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TWR Lighting E-2/3DB Manual

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PLEASE TAKE THE TIME TO FILL OUT THIS FORM COMPLETELY. FILE IT
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
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!!!
E-2/3DB

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Summary of Contents for TWR Lighting E-2/3DB

  • 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-2/3DB SERIAL # PURCHASE DATE PURCHASED FROM E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc Rev.

  • Page 2: Table Of Contents

    E-2/3DB 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 ................4 2.5.1...
  • Page 3 E-2/3DB CONTROLLER TABLE OF CONTENTS CONTINUED 3.5.5 SIDELIGHT ALARM (SA1 and SA2) ..........14 BLEEDER CIRCUIT ................. 15 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...
  • Page 4 E-2/3DB CONTROLLER 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 ..................

  • Page 5: Introduction

    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.

  • Page 6: Installation

    E-2/3DB 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 INSTALLING SYSTEM PERFORMING MAINTENANCE ON THIS SYSTEM, MAKE SURE THE POWER IS TURNED OFF...

  • Page 7: Power Wiring

    E-2/3DB CONTROLLER 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.

  • Page 8: Tower Lighting Kit

    E-2/3DB CONTROLLER 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.

  • Page 9: Lighting Kit Wiring

    E-2/3DB CONTROLLER 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: Lamp platform Terminal...
  • Page 10 E-2/3DB CONTROLLER 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.
  • Page 11 E-2/3DB CONTROLLER 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.

  • Page 12: Alarm Wiring

    E-2/3DB CONTROLLER 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. ALARM WIRING Alarm contacts (Form C) are provided for strobe failures, power failure and photocell on.

  • Page 13: Power Failure (Pf)

    E-2/3DB CONTROLLER 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.

  • Page 14: Red Strobe Failure (Rf)

    E-2/3DB CONTROLLER 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.
  • Page 15 E-2/3DB CONTROLLER 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.

  • Page 16: Theory Of Operation

    E-2/3DB CONTROLLER THEORY OF OPERATION 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.

  • Page 17: Timing Circuit

    E-2/3DB 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 duration high voltage pulse is impressed on the trigger...

  • Page 18: Alarm Circuits

    E-2/3DB CONTROLLER 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.

  • Page 19: Bleeder Circuit

    E-2/3DB CONTROLLER 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.

  • Page 20: Trigger Voltage

    E-2/3DB CONTROLLER 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.

  • Page 21: Strobe Fail Test

    E-2/3DB CONTROLLER Current from the Cathode side of the flashtube (FTC1, FTC2, and FTC3) are sent through the current sensing transformers T1, T2, T3, T4, T5, and T6 on PCB #1. T1, T2, T3, T4, T5, and T6 will send a pulse to the gate of the SCR's Q6, Q8, Q10, Q13, Q14, and Q17, and turns it on.

  • Page 22: Trouble Shooting

    E-2/3DB CONTROLLER TROUBLE SHOOTING Much of the trouble shooting of this system will consist of correcting a "beacon out" situation. There may also be a failure mode where flashtube is still flashing, but at the wrong rate or the wrong intensity.

  • Page 23: Trouble Shooting Assistance

    E-2/3DB CONTROLLER TROUBLE SHOOTING ASSISTANCE 4.3.1 Flash Verify LED - Out 4.3.1.1 Observe high voltage LED (D14, D15, and D16) 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 - C131 day, C102, C112, and C122 night) for a short.

  • Page 24: False Or Nonexistent Beacon Alarm (Rf)

    E-2/3DB CONTROLLER one (1) or more coils are open, replace relay. 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 eight (8) seconds. This delay period can be tested by throwing "on"...

  • Page 25: Maintenance Guide

    E-2/3DB 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;...

  • Page 26: Red Obstruction Lighting

    E-2/3DB CONTROLLER 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 the lamp in the base up position. 5.1.11 Insert the flashtube with the pins aligned with the socket.

  • Page 27: Power Supply

    E-2/3DB CONTROLLER POWER SUPPLY only required maintenance performed periodic inspection/cleaning of the vent filter. Monthly inspections should be made at first to familiarize yourself with power supply’s particular maintenance requirements. Maintenance intervals can vary due to location, seasonal weather conditions, and general housekeeping of site.
  • Page 28 E-2/3DB CONTROLLER The photocell is a sealed unit. No maintenance is needed or required other than replacement as necessary. 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.

  • Page 29: Major Components List

    E-2/3DB CONTROLLER MAJOR COMPONENTS LIST SCHEMATIC DESCRIPTION PART NUMBER TAG # BSS1, BSS2, BEACON SAFETY SWITCH STJ02003 BSS3 C101 4UF 660V AC CAP STB99005 C101A 5UF 660V AC CAP STB99001 C102, C112, C122 4UF 2.5 KV CAP CSI STB99010 C103 - C131...
  • Page 30 E-2/3DB CONTROLLER SCHEMATIC DESCRIPTION PART NUMBER TAG # L11, L22, L33 INDUCTOR 100453 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)
  • Page 31 MOV 2, 3, 4, 5, 6, METAL OXIDE VARISTOR V1000LA80A MOV 7 P1, J1 15 POSITION PLUG STT60009 12 POSITION PLUG STT60019 PCB #1 E-2/3DB CONTROL PCB STH01279 HIGH VOLTAGE RECTIFIER PCB PCB #2 STH02258A PCB #3 RELAY PCB STH03279 TRIGGER VOLTAGE RECTIFIER PCB #4...

  • Page 32: Warranty & Return Policy

    E-2/3DB CONTROLLER MAJOR COMPONENTS LIST (continued) SCHEMATIC TAG DESCRIPTION PART NUMBER T3A, T3B, T3C BURSTING CHOKE 100273 T4, T5, T6, T7, TRIGGER TRANSFORMER STC05005 T8, T9 17 PART TERM BLK TERMBLK-17 7 PARK TERM BLK TERMBLK141-7 12 PART TERM BLK...

  • Page 33: Suggested Spare Parts List

    E-2/3DB CONTROLLER SUGGESTED SPARE PARTS LIST QUANTITY DESCRIPTION PART NUMBER 1 amp FUSE KTK1 10 amp FUSE KTK10 20 amp FUSE KTK20 1/2 amp FUSE FUSE.5 1/8 amp FUSE FUSE.125 E2/3DB PCB #1 STH01279 120V AC PHOTOCELL P2455L E:\Documents and Settings\Administrator\Local Settings\Temporary Internet Files\OLK3\E2-3DB.doc Rev.

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