H 311 Night Navigator 003-8118-005-Modified for Hong Kong Only

Night Navigator™ Model 8540 User Manual1.

Document: 003-8118-004

www.currentcorp.com [email protected]

+1 604 461 5555

1 © 2002 to 2007 The Current Sales Corporation.

Use Restrictions The Current Corporation Night Navigator™ 8540/8520 System incorporates a Generation III Image Intensifier Tube. This is a restricted commodity and is subject to export controls. This product has been shipped to you with an export license from Canada. If it is used in a different location or an application other than originally approved, then an export application, from your country may be required.

Warnings and Precautions Please read all instructions carefully before operating your Night Navigator™. This is an image-intensified camera. Each unit is registered for export. An export license may be required for re-export. The camera must be returned to your local agent or the Current Corporation for repair, re-focus or calibration. Opening the unit will void warranty. The Current Corporation’s Night Navigator ™ image intensifier - as with any other night vision intensifier - is designed to be operated at night and is, therefore, highly sensitive to bright light conditions. Exposure to continuous high light levels will result in permanent damage to your image intensifier. Please ensure that you read and strictly adhere to the operating instructions and precautions provided. The Current Corporation reserves the right to waive warranty liability if it is determined that the operating instructions and precautions were not followed. Warning: This system is not for use as the primary night navigation device. Warning: The Night Navigator™ is an image-intensified system intended for use only at

night. Use of the image intensifier in the presence of strong lighting will cause permanent damage as the bright image is “burned in”. This type of damage will void the warranty.

CAUTION: To reduce the risk of injury due to electric shock or sudden release of pressure, do not remove cover (or back). No user-serviceable parts inside. Refer servicing to qualified service personnel.

Current Corporation 2933 Murray St,

Port Moody, BC, V3H 1X3 www.currentcorp.com Canada

Night Navigator™ 8540/8520 User Manual

Doc: 003-8118-004 © 2002-2007 The Current Sales Corporation. Mar. 19, 07 Page 1

TABLE OF CONTENTS

1 NIGHT NAVIGATOR™ SYSTEM OVERVIEW.......................................................... 5

1.1 About the 8540/8520.....................................................................................................................................5

1.2 Components & Basic Functions ...............................................................................................................6

1.3 Comparison of Night Navigator™ model 8540 and model 8520 .......................................................7

2 NIGHT NAVIGATOR™ OPERATION........................................................................ 8

2.1 Night Navigating Overview.........................................................................................................................8

2.2 Operational Requirements .........................................................................................................................8

2.3 Comparison with Radar ..............................................................................................................................8

2.4 Horizontal Field of View and Speed-Distance Charts..........................................................................9 2.4.1 20º Field of View .....................................................................................................................................9 2.4.2 9.5º Field of View ..................................................................................................................................10 2.4.3 7.5º Field of View ..................................................................................................................................11 2.4.4 Speed Distance Time Charts ..............................................................................................................12

2.5 Precautions to Remember ........................................................................................................................13 2.5.1 System Power........................................................................................................................................13 2.5.2 Harbour & High Light Operations: ......................................................................................................13 2.5.3 Adjusting the brightness or contrast control on the monitor. ..........................................................13 2.5.4 Atmospheric conditions ........................................................................................................................14

2.6 Night Navigator™ Controllers .................................................................................................................15 2.6.1 Control Panel layout .............................................................................................................................15 2.6.2 Camera Controls ...................................................................................................................................16 2.6.3 Light Controls.........................................................................................................................................17 2.6.4 Other Controls .......................................................................................................................................19 2.6.5 4 Button Keypad Layout (10º/20º PAN controls).............................................................................20 2.6.6 10º/20º PANNING Controls for model 8540/8520............................................................................20 2.6.7 Optional 10º/20º PANNING Controls for model 8520......................................................................20 2.6.8 4 Button Keypad Dimmer Control .......................................................................................................20

2.7 Display Operation .......................................................................................................................................21 2.7.1 Night Navigator™ on-screen displays................................................................................................21

2.8 On Screen Programming ..........................................................................................................................22 2.8.1 MENU access ........................................................................................................................................22 2.8.2 Availability of NN Control Panel Key functions in MENU mode .....................................................23 2.8.3 General Menu functions .......................................................................................................................23 2.8.4 PAN/TILT Over-ride ..............................................................................................................................23 2.8.5 Range Line Position and Threshold Calibration ...............................................................................24 2.8.6 Calibration Procedures.........................................................................................................................25





3 NIGHT NAVIGATOR™ INSTALLATION................................................................. 26

3.1 Night Navigator™ 8540/8520 Installation Data ....................................................................................26

3.2 Power Requirements..................................................................................................................................27 3.2.1 Vac connections ....................................................................................................................................27 3.2.2 Vdc Terminal block ...............................................................................................................................27

3.3 Panel mounted Controllers Installation ................................................................................................28 3.3.1 Control Panel .........................................................................................................................................28 3.3.2 Optional 4 button Keypad ....................................................................................................................28

3.4 Video Display Unit (VDU) Installation ....................................................................................................29

3.5 Main Control Unit (MCU) Installation .....................................................................................................30 3.5.1 MCU Door Key ......................................................................................................................................30 3.5.2 MCU Mounting.......................................................................................................................................31 3.5.3 Field Wiring Procedure to meet IMO requirements for EMC ..........................................................32

3.6 Sensor Package Mounting .......................................................................................................................45 3.6.1 General Information ..............................................................................................................................45 3.6.2 Sensor Package Mechanical Installation...........................................................................................46

3.7 Optional Wash and AIR Unit ....................................................................................................................48 3.7.1 Compressor Unit ...................................................................................................................................48

3.8 System Interconnections ..........................................................................................................................49

3.9 Electrical System Cable Routing ............................................................................................................50 3.9.1 Connections to Sensor Package ........................................................................................................50

4 NIGHT NAVIGATOR™ INITIALIZATION ................................................................ 51

4.1 Initial Power up............................................................................................................................................51

4.2 Focus Confirmation....................................................................................................................................52 4.2.1 Focus Adjustment .................................................................................................................................52

4.3 PAN / TILT LIMIT Adjustments ................................................................................................................53 4.3.1 Internal Access ......................................................................................................................................53 4.3.2 Method to Adjust limits .........................................................................................................................54 4.3.3 TILT LIMIT Adjustments.......................................................................................................................54 4.3.4 PAN LIMIT Adjustments.......................................................................................................................54

5 NIGHT NAVIGATOR™ MAINTENANCE ................................................................ 55

5.1 General Maintenance .................................................................................................................................55

5.2 Night Navigator™ Maintenance Checklist ............................................................................................55

5.3 MCU Troubleshooting................................................................................................................................56

5.4 Pan & Tilt Maintenance..............................................................................................................................57





5.4.1 Routine Maintenance............................................................................................................................57 5.4.2 Inspection Intervals ...............................................................................................................................57 5.4.3 Pan & Tilt Troubleshooting ..................................................................................................................58

5.5 IR Searchlight Maintenance .....................................................................................................................59 5.5.1 Warnings ................................................................................................................................................59 5.5.2 Maintenance ..........................................................................................................................................59 5.5.3 IR Searchlight Troubleshooting...........................................................................................................60 5.5.4 Pressurized Tube Maintenance ..........................................................................................................60 5.5.5 Opening and Removing Searchlight from Enclosure.......................................................................61 5.5.6 Lamp Change ........................................................................................................................................61 5.5.7 Lamp Focus ...........................................................................................................................................62 5.5.8 Reassembling the Enclosure...............................................................................................................62 5.5.9 Optical Filters .........................................................................................................................................63

5.6 Video Display Unit (VDU) Warnings .......................................................................................................63

6 8540/8520 NIGHT NAVIGATOR™ TECHNICAL DESCRIPTION .......................... 64

6.1 Night Navigator™ Control Panel (100-2028 and 100-2030) ..............................................................64 6.1.1 Block Diagram .......................................................................................................................................64 6.1.2 Functional description ..........................................................................................................................64 6.1.3 Details .....................................................................................................................................................65

6.2 Night Navigator™ 4 Button Keypad (100-2032 and 100-2033) ........................................................66 6.2.1 Block Diagram .......................................................................................................................................66 6.2.2 Functional description ..........................................................................................................................66 6.2.3 Details .....................................................................................................................................................66

6.3 Compressor connections for optional Wash/Dry Unit ......................................................................67

6.4 MCU Assembly ............................................................................................................................................67 6.4.1 MCU Block Diagram .............................................................................................................................67 6.4.2 MCU Layout (Top View).......................................................................................................................68

6.5 MCU Power distribution ............................................................................................................................69 6.5.1 Overall Power diagram.........................................................................................................................69 6.5.2 Fuse Replacements..............................................................................................................................69

6.6 Shutdown Module (100-2060B)................................................................................................................70 6.6.1 Block Diagram .......................................................................................................................................70 6.6.2 Functional description ..........................................................................................................................70 6.6.3 Details .....................................................................................................................................................70 6.6.4 Functional Diagram...............................................................................................................................71

6.7 MCU Back Plane PCB (100-2040B) .........................................................................................................72 6.7.1 Block Diagram .......................................................................................................................................72 6.7.2 Functional description ..........................................................................................................................72 6.7.3 Outline & component location .............................................................................................................73 6.7.4 LED's.......................................................................................................................................................73 6.7.5 Connectors .............................................................................................................................................74

6.8 MCU Master Controller (100-2044B).......................................................................................................75 6.8.1 Block Diagram .......................................................................................................................................75





6.8.2 Functional description ..........................................................................................................................75 6.8.3 Outline & component location .............................................................................................................76 6.8.4 LED's.......................................................................................................................................................76 6.8.5 Details .....................................................................................................................................................77

6.9 MCU Camera / Video Controller (100-2042D).......................................................................................78 6.9.1 Block Diagram of full-featured version. ..............................................................................................78 6.9.2 Functional description ..........................................................................................................................78 6.9.3 100-2042D Component-side (2-Channel Version)...........................................................................79 6.9.4 LED's (Component Side) .....................................................................................................................79 6.9.5 Connectors (Component-side) ............................................................................................................80 6.9.6 100-2042D Solder-side (2-Channel Version)...................................................................................80 6.9.7 Connectors (Back side) ........................................................................................................................80

6.10 MCU IR Lamp Controller (100-2046B)....................................................................................................81 6.10.1 Block Diagram .......................................................................................................................................81 6.10.2 Functional description ..........................................................................................................................81 6.10.3 Outline & component location .............................................................................................................82 6.10.4 LED's.......................................................................................................................................................82 6.10.5 Connectors .............................................................................................................................................83

6.11 MCU Pan & Tilt Controller (100-2048C) .................................................................................................84 6.11.1 Block Diagram .......................................................................................................................................84 6.11.2 Functional description ..........................................................................................................................84 6.11.3 Connectors .............................................................................................................................................84 6.11.4 Outline & component location .............................................................................................................85 6.11.5 LED’s.......................................................................................................................................................85

7 WARRANTY AND REPAIR .................................................................................... 86

7.1 Returns For Repair .....................................................................................................................................86

7.2 Warranty Conditions ..................................................................................................................................86

APPENDIX A • NIGHT NAVIGATOR™ 8540/8520 SPECIFICATIONS ......................A

APPENDIX B • CABLE AND CONNECTION DRAWINGS..........................................B

APPENDIX C • ADDITIONAL DRAWINGS AND BULLETINS....................................C





1 Night Navigator™ System Overview

1.1 About the 8540/8520 The Night Navigator™ System provides a clear image-intensified view of the water at night, displayed on a monochrome monitor (optional green-tint) with on-screen position and distance displays. The operator has complete pan and tilt controls of the camera and Infrared searchlight.





1.2 Components & Basic Functions The Night Navigator™ Model 8540/8520 offers exceptional performance and image clarity at night. This reliable all-weather system includes the following main components:

i. Image Intensified Night Vision System. The image intensifier is a high resolution and proven component.

