TWR Lighting E-2/3DB User manual

E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp)
IMPORTANT!!!
PLEASETAKETHETIMETOFILLOUTTHISFORMCOMPLETELY. FILEIT
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-2/3DB
SERIAL #
PURCHASE DATE
PURCHASED FROM

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp)
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.............................................................................4
2.5.1 BEACON MOUNTING AND WIRING.............................................4
2.5.2 LIGHTING KIT WIRING.................................................................5
2.6 ALARM WIRING ........................................................................................8
2.6.1 WHITE STROBE #1 FAILURE (ST1).............................................8
2.6.2 WHITE STROBE #2 FAILURE (ST2).............................................8
2.6.3 WHITE STROBE #3 FAILURE (ST3).............................................8
2.6.4 RED STROBE FAILURE (RF)........................................................8
2.6.5 POWER FAILURE (PF).................................................................9
2.6.6 PHOTOCELL (PC).........................................................................9
2.6.7 SIDELIGHT #1 ALARM (SA1)........................................................9
2.6.8 SIDELIGHT #2 ALARM (SA2)........................................................9
2.7 ALARM TESTING ......................................................................................9
2.7.1 WHITE STROBE FAILURE (ST1, ST2, and ST3) .........................9
2.7.2 RED STROBE FAILURE (RF)......................................................10
2.7.3 POWER FAILURE (PF)...............................................................10
2.7.4 PHOTOCELL (PC).......................................................................10
2.7.5 SIDELIGHT #1 ALARM (SA1)......................................................10
2.7.6 SIDELIGHT #2 ALARM (SA2)......................................................10
2.8 CONTROLLER CONFIGURATION..........................................................10
3.0 THEORY OF OPERATION.................................................................................12
3.1 THE POWER SUPPLY...................................................................................12
3.2 THE FLASHTUBE....................................................................................12
3.3 TIMING CIRCUIT.....................................................................................13
3.4 TRIGGER CIRCUIT.................................................................................13
3.5 ALARM CIRCUITS...................................................................................14
3.5.1 WHITE STROBE FAILURE (ST1, ST2, and ST3) .......................14
3.5.2 RED STROBE FAILURE (RF)......................................................14
3.5.3 POWER FAILURE (PF)...............................................................14
3.5.4 PHOTOCELL (PC).......................................................................14

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp)
TABLE OF CONTENTS
(CONTINUED)
3.5.5 SIDELIGHT ALARM (SA1 and SA2)............................................14
3.6 BLEEDER CIRCUIT.................................................................................15
3.7 STROBE DIAGNOSTIC CIRCUITS.........................................................15
3.7.1 CONTROL POWER ON ..............................................................15
3.7.2 HIGH VOLTAGE..........................................................................15
3.7.3 TRIGGER VOLTAGE...................................................................16
3.7.4 NIGHTMODE...............................................................................16
3.7.5 PRIMARY TIMING .......................................................................16
3.7.6 TIMING SIGNAL VERIFY.............................................................16
3.7.7 FLASH VERIFIED........................................................................16
3.7.8 STROBE FAIL TEST....................................................................17
4.0 TROUBLE SHOOTING ......................................................................................18
4.1 TOOL REQUIREMENTS..........................................................................18
4.2 DIAGNOSTIC EVALUATION...................................................................18
4.3 TROUBLE SHOOTING ASSISTANCE.....................................................19
4.3.1 FLASH VERIFY LED –OUT........................................................19
4.3.2 CONTROL POWER ON LED –OUT...........................................19
.4.3.3 PRIMARY TIMING LED –OUT....................................................19
4.3.4 FALSE OR NONEXISTENT BEACON ALARMS
(ST1, ST2, and ST3)....................................................................19
4.3.5 FALSE OR NONEXISTENT BEACON ALARM (RF)....................20
4.3.6 NO RED STROBE OPERATION .................................................20
5.0 MAINTENANCE GUIDE .....................................................................................21
5.1 FLASHTUBE REPLACEMENT ................................................................21
5.2 RED OBSTRUCTION LIGHTING.............................................................22
5.2.1 LAMP REPLACEMENT................................................................22
5.3 POWER SUPPLY ....................................................................................23
5.4 PHOTOCELL ...........................................................................................23
6.0 MAJOR COMPONENTS LIST............................................................................24
7.0 SUGGESTED SPARE PARTS LIST ..................................................................27
WARRANTY & RETURN POLICY................................................................................28
RETURN GOODS AUTHORIZATION FORM (RGA)....................................................30

