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TWR Lighting E-1DBSL Manual

Dual medium intensity led/strobe
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10810 W. LITTLE YORK RD. STE. 130 - HOUSTON, TX 77041-4051
VOICE: 713-973-6905 - FAX: 713-973-9352
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-2018.E-1DBSL
11-11-08 REV 1-19-18
web: www.twrlighting.com
IMPORTANT!!!!
________
E-1DBSL

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  • Page 1 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 # E-1DBSL ________ SERIAL # PURCHASE DATE PURCHASED FROM M.E-2018.E-1DBSL...

  • 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 DIAGNOSTIC CIRCUITS .................12 3.8.1 Control Power On .................12 3.8.2 High Voltage ..................13 3.8.3 Trigger Voltage ..................13 3.8.4 Nightmode ....................13 3.8.5 Primary Timing ..................13 3.8.6 Timing Signal Verify ................14 3.8.7 Flash Verified ..................14 3.8.8 Strobe Fail Test ..................14 TROUBLESHOOTING ....................15...
  • Page 4 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL APPENDIX CHASSIS COMPONENT LAYOUT ............... H40-264 (REV S) WIRING DIAGRAM ..................M01-264 (REV K) HOUSING DETAIL ..................HD0-264 (REV D) INSTALLATION GUIDELINE ............... INS-264 (REV A) PHOTOCELL HOUSING DETAIL ..............100239i (REV H) TOWER LIGHTING KIT 201’ TO 350’ CABLE ..........602 (REV E) SIDELIGHT MOUNT ASSEMBLY ..............

  • Page 5: 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 6: 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 7: 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 8: Tower Lighting Kit

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 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 9: 2.5.2 Tower Kit Wiring

    2.5.2 Tower 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 10 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL All the necessary information for wiring the STLDBEACON2A and sidelights is contained on the tower kit drawing 602. The connections for the STLDBEACON2A and sidelights in the controller are as follows: 2.5.2.1 Connect gauge...

  • Page 11: Alarm Wiring

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL ALARM WIRING Individual alarm contacts (Form C) are provided for strobe failures, power failure, and photocell on. It is left up to the customer or installer on how they choose to utilize these contacts with their monitoring equipment.

  • Page 12: 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 13: 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 14: The Flashtube

    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 15: Trigger Circuit

    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 16: 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 17: High Voltage

    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 18: Timing Signal Verify

    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 19: Troubleshooting

    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 20: Diagnostic Evaluation

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL DIAGNOSTIC EVALUATION The first step in troubleshooting of this system or performing annual maintenance will require the technician to open the controller door. With the power off to the controller, the technician shall look over the controller circuit, and repair or replace any apparent problems, such as loose wire connections, or corroded terminations.

  • Page 21: Troubleshooting Assistance

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL TROUBLESHOOTING ASSISTANCE 4.3.1 Strobe Flash Verify LED - Out 4.3.1.1 Observe high voltage LED (D14) on the high voltage rectifier PCB #2, to determine if it is available. If the LED is dim or out completely, then check the high voltage capacitor bank (C103 - C109 daymode, C102 nightmode) for a short.

  • Page 22: 4.3.5. Stldbeacon2A/Flasher Failure

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 4.3.4.2 Check relay K11 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 at about eight (8) seconds.

  • Page 23: 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 24: Red Obstruction Lighting

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL 5.1.7 Re-tighten the single quick open bolt on the STLDBEACON2A hinge. 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 25: 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 C101, C102 STJ02001 CABINET SAFETY SWITCH FNQ10...
  • Page 26 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL MAJOR COMPONENTS LIST (continued) PART NUMBER DESCRIPTION SCHEMATIC TAG # SPM-120 (This replaces the SURGE ARRESTOR 120V AC MOV1 DTK-120HW) STH03264A RELAY PCB w/ALARM LOCKOUT PCB #3 ELIMINATION MODIFICATION 6390 – FAA2 (This replaces the...
  • Page 27 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL MAJOR COMPONENTS LIST (continued) PART NUMBER DESCRIPTION SCHEMATIC TAG # STDBCLENS CLEAR DUAL BEACON LENS STBEAGSK2 BEACON GASKET RM22JA31MRSP01 CURRENT SENSOR M1, M2 STC05005 TRIGGER TRANSFORMER STA22011 AUXILIARY LOAD RESISTOR DBTERMBLK8KIT DUAL BEACON UPPER...

  • Page 28: Suggested Spare Parts List

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL SUGGESTED PARTS LIST PART NUMBER DESCRIPTION STH01226B PCB #1 PRINTED CIRCUIT BOARD STJ10016 BLEEDER RELAY STFLSHTB8 STROBE FLASHTUBE 6390 – FAA2 120 – 240V PHOTOCELL (This replaces the P2455L Photocell) FNQ10 10 amp FUSE...

  • Page 29: Warranty & Return Policy

    DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL Warranty & 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.
  • Page 30 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 77041-4051, within 30 days of issuance.
  • Page 31 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL Warranty & Return Policy (continued) RMA 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 32 DUAL MEDIUM INTENSITY LED/STROBE MODEL E-1DBSL Warranty & Return Policy (continued) Credits – Credits are issued once it is determined that all of 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.

  • Page 33: Return Merchandise Authorization (Rma) Form

    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: PLEASE RETURN PRODUCT TO: 10810 W. LITTLE YORK RD. #130 HOUSTON, TX 77041-4051 M.E-2018.E-1DBSL...
  • Page 34 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: PLEASE RETURN PRODUCT TO: 10810 W. LITTLE YORK RD. #130 HOUSTON, TX 77041-4051 M.E-2018.E-1DBSL...
  • Page 41 FAA requirements as published in Advisory Circular 150/5345-43. NOTICE: The drawings and photographic images contained herein are the sole property of TWR Lighting, Inc. All information contained herein that is not generally 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.
  • Page 45 Parts List ITEM PART NUMBER DESCRIPTION OL1VLED2 L810 OBSTRUCTION LIGHT 100588_RE OL 6LED BASE PLATE 100591 OL 6LED STAR DISK 100680 OL1/2 SERIAL # LABEL A10290 5/32" ID RUBBER GROMMET STD05008 LED EMITTER OL GASKET AP100846 SIDELIGHT LENS CLEAR ACYRLIC 106V LENS HOLDER RING STE01-047...
  • Page 46 *NO MEMORY FUNCTIONS 1) Configuration: Selection of operation mode (<1 / >1 / >1< ) with or without memory. 2) Adjustment of current threshold as % of setting range. 3) Hysteresis adjustment from 5% to 50%. 4) Time Delay adjustment from 0.1 to 30sec. 5) Diagnostic button.

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