Cooper Industries
Crouse-Hinds Division
Crouse-Hinds Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095
860 683-4300
Fax 860 683-4354
Title:
DOCUMENT 2520
April 28, 2009
Revision D
FAA L-804
P/N 804E2
(for P/N 804E1 See Doc. 2107)
AIRPORT ELEVATED RUNWAY GUARD LIGHT
U.S. PATENT DES. 403, 263
Copyright  2009 Cooper Technologies company
CROUSE-HINDS AIRPORT LIGHTING PRODUCTS
DOCUMENT 2520
Rev. D
INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
REVISIONS
REVISION ISSUE/REISSUE
NUMBER
LTR NUMBER
A
A205-208
B
A206-459
C
A207-083
D
A209-004
DESCRIPTION
CHKD
Released for production
5/25/05
APPRV’
D
DRK
12/14/06
PG
3/12/07
PG
4/28/09
PG
Fig 10, added Cap & Reflector
Bracket P/N’s; revised copyright on
Title page
Revised copyright year from 2006 to
2007 on title page; 1.9, FAA AC
150/5345-46C was -46B; Figure 11,
P/N 50496 was 50249
Para. 2.7, FAA AC 150/5340-30D,
para. 4.4d & 4.4 e was FAA AC
150/5340-28, Para. 4.e; Appendix 2
title was FAA AC 150/5340-28, para
4.e
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CROUSE-HINDS AIRPORT LIGHTING PRODUCTS
DOCUMENT 2520
Rev. D
INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
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 Product’s obligation under this warranty is limited to use
reasonable effects 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
under the terms of this warranty are warranted for the remainder of the 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 the date of shipment or 12 months from date of first use whichever occurs first.
iii
CROUSE-HINDS AIRPORT LIGHTING PRODUCTS
DOCUMENT 2520
Rev. D
INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
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 techniques for resuscitation
found in widely published manuals of first aid instructions.
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CROUSE-HINDS AIRPORT LIGHTING PRODUCTS
DOCUMENT 2520
Rev. D
INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
SAFETY SYMBOLS
DANGER:
DANGER
The hazard or unsafe practice will result in severe injury or death.
WARNING:
WARNING
The hazard or unsafe practice could result in severe injury or death.
CAUTION:
CAUTION
The hazard or unsafe practice could result in minor injury.
NOTICE:
NOTICE
Possibly dangerous situation, goods might be damaged.
IMPORTANT:
IMPORTANT
Helpful information.
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DOCUMENT 2520
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INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
TABLE OF CONTENTS
Title Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
ii
iii
iv
v & vi
1.0
1
1
1
2
2
2
2
2.0
3.0
4.0
5.0
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
6.6A Series Unit with Monitoring . . . . . . . . . . . . . . . . . . . . . . . .
1.3
Intentionally Left Blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4
Intentionally Left Blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5
Units without Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
1.6
On/Off Switch (Option 1 & 2) . . . . . . . . . . . . . . . . . . . . . . . . . ..
1.7
Internal Logitrac Digital Control and Monitoring (6.6A Series
Circuit Only) (Option 4) . . . . . . . . . . . . . . . . . . . . . . . .
1.8
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9
FAA Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Tools Required for L-804 Installation . . . . . . . . . . . . . . . . . . . .
2.3
L-804 Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
Standard Monitoring Connection (Does not apply to Option 4)
2.5
Vertical Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6
Horizontal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7
Intentionally Left Blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8
External Ground Stud (Options 3 and 4). . . . . . . . . . . . . . . . .
2.9
Internal Logitrac Digital Monitoring Programming
(Options 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10
Logitrac Adapter (Lighting Vault) for Option 4 Monitoring
Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Relamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
Problem Solving Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
Recommended Field Quick Fix . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Spare Parts (2-year supply) . . . . . . . . . . . . . . . . . . . . . .
vi
2
3
3
6
6
6
7
7
7
8
8
8
8
9
13
13
13
13
13
14-17
17
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DOCUMENT 2520
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INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Part Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Illustration (continued). . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Illustration (continued). . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram, 6.6A Units (except Options 4) . . . . . . . . . . . . . . .
