FTB 204 FTB 205 FTB 207 FTB 208 - Flash Technology · PDF fileany safety interlock switch. iv...

Flash Technology Corporation of America®, 332 Nichol Mill Lane, Franklin TN 37067(615) 261-2000

SN

W

FTB 204

FTB 205

FTB 207

FTB 208

High Intensity Obstruction Lighting System

Reference Manual

ii Revision 13 —3-16-01 FTB 204, 205, 207 & 208

Front MatterAbstract

This manual contains information and instructions for installing, operating, and maintaining the FTB 204 and 205 High Intensity Obstruction Lighting Systems and FTB 207, 208 and 208P Catenary Obstruction Lighting Systems.

CopyrightCopyright © 1999 - 2001 Flash Technology Corporation of America®, Franklin TN 37067, U.S.A.

All rights reserved. Reproduction or use of any portion of this manual is prohibited without express written permis-

sion from Flash Technology Corporation of America and/or its licenser.

Trademark AcknowledgmentsFlash Technology Corporation of America® is a registered trademark name.

Flash™, ElectroFlash™, Flash Tech™, Flash Technology™, and FTCA™ are trademarks of Flash Technology Cor-

poration of America®.

All trademarks and product names mentioned are properties of their respective companies, and are recognized and

acknowledged as such by Flash Technology Corporation of America.

Applicable SpecificationThis equipment meets or exceeds requirements in FAA Advisory Circulars 150/5345-43, 70/7460-1, and 150/5345-1

for an FAA Type L-856 and L-857 white high intensity obstruction light.

DisclaimerWhile every effort has been made to ensure that the information in this manual is complete, accurate and up-to-date,

Flash Technology Corporation of America assumes no liability for damages resulting from any errors or omissions in

this manual, or from the use of the information contained herein. Flash Technology Corporation of America reserves

the right to revise this manual without obligation to notify any person or organization of the revision.

In no event will Flash Technology Corporation of America be liable for direct, indirect, special, incidental, or conse-

quential damages arising out of the use of or the inability to use this manual.

WarrantyAll components are fully warranted, under normal operating conditions, for two years.

Parts ReplacementThe use of non-OEM parts or unauthorized modification of this equipment will void the warranty and could invali-

date the assurance of complying with FAA requirements as published in Advisory Circular 150/5345-43, 70/7460-1,

and 150/5345-1.

Pub. No. 0594-204578--0013

FTB 204, 205, 207 & 208 Revision 13 —3-16-01 iii

PERSONNEL HAZARD WARNINGDangerous line voltages reside in certain locations in this equipment. Also,this equipment may generate dangerous voltages. Although FTCA hasincorporated every practical safety precaution, exercise extreme caution atall times when you expose circuits and components, and when you operate,maintain, or service this equipment.

Avoid Touching Live CircuitsAvoid touching any component or any part of the circuitry while the equip-ment is operating. Do not change components or make adjustments insidethe equipment with power on.

Dangerous Voltages Can Persist with Power DisconnectedUnder certain conditions, dangerous voltages can be present becausecapacitors can retain charges even after the power has been disconnected.

Protect yourself — always turn off the input (primary) power and wait forone minute for storage capacitors to drain their charge. Then checkbetween the red and blue wires on the TB2 terminal block with a voltmeterfor any residual charge before touching any circuit element or component.

Do Not Depend on InterlocksNever depend on interlocks alone to remove unsafe voltages. Alwayscheck circuits with a voltmeter. Under no circumstances remove or alterany safety interlock switch.

iv Revision 13 —3-16-01 FTB 204, 205, 207 & 208

Table of ContentsSection PageFront Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Section 1 — Introduction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1System Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Variations and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Beacon/Power Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Catenary Operation (FTB 207, 208, 208PB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Flash Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-260/50 Hz Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Fixed Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Setting Up PCB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Cuttable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Section 2 — Outline, Mounting, and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Beacon/Power Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Flashhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Beacon Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Beacon Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2PEC Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Beacon Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Lightning Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Section 3 — Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1RFI Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wiring and Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2C1 — High Intensity Capacitor Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2C2 — Medium Intensity Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2C3 — Low Intensity Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2C4 — Tuning Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2FT101 — Flashtube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2K1, K2 — Mode Relays, 24-volt DC Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3K3 — Discharge Relay, 120 VAC Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3L1 — Burst Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3L2 — Flash Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3PCB1 — Timing and Trigger Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

FTB 204, 205, 207 & 208 Revision 13 —3-16-01 v

Table of Contents (cont’d)Section Page

R1A, R1B — Bleed Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3PCB2 — HV Rectifier Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3R2A, R2B — Burst Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3T1 — Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3PCB3 — Sense Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3T101 — Trigger Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3VR1 — Suppressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Component Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Removal & Replacement — General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6BR1 — Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6K1/K2/K3 — Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6L1 — Burst Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6L2 — Flash Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6R1A/R1B & R2A/R2B — Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7T1 — Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7T3 — Coupling Transformer (PC 204, 207) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7PCB1/PCB2 Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Flashtube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Flashtube Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Trigger Transformer T101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Section 4 — Replaceable and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Beacon/Power Converter Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Flashhead Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Repackaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-11

List of FiguresPage

Figure 1-1 PCB1 (24988xx) Timing and Trigger Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Figure 1-2 Typical 2-Tower 3-Tier Layout and Catenary Beacon Operation . . . . . . . . . . . . . . . . 1-4Figure 1-3 High Intensity Lighting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Figure 2-1 PC 204 or PC 207 Power Converter Mounting and Outline . . . . . . . . . . . . . . . . . . . . . 2-5Figure 2-2 FH 204 Flashhead Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Figure 2-3 FTB 205 or FTB 208 Beacon Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Figure 2-4 Wiring Overview of a System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Figure 2-5 Junction Box; Three-phase Installation Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Figure 2-6 Single-Phase Installation Wiring for FTB 204 or 207 . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Figure 2-7 Single-Phase Installation Wiring for FTB 205 or 208 . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Figure 2-8 Single-Phase Installation Wiring for FTB 208 and FTB 208PB . . . . . . . . . . . . . . . . . 2-12Figure 2-9 Optical Assembly Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13Figure 2-10 PC 204 and PC 207 Power Converter Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . 2-14Figure 2-11 FTB 205 and FTB 208 Beacon Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Figure 2-12 FTB 205PB/FTB 208PB Beacon Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

vi Revision 13 —3-16-01 FTB 204, 205, 207 & 208

List of Figures (cont’d)Page

Figure 2-13 PC 204PB/PC 207PB Power Converter Internal Wiring . . . . . . . . . . . . . . . . . . . . . . 2-17Figure 3-1 T3 Winding Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Figure 4-1 PC 204 and PC 207 Power Converter Component Locations . . . . . . . . . . . . . . . . . . . . 4-3Figure 4-2 PC 204PB and PC 207PB Power Converter Component Locations . . . . . . . . . . . . . . . 4-4Figure 4-3 FTB 205 and FTB 208 Beacon Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Figure 4-4 FTB 205PB/FTB 208PB Beacon Component Locations . . . . . . . . . . . . . . . . . . . . . . . . 4-5Figure 4-5 FTB 205 Optical Assembly; FH 204 Flashhead Component Locations . . . . . . . . . . . . 4-6

List of TablesPage

Table 1-1 Mode Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Table 1-2 Cuttable Jumper Programming and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Table 2-1 Beacon/Flashhead Elevation Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Table 3-1 Power Transformer Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Table 3-2 Major Troubleshooting Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Table 3-3 Defective Component Locator Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Table 4-1 Beacon/Power Converter Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Table 4-2 Flashhead Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 1-1

Section 1 — Introduction and Operation

The FTB 204 High Intensity Beacon consists of an FH 204 Flashhead and a PC 204 Power Converter in seperate enclosures.

