Document Revision April 10, 2012 9211 Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 62 Watt Lamp Cooper Industries Crouse-Hinds Division Crouse-Hinds Airport Lighting 1200 Kennedy Road Windsor, CT 06095 Copyright © 2012 Cooper Technologies Company For Parts or Technical Service Call (860) 683-4300 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Revisions Revision Number T Issue/Reissue Letter Number A203-281A U A204-291 V A205-056 W Description See Record Copy for Previous Revisions. Revised extensively to delete use of 60880-X P.C. Board and related data. Added 61153-1 P.C. Board and related data Checked 1/21/04 Approved GFR Removed all references to LED Lamp out Indicator P/N 61158 and its operation. Incorporated Option 13 (tethers) as standard equipment. Added Options 19 and 20 to 1.3 Part Number and deleted Options 13 & 14. Added Symptom 5 to Table 1. Added Para 4.5 and Figure 10A. Added instructions and info to Para. 4.5 1/10/05 GFR 8/30/05 GFR A208-004 Added copyright to cover page; Figure 21, deleted alternate method (used Rawl 7324 or equal) 1/23/08 PG X A208-243 11/7/08 AJ Y A212-165 Updated Table 6 and Table 7; Updated Figures 1 thru 7 to reflect changes in Table 6 and Table 7. Page 12, Item 24 was 62241-1 thru 62241-3 5/10/12 MCB ii Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Limited Product Warranty THE FOLLOWING WARRANTY IS EXCLUSIVE AN 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 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 specifications 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 judgement proved not to be as warranted within the applicable warranty period. All cost 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 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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. WARNING: WARNING DO NOT PERFORM MAINTENANCE ON INTERNAL COMPONENTS FOR RELAMP WITH POWER ON. RESUSCITATION Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of first aid instruction. iv Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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. v Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Table of Contents Title Page .....................................................................................................................................i Revisions ................................................................................................................................... ii Limited Product Warranty ......................................................................................................... iii Safety Notices ............................................................................................................................ iv Table of Contents ....................................................................................................................... vi Test Equipment and Tools .......................................................................................................... ix Section 1. General Information ................................................................................................... 1 1.1 General Description ................................................................................................... 1 1.2 Classification of Signs ............................................................................................... 1 1.3 Part Numbers ............................................................................................................. 2 Section 2. Installation ................................................................................................................. 3 Section 3. Adding Additional Sign Modules ............................................................................... 4 Section 4. Maintenance and Troubleshooting – Electrical ............................................................ 4 4.1 Lamp Current Check for Style 2 (3-step) and Style 3 (5-step) AGS Signs .................. 4 4.2 Troubleshooting 3/5 Step AGS Signs ......................................................................... 5 4.3 Lamp Current Check for Style 5 (5.5A fixed current) AGS signs ............................... 