FOR FAA Medium Intensity L-864 and L-865 LED · PDF filenote: use this manual with the...

NOTE: USE THIS MANUAL WITH THE APPROPRIATE CONTROLLER’S SCHEMATIC & WIRING DIAGRAM

PART # __________________________________

DATE MANUFACTURED __________ __________ (month) (year)

Obstruction Lighting Controller Manual

3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com

INSTALLATION AND MAINTENANCE MANUALFOR

FAA Medium Intensity L-864 and L-865LED Obstruction Lighting System

D1RW-C13-008SP-A-RevA withPower Supply / Controller

Meets AC No. 150/5345-43G120 VAC DLS1-008SP230VAC DLS2-008SP48 VDC DLS4-008SP

2

May 002015[D1RW-C13-008SP-A-revA]

3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com May 002015[D1RW-C13-008SP-A-revA]

Table of ContentsContents

I. RECOMMENDED TOOLS - Flash Head Cable Termination .................................................3

II. SAFETY NOTICES .................................................................................................................4

III. INPUT POWER ....................................................................................................................5

IV. INSTALLATION ....................................................................................................................5

V. OPERATION - LED Dual Lighting Systems (L864/L865) ....................................................6A. PANEL LAYOUT - E1 6B. WHITE STROBE DRIVER 7C. RED BEACON DRIVER 8D. MICROCONTROLLER BOARD 8E. CAPACITOR MODULE 8F. OBSTRUCTION LIGHT ALARM MODULE 8G. CONTROL RELAYS 9H. 48VDC POWER SUPPLY (Not present on 48 VDC model) 9I. TEST SWITCHES 9J. ALARM AND STATUS RELAYS 10K. RECOMMENDED SPARE PARTS & USER REPLACEMENT PARTS 10

VI. LIGHTNING .......................................................................................................................10

VII. PHOTOELECTRIC CONTROL (PCR) ............................................................................ 11

VIII. TESTING AND MAINTENANCE ......................................................................................12

IX. ELECTRICAL CONNECTIONS ............................................................................................13

X. TROUBLESHOOTING - LIGHTING CONTROLLER ..............................................................14

XI. LIMITED PRODUCT WARRANTY ......................................................................................15

XII. SYSTEM INSTALLATION REQUIREMENTS FOR EMC AND LIGHTNING IMMUNITY .....16

APPENDIX A - RECOMMENDATIONS FOR PROPER GROUNDING TO MINIMIZE RISK OF

LIGHTNING DAMAGE (D1RW-C13-008SP-A-RevA/ Single Level Version) ................................17Cable Grounding (Power Supply Side) 17

APPENDIX B - TROUBLESHOOTING GUIDE - LED BEACONS ...............................................22

APPENDIX C - DLS1-008SP-A QUICK REFERENCE GUIDE ...................................................36

APPENDIX C - COMMISSIONING CHECKLIST .......................................................................37

3



I. RECOMMENDED TOOLS - Flash Head Cable Termination

1/8" Screwdriver .................................. Terminal Blocks in Controller and Flash Head

SUPPLIER P/N: 1/8" SCREWDRIVER IMAGE OVERALL LENGTH

Fastenal 0263735 2.5 Inches

Grainger 1CLP9 5.5 Inches

Grainger 1CLH3 8.75 Inches

4



II. SAFETY NOTICESThis equipment is normally used or connected to circuits that may employ voltages which are dangerous and may be fatal if accidentally contacted by operating or maintenance personnel. Extreme caution should be exercised when working with this equipment. While practical safety precautions have been incorporated in this equipment, the following rules must be strictly observed:

KEEP AWAY FROM LIVE CIRCUITS Operating and maintenance personnel must at all times observe all safety regulations. Do not perform maintenance on internal components or re-lamp with power ON.

RESUSCITATION Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of �rst aid instructions.

IMPORTANT NOTICES: Be certain this is the correct lighting system for the project. Verify the lighting system and equipment received are in accordance with the project speci�cations. Locations on Not Grounded (Isolated) towers, High RF antennas, hazardous areas due to explosive gas, fumes, dust, salt air or other highly corrosive/chemical environments often require special components or system modi�cation for proper function and system longevity.

A schematic-wiring blueprint drawing is supplied and included with the controller. Reference must be made to the drawing before making any wiring connections. This manual of instructions outlines the function of the controller and its components. There should be no maintenance performed on the OLC or the system without reference to the manual and the OLC schematic wiring.

The relays are factory preset for their indicated operations. Changing the switch selections will cause a malfunction of the circuit and may damage the relay. For applications using fewer than the designated number of lights for a given OLC, note the following:

For fewer double obstruction lights, do not wire the appropriate alarm relays to the alarm circuit (unused alarm relays will indicate a fault). NOT GROUNDED (ISOLATED) TOWER APPLICATIONS:The OLC must be isolated from the input power by means of a standard isolation transformer or an appropriate choke (�lter) system.

5



III. INPUT POWER

Power to the Obstruction Lighting Controller (OLC) will vary based on the P/N of your system (see accompanying documentation). Controller circuit protection (fuse or circuit breaker) for incoming power is external and provided by others. It is important to use the speci�c OLC schematic-wiring diagram together with this manual.

IV. INSTALLATION

Mount the controller cabinet in a vertical position ensuring the cabinet is level and there is ample space to mount the unit. The enclosure is provided with bracket mounting feet at the top and bottom back edges for use against a vertical surface or frame. Be sure the mounting location is square so as not to twist or warp the enclosure during mounting. Prior to wiring the controller to incoming power and loads, make sure all hardware and electrical connections have not loosened during shipping.

