Avlite AV-OL-FL864-12-R User manual

AV-OL-FL864-12-R & AV-OL-FL864-UM-R
FAA L-864 Medium Intensity Obstruction Light
Universal DC & Universal AC Models
V1.6
INSTALLATION & SERVICE MANUAL

2
Table of Contents
Introduction 4
Technology 5
AV-OL-FL864-12-R & AV-OL-FL864-UM-R Medium Intensity Obstruction Light 6
Technical Drawings.............................................................................................................................................................. 6
Specifications .......................................................................................................................................................................... 8
Safety Information 9
Unpacking, Installation, Wiring & Setup 10
Unpacking................................................................................................................................................................................ 10
Installation & Wiring........................................................................................................................................................... 10
AC Wiring Configuration...........................................................................................................................................11
DC Wiring Configuration.........................................................................................................................................12
Power Supply Design Considerations......................................................................................................................13
(1) PV Power Systems ..............................................................................................................................................13
(2) Alternating Current (AC) Utility Power.....................................................................................................13
Operation & Setup...............................................................................................................................................................14
Intensity Setting ............................................................................................................................................................14
Alarm Relay Output....................................................................................................................................................14
Led Fault............................................................................................................................................................................15
RS232 and RS422/485 Communication (Optional)..................................................................................15
Optional IR Remote Control 16
Avlite IR Controller / Universal Remote Compatibility.....................................................................................16
IR Controller Functions......................................................................................................................................................17

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
3
Version No. Description Date Author
1.0 Manual launch March 2015 W. Evans
1.1 Spec table update March 2015 J. Dore
1.2 Warranty update March 2015 W. Evans
1.3 Update installation & wiring June 2015 W. Evans
1.4 Spec table update Dec 2016 W. Evans
1.5 Update for FAA AC150_5345_43H May 2017 J. Ohle
1.6 Update Pg 22 Jan 2018 J. Ohle
Optional GPS Synchronization 19
Operating Principle......................................................................................................................................................19
Light Activation..............................................................................................................................................................19
Daylight Operation.......................................................................................................................................................19
Dark Operation ............................................................................................................................................................ 20
GPS Power Demand................................................................................................................................................. 20
Optional GSM Monitoring & Control 21
Troubleshooting 21
Lantern Status 22
Certification 23
Avlite Light Warranty V1.2 24
Other Avlite Products Available 28

4
Introduction
Congratulations! By choosing to purchase an Avlite light, you
have become the owner of one of the most advanced LED
obstruction lights in the world.
Avlite Systems draws on more than 25 years’ experience in the design and
manufacture of navigation aids, and particular care has been taken to ensure
your light 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 light, and be able to maximize its operating function.
Please remember to complete the Avlite warranty registration card
accompanying your light.

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
5
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
AV-OL-FL864-12-R & AV-OL-FL864-UM-R
Medium Intensity Obstruction Light
This Avlite medium intensity LED obstruction light is certified to
the FAA L-864 Medium Intensity Obstruction Lighting advisory
circular 150/5345-43. The light is used to mark obstacles such
as telecommunication and utility towers, wind turbines, cranes,
buildings and other tall structures.
Avlite’s LED obstruction lights offer an ultra-bright, energy efficient and cost effective
lighting solution. The light fixture is available in two configurations, universal DC (12–48VDC)
or universal AC (110–240VAC).
The light fixture incorporates internal diagnostic checking and an alarm contact for remote
monitoring. The alarm relay is energized in normal operation and is released if there is an
LED or power fault.
Technical Drawings
Multiple
LED Optic
7-stage
powder coated
aluminium base
Impact modified
UV-stabilised
acrylic lens
Automatic night
operation
200mm bolt pattern
for ease of installation

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
7
9.06
230
7.07
180
4.21
107
PCD
7.874
200.00
6 Places