Basic Theory: The camera takes small amounts of ambient light photons and converts them into electrons, which pass through a wafer thin disc; this disc has 6 million channels or holes, which multiply the electrons thousands of times. The electrons then are bounced off a phosphor screen, which converts them back into photons for the final intensified image display.

ii. Infrared Light System. The Infrared light source is a 6 million candlepower short-arc Xenon

system with an IR filter. The beam can be seen at 2000 meters through the Night Navigator™ monitor, even though it is invisible to the human eye. When the Infrared light is on and strikes an object, the image on the monitor appears as if the object has its own light source. It is mounted on the same pan/tilt unit as the camera in its own environmental housing. The Xenon light is highly efficient operating at 75 watts and providing excellent penetration in the near Infrared Spectrum (see chart below.)

iii. Pan and Tilt Unit. This heavy duty, all-weather environmental pan/tilt is designed to remotely

position the Image Intensifier & IR Light, to a relative bearing of +180° to -180° (degrees of azimuth from heading) or to relative tilt +90° to -90° (degrees of elevation from horizon). Limits to motion are preset as per Specifications data, refer to “APPENDIX A - Night Navigator™ 8540/8520 Specifications”

iv. Main Control Unit (MCU). This component manages all video, control and power.

v. Control Panel. (a wired control panel). This is the main, panel mounted, controller that displays

status of equipment and provides all the control interfaces.

vi. Optional 4 button Keypad. (a wired control panel). This is a 4 Button Keypad, panel mounted, controller that provides for remote auxiliary or remote controls.

vii. Video Display (VDU). Image is viewed on a 9” high-resolution display with indications of direction,

angle of tilt and distance ahead. These are provided to assist the operator when it is so dark that visual cues normally used to orient the viewer are not visible.





viii. Optional Air/Wash Unit. This optional cleaning system adds a small compressor box, fluid tank,

and airline to the system.

1.3 Comparison of Night Navigator™ model 8540 and model 8520 The Night Navigator™ 8540 System was designed for compliance to ANNEX 12 of IMO MSC.94 (72). The model 8540 is a standard configuration of the model 8520. The table below outlines the options and standard features.

Function 8520 Series Model 8540

Control Panel Included Included 4 Button Keypad (10º /20º PAN controls) Optional Included

2nd 4 Button Keypad (10º /20º PAN controls) Optional Optional

Video Display (Green Tint) Included Included

2nd Video Display (Green Tint) Optional Optional

Field of View (FOV) (4:3 aspect ratio)

20º H Standard (Optional 9.5ºH) (Optional 7.5ºH)

20ºH x 15ºV

Washer system Optional Included





2 Night Navigator™ Operation

2.1 Night Navigating Overview The Night Navigator™ 8540/8520 System was designed to provide a clear image intensified view of the water at night that is displayed on a monitor. The operator has 180° pan and 90° tilt controls of the camera and searchlight with on-screen direction and distance displays shown on the monitor. The design goal of the system was to provide a special bridge mounted system that gave the night vision clarity that can be obtained when using hand held night vision equipment in an outside environment. The main marine markets in mind were high-speed craft, search and rescue, pleasure craft above 50’ and large vessels for the purpose of avoiding other unlit craft, ice, debris and mammals. Hand held night vision is severely limited when used inside a bridge due to the reflection of lights within the bridge and reflected lights on a commercial vessel (i.e. railings, car decks, deck lights). The bridge-mounted system is superior to handheld night vision because of the powerful Xenon Infrared Searchlight that is added to enhance the vision. The Infrared Light is required because water absorbs most of the Infrared light from the atmosphere and floating objects are still hard to see. On a clear night without much moisture or dust in the air, the infrared light is almost unnoticeable until it strikes an object. That object then reflects the infrared light to create a bright indication on the monitor and becomes easy to avoid. The Night Navigator™ will easily display objects ranging in size from tide line debris to small-unlit craft. Spotting kayaks and canoes, detecting whales and ice (growlers), avoiding branches, logs, crab/lobster pot floats and lines are all within the capability of this unit.

2.2 Operational Requirements

• The Night Navigator™ system is easy to operate and will quickly become indispensable as an aid to navigation.

• The Night Navigator™ system is only an effective aid in navigation if there is a dedicated observer watching the monitor.

• The Night Navigator™ system is not a stand-alone piece of equipment and must be used in conjunction with all other navigation systems on board the vessel.

2.3 Comparison with Radar

• The Night Navigator™ system will assist with confirming visually what is detected on the radar and will also assist in detection of objects that may not be seen on radar due to sea state and range.

• The radar has a 360° view of the vessel. The Night Navigator™ 8540/8520 has a view of the

immediate path of the vessel.





2.4 Horizontal Field of View and Speed-Distance Charts

2.4.1 20º Field of View

20º FOV

214 ft [65.2 m] 1 Cable (0.1NM)

3 Cables (0.3NM)

4 Cables (0.4NM)

2 Cables (0.2NM)

6 Cables (0.6NM)

based on 1 cable = 607.6 ft

429 ft [130 m]

643 ft [196 m]

857 ft [261 m]

1286 ft [392 m]

20º FOV





2.4.2 9.5º Field of View

9.5º FOV

101 ft [30.8 m] 1 Cable (0.1NM)

3 Cables (0.3NM)

4 Cables (0.4NM)

2 Cables (0.2NM)

6 Cables (0.6NM)


202 ft [61.5 m]

303 ft [92.3 m]

404 ft [123 m]

606 ft [185 m]

9.5º FOV (angle shown not to scale)





2.4.3 7.5º Field of View

7.5º FOV

79.6 ft [24.3m] 1 Cable (0.1NM)

3 Cables (0.3NM)

4 Cables (0.4NM)

2 Cables (0.2NM)

6 Cables (0.6NM)


159 ft [48.6 m]

239 ft [72.8 m]

319 ft [97.1 m]

478 ft [146 m]

7.5º FOV (angle shown not to scale)





2.4.4 Speed Distance Time Charts

Time (seconds) to target Speed Distance (Nautical Miles) (Knots) 0.1 0.2 0.3 0.4 0.5 0.6

6 60.0 120 180 240 300 360 8 45.0 90 135 180 225 270

10 36.0 72 108 144 180 216 12 30.0 60 90 120 150 180 14 25.7 51 77 103 129 154 16 22.5 45 68 90 113 135 18 20.0 40 60 80 100 120 20 18.0 36 54 72 90 108 22 16.4 33 49 65 82 98

Speed Distance Time Chart for High speed Craft

Time (seconds) to target Speed Distance (Nautical Miles) (Knots) 0.1 0.2 0.4 0.6 0.8 1 NM

20 18.0 36 72 108 144 180 22 16.4 33 65 98 131 164 24 15.0 30 60 90 120 150 26 13.8 28 55 83 111 138 28 12.9 26 51 77 103 129 30 12.0 24 48 72 96 120 32 11.3 23 45 68 90 113 34 10.6 21 42 64 85 106 36 10.0 20 40 60 80 100 38 9.5 19 38 57 76 95 40 9.0 18 36 54 72 90 42 8.6 17 34 51 69 86





2.5 Precautions to Remember

2.5.1 System Power

WARNING: The Night Navigator’s™ image-intensified camera is intended for use only at night and will be damaged if directed at bright lights. If the system is turned on during the day, be sure the camera is not accidentally turned on. Damage will take place even if no picture is present on the monitor.

2.5.2 Harbour & High Light Operations: The Night Navigator™ is an Image Intensified System. Care must be taken when approaching harbour lights. When approaching harbour lights:

• Tilt Sensor unit down so that the camera image is observing the water only. This allows the harbour lights to enhance the image.

• Do not aim the sensor head directly at the harbour lights for more than 15 seconds. It is best when observing the bright shore to pan & tilt the head so the bright light source does not remain in the same position on the monitor.

A latent image may appear after the Night Navigator™ has been aimed at bright light sources. The latent image will normally fade over the next few minutes or hours depending on the time exposure to the light. If the latent image does not fade, that will be because the Night Navigator™ was aimed too long at a light. This will not stop the Night Navigator™ from being used but the dark spots will mean that the sensor needs to be re-positioned for the clearest image on the monitor. When the harbour lights are too bright the image will deteriorate, as it is focused for complete darkness. At this point the Night Navigator™ Image should be shut off. The harbour lights should be bright enough to navigate. At the end of the shift or when coming into harbour, the operator must take care not to turn only the monitor off and assume the system is shut down. The camera may still be operating if the main system power is not turned off.

2.5.3 Adjusting the brightness or contrast control on the monitor. The image the camera sees remains the same so if you are heading towards bright lights, and are seeing some crescent moon reflections (this is normal in high light situations when the Cat Lens is used), tilt the camera down, or if there is enough light, shut the Night Navigator™ camera off. Light works the same in the visible and infrared spectrum. In the case when there is high moisture content in the air, infrared light may cause too much backscatter, and then it can be beneficial to turn off the searchlight.





2.5.4 Atmospheric conditions Although the Night Navigator™ offers a clear image on most nights, it is not magic - the more adverse the weather is, the less the clarity will be on the display. All other precautions should be taken on these nights. The Night Navigator™ 8540/8520 system will not provide a clear image in darkness when foggy. However, you will be able to observe light sources sooner than without the navigation system. Each night is different so your intensified view will vary dependent on the following factors that also supply the infrared light that is required for the image-intensified camera:

• Moon – clear night, cloudy night • Stars – clear night, cloudy night • City or shore lights reflected though cloud cover • City or shore lights directly (at a distance)





2.6 Night Navigator™ Controllers

2.6.1 Control Panel layout





2.6.2 Camera Controls The operator may control the Camera functions through the Control Panel using the following push buttons and Joystick controls:

IMAGE (push button) Turns the camera ON and OFF. • To turn off press button and hold for 2 seconds. • To turn on press button and hold for 2 seconds • The indicator will be on when the camera is activated.

To prevent the Night Vision camera from damage during daylight, the IR Lamp and the Camera will time out and turn off after 10 minutes of Control Panel inactivity.

• After 9 minutes of inactivity, the backlights for the Keypads will flash. • After 1 Minute of flashing Key pads the IR light and Night Camera will power down. • Any Joystick action, ACK key or either Panel Dim/Bright keys will reset this timer. • Any of the 10º / 20º Preset functions will reset the timer.

CENTER (push button) Returns the Pan & Tilt to its pre-programmed home position.

• To activate, press button once. • The home position is normally dead ahead.

• The Home position (Horizon and Heading) can be compensated for periodic changes in the Pitch or Yaw angle of the ship, for example to adjust for unique cargo loading patterns.

• To make minor adjustments to the Home position, refer to AUX Key in section 2.6.4 Other Controls

• To Setup the coordinate origin refer to the Performing the calibration sequence as described in section 2.8 On Screen Programming.

PAN/TILT Control (joystick) Pans and Tilts the Camera and Light together.

• The joystick can Pan Left, Pan Right, Tilt Up and Tilt Down. • The unit continues turning or tilting as long as the joystick is being held and

stops when the joystick is released. • It can be moved in the vertical (TILT) and horizontal (PAN) directions at the

same time.

• If the Camera was previously returning to the center/home position, the joystick action will cancel the Center command.





2.6.3 Light Controls

The operator may control the IR Light functions through the Control Panel using the following push buttons and Joystick controls (see 2.6.2 Camera Controls for PAN/TILT operations)

IR LIGHT (push button) Turns the infrared searchlight ON and OFF. • To turn off press button and hold for 1 second. • The indicator change is delayed until action is complete. • To turn on press button and hold for 1 second. • The Light will timeout after 10 minutes of inactivity and turn off. • SEE 2.6.2 Camera Controls for further explanation.

IR NARROW (push button) To concentrate the beam or spot light effect.

• To activate, press button once or hold until focused.

IR WIDE (push button) To spread the beam or flood light effect. • To activate, press button once or hold until focused.

2.6.3.1 Setting the initial focus position of the searchlight The Focus of the Infrared searchlight has the ability to be programmed to assist the operator in navigating the vessel at night. Programming is done with the light initially turned on and as follows:

Step1

• Turn on searchlight. Step2

• Move the focus to the desired position using the buttons (Narrow beam and Wide beam).

OR

Step3

• Push the Light button and hold it while pushing the Narrow beam button.

AND • Release Light first, and then Narrow.

Next time the light is turned on it will initially focus at the newly programmed position.





2.6.3.2 Setting the smallest spot of the searchlight If you notice a delay before the lamp starts moving when moving out of the full spot position, then the spot position was set beyond the point at which the lamp is physically able to move. If this occurs, the spot position should be reset to a point at or within the physical limits of the lamp’s travel. Step1 Turn on searchlight. Step2

• Hold the Light Button, then press and release the Narrow button 2X.

AND then • Do Not Release the Light

Button. Step3

• Do Not Release the Light Button.

AND OR

• Move the focus to the desired smallest spot position using the Narrow or Wide buttons. • Release the Narrow or Wide buttons.

Step4 • Finally, release the Light button, now the spot (narrowest) position will be reset to as selected.

