PAPI with Permanent Mounting

Transcription

1 PAPI with Permanent Mounting Technical Support: Toll Free: (US & Canada) Worldwide: Fax: Web: carmanah.com 2016 Carmanah Technologies Corporation

2 Contents 1.0 Safety & Usage Viewing Precautions Battery Precautions Wireless Precautions Regulatory Warranty Disclaimer Recycling Handling Abbreviations Equipment Characteristics Theory of Operation Light Housing Assembly (LHA) Power Control Unit (PCU) Charging and AC-Powered Operation (Solar Primary) Installation System Overview Site Design Installation of the Light Housing Assemblies Cable Routing: Installation of the Power Control Unit Installation of the Battery Box Assembly Installation of Solar Panels Electrical Connections Tilt Switch (optional) Aiming Overview Aiming the fixtures (LHAs) Power Control Unit Operating Procedures Power Control Unit Switches Power Power Control Unit Manual Operation Remote Control and Photocell Operating Procedures Operation in Unusual Conditions Unusual Environment and Weather Emergency Procedures Carmanah Technologies Corporation 2

3 9.0 Maintenance System Checks Before and After Installation Maintenance Periodic Preventative Maintenance Cleaning the Lenses of a Light Housing Assembly Parts Replacement Removal of LHA Weather Cover Replacement of White LED Module Replacement of Red LED Module Replacement of an LHA Power Circuit Board Replacement of Batteries in the Battery Box Assembly Troubleshooting Power LHA Power Control Board White LED Modules Red LED Modules Tilt Switch Solar Module Inclinometer Instructions Warranty Carmanah Technologies Corporation 3

4 1.0 Safety & Usage The following symbols indicate important safety warnings and precautions throughout this manual: WARNING indicates that serious bodily harm or death may result from failure to adhere to the precautions. CAUTION indicates that damage to equipment may result if the instructions are not followed. NOTE suggests optimal conditions and provides additional information. WIRELESS features and functions that require a Handheld Controller. 1.1 Viewing Precautions Do not view an actively emitting infrared or visible light from the side or top of the light (close to or on beam) from a range of less than 4 ft. (1.2 m). A safe limit for near-infrared viewing, established by the American Conference of Governmental and Industrial Hygienists (ACGIH), is 65 mw/in 2 (10 mw/cm 2 ) as the maximum exposure limit for viewing for up to 16 minutes. This power density can be produced at the lens surface when actively emitting infrared light. 1.2 Battery Precautions Use extreme caution when handling the light. This product is capable of generating enormous shortcircuit currents. Remove all jewelry (bracelets, metal-strap watches, rings) before attempting to handle or remove the batteries. Charge your battery periodically. Permanent damage and reduced capacity will result if the battery is not correctly maintained. The rate of battery self-discharge is very dependent upon temperature. The warmer the temperature, the faster the batteries will discharge. Lights that have been stored will usually require a top-up charge before they are put into service. The most accurate battery health status reading is obtained when the unit has been in a dark location and in off mode for at least 24 hours Carmanah Technologies Corporation 4

5 1.3 Wireless Precautions Keep the Handheld Controller at a distance of at least 3 ft. (1 m) from the antennas of lights or other Handheld Controllers. It transmits a powerful radio signal that could damage sensitive receiver circuitry if operated at close range. 1.4 Regulatory This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications; however, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off or on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna; Increase the separation between the equipment and receiver; Connect the equipment into an outlet on a circuit different from that to which the receiver is connected; Consult the dealer or an experienced radio/tv technician for help. This Class [B] digital apparatus complies with Canadian ICES-003. Cet appareil numérique de la classe [B] est conforme à la norme NMB-003 du Canada. 1.5 Warranty Disclaimer This manual will familiarize you with the features and operating standards of the product. Failure to comply with the use, storage, maintenance, or installation instructions detailed in this manual could void the user warranty. Changes or modifications not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment. Installation work must be done by a qualified person(s) in accordance with all application local codes and standards. 1.6 Recycling This product required the extraction and use of natural resources. It may contain substances that could be harmful to the environment or human health if improperly handled at the product s end of life. In order to avoid release of such substances into the environment and to reduce the use of natural resources, we encourage you to recycle the product in an appropriate way that will ensure most of the materials are reused or recycled appropriately. Check your local municipality for electronics recyclers Carmanah Technologies Corporation 5

6 The symbol indicates that this product complies with the European Union s requirements according to Directive 2002/96/EC on waste electrical and electronic equipment (WEEE). The battery is a rechargeable lead-acid battery. Consult your local laws for information on recycling. 1.7 Handling The Light Housing Assemblies (LHA) contain glass components. Care should be taken to avoid unnecessary shock. Do not drop. The Light Housing Assembly (LHA) is designed to be transported in the horizontal position. DO NOT store, carry, or use the Battery Box Assemblies (BBA) in any position other than the top side up. DO NOT STEP on the top of the Light Housing assemblies (LHA), Battery Box Assemblies (BBA), or Power Control Unit (PCU). Improper cleaning methods and use of unauthorized cleaning agents can injure personnel and damage equipment DO NOT place battery in backwards. Refer to Appendix B, Inclinometer Instructions. The digital inclinometer must be calibrated before use to ensure accurate readings. To calibrate, perform the Superset instructions in Appendix B. DO NOT expose the inclinometer to temperature extremes. DO NOT connect the Power Control Unit (PCU) directly to the DC output of a generator or any unregulated power source. Refer to Section 5 for instructions. DO NOT connect power to the Power Control Unit (PCU) with the control panel power switch set to the "ON" position. Doing so may result in damage to the power sources or the PCU. Refer to Section 5 for instructions. 1.8 Abbreviations The following is a list of abbreviations used in the description of Airfield Lighting Systems. Some terms listed below may not be used in this document. A ampere AC alternating current AGM absorbed glass mat AH ampere-hour APAPI Abbreviated Precision Approach Path Indicator BBA Battery Box Assembly cm centimeter DC Direct Current FAA United States Federal Aviation Administration ft. foot Hz Hertz ICAO International Civil Aviation Organization 2016 Carmanah Technologies Corporation 6

7 ILS Instrument Landing System in inch IR Infrared kg kilogram lb. pound (US) LED Light Emitting Diode LHA Light Housing Assembly m meter mm millimeter MTBF Mean Time Between Failure NATO North Atlantic Treaty Organization NSN National Stock Number NVE Night Vision Equipment NVG Night Vision Goggle PAPI Precision Approach Path Indicator PCB Printed Circuit Board PCL Pilot Controlled Lighting PCU Power Control Unit RCT Remote Control Transmitter s Second SE Solar Engine STANAG (NATO) Standardization Agreement TDZ Touchdown Zone UFC Unified Facilities Criteria V volt VAC volts, alternating current VDC volts, direct current Location terms Throughout this manual, the terms front, rear, top, bottom, starboard side, and port side are used to describe the views of the light housing assemblies (LHA). Glass lenses are located on the front panel. The power connector and manufacturer s labels are located on the rear panel. The port side is the side to the right when looking at the front of the LHA, and the starboard side is the side to the left when looking at the front of the LHA Limitations of scope This manual provides an overview of Carmanah Precision Approach Path Indicator Systems This manual is not specific to either solar or AC-powered systems, nor is it specific to system configurations within those categorizations. Supplemental information specific to each Precision Approach Path Indicator configuration is supplied with the purchased equipment under separate cover. This manual is for visible light (non-infrared) systems only 2016 Carmanah Technologies Corporation 7

8 2.0 Equipment Characteristics The Carmanah PAPI is an approach path indicator that utilizes highly-efficiency light emitting diode (LED) light sources to provide glideslope guidance to aircraft on final approach to landing. General Description The Carmanah PAPI provides glideslope guidance to pilots on approach to landing that indicate an aircraft s vertical position with respect to the proper glideslope. Light emitting diodes (LEDs) provide corridors of red and white lights emanating from a location that is typically off to the left side of the landing zone. The PAPI is composed of a power control unit, a battery box assembly, solar panels and two or four light housing assemblies. Each light housing assembly (LHA) projects beams of steady white and steady red light. The indication for proper glideslope is two LHA showing a red light and the other two showing a white light to the pilot on approach to landing. When the aircraft is well above the proper glideslope, then the pilot sees white lights from all four LHA. When the aircraft is above the proper glideslope, then the pilot sees white lights from three LHAs and a red light from one LHA. When below the proper glideslope, then the pilot sees red lights emanating from three LHAs and a white light from one LHA. When well below the proper glideslope, then the pilot sees red lights emanating from all four LHAs. General Performance Specifications Carmanah provides a variety of options and alternatives for its LED-based Precision Approach Path Indicators (PAPI) and Abbreviated Precision Approach Path Indicators (APAPI). All models have the following characteristics: 2 or 4 Light Housing Assemblies for the 4-box configuration signals are compliant with L880 for four LHA systems and L-881 (2 LHA) 5 levels of intensity radio remote control (optional) configured for fixed installations battery operation, 24 VDC batteries charged by 95 to 250 VAC, 50 or 60Hz batteries charged by solar panels (optional) tilt switch (optional) photocell for autonomous operation (optional) inclinometer frangible couplings for solar panel array, power control unit and LHAs All Carmanah PAPI Light Housing Assemblies (LHAs) are constant voltage fixtures. Light output is PWM controlled via integrated LED drive circuitry within each LHA. Major Components The PAPI system is comprised of the following major components: Two or four light housing assemblies (LHA) Power control unit (PCU) Battery box assembly (BBA) (solar only) Solar panel array (solar only) Also included are: Inclinometer 2016 Carmanah Technologies Corporation 8

