Avlite AV-09-4WL Supplement

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Department of Defence
 

Avlite Systems
AUSTRALIA
t: [phone]
USA
t: [phone]
w: www.avlite.com
e: [e-mail]
Avlite Systems’AV-09-4WL Solar Windsock Light Kit provides users with a
complete, reliable and low maintenance solution to windsock illumination.
This complete windsock lighting kit incorporates four (4) AV-09 lights mounted onto 12mm
powder-coated square tubing arms, a 140watt multicrystalline solar module and mounting
bracket, and 110Ah SLA battery (2 X 55Ah) housed in a rotationally moulded weatherproof
battery box with galvanized lockable cage for improved security.
Each AV-09 light incorporates a 3watt ultra-high intensity LED as a light source offering up
to 100,000 hours of service - no need to change any globes! With low power consumption
and external sun-switch for automatic night activation, the AV-09-4WL is a fantastic
alternative to traditional hard-wired or uorescent products.
The AV-09-4WL can be installed immediately and requires no costly underground wiring.
The complete kit comes packaged in a 155x69x76cm pallet for ease of shipping. Other
congurations are available on request.
Features
• Integrated solar/battery system
• 140watt solar module
(standard)
• 2 x 55Ah SLA batteries
(standard)
Typical Applications
• Lighting kit to suit existing
windsock assemblies
Solar Powered Windsock Light Kit
AV-09-4WL
Solar module/battery
conguration of
AV-09-4WL Windsock Light
AV-09 lights with 3watt
ultra-high intensity LED -
no globes to change!
Solar module mounted
for maximum solar
collection
Flexible installation with
adjustable 2-piece
clamp
(50-150mm pipe)
Weatherproof battery
box and lockable
galvanised cage for
improved security
Windsock & pole
not included

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Department of Defence
 

Avlite Systems
AUSTRALIA
t: [phone]
USA
t: [phone]
w: www.avlite.com
e: [e-mail]
Solar Powered Windsock Light Kit
AV-09-4WL
•Specications subject to change or variation without notice
*Subject to standard terms and conditions
“In addition to the AV-70 airstrip lights we purchased, the
Windsock Lighting Kit is great - just what we needed. It lights up
the sock perfectly!”
Kathy Dyer,
Heli-Muster (NT) Pty Ltd
SPECIFICATIONS•* AV-09-4WL
Light Characteristics
Light Source 4 x domed luminaires each with 1x 3watt ultra-high intensity
surface-mounted LED
Available colors White
Horizontal & Vertical Divergence
(degrees)
120
LED Life Expectancy (hours) >100,000
Electrical Characteristics
Current Draw (mA) 1000
Circuit Protection Polarity protected
Operating Voltage (V) 12
Temperature Range -40 to 80°C
Solar Characteristics
Solar Module Type Multicrystalline
Output (watts) 140
Solar Module Efciency (%) 15
Charging Regulation Controller
Power Supply
Battery Type SLA (Sealed Lead Acid)
Battery Capacity (Ah) 2 x 55Ah
Nominal Voltage (V) 12
Autonomy (nights) 8
Certications
CE EN61000-6-3:1997. EN61000-6-1:1997
Quality Assurance ISO9001:2008
Intellectual Property
Trademarks AVLITE® is a registered trademark of Avlite Systems
Warranty * 3 year warranty
Options Available • External ON/OFF Switch

