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Honeywell SG-60 User's Manual

1. DS1 LOGIC POWER RED CO CO 2 Eb 7 ae 051 N 0 T1 5 51 O POWER J1 22 UNO 7 P _ HIGH VOLTAGE INDICATOR 051 e i 2 J3 C2 fe DB1 m 9 172 EE 111 1 01111 n c e sss TE o
2. i 1 lo Eisen e OQ 2 OOO O 1 QO 0 FID 6 6 o 1 0 0 M L N Q Q m HE On te den JO 5 ERES agii We 5 Oa 8 FP BBE 235 ya 382 Cg 2069 815 E W g sim 7 Fiori m a N mo 8 E Be 5 mm oF 5 lt 0 c lt e O 9 Figure 1 1 Model SGC 60 Master Controller SG 60 High Intensity Strobe System 1 2 Manual EPM 00000019 Rev A AirportSystems 053 COMMUNICATION STATUS GREEN 052 FLASH STATUS YELLOW SW1 AUTO RESET TEST BUTTON
3. BLK wire Csee step 10 UP WHT wire Figure 5 1 SGC 60 Replacement Transformer Transformer replacement instructions 1 Open Controller unit and set power switch to off 2 Secure Controller input power at the circuit breaker 3 Verify power to the controller is off 4 Remove 4 screws attaching Switch panel to standoffs 5 Swing panel up and out of the way 6 Remove 2 screws attaching the white wire pair to the transformer outer terminals 7 Disconnect the black and white wire connectors from transformer inner terminals 8 Remove 2 screws securing transformer to back panel and remove transformer 9 Place new transformer in controller with terminals facing right and secure with upper screw only Bottom screw not matched to back panel but should not affect operation SG 60 High Intensity Strobe System 5 1 Manual EPM 00000019 Rev A AirportSystems Honeywell 10 Attach wires with the push on connectors to the following terminals a White wire to the outer bottom right terminal b Black wire to the terminal that matches the Controller input voltage 240v shown in Figure 5 1 11 You will need to replace the terminal lugs on the other 2 white wires before attaching to the transformer a Cut off wire terminal lugs as close to lug as possible b Strip insulation back and crimp on new
4. TRANSFORMER UNDER Figure 7 4 SG 60 AOL Flashhead Component Locations SG 60 High Intensity Strobe System 7 5 Manual EPM 00000019 Rev A AirportSystems e a o 6 COE YS O 9 elle e e e e T eet AE _ O 3 P gt w EE 6 CEA 0 8 1 2 er me E J CI i Eo os e Be o nn amp B amp 0002 ca
5. 3 3 3 22 SGF 60 Digital Board u u S p tas sta NUR aaah RSS 3 3 3 2 3 SGF 60 Trigger High Voltage 3 6 3 3 500 60 MASTER CONTROLLER hka a a a aa a aa a EE 3 8 3491 OU D ELE 3 8 3 3 2 Flash Requests and Flashhead Status n 3 8 333 System 6 ii m n u at 3 9 EPM 00000019 001 iii Rev A AirportSystems 3 34 Communications 3 10 SECTION 4 2 4 1 5 55 5 1 bi SGG 00 MASTER CONTROLLER 5 1 Transformer apasqa saka kahani saya sat 5 1 5 2 SGF 60 FLASHHEAD m 5 2 52 1 Elashtube Replacemient 5 2 5 3 AMBIENT LIGHT SENSOR 2 5 3 SECTION 6 REPLACEMENT PARTS 6 1 SECTION 7 ANTENNA OBSTRUCTION LIGHT AOL 7 1 TABLE OF FIGURES Figure 1 1
6. v o S s 9 Te e 82 1 12588812 64144 511811216 r S310N 4 9 ma S 1 Ans T 24 dvo Sa Y ia THM 3 Oom T 93 2 QNO SISSVH2 a Hova T 93 am 1 112 88 ET 5 une 61 8 2 112 WALSAS 9 0686 11 L 336 isa 1531 WO2 33 LL got RI i 21 18 Kis ong 34 Ma Av a v e EX T 1 L HOMIML 0 2 2 9 J 1 19 m 4 4 yu s 8 aN VI aN U iu viva Zion 335 577 32194383 3 i 3 3T H As IH 3 aj aj Z 3svHd 3 al alzx zo ALON 335 1H9IN LHOMIML Ava NUS 7 171 29 suo 831 lt 9 E EN 181 ml gt i _1 gt a L J 2 gan HSY MOY 2 5 onal 9 4 aaa 4 m 2 6619 12 1 ONINIHON AGONY OM 3 Z 310N 33S IA us 35836 L 5 L rors LL vL Ha Airport Systems Ic Manual EPM 00000019 Rev A SGF 60 Flashhead System Schemat 3 12 Figure 3 2 SG 6
7. 000005 Trigger transformer 277 3324 Power resistor 277 5101 Surge Arrestor 77 4139 SGC 60 Master Controller PC Board Master Controller 34E00240 001 Transformer T1 50Hz 60Hz 000005 12 00107 001 50 60 High Intensity Strobe System 6 1 Manual EPM 00000019 Rev A AirportSystems SECTION 7 ANTENNA OBSTRUCTION LIGHT AOL This addendum includes the following Figures Figure 7 1 SG 60 AOL Flashhead Mounting Dimensions Figure 7 2 SG 60 AOL Power Supply Mounting Dimensions Figure 7 3 SG 60 AOL Wiring Installation Figure 7 4 SG 60 AOL Flashhead Component Locations Figure 7 5 SG 60 AOL Power Supply Component Location Figure 7 6 SG 60 AOL Schematic SG 60 High Intensity Strobe System 7 1 Manual EPM 00000019 Rev A AirportSystems d mE EO D NE 5 00 TS x ME x 127 0 A CLEARANCE I 1 1 T ll E MIC NS I ll N 11 GLOBE LIFTS GLOBE TILTS FOR ACCESS I 15 92 ACCESS FLASHTUBES 404 4 TO WIRING 18 1
8. LTS L2 N 214 LARRESTOR 66 0 DENEA CE 9 1 REFLECTOR ASSEMBLY P DANGER gt DANGER HIGH HIGH 4 VOLTAGE VOLTAGE Re 8 Figure 1 2 Model SGF 60 Flashhead SG 60 High Intensity Strobe System 1 3 Manual EPM 00000019 Rev A AirportSystems 1 3 Safety Precautions The following general safety precautions must be observed during all phases of operation service and repair of this equipment Failure to comply with these precautions or with specific warnings elsewhere in this manual violates safety standards of design manufacture and intended use of this equipment Honeywell assumes no liability for the customer s failure to comply with these requirements as listed below 1 Any interruption of the protective grounding conductor inside or outside the instrument or disconnecting the protective earth ground terminal is likely to make this equipment dangerous Intentional interruption is prohibited 2 Whenever it is likely that the ground protection has been impaired the equipment must be made inoperative by removing AC line power and then shall be secured against any unintended operation 3 Ensure that only fuses with the required rated current and of the specified type normal blow time delay etc are used for replacement The use of repaired fuses and the short circuiting of fuseholders must be avoided 4 Electrical energy avail
9. FLASHHEAD FLASHHEAD FLASHHEAD ANGHT SGF 60 5 60 SGF 60 SENSOR JUNCTION BOX CRN GRN WHT WHT BLK BLK WHT BLU BLU SHIELD SHIELD MASTER CONTROLLER SGC 60 WCO000001 FLASHHEAD CABLE o COMBINED POWER WIRING AND DATA CABLE K3 K4 K BLU WHT gt x 5 Bl X DATA COMMUNICATIONS CABLE TWISTED PAIR CABLE WITH DOUBLE SHIELDING FAULT ALARM OUTPUTS CONNECT INNER SHIELDS TOGETHER BUT NOT TO JUNCTION BOX OR OUTER SHIELDS INSULATE WITH ELECTRICAL TAPE PRIMARY AC INPUT POWER OUTER SHIELDS MAY BE TIED TO JUNCTION BOX PRIMARY AC INPUT POWER Figure 2 5 Typical Wiring Installation SG 60 High Intensity Strobe System 2 11 Manual EPM 00000019 Rev A AirportSystems Honeywell 2 4 1 Master Controller to Photocell Wiring The photocell is supplied with a length of wire attached If a longer wire is needed this should be accomplished using a junction box Make the interconnect between the external Photocell and the Master Controller TB2 per Figure 2 5 Page 2 11 as follows Black wire Photocell tO Master Controller TB2 B White wire P
10. Honeywell Check if problem is resolved after each step taken 1 Replace Digital Board 2 Check for loose connections to coil of FH K2 Relay 3 Replace FH 2 relay Check for loose mounting nuts on FH switch assembly Make sure FH Remote Local interlock is pressed when door latched Locate and repair break Per Section 2 4 2 Per Section 2 4 5 Section 2 5 4 Per page 4 2 Figure 4 3 General Troubleshooting Flashhead Stuck in Day Mode SG 60 High Intensity Strobe System 4 5 Manual EPM 00000019 Rev A AirportSystems Red Lights don t turn on at night Disconnect RLC Photocell Connect wiring from MC Red Night relay K4 to RLC Photocell Input Is MC K4 wired to RLG Photo Input Yes Is MC TB6 wired to RLG Top Beacon Manually turn on Red Lights at RLC Does MC Red Ready LED light up DS36 Connect wiring from MC TB 6 to Top Red Beacon alarms Yes Check wiring from MC Red Night relay K4 to RLC Photocell Input No is RLC reporting Check wiring from MC TB 6 to a Top Beacon Alarm Top Red Beacon alarms Yes Per Section 2 4 4 1 Repair Failed Top Beacon Per Section 2 4 4 2 Figure 4 4 Dual System Specific Troubleshooting SG 60 High Intensity Strobe System 4 6 Manual EPM 00000019 Rev A Airport Systems All Flashheads flash too slow 40 flashes per minute Does MC show
11. OVASOZ 2 VOL OVAOZL OVAOOI 9015 ON 980 Ine EOS 6 109 NOWONYLSSO VNN3INVY N3NHOJSNVHI 25082246 5205 7 dui H3TIOMINOO WIIG AH 9 1 7 a 2005 72 OVAQOZ 144 ee La 8 2 Za F Nuo eee run 2 240006572 gt NAOT 5 53 6 8 ON IVd H3WHOJSNVHIZHO9 2 001 804 EEDE 821141 2318 1 641549 z o e s 9 e e e o 41 46 2498 e 2 e L sparse Te Te T gt 89 m di 111 10 87 85 vuors 93 jl 55 LAON 14 S310N c al T 113 m v va T HM L Ie aid e mie 3 EM mms y QNvOBH3HION L4 sus a mo ob m H T r La z ES ut A008 OQAH Conon HOLOZTAS SOVLIOA 2 A00S 90NH ij G a H ovAd 93 613 St L T ond aay L 300N 1531 83 QMVOS 300N L 22 4 2 i sa 1018 B Caine OMAS 4 22 vasru 4 x ANI HRA i ras Tef 6 V9 Migi e eea 01 S 919 Er Xia en 4134 e i ila 3sN3 L 310N 336 m AVN away de er 2 m qais S 8 viva U qu V mal ma ms
12. OO SEIS LO ot 5 O 1 h Jo 1 1 H t 4 M S H 117 n M Ez s 63 DS1 LOGIC POWER RED rm VOLTAGE INDICATOR DS1 DS2 FLASH STATUS YELLOW SW1 AUTO RESET TEST BUTTON DS3 COMMUNICATION STATUS GREEN Figure 7 5 SG 60 AOL Power Supply Component Locations SG 60 High Intensity Strobe System 7 6 Manual EPM 00000019 Rev A Honeywell Airport Systems Gaziou3N3 30 G3ZI983N3 INY WALSAS j v 15 5 2 NOSY JWA B IWA voL Z OVAOSY X v9
13. 2 Check that all printed circuit boards are properly seated in their sockets and retaining brackets are securely fastened 3 Check that any user installed wiring does not interfere with relay operation when covers are closed 4 Check that all Flashheads are mounted are mounted at the correct elevation per Section 2 3 2 1 Page 2 7 Check that all Flashhead covers are shut properly for a weather tight seal with all latches closed 5 Set Master Controller switches as follows POWER SWITCH OFF LOCAL REMOTE Switch LOCAL MODE Switch DAY 2 5 2 Verify Correct Wiring in Master Controller Verify correct wiring of the Master Controller as specified in section 2 4 page 2 11 2 5 3 Verifying Photocell Wiring Verify correct wiring of the photocell as specified in section 2 4 3 page 2 12 2 5 4 Verify Proper Tower Wiring for Data Control Cable This test assumes a typical tower configuration with the data cable terminating at the Master Controller 1 Unplug Data Cable connector TB5 from PCB1 in Master Controller 2 Verify 120 140 ohms resistance between TB5 A and TB5 B on the Data Cable This checks that a single 100 ohm data line termination resistor is in the circuit Resistance of 70 ohms or less indicates that more than one Flashhead has the ter
14. Honeywell labels all the Flashheads with numbers ranging from 1 to 24 depending on the number of required lights for the structure Typically the upper most level of lights will contain the lights with numbers 1 through 3 or 4 If the structure has appurtenance of greater that 40 feet an AOL Antenna Obstruction Light is required and it will have a Flashhead Number of 1 The High Intensity Flashheads will start with Flashhead Number 2 The flashheads should continue down the tower from the top sequentially ending with the highest number at the bottom level The vent hole on the bottom surface of the power supply is covered with a solid plug prior to shipping Optional screened plugs are furnished separately SG 60 High Intensity Strobe System 2 6 Manual EPM 00000019 Rev A AirportSystems 1 Typically the Flashhead is mounted to a bracket which is then attached to the structure Honeywell can supply brackets for most types of installations A detailed drawing for mounting the Flashhead is shown in Figure 2 3 Page 2 10 2 3 2 1 Setting the Flashhead Elevation Flashheads must be mounted at the proper vertical angle to assure proper light output Depending on the elevation of the light level the Flashhead may need to be adjusted to reduce the amount of ground scatter Please refer to the table below for proper elevation for the lights 1 Slightly loosen the angle lock bolts which are at the bottom of the
15. SRM i FOCAL PLANE 3 88 98 4 1 E 5 CLEARANCE 10 25 260 4 16 50 419 1 21 9 95 4 CABLE CONNECTOR S 515 00 0 69 0 81 SLOT 6 PLACES 17 5 20 7 5 22 E 015 25 336 6 ot HOLE 4 TOP OF FLASHHEAD BASE FOR MOUNTING WITH 3 OR 4 FASTENERS 90 Figure 7 1 SG 60 AOL Flashhead Mounting Dimensions SG 60 High Intensity Strobe System 7 2 Manual EPM 00000019 Rev A Airport Systems 23 00 584 20 21 50 546 10 9 44 011 11 1 ae qu HINGE HINGE ee 66 46 04 16 19 411 2 2 88 222 2 1 2 50 63 50 XO C l P e OTN hy i xS I y 1 00 21 08 2 75 69 85 25 4 927 4 4x 2 00 50 80 2 2 4 00 101 601 2 00 50 80 1 2 00 50 80 Figure 7 2 50 60 AOL Power Supply Mounting Dimensions SG 60 High Intensity Strobe System 7 3 Manual EPM 00000019 Rev A Airport Systems FLASHHEAD FG2000B T SHIELD WHT lt BLU BLK
16. C3 or C4 shorted out Check to see if problem is resolved after each step 1 Replace Trigger HV Card 2 Replace Digital Card 3 Replace Flashtube 4 Replace Trigger Transformer Once problem is resolved try restoring one at a time components replaced in previous steps Select Manual Day Mode from FH Switch panel Apply power to Flashhead Check to see if problem is resolved after each step 1 Check fast on connectors No 2 Replace Digital Board Does K3 Relay pull in at power on 3 Replace K3 Relay Check FH resistor pack R2 R4 stack closest to door Replace if visually damaged Rectification Failure Replace Trigger High Yes Voltage Board Figure 4 2 General Troubleshooting Flashhead Does Not Flash SG 60 High Intensity Strobe System 4 4 Manual EPM 00000019 Rev A Airport Systems Flashhead stuck in Day Mode Will FH operate in other modes with manual election Is DB 053 green LED steady off No No Yes Are Comm wires correctly wired in FH TB1 ga Correct wiring Yes Are Comm wires correctly wired in MC TB5 No Correct wiring o Yes Remove all power from FH and MC Perform Comm Wiring Did wires pass _No isolation and continuity checks tests Installation Check and Continuity Check 4 Yes Replace Digital Board
17. No Yes Visually examine MC for damage near TB5 If damaged replace Master Controller PC Board Is Comm Cable wired to MC TB5 1 correctly Correct wiring Otherwise replace Master Controller chip U2 Yes Make sure only a single a No top level Flashhead has Perform Comm Wiring Tests Is wiring OK SW4 1 TERM set to on Check for shorts or breaks in the communication cable Yes Troubleshoot each Flashhead Section 2 4 2 individually Per Section 2 5 4 and page 4 2 Figure 4 1 General Troubleshooting All Flashheads Stuck in Day Mode SG 60 High Intensity Strobe System 4 3 Manual EPM 00000019 Rev A AirportSystems Honeywell Flashhead does not This test assumes that F1 flash and F2 have tested OK Yes Is FH Flashtube broken Replace Flashtube Microcontroller Failure Replace Digital Board Yes Press DB SW1 pushbutton 1 sec No Yes Is DB DS1 red LED 5V Indicator lit Is THVB DS1 High Voltage Indicator Lit and release No Remove Power at Power Supply Failure Breakers Discharge Replace Digital Board Capacitors Do DB DS2 yellow and DS3 green blink twice together No Yes Replace capacitor If THVB Yes DS1 High Voltage Indicator still does not light or system flashes erratically replace FH T1 Transformer Is FH capacitor C1A C1B C2
