Product Manual for YHJ-800 and YHJ-1500 Intrinsically Safe Laser Pointers for Mining

YHJ-800 YHJ-1500
                        
    
Intrinsically Safe Laser Pointer for Mining
Instruction Manual

Implementation Standard: GB/T 3836.1-2021
GB/T3836.4-2021
MT209-1990
Q/HGY 37-2023(YHJ-800)
Q/HGY 39-2023(YHJ-1500)
Publication Date: April 2023
Version Number: V1.0
Safety Certification Numbers: MFA240026 (YHJ-800), MFA240025 (YHJ-1500)
Explosion-proof certification numbers: CCRI 23.2604 (YHJ-800), CCRI 23.2603 (YHJ-1500)
  

Harbin Optical Instruments Factory Co., Ltd.

I. Overview
1. Product Features
The YHJ-800 and YHJ-1500 intrinsically safe laser alignment instruments for mining are multifunctional devices that integrate electronics, optics, and precision mechanics. They feature an aesthetically pleasing design, compact size, light weight, and explosion-proof construction. The instrument can be quickly mounted on anchor bolts via a suspension assembly and offers 360° full-range coarse adjustment with highly precise fine adjustment; adjustment is convenient and the braking mechanism is reliable. The product incorporates a self-developed optical system and supports both red and green light sources, with beam spot size and effective range tailored to meet the requirements of underground mining operations. It can be powered by either the DXH6/4.3 intrinsically safe battery pack for mining or the associated KDY127/5 intrinsically safe DC power supply, enabling operation on both AC and DC power in underground environments.
2. Complies with the following standards: GB/T 3836.1-2021, GB/T 3836.4-2021, MT 209-1990, Enterprise Standard Q/HGY37-2023, and Enterprise Standard Q/HGY39-2023.
3. Main Uses and Scope of Application
The instrument is primarily used in underground coal mine roadways to provide precise positioning of the center and waist lines, as well as directional alignment for the installation of transport pipelines, conveyor belts, ventilation ducts, water pipes, and cables.
4. Instrument Model Definition

5. Operating Environment
a Ambient temperature: 0°C to +40°C
b Relative humidity: ≤95% RH (at +25°C)
c Ambient atmospheric pressure: 86 kPa ~ 110 kPa
d in the underground environment of coal mines containing a mixture of explosive gases (methane) and coal dust
e in an environment free of gases or vapors that would visibly damage the insulation
Pollution degree: Level 3
II. Structural Features and Operating Principle
1. Structural Features:
The instrument integrates electronics, optics, and precision mechanics into a single unit and can operate in either AC or DC mode when connected to either the DXH6/4.3 intrinsically safe battery pack for mining use or the associated KDY127/5 intrinsically safe DC power supply for mining use.
The instrument’s coarse adjustment is achieved via a 360° rotatable locking mechanism, while installation employs a fixing rod and a suspension assembly with a locking device, enabling more convenient and rapid instrument fixation. Coarse adjustments in both the horizontal and vertical directions can be made arbitrarily over a full 360° range. Furthermore, the instrument’s fine adjustment mechanism allows for minute horizontal and vertical adjustments within a range of no less than 1.5°.
2. Operating Principle:
The laser module is powered by either the DXH6/4.3 intrinsically safe battery box for mining applications or the associated KDY127/5 intrinsically safe DC power supply, enabling it to emit a laser beam. The instrument generates the laser beam and then uses an optical system to produce a long-range pointing laser beam, with a respective effective range of 800 meters.
III. Basic Parameters, Effective Range, Spot Diameter, Spot Drift, and Horizontal and Vertical Adjustment Ranges
1. Installation method: Portable
Explosion-proof type: intrinsically safe for mining applications
Explosion-proof marking: Ex ibI Mb
Continuous operating time: ≥40 hours (when equipped with the DXH6/4.3 intrinsically safe battery box for mining use).
24-hour continuous operation (compatible with KDY127/5 intrinsically safe DC power supply for mining use)
YHJ-800 host unit dimensions: 195 mm × 250 mm × 136 mm
YHJ-1500 host unit dimensions: 230 mm × 250 mm × 136 mm
Weight: Host + suspension assembly 2.8 kg (YHJ-800), Host + suspension assembly 2.9 kg (YHJ-1500)
Intrinsic safety parameters:
Rated operating voltage: 3.7 V DC; operating current: ≤90 mA
2. Effective range, spot diameter, and spot drift:
The YHJ-800 intrinsically safe laser pointer for mining applications has an effective range of 800 m; at 800 m, the spot diameter shall not exceed 60 mm, and the spot drift shall not exceed 10 mm.
The YHJ-1500 intrinsically safe laser pointer for mining applications has an effective range of 1,500 m; at 1,500 m, the spot diameter shall not exceed 100 mm, and the spot drift shall not exceed 10 mm.
3. The lateral and longitudinal adjustment range of the laser pointer’s fine-adjustment mechanism shall be ≥1.5°.
IV. Installation, Adjustment, and Use

