Avlite AV-OL-KT-A1, AV-OL-KT-E1 Installation & Service Manual

AV-OL-KT-A1

Obstruction Lighting Kit

FAA - A-1

INSTALLATION & SERVICE MANUAL

V1.0

Version No. Description Date Reviewed Approved Design

1.0

AV-OL-KT-A1 Manual Launch September 2019

P. Naidu W. Eva ns M. Sugars

2

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

Table of Contents

1.0 Introduction ...............................................................................................................4

2.0 Technology ................................................................................................................. 5

3.0 AV-OL-KT-A1 Models ................................................................................................6

3.1 Available Options ....................................................................................................................................... 9

4.0 AV-OL-KT-A1 Data Sheet ....................................................................................... 10

5.0 Safety Information ................................................................................................... 11

6.0 Operation and Setup .............................................................................................. 12

6.1 System Overview ......................................................................................................................................12

6.1.1 GPS Synchronisation .....................................................................................................................12

6.1.2 L-864 ......................................................................................................................................................13

6.1.3 L-810(F) .................................................................................................................................................15

6.1.4 T2 Controller ......................................................................................................................................16

6.1.5 Interface Wiring ...............................................................................................................................17

7.0 Unpacking, Installation, Wiring and Setup ......................................................... 18

7.1 Unpacking ......................................................................................................................................................18

7.2 Installation ......................................................................................................................................................18

7.2.1 Tools Required ..................................................................................................................................19

7.2.2 Additional Tools Required ........................................................................................................ 20

7.2.3 Cabling Requirements............................................................................................................... 20

7.2.4 Factory Settings ............................................................................................................................ 20

7.2.5 Installation Recommendation ............................................................................................... 20

7.3 Testing Procedure ...................................................................................................................................37

8.0 Maintenance and Servicing ................................................................................. 38

9.0 Replacement Parts ................................................................................................ 38

10.0 Troubleshooting ..................................................................................................... 39

Latest products and information available at www.avlite.com 3

1.0 Introduction

Congratulations! By choosing to purchase an Avlite product, you have become the owner
of one of the most advanced obstruction products in the world.

Avlite Systems draws on more than 25 years of experience in the design and manufacture
of navigation aids, and particular care has been taken to ensure your light gives years of
trouble-free service.

As a commitment to producing the highest quality products for our customers, Avlite has
been independently certified as complying with the requirements of ISO 9001:2015 quality
management system.

By taking a few moments to browse through this booklet, you will become familiar with the
versatility of your lighting kit, and be able to maximise its operating function.

Please remember to complete the Avlite warranty registration card accompanying your
light.

Acronyms and Abbreviations

The following abbreviations will be used throughout this Installation Manual:

cd candela

ft. foot

in. inch

LED Light Emitting Diode

VAC Volts, Alternating Current

VDC Volts, Direct Current

AWG American Wire Gauge

CMI Combined Medium Intensity

4

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

2.0 Technology

Avlite Systems is a world-class solar lighting systems manufacturer with a proven
reputation for rapid, innovative, and agile technology solutions designed specifically
for defence, government, civil and humanitarian aid operations in the most remote,
toughest environments.

Electronics

Avlite employs leading in-house electronic engineers in the design and development of
software and related circuitry. All individual electronic components are sourced directly by
Avlite procurement staff ensuring that only the highest quality components are used in our
products.

LED Technology

All Avlite lights use the latest advancements in LED (Light Emitting Diode) technology as a
light source. The major advantage of LED’s over traditional light sources is well established
in that they typically have an operational life in excess of 100,000 hours, resulting in
substantial savings to maintenance and servicing costs.

Precision Construction

Commitment to investing in the design and construction of injection-moulded parts
including optic lenses, light bases and a range of other components ensures that all Avlite
products are of a consistent and superior quality.

Optical Performance

Avlite manufactures a range of aviation LED lenses moulded from multi-cavity dies. The
company has superior in-house lens manufacturing capabilities to support outstanding
optical performance.

Award-winning, Patented Technology

Several United States and Australian patent registrations are held on Avlite’s range of
innovative designs, with other regional patents pending in Canada, United Kingdom and
Europe.

Latest products and information available at www.avlite.com 5

3.0 AV-OL-KT-A1

The AV-OL-KT-A1 Obstruction Lighting Kit integrates Avlite’s world class LED fixtures with
an application specific control and monitoring system to provide a full turnkey solution for
A1 defined structures ranging between 150 and 350 feet (45-106 meters). These include
telecommunication towers and utility towers, wind turbines, cranes, buildings and other tall
structures.

