Obstruction Lighting Controller Manual

Obstruction Lighting Controller Manual LED RED OBSTRUCTIO LIGHTIG COTROLLER ISTALLATIO & OPERATIO MAUAL A TYPE SYSTEMS Meets AC o. 150/5345-43G 120VAC/230VAC OTE: USE THIS MAUAL WITH THE APPROPRIATE COTROLLER S SCHEMATIC & WIRIG DIAGRAM PART # DATE MAUFACTURED (month) (year)

2 Table of Contents I. SAFETY OTICES...3 II. IPUT POWER...4 III. ISTALLATIO...4 IV. OPERATIO...5 V. COTROLLER COMPOETS AD FUCTIOS - A Systems...6 A. TYPICAL PAEL LAYOUT & PARTS LIST 6 B. RED BEACO FLASHERS 7 C. OBSTRUCTIO LIGHT ALARM RELAYS 8 D. BEACO & OBSTRUCTIO LIGHT ALARM RELAYS 9 E. RED BEACO FLASHER ALARM RELAY 10 F. ISOLATED ALARM COTACTS for Remote Annunciation 10 VI. PHOTOELECTRIC COTROL (PCR)... 11 VII. ELECTRICAL COECTIOS...13 VIII. TROUBLE SHOOTIG - LIGHTIG COTROLLER...14 IX. LIMITED PRODUCT WARRATY...15

3 I. SAFETY OTICES This equipment is normally used or connected to circuits that may employ voltages which are dangerous and may be fatal if accidentally contacted by operating or maintenance personnel. Extreme caution should be exercised when working with this equipment. While practical safety precautions have been incorporated in this equipment, the following rules must be strictly observed: KEEP AWAY FROM LIVE CIRCUITS Operating and maintenance personnel must at all times observe all safety regulations. Do not perform maintenance on internal components or re-lamp with power O. RESUSCITATIO Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of first aid instructions. IMPORTAT OTICES: Be certain this is the correct lighting system for the project. Verify the lighting system and equipment received are in accordance with the project specifications. Locations on Hot AM towers, High RF antennas, hazardous areas due to explosive gas, fumes, dust, salt air or other highly corrosive/chemical environments often require special components or system modification for proper function and system longevity. A schematic-wiring blueprint drawing is supplied and included with the controller. Reference must be made to the drawing before making any wiring connections. This manual of instructions outlines the function of the controller and its components. There should be no maintenance performed on the OLC or the system without reference to the manual and the OLC schematic wiring. The relays are factory preset for their indicated operations. Changing the switch selections will cause a malfunction of the circuit and may damage the relay. For applications using fewer than the designated number of lights for a given OLC, note the following: For fewer double obstruction lights, do not wire the appropriate alarm relays to the alarm circuit (unused alarm relays will indicate a fault).

4 II. IPUT POWER Power to the Obstruction Lighting Controller (OLC) is either 120VAC, 50/60HZ or 230VAC, 50/60HZ. Controller circuit protection (fuse or circuit breaker) for incoming power is external and provided by others. It is important to use the specific OLC schematic-wiring diagram together with this manual. III. ISTALLATIO Mount the controller cabinet in a vertical position ensuring the cabinet is level and there is ample space to mount the unit. The enclosure is provided with bracket mounting feet at the top and bottom back edges for use against a vertical surface or frame. Be sure the mounting location is square so as not to twist or warp the enclosure during mounting. Prior to wiring the controller to incoming power and loads, make sure all hardware and electrical connections have not loosened during shipping. Wire and conduit entrances and their location on the cabinet are to be provided by the installer. On some lighting controllers, knockout openings are provided on the cabinet. All cabinet openings should be from the bottom of the enclosure. Wiring entrances for power input, external photo control leads, and external lighting loads should be located opposite to their terminal connections, if possible. The external Photoelectric Control should be located near the controller and must also have the wiring and conduit enter through the bottom of the unit. Refer to the PCR instructions for proper location and circuit wiring. Standard and special lighting controllers incorporate a ground lug (GD) normally located at the lower right corner of the interior back panel. It is near the power input terminals and it is comprised of a box lug or singular screw-hold lug, which is fastened to the metal back panel. The metal back panel is secured to the enclosure housing forming a solid equipment ground path through an attached conductor from the ground lug to external ground (earth). A green colored wire ( # 8 - # 10 AWG stranded copper conductor ) should be used for connection from the ground lug to an external ground (earth). The system neutral is OT considered a grounded contact and must OT be connected to the ground lug or controller chassis. The purpose of grounding is to protect equipment, personnel, and circuits by eliminating the possibility of dangerous fault current or excessive voltages. The equipment ground for the controller s metal enclosure that contains electrical wires or component devices is there to eliminate the possibility that an insulation failure in such an enclosure might place a potential (voltage) on the enclosure and constitute a shock or fire hazard. The OLC ground lug is provided to fulfill the requirement of the ational Electric Code for fault current protection.