1. Installation
(1) First, drive a 20–22 mm anchor bolt (provided by the user) into the roadway roof for secure fixation.
(2) Pass the mounting rod through the mounting bracket, secure the instrument to the rod using bolts, and then, as shown in the figure, fasten the screw plug, retaining ring, and locking bracket to the pre-installed anchor bolt.
2. Adjustment and Use
Instrument power connection: Connect to the DXH6/4.3 intrinsically safe battery box for mining use (see Appendix 1) or to the associated KDY127/5 intrinsically safe DC power supply for mining use (see Appendix 2). After confirming that there are no loose connections or short circuits in the circuit, tighten the retaining sleeve on the connector; the laser module will then be powered on and illuminated.
(1) Perform coarse adjustments in the vertical and horizontal directions of the instrument as required by the instrument’s aiming direction.
Vertical coarse adjustment: Loosen the set screw, rotate the instrument along the anchor bolt to align the laser beam in the vertical direction to the desired position (at the mid-chest line), then tighten the set screw.
Horizontal coarse adjustment: Loosen the bolt, slide the instrument along the mounting rod to align the laser beam horizontally to the desired position (at the midline), then tighten the bolt.
(2) Then, precisely adjust the direction of the laser beam according to the project requirements, as follows:
Horizontal adjustment: First lock the vertical adjustment screw, then simultaneously rotate the left and right horizontal adjustment screws in the same direction to move the light spot horizontally. Once properly adjusted, lock both screws.
Vertical adjustment: First lock the horizontal adjustment screw, then rotate the upper and lower vertical adjustment screws in the same direction to move the light spot vertically. Once properly adjusted, lock both screws.
(3) When the voltage of the DXH6/4.3 intrinsically safe battery pack for mining drops too low, the laser will dim or fail to illuminate. In this case, loosen the retaining sleeve and promptly replace it with another fully charged DXH6/4.3 intrinsically safe battery pack for mining.
(4) The DXH6/4.3 intrinsically safe battery box for mining use must be charged on the surface!
Please note: After the spot has been accurately adjusted in both the horizontal and vertical directions, the adjustment screws must be locked simultaneously. The instrument is factory-calibrated to ensure the spot remains within the specified range, so no on-site adjustment is required by the user. If adjustment is nevertheless necessary, please follow the procedures outlined in the troubleshooting section.
V. DXH6/4.3 Intrinsically Safe Battery Box and Charger for Mining Use
1. Precautions for Use of the DXH6/4.3 Intrinsically Safe Battery Box for Mining
(1) Do not place in fire or attempt to disassemble.
(2) Do not short-circuit the power supply terminals to avoid permanent damage.
(3) Please connect the power supply with the correct polarity; reverse connection is not permitted.
(4) To ensure that the DXH6/4.3 intrinsically safe battery box for mining applications maintains its capacity level, it shall be stored in an environment free of corrosive gases and protected from storage at elevated temperatures or high humidity, as such conditions can lead to a reduction in the battery box’s capacity.
(5) Please use the supplied charger to charge the DXH6/4.3 intrinsically safe battery pack for mining applications, ensuring that the charging time does not exceed 8 hours. If any abnormalities or issues are detected during operation, please contact your distributor or the manufacturer.
2. Charger Technical Specifications
(1) Ambient temperature: 0°C to 40°C
(2) Charging indicator instructions:
Two-color LED: when the red light is on, the power is connected and the charging process is underway;
When the green light is on, the battery is either charging or fully charged;
(3) AC input: Chinese national standard two-pin plug; DC output: WY16-J3Z aviation connector.
VI. Safety Warnings
Warning: Do not look directly into the light-emitting window!
VII. Maintenance, Servicing, and Usage Precautions
1. When the instrument is not used for an extended period, it should be stored in a cool, dry, and non-corrosive environment.
2. The optical system is calibrated before the instrument leaves the factory; do not disassemble it arbitrarily. During transportation, handle with care to avoid severe vibration.
3. After use, it is recommended to perform a charge–discharge maintenance cycle every six months during long-term storage to prevent battery capacity degradation.
4. The window glass of the laser output aperture should be regularly wiped with lens paper or a soft cloth to ensure the surface is clean and free of dust.
5. Live maintenance is prohibited; when it is necessary to open the enclosure for maintenance, such work must be carried out in a safe location. During operation and maintenance, the electrical parameters and protective performance of the intrinsically safe circuit must be maintained in accordance with its original design, and the model, specifications, and parameters of components in the product’s intrinsically safe circuit must not be altered.
VIII. Fault Analysis and Troubleshooting
“If the instrument is not functioning,” please check your instrument according to the table below. If, after inspection, the instrument still cannot operate normally, please contact a service center or the manufacturer.
Fault Phenomenon Cause Analysis Troubleshooting Methods
Instrument not functioning 1. Is the voltage of the DXH6/4.3 intrinsically safe battery box for mining correct?
2. Power supply is not connected
3. Insufficient battery charge in the DXH6/4.3 intrinsically safe battery box for mining use. 1. Check and verify that the power supply unit voltage is normal.
2. Check that the plug and socket are making good contact.
3. Replace with a DXH6/4.3 intrinsically safe battery box for mining use that has sufficient charge.
No laser beam when the battery box is connected: 1. Poor contact between the battery box plug and socket.
2. Laser module damage 1. Inspect the battery box switch, plug, and socket connections for proper connectivity.
2. Replace the laser module
Unclear or enlarged light spot 1. Loose optical lens
2. Damage to the laser module lens
3. Misalignment of the focusing barrel causes inaccurate focusing 1. Return to factory for repair and calibration
2. Replace the laser module
3. Return the instrument to the factory for recalibration, or loosen the set screw and rotate the focusing barrel (do not rotate the objective lens tube at the same time). Once the desired adjustment is achieved, tighten the set screw.
Range is insufficient. 1. Heavy ambient fog.
2. High levels of environmental dust
3. Heavy ambient smoke 1. Avoid heavy fog
2. Use after dust reduction
3. Use after reducing smoke
Spot displacement occurs: 1. The coarse adjustment mechanism is not locked.
2. Precise adjustment mechanism not locked 1. Tighten the coarse adjustment mechanism
2. Tighten the precision adjustment mechanism