The FTB 207 High Intensity Catenary Beacon consists of an FH 204 Flashhead and a PC 207 Power Converter in seperate enclosures.

The FTB 205 High Intensity Beacon is a self-con-tained unit with an optical assembly mounted in the enclosure.

The FTB 208 High Intensity Catenary Beacon is a self-contained unit with an optical assembly mounted in the enclosure.

System Controller

An ElectroFlash FTC 140 System Controller directs flash timing and intensity, and records and reports Beacon operating status. It enables either automatic or manual intensity control, and it continuously displays the flashing status of each Beacon. For further information, consult the FTC 140 System Controller Manual.

Variations and Options

Contact Customer Service at 1-800-821-5825 for a description of equipment variations and options.

Equipment Specifications

Dimensions are nominal. See Section 2 for mount-ing dimensions.

PhysicalPC 204 or PC 207 (or PB) Power Converter):

(H x W x Depth, Wgt.)23 x 17.13 x 9.44 in., 70 lbs.

584.2 x 435.1 x 239.8mm., 31.8 kg.Wind Area: 2.4 sq. ft., .22 sq. m.

FH 204 Flashhead: (H x W x Depth, Wgt.)

23 x 18.6 x 12.8 in., 18 lbs.584 x 472 x 325 mm., 8.2 kg.

Wind Area: 1.99 sq. ft., .18 sq. m.FTB 205 or 208 (or PB) Beacon:

(H x W x Depth, Wgt.)22.35 x 20.88 x 11.23 in., 85 lbs.

567.7 x 530.4 x 285.2 mm. 38.6 kg.Wind Area: 2.9 sq. ft., .27 sq. m.

A p p l i c a t i o nFTB 204, 205 L-856FTB 207, 208 Catenary L-857

Flash Intensity: (nominal)FTB 204, 205:

Day Intensity 270,000 ± 25% ECDFTB 207, 208:

Day Intensity 140,000 ± 25% ECDAll Units:

Twilight Intensity 20,000 ± 25% ECDNight Intensity 2,000 ± 25% ECD

Beam Spread:Horizontal: 120º; Vertical: 3º

Flash Rate:FTB 204, FTB 205 40 flashes per min.FTB 207, FTB 208 Catenary 60 flashes per min.

Electrical (factory pre-wired):AC Voltage

120, 208, 240, 480VAC ± 10%,60 Hz ±1% 1Ø230 VAC 50Hz

Volt-Amperes 600 VA peak; 400 VA avg.Watts Day Mode: 255

Environmental: 55 to +55 degrees CentigradeControl: Responds to system controller

Operation

The controller determines the operating intensity of the structure lights, and then informs the Tim-ing and Trigger Board (PCB1) in each beacon.

Beacon/Power Converter

The beacon starts flashing when power is applied.

A pair of shielded conductors between the beacons and the controller carry the control and monitor-ing signals for an entire system. A beacon sends a flash confirmation signal to the controller for

1-2 Revision 13 —5-8-01 FTB 204, 205, 207, 208

monitoring. Individual encoding identifies the beacon of origin, thus enabling all beacons in a system to individually report to the controller.

All beacons are capacitive discharge lights that use a xenon flashtube.

If the controller is disconnected, or fails, all bea-cons flash by default at high intensity.

Catenary Operation (FTB 207, 208, 208PB)

High intensity lights for towers that support cate-nary wires provides the highest degree of visibil-ity in daylight and night. Three levels (tiers) of sequentially flashing lights are required. One tier of lighting is required at the top, one tier at the midpoint, and one tier at the bottom.

The tier flash sequence is middle, top, bottom. All lights at the same tier flash simultaneously. The catenary flash rate is 60 flashes per minute. See jumper JP13 in Table 1-2 for catenary program-ming.

FTCA uses a standard format: it refers to the low-est level as Tier 1 and the most northerly facing light as beacon 1. Higher numbered beacons are placed around the structure in a North-East-South-West direction. Figure 1-2 shows a typical installation.

Flash Modes

Night: At nightfall, the controller switches the beacon to night mode operation; the flashhead flashes at the night intensity of 2,000 ± 25% ECD.

Twilight: At twilight, the controller switches the beacon to twilight mode operation; the flashhead flashes at the twilight intensity of 20,000 ± 25% ECD.

Day: At daybreak, the controller switches the beacon to day mode operation; the flashhead flashes at the daylight intensity of 270,000 ± 25% ECD.

60/50 Hz Operation

PCB1 can operate from either a 60Hz or a 50Hz power source. Cut JP12 jumper on PCB1 for 50 Hz operation.

Fixed Mode Operation

Table 1-1 explains how to force the beacon to oper-ate continuously at a fixed flash intensity (mode). Use Table 1-1 to check its operation at all three flash intensities.

Setting Up PCB1

PCB1 (24988xx) governs all the functions pertain-ing to operation. It has eight red light emitting diode (LED) indicators, and one clear neon indica-tor that you can use to monitor equipment opera-tions during checkout and troubleshooting. To monitor operation the following subsections instruct you to observe specified LEDs. The LEDs are mounted at the top left edge of PCB1. The essential features on PCB1 for troubleshooting are shown in Figure 1-1.

The factory programs PCB1 according to your purchase order.

When replacing PCB1 in the field, ensure that the jumpers on the replacement board are cut in the same manner as the jumpers on the board you are

Table 1-1 Mode ControlIntensity Procedure†

DAY (High) Place a jumper between Test Point 1 (TP1) labelled TEST and TP5 labelled DAY.

TWI (Twilight) Place a jumper between Test Point 1 (TP1) labelled TEST and TP4 labelled TWI.

NITE (Low) Place a jumper between Test Point 1 (TP1) labelled TEST and TP3 labelled NITE.

LTV Factory use only. Causes continuous triggering. Do not use.

† Be certain to remove all jumpers after checking the beacon.

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 1-3

replacing. You can change some operations in the field by using the information in the Figure 1-1 and Table 1-2. Figure 1-1 shows the locations of programming jumpers and of indicator lights use-ful for monitoring the equipment’s operation. Table 1-2 shows the jumper functions.

Cuttable Jumpers

NOTECuttable jumpers JP12, JP14, JP15,and JP16 are for factory use only. Thefactory cuts all jumpers according tothe installation requirements. Otherjumpers are cut according to the loca-tion (on the structure) or use (catenaryor not), only if necessary.

Table 1-2 Cuttable Jumper Programming and UseJumper Name Purpose

JP1 TIER 1 Cut jumper selects tier #1.






JP7 TIER 7Cut jumper selects tier #7. NOTE: This jumper is cut in the backup lighting unit of primary/backup systems, such as the FTB 208PB. For these systems JP7 and the proper Tier and Side Jumpers are also cut.