9 One BBA to PCU cable Four LHA cables Solar Panel to battery box connection cables (solar only) Flexible conduit and junction boxes (rigid subterranean conduit not supplied) General arrangement of a 4-LHA permanent, solar PAPI Light Housing Assembly The light housing assemblies (LHA) are 14.2 inches (360 mm) wide, 30.7 inches (780 mm) long, and 7.6 inches (194 mm) high. The weight of an LHA is 23 lb. (11 kg). Light Housing Assembly (LHA) 2016 Carmanah Technologies Corporation 9

10 Light Housing Assembly (LHA) dimensions (mounting legs not shown) Power Control Unit The LHAs are powered and controlled from the power control unit (PCU). The PCU box is 15.5 by 12 by 6.3 inches (36 x 31 x 15 cm). The PCU requires 24 VDC and uses approximately 220 W of power when the four LHAs are on at the highest intensity (daytime) setting. Power Control Unit (PCU) general arrangement The PCU control panel has switches for system on-off control, radio remote or local operation, and five for intensity levels. Local operation is manual control of the PCU switches Intensity step 5 is high (100%), intensity step 4 is 20%, intensity step 3 is 4%, intensity step 2 is 0.8% and the lowest intensity step 1 is 0.16%. The PCU control panel also has toggle switches for tilt switch bypass and to enable photocell operation Carmanah Technologies Corporation 10

11 Note: Remote radio control via the Carmanah Handheld Controller provides three intensity steps: 100% (Step 5), 20% (Step 4) and 4% (Step 3) Power Control Unit (PCU) control panel. On the bottom of the PCU are two compression fittings for flexible conduit to the left and right of the support leg fitting. The first compression fitting is the entry point for providing 24VDC from either the battery box or other regulated DC source, depending on the system configuration. The second compression fitting provides the exit point for the 24VDC power and control lines that feed the each LHA. The PCU may also have either a photocell, antenna (or both) mounted on the top of the enclosure depending on the system configuration. Also, if applicable, the PCU will contain the radio module for remote activation. Power Control Unit (PCU); power input and power output and signal connections; support leg fitting (extension not shown) 2016 Carmanah Technologies Corporation 11

12 Battery Box Assembly Note: The following section describes and illustrates the large 500AH battery box and solar charge system. Components and configurations will vary depending on the system configuration. The 500AH system is contained in a steel enclosure 24 X 48 X 28 inches in size and has 4 solar panel power input cables on the back side. This box does not have frangible couplings and is not bolted to the ground but simply set in place with the large weight of the box sufficient to keep it in position. A photo of the outside back of the box is shown below. All PAPI battery boxes have an AC battery charger on the inside. This provides a means of charging or operating the PAPI system during unexpected periods of low sun light, recognizing the high duty cycle of PAPI usage. 500Ah battery box assembly rear view Inside the enclosure there are 4 8D framed batteries mounted on the bottom. On the inside back panel of the enclosure are the solar charge controller (on the left) and 4 DIN rail mounted circuit breakers (in the center). A photograph of the inside of the 500AH battery box is shown below: 500AH Battery box assembly interior 2016 Carmanah Technologies Corporation 12

13 Located on the exterior of the battery box on the port side are the AC power receptacle and the DC power-out fitting and lead wires, which provides voltage to the power control unit (PCU) Battery Box AC inputs and DC output (to PCU) 500 AH Battery Box Dimensions (inches) Inclinometer A digital inclinometer is included to set the side-to-side level and tilt angles of the LHA. Instructions for its use are contained in the Appendix Carmanah Technologies Corporation 13

14 Digital inclinometer 3.0 Theory of Operation 3.1 Light Housing Assembly (LHA) Light-emitting diodes (LED) have significant advantages over conventional lighting. Estimates of LED lifetimes range from 100,000 hours up to 10,000,000 hours, which can be compared to the 1,000 to 2,000 hours for conventional incandescent bulbs. The LED is a solid-state device with no fragile glass bulbs or filaments that are susceptible to shock and vibration. And the LED is significantly more efficient at conversion of electrical power into illumination than conventional lighting. Besides being more efficient, there are no losses through filters, so that depending on the color, the efficiency of LED is a factor of 5 to 20 times greater than incandescent bulbs. Thus LED-based lighting has much low power consumption and requires small diameter cables for continuous operation. In addition, the light beam from the LED can be formed to be directional, so that light does not need to be wasted in directions where it is not desired or useful. There is also increased safety in handling because the LED does not get significantly hotter than its environment. In addition, an LED light has multiple sources which permits continued operation if it experiences a failure or damage. The light housing assembly (LHA) utilizes a row of high power LEDs to generate light of the required color: red for the bottom corridor and white for the top corridor. The signal format seen by the pilot is illustrated in the figure below. Signal format as seen by pilot on approach to landing for the 4-box configuration. Light emitting diodes (LEDs) provide corridors of red and white lights emanating from a location that is typically off to the left side of the landing zone. Each of the light housing assemblies (LHAs) projects beams of steady white and steady red light. The indication for proper glideslope is two LHAs showing a red light and the other two showing a white light to the pilot on approach to landing. When the aircraft is well above the proper glideslope, then the pilot sees white lights from all four LHAs. When the aircraft is above the proper glideslope, then the pilot sees white lights from three LHAs and a red light from one LHA. When below the proper glideslope, then the pilot sees red lights emanating from three LHAs and a white light from one LHA. When dangerously well below the proper glideslope, then the pilot sees red lights emanating from all four LHA Carmanah Technologies Corporation 14

15 3.2 Power Control Unit (PCU) The Power Control Unit (PCU) receives 24 VDC power from the Battery Box Assembly (BBA) and control signals from a radio remote control receiver (optional). The PCU sends power and control signals to each of the Light Housing Assemblies (LHAs). The PCU has switches on its control panel to select the operating mode of the PAPI and provide local system operation. Power Control Unit (PCU) control panel. The toggle switches on the top row of the PCU control panel are used to: turn the system on and off; select radio remote control or local manual control; and one of 5 intensity steps. The toggle switches on the bottom of the PCU control panel are used to enable and disable autonomous photocell control of day or night intensity settings; and enable or disable the tilt switches on each LHA. Note: Remote radio control via Carmanah s Handheld Controller provides three intensity steps: 100%, 20% and 4% 3.3 Charging and AC-Powered Operation (Solar Primary) The 500AH BBA contains 4 12-VDC, 250 AH AGM-type batteries that supply 24 VDC to the PCU. The BBA plugs into the PCU. The batteries of the BBA are recharged by 95 to 250 VAC, 50 or 60Hz, which is input on the side of the BBA or by the solar panel array. There is a circuit breaker with an on-off switch inside the BBA. The solar charge controller is located inside the BBA. When AC Charging is being used, the AC charger will charge the batteries, and the system will revert to solar automatically when the AC is disconnected or turned off. DO NOT store, carry, or use the Battery Box Assemblies (BBA) in any position other than the top side up. DO NOT STEP on the top of the Battery Box Assemblies (BBA) Carmanah Technologies Corporation 15

16 4.0 Installation 4.1 System Overview See fixture placement guidelines contained in this section System overview Top View Notes: 1. The above diagram is for general reference and applies to both 2-fixture and 4-fixture systems and to base can and conduit only cable routing configurations. 2. The Power Control Unit (PCU), is common to both solar and AC-powered systems. 3. See section 4.8 for electrical connectivity details Carmanah Technologies Corporation 16

