting bracket 2XD 011 557-301

BST front flashersHigh-performance BST strobe headlight with different flashing patterns. ECE-R10 and ECE-R65 type-tested, incl. approved 3x flasher (amber incl. k-approval as rear warning light system for stationary vehicle according to §53a of the German Road Licensing Regulations (StVZO)). Flat, compact design enables straightforward mounting.

➔ ECE-R65 type tested, incl. approved 3x flash ➔ ECE-R10 approved ➔ Multivolt 11 – 30 V ➔ Various flashing patterns ➔ Flat, compact design enables straightforward installation ➔ BST can be synchronised with 2 or more units

For horizontal mountingFixed attachment 2XD 012 160-851Bracket mounting 2XD 012 160-861

For vertical mountingFixed attachment 2XD 012 160-951Bracket mounting 2XD 012 160-961

22 | 23LED PRODUCTS

LED WORK LIGHTS

Module 70 LED Gen. IVDespite its compact size, this is a robust work light that can be used in many applications. The light beams of the LEDs illuminate the entire work area thanks to the multifaceted reflector and lens. Equipped with 3 high-performance multichip LEDs, the Module 70 LED is rated to 2,500 lumens while consuming just 30 watts of energy. The black housing of the work light is made of aluminum and incorporates cooling fins. These ensure the necessary dissipation of the heat produced by the high-power LEDs.

➔ Compact design enables attachment in mounting positions where space is tight ➔ Modular design ➔ Simple conversion ➔ Powerful light output despite low mounting depth

Close-range illumination 1G0 996 476-001Long-range illumination 1G0 996 476-011

Module 70 LED Gen. IIIThe 4 high-output LEDs are suitable for multi-voltage use (12 and 24 V). Its low power consumption makes the Module 70 generation III LED ideal for use in vehicles with battery operation or where the alternator is already operating under heavy load. The Module 70 generation III LED is absolutely resistent to impacts, vibration and voltage fluctuations. After installation, the work light does not require any maintenance. The integrated electronics protect the device in the event of polarity inversion and ensure constant brightness, even when the operating voltage fluctuates between 9 - 33 volts.

➔ Work light with innovative LED technology and compact design ➔ 30% more light than Generation II with the same power consumption ➔ Modular Line facilitates straightforward conversion

Close-range illumination, upright 1G0 996 276-451Close-range illumination, pendant 1G0 996 276-481

Q90 compact LEDA robust work light with a universal, attractive design. The light output of the 4 high-power LEDs is an impressive 1,000 lumens. The light is distributed by a specially developed multi-faceted reflector, thus ensuring homogeneous illumination. The Q90 compact LED is thus perfect for close-range illumination. But the energy consumption is just 15 watts. The innovative THERMO PRO plastic casing, which along with thermal conductivity, also features high impact resistance, weight savings and complete corrosion resistance.

➔ Thermo Pro series ➔ Innovative compact work light ➔ For universal use ➔ ADR/GGVS tested (DT connector)

Close-range illumination, 2,000 mm cable 1GA 996 284-001Close-range illumination, DT connector 1GA 996 284-081

Module 50 LEDWith the Module 50 LED, HELLA now offers an ultra-compact work light that achieves a high light output despite its size. A specially developed lens system concentrates the light and distributes it to the range of operation. At 800 lumens, the light output is well suited to close-range illumination. There is also an optic-free version that facilitates long-range and /or spot illumination.

➔ Innovative LED technology ➔ Ultra-compact design ➔ Robust housing

Close-range illumination, upright 1G0 995 050-001Close-range illumination, pendant 1G0 995 050-011Long-range illumination 1G0 995 050-021

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Power Beam 1800The Power Beam 1800 is an ideal LED work light that combines a powerful light output with a practical design. The work light is designed so that it can be used anywhere thanks to its compact dimensions. The light output from the 6 high-power LEDs is an impressive 1,850 lumens. The light is distributed by a specially developed multi-faceted reflector, which ensures homogenous illumination. The energy consumption is just 36 watts. The LED work light is equipped with an additional dimming function.

