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Document: 003-8118-004
Use Restrictions
The Current Corporation Night Navigator 8540/8520 System incorporates a Generation III Image Intensifier Tube. This is a restricted commodity and is subject to export controls. This product has been shipped to you with an export license from Canada. If it is used in a different location or an application other than originally approved, then an export application, from your country may be required.
Use of the image intensifier in the presence of strong lighting will cause permanent damage as the bright image is burned in. This type of damage will void the warranty.
CAUTION:
To reduce the risk of injury due to electric shock or sudden release of pressure, do not remove cover (or back). No user-serviceable parts inside. Refer servicing to qualified service personnel.
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TABLE OF CONTENTS
1
1.1 1.2 1.3
2
2.1 2.2 2.3
2.4 Horizontal Field of View and Speed-Distance Charts..........................................................................9 2.4.1 20 Field of View .....................................................................................................................................9 2.4.2 9.5 Field of View ..................................................................................................................................10 2.4.3 7.5 Field of View ..................................................................................................................................11 2.4.4 Speed Distance Time Charts ..............................................................................................................12 2.5 Precautions to Remember........................................................................................................................13 2.5.1 System Power........................................................................................................................................13 2.5.2 Harbour & High Light Operations: ......................................................................................................13 2.5.3 Adjusting the brightness or contrast control on the monitor. ..........................................................13 2.5.4 Atmospheric conditions ........................................................................................................................14 2.6 Night Navigator Controllers .................................................................................................................15 2.6.1 Control Panel layout .............................................................................................................................15 2.6.2 Camera Controls ...................................................................................................................................16 2.6.3 Light Controls.........................................................................................................................................17 2.6.4 Other Controls .......................................................................................................................................19 2.6.5 4 Button Keypad Layout (10/20 PAN controls).............................................................................20 2.6.6 10/20 PANNING Controls for model 8540/8520............................................................................20 2.6.7 Optional 10/20 PANNING Controls for model 8520......................................................................20 2.6.8 4 Button Keypad Dimmer Control.......................................................................................................20 2.7 Display Operation .......................................................................................................................................21 2.7.1 Night Navigator on-screen displays................................................................................................21 2.8 On Screen Programming ..........................................................................................................................22 2.8.1 MENU access ........................................................................................................................................22 2.8.2 Availability of NN Control Panel Key functions in MENU mode .....................................................23 2.8.3 General Menu functions .......................................................................................................................23 2.8.4 PAN/TILT Over-ride ..............................................................................................................................23 2.8.5 Range Line Position and Threshold Calibration ...............................................................................24 2.8.6 Calibration Procedures.........................................................................................................................25
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
3
3.1
3.2 Power Requirements..................................................................................................................................27 3.2.1 Vac connections ....................................................................................................................................27 3.2.2 Vdc Terminal block ...............................................................................................................................27 3.3 Panel mounted Controllers Installation ................................................................................................28 3.3.1 Control Panel .........................................................................................................................................28 3.3.2 Optional 4 button Keypad ....................................................................................................................28 3.4 Video Display Unit (VDU) Installation ....................................................................................................29
3.5 Main Control Unit (MCU) Installation .....................................................................................................30 3.5.1 MCU Door Key ......................................................................................................................................30 3.5.2 MCU Mounting.......................................................................................................................................31 3.5.3 Field Wiring Procedure to meet IMO requirements for EMC..........................................................32 3.6 Sensor Package Mounting .......................................................................................................................45 3.6.1 General Information ..............................................................................................................................45 3.6.2 Sensor Package Mechanical Installation...........................................................................................46 3.7 Optional Wash and AIR Unit ....................................................................................................................48 3.7.1 Compressor Unit ...................................................................................................................................48 3.8 System Interconnections..........................................................................................................................49
3.9 Electrical System Cable Routing ............................................................................................................50 3.9.1 Connections to Sensor Package ........................................................................................................50
4
4.1
4.2 Focus Confirmation....................................................................................................................................52 4.2.1 Focus Adjustment .................................................................................................................................52 4.3 PAN / TILT LIMIT Adjustments ................................................................................................................53 4.3.1 Internal Access ......................................................................................................................................53 4.3.2 Method to Adjust limits .........................................................................................................................54 4.3.3 TILT LIMIT Adjustments.......................................................................................................................54 4.3.4 PAN LIMIT Adjustments.......................................................................................................................54
5
5.1 5.2 5.3 5.4
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Routine Maintenance............................................................................................................................57 Inspection Intervals ...............................................................................................................................57 Pan & Tilt Troubleshooting ..................................................................................................................58
5.5 IR Searchlight Maintenance .....................................................................................................................59 5.5.1 Warnings ................................................................................................................................................59 5.5.2 Maintenance ..........................................................................................................................................59 5.5.3 IR Searchlight Troubleshooting...........................................................................................................60 5.5.4 Pressurized Tube Maintenance ..........................................................................................................60 5.5.5 Opening and Removing Searchlight from Enclosure.......................................................................61 5.5.6 Lamp Change ........................................................................................................................................61 5.5.7 Lamp Focus ...........................................................................................................................................62 5.5.8 Reassembling the Enclosure...............................................................................................................62 5.5.9 Optical Filters.........................................................................................................................................63 5.6 Video Display Unit (VDU) Warnings.......................................................................................................63
