Cooper Industries DOCUMENT September 29, 2009 Revision B Crouse-Hinds Division Crouse-Hinds Airport Lighting Products 1200 Kennedy Road Windsor, CT 06095 860 683-4300 Fax 860 683-4354 Title: INSTRUCTION MANUAL L-807 36 WIND CONE SERIES WC-36 Copyright 2009 Cooper Technologies Company
REV. DESCRIPTION LTR. CHK. APV A Revised Para 4.1 was 69 watt; Para 4.2 was four 150 watt 120 volt PAR-38 lamps #150PAR/FL-120 and for RF 200 watt, 200A/99CL ; Para 6.1, power requirements for WC-36 was 716W at 120 volts (6 amps); Updated Figures per latest Manufacturing A204-092 5/3/04 GFR B Added P/N 10046-269 for item 87, and 10046-270 for item 88; Revised Copyright to 2009. A207-232 9/29/09 ii
LIMITED PRODUCT WARRANTY THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. Crouse-Hinds Airport Lighting Products (the Company ) warrants to each original Buyer of Products manufactured by the Company that such Products are, at the time of delivery to the Buyer, free of material and workmanship defects, provided that no warranty is made with respect to: (a) (b) (c) (d) any Product which has been repaired or altered in such a way, in Company's judgment, as to affect the Product adversely; any Product which has, in Company's judgment, been subject to negligence, accident or improper storage; any Product which has not been operated and maintained in accordance with normal practice and in conformity with recommendations and published specification of Company; and, any Products, component parts or accessories manufactured by others but supplied by Company (any claims should be submitted directly to the manufacturer thereof). Crouse-Hinds Airport Lighting Products obligation under this warranty is limited to use reasonable efforts to repair or, at its option, replace, during normal business hours at any authorized service facility of Company, any Products which in its judgment proved not to be as warranted within the applicable warranty period. All costs of transportation of Products claimed not to be as warranted and of repaired or replacement Products to or from such service facility shall be borne by Purchaser. Company may require the return of any Product claimed not to be as warranted to one of its facilities as designed by Company, transportation prepaid by Purchaser, to establish a claim under this warranty. The cost of labor for installing a repaired or replacement product shall be borne by Purchaser. Replacement parts provided warranty period of the Products upon which they are installed to the same extent as if such parts were original components thereof. Warranty services provided under the Agreement do not assure uninterrupted operations of Products; Company does not assume any liability for damages caused by any delays involving warranty service. The warranty period for the Products is 24 months from date of shipment or 12 months from date of first use whichever occurs first. iii
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: 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 RE-LAMP WITH POWER ON. RESUSCITATION Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of first aid instructions. iv
Table of Contents Title Page... i Revision Page... ii Limited Product Warranty... iii Safety Notices... iv Table of Contents... v 1.0 General Information... 1 2.0 Wind Cone Assembly... 1 3.0 Hinged Standard... 1 4.0 Lamps Required..... 1 5.0 Installation..... 2 6.0 Wiring...... 2 7.0 Painting...... 3 8.0 Lubrication...... 3 9.0 Maintenance Parts.... 3 Figures Figure 1 Foundation Details...... 6 Figure 2 Base Dimensions.... 7 Figure 3 Standard Illuminated Wind Cone Pole Assy (48310)... 8 Figure 4 Position of Hinged Pole Lowered for Servicing... 9 Figure 5 -RF Option (Reflector Floodlights)... 10 Figure 6 Obstruction Light Only (48312)... 11 Figure 7 Floodlights Only (48313)... 12 Figure 8 Non-Illuminated (48311)... 13 Figure 9 Bearing Assembly... 14 Figure 10 Wind Cone Basket Assembly... 15 Figure 11 Wiring Diagram... 16 v
1.0 GENERAL INFORMATION 1.1 General Description This bulletin covers instructions for the wind cone fixture which is constructed in accordance with FAA Specification L-807. It consists of a two piece shaft assembly, a reducer, two bearing supports, a cylindrical framework, a fabric cone, a lighting fixture assembly to illuminate the cone and an obstruction light. The wind cone standard is a hinged pole constructed so that the wind cone fixture assembly can be lowered to the ground for servicing. 2.0 WIND CONE ASSEMBLY 2.1 The WC-36 wind cone assembly as illustrated, includes all parts above the hinged standard. The assembly is shipped in knocked down form. 2.2 The top vertical shaft is a one inch pipe that is attached to the 1 ½ bottom sections by means of a reducer fitting. The junction box at top has a hub cover on which the obstruction light with a red globe can be mounted by use of a nipple. The cylindrical framework is attached to two ball bearing assemblies that are installed on the lower vertical shaft. The fabric cone is drawn over this framework and held in place by an outer clamp ring. Grease fittings are provided for lubricating the bearings. 2.3 The standard fabric cone is orange nylon but cones are also available in white nylon. 3.0 HINGED STANDARD 3.1 Hinged standard (Cat. No. 71048-36) consists of an upper and lower section hinged together to allow the upper section to be lowered to the ground for servicing of the wind cone assembly. The standard is welded steel construction having one coat of red oxide primer. 3.2 Four anchor bolts each having two nuts and washers are included in the package. The hinged standard is locked in the upright position by use of a stud and nut. 4.0 LAMPS REQUIRED 4.1 For the obstruction light: One 116 watt 120 volt medium base A-21 lamp, traffic signal type. 4.2 For cone illuminating floodlights: Four 250 watt 120 volt PAR-38 lamps, Crouse-Hinds Airport Lighting Products P/N 10047-2882. Lamps and Lamp Holders are to be adjusted for a 45 angle off the vertical (see Figures 3 and 7). 4.3 For optional 120 VAC RF reflector floodlights use four 150 watt 120 volt medium base general service lamps #150/CL or for 220/240 VAC, four 200 watt, 220-240 volt lamps, Crouse-Hinds Airport Lighting Products P/N 10047-2572. 1
