Document No. 9100-127-1109-99 Rev A Release Date: SEPT, 11 2007 ______________________________________________________________________ INSTALLATION AND MAINTENANCE MANUAL FOR P/N: D1RW-C13-006 100-230VAC, 50/60 Hz, (20,000cd white/2,000cd red beacon) P/N: D1RW-G13-006 100-230VAC, 50/60 Hz, (20,000cd white/170cd red beacon) DUAL WHITE STROBE & RED BEACON Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 1 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Contents Page Overview ..............................................................................................................3 Options ................................................................................................................3 Installation and Wiring .......................................................................................6 Switch Settings ...................................................................................................8 Operation and Initial Test .................................................................................10 Lightning Protection.........................................................................................10 Maintenance and Troubleshooting..................................................................11 Specifications....................................................................................................14 List of Figures and Tables Figure 1: Block Diagram.....................................................................................5 Figure 2: System Wiring Diagram......................................................................6 Figure 3: Base - Bottom View ...........................................................................9 Figure 4: Power/Signal Terminal Arrangement .............................................10 Table 1: Troubleshooting ................................................................................12 Table 2: Recommended spare parts & user replaceable parts ....................13 _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 2 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Overview The Dialight Medium Intensity White Strobe and Red Beacon is designed for the lighting of radio towers, wind generators and other obstructions to aerial navigation. 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. With output magnitudes of less than 200VDC, working voltages are much lower than with xenon flashtube designs; therefore, this system represents an advance in safety. The light operates from a 100/230VAC 50/60 Hz supply. It consists of a White Strobe section and a Red Beacon section controlled and monitored by a microcontroller circuit. The red beacon type is determined by the top level part number selection, either 2,000cd red or 170cd red to meet the Specific requirements of the German “Wred” specification. The system consists of a light engine and a power supply box joined by a multiway cable. The White Strobe section of the light engine consists of three layers of white LEDs each driven from its own driver module contained in the power supply enclosure. The Beacon section consists of 36 high-performance LEDs driven by another module in the power supply enclosure. In addition, a control box that may be located a considerable distance away from the light engine and power supply, such as at the base of the tower, allows the system to be controlled and monitored. Options See section on Switch Settings for additional information Dimming The light output can be dimmed to 30% and 10% of full output by means of two control inputs (DIM0 and DIM1). For 30% dimming connect DIM0 to the Live input terminal. For 10% dimming connect both DIM0 and DIM1 to the live terminal. Note that the dimming feature affects both the Red Beacon and White Strobe. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 3 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Night Mode A number of options may be selected to determine how the light behaves when in night mode. Either the Red Beacon or White Strobe can be chosen to come on at night by means of the switches on the microcontroller board. When White at night is chosen, it operates at 2000cd. The brightness when in White night mode is not affected by the dimming inputs. Red Beacon Flash Rate and Synchronization The Red Beacon may either be flashed or steady burned. For steady burning hold the Sync input terminal to the live terminal. For flashing either do nothing with the Sync input (in which case the Beacon will flash at a default 20FPM) or pulse the Sync input with 100-230Vac at the desired flash rate. The flashing will synchronize to this pulsing. The flashing duty cycle is 50/50. WRED Flashing Mode The Wred flashing rate is; 1s light, 0.5s dark, 1s light and 1.5s dark. This may be selected by means of a DIP-switch on the microcontroller board White Strobe Flash Rate and Synchronization Either do nothing with the Sync. input (in which case the White Strobe will flash at a default 20FPM) or pulse the Sync input with 100-230Vac at the desired flash rate. The flashing will synchronize to this pulsing. Fault Signals A fault is indicated if the microcontroller has detected a fault for 20 consecutive flashes. Two uncommitted solid-state relays provide indication of faults. One allows the Red Beacon to be monitored and the other the White Strobe. The behavior of the relays can be programmed using the DIP switch on the microcontroller board. The relays can either be closed when a fault is detected, open on a fault or pulsing when all is well. The latter mode is a fail-safe mode of operation. If the fault clears, the fault signal will remain until power to the unit is cycled. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 4 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ L Red Beacon N E Day ht Contac Light Engine Micro Controller Strobe Driver Strobe Driver Sync Strobe Driver Dim 0 Dim 1 Red Fault A White Fault A B B Figure 1: 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 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Installation and Wiring The Power supply cabinet is designed to mount vertically, with power and interconnection cables emerging from the bottom of the unit, and no more than 10m from the Light Engine. Power Supply Cabinet Control Box Power In Multi-way connection cable Light Engine Control Box to Power Supply Connections Figure 2: System Wiring 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 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Terminal Block Connections EARTH/GROUND Safety Earth/Ground NEUTRAL LIVE DAY/NIGHT SYNC Neutral supply conductor 100-240Vac, Live supply conductor Connect to live for Night Mode DIM0 DIM1 RED FAULT A RED FAULT B WHITE FAULT A WHITE FAULT B Pulse from live at desired flash rate to synchronize, or connect constantly to live for steady Red Beacon Connect Dim 0 to live for 30%, connect Dim 0 and 1 to live for 10% Connect Dim 0 to live for 30%, connect Dim 0 and 1 to live for 10% Uncommitted solid state relay output (600V/40mA max, 20mA continuous) Uncommitted solid state relay output (600V/40mA max, 20mA continuous) Uncommitted solid state relay output (600V/40mA max, 20mA continuous) Uncommitted solid state relay output (600V/40mA max, 20mA continuous) Notes: 1: After initial power up there may be a few seconds of delay before flashing begins. 