2.6.3.3 Setting the widest flood of the searchlight If you notice a delay before the lamp starts moving when moving out of the full flood position, then the flood position was set beyond the point at which the lamp is physically able to move. If this occurs, the flood position should be reset to a point at or within the physical limits of the lamp’s travel. Step1 Turn on searchlight. Step2

• Hold the Light Button, then press and release the Wide button 2X.

AND then • Do Not Release the Light

Button. Step3

• Do Not Release the Light Button.

AND OR

• Move the focus to the desired smallest spot position using the Narrow or Wide buttons. • Release the Narrow or Wide buttons.

Step4

• Finally, release the Light button, now the Flood (widest) position should be reset to as selected.





2.6.4 Other Controls

WASH / AIR (push buttons) Used to clean the Camera lens. • Press button and hold about 1 to 2 seconds. • Press Wash to clean the camera lens • Press Air to Dry the camera lens • Short press of each will provide a clear view. • The compressor is enabled only when the camera is turned on. • The compressor will turn on as required to maintain pressure.

PANEL Dim/Bright (buttons) To adjust the Keypad illumination level.

• To activate, press button once or hold until level reached. • Press the small Light Bulb to Dim Key pads. • Press the large Light Bulb to Brighten key pads. • The indicator “Minimum” will go on at the lowest level. • The indicator “Maximum” will go on at the highest level.

AUX (push button) To access auxiliary modes

• To ENTER AUX mode, press and hold until the “AUX LED” comes on. • To EXIT AUX mode, press and hold until the “AUX LED” goes off. • In AUX mode, the PANEL Dim/Bright buttons will adjust the LED light Level. • In AUX mode, the JOYSTICK will PAN in micro speed.

• In AUX mode, the CENTER button will cause the current angles to be saved as the new home Position. The Pan/Tilt angles displayed on-screen will still represent the calibrated angles.

• To Setup the coordinate origin refer to the Performing the calibration sequence as described in section 2.8 On Screen Programming.

ACK (push button) To access MENU modes

• To ENTER MENU mode, press and hold for 5 seconds. • To EXIT MENU mode, press and hold for 5 seconds. • In MENU mode, the “Maximum” and “Minimum” indicators will turn on.

POWER ON/OFF (buttons) Standby power ON/OFF • To operate, press and hold ON for 2 seconds. • The solid Green LED above ON indicates power up. • The Flashing COMM LED above ACK indicates operation. • To go to Standby, press and hold OFF for 2 seconds. • The solid RED LED above POWER OFF indicates power down/

STANDBY MODE.





2.6.5 4 Button Keypad Layout (10º/20º PAN controls)

2.6.6 10º/20º PANNING Controls for model 8540/8520 To PAN, HOLD and RETURN to CENTER at any of the 10º or the 20º horizontal PAN positions:

• Press and hold the appropriate button until the PAN reaches the desired location • Continue to hold the button; the position will stay until the button is released. • Release the button and the unit will PAN to CENTER. • Any of the above functions will clear or reset the Control Panel Timeout timer.

2.6.7 Optional 10º/20º PANNING Controls for model 8520

To PAN and STOP at any of the 10º or the 20º horizontal PAN positions: • Press and hold the appropriate button for ½ second and release. To RETURN to CENTER after the above command: • Press and hold the same button for ½ second, release and the unit will PAN to CENTER.

2.6.8 4 Button Keypad Dimmer Control PORT 20º +PORT 10º (push button) To DIM

• To DIM the illumination, press and hold both keys. STBD 20º +STBD 10º (push button) To Brighten

• To brighten the illumination, press and hold both keys.

AND

AND





2.7 Display Operation Operation of the monitor is similar to any television. Please note the following controls:

Contrast: Adjust to user’s preference Brightness: Adjust to user’s preference taking care not to produce too much light on the bridge and thereby interfere with the safe operation of the vessel at night.

Underscan: When this button is pushed, the size of the image on the monitor is reduced in order to see all the field of view available from the camera. It has the effect of reducing the magnification of the lens. It is toggled on and off using the bottom left-hand button on the front of the monitor.

The sample display image, as shown above is as supplied for Night Navigator™ model 8540 and model 8520 with 20º FOV.

2.7.1 Night Navigator™ on-screen displays • The on-screen displays of direction, angle of tilt and distance ahead are provided to assist the

operator when it is so dark that visual cues normally used to orient the viewer are not visible.

• The cursor on the top of the screen indicates angle left

or right from the centerline and moves when the pan function is operated. The full FOV is shown with a preset scale of 1° per line. For example, a 9.5º FOV will show 10º across the monitor. Accuracy is ± 1º.

• The distance indications are initially set at 1, 2 and 3 cables. They are approximate and are user definable, using the On Screen Programming Menu at the Control Panel. A cable is 0.1 NM.

• When the Night Navigator™ is tilted up or down from the center position, the distance display will disappear since it is no longer accurate. Pushing the “Center” button on the Control Panel brings the system back to its calibrated position and the distance indications will re-appear.





2.8 On Screen Programming

2.8.1 MENU access • To ENTER MENU mode, press ACK button and hold for 5 seconds. • While in MENU mode, the “Maximum” and “Minimum” indicators will turn on. • To EXIT MENU mode, press and hold ACK button for 5 seconds. • To NAVIGATE throughout the menu’s, use the Joystick and the “IR Narrow” Button acts as the

enter key.

MENU Startup screen

System Run Time Screen

Set System Date/Time





ABOUT Screen

2.8.2 Availability of NN Control Panel Key functions in MENU mode While in MENU mode, the following Control Panel functions are disabled:

• TRACK RADAR • Return to CENTER • IR NARROW focus • IR WIDE focus

While in MENU mode, the following Control Panel functions are enabled:

• IR LIGHT ON/OFF • IMAGE ON/OFF • WASH / AIR • PANEL Dim/Brighten (however, the MIN/MAX LEDS will not be displayed)

2.8.3 General Menu functions The MENU cursor is provided by joystick actions

• Mouse Up = Joystick Forward • Mouse Down = Joystick Back • Mouse Left = Joystick Left • Mouse Right = Joystick Right • Mouse Left Button/Select = IR NARROW Button • Mouse RB = IR WIDE Button

Mouse movement commands move the highlighted cursor through displayed menu and sub-menu fields. The Mouse Left Button/Select button will be used to select the currently highlighted menu function, open sub-menus or when the menu parameter is numeric, select the numeric value displayed. Also, when the menu parameter is numeric, Mouse Left/Right action will decrease/increase the parameter value.

2.8.4 PAN/TILT Over-ride The CENTER button is used as a toggle between cursor mode and Pan/Tilt mode in the same way that the SHIFT key on a PC keyboard operates. So, while the CENTER button is held he mouse (Joystick) temporarily reverts to Pan/Tilt functions, without exiting the MENU mode.





2.8.5 Range Line Position and Threshold Calibration Step 1 Once the system is running, enter the Menu Mode (see section 2.8.1 MENU access Step 2 Use the joystick and navigate the Menu to the screen shown.

Step 3 Hi-light the “Navigator Range Line Configuration” option and press the IR Narrow button. The window shown below. (Range Line markers are shown as 3CA, 2CA and 1CA in the example below.

Step 4 Move the joystick Up or Down to hi-light the

option(s) that are desired to be changed. Move the joystick Left or Right to change the values.

Step 5 When changes are complete, hi-light the Apply button and press the IR Narrow button. The changes should then be apparent.

Step 6 Once all the settings are complete, hi-light the Save button and press the IR Narrow button. This will maintain the settings when the application is restarted.

Step 7 The Tilt information can also be removed from

the screen by hi-lighting the “Navigator Text Display Configuration” shown and pressing the IR Narrow button. This will bring up the window shown below.

Step 8 Move the joystick Right to hi-light the “Off”

option and move the joystick Down to hi-light the OK button. Press the IR Narrow button.

Step 9 Once all settings are complete, Exit the Menu Mode (see section 2.8.1 MENU access)





2.8.6 Calibration Procedures

1) Once the system is running, in the MCU on the 100-2044 module, set Dip Switch2, position 8 to OFF. This will enable the Set Pan/Tilt menu.

2) Once Dip Switch2, position 8 is off, enter the Menu Mode (see section 2.8.1)

SET 90º PORT 3) Hold the Center button and using the joystick move the Pan/Tilt to 90º PORT. Now release the

Center button. 4) Using the joystick, navigate the Main Menu to the screen shown below. Highlight the “Set Port 90

Degrees” option and now press the IR Narrow button to set position. (Note, menu should flash indicating command was sent)

SET 90º STBD 5) Hold down the Center Button and using the joystick move the Pan/Tilt to 90º STBD. Now release

the Center button. 6) Repeat Step 3 but highlight the “Set STBD 90 Degrees” option and now press the IR Narrow

button to set position.

SET 15º UP 7) Hold down the Center button and using the joystick move the Pan/Tilt to 15º degrees UP.

Release the Center button. 8) Using the joystick, navigate the Main Menu to the screen shown below. Highlight the “Set Up 15

Degrees” option and press the IR Narrow button to set position. (Note, menu should flash indicating command was sent)

SET 25º DOWN 9) Repeat steps 6 and 7 except move Pan/Tilt to 25º degrees down and hi-light the “Set Down 25

Degrees Option” SET 0º HEADING

10) Hold down the Center button and using the joystick move the Pan/Tilt to 0º from Heading and 0º from Horizon.

11) Repeat Step 3 except hi-light the “Set 0 Degrees” option”. SET 10/20º PAN Presets

12) Finally, repeat Step 3 except hi-light the “Set 10 and 20 Degrees” option. Now the PORT and STBD 10 and 20 Degrees positions will be calculated and stored.

13) When Calibration is complete, in the MCU on the 100-2044 module, Set Dip Switch2, position 8 to ON. This will lock this Menu.

14) The calibrated positions can be tested or used by

selecting the Go To *** option in the sub-menu shown below.

15) Once all settings are complete, Exit the Menu Mode (see section 2.8.1 )





3 Night Navigator™ Installation

Please read these instructions before starting installation.

3.1 Night Navigator™ 8540/8520 Installation Data The following information is provided to facilitate your installation work:

1) Dimensional drawings (Size and weight of each component) See section 3.8 System Interconnections

2) The maximum length of each interconnection cable / air hose: See section 3.8 System Interconnections

• The maximum hose length between external sensor and MCU is 18 m. • The maximum length between MCU and other components is 60 - 80 m.

3) Installation criterion of each component (such as mini-spacing required for maintenance,

interference with other navigation equipment)

External Sensor: • Must have a clear unobstructed view ahead of the bow of the vessel. • No lights in front of the unit as they impair the operation of the night vision. • No obstacles ahead of the unit, which could possibly reflect light back at the camera, (even

indirectly, such as railing, spars or davits.) • Clear of all other equipment within a 400mm radius of the center of the mount • See section 3.6 Sensor Package Mounting

MCU: • Mount in a dry, protected area within 15 m. of the sensor package.

Control Panel / 4Button Keypad: • Warning: Control Panel must be connected to MCU for proper operation and power up. • Install on a horizontal console within easy reach of the night vision operator with a clear view

of the monitor screen. • Cut out dimensions: Control Panel: 138mm x 138mm. • Cut out dimensions: 4 button keypad: 138mm x 33mm

Safe distance to magnetic compass: • External Sensor package: minimum 0.4 meters (external equipment) • Compressor box: minimum 1 meter • MCU: 1.4 meters • Control Panel: 0.3 meters • 4 Button Keypad: 0.3 meters

4) Power equipment ratings: (voltage current rating) • Refer to APPENDIX A





Fuse AC3

Fuse AC4

Fuse AC5

Fuse AC6

TB_AC3

TB_AC4

TB_AC5

TB_AC6

TB_AC16

TB_AC15

TB_AC14

TB_AC13

12V/24V PSU Assembly

VOP

12V/24V PSU Assembly

VOP

TB_AC7

TB_AC9

TB_AC8

TB_AC12

Earth

TB_AC11

TB_AC10

Install Ferrite 130-0414On Wires Near Cable Gland.

Right

LeftRFI Filter

Isol

atio

nTr

ansf

orm

er3.2 Power Requirements (As per Specifications data, refer to “APPENDIX A - Night Navigator™ 8540/8520 Specifications”)

VDU: 100/240 V AC, 50/60 Hz, 56 W max. MCU: 100/240 V AC, 50/60 Hz, 850 W max.

