Vega Industries PEl 6 Quick guide

PEL 6 Marine Sector Light
Installation and Instruction Manual
PEL-6 Sector Light Product Manual
Available colour range Red, White, Green
Subtense 3.5°, 5.0°, 7.5°, 10°, 15°, 20°
This manual applies from serial #:
Calc version: Calc2001
Manual version: 1.1.1
Date released: 21 October 2008
Status: Released by IG
VEGA INDUSTRIES LIMITED

Installation and Operation Manual PEL - 6 © Vega Industries Ltd, April 2008
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Manual quick reference
WARNING!
DO NOT CONNECT TO ANY POWER SUPPLY BEFORE READING THE
MOUNTING AND INSTALLATION INSTRUCTIONS
PEL 6 POWER SUPPLY REQUIREMENTS
Nominal Input voltage 24 Volts DC
Nominal Current 12 Amps
Product Warranty
Vega warrants that all products supplied are free from labour and material defects, and will repair or replace (at
its option) the whole or any part of the products found to be faulty. The standard warranty is valid for 12
months from the date of dispatch. Vega is not to be liable for any charge beyond the point of delivery,
including installation, alignment or testing. To claim under warranty the product must be returned to the Vega
factory in New Zealand at the users expense.
Patent Notice
The PEL Marine Sector Light has been developed from a prototype developed by the Physics and Engineering
Laboratory of the New Zealand Department of Scientific and Industrial Research. The design concept is fully
protected by world-wide patents held by the New Zealand Government.
VEGA INDUSTRIES LIMITED
21 Heriot Drive, Porirua 5022, New Zealand
Tel: [phone]; Fax: [phone]
E-mail: [email protected]; web site: http://www.vega.co.nz
Designers and manufacturers of lighted navigational aids and optical, electronic and electro-mechanical instruments
Description of Change Date manual released Manual version Software version PEL Serial number
Re-issue of manual
-updated formatting April - 08 1.1 Calc2001
Warranty clause added October 2008 1.1.1
AUTHORIZED DISTRIBUTOR
Go Deep International Inc.
10 Watertower Road
Saint John, NB
Canada
E2M7K2
Website:http://www.buoysandlights.com Email:[email protected] Phone: [phone] Fax: [phone]
Phone: [phone] Fax: [phone]

Installation and Operation Manual PEL - 6 © Vega Industries Ltd, April 2008
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1.0 General Description.......................................................................................................................... 4
1.1 Introduction......................................................................................................................... 4
1.2 Lamps Used in PEL Sector Lights...................................................................................... 4
1.21 Power Supplies for PEL Sector Lights ............................................................................... 5
1.5 Colour Filter Assembly....................................................................................................... 5
1.6 Intensity Reduction Filter ................................................................................................... 6
1.7 Projection System ............................................................................................................... 7
1.8 Aperture Stop...................................................................................................................... 7
1.9 Air Cooling System ............................................................................................................ 7
1.10 Electric Motors ................................................................................................................... 7
1.11 Electronic Controller........................................................................................................... 7
2.0 Mounting and Installation................................................................................................................. 8
2.1 Acceptance Inspection........................................................................................................ 8
2.2 Exclusion of Moisture......................................................................................................... 8
2.3 Physical Mounting.............................................................................................................. 8
2.4 Alignment of Sector Light.................................................................................................. 9
2.5 Masking Stray Light ......................................................................................................... 10
3.1 Input Power Connections.................................................................................................. 10
3.2 CALC (Electronic Controller) Connections ..................................................................... 11
3.3 Stepping Motor Inverters.................................................................................................. 11
4.0 Lampchanger Operation ................................................................................................................. 12
4.1 Fitting of Lamps................................................................................................................ 12
4.2 Lamp Alignment on Lampchanger................................................................................... 13
4.3 Lamp Changer Alignment ................................................................................................ 13
5.3 Parts Listing: Intensity Reduction Filter Assembly.......................................................... 17
6.0 Air Cooling System ........................................................................................................................ 17
7.0 Oscillating Boundary Device (optional extra)................................................................................ 18
7.1 General Description.......................................................................................................... 18
7.2 Mechanical Arrangement.................................................................................................. 18
7.3 Servicing the Oscillating Boundary Device...................................................................... 18
7.5 Reassembly of the Oscillating Boundary Device and Colour Filters............................... 19
7.6 Exploded View ................................................................................................................. 21
7.7 Parts Listing: Intensity Reduction Filter and Oscillating Boundary Device .................... 22
8.0 Maintenance Procedures................................................................................................................. 23
8.1 Objective Lens.................................................................................................................. 23
8.2 Oscillating Boundary........................................................................................................ 23
8.3 Internal Optical Surfaces .................................................................................................. 23
8.4 Aluminised Mirror............................................................................................................ 23
8.5 Filter Glasses..................................................................................................................... 23
8.6 Seals.................................................................................................................................. 24
9.0 Trouble Shooting List..................................................................................................................... 24
9.1 Loss of Intensity or Change in Intensity Profile............................................................... 24
9.2 Poor Sector Resolution ..................................................................................................... 24
9.3 Oscillating Boundary Fails to Oscillate............................................................................ 24
9.4 Lamp Inoperative / Lampchanger Faults.......................................................................... 24
9.5 Electronic Controls ........................................................................................................... 24

