Cooper Industries
Crouse-Hinds Division
Crouse-Hinds Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095
DOCUMENT 8922
August 24, 2006
Revision P
860 683-4300
Fax 860 683-4354
Title:
INSTRUCTION MANUAL
HIGH INTENSITY RUNWAY LIGHT/QUARTZ (HRLQ)
FAA L-862
Copyright  2006 Cooper Technologies Company
Document 8922
Revision P
REVISIONS
REVISION
NUMBER
F
ISSUE/REISSUE
LTR NUMBER
G
A96-407/408
H
A97-091
J
A97-365
K
A99-052
L
A99-199
M
A203-127
N
A203-151
P
A206-296
DESCRIPTION
REVISED EXTENSIVELY, SEE RECORD
COPIES..
CHKD
12/05/96
EFL
APPROVED
ADDED NOTE 2 WHICH LISTS THE P/N’S
THIS FIXTURE COULD LEVEL & ALIGN
LOCATING DEVICE WAS 2.159 DIA
HOLES ADDED LEVELING DEVICE P/N
40999 TO PAGE 1 OF INSTALLATION
INSTRUCTIONS.
CHANGED FRANGIBLE COUPLINGS ON
UNITS NON 14” STD. IN HEIGHT
CREATED NEW DRAWING FOR UPPER
SECTION OF SUPPORT COLUMN
DELETED 40994 IN FAVOR OF 40878 TO
ELIMINATE REDUNDANCY AND
ADDED THE -12P VERSION.
P/N ITEM 26 WAS 10047-2233 ADDED
ITEMS 48 & 49
ADDED ITEM 43 TO SHEET 4; ADDED
ITEM 3 & 4 TO VIEW IN DIRECTION A
ON SHEET 5; ADDED NOTE ON OPTICAL
SUB-ASSY TO SHEET 6; ADDED
PICTORAL PLUG TO SHEETS 6 & 7;
ITEM 10 WAS 40988; ITEM 12 WAS
10A07-016D16, #8-32 X 1/2 LG.; ITEM 27,
40995-7 & -8 WERE -5 & -6 ON SHEET 9;
ON SHEET 9, ITEM 47 WAS QTY 1
REVISED PICTURE OF VIEW IN
DIRECTION A (SHEET 5) TO AGREE
WITH LATEST MANUFACTURING
PRACTICE.
SHEET 8, ITEM 16 WAS 40971
01/10/97
EFL
JMM
REVISED FIGURES ON SHEETS 4 THRU 7
TO AGREE WITH LATEST
MANUFACTURING
REVISED COPYRIGHT ON TITLE PAGE;
REVISED ITEM 5 PICTORIAL ON PAGE 7
ii
JMM
02/19/97
EFL
06/27/97
EFL
3/19/99
KWF
11/8/99
DCW
BAC
5/14/03
GFR
6/18/03
GFR
8/24/06
PG
KWF
Document 8922
Revision P
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)
any Product which has been repaired or altered in such a way, in Company's
judgment, as to affect the Product adversely;
(b)
any Product which has, in Company's judgment, been subject to negligence,
accident or improper storage;
(c)
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,
(d)
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
Document 8922
Revision P
PART NUMBER ORDERING DATA
HIGH INTENSITY RUNWAY LIGHT/QUARTZ (HRLQ) FAA L-862
862 4
X - X XX - XXX - XX
CATALOG NO.
FIXTURE HEIGHT
MODEL NO.
BLANK = STD. 14” HGT
HGT INCREASES IN 2”
INCREMENTS UP TO
30” (16, 18, 24 ETC.)
COUPLING
1 = 1 1/2-12 UNF
2 = 2” NPT
LAMP WATTAGE
120 = 120 W, BI-PIN
150 = 150 W, BI-PIN
200 = 200W, BI-PIN
201 = 200 W, PK-30d
101 = 100 W, PK-30d
122 = 115 W, DCR
202 = 200 W, DCR
APPLICATION
E = ELEVATED
T = THRESHOLD
COLOR/COLOR
C = CLEAR.
B = BLUE
G = GREEN
R = RED
Y = YELLOW
X = OPAQUE/BLANK
1
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Revision P
1.0
INSTALLATION
1.1
Installation of Standard Height (14”) Light Fixture
1.1.1
Prior to installing light fixture, remove lockpin (22), clamp band (23), outer lens
(19), and gasket (18).
1.1.2
Detach lamp holder assembly (8), (34), or (44) by removing two screws (6).
1.1.3
Make electrical connection of L-823 Plug (7), (33), or (47) and socket.
1.1.4
Support column (1) or (2) can now be threaded into base plate (Crouse-Hinds P/N
50044) or stake mount (Crouse-Hinds P/N 50056). Do not tighten locknut (20) or (21).
1.1.5
Turn support column (1) or (2) until flag lug of optical sub-assembly (3), (32) or
(43) is perpendicular to but pointed away from Runway Centerline. Tighten locknut (20) or (21).
