led red obstruction lighting controller ... lightn contole manual 3195 vickery rd. n. syracuse, ny...

Obstruction Lighting Controller Manual

3195 Vickery Rd. N. Syracuse, NY 13212 • Ph: (315) 699-4400 or (800) 739-9169 • Fax: (315) 699-3700 • www.unimar.com

LED RED OBSTRUCTION LIGHTING CONTROLLER

INSTALLATION & OPERATION MANUAL

A TYPE SYSTEMS

Meets AC No. 150/5345-43G

120VAC/230VAC

NOTE: USE THIS MANUAL WITH THE APPROPRIATE CONTROLLER’S SCHEMATIC & WIRING DIAGRAM

PART # __________________________________

DATE MANUFACTURED __________ __________ (month) (year)

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December 002015[120_230_LED_2015_ED1]


Table of Contents

I. SAFETY NOTICES ..................................................................................................................3

II. INPUT POWER .....................................................................................................................4

III. INSTALLATION....................................................................................................................4

IV. OPERATION ........................................................................................................................5

V. CONTROLLER COMPONENTS AND FUNCTIONS - A Systems ...........................................6A. TYPICAL PANEL LAYOUT & PARTS LIST 6B. RED BEACON FLASHERS 7C. OBSTRUCTION LIGHT ALARM RELAYS 8D. BEACON & OBSTRUCTION LIGHT ALARM RELAYS 9E. RED BEACON FLASHER ALARM RELAY 10F. ISOLATED ALARM CONTACTS for Remote Annunciation 10

VI. PHOTOELECTRIC CONTROL (PCR) .................................................................................. 11

VII. ELECTRICAL CONNECTIONS ..........................................................................................13

VIII. TROUBLE SHOOTING - LIGHTING CONTROLLER .........................................................14

IX. LIMITED PRODUCT WARRANTY ......................................................................................15

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I. SAFETY NOTICESThis 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 ON.

RESUSCITATION Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of first aid instructions.

IMPORTANT NOTICES: 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).

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December 002015[120_230_LED_2015_ED1]


II. INPUT 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. INSTALLATION

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 (GND) 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 NOT considered a grounded contact and must NOT 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 National Electric Code for fault current protection.

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December 002015[120_230_LED_2015_ED1]


IV. OPERATION

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.

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8

5

6

4312

79

10

1. Flasher Fail Alarm (90-277VAC) 4706-001

2. FLR Red Flasher (90-277VAC) 0806-004

3. Relay (2 Pole)

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

V. CONTROLLER COMPONENTS AND FUNCTIONS - A Systems

A. PANEL LAYOUT & PARTS LIST

3003-017-120V3003-015-230V

3003-024-120V3003-025-230V0402-xxx-120V0403-xxx-230V

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December 002015[120_230_LED_2015_ED1]


B. RED BEACON 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.

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.

P/N: 0806-004

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C. OBSTRUCTION LIGHT ALARM RELAYS

IMPORTANT: ENSURE THAT ALL LOADS ARE PROPERLY OPERATING BEFORE PROCEEDING!REMOVE TAMPER-PROOF COVER IF ADJUSTMENT IS NECESSARY (DO NOT DISCARD).

PROCEDURE FOR DETERMINING CURRENT SENSOR SET POINT FOR SIDE-LIGHTS: 1. APPLY POWER TO THE SYSTEM. 2. DETERMINE TOTAL CURRENT OF ALL SIDE-LIGHTS CONNECTED TO FUSED OUTPUT “OLx”, (THIS VALUE WILL APPEAR IN THE CURRENT SENSORS DISPLAY, FIG. A). I = ___________ 3. DIVIDE THIS VALUE BY THE TOTAL NUMBER OF SIDE-LIGHTS ON THAT SAME OUTPUT. I =____________ 4. DIVIDE THE VALUE DETERMINED IN STEP #3 BY TWO. IF DOUBLE, PROCEED TO STEP 6 (BELOW DIAGRAMS). IF SINGLE, PROCEED TO STEP 5 (BELOW). I = ____________ 5. SUBTRACT THE VALUE DETERMINED IN STEP #4 FROM THE VALUE DETERMINED IN STEP #2

I = ____________ THE VALUE DETERMINED IN STEP #5 IS THE SIDE-LIGHT SET POINT.

