Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 TROUBLESHOOTING GUIDE AND IN-DEPTH TROUBLESHOOTING MANUAL 3-Level, P/N: D1RW-C13-007 110/240VAC, 50/60 Hz L865, DUAL MEDIUM INTENSITY WHITE STROBE & L864 RED BEACON _____________________________________________________________________________ 1 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 Troubleshooting Guide Symptom Red and White not lit, power supply is totally inactive White Strobe Will not Operate. Alarm and/or Error LED (LED1 on Micro/ Filter Module) flashing. Possible Causes (Frequency) Check Incoming power wiring in conductors Refer to Problem 1 for instructions. Check Voltage Coming out from AC to DC Converter Module. Should be 48VDC. Refer to Problem 2 for instructions Light Engine 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 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 48VDC 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. LED String Failure in Light Engine [Very Rare] One or more LED return conductors shorted to ground. [Frequent] Damaged Driver Board [Rare] Damaged Micro Controller Board [Extremely Rare] Red Beacon will not operate. Diagnostic LED (LED1) on Red Driver Board is Lit. Additional Notes Lack of incoming Power 110240VAC to AC to DC Converter Module [Frequent] AC to DC Converter Module Problem [Very Rare] Driver Board Module Problem [Rare] White Strobe (some or all LED strings) are steady on (not flashing). Alarm and/or Error LED (LED1 on Micro/ Filter Module) flashing. Corrective Actions Problem with cable from Power supply to Light Engine. In particular the two conductors labeled Beacon+ and Beacon- [Frequent] Damaged Driver Board [Rare] 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. Replace Micro Controller Board Refer to Problem 2 and 3 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 crushed between inspection cover and enclosure Check voltage on J3 of the Red Driver Board. Check Voltage on Beacon(+) and Beacon Rtn on the Terminal Block Refer to Problem 4 for instructions. Refer to Problem 2 and 3 for instructions. Refer to Problem 3 for instructions. 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 48VDC supply voltage on J1 on the Red Driver Board Refer to Problem 5 for instructions. FALSE ALARMS. ALL ALARMS ARE REAL ALARMS UNTIL ALL STEPS ABOVE ARE CHECKED!!! Problem with Micro/Filter Board [Extremely Rare] Problem with Alarm Unit [Rare] Check DIP switches on Micro/Filter Board Contact alarm unit manufacturer Refer to Problem 8 for instructions. Refer to Problem 8 for instructions. _____________________________________________________________________________ 2 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 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. 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 120-230VAC. (Fig.1). Figure 1. Measure INCOMING Supply voltage on the AC-DC Converter _____________________________________________________________________________ 3 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 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 _____________________________________________________________________________ 4 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 3. Check the Power In to Micro/Filter Board Module 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 the Power wires two wires. (Fig.3). When in operational, the voltage between the two Power wires should be nominal 48VDC. Figure 3. J11 on the Filter Board. _____________________________________________________________________________ 5 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 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 LEDs Corrective Actions 1. Inspect the Error LED (LED1) on the Micro/Filter Board (Fig.4). During normal operations, LED2 flashes and LED1 stays off. LED1 blinking confirms that there is an error. Observe the number of blinks. The number of blinks corresponds to the connector J1, J2, J4, 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 _____________________________________________________________________________ 6 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 2. Check power going to Driver Module J1 (Fig. 5) on the Driver Board in question (should be ≈48VDC). 3. Check LED4 (Fig.5) on the Driver Board in question is ON Steady. 4. Check LED1, 2 and 3 (Fig.5) on the Driver Board in question are blinking. 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 and the intensity of the LED1, 2 and 3 should be uniform (same brightness). These indicate the driver module is operating. If some of the White LEDs in the light engine do not operate yet these diagnostic LEDs (LED1, 2 and 3) do blink, this would indicate the fault is not with the Driver module but, elsewhere. Should one or more of these LEDs be stuck on, blinks with a different intensity to the others, or not flash at all; this would indicate a fault with the driver module. However, continue with the steps below in case the fault is elsewhere. Figure 5. Driver Board. Connectors J1, J2, J3&J4. LED4 should be steady on if power is being supplied. _____________________________________________________________________________ 7 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 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 120VDC ~ 140VDC. Due to strobe flashing, the voltage will fluctuate but the peak voltage should be roughly 120VDC ~ 140VDC. If VDC is close to 180VDC, one or more of the LED Strings in the Light Engine is disconnected. 