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SolaMax-65 Series

Solar Powered Marine Navigation Lights 011 1280-00

Alfredo Dominguez Larry Mitschke Hernando Ramirez

Engineering Mgr. Project Engr. Checker

E 0042 Add Safety Note 17Nov17 JAD

D 0302 Update to New Format 01SEP16 RBT

C 0178 Added Appendix C and Spare Parts 17FEB16 RBT

B 0116 Fixed IR Commands & Appendix 02OCT15 LWM

A 0045 Released 01JUL15 LWM

REV ECO Description Date By

MAINTENANCE AND OPERATION MANUAL SolaMax-65 Series Lights 011 1280-00

TIDELAND SIGNAL HEADQUARTERS (Houston, TX) TEL + 1 713-681-6101 FAX + 1 713-681-6233 EMAIL [email protected] TIDELAND SIGNAL (Nova Scotia) DSS Marine Incorporated TEL + 1 844 843 3526 FAX + 1 613-680-7418 EMAIL [email protected] TIDELAND SIGNAL (Burgess Hill, UK) TEL + 44 (0) 1444-872240 FAX + 44 (0) 1444-872241 EMAIL [email protected] TIDELAND SIGNAL (Dubai, UAE) TEL + 971 (0) 4-885-5842 FAX + 971 (0) 4-885-7352 EMAIL [email protected] TIDELAND SIGNAL (Singapore) TEL + 65 6333-0078 FAX + 65 6333-0079 EMAIL [email protected] TIDELAND SIGNAL (China) TEL + 86 (0) 21- 1380 101 4639 FAX + 86 (0) 21-3868-8087 EMAIL [email protected] WEBSITE: www.tidelandsignal.com

mailto:[email protected]






http://www.tidelandsignal.com/


TABLE OF CONTENTS ......................................................................................................................................................... 1

1. FEATURES AND OPTIONS ......................................................................................................... 1

1.1 FEATURES ......................................................................................................................... 1

2. TECHNICAL DESCRIPTION ........................................................................................................ 2

2.1 ELECTRO-OPTICAL ............................................................................................................ 2

2.2 MECHANICAL .................................................................................................................... 2

2.2.1 Light Source ............................................................................................................... 2

2.2.2 Main Solar Array Body .............................................................................................. 2

2.2.3 Base Housing ............................................................................................................. 2

2.3 ELECTRICAL ....................................................................................................................... 3

2.3.1 Main Microcontroller ................................................................................................ 3

2.3.2 Batter Power ............................................................................................................. 3

2.3.3 Solar Array ................................................................................................................. 3

2.3.4 Current Regulator ..................................................................................................... 3

2.3.5 Battery Charge Regulator ......................................................................................... 4

2.3.6 Flash Codes ............................................................................................................... 4

2.3.7 Depot Level Programming SolaMax-65 .................................................................... 4

2.3.8 Field Testing of SolaMax-65 Using QuickCheck ........................................................ 4

2.3.9 Day/Night Control ..................................................................................................... 4

2.3.10 Adjusting Power ........................................................................................................ 4

2.3.11 GPS Synchronization ................................................................................................. 4

2.3.12 LED Voltage Monitor ................................................................................................. 4

2.3.13 Fail Terminal .............................................................................................................. 5

2.3.14 LED Drive Circuit ........................................................................................................ 5

2.4 SPECIFICATIONS................................................................................................................ 6

2.5 MODES OF OPERATION .................................................................................................... 6

2.5.1 Configuration/Reprogramming ................................................................................ 6

2.5.2 Main/Standby Installations ....................................................................................... 8

2.5.3 Alternate Code .......................................................................................................... 8

2.5.4 Sequence Flash ......................................................................................................... 8

2.5.5 Standby to a Rotating Beacon ................................................................................... 8

2.6 MONITORING ................................................................................................................... 9

2.6.1 SignalView ................................................................................................................. 9

2.6.2 E-NavLink................................................................................................................... 9

2.6.3 Connecting the Fail Terminal .................................................................................... 9

3. INSTALLATION AND SETUP ...................................................................................................... 9

3.1 UNPACKING INSTRUCTIONS ............................................................................................. 9

3.2 SITE SELECTION ................................................................................................................ 9

3.3 INITIAL INSPECTION .......................................................................................................... 9

3.4 TESTING THE LANTERN ..................................................................................................... 9


3.5 MOUNTING THE LANTERN ............................................................................................. 10

3.5.1 Mounting Procedure – Flat Surface ........................................................................ 10

3.5.2 Mounting Procedure – Irregular Surface ................................................................ 11

4. TROUBLESHOOTING .............................................................................................................. 12

5. MAINTENANCE ...................................................................................................................... 12

6. SERVICE AND COMMON PROCEDURES ................................................................................. 12

6.1 BATTERY CHARGING ....................................................................................................... 12

6.2 CLEANING SCHEDULE ..................................................................................................... 12

6.3 BATTERIES....................................................................................................................... 13

6.4 HANDLING AND STORAGE INSTRUCTIONS .................................................................... 13

7. SETUP ..................................................................................................................................... 14

7.1 SYNCHRONIZED MULTI-LIGHT SYSTEMS ........................................................................ 14

7.1.1 Connecting Multiple Units for Synchronized Operation (without GPS Sync) ......... 14

7.1.2 Setting Flash Characteristic ..................................................................................... 14

7.1.3 Sequenced Flash ..................................................................................................... 14

7.2 SOFTWARE OPTION SETTING ......................................................................................... 15

7.2.1 Invert Fail Output .................................................................................................... 15