JP8 SIDE 1 Cut jumper selects side #1.




JP12 50HzCut jumper selects 50Hz board operation for 50Hz power source. Factory cut; internal power con-verter wiring is also changed for 50Hz.

JP13 CATCut jumper allows catenary operation for this power converter. The controller directs catenary opera-tion. Factory cut for your installation. (For FTB 207, 208, or 208PB only.)

JP14 2X Factory cut.

JP15 SENS Cut jumper selects energy thresholds appropriate for a ferrite core sense transformer. Factory cut.

JP16 SENS Cut jumper configures sense signal hardware for ferrite core sense transformer. Factory cut.

1-4 Revision 13 —5-8-01 FTB 204, 205, 207, 208

20457831

Figure 1-1 PCB1 (24988xx) Timing and Trigger Board

20457832

Figure 1-2 Typical 2-Tower 3-Tier Layout and Catenary Beacon Operation

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 1-5

20457811

Figure 1-3 High Intensity Lighting Equipment

1-6 Revision 13 —5-8-01 FTB 204, 205, 207, 208

This page is intentionally left blank.

FTB 204, 205, 207, 208 Revision 13 —5-8-01 2-1

Section 2 — Outline, Mounting, and Installation

Unpacking

Inspect shipping cartons for signs of damage before opening. Check package contents against the packing list and inspect each item for visible damage, and promptly report damage claims to the freight handler.

FTCA factory programs beacons for operation at particular locations, and marks the shipping con-tainers accordingly on the outside. FTCA refers to the lowest level as Tier 1 and the most northerly facing light as Beacon 1. Higher numbered bea-cons are placed around the structure in a North-East-South-West direction. Therefore, you must maintain the beacon’s identity according to the package identity of each beacon (for example, Beacon 1, Tier 1; Beacon 2, Tier 1; and so forth), and install it as called out on drawings.

Tools

Although no special tools are necessary, the fol-lowing hand tools are suggested for installation and maintenance:

• #1 Phillips-head screwdriver, 8-inch long shank

• #2 Phillips-head screwdriver

• 3/16-in. flat blade screwdriver

• 1/4-inch flat blade screwdriver

• Medium slip-joint pliers

• 8-in. or 10-in. adjustable wrench

• Assorted nut drivers and combination wrenches

• Hand tools for electrical wiring

• Triplett™ Model 630-NA VOM, or equivalent analog volt-ohm meter, or a digital meter with an averaging function.

Access

HAZARD WARNINGDisconnect the primary power before open-ing the beacon or flashhead enclosures.

Beacon/Power Converter

Latches secure the hinged cover of the power con-verter or the beacon. When you release these you can swing open the cover for access to the inside.

Flashhead

Latches secure the hinged cover of the flashhead. When you release these you can swing open the cover for access to the inside.

Mounting

Outline, mounting, and clearance dimensions for your equipment are shown in the following fig-ures:

• Figure 2-1 PC 204 or PC 207 Power Converter Mounting and Outline

• Figure 2-2 FH 204 Flashhead Mounting and Outline

• Figure 2-3 FTB 205 or FTB 208 Beacon Mount-ing and Outline

Beacon Location

FAA Guidelines for beacon placement are pub-lished in AC 70/7460-1. Avoid placing a beacon within a strong radio frequency (RF) field. For example, a beacon within four feet of a radiating FM antenna is likely to pick up electromagnetic interference (EMI) that could cause improper operation or damage. Place a beacon at an ade-quate distance from a powerful RF radiator. Con-tact the factory for instructions when you cannot avoid this situation.

2-2 Revision 13 — 5-8-01 FTB 204, 205, 207, 208

Beacon Angle

NOTEBeacons (except AOL lights) areinstalled with specific elevation angles.

Various factors may influence the angle of beacon elevation for the units on your structure. These

include: location of the structure, height of the beacon above ground, and other characteristics of the site and surrounding terrain. Advisory Circu-lar 70-7460-1 contains guidelines for setting the elevation angle. Information derived from that source forms Table 2-1 Beacon/Flashhead Eleva-tion Angle.

First, level the unit to obtain a reference elevation angle (the specified elevation angle is added to the reference angle). Use the spirit level located inside the enclosure for initial leveling—the tilt-ing bracket has an incremental scale. The tilt mechanism is part of the permanently attached mounting bracket. To level the enclosure, tilt it by using the mounting brackets.

Controller Mounting

Locate the system controller in an area with restricted access. Controllers are available either in outdoor enclosures that can be attached to any vertical surface, or as an indoor, rack-mounted controller.

You can place the system controller anywhere within 2500 feet of the most distant beacon with-out further consideration. Consult with the fac-tory if a greater distance is necessary.

PEC Mounting

You may locate the PEC at any practical distance from the system controller. To ensure proper oper-ation, observe the following requirements. Mount the PEC:

• With an unobstructed view of the polar sky.

• In a way that direct or reflected sunlight does not strike it.

• Vertically on the top end of a vertical length of conduit to prevent water from entering.

Refer to the system controller manual for mount-ing and outline dimensions of the FTC 140R/W Controller and PEC.

Wiring

NOTEOnly general information for a typical instal-lation is presented here. Thus, more specificinformation may be needed for your site.

Consult any installation drawings preparedespecially for your site or supplied with theequipment.

If installation drawings prepared specificallyfor your site disagree with information pro-vided in this manual, the installation draw-ings should take precedence.

See Figure 2-4 Wiring Overview of a System. Sys-tem wiring consists of primary power and signal distribution wiring. Primary power is usually taken from a load center to the various items of equipment. Signal wiring is between the beacons and the system controller. Make connections to beacons at nearby junction boxes. Always position junction boxes below the beacons with drain holes facing downward.

Table 2-1 Beacon/Flashhead Elevation Angle

Tier Level - Above Ground Level (AGL) Elevation Angle

0 to 300 feet (91 meters) +3 degrees

300 feet to 400 feet (122 meters) +2 degrees

400 feet to 500 feet (152 meters) +1 degree

500 feet and higher 0 degree

FTB 204, 205, 207, 208 Revision 13 —5-8-01 2-3

Beacon Wiring

Three-phase power often supplies large systems. However, the beacons are single-phase units that are connected from line-to-line (A-B, B-C, A-C). Therefore, phase differences occur between groups of beacons in the same three-phase sys-tem. In a three-phase system, phase A-C must supply the controller (not C-A) to allow the con-troller to be compatible with all beacons. Failure to ensure optimum phasing as described could result in intensity control problems.

Use circuit breakers or a safety switch with fuses for the primary power load center. Insulation should be rated at 600 VDC minimum. Wire size is a factor affected by the service voltage, the number of beacons in the system, and the length of the wire run to the beacons. To determine wire gauge, consider each beacon as a 400 volt-ampere load and do not permit the voltage drop caused by wire resistance to exceed 5% at any beacon. You may use this volt-ampere value to determine rat-ings for slow-acting fuses or circuit breakers for the system. For fast-acting fuses and a system feeder transformer (if used) consider a peak load of 600 volt-amperes for each beacon. FTCA recom-mends that you use National Electric Code guide-lines for all primary wiring.

