Uni-Directional Voltage-Powered User`s Manual
Contents
1. le Specifications Use of Generic 8 Contact Information Table of Contents List of Figures List of Tables General Description Access Equipment Specifications Installation Mounting the Power Supply Primary Power Hookup Control Line Hookup Remote Control Hookup Functional Description Applications Circuit Board Programming Operation SLC Control Three Levels of Intensity From a 3 Step CCR Three Levels of Intensity From a 5 Step CCR Single Intensity Setup Theory of Operation Maintenance Troubleshooting Status Lights Normal Indications Problems Evolving Problems Replacing Flash Head Components Flash Lamp Trigger Transformer Replaceable Parts At Installation iii 1 2 2 12 15 04 02 2015 1 2 2 LIST OF FIGURES PAGE la Power Supply 1 1b Flash Head 1 1 Co mounted2. 18 14a amp b Flash Head Component Identification 18 15 PCB 1 Status Lights 19 16 PCB 2 Status and Safety Lights 19 17a Front View of Flash Head 24 17b Flash lamp Terminals 24 18a Flash Head Bracket 26 18b Trigger Transformer Replacement 26 19 Component Location Diagrams 27 LIST TABLES Table 1 Three Step CCR 12 Table 2 Five Step CCR 12 Table 3 Relay Mode Conditions 23 Table 4 Replaceable Parts 27 iv PSUV 101 102 04 02 2015 1 2 2 GENERAL DESCRIPTION A flashing runway approach light from SAL Technology consists of a power supply and a flash head The power supply
3. 56 5 25 7 PSUV 102 Slave Power Supply Co mounted Figure 1c Dimensions 19 5H x 16W x 14D 495 x 406 x 356 Weight 51 5 23 3 OPERATIONAL Voltage rms 120 or 240 Volts 60 Hz 230 Volts 50 Hz Power Watts 150 Ave 290 Peak Flashes Per Minute 120 Intensity Effective Candelas total beam spread High 8000 to 22500 Med 800 to 2250 Low 160 to 450 Beam Spread 30 Horizontal 10 Vertical AVAILABLE OPTIONS Must be factory installed Remote Control by a Series Lighting Circuit Flash Monitoring Elapsed Time Meter PSUV 101 102 04 02 2015 1 2 2 INSTALLATION Installation consists of mounting the power supply onto previously prepared supports and making electrical connections Some installation details could depend on site drawings and specifications originated by others Basic requirements are given below If you are installing a system with sequentially flashing lights you should place each light in its assigned position Light 1 is intended to be nearest to the runway threshold Light 2 is intended to be next and so on A light that has not been placed in its intended position can be reprogrammed using the information in Figure 10 MOUN
4. Figure 1a may be either a master unit or a slave The catalog designation for a Master Power Supply is PSUV 101 A Slave Power Supply is PSUV 102 The Flash Head Figure 1b in either case is FHUD 109 The flash head may be attached directly to a power supply enclosure co mounted as in Figure 1c or installed separately and connected by up to 100 feet of suitable cable This equipment is classified as a unidirectional discharge flasher strobe that operates from 120 or 240 V 60 Hz specify when ordering It can also be provided to operate at 230 Volts 50 Hz It is specifically designed and tested to meet the requirements for L 849V applications as defined by the FAA in Specification for Discharge Type Flashing Light Equipment AC 150 5345 51A L 849V is the designation applied by the FAA to voltage driven Runway End Identification Lights REIL L 849V lights from SAL Technology are certified by third party testing under the FAA s Airport Lighting Equipment Certification Program ALECP These lights also meet the photometric and functional requirements for discharge flashers in high or medium intensity precision Approach Lighting Systems ALS Figure la Power Supply PSUV 101 or 102 Figure 1c Co Mounted Unit Figure 1b Flash Head FHUD 109 ACCESS The power supply cover is secured by quarter turn latches with padlock provisions on the two front corners of the enclosure A co mounted unit also has two self releasing l
5. Wire size can be based on mechanical considerations alone because the electrical load is so low Remote Switch Master Unit Figure 7 Remote Control Switch Circuit A Series Lighting Circuit SLC can also be used for remote control This requires an optional module in the master unit and should be specified when the equipment is ordered The wiring connections are shown in Figure 8 The L 823 cord set shown from terminals A amp B is part of the optional equipment but the L 830 1 Isolation Transformer shown in Figure 8 is usually provided by others This option may require initial setup adjustments in order to attain flash intensities at specific levels of SLC current Refer to the setup procedures on Pages 12 through 15 Series Lighting Circuit MASTER UNIT ISOLATION TRANSFORMER L 830 1 35 45 WATT 6 6 6 6 AMPS L 823 i CORD SET 1 EB I poe rM erac E E er ee 1 2 3 4 5 6 olololololololo onononogonongononon1o Figure 8 Remote Control By A Series Lighting Circuit PSUV 101 102 04 02 2015 1 2 2 FUNCTIONAL DESCRIPTION Each power supply whether it is a master unit or a slave has an identical PCB 1 circuit board for timing and control functions These circuit boards communicate with one another over an interconnecting control line System power for up to seven lights is typically controlled by a circuit breaker that is part of a control module located in the master
6. 1 2 Mounting Details 3 3 Installation Wiring Guidelines 4 4 TB1 Labeling 5 5 TB1 Control Line Connections 6 6 System Interconnection Wiring 7 7 Remote Control Switch Circuit 8 8 Optional Series Circuit Hookup 8 9 1 9 9b Programming Switch Detail 9 10 Circuit Board Programming 10 11a Control Module 11 11b Optional Module For Series Circuit Control 11 12a amp b Flash Head Sealing 17 13 Power Supply Component Identification
