Megaleds Orphos System manual
REV. 02 - MAY., 2020th
INSTALLATION HANDBOOKINSTALLATION HANDBOOK
by
MEGALEDS Indústria, Comércio e Prestação de Serviços em Iluminação Ltda EPP.
Rua Heriberto Hulse, 1985 – Sala 03 – Jardim Santiago
SÃO JOSÉ - SC - Brazil – CEP 88113-000
tel. (48) 3035.7755
e-mail: [email protected]
website: www.megaleds.com.br
All rights reserved. No part of this publication may be reproduced, stored in a retrieval sys-
tem, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of MEGALEDS Indústria,
Comércio e Prestação de Serviços em Iluminação Ltda. (brazilian company) (MEGALEDS
Industry, Commerce and Services in Ligthing Ltd.) Printed and Published in the Brazil simul-
taneously in United State of America.
I
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (JAN., 2020th)
SUMMARY:
1. INTRODUCTION: 1
2. SAFETY RECOMMENDATIONS: 3
3. WARRANTY: 5
4. GENERAL DESCRIPTION OF ORPHOS LINE: 7
5. TECHNICAL DATA AND CONFORMITY: 22
5.1 TECHNICAL DATA 22
5.2 CERTIFICATION OF CONFORMITY 26
6. PREPARING PROCEDURES FOR INSTALLATION: 29
7. INSTALLATION PROCEDURE OF THE ORPHOS Fi8: 31
7.1 PROCEDURE OF THE ORPHOS WITHOUT THE EXTENSIVE BASE SET (44): 31
7.1.1 INSTALLATION OF C-TOOGLE NYLON ANCHOR (38): 31
7.1.2 INSTALLATION OF THE BOAT POWER ELECTRIC WHIP (46): 36
7.1.3 AMENDMENT OF THE BOAT POWER ELECTRIC WHIP (46)
AND THE FEMELE CONNECTOR POWER ELECTRICH WHIP (47): 37
7.1.4 ASSEMBLY OF THE BRACKET BOULTED SET (35) ON THE TARGA
OR TOP OF THE BOAT: 41
7.2 PROCEDURE OF THE ORPHOS WHIT THE EXTENSIVE BASE SET (44): 44
7.2.1 INSTALLATION OF C-TOOGLE NYLON ANCHOR (38): 44
7.2.2 INSTALLATION OF THE BOAT POWER ELECTRIC WHIP (46): 46
7.2.3 AMENDMENT OF THE BOAT POWER ELECTRIC WHIP (46)
AND THE FEMALE CONNECTOR POWER ELECTRIC WHIP (47): 47
7.2.4 ASSEM. OF THE EXT. BASE (44) AND THE BRACK. BOLT. SET (35): 47
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INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (JAN., 2020th)
8. INSTALLATION OF THE COAXIAL CABLE TO THE DIGITAL TV ANTENNA: 52
8.1 PROCEDURE OF THE COAXIAL CABLE TO THE DIGITAL TV ANTENNA (44): 52
8.1.1 INSTALLATION OF C-TOOGLE NYLON ANCHOR (38): 52
8.1.2 INSTALLATION OF THE POWER ELECTRIC WHIP (46) AND
THE COAXIAL CABLE (50) OF THE DIGITAL TV ANTENNA (16): 52
8.1.3 INSTALLATION OF THE BRACKET BOLTED SET (35): 54
8.1.4 CONNECTION OF THE COAXIALCABLE (50) IN THE CONECTOR (51): 55
8.2 PROCEDURE OF THE ORPHOS WHIT THE EXTENSIVE BASE SET (44): 56
8.2.1 INSTALLATION OF C-TOOGLE NYLON ANCHOR (38): 56
8.2.2 INSTALLATION OF THE POWER ELECTRIC WHIP (46) AND
THE COXIAL CABLE (50) OF THE DIGITAL TV ANTENNA (16): 56
8.2.3 AMMENDIMENT OF THE BOAT POWER ELECTRIC WHIP (46)
AND THE FEMALE CONNECTOR POWER ELECTRIC WHIP (47): 59
8.2.4 ASSEMBLY OF THE EXTENSIVE BASE (44) AND THE
BRACKET BOLTED SET (35): 59
8.2.5 CONNECTION OF THE COAXIAL CABLE (50) IN THE CONNECTOR (51): 59
8.3 FINAL PROCEDURE AFTER THE ASSEMBLY OF THE ORPHOS: 60
9. ELECTRIC SYSTEM: 61
10. TROUBLE SHOOTING: 65
11. SPARE PARTS: 73
NOTE: 91
1
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (MAY, 2020th)
ORPHOS is an integrated navigation light system developed by MEGALEDS
for boats ranging from 24 ft (7 m) to 39 ft (12 m), with the purpose of bringing
together navigation lights (port, starboard, all-round white, anchor), and auxiliary
lights to illuminate the bow and stern. Also, it is possible to incorporate in this same
set, as optional accessories, as TV Digital Antenna and Horn.
