TWR Lighting D-1LVS User manual

M.2016.D.D-1LVS
10-14-08 – REV 6-23-16
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 THE FORMCOMPLETELY. FILEIN
A SAFE PLACE. IN THE EVENT YOU EXPERIENCE PROBLEMS WITHOR
HAVE QUESTIONS CONCERNING YOUR CONTROLLER, THE
FOLLOWING INFORMATION IS NECESSARY TO OBTAIN PROPER
SERVICE AND PARTS.
MODEL # D-1LVS
SERIAL #
PURCHASE DATE
PURCHASED FROM

D-1LVS CONTROLLER
M.2016.D.D-1LVS
10-14-08 – REV 6-23-16
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) .................................................................................... 5
2.6.4 Photocell (PC)............................................................................................ 5
2.7 CONTROLLER CONFIGURATION ....................................................................... 5
3.0 THEORY OF OPERATION................................................................................................. 6
3.1 THE POWER SUPPLY........................................................................................... 6
3.2 THE FLASHTUBE .................................................................................................. 6
3.3 TIMING CIRCUIT.................................................................................................... 7
3.4 TRIGGER CIRCUIT................................................................................................ 7
3.5 ALARM CIRCUITS ................................................................................................. 7
3.5.1 Strobe Failure (SF).................................................................................... 7
3.5.2 Photocell (PC)............................................................................................ 8
3.6 BLEEDER CIRCUIT ............................................................................................... 8
3.7 STROBE DIAGNOSTIC CIRCUITS ....................................................................... 8
3.7.1 Control Power On ..................................................................................... 8
3.7.2 High Voltage.............................................................................................. 9
3.7.3 Trigger Voltage.......................................................................................... 9
3.7.4 Nightmode ................................................................................................. 9
3.7.5 Primary Timing.......................................................................................... 9
3.7.6 Timing Signal Verify.................................................................................. 9
3.7.7 Flash Verified........................................................................................... 10
3.7.8 Strobe Fail Test....................................................................................... 10

D-1LVS CONTROLLER
M.2016.D.D-1LVS
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4.0 TROUBLESHOOTING ..................................................................................................... 11
4.1 TOOL REQUIREMENTS...................................................................................... 11
4.2 DIAGNOSTIC EVALUATION ............................................................................... 11
4.3 TROUBLESHOOTING ASSISTANCE................................................................. 12
4.3.1 Flash Verify LED - Out............................................................................ 12
4.3.2 Control Power On LED - Out.................................................................. 12
4.3.3 Primary Timing LED Out......................................................................... 13
4.3.4 False or Nonexistent Beacon Alarms................................................... 13
5.0 MAINTENANCE GUIDE ................................................................................................... 14
5.1 FLASHTUBE REPLACEMENT............................................................................ 14
5.2 POWER SUPPLY................................................................................................. 14
5.3 PHOTOCELL........................................................................................................ 14
6.0 MAJOR COMPONENTS PARTS LIST............................................................................ 15
7.0 RECOMMENDED SPARE PARTS LIST.......................................................................... 17
WARRANTY & RETURN POLICY
RETURN MERCHANDISE AUTHORIZATION (RMA) FORM

D-1LVS CONTROLLER
M.2016.D.D-1LVS
10-14-08 – REV 6-23-16
APPENDIX
CHASSIS COMPONENT LAYOUT........................................................H40-283 (REV F)
SCHEMATIC LAYOUT .........................................................................M01-283 (REV B)
HOUSING DETAILS D-1LVS ...............................................................HD0-283 (REV B)
INSTALLATION GUIDELINE...............................................................................INS-283
PHOTOCELL HOUSING DETAIL...........................................................100239 (REV H)
TOWER LIGHTING KIT - CABLE............................................................500-12 (REV B)
CONTROL PCB #1.............................................................................H01-226B (REV F)
HIGH VOLTAGE RECTIFIED PCB #2 ...............................................H02-226A (REV A)
RELAY PCB #3..................................................................................... H03-226 (REV B)
STROBE BEACON DETAIL...................................................................100437 (REV G)
WRAPLOCK FASTENING DETAIL...................................................................... 100984

