Avlite AV-OL-CTRL-T2 Supplement

V1.0
INSTALLATION & SERVICE MANUAL
AV-OL-CTRL-T2
Obstruction Lighting Controller

2
Version No. Description Date Reviewed Approved Design
1.0 AV-OL-CTRL-T2 Manual Launch October 2020 P. Naidu W. Evans M. Sugars

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 3
Table of Contents
1.0 Introduction ...............................................................................................................4
2.0 Technology.................................................................................................................5
3.0 AV-OL-CTRL-T2 Models...........................................................................................6
3.1 Available Options........................................................................................................................................7
4.0 AV-OL-CTRL-T2 Data Sheet....................................................................................8
5.0 Safety Information....................................................................................................9
6.0 Operation and Setup.............................................................................................. 10
6.1 System Overview..................................................................................................................................... 10
6.1.1 T2 Controller...................................................................................................................................... 10
6.1.4 Interface Wiring................................................................................................................................11
7.0 Unpacking, Installation, Wiring and Setup ......................................................... 12
7.1 Unpacking ......................................................................................................................................................12
7.2 Installation......................................................................................................................................................12
7.2.1 Tools Required ..................................................................................................................................13
7.2.2 Factory Configuration..................................................................................................................13
7.2.3 Installation Recommendation.................................................................................................13
7.3 Testing Procedure....................................................................................................................................18
8.0 Maintenance and Servicing .................................................................................. 19
9.0 Replacement Parts ................................................................................................. 19
10.0 Troubleshooting..................................................................................................... 20

4
1.0 Introduction
Congratulations! By choosing to purchase an Avlite product, you have become the owner
of one of the most advanced obstruction products in the world.
Avlite Systems draws on more than 25 years of experience in the design and manufacture
of navigation aids, and particular care has been taken to ensure your product gives years
of trouble-free service.
As a commitment to producing the highest quality products for our customers, Avlite has
been independently certified as complying with the requirements of ISO 9001:2015 quality
management system.
By taking a few moments to browse through this booklet, you will become familiar with the
versatility of your lighting control unit, and be able to maximise its operating function.
Please remember to complete the Avlite warranty registration card accompanying your
product.
Acronyms and Abbreviations
The following abbreviations will be used throughout this Installation Manual:
cd candela
ft. foot
in. inch
LED Light Emitting Diode
VAC Volts, Alternating Current
VDC Volts, Direct Current
AWG American Wire Gauge
MI Medium Intensity
LIOL Low Intensity Obstruction Light
LI Low Intensity

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
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2.0 Technology
Avlite Systems is a world-class solar lighting systems manufacturer with a proven
reputation for rapid, innovative, and agile technology solutions designed specifically
for defence, government, civil and humanitarian aid operations in the most remote,
toughest environments.
Electronics
Avlite employs leading in-house electronic engineers in the design and development of
software and related circuitry. All individual electronic components are sourced directly by
Avlite procurement staff ensuring that only the highest quality components are used in our
products.
LED Technology
All Avlite lights use the latest advancements in LED (Light Emitting Diode) technology as a
light source. The major advantage of LED’s over traditional light sources is well established
in that they typically have an operational life in excess of 100,000 hours, resulting in
substantial savings to maintenance and servicing costs.
Precision Construction
Commitment to investing in the design and construction of injection-moulded parts
including optic lenses, light bases and a range of other components ensures that all Avlite
products are of a consistent and superior quality.
Optical Performance
Avlite manufactures a range of aviation LED lenses moulded from multi-cavity dies. The
company has superior in-house lens manufacturing capabilities to support outstanding
optical performance.
Award-winning, Patented Technology
Several United States and Australian patent registrations are held on Avlite’s range of
innovative designs, with other regional patents pending in Canada, United Kingdom and
Europe.

