Install and Maintain High Intensity Strobe Light System

Document: 9100-127-2905-99
Revision B
Release Date: 1/23/2017
INSTALLATION AND MAINTENANCE MANUAL

FOR
L-856 / L-864 High Intensity Strobe
D266-A57-CTR-AC
(Base Controller)
D266-A57-270 (Power Supply and Flash Head)
Diali gh t Corp orat io n 1501 Route 34 South F armingda le NJ 07727

Tel: 732.919.3119 F ax: 732.751.5778 Web: www.diali gh t.com
Document: 9100-127-2905-99
Revision B
C O NTEN TS PAGE
Notice and Warnings --------------------------------------------------------------------------------- 3

Product Overview -------------------------------------------------------------------------------------- 4
Terminology --------------------------------------------------------------------------------------------- 6
Getting Started ----------------------------------------------------------------------------------------- 7
Section 1.0: Tower Preparation ------------------------------------------------------------------ 7
Section 2.0: Choosing a circuit breaker ------------------------------------------------------- 8
Section 3.0: Base Controller Preparation ---------------------------------------------------- 9
Section 4.0: Photocell Installation ------------------------------------------------------------- 11
Section 5.0: OB or L810 Connections --------------------------------------------------------- 12
Section 6.0: Sync Input (with Optional GPS Hardware) -------------------------------- 12
Section 7.0: Sync Output (with Optional GPS Hardware) ------------------------------ 13
Section 8.0: AOL Enable / Disable ------------------------------------------------------------- 13
Section 9.0: Adding Additional Interfaces -------------------------------------------------- 13
Section 10.0: Photocell Validation ------------------------------------------------------------- 14
Section 11.0: Initial Power Supply Preparation ------------------------------------------- 15
Section 12.0: Power Supply Addressing ---------------------------------------------------- 16
Section 13.0: Power Supply Cable Definition & DC Connections------------------- 18
Section 14.0: Flash Head Communication Connections ------------------------------- 22
Section 15.0: Other Power Supply Preparation ------------------------------------------- 22
Section 17.0: Mounting Power Supply Enclosures -------------------------------------- 25
Section 18.0: Mounting Flash Heads ---------------------------------------------------------- 27
Section 20.0: System Power Up ---------------------------------------------------------------- 31
Section 21.0: Alarm Relays ----------------------------------------------------------------------- 31
Section 22.0: Additional Information ---------------------------------------------------------- 33
Section 23.0: Troubleshooting ------------------------------------------------------------------- 33
Section 24.0: System Specifications----------------------------------------------------------- 38
Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Tel: 732.919.3119 Fax: 732.751.5778 Web: www.dialight.com
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Notice and Warnings
This manual contains important information regarding the proper installation, operation, and
maintenance of this product. Before using the product, read and understand all instructions,
cautions, and warnings; as well as all of the labels affixed to the product. Failure to do so
could result in personal injury or damage to the equipment, and/or void the product warranty.
FAILURE TO LEAVE THE ENCLOSURES FREE FROM DEBRIS UPON COMPLETION OF

INSTALLATION MAY CAUSE SHORT CIRCUITS AND VOID THE SYSTEM WARRANY.
FAILURE TO TIGHTEN DOWN CLAMP WASHERS WILL MAKE INTERNAL COMPONENTS

VULNERABLE TO SURGE OR LIGHTNING DAMAGE AND VOID THE SYSTEM WARRANY.
FAILURE TO PROPERLY BOND THE EARTH GROUND WIRE TO THE JUNCTION BOX WILL
RESULT IN EVENTUAL LIGHTNING DAMAGE OF THIS SYSTEM. TO AVOID WARRANTY
NULLIFICATION, FOLLOW ALL DIRECTIONS IN THEIR ENTIRETY.
CAUTION: PHOTOCELL ONLY TO BE CONNECTED TO MONITOR BOARD USING

TERMINAL BLOCKS PROVIDED
WARNING: FAILURE TO PROPERLY BOND THE FLASH HEADS AND POWER SUPPLY
ENCLOSURES TO THE TOWER STRUCTURE WILL RESULT IN EVENTUAL LIGHTNING
DAMAGE OF THIS SYSTEM. THE SYSTEM’S WARRANTY SHALL BE VOID IF ALL FLASH
HEADS AND POWER SUPPLY ENCLOSURES ARE NOT PROPERLY BONDED TO THE TOWER
STRUCTURE. TO AVOID WARRANTY NULLIFICATION, FOLLOW ALL DIRECTIONS IN
THEIR ENTIRETY.
CAUTION: NEVER LOOK AT THE FRONT OF A FLASH HEAD WHILE THE SYSTEM IS
ENERGIZED. THE FLASH HEAD COULD START FLASHING CAUSING TEMPORARY
BLINDNESS WHICH WOULD BE DANGEROUS AT HIGH ELEVATIONS.

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FAILURE TO SET UP SYSTEM CORRECTLY DURING START UP WILL RESULT IN THE

TOWER HAVING TO BE CLIMBED AGAIN TO PERFORM TROUBLESHOOTING.
DIALIGHT CORPORTATION DOES NOT WARANTEE THE HIGH INTENSITY SYSTEM WHEN
USING IT WITH A TEMPORARY POWER SOURCE.
DIALIGHT CORPORTATION DOES REQUIRE PICTURES OF THE INSTALLATION FOR

COMMISIONING PURPOSES. FAILURE TO DO WILL VOID ALL ALL WARRANTIES.
THE SITE MANAGER OR OWNER MUST SUPPLY RECENT PICTURES OF THE STRUCTURE
TO ENSURE ACCURACY OF THE LIGHTING SYSTEM AND HARDWARE SUPPLIED.
ADEQUATE WIRING GAUGES AND BREAKER SIZES ARE THE RESPONSIBILITY OF THE
SUPPLIER OF THE SYSTEM.
SPECIAL CONSIDERATIONS ARE REQUIRED FOR INSTALLING ON HOT AM TOWERS.