5 IV. OPERATIO All wiring from the Obstruction Lighting Controller (OLC) power input and lighting circuits must be connected to their proper terminals. Reference should be made to the accompanying schematic/ wiring diagram. After all wiring is secured to the controller and the photoelectric controller the system is ready to operate. The Controller s over current protection shall be made with a fuse or circuit breaker at the power source provided by others. Refer to the controller drawing for line input and wattage rating. OLC controllers are energized either through a contactor and PCR or directly by the PCR. If no contactor is required, the PCR contacts are rated to supply the current demand of that particular controller. The OLC incorporates a PCR Override Switch (auto/manual) which allows for automatic control of the OLC by the PCR or switched to a manual mode which overrides the PCR during daylight for preventative maintenance. There must be no wiring changes made in the PCR override switching of the photo-electric control. Circuitry for the PCR is detailed in the accompanying instructions shipped with the PCR.

6 V. COTROLLER COMPOETS AD FUCTIOS - A Systems A. PAEL LAYOUT & PARTS LIST 2 1 3 5 4 6 9 7 8 10 1. Flasher Fail Alarm (90-277VAC) 4706-001 2. FLR Red Flasher (90-277VAC) 0806-004 3. Relay (2 Pole) 3003-017-120V 3003-015-230V 4. Beacon Alarm Relay 4501-011 5. Red Sidelight Alarm Relay 4501-011 or 4501-012 6. Photo-control Override Switch 9006-007 7. Sidelight Fuse (2 amp, 5x20mm) 1001-004 8. Beacon Fuse (2 amp, 5x20mm) 1001-004 9. Remote Status Relays A-B 10. Circuit breaker 3003-024-120V 3003-025-230V 0402-xxx-120V 0403-xxx-230V

7 B. RED BEACO FLASHERS The flasher circuitry consists of a master flasher module and one or more auxiliaries (AUX) where the number of LED beacons warrants their use. The flash rate is 30 ± 10 flashes per minute per FAA specifications. Output of the flasher is 3 amperes maximum. Failure of the flasher creates a fail-safe condition in which the beacon lamps will continue to burn in a steady state and maintain its safety warning function. There is a flasher failure alarm relay to also insure this fail safe condition is met. In the event of a flasher failure, the flasher fail alarm relay will also provide a remote alarm output. P/: 0806-004 Flasher and AUX circuitry are protected against shock, vibration and humidity. Each module has internal transient protection. The normal operating temperature is -40 F to +150 F. There are no moving contacts, moving parts, or adjustments in the flasher or auxiliary modules.