7. 10 Set the CCR to Step 2 e The MED LED should turn off If it does not adjust the MED potentiometer incrementally CCW until the MED LED turns off The LOW LED should remain on and the unit should be flashing at Low intensity Set the CCR to Step 1 e There should be no change from the conditions in Step 12 It is advisable to run through the CCR steps once more to verify that switching is correct Make any necessary adjustments to the potentiometers to achieve correct switching by repeating the steps above Leave the Control Switch in the REMOTE position for continuous control by the CCR No adjustments are required at a slave unit 15 1 2 2 04 02 2015 Set Up Procedure for Single Intensity Operation THE FOLLOWING INSTRUCTIONS REQUIRE SERVICING THE EQUIPMENT WHILE POWER IS APPLIED USE APPROPRIATE CAUTION WHILE ACCESSING INTERIOR COMPONENTS The procedure for single intensity operation is essentially the same for all CCRs whether they are three or five step regulators Style 1 or Style 2 Most single intensity runway approach strobes operate at High intensity although the system could also be set up for a single intensity of Medium or Low For single High intensity operation 1 Open the cover to the master unit and set the Interlock Switch to the service position pull up on the stem of the switch Flip the Circuit Breaker to the ON position up 3 Turn the Control Switch to REMOTE At PCB 201
8. Correctly Most problems that develop after a system has been working correctly affect only one light These typically fall into one of the following categories A No Flash B Wrong Intensity C Skipping Flashes The method of fault isolation prescribed below consists mainly of following the tips leading to a specific component and verification by temporarily exchanging that component with one known to be working correctly A No Flash 1 Blown fuse in the power supply 2 No High Voltage evidenced by DS1 DS2 amp DS3 on PCB 2 not being lit a PCB 2 defective b T1 Power Transformer defective c Bank capacitor shorted Call 1 603 598 4100 for assistance 3 No Trigger evidenced by no audible snap a Change PCB 1 if DS7 is lit steady b Change PCB 2 if DS7 on 1 is not lit then change PCB 1 if DS7 remains unlit c Change T101 trigger transformer in flash head if the problem is yet unresolved 4 Defective flash Lamp Change out the flash lamp 5 SW2 8 on PCB 1 incorrectly set Be sure this switch is in the off position 23 04 02 2015 1 2 2 EVOLVING PROBLEMS Cont B Wrong Intensity l 055 054 or 053 do not agree with the mode indications at the CMV 111 a Change out PCB 1 b Change out PCB 101 DS5 DS4 amp DS3 agree with the CSM 111 yet the flash intensity is wrong a Check K1 amp K2 for correct switching responses as shown in Table 3 below Table 3 Mode Relay
9. See Figure 11b adjust all three potentiometers LOW MED amp HIGH fully counter clockwise CCW Set the CCR to the current level at which you want the light to start flashing must be at least 5 2 amperes Adjust the HIGH potentiometer CW until the adjacent LED comes on The strobe will begin flashing at High intensity Do not adjust the MED or LOW potentiometers They must remain fully CCW Set the CCR whether 3 step or 5 step to the next lower step The HIGH LED should extinguish and the strobe should stop flashing If it does not adjust the HIGH potentiometer incrementally CCW until it does Test the adjustments by observing the results as the CCR is switched from one step to another 10 Leave the Control Switch in the REMOTE position for continuous control by the CCR 11 No adjustments are required at a slave unit Contact the factory for other custom flash control conditions PSUV 101 102 16 1 2 2 04 02 2015 1 2 2 THEORY OF OPERATION A xenon capacitive discharge light is often referred to as a strobe A flash is produced when sufficient electrical energy is abruptly dumped into a lamp filled with xenon gas The gas which is normally nonconductive must be brought to a conductive state for a flash to occur This requires applying a pulse of high amplitude a triggering pulse to the lamp The energy producing the flash is stored in a bank of capacitors connected to the lamp electrodes
10. The capacitors charged to a relatively high potential discharge through the lamp when the internal gas becomes conductive SAL Technology strobes consist of two major subassemblies called power supplies and flash heads A power supply converts external ac primary power to dc direct current that is fed to a bank of energy storage capacitors bringing them to a charge potential of about 1000 Volts dc 500 Volts Most runway approach strobes must be capable of 3 levels of flash intensity High Medium and Low Hlash intensity levels are changed by switching the lamp to different values of bank capacitance Flash head components consist of a sealed beam xenon lamp a triggering transformer and additional minor circuitry The flash head is connected to the power supply by a short harness if it is co mounted or by a cable when it is installed remotely The harness cable connects the bank of capacitors in the power supply to the anode and cathode flash lamp electrodes The maximum voltage on the anode conductor is 500 Volts dc The maximum voltage on the cathode conductor is 500 Volts dc The total lamp voltage at discharge is therefore 1000 volts The harness cable also carries a low level triggering pulse that is applied to a small transformer in the flash head where it is boosted to a voltage level high enough to trigger the flash lamp into its conductive state A coupling transformer located in the power supply provides an intermediate signal
11. boost that improves triggering when a very long flash head cable is used A REIL system has two lights that flash simultaneously Some approach lighting systems have as many as 21 lights that flash sequentially The practical limit for SAL Technology sequential flashers is even higher The point is that these lights must always operate as an integrated system This requires a form of communication between the lights The method used in SAL Technology systems is an encoded signal that is distributed by an interconnecting control line The encoded signal carries timing and flash intensity information that originates at a master unit The only difference between a master unit and a slave unit is an internal control module residing in the master unit The control module monitors the current in a Series Lighting Circuit and provides adjustments for setting intensity switching thresholds at specific levels of SLC current 17 PSUV 101 102 04 02 2015 MAINTENANCE SAL Technology approach lights require minimal maintenance Every 6 months Make sure that the cover latches are secured and holding the cover tightly closed Check the venting plug on the bottom of the power supply and clear the breathing holes if they have become clogged Check co mounted flash head sealing There should be a continuous bead of sealing compound between the housing hub and the EMT compression nut as shown is Figure 12a Sealing compound must also be packed all around t
