Avlite AV-SIGN-20 Supplement
Version 2.0
AV-SIGN-20
Solar Sign Light
Installation & Service Manual
AV-SIGN-20
Solar Sign Light
AV-SIGN-20-1-FM
Convenient frangible stake
mount as standard (optional post
mounting assembly available)
448.5
332
Battery
674
97
90mm\~post
Luminaire
with adjustable
vertical
positioning
Sign
Frangible\~Sleeve
Stake
Optional power
connection
to second
luminaire
Regulator
Hinged assembly for
easy access to battery &
driving circuitry
20watt multicrystalline
solar module
Lockable
heavy-duty powder
coated aluminium
assembly
Domed luminaire with 3watt
surface-mounted
ultra-high intensity LED for
optimal area illumination
(>120 degrees)
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3
AV-SIGN-20
Solar Sign Light
Table of Contents
Introduction..........................................................................................Page 4
Operating Principle .............................................................................Page 4
Technology...........................................................................................Page 4
AV-SIGN-20 Model ...............................................................................Page 5
Installation............................................................................................Page 7
Activation .............................................................................................Page 8
Regulator Connection & Operation ...................................................Page 9
Maintenance and Servicing ..............................................................Page 11
Replacing the Battery................................................................Page 11
Trouble Shooting...............................................................................Page 12
Avlite Light Warranty.........................................................................Page 14
Version No. Description Date Approved
1.0 Manual Launch February 2010 A. Dixon
1.1 Graphic Update August 2010 K. Paton
2.0 Spec table update January 2013 J. Dore
Latest products and information available at www.avlite.com
4
AV-SIGN-20
Solar Sign Light
Introduction
Congratulations! By choosing to purchase an Avlite light, you have become the
owner of one of the most advanced solar LED aireld lights in the world.
Avlite Systems draws on more than 25 years experience in the design and manufacture of navigation
aids, and particular care has been taken to ensure your light gives years of trouble free service.
As a commitment to producing the highest quality products for our customers, Avlite has been
independently certied as complying with the requirements of ISO 9001:2000 quality management
system.
By taking a few moments to browse through this booklet, you will become familiar with the versatility of
your light, and be able to maximise its operating function.
Please remember to complete the Avlite warranty registration card accompanying your light.
Operating Principle
The solar module of the light converts sunlight to an electrical current that is used to charge the
battery. The battery provides power to operate the light at night.
The asher unit has very low current requirements. A microprocessor drives an array of ultra bright
LED’s through a DC/DC converter, which enables the LED’s to operate within the manufacturer’s
specications. The battery is protected from over-charging within the circuit to ensure maximum
battery life.
On darkness, the microprocessor will initiate a program check and after approximately 1 minute will
turn on.
Technology
Avlite Systems is a world-class solar lighting systems manufacturer with a proven
reputation for rapid, innovative, and agile technology solutions designed specically
for defense, government, civil and humanitarian aid operations in the most remote,
toughest environments.
Electronics
Avlite employs leading in-house electronic engineers in the design and development of software and
related circuitry. All individual electronic components are sourced directly by Avlite procurement staff
ensuring that only the highest quality components are used in our products.
LED Technology
All aviation lights use the latest advancements in LED (Light Emitting Diode) technology as a light
source. The major advantage of LED’s over traditional light sources is well established in that they
typically have an operational life in excess of 100,000 hours, resulting in substantial savings to
maintenance and servicing costs.
Precision Construction
Commitment to investing in the design and construction of injection-moulded parts including optic
lenses, light bases and a range of other components ensures that all Avlite products are of a
consistent and superior quality.
Optical Performance
Avlite manufactures a range of aviation LED lenses moulded from multi-cavity dies. Complex shapes
such as the AV70 and 16-segment multi-focus lenses are a testament to the company’s superior in-
house lens manufacturing capabilities and outstanding optical performance.
Award-winning, Patented Technology
Several United States and Australian patent registrations are held on Avlite’s range of innovative
designs, with other regional patents pending in Canada, United Kingdom and Europe.
AV-SIGN-20 Model
Avlite Systems’ Solar Sign Light is a remote solar powered sign light specically designed for
aireld signage illumination.
