Airport Systems Installation and Operation Guide for Programmable Logic Controller Health Monitoring System Model 40002083 Manual Number EPM40002083-001 Honeywell Airport Systems 550 State Route Urbana, OH 43078 Phone (937) 484-2000 Fax (937) 484-2101 www.oblighting.
Airport Systems HISTORY OF REVISIONS Rev. 1 Comment Preliminary ECO# Approved Date NOTICE 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”).
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.
Airport Systems TABLE OF CONTENTS 1.1 LIMITED WARRANTY .................................................................................................................. I SAFETY INFORMATION................................................................................................V SECTION 2. GENERAL INFORMATION..................................................................... 2-1 2.1 SCOPE ............................................................................................................
Airport Systems 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.
Airport Systems 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.
Airport Systems 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.
Airport Systems WARNING! 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.
Airport Systems 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.
Airport Systems 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).
Airport Systems PLCHMR Configuration Serial Port Power On LED Power Supply Single Board Computer Top view Side view Relay Interface Card Mounting Plate StrobeGuard Control and Status Network wiring. Figure 2.
Airport Systems Figure 2.
Airport Systems NO NC NC C NO C NC + AC AC - NO C Figure 2.
Airport Systems 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.
Airport Systems 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.
Airport Systems WARNING! 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.
Airport Systems 2.3 Specifications Electrical Input: PLCHMR Module .................................................................................... 3 Watts. 5 VDC. Mechanical Properties: PLCHMR Module Weight.............................................................................................2 pounds (4.4 kg) Dimensions ......................................5.6"w (142mm) x 5.7"h (145mm) x 2"d (51mm) Operating Environment: Operating Temperature ...................................................
Airport Systems SECTION 3. INSTALLATION & POWER UP WARNING! Modifications to the Power Supply are required for certain applications. Remove input power at circuit breakers and discharge capacitors with an approved grounding rod before attempting any necessary modifications. 3.1 Unpacking Carefully unpack each item and remove any internal packing material from the PLCHMR. Carefully check the supplied materials with the PLCHMR bill of materials.
Airport Systems • POWER SWITCH: Toggle switch that turns input AC line power on/off in the Master Controller. Does not affect AC power to the Flash-heads. Input voltage is present at terminal block PB1, even with the power switch turned off. • RESET Switch: Momentary pushbutton that resets the Master Controller. Switch must be held for about one second to activate.
Airport Systems MCU’s socket has a notch along the outside edge on one of the short sides this is the top side of the socket. CAUTION! Do not use excessive force when you remove or install the chip from/into its socket. Excessive force can bend or damage the MCU Pins or the socket. Step 1 Gently remove the old MCU using a small flat head screwdriver to pry it free of its socket. Set aside the old MCU.
Airport Systems 40000328-001 Replace existing MCU PN40000328 with new MCU PN40002085 Location of 4 Screws to be removed for the PLCHMR Module Standoffs Figure 3.
Airport Systems 3.3.3 PLCHMR Module Installation The installation kit provides a PLCHMR module P/N 40002083 that is mounted inside the Master Controller Enclosure. This module is mounted to four 2.5” high standoffs and has five (5) wires to connect to the Master Controller board. 3.3.3.1 PLCHMR Module 2.5” Standoff Installation Remove and save the four (4) 6-32 screws that secure the Master Controller to the enclosure’s bottom panel (Refer to Figure 3.3-1 for exact screw locations).
Airport Systems TB8 Output Relay Terminal Blocks PLCHMR Module Red Black TB-5 Figure 3.
Airport Systems Black Wire Red Wire Figure 3.3-3 Terminal Block- 8 +16V - Red and GND –Black Wire Connections 3.3.3.3 PLCHMR Module Mount The PLCHMR module mounts to the four 2.5” high standoffs that were installed per directions in Section 3.3.3.1. Note the location and orientation of the PLCHMR module as shown in Figure 3.3-2 relative to the Master Controller. Oriented the PLCHMR module and place it approximately as shown per Figure 3.3-2 on the 2.5” high standoffs.
Airport Systems b) Next, loosen the plug-in terminal’s screw labeled #2 as shown in Figure 3.3-4 sufficiently to insert the PLCHMR module’s Blue wire into this terminal position along with maintaining any existing wiring connections. c) Finally, sufficiently loosen the plug-in terminal’s screw labeled #4 as shown in Figure 3.3-4 and insert the PLCHMR module’s Black wire into the terminal position while maintaining any existing wiring connections.
Airport Systems The MCU is pressed into a rectangular socket. This socket has a notch along the outside edge on one of the short sides this is the top side of the socket. CAUTION! Do not use excessive force when you remove or install the chip from/into its socket. Excessive force can bend or damage the MCU Pins or the socket. Step 1 Gently remove the old MCU using a small flat head screwdriver to pry it free of its socket. Set aside the old MCU.
