FTB 20X-2 Rev 6

Flash Technology, 332 Nichol Mill Lane, Franklin, TN 37067www.spx.com/en/flash-technology

(615) 261-2000

FTB 204-2, S, PB; 204-3X, SX; 205-11, S;207-2, S, PB; 208-2, S; 304-2, S; 305-2, S

Obstruction Lighting System

Reference Manual

Part Number 79120X2

SERIAL NUMBER

ii Revision 6 – 1-31-2014 FTB 20X-2

Front Matter

AbstractThis manual contains information and instructions for installing, operating and maintainingthe FTB 204, 205, 207, 208, 304 & 305 Obstruction Lighting Systems.

CopyrightCopyright © 2014, Flash Technology®, Franklin, TN, 37067, U.S.A.

All rights reserved. Reproduction or use of any portion of this manual is prohibited withoutexpress written permission from Flash Technology and/or its licenser.

Trademark AcknowledgementsFlash Technology® is a registered trademark name.

All trademarks and product names mentioned are properties of their respective companies,and are recognized and acknowledged as such by Flash Technology.

Applicable SpecificationsThis equipment meets or exceeds requirements for an FAA Type L-856 and L-857.

DisclaimerWhile every effort has been made to ensure that the information in this manual is complete,accurate and up-to-date, Flash Technology assumes no liability for damages resulting fromany errors or omissions in this manual, or from the use of the information contained herein.Flash Technology reserves the right to revise this manual without obligation to notify anyperson or organization of the revision.

In no event will Flash Technology be liable for direct, indirect, special, incidental, orconsequential damages arising out of the use of or the inability to use this manual.

WarrantyFlash Technology warrants all components, under normal operating conditions, for 2 years.

Parts ReplacementThe use of parts or components, in this equipment, not manufactured or supplied by FlashTechnology voids the warranty and invalidates the third party testing laboratory certificationwhich ensures compliance with FAA Advisory Circulars 150/5345-43G and 150/5345-53D.The certification is valid as long as the system is maintained in accordance with FAAguidelines (FR doc. 04-13718 filed 6-16-04).

FTB 20X-2 Revision 6 – 1-31-2014 iii

Personnel Hazard Warning

Dangerous VoltagesDangerous line voltages reside in certain locations in this equipment. Also, this equipmentmay generate dangerous voltages. Although Flash Technology has incorporated everypractical safety precaution, exercise extreme caution at all times when you expose circuitsand 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 equipment is operating.Do not change components or make adjustments inside the equipment with power on.

Dangerous Voltages Can Persist with Power DisconnectedUnder certain conditions, dangerous voltages can be present because capacitors can retaincharges even after the power has been disconnected.

Protect yourself — always turn off the input (primary) power and wait for one minute forstorage capacitors to drain their charge. Then check between the red and blue wires on theflashhead terminal block with a voltmeter for any residual charge before touching any circuitelement or component.

Do Not Depend on InterlocksNever depend on interlocks alone to remove unsafe voltages. Always check circuits with avoltmeter. Under no circumstances remove or alter any safety interlock switch.

iv Revision 6 – 1-31-2014 FTB 20X-2

Table of Contents

Front Matter .............................................................................................................................. iiAbstract ................................................................................................................................. iiCopyright .............................................................................................................................. iiTrademark Acknowledgements ............................................................................................ iiApplicable Specifications ..................................................................................................... iiDisclaimer ............................................................................................................................. iiWarranty ............................................................................................................................... iiParts Replacement................................................................................................................. ii

Personnel Hazard Warning ...................................................................................................... iiiDangerous Voltages ............................................................................................................. iiiAvoid Touching Live Circuits ............................................................................................. iiiDangerous Voltages Can Persist with Power Disconnected................................................ iiiDo Not Depend on Interlocks .............................................................................................. iii

Table of Contents..................................................................................................................... ivList of Figures .......................................................................................................................... viList of Tables ........................................................................................................................... viSection 1 – Introduction and Operation .................................................................................... 1

System Controller ................................................................................................................. 1Variations and Options ......................................................................................................... 1Specifications........................................................................................................................ 1

Physical ............................................................................................................................. 1Performance Characteristics ............................................................................................. 1

Operation............................................................................................................................... 2Beacon/Power Converter .................................................................................................. 2Catenary Operation (FTB 207, 208) ................................................................................. 2Location ............................................................................................................................ 2Flash Modes ...................................................................................................................... 260/50 Hz Operation........................................................................................................... 2Fixed Mode Operation ...................................................................................................... 3

Configuring PCB1 ................................................................................................................ 3Section 2 - Mounting and Installation....................................................................................... 7

Unpacking ............................................................................................................................. 7Tools ..................................................................................................................................... 7Access ................................................................................................................................... 7

Beacon/Power Converter .................................................................................................. 7Mounting............................................................................................................................... 7

Beacon Location ............................................................................................................... 7Beacon Angle.................................................................................................................... 8Controller Mounting ......................................................................................................... 8

Photocell Mounting............................................................................................................... 8Wiring ................................................................................................................................... 8

Beacon Wiring .................................................................................................................. 9Lightning Protection ......................................................................................................... 9

Installation Checklist ............................................................................................................ 9Section 3 — Maintenance and Troubleshooting..................................................................... 21

Safety .................................................................................................................................. 21

FTB 20X-2 Revision 6 – 1-31-2014 v

Preventive Maintenance...................................................................................................... 21Storage ................................................................................................................................ 21RFI Problems ...................................................................................................................... 21Component Testing............................................................................................................. 22Troubleshooting .................................................................................................................. 24Component Removal and Replacement.............................................................................. 27

Removal & Replacement — General ............................................................................. 27Section 4 – Recommended Spare & Replaceable Parts.......................................................... 31

Customer Service ................................................................................................................ 31Ordering Parts ..................................................................................................................... 31Beacon / Power Converter Parts ......................................................................................... 31Flashhead / Optical Assembly Parts ................................................................................... 31

Appendix 1 – Programming the Timing and Trigger Board................................................... 36Connecting the Handheld.................................................................................................... 36Using the Programmer ........................................................................................................ 36Standard Version (2904411) ............................................................................................... 37“S” Version (2904410) ....................................................................................................... 40

Appendix 2 - FTB 204SPB and 207SPB Primary Backup ..................................................... 43Operation............................................................................................................................. 43Installation........................................................................................................................... 43

Appendix 3 - FTB 204-3X, SX Extended Separation............................................................. 45Introduction and Operation ................................................................................................. 45Mounting and Installation ................................................................................................... 45

Flashhead Wiring ............................................................................................................ 45Securing the Cable .......................................................................................................... 45

Appendix 4: Return Material Authorization (RMA) Policy .................................................. 52

vi Revision 6 – 1-31-2014 FTB 20X-2

List of Figures

Figure 1-1 – PCB1 (2904411) Timing and Trigger Board Standard Version .......................... 4Figure 1-2 – PCB1 (2904410) Timing and Trigger Board “S” Version................................... 5Figure 1-3 – Typical 2-Tower 3-Tier Layout and Catenary Beacon Operation ....................... 6Figure 2-1 – PC 204/207 Power Converter Mounting and Outline ........................................ 11Figure 2-2 – FH 204 Flashhead Mounting and Outline.......................................................... 12Figure 2-3 – FTB 205/208 Beacon Mounting and Outline..................................................... 13Figure 2-4 – Wiring Overview of a System............................................................................ 14Figure 2-5 – Junction Box, Three-Phase Installation Wiring ................................................. 15Figure 2-6 – Single-Phase Installation Wiring for FTB 204/207 ........................................... 16Figure 2-7 – Single-Phase Installation Wiring for FTB 205/208 ........................................... 17Figure 2-8 – PC 204/207 Power Converter Internal Wiring................................................... 18Figure 2-9 – FH 204 Internal Wiring...................................................................................... 19Figure 2-10 – PC 205/208 Power Converter Internal Wiring................................................. 20Figure 3-1 – Winding Directions ............................................................................................ 28Figure 4-1 – PC 204/ 207 Power Converter Component Locations ....................................... 33Figure 4-2 – FTB 205/208 Power Converter Component Locations...................................... 34Figure 4-3 – FH 204 FTB 205/208 Optical Assembly Component Locations ....................... 35Figure A1-1 – DB9 Female..................................................................................................... 36Figure A1-2 – Handheld Programmer .................................................................................... 36Figure A2-1 – PC 204SPB / 207SPB Installation Wiring ...................................................... 43Figure A2-2 – PC 204SPB / 207SPB Internal Wiring............................................................ 44Figure A3-1 – PC 204-2 / 204-3X Mid-Tower Installation Example..................................... 47Figure A3-2 – PC 204-3X Ground Level Installation Example ............................................. 48Figure A3-3 – PC 204-3X Power Converter Mounting and Outline ...................................... 49Figure A3-4 – PC 204-3X Power Converter Component Locations ...................................... 50Figure A3-5 – PC 204-3X Power Converter Internal Wiring................................................. 51

List of TablesTable 3-1 – Major Troubleshooting Symptoms...................................................................... 25Table 3-2 – Defective Component Locator Code ................................................................... 26Table 4-1 – Power Converter Major Replaceable Parts.......................................................... 32Table 4-2 –Flashhead / Optical Assembly Replacement Parts ............................................... 35

FTB 20X-2 Revision 6 – 1-31-2014 1

Section 1 – Introduction and Operation

The FTB 204 High Intensity Beaconconsists of an FH 204 Flashhead and a PC204 Power Converter in separateenclosures. The FTB 204X allows forextended separation, up to 700’, betweenthe PC 204 and the FH 204.

Note: See Appendix 3 for informationspecific to 204X systems.

The FTB 207 High Intensity CatenaryBeacon consists of an FH 204 Flashheadand a PC 207 Power Converter in separateenclosures.

Note: See Appendix 2 for informationspecific to 204SPB and 207SPBsystems.