18. Green FH Status LED for each working FH No es Set MC switch SW 2 to on All Flashheads are flashing together but not in catenary pattern Does MC show Green FH Status LED for each working FH No Yes e For each top level FH Set DB switch SW2 1 to on Set DB switch W2 2 to off e For each bottom level FH Set DB switch SW2 1 to off Set DB switch SW2 1 to off e For each mid level FH Set DB switch SW2 1 to on Set DB switch SW2 2 to on See General System Troubleshooting Honeywell A Flashhead is out of sync with its catenary level Does MC show Green FH Status LED for that FH No Yes If FH is on top level Set DB SW2 1 to on Set DB SW2 2 to off If FH is on bottom level Set DB SW2 1 to off Set DB SW2 2 to on FH is on middle level Set DB SW2 2 to on Set BD SW2 2 to on Figure 4 5 Catenary System Specific Troubleshooting Chart SG 60 High Intensity Strobe System 4 7 Manual EPM 00000019 Rev A AirportSystems SECTION 5 MAINTENANCE 5 1 SGC 60 Master Controller The Master Controller required no periodic maintenance However below are the instructions for installing a new transformer 5 1 1 Transformer Replacement O A 0 1 9 WHT wire pair with new terminals o 277 240v 208v o 380 120v o 480
19. Model SGC 60 Master Controller 1 2 Figure 1 2 Model SGF 60 Flashhead 1 3 Figure 2 1 Flashtube 0 2 6 Figure 2 2 Master Controller Mounting Dimensions 2 9 Figure 2 3 Flashhead Outline and Mounting Dimensions 2 10 Figure 2 4 Typical Wiring 2 11 Figure 2 5 Flex Conduit Typical Installation 2 15 Figure 2 6 Junction Box Wiring 2 19 Figure 2 7 Flex Conduit Installation 2 20 Figure 2 8 WC000001 Cable Overview 2 nennen 2 21 Figure 2 9 2 e e Ren beet 2 24 Figure 2 10 Master Controller Circuit Board 2 25 Figure 2 11 Flashhead Digital Control Board 2 26 Figure 3 1 Master Controller Board 3 11 Figure 3 2 SGF 60 Flashhead System 3 12 Figure 3 3 SGF 60 Digital Board Schematic 242244444221 3 13 Figure 3 4 SGF 60 Trigger H
20. e lt Adequate slack should be pulled back up into the uppermost junction box to effect strain relief and to make proper wiring connections Once wiring bundle is supported by the strain relief mechanism make all wiring connections in the junction box i To make proper connections the wiring entering the box from above and the wiring above the strain relief mechanism at the bottom of the box must be long enough The wires at the top of the box should be formed into a J shape and the last 1 2 inch of insulation should be stripped off the conductor The wires from the bottom of the box supported by the strain relief mechanism should be run up to a point just short of the top of the junction box and cut off The last 1 2 inch of insulation should then be stripped from those Wire connections should be made with proper sized Scotch Twist wire nuts or split bolt connectors ii Once a wire nut is installed hold the wire nut and tug on all wires firmly to ensure the connection of all conductors is tight iii Finish each connection with at least 6 wraps of Scotch 33 tape or equivalent for proper moisture protection iv When a proper connection is complete the wire nut should be positioned upside down wire nut opening pointing downward SG 60 High Intensity Strobe System 2 16 Manual EPM 00000019 Rev A AirportSystems 1 1 Honeywell and the connection should be at the top end of the junction box Wiring from ports in the sides of
21. shut off current Once the capacitors discharge below a certain level the current flowing through the tube cannot keep the xenon gas ionized and the flashtube becomes a non conductor and shuts off self extinguishes Once the flashtube shuts off the selected energy storage capacitors immediately begin charging the next flash Relays K1 and K2 control which energy storage capacitors are charged and thus determine how bright the next flash will be When K1 and K2 are de energized as shown in Figure 3 2 Page 3 12 C1 C2 and C3 are charged C3 includes C3A and C3B This is provides the energy required for the Day Mode flash approximately 270 000 candela cd effective intensity If K2 is energized C3 is removed from the charging circuit and the reduced energy produces a Twilight Mode flash approximately 20 000 cd effective intensity If K1 and K2 are energized C2 and C3 are removed from the charging circuit The remaining C1 provides the energy for the pulsed Night Mode flash approximately 2 000 cd effective intensity The DB1 diode block isolates the capacitors from each other during charging so that they can be charged independently but allows them to all discharge through the flashtube simultaneously As an automatic safety feature the K3 relay will discharge the energy stored in C1 C2 and C3 when the case is opened opening the S1 interlock Never rely solely on the K3 discharge relay because if the safety discharge w
22. verify the voltage is 12 18 VAC Repeat steps 7 10 to assure proper recovery after reset Verify Local Mode Operation All switches and indicators listed in this section are in the Master Controller 2 6 4 1 Day Mode Verify MODE Switch is set to DAY Verify Day mode LED DS25 Figure 2 10 Item 3 Page 2 25 is lit red After about 6 seconds verify all Flashheads are flashing in sync and in Day mode maximum brightness Verify that the Flashhead Status LED for each Flashhead on the tower is lit green including any AOL Unused Flashhead status LEDs shall be off DS1 DS24 Figure 2 10 Item 4 Page 2 25 Verify relay status LEDs 0529 0532 are lit green ans 0533 is OFF Figure 2 10 Item 5 Page 2 25 SG 60 High Intensity Strobe System 2 30 Manual EPM 00000019 Rev A AirportSystems Honeywell 6 7 2 6 4 2 If you have a Dual Red White System the Red Lights should be OFF If you have a Catenary System Verify Catenary flash timing a Flashhead on Middle Level should flash together b All Flashheads on Top Level should flash together C All Flashheads on Bottom Level should flash together d Middle Level Flashheads should flash first e TopLevel Flashheads should flash second 1 13 second later f Bottom Level Flashheads should flash third 2 13 second after Top g Sequence should repeat every 1 second Time between Bottom and Middle flash is 10 13 seconds Twilight Mod
23. 19 Manual EPM 00000019 Rev A Honeywell Airport Systems TIVA 0 5 14 AOLVINSNI ONIHSNE ONIX 1935 3 193 1nu x20 auog a6p3 ajos 5 uoYAN 60000003 N d Assy 14 4801 N d 4039jnsu 801 1995 LAWWOSS 20000012 N d FINPUCDXS 4 v E 39034 3 95 ONIN ONT WAS NOTAN LAN NV 15 311194171 LINGNOD X314 47 6 10000024 TINA Figure 2 7 Flex Conduit Installation Detail Manual EPM 00000019 Rev A 2 20 SG 60 High Intensity Strobe System AirportSystems The flex conduit will need to be properly mounted to the horizontal and vertical struts by way of the supplied 20 inch cable ties These cable ties should be placed at a minimum of 3 feet apart for proper bonding to the tower structure The distance between the cable ties may need to be reduced if the installer sees that the 3 foot distance will not allow for proper bonding and securing to the tower Figure 2 5 Page 2 15 depicts a standard installation layout for the Flashhead pigtails and flex conduit 2 4 7 2 Splicing Details for WC000001 Cable The installation of the data communication cable is the most important part of the High Intensity Lighting system installation Without a sound connection for the data ca
24. 4 Manual EPM 00000019 Rev A Airport Systems Honeywell WARNING This system uses lethal voltages in the Flashhead Unless absolutely necessary do not attempt to service or adjust the equipment with AC line power applied Safety interlock switches are provided in the Flashhead enclosure to interrupt main AC power to the power supply These interlock switches are activated when the Flashhead door is opened in a conventional manner No interlock is provided when other means of access are used Never tamper with remove short circuit the interlocks in any way AC LINE VOLTAGE IS STILL PRESENT WHEN INTERLOCKS ARE ACTIVATED DISCONNECT POWER AT THE MAIN AC CIRCUIT BREAKERS BEFORE INSPECTING SERVICING UNLESS ABSOLUTELY NECESSARY TO PERFORM MAINTENANCE WITH POWER ON WARNING Flashtubes in this lighting system produce brilliant flashes of light containing some ultraviolet radiation that can cause temporary or permanent eye damage DO NOT LOOK DIRECTLY AT THE FLASHHEAD WHILE IT IS IN OPERATION SG 60 High Intensity Strobe System 1 5 Manual EPM 00000019 Rev A AirportSystems 1 1 1 4 Specifications Light Output Day Intensity 270 000 25 effective candelas single flash Twilight Intensity 20 000 25 effective candelas single flash Night Intensity 2 000 25 effecti
25. 60 High Intensity Strobe System 2 21 Manual EPM 00000019 Rev A AirportSystems Item 6 is a shield drain wire that will not be used for interconnection This wire should be cut off flush from the cable when the outer jacket is stripped back for interconnection of the system The following section is a guideline to a proper installation of the WCO000001 cable Please follow this guideline to ensure a proper installation and interconnection in the junction box 1 Strip back at least 16 of the outer jacket of the WCO000001 cable Make sure that during this removal the other wires are not damaged If the insulation is damaged on one of the other wires a potential of lighting problems can occur shortly after the system is connected 2 Remove all the aluminum foils and braids from the exposed conductors These will not be used for interconnection 3 Cut off Item 6 bare shield wire that protrudes from the cable This wire will not be used for interconnection 4 Connect Item 5 bare shield wire and Item 4 12 AWG Green wire from all the cables to the ground lug inside the junction box This ground lug can be found on the back plane of the junction box or at an internal locknut that has a ground screw attached No other wires will be connected to ground 5 Connect Item 1S data communication inner shield drain wire to the other data shield drain wires from the additional data cables Trim back the asso
26. Administration Advisory Circular 150 5345 43E The StrobeGuard system can support up to 24 Flashheads controlled by a single controller at distances up to 2500 feet The Flashheads are FAA light type L 856 or L 857 System components are shown in Figure 1 1 on Page 1 2 and Figure 1 2 on Page 1 3 The system consists of the following units e Model SGC 60 Master Controller e Model SGF 60 Flashhead e Ambient Light Sensor 1 2 1 Model SGC 60 Master Controller The Master Controller is a microprocessor based system that controls the flash interval and timing flash intensity and monitors the complete StrobeGuard system The controller is designed with LED status indicators and relays for remote alarming 1 2 2 Model SGF 60 Flashhead The Flashhead is designed as a capacitor discharge xenon flashtube unit The Flashhead consists of the following major components e Xenon flashtube e Reflector e High voltage trigger transformer e Power supply including high voltage e Control circuits 1 2 8 Ambient Light Sensor P N 12 00107 001 The Ambient Light Sensor photocell is used to provide input to the controller With this input the controller adjusts the operation of the system between day twilight and night SG 60 High Intensity Strobe System 1 1 Manual EPM 00000019 Rev A Airport Systems c8
27. Automatic Mode Control e Master Controller is turned on e Main Circuit Breakers are not tripped e Flashhead Fuses F1 and F2 are intact Remove power at breakers SG 60 High Intensity Strobe System 4 1 Manual EPM 00000019 Rev A AirportSystems 1 The charts assume that that you have already eliminated these as possible causes for the observed problem The charts may instruct you to make temporary changes for testing such as select operating modes manually or installing a jumper These temporary measures are marked with rectangles with rounded corners Always return the systems to their normal state after completing your troubleshooting To reduce chart complexity the charts not specify the individual actions necessary Multiple strobe problems are most commonly cause by faults in the communications cabling If you have determined that there is a short or break we recommend disconnecting communication wiring leading to the upper sections of the tower while checking and or repairing the lower sections Individual flashheads may be isolated in the same way Using this technique work upward from one flashhead level to the next to create known good wiring per Section 2 5 4 If the cable test shows an open between TB5 A and TB5 B even though a terminator is set in a top most strobe then there is a break in either the A or B line Use the following test to determine if the break is above or below a Flashhead lev
28. Circuit Board SG 60 High Intensity Strobe System 2 25 Manual EPM 00000019 Rev A Honeywell Airport Systems S Q0 34E00031 001 REV 268699 10000 0 k ONL m mmm m TOP eee 5 05 0 REV gt le e AT 051 052 063 Swi 12 4 8 18 e cm eNO NITE Honeywell 5115 FLASHHEAD m e SPARE BER lt 2 00000000000000000000 U6 e o un Neo v e 2 4 e Fa 22 6 R45 e c4 417 x g e A i e U3 ee 081 C5 GD DB2 Figure 2 11 Flashhead Digital Control Board SG 60 High Intensity Strobe System 2 26 Manual EPM 00000019 Rev A AirportSystems Honeywell 2 5 Final Installation Check Before applying power to the equipment perform the procedures in Sections 2 5 1 2 5 4 If any test does not pass please consult SECTION 4 TROUBLESHOOTING in this manual or call Honeywell Technical Support at 805 581 5591 2 5 1 Preliminary 1 Verify that all AC input power circuit breakers are turned off
29. Dual system has switched to White Night Backup Once the Master Controller has switched into White Night Backup it will remains latched in that mode until switched into Twilight or Day Mode either automatically or manually If the Red Light Controller indicates is ready DS36 is lit at the next transition to into Night Mode the Red Lights will be tried again Typically Red Light Systems such as the Honeywell 9LCA series do not report any Beacon Failures SG 60 High Intensity Strobe System 3 9 Manual EPM 00000019 Rev A AirportSystems Honeywell during the daytime In this case the Master Controller will briefly try the Red Lights each night until the top beacon is repaired Troubleshooting Tip To check system communications independent of most Flashhead failures place a jumper across TB6 1 and TB6 2 set SW2 2 On and select Local Night Mode from the switch panel Because an Off Mode flash cannot fail all the Flashheads will reply OK if they can Be sure to restore your Master Controller to its proper configuration after testing 3 3 4 Communications Circuitry The Master Controller transmits it flash requests and receives replies via an RS485 serial link The RS485 transceiver chip U2 is protected from voltage transients by surge suppression devices and by transformer optical isolation from chassis ground and the rest of the digital board The microcontroller U1 monitors its own transmissions After each transmission th