IX. Maintenance Services
1. In principle, maintenance of explosion-proof electrical equipment shall be carried out by the equipment manufacturer. If maintenance is performed in-house, the maintenance organization must possess the necessary inspection and testing facilities, and may proceed only with the prior consent of the equipment manufacturer. During maintenance, the electrical parameters and protective performance of the intrinsically safe circuit must be maintained in accordance with its original design; the model, specifications, and parameters of components in the intrinsically safe circuit shall not be altered. Following maintenance, explosion-proof parameter measurements and inspections must be conducted, and the equipment must comply with the requirements of GB/T 3836-2021 before it can be put into service. The maintenance organization shall bear all responsibilities arising from the maintenance of the equipment. The use of batteries other than those specified in the instruction manual is strictly prohibited.
2. Starting from the date of invoice issuance, the instrument is covered by a 12-month warranty and eligible for lifetime repair and calibration services.
3. During the warranty period, any component damage caused by manufacturing defects will be replaced free of charge.
4. During the warranty period, any damage not caused by product quality issues shall be subject to appropriate charges.
X. Product Packing List
1. Laser pointer 1 unit 2. Fixed pole 1 piece 3. Suspension assembly 1 set
4. Hex key, 1 piece 5. Instrument case, 1 piece 6. Product manual, 1 copy
7. Certificate of Product Conformity: 1 copy 8. Charger (optional): 1 unit 9. DXH6/4.3 Intrinsically Safe Battery Box for Mining Use (optional): 1 unit 10. KDY127/5 Intrinsically Safe DC Power Supply for Mining Use (optional)
(The suspension assembly includes a screw plug, a retaining ring, and a locking seat.)

