Kahlenberg M-522 Manual

Kahlenberg Instructions, M-522, Software Rev. R., Rev. 10/7/2019
Page 1 of 10
KAHLENBERG MODEL M-522
INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS
SOUND AND LIGHT SIGNAL CONTROLLER
1.) GENERAL FUNCTIONS AND DESCRIPTION -
The function of the M-522 Sound and Light Controller is to provide convenient operation of
sound signaling devices including navigation horns (ship’s whistles), and Morse Light from a
single control panel. At-Will signaling of any sounding device or light connected can be
accomplished from this panel. Automated signals for Restricted Visibility and Maneuvering
Signaling, as required by IMO (COLREGS) are programmed for output from this unit. In
addition, the M-522 generates the SOLAS General Emergency Alarm Signal and Abandon Ship
signals, to be activated by external push buttons if installed. External General Alarm Systems
that generate the GEA signal can be alternatively be connected to the M-522, passing the signal
through to all sound devices and lights connected to the M-522. The M-522 Sound and Light
Control is also designed to be operated in conjunction with external Sound Surveillance Systems
and/or Public Address systems.
Multiple M-522 units can be utilized on the vessel and will communicate with each other in
cases where multiple control stations are required. The M-522 operates on both A.C. and D.C.
electrical current and thereby will operate on the main voltage of the vessel, and on the backup
24 Volt D.C. emergency voltage in case of main power failure.
The M-522 is a compact solid state electronic control enclosed in an IP65 gasketed enclosure that
allows for bulkhead or console mounting. It includes three watertight cable glands for 10-14 mm
cable entry. All electrical connections are made internal to the enclosure. The unit is operated
from a flush mounted, dimmable, illuminated membrane switch keypad with embossed keys.
Power Source Required: 100-240 Volt A.C., 50/60 Hz, 1 Ph. AND/OR 8-30 Volts D.C.
(See wiring diagrams herein for specific connections)
Electrical Current Flow Required : .5 Amp
Output Power: 100-240 Volt A.C., 50/60 Hz, 1 Ph., AND/OR 8-30 Volts D.C.
Switching Capacity of Outputs: 2 Amps maximum, each output
Operating Temperature Range: 0-70 deg. C., 32-158 deg. F.
Installation Environment: Protected from weather, code B, IEC60945.
Safe Vicinity to Compass: TBD
POWER INPUTS:

Kahlenberg Instructions, M-522, Software Rev. R., Rev. 10/7/2019
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Main Power M-522 Controller, A.C. 100-240 VAC 50/60Hz (Terminals 1 and 2)
Emergency Power M-522 Controller, D.C. 8-30 VDC (Terminals 3 and 4)
Main Power for Morse Light: 110-240VAC OR 24 VDC (Terminals 23 and 24)
POWER OUTPUTS:
Output Forward Horn: 110-240 VAC (Terminals 5 and 6)
Output Aft Horn: 110-240 VAC (Terminals 7 and 8)
Output Forward Horn: 24 VDC (Terminals 9 and 10)
Output Aft Horn: 24 VDC (Terminals 11 and 12)
Output Morse Light: 110-240 VAC or 24VDC (Terminals 25 and 26)
**NOTE: 24 Volt output to horns will only function when main A.C. input to controller is not connected,
or is interrupted in the case of A.C. mains failure on board.
External Switch Connections (Relays using External 24 Volt D.C. Power Source):
External At-Will Push Buttons, Horns (1) (Terminal 30)
External Morse Key or Momentary Push button, Morse Light (1) (Terminal 31)
External General Emergency Alarm Push Button or External GEA Input (1) (Terminal 32)
External Abandon Ship Push Button (1) (Terminal 33)
PA Interrupt (1) (Terminal 34)
External Momentary Pushbutton for Automated Horn Signals (1) (Terminal 29)
Negative D.C. Connection, External 24 VDC Power, (1) (Terminals 35, 36)
Additional Contact Closure Connections:
General Emergency Alarm: Output for GEA Signal from M-522 for relay connection to other external
sound/light devices, (Terminals 19 and 20)
Sound Surveillance System: Normally Open Contacts close upon M-522 activation of horn, bell, or gong,
for connection to mute external Sound Surveillance System, (Terminals 21 and 22)
Other Connections:
CAN (Control Area Network) (CAN 2.0A, 29 bit identifiers) Connection to connect additional
M-522 Controllers (Terminals 37-39) Note: If CAN connection is utilized to wire only M-522s
to each other, external of a properly configured CAN bus, a 120 Ohm resistor must be wired in
parallel as a jumper between terminals 37 and 38 (CAN HIGH and CAN LOW) on each
networked M-522 to provide resistance on this circuit.
2.) INSTALLATION -
WARNING: HIGH VOLTAGE MAY BE PRESENT INSIDE ENCLOSURES. BE SURE
TO SHUT OFF POWER, TAG OUT, AND VERIFY NO VOLTAGE IS PRESENT
BEFORE INSTALLING OR ATTEMPTING TO SERVICE THIS UNIT. FAILURE TO
FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH.

