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Cooper Crouse-Hinds CHB 204 Instructions Manual

Obstruction lighting system
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CHB204 -2S, PB, X; 205-11S; 204-2S, PB;
208-2S; 304-2S; 305-2S
IF 1544
Obstruction Lighting System
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
Front Matter
Abstract
This manual contains information and instructions for installing, operating and maintaining
the CHB 204, 304, 205, 305, 207 and 208 Obstruction Lighting Systems.
Copyright
Copyright © 2007, Cooper Crouse-Hinds, Syracuse, NY 13221
All rights reserved. Reproduction or use of any portion of this manual is prohibited without
express written permission from Cooper Crouse-Hinds and/or its licenser.
Trademark Acknowledgements
Cooper Crouse-Hinds is a registered trademark name.
All trademarks and product names mentioned are properties of their respective companies,
and are recognized and acknowledged as such by Cooper Crouse-Hinds.
Applicable Specifications
This equipment meets or exceeds requirements for an FAA Type L-856 and L-857.
Disclaimer
While every effort has been made to ensure that the information in this manual is complete,
accurate and up-to-date, Cooper Crouse-Hinds assumes no liability for damages resulting
from any errors or omissions in this manual, or from the use of the information contained
herein. Cooper Crouse-Hinds reserves the right to revise this manual without obligation to
notify any person or organization of the revision.
In no event will Cooper Crouse-Hinds be liable for direct, indirect, special, incidental, or
consequential damages arising out of the use of or the inability to use this manual.
Cooper Industries Inc.
Crouse-Hinds Division
IF 1544
PO Box 4999,
Rev 1
Syracuse, New York 13221 • U.S.A.
New 01/08
Copyright© 2007, Cooper Industries, Inc.

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  • Page 1 Cooper Crouse-Hinds reserves the right to revise this manual without obligation to notify any person or organization of the revision. In no event will Cooper Crouse-Hinds be liable for direct, indirect, special, incidental, or consequential damages arising out of the use of or the inability to use this manual.

  • Page 2: Warranty

    Warranty Cooper Crouse-Hinds warrants all components, under normal operating conditions, for 2 years. Parts Replacement The use of parts or components, in this equipment, not manufactured or supplied by Cooper Crouse-Hinds voids the warranty and invalidates the third party testing laboratory certification which ensures compliance with FAA Advisory Circulars 150/5345-43E, 150/5345-51 and 150/4345-53B.

  • Page 3: Table Of Contents

    Table of Contents CHB 204-2S,PB,X; 205-11S; 207-2S,PB; 208-2S; 304-2S; 305-2S..Error! Bookmark not defined. Front Matter ..........................i Abstract ..........................i Copyright ..........................i Trademark Acknowledgements ..................... i Applicable Specifications ...................... i Disclaimer ..........................i Warranty ..........................ii Parts Replacement......................... ii Personnel Hazard Warning .......................
  • Page 4 Installation Checklist ......................10 Section 3 — Maintenance and Troubleshooting..............22 Safety ..........................22 Preventive Maintenance...................... 22 Storage ..........................22 RFI Problems ........................22 Component Testing......................23 Wiring and Cabling......................23 Inspection........................23 Capacitors ........................23 C1 — High Intensity Capacitor Bank................23 C2 —...

  • Page 5: List Of Figures

    Installation........................... 45 Appendix 3 - CHB 204-2X and 204-2SX Extended Separation..........48 Introduction and Operation ....................48 Mounting and Installation ....................48 Flashhead Wiring ......................48 Securing the Cable ......................48 Spare Parts (for 204-2X/204-2SX versions only)............... 52 List of Figures Figure 1-1 –...

  • Page 7: Section 1 - Introduction And Operation

    Operation The CHB304/305 (S) medium intensity systems operate in twilight and night The CHB 204 High Intensity Beacon modes only. In this case, wherever 204 consists of an FH 204 Flashhead and a PC and 205 appear in the manual substitute...

  • Page 8: Operation

    40 flashes per min. 60 flashes per minute. See CHB 207/208 60 flashes per min. Cooper Crouse-Hinds uses a standard Electrical (factory pre-wired) format: it refers to the lowest level as Tier AC Voltage 1 and the most northerly facing light as 120-480 VAC ±...