The A-1 Obstruction Solution comes fully assembled, ready to install, and includes the
following items:

• 1 x L-864 Medium Intensity Obstruction Light

• 3 x L-810(F) Obstruction Lights

• All necessary Junction Boxes

• Central Control Unit
The top light (L-864) and middle lights (L-810(F)) are illuminated for night operation and are

designed to flash with GPS flash synchronisation.
The A-1 Obstruction Solution is available in two input power configurations, a universal AC

(90-264VAC) or 24-48 VDC (solar compatible) and comes with Star2M monitoring via GSM
or SATCOM as options.

The best in class system power draw allows tower owners to utilize solar for locations
lacking reliable and or cost-effective access to regular utility power. Avlite’s experience,
knowledge and tools for solar applications provides years of maintenance free, off-grid
operation with an emphasis on FAA compliance.

With a range of accessories including brackets, cable and junction boxes, utility and
telecommunication companies, electrical contractors and state and local governments can
now quickly and easily purchase all obstruction lighting components from a single source,
simplifying the ordering process and reducing the possibility of incompatible, stand-alone
components from different manufacturers.

Note: This installation and service manual must be used in conjunction with the installation
manuals of the individual components.

6

AV-OL-KT-A1 - Obstruction Light Kit

167 (6.57”)

121 (4.75”)

119 (4.69”)

121 (4.75”)

119 (4.69”)

2

345

1

Zone Rev

Model

Rev

ECR No.

Description Date:- Drawn:- Approved:-

26.5in

673mm

2

345

1

18.5in

470mm

24in

610mm

652mm

25.6in

20in

508mm

Zone Rev

Model

Rev

ECR No.

Description Date:- Drawn:- Approved:-

26.5in
673mm

1 x L-864 Beacon - AV-OL-FL864

[9in]

230mm

3 x L-810(F) - AV-OL-L810F

[4.75in]
121mm

[4.69in]
119mm

Installation & Service Manual

[4in]

104mm

[6in]

151mm

[5.4in]

137mm

1 x Control Unit

Note: Mounting hardware not included.

Latest products and information available at www.avlite.com 7

[15.8in]

400mm

200mm

[7.9in]

[23.6in]

600mm

1 x Top Level Junction Box

Zone

Rev

Model

Rev

ECR No.

Description

Date:-

Drawn:-

-

General Tolerances

Linear
X
X.X
X.XX

±1.2
±0.3
±0.1

Angular
X
X.X

±1.0°
±0.5°

±2.0
±0.5

Radii
X
X.X

002210-001-000

Description

Date:-

Drawn:-

Approved:-

Zone

Rev

Model

Rev

ECR No.

Description

Date:-

Drawn:-

-

002210-002-000

General Tolerances

Linear
X
X.X
X.XX

±1.2
±0.3
±0.1

Angular
X
X.X

±1.0°
±0.5°

±2.0
±0.5

Radii
X
X.X

Model Rev:-

0

Description

Date:-

Drawn:-

Approved:-

Note: Mounting hardware not included.

[7.74in]

197mm

1 x Mid Level Junction Box

Note: Mounting hardware not included.

[11.77in]

299mm

[4.86in]
123mm

[4.78in]
121mm

[8.68in]

221mm

8

[10.32in]

262mm

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

3.1 Available Options

• Solar Input Power (for 24VDC) – Call Avlite for details.

• Cable Kit (suitable for 350 ft. structure) Includes:
275’ of 18 AWG, 3 Conductor wire
275’ of 10 AWG, 2 Conductor wire
165’ of 18 AWG, 5 Conductor wire

• Light Mounting Brackets (each)
For L864 Right Angle Pole Mounting Bracket-Medium Intensity Fixtures
For L-810(F): Right Angle Mounting Bracket-Low Intensity Fixtures

• Remote Monitoring and Control
Avlite offers remote Star2M monitoring via GSM or SATCOM.

Operators can remotely monitor the status of their installation from a compatible
device. The system can also be configured to send out SMS text messages or
e-mail alerts to designated operators should alarm conditions be triggered, such
as low voltage or light failure.

Please contact Avlite for operational information for the Monitoring & Control
options. Visit https://www.star2m.com to find out more about Star2M

• Mounting Bolt Kit (includes bolts, nuts, washers)
Please contact Avlite for further details

• Control Unit Mounting Hardware
2” pipe clamps
¾” pipe clamps

Please contact Avlite for further details.