Kahlenberg Instructions, M-522, Software Rev. R., Rev. 10/7/2019
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INITIAL SETUP:
The M-522 is a programmable unit requiring initial setup in order to properly operate the devices
intended, and to customize the function of the unit dependent on various connection
requirements to other controllers that are to operate in conjunction with the M-522 such as
external General Alarm Systems.
Setting SW1 Switches
On the internal circuit board of the M-522 there is a switch assembly labeled SW1. Settings on
this switch assembly determine permanent functionality of the unit not programmable from the
keypad. Settings and functionality are as follows:
SW1 Functionality:
SW1
Tab 1
CAN Address (LSB)
Tab 2
CAN Address (MSB)
Tab 3 CAN Communication
(Off = Disable On = Enable)
Tab 4
Ship Size (Off <100m On >100m)
Tab 5
GEA Function (MSB)
Tab 6
GEA Function (LSB)

Kahlenberg Instructions, M-522, Software Rev. R., Rev. 10/7/2019
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STEP 1.)
Tabs 1 through 3: Factory Default Setting is OFF.
Tabs 1 through 3 concern installations where 2 or more M-522 Controllers are installed onboard.
These tabs control how the M-522 Controllers will communicate with each other.
If there is only one M-522 Controller to be installed, all Tabs 1 through 3 should remain OFF.
Proceed to step 2.
For 2 or more M-522 Controllers, Tab 3 must be set to ON. Tab 1 and 2 must be set to OFF on
the main M-522 Unit that is wired to the sound and light producing devices. Any additional M-
522 Controllers that are connected act only through CAN connection to the main M-522, and
must have Tab 1 and 2 set as follows for up to 3 additional units:
Tab 1
Tab 2
Unit 2
ON
OFF
Unit 3
OFF
ON
Unit4
ON
ON
STEP 2.)
Tab 4: Factory Default Setting is OFF.
Tab 4 determines whether or not the M-522 Controller will allow the aft and forward horn to
sound simultaneously. Per IMO Rules, where two ship whistles are installed a distance greater
than 100M apart, they must not be sounded simultaneously. The factory default setting of OFF
will allow simultaneous sounding of the whistles. If the ship whistles are greater than 100 meters
apart, Tab 4 should be changed to the ON position to prevent the ship whistles from being
sounded simultaneously as a combined whistle system per IMO Rules.
STEP 3.)
Tabs 5 and 6: Factory Default Setting is OFF.
Tabs 5 and 6 control the General Emergency Alarm function (12-24VDC input at terminal 32).
Depending on the configuration of the tabs, the controller will either generate the GEA code as
activated by a momentary pushbutton or maintained pushbutton; OR will accept an externally
generated signal from an external alarm panel. See the table below for valid configurations of
the GEA Function tabs.
Tab 5
Tab 6
Function
OFF
OFF
Momentary Pushbutton
OFF
ON
Maintained Pushbutton
ON OFF
Externally Generated GEA
Signal

