TWR Lighting AA1TSS LED User manual

M.A-2016.AA1TSS LED
9-14-15 REV 9-13-16
10810 W. LITTLE YORK RD., #130 -HOUSTON, TX 77041-4051
VOICE [phone] - FAX [phone]
web: www.twrlighting.com
IMPORTANT!!!
PLEASE TAKE THE TIME TO FILL OUT THIS FORM COMPLETELY. FILE
IT IN A SAFE PLACE. IN THE EVENT YOU EXPERIENCE PROBLEMS
WITH OR HAVE QUESTIONS CONCERNING YOUR CONTROLLER, THE
FOLLOWING INFORMATION IS NECESSARY TO OBTAIN PROPER
SERVICE AND PARTS.
MODEL # AA1TSS LED
TYPE # LED
SERIAL #
PURCHASE DATE
PURCHASED FROM

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
9-14-15 REV 9-13-16
TABLE OF CONTENTS
1.0 GENERAL INFORMATION...................................................................................... 1
2.0 INSTALLATION INSTRUCTIONS .......................................................................... 2
2.1 MOUNTING THE CONTROL CABINET.................................................... 2
2.2 EXTERNAL PHOTOCELL WIRING........................................................... 2
2.3 POWER WIRING............................................................................................. 3
2.4 LED RED BEACON AND SIDELIGHT WIRING....................................... 3
3.0 THEORY OF OPERATION ....................................................................................... 4
3.1 POWER SUPPLY............................................................................................. 4
3.2 SIDELIGHTS.................................................................................................... 4
3.3 BEACONS ......................................................................................................... 4
4.0 TROUBLESHOOTING GUIDE................................................................................. 5
4.1 SYMPTON – BEACON NOT FLASHING.................................................... 5
4.2 SYMPTON – SIDELIGHT OUT..................................................................... 5
4.3 SYMPTON – CONTROLLER ALWAYS “ON”........................................... 5
5.0 MAINTENANCE GUIDE............................................................................................ 6
5.1 RED OBSTRUCTION LIGHTING................................................................ 6
5.2 L-864 LED BEACON REPLACEMENT ....................................................... 6
5.3 L-864 CONTROLLER..................................................................................... 6
5.4 PHOTOCELL ................................................................................................... 6
6.0 MAJOR COMPONENTS PARTS LIST.................................................................... 7
7.0 SUGGESTED SPARE PARTS LIST.......................................................................... 8
WARRANTY & RETURN POLICY
RETURN MERCHANDISE AUTHORIZATION (RMA) FORM

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
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APPENDIX
CHASSIS COMPONENT LAYOUT..............................................................................1306-R
SCHEMATIC LAYOUT...................................................................................................1306-S
TROUBLESHOOTING FLOW CHART .......................................................................1306-F
PHOTOCELL HOUSING DETAIL...............................................................100239 (REV H)
TOWER LIGHTING KIT CABLE RUN 151’ TO 350’ ................................800-01 (REV C)
TOWER LIGHTING KIT CONDUIT RUN 151’ TO 350’...........................800-02 (REV C)
SIDELIGHT MOUNT ASSEMBLY............................................................... 100489 (REV A)
LEDBEACON2 ASSEMBLY.......................................................................... 100761 (REV C)
OL1VLED2 (L810 SINGLE OBSTRUCTION LIGHT)................................100656 (REV E)
OL2VLED2 (L810 DOUBLE OBSTRUCTION LIGHT)..............................100658 (REV F)
JUNCTION AND STRAIN RELIEF BOXES ...............................................100089 (REV A)
WRAPLOCK FASTENING DETAIL............................................................................100984