The FTB 205 High Intensity Beacon is aself-contained unit with an opticalassembly mounted in the enclosure.

The FTB 208 High Intensity CatenaryBeacon is a self-contained unit with anoptical assembly mounted in theenclosure.

System ControllerFor standard (non-S) versions, an FTC 140system controller directs flash timing andintensity and records and reports Beaconoperating status. It enables eitherautomatic or manual intensity control, andit continuously displays the flashing statusof each Beacon. For further information,consult the FTC 140 System ControllerManual.

For “S” versions, an FTC 121 systemcontroller monitors the status andoperating parameters of the lights. Thelights can be interrogated by the controller,or remotely via a telephone lineconnected to the controller. For furtherinformation, consult the FTC 121 SystemController Manual.

Variations and OptionsThe FTB304/305 (S) medium intensitysystems operate in twilight and nightmodes only. In this case, wherever 204and 205 appear in the manual substitute304 and 305, respectively. ContactCustomer Service at 1-800-821-5825 for adescription of equipment variations andoptions.

Specifications

Physical

PC 204/207 (H x W x D, Weight)23 x 17.13 x 9.42 in., 70 lbs.584.2 x 435.1 x 239.2 mm, 31.8 kgWind Area: 2.4 ft2, 0.22 m2

FH 204 (H x W x D, Weight)22.5x 18.2 x 12.8 in., 18 lbs571.5 x 462.3 x 325 mm, 8.2 kgWind Area: 1.99 ft2, 0.18 m2

FTB 205/208 (H x W x D, Weight)22.35 x 20.88 x 11.23 in., 85 lbs.567.7 x 530.4 x 285.2 mm, 38.6 kgWind Area: 2.9 ft2, 0.27 m2

EnvironmentalComplies with FAA specifications in

AC 150/5345-43.

Performance Characteristics

ApplicationFTB 204/205 L-856FTB 207/208 L-857

Flash Intensity (nominal):Day (204/205) 270,000 ± 25%ECDDay (207/208) 140,000 ± 25%ECDTwilight 20,000 ± 25% ECDNight 2,000 ± 25% ECDBeam Spread Horizontal: 120º

Vertical: 3º

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Flash RateFTB 204/205 40 flashes per min.FTB 207/208 60 flashes per min.

Electrical (factory pre-wired)AC Voltage

120-480 VAC ± 10%, 60 Hz110-230 VAC ± 10%, 50 Hz

Volt-Amperes 600 peakDay 255W

OperationThe controller determines the operatingintensity of the structure lights, and theninforms the Timing and Trigger Board(PCB1) in each beacon.

Beacon/Power Converter

The beacon starts flashing when power isapplied. A pair of shielded conductorsbetween the beacons and the controllercarries the control and monitoring signalsfor an entire system. Each beacon sends aflash confirmation signal to the controllerfor monitoring. Individual encodingidentifies the beacon of origin, thusenabling all beacons in a system toindividually report to the controller.

All beacons are capacitive discharge lightsthat use a xenon flashtube.

Note: If the controller is disconnected,or fails, all beacons flash by default athigh intensity.

Catenary Operation (FTB 207,208)

High intensity lights for towers thatsupport catenary wires require three levels(tiers) of lights. An example of a typicalcatenary installation is shown in Figure 1-3. One tier is installed at each of thefollowing three locations: top of thestructure, lowest point of the catenary andhalf way between the upper and lowerlevels. Each level must be lit to provide360-degree coverage. The flash rate is 60flashes per minute in all modes and the

flash sequence is as follows: middle – top– bottom. All lights at the same tier flashsimultaneously.

Note: Flash Technology recommendsFTC 121 controllers and GPSsynchronization for catenary lightingsystems.

Location

Flash Technology uses a standard format:it refers to the lowest level as Tier 1 andthe most northerly facing light as beacon1. Higher numbered beacons are placedaround the structure in a North-East-South-West direction. Figure 1-3 shows atypical installation.

Flash Modes

Night

At nightfall, the controller switches thebeacon to night mode operation; theflashhead flashes at the night intensity of2,000 ± 25% ECD.

Twilight

At twilight, the controller switches thebeacon to twilight mode operation; theflashhead flashes at the twilight intensityof 20,000 ± 25% ECD.

Day

At daybreak, the controller switches thebeacon to day mode operation; theflashhead flashes at the required daylightintensity: 270,000 ± 25% ECD for FTB204 & 205 and 140,000 ± 25% ECD forFTB 207 & 208.

60/50 Hz Operation

PCB1 can operate from either a 60Hz or a50Hz power source.

FTB 20X-2 Revision 6 – 1-31-2014 3

Fixed Mode Operation

The following table explains how to forcethe beacon to operate continuously at afixed flash intensity (mode). Use theseprocedures to check operation at all threeflash intensities. A handheld terminal (PN1903776) can also be used to control themodes (see Appendix 1).

Intensity ProcedureDAY (High) Place a jumper between Test

Point 1 (TP1) labeled TESTand TP6 labeled DAY.

TWI(Twilight)

Place a jumper between TestPoint 1 (TP1) labeled TESTand TP5 labeled TWI.

HITE (Low) Place a jumper between TestPoint 1 (TP1) labeled TESTand TP4 labeled NITE.

LTV Factory use only. Causescontinuous triggering. Donot use.

Note: Remove all installed test jumpersafter beacon tests are completed.

Configuring PCB1PCB1 (2904411 for standard version,2904410 for “S” version) communicateswith the system controller and governs allfunctions pertaining to the lighting unit’soperation. It has nine light emitting diode(LED) indicators, and one clear neonindicator that can be used to monitorequipment operations during checkout andtroubleshooting. A handheld terminal (PN1903776) is available and can providemore in-depth information whentroubleshooting and testing the unit.Figures 1-1 and 1-2 show the location ofthe key components used fortroubleshooting PCB1. Appendix 1provides complete information regardingthe functions of the handheld terminal.

The lighting unit is shipped from thefactory with PCB1 programmed asspecified by the purchase order. If fieldreplacement of PCB1 becomes necessary,the handheld terminal may be used toprogram the replacement to match theprogramming of the original. Otherwise,the programming of the original PCB1should be specified when ordering areplacement.

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Figure 1-1 – PCB1 (2904411) Timing and Trigger Board Standard Version

FTB 20X-2 Revision 6 – 1-31-2014 5

Figure 1-2 – PCB1 (2904410) Timing and Trigger Board “S” Version

INT RED

JP1

6 Revision 6 – 1-31-2014 FTB 20X-2

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

CATENARY WIRES

CATENARYBEACONS

TOP

MIDDLE

BOTTOMBOTTOM

MIDDLE

TOP

WIRE DROOPEXAGERATED

FLASH RATE = 60 FPMCATENARY SEQUENCE = MIDDLE, TOP, BOTTOM

FTB 20X-2 Revision 6 – 1-31-2014 7

Section 2 - Mounting and Installation

UnpackingInspect shipping cartons for signs ofdamage before opening. Check packagecontents against the packing list andinspect each item for visible damage.Promptly report damage claims to thefreight handler.

Flash Technology programs beacons at thefactory for operation at particularlocations, and marks the shippingcontainers accordingly on the outside. Thelowest level is referred to as Tier 1 and themost northerly facing light is referred to asBeacon 1. Higher numbered beacons areplaced around the structure in a North-East-South-West direction. Therefore,you must maintain the beacon’s identityaccording to the package identity of eachbeacon (for example, Beacon 1, Tier 1;Beacon 2, Tier 1; and so forth), and installit as called out.

ToolsAlthough no special tools are necessary,the following hand tools are suggested forinstallation and maintenance:

#1 Phillips-head screwdriver, 8-inchlong 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 combinationwrenches

Hand tools for electrical wiring

Triplett™ Model 630-NA VOM, orequivalent analog volt-ohm meter, or adigital meter with an averagingfunction.

Access

WARNING!Read the warning on Page iii now.Disconnect primary power before openingenclosures.

Beacon/Power Converter

Latches secure the hinged cover of thepower converter or the beacon. Releasethe latches and swing the cover open forinternal access.

MountingOutline, mounting, and clearancedimensions are shown in the followingfigures:

Figure 2-1 – PC 204 or PC 207 PowerConverter Mounting and Outline

Figure 2-2 – FH 204 FlashheadMounting and Outline

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

Beacon Location

FAA Guidelines for beacon placement arepublished in AC 70/7460-1. Avoid placinga beacon within a strong radio frequency(RF) field. For example, a beacon withinfour feet of a radiating FM antenna islikely to pick up electromagneticinterference (EMI) that could causeimproper operation or damage. Place abeacon at an adequate distance from apowerful RF radiator. Contact the factoryfor instructions when you cannot avoidthis situation.

8 Revision 6 – 1-31-2014 FTB 20X-2

Beacon AngleNOTE

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

Various factors may influence the angle ofbeacon elevation for the units on yourstructure. These include: location of thestructure, height of the beacon aboveground, and other characteristics of the siteand surrounding terrain. Advisory Circular70-7460-1 contains guidelines for settingthe elevation angle. Information derivedfrom that source is shown in the followingtable.

AGL (ft) Angle0-300 +3°300-400 +2°400-500 +1°500 > 0°

First, level the unit to obtain a referenceelevation angle (the specified elevationangle is added to the reference angle). Usethe spirit level located inside the enclosurefor initial leveling—the tilting bracket hasan incremental scale. The tilt mechanismis part of the permanently attachedmounting bracket. To level the enclosure,tilt it by using the mounting brackets.

Controller Mounting

Locate the system controller in an areawith restricted access. Controllers areavailable either in outdoor enclosures thatcan be attached to any vertical surface, oras an indoor, rack-mounted controller.

You can place the system controlleranywhere within 2500 feet of the mostdistant beacon without furtherconsideration. Consult with the factory ifa greater distance is necessary.

