SERIAL NUMBER FTB 312-4 Medium Intensity Obstruction Lighting System Reference Manual Part Number 7913124 Flash Technology, 332 Nichol Mill Lane, Franklin, TN 37067 (615) 261-2000
Front Matter Abstract This manual contains information and instructions for installing, operating and maintaining the FTB 312-4 Medium Intensity Obstruction Lighting System. Copyright Copyright © 2008, Flash Technology®, Franklin, TN, 37067, U.S.A. All rights reserved. Reproduction or use of any portion of this manual is prohibited without express written permission from Flash Technology and/or its licenser. Trademark Acknowledgements Flash Technology® is a registered trademark name.
Personnel Hazard Warning Dangerous Voltages Dangerous line voltages reside in certain locations in this equipment. Also, this equipment may generate dangerous voltages. Although FTCA has incorporated every practical safety precaution, exercise extreme caution at all times when you expose circuits and components, and when you operate, maintain, or service this equipment. Avoid Touching Live Circuits Avoid touching any component or any part of the circuitry while the equipment is operating.
Table of Contents FTB 312-4 .................................................................................................................................. i Front Matter .............................................................................................................................. ii Abstract ................................................................................................................................. ii Copyright ........................................................
Flashhead .......................................................................................................................... 8 Photocell ........................................................................................................................... 9 Installation............................................................................................................................. 9 Power Converter Wiring ..............................................................................
List of Figures Figure 1-1 – TB1 Alarm Contacts ............................................................................................ 2 Figure 1-2 – 2903800 Board Configuration.............................................................................. 4 Figure 2-1 – Power Converter Mounting and Outline ............................................................ 12 Figure 2-2 – Flashhead Mounting and Outline .......................................................................
Section 1 – Introduction and Operation System Performance Characteristics The photocell senses changes in lighting conditions from day to night and from night to day thus signaling the power converter to change its operation appropriately. Also, a manual intensity switch can override the photocell if required.
Configurations Models Lights Operation 312-4 312-4E L-865 White (40 FPM) L-864 Red (20 FPM) L-810 Incandescent Markers White During Daylight Red During Night 312-4H 312-4EH L-865 White (40 FPM) L-864 Red (20 FPM) L-810 Halogen / LED Markers White During Daylight Red During Night The “E” option shown above denotes the addition of the optional modem card for remote diagnostics and monitoring.
Contact White Alarm Red Alarm Day Intensity Error Night Intensity Error Photocell Error Day Mode Night Mode Indication Combination of Day Intensity and Photocell Errors. Combination of Night Intensity and Photocell Errors. Incorrect day intensity. Incorrect night intensity. Photocell alarm. The PEC failed to transition within 19 hours. Day mode operation. Night mode operation. Photocell The photocell changes resistance as ambient light changes from day to night or from night to day.
PCB1 Timing and Trigger Board PCB1 controls and monitors the operation of the PC 312-4. Status indicators and setup options are shown below.
slave units from causing the system to go to white back up if a red failure occurs on the slave. Generally, a system should only go to white back up if the top (master beacon) fails in red night mode. Board Configuration RS-485 Communication The 2903800 board is programmed from the manufacturer for operation in the PC 312-4. The board will be clearly marked in the area shown in Figure 1-2. RS-485 is used to communicate with the FTM-5000 for monitoring of multiple beacon systems as shown in Figure 2-10.
RES PEC Jumper RS-232 The RS-232 port allows programming and troubleshooting using Tech Eagle shown below (available for download from www.flashtechnology.com): The RES PEC jumper is removed by default. The FTB 312-4 uses a PEC 510 resistive photocell for determining mode transition. To use an AC photocell, short this jumper and connect the output of the photocell to pins 4 (AC) and 5 (Return) of J5.
Internal Red Jumper Status LEDs The status LEDs display alarm and mode information as follows: LED NITE ERR DAY ERR PEC ALM WHT ALM RED ALM MKR ALM FAN SYNC CONF DAY NITE MKRS Indication Incorrect night intensity. Incorrect day intensity. Photocell alarm. The PEC failed to transition within 19 hours. Combination of DAY ERR and PEC alarm. Combination of NITE ERR and PEC alarm. Detected markers have fallen below the level set by the options switch. Not used. The Master / Slave Interconnect is active.
