Vega Industries VLB-44 User manual

Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
VEGA INDUSTRIES
VLB-44 LED LANTERN INSTRUCTIONS
General Information
The Vega VLB-44 LED lantern is a versatile lantern capable of being installed on buoys, fixed
structures and lighthouses. It is generally used when a self-contained LED lantern is not feasible
or cost effective to operate. The lantern is available in white, yellow (except 2.5 degree), red and
green, and three vertical divergences; 10 degrees (total to 50% peak intensity) for use on buoys, 5
degrees for fixed structures and 2.5 degrees for lighthouses. The narrow divergence (2.5 degrees)
concentrates light in the horizontal plane, but requires a stable platform to remain level. This
regulates the 2.5 degree lantern to lighthouses or rock-solid structures unaffected by wind or
waves.
The VLB-44 is available with up to 8 tiers of LEDs to increase intensity. This lantern requires an
external 12 VDC power source from a DC power supply or a legacy solar power system
consisting of solar panels and rechargeable lead-acid batteries. Note: due to the nature of LED
lanterns this signal can not be used with a color sector.
Vega VLB-44 5-Tier LED Lantern
Selection Criteria
Intensity selection should be based on the operational requirements of the aid. To determine the
intensity requirements for any aid, Districts shall use the standard procedures for selecting an
AtoN light signal as prescribed in the AtoN Technical Manual (Chapter 6, Section 6.B, page 6-1)
and the Visual Signal Design Manual (Chapter 3). These references describe how operational
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Selection Criteria (cont’d)
range, luminous range, light color, light characteristic, background lighting, and meteorological
visibility are used to calculate intensity needs.
The VLB-44 has a feature that allows the lantern to produce the same effective intensity
regardless of flash rhythm. The intensities cannot be tabulated because the operating current and
peak intensity capabilities are different for each flash rhythm. Use one of the solar design
spreadsheets to select the lantern, number of tiers, color and flash rhythm, available at:
http://www.uscg.mil/hq/cg4/cg432/publications.asp.
Nonstandard and custom flash rhythms, along with double stack (16 tier) lantern combinations
are not listed in the solar design spreadsheets. In this case, use the Vega VLB-44 Current
Calculator available at the above link and enter the data in the Old Solar Sizing Program,
available at the same link. Assistance in using the Old Solar Sizing Program is available from
COMDT (CG-432A) http://www.uscg.mil/hq/cg4/cg432/organization.asp.
For most desired effective intensity settings, the user has the option of picking lanterns with
different numbers of tiers. For a desired effective intensity, the greater number of tiers will lower
the overall power draw. However, more tiers than necessary will significantly increase the cost
of the lantern and the height. Unless there is a compelling reason, pick the lantern with the fewest
number of tiers.
LED Version – The capabilities of LEDs change rapidly. Periodically Vega uses new LEDs in a
specific lantern (or group of lanterns). This impacts the lantern’s intensity values, current draw
and solar sizing. In order to identify the LEDs used in a lantern, Vega uses a 3-digit number to
identify the “LED version.” For example, the white LEDs available in late 2007 and early 2008
were designated LED version 421. LEDs available in mid 2008 were designated version 422.
The Solar Sizing Programs used to size a solar power system for VLB-44 have a picklist that is
used to select the LED version. The picklist choices depend on the user-selected lantern and
color. The newest LED version is the upper-most choice in “LED version” picklist.
When ordering a lantern, one needs to know what LED version will be shipped with the lantern.
If ordering directly from Vega, contact Vega or COMDT (CG-432A) to find out what LED
version will be provided. If a VLB-44 will be sent from the supply stocked at the SFLC then
contact COMDT (CG-432A) to learn what LED version will be provided.
For lanterns in-hand, the LED version can be determined by: (1) the LED version may be
written on the lantern’s label; (2) the LED version can be retrieved from the lantern using the IR
programmer (see instructions below in the “Programming” section); or (3) use the Vega VLB-44
“Installation and Operation Manual” that was shipped with the lantern (go to the table at the back
of the manual that corresponds to the color and vertical divergence of the lantern – the LED
version is the number in parenthesis between the color and “Current (mA)”).
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Purchase
CGHQ established a 5 year requirements contract with Vega Industries. Orders for lanterns are
placed through Ms. Jing Liu at the SILC in Alameda, CA. Provide a copy of the funded
procurement request to her with the “CIMS bound box” checked, routed to inbox 7513C and she
will draft a delivery order with Vega. You must contact Mr. Jon Grasson at COMDT (CG-432A)
upon receipt of the lanterns so payment can be authorized. Current pricing for Vega lanterns is
available from your training team chief or COMDT (CG-432A)
http://www.uscg.mil/hq/cg4/cg432/organization.asp.