The unit can be tted with either 1 or 2 domed LED light xtures, each featuring a 3 watt
surface-mounted ultra-high intensity LED for maximum illumination with an even 120 degree
light spread.
The light xture also features a domed UV stabilized LEXAN® polycarbonate lens and base,
and convenient mounting bracket ensuring exibility and ease of installation.
The Power Box, consisting of a 20watt multicrystalline solar module, 18Ah SLA battery and
charge regulator, is made from 7-stage powder-coated aluminium making the unit extremely
robust. The Solar LED Sign Light is designed to withstand a range of environmental conditions,
and once installed requires minimal maintenance.
•Specications subject to change or variation without notice
*Subject to standard terms and conditions
SPECIFICATIONS•* AV-SIGN-20
Light Characteristics
Light Source Up to 2 domed LEXAN® luminaires each containing 1x 3watt ultra-high
intensity surface-mounted LED
(standard AV-SIGN-20 comes with 1 domed luminaire)
Light Spread Approx. 120 degrees
LED Life Expectancy (hours) >100,000
Electrical Characteristics
Current Draw (mA) Up to 250mA per domed luminaire (dependent on numbers)
Circuit Protection Integrated
Nominal Voltage (V) 12
Temperature Range -40 to 80°C
Solar Characteristics
Solar Module Type Multicrystalline
Output (watts) 20
Solar Module Efciency (%) 14
Charging Regulation Integrated charge regulator
Power Supply
Battery Type SLA (Sealed Led Acid)
Battery Capacity (Ah) 18
Nominal Voltage (V) 12
Autonomy (nights) 6
Physical Characteristics
Body Material (Domed Luminaire) LEXAN® Polycarbonate – UV stabilized
Lens Material LEXAN® Polycarbonate – UV stabilized
Body Material (Power Box) 7-stage powder-coated aluminium
Mounting Frangible stake mount as standard (optional post mount available)
Length (mm/inches) 674 / 26½
Width (mm/inches) 332 / 131/8
Mass (kg/lbs) 12 / 26½
Product Life Expectancy Up to 12 years
Certications
CE EN61000-6-3:1997. EN61000-6-1:1997
Quality Assurance ISO9001:2008
Intellectual Property
Trademarks AVLITE® is a registered trademark of Avlite Systems
Warranty * 3 year warranty
Options Available • Radio controlled
• Avlite Pilot Activated Lighting Control
• External ON/OFF Switch
• Post mount assembly
Latest products and information available at www.avlite.com
6
AV-SIGN-20
Solar Sign Light
448.5
332
Battery
674
97
90mm\~post
Luminaire
with adjustable
vertical
positioning
Sign
Frangible\~Sleeve
Stake
Optional power
connection
to second
luminaire
Regulator
Typical installation of
AV-SIGN-20-FM
Latest products and information available at www.avlite.com
7
AV-SIGN-20
Solar Sign Light
448.5
332
Battery
674
97
90mm\~post
Luminaire
with adjustable
vertical
positioning
Sign
Frangible\~Sleeve
Stake
Optional power
connection
to second
luminaire
Regulator
Installation
The AV-SIGN-20 can be mounted directly into the ground with frangible stake mounts or to a post
depending on your application.
Installing the Light Assembly to the Frangible Stake Mounts (AV-SIGN-20-FM)
The completed AV-SIGN-20-FM assembly can be mounted on stakes in rm soil (not loose sand,
screenings or other unbound material).
a. Lay the AV-SIGN-20-FM on its side where it is to be located and mark the position for each
frangible stake.
b. Use a sledge hammer to drive the stake into the soil at the chosen location. Drive the stake down
until the bottom of the stake sleeve is at ground level.
c. Fit the boss of the mount plate into the shorter barrel of the frangible sleeve. Using a 6mm Allen
key, tighten the socket head cap screw against the stake mount boss.
d. Fit the AV-SIGN-20-FM on top of the 2 x stakes. The longer barrel of the frangible sleeve should
completely cover the stake sleeve. Using a 6mm Allen key, tighten the bottom socket head cap
screws against the stake sleeve.
e. Position and mount the lights as required.
