TWR Lighting E-1DBSL User manual

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
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.
FILEINASAFEPLACE. INTHEEVENTYOUEXPERIENCEPROBLEMS
WITH ORHAVEQUESTIONSCONCERNINGYOURCONTROLLER, THE
FOLLOWING INFORMATION IS NECESSARY TO OBTAIN PROPER
SERVICE AND PARTS.
MODEL # ________E-1DBSL
SERIAL #
PURCHASE DATE
PURCHASED FROM

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
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 ..........................................................................................3
2.4 POWER WIRING....................................................................................................3
2.5 TOWER LIGHTING KIT........................................................................................4
2.5.1 LED Red Beacon Mounting and Wiring ..................................................4
2.5.2 Tower Kit Wiring......................................................................................6
2.6 ALARM WIRING .................................................................................................7
2.6.1 White Strobe Failure (SF).........................................................................8
2.6.2 Lights On (LO) .........................................................................................8
2.6.3 Power Failure (PF)....................................................................................8
2.6.4 LED Red Beacon Burnout (BB)...............................................................8
2.6.5 Sidelight Failure (SL) ...............................................................................8
2.7 ALARM TESTING................................................................................................9
2.7.1 White Strobe Failure (SF).........................................................................9
2.7.2 Lights On (LO) .........................................................................................9
2.7.3 Power Failure (PF)....................................................................................9
2.7.4 LED Red Beacon Burnout (BB)...............................................................9
2.7.5 Sidelight Failure (SL)98
3.0 THEORY OF OPERATION ..........................................................................................10
3.1 THE POWER SUPPLY ......................................................................................10

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
3.2 THE FLASHTUBE................................................................................................11
3.3 LED BEACON ......................................................................................................11
3.4 TIMING CIRCUIT................................................................................................11
3.5 TRIGGER CIRCUIT.............................................................................................11
3.6 ALARM CIRCUITS..............................................................................................11
3.6.1 White Strobe Failure (SF).......................................................................11
3.6.2 LED Red Beacon Burnout (BB).............................................................11
3.6.3 Power Failure (PF)..................................................................................12
3.6.4 Sidelight Failure (SL) .............................................................................12
3.7 BLEEDER CIRCUIT.............................................................................................12
3.8 DIAGNOSTIC CIRCUITS....................................................................................13
3.8.1 Control Power On...................................................................................13
3.8.2 High Voltage...........................................................................................13
3.8.3 Trigger Voltage.......................................................................................14
3.8.4 Nightmode...............................................................................................14
3.8.5 Primary Timing.......................................................................................14
3.8.6 Timing Signal Verify..............................................................................15
3.8.7 Flash Verified .........................................................................................15
3.8.8 Strobe Fail Test.......................................................................................15
4.0 TROUBLESHOOTING..................................................................................................16
4.1 TOOL REQUIREMENTS.....................................................................................16
4.2 DIAGNOSTIC EVALUATION............................................................................16
4.3 TROUBLESHOOTING ASSISTANCE................................................................17
4.3.1 Strobe Flash Verify LED - Out...............................................................17
4.3.2 Control Power on LED - Out..................................................................18
4.3.3 Primary Timing LED - Out.....................................................................18
4.3.4 False or Nonexistent Beacon Alarm (SF)...............................................18
4.3.5 LED/BEACON/Flasher Failure..............................................................18

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
5.0 MAINTENANCE GUIDE...............................................................................................20
5.1 FLASHTUBE REPLACEMENT ..........................................................................20
5.2 RED OBSTRUCTION LIGHTING.......................................................................21
5.3 PHOTOCELL........................................................................................................21
6.0 MAJOR COMPONENTS LIST
7.0 SUGGESTED SPARE PARTS LIST
WARRANTY & RETURN POLICY
RETURN MERCHANDISE AUTHORIZATION (RMA) FORM

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
APPENDIX
CHASSIS LAYOUT............................................................................................ H40-264 (Rev. O)
WIRING DIAGRAM........................................................................................... MO1-264 (Rev. I)
HOUSING DETAIL...........................................................................................HDO-264 (Rev. C)
INSTALLATION GUIDELINE..........................................................................................INS-264
PHOTOCELL HOUSING DETAIL.......................................................................100239 (Rev. A)
TOWER LIGHTING KIT 201’ TO 350’ CABLE........................................................602 (Rev. C)
SIDELIGHT MOUNT ASSEMBLY …………………………………………….100489
(REV.A)
TIMING/CONTROL PCB................................................................................. H01-226B (Rev. F)
HIGH VOLTAGE RECTIFIER PCB............................................................... H02-226A (Rev. A)
RELAY PCB w/ALARM LOCKOUT ELIMINATION MODIFICATION .................. H03-264A
OL1VLED2 (L810 OBSTRUCTION LIGHT).......................................................100656 (Rev. A)
LED BEACON AND SIDELIGHT CURRENT SENSOR....................................100694 (Rev. A)
L865/864 LED DUAL BEACON ASSEMBLY ...................................................................100604
JUNCTION BOX DETAIL....................................................................................100089 (Rev. A)