Wire and conduit entrances and their location on the cabinet are to be provided by the installer. On some lighting controllers, knockout openings are provided on the cabinet. All cabinet openings should be from the bottom of the enclosure. Wiring entrances for power input, external photo control leads, and external lighting loads should be located opposite to their terminal connections, if possible. The external Photoelectric Control should be located near the controller and must also have the wiring and conduit enter through the bottom of the unit. Refer to the PCR instructions for proper location and circuit wiring.

Standard and special lighting controllers incorporate a green and yellow ground lug (GND) located on the left end of the terminal strip which lies on the left end of the terminal block. It is near the power input terminals and it is comprised of a box lug or singular screw-hold lug, which is fastened to the metal back panel. The metal back panel is secured to the enclosure housing forming a solid equipment ground path through an attached conductor from the ground lug to external ground (earth). A green colored wire ( # 8 - # 10 AWG stranded copper conductor ) should be used for connection from the ground lug to an external ground (earth). The system neutral is NOT considered a grounded contact and must NOT be connected to the ground lug or controller chassis.

The purpose of grounding is to protect equipment, personnel, and circuits by eliminating the possibility of dangerous fault current or excessive voltages. The equipment ground for the controller’s metal enclosure that contains electrical wires or component devices is there to eliminate the possibility that an insulation failure in such an enclosure might place a potential (voltage) on the enclosure and constitute a shock or �re hazard. The OLC ground lug is provided to ful�ll the requirement of the National Electric Code for fault current protection.

6



V. OPERATION - LED Dual Lighting Systems (L864/L865)A. PANEL LAYOUT - E1

E1 Panel Part Number1 Two White Strobe Drivers D1RW0084W

2 One Red Beacon Driver D1RW0084R 3 One Micro-controller module D1RW0084FM 4 One Capacitor Module D1RW0084CP 5 Obstruction Light Alarm Module 4501-011 6 Three Control Relays (Qty may vary based on system) 3003-017 (120 VAC) 3003-015 (230 VAC) 3003-026 (48 VDC) 7 One 120VAC to 48VDC Power Supply D1RW-9005 8 Alarm and Status Relays with Isolated Alarm Contacts 3003-024 (120 VAC) (Qty may vary based on system) 3003-025 (230 VAC) 3003-033 (48 VDC) 9 Flash Head Interface Board D7201SUR 10 Line Filter D7202-SUR - AC Volts

D7204-SUR - DC Volts

1 1

9 4

7

2

3

5

8 6 6 6 10

7



This design uses LED technology for light output both from the Beacon and White Strobe. Unlike conventional xenon �ashtube technology, little or no maintenance is required during its lifetime. Working voltages of less than 200VDC are much lower than with xenon �ashtube designs; therefore, this system represents an advance in safety.

A high level of functionality and versatility is provided by the Controller / Power Supply. Not only does it generate the required LED drive currents, but also provides:

• Timing and synchronization• Fault monitoring with Isolated Alarm Contacts• Control Functions

Controller / Power Supply Block Diagram

I/O Signal Opto-Isolators

White Strobe Driver 1

White Strobe Driver 2

Red Beacon Driver

To Light EngineMicro-

controller Circuit

EMI Filter, Transient &

Reverse Polarity

Protection

DC in

Control Signals

B. WHITE STROBE DRIVER

The two white strobe drivers provide the voltage and drive current to each of its respective portions of White LED in the Flash Head. Each driver has two individual driver circuits and a common return. Measure each driver output from Ground to each Strobe(+) on the Flash Head output terminal block. The output voltage of each driver circuit is approximately 100VDC to 140VDC. The current in each circuit is approximately 1.5 Amps, 100ms pulses.

The two Strobe Driver modules each have three indicator LED’s. LED 2 and 3: Each is driven from one of the driver’s two outputs. Therefore normally each one should blink at the same rate as the Strobe output. These indicate the driver module is operating. If for some reason some of the White LED’s in the light engine do not operate yet these diagnostic LED’s do blink, this would indicate the

8



fault is not with the Driver module. Should one or more of these LED’s be stuck on or not �ash at all, this would indicate a fault with the driver module.

LED 4: Lights continuously when the Strobe is energized to show an excess of 50V is present at its output. If this does not light it might indicate either the Driver module is faulty or not receiving any power.

C. RED BEACON DRIVER

The Red Beacon Driver provides the power to the Red LED’s in the Flash Head. There is one output and one return. Measure across the Beacon(+) and Beacon Return. The output voltage to the Flash Head is approximately 50VDC.

LED 1 on the Red Beacon Driver indicates more than 50V is present on the output and gives a good indication that the Beacon Driver module is working.

D. MICROCONTROLLER BOARD

The Microcontroller Board provides the timing, control inputs and monitoring of the system.

LED 1 on the microcontroller board shows the status of the light engine. In white mode, it will �ash the layer number of any white layers that currently have faulty strings. In red fault mode, it will not �ash as the system will go into white backup mode.

LED 2 on the microcontroller board pulses once every time a �ash is initiated in the light engine.

E. CAPACITOR MODULE

The capacitor Module stores su�cient energy to provide the very high output power during the �ash duration.

