Avlite AV-70 User manual

AV70
Solar Airfield Light
Version 3.1

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2
AV70 Solar Airfield Light
AV70
Solar Airfield Light
Rev. 03
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03 Assembly instructions revised (minor) 17/08/2006 C. Procter
Head Office
Avlite Systems
11 Industrial Drive
Somerville, Vic 3912
Australia
Tel: [phone]
Fax: [phone]
Email:[email protected]
Internet: www.avlite.com
USA Customers:
GulfRim Navigation
1401 South State
Abbeville, LA 70510
USA
Ph: 877-893-0789
Fax: [phone]
Internet: www.gulfrim.com
Email: [email protected]

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3
AV70 Solar Airfield Light
Table of Contents
1General...................................................................................................................4
1.1 Introduction ............................................................................................................4
1.2 Features..................................................................................................................4
1.3 Specifications ..........................................................................................................6
2Technical Description.............................................................................................7
3Assembly & Installation.........................................................................................8
3.1 Assembly & installation of the AV70 with rubber tile ...................................................8
3.1.1 Unpacking instructions........................................................................................8
3.1.2 Initial inspection.................................................................................................8
3.1.3 Assembly...........................................................................................................8
3.1.3.1 Assembling the light.....................................................................................8
3.1.3.2 Installing the light assembly .......................................................................10
3.2 Assembly & installation of the AV70 with Frangible Stake Mount................................11
3.2.1 Unpacking instructions......................................................................................11
3.2.2 Initial inspection...............................................................................................11
3.2.3 Assembly.........................................................................................................11
3.2.3.1 Assembling the light...................................................................................11
3.2.3.2 Installing the light assembly .......................................................................13
4Maintenance and Servicing..................................................................................14
4.1 General Maintenance..............................................................................................14
4.2 Replacing the Battery.............................................................................................14
4.3 Charging the Battery..............................................................................................14
5Trouble Shooting..................................................................................................15
Introduction
Congratulations! By choosing to purchase an Avlite lantern you have become the owner of one of the most
advanced solar LED airfield lights in the world.
Avlite Systems draws on more than 20 years experience in the design and manufacture of navigation aids, and
particular care has been taken to ensure your light gives years of trouble free service.
As a commitment to producing the highest quality products for our customers, Avlite has been independently
certified as complying with the requirements of ISO 9001:2000 quality management system.
By taking a few moments to browse through this booklet, you will become familiar with the versatility of your light,
and be able to maximise its operating function.
Please remember to complete the Avlite warranty registration card accompanying your lantern.

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AV70 Solar Airfield Light
1 General
1.1 Introduction
This manual provides installation and maintenance instructions for the AV70 Solar Powered Airfield light
manufactured by Avlite Systems.
1.2 Features
Electronics
Avlite employs leading in-house electronic engineers in the design and development of software and related
circuitry. All individual electronic components are sourced directly by Avlite procurement staff ensuring that only the
highest quality components are used in our products.
LED Technology
All products use the latest advancements in LED (Light Emitting Diode) technology as a light source. The major
advantage of LED’s over traditional light sources is well established in that they typically have an operational life in
excess of 100,000 hours, resulting in substantial savings to maintenance and servicing costs.
Precision Construction
Commitment to investing in the design and construction of injection-moulded parts including optic lenses, light
bases and a range of other components ensures that all Avlite products are of a consistent and superior quality.
Optical Performance
Avlite manufactures a range of LED lenses moulded from multi-cavity dies. Complex shapes such as the AV70
lens are a testament to the company’s superior in-house lens manufacturing capabilities and outstanding optical
performance.
Award-winning, Patented Technology
Several United States and Australian patent registrations are held on Avlite’s range of innovative designs, with
other regional patents pending in Canada, United Kingdom and Europe.