AV-09-4WL
Solar Windsock Light Kit
Installation & Service Manual
Version 2.0

AV-09-4WL
Solar Windsock Light Kit

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3
AV-09-4WL Solar Windsock Light Kit
Table of Contents
Version No. Description Date Approved
00 Manual Launch Feb 2005 C. Procter
01 Installation Details Updated March 2006 C. Procter
02 Note added to Assembly & Installation, washers added
to Fig 5, style of battery change to Fig 7, spring washers
added to Fig 8, appendix added (wiring schematic)
Aug 2007 C. Procter
1.3 Tech Drawing Update July 2010 K. Paton
2.0 Product Code Update October 2013 J. Dore
Introduction..................................................................................................................4
Operating Principle .....................................................................................................4
Technology...................................................................................................................4
AV-09-4WL Model.........................................................................................................5
Assembly & Installation.............................................................................................. 6
Assembly of the Solar Panel & Mounting Frame......................................................6
Unpacking Instructions.....................................................................................................................................6
Initial Inspection................................................................................................................................................6
Assembly..........................................................................................................................................................6
Installation of the Solar Panel & Battery Box Cage..................................................8
Unpacking Instructions.....................................................................................................................................8
Initial Inspection................................................................................................................................................8
Assembly..........................................................................................................................................................8
Installing the Solar Panel & Battery Box Cage...............................................................................................10
Installation of the Battery & Battery Box.................................................................12
Unpacking Instructions...................................................................................................................................12
Initial Inspection..............................................................................................................................................12
Installing the Battery Box................................................................................................................................12
Regulator Connection & Operation ......................................................................... 14
Regulator Connection Order...........................................................................................................................14
Selecting Lighting Control Option...................................................................................................................14
Day/Night Transition.......................................................................................................................................15
LED Indicators................................................................................................................................................15
Assembly & Installation of the Solar Windsock Light ........................................... 16
Unpacking Instructions...................................................................................................................................16
Initial Inspection..............................................................................................................................................16
Installation ......................................................................................................................................................16
Wiring of Completed Windsock Light Assembly.................................................... 19
Unpacking Instructions...................................................................................................................................19
Initial Inspection..............................................................................................................................................19
Wiring of Windsock Light................................................................................................................................19
Maintenance & Servicing.......................................................................................... 23
Trouble Shooting.......................................................................................................24
Avlite Light Warranty.................................................................................................26

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4
AV-09-4WL Solar Windsock Light Kit
Introduction
Congratulations! By choosing to purchase an Avlite light, you have become the
owner of one of the most advanced solar LED aireld lights in the world.
Avlite Systems draws on more than 25 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 certied as complying with the requirements of ISO 9001:2008 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 light.
Operating Principle
The solar module of the light converts sunlight to an electrical current that is used to charge the
battery. The battery provides power to operate the light at night.
The asher unit 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
specications. 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 will
turn on.
Technology
Avlite Systems is a world-class solar lighting systems manufacturer with a proven
reputation for rapid, innovative, and agile technology solutions designed specically
for defense, government, civil and humanitarian aid operations in the most remote,
toughest environments.
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 aviation lights 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 aviation LED lenses moulded from multi-cavity dies. Complex shapes
such as the AV70 and 16-segment multi-focus lenses 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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5
AV-09-4WL Solar Windsock Light Kit
AV-09-4WL Model
The light source for the AV-09-4WL is a high intensity 3watt LED with an appropriate current
control driving circuit. Four lighting arms spaced at 90 degrees apart and facing downwards over
the windsock provide clear illumination of the windsock position.
A master light controller enables activation of the lights once the light level falls to a
predetermined level.
Power to the lights is provided by 2x 55Ah 12volt SLA batteries. This battery is recharged each
day by a 140watt solar module. A 10amp solar regulator is tted between the solar module and the
battery to ensure the battery is charged correctly and to prevent over charging.
The solar module charging is critical to reliable ongoing operation. It must face the midday sun
and be clear of shadowing by trees or obstructions.
•Specications subject to change or variation without notice
*Subject to standard terms and conditions
SPECIFICATIONS•* AV-09-4WL
Light Characteristics
Light Source 4 x domed luminaires each with 1x 3watt ultra-high intensity
surface-mounted LED
Available colors White
Horizontal & Vertical Divergence
(degrees)
120
LED Life Expectancy (hours) >100,000
Electrical Characteristics
Current Draw (mA) 1000
Circuit Protection Polarity protected
Operating Voltage (v) 12
Temperature Range -40 to 80°C
Solar Characteristics
Solar Module Type Multicrystalline
Output (watts) 140
Solar Module Efciency (%) 15
Charging Regulation Controller
Power Supply
Battery Type SLA (Sealed Lead Acid)
Battery Capacity (Ah) 2 x 55Ah
Nominal Voltage (v) 12
Autonomy (nights) 8
Certications
CE EN61000-6-3:1997. EN61000-6-1:1997
Quality Assurance ISO9001:2008
Intellectual Property
Trademarks AVLITE® is a registered trademark of Avlite Systems
Warranty * 3 year warranty
Options Available • External ON/OFF Switch

