DOCUM
MENT
REVISIO
ON
Jan 8, 20
014
1144
A
Ins
struc
ction
n Ma
anua
al
PRO AP
PF Series LED Stylle III
Runway Centerlinne Light (R
(RCL)
Touchdoown Zonee Light (T
TDZ)
L-850A
A&B
8-inch aluminum opttical assembly with ductile iroon support ringg
Eaton’s Crouse-Hin
nds
Businesss
Airport Lighting Prroducts
1200 Ken
nnedy Road
d
Windsorr, CT 06095
5
Copyright © 2014 Eaton’’s Crouse-Hind
ds Business
For Parts
P
or Tecchnical Servvice Call (8660) 683-4300
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
1
Revisions
Revision
Issue/Reissue
Letter Number
Description
Checked
Approved
A
A213-330
Initial Issue
KF
SB, VH, TR
ii
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
2
Product Warranty
Warranty
Refer to Eaton’s Crouse-Hinds Airport Lighting Products Terms and Conditions for product specific
warranty information.
Refer to Cooper Crouse-Hinds Airport Lighting Products Terms and Conditions for product
specific warranty information.
iii
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
3
Warning
W
Lab
bels
DAN
NGER:
DANGE
ER
The hazard or unsafee practice wiill result in ssevere injuryy or death.
WARN
NING:
WARN
NING
The hazarrd or unsafe practice
p
couuld result in severe injury
ry or death.
CAUT
TION:
CAUTION
The hazard
h
or unsafe practicee could resuult in minor iinjury.
NOT
TICE:
NOTICE
Posssibly dangerrous situatioon, goods migght be damaaged.
IMPOR
RTANT:
IMPORT
TANT
Helpful inf
nformation.
iv
DO
OCUMENT 1144
RE
EV. A
uction Manuual
Instru
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
4
Safety Noticees
Th
his equipment is normally ussed or connecteed to circuits thhat may employy voltages thatt are dangerouss and
may
m be fatal if accidentally
a
con
ntacted by opeerating or mainntenance personnnel. Extreme caution shouldd be
ex
xercised when working with this
t equipmentt. While practiccal safety precautions have bbeen incorporatted in
th
his equipment, the following rules
r
must be strictly
s
observeed:
4.1
Keep
K
Away from
f
Live Circuits
C
Operating
O
and maintenance
m
peersonnel must at
a all times obsserve all safetyy regulations. D
Do not perform
m
maintenance
m
on internal components or re-laamp with poweer ON.
4.2
Reesuscitation
n
Maintenance
M
personnel should
d familiarize th
hemselves withh the technique for resuscitatioon found in wiidely
pu
ublished manuals of first aid instructions.
IMPOR
RTANT:
IMPORT
TANT
See FAA
FA Advisoryy Circular A
AC 150/53400-26 for addditional
inform
mation.
v
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
5
Table of Contents
TableofContents
1 Revisions ................................................................................................................................. ii 2 Product Warranty ................................................................................................................... iii 3 Warning Labels ...................................................................................................................... iv 4 Safety Notices ......................................................................................................................... v 4.1 Keep Away from Live Circuits ............................................................................................ v 4.2
Resuscitation ........................................................................................................................ v 5 Table of Contents ................................................................................................................... vi 6 Part Number Explanation – RCL & TDZ L-850A&B............................................................ 1 7 General Description ................................................................................................................ 2 8 Installation............................................................................................................................... 3 8.1 Specifying the Location ....................................................................................................... 3 8.2 Installation of a Light Unit ................................................................................................... 3 9 Maintenance ............................................................................................................................ 4 9.1 Cleaning Lenses ................................................................................................................... 4 9.2 Light Module Replacement.................................................................................................. 4 9.3 O-Ring Replacement ............................................................................................................ 5 9.4 Lens Replacement ................................................................................................................ 5 9.5 Feed-thru Replacement ........................................................................................................ 6 9.6 Pressure Test ........................................................................................................................ 6 9.7 Power Supply Replacement ................................................................................................. 7 9.8 Optional External Gasket Replacement ............................................................................... 8 9.9 Cleanliness and Workmanship............................................................................................. 8 9.10 Maintenance Program .......................................................................................................... 9 10 Spare/Replacement Parts List ............................................................................................... 10 11 Troubleshooting .................................................................................................................... 11 11.1 Visual Inspection ............................................................................................................... 11 11.2 Electrical Inspection........................................................................................................... 12 12 Tables & Figures ................................................................................................................... 14
vi
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
6
Part Number Explanation – RCL & TDZ L-850A&B
1
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
7
General
G
Desccription
Th
he Crouse-Hin
nds Runway Ceenterline Light (RCL) and Toouchdown Zonne Light (TDZ) are Style 3, ET
TL
ceertified FAA L-850A&B
L
ligh
ht units per FAA
A AC 150/53445-46. RCL andd TDZ lightingg systems are
deesigned to facilitate landings,, rollouts, and takeoffs.
