Cooper Crouse-Hinds CHB 204 User manual

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
CHB204 -2S, PB, X; 205-11S; 204-2S, PB;
208-2S; 304-2S; 305-2S
Obstruction Lighting System IF 1544
Front Matter
Abstract
This manual contains information and instructions for installing, operating and maintaining
the CHB 204, 304, 205, 305, 207 and 208 Obstruction Lighting Systems.
Copyright
Copyright © 2007, Cooper Crouse-Hinds, Syracuse, NY 13221
All rights reserved. Reproduction or use of any portion of this manual is prohibited without
express written permission from Cooper Crouse-Hinds and/or its licenser.
Trademark Acknowledgements
Cooper Crouse-Hinds is a registered trademark name.
All trademarks and product names mentioned are properties of their respective companies,
and are recognized and acknowledged as such by Cooper Crouse-Hinds.
Applicable Specifications
This equipment meets or exceeds requirements for an FAA Type L-856 and L-857.
Disclaimer
While every effort has been made to ensure that the information in this manual is complete,
accurate and up-to-date, Cooper Crouse-Hinds assumes no liability for damages resulting
from any errors or omissions in this manual, or from the use of the information contained
herein. Cooper Crouse-Hinds reserves the right to revise this manual without obligation to
notify any person or organization of the revision.
In no event will Cooper Crouse-Hinds be liable for direct, indirect, special, incidental, or
consequential damages arising out of the use of or the inability to use this manual.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Warranty
Cooper Crouse-Hinds warrants all components, under normal operating conditions, for 2
years.
Parts Replacement
The use of parts or components, in this equipment, not manufactured or supplied by Cooper
Crouse-Hinds voids the warranty and invalidates the third party testing laboratory
certification which ensures compliance with FAA Advisory Circulars 150/5345-43E,
150/5345-51 and 150/4345-53B. The certification is valid as long as the system is
maintained in accordance with FAA guidelines (FR doc. 04-13718 filed 6-16-04).
Personnel Hazard Warning
Dangerous Voltages
Dangerous line voltages reside in certain locations in this equipment. Also, this equipment
may generate dangerous voltages. Although Cooper Crouse-Hinds has incorporated every
practical safety precaution, exercise extreme caution at all times when you expose circuits
and components, and when you operate, maintain, or service this equipment.
Avoid Touching Live Circuits
Avoid touching any component or any part of the circuitry while the equipment is operating.
Do not change components or make adjustments inside the equipment with power on.
Dangerous Voltages Can Persist with Power Disconnected
Under certain conditions, dangerous voltages can be present because capacitors can retain
charges even after the power has been disconnected.
Protect yourself — always turn off the input (primary) power and wait for one minute for
storage capacitors to drain their charge. Then check between the red and blue wires on the
flashhead terminal block with a voltmeter for any residual charge before touching any circuit
element or component.
Do Not Depend on Interlocks
Never depend on interlocks alone to remove unsafe voltages. Always check circuits with a
voltmeter. Under no circumstances remove or alter any safety interlock switch.

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Table of Contents
CHB 204-2S,PB,X; 205-11S; 207-2S,PB; 208-2S; 304-2S; 305-2S.....Error! Bookmark not
defined.
Front Matter...............................................................................................................................i
Abstract..................................................................................................................................i
Copyright ...............................................................................................................................i
Trademark Acknowledgements.............................................................................................i
Applicable Specifications ...................................................................................................... i
Disclaimer..............................................................................................................................i
Warranty ...............................................................................................................................ii
Parts Replacement.................................................................................................................ii
Personnel Hazard Warning.......................................................................................................ii
Dangerous Voltages..............................................................................................................ii
Avoid Touching Live Circuits..............................................................................................ii
Dangerous Voltages Can Persist with Power Disconnected.................................................ii
Do Not Depend on Interlocks...............................................................................................ii
Table of Contents.....................................................................................................................iii
List of Figures........................................................................................................................... v
Section 1 – Introduction and Operation.................................................................................... 1
System Controller ................................................................................................................. 1
Variations and Options ......................................................................................................... 1
Specifications........................................................................................................................ 1
Physical............................................................................................................................. 1
Performance Characteristics ............................................................................................. 1
Operation............................................................................................................................... 2
Beacon/Power Converter.................................................................................................. 2
Catenary Operation (CHB 207, 208)................................................................................ 2
Flash Modes...................................................................................................................... 2
60/50 Hz Operation........................................................................................................... 2
Fixed Mode Operation...................................................................................................... 2
Configuring PCB1 ................................................................................................................3
Section 2 - Mounting and Installation....................................................................................... 7
Unpacking............................................................................................................................. 7
Tools ..................................................................................................................................... 7
Access................................................................................................................................... 7
HAZARD WARNING...................................................................................................... 7
Beacon/Power Converter.................................................................................................. 7
Flashhead .......................................................................................................................... 7
Mounting............................................................................................................................... 7
Beacon Location ............................................................................................................... 8
Beacon Angle....................................................................................................................8
Controller Mounting ......................................................................................................... 8
PEC Mounting .................................................................................................................. 8
Wiring................................................................................................................................... 8
Beacon Wiring.................................................................................................................. 9
Lightning Protection ......................................................................................................... 9

