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FTB 324 User Manual

1. Table 1 5 Alarm Table 3 1 Transformer Table 3 2 Checkout of Power Converters with PCB1 24740xx Table 3 3 Checkout of Power Converters with PCB1 24747 Table 3 4 Selecting the Correct Troubleshooting 4 Table 3 5 Unit Troubleshooting 4 Table 3 6 System Troubleshooting 4 Table 4 1 Power Converter Major Replaceable Table 4 2 Flashhead Major Replaceable vi Revision 8 07 17 2002 Page 1 5 1 6 1 7 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 4 3 4 4 4 5 Page 1 2 1 3 1 4 1 4 1 5 3 3 3 8 3 10 3 12 3 12 3 13 4 2 4 4 824 Section 1 FTB 324 Introduction and Operation System The ElectroFlash FTB 324 System is a dual white red flashing medium intensity obstruc tion lighting system consisting of an FH 324 Flashhead a PC 324 Power Converter anda PEC 510 Photocell with cable The power converter provides discharge energy to the flashhead and contains components and cir cuitry to control flashing The power converter operates a white l
2. EN I E i lit 1 d _ 5 BEI 0 TL JL L L ieu c wt nah wp na t8 m 3 AT iif Poa iri PD E z m Figure 2 8 PC 324 Power Converter Internal Wiring FTB 324 Revision 8 07 17 2002 FT 101 T101 TRIGGER TRANSFORMER FLASHTUBE BETWEEN UPPER AND 8 6 14 BLUE T101 TRIGGER TRANSFORMER 3 FT 101 FLASHTUBE 14 BLUE Figure 2 9 FH 324 Flashhead Internal Wiring FTB 324 Revision 8 07 17 2002 UPPER RED FLASHHEAD T102 COUPLING TRANSFORMER PUR SHIELD FLASHHEAD T102 COUPLING TRANSFORMER SHIELD CABLE TO POWER CONVERTER fh324iw 2 14 Section 3 Maintenance and Troubleshooting Safety Read the warning on Page iii Work safely as fol lows 1 Remove all jewelry before opening equipment 2 Shut off the equipment 3 Remove component or connect test equipment 4 Replace the component 5 Turn on the power and test the system 6 Turn off power and disconnect test equipment Preventive Maintenance Carry out the following inspection and cleaning procedures at least once a year 1 Verify that moisture has not entered the equipment through gaskets or seals or col lected inside as condensation 2 Verify that all drain holes are clear 3 Check terminal blocks and relays for evidence of corrosion and electri
3. ALM I 7 LED is on indicating a Remove the temporary opaque cover marker alarm placed over the photocell in Step 2 The top flashhead red is flashing Set Intensity Select Switch to AUTO Remove power Replace Fuse F4 Setup Check White Alarm for Daytime Operation Response LEDs and Structure Lights 1 Remove the opaque cover from the photocell 2 Set the intensity select switch or switches to AUTO 3 Remove power 4 Disconnect the black wire from TB2 4 This fails the white flash head 5 Reapply power The following responses indicate a failure to flash The DAY ERR LED I 7 is on in day mode Verify that they occur as compared The SYNC LED I 6 flicks on regu to those in Check Normal Daytime Operation larly except for those in the following list after three The CONF flash confirm LED flash cycles I 11 is off The WHT ALM LED I 8 is on The power Remove power converter executes 3 flash cycles internally Reconnect the black wire to TB2 4 after power application The White Alarm Reapply power turns on at the end of the three cycles Verify operation as in Daytime Operation Setup Check Red Alarm for Night Operation Response LEDs and Structure Lights 1 Place the opaque cover over the photocell 2 Set the intensity select switch or switches to AUTO 3 Remove power 4 Disconnect the purple wire from TB2 6 5 Reapply power The following
4. Also note that FTCA wiring diagrams define min imum requirements recommended for satisfactory equipment operation These minimum require ments may not be enough by themselves to com ply with local electrical codes It is the responsibility of the installer to comply with all applicable electrical codes Consider the following wiring power service marker lights power converter master slave interconnect and the flashhead installation wiring should have an insulation rating of 600 volts or higher You can find conduit and other distribution wir ing details on electrical installation diagrams pro vided by FTCA or others FAA Advisory Circular 70 7460 1K gives the lighting requirements for various types of struc tures Power Converter Wiring Power Service Wiring Power service wiring must be sized to satisfy the load demand of the red light markers and the power converters Each marker lamp draws 116 watts Night operation of each power converter 2 2 Revision 8 07 17 2002 FTB 324 requires 250 volt amperes See Specifications in Section 1 A typical installation has three power converters and two tiers of markers Thus the last slave power converter connected together in a chain of units is connected to a flashhead only no mark ers are connected to this unit Each steady burn ing marker draws approximately 1 ampere To determine wire gauge consider the total ampere load and the length of the run
5. PLAM DAY MODE NIGHT MODE COMMON 9 CLOSE AT MIGHT R d ze 878 THESE ERROR CONTACTS ARE AVAILABLE ON A EXTENDED ALARM MODELS ONLY Figure 1 1 View of TB1 Wiring Functions for PC 324 Alarm System Table 1 5 Alarm Functions Function White Alarm all Red Alarm all Marker Alarm all Intensity Error A Option PEC Error A Option Day Mode A Option Night Mode A Option FTB 324 Connections between TB1 7 and TB1 6 or TB1 8 signal the alarm for improper flash intensity or no flash at all The normally open NO contacts close and the normally closed NC contacts open Connections between TB1 10 and TB1 9 or TB1 11 signal the alarm when the PC 324 detected improper flash intensity or no flash at all during red night mode operation The normally open NO con tacts close and the normally closed NC contacts open Connections between TB5 5 and TB5 4 or TB5 6 signal the alarm under the following conditions One or more marker lamps is not functioning The marker lamp current is too low or not present iIhe normally open NO contacts close the normally closed NC contacts open Signals a day intensity error between TB1 12 and TB1 17 or a night intensity error between TB1 13 and TB1 17 Error occurs if a flashhead is flashing at the incorrect intensity for the day or night lighting con dition determined by the photocell The normally closed NC
6. 3 Ensure that the tube is vertical 4 Tighten the three screws on the screw lugs to secure the flashtube White Lens Section Removal 1 Loosen the two screws securing the upper flashtube assembly and lift the plate up and out of the way to allow access to the bottom flashtube 2 Pull out the flashtube in the white lens bottom section You may have to rock it back and forth slightly to remove the tube Replacement 1 Align the pins on the flashtube base with their sockets Notice that the spacing of the flash tube pins must match that of its sockets 2 Insert the flashtube and settle it into place making sure the ceramic base is resting directly on the tops of the pin sockets 3 Ensure that the tube is vertical 4 Close the top red lens section and secure the latches Trigger Transformer T101 Refer to Figure 4 2 FH 324 Flashhead Component Location Removal 1 At the trigger wire post adjacent to the flash tube remove the large diameter wire coming from the trigger transformer 2 At one of the smaller side mounted ceramic posts remove the small wire to the trigger transformer Do not disconnect the primary winding wires seven turns of hook up wire 3 Remove the two 4 40 x 2 Phillips head screws holding the transformer assembly to the bracket Note the orientation of the 3 6 Revision 8 07 17 2002 FTB 324 molded secondary winding with respect to fixed features on the bracket since it must b
7. f Refer to Table 1 1 for indicator and lamp func actory tions and Table 1 2 for jumper settings Setting Up PCB1 PCB1 24747xx Eagle Board Function Indicators PCB1 24747xx has the following features LED indicators on the PCB1 board signal alarms and internal functioning Observe these LEDs to Twelve LED indicators indicating function monitor equipment operations during checkout and troubleshooting The essential features on One neon lamp indicating trigger power PCBI for troubleshooting are shown in Figure 1 2 Two jumpers for external programming and Figure 1 3 One RJ11 telephone line socket for remote PCB1 24740xx EagleWin monitoring PCB1 24740xx has the following features One RS 232 socket for internal programming LED indicators indicating function Refer to Table 1 3 for indicator and lamp func ce fad tions and Table 1 4 for jumper settings A neon lamp indicating trigger power Jumpers for external programming Table 1 1 PCB1 24740xx Neon or LED Function Indicators Lamp pan Function Label atin NITE ERR On for incorrect intensity for night operation DAYERR 17 On for incorrect intensity for day operation PEC ALM 12 Photocell alarm Power converter failed to switch the day night mode to the opposite state within a 19 hour period perhaps due to its input WHT ALM 18 White alarm on when a white alarm occurs RED ALM 13 Red alarm on when a red alarm occurs MKR ALM 19 Marke
8. 5 Remove any additional connections that you must to remove the Input Power Module bracket Replacement 1 Replace the Input Power Module in the reverse sequence to that of Removal 2 Verify that wiring matches the Information Card and restore the wire routing to its origi nal state K2 Mode Relay You must first remove the Red Light Module and PCBI as in Section Red Light Module Section Timing and Trigger Board PCB1 and the Com ponent Bracket for adequate access to the K2 Mode Relay Removal 1 Remove the Red Light Module 2 Remove PCBI 3 4 Revision 8 07 17 2002 FTB 324 3 Loosen the four truss head screws in the base that fasten the bracket to the base 4 Loosen the screw that fastens the bracket to the Input Power Module 5 Slide the bracket up off the screws Be careful ofthe cable and cable connectors You may hang the bracket over the edge of the connec tor panel to perform the remaining steps 6 Carefully disconnect the wires from the termi nals of the component and note their locations so that you may more easily replace them 7 Remove the screws that hold the K2 relay to the base 8 Remove the K2 relay Replacement 1 Replace the K2 relay in the reverse sequence of that of removal 2 Verify that wiring matches the Information Card and restore the wire routing to its origi nal state K3 Discharge Relay Removal and replacement are similar to those in Section K2 Mode Relay K5 M
9. NIGHT MODE CONTACTS CLOSE AT NIGHT OMMON BLK MASTER SLAVE WHT INTERCONNECT FEMP SENSE MODE F MONITORING NOTE 1 amp 5 TWO CONDUCTORS 16 AWG MINIMUM RIMARY neur POWER NOTE 6 NOTE 13 SURGE SUPPRESSED TELEPHONE LINE CONNECTION FOR A REMOTE COMPUTER AND EAGLEWIN SOFTWARE SUPPLY LIGHTNING PROTECTION FOR THE TOP FLASHHEAD FLASHHEAD CABLE CHART FOR USER S CABLE BLU BLK WHT PUR MIN INSULATION 600V COLORS FOR REF ONLY OUTPUT TO 10 AWG 16 AWG 16 AWG 16 AWG CLOSES HARFERS TWI DENOTES WIRE SPLICE CONNECTIONS FH 324 FLASHHEAD PUR SHIELD SEE CABLE CHART TYPICAL MARKER TIER L 810 S 28 Ei El 01 006 11 20 8 UOISTAOY 778 GLA Bum uonejjejsuj weIs S lun adult 726 14 9 aunbiy NOTES 1 AC INPUT POWER CONDUCTOR SIZE DEPENDS ON THE SERVICE VOLTAGE THE DISTANCE FROM THE SOURCE THE NUMBER OF POWER CONVERTERS AND NUMBER OF L 810 MARKER LIGHTS SERVED USE 250 VA PER POWER CONVERTER PLUS 116 VA FOR EACH L 810 MARKER LIGHT ALSO SEE NOTE 9 2 USE A CONTINUOUS CABLE FROM THE POWER CONVERTER TO THE FLASHHEAD WITHOUT JUNCTIONS OR SPLICES 3 CONTACT RATING 1 AMPERE 120 VAC EXTENDED MONITORING IS AVAILABLE ON THE 324 A MODELS ONLY 4 USER S ALARM CIRCUIT NOT SHOWN 5 USE LINE 1 AND NEUT FOR 120V 60 Hz USE LINE1 LINE 2 AND NEUT FOR 240 120V 60Hz 6 UNIT IS FACTORY