17 System overview Rear View Notes: 1. The above diagram is for general reference and applies to both 2-fixture and 4-fixture systems and to base can and conduit only cable routing configurations. 2. The Power Control Unit (PCU), is common to both solar and AC-powered systems. 3. See section 4.8 for electrical connectivity details Carmanah Technologies Corporation 17

18 4.2 Site Design For permanent installation a concrete pad should be placed under each LHA in accordance with the local regulatory agency requirements. The illustration below shows an example of a mounted LHA with the earth shown as a semitransparent green so the concrete can be seen both above and below ground level. The concrete pad must be at least 0.3 meters in depth, and up to 1 meter in depth depending on ground conditions to assure stability. Pad, mounting, and junction box arrangement Minimum pad dimensions with 0.3 m thickness Note: Overall pad dimensions above shown in inches Carmanah Technologies Corporation 18

19 Note that the pad must be no less than 0.3 meters thick to conform to specifications and may be a thick as 1 meter depending on the terrain. The pad should extend a few centimeters above the earth for drainage. The LHA is mounted to the concrete using the supplied anchor bolts and sleeves. PAPI LHA Configuration as recommend by the FAA Note: The above diagram shows base cans installed in the concrete for cable routing purposes. This is one option for cable routing however, it is not required for installation of a Carmanah PAPI system. See section 4.4 for more details Carmanah Technologies Corporation 19

20 4.3 Installation of the Light Housing Assemblies Fixture Placement The PAPI system is placed to the left of the runway as seen by the approaching aircraft across from the touchdown zone. The location is determined based on the type of aircraft, the grade of the runway, the nominal glideslope angle, and the height of the LHA above the ground. Note that the site requirements are more complex than illustrated in this document as they must take into consideration the aircraft type, the grade of the runway, and whether or not there is an ILS. In addition, there are different rules for a general aviation runway used by non-jet aircraft. A table with general guidelines for lateral fixture placement is located below: Fixture Placement Organization Number of fixtures Distance from runway edge to first fixture ft (m) Distance between fixtures ft (m) FAA 2 50 (15.2) 20 to 30 (6.0 to 9.1) FAA 4 50 (15.2) 20 to 30 (6.0 to 9.1) ICAO (10.0) 19.7 (6.0) ICAO (15.0) 29.5 (9.0) Example from ICAO for lateral positioning of a 4-LHA system Note: The above is for general reference ONLY, ensure to reference latest versions of all relevant national or international guidelines for correct placement, alignment and operation of PAPI systems Carmanah Technologies Corporation 20

21 Diagram of the layout on the runway for PAPI Light Housing Assemblies (LHA) from FAA AC 150/ d. This is an example only. **PAPI system set-back distance is calculated in consideration of a number of factors pertaining to aircraft size and type and surface topography in close proximity to the runway. Therefore, discussion of set-back distance is beyond the scope of this document. The installer is responsible for placing the LHAs in accordance with the specifications from the applicable regulatory agency, for example FAA or ICAO Carmanah Technologies Corporation 21

22 For permanent installations, install the frangible couplings, tubing, and threaded rod on the concrete pad for the LHA. Carry the light housing assembly to the location adjacent to the runway. Orient the LHA so that its front (the side with the glass lenses) is facing the approach end of the runway. Rotate the LHA until the side of the weather cover is parallel to the runway centerline. Plan view indicating the distances between the three legs of the LHA Note: Dimensions in inches. Note: See section 5.0 for instructions on aiming fixtures. Side view of an LHA on frangible legs, set for a 3 glideslope. Procedure for checking correct alignment with runway edge Alignment in the azimuthal direction can be checked by measuring the perpendicular distance from the runway centerline to a side of the weather cover, then setting a mark the same distance forward of the LHA and perpendicular to the runway centerline. The LHA is then rotated until the mark is visually sighted along the same edge of the weather cover from which the distance to the runway centerline was measured. Note that either side of the weather cover can be used, so long as the same side is used for the distance measurement and sighting. Also note that any distance forward of (or backward from) the LHA can be used, but if an equal distance is used, then it can be marked with any linear length (e.g. a string) and does not require a tape measure Carmanah Technologies Corporation 22

23 4.4 Cable Routing: Option 1: FAA Base Can Cable Routing In the following example, FAA style base cans are used as a cable routing juncture and access point between the sections of subterranean rigid conduit. Note: Junction boxes and flexible conduit are supplied. Base cans, mounting flanges and rigid conduit are not supplied and must be ordered separately. Note: the FAA L-867 base can be mounted in different locations: Beneath the PAPI fixture (in the concrete) Behind the fixture (in the concrete) Behind the concrete pad (in compacted gravel) Option 2: Conduit Only No Base Cans: In the following example, rigid conduit is buried directly behind the LHA concrete pads. For this method, preassembly of conduit segments with cables installed is necessary. Note: Junction boxes and flexible conduit supplied. Rigid conduit is not supplied and must be ordered separately Carmanah Technologies Corporation 23

24 Rigid Conduit and Wiring Routing, Pre-Burial Assembly (Option 2 No Base Cans) Note: The following depiction of pre-assembly of rigid conduit and wiring does not apply and is not required for base can wiring configurations *See section 4.8 for electrical connection information To next LHA From PCU or LHA Section View of rigid conduit Tee junction Step 1: Pull power wire and control cable sections through horizontal conduit sections Carmanah Technologies Corporation 24

25 Step 2: Install Tee junction between horizontal conduit sections. Step 3: Feed power wires and control cables through vertical segment and connect to Tee Carmanah Technologies Corporation 25

26 Step 4: Feed power wires and control cable through threaded hole in juncion box and install junction box. Step 5: Place rigid conduit subassembly into trench behind LHA concrete pads. Cover with appropriate fill material Carmanah Technologies Corporation 26

27 4.5 Installation of the Power Control Unit For solar applications, the PCU is typically mounted on the same cement pad as the battery box and solar panel array. The PCU is mounted to the cement pad via a single 2 or 4-bolt base flange and either pre-set studs or wedge anchors. Enough space should be provided around the PCU for safe passage and maintenance with respect to the surrounding equipment. 4.6 Installation of the Battery Box Assembly The 500AH battery box shown in this manual is sufficiently heavy to rest in place without additional securement, and as a result of the weight, it is not supplied with frangible couplings. Systems requiring smaller solar engines with smaller battery boxes may have a combination of frangible and nonfrangible legs. Below are images of the 500Ah, 110Ah and 75Ah battery boxes. 110 Ah and 500 Ah battery box configurations The frames for the solar panels and battery boxes should be grounded to a standard grounding rod driven into the earth near the installation and connected to the metal frame using 10 gauge or larger wire. Note: Due to the weight of the 500 Ah battery boxes, the boxes should be positioned as far outboard from the last PAPI fixture as is practical Carmanah Technologies Corporation 27

28 4.7 Installation of Solar Panels Solar panel arrays are typically mounted on the same cement pad as the battery box and power control unit. Solar panel arrays are constructed differently depending on the system size and required tilt angle. The required tilt angle of the solar panels is determined prior to manufacture based on the latitude of the deployment site. The solar array is built to provide the required tilt angle and is not adjustable. Assemblies are supplied with standard MC4 style connectors and may have a central junction box depending on the system sizing. Instructions are supplied under separate cover for specific system configuration. 2-Panel Array Below is an example of a low-angle solar panel array that is comprised of two 275W panels and a tube and rail framing system. This system is generally used only with an APAPI, or in areas with high solar irradiance and a moderate usage profile for the PAPI. The 4- Panel Array will be shown in the following section. This system below is attached to the cement pad via pre-set studs or wedge anchors. Solar array assembly example with tube and rail frame and frangible couplings. The frames for the solar panels and battery boxes should be grounded to a standard grounding rod driven into the earth near the installation and connected to the metal frame using 10 gauge or larger wire. 4-Panel Array Overview Similar to the 2-panel array, but due to the size of the cross members, the 4-panel array is provided in two segments with a coupler in between. In the example shown below, the system is configured for a non-equatorial installation, which means that the panels are at a higher angle. As a result, an additional cross support is provided for security during installation. Each of the panels is provided with 2 C section supports which are bolted to the longer of the sides of the panel. The C s should be oriented to point toward the middle of the panel. Unlike the 2-panel systems, the 4-panel system is too large to be conveniently carried. Therefore, the base of the support structure is assembled first. The long, horizontal lengths of the support are in two segments each. One of the segments for each support has a 2016 Carmanah Technologies Corporation 28