40000324-001 Airport Systems Figure 3.
Airport Systems 3.4 Flash Head Status Reporting Relay Installation Wiring The PLCHMR features eight (8) configurable status reporting outputs. Each output connects to a form-c relay via three screw terminal connections. Each screw terminal connection is uniquely tied to one of the relay’s contacts. In accordance with Figure 3.
Airport Systems Relay 2 Relay 3 Relay 4 Relay 5 Relay 6 Relay 7 Relay 8 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 Digital Inputs Do Not Use http://www.Tri-M.com R104-V2 0896 Relay 1 Tri-M Engineering Figure 3.
Airport Systems 3.5 Final Installation Check Before applying power to the equipment, perform the procedures in the following sections. If any test does not pass, please consult Sections 3.3.3.2 and 3.3.3.4 in this manual or call Honeywell Technical Support at (805) 581-5591. 3.5.1 Preliminary 1. Verify that all AC input power circuit breakers are turned off. 2. Check that the MCU on the Master Controller’s printed circuit boards is properly seated in its socket. 3.
Airport Systems 1. Verify POWER SWITCH is turned OFF. 2. Verify LOCAL / REMOTE switch is set to LOCAL. 3. Verify MODE switch is set to DAY. 4. Turn on circuit breaker to apply power to Master Controller. 5. Turn on circuit breaker to apply power to Flash-heads. 6. Turn POWER SWITCH to ON. 7. Verify that the Master Controller LED test sequence has started (See EPM-00001152 - Installation and Operating Guide for High Intensity Obstruction lighting).
Airport Systems Wait 1 minute and measure the voltage between TB1-1 and TB1-2 to verify the voltage is 12-18 VAC. Repeat steps 7 - 10 to assure proper recovery after reset. Figure 3.
Airport Systems Note: Before performing any tests of the Flash Head Reporting Relay wiring the system must be configured using the PLCHMR System Maintenance and Configuration Menus. 3.7 3.7.1 PLCHMR System Maintenance and Configuration Menus PLCHMR System Maintenance & Configuration Menus Overview The PLCHMR system must be configured as part of the on-site installation. The PLCHMR’s maintenance menus are used to view and modify the site specific configuration data.
Airport Systems Figure 3.
Airport Systems HMS Maintenance Menu 1) Light Configuration 2) Report Configuration Press 1 3) Facility Information Press 3 4) Exit Press 25 Press 9 Press 2 Press 5 HMS Report Configuration Menu Current Report Method: Relays + ETHERNET HMS Facility Configuration Menu 1) NONE – Change report method to none 1) OWNER 2) Relays – Change report method to relays 2) CONTACT NUMBER 3) ETHERNET – Change report to ethernet 4) Relays & ETHERNET – Change report method to include both 5) Exit 7) Longitud
Airport Systems iii) no parity, iv) 1 stop bit. d) Apply power and wait for login prompt. If power is already applied and a login prompt is not shown press the enter key. e) After the login prompt “login >” is displayed then type “maint” and wait for the password prompt. f) At the password prompt “password>” type “grimes” and wait for Home Maintenance Window to be displayed (See Figure 3.7-3 ).
Airport Systems iii. iv. v. 4 flash heads are assigned to a tier as this would represent the physical installation of the flash heads on one tier of a tower. Height – The height as measured from ground level of the obstruction/tower. Facing_Dir – Nearest facing cardinal compass direction of the Flash Head. System defines eight (8) valid cardinal directions and they are: i. N ii. NW iii. E iv. SE v. S vi. S vii. SW viii. W ix. NW Priority – Maintenance Priority associated with Flash Head.
Airport Systems Menu (see Figure 3.7-5. Once in the Modify Light Menus select the menu item to edit by entering the row number of the menu item and pressing enter. To erase all configuration data for a specific light listed in the HMS Light Configuration Menu enter the row number of the light. This action brings up the HMS Modify Light Menu. Next input the number 6 followed by the “Enter” key.
Airport Systems HMS Report Configuration Menu Current Report Method: RELAYS + ETHERNET 1) NONE - Change Report method to none. 2) RELAYS - Change Report method to relays. 3) ETHERNET - Change Report method to ethernet. 4) RELAYS+ETHERNET - Change Report method to include both. 5) Exit maint> Figure 3.7-6 HMS Report Confguration Menu 3.7.5 PLCHMR Facility Configuration Menu The Facility Configuration menu displays data about the facility’s operator and its location.
