Document No. 9100-127-1235-99 Rev B Release date: 11/18/09 INSTALLATION AND MAINTENANCE MANUAL FOR OEM Dual Red Beacon/White Strobe D1RW-C13-007 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 1 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Contents Page Contents----------------------------------------------------------------------------------------------2 Tables and Figures -------------------------------------------------------------------------------3 Section 1: Overview ------------------------------------------------------------------------------4 Section 2: Installation and Wiring -----------------------------------------------------------6 Section 3: EMC and Lightning Immunity--------------------------------------------------9 Section 4: Detailed Procedure for Proper Grounding to Minimize Risk of Lightning Damage ------------------------------------------------------------------------------ 11 Section 4a: Cable Grounding (Power Supply Side) ------------------------ 11 Section 4b: Light Engine Grounding (Flash Head Unit) ------------------ 18 Section 5: Ferrites ------------------------------------------------------------------------------ 23 Section 6: Flash Rate & Steady Burn ---------------------------------------------------- 23 Section 7: Control Inputs--------------------------------------------------------------------- 24 Section 8: Configuration Options Switch----------------------------------------------- 26 Section 9: Configuration Via Serial Port ------------------------------------------------ 26 Section 10: Mounting the Light Engine-------------------------------------------------- 27 Section 11: Maintenance and Troubleshooting -------------------------------------- 28 Section 12: Recommended Spare Parts and User Replaceable Parts-------- 30 Section 13: 100-240Vac Operated Systems -------------------------------------------- 30 Appendix A: Serial Port Specification --------------------------------------------------- 31 Appendix B: Specifications------------------------------------------------------------------ 37 Section 14: Commissioning Checklist--------------------------------------------------- 38 _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 2 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Tables and Figures Figure 1. Power Supply / Heat Sink Assembly -------------------------------------------------------------- 5 Figure 2. Driver Block Diagram ---------------------------------------------------------------------------------- 5 Figure 3. System Block Diagram -------------------------------------------------------------------------------- 6 Figure 4. Power Supply Din Rail Terminal Connection -------------------------------------------------- 7 Figure 5. Light Engine Terminal Block Connection ------------------------------------------------------- 8 Figure 6. Cutting the Outer Cable Cover ---------------------------------------------------------------------11 Figure 7. Expose the Drain wire --------------------------------------------------------------------------------12 Figure 8. Unravel the Metal Foil---------------------------------------------------------------------------------12 Figure 9. Remove the yellow fiber material -----------------------------------------------------------------13 Figure 10. Wrapping the foil around the cable -------------------------------------------------------------13 Figure 11. Tape the wrap of foil ---------------------------------------------------------------------------------14 Figure 12. Insert cable into power supply housing cabinet -------------------------------------------14 Figure 13. Connect wires into terminal block --------------------------------------------------------------15 Figure 14. P-clip attached to foil--------------------------------------------------------------------------------15 Figure 15. Secure P-Clip and drain wire ---------------------------------------------------------------------16 Figure 16. Attach Ferrite to wires ------------------------------------------------------------------------------16 Figure 17. Correct installation and placement -------------------------------------------------------------17 Figure 18. Wrapping foil, Silver side facing OUT, around the insulation--------------------------18 Figure 19. The metal foil is inside the nipple ---------------------------------------------------------------19 Figure 20. Check Ω (resistance) to ensure a good grounding connection -----------------------19 Figure 21. Internal View of the Flash Head Unit -----------------------------------------------------------20 Figure 22. Connect Drain Wire to Grounding Screw -----------------------------------------------------20 Figure 23. Connecting all wires, color for color, 1:1 -----------------------------------------------------21 Figure 24. Attach the Ferrite (provided) to the wires and close --------------------------------------21 Figure 25. Ensure no obstruction is between the Bottom plate & O-ring of the Unit frame-22 Figure 26. Micro Controller Board (Power Supply) -------------------------------------------------------24 Figure 27. Synchronizing Flash Rates------------------------------------------------------------------------25 Figure 28. Configuration Switch Settings (on Microcontroller Board) -----------------------------26 Figure 