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Navigation Light Controller and

Panel

Rev. 2 March 2015

Manual

Navigation light controller

Panel

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Contents:

Section: Page: Text: 1 3 Preface 1.1 3 Modular principle 1.2 3 Basic working principle 1.3 4 System overview 2.0 5 Standards 3.0 6 Controller, basic data 3.1 6 Controller power-supply and connections 3.2 7 Controller installation guidelines 3.3 8 Controller, direct operation 3.4 9 Controller schematics 3.5 10 Controller, service and maintenance 4.0 11 Panel, basic data 4.1 12 Panel installation guidelines 4.2 13 Panel [A] – detailed drawing 28 position 4.3 14 Panel [B] – detailed drawing 21 position 4.4 15 Panel [C] – detailed drawing 14 position 5.0 16 Initial installation and set-up 5.1 17 Connections and operations NLC 6.0 18 Programming of panel functions 6.1 19 Panel keyboard definitions 7.0 20 Manual control of NLC 8.0 20 Test procedure 8.1 20 System reset 8.2 21 Setting address of LMR/P 9 21 Sparepart list 9.1 22 User manual

Page 3 of 22 1 Preface

The Lopolight Navigation Light Controller and Panel, described in the following, is a simple to install and simple to operate system that can control a number of Lopolight navigation lights. It it is delivered pre-setup on an almost ready to use basis. The modular-built system offers integrated power-supply, monitoring and control functions and an elegant control panel. The system fulfils all required demands for a complete navigation light installation for all ships, meeting and exceeding relevant standards and resolutions. The system is based on the type-approved Lopolight Monitoring Relay (LMR/P). Refer to section 2 for further information concerning approvals. Only the full 28 key version is described in the following.

1.1 Modular Principle – up to 28 outputs. The basic system consist of up to 14 outputs (navigation light connections), and can be extended with 2 times 7 additional outputs, totalling 28 controllable outputs. (In the case where further controls are needed, two parallel systems may be used). The panel is delivered with customer specified texts. Please refer to www.lopolight.com for ordering information.

1.2 Basic working principle The complete system consist of two basic components:

A: The NLC CONTROLLER that holds the LMR/P monitoring relays, primary power-supply, secondary (emergency) power-supply, emergency operation features and navigation light connection terminals. The controller can be operated by a remote panel (LPL P/N: 500-100) –and/or a customer designed control system, using RS-485 data communication. The NLC, and the connected navigation lights, functions work independently and is not depending on the panel. B: The PANEL (remote panel) that holds a number of operation buttons, group buttons, alarm and dimming features. The panel and the controller are interconnected via a flexible 7 wire cable Multi-processor principle: The controller holds a number of Lopolight Monitoring Relays (LMR/P´s), that are the basic component in the system. One LMR/P is assigned to every output. Each LMR/P is assigned to a logical address, that can be controlled by a data telegram from the panel. The multi LMR/P processor principle offers the highest possible degree of redundancy as every navigation light are monitored by “it´s own” Monitoring Relay. The LMR/P can also be controlled manually using the on-board pushbutton to control the assigned navigation light.

Page 4 of 22 1.3 System overview

Page 5 of 22 2 Standards and resolutions

The system meets and exceeds the following standards, type approvals and resolutions: Lloyds register type approval: 12/70035* EN-60945 MSC 253(83) Annex 31 MSC 79/23/Add.2 Annex 33 IEC 62288 IEC 61162-1 *Refer to “certificates/type approvals, LMR” under www.lopolight.com/downloads

Page 6 of 22 3 Controller basic data

Cabinet: Steel enclosure (Schneider-Electric: Spacial S3D) Dimensions: 400*400*200mm Mounting: 4 wall screws (not supplied with system) Weight: ~13 kg. (full version) Ingress protec. IP66 (depending on selected cable entry system) Cabinet certificates: BV, CUL, DNV, GL, LR, UL Colour: RAL 7035 (Light grey) Protective ground connection: M6 bolt connection protruding from cabinet Theoretical temperature rise: 25 deg C. above ambient @ 200W load.

