Federal Signal Corporation 191XL Series, 191XL, 191XL-S Installation And Maintenance Manual

2561421G
REV. G 513
Printed in U.S.A.

Model 191XL Series Beacon

for Use in Hazardous Conditions

Installation and

Maintenance Manual

français...............page 21

español...............página 41

2

Warranty – Seller warrants all goods for ve years on parts and 2-1/2 years
on labor, under the following conditions and exceptions: Seller warrants that
all goods of Seller's manufacture will conform to any descriptions thereof for
specications which are expressly made a part of this sales contract and at the
time of sale by Seller such goods shall be commercially free from defects in
material or workmanship. Seller reserves the right at the Seller’s discretion
to “Repair and Return” or “Replace” any item deemed defective during the
warranty period. This warranty does not cover travel expenses, the cost of
specialized equipment for gaining access to the product, or labor charges for
removal and reinstallation of the product. This warranty shall be ineffective
and shall not apply to goods that have been subjected to misuse, neglect,
accident, damage, improper maintenance, or to goods altered or repaired by
anyone other than Seller or its authorized representative, or if ve years have
elapsed from the date of shipment of the goods by Seller with the following
exceptions: lamps and strobe tubes are not covered under this warranty.
Outdoor warning sirens and controllers manufactured by Federal Warning Sys­tems are warranteed for two years on parts and one year on labor. No agent,
employee, representative or distributor of Seller has any authority to bind the
Seller to any representation, afrmation, or warranty concerning the goods
and any such representation, afrmation or warranty shall not be deemed to
have become a part of the basics of the sales contract and shall be unenforce­able. THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU
OF ALL OTHER WARRANTIES OR MERCHANTABILITY, FITNESS
FOR PURPOSE AND OF ANY OTHER TYPE, WHETHER EXPRESS
OR IMPLIED. These warranties shall not apply unless Seller shall be given
reasonable opportunity to investigate all claims for allegedly defective goods.
Upon Seller's instruction a sample only of allegedly defective goods shall be
returned to Seller for its inspection and approval. The basis of all claims for al­leged defects in the goods not discoverable upon reasonable inspection thereof
pursuant to paragraph 8 hereof must be fully explained in writing and received
by Seller within thirty days after Buyer learns of the defect or such claim shall
be deemed waived.

Industrial Systems

2645 Federal Signal Drive • University Park, IL 60484-3167
Phone: [phone] • 1-708-534-4756 • Fax: [phone]
www.federalsignal-indust.com • www.fs-isys.com

Model 191XL LED Series Beacon

3

Contents

Safety Messages to Installers .......................................................... 5

An Overview of the 191XL Series ..................................................... 6

Unpacking the Beacon ...................................................................... 7

Pipe-Mounting the Beacon (191XL) ................................................. 8

Surface-Mounting the Beacon (191XL-S) ...................................... 10

Wiring the Beacon ........................................................................... 11

Wiring 120-240 Vac, 277 Vac Models .................................... 12

Wiring 24 Vac/dc Models

....................................................... 12

Safety Message to Maintenance Personnel .................................. 12

Changing from Flash Mode to Steady Mode ................................. 13

Cleaning the Fixture ........................................................................ 16

Lubricating the Threaded Joint ...................................................... 17

Ordering Replacement Parts .......................................................... 17

Getting Repair Service and Technical Assistance ...................... 18

Returning the Product for Credit ................................................... 18

Tables

Table 1 Electrical ratings .................................................................... 7

Table 2 Installation environment ratings .............................................7

Table 3 Ambient and operating temperature range ............................8

Table 4 Replacement parts ..............................................................17

4

Model 191XL Series LED Beacon

Contents

Figures

Figure 1 Pipe-mounted beacon .........................................................9

Figure 2 Surface-mounted beacon .................................................. 10

Figure 3 PCB removed from housing ..............................................15

Figure 4 Location of jumper J3 on PCB ...........................................16

5

Installation and Service Instructions

Model 191XL Series LED Beacon

Safety Messages to Installers

It is important to follow all instructions shipped with this product.
This device is to be installed by a trained electrician who is
thoroughly familiar with the National Electrical Code and/or
Canadian Electrical Code and will follow the NEC and/or CEC
Guidelines as well as all local codes. This beacon should be
considered a part of the warning system and not the entire warning
system.