The following VLB-44 lanterns will be stocked at the SFLC in project 98A (free-issue) for
approved buoy, fixed aid and lighthouse projects (contact Son Nguyen at above link.)
VLB-44-10 Single tier buoy lanterns, white with a high base (all lanterns include bird spikes)
VLB-44-5 Single tier fixed aid lanterns, red, white and green
VLB-44-2.5 Eight tier lighthouse lanterns, white
Remote 1 Vega infrared remote control
Lanterns not listed above must be purchased directly from Vega via the SILC using the following
format (it would be helpful to the contract specialist if the Item No. listed in the contract is
included with your order):
VLB-44-(Color)-(Divergence)-(Tiers)-(Base Mount)
Where: Color = WHT, RED, GRN, YEL
Divergence = 2.5, 05, 10 for lighthouses, structures or buoys, respectively
Tiers = 1T, 2T…..8T for 1 through 8 tiers.
Base Mount = 3H (for 3 hole mount, regular base; if replacing a 250mm, you
can order a 4-hole mount; 4H), use HB for high base on buoys.
Example: VLB-44-WHT-2.5-6T-3H White, 2.5 degrees, 6 Tier, 3-hole mount.
A requirements contract that lists all VLB-44 combinations and pricing was distributed to
districts in September 2009 and updated annually as options are exercised.
Additional Notes:
•You can specify the desired intensity setting and flash rhythm when ordering.
•A high base is required for buoy installations to prevent obstruction by the lantern ring
when viewed at low heights-of-eye.
•VLB-44 High Base; change the suffix from 3H to HB in the VLB-44 item description.
•Bird spikes are included. Replacement bird spikes are available; order part number 138-
800, Bird Spikes.
•Standard cable length is 1.5 meters for VLB-44 2.5 and 10 degree versions. 3 meter
cable is standard for 5 degree versions (longer cables are available upon request).
•Mount-Kit-2 (ordered separately) is used to stack two VLB-44-8T lanterns (see design
considerations) to increase the intensity for lighthouse applications.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Programming - Overview
The lantern must be programmed to the proper flash rhythm and intensity before deployment.
The lantern is programmed using the Vega Infrared (IR) Remote Control or any RCA TV remote.
There are about 30 different RCA TV Universal Remote Controls. Non-Vega remotes must be
initialized so that the remote can communicate with the lantern. Different models have different
initialization procedures. If the remote purchased uses a 3-digit code use code 0 6 2 If the remote
uses a 4-digit code, then use code 1 0 6 2. Consult the instructions that come with the remote.
Follow the “Direct Entry Method” for programming a TV as shown in the instructions.
Initialization will likely take one of the following two forms:
Press and hold CODE SEARCH until red light on remote turns on
Press TV red light on remote will blink once
Enter 0 6 2 red light will blink once after each entry
or
Press and hold TV keep holding TV button!
Enter 1 0 6 2 while still holding TV button
Release TV button
(Note: the codes for RCA remote needs to be verified. Use the Vega remote until positive confirmation is
received.)
You are now ready to program the Vega VLB-44 lantern.
Gather the information needed to program the lantern; intensity and flash rhythm code (note: if
the lantern is purchased directly from Vega for a specific project it may come pre-programmed.
You can check the entries; see Programming – Reading a Program Setting detailed later in this
instruction.) Standard CG Flash Rhythms
Rhythm Code Rhythm Code Rhythm Code
FL2.5 (0.3) 310 Mo(A) 801 FL (2) 6 416
FL4 (0.4) 321 Iso 2 100 FL (2) 5 406
FL6 (0.6) 337 Iso 6 104 FL (2+1) 6 472
Q 601 Oc 4 205 Fixed 000
The following is a list of nonstandard, but common flashed lighthouse rhythms used at CG aids.
Also posted is the actual flash (FL) and eclipse (EC) times of each rhythm.
Non-Standard Flash Rhythms
Rhythm Code FL EC FL EC
FL5 (0.5) 329 0.5 4.5
FL7.5 343 0.8 6.7
FL10 350 1.0 9.0
FL15 354 1.0 14.0
FL (2) 10 428 1.0 1.0 1.0 7.0
FL (2) 15 435 1.0 2.0 1.0 11.0
FL (2) 20 436 1.0 3.0 1.0 15.0
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Programming - Overview (cont’d)
For flash rhythms not listed on the previous page, consult Vega’s IR Programmer manual
supplied with each programmer for a nonstandard code. Pay careful attention to the existing
ON/OFF times of the light and try to match the rhythm to one listed in the manual. Note that
existing rotating beacons generally have very short flash lengths (0.05-0.2 seconds), but when
replicated by the VLB-44 the flash length is increased to 0.5-1 second (typical) with a
corresponding reduction in eclipse time (period remains the same). Strive to achieve a duty cycle
of around 10% (duty cycle is the sum of the on-times divided buy the period). As an example, a
DCB-224 in a lighthouse with a FL(2)W15 rhythm may have an existing flash rate of 0.1s FL,
4.9s EC, 0.1s FL, 9.9s EC (as detailed in the Light List). It is not practical to flash the VLB-44 at
a 0.1 second rate. A typical rhythm would be 1s FL, 4s EC, 1s FL, 9s EC. Note that the period
remains the same (15 seconds) and the duty cycle is 2s/15s x100=13.3% (close to the desired
10% mentioned above). If this desired rhythm is not listed in the IR Programming manual (it
isn’t for this example), see the section on custom rhythms.
