Kahlenberg M-522 User manual

Instructions, M-6522, Software Rev. T. Rev. 12/19/2023
1
INSTRUCTIONS
INSTALLATION, OPERATION, AND
MAINTENANCE
KAHLENBERG MODEL M-522
SOUND AND LIGHT (WHISTLE) CONTROL
M-522 SOUND AND LIGHT CONTROL, BULKHEAD OR FLUSH MOUNT, IP56 ENCLOSURE, WITH
BACKLIT DIMMABLE MEMBRANE SWITCH, 110-240 VOLT A.C. 50/60HZ 1 PH., AND 24 VOLT D.C..
CONTROLS MULTIPLE HORNS AND MORSE LIGHT WHEN MANEUVERING AND IN RESTRICTED
VISIBILITY PER COLREG '72 INCLUDING SOLAS GENERAL EMERGENCY ALARM. BASIC DIMENSIONS:
6.5'' x 4.5'' x 6.3'' (165mm x 114mm x 160mm). Net Weight: 2.62 lbs./ 1.19 kg, ANODIZED
ALUMINUM PANEL BEZEL, RAL 9005 JET BLACK PER DRG. 3-6728.
**INCLUDES SPARE FUSE SET INTERNAL TO UNIT

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Table of Contents Page
Introduction 2
Important Safety Instructions 3
General Description 3
Package Contents 4
Electrical Requirements 4
Performance and Technical Data 4
Installation 4-8
Operation 8-13
Troubleshooting 13
Maintenance 13
Storage 13
Reference Document List 14
Drawings 15-17
WARNING! This instruction
manual contains important
instructions for operating this product.
Read this manual thoroughly before
operating the product.
Failure to properly follow all the
instructions and precautions can cause
serious injury or death.
Thank you for purchasing a Kahlenberg
Industries product. Please contact us if you
have any questions.
Record the model and serial numbers from
your product’s nameplate below for future
reference:
Model No.:_________________________
Serial No.:__________________________
Date of Purchase:____________________

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IMPORTANT SAFETY INSTRUCTIONS
WARNING
SHOCK
There is a danger of electric shock.
Ensure you have sufficient electrical supply for supporting the requirements of the controller.
The M-522 Enclosure must be grounded. See appropriate wiring diagrams included herein.
ALWAYS remove and lock out/tag out electrical power before performing maintenance.
GENERAL DESCRIPTION
The function of the M-522 Sound and Light Control 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 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 four 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.

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PACKAGE CONTENTS
The M-522 Sound and Light Control ships as a complete assembled unit. In addition, (3) three
P546-10 and (2) two P546-11 Button Overlays are included in a poly bag taped to the outside of
the M-522 enclosure. The complete M-522 and button overlays are packaged together within
anti-static wrap.
ELECTRICAL POWER REQUIREMENTS
Voltage Required: 100-240 Volts A.C. 1 Ph., 50 or 60 Hz
8-30 Volts D.C. (optional emergency backup voltage)
Max. Current: .5 Amps
Output Relay Capacities: 110-240 Volt A.C., 50/60 Hz, 1 Ph.,
OR 8-30 Volts D.C. (as indicated in wiring diagrams)
2 Amps Max. each output relay
Weight: 2.62 lbs./1.18 kg
Dimensions: 6.5” x 4.5” x 6.3” (165 x 114 x 160mm)
Enclosure Cable Fittings: (3) Four, 10-14 mm cable
Operating Temperature Range: 0-70 deg. C., 32-158 deg. F.
Installation Environment: Protected from weather, code B, IEC60945.
Ingress Protection: IP65
Safe Vicinity to Compass: TBD
ADDITIONAL DRAWINGS INCLUDED IN THIS MANUAL FOR REFERENCE:
Outline Dimensions: 3-6728
Parts List: 3-6729
Wiring Diagrams: 3-6749 (General) or as Specified by Contract
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.
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.

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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)

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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 Controls are installed onboard.
These tabs control how the M-522 Control will communicate with each other.
If there is only one M-522 Control to be installed, all Tabs 1 through 3 should remain OFF.
Proceed to step 2.
For 2 or more M-522 Controls, 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
Unit 4
ON
ON
STEP 2.)
Tab 4: Factory Default Setting is OFF.
Tab 4 determines whether or not the M-522 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.

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Tab 5
Tab 6
Function
OFF
OFF
Momentary Pushbutton
OFF
ON
Maintained Pushbutton
ON OFF
Externally Generated GEA
Signal
INSTALLATION, PLACEMENT:
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-522 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.
ELECTRICAL CONNECTIONS:
The M-522 includes male/female terminal blocks that can be disconnected for easier wiring to
the unit, labeled and defined per Drg. 3-6749. Wiring should be connected per Drg. 3-6749
utilizing shielded cables per electrical requirements as given above in the Electrical
Requirements Section.
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 Auto 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. See Drg. 3-6749 for
connection locations. An optional 100-240 VAC to 24 VDC power supply model M-800 is
available as an optional additional item to provide power for the external push buttons.

