Honeywell 40002083 User Manual
Airport Systems
Installation and Operation Guide
Programmable Logic Controller
Manual Number EPM40002083-001
for
Health Monitoring System
Model 40002083
Honeywell Airport Systems
550 State Route
Urbana, OH 43078
Phone (937) 484-2000
Fax (937) 484-2101
www.oblighting.com
Copyright 2007 Honeywell International
All Rights Reserved
Airport Systems
HISTORY OF REVISIONS
Rev. Comment ECO# Approved Date
1 Preliminary
The integrity and reliability of Honeywell airport lighting systems are dependent on the use of Honeywell parts and components. To ensure
the optimum performance and reliability of your Honeywell system, it is strongly advised that only components and modules provided by
Honeywell be used.
The following is Honeywell’s standard Limited Warranty for Airport Systems Products (“Products”). This warranty applies unless a
different warranty has been specifically agreed to and signed by Honeywell’s authorized representative.
1.1 LIMITED WARRANTY
(a) “Nonconformance” means a defect in workmanship or material; a failure to comply with applicable Honeywell drawings; or a
failure to comply with applicable FAA specifications. Normal wear and tear (including but not limited to incandescent lamp failure) or
the need for periodic maintenance shall not constitute a Nonconformance.
(b) Honeywell warrants that at time of delivery to Buyer, its Products will comply with applicable Honeywell drawings and FAA
specifications and will be free from defects in workmanship and material. These warranties shall run to Buyer, its successors and
NOTICE
assigns. The duration of these warranties shall be as follows:
(c) Buyer must notify Honeywell in writing of a Nonconformance within the warranty period and return the Product to Honeywell
within thirty (30) calendar days after such notice, in accordance with instructions which shall be issued by Honeywell. Honeywell's
obligation and Buyer's remedy under this warranty is limited to either repair or replacement, at Honeywell’s option, of the
nonconforming Product. All Products repaired or replaced hereunder shall be warranted only for the unexpired portion of the original
warranty period. Honeywell agrees to assume round trip transportation costs for a nonconforming Product in an amount not to
exceed normal ground shipping charges to the warranty service facility designated by Honeywell. The risk of loss or damage to all
Products in transit shall be borne by the Party initiating the transportation of such Products.
(d) Honeywell shall not be liable under this warranty if the Product has been exposed or subjected to (1) any maintenance, repair,
installation, handling, transportation, storage, operation or use which is improper or otherwise is not in compliance with Honeywell's
instructions; or (2) any alteration, modification or repair by anyone other than Honeywell or those specifically authorized in writing by
Honeywell; or (3) any accident, contamination, foreign object damage, abuse, neglect or negligence after delivery to Buyer; or (4)
any damage precipitated by failure of a Honeywell supplied Product not under warranty or by any product not supplied by Honeywell.
(e) THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN OR ORAL, EXPRESS,
IMPLIED OR STATUTORY, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTIES OF MERCHANTABILITY,
FITNESS FOR PARTICULAR PURPOSE, OR NON-INFRINGEMENT, ALL OF WHICH ARE HEREBY EXPRESSLY DISCLAIMED.
NO EXTENSION OR EXPANSION OF THIS WARRANTY SHALL BE BINDING UPON HONEYWELL UNLESS SET FORTH IN
WRITING AND SIGNED BY HONEYWELL’S AUTHORIZED REPRESENTATIVE.
