Dialight D1RW-LPK08 User Manual

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

_____________________________________________________________________

INSTALLATION MANUAL

FOR

Lightning Protection Kit (D1RW-LPK08)

In

OEM Dual Red Beacon/White Strobe

D1RW-C13-008

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 1 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

_____________________________________________________________________

Contents Page

Section 1: Overview------------------------------------------------------------------------------3
Section 2: System Block Diagram-----------------------------------------------------------3
Section 3: Instructions --------------------------------------------------------------------------4

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 2 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

_____________________________________________________________________

Section 1: Overview

The Lightning Protection Kit (D1RW-LPK08) has been designed to further protect
the Flash Head and Power Supply from transients and surges caused by direct
and indirect lightning strikes. The Lightning Protection Kit consists of a
lightning/surge protection board, means for properly grounding the cables and
Lightning Protection Kit. The Lightning Protection Kit will be installed in series
with the flash head cable, between the power supply and flash head. It must be
installed within 2 feet of the power supply for maximum protection against
transients.

WARNING: All ground bonds must be made properly and securely for the
Lightning Protection Kit to be effective.

This manual will give step by step instructions on the proper installation and
testing of the Lightning Protection Kit.

Section 2: System Block Diagram

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 3 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

_____________________________________________________________________

Section 3: Instructions

Step 1. Shut down the system and wait 1 min. for the capacitors to discharge.
Step 2. Locate and remove the lid of the Lightning Protection Kit using a screw

driver.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

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Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

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Step 3. Keeping in mind that this Lightning Protection Kit should be close to the
power supply so the grounding wire can reach the power supply box or chassis,
cut the multi-way conductor wire that goes from the Flash Head to the power
supply as shown below.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 5 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

_____________________________________________________________________

Step 4. Measure roughly 8 inches of the cable. Start with the tower side.

Step 5. Using a knife/ razor, carefully cut the protective cover of the wire,
ensuring not to damage the wires and insulating foil inside.

DO NOT CUT OFF ANY WIRE, BARE WIRE and/or FOIL.

Step 6. Separate the Drain Wire (Bare wire) from the rest of the bundle. And
carefully unravel the shielding foil from the bundle of wires.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 6 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

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Step 7. If yellow fiber material is present, expose the yellow fiber material and
remove by cutting. Be careful not to damage the wires or shielding foil.

Step 8. Measure roughly 1½ - 2 inches of the foil from the protective wire cover
and cut the foil as shown below. Ensure that the foil shield is wrapped around the
cable and the silver foil side is facing out.

Step 9. Strip each ends of each the wires, as shown below.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 7 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

_____________________________________________________________________

Step 10. Insert the wires and cable through the cable gland nut as shown below.
Do not tighten the Gland nuts yet.

Step 11. Connect the Wires to J2 “To Tower” of the Lightning Protection Board
following the label “To Flash Head” for the colors as shown below. Using a small
screwdriver to press in the tabs of each terminal will help ease the process of
connecting the wires.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 8 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

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Step 12. Repeat steps 4 – 9, this time using the cable on the Power supply side.
Step 13. Insert the wires and cable through the cable gland nut as shown below.

Do not tighten the Gland nuts yet.

Step 14. Connect the Wires to J1 “From Power Supply” of the Lightning
Protection Board following the label “From Power Supply” for the colors as shown
below. Using a small screwdriver to press in the tabs of each terminal will help
ease the process of connecting the wires.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 9 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

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Step 15. Ensure that the wire colors on both sides of the board match, as shown
below.

Step 16. Remove the wing nut and clamping washer as shown below.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 10 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

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Step 17. Adjust the two cables so the foil on both cables are next to the stud.

Step 18. Place clamping washer and tighten wing nut as shown below.

Step 19. Tighten the cable gland nuts for the incoming cables into the box to
roughly 20 in/lbs. A correct tight seal will prevent moisture from entering the box.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 11 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

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Step 20. Tie the two drain (Bare) wires to the grounding stud as shown below.
Cut off excess wire to prevent accidental short circuits.

Step 21. If Grey and White wires are present, strip wires as shown below. Group
all Grey and White wires together and secure them to the grounding stud
between the two washers as shown below.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 12 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

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Step 22. Tuck in the wires neatly so the lid does not close on top of the wires as
shown below. Take care not to break any of the components or wires.

Step 23. Final assembly should look like below. Place lid and ensure no wires
are caught underneath and tighten screws to 20 in/lbs. A correct, tight seal will
prevent moisture from entering the box.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 13 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

_____________________________________________________________________

Step 24. Ground the Ground wire of the Lightning Protection Kit to the chassis of
the power supply. Note that there are multiple options and below is just a few
possible locations to ground the ground cable to.

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

Page 14 of 15

Document No.

9100-127-1560-99 Rev B

Release Date: 10/10/2011

_____________________________________________________________________

REVISION HISTORY

REV ECO No. DRN CKD APP QA CM DATE

A 4717 JC SA AR RL JB 09/22/11
B 4869 JC SA AR RL JB 10/10/11

Dialight Corporation 1501 Route 34 South Farmingdale NJ 07727

Tel: [phone] Fax: [phone] Web: www.dialight.com

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