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M.E-2009.E-1DB2
3/25/07 – rev. 5/28/09

E-1DB2 CONTROLLER

6.0

MAJOR COMPONENTS LIST

SCHEMATIC TAG #

DESCRIPTION

PART NUMBER

BSS

BEACON SAFETY SWITCH

STJ02003

C101, and C102

3 uf 660V AC

STB99008csi

C103 - C110

40 uf 1.1KV CAP

STB99006

CSS

CABINET SAFETY SWITCH

STJ02001

f1

0.5 amp FUSE

FUSE.5

F2

10 amp FUSE

FNQ10

F1

1 amp FUSE

KTK1

F3

1/8 amp FUSE

FLQ18

FT1 DAYMODE

FLASHTUBE

STFLSHTB6

FT2 NIGHTMODE

FLASHTUBE

STFLSHTB7

K1, K4, K5, K6, K8

DPDT OCTAL RELAY

KRPA11AG120V

K2, K3

HV RELAY

STJ10006

K7

SPDT OCTAL RELAY

KRPA5AG120V

K9

TIME DELAY RELAY

SPEC224

L1 INDUCTOR

INDCTR3001

L2 INDUCTOR

100453

M1 CURRENT

SENSOR

RM4JA32MW

MOVMOD1 SURGE

SUPPRESSOR DTK-120HW

MOV 2

METAL OXIDE VARISTOR

MOV524V15

MOV5, 6

METAL OXIDE VARISTOR

V275LA20A

P1, P2, J1

15 POSITION PLUG

STT60021

PCB1 CONTROL

PCB

STH01329

PCB2 RECTIFIER

PCB

STH02329

20

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Summary of Contents for E-1DB2

Page 1: ...2 web www twrlighting com IMPORTANT PLEASE TAKE THE TIME TO FILL OUT THE FORM COMPLETELY FILE IN A SAFE PLACE IN THE EVENT YOU EXPERIENCE PROBLEMS WITH OR HAVE QUESTIONS CONCERNING YOUR CONTROLLER THE FOLLOWING INFORMATION IS NECESSARY TO OBTAIN PROPER SERVICE AND PARTS MODEL E 1DB2 SERIAL PURCHASE DATE PURCHASED FROM ...

Page 2: ...t Wiring 5 2 6 ALARM WIRING 6 2 6 1 White Strobe Failure SF 6 2 6 2 Red Strobe Failure RF 6 2 6 3 Power Failure PF 6 2 6 4 Photocell PC 6 2 6 5 Sidelight Alarm SA 7 2 7 ALARM TESTING 7 2 7 1 White Strobe Failure SF 7 2 7 2 Red Strobe Failure RF 7 2 7 3 Power Failure PF 7 2 7 4 Photocell PC 7 2 7 5 Sidelight Alarm SA 8 2 8 CONTROLLER CONFIGURATION 8 3 0 THEORY OF OPERATION 9 3 1 THE POWER SUPPLY 9 ...

Page 3: ... Fail Test 13 4 0 TROUBLESHOOTING 14 4 1 TOOL REQUIREMENTS 14 4 2 DIAGNOSTIC EVALUATION 14 4 3 TROUBLESHOOTING ASSISTANCE 15 4 3 1 Flash Verify LED Out 15 4 3 2 Control Power on LED Out 15 4 3 3 Timing LED Out 15 4 3 4 False or Nonexistent Beacon Alarm SF 15 4 3 5 False or Nonexistent Beacon Alarm RF 16 4 3 6 No Red Strobe Operation 16 5 0 MAINTENANCE GUIDE 17 5 1 FLASHTUBE REPLACEMENT 17 5 2 RED ...

Page 4: ...IGHT MOUNT ASSEMBLY 100489 REV A TOWER LIGHTING KIT 200 TO 350 CONDUIT RUN T1369 REV A TIMING CONTROL PCB H01 329 REV A E 1DB2 RECTIFIER PCB H02 329 REV A RELAY PCB w ALARM LOCKOUT ELIMINATION MODIFICATIONH03 269A REV A CURRENT MEASUREMENT RELAY 100664 REV E L 810 OL 1 SINGLE OBSTRUCTION LIGHT FM10018 REV D L 810 OL 1 SINGLE OBSTRUCTION LIGHT DETAIL 279 OL REV B L 810 OL 1 SINGLE OBSTRUCTION WIRIN...