A label inside the beacon near the fuse block indi-cates the operating voltage and frequency of your beacon. Two internal fuses are sized according to the operating voltage. When Line 2 is neutral, the factory replaces the F2 fuse with a jumper wire.

Make connections to distribution wiring at a nearby junction box. Consult the following instal-lation wiring diagrams to guide you in wiring the equipment at your installation:

CAUTIONThese figures are guidelines only. If they dif-fer from the installation drawings for yoursite, use the site installation drawings.

Installation drawings in this manual are as fol-lows:

• Figure 2-5 Junction Box; Three-phase Installa-tion Wiring

• Figure 2-6 Single-Phase Installation Wiring for FTB 204 or 207

• Figure 2-7 Single-Phase Installation Wiring for FTB 205 or 208

• Figure 2-8 Single-Phase Installation Wiring for FTB 208 and FTB 208PB

Lightning Protection

Though ElectroFlash equipment is designed to withstand severe transient over-voltages, a light-ning arresting system must be installed to pre-vent damage by lightning. Install a lightning arresting system to protect a light at the top of a mast or antenna. Transient suppressors from line-to-line and line-to-neutral are recommended at the primary power load center.

Installation Checklist

Complete the following steps before applying power to the lights.

1. Equipment Damage:Inspect all equipment for damage.

2. Required Equipment:Verify the received equipment against the packing list to ensure completeness.

3. Beacon/Power Converter Mounting:Position and mount each unit correctly, allow-ing adequate clearance for opening the covers. Also, use the following guidelines:

– Ensure that the case is mounted upright, is water tight, and grounded.

– Check hardware inside the case to ensure that the mounting screws and nuts are tight.

– Ensure that only the bottom of the case has drain holes and that they are clear.

– Ensure that no holes are punched or drilled on the top surface of the case.

– Ensure that air can flow around the case.

– Mount the unit away from radio fre-quency interference (RFI).

2-4 Revision 13 — 5-8-01 FTB 204, 205, 207, 208

4. Beacon/Power Converter Wiring:

Use the installation drawings and the follow-ing guidelines:

– Check for proper incoming service volt-age.

– Wire each unit according to the instruc-tions.

– In installations with multiple units, ensure that all units are wired to the same phase. In installations with mul-tiple tiers and three phase wiring, fol-low the phasing chart in the installation drawings, or site drawings.

– Check all electrical connections for tightness.

– Check all terminal strip connections for tightness.

– Ground the power converter/beacon using a bonding strap from the case leg to the structure.

5. Flashhead Mounting:

Ensure that the flashhead lens can be opened without striking other objects.

– Level and set the flashhead at the required elevation angle.

6. Flashhead Wiring:

– Ground the flashhead.– Check the wiring of the flashhead cable

to the flashhead.– Secure the flashhead cable to the tower.

Support and tape the flashhead cable to prevent its movement by the wind.

7. Photocell:

– Locate photocell where it views unob-structed polar sky with no direct or reflected artificial lighting striking it.

– Mount the photocell vertically on the top end of a vertical length of conduit to prevent water from entering the unit.

– Ground the wire shield around the pho-tocell wires, if one is present.

– After running the photocell wires, check for continuity and shorts.

After completing all the steps listed above, turn on the power and perform an operational check-out from procedures in Section 3 of this manual.

FTB 204, 205, 207, 208 Revision 13 —5-8-01 2-5

20457821

Figure 2-1 PC 204 or PC 207 Power Converter Mounting and Outline

2-6 Revision 13 —5-8-01 FTB 204, 205, 207, 208

20457822

Figure 2-2 FH 204 Flashhead Mounting and Outline

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 2-7

20457823

Figure 2-3 FTB 205 or FTB 208 Beacon Mounting and Outline

2x Ø1.31

.62

9.23

11.23

2.00

TOP VIEW

FRONT VIEW

BOTTOM VIEW

RIGHT SIDE VIEW REAR VIEW

NOTES:

1. WEIGHT: 85 LBS. (38.6 KG.)2. WIND AREA: 2.9 SQ. FT. (.27 SQ. M.)3. DIMENSIONS ARE IN INCHES (MILLIMETERS)

(567.7)

22.35

20.00

21.25(539.8)

(508)

(33.28)

(50.8)

(15.7)

(234.4)

(285.2)

31.23(793.2)

2.6 TYPICAL(66.0)20.0

(508)

17.8(453)

20.88(530.4)

00.0

5.50

7.50

13.0

0

14.6

8

00.0

4.00

7.00

1.12(28.5)

.88(22.4)

.10(2.54)

2-8 Revision 13 —5-8-01 FTB 204, 205, 207, 208

20457812

Figure 2-4 Wiring Overview of a System

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 2-9

3PHSWRNG

Figure 2-5 Junction Box; Three-phase Installation Wiring

2-10 Revision 13 —5-8-01 FTB 204, 205, 207, 208

204207INSWRNG

Figure 2-6 Single-Phase Installation Wiring for FTB 204 or 207

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 2-11

205208INSTWRG

Figure 2-7 Single-Phase Installation Wiring for FTB 205 or 208

2-12 Revision 13 —5-8-01 FTB 204, 205, 207, 208

208208PINSWRNG

Figure 2-8 Single-Phase Installation Wiring for FTB 208 and FTB 208PB

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 2-13

FH204IW

Figure 2-9 Optical Assembly Internal Wiring

2-14 Revision 13 —5-8-01 FTB 204, 205, 207, 208

3743104HIW

Figure 2-10 PC 204 and PC 207 Power Converter Internal Wiring

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FTB 204, 205, 207, 208 Revision 13 — 5-8-01 2-15

3726112HIW

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2-16 Revision 13 —5-8-01 FTB 204, 205, 207, 208

3726122AIW

Figure 2-12 FTB 205PB/FTB 208PB Beacon Internal Wiring

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FTB 204, 205, 207, 208 Revision 13 — 5-8-01 2-17

3743109CIW

Figure 2-13 PC 204PB/PC 207PB Power Converter Internal Wiring

2-18 Revision 13 —5-8-01 FTB 204, 205, 207, 208

This page is intentionally left blank.

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 3-1

Section 3 — Maintenance and Troubleshooting

Safety

HAZARD WARNINGSome procedures in this section may requiremaking contact with electrical circuits. Readthe warning on Page III.

Work safely, as follows:

1. Remove rings and watches before opening the equipment.

2. Shut off the equipment.

3. Remove the component or connect the test instruments.

4. Replace the component.

5. Turn on the power and test the system.

6. Turn off the power and disconnect the test equipment.

Preventive Maintenance

Carry out the following inspection and cleaning procedures at least twice a year:

1. Verify that moisture has not entered the equipment accidentally through gaskets or seals, or collected as condensation.

2. Verify that all drain holes are clear.

3. Check terminal blocks and relays for evidence of corrosion and electrical arcing. Clean or replace any component that shows evidence of high-voltage damage.

4. Check flashtube connections for signs of pit-ting or arcing. Verify that anode and cathode connections are firmly tightened.

