U. S. DEPARTMENT 

OF HOMELAND SECURITY 

UNITED STATES 

COAST GUARD 

 

SHORT RANGE

AIDS TO NAVIGATION

SERVICING GUIDE

5

 COMDTINST M16500.19B 
Commandant 

United States Coast Guard 

1900 Half Street, S.W. 

Washington, DC 20593-0001 

Staff Symbol: CG-432A 

Phone: (202) 475-5629 

FAX: (202) 475-5959 

Email: jon.t.grasson@uscg.mil 

 COMDTINST M16500.19B 

 JUN 4, 2008 

COMMANDANT INSTRUCTION M16500.19B 

Subj: SHORT RANGE AIDS TO NAVIGATION SERVICING GUIDE 

1. PURPOSE. This Manual is a field guide for U.S. Coast Guard personnel who service minor 

aids to navigation hardware powered by direct current (DC). 

2. ACTION. Area, district, and sector commanders, commanders of maintenance and logistics 

commands, commander deployable operations group, commanding officers of headquarters 

units, assistant commandants for directorates, Judge Advocate General, and special staff 

offices at Headquarters shall ensure that the provisions of this manual are followed. Internet 

release is authorized. 

3. DIRECTIVES AFFECTED. Commandant Instruction M16500.19A is canceled. 

4. DISCUSSION. This Manual provides field units with a pocket-sized guide for installing, 

maintaining and troubleshooting DC powered minor aids to navigation. Changes from the 

previous issue include the addition of Light Emitting Diode (LED) lanterns and removal of 

the FA-240 range lantern and XFB flashtube. 

5. CHANGES. Recommendations for the improvement of this Manual shall be submitted to 

Commandant (CG-432A) at jon.t.grasson@uscg.mil. 

6. ENVIRONMENTAL ASPECT AND IMPACT CONSIDERATIONS. Environmental 

considerations were examined in the development of this Manual and have been determined 

to be not applicable. 

7. FORMS/REPORTS. None. 

 D. G. GABEL/s/ 

 Assistant Commandant for Engineering and Logistics 

DISTRIBUTION – SDL No. 149 

 a b c d e f g h I j k l m n o p q r s t u v w x y z 

A 2 2 2 2 2 2 

B 8 20* 1 

C 2 3 

D 1 E F G 

H 

NON-STANDARD DISTRIBUTION: *MLCLANT & MLCPAC (6 extra), Bn: RTC Yorktown (t-naton) (500 copies), Ci: Station 

Channel Islands (2 copies) 

 
TABLE OF CONTENTS 

CHAPTER 1 - GENERAL 1-1 

 A. Introduction 1-1 

 B. Maintenance 1-1 

 C. Configurations 1-2 

 D. Safety Requirements 1-4 

 E. Conventions 1-4 

 F. Equipment 1-4 

 G. Stuffing Tubes 1-5 

CHAPTER 2 - POWER SYSTEMS 2-1 

 A. Solar Panels 2-1 

 B. Local Terminal Box (LTB) 2-7 

 C. Junction Boxes (Buoy & LED) 2-9 

 D. Megger 2-11 

 E. 12V Secondary Batteries 2-15 

 F. Large Stationary Batteries 2-22 

 G. Range Power Box (RPB) 2-31 

 H. Range Switch Box (RSB-DC) 2-39 

CHAPTER 3 - SIGNALS 3-1 

 A. 155mm Lantern 3-1 

 B. Carmanah 700 Series Self Contained LED Lanterns 3-7 

 C. Vega VLB-36 Self Contained LED Lantern 3-11 

 D. BWT 100 Series Self Contained LED Lantern 3-16 

 E. 250mm Lantern 3-21 

 F. 300mm Lantern 3-30 

 G. Tideland MLED-120 & Sealite SL-125 LED Lanterns 3-37 

 H. Vega VLB-44 LED Lantern 3-41 

 I. RL-14 Range Light 3-45 

 J. VRB-25 Rotating Beacon 3-50 

 K. Sound Signals 3-87 

CHAPTER 4 - HARDWARE 4-1 

 Minor Aid Hardware 4-1 
FOREWARD 

The Short Range Aids to Navigation Servicing Guide was prepared by 

the Ocean Engineering Division (Commandant (CG-432A)) with 

assistance from the National Aids to Navigation School. Its purpose is to 

provide a “field” manual for the servicing of the short range aids to 

navigation system of the United States by U.S. Coast Guard personnel. 

It should be closely adhered to by servicing personnel unless changed 

by subsequent guidance. 

This servicing guide is intended only for the internal guidance of U.S. 

Coast Guard personnel. It creates no duties or obligations to the public 

to comply with the procedures described herein. The U.S. Coast Guard 

retains the discretion to deviate or authorize deviation from these 

procedures. 

Mariner Expectations: The mariner expects each aid to navigation 

encountered will be operating in accordance with the Light List 

description. It’s a matter of navigation safety, of legal necessity and of 

professional and personal pride to properly inspect, service and maintain 

all assigned Aids to Navigation.
CHAPTER 1. GENERAL

A. Introduction. This guide provides servicing personnel the information 

needed to install, maintain and troubleshoot 12-volt minor aids to 

navigation. 

1. Personnel using this guide are expected to have completed at 

least the Basic Minor Aids to Navigation Course at the National 

Aids to Navigation School or instruction by a district training 

team. 

2. The following three chapters provide information on: Power, 

Signals and Hardware. Consult with the appropriate sections 

when installing, maintaining or troubleshooting hardware. 

B. Maintenance. Aids to navigation must be properly maintained to 

ensure proper performance. The team leader must identify what 

equipment is used at the aid and what service is required. Each 

chapter details each piece of equipment and what maintenance is 

required. In general, most minor aids consist of a single solar panel, 

one or more secondary batteries, a lantern and associated 

hardware. These aids will have the following maintenance

performed either annually, biennially or triennially, depending on its 

scheduled visit: 

Solar Panel - Visual inspection, clean;;

Secondary Batteries - Visual inspection, load test; 

Power Cable – Visual inspection;

Lantern - Visual Inspection, clean;

Minor Aid Hardware - Relamp, minor aid quick check. 

Aids with self contained lanterns require less maintenance. Other 

aids will require more detailed maintenance. Consult with all the 

sections in this guide that apply. 

1-1
C. Configurations. 

1. Minor Aids. With the addition of the appropriate lantern, the 

components shown in Figure 1-1 are used on buoys, structures 

and nighttime ranges with single lights. Rotating beacons and 

high intensity nighttime ranges will have the same lighting 

equipment; however larger batteries and more solar panels may 

be used. 

Figure 1-1 

L S S F + _

FLASHER

FL4(.4)

LAMPS

CG6P

LAMPCHANGER

CG-504, 493, 

481 or 181

FLASHER

DAYLIGHT

CONTROL

SECONDARY BATTERY

SOLAR PANEL

TYPICAL MINOR AID SYSTEM

WIRING KIT

 In most cases, these components can be replaced by a self 

contained LED lantern. 

1-2
2. Day/Night Ranges. Day/night ranges generally use more power 

than a typical minor aid. Multiple solar panels are terminated 

into a Local Terminal Box (LTB). Overcharge protection, 

disconnects and low voltage cutoff are provided by the Range 

Power Box (RPB). Batteries are multiple 2-volt cells wired in 

series (Exide Classic, Absolyte II, Dryfit) or, for small systems, 

up to 4 minor aid batteries wired in parallel. The Range Switch 

Box (RSB) controls which light (day or night) operates. With the 

exception of the day/night lanterns, the power and control 

system is shown in Figure 1-2. 

12.5

AB CD

BATTERY

SWITCH POSITIONS

-1

-2

-3

-4

ARRAY

LOAD

TEMP

COMP

LOAD

DISCONNECT

RESET PHOTOVOLTAIC POWER CONTROLLER

LOAD

DISCONNECT

ADJUST

RY1

CB1

RANGE SWITCH BOX - DC (RSB-DC)

SOLAR PANELS

LTB

RPB

RSB

BATTERIES

TO DAY/NIGHT

RANGE LIGHTS

Figure 1-2 

1-3
D. Safety Requirements. The following shall be worn and performed at 

the aid site: 

1. Hard hats, safety toe boots, gloves and eye protection. 

2. Coast Guard Approved PFD, as required. 

3. Personal fall protection equipment, as required if the structure is 

6 feet or higher. See Aids to Navigation Manual – Structures, 

COMDTINST M16500.25A. 

4. Equipment shall be deenergized (when possible) while installing 

or replacing components. 

E. Conventions. 

1. Wire Color Coding. Wires are color-coded and shall be installed 

such that BLACK is "Positive (+)" (12VDC) and WHITE is 

"Negative (-)" (0 VDC). 

 

F. Equipment. 

1. The following equipment shall be carried to the aid site: 

a. Fluke 77 meter or equivalent. 

b. Small and medium tipped flathead screwdrivers. 

c. Small and medium tipped Phillips screwdrivers. 

d. Needle nose pliers. 

e. 12 AWG, 10” jumper wire, and 6 feet of 12/2 SO cable. 

f. Crimping tool. 

g. Solderless terminal assortment. 

h. Crescent wrench. 

i. 9" torpedo level. 

j. Flashlight. 

k. Stainless hardware assortment. 

l. Focus fixture. 

1-4
m. Glass cleaner. 

n. Medicinal swabs or denatured alcohol. 

o. Clean rags. 

p. Daylight Control Cover (wire nut, Ideal Mfg #415). 

q. Splash proof apron (also used for solar panel test). 

r. No-ox grease (all batteries). 

s. Stopwatch. 

t. Small paper clip (to clean drain holes). 

2. The following equipment, where appropriate, shall be carried to 

the aid: 

a. Lampchanger (CG-6P or CG-6PHW). 

b. Flasher (CG-181, CG-493, CG-481 or CG-504). 

c. Daylight control (Type L, C or R). 

d. Lantern accessories (screws, stuffing tubes, etc.) 

e. Lamps. 

f. Spare LED lantern (appropriate type). 

g. Spare Parts Kits (Lighthouse, Range, VRB-25). 

h. 5/32”, 1⁄4” drive hex bit socket, 18” extension, “T” handle, 

5/64” Allen wrench and 7/16” open end wrench to service 

the VRB-25. 

i. Torque wrench & socket set (stationary batteries). 

j. Cordless drill & hole saw (stuffing tubes in RPB, etc.) 

k. Distilled water (stationary batteries). 

l. Baking soda & bucket (stationary batteries). 

m. Bristle brush (stationary batteries). 

n. Denatured alcohol (stationary batteries). 

o. 12 AWG and 18 AWG wires (see VRB section). 

G. Stuffing Tubes. Stuffing tubes shall be installed in all AtoN 

equipment when the wire or cable passes through a bulkhead. It 

provides strain relief for the connections inside the apparatus and 

maintains weather tight protection from the environment. A drip loop 

of wire just outside of the stuffing tube prevents excess water from 

following the wire into the bulkhead. Technical Data Sheet 05-02 on 

www.uscg.mil/systems/gse/gse2 describes stuffing tubes in detail. 

1-5
1. Inspection. Replace if cracked or deteriorated. 

2. To prevent twisting of the packing, assemble stuffing tubes as 

shown in Figure 1-3. Note the difference between a bulkhead 

stuffing tube (hole with no threads) and a NPT stuffing tube. 

3. Be sure wire is arranged to provide a drip loop. 

Packing 

Cap

Wire

Bulkhead (NEMA Box, etc)

Packing

Washers

Drip

Loop

O-ring & cap

Bulkhead Type 

Stuffing Tube

Cap

NPT

Body

Washers

Packing

Lantern

Wall Thickness: 3/16” – 3/4”

National Pipe Taper

(NPT) Stuffing Tube

Figure 1-3

1-6
CHAPTER 2. POWER SYSTEMS 

A. Solar Panels. 

1. Notes. 

a. Solar panels are used on most minor aids to navigation to 

charge batteries that operate the light. Depending on the 

power requirements of the aid, a 10, 20 or 40 watt solar 

panel will be used. Some minor aids may use multiple 

solar panels mounted on an array, or around the 

superstructure or lantern stand of a buoy. 

 

2. Installation. 

 

a. Solar Power Installation Kits, available from ELC Baltimore, 

are used to isolate and protect the solar panel from the 

mounting frame. The kits contain plastic bushings, stainless 

steel hardware, zip ties, bird springs and stuffing tubes. 

b. Solar panels mounted on structures must face the equator. 

c. The tilt angle of the array may depend on the specific 

project. Otherwise, minor aid structures have a tilt angle 

with respect to horizontal of 60 degrees in CONUS, 75 

degrees in Alaska, and 30 degrees in Hawaii, Guam and 

Puerto Rico. Tilt angles on buoys are 0 degrees (single flat 

mount above lantern), 60 degrees (tripod), 90 degrees (dual 

or quad mount on superstructure), or 15 or 45 degrees (dual 

mount). 

d. Mount the solar panel to the array stand using stainless steel 

hardware and isolation spacers as shown in Figure 2-1. 

Vandal resistant nuts should be used in areas that have a 

history of theft. The nut is installed on a welded bolt and 

torqued until the hex head breaks off leaving a conical 

2-1
fastener that is difficult to remove. 

Figure 2-1 

WELDED

BOLT

STRUCTURE

SPACER

SOLAR PANEL

LOCK WASHER

VANDAL RESISTANT NUT*

* USE A STANDARD NUT ON BOLTS NOT WELDED TO STRUCTURE

e. Measure the tilt angle of solar panels, as shown in Figure 2-

2 when installed on structures, and adjust if necessary. 

60o FOR

CONUS

Figure 2-2 

f. The solar panel may be wired at the flasher, LED junction 

box or battery, as shown in Figure 2-3 whichever is 

convenient. 

 

2-2
S S L F +

_

FLASHER

FL4(.4)

S S L F +

_

FLASHER

OR FL4(.4)

BUOY BUOY/SHORE AID SHORE AID

LED J-Box OR

 Figure 2-3 

g. If wired to the flasher, install the stuffing tube in an unused 

threaded entrance in the lantern. Do not try to install two 

wires in one stuffing tube. 

h. Secure solar panel cable to structure using zip ties. Do not 

shorten this cable (the panel may be used at another site). 

i. Areas of high bird fouling may install bird deterrent devices 

like bird springs or Nixalite (www.nixalite.com) on the top 

row of mounting bolts by screwing the compressed end of 

the spring on a stud. Bend springs up when mounted on 

structures to prevent shadowing. 

2-3
3. Maintenance. Perform the following procedures during every 

visit. 

a. Check to be sure that tilt angle is properly set for aid. 

b. Check panel orientation – Northern hemisphere: panels face 

due south. 

c. Check solar panel for evidence of water intrusion (around 

edges of glass). Discoloration of the solar cells and potting 

are typical signs of water intrusion. Replace if necessary. 

d. Inspect wiring for cuts and abrasions. Replace panel if 

necessary. Panel wires are not field replaceable. 

e. Clean solar panel with glass cleaner. 

f. To remove vandal nuts, screw a used vandal nut onto bolt 

and remove both with vice grips, as shown in Figure 2-4. 

Figure 2-4 

WELDED

BOLT

STRUCTURE

SPACER

SOLAR PANEL

VANDAL RESISTANT NUTS

VANDAL NUT REMOVAL PROCEDURE

VICE GRIPS

 

2-4
4. Troubleshooting Procedures. If the aid is discrepant or the 

battery fails the load test, perform the maintenance procedures 

outlined in section 4, above and the following tests: 

a. Power output/diode test: 

SHINE LIGHT ON PANEL. MEASURE VOLTAGE BETWEEN 

POSITIVE PANEL LEAD AND NEGATIVE PANEL LEAD

DISCONNECT POSITIVE PANEL (BLACK) LEAD.

LEAVE BATTERY LEADS CONNECTED

IS VOLTAGE 

GREATER THAN 0V?

COVER PANEL COMPLETELY AND CONNECT 

LOAD TESTER (ANY SETTING) TO POSITIVE PANEL 

LEAD AND POSITIVE BATTERY/FLASHER LEAD

MEASURE VOLTAGE ACROSS LOAD TESTER (POSITIVE

PANEL LEAD AND POSITIVE BATTERY/FLASHER LEAD)

IS VOLTAGE 

GREATER THAN 0V?

REPLACE PANEL

(SHORTED DIODE)

REPLACE PANEL

(OPEN DIODE OR 

BROKEN CONNECTION)

PANEL IS GOOD.

RECONNECT PANEL LEADS

YES

NO

YES

NO

SOLAR PANEL SERVICING FLOWCHART

2-5
DISCONNECT POSITIVE PANEL (BLACK) LEADS

AT LTB. RANGE POWER BOX/CHARGE CONTROLLER

CIRCUIT BREAKERS MUST BE ON

SHINE LIGHT ON EACH PANEL. MEASURE VOLTAGE BETWEEN EACH

POSITIVE PANEL LEAD AND NEGATIVE TERMINAL STRIP IN LTB 

IS VOLTAGE 

GREATER THAN 0V?

COVER EACH PANEL COMPLETELY AND CONNECT 

LOAD TESTER (ANY SETTING) TO EACH POSITIVE

PANEL LEAD AND POSITIVE TERMINAL STRIP IN LTB

MEASURE VOLTAGE ACROSS LOAD TESTER (POSITIVE

PANEL LEAD AND POSITIVE TERMINAL STRIP IN LTB)

IS VOLTAGE 

GREATER THAN 0V?

REPLACE PANEL

(SHORTED DIODE)

REPLACE PANEL

(OPEN DIODE OR

BROKEN CONNECTION)

PANEL IS GOOD. 

REPEAT FOR ALL PANELS, THEN

RECONNECT ALL PANEL LEADS

YES

NO

YES

NO

MULTIPLE SOLAR PANEL SERVICING FLOWCHART

b. If the aid has multiple solar panels or uses a Local Terminal Box, 

perform the following procedure: 

 

2-6
B. Local Terminal Box (LTB). 

1. Notes. 

1. Local Terminal Boxes (LTBs) are used on fixed aids to 

navigation requiring multiple solar panels. The LTB 

provides a convenient place to terminate the panels and 

step-up to a larger wire size. Up to ten solar panels may 

be terminated in one LTB. 

There is a version of the Local Terminal Box with diodes 

for use with high density solar panels which do not contain 

blocking diodes. This version is designated LTB-D and 

has an additional vertical terminal strip with diodes 

installed across the terminal strips. 

 

2. LTBs are available from Commandant (CG-432A). 

 

2. Installation. 

 

a. The LTB is installed on the solar array structure so that the 

solar panel leads do not have to be extended. 

b. Install the appropriate number of stuffing tubes in the box 

using a hole saw or knockout punch. See TDS 05-02 at 

www.uscg.mil/systems/gse/gse2 for diameters. Do not 

install stuffing tubes on top of the box where rainwater can 

collect. 

c. Route each solar panel lead through a stuffing tube. Leave 

enough slack inside the box to allow attachment to the 

terminal strip. 

d. Attach the provided ring lugs (or substitute locking spade 

lugs) to the solar panel leads. 

2-7
e. Attach the black lead to the “+” terminal strip and the white

lead to the “-“ terminal strip. Be sure that the leads are 

connected to the strip opposite the jumpers. 

f. Wire up to 6 AWG may be installed between the LTB and 

Battery/Range Power Box. Consult with your District or Civil 

Engineering Unit for assistance in choosing the correct wire 

size. Failure to install adequate wiring will result in 

excessive voltage drop in the charging system. 