Intentionally Left Blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram, Option 4 Units. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Identification (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Identification (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Identification (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
10
11
12
18
19
20
22
23
24
25
Appendix 1 Typical Photometric Output 6.6 Amperes, Part Number 804E2. . . .
Appendix 2 FAA AC 150/5340-30D, Paragraph 4.4e . . . . . . . . . . . . . . . .. . . .. .
Appendix 3 Logitrac (Options 4) Circuit Card Monitoring Problem. . . . . . . . . . .
Appendix 4 Logitrac Adapter Problem (Option 4 Units) . . . . . . . . . . . . . . . . . . .
Appendix 5 Logitrac Adapter Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 6 Logitrac Programmer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .
26
27
28
29
30
31
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INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
1.0
GENERAL DESCRIPTION
1.1.
General
The Crouse-Hinds elevated runway guard light is an ETL verified FAA L-804. The flash rate
is 45-50 per minute alternately. The yellow traffic signal lenses are glass and are
housed in aluminum enclosures. Access to each PK30d 100w, 6.6A lamp is made
through a hinged cover secured by a wing nut. No special tools are required to
change the lamp. Circuit cards are housed in an aluminum enclosure attached
between the two light heads. Circuit cards can be changed without tools by
disconnecting the fast-on terminals from the terminal blocks and sliding the door off its
hinge pin. A spare door with replacement circuit cards can be slid back onto the hinge
pin and fast-on terminals reattached to circuit card terminal blocks. Positive angular
adjustment is made by bolting through the appropriate hole in the steel side supports
and yoke. The unit is attached to a standard steel 10-1/4 dia. B.C. L-867 light base
(customer supplied) and heavy 12-inch diameter baseplate (customer supplied, see
accessories, page 4) with a 2-11 1/2 NPSM threaded aluminum coupling. The
coupling is prevented from rotating due to jet blast by an aluminum anti-rotation plate
bolted to the baseplate. In addition, the coupling is prevented from rotating and lifting
out of its aluminum slide fit mount by three sets of set screws. A galvanized steel
tether is provided for securing the unit to the baseplate. Power is provided to the unit
through an L-823 style plug. A ground stud is provided internal for units with
monitoring and external for units without. All hardware is type 18-8 stainless steel.
Power is provided to the unit through an appropriate size isolation transformer (not
provided). The average weight of the unit is approximately 45 lbs.
1.2.
6.6A Series Unit with Monitoring
Unit requires connection to a 100W, 6.6A series secondary isolation transformer. A
molded female connector is provided for connection to a 5 pin L-823 style plug. The 5
pin female connector provides for connection to the isolation transformer, a ground
lead for connection to the L-867 internal ground stud, and for connecting the
monitoring signal lines. Shielded monitor leads are connected to the circuit card relay
common and normally open or closed contact (customer to make this connection
depending on their preference). The monitoring relay (rated 120V, 2 A resistive load)
will provide a signal for failure of lamp(s), failure of a lamp(s) to flash and failure of the
monitoring device to a customer provided indicator. Per FAA AC 150/5340-28, a three
step FAA L-828 constant current regulator should be used for powering the Runway
Guard Light. Connection to a 5 step regulator is not recommended because a 5 step
will not provide the unit with enough current for visual intensity (unit will be very dim on
steps 1 & 2) see Figure 6 (with monitoring). If a 5 step CCR is to be used, then steps
B3, B4 and B5 are to be used.
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FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
1.3.
Intentionally Left Blank
1.4.
Intentionally Left Blank
1.5.
Units without Monitoring (Option -3)
Monitor circuit card, associated hardware and wiring not supplied with unit. In addition,
5 pin male and female connectors not provided. Power provided to unit from the
appropriate size isolation transformer through a supplied 2-pin molded L-823 plug.
See Figure 6 (without monitoring).
1.6.
On/Off Switch (Option -1 (6.6A))
Allows unit to be relamped or have circuit cards changed in field without turning power
off at source. Switch isolates the secondary of isolation transformer from the internal
circuitry.
1.7.