F. OBSTRUCTION LIGHT ALARM MODULE

The Obstruction Light Alarm Module provides the monitoring of the obstruction lights. The settings on the module are factory set to coincide with number of obstruction lights in the system. The module will detect a fault if any one obstruction light in the system fails. The display on the module will �ash if there is a fault condition. If changing System con�guration call Unimar Tech Support at (315) 699-4400.

9



G. CONTROL RELAYS

There are three control relays in the Controller / Power Supply. Their functions are as follows:

Relay K1: Red Beacon Failure, Energized when GoodRelay K2: Night ModeRelay K3: White Night Test Mode

The three relays are pluggable for easy replacement.

H. 48VDC POWER SUPPLY (Not present on 48 VDC model)

The 48VDC power supply requires a 100-240VAC supply input. It provides the required 48VDC to power the strobe system.

The power supply is rated for 150W output.

I. TEST SWITCHES

Test Switches are provided for testing all the functions of system for proper operation (see photo pg. 7). Their functions are as follows:

Auto – Test SwitchAuto – When in this position the system is under control of the Photo-

Control. When in this mode the other switches are not operational. This is normal operating mode. Test – When in this position the other mode switches are operational.

Red – White SwitchRed – When in this position the system will be in Red mode.

White – When in this position the system is in White mode - The Day-Night Switch controls intensity. Day–Night Switch Day – When in this position the system is in White Day mode and the light output is 20,000 candelas. Night – When in this position the system is in White Night mode (night backup) and the White light output is 2,000 candelas

10



K. RECOMMENDED SPARE PARTS & USER REPLACEMENT PARTS

Description Dialight Part NumberLight Engine Module (Flash Head) D1RWFH008White Driver Module D1RW0084WRed Driver Module D1RW0084RMicro-controller/Filter Module D1RW0084FMCapacitor Module D1RW0084CPObstruction Light Alarm Relay 4501-011Control Relays 3003-017, 3003-015, 3003-026Fuses 1001-004Flash Head Interface Board D7201SURLine Filter D7202-SUR, D7204-SUR48VDC Power Supply D1RW-9005Alarm Relays 3003-024, 3003-025, 3003-033

VI. LIGHTNING

Refer to Appendix A - PROPER GROUNDING TO MINIMIZE RISK OF LIGHTNING DAMAGE for detailed installation procedures.

J. ALARM AND STATUS RELAYS

The Alarm and Status Relays provide the isolated contacts for interfacing with the customer's remote alarm system. The relays each had an LED indicator to indicate when the particular relay is energized.

The relays indicate the following:WFA – White Strobe Alarm, Energized when there is NO fault.

RFA – Red Beacon Alarm, Energized when there is NO fault. OLA – Obstruction Light Alarm, Energized when there is NO fault. PFA – Power Fail Alarm, Energized when supply power is present. NGT – Night Mode, Energized at night.

11



VII. PHOTOELECTRIC CONTROL (PCR)

Photoelectric Control ( PCR) - P/N 18001-006 (120 VAC) 18002-006 (230 VAC)

The PCR is designed and calibrated to meet both the FAA and FCC regulation.The PCR must be mounted in a vertical position. The PCR should face

the NORTH (polar sky) away from the Sun's rays and away from sunlight re�ections. The PCR should protrude above the height of nearby structures or other obstructions that might cast shadows upon the PCR's window.

The PCR is used for automatic switching of the load circuits. It is located externally from the controller cabinet. When wiring the PCR to the controller, use # 12 AWG stranded wire conductors.

The AUTO - TEST switch inside of the DOLC cabinet is used to bypass the PCR, permitting the lights to be turned on manually. The AUTO - TEST switch allows for testing and calibration of all modes of operation. This is a maintenance feature. The switch should be in the automatic (auto) mode for normal operation.

Refer to the accompanying PCR instruction sheet.

Note: When the PCR is connected properly and the test switch is set to "Auto", the Red LED on the PCR will be energized.

Locking-type Photocontrols – P/N 18001-008 (120 VAC) 18002-008 (230 VAC) 18003-005 (48 VDC)

Delayed response thermal series for white strobe/dual systems. Built-in time delay prevents false cycling caused by lightning �ashes or stray headlights. All-weather locking type receptacle and Lexan housing with 14”, 14 AWG wire color-coded as follows: line-black, neutral-white, load-red. Threaded stem �ts through a ½”

knockout. Dimensions: 2 5/8” diameter (socket), 2 5/8” high (including stem), ½” NPT at bottom �tting.

18001-006

18001-008

12



VIII. TESTING AND MAINTENANCE

All lighting controllers (DOLC) are tested at the factory under simulated lighting conditions. The lighting system can be tested in the �eld during daytime by using the photoelectric control override switch (set to manual), or by totally covering the photoelectric cell face. Use of the AUTO - TEST switch is recommended for maintenance.

During the testing procedure, all wiring is assumed to be correct and secure throughout the system.

It is suggested that an inspection and testing of the controller be made after a direct lightning strike on the lighted structure. Wiring and/or lamps may have been subjected to damage even if the DOLC seems una�ected. Before any extensive maintenance is performed, it is advisable that the external power be disengaged before probing within the controller. The fail-safe feature of the �asher unit permits a �ashing beacon to operate steady burning if the �asher module fails. If either the side light or beacon alarm relay sensors fail, the �asher and/or the obstruction lights will continue to be energized but the alarm indicators will be inoperable.

With the use of the PCR and the �asher circuit, time delays will prevent the controller from operating immediately upon application of power at the threshold of darkness. About two minutes or less will elapse before all circuits are operating.