The selection of the mounting location for the beacon, its controls
and the routing of the wiring are to be accomplished under the
direction of the facilities engineer and the safety engineer. In
addition, listed below are some other important safety instructions
and precautions you should follow:

• Read and understand all instructions before installing or
operating this beacon.

• Do not connect this beacon to the system when power is on.

• Do not disconnect the beacon while circuit is live or unless the
area is known to be free of ignitable concentrations. Keep the
beacon tightly closed when in operation.

• After installation, make sure that all set screws and threaded
joints are properly tightened.

• Never alter the unit in any manner. Safety in hazardous
locations may be endangered if additional openings or other
alterations are made in units specically designed for use in
these locations.

• To be an effective warning device, this product produces bright
beacon that can be hazardous to your eyesight when viewed at
a close range. Do not stare directly into this lighting product at
a close range or permanent damage to your eyesight may occur.

6

Installation and Service Instructions

Model 191XL Series LED Beacon

• After installation, test the beacon to make sure that it is
operating properly.

• Keep the unit tightly closed when in operation.

• After testing is complete; provide a copy of this instruction
booklet to all personnel.

• Establish a procedure to routinely check the beacon for proper
activation and operation.

Failure to follow all safety precautions and instructions may result
in property damage, serious injury, or death.

An Overview of the 191XL Series

This equipment is suitable for use in Class I, Division 2, Groups A,
B, C and D; Class II, Division 1, Groups E, F & G; Class III OR
non-hazardous locations only.

This strobe light can be mounted to a Federal Signal Model
LHWB bracket. If installed in this way, the entire assembled
device is suitable only for Class I, Div. 2, Groups A, B, C, and D;
Class II, Div. 2, Groups F and G; Class III locations.

The Model 191XL LED Beacon is a UL listed visual signal for
operation in harsh environments and hazardous locations and has
been investigated by UL as meeting Type 4X and IP66 enclosure
requirements. The unit is rated for operation on 100 Vac to
265 Vac, 50/60 Hz, 0.21 A; 277 Vac, 50/60 Hz, 0.13A; or 24 Vdc/
ac 50/60 Hz, 0.40 A. The 191XL can be supplied with colors
of red, amber, green, blue, and clear. The 191XL is factory-set
to operate 60 ashes/minute. There is an option to operate the
LED Beacon in Steady Mode. (See “Changing from Flash Mode
to Steady Mode” on page 13). Models are available for pipe
mounting (191XL) or surface mounting (191XL-S).

These devices are intended for permanent installation and
operation in accordance with Title 46, Code of Federal
Regulations, Parts 110–113, or Title 33, Code of Federal
Regulations, Part 183, Sub-part I, Section 183.410, and the

7

Installation and Service Instructions

Model 191XL Series LED Beacon

applicable requirements of the American Boat and Yacht Council,
Inc., and/or ANSI/NFPA 302, “Fire Protection Standard for
Pleasure and Commercial Motor Craft.”

Unpacking the Beacon

EXPLOSION HAZARD—Damaged domes can lead to explosions
that could result in serious injury or death.

After unpacking the beacon, examine it for damage that may
have occurred in transit. If the beacon has been damaged, do not
attempt to install or operate it. File a claim immediately with
the carrier, stating the extent of the damage. Carefully check all
envelopes, shipping labels, and tags before removing or discarding
them. Disposal of all shipping materials must be carried out in
accordance with national and local codes and standards. If any
parts are missing, please call Federal Signal Customer Support at
708-534-4756 or 877-289-3246.

Table 1 Electrical ratings

Operating Voltage: 24 Vdc/ac

100–265,
277 Vac

277 Vac

Flashes/Minute: 60 FPM 60 FPM 60 FPM
Maximum Operating

Current:

380 mA 210 mA 130 mA

Frequency: DC/50/60 50/60 50/60
DC In-Rush Current: 1.75 A at 24 Vdc for 5 ms

AC In-Rush Current:

2.0 A at 85 Vac and 1.5 A at 265 and
277 Vac for 0.25 ms

Table 2 Installation environment ratings

Ambient Storage Rating: –55 °C to +70 °C
Ambient Operating Rating: –50 °C to +66 °C
Type 4X (water-tight and corrosion resistant) and indoor/outdoor use
IP66 (dust-tight and protection against heavy seas) and outside type