Internal Logitrac Digital Control & Monitoring (6.6A Series Circuit Only)
(Option -4)
This option is recommended for use with a Crouse-Hinds Digitrac computer system,
but not required. In addition, a Logitrac Adapter, See Appendix 5, must be ordered as
a separate item and installed in the lighting vault (see Section 2.10). Contact CrouseHinds sales for assistance. This option provides circuit cards that replace the 6.6A
series unit with monitoring per paragraph 1.2. Unit still requires connection to a 100W,
6.6A series secondary isolation transformer. (In addition, 5 pin male and female
connectors not provided.) Power provided to the unit from the isolation transformer
through a supplied 2-pin molded L-823 plug. Monitoring signals are sent from the L804 unit through the series circuit primary power cable. A circuit number (CKT) and
address number (ADRS) must be programmed onto the circuit card in order for
monitoring portion to function with Logitrac Adapter. The Logitrac Adapter can report
the monitoring information directly to the Crouse-Hinds Digitrac Computer System, or
the monitoring information can be obtained from a dry contact that indicates (1) or
more lamps are out on the circuit. See Section 2.9. Connection to a three step FAA
L-828 Constant Current Regulator is still required. See Figure 8.
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INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
1.8.
Environmental
Temperature:
Altitude:
Humidity:
Wind Loading:
1.9.
-55º to +55ºC
(-67º to +131ºF)
0 to 10,000 feet
Up to 100 percent
Up to 300 MPH
FAA Specification
Meets requirements of L-804 per FAA AC 150/5345-46C. Light housing front
surfaces, baffle plate and lens caps painted black. All other external parts are painted
aviation yellow with the exception of frangible coupling, stainless steel hardware,
tether, hinge, and latch..
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INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
PART NUMBER EXPLANATION
8 0 4
E 2
-
-
FAA L-804
ELEVATED
MODEL
INPUT POWER
066 = 6.6 AMP SERIES CIRCUIT
OPTIONS
1= EXTERNAL ON/OFF SWITCH, 6.6A
2 = NOT AVAILABLE
3 = WITHOUT MONITORING FEATURE
4 = INTERNAL LOGITRAC DIGITAL CONTROL & MONITORING
(6.6A SERIES CIRCUIT ONLY)
IN ADDITION, A LOGITRAC ADAPTER MUST BE INSTALLED IN THE VAULT.
ORDER THIS ITEM SEPARATELY.
CONSULT SALES FOR ASSISTANCE.
5 = ANTI-ROTATION PLATE FOR 16 INCH DIAMETER BASEPLATE.
ACCESSORIES:
33004 100W 6.6/6.6 AMP SERIES ISOLATION TRANSFORMER - 6.6 A INPUT
33005 100W 20/6.6 AMP SERIES ISOLATION TRANSFORMER - 20 A INPUT
P/N AP1832, 12-3/8 INCH DIAMETER (10-1/4 DIA. B.C.) HEAVY BASEPLATE WITH 2 INCH NPS
THREAD
P/N AP2832, 16 INCH DIAMETER (14-1/4 DIA. B.C.) HEAVY BASEPLATE WITH 2 INCH NPS
THREAD
50500, DOOR SUBASSEMBLY (INCLUDES GASKET, WARNING LABEL, HINGE HALF & STRIKE)
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INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
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DOCUMENT 2520
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INSTRUCTION MANUAL
FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
2.0.
INSTALLATION
2.1.
General
Locations for L-804 elevated runway guard lights are shown in FAA AC150/5340-28
and FAA AC 120-57A. In addition, the 10-1/4 diameter B.C. steel L-867 light base
should be installed per above mentioned advisory circular. The L-867 light base flange
is installed with the top of the flange flush with the concrete as finished grade
reference. This will maintain the maximum 26-inch unit mounting height at 20º vertical
or the 14-inch unit minimum mounting height to bottom of lens. If monitoring is
included with unit (exception: Option 4), use an L-867 base with an internal ground
(for connecting 5-pin female connector ground). A heavy baseplate (P/N AP1832 [123/8 dia.] or AP2832 [16-inch dia.]) should be used with this unit due to high wind
loading requirement. The 3/8 hardware used to secure the baseplate should have
bolts 1-3/4 inches long as a minimum (to attach tether and anti-rotation plate - 2-inch
long bolts provided). Baseplate gasket and baseplate should be installed on light
base, but do not fully secure bolts until L-804 unit has been installed. INSTALLATION
OF UNIT TO BE DONE WITH PRIMARY INCOMING POWER OFF AND SECURED.