10. Please read the notes on the installation wiring diagrams sup plied both in this manual and with the equip ment Please note that FTCA recommends the following guidelines for red light wiring Using a maximum wire size of 12 AWG from the red light module terminal block inside the power converter Running a short length of 12 AWG wire to a junction box near the power converter when load requirements call for heavier gauge wire to red light fixtures Flashhead Wiring The wiring between the power converter and flashhead requires five conductors with 600 volts minimum insulation Two of the conductors must be 10 AWG The other three may be 16 AWG minimum for mechanical strength if you are cabling together individual wires FTCA rec ommends using FTCA Part Number 6340 cable for this application To ensure reliable operation FTCA recommends continuous wiring between the power converters and their associated flashheads without interven ing junctions or splices If you use FTCA Part Number 6340 cable without electrical conduit you should secure it to the main structure not more than 5 feet 1 5 meters below the flashhead and at 5 foot minimum intervals between the flashhead and power converter Securing the Cable Use the following method for securing the flash head cable to a skeletal structure 1 Run the cable along one of the tower legs and wrap one full turn of two inch Scotchrap 50 tape or the equ
11. contacts open Signals a photocell error between TB1 14 and TB1 17 The error occurs when the PC has failed to switch from night to day as a result of reading the photocell circuit within a 19 hour period This period is factory adjustable The normally closed NC contacts open Signals day mode operation between TB1 15 and TB1 17 when the internal operation of the power con verter is in day mode When the signal occurs as it should during daylight the normally closed NC con tacts are closed These contacts open at night Signals night mode operation between TB1 16 and TB1 17 when the internal operation of the power converter is in night mode When the signal occurs as it should during nighttime the normally closed NC contacts are closed These contacts open during daylight Revision 8 07 17 2002 1 5 J16 214 000000600 000000 000000 SW1 2 JP8 JUMPERS JREDSENSE MARKERNO AILCLOSE 85 n COMPUTER JACK TO SET RS 232 5 UP BOARD PROGRAMMING LA Figure 1 2 1 Pictorial 24740 1 6 Revision 8 07 17 2002 FUNCTION NT RED Not cut in the P 4 This Jumper Is for power converters with internal controllers for external red beacon lamps photocell Cut in the PC 324 ALRMON Applies to beaco K Gut to disable white lig failure night flashhead operation Apples TO pow Backup upon board shows
12. ues ee Eme RE RE 8 8 Component Removal and 8 8 Power Converter sot cn HERE PES M ME ei 3 4 Capacitors uo Alan utu ee ee ae nee 3 4 TIuput Power Module Ernie ns ei 8 4 K2 Mod R lay eee IRSE variety vies 3 4 K3 Discharge Relay J uec seen MIE RR Van 8 5 K5 Marker Control 3 5 11 Burst Choke ehh Beim ed nad rar 3 5 Timing and Trigger 8 5 PCB2 HV Rectifier 1 8 5 PCB4 Sense 0 1 3 5 Red Tight Module eie nn NIRE NIS US EON RE e READ ed 8 5 R2A and R2B Burst 3 6 1 Power 2 3 6 Trigger Coupling 3 6 Flashh eadu tum yan cot mus maa ne lade as Ehe 3 6 Trigger Transformer 101 3 6 Coupling Transformer 7109 3 7 Operational Checkout i eu zen en rauen SURE ELA 3 7 S
13. 324 2 13 PC 324AE 2 12 Introduction system 1 1 J Jumper settings table 24740xx 1 3 K K2 removal 3 4 K3 removal 3 5 K5 removal 3 5 L L1 removal 3 5 LED indicator table 24740xx 1 2 24747xx 1 4 on PCB1 1 2 Leveling 2 2 Location component power converter 4 3 M Main panel day mode 1 5 intensity alarm connection 1 5 intensity error connection 1 5 marker alarm connection 1 5 master slave connection 1 5 night mode 1 5 photocell alarm connection 1 5 photocell connection 1 4 photocell error 1 5 power converter alarms and signals 1 4 red alarm connection 1 5 white alarm connection 1 5 Maintenance preventive 3 1 Marker alarm connection main panel 1 5 lamp current 2 3 light fixtures installation 2 2 Master slave 1 5 connection main panel 1 5 wiring 2 3 Mode day 1 5 night 1 5 Mounting components 2 1 flashhead 2 1 photocell 2 2 power converter 2 1 Mounting and outline figure flashhead 2 7 photocell 2 8 power converter 2 6 Revision 8 07 17 2002 FTB 324 Triple unit system 3 7 checkout 3 7 N Night intensity remaining in 3 2 Night mode 1 5 connection main panel 1 5 Operation system 1 1 Ordering parts 4 1 Part flashhead 4 4 lists 4 1 ordering 4 1 photocell 4 1 power converter 4 2 Part replacement policy ii PC 324 internal wiring figure 2 13 PC 324 TB1 wiring function view 1 5 PC 324AE internal wiring figure 2 12 PCB1 E models 1 2 24740xx checkout table 3
14. 8 jumper settting table 1 3 LED indicator table 1 2 2474 7xx Jumper programming 1 4 LED indicator table 1 4 daytime operation 24740xx checkout 3 8 2474 7xx checkout 3 10 defined 1 1 LEDs 1 2 marker alarm operation 24740xx checkout 3 8 2474 7xx checkout 3 10 nighttime operation 24740xx checkout 3 8 2474 7xx checkout 3 10 non E models 1 2 FTB 324 removal 3 5 setup 1 2 testing 3 2 white alarm operation 24740xx checkout 3 8 white light backup operation 24740xx checkout 3 8 checkout 3 10 PCB1 24740xx pictorial 1 6 PCB1 24747xx pictorial 1 7 checkout table 3 10 PCB2 removal 3 5 testing 3 3 PCB4 removal 3 5 testing 3 3 Photocell alarm connection main panel 1 5 basic connection 1 1 component locations 4 5 connection main panel 1 4 error 1 5 main panel 1 5 mounting 2 2 mounting and outline figure 2 8 parts 4 1 testing 3 3 3 7 wiring 2 3 Power converter access 2 1 basic purpose 1 1 component removal 3 4 component location 4 3 main panel alarms and signals 1 4 mounting 2 1 mounting and outline figure 2 6 parts 4 2 power service wiring 2 2 shipping 4 1 testing components 3 2 Power service wiring 2 2 Preventive maintenance 3 1 Revision 8 07 17 2002 1 3 R R1 testing 3 3 R2 removal 3 6 testing 3 3 Radio frequency interference See RFI Red alarm connection main panel 1 5 Red light module removal 3 5 Relays testing 3 2 Removal capacitor 3 4 component 3 3 flashtube 3
15. 810 MARKER LIGHT ALSO SEE NOTE 9 DETERMINE THE BRANCH CONDUCTOR SIZE 8 FTCA RECOMMENDS 12 AWG AS THE MAXIMUM CONDUCTOR SIZE FROM TBS TO THE JUNCTION BOX USE LARGER 2 USE A CONTINUOUS CABLE FROM THE POWER CONVERTER 9 THE TOTAL LINE DROP INCLUDING INPUT SERVICE WIRING TO THE FLASHHEAD WITHOUT JUNCTIONS OR SPLICES AND BRANCH LINES TO THE L 810 MARKER LIGHT SOCKETS 3 CONTACT RATING 1 AMPERE 120 VAC EXTENDED MONITORING IS MUST NOTEXGERD 2 OF HATED VOLTAGE AVAILABLE ON FTB 324 SYSTEMS ONLY MODELS 10 THE MARKER FIXTURES MAY BE SUPPLIED BY OTHERS 4 USER S ALARM CIRCUITS NOT SHOWN 11 MOUNT THE POWER CONVERTER VERTICALLY 5 USE LINE 1 AND NEUT FOR 120V 60 Hz 12 INSERT TELEPHONE PLUG INTO SURGE SUPPRESSOR USE LINE 1 LINE 2 AND NEUT FOR 240 120V 60 Hz MODULE LOCATED NEAR CONDUIT HOLES 6 UNIT IS FACTORY WIRED FOR NAMEPLATE VOLTAGE 13 BOND CASE TO THE SITE GROUNDING SYSTEM 7 JUNCTION BOX FOR DISTRIBUTION WIRING TO MARKERS TYPICALLY FURNISHED BY OTHERS AND LOCATED AS CLOSE AS POSSIBLE TO THE POWER CONVERTER PC 324 POWER CONVERTER NOTE 11 MOUNT THE PHOTOCELL OUTPUT ALARM CONTACTS HV TO FACE THE POLAR SKY DAY MJNIGHT CONTACTS SHOWN IN NORMAL WARNING AND MOUNT IT AU OPERATING STATE VERTICALLY AT THE TOP NO ALARMS OR ERRORS END OF A VERTICAL INTENSITY LENGTH OF CONDUIT TO SELECT PREVENT WATER FROM ENTERING THE UNIT PHOTOCELL II Jg ITENSITY CONTACTS CLOSE CURING DAY
16. FTB 324 Ensure that TB1 1 and TB1 2 on the slave units are jumpered together 10 Alarm Wiring FTB 324 If external alarm detection circuit responds to closed contacts ensure that they are wired to the contacts on TB1 that close on alarm If external alarm detection circuit responds to open contacts ensure that they are wired to the contacts on TB1 that open on alarm Alarm wiring should be lightning and RFI protected shielded grounded shield and in a conduit If a specific alarm is ganged together from all power converters as one ensure that the wiring follows local installation instructions 11 Marker Wiring Sidelights Ensure that each power converter powers only one tier of markers Ensure that the top tier of markers is wired to the master power converter Check the wiring gauge to the markers to ensure less than 3 voltage drop at the sockets Ensure that all markers have all their lamps installed Ensure that marker lamps are 116 Watts only After completing all the steps listed above turn on the power and perform an operational check out from procedures in Section 3 of this manual Revision 8 07 17 2002 2 5 16 75 425 5 1 1 LEFT SIDE VIEW FRONT VIEW AS WALL MOUNTED AS WALL MOUNTED 1 1 Li NOTES 1 Weight 50 5 pounds 22 9 kilograms 2 Max wind loading 1 63 sq ft 152 sq m BOTTOM VIE
17. TI spectlonzz oec SE ORNS SE teta RN RN BAPE BRET 3 2 Power Converter Component 3 2 is EA i ea 3 2 Burst Choke L1 yz nib bate bahay RUE 3 2 Relays ardoa udn le SOS Oe a hura unb er a hes UP DS 8 2 Timing and Trigger Board 1 8 2 HV Rectifier Board 2 3 3 Alarm Relay Board PCB5 PC 324 3 3 Sense Module 4 8 3 iv Revision 8 07 17 2002 FTB 324 Table of Contents Page Discharge Resistor 1 3 3 Burst R sistor R2 cci etes EN PERO na ae an 8 8 Power Transformer 3 3 Trigger Coupling Transformer 3 3 Red Light Module 8 8 Flashhead Component 2 8 8 FlashtubeXFT101 sa rasen re DE bene 3 3 Trigger Transformer 101 2 3 3 Trigger Coupling Transformer 102 3 3 Photocell Testing
18. WIRED FOR NAMEPLATE VOLTAGE 7 OTHERS TYPICALLY FURNISH THE JUNCTION BOX FOR DISTRIBUTION WIRING TO THE MARKERS LOCATE THE JUNCTION BOX AS CLOSE AS POSSIBLE TO THE POWER COVNERTER 8 FTCA RECOMMENDS USING 12 AWG AS THE MAXIMUM CONDUCTOR SIZE FROM TB5 TO THE JUNCTION BOX USE LARGER CONDUCTORS FOR THE BRANCH FROM THE JUNCTION BOX TO THE MARKER FIXTURES IF REQUIRED SEE NOTE 9 TO DETERMINE THE BRANCH CONDUCTOR SIZE 9 THE TOTAL LINE DROP INCLUDING THE INPUT SERVICE WIRING AND BRANCH LINES TO THE 1 810 MARKER LIGHT SOCKETS MUST NOT EXCEED 3 OF THE RATED VOLTAGE 10 MARKER FIXTURES MAY BE SUPPLIED BY OTHERS 11 MOUNT THE POWER CONVERTER VERTICALLY 12 TERMINALS AT TB1 1 amp 2 MUST BE JUMPERED ON SLAVE UNITS 13 BOND THE CASE TO SITE GROUNDING SYSTEM MOUNT THE PHOTOCELL VERTICALLY AT THE TOP END OF A VERTICAL LENGTH OF CONDUIT TO PREVENT WATER FROM ENTERING THE UNIT FACE IT TOWARD THE POLAR SKY SEE CABLE CHART PC 324 POWER CONVERTER MASTER Contacts SHOWNINNORMAL 73 pm OPERATING STATE e NO ALARMS OR ERRORS AU i PHOTOCELL 4 SELECT i z i 2 81 5 3 55 BOE oor 4 5 Zus 5 Fu a az 489882 8 A z 2 281828 ug 5 59 24 68 5 ai S 250505 u 5 5 2 xt xtd 8 2 s d i 9 TB1 TH T UDPTLITIILLLIITDIITTITIT won 384 MONITORING NOTE 11 Two CONDUCTORS 16 AWG MINIMUM TWO 2 16 AWG 600V MIN CONDUCTOR
19. are jum pered together as is 1 1 and TB1 2 of slave 2 Alarms and Signals Terminals on TB1 of the PC 324 indicate various system failures and day or night modes of opera tion and they are connected to electrically iso lated contacts of relays inside the PC 324 Electrically isolated contacts are not connected to any other circuitry They act as switches rated at 1 ampere 120 VAC allowing you to connect the PC 324 to external monitoring equipment They change state for example from normally closed NC to open or from normally open NO to closed when the condition indicated on the front panel occurs 1 4 Revision 8 07 17 2002 Table 1 5 describes the available alarm functions A synchronization signal to flash the lights on 1 of the power converter Master Slave Interconnect simultaneously A failure of a top light in night mode causes the master power converter wired to that fail The master slave interconnect terminals at TB1 4 ing light to signal backup mode to all power and TB1 5 are connected between power convert ers in triple unit installation These terminal converters all flashheads on the structure flash in backup mode correct night intensity connections supply two functions white back up Marker lights are turned off OUTPUT ALARM CONTACTS CONTACTS SHOWN IN NORMAL OPERATING STATE NO ALARMS OR ERRORS Z QAYLIGKT MASTER SLAVE INTERCONNECT PEC ERROR