Intensity Setting – The intensity setting or value can be found on the solar design spreadsheet,
form 3213A or the district work order. A value of 1390, for example in the effective intensity
(cd) block refers to an effective intensity of 1390 candelas and the code for that intensity is 1390.
Note: all intensity codes are 4 digits, so an effective intensity of 77 candelas is entered as code
0077; 109 candelas is entered as code 0109. Note the intensity setting in the aid log and in
IATONIS under notes so that a replacement lantern can be programmed to the correct intensity.
Improper settings can affect the nominal range and the solar sizing of the aid.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Programming Notes:
•The lantern must be programmed with power applied in daytime conditions outside or in
a lighted room (fluorescent lighting may not allow proper programming).
•Programming entries must not lag by more than 10 seconds or the lantern will exit the
programming mode. Write down the programming codes for each session to avoid
delays.
•The Infrared Receiver (IR) is located in the base of the lantern through a window just
above the label. Aim the remote control here 6-12” from the lantern.
•The lantern enters the programming mode by pressing the “red standby”, “power” or
“program” key on the remote for 5 seconds. The lantern will display 4 quick flashes (.1
sec on, 0.1 sec off) indicating that it is in the programming mode.
•Each successful numeric keypad entry will result in 1 flash for each key pressed.
•Wait for the lantern to flash before entering the next digit (don’t rush programming).
•When the programming code is recognized, the lantern will display the 3 or 4 digit code
with a series of quick flashes with a gap of 0.5 seconds between each “number” of the
code. A zero (0) is displayed as a 2 second flash.
•If the programming code is not recognized, the lantern will display 3 quick flashes and
the lantern will return to the programming mode (re-enter entire program code again).
•When exiting programming mode, the lantern will display 2 quick flashes, followed by a
short pause and another 2 quick flashes, then display the flash rhythm for 16-20 seconds.
•If the VLB-44 is the main light controlled by a SACII/III, the lantern must be
commanded on both day and night, and intensity set for both day and night. The daylight
control function is performed by the SACII/III and the lantern is controlled by power
being applied at dusk and secured at dawn by the SACII/III. If this is not done there is a
conflict between the daylight controls in the lantern and SACII/III. Setting the intensity
for both day and night is necessary to ensure that the light displays the correct intensity
during the transitions between night/day and day/night. See page 8 for specific
instructions.
Programming
Apply 12 VDC to the input leads of the lantern. Black or brown is positive and white or blue is
negative. The green/yellow sync wire is left disconnected. If you are using a power supply, be
sure that it is capable of providing enough power; approximately 1.25 amps per tier.
The lantern will power up in the default setting from the factory (or if it came pre-programmed).
After 10 seconds it will monitor the ambient light level and if bright enough will turn off (the
desired mode for programming). If, for some reason the voltage at the lantern is below 11.0
volts, the lantern will shut down to conserve energy and protect the battery and will not relight
unless power is reapplied or the voltage exceeds 13.0 volts and at least one daytime cycle is
detected (to prevent oscillation on and off at night).
The programming sequences are grouped together so that all codes are entered at one time. It is
suggested and acceptable to perform the programming operation in two separate sessions
(detailed A& B), however the code sequences can be entered sequentially after confirmation of
the code, but before the lantern exits the programming mode (within 10 seconds after the
confirmation flashes.) The two programming sequences required for most sessions are: flash
rhythm and intensity.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
7
A. Flash Rhythm. To start a programming session, gather the data for each operation. For
example, the following VLB-44 has a flash rhythm of FL6(.6) and an intensity setting of 7280
candelas. The code for FL6(.6) is 337 and the intensity value is 7280. The remote is capable of
many operations (more on that later). The programming operation is code 1. The flash rhythm
feature is code 0.
Assemble the codes, as shown below for your flash rhythm programming sequence:
Code
Operation Programming 1
Feature Flash Rhythm 0
Value FL6(.6) 337
The programming sequence for this example is 1 0 3 3 7.