Appendix 1: Instruction Manual for the DXH6/4.3 Intrinsically Safe Battery Box for Mining
(Anbang Certification Number: MAA240015, Explosion-Proof Certification Number: CCRI 23.7061)

Warning: During maintenance, do not alter the electrical parameters, specifications, or model numbers of intrinsically safe circuits or components associated with such circuits.
The product shall only be connected and used with the equipment specified in the instruction manual; if it is to be connected to other equipment, it must undergo explosion-proof inspection.
Charging underground is strictly prohibited.

1. Overview
1.1 Main Uses and Scope of Application
The DXH6/4.3 intrinsically safe battery box for mining use (hereinafter referred to as the “battery box”) is primarily used to supply power to the terminal devices of the YHJ series intrinsically safe laser alignment instruments for mining applications, providing backup power support.
1.2 Model Composition and Significance
• Explosion-proof type and explosion-proof marking
Explosion-proof type: intrinsically safe for mining use; explosion-proof marking: Ex ibⅠMb
• Model Definition

1.3 Operating Environment Conditions
The battery box shall operate normally under the following environmental conditions:
a. Ambient temperature: (0～+40)°C
b. Relative humidity: ≤95% (+25°C)
9 Atmospheric pressure: 80–106 kPa
10. Permitted for use in hazardous environments containing explosive mixtures of methane and coal dust.
11. Applications with no significant vibration or impact
The battery box shall be capable of withstanding the most severe storage and transportation conditions, namely:
a. Temperature: -40°C to +60°C
b. Average relative humidity: ≤95% (+25°C)
8 Vibration: Acceleration 50 m/s²
9 Impact: Peak acceleration of 500 m/s²
2. Structural Characteristics
The battery box consists of the battery, its protection circuit, intrinsically safe circuit, charging protection circuit, and housing, among other components; its external appearance and internal structure are shown in the figure below.

