DOCUMENT
REVISION
Jul,20, 2011
IM0117
A
Instruction Manual
LED GUIDANCE SIGN
ICAO
SERIES 814S5A-X1
Copyright @ 2011 Cooper Technologies Company
Cooper Industries
Crouse-Hinds Division
Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095
For Parts or Technical Service Call (860) 683-4300
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ICAO SERIES 814S5A-X1
1.0
REVISIONS
Revision
Issue/Reissue
Letter
Number
A
ECN-TECCH-11105
Description
First Release
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ii
Checked
Approved
LZ
CX
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2.0
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 the Company’s judgment, as to affect
the Product adversely;
(b) any Product which has, in the 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 the Company; and;
(d) any Products, component parts or accessories manufactured by others, but supplied by the Company
(any claims should be submitted directly to the manufacturer thereof).
Crouse-Hinds Airport Lighting Products’ obligation under this warranty is limited to use of reasonable
efforts to repair or, at its’ option, replace, during normal business hours, at any authorized service facility of
the 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. The Company may
require the return of any Product claimed not to be as warranted to one of its facilities as designed by the
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 does not assure uninterrupted operations of Products; The
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.
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3.0
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 will result in severe injury or death.
NOTICE:
NOTICE
Possibly dangerous situation, goods might be damaged.
IMPORTANT:
IMPORTANT
Helpful information.
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3.1
Lamps Warning
DANGER:
DANGER
3.2
When changing lamps, the switch on the exterior end of the sign must be in the OFF
position. DO NOT ATTEMPT TO CHANGE LAMPS WHILE THE POWER IS
ON.
Ballast Warning
DANGER:
DANGER
3.3
If a ballast or other electrical component is to be changed, turn the entire circuit OFF
and use lockout procedures. Then completely disconnect the sign before doing any
work.
Keep Away from Live Circuits
DANGER:
DANGER
3.4
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.
Circuit Warning
CAUTION:
CAUTION
These signs are designed for use on 2.8 to 6.6 ampere constant current series circuits
normally found at airports. DO NOT USE ON ANY OTHER TYPE OF CIRCUIT.
If there are questions, contact Crouse-Hinds for technical help.
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3.5
Regulations Warning
NOTICE:
NOTICE
3.6
Operating and maintenance personnel must, at all times, observe all applicable safety
regulations.
Safety Notices
NOTICE:
NOTICE
3.7
This equipment is normally used or connected to circuits that may employ voltages that
are dangerous and may be fatal if accidentally contacted by operating or maintenance
personnel. Extreme caution should be exercised when working with this equipment.
While practical safety precautions have been incorporated in this equipment, the following
rules must be strictly observed.
Resuscitation
IMPORTANT:
IMPORTANT
Maintenance personnel should familiarize themselves with the technique for
resuscitation found in widely published manuals of first aid instructions.
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4.0
TEST EQUIPMENT AND TOOLS
There is a wide variety of tools and equipment needed to safely and correctly perform airfield lighting equipment
installation and maintenance. In addition to the obvious tools (screwdrivers, wrenches, etc.), there is specialized
equipment needed to do the job.
4.1
Multi-meter
Refer to the equipment manufacturer’s manuals for the proper use, maintenance and calibration (if necessary) of all
meters.
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 readings 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.
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5.0
1.0
2.0
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.0
4.1
5.0
6.0
7.0
7.1
8.0
9.0
9.1
9.2
10.0
10.1
10.2
10.3
10.4
10.5
11.0
11.1
11.2
11.3
12.0
12.1
12.2
13.0
TABLE OF CONTENTS
REVISIONS ................................................................................................................................................................... ii
LIMITED PRODUCT WARRANTY ...........................................................................................................................iii
SAFETY SYMBOLS .................................................................................................................................................... iv
Lamps Warning .............................................................................................................................................................. v
Ballast Warning .............................................................................................................................................................. v
Keep Away from Live Circuits....................................................................................................................................... v
Circuit Warning .............................................................................................................................................................. v
Regulations Warning ..................................................................................................................................................... vi
Safety Notices ................................................................................................................................................................ vi
Resuscitation ................................................................................................................................................................. vi
TEST EQUIPMENT AND TOOLS ............................................................................................................................. vii
Multi-meter ................................................................................................................................................................... vii
TABLE OF CONTENTS ............................................................................................................................................. 30
PART NUMBER EXPLANATION ............................................................................................................................. 31
GENERAL INFORMATION....................................................................................................................................... 32
General Description ...................................................................................................................................................... 32