Kahlenberg Instructions, M-522, Software Rev. R., Rev. 10/7/2019
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MOUNTING AND CONNECTIONS:
The M-522 is to be installed in a location protected from weather. It mounts easily into a console
and is secured by fastening the bezel through the console to the enclosure with four (4) 4mm x
40mm flat head screws (provided). An opening of 5.89” (150mm) wide x 3.28” (84mm) high
should be made in the console where the unit is to be placed. The M-522 includes a gasket used
to provide a seal between the bezel of the M-611 and the console surface. See details per Drg. 3-
6728. An additional bead of RTV silicone sealant may be applied around the perimeter of the
Bezel for additional ingress protection if the mounting surface is not perfectly flat or has a poor
finish.
For bulkhead mounting the rear of the housing includes (4) holes for mounting the housing
directly to the bulkhead, per Drg. 3-6728. If the unit is bulkhead mounted, the mounting
fasteners should be sealed with RTV silicone sealant or equivalent to protect against water
ingress.
The M-522 includes male/female terminal blocks that can be disconnected for easier wiring to
the unit, labeled per Drg. 3-6749. Wiring should be connected per Drg. 3-6749 utilizing shielded
cables and wire gauge per electrical requirements as given below:
Power Source Required: 100-240 Volt A.C., 50/60 Hz, 1 Ph. AND/OR 8-30 Volts D.C.
Electrical Current Flow Required : .5 Amp
Output Power: 100-240 Volt A.C., 50/60 Hz, 1 Ph., AND/OR 8-30 Volts D.C.
Switching Capacity of Outputs: 2 Amps maximum, each output
Operating Temperature Range: 0-70 deg. C., 32-158 deg. F.
Enclosure Cable Fittings: (3), requiring 10-14 mm cable
ADDITIONAL PROGRAMMING REQUIRED AT THE KEYPAD:
1.) Device Setup:
On certain vessels, some of the sound signaling devices such as aft horn, may not be installed. In
those cases, the M-522 can be customized to exclude the user from being able to select or attempt to
operate those devices that do not exist. To disable a device, simultaneously press and hold the
“Horn Select” Button and the button of the device to be disabled for ten seconds continously.
TheLED on the deselected device will flash, notifying the user when the device is disabled. For
example, pressing the “Horn Select” and “Aft Horn” button simultaneously for 10
seconds will disable the “Aft Horn” switch. To re-enable a device, the process is the same, and the
LED will stop flashing when the device is returned to active status. Once the devices that are not
included in the sound signal system have been disabled, the M-522 is set up and ready for normal
use.

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3.) OPERATION
At-Will Operation of Connected Devices:
The buttons above the ship graphic on the membrane switch panel correspond to each of the
devices controlled by the M-522 unit. To operate any device connected to the M-522 on an “At-
Will basis, simply press the appropriate button as follows:
These switches will illuminate whenever the corresponding device is activated.
Automatic Operation of Connected Devices:
The M-522 generates automated signal codes for vessels in restricted visibility conditions
according to International Maritime Organization requirements (IMO COLREGS, RULE 35).
These automated signals are controlled by the row of buttons directly beneath the ships graphic
on the faceplate as shown below:
Automatic On/Off
The Automatic On/Off button starts and stops the automatic signaling of any selected horns or
morse light. A red LED on this switch will illuminate when automatic signaling is turned on.
When turning automatic signaling on, the first “on” signal or blast from the horn occurs
approximately 5 seconds after the button is pressed.
Cycle Code Interval
The Cycle Code Interval button selects the interval (120, 90, 60, or 40 seconds) that the selected
code will be repeated. Per IMO requirements, a 120 second interval is standard. However, this
button can be pressed repeatedly to cycle through the available time intervals to signal more
frequently.
AFT HORN
MORSE LIGHT
FORWARD
HORN

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Horn Select Button
The Horn Select Button will select which horns are to be activated by the automated signal. Aft
Horn, Forward Horn, or Both Horns (if installed) can be selected by repeatedly pressing the
button. Red LEDs will illuminate on the corresponding buttons above the ship graphic that
represent each horn to indicate the current selection.
Morse Light On/Off Button
The Morse Light is activated by the automated restricted visibility code when selected by this
button. The Red LED in the Morse Button above the ship graphic will illuminate when it is
“On”.
Automatic Restricted Visibility Code Selections:
Pressing any of the Restricted Visibility Code Selection buttons will choose the automated
restricted visibility signal to be produced as follows per IMO COLREGS, RULE 35:
One Prolonged Signal______________________Making Way through Water (Underway)
Two Prolonged Signals____ Underway But Stopped and making no way through the water
One Prolonged Signal and Two Short Signals______________Vessel not under command
One Short Signal, One Long Signal, One Short Signal_______________Vessel At Anchor
**This signal will only operate at 60 seconds intervals per Rule 35g, regardless of cycle
interval selected.
One Prolonged Signal and Three Short Signals__________________Vessel being Towed
Once automatic restricted visibility signaling is activated, it will continue until turned off by the
“Automatic On-Off” switch. Any other At-Will button, externally connected or internal to the
M-522 will discontinue the automated signal which must be restarted at the “Automatic On-Off”
switch, or at a remotely located “Automatic On-Off” switch if installed. The General Alarm,
Abandon Ship, Anchor, Aground or Maneuvering Signals if activated will also discontinue the
restricted visibility code.