3. Maintenance. 

a. Inspect terminations for corrosion. Clean or replace if 

necessary. Lugs may be moved to unused terminals if 

necessary. Replace desiccant bag if saturated (if used). 

4. Troubleshooting Procedures. 

a. Consult with the Multiple Solar Panel Servicing Flowchart in 

section 2.A.4.b. 

b. For LTB-D, the positive solar panel leads may be 

disconnected and each diode checked using the “Diode 

Test” feature on your Fluke 77 or equivalent. 

 

2-8
C. Junction Boxes (Buoy and LED). 

1. Notes. 

a. The LED Junction Box is used on buoys 

where a self-contained LED lantern is not 

viable, but a conventional LED lantern can be 

used. Conventional LED lanterns do not have 

provisions to terminate the solar panel, so an 

external junction box is used. 

b. The Buoy Mounted Junction Box is a larger 

version of the LED junction box and can be 

used on buoys with conventional lanterns and 

LED lanterns that require an external power 

source. The box has provisions to connect up 

to 4 solar panels, a bank of batteries, lantern, 

sound signal and racon. 

 

SOLAR PANEL +

SOLAR PANEL +

SOLAR PANEL +

SOLAR PANEL +

SOLAR PANEL -

SOLAR PANEL -

SOLAR PANEL -

SOLAR PANEL -

BATTERY +

BATTERY -

FLASHER +

FLASHER -

RACON +

RACON -

SOUND +

SOUND -

2. Installation. 

 

a. The boxes contain templates for drilling holes in the radar 

reflector on a buoy. The preferred location is under the 

closed portion of the radar reflector with the stuffing tubes 

facing down or out to either side. The vent must be facing 

down or to the side; never up. Alternatively, the box may be 

mounted next to the lantern on top of the radar reflector, but 

water intrusion may be a problem at this location. 

b. Stuffing tubes are sized for standard solar panel cables and 

12/2 SO cable. If a different packing is needed, consult TDS 

05-02 at www.uscg.mil/systems/gse/gse2 for the proper 

size. Packings must be tight to prevent water intrusion. 

Packing plugs are provided for unused stuffing tubes. 

c. Route each lead through a stuffing tube. Leave enough 

slack inside the box to allow attachment to the terminal strip. 

2-9
d. Attach the provided locking spade lugs to the leads, except 

when using the LED junction box. The bare wire is inserted 

in the Eurostrip terminal block. 

e. Attach the black lead to the “+” terminal strip and the white

lead to the “-“ terminal strip. 

f. Place desiccant bag inside box prior to securing cover. 

3. Maintenance. 

a. Inspect terminations for corrosion. Clean or replace if 

necessary. Lugs may be moved to unused terminals if 

necessary. Replace desiccant bag when servicing. 

4. Troubleshooting Procedures. None 

.

 

2-10
D. Megohmeter (Megger) or Insulation Tester. 

1. Notes. 

a. The Megger is used to inspect power cables used on 

fixed and floating aids to navigation. This generator 

develops 500 volts DC to check for damaged 

conductors and insulation. The older, hand cranked 

version is slowly being replaced by the versatile 

Fluke 1577 or 1587 multipurpose VOM and 

insulation tester. On the Fluke 1577/1587, pay 

careful attention to the letter “M” in the display. This 

indicates that the reading is greater than 1 megohm. 

Lack of this letter indicates a reading under 1 

megohm. Use the 500 volt setting for all tests as the 

insulation is generally rated at 600 volts. 

M

2. Safety. 

a. This device will produce 500 volts DC. Be sure equipment 

(flashers, battery, etc.) is disconnected from the cable being 

tested otherwise damage may occur. 

b. Be sure personnel are clear of cable being tested. While the 

current generated is not lethal, the shock can be unpleasant. 

2-11
3. Equipment Test. 

a. The megger should be tested as described below prior to 

use to ensure that it is functioning correctly. 

INSPECT MEGGER AND

LEADS FOR VISUAL DEFECTS

CONNECT LEADS TO MEGGER

WITH LEAD ENDS APART,

TURN HANDLE

IS READING INFINITY? 

CONNECT LEAD ENDS.

TURN HANDLE

IS READING ZERO?

MEGGER IS GOOD

REPLACE MEGGER

REPLACE LEADS AND RETEST

YES

YES

NO*

NO

MEGOHMETER EQUIPMENT TEST

*DIGITAL INSULATION TESTERS LIKE THE FLUKE 1577/1587 WILL NOT READ

INFINITY. THE VALUE WILL BE IN THE MEGOHM RANGE, WHICH IS ACCEPTABLE.

 

2-12
4. Troubleshooting an Aid. 

a. Perform the following test on SO power cable when 

troubleshooting an aid because of a discrepancy. 

DISCONNECT POWER CABLE

FROM BATTERY AND FLASHER

ATTACH A MEGGER LEAD TO

THE WHITE WIRE AND THE 

OTHER TO THE BLACK WIRE

OF THE POWER CABLE

WITH POWER CABLE LEADS APART

AT OTHER END, TURN HANDLE

OR PRESS “INSULATION TEST” BUTTON

IS READING GREATER 

THAN OR EQUAL TO 

1 MEGOHM?

WITH POWER CABLE LEADS 

TOGETHER AT OTHER END,

TURN HANDLE OR PRESS 

“INSULATION TEST” BUTTON

IS READING ZERO?

DISCONNECT MEGGER

FROM POWER CABLE

REPLACE POWER CABLE

(SHORTED CONDUCTORS)

REPLACE POWER CABLE

(OPEN CONDUCTOR)

POWER CABLE MEGOHMETER TEST

YES

YES

NO

NO

GO TO NEXT PAGE

POWER CABLE

POWER CABLE

2-13
ATTACH BOTH MEGGER LEADS

TO THE STRUCTURE/BUOY.

TURN THE HANDLE OR PRESS

“INSULATION TEST” BUTTON.

DISCONNECT ONE MEGGER LEAD AND

CONNECT TO ONE POWER CABLE LEAD

IS READING ZERO?

WITH OPPOSITE POWER

CABLE LEADS TOGETHER,

TURN THE HANDLE OR PRESS 

“INSULATION TEST” BUTTON

CHECK CONNECTIONS

AT STRUCTURE/BUOY.

REMOVE PAINT, RUST, ETC.

AND RETEST

REPLACE POWER CABLE

(GROUNDED CONDUCTOR)

POWER CABLE MEGOHMETER TEST (CONTINUED)

YES

NO

IS READING GREATER 

THAN OR EQUAL TO 

1 MEGOHM?

POWER CABLE IS GOOD

YES

NO

STEEL

STRUCTURE

BARE

METAL

STEEL

STRUCTURE

POWER

CABLE

 

2-14
E. 12 Volt Secondary Batteries. 

1. Notes. 

a. 12 volt secondary batteries are used to power solar 

powered aids to navigation. The solar panel(s) 

recharge the battery during the daytime and the 

battery operates the load at night. Secondary 

batteries are also used as Hot Packs. 

b. Two sizes of batteries are used: minor aid batteries, like the 

Delco-2000 pictured, and large stationary batteries used at 

some day/night ranges and lighthouses (Section F). 

c. Three types of batteries are available: Wet, absorbed and 

gelled electrolyte. Each has advantages and disadvantages. 

A complete listing of the types, their use and sources of 

supply is provided in Commandant Instruction M16500.24, 

Solar Design Manual. 

d. All aids to navigation batteries must be disposed of in 

accordance with the Hazardous Waste Management 

Manual, COMDTINST M16478.1B. Chapter 7 of the manual 

gives instructions for disposal of various types of batteries 

used by Coast Guard units. If any questions should arise 

about appropriate disposal procedures, contact the 

Hazardous Waste Disposal Manager at your nearest Civil 

Engineering Unit (CEU) or the Environmental Management 

Division at COMDT (CG-49). 

2. Safety. 

a. Secondary lead-acid batteries contain electrolyte (dilute 

sulfuric acid). Wear chemical goggles and rubber gloves 

when handling batteries. If electrolyte comes into contact 

2-15
with the skin, wash immediately with water. If electrolyte 

comes into contact with the eyes, flush with water for 15 

minutes and consult a physician immediately. 

b. Secondary batteries may vent hydrogen when charging. 

Allow the battery pocket, battery box or battery enclosure to 

air out for 5 minutes before entering or servicing battery. 

c. Secondary batteries are a source of virtually unlimited 

current. The battery should be the last connection made at 

an aid. Do not allow “+” and “-“ wires to touch as the current 

is high enough to melt wiring, possibly damage the battery or 

cause personal injury. 

3. Installation. 

a. Batteries shall be charged no more than two months prior to 

installation. Multiple battery installations shall be of the 

same type (i.e., Delco, Sunlyte, etc.) and preferably with the 

same date code. All batteries shall be load tested prior to 

installation (section 5.b.). 

b. Batteries must be installed in a battery pocket or battery box 

on buoys, in a battery box or indoors on fixed structures. 

Use 10/2 or 12/2 SO cable (or larger wire as specified by 

your District) between the battery and load. Wires are 

terminated at the battery using ring lug terminals. Bare 

wires shall not be wrapped around the battery terminals. 

c. Fixed aid installations are limited to 4 minor aid batteries in 

parallel, otherwise six 2 volt Classic, Absolyte II or 

Sonnenschein stationary batteries shall be used (Section E). 

Buoy installations may use up to 10 minor aid batteries in 

parallel. 

 

2-16
d. Multiple battery installations are wired in parallel (+ to + and 

- to -) to increase capacity (ampere-hours). Power leads are 

connected to opposite corners of the batteries to reduce the 

effects of voltage drop in the jumper wires, as shown in 

Figure 2-5. 

Figure 2-5 

+

-

+

-

SO CABLE

12 VOLTS, 200 AMP-HOURS

TO LIGHT

e. When installing Delco 2000 batteries in tube type buoy hulls, 

the battery vent must face “up” towards the lifting bail with 

the terminals facing the pocket cover; otherwise electrolyte 

will drip out of the battery when it is serviced on deck, as 

shown in Figure 2-6. Bell-stand battery boxes may have to 

be remounted to achieve the proper battery orientation. 

VENT

Figure 2-6 

2-17
f. Do not over tighten terminals. Apply No-Ox grease to 

connections to prevent corrosion. 

g. The battery may be wired, as shown in Figure 2-7, 

whichever is convenient. 

S S L F +

_

FLASHER

FL4(.4)

S S L F +

_

FLASHER

OR FL4(.4)

BUOY BUOY/SHORE AID SHORE AID

LED J-Box OR

Figure 2-7 

4. Hot Packs. 

a. Secondary batteries may be used as Hot Pack batteries as 

long as the following conditions are met: 

(1) Sealed (Delcos are acceptable); 

(2) Permanently marked “For discrepancy use only”; 

(3) Derated to one-half of the advertised capacity; 

 

2-18
(4) Protected from rain, sun and salt spray if possible; 

(5) Recharged as soon as it is removed from the aid. 

b. The following Rated Battery Discharge Time (RBDT) table 

provides the number of days one battery (derated) will 

operate a given daylight controlled lamp/flasher combination. 

 Hot Pack* RBDT in Days

Flash Lamp Size

Rhythm 0.55 0.77 1.15

Fl 6(.6) 36 28 20

Fl 4(.4) 35 27 20

Fl 2.5(.3) 31 23 16

Fl (2+1)6 26 20 14

Fl (2)5 25 19 13

Fl 4(1.0) 19 14 10

MO A 16 12 8

Fl (2)6 15 11 8

Q 15 11 7

Iso 6 11 8 5

Occ 4 7 5 4

*Using one 12 volt, 100 AH secondary battery

2-19
5. Maintenance. 

a. Load test the battery, as shown below: 

 

2-20

DISCONNECT

SOLAR PANEL

TWO OR 

MORE BATTERIES

IN PARALLEL?

CONNECT LOAD TESTER

TO POSITIVE AND NEGATIVE

POWER UNIT TERMINALS

WAIT 10 MINUTES

WITH LOAD TESTER 

CONNECTED, 

MEASURE VOLTAGE

IS VOLTAGE 

GREATER THAN 

OR EQUAL TO

12.O V*?

BATTERY IS GOOD

PREFERRED METHOD

DISCONNECT PARALLEL

WIRING AND LOAD TEST

EACH BATTERY

BATTERY LOAD TEST

ALTERNATE METHOD

CONNECT 2 OR MORE 

LOAD TESTERS IN PARALLEL

OR USE THE SOLAR BATTERY

LOAD TESTER TO CORRESPOND 

WITH THE NUMBER OF

BATTERIES IN PARALLEL.

REPLACE BATTERY

IF MULTIPLE BATTERIES,

REPLACE ALL BATTERIES

RETURN OLD BATTERY TO UNIT

 AND PERFORM BENCH TEST

NOTE: DO NOT ALLOW CLIPS TO

TOUCH TOGETHER OR SEVERE

ARCING WILL OCCUR.

YES

NO

NO

YES

*SEE VOLTAGE CHART ON COVER OF

SOLAR BATTERY LOAD TESTER WHEN

TESTING BATTERIES IN BUOY POCKETS
b. Inspect wiring for cuts or abrasions. Replace if necessary. 

c. Inspect connections for corrosion. Clean and replace if 

necessary. Reapply No-Ox grease to terminals. 

6. Troubleshooting Procedures. 

a. If the aid is found discrepant, perform the solar panel 

troubleshooting flowchart (section 2.A.4.a.). 

b. Inspect wiring for cuts, abrasions, dirt or loose connections. 

Clean and replace as necessary. 

c. Meg SO power cable (section 2.D.4.a.). 

d. If battery is replaced, perform the Bench Test Procedure 

detailed in the Aids to Navigation Manual – Technical, 

COMDTINST M16500.3A on the discrepant battery if you 

desire to retain it as a Hot Pack. 

2-21
F. Large Stationary Batteries. 

1. Notes. 

a. Large stationary batteries are 12 volt secondary 

batteries used in solar powered aids to navigation that 

have loads higher than a typical minor aid. An example 

is a VRB-25 rotating beacon with fixed burning lamps or 

day/night ranges. The battery is comprised of six 

individual 2 volt cells that are wired in series to achieve 

12 volts. 

CLASSIC

b. Large stationary batteries are available in three types, wet 

(Exide, Fulmen and Classic), absorbed (GNB Absolyte IIP) 

and gelled electrolyte (Sonnenschein Dryfit). Wet batteries 

require semiannual watering. Absorbed and gelled batteries 

are maintenance-free. 

c. All aids to navigation batteries must be disposed of in 

accordance with the Hazardous Waste Management 

Manual, COMDTINST M16478.1B. Chapter 7 of the manual 

gives instructions for disposal of various types of batteries 

used by Coast Guard units. If any questions should arise 

about appropriate disposal procedures, contact the 

Hazardous Waste Disposal Manager at your nearest Civil 

Engineering Unit (CEU) or the Environmental Management 

Division at COMDT (CG-49). 

2. Safety. 

a. Secondary lead-acid batteries contain electrolyte (dilute 

sulfuric acid). Wear chemical goggles and rubber gloves 

when handling/servicing batteries. If electrolyte comes into 

contact with the skin, wash immediately with water. If 

 

2-22
electrolyte comes into contact with the eyes, flush with water 

for 15 minutes and consult a physician immediately. 

b. Secondary batteries may vent hydrogen when charging. 

Allow the battery pocket, battery box or battery enclosure to 

air out for 5 minutes before entering or servicing battery. 

c. Secondary batteries are a source of virtually unlimited 

current. The battery should be the last connection made at 

an aid. Do not allow “+” and “-“ wires to touch as the current 

is high enough to melt wiring, possibly damage the battery or 

cause personal injury. 

d. These large secondary batteries can be very heavy. Some 

cells are over 300 pounds each. Weight handling equipment 

is required to safely transport these batteries to the aid site. 

Batteries shall not be lifted by their posts. 

3. Installation. 

a. The battery shall receive a freshening charge prior to 

service. The battery may be charged on-site using the 

portable diesel engine-generator, or using the array with no 

load connected. Maximum charge currents, stated in the 

instruction manual provided with the battery, shall not be 

exceeded. 

b. Batteries must be installed in a protected environment. 

Additionally, they should not be exposed to direct sunlight or 

installed close to vents as it could cause uneven cell 

heating. Wires are terminated at the battery using ring lug 

terminals. Bare wires shall not be wrapped around the 

battery terminals. Interconnections between cells shall be 

made with the supplied buss bars. 

2-23
c. Batteries installed on offshore platforms shall be anchored to 

the floor and wall to prevent tipping. A containment system 

beneath wet batteries shall be installed and filled with either 

absorbent pads or limestone to neutralize spilled acid. 

Figure 2-8 

12 VOLTS

-

+

+

-

-

+

+

-

-

+

+

-

d. All large secondary batteries are wired in series, (+) to (-), to 

add cell voltages. Six 2 volt cells wired in series will provide 

a nominal 12 volts, as shown in Figure 2-8. 

e. Cell connections shall be covered with No-Ox grease or 

other suitable protective coating to prevent corrosion. 

f. Intercell connectors shall be protected with insulated covers 

to prevent accidental shorting. 

g. Due to the differences in battery types and because they 

come with detailed installation instructions, refer to the 

manual enclosed with the battery. 

4. Maintenance. 

a. Open battery box or battery enclosure and allow venting for 

5 minutes before entering or working on any components. 

b. Measure the charge voltage of each cell in the battery (the 

cells do not have to be disconnected) with Array and Battery 

 

2-24
circuit breakers in the Range Power Box (RPB) ON (solar 

panels connected) and the Load circuit breaker OFF. Record 

the voltages in the aid log. The voltages should be 2.30 to 

2.50 volts per cell, however in this test they may be low if it's 

cloudy. Cell to cell variation should be within + 0.02 volts. 

c. Disconnect the solar array and loads by turning the Array 

and Load circuit breaker in the RPB OFF and wait at least 

10 minutes. Measure the voltage of each cell and record the 

readings in the aid log. The voltages should be 2.05 to 2.14 

volts per cell with a maximum permissible variation of + 0.02. 

d. With the solar panels still disconnected, turn the Load circuit 

breaker in the RPB ON so that the daytime light comes on 

(cover daylight control if nighttime only light). Measure the 

voltage of each cell and record the readings in the aid log. 

The voltages should be 1.96 to 2.13 volts per cell with a 

maximum permissible variation of + 0.02. Remove the 

cover on the daylight control (if covered). 

e. Measure the specific gravity of each cell 

(Exide/Classic/Fulmen only) by removing the corner caps on 

the top of each cell and extending the tube of the hydrometer 

halfway into the cell to withdraw electrolyte. Record the 

electrolyte temperature (as read on the hydrometer) and 

specific gravity readings in the aid log. Find the appropriate 

specific gravity correction, listed on the next page, and 

record in the aid log. Do not add water to the cells prior to 

taking the specific gravity; low readings will result. Be sure 

hydrometer is clean and has not been used in NiCads or it 

will damage these batteries. 

 

2-25
TEMPERATURE CORRECTION POINTS 

 Temperature Correction Temperature Correction 

 Deg., F (C) Points Deg., F (C) Points 

 20 (-6.7) -.024 70 (21.1) -.004 

 25 (-3.9) -.022 75 (23.9) -.002 

 30 (-1.1) -.020 80 (26.7) 0 

 35 ( 1.7) -.018 85 (29.4) +.002 

 40 ( 4.4) -.016 90 (32.2) +.004 

 45 ( 7.2) -.014 95 (35.0) +.006 

 50 (10.0) -.012 100 (37.8) +.010 

 55 (12.8) -.010 105 (40.6) +.012 

 60 (15.6) -.008 110 (43.0) +.014 

 65 (18.3) -.006 115 (46.1) +.016 

f. The estimated state of charge can be found by either the 

corrected specific gravity (preferred method) or the open 

circuit voltage. The system is designed so that the state of 

charge never falls below 80%, however extended cloudy 

conditions may cause it to fall as low as 60%. If the state of 

charge is any lower than 60% and system checks indicate 

no apparent cause, contact your district training team chief 

with this information. Additional panels may be added to the 

array to correct this problem. Any modification to the system 

should only be undertaken after consultation with District 

(dpw) and your Civil Engineering Unit (CEU). 