CONTACT THE SUPPLIER OF THE SYSTEM WHEN IN DOUBT.
AC INPUT TOLERANCES ARE A MAXIMUM OF +/-10% OF THE NOMINAL VOLTAGES

SHOWN IN THE MANUAL

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Product Overview
The Dialight L-856 / L-864 High Intensity White / Red Strobe System, herein referred
to as the System, is designed to for the lighting of tall structures such as television and radio
towers, chimneys, cooling towers, tall buildings, wind generators and other obstructions to
aerial navigation, per specification by the FAA.
This product uses LED technology within each Flash Head to produce white strobe
light. Unlike conventional xenon flashtube technology, little or no maintenance is required
during the lifetime of this System. Working voltages within this System never exceed 200
Volts DC. Therefore by significantly lowering the working voltage with respect to Xenon white
strobes, this System represents an advance in obstruction lighting safety and efficiency.
One Base Controller Enclosure is required to enable the System regardless of system
scale. For example a System with three Flash Heads and a System with eighteen Flash
Heads both need the same Base Controller Enclosure to operate.
With the use and proper setup of the Base Controller each of the below systems can
be configured through the LCD display.
White Only System

The System may comprise up to eighteen L-856 High Intensity White Strobe Flash
Heads; each with a corresponding Power Supply Enclosure, e.g. one Power Supply
Enclosure per Flash Head. The Flash Heads are typically distributed as three per level on up
to six levels, for a maximum of eighteen Flash Heads.
Red/White System
The System may comprise up to eighteen L-856/864 High Intensity White Strobe Flash
Heads which have the RED L-864 included in each of the LED modules. Each has a
corresponding Power Supply Enclosure, e.g. one Power Supply Enclosure per Flash Head.
The Flash Heads are typically distributed as three per level on up to six levels, for a maximum
of eighteen Flash Heads. L810 Marker Lights are also monitored through the base controller.
AOL Strobe
Additionally, one L-864/L-865 Medium Intensity Strobe may be integrated into the
system as an Antenna Obstruction Light (AOL). The Base Controller will synchronize,
monitor, and control the entire System, as well the Antenna Obstruction Lights.

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Terminology
The following definitions apply to the System:
L856 FAA classification of a flashing white High Intensity Obstruction Light, 40 FPM
L864 FAA classification of a flashing Red Medium Intensity Obstruction Light, 20-30 FPM
L810 FAA classification of a Red Steady Burning Obstruction Light
Base Controller Master Control Cabinet
LCD Screen Liquid Crystal Display; forty character module
Micro Board Printed circuit board with onboard micro controller
Relay Board Provides 8 external connections for alarm status and monitoring
Alarms Alarm faults that need to verified and corrected, NOTAM must be reported
Events are notice to the site manager that an “event” occurred but has NOT caused
Events an alarm. I.E. power on, Power Supply was turned off. These are also used to
troubleshoot alarms.
Power Supply Enclosure mounted to the tower controlling the individual Flash Head
Dip Switches Located in Power Supplies to assign addresses to Flash Heads
Flash Head The 3 individual Flash LED Modules mounted together
Flash “LED” Module The individual module numbered 1, 2or 3 containing the LED’s and reflectors
PEC Mode Flash intensity based on outdoor ambient light condition
Blinking LED which indicates a Micro Board is healthy. NOTE: Located in both the
Heartbeat
Base Controller and Power Supply
Red System When properly configured through the main micro provides RED at night operation
AOL Antenna Obstruction Light, also can be added through the Base Controller
Synchronization All lights flash simultaneously to the human eye
Communication RS485 signals between Controller, Power Supply and Flash Head
Alarm occurs when greater than 25% of a single Flash Head is out, monitors for
25% Failure
both in Red operation and white operation
The lighting, hardware, wiring and any other materials required for installing the
The System
system.

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Getting Started
Carefully unpack and take inventory of all system components before beginning the
following steps. Flash Heads and Power Supply Enclosures come in separate boxes. They
must be paired together and laid out in a clean work area.
Parts Typically Supplied:

1: 1 Base Controller
2: 3 or More LED Flash Heads (Consisting of 3 modules factory secured together)
3: 3 or More Flash Head Power Supply enclosures
4: Spare Parts Kit(s)
5: This manual
6: Quick start Manual (For configuring the Base Controller)
NOT Supplied with this Manual is the site specific wiring diagram. This is supplied by the
seller of the system.
Section 1.0: Tower Preparation
It is recommended that the tower on which the System is to be installed be inspected

prior the installation.
1: If using existing junction boxes, they should be opened and checked for leaks.
2: If re-using wiring from an existing system it must be checked at this time for ratings, breaks,
oxidation and other damage that could cause electrical issues during the installation and
operation. Failures in the wiring during or after the installation are the responsibility of the Site
Manager and the owner of the structure.
NOTE: It is recommended that any reused existing cable has the bare wire cut far enough
back to expose clean copper. If this is not possible then the cabling MUST be replaced.
3: The Dialight High Intensity system uses RS485 for communications. The signal integrity,
ratings and wire gauge should be verified before installing this system.
4: The Base Controller and Power Supply enclosures have terminal blocks for AC wiring that
can accept up to 8 gauge (8AWG) wires.
NOTE: Do not use less than 14 gauge (14AWG) mains cord for powering the system. Refer
to electrical specifications below for further details.

