Instruction Manual PRO APF SERIES FAA L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT & ICAO, NATO, UFC AND CANADA IN-PAVEMENT TAXIWAY EDGE LIGHT

Transcription

1 REVISION C October 05, 2016 Instruction Manual PRO APF SERIES FAA L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT & ICAO, NATO, UFC AND CANADA IN-PAVEMENT TAXIWAY EDGE LIGHT Eaton Crouse-Hinds Series Airport Lighting Products 1200 Kennedy Road Windsor, CT Copyright 2016 Cooper Technologies Company

2 Instruction Manual PRO APF L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT Table of Contents 1 Revisions... iv 2 Product Warranty... v 3 Safety Notices... vi 3.1 Keep Away from Live Circuits... vi 3.2 RESUSCITATION... vi 4 Safety Symbols... vii 4.1 Danger... vii 4.2 Warning... vii 4.3 Caution... vii 4.4 Warning: Notice... vii 4.5 Warning: Important... vii 5 Recommended Test Equipment and Tools... viii 6 General Information General Description Taxiway Omni-Directional Light Fixture Type/Color and Agency Compliance... 2 Table 1, Part number Explanation... 4 Figure 1, Fixture Dimensions Installation ANSI Installation Bolt Torque and Installation Method Heico-Lock Installation Guide (2014)... 9 Figure 2, Installation (Lifting) Tool Maintenance General Recommended Spares Cleaning Lens O-Ring Replacement Feed-thru Replacement Outer Lens/Heater Replacement LED Replacement Power Supply Replacement Resetting a TOL Power Supply s E-Prom Inch Fixture External Gasket Replacement Pressure Test Cleanliness and Workmanship Maintenance Program ii

3 Instruction Manual PRO APF L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT 9 Troubleshooting Visual Inspection Electrical Inspection Figure 3, Power Supply Wiring Diagrams Jumper Diagrams Figure 4, Part Identification Fixture Mounting Bolts & 2-Piece Washers iii

4 Instruction Manual PRO APF L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT 1 Revisions Rev. No. Issue/Reissue Number Letter Description Checked Approved A A Initial release PG 6/1/16 B A Section 8.9, Page 17, J200 positions was 13 to 14. IM 8/22/16 C A Page 5, Fig 852T-AP1-12X, Added base flange diameter Z, Ø9.94 for -12A & -12C versions & Ø9.19 for -12B & -12D versions. IM 10/5/16 iv

5 Instruction Manual PRO APF L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT 2 Product Warranty Warranty Refer to Eaton s Crouse-Hinds Airport Lighting Products Terms and Conditions for product specific warranty information. v

6 Instruction Manual PRO APF L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT 3 Safety Notices This equipment is normally used or connected to circuits that may employ voltages which are dangerous and may be fatal if accidentally contacted by operating or maintenance personnel. Extreme caution should be exercised when working with this equipment. While practical safety precautions have been incorporated in this equipment, the following rules must be strictly observed: 3.1 Keep Away from Live Circuits Operating and maintenance personnel must at all times observe all safety regulations. Do not perform maintenance on internal components or service with power ON. DANGER: DANGER DO NOT PERFORM MAINTENANCE ON INTERNAL COMPONENTS OR SERVICE WITH POWER ON. 3.2 RESUSCITATION Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of first aid instruction. vi

7 Instruction Manual PRO APF L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT 4 Safety Symbols 4.1 Danger DANGER: DANGER The hazard or unsafe practice will result in severe injury or death. 4.2 Warning WARNING: WARNING The hazard or unsafe practice could result in severe injury or death. 4.3 Caution CAUTION: CAUTION The hazard or unsafe practice could result in minor injury. 4.4 Warning: Notice WARNING: NOTICE Possibly dangerous situation, goods might be damaged. 4.5 Warning: Important WARNING: IMPORTANT Helpful information. vii

