Kahlenberg M-611 Installation and operating instructions

Instructions, M-611, Software Rev. R. Rev. 12/19/2023
1
INSTRUCTIONS
INSTALLATION, OPERATION, AND
MAINTENANCE
KAHLENBERG MODEL M-611
SOUND AND LIGHT (WHISTLE) CONTROL
M-611 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 HORNS, BELL AND GONG, AND MORSE LIGHT WHEN MANEUVERING AND IN RESTRICTED
VISIBILITY PER COLREG '72 INCLUDING SOLAS GENERAL EMERGENCY ALARM. BASIC DIMENSIONS:
7.5'' x 5'' x 3.375'' (191mm x 127mm x 86mm). Net Weight: 2.62 lbs./ 1.19 kg, RAL 9005 JET BLACK,
PER DRG. 3-6540. (**INCLUDES SPARE FUSE SET INTERNAL TO UNIT)

Instructions, M-611, Software Rev. R. Rev. 12/19/2023
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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 8-14
Troubleshooting 14
Maintenance 14
Storage 14
Reference Document List 15
Drawings 16-18
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-611 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-611 Sound and Light Control is to provide convenient operation of sound
signaling devices including navigation horns (ship’s whistles), Bell, Gong, 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-611 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-611, passing the signal
through to all sound devices and lights connected to the M-611. The M-611 Sound and Light
Control is also designed to be operated in conjunction with external Sound Surveillance Systems
and/or Public Address systems.
Multiple M-611 units can be utilized on the vessel and will communicate with each other in
cases where multiple control stations are required. The M-611 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-611 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-611 Sound and Light Control ships as a complete assembled unit. In addition, (3) three
of each P546-12 and P546-10 Button Overlays are included in a poly bag taped to the outside of
the M-611 enclosure. The complete M-611 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: 7.75” x 3.63” x 5.25” (197 x 92 x 133mm)
Enclosure Cable Fittings: (4) 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: 3-6540
Parts List: 3-6542
Wiring Diagrams: 3-6705 (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-611 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-611 such as
external General Alarm Systems.

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Setting SW1 Switches
On the internal circuit board of the M-611 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-611 Controls are installed onboard.
These tabs control how the M-611 Control will communicate with each other.
If there is only one M-611 Control to be installed, all Tabs 1 through 3 should remain OFF.
Proceed to step 2.
For 2 or more M-611 Controls, Tab 3 must be set to ON. Tab 1 and 2 must be set to OFF on the
main M-611 Unit that is wired to the sound and light producing devices. Any additional M-611
Controllers that are connected act only through CAN connection to the main M-611, 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-611 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-611 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 6-1/2” (165mm) wide x 4” (101mm)
high should be made in the console where the unit is to be placed. The M-611 includes a
gasket used to provide a seal between the bezel of the M-611 and the console surface. See
details per Drg. 3-6540. 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. 3-6540. 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-611 includes male/female terminal blocks that can be disconnected for easier wiring to
the unit, labeled and defined per Drg. 3-6705. Wiring should be connected per Drg. 3-6705
utilizing shielded cables per electrical requirements as given above in the Electrical
Requirements Section.
EXTERNAL PUSH BUTTON CONNECTIONS:
The M-611 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-
611 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. 3-705 for connection locations. These external push buttons make
contact for 24 Volts to the M-611 input from a remote power source. See Drg. 3-6705 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-611 Units via CAN Connection:
If installing more than one M-611 unit on a vessel, the CAN connection must be utilized so the
M-611 units can communicate with each other. When installed with the CAN connection
(Terminals 37-39 per Drg. 3-6705), the “master” M-611 is connected to installed output devices
(horns, lights), while additional M-611 units are connected only to a power source, and the
“master” M-611 via the CAN connection.
Note: If CAN connection is utilized to wire only M-611s 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-611 to provide resistance
on this circuit.
OPERATION
INITIAL FIRST TIME PROGRAMMING REQUIRED AT THE KEYPAD:
1.) Date and Time Setup:
To set date and time, press and hold the “clock” button for 10 seconds. The year
will display in the Date and Time LCD Display on the unit. To change the year, use the
“Dimmer” buttons and . Press the Morse Light Select Button to set.
Once the year is set, the month will appear, followed by day, hour, and minute, all
changed and set with the same procedure as was done to set the year.
2.) Device Setup:
On certain vessels, some of the sound signaling devices such as aft horn, or gong may
not be installed. In those cases, the M-611 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. The Date and Time Display will
notify the user when the device is disabled. For example, pressing the “Horn Select”
and “Gong” button simultaneously for 10 seconds will disable the “Gong”
switch. To re-enable a device, the process is the same. The Date and Time Display will
notify the user when the device is re-enabled. Once the devices that are not included in
the sound signal system have been disabled, the included P546-12 and P546-10 Button
Overlays may be permanently placed over the unused switches, to eliminate them from
view on the keypad. The M-611 is now set up and ready for normal use.