7.2.2 Main/Standby ......................................................................................................... 15

7.2.3 Alternate Code During Low Voltage ....................................................................... 16

7.3 SWITCH OPTIONS ........................................................................................................... 16

7.4 LOW VOLTAGE CUTOFF .................................................................................................. 16

7.4.1 Configuration of Low-Voltage Cutoff and Alternate Code ..................................... 16

7.4.2 For Low Voltage Cutoff Only ................................................................................... 16

7.4.3 Low Voltage Cutoff and Alternate Code During Low Voltage ................................ 16

7.4.4 Defaults ................................................................................................................... 17

7.5 SUNSWITCH CONFIGURATION ....................................................................................... 17

8. TROUBLESHOOTING .............................................................................................................. 17

8.1 CONFIGURATION VERIFICATION .................................................................................... 17

8.2 TESTING THE SOLAMAX-65 ARRAY ................................................................................ 17

8.3 TROUBLESHOOTING WITH SIGNALVIEW ....................................................................... 17

8.3.1 LEDs Enabled ........................................................................................................... 17

8.3.2 Error Status Messages ............................................................................................ 18

9. APPENDIX A: QUICKCHECK OPERTATION .............................................................................. 19

10. APPENDIX B: IR PROGRAMMER OPERATION ..................................................................... 21

11. APPENDIX C: PROCEDURE TO OPEN AND REPLACE THE BATTERY FOR SOLAMAX-65, 9011358-00 ................................................................................................................................... 29

11.1 SPARE PARTS .................................................................................................................. 36


LIST OF FIGURES

Figure 1: SolaMax-65 (left) and SolaMax65-T (right) ...................................................................... 1

Figure 2: Block Diagram of the Control Circuit ............................................................................... 3

Figure 3: SolaMax-65 Layout and Wiring Diagram ......................................................................... 5

Figure 4: Opening the SolaMax-65 Lantern .................................................................................... 7

Figure 5: Alternate Code and Low-Voltage Cutoff Functions ......................................................... 8

Figure 6: Mounting Bolt Pattern ................................................................................................... 10

Figure 7: Mounting Hardware -- Flat Surface ............................................................................... 11

Figure 8: Level Hardware for the SolaMax-65 - Irregular Surface ................................................ 12

Figure 9: Field Wiring of Multiple Lights in Synchronization (Cable Access is Optional).............. 14

Table 1: Default Options ............................................................................................................... 15

Table 2: LED Arrary Power ............................................................................................................ 16

Figure 10: Logic Diagram of QuickCheck Programming ................................................................ 19

LIST OF TABLES

Table 1: Default Options ............................................................................................................... 15

Table 2: LED Arrary Power ............................................................................................................ 16


Tideland Signal Corporation Page 1 of 35 011 1280-00 Rev. D 17-Nov-17

1. FEATURES AND OPTIONS

The SolaMax-65 is a multi-purpose, self-contained solar-powered LED light. It features unique and proprietary optics which provide a 360° beam at 5°, 10°, 20° or 30° vertical divergence. It is available in two solar/battery configurations with the designations SolaMax-65 and SolaMax-65T. In the following, these will be referred to as SolaMax-65 unless a particular model is identified.

1.1 FEATURES

SolaMax-65 has the following features and options:

Figure 1: SolaMax-65 (left) and SolaMax65-T (right)

Solar array, battery, control circuitry and light in a rugged, low maintenance unitized design.

High efficiency DC to DC converter that maintains constant current to the LED array. Conservative operating current, along with careful attention to thermal design, assures a long operational life of the LED array.

256 preprogrammed flash code settings.

Available in IALA recommended signal colors of white, red, green, yellow and blue.



Photocell sun switch that commands the control circuit to disable the light during daylight hours to conserve battery power. Threshold switching levels, at both dawn and dusk, are independently adjustable.

Multiple SolaMax-65 lights can be synchronized to flash in unison when the same flash code is selected for each,

o Interconnection of synchronization terminals, or

o Wireless synchronization by an optional GPS module

Tideland’s optional SignalView application for monitoring and control.

Sequenced flashing when GPS synchronization is used.

Reverse polarity protection and special circuitry to protect against induced lightning transients.

An output monitor signal that is energized upon failure.

Battery voltage sensor that shuts down the flasher if voltage is too low, which may result in permanent damage. Power must be recycled to re-enable normal operation.

Infrared programming and control.

2. TECHNICAL DESCRIPTION

2.1 ELECTRO-OPTICAL

SolaMax-65 uses a specially designed lens to focus the light on the horizon. The light source consists of a string of 10 high intensity LEDs. Relative power to the LED array can be adjusted between 25% and 100% of full intensity in 4 settings.

2.2 MECHANICAL

SolaMax-65 consists of three main sub-assemblies:

2.2.1 Light Source

The LED sub-assembly consists of a cylindrical heat sink with 10 LEDs mounted on its perimeter, and a toroidal lens.

2.2.2 Main Solar Array Body

The main solar array body sub-assembly consists of four solar panels mounted at 90 degrees vertical. A one-way vent vents any gases to the atmosphere and prevents moisture build-up inside the housing. The QuickCheck port permits field-testing and other functions. See Appendix A for QuickCheck operation.

2.2.3 Base Housing

The base housing contains a battery compartment, which houses the 12, 18, 34, or 50 Ah lead acid batteries. The bottom section of the housing forming the mounting base features a universal hole pattern that accommodates both standard three and four hole lantern mounting patterns of 200 mm diameter.



