Obstruction Lighting Controller Manual

Obstruction Lighting Controller Manual
INSTALLATION AND MAINTENANCE MANUAL
FOR
FAA Medium Intensity L-864 and L-865
LED Obstruction Lighting System
D1RW-C13-008SP-A-RevA with
Power Supply / Controller
Meets AC No. 150/5345-43G
120 VAC
DLS1-008SP
230VAC
DLS2-008SP
48 VDC
DLS4-008SP
NOTE: USE THIS MANUAL WITH THE APPROPRIATE CONTROLLER’S SCHEMATIC
& WIRING DIAGRAM
PART # __________________________________
DATE MANUFACTURED __________ __________
(month)
(year)
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Table of Contents
Contents
I. RECOMMENDED TOOLS - Flash Head Cable Termination .................................................3
II. SAFETY NOTICES .................................................................................................................4
III. INPUT POWER ....................................................................................................................5
IV. INSTALLATION....................................................................................................................5
V. OPERATION - LED Dual Lighting Systems (L864/L865) ....................................................6
A. PANEL LAYOUT - E1
6
B. WHITE STROBE DRIVER
7
C. RED BEACON DRIVER
8
D. MICROCONTROLLER BOARD
8
E. CAPACITOR MODULE
8
F. OBSTRUCTION LIGHT ALARM MODULE
8
G. CONTROL RELAYS
9
H. 48VDC POWER SUPPLY (Not present on 48 VDC model)
9
I. TEST SWITCHES
9
J. ALARM AND STATUS RELAYS
10
K. RECOMMENDED SPARE PARTS & USER REPLACEMENT PARTS
10
VI. LIGHTNING .......................................................................................................................10
VII. PHOTOELECTRIC CONTROL (PCR)
............................................................................ 11
VIII. TESTING AND MAINTENANCE ......................................................................................12
IX. ELECTRICAL CONNECTIONS............................................................................................13
X. TROUBLESHOOTING - LIGHTING CONTROLLER..............................................................14
XI. LIMITED PRODUCT WARRANTY ......................................................................................15
XII. SYSTEM INSTALLATION REQUIREMENTS FOR EMC AND LIGHTNING IMMUNITY .....16
APPENDIX A - RECOMMENDATIONS FOR PROPER GROUNDING TO MINIMIZE RISK OF
LIGHTNING DAMAGE (D1RW-C13-008SP-A-RevA/ Single Level Version) ................................17
Cable Grounding (Power Supply Side)
17
APPENDIX B - TROUBLESHOOTING GUIDE - LED BEACONS ...............................................22
APPENDIX C - DLS1-008SP-A QUICK REFERENCE GUIDE ...................................................36
APPENDIX C - COMMISSIONING CHECKLIST .......................................................................37
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I. RECOMMENDED TOOLS - Flash Head Cable Termination
1/8" Screwdriver .................................. Terminal Blocks in Controller and Flash Head
SUPPLIER
P/N: 1/8" SCREWDRIVER
IMAGE
OVERALL LENGTH
Fastenal
0263735
2.5 Inches
Grainger
1CLP9
5.5 Inches
Grainger
1CLH3
8.75 Inches
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II. SAFETY NOTICES
This equipment is normally used or connected to circuits that may employ voltages which are
dangerous and may be fatal if accidentally contacted by operating or maintenance personnel.
Extreme caution should be exercised when working with this equipment. While practical safety
precautions have been incorporated in this equipment, the following rules must be strictly
observed:
KEEP AWAY FROM LIVE CIRCUITS
Operating and maintenance personnel must at all times observe all safety regulations. Do not
perform maintenance on internal components or re-lamp with power ON.
RESUSCITATION
Maintenance personnel should familiarize themselves with the technique for resuscitation found in
widely published manuals of first aid instructions.
IMPORTANT NOTICES:
Be certain this is the correct lighting system for the project. Verify the lighting
system and equipment received are in accordance with the project specifications.
Locations on Not Grounded (Isolated) towers, High RF antennas, hazardous areas
due to explosive gas, fumes, dust, salt air or other highly corrosive/chemical
environments often require special components or system modification for proper
function and system longevity.
A schematic-wiring blueprint drawing is supplied and included with the controller.
Reference must be made to the drawing before making any wiring connections.
This manual of instructions outlines the function of the controller and its
components. There should be no maintenance performed on the OLC or the
system without reference to the manual and the OLC schematic wiring.
The relays are factory preset for their indicated operations. Changing the switch
selections will cause a malfunction of the circuit and may damage the relay. For
applications using fewer than the designated number of lights for a given OLC,
note the following:
For fewer double obstruction lights, do not wire the appropriate alarm relays to
the alarm circuit (unused alarm relays will indicate a fault).
NOT GROUNDED (ISOLATED) TOWER APPLICATIONS:
The OLC must be isolated from the input power by means of a standard isolation transformer or an
appropriate choke (filter) system.
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III. INPUT POWER
Power to the Obstruction Lighting Controller (OLC) will vary based on the P/N of your system (see
accompanying documentation). Controller circuit protection (fuse or circuit breaker) for incoming
power is external and provided by others. It is important to use the specific OLC schematic-wiring
diagram together with this manual.
IV. INSTALLATION
Mount the controller cabinet in a vertical position ensuring the cabinet is level and there is ample
space to mount the unit. The enclosure is provided with bracket mounting feet at the top and
bottom back edges for use against a vertical surface or frame. Be sure the mounting location is square
so as not to twist or warp the enclosure during mounting. Prior to wiring the controller to incoming
power and loads, make sure all hardware and electrical connections have not loosened during
shipping.