Latest products and information available at www.avlite.com
6
AV-09-4WL Solar Windsock Light Kit
Assembly & Installation
The installation of the AV-09-4WL Solar Windsock Light includes the following steps:-
• Unpacking
• Initial Inspection
• Assembling the solar panel and mounting frame
• Installing the battery box cage and solar panel
• Installing the battery with battery box
• Assembling and installing windsock lights
• Wiring of completed assembly
Tools required
• Adjustable spanner
• 6mm Allen key
Unpacking Instructions
Unpack all hardware and verify container contents in accordance with Figure 3 “Assembly of Solar
Panel and Mounting Frame”. Please contact your Avlite ofce if there is any hardware missing.
Initial Inspection
Inspect all hardware for damage. If there is any damage, please contact your Avlite Ofce.
Note:- If the solar panel and mounting frame have been supplied pre-assembled then proceed to
‘Installation of the Solar Panel & Battery Box Cage’ section of this manual.
Assembly
Refer to Figure 3 “Assembly of Solar Panel and Mounting Frame”.
Assembling the panel & frame
The 120W Solar Panel (Ref 3.1) is attached to the Mounting Frame (Ref 3.2) using bolts (Ref 3.3),
washers (Ref 3.4) and nuts (Ref 3.5).
a. Insert bolts through the holes in the mounting frame, entering from the side of the angle.
b. Fit the Solar Panel ush against the Mounting Frame.
c. Install a washer and a self locking nut on each bolt. Tighten using spanner.
Assembly of the Solar Panel & Mounting Frame
Figure 2 Leading Dimensions of AV09

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7
AV-09-4WL Solar Windsock Light Kit
1
2
3
4
5
Figure 3 Assembly of Solar Panel & Mounting Frame
Item Description Qty
3.1 140W Solar Panel 1
3.2 Solar Panel Frame 1
3.3 Bolt, 8mm x 20 8
3.4 Washer, 8mm 8
3.5 Self Locking Nut, 8mm 8

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8
AV-09-4WL Solar Windsock Light Kit
Installation of the Solar Panel & Battery Box Cage
Tools required
• Digging implement (for post)
• Under size drill for 12mm screws
• Spanner
Unpacking Instructions
Unpack all hardware and verify container contents in accordance with Figure 5 “Installation of Solar
Panel & Battery Box Cage”. Please contact your Avlite ofce if there is any hardware missing.
Initial Inspection
Inspect all hardware for damage. If there is any damage, please contact your Avlite Ofce.
Installation
Refer to Figure 4 “Panel & Cage Footprint” and Figure 5 “Installation of Solar Panel & Battery Box
Cage” during installation of the panel and cage.
Installing the Post
A suitable mounting point for the Solar Panel and Battery Box Cage is to be provided by the client. It is
usual to use a purpose installed post. The following should be observed:-
• The post should be of a durable timber, or other durable material.
• Recommended minimum post size is 150mm x 150mm, or larger if the Battery Box Cage needs to
be installed immediately beneath the Solar Panel.
• The length of post required is the sum of exposed length (normally 1.25m) plus the required depth
into the ground which is dependant on local soil conditions (recommended depth 850 minimum).
• The Solar Panel is to face south if installed in the northern hemisphere and north if in the
Southern hemisphere. Therefore, faces of the post must be aligned with the cardinal points of the
compass.
• The post should not be more than 20m from the windsock post, and should not be located so as to
place the Solar Panel in shade for a signicant time.
• The Solar Panel is tempered glass, so the post should be located away from any objects which
might fall on the installation.
• The post and equipment footprint should be at least 300mm clear of the windsock itself under all
conditions.
a. If you are mounting the Panel and Cage on a post, then dig a hole and install the post in the
chosen location.