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TWR Lighting E-1DBSL Manual

Dual medium intensity led / strobe
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DUAL MEDIUM INTENSITY LED/STROBE
4300 WINDFERN RD STE 100 HOUSTON TX 77041-8943
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 #
SERIAL #
PURCHASE DATE
PURCHASED FROM
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)
MODEL E-1DBSL
VOICE: 713-973-6905 FAX: 713-973-9352
web: www.twrlighting.com
IMPORTANT!!!!
E-1DBSL
________

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Summary of Contents for TWR Lighting E-1DBSL

  • Page 1 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 4300 WINDFERN RD STE 100 HOUSTON TX 77041-8943 VOICE: 713-973-6905 FAX: 713-973-9352 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...

  • Page 2: Table Of Contents

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL TABLE OF CONTENTS INTRODUCTION ......................1 APPLICATION .......................1 SPECIFICATIONS OF EQUIPMENT ..............1 INSTALLATION .......................2 POWER SUPPLY CONTROL CABINET MOUNTING ........2 PHOTOCELL HOUSING ..................2 PHOTOCELL WIRING ..................3 POWER WIRING ....................3 TOWER LIGHTING KIT ..................4 2.5.1 LED Red Beacon Mounting and Wiring ..........4 2.5.2...
  • Page 3 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL THE FLASHTUBE ....................11 LED BEACON ......................11 TIMING CIRCUIT ....................11 TRIGGER CIRCUIT .....................11 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...
  • Page 4 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL MAINTENANCE GUIDE ....................20 FLASHTUBE REPLACEMENT ................20 RED OBSTRUCTION LIGHTING...............21 PHOTOCELL ......................21 MAJOR COMPONENTS LIST SUGGESTED SPARE PARTS LIST WARRANTY & RETURN POLICY RETURN MERCHANDISE AUTHORIZATION (RMA) FORM M.2006 MANUALS.E-1DBSL REV. 08/10/04, 12/09/05, 2/08/06, 04/11/06 (load resistor) REV.

  • Page 5: Led Beacon

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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...

  • Page 6: Introduction

    APPLICATION 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.

  • Page 7: Installation

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL INSTALLATION WARNING DANGER!!! THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE LETHAL SERVICE PERSONNEL. INSTALLATION MAINTENANCE WORK MUST BE DONE BY QUALIFIED SERVICE PERSONNEL ONLY. WHEN PERSONNEL IS INSTALLING SYSTEM OR PERFORMING MAINTENANCE ON THIS SYSTEM, MAKE SURE THE POWER...

  • Page 8: Photocell Wiring

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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.

  • Page 9: Tower Lighting Kit

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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.
  • Page 10 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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"...

  • Page 11: Tower Kit Wiring

    2.5.2 Lighting Kit Wiring Install wiring between the controller and the beacon utilizing strobe cable. (TWR LIGHTING CANNOT WARRANTY SYSTEMS THAT EMPLOY SPLICING CABLE.) Refer to drawings HDO-264 and 602 for installation 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.

  • Page 12: Alarm Wiring

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 2.5.2.5 Connect the 16 gauge Blue wire from STLDBEACON wiring to TB1-5. 2.5.2.6 Connect the 10 gauge Red wire from STLDBEACON wiring to Fuse Block marked “B.” 2.5.2.7 Connect the 14 gauge White/Green wire from STLDBEACON wiring to TB1-11.

  • Page 13: White Strobe Failure (Sf)

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 2.6.1 White Strobe Failure (SF) Connect the customer's alarm common to plug P12, terminal #5. Connect the customer's alarm wire to plug P12, terminal #6, for normally open (or) terminal #4, for normally closed monitoring.

  • Page 14: Alarm Testing

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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.

  • Page 15: Theory Of Operation

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL THEORY OF OPERATION THE POWER SUPPLY The AC line is sent to transformers T1 through fuse F1, MOVMOD, and relay K1. In order for K1 to energize and complete the circuit to T1, the safety interlock switches (CSS &...
  • Page 16 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL THE FLASHTUBE The flashtubes FT1 (daymode) is a quartz tube containing two (2) electrodes. The electrode at the positive (+) end is called the anode and is connected to the positive side of the storage capacitors through inductor L1. The electrode at the negative (-) end of the tube is called the Cathode, and is connected to the negative (-) side of the energy storage capacitors banks.
  • Page 17 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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 the action of the high voltage circuit. The main difference is that the storage capacitor is much smaller.

  • Page 18: Bleeder Circuit

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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.
  • Page 19 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 3.8.2 High Voltage (PCB #2, LED 1, #D14) The Cathode side of the high voltage HV is routed through a current limiting resistor. When the unit is in daymode, LED 1, D14 will be at full brightness when the capacitors are at full charge, but dims with the discharging of the storage capacitors.
  • Page 20 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 3.8.6 Timing Signal Verify (PCB #1, LED9) Timing pulses (either primary or secondary) are received at LED9 (D28). The LED will flash according to the pulses received from the timing circuit, but should be 40 +/-2 FPM. In the unlikely event that this LED is out, then total timing failure has occurred.
  • Page 21 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL TROUBLESHOOTING Much of the troubleshooting of this system will consist of correcting a "beacon out" situation. There may also be a failure mode where the flashtube is still flashing, but at the wrong rate or the wrong intensity.