8 Instruction Manual PRO APF L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT 5 Recommended Test Equipment and Tools There is a wide variety of tools and equipment needed to safely and correctly perform airfield lighting equipment installation and maintenance. In addition to the obvious tools (screwdrivers, wrenches, etc.), there is a specialized equipment needed to do the job. Multimeter One of the most important pieces of test equipment is the Multimeter. It is used to measure voltages, currents, and resistances. Almost every single maintenance task requires the use of a multimeter at one point or another. A quality meter in good repair and calibration is a must because airfield lighting power distribution equipment produces non-sinusoidal waveforms, traditional average reading meters are inaccurate and have very limited use. Checking or adjusting equipment based upon incorrect current reading may dramatically reduce lamp life and adversely affect power equipment performance. A meter with TRUE RMS measuring capability with a current clamp-on accessory is needed to accurately measure distorted or chopped waveforms. All meter manufacturers offer TRUE RMS measuring meters. The following is a short list of TRUE RMS Multimeters from Fluke: Manufacturer Fluke 287 Model Number Our recommended multimeter is the Fluke 287 with the Fluke I800 current clamp accessory. Refer to the equipment manufacturer s manuals for the proper use, maintenance and calibration (if necessary) of all meters. Thread Lubricant Anti-seize (marine grade preferred, Henkel/Loctite P/N or or equal customer supplied [ with a K factor of 0.18 for fully coating the fixture installation bolts. Drive and Ratchet A 3/8 inch square drive socket and ratchet (use ratchet for loosening bolts only and a torque wrench to tighten), size 9/16 or 14 mm for the fixture 3/8-16 UNC hex installation (customer supplied) bolts installed into a FAA L-867 or L-868 base. Torque Wrench A calibrated torque wrench (micrometer adjustable solid audible/tactile click impulse when torque value attained with an accuracy of +/- 4%) to fit a 9/16 or 14 mm socket for drive size of the socket to tighten the fixture hex bolts to per sections 7.1 and 7.2. Torque wrenches: Sturtevant Richmont P/N , range 100 to 600 in-lbs or equal, or Sturtevant Richmont P/N , range 10 to 50 Nm or equal. Certificate of calibration included with suggested torque wrenches. Note, never loosen bolts with a torque wrench. viii

9 Instruction Manual PRO APF L-852T LED (L) OMNI-DIRECTIONAL TAXIWAY EDGE LIGHT Torque Screwdriver A calibrated adjustable torque screwdriver to torque the smaller internal hardware and the bottom cover external screws if the fixture is opened for maintenance. Sturtevant Richmont P/N (comes with bits [hex, slotted, Torx, Phillips, sq. recess, bit holder, socket adapter], case and certificate of calibration), range 2 to 36 in-lbs/0.2 to 4 Nm or equal. Note, never loosen screws with a torque screwdriver. Pliers Needle nose pliers for installing the extremely small header jumper onto a spare Power Supply J203 header when required, or removing the flag type fast-on terminals from the power supply. Xcelite P/N NN54-2 miniature pliers, fine needle nose, ESD-Safe or equal. ESD Protection A grounded ESD Wrist Strap when working on or handling fixture power supplies or LED/Heat sink assemblies. ESD Wrist Straps, also known as anti-static Wrist Straps, are used to prevent electrostatic discharge (ESD) by safely grounding a person working with electronic equipment or at an electronic assembly facility. It consists of a band of fabric with fine conductive fibers woven into it. The fibers are usually made of carbon-filled rubber, and the strap is bound with a stainless steel clasp or plate. They a usually used in conjunction with an ESD table mat on the workbench, or a special static-dissipating plastic laminate on the workbench. ESD Products brand ( ) or equal. Fixture Removal/ Install Tool A Crouse-Hinds P/N installation tool to aid in the installation and removal of 12 inch diameter fixtures (only available from Crouse-Hinds). Most tools indicated above can be purchased from MSC Industrial Supply Co. ( ), or McMaster-Carr ( ). ix