Substitution of any components other than with original manufacturer original spares is not recommended and may void any warranty.

No oiling is required in the DOLC. Anti-fungicidal agents or desiccants should be applied ONLY by quali�ed personnel. No warranty can be implied to any alteration of the controller, by others.

13



Electrical connections between the PCR and lighting controller: Warning: Voltage between P1 and N, and P2 and N must not exceed 150 volts.

PHOTO-CONTROL

PHOTO-CONTROL

L1

L2

L1

N

N

N

N

N P2

P1

P1

L1

L1 L2

N

N P2

P1

P1

L1

N

P1

LIGHTING CONTROLLER

LOAD 1

LOAD 1

LOAD 2

POWER 1

POWER 1

POWER 2

P/N 18001-006 / 18002-006

P/N 18001-008 / 18002-008 / 18003-005

Red

Black

White

IX. ELECTRICAL CONNECTIONS

14



X. TROUBLESHOOTING - LIGHTING CONTROLLER

CAUTION: Turn Power o� to the lighting controller at the source before any maintenance is performed on controller or light �xtures.

A. PFA - Power Fail Alarm

1. Check Supply power to the system

B. WFA - WHITE Strobe Fault Alarm

1. Check the WHITE Strobe for proper operation - Refer to Dialight Manual - "Maintenance and Troubleshooting".

C. RFA - RED Beacon Fault Alarm

1. Check RED Beacon for proper operation - Refer to Dialight Manual - "Maintenance and Troubleshooting".

D. OLA - Obstruction Light Alarm

1. Check obstruction light output fuse.2. Check obstruction lights for failure, and replace failing light.

Call Unimar, Inc. for assistance: Phone # 315-699-4400; Fax # 315-699-3700

15



XI. LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

UNIMAR, INC. warrants to each original Buyer of Products manufactured by the Company that such Products are, at the time or delivery to the Buyer, free of material and workmanship defects, provided that no warranty is made with respect to:

(a) any Product which has been repaired or altered in such a way, in Company's judgment, as to a�ect the Product adversely;

(b) any Product which has, in Company's judgment, been subject to negligence, accident or improper storage;(c) any Product which has not been operated and maintained in accordance with normal

practice and in conformity with recommendations and published speci�cation of Company; and, (d) any Products, component parts or accessories manufactured by others but supplied by Company (any claims should be submitted directly to the manufacturer thereof).

UNIMAR, INC.'s obligation under this warranty is limited to use reasonable e�ects to repair or, at its option, replace, during normal business hours at any authorized service facility of Company, any Products which in its judgment proved not to be as warranted within the applicable warranty period. All costs of transportation of Products claimed not to be as warranted and of repaired or replacement Products to or from such service facility shall be borne by Purchaser. Company may require the return of any Product claimed not to be as warranted to one of its facilities as designed by Company, transportation prepaid by Purchaser, to establish a claim under this warranty. The cost of labor for installing a repaired or replacement product shall be borne by Purchaser. Replacement parts provided under the terms of this warranty are warranted for the remainder of the warranty period of the Products upon which they are installed to the same extent as if such parts were original components thereof. Warranty services provided under the Agreement do not assure uninterrupted operations of Products; Company does not assume any liability for damages caused by any delays involving warranty service. The warranty period for the Products is for a period of 5 years on standard products and custom assemblies from the date of shipment or �rst use whichever occurs �rst.

16



1. Ensure the shield of the cable that connects the Flash head to the power supply is grounded at both ends. Make 360- degree ground connections around the braid or foil (avoid pigtails).

2. Ensure that a lightning rod extends up 3 feet above the �xture is installed and 18 inches away from the light.

3. The drain-wire in the Flash head cable must be connected to ground at both ends. Ensure that the wire is short as possible and avoid loops.

4. Ensure the Flash head is electrically bonded to the tower. Scrape away access paint/ powder coating as necessary.

5. Minimize loop areas by tying all cables against the tower or passing through conduit. NOTE: Refer to kit drawing for proper cable attachment to tower.

6. Ensure the power supply enclosure is electrically bonded to the tower. Scrape away access paint/ powder coating as necessary.

7. Ground any spare/ unused conductors in the �ash head connection cable at both ends.

8. Service loops should be added as required to prevent moisture entering through the cable and in to the �xture or enclosure. 2-3, 6-12 inch loops is recommended.

9. Service loops must be taped to the structure. In proper securing could cause premature failures due to vibration or lightning.

10. DO take pictures of all cable runs, wiring connections and junction boxes used during the installation. This is required for warranty purposes and site commissioning purposes.

11. Pictures must be given to site manager and system provider for commissioning purposes.

XII. SYSTEM INSTALLATION REQUIREMENTS FOR EMC AND LIGHTNING IMMUNITY

17



APPENDIX A - RECOMMENDATIONS FOR PROPER GROUNDING TO MINIMIZE RISK OF LIGHTNING DAMAGE (D1RW-C13-008SP-A-RevA/ Single Level Version)

Cable Grounding (Power Supply Side) 1. Remove about 6" of protective outer cladding taking care not to damage underlying mesh braid.

Remove white �ber insulator

NOTE: Flash Head end cable needs only 6-7 inches of jacket removed.

2a. Push back on the braiding to loosen the cross-hatchings in order to create an opening. Remove the foil between the braid and the conductors.