Install appropriate isolation transformer into light base and make necessary primary
power connections using L-823 connectors. If no monitoring is ordered, isolation
transformer secondary connector will seat in baseplate L-823 connector holder. If unit
is ordered with monitoring (except Option 4), be sure to terminate remote signal lines
into a L-823 plug. Note: Large diameter contact for monitor relay common contact
and small diameter contact for monitor relay normally closed or open contact. With
monitoring (except Option 4), connect supplied 5 connect molded female connector as
follows: L-823 plug to isolation transformer, L-823 receptacle to field remote signal
line L-823 plug and green lead with ring terminal to light base internal ground stud. 5
contact L-823 style receptacle will connect to L-804 unit 5 pin L-823 style plug, 5
contact receptacle seats in baseplate L-823 connector holder (see Figure 5).
2.2.
Tools Required for L-804 Installation
Tools required for installation are 1/8 inch allen key, 7/16 socket and wrench, 9/16
socket, flat bladed screwdriver and channel locks to accommodate a minimum opening
of 1-3/4 inches.
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FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
2.3.
2.4.
L-804 Unit Installation
WARNING:
WARNING
Be sure POWER is OFF and secured.
Place the anti-rotation plate on top of baseplate. Hex cutout to be over threaded
center hub in baseplate. Plug L-804 unit 2 pin L-823 plug or 5 pin L-823 style plug into
mating receptacle held in center of baseplate. With L-804 unit upright, engage
frangible coupling threads into baseplate threaded center hub a couple of turns.
It is recommended that antiseize compound (i.e. Loctite Antiseize 767 or equal) be
applied to frangible coupling threads prior to installation to prevent galling and seizing.
Loosen the six set screws in L-804 unit leg holding the frangible coupling. Thread
frangible coupling all the way down into the baseplate. Align anti-rotation plate hex
with frangible coupling hex. Bolt anti-rotation plate to baseplate. Note: the antirotation plate will bend slightly when fully bolted in place. Bolt tether to a baseplate
mounting hole. Align L-804 unit yoke perpendicular with taxiway centerline and tighten
the six previously loosened set screws. Be sure #10 round head screws securing lens
caps are tight. Return power to circuit. L-804 unit should begin flashing. If L-804 unit
provided with optional On/Off switch, be sure switch is in ON position.
2.5.
Standard Monitoring Connection (Does not apply to Option 4)
A connection must be made to relay (relay rated 120V, 2 A resistive load) normal
contact. You have an option of a normally open or normally closed contact. With
POWER OFF and secured, open circuit card control box. Locate lead “Norm” from 5
pin plug and plug it into either lead “N.O.” (No Alarms) or “N.C.” (Alarm Indication)
depending on your choice. Return power to unit. (See Figure 5.)
2.6.
Vertical Adjustment
The vertical adjustment has been factory preset at zero degrees. There are four pivot
bolts (2 on each side) on the side supports. Loosen these bolts but DO NOT remove.
Remove the bolts located at zero degrees on the side supports. Position the L-804
unit to the desired vertical adjustment by aligning the appropriately marked degree
hole in the side supports with its mating hole in the yoke. Install bolts removed from
zero degree holes through new desired vertical adjustment holes and tighten. Tighten
side support pivot bolts. Vertical angle setting will be determined by the local airfield
engineer. Refer to FAA AC 150/5340-28, Para. 4.e. (see Appendix 2).
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FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
2.7.
Horizontal Adjustment
The horizontal adjustment has been factory pre-set to zero degrees. If required,
remove the two bolts located at zero degrees located on top of yoke. Loosen the
painted hex fitting (not the conduit fitting) located on top of the yoke. Rotate the L-804
to the desired horizontal adjustment by aligning the appropriate marked degree holes
in the yoke with their mating holes in leg plate. Install bolts removed from zero degree
holes through new desired horizontal adjustment holes and tighten. Tighten painted
center hex fitting previously loosened. Horizontal angle setting will be determined by
the local airfield engineer. Refer to FAA AC 150/5340-30D, paragraphs 4.4d & 4.4e.
