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FTS 430/830-4 Approach Lighting Systems Reference Manual Part Number 791430830 SERIAL NUMBER Flash Technology, 332 Nichol Mill Lane, Franklin, TN 37067 (615) 261-2000 Front Matter Abstract This manual describes the Installation, Maintenance, and Operation of the FTS 430 and FTS 830 Approach Lighting Systems manufactured by Flash Technology Corporation of America®. Copyright Copyright © 2016 Flash Technology Corporation of America, Franklin, TN, 37067, U.S.A. All rights reserved. Reproduction or use of any portion of this manual, without express written permission from Flash Technology Corporation of America and/or its licenser, is prohibited. Trademark Acknowledgments Flash Technology Corporation of America® is a registered trademark name. ElectroFlash™, Flash Tech™, Flash Technology™, FTCA™, Flash™, and the Flash Technology Logo are all trademarks of Flash Technology Corporation of America®. All trademarks and product names mentioned are properties of their respective companies, and are recognized and acknowledged as such by Flash Technology Corporation of America. Disclaimer While every effort has been made to ensure that the information in this manual is complete, accurate and up-to-date, Flash Technology Corporation of America assumes no liability for damages resulting from any errors or omissions in this manual, or from the use of the information contained herein. Flash Technology Corporation of America reserves the right to revise this manual without obligation to notify any person or organization of the revision. In no event will Flash Technology Corporation of America be liable for direct, indirect, special, incidental, or consequential damages arising out of the use of or the inability to use this manual. Applicable Specification This equipment meets or exceeds requirements for an FAA Type L-849 Style A, C, and E, and Type L-859, Styles B, D, and F. Warranty Flash Technology Corporation of America warrants all components, under normal operating conditions, for two years. Parts Replacement The use of non-OEM parts or unauthorized modification of this equipment will void the warranty and could invalidate the assurance of complying with FAA requirements as published in Advisory Circular 150/5345-51. 0594-430/830-0007 ii Revision 10 — 01-05-2016 FTS 430/830 PERSONNEL HAZARD WARNING DANGEROUS VOLTAGES Dangerous line voltages reside in certain locations in this equipment. Also, this equipment may generate dangerous voltages. Although FTCA has incorporated every practical safety precaution, exercise extreme caution at all times when you expose circuits and components, and when you operate, maintain, or service this equipment. Avoid Touching Live Circuits Avoid touching any component or any part of the circuitry while the equipment is operating. Do not change components or make adjustments inside the equipment with power on. Dangerous Voltages Can Persist with Power Disconnected Under certain conditions, dangerous voltages can be present because capacitors can retain charges even after the power has been disconnected. Protect yourself — always turn off the input (primary) power and wait for one minute for storage capacitors to drain their charge. Then check between the red and blue wires on the flashhead terminal block with a voltmeter for any residual charge before touching any circuit element or component. Do Not Depend on Interlocks Never depend on interlocks alone to remove unsafe voltages. Always check circuits with a voltmeter. Under no circumstances remove or alter any safety interlock switch. EQUIPMENT CAUTION Do not apply power to this equipment if any Printed circuit board, or any components have been removed. Serious damage will occur! If any components have been removed, and you want to close the cover, which automatically applies power because of the interlock switch, then you MUST ensure that TB1, terminals 10 and 11 are shorted to each other. If you do not use this procedure, damage will occur and it is not covered under warranty. FTS 430/830 Revision 10 — 01-05-2016 iii Table of Contents Section Page Section 1 — FTS 430/830 Introduction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elapsed Time Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Style 1 Current Regulator — Three Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Style 1 Current Regulator — Two Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Style 2 Current Regulator — Three Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-4 1-4 1-5 Section 2 — Outline, Mounting, and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH 400 Flashhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH 800 Flashhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Rating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-2 2-3 2-3 2-3 Section 3 — Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Line Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring and Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relays (K1, K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing and Trigger Board (PCB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HV Rectifier Board (PCB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleed Resistor (R1, R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interlock Switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flashtube (FT101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger Transformer (T101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-3 3-3 3-3 3-3 3-3 iv Revision 10 — 01-05-2016 FTS 430/830 Table of Contents (cont’d) Section Page Component Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Voltage Transformer (T4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger Coupling Transformer (T3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing and Trigger Board (PCB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HV Rectifier Board (PCB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flashhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH 400 Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH 400 Flashtube (FT101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH 800 Flashtube (FT 101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger Transformer (T101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System-Level Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems with Individual Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-4 3-4 3-4 3-4 3-4 3-5 3-5 3-6 Section 4 — Replaceable and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Converter Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flashhead Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repackaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-1 4-1 4-1 4-1 4-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 List of Figures Page Figure 1-1 PCB1 Timing and Trigger Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-1 Typical REIL Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-2 Typical ALS Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-3 PC 430 or PC 830 Power Converter Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-4 FH 400 Flashhead Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-5 FTS 430 Comounted Unit Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-6 FH 800 Flashhead Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-7 FTS 830 Comounted Unit Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-8 Typical FTS 430/830 System Installation Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-9 PC 430 or PC 830 Power Converter Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-10 FH 400 or FH 800 Flashhead Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-1 FH) 2XWOLQHDQG:LULQJ. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . Figure 2-2 FH) Sample Installation .. . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . Figure 4-1 PC430 or PC 830 Power Converter Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-2 FH 400 Flashhead Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-3 FH 800 Flashhead Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FTS 430/830 Revision 10 — 01-05-2016 1-4 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 4-3 4-5 4- Y List of Tables Table 1-1 Style 1 Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 1-2 Style 2 Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 2-1 L-828 Power Rating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3-1 System-Level Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3-2 Lighting Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4-1 Power Converter Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4-2 Flashhead Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Revision 10 — 01-05-2016 Page 1-3 1-3 2-2 3-5 3-6 4-2 4-4 FTS 430/830 Section 1 — FTS 430/830 Introduction and Operation System Application FTS 430 System: An FTS 430 Approach Lighting System is a current driven system consisting of two or more lighting units. Each lighting unit is composed of a white FH 400 Flashhead and PC 430 Power Converter. FTS 830 System: An FTS 830 Approach Lighting System is a current driven system consisting of two or more lighting units. Each lighting unit is composed of a white FH 800 Flashhead and PC 830 Power Converter. The FH 400 Flashhead produces a beam covering 360 degrees horizontally and 8 degrees, or more, vertically. The lens directs the main part of the beam upward toward the airways, while limiting stray light toward the ground. The FH 800 Flashhead directs the beam 30 degrees horizontally and 10 degrees vertically. The flashhead is attached to a two-inch threaded pipe by a yoke that has provisions for horizontal and vertical aiming and locking. Power Requirements: Current and Frequency Isolation Transformer FTS 430 Power (Watts) FTS 830 Power (Watts) 2.8A to 6.6A, 50/60 Hz FAA Type L-830 high int. 80 medium int. 50 low int. 30 120 fpm high int. 175 medium int. 65 low int. 30 60 fpm high int. 100 medium int. 45 low int. 25 FTS 430 Flash Intensity: High Intensity Medium Intensity Low Intensity 5,000 cd 1,500 cd 300 cd FTS 830 Flash Intensity: Specifications High Intensity Medium Intensity Low Intensity Physical: FTS 430 Comounted Assembly: (H x W x D) 28.50 x 25 x 14.00 in., 25 lbs. 724 x 635 x 355.60 mm, 11.53 kg. FTS 830 Comounted Assembly: (H x W x D) 24.50 x 25 x 14.00 in., 25 lbs. 622.30 x 635 x 355.60 mm, 11.53 kg. PC 430 or PC 830 Power Converter: (H x W x D) 12.25 x 20.00 x 14.00 in., 21 lbs. 311.2 x 508.0 x 355.6 mm, 9.53 kg. FH 400 Flashhead: (H x W x D) 16.5 x 13.5 x 13.5 in., 10 lbs. 419 x 342.9 x 342.9 mm., 4.5 kg. FH 800 Flashhead: (H x W x D) 10.75 x 7.80 in., 4 lbs. 273.1 x 198.1 mm, 1.82 kg. Heights include dimensions of the units only and do not include the distance from the bottom of each unit to the ground. Performance Characteristics: FTS 430/830 L-849 20,000 cd 2,000 cd 450 cd Flash Rate: FTS 430 FTS 830 60 flashes per minute 120 flashes per minute Flash Coverage: FH 400: Horizontal Vertical 360 degrees 8 degrees (minimum) FH 800: Horizontal Vertical 30 degrees (minimum) 10 degrees (minimum) Control Interface: Senses constant current level in a series line. Inter-Unit Control: Master/slave with common reference timing. Monitoring: FAA Advisory Circ. AC 150/5345-51 compliance. Environmental: FAA Advisory Circ. AC 150/5345-51 compliance. Revision 10 — 01-05-2016 1-1 Options Intensity stepping or either light is controlled by the level of current from a constant current regulator. They are designed for use with L-828, Class 1, Styles 1 and 2 constant current regulators. Elapsed Time Meter The Elapsed Time Meter shows the hours of operation at high intensity. You can use this timer, for example, to schedule inspections, cleaning, or flashtube replacement as preventive maintenance. Flash Monitor The Flash Monitor allows monitoring flash operation with external monitoring equipment. The main terminal block TB1 has two connections at TB1-4 and TB1-5 to which you can connect the monitoring device. These contacts open upon failure of the flashtube for more than approximately 12 seconds. When you first turn the unit on, a failure may be indicated for about 12 seconds until the monitor detects sufficient flashes to close the contacts. After this initial period, the contacts remain closed until a failure occurs or the power is removed. Internal timing circuitry in each lighting unit (power converter) fixes the instant at which it flashes. The factory sets simultaneous or sequential flashing. The master unit is the one designated by the factory. It distributes a reference timing signal to all units in a system. The reference timing signal from the master also contains encoded flash intensity information. A control line, which enables sequential flashing, interconnects all the lights. Setup This section applies to FTS 430 or FTS 830 Systems drawing power from an L-828, Class 1 Constant Current Regulator. A Class 1 regulator delivers a maximum of 6.6 amps. Two styles are in general use for runway lighting: Style 1 and Style 2. The Style 1 regulator has three current steps and the Style 2 has five. FTS 430 or FTS 830 Systems can be set to step from one of three intensity levels to another as the equipment input current changes. Table 1-1 and Table 1-2 summarize typical ways to set up the operation of the equipment. Operation The lights operate when power is applied. A REIL (Runway End Identifier Lights) system consists of only two lights that are located on each side of the runway at the landing threshold. The REIL lights flash (simultaneously) after the last center line light has flashed. Do not apply power to this equipment if any Printed circuit board, or any components have been removed. Serious damage will occur! In ALS applications, the lights are aligned with the center line of the runway, and they flash sequentially toward the landing threshold. An ALS installation may have from 3 to 21 (or more) sequentially flashing lights. FTS 430 or 830 lights are also used in a combined ALS and REIL configuration where the REILs flash (simultaneously) after the last center line light has flashed. If any components have been removed, and you want to close the cover, which applies power because of the interlock switch, you MUST ensure that TB1, terminals 10 and 11 are shorted to each other. If you do not use this procedure, damage will occur and it is not covered under warranty. 1-2 EQUIPMENT CAUTION Revision 10 — 01-05-2016 FTS 430/830 powers the runway lights. If the total number of lights changes substantially any time after you make FTS 430 or FTS 830 set-up adjustments, it could affect system switching operation. Permanent changes, such as adding or deleting runway lights, require making readjustments to FTS 430 or FTS 830 lights. Table 1-1 Style 1 Current Regulator Current Step Flash Intensity Three Levels Two Levels 1 (4.8A) LOW OFF OFF OFF OFF 2 (5.5 A) MED LOW LOW MED OFF 3 (6.6 A) HIGH HIGH MED HIGH ANY Table 1-2 Style 2 Current Regulator 4. To calculate the power required from the CCR, use 400 watts per light. Setup Procedures If you do not understand how to set up your system, consult Technical Support @ 1-800-821-5825. Current Step Flash Intensity 1 (2.8 A) OFF 2 (3.4 A) LOW 3 (4.1 A) MED 4 (5.2 A) MED CAUTION 5 (6.6 A) HIGH Setting up the system requires operation of lighting units while enclosures are opened, thus exposing dangerous potentials. Do not touch any component except PCB1 during these procedures. Adjustment potentiometers and indicator LEDs reside on the Timing and Trigger Board (PCB1) of each unit. Figure 1-1 shows potentiometer and LED locations. Set up each unit in the system as described in the following text. Step-by-step procedures for