 

2-26
BATTERY STATE OF CHARGE 

 

 (Absolyte/Dryfit/Exide) (Classic/Fulmen)

Open Circuit Specific State of Specific State of 

 Voltage Gravity Charge Gravity Charge 

12.7 1.300 100% 

12.6 1.265 90% 

12.5 1.244 80% 1.240 100% 

12.4 1.218 70% 

12.3 1.194 60% 1.200 75% 

12.2 1.170 50% 

12.1 1.148 40% 

12.0 1.122 30% 1.165 50% 

11.9 1.098 20% 

11.8 1.073 10% 1.130 25% 

11.7 1.040 0% 1.095 0% 

g. Check each cell for sediment buildup (wet batteries only). 

This is a sign of the amount of cycling or overcharge that a 

battery has received. It is also an indication of end of life. A 

battery that has one-half of its sediment space full will 

continue to perform for a number of years. When the 

sediment space fills up, shorts develop between the plates 

causing low voltage cells. 

h. Add distilled water to the cells (we batteries only) to bring the 

electrolyte level to the HIGH mark on the cell jar. To add 

water, remove the dust cap from the arrestor. Record the 

amount of water added to all 6 cells in the aid log. 

i. Remove accumulation of dust or other contaminates from 

the cell covers and jars with a cloth dampened with clean 

potable water. Do not use cleaning solutions (solvent, 

detergent, etc.) as these will damage the plastics used in the 

2-27
cell jars. Isopropyl alcohol may be used to dampen the cloth 

for stubborn dirt and is the only other approved cleaning 

solution. Dirty intercell connections are a common cause of 

excessive cell to cell voltage variations. Clean intercell 

connections, if necessary, with a cloth dampened in 

bicarbonate of soda (1 pound of baking soda mixed with 1 

gallon of water). Do not get solution into cell; it will 

neutralize acid and ruin the cell. Severe corrosion requires 

removal of intercell connectors, neutralization with a solution 

of bicarbonate of soda and cleaning with a nonmetallic, stiff 

bristled brush. Before removing intercell connectors, 

disconnect the battery from both the load and solar array by 

turning off all circuit breakers in the RPB. Be careful not to 

damage the lead plating on the connectors as the copper 

beneath it will corrode rapidly. Apply No-ox grease to 

contact surfaces. Retorque connector bolts to the 

appropriate torque (see instruction manual). 

j. Electrical resistance of a loose connection is significantly 

higher than one that is properly tightened. Loose 

connections may cause cell-to-cell voltage variations, post 

heating and accelerated corrosion. Before tightening 

connections, disconnect the battery from both the load and 

solar array by turning off all circuit breakers in the RPB. If 

the connections exhibit corrosion, disassemble, and clean as 

described in paragraph i, above. Use an insulated inchpound torque wrench to ensure that all intercell and post 

connections are torqued (see instruction manual). Recoat 

the terminals and connections with No-Oxide grease when 

complete. Turn on the breakers in the RPB, 

reconnecting the array and loads.

k. The battery should be charged onsite if either a scheduled or 

unscheduled visit to the aid reveals that the state of charge 

falls below 60 percent. The cause of the low state of charge 

must be corrected prior to returning the aid to normal 

 

2-28
operation. Charging may be done with the portable genset, 

any commercial unit capable of charging 12-volt batteries or 

by securing the main loads and allowing the array to 

recharge the battery (7-14 days). Cell temperature shall be 

monitored during the charging process (genset only) to 

ensure that it does not rise above 110 degrees F. Should 

this occur, the charging should be terminated and the battery 

permitted to stand open circuit until it cools down to 90 

degrees F, at which time charging may resume. The 

thermometer may be inserted in the first cell through the 

funnel in the flame arrestor (wet batteries only). 

NOTE: rinse thermometer thoroughly with distilled water 

before inserting into cell jar. Charging voltage shall be 15 

volts, which should be reduced if this causes electrolyte 

flooding out onto the cover, if the cell temperature exceeds 

the above limitations, or if this voltage exceeds the 

manufacturer’s fast-charge voltage/current limit. The current 

limit is 5 amps per 100 AH of capacity or the manufacturer’s 

predetermined maximum charge current (example: a 500 AH 

battery can be charged at 25 amps). Charge voltages may 

be adjusted to meet these values to promote fast recharging 

of the battery. All circuit breakers in the RPB shall be OFF

during the charging process. 

l. Report all readings and problems that are not within these 

guidelines to your Training Team Chief. 

5. Troubleshooting Procedures. 

a. If the aid is found discrepant due to low voltage, perform the 

Multiple Solar Panel Servicing Flowchart (section 2.A.4.b). 

b. Inspect wiring for cuts, abrasions, dirt or loose connections. 

Clean and replace as necessary. 

c. Check torque on all intercell connectors. Clean if dirty. 

2-29
d. If fault is found in the charging system, charge battery if 

lower than 60 percent state of charge or if cells are 

imbalanced (cell to cell voltage variation exceeds limits). 

e. If no obvious fault is found (end of life), identify the bad 

cell(s) by performing maintenance procedures listed in 

section 4 and replace either the bad cell(s) or entire battery 

rack. 

 

2-30
G. Range Power Box (RPB). 

 1. Notes. 

a. The Range Power Box (RPBs, Figure 2-9) is a commercially 

available photovoltaic power controller used on ranges and 

small lighthouses to protect lead-acid batteries from 

overcharge. 

 

b. The RPB contains circuit breakers to disconnect the solar 

array, battery and load from it and each other. The RPB 

contains a charge regulator with adjustable setpoints to 

prevent the battery from overcharging. It also contains 

circuitry that disconnects the load from the battery to protect 

it from deep discharge. This feature is adjustable and can 

be disabled. 

 

 SCI PPC-50 ProStar-30 

 Figure 2-9 

2-31
2. Installation. 

a. The RPB should be installed near the battery as the 

temperature compensation cable is only 10 feet (33 ft for the 

ProStar) long and should be attached to the battery. The 

RPB is housed in a raintight box suitable for installation 

outdoors, if necessary. Attach the temperature 

compensation probe to the outside of the battery with the 

foam pad (SCI). The probe must be placed about halfway 

up the side of the battery case out of direct sunlight and 

away from drafts that could affect its operation. The ProStar 

version is attached directly to either battery terminal. 

b. All wires may be terminated at the Euro-style terminal strips 

without lugs as they readily accept bare copper wire up to 6 

AWG. 

c. Installations with multiple solar panels should be combined 

at a Local Terminal Box (LTB) or other suitable junction box 

with one pair of 6 AWG wires connected to the RPB. 

d. The jumpers between the BATTERY VOLTAGE SENSE and 

BATTERY terminals must remain connected (SCI only). The 

jumpers may be moved to the top row of terminals if they 

interfere with wire terminations. The jumpers should be 

removed and an extra pair of wires (18 AWG is sufficient) 

connected between the battery sense and the lead-acid 

battery terminals if the battery is more than 8 feet from the 

controller (applies to both SCI and ProStar) 

e. Attach leads from the battery, array and load(s) to the 

terminal strip in the RPB (in that order). All circuit breakers 

should be OFF during this period. In the ProStar controller 

push the button for 2 seconds to disconnect the array and 

load. Push the button again to reconnect the array and 

battery after the leads are attached. Additionally, the leads 

 

2-32
at the battery must be disconnected to prevent accidental 

shorting while routing through stuffing the tube (NOTE: 

LARGE BATTERY SYSTEMS ARE A SOURCE OF 

UNLIMITED CURRENT, CAPABLE OF MELTING COPPER 

WIRE, AND POSSIBLY CAUSING AN EXPLOSION). 

Attach leads to battery with the circuit breakers in the RPB 

OFF. 

f. Be sure CHARGE SET-POINT SELECTOR is in the “B” 

position which corresponds to 14.8 volt charge termination 

for the SCI version. This setting should be used for all 

batteries, unless directed otherwise. The ProStar has three 

settings, gelled, sealed and flooded. Flooded batteries have 

liquid electrolyte like the Delco and Classic batteries, Sunlyte 

and Absolyte are sealed, and the Sonnenschein Dryfit is 

gelled. 

g. The LOAD DISCONNECT switch should be in the AUTO 

LVD position, unless directed otherwise. This corresponds 

to 11.5 volt load disconnect. The load will automatically 

reconnect when the battery voltage reaches 13.0 volts. 

h. Indicators – The SCI controller has a “charging light” 

displayed when the array is charging the battery. The 

ProStar controller has a series of LEDs that display the 

following information: 

Charging – Green when array is charging battery 

Battery Status – Green – Full charge, Yellow – middle 

capacity, Red Blinking – Low state of charge, Red ON – 

Load has been disconnected. 

i. Turn on all circuit breakers, close and latch door and check 

aid for proper operation. 

2-33
 3. Maintenance. 

a. If there is evidence that the batteries have been 

overcharging (excessive water usage, boiling of electrolyte 

onto cell jars, excessive heat in cells), perform the 

troubleshooting procedure detailed in Section 4. 

b. Be sure the terminals are tight and inspect for evidence of 

corrosion. Clean or replace as necessary. 

c. Be sure temperature sensor lead is attached to the controller 

and the sensor is attached to the battery. 

d. Confirm that the correct battery type/switch setting is 

selected. 

e. Check LED status of ProStar controller (see previous page) 

 

2-34
4. Troubleshooting. 

UNPLUG 

TEMPERATURE

SENSOR

MEASURE RESISTANCE

BETWEEN INNER AND 

AND OUTER JACKET

IS RESISTANCE

BETWEEN

3K-6K OHMS?

REPLACE SENSOR

(LEAVE SENSOR UNPLUGGED

UNTIL REPLACEMENT IS OBTAINED)

SWITCH BATTERY, 

LOAD AND ARRAY

CIRCUIT BREAKERS OFF

DISCONNECT AND SECURE 

BATTERY (+), BATTERY SENSE (+)

JUMPER, AND SOLAR PANEL (+) WIRES

SWITCH ARRAY AND BATTERY

CIRCUIT BREAKERS ON

IS RESISTANCE BETWEEN

SOLAR PANEL (+) AND BATTERY (+)

GREATER THAN 50k OHMS?

SWITCH ARRAY AND BATTERY

CIRCUIT BREAKERS OFF

REPLACE CONTROLLER

RPB TROUBLESHOOTING

FLOWCHART (SCI Version)

NO

NO

YES

YES

BE SURE SENSOR IS 

ATTACHED TO BATTERY

CONTINUED ON NEXT PAGE

2-35
RECONNECT SOLAR PANEL (+)

WIRE TO CONTROLLER

IS VOLTAGE 

BETWEEN SOLAR PANEL (+) 

AND BATTERY (-)

16-18 VOLTS?

SWITCH THE BATTERY, LOAD AND

ARRAY CIRCUIT BREAKERS ON

DOES THE CHARGE

LIGHT GO ON FOLLOWED

BY THE LVD LIGHT?

IS VOLTAGE BETWEEN

BATTERY (+) AND BATTERY (-)

16-18 VOLTS?

IS VOLTAGE BETWEEN 

LOAD (+) AND LOAD (-) 

ZERO?

INSTALL JUMPER BETWEEN

BATTERY (+) AND BATTERY SENSE (+)

PERFORM SOLAR PANEL

TROUBLESHOOTING FLOWCHART

(VOLTAGE SHOULD BE SOLAR

PANEL OPEN CIRCUIT VOLTAGE)

REPLACE CONTROLLER

REPLACE CONTROLLER

IS LVD SWITCH

IN AUTO?

REPLACE CONTROLLER

SWITCH LVD

TO AUTO

RPB TROUBLESHOOTING 

FLOWCHART (SCI - CONT’D)

NO

YES

YES

YES

YES YES

NO

NO

NO

NO

CONTINUED ON NEXT PAGE

 

2-36
DOES CHARGE LIGHT

AND LVD LIGHT GO OFF?

IS VOLTAGE BETWEEN 

BATTERY (+) AND BATTERY (-)

BETWEEN 13.5 AND 

14.2 VOLTS?

IS VOLTAGE BETWEEN 

LOAD (+) AND LOAD (-) BETWEEN 

13.5 AND 14.2 VOLTS?

REPLACE CONTROLLER

REPLACE CONTROLLER

VOLTS, CHARGE LIGHT MAY OSCILLATE

IF VOLTAGE BETWEEN BATTERY (+)

AND BATTERY (-) IS LESS THAN 16.5

ON AND OFF, WHICH IS NORMAL.

IF LIGHTS STAY ON, REPLACE CONTROLLER.

END

NO

NO

NO

YES

YES

YES

RPB TROUBLESHOOTING

FLOWCHART (SCI – CONT’D)

a. If the controller fails any of these tests, it is defective and should be 

replaced. Install rotational spare, if available. 

b. If the aid is reported out and no problem is found, the LVD could be 

disconnecting the load at night and reconnecting during the day 

when the battery is charging. In this case, the battery is operating at 

a lower state of charge than anticipated or there is excessive voltage 

drop in the system. Contact your CEU with this information to 

determine if additional solar panels or larger conductors are 

necessary. Leave the LVD in the “NO LVD” position until the 

problem is resolved. 

2-37
THE FOLLOWING SHOULD BE DISPLAYED:

8.8.8 – START SELF TEST

12u – 12 VOLT SYSTEM

30A – CURRENT RATING

R1.8 – SOFTWARE VERSION

EO# – ERROR DETECTED (SEE BELOW) OR

--- - NO ERROR

25c – CONTROLLER TEMP (MAY BE OTHER THAN 25C)

Rp – REMOTE TEMP PROBE DETECTED

25c – BATTERY TEMP (MAY BE OTHER THAN 25C 

SEn – BATTERY SENSE DETECTED (IF CONNECTED)

S-1, 2 OR 3 – BATTERY SELECT POSITION

END – END OF SELF TEST

PUSH BUTTON ONCE TO RETURN TO NORMAL OPS.

PUSH BUTTON 

FOR 4 SECONDS, 

THEN RELEASE 

REPLACE CONTROLLER

END

NO

YES

RPB TROUBLESHOOTING

FLOWCHART (ProStar)

ERROR DETECTED (EO#)

 

 

2-38
H. Range Switch Box-DC (RSB-DC). 

1. Notes. 

a. The RSB-DC (Figure 2-10) is used on DC powered ranges 

to switch between daytime and nighttime lights. The device 

is comprised of a circuit breaker, type-L daylight control, 

relay driver circuit card and a single pole, double throw 

(SPDT) relay. 

b. Relay RY1 is energized during the day disabling the 

nighttime signal and enabling the daytime signal. Failure of 

the relay driver circuit card causes the nighttime light to 

operate 24 hours a day. 

+ -

DAY

+ -

NIGHT

RY1

CCA

TYPE-L

DAYLIGHT

CONTROL

(+) (-)

12VDC -------POWER IN ---------12VDC

RANGE SWITCH BOX - DC (RSB-DC)

GND

TB1 TB3 TB4 TB2

CB1

Figure 2-10 

2-39
2. Installation. 

a. The RSB-DC is typically installed near the day and night 

range optics. It is housed in a raintight box suitable for 

installation outside. Power is provided by the Range Power 

Box (RPB) or AtoN power supply, and depending on the 

loads, may be fed with up to 1/0 AWG wire. 

b. All wires may be terminated at the compression terminal 

strips without lugs as they readily accept bare copper wire. 

c. Flashers installed in the range lights are wired to the day 

and night terminal strips using either 12/2 or 10/2 SO cable. 

3. Maintenance. 

a. Perform the following system status check when arriving at 

the range in the daytime: 

(1) Note if the daytime light is on. 

(2) Cover daylight control and determine if the daytime light 

turns off and nighttime light turns on. 

(3) Check components for frayed wiring and corrosion. 

Replace or repair as necessary. 

4. Troubleshooting. 

a. The RSB-DC is simple in operation. During the daytime, the 

type-L daylight control causes the relay driver card to power 

the coil of the relay turning off the nighttime light and turning 

on the daytime light. The relay is an open model type that 

allows visual and audible indication that it is working. 

Voltage checks at various points (Figure 2-11) can be used 

to detect the cause of discrepancies: 

 

2-40
12 VDC AT TB1

AND TB2?

SHINE LIGHT ON

DAYLIGHT CONTROL

12 VDC AT TB4

+ AND -?

IS CIRCUIT

BREAKER

STILL ON?

PERFORM POWER

SYSTEM SERVICE

DISCONNECT LOAD

FROM TB4

AND RESET BREAKER

12 VDC AT CCA

TERM R AND R?

IS CIRCUIT

BREAKER

STILL ON?

JUMP TERMINALS

S AND S ON CCA

PROBLEM WITH 

DAY OPTIC

12 VDC AT 

TERMINALS

R AND R?

REPLACE 

CCA REPLACE 

DAYLIGHT

CONTROL

REPLACE CIRCUIT

BREAKER/CHECK FOR

INTERNAL SHORTS

REPLACE 

RELAY

NO

NO

NO

YES

YES

YES

NO

YES

NO

YES

YES

NO

START DC RANGE SWITCH BOX (RSB-DC)

Continued on

Next page 

Figure 2-11 

2-41
COVER 

DAYLIGHT 

CONTROL

IS CIRCUIT

BREAKER

STILL ON?

12 VDC AT TB3

+ AND -?

FINISHED

DISCONNECT LOAD

FROM TB3

AND RESET BREAKER

IS CIRCUIT

BREAKER

STILL ON?

REPLACE CIRCUIT

BREAKER/CHECK FOR

INTERNAL SHORTS

PROBLEM WITH 

NIGHT OPTIC

NO

YES

YES

YES

DC RANGE SWITCH BOX (RSB-DC) (cont’d)

REPLACE 

RELAY

NO

12 VDC AT CCA

TERM R AND R?

REPLACE 

DAYLIGHT

CONTROL

NO

YES

DISCONNECT

DAYLIGHT

CONTROL

12 VDC AT CCA

TERM R AND R?

REPLACE 

CCA

YES

NO

NO

Continued from

previous page

Figure 2-11 (cont’d) 

 

2-42
CHAPTER 3 - SIGNALS 

A. 155mm Lanterns. 

 1. Notes. 

 

a. The 155mm lantern is used on buoys and structures. 

This omnidirectional lantern is prefocused but 

requires precision leveling on structures to ensure 

proper operation. The lens is replaceable and 

available in clear, yellow, red and green. 

 2. Installation. 

a. Buoys.

(1) Align lantern base with holes in buoy plate. 

(2) Place a 1⁄2” threaded stainless steel bolt and flat washer 

through each of the aligned holes in the lantern base. 

(3) Place a stainless steel nylock nut on each bolt and 

tighten. 

(4) Note: Lanterns installed on buoys are not leveled. Go to 

Paragraph c. 

b. Structures. 

(1) Install three 1⁄2” stainless steel threaded rods or bolts on 

the platform as shown in Figure 3-1. Add the leveling 

nut and flat washer at this time. 