(see Appendix 2).
2.8.
Intentionally Left Blank
2.9.
External Ground Stud (Options 3 and 4)
An external ground stud is provided on the bottom of the circuit card control box for
grounding the L-804 unit. Use #12 AWG (3.5 sq. mm) minimum for ground wire.
(Note: L-804 units with monitoring (except Option 4) have an internal ground. Also,
the female 5 pin L-823 style plug ground should be connected to the internal L-867
ground stud as explained in Section 2.1.)
2.10. Internal Logitrac Digital Monitoring Programming (Option 4)
(Crouse-Hinds Logitrac System only. Other monitoring schemes are the responsibility
of the manufacturer.)
Each L-804 fixture requires the assignment of a circuit (CKT) number to identify an
address (ADRS) number to identify the individual L-804 fixture. Circuit numbers are
two digit numbers between and including 01 through 31. Address numbers are two
digit numbers between and including 01-128, above 99 only last 2 digits will be
displayed. No L-804 fixture on the same circuit can be assigned the same address
number. Each L-804 fixture must have a circuit and address number programmed into
its circuit card for monitoring function (L-804 control function; i.e., flashing, on/off will
function without programming). See instruction manual 9802 for
8
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FAA L-804 AIRPORT ELEVATED RUNWAY GUARD LIGHT
programming instructions. Circuit card in L-804 fixture usually come from the factory
pre-programmed (factory must be provided circuit and address number), but may also
be programmed at the airfield using Crouse-Hinds programmer, P/N 10056-192 (120V,
60Hz) with appropriate interface cable (order separately). See Appendix 6. Factory
programmed circuit cards will have a tag on them indicating their circuit and address
number. Crouse-Hinds suggests airfield programmed circuit cards should have this
information marked onto the tag located inside the circuit card control box. Also for
Crouse-Hinds Digitrac airfield lighting computer on/off control of L-804 fixture pairs
(one L-804 fixture each side of taxiway), assign the same circuit (CKT) number to the
L-804 fixture pairs. Other L-804 fixture pairs on the same loop power must be
assigned different circuit (CKT) numbers for the L-804 fixture pairs to have separate
on/off control. If all L-804 fixtures on the same power loop are to turn on or off at the
same time, assign the same circuit (CKT) number to all fixtures.
2.11. Logitrac Adapter (Lighting Vault) for Option 4 Monitoring Interface
See instruction manual 9803 for installation and operating instructions. Each
regulator, which has a monitored Crouse-Hinds internal Logitrac Digitrac Control and
Monitoring (Option 4) L-804 fixtures installed in the field circuit, requires the use of a
Logitrac Adapter, P/N 10056-96 (120V, 60Hz). In addition, each Logitrac Adapter
requires a 200W 6.6/6.6A series isolation transformer to be attached to the regulator
after one of the load (field loop) terminals, a 120V, 60Hz (5W) (or 220V if 50 Hz)
source is also required for the Logitrac Adapter. This may be the internal regulator
source, if 120V, and adequate capacity is available.
The Logitrac Adapter can be connected to the Crouse-Hinds Airfield Lighting Digitrac
Computer (contact Crouse-Hinds sales for information). This will provide tower control
for each L-804 fixture pair by its circuit number. It will also provide tower monitoring
for each L-804 fixture per FAA AC 150/5345-46B.
Each Logitrac Adapter at the regulator will indicate if there is a lamp failure or circuit
card failure for each L-804 fixture by circuit and address number. Two sets of dry
contacts are also available on the Logitrac Adapter, one set sends a remote indication
of a L-804 fixture lamp or circuit card failure in the circuit loop, and the other set sends
a remote indication if the Logitrac Adapter itself fails.
An RS/232 link is located on each Logitrac Adapter. This link can be used by other
manufacturer’s of airfield lighting system computers to interface their airfield tower
lighting control and monitoring. It will be the responsibility of the airfield computer
system manufacturer to provide the necessary information for interface connections
and protocol/software interface.
