Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
______________________________________________________________________
INSTALLATION AND MAINTENANCE
MANUAL
FOR
P/N D1RW-C13-006: 110/240VAC, 50/60 Hz,
L865, DUAL MEDIUM INTENSITY WHITE
STROBE & L864 RED BEACON
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 1 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Contents
Page
Section 1: Overview-----------------------------------------------------------------------------3
Section 2: Installation and Wiring ----------------------------------------------------------5
Section 3: Operation and Initial Test ---------------------------------------------------- 12
Section 4: Lightning Protection ----------------------------------------------------------- 13
Section 5: Maintenance and Troubleshooting --------------------------------------- 13
Section 6: Specifications -------------------------------------------------------------------- 16
Section 7: Regulatory Compliance and Certifications----------------------------- 17
Section 8: Dialight Warranty Statement ------------------------------------------------ 17
List of Figures and Tables
Figure 1. Internal Block Diagram ........................................................................................................... 4
Table 1. Conductor Color and Pin Out of Supplied 15 ft Cable .................................................... 6
Figure 2. DIN Rail Label ........................................................................................................................... 6
Figure 3. System Block Diagram ........................................................................................................... 7
Figure 4. Internal Equivalent Circuit of Monitor Output .................................................................. 9
Figure 5. Base – Bottom View .............................................................................................................. 10
Figure 6. Light Engine Dimensions..................................................................................................... 11
Table 2. Troubleshooting...................................................................................................................... 14
Figure 7. Internal View of Power Supply Cabinet............................................................................ 15
Table 3. Recommended Spare Parts ................................................................................................. 16
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 2 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Section 1: Overview
The Dialight Medium Intensity White Strobe and Red Beacon is designed for the
lighting of radio towers, wind generators and other obstructions to aerial
navigation, as specified by the FAA and FCC.
This design uses LED technology for light output both from the Beacon and
White Strobe. Unlike conventional xenon flashtube technology, little or no
maintenance is required during its lifetime. Working voltages of less than
200VDC are much lower than with xenon flashtube designs; therefore, this
system represents an advance in safety.
The Dual L865 & L864 operate from a 110/240VAC 50/60 Hz supply. It consists
of a White Strobe section and a Beacon section, which operate independently of
each other. The system consists of a light engine and a power supply box joined
by a multi-way cable. The White Strobe section of the light engine consists of
several layers of white LEDs. Each layer is driven from its own driver module
contained in the power supply box. The Beacon section consists of 36 High
Performance LEDs driven by a module in the power supply box. In addition, a
control box that may be located a considerable distance away from the light
engine and power supply, such as at the base of the tower, allows the system to
be controlled and monitored.
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 3 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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110-240V Beacon Supply
Beacon driver
Beacon LED’s
Strobe driver
3x Strobe LED strings
Strobe driver
3x Strobe LED strings
Strobe driver
3x Strobe LED strings
110-240V Strobe supply
Optoisolators
Microcontroller
Power Supply Box
Light Engine
Figure 1. Internal Block Diagram
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 4 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Section 2: Installation and Wiring
The Power supply cabinet is designed to mount vertically, with power and
interconnection cables emerging from the bottom of the unit, and with up to 550ft
of cable between the Power Supply and Light Engine.
There are three options for wiring the Light Engine to the Power Supply:
1. DIN Rail of Power Supply to Light Engine
Use the cable supplied (15ft) to connect the Power Supply using the DIN
Rail Terminals and connector at base of Light Engine. This will require the
power supply to be mounted within the extent of the supplied cable.
The following two options are for mounting the Power Supply at an extended
distance (550 ft Max.) from the Light Engine. Use the prescribed cable (below).
This will allow the installer to select a length more suitable to the application and
permit the use of the quick connector when attaching to the light engine.
2. Using the supplied cable with connector, splice cable onto Light Engine side
of Long Run Cable. NOTE THE COLOR MATCH FROM SUPPLIED CABLE
AND THE LONG RUN CABLE SELECTED! Attach female connector to Light
Engine.
3. Using the supplied Female connector and insert, attach to Light Engine side
of Long Run Cable and connect directly to Light Engine.
All options utilize the available DIN Rail Terminals supplied in the Power Supply
Box. These DIN Rail terminals allow a direct connect to the Power Supply. The
procedure for this is as follows:
A. Punch a 1.05” hole, in a convenient location, in the bottom of the box.
B. Choose a ¾” NPT liquid tight connector with a grip range suitable for the
Long Run Cable selected (Supplied).