6.1 Night Navigator Control Panel (100-2028 and 100-2030) ..............................................................64 6.1.1 Block Diagram .......................................................................................................................................64 6.1.2 Functional description ..........................................................................................................................64 6.1.3 Details .....................................................................................................................................................65 6.2 Night Navigator 4 Button Keypad (100-2032 and 100-2033) ........................................................66 6.2.1 Block Diagram .......................................................................................................................................66 6.2.2 Functional description ..........................................................................................................................66 6.2.3 Details .....................................................................................................................................................66 6.3 Compressor connections for optional Wash/Dry Unit ......................................................................67
6.4 MCU Assembly ............................................................................................................................................67 6.4.1 MCU Block Diagram .............................................................................................................................67 6.4.2 MCU Layout (Top View).......................................................................................................................68 6.5 MCU Power distribution ............................................................................................................................69 6.5.1 Overall Power diagram.........................................................................................................................69 6.5.2 Fuse Replacements..............................................................................................................................69 6.6 Shutdown Module (100-2060B)................................................................................................................70 6.6.1 Block Diagram .......................................................................................................................................70 6.6.2 Functional description ..........................................................................................................................70 6.6.3 Details .....................................................................................................................................................70 6.6.4 Functional Diagram...............................................................................................................................71 6.7 MCU Back Plane PCB (100-2040B).........................................................................................................72 6.7.1 Block Diagram .......................................................................................................................................72 6.7.2 Functional description ..........................................................................................................................72 6.7.3 Outline & component location .............................................................................................................73 6.7.4 LED's.......................................................................................................................................................73 6.7.5 Connectors.............................................................................................................................................74 6.8 MCU Master Controller (100-2044B).......................................................................................................75 6.8.1 Block Diagram .......................................................................................................................................75
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
Functional description ..........................................................................................................................75 Outline & component location .............................................................................................................76 LED's.......................................................................................................................................................76 Details .....................................................................................................................................................77
6.9 MCU Camera / Video Controller (100-2042D).......................................................................................78 6.9.1 Block Diagram of full-featured version...............................................................................................78 6.9.2 Functional description ..........................................................................................................................78 6.9.3 100-2042D Component-side (2-Channel Version)...........................................................................79 6.9.4 LED's (Component Side) .....................................................................................................................79 6.9.5 Connectors (Component-side) ............................................................................................................80 6.9.6 100-2042D Solder-side (2-Channel Version)...................................................................................80 6.9.7 Connectors (Back side)........................................................................................................................80 6.10 MCU IR Lamp Controller (100-2046B)....................................................................................................81 6.10.1 Block Diagram .......................................................................................................................................81 6.10.2 Functional description ..........................................................................................................................81 6.10.3 Outline & component location .............................................................................................................82 6.10.4 LED's.......................................................................................................................................................82 6.10.5 Connectors.............................................................................................................................................83 6.11 MCU Pan & Tilt Controller (100-2048C) .................................................................................................84 6.11.1 Block Diagram .......................................................................................................................................84 6.11.2 Functional description ..........................................................................................................................84 6.11.3 Connectors.............................................................................................................................................84 6.11.4 Outline & component location .............................................................................................................85 6.11.5 LEDs.......................................................................................................................................................85
7
7.1 7.2
NIGHT NAVIGATOR 8540/8520 SPECIFICATIONS ......................A CABLE AND CONNECTION DRAWINGS..........................................B ADDITIONAL DRAWINGS AND BULLETINS....................................C
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Basic Theory: The camera takes small amounts of ambient light photons and converts them into electrons, which pass through a wafer thin disc; this disc has 6 million channels or holes, which multiply the electrons thousands of times. The electrons then are bounced off a phosphor screen, which converts them back into photons for the final intensified image display.
ii. Infrared Light System. The Infrared light source is a 6 million candlepower short-arc Xenon system with an IR filter. The beam can be seen at 2000 meters through the Night Navigator monitor, even though it is invisible to the human eye. When the Infrared light is on and strikes an object, the image on the monitor appears as if the object has its own light source. It is mounted on the same pan/tilt unit as the camera in its own environmental housing. The Xenon light is highly efficient operating at 75 watts and providing excellent penetration in the near Infrared Spectrum (see chart below.)
iii. Pan and Tilt Unit. This heavy duty, all-weather environmental pan/tilt is designed to remotely position the Image Intensifier & IR Light, to a relative bearing of +180 to -180 (degrees of azimuth from heading) or to relative tilt +90 to -90 (degrees of elevation from horizon). Limits to motion are preset as per Specifications data, refer to APPENDIX A - Night Navigator 8540/8520 Specifications iv. Main Control Unit (MCU). This component manages all video, control and power. v. Control Panel. (a wired control panel). This is the main, panel mounted, controller that displays status of equipment and provides all the control interfaces. vi. Optional 4 button Keypad. (a wired control panel). This is a 4 Button Keypad, panel mounted, controller that provides for remote auxiliary or remote controls. vii. Video Display (VDU). Image is viewed on a 9 high-resolution display with indications of direction, angle of tilt and distance ahead. These are provided to assist the operator when it is so dark that visual cues normally used to orient the viewer are not visible.
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viii. Optional Air/Wash Unit. This optional cleaning system adds a small compressor box, fluid tank, and airline to the system.