In designing the Night Navigator™ System, efforts have been made to ensure satisfactory operation with power supplied by most prime power systems. In an attempt to guard against system malfunctions caused by externally radiated or conducted transients, or from electrical signals superimposed on the power lines supplying the system, power distribution to the system should comply with the following guidelines:

• The system power source should be capable of handling the originally installed equipment. • The power source should be stable and noise free. If possible, the power should be derived from

a dedicated line via an Isolation transformer (provided) and/or a UPS. • Connect the power cord from a 110/240 Vac 60/50 Hz circuit to the Main Control unit. • Connect the power cord from a 110/240 Vac 60/50 Hz circuit to the monitor. • Do Not Power Up MCU or VDU until proper Startup procedure is followed.

3.2.1 Vac connections

See drawing 100-0442A for more details

3.2.2 Vdc Terminal block See drawing 100-0445A for more details





3.3 Panel mounted Controllers Installation

3.3.1 Control Panel Location: to be hard-wired to the Main Control Unit and is normally installed in a console on the bridge. Panel cutout: 5.43” [138mm] W x 5.43” [138mm] H; allow for 5” depth. Cover Plate: 5.67” [144mm] W x 5.67” [144mm] H

3.3.2 Optional 4 button Keypad Location: is to be hard-wired to the Control Panel and is normally installed in a console on the bridge

0.75” [19mm] below the Control Panel. Panel cutout: 5.43” [138mm] W x 1.29” [33mm] H; allow for 5” depth. Cover Plate: 5.67” [144mm] W x 1.42” [36mm] H

144.0mm.

138.0mm.

144.00mm.

138.00mm.

36.00mm. 33.00mm.

0.75in.

Main Controller

Remote Keypad (4button)

144.00mm.

Required CUTOUTFACE PLATE Outline

138.00mm.

FACE PLATE Outline Required CUTOUT

MinimumDistancecutout tocutout





3.4 Video Display Unit (VDU) Installation Care should be taken to mount the monitors so that the glare from the screen does not deter from the smooth operation of bridge personnel.

Note optional Mounting Bracket in figure below.

Optional Mounting Bracket





3.5 Main Control Unit (MCU) Installation

MCU Package

3.5.1 MCU Door Key The MCU door key is shipped with the MCU, Please keep with MCU after installation.





3.5.2 MCU Mounting The Main Control Unit must be mounted in a dry, protected environment. It can be located in the bridge, the electronics room or some other site distant from the Control Panel and 4 Button keypads, but can be no further than the cables supplied to the Pan & Tilt Unit. The MCU can be mounted flat (desktop) or vertically. In either case consideration must be given to ventilation and cable access. Refer to wiring diagrams for all connection details Space requirement: 27” L x 20“ W x 9” H Minimum if mounted flat. Space requirement: 27” H x 20“ W x 9” D Minimum if mounted vertically.

From drawing NN-004-132C • The Mounting feet are located on the sides of the MCU near the corners of

the box. • Fasten MCU to Wall, deck or existing Mounting channels by securing the

mounting feet with four 3/8” stainless steel bolts. • Do not connect cables to MCU or install cables into cable glands until

wiring phase of installation. • Do not Power on the MCU until start up procedure has begun.





3.5.3 Field Wiring Procedure to meet IMO requirements for EMC

3.5.3.1 Main Controller cable wiring. Drawing# 100-0102F (use EMC wiring kit # 590-0176E and hardware kit 590-0070B shipped inside MCU box)

3.5.3.1.1 Main Controller end Remove exactly 2¾” cable outer jacket. See figure 1.1 below:

Figure 1.1

Cut down braided shield (keep ½” long maximum). Remove aluminum foil up to end of braided shield. Remove nylon cords (fillers). Tin (solder) the ½” long braided shield (be careful not to melt the wire jackets). See figure 1.2

below





Figure 1.2

Square off the edge of the tinned braided shield using side cutters Take EMC cable clamp from back of Main Controller and push tinned braid through the loop

(open the loop more if necessary). Close the loop tightly. See figure 1.3 below:

Figure 1.3





Trim the wires so there are no excessive wire loops. Install a white ferrule on each wire as

shown in figure 1.4 below:

Figure 1.4

Install wires on green connector (plug) provided Install and tighten EMC cable clamp (with cable) on back of Main Controller Plug and screw down connector Install ferrite choke (square one) on cable. Install cable inside nylon cable loop. Fasten down nylon cable loop. See figures 1.4 above,

and 1.5 & 1.6 below:





Figure 1.5

Figure 1.6





3.5.3.1.2 MCU BOX end (Drawing# 100-0102F) Remove 14” cable outer jacket Cut down braided shield (keep 3/4” long maximum). Remove aluminum foil up to end of braided shield. Remove nylon cords (fillers). Tin (solder) braided shield (be careful not to melt the wire jackets). Attach (solder) a 14” long black wire AWG18 to the braid (this wire will go to TB_DC20

terminal block, earth GND). Crimp ferrule at other end of wire. Wrap copper tape (provided) over braided shield Carefully insert cable with copper tape into cable gland (cable entry). Copper tape will make

contact with the EMC fingers inside the cable gland. Tighten cable gland nut firmly Do wiring to MCU Mainboard (100-2040B) connector as per Drawing# 100-0102F Clamp a ferrite choke (provided in EMC kit 590-0176E) over the bundled wires

3.5.3.2 PAN Controller (4-Button Keyboard) cable wiring OPTION A (to MCU Mainboard) (Drawing# 100-0099F). Use EMC kit# 590-0177A and hardware kit 590-0070B shipped inside MCU box.

NOTE: When two PAN Controllers are used, the MAIN one can be connected directly to Main Controller using Drawing# 100-0101C (OPTION B) and the SLAVE one can be connected to MCU Mainboard using Drawing# 100-0099F. Or both can be connected to MCU Mainboard using Drawing# 100-0099F.

3.5.3.2.1 PAN Controller end Remove exactly 2¾” cable outer jacket. Cut down braided shield (keep ½” long maximum). Remove aluminum foil up to end of braided shield. Remove nylon cords (fillers). Tin (solder) the ½” long braided shield (be careful not to melt the wire jackets). Square off the edge of the tinned braided shield using side cutters Take EMC cable clamp from back of PAN Controller and push tinned braid through the loop

(open the loop more if necessary). Close the loop tightly. Install a white ferrule on each wire (ferrules provided in hardware kit). All wires remain the

same length. See figure 1.7 below:

Figure 1.7





Install wires on green connector (plug) provided Install and tighten EMC cable clamp (with cable) on back of PAN Controller. Plug and screw down connector Install ferrite choke (big square one) on cable. Secure ferrite choke with two cable ties, one

on each side of the choke. Fasten down cable using nylon mount and cable tie. See figure 1.8 below:

Figure 1.8

3.5.3.2.2 MCU BOX end (to MCU Mainboard) (Drawing# 100-0099F) Remove 14” cable outer jacket Cut down braided shield (keep 3/4” long maximum). Remove aluminum foil up to end of braided shield. Remove nylon cords (fillers). Tin (solder) braided shield (be careful not to melt the wire jackets). Attach (solder) a 14” long black wire AWG18 to the braid (this wire will go to TB_DC20

terminal block, earth GND). Crimp ferrule at other end of wire. Wrap copper tape (provided) over braided shield Carefully insert cable with copper tape into cable gland (cable entry). Copper tape will make

contact with the EMC fingers inside the cable gland. Tighten cable gland nut firmly Do wiring to MCU Mainboard (100-2040) connector as per DWG# 100-0099F Clamp a ferrite choke (the big round one) (provided in EMC kit 590-0177A) over the bundled

wires

3.5.3.3 PAN Controller (4-Button Keyboard) cable wiring OPTION B (directly to Main Controller) (Drawing# 100-0101C). Use EMC kit# 590-0177A and hardware kit 590-0070B shipped inside MCU box.

NOTE: When two PAN Controllers are used, the MAIN one can be connected to Main Controller using Drawing# 100-0101C and the SLAVE one can be connected to MCU Mainboard using Drawing# 100-0099F. Or both can be connected to MCU Mainboard using Drawing# 100-0099F.





3.5.3.3.1 PAN Controller end (Drawing# 100-0101C) Remove exactly 2¾” cable outer jacket. Cut down braided shield (keep ½” long maximum). Remove aluminum foil up to end of braided shield. Remove nylon cords (fillers). Remove RED and BLACK/RED pair (unused) Tin (solder) the ½” long braided shield (be careful not to melt the wire jackets). Square off the edge of the tinned braided shield using side cutters Take EMC cable clamp from back of PAN Controller and push tinned braid through the loop

(open the loop more if necessary). Close the loop tightly. Install a white ferrule on each wire (ferrules provided in hardware kit). All wires remain the

same length. See figure 1.7 above. Install wires on green connector (plug) provided Install and tighten EMC cable clamp (with cable) on back of PAN Controller. Plug and screw down connector Install ferrite choke (big square one) on cable. Secure ferrite choke with two cable ties, one

on each side of the choke. Fasten down cable using nylon mount and cable tie. See figure 1.8 above.

3.5.3.3.2 Main Controller end (Drawing# 100-0101C)

Remove exactly 4” cable outer jacket. See figure 1.9 below:

Figure 1.9

Cut down braided shield (keep ½” long maximum). Remove aluminum foil up to end of braided shield. Remove nylon cords (fillers). Remove RED and BLACK/RED pair (unused) Tin (solder) the ½” long braided shield (be careful not to melt the wire jackets). See figure

1.10 below





Figure 1.10

Square off the edge of the tinned braided shield using side cutters Take EMC cable clamp from back of Main Controller box (left side) and push tinned braid

through the loop (open the loop more if necessary). Close the loop tightly. Trim the wires so there are no excessive wire loops once connected. Install a white ferrule on each wire. Ferrules provided in hardware kit 590-0070B. Install and tighten EMC cable clamp (with cable) on back of Main Controller. See figure 1.11

below: Note: The Main Controller cable goes to the right on the back of the Main Controller box, and the PAN Controller cable goes to the left on the back of the Main Controller box. See figures 1.12 & 1.13 below:





Figure 1.11

Figure 1.12





Figure 1.13

Install wires on green connector (plug) provided, doubling up the connections with the Main

Controller cable wires (2 wires per position). See Drawing# 100-0101C. Plug and screw down connector Install ferrite choke (square one) on each cable. Install each cable inside nylon cable loop. Fasten down nylon cable loops. Install ferrite choke (small round one) over exposed wires on PAN Controller wires only. See

figure 1.13 above.

3.5.3.4 Compressor cable wiring (Drawing# 100-0068E and EMC wiring kit# (590-0179A)

3.5.3.4.1 MCU BOX end Remove 12” cable outer jacket Remove aluminum foil Keep shield (drain) wire at 12” Wrap copper tape around wires near end of jacket Insulate shield (drain) wire with heatshrinkable tubing Crimp ring terminal at end of shield (drain) wire. Carefully insert cable with copper tape into cable gland (cable entry). Copper tape will make

contact with the EMC fingers inside the cable gland. Tighten cable gland nut firmly Do wiring to DC terminal block as per Drawing# 100-0068E





Connect shield (drain) wire to earth stud on MCU plate Clamp a ferrite choke (provided in kit) over both wires near cable gland inside box Secure the ferrite choke with a cable tie

3.5.3.4.2 Compressor box end: No ferrite choke needed. Factory installed.

3.5.3.5 AC POWER INPUT cable wiring. Use Drawings# 100-0442A & 100-0445A, and EMC wiring kit# 590-0180 shipped inside MCU box.

NOTE: The end user provides the cable.

3.5.3.5.1 MCU BOX end Remove 7” cable outer jacket Carefully insert cable into cable gland on the side of the MCU (cable entry) Tighten cable gland nut firmly Do wiring to AC terminal blocks as per Drawings# 100-0442A & 100-0445A Clamp a ferrite choke (provided in kit) over all 3 wires near cable gland inside box Secure the ferrite choke with cable ties

3.5.3.5.2 ISOLATION TRANSFORMER end. Use Drawing# 100-0442A. Set the jumpers inside the transformer box for the appropriate input & output voltages of the

transformer Set the fuses inside the MCU Box (AC terminal blocks) for the appropriate operational

voltage of the MCU. Hook up the transformer

3.5.3.6 CAMERA Control cable wiring (Drawing# 100-0058H and EMC wiring kit# 590-0178A)

3.5.3.6.1 MCU BOX end Remove 14” cable outer jacket Uncover individual twisted pairs Uncover all shield wires up to the cable jacket end Twist together the shield wires Where jacket ends, wrap copper tape (provided) around wires. Make sure the copper tape is

in electrical contact with the shields. Carefully insert cable & shields into cable gland (cable entry). Carefully push cable in until

copper tape comes in contact with the EMC fingers inside the cable gland Tighten cable gland nut firmly Do wiring to Camera Control Card (100-2042) as per Drawing# 100-0058H Clamp a ferrite choke (provided in kit) over all wires (except shields). Position ferrite choke

near cable gland. Secure ferrite choke with cable ties Insulate the bundle of twisted shield wires with heatshrinkable tubing Crimp ring terminal (provided in kit) at end of bundled shields Connect shields to earth stud on MCU plate Do wiring to DC Terminal block (2 wires AWG16: WHT, BLK) as per Drawing# 100-0058H.