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1.0 General Description.
1.1 Introduction
The standard light source of the PEL Sector Light is the 250 watt long-life Thorn M36
tungsten-halogen (TH) lamp. A highly efficient and patented optical condenser system
collects most of the available light energy into an intense beam which is emitted through a
precision projection system. The beam is optically separated into accurately controlled
sectors.
These sectors are recognisable by colour alone (normally red, white and green), or by
alternation between two colours of adjacent sectors (when optical coding device is fitted).
Functionally the PEL Sector Light consists of the following integrated sections:
1.2 Lamps Used in PEL Sector Lights
The PEL-6 Sector Light optical system was designed specifically to utilise the special
features of the 2000-hour 250 Watt tungsten halogen lamp designated (M36) which was
originally developed in the UK by Thorn. To our knowledge in 1978 this was the only lamp
available with this label (M36). The original lamps had Ø1.0 mm pins on a 6.35mm pitch, a
Light Centre Length of 33 mm and Max Overall Length of 55mm. In the early 1980’s this pin
diameter was increased to Ø1.25 mm.
In the last few years other lamps from other manufacturers designated ‘M36’ have
appeared on the market. Most of these do not compare with the original ‘M36’ lamp and in
fact are extremely suspect in design. They can degrade the optical performance of the
PEL-6 Sector Light, and also cause damage because they are prone to exploding. Such
explosions can fracture the first (spherical) condenser lens, damage the primary mirror with
shards of flying glass, and coat the optics with a thin film of ash and soot, mainly tungsten
oxide. The first condenser lens can also be cracked by excessive heat - some non-genuine
M36 lamps run at higher temperatures than the original, and the increased resistance of
poorly-adjusted or corroded lampchanger collets can add to the heat load.
Vega now understands that Thorn has sold its plant and lamp designs to GE from whom
Vega now sources lamps. The lamps now sold into Australasia by Thorn, designated ‘M36’
are of Japanese origin, have a shorter LCL and must not be used in PEL-6 Sector Lights.
They have a much shorter life, easily over-heat and are prone to exploding.
If a Tungsten Halogen lamp is operated at a voltage higher than its rated voltage then its
expected life deteriorates rapidly as the operating voltage increases. The envelope
temperature of a TH lamp is in excess of 500° F at rated voltage, so any increases in voltage
will increase the chance of a lamp exploding. If the Spherical Condenser lens is cracked
then boundary resolution is destroyed.
Summary
Use only M36 lamps manufactured by GE. Do not run lamps in excess of 24 Volts when
controlled by CALC-88 controllers. CALC-92, CALC-2000 and CALC-2001 controllers have
pulse-width modulation (PWM) applied to the output to the lamp to ensure that the RMS
voltage does not exceed the nominal value. Size and check the grip tension on the lamp