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Installation Checklist .......................................................................................................... 10
Section 3 — Maintenance and Troubleshooting..................................................................... 22
Safety .................................................................................................................................. 22
Preventive Maintenance...................................................................................................... 22
Storage ................................................................................................................................ 22
RFI Problems...................................................................................................................... 22
Component Testing............................................................................................................. 23
Wiring and Cabling......................................................................................................... 23
Inspection........................................................................................................................ 23
Capacitors ....................................................................................................................... 23
C1 — High Intensity Capacitor Bank............................................................................. 23
C2 — Medium Intensity Capacitor................................................................................. 23
C3 — Low Intensity Capacitor....................................................................................... 24
C4 — Tuning Capacitor.................................................................................................. 24
FT101 — Flashtube ........................................................................................................ 24
K1, K2 — Mode Relays, 24-volt DC Coil...................................................................... 24
K3 — Discharge Relay, 120 VAC Coil.......................................................................... 24
L1 — Burst Choke.......................................................................................................... 24
L2 — Flash Choke.......................................................................................................... 24
PCB1 — Timing and Trigger Board............................................................................... 24
R1A, R1B — Bleed Resistors......................................................................................... 24
PCB2 — HV Rectifier Board ......................................................................................... 24
R2A, R2B — Burst Resistors ......................................................................................... 24
T1 — Power Transformer............................................................................................... 24
PCB3 — Sense Module.................................................................................................. 25
T101 — Trigger Transformer......................................................................................... 25
VR1 — Suppressor Assembly........................................................................................ 25
Troubleshooting.................................................................................................................. 25
Component Removal and Replacement.............................................................................. 28
Removal & Replacement — General ............................................................................. 28
Section 4 – Recommended Spare & Replaceable Parts.......................................................... 32
Customer Service................................................................................................................ 32
Ordering Parts..................................................................................................................... 32
Beacon / Power Converter Parts......................................................................................... 32
Flashhead Parts ................................................................................................................... 32
Returning Equipment – Return Material Authorization (RMA)......................................... 37
Return to Stock Policy.................................................................................................... 38
Appendix 1 – Programming the Timing and Trigger Board................................................... 39
Connecting the Handheld.................................................................................................... 39
Using the Programmer........................................................................................................ 39
SETUP for Non S Versions ............................................................................................ 41
SETUP for S Versions.................................................................................................... 41
Parameters for Non S Versions....................................................................................... 41
Parameters for S Versions............................................................................................... 42
INFO............................................................................................................................... 43
MODE CHANGE........................................................................................................... 43
Appendix 2 - CHB 204SPB and 207SPB Primary Backup.................................................... 45
Operation............................................................................................................................. 45