Section 2 - Mounting, and Installation Unpacking Inspect shipping cartons for signs of damage before opening them. Check package contents against the packing list and inspect each item for visible damage. Report damage claims promptly to the freight handler. secure the lens. The flashhead normally contains no interlock. Disconnect primary power to the power converter before you open the flashhead. Wait one minute for storage capacitors to drain down.
interfere with access by maintenance or service personnel. You must use a bonding strap with a flashhead mounting bolt when mounting the flashhead to the structure, using the mounting bolt to fasten the strap to the leg that contains the ground connection. Flashhead Leveling The flashheads must be level for correct vertical beam alignment. Two leveling vials—aligned with the mounting feet— are permanently attached to the flashhead assembly.
amperes per light to determine fast-acting fuse ratings at the power distribution panel and to select a system feeder transformer (if used). In multiple-unit systems, the master unit and slave units communicate over the “master/slave” interconnect wiring. Twist the wires together at the rate of 12 twists per foot. The recommended minimum size for control and signal conductors is #14 AWG. Flashhead Wiring The power converter and flashhead are interconnected by the flashhead cable.
3. Ensure that only the bottom of the case has drain holes and that they are clear. 4. Ensure that no holes are punched or drilled on the top surface of the case. 5. Ensure that air can flow around the case. 6. Mount the power converter away from radio frequency interference (RFI). 4. Power Converter Wiring. Examine the installation drawings and use the following checks: 1. Check for proper incoming service voltage. 2. Wire each unit according to the instructions. 3.
(425.5) 5.00 (127) LEFT SIDE VIEW AS WALL MOUNTED FRONT VIEW AS WALL MOUNTED (356) COVER (214) BOTTOM VIEW AS WALL MOUNTED 1.06 (27) .875 (22.2) .875 (22.2) BOTTOM VIEW AS WALL MOUNTED 1.06 (27) (170) .344 (8.74) .875 (22.2) REAR OF CHASSIS AS WALL MOUNTED (311) (54.9) Ø .44 INCH (11.2) BASEPLATE (127) 15.2 (386) Ø.44 INCH (11.
23.8 (603) CLEARANCE REQUIRED 17 (430) 18.3 (463) .625 (15.9) DIA. MOUNTING HOLE (4 PLACES EQUALLY SPACED) Ø13.25 BOLT HOLE CIRCLE NOTES: 1. WEIGHT: 17 LBS (7.7 KG) 2 2 2. AERODYNAMIC WIND AREA: .93 FT (.0864 M ) 3. DIMENSIONS ARE IN INCHES (MILLIMETERS) 4. ACCESS TO THE FLASHHEAD MUST REMAIN UNOBSTRUCTED 5.
2.58 (65.5) 2.28 (57.8) 1.02 (25.9 ) 0.10 (2.54) 0.375 (9.53) 1.92 (48.8) 3.06 (77.7) 0.33 (8.38) HEX 1.0 (25.4) 0.125 (3.
Figure 2-4 – Typical System Installation Revision 4 – 1-8-2008 ALARM (NOTE 6) NOTE 12 GND PRIMARY NEUT POWER LINE 2 LINE 1 NOTE 1 & 5 NOTES 3&4 TB1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TWO CONDUCTORS (#16 AWG MINIMUM) PHOTOCELL WHT PHOTOCELL BLK AUTO ALARM INTENSITY SELECT COM RED OUTPUT ALARM CONTACTS CONTACTS SHOWN IN NORMAL OPERATING STATE (NO ALARMS OR ERRORS) NIGHT ERROR NIGHT PEC ERROR DAY MODE DAY BLK MASTER/SLAVE INTERCONNECT WHT INTENSITY DAY MOUNT THE PHOTOCELL TO
Figure 2-5 – Typical Multiple System Installation COM RED ALARM COM WHITE ALARM PRIMARY POWER FROM A SINGLE 20A BREAKER (NOTE 6) TWO (2) #16 AWG 600V MIN CONDUCTORS TWISTED TOGETHER NOTE 1 & 5 GND LINE 1 NEUT LINE 2 NOTE 11 NOTE 13 NOTES 3&4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TWO CONDUCTORS (#16 AWG MINIMUM) TB1 NIGHT INTENSITY SELECT BLK PHOTOCELL WHT INTENSITY ERROR DAY NIGHT AUTO PHOTOCELL ERROR DAY MODE DAY BLK MASTER/SLAVE INTERCONNECT WHT PHOTOCELL CONTACTS CLOSE DURI
Figure 2-6 – PC 312-4 Power Converter Internal Wiring (110-120V) FTB 312-4 Revision 4 – 1-8-2008 17
Figure 2-7 – PC 312-4 Power Converter Internal Wiring (208-240V) 18 Revision 4 – 1-7-2008 FTB 312-4
ALARM 130VAC MOV 130VAC MOV GND SHIELD CUSTOMER CONNECTION TO ALARM RELAY CONTACTS METALLIC CONDUIT FLASH TECHNOLOGY ALARM RELAY CONTACTS ARE PROTECTED FROM VOLTAGE TRANSIENTS OF UP TO 1000 VOLTS. HOWEVER, WIRED ALARM CONTACTS CAN BE SUBJECTED TO VOLTAGES GREATER THAN 1000 VOLTS BECAUSE OF LIGHTNING. THE FOLLOWING RECOMMENDATIONS MINIMIZE THE POSSIBILITY OF DAMAGE CAUSED BY HIGH VOLTAGE NOTES: 1. 2. 3. 4. USE SHIELDED CABLE TO ATTACH FLASH TECHNOLOGY ALARM RELAY CONTACTS TO EXTERNAL EQUIPMENT.