3.1 Controller power and connections: Primary power-supply, Option A: 100-240VAC 50/60Hz, Maximum 250W Primary power-supply, Option B: 19-32VDC, Maximum 250W Sec. power-supply, Option C: 100-240VAC 50/60Hz, Maximum 250W Sec. power-supply, Option D: 19-32VDC, Maximum 250W Internal circuit protection: 100-240 VAC: 6A[C], 19-32 VDC: 20A[C] Connections: Elevator type screw terminals: 1.5 to 6 sqmm Isolation: Power supplies are galvanic isolated from ships installations. Outputs: Number of nav light connections: 1 to 28 LMR/P* based outputs Max output voltage: 32VDC Max output current: 1 Amp per output – automatic current limiter Fuse: One 7A on-board (LMR/P) fuse per output. (Non-replacable). Max total output: 220W (total max consumption must be calculated) HW alarm output: Max 200 mA open collector (sink) HW alarm reset: Edge trigged low-going. (apply system minus to reset) Power supply to panel: 24 to 32VDC, max 200 mA via data plug(s) Data communication: Physical: RS-485: 38400, N,8,1 Data protocol: Lopolight LMR/P protocol (protocol code “P”. refer to 5.0) Data comm. interface option 1: Sub-D09 (refer to 3.4) Data comm. interface option 2: 7-pin screw terminal plug (refer to 3.4) Termination resistor: 120 Ohm in screw terminal. Normally located in NLC. Use only one per system. Control panel: Lopolight P/N: 500-100-XX may be used to control the outputs. Number of control panels: Up to 12 panels may be connected simultanesly to the controller. Other control possibilities: A customer designed (computer based) control system may be used, provided it complies with the Lopolight Protol code “P”.

* LMR/P: Type approved by Lloyds register: certificate #: 12/70035

Page 7 of 22 3.2 Controller installation guide Location: The controller must be installed in a protected* environment at bridge level. (* refer to EN-60945 chapter 8.2) Access: The enclosure door must be reachable, and it must be possible to open it fully in order to gain access to the manual (emergency) control buttons. It must be possible to gain full access to the manual control buttons within 2 minutes. Temperature: Ambient temperature: Max:50 Min:-15 deg. C Avoid placing the controller near other equipment that creates excessive heat. Mechanical: Secure to bulkhead/wall using four pcs. of min 10mm bolts. Ensure that the bulkhead/wall is suitable of carrying a load of 13 kilo – also under heavy vibration. Power supply: Ensure that proper cable types and dimensions are used for power-supply. Refer to 3.1 for details (suggested minimum 2.5 sqmm) Cable entries: Power, communication and output cables must be strain relieved externally, according to “good workmanship practise” and relevant standards. Output cable installation – internal: Connect the individual cables to relevant output plug/terminal using appropriate ferrules to protect the wire strands. Ensure correct polarity (L+ = positive, L- = negative). Scr. = screen/protective earth should be connected to cable screen, unless cable screens are ground connected elsewhere near the controller. Secure plugs with screw before finishing installation. Recommended cable dimensions: 0.5 to 2.5 sqmm Output cables: Output cables may be connected directly to the controller. If heavy-duty ships cables are used, it may be necessary to terminate these at an external terminal bar, and then connect the external bar to the output plugs of the controller using smaller dimension cable or wire. Cables should be drawn from the gland plate (fittet at the bottom of the enclosure) at the underside of the support plate and emerge just before the dedicated connector (K1-14) Protective ground: Protective ground must be connected to the cabinets ground point using proper sized grounding wire or mesh. (suggested minimum: 6 sqmm) Compass safe distance: 0.5 meter (controller only).

Page 8 of 22 3.3 Controller, direct control (emergency operation) The individual Monitoring Relay outputs can be controlled manually by a simple keypress. The output will toggle between on and off at every key press. The output can be in three states: OK, ALARM and OFF If an output is off, then the indicator will be off. If the output is on the green “ok” indicator will illuminate. If the connected navigation light is faulty the red indicator will illuminate. The direct controls are independent from the control panel and are classified as “Manual Emergency Control” (Refer to section 11 for full description.)

