Cooper Industries
Crouse-Hinds Division
Crouse-Hinds Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095
860 683-4300
Fax 860 683-4354
DOCUMENT 9218
January 8, 2007
Revision M
Title:
INSTRUCTION MANUAL
L-802 HIGH INTENSITY
AIRPORT ROTATING BEACON
ARB-802XX
Copyright
 2007
Cooper Technologies Company
9218
Rev. M
REV.
A
DESCRIPTION
Revised Pages 9-12, 16-25
LTR.
A93-
CHK.
RBM
APV
RBM
B
Revised pages I, ii, iii, viii, 1, 15
A94311
RBM
RBM
C
Added option WWG, added shipping weight to para. 1.1, updated
Figure page numbers extensively, see record copy.
A97074
5/4/98
JAS
D
Reversed position of green and yellow lenses in Figure 8A
A98178
5/29/98
GFR
E
Revised Figures 1 & 2 to bring heater circuit out to external junction
box. Modified Section II, Para. 2.0 and Section III, Para. 3.0 to
cover change to wiring.
On page viii, Class 1 temperature was –35 degrees C
A99154
9/28/99
JAS
A200280
A201225
9/20/00
JAS
12/4/01
GFR
A202263
12/9/02
GFR
A203090
A203238
A205204
A205204
4/9/03
GFR
10/13/03
GFR
5/27/05
GFR
1/8/07
PG
F
G
H
J
K
L
M
Updated schematics Figures 1 thru 4, updated Figure 18 to add –5
version, updated Parts Lists Figures 11 thru 15, updated Figure 9 to
show new relay configuration, K1
Changed schematics Figs. 1 & 2 wire no. 15 was blue; updated Fig 9
to shown new Item 17 configuration and mounting; Fig. 19 worm gear
was KL2602
1000 Watt H.I.D. lamp was 10047-2292; Revised Figure 16 & 16A
to show new configuration for adjusting lamp height
Added Airport (Canada) to para. 1.1; Fig. 1 & 2 K1 Internal
Schematic, Wire No. 15 was Blue
Figure 16A, Item 22 was 65036
Figure 9, added note with regards to capacitor resistor; title page,
revised copyright
ii
9218
Rev. M
TABLE OF CONTENTS
Title Page....................................................................................................................... i
Revisions...................................................................................................................... ii
Table of Contents......................................................................................................... iii
Figures........................................................................................................................... iv
Limited Product Warranty............................................................................................. v
Safety Notices............................................................................................................... vi
Ordering Information.................................................................................................... viii
SECTION I - DESCRIPTION
1.0 Compliance.............................................................................................................. 1
2.0 Detailed Description................................................................................................ 1
SECTION II - INSTALLATION AND DESCRIPTION
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Mounting.................................................................................................................. 4
Wiring...................................................................................................................... 4
Lamping................................................................................................................... 4
Fuse.......................................................................................................................... 4
Lamp Elevation........................................................................................................ 4
Focusing................................................................................................................... 5
Lubrication............................................................................................................... 5
SECTION III - MAINTENANCE
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
Service Inspection.................................................................................................... 6
Relamping................................................................................................................ 6
Wiring...................................................................................................................... 6
Ring Gear and Ball Bearing Replacement.............................................................. 6
Troubleshooting....................................................................................................... 8
Lubrication............................................................................................................... 8
Focusing................................................................................................................... 8
Spare Parts............................................................................................................... 8
iii
9218
Rev. M
FIGURES
PAGE
Figure 1 - Wiring Diagram, 120V, 60Hz, Class 2 Beacon........................................... 9
Figure 2 - Wiring Diagram, 220V, 50Hz, Class 2 Beacon......................................... 10
Figure 3 - Wiring Diagram, 120V, 60Hz, Class 1 Beacon........................................ 11
Figure 4 - Wiring Diagram, 220V, 50Hz, Class 1 Beacon......................................... 12
Figure 5 - Wiring Diagram for Tell-Tale Circuit (Option -TR).. ............................... 13
Figure 6 - Beacon Mounting Pattern............................................................................ 14
Figure 7 - High Intensity Beacon Assembly.................................................................15
Figure 7A High Intensity Beacon................................................................................. 16
Figure 8 - Beacon Head Assembly............................................................................... 17
Figure 8A Beacon Head Assembly............................................................................... 18
Figure 9 - 1000W Beacon Base Assembly.............................................. .................... 19
Figure 10- 1000W Beacon Base Assembly.................................................................. 20
Figure 10A 1000W Beacon Base Assembly.................................................................. 21
Figure 11- Parts List-1000W Beacon Base Assembly.................................................. 22
Figure 16- Motor Base Sub-Assembly 1000W Beacon................................................ 27
Figure 16A Motor Base Sub-Assembly 1000W Beacon................................................ 28
Figure 17- Shaft and Ball Bearing Assembly................................................................ 29
Figure 18- Ballast Assembly.......................................................................................... 30
Figure 19- Motor Assembly........................................................................................... 31
Figure 20- Rotating Beacon External Wiring................................................................ 32
Spare Parts List............................................................................................................... 33
Figure 21 - Suggested Optional Vibration Isolation Mounting .................................... 34
iv
9218
Rev. M
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-Hins 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.
v
9218
Rev. M
SAFETY NOTICES
This equipment is normally used or connected to circuits that may employ voltages which are dangerous
and may be fatal if accidentally contacted by operating or maintenance personnel. Extreme caution should
be exercised when working with this equipment. While practical safety precautions have been
incorporated in this equipment, the following rules must be strictly observed:
KEEP AWAY FROM LIVE CIRCUITS
Operating and maintenance personnel must at all times observe all safety regulations. DO NOT
PERFORM MAINTENANCE ON INTERNAL COMPONENTS OR RE-LAMP WITH POWER
ON.
RESUSCITATION
Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely
published manuals of first aid instructions.
vi
9218
Rev. M
SAFETY SYMBOLS
DANGER:
DANGER
The hazard or unsafe practice will result in severe injury or death.
