TWR Lighting REDSTAR User manual

10810 W LITTLE YORK RD. STE 130-HOUSTON TX 77041-4051
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 BEACON, THE FOLLOWING INFORMATION IS NECESSARY TO
OBTAIN PROPER SERVICE AND PARTS.
MODEL # REDSTAR (FAA L-864 BEACON)
SERIAL #
PURCHASE DATE
PURCHASED FROM

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Questions or information beyond this manual, please contact TWR Lighting, Inc.
TWR Lighting, Inc.
10810 W Little York Rd. Ste 130 - Houston, TX 77041-4051
Voice: 713-973-6905 - Fax: [phone] – Toll Free: 800-661-8606
E-mail: [e-mail]
web: www.twrlighting.com
The use of Non-original manufacturer parts which are not approved by TWR Lighting, Inc. may invalidate the
warranty as well as compliance with requirements as published in the FAA Advisory Circulars AC70/7460-1M,
AC150/5345-43J and AC150/5345-53 and ICAO Annex 14 Volume 2 standards.
DISCLAIMER
While every effort has been made to provide a complete, up-to-date, accurate manual, no liability claims for
damages resulting from any errors or omissions in this manual will be accepted by TWR Lighting, Inc.
COPYRIGHT
Copyright © 2005 TWR Lighting, Inc.
All rights reserved. Reproduction or use of any part of this installation & operation manual is prohibited without
express written permission from TWR Lighting, Inc.

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Contents
1GENERAL INFORMATION .....................................................................................................................................6
1.1 Optional User Interface functions ...................................................................................................................6
1.1.1 Control options ............................................................................................................................................6
2INSTALLATION ......................................................................................................................................................6
2.1 L864 Beacon Light (Part # REDSTAR)...............................................................................................................7
2.1.1 Beacon mounting.........................................................................................................................................7
2.1.2 Beacon electrical..........................................................................................................................................7
2.2 Cable (Part # LCABLE-2)...................................................................................................................................7
2.2.1 Cable specifications .....................................................................................................................................7
2.2.2 Cable connection .........................................................................................................................................7
2.3 Optional: ADLS Junction Box (Part # JBWT-ADLS) ...........................................................................................8
(Aircraft Detection Lighting Systems) ......................................................................................................................8
2.3.1 JB mounting .................................................................................................................................................8
2.3.2 JB electrical connection ...............................................................................................................................8
2.3.3 JB beacon connections ................................................................................................................................8
2.3.4 JB alarm monitoring connection..................................................................................................................8
2.3.5 JB Ethernet connection................................................................................................................................8
3OPERATION ..........................................................................................................................................................9
3.1 JP202 Jumper Functions..................................................................................................................................9
3.1.1 JP202 Position 1...........................................................................................................................................9
3.1.2 JP202 Positions 2 & 3...................................................................................................................................9
3.2 Input and Output...........................................................................................................................................10
3.2.1 Beacon Alarm.............................................................................................................................................10
3.3 LED Indicators................................................................................................................................................11
4MAINTENANCE...................................................................................................................................................12
4.1 Troubleshooting ............................................................................................................................................12
4.1.1 No Power: (Note: REDSTAR ONLY OPERATES IN NIGHT MODE)................................................................12
4.1.2 No Mode Change (Beacon Photocell)........................................................................................................12
4.1.3 GPS Failure:................................................................................................................................................12
4.1.4 Beacon Alarms: ..........................................................................................................................................12

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5MAJOR COMPONENTS PARTS LIST.....................................................................................................................13
6WARRANTY AND RETURN POLICY ......................................................................................................................14
6.1 RMA FORM ....................................................................................................................................................17
7Drawing - REDSTAR BEACON CHASSIS ...............................................................................................................18
8Drawing - CABLE DATA SHEET............................................................................................................................18
9Drawing – LIGHT KIT FOR WIND TURBINE..........................................................................................................18
10 Drawing – (OPTIONAL) ADLS JUNCTION BOX DETAIL ........................................................................................18
11 Drawing - (OPTIONAL) ADLS LIGHTING KIT CHASSIS FOR WIND TURBINE.........................................................18
12 Drawing - (OPTIONAL) ADLS LIGHTING KIT SCHEMATIC FOR WIND TURBINE ...................................................18

