SN FTS 400/800-4 Approach Lighting Systems Reference Manual P/N #7914008004 Flash Technology, 332 Nichol Mill Lane, Franklin TN 37067 (615) 261-2000 Front Matter Abstract This manual contains information and instructions for installing, operating, and maintaining the FTS 400 and 800 Approach Lighting Systems ® manufactured by Flash Technology , a Dielectric Company. Copyright ® Copyright © 1997-2003 Flash Technology , Franklin, TN, 37067, U.S.A. All rights reserved. Reproduction or use of any portion of this manual is prohibited without express written permission from Flash Technology and/or its licenser. Trademark Acknowledgments Flash Technology ElectroFlash ® is a registered trademark name. ™, Flash Tech™, Flash Technology™, FTCA™, Flash™ and the Flash Technology Logo are all trademarks of Flash Technology. All trademarks and product names mentioned are properties of their respective companies, and are recognized and acknowledged as such by Flash Technology. Applicable Specification This equipment meets or exceeds requirements for an FAA Type L-849 Styles A, C, and E, and Type L-859, Styles B, D, and F. Disclaimer While 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 from any 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 any person or organization of the revision. In no event will Flash Technology be liable for direct, indirect, special, incidental, or consequential damages arising out of the use of or the inability to use this manual. Warranty Flash Technology warrants all components, under normal operating conditions, for two years. Replacement Parts The use of parts not manufactured or supplied by Flash Technology or unauthorized modification of this equipment voids the warranty and could invalidate the assurance of complying with FAA requirements for Type L-849 Style A and E lights as published in Advisory Circular 150/5345-51. Pub. No. 0594-400/800-0009 ii Revision 1 — 12-11-2003 FTS 400/800-4 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 TB2 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 circuits with a voltmeter. Under no circumstances remove or alter any safety interlock switch. FTS 400/800-4 Revision 1 — 12-11-2003 iii Table of Contents Front Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trademark Acknowledgments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applicable Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1 — Introduction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elapsed Time Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FTC 435 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Up the FTC 435 Series Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Note the following abbreviations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Style 1 Current Regulator — Three Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Style 1 Current Regulator — Two Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Style 2 Current Regulator — Three Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 — Outline, Mounting, and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH 400 Flashhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH 800 Flashhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outline and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3 — Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Signal Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RFI Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Line Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Unit Checkout P/N 2652318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slave Unit Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Unit Checkout P/N 2904413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slave Unit Checkout P/N 2904413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Revision 1- 12-11-2003 ii ii ii ii ii ii ii ii 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-4 1-4 1-4 1-4 1-5 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-2 2-2 3-1 3-1 3-1 3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-3 3-4 3-4 3-5 FTS 400/800-4 System Level Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual Light Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitors (C1, C2, C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flashtube (FT101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relays (K1, K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Rectifier Board(PCB2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger Coupling Transformer (T3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing and Trigger Board (PCB1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleed Resistor (R1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interlock Switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger Coupling Transformer (T3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing and Trigger Board (PCB1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HV Rectifier Board (PCB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4 — Replaceable & Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Converter Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Controller Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Series Controller Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flashhead Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repackaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5 — Programming T&T Board P/N 2904413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Handheld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX I-1 FTS 400/800-4 Revision 1 — 12-11-2003 3-5 3-5 3-10 3-10 3-10 3-10 3-10 3-10 3-11 3-11 3-11 3-11 3-11 3-11 3-11 3-11 3-12 3-12 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 5-1 5-1 5-1 5-2 5-3 5-3 5-4 v List of Figures FTC 415 Internal Controller - Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 FTC 435 Series Controller - Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 FTC 435 Series Controller - Current Sense Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Typical REIL Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Typical ALS Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 PC 400-2 or PC 800-2 Power Converter Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 FH 400 Flashhead Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 FH 800 Flashhead Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 FTC 435 Series Controller Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 PC 400 and FH 400 Comounted Unit Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 PC 800 and FH 800 Comounted Unit Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Typical Wiring for FTS 410 or FTS 810 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 Typical Wiring for FTS 410 or FTS 810 with FTC 435 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 FH 400 or FH 800 Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14 PC 400 & PC 800 Power Converter Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 FTC 415 Controller Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 FTC 435 Series Controller Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 PCB1 Timing and Trigger Board Pictorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 PCB1 Timming and Trigger Board P/N 2904413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 PC 400 and PC 800 Power Converter Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 FTC 415 Controller Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 FTC 435 Series Controller Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 FH 400 Flashhead Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 FH 800 Flashhead Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 FIGURE 5-1 Handheld Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 vi Revision 1 — 12-11-2003 FTS 400/800-4 List of Tables FTC 415 Internal Controller—Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System-Level Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighting Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Transformer (T1) Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Converter Major Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FTC 415 Controller Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FTC 435 Controller Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH 400 and FH 800 Flashhead Major Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FTS 400/800-4 Revision 1 — 12-11-2003 1-3 3-6 3-7 3-10 4-2 4-4 4-5 4-6 5-1 vii Section 1 — Introduction and Operation System The lights can be used in a combined ALS and REIL configuration. FTS 400 System: An FTS 400 Approach Lighting System consists of two or more lighting units. Each lighting unit is composed of an FH 400 Flashhead and PC 400 Power Converter. The power converter in the system is a PC 410 with an FTC 415 Internal Controller. Power converters without controllers are slaves known as PC 400-2 Power Converters. FTS 800 System: An FTS 800 Approach Lighting System consists of two or more lighting units. Each lighting unit is composed of an FH 800 Flashhead and PC 800 Power Converter. The power converter in the system is a PC 810 with an FTC 415 Internal Controller . Power converters without controllers are slaves known as PC 800-2 Power Converters. The FH 400 Flashhead produces a beam covering 360 degrees horizontally and 8 degrees, or more, vertically. The lens directs the main part of the beam upward toward the airways, while limiting stray light toward the ground. The FH 800 Flashhead directs the beam 30 degrees horizontally and 10 degrees vertically. The flashhead is attached to a two-inch threaded pipe by a yoke that has provisions for horizontal and vertical aiming and locking. In ALS applications, the lights are aligned with the center line of the runway and flash sequentially toward the landing threshold. An ALS installation may have from 3 to 21 (or more) sequentially flashing lights. A REIL (Runway End Identifier Lights) system consists of only two lights that are located on each side of the runway at the landing