WARNING:
WARNIN
G
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.
vii
9218
Rev. M
ORDERING INFORMATION
802 X X - X - XX
FAA SPECIFICATION
802 = L-802 High Intensity
APPLICATION
A = Airport (white/green)
S = Seaplane (white/yellow)
H = Heliport (white/green/yellow)
CLASS
1 = -30°C
2 = -55°C (requires -TR option)
POWER
1 = 120 Volts, 60 Hz (12 RPM)
2 = 220 Volts, 50 Hz (10 RPM)
OPTIONS
BC = Low Angle Beam Cutoff
TR = Telltale Relay (see 80XXX-X-TR)
WW = Two White Lenses (see 80XXX-X-WW)
WWG = Two White Lenses and One Green Lens (Special) (See 80XXX-X-WWG)
9218
Rev. M
viii
9218
Rev. M
SECTION I - DESCRIPTION
1.0
COMPLIANCE
The products described herein comply with all applicable sections of FAA Advisory Circular
150/5345-12C (latest revision).
1.1
General
This manual provides instructions for the installation, operation and maintenance of the CrouseHinds ARB Type L-802 Rotating Beacon.
Type L-802 is a high intensity Beacon with a beam supplied by a single, replaceable, 1000 watt
lamp.
The ARB Beacon has a beam which revolves at a pre-determined speed of 12 RPM at 60 Hz, or
10 RPM at 50 Hz.
The ARB Beacon will supply two or three beams of light depending on the application.
APPLICATION
LENSES
LENS COLORS
Airport
Seaplane
Heliport
Airport (Canada)
2
2
3
2
White/Green
White/Yellow
White/Green/Yellow
White/White
Both types of Beacons can be supplied for Class 1 or Class 2 operation.
CLASS
TEMPERATURE RANGE
1
2
+55°C to -30°C
+55°C to -55°C
Shipping weight is 210 pounds.
2.0
DETAILED DESCRIPTION
2.1
Optical System
The Optical System consists of a stationary lamp mounted inside a rotating, cast aluminum head,
which contains two or three Fresnel type lenses of the required colors.
-1-
9218
Rev. M
SECTION I - DESCRIPTION (Cont'd)
2.2
Beam Adjustment
Provision has been made for adjustment of the beams in the vertical plane. The beams can be set
at any point between 1 degree to 10 degrees above horizontal. The factory setting of the beam
centers is 5 degrees above the horizontal.
2.3
Basic Construction
The ARB Beacon has a spun aluminum base which is supported by two channels. Four mounting
holes are provided for 3/8" bolts. The main shaft utilizes two single row, sealed, precision ball
bearings which support the turntable. A 1/6 HP motor is connected to the main shaft by means of
a worm and gear.
2.4
Motor
The motor supplied is 1/6 HP, 115 volt, 50/60 Hz. The 230V version uses the same motor with a
stepdown transformer.
2.5
Tell-Tale Lamp Circuit (Option -TR on Class 1, required on Class 2)
To provide remote indication of the H.I.D. lamp failure, a tell-tale lamp circuit is supplied. A relay
is located in the ARB Beacon Housing. It is wired to close the tell-tale lamp circuit when the
H.I.D. lamp fails. Two blue wires are provided in the junction box under the ARB Beacon
Housing for connecting to a remote indicating tell-tale device. See Figure 5.
The tell-tale circuit will remain closed until the burned out H.I.D. lamp is replaced. The relay will
reset itself when the new H.I.D. lamp is installed.
When the ambient temperature is below -29°C (-4°F), the H.I.D. lamp may not start. In order to
raise lamp temperature, a 250 watt quartz lamp is mounted adjacent to the H.I.D. lamp. A relay in
series with the H.I.D. lamp detects that the H.I.D. lamp is not operating and turns on the quartz
lamp. When the H.I.D. lamp starts, the relay turns the quartz lamp off.
-2-
9218
Rev. M
SECTION I - DESCRIPTION (Cont'd)
2.6
Motor Protection
To keep the motor at proper operating temperatures in cold weather, a 250 watt strip heater is
provided. The strip heater is located adjacent to the motor. A thermostat in series with the heater
turns on when the temperature reaches 0-3°C (32-38°F). The thermostat turns the heater off
when the ambient temperature reaches 5-9°C (42-48°F).
An externally replaceable fuse is wired in series with the motor. It is located on the underside of
the Beacon Housing and in front of the junction box. The fuse is a 15 amp, 500V time delay type.
-3-
9218
Rev. M
SECTION II - INSTALLATION AND OPERATION
1.0
MOUNTING
Remove the Beacon from the shipping container, but leave it bolted to the wooden platform. This
platform should be used for hoisting purposes and protection of the Beacon while doing so.
CAUTION must be used during hoisting to prevent the Beacon or platform from striking any
object.
Figure 6 shows the mounting dimensions for the Beacon. Four #3/8-16 bolts, lock washers and
flat washers must be used to mount the Beacon.
It may be desirable to make provision on the Beacon tower platform for a step to make access to
the lamp easier. See paragraph 3.0.
2.0
WIRING
There are six no. 16 AWG wires coiled up in the junction box. The black, white and green wires
are for normal AC wiring. The two blue wires are for the tell-tale lamp circuit (Option TR). The
black wire, 16 AWG, wire No. 4, is for the heater option.
3.0
LAMPING
The Beacon is supplied with one 1000 watt H.I.D. lamp. One 250 watt quartz lamp is supplied
with Option TR. Recommended replacement lamps are:
LAMP
1000 W H.I.D.
250 W Quartz
CROUSE-HINDS REPLACEMENT
10047-2795
10047-2293
Relamping is done through the top of the Beacon. Remove the three thumb screws, remove the
top cover and reach down into the Beacon to unscrew the lamp.