(saltwater)

8

Installation and Service Instructions

Model 191XL Series LED Beacon

Table 3 Ambient and operating temperature range

Temperature Code or Maximum Temperature, °C

40 °C Ambient 55 °C Ambient 66 °C Ambient

Hazardous
Locations

24 V100–265

Vac

277
Vac

24 V100–265

Vac

277
Vac

24 V100–265

Vac

277
Vac

Class I,
Div 2,
Groups A,
B, C, and D

T6 T6 T5 T5 T5 T5 T4A T4A T5

Class II, Div
1, Groups
E, F, and G

T6 T6 T6 T6 T6 T6 T6 T6 T6

Class III T6 T6 T6 T6 T6 T6 T6 T6 T6

Pipe-Mounting the Beacon (191XL)

EXPLOSION HAZARD—To reduce the risk of re or explosion,

do not install the beacon in a hazardous location if the operating

temperature exceeds the hazardous atmosphere’s ignition
temperature. Before proceeding, consult the product nameplate

and determine the operating temperature of the beacon.

NOTE: To comply with NEC Section 300-14, which requires a
minimum of 6 inches (15.25 cm) of free conductor at a junction, when
mounting the Model 191XL, the mounting pipe used to join the unit to
a splice box should be no longer than 10 inches (25.4 cm).

The Model 191XL has provisions for mounting a 3/4" pipe and can
be mounted in any position.

1.

Before mounting the beacon, ensure that the mating threads

are clean.

2.

To prevent the ingress of water and dust, apply conductive

sealant to the conduit threads prior to mounting. If non­conductive sealant is used, the enclosure must be earthed
via the provided internal grounding wire/grounding screw to
ensure proper grounding continuity.

9

Installation and Service Instructions

Model 191XL Series LED Beacon

3. In high-humidity environments when units are mounted dome

down, condensation may occur in the conduit system. Use
properly rated conduit seals/drains to prevent moisture from
entering the xture.

IMPORTANT: To prevent the connection from loosening,

tighten the xture to a MINIMUM torque of 5 ft-lb (6.8 N·m)
after threading it onto the pipe.

4.

Thread the xture onto the 3/4" pipe and secure it with the set

screw.

Figure 1 Pipe-mounted beacon

191XL LIGHT
ASSEMBLY

3/4" NPT PIPE

290A6881

10

Installation and Service Instructions

Model 191XL Series LED Beacon

Surface-Mounting the Beacon (191XL-S)

To surface mount the beacon:

1.

Use the mounting base as a template to mark the location of

the two mounting holes.

2.

Drill a 9/32 inch (7.143 mm) hole at each mark.

3. Secure the beacon to the mounting surface with installer

supplied hardware.

Figure 2 Surface-mounted beacon

191XL-S LIGHT

ASSEMBLY

DRILL TWO 9/32"

(7.143 mm) HOLES

MOUNTING SURFACE

290A6880

INSTALLER-SUPPLIED

MOUNTING HARDWARE

11

Installation and Service Instructions

Model 191XL Series LED Beacon

Wiring the Beacon

SHOCK HAZARD—To avoid electrical shock hazards, do not

connect wires while power is applied.

EXPLOSION HAZARD
Do not disconnect the beacon while the circuit is live or unless
the area is known to be free of ignitable concentrations. Keep
the beacon tightly closed when in operation.

Wiring must comply with the National Electrical Code or Canadian
Electrical Code and the local authority having jurisdiction.

The Model 191XL Series LED Beacon should be installed per the
NEC or CEC, STATE and LOCAL CODES. Alternate installation
locations and/or orientations should only be performed with the
approval of the authority having jurisdiction. In addition, the unit
can be mounted using an optional ceiling mount or optional wall
mount.

SHOCK HAZARD—To avoid electrical shock hazards, do not

connect wires while power is applied.

NOTE: 191XL beacons that are 24 V models are designed to
operate on AC and DC supply voltages. The 120-240 Vac model is
designed to operate 100 Vac to 265 Vac at 50/60 Hz. See Table 1
on page 7 for electrical ratings.

REVERSE POLARITY/MISWIRING—The 191XL is not polarity

sensitive, but MAY BE DAMAGED by incorrect electrical hookup.

Damage will result if the voltage rating of the particular model is
exceeded.

