DOCUMENT
REVISION
February 4, 2014
1154
A
Instruction Manual
Pro APF Series LED
Inset Runway Guard Light
FAA Type L-852G
Cooper Industries
Crouse-Hinds Airport
Lighting Division
Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095
Copyright © 2014 Eaton’s Crouse-Hinds Business
For Parts or Technical Service Call (860) 683-4300
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Revisions
Revision
Issue/Reissue
Letter Number
Description
Checked
Approved
A
A214-046
INITIAL RELEASE
KF
SB, TR
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Product Warranty
Warranty
Refer to Cooper Crouse-Hinds Airport Lighting Products Terms and Conditions for product
specific warranty information.
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Safety Notices
This equipment is normally used or connected to circuits that may employ voltages that are
dangerous and may be fatal if accidentally contacted by operating or maintenance personnel.
Extreme caution should be exercised when working with this equipment. While practical safety
precautions have been incorporated in this equipment, the following rules must be strictly
observed:
3.1
Keep Away from Live Circuits
Operating and maintenance personnel must at all times observe all safety regulations. DO NOT
PERFORM MAINTENANCE ON INTERNAL COMPONENTS OR RE-LAMP WITH
POWER ON.
3.2
Resuscitation
Maintenance personnel should familiarize themselves with the technique for resuscitation found
in widely published manuals of first aid instructions.
IMPORTANT:
IMPORTANT
4
See FAA Advisory Circulars AC 150/5340-30, AC 150/5345-46, and EB/67 for additional
information.
Test Equipment and Tools
There is a wide variety of tools and equipment needed to safely and correctly perform airfield
lighting equipment installation and maintenance. In addition to the obvious tools (screwdrivers,
wrenches, etc.), there is specialized equipment needed to do the job. The following list should be
used as a guide for procuring equipment to service the light light units;
Multimeter,
One of the most important pieces of test equipment is the Multimeter. It is used to measure
voltages, currents, and resistances. Almost every single maintenance task requires the use of a
multimeter at one point or another. A calibrated true rms meter is a must because airfield lighting
power distribution equipment produces non-sinusoidal waveforms, traditional average reading
meters are inaccurate and have very limited use. Checking or adjusting equipment based upon
incorrect current readings may dramatically reduce light source life and adversely affect power
equipment performance. A meter with TRUE RMS measuring capability and a current clamp-on
probe is needed to accurately measure distorted or chopped waveforms. Crouse-Hinds Airport
Lighting recommends the following ‘TRUE RMS’ Multimeters from Fluke:
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Manufacturer
Model Number
Fluke
87V, 287
It is also recommended to purchase the Fluke I800 current clamp with the Fluke 87V meter.
Refer to the equipment manufacturer’s manuals for the proper use, maintenance and calibration
(if necessary) of all meters.
Torque Wrench,
Crouse-Hinds Airport Lighting recommends torque values for the attachment hardware in
order to properly secure the components and the light unit to their mountings. The internal parts
require torques in the range of 4 in-lbs to 55 in-lbs. The light unit mounting hardware requires a
torque in the range of 225 in-lbs (19 ft-lbs). There are many brands and styles of torque
wrenches in the market to choose from. Crouse-Hinds Airport Lighting recommends the use of a
properly calibrated torque wrench when performing the job.