10 6 General Information 6.1 General Description Taxiway Omni-Directional Light The Crouse-Hinds Taxiway part number 852T-AP1-12A and 852T-AP1-12B Omni-directional Light is a Style 3, FAA L-852T (L) in-pavement fixture per FAA AC 150/ (latest revision). It is designed for installation at the taxiway edge or any other location where visual guidance of moving aircraft or ground vehicles is desirable. The fixture is designed to fit on a FAA L-868, size B (-12A & -12C) or FAA L-867 size B (-12B or -12D) light base per FAA AC 150/ (latest version), and have a total height above grade/ground level of.250 inch. Part Numbers 852-AP1-008 (fits Crouse-Hinds shallow bases X-X), 852T-AP1-12C and 852T-AP1-12D meet the latest photometric and chromaticity requirements of ICAO Annex 14 Volume I, NATO STANAG 3316 & 3711, UFC and Canadian TP312 for in-pavement taxiway edge fixtures. The fixture is Omni-directional, projecting the beam of light 360 in the horizontal direction. It is weatherproof and will endure roll over loads without damage. The LED AP1 power supply can be used with either a 3 (4.8, 5.5, 6.6A output) or 5 step (2.8, 3.4, 4.1, 5.2, 6.6A output) Constant Current Regulator (CCR), 50 or 60 Hz. The power supply has a power factor of 0.99 in all steps, and an efficiency greater than 80% at 6.6A. The power supply is compatible with all known CCR types, has a 3.5 crest factor to ensure compatibility with series CCRs, has a 0.88 second switch-on time, a typical initial turn on voltage of 1.5V, high frequency 400 Hz PWM to help eliminate flicker perception, and a 10k/5kA surge protection. The LED(s) have a projected life of greater than L70 (L70 = elapsed operating time in hours over which the LED light source maintains 70% of its initial 50,000 hours at 6.6A (1). If an Arctic Kit is ordered with the fixture, it will comply with the requirements of FAA EB67 (latest), which will raise the light emitting surface temperature 15 degree C (59 degrees F) after 30 minutes of operation at the CCR high step of 6.6A. The arctic kit heating filament is applied directly to the glass dome interior and does not obstruct the photometric output. All fixtures are factory illuminated a minimum of 4 hours and meet the FAA requirements for EMI (electromagnetic interference) suppression. The light fixture consists of a 1-piece aluminum optical assembly. The 12 inch diameter aluminum optical assembly is mounted to a FAA size B light base with six bolts and six 2-piece locking washers (order separately, see Section 10). The 8 inch diameter aluminum optical housing assembly is mounted to a Crouse-Hinds shallow base, P/N X-X (order separately) which is supplied with mounting hardware. All fixtures have aluminum housing and a die cast bottom cover that is attached using 4 screws. An O-ring is used to provide a watertight seal between the inner cover and the optical housing. An LED module is secured to the lens bracket, which is fastened to the optical housing. The power supply is secured to the inner cover using a bracket. Electrical connections are made at one feed-thru assembly in the inner cover. The feedthru is a 2 conductor molded cable and has an ITS verified L-823 plug for connecting to FAA L- 830/ L-831 isolation transformer. The outer lens is held into the aluminum housing with a bracket, gasket, molded elastomeric boot and 12 screws. All hardware is type 18-8 stainless steel except for the 12 screws holding the outer lens bracket onto the aluminum housing, which are type 410 heat-treated black oxide stainless steel. The complete 852T-AP1-12A or 852T-AP1-12B light unit is inches in diameter, 2.75 inches deep from grade, and weighs 10.5 lbs. 1

11 The 8 inch unit is the same depth as the 12 inch unit. The fixture requires a minimum 6.6A/6.6A, 10/15 watt series isolation transformer without the arctic (heater) kit (minimum 20/25 watt or 30/45 watt with the arctic kit). (1) 862T-AP1-12C or -12D L70 status undetermined due to insufficient data. 6.2 Fixture Type/Color and Agency Compliance a. U.S. DOT FAA ( ) See part number breakdown in Table 1. The following fixtures are approved to U.S. Department of Transportation Federal Aviation Administration (FAA) Advisory Circular (AC) AC 150/ (latest) and also meet FAA Engineering Brief (EB) EB67 (latest): Taxiway: L-852T(L) (blue), P/N 852T-AP1-12A - _ or 852T-AP1-12B Refer to FAA AC 150/ (latest) for taxiway lighting standards installation and spacing. b. U.S. DOD UFC ( ) See part number breakdown in Table 1. The following fixtures meet U.S. Department of Defense Unified Facilities Criteria (UFC) (latest) for photometry, the mechanical requirements of FAA AC 150/ (latest), and requirements for light sources other than incandescent or xenon per FAA EB67 (latest), except meets the chromaticity requirements of NATO STANAG 3316 (latest): Taxiway: UFC (blue), P/N 852T-AP1-12C - _ or 852T-AP1-12D-_ Refer to UFC (latest) for taxiway lighting standards installation and spacing. c. Canada TP312 ( See part number breakdown in Table 1. The following fixtures meet the requirements of Canada Aerodromes Standards and Recommended Practices TP312 (latest): Taxiway: TP312 (blue), P/N 852T-AP _ or 852T-AP1-12C-_ or 852T-AP1-12D-_ Refer to TP312 (latest) for taxiway lighting standards installation and spacing. 2

12 d. ICAO Annex 14 ( aerodromes-volume-i-aerodrome-design-and-operations-english-printed html ) ( ) ( frangibility-doc-9157p6-english-printed.html ) ( ) See part number breakdown in Table 1. The following fixture meets International Civil Aviation Organization (ICAO) Annex 14 Aerodromes Volume I Aerodromes Design and Operations (latest) for photometry and chromaticity. Taxiway: ICAO (blue), P/N 852T-AP _ or 852T-AP1-12C-_ or 852T-AP1-12D-_ Refer to ICAO Document 9157 (AN/901) (latest) Aerodrome Design Manual Part 4 Visual Aids for taxiway edge fixture spacing. e. NATO STANAG 3316 ( ) See part number breakdown in Table 1. The following fixture meets North Atlantic Treaty Organization (NATO) STANAG (latest) for photometry and NATO STANAG 3711 for chromaticity. Taxiway: NATO (blue), P/N 852T-AP _ or 852T-AP1-12C-_ or 852T-AP1-12D-_ Refer to NATO STANAG 3316 (latest) for taxiway edge fixture spacing. 3