CLASSIFICATION OF SIGNS ................................................................................................................................... 32
SPECIFICATIONS ...................................................................................................................................................... 33
Environmental Data ...................................................................................................................................................... 33
Technical Characteristics .............................................................................................................................................. 33
STRUCTURE OF SIGN............................................................................................................................................... 33
Outline Dimension ........................................................................................................................................................ 33
Enclosure Structure and Parts ....................................................................................................................................... 34
Inverter / Driver ............................................................................................................................................................ 35
LED Arrays Connection ............................................................................................................................................... 36
Internal Electrical Configuration .................................................................................................................................. 37
INSTALLATION ......................................................................................................................................................... 38
Guidance Sign and base Installation Specification ....................................................................................................... 38
Steps to Installation....................................................................................................................................................... 39
Guidance Sign Circuit Diagram .................................................................................................................................... 40
MAINTENANCE ......................................................................................................................................................... 43
Routine maintenance .................................................................................................................................................... 43
LED Strip Replacement ................................................................................................................................................ 43
TROUBLESHOOTING GUIDE .................................................................................................................................. 44
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6.0
PART NUMBER EXPLANATION
8 1 4 S 5 A
1
2
SIZE
1 = 200mm Legend Height
2 = 300mm Legend Height
3 = 400mm Legend Height
Number of Faces:
1 = Single Face
Style:
1 = Parallel, 220V
3 = Series, 2.8 to 6.6A, 5 steps
Luminance:
H= High brightness
L= Low brightness
CLASS:
2= -40
℃～ +55℃*
Mode:
1= 160km/h
2= 320km/h
Sign Width in mm:
09=900mm
…
40=4000mm
900mm minimum, up to 4000mm per 100mm increments **
* Contact CHALP for wide environment temperature application.
** Contact CHALP for sign width over 4000mm. Face width = Sign width – 100mm
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7.0
GENERAL INFORMATION
7.1
General Description
Crouse-Hinds Airport Lighting Products, LED Guidance Sign ICAO, (Model 814S5A-X1) internally illuminated
Taxiway and Runway Signs provide outstanding message visibility, day or night. The Model 814S5A-X1is designed
to meet the latest version of the International Civil Aviation Organization (ICAO), Annex 14. White on Red,
Yellow on Black, and Black on Yellow color, combinations may be ordered with any desired message. Signs are
available as single faced. For further information on Taxiway Signs and their use, consult International Standards
(Aerodrome Design Manual, Part 4 and ANNEX 14).
8.0
CLASSIFICATION OF SIGNS
The signs covered in this manual are designed and manufactured in accordance with the requirements of ICAO
ANNEX 14 and conform to the following classifications:
TYPES
Information Sign - black legend on a yellow background.
Mandatory Instruction Sign - white legend on a red background.
Taxiway and Runway Location Sign - yellow legend and border on a black background.
A sign may consist of multiple arrays of the above messages.
SIZES
Small size
-200mm legend height
Mid-size
-300mm legend height
Large size
-400mm legend height
STYLE
For operation from a M (220V AC) power source or S (2.8 to 6.6 Amperes) 5 step series lighting circuit
CLASS
For operation down to -40°C, up to 55°C.
NOTE: If signs are installed on a dedicated sign only circuit, the calculated VA (volt ampere) load for the circuit
should be between 60% to 90% of the rating of the constant current regulator. If this recommendation is not
followed, contact Crouse-Hinds Airport Lighting Products Engineering Department for instructions.
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9.0
SPECIFICATIONS
9.1
Environmental Data
Temperature:
-40ºF to +131ºF (-40°C to +55°C)
Weather:
All normal outdoor conditions
Wind:
Up to 200 MPH continuous (322 Kilometers Per Hour)
Radio and Navigation Interference:
9.2
None
Technical Characteristics
Unique patented no hinge design, c/w labyrinth seal waterproof structure and easy access for maintenance service
Detachable front panel frame, provide convenient access for inner enclosure cleaning and other service work
Aluminum enclosure frame internal mounted with leg support poles, sturdy, durable and meets ICAO wind load
requirement
Stainless steel fastener.
Polycarbonate front panel, anti-UV, high UV and impact resistance
Distinct bright color and clear text provide excellent guidance information to maneuvering airplane.
ICAO Annex 14 compliance
Operates under wind velocity up to 160 km/h or 320 km/h
Precision machined frangible pole meets FAA requirement; enhances 814S5A-X1 structure stability and reliability
Installed with safety tether enhances airfield safety operation
Excellent light output by OSRAM high performance LED that prolong operational life span
LED arrays with long MTBF and power efficiency reduce lamp replacement frequency for lower operation cost
Modular design creates user friendly and convenience maintenance and operation environment
10.0
STRUCTURE OF SIGN
10.1
Outline Dimension
Guidance Sign minimum length is 900mm; customization to required dimension shall be incremented by 100mm
(min) per incremental length, up to maximum guidance sign length of 4000mm.