12. bracket by two 4 40 Phillips head screws It is generally unnecessary to replace the entire transformer assembly if a problem develops A replacement kit 255 20027 consists of a potted secondary HV coil and two ferrite C cores a Removal At the front of the housing Remove the bezel holding the flash lamp and tip the flash lamp out far enough to access the electrode screws on the back of the lamp Note the manner in which the white wire approaches the electrode terminal post on the lamp then loosen but do not remove the screw holding the wire See Figure 17b Do not loosen the screws holding the blue wire or the red wire Disconnect the white wire from the lamp At the back of the housing PSUV 101 102 Disengage the two captive screws from the main body of the housing allowing rear plate to be opened as shown in Figure 18 Identify the black wire from the potted HV coil and detach it at its ceramic post connection Remove the two 4 40 Phillips head screws identified in Figure 18a These screws hold the trigger transformer to the bracket Try to avoid disturbing the position of the loosened parts after the screws have been removed Remove the small flat plate lying across the top of the ferrite core Carefully remove the top half of the ferrite core The bottom half can be left undisturbed Lift the HV secondary coil away from the bottom half of the ferrite core Figure 18b Examine the top half and bottom half of th
13. carton is damaged Promptly file a claim with the freight carrier if you have received damaged equipment TOOLS RECOMMENDED 2 Phillips screwdriver 10 inch shank 1 4 inch flat blade screwdriver 10 inch shank 1 8 inch flat blade screwdriver short shank for circuit board potentiometer adjustments Water pump pliers opening to 3 inches for 2 inch EMT compression fittings Wire strippers Wire cutters for small gage wire Volt Ohm meter 1000 volt range ABBREVIATIONS USED IN THIS MANUAL PSUV Power Supply Unidirectional Voltage driven FHUD Flash Head Uni Directional REIL Runway End Identifier Lights ALS Approach Lighting System SLC Series Lighting Circuit NPT National Pipe Tapered thread EMT gt Electrical Metallic Tubing PSUV 101 102 04 02 2015 1 2 2 DISCLAIMER The information in this manual is believed to be accurate and up to date however SAL Technology assumes no liability for damages or injuries that may result from errors or omissions or from the use of information presented herein SAL Technology reserves the right to modify this manual at its discretion without notification to any person or organization APPLICABLE SPECIFICATIONS This equipment meets or exceeds the requirements in the FAA Advisory Circular AC 150 5345 51A and is listed as FAA approved equipment in AC 150 5345 53 Addendum B WARRANTY SAL Technology warrants this equipment and all of its components when used u
14. the first troubleshooting clue Procedures for identifying the cause of a problem are broken down into categories in order to speed up troubleshooting The broadest category is whether the problem is occurring at initial turn on of the system or after the system has previously worked correctly The next category is whether the problem affects one light only or appears to be a system problem affecting all or most of the lights Possible causes are generally listed according to estimated probability 21 PSUV 101 102 04 02 2015 I PROBLEMS OCCURRING AT INSTALLATION The most common problems when a system is first turned on are Hlashing at the Wrong Intensity or Erratic Flashing 2 No Flash at all Erratic Flashing is the term used when a light skips flashes or toggles from one intensity to another as it flashes Erratic flashing that affects an entire system could be caused by sporadic intensity changes that could appear as missed flashes when viewed from a distance These problems would typically affect all of the lights the same way but there can be exceptions A When all of the lights are affected Flashing at the Wrong Intensity or Erratic Flashing Probable cause Electrical interference on the control line Disconnect the control line at TB1 Terminal 7 in the master unit If the master unit then works properly reconnect the control line and remove the control line from TBI Terminal 7 in the slave unit If the slave unit
15. 5 uf 55 00110 Tuning Capacitor 3 uf 55 00259 Circuit Breaker 20 Amp For CMV 111 1 amp 111 2 55 00406 Circuit Breaker 20 Amp For CMV 111 3 55 00483 Flash Lamp See Figure 15a 55 00145 Fuse 1 5 Amps Master unit only Remote Control 55 00267 8 Amps F1 only for 120 volts or 230 Volts 50 Hz 55 00186 Relay Mode Switching 55 00193 Printed Circuit Board Timing amp Control 255 20079 Printed Circuit Board High Voltage Rectifier 255 20082 Printed Circuit Board Current Sensing Option See Figurellb 255 20086 Ceramic Standoff 1 inch for R1 See Figure 19 55 00200 Capacitor Bleed Resistor 75 50 W 55 00228 Interlock Switch 55 00201 Power Transformer High Voltage 60 Hz Specify 120 or 240 V 55 00224 Power Transformer High Voltage 230 Volts 50 Hz 55 00386 T 101 Trigger Transformer Kit 255 20027 TB1 TB3 Terminal Block 8 Position 55 00146 Terminal Block 11 Position for PCB 2 55 00273 Terminal Block 10 Position Master unit only 55 00147 MASTER UNIT ONLYI COMPONENT BRACKET SIDE A ENTRANCE HOLE n P2 R1 MOUNTING DETAIL SIDE B Figure 19 Component Location Diagrams 28 PSUV 101 102 04 02 2015