  • Page 22: Control Power On

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL LEDs on PCB #1 are numbered from top to bottom, 1-9. LEDs on PCB #2 are numbered from top to bottom, D14 - D16. The following chart will indicate normal LED operation. INDICATOR OPERATION...

  • Page 23: 4.3.2 Control Power On Led - Out

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 4.3.2 Control Power on LED - Out Check interlock circuit for an open circuit. If open, make the necessary repairs. If okay, check fuse F3 in the cabinet. Replace if bad. 4.3.3 Primary Timing LED – Out Observe the status of the timing LED8.
  • Page 24 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL To troubleshoot the red beacon portion: 1) turn power off at circuit breaker to reset the light system, 2) pull Relay K8 out of socket, and set SW3 to nightmode (upward position), 3) then turn power on at circuit breaker. Observe the red LED Beacon.

  • Page 25: Maintenance Guide

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL MAINTENANCE GUIDE **WARNING - HIGH - VOLTAGE** THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE LETHAL SERVICE PERSONNEL. INSTALLATION MAINTENANCE WORK MUST BE DONE BY QUALIFIED SERVICE PERSONNEL. READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY MESSAGES BEFORE ATTEMPTING INSTALLATION OF THIS SYSTEM.

  • Page 26: Red Obstruction Lighting

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL RED OBSTRUCTION LIGHTING The only required maintenance needed to be performed is replacement of the lamps in the L-810 fixture. Lamps should be replaced after being operated for not more than 75% of the rated life or immediately upon failure as per FAA Advisory Circular 70/7460-1K.

  • Page 27: Major Components List

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL MAJOR COMPONENTS LIST PART NUMBER DESCRIPTION SCHEMATIC TAG # STJ02003 BEACON SAFETY SWITCH STB99006 40 uf 1kv CAP C103 - C109 STB99008CSI 3 uf 660V AC CAP C102 STB99008 3 uf 660V AC CAP GE...
  • Page 28 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL PART NUMBER DESCRIPTION SCHEMATIC TAG # PRD5AYO DAY/NIGHT RELAY STH02226A HIGH VOLTAGE RECTIFIER PCB PCB #2 DTK-120HW SURGE ARRESTOR 120V AC MOV1 STH03264A RELAY PCB w/ALARM LOCKOUT PCB #3 ELIMINATION MODIFICATION P2455L 120V AC PHOTOCELL...
  • Page 29 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL PART NUMBER DESCRIPTION SCHEMATIC TAG # STBEAGSK2 BEACON GASKET RM4JA31MW CURRENT SENSOR M2, M3 STC05005 TRIGGER TRANSFORMER STA22011 AUXILIARY LOAD RESISTOR 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 &...

  • Page 30: Suggested Spare Parts List

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL SUGGESTED PARTS LIST QUANTITY# PART NUMBER DESCRIPTION STH01226B PCB #1 PRINTED CIRCUIT BOARD STJ10016 BLEEDER RELAY STFLSHTB8 STROBE FLASHTUBE P2455L PHOTOCELL FNQ10 10 amp FUSE FLQ18 1/8 amp FUSE FUSE .5 ½ amp FUSE...

  • Page 31: Warranty & Return Policy

    “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”...
  • Page 32 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., 4300 WINDFERN RD #100, HOUSTON TX 77041-8943, within 30 days of issuance.
  • Page 33 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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.
  • Page 34 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL Warranty & Return Policy (continued) 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...
  • Page 35 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL RETURN MERCHANDISE AUTHORIZATION (RMA) FORM RMA#: DATE: CUSTOMER: CONTACT: PHONE NO.: ITEM DESCRIPTION (PART NO.): MODEL NO.: SERIAL NO.: ORIGINAL TWR INVOICE NO.: DATED: DESCRIPTION OF PROBLEM: SIGNED: DATE NEEDED: RETURN ADDRESS: M.2006 MANUALS.E-1DBSL REV.
  • Page 36 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL RETURN MERCHANDISE AUTHORIZATION (RMA) FORM RMA#: DATE: CUSTOMER: CONTACT: PHONE NO.: ITEM DESCRIPTION (PART NO.): MODEL NO.: SERIAL NO.: ORIGINAL TWR INVOICE NO.: DATED: DESCRIPTION OF PROBLEM: SIGNED: DATE NEEDED: RETURN ADDRESS: M.2006 MANUALS.E-1DBSL REV.
  • Page 47 * = ITEMS NOT SHOWN 4.813" 7.342" 2.368" FIXTURE * GROUND WIRE MUST BE CONNECTED TO PROPERLY PROTECT POWER SUPPLY. FAILURE TO GROUND WILL VOID ALL WARRANTIES. 120/240VAC TWR Lighting, Inc. DRAWN gsebek 6/24/2005 CHECKED 9/27/2006 Enlightened Technology TITLE OL1VLED2 120VAC FAA-OL16LED APPROVED...
  • Page 49 TOP LED ENGINE PLATE (stldsubkit) 100601M_RA BOTTOM LED ENGINE PLATE NONOEMLBL NON-OEM PARTS WARNING LABEL TERMARKSTRIP-8B MS8-141 CINCH TERMINAL MARKER * = ITEMS NOT SHOWN TWR Lighting, Inc. DRAWN Gavin Sebek 3/3/2004 CHECKED Enlightened Technology TITLE L865/864LED DUAL BEACON ASSEMBLY...

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