8 4.4 Lamp Replacement .................................................................................................... 8 4.4 Sign PC Board P/N 61153-1 Calibration .................................................................... 9 vi Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 List of Tables Table 1 – Troubleshooting 3/5 step signs ..................................................................................... 6 Table 2 – Three step current levels .............................................................................................. 7 Table 3 – Five step current levels ................................................................................................ 7 Table 4 – Measured Load and Power Factor (Style 2 and Style 3) ............................................. 10 Table 5 – Measured Load and Power Factor (Style 5)................................................................ 10 Table 6 – Parts list ..................................................................................................................... 11 Table 7 – Recommended two year Spare Parts Stock................................................................. 14 vii Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 List of Figures Figure 1 – Typical AGS sign, side view.................................................................................. 5 Figure 2 – Single Module Sign, Series Circuit ...................................................................... 15 Figure 3 – Double Module Sign, Series Circuit ..................................................................... 16 Figure 4 – Single Module with Join Section, Series Circuit .................................................. 17 Figure 5 – Double Module with Joint Section, Series Circuit ................................................ 18 Figure 6 – Typical Jointing of Signs ..................................................................................... 19 Figure 7 – Joint Section ........................................................................................................ 20 Figure 8 – Wiring Schematic, Single Module, 3 or 5 Step...................................................... 21 Figure 9 – Wiring Schematic, Double Module. 3 or 5 Step .................................................... 22 Figure 10 – Tapped Transformer Wiring Detail, 3/5-Step ....................................................... 23 Figure 10A – Calibration of the 61153-1 Printed Circuit Board ................................................. 24 Figure 11 – Other configurations ............................................................................................ 25 Figure 12 – Wiring Schematic, Single Module, Style 5 (5.5A Fixed Current) .......................... 26 Figure 13 – Wiring Schematic, Double Module, Style 5 (5.5A Fixed Current)......................... 27 Figure 14 – Tapped Transformer Wiring Detail, Style 5 (5.5A Fixed Current) ........................ 28 Figure 15 – Not Used ............................................................................................................. 29 Figure 16 – Concrete Pad Dimensions .................................................................................... 30 Figure 17 – Concrete Pad Dimensions, Elbow to Base ............................................................ 31 Figure 18 – Sign Dimensions ................................................................................................. 32 Figure 19 – Mounting Detail, Steel Base ................................................................................ 33 Figure 20 – Mounting Detail, Elbow Assembly ...................................................................... 34 Figure 21 – Flange Installation ............................................................................................... 35 viii Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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 a specialized equipment needed to do the job. Refer to the equipment manufacturer’s manuals for the proper use, maintenance and calibration (if necessary) of all meters. 