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Section 2.0: Choosing a circuit breaker
Also refer to the wiring diagram that is sent with the cables and hardware for site
specific information. This information is required to be sent by the system provider or the
hardware provider.
For the purpose of sizing tower conductor gauges and circuit breakers follow the table
and formula below. Input current is inversely proportional to supply voltage, so low supply
voltages result in higher input currents. It is the responsibility of the system supplier to
calculate the required cable gauges and breaker sizes.
All tolerances are +/- 10% from nominal voltages shown below.
Measurements are actual measurements and not scaled in any matter
Nominal Supply Voltage /Freq RMS Current (A) per Flash Peak Current (A) per Flash
(VAC)/Hz Head Head
208 / 60Hz 1.12 2.18
240 /50Hz .96 1.98
277 /60Hz .87 1.68
Table 1 - High Intensity Strobe Current Ratings
Find the voltage you are planning to run the System in the table above; then multiply
the number of Flash Heads on the System times the RMS current to find the total operating
current. Also multiply the number of Flash Heads on the System times the peak current to
find the total peak current.
If using a Dialight DR1W strobe as an AOL, then you must add the current of the AOL
to the total calculated below if the AOL is to be powered off the same breaker.
Nominal Supply Voltage RMS Current (A) for AOL Peak Current (A) for AOL
(VAC)
208 0.8 1.3
240 0.50 0.8
277 0.50 0.8
Table 2 - AOL (D1RW) Current Ratings
WARNING: The above tables are for individual Flash Heads and the AOL. The system power
requirements must be calculated.
WARNING: It is recommended that no more than 80% of the breaker rating is used.

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Section 3.0: Base Controller Preparation
The Base Controller should be permanently mounted in a location which has easy
access for inspections or upgrades.
The Base Controller can be energized from the same circuit breaker as the Power
Supply Enclosures, or it can be run from a different voltage or breaker. In the case of different
voltages and breakers, it is recommended that the Power Supplies be powered up first, then
the Base Controller. This will only be required during the installation process and configuring
the system. Thus it is preferred that the Base Controller be on its own breaker.
Base Controller Electrical Parameters:

NOTE: This is only for the High Intensity Base Controller
NOTE: Only the Base controller can run from 120Vac
WARNING: Power Supplies/Flash Heads can NOT properly operate from 120VAC.
Nominal Supply Voltage Watts Information

(VAC) Hz
120 +/-10% Max 50/60Hz 6.5 Can only be used if Controller
has its own power
208 +/-10% Max 50/60Hz 6.5
240 +/-10% Max 50/60Hz 6.5
277 +/-10% Max 50/60Hz 6.5
Table 3 - AOL (D1RW) Base Controller Electrical Parameters
The following steps are recommended for a successful installation:
The Base Controller can be mounted to any sufficient location the installer/electrician
sees fit. The dimensions are given below. If the Base Controller is to be mounted to an exterior
structure such as the tower, then special grounding considerations must be adhered to avoid
voided warranties. See Section 17.0 for further details.
For exterior mounting it is suggested that the conduit or glands be mounted on the
bottom of the enclosure using holes provided by Dialight to ensure a weather tight seal for
the life of the product.

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NOTE: If there is a possibility of water or condensation entering through the conduit or cables,
the installer must take all necessary precautions to prevent water entering the enclosure.
Failure to do so will void all warranties. Cable loops and drain plugs must be added to the
system as seen fit. If in doubt, please contact www.dialight.com or the system provider.
 For cable loops it is suggested that a minimum of 3 to 4 loops with a diameter of 12

inches are used.
 Drain plugs should be located at the bottom of any conduit run and or at the lowest
point of the conduit run.
 For horizontal conduit runs it is required that the conduit be tilted or angled toward
junction boxes that have drain plugs. Conduit should not tilt downwards to un-drained
enclosures or to breaker panels.
Refer to the Quick Start Manual for information regarding connection of AC power and
RS485 Communications.
Spacing of the mounting tabs is shown below:
Open the Base Controller enclosure and set aside any spare parts bags.

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NOTE: Some spare parts included in this bag may be required for the fixtures being
mounted on the structure
L810 Monitor & Photocell

Main Controller Board
Control Board
RS485
Junction Board 48V Power Supply
Filter / Surge Board
Dry Contact Relay

Board
Section 4.0: Photocell Installation

NOTE: See the Photocell manual included in its packaging box for connections and additional
information.
Cable Requirements:
NOTE: The connection cord to the photocell is required to be 3 conductors of 18 to 14
gauge stranded wire. Refer to structure’s wiring diagram supplied with the hardware kit.
A separate ¾” conduit must be run for the Photocell to connect to the Base Controller.
A single Photocell is required for transitioning between day, twilight and night modes. The
Photocell is pre-calibrated to the correct trigger light intensity. No additional adjustments are
required.
When mounting, it is important to orientate the Photocell so that it faces north with no
obstructions. The Photocell is powered by the Base Controller through the Monitor Board
and no additional power is required as shown below.

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NOTE: Only Dialight Photocells can be used with this system

NOTE: Additional Photocell relay testing will be included in Section 10.0 of this manual.
CAUTION: PHOTOCELLS ARE TO BE CONNECTED TO J4 OF THE MONITOR BOARD ONLY

USING THE DIN RAIL TERMINAL BLOCKS IN THE CONTROLLER ENCLOSURE
Section 5.0: RED Side lights (OB) or L810 Connections

Refer to Quick Start manual for instructions to calibrate and connect side lights to the
System.
Section 6.0: Sync Input (with Optional GPS Hardware)
This connection will synchronize the System with either a GPS controller or another
local Base Controller. The contact looks for a pulsed signal with a period of 1,500
milliseconds, where the leading edge to falling edge of the pulse is greater than 100
milliseconds. This will trigger forty flashes per minute synchronized with the other system’s
output.
In order for the system to work with a GPS controller the Base Controller must be
configured through the “config” setup screens. See the Quick Start Manual for details and set
up.
NOTE: The maximum distance between the Base Controller and the device receiving the
sync signal is 50 feet. If longer distances are required please contact www.dialight.com.