➔ Compact design with high light output ➔ Innovative work light with dimming function ➔ For universal use

Close-range illumination 1GA 996 388-011Long-range illumination 1GA 996 388-031

Oval 100 LED Gen. IIThe light output is a powerful 3,800 lumen which means that the Oval 100 LED Gen. II is a more than adequate replacement for xenon work lights. The light is distributed by a specially developed multi-faceted reflector, thus ensuring homogeneous illumination. The Oval 100 LED can be upright (0°) or pendant (180°) mounted. The black housing of the work light is made of aluminum and incorporates cooling fins. These ensure sufficient heat dissipation from the 8 high-output LEDs.

➔ Powerful LED work light ➔ Modular series – easy conversion ➔ More than twice as much light as Generation I

Close-range illumination 1GA 996 761-001Long-range illumination 1GA 996 761-011

WORK LIGHT ILLUMINATION – IMPORTANT POINTS:

Close-range illumination ➔ Range of up to approx. 30 m around the vehicle ➔ Wide illumination at the sides ➔ Homogeneously illuminated areas with no

shadowing or dark spots

Long-range illumination ➔ Identification of obstacles in good time. Long-range

visibility (up to 100 m) is therefore crucial. ➔ A smooth transition between close-range and

long-range illumination makes work easier. ➔ Take advantage of the benefits LED technology

offers: powerful light output and high energy efficiency.

24 | 25LED PRODUCTS

90 MM LED MODULES

LED low beam L 4060The module headlight is equipped with a robust, passively cooled housing made from die-cast aluminum and a cover lens made of polycarbonate. The module is therefore lighter and particularly resistant to impact from stones. Thanks to the modularity and integrated light rings, there are no limits to the vehicle design scope.

ES/SAE version, FEP connector 1BL 012 488-001LES version, FEP connector 1ML 012 488-011ES/SAE version, DEUTSCH connector 1BL 012 488-101LES version, DEUTSCH connector 1ML 012 488-111

With daylight running light and position lightES/SAE version, FEP connector 1BL 012 488-021LES version, FEP connector 1ML 012 488-031ES/SAE version, DEUTSCH connector 1BL 012 488-121LES version, DEUTSCH connector 1ML 012 488-131

LED high beam L 4060High-end illumination. High beam, daytime running and position lights in one module or as a separate high beam module. 40 x 60 mm PC lens with new design. Pattern-free and hardened plastic cover lens. High-beam headlamp either with preassembled carrier frame or, as is the case with the 90 mm performance module, attachment for 1:1 replacement. Integrated FEP plug and driver electronics.

Preassembled carrier frame 1F0 011 988-021Performance mount 1F0 011 988-121

With daylight running light and position lightPreassembled carrier frame 1F0 011 988-031Performance mount 1F0 011 988-131

With direction indicatorWith pulse generator, preassembled carrier frame 1F0 011 988-081With pulse generator, performance mount 1F0 011 988-181Without pulse generator, preassembled carrier frame 1F0 011 988-071Without pulse generator, performance mount 1F0 011 988-171

L 70 Bi-Module 2nd generation2nd generation Bi-LED module with enhanced lighting/electronics. 55 x 70 mm polycarbonate lens, pattern-free hardened plastic cover lens, no moving parts, passive cooling. FEP and DEUTSCH connector, USA version available. Integrated function output for failure monitor. Multi-voltage 9 - 32 V.

Right-hand traffic, FEP connector 1AL 012 758-001Left-hand traffic, FEP connector 1LL 012 758-011USA version, FEP connector 1AL 012 758-021Right-hand traffic, DEUTSCH connector 1AL 012 758-101Left-hand traffic, DEUTSCH connector 1LL 012 758-111USA version, DEUTSCH connector 1AL 012 758-121

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LED DAYTIME RUNNING LIGHTS

LEDayFlex II rectangularIndividual front light design with rectangular modules. The system of flexibly interconnected rectangular modules opens up new design opportunities and adaptation to vehicle contours is possible due to a wide range of type-tested attachment systems. Each module contains 2 high-power LEDs.