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 quality meter in good repair and calibration 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 reading may dramatically reduce lamp 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. All meter manufacturers offer TRUE RMS measuring meters. The following is a short list of TRUE RMS Multimeters from Fluke: Manufacturer Model Number Fluke 85III, 87III, 187, 189, 335, 336, 337 Our recommended meter is the Fluke 87III with the Fluke 80I-600A current clamp. ix Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 1.0 General Information 1.1 General Description Crouse-Hinds Airport Lighting Products, “AIRSIDE” internally illuminated Taxiway and Runway Signs provide outstanding message visibility, day or night. White on Red and Yellow on Black and Black on Yellow color combinations may be ordered with any desired message. Signs are available as single or double faced and are provided with retroreflective sign face. For further information on Taxiway Signs and their use, consult the latest revision FAA Advisory Circulars AC 150/5340-18 and AC 150/5345-44. 1.2 Classification of Signs The signs covered in this manual are designed and manufactured in accordance with the requirements of FAA Advisory Circular AC 150/5345-44H. Specifications for Taxiway and Runway Signs and conform to the following classifications as indicated in paragraph 1.2 of the above Advisory. Types: Type L-858Y – Direction destination and boundary sign – black legend on a yellow background. Type L-858R – Mandatory instruction sign white legend on a red background. Type L-858L – Taxiway and runway location sign yellow legend and border on a black background. A sign may consist of multiple arrays of the above messages. NOTE: Size 5 information in this manual is the same as the Size 3 single module unless noted otherwise. For size 4 distance marker signs, see Manual 9213. P/N 8581X-X 8582X-X 8583X-X 8585X-X Sizes Size 1 – 12 inch legend (small body) Size 2 – 15 inch legend (mid-size body) Size 3 – 18 inch legend (large body) Size 5 – 25 inch legend (large body DMS) 1 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 CAT. # -3 -5 -1 FAA Styles Style 2 – For operation from a 3 step series lighting circuit (4.8 to 6.6 amperes) Style 3 – For operation from a 5 step series lighting circuit (2.8 to 6.6 amperes) Style 5 – A (fixed) 5.5 ampere series lighting circuit Environmental Requirements Class 2 – For operation from -55ºC to +55ºC (+131ºF) Mode 2 – Sign for use in areas subjected to wind speed of up to 200 mph (322 km/h) 1.3 Part Numbers: 8 5 8 - FAA Type: FAA Size: 1 = Taxiway Sign, 30” High 2 = Taxiway Sign, 36” High 3 = Taxiway Sign, 42” High 4 = Distance Marker, 60” High 5 = Distance Marker, 42” High Number of Faces: 1 = Single Face 2 = Double Face Brightness Levels: 1 = FAA Style 5 (fixed, 5.5A)* 3 = FAA Style 2 (3 Steps, 4.8 o 6.6A)** 5 = FAA Style 3 (5 Steps, 2.8 to 6.6A)** Number of Lamp Modules: 1 to 4 (Note: 4 Module Size 2 exceeds spec. by 0.6 in) Options: 10 = Unenclosed Power Cable: 3 Ft. with Plug 11 = Flexible Liquidtight Conduit Enclosed 3 Ft. Power Cable 12 = External Power Switch 19 = Lamp Out Indicator 20 = Additional Tether (Single Module Sign Only) * Use 33101 and 33102 isolation transformers only. Use step 2 of a 3 step regulator. ** Circuit board P/N 61153-1 allows for either 3 or 5 step operation, with no adjustments. 2 - - Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 2.0 Installation PLEASE READ ALL OF THIS SECTION CAREFULLY BEFORE DOING ANYTHING! a. Refer to Figures 16 to 20 for the sign mounting pad layout and power feed location. b. Remove sign from the shipping container. c. Signs are usually installed so that the power connections are located towards the Taxiway or Runway. See Figures 2, 3 and 18. Notice the POWER LEG location in relation to the sign SIDE “B”. d. The concrete foundation for the sign must be flat and level (see Concrete Pad Dimensions – Figures 16 and 17). The foundation must extend below the frost line. The overall length of the pad will depend on the number of sign modules and the location of the transformer base. If the transformer base is to be located directly under a