5.0 INSTALLATION 5.1 A concrete foundation with material strength and dimensions that will fulfill the requirements presented by the local soil conditions must be provided. The four anchor bolts, each with two nuts and washers, that are provided must be installed in the foundation on an 11 inch bolt circle and have four inches of the bolt above the concrete as shown in the illustrations. A one inch conduit may also be installed in this base to bring underground wiring into the center of the pole. 5.2 An access hole with cover in the side of the pole has been provided to make wiring easier. An earth ground nut is located under the cover. A piece of flexible conduit is located inside the pole at the hinge point. The internal wiring should be pulled through the flex conduit to prevent damage to the wire insulation when the pole is lowered. Be sure to allow approximately two feet of slack wire to avoid tension on wire connections. Be sure to check the actual current flow when the installation is complete. Then check to be sure the circuit breaker (or other device) protecting the wind cone lighting is of the proper rating. See National Electric Code and section 6 Wiring. 5.3 Before installing the hinged pole put one nut on each anchor bolt and tighten them down to rest on the concrete. Using a level adjust these nuts just enough to have them all level with each other. Put one washer on each nut. Then install hinged standard over the bolts and washers and tighten second washers and nuts on bolts only finger tight. Check standard to be sure it is exactly vertical (plumb). Adjustments can be made by turning the BOTTOM nuts. After the standard is plumb tighten top nuts securely. When installation is checked and completed, fill any void between base plate and foundation with non-shrinking grout, shaping and finishing it to a neat appearance. 5.4 Assemble the wind cone assembly beginning with the 1 ½ lower shaft, reducer, 1 upper shaft and junction box. Install the four lamp holders, junction box cover and obstruction light, if ordered. Assembly the cylindrical framework and attach it to the two bearings on the shaft. The fabric wind sock cone is then drawn over the framework and held by tightening the clamping ring over the inner end of the cone. 5.5 For the RF option, install the four ½ pipe arms, the four reflectors, junction box cover and obstruction light if ordered. Assemble the cylindrical framework and attach it to the two bearings on the shaft. The fabric wind sock cone is assembled as above. See Figures 3, 4, 5, 6, 7, 8, 9, and 10. 5.6 When installing wind cone assembly in slip fitter at top of center pipe support, align clearance holes through wind cone pipe at correct locations so that two set screws will project through pipe (see Figure 9) (before proceeding with installation, refer to Paragraph 6, Wiring.) Tighten remaining set screws, locking them in place. 6.0 WIRING 6.1 Power required for the WC-36 is 1,116 watts 120 volts. Wiring is run underground, up through the foundation, inside the hinged standard, and inside the center shaft of the WC-36. In the hinged standard and the WC-36 shaft assembly #12 or #14 Type RHW or THW wire may be used. 2
At the hinge point the wires are run through flexible tubing. Splices may be made in the junction box at the top to run 120 volts to the four lamp holders and to the obstruction light. Power required for the lighting on the wind cone is 2-wire, 115-volt or 220-240 volt, AC or DC. Voltage drop from the transformer vault to the wind cone should be held within 5% of the line voltage by using wire of sufficient size. If the wire run from the transformer vault to the wind cone is exceptionally long, it may be more economical to utilize wires of a smaller size with a voltage booster transformer such as 1.0 KW transformer, outdoor weatherproof type Catalog No. 44513, See Figure 10. WC-36 is 1,116W at 120V (9.5 amps) or 900W at 220-240 V (4 amps). 7.0 PAINTING 7.1 The finish required under FAA Installation Specification AC 150/5370-10, Item L-107 consists of three coats (prime, body and finish coats) applied to all exposed parts except cone, red globe and the four lampholders. 7.2 The prime coat shall be red oxide type. The body and finish coats shall be equipment orange. A primer coat is applied to the hinged standard at the factory. Apply the two final coats after installation. 8.0 LUBRICATION 8.1 The wind cone bearings are factory lubricated. Approximately once a year lubricate the bearings (each bearing housing is provided with grease fitting) with Exxon Beacon #325 Grease, or equivalent low temperature high quality silicone grease. Note: Local environmental conditions may require more frequent lubrication. 9.0 MAINTENANCE PARTS 9.1 See pages 4 and 5. 3
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CAUTION: If at any time the wind cone does not rotate freely (in a 3 MPH or higher wind), thoroughly clean and relubricate the bearings. If the bearings are worn, so that there is binding at any point, replace both bearings immediately. All statements, technical information and recommendation contained herein are based on information and tests we believe to be reliable. The accuracy or completeness thereof are not guaranteed. In accordance with Crouse-Hinds Standard Aviation Products Terms and Condition of Sale, and since conditions of use are outside our control, the purchaser should determine the suitability of the product for the intended use and assumes all risk and liability whatsoever in connection herewith. 17