6. PROCEDURE FOR CALIBRATING “SET POINTS” FOR SIDE-LIGHTS AND BEACONS: A. PRESS THE RETURN BUTTON, FIG. B, FOR ~0.5 SECONDS. B. PRESS AND HOLD THE “UP” BUTTON, FIG. C, UNTIL THE INCREASING VALUE IN THE DISPLAY, FIG. A, READS “OFF”. C. PRESS THE RETURN BUTTON, FIG. B, FOR ~0.5 SECONDS. D. PRESS THE “UP OR DOWN” BUTTON, FIG. C OR D, UNTIL THE DISPLAY READS THE VALUE DETERMINED IN STEP #5 FOR SIDE-LIGHTS OR STEP #3 FOR BEACONS. E. PRESS THE RETURN BUTTON, FIG. B, FOR ~0.5 SECONDS.

THE DEVICE IS NOW SET REPLACE TAMPER-PROOF COVER

A1 IN M

141112

A2

3-500mA

NOCOMNC

+A1 IN M

141112

A2

50mA-10A

NOCOMNC

+

A

BCD

A

BCD

ARx BRx

Side-Lights Beacons

OLS1 N

Side Light (doubles)Wire Diagram

Controller

Primary Backup (spare)

NOTE: If sidelights are double, follow steps as directed below. Step (1) Step (2) Step (3) + 1 Lamp is normal Step (4) = Divide by #2

OL N

3 - Singles

Side Light (singles)Wire Diagram

Controller

NOTE: If sidelights are singles, follow each step from 1 - 6

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December 002015[120_230_LED_2015_ED1]


D. BEACON & OBSTRUCTION LIGHT ALARM RELAYS

IMPORTANT: ENSURE THAT ALL LOADS ARE PROPERLY OPERATING BEFORE PROCEEDING!REMOVE TAMPER-PROOF COVER IF ADJUSTMENT IS NECESSARY (DO NOT DISCARD).

PROCEDURE FOR DETERMINING CURRENT SENSOR SET POINT FOR SIDE-LIGHTS: 1. APPLY POWER TO THE SYSTEM. 2. DETERMINE TOTAL CURRENT OF ALL SIDE-LIGHTS CONNECTED TO FUSED OUTPUT “OLx”, (THIS VALUE WILL APPEAR IN THE CURRENT SENSORS DISPLAY, FIG. A). I = ___________ 3. DIVIDE THIS VALUE BY THE TOTAL NUMBER OF SIDE-LIGHTS ON THAT SAME OUTPUT. I =____________ 4. DIVIDE THE VALUE DETERMINED IN STEP #3 BY TWO. I = ____________ 5. SUBTRACT THE VALUE DETERMINED IN STEP #4 FROM THE VALUE DETERMINED IN STEP #2

I = ____________ THE VALUE DETERMINED IN STEP #5 IS THE SIDE-LIGHT SET POINT.

PROCEDURE FOR DETERMINING CURRENT SENSOR SET POINT FOR BEACONS: 1. APPLY POWER TO THE SYSTEM. 2. DETERMINE TOTAL CURRENT OF BEACON CONNECTED TO FUSED OUTPUT “BRx”, (THIS VALUE WILL APPEAR IN THE CURRENT SENSORS DISPLAY, FIG. A). I = ___________ 3. DIVIDE THE VALUE DETERMINED IN STEP #2 BY TWO. I = ____________ THE VALUE DETERMINED IN STEP #3 IS THE BEACON SET POINT. NOTE: THE VALUES DISPLAYED IN THE CURRENT SENSORS DISPLAY WINDOW, “A”, MAY FLUCTUATE DUE TO FLASHING. USE THE HIGHEST CURRENT VALUE READ TO MAKE APPROPRIATE CALCULATIONS MENTIONED ABOVE.