2.3 ELECTRICAL

Figure 2 shows a block diagram of the control circuit.

Figure 2: Block Diagram of the Control Circuit

2.3.1 Main Microcontroller

The microcontroller regulates current to the LED, reads a temperature sensor, commands LED power control to adjust power to the LEDs, controls battery charge and reads switches S1 through S3. It also reads the QuickCheck magnetic switch.

2.3.2 Batter Power

The battery system consists of a high energy density, sealed, lead-acid battery. Nominal voltage is 12V, with capacity options of 12 Ah, 18 Ah, 34 Ah and 50 Ah.

Battery power is supplied through an input filter, which protects the control circuit from induced transient surges.

The SolaMax-65, programmed for low voltage cutoff, ceases flashing when the battery voltage falls below a preset threshold. When the voltage rises above the threshold, the SolaMax-65 resumes normal operation.

2.3.3 Solar Array

The solar generator consists of 4 panels of 4.2 watts each in the SolaMax-65. The SolaMax-65T has 4 solar panels of 8.5 watts each.

2.3.4 Current Regulator

The current regulator is a high efficiency, switch-mode power supply which supplies DC current to the LED, for constant light intensity.



2.3.5 Battery Charge Regulator

The microcontroller compensates battery charging voltage for variations in ambient temperature.

2.3.6 Flash Codes

Flash codes are factory programmed into the Microcontroller memory and are user- selectable by hexadecimal (sixteen position) switches, S1 and S2, or by the infrared remote programmer.

2.3.7 Depot Level Programming SolaMax-65

SolaMax-65 is programmed by a combination of switch settings and use of SignalView, a PC application, or Infrared Programmer. Using SignalView requires a special connecting cable – contact Tideland for information. Infrared programming requires a TV remote. Refer to Appendix C for more information on infrared programming

2.3.8 Field Testing of SolaMax-65 Using QuickCheck

SolaMax-65 uses an externally applied magnetic probe to excite a reed switch for performing QuickCheck functions:

Battery charge state test.

Flash test - provides 30 seconds of the programmed flash code, overriding the sun switch in daylight

Charge only - disables flashing for faster solar charging

Shutdown - Electronically disconnects the battery for maximum shelf life

See Appendix A for details

2.3.9 Day/Night Control

The control circuit monitors solar panel current to determine ambient light level and shuts off or turns on the light. Day (Off) and night (On) threshold levels are set using SignalView or the infrared Remote Programmer, from 100 lux to 1000 lux. The “On” level setting must be lower in value than the “Off” level setting.

2.3.10 Adjusting Power

A 2-position power switch, S3, provides a choice of 4 different power levels to the LED array from 25% to 100%. Lantern must be powered up (not in shutdown mode) while changing settings. With the IR Programmer, power can be adjusted in 1% increments from 10% to 100%.

2.3.11 GPS Synchronization

An Optional GPS Sync Module P.N. 530.1661-00 synchronizes SolaMax-65 with other GPS-enabled Tideland flashers. The GPS module is powered only long enough to obtain a satellite reading; once every 30 minutes and only at night. A small LED on the GPS module illuminates to indicate that the module is currently attempting a satellite reading.

2.3.12 LED Voltage Monitor

The LED voltage monitor measures LED array forward voltage, which is displayed in SignalView. LED forward voltage varies from color to color and LED array to LED array.



2.3.13 Fail Terminal

The Fail Terminal (See Figure 3) is used to signal a failure to an external device. It is electrically switched to ground under normal operating conditions. This is the default mode in a Fail-Safe system, in which either a lack of power or a failure asserts a fail condition. In event of failure, the terminal is open circuit. The Fail Terminal can sink up to twelve milliamperes. The default operation can be reversed (open circuit during normal operation, switched to ground during failure) using SignalView.

Figure 3: SolaMax-65 Layout and Wiring Diagram

2.3.14 LED Drive Circuit

A high efficiency DC to DC converter provides virtually constant luminous output under a wide range of input power conditions. The DC to DC converter compensates for temperature changes of the LED array, conserving power at low ambient temperatures where LED(s) are most efficient, but batteries are least efficient. LED power is reduced below 100%, using switch S3 (See Table 2.)

Caution: Power consumption is influenced by duty factor (the ratio of total on time to flash period) and the relative intensity setting of the controller. Any change of flash character resulting in an increase in duty factor or an increase in relative power setting may result in catastrophic failure of the light. These changes should be made only by persons with a full understanding of the consequences.



2.4 SPECIFICATIONS

Power

Short version 4.5 W

Tall version 5.5 W

Range

Short version Up to 5 NM

Tall version Up to 7 NM

Colors Available Red, green, yellow, and white

Visibility 360° horizon (omnidirectional)

Lens Diameter 65 mm

Vertical Divergence at 50% 5, 10, 20, and 30 degrees

Operating Temperature -40° to +60°C

LED Expected Service Life 50,000 hours / Duty Factor

Solar Panel Tilt Angle 4 each @ 90°

Battery Type Lead Acid 12V 12Ah

Optional 18, 34, & 50Ah

Height

Short version 295 mm (11.6 in)

Tall version Tall version 425 mm (16.7 in)

Diameter 275 mm (10.8 in)

Weight (varies according to battery option)

w/12 Ah battery 7.8 kg (17.1 lbs)




Base and Main Housing Molded polycarbonate plastic

Lens Molded optical grade acrylic

Quiescent Current <5.0ma

GPS Power (Average) 3.6 mW

Infrared communication range indoors Up to 3m.