18



4. Using black electrical tape, tape down the conductors where they exit the braid, leaving 1/2" of braiding exposed between the cladding and the tape

2b. One at a time, carefully begin to pull each conductor through the braiding about 1" above where the cladding was cut. A small �at blade screwdriver makes this process easier.

BE CAREFUL NOT TO DAMAGE THE BRAIDING

3. Separate each of the 8 conductors and remove the yellow �ber �ller. Strip each conductor back 1/2" and twist each stranded end.

19



5. The J3 terminal block has 8 position with 2 openings for each position. One is for inserting and removing each of the conductors the other is for applying and releasing pressure of the spring terminals inside the block to secure the conductors. Place the blade of a small screwdriver in the TOP opening and turn the blade 90°. Place the appropriate colored conductor into the lower opening and release the screwdriver to secure the conductor. Strip the end of each wire 1/2"back.

6. Repeat for all conductors taking care that the insulating material of the conductors is not hindering connection with the terminal block.

20



7. Carefully separate the top of the seating clip and press the exposed braiding of the cable into place. Using the “T” shaped tab on the clip bracket, secure the cable with a wire tie tied to the exposed braided section.

8. Secure the twisted braided shield to the copper grounding lug using a �at blade screwdriver. If twisted braid is too long, cut to appropriate length allowing for a small amount of slack.

21



(Must be water-tight)

Tighten the cable gland nut to 40-60 inch/lbs. Pull on the cable and ensure that the cable does not slip out of the cable gland nut.

Hookup to �ashhead. For instructions on how to install, please refer back to the previous pages. (17-20)

22



TROUBLESHOOTING GUIDEAND

IN-DEPTH TROUBLESHOOTING MANUAL

1-Level, P/N: D1RW-C13-008SP-A-RevA

110/240VAC, 50/60 Hz, 48VDCL865, DUAL MEDIUM INTENSITY WHITE STROBE & L864 RED

BEACON

APPENDIX B - TROUBLESHOOTING GUIDE - LED BEACONS

23



Troubleshooting GuideSymptom Possible Causes [Frequency] Corrective Actions Additional Notes

White not lit; power supply is totally inactive

Lack of incoming power 110-240VAC to AC to DC Converter Module [Frequent]

Check incoming power wiring in conductors Refer to Problem 1 for instructions. (p.26)

AC to DC converter Module Problem [Very Rare]

Check voltage coming out from AC to DC converter module. Should be 48VDC

Refer to Problem 2. (p.28)

White strobe will not operate. Alarm and/or Error LED (RED LED1 on Micro/Filter Module) �ashing.

Flash Head Cable Problem [Frequent]

1. At Power Supply, check multi way cable conductors are wired securely and in the correct order to terminal blocks.2. At Flash Head, check multi way cable conductors are wired securely and in the correct order to the terminal block.3. At Flash Head, check wires have not been trapped between Light Engine and Base housing.

Refer to Problem 2 for instructions.

Driver Board Module Problem [Rare]

Check nominal 48VDC supply voltage on J1 on the driver board.

Refer to Problem 2 and Problem 3.

LED String Failure in Light Engine [Very Rare]

Replace light engine (only when all other possibilities have been explored).

Refer to Problem 6.

White Strobe (some or all LED strings) are steady ON (not �ashing).Alarm and/or Error LED (RED LED1 on Micro/Filter Module) �ashing.

One or more LED return conductors shorted to ground. [Frequent]

Check all connectors, mainly Strobe commons (+'s) and the two return wires on each of the levels. At Flash Head, check wires have not been trapped between Light Engine and Base housing.

Refer to Problem 2 and Problem 3 for instructions.

Damaged Driver Board [Rare] Look for white driver module with any of LED 2 or 3 stuck ON. Replace this driver module.

Refer to Problem 2 and Problem 3.

Damaged Micro-Controller Board [Extremely Rare]

Replace Micro-Controller Board. Refer to Problem 3.

Red Beacon will not operate. Diagnostic LED (LED1 on Red Driver Board) is Lit.

Problem with cable from Power Supply to Flash Head. In particular, the 2 conductors labeled 'Beacon+' and 'Beacon-' [Frequent]

1. At Power Supply, check multi way cable conductors are wired securely and in the correct order to terminal blocks.2. At Flash Head, check multi way cable conductors are wired securely and in the correct order to the terminal block.3. At Flash Head, check wires have not been crushed between Light Engine and Base housing.


Damaged Driver Board [Rare] Check voltage on J3 of the Red Driver Board. Check voltage on Beacon(+) and Beacon Rtn on the Terminal Block.


Red Beacon will not operate. Diagnostic LED (LED1 on Red Driver Board) is NOT Lit.

No Power to Beacon Module. [Frequent]

Check nominal 48VDC supply voltage on J1 on the driver board.


FALSE ALARMS: ALL ALARMS ARE REAL ALARMS UNTIL ALL STEPS ABOVE HAVE BEEN CHECKED!!!

Problem with Micro/Filter Board [Extremely Rare]

Check DIP Switches on Micro/Filter Board Refer to Problem 4 for instructions.

Problem with Alarm Unit [Rare] Contact alarm unit manufacturer Refer to Problem 4 for instructions.

24



L-865 StrobeIn-Depth Troubleshooting Manual

Problem 1.Symptom -Flash Head not working and NO indicator lights or diagnostic LED(s).

-White and Red lights not working.