16. Conditions INTENSITY IN means the relay is pulled in that is energized C Skipping Flashes When a flash lamp skips flashes it is probable that either the flash lamp or the trigger transformer is approaching failure To pin down which one a S moan PSUV 101 102 Turn off the power Power is automatically turned off when the power supply cover is opened Do not pull up the stem of the interlock switch to the service position Disconnect the RED wire from TB3 in the power supply be sure DS3 on PCB 2 is not lit Apply power pull up on the interlock switch plunger Listen for trigger snaps as mentioned earlier Change out the T101 trigger transformer if trigger skipping is detected Change out the flash lamp if the trigger does not skip Replace the RED wire to TB3 and tighten the terminal block screw firmly 24 04 02 2015 1 2 2 REPLACING FLASH HEAD COMPONENTS The following instructions apply to replacing major flash head components CAUTION Be sure that the power supply connected to this flash head has been turned off and the safety lamp DS3 on PCB 2 is not lit see Figure 16 The interlock switch in the power supply removes power when the cover is open however removing primary power by disconnecting it at its source to the system is recommended for safety 1 FLASH LAMP a Removal e Referring to Figure 17a disengage four captive screws from the housing but do not rem
17. E SERVICING THE EQUIPMENT WHILE POWER IS APPLIED USE APPROPRIATE CAUTION WHILE ACCESSING INTERIOR COMPONENTS 10 11 12 13 14 15 16 PSUV 101 102 Open the cover to the master unit and set the interlock switch to the service position pull up on the stem of the switch Flip the Circuit Breaker to the ON position up Turn the Control Switch to REMOTE At PCB 201 See Figure 8 adjust all three potentiometers LOW MED amp HIGH fully counter clockwise CCW Set the CCR to Step 1 2 8 amps Carefully adjust the LOW potentiometer CW until its adjacent LED comes on Flashing will begin at Low intensity Set the CCR to Step 2 3 4 amps e The LOW LED should remain on and flash intensity should be unaffected Set the CCR to Step 3 4 1 amps e Carefully adjust the MED potentiometer CW until its adjacent LED comes on The unit will switch to Medium intensity flashes Set the CCR to Step 4 5 2 amps e The MED LED should remain on and flash intensity should be unaffected Set the CCR to Step 5 6 6 amps e Carefully adjust the HIGH potentiometer CW until its adjacent LED comes on The unit will switch to High intensity flashes Set the CCR back to Step 4 e The HIGH LED should turn off If it does not adjust the HIGH potentiometer incrementally CCW until the LED turns off MED amp LOW LEDs should remain on Set the CCR to Step 3 e There should be no change from the conditions in Step
18. STROBE APPROACH LIGHTING TECHNOLOGY Technology G UNI DIRECTIONAL VOLTAGE POWERED APPROACH LIGHTING SYSTEM L849 V A E USER S MANUAL STROB 4 iu uide NON OGY 108 F ou Y 13104 p 598 Mors 4 2 2015 1 2 2 SCOPE This manual contains Installation Operation and Maintenance information for Unidirectional Runway Approach Lights manufactured by Strobe Approach Lighting Technology SAL Technology Manlius NY USA CARTON LABELING Each carton contains one complete light consisting of a power supply and a flash head The contents are identified by external labeling A REIL system typically consists of two cartons one labeled Master and the other labeled Slave A system of sequential lights requires at least one carton for each light and one of the cartons will be identified as Master The remaining cartons containing Slave units are identified as Light 2 Light 3 and so on The Master unit is considered to be Light 1 Some systems may have accessory items that require separate packaging Those packages are also appropriately identified In addition to a power supply and flash head each carton contains two frangible fittings with short EMT couplings for power supply installation An Owner s Manual is included in the carton containing the master unit UNPACKING Inspect each shipping carton for external damage immediately upon receipt There could be damage to the contents if the
19. TING THE POWER SUPPLY The power supply requires two 2 inch NPT base supports at ground level such as NPT flanges anchored in concrete at a spacing of 8 00 inches center to center or a burial can cover with threaded entrance holes at the required spacing The power supply itself is provided with two attached 2 inch EMT compression fittings Frangible fittings shipped with the equipment have male threads at one end and 2 inch EMT compression fittings at the other Each one is furnished with a short 2 2 inch length of EMT by which they may be coupled to the compression fittings on the bottom of the power supply enclosure The frangible fittings must first be screwed into the ground supports and securely tightened The EMT couplings must be adjusted to extend out of the frangible fittings by 3 4 to 1 inch and the compression nuts securely tightened Set the power supply down over the two EMT couplings and securely tighten the compression nuts A power supply with a co mounted flash head meets the maximum height restriction set by the FAA when installed as described above and as shown in Figure 2 The 2 inch long EMT sections may be replaced by slightly longer sections if local conditions require raising the elevation of the light source by a few inches This is not recommended for a substantial increase in light center elevation mounting the flash head on a separate support while leaving the power supply close to the ground is recommended instead
20. This situation does not usually arise with REIL installations but it is common with ALS installations Please note that separate flash head mounting in not intended as a field option The method of flash head mounting should be specified when the equipment is ordered Details pertaining to separate mounting are usually supplied by others COMPRESSION P ii iT FITTING COUPLING FRANGIBLE 2 INCH NPT TO FITTING COMPATIBLE 4 GROUND FITTING 8 00 INCHES 23 modi c ud ee ee i ii Figure 2 Typical Mounting Details 3 PSUV 101 102 04 02 2015 1 2 2 INSTALLATION Cont PRIMARY POWER HOOKUP FOR REILs Please refer Figure 19 on Page 27 to find the locations of TB1 and TB5 mentioned in the text that follows Note that TB5 is found only in a master unit A slave unit does not have a TB5 terminal block Power is brought into a REIL system through the master unit where it is connected to terminal TB5 as shown in Figure 3 Power distribution wiring for an ALS would be shown on a customized drawing prepared for each particular site but in general ALS units are connected just as described for REIL slave units In either case a neutral wire is required only for units powered by 120 volts A neutral wire is not required for 240 volt units but if 240 volt power is supplied in a 3 wire format the neutral wire may be connected to position 2 on TB5 It is not necessary to