Output in off-state Control button

Output in alarm state Output in ok state

Page 9 of 22 3.4 Controller schematic Including power-supply and power monitoring function. Note that the individual units can have different basic power supplies. I.e: either 24 VDC or 110-240VAC as either/or primary and secondary supply.

Page 10 of 22 3.5 Controller, service and maintenance Adjustment of power-supplies: (only applies if redundant power-supply is fittet) Tools: a proper quality multimeter set to “DC voltage”. Measuring points: Output terminals of power-supplies. Adjust the power-supply that shall be defined as primary to 28.0 VDC. Adjust the power-supply that shall be defined as secondary to 26.0 VDC LMR/P replacement: 1: Open cabinet door. 2: Turn off both primary and secondary power source on the circuit breakers. 3: Unscrew the two black finger screws, and lift the cover off. 4: Unscrew the two M4 inhex bolts, and lift off the stabilizer-bar. (note the orientation -shall not be turned 180 deg. when refitting) 5: Carefully pull the LMR/P in question out. 6: Note the dip switch settings and set the new LMR/P exactly as the original. 7: Replace the new LMR/P – taking care to insert it precisely into the two plugs. 8: Assemble and reapply power. 9: Turn on the navigation light - wait 10 seconds and activate the teach-in button by a brief push.

Page 11 of 22 4.0 Panel, basic data Sizes: Customer specified number of control buttons (1 to 28): A) 22-28 lights, 280 x 205 x 40 mm, panel cut-out: 250 x 175mm

B) 15-21 lights, 230 x 205 x 40mm, panel cut-out: 200 x 175mm C) 1-14 lights, 180 x 205 x 40mm, panel cut-out: 150 x 175mm

Ingress protection: IP-67 from front. Panel must be sealed along edges toward waterproof console, if installed in wet environment. The basic control panel consist of: A waterproof aluminium base plate with laser engraved customer specific texts, holding number of navigation light control buttons, including dimmable status indicators. Four function buttons, one dimmer dial and one alarm reset button. Power-supply: Directly from controller, via Sub-D09 male. (Com 1) Interfaces: COM 1: (RS-485), Sub-D09, male: Connection to Navigation light Controller only (1:GND, 2:PWR-ok*, 3:RS-485 B, 4:RS-485 A, 5:Alarm reset**, 6:+24V, 7:Alarm***, 8:NC, 9:NC) * PWR ok: signal is low when both primary and secondary P-S are working properly ** Alarm reset: Pull down to system GND to reset audible alarm *** Alarm: Signal pulls down to system GND when in alarm state. Max sink: 200mA COM 2: Sub-D09, female: NMEA-0183 connection to VDR and other Auxiliary equipment, according to IEC-61162 (RS-232, 4800, n,8,1) (2:TX, 3:RX, 5:GND 1,4,6,7,8,9:NC). Refer to section 5 for details. Protective ground: M3 bolt at rear of panel, marked with earth sign. Recommended earthing cable: 2.5 sqmm Working principle: Any key-press will be interpreted and converted into a RS-485 telegram, and sent on the Com port(s). The telegram can control four basic Lopolight products: 1: NLC (refer to chapter 3 and others in this manual) 2: LMR (free-standing monitoring relay P/N: 400-018) 3: Equipment based on the Lopolight NPC driver (nav-lights with integrated RS-485 com ports. Typically used in navy and SAR vessels) 4: Equipment based on the Lopolight MTG driver (High power LED driver) Baudrate: 38400,N,8,1 Protocol: Lopolight protocol code “N or P”

Page 12 of 22 4.1 Panel, installation guidelines Make an appropriate rectangular cut-out in the console. De-burr sharp edges Type A: 255*180mm +/- 2.5mm Type B: 205*180mm +/- 2.5mm Type C: 155*180mm +/- 2.5mm (types: Refer to chapter 4.0, and drawings at end of this section) Place the panel and align as needed. Mark the four holes, and drill after removal of display. The holes may be threaded to M4, else use appropriate nuts. Bolts should be DIN 912, (half-countersunk in panel). Protective Ground must be connected to ground-point art rear of panel. Use star washer under ring terminal to ensure proper GND connection. Connect Sub-D09 based interconnection cable to COM-1. Connect free end to NLC J1 or J3. Screen must be connected to earth rail in NLC enclosure. If two panels are connected they must be connected in parallel – to NLC J1 or J3

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Type A – max 28 positions.