6
3.0 AV-OL-CTRL-T2
The AV-OL-CTRL-T2 Obstruction Lighting Controller is an application specific control and
monitoring system to provide a full turnkey solution for A1/I2 structures ranging between
45-106 meters (150 and 350 feet). These include telecommunication towers and utility
towers, wind turbines, cranes, buildings and other tall structures.
The T2 Obstruction Controller comes as a fully assembled, ready to install central control
unit.
The T2 Obstruction Controller is available in two input power configurations, a universal AC
(90-264VAC) or 24-48 VDC (solar compatible) and comes with Star2M monitoring via GSM
or SATCOM as options.
The best in class system power draw allows tower owners to utilize solar for locations
lacking reliable and or cost-effective access to regular utility power. Avlite’s experience,
knowledge and tools for solar applications provides years of maintenance free, off-grid
operation with an emphasis on FAA and ICAO compliance.
With a range of accessories including brackets, cable and junction boxes, utility and
telecommunication companies, electrical contractors and state and local governments can
now quickly and easily purchase all obstruction lighting components from a single source,
simplifying the ordering process and reducing the possibility of incompatible, stand-alone
components from different manufacturers.
Note: This installation and service manual must be used in conjunction with the
installation manuals of the individual components.
[23.6in]
600mm
[15.8in]
400mm
2
0.00 A3
SolidWorks
mm
Drawn in:-
Units
Sheet Size:-
naturalFinish:-
Assem1
Material <not specified> -
Wt(Kg) each:-
Material/Quantity
N/A
XXXXXX-XXX
N/A
General Tolerances
345
X.XX
X.X
X
±0.1
±0.3
±1.2
X.X
X
±0.5°
±1.0°
±0.5
±2.0
Angular
X.X Drawing Rev:-
Drawn:-
Approved:-
Checked:-
0
E1 Marketing Drawing
Qty per Ass'y:-
Drawing No:-
File Name:-
Sheet
Scale
Projection
Next Ass'y:-
1:10 1 of 1
Model Rev:-
Sealite
0
A
B
C
D
E
F
G
9876
Linear Radii
X
1
18.5in
470mm
24in
610mm 652mm
25.6in
20in
508mm
Notes:-
Break all sharp edges.1.
Use 3D Model for Machining.2.
Refer Drawing for GEO Tol and Dimension Tol.3.
Part Nº .4.
Zone Rev Model
Rev ECR No. Description Date:- Drawn:- Approved:-
261mm
10.3in
26.5in
673mm
[7.9in]
200mm
2
0.00 A3
SolidWorks
mm
Drawn in:-
Units
Sheet Size:-
naturalFinish:-
Assem1
Material <not specified> -
Wt(Kg) each:-
Material/Quantity
N/A
XXXXXX-XXX
N/A
General Tolerances
345
X.XX
X.X
X
±0.1
±0.3
±1.2
X.X
X
±0.5°
±1.0°
±0.5
±2.0
Angular
X.X Drawing Rev:-
Drawn:-
Approved:-
Checked:-
0
E1 Marketing Drawing
Qty per Ass'y:-
Drawing No:-
File Name:-
Sheet
Scale
Projection
Next Ass'y:-
1:10 1 of 1
Model Rev:-
Sealite
0
A
B
C
D
E
F
G
9876
Linear Radii
X
1
18.5in
470mm
24in
610mm
652mm
25.6in
20in
508mm
Notes:-
Break all sharp edges.1.
Use 3D Model for Machining.2.
Refer Drawing for GEO Tol and Dimension Tol.3.
Part Nº .4.
Zone Rev Model
Rev ECR No. Description Date:- Drawn:- Approved:-
261mm
10.3in
26.5in
673mm

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
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3.1 Available Options
• Solar Input Power (for 24VDC) – Call Avlite for details.
• Cable Kit (suitable for 106 m structure) Includes:
80m of 2.5mm2, 3 conductor wire
80m of 14mm2, 2 conductor wire
50m of 4mm2, 5 conductor wire
• Remote Monitoring and Control
Avlite offers remote Star2M monitoring via GSM or SATCOM.
Operators can remotely monitor the status of their installation from a compatible
device. The system can also be configured to send out SMS text messages or
e-mail alerts to designated operators should alarm conditions be triggered, such
as low voltage or light failure.
Please contact Avlite for operational information for the Monitoring & Control
options. Visit https://www.star2m.com to find out more about Star2M
• Mounting Bolt Set (includes bolts, nuts, washers)
Please contact Avlite for further details
• Control Unit Mounting Hardware
2” pipe clamps
¾” pipe clamps
Please contact Avlite for further details.