C. Install a Liquid Tight connector and cable into the Power Supply Box. The
shield of the cable should be connected to ground by means of a metal
ring-clamp surrounding the braid and screwed to the base plate using the
1/4-20 threaded hole located below and to the right of the DIN rail.
D. Connect the Long run cable conductors to the DIN Rail Connectors per
the Color Code Chart (Table #1) below.
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 5 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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BEACON(+)
BEACON RTN
STROBE 3 (+)
STROBE 3 RTN 1
STROBE 3 RTN 2
STROBE 3 RTN 3
STROBE 4 (+)
STROBE 4 RTN 1
STROBE 4 RTN 2
STROBE 4 RTN 3
STROBE 1 (+)
STROBE 1 RTN 1
STROBE 1 RTN 2
STROBE 1 RTN 3
17
7
13
3
4
5
16
8
9
10
12
11
1
2
WHITE
BLACK
ORANGE
RED/GREEN
RED/YELLOW
BLUE
RED
BROWN
YELLOW
VIOLET
GREEN
GRAY
PINK
TAN
Table 1. Conductor Color and Pin Out of Supplied 15 ft Cable
ATTENTION : THESE COLORS APPLY TO THE SUPPLIED CABLE AND
SHOULD BE CONVERTED FOR LONG RUN CABLE COLORS!
Figure 2. DIN Rail Label
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 6 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Controller Cabinet
Power
Supply
Cabinet
Light
Engine
Power In
Multi-way connection
cable
Figure 3. System Block Diagram
Controller to Power Supply Connections
Ground
Neutral
White Strobe Line
Red Beacon Line
Night Mode
Sync
Strobe Monitor
Safety ground/earth wire
Neutral, common to Beacon and Strobe
110-240VAC Strobe power
110-240VAC Red Beacon power
Apply 110-240V for night mode
Apply 110-240V bursts to synchronize Strobe flashes
Open collector transistor output indicating strobe is
operating correctly
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 7 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Note:
1: The sync signal is not required if there is no need to synchronize with another
strobe. In the absence of a sync signal, the strobe will operate at one flash every
1.5 seconds (40FPM).
2: In order to be used with up to 550ft cable length, the cable must meet the
following minimum specification:







14 conductors
20 AWG
Rated for outdoor use
-40 to +55C temperature range
Rated for at least 200V between conductors
Shielded
Max overall diameter 12mm
This model has been ETL tested with the following cable type:
15 conductor, 20AWG, -49C to 125C, 300V, shielded.
One possible source is Industrial Electric Wire and Cable Inc. (888-530-3211)
part number PLTC2015COSS-0DG (1,000ft reel).
3: For maximum immunity from the effects of radiated interference, the cable
from the Control Box to Power Supply Cabinet should be shielded with the shield
grounded at both ends.
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 8 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Strobe Monitor Signal
The Strobe Monitor signal provides an alternative means of monitoring the
Strobe. An open-collector transistor whose emitter is connected to earth/ground
generates this signal.
When working properly, the transistor is turned on during the strobe flash and
turned off during the off period. If the transistor is permanently on or off while the
strobe is powered, this indicates a strobe fault.
The collector of the transistor may be pulled up to a DC voltage of +14V
maximum with respect to ground, and has a series impedance of 440 ohms.
440 ohms
Monitor Output
Figure 4. Internal Equivalent Circuit of Monitor Output
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 9 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Mounting the Light Engine
Dialight recommends the installation of one or more lightning rods near the
installed Light Engine. The lightning rods should extend a minimum of three feet
above the height of the Beacon.
The Light Engine is mounted to the tower pedestal utilizing customer supplied ½”
hardware. Six mounting holes are provided on the Light Engine base (Figure 2).
These mounting holes will align with most tower pedestals. The Light Engine
must be installed level to maintain light output in accordance with FAA
requirements.
Figure 5. Base – Bottom View
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 10 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
_____________________________________________________________________
Figure 6. Light Engine Dimensions
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 11 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Section 3: Operation and Initial Test
Warning: The power supply must be grounded
Prior to installation, it is recommended that the unit be tested to ensure no
damage was incurred during shipping.