13 Table 1, Part number Explanation 852T - AP1 - - FIXTURE TYPE: In-Pavement Taxiway, Blue SERIES VERSION: AP1 = Pro APF1 FIXTURE DIAMETER: 008 = 8" Fixture with mounting bolt pattern per IEC specifications and meets ICAO, NATO, UFC and Canada Taxiway photometric and chromaticity specs 12A = 12" Fixture with 11.25" mounting BC for FAA L-868 base can, meets FAA L-852T 12B = 12" fixture with 10.25" mounting BC for FAA L-867 base can, meets FAA L-852T 12C = Same bolt pattern as 12A, except meets ICAO, NATO, UFC and Canada Taxiway photometric and chromaticity specs 12D = Same bolt pattern as 12B, except meets ICAO, NATO, UFC and Canada Taxiway photometric and chromaticity specs OPTIONS: 1 = Artic Kit 4

14 Figure 1, Fixture Dimensions 852T-AP1-008 Note, there are two blind holes on the underside of the optical forging to accept the Shallow Base pins/studs. 852T-AP1-12X 5

15 7 Installation WARNING: NOTICE 852T-AP1 base can pavement specifications and design are the responsibility of the installer and/or airport. Transformer housing, series isolation transformers, primary connector kits, heat shrink kits, series loop primary wire, counterpoise cable/wire, grounding rods, ground wire and connectors, fixture mounting bolts and 2-piece washers are not included as part of the 852T-AP1. Additionally, the electrical power originating from the CCR and any electrical equipment required to bring utility power or generator power to the CCR is the responsibility of the installer and/or airport. Underlined items may be ordered from Crouse-Hinds Airport Lighting. See Section 10 for mounting bolts and 2-piece washer part numbers. a. Refer to your agency s installation and fixture spacing recommendations (see each agency listing in Section 6.2, Fixture Type/Color and Agency Compliance ) and/or your airport construction plans. DANGER: DANGER Lock out electrical power to the series loop that will power the fixture at its source before attempting any electrical connections/splices per your safety procedures. WARNING: IMPORTANT Check the fixture for shipping damage upon arrival and in all cases, check for damage prior to installation. 6

16 CAUTION: CAUTION Never handle the light assembly by the leads as this can break the waterproof seals. b. A list of tools which can help during installation are referenced in Section 5, Recommended Test Equipment and Tools. c. Check the fixture part number before installation to be sure it will be installed at the correct location. d. Be sure the correct series isolation transformer size is installed for the fixture; minimum 10/15 watt, 6.6/6.6A secondary without an arctic (heater) kit, or a minimum 20/25 watt or 30/45 watt 6.6/6.6A secondary for fixtures with the arctic kit installed. WARNING: IMPORTANT Crouse-Hinds P/N will ease in the installation and removal of 12 inch diameter fixtures (see Figure 2). The threaded eyebolts on the lifting tool screw into threaded holes in the fixture. e. Plug the fixture s L-823 plug into the series isolation transformer secondary receptacle located in the base can. Apply electrical tape to this connection to keep this secondary connection from possible disconnection in the base due to freeze/thaw cycles that may occur from water intrusion into the base can. Note, if you are using a Crouse-Hinds type SIB-8 Shallow Base, the series isolation transformer will not be located in the shallow base. A secondary extension cable (length dependent on installation) will be required to make the connection between the fixture and series isolation transformer secondary plug and receptacle. f. Verify that the mounting flange on the fixture base can is clean and the O-ring (optional on deep cans) is coated with Dow Corning FS 1292 grease and is in place on the base can. The 8 inch diameter fixture, P/N 852UL-AP1-XXX- 008 comes with a gasket on the bottom cover exterior to seal it to a Crouse-Hinds Shallow Base having an inner bore diameter of 6.61 inches. This gasket should also be coated with the Dow Corning grease if using this size fixture. 7

17 WARNING: IMPORTANT Failure to apply anti-seize to fixture mounting bolts at installation may result in difficult removal of mounting bolts and poor clamping force. The correct k value anti-seize must be used in addition to 2- piece locking washers as described in Section 7.1 to maintain to correct bolt clamping force. g. Torque the fixture installation per Section 7.1 instructions. h. Return power to the circuit per your safety procedures. 7.1 ANSI Installation Bolt Torque and Installation Method Use fully threaded, cold-worked 18-8 stainless steel 3/8-16 bolts. (P/N is recommended). Use Heico-Lock or Nord-Lock stainless steel lock-washers per FAA Advisory Circular (AC) 150/ (latest), AC 150/ (latest) and FAA Engineering Brief (EB) 83 (latest). Mounting base holes must be degreased, cleaned, and dried prior to bolt installation. Base-to-fixture mating surfaces must be degreased, cleaned, and dried prior to installation. Apply marine grade anti-seize (K=.18) per manufacturer s instructions to each bolt. Install the 3/8-16 bolts with lock-washers per lock-washer manufacturer s guidelines. See section 7.2 for Heico-Lock installation guidelines (2014) Achieve a full final torque of 225 in-lb (25.4 N-m) +10%, -0% with a calibrated torque wrench. Impact wrenches are not recommended as installation tools. Check torque and re-torque all bolts within 2 weeks of initial installation. Maintain all bolts by checking and re-torqueing per FAA AC 150/ (latest). If any lubricants or thread locking compounds are used (not recommended), torque must be recalculated based on K factor provided by lubricant or compound manufacturer. New bolts and lock-washers shall be used each time a light unit is removed from its base. 8