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Table Of Contents
Table of Contents
1
Revisions ........................................................................................................................... ii
2
Product Warranty ........................................................................................................... iii
3
Safety Notices................................................................................................................... iv
3.1
Keep Away from Live Circuits .............................................................................................. iv
3.2
Resuscitation ......................................................................................................................... iv
4
Test Equipment and Tools .............................................................................................. iv
5
Table Of Contents ........................................................................................................... vi
6
Part Number Explanation / Data Sheet ............................................................................1
7
General Description of Inset Runway Guard Light - LED ..............................................2
8
Installation .........................................................................................................................3
9
Maintenance ......................................................................................................................4
9.1
Cleanliness and Workmanship ................................................................................................ 4
9.2
Maintenance Program ............................................................................................................. 4
9.3
Cleaning Lenses...................................................................................................................... 5
9.4
Replacing the LED Module..................................................................................................... 6
9.5
O-Ring Replacement............................................................................................................... 6
9.6
Lens and Arctic Kit Replacement ............................................................................................ 7
9.7
Power Lead/Feed-thru Replacement ........................................................................................ 8
9.8
Power Supply Expansion Board Replacement ......................................................................... 9
9.9
Power Supply Replacement .................................................................................................. 10
9.10
Pressure Test ........................................................................................................................ 11
10
Troubleshooting............................................................................................................... 12
11
Spare/Replacement Parts List ......................................................................................... 15
12
Figures and Tables .......................................................................................................... 16
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Part Number Explanation / Data Sheet
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General Description of Inset Runway Guard Light - LED
The Crouse-Hinds Airport Lighting LED equipped Inset Runway Guard Light (IRGL) is a Style
II, (≤ 1/2 inch) light unit that meets the requirements of FAA Advisory Circular AC 150/5345-46
(latest version), Type L-852G and EB67 (latest version). It is designed for installation at
taxiway/runway interSections or any other location where visual guidance of moving aircraft is
desirable. The light unit is designed to fit on a FAA L-868 steel, size B light base per FAA AC
150/5345-42 (latest version), and have a total height above grade/ground level of  ½ inch. The
light unit is mounted to the light base with six bolts (3/8-16 UNC x 7/8 lg., SS) and lock washers
(3/8, SS). It is weatherproof and will endure roll over loads without damage. The light unit is an
assembly, consisting of a 1-piece aluminum optical (light) housing, and a 1-piece aluminum sand
cast inner housing (cover) bolted together with 6 flat head screws. A silicone o-ring is used to
provide a watertight seal between the inner cover and the optical housing. The LED optical light
engines are secured in place using brackets, which are fastened to the light housing. The power
board and components are secured into the inner cover. Electrical connections are made at one
feed-thru assembly in the inner cover. The feed-thru has an ITS verified L-823 plug for
connecting to FAA L-830/ L-831 isolation transformers. Each outer lens is held into the
aluminum housing with a bracket, gasket, molded elastomeric boot and 2 screws. The yellow light
beam color is produced using amber LEDs with optics. All hardware is type 18-8 stainless steel.
The complete light unit is 11.94 inches in diameter, 6 inches deep, and weighs 14 lbs. All units
leave the factory pressure tested. If the unit is serviced during it lifetime, it must be re-tested to
ensure it remains waterproof.
CAUTION:
CAUTION
Never handle the light assembly by the leads as this can break the
waterproof seal.
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Installation
The light units are shipped complete and are ready for installation as received. Installation of a
light unit is to be done with primary POWER OFF and SECURED. At each light location,
install one steel, size-B, L-868 light base per FAA AC 150/5340-4 (latest revision). If installation
is replacing existing light units, it is necessary that the mounting surface and inside locating
diameter of the light bases are free of rust and debris. If necessary, use appropriate methods to
clean these surfaces. The light unit requires an isolation transformer. Isolation transformer
requirements are dependent on a light unit’s heater option and whether or not it is used with a
Logitrac device. Minimum isolation transformer requirements can be found in Section 12, Table
2. All isolations transformers are 6.6 ampere secondary models. Place the properly sized isolation
transformer in the light base and make necessary primary power connection using L-823
connectors. Verify that the mounting flange on the light base is clean and the o-ring (optional on
deep cans) is coated with Dow Corning FS 1292 grease and is in place on the light base. Connect
the plug from the light unit to the secondary of the previously installed isolation transformer.
Installation tool, Crouse-Hinds Airport Lighting P/N 19999, will ease the installation and removal
of the light unit. The threaded eyebolts on the lifting tool screw into threaded holes in the light
unit. Lower the light unit straight down onto the base. The light unit is subject to optical
misalignment or mechanical damage if not seated properly. Secure the light unit to the base with
six 3/8-16 UNC x 7/8 lg., SS bolts and lock-washers and tighten to 225 -0 +10 in-lbs (19 -0 + 1 ftlbs). It is recommended that Loctite 243 be used on the mounting bolts to prevent loosening due
to vibration.