6. 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.) In the case that all connections are good and yet there is still a problem with one or more the LED strings in the Light Engine 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. Proceed to Problem 6 in this Troubleshooting manual. 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. _____________________________________________________________________________ 8 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 Problem 3. Symptom -One or more of the LED strings are STEADY ON (not flashing) Corrective Actions 1. Error LED on the Micro/Filter Board Inspect LED1 (Error LED) on the Micro/Filter Board (Fig.4). LED1 blinking confirms there is an error. Observe the number of blinks. The number of blinks corresponds to the connector J1, J2, J4, 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 Manual. Check for wires shorted to ground by crushed/ damaged cables. Check wires going into the Light Engine 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 system still showing problems, proceed to Step 4. 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. _____________________________________________________________________________ 9 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 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 During normal operations, voltage on J3 is ≈105VDC. If the voltage is ≈150VDC, the load is an open circuit, proceed to step 3. 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. _____________________________________________________________________________ 10 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 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 Light Engine. Ensure that none of the wires are pinched, damaged, disconnected or loose. 6. Visually check the Light Engine for damage. Figure 7. Terminal Block. Beacon(+) and Beacon RTN. NOTE: Wire colors may differ from picture. _____________________________________________________________________________ 11 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 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. _____________________________________________________________________________ 12 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 Problem 6. Symptom Engine. -One or more LED strings not lighting on the Light 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. 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 light engine 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 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 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 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 on Strobe Common1(+) and Strobe Return3. c. Repeat step 2, 2a and 2b for Strobe 2. If continuity is present, locate and remove short circuit. _____________________________________________________________________________ 14 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 Problem 8. Symptom -False Alarms !!WARNING!! ALL ALARMS ARE REAL ALARMS UNTIL ALL OTHER PROBLEMS HAVE BEEN CHECKED IN THIS MANUAL. Corrective Actions 1. Figure 8. Utilizing this manual, check for any/all Errors before proceeding. 1.1 Check the Error LED (LED1) on the Micro/Filter Board Module. If flashing, it is a TRUE alarm. If not flashing, 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. Micro/Filter Board. DIP SWITCH (SW1). NOTE: Switch position UP is on and DOWN is OFF. Factory Default is all DOWN, OFF. _____________________________________________________________________________ 15 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 2. Check the DIP Switches (SW1) shown on Figure 8. Refer to Configuration Options Switch. Check Switch 4 in the DIP Switch and ensure that the switches are set to the requirement for the alarm unit. E.g. - Normally Open is OFF position on Switch 4. If DIP switches are correct, check the wires going to and from the alarm relay in J3 and the alarm module (third party). Check the output of the alarm signals (J3) using a multimeter for continuity. [E.g. - If the system is normally open (Dip Switch 4 in off position), the relay will close upon receiving an alarm signal. Thus you would have a closed connection when alarm signal is initiated.] Configuration Options DIP 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 DIP SWITCH SETTINGS (on Microcontroller Board) 1 2 3 4 OFF ON Switch # 1 2 3 4 ON White at night W. Red mode Relays pulse while system is OK Relays open on fault (Normally CLOSED) OFF Red at night 50% duty cycle mode Relays do not pulse Relays close on fault (Normally OPEN) _____________________________________________________________________________ 16 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com Document No. 9100-127-1355-99 Rev A _____________________________________________ Release Date: 11-18-09 REVISION HISTORY REV ECO No. DRN CKD APP QA CM DATE A ---- JC KH GB RL JB 10/18/09 _____________________________________________________________________________ 17 of 17 Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com