2: The default red Beacon and White Strobe flash rate is 20 flashes per minute. 3: The sync signal is not required if there is no need to synchronize with another strobe. In the absence of a sync signal, the Strobe and Red Beacon will default to 20 FPM. 4: For maximum immunity from the effects of radiated interference, the cable from the Control Box to Power Supply Cabinet should be shielded with the screen grounded at both ends. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 7 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Switch Settings The microcontroller board has a switch block allowing a number of options to be set up as follows: 1 2 3 4 ON ON 1 2 3 4 OFF White at night WRED pattern for red Relays pulse while OK Relays open on fault Red at night 50% duty cycle for red Relays static Relays close on fault Note: 1: For both the Red Beacon and White Strobe a fault is indicated after 20 consecutive faulty flashes. 2: When the fault relays are in pulse mode and their respective light is OK, they pulse at 0.5 seconds off and 0.5 seconds on. Power Supply to Light Engine Cable The connection between the power supply and light engine is made by means of a shielded multi-way connection cable. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 8 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ 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 Beacon. 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 correct light output. Figure 3: 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 9 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Operation and Initial Test Warning: The power supply must be earthed Prior to installation, it is recommended that the unit be tested to ensure no damage was incurred during shipping. 1: Connect the multi-way cable between the light engine and power supply. Do not force the connectors into their mating halves. Carefully align the mating halves of the polarized connectors before tightening the locking ring. 2: Connect the power supply either to the Controller or to a mains supply in accordance with the wiring table in section 2, using the connection terminals located towards the bottom of the power supply cabinet. Figure 4: Power/Signal Terminal Arrangement Lightning Protection The light incorporates protection against voltage surges that may be induced by into the mains supply by nearby lightning strikes by means of MOVs and Gas Discharge Tubes (GDTs). It is designed to withstand 6kV/3kA, 1.2/50us, 8/20us Combination Wave Transients as described in IEC61000-4-5. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 10 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Maintenance and Troubleshooting No regular scheduled maintenance is required for the light. Warning: Remove power from all wiring and circuitry before installing or working on the light. Each driver module has a red indicator light to indicate more than 50VDC present on its output. In addition, the capacitor board has red indicator lights (one for each of the large energy storage capacitors) to show the capacitor is charged to at least 50V. For safety, when the Power supply cabinet door is opened, an interlock switch disconnects power from all the driver modules. If the unit has just been running, a number of driver module indicators lights will be lit. These should go out within about 30 seconds to indicate voltages on capacitors have been discharged to less than 50V. Table 1 Lists possible faults and repair procedures for the light _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 11 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Table 1: Troubleshooting Symptom One or more White Strobe layers not lit and indicator LED not lit on driver of faulty layers One or more White Strobe layers not lit, but all Indicator LED’s are lit on driver modules Red Beacon will not operate. Indicator on Beacon driver module not lit Red Beacon will not operate. Indicator on Beacon driver module is lit Possible Cause Corrective Action One or more drive Check modules receiving power. modules not receiving Replace any faulty driver modules. power or module is faulty Cable between power supply and light engine disconnected or faulty Check cable connections. No power to Beacon module or faulty driver module Check power connections to Beacon driver module. Replace module if faulty Possible bad connection between driver module and light engine. Check cable between light engine and power supply is connected properly. Possible LED string failure. Possible LED string failure. Replace light engine. _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 12 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Table 2: Recommended spare parts & user replaceable parts Description Light Engine Module (2000cd) Light Engine Module (170cd) Power Supply Light Engine to Power Supply Cable Dialight Part Number 8800-865-0017-00 8800-865-0018-00 8800-865-0067-00 8800-865-0089-00 _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 13 of 14 Document No. 9100-127-1109-99 Rev A Release Date: Sept 11, 2007 _____________________________________________________________________ Specifications Operating Temperature Range Default flash rate -40°C to +55°C 20 FPM (W Red 30FPM) Power Supply Specifications Input Voltage Range Input Power, White Strobe Frequency Power Factor 100-230VAC, +/-15% 50/60Hz 80W (day mode at 20FPM) 50/60Hz >0.9 Light Engine Specifications Weight Height Diameter Bolt Hole down Pattern 21.5 kg 297.3 mm 470 mm Standard Pattern provided (See Fig. 3) _____________________________________________________________________________ Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727 Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com Sheet 14 of 14