30. RES ORIS 244 PES m e pr HH ANO ig ord 5 1 8 Y t WANN YO 3svHd mos 8 T 24 in 1 IH 0 5 Sl MO 3SHd S Son ONAS 3SVHd i i 8 v 3604 Why T Wy MS z 43407402 18 o 15 nor 8 9480 LHN BA nia 92 aoa LHM M fy 300 5 1 xu 4 POORAN v is d T 8 6619 12 Q2 m MOIS3HHV Tm nw fer Ava 38015 TS EU E IC Manual EPM 00000019 Rev A SG 60 AOL Schemat 7 7 Figure 7 6 SG 60 High Intensity Strobe System
31. Rev A AirportSystems Honeywell Eur LL 2 4 6 1 1 3 FLEX 2 CONDUIT 56 60 FLASHHEAD TYP JUNCTION BOX CONDUIT Figure 2 5 Flex Conduit Typical Installation Layout Procedures for installation of conduit and tower wiring All conduit junction boxes mounting hardware fixtures etc provided for installation of the electrical system i e lighting or equipment power distribution should be inventoried and checked against the appropriate bills of materials a Conduit and junction box components provided for electrical systems should be checked against appropriate bills of materials to ensure all are present and of proper size b Numbers of wires to be carried by each conduit run should be checked against National Electrical Code Honeywell sizes the conduit run for a 40 fill of the conduit by the NEC Use pipe compound or equivalent for all threaded connections in the conduit run This will prevent water from entering the conduit system and make an electrical connection between the conduit and ground All custom cut pieces of conduit must be de burred after they are threaded to remove sharp edges that may cut wiring insulation Honeywell supplies conduit in 10 foot lengths therefore cutting and threading of the conduit may be necessary Insure that chase nipples or bushings are properly installed in all junction box ports to protect the wiring insulation from pipe threads an
32. Shield not connected at either end 2 4 3 Master Controller Power Wiring Make the connections for incoming AC line power to Master Controller PB1 per Figure 2 5 Page 2 11 as follows These wires or cable are not supplied by Honeywell A separate circuit breaker is recommended for the Master Controller The Master Controller may if desired use a different AC line voltage than the Flashheads The wire colors below are typical for single phase power Be sure to check your own installation colors Black wire Phase or hi tO Master Controller PB1 L White wire Phase or neutral to Master Controller PB1 L N Green wire Equipment ground to Master Controller PB1 G SG 60 High Intensity Strobe System 2 12 Manual EPM 00000019 Rev A AirportSystems 2 4 4 Master Controller Wiring For Dual Systems If your installation is a Dual Red White system you must make additional connections to coordinate between the High Intensity Strobe System and the Red Light System See the sections below for wiring details For configuration switch settings for a Dual system see 2 2 1 3 on Page 2 2 2 4 4 1 Controlling the Red Light System The Master Controller uses Relay K4 to control the Red Light System The Relay K4 contacts should be wired to the Red Light System in such a
33. W BRN RED i SG60AOL POWER SUPPLY ON So OUTPUT TYPICAL TB1 WIRING 2 2 m lt 1 SE 8418 82 T 55 I o AMBIENT 3 lt lt no LIGHT SENSOR 2 mm 6542151 o D MASTER CONTROLLER BOR SGC 60 ALARM ALARM eo o o e 0090 Inet ca 2 ca jvos Nce cs UJIJI o C FAULT ALARM OUTPUTS PRIMARY AC INPUT POWER TWISTED PAIR CABLE WITH DOUBLE SHIELDS CONNECT INNER SHIELDS TOGETHER BUT NOT TO JUNCTION PRIMARY AC INPUT POWER BOX OR OUTER SHIELDS INSULATE WITH ELECTRICAL TAPE OUTER SHIELDS MAY BE TIED TO JUNCTION BOX Figure 7 3 SG 60 AOL Wiring Installation SG 60 High Intensity Strobe System 7 4 Manual EPM 00000019 Rev A AirportSystems 1 GLOBE ff REFLECTOR FT 1 FLASHTUBE ASSEMBLY 51 INTERLOCK SWITCH
34. from Flashhead transformer T2 T2 15 and T2 16 entering the Digital Board at P2 21 and P2 23 respectively Asa failsafe measure the Digital Board will issue a trigger request after a timeout period even if no zero crossing is detected When acting as a Top or Bottom Catenary Flashhead the Digital Board will delay by 1 13 and 3 13 seconds respectively before looking for the first T2 zero crossing to achieve the required Catenary flash sequence Middle 1 13 s Top 2 13 s Bottom 10 13 s Middle etc The SW2 1 and SW2 2 switches instruct the Digital Board to apply the correct timing delays for Catenary Systems The faster flash rate 60 flashes per minute is set by an option on the Master Controller SW2 1 3 2 2 5 Flash Feedback The Digital Board monitors the current discharged through the flashtube with the Flashhead current sense transformer T3 The T3 output is used to peak charge a capacitor C17 The microcontroller reads the captured voltage level at the capacitor with A D converter U5 before and after the flash to determine if the flash occurred successfully C17 will fully discharge before the next flash The yellow LED DS2 indicates the results of the most recent flash If the Digital Board considered the flash successful the DS2 will be on If the Digital Board considers the flash to have failed DS2 will be off If four consecutive flashes fail the Digital Board reports a Flash Fail alarm to the Master Contro
35. in night mode red lights are turned off and white strobes are operating OFF indicates NORMAL operation If SW2 2 is set for no EXTERNAL RED system OFF then e DS32 ON during DAY and TWILIGHT OFF during NIGHT mode e 0533 Not used lower right of board DS31 Figure 2 10 Item 5 Page 2 25 ON indicates power OK OFF indicates power failure DS30 Figure 2 10 Item 5 Page 2 25 ON indicates photocell is GOOD OFF indicates photocell is BAD or not connected DS29 Figure 2 10 Item 5 Page 2 25 ON indicates all Flashheads are good OFF indicates one or more Flashheads are bad Flashhead Status Indicators Miscellaneous Indicators Figure 2 11 Item 1 Page 2 26 051 Red ON for 5 Volt logic power DS2 Yellow ON for Flash Current Feedback OK DS3 Green ON Steady for communications OK receive amp transmit OFF for no communications reception Slow Blink 1 sec for receiving but not being addressed to transmit Fast Blink 4 sec for receiving being addressed to transmit but failing to transmit System Power Up All switches and indicators listed in this section are in the Master Controller except for the external system circuit breakers Verify POWER SWITCH is turned OFF Verify LOCAL REMOTE switch is set to LOCAL Verify MODE switch is set to DAY Turn on circuit breaker to apply power to Master Controller Turn on circuit breaker to apply power to Flashheads Turn POWER SWITCH to ON SG 60 High Intensity S
36. intended to be used as a general guide and do not cover every possible mode of failure 1 Always turn off power when changing any component or printed circuit board 2 High voltage is present in the Flashhead Do not cheat the interlocks 3 Do not put hands or tools in the Flashhead until the High Voltage Indicator neon lamp DS1 on the High Voltage amp Trigger board is extinguished Refer to Figure 1 2 Page 1 3 for the location of High Voltage Indicator DS1 do not confuse the High Voltage Indicator DS1 with the PWR ON lamp 051 Note that it is possible for the High Voltage Indicator DS1 to be lit even when the PWR ON lamp DS1 if off If this happens the energy storage capacitors C1 C3 must be discharged before performing maintenance 4 Do not look directly into the Flashhead at close range when it is flashing Flashtubes in this lighting system produce brilliant flashes of light containing some ultraviolet radiation which can cause temporary or permanent eye damage 5 The components and assemblies in this system were designed by Honeywell to handle the high voltages that are present Honeywell strongly recommends against substituting components or assemblies that might be available through other vendors Before consulting the troubleshooting charts check the following e The Master Controller Local Remote Switch is in Remote Photocell e f you have a Dual System check that the Red Light Controller is also set for
37. junction boxes should also be made such that the wire nuts are at the top of the junction box with the wire nut openings pointing downward see Figure 2 6 Page 2 19 for proper moisture protection f Move down to the next intermediate strain relief junction box and pull enough of the wiring into the box to provide for the proper installation of the strain relief mechanism g Move down to the next intermediate junction box and repeat the above procedure until the entire tower is wired SG 60 High Intensity Strobe System 2 17 Manual EPM 00000019 Rev A AirportSystems Honeywell 2 4 7 Junction Box Details This section will detail the proper wire interconnection details for the input voltage and data cable to the flashhead pigtail cable These connections are very important to the proper operation of the lighting system The flashhead pigtail contains all the wires required for proper interconnection between the conduit wiring and flashhead Additional reference materials can be found on the High Intensity Lighting system drawing set Please reference the below information and drawings for a proper installation Mis wiring of these wires will not allow the flashheads to operate properly Please call the Honeywell Technical Support if you have any questions regarding the installation of these connections Systems that are improperly wired may void the warranty 2 4 7 1 Flex Conduit Installation On each of the high intensity flashhead
38. mounting arms see Figure 2 3 Page 2 10 The bolt heads and nuts fit 7 16 wrenches or nut drivers tightening will require a pair of tools 2 Adjust the Flashhead enclosure until the bubble indicator on top of the enclosure reads level 3 Take note of the position of the bolt with respect to the silk screened markings on the angle indicator This position is the zero degree position The markings are screened at intervals of one degree 4 Adjust the Flashhead enclosure to aim the beam upward until the bolt head has shifted by the number of degrees indicated in the table below 5 Securely tighten both angle lock bolts Light Unit Elevation Above the Horizontal Height of Light Unit Above Degrees of Elevation above Ground Level Horizontal More than 500 feet 0 401 feet to 500 feet 1 301 feet to 400 feet 2 Less than 300 feet 3 2 3 3 Ambient Light Sensor Photocell The Ambient Light Sensor when supplied with the system shall be mounted upright away from artificial light e g floodlights and in a location that will enable the sensor window to have an unobstructed view of the polar sky pointed north in the northern hemisphere not pointed toward the sun The photocell housing wire entry is tapped to allow mounting to 1 2 threaded pipe Conduit and related hardware will be supplied by the customer A 21 foot 3 conductor cable is attached to the photocell for remote installation SG 60 High I
39. resistance for the RS485 serial network Each end of the cable should be terminated with a resistor Typically only one flashhead one of the ones farthest from the Master Controller will have SW4 1 set to ON All other flashheads will have SW4 1 set to OFF Every Flashhead must be assigned a unique address or ID flashhead number from 1 through 24 inclusive so the Master Controller can monitor the status of each individual Flashhead The Flashhead number is set using SW3 Set the SW3 switches so that their total value equals the desired flashhead number The value for each switch SG 60 High Intensity Strobe System 3 4 Manual EPM 00000019 Rev A AirportSystems position is shown on the board silkscreen Note that ON means zero and that OFF means the indicated value negative binary The Digital Board will only transmit a reply when its number is specified by the Master Controller The Digital Board monitors its transmission quality by reading the transmission as it sends it The green LED DS3 indicates the current communications status It is updated after every flash If no valid requests are being received from the Master Controller the LED will stay off If DS3 comes on this indicates a valid data reception from the Master Controller The DS3 flash pattern indicates the status of the most recent transmission from this Flashhead to the Master Controller A slow blink indicates that no transmission has been at
40. the high voltage to be shut off and the energy storage capacitors to discharge When door is open and S1 is pulled out manually the interlock is defeated which allows the Flashhead to operate under power S2 MODE _ Interlock Switch Three position push pull switch When the Flashhead door is opened transfers flash intensity mode select from remote control by SGC 60 Master Controller to local control using switch S3 When door is open and S2 is pulled out manually the interlock is defeated which allows the Flashhead to operate under remote mode control S3 MODE TEST Switch Three position rotary switch allows local flash intensity mode selection Day Twilight or Night for the individual Flashhead while not affecting the operation of any other Flashhead in the system F1 Main Power Line Fuse Provides protection for AC power to transformer T1 Value varies with input AC line voltage Refer to Section 7 0 for the correct fuse values Honeywell provides the correct fuse for the supplied power configuration F2 Logic Power Line Fuse Provides protection for the AC power to the logic transformer T2 Value varies with input line voltage Refer to Section 7 0 for the correct fuse values Honeywell provides the correct fuse for the supplied power configuration SG 60 High Intensity Strobe System 2 3 Manual EPM 00000019 Rev A AirportSystems 2 2 2 1 Power Configuration The Flashhead s are factory set for the correct AC
41. when the High Voltage Indicator DS1 indicator is lit DS1 is the neon lamp located on the High Voltage amp Trigger board do not confuse the High Voltage Indicator DS1 with the PWR ON lamp 081 It is possible to have high voltage on the energy storage capacitors even if all AC power has been removed from the system even though the system is designed to drain the energy storage capacitors when power is removed 3 2 1 SGF 60 Motherboard The Motherboard has no active components It provides the necessary connections between the external power and control wires and the Digital and Trigger High Voltage Cards It provides card edge sockets for the Trigger High Voltage Board J1 and the Digital Board J2 Logic signals enter the motherboard through the J3 cable connector Most of the fast on terminals E1 E10 are used for high voltage and or high current connections 3 2 2 SGF 60 Digital Board The digital board is responsible for coordinating all the activity within the Flashhead The microcontroller U6 is the main processing units of the Flashhead It receives interprets acts on and replies to commands from the Master Controller It also controls the energy selection relays reads the manual mode select switches controls the flashtube triggering monitors the flash current In the absence of any signals from the Master Controller it will autonomously operate the strobe in Day Mode The following is a simplified sequence of events
