Model CPS A0 For USA 120 VAC Units Only

Model CPS A0
Installation & Operator Manual
Version 4.05 Rev D and Above
Copyright © 1996 - 2005
Printed in U.S.A. All Rights Reserved
12/1/2004
For U.S.A. 120 VAC Units Only
Phone: (800) 288-7362
Fax: (574) 259-5769
Xcel.com
Table of Contents
CHAPTER 1: INSTALLATION ................................................................................................... 4
PROPER LOCATIONS .................................................................................................................................................. 4
Figure 1.1 Post Mounting.................................................................................................................................................. 4
Figure 1.2 Outside Wall Mounting..................................................................................................................................... 4
Tower Lights Panel Mounting .............................................................................................................................. 5
Figure 1.3 Inside Wall Mounting ....................................................................................................................................... 5
Lightning Arrestor Panel Mounting ...................................................................................................................... 5
Photocell Mounting .............................................................................................................................................. 5
Figure 1.4 Photocell Mounting ......................................................................................................................................... 5
WIRING ..................................................................................................................................................................... 6
Tower Lights Panel Wiring................................................................................................................................... 6
Figure 1.5 Controller Wiring ............................................................................................................................................. 6
Lightning Arrestor Wiring ..................................................................................................................................... 6
Figure 1.6 Lightning Arrestor Wiring ................................................................................................................................ 6
Photocell Wiring................................................................................................................................................... 7
Figure 1.7 Photocell Wiring.............................................................................................................................................. 7
CHAPTER 2: OPERATION & CHECKOUT ............................................................................... 8
Figure 2.1 Panel Layout................................................................................................................................................... 8
MAIN MOTHERBOARD PCB........................................................................................................................................ 9
Figure 2.2 Main Motherboard........................................................................................................................................... 9
Photocell Control Circuit .................................................................................................................................... 10
New Photocell Timed Overide Feature ............................................................................................................. 10
Obstruction Light Sensor Circuit........................................................................................................................ 10
Alarm Output Relays.......................................................................................................................................... 11
Flashing Option.................................................................................................................................................. 11
CHAPTER 3: ALARMING ........................................................................................................ 12
Multi Close on Alarm Loop Example ................................................................................................................. 12
Figure 3.1........................................................................................................................................................................ 12
Multi Close on Alarm w/Common Voltage Leg Example................................................................................... 13
Figure 3.2........................................................................................................................................................................ 13
Single Closed Loop open on Alarm Example.................................................................................................... 14
Figure 3.3........................................................................................................................................................................ 14
Multi Closed Loop Opens on Alarm Example.................................................................................................... 15
Figure 3.4........................................................................................................................................................................ 15
CHAPTER 4: TROUBLESHOOTING....................................................................................... 16
CHAPTER 5: WARRANTY ...................................................................................................... 17
Control Power Systems 90 Days Limited Warranty .......................................................................................... 17
Warnings............................................................................................................................................................ 17
CHAPTER 6: DRAWINGS ....................................................................................................... 18
2
Standard Features
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•
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Meets FAA and FCC requirements for Light control & monitoring systems.
Multi Fixture Ready (Incandescent and LED)
Steady or Flashing at a flip of the switch.
Photocell controlled with Factory Pre-calibrated unit.
NO/NC Alarm contacts provided for Obstruction lights & System Failure.
NO/NC Photocell Status Relay
Photocell Timed Failure Override
Light circuit is fuse protected with standard type fuse.
Indoor/Outdoor ready
Compliant to FAA, IAOC, and DGAC for lighting control.
Panel is I.B.E.W. labeled and UL Compliant.
Panel has 90 Days Ltd warranty from purchase including lightning damage.
3
Chapter 1: Installation
Proper Locations
Figure 1.1 Post Mounting
It is imperative that the Tower Lights controller, as well as the supporting systems, is mounted properly to the
specifications outlined in this manual. Figures 1.1, 1.2 & 1.3 show different mounting configurations of the A0
lighting system.
WARNING
Failure to follow Proper Mounting and Wiring
Instructions will VOID YOUR WARRANTY.
Figure 1.2 Outside Wall Mounting
4
Tower Lights Panel Mounting
You have several options in mounting of the CPS A0 panel since it comes standard as an outdoor enclosure.