18 7.2 Heico-Lock Installation Guide (2014) Step 1: Hand tighten to ensure that 2-3 threads extend beyond the nut on through-bolt applications. Step 2: Tighten each bolt to one-third of the final required torque following the pattern as shown below. Step 3: Increase the torque to two-thirds following the pattern shown below. Step 4: Increase the torque to full torque following the pattern shown below. Step 5: Perform one final pass on each bolt working clockwise from bolt 1, at the full final torque. 9

19 Figure 2, Installation (Lifting) Tool (Note, fixture illustrated in not a TOL) 10

20 8 Maintenance 8.1 General The preferred method of maintaining a light unit is to periodically replace the unit and return it to the maintenance shop for renovation. As an alternative, the optical assembly can be serviced in the field. Work on electrical circuits should only be performed by qualified electricians with a working knowledge of airfield lighting circuits. However, it is recommended that field servicing be limited to bolt torque checks per Section 7.1 and cleaning the lens as described in Section 8.3. Users should also reference FAA AC 150/ (latest), Maintenance of Airport Visual Aid Facilities for their recommended practices for runway and taxiway edge lighting systems. A list of tools which can help during maintenance are referenced in Section 5, Recommended Test Equipment and Tools. Figure 4 will aid in part identification and replacement part numbers. 8.2 Recommended Spares The number of recommended spare fixtures is 2% installed at the airfield. If the quantity for each type is less than 50, then at least two fixtures. The number of individual spare parts should be at least 3% of the total fixtures installed at the airfield. This number may vary greatly if aggressive snow removal operations occur. WARNING: IMPORTANT Do not open any light fixture unless the warranty period has expired. Opening a light fixture will void the warranty. DANGER: DANGER Lock out electrical power to the series loop that will power the fixture at its source before attempting servicing to the fixture. 11

21 DANGER: DANGER Do not remove the fixture from the base can while the fixture is powered. Dangerous voltage may be present on the primary and secondary sides of the isolation transformer. WARNING WARNING: A buzzing or humming noise coming from the isolation transformer may indicate a failed power supply or LED. It is also an indicator of dangerous voltage on the primary and secondary sides of the isolation transformer. 8.3 Cleaning Lens Clean the outer surface of the glass lens with a detergent solution. If the lens is coated with a substance impervious to the detergent, a suitable solvent should be sparingly applied with a wad of cotton or a patch of cloth on the end of a wood splint. After the solvent has acted the remaining solvent and softened coating should be removed with a clean piece of cotton or cloth. Care should be taken to avoid excessive contact between the solvent and the lens seal. Remove all remaining solvent from lens and seal. A gentle air blast may be used. 8.4 O-Ring Replacement Every time the fixture is opened, the O-ring must be replaced. IMPORTANT WARNING: Every time a fixture is opened, its O-ring and fixture exterior gasket (present on 8 inch fixtures only) is recommended to be replaced. O- rings and gaskets will develop a permanent deformation over time. A bad O-ring is the most common cause of in-pavement fixture leaks. Failure to replace them when the fixture is opened may result in a fixture leak. Apply Dow Corning FS 1292 grease to the fixture O-ring and exterior gasket. Remove and secure power to the fixture. Remove and discard the old O-ring from the groove in the optical housing using a plastic, or comparably soft, tool. Carefully clean the O-ring groove and flange mating surface on the inner cover. Take care not to damage the mating surface or the new O-ring. Coat the new O-ring with a thin layer of Dow Corning FS 1292 lubricating grease. Position the new O-ring concentric with the groove and press it into place. Torque the inner cover screws to 30 in-lbs. Perform a pressure test as 12