Corrective Actions – 1. Check Incoming Supply Voltages

Using a multimeter, measure Voltage coming in to the AC to DC Converter (Fig.1). Measure between Neutral and the Live as shown in Fig.1. Incoming Voltage should be nominal 120-240VAC. (Fig.1).

Figure 1 - Measure INCOMING Supply voltage on the AC-DC Converter

25



2. Check the Supply out from AC to DC Converter Module

Using a multimeter, measure Voltage coming out from the AC to DC Converter (Fig.2).

Measure as shown above. Output Voltage should be nominal 48VDC. (Fig.2).

Figure 2 - Output Supply voltage on the AC-DC Converter. Should read ≈48VDC

3. Check the Power In to Micro/Filter Board Module

Using a multimeter, check J1 on �lter board (Fig.3). Make sure J1 is plugged in and check connection wires. Make sure wires are secure.

Check power at J1 between the Power wire's two wires. (Fig.3).

When in operational, the voltage between the two Power wires should be nominal 48VDC.

Figure 3 - J1 on the Filter Board

26



Problem 2.Symptom -White Strobe will not operate

-One or more of the LED strings are NOT lighting on the Light Engine. -Open circuit or Open LED's

Corrective Actions – 1. Inspect the Error LED: LED1 (Red LED) on the Micro/Filter Board (Fig.4).

During normal operations, LED2 (Green LED) �ashes and LED1 stays o�.

LED1 (Red LED) blinking con�rms that there is an error. Observe the number of blinks. The number of blinks corresponds to the connector J1, J2, etc. on the Micro Board (Fig.4). (E.g. Two blinks are referring to J2 connector on the Micro Board, the Driver Module and Light Level connected to J2). Inspect the corresponding connector on the Micro Board and the driver board that is connected to the corresponding connector. Secure any/all loose connections. Proceed to Step 2.

Figure 4 - J1, J2& J4 Connections and LED1&2 on the Micro Board

27



2. Check power going to Driver Module J1 (Fig. 5) on the Driver Board in question (should be ≈48VDC).

Figure 5 - Driver Board. Connectors J1, J2, J3&J4. LED4 should be steady on if power is being supplied.

3. Check LED4 (Fig.5) on the Driver Board in question is ON Steady.

4. Check LED2 and 3 (Fig.5) on the Driver Board in question are blinking.

LED2 and 3 each is driven from one of the driver's two outputs. Therefore, normally each one should blink at the same rate as the Strobe output and the intensity of the LED2 and 3 should be uniform (same brightness). These indicate the driver module is operating.

If some of the White LED's in the Flash Head do not operate, yet these diagnostic LED's (LED2 and 3) do blink, this would indicate the fault is not with the Driver module but elsewhere.

Should one or more of these LED's be stuck on, blinks with a di�erent intensity to the others, or not �ash at all; this would indicate a fault with the driver module. However, continue with the steps below in case the fault is elsewhere.

J1 J2

J3

J4 LED2 & 3

LED4

28



5. Wait 45 seconds after turning the system on, then using a Multimeter, check J3 and measure the Voltage VDC.

During normal operations, the voltage will read roughly 100VDC ~ 140VDC. Due to strobe �ashing, the voltage will �uctuate but the peak voltage should be roughly 100VDC ~ 140VDC. If VDC is close to 160VDC, one or more of the LED Strings in the Flash Head is disconnected.

6. Check wires and connector J3 (Fig.5) of the Driver Board in question.

Also check wires in Terminal Block. Make sure all connection wires make good contact in each terminal. Make sure all wires going into and out from terminal block are color matched 1:1. (E.g. Yellow wire going into the terminal block from the power supply side should be matched at the terminal block by a Yellow wire from the Flash Head side.) In the case that all connections are good and yet there is still a problem with one or more of the LED strings in the Flash Head not lighting up, proceed to Step 7.

7. Replace the Driver Board Module in question with a known working Module.

Replace using a spare Driver Board Module, if possible. If not, switch with another working unit and observe if the symptom moves. If the problem moves, the Driver Module is likely to be damaged and should be replaced. If the problem does not move and the status is as before swapping, the fault is elsewhere. If an additional problem other than the original is created, this indicates that there is a problem in both the Driver Board and either the cable up to the Flash Head or the Flash Head itself. Proceed to Problem 6 in this Troubleshooting Guide.

NOTE: Per FAA regulation 150-5345-43F, if 25% or more of the LED Strings are not functioning, system will send alarm signal which may shut down the system.

29



Problem 3.Symptom -One or more of the LED strings are STEADY ON (not �ashing)

Corrective Actions – 1. Error LED on the Micro/Filter Board

Inspect LED1 (Red Error LED) on the Micro/Filter Board (Fig.4).

LED1 blinking con�rms that there is an error. Observe the number of blinks. The number of blinks corresponds to the connector J1, J2, etc on the Micro Board (Fig.4). (E.g. Two blinks are referring to J2 connector on the Micro Board, the Driver Module and Light Level connected to J2).

Inspect the corresponding connector on the Micro Board and the Driver Board that is connected to the corresponding connector. Secure any/all loose connections. Proceed to Step 2.

2. Checking for Short Circuits Check system for short circuit to ground, in the return wires of the level in question. Proceed to Problem 7 in this In-depth Troubleshooting Guide.

Check for wires shorted to ground by crushed/ damaged cables.

Check wires going into the Flash Head housing. Wires may have been crushed during installation.