8520 Series Included Optional Optional Included Optional 20 H Standard (Optional 9.5H) (Optional 7.5H) Optional
Model 8540 Included Included Optional Included Optional 20H x 15V Included
Video Display (Green Tint) 2nd Video Display (Green Tint) Field of View (FOV) (4:3 aspect ratio) Washer system
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20 FOV
1286 ft [392 m]
6 Cables (0.6NM)
20 FOV
857 ft [261 m]
4 Cables (0.4NM)
643 ft [196 m]
3 Cables (0.3NM)
429 ft [130 m]
2 Cables (0.2NM)
214 ft [65.2 m]
1 Cable (0.1NM)
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606 ft [185 m]
6 Cables (0.6NM)
9.5 FOV
404 ft [123 m]
4 Cables (0.4NM)
303 ft [92.3 m]
3 Cables (0.3NM)
202 ft [61.5 m]
2 Cables (0.2NM)
101 ft [30.8 m]
1 Cable (0.1NM)
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478 ft [146 m]
6 Cables (0.6NM)
7.5 FOV
319 ft [97.1 m]
4 Cables (0.4NM)
239 ft [72.8 m]
3 Cables (0.3NM)
159 ft [48.6 m]
2 Cables (0.2NM)
79.6 ft [24.3m]
1 Cable (0.1NM)
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
Speed
(Knots)
6 8 10 12 14 16 18 20 22
Time (seconds) to target Distance (Nautical Miles) 0.1 0.2 0.3 0.4 0.5 60.0 120 180 240 300 45.0 90 135 180 225 36.0 72 108 144 180 30.0 60 90 120 150 25.7 51 77 103 129 22.5 45 68 90 113 20.0 40 60 80 100 18.0 36 54 72 90 16.4 33 49 65 82
Speed
(Knots)
20 22 24 26 28 30 32 34 36 38 40 42
Time (seconds) to target Distance (Nautical Miles) 0.1 0.2 0.4 0.6 0.8 18.0 36 72 108 144 16.4 33 65 98 131 15.0 30 60 90 120 13.8 28 55 83 111 12.9 26 51 77 103 12.0 24 48 72 96 11.3 23 45 68 90 10.6 21 42 64 85 10.0 20 40 60 80 9.5 19 38 57 76 9.0 18 36 54 72 8.6 17 34 51 69
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A latent image may appear after the Night Navigator has been aimed at bright light sources. The latent image will normally fade over the next few minutes or hours depending on the time exposure to the light. If the latent image does not fade, that will be because the Night Navigator was aimed too long at a light. This will not stop the Night Navigator from being used but the dark spots will mean that the sensor needs to be re-positioned for the clearest image on the monitor. When the harbour lights are too bright the image will deteriorate, as it is focused for complete darkness. At this point the Night Navigator Image should be shut off. The harbour lights should be bright enough to navigate. At the end of the shift or when coming into harbour, the operator must take care not to turn only the monitor off and assume the system is shut down. The camera may still be operating if the main system power is not turned off.
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To prevent the Night Vision camera from damage during daylight, the IR Lamp and the Camera will time out and turn off after 10 minutes of Control Panel inactivity. After 9 minutes of inactivity, the backlights for the Keypads will flash. After 1 Minute of flashing Key pads the IR light and Night Camera will power down. Any Joystick action, ACK key or either Panel Dim/Bright keys will reset this timer. Any of the 10 / 20 Preset functions will reset the timer.
CENTER (push button) Returns the Pan & Tilt to its pre-programmed home position. To activate, press button once. The home position is normally dead ahead.
The Home position (Horizon and Heading) can be compensated for periodic changes in the Pitch or Yaw angle of the ship, for example to adjust for unique cargo loading patterns. To make minor adjustments to the Home position, refer to AUX Key in section 2.6.4 Other Controls To Setup the coordinate origin refer to the Performing the calibration sequence as described in section 2.8 On Screen Programming. Pans and Tilts the Camera and Light together.
The joystick can Pan Left, Pan Right, Tilt Up and Tilt Down. The unit continues turning or tilting as long as the joystick is being held and stops when the joystick is released. It can be moved in the vertical (TILT) and horizontal (PAN) directions at the same time.
If the Camera was previously returning to the center/home position, the joystick action will cancel the Center command.
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IR NARROW (push button) To concentrate the beam or spot light effect. To activate, press button once or hold until focused.
IR WIDE (push button) To spread the beam or flood light effect. To activate, press button once or hold until focused.
2.6.3.1
The Focus of the Infrared searchlight has the ability to be programmed to assist the operator in navigating the vessel at night. Programming is done with the light initially turned on and as follows: Step1 Turn on searchlight. Step2 OR Move the focus to the desired position using the buttons (Narrow beam and Wide beam).
Step3 AND Release Light first, and then Narrow. Push the Light button and hold it while pushing the Narrow beam button.
Next time the light is turned on it will initially focus at the newly programmed position.
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2.6.3.2
If you notice a delay before the lamp starts moving when moving out of the full spot position, then the spot position was set beyond the point at which the lamp is physically able to move. If this occurs, the spot position should be reset to a point at or within the physical limits of the lamps travel. Step1 Turn on searchlight. Step2 Hold the Light Button, then press and release the Narrow button 2X. Do Not Release the Light Button. Do Not Release the Light Button.
AND
then
Step3 AND OR
Move the focus to the desired smallest spot position using the Narrow or Wide buttons. Release the Narrow or Wide buttons. Step4 Finally, release the Light button, now the spot (narrowest) position will be reset to as selected. 2.6.3.3 Setting the widest flood of the searchlight
If you notice a delay before the lamp starts moving when moving out of the full flood position, then the flood position was set beyond the point at which the lamp is physically able to move. If this occurs, the flood position should be reset to a point at or within the physical limits of the lamps travel. Step1 Turn on searchlight. Step2 Hold the Light Button, then press and release the Wide button 2X. Do Not Release the Light Button. Do Not Release the Light Button.
AND
then
Step3 AND OR
Move the focus to the desired smallest spot position using the Narrow or Wide buttons. Release the Narrow or Wide buttons.
Step4 Finally, release the Light button, now the Flood (widest) position should be reset to as selected.
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In AUX mode, the CENTER button will cause the current angles to be saved as the new home Position. The Pan/Tilt angles displayed on-screen will still represent the calibrated angles. To Setup the coordinate origin refer to the Performing the calibration sequence as described in section 2.8 On Screen Programming. ACK (push button) To access MENU modes To ENTER MENU mode, press and hold for 5 seconds. To EXIT MENU mode, press and hold for 5 seconds. In MENU mode, the Maximum and Minimum indicators will turn on.
POWER ON/OFF (buttons) Standby power ON/OFF To operate, press and hold ON for 2 seconds. The solid Green LED above ON indicates power up. The Flashing COMM LED above ACK indicates operation. To go to Standby, press and hold OFF for 2 seconds. The solid RED LED above POWER OFF indicates power down/ STANDBY MODE.
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PORT 20 +PORT 10 (push button) To DIM To DIM the illumination, press and hold both keys. AND STBD 20 +STBD 10 (push button) To Brighten To brighten the illumination, press and hold both keys. AND
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Contrast:
Brightness: Adjust to users preference taking care not to produce too much light on the bridge and thereby interfere with the safe operation of the vessel at night. Underscan: When this button is pushed, the size of the image on the monitor is reduced in order to see all the field of view available from the camera. It has the effect of reducing the magnification of the lens. It is toggled on and off using the bottom left-hand button on the front of the monitor. The sample display image, as shown above is as supplied for Night Navigator model 8540 and model 8520 with 20 FOV.