3-1
LANTERN

THREADED ROD OR BOLT

NUT

SPLIT

WASHER

NYLOCK

NUT

PLATFORM

LEVELING

NUT

FLAT

WASHER

 Figure 3-1

(2) Position lantern over threaded rods. Place a flat washer 

and nylock nut on each rod but do not tighten 

completely. 

(3) With lens open, place a level on the flange of the lantern 

base. Use the “T” method shown in Figure 3-2 so that 

adjustment of one leveling bolt won’t affect the other 

adjustment. 

(4) Adjust the leveling nuts up or down until level. 

3-2
 Figure 3-2 

90o

155 mm LANTERN

LEVEL

“T” METHOD

BASE

THREADED

RODS

(5) Move the level ninety (90) degrees from your first 

position and readjust. See Figure 3-2. 

(6) Repeat steps until the lantern is level in both positions. 

(7) Tighten top nuts on mounting studs/bolts and recheck 

levelness of lantern. DO NOT OVERTIGHTEN. 

(8) Obtain a tested CG-6P lampchanger and CG181/493/504 flasher with the appropriate hardware (see 

Chapter 4). 

c. Attach the mounting bracket between the base of the CG6Plampchanger and flasher with four 10-32x1" screws 

supplied so that the dip in the bracket is down (see Figure 3-

3). The wires from the WK-681 wiring kit must pass under

the bracket. Attach the bracket to the screws in the base. 

Note: The lock washer must be on top of the bracket or the 

focal height of the lamp will be affected. 

3-3
d. Wiring shall be 12/2 SO cable through a watertight stuffing 

tube, or individually insulated wires installed in conduit 

(Liquid-Flex near lantern). Wires shall have insulated spade 

lugs and terminated at the Black (+) and White (-) terminals 

of the CG-181 flasher. 

Figure 3-3 

e. Install a focus fixture in the first lamp position. 

3. Focusing. 

a. The lantern is prefocused, however it should be checked to 

ensure that components are installed correctly and that the 

bracket and base are not bent or distorted. 

b. Secure each of the lens clamping screws/clamps. 

c. Sight through the sighting marks on the lens. The focus 

fixture should appear centered in the sight marks, as shown 

in Figure 3-4. 

d. Verify proper focus through second set of sight marks. 

3-4
e. If lantern is not focused, check for proper installation of 

lampchanger bracket (dip down), bent bracket, broken 

standoffs in base. Replace or modify as necessary to 

ensure lantern is focused. 

Figure 3-4 

IDEAL

FOCUS

VERTICLE

TOLERANCE

+ OR - 1/4

DIAMETER

OF REAR

CIRCLE

HORIZONTAL

TOLERANCE

+ OR - 1/4

DIAMETER

OF REAR

CIRCLE

4. Maintenance. 

a. Visually inspect the lens and base for cracks, crazing, holes, 

etc. Replace if necessary. 

b. Open lantern and swing lens open against stops. Inspect 

drain holes in base. Clean if necessary with a paper clip. 

c. Place a level on the base and check levelness in both 

directions (structures only). Use the “T” method. 

d. Install a focus fixture in the first lamp position and check 

focus as discussed in section 3. 

e. Advance unused lamps forward and install new lamps in the 

remaining positions. 

f. Check O-ring gasket in the base and replace if necessary. 

g. Perform the quick aid test outlined in Chapter 4. 

h. Rotate turret to the first position. CAUTION - LAMPS AND 

TURRET MAY BE HOT. 

3-5
i. Close and secure the lens assembly. 

j. Clean the lens, if necessary, with a soft bristle brush, rags 

and mild soap and water. 

5. Troubleshooting. 

a. If the light is reported burning dim, perform the following 

system checks: 

(1) Load test the battery (Chapter 2); 

(2) Check focus of lantern (Section 3). Be sure correct 

lamps are installed; 

(3) Clean lens cover if necessary. 

b. If the light is reported out, perform the following system 

checks: 

(1) Load test the battery (Chapter 2); 

(2) Meg power cable (Chapter 2) 

(3) Perform the Minor Aid Troubleshooting Test (Chapter 4). 

3-6
B. Carmanah 700 Series Self Contained LED Lanterns. 

1. Notes. 

a. The Carmanah 700 series self 

contained LED lanterns are available 

in two versions; the 701/702/702-5 

and the 704-5. The first version has 

multiple power system sizes, but only 

one intensity setting. The 704-5 has 

two intensity settings (high and low) 

but only one power system size. 

Proper selection of the intensity and 

solar system sizing must be made by 

District (dpw) prior to installation. 

2. Installation. 

a. Lanterns shall be programmed and fully charged at the Unit 

prior to installation. Consult Technical Data Sheets 04-01 

and 07-01 on www.uscg.mil/systems/gse/gse2 for the 

procedures prior to transporting the lantern to the aid. 

b. The top solar panel on the 702-5 and 704-5 lanterns is not 

designed to support the full weight of the lantern. Never use 

the top solar panel to lift the lantern.

c. On steel buoys, install three 1⁄2” stainless steel bolts and flat 

washers through the lantern mounting holes, three flat 

washers between the lantern and buoy top plate and finally 

three split lock washers and nuts to secure the lantern. The 

lantern vents through a hole in the bottom of the 

lantern’s base, so the lantern CAN NOT be mounted 

flush with the buoy’s mounting plate. The flat washers 

provide this air-space. Avoid tall bolts that could shadow the 

solar panels. Nylock nuts can replace split washers and 

nuts. See Figure 3-5. 

3-7
Top of 

Radar

Reflector

1/2” Bolt

Flat Stainless

Washers

Nylock Nut

Or Split Washer 

and Nut

Figure 3-5 

d. Secure three 1⁄2” stainless steel bolts (or all-thread) to the 

structure’s mounting plate as shown in Figure 3-6. Install 

three jam nuts on the bolts so that about 1” of thread is 

exposed. Place the lantern on top of the leveling nuts, then 

drop on the split washers and position the uppermost nuts at 

the very upper end of the thread. Do not tighten these 

uppermost nuts – they are positioned at this time to ensure 

that the lantern doesn’t fall off. Level the lantern on 

structures by adjusting the leveling nuts (use a torpedo level 

on the top of the lens or base plate of the lantern - use the 

“T” method. When the lantern is level, tighten the uppermost nuts. 

e. Cover the lantern with a jacket, box or blanket and 

determine if it turns on and flashes on-rhythm. Remove the 

cover and the lantern should turn off in the daytime. 

3-8
1⁄2”-13 UNC All -Thread, 

3 ea on a 7-7/8”

-

bolt circle

Leveling Nut

Nut

Split Washer

Platform/

Lifting Plate

All-Thread

Or Bolt

Nylock Nut

Flat Washer

Lantern

Figure 3-6 

3. Servicing. 

a. Servicing should be performed in accordance with the 

standard cycle established for the aid. 

b. Ensure that the lens and solar panels are clean. Wipe with a 

cloth dampened with mild soap and water, if necessary. 

c. Cover the lantern with a shroud, jacket, box, blanket, etc., to 

3-9
simulate darkness. The lantern should flash on rhythm after 

a few seconds. It should stop flashing after the cover is 

removed in the daytime. While covered, observe the LEDs 

through the lens. Dark sectors indicate that a LED cluster is 

not operating, necessitating replacement of the optic head. 

d. Uncover the lantern. It should stop flashing. 

4. Troubleshooting. 

a. If the lantern is reported discrepant or is flashing irregularly, 

replace the lantern and troubleshoot completely at the base 

using the referenced Technical Data Sheets. Corrective 

action cannot be performed on-station.

3-10
C. Vega VLB-36 Self Contained LED Lanterns. 

1. Notes. 

a. The VLB-36 self contained LED lanterns are 

available in two versions; a buoy lantern 

using three solar panels and a fixed aid 

lantern using two solar panels. Each version 

has three power system sizes, small, 

medium and large and multiple intensity 

settings. Proper selection of the intensity 

and power system sizing must be made by 

District (dpw) prior to installation. 

2. Installation. 

a. Lanterns shall be programmed and fully charged at the base 

prior to transport and installation at the aid. Consult the 

Commandant (CG-432A) website for specific instructions 

regarding this lantern. 

b. The lantern has three blind holes in the base drilled to a 

depth of 2” for a 1⁄2” stainless steel bolt or threaded rod. 

c. On steel buoys, loosely install one 1⁄2” stainless steel 

threaded rod or a bolt with the head removed to act as a 

locating pin for the lantern mount on top of the radar 

reflector. Install the lantern in one of those holes and swing 

the base until the other two holes are lined up. Insert two 1⁄2” 

stainless steel bolts with lock washers to secure the lantern. 

Remove the treaded rod and insert a 1⁄2” bolt, or install a lock 

washer and nut on the rod. Tighten all fasteners. See Figure 

3-7. 

3-11
Bird spike indicates 

Lantern color

1⁄2”-13 UNC Hex bolt, lock washer 

(max depth 2”), 3 ea on a 7-7/8” bolt circle

Buoy

Figure 3-7 

d. On structures, Insert three 6” lengths of stainless steel 1⁄2”-13 

UNC All-Thread in the base of the lantern as far as they will 

go (about 2”). Thread three 1⁄2” stainless steel nuts and 

tighten against the base of the lantern. These act as jam 

nuts and prevent the All-Thread from loosening in the 

lantern. Thread three stainless steel 1⁄2” nuts about half-way 

up the All-Thread. Place three stainless steel flat washers 

on the platform, then install the lantern on the platform. See 

Figure 3-8. 

3-12
Bird spike indicates 

Lantern color

1⁄2”-13 UNC All-Thread, 

3 ea on a 7-7/8” bolt circle

Lantern

Jam Nut

Leveling Nut

Platform Flat Washer

All-Thread

If lantern has two solar panels, 

point this area between them 

South +/- 5 degrees

Split Washer

Nut

Figure 3-8 

e. Place a torpedo level on the bottom of the lantern (there is a 

circular pad in the center) in-line with two of the mounting 

holes. Using the “T” method, level the lantern using one or 

both of the nuts on top of the platform corresponding to 

those two mounting holes. Turn the level 90 degrees and 

level the lantern in that direction by turning the one nut on 

top of the platform opposite the other two nuts. The lantern 

should be level in both directions. See Figure 3-9. 

f. Install a stainless steel split lock washer and nut or nylock 

nut on the bottom of the All-Thread and secure the lantern to 

3-13
the platform. If the nothing moved, the lantern should still be 

level; check with the torpedo level and adjust, if necessary. 

Torpedo Level

Mounting Holes

“T” Method

90o

Pad Under

Lantern

Figure 3-9 

g. Cover the lantern with a jacket and note if it turns on and 

flashes at the correct rhythm. 

 

h. Install the three bird deterrents by pushing the supplied 

springs into the holes on top of the lantern at approximately 

a 30 degree angle.

3. Servicing. 

a. Servicing should be performed in accordance with the 

standard cycle established for the aid. 

b. Ensure that the lens and solar panels are clean. Wipe with a 

cloth dampened with mild soap and water, if necessary. 

3-14
c. Cover the lantern with a shroud, jacket, blanket, etc., to 

simulate darkness. The lantern should flash on rhythm after 

a few seconds. It should stop flashing after the cover is 

removed in the daytime. While covered, observe the LEDs 

through the lens. Dark sectors indicate that a LED cluster is 

not operating, necessitating replacement of the optic head. 

d. Uncover the lantern. It should stop flashing. 

4. Troubleshooting. 

a. If the lantern is reported discrepant or is flashing irregularly, 

replace the lantern and troubleshoot completely at the base 

using the referenced Technical Data Sheets. Corrective 

action should not be performed on-station.

3-15
D. BWT 100 Series Self Contained LED Lanterns. 

1. Notes. 

a. The BWT 100 series self contained LED 

lanterns are available in system sizes, small, 

medium and large and 3 intensity settings. 

Proper selection of the intensity and power 

system size must be made by District (dpw) 

prior to installation. Its rugged construction 

makes it suitable for extreme locations. 

 

2. Installation. 

a. Lanterns shall be programmed and fully charged at the base 

prior to transport and installation at the aid. Consult the 

Commandant (CG-432A) website for specific instructions 

regarding this lantern. 

b. The lantern has three blind holes in the base drilled to a 

depth of 2” for a 1⁄2” stainless steel bolt or threaded rod. 

c. On steel buoys, loosely install one 1⁄2” stainless steel 

threaded rod or bolt with the head removed to act as a 

locating pin for the lantern mount on top of the radar 

reflector. Install the lantern in one of those holes and swing 

the base until the other two holes are lined up. Insert two 1⁄2” 

stainless steel bolts with lock washers to secure the lantern. 

Remove the treaded rod and insert a 1⁄2” bolt, or install a lock 

washer and nut on the rod. Tighten all fasteners. See Figure 

3-10. 

3-16
Bird spike indicates 

Lantern color

1⁄2”-13 UNC Hex bolt, lock washer 

(max depth 2”), 3 ea on a 7-7/8” bolt circle

Buoy

Be sure washers are 

glued to base

Figure 3-10 

d. On structures, Insert three 6” lengths of stainless steel 1⁄2”-13 

UNC All-Thread in the base of the lantern as far as they will 

go (about 2”). Thread three 1⁄2” stainless steel nuts and 

tighten against the base of the lantern. These act as jam 

nuts and prevent the All-Thread from loosening in the 

lantern. Thread three stainless steel 1⁄2” nuts about half-way 

up the All-Thread. Place three stainless steel flat washers 

on the platform, then install the lantern on the platform. See 

Figure 3-11. 

3-17
Bird spike indicates 

Lantern color

1⁄2”-13 UNC All-Thread, 

3 ea on a 7-7/8” bolt circle

Lantern

Jam Nut

Nut

Platform Flat Washer

Split Washer

Nut

All-Thread

Figure 3-11 

e. Place a torpedo level on top of the lantern in-line with two of 

the mounting holes. Using the “T” method, level the lantern 

using one or both of the nuts on top of the platform 

corresponding to those two mounting holes. Turn the level 

90 degrees and level the lantern in that direction by turning 

the one nut on top of the platform opposite the other two 

nuts. The lantern should be level in both directions. See 

Figure 3-12. 

f. Install a stainless steel split lock washer and nut or nylock 

nut on the bottom of the All-Thread and secure the lantern to 

3-18
the platform. If the nothing moved, the lantern should still be 

level; check with the torpedo level and adjust, if necessary. 

Torpedo Level

Mounting Holes

“T” Method

90o

 Figure 3-12 

g. Cover the lantern with a jacket and note if it turns on and 

flashes at the correct rhythm. 

3. Servicing. 

a. Servicing should be performed in accordance with the 

standard cycle established for the aid. 

b. Ensure that the lens and solar panels are clean. Wipe with a 

cloth dampened with mild soap and water, if necessary. 

c. Cover the lantern with a shroud, jacket, blanket, etc., to 

simulate darkness. The lantern should flash on rhythm after 

a few seconds. It should stop flashing after the cover is 

3-19
removed in the daytime. While covered, observe the LEDs 

through the lens. Dark sectors indicate that an LED cluster 

is not operating, necessitating replacement of the optic 

head. 

d. Uncover the lantern. It should stop flashing. 

4. Troubleshooting. 

a. If the lantern is reported discrepant or is flashing irregularly, 

replace the lantern and troubleshoot completely at the base 

using the referenced Technical Data Sheets. Corrective 

action should not be performed on-station.

3-20
E. 250 mm Lanterns. 

1. Notes. 

a. The 250mm lantern is used on stable platforms. This 

omnidirectional lantern requires precision focusing 

and leveling to ensure proper operation. The lens 

and lens cover are replaceable; beam color (white, 

yellow, red or green) is determined by the lens cover. 

Color sectored lens covers can be used and 

condensing panels can be added for range 

applications. 

2. Installation. 

a. Install three 1⁄2” threaded rods or bolts on the platform as 

shown in Figure 3-13 (only three of the four holes in the 

base are used). Add the leveling nut and flat washer at this 

time. 

b. Position lantern legs over leveling bolts. 

c. Place a flat washer and nylock nut on each bolt. Do not 

tighten completely. 

3-21
LANTERN

NYLOCK NUT

PLATFORM

BOLT OR

ALL-THREAD

NUT

SPLIT

WASHER

FLAT

WASHER

LEVELING

NUT

Figure 3-13 

d. With lens open, place a level on the flange of the lantern 

base. The bubble level on the lantern shall not be used. 

Use the “T” method shown in Figure 3-14 so that adjustment 

of one leveling bolt won’t affect the other adjustment 

e. Adjust the leveling nuts up or down until level. 

f. Move the level ninety (90) degrees from your first position 

and readjust. 

g. Repeat the steps until the lantern is level in both positions. 

3-22
90o

LEVEL

“T” METHOD

BASE

THREADED

RODS

Figure 3-14 

h. Tighten the top nuts securing the lantern. DO NOT 

OVERTIGHTEN. 

i. Recheck levelness of lantern. 

j. Obtain a tested CG-6P lampchanger and flasher with the 

appropriate hardware (see Chapter 4). 

k. Attach the mounting bracket between the base of the CG-6P 

lampchanger and flasher with four 10-32x1" screws supplied 

so that the outer ring of the bracket is above the flasher and 

the flasher’s terminals are not covered, as shown in Figure 

3-15. The wires from the WK-681 wiring kit must pass 

inside the bracket ring. 

3-23
Figure 3-15 

INSTALL FLASHER SO 

THAT TERMINALS ARE 

POSITIONED HERE

l. Wiring shall be 12/2 SO cable through a watertight stuffing 

tube, or individually insulated wires installed in conduit 

(Liquid-Flex near lantern). Wires shall have insulated spade 

lugs and terminated at the Black (+) and White (-) terminals 

of the flasher. 

m. Install a focus fixture in the first lamp position. 

n. Install assembly into lantern by lining up slots with studs in 

the lantern ring. Insert, rotate and secure wing nuts to 

secure. Note: Mount lampchanger/flasher bracket flush 

against the arms with the spacers on the studs between the 

wing nuts and bracket, as shown in Figure 3-16. 

 3. Focusing. 

 

a. Loosen (do not remove) all screws on the lens cover 

clamping ring. See Figure 3-16. 

3-24
 

Figure 3-16 

250 mm

LANTERN

BASE

CLAMPING

RING

MOUNTING

BRACKET

FOCUS

KNOB

LENS

SUPPORT

RING

CAPTIVE

SCREW

LENS

COVER

CG-6P

SPACER

FOCUS

FIXTURE

b. With lantern open, look into the lens cover. Check to see if 

one knob is aligned with sight marks. If not, rotate the lens 

cover until one of the focus knobs is aligned with one set of 

sighting marks. See Figure 3-17 

SIGHTING MARKS

250MM LANTERN LENS COVER

NOTE

ALIGNMENT

 

Figure 3-17 

3-25
c. Secure the screws on the lens clamping ring 

d. Secure the flasher/lampchanger assembly on studs above 

the spacers. 

e. Tighten the focus knobs ("D" rings) on the mounting bracket 

COUNTER- CLOCKWISE until the mounting bracket is tight 

against the mounting ring. 

f. Turn each focus knob CLOCKWISE six (6) complete 

revolutions. You should observe the focus fixture slightly 

below the sighting marks - if not right on. 

g. Sight through the set of sighting marks (through "O" to "X") 

that are aligned with the focus knob. 

h. Observe the focus fixture. Is it right or left or low? If so, turn 

one of the two focus knobs not aligned with the sighting 

marks you are using until the focus fixture is centered. 