29 coupler mounted on it. The other side of the support is screwed into the coupler for form the long horizontal support pole. 4-Panel Array Assembly Steps 1. Assemble the 3 upright sections of the supports. These are composed of 2 mounting flanges, 2 frangible couplers, a tall and a short vertical leg (tubular) and a cross brace at the base. A photo of this structure is shown below: 2. Assemble the 3 upright supports to the horizontal supports as shown. It is important to temporarily install 4 of 8 of the C channels between the two horizontal supports in order to assure that the spacing of the horizontal supports is correct. The crossbar at the base of the vertical supports is adjustable to assure a good fit. This is shown in the photo above and below: 3. With the support structure assembled, anchor the structure to a concrete pad. Be sure the panels are oriented properly - which is South in the Northern Hemisphere and North is the Southern Hemisphere. As an easy check the panels should be pointed at the Sun at noon in your location. 4. Remove the C channels that were temporarily installed and install them on the solar panels. Mount the 4 solar panels. This is done using the provided clamps that mount around the horizontal support structure. This is most easily accomplished by placing the upper part of the panel on the upper support. Have one person hold the foot of the panel to keep it horizontal. It is then easy for the second person to move the C channels about the upper support until the clamps align properly. The panel can then be lowered gently and the lower set of clamps installed. This is done for all 4 panels and the resulting structure is shown below Carmanah Technologies Corporation 29

30 With the panels in place, and the solar battery box installed nearby, the 4 sets of solar panel plugs are connected into the 4 solar input plugs on the back of the solar battery box. This box is the source of power for the solar PAPI. There are circuit breakers within the box for each panel and a large Knife switch for turning the entire system on. Be sure all wiring with the PAPI is finished and checked prior to engaging the knife switch-then position the solar panel circuit breakers to the on position Carmanah Technologies Corporation 30

31 4.8 Electrical Connections Required components, assembly steps and order of operations are unique to specific system configurations. Supplemental documentation for specific systems may supplied under separate cover. Power is supplied to the PCU from the battery box or other DC source via supplied power cable and flexible conduit. Power and control lines are subsequently fed to the external PCU junction box. From the PCU junction box, power and signal is fed to each LHA junction box via rigid conduit. Within each LHA junction box, power and signal lines are connected in parallel to the supplied terminal strips. From the first junction box, subsequent LHA fixtures are wired in a similar manner with the power and signal lines running through the rigid conduit between fixtures. Cabling overview Notes: For LHAs using a tilt switch, the tilt switch cable is run through the same conduit with the tilt sensors being connected together within the junction boxes. Junction boxes, flexible conduit, power wires and signal cables are supplied. Rigid conduit is not supplied* For FAA style base can configurations, base cans, mounting plates and rigid conduit are not supplied as standard equipment and must be ordered separately*. The LHAs should be grounded to a standard grounding rod driven into the earth near the installation and connected to the LHA chassis using 10 gauge or larger wire Carmanah Technologies Corporation 31

32 4.8.1 Electrical Connections - Overview LHA electrical connections are made within supplied junction boxes. There are three separate wires coming from the output of the PCU, a red single conductor wire for + 24 volts, a black single conductor wire for DC return, and a 6 conductor cable for control. These wires are designed to be inside a flexible conduit section (provided) and terminate in a junction box (also provided), all of the junction boxes provided are the same and can be used at any station. There are a total of 5 junction boxes (3 for a 2-LHA system) that must be wired, the first near the PCU and the other 4 behind each of the LHA s. The PCU and LHAs have 2 meter pigtails of wire coming out of the bottom of each box for connection to power and control. Each Junction box has 3 connection points on the bottom; 2 will be used and the 3 rd will have a plug installed. The flexible conduit from either the PCU or the LHA should terminate in one of the holes; there is a flex conduit fitting to make the connection. The other hole is used to connect the ridged conduit (not provided) that runs underground with vertical T sections protruding up above ground near the PCU and LHA s. Photographs of the wiring of the junction boxes is shown in the following section. It is important to note that the vertical fixed conduit section contains both the wires coming from the PCU, or previous LHA, and the wires going to the next LHA in the chain. The flexible conduit contains only the wires going to the LHA just in front of the box. Junction boxes can be located either behind the LHA mounting pad or at a convenient location near the LHA. The length of the flexible conduit connection between the LHA and the junction box should be 2 meters or less Carmanah Technologies Corporation 32

33 4.8.2 Electrical Connections to LHAs - Junction Boxes Cable Routing and Creating Pass-Through Connections via Junction Boxes 1. Feed power and control lines in to first junction box. a. The first group of power wires and control cables will be fed from the PCU. b. The second group of power wires and control cables will be fed from the next junction box at the next LHA. 2. Remove a portion of the outer jacket on the 6-conductor control cable. a. Using the supplied ring terminals, create parallel connections between the two groups of control cable conductors. b. Ensure that all like-colored conductors are paired together. c. Note: There are no parallel power connections created at this step Carmanah Technologies Corporation 33

34 Creating Parallel Power Connections 3. Add supplied terminal jumper clips to terminals above existing power connections. a. Note: Fasten jumper clips with a single screw only (see above). 4. Feed in power wires and control cable from the LHA into the flexible conduit, and into the junction box Carmanah Technologies Corporation 34

35 Create Final Connections to LHA 5. Remove a portion of outer jacket from 6-conductor control cable. a. Attach individual control line wires to upper terminals on the terminal block. b. Attach power wires to upper terminals on terminal block. c. Note: Verify that all connections match in terms of wire color before supplying power to the system. Note: Tilt switch cable routing and connectivity not shown Carmanah Technologies Corporation 35

36 4.9 Tilt Switch (optional) Place the "Tilt Switch Bypass" toggle on the PCU control panel in the disable (up) position. Clean the bottom of the tilt switch assembly. Place the inclinometer against the bottom of the tilt switch assembly. Loosen the screw on the front side of the tilt switch bracket. Adjust the tilt switch with the inclinometer firmly against the bottom of the tilt switch until the inclinometer reads level within ±0.05 deg (3 arcmin). Tighten the screw that holds the tilt switch in position. If this LHA is the last LHA in the chain of cable connections (typically the LHA that is closest to the runway) place the tilt switch toggle on the bottom of the LHA into the position pointed towards the rear of the LHA by first pulling the toggle out past its stop, switching the toggle, then letting the toggle spring back. DO NOT FORCE the toggle switch, just pull it out before moving to change positions. This action completes the tilt switch series electrical circuit. Tilt switch assembly. Note the screw on the front side (on the right in this picture). Note: Image above is of a portable configuration LHA. Fixed LHA configuration may differ. If this LHA is not the last LHA in the chain of cable connections, place the tilt switch toggle on the bottom of the LHA into the position pointed towards the front of the LHA by first pulling the toggle out past its stop, switching the toggle, then letting the toggle spring back. DO NOT FORCE the toggle switch (pull it out to change positions) Carmanah Technologies Corporation 36

37 Tilt switch toggle on the bottom of the LHA. Note: Image above is of a portable configuration LHA. Fixed LHA configuration may differ. To enable the tilt switches after all LHA are set at the proper incline and horizontal angles, place the "Tilt Switch Bypass" toggle on the PCU control panel to the down position. Note that the purpose of the tilt switch is to automatically remove power from the PAPI if any LHA is off of its proper setting by more than ½ degree, for example if an LHA is displaced by a vehicle. The use of the tilt switches is optional Carmanah Technologies Corporation 37