Figure 1: Structure and Dimensions
3. Technical Characteristics
3.1 Implementation Standards
Battery box compliance standards: MT/T 1078-2008, GB/T 3836-2021, Q/HGY 038-2023.
3.2 Appearance
3.2.1 The outer surface of the enclosure shall be free from obvious dents, scratches, cracks, and deformation, and its components shall be free from rust and detachment.
3.2.2 The indicator lights shall have distinct colors, and the signs and nameplates shall have clear, neat lettering and be securely installed.
3.2.3 Permanent “Ex” markings, as well as markings such as “MA” and “Warning: Charging Prohibited Underground,” shall be affixed in conspicuous locations on the enclosure.
3.2.4 Components shall be securely fastened with no looseness, and shall be free from mechanical damage such as rust, burrs, and cracks; mating moving parts shall engage and disengage smoothly.
3.3 Structure
3.3.1 The housing body is made of antistatic, flame-retardant ABS plastic.
3.3.2 Intrinsically safe and non-intrinsically safe circuits shall be routed separately and kept separate from other wiring.
3.3.3 Intrinsically safe and non-intrinsically safe circuit plugs and sockets shall be arranged separately and equipped with measures to prevent misconnection.
3.3.4 The requirements for parts, components, and other structural elements shall comply with the relevant provisions of Chapters 7 and 8 of MT/T 209.
3.4 Main Technical Specifications
3.4.1 Battery Parameters
Model name: PL205667 lithium-ion battery for mining use; Manufacturer: Shaanxi Tianmao New Energy Technology Co., Ltd.; Quantity: 1 unit; Rated voltage: 3.7 V; Rated capacity: 6 Ah. The battery shall be encapsulated with BEEP 6225 (No. 8) A/B, a flame-retardant two-component epoxy potting compound manufactured by Shanghai Baigao Chemical Technology Co., Ltd., with a potting thickness of not less than 2 mm. The battery shall comply with the relevant provisions of MT/T 1051–2007.
3.4.2 Output Parameters
3.4.2.1 The battery box has a single intrinsically safe output.
3.4.2.2 Minimum output voltage: ≥3.5 V;
3.4.2.3 Rated operating current: 500 mA.
3.4.2.4 Open-circuit voltage ≤4.3 V
3.4.2.5 Overvoltage Protection Threshold: 4.5 V
3.4.2.6 Short-Circuit Current ≤1A
3.4.2.7 Period and Random Offset ≤250 mV
3.4.3 Charging Parameters:
3.4.3.1 Charging voltage: ≤ 5 V.
3.4.3.2 Charging current: ≤ 2.0 A.
3.4.3.3 Charging cut-off voltage: ≤ 5.5 V.
3.4.3.4 Cut-off discharge voltage: ≤ 3.2 V.
3.5 Basic Functions
• The battery box provides intrinsically safe power output for connected loads.
• The battery box features input and output power indicator lights.
• The battery box features overcurrent protection and short-circuit protection.
• The battery box employs float charging and features overcharge and overdischarge protection.
3.6 Intrinsically Safe Parameters
Single-cell PL205667 lithium-ion battery for mining applications: UO: DC 4.3 V, IO: 1.1 A, CO: 50 µF, LO: 0.1 mH.
4. Dimensions and Weight
4.1 External Dimensions and Mounting Dimensions: (Length × Width × Height) 109 mm × 53 mm × 102 mm.
4.2 Weight: 0.75 kg.
5. Installation and Adjustment
5.1 Installation Conditions and Technical Requirements
Before installation, the mounting location of this intrinsically safe battery box must be determined.
5.2 Installation Method and Precautions
5.2.1 Secure the intrinsically safe battery box using the mining-grade intrinsically safe laser pointer suspension assembly.
5.2.2 The output leads of the intrinsically safe battery box shall be directly connected to the terminal of the mine-used intrinsically safe laser pointer.
5.3 Pre-Commissioning Preparations
5.3.1 Verify that the battery box power supply is securely installed.
5.3.2 Verify that the output voltage matches the equipment’s requirements.
6. Usage and Operation
The intrinsically safe battery box is primarily used to supply power to underground electronic equipment and does not provide any user-operated functions. During operation, pay close attention to the status of the indicator lights, and if any issues arise, perform maintenance and repairs promptly in accordance with Section 7 of this manual.
7. Fault Analysis and Troubleshooting
Fault Phenomenon Cause Analysis Troubleshooting Methods Remarks

No output from the battery box. Battery is dead. Carry it to the ground for charging.
Internal circuit damage – Replace the battery box.

Appendix 2: Instruction Manual for the KDY127/5 Mine-Use Potting and Intrinsically Safe DC Power Supply
(Anbang Certification No.: MAA240014, Explosion-Proof Certification No.: CCRI23.1534)
Warning:
Please read the following simple instructions and adhere to these rules to prevent hazards caused by improper operation:
This manual provides a detailed description of the product’s performance, installation procedures, and operating instructions. Whether you are using this product for the first time or have prior experience with similar equipment, you must carefully read this manual before use. Harbin Optical Instruments Factory Co., Ltd. shall not be liable for any losses resulting from violations of safety precautions.
1. Do not connect to equipment that has not undergone explosion-proof inspection!
2. The product features an integrated potting design; it is strictly prohibited to damage the internal potting compound, as this will compromise the product’s explosion-proof performance.
3. Do not connect or use without passing the intrinsic safety compatibility test!
4. It is strictly prohibited to open the cover while energized!
5. If deformation, discoloration, softening, or other conditions that impair the explosion-proof performance of the potting compound are detected, immediate cessation of use is required.
6. Prior to use, the product shall be properly grounded. Internal grounding shall be connected via the grounding conductor in the incoming cable, while the external grounding connection shall be made using a user-supplied wire with a cross-sectional area of no less than 4 mm².
1. Overview
1.1 Purpose and Location
The KDY127/5 mining-grade potting-and-intrinsically safe DC power supply (hereinafter referred to as the “power supply”) is suitable for use in explosive hazardous environments containing gas, coal dust, and other flammable substances. Its enclosure has an IP54 protection rating; the enclosure is fabricated from precision-machined Q235B steel tubing, with both internal and external surfaces treated for rust prevention and coated with paint, and the explosion-proof joints are phosphated. The power supply provides intrinsically safe output and incorporates ia-class resistive current-limiting, dual overvoltage protection, and short-circuit protection.
This power supply provides a single intrinsically safe DC 3.5 V, 200 mA output, suitable for coal mines and other underground environments where there is a risk of gas and coal-dust explosions.
1.2 Name and Model
1.2.1 Name: Mining-Use Potting and Intrinsically Safe DC Power Supply
1.2.2 Model: KDY127/5
1.3 Product Model and Its Meaning