21. atches across the hinge The hinged cover when fully opened is supported by a lanyard The flash head does not have to be accessed for installation even if it is mounted separately The front bezel can be removed to gain access to the flash lamp by loosening four captive screws A plate secured by two captive screws at the rear of the housing allows access to other internal flash head components There is no interlock switch in an FHUD 109 flash head Always turn off and lock out the power supply when accessing the flash head PSUV 101 102 04 02 2015 1 2 2 EQUIPMENT SPECIFICATIONS PHYSICAL Dimensions are in inches mm Weight in 165 kg PSUV 101 Master Power Supply Figure 1a Dimensions 8H x 16W x 14D 203 x 406 x 356 Weight 52 23 6 PSUV 102 Slave Power Supply Figure 1a Dimensions 8H x 16W x 14D 203 x 406 x 356 Weight 47 21 3 FHUD 109 Flash Head Figure 1b Dimensions 11 5H x 8 5W x7D 292 x 216 x 178 Weight 4 5 2 PSUV 101 Master Power Supply Co mounted Figure Ic Dimensions 19 5H x 16W x 14D 495 x 406 x 356 Weight
22. bumped while working in a power supply during electrical hookup causing it to become unintentionally reprogrammed Faults that may arise after a system has been working properly are usually due to rather predictable causes brought on by component aging deferred maintenance or perhaps some type of damage These problems usually affect only one light although there can be exceptions It is important to know where the major components are located especially when attempting to follow troubleshooting procedures Use Figures 13 and 14 for this purpose A slave power supply does not have a CMV 111 Control Module it is otherwise identical to a master unit shown in Figure 13 b CIRCUIT __ BREAKER Figure 14a FHUD 109 Front Figure 13 Figure 14b Master Power Supply Component Identification FHUD 109 Back 19 PSUV 101 102 04 02 2015 1 2 2 TROUBLESHOOTING STATUS LIGHTS Each power supply has two circuit boards with indicator lights that can be used to interpret operating conditions PCB 1 Figure 15 is the timing and control circuit board Its location is shown in Figure 13 It has six red LEDs but only four of these apply to standard functions DS1 and DS2 labeled Monitor and Confirm are used only when the Monitoring option has been elected at the time of purchase DS7 is a neon glow lamp SW1 and SW2 are programming switches LOW MED HIGH SYNC TRIG Figure 15 PCB 1 Status Lights PCB 2 does not show in Figure 13 but its l
23. carry the neutral wire to any of the 240 volt slave units OUOUOUOUOUOUOUOUOUM OO CD OO STOTE rono ToT rona FROM A SERIES LIGHTING CIRCUIT A B 1 2 3 4 5 m S en WHEN USED FOR REMOTE CONTROL CONT L1 N L2 SEE PAGE 8 FOR DETAILS VOLTS MAIN OUT POWER IN PRIMARY POWER 120 OR 240 VOLTS SEE WIRE SIZE GUIDELINES ON PAGE 5 REMOTE CONTROL L1 SEE NOTE BELOW L2 USELI AND NEUTRAL FOR 120 VOLTS USELI AND L2 FOR 240 VOLTS NEUTRAL IS NOT REQUIRED FOR 240 VOLT POWER BUT IF NEUTRAL IS PROVIDED IT MAY BE CONNECTED TO 5 2 SEE PAGE 8 FOR DETAILS CONCERNING REMOTE CONTROL WIRING 120 VOLTS TO REMOTE DEVICE FROM TB5 4 REMOTE FROM REMOTE DEVICE TO TB5 6 FOR LOW INTENSITY CONTROL FROM REMOTE DEVICE TO TB5 7 FOR MEDIUM INTENSITY DEVICE FROM REMOTE DEVICE TO TBS 8 FOR HIGH INTENSITY CONNECTIONS TO A SWITCH OR L 854 RADIO RECEIVER FOR REMOTE CONTROL Figure 3 Installation Wiring Guidelines For a Master Unit 4 PSUV 101 102 04 02 2015 PRIMARY POWER HOOKUP FOR REILs Cont PSUV 101 102 A slave unit does not have a TB5 terminal block but all units whether master or slave have a terminal block Primary power is distributed from in the master unit to TB1 in a slave TBI is labeled differently in a 240 volt unit than in a 120 volt unit as shown in Figure 4 The terminals labeled next unit are used in a master unit and the terminals labeled From previous
24. e ferrite core for chipping or fracture and replace either one if necessary 26 04 02 2015 V 1 2 2 TRIGGER TRANSFORMER Cont b Replacement e Install the replacement HV coil over the bottom half of the ferrite core with the white HV lead positioned in the same manner as the original e Insert the upper half of the ferrite core down through the center of the HV coil and the spool that holds the primary coil e Re install the small flat plate and the long 4 40 screws e Tighten the screws symmetrically alternating from one to the other until the two screws begin to tighten Be very careful when tightening these screws Over tightening can fracture the ferrite core Re attach the black wire from the HV coil to the ceramic insulating post Set the bracket back into the housing with the component shelf towards the bottom Secure the rear plate with the two captive screws At the front of the housing attach the white wire to the proper lamp terminal taking care to bring the wire to the lamp terminal as shown in Figure 17b e Follow the instructions on Page 25 for re installing the flash lamp HV COIL Figure 18a Figure 18b Flash Head Bracket Trigger Transformer Replacement 27 PSUV 101 102 04 02 2015 1 2 2 Table 4 Replaceable Parts DESCRIPTION PN Flash Head Bracket Ass y See Figure 18a 255 20140 Bank Capacitor 70 uf 55 00105 Bank Capacitor 30 uf 55 00257 Bank Capacitor 8 uf 55 00109 Bank Capacitor