3. Replacing a Driver Board Module Replace the Driver Board Module in question with a known working Module. Replace using a Spare Driver Board Module if possible. If not, switch with another working unit and observe if the problem moves. In the case that the problem moves, the Driver Board Module would be suspected of being damaged. If the problem does NOT move and the system is still showing problems, proceed to Step 4. If an additional problem other than the original is created, this indicates that there is a problem in both the Driver Board and either the cable up to the Flash Head or the Flash Head itself.

4. Replacing a Micro/ Filter Module In the case where the system is still not working, replace the Micro/ Filter Board Module in question with a working spare or from a working system.

30



Problem 4.Symptom -Red Beacon will not operate. Diagnostic LED is lit.

Corrective Actions – 1. Check the cables are snuggly plugged into J1, J2 and J3. (Fig. 6)

2. Check the voltage from J3

NOTE: The following readings must be taken before the system goes into White backup.

During normal operations, voltage on J3 is ≈50VDC. If the voltage is ≈65VDC or greater, the load is an open circuit, proceed to Step 3. If ≈30VDC or less, the load is a short circuit.

Figure 6 - Red Beacon Driver Board. LED1 indicates more than 50V is present on the output and gives good indication that the Red Beacon Driver Module is working.

J1 J2

LED1

J3

31



3. Check Beacon (+) and Beacon RTN on the terminal block (Fig. 7).

4. Check for integrity of the wires in the terminal block. Make sure all wires are making contact and secured.

5. Check the connections in the Flash Head. Ensure that none of the wires are pinched, damaged, disconnected or loose.

6. Visually check the Flash Head for damage.

NOTE: Wire colors may di�er from picture.

32



Problem 5.Symptom -Red Beacon will not operate. Diagnostic LED is NOT Lit.

Corrective Actions – 1. Check and verify incoming power from the AC-DC Converter Module. (Fig.2).

2. Check Power Connection to J1 on Beacon Section (Fig.6) Make sure all wires are secured.

Problem 6. Symptom -One or more LED strings not lighting on the Flash Head.

Corrective Actions – 1. Check cables as stated in Problem 2, 3 in this In-Depth Troubleshooting Guide.

2. Check boards as stated in Problem 2, 3 in this In-Depth Troubleshooting Guide.

3. Verify ALL Flash Head connections are installed in the proper location and securely attached. Check that all wires, cables, connectors are NOT shorted, open, damaged and/or loose. Check both the power supply side and Flash Head side. Check junction box connections if applicable; also connections on the bottom of the Flash Head, under the base plate. Make sure to fully check before proceeding to Step 4.

4. Check Flash Head for visible damage to LEDs. Look for Loose and/or Burnt LEDs/ Circuit boards.

5. If visible damage is present, Light Engine must be replaced. Replace light engine only when all other possibilities have been explored. Repair of Light Engine is not possible due to the self enclosed system. If opened, condensation and/or other contaminants may further damage the system. If all checks are complete and yet the problem persists, call service only when all other possibilities have been explored.

33



Problem 7.Symptom -Short Circuit within System

Corrective Actions – 1. Check inside the Power Supply Box for loose wires, wires connected improperly, foreign objects

making contact with two or more locations that are not supposed to, and/or damaged/crushed wires causing a short to ground.

2. Using a multimeter on continuity setting, place one probe on Strobe Common1(+) and the other to Strobe Return1 and observe for continuity (audible sound from multimeter).

a. Repeat step 2 on Strobe Common1(+) and Strobe Return2. b. Repeat step 2, 2a and 2b for Strobe 2. If continuity is present, locate and remove short circuit.

Note: Good Resistance Reading: Strobe Common(+) to Strobe Return is 152k Ω ± 5%

34



Problem 8.Symptom -False Alarms

!!WARNING!! ALL ALARMS ARE REAL ALARMS UNTIL ALL OTHER PROBLEMS HAVE BEEN CHECKED IN THIS MANUAL.

Corrective Actions – 1. Utilizing this manual, check for any/all Errors before proceeding.

1.1 Check the Error LED (LED1) on the Micro/Filter Board Module. If �ashing, it is a TRUE alarm. If not �ashing, it is a false alarm.

1.2 Check that all connections and connectors are secure. Loose wires to the alarm relays (J3) may cause false alarms.

1.3 Check all voltages are correct as stated in previous Problems in this manual.

Figure 8 - Micro/Filter Board. DIP SWITCH (SW1). NOTE: Switch position UP is ON and DOWN is OFF. Factory default is 1-3 DOWN and Switch 4 UP.

35



2. Check the DIP Switches (SW1) shown in Figure 8. Refer to Con�guration Options Switch. Check Switch 4 in the DIP Switch and ensure that the switches are set to the requirement for the alarm unit (Switch 4 should be ON and all others OFF).

If DIP switches are correct, check the wires going to and from the alarm relay in J3 and the isolated alarm module. Check the output of the alarm signals (J3) using a multimeter for continuity [eg: If the system is normally closed (DIP Switch 4 in ON position), the relay will open upon receiving an alarm signal. Thus you would have an open connection when alarm signal is initiated].