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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-611 unit. To operate any device connected to the M-611 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-611 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
GONG
MORSE LIGHT
FORWARD
HORN
BELL

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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-611 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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Anchor Button (ON/OFF)
The Anchor Button automatically generates the “At Anchor” signal to the Bell and Gong, or Bell
only if the Gong is not installed on vessels under 100 meters in length. At Anchor will sound the
Bell, immediately followed by the Gong 5 seconds on, 50 seconds off, repeating. If an
automatic horn/light signal is already activated when this button is pressed, the horn/light code
will automatically change to “At Anchor” code on the horn/light signal as well.
Aground Button (ON/OFF)
The Aground Button generates the “Ship Aground” signal to the Bell and Gong, or Bell only if
the Gong is not installed on vessels under 100 meters in length. “Aground” sounds the Bell
three strokes, 5 seconds continuous, three strokes, followed by the Gong, 5 seconds on, 43
seconds off, repeating.
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-611. Red LEDS, and all white backlighting are controlled by these switches.
OTHER FUNCTIONS OF THE M-611:
General Emergency Alarm: (See also SW1 Switch Settings in “Installation” Section)
The M-611 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

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external push button (momentary or maintained, not included with M-611) 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-611) or by the Abandon Ship Code. See inputs 32 and
33 on Drg. 3-6705 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-611 to accept this signal which will in turn operates all lights and
horns connected to the M-611. See Drg. 3-6705 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-611 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.
Abandon Ship Code:
The M-611 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-611)
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-611 except the PA Interrupt, to mute the signal in the event the external
Public Address is used. See input 33, Drg. 3-6705 for connections.
Sound Surveillance “Mute” Relay:
A normally open relay is included in the M-611 that closes upon the activation of any horn, bell,
or gong controlled by the M-611 Control. This is available to mute an external Sound
Surveillance System if installed on the vessel. See relay output 21 and 22, Drg. 3-6705 for
connection location.
Internal Log Function:
The M-611 automatically records the last 80 events that have occurred within the controller.
An internal USB connection is included which can be connected to an external P.C. to access
and retrieve this data. Using a terminal program, connect the M-611 via USB connection to a
COM port on the P.C.. Once the COM port is known, set up the port as in the following
example:

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Once connected, type “?” at the command prompt and the last 80 events will display as text.
External (Remote) Switches (if installed as additional items):
The M-611 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-611 per Drg. 3-6705 will
activate the horn or horns currently selected as active on the M-611 unit. This momentary
push button when pressed will also discontinue any automatic signaling cycle currently running
on the M-611 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-611 per Drg. 3-6705 will
activate the morse light connected to the M-611 unit. This momentary push button when
pressed will also discontinue any automatic signaling cycle currently running on the M-611 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:

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When pressed, this momentary push button connected to the M-611 per Drg. 3-6705 will
remotely activate the automatic restricted visibility code currently selected on the M-611 unit.
Output of the restricted visibility code is to devices (horns, morse lights) as currently selected at
the M-611 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-
611 unit.
CARE AND MAINTENANCE
Troubleshooting, Repair, and Service:
The M-611 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-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.
If the M-611 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-611
when initially setup matches the operation expected of the unit in your installation.
There are no additional user serviceable components included in the M-611. 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-611 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-611 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-611 Whistle Control
Drawing 3-6540
Parts List, M-611 Whistle Control
Drawing 3-6542
General Wiring Diagram, M-611 Whistle Control
Drawing 3-6705
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