20. chassis may fail to discharge it Remove the fuse for this procedure to prevent accidental application of power if the interlock switch is inadvertently depressed Removal 1 Disconnect the wires leading to capacitors 2 Remove the hold down screws 3 Lift the capacitors from their receiving holes Replacement 1 Reverse the removal procedure 2 Verify that wiring agrees with the wiring dia gram on the Information Card Wires must be replaced exactly as removed In some instances a quick connect wire terminal does not seat properly if it is not placed on the ter minal cluster exactly as it was before removal This occurs by interference between the insu lation on the wire terminal and the insulation surrounding their terminal cluster on the capacitor FTCA recommends that you lightly squeeze the quick connect wire terminals with pliers before reinstalling them over the capaci tor terminal blades Input Power Module Removal 1 Remove all accessible wires and cable connec tors attached to the Input Power Module and to T1 located under the Input Power Module 2 Loosen the truss head screws in the base that fasten the Input Power Module to the base 3 Remove the screw under the ground terminal to the left of TB4 This screw fastens the Input Power Module bracket to the Component Bracket 4 Carefully slide the Input Power Module bracket to the right and lift it out Ensure that connectors are not bent while doing so
21. night intensity RFI on the photocell line could switch a light to night intensity and force it to remain there RFI would not normally cause a light to switch to day intensity Strong RFI could burn out circuit board com ponents While FTCA designed the circuits to reject or bypass RFI FTCA cannot guarantee complete immunity beforehand After installation it may be necessary to add external filters or use other methods to reduce RFI entering the equipment Component Testing The following procedures describe how to check most of the unit s major electrical components Always make resistance measurements with the primary power turned off Before applying power for voltage measurements connect test leads or circuit jumpers or disconnect existing circuit con nections with the power turned off and storage capacitors discharged Wiring and Cabling Wires or cables that move repeatedly will eventu ally break Ensure that all cables the flashhead cable in particular are securely fastened at short intervals to the structure or other supports Inspection Closely inspect the units and check the connec tions against the installation instructions Also a close inspection may reveal insulation break down an overheated component corrosion loose connections faulty relays incorrect hookup and so forth Power Converter Component Testing Capacitors Evaluate the condition of a capacitor with an ana log volt ohmmete
22. 1 4 AND TB1 5 N A METALLIC CONDUIT CUSTOMER CONNECTION TO ALARM RELAY CONTACTS FLASH TECHNOLOGY ALARM RELAY CONTACTS ARE PROTECTED FROM VOLTAGE TRANSIENTS OF UP TO 1000 VOLTS HOWEVER WIRED ALARM CONTACTS CAN BE SUBJECTED TO VOLTAGES GREATER THAN 1000 VOLTS BECAUSE OF LIGHTNING THE FOLLOWING RECOMMENDATIONS MINIMIZE THE POSSIBILITY OF DAMAGE CAUSED BY HIGH VOLTAGE TRANSIENTS ON THE ALARM RELAY CONTACTS OF FLASH TECHNOLOGY POWER CONVERTERS THE INSTALLER IS RESPONSIBLE FOR COMPLYING WITH ALL APPLICABLE ELECTRICAL CODES NOTES USE SHIELDED CABLE TO ATTACH FLASH TECHNOLOGY ALARM RELAY CONTACTS TO EXTERNAL EQUIPMENT ATTACH THE SHIELD WIRE TO A GND GROUND TERMINAL ON THE FLASH TECHNOLOGY POWER CONVERTER AS SHOWN WHEN POSSIBLE ROUTE ALARM CONTACT WIRING IN METALLIC GROUNDED CONDUIT FOR ADDITIONAL PROTECTION ADD MOVs VARISTORS FROM EACH ALARM RELAY CONTACT TERMINAL TO A GND TERMINAL AT THE FLASH TECHNOLOGY POWER CONVERTER Figure 2 6 Recommended Alarm Relay Wiring Protection FTB 324 Revision 8 07 17 2002 2 11 E E r pm er pf D JINON LHOM Figure 2 7 PC 324AE Power Converter Internal Wiring Revision 8 07 17 2002 FTB 324 2 12 Te 1 HE HEH SIIM ea o YT gt zi E SI ye ip ai B ai PE 4 en MR IE IM o K K JJ TILL TE n i L P
23. 1 Red Light Module 11811502 Varistor 6901079 PCB1 Timing and Trigger Board PC 324 non E models 70474019 PCB1 Timing and Trigger Board PC 324E Two Markers 5474719 PCB1 Timing and Trigger Board PC 324E Three Markers 70474749 PCB2 HV Rectifier Board 75458005 PCB4 Sense Module 2811101 PCB5 Alarm Board AE models 2805404 R1 Resistor Discharge 35K 50W 6900541 R2A amp B Resistor Burst two 500 ohm resistors of the indicated part number comprise one burst resistor 6900532 S1 Switch Interlock 4901220 S2 Switch Toggle 18799201 1 Transformer Power 60 Hz 8841201 1 Transformer Power 50 Hz 8842901 T3 Transformer Coupling 8336701 TB1 Terminal Strip 18 position 4901930 TB2 TB7 Terminal Strip 6 position 4902257 TB3 Terminal Strip 11 position 8721011 TB4 TB5 Terminal Strip 3 position 4902134 TB5 Terminal Strip 6 position 4902257 TB6 TB8 Terminal Strip 3 position 4902157 VR1 Varistor 130V 8250801 VR1 Varistor 250V 8250802 This part number varies according to the specific equipment configuration and function Be prepared to describe the system configuration when you call Customer Service for the correct PCB1 Timing and Trigger Board or fuse part number for your particular system Have available the part number of your current PCB1 when you call Recommended as a spare part 4 2 Revision 8 07 17 2002 FTB 324 INTENSITY SELECT LOOSEN SCREWS 4 PLACES TO REMO
24. 2 NT RED Cut to use the internal red ontroller of the power converter Not cut in he PC 324 12 NITE ERR On for night intensity error 15 19 DAY ERR On for day intensity error 114 PEC ALM On for PEC alarm 8 WHT ALM On for white alarm 113 RED ALM On for red alarm 17 MKR ALM On for marker alarm 112 FAN Not used ON board detects a valid flash DAY On when in day mode 111 110 NITE On when in night mode 4 MKRS On when the board is commanding markers to be on TX CARRIER RX CJ transformer is applied to PCB1 RD Modem is receiving a signal TD Modem is transmitting a signal COMPUTER PHONE CONNECTOR CONNECTOR 1 474732 Figure 1 3 PCB1 Pictorial 24747xx FTB 324 Revision 8 07 17 2002 1 7 1 8 This page is intentionally blank Revision 8 07 17 2002 FTB 324 Section 2 Outline Mounting Installation Unpacking Inspect shipping cartons for signs of damage before opening them Check package contents against the packing list and inspect each item for visible damage Damage claims should be reported promptly to the freight handler Tools Although no special tools are necessary FTCA suggests the following tools for installation and maintenance 2 flat blade screwdriver 5 16 inch flat blade screwdriver 2 Phillips 9 inch shank screwdriver Set of combination wren
25. 3 13 guide selecting 3 12 system 3 13 unit 3 12 inspection 3 2 tables 3 11 wires and cables 3 2 U Unit testing with triple units 3 7 Unpacking 2 1 FTB 324 W Warning notice iii Warranty 11 White alarm connection main panel 1 5 Wiring 2 2 alarm 2 4 alarms 2 11 flashhead 2 3 general description 2 2 insulation required 2 2 master slave 2 3 photocell 2 3 service 2 2 Revision 8 07 17 2002 L5 I 6 End of Document Revision 8 07 17 2002 FTB 324
26. 3 PCB1 Pictorial 24747xx Figure 2 1 PC 324 Power Converter Mounting and Figure 2 2 FH 324 Flashhead Mounting and Figure 2 3 PEC 510 Photocell Mounting and Figure 2 4 FTB 324 Single Unit System Installation amp Figure 2 5 FTB 324 Triple Unit System Installation Figure 2 6 Recommended Alarm Relay Wiring Figure 2 7 PC 324AE Power Converter Internal Wiring Figure 2 8 324 Power Converter Internal Figure 2 9 FH 324 Flashhead Internal Wiring Figure 4 1 PC 324 Power Converter Component Figure 4 2 324 Flashhead Component Figure 4 3 510 List of Tables Table 1 1 PCB1 24740xx Neon LED Function Indicators Table 1 2 PCB1 24740xx Jumper and Switch Table 1 3 PCB1 24747xx Neon or Lamp Function Indicators Table 1 4 PCB1 24747xx Jumper
27. 3 m 2 Power Converter 1 63 ft 2 15 m 2 Environmental Complies with FAA specifications in AC 150 5345 43 Performance Characteristics Application L 865 and L 864 Flash Intensity nominal Day White 20 000 25 ECD Night Red 2 000 25 ECD Default Night White Backup 2 000 25 ECD Beam Spread Horizontal 360 Vertical 5 Flash Rate Day White 40 flashes per minute Night Red 20 flashes per minute Default Night White backup 40 flashes per min Electrical Power Converter AC Voltage sine wave 120 or 240V 60 Hz Volt Amperes 250 peak Watts Day White 130W Night Red 145W Night Default White 55W Markers Sidelights each 116W System Operation PCB1 Timing and Trigger Board PCBI governs all automatic functions T wo differ ent PCB1 boards are used in the PC 324 Power Converter The 24740xx board is used in all except the E models The 24747xx board is used in the E models The xx in the board s part number refers to its dash number which changes with the board s internal programming The major differ ence between the two is their jumpers internal control and programming Additionally PCB1 for EagleWin E systems connects to a telephone FTB 324 Revision 8 07 17 2002 1 1 line for remote monitoring by a computer suing An RS 232 socket for internal programming Eagle monitoring software The factory sets the jumpers and programs 1 before it leaves the
28. 6 input power module 3 4 K2 3 4 K3 3 5 K5 3 5 L1 3 5 PCB1 3 5 PCB2 3 5 PCB4 3 5 power converter component 3 4 R2 3 6 red light module 3 5 T1 3 6 T101 3 6 T102 3 7 T3 3 6 Repackaging 4 1 Replaceable part power converter 4 2 Returning equipment 4 1 RFI problems 3 1 5 Safety 3 1 Shipping 4 1 flashhead 4 1 power converter 4 1 Signals and alarms main panel 1 4 Specifications 1 1 Storage 3 1 Sync signal 3 1 evaluation 3 1 pulses 3 1 Sync master slave 1 5 System introduction 1 1 operation 1 1 specifications 1 1 T T on PCB3 testing 3 3 removal 3 6 testing 3 3 voltages table of 3 3 T101 removal 3 6 testing 3 3 T102 removal 3 7 T3 removal 3 6 testing 3 3 TB1 1 5 alarms and signals 1 4 day mode 1 5 intensity alarm connection 1 5 intensity error connection 1 5 marker alarm connection 1 5 master slave connection 1 5 night mode 1 5 photocell alarm connection 1 5 photocell connection 1 4 photocell error 1 5 red alarm connection 1 5 terminals 1 4 white alarm connection 1 5 Testing burst choke L1 3 2 capacitors 3 2 components 3 2 flashhead components 3 3 flashtube 3 3 PCB1 3 2 PCB2 3 3 PCB4 3 3 photocell 3 3 3 7 R1 3 3 R2 3 3 relays 3 2 T1 3 3 T1 on PCB3 3 3 T101 3 3 T3 3 3 Testing each unit of triple units 3 7 Tools for installation 2 1 Top flashhead 1 4 Transformer voltages table of 3 3 Revision 8 07 17 2002 FTB 324 Troubleshooting failing unit at night