obtaining these operations follow in Section Setup Preliminaries. Setup Preliminaries Tilt the enclosure open and pull the interlock plunger up to the service position to perform set-up procedures. The following abbreviations apply: Follow these general rules: 1. You cannot achieve full HIGH intensity light output at any input current level lower than 6.6 amps. 2. You may not be able to achieve reliable MEDIUM intensity switching at an input current level less than 4.0 amps. 3. FTCA expects operation of the FTS 430 or FTS 830 System from the same constant current regulator that FTS 430/830 • CCR (Constant Current Regulator) • CCW (Counterclockwise) • CW (Clockwise) • LED (Light Emitting Diode) Revision 10 — 01-05-2016 1-3 43000031 Figure 1-1 PCB1 Timing and Trigger Board Style 1 Current Regulator — Three Intensity Levels For this style, the lighting system switches off only when the CCR is switched off. 1. Turn the HIGH, MED, and LOW controls fully CW. 2. Set the CCR to STEP 1 and adjust the LOW pot CCW until LOW LED just comes on. 3. Set the CCR to STEP 2 and adjust MED pot CCW until the MED LED just comes on. 4. Set the CCR to Step 3 and adjust the HIGH pot CCW until the HIGH LED just comes on. 5. Recheck the light at all current steps and verify that LEDs respond correctly at each step. Also verify by visual comparison that flashing intensity decreases when the CCR is switched from Step 3 to Step 2, and that it decreases further when the CCR is switched from Step 2 to Step 1. 1-4 6. Recheck each light in the system. It may be necessary to readjust some lights after all lights are operational and flashing. Style 1 Current Regulator — Two Intensity Levels For this style, the lighting system switches off when the CCR is at Step 1. It flashes at LOW intensity when the CCR is at Step 2, and at HIGH intensity when the CCR is at Step 3. 1. Turn the HIGH, MED, and LOW control fully CW. 2. Set the CCR to Step 2 and adjust the LOW control CCW until the LOW LED just comes on and the strobe light flashes in low intensity. 3. Set the CCR to Step 3 and adjust the HIGH control CCW until the HIGH LED just comes on. 4. Recheck the light at all current steps and verify that LEDs respond correctly at each step. Also verify by visual comparison that flashing intensity decreases Revision 10 — 01-05-2016 FTS 430/830 when the CCR is switched from Step 3 to Step 2, and that the light switches off completely when the CCR is switched from Step 2 to Step 1. 5. Recheck each light in the system. It may be necessary to readjust some lights after all lights are operational and flashing. Style 2 Current Regulator — Three Intensity Levels For this style, the lighting system switches on when the CCR is at Step 1 and switches to progressively higher intensities as you switch the CCR to higher steps. 1. Turn the HIGH, MED, and LOW controls fully CW. 2. Set the CCR to Step 1 and adjust the LOW control CCW until the LOW LED just comes on. 3. Set the CCR to Step 3 and adjust the MED control CCW until the MED LED just comes on. FTS 430/830 4. Set the CCR to Step 5 and adjust the HIGH control CCW until the HIGH LED just comes on. 5. Set the CCR to Step 4 and verify that the HIGH LED goes off. If not, you may need to adjust the HIGH control slightly CW until it does. 6. Set the CCR to Step 2 and verify the MED LED goes off. 7. Recheck the light at all current steps and verify that LEDs respond correctly at each step. Make trimming adjustments if necessary. Also verify by visual comparison that flashing intensity decreases when the CCR is switched from Step 5 to Step 4, and that it decreases further when the CCR is switched to Step 2. 8. Recheck each light in the system. It may be necessary to readjust some lights after all lights are operational and flashing. Revision 10 — 01-05-2016 1-5 This page is intentionally blank. 1-6 Revision 10 — 01-05-2016 FTS 430/830 Section 2 — Outline, Mounting, and Installation Unpacking FH 800 Flashhead Inspect shipping cartons for signs of damage before opening. Check package contents against the packing list and inspect each item for visible damage. Damage claims should be reported promptly to the freight handler. Tools Screws fasten the bezel ring, which retains the flashtube, to the housing. Remove the screws and bezel, and then remove the flashtube for access to the interior. Mounting ATTENTION The following are hand tools suggested for installation and maintenance: • #2 Phillips-head screwdriver • #2 flat-blade screwdriver • 1/8" flat blade screwdriver (for adjustments) • Spanner wrench (or large slip-joint pliers) for 2-inch conduit locking nut • TriplettTM Model 630-NA VOM, or equivalent analog volt-ohm meter Access WARNING Before proceeding, read the warning on Page iii. Disconnect primary power before opening the enclosure. Each light is packaged in its own shipping carton. The position at which the light is to be installed is marked on the outside of the carton and on an ID label on the outside of the power converter. Refer to Figure 2-1 and Figure 2-2 to identify positions. The light’s position is particularly important in a system of sequentially flashing lights. In-general, lights at the runway threshold are labeled A and B. Sequential lights are labeled numerically in the order of the flashing sequence. Thus PC #1 is to be installed farthest from the runway threshold. Mounting and outline information for the FTS 430 and FTS 830 Systems are shown in: Figure 2-3, Figure 2-4, Figure 2-5, Figure 2-6, and Figure 2-7. Use the following guidelines: • Allow adequate space around the equipment for access during installation and service. • Connect the power converter to a grounding rod or the site grounding system, but not to the counterpoise. See the installation guideline in Figure 2-8. Power Converter Five latches secure the cover. Turn the latch handles to release the cover, which swings open for access. FH 400 Flashhead Installation Retaining clips secure the lens. Loosen the two screws that hold each of these to turn and then lift the lens off the base. FTS 430/830 This manual may not contain all the information about installation wiring for your installation. Revision 10 — 01-05-2016 2-1 NOTE If installation drawings prepared specifically for your site disagree with information provided in this manual, the site installation drawings should take precedence. Consult any site-specific installation wiring diagram supplied with your equipment. FTCA wiring diagrams define only minimum requirements recommended for satisfactory equipment operation. It is the responsibility of the installer to comply with all applicable electrical codes. Conduit and other distribution wiring details can be found on electrical installation diagrams provided by FTCA or others. Figure 2-1 Typical REIL Configuration on Page 2-4 shows a typical REIL configuration. For the FTS 430, the two lights are functionally and physically interchangeable. The master light is designated as A. Although these lights flash simultaneously, lights for positions A and B should not be interchanged unless each one is re-aimed. The factory presets aiming for the position. Flashheads are typically comounted with power converters for REIL applications. Figure 2-2 Typical ALS Configurations on Page 2-5 shows a typical RAILs. The five RAILs are labeled from 1 to 5 to identify their positions; the light with the lowest number is located farthest from the runway and is the first to flash. RAILs are typically configured by mounting power converters and flashheads as separate units. The two REILs are labeled A and B, with the master light as A. Power Rating Guidelines EQUIPMENT CAUTION! If any components have been removed, and you want to close the cover, which casues the interlock switch to apply power, you MUST ensure that TB1, terminals 10 and 11 are shorted to each other. If you do not do this, damage will