42. 0 High Intensity Strobe System Airport Systems 4 4 gt 4 IRERE 1 E T 4 4 1 4 2 1 4 2 y EI Figure 3 3 SGF 60 Digital Board Schematic SG 60 High Intensity Strobe System we o is 3 H 2 ES 3 13 Honeywell 4 5 e o z ul 4 43 a i I 3 2 2 gt Manual 00000019 Rev Airport Honeywell P1 C P RS 3628 1843825 4 1457920 4720 5101 lt 2 7 1 4007 weer ae u Di lt 3 19 2 55 lt xh 2 46 0 oe lt SE a gt be 5 dj 20 1 rast A 5 rj y P gt Figure 3 4 SGF 60 Trigger High Voltage Board Schematic SG 60 High Intensity Strobe System 3 14 Manual EPM 00000019 Rev A Airport Systems SECTION 4 TROUBLESHOOTING Refer to the troubleshooting flowcharts Replace components in the order stated and keep track of those replaced The following troubleshooting procedures presume that all fuses interlocks and controls are functioning properly Note that the troubleshooting flowcharts are
43. 0000019 Rev A Airport Systems 0 44 16 00 T 28 5 1500 11 406 16 222 76 1 1 15 25 14 58 17 00 387 1 0 432 e Mb g 1 0 44 111 18 88 480 1 RELATIVE ANGLE MARKERS ANGLE LOCK BOLT BOTH SIDES DIMENSIONS ARE INCHES MILLIMETERS 2 38 6017 WEIGHT 82 LBS 37 2 Kg Figure 2 3 Flashhead Outline and Mounting Dimensions SG 60 High Intensity Strobe System 2 10 Manual EPM 00000019 Rev A AirportSystems 2 4 Installation Wiring Follow the procedure below to perform the installation wiring Note that the wiring of the Alarm Relay outputs is customer and site specific and is therefore not specified in this manual OWL 2 OWL 1 OWL 3 TYPICAL TB1 WIRING z 5 n 5 o 1 N PHASE NEU PHASE HI DATA LINE A DATA LINE CX WHT BLI SHIELD 5
44. 5 07 18 0 nt ern ek 1 6 SECTION 2 INSTALLATION 8 POWER 2 1 UNPACKING merentas DL tt 2 1 2 2 SYSTEM CONFIGURATION n un ea rar Mun re REN Ae dune epu aun ue seed 2 1 2 2 4 Master Controller 2 1 2 2 2 Flashhead 2 2 3 295 INSTALLATION O u aeta 2 6 231 SGC 60 Master 2 nnne nnn nnns 2 6 2 3 2 SGF 60 Flashhead d Q n n 2 6 2 8 8 Ambient Light Sensor 2 7 2 3 4 Cables and Junction Boxes 2 8 2 4 INSTALLATION WIRING REM 2 11 2 4 1 Master Controller to Photocell Wiring aaa 2 12 2 4 2 Master Controller Data Communications 0 2 12 243 Master Controller Power Wiring 2 12 2 4 4 Master Controller Wiring For Dual 2 13 24 5 Wirlrngo tte teo ete RR DOE RA AR EATUR RA CUR eR EE 2 14 2 4 6 Conduit and Tower Wiring 2 14 2 4 4 Junc
45. 6 seconds Set the MODE switch back to NIGHT Wait for the Flashheads to switch to OFF mode about 6 seconds 5 k lt Verify normal red night mode operation per Step 6 above I If you have more than one Red Beacon at the top level repeat the simulated failure test for each Red Beacon SG 60 High Intensity Strobe System 2 32 Manual EPM 00000019 Rev A AirportSystems Honeywell 2 6 5 2 6 6 15 16 17 20 21 22 23 Verify Photocell Operation Connected to Controller Verify proper mounting and orientation of photocell Photocell shall face toward the polar sky e g North in the northern hemisphere not toward the sun Set LOCAL REMOTE switch to REMOTE Verify that the correct Mode status LED DS25 0527 Figure 2 10 Item 3 Page 2 25 is lit red according to the ambient light conditions during normal daylight DS25 shall be lit red Completely cover photocell use a glove or hat for example Verify Night Mode status LED DS27 is lit red Verify all other LEDs are in normal operating condition Verify that the Tower Lighting System is operating in normal night mode per 2 6 4 3 Steps 2 through 6 only Uncover the photocell to expose it to ambient light Verify Mode status LEDs are in normal status for current ambient light conditions during normal daylight DS25 shall be lit red and DS26 and DS27 shall be unlit Verify Photocell Operation Not Connecte
46. Airport Systems Installation and Operation Guide for High Intensity Obstruction Lighting System Model SG 60 Manual Number 00000019 001 Honeywell Airport Systems 2162 Union Place Simi Valley CA 93065 Phone 805 581 5591 Fax 805 581 5032 www oblighting com Copyright 2002 Honeywell Inc All Rights Reserved AirportSystems HISTORY OF REVISIONS Rev Comment ECO Approved Date A First Release New Boards 3637 S Hammond 8 30 2002 NOTICE The integrity and reliability of Honeywell airport lighting systems are dependent on the use of Honeywell parts and components To ensure the optimum performance and reliability of your Honeywell system it is strongly advised that only components and modules provided by Honeywell be used WARRANTY Honeywell warrants the equipment described in this instruction manual and sold to the purchaser to be free from defects in material and workmanship at the time of shipment Honeywell s liability under this warranty being limited to repairing or replacing at Honeywell s option items which are returned to it prepaid within one year from date of installation or a maximum of two years from date of shipment whichever is less to the original Purchaser and found to Honeywell s satisfaction to have been defective In no event shall Honeywell be liable for consequential damages NO PRODUCT
47. IS WARRANTED AS BEING FIT FOR A PARTICULAR PURPOSE AND THERE IS NO WARRANTY OF MERCHANTABILITY This warranty applies only if l the items used solely under the operating conditions and in the manner recommended in Honeywell s instruction manual specifications or other literature Il the items have not been misused or abused any manner or repairs attempted thereon 111 written notice of the failure within the warranty period is forwarded to Honeywell and the directions received for properly identifying items returned under warranty are followed and IV such return notice authorizes Honeywell to examine and disassemble returned products to the extent Honeywell deems necessary to ascertain the cause of failure The warranties stated herein are exclusive THERE ARE NO OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED BEYOND THOSE SET FORTH HEREIN and Honeywell does not assume nor does Honeywell authorize anyone else to assume for it any other obligation or liability in connection with the sale or use of said products Honeywell s liability on any claim of any kind including negligence for loss or damages arising out of or connected with the manufacture sale delivery repair or use of any equipment or services provided by Honeywell shall in no case exceed the price allocable to the item or service or part thereof which gives rise to the claim EPM 00000019 001 i Rev A AirportSystems Honeywell DISCLAIMERS This manual could
48. SERIOUS INJURY FROM CIRCUITS WITH POWER CONTROLS IN THE OFF POSITION THIS IS DUE TO CHARGES RETAINED BY THE CAPACITORS TO AVOID SERIOUS INJURY ALWAYS DISCONNECT POWER THEN DISCHARGE CAPACITORS BY USING AN APPROVED GROUNDING ROD PRIOR TO TOUCHING ANY PART RESUSCITATION MAINTENANCE PERSONNEL SHOULD BE TRAINED IN CARDIOPULMONARY RESUSCITATION CPR CAUTION This equipment contains static sensitive semiconductor devices and integrated circuits that may be damaged by Electro Static Discharge ESD Take the necessary precautions before attempting service Any replacement circuit boards should be kept in metallized anti static bags until immediately before installation Ground yourself touch the outside of a grounded metal enclosure before removing circuit boards from their protective bags Avoid touching components when handling the boards EPM 00000019 001 vii Rev A AirportSystems SECTION 1 GENERAL INFORMATION 1 1 Scope This manual provides information about the installation operation and maintenance of the StrobeGuard Model SG 60 High Intensity Obstruction Lighting System manufactured by Honeywell 1 2 General Description The StrobeGuard system is a high intensity flashing white obstruction lighting system with a xenon flashtube as the light source It designed for use as a high intensity aviation obstruction warning system The system is designed and manufactured to comply with Federal Aviation
49. able at many points may result in personal injury or death if touched Any adjustment maintenance and repair of the opened equipment while power is applied shall be avoided as much as possible however some maintenance described in this manual is performed with power supplied to the equipment while protective covers are removed When repair with power applied is unavoidable maintenance shall be carried out only by a skilled person who is aware of the hazard involved Do not attempt internal service or adjustment unless another person capable of rendering first aid and resuscitation is present 5 Do not install substitute parts or perform any unauthorized modification to the equipment 6 Capacitors inside the equipment may still be charged after the equipment has been disconnected from its power source even though the equipment was designed to drain charge from the capacitors when power is removed Do not put hands or tools in the Flashhead until the High Voltage Indicator neon lamp DS1 on the High Voltage amp Trigger board is extinguished Refer to Figure 1 2 Page 1 3 for the location of High Voltage Indicator DS1 do not confuse the High Voltage Indicator DS1 with the PWR ON lamp DS1 Note that it is possible for the High Voltage Indicator DS1 to be lit even when the PWR ON lamp 051 is off If this happens the energy storage capacitors C1 C3 must be discharged before performing maintenance SG 60 High Intensity Strobe System 1
50. alled Should you need to install or replace this cable make the connections for incoming AC power and data to Flashhead TB1 per Figure 2 5 Page 2 11 and Figure 2 10 Page 2 24 as follows Green wire Equipment ground tO Flashhead TB1 1 White wire Phase or neutral tO Flashhead TB1 2 Black wire Phase or hi tO Flashhead TB1 3 Data Cable White or Clear wire Data signal A to Flashhead TB1 4 Blue wire Data signal B tO Flashhead TB1 5 Inner shield Data shield to Flashhead TB1 6 Outer shield trim short not connected 2 4 6 Conduit and Tower Wiring Detail This section details a standard practice of installing conduit and the related tower lighting wires for the system Please use this guide to help install the wires into the conduit system The wires and cables for the SG 60 High Intensity system need to be run properly to insure that the system will work properly Wire insulation that is damaged will lead to a system that will not function properly and may void the warranty Insure that the following procedure is followed Pay close attention to all bold text SG 60 High Intensity Strobe System 2 14 Manual EPM 00000019
51. allowing capacitor C4 to charge again in time for the next flash If another trigger request signal has arrived from the Digital Board C3 is immediately charged and the process is repeated until all trigger requests are processed The Trigger High Voltage Board will only fire the flashtube in response to a trigger request from the Digital Board For night flashes composed of multiple pulses the Trigger High Voltage Board requires a series of requests from the Digital Board If the U1 microcontroller cannot detect the high voltage zero crossing it will fire the flashtube immediately after receiving the trigger request from the Digital Card SG 60 High Intensity Strobe System 3 7 Manual EPM 00000019 Rev A AirportSystems 3 3 SGC 60 Master Controller 3 3 1 Power Supply The Master Controller input power is connected to PB1 which then feeds transformer T1 under the switch panel The Master Controller can accept a number of input voltages depending on the primary tap connections to T1 and will operate at 50 or 60 Hz The T1 transformer output provides 12VAC to the Master Controller circuit board PCB1 1 17 and T1 18 connecting to PCB1 1 1 1 2 The input voltage passes through fuse F1 is rectified by DB1 and filtered by C16 This unregulated voltage about 16VDC is available for external use TB8 The 16VDC is also fed into the switch mode power supply including voltage regulator VR1 which
52. ble the entire system will not work properly Insure that the following steps are followed to insure a proper installation and connection NOTE Splicing of the cables at any other location besides the light level is not recommended The intermediate junction boxes between the light levels should be used as pull boxes and for strain relief only with no splices The WC000001 cable is a multi conductor cable that is used for the interconnection of the flashhead to the junction box The 00001 cable consists of the following wires cable CONDUCTORS JACKET 2 ITEM WIRE INSULATION NO SIZE STRANDS COLOR FILLER ZX gt 1A 20 AWG 7 28 CLEAR 6 lt 1B 20 AWG 7 28 BLUE 5 15 20 AWG 10 30 BARE DRAIN WIRE 5 2 2 41 30 BLAC 5 12 AWG 41 30 ts ALUM WRAP BRAID 4 112 awe 41 30 CREE INNER SHIELD 5 4 AWG 41 30 BARE DRAIN WIRE JACKET 6 4 AWG 4 30 BARE DRAIN WIRE BRAID OUTER SHIELD ALUM MYLAR WRAP Figure 2 9 WC000001 Cable Overview Item 1 A B S is the data communication cable that is used to transmit all the data from the master controller SGC 60 to the flashhead SGF 60 Without a proper connection the lighting system will flash erratically or default to Day mode Items 2 3 and 4 are used for the power input from the junction box to the flashhead Item 5 is the Drain Wire for the outer cable shield SG
53. ciated shield neatly Make sure that this drain wire and the shield cannot contact the walls of the junction box or other wires Do not connect inner shield to outer shield Extra taping may be required for proper isolation The inner shield should only have a connection to ground inside the SGC 60 controller On a typical installation there will be a total of 5 wires that will be connected together One from the lower junction box level three from the flashhead cables on that level and one for the cable going to the next level 6 Connect Item 1A to corresponding wires in other four cables as stated above in step 5 7 Connect 1B to corresponding wires in other four cables as stated above in step 5 8 Connect the 12 AWG Black and 12 AWG White wires as required by the installation drawing set supplied with the lighting system If the system has a 3 phase input ensure proper connection between the 3 phase wires typically brown orange and yellow and the black and white wires from the flashhead Proper load balancing is required on the three phase input to operate efficiently distribute the flashheads as evenly as possible across the phases SG 60 High Intensity Strobe System 2 22 Manual EPM 00000019 Rev A AirportSystems ss 9 The power wires should be spliced together using split bolt connectors The data wires should be spliced together using Scotch Twist Lock connectors After splicing ensure all