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Maintenance
The preferred method of maintaining these lights is to periodically and systematically replace the
units and return them to the maintenance shop for renovation. As an alternative, the units can be
serviced in the field. However, it is recommended that field servicing be limited to cleaning the
lens only as described in Section 9.3. Also, when performing lens cleaning, the (6) light unit
mounting bolts should be re-torqued to the installation spec of 225 -0 +10 in-lbs (19 -0 + 1 ft-lbs).
NOTICE:
NOTICE
The warranty is void if other than Crouse-Hinds Airport Lighting Products parts are used
to re-lamp or rebuild the light unit.
WARNING:
WARNING
9.1
The warranty is void if the screws holding the L852G optical housing to the inner cover are
loosened or removed.
Cleanliness and Workmanship
Service life depends upon the entire assembly being waterproof. All surfaces must be clean, dry
and free of all foreign matter if the light unit is to operate for extended periods without requiring
maintenance.
9.2
Maintenance Program
In order to insure maximum light unit life, the installed units should be subject to a maintenance
program in accordance with the following: A daily operation check should be made of the
lighting unit. The lights should be energized and visually inspected. If any units are not lit and/or
partially lit, the location of the unit, along with the pocket that is out, should be recorded for
future troubleshooting. A replacement light unit should be installed per instruction in Section 8
with the primary POWER OFF and SECURED. The affected light unit can be troubleshot in a
clean, safe working area or returned to Crouse-Hinds Airport Lighting for repair.
WARNING:
WARNING
The warranty is void if the screws holding the L852G optical housing to the inner cover are
loosened or removed.
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9.2.1 Regular cleaning is necessary to insure inset lighting units operate at maximum efficiency.
The lens should be cleaned periodically per Section 9.3. The weather and the location of
the units will dictate the regularity and type of cleaning.
9.2.2 Inset light hold-down bolts should be checked for proper torque (225 +5, -0, in-lbs.) at
least once every three months or whenever a unit is serviced regardless of the season.
Light units in and around the touchdown zone area are especially prone to vibration
damage if the mounting bolts are not properly torqued. The mounting surface of the light
base must be clean and free of foreign matter when checking mounting bolts.
9.2.3 Snowplow operators should exercise extra care not to strike the light units with snowplow
blades. Use rubber blades for added protection to the unit. After snow removal operations,
inspect all light units to locate and replace, if necessary, any damaged light assemblies.
Passes over the light rows should be made with a power broom only if practical.
Whenever snowplows must traverse in-pavement light units, they should be traveling at
less than 5 mph or have the blades lifted clear of the unit. Recommended snow removal
techniques are described in AC 150/5200-23.
9.2.4 The light is designed to exclude both ground and surface water from entering. If the lights
are not properly maintained (i.e., bolts tightened and seals in good condition) water may
enter the unit. To prevent this from occurring, it is recommended that each unit be
inspected for the presence of water at least once a month. More frequent inspection is
desirable during and following rainy seasons.
9.2.5 If any light unit contains water, the water should be removed and the entire unit cleaned
and dried. If any of the electronics have been damaged, it may not be cost effective to
make a field repair, but rather send it back to Crouse-Hinds Airport Lighting for rebuild.
Perform a pressure test per Section 9.8 to locate the source of the leak. Refer to the o-ring,
lens, and power lead Sections, 9.5, 9.6 & 9.7 as needed to make repairs. After any repair,
pressure test again per Section 9.8.
9.3
Cleaning Lenses
With a compressed air blast or suitable brushes, remove all accumulated debris from the light
channel. Clean the outer lens surface with a detergent solution. If the lens is coated with a
substance impervious to the detergent, a suitable solvent should be sparingly applied with a wad
of cotton or a patch of cloth on the end of a wood splint. After the solvent has acted, the
remaining solvent and softened coating should be removed with a clean piece of cotton or cloth.
Care should be taken to avoid excessive contact between the solvent and the lens seal. Remove all
remaining solvent from lens and lens seal. A gentle air blast may be used. It is good practice to
inspect for damage to the optical housing and/or water intrusion into the unit anytime a lens is
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cleaned. Water droplets would be visible on the inside of the lens if moisture had entered the unit.
If it is determined that moisture has entered the unit, refer to Section 9.2.5 for possible causes and
maintenance procedures.