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1GENERAL INFORMATION
The REDSTAR beacon is for lighting structures such as towers and wind turbines in accordance with the FAA
Advisory Circular AC 70/7460-1M, CAR 621 and ICAO Annex 14.
The REDSTAR is equipped with red visible and infrared LEDs, photocell, and GPS for independent operation
without need for controls with the ability to report failures specified by FAA, CAR and ICAO that need to be
advised to proper authorities. The pigtail cable (LCABLE-2) combines power, alarms, and communication
wires for ease of lighting system installation.
1.1 Optional User Interface functions
1.1.1 Control options
a) LC-STAR Controller with display for a user-friendly interface allowing full access and
diagnostics including Ethernet Modbus interface for use such as Aircraft Detecting Lighting
System (ADLS).
b) JBWT-ADLS Junction box for power & alarm terminations including Ethernet Modbus
interface for Aircraft Detecting Lighting System (ADLS) or remote SCADA MODBUS TCP/IP
control and monitoring.
c) Beacon also has RS-485 MOSBUS RTU Slave interface for direct local control and monitoring
by customer SCADA system.
2INSTALLATION
Before installing the REDSTAR beacon read this manual completely. Check equipment for damage if damage
is evident report to TWR technical server before proceeding.
Suggested tools:
1. #1 flat head cabinet tip screwdriver (small for spring terminal blocks)
2. 18” Crescent wrench
3. Electrical Multi-Meter (Able to measure up to 40Mega-ohms of resistance)
Note: System warranty is to be declared null and void if this lighting system is not installed according to
instructions and diagrams within this manual.

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2.1 L864 Beacon Light (Part # REDSTAR )
Figure 1 REDSTAR BEACON
2.1.1 Beacon mounting
The Beacon has four mounting feet arranged every 90 degrees on a 13-1/4” bolt hole circle. It
will be necessary to have bracket and/or hardware for mounting on structure. Refer to
mounting dimension on the Beacon drawing toward the back of this manual.
2.1.2 Beacon electrical
The standard beacon operates on 120/240 VAC 50/60Hz power (15 Watts during night
operation). Optional 24/48 VDC beacons are available. Refer to the beacon drawing toward the
back of this manual.
2.2 Cable (Part # LCABLE-2 )
2.2.1 Cable specifications
TWR uses a single composite PVC jacketed cable with 0.655-inch diameter using 2x 12awg
(Black and White) for power, 1x 14awg (Green) for ground, 4x 22awg (Blue, Yellow and Orange,
Gray) for communications and 2x 22awg (Red and Tan) for alarms. All shield wires must be
twisted together and terminated to ground, except within REDSTAR Beacon do not terminate,
cut of shield wires.
2.2.2 Cable connection
LCABLE-2 cable uses a cord connector/cable gland over PVC jacket of cable for watertight entry.
Refer to drawings toward the back of this manual.

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2.3 Optional: ADLS Junction Box (Part # JBWT-ADLS )
(Aircraft Detection Lighting Systems)
2.3.1 JB mounting
The ADLS junction box (JBWT-ADLS) is typically installed at the base of a structure or within
wind turbine nacelle. The junction box has mounting feet 8.39”x 13.08”. Refer to details on the
Chassis layout drawing toward the back of this manual.
2.3.2 JB electrical connection
Route your specific Electrical power input through the base of enclosure by a ¾” NPT hub.
Installation should be in accordance with local methods and National Electrical Codes (NEC).
2.3.3 JB beacon connections
Maximum of two REDSTAR cable glands entries are available through the base of the enclosure
with terminal connections for power, data, and alarms.
2.3.4 JB alarm monitoring connection
One alarm entry through base of enclosure is for monitoring beacon to indicate if light has failed
through a relay prewired to normally closed. Normally open is available within REDSTAR base
pcb, see operation section.
2.3.5 JB Ethernet connection
One RJ45 Ethernet connection is at base of enclosure for ADLS communications.

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3OPERATION
REDSTAR is factory configured to operate without additional setup, simple apply required voltage.
During initial power up unit will take a few minutes to initialize and receive GPS satellite synchronization.
Alarm condition will clear after initialization indicating system is functioning without fault. REDSTAR will not
come on during the daylight without the photocell receiving required minimum ambient light.(Photocell is
Inside the beacon lens on the opposite side of leveling bubble)
TWR technical service is available 24/7 and can assist you with measurements at [phone].
3.1 JP202 Jumper Functions
3.1.1 JP202 Position 1
a) 120 Ohm terminator resistor
i. Jumper to be installed on beacons that are at the ends of the RS485 communication
bus.
ii. Lights in the middle of the string should not be terminated.
3.1.2 JP202 Positions 2 & 3
a) Bias voltage supply for RS485 A and B signal lines.
i. The jumpers are to be installed on the single light installations.
ii. On multiple light installations jumper should only be installed on the light at the end of
the RS485 bus.
iii. Both positions 2 & 3, jumpers must be installed, as loss of communication can occur if
only of them is installed.

