AgricultureJournal Edition: 2014-01

HELLA technology in agriculture

The biggest LED quality comparison: The difference between HELLA worklights and their competitors (pages 6 + 7) Thermal management: Introducing: BEHR HELLA SERVICE, the specialist for vehicle air conditioning and engine cooling (page 9) The connector for professionals: Maximum protection with the DEUTSCH connectors in the DT series (page 10)

Optimum light gain for night driving Worklights in practice: LED versus halogen

Halogen worklights; unevenly illuminated

Albert Feldmann is an agricultural contractor from Münster. In addition to various other agricultural machinery, he possesses two powerful combine harvesters which must work around the clock during the harvesting season, even deep into the night. An ideal test case for HELLA.

illuminated the night-time grain harvest. The difference was immediately apparent. The luminous efficiency of the LEDs on the illuminated, working area immediately convinced the experienced agricultural contractor: “LEDs make night-time work much easier. You feel safer and more relaxed when driving.”

We wanted to know: how does the light output of halogen worklights compare with LED worklights in night-time use? Both combine harvesters were appropriately fitted out – one with standard halogen equipment, the other with the Power Beam 1500 LED worklights (closerange illumination: 1GA 996 288-011 and long-range illumination: 1GA 996 288-001). Dietmar Bengsch from HELLA’s Technical Field Service Department installed the headlights in the correct manner.

Better visibility, better safety

working area, reduced range!

Significantly more visibility and safety with LED worklights

Dietmar Bengsch from HELLA’s Technical Field Service Department reiterates the benefits of HELLA worklights: “HELLA LEDs have a lifetime more than 130 times longer than halogen lamps. That saves costs which can otherwise arise from repairs and downtimes with halogen headlights. As there is more visibility around the combine harvester’s working area, this also significantly increases work safety.”

At night, not all fields are grey The practical test commenced at 9pm: the halogen worklights were utilised first; they previously represented the ultimate night-time work lighting as far as Albert Feldmann was concerned. Subsequently, the lighting systems were replaced and the LED worklights

Result of the practical test: LED worklights provide an evenly illuminated working area with increased range. HELLA would like to express sincere thanks to agricultural contractor Albert Feldmann for his cooperation in the test.

A real all-rounder: the Power Beam 1500 LED in night-time use

2 pm: Assembly Dietmar Bengsch from HELLA’s Technical Field Service Department installs the LED worklights in the correct manner

5 pm: Ready for work The combine harvesters are ready for operation and are driven into the field

9 pm: The practical test begins Direct comparison: one combine harvester with halogen worklights and the other with LED worklights

Midnight: A conclusive result The LED worklights provide better luminous efficiency

WORKLIGHTS

Editorial HELLA Technology for agriculture

Dr. Thomas Hiebaum Managing Director HELLA FAHRZEUGTEILE AUSTRIA

How times change: around 100 years ago, almost one working week was needed to produce 100 bushels of grain. Today, three hours is enough for the same quantity. This huge increase in productivity has only been possible thanks to technical advancement and new developments in agriculture. HELLA has also a key contribution. A contribution which always involves innovative ideas for farmers and agricultural contractors. Or as Dr. Thomas Hiebaum, managing director of HELLA FAHRZEUGTEILE AUSTRIA, puts it: “With durable, efficient and world-leading products, we support the agricultural machinery manufacturers to offer to the agricultural industry a greater level of safety, comfort and system integration.” A statement that continues to remain valid. HELLA has been concentrating on the future for more than 100 years, and is still developing the technology for tomorrow every single day...

The challenges for agricultural engineering Workloads in the agriculture sector have been increasing exponentially in recent years. Ever tighter margins force farmers and agricultural contractors to implement more efficient agricultural technology. HELLA is well prepared for this. Let us take, for example, the speed of the agricultural industry’s no. 1 workhorse – the tractor. Here, there is far greater momentum than was the case a few years ago. Another trend: consolidation and the discontinuation of smaller agricultural operations increases the average size of the farm. This retrospectively increases the special demands on man and technology: farmers and agricultural contractors must increasingly work after nightfall in the harvesting season. Lighting solutions from HELLA The need for contemporary working light solutions, with superior illumination, is also growing. At the same

The HELLA 360° principle

time, the demands on safety and working comfort are also rising. HELLA has therefore responded to this trend and works to develop ever improving, high performance worklights which, in conjunction with their excellent quality, also provide energy efficiency and a longer design life. When it comes down to the bottom line, farmers and agricultural contractors can rely 100% on the worklights from HELLA. All-round visibility thanks to surround light Today’s modern agricultural machinery not only has higher engine power, it must also pull increasingly efficient attachments. In order to also be able to manoeuvre safely, creative lighting ideas are needed. HELLA has worklights in its product range which can provide optimum illumination for all working areas, and which can also be installed on the rear end and sides of machinery and attachments. We call this the HELLA 360° principle.

