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