8
Specifications • * FAA L-864 MIOL
• Specifications subject to change or variation without notice
*Subject to standard terms and conditions
† Intensity setting subject to solar availability
12–48 VDC 110–240 VAC
Light Characteristics
Available colours Red as standard. Other colours available on request Red as standard. Other colours available on request
Effective Intensity (cd)† 2000cd ± 25% 2000cd ± 25%
Horizontal Output (degrees) 360 360
Vertical Divergence (degrees) 3° 3°
Available Flash Characteristics 0.2s ON, 1.8s OFF – 10% duty cycle 0.2s ON, 1.8s OFF – 10% duty cycle
Electrical Characteristics
Operating Voltage 12 – 48 VDC 110 – 240 VAC 50/60Hz
Power (Average Flashing) 5W Pmax: 5W, Smax: 7.6VA
Power (Peak) 60W Pmax: 60W, Smax 80VA
Circuit Protection Integrated Integrated
Temperature Range -40 to 55°C -40 to 55°C
Physical Characteristics
Body Material 7-stage powder-coated aluminium 7-stage powder-coated aluminium
Lens Material Impact modified UV stabilized acrylic Impact modified UV stabilized acrylic
Lens Diameter (mm/inches) 171 / 6¾ 171 / 6¾
Lens Design Multi LED Optic Multi LED Optic
Mounting 200mm bolt pattern 200mm bolt pattern
Height (mm/inches) 151 / 6 151 / 6
Width (mm/inches) 230 / 9 230 / 9
Depth (mm/inches) 230 / 9 230 / 9
Mass (kg/lbs) 5.5 / 12¼ 5.8 / 12¾
Product Life Expectancy 12 years plus 12 years plus
Environmental Factors
Humidity 0 to 100%, MIL-STD-810F 0 to 100%, MIL-STD-810F
Icing 3.41kg per square cm /
48.5lbs per square inch
3.41kg per square cm /
48.5lbs per square inch
Wind Speed Up to 240kph / 150mph Up to 240kph / 150mph
Certifications
CE EN61000-6-3:2007
EN61000-6-1:2007
EN61000-6-3:2007
EN61000-6-1:2007
Quality Assurance ISO9001:2015 ISO9001:2015
FAA, DGAC. L-864 Medium Intensity Obstruction Light
(Qualified by Intertek)
L-864 Medium Intensity Obstruction Light
(Qualified by Intertek)
Waterproof IP68 IP68
Intellectual Property
Trademarks AVLITE®is a registered trademark of Avlite Systems AVLITE®is a registered trademark of Avlite Systems
Warranty * 5 year warranty 5 year warranty
Options Available • Variety of solar/battery configurations
• GSM Cell-Phone Monitoring
• GPS Synchronisation
• RS422/485 communications port
• GSM Cell-Phone Monitoring
• GPS Synchronisation
• RS422/485 communications port

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
9
Safety Information
• Install the light in compliance with the effective 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.
• Operate the light only within the indicated electrical ratings and product usage
instructions.
• To ensure that the light and peripheral equipment function safely and correctly, use
cable in compliance with the effective local electrical code.
• Do not stare at the LED or shine the LED into your eyes or those of another person.
• Do dispose of the product according to the local laws and regulations for your region, for
example, at a recycling center that accepts electronic devices.

10
Unpacking, Installation, Wiring & Setup
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.
Installation & Wiring
Before proceeding with installation or service, make sure the following conditions are met:
• Ensure the tower or mast is grounded (NO RF 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.
The obstruction light is manufactured with an input power cable of
length defined at the time of order. One end of the input power cable is
pre-terminated at the light fixture.
Connect the provided input power cable to the corresponding power
source in accordance with figure 1 for AC installations and figure 2 for
DC installations.

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
11
AC Wiring Configuration
External:
Internal:
Australia/ Europe/ UK USA/ Canada
Active/Live (L1) Brown Black
Neutral (L2) Blue White
Earth Green/Yellow Green
Cable: 3-core
1 2 4 5 6
RS422RS422
RS232RS232
ALARM
7 8 93 10 11 12 13 14
AC/DC
LED driver
uP
LED
POWER
Light in
normal
operation
Programming Port
No. Connector Signal
1POWER L1
2POWER L2
3POWER GND
4ALARM COMM
5ALARM NO
6ALARM NC
7RS232 GND
8RS232 RxD
9RS232 TxD
10 RS422 GND
11 RS422 -VE (Rx)
12 RS422 +VE (Rx)
13 RS422 -VE (Tx)
14 RS422 +VE (Tx)
15 IO-1 3V3
16 IO-1 OUT-1
17 IO-1 0V
18 IO-1 IN-1
19 IO-1 0V

12
DC Wiring Configuration
External:
Internal: No. Connector Signal
1+VIN +VDC
2-VIN -VDC
3ALARM COMM
4ALARM NO
5ALARM NC
6RS232 GND
7RS232 RxD
8RS232 TxD
9RS422 GND
10 RS422 -VE (Rx)
11 RS422 +VE (Rx)
12 RS422 -VE (Tx)
13 RS422 +VE (Tx)
14 IO-1 3V3
15 IO-1 OUT-1
16 IO-1 0V
17 IO-1 IN-1
18 IO-1 0V
Figure 2
Cable: 2-core
1 2 3 4 5
RS422
RS232
6 7 8 9 10 11 12 13 14 15 16 17 18
LED driver
uP
DC/DC
Light in normal
operation
Programming Port
+Vin -Vin ALARM RS232 RS422 IO-1
LED