With power applied to the lantern in a lighted room or outside, aim the remote at the window
above the label and:
1. Press and hold the
standby/program/power button for 5
seconds.
2. Enter the programming sequence for
the flash rhythm 10337 (wait for
confirmation flash after each digit)
3. Leave the programmer idle for 10
seconds to exit the programming
mode.
The lantern will give 4 quick flashes to
indicate that it has entered the programming
mode.
The lantern will flash once each time a key
on the programmer is pressed. When the
sequence is entered and accepted, the lantern
will display the value 337 as a series of
flashes as: 3 quick flashes followed by a 0.5
sec gap, 3 quick flashes followed by a 0.5
sec gap and finally 7 quick flashes.
The light will give 2 quick flashes followed
by a short pause, then another 2 quick
flashes. After this it will flash on the
programmed rhythm for 16-20 seconds.
Important Note: unsuccessful programming sessions will be followed by 3 quick
flashes followed by the lantern returning to the programming mode (step 2). Try
the code again, or wait at least 10 seconds to exit the programming mode and
reenter the above sequence (step 1).

Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Programming (cont’d)
B. Intensity. Next, assemble the codes, as shown below for your intensity setting programming
sequence:
Code
Operation Programming 1
Feature Nighttime Intensity 1 (daytime intensity code 2; see below)
Value Intensity, 7280 7280
The programming sequence for this example is 1 1 7 2 8 0. Important Note: if you omit or fail
to program the zero (0) in this code, the lantern will have an intensity of 728 candelas, not 7280
candelas. Intensity codes are 4 digits, so an intensity of 83 candelas has a code of 0083.
With power applied to the lantern in a lighted room or outside, aim the remote at the window
above the label and:
1. Press and hold the
standby/program/program button for
5 seconds.
2. Enter the programming sequence for
the intensity 117280 (wait for
confirmation flash after each digit)
3. Leave the programmer idle for 10
seconds to exit the programming
mode.
The lantern will give 4 quick flashes to
indicate that it has entered the programming
mode.
The lantern will flash once each time a key
on the programmer is pressed. When the
sequence is entered and accepted, the lantern
will display the value 7280 as a series of
flashes as: 7 quick flashes followed by a 0.5
sec gap, 2 quick flashes followed by a 0.5
sec gap, 8 quick flashes followed by a 0.5
sec gap and finally a 2 second flash
representing zero (0).
The light will give 2 quick flashes followed
by a short pause, then another 2 quick
flashes. After this it will flash on the
programmed rhythm at the selected intensity
for 16-20 seconds.
Note: unsuccessful programming sessions will be followed by 3 quick flashes followed by the
lantern returning to the programming mode (step 2). Try the code again, or wait at least 10
seconds to exit the programming mode and reenter the above sequence (step 1).
If the VLB-44 is the main light controlled by a SACII/III, the lantern must be commanded on
both day and night, and intensity set for both day and night. The code to turn the lantern on
during the day (ignoring the daylight control input) is 14109. The daytime intensity must also be
programmed so that the lantern displays the same intensity both night and day since the SACII/III
has the daylight control function. The SACII/III controls day/night operation of the lantern by
switching power on at dusk and off at dawn. In the above example, the code for the daytime
intensity is 127280. Three program codes must be entered (four including the flash rhythm):
command lantern on during day – 14109, nighttime intensity – 117280 and daytime intensity –
127280. These codes (along with the flash rhythm) can be entered sequentially after the lantern
flashes back the sequence, but before the lantern exits the programming mode (within 10 seconds
after the confirmation flashes.) It is best to write down the sequences so programming can be
accomplished without the lantern exiting the programming mode.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Programming – Reading a Program Setting
The program settings can be deciphered by reading and recording (writing down) lantern flash
sequences upon activation with the IR remote control. The flash rhythm and intensity are read as
separate sequences and may be used to verify the setting(s) without reprogramming the lantern.
To check a program setting, power the lantern from a 12 VDC source in daytime conditions, aim
the programmer at the window above the label and enter the following codes:
To check flash rhythm: To check intensity setting:
Code Code
Operation Read Settings 9 Operation Read Settings 9
Feature Flash Rhythm 0 Feature Intensity Setting (night) 1 or
Feature Intensity Setting (day) 2
To check LED version:
Code
Operation System Check 3
Feature LED Version 5 (for example, will display 421 as a series of flashes)
For example, to check if a lantern is programmed as a FL4(.4), look up the code on page 3 (code
321):
1. Press and hold the
standby/program/power button for 5
seconds.
2. Enter the programming sequence to
determine the flash rhythm: 90 (wait
for confirmation flash after each
digit). The sequence to determine
intensity is 91 and the sequence to
determine the LED version is 35.
