FTS 430/830-4 Approach Lighting Systems Reference Manual Part Number 791430830
SERIAL NUMBER
Flash Technology, 332 Nichol Mill Lane, Franklin, TN 37067 (615) 261-2000 Front Matter
Abstract
This manual describes the Installation, Maintenance, and Operation of the FTS 430 and FTS 830 Approach Lighting Systems manufactured by Flash Technology Corporation of America®.
Copyright
Copyright © 2016 Flash Technology Corporation of America, Franklin, TN, 37067, U.S.A. All rights reserved. Reproduction or use of any por- tion of this manual, without express written permission from Flash Technology Corporation of America and/or its licenser, is prohibited.
Trademark Acknowledgments
Flash Technology Corporation of America® is a registered trademark name.
™ ™ ™ ™ ™ ElectroFlash , Flash Tech , Flash Technology , FTCA , Flash , and the Flash Technology Logo are all trademarks of Flash Technology Corporation 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.
Disclaimer
While every effort has been made to ensure that the information in this manual is complete, accurate and up-to-date, Flash Technology Corpora- tion of America assumes no liability for damages resulting from any errors or omissions in this manual, or from the use of the information con- tained 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 consequential damages arising out of the use of or the inability to use this manual.
Applicable Specification
This equipment meets or exceeds requirements for an FAA Type L-849 Style A, C, and E, and Type L-859, Styles B, D, and F.
Warranty
Flash Technology Corporation of America warrants all components, under normal operating conditions, for two years.
Parts Replacement
The use of non-OEM parts or unauthorized modification of this equipment will void the warranty and could invalidate the assurance of com- plying with FAA requirements as published in Advisory Circular 150/5345-51.
0594-430/830-0007 ii Revision 10 — 01-05-2016 FTS 430/830 PERSONNEL HAZARD WARNING DANGEROUS VOLTAGES Dangerous line voltages reside in certain locations in this equipment. Also, this equipment may generate dangerous voltages. Although FTCA has incorporated every practical safety precaution, exercise extreme caution at all times when you expose circuits and components, and when you operate, maintain, or service this equipment.
Avoid Touching Live Circuits Avoid touching any component or any part of the circuitry while the equipment is operating. Do not change components or make adjustments inside the equipment with power on.
Dangerous Voltages Can Persist with Power Disconnected Under certain conditions, dangerous voltages can be present because capacitors can retain charges even after the power has been disconnected.
Protect yourself — always turn off the input (primary) power and wait for one minute for storage capacitors to drain their charge. Then check between the red and blue wires on the flashhead terminal block with a voltmeter for any residual charge before touching any circuit element or component.
Do Not Depend on Interlocks Never depend on interlocks alone to remove unsafe voltages. Always check cir- cuits with a voltmeter. Under no circumstances remove or alter any safety inter- lock switch.
EQUIPMENT CAUTION Do not apply power to this equipment if any Printed circuit board, or any com- ponents have been removed. Serious damage will occur!
If any components have been removed, and you want to close the cover, which automatically applies power because of the interlock switch, then you MUST ensure that TB1, terminals 10 and 11 are shorted to each other. If you do not use this procedure, damage will occur and it is not covered under war- ranty.
FTS 430/830 Revision 10 — 01-05-2016 iii Table of Contents Section Page
Section 1 — FTS 430/830 Introduction and Operation ...... 1-1 System ...... 1-1 Specifications ...... 1-1 Options ...... 1-2 Elapsed Time Meter ...... 1-2 Flash Monitor ...... 1-2 Operation ...... 1-2 Setup ...... 1-2 Setup Preliminaries ...... 1-3 Setup Procedures ...... 1-3 Style 1 Current Regulator — Three Intensity Levels ...... 1-4 Style 1 Current Regulator — Two Intensity Levels ...... 1-4 Style 2 Current Regulator — Three Intensity Levels ...... 1-5
Section 2 — Outline, Mounting, and Installation ...... 2-1 Unpacking ...... 2-1 Tools ...... 2-1 Access ...... 2-1 Power Converter ...... 2-1 FH 400 Flashhead ...... 2-1 FH 800 Flashhead ...... 2-1 Mounting ...... 2-1 Installation ...... 2-1 Power Rating Guidelines ...... 2-2 Isolation Transformer ...... 2-3 Wiring ...... 2-3 Installation Checklist ...... 2-3
Section 3 — Maintenance and Troubleshooting ...... 3-1 Safety ...... 3-1 Preventive Maintenance ...... 3-1 Storage ...... 3-1 Diagnostic Testing ...... 3-1 Control Line Interference ...... 3-2 Component Testing ...... 3-2 Capacitors ...... 3-2 Wiring and Cabling ...... 3-2 Inspection ...... 3-2 Relays (K1, K2) ...... 3-2 Timing and Trigger Board (PCB1) ...... 3-2 HV Rectifier Board (PCB2) ...... 3-2 Bleed Resistor (R1, R2) ...... 3-3 Interlock Switch (S1) ...... 3-3 Flashtube (FT101) ...... 3-3 Trigger Transformer (T101) ...... 3-3 High Voltage Transformer (T1) ...... 3-3 iv Revision 10 — 01-05-2016 FTS 430/830 Table of Contents (cont’d) Section Page Component Removal and Replacement ...... 3-3 High Voltage Transformer (T1) ...... 3-3 Low Voltage Transformer (T4) ...... 3-3 Trigger Coupling Transformer (T3) ...... 3-3 Timing and Trigger Board (PCB1) ...... 3-3 HV Rectifier Board (PCB2) ...... 3-3 Capacitors ...... 3-3 Flashhead ...... 3-4 FH 400 Lens ...... 3-4 FH 400 Flashtube (FT101) ...... 3-4 FH 800 Flashtube (FT 101) ...... 3-4 Trigger Transformer (T101) ...... 3-4 Troubleshooting ...... 3-5 System-Level Problems ...... 3-5 Problems with Individual Lights ...... 3-6
Section 4 — Replaceable and Spare Parts ...... 4-1 Customer Service ...... 4-1 Ordering Parts ...... 4-1 Power Converter Parts ...... 4-1 Flashhead Parts ...... 4-1 Returning Equipment ...... 4-1 Repackaging ...... 4-1
Index ...... I-1
List of Figures Page Figure 1-1 PCB1 Timing and Trigger Board ...... 1-4 Figure 2-1 Typical REIL Configuration ...... 2-4 Figure 2-2 Typical ALS Configurations ...... 2-5 Figure 2-3 PC 430 or PC 830 Power Converter Mounting and Outline ...... 2-6 Figure 2-4 FH 400 Flashhead Mounting and Outline ...... 2-7 Figure 2-5 FTS 430 Comounted Unit Mounting and Outline ...... 2-8 Figure 2-6 FH 800 Flashhead Mounting and Outline ...... 2-9 Figure 2-7 FTS 830 Comounted Unit Mounting and Outline ...... 2-10 Figure 2-8 Typical FTS 430/830 System Installation Wiring ...... 2-11 Figure 2-9 PC 430 or PC 830 Power Converter Internal Wiring ...... 2-12 Figure 2-10 FH 400 or FH 800 Flashhead Internal Wiring ...... 2-13 Figure 2-11 FH 83F-2 Outline and Wiring...... 2-14 Figure 2-12 FH 83F-2 Sample Installation ...... 2-15 Figure 4-1 PC430 or PC 830 Power Converter Component Locations ...... 4-3 Figure 4-2 FH 400 Flashhead Component Locations ...... 4-5 Figure 4-3 FH 800 Flashhead Component Locations ...... 4-6 FTS 430/830 Revision 10 — 01-05-2016 v List of Tables Page Table 1-1 Style 1 Current Regulator ...... 1-3 Table 1-2 Style 2 Current Regulator ...... 1-3 Table 2-1 L-828 Power Rating Guidelines ...... 2-2 Table 3-1 System-Level Troubleshooting ...... 3-5 Table 3-2 Lighting Unit Troubleshooting ...... 3-6 Table 4-1 Power Converter Replaceable Parts ...... 4-2 Table 4-2 Flashhead Replaceable Parts ...... 4-4
vi Revision 10 — 01-05-2016 FTS 430/830 Section 1 — FTS 430/830 Introduction and Operation