Installation and Operation Manual PEL - 6 © Vega Industries Ltd, April 2008
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collets every time lamps are replaced. Ensure the pin size of the lamp is Ø1.25mm
1.21 Power Supplies for PEL Sector Lights
There is a potential problem when using power supplies with a high internal inductance to
drive low-voltage lighted navigation aids. The problem is that when a lamp is switched off
(either at dawn or when it is being periodically flashed), or when a lamp fails at the end of its
life, very large transient voltages can be generated. These voltages - of the order or 100-200
Volts - can cause damage to electronic lamp controllers (eg CALC-2001 and CALC-20)
which operate at typically 12 or 24 Volts.
The reason for the high inductance in the power supply is that an inductive element
(typically a “choke”) is often used in conjunction with a capacitor to form an “LC” circuit
which smoothes the pulsed DC after rectification. Unfortunately, such inductors also store
large amounts of energy during normal operation, and it is the rapid discharge of this
energy which is responsible for the voltage spike when sudden changes are made to the
current flowing.
A further hazard is that when such power supplies are initially installed, typically as a
continuous battery charger into a bank of batteries, the batteries are in good condition and
undamaged. In this situation the batteries may well have sufficient capacity to absorb
voltage spikes and prevent them being passed on to the electronics in the light. However, as
the batteries deteriorate with time, their condition possibly aggravated by poor maintenance
or damage, their capacity to absorb such spikes reduces and more frequent damage to
electronics can result.
1.3 Lamp System
The tungsten-halogen lamp is slightly displaced in the vertical plane from the centre of
curvature of a concave spherical mirror. This mirror gathers the light emitted from the rear of
the lamp and forms a real image of the lamp filament adjacent to the actual filament. The
mirror is a spherical, optically worked concave glass surface onto which aluminium has been
evaporated under vacuum. On anamorphic (wide-angle) lights the displacement may be
horizontal rather than vertical to give a wider light source.
1.4 Aspheric Condenser System
The condenser system is arranged to collect as much light as is practicable from the filament
and its image generated by the mirror, and to form this light into a narrow beam of high
intensity light. In doing so, an enlarged image of the filament (and its mirror image) is
formed between the two projector lenses. This is the source of light which the mariner
actually sees.
1.5 Colour Filter Assembly (and Optional Oscillating Boundary Device)
The colour filter assembly is a set of optically-worked filters located in the illumination plane
of the condenser system and at the focus of the projection lens. The width of the individual
filters is accurately scaled to provide the required sector subtenses.
The “oscillating boundary” device mechanically reciprocates the filter assembly to provide
additional defined sectors. These are characterised by an alternation between the colours of
the solid sectors on either side of the alternating sector.

Installation and Operation Manual PEL - 6 © Vega Industries Ltd, April 2008
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1.6 Intensity Reduction Filter
This is a neutral density filter which is mechanically inserted into the beam to reduce the
intensity of the emitted light for night operations.

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1.7 Projection System
The sharp boundaries of the PEL Sector Light are produced by a two-component positive
projection lens in models with a subtense greater than 10° and a singlet projection lens in
the case of the 5° and 3.5° models. This system forms an enlarged image of the coding
device (coloured filters) at a considerable distance from its focus. Sector positions are
determined solely by the relative positions of coding device and projection lens, and are
independent of lamp filament position, errors in which can affect only the beam intensity of
the lamp.
1.8 Aperture Stop
The boundary definition is further enhanced by an aperture stop situated between the two
projection lens components. The aperture stop reduces the amount of light which is
scattered outside the beam angle, and also enables a long-life filament lamp such as the
M36 to be used without incurring any loss of boundary definition.
1.9 Air Cooling System
Because the PEL Sector Light is a sealed unit, a slow speed internal fan is used to
move the air through a fixed circuit enabling the inside temperature to be held at an
acceptably low level.
1.10 Electric Motors
There are up to three motors in this Sector Light - a DC Brushless type used in the cooling
fan, and stepper motors to drive the neutral density filter and optional oscillating boundary
device. Stepper motors are employed where speed control and good reliability in high
temperature situations are essential.
1.11 Electronic Controller
The total electronic monitoring and control system, including inverter supplies, is
controlled by a micro-processor in a module called the CALC-2001. This is a sealed unit
contained within the Light. Up to two sealed converters can be mounted directly to this
module.