Another benet is the practicality of the installation of ORPHOS on a
Bracket, by means of a locking mechanism, where it is possible to easily connect
and disconnect the part without any tools.
It is a product created with innovation and design, which incorporates
advanced LED (Light Emitting Diode) and ber optic technologies. The structur-
al materials used in ORPHOS are of high resistance to impacts and weathering,
appropriate to the environment that is submitted.
The maintenance is simple, easy, and low cost, and requires only skilled
labor to perform this service. Therefore, MEGALEDS has a network of specialized
assistance to attend cases of maintenance, repairs, and spare parts.
ORPHOS was designed, certied and manufactured in compliance with
the international standards that regulate navigation (USCG COLREG 72) of the
AmericanCostGuardandNavy,andotherspecicregulations,asABYCA-16:2016
(SeetheCerticationTestReportsofIMANNALab.Inc.forUSCG-Certicateof
ConformityandtheCerticationofBrazilian´sNavyinthesub-clause5).
Theinstallationissimple,quickandsignicantlyreducesthelaborcostsby
80%overconventionalinstallations.
Forthisinstallationqualiedandskilledtechnicallaborisrequired,because
all the instructions are described in this Handbook. The use of conventional tools
is minimal.
1. INTRODUCTION:
2
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (MAY, 2020th)
ORPHOSispresentedinthemodeldescribedbelow.Figure01illustrates
this set, with the functions presented.
model: ORPHOS Fi 8:has8functionsincorporated,being:
• four navigation lights (starboard, port, mast, and anchor);
• front-facing light;
• rear-facing light;
• radarreector;
• ag.
OPTIONAL ACCESSORIES (*): in addition to the 8 functions of ORPHOS Fi 8,
alsoprovides:
• Horn;
• Digital TV antenna.
STARBOARD NAVIGATION LIGHT
REAR-FACING LIGHT
ALL-ROUND WHITE LIGHT
ANCHOR LIGHT
RADAR REFLECTOR
PORT NAVIGATION GHT
FRONT-FACING LIGHT
HORN (*)
gure 01
(*) DIGITAL TV ANTENNA
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INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (MAY, 2020th)
2. SAFETY RECOMMENDATIONS:
Although assembly, disassembly, installation and maintenance services are
simple and fast, there are safety aspects that shall be observed by the profession-
als who perform such tasks.
- READ CAREFULLY all safety recommendations
contained in this Installation Handbook;
- USE Personal Protective Equipment - PPE during all tasks performed. These
recommendations shall be observed in the tasks described in this Installation
Handbook:
• ALWAYSUSESafetyGlasses;
• USE knitted nylon Protective Gloves to better
handle tools;
• USE Safety Shoes with non-slip soles for ser-
vices on the roof or targa of the boat.
- USE ladders, decks, or other means of adequate and safe access to the top
(targa) of the boat;
- CERTIFY that upper parts of the boat are safe and structured to support one
or more professional's weight on it;
For WORKS at HEIGHT above 6.5 ft (2.0 m) from the oor
(Boatonacartorasupportplatforminashipyard):
ATTENTION! RISK OF FALLING WITH INJURY DUE WORK AT HEIGHT
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INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (MAY, 2020th)
- USE Safety Belt with double Y-shaped
lanyard (gure 02) for works at height, xed
with live line or in a rigid structure;
- REQUEST safety guidance for this ser-
vice in height by Occupational Safety profes-
sionals;
- READ and FOLLOW the recommenda-
tions and requirements of Safety Regulations
ofLaborMinistryofeachcountry;
- CLEAN and DRY the top of the roof or the targa before starting any service;
- CERTIFY if the top of the roof is dry and clean before starting any service;
For WORKS at HEIGHT above 6.5 ft (2.0 m) from the water
(Anchoredboat):
- PLAN the safest way to work on the top of the roof or targa of the boat before
starting any service;
- REQUEST safety guidance for this service in height by Occupational Safety
professionals;
- USESafetyBeltwithdoubleY-shapedlanyardforworksatheight,xedwith
provisionallivelineforthisservicetype(gure02);
- CLEAN and DRY the top of the roof or the targa before starting any service;
- CERTIFY if the top of roof is dry and clean before starting any service.
gure 02
5
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (MAY, 2020th)
3. WARRANTY:
MEGALEDS Indústria, Comércio e Prestação de Serviços em Iluminação Ltda EPP.