Wire and conduit entrances and their location on the cabinet are to be provided by the installer. On
some lighting controllers, knockout openings are provided on the cabinet. All cabinet openings
should be from the bottom of the enclosure. Wiring entrances for power input, external photo
control leads, and external lighting loads should be located opposite to their terminal connections, if
possible.
The external Photoelectric Control should be located near the controller and must also have the
wiring and conduit enter through the bottom of the unit. Refer to the PCR instructions for proper
location and circuit wiring.
Standard and special lighting controllers incorporate a green and yellow ground lug (GND) located
on the left end of the terminal strip which lies on the left end of the terminal block. It is near the
power input terminals and it is comprised of a box lug or singular screw-hold lug, which is fastened
to the metal back panel. The metal back panel is secured to the enclosure housing forming a solid
equipment ground path through an attached conductor from the ground lug to external ground
(earth). A green colored wire ( # 8 - # 10 AWG stranded copper conductor ) should be used for
connection from the ground lug to an external ground (earth). The system neutral is NOT considered
a grounded contact and must NOT be connected to the ground lug or controller chassis.
The purpose of grounding is to protect equipment, personnel, and circuits by eliminating the
possibility of dangerous fault current or excessive voltages. The equipment ground for the
controller’s metal enclosure that contains electrical wires or component devices is there to eliminate
the possibility that an insulation failure in such an enclosure might place a potential (voltage) on
the enclosure and constitute a shock or fire hazard. The OLC ground lug is provided to fulfill the
requirement of the National Electric Code for fault current protection.
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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V. OPERATION - LED Dual Lighting Systems (L864/L865)
A. PANEL LAYOUT - E1
1
1
9
4
7
3
2
5
8
1
2
3
4
5
6
6
6
6
E1 Panel
Two White Strobe Drivers
One Red Beacon Driver
One Micro-controller module
One Capacitor Module
Obstruction Light Alarm Module
Three Control Relays (Qty may vary based on system)
7
8
One 120VAC to 48VDC Power Supply
Alarm and Status Relays with Isolated Alarm Contacts
(Qty may vary based on system)
9
10
Flash Head Interface Board
Line Filter
10
Part Number
D1RW0084W
D1RW0084R
D1RW0084FM
D1RW0084CP
4501-011
3003-017 (120 VAC)
3003-015 (230 VAC)
3003-026 (48 VDC)
D1RW-9005
3003-024 (120 VAC)
3003-025 (230 VAC)
3003-033 (48 VDC)
D7201SUR
D7202-SUR - AC Volts
D7204-SUR - DC Volts
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This design uses LED technology for light output both from the Beacon and White Strobe. Unlike
conventional xenon flashtube technology, little or no maintenance is required during its lifetime.
Working voltages of less than 200VDC are much lower than with xenon flashtube designs; therefore,
this system represents an advance in safety.
A high level of functionality and versatility is provided by the Controller / Power Supply. Not only
does it generate the required LED drive currents, but also provides:
• Timing and synchronization
• Fault monitoring with Isolated Alarm Contacts
• Control Functions
DC
in
EMI Filter,
Transient &
Reverse
Polarity
Protection
White Strobe
Driver 1
I/O Signal
Opto-Isolators
Control Signals
Microcontroller
Circuit
White Strobe
Driver 2
To Light
Engine
Red Beacon
Driver
Controller / Power Supply Block Diagram
B. WHITE STROBE DRIVER
The two white strobe drivers provide the voltage and drive current to each of its respective portions
of White LED in the Flash Head. Each driver has two individual driver circuits and a common return.
Measure each driver output from Ground to each Strobe(+) on the Flash Head output terminal block.
The output voltage of each driver circuit is approximately 100VDC to 140VDC. The current in each
circuit is approximately 1.5 Amps, 100ms pulses.
The two Strobe Driver modules each have three indicator LED’s. LED 2 and 3: Each is driven from one
of the driver’s two outputs. Therefore normally each one should blink at the same rate as the Strobe
output. These indicate the driver module is operating. If for some reason some of the White LED’s in
the light engine do not operate yet these diagnostic LED’s do blink, this would indicate the
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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fault is not with the Driver module. Should one or more of these LED’s be stuck on or not flash at all,
this would indicate a fault with the driver module.
LED 4: Lights continuously when the Strobe is energized to show an excess of 50V is present at its
output. If this does not light it might indicate either the Driver module is faulty or not receiving any
power.
C. RED BEACON DRIVER
The Red Beacon Driver provides the power to the Red LED’s in the Flash Head. There is one output
and one return. Measure across the Beacon(+) and Beacon Return. The output voltage to the Flash
Head is approximately 50VDC.
LED 1 on the Red Beacon Driver indicates more than 50V is present on the output and gives a good
indication that the Beacon Driver module is working.
D. MICROCONTROLLER BOARD
The Microcontroller Board provides the timing, control inputs and monitoring of the system.
LED 1 on the microcontroller board shows the status of the light engine. In white mode, it will flash
the layer number of any white layers that currently have faulty strings. In red fault mode, it will not
flash as the system will go into white backup mode.
LED 2 on the microcontroller board pulses once every time a flash is initiated in the light engine.
E. CAPACITOR MODULE
The capacitor Module stores sufficient energy to provide the very high output power during the flash
duration.
F. OBSTRUCTION LIGHT ALARM MODULE
The Obstruction Light Alarm Module provides the monitoring of the obstruction lights. The settings
on the module are factory set to coincide with number of obstruction lights in the system. The
module will detect a fault if any one obstruction light in the system fails. The display on the module
will flash if there is a fault condition. If changing System configuration call Unimar Tech Support at
(315) 699-4400.
