OBELUX CSW-DCW User manual

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OBELUX
A V I A T I O N L I G H T S
OBELUX CSW-DCW
Fault monitoring, switch-over and flash controller unit
Manual
Version 1.1

CSW-DCW –Manual
Obelux Oy, Kutomotie 6 B, 00380 Helsinki FINLAND
© Obelux Oy 2016 Technical information in this document is subject to change without notice.
Page: 2(17)
CONTENTS
1CHANGE LOG....................................................................................................................................................... 3
2ABOUT THIS DOCUMENT .................................................................................................................................... 4
3ABOUT THIS PRODUCT ........................................................................................................................................ 5
3.1 VERSIONS............................................................................................................................................................... 5
4SAFETY INSTRUCTIONS........................................................................................................................................ 6
4.1 GENERAL CONSIDERATIONS........................................................................................................................................ 6
4.2 END-OF-LIFE/DISPOSAL ............................................................................................................................................ 6
4.3 PERSONAL CONSIDERATIONS ...................................................................................................................................... 6
5INSTALLATION..................................................................................................................................................... 7
5.1 DEVICE INSTALLATION ............................................................................................................................................... 7
5.2 WIRING ................................................................................................................................................................. 8
5.2.1 DC power input ........................................................................................................................................... 9
5.2.2 Outputs 1-4 ................................................................................................................................................. 9
5.2.3 Alarm relay output ...................................................................................................................................... 9
5.2.4 GPS External Antenna ................................................................................................................................. 9
6CONFIGURATION ...............................................................................................................................................10
6.1 BASE SEQUENCE .................................................................................................................................................... 10
6.2 FLASH DURATION ................................................................................................................................................... 11
6.3 FLASH MODE......................................................................................................................................................... 11
6.4 TEST MODE........................................................................................................................................................... 11
6.5 PHOTOCELL SENSITIVITY .......................................................................................................................................... 11
6.6 PHOTOCELL OPERATION .......................................................................................................................................... 12
6.7 MAIN/SPARE OPERATION ........................................................................................................................................ 12
6.8 OPTIONS .............................................................................................................................................................. 12
6.9 ALARM WINDOWS.................................................................................................................................................. 12
6.10 CONFIGURATION EXAMPLE....................................................................................................................................... 13
6.11 DIP SWITCH SETTINGS ............................................................................................................................................ 14
7OPERATION........................................................................................................................................................15
7.1 START-UP............................................................................................................................................................. 15
7.2 FLASH SEQUENCE ................................................................................................................................................... 15
7.3 POWER MONITORING ............................................................................................................................................. 15
7.4 GLOBAL SYNCHRONIZATION WITH GPS ...................................................................................................................... 15
7.5 PHOTOCELL .......................................................................................................................................................... 15
7.6 ALARMS............................................................................................................................................................... 16
7.6.1 Output power alarm ................................................................................................................................. 16
7.6.2 GPS alarm.................................................................................................................................................. 16
7.7 MAIN/SPARE OPERATION ........................................................................................................................................ 16
7.8 ON-BOARD LEDS................................................................................................................................................... 17

CSW-DCW –Manual
Obelux Oy, Kutomotie 6 B, 00380 Helsinki FINLAND
© Obelux Oy 2016 Technical information in this document is subject to change without notice.
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1 CHANGE LOG
Version
Date:
Description:
Author
0.1
24.03.2016
Document created
AHa
1.0
07.07.2016
Document release
AHa
1.1
05.10.2016
External photocell support added
AHa

CSW-DCW –Manual
Obelux Oy, Kutomotie 6 B, 00380 Helsinki FINLAND
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2 ABOUT THIS DOCUMENT
This document describes the installation and setup of the CSW-DCW unit, DIP switch effects and operation
of the unit on practical level.
CPU
Central Processing unit, Microprocessor
GPS
Global Positioning System
Light Head
Aviation light
Table 1: Acronyms and Abbreviations