5. Check all electrical connections for tightness and verify the absence of corrosion or electri-cal arcing.

6. Clean the inside and outside surface of the glass with a non-abrasive glass cleaner.

Storage

No special considerations are required for long-term storage of the equipment. Circuit boards, when not installed in the equipment, should be kept in antistatic bags or containers.

RFI Problems

Radio frequency interference (RFI) can cause a light to flash intermittently, at the wrong rate, or at the wrong intensity. RFI can enter the light by way of any wire to or from the unit. For example:

• RFI on primary power wires could cause errors in flash rate and intensity.

• RFI on the control wire could cause a light to stay at night intensity.

• RFI on the PEC line could cause a light to stay at night intensity. RFI would not normally cause a light to stay at day/twilight intensity.

• Strong RFI could burn out PCB1 Timing and Trigger Board components.

The circuits are designed to reject or bypass RFI, but complete immunity cannot be guaranteed beforehand. It may be necessary after installation to add external filters or use other methods to reduce RFI entering the equipment.

Component Testing

The following procedures describe how to check most of the major electrical components. Always make resistance measurements with the power turned off. However, you must make voltagemeasurements with power applied. Thus, for your safety, perform all preliminary steps, such as con-necting test leads or circuit jumpers, or discon-necting existing circuit connections, with the power turned off and storage capacitors dis-charged.

Refer to Figure 4-1, Figure 4-3, Figure 4-4, and Figure 4-5 for component layouts and locations.

3-2 Revision 13 —5-8-01 FTB 204, 205, 207, 208

Wiring and Cabling

Wires or cables that move repeatedly will ulti-mately break. Ensure that all cables (the flash-head cable in particular) are securely fastened at short intervals to the structure or other supports.

Inspection

Closely inspect the units and check the connec-tions against the installation instructions. Also, a close inspection may reveal insulation break-down, and overheated component, corrosion, loose connections, faulty relays, incorrect hookup, and so forth.

Capacitors

Evaluate the condition of a capacitor with an ana-log volt-ohmmeter operating in the resistance mode. The following method assumes an instru-ment with a X100 resistance scale.

Place the meter leads across the terminals of an isolated (no electrical connections to other cir-cuits) and fully discharged capacitor, and observe the subsequent needle movement.

If the capacitor is OK, the needle initially indi-cates zero ohms, but soon begins to rise higher indicated values. A capacitor that is disconnected from other circuitry is defective if it does not exhibit this behavior. The length of time it takes the needle to reach the 1 megohm (about 65% of full-scale) reading is a measure of the capaci-tance. For example, the time is about 5 seconds for a 10 mfd capacitor; 10 seconds for a 20 mfd capacitor, and so forth.

Manually discharge the capacitor before repeat-ing this measurement. This test may not detect a malfunction that occurs only at high voltage.

A bank of capacitors connected in parallel may be checked as a single unit. If a short circuit is indi-cated, the individual capacitors have to be discon-nected and checked separately. A shorted capacitor is indicated if the resistance does not rise above zero after several seconds of measure-ment.

C1 — High Intensity Capacitor Bank

The C1 main capacitor bank consists of several capacitors. Test these capacitors as described in Section Capacitors.

If the meter indicates a short circuit, you must isolate the individual capacitors and check them on at a time until you locate the defective capaci-tor.

C2 — Medium Intensity Capacitor

Test C2 as described in Section Capacitors. Check the bank as a whole by placing the meter leads to the terminals of any C2 capacitor and pressing down the armature of the K3 discharge relay.

If a short circuit is indicated, you must isolate the capacitors and check them one at a time.

C3 — Low Intensity Capacitor

Test C3 as described in Section Capacitors. Remove all leads from one terminal cluster of this capacitor. The measured resistance across this capacitor should increase from zero to one megohm in approximately 1.5 seconds.

C4 — Tuning Capacitor

Test C4 as described in Section Capacitors. Remove the lead from one terminal of this capaci-tor. The measured resistance across the capacitor should increase from zero to one megohm in approximately 1.5 seconds.

FT101 — Flashtube

Visually inspect the flashtube for broken elec-trodes, cracked glass, and the solder connections of the pins. A darkened envelope does not neces-sarily mean the light output would be unaccept-able. Before concluding that a faulty flashtube is responsible for an inadequate flash, first rule out other possible causes such as weak or absent dis-charge voltage or triggering pulses.

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 3-3

K1, K2 — Mode Relays, 24-volt DC Coil

First remove PCB1. The resistance from TB3-8 and TB3-7 to TB3-10 or the chassis should be approximately 290 ohms.

K3 — Discharge Relay, 120 VAC Coil

Disconnect one of the coil wires from the relay (terminal 1 or 2). The resistance across the relay coil should be approximately 290 ohms.

L1 — Burst Choke

The measured resistance of this choke should be approximately 15 ohms.

L2 — Flash Choke

The resistance of this coil should be zero ohms. An infinite reading indicates an open coil.

PCB1 — Timing and Trigger Board

Replace this circuit board with one known to be in good condition. Be careful. For testing by substi-tution, the circuit board must have the same jumper configuration for JP12 through JP16 as the one being replaced in the unit. If the board is to remain in the unit, JP1 through JP11 must also be configured as the one being replaced.

R1A, R1B — Bleed Resistors

The measured resistance of the discharge resis-tors in parallel should be 17,500 ohms.

PCB2 — HV Rectifier Board

Replace this circuit board with one known to be in good condition.

R2A, R2B — Burst Resistors

The measured resistance of the burst resistors in parallel should be 600 ohms.

T1 — Power Transformer

Prepare to test this transformer by removing PCB1 and PCB2. Energize the unit and measure secondary winding voltages as described inTable 3-1.

PCB3 — Sense Module

Replace this circuit board with one known to be in good condition.

T101 — Trigger Transformer

The measured resistance of the flashtube cathode and trigger wire should be approximately 180 ohms. Check the potted secondary winding for evidence of high-voltage breakdown. Check the assembly screws for tightness and verify that the ferrite core is not fractured.

VR1 — Suppressor Assembly

First remove one of the VR1 leads from the fuse block terminal. The resistance across VR1 on the x100K ohm scale should be infinite.

Troubleshooting

Effective troubleshooting procedure, beginning with the observation of beacon behavior, often leads directly to a faulty component or other abnormal condition. Table 3-2 Major Trouble-shooting Symptoms lists many of the symptoms that a malfunctioning beacon might exhibit. In Table 3-3 Defective Component Locator Code these symptoms are correlated with components, assemblies, or conditions that, if defective or abnormal, could cause the beacon to behave as observed.

Table 3-1 Power Transformer Voltage TestTest Points Voltage

TB4-1 to TB4-9 900 - 1050 VAC1

TB3-9 to TB3-10 110 - 120 VAC

TB3-2 to TB3-3 22- 26 VAC

Across C4 550 to 600 VAC

1. If this AC voltage is substantially less than the speci-fied minimum value, check the C4 tuning capacitor.

3-4 Revision 13 —5-8-01 FTB 204, 205, 207, 208

For example, assume that the beacon does not flash at all but some of its circuits are still operat-ing; that is, fuses are not blown, relays operate, and so forth. This behavior is symptom C in Table 3-2. Table 3-3 indicates that a defective timing and trigger board would most likely cause symp-tom C behavior. The next most likely cause would be a defective rectifier board. The third would be the NITE capacitor, and so forth. Each item in Table 3-3 is listed in the order of its likelihood of causing the failure.