When the Night Navigator is tilted up or down from the center position, the distance display will disappear since it is no longer accurate. Pushing the Center button on the Control Panel brings the system back to its calibrated position and the distance indications will re-appear.
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ABOUT Screen
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Step 3 Hi-light the Navigator Range Line Configuration option and press the IR Narrow button. The window shown below. (Range Line markers are shown as 3CA, 2CA and 1CA in the example below. Step 4 Move the joystick Up or Down to hi-light the option(s) that are desired to be changed. Move the joystick Left or Right to change the values. Step 5 When changes are complete, hi-light the Apply button and press the IR Narrow button. The changes should then be apparent. Step 6 Once all the settings are complete, hi-light the Save button and press the IR Narrow button. This will maintain the settings when the application is restarted.
Step 7 The Tilt information can also be removed from the screen by hi-lighting the Navigator Text Display Configuration shown and pressing the IR Narrow button. This will bring up the window shown below. Step 8 Move the joystick Right to hi-light the Off option and move the joystick Down to hi-light the OK button. Press the IR Narrow button. Step 9 Once all settings are complete, Exit the Menu Mode (see section 2.8.1 MENU access)
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SET 90 PORT 3) Hold the Center button and using the joystick move the Pan/Tilt to 90 PORT. Now release the Center button. 4) Using the joystick, navigate the Main Menu to the screen shown below. Highlight the Set Port 90 Degrees option and now press the IR Narrow button to set position. (Note, menu should flash indicating command was sent) SET 90 STBD 5) Hold down the Center Button and using the joystick move the Pan/Tilt to 90 STBD. Now release the Center button. 6) Repeat Step 3 but highlight the Set STBD 90 Degrees option and now press the IR Narrow button to set position.
SET 15 UP 7) Hold down the Center button and using the joystick move the Pan/Tilt to 15 degrees UP. Release the Center button. 8) Using the joystick, navigate the Main Menu to the screen shown below. Highlight the Set Up 15 Degrees option and press the IR Narrow button to set position. (Note, menu should flash indicating command was sent) SET 25 DOWN 9) Repeat steps 6 and 7 except move Pan/Tilt to 25 degrees down and hi-light the Set Down 25 Degrees Option SET 0 HEADING 10) Hold down the Center button and using the joystick move the Pan/Tilt to 0 from Heading and 0 from Horizon. 11) Repeat Step 3 except hi-light the Set 0 Degrees option. SET 10/20 PAN Presets 12) Finally, repeat Step 3 except hi-light the Set 10 and 20 Degrees option. Now the PORT and STBD 10 and 20 Degrees positions will be calculated and stored. 13) When Calibration is complete, in the MCU on the 100-2044 module, Set Dip Switch2, position 8 to ON. This will lock this Menu. 14) The calibrated positions can be tested or used by selecting the Go To *** option in the sub-menu shown below. 15) Once all settings are complete, Exit the Menu Mode (see section 2.8.1 )
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3 Night Navigator Installation Please read these instructions before starting installation. 3.1 Night Navigator 8540/8520 Installation Data
The following information is provided to facilitate your installation work: 1) Dimensional drawings (Size and weight of each component) See section 3.8 System Interconnections 2) The maximum length of each interconnection cable / air hose: See section 3.8 System Interconnections The maximum hose length between external sensor and MCU is 18 m. The maximum length between MCU and other components is 60 - 80 m. 3) Installation criterion of each component (such as mini-spacing required for maintenance, interference with other navigation equipment) External Sensor: Must have a clear unobstructed view ahead of the bow of the vessel. No lights in front of the unit as they impair the operation of the night vision. No obstacles ahead of the unit, which could possibly reflect light back at the camera, (even indirectly, such as railing, spars or davits.) Clear of all other equipment within a 400mm radius of the center of the mount See section 3.6 Sensor Package Mounting MCU:
Control Panel / 4Button Keypad: Warning: Control Panel must be connected to MCU for proper operation and power up. Install on a horizontal console within easy reach of the night vision operator with a clear view of the monitor screen. Cut out dimensions: Control Panel: 138mm x 138mm. Cut out dimensions: 4 button keypad: 138mm x 33mm Safe distance to magnetic compass: External Sensor package: Compressor box: MCU: Control Panel: 4 Button Keypad:
minimum 0.4 meters (external equipment) minimum 1 meter 1.4 meters 0.3 meters 0.3 meters
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Isolation Transformer
TB_AC7
TB_AC12
Right
TB_AC10 RFI Filter
TB_AC9
Earth
TB_AC8
TB_AC11
Left
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144.0mm.
138.00mm.
138.0mm.
Main Controller
144.00mm.
0.75in.
Minimum Distance cutout to cutout 138.00mm. 36.00mm. Remote Keypad (4button) 33.00mm.
144.00mm.
Required CUTOUT
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Figure 1.1 Cut down braided shield (keep long maximum). Remove aluminum foil up to end of braided shield. Remove nylon cords (fillers). Tin (solder) the long braided shield (be careful not to melt the wire jackets). See figure 1.2 below
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Figure 1.2 Square off the edge of the tinned braided shield using side cutters Take EMC cable clamp from back of Main Controller and push tinned braid through the loop (open the loop more if necessary). Close the loop tightly. See figure 1.3 below:
Figure 1.3
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Trim the wires so there are no excessive wire loops. Install a white ferrule on each wire as shown in figure 1.4 below:
Figure 1.4 Install wires on green connector (plug) provided Install and tighten EMC cable clamp (with cable) on back of Main Controller Plug and screw down connector Install ferrite choke (square one) on cable. Install cable inside nylon cable loop. Fasten down nylon cable loop. See figures 1.4 above, and 1.5 & 1.6 below:
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Figure 1.5
Figure 1.6
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(Drawing# 100-0099F). Use EMC kit# 590-0177A and hardware kit 590-0070B shipped
inside MCU box.