Photocell Mounting

The photocell, also referred to as PEC 510,may be located any practical distance from

the system controller. Photocells withcable lengths up to 75’ are available. Thecable may be spliced using 16 AWG wireminimum to provide additional length ifnecessary.

The photocell uses a male 1/2” NPT formounting. Use the following guidelines tomount the photocell:

Locate the photocell where it hasan unobstructed view of the polarsky.

It must not view direct or reflectedartificial light.

The photocell should be supporteddirectly by electrical conduit. Itshould not be mounted underneaththe controller where it could beshadowed.

Ensure that the installation iswatertight.

Refer to the system controller manual formounting and outline dimensions of theFTC140 and FTC121 Controllers and PEC510.

WiringNote: Flash Technology wiringdiagrams define only minimumrequirements recommended forsatisfactory equipment operation. It isthe responsibility of the installer tocomply with all applicable electricalcodes. You can find conduit and otherdistribution wiring details on electricalinstallation diagrams provided by FlashTechnology or others. All installationwiring should have an insulation ratingof 600 volts. Size input power wiring tosatisfy the load demand of the system.

If installation drawings preparedspecifically for your site disagree withinformation provided in this manual, theinstallation drawings should takeprecedence. Consult any site-specificinstallation wiring diagram supplied withyour equipment.

FTB 20X-2 Revision 6 – 1-31-2014 9

System wiring consists of primary powerand signal distribution wiring as shown inFigure 2-4. Primary power is usuallytaken from a load center to the variousitems of equipment. Signal wiring isbetween the beacons and the systemcontroller. Make connections to beacons atnearby junction boxes. Always positionjunction boxes below the beacons withdrain holes facing downward.

Beacon Wiring

Three-phase power often supplies largesystems. However, the beacons are single-phase units that are connected from line-to-line (A-B, B-C, A-C). Therefore, phasedifferences occur between groups ofbeacons in the same three-phase system.In a three-phase system, phase A-C mustsupply the controller (not C-A) to allowthe controller to be compatible with allbeacons. Failure to ensure optimumphasing as described could result inintensity control problems.

Use circuit breakers or a safety switchwith fuses for the primary power loadcenter. Insulation should be rated at 600 Vminimum. Wire size is a factor affectedby the service voltage, the number ofbeacons in the system, and the length ofthe wire run to the beacons. To determinewire gauge, consider each beacon as a 400volt-ampere load and do not permit thevoltage drop caused by wire resistance toexceed 5% at any beacon. You may usethis volt-ampere value to determine ratingsfor slow-acting fuses or circuit breakersfor the system. For fast-acting fuses and asystem feeder transformer (if used)consider a peak load of 600 volt-amperesfor each beacon. Flash Technologyrecommends that you use National ElectricCode guidelines for all primary wiring.

A label inside the beacon near the fuseblock indicates the operating voltage andfrequency of your beacon. Two internal

fuses are sized according to the operatingvoltage. When Line 2 is neutral, thefactory replaces the F2 fuse with a jumperwire.

Make connections to distribution wiring ata nearby junction box. Consult thefollowing installation wiring diagrams toguide you in wiring the equipment at yourinstallation:

Important! The following figures areguidelines only. If they differ from theinstallation drawings for your site, usethe site installation drawings.

Installation drawings in this manual are asfollows:

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

Figure 2-6 – Single-Phase InstallationWiring for FTB 204 or 207

Figure 2-7 – Single-Phase InstallationWiring for FTB 205 or 208

Lightning Protection

Though Flash Technology equipment isdesigned to withstand severe transientover-voltages, a lightning arresting systemmust be installed to prevent damage bylightning. Install a lightning arrestingsystem to protect a light at the top of amast or antenna. Transient suppressorsfrom line-to-line and line-to-neutral arerecommended at the primary power loadcenter.

Installation ChecklistComplete the following steps beforeapplying power to the lights.

1. Beacon/Power Converter Mounting:

Position and mount each unit correctly,allowing adequate clearance foropening the covers. Also, use thefollowing guidelines:

Verify that position number writtenon the outside of the lighting unit

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matches the location on the toweras described in Section 1“Location”.

Ensure that the case is mountedupright, is water tight, andgrounded.

Check hardware inside the case toensure that the mounting screwsand nuts are tight.

Ensure that only the bottom of thecase has drain holes and that theyare clear.

Ensure that no holes are punchedor drilled on the top surface of thecase.

Ensure that air can flow around thecase.

Lighting unit is mounted awayfrom radio frequency interference(RFI).

2. Beacon/Power Converter Wiring:

Use the installation drawings and thefollowing guidelines:

Check for proper incoming servicevoltage.

Wire each unit according to theinstructions.

In installations with multiple units,ensure that all units are wired tothe same phase. In installationswith multiple tiers and three phasewiring, follow the phasing chart inthe installation drawings, or sitedrawings.

Check all electrical connections fortightness.

Check all terminal stripconnections for tightness.

Ground the powerconverter/beacon using a bondingstrap from the case leg to thestructure.

3. Flashhead Mounting:

Ensure that the flashhead lens can beopened without striking other objects.

Level and set the flashhead at therequired elevation angle.

4. 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 theflashhead cable to prevent itsmovement by the wind.

5. Photocell:

Locate the photocell where it hasan unobstructed view of the polarsky.

It must not view direct or reflectedartificial light.

The photocell should be supporteddirectly by electrical conduit. Itshould not be mounted underneaththe controller where it could beshadowed.

Ensure that the installation iswatertight.

6. Controller:

Perform the steps listed in“Installation Checklist” located inthe supplied controller manual.

After completing all steps listed in theInstallation Checklist, turn the power andperform an operational checkout fromprocedures in Section 3 of this manual.

FTB 20X-2 Revision 6 – 1-31-2014 11

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

2. DIMENSIONS ARE IN INCHES (MILLIMETERS).

1. WIND AREA = 2.4 SQ.FT. (.22 SQ.M)

NOTES:

9.42 (239.2)

0.44 (11.2) DIA. MOUNTING HOLE2 places

23.00(584.2)

21.75(552.5)

20.88(530.4)

.75 (19.05)0.44 (11.2)

17.13 (435.1)

12.25 (311.2)

17.50 (444.8)CLEARANCEREQUIRED

16.75 (425.5)2.50

(63.5)(TYP)

3.00(76.2)

7.00(177.8)

3. WEIGHT = 70 LBS. (31.8 KG.)

Ø1.06(27.0)

2 PLACES

4.75(120.5)

6.75(171.5)

Ø1.32(33.4) Ø0.88

(22.4)

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Figure 2-2 – FH 204 Flashhead Mounting and Outline

(76.20)3.00

3.00(76.20)

16.25 (412.75)

12.82 (325.63) MIN

NOTES:

(539.75)21.25

REQUIREDCLEARANCE16.88 (428.75)

(571.5)22.5

(235)9.25

1.06 DIA. (26.9)

(530.35)20.88

A

A

VIEW A-A

1. Weight: 18 lbs (8.2 kg)2.3. Dimensions are in inches (millimeters)

Wind area: 1.99 sq ft (.18 sq m)

(TY

P)

(63.5)

2.5

ADD .40 (10.2) FOREACH DEGREE OF TILT

MOUNTING SLOTS.56 X .63

(14.2 X 16.0)

.44(11.18)

ENTRANCE HOLE

18.23 (463.04)

9.41 (239.01)

FTB 20X-2 Revision 6 – 1-31-2014 13

Figure 2-3 – FTB 205/208 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

5.5

0

7.5

0

13.0

0

14.6

8

00.0

4.00

7.00

1.12(28.5)

.88(22.4)

.10(2.54)

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Figure 2-4 – Wiring Overview of a System

PRIMARYPOWER

DISCONNECTSWITCH

FEEDERTRANSFORMER

SYSTEMCONTROLLER

TYPICAL JUNCTION BOX

TOBEACONSASREQUIRED

ASREQUIRED

BEACONSTO

TO ADDITIONAL TIERSAS REQUIRED

PRIMARYPOWER

NOTES:1. CONDUCTOR SIZE DEPENDS UPON VOLTAGE, LOAD, AND RUN LENGTH. SEE INSTALLATION

WIRING IN SECTION 2 OF THE MANUAL.

2. THESE ITEMS AND THE CONNECTION WIRING ARE SUPPLIED BY OTHERS.

**

*

SINE WAVE

SINE WAVE

*

PEC 510

FTB 20X-2 Revision 6 – 1-31-2014 15

Figure 2-5 – Junction Box, Three-Phase Installation Wiring

3. DENOTES WIRE NUT CONNECTION.

THREE PHASE CONNECTION CHARTBEACON BEACON BEACON BEACON

(IF USED)1 2 3 4

TIER F1 F2 F1 F2 F1 F2 F1 F2

6

5

4

3

2

1

B C A C A B B C

A C A B B C A C

A B B C A C A B

PHASE: A BLACK WIRE

B RED WIREC BLUE WIRE

INTERCONNECT CABLE

FTCA PN 3360

ANY TYPICAL TIER

BELDEN #8719 (OR EQUIV.)

FTCA PN 3360

BY OTHERS(PRIMARY POWER

4/C, SIZE AS REQ'DSEE NOTE 1

NOTES:

B C A C A B B C

A C A B B C A C

A B B C A C A B

1. CONDUCTOR SIZE DEPENDS ON THE SERVICE VOLTAGE, THE LENGTH OF THE WIRE RUN,AND THE NUMBER OF BEACONS CONNECTED. USE 400-VOLT AMPERES PER BEACON TOCALCULATE THE TOTAL LOAD. DETERMINE THE WIRE GAUGE REQUIRED TO PREVENTTHE VOLTAGE DROP CAUSED BY WIRE RESISTANCE FROM EXCEEDING 5% AT ANY BEACON.SEE THE EQUIPMENT LABEL FOR UNIT VOLTAGE AND FREQUENCY.