➔ Adaptation to the vehicle contour within the context of type-approved attachment systems

➔ Extremely flat installation depth of modules ➔ Modern design combined with LED power

Module chain with 5 light modules12 V, daytime running light/position light 2PT 980 789-051

24 V, daytime running light/position light 2PT 980 789-051*2PT 980 789-061*

Module chain with 6 light modules12 V, daytime running light/position light 2PT 980 789-251

24 V, daytime running light/position light 2PT 980 789-251*2PT 980 789-261*

Accessories12 V, control unit with connecting cables 8KA 959 186-90124 V, control unit with connecting cables 8KA 959 186-911

* For 24 V operation, please observe the requirements as per the installation guide: The lamps are wired in series. You must order both items for this!

LED daytime running light – Ø 83 mmThe 83 mm LED daytime running lights combine a compact design with simple installation. With low energy consumption and excellent lighting performance, they improve the visibility of the vehicle and therefore reduce the likelihood of accidents.

➔ 83 mm LED 3-function lights: direction indicator, position light, daytime running light

➔ The integrated electronics switch off the daytime running light function when the direction indicator light in activated

➔ Pre-wired with 2.5 m sheathed four-core cable ➔ No integrated pulse for indicator failure check

Individual lights12 V 2BE 980 691-001*24 V 2BE 980 690-001** This variant is required for vehicles that must be rehomologised in accordance

with ECE-R48 (from ECE-R48 version dated 22.07.09, series 04, supplement 02)

Optional accessoriesAdapter ring 90 mm 9GD 980 696-001

LEDayline ZeroThe LED daytime running light LEDayLine Zero is best suited for vehicles with no angle at installation location. The daytime running light is simply clipped into the mounting frame which is mounted on the vehicle beforehand. The compact design can be integrated harmoniously into the vehicle and is ideal for retrofitting.

➔ LED daytime running light set for horizontal installation ➔ Compact design ➔ 8 high-performance LEDs per daytime running light

12 V, daytime running light set 2PT 980 970-82124 V, daytime running light set 2PT 980 970-871

26 | 27LED PRODUCTS

LED REAR COMBINATION LAMPS

"COLUNA" full LED rear combination lampThe tail light, in combination with the reflex reflector, is generated by means of a ground-breaking flat LED light guide, and has been registered as a patent. And this light guide succeeds in producing a particularly homogenous illumination. As a result, the tail light function, with its large surface area of around 145 cm², is highly visible in the dark and thus enhances road safety.

➔ The rectangular reflex reflector can be used horizontally and vertically ➔ Maintenance-free, fully sealed LED light ➔ Impact-resistant lens ➔ With pulse for direction indicator failure monitor and 500 mm open cable ends

12 V 2VP 345 900-40124 V 2VP 345 900-201

DuraLED Combi multifunction lightCombination of tail light, stop light and direction indicator with or without direction indicator failure monitor (compatibility according to ISO 13207-1), can be mounted horizontally or vertically. Polarity reversal protection ensures no damage to the light if the poles are incorrectly contacted.

➔ Maintenance-free, fully hermetically sealed, shock-resistant and lastingly UV-resistant

➔ Slim design with an installation height of just 25 mm ➔ Dual-voltage 12/24 V

With 2,500 mm cable 2SD 980 613-211With integrated DEUTSCH connector 2SD 980 602-211With 2,500 mm cable 2SK 980 613-501With integrated DEUTSCH connector 2SK 980 602-501

LED circular ring module Ø 112 mmThe innovative LED edge light technology of these peripheral tail and stop light functions ensures a homogenous appearance.

➔ Technological further development: LED edge light technology ➔ ECE approval ➔ Ideal for combining with lamp series 009 001 (Ø 66 mm) ➔ 1:1 compatibility with lamp series 009 362

12 V, tail light/stop light, red 2SB 009 362-30124 V, tail light/stop light, red 2SB 009 362-32112 V, tail light/stop light, clear 2SB 009 362-31124 V, tail light/stop light, clear 2SB 009 362-331

LED direction indicator for combination with circular ring modulesWith 12 amber LEDs, clear lens, plastic housing, low weight, small installation depth, water-proof exterior plug connection. Suitable for light series 009 362-...