Observe components carefully. Check for loose connections. Many times, components such as resistors and relays show signs of their failures. Resistors discolor when overheated. Relay con-tacts may become dirty, or pitted and corroded. Check relay armatures, to see if they function freely, by moving the armature by hand (with power off). Most components suspected of causing a problem can be checked by following the proce-dures in Section Component Testing.

Table 3-2 Major Troubleshooting SymptomsOBSERVED BEHAVIOR

Symptom Code

Flash Condition

CommentsDay (Full) Intensity

TWI IntensityNITE (Low)

Intensity

A NO NO NO All circuits are dead

B NO NO NO Primary line fuse repeatedly blows

C NO NO NO Some circuits functioning

D OK OK OK No confirmation

E OK OK OK No DAY confirmation, but NITE OK

F OK OK NO

G OK OK HIGH NITE too bright; ragged flash

H SKIPS OK OK

I LOW OK HIGH

J SKIPS SKIPS SKIPS

K NO NO NO PCB2

L — — — Inconsistent and erratic flash

M NO NO NO No FAIL indication

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 3-5

Table 3-3 Defective Component Locator Code

Item No. ComponentCodes

A B C D E F G H I J K L M

C1A-C1M DAY Capacitor Bank 4

C2A-C2B TWI Capacitor Bank 4

C3 NITE Capacitor 3

C4 Tuning Capacitor 2

F1, F2 Line Fuses 1

FT101 Flashtube 6 2

K1 Day Mode Relay 2

K2 Nite Mode Relay 1 1

L2 Burst choke 3

PCB1 Timing andTrigger Board

2 1 2 2

PCB2 HV Rectifier Board 1 2 1

R2 Burst Resistor 1

S1 Interlock Switch 2

T1 Power Transformer 3 2 5

PCB3 Sense Board 3 2

T101 Trigger Transformer 7 3

VR1 Suppressor 1

Footnote 1 1

Footnote 2 1

Footnote 3 1

Footnote 4 2

Footnote 5 1 1 1

Footnote 6 2 1

Footnote 7 1

Footnote 8 1

1. Blown fuse in one leg of 3-phase power distribution; all beacons on the same phase are affected.2. Wrong phase between system controller and beacon.3. Trigger potential arcing to chassis.4. Wrong confirmation programming at the beacon.5. RF interference (RFI).6. Poor connection in the discharge circuit between capacitors and the flashtube; or arcing to chassis.7. Monitor wiring.8. Controller setup.

3-6 Revision 13 —5-8-01 FTB 204, 205, 207, 208

Component Removal and Replacement

The following procedures explain how to remove and re-install selected components that may require procedures that are not self-evident.

FOLLOW FLASHTUBE HANDLINGPRECAUTIONS

Always handle a flashtube by grasping themetallic end caps. Never touch the glasssection with bare hands because skin oils orother contaminants can shorten flashtubelife.

Removal & Replacement — General

Typically, follow these steps:

• Locate the component using the component location figures in Section 4.

• Note the location of the wire connections and the wire colors. Record these for reassembly.

• Disconnect the wire terminals.

• Remove or loosen as necessary the screws or nuts that hold the component.

• Remove the component.

• For replacement, typically reverse the removal procedure. Replace the wires to the correct ter-minals. Position the wires as closely as possi-ble to their original routing position.

Capacitors

Removal1. Using long-nose pliers, remove the wire termi-

nals from the capacitor terminals.2. Each capacitor is fastened by two Phil-

lips-head screws. Remove these screws.3. Lift the capacitor out of its retaining hole.

Replacement1. Reverse the Removal procedure.

BR1 — Bridge Rectifier

Removal1. Using long-nose pliers, pull off the wire termi-

nals from the rectifier.

2. Remove the screw that holds the rectifier to the chassis.

3. Remove the rectifier


K1/K2/K3 — Relays

Removal1. Remove the wires on the relay terminals that

connect the relays to the wiring harness or other components. Note the position and color of the wires.

2. Each relay has two screws that fasten the relay to the chassis. Remove these screws.

3. Lift the relay from the chassis.


L1 — Burst Choke

Removal1. Remove the two wires that connect to the

choke.2. Remove the two screws that fasten the choke

to the base plate.3. Remove the choke.


L2 — Flash Choke

Removal1. Find the connection points on relays K1 and

K2 of the two wires connected to the flash choke.

2. Remove these two wires from the relays that connect to the choke. Note the color and con-nections of these wires.

3. Remove the two screws that fasten the choke to the base plate. NOTE: The choke is held by two screws with insulation. Be sure the insula-tion stays in place.

Replacement1. Reverse the Removal procedure.2. Replace the wires on their correct terminals.

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 3-7

R1A/R1B & R2A/R2B — Resistors

Removal1. Remove the wires connected to the resistors.

Note the color and connections of these wires.

2. Remove the two screws that hold the resistors to their ceramic posts.

3. Remove the resistors.


T1 — Power Transformer

Removal1. Many wires connect to the power transformer.

Note the wire colors and numbers on the trans-former to which these wires are connected.

2. Using long-nose pliers, remove the eas-ily-accessible wire terminals from the trans-former.

3. Remove the nuts holding the transformer to the base plate.

4. Partially lift out the transformer.

5. Remove the remaining wires.


T3 — Coupling Transformer (PC 204, 207)

Removal1. Remove the two Phillips-head screws in the

top of the transformer retaining bar that hold the transformer to the chassis.

2. The core is in two parts. Separate the core halves and slide the coils off the core.

3. Disconnect the wire terminals of the coils from their connections.

Replacement1. Re-assemble the coils on the cores. NOTE: The

coils must have the same winding direction on the core. That is, the coils are wound clockwise looking down at the top retainer strap of the transformer. The top wire, using a male Fas-

ton connector, leaves the coil in a clockwise direction. Refer to Figure 3-1.

2. Fasten the assembled transformer to the chas-sis using the two long 4-40 Phillips-head-screws.

PCB1/PCB2 Circuit Boards

Removal1. Loosen the screws on the terminal block that

connect the wires to the Circuit Board.2. Loosen the two screws (one in each corner of

the Circuit Board) that fasten the Circuit Board to the chassis. Do not remove these screws because the board sits on standoffs, and if you remove the screws the standoffs will fall out of position.

3. Slide the board slightly to clear the heads of the four retaining screws.

4. Lift the board slightly to clear the four retain-ing screws and slide it out from under the screws on the terminal block.


FlashtubeLocation: Part of the optical assembly

Removal:1. Loosen two screws that hold each plate that

covers each end of the flashtube on the optical assembly.

2. Disconnect the trigger wire at the P101 ceramic post on the left side of the optical assembly viewed as in Figure 4-5.

Figure 3-1 T3 Winding Directions

3-8 Revision 13 —5-8-01 FTB 204, 205, 207, 208

3. The flashtube is supplied with connecting leads soldered to its ends. Loosen the screw on the end of each flashtube lead.