2. THE CONTROLLER MIGHT OPERATE AT A LINE VOLTAGE DIFFERENT FROM THE BEACONS.

CHECK THE EQUIPMENT LABEL AND ENSURE CORRECT LINE PHASING.

BL

UR

ED

BL

K

ANY TYPICAL TIER

WHTBLK

WHTBLK

WHTBLK

WH

TB

LK

VIOYEL

YELVIO

YELVIO

BLK

REDBLU

BLKREDBLU

BLKREDBLU

GROUND BUSSHIELDOUTER

SHIELDOUTERSHIELD

SHIELD

OUTERSHIELD

SHIELD

SH

IEL

D

TYPICALLY SUPPLIED

TYPICAL

GR

N

NOTE 5

5. PRIMARY POWER CONNECTIONS IN THE JUNCTION BOX ARE CONNECTEDAS REQUIRED BY THE THREE-PHASE CONNECTION CHART.

NOTE 1 TO OTHER TIERSAS REQUIRED

INTERCONNECT CABLE

(PHASE BC)

(PHASE AC)

INTERCONNECT CABLE

(PHASE AB)

NOTE:CONTROLLER WIRED TOPHASE AC

4. UNUSED WIRES IN THE JUNCTION BOX MUST BE CAPPED WITH NUTS.INDICATES A CAPPED WIRE END.

COMM. LINK TO SYSTEM CONTROLLER

NOTES 3 & 4

16 Revision 6 – 1-31-2014 FTB 20X-2

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

FACE THE PEC 510 TOWARDTHE POLAR SKY AND DO NOTALLOW IT TO VIEW ARTIFICIALLIGHTING. MOUNT THE UNITVERTICALLY AT THE TOP ENDOF A VERTICAL LENGTH OFCONDUIT TO PREVENT WATERFROM ENTERING THE UNIT.

INTERCONNECT CABLE

BL

K

BL

U

RE

D

YE

LV

IO

MO

NIT

OR

SH

IEL

D

LIN

E2

LIN

E1

GND

WHTBLK RED

BLU

F2F1

TB201

SHIELD

VIO

WHTBLK

TB2

CO

NT

RO

L

TRIG RTNTRIGGERCATHODE

ANODE

GND

1 2 3

654321

78

TYPICAL PC 204 OR PC 207 POWER CONVERTER

FTB 204 OR FTB 207 BEACON

FH 204 FLASHHEAD

BLKG

NDC

AT

HO

DE

AN

OD

E P1

TR

IGG

ER

P2

RE

D

BL

U

VIO

SH

IEL

D

TR

IGR

TN

P4

P5

GN

D

WH

T

TB2 WIRING FOR SINGLEFLASHHEAD

FTB 204 OR FTB 207

FTCA PN. 6340

NOTES:1. FACTORY WIRES EQUIPMENT TO NAMEPLATE VOLTAGE.2. WHEN LINE 2 IS NEUTRAL, FTCA REPLACES F2 BY A JUMPER.3. UNUSED WIRES IN THE POWER CONVERTER SHOULD BE CAPPED WITH WIRE NUTS.

INDICATES A CAPPED WIRE END.

NOTE 2

NOTE 3

PEC 510PHOTOCELL

SYSTEM CONTROLLER FTC 140R/140W

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 18

PEC 510PHOTOCELL

WH

T

BLK

1 2 3 4

SH

IEL

D

WH

T

BL

K

GN

D L2

NE

UT

RA

L

L1

CONTROLLERPRIMARY POWER


COMM. LINK

NOTE:

ONLY ONE CONTROLLER USED - NOT BOTH.

COMM

TB2 1 2 3 4

PHOTOCELL

16311

LINK

6 75

SHIELD

108 9 12 1 2 104 5 6 8 97 131211 14 15

FTC 121 SYSTEM CONTROLLER

WH

TB

LK

1718 TB3

TB2 TB3TB1


COMM. LINK

JUNCTIONBOX

PRIMARY POWER

FTCA PN 3360

FTB 20X-2 Revision 6 – 1-31-2014 17

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

FACE THE PEC 510 TOWARDTHE POLAR SKY AND DO NOTALLOW IT TO VIEW ARTIFICIALLIGHTING. MOUNT THE UNITVERTICALLY AT THE TOP ENDOF A VERTICAL LENGTH OFCONDUIT TO PREVENT WATERFROM ENTERING THE UNIT.

INTERCONNECT CABLE

NOTES:1. FACTORY WIRES EQUIPMENT TO NAMEPLATE VOLTAGE.2. WHEN LINE 2 IS NEUTRAL, FTCA REPLACES F2 BY A JUMPER.3. UNUSED WIRES IN THE POWER CONVERTER SHOULD BE CAPPED WITH WIRE NUTS.

INDICATES A CAPPED WIRE END.

PEC 510PHOTOCELL

SYSTEM CONTROLLER FTC 140R/140W

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 18

PEC 510PHOTOCELL

WH

T

BL

K

1 2 3 4

SH

IEL

D

WH

T

BL

K

GN

D L2

NE

UT

RA

L

L1

CONTROLLERPRIMARY POWER


COMM. LINK

NOTE:

ONLY ONE CONTROLLER USED - NOT BOTH.

COMM

TB2 1 2 3 4

PHOTOCELL

16311

LINK

6 75

SHIELD

108 9 12 1 2 104 5 6 8 97 131211 14 15

FTC 121 SYSTEM CONTROLLER

WH

TB

LK

1718 TB3

TB2 TB3TB1


COMM. LINK

JUNCTIONBOX

PRIMARY POWER

FTCA PN 3360

G4

TYPICAL FTB 205 OR FTB 208 BEACON

G5

SH

IELD

CO

NT

RO

L

MO

NIT

OR

31 2

LIN

E1W

HT

LIN

E2B

LK

RE

D

BL

U

BL

K

USEDNOT

VIO

YE

L

F1 F2

G3

TB1

SH

IELD

NOTE 1 & 2

NOTE 3

18 Revision 6 – 1-31-2014 FTB 20X-2

Figure 2-8 – PC 204/207 Power Converter Internal Wiring

FTB 20X-2 Revision 6 – 1-31-2014 19

Figure 2-9 – FH 204 Internal Wiring

P4

P3

CHASSISGND

P2

P1

WHT

BLK

VIO

BLU

RED

LARGE CERAMICPOST (TYP)

ANODE

CATHODE

FT101FLASHTUBE

T101TRIGGER

TRANSFORMER

T102 TRIGGERCOUPLINGTRANSFORMER

P5

20 Revision 6 – 1-31-2014 FTB 20X-2

Figure 2-10 – PC 205/208 Power Converter Internal Wiring

FTB 20X-2 Revision 6 – 1-31-2014 21

Section 3 — Maintenance and Troubleshooting

SafetyHAZARD WARNING

Some procedures in this section mayrequire making contact with electricalcircuits. Read the warning on Page III.

Work safely, as follows:

Remove rings and watches beforeopening the equipment.

Shut off the equipment.

Remove the component or connect thetest instruments.

Replace the component.

Turn on the power and test the system.

Turn off the power and disconnect thetest equipment.

Preventive MaintenanceCarry out the following inspection andcleaning procedures at least twice a year:

Verify that moisture has not enteredthe equipment accidentally throughgaskets or seals, or collected ascondensation.

Verify that all drain holes are clear.

Check terminal blocks and relays forevidence of corrosion and electricalarcing. Clean or replace anycomponent that shows evidence ofhigh-voltage damage.

Check flashtube connections for signsof pitting or arcing. Verify that anodeand cathode connections are firmlytightened.

Check all electrical connections fortightness and verify the absence ofcorrosion or electrical arcing.

Clean the inside and outside surface ofthe glass with a non-abrasive glasscleaner.

StorageNo special considerations are required forlong-term storage of the equipment.Circuit boards, when not installed in theequipment, should be kept in antistaticbags or containers.

RFI ProblemsRadio frequency interference (RFI) cancause a light to flash intermittently, at thewrong rate, or at the wrong intensity. RFIcan enter the light by way of any wire toor from the unit. For example:

RFI on primary power wires couldcause errors in flash rate and intensity.

RFI on the control wire could cause alight to stay at night intensity.

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

Strong RFI could burn out PCB1Timing and Trigger Boardcomponents.

The circuits are designed to reject orbypass RFI, but complete immunitycannot be guaranteed beforehand. It maybe necessary, after installation, to addexternal filters or use other methods toreduce RFI entering the equipment.

22 Revision 6 – 1-31-2014 FTB 20X-2

Component TestingThe following procedures describe how tocheck most of the major electricalcomponents. Always make resistancemeasurements with the power turned off.However, you must make voltagemeasurements with power applied. Thus,for your safety, perform all preliminarysteps, such as connecting test leads orcircuit jumpers, or disconnecting existingcircuit connections, with the power turnedoff and storage capacitors discharged.

Refer to Figure 4-1, Figure 4-2, and Figure4-3 for component layouts and locations.

Wiring and Cabling

Wires or cables that move repeatedly willultimately break. Ensure that all cables(the flashhead cable in particular) aresecurely fastened at short intervals to thestructure or other supports.

Inspection

Closely inspect the units and check theconnections against the installationinstructions. Also, a close inspection mayreveal insulation breakdown, anoverheated component, corrosion, looseconnections, faulty relays, incorrectconnections, and so forth.

Capacitors

Many digital multimeters have the abilityto measure capacitance. If a digital meterwith this feature is not available, an analogvolt-ohmmeter operating in the resistancemode may be used to evaluate thecondition of a capacitor. The followingmethod assumes an analog instrument witha resistance scale of X100.

Place the meter leads across the terminalsof a fully discharged and isolated (noelectrical connections to other circuits)capacitor. The meter will initially indicatezero ohms and the resistance measurement

will increase if the capacitor is functioningnormally. A capacitor that is isolated fromother circuitry that does not exhibit thisbehavior is defective. The length of time ittakes the meter to reach one meg-ohm is ameasure of the capacitance. For example,the time is about 5 seconds for a 10microfarad capacitor; 10 seconds for a 20microfarad capacitor, and so forth.Manually discharge the capacitor beforerepeating this measurement.