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
9-14-15 REV 9-13-16
1.0 GENERAL INFORMATION
The TWR Lighting®, Inc. (TWR®) Model AA1TSS LED Controller is for A1 lighting of
towers 151’ to 350’ AGL (above ground level) in accordance with the Federal Aviation
Advisory Circular 70/7460-1K. One (1) LED beacon should be placed at the top of the
structure. Three (3) LED obstruction lights should be placed at the mid-level with
respect to overall tower height.
The flash rate of the LED beacon is 30 per minute. The LED sidelights burn steady.
A by-pass switch (SW1) allows the controller to be turned on during daylight hours
without covering the photocell. This is particularly helpful since the controller can be
mounted indoors while the photocell is outdoors. SW1 can be operated by turning the
switch to “ON.”
The photocell is the three (3) blades, twist to lock, type.
Power supplied to the controller shall be 120V AC 50/60 Hz.
The controller housing is rated at NEMA 4X. It is suitable for indoor or outdoor
mounting.
1

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
9-14-15 REV 9-13-16
2.0 INSTALLATION INSTRUCTIONS
2.1 MOUNTING THE CONTROL CABINET
(Refer to Drawing 1306-R)
The power supply control cabinet can be located at the base of the structure or in
an equipment building. Mounting footprints are shown on drawing 202-R. Power
wiring to the control cabinet should be in accordance with local methods and the
National Electrical Codes (NEC).
2.1.1 If the control cabinet is mounted inside an equipment building, the
photocell should be mounted vertically on ½” conduit outside the building
above the eaves facing north. Wiring from the photocell socket to the
control cabinet should consist of one (1) each, red, black, and white wires.
The white wire is connected to the socket terminal marked “N,” the black
wire is connected to the socket terminal marked “Li,” and the red wire is
connected to the socket terminal marked “Lo.” The photocell should be
positioned so that it does not “see” ambient light, which would prevent it
from switching to the nightmode.
2.1.2 If the control cabinet is mounted outside an equipment building, the
photocell should be mounted vertically on ½” conduit so the photocell is
above the control cabinet. Care must be taken to assure that the photocell
does not “see” any ambient light that would prevent it from switching into
the nightmode. The photocell wiring is the same as in 2.1.1.
2.1.3 The wiring from the photocell, the service breaker, the red incandescent
beacon, and the sidelights should enter the control cabinet through the
watertight connectors in the bottom of the cabinet. Inside the cabinet, the
connections will be made on the terminal strips and circuit breakers
located at the bottom of the chassis. These connections are made as
follows:
2.2 EXTERNAL PHOTOCELL WIRING
(Refer to Drawing 1306-R)
2.2.1 Connect the BLACK wire from the photocell to terminal block TB2
marked “L.”
2

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
9-14-15 REV 9-13-16
2.2.2 Connect the RED wire from the photocell to terminal block TB2 marked
“SSR.”
2.2.3 Connect the WHITE wire from the photocell to terminal block TB2
marked “N.”
2.3 POWER WIRING
(Refer to Drawing 1306-R)
2.3.1 Power wiring to the control cabinet should be in accordance with local
methods and the National Electrical Codes (NEC).
2.3.2 Circuit breaker needs to be rated at 5 amps.
2.3.3 Connect incoming 120V AC to terminal block TB1 marked “L.”
2.3.4 Connect the neutral wire(s) to one (1) of the terminal blocks on TB1
marked “N.”
2.3.5 Connect the AC ground to the aluminum mounting plate.
2.4 LED BEACON AND LED SIDELIGHT WIRING
(Refer to Drawings 1306-R, 800-01, and 800-02)
2.4.1 Connect the YELLOW wire from the LED beacon to the circuit breaker
marked “B.”
2.4.2 Connect the RED wire from the LED sidelight group to the circuit breaker
marked “S.”
2.4.3 Connect the WHITE neutral wire(s) to one (1) or more of the terminals on
TB1 marked “N.”
3