C. OBSTRUCTIO LIGHT ALARM RELAYS IMPORTAT: ESURE THAT ALL LOADS ARE PROPERLY OPERATIG BEFORE PROCEEDIG! REMOVE TAMPER-PROOF COVER IF ADJUSTMET IS ECESSARY (DO OT DISCARD). A1 I M PROCEDURE FOR DETERMIIG CURRET SESOR SET POIT FOR SIDE-LIGHTS: + 1. APPLY POWER TO THE SYSTEM. 3-500mA 2. DETERMIE TOTAL CURRET OF ALL SIDE-LIGHTS COECTED TO FUSED OUTPUT OLx, ARx (THIS VALUE WILL APPEAR I THE CURRET SESORS DISPLAY, FIG. A). C I = D A2 3. DIVIDE THIS VALUE BY THE TOTAL UMBER OF SIDE-LIGHTS O THAT SAME OUTPUT. 12 11 14 C COM O I = Side-Lights 4. DIVIDE THE VALUE DETERMIED I STEP #3 BY TWO. IF DOUBLE, PROCEED TO STEP 6 (BELOW DIAGRAMS). IF SIGLE, PROCEED TO STEP 5 (BELOW). I = 5. SUBTRACT THE VALUE DETERMIED I STEP #4 FROM THE VALUE DETERMIED I STEP #2 I = THE VALUE DETERMIED I STEP #5 IS THE SIDE-LIGHT SET POIT. 8 A B Side Light (singles) Wire Diagram Side Light (doubles) Wire Diagram Primary Backup (spare) OTE: If sidelights are singles, follow each step from 1-6 S1 OL Controller Controller OL 3 - Singles OTE: If sidelights are double, follow steps as directed below. Step (1) Step (2) Step (3) + 1 Lamp is normal Step (4) = Divide by #2 6. PROCEDURE FOR CALIBRATIG SET POITS FOR SIDE-LIGHTS AD BEACOS: A. PRESS THE RETUR BUTTO, FIG. B, FOR ~0.5 SECODS. B. PRESS AD HOLD THE UP BUTTO, FIG. C, UTIL THE ICREASIG VALUE I THE DISPLAY, FIG. A, READS OFF. C. PRESS THE RETUR BUTTO, FIG. B, FOR ~0.5 SECODS. D. PRESS THE UP OR DOW BUTTO, FIG. C OR D, UTIL THE DISPLAY READS THE VALUE DETERMIED I STEP #5 FOR SIDE-LIGHTS OR STEP #3 FOR BEACOS. E. PRESS THE RETUR BUTTO, FIG. B, FOR ~0.5 SECODS. THE DEVICE IS OW SET REPLACE TAMPER-PROOF COVER