Airport Systems 3.7.6 Verify Local Mode Operation All switches and indicators listed in this section are in the Master Controller. 3.7.6.1 Day Mode: 1. Verify MODE Switch is set to DAY. 2. Verify Day mode LED DS25 (Figure 3.6-1, Item 3) is lit red. 3. After about 6 seconds, verify all Flash-heads are flashing in sync and in Day mode (maximum brightness). 4. Verify that the Flash-head Status LED for each Flash-head on the tower is lit green (including any AOL).
Airport Systems 5. Verify relay status LEDs DS29-DS31 are lit green, and DS32 and DS33 are off. (DS29 - DS33: Figure 3.6-1, Item, 5,) 6. If you have a White-Only System: After 6 seconds, Verify all Flash-heads are flashing in sync and in Night mode (lowest brightness, ~1/8 second duration bursts at 40 bursts per minute). 7. If you have a Dual (Red/White) System: Verify normal red night mode operation. 8.
Airport Systems (l) If you have more than one Red Beacon at the top level, repeat the simulated failure test for each Red Beacon.
Airport Systems SECTION 4. PRINCIPLES OF OPERATION 4.1 Overall Description The PLCHMR is a product that consists of hardware and software to provide health monitoring and remote reporting services. PLCHMR is integrated into the StrobeGuard® System. The PLCHMR uses a single board computer; manufactured by a respected industrial supplier of single board computers (SBC). The SBC provides sufficient processor bandwidth and memory support the intended health monitoring and reporting tasks.
Airport Systems SECTION 5. MAINTENANCE 5.1 PLCHMR Module The PLCHMR module requires no periodic maintenance.
Airport Systems SECTION 6.
Airport Systems SECTION 7. APPENDIX A – EXAMPLES 7.1 Light Configuration Examples The HMS Light Configuration Menu provides the flexibility and configurability to address most field installations. This section provides specific examples that demonstrate some possible configuration values that are the results of choices made in the Light Configuration Menu. The PLCHMR system has eight (8) relays that can report the status of up to 24 Flash Heads.
Airport Systems Tier 1 Tier 2 Tier 3 3 6 2 5 1 Flash Head Installation with 9 Flash Heads, installed on three tiers (levels). Each tier has three Flash Heads. Flash Heads numbers correspond to the unique ID or address set on the Flash Head’s digital logic board switch #3. 4 9 7 8 Flash Head # Figure 7.
Airport Systems HMS Light Configuration Menu Lamp_ID 1) 1 2) 2 3) 3 4) 4 5) 5 6) 6 7) 7 8) 8 9) 9 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) Exit maint> Tier_Lvl 1 2 3 4 5 6 7 7 7 Height 151 152 153 133 133 133 113 113 113 Facing_Dir NW SE SW NW SE SW NW SE SW Priority 1 1 1 2 2 2 5 5 5 Figure 7.
Airport Systems Relay #1 Relay State 2 3 TRM #1 Flash/Fail Status 1 FLASH HEAD 1 Relay #2 Relay State 2 3 TRM #2 Flash/Fail Status 1 FLASH HEAD 2 Relay #3 Relay State 2 3 TRM #3 Flash/Fail Status 1 FLASH HEAD 3 Relay #4 Relay State 2 3 TRM #4 Flash/Fail Status 1 FLASH HEAD 4 Relay #5 Relay State 2 3 TRM #5 Flash/Fail Status 1 FLASH HEAD 5 Relay #6 Relay State 2 3 TRM #6 Flash/Fail Status 1 FLASH HEAD 6 FLASH HEAD 7 Flash/Fail Status Relay #7 7 & 9 FLASH HEAD 9 Relay
Airport Systems A typical configuration would be to create eight tiers (or groups). Each tier would be a collection of three Flash Heads. Each tier’s status would be collect by its assigned TRM and then reported by the relay whose number identifies the tier or (TRM) number. The Light Configuration Menu setting would appear as shown in Figure 7.1-4. An alternative view is presented in Figure 7.
Airport Systems FLASH HEAD 1 FLASH HEAD 13 Flash/Fail Status Relay #1 2 0 3 FLASH HEAD 3 FLASH HEAD 4 TRM #1 Flash/Fail Status Relay #2 & Relay State 5 6 FLASH HEAD 6 FLASH HEAD7 FLASH HEAD 19 Flash/Fail Status 0 9 FLASH HEAD 10 FLASH HEAD 22 Flash/Fail Status Relay #4 & 0 12 Relay State Flash/Fail Status Relay #6 16 & Relay State 18 TRM #6 Flash/Fail Status Relay #7 19 & Relay State FLASH HEAD 23 21 TRM #7 Flash/Fail Status Relay #8 22 23 FLASH HEAD 24 TRM #4 & 0 24