Page 5: ...h Dual White Red Flashing Medium Intensity Strobes in accordance with the FAA s Advisory Circular 70 7460 1K 1 2 SPECIFICATIONS OF EQUIPMENT Dimensions Controller H X W X D Weight 22 x 17 5625 x 10 75 62 0 lbs Mounting Dim H X W 21 25 x 10 0 Beacon Height Weight 28 0 36 lbs Cable Diameter Weight per 100 ft 625 10 24 lbs Electrical Voltage 120V AC 10 60 Hz Standard 240V AC 10 60 Hz Available Intens...

Page 6: ...ll housing is supplied with a 20 pigtail of 16 AWG TYPE TFFN wire On occasion in mounting of the photocell an additional amount of wire may be required Refer to drawing 100239 for proper assistance on determining gauge of wire for your specific needs 2 3 PHOTOCELL WIRING Refer to Drawings HD0 329 and H40 329 If the control cabinet is mounted inside an equipment building the photocell should be mou...

Page 7: ...breaker is recommended at service panel 2 4 2 Connect the HOT side of the 120V AC line to TB1 11 2 4 3 Connect the NEUTRAL side of the 120V AC line to TB1 12 2 4 4 Connect the AC ground to the ground stud to the lower right of the terminal block TB1 2 4 5 Controller panel should be connected to the tower and or building grounding system with the exception of installations on AM RF Applications whe...

Page 8: ...plied Installer should make sure to check for full thread engagement on Anco locknut Allow 16 clearance in back of the hinge 25 from the center of the base to tilt lens back without hitting an obstruction 2 5 1 2 Level the beacon using the spirit level at the base of the lens Shims may be used under beacon base or triple nutting each bolt with palnuts on all four 4 nuts 2 5 1 3 Slip the electrical...

Page 9: ...e to regulations NOTE On occasion a set of custom lighting kit drawings may be specifically requested by a customer and installed in this manual In cases such as this the drawings will precede the manual if a conflict occurs All the necessary information for wiring the dual beacon and sidelights is contained on the tower kit drawings 600 04 and T1369 The connections for the dual beacon and sidelig...

Page 10: ...ations are shown on drawings H40 329 and M01 329 2 6 1 White Strobe Failure SF Connect the customer s alarm common to plug J3 terminal 5 Connect the customer s alarm wire to plug J3 terminal 4 for normally open or terminal 6 for normally closed monitoring 2 6 2 Red Strobe Failure RF Connect the customer s alarm common to plug J3 terminal 11 Connect the customer s alarm wire to plug J3 terminal 10 ...

Page 11: ...ion down position 2 7 2 Red Strobe Failure RF Red strobe failure testing can be performed in the nightmode operation Check for status of strobe beacon Turn off switch SW2 on controller panel and status will change after a ten 10 second delay This testing will cause the unit to go into the back up white strobe operation To clear this situation turn on switch SW2 and reset the breaker 2 7 3 Power Fa...

Page 12: ...ctions will need to be interfaced between systems 2 8 1 Connect at least an 18 gauge wire from PCB 1 connector P1 15 from unit setup to be the master unit to PCB 1 connector P1 15 of unit setup to be the slave unit 2 8 2 Connect at least an 18 gauge wire from J1 5 item 10 of master unit to slave unit J1 5 item 10 2 8 3 Connect at least an 18 gauge wire ground from one chassis to the other chassis ...

Page 13: ...iting resistors R31 T3 and steering diode D5 for nightmode operation Energy storage capacitors bank C103 110 is used for the daymode operation and are connected to the high voltage through the normally closed contacts of relay K5 When the light level drops below 3 foot candles the photocell supplies 120V AC to relay K5 which removes C103 110 from the discharge path leaving capacitor C102 in the ci...

Page 14: ...cuit has its own power supply This circuit converts the AC voltage to approximately 12V DC which is used to supply all of the components in this circuit It uses this low voltage DC to generate pulses that control the flash rate of the flashtube It actually generates two 2 groups of pulses The first is a pulse approximately once every 1 5 seconds to operate the flashtube during daylight hours The s...