Cab roof, front: 4 x Oval 90 LED (1GB 996 386-001 and 1GB 996 386-021) Mirror brackets, front: 2 x Oval 90 LED Cab roof, rear. 4 x Power Beam 1500 LED (1GA 996 288-011 and 1GA 996 288-001 Lateral installation/ object illumination: 1 x Module 70 LED Gen. III (1GO 996 276-481)

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WORKLIGHTS

In the

public eye

Four new, high performance worklights round off the extensive existing range of products from HELLA and with their diverse features provide farmers, agricultural contractors and municipal companies with a variety of additional options.

Power Beam 1800 LED The Power Beam 1800 (1GA 996 388-001) is an LED worklight with an additional dimming function. It combines a strong light output of 1,850 lumen with a compact design, which makes it very versatile. The energy consumption is just 36 watts. The additional dimming can be implemented by the adjustable, dutycycle of the pulse width modulated signal (PWM) and is effected by interposing a conventional LED PWM dimmer in the supply line (maximum input current for the headlight is 1.5 A ; frequency 100-1000 Hz).

New technology The Ultra Beam LED The Ultra Beam LED (1GA 995 506-001) expands the world’s best-selling worklight series, Ultra Beam, to include an LED version. It offers a high light output in a practical design because, due to its compact dimensions, it can be used anywhere. The light output is 2,200 lumen, and the light is distributed with a specially developed multi-faceted reflector. This ensures homogeneous illumination. With its various lenses, this worklight can be utilised for both closerange and long-range illumination. Due to its high light output, the Ultra Beam LED effortlessly replaces Xenon worklights – with just 30 watts of power consumption. Q 90 LED The Q90 LED (1GA 996 283-001) is the first worklight in the “Thermo Pro Series” which, in the near future, will be expanded with additional headlights. It is a robust worklight with compact dimensions and a universal, attractive design. Specially designed to prevent the inherent risks from high-power LEDs, the innovative heat-conductive synthetic material housing is also equipped with additional cooling fins that provide the necessary heat dissipation. The new material not only provides weight savings, but also another important advantage: total corrosion resistance. In addition, there is the high light output from the four high-power LEDs with 1,200 lumen. The start-up model in a promising product line!

AP 1200 LED The AP 1200 LED (1GA 011 720-041) is a flexible-use worklight which has repeatedly proven itself in practice and in harsh conditions. In this case, too, the cooling fins of the black aluminum housing provide the allimportant heat dissipation. With its flat design, there is no need for a reflector: instead, double-sided optics are inserted in the plastic lens. These special optics bundle the light on the inside, and then distribute it extensively and homogeneously to the entire work area. The AP 1200 LED provides a light output of 1,200 lumen with a power consumption of just 22 watts and impresses with its excellent value for money.

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DAY AND NIGHT

More light, less energy consu easy, more efficient night-time

Especially when it comes to balancing cost and use, LED worklights provide many advantages: they consume noticeably less energy compared to halogen headlights, have a considerably longer service life and, in addition, provide a brighter, more pleasant light that does not create eyestrain and therefore relieves fatigue, even during night-time use. There are many arguments for migrating to this new technology. Halogen and LED: easily combinable You do not have to change over in one, radical step: functioning halogen worklights can continue to be utilised and replaced with LEDs as, and when, required.

Standard equipment: 4 x halogen worklights

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Both systems can easily be combined. If the halogen headlights cease to function during future operations, they can be easily replaced with new LED headlights. Relieve generator strain, save fuel No-one knows it better than you: light uses energy – and energy must come from somewhere. If the generator has to produce more current, then it will obviously have to rotate quicker and take up more power from the internal combustion engine. To put it another way: if less current has to be generated, then the engine requires less fuel.

Generator load:

Upgrade option I: 2 x halogen worklights 2 x LED worklights Generator load:

11.67 amperes

7.66 amperes

DAY AND NIGHT

mption: working

Highcontrast working light

Older machines have performance deficits If more light is needed, the generator has to work harder. Many older tractors have generators which cannot provide this additional power. It is therefore very important to select worklights which operate with energy efficiency and/or have low power consumption and, at the same time, have a higher light output. First choice: the HELLA LED worklights.

