Mandala Lightserve



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Mandala Lightserve

Model MWJB190A

Operating Manual

Distributed 

by: 

     Manufactured 



by:

BJ Electric Supplies Ltd. 

 

 

 



Mandala Controls Inc.

4143 97 Street NW 

 

 

 



 

22330 Township Road 522

Edmonton, 

Alberta     Sherwood 

Park, 

Alberta


Canada 

T6E 


6E9 

     Canada 

T8C 

1G3


Telephone (780) 461-2334  

 

 



 

Telephone (780) 922-3000

    

Document


 

Revision 03/10




Table of Contents

Overview, Benefits, Warnings   

 

Page 2


Operation, 

Installation 

   Page 

3

Setup and Handheld Programmer Operation 



Page 4

Modbus 


registers    Page 

6

Selection of Solstice Data 



 

 

Page 7



Troubleshooting    Page 

8

Specifications   



 

 

 



Page 9

Overview


The Mandala Lightserve automates the control of lights in an industrial plant. It performs an astronomical calculation to determine 

sunrise and sunset times at the plant’s location on the particular date. It turns the lights on before sunset, and turns them off after 

sunrise.

An operator can override the Lightserve by commanding it to turn on the lights at any time of the day. The lights will remain on until 

the next sunrise; the Lightserve will then return to automatic operation.

The Lightserve logs the total time that the lights have been turned on since installation. A Relamp Alarm can be configured to indicate 

to the operator when the total lamp time has exceeded a setpoint. This allows plant maintenance staff to replace all lamps at the same 

time, reducing maintenance costs.

An optional sensor monitors the ambient temperature to ensure that the lamps will light correctly when energized. If the ambient 

temperature approaches the low temperature limit of the lamps, the Lightserve turns the lamps on to prevent starting problems.

The Lightserve is rated for operation in Class 1 Division 2/Zone 2 hazardous locations.

Benefits


Reduced energy consumption

: lights are on only when needed.



Longer lamp life

: lights are off during daylight hours.



Reduced maintenance costs

: all lamps can be replaced at end of life, without waiting for failures.



Improved safety

: Longer lamp life and group relamping mean less risk of reduced light in the area.

WARNINGS

WHEN OPERATING IN A HAZARDOUS AREA, DO NOT MAKE OR BREAK ANY CONNECTIONS WHILE THE 

LIGHTSERVE CONTROLLER IS ENERGIZED UNLESS THE AREA IS KNOWN TO BE FREE OF EXPLOSIVE GAS.

THE HANDHELD PROGRAMMER FOR THE LIGHTSERVE CONTROLLER IS NOT RATED FOR USE IN HAZARDOUS 

AREAS. DO NOT ENERGIZE THE HANDHELD PROGRAMMER IN A HAZARDOUS AREA UNLESS THE AREA IS KNOWN 

TO BE FREE OF EXPLOSIVE GAS.

THE LIGHTSERVE CONTROLLER IS TO BE MOUNTED WITHIN A WEATHERPROOF ENCLOSURE THAT PROVIDES 

CONDUIT AND/OR CABLE ENTRIES.




Lightserve Operation

The Mandala Lightserve automatically turns the lights on before sunset, and turns them off after sunrise. To turn the lights on during 

daylight hours, press the Bypass pushbutton. The lights will be turned on, and they will remain on until they are automatically turned 

off after the next sunrise.

Some light fixtures do not restart well in cold temperatures. A thermostat can be connected to the Lightserve to turn the lights on and 

keep them on until the ambient temperature goes above the thermostat setpoint. (Software version 1.12 or higher only.)

Two diagnostic lights on the Lightserve help the operator to determine that the unit is operating normally. The green “Heartbeat” light 

on top flashes when the Lightserve is operating correctly. If this Heartbeat signal stops, either with the light steadily on or steadily 

off, the controller has failed. Refer to the Troubleshooting section of this document if this occurs. The red “Relay” light on the bottom 

follows the state of the Lightserve output relay. If the output relay is energized, the plant lights should be on, and the Relay light will 

also be on. If the output relay is not energized, the plant lights should be off, and the Relay light will also be off.

Lightserve Installation

For proper operation of the Lightserve controller, make the following connections to the Power Supply connector TB1:

Terminal 1: 

120 VAC +/- 10%

Terminal 2: 

Neutral

Terminal 3: 



Ground

Terminal 4: 

Main relay output. This terminal will be at 120 VAC when the contactor is to be energized and at 0 VAC when the 

contactor is not energized. Connect this terminal to one side of the lighting contactor coil.

