TWR Lighting E-1DB2 User manual

M.E-2009.E-1DB2
3/25/07 – rev. 5/28/09
4300 WINDFERN RD STE 100 - HOUSTON, TX 77041-8943
VOICE: 713-973-6905 FAX: [phone]
web: www.twrlighting.com
IMPORTANT!!!!
PLEASE TAKE THE TIME TO FILL OUT THE FORM COMPLETELY. FILE
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 # E-1DB2
SERIAL#
PURCHASE DATE
PURCHASED FROM

M.E-2009.E-1DB2
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E-1DB2 CONTROLLER
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 and Wiring ..........................................................................4
2.5.2 Lighting Kit Wiring............................................................................................5
2.6 ALARM WIRING.................................................................................................................6
2.6.1 White Strobe Failure (SF).................................................................................6
2.6.2 Red Strobe Failure (RF).................................................................................... 6
2.6.3 Power Failure (PF) ............................................................................................6
2.6.4 Photocell (PC) ................................................................................................... 6
2.6.5 Sidelight Alarm (SA)......................................................................................... 7
2.7 ALARM TESTING...............................................................................................................7
2.7.1 White Strobe Failure (SF).................................................................................7
2.7.2 Red Strobe Failure (RF).................................................................................... 7
2.7.3 Power Failure (PF) ............................................................................................7
2.7.4 Photocell (PC) ................................................................................................... 7
2.7.5 Sidelight Alarm (SA)......................................................................................... 8
2.8 CONTROLLER CONFIGURATION....................................................................................8
3.0 THEORY OF OPERATION..............................................................................................................9
3.1 THE POWER SUPPLY.......................................................................................................9
3.2 THE FLASHTUBE ..............................................................................................................9
3.3 TIMING CIRCUIT..............................................................................................................10
3.4 TRIGGER CIRCUIT ..........................................................................................................10
3.5 ALARM CIRCUITS ...........................................................................................................10
3.5.1 White Strobe Failure (SF)...............................................................................10
3.5.2 Red Strobe Failure (RF).................................................................................. 10

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TABLE OF CONTENTS (CONTINUED)
3.5.3 Power Failure (PF) ..........................................................................................10
3.5.4 Photocell (PC) ................................................................................................. 11
3.5.5 Sidelight Alarm (SA)....................................................................................... 11
3.6 BLEEDER CIRCUIT .........................................................................................................11
3.7 STROBE DIAGNOSTIC CIRCUITS..................................................................................12
3.7.1 Control Power On ...........................................................................................12
3.7.2 High Voltage....................................................................................................12
3.7.3 Trigger Voltage................................................................................................12
3.7.4 Nightmode ....................................................................................................... 12
3.7.5 Operation Timing ............................................................................................13
3.7.6 Timing Signal Verify .......................................................................................13
3.7.7 Flash Verified .................................................................................................. 13
3.7.8 Strobe Fail Test...............................................................................................13
4.0 TROUBLESHOOTING...................................................................................................................14
4.1 TOOL REQUIREMENTS ..................................................................................................14
4.2 DIAGNOSTIC EVALUATION ...........................................................................................14
4.3 TROUBLESHOOTING ASSISTANCE .............................................................................15