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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G. CONTROL RELAYS
There are three control relays in the Controller / Power Supply. Their functions are as follows:
Relay K1: Red Beacon Failure, Energized when Good
Relay K2: Night Mode
Relay K3: White Night Test Mode
The three relays are pluggable for easy replacement.
H. 48VDC POWER SUPPLY (Not present on 48 VDC model)
The 48VDC power supply requires a 100-240VAC supply input. It provides the required 48VDC to
power the strobe system.
The power supply is rated for 150W output.
I. TEST SWITCHES
Test Switches are provided for testing all the functions of system for proper operation (see photo
pg. 7). Their functions are as follows:
Auto – Test Switch
Auto – When in this position the system is under control of the PhotoControl. When in this mode the other switches are not operational.
This is normal operating mode.
Test – When in this position the other mode switches are operational.
Red – White Switch
Red – When in this position the system will be in Red mode.
White – When in this position the system is in White mode - The Day-Night Switch
controls intensity.
Day–Night Switch
Day – When in this position the system is in White Day mode and the light
output is 20,000 candelas.
Night – When in this position the system is in White Night mode (night
backup) and the White light output is 2,000 candelas
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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J. ALARM AND STATUS RELAYS
The Alarm and Status Relays provide the isolated contacts for interfacing with the customer's remote
alarm system. The relays each had an LED indicator to indicate when the particular relay is energized.
The relays indicate the following:
WFA – White Strobe Alarm, Energized when there is NO fault.
RFA – Red Beacon Alarm, Energized when there is NO fault.
OLA – Obstruction Light Alarm, Energized when there is NO fault.
PFA – Power Fail Alarm, Energized when supply power is present.
NGT – Night Mode, Energized at night.
K. RECOMMENDED SPARE PARTS & USER REPLACEMENT PARTS
Description
Light Engine Module (Flash Head)
White Driver Module
Red Driver Module
Micro-controller/Filter Module
Capacitor Module
Obstruction Light Alarm Relay
Control Relays
Fuses
Flash Head Interface Board
Line Filter
48VDC Power Supply
Alarm Relays
Dialight Part Number
D1RWFH008
D1RW0084W
D1RW0084R
D1RW0084FM
D1RW0084CP
4501-011
3003-017, 3003-015, 3003-026
1001-004
D7201SUR
D7202-SUR, D7204-SUR
D1RW-9005
3003-024, 3003-025, 3003-033
VI. LIGHTNING
Refer to Appendix A - PROPER GROUNDING TO MINIMIZE RISK OF LIGHTNING DAMAGE for detailed
installation procedures.
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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VII. PHOTOELECTRIC CONTROL (PCR)
Photoelectric Control ( PCR) - P/N 18001-006 (120 VAC)
18002-006 (230 VAC)
18001-006
The PCR is designed and calibrated to meet both the FAA and FCC regulation.
The PCR must be mounted in a vertical position. The PCR should face
the NORTH (polar sky) away from the Sun's rays and away from sunlight
reflections. The PCR should protrude above the height of nearby structures or
other obstructions that might cast shadows upon the PCR's window.
The PCR is used for automatic switching of the load circuits. It is located externally from the
controller cabinet. When wiring the PCR to the controller, use # 12 AWG stranded wire conductors.
The AUTO - TEST switch inside of the DOLC cabinet is used to bypass the PCR, permitting the lights
to be turned on manually. The AUTO - TEST switch allows for testing and calibration of all modes
of operation. This is a maintenance feature. The switch should be in the automatic (auto) mode for
normal operation.
Refer to the accompanying PCR instruction sheet.
Note: When the PCR is connected properly and the test switch is set to "Auto", the
Red LED on the PCR will be energized.
Locking-type Photocontrols – P/N 18001-008 (120 VAC)
18002-008 (230 VAC)
18003-005 (48 VDC)
Delayed response thermal series for white strobe/dual systems. Built-in time delay
prevents false cycling caused by lightning flashes or stray headlights. All-weather
locking type receptacle and Lexan housing with 14”, 14 AWG wire color-coded
18001-008
as follows: line-black, neutral-white, load-red. Threaded stem fits through a ½”
knockout. Dimensions: 2 5/8” diameter (socket), 2 5/8” high (including stem), ½” NPT at bottom
fitting.
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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VIII. TESTING AND MAINTENANCE
All lighting controllers (DOLC) are tested at the factory under simulated lighting conditions. The
lighting system can be tested in the field during daytime by using the photoelectric control override
switch (set to manual), or by totally covering the photoelectric cell face. Use of the AUTO - TEST
switch is recommended for maintenance.
During the testing procedure, all wiring is assumed to be correct and secure throughout the system.
It is suggested that an inspection and testing of the controller be made after a direct lightning strike
on the lighted structure. Wiring and/or lamps may have been subjected to damage even if the DOLC
seems unaffected. Before any extensive maintenance is performed, it is advisable that the external
power be disengaged before probing within the controller. The fail-safe feature of the flasher unit
permits a flashing beacon to operate steady burning if the flasher module fails. If either the side
light or beacon alarm relay sensors fail, the flasher and/or the obstruction lights will continue to be
energized but the alarm indicators will be inoperable.
With the use of the PCR and the flasher circuit, time delays will prevent the controller from operating
immediately upon application of power at the threshold of darkness. About two minutes or less will
elapse before all circuits are operating.
Substitution of any components other than with original manufacturer original spares is not
recommended and may void any warranty.