(f) IN NO EVENT SHALL HONEYWELL BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES
UNDER THIS WARRANTY EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGES INCLUDING, WITHOUT LIMITATION,
INTERRUPTION OF BUSINESS, LOSS OF PROFITS, OR LOSS OF USE. THE EXCLUSION OF INCIDENTAL AND
CONSEQUENTIAL DAMAGES AS SET FORTH IN THIS WARRANTY SHALL BE DEEMED INDEPENDENT OF, AND SHALL
SURVIVE, ANY FAILURE OF THE ESSENTIAL PURPOSE OF ANY LIMITED REMEDY UNDER THE TERMS OF THIS
WARRANTY
(1) for non-LED-based obstruction lights, twenty-four (24) months after shipment of the Product;
(2) for non-LED-based airfield lights and for Control and Monitoring Systems (excluding software and third-party
components), twenty-four (24) months after shipment of the Product or twelve (12) months after date of first use,
whichever occurs first;
(3) for LED-based airfield and obstruction lights, five (5) years after shipment of the Product;
(4) for Control and Monitoring System software developed by Honeywell, ninety (90) days from date of first use; and
(5) for third party hardware and software components of Control and Monitoring Systems, in accordance with the warranty
from the third party.
PLC Health Monitoring & Reporting Sys i Manual EPM40002083-001 Rev -
Airport Systems
DISCLAIMERS
This manual could contain technical inaccuracies or typographical errors. Honeywell
reserves the right to revise this manual from time to time of the contents thereof without
obligation of Honeywell to notify any person of such revision or change. Details and
values given in this manual are average values and have been compiled with care. They
are not binding, however, and Honeywell disclaims any liability for damages or
detriments suffered as a result of reliance on the information given herein or the use of
product, processes or equipment to which this manual refers. No warranty is made that
the use of the information or of the products processes or equipment to which this
manual refers will not infringe any third party’s patents or rights. The information given
does not release the buyers from making their own experiments and tests.
PLC Health Monitoring & Reporting Sys ii Manual EPM40002083-001 Rev -
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TABLE OF CONTENTS
1.1 LIMITED WARRANTY ..................................................................................................................I
SAFETY INFORMATION................................................................................................V
SECTION 2. GENERAL INFORMATION..................................................................... 2-1
2.1 SCOPE .......................................................................................................................................2-1
2.2 GENERAL DESCRIPTION...............................................................................................................2-1
2.2.1 PLCHMR System Module......................................................................................................2-1
2.2.2 Model SGC-60 Master Controller replacement Micro-Controller Unit....................................2-1
2.2.3 Model SGF-60-E Flash-head replacement Micro-Controller Unit ..........................................2-2
SAFETY PRECAUTIONS .............................................................................................................................2-6
2.3 SPECIFICATIONS .........................................................................................................................2-9
SECTION 3. INSTALLATION & POWER UP .............................................................. 3-1
3.1 UNPACKING ................................................................................................................................3-1
3.2 USER SUPPLIED TOOLS ...............................................................................................................3-1
3.2.1 Master Controls Switch Setting For Installation ...................................................................3-1
3.2.2 Power Configuration.............................................................................................................3-2
3.3 INSTALLATION .............................................................................................................................3-2
3.3.1 Installation Overview ............................................................................................................3-2
3.3.2 SGC-60 Master Controller MCU Upgrade ...........................................................................3-2
3.3.3 PLCHMR Module Installation ...............................................................................................3-5
3.3.4 SGF-60-E Flash-head Digital Controller MCU Upgrade ......................................................3-8
3.4 FLASH HEAD STATUS REPORTING RELAY INSTALLATION WIRING .................................................3-11
3.5 FINAL INSTALLATION CHECK ......................................................................................................3-13
3.5.1 Preliminary..........................................................................................................................3-13
3.5.2 Verify Correct Wiring from the PLCHMR Module to Master Controller..............................3-13
3.6 POWER UP AND SYSTEM TESTS.................................................................................................3-13