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Installation........................................................................................................................... 45
Appendix 3 - CHB 204-2X and 204-2SX Extended Separation............................................. 48
Introduction and Operation................................................................................................. 48
Mounting and Installation................................................................................................... 48
Flashhead Wiring............................................................................................................ 48
Securing the Cable.......................................................................................................... 48
Spare Parts (for 204-2X/204-2SX versions only)............................................................... 52
List of Figures
Figure 1-1 – PCB1 (2904411) Timing and Trigger Board....................................................... 4
Figure 1-3 – Typical 2-Tower 3-Tier Layout and Catenary Beacon Operation ....................... 6
Figure 2-1 – PC 204/207 Power Converter Mounting and Outline........................................ 12
Figure 2-2 – FH 204 Flashhead Mounting and Outline.......................................................... 13
Figure 2-3 – CHB 205/208 Beacon Mounting and Outline.................................................... 14
Figure 2-4 – Wiring Overview of a System............................................................................ 15
Figure 2-5 – Junction Box, Three-Phase Installation Wiring................................................. 16
Figure 2-6 – Single-Phase Installation Wiring for CH 204/207............................................. 17
Figure 2-7 – Single-Phase Installation Wiring for CH 205/208............................................. 18
Figure 2-8 – Optical Assembly Internal Wiring..................................................................... 19
Figure 2-9 – PC 204/207 Power Converter Internal Wiring................................................... 20
Figure 2-10 – PC 205/208 Power Converter Internal Wiring................................................. 21
Figure 3-1 – Major Troubleshooting Symptoms .................................................................... 26
Figure 3-2 – Defective Component Locator Code.................................................................. 27
Figure 3-3 – Winding Directions............................................................................................ 30
Figure 4-1 – Beacon / Power Converter Replacement Parts................................................... 33
Figure 4-2 – PC 204/207 Power Converter Component Locations........................................ 34
Figure 4-3 – PC 205/208 Power Converter Component Locations........................................ 35
Figure 4-4 – Flashhead Replacement Parts............................................................................. 36
Figure 4-5 – CHB 205 Optical Assembly, FH 204 Flash Component Locations................... 36
Figure A1-1 – DB9 Female..................................................................................................... 39
Figure A1-2 – Handheld Programmer .................................................................................... 39
Figure A2-1 – PC 204SPB / 207SPB Installation Wiring ...................................................... 46
Figure A2-2 – PC 204SPB / 207SPB Internal Wiring............................................................ 47
Figure A3-1 – PC 204-2X / 204-2SX Mid-Tower Installation Example................................ 49
Figure A3-2 – PC 204-2X / 204-2SX Ground Level Installation Example............................ 50
Figure A3-3 – PC 204-2X / 204-2SX Component Locations................................................. 51
Figure A3-4 – PC 204-2X / 204-2SX Internal Wiring ........................................................... 51

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Section 1 – Introduction
and Operation
The CHB 204 High Intensity Beacon
consists of an FH 204 Flashhead and a PC
204 Power Converter in separate
enclosures.
The CHB 207 High Intensity Catenary
Beacon consists of an FH 204 Flashhead
and a PC 207 Power Converter in separate
enclosures.
The CHB 205 High Intensity Beacon is a
self-contained unit with an optical
assembly mounted in the enclosure.
The CHB 208 High Intensity Catenary
Beacon is a self-contained unit with an
optical assembly mounted in the
enclosure.
System Controller
For standard (non-S) versions an CHC 140
system controller directs flash timing and
intensity, and records and reports Beacon
operating status. It enables either
automatic or manual intensity control, and
it continuously displays the flashing status
of each Beacon. For further information,
consult the CHC 140 System Controller
Manual.
For S versions a CHC 121 system
controller monitors the status and
operating parameters of the lights. The
lights can be interrogated by the controller,
or remotely via a telephone line
connected to the controller. The controller
sends intensity information to the lights to
make them operate in the correct mode.
The controller sends and receives coded
signals over a two-wire communications
cable (COMM LINK).
Variations and Options
The CHB304/305 (S) medium intensity
systems operate in twilight and night
modes only. In this case, wherever 204
and 205 appear in the manual substitute
304 and 305, respectively. Contact
Customer Service at 1-800-821-5825 for a
description of equipment variations and
options.
Specifications
Physical
PC 204/207 (H x W x D, Weight)
23 x 17.13 x 9.44 in., 70lbs.
584.2 x 435.1 x 239.8 mm, 31.8 kg
Wind Area: 2.4 ft2, 0.22 m2
FH 204 (H x W x D, Weight)
23 x 18.6 x 12.8 in., 18lbs
584 x 472 x 325 mm, 8.2 kg
Wind Area: 1.99 ft2, 0.18 m2
CHB 205/208 (H x W x D, Weight)
22.35 x 20.88 x 11.23 in., 85 lbs.
567.7 x 530.4 x 285.2 mm, 38.6 kg
Wind Area: 2.9 ft2, 0.27 m2
Environmental
Complies with FAA specifications in
AC 150/5345-43.
Performance Characteristics
Application
CHB 204/205 L-856
CHB 207/208 L-857
Flash Intensity (nominal):
Day (204/205) 270,000 ± 25%ECD
Day (207/208) 140,000 ± 25%ECD
Twilight 20,000 ± 25% ECD
Night 2,000 ± 25% ECD
Beam Spread Horizontal: 120º
Vertical: 3º