System Application L-849 Power Requirements: FTS 430 System: An FTS 430 Approach Lighting Sys- Current and Frequency 2.8A to 6.6A, 50/60 Hz tem is a current driven system consisting of two or more Isolation Transformer FAA Type L-830 lighting units. Each lighting unit is composed of a white FTS 430 Power (Watts) high int. 80 FH 400 Flashhead and PC 430 Power Converter. medium int. 50 FTS 830 System: An FTS 830 Approach Lighting Sys- low int. 30 tem is a current driven system consisting of two or more FTS 830 Power (Watts) 120 fpm high int. 175 lighting units. Each lighting unit is composed of a white medium int. 65 FH 800 Flashhead and PC 830 Power Converter. low int. 30 The FH 400 Flashhead produces a beam covering 360 60 fpm high int. 100 degrees horizontally and 8 degrees, or more, vertically. medium int. 45 The lens directs the main part of the beam upward toward low int. 25 the airways, while limiting stray light toward the ground. FTS 430 Flash Intensity: The FH 800 Flashhead directs the beam 30 degrees hori- zontally and 10 degrees vertically. The flashhead is High Intensity 5,000 cd attached to a two-inch threaded pipe by a yoke that has Medium Intensity 1,500 cd provisions for horizontal and vertical aiming and locking. Low Intensity 300 cd FTS 830 Flash Intensity: Specifications High Intensity 20,000 cd Medium Intensity 2,000 cd Physical: Low Intensity 450 cd FTS 430 Comounted Assembly: (H x W x D) Flash Rate: 28.50 x 25 x 14.00 in., 25 lbs. 724 x 635 x 355.60 mm, 11.53 kg. FTS 430 60 flashes per minute FTS 830 120 flashes per minute FTS 830 Comounted Assembly: (H x W x D) 24.50 x 25 x 14.00 in., 25 lbs. Flash Coverage: 622.30 x 635 x 355.60 mm, 11.53 kg. FH 400: PC 430 or PC 830 Power Converter: (H x W x D) Horizontal 360 degrees 12.25 x 20.00 x 14.00 in., 21 lbs. Vertical 8 degrees (minimum) 311.2 x 508.0 x 355.6 mm, 9.53 kg. FH 400 Flashhead: (H x W x D) FH 800: Horizontal 30 degrees (minimum) 16.5 x 13.5 x 13.5 in., 10 lbs. Vertical 10 degrees (minimum) 419 x 342.9 x 342.9 mm., 4.5 kg. FH 800 Flashhead: (H x W x D) Control Interface: 10.75 x 7.80 in., 4 lbs. Senses constant current level in a series line. 273.1 x 198.1 mm, 1.82 kg. Inter-Unit Control: Heights include dimensions of the units only and do not Master/slave with common reference timing. include the distance from the bottom of each unit to the Monitoring: ground. FAA Advisory Circ. AC 150/5345-51 compliance. Environmental: Performance Characteristics: FAA Advisory Circ. AC 150/5345-51 compliance.
FTS 430/830 Revision 10 — 01-05-2016 1-1 Options Intensity stepping or either light is controlled by the level of current from a constant current regulator. They are designed for use with L-828, Class 1, Styles 1 and 2 con- Elapsed Time Meter stant current regulators.
The Elapsed Time Meter shows the hours of operation at Internal timing circuitry in each lighting unit (power con- high intensity. You can use this timer, for example, to verter) fixes the instant at which it flashes. The factory schedule inspections, cleaning, or flashtube replacement sets simultaneous or sequential flashing. The master unit as preventive maintenance. is the one designated by the factory. It distributes a refer- ence timing signal to all units in a system. The reference timing signal from the master also contains encoded flash Flash Monitor intensity information. A control line, which enables The Flash Monitor allows monitoring flash operation sequential flashing, interconnects all the lights. with external monitoring equipment. The main terminal block TB1 has two connections at TB1-4 and TB1-5 to Setup which you can connect the monitoring device. These con- tacts open upon failure of the flashtube for more than This section applies to FTS 430 or FTS 830 Systems approximately 12 seconds. When you first turn the unit drawing power from an L-828, Class 1 Constant Current on, a failure may be indicated for about 12 seconds until Regulator. A Class 1 regulator delivers a maximum of 6.6 the monitor detects sufficient flashes to close the contacts. amps. Two styles are in general use for runway lighting: After this initial period, the contacts remain closed until a Style 1 and Style 2. The Style 1 regulator has three cur- failure occurs or the power is removed. rent steps and the Style 2 has five.
FTS 430 or FTS 830 Systems can be set to step from one Operation of three intensity levels to another as the equipment input current changes. Table 1-1 and Table 1-2 summarize typi- The lights operate when power is applied. cal ways to set up the operation of the equipment.
A REIL (Runway End Identifier Lights) system consists EQUIPMENT CAUTION of only two lights that are located on each side of the run- Do not apply power to this equipment if way at the landing threshold. The REIL lights flash any Printed circuit board, or any compo- (simultaneously) after the last center line light has nents have been removed. Serious flashed. damage will occur!
If any components have been removed, In ALS applications, the lights are aligned with the center and you want to close the cover, which line of the runway, and they flash sequentially toward the applies power because of the interlock landing threshold. An ALS installation may have from 3 switch, you MUST ensure that TB1, ter- to 21 (or more) sequentially flashing lights. FTS 430 or minals 10 and 11 are shorted to each 830 lights are also used in a combined ALS and REIL other. If you do not use this procedure, configuration where the REILs flash (simultaneously) damage will occur and it is not covered after the last center line light has flashed. under warranty.
1-2 Revision 10 — 01-05-2016 FTS 430/830 powers the runway lights. If the total number of lights Table 1-1 Style 1 Current Regulator changes substantially any time after you make FTS Current 430 or FTS 830 set-up adjustments, it could affect Flash Intensity Step system switching operation. Permanent changes, such as adding or deleting runway lights, require making Three Levels Two Levels readjustments to FTS 430 or FTS 830 lights. 1 (4.8A) LOW OFF OFF OFF OFF 4. To calculate the power required from the CCR, use 2 (5.5 A) MED LOW LOW MED OFF 400 watts per light. 3 (6.6 A) HIGH HIGH MED HIGH ANY Setup Procedures Table 1-2 Style 2 Current Regulator If you do not understand how to set up your system, con- sult Technical Support @ 1-800-821-5825. Current Step Flash Intensity Adjustment potentiometers and indicator LEDs reside on 1 (2.8 A) OFF the Timing and Trigger Board (PCB1) of each unit. Fig- 2 (3.4 A) LOW ure 1-1 shows potentiometer and LED locations. Set up 3 (4.1 A) MED each unit in the system as described in the following text. 4 (5.2 A) MED CAUTION 5 (6.6 A) HIGH Setting up the system requires operation of lighting units while enclosures are Step-by-step procedures for obtaining these operations opened, thus exposing dangerous follow in Section Setup Preliminaries. potentials. Do not touch any component except PCB1 during these procedures.
Setup Preliminaries Tilt the enclosure open and pull the interlock plunger up Follow these general rules: to the service position to perform set-up procedures. The following abbreviations apply: 1. You cannot achieve full HIGH intensity light output at any input current level lower than 6.6 amps. • CCR (Constant Current Regulator) 2. You may not be able to achieve reliable MEDIUM CCW (Counterclockwise) intensity switching at an input current level less than • 4.0 amps. • CW (Clockwise) 3. FTCA expects operation of the FTS 430 or FTS 830 System from the same constant current regulator that • LED (Light Emitting Diode)
FTS 430/830 Revision 10 — 01-05-2016 1-3 43000031 Figure 1-1 PCB1 Timing and Trigger Board
Style 1 Current Regulator — Three Intensity Lev- 6. Recheck each light in the system. It may be necessary els to readjust some lights after all lights are operational and flashing. For this style, the lighting system switches off only when the CCR is switched off. Style 1 Current Regulator — Two Intensity Lev- els 1. Turn the HIGH, MED, and LOW controls fully CW. For this style, the lighting system switches off when the 2. Set the CCR to STEP 1 and adjust the LOW pot CCR is at Step 1. It flashes at LOW intensity when the CCW until LOW LED just comes on. CCR is at Step 2, and at HIGH intensity when the CCR is at Step 3. 3. Set the CCR to STEP 2 and adjust MED pot CCW until the MED LED just comes on. 1. Turn the HIGH, MED, and LOW control fully CW.