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PERIODIC MAINTENANCE
WARNING:
WARNING
3.0.
Verify power is OFF and secured before accessing interior of light heads
and circuit card control box.
General
At least every 6 months, the L-804 unit should be checked for the following: loose
hardware; tighten all loose hardware. Water inside light heads; replace broken lenses
and worn gaskets. Water inside circuit card control box; replace worn gaskets and
check hole plug seal (apply RTV if necessary). Wiring; open light heads and circuit
card control box, making sure terminals are properly seated. Chipped paint; touch up
paint as necessary. Dirty lenses; clean with alcohol and dry with clean soft cloth. Dirty
photocell sensor: same as lens cleaning.
3.1.
Relamping
CAUTION:
Do not work on fixture when energized. Lenses and reflectors are
HOT when lamps are energized. After de-energizing, allow time for
lamps to cool down before servicing.
Lamps have a minimum average rated life of 1,000 hours at full current (6.6A).
Replace with Crouse-Hinds part number 10047-2138 (PK30d 100W, 6.6A) lamp only.
Avoid touching lamp glass envelope with bare fingers as this may shorten lamp life.
No tools are required for changing lamps. Loosen wing nut on light head door and
open to gain access to lamp, lift up reflector 180 degrees. Disconnect lamp lead
terminals. Lift both outer tabs on spring clips and rotate lamp 90 degrees and remove
lamp from rear. Install new lamp from rear by lifting both outer tabs on spring clips and
rotating lamp 90 degrees to seat it in spring clip bosses on reflector. Connect lamp
leads to wire leads (connections are not polarized) previously disconnected. Slowly let
reflector fall into rest position. Bottom tab will secure reflector when light head door is
closed and fastened. Close light head door and tighten wing nut making sure washer
is under wing nut and against door.
CAUTION
4.0.
TROUBLE-SHOOTING
4.1.
General
Work on electrical circuits should be done only by a qualified electrician with a working
knowledge of airfield lighting circuits. Trouble-shooting is accomplished by means of
process of elimination. It should be checked that the POWER is OFF and secured,
and
once one solution is tried, POWER is reapplied. Then POWER turned OFF and
secured and another solution tried, etc. until the problem is solved.
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4.2.
General (continued)
It is also assumed that the circuit is in proper working order from the isolation transformer
secondary connector/or 5 pin L-823 style receptacle all the way to and including the
power source. Use of a quality true RMS reading multi-meter with a current sensing
clamp-on attachment will aid in the trouble shooting of electrical circuits. A wiring
diagram is located on the unit inside the circuit card control box on the back wall.
4.3.
Problem Solving Guide
NOTE: Any time Options 4 circuit card is replaced, the replacement circuit card must be
programmed with correct circuit number and address for monitoring portion to function.
See Section 2.9.
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
Lamp(s) will not light
Lamp(s) will not flash
Burnt out lamp(s)
Change lamp(s)
Loose/broken wire(s)
Make proper connection.
Verify connections to
wiring diagram.
Optional ON/OFF switch in OFF position (also
see ON/OFF switch
problems).
Turn switch on
Check for power at one of the leads marked
“INPL” with your clamp on current sensing
probe. If power is
present, problem with circuit card.
Change circuit card 50260-1 or
50280-1 or 10056-1752
If no power at “INPL” lead
Change L-804 L-823 plug
lead
If L-804 still will not function.
Problem not with L-804 unit.
Possible field wiring problem
Loose/broken wire(s)
Make proper connection.
Verify connections to
wiring diagram.
Problem with circuit card
Change circuit card 50260-1 or
10056-1752
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Problem Solving Guide (continued)
PROBLEM
Lamp(s) appears dim
(series circuit unit)
POSSIBLE CAUSE
Constant current regulator setting to low
(Note: L-804 units used with a 5 step
constant current regulator will appear dim
or OFF on the 2 lowest brightness
steps).
CORRECTIVE ACTION
Verify current levels are
correct at regulator, if not
adjust regulator brightness
step
If still no change, set regulator to highest
step and verify 6.6A present on one of the
leads marked “INPL” with
your true RMS ammeter current clamp on.
