Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 TROUBLESHOOTING GUIDE AND IN-DEPTH TROUBLESHOOTING MANUAL 4-Level, P/N: D1RW-C13-006 And 3-Level, P/N: D1RW-C13-037 110/240VAC, 50/60 Hz, L865, DUAL MEDIUM INTENSITY WHITE STROBE & L864 RED BEACON PRINT IN COLOR _____________________________________________________________________________ 1 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 Troubleshooting Guide Symptom Red and White not lit, power supply is totally inactive White Strobe Will not Operate or initially operates then shuts down after about 1 minute Possible Causes [Frequency] Interlock Switch Disengaged (either not pushed down or pulled out) [Frequent] Lack of incoming Power 110240VAC [Frequent] Light Engine Cable Problem [Frequent] Driver Board Module Problem [Rare] LED String Failure in Light Engine [Very Rare] White Strobe (some or all LED strings) are steady on (not flashing) One or more LED return conductors shorted to ground. [Frequent] Corrective Actions Additional Notes Fully Close Power Supply Door OR Pull the switch out. Refer to Problem 1 for instructions. Check power wiring in conductors labeled; Neutral, common neutral Strobe (should be live when White is powered) Beacon, (should be live when Red is powered) Refer to Problem 1 for instructions. 1: At power supply, check multi way cable conductors are wired securely and in the correct order to terminal blocks 2: At Light Engine, check multi way cable conductors are wired securely and in the correct order to the terminal block 3: At light engine check wires have not been trapped between inspection cover and enclosure Check nominal 120 or 230Vac supply voltage on J1 on the driver board Replace light engine (only when all other possibilities have been explored) Refer to Problem 2 for instructions. Refer to Problem 2 and 3 for instructions. Refer to Problem 6. Check all connectors, mainly Strobe commons (+'s) and the 3 return wires on each of the levels. At light engine, check wires have not been trapped between inspection cover and enclosure. Look for white driver module with any of LED 2, 3 or 4 stuck on. Replace this Driver module. Refer to Problem 2 and 3 for instructions. Damaged Micro Controller Board [Extremely Rare] Replace Micro Controller Board Refer to Problem 3 for instructions. Red Beacon will not operate. Diagnostic LED (LED1) on Red Driver Board is Lit. Problem with cable from Power supply to Light Engine. In particular the two 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 Light Engine and Junction box if any, check multi way cable conductors are wired securely and in the correct order to the terminal block 3: At light engine, check wires have not been crushed between inspection cover and enclosure Refer to Problem 4 for instructions. Red Beacon will not operate. Diagnostic LED (LED1) on Red Driver Board is NOT Lit. No power to Beacon Module. [Frequent] Check nominal 120 or 230Vac supply voltage on J1 on the Red Driver Board Refer to Problem 5 for instructions. Damaged Driver Board [Rare] Refer to Problem 2 and 3 for instructions. _____________________________________________________________________________ 2 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 L-865 Strobe In-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. Interlock Switch Position If working with the power supply door open, ensure the interlock switch is pulled fully out (Fig.1) When door is closed, ensure it is fully closed and the door lock is fully turned clockwise. Figure 1. Interlock Switch _____________________________________________________________________________ 3 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 2. Checking Incoming Supply Voltages Using a multimeter, measure Voltage coming in to the terminal block (Fig.2). Measure between Neutral and each of the Live (terminals marked Beacon and Strobe) (Fig.2). When in White Strobe mode, the voltage between the terminal marked ‘Neutral’ and terminal marked ‘Strobe’ should be nominal 120 or 230VAC. When in Red Beacon mode, the voltage between the terminal marked ‘Neutral’ and terminal marked ‘Beacon’ should be nominal 120 or 230VAC. Figure 2. Measure INCOMING Supply voltage for White Strobe. _____________________________________________________________________________ 4 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 3. Checking the Supply to J11 Using a multimeter, check J11 on filter board (Fig.3). Make sure J11 is plugged in and check connection wires. Make sure wires are secure. Check power at J11 between White and Red, and then White and Black wires (Fig.3). When in White Strobe mode, the voltage between the white wire and black wire should be nominal 120 or 230Vac. When in Red Beacon mode, the voltage between the white wire and red wire should be nominal 120 or 230Vac. If there voltage is not as expected, check the integrity of wiring to the interlock switch (Fig.1). Check all four spade terminals are attached to the underside of the interlock switch. Figure 3. J11 on the Filter Board. _____________________________________________________________________________ 5 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 Problem 2. Symptom -White strobe initially operates and shuts down after 1-2 mins. -One or more of the LED strings are NOT lighting on the Light Engine. -Open circuit or Open LEDs Corrective Actions – 1. Turn on system by pulling out the Interlock Switch (Fig.1). 2. Inspecting the error LED on the Micro/Filter Board Inspect LED2 (Error LED) on the Micro/Filter Board (Fig.4). LED2 blinking confirms that there is an error. Observe the number of blinks. The number of blinks corresponds to the connector J1, J2, J3 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 3. Figure 4. J1, J2& J3 Connections and LED1&2 on the Micro Board _____________________________________________________________________________ 6 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 3. Check power going to Driver Module J1 (Fig. 5) on the Driver Board in question (should be G120VAC or G230VAC). 4. Turn off the system by pushing in the Interlock Switch (Fig.1) to center position. 5. Wait 30 seconds and restart system by pulling out the interlock switch. Figure 5. Driver Board. Connectors J1, J2, J3&J4. LED1 should be steady on if power is being supplied. LED 4,3,2 should be flashing in sync with the strobe. 6. Check LED1 (Fig.5) on the Driver Board in question is ON Steady. 7. Check LED2, 3 and 4 (Fig.5) on the Driver Board in question are blinking. 