CSW-DCW –Manual
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3 ABOUT THIS PRODUCT
Obelux CSW-DCW is a combined all-in-one aviation obstacle light controller, flasher and photocell unit with
independent outputs to drive obstacle warning lights.
GPS options are factory-installable so they need to be included in the first order. This manual explains using
options that are not present at every CSW-DCW.
CSW-DCW has four output channels that have power monitoring feature. Power monitoring windows can be
set for all individual channels with dial switches. In addition to sending an alarm via dry contact, the CSW-
DCW can drive backup light(s) during master light outage.
CSW-DCW is microprocessor-controlled. Application software is stored in the CPU, the central processing
unit. CPU programming is done at the factory. Application upgrade, if such exists, can be done at Obelux.
This requires that the CSW-DCW is sent to Obelux for the upgrade. The customer can also do the update
on-site with a programming device and instructions that Obelux can provide.
3.1 Versions
Obelux CSW-DCW is available as the following models:
Order code
GPS synch.
GPS antenna cable
CSW-DCW-B-F
No
NA
CSW-DCW-B-G
Yes
NA
CSW-DCW-B-G3
Yes
3m
CSW-DCW-B-G5
Yes
5m
CSW-DCW-B-G10
Yes
10m
Antenna for use with Obelux CSW-DCW:
GPS External Antenna
Order code: -G, -G3, -G5, -G10

CSW-DCW –Manual
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4 SAFETY INSTRUCTIONS
In this section you will find general safety instruction for the device. Please read the instructions carefully
before installing or using the device to avoid any personal, environmental or material damages.
4.1 General considerations
Install device observing manufactures installation guide
Use only cables and connectors specified by the manufacture
Keep your device away from heat sources, dust, smoke or other harmful substances
Do not add or remove any components inside the device unless otherwise approved by the manufacture
Do not spill food or other liquids on device
If you have any error situation with the device, do not try to fix it by yourself, contact your reseller.
4.2 End-of-Life/Disposal
The European Parliament and the Council of European Union issued directive 2012/19/EU to contribute to
sustainable production and consumption by, as a first priority, the prevention of WEEE and, in addition, by
the re-use, recycling and other forms of recovery of such wastes so as to reduce the disposal of waste and
to contribute to the efficient use of resources and the retrieval of valuable secondary raw materials.
Obelux aviation obstacle light products sold inside European Union can be returned to manufacturer if no
local WEEE separate collection and re-use services are available. Please contact Obelux for details.
Obelux does not refurbish returned items but forwards them to authorized WEEE treatment facility.
4.3 Personal considerations
HIGH VOLTAGE! Device contains high voltage which is very dangerous to human beings. Any direct contact
to high voltage could lead to serious injury, worst case even death. Make sure the mains power supply is
disconnected before starting the installation process.
CAUTION. Do not look directly in to the lights from close range. In some cases, this can cause damage to
your eyes. Make sure that the system is off before servicing the aviation lights.

CSW-DCW –Manual
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5 INSTALLATION
5.1 Device installation
Mount the CSW device to the selected mounting point using quality made fasteners. When the cover door is
open, check that there is no inflow of water (incl. hail and snow) into the cabinet.

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5.2 Wiring
Route cables using cable glands on the bottom side of controller. Connect the cable wires securely to
appropriate terminal block connectors. Connect GND connection on the DC power input directly to a good
ground point to ensure system is properly protected from overvoltage and electrostatic discharges. If you are
using shielded cables connect shields to the appropriate GND connection. Place the cover properly on its
place and securely tighten all four screws on all corners of the cover. There are two different size cable
glands available on the cabin. Make sure that unused glands and gland holes are plugged shut.
Cable gland 5 x M25 for 13-18 mm cable diameter
Cable gland 2 x M16 for 4.5-10 mm cable diameter
Figure 1: Controller module
1. CSW-DCW Application software version label
2. DC power input
3. Output connectors (four channels)
4. Alarm relay output connector
5. GPS External Antenna connector
6. External photocell data and power connection. Power supply and data to GSM modem.
7. Internal photocell
8. Status LEDs
9. Rotary DIP switches to set power monitoring window for each output channel
10. Configuration DIP switches (two switch blocks with eight switches in each)
11. Status LEDs for alarms.
Positive (+) DC supply power to CSW and positive (+) DC supply on outputs
to lamps are connected together i.e. hard-wired to each one.
DC input voltage must match lamp voltage.