NOTE:
When two PAN Controllers are used, the MAIN one can be connected directly to Main Controller using Drawing# 100-0101C (OPTION B) and the SLAVE one can be connected to MCU Mainboard using Drawing# 100-0099F. Or both can be connected to MCU Mainboard using Drawing# 100-0099F.
Figure 1.7
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Install wires on green connector (plug) provided Install and tighten EMC cable clamp (with cable) on back of PAN Controller. Plug and screw down connector Install ferrite choke (big square one) on cable. Secure ferrite choke with two cable ties, one on each side of the choke. Fasten down cable using nylon mount and cable tie. See figure 1.8 below:
Figure 1.8
3.5.3.3
PAN Controller (4-Button Keyboard) cable wiring OPTION B (directly to Main Controller) (Drawing# 100-0101C). Use EMC kit# 590-0177A and hardware kit 590-0070B shipped inside MCU box.
NOTE:
When two PAN Controllers are used, the MAIN one can be connected to Main Controller using Drawing# 100-0101C and the SLAVE one can be connected to MCU Mainboard using Drawing# 100-0099F. Or both can be connected to MCU Mainboard using Drawing# 100-0099F.
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Figure 1.9 Cut down braided shield (keep long maximum). Remove aluminum foil up to end of braided shield. Remove nylon cords (fillers). Remove RED and BLACK/RED pair (unused) Tin (solder) the long braided shield (be careful not to melt the wire jackets). See figure 1.10 below
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Figure 1.10 Square off the edge of the tinned braided shield using side cutters Take EMC cable clamp from back of Main Controller box (left side) and push tinned braid through the loop (open the loop more if necessary). Close the loop tightly. Trim the wires so there are no excessive wire loops once connected. Install a white ferrule on each wire. Ferrules provided in hardware kit 590-0070B. Install and tighten EMC cable clamp (with cable) on back of Main Controller. See figure 1.11 below:
Note: The Main Controller cable goes to the right on the back of the Main Controller
box, and the PAN Controller cable goes to the left on the back of the Main Controller box. See figures 1.12 & 1.13 below:
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Figure 1.11
Figure 1.12
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Figure 1.13 Install wires on green connector (plug) provided, doubling up the connections with the Main Controller cable wires (2 wires per position). See Drawing# 100-0101C. Plug and screw down connector Install ferrite choke (square one) on each cable. Install each cable inside nylon cable loop. Fasten down nylon cable loops. Install ferrite choke (small round one) over exposed wires on PAN Controller wires only. See figure 1.13 above.
3.5.3.4
Compressor cable wiring (Drawing# 100-0068E and EMC wiring kit# (590-0179A)
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
Connect shield (drain) wire to earth stud on MCU plate Clamp a ferrite choke (provided in kit) over both wires near cable gland inside box Secure the ferrite choke with a cable tie
3.5.3.5
AC POWER INPUT cable wiring. Use Drawings# 100-0442A & 100-0445A, and EMC wiring kit# 590-0180 shipped inside MCU box. NOTE: The end user provides the cable.
3.5.3.6
CAMERA Control cable wiring (Drawing# 100-0058H and EMC wiring kit# 590-0178A)
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3.5.3.7
IR LIGHT Control & Power cable wiring (Drawing# 100-0056G and EMC wiring kit# 5900182)
3.5.3.8
PAN & TILT cable wiring (Drawing# 100-0054H and EMC wiring kit# 590-0184)
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3.5.3.9
3.5.3.10 GENERAL wiring procedures Screw down all unused Terminal Block entry points Screw down all unused Phoenix connectors (green plugs) entry points All wire harnesses must be supported every 6 inches
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
Item
1 2 3 4 5 6 7 8 9 10
Qty
3 3 1 1 8 4 2 5 1 4
P/N
520-0226 520-0228 520-0230 520-0232 520-0402 520-0504 590-0044 590-0000 590-0002 520-0225
Title
BOLT BOLT BOLT BOLT WASH NUT HDWR HDWR HDWR BOLT
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144mm
Night Navigator
144mm
36mm
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Before turning on the CAMERA, Ensure Darkness and that there are no Bright lights directly in the camera view.
10) Press and hold the IMAGE button for at least 2 seconds. (To toggle Camera OFF, Repeat) The camera will be powered on. The Green ACTIVE LED, located above the IMAGE button, will be illuminated. A Video Image will now appear on the monitor. Check for Focus. It is focused at infinity in complete darkness and excessive light will affect the focus. 11) Press and hold the IR LIGHT button for at least to 1 second. (To toggle LIGHT OFF, Repeat) The IR searchlight will come on and a green ACTIVE LED, located above the IR LIGHT button, will be illuminated. The light should be visible on the monitor. 12) Test light controls by operating the IR Narrow & IR Wide buttons and observing the light beam diameter change on the monitor.
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TILT Limit Rings RED (B4) BLUE (B3) WHITE (B6) / GREEN (B5) PAN Limit Rings
BLUE (B2) RED (B1)
Effect of Adjustment For upward range and stop at +90 For downward range and stop at 90 N/A Effect of Adjustment Left final limit stop (manual mode). Right final limit stop (manual mode).
3) Rotate the blue "Up" limit ring "B3" (use a screwdriver blade in the slots around the periphery) until its associated switch "S3" is activated; the tension ring will provide enough friction to keep the limit ring in place during normal operations, until you readjust it. 4) Repeat steps 1 and 2 to set the red "Down" limit ring "B4" and switch "S4".