8
4.0 AV-OL-CTRL-T2 Data Sheet
AC DC
Electrical Characteristics
Input Voltage 90-264VAC 24-48VDC
Input Frequency 50/60 Hz N/A
Power Consumption (Full Load)
Peak 84VA 70W
Physical Characteristics
Mounting Wall mounted (mounting accessories available)
Height (mm/inches) 600/23.6
Width (mm/inches) 400/15.8
Length (mm/inches) 200/7.9
Mass (kg/lbs) 28.5/63
Service Life 12 years +
Intellectual Property
Trademarks AVLITE® is a registered trademark of Avlite Systems
Compliance
CE EN61000-6-3:2007, EN61000-6-1:2007
FCC 47 CFR Part 15, subpart B
Quality Assurance ISO9001:2015
Protection Rating IP65/NEMA4X
Other
Warranty * 3 year warranty
Options Available SATCOM or GSM
Mounting Brackets
Solar Input Power (for 24-48VDC)
Cable Kit (for 106m height)
Monitoring and Control
Mounting Bolt Set (includes bolts, nuts, washers)
Star2M
Terms and Conditions Please refer to the individual light installation manuals for further
specifications

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
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5.0 Safety Information
Before proceeding with installation or service, make sure the following conditions are met:
• Ensure the tower or mast is grounded (NO RF OR SHOCK HAZARD)
• Check the mast lighting circuit is not faulty
• Ensure power lines are not ‘live’ (NO ELECTRICAL HAZARD)
• Avoid touching live circuits!
• Avoid touching any component or any part of the circuitry while the unit is operating.
Do not change components or make adjustments inside the unit with power on.
• When installing, comply with all local electrical code(s).
• Mains power should always be disconnected when work is being done in close
proximity to electrical fittings, and electrical work should only be done by a licensed
electrician.
• To ensure that the light and peripheral equipment function safely and correctly, use
cable in compliance with the effective local electrical code.
• Dispose of the product according to the local laws and regulations for your region, for
example, at a recycling centre that accepts electronic devices.

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6.0 Operation and Setup
Avlite’s AV-OL-CTRL-T2 Obstruction Control Unit can connect to four components: A single
red Medium Intensity obstruction beacon (MI), and three red, single fixture obstruction
lights (LI).
An External Photocell allows the lights to automatically switch between day and night
mode. The Photocell output can also be overridden for system testing and maintenance via
the Photocell Bypass Switch.
The Control Unit automatically evaluates the T2 lights for operation and performance while
providing local and remote display of information and alarms; operators can conveniently
view the lights’ real time status from the web based Star2M™ portal.
6.1 Product Overview
6.1.1 T2 Controller
The T2 Control Unit provides power, control and monitoring of the light fixtures.
For safety and security, the control unit comes with a safety interlock which prevents
access to the controller while the system is powered on.
The Controller is available in two input power configurations; a universal AC or DC and
comes with optionalremote monitoring via Star2M with either GSM or SATCOM telemetry.
By default, the control unit comes with 2 dry contacts for external monitoring of both the
MI and LI light fixtures which receive the associated alarm in the event of a power or LED
fault. (Note: External dry contact monitoring is unavailable if remote monitoring via GSM or
Satcom has been enabled)
A Photocell Bypass Switch is provided with the Control Unit to override the Photocell output
for system testing and maintenance and is factory-set to AUTO (auto day/night) mode.
The Control Unit with the AC option has an interface switch on the door. The DC version
has a circuit breaker in the cabinet for switching the power ON and OFF.
To test the function of lights for night operation, the system must be operating in Day
mode. Toggle the switch to Override by turning the switch to the right. All lights should
illuminate. To return to the Auto mode, return the switch to the Auto position.
Note: Time delays are to be expected when changing modes. Allow up to 1 minute to
change between functions.