Page 14 of 22 Type B – max 21 positions.

Page 15 of 22 Type C – max 14 positions.

5.0 Initial installation and set-up. Earth connections - general guidelines: The NLC must be connected to ships protective ground (hull) via the external grounding point, marked PE. Use M6 terminal and appropriate lock washers. If the feed wires to the individual navigation lights are of screened type, then the screen must be connected to PE. This may be by using the mid-pin on the 3-pin connector(s), or outside the enclosure at another PE point. It is permitted not to use un-screened cable the last ~2 meters before the enclosure.

Page 16 of 22 Hardware connections, NLC control box:

1) Make sure the two circuit breakers are open.

2) Connect the individual navigation lights to the NLC terminals. Also refer to

section 9.0, and illustrations P. 17 and 19

3) Connect primary and secondary power to the NLC.

4) Connect the inter-connection cable (Sub-D09) between NLC – J1 and the panel. (Ref. wiring diagram P. 9 for connections. Use either Sub-D 09 or J1/J3 plug/screw terminal).

5) Turn on system by closing the circuit-breakers. (Alarm will sound now. Can be silenced by pressing Alarm reset button on panel)

Now the system is ready for set-up.

5.1 Teach-in procedure: “Every LMR/P must learn the individual characteristics of it´s own navigation light”

1) Turn off all lamps, using the individual control buttons. 2) Turn on lamp connected to POS1 3) Activate the hidden teach-in switch in POS1. (Insert 2mm plastic pin and pry carefully to activate the switch. The alarm LED will turn off and the OK LED will light up.) Hint: it may be easier to unscrew the two black finger screws to locate the teach-in button. 4) Turn off lamp connected to POS1 5) Repeat step 2-4 for all active positions

Page 17 of 22 Connections and operations of NLC. Shown here with one LMR/P enclosure removed – and one fittet

Yellow: Manual on/off toggle

Red: Teach-in

Green: Nav-light connection

White: Connection to panel Sub-D, optional: terminals

Blue: Primary power Brown: Secondary power

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6.0 Programming the panel

The panel works with two important definitions. a) Pairing: Two (and only two) keys in the panel can be paired. This is used to pair the

control keys for a Primary and a Secondary navigation light placed at same physical position. If two positions are paired, then the secondary (back-up) navigation light will automatically take over in case an error is detected on the primary unit. (alarm will still be given).

b) Grouping: A number of nav-lights can be assigned to a group. This function is used to combine f.inst. All lights that should be activated when “under way”, “at anchor”, “not under command”, etc. The panel is prepared for four individual groups. Any one lamp can be assigned to several different groups.

Pairing procedure: Press the two keys to be paired simultanesly for 10 seconds. They will both light up, and switch off when the pairing is succesfull. De-pairing: press two already paired keys simultanesly for 10 seconds. Grouping procedure: Turn on the navigation lights that should be grouped. (example, “under way”: Primary Masthead Aft, Primary Masthead fore, Starboard and Port primary sidelights, Primary sternlight.) Press the desired “Group key” and the key marked “Alarm reset / All off” simultanesly for 10 seconds. De-grouping: Activate group key. Press “group key”and the key marked “alarm reset / all off” simultanesly for 10 seconds.