1.1.6
Re-assemble lamp holder sub-assembly (8), (34) or (44) to optical sub-assembly
(3), (32) or (43) using the two screws (6).
1.2
Installation of Extended Height Light Fixtures
1.2.1
Slide extension (30) over wire assembly (7), (33), or (47) and into top of base (28)
or (29). Slide frangible base (28) or (29) over wire assembly (7), (33) or (47) and onto extension
(30).
1.2.2
Make connection of wire assembly with L-823 plug (7), (33) or (47) into socket.
1.2.3
Turn frangible base (28) or (29) into base plate (Crouse-Hinds P/N 50044) or stake
mount (Crouse-Hinds P/N 50056) and tighten locknut (20) or (21).
1.2.4
With extension (30) bottomed in frangible base (28) or (29) and in a vertical
position, tighten lower screw (31).
1.2.5
Turn optical sub-assembly (3), (32) or (43) until arrow on top of outer lens is
pointed towards Runway Centerline and tighten upper screw.
1.3
Leveling & Aligning Light Fixtures
1.3.1
Prior to leveling, lockpin, clamp band, outer lens and gasket must be removed.
1.3.2
Leveling is achieved by adjusting appropriate screws (25) to maintain optical sub-assembly in a
level position. Leveling and aligning may be expedited with the aid of two devices (Crouse-Hinds
P/N 50029 & P/N 40999) which fit into flag holes and can be supplied upon request.
2
Document 8922
Revision P
1.4
Installing Lamp
1.4.1
Insert lamp (26) into lamp holder assembly (8) or (34).
1.4.2
For DCR lamps, loosen the two screws (6) holding the lamp holder sub-assembly
(44- sheet 7) and remove. Insert the DCR from the underside of this assembly. Attach the socket
assembly (45) to the lamp socket and re-assemble. It should be noted that installation of the DCR
lamps does not require removal of the inner dome assembly (14).
1.4.3
If lamp glass is handled during installation, clean lamp with alcohol and dry with
clean soft cloth prior to operating. Contamination of the quartz may result in reduced lamp
performance.
1.5
Installing Inner Dome Assembly
1.5.1
To replace lamp, remove lockpin (22), clamp ring (23) and outer lens (19).
1.5.2
Loosen the two screws (6) holding the DCR lamp holder sub-assembly (44) and
remove the entire sub-assembly including the inner dome (14). It is not necessary to remove the
inner dome (14) from the lamp holder sub-assembly (44).
1.5.3
Remove the Socket Assembly (45) from the lamp base. Remove the lamp (26)
from the lamp holder sub-assembly, replace and re-assemble parts.
1.6
Re-Lamping (Bi-Pin and PK30d)
1.6.1
To replace lamp, remove lockpin (22), clamp ring (23) and outer lens (19).
1.6.2
Remove inner dome assemble (14) by loosening screws (12) holding spring clips.
1.6.3
Replace lamp (26) and reassemble parts.
1.7
Re-Lamping (DCR)
1.7.1
To replace DCR lamp, remove lockpin (22), clamp ring (23) and outer lens (19).
1.7.2
Loosen the two screws (6) holding the DCR lamp holder sub-assembly (44) and
remove the entire sub-assembly including the inner dome (14). It is not necessary to remove the
inner dome (14) from the lamp holder sub-assembly (44).
1.7.3
Remove the socket assembly (45) from the lamp base. Remove the lamp (26) from
the lamp holder sub-assembly (44), replace and re-assemble parts.
3
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8 ASSY
3 ASSY
9
25
LOCATING LUGS FOR OUTER
LENS AND GASKET
10
6
REF
27
4
REF
42
11
12
VIEW IN DIRECTION
FOR BI-PIN LAMPS
31
30
31
29 OR
5
28
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PARTS LIST
PART NUMBER 40998 HIGH INTENSITY ELEVATED EDGELIGHT
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
PART NO.
QTY
40983-1
40983-2
40992
40992-1
40992-2
40986
10047-621
10A07-016D12
40918
40918-2
40918-7
40993
40749
40987
40990
10A07-016D12
40911
40972-XX
40969
50366
10050-23-C
10050-23-Y
10050-23-G
10050-23-R
10050-23-B
40989
10050-20
10050-21
10050-22
10050-26
10050-27
40718
10047-589
10038-31
40947
40991
10B06-019D20
20058
40925
20172
10047-2138
10047-2477
20496
20268
40995-2
40995-3
40995-4
40995-5
40995-6
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
2
1
1
1
1
A/R
A/R
A/R
A/R
A/R
1
A/R
A/R
A/R
A/R
A/R
1
1
1
1
1
4
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
DESCRIPTION
SUPPORT COLUMN, 1 1/2-12 UNF
SUPPORT COLUMN, 2" NPT
OPTICAL SUB ASSY (14" STD HGT)
OPTICAL SUB ASSY (16,18, & 20" FIX. HGT)
OPTICAL SUB ASSY (22"-30" FIX. HGT)
UPPER HOUSING
RELIEF BUSHING
SCREW RD. HD. #8-32 x 3/8 LG.