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NOTE: Be sure the GPS antenna is located at an adequate height and does not have
obstructed views of the sky when selecting a location.
Section 7.0: Sync Output (with Optional GPS Hardware)
This connection will synchronize the System to another local Base Controller. The
contact generates a pulsed signal with a period of 1,500 milliseconds, where the leading edge
to falling edge of the pulse is approximately 100 milliseconds.
The System generates this output in all operational modes after startup.
This connection would be typically used when 2 structures are situated side by side and
requires both structures to flash simultaneously.
NOTE: 2 Base Controllers are required for this option
NOTE: If a single Base Controller is used then the RS485 or a sync cable can be ran between
structures. There are no further details in this manual for this connection, please contact
www.dialight.com for connections, maximum distances and more information.
Section 8.0: AOL Enable / Disable
An AOL light can be added to the System at anytime by way of RS485

communications. By connecting RS485 from the AOL Power Supply to the last junction box
and the Base Controller configured for the AOL, the system then will control the AOL.
WARNING: The AOL must be an approved Dialight version or delivered from one of their
partners.
WARNING: Refer to the AOL instruction manual for wiring and mounting.
To enable the use of an AOL requires configuration through the config screen. See the Quick
Start Manual for setup.
Section 9.0: Adding Additional Interfaces
If at a later date an AOL is required for the structure that has this system already
installed then just the AC connection and a link in to the RS485 bus is required for connecting.
Once installed the Base Controller requires configuring for AOL. Only a single AOL can be
added to the system. Multiple AOL’s can not be added. The AOL must be fed from the same
AC power source as feeding the lights.

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Section 10.0: Photocell Validation
Perform the following to make sure the Photocell is correctly connected and controlling the
System mode.
1. NOTE: This can be done as a stand alone test; no Flash Heads are required to be
powered.
2. Turn on the Base Controller, and using the up/down arrows go to the “alarm screen”
3. On the Monitor Board confirm LED Photo_Fault is not lit.
If the LED is lit RED then the Photocell is not being detected and wiring and
connections must be confirmed before continuing the testing of the Photocell.
4. Remove the Phoenix connector that connects the 3 wires that go to the Photocell.
Located on the Monitor Board J4.
5. The status alarm must go from “normal” to alarm and by selecting the “ent” button the
last alarm will be PEC lost “act”.
6. A red LED labeled LED Photo_Fault on the monitor board will be turned on this
indicates there is no Photocell detected.
7. Re-install the Photocell J4 and the LED will be turned off and then by pressing the up
arrow the next entry will be PEC lost “Clr” which means the Photocell is detected.
For testing the actual operation of the Photocell it is required that the Photocell be
covered to indicate night mode operation.
NOTE: Since twilight mode is triggered between day and night mode, only day and night
mode are required to be tested to ensure proper operation of the Photocell.
1: With the Base Controller powered on, using the up/down arrows select the Mode screen.
2: Verify the present mode which will be day, twilight or night
NOTE: If the present mode is not shown it is due to the connections of the Photocell not being
correct.
3: If the System mode is day then simply covering the Photocell with a glove will change the
state of the Photocell to twilight then night.
NOTE: There is a factory default setting of approximately 1 minute before switching modes.
If the system mode is shown as night then a flash light focused on the Photocell can be used
to change the state of the system to day.

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WARNING: If Flash Heads are connected then the structure will go to 270,000cd day mode
and changing back has a 1 minute delay.
WARNING: If the Photocell is removed or not connected properly all Flash Heads will operate
in night mode based on if the system is set for red night or white night.
Section 11.0: Initial Power Supply Preparation
The Power Supply Enclosure requires the most field wiring and should be configured
and reviewed before being brought up the tower.
At the bottom of the enclosure there are six factory installed holes. 3 of these
are for connection to the Flash Head and 1 for AC mains and RS485 communications
cable. The AC and RS485 can be run together and must be in seal tight or conduit.
Unused holes must remain plugged to maintain ingress protection ratings.
NOTE: If for some un-foreseen reason additional holes are required for the
installation. Contact the seller of the system or Dialight for instructions.
NOTE: The AC and RS485 can be run together and must be in seal tight or conduit.
The enclosure comes with mounting tabs that are to be joined to the body of the
tower.

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Section 12.0: Power Supply Addressing
Open the enclosure and orientate your view to match the illustration shown below. On
the Micro Board there is a DIP switch array designated as SW1. This is the addressing switch
used to identify this Power Supply Enclosure / Flash Head on the system.
P/S Micro Board

DIP switch SW1 for
setting addresses of
the Power Supply
150V
Power
Supplies
Filter/Surge Board

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The default factory address is 1. One of the Power Supply Enclosures must be
set as address 1. The addresses of all other Power Supply Enclosures must be
changed. The inside of the enclosure will have a sticker showing all the possible
address positions for switch SW1.
WARNING: No two Power Supplies can have the same address setting.
If duplicate settings are made then configuration errors will be shown in the event
log.
Flip the DIP switches on SW1 to match the desired address for that Power
Supply location, as shown below, and then immediately mark the inner label with an
X in permanent marker as to which address was set. The enclosure should be closed
up tightly before being lifted to the mounting location. Therefore before mounting the
address should also be written on the outside of the enclosure with a grease pencil
or marker.
NOTE: Typical installations are that Power Supply #1 is located on the lowest level
and mounted to the Northern most leg. Looking down from the top of the structure
counting clockwise the next is 2 and the next is 3. So that above #1 is #4 and above
that is #7 and so one.
NOTE: This is required unless the Site manager wants something different than the
above states.
NOTE: Refer to the below and section 23.0 for additional information.

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Level 6
Level 5
Level 4
Level 3
Level 2
Level 1
Section 13.0: Power Supply Cable Definition & DC Connections
The Flash Head cable is supplied factory installed into each of the modules that make
up the Flash Head.
Connect the Flash Head cables to the Power Supply Enclosure so that the electrical
connections can be tested on the ground. Each of three red cables should be passed through
a corresponding cable grip. All cables and cable grips are numerically labeled for easy match
up.
The ends of each cable have been prepared for connections within the enclosure. The
triad of blue, yellow, and gray wires is for communication. The pair of black and red wires is
for DC power from the Power Supply Enclosure to the Flash Head. Do not alter the length of
these wires or attempt to cut back or modify the exposed braided shield. The picture below
shows the prepared cable end.