With pulse for direction indicator failure monitor12 V 2BA 009 001-43124 V 2BA 009 001-531

Without pulse for direction indicator failure monitor12 V 2BA 009 001-41124 V 2BA 009 001-511

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LED LICENCE PLATE LIGHTS

LED licence plate lightClear lens, with 4 LEDs, black plastic housing. With blade terminal 6.3 x 0.8 mm.

➔ Licence plate light with extremely low energy consumption by using 4 high-power LEDs

➔ Available as flush-mounting or surface-mounting variant ➔ High dust and water resistance

For surface-mounting on the right or left next to the license plate, only 1 lamp needed for illumination.Licence plate 520 x 120 mm12 V 2KA 010 278-32124 V 2KA 010 278-021

Licence plate 340 x 240 mm or 280 x 200 mm12 V 2KA 010 278-42124 V 2KA 010 278-121

LED rubber arm clearance lightDue to its innovative design, this clearance light is highly resistant to vibrations and impacts. The rubber arm always returns to the "0" position, even following impacts, and ensures the light also remains stable at higher speeds as well. The rubber trim provides additional protection for the light head against damage.

➔ For trailers, semi-trailers and special vehicles ➔ The rubber trim provides additional protection for the light head ➔ Clear lens made of shatterproof polycarbonate

Short, with Quicklink connector, 500 mm cable2XS 011 768-001

Short, with AMP-SUPERSEAL connector, 2,000 mm cable2XS 011 768-031

Short, with 6.3 mm flat receptacle, 3,000 mm cableLeft 2XS 011 768-071Right 2XS 011 768-061

For mounting above the licence plate, 2 lamps required.Licence plate 520 x 120 mm12 V 2KA 010 278-31124 V 2KA 010 278-011

Licence plate 340 x 240 mm or 280 x 200 mm1 light required for illuminating the licence plate12 V 2KA 010 278-41124 V 2KA 010 278-111

Vertical, with 6.3 mm flat receptacle, 3,000 mm cableLeft 2XS 011 744-031Right 2XS 011 744-041

Vertical, with AMP-SUPERSEAL connector, 2,000 mm cableLeft 2XS 011 744-051Right 2XS 011 744-061

Vertical, with Quicklink connector, 500 mm cableLeft 2XS 011 744-071Right 2XS 011 744-081

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Good product ideas are the answer to real problems that occur in practice. Quality, practicability, safety and cost effectiveness are the criteria for every new development and are already met by the comprehensive range of HELLA products.

You can save costs on a reliable and long-term basis with LED products from HELLA. Fleet managers and drivers expect functional safety at all times - with no ifs or buts. In other words, vehicle components with a high quality standard and long service life. HELLA LED lights meet these requirements. They have been developed and produced according to the strictest quality standards.

MUNICIPAL FLEET

Using sample calculations drawn from practice, on the following pages we would like to demonstrate the vast potential for achieving cost savings in your vehicle fleet in respect of material costs, labour costs, and repair hours spent on maintenance work through the systematic and consistent use of LED lighting from HELLA. For design reasons, the light sources are installed with their max. expected service life specified. Malfunctions of light sources are therefore correspondingly low when you change over to LED lighting and this in turn means that maintenance work can be reduced to a minimum. The use of LED products from HELLA also considerably reduces energy consumption: Consequently, fuel consumption and exhaust emissions drop.

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MUNICIPAL FLEET

Enjoy the benefits of HELLA LED technology in your vehicle fleet! Save time and money, and be ahead of the pack in CO₂ reduction. See for yourself:

1. Sample calculation

The sample calculations are based on the following data: ➔ Garage labour costs per hour: € 50 ➔ Repair times work lights and beacons:

Replacement time work lights / beacons: 30 minutes (0.5 h), Changing light source on work lights/beacons: 15 minutes (0.25 h)

➔ Average replacement rates work lights/beacons per vehicle (p.a.)