29. 9 is off FAN LED I 4 not used SYNC LED I 10 flashes on in a regular DAY LED I 11 is on On during daylight NITE LED I 6 is off Off during daylight MKRS LED I 12 is off during daylight NEON bulb I 13 is on trigger voltage is available this bulb may blink White strobe is flashing at daylight high intensity Red markers are off pattern May be difficult to see CONF LED I 5 flashes on after each strobe flash May be difficult to see Response LEDs and Structure Lights Place opaque cover over photo cell block all light 1 Intensity Select Switch in AUTO 2 Apply power pull out interlock switch plunger Setup to Check Default Night Operation HV Warning Light is ON NITE ERR LED I 1 is off DAY ERR LED I 7 is off PEC ALM I 2 is off WHT ALM LED I 8 is off RED ALM LED 13 is off ALM LED 1 9 is off FAN LED I 4 not used DAY LED I 11 is off Off at night NITE LED I 6 is on On at night MKRS LED I 12 is on at night if markers are associated with the power converter being observed NEON bulb I 13 is on trigger voltage is available this bulb may blink Red strobe is flashing at night intensity SYNC LED I 10 flashes on in a regular Associated red markers are on pattern May be difficult to see CONF LED I 5 flashes on after each strobe flash May be difficult to see Response LEDs and
30. ALARM AT thresholds MARKER Parameter in Board Softwere 4ORLESS Two bulbs lit Three bulbs li Bulb WT TMRKO msaa 5 6 7 a catenary system If both JP8 and JP9 are cut or both uncut operation is for the bottom tier Internal programming must be set to CATENARY or RED CAT for this jumper to be operative in a catenary system If both JP8 and JP9 are cut or both uncut operation is for the bottom tier Internal programming must be set to CATENARY or RED CAT for this jumper to be operative Oten ata this Not cut to allow local alarms and alarms signaled to this power converter through a communications bus wire atoma 5 on a tower of mixetreircuit boards The parameter RETROFIT TYPE in internal programming on the 4740 must also be set to the board type that the 4740 is to emulate 7413 7740 CMOS or 7740 PLD relay during the day ancde energize it at night Cut to de energize the power converter marker relay in day mede and energize it at night sense boards Unettto allow use with laminated transformers 8111 This refere te internal design changes Factory use only 4740 FTB 324 12 12 12 12 FUNCTION 2999999 he circuit board at the factory 16 JIS 4 J12 JUMPER JP1 JUMPER FUNCTION 3 JUMPER JP1 ut to use the power converter with a JP2 resistive photocell Cut on the PC 324 RES PEC 9 JP
31. CB1 24740xx 3 8 white alarm operation PCB1 24740xx 3 8 white light backup operation 3 10 FTB 324 PCB1 24740 3 8 Codes electrical 2 2 Component burnout 3 2 locations flashhead 4 4 photocell 4 5 power converter 4 3 removal 3 3 flashhead 3 6 power converter 3 4 testing 3 2 Current marker lamp 2 3 Customer service 4 1 D Day mode 1 5 connection main panel 1 5 Diagnostic testing 3 1 E Electrical codes 2 2 Equipment returning 4 1 Error intensity 1 5 marker 1 5 photocell 1 5 red 1 5 white 1 5 F Flash rate errors 3 2 Flashhead access 2 1 basic description 1 1 cable basic description 1 1 securing 2 3 component locations 4 4 removalt 3 6 internal wiring figure 2 14 leveling 2 2 mounting 2 1 mounting and outline figure 2 7 parts 4 4 shipping 4 1 testing components 3 3 top 1 4 wiring 2 3 Flashtube Revision 8 07 17 2002 I 1 removal 3 6 testing 3 3 FTB 324 installation wiring figure triple unit 2 10 single unit 2 9 H Hazard warning iii I Input power module removal 3 4 Installation AWG gauge 2 3 checklist 2 4 flashhead cable securing 2 3 red light fixtures 2 2 wiring 2 2 flashhead 2 3 service 2 2 site specific 2 2 Installation wiring figure FTB 324 triple unit 2 10 single unit 2 9 single unit FTB 324 2 9 Insulation wiring 2 2 Intensity errors 3 2 main panel alarm connection 1 5 error connection 1 5 select switch using 3 13 Internal wiring figure flashhead 2 14 PC
32. R SW1 1 above in this table CT JP8 Cut to indicate top tier operation for this power converter in a catenary system If both JP8 and JP9 are cut or both uncut operation is for the bottom tier CM Jpg Cutto indicate middle tier operation for this power converter in a catenary system If both JP8 and JP9 are cut or both uncut operation is for the bottom tier Cut to allow an alarm for only local alarm conditions on this power converter ISOL JP10 Uncut to allow an alarm for local alarms and alarms signalled though a communications device RETROFIT JP11 Cut to allow the 24740xx Circuit Board to emulate other boards on a tower of mixed circuit boards MARK Uncut energizes the marker relay in day mode and de energizes it in night mode JP12 BERN ERNO Cut de energizes the marker relay in day mode and energizes it in night mode An energized marker relay turns off markers REDSENSE JP13 Cut to enable the usage of sense boards Uncut to allow usage with laminated transformers 8111 For internal design changes Factory use only JP14 Uncut factory use only JP15 Uncut factory use only t Jumpers OFF CUT OPEN FTB 324 Revision 8 07 17 2002 1 3 Table 1 3 PCB1 24747xx Neon or Lamp Function Indicators Lamp UB Function Label een Lamp NITE ERR 115 On for incorrect intensity for night operation DAYERR 19 On for incorrect intensity for day operation PEC ALM 114 Photocell a
33. S TWISTED TOGETHER NOTE 1 amp 5 PRIMARY POWER ume FROM SINGLE 20A NEUT BREAKER GND PN 6340 OR USER S CABLE FH 324 FLASHHEAD 52 RED BLU BLK FH 324 FLASHHEAD USE LIGHTNING PROTECTION FOR THE TOP FLASHHEAD FLASHHEAD CABLE CHART WHT WHT 7 PUR BLU 10 AWG PUR BLK 16 AWG e WHT 16 AWG x PUR 16 AWG GND MIN INSULATION 600V COLORS FOR REF ONLY TYPICAL MARKER TIER L 810 S Se fp FTCA PN 6340 OR USER S CABLE SEE CABLE CHART PC 324 POWER CONVERTER SLAVE DAY NIGHT 7 FP Contacts SHOWNINNORMAL OPERATING STATE NO ALARMS OR ERRORS HV i WARNING P SELECT i TB2 SE dH TLL Bosal ee es Ba Eint 2 z 54812928 Im um uu 5 5i eS 23 852627505 5 7 E H a 2 wi E p j Ji 1 221 de B IPTTTTITITIIIILLIIIII i IT gt INOTE 12 IO SPLICE CONNECTIONS E MSS LEN LAST SLAVE UNIT NOT SHOWN HAS SIMILAR TYPICAL MARKER TIER L 810S AAA LAST SLAVE UNIT NOT SHOWN DOES NOT HAVE MARKERS MARKERS ARE CONNECTED TO THE MASTER UNIT AND FIRST SLAVE UNIT NOTES POWER AND FLASHHEAD NOTES 1 amp 5 waki MASTER SLAVE INTERCONNECT LINE TO ADDITIONAL SLAVE UNIT TYPICALLY ONE MASTER AND TWO SLAVES ARE CONNECTED TOGETHER AT TB
34. Structure Lights Perform this procedure for each power converter individually in a multi unit system 1 Place opaque cover over pho tocell block all light 2 Intensity Select Switch in AUTO 3 Remove power 4 Disconnect purple wire on TB2 6 This fails the red flash ing light 5 Reapply power 8 8 Responses after three flash cycles DAY LED 11 is off Off at night HV Warning Light is ON NITE LED 6 is on On at night NITE ERR LED I 1 is off MKRS LED 1 12 is off at night during white DAY ERR LED I 7 is off back up operation PEC ALM I 2 is off NEON bulb I 13 is on trigger voltage is WHT ALM LED I 8 is on available this bulb may blink RED ALM LED I 3 is on White strobe is flashing at white back up MKR ALM LED I 9 is off Goes on initially intensity but then goes off when structure enters Associated red markers are off white night back up mode Remove power FAN LED I 4 not used Restore all wires to their previous positions SYNC LED I 10 flashes on in a regular before disconnecting any new wires pattern May be difficult to see Reconnect the purple wire on TB2 6 CONF LED I 5 flashes on after each Reapply power strobe flash May be difficult to see Revision 8 07 17 2002 FTB 324 Table 3 2 Checkout of Power Converters with PCB1 24740xx Board Continued Setup to Check Marker Alarm Response LEDs and Structure Lig
35. Tower Beacon LLC 1312 B Alpine Drive PO Box 31604 mail only Clarksville TN 37040 Toll Free 866 94 TOWER info TowerBeacon com FTB 324 FTB 324AE Dual Medium Intensity Obstruction Lighting System Reference Manual PERSONNEL HAZARD WARNING DANGEROUS VOLTAGES Dangerous line voltages reside in certain locations in this equipment Also this equipment may generate dangerous voltages Although FTCA has incorporated every practical safety precaution exercise extreme caution at all times when you expose circuits and compo nents and when you operate maintain or service this equipment Avoid Touching Live Circuits Avoid touching any component or any part of the circuitry while the equipment is operating Do not change components or make adjustments inside the equipment with power on Dangerous Voltages Can Persist with Power Disconnected Under certain conditions dangerous voltages can be present because capacitors can retain charges even after the power has been disconnected Protect yourself always turn off the input primary power and wait for one minute for storage capacitors to drain their charge Then check between the red and blue wires on the flashhead terminal block with a voltmeter for any residual charge before touching any circuit element or component Do Not Depend on Interlocks Never depend on interlocks alone to remove unsafe voltages Always check circuits with a voltmeter Under no circumstances rem
36. VE COMPONENT BRACKET SHOWING ITEMS BELOW COMPONENT BRACKET LOOSEN SCREW TO REMOVE COMPONENT BRACKET 13 845137 REVA Figure 4 1 PC 324 Power Converter Component Location FTB 324 Revision 8 07 17 2002 4 3 Table 4 2 Flashhead Major Replaceable Parts 20000 De Dee NN Resistor capacitor networ 2 O 1 Resistor capacitor networl ranstormer Trigger 0 FH 324 White Lower Flas hasd Component 1 FH324CL Figure 4 2 FH 324 Flashhead Component Location 4 4 Revision 8 07 17 2002 FTB 324 PEC510CL Figure 4 3 PEC 510 Photocell FTB 324 Revision 8 07 17 2002 4 5 4 6 This page is intentionally blank Revision 8 07 17 2002 FTB 324 INDEX A Access flashhead 2 1 instructions 2 1 power converter 2 1 Alarm connection wiring figure 2 11 intensity 1 5 marker 1 5 PEC 1 5 red 1 5 white 1 5 wiring 2 4 wiring figure 2 11 Alarm functions table of 1 5 Alarms and signals main panel 1 4 AWG gauge required 2 3 B Burnout of components 3 2 Burst choke L1 testing 3 2 Cable flashhead basic description 1 1 securing 2 3 Capacitor removal 3 4 testing 3 2 Checklist installation 2 4 Checkout daytime operation PCB1 24740xx 3 8 1 24747xx 3 10 marker alarm operation PCB1 24740xx 3 8 1 24747xx 3 10 triple unit system 3 7 nighttime operation PCB1 24740xx 3 8 1 24747xx 3 10 procedures 3 7 single unit system 3 7 table 3 10 P
37. W AS WALL MOUNTED BOTTOM VIEW AS WALL MOUNTED REAR CHASSIS AS WALL MOUNTED 44 INCH 11 2 BASEPLATE Figure 2 1 PC 324 Power Converter Mounting and Outline 2 6 Revision 8 07 17 2002 FTB 324 OPEN FOR ACCESS TO INTERIOR OF TOP FLASHHEAD TOP BEACON FITS FLUSH ON TOP OF LOWER BEACON 1325 BOLT HOLE CIRCLE 625 15 8 DIA MOUNTING HOLE 4 PLACES EQUALLY SPACED NOTES 1 WEIGHT FH 324 361 85 16 4 2 AERODYNAMIC WIND AREA 1 86 FT 173 M 3 DIMENSIONS ARE IN INCHES WLLIWETERSI 4 ACCESS TO THE FLASHHEAD MUST REMAIN UNOBSTRUCTED 8 FLASHHEAD SHOULD HAVE LIGHTNING PROTECTION Figure 2 2 FH 324 Flashhead Mounting and Outline FTB 324 Revision 8 07 17 2002 FH324MO 2 7 2 58 65 5 2 28 57 8 1 02 25 9 0 10 2 54 0 375 9 53 1 92 48 8 3 06 77 7 0 33 8 38 0 125 3 18 Figure 2 3 510 Photocell Mounting and Outline 2 8 Revision 8 07 17 2002 FTB 324 vee 6005 21 20 8 UOISTAOY 6 6 uorejjejsuj 6 un lBu S 914 v z nB d NOTES 1 THE AG INPUT POWER CONDUCTOR SIZE DEPENDS ON THE SERVICE VOLTAGE THE DISTANCE FROM THE SOURCE THE NUMBER OF POWER CONVERTERS AND THE NUMBER OF L 810 MARKER LIGHTS CONDUCTORS FOR THE BRANCH FROM THE JUNCTION BOX SERVED USE 250 VA PER POWER CONVERTER PLUS 116 VA PER TO THE MARKER FIXTURES IF REQUIRED SEE NOTE 9 1