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3.2 Input and Output
3.2.1 Beacon Alarm
Mechanical Relay - REDSTAR alarm is
normally closed (NC) and will open if
failure occurs. Normally open (NO) is
available within REDSTAR base pcb,
see detail of connection in the
following image. Alarm wires: Red is
“NC” or “NO” and tan is (C) common.
Alarm relay rating:
* Alarm relay is also software
reconfigurable for both Energizing
or De-Energizing on failure.
OUT1 (+,-)
Solid-State Relay
60V DC/AC 100mA max.
On/Off toggling with flash code,
default operating mode
IN1 (+,-)
Opto-isolated Input
12/24VDC min 10mA
Not Enable, default operating mode
12VDC OUT (+,-)
Isolated 12VDC 1W power supply
Optional Bias voltage for inputs and outputs
Figure 3 Power Supply
Figure 2 Alarm Relay Rating

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3.3 LED Indicators
REDSTAR Beacon Indicator Legend:
a) Driver Fault (IR, RED)
1. Red on Fault, normally off
2. Shows fault in either LED driver or LEDs
b) 24V
1. Green, normally on
2. 2.Shows 24VDC supply voltage present
c) 3.3V
1. Green, normally on
2. Shows 3.3VDC supply voltage present
d) LED2
1. Green, quick flashing once per second
2. Shows normal microprocessor operation loop
e) LED1
1. Green, Flashing with beacon LED head
2. Shows normal flash code operation loop
f) ALARM_OUT
1. Green, on when Mechanical relay is energized
2. Visual indicator for Alarm Relay Status
g) D_OUT1
1. Green, on when Solid-State relay is energized
2. Visual indicator for Solid-State Relay OUT1 Status
h) D_IN1
1. Green, on when 12/24VDC voltage present on Input IN1 terminals
2. Visual indicator for IN1 status (Not Enabled)
Figure 4 Power Supply LEDs
a-e
f
g
h

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4MAINTENANCE
This FAA L864 REDSTAR Beacon is constructed to be maintenance free. It is necessary to install all
components and perform all tasks and described in this manual. Testing of opened device under voltage
should be avoided if possible and when required should be carried out only by a skilled person who is aware
of the hazards involved.
4.1 Troubleshooting
4.1.1 No Power: (Note: REDSTAR ONLY OPERATES IN NIGHT MODE)
a) Check that AC power is present on REDSTAR pigtail across black and white power wires.
b) Check within base of beacon at power termination to confirm power is present. Opening
device under voltage should be carried out only by a skilled person who is aware of the
hazards involved.
c) AC power is present if green indicator is lit see image on section 3.
4.1.2 No Mode Change (Beacon Photocell)
a) If photocell fails, REDSTAR will provide failure alarm.
b) Power cycle the beacon.
4.1.3 GPS Failure:
a) If the GPS fails to receive signal (out of synchronization)
b) Check that the GPS board cable is plugged in correctly and the antenna has a clear view of
the sky.
c) Power cycle the beacon.
4.1.4 Beacon Alarms:
a) Verify the beacons has not been with or without daylight for more than 19 hours. If this is
the case the beacon will reset upon normal day/night cycle.
b) Power cycle the beacon.
c) Check power supply pcb within beacon base for red LED on Driver fault, if present unit is in
fail mode. TWR technical service is available 24/7 and can assist you with troubleshooting
at [phone].

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5MAJOR COMPONENTS PARTS LIST
No spare parts are expected to be needed during the warranty period.
In case a site requires maintaining some spare parts at hand the ‘SP’ marked is suggested and all
parts can be bought in advance.
The warranty statement as written in this manual is applicable during the installation and daily
operation.
QTY.
DESCRIPTION
PART NUMBER
SP
1
L864 Power Supply
LP01-105
Y
2
REDSTAR PIGTAIL 33’ (10m)
LCABLE-2
N
1
Cable liquid tight connector
S2521
N