Experience has shown that light sources and products have the following replacement rates on an annual basis:Light sources: 2 x per year Work lights: 1 x per year, beacon lights: 1 x per year(assuming an average use of 6 hours per day and no mechanical damage)

➔ Number of work lights /beacons per vehicle: work lights: 2, beacons: 2

➔ Average product costs:

The sample calculations below show the potential savings that can be achieved for the work light and beacon product groups over various time periods. You'll be amazed by how significant savings can be made even with small fleets!

Halogen LED

Work lights 20 € 80 €

Beacon lights 60 € 120 €

Bulb 3 € –

30 | 31MUNICIPAL FLEET

2. Sample calculation (halogen)

for 1 vehicle with halogen work lights/beacons

A) Labour costs (per vehicle)Replacement costs for work lights(1 work light x 0.5h x 50 €/h) 25 €

Replacement costs for beacons(1 beacon x 0.5h x 50 € /h) 25 €

Light source change on work lights (2 work lights x 0.25h x 2 changes per year x € 50/h) 50 €

Light source change on beacons(1 beacon x 0.25 h x 2 changes per year x 50 €/h) 25 €

Total annual labour costs (per vehicle) 125 €

B) Material costs (per vehicle)Work light costs(€ 20 product costs + € 12 light source costs) 32 €

Cost of beacons(€ 60 product costs + € 6 light source costs) 66 €

Total annual material costs (per vehicle) 98 €

Total costs:

A) Labour costs 125 €

B) Material costs 98 €

Halogen work lights/beacons

Important:Recurring, annual costs per vehicle!

223 €

3. Sample calculation (LED)

for 1 vehicle with LED work lights/beacons

A) Labour costs (per vehicle)In the case of LED work lights and beacons, labour costs are incurred only when converting existing vehicles. You should specify direct installation of HELLA LED products in new vehicles in order to benefit from the potential savings in full from the outset.

Replacement costs for work lights(2 work lights x 0.5 h x € 50/h) 50 €

Replacement costs for beacons(1 beacon x 0.5 h x 50 €/h) 25 €

One-off total labour costs (per vehicle) 75 €

B) Procurement costs (per vehicle)LED work lights(2 work lights x € 80) 160 €

LED beacons(1 beacon x € 120) 120 €

One off procurement costs (per vehicle) 280 €

Total costs:

A) Labour costs 75 €

B) Procurement costs 280 €

LED work lights/beacons

Important: One-off costs per vehicle!

355 €

1. 2. 3. 4. 5. 6. 7. 8. Total

Halogen costs (€) per year 223 223 223 223 223 223 223 223 1,784 (€)

LED costs (€) per year 355 0 0 0 0 0 0 0 355 (€)

Maintenance cost savings per vehicle (€) per year

-132 223 223 223 223 223 223 223 1,429 (€)

The higher acquisition costs of LED products have paid dividends after just 24 months.

Comparison of total costs for halogen compared to LED over a vehicle service life of 8 years.

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5. Savings potential for a fleet of 10 vehicles over 8 years

The following table applies the potential savings calculated above to a fleet of 10 vehicles over an 8 year period and shows just how much can be saved by choosing the right lighting from the right manufacturer. The average vehicle is assumed to be driven for 200 days.

1. 2. 3. 4. 5. 6. 7. 8. Total

Costs of halogen (€) 2,230 2,230 2,230 2,230 2,230 2,230 2,230 2,230 17,840 (€)

Costs for LED (€) 3,550 0 0 0 0 0 0 0 3,500 (€)

Maintenance cost savings (€) -1,320 2,230 2,230 2,230 2,230 2,230 2,230 2,230 14,290 (€)

Fuel savings (litre)340 340 340 340 340 340 340 340 2,720 (l /12 V)420 420 420 420 420 420 420 420 3,360 (l /24 V)

CO2 savings (kg)889 889 889 889 889 889 889 889 7,112 (kg/12 V)

1092 1092 1092 1092 1092 1092 1092 1092 8,736 (kg/24 V)

These non-binding figures are based on average values and general technical assumptions; they are provided purely as information for your support. We accept no liability for the correctness of this data.