Figure 3-18 

IDEAL

FOCUS

VERTICLE

TOLERANCE

+ OR - 1/4

DIAMETER

OF REAR

CIRCLE

HORIZONTAL

TOLERANCE

+ OR - 1/4

DIAMETER

OF REAR

CIRCLE

i. If the focus fixture is above the sighting marks, turn all the 

focus knobs the same amount to lower or raise the focus 

fixture. 

j. Sight through the other set of sighting marks. 

3-26
k. Observe the focus fixture. Is it right or left or low? If so, turn 

only the third focus knob until the focus fixture is centered 

See Figure 3-18. 

l. Repeat steps until you observe the focus fixture centered 

under the sighting marks. 

m. Finally, turn all focus knobs evenly until the focus fixture is 

centered in the sighting marks. 

o. If you are still unable to focus -- Check for improper 

mounting, spacers, bent mounting bracket, etc. Then, 

REPEAT PROCEDURES. 

p. Remove lampchanger/flasher assembly by loosening the 

three wing nuts. DO NOT TURN THE "D" RINGS ON THE 

BRACKET. 

q. Remove the focus fixture by turning it counterclockwise. 

Install six lamps in the lampchanger, as described in 

Chapter 4. Advance the lampchanger to the first position 

and reinstall in the lantern. 

4. Maintenance. 

a. Visually inspect the lens and base for cracks, crazing, holes, 

etc. Replace if necessary. 

b. Open lantern by loosening four captive screws on base 

below lantern ring. Swing lens open against stops. 

c. Inspect drain holes in base. Clean if necessary. 

d. Place a level on the base and check levelness in both 

directions. Correct if not level. 

3-27
e. Remove lampchanger/flasher assembly by loosening the 

three wing nuts. DO NOT TURN THE "D" RINGS ON THE 

BRACKET. 

f. Remove the operating lamp and any burned out lamps. 

CAUTION - LAMPS MAY BE HOT. Use a clean rag when 

removing lamps. 

g. Install the focus fixture in the lampchanger. 

h. Reinstall the lampchanger assembly onto the lantern arms, 

then the spacers and secure. 

i. Check the focus and adjust, if necessary, as described in 

Section 4. 

j. Remove the lampchanger assembly from the lantern. 

k. Advance unused lamps to the first positions and install new 

lamps in the remaining positions, as described in Chapter 4. 

l. Perform the quick aid test outlined in Chapter 4. 

m. Rotate turret to the first position. CAUTION - LAMPS AND 

TURRET MAY BE HOT. 

n. Reinstall the lampchanger assembly. 

o. Close and secure the lens assembly. 

p. Clean the lens cover, if necessary with a soft bristle brush 

and mild soap and water. 

3-28
5. Troubleshooting. 

a. If the light is reported burning dim, perform the following 

system checks: 

(1) Load test the battery (Chapter 2); 

(2) Check focus of lantern (Section 3). Be sure correct 

lamps are installed; 

(3) Clean lens cover if necessary. 

b. If the light is reported out, perform the following system 

checks: 

(1) Load test the battery (Chapter 2); 

(2) Meg the power cable (Chapter 2); 

(3) Perform the Minor Aid Troubleshooting Test (Chapter 4). 

3-29
F. 300mm Lanterns. 

1. Notes. 

a. The 300mm lantern is used only on stable platforms. 

This omnidirectional lantern requires precision 

focusing and leveling to ensure proper operation. 

The lens is replaceable and available in clear, yellow, 

red and green. 

2. Installation. 

a. Install three 1⁄2” threaded rods or bolts on the platform as 

shown in Figure 3-19. Add the leveling nut and flat washer 

at this time. 

 Figure 3-19

LANTERN

THREADED ROD OR BOLT PLATFORM

SPLIT

WASHER

FLAT

WASHER

LEVELING

NUT

NYLOCK

NUT

3-30
b. Position lantern over threaded rods. Place a nylock nut and 

flat washer on each rod but do not tighten completely. 

c. With lens open, place a level on the flange of the lantern 

base. Use the “T” method shown in Figure 3-20 so that 

adjustment of one leveling bolt won’t affect the other 

adjustment. DO NOT USE THE LANTERN BUBBLE 

LEVELS. 

d. Adjust the leveling nuts up or down until level. 

90o

300 mm LANTERN

LEVEL

“T” METHOD

BASE

THREADED

RODS

Figure 3-20 

e. Move the level ninety (90) degrees from your first position 

and readjust. See Figure 3-20. 

f. Repeat steps until the lantern is level in both positions. 

g. Tighten top nuts on leveling bolts and recheck levelness of 

lantern. DO NOT OVERTIGHTEN. 

3-31
h. Obtain a tested CG-6P lampchanger and flasher with the 

appropriate hardware (see Chapter 4). 

i. Attach the mounting bracket between the base of the CG-6P 

lampchanger and flasher with four 10-32x1" screws supplied 

so that the dip in the bracket is down, as shown in Figure 3-

21. The wires from the WK-681 wiring kit must pass under

the bracket. Attach the bracket to 300mm tripod by turning 

the assembly onto the studs, and then tighten the wing nuts. 

Figure 3-21 

j. Wiring shall be 12/2 SO cable through a watertight stuffing 

tube, or individually insulated wires installed in conduit 

(Liquid-Flex near lantern). Wires shall have insulated spade 

lugs and terminated at the Black (+) and White (-) terminals 

of the flasher. 

k. Install a focus fixture in the first lamp position. 

l. Install assembly into lantern by lining up the opposing 

triangles (><, on most lanterns) on the tripod and lantern 

ring. Insert, rotate and tighten wing nuts to secure. 

3-32
 

3. Focusing. 

a. With lantern open, look into the lens and see if one of the 

focus screws is aligned with one set of sighting marks. If 

not, loosen lens clamps and rotate the lens. 

b. Secure each of the lens clamping screws. 

c. Insert a focus fixture in the lampchanger. 

d. Secure tripod flasher/lampchanger assembly on lens support 

ring. HINT: the bracket can only be installed one way and 

some lanterns have alignment triangles on the lens support 

ring and tripod. Tighten the wing nuts. 

e. Tighten focus screws on lens support ring CLOCKWISE 

until tight against the lens base. 

f. Turn each focus screw COUNTER-CLOCKWISE nine (9) 

complete revolutions. 

g. Install the focus prism over one of the focus dots on the lens. 

You should observe the focus fixture slightly below the 

sighting marks if not right on. See Figure 3-22. 

IDEAL

FOCUS

VERTICLE

TOLERANCE

+ OR - 1/2

DIAMETER

OF REAR

CIRCLE

HORIZONTAL

TOLERANCE

+ OR - 1/2

DIAMETER

OF REAR

CIRCLE

Figure 3-22 

3-33
h. Sight through the set of sighting marks using the focus prism 

that is aligned with the focus knob. 

i. Observe the focus fixture. Is it right or left or low? If so, turn 

one of the two focus screws not aligned with the sighting 

marks until the focus fixture is centered. See Figure 3-22. 

j. If the focus fixture is above the sighting marks, turn each 

focus screw two (2) or three (3) more complete turns until it 

is either below it or right on. 

k. Sight through the other set of sighting marks using the focus 

prism. 

l. Observe the focus fixture. Is it right or left or low? If so, turn 

only the third focus screw until the focus fixture is centered. 

m. Repeat steps until you observe the focus fixture centered 

under the sighting marks. 

n. Finally, turn all focus screws CLOCKWISE until the focus 

fixture is centered in the sighting marks. 

o. If unable to focus, check for improper mounting, spacers, 

bent mounting bracket, etc. Then, repeat above procedures. 

p. Remove lampchanger/flasher assembly by loosening the 

three wing nuts. 

q. Remove the focus fixture. Install six lamps in the 

lampchanger, as described in Chapter 4. 

4. Maintenance. 

a. Visually inspect the lens and base for cracks, crazing, holes, 

etc. Replace if necessary. 

b. Open lantern by loosening four screws on base below 

3-34
lantern ring. Swing lens open against stops. 

c. Inspect drain holes. Clean if necessary. 

d. Place a level on the base and check levelness in both 

directions. Correct if not level. 

e. Remove lampchanger/flasher assembly by loosening the 

three wing nuts. DO NOT TURN THE THREE SCREWS ON 

THE LANTERN RING. 

f. Remove the operating lamp and any burned out lamps. 

CAUTION - LAMPS MAY BE HOT. Use a clean rag when 

removing lamps. 

g. Install the focus fixture in the lampchanger. 

h. Reinstall the lampchanger/flasher assembly onto the lantern 

ring and secure. 

i. Check the focus and adjust, if necessary, as described in 

Section 3. 

j. Remove the lampchanger/flasher assembly from the lantern. 

k. Advance unused lamps to the first positions and install new 

lamps in the remaining positions, as described in Chapter 4. 

l. Perform the quick aid test outlined in Chapter 4. 

m. Rotate turret to the first position. CAUTION - LAMPS AND 

TURRET MAY BE HOT. 

n. Reinstall the lampchanger assembly. 

o. Close and secure the lens assembly. 

3-35
p. Clean the lens cover, if necessary with a soft bristle brush 

and mild soap and water. 

5. Troubleshooting. 

a. If the light is reported burning dim, perform the following 

system checks: 

(1) Load test the battery (Chapter 2); 

(2) Check focus of lantern (Section 3). Be sure correct 

lamps are installed; 

(3) Clean lens cover if necessary. 

b. If the light is reported out, perform the following system 

checks: 

(1) Load test the battery (Chapter 2); 

(2) Meg the power cable (Chapter 2); 

(3) Perform the Minor Aid Troubleshooting Test (Chapter 4).

3-36
G. Tideland MLED-120 and Sealite SL125 LED Lanterns. 

1. Notes. 

a. The Tideland MLED-120 and Sealite SL125 

(pictured) are similar in appearance, operation and 

installation. Both will be covered in this section. 

The Sealite lantern is completely sealed and is 

equipped with a power cord. The Tideland lantern 

is accessible for power cable installation and 

replacement of the daylight control. These lanterns 

require a legacy power system (solar panel and 

battery). Proper selection must be made by District 

(dpw) prior to installation. 

2. Installation. 

a. Lanterns shall be programmed at the base prior to transport 

and installation at the aid. Consult the Commandant (CG432A) website (www.uscg.mil/systems/gse/gse2) for specific 

instructions regarding these lanterns. 

b. The lanterns are installed on a standard 3-hole mount with a 

7-7/8” bolt circle using either 1⁄2” stainless steel bolts or 

threaded rod. 

c. On buoys the lantern should be elevated at least 4” so that 

the lantern ring does not obstruct the light, as shown in 

Figure 3-23. Spacers are available from the manufacturer or 

can be fabricated locally. 

3-37
Top of Radar

Reflector

Solar Panel

Mounting Frame

Split Lock Washer

Nut

1/2” Bolt

Flat Washer

Spacer

Figure 3-23

d. On structures, secure three 1⁄2” stainless steel bolts (or allthread) to the structure’s mounting plate as shown in Figure 

3-24. Install three jam nuts and flat washers on the bolts so 

that about 1” of thread is exposed. Place the lantern on top 

of the leveling nuts, and then install the flat washer and 

nylock nuts at the very upper end of the thread. Do not 

tighten these uppermost nuts – they are positioned at this 

time to ensure that the lantern doesn’t fall off. Level the 

lantern on structures by adjusting the leveling nuts (use a 

torpedo level on the top of the lens or base plate of the 

lantern, whichever is flat) - use the “T” method. When the 

lantern is level, tighten the nylock nuts. 

3-38
1⁄2”-13 UNC Bolt

3 ea on a 7 7/8” bolt circle -

Leveling Nut

Nut

Split Washer

Platform

All -Thread

Or Bolt

Nylock Nut

Flat Washer

Lantern

Figure 3-24. Installation – Structure 

e. Route the power cables from the lantern and solar panel to 

the battery and attach the black to the positive terminal and 

white to the negative terminal using ring lugs. The Sealite 

cable is fixed, so if it doesn’t reach, use a LED Junction Box 

or replace the cable. Also, some Sealite lanterns may have 

European color coding; brown is positive and blue is 

negative. 

 

f. Apply power to the lantern, cover the lens with a jacket or 

3-39
blanket, or the external daylight control and note if the 

lantern flashes on-rhythm.

3. Servicing. 

a. Servicing should be performed in accordance with the 

standard cycle established for the aid. 

b. Ensure that the lens and solar panels are clean. Wipe with a 

cloth dampened with mild soap and water, if necessary. 

c. Load test the battery. 

d. Cover the lantern with a shroud, jacket, blanket, etc., or the 

daylight control to simulate darkness. The lantern should 

flash on rhythm after a few seconds. It should stop flashing 

after the cover is removed in the daytime. While covered, 

observe the LEDs through the lens. Dark sectors indicate 

that an LED cluster is not operating, necessitating 

replacement of the lantern. 

e. Uncover the lantern/daylight control. It should stop flashing. 

4. Troubleshooting. If the lantern is reported discrepant or is 

flashing irregularly: 

a. Load test the battery (Chapter 2) 

b. Meg the power cable (Chapter 2); 

c. Replace the lantern and troubleshoot completely at the Unit 

using the referenced Technical Data Sheets. Corrective 

action to the lantern should not be performed on-station.

3-40
H. Vega VLB-44 LED Lantern. 

1. Notes. 

a. The Vega VLB-44 is a high intensity LED lantern 

suitable for use on buoys, structures and 

lighthouses. This lantern requires a legacy 

power system (solar panel and battery). It is 

available in three divergences; 10 degrees for 

buoys (with a tall base), 5 degrees for structures 

and 2.5 degrees for lighthouses. LED optic 

heads may be stacked (up to 8) to increase 

intensity. Proper selection must be made by 

District (dpw) prior to installation. 

2. Installation. 

a. Lanterns shall be programmed at the base prior to transport 

and installation at the aid. Consult the Commandant (CG432A) website for specific instructions regarding these 

lanterns. 

b. The lanterns are installed on a standard 3-hole mount with a 

7-7/8” bolt circle using either 1⁄2” stainless steel bolts or 

threaded rod. 

c. On buoys the lantern should be purchased with the high 

base or elevated at least 4” so that the lantern ring does not 

obstruct the light, as shown in Figure 3-25. Spacers can be 

fabricated locally. 

3-41
Top of Radar

Reflector

Solar Panel

Mounting Frame

Split Lock Washer

Nut

1/2” Bolt

Flat Washer

Figure 3-25

d. On structures, secure three 1⁄2” stainless steel bolts (or allthread) to the structure’s mounting plate as shown in Figure 

3-26. Install three leveling nuts and flat washers on the bolts 

so that about 1” of thread is exposed. Place the lantern on 

top of the leveling nuts, and then install the flat washers and 

nylock nuts at the very upper end of the thread. Do not 

tighten these uppermost nuts – they are positioned at this 

time to ensure that the lantern doesn’t fall off. Level the 

lantern on structures by adjusting the leveling nuts (use a 

torpedo level on the top of the lens) - use the “T” method. 

When the lantern is level, tighten the nylock nuts. 

3-42
1⁄2”-13 UNC All-Thread, 

3 ea on a 7-7/8” bolt circle

Leveling Nut

Nut

Split Washer

Platform

All -Thread

Or Bolt

Nylock Nut 

Flat Washer

Lantern

 Figure 3-26. 

e. Route the power cables from the lantern and solar panel to 

the battery and attach the black to the positive terminal and 

white to the negative terminal using ring lugs. The cable has 

a molded connector at the lantern, so if it doesn’t reach, use 

a LED Junction Box. 

 

f. Apply power to the lantern, cover the lens with a jacket or 

blanket, or the external daylight control and note if the 

lantern flashes on-rhythm.

3. Servicing. 

a. Servicing should be performed in accordance with the 

standard cycle established for the aid. 

3-43
b. Ensure that the lens is clean. Wipe with a cloth dampened 

with mild soap and water, if necessary. 

c. Cover the lantern with a shroud, jacket, blanket, etc., to 

simulate darkness. The lantern should flash on rhythm after 

a few seconds. It should stop flashing after the daylight 

control is uncovered. While covered, observe the LEDs 

through the lens. Dark sectors indicate that an LED cluster 

is not operating, necessitating replacement of the optic 

head. 

d. Uncover the lantern. It should stop flashing in the daytime. 

4. Troubleshooting. If the lantern is reported discrepant or is 

flashing irregularly: 

a. Load test the battery (Chapter 2) 

b. Meg the power cable (Chapter 2); 

c. Replace the lantern and troubleshoot completely at the base 

using the referenced Technical Data Sheets. Corrective 

action to the lantern should not be performed on-station.

3-44
I. 14 Inch Range Light (RL-14). 

1. Notes. 

a. The RL-14 is a 14 inch range light. The beam 

color can be white, yellow, red or green when 

using the appropriate colored spread or nonspread lens. All 12 volt lamps may be used in 

the lantern, however all C-8 filament lamps 

(0.25, 0.55, 0.77, 1.15, 2.03, 3.05) must use a 

spread lens. Two versions of the RL-14 are 

currently installed in the field: the Tideland 

Signal RL355 and the Carlisle & Finch 

RL10668; the latter is considered the Coast 

Guard standard 14 inch range light. Parts 

between these beacons are not 

interchangeable. Additional information can be 

obtained from the instruction book included with 

each lantern. 

b. RL14s are available from ELC Baltimore. Spread Lenses 

are available from Tideland Signal Corporation, Houston, 

Texas. 

c. Note: some lanterns were converted to LED light sources 

manufactured by BWT lighting or CR Control Systems. 

Consult our website www.uscg.mil/systems/gse/gse2 for 

specific instructions. 

 

2. Installation. 

a. The lantern must be installed on a stable platform to ensure 

that accurate aim is maintained. Secure the lantern to the 

platform using 3/8" bolts as shown in Figure 3-27. 

b. Leveling bushings are provided in the base to assist in 

leveling the lantern. Use the spirit levels on top of the 

3-45
beacon to determine if the lantern is level. These levels are 

certified to be true. 

c. The drum is attached to the base in a manner that allows the 

beacon to be aimed regardless of the position of the base. 

Figure 3-27 

BOLT

FLAT WASHER

LEVELING BUSHING

PLATFORM

LOCK WASHER

NUT

11-1/16”

7-3/8”

(APPROX)

12-3/4”

DRUM PIVOT POINT

FRONT

d. Wiring shall be 12/2 SO cable through a watertight stuffing 

tube, or individually insulated wires installed in conduit 

(Liquid-Flex near lantern). Pull enough slack through the 

lantern to attach to the flasher. 

e. Obtain a tested CG-6P/CG-6PHW lampchanger and 

appropriate flasher with the proper hardware (see Chapter 

4). 

f. Attach the mounting bracket between the base of the CG6P(HW) lampchanger and flasher with four 10-32x1" screws 

so that the dip in the bracket is up (cover “CG6P” stamped 

on bracket with lampchanger). The wires from the WK-681 

3-46
wiring kit must pass under the bracket, shown in Figure 3-

28. 

g. Rotate the spacer blocks in the drum of the lantern to the 

correct lampchanger/lamp combination, as shown in Figure 

3-28. Loosen the mounting screw and rotate the block until 

the selected surface aligns with the threaded hole in the 

back wall. Gently tighten the mounting screw. 