occur and it is not covered under warranty. You can connect FTS 430 or 830 lights directly to the series runway lighting circuit through the same type of isolation transformer used for incandescent runway edge and threshold lights. In this case, a voltage conversion adaptor is not required. You may couple FTS 430 and FTS 830 Systems directly to the series runway lighting circuit through a Type L-830-10 or Type L-830-11 (300 watt) isolation transformer. You must use one isolation transformer for each light. Fixed rules regarding the size (power rating) of the constant current regulator required for FTS 430 or FTS 830 Systems are difficult to establish because of the following installation variables: 1. The number of steady burning runway lights taking power from the same series lighting circuit 2. The number of FTS 430 or FTS 830 lights 3. The flash rate (60 or 120 FPM) of the FTS 430 or FTS 830 System However, general practice has led to the guidelines in Table 2-1. The recommended sizes allow up to 50% of the rated capacity for shared loading with steady-burning runway and approach lights. Table 2-1 L-828 Power Rating Guidelines Number of FTS Approach Lights Constant Current Regulator Rating 2-7 4 KW 8-15 7.5 KW 16-21 10 KW Do not apply power to this equipment if any Printed circuit board, or any components have been removed. Serious damage will occur! 2-2 Revision 10 — 01-05-2016 FTS 430/830 EQUIPMENT CAUTION! Do not attempt to operate this equipment from a voltage adaptor. Connection to a voltage adaptor could cause internal damage and will void the warranty. Isolation Transformer When the series line is driven by a Class 1 (6.6 ampere) constant current regulator, each light should be coupled to the series line through a Type L-830-10 (6.6/6.6 amperes, 300 watt) isolation transformer. If the series line is driven by a class 2 (20 ampere) constant current regulator, each light should be coupled to the series line by a Type L-830-11 (20/6.6 amperes, 300 watt) isolation transformer. Either a Style 1 (3 current steps) or a Style 2 (5 current steps) regulator may be used. Wiring Figure 2-8 provides wiring guidelines for FTS 430 or FTS 830 Systems. Connect the power from the airport series line to an isolation transformer (FAA Type L-830) placed near each power converter. Connect each transformer to its respective power converter by using two conductors. All power converters must be interconnected for synchronous timing with two unshielded #14 AWG (or larger) conductors, twisted together (6 turns per foot is recommended). NOTE: FTCA recommends 600 Volt insulation on all wires that interconnect the lighting system. FTCA recommends a counterpoise using bare solid copper. When you mount flashheads separately from power converters, wire each flashhead to its corresponding power FTS 430/830 converter. You must use five conductors. FTCA PN 6340 cable is recommended. Ground all cases. FTCA provides a grounding lug on each power converter base. Install a grounding rod at each unit. Do not ground to the counterpoise for lightning protection. Installation Checklist Carry out the following steps before applying power: 1. Inspect equipment for shipping damage. 2. Verify equipment against the packing list to ensure completeness. 3. Examine and verify installation drawings. 4. Position and mount each unit correctly according to packaging and labeling. 5. Ensure that the case is mounted upright, water-tight, and grounded. 6. Check to ensure that all mounting hardware is tight. 7. Ensure that no holes are punched or drilled in the top surface of the case. 8. Wire units according to instructions. 9. Check for proper series current. 10. Check all electrical connections for tightness. 11. Check all terminal strip connections for tightness. 12. Ground the power converter. 13. Install the proper isolation transformer (L-830) to match series line current (either 6.6 to 6.6 amp or 20 to 6.6 amp). 14. Do not use voltage adaptors. When you are certain that the installation is correct and complete, use the set-up instructions in Section Setup on Page 1-2. Revision 10 — 01-05-2016 2-3 Figure 2-1 Typical REIL Configuration 2-4 Revision 10 — 01-05-2016 43000021 FTS 430/830 43000022 Figure 2-2 Typical ALS Configurations FTS 430/830 Revision 10 — 01-05-2016 2-5 12.3 (311) 2" NPT PIPE (NOT SUPPLIED) 2.25 (57.2) (NOMINAL) FRANGIBLE COUPLING GROUND LEVEL PAD 2.38 DIA (60.5) 14.0 (356) NOTE: 1. DIMENSIONS ARE IN INCHES (MILLIMETERS). 8.00 (203) 20.0 (508) 43000023 Figure 2-3 PC 430 or PC 830 Power Converter Mounting and Outline 2-6 Revision 10 — 01-05-2016 FTS 430/830 16.5 (419) LEVELING NUTS (3 PLACES) 13.5 (343) DIA. NOTES: 1. WIND AREA = 1 SQ.FT. (.09 SQ.M.) 2. DIMENSIONS ARE IN INCHES (MILLIMETERS). 3. EXTRA HOLE IS USED WHEN FLASHHEAD IS MOUNTED ON A FRANGIBLE MAST. 2.38 (60.3) DIA MOUNTING HOLE IN LEVELING PLATE 1.06 (27) DIA 43000024 Figure 2-4 FH 400 Flashhead Mounting and Outline FTS 430/830 Revision 10 — 01-05-2016 2-7 15.0 (381) LEVELING SCREWS (3 PLACES) 28.5 (724) 12.3 (311) 2" NPT PIPE (SUPPLIED BY OTHERS) 2.25 (57) NOMINAL FRANGIBLE COUPLING GROUND LEVEL PAD 14.0 (356) NOTE: CL 8.00 (203) 1. DIMENSIONS ARE IN INCHES (MILLIMETERS) 20.0 (508) 25 (635) 43000025 Figure 2-5 FTS 430 Comounted Unit Mounting and Outline 2-8 Revision 10 — 01-05-2016 FTS 430/830 8.9 (226) 6.7 (170) 15° 11 (273) 7.80 (198) 2.38 DIA (60.5) 5.25 (133) FH800MO Figure 2-6 FH 800 Flashhead Mounting and Outline FTS 430/830 Revision 10 — 01-05-2016 2-9 24.5 (622) 12.3 (311) 2" NPT PIPE (SUPPLIED BY OTHERS) 2.25 (57) NOMINAL FRANGIBLE COUPLING GROUND LEVEL PAD 14.0 (356) NOTE: CL 8.00 (203) 1. DIMENSIONS ARE IN INCHES (MILLIMETERS) 20.0 (508) 25 (635) 800CMUMO Figure 2-7 FTS 830 Comounted Unit Mounting and Outline 2-10 Revision 10 — 01-05-2016 FTS 430/830 43083028 Figure 2-8 Typical FTS 430/830 System Installation Wiring Revision 10 — 01-05-2016 TB1 RTN DENOTES GROUNDING ROD CONNECTION. GROUNDING TO COUNTERPOISE NOT RECOMMENDED. BLU RED NOTE 2 5. ALARM IS OPTIONAL EQUIPMENT. CONTACTS OPEN ON FAIL. 4. SET UP ADJUSTMENTS MAY BE REQUIRED AT EACH LIGHTING UNIT FOR INTENSITY CONTROL. REFER TO EQUIPMENT MANUAL. 3. THIS EQUIPMENT IS PHASE SENSITIVE. ALL UNITS MUST BE WIRED THE SAME WAY. 2. BLK 1 CONTROL TB2 2 RED ANODE 1 3 GND 2 ALARM 4 BLU SEE 5 CATHODE 3 BLK NOTE 5. 6 TRIGGER 4 WHT TRIG RTN 5 7 8 6 9 7 PRIMARY 10 8 POWER (2.8 TO 6.6A) 11 PUR NOTE 3 GND SHIELD CONTROL 1. BARE COPPER WIRE RECOMMENDED FOR COUNTERPOISE CONTROL 2.8 - 6.6 AMP SERIES LINE COUNTERPOISE TO ADDITIONAL FTS 830 LIGHTS IF USED ANODE RED TRIG BLK CATHODE BLU PC 430 OR PC 830 PUR TRIG RTN WHT GND SHIELD TB1 RTN BLU RED WHT PUR SHIELD BLK RTN FH 800 COUNTERPOISE NOTE 1 PN 6340 CABLE (TYPICAL ALL LIGHTS) PUR SHIELD 7-7257-02D FROM SYSTEM CURRENT REGULATOR 6.6 TO 6.6A 300W TYPICAL LINE ISOLATION TRANSFORMER L-830-10 NOTE 2 1 CONTROL TB2 2 RED ANODE 1 3 GND 2 ALARM 4 BLU CATHODE 3 SEE 5 BLK NOTE 5. 6 TRIGGER 4 WHT TRIG RTN 5 7 8 6 9 7 PRIMARY 10 8 POWER (2.8 TO 6.6A) 11 PUR NOTE 3 GND SHIELD TB1 CONTROL PC 430 OR PC 830 NOTE 2 (TYPICAL) (NOT REQUIRED AT FLASHHEAD IF CO-MOUNTED) (2 SEPARATE WIRES TWISTED TOGETHER, UNSHIELDED) #14 AWG 600VAC, MIN. NOTE 2 1 CONTROL TB2 2 RED ANODE 1 3 GND 2 ALARM 4 BLU SEE 5 CATHODE 3 BLK NOTE 5. 6 TRIGGER 4 WHT TRIG RTN 5 7 8 6 9 7 PRIMARY 10 8 POWER (2.8 TO 6.6A) 11 PUR NOTE 3 GND SHIELD CONTROL PC 430 OR PC 830 SYSTEM AND FLASHHEAD TYPES CANNOT BE INTERMIXED. WITH FTS 430 SYSTEMS WITH FTS 830 SYSTEMS OR USE FH 400 FLASHHEADS SHIELD USE FH 800 FLASHHEADS ANODE RED FH 400 BLU RED WHT REIL PAIR TRIG BLK FH 400 FH 800 BLK FLASHHEADS MAY BE CO-MOUNTED WITH POWER CONVERTERS OR MOUNTED SEPERATELY UP TO 150 FEET AWAY. ANODE RED TRIG BLK CATHODE BLU CATHODE BLU FH 400 NOT SUPPLIED BY FTCA PUR GND SHIELD GND PUR TRIG RTN WHT NOT SUPPLIED BY FTCA TRIG RTN WHT NOT SUPPLIED BY FTCA FH 800 WHT FTS 430/830 2-11 PUR SHIELD B A 5 2 BRN YEL BLK RED 3 4 BLK PC 430 PC 830 HIGH C1,2 C1,2,6 MED C5,6 C5 LOW C7 C7 1. SHOWN WIRED FOR PC 430. WHEN WIRING FOR PC 830: CONNECT WHT/RED TO T1-2 CONNECT WHT/ORN TO T1-4. 