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5.2.1 DC power input
Mark
Description
Information
+
Positive
Connect to power supply positive
-
Negative
Connect to power supply negative
GND
Ground
Protective earth
The positive connector (+) on each output channel is hard-wired to positive connector (+) of supply power
connector. Supply voltage shall not exceed 60 V DC. Tighten the connector screws using flat-head (straight)
screwdriver.
Conductor cross-section (stranded)
0.2mm² - 4mm²
Conductor cross-section (solid)
0.2mm² - 4mm²
5.2.2 Outputs 1-4
Mark
Description
Information
+
Positive
Connect to light head positive
-
Negative
Connect to light head negative
GND
Ground
Connect to light head PE
The positive connector (+) on each output channel is hard-wired to positive connector (+) of supply power
connector. Unused output connectors can be left floating i.e. no wiring there is required. They shall not be
short-circuited. Tighten connectors securely using flat-head (straight) screwdriver.
Conductor cross-section
0.2mm² - 4mm²
5.2.3 Alarm relay output
Mark
Description
Information
NO
Normally Open
In alarm, connected with COM (Common)
NC
Normally Connected
During normal operations, connected with COM (Common)
COM
Common
Common relay contact
This relay is a small signal relay. Unused alarm relay connectors can be left floating i.e. no wiring there is
required. When CSW-DCW is without power and when it starts (reboots), the relay signals an alarm. Alarm
relay state changes during start-up process if there are no pending alarms to be signalled.
Conductor cross-section
0.2mm² - 4mm²
5.2.4 GPS External Antenna
GPS receiver is factory-installed option. If the CSW-DCW is mounted indoors or with limited sky view, an
external GPS antenna needs to be used. Antenna is connected to the SMA connector on the CSW board.
Connector location can be seen in the Figure 1. Be careful not to overtighten the connector.

CSW-DCW –Manual
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6 CONFIGURATION
This chapter describes the configuration of the CSW-DCW board. The configuration is carried out by setting
the 16 DIP switches on the CSW-DCW board. OFF position for a dip-switch is towards the left edge of the
CSW-DCW board.
Having all 16 DIP switches to OFF is a special case. CSW-DCW reads stored configuration from memory
and starts using this configuration if it is a valid one. If there is no valid configuration, the CSW-DCW uses
configuration where all DIP switches are set to OFF. This configuration disables all channels.
Figure 2: DIP switches in off position
6.1 Base sequence
DIP switches named FLASH SEQ 1, 2, 3 select the Base Sequence.
(off,off,off) Selects always Steady-burn.
(on,off,off) Selects 60 flashes per minute total. (One flash / second)
(off,on,off) Selects 40 flashes per minute total. (One flash / 1.5 seconds)
(on,on,off) Selects 20 flashes per minute total. (One flash / 3 seconds)
(off,off,on) Selects the BMVBW flash sequence. 1s on - 0.5s off - 1s on - 1.5s off
Please note: Set DIP switches 4 and 5 to OFF when using this base sequence.
(off,on,on) Selects 30 flashes per minute total. (One flash / 2 seconds)
Any other selection is RESERVED for future expansions.

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6.2 Flash duration
DIP switches named FLASH DUR 1, 2 select the Flash duration. The Flash duration tells the CSW how long
each flash is.
(off,off) Selects 100ms flash duration. (1/10 of a second)
(on,off) Selects 250ms flash duration. (¼ of a second)
(off,on) Selects 500ms flash duration. (½ of a second)
(on,on) Selects CASA compliant flash duration (Duty cycle: 2/3 ON, 1/3 OFF)
IMPORTANT: Only use Steady Burn, 20 FPM, 30FPM, 40 FPM or 60 FPM base sequences with the CASA
compliant flash duration setting! Other base sequences may cause undesired operation.
6.3 Flash mode
DIP switches named FLASH MODE 1, 2 select the flash mode. The flash mode setting effects the method
with which the flashes are directed to the outputs.
(off,off) All enabled outputs flash together.
6.4 Test mode
DIP switch named TEST MODE selects the test mode. Test mode makes CSW-DCW system testing easier.
Set the test-mode DIP switch to ON to enter test mode. In test mode output channel 1 can set ON from the
Option 1 DIP. Option 2 DIP turns on the channel 2. Same applies to Option 3,4 DIP switches and output
channels 3,4. In test mode, the CSW-DCW shortens the photocell timing periods. By physically blocking the
photocell all the channels are set to night mode with a short delay.
After using test mode, turn off the Option 1-4 DIP switches. If they are not off, the CSW will not function
normally.
In production environment, use test mode with appropriate caution.
6.5 Photocell sensitivity
DIP switches named PHOTOCELL 1, 2 select the photocell sensitivity.
(off,off) Photocell operation disabled
(on,off) Photocell enabled, disables outputs if light level above 400 Lux.
(off,on) Photocell enabled, disables outputs if light level above 800 Lux.
(on,on) Photocell enabled, disables outputs if light level above 1600 Lux.