Latest products and information available at www.avlite.com 9

4.0 AV-OL-KT-A1 Data Sheet

FAA E1 Obstruction Kit AC DC
Electrical Characteristics

Input Voltage
Input Frequency

Power Consumption

Peak
Average

Physical Characteristics

Dimensions

(inches/mm)

L-864 6 / 151 9 / 230 6.75 / 171 12.3 / 5.5
L-810(F) 5.4 / 137 4.75 / 121 3.875 / 100 0.375 / 0.4
Control Unit 23.9 / 600 15.8 / 400 7.9 / 200 63 / 28.5
Top Junction Box 4.86 / 123 8.68 / 221 7.74 / 197 7.05 / 3.2
Middle Junction Box 4.78 / 121 10.32 / 262 11.77 / 299 9.92 / 4.5

Mounting

L-864 200mm bolt pattern
AV-OL-L-810(F) ¾ inch pipe thread
Control Unit Wall mounted (mounting accessories available)
Top Junction Box Mounting accessories available
Middle Junction Box Mounting accessories available

Certifications and Compliance

CE EN61000-6-3:2007, EN61000-6-1:2007
Quality Assurance ISO9001:2015
Protection Rating Junction and Control Box: IP65/NEMA4X Lights: IP68
FAA L-810(F), L-864, Medium Intensity Obstruction Light, FAA AC 150/5345-

Transport Canada CL-864 Canadian Aviation Regulations 2015-2, Standard 621 -

DGAC L-864 Medium Intensity Obstruction Light, L-810(F) Low Intensity

Intellectual Property

Trademarks AVLITE® is a registered trademark of Avlite Systems

Warranty *

Options Available

90-264VAC 24-48VDC

50/60 Hz N/A

84VA 70W

Night: 6.6VA Night: 5.5W

Height

Obstruction Marking and Lighting, March 2016 Appendix B

• Mounting Brackets for L-864 and L-810(F)

Width

(inches/mm)

Obstruction Light (Qualified by Intertek)

5 year warranty on light fixtures
3 year warranty on Control Unit

• Cable Kit suitable for 350’ structures

Lens Diameter

(inches/mm)

43H

Mass

(lbs./kg)

*Please refer to the individual light installation manuals for further specifications

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AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

5.0 Safety Information

Before proceeding with installation or service, make sure the following conditions are met:

• Ensure the tower or mast is grounded (NO RF OR SHOCK HAZARD)

• Check the mast lighting circuit is not faulty

• Ensure power lines are not ‘live’ (NO ELECTRICAL HAZARD)

• Avoid touching live circuits!

• Avoid touching any component or any part of the circuitry while the unit is operating.
Do not change components or make adjustments inside the unit with power on.

• Make sure the light fixture mounting is vertically aligned to guarantee the required
beam pattern of the obstruction light.

• Make sure any nearby obstacles do not impede the lights’ beam pattern.

• When installing, comply with all local electrical code(s).

• Mains power should always be disconnected when work is being done in close
proximity to electrical fittings, and electrical work should only be done by a licensed
electrician.

• Operate the light only within the indicated electrical ratings and product usage
instructions.

• To ensure that the light and peripheral equipment function safely and correctly, use
cable in compliance with the effective local electrical code.

• Do not stare at the LED or shine the LED into your eyes or those of another person.

• Dispose of the product according to the local laws and regulations for your region, for
example, at a recycling centre that accepts electronic devices.

Latest products and information available at www.avlite.com 11

6.0 Operation and Setup

Avlite’s A1 Obstruction Lighting Solution Kit consists of five components: A Control Unit
which provides power, day & night control and (optional) remote monitoring, a single L-864
red Medium Intensity obstruction beacon, and three L-810(F) red obstruction lights.

Both the L-864 and L-810(F) incorporate internal diagnostic checking and an alarm contact
for remote monitoring. The alarm relay is energized in normal operation and is released if
there is an LED or power fault.

An External Photocell allows the lights to automatically switch between day and night
mode. In night mode, all lights flash in synchronization with one another via integrated
GPS synchronisation, per the guidelines in the FAA 7460-1L Advisory Circular for lighting
A1 structures. In day mode, all lights are not illuminated. The Photocell output can also be
overridden for system testing and maintenance via the Photocell Bypass Switch. (See
section 6.1.3 for more information).

