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TWR Lighting E-1DB2 Manual

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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.E-2009.E-1DB2
3/25/07 – rev. 5/28/09
VOICE: 713-973-6905 FAX: 713-973-9352
web: www.twrlighting.com
IMPORTANT!!!!
E-1DB2

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Summary of Contents for TWR Lighting E-1DB2

  • Page 1 IN A SAFE PLACE. IN THE EVENT YOU EXPERIENCE PROBLEMS WITH OR HAVE QUESTIONS CONCERNING YOUR CONTROLLER, THE FOLLOWING INFORMATION IS NECESSARY TO OBTAIN PROPER SERVICE AND PARTS. MODEL # E-1DB2 SERIAL # PURCHASE DATE PURCHASED FROM M.E-2009.E-1DB2 3/25/07 – rev. 5/28/09...

  • Page 2: Table Of Contents

    E-1DB2 CONTROLLER TABLE OF CONTENTS INTRODUCTION 1 APPLICATION ........................1 SPECIFICATIONS OF EQUIPMENT .................. 1 INSTALLATION ..........................2 POWER SUPPLY CONTROL CABINET MOUNTING ............2 PHOTOCELL HOUSING ....................2 PHOTOCELL WIRING ......................2 POWER WIRING ........................ 3 TOWER LIGHTING KIT ...................... 3 2.5.1...
  • Page 3 E-1DB2 CONTROLLER TABLE OF CONTENTS (CONTINUED) 3.5.3 Power Failure (PF) ..................10 3.5.4 Photocell (PC) ....................11 3.5.5 Sidelight Alarm (SA) ..................11 BLEEDER CIRCUIT ......................11 STROBE DIAGNOSTIC CIRCUITS .................. 12 3.7.1 Control Power On ................... 12 3.7.2 High Voltage ....................12 3.7.3...
  • Page 4 TOWER LIGHTING KIT 200’ TO 350’ CONDUIT RUN ......T1369 (REV A) TIMING/CONTROL PCB ..............H01-329 (REV A) E-1DB2 RECTIFIER PCB ..............H02-329 (REV A) RELAY PCB w/ALARM LOCKOUT ELIMINATION MODIFICATION H03-269A (REV A) CURRENT MEASUREMENT RELAY ............. 100664 (REV E) L-810 OL-1 SINGLE OBSTRUCTION LIGHT ........

  • Page 5: Introduction

    APPLICATION The E-1DB2 Controller is for use on lighting structures or towers (201' to 350' AGL) that are approved to be lighted with Dual White/Red Flashing Medium Intensity Strobes in accordance with the FAA’s Advisory Circular 70/7460-1K.

  • Page 6: Installation

    E-1DB2 CONTROLLER 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...

  • Page 7: Power Wiring

    E-1DB2 CONTROLLER 2.3.1 Connect the BLACK wire from the photocell to TB1-8. 2.3.2 Connect the RED wire from the photocell to TB1-9. 2.3.3 Connect the WHITE wire from the photocell to TB1-10. 2.3.4 Install the photocell into the receptacle and twist to the right while depressing to lock into place.

  • Page 8: Beacon Mounting And Wiring

    E-1DB2 CONTROLLER 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 INSTALLING SYSTEM PERFORMING MAINTENANCE ON THIS SYSTEM, MAKE SURE THE POWER IS TURNED OFF...

  • Page 9: Lighting Kit Wiring

    2.5.2 Lighting Kit Wiring Install wiring from the controller to the beacon utilizing strobe cable method. (TWR LIGHTING CAN NOT WARRANTY SYSTEMS THAT EMPLOY SPLICING CABLE.) Refer to drawings HD0-329, 600-04, and T1369, for install of light kits. Following these minimum guidelines as well as any local or end user additional requirements, installing light kits will require lifting of the cable by the supplied cable grip or conduit to affix to the tower.

  • Page 10: Alarm Wiring

    E-1DB2 CONTROLLER 2.5.2.9 Connect the Neutral wire from sidelight wiring to TB1-12. 2.5.2.10 Connect the Red wire from sidelight wiring to TB1-13. 2.5.2.11 Connect the ground wire (if cable is used) from sidelight wiring to ground screw right of TB1.

  • Page 11: Sidelight Alarm (Sa)

    E-1DB2 CONTROLLER 2.6.5 Sidelight Alarm (SA) Connect the customer's alarm common to plug J3, terminal #2. Connect the customer's alarm wire to plug J3, terminal #1, for normally open (or) terminal #3, for normally closed monitoring. ALARM TESTING To test alarms, follow these procedures using an "ohm" meter between alarm common and alarm points.

  • Page 12: Sidelight Alarm (Sa)

    E-1DB2 CONTROLLER 2.7.5 Sidelight Alarm (SA) Controller should be in the nightmode of operation. Check status of operation. Pull fuse switch “S1” open. Alarm shall occur within 30 seconds. After test, re-engage fuse switch ”S1.” CONTROLLER CONFIGURATION (Refer to Drawings H01-329, and H40-329) This unit is factory setup to be a master controller.

  • Page 13: Theory Of Operation

    E-1DB2 CONTROLLER THEORY OF OPERATION THE POWER SUPPLY The AC line is sent to transformers T1, and T2 through fuse F2, MOVMOD1, and relay K1. In order for K1 to energize and complete the circuit to T1, the safety interlock switch CSS, BSS, must be closed. The BSS switch is located in the beacon.

  • Page 14: Timing Circuit

    E-1DB2 CONTROLLER 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...
  • Page 15 E-1DB2 CONTROLLER 3.5.2 Red Strobe Failure (RF) Red Strobe Failure alarm circuit monitors each flash of the nightmode flashtube within the beacon. If the flashtube fails to flash (for any reason), the alarm circuit operates relay K8 (on PCB #3) that the customer can connect to their alarm transmitting devices.