D. BEACO & OBSTRUCTIO LIGHT ALARM RELAYS IMPORTAT: ESURE THAT ALL LOADS ARE PROPERLY OPERATIG BEFORE PROCEEDIG! REMOVE TAMPER-PROOF COVER IF ADJUSTMET IS ECESSARY (DO OT DISCARD). PROCEDURE FOR DETERMIIG CURRET SESOR SET POIT FOR SIDE-LIGHTS: 1. APPLY POWER TO THE SYSTEM. 2. DETERMIE TOTAL CURRET OF ALL SIDE-LIGHTS COECTED TO FUSED OUTPUT OLx, (THIS VALUE WILL APPEAR I THE CURRET SESORS DISPLAY, FIG. A). I = 3. DIVIDE THIS VALUE BY THE TOTAL UMBER OF SIDE-LIGHTS O THAT SAME OUTPUT. I = 4. DIVIDE THE VALUE DETERMIED I STEP #3 BY TWO. C D I = 5. SUBTRACT THE VALUE DETERMIED I STEP #4 FROM THE VALUE DETERMIED I STEP #2 I = THE VALUE DETERMIED I STEP #5 IS THE SIDE-LIGHT SET POIT. PROCEDURE FOR DETERMIIG CURRET SESOR SET POIT FOR BEACOS: 1. APPLY POWER TO THE SYSTEM. 2. DETERMIE TOTAL CURRET OF BEACO COECTED TO FUSED OUTPUT BRx, (THIS VALUE WILL APPEAR I THE CURRET SESORS DISPLAY, FIG. A). I = C D 3. DIVIDE THE VALUE DETERMIED I STEP #2 BY TWO. I = THE VALUE DETERMIED I STEP #3 IS THE BEACO SET POIT. OTE: THE VALUES DISPLAYED I THE CURRET SESORS DISPLAY WIDOW, A, MAY FLUCTUATE DUE TO FLASHIG. USE THE HIGHEST CURRET VALUE READ TO MAKE APPROPRIATE CALCULATIOS METIOED ABOVE. A1 I M + PROCEDURE FOR SETTIG SET POITS FOR SIDE-LIGHTS AD BEACOS: 1. PRESS THE RETUR BUTTO, FIG. B, FOR ~0.5 SECODS. 2. PRESS AD HOLD THE UP BUTTO, FIG. C, UTIL THE ICREASIG VALUE I THE DISPLAY, FIG. A, READS OFF. 3. PRESS THE RETUR BUTTO, FIG. B, FOR ~0.5 SECODS. 4. PRESS THE UP OR DOW BUTTO, FIG. C OR D, UTIL THE DISPLAY READS THE VALUE DETERMIED I STEP #5 FOR SIDE-LIGHTS OR STEP #3 FOR BEACOS. 5. PRESS THE RETUR BUTTO, FIG. B, FOR ~0.5 SECODS. 3-500mA 12 C ARx 11 COM A2 14 O Side-Lights A1 I M + 50mA-10A 12 C BRx 11 COM A2 14 O Beacons 9 A B A B THE DEVICE IS OW SET REPLACE TAMPER-PROOF COVER

10 E. RED BEACO FLASHER ALARM RELAY The OLC utilizes an alarm module (FFA) that constantly monitors the output voltage of the solid state flasher. Should the flasher fail in a steady OPE or CLOSED status, the alarm module will energize relay K-1 and energize the FFA alarm relay. P/: 4706-001 F. ISOLATED ALARM COTACTS for Remote Annunciation Isolated alarm contacts consist of individual relays with SPST isolated contacts. The relays have LED indication when energized. The alarm relays are de-energized when conditions are good. The GT relay is energized at night only. Contact Rating: 6A @ 250 VAC 1A @ 30 VDC

11 VI. PHOTOELECTRIC COTROL (PCR). P/ 18001-001 / 18002-001 The PCR is designed and calibrated to meet both the FAA and FCC regulation. The PCR must be mounted in a vertical position. The PCR should face the ORTH (polar sky) away from the Sun's rays and away from sunlight reflections. The PCR should protrude above the height of nearby structures or other obstructions that might cast shadows upon the PCR's window. The PCR is used for automatic switching of the load circuits. It is located externally from the controller cabinet. When wiring the PCR to the controller, use # 12 AWG stranded wire conductors. The PCR override switch on the front door of the OLC cabinet is used to bypass the PCR permitting the lights to be turned on manually. The PCR switch allows the beacon and side lights to be energized during daylight when the photoelectric controller would normally have the lights out. This is a maintenance feature. The switch should be in the automatic (auto) mode for normal operation. ote: When the PCR is connected properly and the test switch is set to "Auto", the Red LED on the PCR will be energized. RECOMMEDED PHOTOCELL ISTALLATIO PLUG 1 PT with sealing compound TO LIGHT FIXTURES PHOTOCELL 18001-001 = 120 VAC 18002-001 = 230 VAC POWER

12 Locking-type Photocontrols P/ 18001-007 / 18002-007 18001-007 / 18002-007 Delayed response thermal series for white strobe/dual systems. Built-in time delay prevents false cycling caused by lightning flashes or stray headlights. Allweather locking type receptacle and Lexan housing with 14, 14 AWG wire colorcoded as follows: line-black, neutral-white, load-red. Threaded stem fits through a ½ knockout. Dimensions: 2 5/8 diameter (socket), 2 5/8 high (including stem), ½ PT at bottom fitting.