54. contain technical inaccuracies or typographical errors Honeywell reserves the right to revise this manual from time to time of the contents thereof without obligation of Honeywell to notify any person of such revision or change Details and values given in this manual are average values and have been compiled with care They are not binding however and Honeywell disclaims any liability for damages or detriments suffered as a result of reliance on the information given herein or the use of product processes or equipment to which this manual refers No warranty is made that the use of the information or of the products processes or equipment to which this manual refers will not infringe any third party s patents or rights The information given does not release the buyers from making their own experiments and tests EPM 00000019 001 i RevA AirportSystems Honeywell TABLE OF CONTENTS SAFETY INFORMATION U u J V SECTION 1 GENERAL INFORMATION 1 1 141 1 2 GENERAL DESCRIPTION 7 1 1 1 2 1 Model SGC 60 Master n 1 1 1 2 2 Model SGF 60 Flashhead a 1 1 1 2 8 Ambient Light Sensor P N 12 00107 001 a 1 1 IRE cia duisi ze Ugo REM 1 4 124 1 1 161
55. d The WARNING calls attention to a procedure or practice which if not correctly performed or adhered to could result in property damage injury or death Do not proceed beyond a WARNING sign until the indicated conditions are fully understood and met CAUTION Failure to obey the instructions following a CAUTION marking may result in equipment damage EPM 00000019 001 RevA AirportSystems Honeywell QUALIFIED PERSONNEL The term qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation maintenance and repair Qualified personnel are physically capable of performing the required tasks familiar with all relevant safety rules and regulations and have been trained to safely install operate maintain and repair the equipment It is the responsibility of the company operating this equipment to see that its personnel meet these requirements INTERLOCKS This equipment contains interlocks for your protection To ensure safety always remove power from the equipment prior to opening access panels or doors if possible Do not depend on the interlocks or door switches when working with the equipment Do not short circuit or tamper with any access gate door or other safety interlock switch Discharge capacitors with an approved insulated grounding rod prior to touching any part When it is absolutely mandatory that an interlock be bypassed for the purpose of tracing or correc
56. d other sharp edges in SG 60 High Intensity Strobe System 2 15 Manual EPM 00000019 Rev A AirportSystems the junction box ports Do not begin to run wire through a junction box port before a chase nipple or grommet is in place 5 Before running the wire into a box insure the wire insulation will be protected from any sharp edges on the junction boxes Pieces of carpet wide copper braid etc can be fastened in place over sharp edges to protect wire insulation 6 Precut and bundle method of wire installation a Cut all conductors to length for their respective run with adequate excess to allow for strain relief and additional slack for connections 0 Ensure that there is plenty of wire pulling lubricant on site before beginning to pull wiring Use plenty of lubricant as the wire is being run through the conduit c The wiring bundle should be hoisted above the junction box at the top of the run into which it is to be inserted then lowered down into the conduit There should be someone at the top junction box of the run to insure the wiring does not get scuffed or cut on junction box edges and to apply lubricant to the wiring as it enters the conduit d If the conduit and wire will be installed on the ground use the same methods described here Insure proper amount of lubricant is available and that the wire is shielded from any rough edges on the conduit or ground that might damage the wire cable insulation
57. d to Controller Disconnect connector TB2 from PCB1 in the Master Controller Verify all Flashhead LEDs 051 0524 are lit red Verify Photocell status LED 0528 Figure 2 10 Item 3 Page 2 25 is lit red Verify Photocell alarm LED DS30 Figure 2 10 Item 5 Page 2 25 is un lit Verify all Flashheads are operating in Day mode maximum brightness The Flashheads will very slowly drift out of sync Reconnect connector TB2 to PCB1 in the Master Controller Verify that the Flashhead Status LED for each Flashhead on the tower is lit green including any AOL Unused Flashhead status LEDs shall be off DS1 DS24 Figure 2 10 Item 4 Page 2 25 Verify Photocell status LED DS28 Figure 2 10 Item 3 Page 2 25 is lit green Verify Photocell alarm LED DS30 Figure 2 10 Item 5 Page 2 25 is lit green If the system passed all of the tests in Sections 2 6 3 2 6 6 above the Master Controller photocell and tower wiring were installed properly and the system is ready SG 60 High Intensity Strobe System 2 33 Manual EPM 00000019 Rev A Honeywell for normal operation If any test did not pass please consult SECTION 4 TROUBLESHOOTING in this manual or call Honeywell Technical Support at 805 581 5591 Airport Systems SG 60 High Intensity Strobe System 2 34 Manual EPM 00000019 Rev A AirportSystems SECTION 3 PRINCIPLES OPERATION 3 1 Overall Description The SG 60 High Intensity Obstruction Ligh
58. e Set MODE Switch to TWILIGHT Verify Day and Night mode LEDs DS25 and DS27 respectively Figure 2 10 Item 3 Page 2 25 are unlit and the Twilight mode LED 0526 is lit red After 6 seconds Verify all Flashheads are flashing in sync and in Twilight mode medium brightness Verify that the Flashhead Status LED for each Flashhead on the tower is lit green including any AOL Unused Flashhead status LEDs shall be off DS1 DS24 Figure 2 10 Item 4 Page 2 25 Verify relay status LEDs DS29 DS32 are lit green and DS33 is off Figure 2 10 Item 5 Page 2 25 If you have a Dual Red White System the Red Lights should be OFF Night Mode Set MODE Switch to NIGHT Verify Day and Twilight mode LEDs DS25 and DS26 respectively Figure 2 10 Item 3 Page 2 25 are unlit and Night mode LED DS27 is lit red Verify that the Flashhead Status LED for each Flashhead on the tower is lit green including any AOL Unused Flashhead status LEDs shall be off DS1 DS24 Figure 2 10 Item 4 Page 2 25 Verify relay status LEDs DS29 DS31 are lit green and DS32 and DS33 are off 0529 0533 Figure 2 10 Item 5 Page 2 25 If you have a White Only System After 6 seconds Verify all Flashheads are flashing in sync and in Night mode lowest brightness 1 8 second duration bursts at 40 bursts per minute SG 60 High Intensity Strobe System 2 31 Manual EPM 00000019 Rev A Airportsystems ss 6 If you have a Dual Red Whi
59. e COM OK LED will be lit green if the transmission read back properly or turned off it there was a read back failure This only indicates that the transceiver chip on the Master Controller is functioning properly it does not indicate that the Flashheads are communicating properly SW3 1 TERM provides the necessary termination resistance for the RS485 serial network Each end of the cable should be terminated with a resistor Typically the Master Controller is installed at one end of the communications cable in which case SW3 1 should be ON The Master Controller board also provides the ground connection for the communication cable shielding The shield drain wire terminates at TB5 S position 4 and a heavy trace on the circuit board connects the shield to the lower right mounting screw and fast on connector both marked E1 The factory installs a grounding wire from E1 to PB1 G This should be the only place the communications shield is grounded You can check this by unplugging TB5 and measuring for an open circuit between the unplugged TB5 S screw terminal and earth ground SG 60 High Intensity Strobe System 3 10 Manual EPM 00000019 Rev A AirportSystems 85 232 SERIAL INTERFACE RELAY DOMARO PHOTOCELL 5 O N 8 4 x gt c w
60. el 1 Remove all power from Flashheads and Master Controller at the main circuit breakers 2 Unplug Data Cable connector TB5 from PCB1 in Master Controller 3 In one of the Flashheads on a given level install a jumper or alligator clip between TB1 4 and TB1 5 4 Verify short circuit between 20 ohms TB5 A and TB5 B both on Data Cable If the measurement is open instead the break is below that Flashhead level 5 Remove the jumper between TB1 4 and TB1 5 6 Plug Data Cable Connector TB5 back into PCB1 The Troubleshooting charts use the following abbreviations FH Flashhead MC Master Controller DB Digital Board inside the SGF 60 Flashhead THVB Trigger High Voltage Board inside the SGF 60 Flashhead RLC Red Light Controller such as Honeywell s 9LCA series SG 60 High Intensity Strobe System 4 2 Manual EPM 00000019 Rev A AirportSystems All Flashheads stuck in Day Mode Are any LEDs No on Master Controller lit Yes Replace MC Fuse F1 Does MC show Green Yes troubleshoot Flashheads PC OK LED Individually 0528 Yes N Check Photocell Wiring 9 If wiring OK replace Photocell Is Master Controller COM OK LED lit DS34 Does MC show Green FH Status LEDs No Is Master Controller COM OK LED lit DS34 Yes Check for shorts between communication No No Unplug MC TB5 cable and power wiring
61. el using the DAY TWILIGHT NIGHT rotary switch In normal remote operation permits automatic operation controlled by the Ambient Light Sensor photocell DAY TWILIGHT NIGHT Switch Three position rotary switch that allows manual selection of three light intensities of the system DAY high TWILIGHT intermediate and NIGHT low The REMOTE LOCAL Mode Switch must be in the LOCAL position to use this switch 2 2 1 2 Power Configuration The input voltage selection is set at the factory prior to shipping The user shall verify the correct voltage as indicated by the label by Power In terminal block PB1 Figure 1 1 Page1 2 If the voltage listed on the label does not match the voltage at the site contact Tech Support at 805 581 5591 2 2 1 3 Configuration Switches e SW1 Figure 2 10 Item 1 Page 2 25 This switch is used to set the number of Flashheads including antenna obstruction light AOL in the system up to 24 If the switches are set for more than 24 the system will still monitor only 24 Flashheads The number of lights configured equals the sum of all the switches set to ON positive binary For example to configure for 10 Flashheads set SW1 4 8 lights to ON and SW1 2 2 lights to ON for a total of 10 8 2 lights SW1 1 Set to ON up for 1 light SW1 2 Set to ON up for 2 lights SW1 3 Set to ON up for 4 lights SW1 4 Set to ON up for 8 lights SW1 5 Set to ON up for 16 lig
62. encountered during the normal power up tests 2 6 1 Master Controller Status Indicators e Photo Mode Indicators Figure 2 10 Item 3 Page 2 25 0525 Red indicates active mode is Day 0526 Red indicates active mode is Twilight 0527 Red indicates active mode is Night 0528 Green indicates photocell is OK Red indicates photocell is bad e Individual Flashhead Status Figure 2 10 Item 4 Page 2 25 051 24 Green indicates Flashhead is good OFF indicates Flashhead has not been selected for monitoring Red indicates Flashhead is bad e Miscellaneous Indicators 0534 Figure 2 10 Item 7 Page 2 25 ON indicates transmit OK 0535 Figure 2 10 Item 9 Page 2 25 Flashing indicates sync input read OK 0536 Figure 2 10 Item 10 Page 2 25 ON indicates red lights are available OFF indicates red lights are reporting alarm or not installed SG 60 High Intensity Strobe System 2 28 Manual EPM 00000019 Rev A AirportSystems 2 6 2 2 6 3 o QU e DS32 33 Figure 2 10 Item 5 Page 2 25 The indications on these lights are dependent on the setting for external red light system on SW2 If SW2 2 is set for an EXTERNAL RED system ON then e DS32 ON indicates there has been a red light system alarm sometime during the night and the red light system is off but will reset the next day OFF when in night mode and the red light system is not in alarm e DS33 ON indicates
63. es on the Master Controller The configuration switch blocks may have multiple switches Reference to the individual switches will be made by referring to the switch block number followed by the number of the individual switch as labeled on the switch block For example SW1 Figure 2 10 Item 1 Page 2 25 has 5 individual switches The third switch from the left is labeled as 3 on the switch block and will be referred to as SW1 3 SG 60 High Intensity Strobe System 2 1 Manual EPM 00000019 Rev A AirportSystems 2 2 1 1 System Controls Set Master Controller switches Figure 1 1 Page 1 2 as follows POWER SWITCH OFF LOCAL REMOTE Switch LOCAL MODE Switch DAY The Master Controller has the following control switches Figure 1 1 Page 1 2 e POWER SWITCH Toggle switch that turns input AC line power on off in the Master Controller Does not affect AC power to the Flashheads Input voltage is present at terminal block PB1 even with the power switch turned off e RESET Switch Momentary pushbutton that resets the Master Controller Switch must be held for about one second to activate REMOTE LOCAL Mode Switch Two position toggle switch that permits manual local selection of the flash intensity lev
64. from the perspective of the Digital Board 1 Wait to receive a flash request from Master Controller Wait for next AC zero crossing Send trigger request signal to Trigger High Voltage Board Check flash feedback current ee Abe 219 Transmit a reply to Master Controller if the flash request was addressed to this Flashhead number and flash status is good 6 Set K1 K2 Relays for next flash mode Day Twilight Night 7 Update Indicators DS2 DS3 SG 60 High Intensity Strobe System 3 3 Manual EPM 00000019 Rev A AirportSystems The Digital Board functions discussed more detail below 3 2 2 1 Power Supplies The Digital board rectifies DB1 and filters C4 the 24VAC output of the Flashhead T2 transformer and uses the resulting unregulated voltage to power the K1 K2 and K3 relays The relay coil is wired directly to this supply K3 will be energized whenever power is supplied to the digital board Power to the 1 and 2 relay coils is controlled by the micro controller The unregulated power that feeds the relays is regulated by VR1 to 15VDC This is used to power the logic and control circuitry on the Trigger High Voltage Board Connection between the boards is made by traces on the Motherboard The Digital board also rectifies DB2 and filters C5 one of the 12VAC outputs of the Flashhead T2 transformer This unregulated voltage is supplied to the power down circuit described belo
65. he front panel switch is set to Local the Master Controller will take its operating mode from the position of the Local Mode Select Switch Day Twilight or Night If the Remote Local Switch is set to Remote Photocell the Master Controller will take its operating mode from the analog reading of the photocell input to TB2 of the Master Controller Board If the photocell fails the Master Controller will automatically select Day Mode The Master Controller indicate its current Photo Mode by illuminating the Day Twi or Nite LEDs DS25 DS27 If the Photocell fails including open or short circuit the PC OK LED DS28 will turn red and the Photocell Fail Relay K2 will de energize If the photocell status is good DS28 will be green and K2 will be energized If the Master Controller is configured for a Dual System SW2 2 is On uses the K4 relay to control the Red Light Controller The Master Controller energizes K4 to turn the Red Lights off and de energizes K4 to turn the Red Lights on As long as the Red Lights are operating normally the Master Controller will request Off Mode from the Flashheads instead of Night Mode If the Red Light Controller signals a top beacon failure by creating an open between TB6 1 and TB6 2 the Master Controller will request Night Mode from the Flashheads and energize K4 to turn off down the remaining Red Lights The Master Controller also energizes K5 the Backup Relay to provide an indication that the