  • Page 9: Configuring Pcb1

    Intensity Procedure† DAY (High) Place a jumper between Test Point 1 (TP1) labeled TEST and TP6 labeled DAY. Place a jumper between (Twilight) Test Point 1 (TP1) labeled TEST and TP5 labeled TWI. HITE (Low) Place a jumper between Test Point 1 (TP1) labeled TEST and TP4 labeled NITE.

  • Page 10: Figure 1-1 - Pcb1 (2904411) Timing And Trigger Board

    Figure 1-1 – PCB1 (2904411) Timing and Trigger Board Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.
  • Page 11 J1 PIN FUNCTION (VARIES WITH EQUIPMENT TYPE): 1 -- RED CONTROL A. FLASHES RED OUTPUT: INCANDESCENT BEACON. B. RAISES OR LOWERS RED FILTER IN FLASHHEAD WITH FILTER ACTUATOR. C. TRIGGER STEERING CONTROL FOR RED FLASHHEAD AND INT RED WHITE FLASHHEAD COMBINATION. 2 -- MARKER CONTROL: TURNS MARKER RELAY ON OR OFF.

  • Page 12: Figure 1-3 - Typical 2-Tower 3-Tier Layout And Catenary Beacon Operation

    MIDDLE MIDDLE WIRE DROOP EXAGERATED BOTTOM BOTTOM CATENARY WIRES CATENARY BEACONS FLASH RATE = 60 FPM CATENARY SEQUENCE = MIDDLE, TOP, BOTTOM Figure 1-3 – Typical 2-Tower 3-Tier Layout and Catenary Beacon Operation Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 •...

  • Page 13: Section 2 - Mounting And Installation

    Cooper Crouse-Hinds refers to the lowest Flashhead level as Tier 1 and the most northerly Latches secure the hinged cover of the facing light as Beacon 1. Higher numbered flashhead.

  • Page 14: Beacon Location

    Controller Mounting Beacon Location Locate the system controller in an area FAA Guidelines for beacon placement are with restricted access. Controllers are published in AC 70/7460-1. Avoid placing available either in outdoor enclosures that a beacon within a strong radio frequency can be attached to any vertical surface, or (RF) field.

  • Page 15: Beacon Wiring

    (not C-A) to allow • Figure 2-6 – Single-Phase Installation the controller to be compatible with all Wiring for CHB 204 or 207 beacons. Failure to ensure optimum • Figure 2-7 – Single-Phase Installation phasing as described could result in Wiring for CHB 205 or 208 intensity control problems.

  • Page 16: Installation Checklist

    the same phase. In installations Installation Checklist with multiple tiers and three phase Complete the following steps before wiring, follow the phasing chart in applying power to the lights. the installation drawings, or site drawings. 1. Equipment Damage: • Check all electrical connections for Inspect all equipment for damage.
  • Page 17 7. Photocell: • Locate photocell where it views unobstructed polar sky with no direct or reflected artificial lighting striking it. • Mount the photocell vertically on the top end of a vertical length of conduit to prevent water from entering the unit. •...

  • Page 18: Figure 2-1 - Pc 204/207 Power Converter Mounting And Outline

    Figure 2-1 – PC 204/207 Power Converter Mounting and Outline Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 19: Figure 2-2 - Fh 204 Flashhead Mounting And Outline

    9.41 (239.01) 18.23 (463.04) (63.5) 20.88 (530.35) 12.82 (325.63) MIN (11.18) ADD .40 (10.2) FOR EACH DEGREE OF TILT MOUNTING SLOTS .56 X .63 (14.2 X 16.0) 16.88 (428.75) CLEARANCE REQUIRED 22.5 (571.5) 21.25 (539.75) 3.00 (76.20) 9.25 1.06 DIA. (26.9) (235) ENTRANCE HOLE 3.00...