threshold. The REIL lights flash (simultaneously) after the last center line light has flashed. FTS 400/800-4 Specifications P h y s ic a l : Heights include dimensions of the units only and do not include the distance from the bottom of each unit to the ground. FTS 400 Comounted Assembly: (H x W x D) 29 x 25 x 14 in., 25 lbs. 724 x 635 x 356 mm, 11.5 kg. FTS 800 Comounted Assembly: (H x W x D) 25 x 25 x 14 in., 25 lbs. 622 x 635 x 356 mm, 11.53 kg. PC 400-2 or PC 800-2 Power Converter: (H x W x D) 12.3 x 19.5 x 13.5 in., 21 lbs. 311 x 494 x 341 mm, 9.53 kg. FH 400 Flashhead: (H x W x D) 16.5 x 13.5 x 13.5 in., 10 lbs. 419 x 343 x 343 mm., 4.5 kg. FH 800 Flashhead: (H x W x D) 10.8 x 7.80 in., 4 lbs. 226 x 198 mm, 1.82 kg. P e r f o r m a n c e C h a ra c te r is t ic s : Power R equ iremen ts: Voltage and Frequency Volt-Amperes FTS 400 Power Req. 120 VAC, 60 Hz 300 VA peak 105 W high int. 65 W medium int. 50 W low int. FTS 800 Power Req. 120 fps 190 W high int. 75 W medium int. 55 W low int. 60 fps 135 W high int. 65 W medium int. 50 W low int. Revision 1 — 12-11-2003 1-1 Flash Intensity: FTS 400: High Intensity 5,000 cd Medium Intensity 1,500 cd Low Intensity 300 cd FTS 800: High Intensity 15,000 cd Medium Intensity 1500 cd Low Intensity 300 cd Flash Rate: FTS 400 60 flashes per minute FTS 800 120 flashes per minute Flash Coverage: FH 400: Horizontal 360 degrees Vertical 8 degrees (minimum) FH 800: Horizontal 30 degrees (minimum) Vertical 10 degrees (minimum) Application: L-849 Radio Interface: L-854 Control Interface: FTC 415 Internal Controller C o n t r o l Ty p e : Master/slave with common reference timing. Monitoring & Environ mental: Complies with FAA Advisory CircularAC 150/5345-51. Elapsed Time Meter The Elapased Time Meter shows the hours of operation at high intensity. You can use this timer, for example, to schedule inspections, cleaning, or flashtube replacement as preventive maintenance. 1-2 Flash Monitor The Flash Monitor allows monitoring flash operation with external monitoring equipment. The main terminal block TB1 has two connections at TB1-4 and TB1-5 to which you can connect the monitoring device. These contacts open upon failure of the flashtube for more than approximately 12 seconds. When you first turn the unit on, a failure may be indicated for about 12 seconds until the montior detects sufficient flashes to close the contacts. After this initial period, the contacts remain closed until a failure occurs or the power is removed. FTC 435 Controller The FTC 435 is a series-fed current-operated external controller for the master lighting unit. A switch on its front panel controls low, medium, and high light intensity, or allows control from current steps in a constant current regulator. Operation ElectroFlash ODALS and REIL systems uses an FTC 415 Internal Controller, which is combined with one of the power converters. Each lighting unit (power converter) has internal timing circuitry to fix the instant at which it flashes. This signal also contains encoded flash intensity information. A control line, which enables sequential flashing, interconnects all the lights. Controls and Indicators Table 1-1 describes controls for the FTC 415 Internal Controller, and Figure 1-1 shows these controls. Revision 1 — 12-11-2003 FTS 400/800-4 Table 1-1 FTC 415 Internal Controller—Controls Item Description Function 1 Power Circuit Breaker Applies AC power to the lighting system. 2 Remote Control Fuse Protects the remote control AC line. 3 Selects one of five operating modes: • REMOTE places the system in remote control mode, controlled at another location. • OFF removes power from the lighting units. • LOW activates flashing at low intensity. • MED activates flashing at medium intensity. • HIGH activates flashing at high intensity. MODE Selector CTRL VAC RETURN FROM REMOTE SWITCH 1 3 2 CTRL VAC OUT FOR REMOTE SWITCH REMOTE POWER 1 2 3 4 5 6 CTRL HI M LO MODE N FTC 415 LOW FUSE OFF OFF TB201 OFF REMOTE MED HIGH 3-7355-01G 81000031 Figure 1-1 FTC 415 Internal Controller - Controls and Indicators FTS 400/800-4 Revision 1 — 12-11-2003 1-3 Setting Up the FTC 435 Series Controller Figure 1-3 FTC 435 Series Controller - Current Sense Board For the following procedures, refer to Figure 1-2 and Figure 1-3. Note the following abbreviations: FTC 435 LOW OUT GND CONTROL VOLTAGE LOW MED HIGH MED HIGH IN RUNWAY LOOP SERIES CURRENT 1 2 3 1 2 3 4 TB2 81000033 Figure 1-2 FTC 435 Series Controller - Controls SYNC LOW R22 MED R23 • CCW (Counterclockwise) • CW (Clockwise) • LED (Light Emitting Diode) Style 1 Current Regulator — Three Intensity Levels TB1 R21 CCR (Constant Current Regulator) The FTC 435 Series Controller can be set up for three-intensity operation using a Constant Current Regulator Type L-828, Class 1 (6.6 amps.): Style 1 (Three Step); Style 1 (Two Step); or Style 2 (Five Step). To set up the FTC 435 Series Controller, use the following procedure: INTENSITY CONTROL AUTO • HIGH SENSE R51 For this style, the lighting system switches off only when the CCR is switched off. 1. Turn the SENSE control fully CCW. 2. Turn the HIGH, MED, and LOW controls fully CW. 3. Set the CCR to STEP 1 and adjust the LOW pot CCW until LOW LED just comes on. 4. Set the CCR to STEP 2 and adjust MED pot CCW until the MED LED just comes on. 5. Set the CCR to Step 3 and adjust the HIGH pot CCW until the HIGH LED just comes on. 6. Recheck the light at all current steps and verify that LEDs respond correctly at each step. Also verify by visual comparison that flashing intensity decreases when the CCR is switched from Step 3 to Step 2, and that it decreases further when the CCR is switched from Step 2 to Step 1. Style 1 Current Regulator — Two Intensity Levels 1 2 3 4 5 6 7 8 9 10 11 81000034 1-4 For this style, the lighting system switches off when the CCR is at Step 1. It flashes at LOW intensity when the CCR is at Step 2, and at HIGH intensity when the CCR is at Step 3. Revision 1 — 12-11-2003 FTS 400/800-4 1. Turn the SENSE control fully CCW. 2. Turn the HIGH, MED, and LOW control fully CW. 3. Set the CCR to Step 2 and adjust the LOW control CCW until the LOW LED just comes on and the strobe light flashes in low intensity. 4. Set the CCR to Step 3 and adjust the HIGH control CCW until the HIGH LED just comes on. 5. Recheck the light at all current steps and verify that LEDs respond correctly at each step. Also verify by visual comparison that flashing intensity decreases when the CCR is switched from Step 3 to Step 2, and that the light switches off completely when the CCR is switched from Step 2 to Step 1. Style 2 Current Regulator — Three Intensity Levels For this style, the lighting system switches on when the CCR is at Step 1 and switches to progressively higher intensities as you switch the CCR to higher steps. FTS 400/800-4 1. Turn the SENSE control fully CCW. 2. Turn the HIGH, MED, and LOW controls fully CW. 3. Set the CCR to Step 1 and adjust the LOW control CCW until the LOW LED just comes on. 4. Set the CCR to Step 3 and adjust the MED control CCW until the MED LED just comes on. 5. Set the CCR to Step 5 and adjust the HIGH control CCW until the HIGH LED just comes on. 6. Set the CCR to Step 4 and verify that the HIGH LED goes off. If not, you may need to adjust the HIGH control slightly CW until it does. 7. Set the CCR to Step 2 and verify the MED LED goes off. 8. Recheck the light at all current steps and verify that LEDs respond correctly at each step. Make trimming adjustments if necessary. Also verify by visual comparison that flashing intensity decreases when the CCR is switched from Step 5 to Step 4, and that it decreases further when the CCR is switched to Step 2. Revision 1 — 12-11-2003 1-5 This page is intentionally blank. 1-6 Revision 1 — 12-11-2003 FTS 400/800-4 Section 2 — Outline, Mounting, and Installation Power Converter Unpacking Inspect shipping cartons for signs of damage. Check package contents against the packing list and inspect each item for visible damage. Damage claims should be reported promptly to the freight handler. FH 400 Flashhead ATTENTION Each light is packaged in its own shipping carton. The position at which the light is to be installed is marked on the carton and on an ID label on the outside of the power converter. Refer to Figure 2-1 and Figure 2-2 to identify positions. Tools The following hand tools are suggested for installation and maintenance: • • • • • • • • • • The power converter enclosure consists of a thermoplastic cover attached to an aluminum base. Wing-handled latches secure the cover. The cover tilts open for access to the interior. Phillips®-head screwdriver, #2 9- or 12-inch (# 2 - 3⁄16"), flat-blade screwdriver 9- or 12-inch (# 3 - 5⁄16"), flat-blade screwdriver Three screw-fastened plates secure the lens to its base. Remove these to access the interior of the flashhead. FH 800 Flashhead Three screws fasten the bezel, which holds the flashtube in place. Remove these to access the flashtube or the interior. Outline and Mounting Each lighting unit consists of a power converter and a flashhead, mounted as separate units or comounted as a single unit. Frangible mounting couplings are available from FTCA. Use the outline and mounting dimensions shown in Figures 2-3 to 2-8. Separately Mounted Power Converter: Mounting and outline is shown in Figure 2-3. The base plate has mounting holes for two 2-inch threaded pipes. Medium, slip joint pliers Set of combination wrenches 8-in. adjustable wrench Assorted nut-driver handles (1⁄4", 5⁄16", 3⁄8") Universal terminal crimper Spanner wrench for 2-inch conduit locking nut Triplett™ Model 630-NA VOM, or equivalent analog volt-ohm meter Access Comounted Assembly: Figure 2-7 shows a comounted assembly, a common configuration for REIL applications. Mounting pipe details are similar to those in Figure 2-3, except that you must consider the increased overall height. Installation WARNING Read the warning on Page iii. Disconnect primary power before opening enclosures. FTS 400/800-4 Separately Mounted Flashhead: Mounting and outline is shown in Figure 2-4 and