Worklight configurator: combine them yourself – the best worklights for every scenario

Spreaders and snow vehicles are exposed to tough working conditions and present special challenges. HELLA has developed the Module 70 LED (1GO 996 276-701) worklight with a blue lens especially for such conditions. This unit provides the complete boom with uniform illumination. The blue lens also provides an even light which is rich in contrast, making spray mist visible in even poor weather conditions and darkness. The even distribution of spray mist is then clearly visible.

The blue light provides contrast and makes the spray mist clearly visible

STARTING AID

Ignites reliably Without ignition and a starting switch, it is not possible to set any type of vehicle and working machine in motion, therefore they are essential starting aids. It is very important to pay attention to reliable quality, because if a vehicle cannot be started, this will lead to significant downtimes and cost increases in most cases. So those who save at the start, save in the wrong place!

Upgrade option II: 4 x LED worklights

The embodiment of reliable quality: the ignition and

Generator load:

3.67 amperes

starting switches from HELLA

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LED QUALITY COMPARISON

HELLA makes the difference They exist, the small but subtle differences. Where HELLA invests in quality (+), some cheaper suppliers utilise materials which leave a lot to be desired in terms of robustness and durability (-). All in order to lure customers with an attractive price. But whoever decides to save on the quality, pays more in the end. Using the example of the HELLA Power Beam 1500 LED, the quality differences can be clearly shown on a point by point basis.

Surface coating HELLA worklights are protected by coatings on the aluminum parts against salt and chemicals and, therefore, against corrosion. Corrosion can cause the headlights to become unsightly. In the worst case, water can penetrate and damage the electronics.

Thermal management Thermal management is intelligently thought through and regulated by HELLA worklights. Heat from the LEDs is evenly distributed and discharged via the housing. If overheating is imminent, the affected LEDs are dimmed automatically. Without a thermal regulation system, LEDs can overheat very quickly and their design life is significantly shortened. Such “hotspots” can, in the worst case, deform the complete electronic circuit board, create breaks in the solder joints and then the total failure of the headlight.

Electromagnetic compatibility (EMC) Prevent magnetic interference by design measures at the outset: the arrangement of the LEDs and the design of the reflector in HELLA worklights ensure trouble-free operation. LED headlights that are not correctly shielded produce strong electromagnetic fields which interfere with the on-board electronic system, radio and GPS and can cause safety-relevant parts in the vehicle to fail.

Electrostatic discharge (ESD) Every HELLA employee who enters the LED production area must first discharge their static so that no components are damaged by charges. The absence of such care can cause electronic components, which have been damaged by static electricity, to destroy an entire headlight. The resulting downtime would be correspondingly expensive for all concerned.

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LED QUALITY COMPARISON

CLARIFY THE DIFFERENCES It is the sum of the details which makes HELLA quality stand out clearly.

Quality of the LEDs

The distinguishing features of HELLA are marked with a plus.

The LEDs in the worklights from HELLA are subjected to rigorous inspections and harsh testing. This process ensures the robustness and extremely long LED design life of up to 60,000 hours (compared to halogen bulbs).

A minus sign is shown here when low quality has a detrimental effect.

Cheaper LEDs cannot live up to the actual benefits which LED technology promises – shortened design life, errors and malfunctions are commonplace with these products.

Adhesion

Precision is important when adhering: adhesive robots hermetically assemble the HELLA worklights, the lens is also adhered at the optimum angle. The result: the calculated luminous efficiency is achieved exactly. Headlights of inferior quality are often adhered by hand. This results in irregular adhesive patterns which do not comply with the ideal lens angle and therefore prevent optimal luminous efficiency. If the lens is no longer tight or becomes detached, water can penetrate and make the light unusable.

HELLA LED worklights in endurance testing Durability, robustness and the design life of HELLA LED worklights are tested in numerous test series – the best preparation for tough, uncompromising real-world use. The advantage of these tests: HELLA worklights last much longer than the cheaper competition and therefore always remain fully functional.

Light distribution via the reflector system

The exact calculation of the reflectors from HELLA worklights enables a uniformly illuminated field of work and optimum utilisation of the generated light. Many worklights are equipped with inadequate light control systems. The working area is therefore insufficiently illuminated and the majority of the light is wasted. Bright light spots distract the eyes and, in other places, the details are only diffusely visible.

Heat and cold test

Splash-water test

High-pressure cleaning test

Vibration test

Immersion and pressure tightness test

Dust and salt spray test

Reverse polarity

Accidental, incorrect connections do not have negative effects: HELLA worklights are well protected against reverse polarity. By connecting a headlight which is incorrectly protected, the electronics will be completely destroyed when the unit is turned on.