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NOTE: The cable grip has been pre installed on to the cable. The nut must first be removed
after securing the cable grip to the enclosure.
Land the exposed braid underneath one of two large clamp washers (whichever one which
lines up with that cable grip position). Two cable braids can be landed side by side on the
clamp washers as shown below. Pull enough of the cable length through to reach all
connections before tightening down the washers.
FAILURE TO PROPERLYTIGHTEN DOWN CLAMP WASHERS WILL MAKE INTERNAL

COMPONENTS VULNERABLE TO SURGE OR LIGHTNING DAMAGE AND VOID THE SYSTEM
WARRANY
NOTE: If the Red and Black wires need to be cut and re stripped then ¾” of insulation
should be removed. The wires must be neatly twisted before inserting in to the terminal
blocks.

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Steps for inserting the Red and Black wires:

The DC power wiring needs to be terminated on the DIN rail terminal blocks connected
to J2 of the Filter / Surge board as shown in Figure xx below. The DIN rail terminal blocks are
labeled appropriately for each module.
NOTE: Module #1 gets connected to pins 1 and 2 of J2 (left), Module #2 gets connected to
pins 3 and 4 of J2 (middle), & Module #3 gets connected to pins 5 and 6 (right).
NOTE: It is recommended that each Red and Black wire gets twisted on the exposed copper
before inserting into the terminal block.
Use a small flathead screwdriver to terminate by inserting the blade in to the slot and
easily lifting the screwdriver, then inserting the wire. The wire must go in easily and must not
be forced into the terminal bock.
If it is forced then the wire should be removed re-twisted and inserted again.
NOTE: Tug on these connections to ensure the wire ends were landed properly.
Drain wires from all three Module cables must be terminated on the grounding bus. This
connection is for lightning / surge protection and should be double checked like all other
wiring discussed above. Since the drain wire is a bare wire, extra attention should be placed
on routing these connections neatly.

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1: Take all 3 drain wires from the modules and twist them together at the end, a minimum of
1”.
2: Insert the twisted cable in the ground terminal and tighten the screw securely.
NOTE: It is recommended that the twisted wire be slightly extended beyond the screw so
the installer can see that it is not bunching and making a poor ground connection.
DC Connection
points Drain wires
twisted and fed
under screw.
Screw to be
secured tightly.

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Section 14.0: Flash Head Communication Connections
RS485 connections must now be terminated to the DIN rail terminal blocks wired to
the correct socket on the Micro Board. In front of each terminal will be a label for clear
identification of landing positions. It is very important to land these connections on the correct
terminal for proper function of the Flash Head.
Module #1
Module #2
Module #3
Section 15.0: Other Power Supply Preparation
If running new cable from each Power Supply Enclosure to their respective junction
boxes on the tower, now would be the time to attach these relatively short runs. Even if not
running new cable in these positions, it is recommended to do a dry run of terminating these

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connections. The end of the cable needs to have the outer jacket stripped back to allow for
routing of the communication and AC power wires. Like with the Flash Head cables, the wires
are to be connected to a pre-wired labeled terminal block inside the enclosure. These
locations are shown below in Figure 11.
Communication wires could be various colors and gauges depending on cable
manufacturer. Also, the common wire may be a bare wire similar to a drain wire. They will
always be a group of three and must be terminated on the terminal block pre-wired to the
same green pluggable connector used for the Flash Head communication wires. If using a
Dialight junction box, the junction board has markings for which wire is the “A” wire and which
is the “B” wire. The Micro Board in the Power Supply Enclosure has the same markings next
to its sockets. Both ends of the cable must be wired the same.
AC CONNECTION to Power Supply Enclosure:
Feed the cable through the hole not numbered on the enclosure and connect to the terminal
blocks located on the right side of the Power supply (Marked L and N).
NOTE: This feeds power to both LED Drivers that are mounted to each side of the
enclosure. There are small Green LED’s located on each to show that they are powered.
WARNING: Earth ground must be connected for SAFE and proper operation of the Power
Supply Enclosure.
NOTE: It is recommended that 277Vac, 240Vac or 208Vac (2 hot Lines of 120Vac) is to be

used to power the power supplies. When 3 phases are used, all the phases must be
balanced though out the system. See the wiring diagrams for connections.
WARNING: Operating the power supplies and flash heads from single phase 120Vac (Live
and Neutral) is NOT permitted. Contact www.dialight.com for more information.
AC Input,
Ground
terminal
on right
RS485 Input
coming from
level junction
box.

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Section 16.0: Junction Preparation
NOTE: For commissioning purposes pictures are required of the wiring and mounting of
all the junction boxes to the structure. They MUST be reviewed and verified before de
rigging.
Located in the Junction box that was supplied with the kit is a surge protection board for
the RS 485 communications. These connections are vitally important for proper operation of
the system and the communications for controlling the lights and there functions. The surge
board has 3 ports J2, J3 and J4 that provide communications to the lights on each level of
the structure. J1 is the Input from wither the Base controller or the lower level of lights. J5 is
the output that would feed the next higher level of lights or the AOL if installed.
The installer will need to strip and connect all necessary cables to these ports. Care must
be taken when connecting these cables to avoid un-necessary troubleshooting later.
NOTE: The installer must make sure that all the A and B ports have the same color wire
attached.
NOTE: it is recommended that J2 be beacon #1 J3 be beacon #2 and J4 be beacon #3.
This will make any troubleshooting required later easier.
It is recommended that
J2 be connected to Power supply
#1,
J3 to power supply #2
J4 to power supply #3 3 RS485 Outputs to
power supplies
Next level enclosures that control
J2 to #4 the Flashheads
J3 to #5
J4 to #6
And so on up the structure
Output to next
higher level of
Input from the
lights or AOL if
Base
installed
Controller

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FAILURE TO PROPERLY BOND THE EARTH GROUND WIRE TO THE JUNCTION BOX WILL
RESULT IN EVENTUAL LIGHTNING DAMAGE OF THIS SYSTEM. TO AVOID WARRANTY
NULLIFICATION, FOLLOW THE ABOVE DIRECTIONS IN THEIR ENTIRETY.
NOTE: If there is a question if the protection board is operating correctly, verify by using a
multi-meter set to ohms. By connecting the multi-meter from “A” to “A” and then “B” to “B” the
meter must measure a very low resistance, which should be less than 10 ohms. If an “OL” or
open load is measured than the protection board is bad or there is a bad connection. This
test should be conducted for each of the colored wires. The Green wire is the Earth ground
connection.
Section 17.0: Mounting Power Supply Enclosures

This section is also required when the Base controller is mounted to the exterior structure.
the power supplies to the structure. They MUST be reviewed and verified before de
rigging.
Power Supply Enclosures must be mounted to the tower structure. This may require
the addition of rails welded into the tower structure to create a more narrow spacing to line
up with the enclosure mounting tabs. Spacing of the mounting tabs is shown below.