If 6.6A not present, problem with
isolation transformer or circuit card. Test
isolation transformer secondary circuit
levels with secondary shorted. If current
levels are absent or low, transformer is
bad.
Change isolation
transformer
If current levels are correct, circuit card is
bad.
Change circuit card 50260-1
or 10056-1752
If current level < 6.4 amps regulator may
be overloaded.
Investigate regulator size as
compared to calculated load.
Upgrade to next size
regulator, if necessary.
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4.2 Problem Solving Guide (continued)
PROBLEM
Lamp(s) burns out
prematurely
POSSIBLE CAUSE
CORRECTIVE ACTION
Wrong lamp
Verify proper lamp, Part #
10047-2138 is being used.
Possible overcurrent condition
Re-calibrate regulator
For series circuit, verify constant current
regulator is not exceeding FAA high limit of
6.7A at highest step (for
6.6A regulator).
If power OK, verify current does not
exceed 6.6A at one lead marked “INPL”
with your True R.M.S. clamp-on
current sensing probe.
Optional ON/OFF switch
does not function
If exceeding 6.6A
Change isolation transformer
If 6.6A present
Change circuit card 50260-1
or 10056-1752
Defective switch
Note: Optional ON/OFF switch can be
isolated from circuit and unit made
functional by disconnecting leads marked
“INPL” from switch and connecting to
circuit card switch termination points
(leads marked INPL1 and INPL2).
Disconnect switch leads from circuit card.
Change switch
16
WARNING! Apply 2 layers of
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INPL” to “INPL” connections.
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4.2 Problem Solving Guide (continued)
PROBLEM
Monitoring does not
function
(except Option 4 and
4A)
POSSIBLE CAUSE
CORRECTIVE ACTION
Relay normal contact not connected
See Section 2.4
Relay K1 not seated in 50265-1 circuit
card socket
Push relay into socket
Loose or broken wire
Make proper connections
per wiring diagram
Problem with circuit card (be sure when
you change monitoring circuit card to loop
lamp lead through the center of the toroid
transformer on
circuit card)
Change circuit card 50265-1.
Verify connections per
wiring diagram.
Fix remote signal line wiring
Problem with field remote signal lines
Option 4 and 4A
Monitoring does not
function
4.3
Loose or broken wire
Make proper connection
Problem with circuit card
Change circuit card
10056-165. See Section 2.9
and Appendix 3.
Problem with Logitrac Adapter in vault
Fix vault Logitrac Adapter.
See Appendix 4.
Recommended Field Quick Fix
At times, the process of elimination trouble shooting will not be convenient due to
taxiway down time. Most problems with the L-804 unit generally will be limited to
the lamps and circuit cards. These can be changed in the field very quickly, due to
the fact all wiring utilizes fast-on terminations and no tools are required for changing
the lamps. No tools can be required for changing the circuit cards with the following
recommendation; Disconnect the leads from the circuit cards. Slide the circuit card
cabinet door off of its slip hinge with old circuit cards still attached. Slide a new
spare cabinet door with attached appropriate spare circuit cards back onto the
cabinet slip hinge. Re-attach leads to circuit cards per wiring diagram. You may
then fix circuit cards at your shop or contact Crouse-Hinds for repair or replacement
of defective circuit cards. NOTE: In order for Options 4 monitoring to function, the
circuit card must have had a circuit and address number programmed, see Section
2.9.
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5.0 RECOMMENDED SPARE PARTS (2 YEAR SUPPLY)
ITEM
QUANTITY
Lamp, 100W, 6.6A PK30d, Part No. 10047-2138
2 per unit
Spare circuit card cabinet door assembly (includes gasket, warning label, hinge half and
strike, Part No. 50284
1 per 5 units, 1 unit
minimum
Circuit card mounting screw, pan head with Nylok, #6-32 x 1/4 long, 18-8 stn stl, Part No.