No oiling is required in the DOLC. Anti-fungicidal agents or desiccants should be applied ONLY by
qualified personnel. No warranty can be implied to any alteration of the controller, by others.
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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IX. ELECTRICAL CONNECTIONS
Electrical connections between the PCR and lighting controller:
Warning: Voltage between P1 and N, and P2 and N must not exceed 150 volts.
P/N 18001-006 / 18002-006
PHOTO-CONTROL
L1
L1
LOAD 1
L2
N
P1
N
N
P2
P1
LIGHTING CONTROLLER
POWER 1
PHOTO-CONTROL
L1
LOAD 1
L1
L2
LOAD 2
P1
N
N
N
N
P2
POWER 2
P1
POWER 1
P/N 18001-008 / 18002-008 / 18003-005
L1
Red
P1
Black
N
White
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X. TROUBLESHOOTING - LIGHTING CONTROLLER
CAUTION: Turn Power off to the lighting controller at the source before any maintenance is
performed on controller or light fixtures.
A. PFA - Power Fail Alarm
1. Check Supply power to the system
B. WFA - WHITE Strobe Fault Alarm
1. Check the WHITE Strobe for proper operation - Refer to Dialight Manual - "Maintenance and
Troubleshooting".
C. RFA - RED Beacon Fault Alarm
1. Check RED Beacon for proper operation - Refer to Dialight Manual - "Maintenance and
Troubleshooting".
D. OLA - Obstruction Light Alarm
1. Check obstruction light output fuse.
2. Check obstruction lights for failure, and replace failing light.
Call Unimar, Inc. for assistance: Phone # 315-699-4400; Fax # 315-699-3700
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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XI. LIMITED PRODUCT WARRANTY
THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
UNIMAR, INC. warrants to each original Buyer of Products manufactured by the Company that such
Products are, at the time or delivery to the Buyer, free of material and workmanship defects, provided
that no warranty is made with respect to:
(a)
(b)
(c)
(d)
any Product which has been repaired or altered in such a way, in Company's judgment,
as to affect the Product adversely;
any Product which has, in Company's judgment, been subject to negligence, accident
or improper storage;
any Product which has not been operated and maintained in accordance with normal
practice and in conformity with recommendations and published specification of
Company; and,
any Products, component parts or accessories manufactured by others but supplied by
Company (any claims should be submitted directly to the manufacturer thereof).
UNIMAR, INC.'s obligation under this warranty is limited to use reasonable effects to repair or, at its
option, replace, during normal business hours at any authorized service facility of Company, any
Products which in its judgment proved not to be as warranted within the applicable warranty period.
All costs of transportation of Products claimed not to be as warranted and of repaired or replacement
Products to or from such service facility shall be borne by Purchaser. Company may require the
return of any Product claimed not to be as warranted to one of its facilities as designed by Company,
transportation prepaid by Purchaser, to establish a claim under this warranty. The cost of labor for
installing a repaired or replacement product shall be borne by Purchaser. Replacement parts provided
under the terms of this warranty are warranted for the remainder of the warranty period of the
Products upon which they are installed to the same extent as if such parts were original components
thereof. Warranty services provided under the Agreement do not assure uninterrupted operations
of Products; Company does not assume any liability for damages caused by any delays involving
warranty service. The warranty period for the Products is for a period of 5 years on standard products
and custom assemblies from the date of shipment or first use whichever occurs first.
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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XII. SYSTEM INSTALLATION REQUIREMENTS FOR EMC AND LIGHTNING IMMUNITY
1. Ensure the shield of the cable that connects the Flash head to the power supply is grounded at
both ends. Make 360- degree ground connections around the braid or foil (avoid pigtails).
2. Ensure that a lightning rod extends up 3 feet above the fixture is installed and 18 inches
away from the light.
3. The drain-wire in the Flash head cable must be connected to ground at both ends.
Ensure that the wire is short as possible and avoid loops.
4. Ensure the Flash head is electrically bonded to the tower. Scrape away access paint/
powder coating as necessary.
5. Minimize loop areas by tying all cables against the tower or passing through conduit.
NOTE: Refer to kit drawing for proper cable attachment to tower.
6. Ensure the power supply enclosure is electrically bonded to the tower. Scrape away
access paint/ powder coating as necessary.
7. Ground any spare/ unused conductors in the flash head connection cable at both ends.
8. Service loops should be added as required to prevent moisture entering through the
cable and in to the fixture or enclosure. 2-3, 6-12 inch loops is recommended.
9. Service loops must be taped to the structure. In proper securing could cause premature
failures due to vibration or lightning.
10. DO take pictures of all cable runs, wiring connections and junction boxes used during
the installation. This is required for warranty purposes and site commissioning purposes.
11. Pictures must be given to site manager and system provider for commissioning
purposes.
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
[D1RW-C13-008SP-A-revA]
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APPENDIX A - RECOMMENDATIONS FOR PROPER GROUNDING TO MINIMIZE RISK OF
LIGHTNING DAMAGE (D1RW-C13-008SP-A-RevA/ Single Level Version)
Cable Grounding (Power Supply Side)
1. Remove about 6" of protective outer cladding taking care not to damage underlying mesh braid.
Remove white fiber insulator
NOTE: Flash Head end cable needs only 6-7 inches of jacket removed.
2a. Push back on the braiding to loosen the cross-hatchings in order to create an opening. Remove
the foil between the braid and the conductors.
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2b. One at a time, carefully begin to pull each conductor through the braiding about 1" above where
the cladding was cut. A small flat blade screwdriver makes this process easier.