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The additional use of a grounding strap between each Power Supply Enclosure and
the tower structure may be required to ensure proper grounding. If the Ground strap is added
then it is recommended that the ground strap is located on the front of one of the four
mounting tabs before bolting.
The installer should avoid using numerous bolt-through connections when bonding the
Power Supply Enclosure to the Tower. The use of prefabricated lug bonds made from
annealed size #1 copper cable joined at both ends with tinned copper lugs conforming to
ASTM B-187 is recommended. The lug should be permanently bonded to cable via
exothermic welding i.e. CADWELD.

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WARNING: FAILURE TO PROPERLY BOND THE ENCLOSURES TO THE TOWER STRUCTURE

WILL RESULT IN EVENTUAL LIGHTNING DAMAGE OF THIS SYSTEM. THE SYSTEM’S
WARRANTY SHALL BE VOID IF ALL ENCLOSURES S ARE NOT PROPERLY BONDED TO THE
TOWER STRUCTURE. TO AVOID WARRANTY NULLIFICATION, FOLLOW THE ABOVE
DIRECTIONS IN THEIR ENTIRETY.
Section 18.0: Mounting Flash Heads

For Brackets and Mounting instructions refer to the Structures wiring diagram.
the Flashheads to the structure. They MUST be reviewed and verified before de rigging.
Flash Heads must be mounted to brackets permanently mounted to the tower

structure. Some brackets will have a mechanism for slight pitch adjustment (zero to eight
degrees). Since there could be a mechanical hinge in the bracket, there is not sufficient metal
contact to ensure proper bonding between the Flash Head and the tower structure. Therefore,
use of a grounding strap between each Flash Head and the tower structure is required. Each
Flash Head has Aluminum housing with extra M8x1.25 threaded holes for the purpose of
adding such a strap. After selecting a hole on the Flash Head to use, the installer must grind
the flat surfaces on both sides to expose metal.
Although this one bonding connection will be made with an M8 nut and bolt, the
installer should avoid using numerous bolt-through connections when bonding to the Tower.
See Section 17.0 for additional ground information.
NOTE: Module “#1” MUST be positioned on the bottom bracket due to the orientation of the
optics. The modules are factory marked on the backside.
NOTE: The Flash Head is designed to be mounted parallel to the ground.
NOTE: The installer must level the Flash Head in both orientations to ensure minimal ground
scatter. It is recommended that it is mounted level within 0.25º of zero.

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Table 4 – Light Unit Elevation above the Horizontal
Complete 3 Level Flashhead: (3 Modules make a Flashhead)
Individual Flash Module: Wire Colors coming from Module

Flash Module Power Supply
(Factory Wired) Locations
Drain Wire Ground Lug
RS485 “A” “A” RS485

RS485 ”GND” “GND RS485
RS485 “B” “B” RS485
+150Volts (RED) Terminal B
- 150Volts Gnd (Black) Terminal B
NOTE: The LED Module is factory sealed and no user access is required.
The module comes with a factory installed 7 to 10 feet of cable.

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SECTION 19.0: Final System Checks

Perform the following before applying power to the System!!!
FAILURE TO SET UP THE SYSTEM CORRECTLY DURING START UP WILL RESULT IN THE
TOWER HAVING TO BE CLIMBED AGAIN TO PERFORM TROUBLESHOOTING.
Grounding:
The primary goal of grounding this System is to maintain a low resistance level
between the electrical sub components and the tower structure. Improved lightning immunity
results as this resistance is reduced. For comparison, the National Electrical Code requires
the resistance value between the earth and a grounding bus to not exceed 25 ohms, however
for this application lowering ground resistance values to levels as close to 0 ohms as possible
is the only way to prevent lightning related damage.
It is compulsory for the installer to use an Ohm meter to check the resistance after all
bonding is complete. A normal value range to see between the inside of a Power Supply
Enclosure and the bare metal of the tower structure is 0.3 to 1.3 Ohms. Check each Power
Supply enclosure with a Multimeter set on Resistance/Ohms measurement to ensure the
grounding was done properly.
Communication:
A termination resistor is factory installed in the Base controller. Depending on the type
of tower and the size of the structure (typically larger than 1200 foot structures or 4 levels of
lights an additional termination is required. This can done by adding a jumper to the last power
supply (for example #12 of a 4 level system) on location “terminator” located in the power
supply enclosure.
NOTE: Do not add

jumpers to any
2 pin header, other Power
when supplies for the
required. highest number.
NOTE: By tying or
jumpering the 2
pins together the
terminating resistor
will be added.

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Back probe all of the RS485 ports on each Power Supply Enclosure and the one going
out of the Base Controller with a Multimeter set on Resistance/Ohms. Place one probe where
the “A” wire terminates in the back of the plug and the other probe firmly on the ground bus
of the backplane. Be sure to press firmly. Depending on the model meter you should see an
open circuit symbol, OL, or a value exceeding 20 mega Ohms. Repeat this process by back
probing for the Common wire (middle) and the “B” wire. Then, repeat all of the steps for each
communication port. This step will confirm there are no shorted communication wires within
the System.
Figure 18 - Back Probing Connections
DC Wiring:
Check terminal block J2 on the Filter/Surge board by performing short circuit check
with a Multimeter. Back probe the terminals and ensure that positive terminal positions have
no continuity with negative terminal positions. Perform this check for each Power Supply
Enclosure.
AC Wiring:
On the Base Controller ensure that the Hot and Neutral wires are landed correctly on
the AC connection terminal block.
WARNING: Power Supplies require a minimum of 208vac and a maximum voltage of 305Vac
from live to ground.