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The diagram below shows typical dimension of the guidance sign, A=Face width +100mm:
10.2
Enclosure Structure and Parts
10
11
1.Inscription Panel
2.Front Frame
3.Retractable Screw
4.LED arrays
5.Inverter / Driver
6.Enclosure Body
Frame
7.Frangible Pole
8.Base Plate
9.Tether
10.Nameplate
11.Reflector
To access the guidance sign interior housing for wiring installation and maintenance work; unlock the hasp located
at the removable front panel, flip the front panel towards the front standing position. The guidance sign front panel is
opened which limits by the limit chain mounted at the top left and right corner of the enclosure body frame.
Detachment of the front panel, unhook the limit chain located at the top left and right corner of the front panel, and
flip the front frame panel over 45 degrees forward. The front panel can then be detached from the guidance
enclosure body frame.
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10.3
Inverter / Driver
The high-performance inverter / driver within the Guidance Sign is powered by the CCR that supplies input current
range from 2.8A to 6.6A through the isolation transformer to the 814S5A-X1.
A single dedicated LED inverter/driver has the capacity to power 1 to 15 numbers of LED strip (optional/preference)
10.3.1 Dedicated LED Inverter / Driver
Labels on the LED inverter/driver state the appropriate input power requirement and output terminal configuration;
details are shown in the following diagram:
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10.3.2
Multi-tech Inverter / Driver
Labels on the inverter/driver state the appropriate input power requirement and output terminal configuration for
different light source (LED or Fluorescent); details are shown in the following diagram:
10.4
LED Arrays Connection
The number of inverter/driver to be used in the Guidance Sign is determined by the number of LED arrays require in
the guidance sign. A single inverter/driver can power up to maximum of 15 LED arrays. Subsequently, two
inverters/drivers connect in series will be able to power up to maximum of 30 LED arrays. Two power inputs are
required when more LED arrays are installed in the Guidance Sign.
Use one inverter/driver when the Guidance Sign operate up to max 15 LED arrays, the input and output connection
is shown in the following diagram:
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Connect two inverters/drivers in series when the Guidance Sign operate with more than 15 to 30 LED arrays, the
input and output connection is shown in the following diagram:
Two power inputs are required in the Guidance Sign when more LED arrays are needed. Each individual power
input will connect to the inverter/driver and LED arrays corresponding to the above description.
10.5
Internal Electrical Configuration
For different number of lamps required in the guidance sign, determines the capacity and quantities of the isolation
transformer needed for each sign. The guidance sign tag on each sign indicates the amount of Lamps, Inverters and
Isolation Transformers required as shown in the following:
LED Taxiway Guidance Sign
Number of Lamps
Number of Inverter
(LED Array)
x≤15
1
15 < x ≤ 30
2
30 < x ≤45
3
45< x ≤60
4
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Isolation Transformer
Input Power (line)
Terminal Block
≥100W
≥200W
1 x 100W+ 1 x 200W
2 x 200W
1
1
2
2
3
3
5
5
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11.0
INSTALLATION
For efficient operation of the guidance sign, installation of the 814S5A-X1 is recommended to be carried out by
qualify personnel with appropriate training and professional knowledge.
※
Screw used to tighten the flange must be secured on the ground
Accident occurred may cause damage
Unqualified personnel is not allowed to install the lighting
May cause serious damage and the lighting to malfunction
※
11.1
Guidance Sign and base Installation Specification
Guidance Signs are commonly installed on a prefabricated concrete base and M10 expansion screws (draw-bolt)
shall be used for the ground mounting.
When the length of Guidance Sign (size A) is less than 2000mm, two legs are to be installed as support. The
distance between the two legs are: C=A-120
When the length of Guidance Sign (size A) is ranged between 2000mm to 3000mm, three legs are to be installed as
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support. The distance in between the legs are: E=(A-120)/2
The recommended length for the concrete base is D=A+500mm, width 700mm and the depth should be at
least 300mm.
If the length of sign ranges from 3000mm to 4000mm or has special installation requirements, please contact
CHALP for leg options.