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6.6 Photocell operation
DIP switch named EXT/INT PHOTOCELL selects internal photocell.
(off) Internal photocell is used.
(on) External photocell is used.
6.7 Main/Spare operation
DIP switch named MAIN/SPARE set the main/spare operation.
First pair:
Output 1 (Main 1)
Output 2 (Spare 1)
Second pair
Output 3 (Main 2)
Output 4 (Spare 2)
6.8 Options
DIP switches named OPTION 1, 2, 3, 4 must be set to off in normal operation. If DIP switches Option 1 or 2
are turned on, the CSW will function in modus mode. In this mode it will listen to commands from the RS485
bus. This functionality is not covered in this manual.
6.9 Alarm windows
All four channels have their own rotary switch dials to select minimum and maximum alarm limits. Alarm
window is selected by turning the dials with a flathead screwdriver to the wanted setting. Each number
represents a certain power limit. For example, selecting number 4 from the MIN dial and number 5 from MAX
dial selects the alarm window to be from 5W to 20W. If the power consumption on that channel is outside
this window the alarm is triggered. If the lights are used in flashing mode, the maximum alarm limit must be
selected according to the maximum power consumption during the flash pulse.
When both MIN and MAX dials are set to zero position, the output channel is disabled.
#
MIN
MAX
0
OFF
OFF
1
0.3W
3W
2
1W
5W
3
2W
10W
4
5W
15W
5
10W
20W
6
15W
35W
7
20W
50W
8
35W
80W
9
50W
120W
Table 2: Alarm window settings

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6.10 Configuration example
This example presents how to use Obelux CSW to control Obelux LI-10-DCW-F low intensity aviation
obstacle lights in master/spare set-up with internal photocell. We have selected 400lux to be the threshold
where low intensity lights are turned off. Flashing frequency is selected 40 flashes / minute and flash
duration 100ms.
In this example Lamp1 and Lamp3 are main lamps. Lamp2 and Lamp3 are spare. If Lamp 1 fails, the CSW
turns Lamp1 off and Lamp2 on. If Lamp3 fails, the CSW turns Lamp3 off and Lamp4 on.
Obelux LI-10-DCW-F consumes approx. 70 mA when operated with 12 VDC. Power consumptions during
flash pulse is 0.83W. Power window is selected to be from 0.3W to 3W on all output channels. This is done
by selecting number 1 on both MIN and MAX rotary switch dials and on all four output channels.

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6.11 Dip Switch Settings
DIP Switches
1 -> 3
1
2
3
Flashing sequence selection.
off
off
off
Steady burning. All active channels.
on
off
off
60 flashes / minute
off
on
off
40 flashes / minute
on
on
off
20 flashes / minute
off
off
on
BMVBW sequence: 1s on - 0.5s off - 1s on - 1.5s off.
off
on
on
30 flashes / minute
on
on
on
RESERVED
4 -> 5
4
5
Flash duration.
off
off
100 millisecond flashes.
on
off
250 millisecond flashes.
off
on
500 millisecond flashes.
on
on
CASA Flash duration (Duty cycle: 2/3 ON, 1/3 OFF)
6 -> 7
6
7
Flashing mode.
off
off
All active Outputs flash together.
off
on
Outputs 1-3 are flashing together, output 4 is steady burning.
8
8
Test mode enable
off
Normal operation
on
Test mode. (*See documentation for information about test mode)
9 -> 10
9
10
Photocell operation (External and Internal photocell)
off
off
Photocell not used.
on
off
Lights are disabled if lighting level is above 400 lux.
off
on
Lights are disabled if lighting level is above 800 lux.
on
on
Lights are disabled if lighting level is above 1600 lux.
11
11
External / Internal photocell selection.
off
Use internal photocell
on
Use external photocell
12
12
Main / Spare operation select.
off
Normal operation
on
Main / Spare operation.
13
13
Option1
14
14
Option2
15
15
Option3
16
16
Option4