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Section 20.0: System Power Up
All Power Supply Enclosures must be completely closed with door clamps before
proceeding. Interlock switches inside these enclosures will not make contact unless a good
seal is established.
NOTE: It is highly recommended that upon initial powering of the system that individual levels
be tested as the system is being installed. For example once a level is installed this level
should be tested and verified before adding additional levels.
It is recommended to have one installer stand near a Flash Head, and one installer
near the Base Controller. Energize the System from the circuit breaker. You will see the LCD
Screen illuminate at the Base Controller; displaying the text “please wait.” The next screen
will begin counting down from 15 and once complete the display will be in the main screens
for system setup. See the quick start manual for configuring the system. If the countdown
from 15 does not happen and the screen just stays at 15 then the Base Controller does not
see any Flash Heads on the RS485 communications line. Please check that the
communications is connected and that no wires have been reversed. At the back of the Flash
Head it is possible to see small green and yellow LED’s light up.
CAUTION: NEVER LOOK AT THE FRONT OF A FLASH HEAD WHILE THE SYSTEM IS
ENERGIZED. THE FLASH HEAD COULD START FLASHING CAUSING TEMPORARY
BLINDNESS WHICH WOULD BE DANGEROUS AT HIGH ELEVATIONS.
Section 21.0: Alarm Relays
Eight relay outputs are provided as a means to externally monitor alarms from the
System. Refer to the Quick Start Manual for relay definitions.
To interface outside of the Base Controller, the installer must choose either to use the
Normally Open, or Normally Closed contacts on the relay board depending on the
installation’s requirements. Using the 3-position Phoenix on the header allows for any
combination of normally open and normally closed contacts to be utilized. To wire the dry
contacts it is recommended to use 18-22 AWG wire. The preferred strip length for the Phoenix
connector is ¼ inch.
NOTE: If the existing monitoring system does not have 8 alarm ports than multiple relays can
be multiplexed together.

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NOTE: If a single monitoring port exists than all 8 relays can be multiplexed together.
NOTE: If the monitor monitoring system has 8 ports than each of the dry contacts should
have its own monitoring port.
Section 22.0: Maintenance
There is no regular maintenance required for this System.
Dialight recommends the following spare parts be purchased for emergency replacement.
Description Dialight Part Number

Complete Flash Head D266-1019FH
Flash Head Module D266-1019MOD
Table 5 – System Part Numbers

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Section 23.0: Additional Information
For clarification purposes the addressing scheme is provided below with binary
format.
Address Number Binary Number Drawing

‫־‬ Switch position 1 2 3 4 5 1 = ON, 0 = OFF
1 10000
2 01000
3 11000
4 00100
5 10100
6 01100
7 11100
8 00010
9 10010
Table 6- Power Supply Address Table (1 through 9)

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Address Number Binary Number Drawing

‫־‬ Switch position 1 2 3 4 5 1 = ON, 0 = OFF
10 01010
11 11010
12 00110
13 10110
14 01110
15 11110
16 00001
17 10001
18 01001
Table 7 - Power Supply Address Table (10 through 18)

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Section 24.0: Troubleshooting
PROBLEM CAUSE SOLUTION
1. Diagnostic and Display Board There were no devices detected Make sure communication cable is
in the Base Controller reads on the network during startup. wired correctly at all ends. Check the
“Tower Style : _____ ” “config” screen to make the correct
(blank) selections are made
2. Diagnostic and Display Board There is either an electrical or The missing addresses should be
correctly displays tower style, communication problem with checked for wiring issues while the
but the Power Supply map has the Power Supply Enclosure(s) System is off. If more than one is bad,
missing addresses. at the missing address. proceed by isolating power to just a
single bad address. Observe that
address power up by pulling the
interlock switch outward. This will
allow the Power Supply Enclosure to
power up with the door opened. Wait a
minute after startup. Observe if the
Micro Board powers up correctly.
3. Heartbeat on a Power Supply Communication to this address Observe the RX (receive) and TX
Enclosure Micro Board comes was never established. (transmit) LED indicators on the Micro
on, but other status lights do Board for pulsing. If the RX light
not. comes on every 1.5 seconds then there
is at least a connection to the Base
Controller. If the RX or TX lights are
hanging solid, there are crossed
communication wires, or shorted
communication wires somewhere in
the network. This could be anywhere
and every junction box and Power
Supply Enclosure must be checked.

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4. Adding an AOL interface to the There are crossed The junction box preceding the AOL
System caused the whole communication wires, or must be checked as well as the AOL
system to go down. shorted communication wires enclosure.
inside the AOL enclosure.
5. The Flash Heads are not There is too much RS-485 bias Verify the communications
flashing in sync. Addresses are on the network, or too many connections at the missing Power
missing or dropping on and off termination resistors on the Supplies, Verify the addresses have
the map. network. Weak RS-485 signal. been set correct. Check the level
junction boxes for proper
connections.
Remove good Power Supplies by

unplugging outgoing
communications to the rest of the
tower and individually test the
problematic Power Supplies.
6. A Flash Head appears on the 25% of the lighting in that There is a problem inside the sealed
network but after 25 flashes it Flash Head has failed. Flash Head. Further visual evaluation
appears to shut down and drops should be done. Verify the LED’s on
off the Power Supply map. the driver cards in the Power Supplies
Reappears when the System is are illuminated. Check the red and
restarted. black wires going in to the terminals
wired to J2.
7. A Flash Head will only flash in The Flash Head is in stand Something has changed since startup.
Day mode; eventually looses alone mode. Meaning, it was There is either a loose wire
sync with the rest of the successfully started up but lost intermittently loosing contact or a
System. communication at a later time. similar problem. Check all
communication wiring to the bad
address.