sign leg, the transformer base must be steel. If the transformer base is to be located at the end of the sign (using a 90º elbow to get the power cord into the sign, a plastic base may be used). e. It is recommended that the contractor who is to install the concrete pad use cast in place anchor bolts. See Figure 21. This requires that the anchor bolts be installed accurately as shown in the concrete pad dimensions Figures 16 and 17. Be sure to locate floor flanges so that the ribs are parallel to the sign centerline as indicated on the floor flange. f. Leveling the floor flanges is important for ease of installation of the sign. A long carpenter’s level can be placed across the top of the floor flanges to be sure they are all in line and level. Do not tighten the anchor nuts tight (only finger-tight) until the frangible couplings are installed. The frangible couplings can be removed from the sign and the sign lowered onto the couplings after they have been screwed into the floor flanges. An alternative is to lower the sign with the legs and flanges into place. Check the sign itself with a long carpenter’s level to be sure it is level. Note: Some vertical adjustments can be obtained by rotating the floor flanges a turn or two on the frangible coupling. g. Make sure all flanges are in full contact and sit flush on the pad before tightening the anchor bolts. Once the sign has been leveled, attach the sign tether to the closest anchor bolt and tighten all the anchor nuts securely. (NOTE: Anchor hardware is not supplied with the sign.) Anchor hardware should be corrosion resistant. The sign body must not be bent or distorted due to an uneven installation procedure. h. Install the power cord input lead to the output of isolation transformer. i. Electrical connections are shown in Figures 8-15 as applicable. 3 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 3.0 Installation of Additional Modules If additional sign modules must be added at a later date or during initial installation, proceed as follows: a. See Figures 4-7. b. Examine the construction of an existing joint section if available. c. The joint section is designed like the end of a sign. There is an angle bracket that slides into two vertical grooves in the extrusion. The end of the sign (See Figures 4-7) will connect to the joint section in a manner almost identical to the opposite end of the sign. d. After assembling the joint section, insert the four long screws in the bottom and two long screws at the top. Tighten the screws securely. Do not over-tighten or crush the plastic extrusion. Be sure the color of the joint section matches the sign face. e. Color matching is as follows: 1. For yellow sign face with black and yellow face on either side of the joint, use yellow joint. 2. For red and yellow face on either side of the joint, use yellow or red. In most cases, yellow will be provided. 3. If two red faces are used, the joint must be red. f. Attach the sign tether to the closest anchor bolt and tighten all the anchor nuts securely (NOTE: Anchor hardware is not supplied with the sign.) Anchor hardware should be corrosion resistant 4.0 Maintenance and Troubleshooting – Electrical Problems in this area should be referred to a qualified electrician due to the potential shock hazard. WARNING: WARNING REMOVE POWER BEFORE ATTEMPTING ANY SERVICING. 4.1 Lamp Current Check for Style 2 (3-step) and Style 3 (5-step) AGS Signs a. These signs are not adjustable and are calibrated at the factory. In addition, these signs may be connected to a 3-step or 5-step CCR without any modifications. However, to verify that the sign is operating properly, current delivered to the lamps should be checked. After signs have been installed and with power removed, remove the lamp access cap (see Figure 1) and use a true RMS ammeter to measure current to the lamps. 4 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 1. Typical AGS sign, Side View. b. Turn the lighting circuit on to any step and observe current through lamps. After about 3 seconds, the current should be between 5.9 and 6.4 amps (nominal is 6.2 amps). See Table 1 at the end of this section if there are any problems here or in any of the subsequent steps. c. Repeat (b) through all steps. There may be a 2-4 second a delay between steps before lamps are fired. d. Re-connect lamp, install the lamp access cap and sign is ready for operation. 