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7 OPERATION
The CSW-DCW is used to flash aviation obstruction warning lights. It monitors the current going into each
lamp and raises an alarm if the output power is either lower than expected or higher than expected.
The CSW-DCW can have a GPS receiver mounted on the printed circuit board that is used to synchronize all
CSW-DCW flash sequences so that all CSW-DCW units flash their lights simultaneously all over the planet.
Also, the CSW-DCW has an internal photocell on the board that can be used to switch off the lights at day
time.
7.1 Start-up
The CSW-DCW application takes some time to perform start-up tests as there are numerous features that
require detection and initialization. Also, the start-up process now includes an output test pattern. The Self-
test OK LED blinks during start-up process.
7.2 Flash sequence
The CSW-DCW has several different user selectable flash sequences. Base sequence, Flash duration, Flash
mode. User can select the flash frequency (FPM) and flash duration. In addition to this the CSW also has
special flash sequences. These settings are described in more detail in the Chapter 6.
7.3 Power monitoring
The CSW-DCW monitors the current going into each aviation obstacle light once it is lit. Every time a light is
set to illuminate, the channel output is checked for short-circuit. If short-circuit is detected, the output channel
(light) is disabled and an alarm is raised.
Also, whenever a light is illuminated, the current this obstacle light draws from power supply via CSW-DCW
current monitoring circuit is checked 20 times in each second in order to detect possible light unit failure. If
the current going to a light is outside the selected range, an alarm is raised. Over-current situation will also
disable the light. User sets these limits by selecting the power window with the rotary dial switches
separately for each output. It is important to select the correct power range for the connected lights, as
temperature changes may alter the current required by the lamp.
7.4 Global synchronization with GPS
The CSW-DCW unit has a factory-installed GPS module. When a GPS module is installed with appropriate
antenna, the CSW-DCW synchronizes its clock and the flash models so that units flash simultaneously. The
timing difference from one CSW-DCW to another is less than one millisecond when the units are GPS-
synchronized. GPS synchronization status is signalled with GPS led on the CSW-DCW board. When the
CSW unit is powered on, it can take up to 15 min to synchronize the flashing lights to the GPS signal.
7.5 Photocell
Photocell measures the ambient light in lux. When the ambient light level rises above the set threshold CSW
turns off its outputs. When the lights are turned off by photocell, it will take 15 minutes to turn them on, and
when lights are on, it will take another five minutes to turn them off by photocell. The photocell can be
disabled, or set to threshold of 400, 800 or 1600 lx.

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7.6 Alarms
There are several types of alarms to indicate possible problems in the system.
7.6.1 Output power alarm
Over/Under power alarm is raised when the output power of individual output channel is outside the user
defined window. Output alarm LED is turned on and alarm relay is triggered when the output power on the
output channel is too high. Alarm relay is also triggered when the output power is too low. There is a small
delay implemented in to this feature to minimize the amount of unnecessary alarms. CSW will try to recover
to normal operation when power alarm is triggered.
When the output power is close to the limits, the ON LED will turn orange. In this case the power alarm
window should be adjusted so that unnecessary alarms can be avoided. Normally the ON LED is green.
7.6.2 GPS alarm
When the CSW powered up the GPS alarm is triggered after 30min if GPS signal is not available. In normal
operation GPS alarm is triggered if valid GPS time pulses are not received for 3 hours. CSW-DCW will also
try to clear the error when GPS received. This way, GPS synchronization alarms caused by poor weather or
similar will probably clear without any intervention.
7.7 Main/Spare operation
The Main/Spare operation changes the output layout of the CSW-DCW to use two Main/Spare output
combinations. If the light unit connected to the main output fails, the spare light unit is used instead. CSW will
not try to recover to the main output after it switches to the spare output channel. Alarms are generated as in
normal operation.
First pair:
Output 1 (Main 1)
Output 2 (Spare 1)
Second pair
Output 3 (Main 2)
Output 4 (Spare 2)

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7.8 On-board LEDs
This chapter describes the behaviour of the on-board message LEDs during start-up, normal operation and
during alarms.
Figure 3: Status LEDs
+12V
This LED indicates that internal 12V operating voltage is ok.
+5V
This LED indicates that internal 5V operating voltage is ok.
SELF TEST OK
The Self-test LED flashes when CSW software is running normally.
GSM
Not used
GPS
In normal operation the LED is on if a navigation fix is obtained. If a fix is not found or is lost the LED stays
off.
Photocell indicator
Not used
ON
All the four outputs have their own ON led. The ON LED follows the output of the channel. This means that
the ON light is flashing with the same time and frequency as the aviation light. Green coloured light indicates
that the aviation lights are working normally. Orange light indicates the output power is near limits of the
output power window.
ALARM
All the four outputs have their own ALARM LED. This LED indicates whether there is alarm the output.