** Note: The AWG16 WHITE wire paired with the AWG16 BLACK wire is very similar in appearance to the AWG20 WHITE wire paired with the AWG20 BLUE wire AWG20. The jacket is the same size. Be sure to differentiate the two.





3.5.3.7 IR LIGHT Control & Power cable wiring (Drawing# 100-0056G and EMC wiring kit# 590-0182)

3.5.3.7.1 MCU BOX end Remove 14” cable outer jacket Uncover individual twisted pairs Uncover all shield wires up to the jacket end Twist together the shield wires Where jacket ends, wrap copper tape (provided) around wires. Make sure the copper tape is


copper tape comes in contact with the EMC fingers inside the cable gland Tighten cable gland nut firmly Do wiring to IR Light Control Card (100-2046) as per Drawing# 100-0056G. ** Note: This

applies to the AWG22 wires only. Clamp a ferrite choke (small one provided in kit) over control wires (AWG22) (except shields).

Position ferrite choke near cable gland. Secure ferrite choke with cable ties Do wiring to IR Light Power (DC Terminal Block) as per Drawing# 100-0056G. ** Note: This

applies to the AWG12 wires only. Clamp a ferrite choke (large one provided in kit) over power wires (AWG12). Position ferrite

choke near cable gland Secure ferrite choke with cable ties Insulate the bundle of twisted shield wires with heatshrinkable tubing Crimp ring terminal (provided in kit) at end of bundled shields Connect shields to earth stud on MCU plate

3.5.3.8 PAN & TILT cable wiring (Drawing# 100-0054H and EMC wiring kit# 590-0184)

3.5.3.8.1 MCU BOX end Remove 14” cable outer jacket Uncover individual twisted pairs Uncover all shield wires up to the jacket end Twist together the shield wires Where jacket ends, wrap copper tape (provided) around wires. Make sure the copper tape is


copper tape comes in contact with the EMC fingers inside the cable gland Tighten cable gland nut firmly Do wiring to Pan & Tilt Card (100-2048) as per Drawing# 100-0054H. This applies to the

AWG16 wires only except yellow & black/yellow (which are heater power wires). Do wiring to CPU Card (100-2044) as per Drawing# 100-0054H. This applies to the AWG22

wires only. Do wiring to Heater Power (DC Terminal Block) as per Drawing# 100-0054H. This applies to

two AWG16 wires (Yellow & Black/Yellow). Clamp a ferrite choke (provided in kit) over all wires (except shields). Position ferrite choke

near cable gland. Secure ferrite choke with cable ties Insulate the bundle of twisted shield wires with heatshrinkable tubing Crimp ring terminal (provided in kit) at end of bundled shields Connect shields to earth stud on MCU plate





3.5.3.9 VIDEO coaxial cable wiring (EMC wiring kit# 590-0186)

3.5.3.9.1 MCU BOX end Carefully insert non-terminated coaxial cable into cable gland (cable entry). Tighten cable gland nut firmly Install BNC connector on cable Connect BNC connector to output of Camera Control Card (100-2042) Clamp a ferrite choke (provided in kit) over coaxial cable. Position ferrite choke near cable

gland, inside box. Secure ferrite choke with cable ties

3.5.3.9.2 VIDEO DISPLAY (Monitor) end Install BNC connector on cable Connect BNC connector to “INPUT A” at the back of the video display Select Input A (push-button on left side of front panel, button OUT)

3.5.3.10 GENERAL wiring procedures Screw down all unused Terminal Block entry points Screw down all unused Phoenix connectors (green plugs) entry points All wire harnesses must be supported every 6 inches





3.6 Sensor Package Mounting

3.6.1 General Information The camera and Xenon Searchlight are best mounted on the centerline of the vessel and must have an unobstructed line of sight to the water. There must be NO interference in the FOV (Field of View), such as:

• Railings / Post surfaces (Or other items that may reflect light back into the system.) • Navigation lights • Reflected lights from the ship's decks • Reflection from the Night Navigator™ Infrared Xenon Searchlight when the light is on and the

beam is spread. If the Night Navigator™ detects reflected light, the A.B.C. circuit (Automatic Brightness Control) is activated and the system will not provide optimum resolution. Mount the Sensor package base to vessel using 4 stainless steel 3/8” or equivalent bolts provided. The location of the base must be selected to ensure the Night Navigator™ will not contact any other object as it is rotated and tilted. It should be mounted on the centerline of the vessel and as close as possible perpendicular to the centerline of the vessel. Confirm the Field of View of the camera is clear for its complete required rotation to ensure there are no obstacles or interference as discussed above, that will negatively affect its performance.

From drawing NN-004-202K





3.6.2 Sensor Package Mechanical Installation To achieve optimum and safe results from this unit, proper installation procedures should be followed. These items are reviewed in the following paragraphs.

3.6.2.1 Site Location Select a mounting location that will provide the desired maximum movement angles without permitting any part of the Night Navigator™ to come in contact with, or strike, any objects in the sweep paths. Adjustable limit switches are provided to limit the degree of travel in both pan and tilt. The pan azimuth limits can be adjusted to any angle within +180° to -180° relative bearing to ship’s heading. The tilt elevation limits can be adjusted to any angle within +90° to -90° relative to horizon. Limits to motion are preset as per Specifications data, refer to “APPENDIX A - Night Navigator™ 8540/8520 Specifications”

3.6.2.2 Mounting Consideration of wind and ice load factors on the payload and the pan and tilt is important when calculating how solid the mounting platform needs to be and the strength required in the mounting screws

• Remove the shipping pedestal (14” x 14” x 2.5” stainless steel) from the base of the Sensor Package.

• The mounting base is drilled with four 3/8" diameter holes on a 4 3/4" diameter bolt circle in a 4½" square base.

• An arrow on its side marks the front of the Pan and Tilt. • Fasten the base to a stable platform. We recommend 3/8” high strength stainless steel bolts and

nuts be used. See drawing NN-001-115C. • Apply Anti-Seize compound to threads of bolts. The following are suggested compounds:

o Permtex Copper Anti-Seize Lubricant (PN: 09127) o Loctite Nickel Anti-Seize (PN: 77124)

• Tighten Bolts to a minimum torque of 25 ft-lbs (34 Nm). Do not exceed 40 ft-lbs. (55 Nm) • A Bolt Kit is supplied, however Spare Bolts can be obtained by requesting Night Navigator™

spare kit PN: 590-0032

Item Qty P/N Title Contents of Kit PN: 590-0032 1 3 520-0226 BOLT 3/8-16x2.5", HEX, SS 2 3 520-0228 BOLT 3/8-16x2", HEX, SS 3 1 520-0230 BOLT 3/8-16x2.5", HEX, SS, Drilled for Shaft Hair Pin 4 1 520-0232 BOLT 3/8-16x2", HEX, SS, Drilled for Shaft Hair Pin 5 8 520-0402 WASH 3/8,FLAT, SS 6 4 520-0504 NUT 3/8-16,HEX, NYLOCK, SS 7 2 590-0044 HDWR Shaft Hair Pin, 5/16 x 3/8, 5/16" shaft size, SS 8 5 590-0000 HDWR Vibration Isolator, Hemi-Grommet, HG-38 9 1 590-0002 HDWR Vibration Isolation Pad, 4"x0.5", VSCE-41-PSA1 10 4 520-0225 BOLT 3/8-16x1.5", HEX, SS





Bolt Hole Pattern from Drawing: NN-001-115





3.7 Optional Wash and AIR Unit

3.7.1 Compressor Unit The Compressor Unit must be located in a dry indoor environment, within 3 meters of the MCU. It should be mounted vertically with adequate room on the left and right sides for air flow and cables. Since the lid opens up, space is required above the box as well. This is included in the dimensions below. Power is supplied from the MCU when the camera is turned on and regulated by a pressure switch within the compressor box. Refer to wiring diagrams for all connection details Space requirement: 10” H x 15“ W x 8” D Minimum, mounted vertically.

From drawing NN-004-205B

Front View as installedSide View as installed





3.8 System Interconnections Protected Area

Panel-mount Control

Night Navigator

144mm

36mm

Main Control Unit380 x 600 x 210

144mmCompressor box250 x 200 x 155

Monitor (Standard CRT)217 x 218 x 250

Bridge

Isolation Transformer 1.5 kva230 x 210 x 180(if required)

Sensor Head

Outside

From drawing NN-003-126F





3.9 Electrical System Cable Routing Prior to running any cables and making system connections, the following general guidelines should be considered:

• If a cable passes through an outside bulkhead, or is terminated in a unit that is exposed to the weather, the cable entrance should be made watertight with an approved marine fitting.

• Avoid running cables in areas that are exposed to extremes of heat. • Protect cables with tubing if there is a possibility that the cable will be subjected to mechanical

abrasion or chafing.

• When existing cable runs are used to hang and secure the cables, ensure that there is no possibility of radiated interference.

• Determine cable entry point into the base of the Pan/Tilt Unit. Cable entry to this unit is from the

bottom or from the rear of the base with the optional base extension.

3.9.1 Connections to Sensor Package • Connect cables as shown on the interconnection diagrams found in APPENDICES. Cable ends

are tagged to indicate what they should be connected to in order to minimize the possibility of mistakes.

• Enough slack must be allowed for a 355O rotation of the camera unit.

• Cables are plugged in at the pan / tilt end and hard wired at the MCU. (Refer to connection

diagrams)

• Ensure that the metal Circular connectors are correctly mated to the appropriate connector. • The Inline Camera and IR light cable connections below the Sensor package are identical to

bulkhead connectors on the Camera and IR LIGHT tubes. • The connections for the Camera and the IR LIGHT are very similar. The pin arrangement of the

Camera connector is rotated 90º to the arrangement of the IR LIGHT connector. These plugs are keyed so they cannot be reversed unless excess force is used.

• Take care, to line up the pins to the sockets, to prevent bending pins or damaging the connector. • The sockets of the connections should be treated with contact cleaner/enhancer such as:

Stabilant 22, Contact Enhancer. (Stabilant 22A has NATO Part # 5999-21-900-6937) Or at least, Poly Phenyl Ether based Contact cleaner/Enhancer. (MG Chemicals 801B)

• Cables can now be plugged into the Camera & Light Tubes and Sensor Package Cables (Pan/Tilt

Control, Camera and IR Light.)

• The Metal Shells of the connections under the Sensor Package and External to the Package should be wrapped with Self-Fusing Tape (typically MIL-I-46852B) such as Cole-Flex TYT200





4 Night Navigator™ Initialization

4.1 Initial Power up 1) Ensure the Control Panel is correctly connected to the MCU.

• The system will not Power up without the Control Panel. • Do not make or break the Control Panel cable connection while the MCU is powered.

2) Apply power to Main Control Unit (MCU) and now on the Control Panel locate the following:

• Above the POWER OFF button locate the Red Standby LED. • Above the POWER ON button, locate the Green ON LED.

3) The MCU will power up in the same mode that it was in when powered off.

• Standby mode [Red Standby LED on / Green ON LED off] or • Power On mode [Red Standby LED off / Green ON LED on] • To ensure safe shut down – always select standby mode and wait at least 30 seconds before

powering off MCU

4) To select Power On Mode, press and hold the POWER ON button for at least 2 seconds. • Power On mode [Red Standby LED off / Green ON LED on]

5) To select Standby Mode, press and hold the POWER OFF button for at least 2 seconds. • Standby mode [Red Standby LED on / Green ON LED off]

6) Confirm that the Control Panel and MCU are communicating

• Confirm that the Green COMM LED, located above the ACK button, is flashing.

7) Turn on monitor and adjust, confirm video graphics are present.

8) Test Pan & Tilt functions by operating the joystick. • (The Green LEDs illuminating the four pointers near the Joystick will remain on until the

joystick is active in the direction of the LED. • Confirm Return to CENTER operation by pressing the CENTER button.

9) Test & confirm panel Brilliance controls are working. (refer to section 2.6.4 for instruction)

Before turning on the CAMERA, Ensure Darkness and that there are no Bright lights directly in the camera view.