A bank of capacitors connected in parallelmay be checked as a single unit. If a shortcircuit is indicated, the individualcapacitors have to be disconnected andchecked separately. A shorted capacitor isindicated if the resistance does not riseabove zero after several seconds ofmeasurement.

Note: Review documentation suppliedwith the digital multimeter for measuringcapacitance. Capacitance testsperformed with a multimeter (analog ordigital) may not detect a malfunctionthat occurs only at high voltage.

C1 — High Intensity Capacitor Bank

The C1 main capacitor bank consists ofseveral capacitors. As describedpreviously in “Capacitors”, the capacitorbank can be tested as a single unit. If themeter indicates a short circuit, eachcapacitor must be isolated and testedindividually.

C2 — Medium Intensity Capacitor

Test C2 as described previously in“Capacitors”. Check the bank as a wholeby placing the meter leads to the terminalsof any C2 capacitor and pressing down thearmature of the K3 discharge relay.

If a short circuit is indicated, you mustisolate the capacitors and check them oneat a time.

FTB 20X-2 Revision 6 – 1-31-2014 23

C3 — Low Intensity Capacitor

Test C3 as described previously in“Capacitors”. Remove all leads from oneterminal cluster of this capacitor. Themeasured resistance across this capacitorshould increase from zero to one megohmin approximately 1.5 seconds.

C4 — Tuning Capacitor

Test C4 as described previously in“Capacitors”. Remove the lead from oneterminal of this capacitor. The measuredresistance across the capacitor shouldincrease from zero to one megohm inapproximately 1.5 seconds.

FT101 — Flashtube

Visually inspect the flashtube for brokenelectrodes, cracked glass, and the solderconnections of the pins. A darkenedenvelope does not necessarily mean thelight output would be unacceptable.Before concluding that a faulty flashtubeis responsible for an inadequate flash, firstrule out other possible causes such asweak or absent discharge voltage ortriggering pulses.

K1, K2 — Mode Relays, 24-volt DCCoil

Remove PCB1 to isolate the relay coils.Perform a resistance measurement fromTB3-7 and TB3-8 to TB3-10 (or chassis).The measured resistance should beapproximately 290 ohms.

K3 — Discharge Relay, 120 VACCoil

Disconnect one of the coil wires from therelay (terminal 1 or 2). The resistanceacross the relay coil should beapproximately 290 ohms.

L1 — Burst Choke

The measured resistance of this chokeshould be approximately 9 ohms.

L2 — Flash Choke

The resistance of this coil should be lessthan 1 ohm. An infinite reading indicatesan open coil.

PCB1 — Timing and Trigger Board

Replace this circuit board with one knownto be in good condition. Beforeinstallation, verify that the replacement iscorrectly configured to match the system’scontroller type. See Section 1“Configuring PCB1” and Figures 1-1 and1-2 for additional information. Use thehandheld terminal (PN 1903776) toprogram the replacement circuit board tomatch the programming of the original.

Important! Installation of an incorrectlyconfigured PCB1 (29044xx) could resultin damage to the board, incorrectoperation of the unit or erratic operationof the system. The Board Selectionjumper must not be set to “4063” or“5978” for this application.

R1A, R1B — Bleed Resistors

The measured resistance of the dischargeresistors in parallel should be 17,500ohms.

PCB2 — HV Rectifier Board

Replace this circuit board with one knownto be in good condition.

PCB3 — Sense Module


PCB4 — Surge Resistor


R2A, R2B — Burst Resistors

The measured resistance of the burstresistors in parallel should be 750 ohms.

24 Revision 6 – 1-31-2014 FTB 20X-2

T1 — Power Transformer

Prepare to test this transformer byremoving PCB1 and PCB2. Energize theunit and measure secondary windingvoltages as described in the followingtable.

Test Points VoltageTB4-1 to TB4-9 900 - 1050 VACTB3-9 to TB3-10 110 - 120 VACTB3-2 to TB3-3 22- 26 VACAcross C4 550 to 600 VAC

If this AC voltage is substantially less thanthe specified minimum value, check theC4 tuning capacitor.

T101 — Trigger Transformer

The measured resistance of the flashtubecathode and trigger wire should beapproximately 160 ohms. Check the pottedsecondary winding for evidence of high-voltage breakdown. Check the assemblyscrews for tightness and verify that theferrite core is not fractured.

VR1 — Suppressor Assembly

First remove one of the VR1 leads fromthe fuse block terminal. The resistanceacross VR1 on the x100K ohm scaleshould be infinite.

Note: Flash Technology recommendsreplacing VR1 any time the input powerfuse(s) (F1 & F2) are replaced.

TroubleshootingEffective troubleshooting procedures,beginning with the observation of beaconbehavior, often lead directly to a faulty

component or other abnormal condition.Table 3-1 – Major TroubleshootingSymptoms lists many of the symptomsthat a malfunctioning beacon mightexhibit. Table 3-2 – Defective ComponentLocator Code correlates these symptomswith components, assemblies, orconditions that, if defective or abnormal,could cause the beacon to behave asobserved.

For example, assume that the beacon doesnot flash at all but some of its circuits arestill operating; that is, fuses are not blown,relays operate, and so forth. This behavioris symptom C in Table 3-1. Table 3-2indicates that a defective timing andtrigger board would most likely causesymptom C behavior. The next most likelycause would be a defective rectifier board.The third would be the NITE capacitor,and so forth. Each item in Table 3-2 islisted in the order of its likelihood ofcausing the failure.

Observe components carefully. Check forloose connections. Many components,such as resistors and relays, show signs oftheir failures. Resistors discolor whenoverheated. Relay contacts may becomedirty, or pitted and corroded. Check relayarmatures to see if they function freely bymoving the armature by hand (with poweroff). Most components suspected ofcausing a problem can be checked byfollowing the procedures in Section 3“Component Testing”.

FTB 20X-2 Revision 6 – 1-31-2014 25

Table 3-1 – Major Troubleshooting Symptoms

OBSERVED BEHAVIORSymptom

CodeFlash Intensity

CommentsDAY TWI NITE

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 NOG OK OK HIGH NITE too bright; ragged flash.H SKIPS OK OKI LOW OK HIGHJ SKIPS SKIPS SKIPSK NO NO NO PCB2.L - - - Inconsistent and erratic flash.M NO NO NO No FAIL indication.

26 Revision 6 – 1-31-2014 FTB 20X-2

Table 3-2 – Defective Component Locator Code

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

C1A-C1M DAY Capacitor Bank 5 1C2A-C2B TWI Capacitor Bank 5C3 NITE Capacitor 5 2C4 Tuning Capacitor 4 2F1, F2 Line Fuses 1FT101 Flashtube 6 4 4K1 Day Mode Relay 2K2 Nite Mode Relay 1 1L2 Burst Choke 3PCB1 Timing & Trigger Board 1 4 1 5 2PCB2 HV Rectifier Board 2 7 1PCB4 / R2 Surge or Burst Resistor 6S1 Interlock Switch 2T1 Power Transformer 3 2 7PCB3 Sense Board 3 2T101 Trigger Transformer 3 3VR1 Suppressor 1

--

Blown fuse in one leg of 3-phase power distribution; allbeacons on the same phase areaffected.

3

--Wrong phase between systemcontroller and beacon.

1

--Trigger potential arcing tochassis.

1

--Wrong confirmationprogramming at the beacon.

2

-- RF interference (RFI). 3 1 1

--

Poor connection in thedischarge circuit betweencapacitors and the flashtube;or arcing to chassis.

2 2

-- Monitor wiring. 1-- Controller setup. 1

FTB 20X-2 Revision 6 – 1-31-2014 27

Component Removal andReplacementThe following procedures explain how toremove and re-install selected componentsthat may require procedures that are notself-evident.

Removal & Replacement —General

Typically, follow these steps:

Locate the component using thecomponent location figures in Section4.

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

Disconnect the wire terminals.

Remove or loosen as necessary thescrews or nuts that hold thecomponent.

Remove the component.

For replacement, typically reverse theremoval procedure. Replace the wiresto the correct terminals. Position thewires as closely as possible to theiroriginal routing position.

Capacitors

Removal

1. Using long-nose pliers, remove thewire terminals from the capacitorterminals.

2. Each capacitor is fastened by twoPhillips-head screws. Remove thesescrews.

3. Lift the capacitor out of its retaininghole.

Replacement

1. Reverse the Removal procedure.

BR1 — Bridge Rectifier

Removal

1. Using long-nose pliers, pull off thewire terminals from the rectifier.

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

3. Remove the rectifier.

Replacement


K1/K2/K3 — Relays

Removal

1. Remove the wires on the relayterminals that connect the relays to thewiring harness or other components.Note the position and color of thewires.

2. Each relay has two screws that fastenthe relay to the chassis. Remove thesescrews.

3. Lift the relay from the chassis.

Replacement


L1 — Burst Choke

Removal

1. Remove the two wires that connect tothe choke.

2. Remove the two screws that fasten thechoke to the base plate.

3. Remove the choke.

Replacement


28 Revision 6 – 1-31-2014 FTB 20X-2

L2 — Flash Choke

Removal

1. Find the connection points on relaysK1 and K2 of the two wires connectedto the flash choke.

2. Remove these two wires from therelays that connect to the choke. Notethe color and connections of thesewires.

3. Remove the two screws that fasten thechoke to the base plate.

Note: The choke is held by two screwswith insulation. Be sure the insulationstays in place.

Replacement


2. Replace the wires on their correctterminals.

R1A&B, R2A&B or PCB4 —Resistors

Removal

1. Remove the wires connected to theresistors. Note the color andconnections of these wires.

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

3. Remove the resistors.

Replacement


T1 — Power Transformer

Removal

1. Many wires connect to the powertransformer. Note the wire colors andnumbers on the transformer to whichthese wires are connected.