3. Leave the programmer idle for 10
seconds.
The lantern will give 4 quick flashes to
indicate that it has entered the programming
mode.
The lantern will flash once each time a key
on the programmer is pressed. When the
sequence is entered and accepted, the lantern
will display the value 321 as a series of
flashes as: 3 quick flashes followed by a 0.5
sec gap, 2 quick flashes followed by a 0.5
gap, 1 quick flash.
The lantern will display 2 quick flashes, a
pause followed by 2 quick flashes, display
the FL4(.4) rhythm for 16-20 seconds, then
turn off (if daytime).
Custom Flash Rhythms
For flash rhythms not listed in this manual or in the Vega IR Programming manual, a custom
rhythm can be programmed into the lantern. The programming sequence has the following
limitations: the minimum flash and eclipse is 0.1 seconds (generally not a problem with CG
rhythms), the ADD code must be used for flash and eclipse lengths that exceed 12.75 seconds.
The programming sequence consists of 3-digit codes representing the flash and eclipse intervals.
Each 3-digit code is a multiple of 0.05 seconds. As an example, a 1 second flash is equal to a
code of 1/0.05 = 20 or code 020. A 9.5 second eclipse is equal to 9.5/0.05=190 or code 190. An
eclipse of 15 seconds has to be entered as two codes (split in half for simplicity), so 7.5/0.05=150
using the ADD code (explained later).
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Custom Flash Rhythm (cont’d)
First, determine the desired flash and eclipse lengths for your custom rhythm. Remember, as
discussed earlier in this manual, rotating beacons have very short flash lengths. The minimum
flash length for the VLB-44 is 0.3 seconds on minor aids. For major aids, a practical minimum
flash length is 0.5-1.0 seconds. Try to achieve around 10% duty cycle when assembling a flash
rhythm (period is the sum of the on times divided by the period; example: a FLW(2)15 with 1
second flashes has a duty cycle of 2/15x100=13.3%).
As an example, a fictitious light with a FL(2)W20 might have an existing rhythm of 0.1s FL, 4.9s
EC, 0.1s FL, 14.9s EC. A suitable replacement using the VLB-44 would be a 1s FL, 4s EC, 1s
FL, 14s EC. The mariner still sees 2 flashes every 20 seconds, the flash is longer providing a
better bearing and the duty cycle is at the desired 10% (2/20x100=10%). Now that you know the
flash and eclipse lengths, determine the programming codes.
•The code for a custom rhythm is 2. This is the first entry when programming the lantern;
•For the 1 second flash, the code is 1/0.05=20 or 020;
•For the 4 second eclipse, the code is 4/0.05=80 or 080;
•The 14 second eclipse exceeds the 12.75 second limitation, so it is entered as two 7
second codes: 7/0.05=140. The ADD code is 001;
•000 is the termination code to tell the VLB-44 that the programming sequence has ended.
The sequence of codes mimics the flash rhythm. In this example the code sequence is:
2 start sequence for entering a custom rhythm
020 1 sec flash
080 4 sec eclipse
020 1 sec flash
140 7 sec eclipse
001 ADD code
140 7 sec eclipse (total eclipse -14 seconds)
000 termination code
With power applied to the lantern in a lighted room or outside, aim the remote at the window
above the label and:
1. Press and hold the
standby/program/power button for 5
seconds.
2. Enter the programming sequence for
the new flash rhythm listed above.
Do not pause more than 5 seconds
between codes. (wait for
confirmation flash after each digit)
3. Leave the programmer idle for 10 sec
to exit the programming mode.
The lantern will give 4 quick flashes to
indicate that it has entered the programming
mode.
The lantern will flash once each time a key
on the programmer is pressed.
The light will give 3 long flashes to indicate
code has been accepted and then 2 quick
flashes, a pause followed by 2 quick flashes.
The lantern will display the previously
programmed flash rhythm.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Custom Flash Rhythm (cont’d)
The custom rhythm has been entered into the lantern’s memory. Now the lantern must be
programmed to display that new rhythm. The code for a custom rhythm is 999.
With power applied to the lantern in a lighted room or outside, aim the remote at the window
above the label and:
1. Press and hold the
standby/program/power button for 5
seconds.
2. Enter the programming sequence for
the flash rhythm 10999 (wait for
confirmation flash after each digit)
3. Leave the programmer idle for 10
seconds to exit the programming
mode.
The lantern will give 4 quick flashes to
indicate that it has entered the programming
mode.
The lantern will flash once each time a key
on the programmer is pressed. When the
sequence is entered and accepted, the lantern
will display the value 999 as a series of
flashes as: 9 quick flashes followed by a 0.5
sec gap, 9 quick flashes followed by a 0.5
sec gap and finally 9 quick flashes.