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SIGNAL UNIT

Caution! In terms of safety, the Rota LED beacon sets new standards – thanks to the 20% increase in light output, as well as all-round compelling benefits.

The Rota LED is just one of many HELLA beacons

More light means better visibility, and therefore greater safety. Thanks to its outstanding efficiency, the LED Rota (2RL 010 979-011) displays 20% more luminous efficiency. It additionally impresses with precise simulation of the rotating light image – without moving components. Due to its slim and compact design, and the shock-absorbing rubber foot, it is perfectly suited for external and internal safety in harsh working conditions.

High-performance

horns Take the hearing test! Get an impressing acoustic at www.hella. com/microsite/horns or by using the app.

Horns and trumpet horns have more than 100 years of tradition at HELLA. Based on this experience, the acoustic signal unit impresses with its high level of technology and strict quality standards. Especially when working with heavy equipment or special vehicles, in poor visibility or in hazardous situations, the warning signals provide safety for people and vehicles. In addition to optical warning signals, HELLA offers a wide range of acoustic signal units. For operations in forestry and agriculture, you can select from a wide range of signal horns or loud horns, electric dual-tone trumpet horns as well as compressor or compressed air trumpet horns.

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COOLING AND SWITCHING CENTRES

The thermal management experts.

BEHR HELLA SERVICE is one of the leading suppliers of products for vehicle air conditioning and engine cooling. A range which is aimed at both the independent parts market as well as independent garages. Harvesting or forest work in the blistering summer heat or continuous use in the middle of summer make considerable demands on man and machines. For the driver, it is important to stay cool! It is good to know that you can rely on the thermal management systems from the experts at Behr Hella Service. As the exclusive supplier of Behr products to independent parts retailers, Behr Hella Service can offer you sophisticated and coordinated system components. The product range includes radiator systems, fans and compressors as well as dryers and evaporators. The extensive product range is complemented by other products such as compressor oils etc. As a competent partner, Behr Hella Service supports you with technical information and training as well as sales support. More information is available at www.behrhellaservice.com.

Coolant radiators from Behr Hella Service – one of the many products from the thermal management experts. Here, for example, for John Deere (8MK 376 783-631). The application and reference no. can be readily supplied on request.

Other products for utilisation in agricultural vehicles will be presented in the next edition of our journal.

Switched rapidly As a renowned automotive supplier, HELLA is known both as a provider of lighting systems as well as a manufacturer of elements and components for vehicle electronics. On offer: a broad rocker switch range that provides many advantages. The switch program from HELLA not only offers different switch functions, but also more than 500 switch symbols to choose from. In addition, the new waterproof series 3100 complements the existing range. By fulfilling the stringent requirements of protection class IP 68, it is ideally suitable for utilisation in agricultural and forestry machinery. The perfect switch – both for indoor as well as outdoor use – can be individually configured by clicking on www.hella.com/switch.

For perfect visibility, even under extreme lighting conditions and at night, the night lighting is provided in green and the function controls in red.

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CURRENT CONTACT

Well connected With 16 to a max. of 13 amperes and 2-pole to 12-pole versions, DEUTSCH connectors provide excellent shock and vibration resistance from 55°C to + 125°C as well as maximum protection against external influences.

Maximum protection from environmental influences is provided by the DEUTSCH connectors in the “DT series” and therefore set new standards with regards to operational safety. Dirt and humidity are the major, influential factors that make life difficult for vehicles in agriculture and forestry. It is reassuring when the electrical system is complemented with high-performance and robust connectivity which can withstand these harsh

conditions. For extreme demands, HELLA also stocks DEUTSCH connectors in the “DT series”. Fitted with a housing made of high-performance plastic, they are also extremely shock and vibration resistant as well as corrosion-resistant and flame-resistant and are suitable for utilisation in a wide temperature range. High-performance silicone seals provide a tight jacket and insulation for the wiring as well as protection against most of the substances utilised in industry and

engine compartments. Another plus factor is maximum flexibility, even under extreme temperatures, and high compatibility with various cable cross-sections. The housing lock, with integrated click-in function, guarantees a quick and secure connection with a strong grip. With symmetrical star-crimping, the contacts of the crimp connection additionally provide excellent resistance to temperature-related and oxidationrelated induced resistance fluctuations.

100Dependency % SUPERSEAL connectors are characterised by extreme water resistance and are therefore perfectly suitable for use under extreme conditions.