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp)
APPENDIX
CHASSIS LAYOUT..............................................................................................H40-279
WIRING DIAGRAM (SCHEMATIC).....................................................................M01-279
HOUSING DETAIL ..............................................................................................HD0-279
INSTALLATION GUIDELINE................................................................................INS-279
PHOTOCELL HOUSING DETAIL..........................................................................100239
TOWER LIGHTING KIT 351’ TO 500’.........................................................................601
TOWER LIGHTING KIT 351’ TO 500’ CONDUIT/CABLE......................................601-01
TOWER LIGHTING KIT 51’ TO 500’ CONDUIT.....................................................601-02
TIMING/CONTROL PCB.....................................................................................H01-279
HIGH VOLTAGE RECTIFIER PCB......................................................................H02-258
RELAY PCB.........................................................................................................H03-279
TRIGGER VOLTAGE RECTIFIER PCB..............................................................H04-269
L-810 OL-1 SINGLE OBSTRUCTION LIGHT........................................................100031
L-810 OL-1 SINGLE OBSTRUCTION LIGHT DETAIL..........................................279-OL
L-810 OL-1 SINGLE OBSTRUCTION WIRING DETAIL......................................... 274-S
JUNCTION BOX DETAIL ......................................................................................100089

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 1
1.0 INTRODUCTION
TWR Lighting, Inc.’s Model E-2/3DB 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.
NOTE: Structures exceeding 500’ will require to be painted, in addition to this
lighting, for added visual hazard marking.
1.1 APPLICATION
The E-2/3DB Controller is for use on lighting structures or towers 351' to
700' AGL (above ground level) that are approved to be lighted with Dual
White/Red Flashing Medium Intensity Strobes in accordance with the FAA
Advisory Circular 70/7460-1J.
1.2 SPECIFICATIONS OF EQUIPMENT
Dimensions:
Controller (H x W x D)/Weight 33.00" x 36.75" x 9.0"/210.0 lbs.
Mounting Dim (H x W) 37.375” x 24.0”
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 285 Watts
Red Nightmode 930 Watts
White Nightmode 105 Watts
Temperature: +55°C / -55°C
Beacon Wind Load: 2.1 ft2

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 2
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 DEFEAT THE INTERNAL SAFETY SWITCHES
IN THE CONTROLLER AND BEACONS!!
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 5. Pay particular attention when choosing your controller
mounting location to ensure proper door opening and room for service
personnel. Refer to installation Drawings INS-279 and HDO-279 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 HDO-269 and H40-279)
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 "COM," the black wire
is connected to the socket terminal marked "B," and the red wire is

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 3
connected to the socket terminal marked "R." These socket connections are
made by using .25" quick connect terminals which must be crimped to the
wires. 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 terminal block TB2-5.
2.3.2 Connect the RED wire from the photocell to terminal block TB2-6.
2.3.3 Connect the WHITE wire from the photocell to terminal block TB2-7.
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 H40-279)
Power wiring to the control cabinet should be in accordance with local
methods and the National Electric Code (NEC).
2.4.1 A 30 amp circuit breaker is recommended at service panel
2.4.2 Connect the "HOT" side of the 120V AC line to TB1-16.
2.4.3 Connect the "NEUTRAL" side of the 120V AC line to TB1-17.
2.4.4 Connect the AC ground to the ground lug 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.

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 4
2.5 TOWER LIGHTING KIT
When installing this system, the customer will need to choose between using
strobe cable or conventional conduit wiring methods to wire the strobe
beacons. Refer to Lighting Kit Drawings 601-01 and 601-02 for conduit, and
601 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/ MAINTENANCE OF THIS
SYSTEM. DO NOT ATTEMPT TO DEFEAT THE INTERNAL SAFETY SWITCHES
IN THE CONTROLLER AND BEACONS!!
2.5.1 Beacon Mounting and Wiring
(Refer to Drawings HDO-279 and INS-279)
2.5.1.1 Bolt the beacon 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 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.

E-2/3DB CONTROLLER
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Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 5
2.5.1.3 Slip the electrical cable for the dual beacon 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:
Wire color to match Lamp platform wire color
Terminal
Block No.
10 Gauge Black 12 Gauge Black 1
10 Gauge Red/Black 20 Gauge Red/Black 2
10 Gauge Red 20 Gauge Red/White 3
14 Gauge White 20 Gauge White 4
14 Gauge White/Green
20 Gauge White/Green 5
14 Gauge Green 20 Gauge Green 6
16 Gauge Blue 20 Gauge Blue 7
16 Gauge Brown 20 Gauge Brown 8
16 Gauge Bare Wire Beacon Base
2.5.2 LIGHTING KIT WIRING
Install wiring between the controller to the beacon utilizing either
strobe cable or conduit method. Refer to Drawings HDO-279, 601,
601-01, and 601-02, for installation of light kits. Following these
minimum guidelines as well as any local or end user addition
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 requested by a customer and installed in this
manual. In cases such as this, the drawings will proceed the
manual if a conflict occurs.
All the necessary information for wiring the dual beacon and
sidelights is contained on the tower kit Drawings 601, 601-01, and
601-02. The connections for the dual beacon and sidelights in the
controller are as follows:

E-2/3DB CONTROLLER
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Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 6
2.5.2.1 Connect the 10 gauge Red/Black wire from Beacon #1
wiring to TB1-1.
2.5.2.2 Connect the 10 gauge Red wire from Beacon #1 wiring to
TB1-2.
2.5.2.3 Connect the 10 gauge Black wire from Beacon #1 wiring to
TB1-3.
2.5.2.4 Connect the 14 gaugeWhite wire from Beacon #1 wiring to
TB1-4.
2.5.2.5 Connect the 14 gauge White/Green wire from Beacon #1
wiring to TB1-5.
2.5.2.6 Connect the 10 gauge Red/Black wire from Beacon #2
wiring to TB1-6.
2.5.2.7 Connect the 10 gauge Red wire from Beacon #2 wiring to
TB1-7.
2.5.2.8 Connect the 10 gaugeBlack wire from Beacon #2 wiring to
TB1-8.
2.5.2.9 Connect the 14 gaugeWhite wire from Beacon #2 wiring to
TB1-9.
2.5.2.10 Connect the 14 gauge White/Green wire from Beacon #2
wiring to TB1-10.
2.5.2.11 Connect the 10 gauge Red/Black wire from Beacon #3
wiring to TB1-11.
2.5.2.12 Connect the 10 gauge Red wire from Beacon #3 wiring to
TB1-12.
2.5.2.13 Connect the 10 gaugeBlack wire from Beacon #3 wiring to
TB1-13.
2.5.2.14 Connect the 14 gaugeWhite wirefrom Beacon #3 wiring to
TB1-14.
2.5.2.15 Connect the 14 gauge White/Green wire from Beacon #3
wiring to TB1-15.

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 7
2.5.2.16 Connect the 14 gauge Green wire from Beacon #1 to the
first ground lug located to the left of TB1.
2.5.2.17 Connect the 14 gauge Green wire from Beacon #2 to the
first lug located to the left of TB1.
2.5.2.18 Connect the 14 gauge Green wire from Beacon #3 to the
first lug located to the left of TB1.
2.5.2.19 Connect the 16 gauge Bare Drain wire (if strobe cable
install) from Beacon #1 to second ground lug located to the
left of TB1.
2.5.2.20 Connect the 16 gauge Bare Drain wire (if strobe cable
install) from Beacon #2 to second ground lug located to the
left of TB1.
2.5.2.21 Connect the 16 gauge Bare Drain wire (if strobe cable
install) from Beacon #3 to second ground lug located to the
left of TB1.
2.5.2.22 Connect the 16 gaugeBrown wire from Beacon #1 wiring to
TB2-1.
2.5.2.23 Connect the 16 gauge Blue wire from Beacon #1 to TB2-2.
2.5.2.24 Connect the 16 gauge Blue wire from Beacon #2 to TB2-2.
2.5.2.25 Connect the 16 gauge Brown wire from Beacon #2 to TB2-
3.
2.5.2.26 Connect the 16 gauge Brown wire from Beacon #3 to TB2-
3.
2.5.2.27 Connect the 16 gauge Blue wire from Beacon #3 to TB2-4.
2.5.2.28 Connect the Red wire from the Sidelight #1 to fuse block
marked SL1.
2.5.2.29 Connect the Yellow wire from the Sidelight #2 to fuse block
marked SL2.
2.5.2.30 Connect the White Neutral wire from Sidelights #1 and #2

E-2/3DB CONTROLLER
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Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 8
to TB1-17.
2.5.2.31 Connect the Green ground wire (if cable is used) from
Sidelights #1 and #2, wiring the ground lug to the lower
right of TB1.
2.6 ALARM WIRING
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
equipment is available. Please inquire within the sales staff at the factory for
models available and pricing. Alarm configurations are shown on Drawings
H40-279 and M01-279.
2.6.1 White Strobe #1 Failure (ST1)
Connect the customer's alarm common to plug J3, terminal #2.
Connect the customer's alarm wire to plug J3, terminal #3, for
normally open (or) terminal #1, for normally closed monitoring.
2.6.2 White Strobe #2 Failure (ST2)
Connect the customer's alarm common to plug J3, terminal #5.
Connect the customer's alarm wire to plug J3, terminal #6, for
normally open (or) terminal #4, for normally closed monitoring.
2.6.3 White Strobe #3 Failure (ST3)
Connect the customer's alarm common to plug J3, terminal #8.
Connect the customer's alarm wire to plug J3, terminal #9, for
normally open (or) terminal #7, for normally closed monitoring.
2.6.4 Red Strobe Failure (RF)
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.
NOTE: All three (3) red strobe alarms are grouped due to the fail-
safe operation.