2. ELAPSED TIME METER (OPTION). 3. FLASH MONITOR (OPTION). 4. FLASH INTERLOCK (OPTION). 5. CAPACITORS BANKS: COM BLK BLK 2 1 T4 LOW VOLTAGE TRANSFORMER G2 TB1 CONTROL 1 R3 BLK VR2 2 GND 3 GRN CONTACTS ALARM 4 RED OPEN ON ALARM 5 BRN BRN FAIL 6 7 BLK 8 WHT/BLK 9 GRY BLK 2.8 - 6.6AMP 10 INPUT RED POWER 2.8 - 6.6AMP 11 RED 7 NOTE 4 6 WHT/BLK 5 4 3 2 WHT/ORN GRN 1 3 2 4 T5 ISOLATION TRANSFORMER NO NC S1 INTERLOCK 7 BLK GRY K4 INTERLOCK RELAY GRY WHT/RED NOTE 1 3 4 5 6 1 2 7 8 9 10 11 TB3 GRN GRN 2 GRN GRN PCB1 TIMING & TRIGGER 1 GRN YEL YEL YEL 4 YEL G1 1 2 GRN BLU HIGH 3 WHT/GRN GRN 1 2 1 BLU NOTE 5 NOTE 2 MED P4 BLU P2 R1 PCB2 HV RECTIFIER GRN P1 P3 YEL 2 GRN R2 1 LOW RED GRN NOTE 5 K2 MED MODE RELAY 8 4 6 7 3 5 RED ORN 3 4 5 6 7 8 9 10 11 TB4 WHT/ORN ORN HV 2 8 6 7 5 AC IN L2 FLASHCHOKE YEL R4 YEL RED T1 HIGH VOLTAGE TRANSFORMER WHT/VIO OPTION POWER 24VAC WHT/GRY 2.8 - 6.6A WHT/BRN 24VAC RED MED MODE RELAY WHT/BLK 2.8 - 6.6A YEL GRN HIGH MODE RELAY GROUND BLK CONTROL SIGNAL BLU TRIGGER SIGNAL WHT/RED K1 HIGH MODE RELAY GROUND ORN HV 1 HV 3 SEE NOTE 3 QC4 QC5 6 5 4 RED GRY 3 9 1011 1 2 87 YEL K3 FLASH DETECTION RELAY RED BLU BLU WHT/BLU GRN RED RED QC3 QC6 GRN WHT/BLU TB2 1 2 PCB3 SENSE MODULE TB1 T1 12 CATHODE TRIGGER TRIG RTN ANODE TB2 1 ANODE 2 3 CATHODE 4 TRIGGER 5 TRIG RTN 6 INTERLOCK 7 SHIELD 8 T3 COUPLING TRANSFORMER RED TB2-1 WIRES FROM K2-3 AND TB4-5 ARE MOVED TO TB2-2. BLU ORN BLU BLU -HV Revision 10 — 01-05-2016 AC IN BLU 2-12 YEL RED TO FLASHHEAD BLU BLK WHT PUR 3-7418-01X WHT/GRN BRN Figure 2-9 PC 430 or PC 830 Power Converter Internal Wiring 430830IW FTS 430/830 FT101 FLASHTUBE T101 TRIGGER TRANSFORMER Figure 2-10 FH 430 or FH 830 Flashhead Internal Wiring FTS 430/830 Revision 10 — 01-05-2016 PUR WHT BLK BLU RED RC101 71 2-13 FH 83F-2 Inset Light The FH 83F-2 is used in MALSR or ALSF sequenced flashing approach lighting systems, or wherever inset lights are preferred over elevated lights. It is available for both voltage and current-driven applications and is compatible with all Flash Technology FTS 800 Series Unidirectional Approach Systems. It may be remotely controlled and monitored with the FTC 183 Airport Approach Lighting System Controller. • Dimensions: 6.1 Inches Tall X 12 Inches Wide; 304.5 X 155 mm • Weight: 16.5 lbs (7.5 kg) • IP 67 / NEMA 6 Rating Figure 2-11 FH 83F-2 Outline and Wiring 2-14 Revision 10 — 01-05-2016 FTS 430/830 ATTENTION! THIS DRAWING IS ONLY INTENDED FOR USE AS GENERAL AIRFIELD SYSTEM DESIGN GUIDANCE. THE DESIGNER MUST VERIFY DESIGN WITH LOCAL CODES AND VARYING CHARACTERISTICS FOR EACH UNIQUE AIRFIELD APPLICATION. Figure 2-12 FH 83F-2 Sample Installation FTS 430/830 Revision 10 — 01-05-2016 2-15 This page is intentionally blank. 2-16 Revision 10 — 01-05-2016 FTS 430/830 Section 3 — Maintenance and Troubleshooting Safety SAFETY STOP: Before proceeding—read the warning on Page iii. Work safely as follows: 1. Remove rings and watches before opening the equipment. 2. Shut off the equipment. 3. Remove the component or connect the test instruments. 4. Replace the component. 5. Turn on the power and test the system. 6. Turn off the power and disconnect the test equipment. EQUIPMENT CAUTION! Do not apply power to this equipment if any Printed circuit board, or any components have been removed. Serious damage will occur! If any components have been removed, and you want to close the cover, which automatically applies power because of the interlock switch, then you MUST ensure that TB1, terminals 10 and 11 are shorted to each other. If you do not use this procedure, damage will occur and it is not covered under warranty. Preventive Maintenance Carry out the following inspection and cleaning procedures at least twice a year: 1. Verify that moisture does not enter the equipment through gaskets or seals, or collected inside as condensation. 2. Verify that all drain holes are clear. 3. Check terminal blocks and relays for evidence of corrosion and electrical arcing. Clean or replace any component that shows evidence of high-voltage damage. FTS 430/830 4. Check flashtube connections for signs of pitting or arcing. Verify that anode and cathode connections are firmly tightened. 5. Check all electrical connections for tightness and verify the absence of corrosion or electrical arcing. 6. Clean the outside surface of the FH 800 glass with liquid detergent and water. Wipe it gently with a soft cloth or paper towel. 7. Clean the outside and inside surface of the FH 400 lens with an FTCA-approved professional plastic cleaner. Wipe lens with cheesecloth only. Do not use regular cloth or paper towels. Storage No special considerations are required for long-term storage of any major assembly. Keep circuit boards, when not installed in the equipment, in anti-static bags or containers. Diagnostic Testing In performing functional tests, observe the operation of the system or of individual lights as you step the input current from one level to another. You must understand what is proper operation at this particular installation; that is, how the equipment was set up initially (see Section 1 — FTS 430/830 Introduction and Operation). If the system does not operate exactly according to its set up, you may need to repeat the set-up adjustments described in Section 1. Line interference or an incompatibility between the power system and the lights may prevent obtaining the desired set-up performance of the system. If only one light fails to set up properly, a malfunction in that particular light may be the cause. Control Line Interference Electrical interference on the control line can cause system problems. Interference can occur if the line is open, shorted, or not a twisted pair. Suspect a control line prob- Revision 10 — 01-05-2016 3-1 lem if all units respond correctly to checkout only when you disconnect the control wire. Sometimes, you can eliminate marginal interference by placing a 470 ohm resistor from the control line terminal to the component bracket at one or more lighting units. Wires or cables that move repeatedly will ultimately break. Ensure that all cables (the flashhead cable in particular) are securely fastened at short intervals to the structure or other supports. Inspection Component Testing Always make resistance measurements with the primary power turned off. However, you must make voltage measurements with the power applied. Thus, for your safety, carry out all preliminary steps such as connecting test leads or circuit jumpers, or disconnecting existing circuit connections with the power off. Capacitors Evaluate the condition of a capacitor with an analog volt-ohmmeter operating in the resistance mode. The following method assumes an instrument with a X100 resistance scale. Place the meter leads across the terminals of an isolated (no electrical connections to other circuits) and fully discharged capacitor. Observe the subsequent needle movement. If the capacitor is functional, the needle initially indicates zero ohms, but soon begins to rise to higher indicated values. A capacitor that is disconnected from other circuitry is defective if it does not exhibit this behavior. The length of time it takes the needle to reach the 1-megohm reading (about 65% full-scale) is a measure of the capacitance. For example, the time is about 5 seconds for a 10-mfd. capacitor, or 10 seconds for a 20-mfd. capacitor, and so forth. Manually discharge the capacitor before repeating this measurement. This test may not detect a malfunction that occurs only at high voltage. Closely inspect the units and check the connections against the installation instructions. Also, a close inspection may reveal insulation breakdown, an overheated component, corrosion, loose connections, faulty