38. ansformer 1 Interlock Connections main power No No No OK C2A D or shorted Shorted FH Cable No indicators PCB1 Board No No OK No i lit on 1 Power Transformer OK High OK OK Red Alarm PCB1 Board E K2 Relay Intensity Photocell Circuit Intensity select switch setting F4 Fuse OK OK OK OK All Markers Out PCB1 Board Marker Control Helay Markers Stay On K5 Marker Control Relay PCB1 Board OK Backup ok OK K2 Relay PCB1 Board Intensity OK OK OK TENES KR Markar Cantral Ralau a PCB3 OK OK IncorrectMode 52 Intensity Select Switch PCB1 is not in AUTO position Flashtube top red flash PCB1 OK No OK OK Red Alarm head K2 Relay C3 Capacitor Open L1 Burst Choke K5 Relay R2 Burst Resistor OK Backup ok OK Red Alarm F5 Intensity Red OK OK OK PCB1 Board Red or OK OK OK white Alarm PCB1 Board White Flashtube bottom flash No OK OK OK White Alarm head L2 Flash Choke C2A D Capacitors Open PCB1 Board K5 Rela K2 Relay Y HV High voltage PCB2 or HV neon lamp lit confirms HV t Replace the entire red light module if any components therein fail LV Low voltage Any PCBI LEDs on confirms LV 3 12 Revision 8 07 17 2002 FTB 324 Table 3 6 System Troubleshooting Guide Flash Conditions Other Conditions Probable Causes Day Night OK Day Flash Possible phot
39. arker Control Relay To replace K5 replace the entire Red Light Mod ule L1 Burst Choke Removal and replacement are similar to those in Section K2 Mode Relay PCB1 Timing and Trigger Board PCBI is mounted on the left side of the power con verter as you face the wall mounted power con verter Removal 1 Remove all connector plugs from PCB1 head ers and On J12 Pins 1 amp 2 remove the wht blu and blu wires if present On J14 Pins 1 amp 2 remove the brn and grn wires if present On J15 Pins 1 amp 2 remove the yel and wht yel wires 2 Loosen but do not remove the four screws located near the corners of the board 3 Slide the board so that it clears the four screws and remove it from the power con verter Replacement Reverse the removal procedure PCB2 HV Rectifier Board The HV rectifier board is mounted on the right of the Component Bracket between the Component Bracket and the Red Light Module You access it by first removing the Red Light Module and then the Component Bracket Use the following proce dure Removal 1 Remove the Red Light Module 2 If you have a right angle Phillips head screw driver available it is not necessary to remove the Component Bracket before doing Step 3 Otherwise remove the Component Bracket 3 Loosen but do not remove the screws holding the HV rectifier board to the terminal block TB3 Slide the circuit board out from under the terminal block
40. ashing in white night pared to those in Check Normal Daytime Opera back up intensity tion except for those in the following list after Hemove power three flash cycles Reconnect the purple wire on TB2 6 The WHT ALM LED I 8 is on Restore all wires to their previous con RED ALM LED I 13 is on nections before disconnecting any new The DAY LED I 5 is off wires The NITE LED I 10 is on for night operation Reapply power The MKRS markers LED I 4 is off It is off during white night backup mode 3 10 Revision 8 07 17 2002 FTB 324 Table 3 3 Checkout of Power Converters with PCB1 24747xx Board Continued Setup Check Marker Alarm Operation Response LEDs and Structure Lights 1 Cover the photocell with an opaque blocks all light cover 2 Set the intensity select switch or switches to AUTO 3 Remove power 4 Remove fuse F4 5 Reapply power Verify that the following responses occur as com Replace F4 and recycle the unit with pared to those in Check Normal Daytime Opera the Intensity Select Switch as done in tion except for those in the following list after Setup three flash cycles Reapply power DAY LED 15 is off unit should now be operating The NITE MODE LED I 10 is on normally in night mode that is red The MKRS I 4 LED is on indicating that light flashing markers turned on and markers should be on no alarm
41. ately 160 ohms Check the upper and lower ferrite core pieces for cracks Check the mounting screws for tightness Trigger Coupling Transformer T102 The coupling transformer should not have open windings An ohmmeter will indicate a shorted winding because of wire size Check with an ohm meter at the wire terminals Check upper and lower ferrite core pieces for cracks Photocell Testing The photocell is wired directly to the master power converter at TB1 1 and TB1 2 1 Disconnect the photocell The system should go to nighttime operation in about 45 seconds 2 Disconnect the master slave interconnect line on each power converter 3 Operate the intensity control switch on each power converter in turn 4 If each power converter operates correctly with the intensity control switch the problem is the photocell or its wiring or troubleshoot the circuits in the erroneously operating power converter 5 Reconnect all wires With the Intensity Select Switch in AUTO during daylight completely block light from entering the photocell If the system does not enter night mode after a few minutes replace the photocell At night shine a light on the photocell if the system does not enter day mode after a few minutes replace the photocell Component Removal and Replacement Component location diagrams are provided in Fig ure 4 1 through Figure 4 3 in Section 4 Recom FTB 324 Revision 8 07 17 2002 3 8 mended Spa
42. cal arcing Clean or replace any component that shows evidence of high voltage damage 4 Check flashtube connections for signs of pit ting or arcing Verify that anode and cathode connections are firmly tightened 5 Check all electrical connections for tightness and verify the absence of corrosion or electri cal arcing 6 Clean the outside surface of the lens with liq uid detergent and water Wipe it gently with a soft cloth or paper towel 7 Clean the inside surface of the lens with an FTCA approved professional plastic cleaner Wipe the lens with cheesecloth only Do not use regular cloth or paper towels A lens clean ing kit Part Number 8630801 is available from FTCA Storage No special considerations are required for long term storage of any major assembly such as the power converter flashhead photocell or any internal component Circuit boards when not installed in the equipment should be kept in anti static bags or containers Diagnostic Testing Basic functional testing procedures follow The only effective way to check out interconnected power converters is to disconnect the wire labeled master slave interconnect that is connected to TB1 4 and check them as single units as described in the subsection Checkout Procedures Sync Signal Evaluation Refer to Figure 2 5 Note that for each power con verter a master slave interconnect line and its return line are connected to TB1 4 and TB1 5 respectivel
43. ches Medium slip joint pliers Long nose pliers 8 or 10 inch adjustable wrench Triplett Model 630 NA VOM or equivalent analog volt ohm meter Multi purpose crimp tool Access WARNING STOP Before proceeding read warn ing on Page iii Disconnect the primary power before opening the power con verter enclosure or flashhead Power Converter Quick release latches secure the cover When you release these you can open the cover for internal access Flashhead The flashhead normally contains no interlock Do not open the flashhead unless you have discon nected primary power from the power converter Wait one minute for storage capacitors to drain down Open the flashhead and use a voltmeter to check that no voltage potential exists between the red and the blue wires Look for these wires on the ceramic terminal posts You may pivot the lens open by disengaging quick release latches Be careful when opening the lens to ensure that it does not strike adjacent objects Two lanyard cables secure the lens to the flashhead Mountings Power Converter Mounting and outline dimensions for the power converters are shown in Figure 2 1 Use the fol lowing guidelines for mounting the power con verter Ensure that adequate space exists around the equipment for access during installation maintenance and servicing Allow space for air flow around the power con verter You must use a bonding st
44. dule 2 Remove 3 Loosen the four screws that hold the Compo nent Bracket to the base 4 Slide the Component Bracket up off the screws Be careful of the cable and cable con nectors You may hang the Component Bracket over the edge of the connector panel to perform the remaining steps 5 Pay special attention to the orientation of the wires on the transformer and their connec tions Replace them in the same orientation Replacement 1 Replace T3 in the reverse sequence to that of Removal Note the connections to T3 as in Step 5 of the Removal and replace the wires to their connections in the same way 2 Verify that wiring matches the Information Card and restore the wire routing to its origi nal state Flashhead FT101 Flashtube Red Lens Section Removal 1 Unlatch the two latches and lift the red lens to allow access to the three screws holding the flashtube pins 2 Using a 2 Phillips blade screwdriver loosen the three screws on screw lugs directly under the flashtube which hold the flashtube con nector pins This enables you to remove the flashtube Replacement 1 Align the pins on the flashtube base with the clamps of the terminal screw lugs making sure that the red dot on the flashtube base coincides with the red wire on the support col umn directly under it 2 Insert the flashtube and settle it into place making sure the ceramic base is resting directly on the tops of the screw lugs
45. e reinstalled with this same orientation 4 Remove the outer half of the core and lift off the molded secondary winding The primary winding will remain hanging in place 5 Remove the inner half of the core Replacement 1 Reassemble the primary and secondary wind ings over the two halves of the core Attach the core to the bracket using the two long screws 2 Reattach the wires Verify that wiring is in accordance with Figure 2 8 FH 324 Flashhead Internal Wiring Coupling Transformer T102 Refer to the flashhead component locations dia gram Figure 4 2 and internal wiring diagram Fig ure 2 8 Removal and replacement are similar to the pro cedure for the trigger transformer T101 Operational Checkout Single Unit System During testing expose the photocell to normal out door daylight Carefully perform the following steps and take the suggested action if any of the responses differ from the response described Triple Unit System A system with three power converter units is a triple unit system Refer to Section 2 that shows triple unit installation You connect the top unit designated the master unit terminals TB1 1 and TB1 2 directly to the photocell The two other power converters each jumper together their ter minals TB1 1 and TB1 2 Each power converter sends a synchronization signal over the master slave bidirectional wires at terminals TB1 4 and TB1 5 to flash all lights together The top power conv
46. each power converter in turn 4 If each power converter operates correctly with the intensity control switch troubleshoot the photocell wiring or the circuits in the incorrectly operating power converter 5 Reconnect all wires FTB 324 Revision 8 07 17 2002 8 7 Checkout Procedures Use Table 3 3 to checkout the equipment Open sity select switches to AUTO which allows the photocell to control the intensity The steps in Table 3 2 or Table 3 3 are related the cover of the power converter or converters to perform the procedures To check out multiple units all units must be operating Observe and confirm the operation for each power converter individually The procedures assume the photocell to each other and should be performed together in the sequence given here If a unit does not behave exactly as described proceed to Troubleshooting the System in this section is exposed to daytime sky conditions Set all inten Table 3 2 Checkout of Power Converters with PCB1 24740xx Board Setup to Check Normal Day time Operation Response LEDs and Structure Lights Photocell in daylight 1 Intensity Select Switch in AUTO 2 Apply power pull out interlock switch plunger Setup to Check Normal Night time Operation HV Warning Light is ON NITE ERR LED I 1 is off DAY ERR LED I 7 is off PEC ALM I 2 is off WHT ALM LED I 8 is off RED ALM LED I 3 is off MKR ALM LED I