9.4
Replacing the LED Module
NOTICE:
NOTICE
The LED PCB is warm when light unit is energized and remains warm for a short time
after unit is turned off.
WARNING:
WARNING
The Warranty is void if the screws holding the L852G optical housing to the inner cover
are loosened or removed.
Refer to Section 11 to determine the appropriate replacement kit for your light unit(s). First, remove
and secure power to the light unit. Disconnect the light unit lead(s) from the isolation
transformer(s). Turn the light unit upside down and remove the six screws holding the inner cover
(referred to as the ‘bottom’ cover) to the light housing (sometimes refer to as the ‘optical’ housing).
Being careful not to pull and strain the LED wire cables, gently lift the inner cover up and rotate to the
side. Support the inner cover, on edge, adjacent to the light housing, again being careful not to pull
and strain the LED wire cables. Disconnect the LED leads (6 white wire bundle) from all (3) LED
boards by gently pulling the wires at the connection while adding a slight side-to-side motion to
disengage the connector. The inner cover can then be rested safely on the work surface. The LED
assembly(ies) can be disassembled from the optical housing by removing the #8-32 phillips-head
screws. Clean the mounting surfaces of the optical housing with denatured alcohol, and apply a
small amount of thermal grease to the mating bracket surface. Install the new LED assembly into
the optical housing. Press parts together with a rotating motion to spread the thermal grease
evenly. Install the #8-32 screws and torque to 15-20 in-lbs. Inspect/replace the optical housing’s
o-ring per Section 9.5. Re-connect the LED wire cables, ensuring that the connectors have fully
seated. Check the connections at the power supply (other end of LED lead) to ensure they are still
fully engaged. Assemble the inner cover onto the optical housing. Note: 1 of the 6 mounting holes
is offset, acting as an alignment hole. Identify this hole and align to the appropriate mating hole.
Be careful not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head
screws first until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform
a pressure test as described in Section 9.10. Re-install in field per instructions in Section 8.
9.5
O-Ring Replacement
Refer to Section 11 to determine the appropriate replacement kit for your light unit(s). Every time the
unit is opened, the o-ring must be closely examined and replaced, if necessary. Any o-ring that is
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stretched, torn, has permanent set, or some other defect which would prevent it from forming a
watertight seal, must be replaced with a new o-ring.
NOTICE:
NOTICE
A bad o-ring seal is the most common cause of inset light unit leaks. A new o-ring must be
installed every time the optical assembly is opened
WARNING:
WARNING
The warranty is void if the screws holding the L852G optical housing to the inner cover are
loosened or removed.
First, remove and secure power to the light unit. Disconnect the light unit lead(s) from the
isolation transformer(s). Open the light unit and disconnect the LED wires as described in Section
9.4. Remove the old o-ring from the groove in the optical housing. Carefully use a lint-free cloth
to clean the o-ring groove and flange mating surface on the inner cover with denatured alcohol.
Take care not to damage the mating surface. Clean the new o-ring with denatured alcohol.
Position the new o-ring into the groove and press it into place. Re-connect the LED wire cables,
ensuring that the connectors have fully seated. It does not matter which cable goes where. Check
the connections at the power supply (other end of LED lead) to ensure they are still fully engaged.
Assemble the inner cover onto the light housing. Note: 1 of the 6 mounting holes is offset, acting
as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful not to
pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first until
snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure test as
described in Section 9.10. Re-install in field per instructions in Section 8.
NOTICE:
NOTICE
9.6
The groove is designed to be wider than the o-ring. This provides room for the
displacement of the o-ring when compressed between the housing and mating surface.
Properly tightened screws are important in obtaining a complete seal.
Lens and Arctic Kit Replacement
WARNING:
WARNING
The warranty is void if the screws holding the L852G optical housing to the inner cover are
loosened or removed.