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Flash Rate
CHB 204/205 40 flashes per min.
CHB 207/208 60 flashes per min.
Electrical (factory pre-wired)
AC Voltage
120-480 VAC ± 10%, 60 Hz
110-230 VAC ± 10%, 50 Hz
Volt-Amperes 600 peak
Day 255W
Operation
The controller determines the operating
intensity of the structure lights, and then
informs the Timing and Trigger Board
(PCB1) in each beacon.
Beacon/Power Converter
The beacon starts flashing when power is
applied.
A pair of shielded conductors between the
beacons and the controller carries the
control and monitoring signals for an
entire system. A beacon sends a flash
confirmation signal to the controller for
monitoring. Individual encoding identifies
the beacon of origin, thus enabling all
beacons in a system to individually report
to the controller.
All beacons are capacitive discharge lights
that use a xenon flashtube.
If the controller is disconnected, or fails,
all beacons flash by default at high
intensity.
Catenary Operation (CHB 207,
208)
High intensity lights for towers that
support catenary wires provides the
highest degree of visibility in daylight and
night. Three levels (tiers) of sequentially
flashing lights are required. One tier of
lighting is required at the top, one tier at
the midpoint, and one tier at the bottom.
The tier flash sequence is middle, top,
bottom. All lights at the same tier flash
simultaneously. The catenary flash rate is
60 flashes per minute. See
Cooper Crouse-Hinds uses a standard
format: it refers to the lowest level as Tier
1 and the most northerly facing light as
beacon 1. Higher numbered beacons are
placed around the structure in a North-
East-South-West direction. Figure 1-3
shows a typical installation.
Flash Modes
Night
At nightfall, the controller switches the
beacon to night mode operation; the
flashhead flashes at the night intensity of
2,000 ± 25% ECD.
Twilight
At twilight, the controller switches the
beacon to twilight mode operation; the
flashhead flashes at the twilight intensity
of 20,000 ± 25% ECD.
Day
At daybreak, the controller switches the
beacon to day mode operation; the
flashhead flashes at the daylight intensity
of 270,000 ± 25% ECD.
60/50 Hz Operation
PCB1 can operate from either a 60Hz or a
50Hz power source.
Fixed Mode Operation
The following table explains how to force
the beacon to operate continuously at a
fixed flash intensity (mode). Use these
procedures to check operation at all three
flash intensities. You can also use the
handheld terminal to control the modes
(see section 5).

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Intensity Procedure†
DAY (High) Place a jumper between
Test Point 1 (TP1)
labeled TEST and TP6
labeled DAY.
TWI
(Twilight)
Place a jumper between
Test Point 1 (TP1)
labeled TEST and TP5
labeled TWI.
HITE (Low) Place a jumper between
Test Point 1 (TP1)
labeled TEST and TP4
labeled NITE.
LTV Factory use only. Causes
continuous triggering. Do
not use.
Be certain to remove all jumpers after
checking the beacon.
Configuring PCB1
PCB1 (2904410 for S version, 2904411
for non S version) governs all the
functions pertaining to operation. It has
nine light emitting diode (LED) indicators,
and one clear neon indicator that you can
use to monitor equipment operations
during checkout and troubleshooting. To
monitor operation the following
subsections instruct you to observe
specified LEDs. The essential features on
PCB1 for troubleshooting are shown in
Figure 1-1 and Figure 1-2.
The factory programs PCB1 according to
your purchase order, or the handheld
terminal (p/n 1903776) may be used (see
Section 5).
When replacing PCB1 in the field, ensure
that the board is setup the same way as the
board you are replacing. You can change
some operations in the field by using the
handheld terminal Figure 1-1 shows the
locations of indicator lights useful for
monitoring the equipment's operation.