Figure 2-5. Separately mounted, the flashhead is typically installed on a pedestal or tower. This manual may not contain all the information about installation wiring for your installation. Revision 1 — 12-11-2003 2-1 NOTE If installation drawings prepared specifically for your site disagree with information provided in this manual, the site installation drawings should take precedence. Consult any site-specific installation wiring diagram supplied with your equipment. tions in the Site Installation Diagram supplied with your equipment. CAUTION This equipment is power phase sensitive. L1 and L2 must be wired to F1 and F2 in a consistent manner throughout the entire lighting system. FTCA wiring diagrams define only minimum requirements recommended for satisfactory equipment operation. It is the responsibility of the installer to comply with all applicable electrical codes. Note that the wiring diagrams define minimum requirements and may not comply with all applicable electrical codes. It is the responsibility of the end user to comply with all prevailing electrical codes. Conduit and other distribution wiring details can be found on electrical installation diagrams provided by FTCA or others. Determine the wire gauge for power lines by considering service voltage, length of the wire run, and total load (number of lighting units). Use a value of 300 VA per lighting unit and do not permit the voltage drop caused by wire resistance to exceed 5% at any light. Internal or external control units add less than 25W to the total load. Also, use the value of 300 VA to determine the circuit breaker or the slow-acting fuse rating at the service disconnect box. Figure 2-1 Typical REIL Configurations illustrates a typical REIL configuration. For the FTS 410, the two lights are functionally and physically interchangeable. The master light is designated as A, Although these lights flash simultaneously, lights for positions A and B should not be interchanged unless each one is re-aimed. The factory presents aiming for the position. Flashheads are typically comounted with power converters for REIL applications. Figure 2-2 Typical ALS Configurations shows lights a typical RAILs. The five RAILs are labeled from 1 to 5 to identify their positions; the light with the lowest number is located farthest from the runway and is the first to flash. RAILs are typically configured by mounting power converters and flashheads as separate units. The two REILs are labeled A and B, with the master light as A. Wiring System power is supplied to the system controller. A contactor in the controller uses two conductors to distribute power to all power converters in the system. Wire nuts connect line power wires to the controllers, and include those from the controllers to the power converters. These wires are connected at the power converter fuse terminals with screw connections. Typically, the wires are run through conduits and junction boxes and installed by electricians. Figure 2-9 provides wiring guidelines for systems with internal controllers, while Figure provides guidelines for systems with external controllers. These figures are for reference only and may not exactly agree with details in your installation. Always follow instruc2-2 Wire control lines from the master power converter to all remaining power converters in the system by using two unshielded #14 AWG (or larger) conductors, twisted together (6 turns per foot is recommended). NOTE: FTCA recommends 600 Volt insulation on all wires that interconnect the lighting system. FTCA recommends a counterpoise consisting of bare solid copper. When you mount flashheads separately from power converters, wire each respective flashhead to TB2 in its corresponding power converter by using a five-conductor cable (typically FTCA PN 6340). Ground all power converter and separately- mounted flashhead cases to the site grounding system. FTCA provides a grounding lug on each power converter base. FTCA does not recommend connecting to the counterpoise for lightning protection. Installation Checklist Complete the following steps before applying power: 1. Inspect all equipment for damage. 2. Verify the received equipment against the packing list to ensure completeness. Revision 1 — 12-11-2003 FTS 400/800-4 3. Power Converter Mounting: Position and mount each unit allowing adequate clearance for opening the covers. Also, use the following guidelines: – – – – – – Ensure that the case is mounted upright. Check hardware inside the case to ensure that the chassis mounting screws and nuts are tight. Ensure that the bottom of the case has clear drain holes. Ensure that no holes are punched or drilled on the top surface of the case. Ensure that air can flow around the case. Mount the power converter away from radio frequency interference (RFI). 4. Power Converter Wiring: Examine the installation drawings and use the following guidelines: – Check for proper incoming service voltage and current. FTS 400/800-4 – – Wire each unit according to the instructions. – – Check all electrical connections for tightness. – Ground the power converter to the site grounding system. Ensure that all power converters are on the same line phase. Check all terminal strip connections for tightness. 5. Flashhead Mounting: – Check the aim of the flashhead. 6. Flashhead Wiring: – – Ground the flashhead if not comounted. Check the wiring of the flashhead cable to the flashhead. After completing all the steps listed above, turn on the power and perform an operational checkout from procedures in Section 3 of this manual. Revision 1 — 12-11-2003 2-3 FH 400 B FH 400 LANDING THRESHOLD PC 400 PC 410 A OMNIDIRECTIONAL FLASHHEADS MASTER UNIT CONTAINING FTC 415 INTERNAL CONTROLLER FTS 400 SYSTEM LANDING THRESHOLD B A UNIDIRECTIONAL FLASHHEADS PC 800 FH800 FH800 PC 810 MASTER UNIT CONTAINING FTC 415 INTERNAL CONTROLLER FTS 800 SYSTEM CONFIGURATION WITH INTERNAL CONTROLLER 81000021 Figure 2-1 Typical REIL Configurations 2-4 Revision 1 — 12-11-2003 FTS 400/800-4 FH 40 0 B PC 40 0 FH 40 0 LAND ING TH RESHOL D PC 4 10 A M ASTER U NIT CO NTAINING FTC 41 5 INTERNAL CO NTROL LER F H 4 00 PC 40 0 5 FH 40 0 PC 40 0 4 F H 4 00 PC 40 0 3 F H 4 00 PC 40 0 2 F H 4 00 PC 40 0 1 CO NFIGU RA TION W ITH INTER NA L CO NTROLLE R FTS 400 SY STEM FH 80 0 B PC 80 0 FH 80 0 LAND ING TH RESHOL D PC 8 10 A M ASTER U NIT CO NTAINING FTC 41 5 INTERNAL CO NTROL LER F H 8 00 PC 80 0 5 F H 8 00 PC 80 0 4 F H 8 00 PC 800 3 F H 8 00 PC 800 2 F H 8 00 PC 800 1 CO NFIGU RA TION W ITH INTER NA L CO NTROLLE R F TS 800 S YS TE M 81000022 Figure 2-2 Typical ALS Configurations FTS 400/800-4 Revision 1 — 12-11-2003 2-5 12.3 (311) 2" NPT PIPE (NOT SUPPLIED) 2.25 (57.2) (NOMINAL) FRANGIBLE COUPLING GROUND LEVEL PAD 2.38 DIA (60.5) 13.5 (341) NOTE: DIMENSIONS ARE IN INCHES (MILLIMETERS) 8.00 (203) 19.5 (494) 81000023 Figure 2-3 PC 400-2 or PC 800-2 Power Converter Mounting and Outline 2-6 Revision 1 — 12-11-2003 FTS 400/800-4 16.5 (419) 1. 2. 3. 4. APPROXIMATE WEIGHT = 10 LBS. (4.54 KG.) WIND AREA = 1 SQ.FT. (.09 SQ.M.) DIMENSIONS ARE IN INCHES (MILLIMETERS). EXTRA HOLE IS USED WHEN FLASHHEAD IS MOUNTED ON A FRANGIBLE MAST. LEVELING NUTS (3 PLACES) 13.5 (343) DIA 2.38 (60.3) DIA MOUNTING HOLE IN LEVELING PLATE 1.06 (27) DIA 81000025 Figure 2-4 FH 400 Flashhead Mounting and Outline FTS 400/800-4 Revision 1 — 12-11-2003 2-7 8.9 (226) 6.7 (170) 15° 10.8 (273) 7.80 (198) 2.38 DIA (60.5) 5.25 (133) 81000026 Figure 2-5 FH 800 Flashhead Mounting and Outline 2-8 Revision 1 — 12-11-2003 FTS 400/800-4 10.9 (277) 10.5 (267) 0.88 (22) 0.5 (13) 12.5 (318) 12.9 (329) 14.5 (367) 0.31 (8) 8.0 (203) 12.3 (311) NOTES: DIMENSIONS ARE IN INCHES (MILLIMETERS) WEIGHT=11 LBS. (5 KG.) 15.4 (392) 15.6 (396) R1.5 (R38.1) Ø1.31 (Ø33.3) 6.41 (163) 2.50 (63.5) Ø1.31 (Ø33.3) 5.00 (127) 2.50 (63.5) NOTE DIMENSIONS ARE IN INCHES (MILLIMETERS) .16 (4) 81000024 Figure 2-6 FTC 435 Series Controller Mounting and Outline FTS 400/800-4 Revision 1 — 12-11-2003 2-9 15.0 (381) LEVELING SCREWS (3 PLACES) 28.5 (724) 12.3 (311) 2" NPT PIPE (SUPPLIED BY OTHERS) 2.25 (57.2) NOMINAL FRANGIBLE COUPLING GROUND LEVEL PAD 14.0 (356) CL NOTES: 1.0 WEIGHT 1.1 POWER CONVERTER = 21 [9.5]. 8.00 (203) 1.2 FLASHHEAD = 8 [3.6]. 2.0 DIMENSIONS ARE IN INCHES [MILLIMETERS]. WEIGHTS ARE IN POUNDS [KILOGRAMS]. 20.0 (508) 81000027 Figure 2-7 PC 400 and FH 400 Comounted Unit Mounting and Outline 2-10 Revision 1 — 12-11-2003 FTS 400/800-4 24.5 (622) 2" NPT PIPE (NOT SUPPLIED) 2.25 (57.2) NOMINAL FRANGIBLE COUPLING GROUND LEVEL 2.38 DIA (60.5) PAD 14.0 (356) DIMENSIONS ARE IN INCHES (MILLIMETERS) 8.00 (203) 20.0 (508) 81000028 Figure 2-8 PC 800 and FH 800 Comounted Unit Mounting and Outline FTS 400/800-4 Revision 1 — 12-11-2003 2-11 81000029 Figure 2-9 Typical Wiring for FTS 410 or FTS 810 System BLK BLU RED 1 2 3 4 5 Revision 1 — 12-11-2003 RTN CONTROL FH 400 FOR FTS 400 SYSTEMS (GND) PUR (CATH) BLU (TRIG) BLK (TRIG RTN) WHT (ANODE) RED RED PUR SHIELD 1 2 BLU 3 BLK 4 WHT 5 TB2 RED BLU BLK WHT PUR SHIELD BLK BLU RED 1 2 3 4 5 NOTES 4, 6 F2 F1 TB1 (GND) PUR (CATH) BLU (TRIG) BLK (TRIG RTN) WHT (ANODE) RED PUR SHIELD RED 1 2 BLU 3 BLK 4 WHT 5 TB2 CONTROL WIRES (TWISTED, UNSHIELDED) NOTES 7, 8 & 9. RTN CONTROL PC 400/800 FH 400 FOR FTS 400 SYSTEMS REIL PAIR RED BLU BLK WHT PUR FH 800 FOR FTS 800 SYSTEMS WHT BLK PUR SHIELD INPUT POWER FROM SERVICE DISCONNECT NOTES 8, 9 & 10. GND CB201 FTC 415 K203 NOTE 5 (TYPICAL) NOTES 4, 6 F2 F1 FH 400 FOR FTS 400 SYSTEMS TB201 H M L 5 6 7 8 9 10 OPEN OPEN OPEN CTRL VAC * * OPTIONAL: EITHER CTRL VAC OR OPEN * CTRL VAC * TO TERMINAL 9 TO TERMINAL 10 OFF OPEN OPEN TO TERMINAL 8 LOW OPEN MEDIUM HIGH CTRL VAC FTC 415 TB201 INPUT 1 2 3 4 5 TB2 BLU BLK WHT RED SEE REMOTE CONTROL CHART TYPICAL REMOTE SWITCHING DEVICE FOR EXAMPLE, L-854 RADIO RCVR/CONTROLLER COUNTERPOISE (NOTE 3) PUR SHIELD CTRL VAC L M H (GND) (CATH) BLU (TRIG) BLK (TRIG RTN) WHT (ANODE) RED CONNECTED AT FACTORY (NOT REQ'D AT FLASHHEAD IF CO-MOUNTED) NOTE 2 (TYPICAL) INTENSITY REMOTE CONTROL CHART RTN CONTROL NOTE 2 (TYPICAL) 1 2 3 TB1 PC 410/810 BLU RED POWER TO OTHER LIGHTS NOTES 8, 9 & 10. PN 6340 CABLE (TYPICAL) 1. CTRL VAC, FUSED FOR 150W, MAY BE USED FOR REMOTE CONTROL AND/OR RADIO. 