BE CAREFUL NOT TO DAMAGE THE
BRAIDING
3. Separate each of the 8
conductors and remove the
yellow fiber filler. Strip each
conductor back 1/2" and twist
each stranded end.
4. Using black electrical tape, tape
down the conductors where they
exit the braid, leaving 1/2" of
braiding exposed between the
cladding and the tape
3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com
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5. The J3 terminal block has 8 position
with 2 openings for each position.
One is for inserting and removing
each of the conductors the other is
for applying and releasing pressure
of the spring terminals inside the
block to secure the conductors. Place
the blade of a small screwdriver in
the TOP opening and turn the blade
90°. Place the appropriate colored
conductor into the lower opening and
release the screwdriver to secure the
conductor. Strip the end of each wire
1/2"back.
6. Repeat for all conductors taking
care that the insulating material
of the conductors is not hindering
connection with the terminal block.
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7. Carefully separate the
top of the seating clip and
press the exposed braiding
of the cable into place. Using
the “T” shaped tab on the clip
bracket, secure the cable with
a wire tie tied to the exposed
braided section.
8. Secure the twisted
braided shield to the copper
grounding lug using a flat
blade screwdriver. If twisted
braid is too long, cut to
appropriate length allowing
for a small amount of slack.
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Hookup to flashhead. For instructions on how to install, please refer back to the previous pages. (17-20)
Tighten the cable
gland nut to 40-60
inch/lbs. Pull on the
cable and ensure that
the cable does not
slip out of the cable
gland nut.
(Must be water-tight)
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APPENDIX B - TROUBLESHOOTING GUIDE - LED BEACONS
TROUBLESHOOTING GUIDE
AND
IN-DEPTH TROUBLESHOOTING MANUAL
1-Level, P/N: D1RW-C13-008SP-A-RevA
110/240VAC, 50/60 Hz, 48VDC
L865, DUAL MEDIUM INTENSITY WHITE STROBE & L864 RED
BEACON
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Troubleshooting Guide
Symptom
White not lit; power
supply is totally
inactive
White strobe will not
operate.
Alarm and/or Error
LED (RED LED1 on
Micro/Filter Module)
flashing.
Possible Causes [Frequency]
Corrective Actions
Additional Notes
Lack of incoming power 110240VAC to AC to DC Converter
Module [Frequent]
Check incoming power wiring in conductors
Refer to Problem
1 for instructions.
(p.26)
AC to DC converter Module
Problem [Very Rare]
Check voltage coming out from AC to DC
converter module. Should be 48VDC
Refer to Problem 2.
(p.28)
Flash Head Cable Problem
[Frequent]
1. At Power Supply, check multi way cable
Refer to Problem 2
conductors are wired securely and in the correct for instructions.
order to terminal blocks.
2. At Flash Head, check multi way cable
conductors are wired securely and in the correct
order to the terminal block.
3. At Flash Head, check wires have not been
trapped between Light Engine and Base housing.
Driver Board Module Problem
[Rare]
Check nominal 48VDC supply voltage on J1 on
the driver board.
LED String Failure in Light Engine Replace light engine (only when all other
[Very Rare]
possibilities have been explored).
Refer to Problem 2
and Problem 3.
Refer to Problem 6.
White Strobe (some
or all LED strings)
are steady ON (not
flashing).
Alarm and/or Error
LED (RED LED1 on
Micro/Filter Module)
flashing.
One or more LED return
conductors shorted to ground.
[Frequent]
Check all connectors, mainly Strobe commons
Refer to Problem 2
(+'s) and the two return wires on each of the
and Problem 3 for
levels. At Flash Head, check wires have not been
instructions.
trapped between Light Engine and Base housing.
Damaged Driver Board [Rare]
Look for white driver module with any of LED 2 or Refer to Problem 2
and Problem 3.
3 stuck ON. Replace this driver module.
Red Beacon will not
operate. Diagnostic
LED (LED1 on Red
Driver Board) is Lit.
Problem with cable from
Power Supply to Flash Head.
In particular, the 2 conductors
labeled 'Beacon+' and 'Beacon-'
[Frequent]
1. At Power Supply, check multi way cable
Refer to Problem 4
conductors are wired securely and in the correct for instructions.
order to terminal blocks.
2. At Flash Head, check multi way cable
conductors are wired securely and in the correct
order to the terminal block.
3. At Flash Head, check wires have not been
crushed between Light Engine and Base housing.
Damaged Driver Board [Rare]
Check voltage on J3 of the Red Driver Board.
Check voltage on Beacon(+) and Beacon Rtn on
the Terminal Block.
Refer to Problem 4
for instructions.
Red Beacon will not
operate. Diagnostic
LED (LED1 on Red
Driver Board) is NOT
Lit.
No Power to Beacon Module.
[Frequent]
Check nominal 48VDC supply voltage on J1 on
the driver board.
Refer to Problem 5
for instructions.
FALSE ALARMS: ALL
ALARMS ARE REAL
ALARMS UNTIL ALL
STEPS ABOVE HAVE
BEEN CHECKED!!!
Problem with Micro/Filter Board
[Extremely Rare]
Check DIP Switches on Micro/Filter Board
Refer to Problem 4
for instructions.
Problem with Alarm Unit [Rare]
Contact alarm unit manufacturer
Refer to Problem 4
for instructions.
Damaged Micro-Controller Board Replace Micro-Controller Board.
[Extremely Rare]
Refer to Problem 3.
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L-865 Strobe
In-Depth Troubleshooting Manual
Problem 1.
Symptom
-Flash Head not working and NO indicator lights or diagnostic LED(s).
-White and Red lights not working.