29. Base Bottom View ---------------------------------------------------------------------------------27 Table 1. Recommended Spare Parts And User Replaceable Parts----------------------------------30 Figure 30. Power Supply Heat Sink Assembly -------------------------------------------------------------36 Figure 31. Light Engine Dimensions --------------------------------------------------------------------------36 _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 3 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 1: Overview The Dialight OEM Dual Red Beacon White Strobe Driver and Flash Head is designed to be incorporated into Medium Intensity L865 systems for the lighting of radio towers, wind generators and other obstructions to aerial navigation, as specified by the FAA and FCC. This design uses LED technology for light output both from the Beacon and White Strobe. Unlike conventional xenon flashtube technology, little or no maintenance is required during its lifetime. Working voltages of less than 200VDC are much lower than with xenon flashtube designs; therefore, this system represents an advance in safety. A high level of functionality and versatility is provided by the Driver module. Not only does it generate the required LED drive currents, but also provides: Timing and synchronization Fault monitoring Dimming features Options for night operation Serial port configuration Data logging The Driver module consists of a plate on which are fixed: Two White Strobe Drivers One Red Beacon Driver One Micro-controller module One filter/protection and interface module The system operates from a nominal 48Vdc/100W supply. A switch on the micro-controller board allows various options as to how the system operates to be selected. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 4 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Figure 1. Power Supply / Heat Sink Assembly DC in EMI Filter, Transient & Reverse Polarity Protection I/O Signal Opto-Isolators White Strobe Driver 1 Microcontroller circuit White Strobe Driver 2 To Light Engine Red Beacon Driver Control Signals Figure 2. Driver Block Diagram _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 5 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 2: Installation and Wiring The Driver module should be mounted inside a grounded, metal enclosure to provide environmental, electromagnetic interference and safety protection. For safety, an interlock switch should be fitted to the Controller cabinet door such that when opened, power is disconnected from the system. A multi-conductor cable needs to be provided to connect the Driver to the Light Engine. Enclosure/Cabinet Power In Control Signals Light Engine Alarm Outputs Multi-way connection cable Figure 3. System Block Diagram _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 6 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Figure 4. Power Supply Din Rail Terminal Connection Light Engine Cable Connections Two conductors are required for the Red Beacon and eight for the White Strobe, so ten conductors are required in total. When connecting the cable to the terminal block, for both the Light Engine side and Power Supply side, match the colors on one side to other prewired side. E.g. 1:1, red to red, purple to purple, green to green. Recommended minimum specification for the light engine cable is: 10 conductors 20 AWG Rated for outdoor use -40 to +55ºC temperature range Rated for at least 200V between conductors Overall Shielded Overall diameter: 0.24 0.47 (6 12 mm) Cable length: 0 550 _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 7 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Note: 1: If conductor thickness is reduced the maximum permissible distance between light engine and power supply will be reduced. 2: For maximum immunity to the effects of radiated interference and lightning, the cable from the Control Box to Power Supply Cabinet should be shielded with the screen grounded at both ends. Figure 5. Light Engine Terminal Block Connection The cable connects to the Driver by means of the terminal blocks on the DIN Rail. The conductors connect one to one, to the corresponding terminals in the light engine. Warning: Take care to connect correctly, as incorrect operation can cause damage to the driver modules. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 8 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 3: EMC and Lightning Immunity System Installation Procedure for EMC and Lightning Immunity For further detailed instructions, refer to Detailed Procedures for Proper Grounding to Minimize Risk of Lightning Damage in the following section of this manual. For maximum immunity to RF and Lightning: 1: Ground the light engine cable at both ends. Make 360-degree ground connections around the braid or foil (avoid pigtails). 2: If there is a drain-wire in the cable, ground it at both ends 3: Ensure the Flash Head is electrically bonded to the tower 4: Minimize loop areas by tying all cables against the tower or passing through conduit 5: Ensure the power-supply cabinet is electrically bonded to the tower 6: Clamp a ferrite on each cable entering the power supply box as follows: Around all conductors emerging from the light engine cable (1 turn i.e. twice through center) Incoming power cable, all three conductors (2 turns i.e. 3 times through center) Power to the Side-Lights cable (once through center) Alarm cable Photo cell cable (once through center) Recommended ferrite type: Steward 28B1020-100 7: Ground any spare/unused conductors from the light engine cable inside the power supply cabinet 8: Keep wiring tidy with cables performing different functions tied up separately. Keep power, control and output cables separate. Tie up wires to minimize loop areas. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 9 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 9: To ensure compliance with FCC conducted emissions limits a 0.1uF/250V Xtype Suppression Capacitor should be connected across the incoming Live and Neutral mains conductors. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 10 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 4: Detailed Procedure for Proper Grounding to Minimize Risk of Lightning Damage Lightning Rods Install one or more lightning rods near the Light Engine. The lightning rods should extend a minimum of three feet above the Light Engine. Section 4a: Cable Grounding (Power Supply Side) 1. Measure roughly 10-12 inches (≈1 foot) of the provided cable. (See Fig.6) 2. Using a knife/ razor, carefully cut the protective cover on the wire, ensuring not to damage the wires and insulating foil inside. DO NOT CUT OFF ANY WIRE, BARE WIRE and/or FOIL. You dont have to be too conservative with the length of the cable. Having more cable cut is better than having too little cut. (See Fig.6) Figure 6. Cutting the Outer Cable Cover _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 11 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 3. Separate the Drain Wire (Bare wire) from the rest of the bundle. (See Fig.7) Figure 7. Expose the Drain wire 4. Carefully unravel the shielding foil from the bundle of wires. DO NOT CUT OR RIP THE FOIL. (See Fig.8) Figure 8. Unravel the Metal Foil _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 12 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 5. Expose the yellow fiber material and remove by cutting. Be careful not to damage the wires or shielding foil. (See Fig.9) Figure 9. Remove the yellow fiber material 6. Straighten out the foil and then wrap the shielding foil around the wires in the cable. Ensure the SILVER SIDE is facing out and the Blue side is facing the wires. The tighter the wraps, the better it is. Be careful not to use too much force, the foil may rip. (See Fig.10) Figure 10. Wrapping the foil around the cable _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 13 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 7. After all of the foil is wrapped up, silver side up, place a piece of tape (electrical tape, if possible, but any will do) at the bottom of the wrap to prevent unraveling. Keep the amount of foil being covered by the tape to a minimum. (See Fig.11) Figure 11. Tape the wrap of foil 8. Insert cable to the cable receptacle and push/pull cable through till the metal foil is on the inside of the power supply with some slack (about 12-16 inches). Do NOT tighten cable lock nut yet. (See Fig.12) Figure 12. Insert cable into power supply housing cabinet _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 14 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 9. Connect all wires, matching 1:1, color to color as shown below. Example: red to red, blue to blue, grey to grey, etc. (See Fig.13) Figure 13. Connect wires into terminal block 10. Place the metal P-Clip (Provided) around the foil. (See Fig.14) P-Clips Green Grounding Screw with Cup Washer Figure 14. P-clip attached to foil _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 15 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 11. Screw P-Clip into a hole located toward bottom right of mounting plate using screw (provided). Connect drain wire to mounting plate using Green Screw and Cup Washer (provided) also using a hole near bottom right of mounting plate. Cut off excess Drain wire to prevent accidental short circuits. (See Fig.15) Tighten screws. Ensure that none of the colored wires are pinched. Figure 15. Secure P-Clip and drain wire 12. Using the provided Ferrite, pass the wires through. Close the Ferrite, ensuring that none of the wires are pinched. DO NOT INCLUDE DRAIN WIRE (BARE WIRE) IN THE FERRITE. (see Fig.16 &17) Figure 16. Attach Ferrite to wires _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 16 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Figure 17. Correct installation and placement 13. Tighten cable lock nut until the cable is secure in place. (See Fig.12) _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 17 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 4b: Light Engine Grounding (Flash Head Unit) 1-5. Repeat steps 1-5 of the previous section Power Supply Grounding on other end of cable. 6. Straighten out the foil and then wrap the shielding foil around the insulation (Black Outer cover) of the cable. Ensure the SILVER SIDE is facing out and the Blue side is facing the insulation. The tighter the wraps, the better it is. Be careful not to use too much force, the foil may rip. (see Fig.18) The Goal is to make good electrical bond between the foil and metal framing. Make the cable and foil combination thick enough so the cable clamp has a good grip. Figure 18. Wrapping foil, Silver side facing OUT, around the insulation 7. After all the foil is wrapped up, silver side up, place a piece of tape (electrical tape if possible, but any will do) at the bottom of the wrap to prevent unraveling. Keep the amount of foil being covered by the tape to a minimum. Refer to Figure 11. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 18 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 8. Insert the cable into the cable receptacle and position the cable so that the metal foil is inside the nipple and tighten the cable lock nut. (see Fig.19) Ensure the inner metal clamp is making good electrical contact with the foil. Figure 19. The metal foil is inside the nipple 8-1.Use an ohmmeter or continuity to check drain wire electrically connects (low resistance) to metal (screw hole threads can be used) of light engine. (see Fig.20) Figure 20. Check Ω (resistance) to ensure a good grounding connection _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 19 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 8-2. Internal view of Cable Receptacle in Light Engine Housing. (see Fig.21) Figure 21. Internal View of the Flash Head Unit 9. Connect the Drain Wire (bare wire) to the Grounding Screw. (see Fig.22) Figure 22. Connect Drain Wire to Grounding Screw _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 20 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 11. Connect all wires, matching 1:1, color to color as shown below. Example: red to red, blue to blue, grey to grey, etc. (see Fig. 23) Figure 23. Connecting all wires, color for color, 1:1 12. Using the provided Ferrite, pass the wires through. Close the Ferrite, ensuring that none of the wires are pinched. DO NOT INCLUDE DRAIN WIRE (BARE WIRE) IN THE FERRITE. (see Fig. 24) Figure 24. Attach the Ferrite (provided) to the wires and close _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 21 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ 13. Close the cover, insuring that no cables or obstructions are caught between the cover plate and the housing and tighten cover bolts. If the o-ring is not sealed properly, severe damage may result. (See Fig.25) Figure 25. Ensure no obstruction is between the Bottom plate & O-ring of the Unit frame _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 22 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 5: Ferrites Ferrites act to increase the inductance of a conductor and can be effective at reducing or eliminating RF or lightning immunity problems. Different Ferrite materials have different effectiveness depending of the frequency to be attenuated. They should be chosen for maximum attenuation at the frequency of concern. As a general rule, the more material in the ferrite the higher will be the attenuation. For maximum lightning immunity and EMC performance, choose ferrite materials with good broad band attenuation, such as Steward 28B1020-100. Better attenuation will be obtained if the cable can be put through the center more than once. Inductance is proportional to the square of number of turns so twice through is theoretically 4 times the inductance of 1 turn. Multiple ferrites (including different types in combination) can be used on a single cable. Section 6: Flash Rate & Steady Burn Both Red Beacon and White Strobe default to 40 flashes per minute. The flash rate may be adjusted between 20-40 fpm by means of the Sync input. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 23 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Figure 26. Micro Controller Board (Power Supply) Section 7: Control Inputs Each input is active when the input terminal is connected to the negative of the supply input (Common). Input/Outputs Sync Input Synchronizes both White Strobe and Red Beacon. When held steady (connected to Common) the Red Beacon burns constant, and the White Strobe flashes at 40FPM. To synchronize the white and preset red flash rate, a 1 PPM signal may be provided. Alternately, a synchronization pulse may be applied at every flash to alter the flash rate. In both modes, the synchronization signal must be asserted for at least 0.1s to ensure that it is properly detected. Sync Output Independent synchronization signal which may be connected to the Sync input of other supplies when multiple synchronized lights are required (leave all other Sync Outputs unconnected) In Day mode Sync output defaults to 40FPM In Night mode Sync output defaults to 30FPM _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 24 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Master Strobe Sync In Sync Out Slave Strobe Sync In To Sync In of other synchronized strobes Figure 27. Synchronizing Flash Rates Day/Night contact Connect to Common for Night mode Dim 0 Connect Dim 0 to Common to reduce light output to 30% of maximum Connect Dim 1 to Common to reduce light output to 10% of maximum Note: Dimming affects both White Strobe and Red Beacon Dim 1 Two uncommitted solid-state relay outputs are provided to indicate a fault with the Red or White Beacon; Red Fault A Red Fault B White Fault A White Fault B Each solid state relay is rated for up to 600V/40mA max, 20mA continuous. The relays can either be configured to close or open when there is a fault condition, _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 25 