If an outer lens is broken, leaks, or is badly pitted or scarred, it must be replaced. Lens
replacement kits contain all necessary parts to change a lens. Units with arctic kits (heaters) will
require arctic kit replacement kits, which include replacement lenses. Refer to Section 11 to
determine the appropriate replacement kit(s) for your light unit(s). It is highly recommended that
this task be performed in a clean shop environment. First, remove and secure power to the light
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unit. Disconnect the light unit lead(s) from the isolation transformer(s). Turn the light unit upside
down and remove the six screws holding the inner cover to the optical housing. Follow the
instructions in Section 9.4 to disconnect the LED wires and remove the LED assy. Disconnect the
power supply lead(s) from the LED modules. Remove the two screws holding the LED module to the
optical housing. If you are replacing an arctic kit, remove the #6 tie-down screw which fastens the end
of the arctic kit’s flexible circuit heater to the optical housing. Remove the two lens retaining bracket
screws from the light housing. Remove the lens-retaining bracket and discard the lens-retaining
gasket. Firmly push the lens/boot assembly from the outside of the light housing; discard the old lens
and boot. If you are replacing an arctic kit, discard the arctic kit assembly as an electronic assembly.
Thoroughly clean the lens opening with denatured alcohol and allow it to dry. Inspect the lens opening
for scratches or pits; a damaged lens opening surface will not seal properly. Place a new lens boot
over the replacement lens. Apply a thin coat of Dow Corning FS 1292 grease over the entire
outside surface of the lens boot. Align the lens/boot assembly in the lens opening and press it into
place. Verify that the lens boot is not pinched in the lens opening. Using a new lens retaining
gasket, fasten the lens retaining bracket, and heater tie-down screw on arctic kit versions, to the
light housing. Torque the lens retaining bracket mounting screws to 25-30 in-lbs and the heater
tie-down screw, if applicable, to 8-11 in-lbs. See Figure 9 as an arctic kit visual reference. Reinstall the LED assy per Section 9.4. Inspect/replace the optical housing’s o-ring per Section 9.5.
Assemble the inner cover onto the optical housing. Note: 1 of the 6 mounting holes is offset,
acting as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful
not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first
until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure
test as described in Section 9.10. Re-install in field per instructions in Section 8.
9.7
Power Lead/Feed-thru Replacement
WARNING:
WARNING
The warranty is void if the screws holding the L852G optical housing to the
inner cover are loosened or removed.
Refer to Section 11 to determine the appropriate replacement kit for your light unit(s). First, remove
and secure power to the light unit. Disconnect the light unit lead(s) from the isolation
transformer(s). Turn the light unit upside down and loosen the knurled retaining collar on the power
lead with a pair of pliers or small channel-locks. Unscrew the ring completely and then carefully
remove the rubber flanged grommet from the male threaded adapter with a gentle twisting action. The
key is to keep the internal wires attached to the power lead. Carefully pull the power lead grommet
with attached internal wires a couple of inches away from the light unit. Unplug the internal wires
from the power lead and install them onto the new power lead. It does not matter which lead goes
where. Apply a thin coat of Dow Corning FS 1292 grease to the rubber grommet and slide it into
the threaded adapter. Apply a drop of Loctite 243 to the feed-thru adapter threads. Screw the feedthru retaining collar onto the adapter; refer to Figures 6 & 7 for proper inner cover/ feed-thru
orientation. Torque the retaining collar to 30 in-lbs.
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If the internal leads did not stay connected to the old power lead, or if one wishes to open the light
unit, then the following instruction should be followed for the power lead replacement.
Open the light unit and disconnect the LED wires as described in Section 9.4.
The power leads inside the inner cover have female flag-type crimped terminals which can be pulled
from the L-823 feed-thru power terminal. Remove the feed-thru by unscrewing the retaining collar.
Clean the mating surfaces with isopropyl alcohol and allow it to dry. Feed the black power leads from
inside the inner cover thru the feed-thru adapter and press the flag terminals onto the new L-823 lead.
It does not matter which lead goes where. Apply a thin coat of Dow Corning FS 1292 grease to the
mounting flange of a new feed-thru power lead and slide it into the adapter. Apply a drop of
Loctite 243 to the feed-thru adapter threads. Screw the feed-thru retaining collar onto the adapter.
Torque the retaining collar to 30 in-lbs. Inspect/replace the optical housing’s o-ring per Section 9.5.
Assemble the inner cover onto the optical housing. Note: 1 of the 6 mounting holes is offset,
acting as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful
not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first
until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure
test as described in Section 9.10. Re-install in field per instructions in Section 8.
