TWR Lighting D-1LVS-24V DC User manual

M.2007 Manuals.D-1LVS-24V DC
09/14/07
4300 WINDFERN RD., SUITE 100 - HOUSTON TX. 77041-8943
VOICE [phone] - FAX [phone]
web: www.twrlighting.com
IMPORTANT!!!
PLEASE TAKE THE TIME TO FILL OUT THE 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 # D-1LVS-24V DC
SERIAL #
PURCHASE DATE
PURCHASED FROM

D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
09/14/07
TABLE OF CONTENTS
1.0 INTRODUCTION..........................................................................................................................1
1.1 APPLICATION.................................................................................................................1
1.2 SPECIFICATIONS OF EQUIPMENT...........................................................................1
2.0 INSTALLATION...........................................................................................................................2
2.1 POWER SUPPLY CONTROL CABINET MOUNTING.............................................2
2.2 PHOTOCELL HOUSING ...............................................................................................2
2.3 PHOTOCELL WIRING ..................................................................................................2
2.4 POWER WIRING ............................................................................................................3
2.5 TOWER LIGHTING KIT ...............................................................................................3
2.5.1 Beacon Mounting.................................................................................................3
2.5.2 Lighting Kit Wiring.............................................................................................4
2.6 ALARM WIRING ............................................................................................................4
2.6.1 Alarm testing........................................................................................................4
2.6.2 Strobe Failure (SF) ..............................................................................................4
2.6.3 Power Failure (PF)...............................................................................................4
2.6.4 Photocell (PC).......................................................................................................4
3.0 THEORY OF OPERATION.........................................................................................................5
3.1 THE POWER SUPPLY ...................................................................................................5
3.2 THE FLASHTUBE...........................................................................................................5
3.3 TIMING CIRCUIT...........................................................................................................6
3.4 TRIGGER CIRCUIT .......................................................................................................6
3.5 ALARM CIRCUITS.........................................................................................................6
3.5.1 Strobe Failure (SF) ..............................................................................................6
3.5.2 Photocell (PC).......................................................................................................6
3.6 BLEEDER CIRCUIT.......................................................................................................6
3.7 DIAGNOSTIC LEDs........................................................................................................7
4.0 TROUBLESHOOTING ................................................................................................................8
4.1 TOOL REQUIREMENTS...............................................................................................8
4.2 DIAGNOSTIC EVALUATION.......................................................................................8
4.3 TROUBLE SHOOTING ASSISTANCE ........................................................................9
4.3.1 Flash Verify LED - Out.......................................................................................9
4.3.2 Control Power On LED - Out.............................................................................9
4.3.3 Primary Timing LED Out...................................................................................9
4.3.4 False or Nonexistent Beacon Alarms..................................................................9

D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
09/14/07
5.0 MAINTENANCE GUIDE...........................................................................................................10
5.1 FLASHTUBE REPLACEMENT ..................................................................................10
5.2 POWER SUPPLY...........................................................................................................10
5.3 PHOTOCELL.................................................................................................................10
6.0 MAJOR COMPONENTS PARTS LIST...................................................................................11
7.0 RECOMMENDED SPARE PARTS LIST ................................................................................13
WARRANTY & RETURN POLICY
RETURN MATERIAL AUTHORIZATION (RMA) FORM

D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
09/14/07
APPENDIX
Chassis Layout ......................................................................................... H40-293 (REV D)
Wiring Diagram ...................................................................................... M01-293 (REV A)
Housing Details D-1LVS–24V DC ........................................................ HD0-293 (REV B)
Installation Guideline ............................................................................... INS-293 (REV A)
Photocell Housing Detail ........................................................................... 100239 (REV A)
Tower Lighting Kit - Cable ........................................................................ 500-15 (REV B)
Control PCB #1 ........................................................................................ H01-293 (REV A)
Relay PCB #3 ........................................................................................... H03-226 (REV B)
Power Supply Detail ………………………………………………………….……..100529
Strobe Beacon Detail ................................................................................. 100325 (REV B)

D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
09/14/07
1.0 INTRODUCTION
The TWR Lighting, Inc. (TWR) Model D-1LVS-24V DC Type L-865 Controller has been designed
and built to the Federal Aviation Adm inistration’s (FAA) Advisory Circular 150/5345-43E with
safety and reliability in mind. TWR is committed to providing our customers with some of the best
products and services available. TWR welcom es you to our family of fine product, and we look
forward to servicing your needs now and in the future.