4. Set the CCR to Step 3 and adjust the HIGH pot CCW 2. Set the CCR to Step 2 and adjust the LOW control until the HIGH LED just comes on. CCW until the LOW LED just comes on and the strobe light flashes in low intensity. 5. Recheck the light at all current steps and verify that 3. Set the CCR to Step 3 and adjust the HIGH control LEDs respond correctly at each step. Also verify by CCW until the HIGH LED just comes on. visual comparison that flashing intensity decreases when the CCR is switched from Step 3 to Step 2, and 4. Recheck the light at all current steps and verify that that it decreases further when the CCR is switched LEDs respond correctly at each step. Also verify by from Step 2 to Step 1. visual comparison that flashing intensity decreases
1-4 Revision 10 — 01-05-2016 FTS 430/830 when the CCR is switched from Step 3 to Step 2, and 4. Set the CCR to Step 5 and adjust the HIGH control that the light switches off completely when the CCR CCW until the HIGH LED just comes on. is switched from Step 2 to Step 1. 5. Set the CCR to Step 4 and verify that the HIGH LED 5. Recheck each light in the system. It may be necessary goes off. If not, you may need to adjust the HIGH to readjust some lights after all lights are operational control slightly CW until it does. and flashing. 6. Set the CCR to Step 2 and verify the MED LED goes Style 2 Current Regulator — Three Intensity Lev- off. els 7. Recheck the light at all current steps and verify that For this style, the lighting system switches on when the LEDs respond correctly at each step. Make trimming CCR is at Step 1 and switches to progressively higher adjustments if necessary. Also verify by visual com- intensities as you switch the CCR to higher steps. parison that flashing intensity decreases when the CCR is switched from Step 5 to Step 4, and that it 1. Turn the HIGH, MED, and LOW controls fully CW. decreases further when the CCR is switched to Step 2. Set the CCR to Step 1 and adjust the LOW control 2. CCW until the LOW LED just comes on. 8. Recheck each light in the system. It may be necessary 3. Set the CCR to Step 3 and adjust the MED control to readjust some lights after all lights are operational CCW until the MED LED just comes on. and flashing.
FTS 430/830 Revision 10 — 01-05-2016 1-5 This page is intentionally blank.
1-6 Revision 10 — 01-05-2016 FTS 430/830 Section 2 — Outline, Mounting, and Installation
Unpacking FH 800 Flashhead Screws fasten the bezel ring, which retains the flashtube, Inspect shipping cartons for signs of damage before open- ing. Check package contents against the packing list and to the housing. Remove the screws and bezel, and then inspect each item for visible damage. Damage claims remove the flashtube for access to the interior. should be reported promptly to the freight handler. Mounting Tools ATTENTION The following are hand tools suggested for installation Each light is packaged in its own ship- and maintenance: ping carton. The position at which the light is to be installed is marked on the • #2 Phillips-head screwdriver outside of the carton and on an ID label on the outside of the power converter. • #2 flat-blade screwdriver Refer to Figure 2-1 and Figure 2-2 to identify positions. • 1/8" flat blade screwdriver (for adjustments)
• Spanner wrench (or large slip-joint pliers) for 2-inch The light’s position is particularly important in a system conduit locking nut of sequentially flashing lights. In-general, lights at the runway threshold are labeled A and B. Sequential lights • TriplettTM Model 630-NA VOM, or equivalent analog are labeled numerically in the order of the flashing volt-ohm meter sequence. Thus PC #1 is to be installed farthest from the runway threshold. Access Mounting and outline information for the FTS 430 and WARNING FTS 830 Systems are shown in: Figure 2-3, Figure 2-4, Figure 2-5, Figure 2-6, and Figure 2-7. Use the following Before proceeding, read the warning on Page iii. Disconnect primary power guidelines: before opening the enclosure. • Allow adequate space around the equipment for Power Converter access during installation and service. Connect the power converter to a grounding rod or the Five latches secure the cover. Turn the latch handles to • release the cover, which swings open for access. site grounding system, but not to the counterpoise. See the installation guideline in Figure 2-8.
FH 400 Flashhead Installation Retaining clips secure the lens. Loosen the two screws that hold each of these to turn and then lift the lens off the This manual may not contain all the information about base. installation wiring for your installation.
FTS 430/830 Revision 10 — 01-05-2016 2-1 NOTE If any components have been removed, and you want to close the cover, which casues If installation drawings prepared specifi- the interlock switch to apply power, you cally for your site disagree with informa- MUST ensure that TB1, terminals 10 and 11 tion provided in this manual, the site are shorted to each other. If you do not do installation drawings should take prece- this, damage will occur and it is not covered dence. Consult any site-specific installa- under warranty. tion wiring diagram supplied with your equipment. You can connect FTS 430 or 830 lights directly to the series runway lighting circuit through the same type of FTCA wiring diagrams define only minimum require- isolation transformer used for incandescent runway edge ments recommended for satisfactory equipment opera- and threshold lights. In this case, a voltage conversion tion. It is the responsibility of the installer to comply with adaptor is not required. all applicable electrical codes. You may couple FTS 430 and FTS 830 Systems directly Conduit and other distribution wiring details can be found to the series runway lighting circuit through a Type on electrical installation diagrams provided by FTCA or L-830-10 or Type L-830-11 (300 watt) isolation trans- others. former. You must use one isolation transformer for each light. Figure 2-1 Typical REIL Configuration on Page 2-4 shows a typical REIL configuration. For the FTS 430, the Fixed rules regarding the size (power rating) of the con- two lights are functionally and physically interchange- stant current regulator required for FTS 430 or FTS 830 able. The master light is designated as A. Although these Systems are difficult to establish because of the following lights flash simultaneously, lights for positions A and B installation variables: should not be interchanged unless each one is re-aimed. The factory presets aiming for the position. Flashheads 1. The number of steady burning runway lights taking are typically comounted with power converters for REIL power from the same series lighting circuit applications. 2. The number of FTS 430 or FTS 830 lights
Figure 2-2 Typical ALS Configurations on Page 2-5 3. The flash rate (60 or 120 FPM) of the FTS 430 or shows a typical RAILs. The five RAILs are labeled from FTS 830 System 1 to 5 to identify their positions; the light with the lowest However, general practice has led to the guidelines in number is located farthest from the runway and is the first Table 2-1. The recommended sizes allow up to 50% of the to flash. RAILs are typically configured by mounting rated capacity for shared loading with steady-burning power converters and flashheads as separate units. The runway and approach lights. two REILs are labeled A and B, with the master light as A.