2.5 MODES OF OPERATION

2.5.1 Configuration/Reprogramming

SolaMax-65 is factory configured to meet usual site requirements. If operating parameters need to be changed, the following three options are available:



Switches

The control circuit provides switches for Flash Code and Power reduction. The lantern must be opened per Figure 4 below.

SignalView

Requires special communication cable - contact Tideland for information-. To connect the hardware for using Signalview, the light must be opened for access to switches and programming terminals (See Figure 4)

To open the lantern, remove four screws as shown in Figure 4 below and separate the top cover from the housing. Connect the special comm cable to the SolaMax-65 controller pcb (see Figure 3.) SignalView can now be used to set sunswitch levels, power level, and low-voltage cutoff/lockout level. Refer to the SignalView manual for further details.

IR Remote Programming

The IR remote programmer is used for changing principal settings at the repair depot without having to open the housing. Requires optional IR Remote Programmer PN 570.1011-00. Refer to Appendix C for IR Programmer details.

Figure 4: Opening the SolaMax-65 Lantern



2.5.2 Main/Standby Installations

When redundancy is required, units are paired as Main and Standby units. SolaMax-65 supports up to eight pairs (sixteen units) in this configuration. During normal operation, Main units (with odd addresses) send a signal via sync line that tells Standby units (with even addresses) that Main units are operating normally. If a “Main Fail” signal is received, or if communication is lost, the Standby unit activates. The Standby unit remains activated until it receives a “Main OK” signal.

Note: Standby units respond faster to a “Main Fail” signal than to a communication failure.

2.5.3 Alternate Code

When the “Alternate Code During Low-Voltage Enable” feature is selected SolaMax-65, upon sensing a voltage below the Alternate Code Voltage, initiates an alternate flash code and reduces power by 50%. If the voltage drops below the Low Voltage Cutoff level, SolaMax-65 disables the flasher and asserts a fail condition. If the voltage rises to a preset level, SolaMax-65 is re-enabled and re-initiates the primary flash code. (See Figure 5.)

Note 1: These functions rely on an unloaded voltage measurement (LED array off.) They are not activated while a fixed-flash array is “on”. Once array power is off, however, functions are immediately enabled.

Note 2: SolaMax-65 can be commanded to override the Active Code to flash the Alternate Code by selecting the “Enable Alternate Code” command in SignalView.

2.5.4 Sequence Flash

A group of SolaMax-65 can be configured to flash in sequence similar to aircraft landing lights.

Note: The GPS option must be installed in each flasher.

2.5.5 Standby to a Rotating Beacon

SolaMax-65 can be programmed as backup to a rotating beacon in a main/standby configuration. In this mode, should the rotating beacon fail, SolaMax-65 assumes master status and either mimics the flash character of the rotating beacon or flashes any standard character, depending on how it is programmed.

Figure 5: Alternate Code and Low-Voltage Cutoff Functions



2.6 MONITORING

SolaMax-65 can be monitored with the following communication utilities:

2.6.1 SignalView

This software application is used for configuration changes or for simple on-site monitoring. It requires a wire connection to the monitored unit – refer to Tideland for details-. A PC computer and SignalView kit, which includes the software, adapter, and instruction manual, are required.

2.6.2 E-NavLink

This system is capable of remote monitoring multiple SolaMax-65 units in addition to other navaids. e-NavLink monitors by radio, satellite, or telephone lines. Configuration changes must be made using SignalView or the infrared controller.

2.6.3 Connecting the Fail Terminal

An external monitor can be connected to the Fail Terminal. (See Figure 3 and Section 2.3.13.)

3. INSTALLATION AND SETUP

Inspecting and unpacking

3.1 UNPACKING INSTRUCTIONS

Unpack and inspect all hardware. If there is damage, contact your Tideland representative. Retain the original packing material for possible future use.

3.2 SITE SELECTION

In determining site selection for installation of a self-contained marine lantern, please note that direct sunlight exposure is critical. Partial shading of the product will reduce charging efficiency and may result in insufficient battery charging, leading to lantern failure.

3.3 INITIAL INSPECTION

SolaMax-65 shipping container contents include:

SolaMax-65 Lantern

SolaMax-65 Quick Sheet, P.N. 012.0080-00

SolaMax-65 QuickCheck Magnet P.N. 184.1148-00

Mounting Hardware (purchased separately)

3.4 TESTING THE LANTERN

SolaMax-65 is programmed in the Shutdown Mode for shipping. To activate the light, use the SolaMax-65 QuickCheck Magnet and follow the instructions on the back of the SolaMax-65 Quick Sheet (P.N.012.0080-00) or Appendix A.

*SAFETY NOTE: FAILURE TO ACTIVATE THE LANTERN INTO “NORMAL OPERATION

MODE” WHILE PLACING IT IN DIRECT/INDIRECT LIGHT CAN CAUSE THE BATTERY TO

OVERCHARGE. THIS, IN TURN, CAN MAKE FOR A DANGEROUS SITUATION WHERE THE

LANTERN, IN EXTREME CASES, CAN EXPLODE CAUSING BODILY INJURY.



FLATWASHERS (2)

CAP SCREW

BEACON BASE

MOUNTING SURFACE

LOCK NUT

SK

17602X

1

3.5 MOUNTING THE LANTERN

Recommended Tool--3/4” Wrench

3.5.1 Mounting Procedure – Flat Surface

Mounting the beacon: Flat Surface

1. Locate the mounting hardware supplied with the unit. The mounting hardware is a standard 3-bolt mounting assembly (P.N. 610.1039-00). Each assembly consists of 3 each SST cap screws, 3 each SST washers, and 3 each SST self-locking hex nuts. A 4-bolt mounting assembly is also available (P.N. 610.1039-04).