1.4 Explosion-proof Type
Explosion-proof type: mining potting and intrinsically safe; explosion-proof marking: Ex mb [ia Ma]ⅠMb.
1.5 External Dimensions, Weight, and Material
1.5.1 External Dimensions: Length × Width × Height: 180 mm × 54 mm × 54 mm
1.5.2 Weight: approximately 1.1 kg
1.5.3 Material: Q235B
2. Operating Environment Conditions
2.1 The power supply shall operate normally under the following environmental conditions:
1) Ambient temperature: 0°C to 40°C;
2) Relative humidity: ≤95% (+25°C);
3) Atmospheric pressure: 80 kPa to 110 kPa;
4) Situations in which explosive mixtures of methane and coal dust are present underground in coal mines, but no corrosive gases that can degrade insulation are present;
5) Applications with no significant vibration or impact.
2.2 The most severe storage and transportation conditions that the power supply can withstand:
1) High temperature: +60℃;
2) Low temperature: -40℃;
3) Average relative humidity: 95% RH (25°C);
4) Vibration: 50 m/s²;
5) Impact: 500 m/s².
3. Operating Principle
This power supply converts AC 127 V to DC 9 V via an AC-DC module, then further steps down to 5 V using an LDO regulator, and finally delivers an intrinsically safe DC output voltage through a Zener diode and a current-limiting resistor.
4. Main Performance
4.1 Power Supply
Rated input voltage: AC 127 V
Input apparent power: ≤20 VA
Expected short-circuit current: 340 mA
4.2 Main Technical Parameters
4.2.1 The DC power supply has one intrinsically safe output channel;
4.2.2 Open-circuit voltage: 5 V
4.2.3 Minimum Output Voltage: ≥ 3.5 V
4.2.4 Rated Operating Current: 200 mA
4.2.5 Periodic and Random Drift: ≤250 mV
4.2.7 Short-circuit current: ≤ 1 A
4.3 Intrinsic Safety Parameters
Um: AC 140 V; Uo: 5.8 V; Io: 1.3 A; Co: 20 μF; Lo: 0.1 mH
4.4 Power Supply Function
The power supply features a intrinsically safe power output channel, along with overcurrent and short-circuit protection, as well as a power-status indicator light.
4.5 Wiring Method
As shown in Figure 1:

Figure 1 Power Wiring

5. Safety Precautions for Use
5.1 Common Misuse or Operational Errors: Cable connections are easily made incorrectly, and AC power may be inadvertently left disconnected.
5.2 Emergency Procedures for Abnormal Conditions: Disconnect the power supply and contact the manufacturer or other after-sales service providers for repair.
5.3 Other Safety Precautions: It is strictly prohibited to open the enclosure while energized; when using a multimeter to measure voltage, be sure to select the correct range.
5.4 The cross-sectional area of the PE grounding conductor shall be no less than 4 mm².
6. Fault Analysis and Troubleshooting
If the power indicator light is off, first check whether the external power supply is functioning properly. If you encounter any other issues, please contact our company’s after-sales service.

Harbin Optical Instruments Factory Co., Ltd.

HARBIN OPTICAL INSTRUMENT FACTORY LTD.

Address: Jingwei Third Road, Daoli District, Harbin City 32 Number

Postal Code: 150010

Telephone: 400-030-0319         0451-84286338

Website: www.hrboptical.com           

E-mail： hopt@hopt.cn