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Figure 1-1 – PCB1 (2904411) Timing and Trigger Board

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
WHITE FLASHHEAD COMBINATION.
8 -- SIGNAL GROUND
7 -- BEACON VOLTS:
6 -- MARKER VOLTS:
5 -- ID SENSE:
4 -- MARKER SENSE: SENSES MARKER BULB
3 -- RED SENSE:
2 -- MARKER CONTROL: TURNS MARKER RELAY ON
OUTPUT:
1 -- RED CONTROL A. FLASHES RED
SENSES RED INCANDESCENT
SENSES MARKER SOCKET
HARDWARE CONFIGURATION
VOLTAGE.
CURRENT
BEACON SOCKET VOLTAGE
OF STROBE PRESENT.
GROUND INDICATES THE TYPE
SENSE INPUT: RESISTANCE TO
SENSES FILTER POSITION IF
CURRENT.
OTHERWISE, SENSES BEACON
ACTUATOR IS USED.
FLASHHEAD WITH FILTER
OR OFF.
FOR RED FLASHHEAD AND
FILTER ACTUATOR.
FILTER IN FLASHHEAD WITH
INCANDESCENT BEACON.
C. TRIGGER STEERING CONTROL
B. RAISES OR LOWERS RED
(VARIES WITH EQUIPMENT TYPE):
J1 PIN FUNCTION
INT RED
JP1
Figure 1-2 – PCB1 (2904410) Timing and Trigger Board For S Versions

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
CATENARY WIRES
CATENARY
BEACONS
TOP
MIDDLE
BOTTOMBOTTOM
MIDDLE
TOP
WIRE DROOP
EXAGERATED
FLASH RATE = 60 FPM
CATENARY SEQUENCE = MIDDLE, TOP, BOTTOM
Figure 1-3 – Typical 2-Tower 3-Tier Layout and Catenary Beacon Operation

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Section 2 - Mounting and
Installation
Unpacking
Inspect shipping cartons for signs of
damage before opening. Check package
contents against the packing list and
inspect each item for visible damage, and
promptly report damage claims to the
freight handler.
Cooper Crouse-Hinds factory programs
beacons for operation at particular
locations, and marks the shipping
containers accordingly on the outside.
Cooper Crouse-Hinds refers to the lowest
level as Tier 1 and the most northerly
facing light as Beacon 1. Higher numbered
beacons are placed around the structure in
a North-East-South-West direction.
Therefore, you must maintain the beacon’s
identity according to the package identity
of each beacon (for example, Beacon 1,
Tier 1; Beacon 2, Tier 1; and so forth), and
install it as called out on drawings.
Tools
Although no special tools are necessary,
the following hand tools are suggested for
installation and maintenance:
•#1 Phillips-head screwdriver, 8-inch
long shank
•#2 Phillips-head screwdriver
•3/16-in. flat blade screwdriver
•1/4-inch flat blade screwdriver
•Medium slip-joint pliers
•8-in. or 10-in. adjustable wrench
•Assorted nut drivers and combination
wrenches
•Hand tools for electrical wiring
•Triplett™ Model 630-NA VOM, or
equivalent analog volt-ohm meter, or a
digital meter with an averaging
function.
Access
HAZARD WARNING
Disconnect the primary power before
opening the beacon or flashhead
enclosures.
Beacon/Power Converter
Latches secure the hinged cover of the
power converter or the beacon. When you
release these you can swing open the cover
for access to the inside.
Flashhead
Latches secure the hinged cover of the
flashhead. When you release these you can
swing open the cover for access to the
inside.
Mounting
Outline, mounting, and clearance
dimensions for your equipment are shown
in the following figures:
•Figure 2-1 – PC 204 or PC 207 Power
Converter Mounting and Outline
•Figure 2-2 – FH 204 Flashhead
Mounting and Outline
•Figure 2-3 – CHB 205 or CHB 208
Beacon Mounting and Outline