22 described in Section Connect the light unit lead(s) from the isolation transformer(s). Clean the mounting flange area of the fixture and base. Install the fixture into the base per Section Feed-thru Replacement Remove and secure power to the fixture. Remove the two bolts and 2-piece locking washers (8 inch fixture) or six bolts and 2-piece locking washers (12 inch fixture) securing the fixture to the base. Disconnect the light unit lead(s) from the isolation transformer(s). Turn the fixture upside down and remove the four screws holding the bottom cover to the fixture housing. Disconnect the power supply leads /ferrite leads from the feed-thru terminals. Remove the feed-thru by unscrewing its round retaining collar. Clean the mounting surfaces with denatured alcohol and allow to dry. Apply a thin coat of Dow Corning FS 1292 grease to the mounting flange of a new feed-thru. Apply a drop of Loctite 243 to the feed-thru adapter threads. Screw the feed-thru retaining collar onto the adapter. Torque the round retaining collar to in-lbs. Reconnect the power supply leads/ ferrite leads to the feed-thru terminals. Replace the optical housing s O-ring per Section 8.4. Install the fixture into the base per Section Outer Lens/Heater Replacement Outer Lens: If the outer glass lens is broken, leaks, or is badly pitted or scarred, it must be replaced. It is highly recommended that this task be performed in a clean shop environment. Outer Lens Replacement Kit P/N contains all necessary parts to change a lens. Remove and secure power to the fixture. Remove the two bolts and 2-piece locking washers (8 inch fixture) or six bolts and 2-piece locking washers (12 inch fixture) securing the fixture to the base. Disconnect the light unit lead from the isolation transformer. Turn the fixture upside down and remove the four screws holding the bottom cover to the fixture housing. Remove the lens retaining bracket screws from the light housing. Remove the lens-retaining bracket and discard the lens-retaining gasket. Firmly push the lens/boot assembly from the outside of the light housing; discard the old lens and boot. Thoroughly clean the lens opening with isopropyl alcohol and let dry. Inspect the lens opening for scratches or pits; a damaged lens opening surface will not seal properly. Place a new lens boot (P/N 21256) over the replacement outer lens (P/N 21254). Apply a thin coat of Dow Corning FS 1292 grease over the entire outside surface of the lens boot. Align the lens/boot assembly in the lens opening and press it into place. Verify that the lens boot is not pinched in the lens opening. Using a new lens retaining gasket (P/N 21258), fasten the lens retaining bracket (P/N 21297) to the light housing. Torque the mounting screws to in-lb. Inspect/replace the optical housing s O-ring per Section 8.4. Assemble the bottom cover onto the light housing. Torque the mounting screws to 30 in-lbs. Perform a pressure test per Section Clean the mounting flange area of the fixture and base. Install the fixture onto the base and torque the mounting bolts with anti-seize applied along with 2- piece locking washers for each bolt per Section

23 Outer Lens with Heater: Outer Lens/Heater Replacement Kit P/N and Heater/Bracket Assembly/Thermoswitch Kit P/N contain all necessary parts to change a lens/heater assembly. Do as stated above; however, this fixture will not have a lens retaining gasket since it is incorporated into the heater assembly and make sure that when mounting the lens retaining bracket, the heater wires are aligned with the slot on the lens retaining bracket so the wires are not pinched. The thermostat and its bracket is also part of the replacement kit. For Heater installation: Clean the underside of the outer lens with alcohol and allow to dry. Peal the adhesive strip (not the insulating foil side) from the heater (round disc the leads attached) and adhere to the underside of the outer lens. Make sure when adhering the heater to the outer lens that they remain concentric to each other so light will not be blocked. Clean the back side of the heater (insulation foil side) with alcohol and allow to dry. Peal the adhesive strip from the foam rubber pad (replaces flat circular hard outer lens gasket) and adhere the heater to the foam rubber pad; making sure when adhering the heater to the foam rubber pad that they remain concentric to each other so light will not be blocked. 8.7 LED Replacement NOTICE WARNING: A grounded ESD Wrist Strap should be worn by personal working on or handling fixture LED assemblies. ESD Wrist Straps, also known as anti-static wrist straps, are used to prevent electrostatic discharge (ESD) by safely grounding a person working with electronic equipment. LED Replacement Kit P/N B1 contains all necessary parts to change the LED module. Remove and secure power to the fixture. Remove the two bolts and 2- piece locking washers (8 inch fixture) or six bolts and 2-piece locking washers (12 inch fixture) securing the fixture to the base. Disconnect the light unit lead from the isolation transformer. Turn the fixture upside down and remove the four screws holding the bottom cover to the fixture housing. Disconnect the LED module leads from the power supply. Remove the lens retaining bracket screws from the optical housing. Remove the lensretaining bracket and remove the LED heat sink from it, unscrewing the screws. Install the new LED module heat sink and torque the screws in a star pattern to 30 in-lbs; tightening the lens retaining bracket screws to a torque greater than 35 in-lbs may cause failures under high loads. For the heater option fixture, make sure that the heater wires are aligned with the slot on the lens retaining bracket so that they are not pinched at final assembly. Replace the optical housing s O-ring per Section 8.4. Install the fixture into the base per Section