Corrective Actions –
1. Check Incoming Supply Voltages
Using a multimeter, measure Voltage coming in to the AC to DC Converter (Fig.1).
Measure between Neutral and the Live as shown in Fig.1. Incoming Voltage should be
nominal 120-240VAC. (Fig.1).
Figure 1 - Measure INCOMING Supply voltage on the AC-DC Converter
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2. Check the Supply
out from AC to DC
Converter Module
Using a multimeter,
measure Voltage coming
out from the AC to DC
Converter (Fig.2).
Measure as shown above.
Output Voltage should
be nominal 48VDC.
(Fig.2).
Figure 2 - Output Supply voltage on the AC-DC Converter. Should read ≈48VDC
3. Check the Power In to Micro/
Filter Board Module
Using a multimeter, check J1
on filter board (Fig.3). Make
sure J1 is plugged in and check
connection wires. Make sure
wires are secure.
Check power at J1 between
the Power wire's two wires.
(Fig.3).
When in operational, the
voltage between the two
Power wires should be
nominal 48VDC.
Figure 3 - J1 on the Filter Board
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Problem 2.
Symptom
-White Strobe will not operate
-One or more of the LED strings are NOT lighting on the Light Engine.
-Open circuit or Open LED's
Corrective Actions –
1. Inspect the Error LED: LED1 (Red LED) on the Micro/Filter Board (Fig.4).
During normal operations, LED2 (Green LED) flashes and LED1 stays off.
LED1 (Red LED) blinking confirms that there is an error. Observe the number of blinks.
The number of blinks corresponds to the connector J1, J2, etc. on the Micro
Board (Fig.4). (E.g. Two blinks are referring to J2 connector on the Micro Board,
the Driver Module and Light Level connected to J2).
Inspect the corresponding connector on the Micro Board and the driver board that is
connected to the corresponding connector. Secure any/all loose connections. Proceed
to Step 2.
Figure 4 - J1, J2& J4 Connections and LED1&2 on the Micro Board
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2. Check power going to Driver Module J1 (Fig. 5) on the Driver Board in question (should be
≈48VDC).
J3
LED4
LED2 & 3
J1
J4
J2
Figure 5 - Driver Board. Connectors J1, J2, J3&J4. LED4 should be steady on if power is being supplied.
3. Check LED4 (Fig.5) on the Driver Board in question is ON Steady.
4. Check LED2 and 3 (Fig.5) on the Driver Board in question are blinking.
LED2 and 3 each is driven from one of the driver's two outputs. Therefore, normally each
one should blink at the same rate as the Strobe output and the intensity of the LED2 and 3
should be uniform (same brightness). These indicate the driver module is operating.
If some of the White LED's in the Flash Head do not operate, yet these diagnostic LED's
(LED2 and 3) do blink, this would indicate the fault is not with the Driver module but
elsewhere.
Should one or more of these LED's be stuck on, blinks with a different intensity to the others,
or not flash at all; this would indicate a fault with the driver module. However, continue with
the steps below in case the fault is elsewhere.
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5. Wait 45 seconds after turning the system on, then using a Multimeter, check J3 and measure the
Voltage VDC.
During normal operations, the voltage will read roughly 100VDC ~ 140VDC. Due to strobe
flashing, the voltage will fluctuate but the peak voltage should be roughly 100VDC ~ 140VDC.
If VDC is close to 160VDC, one or more of the LED Strings in the Flash Head is disconnected.
6. Check wires and connector J3 (Fig.5) of the Driver Board in question.
Also check wires in Terminal Block. Make sure all connection wires make good contact in
each terminal. Make sure all wires going into and out from terminal block are color matched
1:1. (E.g. Yellow wire going into the terminal block from the power supply side should be
matched at the terminal block by a Yellow wire from the Flash Head side.) In the case that all
connections are good and yet there is still a problem with one or more of the LED strings in
the Flash Head not lighting up, proceed to Step 7.
7. Replace the Driver Board Module in question with a known working Module.
Replace using a spare Driver Board Module, if possible. If not, switch with another working unit
and observe if the symptom moves. If the problem moves, the Driver Module is likely
to be damaged and should be replaced. If the problem does not move and the status is
as before swapping, the fault is elsewhere. If an additional problem other than the original is
created, this indicates that there is a problem in both the Driver Board and either the cable up
to the Flash Head or the Flash Head itself. Proceed to Problem 6 in this Troubleshooting Guide.
NOTE: Per FAA regulation 150-5345-43F, if 25% or more of the LED Strings are not
functioning, system will send alarm signal which may shut down the system.
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Problem 3.
Symptom
-One or more of the LED strings are STEADY ON (not flashing)
Corrective Actions –
1. Error LED on the Micro/Filter Board
Inspect LED1 (Red Error LED) on the Micro/Filter Board (Fig.4).
LED1 blinking confirms that there is an error. Observe the number of blinks. The number of
blinks corresponds to the connector J1, J2, etc on the Micro Board (Fig.4). (E.g. Two blinks
are referring to J2 connector on the Micro Board, the Driver Module and Light Level connected
to J2).
Inspect the corresponding connector on the Micro Board and the Driver Board that is
connected to the corresponding connector. Secure any/all loose connections. Proceed
to Step 2.
2. Checking for Short Circuits
Check system for short circuit to ground, in the return wires of the level in question. Proceed to
Problem 7 in this In-depth Troubleshooting Guide.
Check for wires shorted to ground by crushed/ damaged cables.
Check wires going into the Flash Head housing. Wires may have been crushed during
installation.