Figure 1.1 shows a typical mounting on posts adjacent to the tower. DO NOT mount the unit on the tower itself.
Mounting on the tower will reduce life expectancy and will subject the controller to more direct lightning strikes.
Figure 1.2 shows more of a conventional mounting on the outside of the service building. Since the controller is
weather proof you do not need to take any special precautions. You also have the option to mount the controller
inside like in figure 1.3. Being designed to work in the changing temperatures outside you do not need to take and
precautions if you mount inside.
Figure 1.3 Inside Wall Mounting
Lightning Arrestor Panel Mounting
Take note that in all examples in figures 1.1, 1.2 & 1.3, the lightning arrestor is still mounted lower than the
lighting controller itself is. This is a very crucial point when deciding the placement of your system. The lightning
arrestor panel has a solid-state surge device inside, which is designed to stop any surges getting back to the
lighting controller. Part of the lightning arrestor’s effectiveness relies on it being lower than the lighting controller is.
If you follow the general accepted rule that lightning travels down the shortest path to ground, you will then
understand this basic rule.
If you mount the entire system outside, as shown in figure 1.1, the service power should also be feed
through the lightning arrestor panel. This assures protection from both directions. However, this is not necessary if
you mount the controller in the building as shown in figures 1.3.
Photocell Mounting
Mounting of the photocell is achieved by attaching it by the
base on the 1/2”conduit threads. The Location of the photocell is
crucial to proper operation. You must be clear of any outside night
light source and up where a clear view to the north is possible as
shown in figure 1.4.
Figure 1.4 Photocell Mounting
5
Wiring
Tower Lights Panel Wiring
The important information to pay attention to when wiring the Tower Lights Panel is wire size and Service
Power protection. The CPS A0 panel requires 120 VAC 50/60 Hz single phase 15 Amp with a single pole breaker.
You must you 14 AWG wire to meet NEC code and to not void your warranty. Example hookup is shown in figure
1.4.
Figure 1.5 Controller Wiring
Lightning Arrestor Wiring
The Lightning Arrestor is designed to be a shunt device, to ground out surges coming back down the
power lines from the lights. The neutral and hot feeds to the panel must be also connected if you are following
figure 1.1’s example. The #6 green GND wire provided must be connected to the nearest ground loop. Do Not
route the ground back up to a ground point higher than the panel itself, if necessary drive a new grounding rod
below the panel.
Figure 1.6 Lightning Arrestor Wiring
6
Photocell Wiring
The connection to the controller is achieved by the red and black wires going to the J3 terminal on the main
PCB. The drain wire for the shield should be connected direct to the panel ground term as shown in figure 1.7.
Figure 1.7 Photocell Wiring
You will notice that the photocell unit comes with 20 foot of shielded wire. If you need to extend the length
beyond the supplied wire, it is not necessary to use shielded wire, although it is preferred. Since the photocell is a
resistive device, it should not be extended beyond 50 foot from the controller. To extend beyond this point will
change the factory calibration and may cause incorrect turn on and off times. If you require a longer length please
contact Xcel from a calibrated unit for your custom length.
Once everything is wired per specifications, you are now ready to proceed to Chapter 2: Operation & checkout.
7
Chapter 2: Operation & Checkout
Figure 2.1 Panel Layout
The CPS A0 unit has been designed and manufactured using the latest technology. The state-of-the-art
design includes the use of solid sate relays, digital electronics and MOVs. Combining this advanced technology
with Xcel’s industrial `know how’ make the CPS A0 capable of meeting today’s requirements and those of
tomorrow.
These next few pages will explain how to operate your new CPS A0 lighting controller. All operations are
controlled by the main motherboard located to the left, inside the enclosure.
8
Main Motherboard PCB
Figure 2.2 Main Motherboard
9
Photocell Control Circuit
The Photocell is attached to the main motherboard by way of J3 (see Figure 2.2). The Photocell circuit
monitors the photocell for resistive levels, which corresponds to lights levels outside. When the circuit sees night
the “PHOTOCELL” LD4 amber LED will light. The red “LIGHTS ON” LED will also lit signifying the lights on the
tower are being turned ON. At this point, if everything is wired properly, the lights on the tower should be lit.