66. hotocell tO Master Controller TB2 W Red wire Photocell tO Master Controller TB2 R 2 4 2 Master Controller Data Communications Wiring Typically the data communications wiring is done with Honeywell P N 00002 shielded twisted pair cable It has one pair of conductors and a drain wire for making shield connections This cable is routed up the structure in the same conduit as the Flashhead power wiring Connect the data cable wires to Master Controller TB5 according to Figure 2 5 Page 2 11 and as follows White or Clear wire Data signal A tO Master Controller TB5 A Blue wire Data signal B tO Master Controller TB5 B Shield drain wire Data shield tO Master Controller TB5 S TB5 S is position 4 The Data Shield TB5 S is grounded by the factory installed wire that connects the E1 ground lug on the Master Controller circuit board to PB1 G If you need to connect a Flashhead directly to the Master Controller using the data cable integrated into Flashhead Cable WC000002 use the following connections White or Clear wire Master Controller TB5 A to Flashhead 1 4 Blue wire Master Controller TB5 B to Flashhead TB1 5 Inner Shield Master Controller TB5 S 4 to Flashhead TB1 6 Outer
67. hts SG 60 High Intensity Strobe System 2 2 Manual EPM 00000019 Rev A AirportSystems 1 Honeywell 2 2 2 SW2 Figure 2 10 Item 2 Page 2 25 This switch is used to set for Catenary operation Suspended cable warning lights and for Dual systems Red lights at night and white strobes during the day SW2 1 Set to ON up for Catenary system SW2 2 Set to ON up for Dual system SW2 3 Set to OFF down Reserved for future use SW3 Figure 2 10 Item 8 Page 2 25 This switch is used to set the termination resistor for the communications line SW3 1 Set to ON if the Master Controller is at the end of the communications line In a typical installation the communications lines are terminated at the Master Controler and at the top level of Flashheads In this case this switch should be set ON Flashhead Configuration All of the configuration for the Flashhead in done on the digital controller board Because of the high voltage present in the Flashhead there are interlock switches and fuses as follows Figure 1 2 Page 1 3 S1 POWER Interlock Switch Three position push pull switch When the Flashhead door is opened S1 interrupts AC line power to transformers T1 and T2 when using 120VAC single phase power When using 2 phase AC power S1 does not interrupt AC power to transformers T1 and T2 When the Flashhead door is opened the PWR ON lamp 051 to turn off Also interrupts power to relay K1 causing
68. ies d 11 5 3 gt 2 1 z Lo a s we TO OTHER FLASH HEADS Figure 3 1 Master Controller Board Schematic SG 60 High Intensity Strobe System 3 11 Manual EPM 00000019 Rev A Honeywell 2 21 9 21 4 41 8 41 01 21 ovaogy OVALLZ OL 804 SNOLLO3NNOO ZL 1109 W3lSAS 8 Nosv4 31V 5 nwa X BH3TIOMINOO NH ADIL vol z OVAOBY V9 2 7 2 802 VOL OVAOZI 9 OVAOO lfidNI M3MOd Ce3m wA 14 2 A SVvA80Z 2 021 1 lt 7 JOIS d H 0124145 5 ISN 2 001 404 SNOILO3NNOO 1171
69. igh Voltage Board Schematic 3 14 Figure 4 1 General Troubleshooting All Flashheads Stuck in Day Mode 4 3 Figure 4 2 General Troubleshooting Flashhead Does Not Flash 4 4 Figure 4 3 General Troubleshooting Flashhead Stuck in Day Mode 4 5 Figure 4 4 Dual System Specific Troubleshooting 4 6 Figure 4 5 Catenary System Specific Troubleshooting Chart 4 7 Figure 5 1 SGC 60 Replacement 5 1 Figure 5 2 FPlashtube Installatiort aor EE EE ER Ri s 5 3 Figure 7 1 SG 60 AOL Flashhead Mounting Dimensions 7 2 Figure 7 2 SG 60 AOL Power Supply Mounting Dimensions 7 3 Figure 7 3 SG 60 AOL Wiring 7 4 Figure 7 4 SG 60 AOL Flashhead Component Locations 7 5 Figure 7 5 SG 60 AOL Power Supply Component Locations 7 6 Figure 7 6 SG 60 AOL Schaermallo 2 rre rrr eid 7 7 EPM 00000019 001 iv RevA AirportSystems Honeywell SAFETY INFORMATION This section contains general safety instructions for using your Honeywell equipment Task and equipment s
70. input line voltage However the user shall verify that the AC line voltage selector block located on the transformer board on top of transformer T1 Figure 1 2 Page 1 3 is labeled with the correct AC line voltage used at the site For example voltage selector block part number 77 3319 is labeled for 120VAC If the voltage selector block is not labeled for the correct AC line voltage used at the site the correct voltage selector block must be obtained from Honeywell and the AC input wiring to transformer T2 must also be verified and corrected if necessary according to Figure 3 2 Page 3 12 2 2 2 2 Configuration Switches e SW1 Figure 2 11 Item 2 Page 2 26 This switch is used to reset the processor Press and hold resets the processor and tests the automatic power reset circuit Press and hold SW1 until the 5v power indicator DS1 Figure 2 11 Item 1 Page 2 26 turns OFF momentarily then release e SW2 Figure 2 11 Item 4 Page 2 26 This switch is used to set special operation options Set all four switches to OFF unless your system meets one of the two conditions below CONDITION 1 You have a Catenary System SW2 1 Set ON for all Flashheads on top level of a Catenary installation SW2 2 Set ON for all Flashheads on bottom level of Catenary installation SW 1 amp 2 Set both to ON for all Flashheads on middle level of a Catenary installation CONDITION 2 You have Dual Red White system with an older
71. iring became loose or damaged the capacitors could still be charged to 2000VDC Although the High Voltage indicator on the Trigger High Voltage is designed to indicate any high voltage still stored in the capacitors you should always discharge the capacitors with an approved grounding rod before working with the system The 450Vp p from T1 is used to charge a trigger capacitor on the Trigger High Voltage Board When the flashtube should be fired this trigger capacitor is discharged through the primary of trigger transformer T4 T4 steps up the trigger pulse to the 15KV Transformer T2 provides power for the digital circuitry and the K1 K3 relays It can accept a variety of input voltages depending on the primary tap connections and it provides outputs of 12VAC and 24VAC The T2 inputs are protected by fuse F2 Logic circuits in the Flashhead receive command signals from the SGC 60 Master Controller However in the absence of command signals the Flashhead generates its own timing signal which controls the rate of flash Test switches located on the Flashhead switch assembly allow the system to operate in either Day Twilight or Night mode When the Flashhead door is closed the system operates in Remote mode regardless of the switch positions See Figure 1 2 Page 1 3 SG 60 High Intensity Strobe System 3 2 Manual EPM 00000019 Rev A AirportSystems Honeywell WARNING HIGH VOLTAGE is on the energy storage capacitors C1 C2 C3A and C3B
72. lative humidity System Operating Status Indicators Flashhead AC line power PWR ON Indicator DS1 Flashhead high voltage present on capacitors High Voltage Indicator DS1 located on Trigger High Voltage board Master Controller Indicators Flashhi ad eei den cerne lcs LEDs DS1 DS24 red green By dro E LED DS25 red Twilight Mode LED DS26 red Night MOGE aaa eae deals LED DS27 red SG 60 High Intensity Strobe System 1 6 Manual EPM 00000019 Rev A AirportSystems Flashhead Fail Relay K1 de energized and LED DS29 Off Photocell Fail Relay K2 de energized and LED DS30 Off Power Fail Relay K3 de energized and LED DS31 Off Night Mode Operation Relay K4 de energized and LED DS32 Off White Night Backup Dual Systems Relay K5 energized and LED DS33 On SG 60 High Intensity Strobe System 1 7 Manual EPM 00000019 Rev A AirportSystems SECTION 2 INSTALLATION amp POWER UP WARNING Modifications to the Power Supply are required for certain applications Remove input power at circuit breakers and discharge capacitors with an approved grounding rod before attem
73. ller per FAA specifications The transformer connections are polarity sensitive If the wires are reversed the Digital Board will not be able to detect good flashes especially in Day and Twilight modes 3 2 3 SGF 60 Trigger High Voltage Board The Trigger High Voltage combines two completely independent functions high voltage rectification and flashtube triggering SG 60 High Intensity Strobe System 3 6 Manual EPM 00000019 Rev A AirportSystems Honeywell 3 2 3 1 High Voltage Rectification This section of the Trigger High Voltage Board provides the DC to charge the energy storage capacitors that power the flashtube The high voltage AC from the ferro resonant power transformer T1 pins T1 7 and T1 8 is output to the Trigger High Voltage board through the Flashhead motherboard pins E5 and E6 respectively The high power diode bridge DB1 rectifies the incoming 2000Vp p voltage to pulsed 2000VDC This DC voltage is sent to charge the energy storage capacitors through Flashhead motherboard pins E7 and E4 Voltage divider circuit R6 R10 with a series neon lamp High Voltage Indicator DS1 is connected to the bridge output High Voltage Indicator DS1 lights whenever high voltage is present 3 2 3 2 Flashtube Triggering The trigger control section receives 15V power from the Digital Board The Digital Board also provides the trigger request signal telling the Trigger High Voltage Board to fire the flashtube The hea
74. minating resistor switch set to on See SW4 page 2 5 3 Verify open circuit by measuring resistance between TB5 S on the Data Cable and panel ground Verify open circuit between TB5 A on the Data Cable and panel ground Verify open circuit between TB5 B on the Data Cable and panel ground SG 60 High Intensity Strobe System 2 27 Manual EPM 00000019 Rev A AirportSystems 1 Verify open circuit between TB5 S and TB5 A both on Data Cable Verify open circuit between TB5 S and TB5 B both on Data Cable In one of the top most Flashheads install a jumper or alligator clip between TB1 5 and TB1 6 9 Verify short circuit between 20 ohms TB5 S and TB5 B both on Data Cable 10 Remove the jumper between TB1 5 and TB1 6 11 Verify open circuit between TB5 S and TB5 B both on Data Cable 12 Master Controller card measure between TB5 A and 5 and verify 120 ohms 10 resistance If not check for proper configuration See SWA on page 2 5 13 Plug Data Cable Connector TB5 back into PCB1 14 Verify short circuit between TB5 S screw terminal and panel ground 2 6 Power Up and System Tests During the power up of the system there are indicator lights which will be checked to verify correct operation and installation The following is a description of all the indicators in the Master Controller and the Flashheads The indicators in the Flashhead need not be checked unless problems are
75. model Master Controller SW2 3 Set to ON This is provided for backward compatibility with older installations only For new installations this switch is always OFF For older white only installations this switch is also OFF To determine if an existing installation has an older Master Controller refer to the new Master Controller in Figure 2 10 Page 2 25 Older Master Controllers do not have terminals TB5 TB9 or an EXT RED switch SW2 2 Item 2 in the figure Note Switch SW2 4 is a spare reserved for future use SG 60 High Intensity Strobe System 2 4 Manual EPM 00000019 Rev A AirportSystems Honeywell e SW3 Figure 2 11 3 Page 2 26 Used to specify the ID number for the Flashhead Each Flashhead must be set with a unique ID number as indicated on the installation drawings There is a diagram next to the switch showing the values for the switch The ID number is the total of the values of the switches set to OFF negative binary For example to set ID 10 set SW3 2 value 2 OFF down and SW3 4 value 8 OFF down for a total of 10 2 8 SW3 1 Set to OFF down for value 1 SW3 2 Set to OFF down for value 2 SW3 3 Set to OFF down for value 4 SW3 4 Set to OFF down for value 8 SW3 5 Set to OFF down for value 16 SW4 Figure 2 11 5 Page 2 26 This is used for the terminating resistor on the communications line SW4 1 Set to ON up for terminating resistor This
76. ntensity Strobe System 2 7 Manual EPM 00000019 Rev A AirportSystems 2 3 4 Cables and Junction Boxes The cables shall be properly supported and terminated in the junction boxes per the detailed description provided in section 2 4 page 2 11 of this document Additional information regarding cables and junction box installation can be found on the drawing set for the lighting system Particular attention should be paid to assure that the data cable shields are isolated from the junction box housings SG 60 High Intensity Strobe System 2 8 Manual EPM 00000019 Rev A Airport Systems 20 31 98 L 10 00 4 PLACES 254 i A Ll 2 14 75 375 Ll 4 1 26 32 REF 13 04 331 RE 1 50 91 06 927 38 4 PLACES WY XL NU 8 00 203 6 00 152 4 00 102 2 00 51 Honeywell 14 22 15 50 361 394 REF REF 6 34 161 REF DIMENSIONS IN INCHES MILLIMETERS PROVIDE MINIMUM 1 00 25 CLEARANCE ON HINGE SIDE TO ALLOW 90 DOOR OPENING HOLES AT BOTTOM ARE SIZED FOR STANDARD 3 4 CONDUIT Figure 2 2 Master Controller Mounting Dimensions SG 60 High Intensity Strobe System 2 9 Manual EPM 0
77. o place Make sure the red mark on the flashtube matches the red mark on the socket assembly 6 Attach the fast on connector at each end of the flashtube to each socket assembly Make sure wires are not twisted the metal to glass bond is fragile SG 60 High Intensity Strobe System 2 5 Manual EPM 00000019 Rev A AirportSystems 7 Refer to Figure 2 1 below Dress the electrode wires away from the sides of the reflector 8 Close and fasten the Flashhead cover RED BAND MARKS ANODE END OF TUBE RED STRIPE MARKS ANODE SOCKET 5 WIRE DRESSED CORRECTLY WIRE DRESSED INCORRECTLY Figure 2 1 Flashtube Installation 2 3 Installation 2 3 1 SGC 60 Master Controller The Master Controller is connected to Flashheads via the data communications cable provided by Honeywell The length of this cable up to 2500 feet determines how far the Master Controller can be mounted from the Flashheads A detailed drawing for mounting the Master Controller is shown in Figure 2 2 Page 2 9 2 3 2 SGF 60 Flashhead Normally the Flashheads are mounted at the uppermost point and additional referenced elevations on the structure The Flashhead is connected to its Master Controller via the data communications cable provided by Honeywell The length of this cable up to 2500 feet determines how far any Flashhead can be mounted from the Master Controller