AA1TSS LED CONTROLLER
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3.0 THEORY OF OPERATION
3.1 POWER SUPPLY
120V AC enters the controller from the circuit breaker panel. Line sits at the
PRD, waiting to be switched on. When the 6390-FAA photocell is activated,
Line “SSR” energizes the coil of the PRD relay. This also can be accomplished
by using the photocell by-pass switch (SW1).
3.2 LED SIDELIGHTS
Line S is sent to the circuit breaker marked “S” which powers the LED sidelight
circuit.
3.3 LED BEACON
Line LD is sent to Module M1. Module M1 is a solid state flasher which its
output is sent to circuit breaker “B” which then powers the beacon at 30 fpm with
duration of 2/3 on 1/3 off.
4

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
9-14-15 REV 9-13-16
4.0 TROUBLESHOOTING GUIDE
4.1 SYMPTOM – BEACON NOT FLASHING
Check for pulsing 120V AC at circuit breaker “B.” If the circuit breaker is
tripped, there may have been a surge or could be a short in the tower wiring. This
can be checked by looking for a short between circuit breaker “B” and the ground.
If it is okay and 120V AC is not present, then check the PF-250 flasher to see if
there is voltage on the input (pin #2). If okay, the flasher module has probably
failed and needs to be replaced. If everything appears to be correct, but the LED
beacon still does not work, check the tower wiring.
4.2 SYMPTOM – SIDELIGHT OUT
Check for constant 120V AC at circuit breaker “S.” If tripped, check for a short
in the tower wiring. If not, and voltage is present, check the tower wiring.
4.3 SYMPTOM – CONTROLLER ALWAYS “ON”
If the tower lights stay on in the daytime, check to see that switch SW1 is off. If
the switch is off, then remove the photocell out of the socket. If the lights go out,
replace the photocell. If not, check for welded contacts on the PRD. Replace if
necessary.
5

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
9-14-15 REV 9-13-16
5.0 MAINTENANCE GUIDE
5.1 LED OBSTRUCTION LIGHTING
No scheduled maintenance is required. Perform on an “as needed” basis only.
TOOLS REQUIRED: NONE
5.2 L-864 LED BEACON REPLACEMENT
No scheduled maintenance is required. Perform on an “as needed” basis only.
5.3 L-864 CONTROLLER
No scheduled maintenance is required. Perform on an “as needed” basis only.
5.4 PHOTOCELL
The photocell is a sealed unit. No maintenance is needed or required other than
replacement as necessary.
6

AA1TSS LED CONTROLLER
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6.0 MAJOR COMPONENTS PARTS LIST
QTY PART NUMBER DESCRIPTION
1
6390-FAA
(This replaces the 102FAA
Photocell)
120 – 240V Photocell
1
PF-250
(This replaces the FS15530T
module)
Solid State Flasher (M1)
1 PRD7AG0 Mechanical Load Contactor (PRD)
1 VJ1008HWPL1X004 Enclosure
2 8WA1808 End Stop
2 S261D1 1 amp Circuit Breaker (B, S)
6 8WA1204 Single Pole Terminal (TB1, TB2)
1 MOV524V15 Metal Oxide Varistor (MOV)
1 SSPIGTAIL 20’ Photocell Pigtail
1 STJ01002 SPDT Switch (SW1)
7

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7.0 SUGGESTED SPARE PARTS LIST
QTY PART NUMBER DESCRIPTION
1
6390-FAA
(This replaces the 102FAA
Photocell)
120 – 240V Photocell
1
PF-250
(This replaces the FS15530T
module)
Solid State Flasher (M1)
8