t
The T
TDZ is primariily a landing aiid while the RC
CL is
ussed for both lan
nding and takeeoff operations.. The light unitt is designed too fit on a FAA L-868, steel, ssize-B
lig
ght base per FA
AA AC 150/53
345-42 (latest version),
v
and hhave a total heigght above gradde/ground levell of ≤
.2
250 inch. The RCL
R
may be un
nidirectional orr bidirectional,, projecting twoo beams of lighht 180° apart. T
The
TDZ is unidirectional only. Th
hey are weatherproof and willl endure roll ovver loads withoout damage. Thhe
lig
ght unit consists of a ductile iron
i
support rin
ng and a removvable aluminum
m optical assem
mbly. The ductile
iron ring is mou
unted to a light base with six bolts
b
(3/8-16 U
UNC x 7/8 lg., stn. stl.) and loock washers (3/8,
sttn. stl.). The op
ptical assembly
y is secured to the
t ductile ironn ring using tw
wo high-strengthh bolts, lock
washers,
w
and tw
wo aligning high
h-strength sheaar pins. The opptical assemblyy has a forged aaluminum opticcal
ho
ousing and an aluminum
a
die--cast inner coveer that are attacched using 4 sccrews. A polyuurethane o-ringg is
ussed to provide a watertight seeal between thee inner cover annd the optical hhousing. Eitheer one or two L
LED
asssemblies are fastened
f
to the optical housing
g. One plug (P
P1) light units hhave one poweer supply fastenned to
th
he inner cover. Two plug (P2)) and one plug with independdent power suppplies (B1) verssions have twoo
po
ower supplies fastened
f
to the inner cover. Electrical
E
conneections are madde at one or tw
wo feed-thru
asssemblies in th
he inner cover. The feed-thruss have ITS veriified L-823 pluugs for connectting to FAA L--830/
L-831 isolation transformers. Lenses
L
are held
d into the opticcal housing witth a bracket, gaasket, molded
ellastomeric boot and two screw
ws. The light beam
b
color cann be changed byy switching LE
ED module
asssemblies and power
p
suppliess. All fastenerss are type 18-8 stainless steel.. The completee light unit withh
su
upport ring is 11.94
1
inches in
n diameter, 3.62
2 inches deep aand weighs 21 lbs. Refer to section 10 for a list
off spare and rep
placement partss.
IMPOR
RTANT
IMPORT
TANT
Do not op
pen any lightt unit unlesss the warran
nty period haas expired.
Opening a light unit w
will void thee warranty
CAUT
TION:
CAUTION
Never handlle the light un
nit by the leadds as this can break the waaterproof seall
2
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
8
In
nstallation
Th
he Style 3 RCL
L and TDZ ligh
ht units are shiipped completee, including thee LED module(s), and are reaady
fo
or installation as
a received. Insstallation of a light
l
unit is to bbe done with pprimary POWE
ER OFF and
SE
ECURED. At each light locaation, install a steel, size B, 112 inch deep m
minimum, L-8688 Light Base pper
FA
AA AC 150/53
340-4 (latest reevision). For RCL
R
or TDZ ligght units, installl the light basee with two oppposing
bo
olt holes perpendicular to thee runway centerrline. Place thee properly sized isolation trannsformer(s) in the
lig
ght base and make
m
necessary
y primary poweer connections using L-823 coonnectors. Thee RCL and TDZ
Z
lig
ght units’ miniimum isolation
n transformer reequirements caan be found in Section 12, Taables 2 & 3. Alll
isolations transfformers are 6.6 ampere secon
ndary models.