2. Using long-nose pliers, remove theeasily-accessible wire terminals fromthe transformer.

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

4. Partially lift out the transformer.

5. Remove the remaining wires.

Replacement


T3 — Coupling Transformer (PC204, 207)

Removal

1. Disconnect the wire terminals of thecoils from their connections.

2. Remove the two Phillips-head screwsin the top of the transformer retainingbar that hold the transformer to thechassis.

Replacement


Important! The coils must have thesame winding direction on the core.That is, the coils are wound clockwiselooking down at the top retainer strap ofthe transformer. The top wire, using amale Faston connector, leaves the coilin a clockwise direction. Refer to Figure3-3.

Figure 3-1 – Winding Directions

7 TURNSWOUNDCLOCKWISE

CLOCKWISE

WOUND

50 TURNS

ENTERS THE CENTEROF THE COIL.

MALE FastonCONNECTOR

RETAINER

MALE FastonCONNECTOR

FTB 20X-2 Revision 6 – 1-31-2014 29

PCB1/PCB2 Circuit Boards

Removal

1. Loosen the screws on the terminalblock that connect the wires to theCircuit Board.

2. Loosen the two screws (one in eachcorner of the Circuit Board) that fastenthe Circuit Board to the chassis. Donot remove these screws because theboard sits on standoffs, and if youremove the screws the standoffs willfall out of position.

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

4. Lift the board slightly to clear the fourretaining screws and slide it out fromunder the screws on the terminal block.

Replacement


Flashtube

Location: Part of the optical assembly

FOLLOW FLASHTUBE HANDLING

PRECAUTIONS

Important! Always handle a flashtubeby grasping the metallic end caps.Never touch the glass section with barehands because skin oils or othercontaminants can shorten flashtube life.

Removal

1. Loosen two screws that hold each platethat covers each end of the flashtubeon the optical assembly.

2. Disconnect the trigger wire at the P101ceramic post on the left side of theoptical assembly viewed as in Figure4-4.

3. The flashtube is supplied withconnecting leads soldered to its ends.

4. Loosen the screw on the end of eachflashtube lead.

5. At one end of the flashtube, use aslender, pointed tool between the endof the flashtube and the spring-loadedclip to pop the flashtube up and out ofthe clip. Do the same at the other endand carefully pull the flashtube out ofthe optical assembly.

Replacement

1. Observe the flashtube handlingprecaution noted previously.

2. Determine the anode and cathode ends:the anode has red wire soldered to itand red ink or dye on the end of thetube.

3. Ensure that the trigger extension wirehas a short length of high voltagesleeving installed.

4. Insert the flashtube with the cathodeend (no red ink) toward the trigger leadceramic post.

5. Align the flashtube with the retainingclips at each end and press it down intothe clips one end at a time. Press onlyat the metallic end caps.

6. Attach the trigger wire (whiteinsulation) at the ceramic post P101.Remove any excess wire and do notleave a tail extending from under thescrew. Do not forcefully tighten thescrew.

7. Attach the red anode wire to itsconnection directly above the tubemounting clip.

8. Attach the black cathode wire of theflashtube to the screw on the upper endof the plate on the left side of theoptical assembly as viewed in Figure4-3.

9. Reinstall the plate on each side of theflashtube and tighten the screws.

30 Revision 6 – 1-31-2014 FTB 20X-2

Flashtube Clips

Location: Part of the optical assembly.

Removal

1. Remove the flashtube as described inSection Flashtube.

2. Remove two 8-32 screws from eachflashtube clip plate.

Replacement

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

Trigger Transformer T101

Location: On the optical assembly

Removal

1. At the flashtube, remove the largediameter white wire to the transformersecondary winding.

2. At a chassis ground screw remove thesmall wire to the transformersecondary winding.

3. Disconnect the primary winding wires.Remove the two 4-40 x 2-inch screwsPhillips-head screws that hold thetransformer assembly to the plate.

Replacement


FTB 20X-2 Revision 6 – 1-31-2014 31

Section 4 – Recommended Spare & Replaceable Parts

Customer ServiceCustomer Service: 1-800-821-5825

Telephone: (615) 261-2000

Facsimile: (615) 261-2600

Shipping Address:

Flash Technology332 Nichol Mill LaneFranklin, TN 37067

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

Beacon / Power Converter PartsTable 4-1 “Power Converter Major Replaceable Parts” lists the major replaceable parts forthe power converter. Figure 4-1 shows the component locations for FTB 205 and 208.Figure 4-2 shows the component locations for PC 204 and 207.

Flashhead / Optical Assembly PartsTable 4-2 lists the part numbers for the major replaceable parts in the flashhead / opticalassembly. Figure 4-3 shows the component locations for all versions.

32 Revision 6 – 1-31-2014 FTB 20X-2

Table 4-1 – Power Converter Major Replaceable Parts

Reference Description Part Number

BR1 Diode Bridge 6902806

C1A-C1G Capacitor, Day, 70 mfd 6720401

C2A Capacitor, Twilight, 40 mfd 6386504

C3 Capacitor, Night, 1 mfd 6848202

C4 Capacitor, Tuning, 3 mfd 6577903

F1, F2 ►Fuse, 120V †4900307

F1, F2 ►Fuse, 208/230/240V †4900303

F1, F2 ►Fuse, 480V †4900335

K1, K2 ►Mode Relay, 24 VDC †8900494

K201 Transfer Relay, 120 VAC 4900499

K3 Bleed Relay, 120 VAC 8900493

L1 Burst Choke 4850601

L2 Flash Choke 4175200

PCB1 ►Timing and Trigger Board S versions 2904410

PCB1 ►Timing and Trigger Board non S versions 2904411

PCB2 HV Rectifier Board 2458005

PCB3 Sense Board 2811101

PCB4 Surge Resistor †2459000

R1A, R1B Burst Resistor, 1.5k 50W †6900535

R2A, R2B Bleed Resistor, 35k 50W 6900541

S1, S2 Switch, Interlock 8205501

TB1 Terminal Strip, 6 Position 8721006




TB3, TB4 Terminal Strip, 11 Position 8721011

T1 Power Transformer, 120V, 60 Hz 8841501





T101 Trigger Transformer 8288201

T3 Coupling Transformer 8336701

VR1 Suppressor, 120V 8250801

VR1 Suppressor, 208-240V 8250802

VR1 Suppressor, 480V 8250804

►Recommended as a spare part.

†Varies by model number.

FTB 20X-2 Revision 6 – 1-31-2014 33

Figure 4-1 – PC 204/ 207 Power Converter Component Locations

34 Revision 6 – 1-31-2014 FTB 20X-2

Figure 4-2 – FTB 205/208 Power Converter Component Locations

FTB 20X-2 Revision 6 – 1-31-2014 35

Table 4-2 –Flashhead / Optical Assembly Replacement Parts

Reference Description Part Number

FT101 ►Flashtube 4587703

T101 Trigger Transformer 8288201

T102 Coupling Transformer 8336701

►Recommended as a spare part.

Figure 4-3 – FH 204 FTB 205/208 Optical Assembly Component Locations

REDVIO

WIREFLASHTUBERED

TRIGGERT101

TRANSFORMER

ANODE ENDRED TIP

COUPLINGTRANSFORMER

BLACK TIPCATHODE END

BLUBLKWHT

FLASHTUBEBLACK

WIRE

FH 204

T102

WIREFLASHTUBERED

TRIGGERT101

TRANSFORMER

ANODE ENDRED TIPBLACK TIP

CATHODE END

FLASHTUBEBLACK

WIRE FT 101FLASHTUBE

FT 101FLASHTUBE

(REAR VIEW)

FTB 205/208 OPTICAL ASSEMBLY(REAR VIEW)

36 Revision 6 – 1-31-2014 FTB 20X-2

Appendix 1 – Programming the Timing and Trigger Board

Connecting the HandheldThe following table shows the connectorpin assignments for the handheld.Transmit and receive directions shown inthe table are with respect to the handheld.The DB9 connector is located at the top ofthe handheld programmer.

DB9Female

EIA-232 Function

3 Receive + receive6 No connection - receive2 Transmit + transmit1 No connection - transmit9 Power5 Ground

Figure A1-1 – DB9 Female

A 9-pin RS-232 cable is used to connectthe handheld to the 29044xx controllerboard at connector J2 (9 pin Maleconnector). Power and ground is providedby this connector.

Using the ProgrammerThe programmer has a four line LCDdisplay and 24 keys as shown in FigureA1-2.

The following is a general discussion ofhow the programmer works. See“Parameters” under the SETUP section formore details.

Figure A1-2 – Handheld Programmer

1

2

3

5

6

9

4

7

8

422 TX-

422 TX+ / 232 TX

422 RX+ / 232 RX

GROUND

422 RX-

POWER

ENTERSHIFT DEL 0

7 8 9

654

1 2 3

SPACE

ESC

F2 F3 F4F1

+ - # *

>

<

.,

Flash Technology

FTB 20X-2 Revision 6 – 1-31-2014 37

In the discussions to follow the 4 line LCDdisplay will be represented as shown:

L1: **********

L2: **********

L3: **********

L4: **********

The display does not show the L1: etc. thisis used to represent line 1, 2, 3 and 4 onthe LCD.

Standard Version (2904411)Once the handheld programmer isconnected to PCB1 (2904411) and poweris applied, the circuit board willautomatically recognize that the terminalis connected to it and will display the signon message.

Note: Only terminals provided by FlashTechnology will work with the 29044xxcircuit board.

The general format of the sign on messagefor non S versions is:

L1: FLASH TECHNOLOGY

L2: BOARD 4988

L3: (Blank or further information)

L4: ENTER TO CONTINUE

Once enter is pressed the first menu isdisplayed as follows:

L1: PRESS A FUNC KEY

L2: F1. SETUP F2. INFO

L3: F3. SHORT TEST

L4: F4. MODE CHANGE

To continue further, a function key mustbe pressed. The function keys are on thetop row of the terminal. See Figure A1-2.