38 5.0 Aiming 5.1 Overview The following example is for aiming a 4-LHA system in accordance to FAA and UFC regulations: The light housing assembly nearest the runway ( LHA-1 ) should be placed with the front (the side with the lenses) facing towards the approach end of the runway (the approach end is the end from which aircraft will be coming) and with the sides of the LHA parallel to the runway at a distance from the runway as specified by the appropriate regulatory agency. The location of LHA-1 and tolerances on the placement of the LHA-1 must be in accordance with the appropriate regulatory agency. For example, the tolerance on azimuthal aiming in UFC and AC 150/ D is ±0.5 deg. Adjust the incline angle of LHA-1 with the procedure in Section 4, except that for a standard FAA installation, the LHA nearest the runway is set at an incline that is 30 arcminutes (0.5 ) above the glide path within ±3 arcmin (0.05 deg). The second light housing assembly ( LHA-2 ) is placed further from the runway edge than the first LHA, with its front facing towards the approach end of the runway and with its sides parallel to the runway at a distance from LHA-1 as specified by the appropriate regulatory agency. The location of LHA-2 and tolerances on its placement must be in accordance with the appropriate regulatory agency regulations. For example, the tolerance on azimuthal aiming in UFC and AC 150/ D is ±0.5 deg and the beam centers of all of the LHA must be within ±1 inch of a horizontal plane. Adjust the incline angle of LHA-2 with the procedure in Section 4, except that for a standard FAA installation, LHA-2 is set at an incline that is 10 arcminutes (0.17 ) above the glide path within ±3 arcmin (0.05 deg). The third and fourth light housing assemblies are placed further from the runway adjacent to LHA-2 and spaced with the same distance as between LHA-1 and LHA-2. The locations of LHA-3 and LHA-4 and tolerances on their placement must be in accordance with the appropriate regulatory agency regulations. For example, the tolerance on azimuthal aiming in UFC and AC 150/ D is ±0.5 deg and the beam centers of all of the LHA must be within ±1 inch of a horizontal plane. Adjust the incline angle of LHA-3 with the procedure in Section 4, except that for a standard FAA installation, LHA-3 is set at an incline that is 10 arcminutes (0.17 ) below the glide path within ±3 arcmin (0.05 deg). Adjust the incline angle of LHA-4 with the procedure in Section 4, except that for a standard FAA installation, LHA-4 is set at an incline that is 30 arcminutes (0.5 ) below the glide path within ±3 arcmin (0.05 deg). There must not be any obstructions in front of (towards the approaching aircraft) the four LHA in order for the pilot to see both LHA on the approach to landing. The obstruction clearance must be in accordance with the appropriate regulatory agency. The ICAO standards have an obstacle protection surface 0.9 below the aim angle of the outer (lower) LHA Carmanah Technologies Corporation 38

39 Example table from the FAA for aiming 4-LHA and 2-LHA systems: 2016 Carmanah Technologies Corporation 39

40 Example diagram from ICAO for aiming 4-LHA systems **PAPI system set-back distance (D1) is calculated in consideration of a number of factors including aircraft size and type and surface topography close to the runway. Therefore, discussion of set-back distance is beyond the scope of this document Carmanah Technologies Corporation 40

41 Example diagram from ICAO for aiming 2-LHA systems **PAPI system set-back distance (D1) is calculated in consideration of a number of factors including aircraft size and type and surface topography close to the runway. Therefore, discussion of set-back distance is beyond the scope of this document Carmanah Technologies Corporation 41

42 5.2 Aiming the fixtures (LHAs) To set the LHA level and at the proper tilt angle, first set the nuts on the threaded rod on all three legs so that they are near the middle of their adjustment range. To set the LHA level side-to-side, place the inclinometer in the middle of the front of the base plate, as shown below. If the LHA is dirty, then first clean the base plate in the spot where the inclinometer will be placed. Rotate the inclinometer so that it is aligned with the front edge of the base plate, perpendicular to the runway direction. To set the side-to-side angle of the LHA to level, place the inclinometer in the middle of the front of the base plate so that it is aligned with the front edge of the base plate. The incline angle is adjusted by turning the nuts on the threaded rods on each of the front legs. Use a wrench to adjust the positions of the nuts. First loosen all of the outside nuts, both on top and bottom. Leg height adjustment is made by turning the inner nuts adjacent to the spherical washers. The outside nuts are used to lock the position when the adjustments are completed. Adjust one front leg shorter and the other front leg longer until the inclinometer indicates level within ±0.05 deg (3 arcmin). Clean the top of the inclinometer bracket. Place the inclinometer on the top of the inclinometer bracket and tighten the thumb screws. A picture that shows the proper position on the inclinometer bracket is shown below Carmanah Technologies Corporation 42

43 To adjust the legs in order to set the proper incline angle of the LHA, place the inclinometer on the inclinometer bracket. Adjust the rear leg of the LHA until the incline angle is proper according to the appropriate regulatory agency. For example, for a standard installation of a 4-box configuration and glideslope is 3 degrees, then set LHA-1 (nearest to the runway) to 3 deg 30 min, LHA-2 (next adjacent) to 3 deg 10 min, LHA-3 to 2 deg 50 min, and LHA-4 (outermost) to 2 deg 30 min. Adjust until the inclinometer indicates the proper angle within ±0.05 deg (3 arcmin) Move the inclinometer back to the position for measurement of the side-to-side level. Repeat the level adjustment by moving one leg down and the other up and equal amount. Move the inclinometer back to the inclinometer bracket. If the incline angle has changed, repeat adjustment of the incline angle until it is set properly as before. Continue these two adjustments until both the incline angle and the side-to-side level are within the tolerance. Secure the leg length adjustment by tightening the outer two nuts on each leg until the nuts are snug against the stops. Remove the inclinometer from the LHA. NOTE: **Ensure to reference correct regulatory aiming angle guidelines for 2-LHA and 4-LHA systems Carmanah Technologies Corporation 43

44 6.0 Power Control Unit Operating Procedures 6.1 Power Control Unit Switches The Power Control Unit (PCU) has nine toggle switches on its control panel. The two switches on the left of the top row are for control. The next five toggle switches are used to select the intensity step. The toggle switch on the left side, below the top row enables or disables autonomous photocell operation used for night dimming. The toggle switch on the bottom is to enable or disable the tilt switch. Power Control Unit (PCU) control panel layout. The toggle switches on the top row are: The switch on the left-hand side marked with "PWR" turns the system on and off. When this switch is in the off position, no power is supplied to the LHAs and radio remote controller signals will not be received by the PCU The local-radio switch determines if the PCU options are chosen by the remaining switches on the PCU control panel or by the radio remote controller. If this switch is in the "RADIO" (radio) position, then the PCU operation options are activated by the radio remote controller (optional). If this switch is in the "LCL" (local) position, then the PCU options are selected by the positions of the switches to the right and below of this switch The intensity switch marked with 5 determines if the corridors of the LHAs are turned on the high setting (100% intensity) when in local control mode. If the local-radio switch is in the "RADIO" position, then the position of this switch is ignored The intensity switch marked with 4 determines if the corridors of the LHAs are turned on the 20% intensity level when in local control mode. If the local-radio switch is in the "RADIO" position, then the position of this switch is ignored The intensity switch marked with 3 determines if the corridors of the LHAs are turned on the 4% intensity level when in local control mode. If the local-radio switch is in the "RADIO" position, then the position of this switch is ignored 2016 Carmanah Technologies Corporation 44

45 The intensity switch marked with 2 determines if the corridors of the LHAs are turned on the 0.8% intensity level when in local control mode. If the local-radio switch is in the "RADIO" position, then the position of this switch is ignored The intensity switch marked with 1 determines if the corridors of the LHAs are turned on the lowest setting (0.16% intensity) when in local control mode. If the local-radio switch is in the "RADIO" position, then the position of this switch is ignored. The controls on the bottom of the PCU control panel are: The switch marked with PHOTOCELL ENABLE determines if the photocell is used to switch the intensity high intensity, for daylight flight operations, or step 4 for night flight operations. If the photocell switch is in the "ON" position, then the intensity of the LHA are set by the ambient light intensity (i.e. the photocell is the dominant control), 100% intensity level for day and 20% intensity level for night. When the photocell switch in the PCU is in the "ON" position, the mode switches in the PCU are ignored. The toggle switch marked "Tilt Switch Bypass" is used to defeat the tilt switch cut-off for testing or other special operations. When the "Tilt Switch Bypass" toggle is in the down position, the tilt switch is enabled. When the tilt switch is enabled, the PCU will turn off all power to all LHAs if any LHA becomes misaligned in incline angle of nominal ±0.5 degree. If issues arise with the operation of the tilt switches, use the tilt switch bypass to continue to operate the PAPI system by placing the "Tilt Switch Bypass" toggle on the PCU control panel in the up (tilt sensing disabled) position. 6.2 Power The PAPI operates on nominal 24VDC and uses 220 W at the step 5 (100%) intensity level. The LHA receive 24 VDC power from the PCU. WARNING DO NOT connect the Power Control Unit (PCU) directly to the DC output of a generator or any unregulated power source. Connecting to an unregulated source may result in damage to the PCU and LHA. WARNING Make sure that the power toggle switch is in the "OFF" position when power is applied to the PCU. DO NOT connect power to the Power Control Unit (PCU) control panel power switch to the "PWR" position. Failure to do so may result in damage the power sources or the PCU. The Battery Box Assemblies (BBA) supply 24 VDC to the PCU. The batteries in the BBA can be charged with 95 to 250 VAC, 50 or 60 Hz. The current draw during LHA operation is dependent upon the AC voltage. At 110 VAC the peak current draw is 15 A and at 220 VAC the peak current draw is 8 A. The current draws during charging are smaller. The batteries in the BBA can also be charged from solar panels. AC Power Option There is an option to power the PAPI off of AC power from standard electrical power grids, or generators without solar power. Solar Power can then be added later as on option. For non-solar powered systems the AC to DC power supply is located inside the PCU. The PCU, on the left side bottom, has an AC power input cable coming out through the Flex Conduit fitting. This is a three conductor line with ground, neutral, and line wires using the conventional (ground = green, neutral = white, and line = black) color coding. For systems designed to be wired to either the power grid or solar, there are two additional Red and Black wires coming from the same fitting. Under no circumstance should these two single conductor wires (Red and Black) be wired to AC power. These are for DCpower operation only. Connect AC to the three wires and connect the optional solar (DC) to the red (positive) and black (negative) wires Carmanah Technologies Corporation 45