4.0
FUSE
The cartridge fuse is 15 amp time delay. Crouse-Hinds replacement is 10047-2344.
5.0
LAMP ELEVATION
The factory setting of the beam centers is 5 degrees above the horizontal. This setting is intended
for level terrain. When the beam is so adjusted that the bottom is parallel to the ground level, the
factory setting is correct according to the specification. If there is too much light at ground level,
shielding may be required. Contact the factory for a recommendation.
-4-
9218
Rev. M
SECTION II - INSTALLATION AND OPERATION (Cont'd)
6.0
FOCUSING
The Beacon is prefocused at the factory.
7.0
LUBRICATION
All ball bearings are sealed with permanent lubrication.
-5-
9218
Rev. M
SECTION III - MAINTENANCE
1.0
SERVICE INSPECTION
A schedule of periodic inspections should be established. The interval between inspections will
depend on the conditions under which the equipment is used, as well as the number of hours that it
operates.
At each periodic inspection, remove the top cover and lamps. Clean both sides of the lenses, as
well as the lamps, using soft cloths with alcohol. Replace any burned out lamps. See paragraph
3.0 of Section II for proper replacement numbers.
2.0
RELAMPING
The top filter cover and air filter must be removed to replace the lamp(s). Three #10-32 thumb
screws should be removed to lift off the top filter cover. Lift off the heat deflector (flat round plate)
and the air filter to gain access to the lamps.
See paragraph 3.0 of Section II for lamp replacement numbers. After relamping; reinstall the air
filter, heat deflector and top filter cover. To complete reassembly, align the three holes in the top
filter cover with the mounting brackets and reinstall the #10-32 thumb screws.
3.0
WIRING
The junction box for wiring the Beacon is located below the base and between the mounting
channels, it has a 1/2" NPT opening at the lower right handside to accept the external wiring
conduit.
Inside the junction box cover are six #16 AWG wires and six wire nuts. The wires connect as
follows:
4.0
WIRE
USAGE
Black
White
Green
Blue (2)
Black (wire no. 4)
AC Hot
AC Neutral
AC Ground
Tell-Tale Lamp
Heater
RING GEAR AND BALL BEARING REPLACEMENT
A)
Remove the air filter and cover. Remove the lamp and store them carefully. (See Figure
9)
-6-
9218
Rev. M
SECTION III - MAINTENANCE (Cont'd)
B)
Remove the head assembly, and the motor housing cover. This is done by loosening the
bolts located in front and just below the lenses. The head casting has been sealed from the
weather by a seam of RTV sealant. If you wish to separate the head casting from the
motor housing cover, cut the RTV with a very sharp knife. (Reseal with RTV after
assembly). If the head assembly is removed with the motor housing cover, two people are
required because of size of the assembly.
When replacing the head, be sure to check the location of the locating pins so that
reassembly can be done correctly. The head assembly will not seat if the location pins are
not aligned.
C)
Remove the wire nuts and disconnect wire numbers 12, 13, 20 and 6. (See Figures 1-4, 9
and 10).
D)
Loosen the set screws in the lamp adjustment collar and lift the collar and lamp sockets off
the top of the shaft, using caution as the wires slide out through the access hole in the side
of the shaft. (See Figure 17).
E)
Remove the lamp socket housing (Item #4). The gear and bearings are now accessible.
(See Figure 17).
F)
Remove and save the retaining ring (Item #14) from the shaft.
G)
The bearings can be replaced by removing the preload ring that holds the bearing in place.
However, if the bearing needs replacement, it is recommended that the worm and worm
gear be replaced at the same time. See Figure 18 for bearing assembly details. The fit of
the bearings into the worm gear casting is very close. If they must be removed, try a large
wooden dowel and mallet to drive the bearings out. Save the preload washers (P/N
10030-119) which go between the two bearings. After new bearings are assembled,
check to be sure they turn with finger pressure. There should be no binding.
After replacing the gear, bearings and retaining ring, very carefully feed the four lamp
socket wires down through the shaft and out the access hole nearest the ballast assembly.
Place the lamp adjustment collar over the shaft and slide it down. The top of the collar
should align with the first ring scribed 7/16" from the top of the shaft.
Reverse Steps C, B and A to reassemble the Beacon.
-7-
9218
Rev. M
SECTION III - MAINTENANCE
5.0
TROUBLESHOOTING
TROUBLE
Beacon will not light
PROBABLY CAUSE
Lamp burned out or fuse
failed.
Loose wiring
connection to lamp
socket.
Ballast failure
Beacon will not rotate
6.0
REMEDY
Replace lamp. Replace fuse.
Check wiring connections to
lamp socket.
Replace failed component.
Motor fuse failed.
Replace fuse.
Motor failed.
Replace motor.
LUBRICATION
All ball bearings supplied are sealed, with permanent lubrication. If a bearing fails, it should be
replaced.
Ring Gear: Apply a small amount of high quality, low temperature, silicone grease (Esso #325 or
equal) whenever the ring gear is serviced.
7.0
FOCUSING
All Beacons shipped from the factory are properly focused. No refocusing should be attempted in
the field, unless it is definitely determined that the lamps are out of focus. Contact Crouse-Hinds
for technical recommendations. Refocusing in the field, if ever required, should only be done with
Crouse-Hinds technical support.
8.0
SPARE PARTS
Spare parts may be ordered by Crouse-Hinds part number as shown in Figures 7 through 21. Do
not use the item numbers in the "balloons".