1.1 APPLICATION
The D-1LVS-24V DC L-865 Controller is for use on lighting structures or towers that are
approved to be lighted with Medium Inte nsity Strobes in accordance with the FAA’ s
Advisory Circular 70/7460-1K. Structures from 201' to 350' may be lighted with Medium
Intensity lights.
1.2 SPECIFICATIONS OF EQUIPMENT
Dimensions:
Controller (HxWxD)/Weight 18.0"x16.0"x9.25" 31 lbs.
Mounting Dim (HxW) 18.74"x12"
Beacon Height/Weight 17.25" 21 lbs.
Cable Diameter/Weight Per 100 ft. .625" +/- 10% 24 lbs.
Electrical 24V DC
Intensity:
Daymode 20,000 +/- 25% Effective Candelas
Nightmode 2,000 +/- 25% Effective Candelas
Beamspread:
Horizontal 360 °
Vertical 3 ° minimum
Flash Rate:
Daymode 40 fpm +/- 2 fpm
Nightmode 40 fpm +/- 2 fpm
Wattage:
Daymode 95 Watts
Nightmode 35 Watts
Temperature: +55 °C / -55°C
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D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
09/14/07
2.0 INSTALLATION WARNING DANGER
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE LETHAL
TO SERVICE PERSONEL. ALL INSTALLATION MAINTENANCE WORK SHOULD BE
DONE BY QUALIFIED SERVICE PERSONEL ONLY. WHEN PERSONNEL ARE
INSTALLINGSYSTEMOR PERFORMINGMAINTENANCE ON THISSYSTEM, MAKE
SURE THE POWER IS TURNED OFF AT THE SERVICE BREAKER PANEL!!
READ AND UNDERSTAND THE THEORY OF OPERATIONS AND ITS SAFETY
MESSAGES BEFORE ATTEMPTING INSTALLATION / MAINTENANCE OF THIS
SYSTEM. DO NOT ATTEMPT TO DEFEAT THE INTERNAL SAFETY SWITCHES IN
THE CONTROLLER AND BEACON.
2.1 POWER SUPPLY CONTROL CABINET MOUNTING
The power supply control cabinet can be located at the base of the structure, or in an equipment
building. Mounting Dim ensions can be found in Section 1.2, on page 1. Pay particular
attention when choosing your controller mounting location to ensure proper door opening and
room for service personnel. Refer to installation drawing HDO-293 for ease of installation.
2.2 PHOTOCELL HOUSING
The standard photocell housing is supplied with a 20' pigtail of 16 AWG Type TFFN wire. On
occasion, in mounting of the photocell, an additional amount of wire may be required. Refer to
drawing 100239 for proper assistance on determining gauge of wire for your specific needs.
2.3 PHOTOCELL WIRING
(Refer to Drawings HD0-293 and H40-293)
If the control cabinet is m ounted inside an equipm ent building, the photocell should be
mounted vertically on ½” conduit outside the building above the eaves facing north. Wiring
from the photocell housing socket to the control cabinet should consist of one (1) each; red,
black, and blue wires. The black wire is connected to the socket terminal marked “N,” the
blue wire is connected to the socket terminal marked “L,” and the red wire is connected to
the socket terminal marked “LO.” The phot ocell should be positioned so that it does not
“see” ambient light, which would prevent it from switching to the nightmode.
If the control cabinet is m ounted outside an equipm ent building, the photocell should be
mounted vertically on ½” conduit so the photocell is above the control cabinet. Care must be
taken to ensure that the photocell does not “see” any ambient light that would prevent it from
switching into the nightmode. The photocell housing socket wiring is the same as above.