2. Drill three (3) 16mm (5/8") diameter holes equally spaced (120° apart) on a 200mm (7.87") diameter circle in the mounting surface to which the SolaMax-65 lantern are affixed. (See Figure 6.)

3. Install cap screws, washers and self-locking hex nuts as shown in Figure 7. Gently tighten the cap screws.

Figure 6: Mounting Bolt Pattern



Figure 7: Mounting Hardware -- Flat Surface

3.5.2 Mounting Procedure – Irregular Surface

1. Locate the leveling hardware (purchased separately.) The leveling hardware is a 3-bolt leveling assembly (P.N. 610.1038-00). Each assembly consists of 3 each SST cap screws, 3 each SST washer, and 3 each SST self-locking hex nuts. A 4-bolt leveling assembly is also available (P.N. 610.1038-04.) A torpedo level is also required.

2. Drill three (3) 16mm (5/8”) diameter holes equally spaced (120 apart) on a 200mm (7.87”) diameter circle in the mounting surface to which the beacon is to be affixed. See Figure 6.

3. Assemble the leveling hardware as shown in Figure 8.

4. Tighten the top hex nut (A) of each bolt against the mounting flange of the beacon as shown in Figure 8.

5. Visually level the beacon by adjusting the top (A) and middle (B) nuts as required.

6. Place the torpedo level on the X-axis of the beacon mounting flange.

7. Adjust the hardware as required until the bubble is centered within the marked area.

8. Reposition the torpedo level to the Y-axis and adjust the hardware as required to center the bubble.

9. Recheck the X-axis and adjust as required.

10. Repeat steps 6 through 8 as required.



Figure 8: Level Hardware for the SolaMax-65 - Irregular Surface 4. TROUBLESHOOTING

SolaMax-65 comes from the factory ready for operation. No external wiring is necessary. It is shipped in Shutdown Mode so that it does not flash while in transit. To enable the SolaMax-65 from Shutdown Mode, see Appendix A.

If SolaMax-65 does not flash in darkness, make sure it is not in either the Charge Only or Shutdown Mode (See Appendix A.) If it still does not flash when in darkness, check the batteries.





5. MAINTENANCE

Inspect the lantern annually for damage to finish or gasket seals. Any housing damage must be promptly repaired or the light replaced to minimize internal corrosion. The routine maintenance interval for the lantern is once per year.

6. SERVICE AND COMMON PROCEDURES

Tideland recommends that maintenance requiring opening of the lantern be conducted at a repair depot where material handling equipment and a clean work environment are available.

6.1 BATTERY CHARGING

When charging batteries in sunlight before deploying SolaMax-65, the lantern should be placed in Charge Only Mode (See Quick Sheet or Appendix A) so that it does not flash at night and needlessly consume power. In this mode, the lantern consumes only enough power to maintain logic functions. Once the batteries are fully charged the solar controller automatically terminates the charging process.





The batteries may also be charged from a 1V battery charger or power supply, which requires that the lantern be opened. Once the lantern is opened and battery terminals exposed, a constant voltage source is attached to the + and – terminals of the battery pack. For float charging, set the charger at 13.8V; for fast charging set the charger at 14.9V.

6.2 CLEANING SCHEDULE

The lens, lantern housing and sunswitch lens should be cleaned as required by local conditions



(minimum once a year.)

To clean the lantern and/or lens:

1. Using a soft cloth or soft bristle brush, wash the lantern with water and a mild nonabrasive soap or detergent.

2. After wetting, remove any caked dirt or mud with the hand; not with any kind of instrument or scraper.

3. Rinse with clear water. 4. Remove grease or oil using hexane or kerosene. Wash with a mild non-abrasive soap or

detergent and dry. 5. Minor foreign matter on the lens can be removed using the Tideland lens cleaning cloth

(P.N. 901.1159-00) by gentle rubbing.

6. Caution: Do not use the following substances on the lens: acetone, alcohol, benzene, carbon tetrachloride, fire extinguisher fluid, dry cleaning fluid, lacquer thinner, pumice soaps, or kitchen scouring compounds.

6.3 BATTERIES

SolaMax-65 batteries should be replaced after 7 years of use.

6.4 HANDLING AND STORAGE INSTRUCTIONS

SolaMax-65 lead-acid batteries have a very low self-discharge rate. They should be fully charged before placing in storage, and recharged in 24 months or when the battery terminal voltage falls to 12.0 volts (35% charge state,) whichever occurs earlier. Do not allow the battery pack voltage to fall below 12 volts, as permanent damage will occur. When placing a SolaMax-65 into storage, use QuickCheck to enable the Shutdown Mode (See Appendix A or Quick Sheet.)

Reference battery safety data sheet for handling, storage and disposal of batteries.







7. SETUP

7.1 SYNCHRONIZED MULTI-LIGHT SYSTEMS

7.1.1 Connecting Multiple Units for Synchronized Operation (without GPS Sync)

For multiple SolaMax-65 units, SYNC and Sync Ret terminals are connected (Figure 9.) Contact Tideland for special hardware connections and cable entries.

Figure 9: Field Wiring of Multiple Lights in Synchronization (Cable Access is Optional)

7.1.2 Setting Flash Characteristic

Caution: Power consumption is influenced by duty factor (the ratio of total on time to flash period) and the relative intensity setting of the controller. Any change of flash character resulting in an increase in duty factor or an increase in relative power setting may result in catastrophic failure of the light. These changes should be made only by persons with a full understanding of the consequences.