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Action
Check for damage Examine for crimping, cracked insulation, frayed or pinched wires or loose connectors Confirm bolts securely tightened Remove foreign matter Replace if missing or damaged Lubricate with broad range synthetic grease. Replace Lubricate with low viscosity oil. Check chain slack, backlash. Do not over-tighten. Clean with damp cloth Clean glass surface Check pressure (3-15 PSIG) Fill to 15 PSI If drops below 10 PSI Clean Replace Check pressure (3-15 PSIG) Fill to 15 PSI If drops below 10 PSI Clean with damp cloth Check & Add Washer Fluid Clean filters
Frequency
Annually 3 months 3 months 6 months 6 months 6 months 2000 hrs. (Or as required) 6 months Weekly (Or as required) As required Monthly (Or as required) Weekly As required* Monthly (Or as required) Weekly (Or as required) Monthly (Or as required) Monthly (Or as required)
Searchlight
*The Xenon lamp is rated at 200 500 hours. The light may be returned to the factory for bulb replacement and refocusing. CAUTION: To reduce the risk of injury due to electric shock or sudden release of pressure, do not remove cover (or back). No user-serviceable parts inside. Refer servicing to qualified service personnel.
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PROBABLE CAUSE
No AC Power, Or Fuse blown in MCU Poor connection of Control Panel cable or poor shield ground in MCU Fuse blown
REMEDY
Confirm AC Feed is on Check AC input fuses in MCU Check all connections and grounds. Reset system power. Check fuses in MCU, VDC TB. Replace Fuse. Confirm LED indicators. Check Lamp/Replace Check all Connections. Reset breakers on PCB 100-2048
Refer to 5.4 Pan & Tilt
Broken Video connections Computer Processor not starting Video card or Processor Failure
Check & fill as required Check 12Vdc 20 Amp fuse in MCU Check all connections/lines for leaks. Check all video connections external & internal at PCB 100-2042 Turn on Image to confirm video signal. Check VAC control fuses. At PCB 100-2042, move the video output cable from PCB connection & connect directly to Black video transceiver. (Camera image directly to the monitor.)
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Inspection of Interior Wiring: Examine the interior wires for signs of crimping, cracked insulation, frayed or pinched wires and loose connections. Loose Hardware: Cleanliness: Check and tighten. Any foreign material such as dust, dirt or chips can act as an abrasive in the gear lubricant and reduces gear life. Make certain to remove all foreign material. Visually check the gears for worn teeth, poor alignment and chips. Lubricate the worms and worm gears every time the unit is opened. Replace if missing or damaged. Ball bearings are sealed and lubricated for life. The four tapered roller bearings in the worm carriers should be lubricated with a broad range synthetic grease such as Exxon Beacon 325, 9M 801 with LSHP-2. These are lubricated for their design life and require no added lubricant. Replace if excessive wear is visible or after 2,000 hours of use, whichever comes first. These should be lubricated with low viscosity oil. Slight slack in chains is not detrimental and does not affect backlash. Do not over-tighten them. Check for unwanted movement (looseness) in either pan or tilt drives. Refer to Section 5.4 for adjustment instructions.
Gear Lubrication:
Seals Bearings:
Backlash:
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5.4.3.2
5.4.3.3 Electrical Problems The electrical control system consists of the Control Panel, the interconnecting cable and the Pan/Tilt itself. A malfunction in any of these components will cause a system failure. Logical troubleshooting procedures must be utilized to isolate the faulty component. It is assumed that the fault has been traced to the pan and tilt. 1. Motor not operating and fuse does not blow Remove the Pan/Tilt covers. Connect a meter across the motor armature. Activate the function. If the meter reads the correct voltage, the problem is probably a defective motor. If there is no voltage at the motor terminals, the problem is in the cabling between the connector and motor or the limit switches. Pan/Tilt units that operate continuously may put flexing stress on the wires. If these wires ever need to be replaced. 2. Motor not operating and fuse does blow Open the pan/tilt cover and remove the four screws securing the male connector to the base of the pan/tilt. Visually inspect the circuitry for any short circuits. Disconnect the motor. Use an ohmmeter to check the cabling. If no apparent problem is found, the motor could be defective. Mechanically uncouple the motor by removing the chain from its sprocket and apply power directly to the motor. If the fuse blows, the motor is probably defective. 3. The Pan/Tilt stalls at the limit switch Check the Limit switch Check the Connections to the motor Check the Motor
4. The Pan/Tilt Unit does not stop when the limit switch is activated Check the Wiring for a short across the normally closed and common contacts Check the Limit switch
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5.5.2 Maintenance
The only maintenance required on the Searchlight is to periodically clean the body with a damp cloth and to keep the front lens cover clean. The front lens can be cleaned with window cleaner. It may become necessary to clean the MIRROR if you notice a slight staining or clouding on the upper surface. The MIRROR is a precision optical unit with a highly polished surface and should be cleaned only when necessary and with great care. Refer to the chapter on LAMP CHANGE for further information on cleaning and care of the MIRROR. Should the light be dropped or receive any heavy impact from transportation or shipping, it may be necessary to re-focus the lamp to insure proper operation and maximum output. Refer to the chapter on FOCUSING PROCEDURE for further information.
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PROBABLE CAUSE
Low input voltage Low input voltage due to low power supply or line loss Defective lamp Defective igniter No power Defective regulator Defective servo or defective controller Lamp is not seated in socket completely
REMEDY
Check input voltage Increase voltage at power supply (still within spec.) or use heavier cable Replace lamp Return light for repair Check power source and power cord Return light for repair Return light for repair See section on lamp change and focus
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IMPORTANT: Always release pressure from inside the enclosure before attempting any work on the searchlight, using the Schraeder valve. Serious injury could result if either end is opened while the enclosure is still pressurized.
1) Remove the searchlight from its mounting and take to a workshop or other dry, clean area suitable for disassembly of the unit. 2) Depress the pin in Schraeder valve to vent all the pressurizing gas in the enclosure. Continue until the gas has all been vented and the pressure is reduced to atmospheric. 3) Remove the rear-retaining ring. Pull the end plate straight back removing the tray and searchlight. 4) Carry out whatever maintenance is required on the searchlight. 5) If necessary, it can be removed from the tray by lifting the small lever at the back of the handle, then sliding the searchlight forward and lifting it out of the slots. Disconnect the power and control cables from the searchlight.