Power Rating Guidelines Table 2-1 L-828 Power Rating Guidelines Number of Constant Current EQUIPMENT CAUTION! FTS Approach Lights Regulator Rating Do not apply power to this equipment if any 2-7 4 KW Printed circuit board, or any components 8-15 7.5 KW have been removed. Serious damage will occur! 16-21 10 KW
2-2 Revision 10 — 01-05-2016 FTS 430/830 EQUIPMENT CAUTION! converter. You must use five conductors. FTCA PN 6340 Do not attempt to operate this equipment cable is recommended. from a voltage adaptor. Connection to a voltage adaptor could cause internal dam- Ground all cases. FTCA provides a grounding lug on age and will void the warranty. each power converter base. Install a grounding rod at each unit. Do not ground to the counterpoise for lightning pro- Isolation Transformer tection. When the series line is driven by a Class 1 (6.6 ampere) constant current regulator, each light should be coupled to Installation Checklist the series line through a Type L-830-10 (6.6/6.6 amperes, 300 watt) isolation transformer. If the series line is driven Carry out the following steps before applying power: by a class 2 (20 ampere) constant current regulator, each light should be coupled to the series line by a Type 1. Inspect equipment for shipping damage. L-830-11 (20/6.6 amperes, 300 watt) isolation trans- 2. Verify equipment against the packing list to ensure former. Either a Style 1 (3 current steps) or a Style 2 (5 completeness. current steps) regulator may be used. 3. Examine and verify installation drawings. 4. Position and mount each unit correctly according to Wiring packaging and labeling. 5. Ensure that the case is mounted upright, water-tight, Figure 2-8 provides wiring guidelines for FTS 430 or and grounded. FTS 830 Systems. 6. Check to ensure that all mounting hardware is tight. Connect the power from the airport series line to an isola- 7. Ensure that no holes are punched or drilled in the top tion transformer (FAA Type L-830) placed near each surface of the case. power converter. Connect each transformer to its respec- 8. Wire units according to instructions. tive power converter by using two conductors. 9. Check for proper series current. 10. Check all electrical connections for tightness. All power converters must be interconnected for synchro- nous timing with two unshielded #14 AWG (or larger) 11. Check all terminal strip connections for tightness. conductors, twisted together (6 turns per foot is recom- 12. Ground the power converter. mended). NOTE: FTCA recommends 600 Volt insulation 13. Install the proper isolation transformer (L-830) to on all wires that interconnect the lighting system. match series line current (either 6.6 to 6.6 amp or 20 to 6.6 amp). FTCA recommends a counterpoise using bare solid cop- 14. Do not use voltage adaptors. per. When you are certain that the installation is correct and When you mount flashheads separately from power con- complete, use the set-up instructions in Section Setup on verters, wire each flashhead to its corresponding power Page 1-2.
FTS 430/830 Revision 10 — 01-05-2016 2-3 43000021 Figure 2-1 Typical REIL Configuration
2-4 Revision 10 — 01-05-2016 FTS 430/830 43000022 Figure 2-2 Typical ALS Configurations FTS 430/830 Revision 10 — 01-05-2016 2-5 12.3 (311)
2" NPT PIPE (NOT SUPPLIED) 2.25 (57.2) FRANGIBLE (NOMINAL) COUPLING GROUND LEVEL
PAD
2.38 DIA (60.5)
14.0 (356)
8.00 NOTE: (203) 1. DIMENSIONS ARE IN INCHES (MILLIMETERS). 20.0 (508)
43000023 Figure 2-3 PC 430 or PC 830 Power Converter Mounting and Outline 2-6 Revision 10 — 01-05-2016 FTS 430/830 16.5 (419)
LEVELING NUTS (3 PLACES)
13.5 (343) DIA.
NOTES: 1. WIND AREA = 1 SQ.FT. (.09 SQ.M.) 2. DIMENSIONS ARE IN INCHES (MILLIMETERS). 3. EXTRA HOLE IS USED WHEN FLASHHEAD IS MOUNTED ON A FRANGIBLE MAST.
2.38 (60.3) DIA MOUNTING HOLE IN LEVELING PLATE
1.06 (27) DIA
43000024 Figure 2-4 FH 400 Flashhead Mounting and Outline FTS 430/830 Revision 10 — 01-05-2016 2-7 15.0 (381)
LEVELING SCREWS (3 PLACES)
28.5 (724)
12.3 (311)
2" NPT PIPE (SUPPLIED BY OTHERS)
FRANGIBLE 2.25 (57) NOMINAL COUPLING GROUND LEVEL
PAD
14.0 (356) CL
8.00 NOTE: (203)
1. DIMENSIONS ARE IN INCHES (MILLIMETERS) 20.0 (508) 25 (635)
43000025 Figure 2-5 FTS 430 Comounted Unit Mounting and Outline 2-8 Revision 10 — 01-05-2016 FTS 430/830 8.9 (226)
6.7 (170)
15°
11 (273)
7.80 (198)
2.38 DIA (60.5) 5.25 (133)
FH800MO Figure 2-6 FH 800 Flashhead Mounting and Outline FTS 430/830 Revision 10 — 01-05-2016 2-9 24.5 (622)
12.3 (311)
2" NPT PIPE (SUPPLIED BY OTHERS)
FRANGIBLE 2.25 (57) NOMINAL COUPLING GROUND LEVEL
PAD
14.0 C (356) L
8.00 NOTE: (203)
1. DIMENSIONS ARE IN INCHES (MILLIMETERS) 20.0 (508) 25 (635)
800CMUMO Figure 2-7 FTS 830 Comounted Unit Mounting and Outline 2-10 Revision 10 — 01-05-2016 FTS 430/830
SHIELD PUR
PN 6340CABLE (TYPICAL ALLLIGHTS)
WHT
BLK
FH800 RED BLU NOTE 1 NOTE COUNTERPOISE 7-7257-02D SHIELD
RED BLU BLK WHT PUR SHIELD 1 2 3 4 5 6 7 8
GND GND TB2 PUR
NOTE 2 NOTE FROM SYSTEM CURRENT REGULATOR TRANSFORMER 300W 6.6 TO 6.6A TO 6.6
L-830-10 TYPICAL LINE TYPICAL ISOLATION
TRIG RTN TRIG
WHT ANODE FTCA BY SUPPLIED NOT
TRIGGER TRIG RTN TRIG
CATHODE
BLK
FH 400 FH CATHODE BLU
PRIMARY POWER (2.8 TO 6.6A) TO (2.8 NOTE 3 NOTE ANODE
GND CONTROL RED 1 2 3 4 5 6 7 8 9 10 11 TB1 SEE ALARM 5. NOTE REIL PAIR CONTROL RTN PC 430 OR PC 830 NOTE 2 NOTE (TYPICAL)
FLASHHEAD IF CO-MOUNTED) (NOT AT REQUIRED
SHIELD
PUR
WHT
BLK
FH 800 RED BLU SHIELD
BLU BLK WHT PUR RED SHIELD
1 2 3 4 5 6 7 8
GND GND TB2 PUR
NOTE 2 NOTE
TRIG RTN TRIG
WHT
ANODE FTCA BY SUPPLIED NOT #14 AWG 600VAC, MIN.
