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Bayco Products, Inc. • 640 South Sanden Blvd. • Wylie, TX 75098 • 1-800-233-2155 • 1-469-326-9400 • www.nightstick.com

INS-XPP-5454GC-LG-19

12-07-2018

Instruction Manual

XPP-5454GC

US PATENT 9,713,217

THE XPP-5454GC IS APPROVED FOR USE 

CLASS I DIV 1 GRPS A-D T3
CLASS II & III GRPS E-G T135ºC
CLASS I ZONE 0 AEx ia IIC T3 Ga
Ex ia IIC T3 Ga

II 1 G Ex ia op is IIC T3 Ga

Ex ia op is IIC T3 Ga
Intertek ITS 13 ATEX27928X
IECEx ITS 18.0030X
-20ºC ≤ Tamb ≤ +40ºC
1.5V/Cell E92 or EN92

0359

ID 5012927

INTRINSICALLY SAFE

SECURITE INTRINSEQUE

Bayco Products, Inc.     XPP-5454GC

640 S. Sanden Blvd., Wylie, TX 75098

Conforms to:

ANSI/UL STD 913, ANSI/UL 
60079-0, ANSI/UL 60079-11

Certified to:

CAN/CSA STD C22.2 No 157
CAN/CSA STD C22.2 No 60079-0
CAN/CSA STD C22.2 No 60079-11
CSA STD C22.2 No 25

INMETRO

Segurança

NCC

Ex ia op is IIC T3 Ga

(-20ºC ≤ Tamb ≤ +40ºC)

15.0296 X

WARNINGS - INTRINSICALLY SAFE

y

Warning: Use only the approved non-rechargeable batteries listed below.

y

Warning: Do NOT attempt to use rechargeable AAA batteries with this light.

y

Warning: To prevent ignition of a hazardous atmosphere, do not open the battery 

compartment in the hazardous environment.  This task must ONLY be performed in an 

area known to be non-hazardous.

y

Warning: When exchanging batteries, use only ENERGIZER E92 or EN92 

BATTERIES.

y

Warning: To prevent ignition of a hazardous atmosphere, the AAA batteries must 

only be exchanged in an area known to be non-hazardous.

y

Warning: To reduce the risk of explosion, do not mix new non-rechargeable batteries 

with used non-rechargeable batteries, or mix non-rechargeable batteries from different 

manufacturers.

y

Warning: Substitution of components may impair intrinsic safety.

SPECIAL INSTRUCTIONS FOR INTRINSIC SAFETY

y

For personal safety, always confi rm the rating of any known hazardous or potentially 

hazardous location where the light is to be used.

BATTERY INSTALLATION

WARNING: In order to maintain the XPP-5454’s Intrinsically Safe rating, the only 

AAA batteries certifi ed for use with this light are the ENERGIZER E92 or EN92 

BATTERIES.

y

Do not attempt to use any other brand or model of AAA batteries with this light.

y

Do not attempt to use any type of rechargeable AAA batteries with this light.

Warning: To prevent ignition of a hazardous atmosphere, do not open the battery 

compartment door in the hazardo us environment.  This task must ONLY be done 

in an area known to be non-hazardous.

y

Loosen the locking screw located on the back of the battery compartment door.  

NOTE:  Do NOT attempt to completely remove the locking screw.  Doing so is not 

necessary and may damage the threads.  The screw simply needs to be loosened 

enough to allow the battery compartment door to open.

y

Using 3 – AAA ENERGIZER E92 or EN92 BATTERIES (make sure that all 3 

batteries are of the same model), install the batteries in the back of the light paying 

close attention to the markings inside the battery compartment for proper battery 

terminal polarity alignment.

y

Close the battery compartment door.

y

Tighten locking screw.  CAUTION:  Do NOT over-tighten.  Doing so may damage the 

threads and impact the light’s Intrinsic Safety. 

OPERATION 

THE XPP-5454GC HAS TWO BUTTONS THAT CONTROL LIGHT OUTPUT:  

LIGHTING MODES

Pressing the Spotlight Button will turn on the spotlight.  Pressing the Floodlight 

Button will turn on the fl oodlight.  Pressing both buttons will turn on both the Spotlight 

and the Floodlight.  This mode is called Dual-Light.
EACH BUTTON HAS TWO BRIGHTNESS SETTINGS

y

High-brightness - Press the desired button once

y

Low-brightness - Press the desired button a second time

y

Pressing the same button a third time will turn that lighting mode off

THE XPP-5454GC HAS A TILT ADJUSTMENT FEATURE:  

Simply adjust the tilt angle of the light to illuminate the desired area.

THE XPP-5454GC FITS ON ANY HARD HAT THAT HAS A HARD HAT LAMP 

BRACKET ATTACHED:

NIGHTSTICK NS-HMC4 HEADLAMP  BRACKET MOUNTING INSTRUCTIONS

y

Ensure mounting surface is clean and oil-free (use alcohol wipe if needed)

y

Prior to installing, determine mounting location that allows headlamp to fully tilt 

without interfering with helmet brim.

y

Remove adhesive backing.

y

Firmly press bracket into place up for 30 seconds with fl at side facing up (see image).

y

While supporting mount, slide headlamp clip into bracket slot. (Note: adhesive 

reaches peak strength in 24 hours)

TO ATTACH TO THE HARD HAT LAMP BRACKET

Slide the clip on the back of the XPP-5454GC into the slot on the top edge of the 

Hard Hat Lamp Bracket and press down fi rmly until the clip is fully engaged into the 

bracket.
TO REMOVE FROM THE HARD HAT LAMP BRACKET

Grasp the XPP-5454GC and pull up until the clip slides out of the Hard Hat Lamp 

Bracket.

XPP-5454GC

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