4.2 Troubleshooting 3/5 Step AGS Signs When the circuit board is operating correctly, upon power up a sequence of 7 green LED’s will turn on and off, and will settle on one of them. Once this is done, the lamp(s) will turn on at the appropriate current (6.2 amps nominal). This circuit selects the proper tap on a transformer which either steps up the current from the airfield current loop to 6.2 amps (nominal) or steps the current down to 6.2 amps (nominal). The flashing sequence of LED’s at power-up is a pre-scan which determines that all taps from the transformer are connected to the circuit board, and whether there is a burned-out lamp or not. If there is a burned-out lamp, the circuit will immediately shunt the lamp(s). See Table 1 below if problems are encountered. 5 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Table 1 Troubleshooting 3/5 step signs Symptom Possible Cause/Solution 1. Lamps do not turn on a) 2.Lamps do not turn on a) 3. Lamps are too bright or too dim 4. Lamps flicker 5. A) Sign will not work in all brightness levels but works in others. B) Sign will not work in any level but lamps and current input are okay. Lamp circuit is open. Check for open lamps, or discontinuity between L1 and L2 of Fig. 8 (single module) or between L1 and B1 of Figs 9-11. b) Check wiring, ensure all connections between tap transformer and circuit board are sound. c) Check input current to circuit board at wires 1 or 10 of Figures 8-10. Should correspond to current loop currents of Tables 2 and 3. Replace isolation transformer if out of spec. If not, there is most likely a problem with the circuit board. Circuit cannot determine which tap to select. Check for proper current levels as in 1 (c) above. Check thoroughly for poor connections between the tap transformer and the circuit board. An open/loose contact can simulate a lamp out condition, or prevent the circuit from selecting the correct tap. In the latter case, the board will wait until a different current is selected on the airfield. If all connections and currents check out ok, then there is likely a bad component on the circuit board. a) Check that current to lamps is between 5.9 and 6.4 amps. If ok, then replace lamp(s). Old lamps can get very dim without burning out. If not within these limits, check input current to sign. It should be within the specifications given in Tables 2 and 3. b) There is a problem with the circuit board. Swap out with another to check, or replace. a) If using a series-type regulator, check that it is over 30% loaded. There is a lamp bypass built into the circuit that may be prematurely triggering, thereby stealing current from the lamps. Unloaded series regulators can produce large voltage spikes on the power line that can trigger the lamp bypass. b) Other sources of noise on the power line can cause the circuit to behave as if the current step is being changed. The circuit will attempt to re-find the ideal tap to be selected, and in the meantime the lamps may be bypassed (no current to lamps) which causes the ‘flicker’. Contact the factory for assistance. a) Do calibration procedure. See Paragraph 4.5 for calibration instructions.. b) Check that the jumpers on PC Board 61153-1 are in the correct positions. 6 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Table 2 For three step regulator circuits, the airfield current levels should be: Regulator Setting B10 B30 B100 Current Range (A, RMS) 4.7-4.9 5.3-5.7 6.4-6.7 Table 3 For five step regulator circuits, the airfield current levels should be: Regulator Setting B1 B2 B3 B4 B5 Current Range (A, RMS) 2.7-2.9 3.3-3.5 4.0-4.2 5.0-5.4 6.4-6.7 Note: See page ix for a list of meters that would be suitable for these measurements. 