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ or pulse (fail safe, at a rate of 1 Hz with a duty cycle of 50%) when all is OK by means of the Configuration Options switch. Section 8: Configuration Options Switch Switch 1 2 3 4 At night, light Red Beacon or White Strobe at 2000cd German W. Red (1s-on, 0.5s-off, 1s-on, 1.5s-off) Selects whether fault relays pulse while system is OK Selects whether fault relays open or close on fault CONFIGURATION SWITCH SETTINGS (on Microcontroller Board) 1 2 3 4 ON Figure 28. Configuration Switch Settings (on Microcontroller Board) ON 1 2 3 4 OFF White at night W. Red mode Relays pulse while system is OK Relays open on fault Red at night 50% duty cycle mode Relays do not pulse Relays close on fault Section 9: Configuration Via Serial Port Certain parameters may be configured via a serial port on the microcontroller board. This allows different pulse times and duty cycles to be set up, as well as allowing for additional monitoring capabilities. See Appendix A for more information about the connection and protocol. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 26 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 10: Mounting the Light Engine Dialight recommends the installation of one or more lightning rods near the installed Light Engine. The lightning rods should extend a minimum of three feet above the height of the Light Engine. The Light Engine is mounted to the tower pedestal utilizing customer supplied ½ hardware. Six mounting holes are provided on the Light Engine base (Figure 2). These mounting holes will align with most tower pedestals. The Light Engine must be installed level to maintain light output in accordance with FAA requirements. Figure 29. Base Bottom View _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 27 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 11: Maintenance and Troubleshooting No regular scheduled maintenance is required for the Driver module or Light Engine. Capacitor Voltage Indication Safety Warning: This board holds a number of large capacitors for storage of the energy required during the Strobes flash duration. These capacitors may be charged with voltages up to about 185Vdc. Associated with each capacitor is a red indicator LED. When lit, this indicates the capacitor voltage is 50V or higher. When power is removed from the module the capacitors automatically discharge to 50V within 30 seconds. Therefore do not attempt any maintenance until the capacitors have been allowed time to discharge to a safe level and all the red indicator LEDs have gone out. Strobe Driver Diagnostic LEDs The two Strobe Driver modules each have four indicator LEDs. LED 1, 2 and 3: Each is driven from one of the drivers three 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 LEDs in the light engine do not operate yet these diagnostic LEDs do blink, this would indicate the fault is not with the Driver module. Should one or more of these LEDs be stuck on or not flash 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. Red Beacon Driver Diagnostic LED 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. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 28 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Microcontroller Board Diagnostic LEDs LED 1 on the microcontroller board shows the status of the light engine. In white mode, it will flash the layer number of any white layers that currently have faulty strings. In red mode, it will flash once every two seconds if the red current is low and twice if the current is too high. It will not flash at all when all layers are operating properly. LED 2 on the microcontroller board pulses once every time a flash is initiated in the light engine. Table 1 below lists possible faults and repair procedures for the L-865 Symptom White Strobe will not operate, or initially operates then shuts down Possible Causes 1: Cable Connection Problem 2: LED string failure 3: Drive module failure Corrective Action Check Diagnostic LEDs on Strobe Driver modules. If not operating properly check power to Driver module (J1), or replace module. Check cable plugged into J2. If LEDs are operating properly, check cable connections to light engine. Red Beacon will not 1: Control cable Check cables are plugged into J1 operate. Diagnostic problem and J2 OK. LED is lit 2: Light Engine cable Check wiring to light Engine Problem 3: LED problem in Light Engine Red Beacon will not 1: No power to Check power connections to operate. Indicator Beacon module. Beacon section (cable in J1). on Beacon driver 2: Faulty Red Driver module not lit module For further information and detailed troubleshooting, refer to the In-Depth Troubleshooting Guide. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 29 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 12: Recommended Spare Parts and User Replaceable Parts Description Light Engine Module White Driver Module Red Driver Module Micro-controller/Filter Module Capacitor Module Dialight Part Number 8800-865-0210-00 8800-865-0202-00 8800-865-0204-00 8800-865-0206-00 8800-865-0207-00 Table 1. Recommended Spare Parts And User Replaceable Parts Section 13: 100-240Vac Operated Systems When it is required to operate the system from a 100-240V mains supply, an additional AC to 48VDC power supply is required. It is recommended that this supply be rated for 150W output. If the system is to comply with FAA 150/5345-43F, certain details of this standard should be considered when choosing the power supply Section 3.3.8 and 4.2.9 3.3.15 and 4.2.11 4.2.2 4.2.3 6kV/3000A combination-wave, transient test. 1.414kV/10uA leakage current test +55ºC operational test -40ºC operational test and -55ºC storage test _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 30 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Appendix A: Serial Port Specification Overview The serial port on the microcontroller is accessible through the J7 connector located on the microcontroller board. It can be used to configure the strobe unit, monitor it for status information, or provide override capability for the external control signals. The port itself, as well as the protocol for accessing it, is described below. Connection This port sends and receives raw serial data; it should be noted that there is no level shift performed on the signals from the microcontroller. If the port is to be used to connect to a computer or other device with a full RS232 port, a level shifter will be required. Also, it is good practice to isolate the microcontroller connection from the computer to protect both the strobe unit and computer from dangerous voltages. The serial port connection is through connector J7 on the microcontroller board, with pin 1 marked by a white arrow. The pinout of this port is listed below. Pin 1: Ground Pin 2: +5V (this pin may be used to power an external level shifter, up to 100mA) Pin 3: RX pin (receive to the microcontroller) Pin 4: TX pin (transmit from the microcontroller) Pin 5: No connect The port has the following characteristics: 19200 baud 8 data bits One stop bit No parity bit No flow control While a connection to the port can be made through HyperTerminal or a similar simple serial communication package, it should be noted that the data received from the port is encoded in binary rather than ASCII, and therefore will be unreadable by such software. Protocol There are three sets of data that can be transmitted across the serial connection: Configuration, Status and Override. All Master transactions are TO the microcontroller board, and all Slave transactions are FROM the microcontroller board. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 31 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Configuration Configuration information can be read or written to the microcontroller board using the following protocol. Note that changing these parameters can cause the unit to no longer be compliant with FAA or ICAO regulations. Read command Master transmission Byte Value 0 C 1 R 2 D Slave response Byte Value 0 C 1 R 2 D 3 Number of white LED layers 4 Number of faulty strings accepted before an alarm is signaled 5 Interval between white flashes, 0.1s increments 6:7 Flash duration in 100% white mode, 4 us increments 8:9 Pulse on time in 30% white mode, 4 us increments 10:11 Pulse off time in 30% white mode, 4 us increments 12:13 Pulse on time in 10% white mode, 4 us increments 14:15 Pulse off time in 10% white mode, 4 us increments 16 Number of pulses per flash in 30% and 10% white modes. There is always only a single pulse in 100% white mode 17 Number of pulses per flash in all red modes. 18:19 Pulse on time in 100% red mode, 4 us increments 20:21 Pulse off time in 100% red mode, 4 us increments 22:23 Pulse on time in 30% red mode, 4 us increments 24:25 Pulse off time in 30% red mode, 4 us increments 26:27 Pulse on time in 10% red mode, 4 us increments 28:29 Pulse off time in 10% red mode, 4 us increments 30 Set to 0 to prevent the red layer from automatically switching over to white when an alarm is raised, set to any other value to enable switchover 31 Interval between red flashes, 0.1s intervals 32 8 bit checksum, computed over bytes 3 to 31 _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 32 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Write Command Master transmission Byte Value 0 C 1 W 2 R 3 Number of white LED layers 4 Number of faulty strings accepted before an alarm is signaled 5 Interval between white flashes, 0.1s increments 6:7 Flash duration in 100% white mode, 4 us increments 8:9 Pulse on time in 30% white mode, 4 us increments 10:11 Pulse off time in 30% white mode, 4 us increments 12:13 Pulse on time in 10% white mode, 4 us increments 14:15 Pulse off time in 10% white mode, 4 us increments 16 Number of pulses per flash in 30% and 10% white modes. There is always only a single pulse in 100% white mode 17 Number of pulses per flash in red modes. 