  • Page 20: Figure 2-3 - Chb 205/208 Beacon Mounting And Outline

    TOP VIEW 22.35 (567.7) 21.25 (539.8) 20.00 (508) FRONT VIEW RIGHT SIDE VIEW REAR VIEW NOTES: 1. WEIGHT: 85 LBS. (38.6 KG.) 2. WIND AREA: 2.9 SQ. FT. (.27 SQ. M.) 3. DIMENSIONS ARE IN INCHES (MILLIMETERS) 31.23 (793.2) 2x Ø1.31 (33.28) 1.12 (28.5)

  • Page 21: Figure 2-4 - Wiring Overview Of A System

    TO ADDITIONAL TIERS AS REQUIRED BEACONS BEACONS REQUIRED REQUIRED TYPICAL JUNCTION BOX ALTERNATIVE PEC 507 & PEC 509 PHOTOELECTRIC CONTROLS PEC 510 PEC 507 PEC 509 SYSTEM CONTROLLER DISCONNECT FEEDER SWITCH TRANSFORMER SINE WAVE PRIMARY POWER SINE WAVE PRIMARY POWER NOTES: 1.

  • Page 22: Figure 2-5 - Junction Box, Three-Phase Installation Wiring

    Figure 2-5 – Junction Box, Three-Phase Installation Wiring Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 23: Figure 2-6 - Single-Phase Installation Wiring For Ch 204/207

    Figure 2-6 – Single-Phase Installation Wiring for CHB 204/207 Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 24: Figure 2-7 - Single-Phase Installation Wiring For Ch 205/208

    Figure 2-7 – Single-Phase Installation Wiring for CHB 205/208 Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 25: Figure 2-8 - Optical Assembly Internal Wiring

    Figure 2-8 – Optical Assembly Internal Wiring Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 26: Figure 2-9 - Pc 204/207 Power Converter Internal Wiring

    Figure 2-9 – PC 204/207 Power Converter Internal Wiring Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 27: Figure 2-10 - Pc 205/208 Power Converter Internal Wiring

    Figure 2-10 – PC 205/208 Power Converter Internal Wiring Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 28: Section 3 - Maintenance And Troubleshooting

    Section 3 — Maintenance and Troubleshooting • Clean the inside and outside surface of the glass with a non-abrasive glass Safety cleaner. HAZARD WARNING Some procedures in this section may Storage require making contact with electrical circuits. Read the warning on Page III. No special considerations are required for long-term storage of the equipment.

  • Page 29: Component Testing

    rise higher indicated values. A capacitor Component Testing that is disconnected from other circuitry is The following procedures describe how to defective if it does not exhibit this check most of the major electrical behavior. The length of time it takes the components.

  • Page 30: C3 - Low Intensity Capacitor

    L2 — Flash Choke C3 — Low Intensity Capacitor The resistance of this coil should be zero Test described Section ohms. An infinite reading indicates an Capacitors. Remove all leads from one open coil. terminal cluster of this capacitor. The measured resistance across this capacitor PCB1 —...

  • Page 31: Pcb3 - Sense Module

    Observe components carefully. Check for PCB3 — Sense Module loose connections. Many times, Replace this circuit board with one known components such as resistors and relays to be in good condition. show signs of their failures. Resistors discolor when overheated. Relay contacts T101 —...
  • Page 32 OBSERVED BEHAVIOR Symptom Flash Intensity Comments Code NITE All circuits are dead. Primary line fuse repeatedly blows. Some circuits functioning. No confirmation. No DAY confirmation, but NITE OK. HIGH NITE too bright; ragged flash. SKIPS HIGH SKIPS SKIPS SKIPS PCB2. Inconsistent and erratic flash.

  • Page 33: Figure 3-2 - Defective Component Locator Code

    Codes Item Component C1A-C1M DAY Capacitor Bank C2A-C2B TWI Capacitor Bank NITE Capacitor Tuning Capacitor F1, F2 Line Fuses FT101 Flashtube Day Mode Relay Nite Mode Relay Burst Choke PCB1 Timing & Trigger Board PCB2 HV Rectifier Board Burst Resistor Interlock Switch Power Transformer PCB3...