9.8
Power Supply Expansion Board Replacement
Refer to Section 11 to determine the appropriate replacement kit for your light unit(s). Remove
and secure power to the light unit. Separate the optical assembly from the light base by removing
the six bolts. Disconnect the light unit lead(s) from the isolation transformer(s). Turn the optical
assembly upside down and remove the six screws holding the inner cover to the optical housing.
Disconnect the LED module cables from the expansion board, located on top of the main power
supply in the inner cover assembly. Remove the single screw and washer and spacer which secure the
expansion board to the power supply underneath it. Note: The spacer is sandwiched between the
expansion board and power supply. Remove the expansion board form the power supply by securing
the power supply against the inner cover while gently pulling the expansion board up and away from
the power supply. Discard the old expansion board as an electronics assembly.
Align and engage the connectors of the new expansion board with the power supply and press it into
place. Place and align the spacer between the expansion board and power supply. Insert the mounting
screw through the washer, expansion board, spacer, and power supply, in that order. Torque the screw
to 16-8 in-lbs. Connect the ends of the LED cables to the new expansion board. Inspect/replace the
optical housing’s o-ring per Section 9.5. Assemble the inner cover onto the optical housing. Note:
1 of the 6 mounting holes is offset, acting as an alignment hole. Identify this hole and align to the
appropriate mating hole. Be careful not to pinch the LED wire cables between the covers. Install
all 6 phillips flat-head screws first until snug, then tighten the mounting screws in a star pattern to
25-30 in-lbs. Perform a pressure test as described in Section 9.10. Re-install in field per
instructions in Section 8.
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9.9
Power Supply Replacement
CAUTION:
CAUTION
Power supply is hot when light unit is energized and remains hot for a short
time after light unit is turned off.
Refer to Section 11 to determine the appropriate replacement kit for your light unit(s). Remove
and secure power to the light unit. Remove the expansion board per the instructions in Section
9.8.With the expansion board removed; disconnect the power supply leads from the power supply. On
P2 units, disconnect the contact closure cables from the power supply. For units with an arctic kit
(heater), disconnect the heaters’ power and temperature sensor cables form the power supply. See
Section 12 for visual reference and wiring diagram figures. Remove the remaining two screws holding
the power supply to the inner cover. Discard the old power supply as an electronics assembly.
Configure the new power supply’s J203 jumper settings per Table 1 in Section 12.
IMPORTANT:
IMPORTANT
The jumpers must be placed in the correct position(s) for proper
operation of the appropriate fixture.
The heater will remain on indefinitely with the temperature sensor
disconnected.
Apply thermal grease to the bottom/mating surface of the power supply. Secure the power supply to
the bottom using two screws on one end of the power supply. Reconnect the expansion board per
Section 9.8. Tighten all 3 screws to 16-18 in-lbs. Reconnect internal cables per the appropriate wiring
diagram, Figures 11 through 14, depending on your light unit options.
IMPORTANT:
IMPORTANT
The jumpers must be placed in the correct position(s) for proper
operation of the appropriate fixture.
The heater will remain on indefinitely with the temperature sensor
disconnected.
Apply thermal grease to mating surface of the power supply and fasten it to the power supply bracket.
Torque the top power supply’s screws to 1.8-2.0 N-m (16-18 in-lbs). Reconnect the power supply(ies)
to the feed-thru terminal(s) and LED assembly(ies) and arctic kit(s), if applicable. Inspect/replace the
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optical housing’s o-ring per Section 9.5. Assemble the inner cover onto the optical housing.
Inspect/replace the optical housing’s o-ring per Section 9.5. Assemble the inner cover onto the
optical housing. Note: 1 of the 6 mounting holes is offset, acting as an alignment hole. Identify
this hole and align to the appropriate mating hole. Be careful not to pinch the LED wire cables
between the covers. Install all 6 phillips flat-head screws first until snug, then tighten the
mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure test as described in Section
9.10. Re-install in field per instructions in Section 8.
9.10
Pressure Test
A light unit should be subjected to a 20-psi maximum air pressure test to verify that it is
waterproof whenever it has been opened or components have been replaced. A tire valve style
pressure fitting is located on the inner of the inner cover. Pressurize the light unit to 20-psi using a
regulated/controlled air source, then place it in a tub of water or use a soap solution to locate
escaping air bubbles. Carefully inspect the areas around the lens, inner cover seal, and feed-thru
adapter for leaks. Relieve the internal air pressure before installing the light unit or attempting to
repair a leak.