-8-
9218
Rev. M
-9-
9218
Rev. M
-10-
120VAC, 60Hz
G
N
L
L3
L2
L1
EXTERIOR JUNCTION BOX
L3 E1
L2
L1
650V
LA1
TB1
11
5
18
1
-11-
11
T2
21
5
COM2
17
CAP
(HID)
DS1
C1
M1
9
12
BALLAST WN
COM1
18
120V
15A
TIME DELAY
1
F1
13
16
WN
9218
Rev. M
FIGURE 3
WIRING DIAGRAM, 120V, 60Hz
CLASS 1 BEACON
220VAC, 50Hz
L
G
N
L3
L2
L1
EXTERIOR JUNCTION BOX
L3 E1
LA1
6
5
4
3
2
1
650V
BLK
WHT
BLK
L2
L1
TB1
29
11
30
18
30
37
11
COM1
120V
T1
T2
X2
X1
COM2
17
CAP
240-120V
H1
H2
H3
H4
32
31
9
12
BALLAST WN
18
220V
37
29
(HID)
DS1
C1
13
16
WN
32
31
6
5
4
3
2
1
TB2
5
1
F1
15A
TIME DELAY
1
21
5
BRN
YEL
BLK
5 BLU
4 RED
1
M1
6
9218
Rev. M
FIGURE 4
WIRING DIAGRAM, 220V, 50Hz
CLASS 1 BEACON
-12-
9218
Rev. M
BLUE WIRE
EXTERNAL
TELL-TALE
DEVICE
(NOT INCLUDED)
ROTATING
BEACON
BLUE WIRE
NOTES:
1.
120V SUPPLIED BY CROUSE-HINDS AIRPORT LIGHTING
FOR -TR OPTION.
2.
EXTERNAL WIRING AND INDICATOR ARE NOT PROVIDED
BY CROUSE-HINDS.
CAUTION
DAMAGE CAUSED BY INCORRECT EXTERNAL WIRING IS NOT
COVERED BY WARRANTY.
FIGURE 5
WIRING DIAGRAM FOR TELL-TALE CIRCUIT
(OPTION -TR)
-13-
9218
Rev. M
19.00
.75
18.00
17.50 TYP
16.00 TYP
30.31 DIA REF
(BEACON MAX.)
1.00
3/8" BOLT HOLE
4 PLACES
BEACON MOUNTING SURFACE
BEACON MOUNTING DETAIL
63.0 REF
BEACON MOUNTING SURFACE
36.0 REF
19" REF
20.00
BEACON MOUNTED ON TOWER PLATFORM
FIGURE 6
BEACON MOUNTING PATTERN
-14-
9218
Rev. M
AIR FILTER
AND COVER
8
2
3
4
42.83
5
6
3.
7
1
30.31
OPTIONS
PART NUMBER
80200-1
80200-2
80200-3
80200-4
80200-5
80200-6
80200-7
80200-8
80200-9
80200-10
80200-11
80200-12
80200-13
80200-14
80200-15
80200-16
80200-17
80200-18
80200-19
80200-20
80200-21
80200-22
80200-23
80200-24
120V
60 Hz
X
220V
50 Hz
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
CLASS
1= -35°C
2= -55°C
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
AIRPORT
X
X
X
X
APPLICATION
SEAPLANE
HELIPORT
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
LOW ANGLE
BEAM CUTOFF
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
FIGURE 7
HIGH INTENSITY BEACON ASSEMBLY
SEE PARTS LIST ON PAGE 16
-15-
CATALOG
NUMBER
802A1-1
802A1-2
802A2-1-TR
802A2-2-TR
802S1-1
802S1-2
802S2-1-TR
802S2-2-TR
802H1-1
802H1-2
802H2-1-TR
802H2-2-TR
802A1-1-BC
802A1-2-BC
802A2-1-BC-TR
802A2-2-BC-TR
802S1-1-BC
802S1-2-BC
802S2-1-BC-TR
802S2-2-BC-TR
802H1-1-BC
802H1-2-BC
802H2-1-BC-TR
802H2-2-BC-TR
-16-
-1
------
QTY
1
-------
QTY
-23
--------
QTY
-24
-22
---1
----
1
-------
1
-----1
1
A/R
1
6
6
-1
1
A/R
1
6
6
1
1
1
A/R
1
6
6
1
1
-21
QTY
--1
-----
---1
----
1
A/R
1
6
6
-1
-20
QTY
--------
-1
----1
1
A/R
1
4
4
1
1
-19
QTY
1
-------
-1
------
-18
QTY
-1
------
----1
---
-17
QTY
--1
-----
----1
---
-16
QTY
--------
--1
---1
1
A/R
1
4
4
1
1
-15
QTY
1
-------
--1
-----
1
A/R
1
4
4
1
1
-14
QTY
-1
------
-----1
--
1
A/R
1
4
4
-1
-13
QTY
--1
-----
-----1
--
1
A/R
1
4
4
-1
-12
QTY
---1
----
1
-------
1
A/R
1
6
6
1
1
-10
QTY
-----1
--
---1
----
1
A/R
1
6
6
-1
-9
QTY
------1
---1
----
1
A/R
1
6
6
-1
-8
QTY
---1
----
-1
------
1
A/R
1
4
4
1
1
-6
QTY
-----1
--
----1
---
1
A/R
1
4
4
-1
-5
QTY
------1
----1
---
1
A/R
1
4
4
-1
-4
QTY
---1
----
--1
-----
1
A/R
1
4
4
1
1
-3
QTY
----1
---
--1
-----
1
A/R
1
4
4
1
1
-2
QTY
-----1
--
-----1
--
1
A/R
1
4
4
-1
FIGURE 7A
-7
QTY
----1
---
-1
------
1
A/R
1
4
4
1
1
-1
QTY
------1
-----1
--
1
A/R
1
4
4
-1
802XX-X-XX
(REQUIRES -TR OPTION)
ITEM
1
1
1
1
1
1
1
2
2
2
2
2
2
1
9
8
7
6
5
4
3
65032-7
65032-6
65032-5
65032-4
65032-3
65032-2
65032-1
65033-6
65033-5
65033-4
65033-3
65033-2
65033-1
65032-8
PART NUMBER
9218
10048-2
65012
10037-506
10B10-019D36
10047-2293
10047-2795
PARTS LIST
BASE ASSEMBLY,
BASE ASSEMBLY,
BASE ASSEMBLY,
BASE ASSEMBLY,
BASE ASSEMBLY,
BASE ASSEMBLY,
BASE ASSEMBLY,
HEAD ASSEMBLY,
HEAD ASSEMBLY,
HEAD ASSEMBLY,
HEAD ASSEMBLY,
HEAD ASSEMBLY,
HEAD ASSEMBLY,
BASE ASSEMBLY,
120V,
220V,
120V,
220V,
120V,
220V,
120V,
DESCRIPTION
60Hz,
50Hz,
60Hz,
50Hz,
60Hz,
50Hz,
60Hz,
CLASS
CLASS
CLASS
CLASS
CLASS
CLASS
CLASS
2
1
1
2
2
1
1
HELIPORT , CLASS 2
SEAPLANE , CLASS 2
AIRPORT , CLASS 2
HELIPORT , CLASS 1
SEAPLANE , CLASS 1
AIRPORT , CLASS 1
220V, 50Hz, CLASS 2
INSTRUCTION MANUAL, L-802
SEALANT, RED, RTV #106
HOUSING, MOTOR
WASHER, FLAT SEALING, SS, #10
SCREW, HEX HD, SS, #10-32 x 1-1/4" LG.