PROCEDURE FOR SETTING “SET POINTS” FOR SIDE-LIGHTS AND BEACONS: 1. PRESS THE RETURN BUTTON, FIG. B, FOR ~0.5 SECONDS. 2. PRESS AND HOLD THE “UP” BUTTON, FIG. C, UNTIL THE INCREASING VALUE IN THE DISPLAY, FIG. A, READS “OFF”. 3. PRESS THE RETURN BUTTON, FIG. B, FOR ~0.5 SECONDS. 4. PRESS THE “UP OR DOWN” BUTTON, FIG. C OR D, UNTIL THE DISPLAY READS THE VALUE DETERMINED IN STEP #5 FOR SIDE-LIGHTS OR STEP #3 FOR BEACONS. 5. PRESS THE RETURN BUTTON, FIG. B, FOR ~0.5 SECONDS.

THE DEVICE IS NOW SET REPLACE TAMPER-PROOF COVER

A1 IN M

141112

A2

3-500mA

NOCOMNC

+A1 IN M

141112

A2

50mA-10A

NOCOMNC

+

A

BCD

A

BCD

ARx BRx

Side-Lights Beacons

A1 IN M

141112

A2

3-500mA

NOCOMNC

+A1 IN M

141112

A2

50mA-10A

NOCOMNC

+

A

BCD

A

BCD

ARx BRx

Side-Lights Beacons

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December 002015[120_230_LED_2015_ED1]


E. RED BEACON 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 OPEN or CLOSED status, the alarm module will energize relay K-1 and energize the FFA alarm relay.

F. ISOLATED ALARM CONTACTS 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 NGT relay is energized at night only.

Contact Rating: 6A @ 250 VAC 1A @ 30 VDC

P/N: 4706-001

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December 002015[120_230_LED_2015_ED1]


VI. PHOTOELECTRIC CONTROL (PCR) P/N 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 NORTH (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.

Note: When the PCR is connected properly and the test switch is set to "Auto", the Red LED on the PCR will be energized.

RECOMMENDED PHOTOCELL INSTALLATION

TO LIGHT FIXTURES TO LIGHT

FIXTURES

PLUG 1” NPT with sealing compound

PLUG 1” NPT with sealing compound

PHOTOCELL 18001-001 = 120 VAC18002-001 = 230 VAC

PHOTOCELL 18001-001 = 120 VAC18002-001 = 230 VAC

DRAIN

POWER

POWER

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December 002015[120_230_LED_2015_ED1]


Locking-type Photocontrols – P/N 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. All-weather locking type receptacle and Lexan housing with 14”, 14 AWG wire color-coded 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” NPT at bottom fitting.

18001-007 / 18002-007

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December 002015[120_230_LED_2015_ED1]


X. ELECTRICAL CONNECTIONS

Electrical connections between the PCR and lighting controller: Warning: Voltage between P1 and N, and P2 and N must not exceed 150 volts.

PHOTO-CONTROL

PHOTO-CONTROL

L1

L2

L1

N

N

N

N

N P2

P1

P1

L1

L1 L2

N

N P2

P1

P1

L1

N

P1

LIGHTING CONTROLLER

LOAD 1

LOAD 1

LOAD 2

POWER 1

POWER 1

POWER 2

P/N 18001-001 / 18002-001

P/N 18001-007 / 18002-007

Red

Black

White

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December 002015[120_230_LED_2015_ED1]


IX. TROUBLESHOOTING - LIGHTING CONTROLLER

CAUTION: 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


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.


5. Replace the LED fixture that had the failure indication or repair connection to the light.

C. Flasher Fault Indicator On


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.


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

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December 002015[120_230_LED_2015_ED1]


X. LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY 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) any Product which has been repaired or altered in such a way, in Company's judgment, as to affect the Product adversely; (b) any Product which has, in Company's judgment, been subject to negligence, accident or improper storage; (c) 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, (d) 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.

led red obstruction lighting controller ... lightn contole manual 3195 vickery rd. n. syracuse, ny...

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