4.3.1 Flash Verify LED - Out....................................................................................15
4.3.2 Control Power on LED - Out ..........................................................................15
4.3.3 Timing LED - Out.............................................................................................15
4.3.4 False or Nonexistent Beacon Alarm (SF) .....................................................15
4.3.5 False or Nonexistent Beacon Alarm (RF).....................................................16
4.3.6 No Red Strobe Operation...............................................................................16
5.0 MAINTENANCE GUIDE ................................................................................................................17
5.1 FLASHTUBE REPLACEMENT........................................................................................17
5.2 RED OBSTRUCTION LIGHTING.....................................................................................18
5.2.1 Lamp Replacement.........................................................................................18
5.3 PHOTOCELL....................................................................................................................19
6.0 MAJOR COMPONENTS PARTS LIST .........................................................................................20
7.0 SUGGESTED SPARE PARTS LIST.............................................................................................22
WARRANTY & RETURN POLICY
RETURN MERCHANDISE AUTHORIZATION (RMA) FORM

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APPENDIX
CHASSIS LAYOUT............................................................................... H40-329 (REV B)
WIRING DIAGRAM...............................................................................M01-329 (REV A)
HOUSING DETAIL................................................................................HD0-329 (REV A)
INSTALLATION GUIDELINE ................................................................INS-329 (REV A)
PHOTOCELL HOUSING DETAIL...........................................................100239 (REV B)
TOWER LIGHTING KIT 201’ TO 350’ CABLE RUN...............................600-04 (REV A)
SIDELIGHT MOUNT ASSEMBLY..........................................................100489 (REV A)
TOWER LIGHTING KIT 200’ TO 350’ CONDUIT RUN............................T1369 (REV A)
TIMING/CONTROL PCB ...................................................................... H01-329 (REV A)
E-1DB2 RECTIFIER PCB..................................................................... H02-329 (REV A)
RELAY PCB w/ALARM LOCKOUT ELIMINATION MODIFICATIONH03-269A (REV A)
CURRENT MEASUREMENT RELAY.....................................................100664 (REV E)
L-810 OL-1 SINGLE OBSTRUCTION LIGHT .....................................FM10018 (REV D)
L-810 OL-1 SINGLE OBSTRUCTION LIGHT DETAIL...........................279-OL (REV B)
L-810-OL-1 SINGLE OBSTRUCTION WIRING DETAIL.......................... 274-S (REV A)
JUNCTION BOX DETAIL .......................................................................100089 (REV A)
STDBEACON ASSEMBLY.....................................................................100414 (REV C)

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E-1DB2 CONTROLLER
1.0 INTRODUCTION
The TWR Lighting, Inc. (TWR) Model E-1DB2 Type L-864/L-865 Controller has been
designed and built to the Federal Aviation Administration‘s (FAA) Advisory Circular
150/5345-43F, with safety and reliability in mind. TWR is committed to providing our
customers with some of the best products and services available. TWR welcomes you to
our family of fine products, and we look forward to servicing your needs now and in the
future.
1.1 APPLICATION
The E-1DB2 Controller is for use on lighting structures or towers (201' to 350' AGL)
that are approved to be lighted with Dual White/Red Flashing Medium Intensity
Strobes in accordance with the FAA’s Advisory Circular 70/7460-1K.
1.2 SPECIFICATIONS OF EQUIPMENT
Dimensions:
Controller (H X W X D) / Weight 22" x 17.5625" x 10.75" / 62.0 lbs
Mounting Dim (H X W) 21.25" x 10.0"
Beacon Height / Weight 28.0" / 36 lbs
Cable Diameter / Weight per 100 ft. .625" +/- 10% 24 lbs
Electrical Voltage: 120V AC +/- 10% 60 Hz (Standard)
240V AC +/- 10% 60 Hz (Available)
Intensity:
White Daymode 20,000 +/- 25% Effective Candelas
Red Nightmode 2,000 +/- 25% Effective Candelas
White Nightmode (Back-up mode) 2,000 +/- 25% Effective Candelas
Beam Spread:
Horizontal 360°
Vertical 3°Minimum
Flash Rate:
White Daymode 40 fpm +/- 2 fpm
Red Nightmode 22 fpm +/- 2 fpm
White Nightmode (Back-up mode) 40 fpm +/- 2 fpm
Wattage:
Daymode 298 Watts
Red Nightmode 128 Watts
White Nightmode 41 Watts
Temperature: +55°C / -55°C
Beacon Wind Load: 2.1 ft2
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2.0 INSTALLATION WARNING DANGER!!!
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE LETHAL TO
SERVICE PERSONNEL. ALL INSTALLATION AND MAINTENANCE WORK SHOULD
BE DONE BY QUALIFIED SERVICE PERSONNEL ONLY. WHEN PERSONNEL IS
INSTALLING SYSTEM OR PERFORMING MAINTENANCE ON THIS SYSTEM, MAKE
SURE THE POWER IS TURNED OFF AT THE SERVICE BREAKER PANEL!!
READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY
MESSAGES BEFORE ATTEMPTING INSTALLATION/MAINTENANCE OF THIS
SYSTEM. DO NOT ATTEMPT TO DEFEATTHE INTERNAL SAFETY SWITCHES IN THE
CONTROLLER AND BEACON!!