47. empt to NITE LED I 6 is on flash in white night backup default WHT ALM LED I 8 is off Remove power RED ALM LED 13 is on Turns on in three Replace wire TB2 4 flash cycles after applying power Reapply power FTB 324 Revision 8 07 17 2002 8 9 Table 3 3 Checkout of Power Converters with PCB1 24747xx Board Setup Check Normal Daytime Operation Response LEDs and Structure Lights 1 Apply power pull out the interlock switch plungers to the service position 2 Set the intensity select switch or switches to AUTO 3 Verify that the responses occur at each power converter in the sys tem Verify that the following responses occur at each The DAY LED I 5 is on It is on dur power converter in the system ing daylight HV Warning Light is on The NITE LED I 10 is off for day The NITE ERR LED I 15 is off light operation The DAY ERR 1 9 is off The MKRS markers LED I 4 is off The PEC ALM I 14 is off during daylight operation The WHT ALM LED I 8 is off The clear NEON bulb I 3 is on indi RED ALM LED I 13 is off cating the presence of trigger voltage The MKR ALM LED I 7 is off for the flash tube This bulb may The FAN LED I 12 is off blink The SYNC LED I 6 flicks on regularly May The white light is flashing at the day be difficult to see in bright daylight time high intensity for this unit T
48. er GConv rter 2 nid kd ke A EX aa a ir REY Ts 2 1 Blas head maa ERES QU US TIN UR omen Saya ama eee tee 2 1 ES essen ette pa et 2 2 Photocel less cco u DEE BIS RED ee EL EEE 2 2 Installation Wiring as nee re Ee eR E er in 2 2 Power Converter 2 2 Rlashhead Wiring ne are Eine TRE ete mie ERR IU Dee 2 3 Secure the Cables rsen rss ee 2 3 Photocell Wiring a os a LE uya a lee 2 3 Master Slave Interconnect 2 3 Installation Checkhst aee Seine a nn EEG 2 4 Section Maintenance and amp 3 1 Safety nes ssc eth arated die Ba DIN IMS Sas E S C 8 1 Preventive Maintenance s s cscs Aca a Ceo eek 8 1 OT En ee en Meder ere et ae le 3 1 Diagnostic Testing rn er cesa Str E Ia EN RU ERN ee RD ER 3 1 Sync Signal Eyaluati n 2 sc vise et bi die ecco RD ER UR ERR ASTE TATE een 8 1 EFEProblenis zoe a ERIS in Leis 3 1 Component Testing se etus a ne ee RD ee 3 2 Wiring andi Cabling z yy lu Soe La enter 3 2
49. erter places a signal on the master slave wires to force the system to flash in white mode white night backup if the top red lamp fails to flash A lamp going out in a tier of red incandescent marker lights indicates a marker alarm but does not cause back up white night operation Each power converter may control and monitor a tier of steady burning marker lights In some installations there may be a power converter that does not have associated marker lights Marker Light Programming The 2 4740 XX timing board PCB1 has jump ers switches labelled MKRO and MKR1 which are cut opened for programming the number of mark ers installed on a tier The 2 4747 XX timing has software programming for selecting the monitoring of marker lights The XX in the 2 4747 XX part number label shows the software program number The program is set at the factory Testing Each Unit To test each unit in a triple unit system use the following procedures 1 Disconnect the wires labeled master slave interconnect at TB1 4 and 1 5 2 Test this unit as described in Section Sin gle Unit System Photocell Testing The photocell is wired directly to the first master power converter at TB1 1 and TB1 2 1 First disconnect the photocell The single unit or triple unit system should revert to nighttime operation in about 45 seconds 2 Disconnect TB1 4 and TB1 5 on each power converter 3 Operate the intensity control switch on
50. form a twisted pair at the rate of 12 twists per foot FTB 324 Revision 8 07 17 2002 2 8 Alarm Relay Wiring The wiring for alarm relay connections in Figure 2 6 minimizes the possibility of damage caused by high voltage transients Installation Checklist Complete the following steps before applying power to the lights 1 Inspect all equipment for damage 2 Verify the received equipment against the packing list to ensure completeness 3 Power Converter Mounting Position and mount each unit correctly allow ing adequate clearance for opening the covers Use the following checks Ensure that the case is mounted upright is water tight and grounded Check hardware inside the case to ensure that the mounting screws and nuts are tight Ensure that only the bottom of the case has drain holes and that they are clear Ensure that no holes are punched or drilled on the top surface of the case Ensure that air can flow around the case Mount the power converter away from radio frequency interference RFT 4 Flashhead Mounting Ensure that the flashhead lens can be opened without striking other objects Level and aim the flashhead 5 Photocell Mounting Locate photocell where it views unob structed polar sky with no direct or reflected artificial lighting striking it Mount the photocell vertically on the top end of a vertical length of conduit to pre vent water from entering t
51. he CONF confirm LED I 11 flashes on The associated red incandescent after each strobe flash May be difficult to see markers are off in bright daylight Setup Check Normal Nighttime Operation Response LEDs and Structure Lights 1 Place an opaque blocks all light cover over the photocell Several seconds may pass before the photocell responds to the dark ened condition after power is applied 2 Set the intensity select switch or Switches to AUTO 3 Apply power pull out the interlock switch plungers to the service position Verify that the responses occur as in Daytime The MKRS markers LED I 4 is on previous except for those in the following list if markers are associated with the The DAY LED I 5 is off power converter being observed The NITE LED I 10 is on for night operation The red light is flashing at the night time intensity for this unit associated red incandescent markers are on Setup Check Normal Default Night Operation Response LEDs and Structure Lights Perform the following procedure for its power converter in a multiple unit system 1 Cover the photocell with an opaque blocks all light cover 2 Set the intensity select switch or switches to AUTO 3 Remove power 4 Disconnect the purple wire on TB2 6 This fails the red flash head 5 Reapply power Verify that the following responses occur as com The system is fl
52. he switched power converter FTB 324 Revision 7 06 05 2002 In Night Mode It does not send a back up signal It operates the red light only It clears its red alarm if it has one and then re establishes the alarm It does not affect the other units In Day Mode It ignores the master slave interconnect line sync and back up signals It operates the white light only When a top red light alarm occurs at night the back up signal from the failing master power con verter switches all units to night intensity white operation With the preceding information you can determine master unit in the system is caus ing the entire system to run in white night inten sity 3 18 This page is intentionally blank 3 14 Revision 7 06 05 2002 FTB 324 Section 4 Recommended Spare and Replaceable Parts Power Converter Parts Table 4 1 lists the major replaceable parts Flashhead Parts Table 4 2 lists the major replaceable parts Photocell Parts The part number for the PEC 510 Photocell is PN 1855001 Repackaging Equipment must be returned in a container that provides maximum protection during shipping and handling If the original cartons and packag ing material are no longer available package the power converter and flashhead separately as in the following subsections Power Converter Package and ship the power converter in an upright position that is with the feet do
53. he unit 6 Marker Mounting Sidelights Ensure that marker junction boxes are mounted with the weep holes down Ensure that the junction boxes are water tight 7 Power Converter Wiring Examine the installation drawings and use the following checks Check for proper incoming service voltage Wire each unit according to the instruc tions In triple installations all power convert ers must be wired to the same electrical phase Wire all three power converters to one 20 amp circuit breaker Check all electrical connections for tight ness Check all terminal strip connections for tightness Ground the power converter case to the site lightning ground system Wires at TB1 4 and TB1 5 should be daisy chained as a twisted pair between the master power converter and the slave units The rate of twist is 12 per foot If a shielded cable is used ground the shield Ensure that TB1 4 is connected to all TB1 4 connections on all units and TB1 5 1s similarly connected 8 Flashhead Wiring Protect the top flashhead against light ning strikes Ground the flashhead Check the wiring of the flashhead cable to the flashhead Secure the flashhead cable to the tower Support and tape the flashhead cable to prevent its movement by the wind 9 Photocell Wiring Connect the photocell to the master power converter the black wire to TB1 1 and the white wire to TB1 2 2 4 Revision 8 07 17 2002
54. hts 1 Place opaque cover over pho tocell block all light 2 Intensity Select Switch in AUTO 3 Remove power 4 Remove fuse F4 removes power to marker lights 5 Apply power Responses are the same as those for normal Red light is flashing at night intensity nighttime previous except for the following Red markers are off MKR ALM LED I 9 is on Remove opaque cover over photocell Remove MKRS LED 12 is on power Replace fuse F4 Reapply power Setup to Check White Alarm for Day Operation Response LEDs and Structure Lights 1 Remove opaque cover over photocell 2 Intensity Select Switch in AUTO 3 Remove power 4 Disconnect black wire from TB2 4 5 Reapply power Responses are the same as those for daylight CONF LED I 5 is off previous except for the following White strobe is off DAY ERR LED I 7 is on Remove power WHT ALM LED I 8 is on Turns on in three Replace wire on TB2 4 flash cycles after applying power Reapply power Setup to Check Red Alarm for Night Operation Response LEDs and Structure Lights 1 Place opaque cover over pho tocell block all light 2 Intensity Select Switch in AUTO 3 Remove power 4 Disconnect purple wire from TB2 6 5 Apply power Responses are the same as those for normal CONF LED I 5 is off nighttime previous except for the following you leave the system on it will next att
55. ight at 40 flashes per minute during the day At night it switches to a red light at 20 flashes per minute and turns on steadily lit markers The power converter is usually installed near ground level The FH 324 Flashhead is a dual white red flash head Together the lenses and base enclose the flashtubes and other interior components Latches secure the lenses which tilt open for internal access Position the flashhead to comply with FAA regulations in Advisory Circular 70 7460 1K Obstruction Lighting and Marking A flashhead cable interconnects the power con verter and flashhead When FTCA Part Number 6340 or equivalent cable is used the two may be separated by up to 600 feet 180 meters Consult the factory when a greater separation is neces sary The photocell is connected directly to the main panel of the power converter at TB1 1 and TB1 2 to control switching between day and night opera tion It can be located up to 100 feet from the power converter Longer distances are possible with heavier wiring Specifications Electrical specifications are listed for a single power converter Physical PC 324 H x W x Depth Wet 14 00 x 16 75 x 8 44 in 51 lbs 355 6 x 425 5 x 214 4 mm 23 kg FH 324 Flashhead x Diam Wet 37 25 x 18 25 in 31 lbs 946 x 463 mm 16 4 kg PEC 510 Photocell H x W x Depth 3 06 x 2 58 x 1 02 in 77 7 x 65 5 x 2 59 mm Aerodynamic Wind Area Flashhead 1 86 ft 2 17