The light will give 2 quick flashes followed
by a short pause, then another 2 quick
flashes. After this it will flash on the custom
rhythm for 16-20 seconds.
Important Note: unsuccessful programming sessions will be followed by 3 quick
flashes followed by the lantern returning to the programming mode (step 2). Try
the code again, or wait at least 10 seconds to exit the programming mode and
reenter the above sequence (step 1).
Bench Test
Bench test each beacon with a 12-volt DC power source to ensure proper operation. The
recommended interval is 24 hours. Color coding: black or brown is (+) and white or blue is (-).
The green/yellow sync wire is left disconnected. The daylight control in the Vega lantern is
above the label through the window in the base and may be covered with black electrical tape to
darken the lantern. Check to be sure that the lantern is flashing at the desired rhythm and that all
LEDs are lit around the perimeter of the lantern.
The LED lanterns do not have provisions for terminating wires from the battery and solar panel
like our current 155mm lantern using a CG series flasher and CG-6P lampchanger. Instead, they
are equipped with a 1.5 meter power cable (3 meters for structures) that is terminated in a LED
Junction Box on buoys (Figure 4), at the battery box on fixed aids (Figure 5) or at the battery box,
Range Power Box (RPB), CAT V Load Center or Low Voltage Drop Box (LVDB) at lighthouses.
The junction box provides a convenient place to terminate the solar panel, lantern and battery
without excessive cable runs. Longer power cables may be specified upon purchase from Vega,
or they can be replaced using the procedure on page 14. On multi-tiered lanterns use the wire
sizing program available on our website to ensure that voltage drop is not excessive.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Design Considerations
The lantern is mounted to the standard 200mm (7.875”) diameter three-hole mount. Additionally,
a 3.5” hole through the center of the lantern allows other apparatus to be mounted above the
lantern without obstructing the lens. Height will vary depending on the number of tiers, the base
height and use of bird spikes. Figure 1 details the dimensions for the various configurations. A
high base (optional) is required for buoy installations to prevent obstruction by the lantern ring
when viewed at low heights-of-eye.
4.8”
A*
9.3”**
No. of
Tiers A
14.4”
25.9”
37.5”
49.1”
5 10.7”
6 12.2”
7 13.8”
8 15.4”
*For high base add 2.8” to
“A” dimension
**2.5 degree lantern is 10.9”
Mount – (3) ½ holes
On a 7-7/8” bolt circle
3.5” hole through center
Figure 1.
For lighthouses requiring more than 8 tiers, the VLB-44 can be double-stacked (16 tiers) using
the Mount-Kit-2 available directly from Vega. The kit is sandwiched between the lower lantern
and leveling mount in the lighthouse with a tube passing through the lower lantern to the upper
lantern. Care must be exercised that that the lantern panes are tall enough to accommodate the 16
tiers and that the assembly is centered in the panes. The Mount-Kit-2 adds 3.9 inches to the
height of the assembly.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Installation – VLB-44-10 on a Buoy
Top of Radar
Reflector
Solar Panel
Mounting Frame
1/2” Bolt
Flat Washer
Split Lock Washer
Nut
Note High Base
For Buoys
Figure 2.
Sandwich the panel stand between the lantern and buoy and attach with ½” threaded stainless
steel bolts, flat washers, split lock washer and nuts, as shown in Figure 2. Do not lose the plastic
inserts in the base or over tighten the fasteners, crushing the inserts as they prevent galvanic
corrosion. Replacements are available from COMDT (CG-432A). Screw the four bird spikes
into the top of the lantern.
Install the appropriate solar panel using the solar panel installation kit and the appropriate number
of batteries, and connect as outlined in the Short Range Aids to Navigation Servicing Guide.
Figure 3.
The LED Lantern Junction Box should be mounted to one of the radar reflectors (preferably one
of the closed sections) to protect it from rain and guano, as shown in Figure 3. Install using the
template provided in the LED Lantern Junction Box; mark the four holes to be drilled on the
radar reflector with a center punch. Be sure the area behind the radar reflector has room to install
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Installation - VLB-44-10 on a Buoy (cont’d)
hardware (no cross ribs, vertical reflectors, etc.). Drill four 9/32” diameter holes through the
reflector. Install the junction box using the provided hardware. Route the wires through the
stuffing tubes, as shown in Figure 4. Tie the cables to adjacent support structures and cut off the
excess in the box (keep the cable as short as possible). Strip the ends of the wire and insert into
the Euro type terminal strips and secure with a 3/16” flat blade screwdriver. The terminals are
labeled and color coded black or brown for positive and white or blue for negative. The
green/yellow wire is a sync wire and is only used to synchronize two lanterns together. DO NOT
connect it to the buoy hull. The box is gray and may be painted to match the buoy, if desired.