Con�guration Options DIP Switch

Switch # Function1 At night, light Red Beacon or White Strobe at 2000 cd2 German W. Red (1s-on; 0.5s-o�; 1s-on; 1.5s-o�)3 Selects whether fault relays pulse while system is OK4 Selects whether fault relays open or close on fault

Switch # ON OFF1 White at night Red at night2 W. Red mode 50% duty cycle mode3 Relays pulse while system is OK Relays do not pulse4 Relays open on fault (Normally CLOSED) Relays close on fault (Normally OPEN)

ON OFF

CONFIGURATION DIP SWITCH SETTINGS (on Microcontroller Board)

1 2 3 4

NOTE: Only Switch 4 should be set to "ON" (Factory Set)

36



APPENDIX C - DLS1-008SP-A QUICK REFERENCE GUIDE

J1

J3

J1

J1

J4

J3

J4

J5

J4

J1

J1

WHITE DRIVER BOARDWHITE DRIVER BOARD

CAPACITO

R BOA

RD

RED DRIVER BOARDMICRO FILTER BOARD

TERMINAL BLOCK

POW

ER SUPPLY

48VDC

120-240VAC

48VDC

100-140VDC 48VDC

100-140VDC

48VDC

50VDC

J3

120-140VDC

120-140VDC

48VDCRED +

MIRCO FILTER BOARD NOTES:LED1 = OFF NORMALLED1 FLASH RED = ALARMLED2 = FLASH GREEN NORNAL

LED1= # OF RED FLASHES CORRSPONDS TO J1,J2,J4(EX. 2 FLASHES = J2)

COMM. CABLES:J1=WHITE DRIVER BOARD 1J2=WHITE DRIVER BOARD 2J4=RED DRIVER BOARD

DIP SWITCHES:1 - OFF2 - OFF3 - OFF4 - ON

J1J2J4

RJ45COMM.CABLE

RED DRIVER BOARD NOTES:LED1 FLAHING = 50VDC PRESENT ON OUTPUT OF BOARD

J3 OUTPUT:50VDC = NORMAL65VDC> = OPEN CIRCUIT30VDC< = SHORT CIRCUIT

WHITE DRIVER BOARD NOTES:LED4 ON STEADY = NORNALLED2&3 FLASHING = NORMAL

J3 OUTPUT:100-140VDC = NORMAL160-180VDC> = OPEN CIRCUIT100VDC< = SHORT CIRCUIT

K1 K2 K3

CONTROL RELAYS:(DUAL)K1 = RED BEACON FAILUREK2 = NIGHT MODEK3 = WHITE NIGHT TEST MODE

TERMINAL BLOCK RESISTANCE READINGS: (POWER OFF)RED & BLACK = 65K OR 29K OHMSPURPLE & BLUE OR PURPLE & GREEN = 150K OHMSORANGE & BROWN OR ORANGE & YELLOW = 150K OHMSTERMINAL BLOCK VOLTAGE READINGS:(POWER ON)RED & BLACK = 50 VDCPURPLE, BLUE OR GREEN TO GROUND = ± 100-140 VDCORANGE, BLUE AND YELLOW TO GROUND= ± 100-140 VDC

48VDC

J4

J1J2

RJ45COMM.CABLE

RJ45COMM.CABLE

RJ45COMM.CABLE

DIPSWITCHES

J1J9J7J4

48VDC

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRETINFORMATION WHICH IS THE PROPERTY OF UNIMAR, INC.OBSTRUCTION LIGHTING AND RECEIPT OR POSSESSION DOES NOT CONVEY ANY RIGHTS TO LOAN, SELL OR OTHERWISE DISCLOSE SAID INFORMATION. REPRODUCTION OR USE OF SAID INFORMATION FOR ANY PURPOSE OTHER THAN THAT IN CONNECTION WITH WHICH SAID INFORMATION WAS SUPPLIED MAY NOT BE MADE WITHOUT EXPRESS WRITTEN PERMISSION OF UNIMAR, INC. OBSTRUCTION LIGHTING. THIS DOCUMENT IS TO BE RETURNED TO UNIMAR, INC. OBSTRUCTION LIGHTING UPON REQUEST AND IN ALL EVENTS UPON COMPLETION OF THE PURPOSE FOR WHICH IT IS LOANED.

DRIVER 1DRIVER 2

37



APPENDIX C - COMMISSIONING CHECKLIST

All items on checklist must be completed correctly to ensure the system functions properly and reliably. Complete and Sign below.

Check that all cables, wires and connections are connected securely in accordance with instructions outlined in this Installation Manual.Check that the Lightning Protection and Proper Grounding is present in accordance with instructions outlined in this Installation Manual including Recommendations For Proper Grounding To Minimize Risk Of Lightning Damage (Appendix A).

Operational ChecksA. Set system to Day mode

1. Pull out the interlock switch

2. Wait at least 2 minutes

3. Check RED Error LED (LED1) on Micro Board does NOT blink. If it blinks, that indicates a fault - see Problems 2 and 3 in the Troubleshooting Guide (Appendix B)

4. Check that the controller does not produce any alarm signals

5. If possible, visually check that the Light Engine is �ashing and operating normally

B. Set system to RED Night mode1. Check LED1 on Red Driver module (bottom left of cabinet) is on if steady burning and

blinking if �ashing.

2. Check that the controller does not produce any alarm signals

3. If testing a White only system, set to White Night mode and repeat step A, starting from step 2

4. If possible, visually check that the Light Engine lights up

I, __________________________________ (Print Name), have completed all �nal checks listed above and observed satisfactory results. No issues to report at this time.

________________________________________ ___________________________

________________________________________ ___________________________

ONCE COMPLETED, TEAR OFF AND TAPE INSIDE THE DOOR OF THE POWER SUPPLY!!

Signature

Installation Site Location (Site Number, City, State)

Date

Company Name

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