10000-367
4 per airfield
8 per airfield with
Option 4
Male-Female hex standoff, #6-32 x 1-7/8 long, stn stl, Part No. 10037-409
4 per airfield
with monitoring
(except Option 4)
Logitrac mounting plate, Part No. 50276
1 per airfield
Option 4 units only
Monitor circuit card, Part No. 50265-1 (6.6A input)
1 per 5 units, 1 min.
monitoring units
only (except Option
4)
Circuit card, Mode 1 (6.6A), Part No. 50260-1
1 per 5 units, 1 min.
6.6A series circuit
without Option 4
only
Logitrac circuit assembly, Part No. 10056-1752 (Option 4)
(Airfield must have Crouse-Hinds Logitrac Programmer, Part No. 10056-192 (120V, 60
Hz) in order to program monitor portion information (circuit and address number) along
with interface cables (order separately, see Appendix 6). Also order part no. 50255 Wire
Group E.
1 per 10 units, 1
min. Option 4 units
only
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2.
Light Beam Orientation for Elevated Runway Guard Lights
RGLs should be oriented to maximize the visibility of the light by pilots of aircraft
approaching the runway holding position. The orientation should be specified by the
(airport) design engineer to aim the center of the light beam toward the aircraft cockpit,
when the aircraft is between 150 feet (45 m) and 200 feet (60 m) from the holding
position, along the predominant taxi path to the holding position. The vertical aiming
angle should be set between 5 degrees and 10 degrees above the horizontal. The
designer should specify aiming of the lights such that the steady burning intensity at all
viewing positions between 150 feet (45 m) and 200 feet (60 m) from the holding
position is at least 300 cd when operated at the highest intensity step. (Refer to AC
150/5345-46 (latest revision), Specification for Runway and Taxiway Light Fixtures, for
specifications for the light intensity and beamspread of the L-804 RGL fixture.) If these
criteria cannot be met for all taxi paths to the holding position, consideration should be
given to the use of multiple fixtures aimed to adequately cover the different taxi paths.
The use of in-pavement fixtures to increase the viewing coverage, or aiming the single
fixtures on each side of the holding position to optimize the illuminations of the
predominant taxi path.
APPENDIX 2
FAA AC 150/5340-30D, Paragraph 4.4e.
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An L-804 internal Logitrac circuit card failure will be indicated on the Logitrac Adapter
connected to the regulator for that particular circuit. The Logitrac Adapter will indicate
the circuit and address number of the L-804 fixture when prompted. To check that a L804 internal Logitrac circuit card is functioning, turn circuit power off and disconnect
the set of lamp leads “LT1” or “LT2” from the circuit card (ref. Figure 8). Turn circuit
power on. The Logitrac Adapter should indicate a lamp failure for that L-804 fixture. If
a L-804 internal Logitrac circuit card fails to perform its function (alternately flashing
lamps) and associated monitoring function, replace the circuit card with another
programmed circuit card (see Section 2.9). You may re-program the failed circuit card.
If the circuit card still does not function on a circuit with a known good Logitrac
Adapter, then that circuit card is defective.
APPENDIX 3
Logitrac (Option 4) Circuit Card Monitoring Problem
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Disconnecting a lamp on several L-804 fixtures on the same circuit from their Logitrac
circuit card will result in multiple lamp failures being indicated at that circuit’s Logitrac
Adapter. If indication not present on the Logitrac Adapter, then it is defective and must
be replaced. Also, a Logitrac Adapter failure will indicate that all Logitrac devices on
that circuit failed. Before replacing the Logitrac Adapter, be sure you did or checked
the following at the time of the test: Power switch to the Logitrac Adapter was on; fuse
on Logitrac Adapter was not blown; 120V, 60 Hz (220V if 50 Hz) source to Logitrac
Adapter was verified; 6.6A was verified at isolation transformer secondary connected
to the Logitrac Adapter; power was returned to field circuit after the lamps on L-804
Logitrac circuit cards were disconnected on that circuit. If one of these conditions
existed, correct the fault and repeat test before replacing Logitrac Adapter. Be sure
circuit power and source power are off before replacing the Logitrac Adapter. For
problems from the Logitrac Adapter to the airfield lighting computer system, consult
your airfield lighting computer system maintenance manual.
APPENDIX 4
Logitrac Adapter Problem (Options 4 Units)
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