IM
MPORTAN
NT:
IMPORT
TANT
8.1
Proper transsformer watttage is depeendent on thee configuratiion options oof
your
y
light un
nit(s) and is necessary fo
for meeting F
FAA perform
mance
requirementts. See sectio
on 12, tabless 2 and 3 forr minimum trransformer
requirementts.
Specifying th
he Location
Th
he correct orientation of the light
l
units is ex
xtremely imporrtant. Refer to the latest revission of FAA A
AC
15
50/5340-30 chaapters 3 and 11
1 when determ
mining and prepparing the locattion and installlation of the ligght
un
nits. Read and understand all instructions to
o guarantee corrrect location oof each unit.
8.2
In
nstallation of
o a Light Unit
U
Verify
V
that the mounting
m
flang
ge on the light base
b
is clean annd the o-ring ((optional on deeep cans) is coaated
with
w Dow Corniing FS 1292 grrease and is in place
p
on the ligght base. Connnect the plug(s)) from the light unit
to
o the secondary
y of the previou
usly installed issolation transfo
former(s). Instaallation tool, Crrouse-Hinds P//N
19
9999, will easee in the installaation and remov
val of the lightt unit (See Figuure 3). The threeaded eyeboltss on
th
he lifting tool screw into threaaded holes in th
he light unit. L
Lower the lightt unit straight ddown onto the bbase.
Th
he light unit is subject to optiical misalignm
ment or mechannical damage iff not seated prooperly. Verify tthe
lig
ght beam(s)/co
olor(s) are prop
perly orientated
d for the indiviidual location. Secure the lighht unit to the baase
with
w six 3/8-16 UNC
U
x 7/8 lg.,, stainless steell bolts and lockk washers and tighten to 18 ft
ft-lbs. It is
reecommended th
hat Loctite 243
3 be used on the mounting boolts to prevent lloosening due tto vibration. L
Loctite
is required for liight units subjeected to repeateed aircraft imppacts and roll-oovers. After insstallation, the
mounting
m
bolts should
s
be perio
odically checkeed for proper to
torque to ensurre a secure instaallation. See seection
9..10.4.
CAUT
TION:
CAUTION
Use Loctite on mounting
g bolts to prevvent the screw
ws from cominng loose and
beco
oming a hazaard in the airffield.
3
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
9
Maintenance
M
e
Th
he preferred method
m
of mainttaining a light unit is to perioodically and syystematically reeplace the unit and
reeturn it to the maintenance
m
sh
hop for renovation. As an alteernative, the ligght unit can be serviced in thee
field. However,, it is recommeended that field
d servicing be llimited to cleanning the lens only as describeed in
seection 9.1. For extensive field
d service, refer to sections 9 aand 10 for instrructions and sppare parts kits.
IMPOR
RTANT:
IMPORT
TANT
9.1
Do not op
pen any lightt unit unlesss the warran
nty period haas expired.
Opening a light unit w
will void thee warranty
Cleaning
C
Len
nses
With
W a compressed air blast orr suitable brush
hes, remove alll accumulated ddebris from thee light channell.
Clean the outer surface of the prism
p
with a detergent solutioon. If the lens is coated with a substance
im
mpervious to th
he detergent, a suitable solven
nt should be spparingly applied with a wad oof cotton or a ppatch
off cloth on the end
e of a wood splint.
s
After th
he solvent has aacted the remaiining solvent aand softened cooating
sh
hould be remov
ved with a cleaan piece of cottton or cloth. Caare should be ttaken to avoid excessive conttact
beetween the solv
vent and the len
ns seal. Remov
ve all remaininng solvent from
m lens and seal. A gentle air bblast
may
m be used.
