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Navigation Light Controller
and
Panel
Rev. 2
March 2015
Manual
Panel
Navigation light controller
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Contents:
Section:
1
1.1
1.2
1.3
2.0
3.0
3.1
3.2
3.3
3.4
3.5
4.0
4.1
4.2
4.3
4.4
5.0
5.1
6.0
6.1
7.0
8.0
8.1
8.2
9
9.1
Page:
3
3
3
4
5
6
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
20
20
21
21
22
Text:
Preface
Modular principle
Basic working principle
System overview
Standards
Controller, basic data
Controller power-supply and connections
Controller installation guidelines
Controller, direct operation
Controller schematics
Controller, service and maintenance
Panel, basic data
Panel installation guidelines
Panel [A] – detailed drawing 28 position
Panel [B] – detailed drawing 21 position
Panel [C] – detailed drawing 14 position
Initial installation and set-up
Connections and operations NLC
Programming of panel functions
Panel keyboard definitions
Manual control of NLC
Test procedure
System reset
Setting address of LMR/P
Sparepart list
User manual
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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 powersupply, 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 RS485 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.
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1.3 System overview
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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
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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
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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).
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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 ok state
Control button
Output in alarm state
Output in off-state
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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.
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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.
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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”
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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.
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Type B – max 21 positions.
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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.
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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
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Connections and operations of NLC. Shown here with one LMR/P enclosure removed – and one fittet
White: Connection to panel
Sub-D, optional: terminals
Yellow: Manual on/off toggle
Red: Teach-in
Green: Nav-light connection
Brown: Secondary power
Blue: Primary 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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Individu al control keys. The logic
cal number
co
orresponds to
o position in NLC
1
8
15
22
2
9
16
23
3
10
17
24
4
11
18
5
12
19
26
6
13
20
27
7
14
21
28
Grroup keys
Alarm
A
reset
All off
Pane
el indicator
dimmer
d
25
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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)
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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:
400-018/P
600-917
600-918
600-944
600-945
600-946
600-927
600-928
600-930
900-733
Name:
LMR/P
115/240 VAC power-supply
24/24 VDC power-supply
Sub-D interconnection cable, 5 meters
Sub-D interconnection cable, 10 meters
Sub-D interconnection cable, 20 meters
Circuit-breaker (20A) for 24VDC
Circuit-breaker (6A) for 115/240VDC
3-pin plug for navigation light connection in NLC
Ground strap for NLC enclosure (15 cm mesh)
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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.