78. pecific Warnings are included in other sections of this manual where appropriate Read all Warnings and follow all instructions carefully Failure to do so may result in personal injury death or property damage To use this equipment safely refer to the following 1 Refer to the FAA Advisory Circular AC 150 5340 26 Maintenance of Airport Visual Aids Facilities for instructions on safety precautions Observe all safety regulations To avoid injuries always remove power prior to making any wire connections and or touching any parts Refer to FAA Advisory Circular AC 150 5340 26 Read and become familiar with the general safety instructions provided in this section of the manual before installing operating maintaining or repairing this equipment Read and carefully follow the instructions given throughout this manual before performing specific tasks and working with specific equipment Store this manual within easy reach of personnel installing operating maintaining or repairing this equipment Follow all applicable safety procedures required by your company industry standards and government or other regulatory agencies Obtain and read Material Safety Data Sheets MSDS for all materials used SAFETY AND WORKMANSHIP ALERTS This manual uses two types of markings when giving instructions requiring special attention The markings will be followed by indented text WARNING The WARNING sign in this manual denotes a hazar
79. provides regulated 5VDC to the rest of the board The 16VDC is also used to provide power for the power down circuit The power down circuit can briefly shut down the regulated 5VDC supply powering the rest of the board logic providing a power on reset for the rest of the board logic The power down circuit will be activated automatically if 1 the microcontroller stops functioning normally or 2 the microcontroller detects a severe communications failure To prevent nuisance alarm chatter the microcontroller will only deliberately activate the power down circuit if at least 24 hours have elapsed since the last power on The power down circuit is intended to allow automatic recovery from rare cases when transients lock up the communications transceiver but it can also be used as a manual board reset You may test this function by holding down the RESET toggle switch the switch panel for about 1 second If input power is lost or fuse F1 is blown the Power Fail Relay K4 terminals TB3 C3 NOS NC3 will de energize 3 3 2 Flash Requests and Flashhead Status The Master Controller transmits a flash request command to the Flashheads every 1 5 seconds or every 1 0 seconds in Catenary mode selected with SW2 1 The flash request also contains the requested operating mode The flash request applies to all Flashheads but is addressed to a specific Flashhead All Flashheads receive the flash request All Flashheads flash in respon
80. pting any necessary modifications 2 1 Unpacking Carefully unpack each item and remove any internal packing material from the master controller and the flashhead power supply Carefully check the supplied materials with the High Intensity Lighting System bill of materials There are many small items that should be supplied inside clear plastic bags verify each of these bags contain the proper amount of parts per the bill of materials Report any shortages of materials immediately to the Honeywell Technical Support Examine each item for obvious physical damage Report any claims to the carrier immediately Pertinent data such as installation drawings schematics interconnection drawings and operation manuals are included in the Master Controller carton The flashtubes are packaged separately inside each Flashhead carton Do not remove flashtubes from their boxes until you are ready to install them 2 2 System Configuration Honeywell pre configures the system to match the installation However there are cases where complete installation information is not available prior to the system leaving the factory or the installation has changed Setting the configuration may also be necessary when replacing individual units in the system The following is a guide for configuring the Master Controller and the Flashheads 2 2 1 Master Controller Configuration There are a number of system control switches and configuration switch blocks DIP switch
81. push on connectors 12 Attach White wires with new connectors to the upper back terminals shown in diagram 13 Re install switch panel assembly to standoffs 14 Visually inspect for loose connectors or any short circuited lines 15 Apply power to the Controller from the Circuit breaker 16 Set Controller power switch to on and verify normal operation 5 2 SGF 60 Flashhead Normal maintenance of the Flashhead requires periodic cleaning of the window with a non abrasive soap WARNING Ensure that the power is off and the energy storage capacitors have been discharged before opening the Flashhead Do not put hands or tools in the Flashhead until the High Voltage Indicator neon lamp DS1 on the High Voltage amp Trigger board is extinguished Refer to Figure 1 2 Page 1 3 for the location of High Voltage Indicator DS1 do not confuse the High Voltage Indicator 051 with the PWR ON lamp 051 Note that it is possible for the High Voltage Indicator DS1 to be lit even when the PWR ON lamp DS1 if off If this happens the energy storage capacitors C1 C3 must be discharged before performing maintenance 5 2 1 Flashtube Replacement Flashtubes that are faulty or degraded in performance by aging shall be replaced per the following procedure 1 Shut off the power to the system by opening the main AC power circuit breakers Release the Flashhead cover latches Swing the cover open exercising caution not to damage the glass face or
82. rd operates the Flashhead in the mode requested by the Master Controller When the Master Controller requests a change in mode there will be a 4 flash delay before the Flashheads update own remote mode selection to match the requested mode If the SW2 3 NO NITE is set ON the Digital Board will not flash at all in night mode This option is provided for backward compatibility with Dual Systems with older Master Controllers installed that can not broadcast an Off mode In these older systems the flashheads were configure the flashheads to not flash at night when the Red Lights were switched on This option should not be used with the Master Controller described in this manual Instead configure the Master Controller to work with a Dual System SG 60 High Intensity Strobe System 3 5 Manual EPM 00000019 Rev A AirportSystems 3 2 2 4 Flash Control To fire the flashtube the Digital Board pulls down the trigger request line P2 17 for about 500uS This signals the Trigger High Voltage Card to trigger the flashtube The Digital Board will issue its trigger request on a T2 zero crossing Normally the first zero crossing it detects after receiving a flash request from the Master Controller In Day and Twilight modes the Digital Board will issue a single trigger request In Night mode the Digital Board will issue a series of 15 pulses at consecutive zero crossings The zero crossing is determined from a 12VAC output
83. red beacon fails The External Red Ready indicator LED DS36 Item 10 in Figure 2 10 Page 1 2 turns on to indicate a closed loop Red Lights OK and turn off to indicate an open loop Red Light Failure SG 60 High Intensity Strobe System 2 13 Manual EPM 00000019 Rev A AirportSystems Honeywell If your red light system has Honeywell 9 Series Red Light Controller locate the Alarm terminals and Flasher Bypass terminals corresponding to the top beacon and make the following connections Master Controller TB6 1 tO 9LCA Flasher Bypass C1 9LCA Flasher Bypass NC1 0 9 Alarm Card C1 Master Controller TB6 2 tO 9LCA Alarm Card NC1 Note Usually the top beacon terminals are found on the top left Flasher Bypass Card TB4 and the left channel of the top Alarm Card TB3 Other Red Light Systems may require different connections Refer the to Tower Kit drawing if both systems were provided as a kit by Honeywell the Red Light System s manual or contact Honeywell for assistance 2 4 5 Flashhead Wiring Incoming AC power and data communications enter the Flashhead in a single cable Honeywell P N WC000001 that combines three wires for AC power with a twisted pair double shielded data cable See Figure 2 9 Page 2 21 Typically Flashheads are supplied with a 10 20 foot length of this cable already inst
84. ription Part Number SGF 60 Flashhead Capacitor 1uF C1 77 4220 Capacitor 4 77 3311 Capacitor 12 5uF C2 AC000003 Capacitor 110uF C3A 77 4133 001 Capacitor 000002 Diode Block Assembly DB1 277 3342 6 Flashtube Assembly 1 71 3295 Fuse FNQ 3 2A F1 for 480VAC 71 2041 Fuse FNQ 6A F1 for 208 240VAC 71 1167 Fuse FNQ 10A F1 120 77 2040 Fuse FLA 1 4A F2 for 120 208VAC FU000003 Fuse FLA 1 4A F2 for 240VAC FU000003 Fuse FLQ 1 10A F2 for 480VAC FU000004 PC Board Motherboard 277 5053 001 PC Board Digital Controller Programmed 34 00031 001 PC Board Trigger High Voltage 34E00010 001 Relays K1 K2 K3 77 3870 Transformer T1 60HZ 77 3890 Transformer T1 50HZ 277 4244 Transformer T2 50Hz 60Hz
85. rt of the Trigger circuit consists of a trigger capacitor C4 SCR 04 and unijunction transistor Q3 The trigger circuit energy is derived from terminals T1 6 and T1 2 of transformer T1 through a rectifier circuit in the trigger control section This trigger energy is stored in a 0 5uF capacitor C4 whose charge path is through the primary coil of the high voltage trigger transformer T2 to ground Microcontroller U1 synchronizes the actual flashtube firing more precisely with the high voltage zero crossing It buffers incoming trigger requests from the Digital Board and U1 9 receives the trigger request signal from Digital Board U3 about a 500usec low U1 waits for a high voltage zero crossing to pass and then drives pin 10 is high to charge C3 As soon as U1 detects the next high voltage zero crossing on pin 6 it drives pin 10 low for 500usec This momentarily forces the gate of Q3 below the anode of Q3 triggering Q3 a snap action unijunction switch C3 discharges through Q3 with a fast rising current driving the gate of SCR Q4 SCR 04 then turns on switching 0 5uF capacitor C4 charged to 450 volts into the primary coil of the series trigger transformer located on the flashtube assembly The series trigger transformer T3 steps the pulse to approximately 15KV flashing the flashtube V1 The recharge current for the capacitor C4 is limited by a series resistor to a value below the hold in current of the SCR Q4 so that it turns off
86. s a pigtail is attached at the factory for installation to the junction box This pigtail may not be long enough for proper routing along the horizontal and vertical struts on the tower The high intensity lighting system will have a 100 foot spool of pigtail cable Honeywell P N WC000001 for installer to use for those flashheads that do not have a long enough pigtail If this spool of cable will not accommodate all the flashheads extra cable can be ordered from Honeywell The 3 flex conduit will be used for shielding of possible RF Interference generated by some broadcast and radio towers The conduit will be positioned over the flashhead pigtail and connected at the junction box and flashhead enclosure by watertight connector designed for the 34 flex conduit The installation will consist of the following materials 34 Flex Conduit Honeywell part number 1 000002 34 Sealing Ring P N 77 1085 34 Bushing Insulator P N 77 1087 34 Flex Conduit Fitting P N CD000003 Consists of Gland nut body edge cone nylon seal ring and 34 locknut Please reference Figure 2 7 Page 2 20 for proper installation of this conduit SG 60 High Intensity Strobe System 2 18 Manual EPM 00000019 Rev A Airport Systems Honeywell 2 BOTTOM Figure 2 6 Junction Box Wiring Details SG 60 High Intensity Strobe System 2
87. se to the request and update their operating mode but only the addressed Flashhead may reply to the Master Controller Whenever a the Flashhead replies OK the Master Controller marks it as good and sets the corresponding Flashhead Status LED to green If the Flashhead does not reply OK the Master Controller marks it as bad and sets the corresponding Flashhead Status LED to red SG 60 High Intensity Strobe System 3 8 Manual EPM 00000019 Rev A AirportSystems The Master Controller gives previously good Flashheads four chances to reply addressing that Flashhead repeatedly before marking them bad Previously bad Flashheads are given one chance to reply OK before moving on to the next Flashhead The Master Controller checks the status of each Flashhead in order of increasing flashhead number cycling repeatedly through the total number of selected Flashheads You can set the number of Flashheads monitored using DIP Switch SW1 If the Master Controller is not monitoring a flashhead the corresponding Flashhead Status LED is turned off If any Flashhead is marked bad Red LED the Master Controller will de energize the Flashheads Alarm Relay K1 1 NO1 NC1 and turn off the corresponding LED DS29 3 3 3 System Mode Selection The master controller determines what mode to transmit with the Flash Request by reading the Photocell input and the Front Panel Switches If the Remote Local Switch on t
88. should be set ON only for the Flashhead where the communication lines are terminated In a typical installation the communications lines are terminated at the Master Controller and the upper most Flashhead In systems with an AOL the AOL is typically the upper most Flashhead In systems without an AOL any one but only one of the Flashheads at the top level can be set to ON For all others set to OFF If the system is being installed in stages as the tower is erected SW4 1 should be set ON for one of the flashheads at the highest installed level As additional flashheads are added at higher levels adjust the configuration by setting SW4 1 to OFF in the previous flashhead and set SW4 1 to ON for one of the flashheads at the highest installed level 2 2 2 3 Flashtube Installation The Flashheads are shipped from the factory without the flashtubes installed to prevent damage during shipping Install the flashtubes per the following procedure 1 If Flashhead is already wired to AC power Shut off the power to the system by opening the main AC power circuit breakers Release the Flashhead cover latches Swing the cover open exercising caution not to damage the glass face or the gasket 4 Unpack the flashtube Do not touch the glass envelope contamination from a fingerprint will degrade the reliability of the flashtube 5 Holding the flashtube by its metal ends center it in the reflector assembly and snap it int