10) Press and hold the IMAGE button for at least 2 seconds. (To toggle Camera OFF, Repeat) • The camera will be powered on. • The Green ACTIVE LED, located above the IMAGE button, will be illuminated. • A Video Image will now appear on the monitor. • Check for Focus. It is focused at infinity in complete darkness and excessive light will affect

the focus.

11) Press and hold the IR LIGHT button for at least ½ to 1 second. (To toggle LIGHT OFF, Repeat) • The IR searchlight will come on and a green ACTIVE LED, located above the IR LIGHT

button, will be illuminated. • The light should be visible on the monitor.

12) Test light controls by operating the IR Narrow & IR Wide buttons and observing the light beam

diameter change on the monitor.





4.2 Focus Confirmation • The camera has been preset at the factory with its focus at infinity. Therefore, objects closer than

100 – 150 meters will not be in focus. • At dusk, the system may not appear focused due to excess ambient light. You must wait until full

darkness to determine whether or not the camera is in focus. • Image intensified systems have an Automatic Brightness Control (A.B.C.) circuit and dim

automatically when too much light is present. In this state the camera will appear to be out of focus. Under these conditions, do not attempt to focus unit, as the image will sharpen, as it gets darker. 9.5º FOV (angle shown not to scale)

4.2.1 Focus Adjustment

Applies to only the 9.5º and 7.5º FOV Cat Lenses. The 20º FOV lens will require factory service. 1) If it is necessary to adjust the focus, first release pressure from the enclosure. Internal pressure

will lock the lens in place and not allow turning. 2) Slowly turn the front lens counter-clockwise while watching the image on the monitor. Use the

tool and sleeve provided for the 68mm Lens, otherwise grip and turn the lens with your hand. Keep turning as long as the image is improving. When it begins to get fuzzy, turn in the opposite direction and repeat until the optimum image is obtained.

3) Re-pressurize the camera enclosure with a dry inert gas (e.g. nitrogen or argon) to 10 – 15 PSIG.





4.3 PAN / TILT LIMIT Adjustments See Diagram and table below to locate Limit Rings for PAN and TILT preset limits.

4.3.1 Internal Access If the tilt table is in a horizontal position then open it by loosening screws at the top of the covers. If the tilt table is not horizontal and interferes with the screws or covers, adjust the table to the horizontal position by use of power if possible. If positioning by power is not practical open at least one cover, use a very large screwdriver and rotate drive shaft "C1" until the table clears the other cover.

PLATE Removedfor diagram.





4.3.2 Method to Adjust limits Limit stops can be set without power being used. Rough set all stops at the shop, leaving final adjustments to be done after installation. With a large screwdriver (a good fit minimizes damage to the slot), turn the tilt worm shaft until the desired position is attained.

4.3.3 TILT LIMIT Adjustments

1) With a large screwdriver (a good fit minimizes damage to the slot), turn the tilt worm shaft "C1" until the desired "Up" position is attained.

2) With a large screwdriver (a good fit minimizes damage to the slot), turn the tilt worm shaft "C1"

until the desired "Up" position is attained.

3) Rotate the blue "Up" limit ring "B3" (use a screwdriver blade in the slots around the periphery)

until its associated switch "S3" is activated; the tension ring will provide enough friction to keep the limit ring in place during normal operations, until you readjust it.

4) Repeat steps 1 and 2 to set the red "Down" limit ring "B4" and switch "S4".

4.3.4 PAN LIMIT Adjustments The pan limit stops are set similarly as the tilt stops.

1) Turn the pan worm shaft "C2" to select the desired position. 2) The bottom pan limit ring "B1" (red) is the right (clockwise rotation) limit adjustment.

3) The second ring up, "B2" (blue), is the left (counterclockwise) adjustment.

TILT Limit Rings Effect of Adjustment RED (B4) For upward range and stop at +90 BLUE (B3) For downward range and stop at –90 WHITE (B6) / GREEN (B5) N/A PAN Limit Rings Effect of Adjustment BLUE (B2) Left final limit stop (manual mode). RED (B1) Right final limit stop (manual mode).





5 Night Navigator™ Maintenance

5.1 General Maintenance This manual was prepared to assist in the maintenance and if necessary, repair of your Night Navigator™. It contains General instructions on the various sub-systems. Ideally you should never have to use most of the instructions contained herein, however, there are some items, which will require maintenance. A checklist for routine maintenance is shown. Feel free to copy it for use on your vessel. If you have any questions, please do not hesitate to call The Current Corporation for technical support.

5.2 Night Navigator™ Maintenance Checklist Item Action Frequency Exterior finish Check for damage Annually

Wiring Examine for crimping, cracked insulation, frayed or pinched wires or loose connectors

3 months

Mounting Confirm bolts securely tightened 3 months Gears Remove foreign matter 6 months Seals Replace if missing or damaged 6 months Tapered roller bearings

Lubricate with broad range synthetic grease. 6 months

Motor brushes Replace 2000 hrs. (Or as required)

Pan & Tilt

Chains Lubricate with low viscosity oil. Check chain slack, backlash. Do not over-tighten.

6 months

Control Panel Wired remote Clean with damp cloth Weekly (Or as required)

Lens Clean glass surface As required Camera Enclosure

Check pressure (3-15 PSIG) Fill to 15 PSI If drops below 10 PSI

Monthly (Or as required)

Front glass Clean Weekly Xenon lamp Replace As required* Searchlight

Enclosure

Check pressure (3-15 PSIG) Fill to 15 PSI If drops below 10 PSI

Monthly (Or as required)

Monitor CRT screen Clean with damp cloth Weekly (Or as required) Washer System Enclosure Check & Add Washer Fluid Monthly (Or as required) MCU Fan Filters Clean filters Monthly (Or as required) *The Xenon lamp is rated at 200 – 500 hours. The light may be returned to the factory for bulb replacement and refocusing.

CAUTION: To reduce the risk of injury due to electric shock or sudden release of pressure, do not remove cover (or back). No user-serviceable parts inside. Refer servicing to qualified service personnel.





5.3 MCU Troubleshooting SYMPTOM PROBABLE CAUSE REMEDY System does not power on No AC Power,

Or Fuse blown in MCU Confirm AC Feed is on Check AC input fuses in MCU

System powers but without any function control or flashing green LED above ACK Button

Poor connection of Control Panel cable or poor shield ground in MCU

Check all connections and grounds. Reset system power.

IR Light does not come on. Fuse blown Check power LEDS

Check fuses in MCU, VDC TB. Replace Fuse. Confirm LED indicators. Check Lamp/Replace

System does not Pan and/or Tilt Loss of communication Breaker’s Tripped on MCU/PCB 100-2048

Check all Connections. Reset breakers on PCB 100-2048 Refer to 5.4 Pan & Tilt

Washer System not working Out of fluid Fuse blown Air Wash line broken

Check & fill as required Check 12Vdc 20 Amp fuse in MCU Check all connections/lines for leaks.

System Powers but no display graphics appear.

Broken Video connections Computer Processor not starting Video card or Processor Failure

Check all video connections external & internal at PCB 100-2042Turn on Image to confirm video signal. Check VAC control fuses. At PCB 100-2042, move the video output cable from PCB connection & connect directly to Black video transceiver. (Camera image directly to the monitor.)





5.4 Pan & Tilt Maintenance

5.4.1 Routine Maintenance Inspect the unit on a regular basis to assure the early detection of any disorder before it becomes a problem.

5.4.2 Inspection Intervals Based on sample testing, it is recommended that the unit be inspected every 6 months.

5.4.2.1 Inspection of Exterior

Finish: Examine for signs of damage to the exterior finish.

Wiring: Examine the exterior wiring harness for signs of crimping, cracked insulation, frayed or pinched wires and loose connectors.

Mounting: Check that the mounting bolts are securely tightened.

Other Hardware: Check that none has come loose

5.4.2.2 Inspection of Interior Wiring: Examine the interior wires for signs of crimping, cracked insulation,

frayed or pinched wires and loose connections. Loose Hardware: Check and tighten. Cleanliness: Any foreign material such as dust, dirt or chips can act as an abrasive in

the gear lubricant and reduces gear life. Make certain to remove all foreign material.

Gear Lubrication: Visually check the gears for worn teeth, poor alignment and chips.

Lubricate the worms and worm gears every time the unit is opened. Seals Replace if missing or damaged. Bearings: Ball bearings are sealed and lubricated for life. The four tapered roller

bearings in the worm carriers should be lubricated with a broad range synthetic grease such as Exxon Beacon 325, 9M 801 with LSHP-2.

Motors: These are lubricated for their design life and require no added lubricant. Motor Brushes: Replace if excessive wear is visible or after 2,000 hours of use,

whichever comes first. Chains: These should be lubricated with low viscosity oil. Chain Adjustment: Slight slack in chains is not detrimental and does not affect backlash. Do

not over-tighten them. Backlash: Check for unwanted movement (looseness) in either pan or tilt drives.

Refer to Section 5.4 for adjustment instructions.





5.4.3 Pan & Tilt Troubleshooting Visual inspection of the unit while operating the pan and tilt will usually reveal if the problem is

mechanical or electrical. Common-sense trouble shooting techniques should reveal the source of the trouble. Some general information to assist in your troubleshooting procedure follows:

5.4.3.1 Determine If the Problem is Mechanical or Electrical • Open the Pan and Tilt covers. • Activate the function at the Control module and determine if the motor is running. If the motor is

running, the problem is mechanical. Refer to section 5.4.3.2 below. If the motor is not running, the problem may be either mechanical or electrical.

• Mechanically uncouple the motor by removing the chain from the sprocket. If the motor operates, the problem is most likely mechanical (binding worm gears, etc.). The problem could also be a defective capacitor (AC units only). If the motor does not run, the problem is electrical. Refer to Section 5.4.3.3 below.

5.4.3.2 Mechanical Problems • Loose sprockets indicating sheared pins or keys. • Chains may have either slipped from sprockets or broken. • Binding gears.

5.4.3.3 Electrical Problems The electrical control system consists of the Control Panel, the interconnecting cable and the Pan/Tilt

itself. A malfunction in any of these components will cause a system failure. Logical troubleshooting procedures must be utilized to isolate the faulty component. It is assumed that the fault has been traced to the pan and tilt. 1. Motor not operating and fuse does not blow

• Remove the Pan/Tilt covers. • Connect a meter across the motor armature. • Activate the function. If the meter reads the correct voltage, the problem is probably a defective

motor. If there is no voltage at the motor terminals, the problem is in the cabling between the connector and motor or the limit switches.

• Pan/Tilt units that operate continuously may put flexing stress on the wires. If these wires ever need to be replaced.

2. Motor not operating and fuse does blow

• Open the pan/tilt cover and remove the four screws securing the male connector to the base of the pan/tilt.

• Visually inspect the circuitry for any short circuits. • Disconnect the motor. Use an ohmmeter to check the cabling. If no apparent problem is found,

the motor could be defective. Mechanically uncouple the motor by removing the chain from its sprocket and apply power directly to the motor. If the fuse blows, the motor is probably defective.

• 3. The Pan/Tilt stalls at the limit switch

• Check the Limit switch • Check the Connections to the motor • Check the Motor

4. The Pan/Tilt Unit does not stop when the limit switch is activated

• Check the Wiring for a short across the normally closed and common contacts • Check the Limit switch





5.5 IR Searchlight Maintenance

5.5.1 Warnings NEVER operate this light in an explosive environment or for any use that is not certified. NEVER operate with the lens removed. The Xenon arc lamp emits ultraviolet rays, which can

cause eye damage. NEVER touch the Xenon lamp connections during operation or ignition, as high voltage is

present. NEVER look directly into the light or any high intensity light source. Doing so can cause eye

damage. NEVER immerse the searchlight in more than 3 meters of water or allow water to enter the

enclosure. While it is waterproof at atmospheric pressure, higher pressures may allow water to enter the enclosure. Submersion in water will cause permanent damage to the lamp inside.

NEVER direct the concentrated beam of light toward flammable materials at close distances.

Due to the intensity of the light source, it is capable of igniting flammable objects. NEVER attempt to operate the light with the case removed. HIGH VOLTAGE IS PRESENT and

there are no user serviceable parts or adjustments inside. NEVER touch the glass portion of the XENON lamp. Handle the lamp by the metal bases only.

Fingerprints may permanently damage the lamp. If the lamp is accidentally touched, clean with the solution supplied in the replacement lamp kit, glass cleaner solution, or alcohol.

NEVER remove the front lens cover or service the lamp without wearing protective eyewear.

The Xenon lamp is under positive pressure and should be handled with care.