Flashers in a synchronized multiple-unit system must have identical flash codes.

1. Refer to code selection guide booklet (P.N. 011.1092-00.)

2. Ensure that the flasher is powered up. Locate code selection switches, S1 and S2, on the control circuit assembly (See Figure 3.) Rotate to set desired flash code.

Note: Flash Code can be set with the IR Programmer without opening the lantern. Refer to Appendix C.

7.1.3 Sequenced Flash

A group of SolaMax-65 lanterns can be configured to flash in sequence similar to aircraft landing lights. This requires that each lantern has a GPS module installed. To enable sequenced flash, use SignalView and select Sequencing Delay Override Enable in the Switch Overrides section. Then



enter the Sequenced Delay Value, in fiftieths of a second. The first lantern in sequence does not need to be set for sequenced flash; alternately, it can be set for “0” seconds delay. Each subsequent flasher must be set for increasing delay depending on how far down in sequenced it will flash.

The sequenced flash feature applies only to solitary lanterns with GPS (as on a buoy), and must not be used in a system of interconnected lanterns.

7.2 SOFTWARE OPTION SETTING

Software options as follows are factory preset but can be changed using SignalView. (Refer to SignalView Manual, P. N. 011.1231-00.) Default settings are shown in Table 1.

Option

Alternate Flash During Low Voltage Disabled

Invert Fail Output Enabled

Main/Standby Mode Disabled

Table 1: Default Options

7.2.1 Invert Fail Output

This option changes the fail signal from open (high voltage) to closed (low voltage) during normal operation.

7.2.2 Main/Standby

This option is selected when two lights are paired as main and standby units. SolaMax-65 can support up to 8 pairs (16 units). In this configuration, the standby unit remains inhibited as long as the main unit is functional. Failure of a main unit automatically enables its corresponding standby unit. Set Main/Standby configurations as follows:

Use SIGNALVIEW to enable the Main/Standby feature for all units.

Set flash codes the same for all units.

Using SignalView in the Switch Override section, set Main units with an odd address. For example 1, 3, 5, etc.

Using SignalView in the Switch Override section, set Standby units with an even address number. For example 0, 2, 4, etc.

Units 0 and 1 are paired, units 2 and 3 are paired, units 4 and 5 are paired, etc.

Note that optional Alternate Code During Low Voltage, is not allowed when SolaMax-65 is set for Main/Standby mode.



7.2.3 Alternate Code During Low Voltage

When selected, this option enables an alternate flash code at half power when battery voltage drops below a user-set level. Note that Main/Standby mode is not allowed when Alternate Code During Low Voltage is enabled.

7.3 SWITCH OPTIONS

Refer to Figure 4 for switch locations.

Switches S1 and S2 control the flash code. Refer to code selection guide booklet (P.N. 011.1092-00.)

The LED Power switch, S3, sets power according to the table below with 100% representing 4.5 Watts input power.

PWR Switches

1 2

100% 0 0

75% 0 1

50% 1 0

25% 1 1

Table 2: LED Arrary Power

7.4 LOW VOLTAGE CUTOFF

7.4.1 Configuration of Low-Voltage Cutoff and Alternate Code

By enabling Low-Voltage Cutoff only, the light ceases flashing at a selectable low voltage and returns to normal operation when the voltage rises above a selectable slightly higher voltage.

By enabling both Low-Voltage Cutoff and Alternate Code During Low Voltage, the light begins flashing the alternate code at half power when voltage is below a selectable low voltage and ceases flashing at a lower selectable voltage. The light resumes normal operation when the voltage rises above the alternate code voltage.

7.4.2 For Low Voltage Cutoff Only

Using SignalView, set the low-voltage cutoff level to the lowest voltage at which the light is to flash.

Using SignalView (under Secondary Data,) set the Alternate Code During Low Voltage Threshold to the voltage level for which the system is to return to normal operation. SolaMax-65 adds 0.1 volt for hysteresis. The Alternate Code During Low Voltage option (under Options) must not be enabled, but its voltage level is used as a “Return to Normal” voltage.

7.4.3 Low Voltage Cutoff and Alternate Code During Low Voltage

Using SignalView (under Options), enable Alternate Code During Low Voltage option.

Using SignalView (under Secondary Data), set Alternate Code During Low Voltage Threshold to the minimum voltage required for the primary flash code and Low Battery Cutoff Threshold to the minimum voltage required for system operation.



7.4.4 Defaults

Default factory settings are:

Low Voltage Cutoff 9.0 VDC

Return to Normal Operation Threshold 11.0 VDC

Lockout Option Disabled

Alternate Code Option Disabled

7.5 SUNSWITCH CONFIGURATION

Sunswitch day level and sunswitch night level can be set using SignalView. (See Section 2.3.9 and the SignalView manual for more information on sunswitch operation.) Optionally, the levels can be changed via the IR Programmer.

Common settings are:

Tideland Signal default – ON 250 / OFF 320 lux

Canada – ON 180 / OFF 290 lux

United Kingdom – ON 100 / OFF 130 lux

8. TROUBLESHOOTING

Following is a guide for field troubleshooting SolaMax-65.

8.1 CONFIGURATION VERIFICATION

Verify flash code and power settings.