LAMP, TH
LAMP, HID
BC = LOW ANGLE BEAM CUTOFF
TR = TELLTALE RELAY
(SEE 80XXX-X-TR)
WW = TWO WHITE LENSES
(SEE 80XXX-X-WW)
OPTIONS
1 = 120 VOLTS, 60 Hz (12 RPM)
2 = 220 VOLTS, 50 Hz (10 RPM)
POWER
1 = -35°C
2 = -55°C
CLASS
A = AIRPORT (WHITE/GREEN)
S = SEAPLANE (WHITE/YELLOW)
H = HELIPORT (WHITE/GREEN/YELLOW)
APPLICATION
802 = L-802 HIGH INTENSITY
FAA SPECIFICATION
ORDERING INFORMATION
HIGH INTENSITY BEACON ASSEMBLY
-11
QTY
----1
---
1
-------
1
A/R
1
6
6
1
1
TEST PER CROUSE-HINDS PRODUCTION TEST PROCEDURE NO. 9243.
4.
1
A/R
1
4
4
-1
APPLY A BEAD OF RED RTV (ITEM 8) ALL AROUND THE BOTTOM OF
THE BEACON HEAD (ITEM 2) AFTER ASSEMBLY.
3.
1
A/R
1
4
4
-1
LEAVE LAMPS IN THE ORIGINAL BOXES AND TAPE THEM SEPERATELY
IN THE SHIPPING CONTAINER.
1
A/R
1
4
4
1
1
THE AIR FILTER AND COVER MUST BE REMOVED TO INSTALL
OR CHANGE LAMPS.
2.
BEACON MOUNTING PATTERN
.406 DIA - 4 MOUNTING HOLES
USE OF #3/8-16 MOUNTING
HARDWARE IS RECOMMENDED
1.
NOTES:
16.00
17.50
30.31 DIA REF
,LABC
,LABC
,LABC
,LABC
9218
Rev. M
9218
Rev. M
-17-
9218
Rev. M
-18-
9218
Rev. M
-19-
9218
Rev. M
54
59
31
1
32
33
34
35
24
PARTIAL FRONT VIEW
FIGURE 10
1000W BASE ASSEMBLY
-20-
XF1
F1
55
9218
Rev. M
7
65
1
2
2.75 REF
MAY BE INSTALLED
AT FINAL ASSEMBLY
SIDE VIEW
FIGURE 10A
1000W BASE ASSEMBLY
SEE FIGURES 11-14 FOR PARTS LIST
-21-
65009
65031-1
10A10-037D24
11A12-037D
10047-2297
10047-2294
11A02-025D
11A12-025D
10K01-025D
10037-589
10047-2298
65045
6
7
-22-
8
9
10
11
12
13
14
15
FIGURE 11
PARTS LIST
1000W BEACON BASE ASSEMBLY
16
17
K1 --
RELAY ASSEMBLY, HID LAMP
--
1
4
8
8
4
--
--
6
6
1
1
6
--
1
--
THIS PARTS LIST FOR FIGURES 9 & 10 ONLY
T1 --
XFMR, STEP-DOWN, 240V-120V
4
8
NUT, HEX, SS, #1/4-20
SPACER
8
LOCKWASHER, SPLIT, SS, #1/4
---
VR1
FLAT WASHER, SS, #1/4
THERMOSTAT
--
STRIP HEATER, 250W, 120V
HR1
6
LOCKWASHER, SPLIT, SS, #3/8
M1 1
1
6
--
--
1
6
, W/O B.C.
C1,T2
C1,T2
C1,T2
2
1
-2
2
1
-3
2
1
-4
2
1
-5
2
1
-6
5
2
1
-7
2
1
-8
1
--
4
14
14
2
1
1
6
6
--
1
6
--
--
1
1
1
4
14
14
6
1
--
6
6
--
1
6
1
--
--
--
--
4
8
8
--
--
--
6
6
--
1
6
--
--
1
--
1
4
8
8
4
--
--
6
6
--
1
6
--
1
--
1
--
4
14
14
2
1
1
6
6
--
1
6
--
--
1
1
1
4
14
14
6
1
--
6
6
--
1
6
1
--
--
A/R A/R A/R A/R A/R A/R A/R A/R
2
1
BOLT, HEX HD, SS, #3/8-16 x 3/4" LG.