18:19 Pulse on time in 100% red mode, 4 us increments 20:21 Pulse off time in 100% red mode, 4 us increments 22:23 Pulse on time in 30% red mode, 4 us increments 24:25 Pulse off time in 30% red mode, 4 us increments 26:27 Pulse on time in 10% red mode, 4 us increments 28:29 Pulse off time in 10% red mode, 4 us increments 30 Set to 0 to prevent the red layer from automatically switching over to white when an alarm is raised, set to any other value to enable switchover 31 Interval between red flashes, 0.1s intervals 32 8 bit checksum, computed over bytes 3 to 31 Slave response Byte Value 0 C 1 W 2 R _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 33 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Status Status information can be read from the microcontroller board using the following protocol: Master transmission Byte Value 0 S 1 R 2 D Slave response Byte Value 0 S 1 R 2 D 3 Number of white LED layers 4 Number of faulty strings in white layer 1, if present 5 Number of faulty strings in white layer 2, if present 6 Number of faulty strings in white layer 3, if present 7 Red layer status: 0 if good, 1 if current is low, 2 if current is high 8 Status array, bits defined as follows: 0) 1 if unit is locked to an external sync signal, 0 if not 1) 1 if unit is receiving a 1PPM signal, 0 if not 2:3) Current dimming mode: 0 indicates 100%, 1 indicates 30%, 2 or 3 indicates 10% 4) 1 if unit is in day mode, 0 if in night mode 5) 1 if unit is set for red night mode, 0 if set for white night mode 6) 1 if unit is set for normal night flash pattern, 0 if set for WRED night flash pattern 7) 1 if red is in steady burning mode, 0 if in flashing mode 9 Red driver voltage control feedback level 10 Red driver current sense feedback 11 Red driver voltage control adjustment level 12 Fault monitor voltage in white layer 1, if present 13 Fault monitor voltage in white layer 2, if present 14 Fault monitor voltage in white layer 2, if present 15 1 if white fault alarm is active, 0 if inactive 16 1 if red fault alarm is active, 0 if inactive 17:18 100ms interval timer value, in 4us increments. In 1PPM mode, this is adjusted to match timing with the sync signal 19 8 bit checksum, computed over bytes 3 to 18 _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 34 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Override Override information can be written to the microcontroller board using the following protocol: Master transmission Byte Value 0 O 1 W 2 R 3 Override array, bits defined as follows: 0) 1 to force unit to use override data, 0 for unit to use external signals (both external and override sync signals are always used, regardless of the value of this bit) 1) 1 to set unit to day mode, 0 to set unit to night mode 2:3) 0 to set dimming level to 100%, 1 to set dimming level to 30%, 2 or 3 to set dimming level to 10% 4) 1 to force unit to clear internal faults and restart monitoring 5) 1 to send an immediate sync signal. Note that this is processed even if bit 0 is 0 6) 1 to put unit in steady burn mode. Note that this only affects the red night mode 4 8 bit checksum, computed over byte 3 Slave Response Byte Value 0 O 1 W 2 R _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 35 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Figure 30. Power Supply Heat Sink Assembly Figure 31. Light Engine Dimensions _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 36 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Appendix B: Specifications Operating Temperature Range -40°C to +55°C Power Supply Specifications Supply voltage: 48Vdc +/-10% Reverse polarity protected Power requirement; 100W nominal at 48V with white strobe in day mode at 40FPM and 550ft of 20AWG cable Red beacon power requirement nominally 30W when steady burning Maximum flash rate 40 FPM Dimensions - 14.2 x 14.2 Weight - 16 Pounds Light Engine Specifications Weight 38 Pounds Height (See Fig. 6) 11.7 Inches Diameter (See Fig. 6) 17.0 Inches Bolt Hold down Pattern - Standard Pattern provided (See Base Bottom View) _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 37 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ Section 14: 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 connectors are connected securely in accordance with Section 2 of the Installation Manual. Check that the Lightning Protection and Proper Grounding is present in accordance with Section 3 and 4 of the Installation Manual and per Procedure for Proper Grounding to Minimize Risk of Lightning Damage manual. Operational Checks A. □ 1) 2) Set system to Day mode. □Pull out the interlock switch. □Wait at least 2 minutes. 3) □Check Error LED (LED1) on Micro Board does NOT blink. If it blinks, 4) that indicates a fault, see Problem 2 and 3, in the Troubleshooting Guide. □Check that the controller does not produce any alarm signals. 5) □If possible, visually check the Light Engine is flashing and operating normally. B. Set system to RED Night mode. 1) □Check LED1 on Red Driver module (bottom left of cabinet) is on if steady burning and blinking if flashing. 3) □Check that the controller does not produce any alarm signals. □If testing a white only system, set to White Night mode and repeat 4) □If possible, visually check the Light Engine lights up. 2) step A, starting from step 2. I, ________________________ (Print Name), have completed all final checks listed above and observed satisfactory results. No issues to report at this time. ________________________________________ ___________________________ Signature Date ________________________________________ ___________________________ Installation Site Location (Site Number, City, State) Company Name ONCE COMPLETED, TEAR OFF AND TAPE INSIDE THE DOOR OF THE POWER SUPPLY!! _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 38 of 39 Document No. 9100-127-1235-99 Rev B Release Date: 11/18/2009 _____________________________________________________________________ REVISION HISTORY REV ECO No. DRN CKD APP QA CM DATE B ---- JC KH GB RL JB 10/18/09 _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Sheet 39 of 39