5.5.2 Maintenance

• The only maintenance required on the Searchlight is to periodically clean the body with a damp cloth and to keep the front lens cover clean. The front lens can be cleaned with window cleaner. It may become necessary to clean the MIRROR if you notice a slight staining or clouding on the upper surface.

• The MIRROR is a precision optical unit with a highly polished surface and should be cleaned only

when necessary and with great care. Refer to the chapter on LAMP CHANGE for further information on cleaning and care of the MIRROR.

• Should the light be dropped or receive any heavy impact from transportation or shipping, it may

be necessary to re-focus the lamp to insure proper operation and maximum output. Refer to the chapter on FOCUSING PROCEDURE for further information.





5.5.3 IR Searchlight Troubleshooting SYMPTOM PROBABLE CAUSE REMEDY

Light ignites but goes out after a second or two

Low input voltage Low input voltage due to low power supply or line loss

Check input voltage Increase voltage at power supply (still within spec.) or use heavier cable

Light comes on but goes out when switched to high beam or strobe

Defective lamp Replace lamp

Lamp strikes but does not ignite Defective igniter Return light for repair

Lamp does not strike but relay can be heard to work No power Check power source and power

cord Nothing happens when light is turned on Defective regulator Return light for repair

Light comes on but focus will not work

Defective servo or defective controller Return light for repair

Light beam will not focus to the full flood position

Lamp is not seated in socket completely

See section on lamp change and focus

5.5.4 Pressurized Tube Maintenance

Each of the enclosures on the Sensor Package is sealed and pressurized to 3-15PSI with dry Inert Gas such as Argon or Nitrogen.

• Too much air pressure in the enclosure can cause damage and personal injury.

• The Schraeder valve shown is protected with a metal dust

cap. Remove the dust cap to expose the valve, in order to check or to adjust air pressure.

Enclosure End Plate

• Ensure the pressure is regulated to below 15psi. • NEVER ALLOW THE PRESSURIZED ENCLOSURE TO EXCEED 15psi.





5.5.5 Opening and Removing Searchlight from Enclosure In order to perform maintenance work on the searchlight, it is necessary to open the enclosure. Please read carefully and follow the instructions to ensure there is no injury to personnel or damage to the equipment. NEVER open the enclosure where rain or wet conditions of any kind are present. This could lead to rapid deterioration of the equipment.

IMPORTANT: Always release pressure from inside the enclosure before attempting any work on the searchlight, using the Schraeder valve. Serious injury could result if either end is opened while the enclosure is still pressurized.

1) Remove the searchlight from its mounting and take to a workshop or other dry, clean area suitable for disassembly of the unit.

2) Depress the pin in Schraeder valve to vent all the pressurizing gas in the enclosure. Continue until the gas has all been vented and the pressure is reduced to atmospheric.

3) Remove the rear-retaining ring. Pull the end plate straight back removing the tray and searchlight.

4) Carry out whatever maintenance is required on the searchlight. 5) If necessary, it can be removed from the tray by lifting the small lever at the back of the

handle, then sliding the searchlight forward and lifting it out of the slots. Disconnect the power and control cables from the searchlight.

5.5.6 Lamp Change

CAUTION: Never attempt a lamp change or remove the front lens cover with power connected to the light.

1) ALWAYS put on the shatterproof protective eyewear provided. The Xenon lamp is under

high pressure and should be handled with care. 2) Use the 1/16” Allen driver provided in the lamp kit and remove the 3 screws holding the front

lens in place and remove. 3) Carefully remove the electrical connector from the front of the lamp by unsnapping it. 4) Remove the lamp from the socket by grasping the metal end and pull gently with a slight

twisting motion. DO NOT touch the glass envelope. If the lamp is touched, it can be cleaned with the cleaning solution provided in the lamp kit.

5) Gently blow any contaminants out of the reflector before cleaning. Use the tissue and

cleaning solution in the lamp kit to clean the lens and mirror. Use very light pressure to prevent scratching of the mirror.





6) Replace the lamp, holding it firmly by the long metal end and pushing it into the socket with a slight twisting motion. Make sure the lamp is seated all the way into the socket or the electronic focus will not operate properly. DO NOT apply any binding or sideways force on the lamp.

7) Reconnect the electrical connector to the lamp.

8) Replace the glass lens by first placing the o-ring over the step on the inside of the plastic ring.

Then push the lens onto the reflector housing with a slight twisting motion, making sure that the front lamp support is seated into the Teflon button in the center of the lens. It may require several attempts the first time you try this to get the o-ring seated properly.

9) Rotate the front lens ring to line up the screw holes. Replace the screws; making sure the

lens assembly is seated properly. DO NOT over tighten these screws. The O-ring is not a compression seal, so snug is good enough.

5.5.7 Lamp Focus Refocusing of the lamp requires centering the lamp within the mirror in order to achieve a good collimated beam and maximum light output.

• Use the 1/16” Allen driver in the lamp kit, remove the 2 focus access screws, one on the right front side of the main body, and one just left of the front of the handle.

• Insert the same Allen driver into one of the focus access holes. A slight rotation and/or side-to-side movement may be required until the Allen driver is properly seated into the adjustment screw.

• After the Allen driver has been inserted into the adjustment screw, turn the Allen driver to move the lamp back into focus.

• Repeat this procedure for the other adjustment screw. • Shine the light beam onto a flat surface about 50 feet away and turn the adjusting screws to

center the beam for the most uniform light pattern. • Replace the focus access screws when focusing is complete. DO NOT over tighten the screws,

snug is good enough.

5.5.8 Reassembling the Enclosure • Secure the searchlight to the tray by putting it the four “feet” into the slots and sliding backwards

until the locking pin at the rear drops into place. • Reconnect the power and control cables to the searchlight. • Slide the searchlight assembly into the enclosure tube with the lens toward the front. • Apply white grease to the O-ring, if necessary, to allow the end plate to slide into place smoothly. • Replace the end plate on the rear of the enclosure. • Install the rear-retaining ring on the enclosure tube to hold the end plate. • Repressurize the enclosure with a dry inert gas such nitrogen or argon. • DO NOT EXCEED 15 PSIG. • Equipment failure and personal injury may result if the unit is over-pressured. • Reinstall the searchlight in its permanent mounting.





5.5.9 Optical Filters The Infrared filter has a vacuum deposited, multi-layer, dichroic coating applied to both surfaces of the glass substrate. These coatings must be handled with care to prevent any scratches, which could damage the filter and allow visible light to appear through the surface. Cleaning: These coatings should be cleaned with a soft lint free cloth and room temperature water. Filter properties: The filter has a metallic mirror-type surface, which reflects visible light and passes the infrared. The spectral curve shows this filter to pass the greatest amount of infrared energy and is recommended for extreme, long-range surveillance. This filter starts turning on in the near infrared, allowing a slight red glow to appear when looking straight into the beam.

5.6 Video Display Unit (VDU) Warnings To prevent fire or shock hazard, do not expose the unit to rain or moisture.

CAUTION: TO REDUCE THE RISK OF ELECTRIC SHOCK, DO NOT REMOVE

COVER (OR BACK). NO USER-SERVICEABLE PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.

This symbol is intended to alert the user to the presence of un-insulated "dangerous voltage" within the product's enclosure that may be of sufficient magnitude to constitute a risk of electric shock to persons.

This symbol is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the appliance.

To Clean VDU

• As a safety precaution, unplug the unit before cleaning it. • Clean the unit with a slightly dampened soft cloth. Use a mild household detergent. • Never use strong solvents such as thinner or benzene as they might damage the finish of the

cabinet.





6 8540/8520 Night Navigator™ Technical Description

6.1 Night Navigator™ Control Panel (100-2028 and 100-2030)

6.1.1 Block Diagram

Joy Stick

DipSwitch

RS422

MicroController

14 buttonKB

RS-422interface J2

LEDIndicators& backlight

Supportcircuits

PowerOn/OffCircuit

12 Vdc Power

StandbyPower

Power_offcontrol

100-2028 and 100-2030 Assy

6.1.2 Functional description The 100-2028C and 100-2030C together form the Main Night Navigator™ Control Panel. The

keypad, joystick and LEDs are the human machine interface to the MCU. Communication with the MCU is a packet based RS-422 protocol.





6.1.3 Details

J1 Inter-board connection between 100-2028C and 100-2030C J2 RS-422 link from Control Panel to MCU

H1, H2, H3, H5, J4, J5 (Reserved for future use) JP1 Control Panel RESET pin (Short to reset)

JP2, JP4, JP5 Factory settings do not adjust, (Short 1-2 is normal) DIP switch SW1 Factory settings do not adjust (pos1, 5,6=ON, pos2, 3,4,7,8= Off)

Position1-2: Indicate 1-3 of RS-422 nodes Position5-6: Indicate Baud Rate (default= 4800, both=ON)

Programmable IC's PIC16F877A-20IL as supplied

BOTTOM VIEW of CONTROL PANEL(pn: 100-2030C)

1on

23

45

67

8

SW1

J2

U3

SW 1default settings

Pos1-2: RS-422 Node# (node1)Pos3-4: ReservedPos5-6: RS-422 Baud rate (4800)Pos7-8: Reserved

J1 Pin1





6.2 Night Navigator™ 4 Button Keypad (100-2032 and 100-2033)

6.2.1 Block Diagram

option JumperJP2

RS422

MicroController

4 buttonKB

RS-422interface J1

LEDIndicators& backlight

Supportcircuits

12 Vdc Power

100-2032 and 100-2033 Assy

6.2.2 Functional description The 100-2032A and 100-2033A together form the Night Navigator™ 4 Button Keypad. The

4button keypad and LEDs are a secondary human machine interface to the MCU. Communication with the MCU is a packet based RS-422 protocol.

6.2.3 Details

J1 RS-422 link from Control Panel to MCU H1, H2 Inter-board connection between 100-2032A and 100-2033A

H3 (Reserved for future use) JP1 Factory settings do not adjust, (Short 1-2 is normal) JP2 Indicates RS-422 node number.

Jumper On = node 3, (1st unit) – default setting for single unit. Jumper Off = node 4, (2nd unit).

Programmable IC's PIC16F628-20I/SS as supplied.





6.3 Compressor connections for optional Wash/Dry Unit

Vdc Supply

- +Output

TERM1(Vout -)

TERM2(Vout +)

Input- +

TERM4(Vin -)

TERM3(Vin +)

Solid StateRelay

(150-0236)

12AWG Wire

18AWG Wire

Compressor EnableCompressor ControlSee Drawings 100-0058H

& 100-0068EFor More Details

Cable ASSY100-0068E

0Vdc

White

Black

Shield

6.4 MCU Assembly

6.4.1 MCU Block Diagram





6.4.2 MCU Layout (Top View)

From drawing NN-004-130G





6.5 MCU Power distribution

6.5.1 Overall Power diagram

6.5.2 Fuse Replacements

Replacement List for AC supply fuses (See drawing 100-0442A for more details)

1/4” x 1 1/4” type 8540/8520 Spares PN:

Bussmann Part number

Littlefuse Part number other

2A 250VAC fast blow 130-0513 AGC-2 312002




Replacement List for DC supply fuses (See drawing 100-0445A for more details)

Flat Blade Type 8540/8520 Spares PN:

Bussmann Part number

Littlefuse Part number

Phoenix Part number

5A 32VDC fast blow 130-0522 ATC-5 257 005 0913692

7.5A 32VDC fast blow 130-0524 ATC-7.5 257 07.5 0913702








6.6 Shutdown Module (100-2060B)

6.6.1 Block Diagram

RS-232

MicroController

PowerRelay

Vac

RS-232interface

J1

LEDIndicators

Supportcircuits 24 Vdc Power

100-2060 Assy

SwitchedVac

5 Vdc Power

Power_off

6.6.2 Functional description The 100-2060B manages Start up and Shut down Sequence for power to the VOP (Video

Overlay Processor). This module also regulates the 24Vdc Standby power down to 5Vdc for use at the MCU and Main Night Navigator™ Controller.

6.6.3 Details

D4-B D4-A

Green Green

Indication of +5Vdc Standby on PCB Indication of +24Vdc active on PCB

D1 Orange Indication of Standby/System off when Flashing at 2Hz, (normally off)

J1

J1 pins 1-4 = Fused Vac to Power relay J1 pins 5-8 = Switched Vac from Power relay J1 pins 9-12 = VOP RS-232 and Power off request J1 pins 13-16 = 24Vdc Input, 5Vdc(Standby) outputs and ground

J2 (Reserved for future use) JP2 Factory settings do not adjust, (Short 1-2 is normal)

Programmable IC's PIC16F628-20I/SS as supplied.