Refer to illustration on next page

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7.0 Manual control: Refer to P.17 for guidelines Every navigation light connected to the system has it´s own “Lopolight Monitoring Relay” [LMR/P] build-into the NLC. The individual LMR/P holds a manual control button and status LED´s. All navigation lights can be controlled via the manual buttons, with or without the panel connected. If the panel is connected/active, then alarms will be experienced if operated manually on the NLC. (Disconnect panel to avoid this.) 8.0 Test procedure Ensure that all navigation lights are connected and teach-in has been performed. Switch on all lights using the individual keys. (ref: P.19) *Check that the lights are working properly Press All Off for 5 seconds. Turn on one navigation light in a pair Disconnect the selected navigation light by pulling out the plug at the NLC position *Check that alarm I given within 15 seconds and that the secondary light in the pair is lit Continue with all other other pairs Activate group button(s). *Check that the correct light-pattern(s) are shown by the navigation lights. Disengage the primary circuit-breaker. (only if system has redundant power supply) *Check that alarm is given, and all navigation lights still active. Engage primary circuit-breaker again. Disengage the secondary circuit-breaker. (only if system has redundant power supply) *Check that alarm is given, and all navigation lights still active. Engage secondary circuit-breaker again. Press All Off for 5 seconds. *Check that all positions (navigation lights) can be controlled manually.

Contact relevant technical support if any of the above mentioned check-points are indicating problems

8.1 System reset: This should only be performed when considered necessary. All group and pairing settings will be lost.

A system reset shall be performed when setting the system up for the first time. Normally this has been done from the factory. Main function: the panel scans for present LMR/P´s. Press and hold key number 1,2,3,4 simultanesly for 20 seconds (key numbers: ref. P.19)

Page 21 of 22 8.2 Setting address of LMR/P: (normally factory-set. only necessary if a LMR/P is swapped. The easy way is simply to replicate the setting from the original to the new LMR/P). Each individual LMR/P must be assigned to an individual address used by the RS-485 network. Address 1 to 28 (incl) can be used. Address “0”is NOT used. The addresses are set using binary logic and are set on the small dip-switch on the LMR/P card. Bit 1=1 Bit 2=2 Bit 3=4 Bit 4=8 Bit 5=16 Bit 6=32 (not used in any combination). Bit 7= internal setting use only. MUST always be set to “on” Bit 8= internal protocol setting. MUST always be set to “on” Example: Address 13 desired: set bit 1,3,4 to “ON” (1+4+8=13) 9.0 Spareparts: Lopolight P/N: Name: 400-018/P LMR/P 600-917 115/240 VAC power-supply 600-918 24/24 VDC power-supply 600-944 Sub-D interconnection cable, 5 meters 600-945 Sub-D interconnection cable, 10 meters 600-946 Sub-D interconnection cable, 20 meters 600-927 Circuit-breaker (20A) for 24VDC 600-928 Circuit-breaker (6A) for 115/240VDC 600-930 3-pin plug for navigation light connection in NLC 900-733 Ground strap for NLC enclosure (15 cm mesh)

Page 22 of 22 9.0 Use of panel (this page can be copied and made available for the relevant officers / nightly users).

Navigation light control panel User manual

Panel dimming: The indicators on the panel can be dimmed from 0 to 100% using the dimmer in the lower left corner of the panel. Make sure the dimming is NOT set to absolute 0 when operating the panel. (simply difficult to see the change in status).

Individual keys: Press to turn a navigation light ON. Press again to switch it OFF. The navigation light connected to this key is active when the indicator shows green light. Group keys: Press the key that corresponds to the ships situation. If any navigation light in the given group is detected faulty, then the group indicator will not be lit, and alarm given. IF a faulty navigation light is paired with a secondary navigation light, and this is activated automatically by the panel, THEN the group indicator will remain lit. Alarm will still be given. All Off / Alarm reset key: (primary function) Press and hold this key for 6 seconds to turn all active navigation lights off. All Off / Alarm reset key: (secondary function) Activate this key briefly to silence the acoustic alarm signal. (Alarm condition will remain, alarm indicator will change from flashing to steady light). Alarms: The system responds with alarm in the following cases: a) Faulty navigation light: The corresponding key will flash. The Alarm reset key will flash. b) Faulty primary or secondary power-supply. The Alarm reset key will flash, individual

indicators will remain active.

c) No data-communication between panel and NLC (control box). All indicators will flash. Action in case of alarm: (Note: These are guidelines only, and DO NOT have priority over ships procedures) Alarm case a): Activate secondary navigation light if present. (may already have happened automatically). Notify technical officer. Alarm case b): Notify technical officer. Alarm case c): Navigation lights can be controlled manually directly in the controller cabinet. Notify technical officer – panel may be disconnected when controlled manually.