24 8.8 Power Supply Replacement IMPORTANT WARNING: Reuse of existing TOL power supplies is acceptable if no damage to the power supply is present. The power supply s e-prom must first be reset to achieve correct detection of LEDs out. This procedure must also be done for new power supplies to be sure its e-prom is set for the fixture s LED(s) it will be used in. See Section 8.9. CAUTION: CAUTION Power supply is hot (temperature) when the fixture is energized and remains hot for a short time after the fixture is turned off. NOTICE IMPORTANT WARNING: A grounded ESD Wrist Strap should be worn by personal working on or handling fixture power supplies. ESD Wrist Straps, also known as anti-static wrist straps, are used to prevent electrostatic discharge (ESD) by safely grounding a person working with electronic equipment. WARNING: The jumpers (on power supply J203) must be in the correct position(s) for proper operation of the fixture to achieve outputs the fixture is specified for. NOTICE WARNING: Applying input current to the power supply without the arctic kit heater or the heater jumper lead assembly installed on the power supply will cause damage to the power supply. 15

25 WARNING: IMPORTANT Applying a constant voltage greater than 50V (AC or DC) to the input will cause damage to the power supply. Remove and secure power to the fixture. Remove the two bolts and 2-piece locking washers (8 inch fixture) or six bolts and 2-piece locking washers (12 inch fixture) securing the fixture to the base. Disconnect the light unit lead from the isolation transformer. Turn the fixture upside down and remove the four screws holding the bottom cover to the fixture housing. Remove the three power supply bracket screws. Disconnect internal cables to power supply termination points. Remove the power supply bracket with attached power supply. Remove the three power supply screws and discard the old power supply as an electronics assembly. Configure the J203 jumper settings for the new power supply per Jumper Diagrams in Section 9. Reconnect internal cables per the appropriate Wiring Diagrams. Apply thermal grease to the mating surface of the new power supply and secure it to the bracket using the three supplied screws. Torque the screws to in-lb. Secure the power supply bracket. Torque the bracket mounting screws to in-lb. Replace O-ring per Section 8.4. Install the fixture to the base per Section Resetting a TOL Power Supply s E-Prom If an new or existing TOL power supply is to be installed in an existing TOL fixture as a replacement part, the following must be done (except if the TOL part is the same as the fixture it will be reused for). This process is required to reset to power supply s e-prom for detecting the number of LEDs that could be out, based on the LED s forward voltage it will be used with. This is best accomplished in your maintenance facility following safe electrical practices during the reprogramming of the power supplies, as dangerous currents will be present on exposed connections when the power supply is energized. DANGER: DANGER Lock out electrical power to the TOL power supply prior to reprogramming jumper set-up, and after reprogramming during removal of programming jumper. With power off, add a jumper, to power supply J200 between positions 1 and 2. Attach the LED type to be used with the power supply, installing the correct jumpers to J203 if required per Jumper Diagrams. Also refer to Figure 3 (install a jumper lead assembly between P102 and P103 if not present). Install the LED lead assembly to the power supply per Figure 3 (red color lead to anode side). With all personal safely isolated from your maintenance facility reprogramming set-up, energize the circuit. The circuit must run for a minimum of 10 seconds, and with the power supply at the high 16

26 step of 6.6A during this 10 second minimum for the e-prom to reset and accept its new settings. The power supply will blink the LED after 10 seconds, indicating it has been reset. Remove the jumper from power supply J200, positions 1 to 2 after the power supply is safely de-energized after the 10 second minimum reset period Inch Fixture External Gasket Replacement Remove and secure power to the fixture. Remove the two bolts and 2-piece locking washers (8 inch fixture) securing the fixture to the base. Disconnect the light unit lead from the isolation transformer. Any gasket that is stretched, torn, has a permanent set or some other defect, will allow water to enter the light base. Remove the old gasket from the inner cover by carefully scraping with a plastic, or comparably soft, tool. Take care not to damage the inner cover. Clean the sealing surface. Form a thin bead of high temperature silicone adhesive, such as GE RTV 106, on the inner cover sealing surface. Position the new gasket on the inner cover in the same location as the old gasket. Apply a thin coat of Dow Corning FS 1292 grease over the entire outside surface of the gasket before placing the optical assembly into the base. Install the fixture onto the base per Section Pressure Test A light unit should be subjected to a 20-psig air pressure test to verify that it is waterproof after it has been opened or components have been replaced. A tire valve style pressure fitting is located on the bottom of the inner cover. Pressurize the unit to 20-psig then place it in a tub of water or use a soap solution to locate escaping air bubbles. Carefully inspect the areas around the lens, inner cover seal, and feed-through adapter for leaks. Relieve the internal air pressure before installing the light unit or attempting to repair a leak Cleanliness and Workmanship Service life depends upon the entire assembly being waterproof. All internal surfaces must be clean, dry and free of all foreign matter if the light unit is to operate for extended periods without requiring maintenance Maintenance Program In order to ensure maximum light unit life, the installed units should be subject to a maintenance program in accordance with the following: A daily operation check should be made of the lighting units. The lights should be energized and visually inspected. If any units are out, the location of the unit should be recorded and the fixture replaced with a spare at a time when the circuit is de-energized. 17