After a delay of about 10-15 seconds the green LD7 “DAY/NIGHT DELAYED” will light. The “DAY/NIGHT
DELAYED” LED signals that the alarm relays have been released to the sensor circuits.
When this circuit sees daylight levels it shuts the lights down and interlocks the alarm relays on (the good
state). On a sunny day the photocell should measure less than 2000 ohms in resistance. At night the unit will read
more than 100,000 ohms resistance.
To test the unit in the day and insure that everything is working properly, you can press and hold the pushto-test button S1 (see figure 2.2). Doing this will override the photocell, fool the system into thinking it’s dark
outside. The tower lighting should illuminate if all connections are correct.
NOTE: This circuit is factory calibrated to match production photocells to maintain FAA & FCC regulations.
These regulations specify that the controller should change over between 32-64 foot-candles. This should not be
adjusted unless there seems to be some kind of malfunction and photocell calibration is identified as the fault. If
this circuit should need to be adjusted you can achieve this by tweeting the P1 potentiometer, located in the upper
right hand corner of the PCB. Turning clockwise will increase the level of darkness required to turn the lights on.
This will also make the lights go off sooner in the night-to-day transition. Proper calibration is required to ensure
the lighting system works within FCC and FAA regulations. Do not adjust it unless told to by Xcel personnel.
New Photocell Timed Override Feature
The Rev D and Above CPS A0 units now have a special feature that will monitor the photocell transitions
by time. What this means is if the photocell has not transited from day-night or night-day with in a 18.5 hours time
frame the system assumes the photocell has malfunctioned and will override and turn the lights on 24 hours a day
until someone resets the system. This ensures your compliance with regulation of light being lit. This feature can
be disabled if you turn off (down) switch 2 (marked POVR) of the configuration switch S3.
If the system detects photocell malfunction it also sets off the SYSTEM ERR Alarm relay which will tell you
something is wrong at the controller. Once the problem has been corrected you only need to push S4 Reset button
to return to normal operation of the system.
Obstruction Light Sensor Circuit
The light sensor circuit has different configurations depending on the Number and Type of lights on the
tower. We will discuss the standard, although the theory it is same for all. The standard A0 has 2 lights 116W
Incandescent fixtures on the top of the tower, wired in parallel and brought down with two wires, a Hot and Neutral.
The sensors can detect one bulb burnout and trigger the alarm relay. Although the standard is two, the circuit can
handle up to 8-9 bulbs depending on type.
Rotary Switch S2 sets the number of bulbs monitored. Turning the knob to the number of lights you have
on your tower will tell the system how many is normal for your tower. Once that is done you need to set the TYPE
of lights you are monitoring. Configuration Switch S3 switches 3-6 determine those types as follows:
Type T1
Type T2
Type T3
Type T4
116Watt Standard Incandescent
Dialight LED L810 Fixture
Future Type
Future Type
After that is set and the light are on and operating, you will need to calibrate the sensing circuit by adjusting
P2 if necessary. The Default system is set up for the Type 1 and may not need recalibrating. If it does, look at
your Digital display DISP1 to see if the number displayed there matches the number of lights you have on the
tower. The correct threshold for the sensing circuit is to adjust P2 until you see the next number higher than you
10
have and back it down until the correct number shows again. This calibrates the system and you should be ready
to go from there.
Alarm Output Relays
Two Alarm and One Status relays are provided on the CPS A0 panel. All are Form C NO/NC dry contacts.
The contacts are rated for 125 VAC at 1/4 Amp or 30 VDC at 1 Amp. DO NOT over run these specifications or
damage to alarm relays will occur and can cause false alarms. The relays and their corresponding LEDs are
energized in the good (non-alarm) state. Therefore, they power down if alarm occurs. This failure off system
ensures you an alarm even if there is a component failure in the controller. Examples for alarm hookup are in
Chapter 3: Alarming.