HeribertoHulse.st,1985–Room03–JardimSantiago
SÃOJOSÉ-SC-Brazil–ZIPCODE88113-000
phone.+55(47)3035.7755
www.megaleds.com.br
WARRANTY CERTICATE
PRODUCT: ORPHOS Fi 8:
The equipments manufactured and marketed by MEGALEDS Indústria,
Comércio e Prestação de Serviços em Iluminação Ltda. are covered by
a 24 months warranty from the invoice issuance, regardless or not the use of
equipment, except to the Flag (33) that is of 12 months.
The Technical Support given during the warranty loses its characteristic of
gratuitousness, in case it does not proceed to claim the defect for any reason.
The replacement of parts or components, which are proven to have factory fault is
free of charge, not including the required labor.
Losethewarrantywhen:
• Inadequate and improper handling purposes for which the product is destined;
• Any type of damage caused by fall, strike or shock in any part of ORPHOS;
•RuptureoftheMast(28)causedbyanytypeofcollision,forexample,during
passing under the bridge, placing of cover on the boat, or other form of impact;
•Inadequatesupplyoruseofelectricpower,indisagreementofthespeci-
cations of equipment;
6
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (MAY, 2020th)
•Natureagents(lightning,oods,res,etc.);
• No observance of installation instruction enclosed in this Installation Hand-
book;
• Interventions by third parties without the consent of MEGALEDS;
• Use of products harmful to the equipment, such as any type of fuel,
solvents, corrosive products, acids, oxidizers, among others, on any part of the
ORPHOS;
• Changes in the technical characteristics of ORPHOS, structural, electrical
oranymodicationnotauthorizedinwritingby MEGALEDS;
No included in the warranty, regular maintenance service of ORPHOS, such
as adjustment, cleaning, lighting capsules, etc. Parts and components, which are
replaced during the warranty period, are owned by MEGALEDS.
MEGALEDS
Indústria, Comércio e Prestação de Serviços em Iluminação Ltda EPP.
7
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (MAY, 2020th)
4. GENERAL DESCRIPTION OF ORPHOS LINE:
ORPHOS is an equipment developed by MEGALEDS in order to bring togeth-
er in a single set all navigation lights, and the auxiliary lights for lighting the front
and rear facing. In addition to these navigation devices, it can incorporate, as op-
tional accessories, Digital TV Antenna and Horn.
Firstly,thissystemconsistsofaStructuralSet(01)
made of injected plastic of high resistance to impact and
weathering, ensuring great durability to the product and
quality.
To ensure the structural quality of ORPHOS, suit-
able materials such as ASA (Acrylonitrile Styrene Acry-
late) and PC ABS (Polycarbonate + Acrylonitrile Butadiene
Styrene-Polycarbonate / Acrylonitrile-Butadiene-Styrene)
are used in its manufacture. Subsequently, this Set, exter-
nally, receives a polyurethane paint coating - PU allowing
greaterprotectiontotheproduct(gure03).
01
gure 03: Structural Set
8
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (MAY, 2020th)
TheStructuralSet(01)consistsoftheRightLateral(02)andtheLeftLater-
al(03),accordingtogure04,whicharejoinedbytheiredgesbyScrew(04)and
Locknut(05).
AttherearoftheStructuralSet(01)istheBackClosing(06),alsomadeofthe
samematerialastheLaterals(02)and(03).ThispartisxedbymeansoftheScrew
(07)andtheTetherBar(08)ontheLaterals(02)and(03),asshowningure04.
All these joined parts form a rigid "box" capable of receiving the other com-
ponents internally and externally, having a characteristic and harmonious design.
gure 04: Structural Set - Components
06 03
02
07
05
01
08
04
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INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (MAY, 2020th)
InsidetheStructuralSet(01),ttheMetallicBase(09)totheLaterals(02)
and(03)arrangedaccordingtogure05,whosefunctionistoserveastherigid
surfaceoftheCentralPCIBoard(10),MastlightCapsuleSet(11)andHornSet
(12),wheninstalled.ThisMetallicBase(09)isconstructedofanodizedaluminum
sheet, which ensures corrosion resistance of this component.
Stillinternally,thereistheRadarReector(13)andtheFixingSupport(14)
of the Anchor Light Set (15).These two components are integral with each oth-
er, rigidly forming a single body when joined, all of which are made of anodized
aluminum plate.