9.2
Light
L
Modulle Replacem
ment
CAUT
TION:
CAUTION
Power supp
ply is hot when
n light unit iss energized annd remains hoot for a short
time after the lighht unit is turneed off
Refer
R
to section 10 to determin
ne the appropriiate replacemennt kit for your light unit. Rem
move and seecure
power to the light unit. Seeparate the optiical assembly frrom the supportt ring by removving the two bollts.
Th
here are two pry
y slots in the op
ptical housing to
o help separate the optical asseembly from the support ring.
Disconnect
D
the liight unit lead(s)) from the isolattion transformer
er(s). Turn the ooptical assemblyy upside down aand
reemove the four screws holding the inner coverr to the light houusing. Disconnnect the power ssupply lead(s) ffrom
th
he LED assemblies. Remove th
he two cap screw
ws holding the light reflector aand LED board to the block heeatsink. Leave the heat-sink
h
fasteneed to the opticaal housing. Cleaan the inside surrfaces of the lenns(es) with denaatured
allcohol. Using a thin layer of theermal grease beetween the bottoom of the boardd and the block heat-sink, placee the
neew LED board on the block heeat-sink. Align the
t small hole aand slot of the L
LED board withh that of the heaat-sink.
Be sure to keep the
t new light reflector clean an
nd free of contam
minants. Insert the new light reeflector’s alignm
ment
piins into the smaall hole and slot of the LED board and the heaat-sink beneath tthe board. Tighhten the screws tto 6-8
in
n-lbs. Connect the
t power supp
ply leads to thee new LED asseemblies. Inspecct the feed-thruu terminals for ssigns
off corrosion. Rep
place feed-thru assemblies per paragraph 9.5. Inspect/replacce the optical hhousing’s o-rinng per
paaragraph 9.3. Assemble
A
the in
nner cover onto
o the light houusing. Tighten tthe mounting sscrews to 30 inn-lbs.
Peerform a pressu
ure test as desccribed in parag
graph 9.6. Connnect the light unnit lead(s) from the isolation
traansformer(s). Clean
C
the moun
nting flange areea of the light bbase. Place thee light unit intoo the support rinng.
4
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
Apply
A
Loctite 24
43, per manufaacturer’s instru
uctions, to all m
mounting bolts and immediateely torque them
m to
23
30 ±5 in-lbs.
9.3
O-Ring
O
Repllacement
Ev
very time the light
l
unit is opeened, the o-ring
g must be clos ely examined aand replaced, iif necessary. Refer to
seection 10 to dettermine the app
propriate replaacement kit forr your light unitt. Any o-ring tthat is stretchedd,
to
orn, has perman
nent set, or som
me other defectt which would prevent it from
m forming a waatertight seal m
must
bee replaced with
h a new o-ring..
NOT
TICE:
NOTICE
A bad o-riing seal is thee most commoon cause of innset light unitt leaks. It is
strongly
s
recom
mmended tha
at a new gaskeet be installedd every time tthe light unit iis
opeened
Remove
R
the old o-ring from th
he groove in the optical housiing using a plastic, or comparrably soft, tooll.
Carefully clean the o-ring groo
ove and flange mating surfac e on the inner cover. Take caare not to damaage
th
he mating surfaace or the o-rin
ng. Coat the o-rring with a thinn layer of Dow
w Corning FS 12292 lubricatingg
grrease. Position the new o-ring
g in the center of the groove aand press it intto place. Torquue the inner covver
sccrews to 30 in-lbs. Perform a pressure test as
a described in paragraph 9.6. Connect the liight unit lead(s)) from
th
he isolation tran
nsformer(s). Cleean the mountin
ng flange area of the light base. Place the liight unit into thhe
su
upport ring. Ap
pply Loctite 24
43, per manufaccturer’s instrucctions, to both mounting bolts and immediaately
to
orque them to 230
2 ±5 in-lbs.