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 11
6.1.2 Interface Wiring
Top Junction
Box
Power cable: 2 x 14mm2
Data cable: 4 x 3mm2
T2 Controller
Data cable: 3 x 2.5mm2
Power cable: 2 x 14mm2
External
Photocell
Power & Data cable: 3 x 2.5mm2
Middle
Junction Box
Power & Data cable:
5 x 4mm2
Power & Data cable:
5 x 4mm2
Power & Data cable:
5 x 4mm2
LI
LI LI
MI
Power & Data cable:
5 x 4mm2

12
7.0 Unpacking, Installation, Wiring and
Setup
7.1 Unpacking
Unpack all hardware and inspect for damage. If there is any damage, please contact your
Avlite Office.
Retain original packing material for possible future use in shipping.
7.2 Installation
WARNING:
Confirm that the power switch is toggled to the OFF position when
power is connected. DO NOT connect power to the PCU when the
control panel power switch is toggled to the PWR position. This may
result in damage to the power sources.
WARNING:
DO NOT connect directly to the DC output of a generator, or any
other unregulated power source. Connecting to an unregulated
source may result in damage.
WARNING:
Do not stare into light emitting diode (LED) beams.
CAUTION:
LED lights contain glass components. Do Not Drop.
Always follow the instructions outlined in the product manual when
cleaning the equipment. Improper cleaning methods and use of
unauthorized cleaning agents can damage equipment.

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
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7.2.1 Tools Required
Tools Needed (not supplied)
Flush Cutter
Tongue & Groove Pliers
Silicone Sealant
Cable Jacket Trimmer (optional)
Utility Knife
Electrical Tape
Insulated Terminal Crimper
Wire Strippers 10AWG to 18AWG Range
2.5mm Hex Key
2.0mm Flat Blade Precision Screwdriver
#2 Phillips Screwdriver
Mounting hardware (optional purchase)
Cables (owner supplied or optional purchase)
7.2.3 Factory Configuration
• External Photocell wired with 7.5 metre flying lead.
• Preassembled T2 Control Unit complete with internal wiring
7.2.4 Installation Recommendation
Note: The sequence of steps can be adjusted for site requirements.
1. Wire and test the system on ground level.
Conduct a basic functional check to ensure that the lights turn on as expected. See section
7.3 Testing Procedure for more information.

14
2. Mount the Control Unit
The Control Unit should be mounted in a reasonable location at eye level to ensure that it
is easily accessible for servicing and maintenance. There should be plenty of clearance
around all sides to allow direct access when the door of the control unit is completely open.
a. Attach the required mounting hardware to the top and bottom of the Control Unit.
b. Mount the Control Unit (with the previously attached mounting hardware) to the tower
or installation structure using the mounting tabs. Secure using the required mounting
fixtures.
Note: Mounting hardware is not included with the Control Unit.
Example of Control Unit mounting hardware
Pre-installed Control Unit tab

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 15
3. Mount External Photocell
Insert the Photocell into the mount (Avlite supplied) by inserting the contact blades into the
receptacle. Secure the Photocell assembly to the tower or installation structure using the
required mounting fixtures.
The following considerations should be taken into account when mounting the external
Photocell:
• Mount in a reasonable location at eye level to ensure that it is easily accessible for
servicing and maintenance.
• The Photocell should be pointed away from the equator (North in Northern
Hemisphere, South in Southern Hemisphere).
• The Photocell should be located away from bright, artificial lighting.
Note: Mounting fixtures are not supplied.

16
4. Wire the Photocell to the Control unit and cut cable to the required length.
Note: The AC version of the Control Unit with remote monitoring is shown throughout
this installation procedure. Details regarding the DC installation are shown on page 19.
Wiring instructions-Power and Data Cable:
• Connect the black positive conductor from the External Photocell to circuit breaker 5
(labelled ‘PC +24VDC’) on terminal block 1 in the Control Unit
• Connect the white negative conductor from the External Photocell to the ‘PC
-Common’ labelled terminal on terminal block 1 in the Control Unit
• Connect the green Photocell signal conductor to the ‘PC Signal’ labelled terminal on
terminal block 1 in the Control Unit
Refer to the AV-OL-KT-A1/I2 Installation and Service manual for recommended cable sizes.