Solar Panel (+)
Battery (-)
Solar Panel (-)
Battery (+)
Lantern (+)
Lantern (-)
Jumpers
Battery
Stuffing Tube
Solar Panel
Stuffing Tube
Lantern
Stuffing Tube
Note:
Cable sizes for the VLB-44 varies.
Single tier lanterns use a 0.39” dia
cable and multi tier lanterns use a
0.44” dia cable.
For multi tier lanterns, use the
supplied 2E packing.
For single tier lanterns order 2D
packings via MILSTRIP,
NSN5330-00-202-2589
Figure 4.
Cover the window above the label accessing the daylight control to simulate nighttime and check
for proper operation.
Installation – VLB-44-05 on a Structure
Figure 5.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Installation – VLB-44-05 on a Structure (cont’d)
Mount and level the lantern using three ½” stainless steel studs or bolts, as shown in Figure 5. Do
not lose the plastic inserts in the base or over tighten the fasteners, crushing the inserts as they
prevent galvanic corrosion. Replacements are available from COMDT (CG-432A). Place the
level on top of the center hole. Use the “T” method as shown in Figure 6 and adjust the nuts until
level. After tightening, recheck using the level in both directions.
Stud or Bolt
Nut
Split Washer
Flat Washer Platform
Torpedo
Level
“T” Method
LED Lantern
Base
Torpedo Level
2-Tier lantern shown
Figure 6.
Screw the four bird spikes into the top of the lantern if installed outside.
Install the appropriate solar panel using the solar panel installation kit and the appropriate number
of batteries, and connect as outlined in the Short Range Aids to Navigation Servicing Guide. Be
sure the tilt angle is appropriate for the area and that the panel is facing south.
The leads from the lantern and solar panel should be terminated in the battery box on structures,
as shown in Figure 5. Route the wire and zip tie it along structural members then cut the excess
inside the battery box. Crimp the proper ring lug onto each wire and attach the black or brown
leads to the (+) battery terminal and white or blue leads to the (-) battery terminal. Apply No-ox
grease or a suitable anticorrosion coating to the battery terminals. The lantern for structures (5
degree) is equipped with a 3 meter (approx 10 ft) cable. If the cable is not long enough, extend
the wire with a waterproof, soldered splice, use the LED junction box or replace the cable (see
page 13). The green/yellow wire is a sync wire and is only used to synchronize two lanterns
together. DO NOT connect it to earth ground.
Cover the window above the label accessing the daylight control to simulate nighttime and check
for proper operation.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Installation - VLB-44-2.5 in a Lighthouse
The physical installation at a lighthouse is the same as for a structure. Leveling is especially
critical as the vertical divergence (beam spread) is very narrow and the light may not project in
the direction of the mariner (an out of level lantern will project the light beam into the sky or into
the water). A “lighthouse” is defined as a rock-solid structure unaffected by wind and wave
action. The VLB-44-2.5 is not suitable on single or multi-pile structures, or any structure with
significant movement by wave or wind.
Wiring is critical to ensure adequate voltage at the lantern. Lighthouses generally use multi-
tiered lanterns and will use a significant amount of current. Expect the VLB-44 to use up to 1.25
amps per tier. Therefore, an 8 tier lantern will have a maximum current consumption of 10 amps.
Voltage drop between the battery and lantern shall not exceed 0.35 volts. Use of a low voltage
drop kit to increase the wire size between the lantern and charge controller, CAT V Load Center
or Solar Distribution Box may be necessary. To prevent excessive voltage drop, keep the wire
run between the junction box and the lantern as short as possible (2-3 feet). Consult with the Solar
Design Manual, COMDT M16500.24 or our website for wire sizing calculations, or contact
COMDT (CG-432A) for assistance.
The operating current of the VLB-44 may be lower than the operating current of the lantern it
replaced. If using a SACII or SACIII to monitor the main light, the SACII/SACIII will have to be
adjusted if the operating current of the VLB-44 is below 1.5 amps (see the programming section
for additional info regarding the daylight control and daytime intensity setting). Technical Data
Sheet 96-03 (http://www.uscg.mil/hq/cg4/cg432/2a_technicaldatasheets.asp) details the procedure
to adjust the SAC. Note: 1.25 amps per tier is the maximum current consumed by the VLB-44.
Selecting an intensity other than the maximum intensity for the number of tiers used will result in
lantern current being lower than 1.25 amps per tier. Either measure the lantern current with a
digital volt/amp meter, use the VLB-44 current calculator (available from CG-432A), or contact
COMDT (CG-432A).