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AV70 Solar Airfield Light
Figure 1 AV70 Solar Airfield Light with Rubber Tile

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AV70 Solar Airfield Light
1.3 Specifications
Light Characteristics
Light Source 12 ultra-high intensity LEDs
Light Colour Red Green White Yellow Amber Blue or Sectored Combinations
Peak Intensity >12 flashing, >5 fixed-on (colour dependent)
Horizontal Output 360 degrees
Vertical Divergence 0 to +10
Flash Settings >250 including fixed-on (user-adjustable)
Lamp Life >100,000 hours
Electrical Characteristics
Current Draw 40mA
Circuit Protection Integrated
Operating Voltage 3.6v
Autonomy >20 (14 hour darkness, 12.5% duty cycle)
Temperature Range -40 to 80°C
Solar
Solar Module Type Multicrystalline
Output 2.5watt
Power Supply
Battery Type High Grade NiMH – Environment friendly
Battery Capacity 8Ah
Battery Voltage 3.6v
Physical Characteristics
Body Material LEXAN® Polycarbonate – UV stabilized
Lense Material LEXAN® Polycarbonate – UV stabilized
Mounting 6 x 17mm holes on 200mm PCD
Height (mm/inches) 240/9.45
Width (mm/inches) 231/9.09
Mass (kg/Ibs) 1.1/2.3
Certifications
CE EN61000-6-3:1997. EN61000-6-1:1997
Quality Assurance ISO9001:2000
Waterproof IP68
Intellectual Property
Patents US Pat. No. 6667582. AU Pat. No. 778918
Trademarks AVLITE® is a trademark of Avlite Systems
Warranty Full 3 year warranty

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AV70 Solar Airfield Light
2 Technical Description
The solar modules of the light convert sunlight to an electrical current that is used to charge the battery. The
battery provides power to operate the lantern at night.
The LED driving circuitry has very low current requirements. A microprocessor drives an array of ultra bright LED’s
through a DC/DC converter, which enables the LED’s to operate within the manufacturer’s specifications. The
battery is protected from over-charging within the circuit to ensure maximum battery life.
On darkness, the microprocessor will initiate a program check and after approximately 1 minute begin steady on
operation.
The Avlite AV70 solar airfield light is exceptional in its unique ability to ‘track the sun’, operating reliably in low
sunlight conditions. Made from tough, durable polycarbonate and using the latest high-intensity LED’s, the AV70
light boasts dual high-performance solar modules incorporated into Avlite’s world-first Solar Collection Lens.
Figure 2 Leading Dimensions of AV70

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AV70 Solar Airfield Light
3 Assembly & Installation
The installation of the AV70 Solar Airfield Light includes the following steps:-
•Unpacking
•Initial Inspection
•Assembling the light
•Installing the light assembly
3.1 Assembly & Installation of the AV70 with Rubber Tile
Tools required
•Large flat blade screwdriver (to suit “Flash Adjustment” bung)
•Hammer
3.1.1 Unpacking instructions
Unpack all hardware and verify container contents in accordance with Figure 3 below. Please contact your
Avlite office if there is any hardware missing.
3.1.2 Initial inspection
Inspect all hardware for damage. If there is any damage, please contact your Avlite Office. Retain original
packing material for possible future use in shipping the AV70.
3.1.3 Assembly
Refer to Figure 3 “General Arrangement of AV70 and Rubber Tile” during assembly and installation of the light.
3.1.3.1 Assembling the light
a. Use a large flat-blade screwdriver to remove the Flash Adjustment bung from the base of the light
(see Figure 2).
A sealed vent on the base allows air transfer without moisture intake and should not be disturbed.
b. Set the toggle switch, which is visible just inside the bung hole, to the “ON” position. This will
activate the AV70.
Intensity and flash settings are factory set using DIP switches and rotary switches next to the
toggle switch. These should not be altered.
c. To test operation of the light, place a dark cover (towel or jacket) on top of the light to activate the
sensor. The light should come on within about 60 seconds.
d. Replace the Flash Adjustment bung.