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6WARRANTY AND RETURN POLICY
TWR Lighting®, Inc. (“TWR®”) warrants its products (other than “LED Product”) against defects in
design, material (excluding incandescent bulbs) and workmanship for a period ending on the earlier
of two (2) years from the date of shipment or one (1) year from the date of installation.
TWR Lighting®, Inc. (“TWR®”) warrants its “LED Product” against defects in design, material, and
workmanship for a period of five (5) years from the date of shipment. TWR®, at its sole option, will,
itself, or through others, repair, replace or refund the purchase price paid for “LED Product” that
TWR® verifies as being inoperable due to original design, material, or workmanship. All warranty
replacement “LED Product” is warranted only for the remainder of the original warranty of the “LED
Product” replaced. Replacement “LED Product” will be equivalent in function, but not necessarily
identical, to the replaced “LED Product.”
TWR Lighting®, Inc. (“TWR®”) warrants its “LED Product” against light degradation for a period
of five (5) years from the date of installation. TWR®, at its sole option, will, itself, or through
others, repair, replace or refund the purchase price paid for “LED Product” that TWR® verifies as
failing to meet 75% of the minimum intensity requirements as defined in the FAA Advisory
Circular 150/5345-43G dated
09/26/12. All warranty replacement “LED Product” is warranted only for the remainder of the
original warranty of the “LED Product” replaced. Replacement “LED Product” will be equivalent
in function, but not necessarily identical, to the replaced “LED Product.”
Replacement parts (other than “LED Product”) are warranted for 90 days from the date of
shipment.
Conditions not covered by this Warranty, or which might void this Warranty are as follows:
x Improper Installation or Operation
x Misuse
x Abuse
x Unauthorized or Improper Repair or Alteration
x Accident or Negligence in Use, Storage, Transportation, or Handling
x Any Acts of God or Nature
x Non-OEM Parts
The use of non-OEM parts or modifications to original equipment design will void the
manufacturer warranty and could invalidate the assurance of complying with FAA
requirements as published in Advisory Circular 150/5345-43.

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Warranty& Return Policy(continued)
Field Service – Repairs are warranted for 90 days from the date of service, except where TWR®
has made recommendations that were not adhered to that may cause premature failure on
previous repairs. Labor, Travel, and Tower Climb are not covered under warranty. Customer
shall be obligated to pay for all incurred charges not related to warranty. All warranty repairs
are performed by trained TWR® personnel or dispatched through an extensive network of
certified and insured Service Representatives.
Return Terms – You must first contact our Customer Service Department at 713-973-6905 to
acquire a Return Merchandise Authorization (RMA) number to return the product(s). Please
have the following information available when requesting an RMA number:
x The contact name and phone number of the tower owner
x The contact name and phone number of the contractor
x The site name and number
x The part number(s)
x The serial number(s) (if any) x A description of the problem x The billing information
x The Ship To address
This RMA number must be clearly visible on the outside of the box. If the RMA number is not
clearly labeled on the outside of the box, your shipment will be refused. Please ensure the
material you are returning is packaged carefully. The warranty is null and void if the product(s)
are damaged in the return shipment.
All RMAs must be received by TWR LIGHTING®, INC., 10810 W LITTLE YORK RD. #130, HOUSTON
TX 77041-4, within 30 days of issuance.
Upon full compliance with the Return Terms, TWR® will replace, repair and return, or credit
product(s) returned by the customer. It is TWR’s sole discretion to determine the disposition of
the returned item(s).

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Warranty& Return Policy (continued)
Replacements – Replacement part(s) will be shipped and billed to the customer for product(s)
considered as Warranty, pending return of defective product(s). When available, a certified
reconditioned part is shipped as warranty replacement with a Return Merchandise
Authorization (RMA) number attached. Upon receipt of returned product(s), inspection, testing,
and evaluation will be performed to determine the cause of defect. The customer is then
notified of the determination of the testing.
x Product(s) that is deemed defective and/or unrepairable and covered under warranty -
a credit will be issued to the customer’s account.
x Product(s) found to have no defect will be subject to a $75.00 per hour testing charge
(1 hour minimum), which will be invoiced to the customer. At this time, the customer
may decide to have the tested part(s) returned and is responsible for the return charges.
x Product(s) under warranty, which the customer does not wish returned, the customer
will be issued a credit against the replacement invoice.
Repair & Return – A Return Merchandise Authorization (RMA) will be issued for all part(s) returned to
TWR® for repair. Upon receipt of returned product(s), inspection, testing and evaluation will be
performed to determine the cause of defect. The customer is then notified of the determination of the
testing. If the returned part(s) is deemed unrepairable, or the returned part(s) is found to have no
defect, the customer will be subject to a $75.00 per hour testing charge (1 hour minimum), which will be
invoiced to the customer. Should the returned parts be determined to be repairable, a written
estimated cost of repair will be sent to the customer for their written approval prior to any work being
performed. To have the tested part(s) repaired and/or returned, the customer must issue a purchase
order and is responsible for the return shipping charges.
Return to Stock – Any order that is returned to TWR® for part(s) ordered incorrectly by the customer, or
unneeded upon receipt, the customer is required to pay a 20% restocking fee. A credit will be issued
once it is determined that the Return Terms are met.
Credits – Credits are issued once it is determined that all the Warranty and Return Terms are met. All
credits are processed on Fridays. In the event a Friday falls on a Holiday, the credit will be issued on the
following Friday.
Freight – All warranty replacement part(s) will be shipped via ground delivery and paid for by TWR®.
Delivery other than ground is the responsibility of the customer.
REMEDIES UNDER THIS WARRANTY ARE LIMITED TO PROVISIONS OF REPLACEMENT PARTS AND
REPAIRS AS SPECIFICALLY PROVIDED. IN NO EVENT SHALL TWR® BE LIABLE FOR ANY OTHER LOSSES,
DAMAGES, COSTS OR EXPENSES INCURRED BY THE CUSTOMER, INCLUDING, BUT NOT LIMITED TO,
LOSS FROM FAILURE OF THE PRODUCT(S) TO OPERATE FOR ANY TIME, AND ALL OTHER DIRECT,
INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, INCLUDING ALL PERSONAL INJURY
OR PROPERTY DAMAGE DUE TO ALLEGED NEGLIGENCE, OR ANY OTHER LEGAL THEORY WHATSOEVER.
THIS WARRANTY IS MADE BY TWR® EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESSED OR IMPLIED. WITHOUT LIMITING THE GENERALITY OF THE FORGOING, TWR® MAKES NO
WARRANTY OF MERCHANTABILITY OR FITNESS OF THE PRODUCT(S) FOR ANY PARTICULAR PURPOSE.
TWR® EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES.