NOT
TICE:
NOTICE
9.4
The groove iss designed to be wider thann the o-ring. This providess room for thee
displacement
d
t of the o-ring
g when comprressed betweeen the groove on the opticaal
housing and mating surface on the inneer cover. Prop
operly tighteneed screws aree
importtant in obtainning a compleete seal.
Lens
L
Replaceement
Iff a lens is brokeen, leaks, or is badly pitted orr scarred, it muust be replacedd. It is highly reecommended thhat
th
his task be perfformed in a cleaan shop enviro
onment. Lens reeplacement kitts contain all necessary parts to
ch
hange a lens. Arctic
A
kit replaccement kits incclude replacem
ment lenses for units with arcttic kits. Refer to
seection 10 to dettermine the app
propriate replaacement kit forr your light unitt. Remove a
and secure
power to thee light unit. Separate
S
the optical assembly ffrom the suppoort ring by remooving the two boolts.
Th
here are two pry
y slots in the op
ptical housing to
o help separate the optical asseembly from the support ring.
Disconnect
D
the liight unit lead(s)) from the isolattion transformer
er(s). Turn the ooptical assemblyy upside down aand
5
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
remove the four screws holding the inner cover to the optical housing. Disconnect the power supply lead(s) from
the LED modules. Remove the two screws holding the light reflector and LED board to the block heat-sink.
Carefully remove the LED board with reflector attached and place aside in a clean location. Leave the heat-sink
attached to the optical housing. If you are replacing an arctic kit, remove the #6 tie-down screw which fastens the
end of the arctic kit’s flexible circuit heater to the optical housing. Remove the two lens retaining bracket screws
from the light housing. Remove the lens-retaining bracket and discard the lens-retaining gasket. Firmly push the
lens/boot assembly from the outside of the light housing; discard the old lens and boot. If you are replacing an
arctic kit, discard the arctic kit assembly as an electronic assembly. Thoroughly clean the lens opening with
denatured alcohol and allow it to dry. Inspect the lens opening for scratches or pits; a damaged lens opening
surface will not seal properly. Place a new lens boot over the replacement lens. Apply a thin coat of Dow
Corning FS 1292 grease over the entire outside surface of the lens boot. Align the lens/boot assembly in the
lens opening and press it into place. Verify that the lens boot is not pinched in the lens opening. Using a
new lens retaining gasket, fasten the lens retaining bracket, and heater tie-down screw on arctic kit
versions, to the light housing. Torque the lens retaining bracket mounting screws to 25-30 in-lbs and the
heater tie-down screw, if applicable, 8-11 in-lbs. Re-install the LED module(s) per paragraph 9.2. Tighten the
cap screws to 6-8 in-lbs. Connect the power supply leads to the LED assemblies. Inspect/replace the optical
housing’s o-ring per paragraph 9.3. Assemble the inner cover onto the light housing. The screw hole
patterns in the inner cover and optical housing are offset to insure proper alignment. Torque the mounting
screws to 25-30 in-lbs. Perform a pressure test per paragraph 9.6. Connect the light unit lead(s) to the
isolation transformer(s). Clean the mounting flange area of the support ring. Place the optical assembly into
the support ring. Install new stainless steel 2-piece lock washers. Apply Loctite 243, per manufacturer’s
instructions, to all mounting bolts and immediately torque them to 230 ±5 in-lbs.