8.2 TESTING THE SOLAMAX-65 ARRAY

Assuming the lantern has been activated from the Shutdown Mode using the QuickCheck probe, if LEDs do not flash in the dark, use SignalView to assure the flasher is not in low-voltage cutoff or other failure mode (see Section 8.3). If not in any fail mode, then the problem is in either the control circuit or the LED array. Measure the voltage between LED+ and LED- when the array is under power. A properly functioning LED string will measure 12 to 22 VDC, depending on LED color. If no or very little voltage is measured, the power supply is malfunctioning and it should be replaced. If 45 to 60 VDC is measured, depending upon input voltage, then the LED string is open and should be returned to the repair depot.

8.3 TROUBLESHOOTING WITH SIGNALVIEW

SignalView monitors SolaMax-65 and provides information that is helpful in troubleshooting. The following sections describe check points that are read and displayed by SignalView.

8.3.1 LEDs Enabled

The control circuit checks conditions listed below to determine if the LED array should flash. If any one of these items is true, SignalView will indicate that the LEDs are not enabled.



Unit is set for low voltage cutoff and input voltage is too low

Lantern is in bright light

Unit is set in software for Main/Standby and has an even address (meaning it is in standby mode)

8.3.2 Error Status Messages

SignalView monitors SolaMax-65 and reports the following:

Low Voltage Cutoff

Indicates battery voltage has dropped below the operator-set voltage level. This condition asserts the “Fail” terminal.

Main Fail

Main/Standby option is selected, the SolaMax-65 has determined that the main lantern has failed and the standby lantern is operating.

Lantern Failure

The fail terminal is asserted. SolaMax-65 has experienced a general failure. If no other failure is indicated by SignalView, a failure other than those specifically detected by SignalView has occurred.

Low Voltage Lockout

Low Voltage Lockout has been activated by a low voltage condition. The lockout is reset by cycling input power.

Standby Fail

The Standby unit in the Main /Standby system has failed.

Flash Inhibited

This indicates that the flash has been suspended. This message is generated either when the flash has been inhibited by overriding sunswitch control or by failure.

Alternate Code During Low Voltage

The alternate code is activated because of a low voltage condition.



9. APPENDIX A: QUICKCHECK OPERTATION

Figure 10 is a diagram, which shows the logic for field-testing of the SolaMax-65 light using the QuickCheck probe (P.N. 184.1148-00) at the QuickCheck Port (Item 9, Figure 2.)

Figure 10: Logic Diagram of QuickCheck Programming

SolaMax-65 is shipped in the Shutdown Mode. To activate, the QuickCheck probe is held against the center of the Tideland logo on the top of the housing for 3 seconds or more. This causes the light to enter the Flash 30 Sec Mode where it flashes the programmed flash character for 30 seconds. Once this process is completed, the light automatically defaults into the Normal Operation Mode where it remains indefinitely until QuickCheck is again invoked. From the Normal Operation Mode, the QuickCheck probe is applied for a length of time which determines which mode the SolaMax-65 assumes, as described below.





If the probe is applied for a time between about 1 to 3 seconds, the LED array dims to a low level and a Battery Test Mode is assumed. For this test, the LED array is illuminated steadily at full power for a 30 second interval, after which the user views a flashing of the array and interprets the battery charge state as follows:



If the battery charge state is below 25%, the test is aborted during the 30 second load interval and no rapid fire flashes are seen. It is recommended that the battery be recharged or replaced.

One grouping of rapid-fire flashes indicates the battery is between 25% and 50% capacity

Two groupings of rapid-fire flashes indicate the battery is between 50% to 67% capacity

Three groupings of rapid-fire flashes indicate the battery is between 67% to 83% capacity

Four groupings of rapid-fire flashes indicate the battery is between 83% to 100% capacity

At 3 seconds the LED passes from dim to medium bright. If the probe is removed at a time between 3 and 6 seconds the SolaMax-65 assumes the Flash 30 Sec Mode. The sunswitch is overridden in daylight, causing the light to flash its programmed flash character for 30 seconds. Once the 30-second interval has elapsed, the light automatically reverts to the Normal Operation Mode.

At 6 seconds the LED passes from medium bright to full bright. If the probe is removed at a time between 6 and 9 seconds the SolaMax-65 assumes the Charge Only Mode. Again, the sunswitch is overridden in darkness causing the light to be extinguished as the Charge Only Mode is entered automatically. In order to cause the light to revert to Normal Operation Mode, the QuickCheck probe is applied for approximately 3 seconds. The LED array illuminates dimly, automatically enters the Flash 30 Sec Mode and reenters the Normal Operation Mode.

At 9 seconds the LED array flickers. If the probe is applied for a time greater than 9 seconds, the SolaMax-65 enters the Shutdown Mode. The Shutdown Mode prepares the light for shipping or storage without the current drain of the batteries required for maintaining active logic function.

(This space intentionally left blank.)



10. APPENDIX B: IR PROGRAMMER OPERATION

NOTE – PROGRAMMING UNINTENDED SETTINGS CAN IMPAIR OPERATION OF THE SOLAMAX-65. BE AWARE THAT SEVERAL LANTERNS CLOSE TOGETHER CAN GET PROGRAMMED AT THE SAME TIME. IF THAT IS NOT DESIRED, SEPARATE THE LANTERNS SO THAT ONLY THE DESIRED UNIT RECEIVES THE IR SIGNAL.