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AV70 Solar Airfield Light
Figure 3 General Arrangement of AV70 & Rubber Tile

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AV70 Solar Airfield Light
The AV70 light (Ref 1) is attached to the rubber tile (Ref 2) using bolts (Ref 3).
e. Insert bolts through the three centremost holes in the tile, entering from the bottom face (within the
triangular recess). It may be necessary to use a rubber mallet to insert the bolts.
f. Fit the AV70 light over the bolts on the top face of the tile. (It is possible to align the lens ridge with
the sides of the tile, but this is not a requirement).
g. Install a penny washer (Ref 4) and a wing nut (Ref 5) on each bolt. Tighten wing nuts to finger-
tightness.
3.1.3.2 Installing the light assembly
The completed AV70 – rubber tile assembly is to be mounted on a surface capable of supporting 6kg
minimum. Securing the rubber tile to the mounting surface is optional, however, Avlite recommend that the
tile be secured at a minimum of two points.
a. Place the completed light assembly in the desired location.
b. Using a hammer, drive steel pegs (Ref 6) through the holes in the corners of the rubber tile being
careful not to damage the AV70 light.
Note:- Other means of securing the tile may be used where the mounting surface is not suited to the use of
steel pegs.
NOTE: Charging Battery
New lights should be left in the sun for
several days to ensure battery is
charged before placing in service. The
light will charge whilst turned off.

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AV70 Solar Airfield Light
3.2 Assembly & Installation of the AV70 with Frangible Stake Mount
Tools required
•Large flat blade screwdriver (to suit “Flash Adjustment” bung)
•Sledge Hammer
3.2.1 Unpacking instructions
Unpack all hardware and verify container contents in accordance with Figure 4 below. Please contact your
Avlite office if there is any hardware missing.
3.2.2 Initial inspection
Inspect all hardware for damage. If there is any damage, please contact your Avlite Office. Retain original
packing material for possible future use in shipping the AV70.
3.2.3 Assembly
Refer to Figure 4 “General Arrangement of AV70 and Frangible Stake Mount” during assembly and installation
of the light.
3.2.3.1 Assembling the light
a. Use a large flat-blade screwdriver to remove the Flash Adjustment bung from the base of the light
(see Figure 2).
A sealed vent on the base allows air transfer without moisture intake, and should not be disturbed.
b. Set the toggle switch, which is visible just inside the bung hole, to the “ON” position. This will
activate the AV70.
Intensity and flash settings are factory set using DIP switches and rotary switches next to the
toggle switch. These should not be altered.
c. To test operation of the light, place a dark cover (towel or jacket) on top of the light to activate the
sensor. The light should come on within about 60 seconds.
d. Replace the Flash Adjustment bung.
The AV70 light (Ref 1) is attached to the stake mount plate (Ref 2) using bolts (Ref 5).
e. Fit the AV70 light on the top of the mount plate. Insert bolts through the four holes in the mount,
entering from the bottom. Install a penny washer (Ref 6) and a wing nut (Ref 7) on each bolt.
Tighten wing nuts to finger-tightness.
f. Fit the boss of the mount plate into the shorter barrel of the frangible sleeve (Ref 3). Using a 6mm
Allen key, tighten the socket head cap screw (Ref 8) against the stake mount boss.

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AV70 Solar Airfield Light
Figure 4 General Arrangement of AV70 & Frangible Stake Mount

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AV70 Solar Airfield Light
3.2.3.2 Installing the light assembly
The completed AV70 - mount plate assembly is to be mounted on the Stake (Ref 4) in firm soil (not loose
sand, screenings or other unbound material).
a. Use a sledge hammer to drive the stake (Ref 4) into the soil at the chosen location. Drive the stake
down until the bottom of the stake sleeve is at ground level.
b. Fit the AV70 – mount plate assembly on top of the stake. The longer barrel of the Frangible Sleeve
(Ref 3) should completely cover the stake sleeve. Using a 6mm Allen key, tighten the bottom
socket head cap screw (Ref 8) against the stake sleeve.
NOTE: Charging Battery
New lights should be left in the sun for
several days to ensure battery is
charged before placing in service. The
light will charge whilst turned off.