Connect the other side of the lighting contactor coil to Neutral.

To connect the Relamp Alarm, make the following connections to the Digital Input/Output connector TB2: 

Terminal 4: 

Relamp relay output. This terminal will be at 120 VAC when the lamp hours have exceeded the relamp setpoint and 

at 0 VAC when the lamp hours are less than the relamp setpoint.

 

Connect the other side of the Relamp Alarm lamp to Neutral.



To connect the Bypass pushbutton switch, make the following connection to the Digital Input/Output connector TB2: 

Terminal 10: 

Connect to one side of the pushbutton. 

Connect the other side of the pushbutton to 120 VAC.

To connect the Thermostat, make the following connection to the Digital Input/Output connector TB2. If the Thermostat feature will 

not be used, the input terminal can be left open.

Terminal 9: 

Connect to one side of the thermostat. 

Connect the other side of the thermostat to 120 VAC.



Lightserve Setup and Handheld Programmer Operation

WARNING: The handheld programmer is NOT approved for use in hazardous locations. Before connecting, disconnecting, or using 

the handheld programmer in a hazardous area, ensure that no explosive gasses are present. 

To set up the operating parameters of the Lightserve, connect the handheld programmer to the Lightserve. Plug the serial cable into the 

programmer. Plug the other end of the serial cable into the serial port on the Lightserve.  

Start the Lightserve program on the handheld computer. Click on the “Start” icon in the top left corner of the screen, then choose 

“Lightserve” from the list. The Lightserve program displays the Main screen at startup. If a good connection has been established 

between the Lightserve controller and the programmer, the date and time, as retrieved from the Lightserve clock, will be displayed. 

If the connection is not good, the programmer will display the message “Unable to locate Lightserve on any comm port.” Most 

connection errors can be corrected by tightening the connections on the serial cables and by terminating, then restarting the program 

on the handheld programmer. Please refer to the Troubleshooting section of this document if these attempts are not successful.

Main Screen 

All calculations in the Lightserve controller are based on the local time. It is very important that the internal clock of the Lightserve 

is set to the correct local time. Before setting the clock on the Lightserve, ensure that the time displayed on the handheld programmer 

is correct. To adjust the time on the programmer, double-click the pointer on the clock icon in the lower right corner of the screen. 

Set the clock to the correct date and time, and click on “Apply”. Once the programmer clock is correct, set the Lightserve clock by 

clicking on the box labeled “Sync Lightserve to this PC”. The correct time should appear on the Main screen within 5 seconds.

The Main screen also displays the number of hours that the lights have been turned on since installation. When the plant is relamped, 

this hour counter should be reset to zero by clicking on “Reset Hour Counter”.

The main screen also shows the setpoint for the Relamp Alarm. If the On hours exceed the value displayed in the “Alarm if Hours 

Exceed…” box, the Relamp Alarm relay will become energized. The manufacturer of the lamps should recommend the correct value 

to be entered into this box. It should correspond to the expected life of the lamps, in hours. If a question mark appears in the setpoint 

box when the program is first started, move to a different screen (for example, the Solstices screen), then return to the Main screen. 

The correct setpoint should now appear in the box.

Solstice Screen 

The Lightserve is programmed for a particular geographical location by way of the Solstice screen.

Normally, the operator needs only to select the location from the list of preprogrammed locations. Click on the arrow beside the 

location selection to see the expanded list. If there is an entry on the list that is within approximately 30 km of the plant site, select that 

location, and click on Send. 

If none of the preprogrammed locations is near the plant site, the solstice data will have to be manually entered. Contact Mandala 

Controls for the correct values to enter, or refer to the section of this document entitled “Selection of Solstice Data” for the procedure 

for determining the solstice values for the plant location.




Amps Screen 

The Amps screen allows the operator to set an Underload setpoint for the Lightserve controller. If the total current on all three phases 

is less than the setpoint, the controller activates an alarm relay. This alarm indicates that an excessive number of lamps have burned 

out.


This feature is available only in plants where current transformers have been installed on the lighting bus. Not all Lightserve 

controllers support this feature. Please contact Mandala Controls for further details.

Comm Screen

The operator will not normally use the Communication screen. It indicates whether good communication has been established between 

the Lightserve controller and the handheld programmer. Normally, the Messages Sent and Messages received counts should increment 

at the same rate. If this is not the case, there is an error in the connection. Most connection errors can be corrected by tightening 

the connections on the serial cables or by terminating, then restarting the program on the handheld programmer. Please refer to the 

Troubleshooting section of this document if these attempts are not successful.   