9.5
Feed-thru Replacement
Refer to Section 10 to determine the appropriate replacement kit for your light unit. Remove and
secure power to the light unit. Separate the optical assembly from the support ring by removing the
two bolts. There are two pry slots in the optical housing to help separate the optical assembly from the support
ring. Disconnect the light unit lead(s) from the isolation transformer(s). Disconnect the power supply leads from
the feed-thru terminals. Remove the feed-thru by unscrewing the retaining collar. Clean the mounting surfaces
with denatured alcohol and allow to dry. Apply a thin coat of Dow Corning FS 1292 grease to the mounting
flange of a new feed-thru. Apply a drop of Loctite 243 to the feed-thru adapter threads. Screw the feed-thru
retaining collar onto the adapter; refer to Figure 1 for proper inner cover/feed-thru orientation. Torque the
retaining collar to 25-30 in-lbs. Reconnect the power supply leads to the feed-thru terminals. Inspect/replace the
optical housing’s o-ring per paragraph 9.3. Assemble the inner cover onto the light housing. The screw hole
patterns in the inner cover and light housing are offset to insure proper alignment. Torque the mounting
screws to 25-30 in-lbs. Perform a pressure test per paragraph 9.6. Connect the light unit lead(s) to the
isolation transformer(s). Clean the mounting flange area of the support ring. Place the optical assembly into
the support ring. Install new stainless steel 2-piece lock washers. Apply Loctite 243, per manufacturer’s
instructions, to all mounting bolts and immediately torque them to 230 ±5 in-lbs.
9.6
Pressure Test
A light unit should be subjected to a 20-psig air pressure test to verify that it is waterproof whenever it has
been opened or components have been replaced. A tire valve style pressure fitting is located on the bottom
6
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
off the inner coveer. Pressurize the
t unit to 20-p
psig then placee it in a tub of w
water or use a ssoap solution tto
lo
ocate escaping air bubbles. Caarefully inspecct the areas arouund the lens, innner cover seall, and feed-thruu
ad
dapter for leakss. Relieve the internal
i
air pressure before innstalling the ligght unit or attem
mpting to repaair a
leeak.
WARN
NING:
WARN
NING
9.7
Do not excceed 20-psig when
w
pressurre testing the llight unit. Serrious injury
and/or
a
perma
anent damage to the light uunit may resullt if a higher aair pressure iis
used. Once the pressure test is compleete, be sure too relieve the aair pressure.
Power
P
Supplly Replacem
ment
CAUT
TION:
CAUTION
Power supp
ply is hot when
n light unit iss energized annd remains hoot for a short
tim
me after light uunit is turnedd off.
9.7.1
Refer
R
to section 10 to determin
ne the appropriiate replacemennt kit for your light unit. Rem
move and seecure
power to the light unit. Seeparate the optiical assembly frrom the supportt ring by removving the two bollts.
Th
here are two pry
y slots in the op
ptical housing to
o help separate the optical asseembly from the light base.
Disconnect
D
the liight unit lead(s)) from the isolattion transformer
er(s). Turn the ooptical assemblyy upside down aand
reemove the four screws holding the inner coverr to the light houusing. Disconnnect the power ssupply leads froom the
feeed-thru terminaals and LED mo
odule and arcticc kit, if applicabble.
9.7.2
or P1 light unitss, remove the th
hree power supp
ply bracket screews. Remove thhe power supplyy bracket with
Fo
atttached power supply.
s
Removee the three poweer supply screw
ws and discard thhe old power suupply as an
ellectronics assem
mbly. Configuree the jumper setttings for the neew power supplyy per Table l. R
Reconnect internnal
caables per the app
propriate wiring
g diagram, Figu
ure 3 through Fiigure 6.
IMPOR
RTANT:
IMPORT
TANT
The jump
mpers must bee placed in tthe correct pposition(s) foor proper
operation of the ap
appropriate ffixture.
The heateer will remain on indefinnitely with thhe temperatuure sensor
disconnnected.
Apply
A
thermal grrease to the matting surface of the
t new power supply and secuure it to the braacket using the tthree
su
upplied screws. Torque the screews to 16-18 in
n-lbs. Secure thee power supplyy bracket. Torquue the bracket
mounting
m
screwss to 25-30 in-lb
bs.
7
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
9.7.3
Fo
or P2 and B1 lig
ght units, the to
op power supply
y must be removved before the ppower supply bbracket can be
reemoved. Discard
d the top powerr supply as an electronics
e
assem
mbly. After rem
moving and insttalling the bottoom
po
ower supply and
d mounting braacket per section
n 9.7.2, configuure the jumper ssettings for the nnew power suppply
peer Table 1. Reco
onnect internal cables per apprropriate wiring diagram, Figurre 7 or Figure 8..