MOTOR BASE SUB-ASSEMBLY
SCREEN
WASHER, VIBRATION
220V, 50Hz
220V, 50Hz
BALLAST ASSY, 1000W,
65069
65058-2
4
120V, 60Hz
BALLAST ASSY, 1000W,
5
65058-1
4
ADHESIVE, RTV-106
BALLAST ASSY, 1000W,
10048-2
3
CHANNEL
65058-5
65027
2
BASE HOUSING
4
65014
1
-1
1
PL65032-X
9218
Rev. M
FIGURE 12
PARTS LIST
1000W BEACON BASE ASSEMBLY
-2365040
20V48-001
10047-2344
10A06-016D24
11A02-016D
15B01-050
10037-590
10037-591
10047-1434
10045-3
65034-15
26
27
28
29
30
31
32
33
34
35
37
1
TERMINAL BLOCK, 6 POSITION
1
1
PLASTIC BAG, 4" x 5"
WIRE ASSY, L1
5
1
COVER, JUNCTION BOX
WIRE NUT
1
1
CLOSE NIPPLE, STL, 1/2" N.P.T.
JUNCTION BOX
2
FLAT WASHER, SS, #8
1
1
2
F1
XF1
SCREW, PAN HD, SS, #8-32 x 3/4" LG.
FUSE, 15 AMP, TIME DELAY
FUSEPOST
1
1
LIGHTNING ARRESTOR ASSY, 650V
BRACKET, ARRESTOR
1
LOCKNUT, CONDUIT
LA1
7
9
LOCKWASHER, SS, #6
NUT, HEX, SS, #6-32
4
FLAT WASHER, SS, #6
TB1,TB2
3
NUT, HEX, SS, #8-32
1
1
5
1
1
1
2
2
1
1
1
1
1
9
13
6
2
3
3
3
LOCKWASHER, SPLIT, SS, #8
THS PARTS LIST FOR FIGURES 9 & 10 ONLY
65046
25
11A12-013D
22
10037-290
11A02-013D
21
24
65039
20
10K01-013D
10K01-016D
19
23
11A12-016D
18
-2
-1
1
1
11
1
1
1
2
2
1
1
1
1
1
7
9
4
1
4
4
-3
1
1
10
1
1
1
2
2
1
1
1
1
1
9
13
6
2
4
4
-4
1
1
5
1
1
1
2
2
1
1
1
1
1
7
9
4
1
3
3
-5
2
1
1
5
1
1
1
2
2
1
1
1
1
1
9
13
6
2
3
3
-6
5
1
1
11
1
1
1
2
2
1
1
1
1
1
7
9
4
1
4
4
-7
1
1
10
1
1
1
2
2
1
1
1
1
1
9
13
6
2
4
4
-8
PL65032-X
9218
Rev. M
65034-6
65034-8
65034-10
40
41
42
FIGURE 13
PARTS LIST
1000W BEACON BASE ASSEMBLY
-2465034-13
65034-9
65034-3
65034-5
65034-4
65034-1
65034-2
46
47
48
49
50
51
52
65043
65031-2
55
56
MOTOR BASE SUB-ASSEMBLY
LABEL, FUSE
NAMEPLATE
WIRE ASSY, 1
WIRE ASSY, 1
WIRE ASSY, 8
WIRE ASSY, 10
WIRE ASSY, 4
WIRE ASSY, 26
WIRE ASSY, 32
WIRE ASSY, 31
WIRE ASSY, 30
WIRE ASSY, 29
WIRE ASSY, 26
WIRE ASSY, 25
WIRE ASSY, L3
WIRE ASSY, L2
, W/B.C.
M1 --
1
1
--
1
--
--
--
--
--
--
--
--
--
--
1
1
--
1
1
1
--
--
--
--
--
1
1
1
1
--
--
1
1
-2
THIS PARTS LIST FOR FIGURES 9 & 10 ONLY
65028
54
53
65034-12
45
44
65034-11
65034-17
39
43
65034-16
38
-1
--
1
1
--
1
1
1
1
--
--
--
--
--
1
1
1
1
-3
--
1
1
1
--
1
1
1
1
1
1
1
1
--
1
1
1
-4
1
1
1
--
1
--
--
--
--
--
--
--
--
--
--
1
1
-5
3
1
1
1
1
--
--
--
--
--
1
1
1
1
--
--
1
1
-6
5
--
1
1
--
1
1
1
1
--
--
--
--
--
1
1
1
1
-7
--
1
1
1
--
1
1
1
1
1
1
1
1
--
1
1
1
-8
PL65032-X
9218
Rev. M
-2510L01-019D
65
FIGURE 14
PARTS LIST
1000W BEACON BASE ASSEMBLY
75
74
73
72
71
70
69
68
67
66
LOCKWASHER, SPLIT, #10 SST
11A12-019D
64
, W/B.C.
M1
, W/O B.C. M1
1
--
--
1
--
1
-3
1
--
1
-4
1
--
--
-5
1
--
--
-6
5
1
1
--
-7
1
1
--
-8
--
--
--
--
--
--
--
--
--
--
1
1
1
1
--
1
1
1
1
1
--
--
--
--
--
--
--
--
--
--
1
1
1
1
--
1
1
1
1
1
A/R A/R A/R A/R A/R A/R A/R A/R
1
--
--
-2
THIS PARTS LIST FOR FIGURES 9 & 10 ONLY
HEX NUT, #10-32 SST
FLAT WASHER, #10 SST
STRIP HEATER, 250W, 240V
11A01-019D
10047-2299
61
LOCTITE, #242
63
10048-30
60
SUPPORT PLATE, BASE
TY-RAP W/MOUNTING HOLE
65049
59
MOTOR BASE SUB-ASSEMBLY
10053-166
65031-4
58
MOTOR BASE SUB-ASSEMBLY
62
65031-3
57
-1
4
PL65032-X
9218
Rev. M
-26-
FIGURE 15
PARTS LIST
1000W BEACON BASE ASSEMBLY
4
2
10037-628
94
THIS PARTS LIST FOR FIGURES 9 & 10 ONLY
STANDOFF, M-F, ALUM, #6-32x3/8" LG.
4
2
MARKER STRIP, 6 POLE
10047-2380
93
2
2
1
1
1
TUBING, HEAT SHRINK, 2" LG.