TRIG TRIGGER
TRIGRTN CATHODE
BLK
FH 400 CATHODE BLU
PRIMARY POWER (2.8 TO6.6A) NOTE 3 NOTE
ANODE
GND CONTROL RED 1 9 5 6 7 8 2 3 4 10 11 TB1 SEE (2 SEPARATE WIRES TWISTEDTOGETHER, UNSHIELDED) ALARM 5. NOTE CONTROL RTN PC 430 OR PC 830 PC OR PC 430
OR FLASHHEADS WITH MAY BE CO-MOUNTED POWER CONVERTERS OR MOUNTED SEPERATELY UPFEET 150 TO AWAY. SYSTEM AND FLASHHEAD TYPES BE CANNOT INTERMIXED. USE FH 800 FLASHHEADS SYSTEMS 830 FTS WITH USE FH 400 FLASHHEADS SYSTEMS 430 FTS WITH
SHIELD
PUR
WHT
BLK
FH800 RED BLU SHIELD RED BLU BLK WHT PUR 1 2 3 4 5 6 7 8
GND
TB2 NOTE 2 NOTE ANODE FTCA BY SUPPLIED NOT
TRIGGER
TRIGRTN CATHODE
SHIELD PRIMARY POWER (2.8 TO 6.6A) TO (2.8 NOTE 3 NOTE
GND GND CONTROL PUR
1 2 3 4 9 5 6 7 8
10 11
TRIG RTN TRIG TB1
WHT
TRIG SEE BLK
ALARM 5. NOTE
FH 400 CATHODE CONTROL RTN BLU
ANODE PC 430 OR PC 830 RED CONTROL SERIES LINE 2.8 - 6.6 AMP 6.6 - 2.8 TO COUNTERPOISE NOT RECOMMENDED. NOT COUNTERPOISE TO COUNTERPOISE WIRED THE SAME WAY. SAME THE WIRED UNIT FOR INTENSITY CONTROL. REFER TO EQUIPMENT MANUAL. IF USED USED IF FTS 830 LIGHTS 830 FTS TO ADDITIONAL 1. BARE COPPER WIRE RECOMMENDED FOR COUNTERPOISE 5. ALARM IS OPTIONAL EQUIPMENT. CONTACTS FAIL. OPEN ON 2. DENOTES GROUNDING ROD GROUNDING CONNECTION. 3. THIS EQUIPMENT IS PHASE SENSITIVE. ALL MUST UNITS BE 4. SET UP ADJUSTMENTS MAY BE REQUIRED AT EACH LIGHTING
43083028 Figure 2-8 Typical FTS 430/830 System Installation Wiring FTS 430/830 Revision 10 — 01-05-2016 2-11 TO FLASHHEAD WHT RED PUR BLU BLK
WHT/GRN 3-7418-01X 21 YEL TB1 PCB3 SHIELD
SENSE
MODULE WHT/BLU ANODE TRIGGER TRIG RTN TRIG CATHODE
T1 ANODE INTERLOCK TRIG RTN TRIG GRN CATHODE TRIGGER 1 2 3 4 5 6 7 8 1 2 TB2 TB2 QC3 QC4 BLU RED RED RED GRN BLU WHT/BLU T3 QC5 QC6 COUPLING RED
TRANSFORMER BRN BLU SEE NOTE 3 SEE NOTE GRN RED LOW 4 NOTE 5 NOTE 3 3 4 2 5 1 6 YEL 11 FLASH DETECTION RELAY K3 RED GRY
7
K2 10 BLU 8 9 RELAY K2-3 AND TB4-5 AND K2-3 TO MOVED ARE TB2-1 WIRES FROM TB2-2. 7 8 6 5 P3 YEL 1 2 P1 MED MODE MED
TB4 ORN IN AC RED
GRN
R2
R1 WHT/RED
GRN 11
-HV
ORN BLU BLU P4
P2
9 BLU
ORN
810
HV 3 HV
R4 YEL
7
MED YEL
L2 NOTE 2 NOTE 1 HV
RED HV 2 HV PCB2
FLASHCHOKE BLU WHT/ORN
1 2 NOTE 5 NOTE
456 HV RECTIFIER AC IN AC
ORN GROUND BLU 4 3
HIGH
GRN 12 3 YEL GRN K1 WHT/GRN G1
7 RELAY 6 GRN 5 8 2 1
HIGH HIGH MODE GRN YEL YEL
GRN
TB3 GRN
YEL SIGNAL TRIGGER GRN BLU
11 GROUND
HIGH MODE RELAY MODE HIGH
GRN
YEL 9
MED MODE RELAY MODE MED
RED
2.8 - 6.6A 6.6A - 2.8
WHT/GRY 78 10
CONTROL SIGNAL CONTROL
BLK
2.8 - 6.6A 6.6A - 2.8 WHT/BLK
NOTE 1 NOTE
24VAC
WHT/BRN 3456
24VAC
WHT/VIO 3 4 POWER OPTION
PCB1 12 TIMINGTRIGGER & GRY T5 NC NO WHT/RED GRN ISOLATION WHT/ORN 1 2 TRANSFORMER 1 2 3 4 5 T1 7 6 S1 INTERLOCKS1 COM HIGH VOLTAGE HIGH BLK 2 TRANSFORMER BLK BLK WHT/BLK BLK T4 G2 BLK 31 4 LOW VOLTAGE LOW TRANSFORMER R3 BRN WHT/BLK GRN BLK BLK RED BRN RED GRY RED C1,2,6 C5 C7 RED RED PC 830 1 2 3 4 5 6 7 8 9 10 11 TB1 C1,2 C5,6 PC 430 VR2 ALARM ALARM NOTE 4 NOTE BLK BRN YEL GND HIGH MED LOW C7 2.8 - 6.6AMP - 2.8 6.6AMP - 2.8 5 2 CONNECTWHT/RED TO T1-2 CONNECTWHT/ORN TO T1-4.
A B CONTROL
WHEN WIRING FOR PC 830: GRY 1. SHOWNWIRED FOR PC430. 5. CAPACITORSBANKS: 3.FLASH MONITOR(OPTION). 2.ELAPSED TIME METER (OPTION). 4.FLASH INTERLOCK(OPTION). FAIL 7 CONTACTS OPEN ON K4 INTERLOCK RELAY INPUT POWER
430830IW Figure 2-9 PC 430 or PC 830 Power Converter Internal Wiring 2-12 Revision 10 — 01-05-2016 FTS 430/830 FT101 FLASHTUBE
T101 TRIGGER TRANSFORMER
RC101 BLK BLU RED PUR WHT
71 Figure 2-10 FH 430 or FH 830 Flashhead Internal Wiring 2-13 FTS 430/830 Revision 10 — 01-05-2016 FH 83F-2 Inset Light The FH 83F-2 is used in MALSR or ALSF sequenced flashing approach lighting systems, or wherever inset lights are preferred over elevated lights. It is available for both voltage and current-driven applications and is compatible with all Flash Technology FTS 800 Series Unidirectional Approach Systems. It may be remotely controlled and monitored with the FTC 183 Airport Approach Lighting System Controller.
• Dimensions: 6.1 Inches Tall X 12 Inches Wide; 304.5 X 155 mm • Weight: 16.5 lbs (7.5 kg) • IP 67 / NEMA 6 Rating
Figure 2-11 FH 83F-2 Outline and Wiring
2-14 Revision 10 — 01-05-2016 FTS 430/830 ATTENTION! THIS DRAWING IS ONLY INTENDED FOR USE AS GENERAL AIRFIELD SYSTEM DESIGN GUIDANCE. THE DESIGNER MUST VERIFY DESIGN WITH LOCAL CODES AND VARYING CHARACTERISTICS FOR EACH UNIQUE AIRFIELD APPLICATION.
Figure 2-12 FH 83F-2 Sample Installation
FTS 430/830 Revision 10 — 01-05-2016 2-15 This page is intentionally blank.
2-16 Revision 10 — 01-05-2016 FTS 430/830 Section 3 — Maintenance and Troubleshooting
Safety 4. Check flashtube connections for signs of pitting or arcing. Verify that anode and cathode connections are SAFETY firmly tightened. STOP: Before proceeding—read the 5. Check all electrical connections for tightness and ver- warning on Page iii. ify the absence of corrosion or electrical arcing. 6. Clean the outside surface of the FH 800 glass with Work safely as follows: liquid detergent and water. Wipe it gently with a soft cloth or paper towel. 1. Remove rings and watches before opening the equip- 7. Clean the outside and inside surface of the FH 400 ment. lens with an FTCA-approved professional plastic 2. Shut off the equipment. cleaner. Wipe lens with cheesecloth only. Do not use 3. Remove the component or connect the test instru- regular cloth or paper towels. ments. 4. Replace the component. 5. Turn on the power and test the system. 6. Turn off the power and disconnect the test equipment. Storage No special considerations are required for long-term stor- EQUIPMENT CAUTION! Do not apply power to this equipment if age of any major assembly. Keep circuit boards, when not any Printed circuit board, or any compo- installed in the equipment, in anti-static bags or contain- nents have been removed. Serious ers. damage will occur!