56. ingle Unit 8 7 Triple Unit System Eee RE Ue 3 7 Testing Each Unites mr 8 7 photocell ii ee Janet ERRARE etd GA acd an eat ac ed tbe 8 7 Checkout 4 8 8 Troubleshooting the 3 11 Using the Intensity Select Switches Finding the Failing Unit at Night 3 13 Section 4 Recommended Spare and Replaceable 4 1 Customer Service c scuta rece ha e s beet eh tO eere 4 1 Ordering Parts tet vede eb lieta Bae dd eeu were 4 1 Power Converter Parts san Le Een dp dE e E eS E Eu weed 4 1 Flashhead Parts re ne Re Rss ee E rS S 4 1 Bhot cell Parts nes eH nue e eese ee dH EE mere eee 4 1 Returning 1 4 1 Repackaging u seien EE Wig x ERE Va RN LE LR CY e E V 4 1 Power Converter cor er tec E oe SS 4 1 ee REY qs bled ERES 4 1 Index s cett tcs eo RS ae Et huele LER e E ES E EN L1 FTB 324 Revision 8 07 17 2002 v List of Figures Figure 1 1 View of TB1 Wiring Functions for PC 824 Figure 1 2 PCB1 Pictorial 21700 sahen Figure 1
57. ivalent around the cable and tower leg at 5 foot minimum intervals 1 5 meters Space the cable one inch away from direct contact with a leg flange or and edge 2 Wrap three full turns of one inch Scotchrap Filament 890 tape or the equivalent over the Scotchrap 50 tape 3 Wrap four full turns of two inch Scotchrap 50 tape or the equivalent over the Scotchrap Fil ament 890 tape 4 Perform steps 1 through 3 also directly above and below any tower leg flanges that the cable may cross Photocell Wiring For triple unit lighting each individual lighting unit requires a power converter and flashhead but the photocell is connected to only one unit ina triple unit This unit is called the master unit the others are called slaves Connect the photocell to TB1 1 and TB1 2 on the master power converter The photocell terminals TB1 1 and TB1 2 on the slave power converters are jumpered together Also you connect the mas ter unit to which the photocell is directly con nected to the top flashhead and top tier of markers Master Slave Interconnect Wiring In a triple unit system the master unit and slave units communicate over the master slave inter connect wiring The master and slave power con verters are connected together for communication at the master slave interconnect terminals TB1 4 and TB1 5 on the main panel The recommended size wiring for this purpose is 16 AWG Twist the wires together to
58. larm Power converter failed to switch the day night mode to the opposite state within a 19 hour period perhaps due to its input WHT ALM 18 On when a white alarm occurs RED ALM 113 On when a red alarm occurs MKR ALM I7 On when marker alarm occurs a marker or markers are out FAN I12 Not used SYNC I6 Flashes when flash control output is on Flashes regularly during normal flashing operation of the power converter CONF I11 Confirm flashes after each valid flash DAY I5 The circuit board is in day mode NITE 110 The circuit board is in night mode MKRS I4 PCB1 is commanding markers to be on NEON 13 Trigger power neon 120VDC trigger power is being supplied to the circuit board TD I1 Modem is in transmit mode RD I2 Modem is in receive mode Table 1 4 1 24747xx Jumper Settings Jumper Jumper Label Board Description Name INT RED JP2 Not cut all models RES PEC JP1 Cut to allow PCB1 to recognize a resistive photocell connection TEST LTV DAY NITE RED TP1 to TP5 Test points for factory use only Photocell Power Converter Main Panel In a single unit installation you connect the pho tocell to TB1 1 and TB1 2 on the main panel of the PC 324 In a triple unit installation you con nect it to TB1 1 and TB1 2 of the first power con verter the master unit Other units are slaves In triple unit installations the first PC 324 is the one that operates the top flashhead In triple unit installations 1 1 and 1 2 of slave 1
59. nsformer Voltages Terminals Voltage Range TB3 1 to TB3 9 900 1050 volts AC PCB1 J5 8 to chassis 100 120 volts DC PCB1 J3 1 to J3 2 22 26 volts AC f this AC voltage is substantially below the specified minimum value check tuning capacitor C4 Trigger Coupling Transformer T3 The coupling transformer should not have open windings An ohmmeter will indicate a shorted winding because of wire size Check with an ohm meter at the wire terminals Check upper and lower ferrite core pieces for cracks Red Light Module Components Marker Relay K5 24 VDC 470 ohm coil Replace the entire Red Light Module to replace the relay Marker Sense Transformer T1 on PCB3 The Marker Sense Transformer is mounted on PCB3 If you suspect the transformer replace the entire Red Light Module Flashhead Component Testing The following subsections describe component testing for the components in the flashhead Flashtube FT101 Visually inspect the flashtube for broken elec trodes cracked glass and the solder connections of the pins A darkened envelope does not neces sarily mean the light output would be unaccept able Before concluding that a faulty flashtube is responsible for an inadequate flash first rule out other possible causes such as weak or absent dis charge voltage or triggering pulses Trigger Transformer T101 The resistance of the secondary winding potted assembly should be approxim
60. ocell E en ay Flas ossible photocell Error Jumper on TB1 amp 2 P ROBI Board 2 units missing Intensity Select Switch Red OK Possible photocell Error Photocell Intensity Select Switch _ _ Photocell cable connected to TB1 1 Units mixed red and white 4 os Intensity Select Switch and 3 all units will be in night mode Master slave interconnect cable con OK OK Units not flashing together PCB1 in one unit nected to TB1 4 and TB1 5 No No No lights Main power line Using the Intensity Select Switches Finding the Failing Unit at Night For normal operation set the intensity select switches on each unit to AUTO In AUTO an intensity signal through the master slave inter connect wires on TB1 4 and TB1 5 controls the day or night intensity level of all power converters and associated lights Any power converter may send the sync signal on these wires which flashes all lights at the same time Normally all units on a structure have backup enabled Should a flash head fail in AUTO night operation the power con verter with the failing flashhead sends a back up signal to the other units on the interconnect wires If the failing flashhead is the top most and is correctly connected to the master all strobes will go into white back up mode You can switch any unit to day or night operation manual operation with its intensity select switch In manual operation the following condi tions occur on t
61. ore tightening the mounting bolts Failure to do so could result in serious damage to the base when you tighten the bolts Photocell Mounting and outline dimensions for the photo cell are shown in Figure 2 3 Use the following guidelines Locate the photocell where it has an unob structed view of the polar sky It must not view direct or reflected artificial light photocell may be supported directly by electrical conduit Mount the photocell vertically on the top end of a vertical length of conduit to prevent water from entering and damaging the unit Red Light Fixtures Obtain outline clearance and mounting details for L 810 markers from separate drawings pro vided by FTCA or others This manual does not contain information about installing red markers Installation Wiring NOTE Only general information for a typical installation is presented here and more specific information may be needed for your site In particular because the L 810 marker side light lighting components for red nighttime lighting are often purchased from others and have many varia tions only general hook up information for flash ing and monitoring the red lights is included This manual may not contain all the information about installation wiring required for your site Consult any installation drawings prepared espe cially for your site or supplied with the equip ment Site installation drawings should take precedence
62. ossibilities by inspection and manually exercising the arma ture You can confirm a defective coil by measur ing the resistance To measure the resistance of relay coils first remove the wires from one of the connections to the coil terminals on the relay Mode Relay K2 24 VDC 290 ohm coil Discharge Relay K3 120 VAC 290 ohm coil Timing and Trigger Board PCB1 Replace this board with one known to be in good condition Note that the PCB1 board part num bers in this manual are either 24740xx or 24747xx Call Customer Service for technical assistance at 1 800 821 5825 PCB1 part numbers vary Be certain that you have the complete number available which is imprinted and written on your board 3 2 Revision 8 07 17 2002 FTB 324 HV Rectifier Board PCB2 Replace this board with one known to be in good condition Alarm Relay Board PCB5 PC 324 Replace this circuit board with one known to bein good condition Sense Module PCB4 Replace this circuit board with one known to be in good condition Discharge Resistor R1 The measured resistance of this component should be 35 000 ohms Burst Resistor R2 The measured resistance of this component should be 250 ohms two 500 ohm resistors in par allel Power Transformer T1 To test this transformer first remove PCB1 and PCB2 Apply power to the unit and measure sec ondary winding voltages at the terminals indi cated in Table 3 1 Table 3 1 T1 Tra
63. ove or alter any safety interlock switch FTB 324 Revision 8 07 17 2002 ni Table of Contents Page Front Matter eco ree v aee air Dee rent C epe Sete ee Ros tide ees ii Section 1 FTB 324 Introduction and 1 1 ER DICES olan ey EE AE EEEE ENEE EEAS 1 1 Specifications oe Rete hiya uy Ener mern Dre CE CIEN CERE 1 1 System Operations RS aoa ei 1 1 PCB1 Timing and Trigger 1 1 Setume Up POBI cie DeC UMEN EDU ME Qu 1 2 F ncti n Indicat rs vou ee UR eed AAY E LEAD 1 2 POB124T40xx i Ree ERRORS CROCI Ee RE CIR EET E 1 2 PCB1 24747xx Eagle 1 2 Photocell i eut Bei Ben CEN ene 1 4 Power Converter Main Panel Alarms and 1 1 4 Master Slave 4 1 5 Section 2 Outline Mounting 2 1 ein neben E EXE RE HAST 2 1 TOOLS Pain nee ee REIN B RU NI RR I ER ee Hed RR at 2 1 Power Converter steil ar We AUS en Beh ernsten 2 1 o ouo Leda bed Pura ci dri Ed bes f 2 1 Pow
64. r alarm on when marker alarm occurs a marker markers are out FAN 14 Not used SYNC 110 Flashes when flash control output is on Flashes regularly during normal flashing operation of the power converter CONF 15 Confirm Flashes after each valid flash DAY 111 The circuit board is in day mode NITE 16 The circuit board is in night mode MKRS 112 PCB1 is commanding markers to be on NEON 113 Trigger power neon 120VDC trigger power is being supplied to the circuit board 1 2 Revision 8 07 17 2002 FTB 324 Table 1 2 PCB1 24740xx Jumper and Switch Settings Jumper Jumper A or Switch or Description Label Quite INT RED 1 Uncut all models RES JP2 all models to allow usage of a resistive photocell ALRMON2 Uncut JP4 Cutto disable white light backup for failure of the flashhead Installation dependent FAILCLOSE JP5 Uncut Selects the marker lamp fail threshold Chart etched on 24740 board shows ALARM AT thresholds MARKER Parameter in Board Software 4ORLESS Bulbs Installed SW1 2 MRK1 SW1 1 MRKO Alarm At MRKO SW1 1 0 OFF OFF No alarms 2 OFF ON One bulb lit 3 ON OFF Two bulbs lit 4 ON ON Three bulbs lit MARKER Parameter in Board Software 50RMORE Bulbs Installed SW1 2 MRK1 SW1 1 MRKO Alarm At 0 OFF OFF No alarms 5 OFF ON Four bulbs lit 6 ON OFF Five bulbs lit 8 ON ON Six bulbs lit MRK1 SW1 2 Selects the marker lamp fail threshold See the chart FO