Kahlenberg Instructions, M-522, Software Rev. R., Rev. 10/7/2019
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Automatic Maneuvering Signals: IMO COLREGS RULE 34
Pressing any of the Maneuvering Signals will generate the automated code for that signal as
indicated on the buttton. Pressing a Maneuvering Signal will discontinue other automated
horn/light restricted visibility signals in progress.
Dimmer Switches:
Dimmer Switches control the brightness of the membrane switch display on the
M-522. Red LEDS, and all white backlighting are controlled by these switches.
EXTERNAL PUSH BUTTON CONNECTIONS:
The M-522 includes 24 Volt D.C. inputs allowing for the connection of external “At-Will”
momentary push buttons for remote control of the horns and morse light connected to the M-522
Control. Also included is an input for additional remote “Start Signal” momentary push buttons
if it is desired to start the automatic horn/light restricted visibility code from a remote location.
See Drg. 3-6749 for connection locations. These external push buttons make contact for 24
Volts to the M-522 input from a remote power source. An optional 100-240 VAC to 24 VDC
power supply model M-800 is available as an additional item to provide 24 V. D.C. power for the
external push buttons.
OTHER FUNCTIONS OF THE M-522:
General Emergency Alarm: (See also SW1 Switch Settings in “Installation” Section.
The M-522 is able to generate the General Emergency Alarm (Seven Short Signals followed by
one long signal repeating without pause (19 seconds total code cycle) per SOLAS requirements.
This signal will operate all connected horns and lights. This must be started and stopped by an
external push button (momentary or maintained, not included with M-522) that is constructed in
accordance with requirements as stated by various flag state authorities. This connection
includes a .5 second delay feature before the signal will be generated, in case the switch is
accidentally depressed. Once started, the GEA signal code can only be interrupted by the Public
Address System (if connected to M-522) or by the Abandon Ship Code. See Drg. 3-6749 for
connections.

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In the event an external General Emergency Alarm System is used to generate the GEA code, an
input is available on the M-522 to accept this signal which will in turn operates all lights and
horns connected to the M-522. See Drg. 3-6749 for connections.
Abandon Ship Code:
The M-522 is able to generate the Abandon Ship Code (1 second on, 1 off, 7 on, 1 off, 1 on, 1
off, 7 on, 3 seconds off, repeating) per certain flag state requirements. This must be started and
stopped by an external push button (momentary or maintained, not included with M-522) that is
constructed in accordance with requirements as stated by various flag state authorities. This
connection includes a .5 second delay feature before the signal will be generated, in case the
switch is accidentally depressed. Once started, the signal overrides all other signaling functions
of the M-522 except the PA Interrupt, to mute the signal in the event the external Public Address
is used. See Drg. 3-6749 for connections.
Sound Surveillance “Mute” Relay:
A normally open relay is included in the M-522 that closes upon the activation of any horn
controlled by the M-522 Control. This is available to mute an external Sound Surveillance
System if installed on the vessel. See Drg. 3-6749 for connection location.
4.) CARE AND MAINTENANCE -
The M-522 Sound and Light Control is a solid state device designed to provide many years of
maintenance free operation. However, in the event that a power surge takes place or
inappropriate wiring connections are made, fuses within the unit will fail to prevent damage to
the circuitry.
SPARE FUSE LOCATIONS: Spare fuses are included with the M-611 Unit and exist on the
circuit board. 2 Amp fuses are located at F13, F14, and F15. These are replacements for fuses
at locations F3-F11. 500 milliamp fuses are located at F12 and F16. These are replacements
for fuses at locations F1 and F2.
There are no additional user serviceable components included in the M-522. However if any
parts or complete circuit boards as listed on the attached Parts List drawings are required for any
reason, please refer to the associated part number when ordering. If the M-522 should fail to
operate correctly for reasons other than a blown fuse as mentioned above, contact Kahlenberg
Industries for recommended action or return to Kahlenberg for prompt analysis and repair.
For long term storage, the M-522 should be kept in dry conditions, inside dustproof corrogated
packaging or equivalent including a silica gel packet for absorption of humidity.
When cleaning the membrane switch panel, we recommend the use of Windex (or equivalent) or
a mild soap/water solution applied with a soft cotton cloth.