If any components have been removed, Diagnostic Testing and you want to close the cover, which In performing functional tests, observe the operation of automatically applies power because of the system or of individual lights as you step the input the interlock switch, then you MUST ensure that TB1, terminals 10 and 11 current from one level to another. You must understand are shorted to each other. If you do not what is proper operation at this particular installation; that use this procedure, damage will occur is, how the equipment was set up initially (see Section 1 and it is not covered under warranty. — FTS 430/830 Introduction and Operation). If the sys- tem does not operate exactly according to its set up, you may need to repeat the set-up adjustments described in Preventive Maintenance Section 1. Carry out the following inspection and cleaning proce- Line interference or an incompatibility between the dures at least twice a year: power system and the lights may prevent obtaining the desired set-up performance of the system. If only one light 1. Verify that moisture does not enter the equipment fails to set up properly, a malfunction in that particular through gaskets or seals, or collected inside as con- light may be the cause. densation. 2. Verify that all drain holes are clear. 3. Check terminal blocks and relays for evidence of cor- Control Line Interference rosion and electrical arcing. Clean or replace any Electrical interference on the control line can cause sys- component that shows evidence of high-voltage dam- tem problems. Interference can occur if the line is open, age. shorted, or not a twisted pair. Suspect a control line prob-
FTS 430/830 Revision 10 — 01-05-2016 3-1 lem if all units respond correctly to checkout only when Wires or cables that move repeatedly will ultimately you disconnect the control wire. Sometimes, you can break. Ensure that all cables (the flashhead cable in par- eliminate marginal interference by placing a 470 ohm ticular) are securely fastened at short intervals to the resistor from the control line terminal to the component structure or other supports. bracket at one or more lighting units. Inspection Component Testing Closely inspect the units and check the connections Always make resistance measurements with the primary against the installation instructions. Also, a close inspec- power turned off. However, you must make voltage mea- tion may reveal insulation breakdown, an overheated surements with the power applied. Thus, for your safety, component, corrosion, loose connections, faulty relays, carry out all preliminary steps such as connecting test incorrect hookup, and so forth. leads or circuit jumpers, or disconnecting existing circuit connections with the power off. Relays (K1, K2) Capacitors A malfunctioning relay may have faulty contacts, a sticky mechanism, or a defective coil. Determine the first two Evaluate the condition of a capacitor with an analog possibilities by inspection and manually exercising the volt-ohmmeter operating in the resistance mode. The fol- armature. Confirm a defective coil by measuring its resis- lowing method assumes an instrument with a X100 resis- tance. To measure the resistance of relay coils, first tance scale. remove the wires from one of the connections to the coil terminals on the relay. The measured coil resistance for Place the meter leads across the terminals of an isolated both relays should be approximately 290 ohms. (no electrical connections to other circuits) and fully dis- charged capacitor. Observe the subsequent needle move- ment. Timing and Trigger Board (PCB1) Carry out the adjustment procedures in Section 1 before If the capacitor is functional, the needle initially indicates concluding that PCB1 is faulty. Then replace this circuit zero ohms, but soon begins to rise to higher indicated val- board with one known to be in good condition. You must ues. A capacitor that is disconnected from other circuitry remove the programming matrix (see Figure 1-1 for loca- is defective if it does not exhibit this behavior. The length tion) from the existing circuit board and plug it into the of time it takes the needle to reach the 1-megohm reading replacement board. (about 65% full-scale) is a measure of the capacitance. For example, the time is about 5 seconds for a 10-mfd. capacitor, or 10 seconds for a 20-mfd. capacitor, and so HV Rectifier Board (PCB2) forth. Replace this circuit board with one known to be in good condition. Manually discharge the capacitor before repeating this measurement. This test may not detect a malfunction that occurs only at high voltage. Bleed Resistor (R1, R2)
A bank of capacitors connected in parallel may be The resistance of R1 is 35 kohms. The resistance of R2 is checked as a single unit. If the test indicates a short cir- 50 kohms. cuit, the individual capacitors have to be disconnected and checked separately. A shorted capacitor is indicated if Interlock Switch (S1) the resistance does not rise above zero after several sec- onds of measurement. Readjust the interlock switch bracket, if necessary.
Wiring and Cabling Flashtube (FT101)
3-2 Revision 10 — 01-05-2016 FTS 430/830 Visually inspect the flashtube for broken electrodes, Replacement cracked glass, and the solder connections of the pins. A Reverse the removal procedure. Verify the wiring with darkened envelope doses not necessarily mean the light Figure 2-9. output would be unacceptable. Before concluding that a faulty flashtube is responsible for an inadequate flash, Low Voltage Transformer (T4) first rule out other possible causes such as weak or absent discharge voltage or triggering pulses. Removal 1. Disconnect wires leading to the transformer. Trigger Transformer (T101) 2. Remove the two screws holding the transformer to the side of the chassis and remove transformer from The measured resistance of the secondary winding (pot- the chassis. ted assembly) should be approximately 150 ohms. Check the ferrite core for cracks. Check the mounting screws for Replacement tightness. Reverse the removal procedure. Verify the wiring with Figure 2-9.
High Voltage Transformer (T1) Trigger Coupling Transformer (T3) Measure the voltage between the terminals TB4-3 and Removal and replacement are similar to the procedure for TB4-11 on PCB2. The voltage should be between 900 the Low Voltage Transformer. and 1050 volts AC. Timing and Trigger Board (PCB1) Component Removal and Removal Replacement 1. Loosen, but do not remove, all eleven screws holding the circuit board to TB3. For the power converter, refer to Figure 4-1 and Figure 2. Loosen the screws at the top that hold the board to the 2-9. chassis and lift the board from TB3. Replacement High Voltage Transformer (T1) 1. To replace PCB1 with a spare board, remove the pro- Removal gramming matrix from the existing board and insert it 1. Disconnect wires leading to the transformer. into the replacement board. See Figure 1-1 for the 2. Remove four screws holding the transformer to the location of the programming matrix. rear of the chassis and remove the transformer from 2. Reverse the removal procedure. the chassis. HV Rectifier Board (PCB2) Removal and replacement are similar to the procedure for PCB1 (except for programming).
Capacitors Removal 1. Disconnect wires leading to the capacitors. 2. Remove the hold-down screws. Lift the capacitors from their receiving holes and away from the chassis. Replacement Insert capacitors into their respective receiving holes.
Replace hold-down screws to secure capacitors to the chassis.
FTS 430/830 Revision 10 — 01-05-2016 3-3 Reconnect wires to capacitors and verify the wiring with 2. Carefully pry the flashtube free of the neoprene Figure 2-9. Wires must be replaced exactly as removed. washer around the edge. In some instances, a quick-connect wire terminal will not 3. Lift out the flashtube assembly and disconnect the seat properly if it is not placed on the terminal cluster attached wires. Note the color of the wires and their exactly as it was before removal. This is caused by inter- connections. ference between the insulation on the wire terminal and the insulation surrounding the terminal cluster on the Replacement capacitor. 1. Connect the flashhead wires to the flashtube. 2. Place the flashtube so that its edge rests squarely on Flashhead the neoprene washer on the base. 3. Rotate the flashtube so that the small arrow on the For the flashhead refer to Figure 4-2, Figure 4-3, and Fig- edge of the lens aligns next to the tiny hole at the ure 2-10. edge of the base lip. 4. Fasten the flashtube by re-attaching the bezel to the WARNING flashhead using the three screws and nuts previously Before opening the flashhead, verify that the power converter has been disabled removed. and that the capacitors have been com- Trigger Transformer (T101) pletely discharged. Removal FH 400 Lens 1. At the trigger wire post adjacent to the flashtube, remove the large diameter wire coming from the trig- Removal ger transformer. 1. Loosen the two screws holding down each of three 2. Remove the two smaller wires originating at the trig- clamps. ger transformer from the ceramic spacers. Do not dis- 2. Rotate the lens so that the hold-down tabs slide out connect the primary winding wires (seven turns of from under the clamps, and then lift the lens free. hook-up wire). Replacement 3. Remove the two 4-40 x 2" Phillips-head screws hold- 1. Place the lens so that its bottom rests on the base. ing the transformer assembly to the bracket. Note the 2. Rotate the lens so that its hold-down tabs slide under orientation of the molded secondary winding with the clamps. Tighten the two screws on each of the respect to fixed features on the bracket, since it must three clamps to secure the lens. be re-installed with this same orientation. 4. Remove the outer half of the core and lift off the FH 400 Flashtube (FT101) molded secondary winding. The seven turns of the Removal primary winding will remain hanging in place. Loosen the three screws on the three screw lugs to free 5. Remove the inner half of the core, taking care not to the flashtube base pins then lift the flashtube from the uncoil any turns of the primary winding. assembly. Replacement Replacement 1. Re-assemble the primary and secondary windings Align the pins on the flashtube base with the clamps of over the two halves of the core. Attach the core to the the terminal screw lugs and insert the pins into place. bracket using the two long screws. Tighten the screws on the terminal screw lugs to secure 2. Re-attach the electrical wires. Verify that the wiring the flashtube. agrees with Figure 2-10.