1: Connect the multi-way cable between the light engine and power supply. Do
not force the connector into its mating half. Carefully align the mating halves of
the polarized connector before tightening the locking ring.
2: Connect the power supply either to the Controller or to a mains supply in
accordance with the wiring table in section 2, using the connection terminals
located towards the bottom of the power supply cabinet.
To test the Red Beacon connect a 110-240VAC supply to the Red Beacon line
terminal.
To test the Strobe, connect 110-240VAC to the White Strobe line terminal.
In the event of Beacon Failure, the white strobe may be operated in a low
intensity Night-mode. For this mode 110-240V is applied to both the Strobe line
terminal and the Night mode terminal.
If a system consists of only one light, the Sync signal need not be used.
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 12 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Section 4: Lightning Protection
Both the Strobe section and Red Beacon incorporate protection against voltage
surges that may be induced by nearby lightning strikes by means of MOVs and
Gas Discharge Tubes (GDTs). It is designed to withstand 6kV/3kA surges as
required by FAA 150-5345-43F.
Section 5: Maintenance and Troubleshooting
No regular scheduled maintenance is required for the L865.
Dialight warranties the light output of the L865 to meet or exceed FAA
requirements for a 5 year period (See Section 8, Dialight Warranty Statement).
Warning:
Remove power from all wiring and circuitry before installing or working on the
L865.
Each driver module has a red indicator light to indicate more than 50VDC present
on its output. In addition, the capacitor board has red indicator lights (one for
each of the large energy storage capacitors) to show the capacitor is charged to
at least 50V.
For safety, when the Power supply cabinet door is opened, an interlock switch
disconnects power from all the driver modules. If the unit has just been running,
a number of driver module indicators lights will be lit. These should go out within
30 seconds to indicate voltages on capacitors have been discharged to less than
50V.
Table 2 Lists possible faults and repair procedures for the L-865
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 13 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Table 2. Troubleshooting
Symptom
White Strobe will not
operate. No
indicator LEDs lit
inside power supply
cabinet
White Strobe initially
operates then shuts
down
White Strobe will not
operate, but all
indicators on
capacitor board are
lit
Red Beacon will not
operate. Indicator
on Beacon driver
module not lit
Red Beacon will not
operate. Indicator
on Beacon driver
module is lit
Possible Cause
No power to Strobe
section
Corrective Action
Check Strobe line connection.
Several LED string
failures and/or driver
module failures,
resulting in automatic
shut down
Cable between power
supply and light
engine disconnected
Replace any faulty driver modules.
No power to Beacon
module
Check power connections to
Beacon section.
Possible bad
connection between
driver module and
light engine.
Check cable between light engine
and power supply is connected
properly.
Check driver module operation.
Check cable connections.
Check LED string for failure.
Possible LED string
failure.
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 14 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Capacitor Board
Strobe Driver
Red Beacon Driver
Filter & Micro Board
DIN RAIL
TERMINALS
Figure 7. Internal View of Power Supply Cabinet
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 15 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Table 3. Recommended Spare Parts
Description
Light Engine Module
Power Supply
Light Engine to Power Supply Cable
Dialight Part Number
8800-865-0015-00
8800-865-0065-00
8800-865-0094-00
Section 6: Specifications
Operating Temperature Range
-40°C to +55°C
Power Supply Specifications
Dimensions
Weight
Input Voltage Range
Input Power, Red Beacon section
Input Power, White Strobe section
Frequency
Power Factor
Maximum Strobe flash rate
16x16x7”
39 Pounds
110-240VAC, 50/60Hz
35W (steady burning)
160W (day mode at 40FPM)
50/60Hz
>0.9
40FPM
Light Engine Specifications
Weight
Height (See Fig. 6)
Diameter (See Fig. 6)
Bolt Hold down Pattern
62 Pounds
18.04 Inches (not including hoist ring)
18.45 Inches
Standard Pattern provided (See Fig. 5)
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 16 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Section 7: Regulatory Compliance and Certifications
7.1 ETL Certified to: Federal Aviation Administration (FAA): AC No. (150/534543F).
7.2 Compliant to: Federal Communications Commission (FCC): This device
complies with part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference. And (2) this
device must accept any interference that may cause undesired operation.