89. te System Verify normal red night mode operation a Verify that all Flashheads are OFF b Verify that all Red Lights are ON and flashing properly and the Red Light Controller does not indicate any alarms in the top most Red Beacons c Verify that LED DS36 EXT RED READY is lit green See Item 10 Figure 2 10 Page 2 25 7 If you have Dual Red White System Perform the following steps to check white night backup operation a Simulate a Red Beacon failure On a Honeywell 9LCA Series Control this may be done with the B1 circuit breaker in the Control Turn the B1 breaker off to activate the 9LCA Beacon Failure Alarm or toggle the breaker momentarily to activate the 9LCA Flasher Bypass Alarm Other Redlight systems have different controls and may require removing Red Beacon power at the input power circuit breakers Verify that the DS36 External Red Ready LED is OFF c Verify that the DS32 Night Red LED is ON Verify that the DS33 Backup LED is ON Verify that all the Red Lights are OFF f Verify that all Flashheads are flashing in sync and in Night mode lowest brightness 1 8 second duration bursts at 40 bursts per minute g _ Repair the simulated Red Beacon failure Verify that DS36 External Red Ready LED is ON Verify that the lighting system is still operating white strobes and not red lights j Set the MODE switch to DAY Wait for the Flashheads to switch to DAY mode about
90. tempted yet status unknown A steady on state indicates that the most recent transmission read back correctly A fast blink indicates that most recent transmission failed to read back correctly The normal cycle on power up is DS3 Off then slow blink then steady on The duration of the slow blink period depends on the number of Flashheads in the system as the Master Controller queries them in numeric order The Digital Board expects the Master Controller to request every flash If the request does not arrive when expected the DS3 will go out and the DS3 status cycle will start over transmission status will start as unknown If no flash requests are received from the Master Controller for 4 consecutive flash periods the Digital Board considers that there has been a communications failure If it has been at least 12 hours since power on it will use the power down circuit to reset itself Otherwise it will switch the strobe to Day Mode For a Dual System when the white lights are not flashing at night the Master Controller is still broadcasting regular flash requests but is requesting that the strobe flash in the Off Mode 3 2 2 3 Mode Selection If the Local Remote switch is open the spring back position after being pushed in the Digital Board will operate the strobe according to the position it reads in the Mode Select Switch If the Local Remote switch is closed pushed in or pulled all the way out the Digital Boa
91. the gasket 4 Release the old flashtube by disconnecting the electrode wire fastons at each end and carefully snapping the flashtube from its holders SG 60 High Intensity Strobe System 5 2 Manual EPM 00000019 Rev A AirportSystems D Unpack the new flashtube Do not touch the glass envelope contamination from a fingerprint will degrade the reliability of the flashtube 6 Holding the flashtube by its metal ends center it in the reflector assembly and snap it into place Make sure the red mark on the flashtube matches the red mark on the socket assembly 7 Attach the faston connector at each end of the flashtube to each socket assembly Make sure wires are not twisted the metal to glass bond is fragile 8 Refer to Figure 5 2 below Dress the electrode wires away from the sides of the reflector 9 Close and fasten the Flashhead cover RED BAND MARKS ANODE END OF TUBE RED STRIPE MARKS ANODE SOCKET 5 WIRE DRESSED CORRECTLY WIRE DRESSED INCORRECTLY Figure 5 2 Flashtube Installation 5 3 Ambient Light Sensor Photocell The only maintenance required for the photocell is periodic cleaning The frequency of cleaning depends on the environment to which the photocell is exposed SG 60 High Intensity Strobe System 5 3 Manual EPM 00000019 Rev A AirportSystems SECTION 6 REPLACEMENT PARTS Desc
92. ting System meets the requirements of the FAA Advisory Circular 150 5345 43E Depending on system configuration the Flashheads are either type L 856 simultaneous flashing 40 flashes per minute FPM or type L 857 catenary flash pattern 60 FPM The main components of the system are the Model SGC 60 Master Controller and the Model SGF 60 High Intensity Flashhead with integrated power supply Depending on tower configuration a Medium Intensity Antenna Obstruction Light AOL may also be part of the system The Master Controller detects the ambient light conditions controls the timing and intensity of the Flashhead flashes monitors the Flashheads operating status and provides alarm and status information to the tower operator See Figure 2 10 Page 2 25 The Flashhead produces a flash of white light from a xenon flashtube The Flashhead Power Supply generates the high voltages and currents needed to trigger the flashtube and create the flash itself The Flashhead Control Logic receives communications from the Master Controller and sets the flash brightness and timing accordingly The Flashhead Control Logic also provide a status reply when queried by the Master Controller The Master Controller and Flashheads communicate with electrical signals carried on a single twisted pair cable two signal conductors Any transmission from either the Master Controller or a Flashhead uses both signal conductors together only one device can be transmi
93. ting a malfunction authorized maintenance personnel may perform the bypass for the specific test to be made Immediately after completing the test restore the interlock to working condition WARNING HONEYWELL IS NOT RESPONSIBLE FOR INJURIES OR DAMAGES RESULTING FROM NONSTANDARD UNINTENDED APPLICATIONS OF ITS EQUIPMENT THIS EQUIPMENT IS DESIGNED AND INTENDED ONLY FOR THE PURPOSE DESCRIBED IN THIS MANUAL USES NOT DESCRIBED IN THIS MANUAL ARE CONSIDERED UNINTENDED USES AND MAY RESULT IN SERIOUS PERSONAL INJURY DEATH OR PROPERTY DAMAGE UNINTENDED USES MAY RESULT FROM TAKING ANY OF THE ACTIONS LISTED BELOW INTENDED USE 1 Making changes to the equipment that have not been recommended or described in this manual or using parts that are not genuine Honeywell replacement parts 2 Failing to make sure that auxiliary equipment complies with approval agency requirements local codes and all applicable safety standards 3 Using materials or auxiliary equipment that are inappropriate or incompatible with your Honeywell equipment 4 Allowing unqualified personnel to perform any task EPM 00000019 001 vi Rev A Airport Systems WARNING KEEP AWAY FROM LIVE CIRCUITS OPERATION AND MAINTENANCE PERSONNEL MUST OBSERVE ALL SAFETY REGULATIONS AT ALL TIMES DO NOT CHANGE PLUG IN COMPONENTS OR MAKE ADJUSTMENTS INSIDE EQUIPMENT WITH THE HIGH VOLTAGE SUPPLY ON UNDER CERTAIN CONDITIONS THERE IS A POTENTIAL FOR
94. tion Box Details 2 18 2 5 FINAL INSTALLATION CHECK nn disini nennen nnn 2 27 Preliminary RH ai atte ec 2 27 2 5 2 Verify Correct Wiring in Master Controller 2 27 2 5 8 Verifying Photocell Wiring enne nnns 2 27 2 5 4 Verify Proper Tower Wiring for Data Control 2 27 2 6 POWER UP AND SYSTEM 5 5 aka akata aquqa sanete 2 28 2 6 1 Master Controller Status r 2 28 2 6 2 Flashhead Status 2 29 2 6 8 System Power 2 29 2 6 4 Verify Local Mode 2 30 2 6 5 Verify Photocell Operation Connected to 2 33 2 6 6 Verify Photocell Operation Not Connected to Controller 2 33 SECTION 3 PRINCIPLES OF 3 1 3 1 OVEBALEDESCRIPTIONS 23 3 e 3 1 3 2 5 00 55 548 58 5854 341 32 1 5 60 u l u n u ul S
95. trobe System 2 29 Manual EPM 00000019 Rev A AirportSystems 2 6 4 7 Verify that the LED test sequence has started The test sequence will exercise every LED and relay e g it will quickly sweep through the Flashhead Status LEDs in red and green mode After the test sequence completes the Flashhead status LEDs for the selected number of Flashheads shall be lit red then change to green as the Flashheads report 051 0524 Figure 2 10 Item 4 Page 2 25 After 1 minute verify the number of Flashhead status LEDs 051 DS24 Figure 2 10 Item 4 Page 2 25 that are lit green matches the total number of white Flashhead lights including AOL on the tower if there are Flashheads on the tower Flashhead status LEDs 051 DSN shall be lit green Verify that the remaining unused Flashhead status LEDs 05 7 DS24 are turned off Once all the flashheads report good green the relay monitor LEDs should display as follows DS29 DS32 GREEN DS33 OFF DS29 DS33 Figure 2 10 Item 5 Page 2 25 Verify Photocell status LED DS28 Figure 2 10 Item 3 Page 2 25 is lit green Verify Day Mode LED DS25 Figure 2 10 Item 3 Page 2 25 is lit red and the Twilight and Night LEDs DS26 and DS27 respectively Figure 2 10 Item 3 Page 2 25 are not lit Hold down the RESET switch for approximately 1 second and verify the LED test sequence has restarted Wait 1 minute and measure the voltage between TB1 1 and TB1 2 to
96. tting at any given time Both the Master Controller and Flashhead have override switches allowing the operator to select Day Twilight or Night Modes manually for test or troubleshooting purposes 3 2 SGF 60 Flashhead The main AC power input to the Flashhead is fed into the T1 ferro resonant transformer It can accept a variety of input voltages depending on how the primaries are tapped using a special voltage selector block The transformer secondaries provide a regulated outputs of 2000 volts peak to peak and 450 volts peak to peak The inputs of the T1 transformer are protected by fuse F1 The Trigger High Voltage card rectifies the 2000Vp p to a pulsating 2000VDC This voltage is then used to charge the energy storage capacitors The flashtube V1 is always connected in parallel with the capacitors but it is non conductive until triggered thus allowing the capacitors to charge to their peak voltage When the flashtube is triggered by a very short high voltage pulse about 15KV the xenon gas in the flashtube ionizes and the flashtube can conduct electricity The SG 60 High Intensity Strobe System 3 1 Manual EPM 00000019 Rev A AirportSystems 1 energy storage capacitors discharge rapidly through the flashtube The high discharge current briefly heats the xenon gas to great temperatures producing a bright flash The short circuit output current of the T1 transformer is limited to less than the flashtube s
97. ve candelas burst of flashes Beam err tree Gar meee eae ee are 120 horizontally 3 min vertically max intensity of 3 of peak at 10 Flash Hate n ute tedio 40 fpm single white flash 40 fpm single white flash pP 40 fpm white burst of flashes Master Slave Operation Up to 24 slave SGF 60 Flashheads may share a common sync and photocell circuit from one SGC 60 Master Controller Electrical Input Master Controller 50 Watts 120 208 240 277 380 480 VAC 50 60Hz Flashhead 500 Watts 120 208 240 277 380 480 VAC 50 6 2 Requires specific voltage selector block and manual change to transformer wiring for different AC voltages Mechanical Properties Flashhead Weight DC 82 pounds 37 2 kg Dimensions 18 88 w 479 4mm x 15 25 h 387 4mm x 10 75 d 273 1mm Stldce isi tette etit ed set tailed tet 1 89 square feet Wind Coad noe nde t eet 100 pounds at 150 mph 240kph Master Controller WV GIG ee LRL 24 pounds 10 89 kg Dimensions 14 w 356mm x 12 h 305mm x e d 152mm Operating Environment Operating iie stab ecu ect state aed exige 55 C to 55 C eet EMEND UNE UH NEU UNE EIE 95 re
98. w and VR2 VR2 provides regulated power to the microcontroller and other logic chips When 5V logic power is present DS1 turns on red The power down circuit can briefly shut down the input to VR2 effectively removing all logic power from the board The power down logic has its own independent 5V power using simple zener diode regulation of the DB2 C5 output The shutdown circuit does not affect the relay or 15V supplies although the K1 and K2 relays cannot be energized as long as the micro controller is You can test the function of the power down circuit by pressing the S1 pushbutton for about 1 second You should see DS1 turn off momentarily and then as DS1 turns back on you should see the LED check as the microcontroller software initializes DS2 and DS3 should quickly blink together twice 3 2 2 2 Communications The Digital Board receives commands from the Master Controller via an RS485 serial link The RS485 transceiver chip U11 is protected from voltage transients by surge suppression devices and by transformer optical isolation from chassis ground and the rest of the digital board If a voltage transient destabilizes the communications hardware the main processor the Digital Board will remove and restore its own logic power thus clearing any momentary hardware or software faults See 3 2 2 1 above for more information on the power down circuit SW4 1 TERM provides the necessary termination
99. way that when K4 is energized the Red Lights turn off and when K4 is de energized the Red Lights turn on Typically this is done by disconnecting the Red Light System photocell and wiring those photocell inputs to the Relay K4 contact The contacts are rated for up to 5A and up to either 30VDC or 250VAC If your red light system has a Honeywell 9LCA Series Red Light Controller the 9LCA photocell is not used Instead of connecting the 9LCA photocell to 9LCA terminal TB3 make the following connections Master Controller TB3 C4 to 9LCA Red Light Controller TB3 B Master Controller TB5 NOA to 9LCA Red Light ControllerTB3 R Configure the 9LCA Red Light Controller to use Automatic mode control Other Red Light Systems may require different connections Refer to the Tower Kit drawing if Honeywell provided both systems as a kit refer to the Red Light System s manual or contact Honeywell for assistance 2 4 4 2 Responding to Top Red Beacon Failures When a top level red beacon fails at night a Dual system must switch from red to white lights The Master Controller will switch to the white strobes at night if it detects an open circuit between TB6 1 and TB6 2 EXT RED Install external wiring must in a single electrical loop from TB6 1 to TB6 2 in such a way that the loop is closed when all the top level red beacons are operating correctly and the loop is opened broken when any top level
100. wires are secure by pulling on each wire Wrap each connection with at least 6 wraps of Scotch 33 tape or equivalent for moisture protection All connection ends should be located in the upper corners of the junction box with all closed end of the connector pointing up See Figure 2 6 Page 2 19 for reference Note The Master Controller can operate from a different AC voltage than the Flashheads if desired SG 60 High Intensity Strobe System 2 23 Manual EPM 00000019 Rev A AirportSystems Honeywell 10 LINE PHASE 10 WHITE NUETRAL PHASE LO 22 WHITE DATA LINE 22 BLUE _ DATA LINE 10 GREEN GROUND SHD DATA CABLE INNER SHIELD It is extremely important to connect all Data cable inner shields together but isolate them from all other shields and grounds SHD CABLE SHIELD SHD DATA CABLE OUTER SHIELD Figure 2 10 Flashhead Cable SG 60 High Intensity Strobe System 2 24 Manual EPM 00000019 Rev A AirportSystems Honeywell 00 07003 ASSV WH 00 07200 76 ASSV 401 05 5 FLASHHEAD STATUS D3 8 h PES TE PT p 8 E SI at 59 zu 1 0 0 R27 Figure 2 10 Master Controller

Honeywell SG-60 User's Manual

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