46 To select AC operation, there are 2 switches on the lower right hand portion of the control panel. One switch turns on the AC power to the power supply, the other connects the output of the power supply to the PAPI system. To run on AC power both switches are placed in the up position as shown in the photo below: For solar operation both switches are turned off. 6.3 Power Control Unit Manual Operation For manual operation from the Power Control Unit (PCU) control panel, the radio-local toggle switch must be in the local ("LCL") position. Note that if all of the intensity level switches are in the off position, then no signal emanates from the LHA. Also note that if the radio-local toggle switch on the PCU is in the radio ("RADIO") position, then the operating intensity is selected from the optional radio remote control receiver. To operate the PCU 1. Before operating the PCU, make sure that the power switch is in the "OFF" position. 2. Set the local-radio toggle switch to the local ("LCL") position. 3. Set all of the intensity step toggle switches on the PCU control panel to the "OFF" position. 4. Move the power toggle switch on the PCU to the "PWR" position. 5. Set one of the intensity step toggle switches to its ON position. Step 1 is the lowest intensity and step 5 is the highest intensity. If more than one of the intensity step toggle switches is in the ON position, then the LHA will operate at the highest step that is switched to the on position Carmanah Technologies Corporation 46

47 7.0 Remote Control and Photocell Operating Procedures In order for a Power Control Unit (PCU) to receive and process the signals for radio remote control, the power switch of the PCU must be in the PWR position and the radio-local toggle switch on the PCU control panel must be in the radio ("RADIO") position. *Radio remote control is optional - See separate the radio remote control manual for set up and operational procedures. Control of PAPI using Photocell The PAPI system may be operated off the installed photocell for systems with this option. For normal photocell operation place the PCU control switch in LCL for local control. Then place the photocell switch in Photocell enable, this is the up position. The PAPI will now operate automatically with no further commands required - changing from day to night mode when the sun goes down. Note that the photocell enable mode will override any other commands that are issued by the controller so, be sure to turn it off for direct local, or radio control. A photo of the control panel in photocell mode is shown below: Two Level Photocell Operation There is an option for the nighttime intensity level to be selected between two different levels for photocell operation. Standard photocell operation is at intensity Level 3. For systems with this option it is possible for the night setting to be switched to Level 4 for a brighter operating point during night operations. This is done by selecting the Photocell Enable mode, and also selecting Intensity Level 4 as shown below. In this case night operations using the photocell mode will be at Level 4. This mode would be used for areas with a large amount of ambient light such as airports located inside of cities, etc. A photo of this mode is shown below: 2016 Carmanah Technologies Corporation 47

48 8.0 Operation in Unusual Conditions 8.1 Unusual Environment and Weather Below Freezing Temperatures If required, clear frost from the exit aperture lenses by wiping them with a clean, soft cloth. Recalibrate the digital inclinometer. Soft Ground and with optional rapid deployment legs (portable systems only) Check the level, angle, and aim of the LHA daily. Snow Clear snow away from the front of the LHA and PCU. If required, wipe the exit aperture lenses with a clean, soft cloth to remove any snow. Heavy Rain If required, clear residual water drops from the exit aperture lenses by wiping them with a clean, soft cloth. Dust storm Clear dust from the exit aperture lenses by wiping them with a clean, soft cloth. 8.2 Emergency Procedures 1. Place the on-off toggle switch on the Power Control Unit (PCU) control panel to the "OFF" position. 2. Turn off the power from the power source. 3. Unplug the cable from the BBA to the PCU. 4. Unplug the cable from the Battery Box Assembly (BBA) to the Solar Array Modules. 5. Unplug the cables from the Solar Array Modules. 9.0 Maintenance 9.1 System Checks Before and After Installation Preliminary Perform all work during appropriate airfield operation and weather conditions. If the LHAs are dirty, rinse the LHA by spraying with clean water and wiping off any debris with a cloth. Clean the exposed surfaces of the lenses according to the instructions in Section 9. Manual Operation Turn the radio-local toggle switch on the PCU to the local ("LCL") position, see Section 5. Place the "Tilt Switch Bypass" toggle on the PCU to the disabled (up) position Carmanah Technologies Corporation 48

49 Operate the LHA in full intensity mode (step 5) according to Section 5. Stand in front of an LHA and place a diffuse reflective surface in front of the weather cover so that you can see the reflection of the beams. CAUTION: DO NOT STARE INTO THE BEAMS. The surface can be a piece of paper, cardboard, or even your clothing. Check that white light is emitted from the top row and red light is emitted from the bottom row Note the intensity of the light on the reflective surface. Move the intensity step 5 toggle switch on the PCU control panel to the "OFF" position, then move the intensity step 4 toggle switch to the ON ( 4 ) position. The intensity of the white and red beams should now be 20% of the step 5 intensity Move the intensity step 4 toggle switch on the PCU control panel to the "OFF" position, then move the intensity step 3 toggle switch to the ON ( 3 ) position. The intensity of the white and red beams should now be 4% of the intensity before the positions of the toggle switches were changed Move the intensity step 3 toggle switch on the PCU control panel to the "OFF" position, then move the intensity step 2 toggle switch to the ON ( 2 ) position. The intensity of the white and red beams should now be 0.8% of the step 5 intensity Move the intensity step 2 toggle switch on the PCU control panel to the "OFF" position, then move the intensity step 1 toggle switch to the ON ( 1 ) position. The intensity of the white and red beams should now be 0.16% of the step 5 intensity. Check the operation of the other LHA in the same manner as for the first LHA in the preceding two paragraphs. Radio Remote Control Operation Turn the radio-manual toggle switch on the PCU to the radio ("RAD") position. Place the "Tilt Switch Bypass" toggle on the PCU to the disabled (up) position. Follow the instructions in the radio remote control manual for testing. 9.2 Maintenance LHAs After installation, the only required maintenance under normal operating conditions is a weekly cleaning of the outer surfaces of the lenses of each of the Light Housing assemblies (LHA). The cleaning procedure is described in Section 9. The lenses should also be cleaned after a storm. Solar Panels (if applicable) After installation, the only required maintenance under normal operating conditions is a weekly cleaning of the solar panels by spraying with clean water and wiping off any debris with a soft cloth. The solar panels should also be cleaned after a storm. 9.3 Periodic Preventative Maintenance No periodic preventive maintenance is required. To maintain readiness, it is recommended that the procedures in Section 9 should be performed every three months Carmanah Technologies Corporation 49

50 9.4 Cleaning the Lenses of a Light Housing Assembly The front surfaces of the lenses of a Light Housing Assembly (LHA) are reached through the front, under the weather cover. Use a clean, soft lint-free cloth or lens tissue to clean the outer surfaces of the lenses. Reach in to clean the lenses. It is best to wipe with a downward motion, and lifting the cloth from the lens surface before repeating the wiping motion. In this way, the dirt and debris is accumulated at the bottom of the lens where it has no effect on the beam. Be careful to apply only light pressure as often the grit on the lens is hard and sharp and will scratch the surface of the lenses. Clean water may be sprayed on the outer surfaces of the lenses. Then use a clean, soft lint-free cloth or lens tissue to clean the outer surfaces of the lenses and wipe the residue water off of the lenses. If the front surfaces of the lenses are very dirty, lens cleaner fluid may be used. Spray or pour a small amount of the lens cleaning fluid on some clean lens tissue of piece of soft cloth, then wipe the lenses in a downward motion, as explained previously. Take another piece of clean, dry lens tissue or soft cloth and wipe the residual lens cleaner fluid off of the lenses with the same downward motion as discussed previously. Note that if lens cleaning fluid is not available, then clean water may be used. NOTE: It is important not to scratch the outer surface of the lenses or leave residue that attracts dust or dirt. CAUTION Be careful to apply only light pressure as often the grit on the lens is hard and sharp and will scratch the surface of the lenses. CAUTION Do not use standard commercial glass window cleaners on the exit windows. While the lens itself is hard, the outer surface is coated and the cleaner may remove or scratch the coating. If necessary, use a standard lens cleaning fluid. Supplies Needed: clean, soft lint-free cloth clean water lens cleaning fluid 10.0 Parts Replacement It is best if replacement of any part is performed in a clean, dry environment. However if necessary, part replacement can be performed while the PAPI-266F is deployed. For greatest safety all power to the PCU should be disconnected, and the LHA cable should be disconnect at the PCU. However, parts replacement in a Light Housing Assembly (LHA) can be performed with the power toggle switch on the Power Control Unit (PCU) control panel to the "OFF" position. In this case, it is recommended that the power toggle switch on the Power Control Unit (PCU) control panel be taped to the "OFF" position so that power cannot be inadvertently applied to the Light Housing Assemblies (LHA) and a tag be placed on the outside of the PCU to indicate that work is underway Carmanah Technologies Corporation 50