D-1LVS CONTROLLER
M.2016.D.D-1LVS
10-14-08 – REV 6-23-16
1.0 INTRODUCTION
The TWR Lighting®, Inc. (TWR®) Model D-1LVS Type L-865Controllerhas been designed
andbuiltto the FederalAviationAdministration’s(FAA)AdvisoryCircular150/5345-43Gwith
safety and reliability in mind. TWR®is committed to providing our customers with some of
thebest products and servicesavailable. TWR®welcomesyoutoourfamilyoffineproducts
and we look forward to servicing your needs now and in the future.
1.1 APPLICATION
The D-1LVS L-865 Controller is for use on lighting structures or towers that are
approved to be lighted with Medium IntensityStrobes in accordancewith the FAA’s
Advisory Circular 70/7460-1K. Structures from 201' to 350' may be lighted with
Medium Intensity lights. NOTE: Structures exceeding 500' will require to be
painted in addition to this lighting for added visual hazard marking.
1.2 SPECIFICATIONS OF EQUIPMENT
Dimensions:
Controller (HxWxD)/Weight 18.0"x16.0"x9.25" 45.0 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 120V AC +/- 10% 60 Hz (Standard)
240V AC +/- 10% 60 Hz (Available)
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 CONTROLLER
M.2016.D.D-1LVS
10-14-08 – REV 6-23-16
2.0 INSTALLATION
2.1 POWER SUPPLY CONTROL CABINET MOUNTING
The power supplycontrolcabinet can be located atthe base of the structure or inan
equipment building. Mounting Dimensions 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-283, for ease of install.
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 HD0-283, and H40-283)
If the control cabinet is mounted inside an equipment building,the photocellshould
be mounted vertically on ½” conduit outside the building above the eaves facing
north. Wiringfromthephotocellhousing socketto thecontrolcabinetshouldconsist
of one 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.
If the control cabinetis mounted outside an equipmentbuilding,thephotocellshould
be mounted vertically on ½” conduit so the photocell is above the control cabinet.
Caremustbe taken to assurethatthe photocelldoes not “see”anyambientlightthat
would prevent it from switching into the nightmode. The photocell housing socket
wiring is the same as above.
2.3.1 Connect the BLACK wire from the photocell to TB1-8.
2.3.2 Connect the RED wire from the photocell to TB1-6.
2.3.3 Connect the WHITE wire from the photocell to TB1-7.
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D-1LVS CONTROLLER
M.2016.D.D-1LVS
10-14-08 – REV 6-23-16
2.3.4 Installthephotocellintothe receptacleandtwisttotherightwhiledepressing
to lock into place.
2.4 POWER WIRING
(Refer to Drawing H40-283)
Power wiring to the control cabinet should be in accordance with local methods and
the National Electric Code (NEC).
2.4.1 A 15 amp circuit breaker is recommended at service panel.
2.4.2 Connect the “HOT” side of the 120V AC line to TB1-9.
2.4.3 Connect the “NEUTRAL” side of the 120V AC line to TB1-10.
2.4.4 Connect the AC ground to the ground stud to the lower right of the terminal
block TB1.
2.4.5 Controller panel should be connected to tower and/or building grounding
system with the exception of installations on AM/RF Applications where
controllergrounding to earthgroundis prohibited. Groundthecontrolleronly
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 to wire the
strobe beacon. Refer to Lighting Kit Drawing 500-12 for cable installation.
2.5.1 Beacon Mounting
(Refer to Drawing HDO-283)
2.5.1.1 Bolt the beacon to the mounting 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 CONTROLLER
M.2016.D.D-1LVS
10-14-08 – REV 6-23-16
2.5.2 Lighting Kit Wiring
Install wiring between the controller and the beacon utilizing strobe cable
method. (TWR LIGHTING CANNOT WARRANTY SYSTEMS THAT
EMPLOY SPLICING CABLE.) Refer to drawings HDO-283 and 500-12
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
responsibilityto installthe lightingkit in a safe manner. Installers canrequest
from OSHA their requirements 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 theirmonitoring equipment. Alarm configurations areshown on
drawing H40-283.
2.6.1 Alarm testing
To test alarms, 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. Checkforstatusof strobebeacon. TurnonswitchS1 on PCB#1
and status should change after an eight (8) second delay. After test,switch
S1 to normal operating position.
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D-1LVS CONTROLLER
M.2016.D.D-1LVS
10-14-08 – REV 6-23-16
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 cover the photocell and alarm
status should change state. After testturn SW3 to normaloperatingposition.
2.7 CONTROLLER CONFIGURATION
(Refer to Drawing H01-226B)
This unit is factory set-up to be a master controller. If this unit is to be used in
conjunction with an additional unit, change dipswitch settings (DS1) as drawing
indicates.
2.7.1 Connect at least an18/20 gauge wire from the master unit D1LVS PCB #1,
P1, Position 15, to D1LVS slave unit PCB #1, P1, Position 15. Refer to
drawing H40-283.
2.7.2 Connect another 18/20 gauge wire, along with the existing wire, into SSR1,
Position 6, of P2, of the master unit.
2.7.3 Remove the existing wire, SSR1, from Position 6, P2, of the slave unit and
capoff.
2.7.4 Connect the 18/20 gauge wire from (Note: 2.7.2) the master unit to Position
6, P2, of the slave unit.
2.7.5 Only one (1) photocell is needed, and is to be connected to the master unit.
2.7.6 Connect at least an 18/20 gauge wire (ground) from one (1) chassis to the
other chassis.
2.7.7 Both controllers must be connected to the same phase of power supply.
2.7.8 Follow standard instructions provided in the manual supplied with the
controller.
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D-1LVS CONTROLLER
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3.0 THEORY OF OPERATION
3.1 THE POWER SUPPLY
The AC line is sent to transformer T1 through fuse F1 and relayK1. In order for K1
to energize and complete the circuit to T1, the safety interlock switch CSS, BSS,
must be closed. The BSS switch is located in the base of the beacon. In order for
the system to operate, the beacon and the power supply must be closed and
secured.
Transformer T1 secondaryoutput is around 1,000V AC. These outputs are sent to
the high voltage rectifier PCB (PCB #3) and converts the 1,000V AC of the
transformer to around +500V DC and -500V DC in daymode and +700V DC and -
550VDC innightmode. This high voltageisthen usedtocharge the energystorage
capacitorC102throughcurrentlimitingresistorR31steeringdiodeD5fornightmode
operation. Resistor R31 is by-passed through relay K5 for daymode operation.
Energy storage capacitors bank C103-109 is used for the daymode operation and
are connected to the high voltage through the normallyclosed contacts of relayK5.
When the lightleveldrops below 3 foot candles,photocell6390-FAA2supplies120V
AC to relayK5, which removes C103-109 fromthe discharge pathleavingcapacitor
C102 in the circuit for nightmode operation.
The energy storage capacitor bank is connected to the flashtube through the
interconnecting tower wiring.
3.2 THE FLASHTUBE
The flashtube FT is a quartztube containing two (2)electrodes each. The electrode
atthepositive(+)endis calledthe Anode and isconnected tothepositivesideofthe
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.
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