relays, incorrect hookup, and so forth. Relays (K1, K2) A malfunctioning relay may have faulty contacts, a sticky mechanism, or a defective coil. Determine the first two possibilities by inspection and manually exercising the armature. Confirm a defective coil by measuring its resistance. To measure the resistance of relay coils, first remove the wires from one of the connections to the coil terminals on the relay. The measured coil resistance for both relays should be approximately 290 ohms. Timing and Trigger Board (PCB1) Carry out the adjustment procedures in Section 1 before concluding that PCB1 is faulty. Then replace this circuit board with one known to be in good condition. You must remove the programming matrix (see Figure 1-1 for location) from the existing circuit board and plug it into the replacement board. HV Rectifier Board (PCB2) Replace this circuit board with one known to be in good condition. Bleed Resistor (R1, R2) A bank of capacitors connected in parallel may be checked as a single unit. If the test indicates a short circuit, the individual capacitors have to be disconnected and checked separately. A shorted capacitor is indicated if the resistance does not rise above zero after several seconds of measurement. The resistance of R1 is 35 kohms. The resistance of R2 is 50 kohms. Wiring and Cabling Flashtube (FT101) 3-2 Interlock Switch (S1) Readjust the interlock switch bracket, if necessary. Revision 10 — 01-05-2016 FTS 430/830 Visually inspect the flashtube for broken electrodes, cracked glass, and the solder connections of the pins. A darkened envelope doses not necessarily mean the light output would be unacceptable. Before concluding that a faulty flashtube is responsible for an inadequate flash, first rule out other possible causes such as weak or absent discharge voltage or triggering pulses. Trigger Transformer (T101) The measured resistance of the secondary winding (potted assembly) should be approximately 150 ohms. Check the ferrite core for cracks. Check the mounting screws for tightness. High Voltage Transformer (T1) Measure the voltage between the terminals TB4-3 and TB4-11 on PCB2. The voltage should be between 900 and 1050 volts AC. Component Removal and Replacement For the power converter, refer to Figure 4-1 and Figure 2-9. High Voltage Transformer (T1) Removal 1. Disconnect wires leading to the transformer. 2. Remove four screws holding the transformer to the rear of the chassis and remove the transformer from the chassis. Replacement Reverse the removal procedure. Verify the wiring with Figure 2-9. Low Voltage Transformer (T4) Removal 1. Disconnect wires leading to the transformer. 2. Remove the two screws holding the transformer to the side of the chassis and remove transformer from the chassis. Replacement Reverse the removal procedure. Verify the wiring with Figure 2-9. Trigger Coupling Transformer (T3) Removal and replacement are similar to the procedure for the Low Voltage Transformer. Timing and Trigger Board (PCB1) Removal 1. Loosen, but do not remove, all eleven screws holding the circuit board to TB3. 2. Loosen the screws at the top that hold the board to the chassis and lift the board from TB3. Replacement 1. To replace PCB1 with a spare board, remove the programming matrix from the existing board and insert it into the replacement board. See Figure 1-1 for the location of the programming matrix. 2. Reverse the removal procedure. HV Rectifier Board (PCB2) Removal and replacement are similar to the procedure for PCB1 (except for programming). Capacitors Removal 1. Disconnect wires leading to the capacitors. 2. Remove the hold-down screws. Lift the capacitors from their receiving holes and away from the chassis. Replacement Insert capacitors into their respective receiving holes. Replace hold-down screws to secure capacitors to the chassis. FTS 430/830 Revision 10 — 01-05-2016 3-3 Reconnect wires to capacitors and verify the wiring with Figure 2-9. Wires must be replaced exactly as removed. In some instances, a quick-connect wire terminal will not seat properly if it is not placed on the terminal cluster exactly as it was before removal. This is caused by interference between the insulation on the wire terminal and the insulation surrounding the terminal cluster on the capacitor. Flashhead For the flashhead refer to Figure 4-2, Figure 4-3, and Figure 2-10. WARNING Before opening the flashhead, verify that the power converter has been disabled and that the capacitors have been completely discharged. FH 400 Lens Removal 1. Loosen the two screws holding down each of three clamps. 2. Rotate the lens so that the hold-down tabs slide out from under the clamps, and then lift the lens free. Replacement 1. Place the lens so that its bottom rests on the base. 2. Rotate the lens so that its hold-down tabs slide under the clamps. Tighten the two screws on each of the three clamps to secure the lens. FH 400 Flashtube (FT101) Removal Loosen the three screws on the three screw lugs to free the flashtube base pins then lift the flashtube from the assembly. Replacement Align the pins on the flashtube base with the clamps of the terminal screw lugs and insert the pins into place. Tighten the screws on the terminal screw lugs to secure the flashtube. FH 800 Flashtube (FT 101) Removal 1. Remove the three screws and nuts holding down the flashtube bezel. 3-4 2. Carefully pry the flashtube free of the neoprene washer around the edge. 3. Lift out the flashtube assembly and disconnect the attached wires. Note the color of the wires and their connections. Replacement 1. Connect the flashhead wires to the flashtube. 2. Place the flashtube so that its edge rests squarely on the neoprene washer on the base. 3. Rotate the flashtube so that the small arrow on the edge of the lens aligns next to the tiny hole at the edge of the base lip. 4. Fasten the flashtube by re-attaching the bezel to the flashhead using the three screws and nuts previously removed. Trigger Transformer (T101) Removal 1. At the trigger wire post adjacent to the flashtube, remove the large diameter wire coming from the trigger transformer. 2. Remove the two smaller wires originating at the trigger transformer from the ceramic spacers. Do not disconnect the primary winding wires (seven turns of hook-up wire). 3. Remove the two 4-40 x 2" Phillips-head screws holding the transformer assembly to the bracket. Note the orientation of the molded secondary winding with respect to fixed features on the bracket, since it must be re-installed with this same orientation. 4. Remove the outer half of the core and lift off the molded secondary winding. The seven turns of the primary winding will remain hanging in place. 5. Remove the inner half of the core, taking care not to uncoil any turns of the primary winding. Replacement 1. Re-assemble the primary and secondary windings over the two halves of the core. Attach the core to the bracket using the two long screws. 2. Re-attach the electrical wires. Verify that the wiring agrees with Figure 2-10. Troubleshooting The most effective troubleshooting procedure begins with accurate observations of the system's operation. These Revision 10 — 01-05-2016 FTS 430/830 observations often lead directly to the cause of a problem. The diagnostic procedures in this subsection are divided into two categories: system-level malfunctions, where all lighting units exhibit the same abnormal behavior; and symptoms applying to one or more individual lighting units, but not to all of them. System-Level Problems Table 3-1 identifies symptoms affecting all lighting units in the same way. Use it to determine possible causes.W Table 3-1 System-Level Troubleshooting Flash Conditions Other Conditions Probable Cause High Med. Low No No No Series current too low Weak Weak OK PCB11 Weak OK OK PCB11 OK Bright Bright PCB11 No No No Series current too low OK OK Bright PCB11 No OK OK Series current too low2 OK OK OK Units may flash out of sequence Control line interference3,4 1. Improper adjustment causes most PCB1 problems. If adjustments cannot be made or do not solve the problem, replace the board. 