LEAD ASSY (14" STD HGT)
LEAD ASSY (16,18 & 20" FIX. HGT)
LEAD ASSY (22"-30" FIX. HGT)
LAMP HOLDER ASSY
LAMP HOLDER (SOCKET)
LAMP HOLDER BRACKET
SPRING CLIP, INNER LENS
SCREW, RD. HD., #8-32 x 3/8 LG.
RETAINER, SOCKET
INNER DOME, ASSY
SPACER
SPRING, INNER FILTER HALVES
INNER GLASS, CLEAR
INNER GLASS, YELLOW
INNER GLASS, GREEN
INNER GLASS, RED
INNER GLASS, BLUE
GASKET
OUTER LENS, CLEAR
OUTER LENS, RED/GREEN
OUTER LENS, GREEN/RED
OUTER LENS, CLEAR/OPAQUE
OUTER LENS, OPAQUE/CLEAR
LOCKNUT, 1 1/2-12 UNF
LOCKNUT, 2" NPT
LOCKPIN
CLAMP BAND
LABEL
SCREW, PAN HD., #10-32 x 5/8 LG.
LAMP, 120 W, 6.6 A
LAMP, 150 W, 6.6 A
LAMP, 200 W, 6.6 A
LAMP, 100 W, 6.6 A, PK30d
LAMP, 200 W, 6.6 A, PK30d
LAMP, 115 W, 6.6 A, DCR
LAMP, 200 W, 6.6 A, DCR
LAMP LABEL (120 W)
LAMP LABEL (150 W)
LAMP LABEL (200 W)
LAMP LABEL (100 W, PK30d)
LAMP LABEL (200 W, PK30d)
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ITEM NO.
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
PART NO.
QTY
40995-7
40995-8
50186
50184
40878-3P
40878-4P
40878-5P
40878-6P
40878-7P
40878-8P
40878-9P
40878-10P
10A10-025D16
50113
50113-1
50113-2
50114
50114-2
50114-7
50112
50111
50109
11A22-013D
10K01-013D
10A06-013D16
11A12-013D
50110
41852
50154
50154-1
50154-2
50153
50157
10037-603
50156
50156-2
50156-7
10047-2223
40995-9
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
2
1
1
1
1
1
1
1
1
1
4
4
2
2
2
1
1
1
1
1
1
2
A/R
A/R
A/R
A/R
A/R
DESCRIPTION
LAMP LABEL (115 W, DCR)
LAMP LABEL (200 W, DCR)
COUPLING, FLANGIBLE 1 1/2"-12 UNF, HRLP
COUPLING, FLANGIBLE, 2"-11 1/2 NPSM, HRLP
EXTENSION, 1" EMT, (16" FIX. HGT)
EXTENSION, 1" EMT, (18" FIX. HGT)
EXTENSION, 1" EMT, (20" FIX. HGT)
EXTENSION, 1" EMT, (22" FIX. HGT)
EXTENSION, 1" EMT, (24" FIX. HGT)
EXTENSION, 1" EMT, (26" FIX. HGT)
EXTENSION, 1" EMT, (28" FIX. HGT)
EXTENSION, 1" EMT, (30" FIX. HGT)
1/4-20 UNC X 1/2" LG HEX HD SCR
OPTICAL SUB ASSY, PK30d LAMP (14" HGT)
OPTICAL SUB ASSY, PK30d LAMP (16,18 & 20" HGT)
OPTICAL SUB ASSY, PK30d LAMP (22-30" HGT)
LEAD ASSY (14" STD HGT)
LEAD ASSY (16,18 & 20" FIX. HGT)
LEAD ASSY (22-30" FIX. HGT)
LAMP MTG BRKT ASSY
LAMP HOLDER BRKT, MODIFIED
BRACKET, LAMP MTG.
LOCKWASHER, INT. TOOTH, #6
HEX NUT, #6-32
SCREW, PAN HD., #6-32 x 1/2 LG.
WASHER, SPRING LOCK, #6
TAB, LAMP HOLD-DOWN
SUPPORT COLUMN-UPPER FITTING
OPTICAL SUB ASSY, DCR LAMP (14" HGT)
OPTICAL SUB ASSY, DCR LAMP (16,18 & 20" HGT)
OPTICAL SUB ASSY, DCR LAMP (22-30" HGT)
LAMP HOLDER, DCR, SUB-ASSY
SOCKET ASSY, DCR
STRAIN RELIEF
LEAD ASSY, DCR (14" STD HGT)
LEAD ASSY, DCR (16,18 & 20" FIX. HGT)
LEAD ASSY, DCR (22-30" FIX. HGT)
LAMP, 150W, 6.6A, PK30d
LAMP LABEL, 150W, PK30d
9