OntheinternalsideoftheLeftLateral(03),asshowningure06,thereis
theDigitalTVAntenna(16).ThisDigitalTVAntenna(16)isconnectedviatwo
cablestotheConnector(17),alsoattachedinternallytotheLeftLateral(03).The
DigitalTVAntenna(16)canbeinstalled,butitisanoptionalitem.
Mountedontheinternalside,thereistheStarboardLightSet(GREEN)(18)
and the Port Light Set (RED) (19), both are xed by the Screw (20) as shown in
gure07.BothareconnectedbymeansofconnectorspropertotheCentralPCIBoard
(10).Inthecaseofreplacementoneofthesesets,simplyreplacethemwithanother
component, of the same code.
AttachedtothefrontpartsoftheLaterals(02)and(03),thereisaFront-Facing
Light Set (WHITE - TRANSPARENT) (21), whose parts (front and rear) are mounted
bythetwoScrews(23)(gure08).
In the upper part of the Fixing Support (14) the Anchor Light Set (15)
(gure05)isxedbytheScrews(24).ThissetisalsoconnectedtothePCICentral
Board(10)byaconnector.Incaseofreplacementofthisset,simplyreplacewith
another component of the same code.
10
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (MAY, 2020th)
10
09
11
12
13
14
15
gure 05: Internal Components
24
37
30
35
11
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (MAY, 2020th)
17
03
16
gure 06: Digital TV Antenna
12
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (MAY, 2020th)
gure 07: Starboard and Port Navigation Lights
18
19
03
20
02
IntheBackClosing(06)(gure09)thereistheRear-FacingLightSet(22)
whichisconnectedtotheCentralPCIBoard(10)alsobymeansofaconnector
proper.ThissetisxedtotheBackClosing(06)bytheScrews(23).Incaseof
replacement of this set, simply replace with another component of the same code.
Finally,theAll-roundWhiteLightCapsuleSet(11)(gure05)ismountedon
theMetallicBase(09)bytheScrews(29).ThisCapsule(11)isalsoconnectedto
thePCICentralBoard(10)throughitsconnectorproper.
13
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (MAY, 2020th)
03
21
gure 08: Front-Facing Light Set
In ORPHOS,thepowerinputofthePCICentralBoard(10)ismadebythe
MaleConnector(30),composedof6cablesofdifferentcolors,dulysizedtosup-
port the electrical current consumption of this equipment.
When assembled, ORPHOScanreceiveaMast(28),madeofacrylicmateri-
al, as high mechanical strength and weathering, as the saline environment and UV
rays.Thiscomponenthasaberopticcableinsideit,capableoftransmittingthe
light from the white All-round White Light Capsule Set (11), that is, translucent, to a
lensinstalledintheMastCollimatorSupport(32)(gure10A).
14
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (MAY, 2020th)
ForasimplettingtheMast(28)canbeeasilyinstalledorremoved,asillus-
tratedingures01and10B,therearoftheStructuralSet(01).Inturn,theMast
(28)islockedbytheMastFixingClamp(31)(gure10B).
TheMast(28)clampingsystemoftheORPHOS is simple, just position the
MastFixingClamp(31)withitsinternalpins(P),facingdownwardsandttheminto
the side slots (Rg),asshowningure10B.
gure 09: Rear-Facing Light Set
22
23
06
15
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM
REVISION - 02 (MAY, 2020th)
gure 10A: All-round White Light Capsule Set (11) Set
11
29
33
32
34
28
16
INSTALLATION HANDBOOK - NAVIGATION LIGHTS INTEGRATED SYSTEM REVISION - 02 (MAY, 2020th)
gure 10B: Lock System of the Mast (28)
TomounttheMast(28)initscorrectlocation,positiontherecess(Rb) from
its lower edge to downward, parallel to the ledge (Rs) of the lower rear hole(Fu 2)
oftheStructuralSet(01).After,insertitthroughtheupperrearhole(Fu 1), through
the hole (Fu 2)untilitreaches(tostop)theMastlightCapsuleSet(11).(gure10A).
When the Mast (28) is inserted into the holes (Fu 1) and (Fu 2), until it
touchestheMastlightSet(11),turnclockwise,¼turntheMastFixingClamp(31)
tolocktheMast(28)initscorrectposition.ToremovetheMast(28),turntheMast
FixingClamp(31)¼turnagain,butcounterclockwise,andthenpullitupwards.
28
31
01
P
Rg
Rb
Fu 1
Fu 2
Rs
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