Flashing Option
The CPS A0 can be configured to Flash the lights if required by the FAA/FCC for your application. This is
simply done by turning ON Switch 1 (Flash) on S3. The lights will flash when the photocell has been cycled from
Day-Night or push RESET S4. If you want to go back to steady burn lights again the turn OFF Switch 1 of S3 and
then either cycle the photocell or push the RESET S4. When the system is configured for flash mode the alarming
is delayed for three flashes. If a bulb failure occurs it will take three cycles of flash before the system
acknowledges the failure. Also the number of Lights Display on DISP1 will change as the light come on and off
which relates to the current sensor is seeing. It should however always peak at the correct number. This will
further help you see that the lights are cycling without visual confirmation since these lights are very hard to see in
the day time.
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Chapter 3: Alarming
Multi Close on Alarm Loop Example
Figure 3.1
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Multi Close on Alarm w/Common Voltage Leg Example
Figure 3.2
13
Single Closed Loop open on Alarm Example
Figure 3.3
14
Multi Closed Loop Opens on Alarm Example
Figure 3.4
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Chapter 4: Troubleshooting
If you are experiencing trouble with the hook-up or operation of the Xcel Tower Lights panel, please refer to
the chart below.
Problem
No lights on PCB or unit appears
dead
LEDs on PCB are lit but the Tower
lights are not on in Night Mode.
Unit is stuck in Night Mode.
Unit is stuck in Day mode.
Light Failure Alarm is active but
lights are working.
Solution
Check inline fuse to see if they are blown. Verify Voltage
source on Terminal Block between L1 and N to see 120 volts is
present. Check the voltage at J4 on the main board for 5 Vdc.
Check the ½ Amp Fuse on the Main Board.
Check the Voltage at the Power Out terminals. Make sure J2
is connected. Check inline AGC10 fuse to see if blown.
Short J3 on PCB to go to Day mode. Check the photocell
(when not connected to the board) with an Ohmmeter it should
be less than 2000 ohms in the day.
Disconnect J3 to go to Night Mode. Check the photocell for a
short in the wiring. Measure with an OHMmeter when not
connected to the board.
Make sure the S2 is in the correct position to the # of lights
you have. See that the DISP1 also verifies the # of lights you
have if not tweak P2 a very little to correct any variance.
If you are experiencing problems not listed above please give us a call and our staff will be happy to help
you. Xcel can be directly contacted Monday thru Friday 8:00 a.m. to 4:30 p.m. EST at (574) 259-7804 and ask for
Tower Lights Technical Assistance. Email should be sent to support@xcel.com or see our WebPages at
www.xcel.com for other email addresses.
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Chapter 5: Warranty
Control Power Systems 90 Days Limited Warranty
Xcel Controls, Inc. (hereinafter referred to as Xcel) warrants its products against defects for a period of 90
Days from date of shipment. During the warranty period, Xcel will at its option, exchange, repair or credit at the
purchase price, for its products returned by the customer. In order for the warranty to apply, customer must notify
Xcel promptly of any warranty claim and receive return authorization. Material must be returned to Xcel at
customer’s expense, for inspection. Xcel will inspect and test the returned material. Adjustment is dependent upon
determination that apparent defects have not been caused by: failure to follow all warnings, installation and
operating instructions, improper installation, or application misuse, abuse, unauthorized or improper repair or
alteration, accident or negligence in use, storage, transportation or handling. This represents the sole warranty
liability of Xcel.
Installers must read and obey all warnings and follow all instructions before applying power to the Control
Power System Tower Lighting Controller. Failure to comply with all applicable instructions of the enclosed manual
and this notice voids warranty.
Warnings
•
Tower Lighting Controllers use only 120 AC. Proper wire sizes and breaker must be installed for a
valid warranty. See drawing installation section for your controller.
•
Use only 120VAC Bulbs and Fixtures. Improper Voltage Bulbs or Fixtures may cause damage to units
and give erratic results.
•
Voltage levels between L1 and N to must be within +/- 10% of 120 VAC. It is the installer’s
responsibility to be certain that the supply voltage is within the acceptable range.
•
All incoming lines from obstruction lights are required to be properly lightning arrested per drawings in
the installation section of the controllers’ manual.
•
Inside ground must be connected to a proper earth ground.
•
Any modification of the Tower Lighting Controller, (wiring or other components) without prior written
consent, voids warranty.
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Chapter 6: Drawings
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