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Beacon Location
FAA Guidelines for beacon placement are
published in AC 70/7460-1. Avoid placing
a beacon within a strong radio frequency
(RF) field. For example, a beacon within
four feet of a radiating FM antenna is
likely to pick up electromagnetic
interference (EMI) that could cause
improper operation or damage. Place a
beacon at an adequate distance from a
powerful RF radiator. Contact the factory
for instructions when you cannot avoid
this situation.
Beacon Angle NOTE
Beacons (except AOL lights) are
installed with specific elevation angles.
Various factors may influence the angle of
beacon elevation for the units on your
structure. These include: location of the
structure, height of the beacon above
ground, and other characteristics of the site
and surrounding terrain. Advisory Circular
70-7460-1 contains guidelines for setting
the elevation angle. Information derived
from that source forms is show in the
following table.
AGL (ft) Angle
0-300 +3°
300-400 +2°
400-500 +1°
500 > 0°
First, level the unit to obtain a reference
elevation angle (the specified elevation
angle is added to the reference angle). Use
the spirit level located inside the enclosure
for initial leveling—the tilting bracket has
an incremental scale. The tilt mechanism
is part of the permanently attached
mounting bracket. To level the enclosure,
tilt it by using the mounting brackets.
Controller Mounting
Locate the system controller in an area
with restricted access. Controllers are
available either in outdoor enclosures that
can be attached to any vertical surface, or
as an indoor, rack-mounted controller.
You can place the system controller
anywhere within 2500 feet of the most
distant beacon without further
consideration. Consult with the factory if a
greater distance is necessary.
PEC Mounting
You may locate the PEC at any practical
distance from the system controller. To
ensure proper operation, observe the
following requirements. Mount the PEC:
•With an unobstructed view of the polar
sky.
•In a way that direct or reflected
sunlight does not strike it.
•Vertically on the top end of a vertical
length of conduit to prevent water
from entering.
Refer to the system controller manual for
mounting and outline dimensions of the
CHC140 and CHC121 Controllers and
PEC.
Wiring NOTE
Only general information for a typical
installation is presented here. Thus,
more specific information may be
needed for your site.
Consult any installation drawings
prepared especially for your site or
supplied with the equipment.
If installation drawings prepared
specifically for your site disagree with
information provided in this manual, the
installation drawings should take
precedence.

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
See Figure 2-4 – Wiring Overview of a
System. System wiring consists of primary
power and signal distribution wiring.
Primary power is usually taken from a
load center to the various items of
equipment. Signal wiring is between the
beacons and the system controller. Make
connections to beacons at nearby junction
boxes. Always position junction boxes
below the beacons with drain holes facing
downward.
Beacon Wiring
Three-phase power often supplies large
systems. However, the beacons are single-
phase units that are connected from line-
to-line (A-B, B-C, A-C). Therefore, phase
differences occur between groups of
beacons in the same three-phase system. In
a three-phase system, phase A-C must
supply the controller (not C-A) to allow
the controller to be compatible with all
beacons. Failure to ensure optimum
phasing as described could result in
intensity control problems.
Use circuit breakers or a safety switch
with fuses for the primary power load
center. Insulation should be rated at 600
VDC minimum. Wire size is a factor
affected by the service voltage, the number
of beacons in the system, and the length of
the wire run to the beacons. To determine
wire gauge, consider each beacon as a 400
volt-ampere load and do not permit the
voltage drop caused by wire resistance to
exceed 5% at any beacon. You may use
this volt-ampere value to determine ratings
for slow-acting fuses or circuit breakers
for the system. For fast-acting fuses and a
system feeder transformer (if used)
consider a peak load of 600 volt-amperes
for each beacon. CHCA recommends that
you use National Electric Code guidelines
for all primary wiring.
A label inside the beacon near the fuse
block indicates the operating voltage and
frequency of your beacon. Two internal
fuses are sized according to the operating
voltage. When Line 2 is neutral, the
factory replaces the F2 fuse with a jumper
wire.
Make connections to distribution wiring at
a nearby junction box. Consult the
following installation wiring diagrams to
guide you in wiring the equipment at your
installation:
CAUTION
These figures are guidelines only. If
they differ from the installation drawings
for your site, use the site installation
drawings.
Installation drawings in this manual are as
follows:
•Figure 2-5 – Junction Box; Three-
phase Installation Wiring
•Figure 2-6 – Single-Phase Installation
Wiring for CHB 204 or 207
•Figure 2-7 – Single-Phase Installation
Wiring for CHB 205 or 208
Lightning Protection
Though ElectroFlash equipment is
designed to withstand severe transient
over-voltages, a lightning arresting system
must be installed to prevent damage by
lightning. Install a lightning arresting
system to protect a light at the top of a
mast or antenna. Transient suppressors
from line-to-line and line-to-neutral are
recommended at the primary power load
center.