FH 800 Flashtube (FT 101) Troubleshooting Removal 1. Remove the three screws and nuts holding down the The most effective troubleshooting procedure begins with flashtube bezel. accurate observations of the system's operation. These
3-4 Revision 10 — 01-05-2016 FTS 430/830 observations often lead directly to the cause of a problem. System-Level Problems The diagnostic procedures in this subsection are divided into two categories: system-level malfunctions, where all Table 3-1 identifies symptoms affecting all lighting units lighting units exhibit the same abnormal behavior; and in the same way. Use it to determine possible causes.W symptoms applying to one or more individual lighting units, but not to all of them.
Table 3-1 System-Level Troubleshooting Flash Other Probable Conditions Conditions Cause
High Med. Low No No No Series current too low
Weak Weak OK PCB11
Weak OK OK PCB11
OK Bright Bright PCB11 No No No Series current too low
OK OK Bright PCB11 Series current No OK OK too low2 Units may flash out Control line OK OK OK of sequence interference3,4 1. Improper adjustment causes most PCB1 problems. If adjustments cannot be made or do not solve the problem, replace the board. 2. High intensity can be achieved only at the highest (6.6 amp) current step. 3. Control wires that are not a twisted pair can cause interference. 4. Control lines exceeding about 7500 feet (2500 meters) may have too much distrib- uted capacitance. Operation may be improved by installing a 470 ohm resistor from TB1-1 to the chassis on one or more lighting units.
FTS 430/830 Revision 10 — 01-05-2016 3-5 Problems with Individual Lights the presence of low voltage (LV). The symptom best describing this condition is No No No OK OK. This Table 3-2 identifies symptoms that apply to a particular symptom has three possible causes listed. The most likely lighting unit. cause, the first one listed, is the flashtube; the next likely cause is PCB1, and so on. Each symptom has one or more suggested causes listed in descending order of probability with the most probable All neon lights out on PCB2 indicates the absence of HV. cause first. As an example, suppose one of the lights does LEDs out on PCB1 indicates the absence of LV. not flash in any mode (low, medium, high), but mode relays operate and circuit board LEDs are lit, indicating
Table 3-2 Lighting Unit Troubleshooting Flash Other Probable Conditions Conditions Cause
High Med. Low HV LV No No No No No S1 No No No No OK PCB2 No No No OK No PCB1 FT 101 No No No OK OK PCB1 T102 No No OK OK OK PCB2 PCB2 OK OK No OK OK PCB1 C3 K1 OK Bright Bright OK OK PCB2 PCB1 K1 Weak OK OK OK OK PCB1 K2 Weak Weak OK OK OK PCB1 K2 OK OK Bright OK OK PCB1 Skips Skips Skips OK OK FT101
3-6 Revision 10 — 01-05-2016 FTS 430/830 Section 4 — Replaceable and Spare Parts
Customer Service Flashhead Parts Table 4-2 Customer Service: 1-800-821-5825 lists the parts for emergency repairs. Telephone: (615) 261-2000 Returning Equipment Facsimile: (615) 261-2600 Shipping Address: A Return Material Authorization (RMA) number is required for all equipment returned to Flash Technology. Flash Technology Corporation of America See Return Material Authorization, located at the end of 332 Nichol Mill Lane this document, for complete details regarding the RMA Franklin TN 37067 process. To obtain an RMA number, please have the equipment serial number and/or sales order number available and call Technical Support @ 1-800-821-5825. Ordering Parts Repackaging To order spare or replacement parts, contact FTCA cus- tomer service. Figure 4-1, Figure 4-2, and Figure 4-3 You must return the equipment in a container that pro- show component locations. vides maximum protection during shipping and handling. If the original cartons and packaging material are no longer available, package the unit in a strong double cor- Power Converter Parts rugated carton.
Table 4-1 lists the parts for emergency repairs. Package and ship the unit with the mounting feet down- ward against the bottom of the box. Pad the unit so that the feet cannot penetrate the box during shipment. Box each unit separately using a double thickness cardboard container and adequate padding. Do not drop. Use appro-priate warning labels on the outside of the container.
FTS 430/830 Revision 10 — 01-05-2016 4-1 Table 4-1 Power Converter Replaceable Parts Unit Description Part No. Quantity 430 Capacitor, (C1), 20 mfd. 6731401 1 430 Capacitor, (C2), 40 mfd. 6386503 1 430 Capacitor, (C5), 15 mfd. 6731301 1 430 Capacitor, (C6), 15 mfd. 6731301 1 430 Capacitor, (C7), 8 mfd. 6731201 1 430 PCB Diode Matrix PC430 2903602 1 830 Capacitor, (C1), 20 mfd. 6731401 1 830 Capacitor, (C2), 70 mfd. 6720401 1 830 Capacitor, (C5), 15 mfd. 6731301 1 830 Capacitor, (C6), 15 mfd. 6731301 1 830 Capacitor, (C7), 5 mfd. 6731101 1 830 PCB Diode Matrix PC830 2903601 1 All Choke, Flash (L2) 4175200 1 All Elapsed Time Meter (optional) 1749201 1 All Enclosure 3727901 1 All Flash Monitor Module (K3; optional) 1851001 1 All HV Rectifier Board (PCB2) 2711402 1† All Interlock Switch (S1) 4901220 1 All Relay, Mode (K1, K2) 8900494 2† All Resistor, Bleed (R1), 35K 6900541 1 All Resistor, Bleed (R2), 50K 6900542 1 All Resistor, 1K 1W (R3) 8435211 1 All Resistor, 1K 2W (R4) 8435212 1 All Resistor, 1M 2W (R5) 8435206 1 All Spacer, Ceramic 5900844 2 All Terminal Strip, 8-Position (TB2) 8721008 1 All Terminal Strip, 11-Position (TB1, TB3, TB4) 8721011 3 All Timing and Trigger Board (PCB1) 2730300 1†‡ All Transformer, Power (T1) 4738302 1 All Transformer, Trigger Coupling (T3) 8336701 1 All Transformer, Low Voltage (T4) 4734500 1 All Transformer, Isolation (T5) 4852801 1 All Varistor (VR2) 6901079 1 † Recommended as a spare part. ‡ Remove the programming matrix from the existing installed board and insert it into the new replacement board..
4-2 Revision 10 — 01-05-2016 FTS 430/830 3-7418-01X TB2 T5 2345678 T4 1 END VIEW G2 11 PCB3 10 S1 (OPTION) T1 7 R4 R1 PCB2 K3 R2 2 REAR VIEW REAR 19 K1 TB4 8 ELAPSED TIME METER (OPTIONAL) METER TIME ELAPSED C7 11 10 G1 FRONT VIEW FRONT C2 9 R3 L2 PCB1 C1 C5 C6 T3 TB1 2 1 3 4 5 6 7 8 9 K2 10 11 2345678 ETM 1 TB3 VR2
62 Figure 4-1 PC430 or PC 830 Power Converter Component Locations FTS 430/830 Revision 10 — 01-05-2016 4-3 Table 4-2 Flashhead Replaceable Parts Unit Description Part No. Quantity FH 400 Lens 8743701 1 FH 400 Trigger Transformer (T101) 8288201 1† FH 400 Clamp, Lens 3893201 3 FH 400 Spacer, Ceramic 5900844 4 FH 400 RC Network (RC 101) 1403411 1 FH 400 Flashtube 8384329 1† FH 400 Terminal Screw Lug 3379102 3 FH 400 Spacer, Ceramic 5900842 4 FH 400 Coupling Transformer 7/50 wrap 8336701 1† † FH 800 Flashtube (FT 101) 8901701 1† FH 800 RC Network (RC 101) 1403411 1 FH 800 Trigger Transformer (T101) 8288201 1† FH 800 Post, Ceramic 5900842 4 FH 800 Retaining Bezel 3735202 1 FH 800 Coupling Transformer 7/50 wrap 8336701 1† † FH 83F-2 Flashtube Linear FH83F-2 8675309 1† FH 83F-2 Terminal Block / 6 Position 4997031 1 FH 83F-2 Coupling Transformer 7/50 wrap 8336701 1 FH 83F-2 Trigger Transformer 8288201 1 FH 83F-2 Spacer, Ceramic 5900842 2 FH 83F-2 RC Network (RC 101) 1403411 1
† Recommended as a spare part. † † Only used if the FH 430 or FH 830 is mounted more than 40 Feet from it's associated PC.