F1: Enters the setup menus, used toconfigure the 2904411.

F2: Enters the information menu, usedto show a limited amount of usefuloperating info.

F3: Causes the 2904411 to perform theshort test.

F4: Enters the mode change menu,used to manually change the operatingmode (DAY, TWI, and NITE). Note:DAY equals HIGH, TWI equals MEDand NITE equals LOW intensity.

Note: The handheld terminal will returnto the sign on message from any othermenu if no key is pressed within twominutes.

Setup

The setup menu has the following format:

L1: SETUP

L2: 0-1-1

L3:

L4: OK NEXT BACK EXIT

The first line displays the current menu.The second line displays the current setup.The numbers correspond to the systemtype, tier and beacon selected. The thirdline is blank. The fourth line displays whatfunctions the keys F1 thru F4 will performif pressed; the words are spaced to be overthe corresponding function key. So, tomove to the next menu you would pressF2 (NEXT).

F1: OK- is used to enter data.

F2: NEXT- moves to the next item.

F3: BACK- moves to the previousitem.

F4: EXIT- exits the setup menu.

Parameters: 204, 204X & 205

(Standard System)

Pressing the NEXT or BACK function keyfrom the SETUP menu takes you to theparameters. The general format is:

38 Revision 6 – 1-31-2014 FTB 20X-2

L1: SETUP

L2: SYSTEM

L3: 0- Std. 1- Air. 2- Cat


The currently selected option will have thecursor under it. For example:

“0-Std 1-Air 2-Cat” shows that thecurrently selected option for the parameteris zero (0) which in this case meansStandard system.

If the board to be configured is not in theStandard mode press 0 and press F1 (OK).

Important! “1-Air” and “2-Cat” are notvalid modes for this application andshould not be selected.

Note: Even if your board is configuredfor Standard mode you will need topress 0 and F1 to change the tier andbeacon number.

The display will change to:

L1: SETUP

L2: TIER # 1

L3: Enter TIER #


Press the number keys to select the tiernumber you wish this board to be and thenpress F1 (OK). The Tier numberdisplayed will change. The display willchange to:

L1: SETUP

L2: BEACON # 1

L3: Enter Beacon #


Press the number keys to select the beaconnumber you wish this board to be and thenpress F1 (OK). The Beacon numberdisplayed will change.

Note: It is recommended to write thesystem type, tier and beacon numberson the white space provided on theboard.

Press NEXT and the display will change toFPM (Flashes Per Minute).

L1: SETUP

L2: FPM 0-40 1-60 2-30

L3: 3-20 4-100 5-120


Press the number keys to select thenumber of flashes per minute and thenpress F1 (OK).

Note: Zero (0) should be selected forthis application.

Press NEXT and the display will change tothe FLICK selection.

L1: SETUP

L2: FLICK

L3: 0-SINGLE 1-DOUBLE


Press the number keys to select the Flicksetting and press F1 (OK).

Note: One (1) should be selected forthis application.

Press F4 (EXIT) to return to the mainmenu.

Parameters: 207 & 208

(Catenary System)


L1: SETUP

L2: SYSTEM

L3: 0- Std. 1- Air. 2- Cat


The currently selected option will have thecursor under it. For example:

“0-Std 1-Air 2-Cat” shows that thecurrently selected option for the parameteris two (2) which in this case meansCatenary system.

FTB 20X-2 Revision 6 – 1-31-2014 39

If the board to be configured is not in theCatenary mode press 2 and press F1 (OK).

Important! “0-Std” and “1-Air” are notvalid modes for this application andshould not be selected.

Note: Even if your board is configuredfor Catenary mode you will need topress 2 and F1 to change the position.


L1: SETUP

L2: CAT TIER

L3: 0-BOT. 1-MID. 2-TOP


Press the number keys to select thecatenary tier you wish this board to be andthen press F1 (OK).

Press NEXT and the display will change toFPM (Flashes Per Minute).

L1: SETUP

L2: FPM 0-40 1-60 2-30

L3: 3-20 4-100 5-120


Press the number keys to select thenumber of flashes per minute and thenpress F1 (OK).


Press NEXT and the display will change tothe FLICK selection.

L1: SETUP

L2: FLICK

L3: 0-SINGLE 1-DOUBLE


Press the number keys to select the Flicksetting and press F1 (OK).


Press F4 (EXIT) to return to the mainmenu.

INFO

The info menu has the following:

L1: INFO

L2: BOARD 4988

L3:

L4: NEXT BACK EXIT

This menu is used to show a limitedamount of information about the current2904411 operation and configuration.

The first line displays the current menu.The second and third lines display boardinformation. The fourth line displays whatfunctions the keys F2 thru F4 will performif pressed; the words are spaced to be overthe corresponding function key. So, tomove to the next item you would press F2(NEXT).



F4: EXIT- exits the setup menu. Itemslike energy, trigger voltage, flash rateand operating mode are displayed.

MODE CHANGE

The mode change menu has the followingformat:

L1: MODE CONTROL

L2: CURRENT DAY

L3:

L4: DAY TWI NITE EXIT

40 Revision 6 – 1-31-2014 FTB 20X-2

“S” Version (2904410)Once the handheld programmer isconnected to PCB1 (29044xx) and poweris applied, the circuit board willautomatically recognize that the terminalis connected to it and will display the signon message.

Note: Only terminals provided by FlashTechnology will work with the 29044xxcircuit board.

The general format of the sign on messagefor S versions is:

L1: FLASH TECHNOLOGY

L2: BOARD 4990

L3: (Blank or further information)

L4: ENTER TO CONTINUE

Once enter is pressed the first menu isdisplayed as follows:

L1: PRESS A FUNC KEY

L2: F1. SETUP F2. INFO

L3: F3. SHORT TEST

L4: F4. MODE CHANGE

To continue further, a function key mustbe pressed. The function keys are on thetop row of the terminal. See Figure A1-2.

F1: Enters the setup menus, used toconfigure the 2904410.

F2: Enters the information menu, usedto show a limited amount of usefuloperating info.

F3: Causes the 2904410 to perform theshort test.

F4: Enters the mode change menu,used to manually change the operatingmode (DAY, TWI, and NITE). Note:DAY equals HIGH, TWI equals MEDand NITE equals LOW intensity

Note: The handheld terminal will returnto the sign on message from any othermenu if no key is pressed within twominutes.

Setup

The setup menu has the following format:

L1: SETUP

L2: DASH 10 T 1 B 1

L3:


The first line displays the current menu.The second line displays the current setup.The numbers correspond to the dashnumber, tier and beacon selected. Thethird line is blank. The fourth line displayswhat functions the keys F1 thru F4 willperform if pressed; the words are spaced tobe over the corresponding function key.So, to move to the next menu you wouldpress F2 (NEXT).

F1: OK- is used to enter data.



F4: EXIT- exits the setup menu.

Parameters: 204S, 204SX & 205S

(“S” Version Standard System)


L1: SETUP

L2: DASH # 10

L3: Enter Dash #


To change the dash number, enter anumber and press F1 OK. Press NEXT tocontinue.

Important! The dash number shown isfor example only and may not becorrect for your application. Dashnumbers should only be programmedby trained Flash Technology personnelor under the direction of same.

FTB 20X-2 Revision 6 – 1-31-2014 41


L1: SETUP

L2: TIER # 1

L3: Enter TIER #


Press the number keys to select the tiernumber you wish this board to be and thenpress F1 (OK). The Tier number displayedwill change. The display will change to:

L1: SETUP

L2: BEACON # 1

L3: Enter Beacon #


Press the number keys to select the beaconnumber you wish this board to be and thenpress F1 (OK). The Beacon numberdisplayed will change. When complete,press NEXT.

Note: It is recommended to write thedash number, tier and beacon numberson the white space provided on theboard.

Parameters: 207S & 208S

(“S” Version Catenary System)


L1: SETUP

L2: DASH # 36

L3: Enter Dash #


To change the dash number, enter anumber and press F1 OK. Press NEXT tocontinue.

Important! The dash number shown isfor example only and may not becorrect for your application. Dashnumbers should only be programmedby trained Flash Technology personnelor under the direction of same.


L1: SETUP

L2: CAT TIER

L3: 0-BOT. 1-MID. 2-TOP


Press the number keys to select thecatenary tier you wish this board to be andthen press F1 (OK).


L1: SETUP

L2: BEACON # 1

L3: Enter Beacon #


Press the number keys to select the beaconnumber you wish this board to be and thenpress F1 (OK). The Beacon numberdisplayed will change. When complete,press NEXT.

Note: It is recommended to write thedash number, tier and beacon numberson the white space provided on theboard.

INFO

The info menu has the following format:

L1: INFO

L2: BOARD 4990

L3:

L4: NEXT BACK EXIT

This menu is used to show a limitedamount of information about the current2904410 operation and configuration.

The first line displays the current menu.The second and third lines display boardinformation. The fourth line displays whatfunctions the keys F2 thru F4 will performif pressed; the words are spaced to be overthe corresponding function key. So, tomove to the next item you would press F2(NEXT).

42 Revision 6 – 1-31-2014 FTB 20X-2



F4: EXIT- exits the setup menu. Itemslike energy, trigger voltage, flash rateand operating mode are displayed.

MODE CHANGE

The mode change menu has the followingformat:

L1: MODE CONTROL

L2: CURRENT DAY

L3:

L4: DAY TWI NITE EXIT

F1: DAY- Changes the mode to DAY.

F2: TWI- Changes the mode to TWI.

F3: NITE- Changes the mode to NITE.

F4: EXIT- exits the mode changemenu and returns the mode toautomatic.

This menu item is used to manuallychange the operating modes and functionsjust like the test jumpers on the board.