12

Installation and Service Instructions

Model 191XL Series LED Beacon

NOTE: Field terminations made inside of the surface mount
enclosure will require the printed circuit board (PCB) assembly
to be removed from the housing. See Figure 3 on page 15 and
follow steps 1‒4 and 6‒8 of “Changing from Flash Mode to Steady
Mode” on page 13 for the PCB removal and installation process.

The surface mount enclosure is not suitable for feed-through
branch-circuit conductors.

Wiring 120-240 Vac, 277 Vac Models

The 120-240 Vac and 277 Vac models are supplied with three
24-inch leads: white, black, and green/yellow. Connect the
black lead to the phase (hot) side of the power source and the
white lead to the common (neutral) side of the power source. If
required, the green/yellow lead in the housing is provided for
connection to an earth ground.

Wiring 24 Vac/dc Models

The 24 Vac/dc models are supplied with two 24" leads, one red
and one black. Connect the red (+) lead to the positive or phase
(hot) side of the power source and the black (–) lead to the
negative or common (neutral) side of power source.

Safety Message to Maintenance Personnel

Listed below are some important safety instructions and
precautions you should follow:

• Read and understand all instructions before operating this system.

• Any maintenance to the light system must be done with power
turned off.

• Any maintenance to the light system must be performed
by a trained electrician who is thoroughly familiar with all
applicable national and local codes in the country of use.

• Do not connect this beacon to the system when power is on.

13

Installation and Service Instructions

Model 191XL Series LED Beacon

• Do not disconnect the beacon while circuit is live or unless the
area is known to be free of ignitable concentrations. Keep the
beacon tightly closed when in operation.

• Never alter the unit in any manner. Safety of the unit may be
affected if additional openings or other alterations are made to
the internal components or housing.

• The nameplate should NOT be obscured, as it contains
cautionary and/or other information of importance to
maintenance personnel. Ensure the nameplate remains readable
if the housing exterior is painted.

• If the dome is damaged in any way, it MUST be replaced.

• After performing any maintenance, test the light system to
ensure that it is operating properly.

Failure to follow all safety precautions and instructions may result
in property damage, serious injury, or death to you or others.

Changing from Flash Mode to Steady Mode

EXPLOSION HAZARD—To prevent ignition of hazardous

atmospheres, disconnect the xture from the supply circuit

before opening it.

EXPLOSION HAZARD—Do not disconnect the beacon while
circuit is live or unless the area is known to be free of ignitable
concentrations. Keep the beacon tightly closed when in
operation.

EXPLOSION HAZARD—To maintain the vapor-tight enclosure,

do not damage the dome or threads while disassembling or
reassembling the unit. Lubricated threaded joints exposed
for long periods of time may attract small particles of dirt or
other foreign materials. Housing and cover joints should be

reassembled immediately, with all the threads fully engaged.

14

Installation and Service Instructions

Model 191XL Series LED Beacon

To change from the default Steady Mode to Flashing Mode.

1. Disconnect power to the beacon.

2. See Figure 3 on page 15. Remove the threaded dome assembly

by twisting it counterclockwise.

3.

Using a No. 2 Phillips screwdriver, remove two #8-32 pan-

head screws holding the printed circuit board assembly to
the die-cast housing. Be sure to retain the two nylon screw
bushings isolating the bracket from the screws.

4.

Gently lift the printed circuit board (PCB) assembly from the

housing and turn the assembly over to access the component
side of the printed circuit board.

5.

See Figure 4 on page 16. Locate jumper J3 and lift the jumper

to remove it from “Flash” setting. Re-seat the jumper over the
pins labeled “Steady.”

6.

Place the printed circuit board assembly back into housing,

making sure that four insulating pads are seated between
the metal bracket and die-cast housing. The bracket must

be oriented so that the notch in the bracket is aligned with

the ground screw in the die-cast housing. This step must be
carefully followed to prevent arcing and dielectric failure.

7.

Slide two #8-32 pan-head screws into the screw bushings and

tighten screws to secure the printed circuit board assembly to
the die-cast housing.

8.

Thread the dome assembly back onto the housing by turning it

clockwise to tighten.

SHOCK HAZARD—To avoid electrical shock hazards, do not

connect wires while power is applied.

9. Reconnect the beacon to power.

15

Installation and Service Instructions

Model 191XL Series LED Beacon

10. Test the device by applying power and verifying the steady

operation of the LED lamp.