RED 14 SHLD ANODE T101 TRIGGER TRANSFORMER TRIGGER FT101 WHT P1 BLU RED BLU 14 P2 CATHODE RC101 P7 T102 COUPLING TRANSFORMER BLU RC102 P3 P6 BLK BLK P4 N.C.
Figure 2-10 – RS-485 Installation FTB 312-4 Revision 4 – 1-8-2008 21
Section 3 - Maintenance and Troubleshooting Safety WARNING STOP: Before proceeding read the warning on Page iii. Work safely, as follows: 1. Remove rings and watches before opening the equipment. it gently with a soft cloth or paper towel. 7. Clean the inside surface of the lens with an Flash Technology-approved professional plastic cleaner. Wipe the lens with cheesecloth only. Do not use regular cloth or paper towels. A lens cleaning kit, Part Number 8630801, is available from Flash Technology.
The sync signal is a pulse and difficult to evaluate with a meter. You can detect the sync pulse as an instantaneous movement of the meter indicator. A digital meter with a max-min function may capture part of the pulse. This is generally a sufficient indication of a pulse being present. (A 24V pulse of 16 ms. width might read 12V on a 100 ms. capture time of max-min function.
Power Transformer (T1) Power Converter Burst Choke (L1) Measure the resistance of L1 from TB3-5 to ceramic post E4 (at burst resistor R2). Its resistance should be approximately 7 ohms. Relays (K2, K3) A malfunctioning relay may have faulty contacts, a sticky mechanism, or a defective coil. You may determine the first two possibilities by inspection and manually exercising the armature. You can confirm a defective coil by measuring the resistance.
Trigger Coupling Transformer (T102) The coupling transformer should not have open windings. An ohmmeter will indicate a shorted winding because of the wire size. Check with an ohmmeter at the wire terminals. The general procedure for removing components follows: 1. Obtain access to the component in question. Photocell Testing Use the following procedure: • 1. First, disconnect the photocell. The system should go to night operation after approximately one minute. 2.
Removal Input Power Module 1. Disconnect the wires leading to capacitors. Removal 2. Remove the hold-down screws. 3. Lift the capacitors from their receiving holes. Replacement 1. Reverse the removal procedure. 2. Verify that wiring is in accordance with the wiring diagram in Figure 2-7. Wires must be replaced exactly as removed. In some instances, a quickconnect wire terminal does not seat properly if it is not placed on the terminal cluster exactly as it was before removal.
Removal 1. Loosen the four screws holding PCB1 to the bracket and lift PCB1 up and out. Mode Relay (K2), Discharge Relay (K3) Remove the Component Bracket for adequate access to Relay K2. 2. Loosen the two truss-head screws below PCB1 on the left side of the bracket that hold the bracket to the base plate. Removal 3. Remove the screw on the left front side of the bracket that fastens the bracket to the Input Power Module. 3. Remove the Component Bracket. 4.
Replacement Replacement 1. Align the pins on the flashtube base with the clamps of the terminal screw lugs, making sure that the red dot on the flashtube base coincides with the red dot marked on the bracket directly under it. 2. Carefully insert the flashtube and settle it into place, making sure the ceramic base is resting directly on the tops of the screw lugs. 3. Secure the flashtube by tightening the three screws on the screw lugs.
Normal Operation Indicator Day Night Dual System Night Function Description I15 NITE ERR – On for night intensity error. OFF OFF OFF I9 DAY ERR – On when a day intensity error has occurred (light flashed at the incorrect intensity). OFF OFF OFF I14 PEC ALARM – On for Photocell alarm (Photocell failed to switch state). OFF OFF OFF I8 WHT ALM – On when a white alarm occurs (white light failed). OFF OFF OFF I13 RED ALARM – On for optional red alarm (red light failure occurred).
Manual Override: Fixed Intensities You may manually override automatic intensity control (as when the manual intensity override switch S2 is set to AUTO), but only if no synchronization line connects to other lights. Remove any wire from external circuitry attached to the master/slave interconnect terminals. Do this either for temporary purposes (testing) or for permanent operation at a fixed flash intensity. 2.