3. Replacing a Driver Board Module
Replace the Driver Board Module in question with a known working Module. Replace using
a Spare Driver Board Module if possible. If not, switch with another working unit and
observe if the problem moves. In the case that the problem moves, the Driver Board Module
would be suspected of being damaged. If the problem does NOT move and the system
is still showing problems, proceed to Step 4. If an additional problem other than the original is
created, this indicates that there is a problem in both the Driver Board and either the cable up
to the Flash Head or the Flash Head itself.
4. Replacing a Micro/ Filter Module
In the case where the system is still not working, replace the Micro/ Filter Board Module in
question with a working spare or from a working system.
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Problem 4.
Symptom
-Red Beacon will not operate. Diagnostic LED is lit.
Corrective Actions –
1. Check the cables are snuggly plugged into J1, J2 and J3. (Fig. 6)
2. Check the voltage from J3
NOTE: The following readings must be taken before the system goes into White
backup.
During normal operations, voltage on J3 is ≈50VDC.
If the voltage is ≈65VDC or greater, the load is an open circuit, proceed to Step 3. If ≈30VDC or
less, the load is a short circuit.
J3
LED1
J1
J2
Figure 6 - Red Beacon Driver Board. LED1 indicates more than 50V is present on the output and gives good
indication that the Red Beacon Driver Module is working.
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3. Check Beacon (+) and Beacon RTN on the terminal block (Fig. 7).
4. Check for integrity of the wires in the terminal block. Make sure all wires are making contact and
secured.
5. Check the connections in the Flash Head. Ensure that none of the wires are pinched, damaged,
disconnected or loose.
6. Visually check the Flash Head for damage.
NOTE: Wire colors may differ from picture.
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Problem 5.
Symptom
-Red Beacon will not operate. Diagnostic LED is NOT Lit.
Corrective Actions –
1. Check and verify incoming power from the AC-DC Converter Module. (Fig.2).
2. Check Power Connection to J1 on Beacon Section (Fig.6) Make sure all wires are secured.
Problem 6.
Symptom
-One or more LED strings not lighting on the Flash Head.
Corrective Actions –
1. Check cables as stated in Problem 2, 3 in this In-Depth Troubleshooting Guide.
2. Check boards as stated in Problem 2, 3 in this In-Depth Troubleshooting Guide.
3. Verify ALL Flash Head connections are installed in the proper location and securely attached.
Check that all wires, cables, connectors are NOT shorted, open, damaged and/or loose. Check
both the power supply side and Flash Head side. Check junction box connections if applicable;
also connections on the bottom of the Flash Head, under the base plate. Make sure to fully check
before proceeding to Step 4.
4. Check Flash Head for visible damage to LEDs. Look for Loose and/or Burnt LEDs/ Circuit boards.
5. If visible damage is present, Light Engine must be replaced. Replace light engine only when
all other possibilities have been explored. Repair of Light Engine is not possible due to the self
enclosed system. If opened, condensation and/or other contaminants may further damage the
system. If all checks are complete and yet the problem persists, call service only when all other
possibilities have been explored.
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Problem 7.
Symptom
-Short Circuit within System
Corrective Actions –
1. Check inside the Power Supply Box for loose wires, wires connected improperly, foreign objects
making contact with two or more locations that are not supposed to, and/or damaged/crushed
wires causing a short to ground.
2. Using a multimeter on continuity setting, place one probe on Strobe Common1(+) and the other to
Strobe Return1 and observe for continuity (audible sound from multimeter).
a. Repeat step 2 on Strobe Common1(+) and Strobe Return2.
b. Repeat step 2, 2a and 2b for Strobe 2.
If continuity is present, locate and remove short circuit.
Note: Good Resistance Reading: Strobe Common(+) to Strobe Return is 152k Ω ± 5%
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Problem 8.
Symptom
-False Alarms
!!WARNING!! ALL ALARMS ARE REAL ALARMS UNTIL ALL OTHER PROBLEMS HAVE BEEN
CHECKED IN THIS MANUAL.
Corrective Actions –
1. Utilizing this manual, check for any/all Errors before proceeding.
1.1
Check the Error LED (LED1) on the Micro/Filter Board Module. If flashing, it is a TRUE
alarm. If not flashing, it is a false alarm.
1.2
Check that all connections and connectors are secure. Loose wires to the alarm relays
(J3) may cause false alarms.
1.3
Check all voltages are correct as stated in previous Problems in this manual.
Figure 8 - Micro/Filter Board. DIP SWITCH (SW1).
NOTE: Switch position UP is ON and DOWN is OFF. Factory default is 1-3 DOWN and Switch 4 UP.
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2. Check the DIP Switches (SW1) shown in Figure 8. Refer to Configuration Options Switch. Check
Switch 4 in the DIP Switch and ensure that the switches are set to the requirement for the alarm
unit (Switch 4 should be ON and all others OFF).
If DIP switches are correct, check the wires going to and from the alarm relay in J3 and
the isolated alarm module. Check the output of the alarm signals (J3) using a multimeter
for continuity [eg: If the system is normally closed (DIP Switch 4 in ON position), the relay will
open upon receiving an alarm signal. Thus you would have an open connection when
alarm signal is initiated].
Configuration Options DIP Switch
Switch #
1
2
3
4
Function
At night, light Red Beacon or White Strobe at 2000 cd
German W. Red (1s-on; 0.5s-off; 1s-on; 1.5s-off )
Selects whether fault relays pulse while system is OK
Selects whether fault relays open or close on fault
CONFIGURATION DIP SWITCH SETTINGS (on Microcontroller Board)
1
2
3
4
ON
OFF
NOTE: Only Switch 4 should be set to "ON" (Factory Set)
Switch #
1
2
3
4
ON
OFF
White at night
W. Red mode
Relays pulse while system is OK
Relays open on fault (Normally CLOSED)
Red at night
50% duty cycle mode
Relays do not pulse
Relays close on fault (Normally OPEN)
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APPENDIX C - DLS1-008SP-A QUICK REFERENCE GUIDE
WHITE DRIVER BOARD NOTES:
LED4 ON STEADY = NORNAL
LED2&3 FLASHING = NORMAL
100-140VDC
RJ45
COMM.