E-2/3DB CONTROLLER
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Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 9
2.6.5 Power Failure (PF)
Connect the customer's alarm common to plug J3, to terminal #11.
Connect the customer's alarm wire to plug J3, terminal #12, for
normally open (or) terminal #10, for normally closed monitoring.
2.6.6 Photocell (PC)
Connect the customer's alarm common to plug J3, terminal #17.
Connect the customer's alarm wire to plug J3, terminal #18, for "off"
operation (or) terminal #16, for "on" operation monitoring.
2.6.7 Sidelight #1 Alarm (SA1)
Connect the customer's alarm common to Module M1, terminal T4.
Connect the customer's alarm wire to Module M1, terminal T5, for
normally open (or) terminal T6, for normally closed monitoring.
2.6.8 Sidelight #2 Alarm (SA2)
Connect the customer's alarm common to Module M2, terminal T4.
Connect the customer's alarm wire to Module M2, terminal T5, for
normally open (or) terminal T6, for normally closed monitoring.
2.7 ALARM TESTING
To test alarms, follow these procedures using an "ohm" meterbetween alarm
common and alarm points.
2.7.1 White Strobe Failure (ST1, ST2, and ST3)
White strobe failure testing can be performed in the day mode
operation. Check for status of strobe beacons. Turn "off" switch S1
on PCB #1 and status should change after a four (4) second delay.
After test, turn S1 to the normal operating position.

E-2/3DB CONTROLLER
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Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 10
2.7.2 Red Strobe Failure (RF)
Red strobe failure testing can be performed in the night mode
operation. Check for status of strobe beacons. Turn "on" switch
SW2 on controller panel and status should change after an eight (8)
second delay. This testing will cause the unit to go into the back-up
white strobe operation. To clear this situation, turn off 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 SW1 on (or) cover the
photocell and operation status should change state. After test, turn
SW1 to normal operating position.
2.7.5 Sidelight #1 Alarm (SA1)
Controller should be in the nightmode of operation. Check status of
operation. Pull fuse switch SL1 open. Alarm should occur within five
(5) seconds. After test, re-engage fuse switch SL1.
2.7.6 Sidelight #2 Alarm (SA2)
Controller should be in the nightmode of operation. Check status of
operation. Pull fuse switch SL2 open. Alarm should occur within five
(5) seconds. After test, re-engage fuse switch SL2.
2.8 CONTROLLER CONFIGURATION
(Refer to Drawing H01-279)
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 switch settings as drawing
indicates. The following connections will need to be interfaced between
systems.

E-2/3DB CONTROLLER
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Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 11
2.8.1 Connect at least an 18/20 gauge wire from PCB #1, connector P1-15,
from unit set-up to be the master unit to PCB #1, connector P1-15, of
unit set-up to be the slave unit.
2.8.2 Connect at least an 18/20 gauge wire from TB1-9 of master unit to
slave unit TB2-6.
2.8.3 Connect at least an 18/20 gauge wire (ground) from one (1) chassis
to the other chassis.
2.8.4 Use a single breaker for supply power to all controllers.
2.8.5 Follow standard instructions provided in the manuals supplied with
the controllers.

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 12
3.0 THEORY OF OPERATION
3.1 THE POWER SUPPLY
The AC line is sent to transformers T2, and T2A through fuses F2, F3,
MOVMOD1, and relay K1. In order for K1 to energize and complete the
circuit to T2 and T2A, 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 beacons and the power supply must be closed and
secured.
Transformers T2, and T2A secondary outputs are around 1,000V AC. These
outputs are sent to the high voltage rectifier PCB (PCB #2) and converts the
1,000V AC of each transformer to around +550V DC and -550V DC in
daymode and +700V DC and –550V DC in nightmode. This high voltage is
then used to charge the energy storage capacitors C102, C112, and C122
through current limiting resistors R31A, R31B, and R31C, and steering
diodes D5, D6, and D8, for nightmode operation. Resistors R31A, R31B,
and R31C are bypassed through K5A, K5, and K5C for daymode operation.
Energy storage capacitors bank C103-131 is used for the daymode
operation and are connected to the high voltage through the normally closed
contacts of relays K5A, K5B, and K5C. When the light level drops below 3
foot candles, the photocell supplies 120V AC to relays K5A, K5B, and K5C,
which removes C103-131 from the discharge path leaving capacitors C102,
C112, and C122 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 FTW1, FTW2, and FTW3 (daymode) and FTR1, FTR2, and
FTR3 (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 inductors L1, L11, L2, L22,
L3, and L33. 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.