IMPOR
RTANT:
IMPORT
TANT
The jump
mpers must bee placed in tthe correct pposition(s) foor proper
operation of the ap
appropriate ffixture.
The heateer will remain on indefinnitely with thhe temperatuure sensor
disconnnected.
Apply
A
thermal grrease to mating surface of the power
p
supply an
and fasten it to th
the power supplly bracket. Torqque the
to
op power supply
y’s screws to 16
6-18 in-lbs. Recconnect the pow
wer supply(ies) tto the feed-thruu terminal(s) andd LED
asssembly(ies) an
nd arctic kit(s), if
i applicable. In
nspect/replace tthe optical houusing’s o-ring pper paragraph 99.3.
Assemble
A
the in
nner cover onto
o the optical ho
ousing. The scrrew-hole patterrns on the innerr cover and optical
ho
ousing are offsset to insure pro
oper alignmentt. Torque the m
mounting screw
ws to 25-30 in-lbs. Perform a
prressure test perr paragraph 9.6
6. Connect the light
l
unit lead(ss) to the isolationn transformer(ss). Clean the
mounting
m
flangee area of the su
upport ring. Plaace the optical assembly into the support rinng. Install new
sttainless steel 2--piece lock washers. Apply Loctite
L
243, perr manufacturerr’s instructions, to all mountinng
bo
olts and immed
diately torque them
t
to 230 ±5
5 in-lbs.
9.8
Optional
O
Extternal Gask
ket Replacem
ment
Ev
very time an optical assembly
y with the optiional external ggasket is removved from the suupport ring, thee
gaasket on the ou
utside surface of
o the inner cov
ver should be eexamined and rreplaced if neccessary. Refer tto
seection 10 to dettermine the app
propriate replaacement kit forr your light unitt. Any gasket tthat is stretchedd,
to
orn, has a perm
manent set or so
ome other defecct, will allow w
water to enter th
the light base. R
Remove the old
gaasket from the inner cover by
y carefully scraaping with a plaastic, or compaarably soft, toool. Take care noot to
daamage the inneer cover. Form a thin bead off high temperatu
ture silicone addhesive, such aas GE RTV 1066, on
th
he inner cover sealing
s
surfacee. Position the new
n gasket on the inner coveer in the same llocation as the old
gaasket. Apply a thin coat of Do
ow Corning FS
S 1292 grease oover the entire outside surfacce of the gaskett
beefore placing th
he optical assembly on the su
upport ring. Insstall new stainlless steel 2-pieece lock washerrs.
Apply
A
Loctite 24
43, per manufaacturer’s instru
uctions, to bothh mounting bollts and immediately torque thhem to
23
30 ±5 in-lbs.
9.9
Cleanliness
C
and
a Workm
manship
Seervice life depeends upon the entire assembly being waterpproof. All surffaces must be cclean, dry and ffree of
alll foreign matteer if the light unit
u is to operatte for extendedd periods withoout requiring m
maintenance.
8
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
9.10
Maintenance Program
In order to ensure maximum light unit life, the installed units should be subject to a maintenance program
in accordance with the following:
A daily operation check should be made of the lighting units. The lights should be energized and visually
inspected. If any units are out, the location of the unit should be recorded and the LED modules replaced
per section 9.2 at a time when the circuit is de-energized.
9.10.1
Regular cleaning is necessary to ensure that inset lighting units operate at maximum efficiency. The lens
and channel in front of the lens should be cleaned periodically with a soft cloth and solvent. The weather
and the location of the units will dictate the regularity and type of cleaning.
9.10.2
Snowplow operators should exercise extra care not to strike the light units with snowplow blades. After
snow removal operations, inspect all light units to locate and replace if necessary, any damaged light units.
Passes over the light rows should be made with a power broom only if practical. Whenever snowplows
must traverse in-pavement light units, they should be traveling at less than 5 mph or have the blades lifted
clear of the units. Recommended snow removal techniques are described in AC 150/5200-23.