10047-1169
92
15
15
10047-1222
91
15
WIR. DIAG.,220V,50HZ,CLASS 1
65042
90
--
--
TYRAP
WIR. DIAG.,120V,60Hz,CLASS 1
65041
89
--
--
--
--
WIR. DIAG.,220V,50Hz,CLASS 2
65038
88
--
-3
--
-2
--
WIR. DIAG.,120V,60Hz,CLASS 2
65037
87
86
85
84
83
82
81
80
79
78
77
76
-1
4
4
1
15
--
--
--
-4
2
2
1
15
--
--
--
-5
5
4
4
1
15
--
--
--
-6
5
2
2
1
15
--
--
--
-7
4
4
1
15
--
--
--
-8
PL65032-X
9218
Rev. M
-27-
4.
65031-3
65031-4
DRAWING NO.
65031-1
65031-2
OPTIONS
6
X
X
2=-55°C
CLASS
1=-35°C
X
X
NO
YES
LOW ANGLE
BEAM CUTOFF
NO
YES
4.
13
12
11
34
FIGURE 16
21
15
6.
34
31
16
21
SEE PARTS LIST ON PAGE 26
MOTOR BASE SUB-ASSEMBLY
1000W BEACON
4
20
25 24
19
6.
23
5.500
REF
17
41
38 37
3.812
REF
REF
3.
BLK
BLK
44
BLK
5.500
5.312
REF
15 29
WHT
22
18
5
36
1
4.
10
9
8
27
45
5.
3 33
14
30
8
2 28 34
42 43
40
39
6.
6.
9218
Rev. M
9218
Rev. M
NOTES:
AT ASSEMBLY, SLIDE TUBING (ITEM 45) OVER THE WIRES OF LAMP SOCKETS (ITEMS 19 & 23) PRIOR
TO FEEDING THE WIRES DOWN THRU THE SHAFT AND OUT OF THE HOLE AT THE BOTTOM.
1.
2.
APPLY LOCTITE (ITEM 28) TO ALL SCREW THREADS AT ASSEMBLY.
3.
PRIOR TO INSTALLING THE MOTOR (ITEM 6), LAY IT IN PLACE ON THE BASE (ITEM 1) AND CHECK THE 3.812
DIMENSION. USE SHIM WASHERS (ITEM 26), IN SETS OF FOUR, UNDER THE MOTOR FEET TO ACHIEVE THE CORRECT
DIMENSION.
4.
USE THE GAUGE (ITEM 7) TO ALIGN THE WORM TO THE GEAR (ITEM 3), BEFORE TIGHTENING THE MOTOR MOUNT
HARDWARE (ITEMS 8,9 & 10).
5.
APPLY GREASE (ITEM 33) TO ALL GEAR THREADS AT ASSEMBLY.
6.
AFTER ASSEMBLING TERMINALS (ITEM 44) TO THE LAMP SOCKET WIRES, SLIDE THE TUBING (ITEM 45)
PREVIOUSLY ASSEMBLED, DOWN INTO THE HOLE IN THE SHAFT TO PROTECT THE INSULATION ON THE WIRES.
7.
WHEN ASSEMBLING 1000 WATT UNIT, PUT LOOP IN LAMP SOCKET WIRE TO CREATE MORE CLEARENCE FOR COLLAR.
8.
1.
7.
IF USE OF UPPER THRUST WASHER (ITEM 30) DOES NOT ALLOW RETAINING RING (ITEM 14) TO SEAT PROPERLY,
SHIMS (ITEM 41) MAY BE USED TO ALLOW PROPER ASSEMBLY OF RING. TYPICALLY SEVEN SHIMS ARE REQUIRED
1
1
4
4
1
1
1
4
4
1
1
-4
4
1
1
-4
4
1
45
44
43
42
41
10053-181
10047-467
11A12-013D
10A06-013D16
10030-119
TUBING, #2, 8" LG.
TERM., FEMALE. .250 SLIP-ON, INSUL.
LOCK WASHER, SS, #6
SCREW, PAN HD, SS, #6-32 x 1/2" LG.
PRELOAD WASHER
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
65035
10047-1236-36
10047-1236-20
10047-1236-13
10047-1236-12
PRELOAD RING
WIRE MARKER, 36
WIRE MARKER, 20
WIRE MARKER, 13
WIRE MARKER, 12
2
A/R
1
2
A/R
1
2
A/R
1
2
A/R
1
40
39
38
37
36
35
34
33
32
11A06-031D
10043-11
10K04-037D
WASHER, PLAIN, 5/16" SST
BEACON GREASE, #325
HEX JAM NUT, 3/8-16 SST
2
2
3
A/R
3
A/R
3
3
1
2
2
3
A/R
3
A/R
--1
2
2
3
A/R
3
A/R
3
3
--
2
2
3
A/R
3
A/R
----
31
30
29
28
27
26
25
24
23
10E02-025D16
10030-116
10B03-019D32
10048-30
10G60-011D06
10030-117
11A22-013D
10A06-013D12
20V24-001
SET SCREW, CUP PT, 1/4-20 X 1/2" LG SST
WASHER,THRUST
SCREW, 82° FLAT HD, #10-32 X 1" LG SST
LOCTITE #242
SCREW, DRIVE, TYPE U, #4 X 3/16" LG SST
WASHER, SHIM, .010 THICK, ST. STEEL
WASHER, LOCK, INT. TOOTH, SS, #6
SCREW, PAN HD, SS, #6-32x3/8" LG.
LAMP SOCKET, QUARTZ
1
2
1
1
1
2
1
1
1
-2
1
1
1
2
1
1
1
1
2
1
1
1
2
1
1
1
-2
1
1
1
2
1
1
1
22
21
20
19
18
17
16
15
14
65056
11B11-031D
65081
10047-2291
65080-2
65080-1
65079
65078
10032-41
LAMP SHIELD
RING, RETAINING, E-RING 5/16" SHAFT DIA.