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 17
5. Wiring the Control Unit:
After installing and wiring the Medium Intensity Fixture to the top junction box, route the
top junction box to the control unit. After installing and wiring the Low Intensity Fixtures
to the middle junction box, route the middle junction box to the control unit. Please see
the AV-OL-KT-A1/I2 Installation and Service Manual for more information.
AC Installation:
Connect the incoming power conductors to the appropriate terminals (i.e. AC Line 1, AC line
2 and AC Neutral) on the power switch on terminal block 1 in the Control Unit.
The grounding conductor will be connected to the ‘Ground’ labelled terminal block (green/
yellow) adjacent to the power switch.

18
7.3 Testing Procedure
Note: Avlite recommends that all testing be done during the day.
1. Power the system on.
2. Check that no circuit breakers have tripped.
3. 4. Check function of all lights (i.e. MI and all LI single fixture lights) by carrying out the
following:
a. -Night mode: Cover the External Photocell and check night operation is
functioning as expected. The MI should either flash red (for Type B) or operate
as a red, steady burning light (for Type C). All of the LI single fixtures should be
illuminated red as steady-burning lights.
b. -Day mode: Uncover the External Photocell and check day operation is
functioning as expected. All lights should be off.
4. Turn the Photocell Bypass Switch to Override and ensure that all lights illuminate in
night mode.
5. Turn the Photocell Bypass Switch back to Auto.
6. For 01 & 02 Variants only:
Trip the breaker for the MI and ensure that the corresponding alarm is
received (if monitoring is installed)
Trip the breaker for the LI lights and ensure that the corresponding alarm is
received (if monitoring is installed)
DC Installation:
Connect the positive DC conductor to circuit breaker 1.
Connect the negative conductor to the common terminal block adjacent to the circuit
breaker on terminal block 1.

AV-OL-CTRL-T2 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 19
8.0 Maintenance and Servicing
Refer to the individual light manuals for light maintenance.
Inspect the Control Unit for evidence of dust or water penetration. Repair gaskets or
conduit entries as required.
Inspect Control wiring for failing insulation, open conductors or other wiring flaws and
repair as required.
Ensure Photocell is free from debris (i.e. snow, leaves, etc.) for reliable and continuous
operation.
9.0 Replacement Parts
If replacement parts are required, please call a local Avlite distributor and reference the
Product or Configuration Code called out in the “Product Configuration and Options” section
of the corresponding product data sheet.

20
10.0 Troubleshooting
Problem Possible Cause Solution
MI beacon is out (No
Alarm)
No power to light • Check for voltage in Control
Box.
• Check controller to Beacon
cable connections at both ends.
Junction box wiring • Check junction box wiring.
MI beacon is flashing
white at night
Photocell input is
high
• Check wiring.
• Confirm there is 0 voltage at
the Photocell input.
Beacon in “limp
mode”
• Visually confirm Beacon is
flashing at ½ the intensity of
normal day mode.
A single LI fixture is
out (No Alarm)
Marker wiring • Check the wiring of the
malfunctioning lamp.
Junction box wiring • Check junction box wiring.
All LI Single fixture
lights are out (No
Alarm)
Junction box wiring • Check junction box wiring.
Cable to junction box • Check controller to junction box
cable connections at both ends.
• Inspect cable for breaks.
Light is out • No power to light
• Light failure
• Light in Alarm
Mode
• Physically check connections in
junction boxes and control box.
• If wiring functions properly, use
an alternate power source to
check the light.
• Replace light if necessary.
MI top light is not
operational (no red
mode)
• Wired
incorrectly or
wire(s) lose
• Light failure
• No power to the
light
• Check wiring of light in top
junction box and Control Box.
• Measure voltage at junction
box. If correct input power,
replace light.
• If no voltage to the junction
box, check output power from
Control Box.