The Control Unit automatically evaluates the A1 lights for operation and performance while
providing local and remote display of information and alarms; operators can conveniently
view the lights’ real time status from the web based Star2M™ portal.

6.1 System Overview

6.1.1 L-864

External

Power

Positive (+VDC) Black

Negative (-VDC) White

Data

Ground Ref (GNDA) White

PC Input (IN1) Black

Alarm Common (COM) Red

Alarm Signal (NC) Green

12

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

Lantern Status

The L-864 is fitted with one red and one yellow status LED and provides the operator with
an indication of the lantern status.

The LEDs are located on the side of the lantern.
The red status LED is used to indicate the health of the lanterns’ power system. The yellow

status LED is used to indicate the operational status of the lantern. These indicator LED’s
can be viewed at the base of the lens.

RED

Status LED Lantern Status Lantern Condition

Steady Flat Battery cut off is in

OFF Battery voltage is less than 43.0V

effect

Slow High Voltage ON Battery voltage is above 54.0V

Off Optimal Voltage ON Battery Voltage is between 50.0V

– 54.0V

1 Quick OK Voltage ON Battery Voltage is between 48.0V

– 50.0V

2 Quick Low Voltage ON Battery Voltage is between 47.0V

– 48.0V

3 Quick Poor Voltage ON Battery Voltage is between 43.0V

– 47.0V

4 Quick Flat Voltage ON Battery voltage is less than 43.0V

Once the Flat Battery cut-off condition is in effect, the lantern will not turn back on until it
sees day light and the battery voltage is above the “OK” threshold for at least one minute.

Latest products and information available at www.avlite.com 13

YELLOW

167 (6.57”)

121 (4.75”)

119 (4.69”)

121 (4.75”)

119 (4.69”)

Status LED Lantern Status Lantern Condition

Off Standby OFF Lantern is in Standby Mode

Quick Flashing

0.15s on, 0.15s
off

2 Quick
Flashes
every 2s

1 Quick
Flashes
every 2s

Slow Flashing

1.5s on, 1.5s off

2 Quick
flashes
every 11s

If the lantern is not fitted with the GPS Synchronisation option, then the following conditions
are not possible: 1 Quick Flash, and Slow Flashing.

For more information regarding the L-864, please consult the relevant sections of the
corresponding service and installation manual.

6.1.2 L-810(F)

External

Day To Night Transitioning
(Dusk Till Dawn Mode)

Operational, Not
Synchronized

Operational, Sync in
Progress

Operational, Synchronized ON Normal operating condition.

Operational, Synchronized
as Slave

OFF Light is activating and will turn

on after detecting 30 seconds of
continuous darkness

ON Lantern is in Normal operating

condition. It is not connected to
any GPS synchronization

ON Lantern is ‘re-syncing’ with GPS.

The lantern re-syncs with the GPS
every 15 minutes

Lantern is synchronized to GPS­enabled lanterns

ON Lantern is a Hard Wire

Synchronization
Slave

14

Power and Data

Positive (+VDC) Red

Negative (-VDC) Black

IN1 White

COM Orange

NO Green

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

LED Fault

In the event of a singular LED fault, either open circuit or closed circuit across the LED, the
light unit will turn off all LED’s and actuate the Fault Relay.

For more information regarding the L-810(F), please consult the relevant sections of
the corresponding service and installation manual.

6.1.3 T2 Controller

The T2 Control Unit is an essential component of the A1 Obstruction Lighting Kit as it
provides power, control and monitoring of the light fixtures in the system.

For safety and security, the control enclosure comes with a safety interlock which prevents
access to the controller while the system is powered on.

The Controller is available in two input power configurations; a universal AC or DC and
comes with remote monitoring via Star2M with either GSM or Satcom telemetry types as
options.

By default, the control unit comes with 2 dry contacts for external monitoring of both the
L-864 and L-810(F) light fixtures which receive the associated alarm in the event of a power
or LED fault. (Note: External dry contact monitoring is unavailable if remote monitoring via
GSM or Satcom has been enabled)

A Photocell Bypass Switch is provided with the Control Unit to override the Photocell output
for system testing and maintenance and is factory-set to AUTO (auto day/night) mode.

The Control Unit with the AC option has an interface switch on the door. The DC version
has a circuit breaker in the cabinet for switching the power ON and OFF.

To test the function of lights for night operation, the system must be operating in Day
mode. Toggle the switch to Override by turning the switch to the right. All lights should
illuminate. To return to the Auto mode, return the switch to the Auto position.

