Avlite AV-OL-KT-I1 Supplement

V1.0
INSTALLATION & SERVICE MANUAL
AV-OL-KT-I1
Obstruction Lighting Kit
ICAO - I-1

2
Version No. Description Date Reviewed Approved Design
1.0 AV-OL-KT-I1 Manual Launch November 2019 P. Naidu W. Evans M. Sugars

AV-OL-KT-I1 - Obstruction Light Kit
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-KT-I1 Models..................................................................................................6
3.1 Available Options....................................................................................................................................... 8
4.0 AV-OL-KT-I1 Data Sheet ..........................................................................................9
5.0 Safety Information..................................................................................................10
6.0 Operation and Setup...............................................................................................11
6.1 System Overview.......................................................................................................................................11
6.2 LI Dual Light Fixture.................................................................................................................................11
6.3 T1 Controller.................................................................................................................................................13
7.0 Unpacking, Installation, Wiring and Setup ......................................................... 14
7.1 Unpacking ......................................................................................................................................................14
7.2 Installation......................................................................................................................................................14
7.2.1 Tools Required ..................................................................................................................................15
7.2.2 Location ...............................................................................................................................................15
7.2.3 Cabling Requirements.................................................................................................................16
7.2.4 Factory Configuration..................................................................................................................16
7.2.4 Installation Recommendation .................................................................................................16
7.3 Testing Procedure....................................................................................................................................21
8.0 Maintenance and Servicing .................................................................................. 21
9.0 Replacement Parts ................................................................................................. 21
10.0 Troubleshooting.......................................................................................................22

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 kit, 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
LIOL Low Intensity Obstruction Light
ILAB ICAO Low Intensity Type A and B
LI Low Intensity

AV-OL-KT-I1 - Obstruction Light Kit
Installation & Service Manual
Latest products and information available at www.avlite.com 5
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-KT-I1
The AV-OL-KT-I1 Obstruction Lighting Kit is a full turnkey solution for I-1 structures of up to
45m above ground level (AGL). These include telecommunication towers and utility towers,
wind turbines, cranes, buildings and other tall structures.
The I-1 Obstruction Solution comes fully assembled, ready to install, and includes the
following items:
• 1 x Low Intensity (LI) Dual Obstruction Light with integral Photocell
• Central Control Unit
The LI dual light fixture is a low intensity LED obstruction light designed to comply with
ICAO LIOL Type A and Type B requirements. It is set to illuminate at night in the Steady-
burning configuration for I-1. The LED optics offer an energy efficient and cost- effective
lighting solution.
The I-1 Obstruction Light Solution is available in two input power configurations; a universal
AC (100-264VAC) or DC (12-48VDC) (solar compatible) and comes with Star2M™ monitoring
via GSM or SATCOM as options.
With a range of available brackets and cables, 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 lighting kit components.
• AV-OL-LI-D Installation and Service Manual

AV-OL-KT-I1 - Obstruction Light Kit
Installation & Service Manual
Latest products and information available at www.avlite.com 7
Note: Mounting hardware not included.
1 x Control Unit
1 x LI Dual Obstruction Light Dual AV-OL-LI-D
[10.3in]
259.2mm
[5.3in]
133mm
[8.5in]
216mm
[12.75in]
323.9mm
[13.5in]
342.9mm
[10in]
254mm
[12in]
304.8mm
[6.66in]
169.1mm

8
3.1 Available Options
• Solar Input Power (for 12-48VDC) – Call Avlite for details.
• Cable Kit (for 45m height)
50m of 2.5mm2, 3 conductor wire.
• Light Mounting Brackets
For LI Dual Obstruction light: Right Angle Mounting Bracket-Low Intensity
Fixtures
Please Contact Avlite for details.
• 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.
• Mounting Bolt Kit (includes bolts, nuts, washers)
Please contact Avlite for further details.