ADJUSTMENT ROD, LAMP ADJUSTMENT
LAMP SOCKET, HID
GUIDE PIN, LMAP ADJUSTMENT
GUIDE PIN, LAMP ADJUSTMENT
UPPER PLATE, LAMP ADJUSTMENT
COLLAR, BOTTOM PLATE, LAMP ADJUSTMENT
RETAINING RING
13
12
11
10
9
8
7
6
5
11A02-019D
11A12-019D
10B06-019D16
11A01-031D
11A11-031D
10C01-031D24
65059
65057
10034-9
WASHER, FLAT, SS, #10
WASHER, LOCK, SS, #10
SCREW, PAN HD, SS, #10-32x1/2" LG.
WASHER, FLAT, SS, #5/16
WASHER, LOCK, SS, #5/16
SCREW, HEX HD, SS, #5/16-18x3/4" LG.
WORM GEAR GAUGE
MOTOR ASSEMBLY
BALL BEARING, SINGLE ROW, SEALED
65011
65018
HOUSING, LAMP SOCKET
WORMGEAR
8
8
8
8
12
12
12
12
12
12
12
12
4
4
4
4
4
4
4
4
4
4
4
4
REF REF REF REF
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
4
3
2
1
QTY
QTY
QTY
QTY
ITEM
-4
-3
-2
65074
BASE & SHAFT SUB-ASSY
PART NUMBER
DESCRIPTION
-1
PARTS LIST
FIGURE 16A
MOTOR BASE SUB-ASSEMBLY
1000W BEACON
PART LIST AND NOTES
-28-
9218
Rev. M
SHAFT (65013)
RETAINING RING (10032-41)
THRUST WASHER (10030-116)
WORMGEAR (65018)
BALL BEARING
(10034-9)
PRELOAD WASHER
(10030-119)
BALL BEARING
(10034-9)
PRELOAD RING
(65035)
THRUST WASHER
(10030-116)
MOTOR & SHAFT BASE
(65023)
FIGURE 17
SHAFT & BALL BEARING ASSEMBLY
-29-
9218
Rev. M
7
C1
3
1
T2
2
2
2
2
7
10047-1560
TY-RAP
2
2
2
2
2
2
2
2
2
6
5
4
10K01-025D
11A12-025D
11A02-025D
NUT, HEX, SS, #1/4-20
LOCKWASHER, SS, #1/4
FLAT WASHER, SS, #1/4
2
1
2
--
2
--
3
2
10A06-025D16
65044-3
SCREW, PAN HD, SS, #1/4-20 x 1/2" LG.
BALLAST, 1000W, 220V, 50Hz (-TR)
---
1
--
-1
2
2
65044-2
65044-1
BALLAST, 1000W, 220V, 50Hz
BALLAST, 1000W, 120V, 60Hz
65021
1
1
1
1
QTY
QTY
QTY
ITEM
-5
-2
-1
65058-
BRACKET, BALLAST AND CAP.
PART NUMBER
DESCRIPTION
PARTS LIST
FIGURE 18
BALLAST ASSEMBLY
-30-
4
5
6
9218
Rev. M
-31-
9218
Rev. M
BEACON
WHT
BLK
GRN
BLU BLU
CROUSE-HINDS WIRING
CUSTOMER WIRING
LAMP
CIRCUIT BREAKER
(SEE TABLE)
120V REMOTE
TELL-TALE LAMP
40 WATTS MAX.
FUSE
110 OR 220 VOLT
POWER SUPPLY
OPER.
VOLTS
120V
FREQ.
BREAKER
RATING
1000W
TEMP.
RATING
CLASS 1
60Hz
15AMP
802_1-2
1000W
CLASS 1
220V
50Hz
10AMP
802_2-1
802_2-2
1000W
1000W
CLASS 2
CLASS 2
120V
220V
60Hz
50Hz
20AMP
10AMP
CATALOG
NUMBER
802_1-1
LAMP
FIGURE 20
ROTATING BEACON
EXTERNAL WIRING
-32-
9218
Rev. M
SPARE PARTS LIST
PART NUMBER
DESCRIPTION
65018
WORM GEAR ASSEMBLY
65020-1
CLEAR LENS
65020-2
GREEN LENS
65020-3
YELLOW LENS
65045
RELAY ASSEMBLY
65046
LIGHTNING ARRESTOR ASSEMBLY
65057
MOTOR ASSEMBLY (WITH CAPACITOR)
65058-1
BALLAST & CAP. ASSEMBLY, 1000W, 120V
65058-2
BALLAST & CAP. ASSEMBLY, 1000W, 220V
65058-5
10034-9
BALLAST & CAP ASSEMBLY, 1000W, 220V,
CLASS 2
BALL BEARING (2 PER UNIT)
10037-587
AIR FILTER
10047-2795
LAMP, 1000W METAL HALIDE
10047-2293
LAMP, 250W QUARTZ (-TR OPTION)
10047-2298
STEP-DOWN TRANSFORMER, 220V-120V
10047-2344
FUSE, F1
KL5197
WORM ( FOR WORMGEAR)
-33-
9218
Rev. M
BEACON MOUNTING CHANNEL (SEE FIGURE 6)
#3/8-16 x 1-1/4" LONG BOLT
#3/8-16 HEX NUT
#3/8 LOCKWASHER
PART NUMBER CMA-60
PURCHASING INFORMATION
1-800-666-6473
OR
FAX# 617-787-3934
3.75
.406 DIA - 2 HOLES
FOR MOUNTING
THE ABOVE PARTS ARE NOT
SUPPLIED BY CROUSE-HINDS
NOTE: IF THE ARB BEACON IS TO BE MOUNTED ON TOP OF
A CONTROL TOWER OR BUILDING, VIBRATION ISOLATION
MOUNTING MAY BE REQUIRED.
FIGURE 21
SUGGESTED OPTIONAL
VIBRATION ISOLATION MOUNTING
-34-