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14
AV70 Solar Airfield Light
4 Maintenance and Servicing
Designed to be maintenance free, the AV70 requires minimal attention, though the following maintenance and
servicing information is provided to help ensure the life of your Avlite product.
4.1 General Maintenance
a. Cleaning Solar Panels-
Occasional cleaning of the solar panels may be required. Using a cloth and warm soapy water, wipe off
any foreign matter before rinsing the panels with fresh water.
b. Battery Check-
Inspection of batteries should be performed every three years (minimum) to ensure that the charger,
battery and ancillary electronics are functioning correctly. Using a voltage meter, check that the battery
voltage is at least 3.6 volts under 100MA load, and ensure all terminals are clear of foreign matter.
4.2 Replacing the Battery
The AV70 light is the only compact airfield light with a double sealed battery compartment. This provides the user
with the ability to change the battery after years of operation.
a. Remove the Flash Adjustment bung and turn light ‘OFF’ via the internal switch.
b. Unscrew small screws to remove battery plate.
c. Remove battery from AV70 case and unscrew positive and negative leads.
d. Discard old battery in a safe manner.
e. Reattach positive and negative leads to new battery and then place back into case.
f. Reattach battery plate and switch light ‘ON’ via internal switch. Replace the Flash Adjustment bung.
g. To test, place dark cover (towel or jacket) on top of light to activate sensor, light will come on within about
60 seconds.
Care must be taken to observe the polarity of the battery before the leads are re-
connected, and ensure the replacement battery is correctly fitted. Always discard old
batteries in a safe manner.
4.3 Charging the Battery
It is strongly recommended that only the factory supplied charger (type MH-C777PLUS II) be used when charging
your Avlite airfield light battery. Refer to Technical Assistance from the Avlite Website (www.avlite.com) for details.

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AV70 Solar Airfield Light
5 Trouble Shooting
Problem Remedy
Light will not activate. •Ensure internal toggle switch is set to the 'ON position.
•Ensure light is in darkness.
•Wait at least 60 seconds for the program to initialise in darkness.
•Ensure rotary switches A and B are both set to “0” and nearby DIP
switches (sw4) are set to “on-on”.
•Ensure battery terminals are properly connected.
•Ensure battery voltage is above 3.4volts.
Light will not operate for the
entire night. •When the light is initially removed from storage the battery may be
discharged and the light may require several days of operational
conditions to 'cycle' up to full autonomy. Expose light to direct sunlight
and monitor operation for several days. Avlite products typically require
1.5 hours of direct sunlight per day to retain full autonomy.
•Ensure solar module is clean and not covered by shading during the
day.

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AV70 Solar Airfield Light
Avlite Systems Warranty
Activating the warranty
Upon purchase, the Avlite Systems warranty must be activated for recognition of future claims.
To do this you have two (2) options:
1. Postal registration
-Please complete the Avlite Warranty Registration card and return to Avlite Systems
within 30 days of your purchase.
2. Online registration
-Please complete the Online Registration form at;
www.avlite.com
Avlite Systems will repair or replace your lantern in the event of electronic failure for a period of
three years from the date of purchase.
The unit must be returned to Avlite freight prepaid.
Warranty Conditions
1. The warranty is applicable to lanterns manufactured from 1/1/2000.
2. The lantern must be installed in accordance with Avlite instructions.
3. No modifications to the original specifications determined by Avlite Systems shall be made
without written approval of Avlite Systems.
4. Input voltage shall not exceed those recommended for the product.
5. Warranty does not cover damage caused by the incorrect replacement of battery in the
AV15, AV60 or AV70 lantern models.
6. Replacement of battery is excluded from the warranty.
7. No recognition shall be given to flooding, or damage incurred from misuse of lanterns.
8. Solar modules are covered by individual manufacturers’ warranty.
Information in this manual is subject to changewithoutnotice and does notrepresenta commitmenton the partof the vendor.
Avlite products are subject to certain Australian and world-wide patent applications.
Head Office
Avlite Systems
11 Industrial Drive
Somerville, Vic 3912
Australia
Tel: [phone]
Fax: [phone]
Email:[email protected]
Internet: www.avlite.com
USA Customers:
GulfRim Navigation
1401 South State
Abbeville, LA 70510
USA
Ph: 877-893-0789
Fax: [phone]
Internet: www.gulfrim.com
Email: [email protected]