2.1 POWER SUPPLY CONTROL CABINET MOUNTING
The power supply control cabinet can be locatedat thebase of thestructure orin an
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 drawings
INS-329, and HD0-329, for ease of install.
2.2 PHOTOCELL HOUSING
The standard photocell housing is supplied witha 20'pigtail of 16AWG TYPETFFN
wire. On occasion in mounting of the photocell an additional amount of wiremay 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 HD0-329, and H40-329)
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. Wiringfromthe photocellhousing socket tothe controlcabinetshould 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 "L," 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 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 housing socket wiring is the same as above.
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2.3.1 Connect the BLACK wire from the photocell to TB1-8.
2.3.2 Connect the RED wire from the photocell to TB1-9.
2.3.3 Connect the WHITE wire from the photocell to TB1-10.
2.3.4 Install the photocellinto thereceptacleand twistto the rightwhile depressing
to lock into place.
2.4 POWER WIRING
(Refer to Drawing H40-329)
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 TB1-11.
2.4.3 Connect the "NEUTRAL" side of the 120V AC line to TB1-12.
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 connectedto thetower and/orbuildinggrounding
system with the exception of installations on AM RF Applications where
controllergroundingto earthground is prohibited. Groundthe controlleronly
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
method to wire the strobe beacon. Refer to drawing 600-04 for cable installations.
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WARNING DANGER!!!
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE
LETHAL TO SERVICE PERSONNEL. ALL INSTALLATION AND MAINTENANCE
WORK SHOULD BE DONE BY QUALIFIED SERVICE PERSONNEL ONLY.
WHEN PERSONNEL IS INSTALLING SYSTEM OR PERFORMING
MAINTENANCE ON THIS SYSTEM, MAKE SURE THE POWER IS TURNED OFF
AT THE SERVICE BREAKER PANEL!!
READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY
MESSAGES BEFORE ATTEMPTING INSTALLATION/MAINTENANCE OF THIS
SYSTEM. DO NOT ATTEMPT TO DEFEAT THE INTERNAL SAFETYSWITCHES
IN THE CONTROLLER AND BEACON!!
2.5.1 Beacon Mounting and Wiring (Refer to Drawings HD0-329, and INS-329)
2.5.1.1 Bolt the beacon to the mounting plate using four (4) 5/8" X 1 1/4"
galvanized bolts that are supplied. Installer should make sure to
check for full thread engagement on Anco locknut. Allow 16"
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 spirit 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.
2.5.1.3 Slip the electrical cable for the dualbeacon through thewatertight
connector (cable gland bushing), and tighten the gland nut to
make a watertight seal. Attach the wires to the terminal strip as
follows:
Connect Cable To Lamp platform Terminal
Wire Color Match Wire Color Block Number
10 Gauge Red/Black 12 Gauge Red/Black 2
10 Gauge Red 12 Gauge Red 3
14 Gauge Green 16 Gauge Green 4
10 Gauge Black 16 Gauge Black 5
14 Gauge White 16 Gauge White 6
14 Gauge White/Green 16 Gauge White/Green 7
16 Gauge Blue 16 Gauge Blue 8
16 Gauge Brown 16 Gauge Brown 9
16 Gauge Bare Wire Beacon Base
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2.5.2 Lighting Kit Wiring
Install wiring from the controller to the beacon utilizing strobe cable method.
(TWR LIGHTING CAN NOT WARRANTY SYSTEMSTHATEMPLOY
SPLICING CABLE.) Refer to drawings HD0-329, 600-04, and T1369, for
install of light kits. Following these minimum guidelines as well as any local
or end user additional requirements, installing light 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 manner. Installers can request 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 requestedby acustomerandinstalledin thismanual.
In cases such as this, the drawings will precede the manual if a
conflict occurs.
All the necessary information for wiring the dual beacon and sidelights is
contained on the tower kit drawings 600-04, and T1369. The connections
for the dual beacon and sidelights in the controller are as follows:
2.5.2.1 Connect the 10 gauge Red/Black wire from beacon wiring to TB1-
1.