Note: Time delays are to be expected when changing modes. Allow up to 1 minute to
change between functions.

Latest products and information available at www.avlite.com 15

6.1.4 Interface Wiring

L-864

L-864

Pow er c abl e: 2 x 10 AWG

Pow er c abl e: 2 x 10 AWG

Data cable: 4 x 18 AWG

Data cable: 4 x 18 AWG

Top Junction

Top Junction

Box

Pow er c abl e: 2 x 10 AWG

Pow er c abl e: 2 x 10 AWG

Data cable: 3 x 18 AWG

Data cable: 3 x 18 AWG

L-810(F)

L-810(F)

Box

L-810(F)

L-810(F)

5 x 18 AWG

5 x 18 AWG

Power & Data cable:

Power & Data cable:

L-810(F)

L-810(F)

16

Externa l

Externa l

Photocell

Photocell

Pow er & Da ta cab le: 3 x 18 AWG

Pow er & Da ta cab le: 3 x 18 AWG

Power & Data cable:

Power & Data cable:

5 x 18 AWG

5 x 18 AWG

T2 Con troller

T2 Con troller

Mid dle

Mid dle

Junction B ox

Junction B ox

Power & Da ta cab le:

Power & Da ta cab le:

5 x 18 AWG

5 x 18 AWG

Power & Data cable:

Power & Data cable:

5 x 18 AWG

5 x 18 AWG

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

6.1.5 GPS Synchronisation

Avlite has utilized the latest advancements in GPS technology to develop an internal
synchronization system that is incorporated into the lights. Using overhead satellites,
multiple obstruction lights set to the same flash pattern will flash in unison. No additional
power supplies, aerials or control systems are required, and with its microprocessor­based system, the GPS option is specifically designed to provide maximum reliability and
performance over a wide range of environmental conditions.

Operating Principle

Each light operates independently and requires no operator intervention. A minimum
of 4 satellites need to be in view for the built-in GPS receiver to collect time data. At
dusk, the light sensor will turn the light on. If time data is available, the light will come on
synchronized to every other light with the same selected flash code. Synchronisation is
achieved using an internal algorithm based on the highly accurate time base and time data
received from the satellites. The satellite data is provided from a number of earth stations
using atomic clocks as the time base. Continuous self-checking ensures that the light will
continue to run in synchronisation.

Light Activation

At power-up the microprocessor checks that the internal GPS module is programmed
correctly and is able to provide valid time base and time data. Once outside with a clear
view of the sky, valid data should become available within 20 minutes.

Note: Lights will not synchronise if different flash codes are selected.

Latest products and information available at www.avlite.com 17

7.0 Unpacking, Installation, Wiring and

Setup

7.1 Unpacking

Unpack all hardware and inspect for damage. If there is any damage, please contact your
Avlite Office.

Retain original packing material for possible future use in shipping.

7.2 Installation

WARNING:

Confirm that the power switch is toggled to the OFF position when
power is connected. DO NOT connect power to the PCU when the
control panel power switch is toggled to the PWR position. This may
result in damage to the power sources.

WARNING:

DO NOT connect directly to the DC output of a generator, or any

other unregulated power source. Connecting to an unregulated
source may result in damage.

WARNING:

Do not stare into light emitting diode (LED) beams.

CAUTION:

LED lights contain glass components. Do Not Drop.
Always follow the instructions outlined in the product manual when

cleaning the equipment. Improper cleaning methods and use of
unauthorized cleaning agents can damage equipment.

18

7.2.1 Tools Required

Tools Needed (not supplied)

Flush Cutter

Tongue & Groove Pliers

Silicone Sealant

Cable Jacket Trimmer (optional)

Utility Knife

Electrical Tape

Insulated Terminal Crimper

Wire Strippers 10AWG to 18AWG Range

2.5mm Hex Key

2.0mm Flat Blade Precision Screwdriver

#2 Phillips Screwdriver

Junction Boxes (2) (owner supplied or optional
purchase)

Light Mounting Brackets (4) (optional purchase)

Cables (owner supplied or optional purchase)

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

7.2.2 Location

Refer to FAA AC 150/5345-43 and FAA AC 70/7460-1L for site requirements for obstruction
lights.

Latest products and information available at www.avlite.com 19

7.2.3 Cabling Requirements

The installation of the AV-OL-KT-A1 Obstruction Lighting Kit requires the following cables (if
optional cable kit is not purchased):

Reference Point Cable

L-864 -Top Junction Box • Power Cable: 10 AWG 2 Conductor.