  • Page 34: Component Removal And Replacement

    Component Removal and Replacement 3. Lift the capacitor out of its retaining The following procedures explain how to hole. remove and re-install selected components that may require procedures that are not Replacement self-evident. 1. Reverse the Removal procedure. FOLLOW FLASHTUBE HANDLING PRECAUTIONS BR1 —...
  • Page 35 L1 — Burst Choke Replacement Removal 1. Reverse the Removal procedure. 1. Remove the two wires that connect to the choke. T1 — Power Transformer 2. Remove the two screws that fasten the Removal choke to the base plate. 1. Many wires connect to the power 3.

  • Page 36: Figure 3-3 - Winding Directions

    Replacement Replacement 1. Reverse the Removal procedure. 1. Re-assemble the coils on the cores. NOTE: The coils must have the same Flashtube winding direction on the core. That is, Location: Part of the optical assembly the coils are wound clockwise looking down at the top retainer strap of the Removal transformer.
  • Page 37 6. Attach the trigger wire (white 3. Do not disconnect the primary winding insulation) at the ceramic post P101. wires. Remove the two 4-40 x 2-inch Remove any excess wire and do not screws Phillips-head screws that hold leave a tail extending from under the the transformer assembly to the plate.

  • Page 38: Section 4 - Recommended Spare & Replaceable Parts

    Section 4 – Recommended Spare & Replaceable Parts Customer Service Customer Service: 1-866-764-5454 Facsimile: 315-477-5590 Shipping Address: Cooper Crouse-Hinds P.O. Box 4999 Wolf & 7 North Street Syracuse, NY 13221 Ordering Parts To order spare or replacement parts, contact customer service at 1-866-764-5454.

  • Page 39: Figure 4-1 - Beacon / Power Converter Replacement Parts

    Reference Description Part Number Diode Bridge 6902806 C1A-C1G Capacitor, Day, 70 mfd 6720401 Capacitor, Twilight, 40 mfd 6386503 Capacitor, Night, 1 mfd 6848202 Capacitor, Tuning, 3 mfd 6577903 F1, F2 ►Fuse, 120V †4900307 F1, F2 ►Fuse, 208/230/240V †4900303 F1, F2 ►Fuse, 480V †4900335 K1, K2...

  • Page 40: Figure 4-2 - Pc 204/207 Power Converter Component Locations

    TIMING & TRIGGER HV RECTIFIER PCB1 PCB2 S2 IS USED FOR 208, 220, 230, 240, 277 AND 480 VAC INPUT INTERLOCK SWITCH FLASHCHOKE HIGH INTENSITY INTENSITY INTENSITY ALTERNATE RELAY RELAY SWITCH FOR 480VAC COUPLING TB201 TRANSFORMER TUNING SENSE MODULE PCB3 R2A&B POWER BURST...

  • Page 41: Figure 4-3 - Pc 205/208 Power Converter Component Locations

    OPTICAL ASSEMBLY (REAR VIEW) T101 FT101 PCB1 PCB2 CATHODE ANODE (RED MARKER) PCB3 BURSTCHOKE G4 G5 Figure 4-3 – PC 205/208 Power Converter Component Locations Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright©...

  • Page 42: Figure 4-4 - Flashhead Replacement Parts

    Reference Description Part Number FT101 ►Flashtube 8671301 T101 Trigger Transformer 8288201 T102 Coupling Transformer 8336701 ►Recommended as a spare part. Figure 4-4 – Flashhead Replacement Parts REAR VIEW ANODE END RED TIP RED WIRE WHITE FLASHTUBE TRIGGER CATHODE WIRE BLACK FLASHTUBE FLASHTUBE WIRE...

  • Page 43: Returning Equipment - Return Material Authorization (Rma)

    Returning Equipment – Return Material Authorization (RMA) If a product purchased from Cooper Crouse-Hinds must be returned for any reason, please follow the procedure below: NOTE: An RMA number must be requested from Cooper Crouse-Hinds prior to shipment of any product. No returned product will be processed without an RMA number. This number will be the only reference necessary for returning and getting information on the product’s...

  • Page 44: Return To Stock Policy

    P.O. when faxed or emailed to RMA Rep. • Cooper Crouse-Hinds will then, at its discretion repair or replace the defective product and return the product to the customer based on the shipping method selected.