3.6.1 PLCHMR Status Indicators ................................................................................................3-13
3.6.2 System Power Up...............................................................................................................3-13
3.7 PLCHMR SYSTEM MAINTENANCE AND CONFIGURATION MENUS ...................................................3-16
3.7.1 PLCHMR System Maintenance & Configuration Menus Overview ...................................3-16
3.7.2 HMS Maintenance Menu Login..........................................................................................3-18
3.7.3 HMS Light Configuration Menu ..........................................................................................3-19
3.7.4 PLCHMR Report Configuration Menu................................................................................3-21
3.7.5 PLCHMR Facility Configuration Menu ...............................................................................3-22
3.7.6 Verify Local Mode Operation..............................................................................................3-23
SECTION 4. PRINCIPLES OF OPERATION............................................................... 4-1
4.1 OVERALL DESCRIPTION ...............................................................................................................4-1
SECTION 5. MAINTENANCE...................................................................................... 5-1
5.1 PLCHMR MODULE .....................................................................................................................5-1
SECTION 6. REPLACEMENT PARTS ........................................................................ 6-1
SECTION 7. APPENDIX A – EXAMPLES...................................................................7-1
7.1 LIGHT CONFIGURATION EXAMPLES...............................................................................................7-1
PLC Health Monitoring & Reporting Sys iii Manual EPM40002083-001 Rev -
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TABLE OF FIGURES
Figure 2.2-1 PLCHMR Module .....................................................................................2-3
Figure 2.2-2 Master Controller with PLCHMR Module Installed ...................................2-4
Figure 2.2-3: Model SGF-60E Flash Head ................................................................... 2-5
Figure 3.3-1 Model SGC-60 Master Controller with MCU High-lighted .......................3-4
Figure 3.3-2 PLCHMR Module Mounted on and Wired to Master Controller................ 3-6
Figure 3.3-3 Terminal Block- 8 +16V - Red and GND –Black Wire Connections ......... 3-7
Figure 3.3-4 StrobeGuard Control & Status Network Wiring Connections ...................3-8
Figure 3.3-5 MCU Location on Flash Head Digital Logic Controler ............................ 3-10
Figure 3.4-1 PLCHMR's Output Relay connection Diagram.......................................3-12
Figure 3.6-1 Master Controller Circuit Board..............................................................3-15
Figure 3.7-1 PC to PLCHMR RS-232 Serial Port Interface Cable Connections .........3-17
Figure 3.7-2 HMS Maintenance Menu Hierarchy ....................................................... 3-18
Figure 3.7-3 HMS Maintenance Menu........................................................................3-19
Figure 3.7-4 HMS Light Configuration Menu .............................................................. 3-20
Figure 3.7-5 HMS Modify Light Menu.........................................................................3-21
Figure 3.7-6 HMS Report Confguration Menu............................................................ 3-22
Figure 3.7-7 HMS Facility Conguration Menu ............................................................3-22
Figure 7.1-1 Tower Example with 9 Flash Heads on Three Physical Tiers .................. 7-2
Figure 7.1-2 Light Configuration Menus Settings for 9 Lights and 7 Relay Outputs ..... 7-3
Figure 7.1-3 System Configuration with 9 Flash Heads using 7 relays ........................7-4
Figure 7.1-4 Light Configuration Menus Settings for 24 Light and 8 Relay Outputs.....7-5
Figure 7.1-5 System Configuration with 24 Flash Heads using 8 relays ......................7-6
PLC Health Monitoring & Reporting Sys iv Manual EPM40002083-001 Rev -
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SAFETY INFORMATION
This section contains general safety instructions for using your Honeywell equipment. Task
and equipment-specific Warnings are included in other sections of this manual where
appropriate. Read all Warnings and follow all instructions carefully. Failure to do so may
result in personal injury, death, or property damage. To use this equipment safely, refer to
the following:
1. Refer to the FAA Advisory Circular AC 150/5340-26, Maintenance of Airport Visual
Aids Facilities, for instructions on safety precautions.
2. Observe all safety regulations. To avoid injuries, always remove power prior to
making any wire connections and/or touching any parts. Refer to FAA Advisory
Circular AC 150/5340-26.
3. Read and become familiar with the general safety instructions provided in this section
of the manual before installing, operating, maintaining, or repairing this equipment.
4. Read and carefully follow the instructions given throughout this manual before
performing specific tasks and working with specific equipment.