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
13
Power Supply
Design Considerations
Avlite’s medium intensity obstruction lights are designed to operate over a wide operational
voltage range and thus the average power consumption will vary accordingly.
There is a vast array of power sources that can be utilized for Avlite’s medium intensity
obstruction lights. However, the vast majority of customer power supplies comprise of
either Photovoltaic Power or AC Utility and as such this bulletin will focus on these types
and how they apply to Avlite’s FAA L864 Medium Intensity Obstruction Lights.
Contact Avlite for advice when designing your power supply.
(1) PV Power Systems
These systems generally comprise of a 1 or more PV panels, a solar regulator and storage
battery. Batteries such as SLAs are very tolerant of fast switch high peak currents as they
electrically behave like large smoothing capacitors, solar sizing depends on a number of
factors. For Avlite obstruction lights, pay particular attention to average power consumption
and power cable sizing.
(2) Alternating Current (AC) Utility Power
In their simplest form, these systems comprise an AC/DC power supply converter. Unlike
PV Power Systems, AC/DC Power Supplies are limited to their internal storage capacity
and as such are not able to maintain voltage regulation to fast switch currents.
As such a lantern’s peak current must be determined when selecting an AC/DC power
supply. For Avlite’s Obstruction Lights, the peak current can be determined by using the
following equation:
Peak current (A) = Peak Power (W)) / (Supply Voltage (Vdc)
Using this method, the peak current for the Avlite FL864 Obstruction Light:
Peak Current (A) = 60 / 12 = 5 A
As an AC/DC power supply has minimal storage capacity the selected power supply must
be capable of delivering the lights peak current for all conditions. Other considerations such
as de-rating the AC/DC power supply due to environment and usage.
Peak Power is the maximum power rating of a light. In an instant of time,
this is the maximum power the light will consume. It is determined when
all a light’s features are on and the LEDs intensity is at 100%.
No. Connector Signal
1+VIN +VDC
2-VIN -VDC
3ALARM COMM
4ALARM NO
5ALARM NC
6RS232 GND
7RS232 RxD
8RS232 TxD
9RS422 GND
10 RS422 -VE (Rx)
11 RS422 +VE (Rx)
12 RS422 -VE (Tx)
13 RS422 +VE (Tx)
14 IO-1 3V3
15 IO-1 OUT-1
16 IO-1 0V
17 IO-1 IN-1
18 IO-1 0V

14
Operation & Setup
When powered up, the light will constantly check day/night status using its internal
ambient light sensor. The ambient light sensor averages its measurement for 30 seconds.
FAA: By default, the lights turn ON when the ambient light decreases to not less than 35
foot-candles (367.7 lux) and turn OFF when the ambient light increases to not more
than 60 foot-candles (645.8 lux). These limits can be factory adjusted, if required.
Intensity Setting
The fixture will be supplied with a FAA compliant optic.
The obstruction light will be pre-set to the intensity setting required to produce a FAA
compliant photometric profile. The intensity is pre-set in the factory and does not need to
be set by the user.
Alarm Relay Output
In normal operation, the relay is energized
• Terminal contacts COMM and NC of the relay are electrically closed
• Terminal contacts COMM and NO of the relay are electrically open
Whenever the LED is not lit due to a power failure and/or a LED failure the relay will not be
energized.
• Terminal contacts COMM and NO of the relay are electrically closed
• Terminal contacts COMM and NC of the relay are electrically open
The alarm relay comes configured as follows:
• Relay normal operation (default, as described above)
The following alarm relay configurations are available as a special order.
These must be specified at the time of order:
• Relay inverse operation (inverse functionality of the normal operation,
used to conserve power)
• Relay disable (in case the relay is not required, used to conserve power)
The alarm relay is intended for low voltage (SELV) connection only.
NOT FOR MAINS CONNECTION

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
15
Led Fault
In the event of a singular LED fault, either open circuit or closed circuit across the LED, the
light unit will turn off all LED’s and actuate the Fault Relay.
RS232 and RS422/485 Communication (Optional)
The Obstruction Light offers a RS232 and a R2422/485 interface.
RS232 Typical 3 pin TxD, RxD and GND arrangement
RS422/485 Typical 4 pin arrangement with Termination selection and Duplex/Simplex
selection. For location details please refer to Figure 1 & 2.
Please contact Avlite for further details.
Duplex
SW3
S1 S2
OFF OFF Simplex operation
ON ON Duplex operation
Termination
SW4
S1 S2
OFF OFF No termination
ON ON 120 Ohm termination