Figure 3-28 

GC 4- P 1/ 0 , 0 51 W0

T( 4- UB

BL )

LC-300/100W

(T3.5 BULB)

CG-6P AND TF-3B CG-4P 2/ 50W

ORIENT SPACER

BLOCKS AS

SHOWN

CG-4P/100,150W

(T-4 BULB)

CG-6P AND TF-3B

CG-4P 2/ 50W

CL 3- 00 1/ 00 W

T( . 3 5 UB

BL )

NOTE ORIENTATION

OF BRACKET

h. Grasp the lampchanger/flasher/bracket assembly and guide 

into the aluminum can of the drum until the bracket rests 

against the spacers. 

i. Insert two 10-32x3/4" screws provided in the installation kit 

through the bracket into the holes in the spacer. Tighten 

screws. 

3-47
j. If a spread lens is used, remove the lens ring and cover 

glass. Reuse the gasket on the spread lens. Install the 

spread lens with the flat side IN and the lens elements 

oriented vertically (up & down). 

k. Aim the beacon using the gunsights built into the lift eye and 

hinge, as shown in Figure 3-29. On long ranges, use an 

observer in a boat to ensure that the brightest part of the 

beam is on the channel centerline. A Southfinder may be 

used to establish aim if the range bearing is known. 

SIGHT PICTURE

Figure 3-29 

3. Focusing. The lantern is prefocused and no adjustments are required. 

4. Maintenance. 

a. Visually inspect the lens for cracks, crazing, holes, etc. 

Replace if necessary. 

b. Loosen the 4 toggle latches and secure the door in an 

upright position with the supplied pin. Allow the lamps to 

cool if they were operating. 

c. Clean the drain hole, if necessary. 

d. Wearing gloves or using a soft cloth, remove the lamp in the 

operating position by rotating counter-clockwise. Remove 

3-48
and discard any burned out lamps at this time. Note: it is 

advisable to secure power when servicing tungsten-halogen 

lamps. 

e. Advance unused lamps to the first positions and install new 

lamps in the remaining positions, as described in Chapter 4. 

f. Perform the quick aid test outlined in Chapter 4. 

g. Rotate turret to the first position. CAUTION - LAMPS AND 

TURRET MAY BE HOT. 

h. Close and secure the door assembly. 

i. Clean the lens with a soft cloth and mild soap and water. 

5. Troubleshooting. 

a. If the light is reported burning dim, perform the following 

system checks: 

(1) Load test the battery (Chapter 2); 

(2) Be sure correct lamps are installed; 

(3) Be sure lampchanger bracket is not twisted, is installed 

correctly and spacer blocks are properly oriented. 

(4) Clean lens cover if necessary. 

b. If the light is reported out load test the battery (Chapter 2), 

meg power cable (Chapter 2) and perform the Minor Aid 

Troubleshooting Test (Chapter 4). 

3-49
J. VRB-25 Rotating Beacon. 

1. Notes. 

a. The VRB-25 is the Coast Guard’s standard 12 volt 

rotating beacon. It is comprised of a direct drive 

turntable assembly with 6 rotating lens panels, has 

a user selectable speed range of 0.67 to 15.9 rpm, 

and is capable of operating up to 110 watt lamps. 

 

b. Spare parts are contained in the VRB spare parts kit, which 

are staged at ANTs with the greatest number of beacons. 

Additionally, spare parts, red and green lens panels, and 

blanking panels are available from Commandant (CG-432A) 

and the manufacturer. Beacons are available from COMDT 

(CG-432A) 

c. The beacon is used only on structures not subjected to 

noticeable vibration (i.e., lighthouses, dolphin type structures 

and steel structures). 

 

2. Pre-installation. Before bringing the beacon to the site, the 

following procedures should be performed at the servicing unit: 

 

a. Ensure that the correct lens panels are installed. The 

beacon is shipped with 6 clear lens panels. If blanking 

(black plastic), red or green panels need to be installed, 

consult with the instruction book supplied with the beacon. 

b. Ensure that the correct RPM is selected. The beacon is 

shipped with the rotation rate preset at 1 rpm. If it needs to 

be changed, consult with the instruction book supplied with 

the beacon, or see section 7.c (Repair Procedures). 

3-50
c. Two different lampchangers can be used in this beacon. 

The CG6P is used for all lamps less than 50 watts (0.55 to 

3.05, inclusive). The CG6PHW is used with lamps 50 watts 

and greater. 

d. The CG-181/493/504 flasher is used in all beacons with 

lamps less than 50 watts (0.55 to 3.05, inclusive). Beacons 

with lamps 50 watts and greater do not use a flasher and 

must be externally controlled (see below). 

e. The beacon may be operated in two different modes: 

internal control and external control. Internally controlled 

beacons use a Fixed flasher and type “L” daylight control to 

perform the lampchanging and daylight control functions. 

Externally controlled beacons are monitored and/or have an 

emergency light and may contain a flasher (for voltage 

regulation). If equipped with a flasher, the daylight control 

function is performed externally with a Solar Aid Controller 

(SACII). If no flasher is installed, both lampchanging and 

daylight control functions are performed externally with a 

SACII. 

3. Installation. 

a. Install three 1⁄2 inch threaded rods or bolts equally spaced on 

a 7-7/8” bolt circle in the platform as shown in Figure 3-30. 

Add the leveling nut and flat washer at this time. Note, the 

beacon is provided with two (2) nylock and two (2) plain nuts 

for each mounting rod. 

3-51
 Figure 3-30 

LANTERN

THREADED ROD OR BOLT

SPLIT

WASHER

FLAT

LEVELING

NUT (PLAIN)

WASHERS

FLAT

WASHERS

SPLIT

WASHER

PLATFORM

PLAIN NUT

NYLOC NUT

NYLOC

 NUT

b. Position beacon over leveling bolts. Do not remove or lose 

the black bushings in the mounting holes. Use ArmyNavy Grommets (McMaster Carr part number 9307K27, 

Phone: 908-329-3200) between the flat washers surrounding 

the beacon base when tower is subject to vibration. 

c. Place a top washer, split washer and nut on each bolt. Do 

not tighten completely. 

3-52
d. Use the bubble level on the bottom of the lens cage to level 

beacon. 

 Figure 3-31 

DO NOT

TURN THESE

SCREWS

e. Adjust the leveling nuts up or down until the bubble is 

centered in the circle on the level, as shown in Figure 3-31. 

f. Tighten top nuts on leveling bolts enough to compress the 

split washer. DO NOT OVERTIGHTEN. 

g. Rotate the lens cage and recheck the levelness of the 

beacon. The bubble should stay centered within the circle 

through an entire rotation of the lens cage. If not, center it 

the best you can through an entire rotation. 

h. Wiring for Internal Control. (If the beacon is to be wired 

for External Control, go to Section i). 

(1) Unscrew the 4 capscrews, which secure the terminal 

plate to the beacon base and tilt the terminal plate down. 

3-53
Figure 3-32 

ROTATION DET.

OR

PHOTORESISTOR

+ -

(MOTOR)

“F”

PULSE

+ -

(LAMP)

REMOVE AND TAPE OFF

TO CALC-20

(2) Four wires should already lead from the terminal strip on 

the cover plate; two for the drive motor and two for the 

rotation detector. Remove the two for the rotation 

detector and cover the ends with tape, or remove the 

wires completely from the CALC-20. They will not be 

used. See Figure 3-32 

(3) Insert the power cable (12 AWG wires in conduit/ 

liquidflex; wires must be shielded) through the stuffing 

tube into one of the threaded openings in the base. 

(4) Remove 12 inches of outer jacket and strip 1⁄4 in of 

insulation from each conductor. 

3-54
Wiring for Internal Control

Figure 3-33 

+ -

(MOTOR)

“F”

PULSE

TO CALC-20

+ INPUT -

JUMPERS

TO CG-181 FLASHER

ROTATION DET.

OR

PHOTORESISTOR

+ -

(LAMP)

TO DAYLIGHT

CONTROL

S S + -

FROM

BATTERY OR

POWER SUPPLY

(5) Install the black wire to the Lamp (+) and the white wire 

to the Lamp (-) terminals. 

(6) Jumper the Lamp (+) to the Motor (+) on the terminal strip 

with 18 AWG or larger wire, as shown in Figure 3-33. 

(7) Jumper the Lamp (-) to the Motor (-) on the terminal 

strip. 

(8) Screw a Type-L daylight control into one of the threaded 

openings in the base. Cut the lugs off and strip 1⁄4 inch 

of insulation off each lead. Attach to the Photoresistor 

input terminals on the terminal strip. 

3-55
(9) Release the 8 thumb latches located on the lower ring of 

the glazing assembly by rotating them 180 degrees. 

Carefully lift the glazing straight up from the beacon and 

set aside. 

Figure 3-34 

(10) Looking down into the beacon, remove the three 

capscrews securing the lampchanger plate (Figure 3-34) 

to the flasher housing. Remove the lampchanger plate. 

(11) Wire the lampchanger with a WK-681 wiring kit. After 

securing the lugs, bend the lugs out 90 degrees from the 

terminals. 

(12) Orient the lampchanger on the Lampchanger Plate so 

that the terminal strip faces away from the opening in the 

plate, as shown in Figure 3-35. 

3-56
Figure 3-35 

BEND

LUGS

UP

(13) Loop the wires from the lampchanger under the plate 

and connect to the flasher. Secure the flasher and 

lampchanger to the lampchanger plate with four 10-32 

screws. 

(14) Make up four wires, one black, one white and two yellow 

each two feet long with lugs attached to ONE end. The 

yellow wires should be 18 AWG, the black and white 12 

AWG, all with PVC or Teflon insulation. 

3-57
Figure 3-36 

TO TERMINAL STRIP

S S L F

+

_

BLACK

WHITE

YELLOW

(15) Attach the leads to the flasher as shown in Figure 3-36. 

(16) Make sure the springs are still in place in the flasher 

housing (inside beacon). 

(17) Pass the four wires from the flasher through the opening 

in the bottom of the flasher housing and pull the leads in 

the beacon base as the assembly is lowered, as shown 

in Figure 3-37. 

(18) Screw the Lampchanger Plate to the Flasher Housing 

with the 3 capscrews. The filament support shadow 

should face the non-critical area. Do not tighten 

capscrews.

(19) Cut excessive wire from the flasher (leave enough to 

easily work on the Terminal Plate and strip 1⁄4 inch from 

each lead. 

3-58
ACCESS

HOLE

Figure 3-37 

(20) Attach the yellow leads to the daylight control, the black 

lead to the Lamp (+) terminal and the white wire to the 

Lamp (-) terminal. 

(21) Install the Terminal Plate on the beacon. 

(22) Go to Section 3, Focusing. 

i. Wiring for External Control (If the beacon is to be wired 

for Internal Control, go to Section h). 

(1) Unscrew the 4 capscrews which secure the terminal 

plate to the beacon base and tilt the terminal plate down. 

3-59
(2) Four wires should already lead from the terminal strip on 

the cover plate; two for the drive motor and two for the 

rotation detector, as shown in Figure 3-38. 

ROTATION DET.

OR

PHOTORESISTOR

+ -

(MOTOR)

“F”

PULSE

+ -

(LAMP)

TO CALC-20

Figure 3-38 

(3) Insert the unswitched power cable (12 AWG wires in 

conduit or liquidflex; wires must be shielded) through the 

stuffing tube into one of the threaded openings in the 

base. Insert four conductors (three 12 AWG 

black/white/blue and one shielded 18 AWG through a 

stuffing tube in the other threaded opening. The black 

and white wires are switched power leads. 

(4) Remove 12 inches of outer jackets and strip 1⁄4 in of 

insulation from each conductor. 

(5) Install the unswitched (so the drive motor operates 

continuously) black wire to the Motor (+), the white wire 

to the Motor (-) terminals. 

3-60
TO CALC-20

JUMPERS

TO CG6P LAMPCHANGER

OR CG-181 FLASHER

TO 

SDB/SACII

USED IF NO

FLASHER

INSTALLED

“F”

PULSE

+ -

(MOTOR)

+ -

(LAMP)

SHIELD

ROTATION DET.

OR

PHOTORESISTOR

+- F ROT

DETECT + INPUT

 -

SACII, TB1-4

SHIELD, TB2-2

SDB, CB1

SACII, TB2-1

SDB, CB12

SDB, NEG BUSS

SACII, TB2-3

Wiring for External Control 

Figure 3-39 

(6) Install the switched black wire to the Lamp (+), the white 

wire (from SACII, Load (-)) to the Lamp (-), the Blue wire 

(from SACII, Lampchanger (F)) to the “F” Pulse and the 

shield and 18 AWG wires to the Rotation Detector 

terminals. See Figure 3-39. 

Note: Some externally controlled beacons use a CG181/493/504 flasher for voltage regulation. In this 

case, the “F” pulse from the SACII is not used.

(7) Jumper the Rotation Detector shield connection to the 

Motor (-) on the terminal strip (do not use Lamp (-) as it 

is switched by the SACII). 

3-61
(8) Release the 8 thumb latches located on the lower ring of 

the glazing assembly by rotating them 180 degrees. 

Carefully lift the glazing straight up from the beacon and 

set aside. 

Figure 3-40 

(9) Looking down into the beacon, remove the three 

capscrews securing the lampchanger plate (Figure 3-40) 

to the flasher housing. Remove the lampchanger plate. 

(10) If not using a flasher, make up three wires, one black, 

one white and one blue each two feet long with lugs 

attached to ONE end and attach to the lampchanger. 

The wires should be 12 AWG with PVC or Teflon 

insulation. After securing the lugs, bend the lugs out 90 

degrees from the terminals 

(11) Orient the lampchanger on the Lampchanger Plate so 

that the terminal strip faces away from the opening in the 

plate (The lampchanger may be installed with the 

terminal strip over the opening when no flasher is used). 

(12) Secure the lampchanger to the plate using 10-32 

machine screws and nuts, as shown in Figure 3-41. Go 

to paragraph (16). 

3-62
Figure 3-41 

BEND

LUGS

UP

(13) If using a flasher, wire the lampchanger with a WK-681 

wiring kit. Loop the wires from the lampchanger under 

the plate and connect to the flasher. Secure the flasher 

and lampchanger with four 10-32 screws. 

(14) Make up two wires, one black and one white each two 

feet long with lugs attached to ONE end. The wires 

should be 12 AWG with PVC or Teflon insulation. 

(15) Attach the black wire to the flasher (+) terminal and the 

white wire to the flasher (-) terminal. 

(16) Make sure the springs are still in place in the flasher 

housing (inside beacon). 

3-63
(17) Pass the two or three wires through the opening in the 

bottom of the flasher housing and pull the leads in the 

beacon base as the assembly is lowered, as shown in 

Figure 3-42. 

ACCESS

HOLE

Figure 3-42 

(18) Screw the Lampchanger Plate to the Flasher Housing 

with the 3 capscrews. Do not tighten.

(19) Cut excessive wire from the flasher (leave enough to 

easily work on the Terminal Plate and strip 1⁄4 inch from 

each lead. 

(20) Attach the black lead to the Lamp (+) terminal, the white 

wire to the Lamp (-) terminal and the blue wire (if used) 

to the “F” Pulse terminal. 

(21) Install the Terminal Plate on the beacon. 

3-64
4. Focusing. 

a. Remove the glazing assembly by releasing the 8 thumb 

latches on the base. 

b. Remove the operating lamp and install a focus fixture. 

c. Sight through the center of 3 adjacent lens sections (Figure 

3-43) and check to see if the tip of the focus fixture is 

centered in the sighting marks (a white sheet of paper held 

behind the lens is helpful if the background is dark). Do not 

rotate the lens cage to line up sight marks; keep beacon 

stationary and move around it. 

Figure 3-43 

d. Using a 5/32 Allen wrench, adjust the height of the three 

legs of the Lampchanger Plate until the focus fixture tip is 

centered in the hole in the lens, as shown in Figure 3-44. 

3-65
Figure 3-44 

IDEAL

FOCUS

VERTICLE

TOLERANCE

+ OR - 1/4

DIAMETER

OF REAR

CIRCLE

HORIZONTAL

TOLERANCE

+ OR - 1/4

DIAMETER

OF REAR

CIRCLE

e. Install lamps in all 6 positions in the lampchanger. 

f. Rotate lampchanger to the first position. 

g. Reinstall the glazing on beacon and tighten latches. 

h. Turn on power, cover daylight control and check operation. 

i. Remove cover on daylight control before departing. 

5. Maintenance. 

a. Cover daylight control. 

b. Note if the light is on and lens is rotating 

c. Secure power to beacon. 

d. Visually inspect lens, lens cover, base and external wiring 

for cracks, crazing, holes, etc. Replace as necessary. 

e. Clean the outside of the glazing using water with household 

detergent. Do not use solvent based cleaners. 

3-66
Figure 3-45 

DO NOT

TURN THESE

SCREWS

f. Remove the access hatch, rotate the lens cage and recheck 

the levelness of the beacon. The bubble should stay 

centered within the circle through an entire rotation of the 

lens cage, as shown in Figure 3-45. If not, center it the best 

you can through an entire rotation. 

g. Check the focus and adjust, if necessary, as detailed in 

Section 4. 

h. Advance unused lamps to the first positions and install new 

lamps in the remaining positions. 

i. Turn on power to beacon and cover daylight control. 

j. Remove operating lamp (tungsten-halogen lamps operate at 

high temperature and are prone to explosive failure. Use 

gloves to remove or handle; Tilt turret until lamp goes out) 

and ensure that a new lamp ratchets into position. 

k. Secure Power to the beacon and reinstall operating lamp. 

3-67
l. Rotate lampchanger to first position. 

m. Reinstall the hatch on beacon and tighten latches. 

n. Turn on power, cover daylight control and check operation. 

o. Remove cover on daylight control before departing. 

6. Troubleshooting. 

a. If lamp is burning dim or is extinguished, perform the 

following system checks: 

1. Check operating lamp. 

2. Load test the battery (Chapter 2); 

3. Meg power cable (Chapter 2) 

4. Check focus (Section 4); 

5. Clean lens cover, if necessary. 

b. If the problem is improper, or no rotation, use flowchart A as 

a starting point for troubleshooting. Figure 3-46 will help you 

identify the components of a VRB-25. Section 7 contains 

procedures that detail how to test or replace a component in 

the beacon. 

3-68
ACCESS HATCH

GLAZING

FLASHER CAN

TURNTABLE

& LENS CAGE

ASSEMBLY

STATOR

BASE

CALC-20 HOUSING

COVER PLATE

VRB-25 COMPONENTS

FLASHER &

LAMPCHANGER

Figure 3-46 

3-69
START

IS BEACON

ROTATING?

IS 

VOLTAGE

AT BEACON

MORE THAN

11.5 VOLTS?

GO TO F

OVERSPEEDS

THEN STOPS?

DONE

PERFORM POWER

SYSTEM SERVICE

AND GO TO START

SWITCH POWER

OFF THEN ON

DOES BEACON

ROTATE?

REPLACE

CALC-20

GO TO B

GO TO G

NO

NO

NO

YES

YES YES

NO

YES

YES

VRB-25 MOTOR DIAGNOSIS 

PROCEDURE A

IS BEACON

SERIAL NUMBER

LESS THAN 25-176?

GO TO D

DOES

BEACON

ROTATE 

SMOOTHLY?

YES

NO

NO

GO TO

START

DOES

CALC-20 HAVE

WATCHDOG 

TIMER? YES NO GO TO G

3-70
NO ROTATION

PROCEDURE B

MANALLY ROTATE

TURNTABLE

DOES

TURNTABLE

ROTATE

FREELY?

LOWER CALC-20

HOUSING AND 

DISCONNECT MOTOR 6V

WIRE FROM CALC-20

IS 6 VDC 

PRESENT BETWEEN 

MOTOR 6V AND 

MOTOR NEG ON

CALC-20?