WARNING:
WARNING
Do not exceed 20-psi when pressure testing the light unit. Serious injury
and/or permanent damage to the light unit may result if a higher air
pressure is used. Once the pressure test is complete, be sure to relieve the
air pressure.
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Instruction Manual
Pro APF LED Inset Runway Guard Light
FAA Type L-852G
10 Troubleshooting
If a light unit is under warranty, please contact Crouse-Hinds Airport Lighting for assistance. DO
NOT open a unit. If the unit is opened, the warranty is VOID. If the warranty period has expired
and troubleshooting is required, follow the steps below to find the root cause. Replacement parts
will be required for testing of the different components of the light unit.
WARNING:
Do not remove the fixture from the base can while the fixture is
powered. Dangerous voltage may be present on the primary and
secondary sides of the isolation transformer.
WARNING
Contact Crouse-Hinds Airport Lighting for assistance prior to
operating a failed fixture. There may be dangerous voltage present on
the input AC pins of the power supply.
10.1 Visual Inspection
Follow the steps in Section 9.8 to open the fixture. Verify that all wires are not pinched or
damaged and that the wire insulation is intact. Verify the input AC is connected to the feed thru
(see Figures 6 & 7). Verify the power supply connections and appropriate jumper setting (see
Figure 1 & Table 1). Note: The L852G has an expansion board that plugs onto the power supply
that will obstruct access to temperature sensor connector and the jumper positions.
Figure 1: Power Supply Connections
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
IMPORTANT:
IMPORTANT
The heater will remain on indefinitely with the temperature sensor
disconnected.
Replace any damaged or burned cables. Replace damaged LED module(s) per Section 9.4.
Replace damaged power supply(ies) per Section 9.9. Replace damaged expansion boards per
Section 9.8. Refer to Section 11 to determine the appropriate replacement kit(s) for your light
unit(s).
NOTICE:
NOTICE
J400, J401 and J500 on the expansion board are not used on the L852G.
The jumper used on L852G sets the ‘first on’ or ‘first off’ option only.
Reference Table 1 for jumper settings. A power supply with no jumper
will default to ‘first on’.
10.2 Electrical Inspection
WARNING:
WARNING
Contact Crouse-Hinds Airport Lighting for assistance prior to operating
a failed fixture. There may be dangerous voltage present on the input AC
pins of the power supply.
It is recommended that a ferro style constant current regulator (2.8 to
6.6ARMS) with a 10/15W isolation transformer or a voltage limited
constant DC current source be used to test failed fixtures to limit the
input voltage.
A buzzing or humming noise coming from the isolation transformer may
indicate a failed power supply or LED module. It is also an indicator of
dangerous voltage on the primary and secondary sides of the
transformer.
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
NOTICE:
NOTICE
Applying a constant voltage greater than 50V (AC or DC) to the input
will cause damage to the power supply.
Applying input current to the power supply without the heater or jumper
installed will cause damage to the power supply.
The expansion board used on the L852G will block direct sight of the
status LED.
Follow the steps in Section 9.8 to open the fixture.
The power supply continuously monitors the status of the LED module. There is a green status
LED (see Figure 2) that may be visible through the potting. A blinking LED indicates the power
supply has detected a fault condition.
Fault conditions include:
 Disconnected or ‘Open’ LED module
o Replace cable if damaged or ‘open’.
 More than 25% of the driven LED ‘Shorted’
o Replace LED module per Section 9.4.
Figure 2: Power Supply Status LED Location
If the status LED is not visible or not lit, replace the power supply per Section 9.9 or contact
Crouse-Hinds Airport Lighting Products for assistance. Refer to Section 11 to determine the
appropriate replacement kit(s) for your light unit(s).