E-2/3DB CONTROLLER
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Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 13
The flashtube contains a gas called Xenon. When 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 transformers T4, T5,
T6, T7, T8, and T9) 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 de-
ionizes returning to its non-conducting state until another trigger pulse
arrives to repeat the process. Meanwhile, the storage capacitor is being re-
charged by the transformer and the high voltage rectifiers.
3.3 TIMING CIRCUIT
The timing circuit is contained entirely on printed circuit board #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 the flashtube. It actually generates two (2) groups of pulses.
The first is a pulse approximately once every 1.2 seconds to operate the
flashtube during daylight hours. The second is a burst at 100Hz 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 T1 secondary windings. The
250V AC is converted to DC, which is stored in a storage capacitor much like
the action of the 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.

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 14
3.5 ALARM CIRCUITS
3.5.1 White Strobe Failure (ST1, ST2, and ST3)
White Strobe Failure alarm circuit monitors each flash of the day
mode flashtube within the beacon. If the flashtube fails to flash (for
any reason) the alarm circuit operates relays K7A, K7B, and K7C (on
PCB #3) that the customer can connect to their alarm transmitting
devices. The alarm point can be accessed on J3 of PCB #3.
3.5.2 Red Strobe Failure (RF)
Red Strobe Failure alarm circuit monitors each flash of the night
mode flashtube within each beacon. If any Red Strobe flashtube fails
to flash (for any reason) the alarm circuit would operate 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 K1A would
drop, creating an alarm for the customer alarm transmitting device.
3.5.4 Photocell (PC)
The photocell alarm relay K4 is energized whenever the photocell or
SW3 is on. This relay will allow the customer to monitor the modes of
operation to determine if switch from day to night mode has occurred.
3.5.5 Sidelight Alarm (SA1, and SA2)
Modules M1, and M2 monitor the current flowing to the sidelights.
These modules can monitor from (1-4) 116W lamps. Factory setting
is generally for three (3) lamps. When the current falls below two (2)
amps (one [1] lamp less than the factory setting), then the onboard
relay will engage, creating an alarm.

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 15
3.6 BLEEDER CIRCUIT
The bleeder circuit is the most important safety item in this system. It
consists of resistors R32A, R32B, and R32C connected to the high voltage
storage capacitor through relays K2, and K2A. 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.
* * C A U T I O N * *
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 the
printed circuit boards 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 safety switches CSS,
BSS, isolation transformer T1, and fuse F11 on PCB #1. Once this
low voltage is at PCB #1, it is rectified, then sent to LED4 (D5). If for
any reason power is interrupted, (beacons opened, controller door
open, blown F1 fuse, failed relay, etc.) LED4 would be extinguished.
3.7.2 High Voltage
The Cathode side of the highvoltage HV1, HV2, and HV3, are routed
through current limiting resistors (R201, R202, and R203). When the
unit is in daymode, D14, D15, and D16 will be at full brightness when

E-2/3DB CONTROLLER
E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc
Rev. 01/13/00; Rev. 07/2000 o2L/H
Rev. 10/2000 (dwgs. 100239, 601, 601-01, 601-02, H02-258, 100031, 279L, 274S, 100089)
Rev. 06/21/00 (Reformatted Text; Revised Pg. 3 (2.4.1, 20 amp to 30 amp) Pg. 16
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 LEDs fail to glow, then the high voltage is no
longer present.
3.7.3 Trigger Voltage
The trigger voltage from fuse F41 (PCB #4) is sent to current limiting
resistor R1, and LED6 (D11). Under normal circumstances, the red
LED should be at full intensity, indicating voltage to be normal. An
absence of this indication means that the voltage is no longer
present.
3.7.4 Nightmode
Output voltage from the photocell (SSR) is connected to the coil of
relay K4 on PCB #3. Whenever the photocell senses the darkness,
or switch SW1 is on, relay K4 will energize, thereby sending 120V to
relay U2. Relay U2 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 Primary Timing
The primary timing pulses are received at LED8 (D12). LED8 will
flash according to the pulses received from the timingcircuit. If LED8
fails to flash, then the primary timing circuit has failed. Check LED9
(D28) for secondary 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