FTB 20X-2 Revision 6 – 1-31-2014 43

Appendix 2 - FTB 204SPB and 207SPB Primary Backup

OperationThe 204SPB and 207SPB provide asecondary trigger output for the operationof a backup flashhead as shown in FigureA2-1. The power converter operates theprimary flashhead until a failure isdetected. Once in alarm, the powerconverter will switch trigger to the backupflashhead and continue to operatenormally.

Once in backup mode, the power converterwill send a “Backup Mode” alarm to theFTC 121 Controller. This is intended to

alert the operator that the primary hasfailed and the unit is operating in backupmode. In the event that both the primaryand backup flashhead fail, the powerconverter will send a normal “StrobeFailure” alarm to the controller.

InstallationThe 204SPB and 207SPB are installed asdescribed in Section 2 with the additionalmounting and wiring of the backupflashhead. The internal wiring is shown inFigure A2-2 for reference.

Figure A2-1 – PC 204SPB / 207SPB Installation Wiring

FTCA PN 3360

INTERCONNECT CABLE

BL

K

BL

U

RE

D

YE

LV

IO

MO

NIT

OR

SH

IELD

LIN

E2

LIN

E1

GND

WHTBLK

F2F1

TB201

CO

NT

RO

L

1 2 3

PC 204SPB OR PC 207SPB POWER CONVERTER

SH

IELD

P1

P5

P4

P2

AN

OD

E

CA

TH

OD

E

TR

IGG

ER

TR

IGR

TN

GN

D

GN

D

BLK

WH

T

VIO

RE

D

BLU

FH 204 FLASHHEAD FH 204 FLASHHEAD

BL

KGN

DCA

TH

OD

E

AN

OD

E P1

TR

IGG

ER

P2

RE

D

BL

U

VIO

SH

IELD

TR

IGR

TN

P4

P5

GN

D

WH

T

TB2 WIRING WHEN BACKUP

CATHODE

TRIG RTN

TRIGGER

3

FLASHHEAD FOR FTB 204

TB21RED

BLU2

ANODE #1

SHIELD

5WHTBLK 4

67

GND

8

VIO

BACK-UP

TRIGGER

IS INSTALLED

VIO

BL

K

WH

T

BLU

RE

D

SHIELD

FTCA PN. 6340

NOTE 2

NOTE 3

(BACKUP)

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Figure A2-2 – PC 204SPB / 207SPB Internal Wiring

FTB 20X-2 Revision 6 – 1-31-2014 45

Appendix 3 - FTB 204-3X, SX Extended Separation

Introduction and OperationThe FTB 204-3X and 204-3SX consist ofan FH 204 flashhead and a PC 204-3power converter. The lighting equipmentoperates and functions in a similar mannerto other FTB 204 models except that thedistance, or separation, between powerconverter and flashhead is greater(between 100 and 700 feet). The two mainreasons for selecting the extendedseparation model are as follows: Thepower converter can either be mountedaway from an antenna’s RF field (seeFigure A3-1) or at ground level (seeFigure A3-2) thus minimizing antennadown time and improve serviceability,respectively. The power converter’scomponent location is shown in FigureA3-4, and the internal wiring is shown inFigure A3-5 for reference.

Mounting and InstallationRefer to Section 2 – “Mounting andInstallation”.

Flashhead Wiring

The power converter and flashhead areinterconnected by the flashhead cable.When Flash Technology Part Number6340, or equivalent cable, is used, the twomay be separated by a distance between100 to 700 feet. The cable between thepower converter and flashhead requiresfive conductors with 600 volts (minimum)insulation. Two of the conductors must be#10 AWG. The other three may be #16AWG (minimum; for mechanical strength)if you are cabling together individualwires.

To ensure long-term equipment reliability,use continuous wiring between the power

converters and their flashheads withoutintervening junctions or splices.

Securing the Cable

Flash Technology recommends thefollowing method for securing theflashhead cable to a skeletal structure:

1. Run the cable along one of the towerlegs and wrap two full turns of two-inch Scotchwrap™ #50 tape, or theequivalent, around the cable and towerleg at regular intervals every 4 to 5 feet(1.5 meters) per NEC.

2. Wrap three full turns of one-inchScotchwrap Filament #890 tape, or theequivalent, over the Scotchwrap #50tape.

46 Revision 6 – 1-31-2014 FTB 20X-2

3. Wrap four full turns of two-inchScotchwrap #50 tape, or theequivalent, over the ScotchwrapFilament #890 tape.

4. Perform steps 1 through 4 also directlyabove and below any tower leg flangesthat the cable may cross. The cableshould be spaced approximately 1 inchfrom the edge of each flange.

FTB 20X-2 Revision 6 – 1-31-2014 47

Figure A3-1 – PC 204-2 / 204-3X Mid-Tower Installation Example

48 Revision 6 – 1-31-2014 FTB 20X-2

Figure A3-2 – PC 204-3X Ground Level Installation Example

FTB 20X-2 Revision 6 – 1-31-2014 49

Figure A3-3 – PC 204-3X Power Converter Mounting and Outline

2. DIMENSIONS ARE IN INCHES (MILLIMETERS).

1. WIND AREA = 2.4 SQ.FT. (.22 SQ.M)

NOTES:

9.42 (239.2)

0.44 (11.2) DIA. MOUNTING HOLE2 places

23.00(584.2)

21.75(552.5)

20.88(530.4)

0.44 (11.2)

17.13 (435.1)

12.25 (311.2)

17.50 (444.8)CLEARANCEREQUIRED

2.50(63.5)(TYP)

3. WEIGHT = 76 LBS. (34.5 KG.)

4.50(114.3)

6.25(158.8)

8.38(212.9)

10.5(266.7)

A

B

B B

C

16.75(425.5)

HOLE CHART

HOLE QTY. DESC.

A 1 Ø0.880 THRU

B 3 Ø1.062 THRU

C 1 Ø1.315 THRU 1.31 (33.3)

2.81 (71.4)

5.31 (134.9)

50 Revision 6 – 1-31-2014 FTB 20X-2

Figure A3-4 – PC 204-3X Power Converter Component Locations

FTB 20X-2 Revision 6 – 1-31-2014 51

Figure A3-5 – PC 204-3X Power Converter Internal Wiring

Revision 2014A RMA Policy

Appendix 4: Return Material Authorization (RMA) Policy

IF A PRODUCT PURCHASED FROM FLASH TECHNOLOGY MUST BE RETURNED FOR ANYREASON (SUBJECT TO THE WARRANTY POLICY), PLEASE FOLLOW THE PROCEDURE BELOW:

Note: An RMA number must be requested from Flash Technology prior to shipment of anyproduct. No returned product will be processed without an RMA number. This number will bethe only reference necessary for returning and obtaining information on the product’s progress.

1. To initiate an RMA: Call Flash Technology’s National Operations Center (NOC) at (800-821-

5825) to receive technical assistance and a Service Notification number. The following

information is required before a Service Notification number can be generated:

• Site Name/Number / FCC Registration number/ Call Letters or Airport Designator

• Site Owner (provide all that apply – owner, agent or subcontractor)

• Contractor Name

• Contractor Company

• Point of Contact Information: Name, Phone Number, Email Address, Fax Number and Cell

Phone (or alternate phone number)

• Product’s Serial Number

• Product’s Model Number or part number

• Service Notification Number (if previously given)

• Reason for call, with a full description of the reported issue

2. The Service Notification number will then serve as a precursor to receiving an RMA number

if it is determined that the product or equipment should be returned. To expedite the RMA

process please provide:

• Return shipping method• Shipping Address• Bill to Address• Any additional information to assist in resolving the issue or problem

3. Product within the Warranty Time Period

a. If to be returned for repair;

• RMA # is generated

• Once product is received and diagnosed;

• Covered under warranty – product is repaired or replaced

• Not covered under warranty – quote is sent to the customer for a bench fee of

$350 plus parts for repair

• If the customer does not want the product repaired, a $50 test fee is

charged before being returned

b. If advance replacement;

• Purchase order may be required before the advance replacement order is created

• RMA # is generated and the advance replacement order is created

• Once product is received and diagnosed;

• Covered under warranty – credit given back if PO received

• Not covered under warranty – credit will not be applied to PO

• Flash Technology has sole discretion in determining warranty claims. Flash

Technology reserves the right to invoice for parts advanced if the associated failed

parts are not returned within 15 days of issue or if product received is diagnosed to be

non-warranty.

• Advance replacements will be shipped ground unless the customer provides alternative

shipping methods.

RMA Policy Revision 2014A

4. Product outside the Warranty Time Period

a. For Xenon System board repair; a purchase order is required at time of request for a RMA #

for a standard $350 repair bench fee

• RMA # is generated with the PO attached

• If the board is deemed non-repairable after diagnosis, the customer is notified. If the

customer purchases a new board, the repair bench fee is waived. If the customer

does not buy a new board, a $50 test fee is charged before being returned or

scrapped.

b. For all other products; no purchase order is required to return the product for diagnosis

• RMA # is generated

• Once product is diagnosed, quote is sent to the customer for a bench fee of $350

plus parts for repair

• Once the purchase order is received, the product will be repaired and returned

• If the customer does not want the product repaired, a $50 test fee is charged

before being returned or scrapped.

5. After receiving the Flash Technology RMA number, please adhere to the following

packaging guidelines:

• All returned products should be packaged in a way to prevent damage in transit. Adequatepacking should be provided taking into account the method of shipment.Note: Flash Technology will not be responsible for damaged items if product is not returned inappropriate packaging.

6. All packages should clearly display the RMA number on the outside of all RMA shipping

containers. RMA products (exact items and quantity) should be returned to:

Flash TechnologyAttn: RMA #XXX332 Nichol Mill LaneFranklin, TN 37067

7. All RMA numbers:

• Are valid for 30 days. Products received after 30 days may result in extra screening and delays.• Must have all required information provided before an RMA number is assigned.

FTB 20X-2 Rev 6

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