25. he harness sleeve as shown in Figure 12b Only the back view is shown but it should also be packed around the harness in front Use Gardner Bender DS 110 or similar Duct Seal when repairing or replacing Check screw tightness on TB1 and TB3 8 position terminal blocks See Figure 13 for locations Check every position that has a wire connection whether to external wiring or to internal circuits You should also check TB5 in master units Figurel2a Figure 12b Annually PSUV 101 102 Check the neoprene cover gasket on the power supply enclosure for nicks or tears If repair is needed use a neoprene compatible adhesive RTV may not adhere well to the neoprene gasket Perform a mode switching response check Verify the lights respond correctly to all commands from the SW101 Control Switch in the master unit Verify that the flash rate is 120 flashes per minute Verify that the threshold lights flash simultaneously and that sequenced lights flash in the correct order 18 1 2 2 04 02 2015 1 2 2 TROUBLESHOOTING Some problems affect only one light while other problems may affect part or all of an entire system Most problems occur at initial turn on This is primarily because the control line is the only untested part of a newly installed system Control line problems usually affect not just one light but all of the lights in a system It is however possible for only one light to be affected if a programming switch was
26. iring sketch for installation is shown in Figure 6 1 2 2 04 02 2015 1 2 2 SEE 5 FOR WIRE SIZE DETAILS PRIMARY POWER PRIMARY POWER REMOTE CONTROL CONTROL CONTROL PRIMARY LINE LINE PRIMARY LINE TO ADDITIONAL SLAVE UNITS AWG 12 STRANDED gt lt SYMBOL FOR WIRES TWISTED TOGETHER TB1 Master GROUNDING ROD GROUNDING ROD GROUNDING ROD Figure 6 Basic System Interconnection Wiring The control line conductors must be twisted together Three or four twists per foot are recommended Shielding is not necessary or recommended AWG 12 is recommended for mechanical considerations only It is not an electrical requirement Each power supply should be grounded locally for protection against lightning damage An external grounding lug on the bottom of the power supply enclosure is provided for this purpose A grounding rod should be installed at each power supply for the best protection GROUNDING THESE POWER SUPPLIES TO A COUNTERPOISE COULD INCREASE THE RISK OF DAMAGE DUE TO LIGHTNING PSUV 101 102 04 02 2015 1 2 2 REMOTE CONTROL HOOKUP Connections to a remote switch or L 854 radio receiver are made at TBS in the master unit as shown in Figures 3 6 amp 7 The control voltage is 120 volts ac It is internally generated and not electrically referenced to primary power except in systems that utilize 120 Volts as primary power The current is less than 03 amperes rms
27. l Switch to REMOTE 4 At PCB 201 See Figure 8 adjust all three potentiometers LOW MED amp HIGH fully counter clockwise CCW 5 Setthe CCR to Step 1 4 8 amps e Carefully adjust the LOW potentiometer CW until its adjacent LED comes on Flashing will begin at Low intensity 6 Setthe CCR to Step 2 5 5 amps e Carefully adjust the MED potentiometer CW until its adjacent LED comes on The unit will now flash at Medium intensity 7 Setthe CCR to Step 3 6 6 amps e Carefully adjust the HIGH potentiometer CW until its adjacent LED comes on The unit will now flash at High intensity 8 Setthe CCR back to Step 2 e The HIGH LED should turn off If it does not adjust the HIGH potentiometer incrementally CCW until it does The unit will then flash at Medium intensity 9 Set the CCR to Step 1 e The MED LED should turn off If it does not adjust the MED potentiometer incrementally CCW until it does The unit will then flash at Low intensity 10 It is advisable to run through the CCR steps once more to verify that switching is correct Make any necessary adjustments to the potentiometers to achieve correct switching by repeating the steps above 11 Leave the Control Switch in the REMOTE position for continuous control by the CCR 12 No adjustments are required at a slave unit 14 PSUV 101 102 04 02 2015 Set Up Procedure for Three Levels of Intensity With a Five Step CCR Style 2 THE FOLLOWING INSTRUCTIONS REQUIR
28. mize effects from electrical fields in close proximity and especially from power conductors The ideal control line consists of two stranded AWG 12 conductors twisted together with 3 to 4 twists per foot A shielded cable is neither required nor recommended AWG 12 wire is cited only for its mechanical strength property it is not an electrical requirement because the control signal current is very low Control line connections are made at TB1 Terminals 7 amp 8 in each power supply Terminal 7 carries the driving signal and Terminal 8 the return Terminal 8 is also tied internally to the equipment chassis Be sure the wires are inserted into the terminal block cavities between the two clamping plates The clamping screws must be firmly tightened to assure long term reliability Always tug on the wires to test them for secure holding after the terminal block screws have been tightened This is especially important when more than one wire is inserted under a clamp Slave Unit Master Unit Figure 5 TB1 Control Line Connections Figure 5 depicts typical control line connections in a REIL system two lights When there are multiple slave units ALS for example the control line must be daisy chained from one slave unit to the next Since the daisy chain connections are made at Terminals 7 and 8 there will be two conductors at those positions in all but the first unit the master and the last slave unit in the chain A complete w
29. nder normal conditions Failure of any component within one year from the date of shipment will be corrected by repair or replacement FOB Nashua NH 03060 USE OF GENERIC PARTS Using parts not manufactured or supplied by SAL Technology or unauthorized modification of any part of this equipment voids the warranty and could render the equipment noncompliant with applicable FAA specifications CONTACT INFORMATION SAL Technology may be contacted by the following methods Tele 315 682 6460 Email sales saltechnology com WARNING Dangerous Voltages This equipment generates voltages that are dangerous to personnel Use appropriate caution while operating or servicing this equipment Capacitors can retain a substantial charge even after power has been removed Allow at least one minute after turning off the power for the capacitors to be drained of charge then check the safety lamps inside provided for this purpose Do Not Depend on Interlocks Never depend on an interlock switch alone to render the equipment safe Always look for the condition of the High Voltage Indicating Lights and check circuits with a voltmeter Do not disable the safety interlock switch ii PSUV 101 102 04 02 2015 TABLE OF CONTENTS PSUV 101 102 Front Matter Carton Labeling Unpacking Tools Re Abbreviations Used in This Manual Applicab