2. DENOTES GROUNDING ROD CONNECTION, GROUNDING TO COUNTERPOISE NOT RECOMMENDED. 3. BARE SOLID COPPER WIRE RECOMMENDED FOR COUNTERPOISE. 4. THIS EQUIPMENT IS PHASE SENSITIVE, THUS ALL UNITS MUST BE WIRED THE SAME WAY. 5. DENOTES A WIRE SPLICE CONNECTION. 6. WHEN LINE 2 IS NEUTRAL, F2 IS REPLACED BY A JUMPER. 7. TWO (2) #14 AWG CONDUCTORS (UNSHIELDED) TWISTED TOGETHER AT 6 TURNS PER FOOT. 8. 600V INSULATION RECOMMENDED FOR ALL INTERCONNECTION WIRES. 9. THIS DRAWING DEFINES MINIMUM SYSTEM REQUIREMENTS FOR WIRING AND MAY NOT MEET ALL APPLICABLE ELECTRICAL CODES. 10. THE SERVICE VOLTAGE, THE LENGTH OF THE WIRE RUN AND THE TOTAL LOAD (NUMBER OF LIGHTING UNITS) ARE FACTORS IN DETERMINING CONDUCTOR SIZE. USE A VALUE OF 200 VOLT-AMPERES PER LIGHTING UNIT AND DO NOT PERMIT THE VOLTAGE DROP DUE TO WIRE RESISTANCE TO EXCEED 5% AT ANY LIGHT. CONTROL UNITS (INTERNAL OR EXTERNAL) ADD LESS THAN 25W TO THE TOTAL LOAD. ALSO USE 200 VOLT-AMPERES PER LIGHT TO DETERMINE CIRCUIT BREAKER OR SLOW-ACTING FUSE RATING AT THE SERVICE DISCONNECT BOX. TO OTHER COUNTERPOISE LIGHTS AS REQD POWER FOR CONTROL ODALS NOTES 4, 6 F2 F1 TB1 PC 400/800 WHT PUR SHIELD LINE 2 LINE 1 WHT PUR SHIELD LINE 2 LINE 1 SHIELD FH 800 FOR FTS 800 SYSTEMS RED BLK LINE 2 LINE 1 FH 800 FOR FTS 800 SYSTEMS CTRL VAC ADDITIONAL LIGHTS FOR ODALS BLK/WHT RED/WHT LINE 1 LINE 2 RED BLU BLK WHT PUR SHIELD NOTE 1 2-12 FTS 400/800-4 C O N NEC TED AT FAC TOR Y PC 410 O R P C 810 TB2 TB1 C ON TR O L R TN F1 F2 1 2 3 4 ANODE C ATH T R IG T R IG R T N F T C 4 1 5 IN T E R N A L C O N T R O L L E R RED LINE 2 LINE 2 W H T /R E D LINE 1 N H M L 5 6 7 8 9 10 C B 2 01 B LK TB201 K 20 3 CTRL VAC W H T /B L K GND RED B LU BLK W HT TO FLASHHEAD PUR S H IE L D LINE 1 W IR E N U T S 1 2 3 4 5 6 C O U N T E R P O IS E TO OTHER L IG H T IN G U N IT S N O TE: ALLO W S M O D E CO N TR O L B Y S E N S IN G C U R R E N T L E V E L S N O TE: R EFER TO ALL A P P L IC A B L E N O T E S IN T H E S Y S T E M IN S T A L L A T IO N D R A W IN G S . F T C 4 3 5 S E R IE S C O N TR O LLE R FTC 435 IN T E N S I T Y C O N T R O L LO W 2 3 2 3 HIGH VOLTAGE 1 MED 1 M ED H IG H LOW T B1 OUT IN 1 2 0 /2 4 0 V A C 6 0 H Z L1 F R O M S E R V IC E D IS C O N N E C T L 2 /N E U T S W IT C H GND RU N WA Y LO O P S E R IE S CU R REN T CONTROL A UTO 4 TB2 S E R IE S CURRENT L IN E T Y P IC A L L IN E IS O L A T IO N L - 8 3 0 -1 T R A N S F O R M E R S U P P L IE D B Y O T H E R S 810000211 Figure 2-10 Typical Wiring for FTS 410 or FTS 810 with FTC 435 Controller FTS 400/800-4 Revision 1 — 12-11-2003 2-13 FT101 FLASHTUBE T101 TRIGGER TRANSFORMER (SHIELD & GROUND) PUR PUR WHT (TRIGGER RTN.) WHT (TRIGGER) BLK BLK (CATHODE) BLU (ANODE) RED BLU RED RC101 CONNECTIONS TO LIGHTING UNITS 810000212 Figure 2-11 FH 400 or FH 800 Internal Wiring 2-14 Revision 1 — 12-11-2003 FTS 400/800-4 400800IW Figure 2-12 PC 400 & PC 800 Power Converter Internal Wiring 4A 3A 4 3 LINE 2 LINE 1 RED RED BLK S1 NOTE 1 F2 VR1 F1 INTENSITY VR2 6 5 4 3 2 CONTROL 1 11 BLK WHT/ORN NOTE 2 WHT/GRN R3 NOTE 3 RED BLK TB1 BLK 4A 10 3A RED 9 4 WHT 7 8 6 3 2 1 BLK WHT/VIO C4 WHT/VIO TB3 G2 2 1 WHT/GRN YEL WHT/VIO WHT/GRN WHT/BRN WHT/BLU WHT/ORN WHT/GRN 4. CAPACITOR BANK: C1,2 C5,6 C7 HIGH MED LOW PC 400 C7 C5 C1,2,6 PC 800 1. F2 IS REPLACED BY A JUMPER WHEN LINE 2 IS NEUTURAL. 2. JUMPER USED IN SLAVE UNITS ONLY. 3. ELAPSED TIME METER (OPTIONAL). F2 S1 BLK POWER TRANSFORMER G1 4 5 TIMING & TRIGGER PCB1 3 2 1 WHT/BLU TRIGGER 110VAC WHT/VIO 24VAC WHT/BRN 24VAC YEL YEL WHT/GRN YEL YEL 10 11 9 8 7 6 BLK CONTROL SIGNAL T1 WHT/ORN INTENSITY RED LOW MODE RELAY YEL HIGH MODE RELAY 2 1 5 6 8 3 BLU HIGH 7 4 BLU P2 P4 R1 R2 MED WHT/GRN 2 1 5 6 7 8 P1 BLU YEL BLU 3 4 LOW SEE NOTE 4 P3 RED ORN K2 RED LOW MODE RELAY RED TB4 1 2 3 4 5 6 7 8 9 10 11 SEE NOTE 4 ORN ORN INPUT WIRE CONNECTION WHT/ORN HV RECTIFIER PCB2 AC HIGH MODE RELAY WHT/GRN GROUND POWER TRANSFORMER 5 WHT/RED HV 2 120 VAC RED L2 YEL FLASHCHOKE WHT/RED K1 HV 1 WHT/GRN WHT/GRN BLU GROUND TRIGGER SIGNAL ORN R4 HV 3 T3 QC2 BLU QC1 G1 BLU QC4 QC3 TRIGGER COUPLING TRANSFORMER N/C 1 2 3 4 5 6 7 8 GND BLU BLK WHT CATHODE TRIGGER TRIG RTN SHIELD PUR RED ANODE TB2 3-7403-01U FLASHHEAD INTERLOCK CONTROL (IF USED) WHT/BRN WHT/GRN RED BLU BLU BLU WHT/GRN T1 BLU BLU -HV Revision 1 — 12-11-2003 AC RED FTS 400/800-4 2-15 WHT/GRN 415-2IW Figure 2-13 FTC 415 Controller Internal Wiring Revision 1 — 12-11-2003 L2 OR NEUTRAL GND L1 YEL LINE RED CB2 LOAD RED BLK BLK WHT/RED WHT/BLK CB1 LOAD CB201 LINE BLK HI LOW MED ORN RED (SIDE) REMOTE OFF BLU (CENTER) BRN F201 TO F2 TO F1 WHT/RED L2 4 3 TB201 1 DENOTES WIRE NUT FOR INSTALLATION CONNECTIONS. POWER 2 5 8 6 1 7 WHT/BLK WHT/RED K203 3. ISOLATED CONTACTS REQUIRED FOR REMOTE SWITCHING. 2. 1. LINE 2 MAY BE THE NEUTRAL FROM SERVICE FEEDER. NOTES: NOTE 1 NOTE 2 S201 BRN POWER TO OTHER LIGHTING UNITS F2 WHT/BLK L1 WHT/RED RED RED WHT/BLK WHT WHT L2 N CTRL VAC H M L (NOTE 3) REMOTE L2/N 2 3 4 5 6 7 8 9 10 11 24K .5W R201 BLU F1 GRN WHT VIO VIO GND RED CHASSIS GND WHT CONNECTIONS TO HOST UNIT BLU VI0 YEL YEL GRN ORN INT RED TB1-5 WHT 2-16 FTS 400/800-4 WHT WHT ORG BLK BLK BLU VIO WHT WHT YEL BLK BLK GRY A B 1 4 3 6 A B 3 6 1 4 K202 MED K201 HIGH 7 9 7 9 3-7355-01G RED GRY RED WHT TB1 3 1 RED 4 2 ORN 11 9 8 7 10 BLK BLU BRN 6 5 4 3 POWER TRANSFORMER WHT/RED T1 WHT/ORN G1 VIO 3 1 GND WHT/ORN 2 2 RED 1 PCB1 CURRENT SENSE WHT/BRN ORN RUNAWAY LOOP SERIES CURRENT VIO LOW 2 MED 3 BRN 1 BLU 2 WHT/RED 3 4 YEL HIGH 4 GRY GRY YEL YEL ORN ORN RED RED ORN CTRL VOLTS 1 AUTO LOW MED HI RED TB2 GRY BLK 5 RED 6 ORN 7 GRY 8 YEL 9 J1 PCB2 RELAY BOARD 3-7682-01REV E S1 INTENSITY CONTROL 435IW Figure 2-14 FTC 435 Series Controller Internal Wiring FTS 400/800-4 Revision 1 — 12-11-2003 2-17 This page is intentionally blank. 2-18 Revision 1 — 12-11-2003 FTS 400/800-4 Section 3 — Maintenance and Troubleshooting Safety cloth or paper towels. A lens cleaning kit, Part Number 8630801, is available from FTCA. Contact Customer Service at 1-800-821-5825. WARNING Before proceeding—read warning on Page iii. Work safely, as follows: 1. Remove rings and watches before opening the equipment. 2. Shut off the equipment. 3. Remove the component or connect the test instruments. 4. Replace the component. 5. Turn on the power and test the system. 6. Turn off the power and disconnect the test equipment. Preventive Maintenance Storage No special considerations are required for long-term storage of any major assembly, such as the power converter or flashhead, or any internal component. Circuit boards, when not installed in the equipment, should be kept in antistatic bags or containers. Diagnostic Testing You can benefit by observing the behavior of the system as a whole and each lighting unit in particular when carrying out these test procedures; the observations will be useful for troubleshooting. Carry out the following inspection and cleaning procedures at least once a year: 1. Verify that moisture has not accidentally entered the equipment through gaskets or seals, or collected inside as condensation. 2. Verify that all drain holes are clear. 3. Check terminal blocks and relays for evidence of corrosion and electrical arcing. Clean or replace any component that shows evidence of high-voltage damage. 4. Check flashtube connections for signs of pitting or arcing. Verify that anode and cathode connections are firmly tightened. 5. Check all electrical connections for tightness and verify the absence of corrosion or electrical arcing. 6. Clean the outside surface of the FH 800 glass with liquid detergent and water. Wipe it gently with a soft cloth. 7. Clean the inside surface of the FH 400 lens with an FTCA-approved professional plastic cleaner. Wipe the lens with cheesecloth only. Do not use regular FTS 400/800-4 NOTE This equipment uses a method of master/slave control that enhances its operation as a system. This type of control can sometimes cause misleading symptoms if one of the lighting units malfunctions. Thus, it may be necessary to disconnect the interconnecting control wire and to verify the operation of each lighting unit independently to pinpoint the cause of a problem. Control Signal Evaluation Refer to Figure 2-1. Note that, for each power converter, a control line and its return line are connected to TB1-1 and TB1-3 respectively. The synchronization signal on this line is a pulse. Therefore, it is difficult to evaluate with a meter. Evaluating the control signal can be performed with a digital voltmeter that has an averaging function. Or, you can use an analog volt-ohmmeter such as the Triplett Model 630 set on the 3-volt scale. With either meter, the pulses that may be present on the line produce only momentary indications. Revision 1 — 12-11-2003 3-1 However, to be aware of how your particular meter responds to these signals, use the following information to evaluate the response: • RFI on primary power wires could cause errors in flash rate and intensity. • RFI on the control (master/slave) interconnecting wire could cause a light to switch intensity. Strong RFI could burn out circuit board components. • The low-intensity pulse is approximately 16 ms in duration • • • The medium-intensity pulse is 33 ms in duration Though the circuits reject or bypass RFI, FTCA cannot guarantee complete immunity beforehand. After installation, it may be necessary to add external filters or use other methods to reduce RFI entering the equipment. The high-intensity pulse is 66 ms in duration The longer pulse deflects the needle more than the shorter pulse on an analog meter, or the longer pulse reads higher than the shorter pulse on a digital meter with an averaging function. Observe these signals with your meter and record the meter readings for future reference. For example, using the Triplett Model 630 set on the 3-volt scale (AC or DC), the high-intensity control pulse deflects the needle 70-80% of full scale, the medium-intensity control pulse deflects the needle 50%, and the low-intensity control pulse deflects the needle 20-30%. On