4. At one end of the flashtube, use a slender, pointed tool between the end of the flashtube and the spring-loaded clip to pop the flashtube up and out of the clip. Do the same at the other end and carefully pull the flashtube out of the optical assembly.

Replacement:1. Observe the flashtube handling precaution

noted previously.2. Determine the anode and cathode ends: the

anode has red wire soldered to it and red ink or dye on the end of the tube.

3. Ensure that the trigger extension wire has a short length of high voltage sleeving installed.

4. Insert the flashtube with the cathode end (no red ink) toward the trigger lead ceramic post.

5. Align the flashtube with the retaining clips at each end and press it down into the clips one end at a time. Press only at the metallic end caps.

6. Attach the trigger wire (white insulation) at the ceramic post P101. Remove any excess wire and do not leave a tail extending from under the screw. Do not forcefully tighten the screw.

7. Attach the red anode wire to its connection directly above the tube mounting clip.

8. Attach the black cathode wire of the flashtube to the screw on the upper end of the plate on the left side of the optical assembly viewed as in Figure 4-5.

9. Reinstall each plate on each side of the flash-tube and tighten the screws.

Flashtube Clips

Location: Part of the optical assembly

Removal:1. Remove the flashtube as described in Section

Flashtube.

2. Remove two 8-32 screws from each flashtube clip plate.

Replacement:

1. Reverse the Removal procedure. Be sure that joining surfaces are clean. Tighten the screws firmly.

Trigger Transformer T101

Location: On the optical assembly

Removal:

1. At the flashtube, remove the large diameter white wire to the transformer secondary wind-ing.

2. At a chassis ground screw remove the small wire to the transformer secondary winding.

3. Do not disconnect the primary winding wires. Remove the two 4-40 x 2-inch screws Phil-lips-head screws that hold the transformer assembly to the plate.

4. Note the orientation of the molded secondary winding with respect to fixed features on the plate because you must install its replacement with this same orientation.

5. Remove the outer half of the core and lift off the molded secondary winding. The primary winding remain hanging in place.

6. Remove the inner half of the core.

Replacement:

1. Reassemble the primary and secondary wind-ings over the two halves of the core and attach the core to the bracket by means of the long screws. Do not overtighten.

2. Reattach the electrical wires. Refer to the elec-trical wiring diagram in Figure 2-11 to verify the connections.

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 4-1

Section 4 — Replaceable and Spare Parts

Customer Service

Customer Service 1-800-821-5825Telephone: (615) 261-2000Facsimile: (615) 261-2600Shipping Address:

Flash Technology Corporation of America332 Nichol Mill LaneFranklin TN 37067

Ordering PartsTo order spare or replacement parts, contact FTCA customer service at 1-800-821-5825.

Beacon/Power Converter PartsTable 4-1 lists the major replaceable parts of the beacons.

Flashhead Parts

Table 4-2 lists the major replaceable parts of the Flashheads.

Returning EquipmentTo return equipment to FTCA, contact Customer Service for a Return Material Authorization (RMA) number.

RepackagingYou must return the equipment in a container that provides maximum protection during ship-ping and handling. If the original cartons and packaging material are no longer available, pack-age the unit in a strong double corrugated carton on its back; that is, with the feet downward against the bottom of the box. Pad the unit so that the feet cannot penetrate the box during ship-ment. Box each unit separately using a double thickness cardboard container and adequate pad-ding. Do not drop. Use appropriate warning labels on the outside of the container.

4-2 Revision 13 —5-8-01 FTB 204, 205, 207, 208

Table 4-1 Beacon/Power Converter Replaceable PartsSystem Item Description Part Number

ALL BR1 Diode Bridge 6902806

ALL C1A-C1G Capacitor, Day, 70 mfd 6720401

ALL C2A Capacitor, Twilight, 40 mfd 6386503

ALL C3 Capacitor, Night, 1 mfd 6848202

ALL C4 Capacitor, Tuning, 3 mfd 6577903

ALL F1, F2 Fuse, 120V †4900307

ALL F1, F2 Fuse, 208/230/240V †4900303

ALL F1, F2 Fuse, 480V †4900335

ALL K1, K2 Mode Relay, 24 VDC †8900494

ALL PB K201 Transfer Relay, 120 VAC 8900493

ALL K3 Bleed Relay, 120 VAC 8900493

ALL L1 Burst Choke 4850601

ALL L2 Flash Choke 4175201

ALL PCB1 Timing and Trigger Board †24988xx

ALL PCB2 HV Rectifier Board †2458005

ALL PCB3 Sense Board 2811101

ALL PB PCB201 Monitor Board 8853002

ALL R2A, R2B Burst Resistor, 1.5K 50W 6900535

ALL R1A & R1B Bleed Resistor 35K, 50W 6900541

ALL S1/S2 Interlock Switch Assembly 8205501

205, 208 TB1 Terminal Block, 6 position 8721006

204, 207 TB2 Terminal Block, 8 position 8721008

205PB/208PB TB201 Terminal Block, 6 position 8721006

204PB/207PB TB202 Terminal Block, 18 position 4901903

ALL TB3 & TB4 Terminal Block, 11 position 8721011

ALL T1 Power Transformer, 120V, 60 Hz 8841501





204, 207 T3 Coupling Transformer 8336701

ALL T101 Transformer, Trigger 8288201

ALL VR1 Suppressor, 120V 8250801

ALL VR1 Suppressor, 208/230/240V 8250802

ALL VR1 Suppressor, 480V 8250804† Recommended as a spare part.

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 4-3

3743104GCL

Figure 4-1 PC 204 and PC 207 Power Converter Component Locations

P2

G1

P1

RESISTOR DETAIL

P4

RESISTOR(S)

RESISTOR(S)BLEEDR1A&B

BURST

G2

P3

R2A&B

F1 F2

VR1

INTERLOCKSWITCH

ALTERNATE

FOR 480VACSWITCH

(UNDER)

R1GND

7

5

1

3

8

6 K3DISCHARGERELAY

T3

TRANSFORMERCOUPLING

1

2

3

11

6

10

9

7

8

4

5

1

2

11

6

10

9

8

7

4

5

3

C1G

C1E C1D

C1F

L2FLASHCHOKE

K2LOW

INTENSITYRELAY

8

6

3

1

C3

C4

LOWINTENSITY

TUNINGTB201

T1POWER

TRANSFORMER

(UNDER)

R2

BURSTCHOKEL1

BR1

SENSEMODULE

FL

AS

HH

EA

D C

AB

LE 2

3

4

5

6

7

8

1

TB2

TB4TB3

SHIELD

G2

G1

PCB2

HV RECTIFIERTIMING & TRIGGER

PCB1

S1

S2

S2 IS USED FOR 208, 220, 230, 240, 277 AND 480 VAC INPUT

PCB3

6 5

3

1

8 7

K1HIGH

INTENSITYRELAY

C1C C1B

C2

C1A

3743104HCL

4-4 Revision 13 — 5-8-01 FTB 204, 205, 207, 208

3743109CCL

Figure 4-2 PC 204PB and PC 207PB Power Converter Component Locations

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 4-5

3726112HCL

Figure 4-3 FTB 205 and FTB 208 Beacon Component Locations

3726122ACL

Figure 4-4 FTB 205PB/FTB 208PB Beacon Component Locations

G4 G5

FT101

(RED MARKER)ANODECATHODE

T101(REAR VIEW)