65. r operating in the resistance mode The following method assumes an instru ment with a X100 resistance scale Place the meter leads across the terminals of an isolated no electrical connections to other cir cuits and fully discharged capacitor Observe the subsequent needle movement If the capacitor is functional the needle initially indicates zero ohms but soon begins to rise to higher indicated values A capacitor that is dis connected from other circuitry is defective if it does not exhibit this behavior The length of time it takes the needle to reach the 1 megohm reading about 65 full scale is a measure of the capaci tance For example the time is about 5 seconds for a 10 mfd capacitor or 10 seconds for a 20 mfd capacitor and so forth Manually discharge the capacitor before repeat ing this measurement This test may not detect a malfunction that occurs only at high voltage A bank of capacitors connected in parallel may be checked as a single unit If the test indicates a short circuit the individual capacitors have to be disconnected and checked separately A shorted capacitor is indicated if the resistance does not rise above zero after several seconds of measure ment Burst Choke L1 The measured resistance of this choke should be approximately seven ohms Relays A malfunctioning relay may have faulty contacts a sticky mechanism a bad ground or a defective coil You may determine the first two p
66. rap on a bolt through the power converter case leg Connect the strap to the site grounding system FTCA does not furnish mounting hardware unless you order it as part of an installation kit Flashhead Mounting and outline dimensions for the flash head are shown in Figure 2 2 Protect the flash head from lightning strikes The flashhead may be mounted to painted or unpainted surfaces Use the following guidelines Use a lightning rod extended above the flash head to protect it when it is mounted at the uppermost part of the structure FTB 324 Revision 8 07 17 2002 2 1 Avoid locating a lightning rod where it would prevent tilting the lens open or interfere with access by maintenance or service personnel Use a bonding strap when mounting the flash head to the structure and fasten the bonding strap to the flashhead with the mounting bolt that goes through the leg that contains the ground connection Leveling The flashhead must be level for correct vertical beam alignment Two leveling vials are perma nently attached to the flashhead assembly When the flashhead is level bubbles in both leveling vials are centered For leveling use the following guidelines If adjustment is necessary raise the appropri ate mounting foot with shims or washers Raising one foot by 1 16 inch 1 6 mm tilts the beam about 1 2 degree Take extreme care to ensure that all four feet rest snugly against a firm mounting surface bef
67. re and Replaceable Parts Internal electrical wiring diagrams are provided in Section 2 and on the Information Card that is fastened inside the power converter cover Note the location and color of all wires that you disconnect When you replace the wiring after you replace the components ensure that the wiring conforms exactly to the wiring diagrams The general procedure for removing components is a logical one and is as follows 1 Obtain access to the component in ques tion a Disconnect completely or partially the wiring to components first that pre vent clear access b Completely remove or relocate these components 3 Disconnect the wiring to the component that you want to replace 4 Remove this component 5 Replace everything in the reverse order first the component then the wiring then the components that allowed you access In some cases you may have to place some wires on the component before you fasten it in place then replace the remaining wires Most components are relatively easy to access for removal Only those that are more difficult are described Power Converter Capacitors Before removing or replacing a capacitor always ensure it is discharged by checking with a voltme ter directly across the terminals Discharge a capacitor by placing a resistance 25 watts 10 000 ohms or greater between its terminals Direct shorting may damage the capacitor and connect ing the terminals to the equipment
68. responses denote a light failure dur The CONF flash confirm LED ing normal nighttime operation Verify that they 1 11 is off occur as compared to those in Check Normal These denote a light failure during nor Daytime Operation except for those in the follow mal nighttime operation ing list after three flash cycles NOTE If you leave the system on it will DAY MODE LED I 5 is off next attempt to flash in white night The NITE MODE LED I 10 is on backup mode default The RED ALM LED I 13 is on The power Remove power converter cycles executes 3 internal flash Reconnect the purple wire to TB2 6 cycles before turning on the Red Alarm Reapply power The SYNC LED I 6 flicks on regularly Remove cover from photocell Verify operation as in Daytime Operation Reapply power Troubleshooting the System Effective troubleshooting begins with careful observations of operating behavior often leading directly to the cause of a problem Diagnostic pro cedures in this subsection are divided into two categories unit level originating in a single unit and system level problems affecting all units in a triple unit system in the same way However in a triple unit system some unit level malfunctions could cause problems involving the entire system FTB 324 For example if one light in a triple unit system fails to flash Table 3 4 directs you to Table 3 5 the troubleshooting guide for a unit level problem b
69. screws Replacement 1 Slide the circuit board under the terminal block screws and tighten them 2 Replace the Red Light Module 3 Verify that wiring matches the Information Card and restore the wire routing to its origi nal state PCB4 Sense Module Removal and replacement are similar to those in Section K2 Mode Relay Red Light Module Removal 1 Remove the external wires connected to TB5 2 Unplug all harness connections to the Red Light Module 3 Loosen two screws in the base that fasten the Red Light Module to the base 4 Remove the Red Light Module Be careful of components and connectors 5 Disconnect the ground wire from the back of the module Replacement 1 Replace the Red Light Module in the reverse sequence to that of Removal 2 Verify that wiring matches the Information Card and restore the wire routing to its origi nal state FTB 324 Revision 8 07 17 2002 8 5 R2A and R2B Burst Resistors Removal and replacement are similar to those in Section K2 Mode Relay T1 Power Transformer Removal 1 Remove the Input Power Module 2 Remove the four screws holding the trans former to the base plate and remove the trans former Replacement 1 Replace the power transformer in the reverse sequence to that of Removal 2 Verify that wiring matches the Information Card and restore the wire routing to its origi nal state T3 Trigger Coupling Transformer Removal 1 Remove the Red Light Mo
70. ut not a system level problem For each symptom the troubleshooting guides list one or more probable causes in descending order of probability Continuing with our example assume that the light fails to flash during the day No in column 1 and at night No in column 2 High voltage is absent No in column 3 but low voltage is present OK in column 4 This condi tion is described in the fourth row of Table 3 5 Revision 8 07 17 2002 3 11 The last column lists possible causes The most probable cause is a shorted capacitor the second most probable cause is a shorted flashhead cable and so on When you trace a problem to a specific compo nent see Subsection Power Converter Component Testing and Subsection Component Removal and Replacement in this Section Table 3 4 Selecting the Correct Troubleshooting Guide Single Light Triple Unit System System Units Affected Differently Usually Only One All Units Affected the Same Way Failing Unit Unit Level Problem System Level Problem Troubleshooting Table 3 5 Table 3 5 Table 3 6 Guide Table 3 5 Unit Troubleshooting Guide Flash Conditions Other Genditigns Probable Causes All Units Unless Specifically Indicated Day Night HV LV t Flashhead cable connec Transformer No No ew tions BR1 Bridge T1 Transformer PCB1 No No No No Blows Fuse F1 Varistor MOV T1 Transformer No No No No F1 Fuse T1 Tr
71. wnward Pad the power converter so that the feet cannot penetrate the box during shipment Box each power converter separately using a double thick ness cardboard container and adequate padding Do not drop Use appropriate warning labels on the outside of the container Flashhead Package and ship the flashhead in an upright position Box each flashhead separately and use adequate padding Attach the flashhead base to a plate measuring 19 inches square e g 3 8 inch plywood Use a double thickness cardboard or wood container which is 19 inches square by about 32 inches high inside dimensions Use soft packing or a cardboard collar around the lens to prevent tipping inside the container Do not drop Use appropriate warning labels on the outside of the container FTB 324 Revision 8 07 17 2002 4 1 Table 4 1 Power Converter Major Replaceable Parts Item Description Part Number BR1 Diode Bridge 6902806 C2A C D Capacitor 70 mfd 6720401 C2B Capacitor 40 mfd 6386503 C3 Capacitor 1 mfd 6848202 C4 Capacitor 3 mfd 6577903 F1 F2 Fuse Power MDL8 14901931 F4 Fuse Marker MDL5 4900345 F5 F6 Fuse MDL1 4900337 HV Neon High Voltage Light 4902317 K2 24V Relay Mode 18000494 K3 120V Relay Discharge 18000493 L1 Choke Burst 4850601 L2 Choke Flash 4175200 LS1 Phone Line Surge Protector 2865301 M
72. y All units place a sync pulse on the line the first sync pulse on the line synchronizes the remaining lights to flash all the lights at the same time in each power converter gener ates a sync pulse The width of the sync pulse con trols the mode of operation The top light must be operated by the master power converter and the photocell must be con nected to the master power converter In the event of a top red light failure at night the master power converter places a back up signal on the line that causes all connected units to flash the white lights at the correct night intensity The sync signal is a pulse and difficult to evaluate with a meter Different meters respond differ ently You may detect the sync pulse as an instan taneous movement of the meter indicator A digital meter with a max min function may cap ture part of the pulse This is generally a suffi cient indication of a pulse being present A 24V pulse of 16 ms width might read 12V on a 100 ms capture time of max min function RFI Problems Radio frequency interference RFI can cause a light to flash intermittently at the wrong rate or at the wrong intensity RFI can enter the light by any wire to or from the unit For example FTB 324 Revision 8 07 17 2002 3 1 RFI on primary power wires could cause errors in flash rate and intensity RFI on the master slave interconnecting wire could cause a light to switch to and remain in

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