Figure 3 PCB removed from housing

DOME ASSEMBLY

LED EMITTER

NYLON SCREW BUSHING

#8-32 PAN-HEAD SCREW

PRINTED CIRCUIT
BOARD ASSEMBLY

INSULATING PADS

CAST HOUSING

290A7308

16

Installation and Service Instructions

Model 191XL Series LED Beacon

Figure 4 Location of jumper J3 on PCB

C1

R16 C16

D6

J1

CX1

C19

U3

L2

C14

R13

+

C15

R14

+

C17

R15

R12

F1

VR1

CR1

+

C13

+

J2

J3

L3

C8

Q1

R11

R10

C10

SPADE

CY1

R9

D1

HS2

U1

C18

+

R6

C12

C2

C7

D3

D4

+

OPTO

-

o

T1

R3

D7

D2

R5

2005416A

C9

D5

1

U2

C11

C4

+

HS1

R1

STEADY

FLASH

2005416A-01

J3 JUMPER LOCATION

(120-240 VAC MODEL SHOWN)

290A6286B

Cleaning the Fixture

EXPLOSION HAZARD—Never use an abrasive material or le to

remove corrosive materials from threaded surfaces. In extremely

corrosive locations, equipment should be periodically inspected
to guard against unusual deterioration and possible porosity,

since this may weaken the enclosure structurally.

Maintenance procedures sometimes require xtures to be hosed
down for good housekeeping. The circuit should be turned off
prior to hosing down the xture.

The xture should be cleaned periodically to maintain maximum
light output. Only mild, non-abrasive cleaning agents should be
used. The glass dome should be regularly inspected for scratches
and chips, and if damaged, MUST be replaced.

17

Installation and Service Instructions

Model 191XL Series LED Beacon

Lubricating the Threaded Joint

The threaded joint on the cover should be kept well lubricated
with a corrosion inhibiting grease such a petrolatum or soap­thickened mineral oil. If corrosive materials have accumulated on
the threaded joints and cannot be removed with solvents, the parts
should be discarded and replaced.

Ordering Replacement Parts

EXPLOSION HAZARD—Substitution of components may impair

suitability for Class I, Division 2.

Typical spare parts are listed Table 4. Due to certication, certain
component parts are not available for eld replacement. Units with
this type of damage must be either replaced entirely or returned to
Federal Signal for service. To order replacement parts, please call
Federal Signal Customer Support at 708-534-4756 or 877-289-

3246.

Table 4 Replacement parts

Description Part Number

Dome Assy., Amber K8449078-01
Dome Assy., Blue K8449078-06
Dome Assy., Clear K8449078-04
Dome Assy., Green K8449078-07
Dome Assy., Red K8449078
Gasket K8449080
Grease, 8 oz Tube KR81-05-01
Dome Guard K8449090
LED Emitter, Amber K14700030-A
LED Emitter, Blue K14700030-B
LED Emitter, Green K14700030-G
LED Emitter, Red K14700030-R
LED Emitter, White K14700030-W

18

Installation and Service Instructions

Model 191XL Series LED Beacon

Getting Repair Service and Technical Assistance

Products returned for repair require a Return Authorization form.
To obtain repair service or technical assistance for the product, call
Federal Signal at 708-534-4756 or 877-289-3246. For instruction
manuals and information on related products, visit:
http://www.federalsignal-indust.com

Returning the Product for Credit

Product returns for credit require a return authorization from your
local distributor prior to returning the product to Federal Signal.
Please contact your distributor for assistance.

A product is qualied to be returned for credit when the following
conditions are met:

• Product is resalable and in the original cartons

• Product has not been previously installed

• Product is the current revision

• Product has not been previously repaired

• Product is a standard product

• Product is not a service part

All returns are subject to a re-stock fee.

Defective products that are returned within the warranty period
will be repaired or replaced at Federal Signal’s sole discretion.
Defective products do not include those products with lamp
failure.

Circumstances other than those listed above will be addressed on a
case-by-case basis.

19

© 2013 Federal Signal Corporation. All rights reserved.

20

Federal Signal Corporation
Industrial Products

2645 Federal Signal Drive

University Park, IL 60484-3167
Phone: [phone] • [phone] • Fax: [phone]
www.federalsignal-indust.com • www.fs-isys.com