Page 15: ...ice The alarm point can be accessed on J3 of PCB 3 3 5 4 Photocell PC The photocell alarm relay K4 is energized whenever the photocell or SW1 is on This relay will allow the customer to monitor the modes of operation to determine if switch from day to nightmode has occurred The monitor point can be accessed on J3 of PCB 3 3 5 4 1 To test daymode operation in night time set SW1 switch in the middle...

Page 16: ...EFEAT THE SAFETY INTERLOCKS 3 7 STROBE DIAGNOSTIC CIRCUITS The diagnostic circuit is provided as a means of making system checks and maintenance more convenient This circuit is entirely contained on PCB 1 and PCB 2 The circuits that are contained on PCB 1 and PCB 2 are as follows 3 7 1 Control Power On Line from the 120V AC input is sent through F2 safety switches CSS BSS isolation transformer T2 ...

Page 17: ...ved from the timing circuit If LED8 fails to flash then check LED9 D28 for timing operation The strobe unit should produce 40 2 pulses per minute in daymode or nightmode back up operation The strobe unit in nightmode operation should produce 22 2 pulses per minute 3 7 6 Timing Signal Verify Timing pulses either primary or secondary are received at LED9 D28 The LED will flash according to the pulse...

Page 18: ...M E 2009 E 1DB2 3 25 07 rev 5 28 09 13 ...

Page 19: ...er or Socket Set 1 Precision Flat Screwdriver 1 Multi meter Analog or Digital 600V AC 1 000V DC Minimum 4 2 DIAGNOSTIC EVALUATION The first step in troubleshooting of this system or performing annual maintenance will require the technician to open the controller door With the power off to the controller the technician should look over the controller circuit and repair or replace any apparent probl...

Page 20: ...ct type of fuse If the fuse blows again check PCB 1 and PCB 2 Replace as necessary If LED is okay go to the next step 4 3 1 3 If steps 4 3 1 1 and 4 3 1 2 check out okay check or re lamp the beacon 4 3 2 Control Power on LED LED 4 Out 4 3 2 2 Check interlock circuit for an open circuit If open make the necessary repairs If okay check fuse F2 in the cabinet Replace if bad 4 3 3 Timing LED LED 9 Out...

Page 21: ...RF If alarm trips when the system appears to be working normally or fails to show an alarm when there is an obvious failure check relay K8 coil for an open condition Normal resistance should be around 2K ohm If coil is open replace K8 4 3 6 No Red Strobe Operation 4 3 6 1 Check if switch SW2 is on If switch is off turn switch to the on position upward If okay go to the next step 4 3 6 2 Turn switc...

Page 22: ...cement of the flashtubes every four 4 years By following these instructions maximum safety and performance can be achieved 5 1 1 Loosen the single quick open bolt located on upper hinge assembly 5 1 2 Open the lens and tilt it back ALWAYS WAIT AT LEAST 30 SECONDS AFTER OPENING THE BEACON BEFORE STARTING ANY WORK ON THE BEACON 5 1 3 Loosen the three 3 socket screws with a 2 Phillips screwdriver to ...

Page 23: ...mbly and latch securely 5 2 RED OBSTRUCTION LIGHTING The only required maintenance needed to be performed is replacement of the lamps in the L 810 fixture Lamps should be replaced after being operated for not more than 75 of the rated life or immediately upon failure as per FAA Advisory Circular 70 7460 1K By following these instructions maximum safety and performance can be achieved Tools Require...

Page 24: ...M E 2009 E 1DB2 3 25 07 rev 5 28 09 E 1DB2 CONTROLLER 5 3 PHOTOCELL The photocell is a sealed unit No maintenance is needed or required other than replacement as necessary 19 ...

Page 25: ...F1 1 amp FUSE KTK1 F3 1 8 amp FUSE FLQ18 FT1 DAYMODE FLASHTUBE STFLSHTB6 FT2 NIGHTMODE FLASHTUBE STFLSHTB7 K1 K4 K5 K6 K8 DPDT OCTAL RELAY KRPA11AG120V K2 K3 HV RELAY STJ10006 K7 SPDT OCTAL RELAY KRPA5AG120V K9 TIME DELAY RELAY SPEC224 L1 INDUCTOR INDCTR3001 L2 INDUCTOR 100453 M1 CURRENT SENSOR RM4JA32MW MOVMOD1 SURGE SUPPRESSOR DTK 120HW MOV 2 METAL OXIDE VARISTOR MOV524V15 MOV5 6 METAL OXIDE VAR...