The VLB-44 can not be used with color sectors. White LED light does not contain as much red
(or green) light as does white light from an incandescent source. Placing a red or green filter in
front of a white LED light will result in an unacceptably low amount of colored light on the far
side of the filter.
The effective intensity of any light signal in a lantern room is reduced by 12% when it passes
through clear glass or acrylic. Be sure to account for this reduction when calculating the effective
intensity, luminous and nominal ranges of the aid.
Power System
Most VLB-44 installations will be wired as self-regulating systems (minor aids that don’t use a
Solar Charge Controller (SCC) or Range Power Box (RPB)). Lighthouses and some installations
in northern latitudes and/or multiple tiers may require a more significant power system. Consult
with the standard aid drawings to determine the proper layout and wiring of components:
http://www.uscg.mil/hq/cg4/cg432/drawings_2a.asp. The power system shall be sized using the
solar design spreadsheets available at http://www.uscg.mil/hq/cg4/cg432/publications.asp.
Assistance is available from COMDT (CG-432A).
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
Servicing
Servicing should be performed in accordance with the standard cycle established for the aid.
Ensure that the lens is clean. Wipe with a cloth dampened with mild soap and water, if necessary.
Cover the window above the label to ensure that the lantern flashes on rhythm. Check to be sure
all LEDs are lit around the lantern. If more than 3 LEDs are out, it may create an area of reduced
intensity or no coverage in that region. Do not open the lantern on station. Parts are not captive
and will be easily lost. The lantern may still provide adequate service to the mariner, but a
replacement should be procured as soon as possible.
Inspect the wiring and power system in accordance with the Short Range Aids to Navigation
Servicing Guide. Replace, if necessary using the procedure listed below.
Power Cable Replacement
The power cable for the VLB-44 is wired to the circuit board inside the lantern through a stuffing
tube. Replacement cable should be 12/2 SOW, SOOW, SJOW, SJOOW for 3-8 tier lanterns and
16/2 for 1-2 tier lanterns (“S” is 600 V insulation, “SJ” is 300 volt insulation, “O” is oil
resistance, and “W” is for outdoor use). Jacket diameters should be approximately 0.385” for the
16/2 cable and 0.441” for the 12/2 cable. Note: the lantern is wired with 3 conductor cable. We
do not use the 3rd conductor for most applications, so 2 conductor wire may be purchased.
Sources are: http://www.delcowireus.com/, www.mcmaster.com, or any local supplier.
The ends of the wires terminating inside the lantern must be sealed as water will travel along the
strands and exit in the lantern. After stripping back the appropriate length of outer jacket and
conductor jacket, tin the ends of the wire with rosin core solder. Slide a ½” long piece of heat
shrink tube on each conductor and crimp and solder a non-insulated ring lug for a number 6 stud
(or M3 stud) onto each wire. After the terminations cool, slide the heat shrink tubing over the
shoulder of the lug and shrink so that the insulation and lug are sealed (see next page).
Open the lantern using a 2.5mm Allen wrench to remove 9 fasteners from the bottom of the base
including the three fasteners inside the center tube. Fasteners have a conical sealing washer on
them (they may stick to the lantern). Do not lose these washers.
Unscrew the old cable from the circuit board. Screws are metric, so do not lose them. Remove
the old cable by loosening the outer cap on the stuffing tube and pulling the cable from the
lantern. Slide the bushing (packing) off the old cable, inspect for tears and replace, if necessary.
Replace the stuffing tube, if necessary. 1-2 tier lanterns use a M16-1.5P stuffing tube and 3-8 tier
lanterns use a M20-1.5P stuffing tube. These have metric threads and are available from
http://www.lappusa.com/index.htm, SKINTOP SLM/SLRM series plastic dome cable connector
part number S2509 and S2513, respectively.
Slide the stuffing tube cap and bushing on the new cable, feed it through the stuffing tube and
connect to the circuit board, as shown below. Be sure that the cable is tight in the stuffing tube
(give it a tug) to prevent water vapor from entering the lantern. Reassemble the lantern paying
careful attention to the two O- rings that seal the base to the optic head. Insert the 9 metric
fasteners with conical sealing washers and tighten in a crisscross pattern until they are snug. Do
not over tighten. Test the lantern before redeployment.
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Vega VLB-44 Lantern 25 Jan 2011 - Rev 9
18
Power Cable Replacement (cont’d)
Black or Brown (+)
White or Blue (-)
Note how ends are
sealed with heat shrink
Green/Yellow
(not used*)
*Only used when double stacking 8 tier lanterns. For most applications a 2-wire power cable will
suffice.
Questions/Comments
Questions and comments may be directed to Mr. Jon Grasson at 202-475-5629, email
[email protected].