27 Regular cleaning is necessary to ensure that in-pavement lighting units operate at maximum efficiency. The lens should be cleaned periodically with a soft cloth and solvent per Section 8.3. The weather and the location of the units will dictate the regularity and type of cleaning. Snowplow operators should exercise extra care not to strike the light units with snowplow blades. After snow removal operations, inspect all fixtures and replace if any damaged fixtures. Passes over the light rows should be made with a power broom only if practical. Whenever snowplows must traverse in-pavement light units, they should be traveling at less than 5 mph or have the blades lifted clear of the units. Recommended snow removal techniques are described in AC 150/ The light is designed to exclude both ground and surface water from entering. If the lights are not properly maintained (i.e., bolts tightened and seals in good condition) water may enter the unit. To prevent this from occurring, it is recommended that each unit be inspected for the presence of water at least once a month. More frequent inspection is desirable during and following rainy seasons. Fixture mounting bolts should be checked for proper torque per Section 7.1 and whenever a unit is serviced regardless of the season. Light units in and around the touchdown zone area are especially prone to vibration and shock damage if the mounting bolts are not properly torqued. The mounting surface of the light base must be clean and free of foreign matter when checking mounting bolts. If any light unit contains water, the water should be removed and the entire light unit cleaned and dried. Perform a pressure test per Section 8.11 to locate the source of the leak. Repair the leak and replace the fixture O-ring per Section

28 9 Troubleshooting If a light unit is under warranty, please contact Crouse-Hinds Airport Lighting for assistance. DO NOT open a unit. If the unit is opened, the warranty is VOID. If the warranty period has expired and troubleshooting is required, follow the steps below to find the root cause. Replacement parts will be required for testing of the different components of the light unit. Review all DANGER, WARNING, IMPORTANT and NOTICE statements in Section 8. All still apply when troubleshooting. 9.1 Visual Inspection Follow the steps in Section 8 to open the fixture. Verify all the wires are not pinched or damaged and that the wire insulation is intact. Verify the input AC is connected to the feed thru secondary plug. Verify the power supply connections and appropriate J203 jumper settings per Wiring Diagrams, Jumper Diagrams and Figure 3. Replace any damaged or burned cables. Replace damaged LED per section 8.7. Replace damaged power supply per Section 8.8. Refer to Figure 4 part identification to determine the appropriate replacement part/kit for your fixture. 9.2 Electrical Inspection Follow the steps in Section 8 to open the fixture. With the powered fixture powered, the power supply continuously monitors the status of the fixture LED. There is a green status LED (see Figure 3) that may be visible through the potting. A blinking status LED indicates the power supply has detected a fault condition. Fault conditions include: Disconnected or Open LED module o Replace cable if damaged or open. Incorrect jumper setting or missing jumpers o See Jumper Diagrams for proper jumper setting. More than 25% of the driven LED Shorted o Replace LED module per Section

29 Figure 3, Power Supply Connections See Jumper Diagrams and Wiring Diagrams for connections for the Part Number installed. Status Indicator When powered, if the status LED is not visible or not lit, replace the power supply per Section 8.8 or contact Crouse-Hinds Airport Lighting Products for assistance. 20

30 Wiring Diagrams Without Heater, 6.6A Input With Heater, 6.6A Input 21

31 Jumper Diagrams Power Supply J203 Jumper Positions for Part Numbers 852T-AP1-12A-X and 852T-AP1-12B-X Power Supply J203 Jumper Positions for Part Numbers 852T-AP1-008-X, 852T-AP1-12C-X and 852T-AP1-12D-X 22

32 Figure 4, Part Identification 23

33 24 DOCUMENT 1273

34 21486-B1 LED/ Heat Sink Module Replacement Kit Heater, Thermostat, Thermostat Bracket and Power Cables Replacement Kit 25

35 Bottom Cover 26

36 Ferrite Placement Without Heater Ferrite Placement with Heater 27

37 10 Fixture Mounting Bolts & 2-Piece Washers P/N XXXX 2-Piece Washer Replacement Kit, customer specified quantity P/N XX Bolt, Hex-Head, 3/8-16, cold worked 18-8 stainless steel, customer specified length, quantity 1 28