16
Optional IR Remote Control
The IR remote is used to communicate with Avlite lighting products
that have an IR sensor fitted. The remote control is used for the
following functions:
• Operational Mode: dusk-to-dawn, standby or always-on.
• Ambient Light Thresholds: read the current light thresholds,
configure new ambient light thresholds.
• Perform a battery health check.
On receiving a valid key signal from the IR Remote, the light will
flash once. The user should wait until the light responds to each
keypress before pressing another key. If there is no response to
the keypress after 3 seconds, it has not been detected by the light
and the key can be pressed again.
If an invalid key is detected, the light will flash quickly 5 times.
In this case, the command will have to be restarted.
Avlite IR Controller / Universal Remote Compatibility
If you lose your Avlite IR Controller, the following Universal Remote Controller has been tested
for compatibility: RCA Type RCR312WR programmed for Phillips TV Type Code 10054
T/CT/C
Read Lux
Flash Code Intensity Battery Status
Test / Congure
R L
FC I B
3
4 5 6
7 8 9
0
1 2
Avlite Key Universal Remote Key
TPower
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
0 0
RChannel+
LMute
FC Volume+
IVolume-
BChannel-

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
17
IR Controller Functions
Test Mode / Configure
T/CT/C
Pressing the T/C button for up to 5 seconds places the light in Test Mode. The light will
flash once in response to the T/C button being pressed and then turn off.
Normal Operation
The light will return to normal operation once it has not detected a valid key press for 30
seconds. The light will flash once to indicate it is returning to normal operation.
Read
Pressing the Read followed by one of the configuration keys shall cause the light to flash
the configured value.
Example Key Sequences:
T/CT/C
RBThe light flashes the current battery status.
T/CT/C
RI
BThe light flashes the Operational Mode. Modes are as follows:
1 flash = Always-On
2 flashes = Standby
3 flashes = Dusk-to-Dawn
Operational Mode
The light has three modes of operation: Always on, Standby Mode and Dusk-to-Dawn
mode. These modes can be selected either via the IR remote control or via the GSM
module (if fitted).
In Always On mode, the daylight sensor is disabled and the lantern will remain ON.
In Standby mode, the lantern is turned off and the daylight sensor is disabled. This mode
does not affect the operation of the GSM module.
In Dusk-to-Dawn, the daylight sensor is enabled.
T/CT/C
T/CT/C
T/CT/C
I
I
I
B
B
B
1
2
3
Always on mode
Standby mode
Dusk-to-Dawn mode

18
Battery Status (12V System Only)
B
This function reads the battery status. The response from the light is:
4 flashes = High Voltage
3 flashes = Good Voltage
2 flashes = Low Voltage
1 flashes = Cut-off Voltage or below
Example Key sequence:
T/CT/C
RB
Error/Acknowledge Indication
If the key sequence is invalid, or an out of bounds value is attempted to be set, the light
flashes 5 times for 1 second. (The command then needs to be sent from the start.)
Example key sequence: (Set the intensity level to 5 – undefined.)
T/CT/C
I5
The light flashes 5 times for 1 second.
When a key sequence has been entered successfully the light will respond
acknowledgement with a 1 second flash.

FAA L-864 Medium Intensity Obstruction Light
Universal AC & Universal DC Models
Latest products and information available at www.avlite.com
19
Optional GPS Synchronization
Avlite has utilized the latest advancements in GPS technology to develop an internal
synchronization system that can be incorporated into the lights. Using overhead satellites,
multiple obstruction lights set to the same flash pattern will flash in unison.
No additional power supplies, aerials or control systems are required, and with its
microprocessor- based system, the GPS option is specifically designed to provide
maximum reliability and performance over a wide range of environmental conditions.
Operating Principle
Each light operates independently and requires no operator intervention. A minimum
of 4 satellites need to be in view for the built-in GPS receiver to collect time data. At
dusk, the light sensor will turn the light on. If time data is available, the light will come on
synchronized to every other light with the same selected flash code.
Synchronization is achieved using an internal algorithm based on the highly accurate
time base and time data received from the satellites. The satellite data is provided from a
number of earth stations using atomic clocks as the time base. Continuous self-checking
ensures that the light will continue to run in synchronization.
Light Activation
At power-up the microprocessor checks that the internal GPS module is programmed
correctly and is able to provide valid time base and time data.
Once outside with a clear view of the sky, valid data should become available within 20
minutes.
Daylight Operation
During daylight hours, the microprocessor is in idle mode to reduce power consumption.
Time data continues to be updated once per second. The microprocessor will automatically
exit the idle mode as soon as dark conditions are detected.

20
Dark Operation
When dark conditions are detected the light:
• Checks for valid time data and is turned on after a delay based on the current time and
the length of the selected flash code;
• If valid time data is not detected the light will turn on after approximately 10 seconds.
This light will not be synchronized.
• If the light turns on unsynchronized it will continually check for valid time data. Once
valid data is found the light will automatically synchronize.
Lights will not synchronize if different flash codes are selected.
GPS Power Demand
The GPS synchronization feature has been designed to function with a very low power
demand. Typically, the total 24hr current used by the GPS module is 36mAh. This is
approximately equivalent to 8 minutes of solar charging.