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Installation Checklist
Complete the following steps before
applying power to the lights.
1. Equipment Damage:
Inspect all equipment for damage.
2. Required Equipment:
Verify the received equipment against
the packing list to ensure
completeness.
3. Beacon/Power Converter Mounting:
Position and mount each unit correctly,
allowing adequate clearance for
opening the covers. Also, use the
following guidelines:
•Ensure that the case is mounted
upright, is water tight, and
grounded.
•Check hardware inside the case to
ensure that the mounting screws
and nuts are tight.
•Ensure that only the bottom of the
case has drain holes and that they
are clear.
•Ensure that no holes are punched
or drilled on the top surface of the
case.
•Ensure that air can flow around the
case.
•Mount the unit away from radio
frequency interference (RFI).
4. Beacon/Power Converter Wiring:
Use the installation drawings and the
following guidelines:
•Check for proper incoming service
voltage.
•Wire each unit according to the
instructions.
•In installations with multiple units,
ensure that all units are wired to
the same phase. In installations
with multiple tiers and three phase
wiring, follow the phasing chart in
the installation drawings, or site
drawings.
•Check all electrical connections for
tightness.
•Check all terminal strip
connections for tightness.
•Ground the power
converter/beacon using a bonding
strap from the case leg to the
structure.
5. Flashhead Mounting:
Ensure that the flashhead lens can be
opened without striking other objects.
•Level and set the flashhead at the
required elevation angle.
6. Flashhead Wiring:
•Ground the flashhead.
•Check the wiring of the flashhead
cable to the flashhead.
•Secure the flashhead cable to the
tower. Support and tape the
flashhead cable to prevent its
movement by the wind.

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
7. Photocell:
•Locate photocell where it views
unobstructed polar sky with no
direct or reflected artificial lighting
striking it.
•Mount the photocell vertically on
the top end of a vertical length of
conduit to prevent water from
entering the unit.
•Ground the wire shield around the
photocell wires, if one is present.
•After running the photocell wires,
check for continuity and shorts.
After completing all the steps listed above,
turn on the power and perform an
operational checkout from procedures in
Section 3 of this manual.

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
Figure 2-1 – PC 204/207 Power Converter Mounting and Outline

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
(76.20)
3.00
3.00
(76.20)
16.25 (412.75)
12.82 (325.63) MIN
NOTES:
(539.75)
21.25
REQUIRED
CLEARANCE
16.88 (428.75)
(571.5)
22.5
(235)
9.25
1.06 DIA. (26.9)
(530.35)
20.88
A
A
VIEW A-A
1. Weight: 18 lbs (8.2 kg)
2.
3. Dimensions are in inches (millimeters)
Wind area: 1.99 sq ft (.18 sq m)
(TYP)
(63.5)
2.5
ADD .40 (10.2) FOR
EACH DEGREE OF TILT
MOUNTING SLOTS
.56 X .63
(14.2 X 16.0)
.44
(11.18)
ENTRANCE HOLE
18.23 (463.04)
9.41 (239.01)
Figure 2-2 – FH 204 Flashhead Mounting and Outline

Cooper Industries Inc.
Crouse-Hinds Division IF 1544
PO Box 4999, Rev 1
Syracuse, New York 13221 • U.S.A. New 01/08
Copyright© 2007, Cooper Industries, Inc.
2x Ø1.31
.62
9.23
11.23
2.00
TOP VIEW
FRONT VIEW
BOTTOM VIEW
RIGHT SIDE VIEW REAR VIEW
NOTES:
1. WEIGHT: 85 LBS. (38.6 KG.)
2. WIND AREA: 2.9 SQ. FT. (.27 SQ. M.)
3. DIMENSIONS ARE IN INCHES (MILLIMETERS)
(567.7)
22.35
20.00
21.25
(539.8)
(508)
(33.28)
(50.8)
(15.7)
(234.4)
(285.2)
31.23
(793.2)
2.6 TYPICAL
(66.0)
20.0
(508)
17.8
(453)
20.88
(530.4)
00.0 5.50 7.50
13.00 14.68
00.0
4.00
7.00
1.12
(28.5)
.88
(22.4)
.10
(2.54)
Figure 2-3 – CHB 205/208 Beacon Mounting and Outline