Dual System (White in Daylight, Red at Night) The following procedures check normal operation of a dual system, a system with red lights operated by an external red light controller. The external red light controller is connected to TB5. 1. Check Daytime Operation: Apply primary power and verify that daytime operation is identical to that for a standard system, step 1. Check Normal Daytime Operation. 2.
master/slave interconnect terminals at TB1-4 and TB1-5. 1. Temporarily disconnect the black master/slave interconnect wire at TB14. 2. Temporarily set the manual intensity override switch S2 to DAY. 3. Verify the Daytime responses are the same as those in Table 3-2 and Section 1. Check Normal Daytime Operation on Page 3-7. 4. Verify that the strobe is operating at daytime intensity (high intensity). 5.
Figure 3-2 – Unit Troubleshooting Guide Flash Conditions Other Conditions 1 Probable Causes 2 Day Night HV LV No No OK OK No No No No No No No No F1 Fuse S1 Interlock T1 Transformer Connections – Main Power No No No OK C2A-D or C3 Shorted Shorted FH Cable No No OK No No indicators lit on PCB1 OK High Intensity OK OK Red Alarm OK OK OK OK Markers Out F4 Fuse 3 K5 Marker Control Relay PCB1 Board OK OK OK OK Markers Stay On K5 Marker Control Relay PCB1 Board OK
4 OK Backup Intensity OK OK Flashtube Mounting Plate Assembly F5 Red OK OK OK Flashtube Mounting Plate Assembly PCB1 Red or White OK OK OK White Alarm OK No OK OK Red Alarm PCB1 Board K2 Relay C3 Burst Capacitor Open L1 Burst Choke R2 Burst Resistor No OK OK OK White Alarm PCB1 Board K2 Relay L2 Flash Chock C2A-D Capacitors Open 34 4 4 Flashtube Mounting Plate Assembly 1 HV = High voltage. PCB2 or HV neon lamp lit confirms HV. 2 LW = Low voltage.
Figure 3-3 – System Troubleshooting Guide Flash Conditions Other Conditions Probable Causes Day Night OK Day Flash Possible PEC Error PEC Photocell PCB1 Board Intensity Select Switch Jumper on TB1 & 2 on Slave Units Missing Red OK Possible PEC Error PEC Photocell Intensity Select Switch - - Units Mixed Red and White OK OK Units Not Flashing Together No No No Lights FTB 312-4 Intensity Select Switch Master / Slave Interconnect Wiring Master / Slave Interconnect Cable Connected to TB1-4
Section 4 – Recommended Spare & Replaceable Parts Customer Service Customer Service: 1-800-821-5825 Telephone: (615) 261-2000 Facsimile: (615) 261-2600 Shipping Address: Flash Technology 332 Nichol Mill Lane Franklin, TN 37067 Ordering Parts To order spare or replacement parts, contact customer service at 1-800-821-5825. Power Converter Parts Figure 4-1 Power Converter Major Replaceable Parts lists the major replaceable parts for the power converter.
Part Number Reference Description BR1 Diode Bridge 6902806 C2A,C,D Capacitor, Main Bank, 70 mfd. 6720401 C2B Capacitor, Main Bank, 40 mfd 6386504 C3 Capacitor, Night Mode, 1 mfd. 6848202 C4 Capacitor, Tuning, 3 mfd.
Figure 4-2 – Power Converter Component Layout 38 Revision 4 – 1-7-2008 FTB 312-4
Reference Description Part Number Ceramic Spacer, ¾” diameter 5900844 Ceramic Spacer, ½” diameter, short 5900842 Ceramic Spacer, ½” diameter, tall 5900843 FT101 Flashtube 8384308 A101 Flashtube Mounting Plate Assembly 8812405 RC101 R.C. Network 1403411 RC102 R.C.
P15 P16 P13 BR102 LOCATED ON ANGLED TAB, UNDER MP101 10 1 SW101 (BOTTOM) C102 BR101 SW102 (TOP) C P14 L101 T101 TRIGGER TRANSFORMER FLASHTUBE LUG SHIELD GROUND SCREW CATHODE MP101 P7 ANODE 01 P1 CLUTCH P6 RC 1 ED R RC102 P2 TRIGGER RING FILTER FLASHTUBE SUPPORT B101B MOTOR U BL P3 T102 K BL COUPLING TRANSFORMER P4 P5 T H W O VI Figure 4-4 – Flashhead Component Layout 40 Revision 4 – 1-7-2008 FTB 312-4
Returning Equipment – Return Material Authorization (RMA) If a product purchased from Flash Technology must be returned for any reason, please follow the procedure below: NOTE: An RMA number must be requested from Flash Technology prior to shipment of any product. No returned product will be processed without an RMA number. This number will be the only reference necessary for returning and getting information on the product’s progress. 1.
• If the P.O. number is NOT available at the time of the call, a Case Number will be given to the customer and should be referenced on the P.O. when faxed or emailed to RMA Rep. • Flash will then, at its discretion repair or replace the defective product and return the product to the customer based on the shipping method selected. • The customer may purchase a new product before sending in the existing product for repair.