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Connecting Multiple M-522 Units via CAN Connection:
If installing more than one M-522 unit on a vessel, the CAN connection must be utilized so the
M-522 units can communicate with each other. When installed with the CAN connection
(Terminals 37-39 per Drg. 3-6749), the “master” M-522 is connected to installed output devices
(horns, lights), while additional M-522 units are connected only to a power source, and the
“master” M-522 via the CAN connection.
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.
OPERATION
INITIAL FIRST TIME PROGRAMMING REQUIRED AT THE KEYPAD:
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 continuously. The LED on the deselected device will flash, notifying the user when the
device is disabled. For example, pressing the “Horn Select” and the “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 included P546-10 and P546-11 Button Overlays may be permanently placed over
the unused switches, to eliminate them from view on the keypad. The M-522 is now set up and
ready for normal use.
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:
AFT HORN
MORSE LIGHT
FORWARD
HORN

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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.
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.

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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.

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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 button. 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.
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 inputs 32 and
33 on Drg. 3-6749 for connections.
In the event an external General Emergency Alarm System is used to generate the GEA code,
input 32 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.
A “GEA active” output relay at terminals 19 and 20 will close synchronous with a GEA code
being produced internall by the M-522 if a push button is connected to the GEA input at
terminal 32. This “GEA active” output can be connected to an external relay (not exceeding 2
amp current draw), and through that relay connected to additional sounding devices on the
vessel.

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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 signalling
functions of the M-522 except the PA Interrupt, to mute the signal in the event the external
Public Address is used. See input 33, 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, bell,
or gong controlled by the M-522 Control. This is available to mute an external Sound
Surveillance System if installed on the vessel. See relay output 21 and 22, Drg. 3-6749 for
connection location.
External (Remote) Switches (if installed as additional items):
The M-522 accepts additional external switches for an External Horn Switch, External Morse
Light Switch, and External Switch for Start Automatic. External switches if connected must be
momentary type, such as Kahlenberg Model M-313 “Horn” Push Button.
Remote Horn Switch:
When pressed, this momentary push button connected to the M-522 per Drg. 3-6749 will
activate the horn or horns currently selected as active on the M-522 unit. This momentary
push button when pressed will also discontinue any automatic signaling cycle currently running
on the M-522 Unit. The horn will sound continuously as long as the button is pressed. When
released, the horn or horns will stop sounding.
Remote Morse Light Switch:
When pressed, this momentary push button connected to the M-522 per Drg. 3-6749 will
activate the morse light connected to the M-522 unit. This momentary push button when
pressed will also discontinue any automatic signaling cycle currently running on the M-522 Unit.
The morse light will light continuously as long as the button is pressed. When released, the
morse light will turn off.
Remote Start Automatic Switch:
When pressed, this momentary push button connected to the M-522 per Drg. 3-6749 will
remotely activate the automatic restricted visibility code currently selected on the M-522 unit.
Output of the restricted visibility code is to devices (horns, morse lights) as currently selected at

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the M-522 unit. Once automatic signaling is remotely started, it must be stopped by pressing
an “at-will” horn, or “at-will” morse light switch, or the “Automatic On/Off” button on the M-
522 unit.
CARE AND MAINTENANCE
Troubleshooting, Repair, and Service:
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, preventing damage to
the circuitry. Fuse replacement is the only user serviceable repair that can be performed on
this unit.
SPARE FUSE LOCATIONS: Spare fuses are included with the M-522 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.
If the M-522 otherwise does not perform as expected, consult the Installation Section of this
manual, in particular the “Initial Setup” section to verify that the configuration of the M-522
when initially setup matches the operation expected of the unit in your installation.
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.
Storage:
For long term storage, the M-522 should be kept in dry conditions, inside anti-static bag or anti
–static plastic wrap, within dustproof corrugated packaging or equivalent including a silica gel
packet for absorption of humidity.
Cleaning:
When cleaning the membrane switch panel, we recommend the use of a mild soap/water
solution applied with a soft cotton cloth. Do not use other cleaning solvents of any kind.

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REFERENCE DOCUMENTS:
Outline Dimensions, M-522 Whistle Control
Drawing 3-6728
Parts List, M-522 Whistle Control
Drawing 3-6729
General Wiring Diagram, M-522 Whistle Control
Drawing 3-6749
Kahlenberg Industries, Inc.
1700 12th St., P.O. Box 358
Two Rivers, WI 54241 USA
Ph: 1-920-793-4507
Fx: 1-920-793-1346
www.kahlenberg.com