2. High intensity can be achieved only at the highest (6.6 amp) current step. 3. Control wires that are not a twisted pair can cause interference. 4. Control lines exceeding about 7500 feet (2500 meters) may have too much distributed capacitance. Operation may be improved by installing a 470 ohm resistor from TB1-1 to the chassis on one or more lighting units. FTS 430/830 Revision 10 — 01-05-2016 3-5 Problems with Individual Lights Table 3-2 identifies symptoms that apply to a particular lighting unit. Each symptom has one or more suggested causes listed in descending order of probability with the most probable cause first. As an example, suppose one of the lights does not flash in any mode (low, medium, high), but mode relays operate and circuit board LEDs are lit, indicating the presence of low voltage (LV). The symptom best describing this condition is No No No OK OK. This symptom has three possible causes listed. The most likely cause, the first one listed, is the flashtube; the next likely cause is PCB1, and so on. All neon lights out on PCB2 indicates the absence of HV. LEDs out on PCB1 indicates the absence of LV. Table 3-2 Lighting Unit Troubleshooting Flash Conditions 3-6 Other Conditions Probable Cause High Med. Low HV LV No No No No No S1 No No No No OK PCB2 No No No OK No PCB1 No No No OK OK FT 101 PCB1 T102 No No OK OK OK PCB2 OK OK No OK OK PCB2 PCB1 C3 OK Bright Bright OK OK K1 PCB2 PCB1 Weak OK OK OK OK K1 PCB1 Weak Weak OK OK OK K2 PCB1 OK OK Bright OK OK K2 PCB1 Skips Skips Skips OK OK FT101 Revision 10 — 01-05-2016 FTS 430/830 Section 4 — Replaceable and Spare Parts Customer Service Flashhead Parts Customer Service: 1-800-821-5825 Table 4-2 lists the parts for emergency repairs. Telephone: (615) 261-2000 Facsimile: (615) 261-2600 Returning Equipment Shipping Address: Flash Technology Corporation of America 332 Nichol Mill Lane Franklin TN 37067 Ordering Parts To order spare or replacement parts, contact FTCA customer service. Figure 4-1, Figure 4-2, and Figure 4-3 show component locations. Power Converter Parts Table 4-1 lists the parts for emergency repairs. FTS 430/830 A Return Material Authorization (RMA) number is required for all equipment returned to Flash Technology. See Return Material Authorization, located at the end of this document, for complete details regarding the RMA process. To obtain an RMA number, please have the equipment serial number and/or sales order number available and call Technical Support @ 1-800-821-5825. Repackaging You must return the equipment in a container that provides maximum protection during shipping and handling. If the original cartons and packaging material are no longer available, package the unit in a strong double corrugated carton. Package and ship the unit with the mounting feet downward against the bottom of the box. Pad the unit so that the feet cannot penetrate the box during shipment. Box each unit separately using a double thickness cardboard container and adequate padding. Do not drop. Use appro-priate warning labels on the outside of the container. Revision 10 — 01-05-2016 4-1 Table 4-1 Power Converter Replaceable Parts † ‡ 4-2 Unit Description Part No. Quantity 430 Capacitor, (C1), 20 mfd. 6731401 1 430 Capacitor, (C2), 40 mfd. 6386503 1 430 Capacitor, (C5), 15 mfd. 6731301 1 430 Capacitor, (C6), 15 mfd. 6731301 1 430 Capacitor, (C7), 8 mfd. 6731201 1 430 PCB Diode Matrix PC430 2903602 1 830 Capacitor, (C1), 20 mfd. 6731401 1 830 Capacitor, (C2), 70 mfd. 6720401 1 830 Capacitor, (C5), 15 mfd. 6731301 1 830 Capacitor, (C6), 15 mfd. 6731301 1 830 Capacitor, (C7), 5 mfd. 6731101 1 830 PCB Diode Matrix PC830 2903601 1 All Choke, Flash (L2) 4175200 1 All Elapsed Time Meter (optional) 1749201 1 All Enclosure 3727901 1 All Flash Monitor Module (K3; optional) 1851001 1 All HV Rectifier Board (PCB2) 2711402 1† All Interlock Switch (S1) 4901220 1 All Relay, Mode (K1, K2) 8900494 2† All Resistor, Bleed (R1), 35K 6900541 1 All Resistor, Bleed (R2), 50K 6900542 1 All Resistor, 1K 1W (R3) 8435211 1 All Resistor, 1K 2W (R4) 8435212 1 All Resistor, 1M 2W (R5) 8435206 1 All Spacer, Ceramic 5900844 2 All Terminal Strip, 8-Position (TB2) 8721008 1 All Terminal Strip, 11-Position (TB1, TB3, TB4) 8721011 3 All Timing and Trigger Board (PCB1) 2730300 1†‡ All Transformer, Power (T1) 4738302 1 All Transformer, Trigger Coupling (T3) 8336701 1 All Transformer, Low Voltage (T4) 4734500 1 All Transformer, Isolation (T5) 4852801 1 All Varistor (VR2) 6901079 1 Recommended as a spare part. Remove the programming matrix from the existing installed board and insert it into the new replacement board.. Revision 10 — 01-05-2016 FTS 430/830 62 Figure 4-1 PC430 or PC 830 Power Converter Component Locations FTS 430/830 Revision 10 — 01-05-2016 4-3 VR2 TB3 1 2 9 8 7 6 5 4 3 1 2 3 TB1 11 10 ETM K2 4 T3 5 6 L2 7 8 PCB1 C5 C6 C1 9 K1 T1 REAR VIEW R2 R1 S1 11 TB4 1 2 K3 7 R4 PCB2 8 11 PCB3 10 (OPTION) 9 ELAPSED TIME METER (OPTIONAL) C7 FRONT VIEW G1 10 R3 C2 G2 END VIEW 1 2 T4 3 T5 4 5 6 TB2 7 8 3-7418-01X Table 4-2 Flashhead Replaceable Parts Unit Description Part No. Quantity FH 400 Lens 8743701 1 FH 400 Trigger Transformer (T101) 8288201 1† FH 400 Clamp, Lens 3893201 3 FH 400 Spacer, Ceramic 5900844 4 FH 400 RC Network (RC 101) 1403411 1 FH 400 Flashtube 8384329 1† FH 400 Terminal Screw Lug 3379102 3 FH 400 FH 400 FH 800 Spacer, Ceramic Coupling Transformer 7/50 wrap Flashtube (FT 101) 5900842 8336701 8901701 4 1† † 1† FH 800 RC Network (RC 101) 1403411 1 FH 800 Trigger Transformer (T101) 8288201 1† FH 800 Post, Ceramic 5900842 4 FH 800 FH 800 FH 83F-2 FH 83F-2 Retaining Bezel Coupling Transformer 7/50 wrap Flashtube Linear FH83F-2 Terminal Block / 6 Position 3735202 8336701 8675309 4997031 1 1† † 1† 1 FH 83F-2 Coupling Transformer 7/50 wrap 8336701 1 FH 83F-2 FH 83F-2 FH 83F-2 Trigger Transformer Spacer, Ceramic RC Network (RC 101) 8288201 5900842 1403411 1 2 1 † Recommended as a spare part. † † Only used if the FH 430 or FH 830 is mounted more than 40 Feet from it's associated PC. 4-4 Revision 10 — 01-05-2016 FTS 430/830 RC NETWORK RED DOT BLUE CONNECTING WIRE PUR WHT BLK BLU RED CONNECTING WIRE RED SMALL BLUE SECONDARY WIRE FROM TRIGGER TRANSFORMER WHITE TRIGGER SECONDARY WIRE FROM TRIGGER TRANSFORMER FLASH HEAD CABLE WIRES BLUE WIRES CONNECTED TO FASTONS ON PRIMARY COIL OF TRANSFORMER RED BLUE BLACK WHITE PURPLE AND GROUND LENS LENS CLAMP (3 PIECES) FLASHTUBE CERAMIC POSTS RC NETWORK WHITE TRIGGER SECONDARY WIRE FASTONS CERAMIC POSTS BLUE SECONDARY WIRE RED DOT TRIGGER TRANSFORMER BLUE WIRES WITH FASTONS 63 Figure 4-2 FH 400 Flashhead Component Locations FTS 430/830 Revision 10 — 01-05-2016 4-5 E Elapsed time meter 1-2 Equipment returning 4-1 storage 3-1 INDEX A Access 2-1 ALS figure, typical configuration 2-5 light alignment 1-1 lights 1-2 B Bleed resistor, testing 3-3 C Capacitor removal and replacement 3-3 testing 3-2 Caution removed components 2-2 voltage adaptor 2-3 Checklist, installation 2-3 Comounted unit FTS 430, mounting and outline figure 2-8 FTS 830, mounting and outline figure 2-10 Component removal and replacement 3-3 removed, caution 2-2 testing 3-2 Component location figure FH 400 flashhead 4-5 FH 800 flashhead 4-6 power converter 4-3 Configuration figure typical ALS 2-5 typical REIL 2-4 Control line connection 2-3 interference 3-2 Counterpoise 2-3 Current regulator Style 1 1-3 setup 1-3 three intensities 1-4 two intensities 1-4 Style 2 1-3 setup 1-3 three intensities 1-5 Customer service 4-1 D Diagnostic testing 3-1 FTS 430/830 F FH 400 flashtube, removal and replacement 3-4 lens, removal and replacement 3-4 FH 800 flashtube removal and replacement 3-4 Flash failure monitor 1-2 