51 Exploded view of the PAPI with the parts numbered: 1 - weather cover, LG6514; 2 - electronic enclosure top, LG6570; 3 - electronic enclosure bottom, LG6526; 4 - optics enclosure, LG6521; 5 - base plate, LG6513; 7 - front bezel, LG6461; 8 - primary lens assembly, LG6454; 9 - LED module red, LG6399; 10 - LED module white, LG6596; 11 - deflector/lens cover, LG Removal of LHA Weather Cover Remove four machine screws along the bottom of the rear panel of the LHA weather cover, and five machine screws along the bottom of both sides of the weather cover. Save these screws in a clean, safe place. Slide the weather cover back slightly, then lift the weather cover straight up until it clears the optical assembly. Set the weather cover away from the remainder of the LHA Carmanah Technologies Corporation 51

52 PAPI with the weather cover removed. The front of the PAPI is on the right. The power circuit board is located in the aluminum enclosure at the rear of the PAPI. Note: Portable LHA assembly shown in above photo Tools Needed: Phillips screwdriver 10.2 Replacement of White LED Module Place the power toggle switch on the Power Control Unit (PCU) control panel to the "OFF" position. Disconnect the LHA cable at the PCU. For greatest safety power to the PCU should be disconnected. Remove the LHA weather cover The white LED modules are located on the top row of the optical head assembly. Disconnect the cables to the module that is to be replaced Carmanah Technologies Corporation 52

53 The white LED modules are located on the top row of the optical head assembly. Red modules are located on the bottom row of the optical head assembly. Remove the aluminum tape that is a seal around the white LED module that is being replaced. Mark the position, relative to the optical head, of the LED module, so that the replacement module can be placed in the same position. Use a 3/32-inch hex wrench to loosen the six machine screws that hold the white LED module to the optical head. Remove all of these screws. Hold on to the LED module while removing the screws. Store the screws in a clean, dry place. Separate the LED module from the optical head assembly by lifting it upwards. Remove the gasket (if there is a replacement gasket available). Gasket on the optical head. Obtain a replacement white LED module and gasket. White LED module from LED side Carmanah Technologies Corporation 53

54 Replace the gasket. Place the white LED module against the optical head assembly so that all six slots are aligned with their corresponding screw holes. Replace the six socket head cap screws that hold the LED module to the optical head assembly. Do not tighten yet. Move the LED module up and down until it is in the same location as the LED module that was removed. Note that the location of the original LED module was marked before the screws were loosened. Tighten these screws with a 3/32-inch hex wrench. Use aluminum tape to seal around the white LED module. Aluminum tape seal on the white LED module. Connect the cables. Note that the connector is keyed so that it cannot be inserted in an incorrect orientation. Perform the checks in Section 8 to ensure that the module is functioning properly. Replace the weather cover by reversing the steps. Tools Needed: Philips screwdriver 3/32-inch hex wrench Spare Part Needed: white LED module gasket for LED module aluminum tape 10.3 Replacement of Red LED Module Place the power toggle switch on the Power Control Unit (PCU) control panel to the "OFF" position. Disconnect the LHA cable at the PCU. For greatest safety power to the PCU should be disconnected. Remove the LHA weather cover Carmanah Technologies Corporation 54

55 The red LED modules are located on the bottom row of the optical head assembly. Disconnect the cables to the module that is to be replaced. Remove the aluminum tape that is a seal around the red LED module that is being replaced. Mark the position, relative to the optical head, of the red LED module, so that the replacement module can be placed in the same position. Use a 3/32-inch hex wrench to loosen the six screws that hold the white LED module to the optical head. Remove all of these screws. Hold on to the LED module while removing the screws. Store the screws in a clean, dry place. Separate the LED module from the optical head assembly. Remove the gasket if there is a new gasket available. Obtain a replacement red LED module. Replace the gasket. Place the red LED module against the optical head assembly so that all six slots are aligned with their corresponding screw holes. Replace the six socket head cap screws that hold the LED module to the optical head assembly. Do not tighten yet. Move the LED module up and down until it is in the same location as the LED module that was removed. Note that the location of the original LED module was marked before the screws were loosened. Tighten these screws with a 3/32-inch hex wrench. Use aluminum tape to seal around the red LED module. Connect the cables. Note that the connector is keyed so that it cannot be inserted in an incorrect orientation. Perform the checks in Section 9 to ensure that the module is functioning properly. Replace the weather cover by reversing the steps. Tools Needed: Philips screwdriver 3/32-inch hex wrench Spare Part Needed: red LED module, LG6399 gasket for LED module, LG6520 aluminum tape 10.4 Replacement of an LHA Power Circuit Board Place the power toggle switch on the Power Control Unit (PCU) control panel to the OFF position. Disconnect the LHA cable at the PCU. Remove the LHA weather cover. Remove the six countersunk-head screws from the top of the aluminum enclosure that is mounted in the rear starboard side of the LHA base plate. Remove the top cover of the box. Store the screws and the cover in a clean, dry place Carmanah Technologies Corporation 55

56 Remove the six nuts that hold the power circuit board to the stand-offs. Store the nuts in a clean, dry place. Mark the Molex connectors to indicate the location and orientation relative to the power control board. Carefully lift the circuit board and remove the Molex connectors from the power control board. Obtain a replacement LHA power control board. LHA Power Control Board Insert the Molex connectors in the same location and orientation on the power control board. Make sure that the Molex connectors are fully engaged to the power control board. Carefully replace the power control board into the box and secure the power control board to the standoffs with the nuts. Replace the cover of the box and secure with its screws. Replace the weather cover by reversing the steps. Tools Needed: #1 Phillips screwdriver 1/4-inch wrench or 1/4-inch nut driver Spare Parts Needed: LHA power control board 10.5 Replacement of Batteries in the Battery Box Assembly Place the power toggle switch on the Power Control Unit (PCU) control panel to the OFF position. Disconnect the input AC power cord to the Battery Box Assembly (BBA), if it is connected. Disconnect the solar Array modules to BBA Carmanah Technologies Corporation 56

57 Open the lid of the BBA. Open the main bus switch (if installed). 110Ah Battery Configuration 500AH Battery Configuration (note AC charger not shown) Carefully remove the black cover from the ground side terminal of the batteries. Using both a 1/2-inch and 9/16- inch wrench, loosen the bolt that holds the cable to the battery terminal Carmanah Technologies Corporation 57

58 Be very careful not to touch the wrenches to any other conductive surface. When the cable is free, cover it with an insulating material and pull it away from the battery terminal. Remove the bolt and store it in a clean, dry place. Cover the battery terminal with an insulating material, so that no cables or tools are able to touch the battery terminal. Carefully remove the black cover from the other battery. Using both a 1/2-inch and 9/16-inch wrench, loosen the bolt that holds the cable to the battery terminal. Be careful not to touch the wrenches to any other conductive surface. When the cable is free, cover it with an insulating material and pull it away from the battery terminal. Remove the bolt and store it in a clean, dry place. Cover the battery terminal with an insulating material, so that no cables or tools are able to touch the battery terminal. Carefully remove the red cover from the positive terminal of the batteries. Using both a 1/2-inch and 9/16-inch wrench, loosen the bolt that holds the cable to the battery terminal. Be careful not to touch the wrenches to any other conductive surface. When the cable is free, cover it with an insulating material and pull it away from the battery terminal. Remove the bolt and store it in a clean, dry place. Cover the battery terminal with an insulating material, so that no cables or tools are able to touch the battery terminal. Note: If there is a bus switch installed, it will have to be removed from the positive battery terminal Carefully remove the red cover from the positive terminal of the other battery. Using both a 1/2-inch and 9/16-inch wrench, loosen the bolt that holds the cable to the battery terminal. Be careful not to touch the wrenches to any other conductive surface. When the cable is free, cover it with an insulating material and pull it away from the battery terminal. Remove the bolt and store it in a clean, dry place. Cover the battery terminal with an insulating material, so that no cables or tools are able to touch the battery terminal. Loosen the battery hold down clamps with a 7/16-inch wrench. Remove the nuts and store in a clean, dry place. Remove the battery hold down frame. Remove the battery hold down clamps, which have a hooked end. Note the orientation of the batteries in the BBA. Lift the batteries out of the BBA. Obtain replacement batteries. Note that both batteries should be replaced at the same time. Place the batteries in the BBA in the same orientation as the original batteries. Replace the battery hold-down clamps, battery hold down frame, and the battery hold down clamp nuts. Tighten the nuts so that the battery do not move, but do not over tighten. Connect the cable between the two batteries using the bolts and nuts that held the cable to the battery terminals. Be sure that the cable is oriented so that the red cover is on the positive terminal of one battery and the black cover is on the negative terminal of the other battery. Slide the battery terminal covers over the terminals. Connect the negative-side cable with the black terminal cover to the negative side of the batteries. Slide the black cover over the terminal. Very carefully attach the positive side cable with the red terminal cover to the positive terminal of the battery Carmanah Technologies Corporation 58