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8
AV-SIGN-20
Solar Sign Light
Charging the Battery
New lights should be left in the sun for 1-2 days to ensure the battery is charged before placing
in service.
Preferred Installation Location
For best light performance, ensure solar modules are not covered and are in clear view of the
sky with no shadows.
Activation
Installing the Light Assembly to a Post (AV-SIGN-20-PM)
The completed AV-SIGN-20-PM assembly can be mounted onto a post. Two people may be required
to install this AV-SIGN-20-PM to a post, depending on the height it is mounted.
a. The AV-SIGN-20-PM is designed to be tted to a 90mm OD pipe, but can be tted to any post from
3”OD to 4”OD.
b. Position the AV-SIGN-20-PM against the post and t 2 x U-Clamps to the upper and lower sections
of the bracket. Position the AV-SIGN-20-PM so the solar panel is not shaded when assembly is
completed.
c. Secure to the post by tightening the U-Clamps.
d. Position and mount the lights as required.
674
332
432 typical
237
114,2
(9.3") (17.0")
(26.5")
(13.1")
(4.5")
Latest products and information available at www.avlite.com
9
AV-SIGN-20
Solar Sign Light
Regulator Connection & Operation
Regulator Connection Order
The label on the Regulator has each system connection labelled from 1 to 6. This is the recommended
order of system connections.
IMPORTANT: The BATTERY must be connected before the SOLAR to properly start the
microcontroller.
1. BATTERY: Connect the battery (+) and battery (-) to the Regulator
2. SOLAR: First, be certain the battery (+) and battery (-) is connected correctly. Then connect the
solar array to the SOLAR terminals.
Selecting Lighting Control Option
After completing the system connections, select the desired LIGHTING CONTROL option.
A brief description is as follows:
OFF Lights remain turned off
2, 4, 6, 8, 10 Hours light is turned off after sundown
3/1, 4/2, 6/2 Light is turned on after sundown, turned off during the night, and turned on again
one hour (3/1) or two hours (4/2, 6/2) before sunrise
D/D Dusk-to-Dawn, light is on all night
The factory setting of the light is D/D (Dusk-to-Dawn).
To select a lighting option, turn the rotary digital switch to the desired position. An arrow in the rotary
switch will point to the selected position. This is a digital switch, so it will click into each of the ten
positions.
To conrm correct selection of the desired control option, press the TEST button located below the
rotary switches.
+ +
+
4 3 2 1 6 5
OFF
2
4
6
8
10
3/1
4/2
6/2
D/D
TEST
SOLAR BATTERY LIGHT SEALED
OR
FLOODED
SELECT
CHARGING
LOW VOLTAGE
DISCONNECT
LIGHTING CONTROL
TEMP SENSE
Regulator Diagram
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10
AV-SIGN-20
Solar Sign Light
Day/Night Transition
The Regulator uses the solar array to detect day and night. The transition to night requires the level
of solar radiation being received to be less than 2 percent. The transition back to day requires a high
solar array open-circuit voltage. Both state changes require 10 minutes of continuous transition values
before making change. These constraints avoid false transitions due to lightning or dark storm clouds.
LED Indicators:
Green LED
The green LED indicator will light whenever sunlight is available for battery charging. The green LED
will turn off at night.
Because the Regulator uses a PWM constant voltage charging process, there is usually some amount
of energy going into the battery at all times. Although the charging current falls to very low levels when
the battery reaches full charge, the green LED will continue to stay ON all day. This is to indicate that
the controller is working and that energy is available from the PV array for charging.
Red LED
The red LED is an indicator for 3 different functions:
• Automatic low voltage load disconnect (LVD)
If the battery charge state falls below the LVD setpoint, the light will be disconnected and the red
LED will light. This indicates the controller has disconnected the load to protect the battery from
further discharge and possible damage. The red LED will turn off when the battery recovers to
about 50% of its rated capacity and the load is automatically reconnected.
• Initial controller start-up
When the regulator is properly connected to the battery, the red LED will ash 3 times.
• Conrm lighting control selection
When the TEST button is pressed, the red LED will conrm the lighting control option selected by
the rotary switch.
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