an analog meter, the needle must return to zero between pulses. If it does not, signal interference may be occurring, as described next; or, you system may have RFI (radio frequency interference) problems as described in Section RFI Problems. If the entire system flashes at the wrong intensity or exhibits any other abnormal flashing behavior affecting all the lighting units, a control signal problem is indicated. Although the problem could originate at the controller or at the master unit, it could also be caused by any of the slave units, because all lighting units communicate bidirectionally in this type of master/slave system. A problem of this type is isolated by disconnecting each lighting unit from the control wire and examining its behavior independently. The following procedures describe how to isolate each control problem to a single lighting unit or to the control signal wire itself. Control Line Interference Electrical interference on the control line can introduce system control problems. This can occur if the line is open, shorted, or not a twisted pair. The condition of all units responding correctly to the master and slave checkout procedures described above, but not when the control wire is connected, indicates a control line problem. Sometimes, you can eliminate marginal interference by placing a 1000 ohm resistor between the control line wires at the master unit. Installing a shunt capacitor can also help, but never exceed a value of 0.01 microfarads. The control line has a ground return to interconnect the unit. Chassis ground is the reference. Power Phasing Input power phasing must be consistent, as noted in Section Wiring on Page 2-2. If even one of the lights is phased differently, none of the lights will switch to low intensity. To isolate an out-of-phase light (or lights), set the system control selector to LOW. Turn off all lights except for the master unit (use interlock switches to accomplish this) and verify that the master flashes at low intensity. Now turn on the remaining lights one at a time and observe the master unit as each one is turned on. If the master unit changes intensity as any of the slave units is turned on, reverse the input power phasing of that slave unit (interchange L1 and L2 at the fuse block). Continue this procedure with all the remaining lights. RFI Problems Master Unit Checkout P/N 2652318 The presence of radio frequency interference (RFI) can cause a light to flash intermittently, at the wrong rate, or at the wrong intensity. RFI can enter the light by any wire to or from the unit. For example: 3-2 The master unit contains an internal controller or a control interface panel. Carry out the following steps on the timing and trigger board. Revision 1 — 12-11-2003 FTS 400/800-4 1. Temporarily disconnect the input control wire from TB3-6 and the intensity control wire from TB3-7. 2. Apply power to the system and set the control switch to any mode except REMOTE or OFF. Verify the following response: a. The LOW LED is not lit. b. The HIGH LED is lit. c. The SYNC LED blinks brightly. d. The TRIG neon lamp glows. e. The light flashes at high intensity. 9. If any LED response in steps 6 through 8 is not exactly as described, replace the controller or interface panel, or both. 10. Before reconnecting the control wire at TB-6, observe the flash intensity of the other (slave) beacons in the system. They should all be flashing at LOW intensity. If not, there is a problem with one of the lighting units or in the system control wire itself. 3. Place a temporary jumper from TB3-7 to TB3-10 (or the chassis). Verify the following responses: a. The LOW LED is lit. b. The HIGH LED is not lit. c. The SYNC LED blinks dimly. d. The TRIG neon lamp glows. e. The light flashes at LOW intensity. 4. Remove the jumper placed in step 3. Place temporary jumper from TB3-10 (or the chassis) to test point TP8 on the board. Do not confuse TP8 on the board with terminal 8 on the terminal block (please refer to Figure 3-1). Verify the following responses: a. The HIGH LED is not lit. b. The LOW LED is not lit. c. The SYNC LED blinks. d. The TRIG neon lamp glows. e. The light flashes at MEDIUM intensity. f. Remove the jumper between TP8 and TB3-10 (or the chassis). 5. If any LED response in items A to C of steps 2, 3, and 4 above is not exactly as described replace the timing and trigger board. Replace relay K1 or K2 if LED responses are correct but the light flashes at the wrong intensity. 6. Reconnect the intensity control wire to TB3-7, while leaving the system control wire disconnected from TB3-6. Set the control switch to LOW and verify that responses are identical to those in step 3. 7. Set the control switch to MED and verify that responses are identical to those in step 4. FTS 400/800-4 8. Set the control switch to HIGH and verify that responses are identical to those in step 2. 11. Reconnect the control wire to TB-6. Repeat steps 6 through 8 and verify that all lights flash properly. If any response is not as described, proceed to verify the operation of each slave unit. Slave Unit Checkout A slave unit is one that does not contain an internal controller or control interface panel. Carry out the following steps on the timing and trigger board of any slave unit. Refer to Figure 3-1. 1. Temporarily disconnect the input control wire from TB3-6 and the intensity control wire from TB3-7. 2. Apply power to the system and at the master unit controller, set the control switch to any mode except REMOTE or OFF. Verify the following responses at the slave unit: a. The LOW LED is not lit. b. The HIGH LED is lit. c. The SYNC LED blinks brightly. d. The TRIG neon lamp glows. e. The light flashes at HIGH intensity. 3. Placed a temporary jumper from TB3-10 (or the chassis) to test point TP8 on the board. Do not confuse TP8 on the board with Terminal 8 on the terminal block. (Please refer to Figure 3-1). Verify the following responses: a. The HIGH LED is not lit. b. The LOW LED is not lit. c. The SYNC LED blinks. d. The TRIG neon lamp flashes. e. The light flashes at MEDIUM intensity. Revision 1 — 12-11-2003 3-3 4. Remove the jumper placed in step 3. Reconnect the intensity control wire removed from TB3-7. Verify the following responses: a. The LOW LED is lit. b. The HIGH LED is not lit. c. The SYNC LED blinks brightly. d. The TRIG neon lamp glows. e. The light flashes at LOW intensity. 5. If any LED response in items 1 through 4 of steps 2, 3, and 4 above is not exactly as described, replace the timing and trigger board. Replace relay K1 or K2 if LED responses are correct but the light flashes at the wrong intensity. 6. Restore the input control wire to TB3-6. Master Unit Checkout P/N 2904413 The master unit contains an internal controller or a control interface panel. Carry out the following steps on the timing and trigger board. 1. Temporarily disconnect the input control wire from TB3-6 and the intensity control wire from TB3-7. 2. Apply power to the system and set the control switch to any mode except REMOTE or OFF. Verify the following response: a. The NITE LED is not lit. b. The DAY LED is lit. c. The TWI LED is not lit. d. The SYNC LED blinks brightly. e. The TRIG neon lamp glows. f. The light flashes at high intensity. Verify the following responses: a. The DAY LED is not lit. b. The NITE LED is not lit. c. The TWI LED is lit. d. The SYNC LED blinks. e. The TRIG neon lamp glows. f. The light flashes at MEDIUM intensity. g. Remove the jumper between TP1 and TP5. 5. If any LED response in items A to C of steps 2, 3, and 4 above is not exactly as described replace the timing and trigger board. Replace relay K1 or K2 if LED responses are correct but the light flashes at the wrong intensity. 6. Reconnect the intensity control wire to TB3-7, while leaving the system control wire disconnected from TB3-6. Set the control switch to LOW and verify that responses are identical to those in step 3. 7. Set the control switch to MED and verify that responses are identical to those in step 4. 8. Set the control switch to HIGH and verify that responses are identical to those in step 2. 9. If any LED response in steps 6 through 8 is not exactly as described, replace the controller or interface panel, or both. 3. Place a temporary jumper from TB3-7 to TB3-10 (or the chassis). Verify the following responses: a. The NITE LED is lit. b. The DAY LED is not lit. c. The Twi LED is not lit. d. The SYNC LED blinks dimly. e. The TRIG neon lamp glows. f. The light flashes at LOW intensity. 4. Remove the jumper placed in step 3. Place temporary jumper from test point TP1 to test point TP5 on the 3-4 board. Do not confuse TP1,5 on the board with terminal 1,5 on the terminal block (please refer to Figure 3-2). 10. Before reconnecting the control wire at TB-6, observe the flash intensity of the other (slave) beacons in the system. They should all be flashing at LOW intensity. If not, there is a problem with one of the lighting units or in the system control wire itself. 11. Reconnect the control wire to TB-6. Repeat steps 6 through 8 and verify that all lights flash properly. If any response is not as described, proceed to verify the operation of each slave unit. Slave Unit Checkout P/N 2904413 A slave unit is one that does not contain an internal controller or control interface panel. Carry out the following steps on the timing and trigger board of any slave unit. Refer to Figure 3-2. Revision 1 — 12-11-2003 FTS 400/800-4 1. Temporarily disconnect the input control wire from TB3-6 and the intensity control wire from TB3-7. Troubleshooting 2. Apply power to the system and at the master unit controller, set the control switch to any mode except REMOTE or OFF. Accurately observe the system’s operating behavior. This often leads directly to the cause of a problem. The diagnostic procedures in this subsection are divided into the two following categories: Verify the following responses at the slave unit: a. The NITE LED is not lit. • System-level malfunctions, where all lighting units exhibit the same abnormal behavior • Symptoms applying to one or more individual lighting units, but not to all of them b. The DAY LED is lit. c. The TWI LED is not lit. d. The SYNC LED blinks brightly. e. The TRIG neon lamp glows. f. The light flashes at HIGH intensity. 