59 Be very careful not to let the cable or the wrenches touch any conductive surface. Slide the red cover over the battery terminal. Reconnect the batteries to the charger by closing the main bus switch (if installed). Reconnect the solar panels. Replace the BBA lid and secure the latches. Tools Needed: 7/16-inch wrench 1/2-inch wrench 9/16-inch wrench Spare Parts Needed: 12V AGM batteries (quantity and capacity dependent on system configuration) 11.0 Troubleshooting In the event that the PAPI system not functioning properly, the first action is to ensure that power is being supplied, that the switches of the Power Control Unit (PCU) are set properly, and all of the cables are attached properly Power If there is no light emitted from all Light Housing assemblies (LHA), first check to see if the local-radio toggle switch on the PCU control panel is in the local ("LCL") position and that all of the intensity switches are in the off position. If this is the case, then no light should emanate from the LHAs. Switch the step 5 toggle switch to the ON ("5") position and check for light from the LHAs. If the local-radio toggle switch is in the radio ("RADIO") position, then change the local-radio toggle switch to the local ("LCL") position and the step 5 toggle switch to the ON ("5") position. If there is no light emitted from all Light Housing assemblies (LHA), disable the tilt switches by placing the "Tilt Switch Bypass" toggle on the PCU control panel to the disabled (up) position. If light is now emitted from the LHA, realign the LHA according to Section 4. If there is still no light emitted from the LHA, then check for power along the power train. Determine if the battery bank is charged. Connect the battery charging cord to the Battery Box Assemblies (BBA) and connect to a known working source of appropriate AC power. If the PAPI operates, then the batteries were discharged. Allow sufficient time for the batteries to charge. Remove the BBA to PCU cables from the BBA. Check the voltage at the output connector of each BBA. It should be a nominal 24 VDC, which can be between 22 and 28.8 VDC, depending upon the state of charge. If the voltage is zero, then open the top of the battery box and check the circuit breaker. Reset the circuit breaker and make sure that its switch is in the on position. Connect the BBA to PCU cable to each BBA and remove the BBA to PCU cable from the PCU. Check the voltage at the end of the cable. The voltage should be nominal 24 VDC. If there is voltage at the BBA and not at the end of the cable, then the wrong cable end was connected to the BBA, the connector was not fastened properly, or the cable is defective and must be replaced Carmanah Technologies Corporation 59

60 Plug the BBA to PCU cables into the PCU. Operate the PCU in manual mode according to the instructions in Section 5. Check to be sure that the radio-local switch on the PCU control panel is in the local "LCL" position. If none of the LHAs are functioning in any mode, then disconnect the PCU to LHA cables and check the voltage across pins A and B of the connector. The voltage should be nominal 24 VDC. If there is no voltage out of the PCU, check that the BBA to PCU cables are connected properly. If still no voltage, return the PCU for repair. Connect the PCU to LHA cables to the PCU, and remove the PCU to LHA cables from the LHA. Check the voltage across pins A and B. The voltage should be nominal 24 VDC. If there is voltage at the PCU and not at the end of the cable, then the wrong cable end was connected to the PCU or the cable is defective and must be replaced. Reconnect the PCU to LHA cables LHA Power Control Board If three LHAs operate properly and one LHA does not emit any light and there is voltage at the PCU to LHA cable to the non-functioning LHA, then the most likely cause is failure of the LHA power control board. Place the power toggle switch on the Power Control Unit (PCU) control panel to the OFF position, see Section 5. Disconnect the LHA cable at the PCU. Remove the LHA weather cover by following the procedure in Section 9. Check all of the connections to the receptacles on the power control board enclosure Remove the six countersunk-head screws from the top of the aluminum enclosure that is mounted in the rear starboard side of the LHA base plate. Remove the top cover of the box. Store the screws and the cover in a clean, dry place. Check all of the connections to the LHA power control board. If all of the connections are good, then the most likely cause is failure of the LHA power control board. Replace the power control board in the non-functioning LHA White LED Modules If three LHA operate properly and the other LHA does not emit any white light from the white LED module and there is power to the non-functioning LHA, remove the weather cover according to the instructions in Section 10. Check that the connector to the non-functioning white LED module is connected properly. If the white LED module still does not function properly, then replace the LED module. If that does not correct the problem, replace the LHA power control board. If one side of a white module does not emit any white light, then check the connector to the non-functioning side to see that is it connected properly. If the white LED module still does not function properly, then replace the LED module. If that does not correct the problem, replace the LHA power control board Carmanah Technologies Corporation 60

61 Note that failure of up to 25% of the white LED sources on the white module of an LHA is allowed before the LHA must be removed from service. The LED sources can be seen by looking into the LHA through the front lenses with the LHA set at the lowest intensity level, step 1. If the white LED modules do not change brightness when switching between the intensity levels, but still emit white light, then return the PCU for repair Red LED Modules If one LHA operates properly and the other LHA does not emit any red light from one of the red LED modules, remove the weather cover according to the instructions in Section 9 and first check that the connector to that LED module is connected properly. If the red LED module still does not function properly, then replace the LED module. If that does not correct the problem, replace the LHA power control board. If one side of a red module does not emit any red light, then check the connector to the non-functioning side to see that is it connected properly. If the red LED module still does not function properly, then replace the LED module. If that does not correct the problem, replace the LHA power control board. Note that failure of up to 25% of the LED sources on the combination of the two red modules in an LHA is allowed before the LHA must be removed from service. The LED sources can be seen by looking into the LHA through the front lenses. If the red LED modules do not change brightness when switching between the intensity levels, but still emit red light, then return the PCU for repair Tilt Switch If there is no light emitted from all Light Housing assemblies (LHA) and there is power all along the power train, disable the tilt switches by placing the "Tilt Switch Bypass" toggle on the PCU control panel to the disabled (up) position. If light is now emitted from the LHA, check the incline of the LHAs according to Section 4. When the LHAs are all aligned within the specification, check that the tilt switches on each LHA are set to level. Check that the tilt switch toggles on the three LHAs closest to the PCU are pointing towards the front of the respective LHA and that the tilt switch toggle on the LHA that is at the end of the connection chain is in the position pointing towards the rear of that LHA. Place the "Tilt Switch Bypass" toggle on the PCU control panel to the enabled (down) position. If there is no light emitted from all Light Housing assemblies (LHA), disable the tilt switches by placing the "Tilt Switch Bypass" toggle on the PCU control panel to the disabled (up) position Solar Module In the event that the Portable Solar Module is not functioning properly, the first action is to ensure that all of the cables are attached properly. Disconnect the cable from the PAPI Battery Box Assembly (BBA) at the BBA. Check the voltages at the output receptacle of the BBA. It should be a nominal 24 VDC, which can be between 22 and 28.8 VDC, depending upon the state of charge Carmanah Technologies Corporation 61

62 If the voltage is zero, then open the top of the BBA box and check the circuit breaker, which is located on the side of the battery box. Reset the circuit breaker and make sure that its switch is in the on position. If the voltage is below 24 VDC, charge the batteries. Repeat the output voltage measurement. If the voltage remains below 22 VDC, replace the batteries. With the solar panels pointed toward the sun (or a suitable bright light source), check the voltage at the end of the cable from the solar panels. The voltage should be greater than 24 VDC, and as high as 47 VDC Carmanah Technologies Corporation 62

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