※
11.2
The recommended size for the concrete base is for reference
only, please follow according to the design requirement
Other factors will also affect the sizing of the concrete base
Steps to Installation
a) Clear the site, especially areas that the mounting flange has contact with
b) Open the packaging of the Guidance Sign, check the exterior of the sign and ensure the integrality before
proceeding
c) Place the Guidance Sign on the concrete base and ensure the position for installation is correct
d) Use the M10 expansion draw-bolt to secure the flange
e) The loosen end of the chain to be secured onto the flange
f) Check to ensure that the four bolts around the flange are tightly secured
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※
11.3
Ensure the bolts on the flange are well secured during the installation
of the Guidance Sign
The Guidance Sign is capable to endure the force of the wind and jet
blasts from the airplanes
Guidance Sign Circuit Diagram
The default method of wiring the power cable into the guidance sign is through the strut (11.3.1)
Base on the customer’s need, the metal hose outside of the guidance sign shall be used to route the power cable in
and out (11.3.2)
The internal electrical components of the Guidance Sign consist of terminal block, inverter/ Driver, lamps and light
fixture. After the Guidance Sign is firmly secured, user may route the power cable into the guidance sign and
connect to the terminal block according to the label.
11.3.1
Circuit Diagram inside the Strut
Metal pipe should be inserted into the concrete base before attempting to route the cable into the strut. Installation
personnel are required to measure the correct length of the cable (4mm2) accordingly.
Using one end of the cable, route it into the guidance sign and connect the power input and the ground terminal to
the terminal block. On the other end of the cable, connect it to the isolation transformer using the A6 plug, ground
wire to be connected to the coupling on isolation transformer box.
Note: Ensure all the ground terminals in the guidance sign is firmly linked to the ground during connection.
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Connection Method Part One: Strut Internal Connection Diagram
※
The cable connection should be well secured
Accident such as damage to electrical elements or equipment
malfunction may occur
Determine the appropriate power needed before connecting the cable for the first time. Always ensure that the
power meets the requirement. Likewise, all specification requirements for other elements shall be comply.
11.3.2
External Metal Hose Wiring Circuit Diagram
To enable guidance sign installation to be more flexible, a metal tube located at the exterior of the Guidance Sign
allows the cable to route in. Secondary cables from the isolating transformer may be link up to the guidance sign
through the metal flexible hose. In this arrangement, the cables will be effectively protected by the flexible metal
hose.
Using one end of the cable, route it into the guidance sign and connect the power input and the ground terminal to
the terminal block. On the other end of the cable, connect it to the isolation transformer using the A6 plug, ground
wire to be connected to the coupling on isolation transformer.
Please note: Ensure all the ground terminals in the guidance sign is firmly linked to the ground during connection.
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Connection Method Part Two: External Metal Hose Connection Diagram
Cable should be enclosed in the metal flexible hose before insert into the PVC tube. In order to avoid rainwater
from entering the tube, foam agent is recommended to seal the PVC tube.
Determine the appropriate power needed before connecting the cable for the first time. Always ensure that the
power meets the requirement. Likewise, all specification requirements for other elements shall be comply.
※
※
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Ensure the contacts between the connector and cables are
tightly secured; make sure that water resistance factor is
considered
May cause malfunction to the circuit
Determine the appropriate power before using the guidance
sign for the first time
May cause malfunction to the circuit
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12.0
MAINTENANCE
Maintenance requirement appended below is for reference only. Maintenance personnel who maintains the signs are
advised to refer to other related regulations or otherwise constitute an appropriate routine maintenance standard base
on their experience. The manufacturer does not constitute compulsory guidelines.
Refer to topic in section 11.0 Foreword, maintenance of signs should be done by personnel who are appropriately
trained with professional knowledge.
DANGER:
If it is necessary to re-lamp the sign without removing regulator power to the
sign loop, an ON-OFF switch on the exterior end of the sign must be in the
OFF position. This removes power to the tube sockets only. DO NOT
ATTEMPT TO CHANGE LAMPS WHILE THE POWER IS ON.
12.1
Routine maintenance
•
•
•
•
12.2
Check and tighten the four hexagon bolts that are secured on the base flanges.
Check the hasp of the front panel.
Maintain cleanliness in the inner and outer layer of the guidance sign panel.
Clean the interior of the guidance sign during lamp replacement, especially the inner surface of the panel.
LED Strip Replacement
Unlock the hasp, and open the front panel.
Unplug the LED strip supply and remove the secured screws both top and bottom, and replace the LED strip in the
strip holder, secure the LED strip with top and bottom screws, and plug back the supply to the strip to complete the
LED strip replacement.
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ICAO SERIES 814S5A-X1
TROUBLESHOOTING GUIDE
PROBLEM
Unit fails to illuminate
PROBABLE CAUSE
SOLUTION
1) Defective isolation transformer
1) Replace transformer
2) Defective driver
2) Replace driver
3) Runway Circuit problem
3) Check runway circuit and
regulator for proper operation
4) Bad Connection
4) Check Wiring
Non-Uniform Brightness
Unit flickers continuously
1) Defective LED arrays
1) Replace LED arrays
2) Defective driver
2) Replace driver
1) Defective LED arrays
1) Replace LED arrays
2) Defective driver
2) Replace driver
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