Page 26: ...PDT 15 amp SWITCH STJ01004 T1 FERRORESONANT TRANSFORMER STC30018 T2 ISOLATION TRANSFORMER 100272 T3 BURSTING CHOKE 100273 T4 T5 TRIGGER TRANSFORMER STC05005 TB1 13 PART TERM BLK TERMBLK 13 TB2 12 PART TERM BLK TERMBLK 141 12 TLS THERMAL LIMITING SW OA210 QCV STJ10008 FLASHTUBE SOCKET 100319 HINGE GASKET STBEAGSKT LENS GASKET STBEAGSKT2 CLEAR LENS STDBCLENS DB STROBE BEACON FIXTURE STDBEACON STROBE...

Page 27: ...1 2 amp FUSE 2 FLQ18 1 8 amp FUSE 1 STH01329 E 1DB2 PCB 1 1 6390 FAA2 120V AC PHOTOCELL 1 STJ10006 HV RELAY 1 STJ02003 BEACON SAFETY SWITCH 1 STJ02001 CABINET SAFETY SWITCH 1 STFLSHTB6 DAYMODE FLASH TUBE 1 STFLSHTB7 NIGHTMODE FLASH TUBE 1 KRPA11AG120V DPDT OCTAL RELAY 1 RM4JA32MW CURRENT SENSOR 1 DTK 120HW SURGE SUPPRESSOR 1 KRPA5AG120V SPDT OCTAL RELAY 1 STB99006 40 uf1 1KV CAP 22 ...

Page 28: ... intensity requirements as defined in the FAA Advisory Circular 150 5345 43E dated 10 19 95 All warranty replacement LED Product is warranted only for the remainder of the original warranty of the LED Product replaced Replacement LED Product will be equivalent in function but not necessarily identical to the replaced LED Product Replacement parts other than LED Product are warranted for 90 days fr...

Page 29: ...compliance with the Return Terms TWR will replace repair and return or credit product s returned by the customer It is TWR s sole discretion to determine the disposition of the returned item s Replacements Replacement part s will be shipped and billed to the customer for product s considered as Warranty pending return of defective product s When available a certified reconditioned part is shipped ...

Page 30: ...ay a 20 restocking fee A credit will be issued once it is determined that the Return Terms are met Credits Credits are issued once it is determined that all of the Warranty and Return Terms are met All credits are processed on Fridays In the event a Friday falls on a Holiday the credit will be issued on the following Friday Freight All warranty replacement part s will be shipped via ground deliver...

Page 31: ...AUTHORIZATION RMA FORM RMA DATE CUSTOMER CONTACT PHONE NO ITEM DESCRIPTION PART NO MODEL NO SERIAL NO ORIGINAL TWR INVOICE NO DATED DESCRIPTION OF PROBLEM SIGNED DATE NEEDED RETURN ADDRESS PLEASE RETURN PRODUCT TO 4300 WINDFERN RD 100 HOUSTON TX 77041 8943 ...

Page 32: ...AUTHORIZATION RMA FORM RMA DATE CUSTOMER CONTACT PHONE NO ITEM DESCRIPTION PART NO MODEL NO SERIAL NO ORIGINAL TWR INVOICE NO DATED DESCRIPTION OF PROBLEM SIGNED DATE NEEDED RETURN ADDRESS PLEASE RETURN PRODUCT TO 4300 WINDFERN RD 100 HOUSTON TX 77041 8943 ...

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Page 49: ... TRIGGER TRANSFORMER STC05005 2 29 10 32 X 3 8 PILLIPS PAN HEAD SCREW 1032X38PHH 1 30 8 32 X 1 4 PH SS SLOT SCREW 832X14PHH 4 31 6 32 X 3 8 PHILLIPS PAN HEAD SCREW 632X38PHH 4 32 6 32 X 1 2 PHILLIPS PAN HEAD SS SCREW 632X12PHH 4 33 10 32 X 3 8 SS PHILIP HD CAPTIVE SCREW 1032X38PHW 24 34 8 32 NUT 832NUT 3 35 T B CONNECTOR 18RAD18277 2 36 8 32 X 1 2 PHILLIPS PAN HEAD 832X12PHH 7 37 GASKET NEOPRENE 1...

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