2.3.1 Connect the BLUE wire from the photocell to TB1-8.
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D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
09/14/07
2.3.2 Connect the RED wire from the photocell to TB1-6.
2.3.3 Connect the BLACK wire from the photocell to TB1-7.
2.3.4 Install the photocell into the receptacl e and twist to the right while depressing to
lock into place.
NOTE: Wheninstallingmultiple controllerstogether,the photocellisonly requiredon
one (1) unit. It can be installed on the master or slave. SSR interconnect wire must be
common to all units. D2/3LV SSR TB3-2 / D-1LVS-24V DC SSR TB1-6.
2.4 POWER WIRING
(Refer to Drawing H40-293)
Power wiring to the control cabinet should be in accordance with local m ethods and the
National Electric Code (NEC).
2.4.1 A 24V DC power supply is required to power the controller.
2.4.2 Connect the “HOT” side of the 24V DC line to TB1-9.
2.4.3 Connect the “GROUND” side of the 24V DC line to TB1-10.
2.4.4 Controller panel should be connected to tower and/or building-grounding system
with the exception of installations on AM/RF Applications where controller
grounding to earth ground is prohibited. Ground the controller only to the tower
itself using a suitable RF ground.
2.5 TOWER LIGHTING KIT
When installing this system, the customer will need to use strobe cable wiring m ethod to
wire the strobe beacons. Refer to Lighting Kit Drawing 500-15 for cable installation.
2.5.1 Beacon Mounting
(Refer to Drawing HDO-293)
2.5.1.1 Bolt the beacon to the m ounting plate using four 5/8" x 1 1/2"
galvanized bolts that are supplied. Installer should make sure to check
for full thread engagement on Anco locknut. Allow 18" clearance in
back of the hinge (25" from the center of the base) to tilt lens back
without hitting an obstruction.
2.5.1.2 Level the beacon using the level at the base of the lens. Shims may be used
under beacon base or triple nutting each bolt with palnuts on all four (4)
nuts.
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D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
09/14/07
2.5.2 Lighting Kit Wiring
Install wiring between the controller and the beacon, utilizing strobe cable method.
(TWR LIGHTING CANNOT WARRANTY SYSTEMS THAT
EMPLOYSPLICING CABLE.) Refer to drawings HDO-293, and 500-15 for
install of lighting kits. Follow these minimum guidelines as well as any local or end
user addition requirements. Installing lighting kits will require lifting of the cable
by the supplied cable grip or conduit to affix to the tower. Always work safely and
adhere to all OSHA Safety Guidelines when lifting wiring or working on the
structure or tower itself. It is the installer’s responsibility to install the lighting kit in
a safe m anner. Installers can request from OSHA their requirem ents 29CFT
1926.21, and 29CFR 1926.105, to ensure compliance to regulations.
NOTE:On occasion a set of custom lighting kit drawings may be specifically requested by a
customer and installed in this manual. In cases such as this, the drawings will precede the manual
if a conflict occurs.
2.6 ALARM WIRING
Individual alarm contacts (Form C) are provided for strobe failure, power failure and
photocell on. It is left up to the customer or installer on how they choose to utilize these
contacts with their monitoring equipment. Alarm configurations are shown on drawing H40-
293.
2.6.1 Alarm testing
To test alarm s, follow these procedures using an “ohm” meter between alarm
common and alarm points.
2.6.2 Strobe Failure (SF)
Strobe failure testing can be performed in either day or nightmode strobe operation.
Check for status of strobe beacon. Turn on switch S1 on PCB #1, and status should
change after an eight (8) second delay . After test, switch S1 to norm al operating
position.
2.6.3 Power Failure (PF)
While the controller is in normal operation, shut off power to the controller at the
breaker panel. Alarm should be prompt. Reset breaker to resume normal operation.
2.6.4 Photocell (PC)
Controller should be in the daymode of operation when performing this test. Check
status of operation. Turn SW3 on or c over the photocell and alarm status should
change state. After test turn SW3 to normal operating position.