AV-OL-KT-I1 - Obstruction Light Kit
Installation & Service Manual
Latest products and information available at www.avlite.com 9
4.0 AV-OL-KT-I1 Data Sheet
* Calculated using Dual LI Type B lights.
+ Please refer to the individual light installation manuals for further specifications
ICAO I-1 Obstruction Kit AC DC
Electrical Characteristics
Input Voltage 100-264VAC 12-48VDC
Input Frequency 50/60 Hz N/A
Power Consumption
Peak 20VA 6W
Average* Night: 15VA Night: 4.5W
Physical Characteristics
Dimensions Height
(inches/mm)
Width
(inches/mm)
Lens Diameter
(inches/mm)
Mass
(lbs./kg)
LI Dual 8.5 / 216 10.3 / 259.2 5.3 / 133 2.53/ 1.15
Control Unit 13.5 / 343 12 / 305 6.66 / 169 16 / 7.3
Mounting
LI Dual ¾ inch pipe thread
Control Unit Wall mounted (mounting accessories available)
Certifications and Compliance
CE EN61000-6-3:2007, EN61000-6-1:2007
FCC 47 CFR Part 15, subpart B
Quality Assurance ISO9001:2015
Protection Rating Junction and Control Box: IP65/NEMA4X Lights: IP68
ICAO Low Intensity Obstruction Light Type A & B
Intellectual Property
Trademarks AVLITE®is a registered trademark of Avlite Systems
Warranty +5 year warranty on light fixtures
3 year warranty on Control Unit
Options Available Mounting Brackets
Solar Input Power (for 12-48VDC)
Cable Kit (for 45m height)
Remote Monitoring and Control
Mounting Bolt Kit (includes bolts, nuts, washers)

10
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.
• Make sure the mounting pole is vertically aligned to guarantee the required beam
pattern of the obstruction light.
• Make sure any nearby obstacles do not impede the lights’ beam pattern.
• 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.
• 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.
• Dispose of the product according to the local laws and regulations for your region, for
example, at a recycling centre that accepts electronic devices.

AV-OL-KT-I1 - Obstruction Light Kit
Installation & Service Manual
Latest products and information available at www.avlite.com 11
6.0 Operation and Setup
6.1 System Overview
Avlite’s I1 Obstruction Lighting Solution Kit consists of two components: A Control Unit
which provides power and (optional) remote monitoring and a red, steady burning, Dual
Obstruction Light fixture.
The LI Dual Light fixture is designed to comply with ICAO LIOL Type A & B requirements
and operates as a concurrent fixture where both individual lights operate at the same time.
The I1 Obstruction Lighting Kit automatically switches between day and night mode via an
integrated Photocell. When powered up, the LI Dual light fixture constantly checks day/
night status using its internal Photocell which then averages the light measurement for 30
seconds.
The Dual 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.
The Control Unit automatically evaluates the LI Dual light fixture 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.
6.2 AV-OL-KT-I1 Obstruction Lighting Kit
Power and Data
Positive (+VDC) Red
Negative (-VDC) Black
Alarm Signal NC Green

12
-A3
Visio 2016
mm
Dra wn i n:-
Units
Sheet Size:-
nat uralFinish:-
Mechanical Layout
N/A
0
Wt(Kg) each:-
Ma te r ia l /Q ua nt i ty
C. Bernardo
N/A
001588-0 06 -000
N/A
Genera l Toler ances
Lin ea r
X
X.X
X.X X
±1.2
±0.3
±0.1
Angul ar
X
X.X
±1.0°
±0.5 °
±2.0
±0.5
Radii
X
X.X Drawing Rev:-
Dr a wn: -
Approve d:-
Checked:-
22/05/2018
-
Qty per Ass' y:-
Dr awing No:-
File Name:-
Sheet
Scale
Pr oj ec t ion
Ne xt A ss 'y :-
N.T.S
Model Rev:-
Sealite
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N:\4. Sales\4. Product Management & Partners\Admin\Strategy - Aviation\FAA lighting kits A0,A1,E1\A0\IMAGES\for interface diagram\
001588-006-000 - DC Dual Lig ht Head, Concurrent Lit C onnection D iagram
Rev3 - with re duced wiring .vsdx
2of 2
J .O hl e 25/05/2018
Y. Chambers 28/05/2018
PCB-1703-01-RE V: 1
DATE: 13/ 11/2017
J1
J7
J6
J3
422+
422 -
422+
422 -
J5
J2
Main Cable
External DC cable length
Max 25 meter
Sea li t e
www.sealite.c om
Red
Grey
White
Black
Violet
Red
Grey
White
Black
Violet
+DC -DC
Not e:
-Light Heads come pre-wired to the board, hence,
wiring not shown.
-Ensure that a ll pr e-existing wiring remains in the
original locations.
Relay
TxD
RxD
GND
TxD
RxD
GND
RS-232
INTENSITY
FULL
HALF
D UP LE X
SW2
ON
1 2 ON
1 2
ON
1 2
TERMIN ATE
+VE -VE +VE -VE GND
Tx Rx
RS-422
ALARM
Relay
TxD
RxD
GND
TxD
RxD
GND
RS-232
INTENSITY
FULL
HALF
D UP LE X
SW2
ON
1 2 ON
1 2
ON
1 2
Tx Rx
RS-422
+VE -VE +VE -VE GND
TERMIN ATE
+VDC
0V
GND
COMM
NO
NC
+VDC
0V
GND
COMM
NO
NC
POWER AL ARM
Light Intensity & Operation Mode Setting
The fixture will be supplied with the ICAO compliant optic. By default, the ICAO compliant
model comes pre-set as an ICAO Type A fixture for a red, steady burning Low Intensity
obstruction light in dusk-till- dawn mode.
If the customer should need to change the intensity or operation mode settings of the ICAO
compliant model they can do this by changing the INTENSITY DIP switch. Please refer to
the table below for DIP switch settings and the figure above for circuit board location.
For more information regarding the LI Dual Obstruction light Fixture, please consult
the relevant sections of the corresponding service and installation manual.
Global
Position 1 Position 2 Light Intensity
OFF OFF ICAO Low Intensity Obstruction Light Type A (10cd), dusk-
till-dawn mode – DEFAULT
OFF ON ICAO Low Intensity Obstruction Light Type A (10cd), 24
hour mode
ON OFF ICAO Low Intensity Obstruction Light Type B (32cd), dusk-
till-dawn mode
ON ON ICAO Low Intensity Obstruction Light Type B (32cd), 24
hour mode