Lights Screen 

The Lights screen allows the operator to set the time interval before sunset that the lights are turned on and the time interval after 

sunset that the lights are turned off. The default value for these setpoints is 40 minutes. If a new value is entered for either setpoint, 

click on the Send button to send the new value to the Lightserve controller.

Maintenance Screen

The operator will not normally use the Maintenance screen. It shows the software versions of the Lightserve controller and the 

Handheld Programmer. It also shows the total hours that the lights have been turned on. Even if the Hours on the Main screen are 

reset, the counter on the Maintenance screen continues to increment. If the hour counter on the main screen is reset in error, the 

value on the Maintenance screen can be used to recover from the error. The date that the counter was reset is also recorded on the 

Maintenance screen.

The Maintenance screen also shows the number of times that the bypass pushbutton switch has been activated. This count might 

indicate that the area is too dark, since the operator is often turning the lights on during daylight hours. The counter is reset when the 

hour counter on the main screen is reset. (Software version 1.12 or higher only.)

 



Modbus Communication

The Lightserve controller supports the Modbus Binary communication protocol. The Lightserve controller acts as a Modbus slave 

device. Communication parameters on the host computer should be set to 9600 baud; no parity, 8 data bits, and one stop bit. All 

registers are located in one contiguous block, as shown in the table below. 

Register Name

Read 


Address

Write 


Address

Register 

Offset

LightsOnResettable_KHours, 



30001

N/A


0

LightsOnResettable_Hours, 

30002

N/A


1

ResetTotalHoursNow,

30003

40003


2

RunKHrsSetpt, 

30004

40004


3

Amps_A, 


30005

40005


4

Amps_B, 


30006

40006


5

Amps_C,


30007

40007


6

AmpSumLoSetpt, 

30008

40008


7

DateAndTime.SetClockNow, 

30009

40009


8

DateAndTime.Year, 

30010

40010


9

DateAndTime.Month, 

30011

40011


10

DateAndTime.DayOfMonth, 

30012

40012


11

DateAndTime.Hour, 

30013

40013


12

DateAndTime.Minute, 

30014

40014


13

DateAndTime.Second, 

30015

40015


14

DateAndTime.DaylightSavNow,

30016

40016


15

SumSolSunriseHour,

30017

40017


16

SumSolSunriseMinute,

30018

40018


17

SumSolSunsetHour,

30019

40019


18

SumSolSunsetMinute,

30020

40020


19

SumSolDaylightSaving,

30021

40021


20

WinSolSunriseHour,

30022

40022


21

WinSolSunriseMinute,

30023

40023


22

WinSolSunsetHour,

30024

40024


23

WinSolSunsetMinute,

30025

40025


24

LightsOffsetBeforeSunset, 

30026

40026


25

LightsOffsetAfterSunrise, 

30027

40027


26

LightsOnTotal_ThousandHours,  30028

N/A

27

LightsOnTotal_Hours, 



30029

N/A


28

LastResetDate_Year,

30030

N/A


29

LastResetDate_Month,

30031

N/A


30

LastResetDate_Day,

30032

N/A


31

SoftwareVersion

30033

N/A


32

BypassCount

30034

N/A


33

DegreesC


30035

N/A


34

DegreesC_Offset

30036

40036


35

DegreesC_LoSetpt

30037

40037


36

  



A host computer can read Modbus registers from the Lightserve by issuing Modbus command 04 (Read Input Registers). A maximum 

of nine registers can be read using a single command.

A host computer can write Modbus registers by issuing Modbus Command 16 (Set Multiple Registers). A maximum of nine registers 

can be written using a single command. Data written to addresses marked “N/A” in the table will be ignored, as these are Read Only 

registers.

Selection of Solstice Data

It will not normally be necessary to manually enter solstice data into the Lightserve controller. It will only be required if the controller 

is installed in a location not anticipated by Mandala Controls. 

The first step in determining the solstice data is to determine the latitude and longitude of the location. If this information is not 

known, it can be determined as follows. 

For locations in Canada, go to the website 

http://geonames.nrcan.gc.ca/search/search_e.php

 and follow the instructions there to 

determine the latitude and longitude of the town nearest the plant location. Then go to the website 

http://aa.usno.navy.mil/data/docs/

RS_OneDay.html

, select Form B (Locations Worldwide) and enter the latitude and longitude to determine sunrise and sunset data for 

the location. 