6.6.4 Functional Diagram





6.7 MCU Back Plane PCB (100-2040B)

6.7.1 Block Diagram

6.7.2 Functional description The 100-2040B is a power and signal distribution back plane for the local BUS to the MCU Control Panel and 4 Button Keypad modules. The RS-422 is distributed to the VOP, Control Panel and MCU Master Controller. 12Vdc is supplied to the Control Panel /Keypads and the Power off signal switches .the MCU AC/DC power supply to shutdown mode.

Shut DownControl

12Vdc

J3

JS1-JS5

JS6-JS10

Indicators andControl Panel

Power

JV3, JV4JV1, JV2

POWER

Power_off

Power

PS Disable

RS422

Local BUS





6.7.3 Outline & component location

6.7.4 LED's

D1 RED +5Vdc Standby power D6 RED Indication of +5Vdc active on PCB D8 RED (Reserved for future use) D10 RED Indication of +12Vdc active on PCB D11 RED Indication of +24Vdc active on PCB D17 RED Indication of +8Vdc active on PCB D13 Green Indication of +12Vdc PTC protected output to keyboards D4 Orange Indication of Standby/System off when Flashing at 2Hz, (normally off)





6.7.5 Connectors

J2 Ground test point J3 RS-422 link from Back plane to MCU Master Controller JV1 Vdc Power supply connection JV2 Vdc Standby Supply and Power Supply Shutdown connections JV3, JV4 RS-422 connections to VOP, Control Panel and Keypads JS1 – JS10 Power and Signals connections to controllers

5Vstby

5Vdc

12Vdc24Vdc

JV4

JV3

JV1

JV2





6.8 MCU Master Controller (100-2044B)

6.8.1 Block Diagram

6.8.2 Functional description The 100-2044B is the MCU master controller for control logic and sequences of all control modules installed. Control functions are received as RS-422 serial commands from slave devices: the VOP, Control Panel or additional Keyboards. Position data is broadcasted, as RS-422 serial packets to slave devices. Local functions are option switches, Analog to Digital conversion of the PAN and Tilt Positions and measurement of the local temperature.

JR3Temperature

Sensor

DipSwitch 1,2

RS

422

JR1

JR2

POWER

I/O

CPUA/DPan/TiltPostion

BUSinterface

RS-422interface

J1






6.8.4 LED's

D1 RED Indication of +5Vdc active on PCB D3 Green (Reserved for future use) D4 Green (Reserved for future use) D5 Green (Reserved for future use)





6.8.5 Details

J1 RS-422 link from Back plane to MCU Master Controller JV3, JV4 RS-422 connections to VOP, Control Panel and Keypads JR1, JR2 Power and Signals connections From Back plane

JR3 Control cable, PAN/TILT position feedback JP1, JP3, JP5 Factory settings do not adjust, (Short 1-2 is normal)

JP 2 (Reserved for future use) JP 4 MCU Master Controller RESET pin (Short to reset)

DIP switch SW1 Factory settings do not adjust (pos3,5,6=ON, pos1,2,4,7,8= Off) Position 1-4: Indicate number of RS-422 nodes Position 5-6: Indicate Baud Rate (default= 4800, both=ON)

DIP switch SW2 Factory settings do not adjust (pos1=ON, pos2-8= Off) 8 to ON after setup, to lock menu. Position1: On=enable Slow AUX PAN Position4: On=enable Extended status Position5: On=Inverted installation Position8: On=Lock calibrate menu

Programmable IC's PIC16F877A-20IL as supplied

1

on

2 3 4 5 6 7 8

SW1 SW2

123

JP5JP3

JP1

1 2 3 4

JP2JP4reset

SW1 & SW2default settings

MCU Master Controller (PN:100-2044B)

Comp side view, shown inverted

JR3

Phoenix Connectorsolder sideJR3 Pin1

Pos1-4: number of RS-422 nodes (shown as 4 nodes)

Pos5-6: RS-422 baud, shown as 4800 baud

Pos7-8: Reserved

Pos6-7: Reserved

Pos8: on = lock calibrate menu

Pos5: on = Inverted Pan/Tilt

Pos2-3: Reserved

Pos1: on = Enable slow Aux+Pan

Pos4: on = Enable Extended status

1

on

4 5 6 7 82 3

3473J1





6.9 MCU Camera / Video Controller (100-2042D)

6.9.1 Block Diagram of full-featured version.

JR3

JR1

JR2

POWER

I/O

Activators(4X)

CameraControls

BUSinterface

OUTB1

OUTB2

SW1: 75R selectR46,R55: Gain-trimU10,U11: 4:1 MUX

Video Distribution Amp(solder side)

VideoAmp

VideoAmp

IN1

IN2

IN3

IN4 4:1

mux

4:1mux

OUTA3

OUTA1

OUTA2

6.9.2 Functional description The 100-2042D is the Camera and Video controller. • Each of the four inputs (IN1-IN4) to the 4:1 multiplexers (MUX) has selectable 75 Ohm termination. • Each MUX drives one of the two output channels (A,B) • Channel A has three equal outputs and channel B has two equal outputs. • This controller has three activators for camera control and one activator for compressor enable. • The MCU master controller (100-2044B) directly controls these activators and selects the input for

each MUX. Video section details:

• In addition, there are two AC-coupled (time constant = 0.15sec) Video Distribution Amplifiers. • There is an option to convert, to DC coupled Amplifiers by shorting the AC coupling capacitor. • Each channel has Gain trims. Adjust R46 for Channel-A and R55 for Channel-B. • The four-position switch SW1 enables any of the four 75-ohm input terminations.

The two-channel version as supplied, can be identified with 6 of the 9 BNC connectors installed. It has two outputs for each channel and these outputs are buffered outputs of non-multiplexed dedicated 75 Ohm terminated inputs. IN1drives OUT A1 and OUTA3, while IN4 drives OUT B1 and OUT B2. The second and third activators for camera control are omitted. (If the 4 Position Switch is present see section below regarding selection of 75Ohm termination)





6.9.3 100-2042D Component-side (2-Channel Version)

6.9.4 LED's (Component Side)

• Grey text applies to full 4 channel version

D7 Green Indication of +12Vdc PTC protected output to Camera1 D10 Green Indication of Compressor power enabled. (Optional device) D13 Green Indication of +12Vdc PTC protected output to Camera2 D16 Green Indication of +12Vdc PTC protected output to Camera3

On/Off= Led status D17 D18 D19 D20

Channel A = IN1 N/A N/A Off Off Channel A = IN2 N/A N/A Off On Channel A = IN3 N/A N/A On Off Channel A = IN4 N/A N/A On On Channel B = IN1 Off Off N/A N/A Channel B = IN2 Off On N/A N/A Channel B = IN3 On Off N/A N/A

D17-20 Green

Channel B= IN4 On On N/A N/A D29 Green Indication of -5Vdc PTC protected output Video circuit





6.9.5 Connectors (Component-side)

JR1, JR2 Power and Signals connections From Back plane

JR3 Control cable, Camera and spare activators

6.9.6 100-2042D Solder-side (2-Channel Version)

6.9.7 Connectors (Back side) • Grey text applies to full 4 channel version

SW 1 (If absent,

Termination is dedicated)

75 ohm input terminator, required, if not otherwise terminated. SW1- pos 1: On= 75R termination of Video IN 1 SW1- pos 2: On= 75R termination of Video IN 2 SW1- pos 3: On= 75R termination of Video IN 3 SW1- pos 4: On= 75R termination of Video IN 4

IN1, 2,3,4 Input Signals to Video MUX Out A1, A2, A3 Outputs of Video Amp A

Out B1, B2 Outputs of Video Amp B R 46 Gain trim of Video Amp A R 55 Gain trim of Video Amp B





6.10 MCU IR Lamp Controller (100-2046B)

6.10.1 Block Diagram

JR3

JR1

JR2

POWER

I/O

Activators(7X)

IR LampControls

BUSinterface

SensorIR LampIndicator

6.10.2 Functional description The 100-2046B is the IR Lamp controller. This controller has 7 activators for lamp control and one dedicated lamp sensor inputs, which are interfaced directly by the MCU master controller (100-2044B). Note, the Lamp power is sourced remotely and is activated by this module. The Functions Strobe and High-Level are optional.






6.10.4 LED's

D1 RED Indication of this 100-0246B module is powered. D2 RED Indication of remote IR Lamp power supply is on. D2 Green Indication of IR Lamp is energized. D3, D6

RED, Green

Indication of Spare1 activator is selected, Indication that Spare1 control is activated.

D7, D10

RED, Green

Indication of Spare2 activator is selected, Indication that Spare2 control is activated.

D11, D14

RED, Green

Indication of WIDE activator is selected, Indication that WIDE control is activated.

D15, D18

RED, Green

Indication of NARROW activator is selected, Indication that NARROW control is activated.

D19, D22

RED, Green

Indication of HIGH-level activator is selected, Indication that HIGH-level control is activated.

D23, D26

RED, Green

Indication of STROBE activator is selected, Indication that STROBE control is activated.

D27, D30

RED, Green

Indication of LAMP ON activator is selected, Indication that LAMP ON control is activated. (Device state is toggled) (See D31 for energized state of LAMP)





6.10.5 Connectors

JR1, JR2 Power and Signals connections From Back plane JR3 Control cable, IR LAMP activators





6.11 MCU Pan & Tilt Controller (100-2048C)

6.11.1 Block Diagram

JR3

JR1

JR2

POWER

I/O

(8X) DC MotorActivators

MotorControls (4x)

BUSinterface

Sensor

Wash,Dry,SpareActivators

(3X)

Compressor Enabled

Speed select

6.11.2 Functional description The 100-2048C is the Pan & Tilt controller. The Pan and Tilt motor controls are 12V or 24Vdc selectable reversible activators (4x) for Panning Left or Right and Tilting Up or down. The power for the Motors is sourced from this module. This controller has 3 additional activators for WASH (optional), DRY (optional) and SPARE1 control. All of these activators are controlled directly by the MCU master controller (100-2044B).

6.11.3 Connectors

JR1, JR2 Power and Signals connections From Back plane JR3 Control cable, PAN and TILT motor controls and spare activators






Circuit Breaker Indication, On if Tripped. Circuit Breakers CB1 thru CB 8.

6.11.5 LED’s

D2 RED Indication of this 100-0248B module is powered. D4 GREEN Indication of +24Vdc PTC protected output to Lens washer/dryer. D8 & D12 RED Indication of Pan to the Left D5 & D13 RED Indication of Pan to the Right D16 & D24 RED Indication of Tilt Down D19 & D23 RED Indication of Tilt Up D35 GREEN Indication of Washer system is selected D29 GREEN Indication of Air Dry system is selected. D36 RED Indication of High Speed (24Vdc) Selected D32 GREEN Indication of Spare1 is selected D7,10,11,15,18,21,22,26 RED Indication of Circuit Breaker Tripped. CB1,2,3,4,5,6,7,8





7 WARRANTY and REPAIR

7.1 Returns for Repair All returns must have a Return Materials Authorization Number (RMA number). All returns without an RMA will be repaired and returned at the customer's expense. Product for repair must be sent freight prepaid along with return shipping instructions and a brief description of the problem. Warranty repairs will be returned freight prepaid by regular UPS unless requested otherwise. Any additional freight costs for special handling (i.e. airfreight) will be billed to the customer. All other repairs will be sent freight and repair costs C.O.D. unless other arrangements are made. Obtain Return Materials Authorization Number (RMA number) by calling or writing the supplier. Email: [email protected]

Phone: (1) 604-461-5555 Fax: (1) 604-461-5525

All repairs should be sent to: The Current Corporation Service Dept.

2933 Murray Street Port Moody, BC, V3H 1X3 Canada

7.2 Warranty Conditions The Current Sales Corporation hereby warrants that products shall be free from defects and/or faulty workmanship for a period of (1) one year from original ship date from factory on searchlights and for a period of (90) ninety days from original ship date from factory on searchlight bulbs. User error and/or misuse are not included in this warranty.




Doc: 003-8118-004 © 2002-2007 The Current Sales Corporation. Mar. 19, 07 Page A

APPENDIX A • Night Navigator™ 8540/8520 Specifications




Doc: 003-8118-004 © 2002-2007 The Current Sales Corporation. Mar. 19, 07 Page B

APPENDIX B • Cable and Connection Drawings




Doc: 003-8118-004 © 2002-2007 The Current Sales Corporation. Mar. 19, 07 Page C

APPENDIX C • Additional Drawings and Bulletins

Documents

H 311 Night Navigator 003-8118-005-Modified for Hong Kong Only