2.5.2.2 Connect the 10 gauge Red wire from beacon wiring to TB1-2.
2.5.2.3 Connect the 10 gauge Black wire from beacon wiring to TB1-3.
2.5.2.4 Connect the 14 gauge White wire from beacon wiring to TB1-4.
2.5.2.5 Connect the 14 gauge White/Green wire from beacon wiring to
TB1-5.
2.5.2.6 Connect the 14 gauge Green wire from beacon wiring to the
ground screw left of TB1.
2.5.2.7 Connect the 16 gauge Brown wire from beacon wiring to TB1-6.
2.5.2.8 Connect the 16 gauge Blue wire from beacon wiring to TB1-7.
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2.5.2.9 Connect the Neutral wire from sidelight wiring to TB1-12.
2.5.2.10 Connect the Red wire from sidelight wiring to TB1-13.
2.5.2.11 Connect the ground wire (if cable is used) from sidelight wiring to
ground screw right of TB1.
2.6 ALARM WIRING
Individual alarm contacts (Form C) are provided for strobe failures, 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. External monitoring
equipmentis available. Pleaseinquirewithin thesalesstaff atthe factoryformodels
available and pricing. Alarm configurations are shown on drawings H40-329, and
M01-329.
2.6.1 White Strobe Failure (SF)
Connect the customer's alarm common to plugJ3, terminal#5. Connectthe
customer's alarm wire to plug J3, terminal #4, for normallyopen (or) terminal
#6, for normally closed monitoring.
2.6.2 Red Strobe Failure (RF)
Connect the customer's alarm common to plug J3, terminal #11. Connect
the customer's alarm wire to plug J3, terminal #10, for normally open (or)
terminal #12, for normally closed monitoring.
2.6.3 Power Failure (PF)
Connect the customer's alarm common to plug J3, terminal #14. Connect
the customer's alarm wire to plug J3, terminal #15, for normally open (or)
terminal #13, for normally closed monitoring.
2.6.4 Photocell (PC)
Connect the customer's alarm common to plugJ3, terminal#8. Connectthe
customer's alarm wire to plug J3, terminal #7, for"off" operation (or)terminal
#9, for "on" operation monitoring.
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2.6.5 Sidelight Alarm (SA)
Connect the customer's alarm common to plugJ3, terminal#2. Connectthe
customer's alarm wire to plug J3, terminal #1, for normallyopen (or) terminal
#3, for normally closed monitoring.
2.7 ALARM TESTING
To test alarms, follow these procedures using an "ohm" meter between
alarm common and alarm points.
2.7.1 White Strobe Failure (SF)
White strobe failure testing can be performed in the daymode operation.
Check for status of strobe beacon. Turn "on" switch S1 on PCB #1, and
status will change after a nine (9) second delay. After test, turn switch “S1”
to the normal operating position (down position).
2.7.2 Red Strobe Failure (RF)
Red strobe failure testing can be performed in the nightmode operation.
Check forstatusof strobebeacon. Turn"off" switchSW2 oncontrollerpanel
and status will change after a ten (10) second delay. This testing will cause
the unit to go into the back-up white strobe operation. Toclear this situation,
turn “on” switch SW2, and reset the breaker.
2.7.3 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 the breaker to resume
normal operation.
2.7.4 Photocell (PC)
Controller should be in the daymode of operation when performing this test.
Check status of operation. Turn “on” switch SW1, (or) cover the photocell
and operation status should change state. After test, turn switch SW1 tothe
normal operating position.
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2.7.5 Sidelight Alarm (SA)
Controller should be in the nightmode of operation. Check status of
operation. Pull fuse switch “S1” open. Alarm shall occur within 30 seconds.
After test, re-engage fuse switch ”S1.”
2.8 CONTROLLER CONFIGURATION
(Refer to Drawings H01-329, and H40-329)
This unit is factory setup to be a master controller. If this unit is to be used in
conjunction with an additional unit, change dip-switchsettingsas drawingindicates.
The following connections will need to be interfaced between systems.
2.8.1 Connect at least an 18-gauge wire from PCB #1, connector P1-15, from unit
setup to be the master unit to PCB #1, connector P1-15, of unit setup to be
the slave unit.
2.8.2 Connect at least an 18-gauge wire from J1-5 (item 10) of master unit to
slave unit J1-5 (item 10).