5. Store this manual within easy reach of personnel installing, operating, maintaining, or
repairing this equipment.
6. Follow all applicable safety procedures required by your company, industry standards,
and government or other regulatory agencies.
7. Obtain and read Material Safety Data Sheets (MSDS) for all materials used.
SAFETY AND WORKMANSHIP ALERTS
This manual uses two types of markings when giving instructions requiring special
attention. The markings will be followed by indented text:
WARNING!
The WARNING sign in this manual denotes a hazard. The WARNING
calls attention to a procedure or practice which, if not correctly
performed or adhered to, could result in property damage, injury or
death. Do not proceed beyond a WARNING sign until the indicated
conditions are fully understood and met.
.
CAUTION
Failure to obey the instructions following a CAUTION marking may
result in equipment damage.
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QUALIFIED PERSONNEL
The term “qualified personnel” is defined here as individuals who thoroughly understand
the equipment and its safe operation, maintenance, and repair. Qualified personnel are
physically capable of performing the required tasks, familiar with all relevant safety rules
and regulations and have been trained to safely install, operate, maintain, and repair the
equipment. It is the responsibility of the company operating this equipment to see that
its personnel meet these requirements.
INTERLOCKS
This equipment contains interlocks for your protection. To ensure safety, always
remove power from the equipment prior to opening access panels or doors if possible.
Do not depend on the interlocks or door switches when working with the equipment. Do
not short-circuit or tamper with any access gate, door or other safety interlock switch.
Discharge capacitors with an approved insulated grounding rod prior to touching any
part. When it is absolutely mandatory that an interlock be bypassed for the purpose of
tracing or correcting a malfunction, authorized maintenance personnel may perform the
bypass for the specific test to be made. Immediately after completing the test, restore
the interlock to working condition.
WARNING!
INTENDED USE
HONEYWELL IS NOT RESPONSIBLE FOR INJURIES OR DAMAGES
RESULTING FROM NONSTANDARD, UNINTENDED APPLICATIONS OF
ITS EQUIPMENT. THIS EQUIPMENT IS DESIGNED AND INTENDED
ONLY FOR THE PURPOSE DESCRIBED IN THIS MANUAL. USES NOT
DESCRIBED IN THIS MANUAL ARE CONSIDERED UNINTENDED USES
AND MAY RESULT IN SERIOUS PERSONAL INJURY, DEATH OR
PROPERTY DAMAGE. UNINTENDED USES MAY RESULT FROM
TAKING ANY OF THE ACTIONS LISTED BELOW.
1. Making changes to the equipment that have not been recommended
or described in this manual, or using parts that are not genuine
Honeywell replacement parts.
2. Failing to make sure that auxiliary equipment complies with
approval agency requirements, local codes, and all applicable
safety standards.
3. Using materials or auxiliary equipment that are inappropriate or
incompatible with your Honeywell equipment.
4. Allowing unqualified personnel to perform any task.
PLC Health Monitoring & Reporting Sys vi Manual EPM40002083-001 Rev -
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KEEP AWAY FROM LIVE CIRCUITS. OPERATION AND MAINTENANCE
PERSONNEL MUST OBSERVE ALL SAFETY REGULATIONS AT ALL
TIMES. DO NOT CHANGE PLUG-IN COMPONENTS OR MAKE
ADJUSTMENTS INSIDE EQUIPMENT WITH THE HIGH VOLTAGE
SUPPLY ON. UNDER CERTAIN CONDITIONS, THERE IS A POTENTIAL
FOR SERIOUS INJURY FROM CIRCUITS WITH POWER CONTROLS IN
THE OFF POSITION. THIS IS DUE TO CHARGES RETAINED BY THE
CAPACITORS. TO AVOID SERIOUS INJURY, ALWAYS DISCONNECT
POWER, THEN DISCHARGE CAPACITORS BY USING AN APPROVED
GROUNDING ROD PRIOR TO TOUCHING ANY PART.