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5.) DRAWING REFERENCES
Outline Dimensions: 3-6728
Parts List: 3-6729
Wiring Diagrams: 3-6749 (General) or as Specified by Contract
Kahlenberg Industries, Inc.
1700 12th St., P.O. Box 358
Two Rivers, WI 54241 U.S.A.
Ph: 920-793-4507
Fx: 920-793-1346
www.kahlenberg.com

M-611, M-522 CAN Messages
Message from Master (should be received only)
CAN-ID – Unit Address (0x001)
Byte 0 – Unit Address (0x01)
Byte 1
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
AFT Horn
Red LED AFT Horn Active Gong RED LED Gong Active Bell Red LED Bell Active Morse Red LED Morse Active
Byte 2
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
FWD
Horn Red
LED
FWD
Horn
Active
Auto Code
Red LED Timer 120 Seconds Timer 90 Seconds Timer 60 Seconds Timer 40 Seconds Code 1 LED
Byte 3
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Code 2
LED Code 3 LED Code 4 LED Code 5 LED Anchor LED Aground LED Abandon PB GEA PB
Byte 4 - Year (2 digits)
Byte 5
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Day LSB Day b2 Day b3 Day b4 Month
LSB Month b2 Month b3 Month MSB
Byte 6
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Hour LSB Hour b2 Hour b3 Hour b4 Hour MSB Unused Unused Day MSB
Byte 7 - Minute
Output On/Active = 1, Output Off/Inactive = 0

Message from slave (or alternate device)
CAN-ID – Unit Address (0x002 to 0x004)
Byte 0 – Unit Address (0x02 to 0x04)
Byte 1
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Horn
Select Morse Select Aft Horn Key Gong Key Bell Key Morse Light Key FWD Horn Key Auto Code Key
Byte 2
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Timer
Select Code 1 Key Code 2 Key Code 3 Key Code 4 Key Code 5 Key At Anchor Key Aground Key
Byte 3
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Alt Stbd
Key Alt Port Key Astern Key Danger Key 120VAC Power Fail Remote Start PB At Will PB Morse Light PB
Byte 4
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
PA Int PB GEA PB Abandon
Ship PB Unused Unused Unused Unused Unused
Key Pressed = 1, Key Released = 0
Example communication
; Message Number
; | Time Offset (ms)
; | | Bus
; | | | Type
; | | | | ID (hex)
; | | | | | Reserved
; | | | | | | Data Length Code
; | | | | | | | Data Bytes (hex) ...
; | | | | | | | |
; | | | | | | | |
;---+-- ------+------ +- --+-- ----+--- +- -+-- -+ -- -- -- -- -- -- --
FWD HORN
171) 5383.214 1 Rx 00000002 00 8 02 00 00 00 00 00 00 00
172) 5408.895 1 Rx 00000001 00 8 01 00 08 00 00 7B 80 2E
173) 5446.479 1 Rx 00000002 00 8 02 40 00 00 00 00 00 00 (Slave FWD Horn Key Pressed)
174) 5450.233 1 Rx 00000001 00 8 01 00 0A 00 00 7B 80 2E (Master FWD Horn Active)
MORSE KEY
102) 3206.715 1 Rx 00000002 00 8 02 00 00 00 00 00 00 00
103) 3229.197 1 Rx 00000001 00 8 01 00 08 00 00 7B 81 31
104) 3269.937 1 Rx 00000002 00 8 02 20 00 00 00 00 00 00 (Slave Morse Key Pressed)
105) 3292.291 1 Rx 00000001 00 8 01 80 08 00 00 7B 81 31 (Master Morse Active)
FWD HORN SELECT
73) 2335.323 1 Rx 00000002 00 8 02 00 00 00 00 00 00 00
74) 2335.920 1 Rx 00000001 00 8 01 00 08 00 00 7B 81 31
75) 2337.157 1 Rx 00000002 00 8 02 01 00 00 00 00 00 00 (Slave Horn Select Pressed)
76) 2399.100 1 Rx 00000001 00 8 01 00 09 00 00 7B 81 31 (Master FWD Horn LED Active)