For locations in the United States, go to the website 

http://aa.usno.navy.mil/data/docs/RS_OneDay.html

, select Form A (U.S. Cities 

and Towns) and enter the name of the nearest town to determine sunrise and sunset data for the location. 

Get the sunrise and sunset data for June 21, 2000 (summer solstice) and December 21, 2000 (winter solstice). Be sure to note whether 

the summer solstice data are given in Daylight Saving Time or Standard Time.

To enter the data on the Solstice screen on the handheld programmer, click on the Manual Entry box, then enter the solstice data 

determined above into the appropriate boxes. Click on the Daylight Saving box if the summer solstice data is given in Daylight Saving 

Time. After sunrise and sunset data have been entered for both the Summer and Winter Solstices, click on the Send button to update 

the Lightserve controller.




Troubleshooting Guide

Symptom

 

    



Solution

Heartbeat light not flashing. 

 

Check power supply fuse.



 

 

 



 

 

Turn power to Lightserve off, then on.



 

 

 



 

 

NOTE: This condition normally indicates a catastrophic



 

 

 



 

 

failure. It is recommended that the Lightserve be removed



 

 

 



 

 

from service unless the cause of the failure is known.



No communication to handheld 

 

Tighten all connections on the serial cable. 



programmer. 

 

 



 

Terminate, then restart the Lightserve program on the

     handheld 

programmer.

 

 

 



 

 

Check the COMM screen on the Lightserve program on the



 

 

 



 

 

handheld programmer. Ensure that the Messages Sent count is



 

 

 



 

 

incrementing. Check whether the Messages Received count is



 

 

 



 

 

incrementing at the same rate; if so, good communication has



     been 

established.

Main relay does not properly switch 

Use of a latching contactor is not supported. Minimum hold

a latching contactor. 

 

 



current for the main relay is 100 mA. Replace the contactor

     with 

an 

electrically-held 



contactor.

Lights remain on after dawn. 

Use the handheld programmer to check the time on the Lightserve controller. Ensure that 

the daylight savings flag is set correctly.

Ensure that the “Lights Offset After Sunrise” setpoint is set correctly. The lights will 

remain on for the selected number of minutes after dawn.

Check the Thermostat by reading the voltage at Terminal 9 on TB2. If this terminal 

reads 120 VAC, the thermostat is preventing the lights from turning off. This is correct 

operation.

If the bypass switch has been pressed, the lights will remain on until the following 

morning. If it is important to turn the lights off before then, cycle power to the Lightserve 

controller.

Check the battery voltage. Open the cover on the Lightserve controller. Use a voltmeter 

to read the voltage on the backup battery. The voltage should read between 2.7 VDC and 

3.4 VDC. A spare battery is shipped with all Lightserve controllers.



Specifications

 

Main Relay



 

Maximum 2 Amps continuous at 240 VAC

 

Maximum 25 Amps Inrush for 16.6 ms



 

Minimum holding current 100 mA

 

Zero-voltage switching



 

Fused on circuit board

Alarm Relay #1 (Ralamp)

 

Maximum 1 Amp continuous at 240 VAC



 

Maximum 4 Amps Inrush for 16.6 ms

 

Minimum holding current 100 mA



 

Fused on circuit board 

Alarm Relay #2

 

Maximum 300 mA continuous at 120 VAC



 

Maximum 2 Amps Inrush for 16.6 ms

 

Minimum holding current 25 mA



 

Fused on circuit board 

Power Supply

 

120 VAC +/- 10% continuous



 

100 mA maximum

 

Rides through 15 electrical cycles of power loss without failure



 

Fuse: 1/8 Amp Slow-Blow, 5x20 mm size

Hazardous Area Classification

 

CSA Approved as a component suitable for use in:



 

 

Class 1 Division 2 Groups A,B,C,D



 

 

Class 1 Zone 2 Groups IIC (AEX n IIC)



 

when installed within an enclosure providing mechanical

 

protection and conduit/cable entries.



Temperature

 

-40 to +70 Degrees C



Wire size for external connections:

 

22 AWG to 12 AWG



Modbus communications:

 

RS-232 protocol, 9600 baud, No parity, 8 data bits, 1 stop bit



 

Read registers via Modbus command 04, maximum of 9 registers per message

 

Set registers via Modbus command 16, maximum of 9 registers per message



 

Lightserve has DB-9 male connector



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