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2.0 Mounting and Installation
2.1 Acceptance Inspection
Before connecting the sector light to any power supply, the following steps should be carried
out:
2.1.1 After removing the unit from the packing case, an inspection should be carried out to
check that no damage has occurred during transit.
2.1.2 Review this manual and become familiar with the general layout of components.
2.1.3 Remove Rear Cover. NOTE: If cover is not totally removed, support underside
of rear cover otherwise damage to CALC-2001 may result.
2.1.4 Remove packing around Suspension Springs of oscillating boundary
mechanism (if installed). NOTE: Packing will be on both sides.
2.1.5 Remove packing around brilliancy control mechanism.
2.2 Exclusion of Moisture - THIS IS VERY IMPORTANT
2.2.1 PEL Sector Lights run at high internal temperatures. One of the common problems
associated with this type of system is condensation, which is introduced when the
light is opened for service or replacement of lamps.
2.2.2 Where it is impracticable to house the light, properly pre-dried packs of silica gel
should be placed in convenient places around the lampchanger area of the light. PEL
Sector Lights are tested to hold 6 psi internal pressure, and it is extremely rare for the
ingress of moisture to be associated with the failure of a seal. When servicing, ensure
that the can-fastening knobs are properly tightened to evenly compress the O-Ring
seal.
2.3 Physical Mounting
2.3.1 The sector light can now be mounted and aligned. The PEL light has two mounting
bases. Care must be taken to ensure that the mating surface is flat and no distortion
is introduced to the light itself when mounting.
2.3.2 In order to achieve the high degree of accuracy of which the PEL Sector Light is
capable, it is essential that the mounting location is not capable of being torsionally
deflected more than 0.2 mm per metre in azimuth under wind loading and other
forces likely to be encountered.
2.3.3 Mounting holes should be drilled to the dimensions shown below. Note that the two
bases are spaced differently for different sizes of sector light.
2.3.4 The “rear” base incorporates a recess for a 12.6 mm Ø (0.5 inch Ø) pin, on which the
light can be pivoted during the alignment phase. To permit extremely fine adjustment
of azimuth angle the “front” mount incorporates a pair of trimming screws.

Installation and Operation Manual PEL - 6 © Vega Industries Ltd, April 2008
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2.4 Alignment of Sector Light
2.4.1 Adjust the angle of elevation of the beam so that the vertical centre is at the average
height of a ship’s bridge at the maximum range at which the light is used. Align the
sector pattern in azimuth using an observer located on the boundary between two
adjacent sectors.
2.4.2 Sector positions should be checked by survey, and the location of the sector
boundaries should be verified from the waterway before commissioning.

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2.5 Masking Stray Light
2.5.1 In an optical projection system at least 0.5% of the light will be scattered by the last
lens surface, and even more if the lens is not completely clean. In the case of a very
powerful sector light there can be enough stray light for an observer outside the
beam to think he or she is inside the beam. This problem may arise with PEL-6
Sector Lights of 5° subtense or less, and is possible with 10° lights at full brilliance at
night against a black background.
2.5.2 PEL-3 Series Lights of small subtense angle are masked with a barrel extension. With
the larger aperture of a PEL-6 (Mark VI) PEL Sector Light this is impractical. The
problem can be largely alleviated by placing a pair of vertical plates some distance in
front of the lens (like blinkers on a horse) to mask the lens from an observer outside
the beam.3.0 Electrical Supply and Circuitry
3.1 Input Power Connections (WARNING)
3.1.1 The PEL Sector Light is supplied fully wired and ready for use. This Sector Light
must be connected to a 24V DC supply which is sufficiently smoothed (eg has a
large enough capacitor across the output of the supply which is the input to the
light) to ensure no high voltage spikes can damage the microprocessor-based
control system.
3.1.2 Prior to switching on any power, please ensure that the power supply is 24 Volts DC
and that Brown = Positive, and Blue = Negative. The absolute maximum voltage must
not exceed 28 V DC. It is normal to energize from a battery bank with “battery-
charger float.”
INPUT CONNECTIONS: BROWN = positive 24V DC
BLUE = negative 24V DC
3.1.3 The voltage at the lamp terminals should normally be at the nominal voltage of the
lamps installed when a lamp of the correct wattage is installed and switched on.
Excessive voltage will reduce lamp life but low voltage will reduce light output while
extending lamp life. Low voltage is therefore acceptable, or even desirable in some
cases. Special limitations apply to tungsten-halogen lamps.
3.1.4 Vega PF and TH lampchangers can be operated on either AC or DC, 12 or 24 volts
depending on the lamp requirements. The DC polarity is of no consequence and the
frame of the lampchanger is insulated from the electrical system.