5.5.6 Lamp Change CAUTION: Never attempt a lamp change or remove the front lens cover with power connected to the light.
1) ALWAYS put on the shatterproof protective eyewear provided. The Xenon lamp is under high pressure and should be handled with care. 2) Use the 1/16 Allen driver provided in the lamp kit and remove the 3 screws holding the front lens in place and remove. 3) Carefully remove the electrical connector from the front of the lamp by unsnapping it. 4) Remove the lamp from the socket by grasping the metal end and pull gently with a slight twisting motion. DO NOT touch the glass envelope. If the lamp is touched, it can be cleaned with the cleaning solution provided in the lamp kit. 5) Gently blow any contaminants out of the reflector before cleaning. Use the tissue and cleaning solution in the lamp kit to clean the lens and mirror. Use very light pressure to prevent scratching of the mirror.
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6) Replace the lamp, holding it firmly by the long metal end and pushing it into the socket with a slight twisting motion. Make sure the lamp is seated all the way into the socket or the electronic focus will not operate properly. DO NOT apply any binding or sideways force on the lamp. 7) Reconnect the electrical connector to the lamp. 8) Replace the glass lens by first placing the o-ring over the step on the inside of the plastic ring. Then push the lens onto the reflector housing with a slight twisting motion, making sure that the front lamp support is seated into the Teflon button in the center of the lens. It may require several attempts the first time you try this to get the o-ring seated properly. 9) Rotate the front lens ring to line up the screw holes. Replace the screws; making sure the lens assembly is seated properly. DO NOT over tighten these screws. The O-ring is not a compression seal, so snug is good enough.
DO NOT EXCEED 15 PSIG. Equipment failure and personal injury may result if the unit is over-pressured.
Reinstall the searchlight in its permanent mounting.
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CAUTION:
TO REDUCE THE RISK OF ELECTRIC SHOCK, DO NOT REMOVE COVER (OR BACK). NO USER-SERVICEABLE PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.
This symbol is intended to alert the user to the presence of un-insulated "dangerous voltage" within the product's enclosure that may be of sufficient magnitude to constitute a risk of electric shock to persons.
This symbol is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the appliance.
To Clean VDU
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6 8540/8520 Night Navigator Technical Description 6.1 Night Navigator Control Panel (100-2028 and 100-2030)
6.1.1 Block Diagram
DipSwitch
LED Indicators & backlight
14 button KB
Micro Controller
RS-422 interface RS422
J2
Joy Stick
Support circuits
12 Vdc Power
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6.1.3 Details
J1 J2 H1, H2, H3, H5, J4, J5 JP1 JP2, JP4, JP5 DIP switch SW1 Inter-board connection between 100-2028C and 100-2030C RS-422 link from Control Panel to MCU (Reserved for future use) Control Panel RESET pin (Short to reset) Factory settings do not adjust, (Short 1-2 is normal) Factory settings do not adjust (pos1, 5,6=ON, pos2, 3,4,7,8= Off) Position1-2: Indicate 1-3 of RS-422 nodes Position5-6: Indicate Baud Rate (default= 4800, both=ON) PIC16F877A-20IL as supplied
Programmable IC's
U3 J1 Pin1
J2
SW 1 default settings
1 2 3 4 5 6 7 8
Pos7-8: Reserved Pos5-6: RS-422 Baud rate (4800) Pos3-4: Reserved Pos1-2: RS-422 Node# (node1)
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on
SW1
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4 button KB
Micro Controller
RS-422 interface RS422
J1
Support circuits
12 Vdc Power
6.2.3 Details
J1 H1, H2 H3 JP1 JP2 RS-422 link from Control Panel to MCU Inter-board connection between 100-2032A and 100-2033A (Reserved for future use) Factory settings do not adjust, (Short 1-2 is normal) Indicates RS-422 node number. Jumper On = node 3, (1st unit) default setting for single unit. Jumper Off = node 4, (2nd unit). PIC16F628-20I/SS as supplied.
Programmable IC's
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18AWG Wire
Compressor Control See Drawings 100-0058H & 100-0068E For More Details
Compressor Enable
0Vdc
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Replacement List for DC supply fuses (See drawing 100-0445A for more details) Flat Blade Type 5A 32VDC fast blow 7.5A 32VDC fast blow 10A 32VDC fast blow 15A 32VDC fast blow 20A 32VDC fast blow 8540/8520 Spares PN: 130-0522 130-0524 130-0525 130-0520 130-0526 Bussmann Part number ATC-5 ATC-7.5 ATC-10 ATC-15 ATC-20 Littlefuse Part number 257 005 257 07.5 257 010 257 015 257 020 Phoenix Part number 0913692 0913702 0913715 0913676 0913744
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5 Vdc Power
Support circuits
24 Vdc Power
100-2060 Assy
6.6.3 Details
D4-B D4-A D1 J1
Indication of +5Vdc Standby on PCB Indication of +24Vdc active on PCB Indication of Standby/System off when Flashing at 2Hz, (normally off) J1 pins 1-4 = Fused Vac to Power relay J1 pins 5-8 = Switched Vac from Power relay J1 pins 9-12 = VOP RS-232 and Power off request J1 pins 13-16 = 24Vdc Input, 5Vdc(Standby) outputs and ground (Reserved for future use) Factory settings do not adjust, (Short 1-2 is normal) PIC16F628-20I/SS as supplied.