Flashhead FH 400 basic description 1-1 figure component locations 4-5 mounting and outline 2-7 FH 800 basic description 1-1 figure component locations 4-6 mounting and outline 2-9 figure internal wiring 2-13 parts 4-4 Flashtube testing 3-3 G Grounding 2-3 H High voltage rectifier board testing 3-2 transformer removal and replacement 3-3 testing 3-3 I Individual lights, troubleshooting 3-6 Installation checklist 2-3 control line connection 2-3 counterpoise 2-3 general 2-1 grounding 2-3 isolation transformer 2-3 mounting 2-1 tools 2-1 wiring 2-3 Revision 10 — 01-05-2016 I-1 wiring figure typical 2-11 Interference, control line 3-2 Interlock switch, testing 3-3 Problems individual lights 3-6 system level 3-5 L Label, indicating unit position 2-1 Lighting unit, troubleshooting 3-6 Locations figure flashhead components FH 400 4-5 FH 800 4-6 power converter components 4-3 Low voltage transformer, removal and replacement 3-3 REIL configuration figure typical 2-4 lights 1-2 Relays, testing 3-2 Removal and replacement capacitors 3-3 component 3-3 FH 400 flashtube 3-4 FH 400 lens 3-4 FH 800 flashtube 3-4 high voltage transformer 3-3 low voltage transformer 3-3 timing and trigger board 3-3 trigger coupling transformer 3-3 trigger transformer 3-4 Removed components, caution 2-2 Repackaging for shipment 4-1 Returning equipment 4-1 M Maintenance, preventive 3-1 Meter, elapsed time 1-2 Mounting 2-1 Mounting and outline figure comounted unit FTS 430 2-8 FTS 830 2-10 flashhead FH 400 2-7 FH 800 2-9 power converter 2-6 O Operation 1-2 Options 1-2 Ordering parts 4-1 P Parts 4-1 flashhead 4-4 ordering 4-1 power converter 4-2 PCB1 figure 1-4 Position unit label 2-1 Power converter figure, component locations 4-3 internal wiring figure 2-12 mounting and outline figure 2-6 parts 4-2 Power rating 2-2 guidelines, table 2-2 Preventive maintenance 3-1 I-2 R S Safety 3-1 Series runway circuit 2-2 Setup 1-2 preliminaries 1-3 procedures 1-3 Style 1 current regulator 1-3 three intensities 1-4 two intensities 1-4 Style 2 current regulator 1-3 three intensities 1-5 Specifications 1-1 Storage 3-1 Style 1 current regulator setup three intensities 1-4 two intensities 1-4 Style 2 current regulator setup, three intensities 1-5 System definition 1-1 ALS 1-2 REIL 1-2 System level problems 3-5 troubleshooting 3-5 Revision 10 — 01-05-2016 FTS 430/830 T Telephone numbers 4-1 Testing bleed resistor 3-3 capacitors 3-2 components 3-2 diagnostic 3-1 flashtube 3-3 high voltage rectifier board 3-2 high voltage transformer 3-3 interlock switch 3-3 relays 3-2 timing and trigger board 3-2 trigger transformer 3-3 Timing and trigger board figure 1-4 removal and replacement 3-3 testing 3-2 Tools 2-1 Transformer, isolation 2-3 Trigger coupling transformer removal and replacement 3-3 Trigger transformer removal and replacement 3-4 FTS 430/830 testing 3-3 Troubleshooting 3-5 individual lights 3-6 inspection 3-2 lighting unit 3-6 system-level problems 3-5 wiring and cabling 3-2 U Unit position, label 2-1 Unpacking 2-1 V Voltage adaptor, caution 2-3 Voltage conversion adapter usage 2-2 W Wiring figure internal flashhead 2-13 internal power converter 2-12 typical installation wiring 2-11 installation 2-3 Wiring and cabling, troubleshooting 3-2 Revision 10 — 01-05-2016 I-3 Return Material Authorization (RMA) Policy IF A PRODUCT PURCHASED FROM FLASH TECHNOLOGY MUST BE RETURNED FOR ANY REASON (SUBJECT TO THE WARRANTY POLICY), PLEASE FOLLOW THE PROCEDURE BELOW: NOTE: An RMA number must be requested from Flash Technology prior to shipment of any product. No returned product will be processed without an RMA number. This number will be the only reference necessary for returning and obtaining information on the product’s progress. Failure to follow the below procedure may result in additional charges and delays. Avoid unnecessary screening and evaluation by contacting Technical Support prior to returning material. 1. To initiate an RMA: Call Flash Technology’s National Operations Center (NOC) at (800-821-5825) to receive technical assistance and a Service Notification number. The following information is required before a Service Notification number can be generated: • • • • • • • • • Site Name/Number / FCC Registration number/ Call Letters or Airport Designator Site Owner (provide all that apply – owner, agent or subcontractor) Contractor Name Contractor Company Point of Contact Information: Name, Phone Number, Email Address, Fax Number and Cell Phone (or alternate phone number) Product’s Serial Number Product’s Model Number or part number Service Notification Number (if previously given) Reason for call, with a full description of the reported issue 2. The Service Notification number will then serve as a precursor to receiving an RMA number if it is determined that the product or equipment should be returned. To expedite the RMA process please provide: • Return shipping method • Shipping Address • Bill to Address • Any additional information to assist in resolving the issue or problem 3. Product within the Warranty Time Period a. If to be returned for repair; • RMA # is generated • Once product is received and diagnosed; • Covered under warranty – product is repaired or replaced • Not covered under warranty – quote is sent to the customer for a bench fee of $350 plus parts for repair • If the customer does not want the product repaired, a $50 test fee is charged before being returned b. If advance replacement; • Purchase order may be required before the advance replacement order is created • RMA # is generated and the advance replacement order is created • Once product is received and diagnosed; • Covered under warranty – credit given back if PO received • Not covered under warranty – credit will not be applied to PO • Flash Technology has sole discretion in determining warranty claims. Flash Technology reserves the right to invoice for parts advanced if the associated failed parts are not returned within 15 days of issue or if product received is diagnosed to be non-warranty. • Advance replacements will be shipped ground unless the customer provides alternative shipping methods. RMA Policy Revision 2014B 4. Product outside the Warranty Time Period a. For Xenon System board repair; a purchase order is required at time of request for a RMA # for a standard $350 repair bench fee • RMA # is generated with the PO attached • If the board is deemed non-repairable after diagnosis, the customer is notified. If the customer purchases a new board, the repair bench fee is waived. If the customer does not buy a new board, a $50 test fee is charged before being returned or scrapped. b. For all other products; no purchase order is required to return the product for diagnosis • RMA # is generated • Once product is diagnosed, quote is sent to the customer for a bench fee of $350 plus parts for repair • Once the purchase order is received, the product will be repaired and returned • If the customer does not want the product repaired, a $50 test fee is charged before being returned or scrapped. 5. After receiving the Flash Technology RMA number, please adhere to the following packaging guidelines: • All returned products should be packaged in a way to prevent damage in transit. Adequate packing should be provided taking into account the method of shipment. Note: Flash Technology will not be responsible for damaged items if product is not returned in appropriate packaging. 6. All packages should clearly display the RMA number on the outside of all RMA shipping containers. RMA products (exact items and quantity) should be returned to: Flash Technology Attn: RMA #XXX 332 Nichol Mill Lane Franklin, TN 37067 7. All RMA numbers: • Are valid for 30 days. Products received after 30 days may result in extra screening and delays. • Must have all required information provided before an RMA number is assigned. Revision 2014B RMA Policy ~~ End of Document ~~