13 X. ELECTRICAL COECTIOS Electrical connections between the PCR and lighting controller: Warning: Voltage between P1 and, and P2 and must not exceed 150 volts. P/ 18001-001 / 18002-001 L1 PHOTO-COTROL L1 LOAD 1 L2 P1 P2 P1 POWER 1 LIGHTIG COTROLLER PHOTO-COTROL L1 LOAD 1 L1 P1 L2 P2 P1 LOAD 2 POWER 2 POWER 1 P/ 18001-007 / 18002-007 L1 P1 Red Black White

14 IX. TROUBLESHOOTIG - LIGHTIG COTROLLER CAUTIO: Turn Power off to the lighting controller at the source before any maintenance is performed on controller or light fixtures. A. Beacon Fault Indicator On 1. Turn the PEC Override / Reset Switch to the Manual position. 2. If no failure is indicated, turn the PEC Override/ Reset Switch back to the Auto position. 3. If a failure is indicated, note which LED fixture has the failure indicated. 4. Remove power from the system. 5. Replace the LED fixture that had the failure indication or repair connection to the light. B. Obstruction Light Fault Indicator On 1. Turn the PEC Override / Reset Switch to the Manual position. 2. If no failure is indicated, turn the PEC Override/Reset Switch back to the Auto position. 3. If a failure is indicated, note which LED fixture has the failure indicated. 4. Remove power from the system. 5. Replace the LED fixture that had the failure indication or repair connection to the light. C. Flasher Fault Indicator On 1. Turn the PEC Override / Reset Switch to the Manual position. 2. If no failure is indicated, turn the PEC Override/Reset Switch back to the Auto position. 3. If a failure is indicated, note which Flasher Bypass Relay has the failure indicated. 4. Remove power from the system. 5. Replace the Flasher that was associated with the Flasher Bypass Relay indicating a failure. Call Unimar, Inc. for assistance: Phone # 315-699-4400; Fax # 315-699-3700

15 X. LIMITED PRODUCT WARRATY THE FOLLOWIG WARRATY IS EXCLUSIVE AD I LIEU OF ALL OTHER WARRATIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, ICLUDIG, BUT OT BY WAY OF LIMITATIO, AY WARRATY OF MERCHATABILITY OR FITESS FOR AY PARTICULAR PURPOSE. Unimar, Inc. warrants to each original Buyer of Products manufactured by the Company that such Products are, at the time or delivery to the Buyer, free of material and workmanship defects, provided that no warranty is made with respect to: (a) (b) (c) (d) any Product which has been repaired or altered in such a way, in Company's judgment, as to affect the Product adversely; any Product which has, in Company's judgment, been subject to negligence, accident or improper storage; any Product which has not been operated and maintained in accordance with normal practice and in conformity with recommendations and published specification of Company; and, any Products, component parts or accessories manufactured by others but supplied by Company (any claims should be submitted directly to the manufacturer thereof). Unimar, Inc.'s obligation under this warranty is limited to use reasonable effects to repair or, at its option, replace, during normal business hours at any authorized service facility of Company, any Products which in its judgment proved not to be as warranted within the applicable warranty period. All costs of transportation of Products claimed not to be as warranted and of repaired or replacement Products to or from such service facility shall be borne by Purchaser. Company may require the return of any Product claimed not to be as warranted to one of its facilities as designed by Company, transportation prepaid by Purchaser, to establish a claim under this warranty. The cost of labor for installing a repaired or replacement product shall be borne by Purchaser. Replacement parts provided under the terms of this warranty are warranted for the remainder of the warranty period of the Products upon which they are installed to the same extent as if such parts were original components thereof. Warranty services provided under the Agreement do not assure uninterrupted operations of Products; Company does not assume any liability for damages caused by any delays involving warranty service. The warranty period for the Products is for a period of 5 years on standard products and custom assemblies from the date of shipment or first use whichever occurs first.