• Data Cable: 18 AWG 4 Conductor.

Top Junction Box - Control Unit • Power Cable: 10 AWG 2 Conductor.

• Data Cable: 18 AWG 3 Conductor.

L-810(F) - Middle Junction Box: • Power & Data Cable (x3) = 18 AWG 5 Conductor.

Middle Junction Box- Control Unit • Power & Data Cable = 18 AWG 5 Conductor.

Photocell - Control Unit: • Power & Data Cable = 18 AWG 3 Conductor.

7.2.4 Factory Configuration

• L-864 wired with 10ft flying leads (Power cable and Data cable).

• 1 x L-810(F) wired with 10ft flying lead.

• 2 x L-810(F) wired with 25ft flying lead.

• External Photocell wired with 25ft flying lead.

7.2.5 Installation Recommendation

Note: The sequence of steps can be adjusted for site requirements.

1. Wire and test the system on ground level.

Conduct a basic functional check to ensure that the lights turn on as expected. See section

7.3 Testing Procedure for more information.

20

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

2. Mount the Control Unit

The Control Unit should be mounted in a reasonable location at eye level to ensure that it
is easily accessible for servicing and maintenance. There should be plenty of clearance
around all sides to allow direct access when the door of the control unit is completely open.

a. Attach the required mounting hardware to the top and bottom of the Control Unit.

Example of Control Unit mounting hardware

Pre-installed Control Unit tab

b. Mount the Control Unit (with the previously attached mounting hardware) to the tower

or installation structure using the mounting tabs. Secure using the required mounting
fixtures.

Note: Mounting hardware is not included with the kit.

Latest products and information available at www.avlite.com 21

3. Mount External Photocell

Insert the Photocell into the mount (Avlite supplied) by inserting the contact blades into the
receptacle. Secure the Photocell assembly to the tower or installation structure using the
required mounting fixtures.

The following considerations should be taken into account when mounting the external
Photocell:

• Mount in a reasonable location at eye level to ensure that it is easily accessible for
servicing and maintenance.

• The Photocell should be pointed away from the equator (North in Northern
Hemisphere, South in Southern Hemisphere).

• The Photocell should be located away from bright, artificial lighting.

Note: Mounting fixtures are not supplied.

22

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

4. Wire the Photocell to the Control unit and cut cable to the required length.

Wiring instructions-Power and Data Cable:

• Connect the black positive conductor from the External Photocell to circuit breaker 5
(labelled ‘PC +24VDC’) on terminal block 1 in the Control Unit

• Connect the white negative conductor from the External Photocell to the ‘PC

-Common’ labelled terminal on terminal block 1 in the Control Unit

• Connect the green Photocell signal conductor to the ‘PC Signal’ labelled terminal on
terminal block 1 in the Control Unit

Refer to section 7.2.3 Cabling Requirements for recommended cable sizes.

Latest products and information available at www.avlite.com 23

5. Install the L-864

Mount the L-864 Medium Intensity Obstruction light directly to the top of the tower or
installation structure either by securing it to the mounting plate or by attaching an optional
Avlite Right Angle Pole Mounting Bracket (for medium intensity fixtures) to the tower and
bolting the L-864 to the bracket.

6. Mount the top junction box.

Note: Mounting hardware for junction boxes is not supplied.

7. Wire L-864 to top junction box

a. Wire L-864 power cable to junction box, then data cable to junction box.

Wiring instructions-Power Cable:

• Connect the black positive conductor from the L-864 to the +48VDC labelled terminal
in the top junction box

• Connect the white negative conductor from the L-864 to the -48VDC labelled terminal
in the top junction box

24

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

Wiring Instructions-Data Cable:

• Connect the white Ground Ref (GNDA) conductor from the L-864 to the GND labelled
terminal in the top junction box

• Connect the red Alarm Common (COM) conductor from the L-864 to the COM labelled
terminal in the top junction box

• Connect the green alarm signal (NC) conductor from the L-864 to the NC labelled
terminal in the top junction box

• Connect the black Photocell Input (IN1) conductor from the L-864 to the PC labelled
terminal in the top junction box

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

b. Run two cables from the top junction box to the Control Unit, one for power and one

for data.

Refer to section 7.2.3 Cabling Requirements for recommended cable sizes.