  • Page 45: Appendix 1 - Programming The Timing And Trigger Board

    Appendix 1 – Programming the Timing and Trigger Board Connecting the Handheld The following table shows the connector pin assignments for the handheld. The receive and transmit directions shown in the table are with respect to the handheld. The DB9 connector is located at the top of the handheld programmer.
  • Page 46 The general format of the sign on message mode (DAY, TWI, and NITE). Note: for non S versions is: DAY equals HIGH, TWI equals MED and NITE equals LOW intensity COOPER CROUSE-HINDS NOTE BOARD 4988 The handheld terminal will return to the (Blank or further information) sign on message from any other menu if no key is pressed within two minutes.

  • Page 47: Setup For Non S Versions

    the corresponding function key. So, to SETUP for Non S Versions move to the next menu you would press The setup menu has the following format: F2 (NEXT). • F1: OK- is used to enter data. • F2: NEXT- moves to the next item. SETUP •...

  • Page 48: Parameters For S Versions

    The display will change to: Press the number keys to select the catenary tier you wish this board to be and then press F1 (OK). SETUP To change the Flash rate press NEXT until TIER # 1 the LCD shows: Enter TIER # OK NEXT BACK EXIT SETUP...

  • Page 49: Info

    The display will change to: The info menu has the following format for S version: SETUP INFO TIER # 1 BOARD 4990 Enter TIER # OK NEXT BACK EXIT NEXT BACK EXIT Press the number keys to select the tier number you wish this board to be and then This menu is used to show a limited press F1 (OK).
  • Page 50 • F1: DAY- Changes the mode to DAY. • F2: TWI- Changes the mode to TWI. • F3: NITE- Changes the mode to NITE. • F4: EXIT- exits the mode change menu and returns the mode to automatic. This menu item is used to manually change the operating modes and functions just like the test jumpers on the board.

  • Page 51: Appendix 2 - Chb 204Spb And 207Spb Primary Backup

    Appendix 2 - CHB 204SPB and 207SPB Primary Backup Operation The 204SPB and 207SPB provide an extra trigger for the operation of a secondary flashhead as shown in Figure A2-1. The power converter operates the primary flashhead until a failure is detected. Once in alarm, the power converter will switch trigger to the backup flashhead and continue to operate normally.

  • Page 52: Figure A2-1 - Pc 204Spb / 207Spb Installation Wiring

    Figure A2-1 – PC 204SPB / 207SPB Installation Wiring Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 53: Figure A2-2 - Pc 204Spb / 207Spb Internal Wiring

    Figure A2-2 – PC 204SPB / 207SPB Internal Wiring Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 54: Appendix 3 - Chb 204-2X And 204-2Sx Extended Separation

    Introduction and Operation flashhead cable to a skeletal structure: The CHB 204-2X and 204-2SX consist of 1. Run the cable along one of the tower an FH 204 flashhead and a PC 204 power legs and wrap two full turns of two- converter.

  • Page 55: Figure A3-1 - Pc 204-2X / 204-2Sx Mid-Tower Installation Example

    Figure A3-1 – PC 204-2X / 204-2SX Mid-Tower Installation Example Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 56: Figure A3-2 - Pc 204-2X / 204-2Sx Ground Level Installation Example

    Figure A3-2 – PC 204-2X / 204-2SX Ground Level Installation Example Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 57: Figure A3-3 - Pc 204-2X / 204-2Sx Component Locations

    Figure A3-3 – PC 204-2X / 204-2SX Component Locations Figure A3-4 – PC 204-2X / 204-2SX Internal Wiring Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright© 2007, Cooper Industries, Inc.

  • Page 58: Spare Parts (For 204-2X/204-2Sx Versions Only)

    Spare Parts (for 204-2X/204-2SX versions only) Reference Description Part Number Capacitor, Twilight, 50 µF 6732600 Power Transformer, 120/240/480V, 60 Hz 4499501 Cooper Industries Inc. Crouse-Hinds Division IF 1544 PO Box 4999, Rev 1 Syracuse, New York 13221 • U.S.A. New 01/08 Copyright©...

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