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
11 Spare/Replacement Parts List
Item Part Number
LED Module Replacements*
1
21673-1
2
21673-3
Lens Replacements
3
21674-1
4
21674-3
5
21674-1-AK
6
21674-3-AK
Power Supply Replacements*
7
21675
8
21675-AK
Expansion Board Replacements
9
21676
Feed-thru Assembly
10 21122
O-Ring, Optical Housing
11 21385
2-Piece Lock Washer Kit
Description
852G-AP1 LED Module Replacement Kit, QTY 1 LED Module
852G-AP1 LED Module Replacement Kit, QTY 3 LED Module
852G-AP1 Lens Replacement Kit, Replaces QTY 1 Lens
852G-AP1 Lens Replacement Kit, Replaces QTY 3 Lens
852G-AP1 Arctic Kit Replacement Kit, Replaces QTY 1 Arctic Kit
852G-AP1 Arctic Kit Replacement Kit, Replaces QTY 3 Arctic Kit
852G-AP1 Power Supply Replacement Kit
852G-AP1 Power Supply Replacement Kit, Arctic Kit Support
852G-AP1 Power Supply Expansion Board Replacement Kit
1 Lamp, 1 Connector
O-Ring, 852G Optical Assembly Seal
12
21647-6
2-Piece Washer Replacement Kit, QTY 6 (For mounting 852G
optical assembly to light base. *Washers Included with LED
module and power supply replacement kits.)
13
21647-XXXX
2-Piece Washer Replacement Kit, Customer Specified QTY
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
12 Figures and Tables
Figure 3: Isometric View of Light Unit
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
Figure 4: Top View with Reference Dimensions
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
Power Supply
Primary Lens Components
See figure 10
LED Module
Figure 5: Section View A-A
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
Feed-thru fitting with knurled collar
Figure 6: Front View with Reference Dimensions
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
Power Supply
Expansion Board
P2 Feed-thru terminals
AC Input Feed-thru terminals
Contact Closure cables
AC input cable
Figure 7: Installation View of Inner Cover
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
LED Modules
Lamp label
Figure 8: Component Installation Side of Optical Housing
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
Heater strain relief
washer and tie-down
screw
Clearance-cut gasket
Artic kit prism heater
Figure 9: Component Installation Side of Optical Housing w/ Arctic Kit
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
Figure 10: Exploded View of Lens Replacement Components
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Pro APF LED Inset Runway Guard Light
FAA Type L-852G
LED MODULE
LED MODULE
LED MODULE
P200
P500
J500
J201
P200
FEED THRU
ASSEMBLY
P1
P100
P101
J402
J403
P102
J400
J203 J401
J404
J301
P103
Figure 11: L-852G, P1 Configuration, Without Heater
LED MODULE
LED MODULE
P200
P500
J500
J201
P200
FEED THRU
ASSEMBLY
P1
P100
P101
J402
J400
HEATER 2
J203 J401
HEATER 3
Figure 12: L-852G, P1 Configuration, With Heater
24
J404
P102
HEATER 1
J403
J301
P103
LED MODULE
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Instruction Manual
Pro APF LED Inset Runway Guard Light
FAA Type L-852G
LED MODULE
LED MODULE
LED MODULE
P200
P500
J500
J201
P200
FEED THRU
ASSEMBLY
P1
P100
P101
J402
J403
P102
J400
J203 J401
J404
J301
P103
FEED THRU
ASSEMBLY
P2
Figure 13: L-852G, P2 Configuration, Without Heater
LED MODULE
LED MODULE
P200
P500
J500
J201
P200
FEED THRU
ASSEMBLY
P1
P100
P101
J402
J400
HEATER 2
J203 J401
HEATER 3
FEED THRU
ASSEMBLY
P2
Figure 14: L-852G, P2 Configuration, With Heater
25
J404
P102
HEATER 1
J403
J301
P103
LED MODULE
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Instruction Manual
Pro APF LED Inset Runway Guard Light
FAA Type L-852G
L852G
Light unit Part Number
852G-AP1-YO-F1-12U-PX-X-0
852G-AP1-YF-F1-12U-PX-X-0
J203 Jumper Setting
19
17
15
13
11
9
7
20
18
16
14
12
10
8
19
17
15
13
11
9
7
20
18
16
14
12
10
8
Table 1: Light Unit Part Numbers and Jumper Settings
Table 2: L852G Minimum Isolation Transformer Power
26
5
5
3
1
4
2
3
1
4
2