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RS422
JS6-JS10 JV1, JV2 JV3, JV4 J3
POW ER
JS1-JS5
Power
12Vdc
PS Disable
Power_off
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6.7.4 LED's
D1 D6 D8 D10 D11 D17 D13 D4 RED RED RED RED RED RED Green Orange +5Vdc Standby power Indication of +5Vdc active on PCB (Reserved for future use) Indication of +12Vdc active on PCB Indication of +24Vdc active on PCB Indication of +8Vdc active on PCB Indication of +12Vdc PTC protected output to keyboards Indication of Standby/System off when Flashing at 2Hz, (normally off)
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6.7.5 Connectors
J2 J3 JV1 JV2 JV3, JV4 JS1 JS10 Ground test point RS-422 link from Back plane to MCU Master Controller Vdc Power supply connection Vdc Standby Supply and Power Supply Shutdown connections RS-422 connections to VOP, Control Panel and Keypads Power and Signals connections to controllers
JV2
JV1
JV3
JV4
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DipSwitch 1,2
JR3
Pan/Tilt Postion
A/D
CPU
Temperature Sensor
I/O
J1
JR2
RS-422 interface
JR1
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RS422
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6.8.4 LED's
D1 D3 D4 D5 RED Green Green Green Indication of +5Vdc active on PCB (Reserved for future use) (Reserved for future use) (Reserved for future use)
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6.8.5 Details
J1 JV3, JV4 JR1, JR2 JR3 JP1, JP3, JP5 JP 2 JP 4 DIP switch SW1 RS-422 link from Back plane to MCU Master Controller RS-422 connections to VOP, Control Panel and Keypads Power and Signals connections From Back plane Control cable, PAN/TILT position feedback Factory settings do not adjust, (Short 1-2 is normal) (Reserved for future use) MCU Master Controller RESET pin (Short to reset) Factory settings do not adjust (pos3,5,6=ON, pos1,2,4,7,8= Off) Position 1-4: Indicate number of RS-422 nodes Position 5-6: Indicate Baud Rate (default= 4800, both=ON) Factory settings do not adjust (pos1=ON, pos2-8= Off) 8 to ON after setup, to lock menu. Position1: On=enable Slow AUX PAN Position4: On=enable Extended status Position5: On=Inverted installation Position8: On=Lock calibrate menu PIC16F877A-20IL as supplied
Programmable IC's
3473 J1
Pos8: on = lock calibrate menu Pos6-7: Reserved Pos5: on = Inverted Pan/Tilt Pos4: on = Enable Extended status Pos2-3: Reserved Pos1: on = Enable slow Aux+Pan
Pos7-8: Reserved Pos5-6: RS-422 baud, shown as 4800 baud Pos1-4: number of RS-422 nodes (shown as 4 nodes)
JR3
1 2 3 JP5
on
on
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
SW1
SW2
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JR3
Camera Controls
Activators (4X)
IN 1 4:1 mux
I/O
IN 2
OUTA3
IN 3
JR2
IN 4
OUTB1
4:1 mux
JR1
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Indication of +12Vdc PTC protected output to Camera1 Indication of Compressor power enabled. (Optional device) Indication of +12Vdc PTC protected output to Camera2 Indication of +12Vdc PTC protected output to Camera3 On/Off= Led status D17 D18 D19 D20 Off On Off On N/A N/A N/A N/A
D17-20
Green
D29
Green
Channel A = IN1 N/A N/A Off Channel A = IN2 N/A N/A Off Channel A = IN3 N/A N/A On Channel A = IN4 N/A N/A On Channel B = IN1 Off Off N/A Channel B = IN2 Off On N/A Channel B = IN3 On Off N/A On On N/A Channel B= IN4 Indication of -5Vdc PTC protected output Video circuit
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6.9.5
Connectors (Component-side)
JR1, JR2 Power and Signals connections From Back plane
JR3
SW 1 (If absent, Termination is dedicated) IN1, 2,3,4 Out A1, A2, A3 Out B1, B2 R 46 R 55
75 ohm input terminator, required, if not otherwise terminated. SW1- pos 1: On= 75R termination of Video IN 1 SW1- pos 2: On= 75R termination of Video IN 2 SW1- pos 3: On= 75R termination of Video IN 3 SW1- pos 4: On= 75R termination of Video IN 4 Input Signals to Video MUX Outputs of Video Amp A Outputs of Video Amp B Gain trim of Video Amp A Gain trim of Video Amp B
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
IR Lamp Indicator
Sensor
JR3
IR Lamp Controls
Activators (7X)
I/O
JR2
JR1
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
6.10.4 LED's
D1 D2 D2 D3, D6 D7, D10 D11, D14 D15, D18 D19, D22 D23, D26 D27, D30 RED RED Green RED, Green RED, Green RED, Green RED, Green RED, Green RED, Green RED, Green Indication of this 100-0246B module is powered. Indication of remote IR Lamp power supply is on. Indication of IR Lamp is energized. Indication of Spare1 activator is selected, Indication that Spare1 control is activated. Indication of Spare2 activator is selected, Indication that Spare2 control is activated. Indication of WIDE activator is selected, Indication that WIDE control is activated. Indication of NARROW activator is selected, Indication that NARROW control is activated. Indication of HIGH-level activator is selected, Indication that HIGH-level control is activated. Indication of STROBE activator is selected, Indication that STROBE control is activated. Indication of LAMP ON activator is selected, Indication that LAMP ON control is activated. (Device state is toggled) (See D31 for energized state of LAMP)
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
6.10.5 Connectors
JR1, JR2 JR3 Power and Signals connections From Back plane Control cable, IR LAMP activators
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
Compressor Enabled
Sensor
JR3
Speed select
JR2
BUS interface
POWER JR1
6.11.3 Connectors
JR1, JR2 JR3 Power and Signals connections From Back plane Control cable, PAN and TILT motor controls and spare activators
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
6.11.5 LEDs
D2
D4
RED GREEN
D8 & D12 D5 & D13 D16 & D24 D19 & D23 D35 D29 D36 D32 D7,10,11,15,18,21,22,26
Indication of this 100-0248B module is powered. Indication of +24Vdc PTC protected output to Lens washer/dryer. RED Indication of Pan to the Left RED Indication of Pan to the Right RED Indication of Tilt Down RED Indication of Tilt Up GREEN Indication of Washer system is selected GREEN Indication of Air Dry system is selected. RED Indication of High Speed (24Vdc) Selected GREEN Indication of Spare1 is selected RED Indication of Circuit Breaker Tripped. CB1,2,3,4,5,6,7,8
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
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Current Corporation 2933 Murray St, Port Moody, BC, V3H 1X3 Canada
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