Section 8: Dialight Warranty Statement
DIALIGHT CORPORATION
Warranty, Obstruction Lighting
Dialight Corporation (“Dialight”) warrants to the original end-user (“Purchaser”) of “Dialight”-brand LED
obstruction lighting (“Products”), that at the date of their purchase, “Products” will: (1) be free of defects
in material and workmanship, and (2) meet their light-emitting requirements as defined in the FAA
(Federal Aviation Administration) – Advisory Circular 150/5345-43F
5 Year Warranty for Materials and Workmanship: For a period of Five (5) years after the date of purchase,
“Dialight”, at its sole option, will, itself, or through others, repair, replace or refund the price paid for
“Product” that “Dialight” verifies as being inoperable due to original material or workmanship.
5 Year Warranty Against Light Degradation: For a period of Five (5) years after the date of installation,
“Dialight”, at its sole option, will, itself, or through others, repair, replace or refund the price paid for
“Product” that “Dialight” verifies as failing to meet 70% of the minimum intensity requirements as defined
in the Advisory Circular 150/5345-43F.
What the Warranty Does Not Cover: This warranty does not cover (1) Product advice or assistance that
“Dialight” furnishes as a courtesy, (2) removal or reinstallation of “Products”, or (3) defects or damage as
a result of accident, modification, misuse, including but not limited to the operation at temperatures above
55oC or voltage levels outside the rated range, improper service or repair, abuse or abnormal use including,
without limitation, improper storage and incorrect installation.
Conditions of Warranties: It is a condition of these warranties that: (1) the “Purchaser” submit all claims
of defect or light-emission degradation within the specified warranty periods, in writing and with detail;
(2) return of “Product” is accompanied with a bill of sale or other evidence showing the date of purchase
and identification of the original “Purchaser”; (3) the “Purchaser” prepay all freight, insurance and other
transportation charges both to send “Product” to “Dialight” for warranty-coverage verification, repair,
replacement or refund, and to return “Product” to the “Purchaser”; and (4) “Dialight” retains all repaired
and replaced parts and “Products”.
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 17 of 18
Document: 9100-127-0962-99
Revision: C
Date: 08-15-08
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Warranty Limitations: In no event shall this warranty run to OEM or component-part buyers. All
replacement “Products” are warranted only for the remainder of the original warranty of the “Product”
replaced. Replacement “Products” will be equivalent in function, but not necessarily identical to, the
replaced “Product”. Repair, replacement or refund as set forth in these warranties is the sole and exclusive
remedy under these warranties or otherwise for “Product” defects or light-emission degradation.
“DIALIGHT” DISCLAIMS ALL OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION,
AND IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
Damage Limitations: “DIALIGHT” IS NOT LIABLE FOR, AND HEREBY DISCLAIMS, ALL
DAMAGES CAUSED BY ANY PRODUCT OR THE FAILURE OF A “PRODUCT” TO PERFORM,
INCLUDING, WITHOUT LIMITATION, DIRECT, INDIRECT, SPECIAL, INCIDENTAL, PUNITIVE
OR CONSEQUENTIAL DAMAGES OR LOSS OF PROFITS OR SAVINGS, UNDER ANY LEGAL
THEORY, INCLUDING, WITHOUT LIMITATION, TORT (INCLUDING NEGLIGENCE AND
STRICT “PRODUCT” LIABILITY) OR CONTRACT, SUSTAINED BY “PURCHASER” OR BY ANY
OTHER PERSON. THIS LIMITATION CAN NOT BE WAIVED OR AMENDED BY ANY PERSON
AND WILL BE EFFECTIVE EVEN IF “DIALIGHT” OR ITS REPRESENTATIVE HAS BEEN
ADVISED OF, OR MIGHT HAVE ANTICIPATED, THE POSSIBILITY OF SUCH DAMAGES. THIS
LIMITATION OF LIABILITY MAY NOT APPLY TO DAMAGES RELATING TO PERSONAL
INJURY OR DEATH IN JURISDICTIONS WHERE SUCH DAMAGES MAY NOT BE DISCLAIMED
AS A MATTER OF LAW.
How to Obtain Warranty Service: To obtain warranty service, “Purchaser” must obtain a "Return Material
Authorization" (RMA) number from the Dialight TPG Customer Service Group in Farmingdale N.J. (732)
919-3119.
_____________________________________________________________________________
Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727
Tel: 732.919.3119 Fax:732.751.5778 Web: www.dialight.com
Sheet 18 of 18