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D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
09/14/07
3.0 THEORY OF OPERATION
3.1 THE POWER SUPPLY
The 24V DC is connected to power converter through F1 and Relay K1. In order for K1 to
energize and complete the circuit to the power converter, the safety interlock switches CSS
and BSS must be closed. The BSS switch is located in the base of the beacon. For the safety
reason, both beacon and power supply m ust be closed and secured to have the sy stem
operate.
The HV output of the power converter sends 1,000V DC to the day capacitor bank. The
energy is stored there and discharged to the flashtube upon the trigger pulses. In the
nightmode, Relay K5 is energized, which inserts R31 and bursting choke between the day
capacitor bank and night capacitor, so a small portion of the energy that stored in night
capacitor is discharged to the flashtube.
3.2 THE FLASHTUBE
The flashtube FT is a quartz tube containing two (2) electrodes each. The electrode at the
positive (+) end is called the Anode and is c onnected to the positive side of the storage
capacitors through inductor L1. The electrode at the negative (-) end of the tube is called the
Cathode and is connected to the negative side of the energy storage capacitors banks.
The flashtube contains a gas called Xenon. Wh en the high voltage energy in the storage
capacitors is connected to the flashtube, nothing will happen since Xenon in its natural state
is not a conductor of electricity. However, when a very short duration high voltage pulse is
impressed on the trigger element of the tube (via the power supply and trigger transformer
T4) the Xenon gas is ionized and thereby becomes a good conductor of electricity. This
allows the electrical energy in the storage capacitors to discharge rapidly through the
flashtube, which converts this energy to light energy and heat energy. When the voltage
stored in the capacitors discharges to a low level the Xenon gas can no longer sustain
conduction and since the short trigger pulse is gone by this time, it deionizes returning to its
non-conducting state until another trigger pulse arrives to repeat the process. Meanwhile, the
storage capacitor is being recharged by the transformer and the high voltage rectifier.
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D-1LVS-24V DC CONTROLLER
M.2007 Manuals.D-1LVS-24V DC
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3.3 TIMING CIRCUIT
The timing circuit is contained entirely on PCB #1, and has its own power supply . This
circuit converts the 24V DC to approxim ately 12V DC, which is used to supply all of the
components in this circuit. It uses this low voltage DC to generate pulses that control the
flash rate of the flashtube. It actually generates two (2) groups of pulses. The first is a pulse
approximately once every 1.4 seconds to operate the flashtube during the day light hours.
The second is a burst of 10 or more very rapid pulses (to elongate the apparent flash) every
flash to operate the flashtube during the nighttime hours at reduced flash energy.
3.4 TRIGGER CIRCUIT
The trigger circuit consists of two (2) m ain com ponents, electronic switch and trigger
capacitor. The trigger capacitor is charged by a 300V DC output of the power converter. The
energy is stored in trigger capacitor m uch like the action of the high voltage circuit. The
main difference is that the storage capacitor is much smaller. When the electronic switch of
the trigger circuit receives a pulse from the timing circuit, it switches on and releases the
stored energy in the trigger capacitor and delivers to trigger transformer to initiate a flash.
3.5 ALARM CIRCUITS
3.5.1 Strobe Failure (SF)
Strobe Failure alarm circuit monitors each flash of the flashtube within each beacon.
If the flashtube fails to flash (for any reason), the alarm circuit operates a relay (on
PCB #1) that the customer can connect to their alarm transmitting devices. The
alarm point can be accessed on J2, on PCB #1.
The power failure alarm relay is energized during normal operation. Should the
power be removed for any reason, then Relay K6 would drop, creating an alarm for
the customer alarm transmitting device.
3.5.2 Photocell (PC)
The photocell alarm relay is energized whenever the photocell or SW3 is on. This
relay will allow the custom er to m onitor the modes of operation to determine if
switch from day to nightmode has occurred.
3.6 BLEEDER CIRCUIT
The bleeder circuit is the most important safety item in this system. It consists of resistor
R32 connected to the high voltage storage capacitor through relay K2. When the 24V DC
power supply is turned off, relays close allowing the resistors to discharge the high voltage
stored in the capacitor bank below 50V in 30 seconds.
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