3. Placed a temporary jumper from TP1 to test point TP5 on the board. Do not confuse TP1,5 on the board with Terminal 1,5 on the terminal block. (Please refer to Figure 3-2). Verify the following responses: System Level Problems Table 3-1 identifies symptoms affecting all lighting units in the same way. Use it to determine possible causes. Individual Light Problems Use Table 3-2 to identify problems that apply to a particular lighting unit only and to determine possible causes. a. The DAY LED is not lit. b. The NITE LED is not lit. c. The TWI LED is lit. d. The SYNC LED blinks. e. The TRIG neon lamp flashes. f. The light flashes at MEDIUM intensity. 4. Remove the jumper placed in step 3. Reconnect the intensity control wire removed from TB3-7. Verify the following responses: a. The NITE LED is lit. b. The DAY LED is not lit. c. The TWI LED is not lit. All neon lights out on the HV rectifier board indicates the absence of HV. All LED lights out on the timing and trigger board indicates the absence of LV. d. The SYNC LED blinks brightly. e. The TRIG neon lamp glows. f. The entries listed in Table 3-2 are numbered in the order of their likely occurrence. For example, assume that one of the lights does not flash in any mode (low, medium, or high) and the high voltage (HV) indicators are not lit. However, mode relays operate and circuit board LEDs are lit, which indicates the presence of low voltage (LV). The symptom best describing this condition is No No No No Ok. This symptom has four causes listed in sequence. The HV Rectifier Board is the most likely and the first cause listed. The Power Transformer is the next likely cause and second one listed. In this way, the causes follow in the sequence of their likelihood of occurrence. The light flashes at LOW intensity. 5. If any LED response in items 1 through 4 of steps 2, 3, and 4 above is not exactly as described, replace the timing and trigger board. Replace relay K1 or K2 if LED responses are correct but the light flashes at the wrong intensity. After determining that the problem’s cause is a specific component, refer to the procedure for testing the component in Section Component Testing. If the component is faulty, replace it according to the appropriate component replacement procedure in Section Component Removal and Replacement 6. Restore the input control wire to TB3-6. FTS 400/800-4 Revision 1 — 12-11-2003 3-5 Table 3-1 System-Level Troubleshooting Flash Conditions Component or Condition Notes No Circuit Breaker CB201/202 or CB301/302 Note 2 No No Remote Control Fuse F201 or F301 Note 1, Note 2 OK Bright Bright High Mode Relay K201 or Low Mode Relay K202 Note 3 Weak Ok Ok High Mode Relay K201 Note 3 Weak Weak Ok Low Mode Relay K202 Note 3 Ok Ok Bright Phase error Note 5 Control line not a twisted pair Note 4 High Medium Low No No No Erratic flashing in all modes Notes: 1. 2. 3. 4. 5. 3-6 Flashes properly when you set the master switch to low, medium, or high but does not flash when you set the switch to remote. 300-series components are associated with an external (remote) control panel; 200-series components are associated with an internal control panel. A system may have either 200 series or 300 series components, but not both. a.) Check relay contacts for dirt or corrosion. b.) Check relay for normal energizing operation (verify that the relay pulls in). A twist of 6 turns per foot is recommended. Refer to Section Power Phasing on Page 3-2 Revision 1 — 12-11-2003 FTS 400/800-4 . Table 3-2 Lighting Unit Troubleshooting Other Conditions Flash Conditions Component Or Condition High Medium Low HV LV No No No No No Primary Fuse F1, F2 Interlock Switch S1 No No No No No Primary Suppressor Asm. VR1 Power Transformer T1 Timing and Trigger Board PCB1 No No No No Ok HV Rectifier Board PCB2 Power Transformer T1 Main Capacitor Bank C1, C2 Flashhead Cable No No No Ok No Timing and Trigger Board PCB1 Power Transformer T1 No No No Ok Ok Flashtube FT101 HV Rectifier Board PCB2 Trigger Transformer T101 Power Transformer T1 Flashhead Cable Main Capacitor Bank C1, C2 No No Ok Ok Ok Main Capacitor Bank C1, C2 HV Rectifier Board PCB2 Ok Ok No Ok Ok Low Mode Capacitor C3 HV Rectifier Board PCB2 Low Mode Relay K2 Weak Weak Ok Ok Ok Low Mode Relay K2 Timing and Trigger Board PCB1 Ok Bright Ok Ok Ok HV Rectifier Board PCB2 Skips Ok Ok Ok Ok Tuning Capacitor C4 Ok Trigger Arcing Flashtube FT101 Trigger Transformer T101 Coupling Transformer T3 Skips FTS 400/800-4 Skips Skips Ok Revision 1 — 12-11-2003 Notes Fuses blow when replaced or circuit breaker trips 3-7 81000052 Figure 3-1 PCB1 Timing and Trigger Board Pictorial 3-8 Revision 1 — 12-11-2003 FTS 400/800-4 Figure 3-2 PCB1 Timming and Trigger Board P/N 2904413 FTS 400/800-4 Revision 1 — 12-11-2003 3-9 Component Testing Do Not Depend on Interlocks The following procedures describe how to check most of the major electrical components. Always make resistance measurements with the power turned off. Voltage measurements require power to be on; however, perform all preliminary steps such as connecting test leads or circuit jumpers, or disconnecting existing circuit connections, with the power turned off and storage capacitors discharged. Capacitors (C1, C2, C3) Test capacitors with an ohmmeter capable of measuring one megohm or greater, using the procedure described following. Resistance measured between the terminals of a fully discharged capacitor is initially zero and increases steadily with time if you leave the ohmmeter leads across the terminals. Eventually, an open circuit condition occurs. The time it takes for the complete transition from zero to maximum depends on the total amount of capacitance. A capacitor disconnected from other circuitry is defective if it does not exhibit this behavior. Manually discharge the capacitor before repeating this measurement. This procedure may not detect a failure that occurs at high voltage only. Please note that the final measured resistance across C1 is limited to 100K ohms unless you disconnect the safety bleed resistor R1. Never depend on interlocks alone to remove unsafe voltages. Always check circuits with a voltmeter. Under no circumstances remove or alter any safety interlock A visual inspection tells you little about the working condition or performance of a flashtube. A darkened envelope does not necessarily mean the light output is unacceptable. Do not replace the flashtube until you rule out other causes, such as a lack of discharge potential or triggering pulses. Relays (K1, K2) A malfunctioning relay may have faulty contacts, a sticky mechanism, or a defective coil. You may determine the first two possibilities by inspection and by manually exercising the armature. Perform the following resistance measurement to confirm a defective coil: 1. Remove the PCB1. 2. Measure coil resistance between TB3-7 and the chassis to test Low Mode Relay K2. 3. Measure coil resistance between TB3-8 and the chassis to test High Mode Relay K1. The measured coil resistance in either case should be approximately 290 ohms. High Voltage Rectifier Board(PCB2) Replace PCB2 with one known to be in good condition. Flashtube (FT101) High Voltage Transformer (T1) PERSONNEL HAZARD WARNING NOTE Protect yourself — always turn off the input (primary) power and wait for one minute for storage capacitors to drain their charge. Capacitors may be manually discharged by placing a resistance (25 Watts, 10,000 ohms or greater) between their terminals. Then check between the red and blue wires on TB2 with a voltmeter for any residual charge before touching any circuit element or component. 3-10 To test this transformer, first remove (PCB1) and (PCB2). Apply power to the unit and measure secondary winding voltages at the terminals indicated. Table 3-3 High Voltage Transformer (T1) Voltages Terminals Voltage Range TB4-3 to TB4-11 900-1050 volts AC* TB3-1 to chassis 100-120 volts AC TB3-2 to TB3-1 22-26 volts AC * If this AC voltage is substantially below the specified minimum value, check tuning capacitor C4. Revision 1 — 12-11-2003 FTS 400/800-4 Trigger Coupling Transformer (T3) High Voltage Transformer (T1) Visually observe the transformer for damage. Check the transformer for open windings by measuring the primary and secondary windings with an ohmmeter. An open winding indicates infinite ohms on the ohmmeter. A normal winding should indicate less than 200 ohms. Removal 1. Disconnect wires leading to the transformer 2. Remove four screws holding the transformer to the rear of the chassis and remove the transformer from the chassis. Timing and Trigger Board (PCB1) Replacement Reverse the removal procedure. Verify that wiring agrees with Figure 2-12. Replace this circuit board with one known to be in good condition. You may use temporarily a general purpose spare board, PN 2652318 or PN 2904413. It exercises all functions of the lighting unit but flashing does not occur in the correct sequence. The spare PN 2652318 or PN2904413 board must be programmed as instructed in the Timing and Trigger Board replacement procedure following if it is to replace the original circuit board. NOTE The PN 2652318 board does not function normally until you program it for one of the lighting units. Snip out the diodes on the replacement board to match those in the board that you are replacing. For PN 2904413 see section 5. for the programming procedure Trigger Coupling Transformer (T3) Removal 1. Disconnect the Faston connectors. Note the wire directions at the top of the primary and secondary coils. 2. Remove the two 4-40 x 2" phillips head screws holding the transformer assembly to the bracket. 3. Remove the transformer. Bleed Resistor (R1) Replacement 1. Reinstall the windings in the directions noted in Step 1 of Removal. Ensure that the wires have the same orientation. 