30. not necessarily have to be the same as those shown in the tables You can customize the response at your site by making new adjustments You can select any three CCR steps for three levels of intensity but the current for a higher intensity must always be greater than the current for a lower intensity For example you cannot set Low intensity to occur at CCR Step 2 if Medium intensity has been set for CCR Step 1 CURRENT AMPS CURRENT Table 1 Table 2 Three Step CCR STYLE 1 Five Step CCR STYLE 2 Although the switching levels are initially set up at the factory it is likely that they will have to be fine tuned upon installation due to specific conditions at your site such as the type of CCR in use and other loads that may be driven by the same CCR Adjustments are made at the current sensing module shown in Figure 11b This module is part of the CMV 111 Controller when Series Circuit Control has been purchased as an option 13 1 2 2 04 02 2015 1 2 2 Set Up Procedure for Three Levels of Intensity With a Three Step CCR Style 1 THE FOLLOWING INSTRUCTIONS REQUIRE SERVICING THE EQUIPMENT WHILE POWER IS APPLIED USE APPROPRIATE CAUTION WHILE ACCESSING INTERIOR COMPONENTS 1 Open the cover of the master unit and set the interlock switch to the service position pull up on the stem of the switch 2 Flip the Circuit Breaker to the ON position up See Figure 7 Turn the Contro
31. ocation beneath the High Voltage Guard is noted The neon lamps on PCB 2 Figure 16 are in prominent view for safety and troubleshooting DS3 is a safety lamp It is lit whenever the dc bank voltage exceeds about 80 volts Do not touch any circuit component within the power supply or flash head when DS3 is lit DS1 and DS2 on PCB 2 are provided for troubleshooting They are lit whenever the total bank voltage exceeds about 800 volts dc 400 The bank voltage consists of a negative component and a positive component each reaching about 500 volts dc at full charge Both lights must be lit for flashing to occur The full bank voltage is 1000 volts dc This is a dangerous potential Use appropriate caution NOTE There is no interlock switch in an FHUD 109 flash head Always turn off the power supply when accessing the flash head Figure 16 500 V PCB 2 Status amp Safety Lights so0v PSUV 101 102 04 02 2015 1 2 2 TROUBLESHOOTING NORMAL INDICATIONS Effective troubleshooting does not necessarily require measuring instruments Most problems can be identified by audio and visual techniques but first one must know what to look and listen for as the equipment operates When a light is working properly there will be characteristic sounds and circuit board status light conditions Recognizing the absence of any typical indication is the first step in tracking down the cause of a malfunction To use sight and sound diagnostically
32. ove them from the bezel Set the bezel aside e Remove the lamp from the housing You might have to use the tip of a flat blade screwdriver or similar tool to free the lamp from the sponge gasket e Loosen but go not remove three Phillips head screws securing electrical wires at the back of the lamp shown in Figure 17b e Remove the wires from the flash lamp terminal posts Figure 17a Figure 17b Front View Flash Lamp Terminals See the next page for replacement instructions 25 PSUV 101 102 04 02 2015 1 2 2 FLASH LAMP Cont b Replacement Replacement is the reverse of removal but with attention to wire routing and flash lamp orientation Be sure that the wires approach the lamp terminals exactly as shown in Figure 17b Attach the blue wire to the blue flash lamp terminal Attach the red wire to the red flash lamp terminal Attach the white wire to the white flash lamp terminal Center the lamp against the foam rubber gasket Make sure that the arrow identified in Figure 17a is in the 12 o clock position Replace the bezel and tighten the four screws 2 TRIGGER TRANSFORMER It will be necessary to access the flash lamp and remove the rear access plate in order to replace the trigger transformer The trigger transformer is an open frame assembly consisting of a primary coil a potted high voltage HV secondary coil a ferrite core and assembly hardware The entire assembly is held to the flash tube
33. same in each light with the exception of SW2 8 just as described above for REILs Figure 10 shows SW1 and SW2 programming for REILs and for each light in an ALS Note particularly that SW2 8 is programmed differently in a master unit PSUV 101 102 04 02 2015 1 2 2 than it is in a slave Switch programming diagrams are also attached to the inside cover of every power supply 10 PSUV 101 102 04 02 2015 1 2 2 RUNWAY THRESHOLD SW1 SW2 SW2 SEQUENCE TIMING l FLASH RATE FLASH lalalalala TWO FLASHES PER SECOND TWO FLASHES PER SECOND m total medal min ul min ul A ul a nuin X Zr T lt 1 4 Um mi a 6 M m m mW 7 a n SWITCH DETAILS m SYMBOL ROCKER SWITCH NH MALSR mH 1234567 8 Sau aus BREED s Lr aiana JL JL e x m h LIGHT POSITION SWITCH SETTINGS FOR ALS SWITCH SETTINGS FOR REIL A amp B Figure 10 Circuit Board Programming 11 PSUV 101 102 04 02 2015 1 2 2 OPERATION The Circuit Breaker CB101 in the master unit must be closed in order to activate
34. the system When the circuit breaker is closed the system can be controlled locally by means of SW101 on the CMV 111 Controller or remotely when SW101 is in the REM Remote position An auxiliary switch must be provided for remote operation It typically would have four settings Off Low Medium amp High or it could be an L 854 radio receiver Figure 11a Figure 11b CMV 111 Control Module Current Sensing Module A Senes Lighting Circuit SLC can also be used for remote control if that option has been elected at the time of purchase A setup procedure is then required at installation Pages 12 through 15 have instructions that cover most set up variations The adjusting potentiometers labeled HIGH MED and LOW are on a circuit board PCB 201 that is added to the CMV 111 Controller as a sub assembly The adjusting potentiometers are shown in Figure 11b 12 PSUV 101 102 04 02 2015 SET UP PROCEDURES FOR REMOTE SLC FLASH CONTROL PSUV 101 102 The equipment is set up at the factory according to sales order instructions when the system is ordered with the option of intensity control from a Series Lighting Circuit A five step regulator is used at the factory for these initial adjustments and the system is set up for three levels of intensity unless it has been ordered for a single intensity application The tables below show the typical factory settings for three step and five step CCRs Bear in mind that the flash mode response does