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
1.0 INTRODUCTION
The TWR Lighting, Inc. (TWR) Model E-1DBSL Type L-864/L-865 Controller has been
designed and built to the Federal Aviation 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 welcomes you to our family of fine products and we
look forward to servicing your needs now and in the future.
1.1 APPLICATION7
The E-1DBSL Controller is for use on lighting structures or towers (201' to 350'
AGL) that are approved to be lighted with Dual Red “LED”/ White “Strobe” Flashing
Medium Intensity in accordance with the Federal Aviation Administration's (FAA)
Advisory Circular 70/7460-1K.
1.2 SPECIFICATIONS OF EQUIPMENT
Dimensions:
Controller (H X W X D) / Weight 18.0" X 16.0" X 9.25" / 45.0 lbs
Mounting Dim (H X W) 18.74" X 12.0"
Beacon Height / Weight 27.0" / 80 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 30 fpm +/- 2 fpm
White Nightmode (Back-up mode) 40 fpm +/- 2 fpm
Wattage:
Daymode 95 Watts
Red Nightmode 145 Watts
White Nightmode 35 Watts
Temperature: +55°C / -55°C
Beacon Wind Load: 2.1 ft2
1

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
2.0 INSTALLATION
WARNING DANGER!!!
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE
LETHAL TO SERVICE PERSONNEL. ALL INSTALLATION AND
MAINTENANCE WORK MUST BE DONE BY QUALIFIED SERVICE
PERSONNEL ONLY. WHEN PERSONNEL IS INSTALLING SYSTEM OR
PERFORMINGMAINTENANCE ON THISSYSTEM, MAKE SURETHE POWER
IS TURNED OFF AT THE SERVICE BREAKER PANEL!!
READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY
MESSAGESBEFORE ATTEMPTINGINSTALLATION/MAINTENANCEOFTHIS
SYSTEM. DO NOT ATTEMPT TO DEFEAT THE INTERNAL SAFETY
SWITCHES IN THE CONTROLLER AND STLDBEACON!!
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 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-264, and HDO-264, 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

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
2.3 PHOTOCELL WIRING (Refer to Drawings HDO-264 and H40-264)
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 housing 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 "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.
2.3.1 Connect the BLACK wire from the photocell to TB1-6.
2.3.2 Connect the RED wire from the photocell to TB1-7.
2.3.3 Connect the WHITE wire from the photocell to TB1-8.
2.3.4 Install the photocell into the receptacle and twist to the right while depressing
to lock into place.
2.4 POWER WIRING (Refer to Drawing H40-264)
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.
3

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
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 the 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
method to wire the STLDBEACON. Refer to tower kit drawing 602, for cable
installations. 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/MAIN-
TENANCE OF THIS SYSTEM. DO NOT ATTEMPT TO DEFEAT THE
INTERNAL SAFETY SWITCHES IN THE CONTROLLER AND
STLDBEACON!!
2.5.1 LED Red Beacon Mounting and Wiring (Refer to Drawings HDO-264, and
INS-264)

DUAL MEDIUM INTENSITY LED/STROBE
MODEL E-1DBSL
M.2006 MANUALS.E-1DBSL
REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor)
REV. 06/21/06 (part numbers), 7/13/06 (Appendix & 6.0 Major Comp. List)
REV 10/20/06 (Appendix & parts lists)
REV. 04/10/07 (text)
4
2.5.1.1 Bolt the STLDBEACON to the mounting plate using four 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 STLDBEACON 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 STLDBEACON through the
watertight 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 16 Gauge Red 1
14 Gauge White/Green 16 Gauge White/Green 2
16 Gauge Brown 16 Gauge Brown 3
16 Gauge Blue 16 Gauge Blue 4
10 Gauge Black 16 Gauge Black 5
14 Gauge White 16 Gauge White 6
14 Gauge Green 16 Gauge Green 7
10 Gauge Red/Black 16 Gauge Red/Black 8
16 Gauge Bare Wire Beacon Base
5