SUPERSEAL connectors are resistant to extreme conditions, such as water, salt, ozone, petrol, diesel fuel, engine oil or brake

The SUPERSEAL connectors from HELLA have been specially developed to meet the increasing requirements for safe and reliable electrical connections. The terminals are connected to existing components and can be utilised in many applications (sensors, oil pressure sensors, water temperature monitoring circuits, etc.).

Handy-Box assortment box without case (9XX 863 801-001) Assortment box, fuses (8JS 009 257-801) Assortment box, crimp connectors (8KW 009 254-801) Assortment box, SUPERSEAL (8JA 009 256-801) Assortment box, shrink sleeves (9JM 178 458-801) available from Sept. 14

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fluid.

LIGHT INDUCER

Small but effective:

bulbs HELLA installs 180,000,000 bulbs in the production process every year. A dimension which speaks volumes for this little light inducer.

Good to know: the most common replacement bulbs have already been

If they function, nobody even thinks about bulbs. But watch out when one of them fails and causes annoying downtimes. Particularly in the agriculture and forestry industries, this can also have financial consequences. It is therefore always advisable to quickly have the suitable spare part close to hand. The innovative light bulb configurator from HELLA assists you when locating the right bulb for your vehicle and your requirements. For a complete overview of the full range, you only need to take a look at the bulbs brochure.

compiled by HELLA for your customers in the new, practical counter display. You can order them simply by using part no. 8GH 002 090-134 (display contains: 30 x H3 bulbs).

A complete overview The new blister packs from HELLA not only put the product in the limelight, but they also provide descriptive and self-explanatory pictograms on the package with useful information. A real HELLA advantage that ensures a perfect overview for customers and dealer personnel alike.

Where industry professionals meet As a leading original equipment manufacturer and supplier to the automotive and commercial vehicle industry, HELLA is of course represented at all important automotive and trade shows. If you have not yet scheduled anything for this autumn, you might like to visit the following trade fairs.

AUTOMECHANIKA 2014 The leading International Trade Fair for the Automotive Industry, Frankfurt am Main, Germany September 16th – 20th 2014 Hall 3, Level 0, Booth D91 Hall 8, Level 0, Booth M53

NKW IAA 2014 Hanover, Germany September 25th – October 2nd 2014 Hall 12, Booth B23 A quick glance is enough to determine which connector is suitable, how high the performance is and for what type of applications the product is intended for – all displayed on the pictogram on the packaging.

EIMA International 2014 International Exhibition for Agricultural Machinery Bologna, Italy November 12th – 16th 2014 Hall 20, Booth D/56

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INFORMATION CENTRE

HELLA online All information – All data – All tests...

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HELLA KGaA Hueck & Co. Rixbecker Straße 75 59552 Lippstadt/Germany Tel.: +49 2941 38-0 Fax: +49 2941 38-7133 E-Mail: [email protected] Internet: www.hella.com © HELLA KGaA & Co., Lippstadt Subject to technical and price modifications. Printed in Germany For information on legal stipulations and attachment regulations, please consult the Internet or a qualified garage.

What was the part number again? Which worklights fits which tractor unit and which beacon is the right one? All the important information relating to your questions can be found on the HELLA homepage – clearly sorted into categories.

Find important topics for professionals, games for entertainment and practical HELLA apps or share views with the HELLA community on Facebook.

Agriculture homepage

ELIVER – experience light

This is where the community meets

Find information specially for the aftermarket/ garages, producers and agriculture. Naturally with a full overview of all HELLA products. www.hella.com/agriculture

With this online tool, you can test HELLA worklights in a realistic, animated environment and see how different beacons match up against each other. Try it for yourself! www.hella.com/eliver

At HELLA4WorkingPeople on Facebook, you can find the latest news about products, interactive promotions and features. Your opinion on current issues is also welcome. Join in at www.facebook.com/hella4workingpeople

Worklight configuration tool

Looking for winners: Tractor World Cup

HELLA worklights app

Which worklight suits which vehicle and what purpose? Use the online configuration tool to find the right HELLA product for your needs in a blink of the eye. www.hella.com/worklight-configurator

Choose your favorite tractor unit, and compete against your challenger in this for this classic game. A special challenge is also waiting for you in the bonus level. Start straight away: www.hella.com/agriculture (in Agriculture > Worklights)

A complete overview on the go. By using the HELLA app, you can experience the interactive world of worklights and learn about the benefits of the various lighting technologies. Find it at: www.hella.com/apps

Please see the assembly instructions for more detailed information.