Avlite AV-OL-CTRL-T3 Supplement

V1.0
INSTALLATION & SERVICE MANUAL
AV-OL-CTRL-T3
Obstruction Lighting Controller

2
Version No. Description Date Reviewed Approved Design
1.0 AV-OL-CTRL-T3 Manual Launch October 2020 P. Naidu W. Evans M. Sugars

AV-OL-CTRL-T3 - 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-T3 Models...........................................................................................6
3.1 Available Options........................................................................................................................................7
4.0 AV-OL-CTRL-T3 Data Sheet....................................................................................8
5.0 Safety Information....................................................................................................9
6.0 Operation and Setup..............................................................................................10
6.1 System Overview..................................................................................................................................... 10
6.1.1 T3 Controller...................................................................................................................................... 10
6.1.2 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 Settings..............................................................................................................................14
7.2.3 Installation Recommendation.................................................................................................14
7.3 Testing Procedure....................................................................................................................................21
8.0 Maintenance and Servicing ..................................................................................22
9.0 Replacement Parts .................................................................................................22
10.0 Troubleshooting..................................................................................................... 23

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 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
CMI Combined Medium Intensity
LI Low Intensity

AV-OL-CTRL-T3 - 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-T3
The AV-OL-CTRL-T3 Obstruction Lighting Controller is an application specific control and
monitoring a full turnkey solution for E1/I3 structures ranging between 61-106 meters (201
and 350 feet). These include telecommunication towers and utility towers, wind turbines,
cranes, buildings and other tall structures.
The T3 Obstruction Controller comes as a fully assembled, ready to install central controller.
The T3 Obstruction Controller is available in two input power configurations, a universal AC
(90-264VAC) or 48 VDC (solar compatible) and comes with Star2M monitoring via GSM or
SATCOM as options.
The best in class system power draw allows structure owners to utilise solar power 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 of the obstruction lighting
solutions.
[24in]
610mm
[25.6in]
652mm
[26.5in]
673mm
[18.5in]
470mm
[20.5in]
505mm
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
[10.3in]
261mm
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-T3 - Obstruction Light Controller
Installation & Service Manual
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3.1 Available Options
• Solar Input Power (for 48VDC) – Call Avlite for details.
• Cable Kit (suitable for 106 m structure) Includes:
114m of 2.5mm2, 3 conductor wire
114m of 14mm2, 2 conductor wire
99m 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.

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4.0 AV-OL-CTRL-T3 Data Sheet
AC DC
Electrical Characteristics
Input Voltage 90-264VAC 48VDC
Input Frequency 50/60 Hz N/A
Power Consumption (Full Load)
Peak 555VA 490W
Physical Characteristics
Mounting Wall mounted (mounting accessories available)
Height (mm/inches) 610/24
Width (mm/inches) 505/19.9
Length (mm/inches) 241/9.5
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 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-T3 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 9
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-T3 Obstruction Control Unit can connect to four components: a single
red and white Combined Medium Intensity obstruction beacon (CMI), 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 T3 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 T3 Controller
The T3 Control Unit provides power, control and monitoring of
the light fixtures in the system.
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 remote monitoring via
Star2M with either GSM or Satcom telemetry types as options.
By default, the control unit comes with 2 dry contacts for
external monitoring of both the CMI and LI single light fixtures
which receive the associated alarm (i.e. Group 2 for the CMI and Group 1 for the LI single
fixture lights) 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. It is factory-set to AUTO (auto day/night) mode.
To test the function of lights for day operation, turn the Photocell Bypass Switch to the Day
position. The CMI should flash white while the LI Single light fixtures remain off.
To test the function of lights for night operation, turn the Photocell Bypass Switch to the
Night position. The CMI should be illuminated red and should either flash (for CMI Type
A & B) or remain steady-burning (for CMI Type A & C). All LI Single Fixtures should be
illuminated red.
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-T3 - Obstruction Light Controller
Installation & Service Manual
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6.1.2 Interface Wiring
Top Junction
Box
Power cable: 2 x 14mm2
Data cable: 4 x 3mm2
T3 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:
4mm2
LI
LI LI
CMI
Power & Data cable:
5 x 4mm2

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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-T3 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 13
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 Brackets (optional purchase)
Cables (owner supplied or optional purchase)
7.2.2 Factory Configuration
• External Photocell wired with 7.5 metre flying lead.
• Preassembled T3 Control Unit complete with internal wiring.
7.2.3 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 control unit is operating as expected.
See section 7.3 Testing Procedure for more information.

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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-T3 - 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 21.
Note: Please see the AV-OL-KT-E1/I3 Installation and Service Manual for recommended
cable sizes.
Wiring instructions-Power and Data Cable:
• Connect the positive conductor from the External Photocell to the circuit breaker
labelled ‘PC +VDC’ in the Control Unit.
• Connect the negative conductor from the External Photocell to the ‘PC Common’
labelled terminal block in the Control Unit
• Connect the Photocell signal conductor to the ‘PC Signal’ labelled terminal block in the
Control Unit
Refer to the AV-OL-KT-E1/I3 Installation and Service manual for recommended cable sizes.

AV-OL-CTRL-T3 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 17
5. Wire the Combined Medium Intensity circuit to the Control Unit
Wiring Instructions-Power Cable:
• Connect the positive conductor from the Combined Medium Intensity Circuit to the
appropriately marked circuit breaker (i.e. Label ‘CMI +VDC’) in the Control Unit
• Connect the negative conductor from the Combined Medium Intensity Circuit to the
‘CMI -VDC’ labelled terminal block in the Control Unit

18
Wiring Instructions-Data Cable:
• Connect the Alarm Common (COM) conductor from the Combined Medium Intensity
Circuit to the ‘CMI Alarm Common’ labelled terminal block in the Control Unit
• Connect the Alarm Signal (NC) conductor from the Combined Medium Intensity Circuit
to the ‘CMI Alarm Signal’ Labelled terminal block in the Control Unit
• Connect the Photocell Signal (PC) conductor from the Combined Medium Intensity
Circuit to the ‘CMI PC Input’ labelled terminal block in the Control Unit

AV-OL-CTRL-T3 - Obstruction Light Controller
Installation & Service Manual
Latest products and information available at www.avlite.com 19
6. Wire the Low Intensity Circuit to the Control Unit
Wiring Instructions-Power and Data Cable:
• Connect the positive conductor from the Low Intensity Circuit to the appropriately
marked circuit breaker (i.e. Label ‘LI +VDC’) in the Control Unit
• Connect the negative conductor from the Low Intensity Circuit to the ‘LI -VDC’ labelled
terminal block in the Control Unit
• Connect the Alarm Common (COM) conductor from the Low Intensity Circuit to the ‘LI
Alarm Common’ labelled terminal block in the Control Unit
• Connect the Alarm Signal (NC) Conductor from the Low Intensity Circuit to the ‘LI
Alarm Signal’ labelled terminal block in the Control Unit
• Connect the PC conductor from the Low Intensity Circuit to the ‘LI PC Input’ labelled
terminal block in the Control Unit
•

20
5. Wiring the Control Unit:
AC Installation:
Connect the incoming power conductors to the appropriate terminals (AC Neutral, AC Line
1 and AC Line 2) on the power switch in the Control Box.
The grounding conductor will be connected to the green/yellow ‘Ground’ terminal block
adjacent to the power switch.