7 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 4.3 Lamp Current Check for Style 5 (5.5A fixed current) AGS signs Note: There is no circuit board in the Style 5 sign. The Style 5 sign operates with a stepup isolation transformer which bumps the current up to 6.2 amps from an input of 5.5 amps and drives the lamps directly. See Figures 12-15 for schematics and wiring configurations for Style 5 signs. a. Remove the lamp access cover nearest the power cord and use a true RMS current meter to measure current to the lamps. b. Turn the lighting circuit on to 5.5 amps c. If there is no current flowing through the lamps, turn the circuit off and check the continuity of each lamp in the sign. Replace the lamps that are open (blown). Turn the lighting circuit on. d. If the current level to the lamps is less than 5.9 A or greater than 6.4 amps, check the input current to the isolation transformer to make sure it is 5.5 amps. If so, replace the isolation transformer. Otherwise, adjust the output current of the regulator to 5.5 Amps and repeat current check. Fortunately there is not much that can go wrong with this type of sign so it is very easy to trouble shoot. 4.4 Lamp Replacement The signs are wired with a maximum of four lamps per power transformer in series, which means that when one lamp goes out, all lamps on that power transformer also go out. WARNING: WARNING BE SURE POWER TO THE SIGN HAS BEEN TURNED OFF. a. Remove the lamp access cap (Figure 1) by loosening the three screws and lifting off the cap. It may be necessary to supply power with the cover removed to determine which lamps are out. It is recommended that all the lamps in this sign loop be replaced at this time, however, you may choose to replace just those lamps that are burned out. Slide the lamps into brackets, install sockets and replace the covers and turn the power back on. 8 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 4.5 Sign PC Board P/N 61153-1 Calibration The 61153-1 PC Board doesn’t normally need to be calibrated in the field if the current levels feeding the sign are reasonably close to the nominal three or five step current levels. If the current levels feeding the sign are substantially different from the nominal, the 611531 PC Board can be calibrated in an attempt to calibrate the sign to the current levels provided. INSTRUCTIONS FOR CALIBRATION OF 61153-1 PC BOARD. 1. Turn the airfield circuit feeding the sign to the highest (6.6 Amp) brightness level. CAUTION: CAUTION The hazard or unsafe practice could result in minor injury. 2. Locate and remove the jumper “P7” from the “P7” pins on the 61153-1 PC Board. See Figure 10A. This operation shuts the PC Board off. 3. Locate and move jumper “P5” from open position on one pin, to the closed position on both pins in the “P5” location. This operation tells the PC Board to calibrate to the incoming current. 4. Replace the “P7” jumper on both of the “P7” pins. This operation turns the PC Board on in the calibrate mode. 5. Wait one minute for the PC Board to calibrate. All the lamps of the sign should be lit and LED 8 on the PC Board will be green if the calibration is complete. LED 8 will be flashing “red” if the circuit board did not calibrate. 6. Remove the “P7” jumper and then move the “P5” jumper back to the open position. Replace the “P7” jumper back on both pins. This operation takes the PC Board out of the calibration mode and puts it back in the operate mode. 7. If the Sign is calibrated, operate the sign through each step of the regulator. The following LED’s on the PC Board will indicate green for proper operation: 5 – Step Regulator Step #1 LED 7 Step #2 LED 6 Step #3 LED 5 Step #4 LED 3 Step #5 LED 1 3 – Step Regulator Step #1 LED 4 Step #2 LED 2 Step #3 LED 1 9 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 TABLE 4 AIRSIDE GUIDANCE SIGNS MEASURED LOAD (VA) AND POWER FACTOR (PF) STYLE 2 AND 3 LAMP MODULES 1 2* 3 4 ISOLATION XFMR, PART NO. 6.6/6.6 VA @ STEP B5/B100 PF 33004 (100W) 100 .95 Min 33006 (200W) 160 .95 Min 33010 (300W) 230 .95 Min 33010 (300W) 290 .95 Min Applies to all FAA sizes, single and double face. Tested on a Crouse-Hinds constant current regulator at 1/2 load. Measured wattage exceeds the total of the lamp wattage due to the power consumption of the sign internal electrical system. *Includes FAA Size 4 distance marker sign TABLE 5 AIRSIDE GUIDANCE SIGN MEASURED LOAD (VA) AND POWER FACTOR (PF) STYLE 5 (FIXED 5.5A CURRENT) LAMP