2.8.3 Connect at least an 18-gauge wire (ground) from one chassis to the other
chassis.
2.8.4 Connect atlease an 18-gaugewire fromPCB#1,J3 (byLED1)of masterunit
to slave unit PCB #1, J3 (by LED1).
2.8.5 Use a single breaker for supply power to all controllers.
2.8.6 Use only one (1) photocell for one (1) system.
2.8.7 Follow standard instructions provided in the manual supplied with the
controller.
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3.0 THEORY OF OPERATION
3.1 THE POWER SUPPLY
The AC line is sent to transformers T1, and T2 through fuse F2, MOVMOD1, and
relay K1. 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
beacon. In order for the system to operate, the beacon and the power supply must
be closed and secured.
Transformer T1 secondary output is around 1,100V AC. These outputs are sent to
the high voltage rectifier PCB (PCB #2) and converts the 1,100V AC to around
+550V DC and -550V DC in daymode, and +750V DC and -550V DC in nightmode.
This high voltage is then used to charge the energy storage capacitor C102 through
current limiting resistors R31, T3 and steering diode D5 for nightmode operation.
Energy storage capacitors bank C103-110 is used for the daymode operation and
are connected to the high voltage through the normally closed contacts of relay K5.
When the light level drops below 3 foot candles the photocell supplies 120V AC to
relay K5, which removes C103-110 from the discharge path leaving capacitor C102
in the circuit for nightmode operation. The energy storage capacitor banks are
connected to the flashtube through the interconnecting tower wiring.
3.2 THE FLASHTUBE
The flashtubes FT1 (daymode) and FT2 (nightmode) are quartz tubes containing
two (2) electrodes each. The electrode at the positive (+) end is called the anode
and is connected to the positive side of the storage capacitors through inductor L1,
and L2. The electrode at the negative (-) end of thetube iscalledthe Cathodeand is
connected to the negative side of the energy storage capacitors banks.
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The flashtube contains a gas called Xenon. When the high voltage energy in the
storage capacitors is connected to theflashtube, nothingwill happensinceXenonin
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 transformers T4 and T5), the Xenon gas is ionized and
therebybecomesa goodconductor of electricity. Thisallows theelectricalenergy 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 deonizes
returning to its nonconducting state until another trigger pulse arrives to repeat the
process. Meanwhile, the storage capacitor is being recharged by the transformer
and the high voltage rectifiers.
3.3 TIMING CIRCUIT
The timing circuit is contained entirely on PCB #1. The timing circuit has its own
power supply. This circuit converts the AC voltage to approximately 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 theflashtube. It actuallygenerates two
(2) groups of pulses. The first is a pulse approximately once every 1.5 seconds to
operate the flashtube during daylight hours. The second is a burst at 50 Hz to
elongate the apparent flash during the night time hours at reduced flash energy.
3.4 TRIGGER CIRCUIT
The trigger circuit is supplied by transformer T2 secondary windings. The 250V AC
is converted to DC, which is stored in a storage capacitor much like theaction ofthe
high voltage circuit. The main difference is that the storage capacitor is much
smaller. The trigger circuit receives the pulses generated by the timing circuit. It
releases its stored energy with each pulse and delivers it to the flashtube's trigger
element to initiate each flash.
3.5 ALARM CIRCUITS
3.5.1 White Strobe Failure (SF)
White Strobe Failure alarm circuit monitors each flash of the daymode
flashtube within the beacon. If the flashtube fails to flash (for any reason),
the alarm circuit operates relay K7 (on PCB #3) that the customer can
connect to their alarm transmitting devices. The alarm point can be
accessed on J3, of PCB #3.
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3.5.2 Red Strobe Failure (RF)
Red Strobe Failure alarm circuit monitors each flash of the nightmode
flashtube within the beacon. If the flashtube fails to flash (for any reason),
the alarm circuit operates relay K8 (on PCB #3) that the customer can
connect to their alarm transmitting devices. The alarm point can be
accessed on J3, of PCB #3.
3.5.3 Power Failure (PF)
The power failure alarm relay is energized during normal operation. Should
the power be removed for any reason, then relay K1 would drop, creating an
alarm for the customer alarm-transmitting device. The alarm point can be
accessed on J3, of PCB #3.