CABLE
J2
J3
RJ45
COMM.
CABLE
120-140VDC
J4
DRIVER 2
J1
120-140VDC
J1
J1
120-240VAC
WHITE DRIVER BOARD
WHITE DRIVER BOARD
J4
48VDC
J3 OUTPUT:
100-140VDC = NORMAL
160-180VDC> = OPEN CIRCUIT
100VDC< = SHORT CIRCUIT
J3
DRIVER 1
100-140VDC
J4
CAPACITOR BOARD
48VDC
RED +
POWER SUPPLY
48VDC
J5
TERMINAL BLOCK
J1
48VDC
J1
DIP
SWITCHES
J4
J2
48VDC
J1
RJ45
COMM.
CABLE
J1
J9
J7
J4
RED DRIVER BOARD
MICRO FILTER BOARD
J3
50VDC
48VDC
J1
J4
MIRCO FILTER BOARD NOTES:
LED1 = OFF NORMAL
LED1 FLASH RED = ALARM
LED2 = FLASH GREEN NORNAL
LED1= # OF RED FLASHES
CORRSPONDS TO J1,J2,J4(EX. 2
FLASHES = J2)
K1
K2
RED DRIVER BOARD NOTES:
LED1 FLAHING = 50VDC PRESENT
ON OUTPUT OF BOARD
K3
CONTROL RELAYS:(DUAL)
K1 = RED BEACON FAILURE
K2 = NIGHT MODE
K3 = WHITE NIGHT TEST MODE
RJ45
COMM.
CABLE
48VDC
J3 OUTPUT:
50VDC = NORMAL
65VDC> = OPEN CIRCUIT
30VDC< = SHORT CIRCUIT
COMM. CABLES:
J1=WHITE DRIVER BOARD 1
J2=WHITE DRIVER BOARD 2
J4=RED DRIVER BOARD
DIP SWITCHES:
1 - OFF
2 - OFF
3 - OFF
4 - ON
TERMINAL BLOCK RESISTANCE
READINGS: (POWER OFF)
RED & BLACK = 65K OR 29K
OHMS
PURPLE & BLUE OR PURPLE &
GREEN = 150K OHMS
ORANGE & BROWN OR ORANGE &
YELLOW = 150K OHMS
TERMINAL BLOCK VOLTAGE
READINGS:
(POWER ON)
RED & BLACK = 50 VDC
PURPLE, BLUE OR GREEN TO
GROUND = ± 100-140 VDC
ORANGE, BLUE AND YELLOW TO
GROUND= ± 100-140 VDC
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET
INFORMATION WHICH IS THE PROPERTY OF UNIMAR, INC.
OBSTRUCTION LIGHTING AND RECEIPT OR POSSESSION DOES
NOT CONVEY ANY RIGHTS TO LOAN, SELL OR OTHERWISE
DISCLOSE SAID INFORMATION. REPRODUCTION OR USE OF SAID
INFORMATION FOR ANY PURPOSE OTHER THAN THAT IN
CONNECTION WITH WHICH SAID INFORMATION WAS SUPPLIED
MAY NOT BE MADE WITHOUT EXPRESS WRITTEN PERMISSION
OF UNIMAR, INC. OBSTRUCTION LIGHTING. THIS DOCUMENT IS
TO BE RETURNED TO UNIMAR, INC. OBSTRUCTION LIGHTING
UPON REQUEST AND IN ALL EVENTS UPON COMPLETION OF
THE PURPOSE FOR WHICH IT IS LOANED.
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APPENDIX C - COMMISSIONING CHECKLIST
All items on checklist must be completed correctly to ensure the system functions properly and
reliably. Complete and Sign below.
Check that all cables, wires and connections are connected securely in accordance with
instructions outlined in this Installation Manual.
Check that the Lightning Protection and Proper Grounding is present in accordance
with instructions outlined in this Installation Manual including Recommendations For
Proper Grounding To Minimize Risk Of Lightning Damage (Appendix A).
Operational Checks
A. Set system to Day mode
1. Pull out the interlock switch
2. Wait at least 2 minutes
3. Check RED Error LED (LED1) on Micro Board does NOT blink. If it blinks, that indicates a
fault - see Problems 2 and 3 in the Troubleshooting Guide (Appendix B)
4. Check that the controller does not produce any alarm signals
5. If possible, visually check that the Light Engine is flashing and operating normally
B. Set system to RED Night mode
1. Check LED1 on Red Driver module (bottom left of cabinet) is on if steady burning and
blinking if flashing.
2. Check that the controller does not produce any alarm signals
3. If testing a White only system, set to White Night mode and repeat step A, starting from
step 2
4. If possible, visually check that the Light Engine lights up
I, __________________________________ (Print Name), have completed all final checks listed
above and observed satisfactory results. No issues to report at this time.
________________________________________
Signature
________________________________________
Installation Site Location (Site Number, City, State)
___________________________
Date
___________________________
Company Name
ONCE COMPLETED, TEAR OFF AND TAPE INSIDE THE DOOR OF THE POWER SUPPLY!!
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[D1RW-C13-008SP-A-revA]
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