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
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Warranty & Return Policy
TWR Lighting®, Inc. (“TWR®”) warrants its products (other than “LED Product”) against
defects in design, material (excluding incandescent bulbs) and workmanship for a period ending
on the earlier of two (2) years from the date of shipment or one (1) year from the date of
installation.
TWR Lighting®, Inc. (“TWR®”) warrants its “LED Product” against defects in design,
material and workmanship for a period of five (5) years from the date of shipment. TWR®, at its
sole option, will, itself, or through others, repair, replace or refund the purchase price paid for
“LED Product” that TWR®verifies as being inoperable due to original design, material, or
workmanship. All warranty replacement “LED Product” is warranted only for the remainder
of the original warranty of the “LED Product” replaced. Replacement “LED Product” will be
equivalent in function, but not necessarily identical, to the replaced “LED Product.”
TWR Lighting®, Inc. (“TWR®”) warrants its “LED Product” against light degradation for a
period of five (5) years from the date of installation. TWR®, at its sole option, will, itself, or
through others, repair, replace, or refund the purchase price paid for “LED Product” that TWR®
verifies as failing to meet 75% of the minimum intensity requirements as defined in the
FAA Advisory Circular 150/5345-43G dated 09/26/12. All warranty replacement “LED
Product” is warranted only for the remainder of the original warranty of the “LED Product”
replaced. Replacement “LED Product” will be equivalent in function, but not necessarily
identical, to the replaced “LED Product.”
Replacement parts (other than “LED Product”) are warranted for 90 days from the date of
shipment.
Conditions not covered by this Warranty, or which might void this Warranty are as follows:
x Improper Installation or Operation
x Misuse
x Abuse
x Unauthorized or Improper Repair or Alteration
x Accident or Negligence in Use, Storage, Transportation, or Handling
x Any Acts of God or Nature
x Non-OEM Parts
The use of Non-OEM parts or modifications to original equipment design will void the
manufacturer warranty and could invalidate the assurance of complying with FAA
requirementsas published in Advisory Circular 150/5345-43.

AA1TSS LED CONTROLLER
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Warranty & Return Policy
(continued)
Field Service – Labor, Travel, and Tower Climb are not covered under warranty. Customer
shall be obligated to pay for all incurred charges. An extensive network of certified and insured
Service Representatives is available if requested.
Repair, Replacement or Product Return RMA Terms – You must first contact our Customer
Service Department at 713-973-6905 to acquire a Return Merchandise Authorization (RMA)
number in order to return the product(s). Please have the following information available
when requesting an RMA number:
x The contact name and phone number of the tower owner or
x The contact name and phone number of the contractor
x The site name and number
x The part number(s)
x The serial number(s) (if any)
x A description of the problem
x The billing information
x The Ship To address
This RMA number must be clearly visible on the outside of the box. If the RMA
number is not clearly labeled on the outside of the box, your shipment will be refused. Please
ensure the material you are returning is packaged carefully. The warranty is null and void if
the product(s) are damaged in the return shipment.
All RMAs must be received by TWR LIGHTING®, INC., 10810 W. LITTLE YORK RD.,
#130, HOUSTON, TX 77041-4051, within 30 days of issuance.
Upon full compliance with the Return Terms, TWR®will replace, repair and return, or credit
product(s) returned by the customer. It is TWR®’s sole discretion to determine the
disposition of the returned item(s).