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6.1 RMA FORM
RMA-Form
RETURN MATERIAL AUTHORIZATION FORM
Please send this form together with the defect product to TWR Lighting,
Inc.
TWR Lighting, Inc. reference RMA #
:
Date (mm-dd-yyyy)
:
Number of pages
:
1 of
Customer name
:
Contact person
:
Delivery address
:
TWR Lighting, Inc., 10810 W Little York Rd. #130 Houston, Tx 77041
Department
:
Service
Telephone
:
[phone]
Fax
:
[phone]
Dear customer,
Please fill in this form completely and return it to the above fax number without indicating an RMA number. The RMA number will be
immediately generated by us. Please complete the following questions. Use one sheet for each item that is returned.
Customer reference RMA nr.
:
Site location
:
Product type
:
Serial number
:
Reason for return delivery
:
Initial TWR Lighting, Inc. PO (order)
number
:
Warranty claimed
:
Yes / No
Replacement product needed in
advance?
:
Yes / No
Inspection costs in the amount of $75.00 will be charged for each product. When a replacement product is ordered, the
inspection cost will be calculated in the price.

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7Drawing - REDSTAR BEACON CHASSIS
8Drawing - CABLE DATA SHEET
9Drawing – LIGHT KIT FOR WIND TURBINE
10 Drawing – (OPTIONAL) ADLS JUNCTION BOX DETAIL
11 Drawing - (OPTIONAL) ADLS LIGHTING KIT CHASSIS FOR WIND TURBINE
12 Drawing - (OPTIONAL) ADLS LIGHTING KIT SCHEMATIC FOR WIND TURBINE

1
1
2
2
3
3
4
4
A A
B B
SCALE
SERV DEPT
DATE
The use of non-OEM parts or modifications to original equipment design will void the manufacturer warranty and could invalidate the assurance of complying with
FAA requirements as published in Advisory Circular 150/5345-43.
DRAWN BY
NOTICE : The drawings and photographic images contained herein are the sole property of TWR Lighting, Inc. All information contained herein that is not generally
known shall be considered confidential except to the extent the information has been previously established. The drawings and photographic images contained herein
may not be reproduced, copied or used as the basis for manufacture or sale or promotion or any other purpose without the expressed written permission of TWR
Lighting, Inc.
ENGINEER
PROD DEPT
DWG. NO.
SHEET QTY.
1
B
SHEET SIZE
1
OF
02/08/2021 101203
N.T.S
J.ZAMORANO
L-864 REDSTAR BEACON CHASSIS
8.60
[218]
13.25 / [337]
BOLT CIRCLE
9.37
[238]
9.37
[238]
10.98
[279]
CABLE GLAND (P/N S2521)
4x Ø0.830
[Ø21]
MAIN PCB (P/N LP01-105)
NOTES:
1. INPUT POWER: 120-240 VAC (24-48
VDC AVAILABLE)
2. BOTTOM PANEL ACCESS TO POWER
SUPPLY
3. PROVIDED WITH A 33' CABLE FOR
POWER, DATA AND ALARM.
4. BEACON WEIGHT: 13LBS

TWR Lighting, Inc.