8. Using a Multimeter, check J3 and measure VDC JUST BEFORE system shuts down. During normal operations, the voltage would be about 120VDC ~ 140VDC. If VDC is close to 180VDC, one or more of the LED Strings in the Light Engine is disconnected. _____________________________________________________________________________ 7 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 9. Check wires and connector J4 (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 Light Engine side.) 10. In the case that all connections are good and yet there is still an issue with one or more the LED strings in the Light Engine not lighting up proceed to Problem 6. NOTE: Per FAA regulation 150-5345-43F, if 25% or more of the LED Strings are not functioning, system will shut down. I.e. if 3 LED strings or more on a 12 LED String system (4layer) do not function, the system will shut itself down after 20 Flashes. _____________________________________________________________________________ 8 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 Problem 3. Symptom -One or more of the LED strings are STEADY ON (not flashing) Corrective Actions – 1. Turn on system by pulling out the Interlock Switch (Fig.1). Wait 1 minute. 2. Inspecting the error LED on the Micro/Filter Board Inspect LED2 (Error LED) on the Micro/Filter Board (Fig.4). LED2 blinking confirms that there is an error. Observe the number of blinks. The number of blinks corresponds to the connector J1, J2, J3 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 3. 3. Checking for Short Circuits Check system for short circuit in the return wires of the layer in question. Proceed to Problem 7 in this In-depth Troubleshooting Manual. Check for wires tied to ground by crushed/ damaged cables. In 3 layer systems, check wires going into the Light Engine housing. Wires may have been crushed during installation. 4. Replacing a Driver Board Module Replace the Driver Board Module in question with a known working Module. (Spare Driver Board Module if possible. If not, switch with another working unit and observe if the issue 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 system still showing issues, proceed to Step 5. 5. Replacing a Micro/ Filter board 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. In the case that the problem moves, the Micro/ Filter Board Module would be suspected of being damaged. Keep in mind; this is a very rare occurrence. _____________________________________________________________________________ 9 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 Problem 4. Symptom -Red Beacon will not operate. Diagnostic LED is lit. Corrective Actions – 1. Check the cables are snuggly plugged into J1 and J3. (Fig. 6) Figure 6. Red Beacon Driver Board. LED1 is lit if 950V is present. _____________________________________________________________________________ 10 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 Figure 7. Terminal Block. Beacon(+) and Beacon RTN. NOTE: Wire colors may differ from picture. However, the color coming into the terminal block should always be matched with the color coming out of the terminal block. 2. Check Beacon (+) and Beacon RTN on the terminal block (Fig. 7). 3. Check for integrity of the wires in the terminal block. Make sure all wires are making contact and secured. 4. Check the VDC voltage on Beacon (+) and Beacon RTN. In the case that the voltage reads G150VDC, there is an open circuit. Check the wire connectors for loose or disconnected wires at the terminal block, the junction box if any, and light engine, in that order. In normal operations, the voltage should read G100VDC. _____________________________________________________________________________ 11 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 Problem 5. Symptom -Red Beacon will not operate. Diagnostic LED is NOT Lit. Corrective Actions – Figure 8. Test points for INCOMING voltage for RED Beacon. NOTE: Wire colors may differ from picture. 1. Check and verify incoming power at the terminal block. (Fig.8) 2. Check for integrity of the wires in the terminal block. Make sure all wires are making contact and secured. 3. Check Power Connection to J1 on Beacon Section (Fig. 6) 4. Check wires for short circuit to ground. Check the terminal block, junction box if any, and light engine for foreign objects, debris or loose wires that are connecting wire(s) to ground. _____________________________________________________________________________ 12 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 Problem 6. Symptom -One or more LED strings not lighting on the Light Engine. Corrective Actions – 1. Check cables as stated in Problem 2, 3 in this In-Depth Troubleshooting Manual. 2. Check boards as stated in Problem 2, 3 in this In-Depth Troubleshooting Manual. 3. Check that all wires, cables, connectors are NOT shorted, open, damaged and/or loose. Make sure to fully check before proceeding to Step 4. 4. Check light engine 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. _____________________________________________________________________________ 13 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 Problem 7. Symptom -Short Circuit within System Corrective Actions – 1. Check inside the Power Supply Box for loose wires, wires connected improperly, foreign laying across connections, and/or damaged/crushed wires causing a short to ground. 2. Using a multimeter on continuity setting or Ohm L, place one probe on Strobe Common1(+) and the other to Strobe Return1 and observe for continuity (audible sound from multimeter). If using Ohm L, observe for resistance. a. Repeat step 2 on Strobe Common1(+) and Strobe1 Return2. b. Repeat step 2 on Strobe Common1(+) and Strobe1 Return3. c. Repeat step 2, 2a and 2b for Strobe 3. Substitute Strobe Common1 to Strobe Common 3. Also Substitute the Strobe1 Return # for Strobe 3 Return #. If continuity is present, locate and remove short circuit. Common places to look for short circuits: terminal block, junction box, light engine, etc. _____________________________________________________________________________ 14 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1334-99 Rev. A _________________________________________________________09-24-09 REVISION HISTORY REV ECO No. DRN CKD APP QA CM DATE A ---- JC KH GB RL JB 09/24/09 _____________________________________________________________________________ 15 of 15 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com