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Warranty & Return Policy
(continued)
RMA Replacements – Replacement part(s) will be shipped and billed to the customer for
product(s) considered as Warranty, pending return of defective product(s). When available, a
certified reconditioned part is shipped as warranty replacement with a Return Merchandise
Authorization (RMA) number attached. Upon receipt of returned product(s), inspection, testing,
and evaluation will be performed to determine the cause of defect. The customer is then notified
of the determination of the testing.
x Product(s) that is deemed defective and/or unrepairable and covered under warranty - a
credit will be issued to the customer’s account.
x Product(s) found to have no defect will be subject to a $75.00 per hour testing
charge (1 hour minimum), which will be invoiced to the customer. At this time
the customer may decide to have the tested part(s) returned and is responsible for the
return charges.
x Product(s) under warranty, which the customer does not wish returned, the
customer will be issued a credit against the replacement invoice.
RMA Repair & Return – A Return Merchandise Authorization (RMA) will be issued for all
part(s) returned to TWR®for repair. Upon receipt of returned product(s), inspection, testing,
and evaluation will be performed to determine the cause of defect. The customer is then
notified of the determination of the testing. If the returned part(s) is deemed unrepairable, or
the returned part(s) is found to have no defect, the customer will be subject to a $75.00 per
hour testing charge (1 hour minimum), which will be invoiced to the customer. Should the
returned parts be determined to be repairable, a written estimated cost of repair will be sent to
the customer for their written approval prior to any work being performed. In order to have the
tested part(s) repaired and/or returned, the customer must issue a purchase order and is
responsible for the return shipping charges.
RMA Return to Stock – Any product order that is returned to TWR®for part(s) ordered
incorrectly or found to be unneeded upon receipt by the customer, the customer may be
required to pay a minimum 20% restocking fee. Product returned for credit must be returned
within 60-days of original purchase, be in new and resalable condition, and in original
packaging. Once the product is received by TWR it’s condition will be evaluated and a credit
will be issued only once it is determined that the RMA Return Terms have been met.
Credits – Credits are issued once it is determined that all of the Warranty and Return Terms are
met. All credits are processed on Fridays. In the event a Friday falls on a Holiday, the credit
will be issued on the following Friday.

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Warranty & Return Policy
(continued)
Freight – All warranty replacement part(s) will be shipped via ground delivery and paid for by
TWR®.Delivery other than ground is the responsibility of the customer.
REMEDIES UNDER THIS WARRANTY ARE LIMITED TO PROVISIONS OF
REPLACEMENT PARTS AND REPAIRS AS SPECIFICALLY PROVIDED. IN NO EVENT
SHALL TWR®BE LIABLE FOR ANY OTHER LOSSES, DAMAGES, COSTS, OR
EXPENSES INCURRED BY THE CUSTOMER, INCLUDING, BUT NOT LIMITED TO,
LOSS FROM FAILURE OF THE PRODUCT(S) TO OPERATE FOR ANY TIME, AND ALL
OTHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, INCLUDING ALL PERSONAL INJURY OR PROPERTY DAMAGE DUE TO
ALLEGED NEGLIGENCE, OR ANY OTHER LEGAL THEORY WHATSOEVER. THIS
WARRANTY IS MADE BY TWR®EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, WHETHER EXPRESSED OR IMPLIED. WITHOUT LIMITING THE
GENERALITY OF THE FORGOING, TWR®MAKES NO WARRANTY OF
MERCHANTABILITY OR FITNESS OF THE PRODUCT(S) FOR ANY PARTICULAR
PURPOSE. TWR®EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES.

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
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RETURN MERCHANDISE AUTHORIZATION (RMA) FORM
RMA#: DATE:
CUSTOMER:
CONTACT: PHONE NO.:
ITEM DESCRIPTION (PART NO.):
MODEL NO.: SERIAL NO.:
ORIGINAL TWR INVOICE NO.: DATED:
DESCRIPTION OF PROBLEM:
SIGNED DATE NEEDED
RETURN ADDRESS:
PLEASE RETURN PRODUCT TO: 10810 W. LITTLE YORK RD., #130 HOUSTON, TX 77041-4051

AA1TSS LED CONTROLLER
M.A-2016.AA1TSS LED
9-14-15 REV 9-13-16
RETURN MERCHANDISE AUTHORIZATION (RMA) FORM
RMA#: DATE:
CUSTOMER:
CONTACT: PHONE NO.:
ITEM DESCRIPTION (PART NO.):
MODEL NO.: SERIAL NO.:
ORIGINAL TWR INVOICE NO.: DATED:
DESCRIPTION OF PROBLEM:
SIGNED DATE NEEDED
RETURN ADDRESS:
PLEASE RETURN PRODUCT TO: 10810 W. LITTLE YORK RD., #130 HOUSTON, TX 77041-4051