AV-OL-KT-I1 - Obstruction Light Kit
Installation & Service Manual
Latest products and information available at www.avlite.com 13
6.3 T1 Controller
The T1 Control Unit is an essential component of the I1 Obstruction Lighting Kit as it
provides power and monitoring of the Dual light fixture in the system.
For safety and security, the control enclosure 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 (100-264 VAC)
or DC (12-48 VDC) and comes with remote monitoring via Star2M with either GSM or
Satcom telemetry types as options.
The Control unit comes with an alarm contact for remote monitoring of the Dual Light
Fixture which receives the associated alarm in the event of a power or LED fault.
6.3.1 Interface Wiring
Power & Data cable :
3 x 4mm2
T1 Controller
LI Dual Light Fixture

14
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-KT-I1 - Obstruction Light Kit
Installation & Service Manual
Latest products and information available at www.avlite.com 15
7.2.1 Tools Required
7.2.2 Location
Refer to ICAO Annex 14 Aerodromes Design and Operations (7th Edition) for site
requirements for obstruction lights.
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
Junction Boxes (2) (owner supplied or optional
purchase)
Light Mounting Brackets (4) (optional purchase)
Cables (owner supplied or optional purchase)

16
7.2.3 Cabling Requirements
The installation of the AV-OL-KT-I1 Obstruction Lighting Kit requires the following cables (if
optional cable kit is not purchased):
7.2.4 Factory Configuration
Dual light fixture with both light heads preassembled.
7.2.5 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. Refer to
Section 7.3 Testing Procedure.
Reference Point Cable
Dual Obstruction Light-Control Unit • Power & Data Cable: 2.5mm2, 3 Conductor

AV-OL-KT-I1 - Obstruction Light Kit
Installation & Service Manual
Latest products and information available at www.avlite.com 17
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 kit.
Example of Control Unit mounting hardware
Pre-installed Control Unit tab

18
3. Install the LI Dual Light Fixture
Mount the Dual Light Fixture onto the rigid conduit using the ¾” NPT thread.
a. Mount dual assembly to 3/4” NPT thread fitting or use optional mounting hardware.
b. Open enclosure by removing the locking pin.
c. Connect wires for interfacing cable into provided junction points as shown in section
6.2 AV-OL-KT-I1 Obstuction Lighting Kit
Note: Dual light head is preassembled.

AV-OL-KT-I1 - Obstruction Light Kit
Installation & Service Manual
Latest products and information available at www.avlite.com 19
4. Route LI Dual light fixture to Control Unit cables
Wiring Instructions - Power and Data Cable:
• Connect the red positive conductor from the dual light fixture to the +24VDC terminal
block in the Control Unit
• Connect the black negative conductor from the dual light fixture to the -24VDC
terminal block in the Control Unit
• Connect the green alarm conductor from the dual light fixture to the Alarm terminal
block in the Control Unit

20
5. Wiring the Control Unit:
AC Installation:
Avlite has supplied a cord grip for installation of the power cord in the bottom of the Control
Box. Connect the incoming power conductors to the appropriate terminals (L1 and L2) on
the power switch in the Control Box.
The grounding conductor will be connected to the green/yellow GND terminal block
adjacent to the power switch.
DC Installation:
Connect the positive conductor to terminal 1 on terminal block 1.
Connect the negative conductor to terminal 3 on terminal block 1.