OPTICAL ASSEMBLY

R2

8

S1

C4

F2

F1

G3

C1A

C1BTB3

1 32 4

11

10

9

G1

T1

65

TB1

AR1

BR1

C1D

C1C

3

7

6

5

4

2

1

C1E

PCB1 PCB2

C1F C1G C2

8

PCB3

TB4

G2

9

10

11

L2

3

4

5

6

7

1

2 K1

C3

3-7261-12H

BR1

P5P6

R2A B

1234

56

78

2 1

K26 5

8 7

34

1234

K36 5

8 7

BURSTCHOKEL1

G4 G5

FT101

(RED MARKER)ANODECATHODE

T101(REAR VIEW)

OPTICAL ASSEMBLY

R2

8

S1

C4

F2

F1

G3

C1A

C1BTB3

1 32 4

11

10

9

G1

T1

65

TB1

K3

AR1

BR1

C1D

C1C

3

7

6

5

4

2

1

C1E

PCB1 PCB2

C1F C1G C2

8

PCB3

TB4

G2

K2

9

10

11

L2

3

4

5

6

7

1

2 K1

C3

BR1

P5P6K

201

TB201PCB201

R2

L1

3-7261-22A

12

34

56

78

34

6 5

2 1

8 7

34

6 5

2 1

8 7

4-6 Revision 13 — 5-8-01 FTB 204, 205, 207, 208

FH204CL

Figure 4-5 FTB 205 Optical Assembly; FH 204 Flashhead Component Locations

Table 4-2 Flashhead Replaceable Parts

Item Description Part Number

FT101 Flashtube †8671301

T101 Trigger Transformer 8288201

T102 Coupling Transformer 8336701† Recommended as a spare part.

RE

D

BLK

WH

T

BLU

COUPLINGTRANSFORMER

VIO

REAR VIEW

REDFLASHTUBEWIRE

BLACKFLASHTUBE

WIRE

WHITEFLASHTUBE TRIGGER

WIRE

TRIGGER COILBLUE

WIRE

TRIGGER COILWIRE

WHITE

TRIGGER COIL

ANODE ENDRED TIPRED WIRE

CATHODEEND

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 I-1

INDEXA

Accessbeacon 2-1flashhead 2-1

Angle, beacon 2-2

BBeacon

access 2-1angle 2-2elevation angles 2-2equipment

figure 1-5figure

component locationFTB 205, 208 4-5FTB 205PB/FTB 208PB 4-5PC 204, 207 4-3PC 204PB, 207PB 4-4

operation 1-1wiring of 2-3

Beacon locationmounting 2-1unpacking 2-1

Beacon/power converter, parts 4-2BR1, removal 3-6

CC1, testing 3-2C2, testing 3-2C3, testing 3-2C4, testing 3-2Capacitor

removal 3-6testing 3-2

Catenarylayout

figure 1-4operation 1-2

figure 1-4Checklist, installation 2-3Component

defectivelocator table 3-5

locationfigure

flashhead 4-6FTB 205, 208 4-5FTB 205PB/FTB 208PB 4-5PC 204, 207 4-3PC 204PB, 207PB 4-4

removals 3-6testing 3-1

Controllermounting 2-2use in system 1-1

Customer service, address and phone 4-1

DDay mode 1-2

EEquipment

high intensityfigure 1-5

returning 4-1

FFlash mode 1-2Flashhead

access 2-1component location

figure 4-6internal wiring

figure 2-13Flashtube

clipremoval 3-8


HHertz 1-2

IInspection, maintenance 3-2Installation

checklist 2-3Installation, checklist 2-3

JJumpers

PCB1 1-3use of 1-3

KK1/K2

testing 3-3K1/K2/K3, removal 3-6K3, testing 3-3

LL1


L2removal 3-6testing 3-3

I-2 Revision 13 — 5-8-01 FTB 204, 205, 207, 208

Lightning protection 2-3Location

componentfigure

flashhead 4-6FTB 205, 208 4-5FTB 205PB/FTB 208PB 4-5PC 204, 207 4-3PC 204PB, 207PB 4-4

MMaintenance, preventive 3-1Mode

day 1-2fixed operation 1-2flash 1-2manual control

table 1-2night 1-2twilight 1-2

Mounting 2-1beacon angles 2-2beacon location 2-1controller 2-2photocell 2-2

Mounting and outlinefigure

FH 204 2-6FTB 205, 208 2-7PC 204 or 207 2-5

NNight mode 1-2

OOperation 1-1

50 or 60 Hertz 1-2beacon 1-1catenary

figure 1-4catenary mode 1-2fixed mode 1-2

Options 1-1Ordering parts 4-1

PPart ordering 4-1Parts, beacon/power converter 4-2PCB1

figure 1-4jumpers 1-3

use of 1-3setup 1-2testing 3-3

PCB1/PCB2, removal 3-7PCB2, testing 3-3PCB3, testing 3-3Photocell, mounting 2-2Power converter/beacon, parts 4-2Power transformer voltage 3-3Preventive maintenance 3-1

RR1, testing 3-3R1/R2, removal 3-7R2, testing 3-3Radio frequency interference (RFI) 3-1Removal

BR1 3-6capacitor 3-6flashtube 3-7flashtube clip 3-8K1/K2/K3 3-6L1 3-6L2 3-6PCB1/PCB2 3-7R1/R2 3-7T1 3-7T101 3-8T3 3-7

Removal and replacement 3-6Repackaging 4-1Returning equipment 4-1RFI 3-1

SSafety 3-1Specifications 1-1Storage 3-1System controller, use of 1-1

TT1


T101removal 3-8testing 3-3

T3removal 3-7winding directions 3-7windings 3-7

Telephone, customer service 4-1Testing

capacitor 3-2component 3-1flashtube 3-2

FTB 204, 205, 207, 208 Revision 13 — 5-8-01 I-3

high intensity capacitorC1 3-2

K1/K2 3-3K3 3-3L1 3-3L2 3-3low intensity capacitor

C3 3-2medium intensity capacitor

C2 3-2PCB1 3-3PCB2 3-3PCB3 3-3R1 3-3R2 3-3T1 3-3T101 3-3tuning capacitor

C4 3-2VR1 3-3

TI, voltage 3-3Timing and trigger board, See PCB1Tools, recommended 2-1Troubleshooting 3-3

tablelocating defective components 3-5major symptoms 3-4

Twilight mode 1-2

UUnpacking 2-1

VVoltage, at power transformer 3-3VR1, testing 3-3

WWarranty iiWindings, T3 3-7Wiring

beacon 2-3checking 3-2figure

internalflashhead 2-13FTB 205 and FTB 208 2-15FTB 205PB/FTB 208PB 2-16PC 204, PC 207 2-14PC 204PB, PC 207PB 2-17

overview 2-8single-phase installation

FTB 204, 207 2-10FTB 205, 208 2-11FTB 208/FTB 208PB 2-12

three-phase installation junction box 2-9gauge 2-3general 2-2

I-4 Revision 13 — 5-8-01 FTB 204, 205, 207, 208

~~ End of Document ~~

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