3.5.4 Photocell (PC)
The photocell alarm relay K4 is energized whenever the photocell orSW1 is
on. This relay will allow the customer to monitor the modes of operation to
determine if switch from day to nightmode has occurred. The monitor point
can be accessed on J3, of PCB #3.
3.5.4.1 To test daymode operation in night time, set SW1 switch in the
middle position. Make sure to switch downward to “NORMAL”
position after testing.
3.5.5 Sidelight Alarm (SA)
Module M1 monitors the current to the sidelights. This module can monitor
one (1) to five (5) 116W lamps. Factory setting is generally for three (3)
lamps. When the current falls to two (2) lamps (1 lamp less than the factory
setting), then the onboard relay will engage, creating an alarm that is then
sent to PCB #3.
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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 AC line voltage is turned off, the relay will close, allowing the resistors to
discharge the high voltage stored in the capacitor banks below 50V in 30 seconds.
It also has auxiliary bleeder resistor R33 connecting day capacitors directly.
**CAUTION**
NEVER RELY ON THIS CIRCUIT TO RENDER THIS SYSTEM HARMLESS. ANY
DEFECT IN THIS CIRCUIT COULD ALLOW A HAZARDOUS HIGH VOLTAGE
CHARGE TO REMAIN ON THE STORAGE CAPACITORS. ALWAYS WAIT AT
LEAST 30 SECONDS AFTER POWER HAS BEEN TURNED OFF BEFORE
STARTING ANY WORK ON THIS SYSTEM. ALWAYS MEASURE THE
VOLTAGE ON THE STORAGE CAPACITORS WITH A VOLTMETER BEFORE
STARTING ANY OTHER WORK ON THIS SYSTEM. NEVER ATTEMPT TO
DEFEAT THE SAFETY INTERLOCKS.
3.7 STROBE DIAGNOSTIC CIRCUITS
The diagnostic circuit is provided as a means of making system checks and
maintenance more convenient. This circuit is entirely contained on PCB #1, and
PCB #2. The circuits that are contained on PCB #1, and PCB #2 are as follows:
3.7.1 Control Power On
Line from the 120V AC input is sent through F2, safety switches CSS, BSS,
isolation transformer T2, and fuse f1 on PCB #1. Once this low voltage is at
PCB #1, it is rectified, and then sent to LED4 (D5). If, for any reason, power
is interrupted, (beacon opened, controller door open, blown fuses, failed
relay, etc.) LED4 would be extinguished.
3.7.2 High Voltage
The Cathode side of the high voltage HV is routed through a current limiting
resistor (R201). When the unit is in daymode, D14 will be at full brightness
when the capacitors are at full charge, but dims with the discharging of the
storage capacitors. A constant intensity indicates that high voltage is
present but capacitors are not discharging (check other indicators for fault).
When the red LED fails to glow, then the high voltage is no longer present.
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3.7.3 Trigger Voltage
The trigger voltage from fuse F3 is sent to PCB #2, current limiting resistor
R1, and PCB #1’s, LED6 (D11). Under normal circumstances, the LED
should be at full brightness when the trigger capacitor is at full charge and
indicating voltage to be normal, but dims with trigger capacitor discharge
(light flashing). An absence of this indication means that the voltage is no
longer present.
3.7.4 Nightmode
Output voltage from the photocell (SSR1) isconnected tothecoil ofrelay K4
on PCB #3. Whenever the photocell senses the darkness or switch SW1 is
on, relay K4 will energize, thereby sending 120V to relay K2, on PCB #1.
Relay K2 will supply 12V DC to the timing circuit as well as LED7 (D7).
LED7 will glow a constant red when in the nightmode.
3.7.5 Operation Timing
The operation timing pulses are received at LED8 (D12). LED8 will flash
according to the pulses received from the timing circuit. If LED8 fails to
flash, then check LED9 (D28) for timing operation. The strobe unit should
produce 40 (+/- 2) pulses per minute in daymode or nightmode back-up
operation. The strobe unit in nightmode operation should produce 22 (+/- 2)
pulses per minute.
3.7.6 Timing Signal Verify
Timing pulses (either primary or secondary) are received at LED9 (D28).
The LED will flash according to the pulses received from the timing circuit.