Latest products and information available at www.avlite.com 25

8. Route top junction box to control unit cables

Wiring instructions-Power Cable:

• Connect the black positive conductor from the +48VDC terminal in the top-level
junction box to circuit breaker 2 (label ‘L-864 +24VDC’) on terminal block 1 in the
Control Unit.

• Connect the white negative conductor from the -48VDC terminal in the top-level
junction box to the ‘L-864 -24VDC’ labelled terminal on terminal block 1 in the Control
Unit.

26

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

Latest products and information available at www.avlite.com 27

Route top junction box to control unit cables

Wiring instructions-Data Cable:

• Connect the white Alarm Common (COM) conductor from the top-level junction box
to the ‘L-864 Alarm Common’ labelled terminal on terminal block 1 in the Control Unit

• Connect the black alarm signal (NC) conductor from the top-level junction box to the
‘L-864 Alarm Signal’ labelled terminal on terminal block 1 in the Control Unit

• Connect the green Photocell Output (PC) conductor from the top-level junction box
to the ‘L-864 PC Input’ labelled terminal on terminal block 1 in the Control Unit

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AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

Latest products and information available at www.avlite.com 29

9. Mount the L-810(F) lights (x3)

Thread a ¾” pipe thread cord grip to the L-810(F) and attach the light to an owner supplied
bracket or optional Avlite Right Angle Mounting Bracket (for low intensity fixtures) with a
locking nut.

¾” Conduit Locknut and Nipple (Optional)

Right Angle Mounting Bracket-Low Intensity
Fixtures (Optional)

10. Mount middle junction box

Note: Mounting hardware for junction boxes is not supplied.

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AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

11. Wire the L-810(F) lights to the middle junction box.

Wiring instructions-Power and Data cable:

• Connect the red positive conductor from the L-810(F) to the appropriately marked
+VDC terminal for marker 1,2,3 or 4 (if installed) in the mid-level junction box

• Connect the black negative conductor from the L-810(F) to the appropriately marked

-VDC terminal for marker 1,2,3 or 4 (if installed) in the mid-level junction box

Latest products and information available at www.avlite.com 31

• Connect the orange Alarm COM conductor from the L-810(F) to the appropriately
marked Alarm COM terminal for marker 1,2,3 or 4 (if installed) in the mid-level junction
box

• Connect the Green NC conductor from the L-810(F) to the appropriately marked Alarm
NC terminal for marker 1,2,3 or 4 (if installed) in the mid-level junction box

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AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

• Connect the White PC Input (IN1) conductor from the L-810(F) to the appropriately
marked PC terminal for marker 1,2,3 or 4 (if installed) in the mid-level junction box

Refer to section 7.2.3 Cabling Requirements for recommended cable sizes.

Latest products and information available at www.avlite.com 33

12. Route middle junction box to Control Unit cables

Wiring instructions-Power and Data Cable:

• Connect the red positive CTRL + 24VDC conductor from the middle junction box to
circuit breaker 3 (i.e. Label L-810F + 24VDC) on terminal block 1 in the Control Unit

• Connect the black negative CTRL -24VDC conductor from the middle junction box to
the ‘L-810F -24VDC’ labelled terminal on terminal block 1 in the Control Unit

• Connect the orange CTRL Alarm COM conductor from the middle junction box to the
‘L-810F Alarm Common’ labelled terminal on terminal block 1 in the Control Unit

• Connect the green CTRL Alarm NC Conductor from the middle junction box to the
‘L-810F Alarm Signal’ labelled terminal on terminal block 1 in the Control Unit

• Connect the white PC conductor from the middle junction box to the ‘L-810F PC Input’
labelled terminal on terminal block 1 in the Control Unit

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AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

Refer to section 7.2.3 Cabling Requirements for recommended cable sizes.

Latest products and information available at www.avlite.com 35

13. Wiring the Control Unit:

AC Installation:

Connect the incoming power conductors to the appropriate terminals (i.e. AC Line 1, AC line
2 and AC Neutral) on the power switch on terminal block 1 in the Control Unit.

The grounding conductor will be connected to the ‘Ground’ labelled terminal block (green/
yellow) adjacent to the power switch.

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AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

DC Installation:

Connect the positive DC conductor to circuit breaker 1.
Connect the negative conductor to the common terminal block adjacent to the circuit

breaker on terminal block 1.

7.3 Testing Procedure

Note: Avlite recommends that all testing be done during the day.