RESUSCITATION. MAINTENANCE PERSONNEL SHOULD BE TRAINED
IN CARDIOPULMONARY RESUSCITATION (CPR).
WARNING!
CAUTION
This equipment contains static sensitive semiconductor devices and
integrated circuits that may be damaged by Electro-Static Discharge
(ESD). Take the necessary precautions before attempting service.
Any replacement circuit boards should be kept in metallized anti-static
bags until immediately before installation. Ground yourself (touch the
outside of a grounded metal enclosure) before removing circuit boards
from their protective bags. Avoid touching components when handling
the boards.
PLC Health Monitoring & Reporting Sys vii Manual EPM40002083-001 Rev -
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SECTION 2. GENERAL INFORMATION
2.1 Scope
This manual provides information about the installation, operation, and maintenance of
the Programmable Logic Controller Health Monitoring and Reporting (PLCHMR) System
manufactured by Honeywell.
2.2 General Description
The PLCHMR system is a retrofitable health monitoring and reporting system for
Honeywell’s high intensity flashing white obstruction lighting system. A majority of the
system’s functionality is contributed by the PLCHMR module. It is designed for use with
the StrobeGuard, Model SG-60E High Intensity Obstruction Lighting System. The
system is designed and manufactured in compliance with Federal Aviation
Administration Advisory Circular 150/5345-43E. The PLCHMR system will monitor and
report on up to 24 flash-heads controlled by a single controller at distances up to 2500
feet.
The PLCHMR System module is shown in Figure 2.2-1. The major components of the
retrofit kit consist of the following:
• PLCHMR System Module P/N 40002083-001
• Model SGC-60 Master Controller replacement Micro-Controller Unit (MCU P/N
40002085-001)
• Model SGF-60 Flash-head replacement micro-controller units (one for every flash
head P/N 40002084-001)
2.2.1 PLCHMR System Module
The PLCHMR module (see Figure 2.2-1) is a configurable microprocessor-based
system that monitors a StrobeGuard, Model SG-60E High Intensity Obstruction
Lighting system via the RS485 control and status network. The PLCHMR outputs alarm
status via dry contact relays to a remote alarm monitoring system. The PLCHMR
module is preassembled and consists of three circuit card assemblies affixed to
mounting plate. The module provides 2 wiring harnesses that must be attached to two
terminal connectors located on the Model SGC-60 Master Controller (See Figure 2.2-2).
2.2.2 Model SGC-60 Master Controller replacement Micro-Controller Unit
The Master Controller (see Figure 3.3-1) is a micro-controller based system that
controls the flash interval and timing, flash intensity, and monitors the complete
StrobeGuard system via the StrobeGuard RS485 control and status network
(SCSN). The MCU must be replaced during the installation process in order for the
PLCHMR to monitor the SCSN. Software in the new micro controller changes the baud
rate of the SCSN from 300 to 9600 baud. A replacement MCU is provided as part of the
upgrade kit (P/N 40002085-001 and replaces P/N40000328-001).
PLC Health Monitoring & Reporting Sys 2-1 Manual EPM40002083-001 Rev -
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2.2.3 Model SGF-60-E Flash-head replacement Micro-Controller Unit
The SGF-60E Flash-head (see Figure 2.2-3) is a micro-controller based system that is
designed to control a capacitor discharge xenon flash tube unit. The Flash-head
receives its flash interval, timing, flash intensity commands from, and returns status to
the Master Controller via the SCSM. Replacement MCUs are provided as part of the
upgrade kit (P/N 40002084-001 and replaces old MCU P/N40000324-001).
PLC Health Monitoring & Reporting Sys 2-2 Manual EPM40002083-001 Rev -
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Power On LED
PLCHMR
Configuration
Serial Port
Power Supply
Single Board
Top view Side view
Mounting Plate
Computer
Relay Interface
Card
StrobeGuard
Control and
Status Network
wiring.