Conclusion:LED technology by HELLA comes out on top: Maintenance cost savings = € 14,290Fuel savings = 2,720 (litres/12 V) and 3,360 (litres/24 V) Reduction of CO2 emissions by 7.1 t (12 V) and 8.7 t (24 V)

These calculations can of course be applied to fleets of other sizes. If you are not convinced by these figures, just carry out the test and see for yourself, or contact us directly.

4. Fuel savings by using LED technology

Savings per vehicle per yearLight functions are activated 200 days a year, 5 hours a day.

Halogen(12 V / 24 V)

LED

1 x beacons consumption 55 / 70 Watt 15 Watt

2 x work lights consumption 110 / 140 Watt 26 Watt

Total consumption 165 / 210 Watt 41 Watt

kWh per vehicle per year – savings(165 W - 41 W) x 5 hours x 200 days/1,000 (210 W - 41 W) x 5 hours x 200 days/1,000

124 / 169 kWh

Possible savings with a diesel engine

Degree of efficiency of a diesel engine 45 %

Degree of efficiency of generator (alternator) 80 %

Fuel value of diesel1 litre of diesel generates 3.6 kWh electrical energy 10 kWh/litre

Diesel in litres – savings potential124 kWh/3.6 kWh169 kWh/3.6 kWh

34 litres (12 V)46 litres (24 V)

Website for municipal vehicles and special vehiclesInformative, compact, interactive. Here, you can find everything you need to know about products and technologies for municipal use.

www.hella.com/municipal

ELIVER – the light comparison toolThis online tool allows you to compare many HELLA work lights and beacons on the basis of their illumination in a realistic environment.

www.hella.com/eliver

Work light configuratorWhich work light is the right choice for your application? The online configurator from HELLA provides you with matching product recommendations, including all relevant information on the product.

www.hella.com/worklight-configurator

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ONLINE TOOLS

FIND THE RIGHT PRODUCT WITH EASE

The purpose of our online information is to give you more ways to efficiently and conveniently identify the latest HELLA products and obtain important information about them. No matter what you are looking for, we are sure to have the right part in our range!

➔ Product information ➔ Product videos ➔ 3D animations ➔ Configuration tools for many applications ➔ Interactive apps for smartphones and tablets ➔ Comparisons of lighting technology ➔ Fitting recommendations ➔ Online catalogues

HELLA online catalogueHelps you in your search for vehicle-specific products. Regardless of where you are beginning your search, the search system helps you find the right solution very quickly.

www.hella.com/catalogue

The online universal parts catalogue also offers a quick and up-to-date overview of products in the categories of lighting, electrics and thermal management for a wide range of vehicles.

www.hella.com/upc

HELLA YouTube channelIn addition to informative product and application videos, you can also find many helpful tips and advice on our comprehensive HELLA product range on the HELLA YouTube channel.

www.youtube.com/HELLAKonzernInstallation video for BST LED front flasherFrom the functional test to the correct installation and wiring: In this video, you learn in a few minutes what is involved in the assembly of the HELLA BST front flasher. Our experts guide you step-by-step to success using clear and easy-to-understand descriptions.

www.hella.com/municipal

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34 | 35NOTES

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HELLA KGaA Hueck & Co.Rixbecker Straße 7559552 Lippstadt, GermanyTel.: +49 2941 38-0Fax: +49 2941 38-7133Internet: www.hella.com

HELLA LimitedUnit 6 Appletree Industrial Estate Chipping Warden Banbury, Oxon OX17 1LL England, UK Tel.: (01295) 662400Fax: 0800 7832571E-mail: hella.sales@hella.comWebsite: www.hella.co.uk

© HELLA KGaA Hueck & Co., Lippstadt 9Z2 999 137-794 J01146/KB/03.16/0.4 Subject to technical and price modifications Printed in Germany