The IR Remote Control is intended for use in a repair depot before deploying the lantern. Aim the Remote at the Tideland logo on the top of the lantern for best reception. Before using the IR Remote commands, a 3 digit security code must be sent to the SolaMax-65. Once that is accepted, the flasher stops flashing for 1 minute to allow you to better observe the flash responses. Thereafter, the 1 minute timer is reset whenever a key is pressed. After 1 minute of no activity, the flasher will return to normal operation in which the day/night function controls the flash (ON in darkness, OFF in daylight). If you do not get a quick flash when you press a key, either it is not a recognized command or else the IR signal was not received. If you are sure of the correct button, press it again until you get a quick flash response. A button entry that is incorrect for a specific command will initiate a flicker from the SolaMax-65. Proceed as if the digit was not received. After the security code has been entered, if you are unsure of your current entries in the IR operation, pressing RESET will clear the entries without exiting the secure mode.

When performing a READ of any of the settings such as Flash Code or Power (see below), the SolaMAX-65 will respond with a number of flashes to indicate the 3 digits of the setting including leading zeros. A zero is represented by a 2-second ON flash.

The following instructions assumes the SolaMax-65 is in darkness, lantern flashing. The infra-red receiver is located under the Tideland logo on the top of the lantern, so best reception is obtained when the remote control is on that side of the lantern.

TO ENTER THE SECURITY CODE 967

Press the SECURITY button – observe a quick flash and the flash code ceasing.

Enter 3 digit security code – observe a single quick flash between each press and a final double quick-flash.

SET FLASH CODE

Warning: Do not use a flash code that has a duty cycle that exceeds the power capacity of the SolaMax-65

Refer to the code tables to find the HEX to DECIMAL conversion of the flash code. You must enter the code in 3 digits, including any leading zeros.

In the FC tile, press SET -- observe a single quick flash.

Press the 3 digits -- observe a single quick flash after each entry, the last one being a double quick-flash.

Note: To force it to flash while remaining in Secure Mode, press ON, in the OVERRIDE tile.



READ FLASH CODE

In the FC tile, press the READ key and observe a quick flash that acknowledges acceptance. Then the SolaMax-65 responds with ON/OFF cycles to represent each of the 3 digits of the flash code. Refer to the code tables to find the HEX to DECIMAL conversion of the flash code switches.

SET POWER (%)

In the PWR tile, press SET -- observe a quick flash.


Note: To force it to flash while remaining in Secure mode, press ON, in the OVERRIDE tile.

READ POWER SETTING (%)

In the PWR tile, press READ -- observe a quick flash. The SolaMax-65 responds with ON/OFF cycles to represent each of the 3 digits of the power setting.

SET TURN-ON SETTING (LUX)

In the SS ON tile, press SET -- observe a quick flash.


READ TURN-ON SETTING (LUX)

In the SS ON tile, press READ -- observe a quick flash. The SolaMax-65 responds with ON/OFF cycles to represent each of the 3 digits of the TURN-ON setting.

SET TURN-OFF SETTING (LUX)

In the SS FF tile, press SET -- observe a quick flash.


READ TURN-OFF SETTING (LUX)

In the SS OFF tile, press READ -- observe a quick flash. The SolaMax-65 responds with ON/OFF cycles to represent each of the 3 digits of the TURN-ON setting.

TO TURN ON THE FLASH CODE DURING THE SECURE TIME PERIOD

In the OVERRIDE tile, press ON -- observe a quick flash and the flash code flashing. Whenever other commands are entered within the Secured time period (1 minute), the SolaMax-65 will again cease the flash code so that responses will be more distinct.

TO TURN OFF THE FLASH (DISABLE LIGHT SENSOR OPERATION)

NOTE: This is a sunlight sensor override, not a shut-down. It will be canceled whenever the power is cycled or the ON button, in the OVERRIDE tile is pressed (Restore Light Sensor Operation) is pressed

In the OVERRIDE tile, press OFF -- observe a quick flash. The flash code will not restart once the 1-minute Secure time period has expired.

TROUBLESHOOTING

If the remote control appears not to be functioning correctly, verify that the battery installed has a proper voltage.



IR REMOTE COMMANDS SUMMARY

SECURITY CODE 967 FLASH CODE SET FLASH CODE FC SET then enter 3 digits Note: To force it to flash while remaining in Secure mode, hit OVERRIDE ON READ FLASH CODE FC READ SUN SWITCH SET SUN SWITCH ON LEVEL SS ON SET then enter 3 digits SET SUN SWITCH OFF LEVEL SS OFF SET then enter 3 digits Note: To force it to flash while remaining in Secure mode, hit OVERRIDE ON READ SUN SWITCH ON LEVEL SS ON READ READ SUN SWITCH OFF LEVEL SS OFF READ POWER SET POWER SETTING (%) PWR SET then enter 3 digits READ POWER SETTING (%) PWR READ FOR TESTING TURN OFF OVERIDE OFF RESTORE SS CONTROL OVERRIDE ON RESET, w/o ABORTING SECURITY RESET



FLASH CODES -- Switch-to-Decimal Conversions for IR Programmer



11. APPENDIX C: PROCEDURE TO OPEN AND REPLACE THE BATTERY FOR SOLAMAX-65, 9011358-00



11.1 SPARE PARTS

PART

NUMBER PART DESCRIPTION QTY.

1821116-00 BATT 12V 12AH SOLAMAX-65 1

1821109-00 BATTERY VRLA 12V 9.0AH 2

1821101-00 BATTERY 12V/34AH@24HR PVX340T 1

1821117-00 BATT 12V 50AH SOLAMAX-65 1

3421232-00 VENT ASSY, SCREW-IN, M12X1.5 1

3601082-00 HOOK AND BATT STRAP SOLAMAX-65 2

6301424-XX BIRD SCARE SOLAMAX-65 1

9011358-00 KIT, BATT REPLACE, SOLAMAX-65 1

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