MODULES 1 ISOLATION TRANSFORMER, PART NO. 5.5/6.2A 33101 (100W) VA 100 PF .95 min 2 33102 (200W) 160 .95 min 3 33101 & 33102 (300W) * 230 .95 min 4 33101 & 33102 (300W) * 290 .95 min * Use Consolidating Harness P/N 26811-27 10 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Parts List TABLE 6 See Figures 2 – 7 for item location ITEM NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 PART NUMBER Frangible Coupling 62245-1 62245-2 62245-3 62245-5 Floor Flange 25684-1 Leg 60684 Power Cord CAS1M-P-B-.86 PC Board Assembly (for item 8 61153-1 lamps) Tapped Transformer 61143 Lamp Cap 60638 Lamp, 62W 20590 Light Tube Assembly 60685-1 60685-2 60685-3 Cover 62243-1 62243-2 62243-3 62243-5 62243-6 62243-7 Bottom 60758-1 60759-1 60760-1 60758-2 60759-2 60760-2 Screw, Hex HD w/Nylok 10000-405 1/4-20 X 1” LG, SS (7/16” socket) Side 60615-1A 60615-2A 60615-3A 11 USED ON Size 1 Size 2 Size 3 Size 5 All Sizes All Sizes All Sizes 3-Step or 5-Step circuits All Sizes All Sizes All Sizes Size 1 Size 2 Size 3 & 5 Size 1, Single Module Size 2, Single Module Size 3 & 5, Single Module Size 1, Double Module Size 2, Double Module Size 3, Double Module Size 1, Single Module Size 2, Single Module Size 3 & 5, Single Module Size 1, Double Module Size 2, Double Module Size 3, Double Module All Sizes Size 1 Size 2 Size 3 & 5 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 ITEM NO. 14 15 16 16A 17 18 19 20 DESCRIPTION NOT USED Screw, Hex HD w/Nylok #6-32 x 3/8 LG, SS NOT USED NOT USED Name Plate Label, Isolation Transformer NOT USED Sign Face Panel (w/Legend) 21 Sign Panel, Black 22 23 24 Bracket, Center Support, Top Bracket, Center Support, Bottom Center Support 25 26 NOT USED Bracket, Top, Joint 27 Joint Channel/ Joint Panel PART NUMBER USED ON 10000-397 All Sizes 62092-2 60870 All Sizes All Sizes 60667-1 60667-2 60667-3 60667-5 60667-6 60667-7 60668-1 60668-2 60668-3 60668-5 60668-6 60668-7 62246 62227 62247-1 62247-2 62247-3 Size 1, Single Module Size 2, Single Module Size 3 & 5 Single Module Size 1, Double Module Size 2, Double Module Size 3, Double Module Size 1, Single Module Size 2, Single Module Size 3 & 5, Single Module Size 1, Double Module Size 2, Double Module Size 3, Double Module All Sizes, Double Module All Sizes, Double Module Size 1, Double Module Size 2, Double Module Size 3, Double Module 60852 All Sizes, Single/Double Module w/Joint, Size 1 & 2, Size 1 Sngl/Dbl Mod w/Joint Size 2 Sngl/Dbl Mod w/Joint Size 3 Sngl/Dbl Mod w/Joint 61098 61099 62448 12 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 ITEM NO. DESCRIPTION 28 Bracket, Joint PART NUMBER 60854 29 Bracket, Bottom, Joint 60851 30 Channel Support 60783 32 33 Rain Cap, End Rain Cap, Joint/Bottom 60633 60634 34 Plastic Extrusion, Machined 35 36 37 38 Cover Bracket Channel Bar Tether Hole Plug 61096 61097 60848 60849 60850 60728-1 10037-621 39 Center Support, Horizontal 62242-3 40 Bracket, Center Support, Middle 62244 41 Bracket Joint Panel 62249 USED ON Size 2, Single/Double Module w/Joint Size 1 & 2, Single/Double Module w/Joint All Sizes, Single/Double Module w/Joint All Sizes All Sizes, Single/Double Module w/Joint Size 1 Sngl/Dbl Mod w/Joint Size 2 Sngl/Dbl Mod w/Joint Size 3 Sngl/Dbl Mod w/Joint All Sizes w/Joint All Sizes w/Joint All sizes All Sizes - Single Module All Sizes - Joint Sections Single and Double Size 3 w/ and w/o Joint Sections, Single and Double Size 3 w/ and w/o Joint Sections, Single and Double Size 3 w/ Joint Note: 3 and 4 module signs are combinations of single and double module signs as shown in Figures 11 and 15. 13 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 RECOMMENDED TWO YEAR SPARE PARTS STOCK TABLE 7 DESCRIPTION Lamp, 62W. PART NUMBER 20590 RECOMMEDED QUANITY 1 Per Module Lamp Socket 61107 1 Per Every 20 Modules Circuit Card 61153-1 1 Per Every 20 Signs *Frangible Coupling 62245-X 1 Set Per Every 20 Signs Internal Tapped X’fmr 61143 1 Per Every 20 Signs **Cover Assembly 60844-X (includes cap, gasket and lamp screws) Lamp Cap 60638 1 Per Every 25 Signs 1 Per Every 25 Signs * = -1 For Size 1 -2 For Size 2 -3 For Size 3 -5 For Size 5 ** = 60844-1 For Size 1 Single 60844-2 For Size 2 Single 60844-3 For Size 3 Single 60844-5 For Size 1 Double 60844-6 For Size 2 Double 60844-7 For Size 3 Double 14 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 2. Single module sign 15 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 3. Double module sign. 16 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 4. Single module with joint section 17 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 5. Double module with joint section. 