2. Reattach the electrical wires. Verify that wiring agrees with Figure 2-12. The total measured resistance of the bleed circuit should be 85,000 ohms. Timing and Trigger Board (PCB1) Interlock Switch (S1) Try adjusting the switch bracket. The switch should clearly read zero ohms when it is closed and infinite ohms when it is open. Component Removal and Replacement This section contains instructions for removal and replacement of most major replaceable components. Refer to Section 4 for parts lists and locations, and component location diagrams for assembly and disassembly. Refer to Section 2 for installation and internal wiring. Figure 2-11 shows a wiring diagram for the flashheads. Internal wiring for the power converters is shown in Figure 2-12. FTS 400/800-4 Removal 1. Loosen, but do not remove, all eleven screws holding the circuit board to TB3. 2. Loosen, but do not remove, the screws at the top that hold the board to the front of the chassis and lift the board from TB3. Replacement 1. If you are replacing the PCB1 with a spare (PN 2652318 or PN 2904413), you must program the spare to initiate flashing in the proper sequence. For PN 2652318 program it by removing diodes from PCB1 for a specific lighting position by snipping out the appropriate diodes to match exactly those that are removed in the board you are replacing. Do not program the spare board until you are certain that you Revision 1 — 12-11-2003 3-11 want to use it in a particular position. For PN 2904413 see section 5. 2. Perform steps 1 and 2 of the Removal procedure in the reverse order. HV Rectifier Board (PCB2) Removal 1. Loosen, but do not remove, all eleven screws holding the circuit board to TB4. 2. Loosen, but do not remove, the screws at the top that hold the board to the front of the chassis and lift the board from TB4. Replacement Reverse the Removal procedure. 3-12 Capacitors Removal 1. Disconnect the wires leading to the capacitors. 2. Remove the hold-down screws. Lift capacitors from their receiving holes and away from the chassis. Replacement 1. Insert capacitors into their respective receiving holes. 2. Replace hold-down screws to secure capacitors to the chassis. 3. Reconnect wires to capacitors and verify that wiring is an accordance with Figure 2-12. Wires must be replaced exactly as removed. In some instances, a quick-connect wire terminal does not seat properly if it is not placed on the terminal cluster exactly as it was before removal. Sometimes the insulation on the wire terminal interferes with the insulation surrounding the terminal cluster on the capacitor. Revision 1 — 12-11-2003 FTS 400/800-4 Section 4 — Replaceable & Spare Parts Customer Service Flashhead Parts Customer Service: 1-800-821-5825 Telephone: (615) 261-2000 Facsimile: (615) 261-2600 Shipping Address: Flash Technology Corporation of America 332 Nichol Mill Lane Franklin, TN, 37067 Table 4-4 lists the major replaceable parts for the FH 400 Flashhead and the FH 800 Flashhead. Ordering Parts To order spare or replacement parts, contact FTCA customer service at 1-800-821-5825. Power Converter Parts Table 4-1 lists the major replaceable parts for the power converter. Internal Controller Parts Table 4-2 lists the major replaceable parts for the FTC 415 Internal Controller. Series Controller Parts Table 4-3 lists the major replaceable parts for the FTC 435 Series Controller. FTS 400/800-4 Returning Equipment Before returning equipment, call Customer Service at 1-800-821-5825 for a Return Material Authorization (RMA) number. Repackaging Return equipment in a container that provides maximum protection during shipping and handling. If the original cartons and packaging material are no longer available, package the units as follows: Ship and package the power converter in an upright position; that is, with the feet downward. 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 appropriate warning labels on the outside of the container. If you send the flashhead separately, package it in any reasonable, strong, corrugated cardboard box with enough firm padding surrounding the flashhead to prevent damage. Revision 1 — 12-11-2003 4-1 Table 4-1 Power Converter Major Replaceable Parts Unit Description Part Number Quantity All Enclosure 3727901 1 All Spacer, Ceramic 5900842 2 All R1, Resistor, 35K, Bleed 6900541 1 All R2, Resistor, 50K, Bleed 6900542 1 All T1, Transformer, Power: 120VAC 230/240VAC 60hz 230/240VAC 50hz 8841201 8841202 8842901 1 1 1 All K1/K2, Relay, Mode 8900494† 2 All L2, Choke, Flash 4175200 1 All T3, Transformer, Trigger Coupling 8336710 1 All TB2 Terminal Strip, 8-position 8721008 1 All PCB2, HV Rectifier Board 2458002† 1 All R4, Resistor 8435212 1 All Terminal Strip, 11-position 8721011 2 PCB1, Timing and Trigger Board, unprogrammed OR 2652318† 2904413† 1 1 All F1/F2, Fuse, Power 4900342 2 All VR1, Suppressor 6901081 1 All VR2, Suppressor 6901079 1 All TB1, Terminal Strip, 6-position 8721006 1 All R3, Resistor, Buffer 8435211 1 All Interlock Switch 4901220 1 PC800 C1, 20 mfd. capacitor 6731401 1 PC800 C2, 70 mfd. capacitor 6720401 1 PC800 C4, 3 mfd. capacitor 6577903 1 PC800 C5, C 6, 15 mfd. capacitor 6731301 2 PC800 C7, 5 mfd. capacitor 6731101 1 PC400 C1, 20 mfd. capacitor 6731401 1 PC400 C2, 40 mfd. capacitor 6386503 1 PC400 C4, 3 mfd. capacitor 6577903 1 PC400 C5, C6 15 mfd. capacitor 6731301 2 PC400 C7, 8 mfd. capacitor 3731201 1 Optional ETM Elapsed Time Meter 1749201 1 Optional K3 Flash Monitor Module 1851001 1 All † 4-2 Recommended as a spare part. NOTE: Program the spare board (PN 2652318) by removing the diodes in the spare to match exactly those that are removed in the PCB1 board that you are replacing. See section 5. for programming PN 2904413. Revision 1 — 12-11-2003 FTS 400/800-4 S1 C4 C2 C1 G2 R1 C5 C6 C7 R2 T3 L2 K2 T1 K1 REAR VIEW VR2 ELAPSED TIME METER (OPTIONAL) ETM 1 2 3 R3 4 5 6 TB1 PCB1 F1 PCB2 F2 TB2 R4 1 2 1 2 3 4 5 6 7 8 TB3 9 10 11 1 2 3 4 5 6 7 8 9 3 4 5 6 7 8 10 11 TB4 G1 FRONT VIEW END VIEW 3-7403-01S 81000041 Figure 4-1 PC 400 and PC 800 Power Converter Component Locations FTS 400/800-4 Revision 1 — 12-11-2003 4-3 Table 4-2 FTC 415 Controller Parts † Description Part Number Quantity Relay: K203< Power 120VAC 230/240VAC 8900493† 4900495† 1 1 Relay: K201 & K202, Mode 120VAC 230/240VAC 4900501† 4901762† 2 2 S201 Rotary Switch 4900893 1 F201 Fuse 4900342 1 Fuse Holder 4900377 1 TB201 Terminal Strip, 11-position 8721011 1 Suppressor: 120VAC 230/240VAC 6901079 6901081 1 1 Resistor 8435210 1 CB1 Circuit Breaker 4900120 1 Recommended as a spare part. K201 K202 MED HIGH RELAY RELAY F201 S201 K203 POWER RELAY CB1 REMOTE POWER OFF OFF 2 3 4 5 6 CTRL HI M LO MODE N FTC 415 LOW FUSE OFF TB201 1 REMOTE MED HIGH 3-7355-01G 81000044 Figure 4-2 FTC 415 Controller Component Locations 4-4 Revision 1 — 12-11-2003 FTS 400/800-4 Table 4-3 FTC 435 Controller Parts Description Part Number Quantity PCB, Current Sense Board 2760702 1 PCB, Relay Board 2767902 1 Enclosure 3714800 1 Transformer 4734500 1 Switch, Rotary 4900892 1 Terminal Strip, TB1, 3-position 4902157 1 Terminal Strip, TB2, 4-position 4902073 1 Terminal Strip, 11-position 8721011 1 PCB RELAY BOARD TRANSFORMER ENCLOSURE INTENSITY CONTROL LOW AUTO MED HIGH ROTARY SWITCH TB1 TB2 PCB CURRENT SENSE BOARD TERMINAL STRIP, 11-POSITION 81000045 Figure 4-3 FTC 435 Series Controller Component Locations FTS 400/800-4 Revision 1 — 12-11-2003 4-5 . Table 4-4 FH 400 and FH 800 Flashhead Major Replaceable Parts † 4-6 Flashhead Description Part No. Quantity FH 400 Lens 8743701 1 FH 400 Trigger Transformer 8288201 1 FH 400 Clamp, Lens 3893201 3 FH 400 Spacer, Ceramic 5900844 4 FH 400 RC Network RC101 1403411 1 FH 400 Flashtube FT 101 8384329† 1 FH 400 Terminal Screw Lug 3379102 3 FH 400 Spacer, Ceramic 5900842 4 FH 800 Flashtube FT101 8901701† 1 FH 800 RC Network RC101 1403411 1 FH 800 Trigger Transformer 8288201 1 FH 800 Post, Ceramic 5900842 4 FH 800 Retaining Bezel 3735202 3 Recommended as a spare part. Revision 1 — 12-11-2003 FTS 400/800-4 RC NETWORK RED DOT BLUE CONNECTING WIRE PUR WHT BLK BLU RED CONNECTING WIRE RED SMALL BLUE SECONDARY WIRE FROM TRIGGER TRANSFORMER WHITE TRIGGER SECONDARY WIRE FROM TRIGGER TRANSFORMER FLASH HEAD CABLE WIRES BLUE WIRES CONNECTED TO FASTONS ON PRIMARY COIL OF TRANSFORMER RED BLUE BLACK WHITE PURPLE AND GROUND LENS LENS CLAMP (3 PIECES) FLASHTUBE CERAMIC POSTS RC NETWORK WHITE TRIGGER SECONDARY WIRE FASTONS CERAMIC POSTS BLUE SECONDARY WIRE RED DOT TRIGGER TRANSFORMER BLUE WIRES WITH FASTONS 81000046 Figure 4-4 FH 400 Flashhead Component Locations FTS 400/800-4 Revision 1 — 12-11-2003 4-7 BLUE WIRE TO FLASHTUBE RED WIRE TO FLASHTUBE WHITE RED RC NETWORK BLUE MOUNTING NUT BLUE SECONDARY WIRE REAR VIEW OF FLASHTUBE CONNECTIONS BLUE WIRES BLUE WIRE BLUE FASTONS GROUND AND MOUNTING NUT PRIMARY SECONDARY WHITE WIRE TO FLASHTUBE PURPLE WIRE GROUND WIRE BLUE WIRE BLACK WIRE RED WIRE WHITE WIRE MOUNTING NUT NOTE: 1. WHEN INSTALLING THE FLASHTUBE IN THE HOUSING, ALIGN THE RAISED ARROW ON THE FLASHTUBE FACE WITH THE STUD ON THE RIM OF THE HOUSING. RC NETWORK STUD RAISED ARROW ON FLASHTUBE FACE FLASHTUBE TRIGGER TRANSFORMER STUD HOLE CERAMIC POSTS BEZEL 81000047 Figure 4-5 FH 800 Flashhead Component Locations 4-8 Revision 1 — 12-11-2003 FTS 400/800-4 Section 5 — Programming T&T Board P/N 2904413 Connecting the Handheld Table 5-1 shows the connector pin assignments for the handheld. The receive and transmit directions shown in the table are with respect to the handheld. The DB9 connector is located at the top of the handheld programmer. Table 5-1 Pin Assignments DB9 Female 3 6 2 1 9 5 EIA-232 Function Receive +receive No connection -receive Transmit +transmit No connection -transmit Power Ground Figure 5-1 FIGURE 5-1 Handheld Programmer Using the Programmer A 9-pin RS-232 cable is used to connect the handheld to the 9044-01 controller board at connector J2 (9 pin Male connector). Power and ground is provided by this connector. The same connector J2 on the 9044-01 is also used to connect a computer serial port for the enhanced user interface. This interface is used to set parameters, run production and vendor tests and display general operating