NO

YES

YES

GO TO C

RECONNECT MOTOR 6V

AND DISCONNECT WIRES

A, B AND C FROM CALC-20

CHECK VOLTAGE BETWEEN MOTOR 6V

ON CALC-20 AND WIRE “A” WHILE SLOWLY 

ROTATING TURNTABLE BY HAND

REPLACE CALC-20

REPLACE BEARINGS

DOES VOLTAGE SWITCH 

FROM LESS THAN 0.5 TO MORE THAN 

5.5 VDC? (REPEAT FOR WIRES

B AND C)

REPLACE

STATOR

REMOVE

GLAZING. ANY 

OBSTRUCTIONS?

GO TO A

YES NO

NO

NO

REMOVE

OBSTRUCTIONS

YES

3-71
DRIVE COILS

PROCEDURE C

DISCONNECT D, E, AND F

WIRES FROM THE CALC-20

IS RESISTANCE

BETWEEN WIRES D

AND E BETWEEN 

20-25 OHMS?

IS RESISTANCE

BETWEEN WIRES E

AND F BETWEEN 

20-25 OHMS?

REPLACE CALC-20

REPLACE

STATOR

(BAD DRIVE COIL)

IN SHOP, CHECK

RIBBON WIRE FOR

CONTINUITY

NO

NO

YES

YES

GO TO A

LOWER CALC-20

3-72
VISUALLY

INSPECT TACHO

TRANSDUCER. IS

GAP OBSTRUCTED

BY RIBBON CABLE

OR DEBRIS?

LOWER CALC-20

HOUSING. ARE CALC-20 

AND TACHO TRANSDUCER

POSITIONED IAW 

FIGURE 3-38?

REINSTALL CALC-20 AND

ENSURE GAP IS FREE OF

OBSTRUCTION

IS GAP

APPROX 4MM

(5/32”)?

GO TO E

REPLACE

TACHO

TRANSDUCER

LOWER CALC-20.

ARE WIRES AND

OPTICAL TRACK DIRTY

OR DAMAGED?

REPLACE

DAMAGED

PARTS

CORRECT AS

PER FIGURE 3-38

NO

NO

NO

YES

YES

YES

OVER SPEED

PROCEDURE D

REMOVE GLAZING

GO TO A

YES

NO

REINSTALL CALC-20 AND

ENSURE GAP IS FREE OF

OBSTRUCTION

REINSTALL CALC-20

AND ENSURE GAP

IS FREE OF

OBSTRUCTION

3-73
LOWER CALC 20

WITH POWER ON,

MEASURE VOLTAGE

ACROSS L AND NEG

TERMINALS ON CALC-20

IS 0.9-1.2 VDC

PRESENT?

MEASURE VOLTAGE

ACROSS P AND NEG

TERMINALS ON CALC-20

IS VOLTAGE

GREATER THAN

4.8 VDC?

HOLD REFLECTIVE

OBJECT 5/32” ABOVE

TRANSDUCER

DOES 

VOLTAGE DROP

BELOW 

1.2 VDC?

OPTICAL

 TRACK

DAMAGED?

REPLACE

CALC-20

CONTROLLER

REPLACE GO TO A

BEACON

REPLACE

TACHO

TRANSDUCER

YES

NO

NO

NO

YES

YES

YES

NO

TACHO TRANSDUCER

PROCEDURE E

REPLACE

TACHO

TRANSDUCER

REPLACE

CALC-20

CONTROLLER

REPLACE DAMAGED

TRACK IN SHOP

3-74
SWITCH OFF POWER

TO MOTOR

REMOVE COVER PLATE

BEARINGS 

PROCEDURE F

REMOVE MOTOR (+) WIRE

CONNECT MILLIAMP

METER IN SERIES

SWITCH ON POWER AND

WAIT 10 SECONDS FOR

BEACON TO REACH

OPERATING SPEED

IS CURRENT

BETWEEN 100-140

MILLIAMPS?

REMOVE METER 

AND REASSEMBLE

TERMINAL STRIP

REPLACE BEARINGS.

GO TO D

GO TO A

NO

YES

3-75
VRB MOTOR IS OPERATING PROPERLY, ONE OR MORE OF THE OF THE FOLLOWING EXTERNAL

INTERFERENCES MAY BE CAUSING THE MOTOR TO SHUT DOWN:

1. POWER SUPPLY VOLTAGE SAGS

2. VOLTAGE SPIKES

3. RADIO FREQUENCY NOISE IN VICINITY (EMI). [POWER LEADS SHOULD BE IN GROUNDED 

CONDUIT.]

4. ELECTRICAL NOISE ON LINE

YOU CANNOT CORRECT THESE PROBLEMS AT THE UNIT LEVEL.

OBTAIN THE FOLLLOWING INFORMATION WHILE AT THE AID IN QUESTION:

1. AID NAME AND LIGHT LIST NUMBER 

2. TYPE OF POWER:

A. SOLAR (TYPE AND NUMBER OF PANELS)

B. BATTERIES (TYPE, AMP-HOUR RATING)

C. COMMERCIAL (TYPE AND SIZE OF TRANSFORMER, TYPE OF POWER SUPPLY)

3. LAMP SIZE, FLASH CHARACTERISTIC AND RPM OF BEACON

4. CABLE SIZE (TO BEACON), LENGTH AND TYPE

5. ALL CG EQUIPMENT (FOG SIGNALS, FOG DETECTORS, ACMS, RACON, RADIO, ETC.)

6. ALL NON CG EQUIPMENT (NOAA WEATHER GEAR, ETC.)

7. LOCATION AND CONDITION OF LIGHTNING PROTECTION EQUIPMENT.

SEND INFORMATION TO YOUR GROUP ATON OFFICER, CEU OR DISTRICT TRAINING

TEAM CHIEF. THEY WILL WORK WITH THE SERVICING UNIT TO ALLEVIATE OR

ELIMINATE THE EXTERNAL PROBLEMS AFFECTING THE AID

ADDITIONAL SERVICE INFO

PROCEDURE G

3-76
7. Repair Procedures. 

a. Bearing Replacement. 

(1) Bearing puller/installer kits and instructions were mailed 

to Units with spare parts kits. Bearings can be field 

changed with this kit. 

b. Turntable Removal/Installation. 

(1) Remove the glazing assembly by releasing the 8 thumb 

latches securing it to the base. 

(2) Lift the glazing straight up off the beacon. 

(3) Disconnect the wiring to the CG-181 flasher or 

lampchanger (if no flasher) at the Terminal Plate on the 

base. 

(4) Remove the 3 capscrews securing the lampchanger 

plate to the base. 

(5) Pull the flasher/lampchanger and wires out of the 

beacon. 

(6) Remove the 3 capscrews securing the flasher can to the 

beacon base. 

(7) Remove the flasher can and the wavy spring (under flasher 

can) from the beacon. DO NOT LOSE THE 3 SPRINGS 

USED UNDER THE LAMPCHANGER PLATE. 

3-77
(8) Grip the turntable assembly by wedging your fingers 

between it and the base to break the magnetic pull of the 

stator/magnets. Two personnel, one on each side of the 

beacon, may be required to pull the turntable straight 

up. 

(9) Install a new turntable assembly by lining up the central 

shaft in the base with the bearings. 

(10) Carefully lower the turntable on the base. Be sure your 

fingers are not under the turntable as the magnetic pull 

of the stator/magnets may pinch your fingers. 

(11) Spin the turntable slowly and ensure it turns freely with 

no binding. 

(12) Install the wavy washer and flasher can in the base 

using the three capscrews. Be sure the 3 springs used 

under the lampchanger plate are still in flasher can. 

(13) Route the wires from the lampchanger/flasher through 

the opening in the flasher can and pull them through by 

reaching into the access hole in the base. 

(14) Attach the lampchanger plate to with 3 capscrews. 

(15) Attach wiring to terminal strip on access plate. If you 

forgot where the wires went, consult with Section 3.h. or 

3.i. 

(16) Turn on power to the Motor terminals and check rotation. 

(17) Secure beacon and focus as described in Section 4. 

3-78
(18) Replace bearings on returned turntable assembly in the 

shop using the appropriate tools and use it as a 

rotational spare. 

c. CALC-20 Replacement. 

(1) Remove the 2 clamps securing the CALC-20 housing to 

the base. 

(2) Pull the housing straight down. It will be tight as an Oring seals it and a locating pin prevents rotation. 

(3) Remove wiring on CALC-20. Check to see if terminal 

lugs are labeled, otherwise note from what terminal each 

wire is removed. 

(4) Remove the Tacho Transducer by removing two screws 

securing it to the CALC-20. 

(5) Remove the 4 hex screws securing the CALC-20 to the 

housing using a 5/64” hex wrench. 

(6) Carefully pull the CALC-20 out of the housing. 

(7) Set the speed on the new CALC-20 as shown below: 

(a) The underside of the controller has two rotary 

switches that control the rpm. Use a small 

screwdriver to set each switch in the proper position, 

as detailed in Figure 3-47. 

3-79
Figure 3-47 

SELECTINGRPM

 

SW1 

 

 0 

 1 

 2 

 3 

 4 

 5 

 6 

 7 

 8 

 9 

 A 

 B 

 C 

 D 

 E 

 F

 SW2 

 

 0 

 1 

 2 

 3 

 4 

 5 

 6 

 7 

 8 

 9 

 A 

 B 

 C 

 D 

 E 

 F

RPM 

0.00 

0.10 

0.16 

0.20 

0.25 

0.30 

0.33 

0.40 

0.50 

0.60 

0.66 

0.70 

0.75 

0.80 

0.83 

0.90

RPM 

 0 

 1 

 2 

 3 

 4 

 5 

 6 

 7 

 8 

 9 

10 

11 

12 

13 

14 

15

Fractions Units

MC33035

47pF

0.1μF

220R 47K CG

27K

47K

1μF +

Z5.6

10n

1.8K

BYV95C

1 MEG

TPIC2301

2K7

2K7

180K 18K

18K

0.1μF

LM358N

50pF

4K7

4K74K7

BYV95C BYV95C

2N6668

5K6

5K6

5K6

4001 D1

+12V -VE

10K

390R

18K

47n

1 MEG 1 MEG

Program 

0.1μF

Link

LDr-REV-LLS-Sol

0.1μF

Spare

LC-SS-SpS- 

 '-ve'-LED

10μF

Alternate

2N6668 2N6668

ROCHFORT INST

4.0 MHZ MC68HC705C8

22pf 22pf

4.7M

10K

100pF

PCF8591 2.2μF

10K

47K

12K

0.1μF

8 x 100K

0.1μF 4K7 Z5.6V

12K

4K7

330R 1W

10K

180K

18K

18K

10K

0.1μF

A B C-- +6 VE D F

10nF

Z5.6V

100μF

1 MEG

0.22μF

100K

5V Reg

8 x 100K

220R

3 4 2

10FEDCBA9 8 67

5

3 4 2

10 FEDC BA9 876 5

SW2 Selects Whole RPMs

SW1 Selects Fraction of RPMs

SW2

SW1

(b) Reinstall the CALC-20 in the housing. The “Rot 

Detector” terminals line up with the notch in the 

housing. 

(8) Install the Tacho Transducer on a new CALC-20. Be 

sure it is oriented as shown in Figure 3-48.

3-80
Figure 3-48 

1 2 Rot Detect

P L

Neg

TACHO

+ _

INPUT

Neg 6v

MOTOR

A B C

D E F

CALC-20 INT

Serial No

CALC-20

HOUSING

TACHO

TRANSDUCER

KEYWAY (NOTCH)

(9) Reattach the wires to the CALC-20. ALL WIRE LUGS 

FACE IN TOWARDS THE CENTER. 

(10) Install the CALC-20 housing into the beacon by lining up 

the notch in the can with the stud in the base. Push the 

housing straight up into the base and resecure with the 

clamps. 

(11) Apply power to beacon and test for proper operation. 

3-81
d. Stator Replacement. 

(1) Remove the Glazing and Turntable assemblies as 

described in sections 7.b. 

(2) Remove the CALC-20 as described in Section 7.c. and 

disconnect the 8 wire leads (A-F, 6V and NEG) on its 

terminal strip. 

(3) Remove the 4 nuts under the stator using a 7/16” open 

end wrench. 

(4) Lift the stator off the base, taking care not to damage the 

wiring harness. 

(5) Install a new stator so that the terminal board is over the 

CALC-20 housing. 

(6) The nuts are very difficult to start. Place each nut on a 

folded piece of paper/cardboard/plastic and slide under 

each stud. Start each nut by hand, remove the 

cardboard and finish with a wrench. DO NOT 

OVERTIGHTEN as the studs will pull out of the stator 

causing it to rub on the turntable. If they pull out, or are 

loose, remove the stator and lock the studs with SuperGlue, Loctite Blue or Loctite Red thread sealer. 

(7) Reattach the wires to the CALC-20. Wire lugs must face 

in towards the center. 

(8) Reinstall the CALC-20, turntable and 

flasher/lampchanger as described in Sections 7.c., 7.b., 

and 3.h. or 3.i. 

3-82
e. Checking the Tacho Transducer for proper clearance or 

obstructions.

(1) Remove the Glazing by releasing the 8 thumb latches 

located on the lower ring of the glazing assembly by 

rotating them 180 degrees. Carefully lift the glazing 

straight up from the beacon and set aside. 

(2) Look between the Base and Turntable above the CALC20 housing for the Tacho Transducer. It should be 

visible against the circuit board on the Stator (a flashlight 

may be used). Note if any wires appear to be rubbing 

on the Turntable and if wires are passing above the 

Tacho Transducer, as shown in Figure 3-49. 

BASE

TURNTABLE

TRANSDUCER

Figure 3-49 

(3) If wires are rubbing or obstructing the Tacho 

Transducer, remove the CALC-20 by removing the 2 hex 

screws loosening the clamps that hold the housing, 

rearrange the wires and reinstall. 

(4) Check the gap between the Tacho Transducer and 

Turntable by sliding a flat sections of a 5/64” hex wrench 

above the transducer and the bottom of the Turntable. If 

the wrench appears very loose or does not slide 

between the two, replace the Tacho Transducer (see 

Section 7.c.). DO NOT TRY TO ADJUST THE GAP. 

3-83
f. Check Optical Track and Tacho Transducer for Damage 

and Correct Operation. 

(1) 

(2) 

(3) 

(4) 

(5) 

(6) 

Remove the CALC-20 as described in section 7.c. 

Inspect wiring for abrasions due to the turntable rubbing 

on the wires. Replace as necessary. 

O P T IC A L T R A C K

Look up into the opening in the base where the CALC20 housing was removed. Rotate the turntable and 

inspect the optical strip. It should be attached to the 

turntable (no drooping or bubbles) and not appear 

scratched (Figure 3-50). 

Figure 3-50

Inspect the Tacho Transducer for dirt. The tip of the 

transducer has two small holes. One houses an infrared 

LED (invisible to the eye), the other contains a receiver. 

Blow out both holes with dry air to ensure they are clear. 

The Tacho Transducer can be tested outside the beacon 

by turning on the power to the beacon and measuring 

the voltage across “P” and “NEG” (older versions have 

 instead of “NEG”) terminals on the CALC-20. The 

voltage should be greater than 4.8 volts. 

Hold a reflective object (chrome wrench, knife blade, 

signal mirror, etc.) over the Tacho Transducer. Slowly 

lower the object over the transducer while measuring the 

voltage across “L” and “NEG” terminals, as shown in 

Figure 3-51. Move the object around and up and 

down until the lowest voltage is observed. The 

voltage should fall to 1.2 volts when the wrench is 5/64” 

3-84
above the top of the transducer. Repeat this step a few 

times if the proper reading is not obtained, as it is hard 

to keep the reflective object square with the transducer. 

Figure 3-51

(7) Reinstall the CALC-20 housing into the base ensuring 

that the wires do not rub the turntable or obstruct the 

Tacho Transducer. 

3-85
g. Watchdog Timer Installed? 

(1) Remove the Calc-20 as described in section 7.c. 

(2) Remove the four hex head screws securing the CALC20 to the Housing. 

(3) Inspect the CALC-20 for installation of the watchdog 

timer (“WD” on board next to black component), as 

shown in Figure 3-52. If none is installed, remove wires 

from CALC-20 and replace with one that has a timer 

installed. 

MC33035 47pF

0.1μF

220R 47K CG

27K

47K

1μF +

Z5.6

10n

1.8K

BYV95C

1 MEG

TPIC2301

2K7

2K7

180K 18K

18K

0.1μF

LM358N

50pF

4K7

4K7

4K7

BYV95C BYV95C

2N6668

5K6

5K6

5K6

4001 D1

+12V -VE

10K

390R

18K

47n

1 MEG 1 MEG

Program 

0.1μF

Link

LDr-REV-LLS-Sol

0.1μF

Spare

LC-SS-SpS- 

 '-ve'-LED

10μF

Alternate

2N6668 2N6668

ROCHFORT INST

4.0 MHZ MC68HC705C8

22pf 22pf

4.7M

10K

100pF

PCF8591

12K

0.1μF

8 x 100K

0.1μF 4K7 Z5.6V

12K

4.7K

330R 1W

10K

180K

18K

18K

10K

0.1μF

A B C-- +6 VE D F

10nF

Z5.6V

100μF

1 MEG

0.22μF

100K

5V Reg

8 x 100K

220R

3 4 2

10FEDCB

A9 8 67

5

3 4 2

10FEDCBA9 876 5

47K

2uf

WD

WATCHDOG

TIMER

 Figure 3-52

3-86
K. Sound Signals. 

 1. Notes. 

 

a. The FA-232 and SA-850 1⁄2 mile sound signals are 

used to warn mariners during foggy conditions. 

The FA-232 is used on land based stations and 

the SA-850 is used on buoys. They should not be 

interchanged as the FA-232 is not robust enough 

to withstand operation on a buoy and the SA-850 

broadcasts a higher frequency which is annoying 

to residents. Both signals are available as stacked 

arrays; dual stack (FA-232/02 and SA-850/2A) as 

1.0 mile signals and quad stacked (FA-232/04) as 

a 2.0 mile signal. 

FA-232

b. Sound signals consist of three electrical 

components: the oscillator, timer and driver. The 

oscillator converts the DC input to the appropriate 

frequency to provide the characteristic tone of the 

signal, the timer provides the coding and the driver 

is the speaker assembly. Stacked sound signals 

have power modules in lieu of the timer/oscillator 

as the master signal provides the coding. The 

timer assembly is the only component common 

between the SA-850 and FA-232. 

c. Sound signals must be secured or adequate ear protection 

must be worn while servicing and troubleshooting. 

Permanent hearing damage may result if these guidelines 

are not followed. Hearing protection must be worn if working 

closer than the minimum safe distances listed in Figure 3-53. 

Chapter 7 of the Aids to Navigation Manual-Technical, 

COMDTINST M16500.3A has additional information on 

hearing protection devices. 

SA-850

d. Sound signals are available from Automatic Power, Inc. 

 

3-87
 2. Installation. 

a. Sound signals must be installed on stable platforms away 

from walls (reflecting surfaces) and vertical obstructions, as 

listed in Figure 3-53. 