35. then works properly the problem is being caused by interfering signals on the control line See control line comments below 2 No flash at all Probable cause Severe interference on the control line could prevent flashing altogether Control line comments The control line wires must be twisted together Shielding is not necessary or recommended Shielding is not a substitute for twisting If the control line consists of two wires twisted together inside of a surrounding shield it might help to disconnect the shield at both ends A control line problem can usually be further verified by temporarily laying a substitute line twisted on the surface between the master and slave units B When only one light is affected PSUV 101 102 No flash or flashing at the wrong time e This is an unusual condition at initial turn on If it does happen it is most likely because a programming switch on PCB 1 was unintentionally bumped while working inside the power supply during installation causing a programming error Correct programming information can be found in Figure 10 and also on the inside of the power supply cover of the unit affected e It is also possible that the equipment was somehow damaged after leaving the factory e If the flash head is located remotely from the power supply the cable could be incorrectly hooked up 22 1 2 2 04 02 2015 II PSUV 101 102 1 2 2 EVOLVING PROBLEMS When a Light Stops Working
36. unit are used in a slave Additional slave units as in ALS can be connected as shown in Figure 6 Terminals 1 and 3 are used for 240 volts Terminal 2 1s unused Terminals 1 and 2 are used for 120 volts and Terminal 3 is unused Units for 230 volts 50 Hz are wired as shown for 240 volts Units for 60 Hz are not interchangeable with units for 50 Hz From previous unit To next unit From previous unit To next unit L erp m Li I2 L L2 CONT RTN Ll N Ll N CONT RTN 240 VOLTS 120 VOLTS Figure 4 TB1 Labeling Wire Size Guidelines For Primary Power Wire size gage depends on the primary voltage the length of the run the total electrical load and the permissible voltage drop due to resistive loss To determine wire size for a REIL system two lights use a load of 300 watts total for two lights and a voltage drop due to wire loss of not more than 10 For systems with sequential flashers use a load of 150 watts for each light Routing system power through the master unit for a system containing more than 7 lights is not recommended Consult the factory for power distribution details pertaining to large sequentially flashing systems It is expected that NEC and local electrical codes will also apply at any installation 1 2 2 04 02 2015 PSUV 101 102 CONTROL LINE HOOKUP Figures 5 amp 6 A two conductor control line must be run between the power supplies These conductors must be twisted together to mini
37. unit Larger systems may require an auxiliary power contactor Flash intensity may be controlled at the master unit by a selector switch on the control module or remotely by a selector switch or L 854 radio receiver The control module is also available with an option that enables the system to be controlled by a Series Lighting Circuit APPLICATIONS These lights may be used in both REIL and sequential ALS applications The two lights in a REIL system must flash simultaneously whereas ALS lights must flash sequentially Switch SW1 on PCB 1 controls when the light will flash i e simultaneously or sequentially SW2 controls the rate at which flashes repeat See Figures 9a and 9b The rate is generally 120 flashes per minute These switches are initially set at the factory to comply with the application as ordered although changes can easily be made in the field fmm gt A oani AMM TE NS 81 ee 3 g n oe x Figure 9b Switch Detail Figure 9a PCB 1 Since the lights in a REIL system must flash simultaneously SW1 in the Master unit and the Slave must be programmed identically and of course the same applies to SW2 for flash rate with the exception of SW2 8 SW2 8 must be in the OFF position in a Master unit but it should in the ON position in a Slave unit SWI in an ALS must be programmed differently in each light in order to achieve sequential flashing SW2 must be programmed the
38. you should know what to look and listen for in normal operation With power applied the interlock switch set to the service position plunger pulled upwards a unit that works correctly will flash steadily at a rate of 120 FPM The flash intensity will depend on the control switch setting in the master unit or at a remote switch when in remote control Diagnostics By Sight and Sound When a light is operating correctly e There will be an audible buzz from the T1 power transformer e There will be an audible thump accompanying each High intensity flash as the capacitors discharge through the lamp This discharge thump may not noticeable for Medium or Low intensity flashes e There will be a sharp audible snap coinciding with each Medium and Low intensity flash if the flash head is co mounted The snap is from the triggering circuit in the flash head At High intensity the snap is likely to be completely masked by the louder discharge thump The snap may not be noticeable if the flash head is remotely mounted from the power supply At PCB 1 DS7 will wink out with each flash e DS6 will blink at the same rate as flashing but does not quite coincide with the flashes In High mode 053 054 amp 055 will be on steady Medium mode DS5 will be off while DS 3 amp DS4 will be on steady In Low mode 054 amp DS5 will be off while DS3 will be on steady An exception to any of the above conditions is
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