1. Power the system on.

2. Check that no circuit breakers have tripped.

3. 4. Check function of all lights (i.e. L-864 and all L-810(F) lights) by carrying out the
following:

a. Night mode: Cover the External Photocell and check night operation is functioning

as expected. All lights should be illuminated red and flashing in synchronization.

b. Day mode: Uncover the External Photocell and check day operation is functioning

as expected. All lights should be off.

4. Turn the Photocell Bypass Switch to Override and ensure that all lights illuminate in
night mode.

5. Turn the Photocell Bypass Switch back to Auto.

6. For 01 & 02 Variants only:

Trip the breaker for the L-864 and ensure that the corresponding alarm is
received (if monitoring is installed)

Trip the breaker for the L-810(F) lights and ensure that the corresponding alarm is
received (if monitoring is installed)

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8.0 Maintenance and Servicing

Refer to the individual light manuals for light maintenance.
Ensure Photocell is free from debris (i.e. snow, leaves, etc.) for reliable and continuous

operation.

9.0 Replacement Parts

If replacement parts are required, please call a local Avlite distributor and reference the
Product or Configuration Code called out in the “Product Configuration and Options” section
of the corresponding product data sheet.

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10.0 Troubleshooting

Problem Possible Cause Solution

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

L-864 beacon is out

(No Alarm)

L-864 beacon is

flashing white at night

A single L-810(F)
marker light is out
(No Alarm)

All marker L-810(F)
lights out (No Alarm)

Light is out • No power to light

L-864 top light is not

operational
(no white or red
mode)

No power to light • Check for voltage in Control

Junction box wiring • Check junction box wiring.

Photocell input is
high

Beacon in “limp
mode”

Marker wiring • Check the wiring of the

Junction box wiring • Check junction box wiring.

Junction box wiring • Check junction box wiring.

Cable to junction box • Check controller to junction box

• Light failure

• Light in Alarm
Mode

• Wired
incorrectly or
wire(s) lose

• Light failure

• No power to the
light

Box.

• Check controller to Beacon
cable connections at both ends.

• Check wiring.

• Confirm there is 0 voltage at
the Photocell input.

• Visually confirm Beacon is
flashing at ½ the intensity of
normal day mode.

malfunctioning lamp.

cable connections at both ends.

• Inspect cable for breaks.

• Physically check connections in
junction boxes and control box.

• If wiring functions properly, use
an alternate power source to
check the light.

• Replace light if necessary.

• Check wiring of light in top
junction box and Control Box.

• Measure voltage at junction
box. If correct input power,
replace light.

• If no voltage to the junction
box, check output power from
Control Box.

Latest products and information available at www.avlite.com 39

Problem Possible Cause Solution

L-810(F) middle light
is not operational
(others turning red
at night or photocell
covered)

L-810(F) middle lights
are not operational
(top light red flashing
at night or when
photocell covered)

L-810(F) middle lights
are not operational
(top light red flashing
during the day)

All lights are not
operational

Light not transitioning
between day-night or
night-day

• Wired
incorrectly or
wire(s) lose

• Light failure

• Wired
incorrectly or
wire(s) lose

• Light failure

• No power to the
light

• Wired
incorrectly or
wire(s) lose

• Photocell failure

• PLC failure

• No or wrong
input voltage

• Tripped breaker
or no output
voltage

• Wired
incorrectly or
lose wire(s)

• Wired
incorrectly or
wire(s) lose

• Photocell failure

• PLC failure

• Check wiring to light in middle
junction box

• Measure voltage at junction
box. If correct voltage replace
light.

• Check wiring of lights in Middle
junction box and Control Box.

• Measure voltage at junction
box. If correct input power,
replace light.

• If no voltage to the junction
box, check output power from
Control Box.

• Check wiring between
Photocell and PLC, check wiring
output of PLC.

• Cover photocell. Check if output
voltage of PLC changes. If no
change, replace Photocell.

• If Photocell operational, replace
PLC.

• Check input power to Control
Box.

• Check output voltage to both
top and middle lights in the
Control Box.

• Check wiring between Control
Box and top and middle
junction boxes.

• Check wiring between
Photocell and PLC, check wiring
output of PLC.

• Cover photocell. Check if output
voltage of PLC changes. If no
change, replace Photocell.

• If Photocell operational, replace
PLC.

40

Notes

AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

Latest products and information available at www.avlite.com 41

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AV-OL-KT-A1 - Obstruction Light Kit

Installation & Service Manual

Latest products and information available at www.avlite.com 43

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