18 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 6. Joining of signs. 19 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 7. Close up of joint section. 20 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 8: Wiring schematic, single module, 3/5 Step. See Figure 10 if P/N 61143 is Rev B. See Figures 9 and 11 for other configurations. 21 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 9: Wiring schematic, double module, 3/5 step. See Figure 10 if P/N 61143 is Rev B. See Figures 8 and 11 for other configurations. 22 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 REV B of P/N 61143, Tap transformer P/N 61143 REV B ACE-12534 T7 REV C of 61143 P/N 61143 REV C ACE-12534 T7 A3 & T2 3 STEP T6 T11 & T2 T6 (3) T8 5 STEP T5 T8 Rev C of 61143 is a change in label only 5 STEP T6, ALSO T9 FOR 50W, 12V LAMP 3 & 5 STEP T9 FOR 65W, 6.6A LAMP 3 & 5 STEP T5 (5) T6 (5) T9 3 STEP T5 T5 (3) T4 To: T11 & T2 plug into back of E11 To: T4 To: T5 (3) To: T5 (5) To: T6 (3) To: T6 (5) To: T7 To: T8 As per label on 61143 REV C. For 61143 REV B, simply match corresponding tab location To: T9 To: T11 & T2 T4 Input Power E1- E9 = FEMALE COUPLERS E11 = FEMALE W/MALE COUPLER FEMALE COUPLER E2 E4 E5 (3) E5 (5) E6 (3) E7 E6 (5) E1 E10 E8 E9 E11 1 TO 4 62 W LAMPS A1 B1 A4 E3 MALE COUPLER P/N 61153-1 Figure 10: Wiring connections for P/N 61153 PCB to P/N 61143 tap transformer, Rev B or Rev C. See Figures 8, 9 and 11 for more details. 23 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 10A Calibration of the 61153-1 Printed Circuit Board. 24 L3 L3 B2 L1 25 B2 Joint Section Single Module B1 B2 Double Module B2 L2 L2 L4 L3 L1 L1 Figure 11: Other Configurations. Joint Section Double Module B2 Double Module B1 Single Module B1 Joint Section Double Module B2 L2 L2 L4 L3 B1 L1 B1 L1 A4 A4 E3 E3 PC Board Figure 11. Wiring schemes for 3 and 4 module signs (not shown in Figs 8 and 9). Viewed from A-side (PC board/Input power on right). L4 L2 L4 L2 B1 L1 A4 E3 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 PC Board PC Board Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 12: Wiring schematic, 5.5A fixed current, single module. See Figures 13, 14 for other configurations. 26 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 13: Wiring schematic, 5.5A fixed current, double module. See Figures 12 and 14 for other configurations. 27 Figure 14: Tapped Transformer Wiring Detail, Style 5 (5.5 A Fixed Current) 28 L3 L3 B2 L1 B2 Single Module B1 B2 Joint Section Double Module B2 L2 L2 L4 L3 B1 B2 Joint Section Double Module L1 Double Module L1 Single Module B1 Joint Section Double Module B2 L2 L2 L4 L3 B1 L1 B1 L1 B1 B1 Figure 14. Wiring schemes for 3 and 4 module Style 5 signs (not shown in Figs 12 and 13). Viewed from A-side with power input on right. L4 L2 L4 1 A1 1 A1 10 10 L2 B1 L1 1 B1 A1 10 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 THIS SHEET INTENTIONALLY LEFT BLANK Figure 15: NOT USED 29 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 16 Concrete pad dimensions 30 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 17: Concrete pad dimensions, elbow to base 31 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 18: Sign dimensions 32 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 19: Mounting detail, steel base 33 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 20: Mounting detail, Elbow Assy 34 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 1 1.25" (31.75mm) REF 6.75" (171.45mm) MINIMUM FLANGE INSTALLATION WITH 'L' ANCHOR BOLTS USE FOUR (4) 'L' TYPE ANCHOR BOLTS PER FLANGE, #1/2-13 x 8" MINIMUM BOLT MATERIAL TO BE ZINC GALVANIZED STEEL OR STAINLESS STEEL 1 ANCHOR BOLTS MUST BE CAPABLE OF WITHSTANDING A MINIMUM PULL-OUT (TENSION) LOAD OF 8750 POUNDS. FIGURE 21: Flange Installation 35