Figure 2.2-1 PLCHMR Module
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Figure 2.2-2 Master Controller with PLCHMR Module Installed
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NO
NO
NC
C
NC
C
NO
+
AC
NC
C
AC
-
Figure 2.2-3: Model SGF-60E Flash Head
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Safety Precautions
The following general safety precautions must be observed during all phases of operation,
service, and repair of this equipment. Failure to comply with these precautions or with
specific warnings elsewhere in this manual violates safety standards of design,
manufacture, and intended use of this equipment. Honeywell assumes no liability for the
customer’s failure to comply with these requirements, as listed below.
1. Any interruption of the protective grounding conductor (inside or
outside the instrument) or disconnecting the protective earth ground
terminal is likely to make this equipment dangerous. Intentional
interruption is prohibited.
2. Whenever it is likely that the ground protection has been impaired, the
equipment must be made inoperative by removing AC line power, and
then shall be secured against any unintended operation.
3. Ensure that only fuse / Breakers with the required rated current and of
the specified type (normal blow, time delay, etc.) are used for
replacement. The use of repaired fuses and the short-circuiting of fuse
holders must be avoided.
4. Electrical energy available at many points may result in personal injury
or death if touched. Any adjustment, maintenance, and repair of the
opened equipment while power is applied shall be avoided as much as
possible, however some maintenance described in this manual is
performed with power supplied to the equipment while protective
covers are removed. When repair with power applied is unavoidable,
only a skilled person who is aware of the hazard involved shall carry
out maintenance. Do not attempt internal service or adjustment unless
another person, capable of rendering first aid and resuscitation, is
present.
5. Do not install, substitute parts or perform any unauthorized
modification to the equipment.
6. Make sure the input voltage selection on the Ferroresonant
transformer assembly matches the line voltage before applying power
to the unit.
Capacitors inside the equipment may still be charged after the equipment has
been disconnected from its power source, even though the equipment was
designed to drain charge from the capacitors when power is removed. Do not put
hands or tools in the Flash-head if the High Voltage Indicator neon lamp NE1 is
ON, which is located on the High Voltage Circuit Board. (Refer to Figure 2.2-3)
7. Do not confuse the High Voltage Indicator NE1, with the POWER ON
Indicator located on the Ferro resonant Transformer Assembly. It is
possible for the High Voltage Indicator NE1 to be ON After the main
AC power to the unit is turned OFF (POWER ON Indicator is OFF). If
this happens, the energy stored in the capacitor Assembly must be
discharged before performing maintenance.
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8. Capacitor Discharge Procedure. Attach one end of the capacitor
discharge tool to chassis ground first, then the other end to any of the
relay terminals. Hold for 3 seconds, or until the indicator turns off.
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This system uses lethal voltages in the Flash-head. Unless absolutely
necessary, do not attempt to service or adjust the equipment with AC
line power applied.
Safety interlock switches are provided in the Flash-head enclosure to
interrupt main AC power to the power supply. These interlock switches
are activated when the Flash-head door is opened in a conventional
manner. No interlock is provided when other means of access are
used. Do not tamper with the interlocks by opening or shorting the
terminals.
The POWER ON Indicator is ON when the Ferroresonant Transformer is
powered. If the POWER ON Indicator is OFF, Line input AC power may
still be present in the system.
WARNING!
AC LINE VOLTAGE IS STILL PRESENT WHEN INTERLOCKS ARE
ACTIVATED. DISCONNECT POWER AT THE MAIN AC CIRCUIT
BREAKERS BEFORE INSPECTING OR SERVICING, UNLESS
ABSOLUTELY NECESSARY TO PERFORM MAINTENANCE WITH
POWER ON.
WARNING!
Flash tubes in this lighting system produce brilliant flashes of light
containing some ultraviolet radiation that can cause temporary or
permanent eye damage.
DO NOT LOOK DIRECTLY AT THE FLASH-HEAD WHILE IT IS IN
OPERATION.
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