information. FTS 400/800-4 The programmer has a four line LCD display and 24 keys as shown in fig. 5.1. The following is a general discussion of how the programmer works. See Parameters under the SETUP section below for more details. In the discussions to follow the 4 line LCD display will be represented as shown: Revision 1— 12-11-2003 5-1 F2: Enters the information menu, used to show a limited amount of useful operating info. L1: ********** F3: Causes the 9044-01 to perform the short test. L2: ********** F4: Enters the mode change menu, used to manually change the operating mode (HIGH, MED, and LOW). Note: For PN 2904413 DAY equals HIGH, TWI equals MED and NITE equals LOW intensity L3: ********** L4: ********** All the messages displayed on the LCD will be in capital letters. The display does not show the L1: etc. this is used to represent line 1, 2, 3 and 4 on the LCD. Once the handheld programmer is connected to the 9044-01 and power is applied the 9044-01 will automatically recognize that the terminal is connected to it and will display the sign on message . Only terminals provided by Flash Technology will work with the 9044-01. The general format of the sign on message is: Note: The handheld terminal will return to the sign on message from any other menu if no key is pressed within two minutes. The 9044-01 does this to take the serial port out of the handheld terminal mode if the terminal has been removed to allow the serial port to be used for the enhanced user interface. This means that if you remove the handheld terminal and connect a computer to use the enhanced interface you must wait at most two minutes before pressing any key on the computer. You can cycle the power to the 9044-01 for faster access to the computer interface. SETUP The setup menu has the following format: L1: FLASH TECHNOLOGY L1: SETUP L2: BOARD 5978 L2: 0-1-1 L3: (Blank or further information) L3: L4: ENTER TO CONTINUE L4: OK Once enter is pressed the first menu is displayed as follows: L1: PRESS A FUNC KEY L2: F1. SETUP F2. INFO NEXT BACK EXIT The first line displays the current menu. The second line displays the current setup. The numbers correspond to the selected parameters. The third line is blank. The fourth line displays what functions the keys F1 thru F4 will perform if pressed; the words are spaced to be over the corresponding function key. So, to move to the next menu you would press F2 (NEXT). L3: F3. SHORTTEST F1: OK- is used to enter data. L4: F4. MODE CHANGE F2: NEXT- moves to the next item. To continue further a function key must be pressed. The function keys are on the top row of the terminal. See fig. 5.1. F3: BACK- moves to the previous item. F4: EXIT- exits the setup menu. F1: Enters the setup menus, used to configure the 9044-01. 5-2 Revision 1 — 12-11-2003 FTS 400/800-4 Parameters L4: OK Pressing the NEXT or BACK function key from the SETUP menu takes you to the parameters. The general format is: Then press 1 for the 400 series or 5 for the 800 series and press F1 (OK) NEXT BACK EXIT L2: SYSTEM Flicks default to single and generally do not need to be changed. To change the flicks press NEXT until the LCD shows: L3: 0- Bec. 1- Air. 2- Hel L1: SETUP L1: SETUP L4: OK NEXT BACK L2: FLICKS EXIT The currently selected option will have the cursor under it. For example: L3: 0-Single 1-Double L4: OK 0-Bec 1-Air 2-Hel shows that the currently selected option for the parameter is zero (0) which in this case means Omni Beacon. If the board your are configuring is not in the Airport mode press 1 and press F1 (OK). **Note: Even if your board is configured for Airport mode you will need to press 1 and F1 to change the light number.** INFO The info menu has the following format: L2: AIRPORT # 1 L3: L3: Enter Light # L4: NEXT BACK INFO L2: BOARD 5978 L1: SETUP L4: OK EXIT Then press 0 or 1 and press F1 (OK) to change it. Note that 0-Single is the default and the standard. L1: The display will change to: NEXT BACK EXIT Press the number keys to select the light number you wish this board to be and then press F1 (OK). The Airport number displayed will change. When you are done press NEXT or BACK. NEXT BACK EXIT This menu is used to show a limited amount of information about the current 9044-01 operation and configuration. To change the Flash rate press NEXT until the LCD shows: NOTE: Valid flash rates are 60fpm for 400 series lights and 120 fpm for 800 series lights. The first line displays the current menu. The second and third lines display board information. The fourth line displays what functions the keys F2 thru F4 will perform if pressed; the words are spaced to be over the corresponding function key. So, to move to the next item you would press F2 (NEXT). L1: SETUP F2: NEXT- moves to the next item. L2: FPM 1-60 2-30 F3: BACK- moves to the previous item. L3: 3-20 4-100 5-120 F4: EXIT- exits the setup menu. FTS 400/800-4 Revision 1— 12-11-2003 5-3 Items like energy, trigger voltage, flash rate and operating mode are displayed. F1: HIGH- Changes the intensity to DAY/HIGH. F2: MED- Changes the intensity to TWI/MED. F3: LOW- Changes the intensity to NITE/LOW. MODE CHANGE The mode change menu has the following format: L1: F4: EXIT- exits the mode change menu and returns the mode to automatic. MODE CONTROL L2: CURRENT DAY/HIGH L3: This menu item is used to manually change the operating modes and functions just like the test jumpers on the board. L4: HIGH MED LOW EXIT 5-4 Revision 1 — 12-11-2003 FTS 400/800-4 INDEX A Access 2-1 FH 400 flashhead 2-1 FH 800 flashhead 2-1 power converter 2-1 ALS figure basic configuration 2-5 FTS 400 basic description 1-1 FTS 800 basic description 1-1 light alignment 1-1 B Bleed resistor testing 3-11 C Capacitor removal 3-12 testing 3-10 Checklist installation 2-2 Checkout master unit 3-2 slave unit 3-3, 3-4 CI 425 control interface part location figure 4-4 Comounted unit mounting and outline figure PC 400 2-10 PC 800 2-11 Component removal and replacement 3-11 testing 3-10 Configuration figure basic ALS 2-5 REIL 2-4 Control line interference 3-2 Control signal evaluation 3-1 Controls figure FTC 435 series controller 1-4 FTC 435 system controller FTS 400/800-4 current sense board 1-4 Controls and indicators 1-2 figure FTC 415 system controller 1-3 table FTC 415 system controller 1-3 Customer service 4-1 D Diagnostic testing 3-1 E Elapsed time meter 1-2 Equipment returning 4-1 storage 3-1 F FH 400 flashhead access 2-1 basic description 1-1 figure mounting and outline 2-7 part location figure 4-7 parts table 4-6 FH 800 flashhead access 2-1 basic description 1-1 figure mounting and outline 2-8 part location 4-8 parts table 4-6 Flash monitor 1-2 Flashhead figure internal wiring 2-14 mounting and outline FH 400 2-7 FH 800 2-8 mounting check 2-3 wiring check 2-3 Flashtube testing 3-10 FTC 415 figure system controller internal wiring 2-16 FTC 415 system controller controls and indicators figure 1-3 Revision 1—12-11-2003 I-1 controls and indicators table 1-3 figure part location 4-4 parts table 4-4 FTC 435 figure system controller internal wiring 2-17 FTC 435 system controller basic description 1-2 figure controls 1-4 current sense board 1-4 mounting and outline 2-9 part location figure 4-5 parts table 4-5 setup 1-4 FTS 400 basic description 1-1 FTS 800 basic description 1-1 switch testing 3-11 L Light problems individual 3-5 Location figure CI 425 control interface parts 4-4 FH 400 flashhead parts 4-7 FH 800 flashhead parts 4-8 FTC 415 system controller parts 4-4 FTC 435 system controller parts 4-5 power converter parts 4-3 M Maintenance preventive 3-1 Master unit checkout 3-2 Meter elapsed time 1-2 Mounting 2-1 flashhead check 2-3 power converter check 2-3 Mounting and outline comounted unit figure PC 400 2-10 PC 800 2-11 figure flashhead FH 400 2-7 FH 800 2-8 FTC 435 system controller 2-9 power converter 2-6 G General information 1-1 H High voltage, See HV HV rectifier board removal 3-12 testing 3-10 transformer removal 3-11 testing 3-10 I Individual light problems 3-5 Installation 2-1 checklist 2-2 figure typical wiring FTC 435 series controller 2-13 FTS 410 or FTS 810 with internal controller 2-12 typical wiring 2-2 Interference control line 3-2 radio frequency 3-2 Interlock I-2 O Operation basic 1-2 Ordering parts 4-1 P Parts 4-1 ordering 4-1 table FH 400 flashhead 4-6 FH 800 flashhead 4-6 FTC 415 system controller 4-4 FTC 435 system controller 4-5 power converter 4-2 PCB1 timing and trigger board figure 3-8 Revision 1— 12-11-2003 FTS 400/800-4 Phase power 3-2 Power converter access 2-1 figure internal wiring 2-15 mounting and outline 2-6 part location 4-3 mounting check 2-3 parts table 4-2 Power phasing 3-2 Preventive maintenance 3-1 Problems individual light 3-5 system level 3-5 R Radio frequency interference, See RFI REIL figure basic configuration 2-4 light alignment 1-1 Relay testing 3-10 Removal capacitor 3-12 component 3-11 components 3-11 HV rectifier board 3-12 HV transformer 3-11 timing and trigger board 3-11 trigger coupling transformer 3-11 Repackaging 4-1 Replacement component 3-11 Returning equipment 4-1 RFI 3-2 S Safety 3-1, 5-1 Setup FTC 435 system controller 1-4 Slave unit checkout 3-3, 3-4 Specifications 1-1 Storage equipment 3-1 System operation FTS 400/800-4 basic 1-2 System-level problems 3-5 T Testing bleed resistor 3-11 capacitors 3-10 components 3-10 diagnostic 3-1 flashtubes 3-10 HV rectifier board 3-10 HV transformer 3-10 interlock switch 3-11 relays 3-10 timing and trigger board 3-11 trigger coupling transformer 3-11 Timing and trigger board figure 3-8 removal 3-11 testing 3-11 Tools 2-1 Transformer removal HV 3-11 trigger coupling 3-11 Trigger coupling transformer removal 3-11 testing 3-11 Troubleshooting 3-5 table individual light 3-7 system-level 3-6 U Unpacking 2-1 W Wiring check flashhead 2-3 power converter 2-3 figure internal flashhead 2-14 FTC 415 system controller 2-16 FTC 435 system controller 2-17 power converter 2-15 typical installation FTC 435 series controller 2-13 Revision 1—12-11-2003 I-3 FTS 410 or FTS 810 with internal controller 2-12 I-4 Revision 1— 12-11-2003 FTS 400/800-4