4-4 Revision 10 — 01-05-2016 FTS 430/830 RC NETWORK SMALL BLUE SECONDARY WIRE FROM TRIGGER TRANSFORMER WHITE TRIGGER SECONDARY WIRE FROM TRIGGER TRANSFORMER
RED CONNECTING WIRE RED RED DOT
BLU BLUE CONNECTING WIRE BLK WHT PUR
RED BLUE FLASH HEAD BLUE WIRES CABLE BLACK CONNECTED WIRES WHITE TO FASTONS PURPLE AND GROUND ON PRIMARY COIL OF TRANSFORMER
LENS
LENS CLAMP (3 PIECES) FLASHTUBE
CERAMIC RC NETWORK POSTS WHITE TRIGGER SECONDARY WIRE
BLUE SECONDARY FASTONS WIRE CERAMIC POSTS
RED DOT TRIGGER TRANSFORMER
BLUE WIRES WITH FASTONS
63 Figure 4-2 FH 400 Flashhead Component Locations FTS 430/830 Revision 10 — 01-05-2016 4-5 INDEX E A Elapsed time meter 1-2 Access 2-1 Equipment ALS returning 4-1 figure, typical configuration 2-5 storage 3-1 light alignment 1-1 F lights 1-2 FH 400 B flashtube, removal and replacement 3-4 Bleed resistor, testing 3-3 lens, removal and replacement 3-4 FH 800 flashtube C removal and replacement 3-4 Capacitor Flash failure monitor 1-2 removal and replacement 3-3 Flashhead testing 3-2 FH 400 Caution basic description 1-1 removed components 2-2 figure voltage adaptor 2-3 component locations 4-5 Checklist, installation 2-3 mounting and outline 2-7 Comounted unit FH 800 FTS 430, mounting and outline figure 2-8 basic description 1-1 FTS 830, mounting and outline figure 2-10 figure Component component locations 4-6 removal and replacement 3-3 mounting and outline 2-9 removed, caution 2-2 figure testing 3-2 internal wiring 2-13 Component location parts 4-4 figure Flashtube testing 3-3 FH 400 flashhead 4-5 FH 800 flashhead 4-6 G power converter 4-3 Grounding 2-3 Configuration figure H typical ALS 2-5 High voltage typical REIL 2-4 rectifier board Control line testing 3-2 connection 2-3 transformer interference 3-2 removal and replacement 3-3 Counterpoise 2-3 testing 3-3 Current regulator I Style 1 1-3 Individual lights, troubleshooting 3-6 setup 1-3 Installation three intensities 1-4 checklist 2-3 two intensities 1-4 control line connection 2-3 Style 2 1-3 counterpoise 2-3 setup 1-3 general 2-1 three intensities 1-5 grounding 2-3 Customer service 4-1 isolation transformer 2-3 D mounting 2-1 Diagnostic testing 3-1 tools 2-1 wiring 2-3
FTS 430/830 Revision 10 — 01-05-2016 I-1 wiring figure Problems typical 2-11 individual lights 3-6 Interference, control line 3-2 system level 3-5 Interlock switch, testing 3-3 R L REIL Label, indicating unit position 2-1 configuration figure Lighting unit, troubleshooting 3-6 typical 2-4 Locations lights 1-2 figure Relays, testing 3-2 flashhead components Removal and replacement FH 400 4-5 capacitors 3-3 FH 800 4-6 component 3-3 power converter components 4-3 FH 400 flashtube 3-4 Low voltage transformer, removal and replacement FH 400 lens 3-4 3-3 FH 800 flashtube 3-4 M high voltage transformer 3-3 Maintenance, preventive 3-1 low voltage transformer 3-3 Meter, elapsed time 1-2 timing and trigger board 3-3 Mounting 2-1 trigger coupling transformer 3-3 Mounting and outline figure trigger transformer 3-4 comounted unit Removed components, caution 2-2 FTS 430 2-8 Repackaging for shipment 4-1 FTS 830 2-10 Returning equipment 4-1 flashhead S FH 400 2-7 Safety 3-1 FH 800 2-9 Series runway circuit 2-2 power converter 2-6 Setup 1-2 O preliminaries 1-3 Operation 1-2 procedures 1-3 Options 1-2 Style 1 current regulator 1-3 Ordering parts 4-1 three intensities 1-4 two intensities 1-4 P Style 2 current regulator 1-3 Parts 4-1 three intensities 1-5 flashhead 4-4 Specifications 1-1 ordering 4-1 Storage 3-1 power converter 4-2 Style 1 current regulator PCB1 setup figure 1-4 three intensities 1-4 Position two intensities 1-4 unit label 2-1 Style 2 current regulator Power converter setup, three intensities 1-5 figure, component locations 4-3 System internal wiring figure 2-12 definition 1-1 mounting and outline figure 2-6 ALS 1-2 parts 4-2 REIL 1-2 Power rating 2-2 System level guidelines, table 2-2 problems 3-5 Preventive maintenance 3-1 troubleshooting 3-5
I-2 Revision 10 — 01-05-2016 FTS 430/830 T testing 3-3 Telephone numbers 4-1 Troubleshooting 3-5 Testing individual lights 3-6 bleed resistor 3-3 inspection 3-2 capacitors 3-2 lighting unit 3-6 components 3-2 system-level problems 3-5 diagnostic 3-1 wiring and cabling 3-2 flashtube 3-3 U high voltage rectifier board 3-2 Unit position, label 2-1 high voltage transformer 3-3 Unpacking 2-1 interlock switch 3-3 relays 3-2 V timing and trigger board 3-2 Voltage adaptor, caution 2-3 trigger transformer 3-3 Voltage conversion adapter usage 2-2 Timing and trigger board W figure 1-4 Wiring removal and replacement 3-3 figure testing 3-2 internal flashhead 2-13 Tools 2-1 internal power converter 2-12 Transformer, isolation 2-3 typical installation wiring 2-11 Trigger coupling transformer installation 2-3 removal and replacement 3-3 Wiring and cabling, troubleshooting 3-2 Trigger transformer removal and replacement 3-4
FTS 430/830 Revision 10 — 01-05-2016 I-3 Return Material Authorization (RMA) Policy
IF A PRODUCT PURCHASED FROM FLASH TECHNOLOGY MUST BE RETURNED FOR ANY REASON (SUBJECT TO THE WARRANTY POLICY), PLEASE FOLLOW THE PROCEDURE BELOW:
NOTE: An RMA number must be requested from Flash Technology prior to shipment of any product. No returned product will be processed without an RMA number. This number will be the only reference necessary for returning and obtaining information on the product’s progress. Failure to follow the below procedure may result in additional charges and delays. Avoid unnecessary screening and evaluation by contacting Technical Support prior to returning material. 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 2014B 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. Adequate packing 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 in appropriate 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 Technology Attn: RMA #XXX 332 Nichol Mill Lane Franklin, 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.
Revision 2014B RMA Policy ~~ End of Document ~~