  • Page 16: Bleeder Circuit

    E-1DB2 CONTROLLER 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 17: Trigger Voltage

    E-1DB2 CONTROLLER 3.7.3 Trigger Voltage The trigger voltage from fuse F3 is sent to PCB #2, current limiting resistor R1, and PCB #1’s, LED6 (D11). Under normal circumstances, the LED should be at full brightness when the trigger capacitor is at full charge and indicating voltage to be normal, but dims with trigger capacitor discharge (light flashing).
  • Page 18 M.E-2009.E-1DB2 3/25/07 – rev. 5/28/09...

  • Page 19: Troubleshooting

    E-1DB2 CONTROLLER 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 20: Troubleshooting Assistance

    E-1DB2 CONTROLLER TROUBLESHOOTING ASSISTANCE 4.3.1 Flash Verify LED (LED 1) - Out 4.3.1.1 Observe high voltage LED (D14) on the same beacon circuit to determine if it is available. If the LED is dim or out completely, then check the high voltage capacitor bank (C103 - C110 daymode, C102 nightmode) for a short.

  • Page 21: False Or Nonexistent Beacon Alarm (Rf)

    E-1DB2 CONTROLLER 4.3.4.2 Check relay K7 coil for an open condition. Normal resistance should be around 2K ohm. If coil is open, replace K7. 4.3.4.3 The time delay between an actual failure and the point where the relay trips is pre-set at the factory or about nine (9) seconds. This delay period can be tested by placing the control board (PCB #1) test switch to “ON.”...

  • Page 22: Maintenance Guide

    E-1DB2 CONTROLLER MAINTENANCE GUIDE **WARNING - HIGH - VOLTAGE** 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. READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY MESSAGES BEFORE ATTEMPTING INSTALLATION OF THIS SYSTEM.

  • Page 23: Red Obstruction Lighting

    E-1DB2 CONTROLLER 5.1.8 Loosen the three (3) socket screws with a #2 Phillips screwdriver. 5.1.9 To remove the flashtube, slide the lamp down to the cable. 5.1.10 To install a flashtube, slide the lamp over the connector on to the cable with lamp in the base up position.

  • Page 24: Photocell

    E-1DB2 CONTROLLER PHOTOCELL The photocell is a sealed unit. No maintenance is needed or required other than replacement as necessary. M.E-2009.E-1DB2 3/25/07 – rev. 5/28/09...
  • Page 25 E-1DB2 CONTROLLER MAJOR COMPONENTS LIST SCHEMATIC TAG # DESCRIPTION PART NUMBER BEACON SAFETY SWITCH STJ02003 C101, and C102 3 uf 660V AC STB99008csi C103 - C110 40 uf 1.1KV CAP STB99006 CABINET SAFETY SWITCH STJ02001 0.5 amp FUSE FUSE.5 10 amp FUSE...
  • Page 26 TERMBLK 141-12 THERMAL LIMITING SW OA210 QCV STJ10008 FLASHTUBE SOCKET 100319 HINGE GASKET STBEAGSKT LENS GASKET STBEAGSKT2 CLEAR LENS STDBCLENS DB STROBE BEACON FIXTURE STDBEACON STROBE BEACON CABLE STROBCABLE-3 SIDELIGHT CABLE STCABLE0B RED LENS STDBRLENS M.E-2009.E-1DB2 3/25/07 – rev. 5/28/09...

  • Page 27: Suggested Spare Parts List

    1 amp FUSE FNQ10 10 amp FUSE KTK5 5 amp FUSE FUSE.5 1/2 amp FUSE FLQ18 1/8 amp FUSE STH01329 E-1DB2 PCB #1 6390 – FAA2 120V AC PHOTOCELL STJ10006 HV RELAY STJ02003 BEACON SAFETY SWITCH STJ02001 CABINET SAFETY SWITCH STFLSHTB6...

  • Page 28: Warranty & Return Policy

    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”...
  • Page 29 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., 4300 WINDFERN RD #100, HOUSTON TX 77041-8943, within 30 days of issuance.
  • Page 30 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. M.E-2009.E-1DB2 3/25/07 – rev. 5/28/09...

  • Page 31: Return Merchandise Authorization (Rma) Form

    CONTACT: PHONE NO.: ITEM DESCRIPTION (PART NO.): MODEL NO.: SERIAL NO.: ORIGINAL TWR INVOICE NO.: DATED: DESCRIPTION OF PROBLEM: SIGNED DATE NEEDED RETURN ADDRESS: PLEASE RETURN PRODUCT TO: 4300 WINDFERN RD #100 HOUSTON TX 77041-8943 M.E-2009.E-1DB2 3/25/07 – rev. 5/28/09...
  • Page 32 CONTACT: PHONE NO.: ITEM DESCRIPTION (PART NO.): MODEL NO.: SERIAL NO.: ORIGINAL TWR INVOICE NO.: DATED: DESCRIPTION OF PROBLEM: SIGNED DATE NEEDED RETURN ADDRESS: PLEASE RETURN PRODUCT TO: 4300 WINDFERN RD #100 HOUSTON TX 77041-8943 M.E-2009.E-1DB2 3/25/07 – rev. 5/28/09...
  • Page 49 6-32 X 1/4 PHILLIPS PAN HEAD SCREW 832X1PHH 8-32 X 1 PHILLIPS PAN HEAD SS SCREW EL190S 1" 90 DEGREE SHORT ELBOW GALV * = ITEMS NOT SHOWN TWR Lighting, Inc. DRAWN Gavin Sebek 3/3/2004 PROD DEPT Enlightened Technology SERV DEPT...

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