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8. Entire System will only flash in Photocell and its respective Check the connections on the Monitor
a certain mode. i.e. Night mode wiring has a problem. Board. Verify that the Photocell
all the time. Regardless of Failure alarm indicators are not lit. If
outdoor light conditions. they are lit, check Photocell
connections.
9. In a style C tower, the AOL is The sync output from the AOL The problem will be located in the
not in sync with the rest of the Interface kit is not being Power Supply enclosure of the AOL.
System. The tower type is accepted by the DR1W Micro Verify by opening the enclosure that
displayed correctly and the Board. all the connections are made correctly
AOL is listed under active and the RS485 communications is
interfaces. attached.
10. In a style C tower, the AOL is The AOL Interface kit is not Use the AOL / Red System manual to
flashing RED. wired correctly to the DR1W troubleshoot the wiring connection
Micro Board. between the AOL Interface kit and the
DR1W Micro Board.
11. In a style F tower, after 100 There is a RED light fault from There is a red fault input being sent to
flashes in NIGHT mode, then the AOL. Which means the the Base Controller. The problem
system behaves like a style C system will go to white night would be either in the Power Supply
tower. by per FAA requirements. where there is a bad red driver or in the
Flash Head.

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Section 25.0: System Specifications
The following physical specifications apply to the System:
Flash Head Weight: 67.5 pounds (40.8 kg)
Flash Head Dimensions:

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Module Weight ( 3 per Flash Head ): 22.5 pounds (10.2 kg)
Flash Head Cable Length ( 3 per Flash Head ): 9 feet (3.66 m)
Flash Head Mounting Holes: Clearance for M8x1.25 thread
Power Supply Enclosure Weight: 40 pounds (18.1 kg)
Base Controller Weight: 40 pounds (18.1 kg)

Table 8 – Mechanical Specifications
The following operational specifications apply to the System:
Flash Head Voltage: 135 - 165 VDC (150 VDC nominal)
Power Supply Enclosure Voltage: 208 - 277 VAC, +/- 10% 50/60 Hz
Base Controller Voltage: 120 - 277 VAC, +/- 10% 50/60 Hz
Day mode: 160 W

Power Supply Enclosure Wattage: Twilight mode: 30 W
White Night mode: 23 W
Red Night Mode 30W
Base Controller Wattage (all modes): 6.5 W Maximum
System Operating Temperature Range: – 40°C to 55°C
Day: 40 FPM
Flash Rate: Twilight: 40 FPM
Night: 40 FPM
RED night: 40FPM
Day: 270,000 Candela ( ± 25% )

Flash Intensity: Twilight: 20,000 Candela ( ± 25% )
Night: 2,000 Candela ( ± 25% )
Light Pattern (all modes): Horizontal plane: 120°

Vertical plane: 3°- 7°
Table 9 – System Specifications

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REVISION HISTORY
REV ECO No. DRN CKD APP QA CM DATE

A 38371 CAG SA BAM YS JN 9/9/16
B 41842 SA EK KH YS JN 1/23/17

Page 40 of 40

Install and Maintain High Intensity Strobe Light System

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INSTALLATION AND MAINTENANCE MANUAL

Diali gh t Corp orat io n 1501 Route 34 South F armingda le NJ 07727

Notice and Warnings --------------------------------------------------------------------------------- 3

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Notice and Warnings

FAILURE TO LEAVE THE ENCLOSURES FREE FROM DEBRIS UPON COMPLETION OF

FAILURE TO TIGHTEN DOWN CLAMP WASHERS WILL MAKE INTERNAL COMPONENTS

CAUTION: PHOTOCELL ONLY TO BE CONNECTED TO MONITOR BOARD USING

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

FAILURE TO SET UP SYSTEM CORRECTLY DURING START UP WILL RESULT IN THE

DIALIGHT CORPORTATION DOES REQUIRE PICTURES OF THE INSTALLATION FOR

SPECIAL CONSIDERATIONS ARE REQUIRED FOR INSTALLING ON HOT AM TOWERS.

AC INPUT TOLERANCES ARE A MAXIMUM OF +/-10% OF THE NOMINAL VOLTAGES

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

White Only System

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

The following definitions apply to the System:

PEC Mode Flash intensity based on outdoor ambient light condition

Synchronization All lights flash simultaneously to the human eye

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Parts Typically Supplied:

Section 1.0: Tower Preparation

It is recommended that the tower on which the System is to be installed be inspected

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Section 2.0: Choosing a circuit breaker

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Section 3.0: Base Controller Preparation

Base Controller Electrical Parameters:

Nominal Supply Voltage Watts Information

The following steps are recommended for a successful installation:

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

 For cable loops it is suggested that a minimum of 3 to 4 loops with a diameter of 12

Spacing of the mounting tabs is shown below:

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

L810 Monitor & Photocell

Filter / Surge Board

Dry Contact Relay

Section 4.0: Photocell Installation

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

NOTE: Only Dialight Photocells can be used with this system

CAUTION: PHOTOCELLS ARE TO BE CONNECTED TO J4 OF THE MONITOR BOARD ONLY

Section 5.0: RED Side lights (OB) or L810 Connections

Section 6.0: Sync Input (with Optional GPS Hardware)

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Section 7.0: Sync Output (with Optional GPS Hardware)

NOTE: 2 Base Controllers are required for this option

Section 8.0: AOL Enable / Disable

An AOL light can be added to the System at anytime by way of RS485

Section 9.0: Adding Additional Interfaces

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Section 10.0: Photocell Validation

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Section 11.0: Initial Power Supply Preparation

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Section 12.0: Power Supply Addressing

P/S Micro Board

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

Section 13.0: Power Supply Cable Definition & DC Connections

Dialight Corporation 1501 Route 34 South Farmingdale, NJ 07727

FAILURE TO PROPERLYTIGHTEN DOWN CLAMP WASHERS WILL MAKE INTERNAL