In the unlikely event that this LED is out, then total timing failure has
occurred.
3.7.7 Flash Verified
Current from the Cathode side of the flashtube (FTC) is sent through the
current sensing transformer T4 on PCB #1. T4 will send a pulse to the gate
of the SCR's Q13, and turn it on. Capacitor C15, via Q13, will send voltage
to LED1 (D20). After each confirmed flash, LED1 will blink. Absence of a
blinking LED signifies that strobe beacon has ceased to flash.
3.7.8 Strobe Fail Test
On PCB #1, switch S1, when turned up, cuts off the timing signal to the
trigger circuit and extinguishes LED8 (D12). At this time a strobe alarm
should be received at J3. The normal position of switch S1 is off (switch
downward).

M.E-2009.E-1DB2
3/25/07 – rev. 5/28/09
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4.0 TROUBLESHOOTING
Much of the troubleshooting of thissystem will consist ofcorrecting a "beaconout" situation.
There may also be a failure mode where the flashtube is still flashing, but at the wrong rate
or the wrong intensity.
You must study and understand the safety messages and the theory of operation before
attempting any service on this system. Servicing this system must be done by qualified
personnel only.
4.1 TOOL REQUIREMENTS
In order to be prepared to trouble shoot or repair this system, aminimum amount of
tools and equipment will be required. A recommendation list includes:
1) 5/16 Flat Electrician's Screwdriver 1) 5/32 Allen Wrench
1) #2 Phillips Screwdriver 1) Needle Nose Pliers
1) Nut Driver or Socket Set 1) Precision Flat Screwdriver
1) Multi meter - Analog or Digital 600V AC / 1,000V DC Minimum
4.2 DIAGNOSTIC EVALUATION
The first step in troubleshooting of this system or performing annual maintenance
will require the technician to open the controller door. With the power off to the
controller, the technician should look overthe controller circuit, andrepair or replace
any apparent problems such as loose wire connections, corroded terminations, or
burnt parts. After the initial visual checks have been completed, restore power to
the controller and pull out on the plunger of the cabinet safety switch (CSS)located
at the right edge of the enclosure. Observe at this time the LEDs located on PCB
#1, and PCB #2. Determine, by observation ofthese LEDindicators, if thecontroller
is performing to normal operation.
LEDs on PCB #1 are numbered from top to bottom, 1-9. LEDs on PCB #2 are
numbered from top to bottom, D14 - D16. (See drawings H02-329, and H01-329.)
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4.3 TROUBLESHOOTING ASSISTANCE
4.3.1 Flash Verify LED (LED 1) - Out
4.3.1.1 Observe high voltage LED (D14) on the same beacon circuit to
determine if it is available. If the LED is dim or out completely,
then check the high voltage capacitor bank (C103 - C110
daymode, C102 nightmode) for a short. If no capacitor is found to
be shorted, check the resonant cap (C101) fora short. Disconnect
strobe cable to see if D14 illuminates. Need to verify if bleeder
relay is operating properly. If the LED is at full illumination, go to
the next step.
4.3.1.2 Check the status of trigger LED6. If LED is dim or off, check fuse
F3. If blown, replace with exact type of fuse. If the fuse blows
again, check PCB #1, and PCB #2. Replace as necessary. If LED
is okay, go to the next step.
4.3.1.3 If steps 4.3.1.1, and 4.3.1.2 check out okay, check or re-lamp the
beacon.
4.3.2 Control Power on LED (LED 4) - Out
4.3.2.2 Check interlock circuit for an open circuit. If open, make the
necessary repairs. If okay, check fuseF2 in the cabinet. Replace
if bad.
4.3.3 Timing LED (LED 9) – Out
4.3.3.1 Observe the status of the timing LED8. If the LED is dim or out
completely, check LED9, and if dim or out, check 18V AC
between P1-13, 14 (Item 12). If yes, replace PCB #1. If one (1)
or both are lit, you should have timing.
4.3.4 False or Nonexistent Beacon Alarm (SF)
4.3.4.1 If alarm trips when the system appears to be working normallyor
fails to show an alarm when there is an obvious failure, check
PCB #1, P1-4, and P1 – 10, for 120V AC output. If voltage is
okay, go to the next step.
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