Sound Minimum Safe Minimum Distance Maximum Diameter

Signal Distance to Reflecting Surface of Obstruction

FA-232 50 ft 136 in 3.5 in

FA-232/02 90 136 3.5

FA-232/04 280 136 3.5

SA-850 50 64 2.5

SA-850/02 100 64 2.5

Figure 3-53 

b. Stacked sound signals must used the supplied stand (SA850s bolt together) as vertical spacing of the emitters is 

critical to sound production. 

c. Install emitters on platform or buoy with 3⁄4” bolts (5/8” for SA850). 

d. Plugs may be installed in the emitter of the FA-232 series to 

control noise pollution on the land side of the horn. If your 

District specifies that plugs are to be installed, consult the 

Aids to Navigation Manual – Technical, COMDTINST 

M16500.3A for instructions. 

e. Remove the top dome on the FA-232(s) by releasing the Vband. Access to the SA-850 is through the bolted plate on 

the side of the emitter. 

f. Install 12/2 (or larger) SO cable through a stuffing tube and 

pull enough slack to reach oscillator board. 

3-88
g. Install spade lugs on each wire and install on the “+” and “-“ 

terminals on the oscillator board, as shown in Figure 3-54. 

The oscillator board is located on the access plate on the 

SA-850 emitter. Wiring is similar. 

Figure 3-54 

+

2

3

4

-

D

D

1

2

OSCILLATOR

TIMER

(TOP BOARD)

DRIVER FA-232

h. Install the dome/cover on the horn and secure. 

Rhythm Timing On/Off in Seconds Blasts/57-63 Sec

1 blast every 10 seconds 1 on, 9 off 6

1 blast every 15 seconds 2 on, 13 off 4

1 blast every 30 seconds 3 on, 27 off 2

2 blasts every 20 seconds 2 on, 2 off, 2 on, 14 off 6

2 blasts every 30 seconds 2 on, 2 off, 2 on, 24 off 4

2 blasts every 60 seconds 3 on, 3 off, 3 on, 51 off 2

i. Apply power to the horn (command fog detector to turn 

sound on, if equipped), and note if horn sounds on rhythm, 

as detailed in Figure 3-55. 

Figure 3-55 

3-89
3. Maintenance. 

a. Secure power to the sound signal. 

b. Visually inspect the housing for cracks, crazing, holes, etc. 

Replace or repair if necessary. 

c. Inspect the emitter openings for debris or dirt and clean if 

necessary. 

d. Apply power to the sound signal, command the fog detector 

to turn the horn on (if equipped) and note if all emitters are 

operating (stacked array), emitting a pure tone and sounding 

on rhythm. 

4. Troubleshooting. Note: Some procedures require monitoring 

voltages which occur only when the horn sounds. Some 

rhythms have periods of up to one minute. 

a. Procedure “A”: 

DOES SOUND 

SIGNAL SOUND?

IS SITE

REMOTE

CONTROLLED?

GO TO “C”

GO TO “E”

GO TO “B”

YES

YES

NO

NO

3-90
b. Procedure “B”: 

IS TIMING CODING

CORRECT FOR A 60

SECOND TEST?

IS TONE

QUALITY

PURE?

ARE SIGNAL

BAFFLES

CLEAR?

ARE MECHANICAL

DRIVER CONNECTIONS

TIGHT?

PULSED

VOLTAGE ACROSS

OSCILLATOR TERMINALS D&D:

24-36 VAC (FA-232)?

30-40 VAC (SA-850)?

COMPLETE

SOUND SIGNAL

SHOULD OPERATE

ON RHYTHM

REPLACE TIMER PCB

GO TO “F”

CLEAR BAFFLES

TIGHTEN DRIVER 

CONNECTIONS

DISCONECT DRIVER

FROM OSCILLATOR

TERMINALS

PULSED

VOLTAGE ACROSS

OSCILLATOR TERMINALS D&D:

24-36 VAC (FA-232)?

30-40 VAC (SA-850)?

REPLACE 

REPLACE DRIVER OSCILLATOR PCB

NO

NO

NO

NO

NO

YES NO

YES

YES

YES

YES

YES

3-91
c. Procedure “C”: 

IS BATTERY

VOLTAGE

11-15 VDC?

IS THERE 11-15 VDC

ACROSS OSCILLATOR

TERMINALS (+) & (-)?

IS THERE 11-15 VDC

ACROSS OSCILLATOR

TERMINALS 2 AND 4?

IS THERE 11-15 VDC

ACROSS TIMER

TERMINALS 1 & 2?

IS THERE A DC

PULSE ACROSS TIMER 

TERMINALS

1 & 4?

IS THERE A DC 

PULSE ACROSS

OSCILLATOR TERMINALS

3 & (+)?

DISCONNECT DRIVER

FROM OSCILLATOR TERMINALS

IS THERE AN AC

PULSE ACROSS

OSCILLATOR TERMINALS

D & D?

TROUBLESHOOT

POWER SYSTEM

REPLACE POWER CABLE

GO TO “D”

REPLACE WIRES FROM

OSCILLATOR TERMINALS 2 & 4

REPLACE TIMER PCB

REPLACE WIRE FROM

TERMINAL 3 OF 

OSCILLATOR PCB

REPLACE

OSCILLATOR

PCB

REPLACE

DRIVER

NO

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

3-92
d. Procedure “D”: 

IS FUSE GOOD?

REPLACE FUSE;

DOES NEW FUSE BLOW?

REMOVE WIRES BETWEEN

TIMER AND OSCILLATOR PCB

REPLACE OSCILLATOR PCB

REPLACE OSCILLATOR

DO PMS

REPLACE TIMER PCB

REPLACE FUSE;

DOES NEW FUSE BLOW?

YES

YES

YES

NO

NO

NO

CHECK FUSE F1 FOR

CONTINUITY

3-93
e. Procedure “E”: 

f. Procedure “F”: 

3-94

REMOVE WIRE FROM TIMER

PCB TERMINAL 3

DOES SIGNAL SOUND?

GO TO PROCEDURE “C”

SEEK ASSISTANCE; REMOTE CONTROL

PROBLEM. IF UNIT IS INSTALLED, CHECK

YES AID FILE FOR SCHEMATIC DRAWING.

NO

TIGHTEN DRIVER CONNECTIONS

IS PROBLEM

FIXED?

REPLACE OSCILLATOR PCB

IS PROBLEM

FIXED?

REPLACE DRIVER

DO PMS

DO PMS

YES

YES

NO

NO
CHAPTER 4 - HARDWARE 

A. Minor Aid Lighting Hardware (Used in non-LED Lanterns). 

1. Notes. 

a. 12 volt minor aid hardware consists of a flasher, 

daylight control, wiring kit, the appropriate lantern 

bracket, lampchanger and lamps. 

b. Flashers (Figure 4-1) are used to regulate battery 

voltage to the lamp, sense lamp failure, provide a 

flash rhythm and turn off the light during the daytime. 

Flashers are available in four versions: the CG-181, 

CG-493, CG-481 and CG-504. The CG-181 and 493 

will operate lamps 3.05 amps or less (35 watt 

tungsten-halogen lamp included). The CG-481 is 

used to operate lamps 50 watts and greater. The CG504 will operate all lamps. Flashers are available in 

standard and non-standard flash rhythms. Standard 

rhythms are stocked at the Engineering Logistics 

Center (ELC) Baltimore. Non-standard rhythms and 

slave flashers must be purchased from the 

manufacturer. NOTE: the proper rhythm must be 

used. Installing a FL 2.5(1) when a FL 2.5(.3) is 

required will result in a power system failure. 

Figure 4-1 

S S L F

+

_

FLASHER

TYPE

FEATURES

IDENTIFIER

MFR CODE

MFD BY

MFR S/N

DUTY CYCLE

FL4(.4)

4-1
 CG-181/493/504 STANDARD RHYTHMS

Rhythm Timing in Seconds** Flashes/57-63 sec

Q 0.3 on, 0.7 off 60

Mo(A) 0.4 on, 0.6 off 30

2.0 on, 5.0 off (114-126 sec)

FL2.5(.3) 0.3 on, 2.2 off 24

FL2.5(1)* 1.0 on, 1.5 off 24

FL4(.4) 0.4 on, 3.6 off 15

FL4(1)* 1.0 on, 3.0 off 15

FL6(.6) 0.6 on, 5.4 off 10

FL(2)5 0.4 on, 0.6 off 24

0.4 on, 3.6 off

FL(2)6 1.0 on, 1.0 off 20

1.0 on, 3.0 off

FL(2+1)6 0.3 on, 0.4 off 30

0.3 on, 1.2 off

0.3 on, 3.5 off

Iso6* 3.0 on, 3.0 off 10

Iso2* 1.0 on, 1.0 off 30

Oc4* 3.0 on, 1.0 off 15

Fixed* Steady on Continuous

*CG-481 Standard Rhythms

**The ON time is the Contact Closure Time (CCT)

c. Lampchangers (Figure 4-2) are used to extend the service 

interval by stocking the lantern with 6 operable lamps. The 

clockwork mechanism is spring wound and triggered by a 

solenoid activated by the flasher. Lampchangers are 

available in two versions: the CG-6P and CG-6PHW. The 

CG-6P will operate lamps 3.05 amps or less (35 watt 

tungsten-halogen lamp included). The CG-6PHW is used to 

operate lamps 50 watts and greater. 

 

4-2
Figure 4-2 

115ο

Figure 4-3 

Type Color Where Used

Type C White Case Yellow and Clear lens

Type R Red Case Red or green plastic lenses

Type-L Gray Plug Any Fixed-ON rhythm, colored glass,

FA-240, RL-14 & VRB-25 Lanterns

c. Daylight controls (Figure 4-3) are photoresistors that change 

resistance with respect to light levels. As the light level 

decreases, the resistance of the daylight control increases. 

The photoresistor is used on the flasher to turn the light off in 

the daytime. A flasher without a daylight control will 

operate continuously, 24 hours a day. Daylight controls are 

available in three types from ELC Baltimore: 

4-3
d. The WK-681 wiring kit (Figure 4-4) is used to transmit power 

between the flasher and lampchanger. Each kit contains 

three wires, color coded red, white and blue, and spring 

spade lugs on each end. Kits, packaged 10 per box, are 

available from ELC Baltimore. 

Figure 4-4 

e. Brackets (Figure 4-5) are used to secure the lampchanger/ 

flasher assembly in the focal position in the lantern. The type 

of bracket will vary from lantern to lantern. Some brackets 

have provisions for focusing the lamp. All brackets are 

sandwiched between the flasher and lampchanger. 

Replacement brackets are available from the lantern 

manufacturer. 

Figure 4-5 

250MM BRACKET 155MM & 300MM BRACKET

 

4-4
f. Lamps for minor aids to navigation (Figure 4-6) are divided 

into two categories: tungsten using C-8 and CC-8 filaments, 

and tungsten-halogen. Tungsten filament lamps are rated 

by amperage and tungsten-halogen lamps are rated by 

wattage. The available lamp sizes are 0.55a, 0.77a, 1.0a, 

1.15a, 1.9a, 2.03a, 3.0a, 3.05a, 35w, 50w, 75w, 100w and 

110w. The 1.0, 1.9 and 3.0 amp lamps contain coiled-coil 

(CC-8) filaments and are not suitable for use in drum lenses 

(155mm, 250mm and 300mm). Lamps are available from 

ELC Baltimore. 

Figure 4-6 

0.55, 0.77

1.15, 2.03, 3.05*

*LARGER BULB

1.0, 1.9, 3.0 35, 50,75,100,110

2. Installation. 

a. Minor aid hardware must be assembled at the ANT or on the 

Cutter and bench tested for 24 hours prior to installation at 

the aid site. 

b. Select the appropriate flasher and lampchanger based on 

the description in section 4.A.b. If using a programmable 

flasher, select the proper rhythm. NOTE: FL2.5 (1), FL4(1), 

FL6(1) and ISO2 are RARELY used. Do not confuse them 

with the other flash rhythms. 

4-5
c. Lay a lampchanger behind a flasher with the terminals facing 

up. Install a WK-681 wiring kit to a lampchanger. The wires 

are color coded to the terminals and contain spring spade 

lugs. Push the lugs on the screws until they snap into place, 

and then tighten screws. 

d. Run the wires across the flasher and install the other end of 

the WK-681 wiring kit to the flasher’s terminals from the 

inside, as shown in Figure 4-7. Then turn the lampchanger 

180 degrees as you place it on the flasher so that the 

terminals are opposite each other with the wires under the 

bracket (note: the wires must pass through the 250mm’s 

bracket, so wire it with the bracket on the flasher).

Figure 4-7 

e. Secure the lampchanger to the flasher with four 1” long 10-

32 screws. If a spare lantern bracket is available, you may 

secure it between the flasher/lampchanger and over the WK-

 

4-6
681 wiring kit. Consult with Chapter 3 for the correct bracket 

and orientation. 

f. Install the proper daylight control (if necessary) to the two 

yellow “S” terminals on the flasher (Note: the CG-504 flasher 

has an S/Sy terminal which is the same). The daylight 

control housing should go next to the “+” terminal, as shown 

in Figure 4-8. 

Figure 4-8 

S S L F

+

_

FLASHER

TYPE

FEATURES

IDENTIFIER

MFR CODE

MFD BY

MFR S/N

DUTY CYCLE

FL4(.4)

g. Install 6 new lamps of the appropriate size in the 

lampchanger. Start at the first position (red paint on turret) 

then manually actuate the lampchanger by turning and 

releasing the solenoid. The notch in the prefocus collar is 

installed opposite the centered mounting stud, as shown in 

Figure 4-9. 

Figure 4-9 

S S L F +

_

FLASHER

FL4(.4)

SOLENOID

NOTCH

LAMP

4-7
h. Turn each lamp clockwise to lock into place. Bench test all 

optical assemblies by applying 12 VDC from a power supply 

or AtoN battery to the “+” and “-“ terminals of the flasher for 

24 hours with a daylight control cover installed. 

 

i. With power applied, while shining a light on the daylight 

control, the lamp should be off. Cover daylight control with a 

daylight control cover and the lamp should light and flash on 

rhythm. 

j. Remove the operating lamp and the lampchanger should 

ratchet to the next position. Note: do remove tungstenhalogen lamps while operating as they are very hot. 

Instead, turn the lampchanger solenoid. The flasher should 

continue to hold it in and advance the next lamp into 

position. 

k. After the 24 hour bench test, install the assembly into the 

lantern. Consult with the appropriate chapter for detailed 

instructions. 

3. Maintenance. 

a. At every scheduled service visit (annual or biennial): 

b. If the light is a shore aid, then replace all extinguished 

lamps and the operating lamp. Rotate remaining good 

lamps to the forward positions and use new lamps to fill 

remainder of lampchanger. 

c. If the light is a floating aid (buoy), then replace all 

extinguished lamps and the operating lamp. Rotate 

remaining good lamps to the forward positions and use new 

lamps to fill remainder of lampchanger. If the buoy has 1952 

type tappers, then replace all lamps. 

 

4-8
d. Wipe lamps with medicinal swab or a clean rag dampened 

with denatured alcohol. 

e. Replace daylight control. 

f. To check for proper operation, perform Quick-Check 

procedure listed below: 

g. Minor aid Quick Check Procedure (Note: Procedures 

referenced here refer to troubleshooting detailed in section 

4. 

SHINE LIGHT ON

DAYLIGHT CONTROL.

IS LIGHT ON?

COVER DAYLIGHT CONTROL

IS LIGHT ON 

AND FLASHING 

ON RHYTHM?

REMOVE OPERATING LAMP

LAMPCHANGER 

RACHETS AND NEW

LAMP LIGHTS?

GO TO PROCEDURE “A”

GO TO PROCEDURE “B”

GO TO PROCEDURE “D”

YES

YES

YES

NO

NO

NO

MINOR AID QUICK CHECK

REMOVE ALL LAMPS.

ENSURE LAMPCHANGER RACHETS

TO LAST POSITION.

(SYSTEM IS GOOD)

IF LAMPCHANGER RACHETS IN LAST

POSITION, REPLACE LAMPCHANGER.

(BAD RESISTOR)

RECHECK AFTER REPLACEMENT.

4-9
4. Troubleshooting. The following flowcharts will enable you to 

locate a minor aids lighting hardware failure. 

a. Procedure A 

IS LAMP LIT?

SHINE LIGHT ON

DAYLIGHT CONTROL

IS LAMP STILL LIT?

JUMP YELLOW

TO YELLOW

ON FLASHER

IS LAMP STILL LIT?

REPLACE FLASHER

(BAD DAYLIGHT CONTROL CIRCUIT)

RECHECK AFTER REPLACEMENT

GO TO PROCEDURE “B”

CHECK FOR:

- SHADING

- INCORRECT DLC

- INCORRECT INSTALLATION OF DLC

GO TO PROCEDURE “D”

REPLACE DAYLIGHT CONTROL

(BAD DAYLIGHT CONTROL)

RECHECK AFTER REPLACEMENT

YES

YES

YES

NO

NO

NO

START

 

4-10
b. Procedure “B”: 

COVER DAYLIGHT CONTROL

DOES LAMP LIGHT?

JUMP BLACK ON FLASHER

TO RED ON FLASHER

LAMP LIGHTS

AND RACHETS?

JUMP RED ON FLASHER TO

RED ON LAMPCHANGER

DOES LAMP LIGHT?

GO TO PROCEDURE “C”

GO TO PROCEDURE “D”

REPLACE FLASHER

(BAD LAMP CIRCUIT)

RECHECK AFTER REPLACEMENT

REPLACE WK-681 WIRING KIT

(BAD RED WIRE)

RECHECK AFTER REPLACEMENT

YES

YES

YES

NO

NO

NO

4-11
c. Procedure “C”: 

JUMP RED ON LAMPCHANGER

TO LAMP COLLAR

LAMP LIGHTS?

JUMP WHITE ON FLASHER TO 

WHITE ON LAMPCHANGER

LAMP LIGHTS?

REMOVE LAMP FROM OTHER

THAN OPERATING POSITION

AND JUMP WHITE TO

LAMPCHANGER CONTACT

LEFT VACANT

LAMP LIGHTS?

REPLACE LAMPCHANGER AND FLASHER

(MULTIPLE PROBLEMS)

RECHECK AFTER REPLACEMENT

CLEAN CONTACTS AND RECHECK OR

REPLACE LAMPCHANGER.

(BAD POSITIVE CONTACT)

RECHECK AFTER REPLACEMENT

REPLACE WK-681 WIRING KIT.

(BAD WHITE WIRE)

RECHECK AFTER REPLACEMENT

CLEAN CONTACTS AND RECHECK OR

REPLACE LAMPCHANGER.

(BAD NEGATIVE CONTACT)

RECHECK AFTER REPLACEMENT

YES

YES

YES

NO

NO

NO

 

4-12
d. Procedure “D”:

COVER DAYLIGHT CONTROL

REMOVE OPERATING LAMP

LAMPCHANGER

RACHETS?

JUMPER BLACK ON FLASHER

TO BLUE ON FLASHER

LAMPCHANGER

RACHETS?

JUMPER BLUE ON FLASHER TO

BLUE ON LAMPCHANGER

LAMPCHANGER 

RACHETS?

REPLACE LAMPCHANGER.

(BAD SOLENOID)

RECHECK AFTER REPLACEMENT

REMOVE ALL LAMPS.

ENSURE LAMPCHANGER RACHETS

TO LAST POSITION.

(SYSTEM IS GOOD)

IF LAMPCHANGER RACHETS IN LAST

POSITION, REPLACE LAMPCHANGER.

(BAD RESISTOR)

RECHECK AFTER REPLACEMENT.

REPLACE FLASHER

(BAD FILAMENT SENSING CIRCUIT)

RECHECK AFTER REPLACEMENT.

REPLACE WK-681 WIRING KIT

(BAD BLUE WIRE)

RECHECK AFTER REPLACEMENT.

YES

YES

YES

NO

NO

NO

4-13