9.10.3
The light is designed to exclude both ground and surface water from entering. If the lights are not properly
maintained (i.e., bolts tightened and seals in good condition) water may enter the unit. To prevent this from
occurring, it is recommended that each unit be inspected for the presence of water at least once a month.
More frequent inspection is desirable during and following rainy seasons.
9.10.4
Optical assembly mounting bolts should be checked for proper torque, 230 ±5 in-lbs, and at least once
every three months or whenever a unit is serviced regardless of the season. Light units in and around the
touchdown zone area are especially prone to vibration and shock damage if the mounting bolts are not
properly torqued. The mounting surface of the light base must be clean and free of foreign matter when
checking mounting bolts.
9.10.5
If any light unit contains water, the water should be removed and the entire light unit cleaned and dried.
Perform a pressure test per paragraph 9.6 to locate the source of the leak. Replace the optical housing oring per section 9.3.
9
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
10 Spare/Replacement Parts List
Item Part Number LED Module Replacements 1 21671‐W 2 21671‐R Lens Replacements 3 21642‐C 4 21644‐1 Power Supply Replacements 5 21645‐1 6 7 8 9 10 11 12 13 Description 8” 850A/B‐AP1 White Module 8” 850A/B‐AP1 Red Module 8” 850A/B‐AP1 Lens Replacement Kit 8” 850A/B‐AP1 Arctic Kit Replacement Kit 85XX‐AP1 Power Supply Replacement Kit 85XX‐AP1 Power Supply Replacement Kit, Arctic Kit Support 1 Lamp, 1 Connector O‐Ring, 8” Optical Housing Gasket, Support Ring 21645‐2 Feed‐thru Assembly 21122 O‐Ring, Optical Housing 10035‐62 Seal, Bottom Cover 21180 Ductile Iron Mounting Ring (Support Ring) 21508 8” 85XA/B/C/D‐AP1 Support Ring Replacement Kit 2‐Piece Lock Washer Kit 2‐Piece Washer Replacement Kit, QTY 2 (For mounting 8” optical housing to support ring. Included with LED module and power supply replacement kits.) 21647‐2 2‐Piece Washer Replacement Kit, QTY 8 (For mounting 12” support ring into base canister. Included with support ring replacement kits.) 21647‐8 21647‐XXXX 2‐Piece Washer Replacement Kit, Customer Specified QTY 10
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
11 Trou
ubleshooting
g
Iff a light unit is under warranty
y, please contaact Crouse-Hinnds Airport Ligghting for assisttance. DO NOT
op
pen a unit. If th
he unit is openeed, the warrantty is VOID. Iff the warranty pperiod has expired and
troubleshooting is required, follow the steps below to find tthe root cause. Replacement parts will be
reequired for testting of the diffeerent components of the lightt unit.
WARN
NING:
WARN
NING
Do
D not remo
ove the fixturre from the bbase can whiile the fixture is poweredd.
Dangerous
D
voltage
v
may be
b present oon the primarry and seconndary sides oof
the
t isolation transformerr.
Contact
C
Cro
ouse-Hinds Airport
A
Lightting for assisstance priorr to operatingg
a failed fixtu
ure. There ma
ay be dangeerous voltagee present on the input AC
C
pins
p of the ppower supplyy.
11.1
Visual
V
Inspection
Fo
ollow the stepss in Section 9.7
7 to open the fiixture. Verify aall the wires arre not pinched oor damaged annd that
th
he wire insulatiion is intact. Verify the input AC is connectted to the feed thru (see Figurre 5). Verify thhe
po
ower supply co
onnections and
d appropriate ju
umper setting pper Figure 1 annd Table 1.
Fiigure 1: Power Supply Coonnections
11
DO
OCUMENT 1144
RE
EV. A
Instru
uction Manuual
Pro AP
PF Series LE
ED
8-inch
h RCL & TD
DZ
IMPOR
RTANT:
IMPORT
TANT
The jump
mpers must bee placed in tthe correct pposition(s) foor proper
operation of the ap
appropriate ffixture.
The heateer will remain on indefinnitely with thhe temperatuure sensor
disconnnected.
Replace
R
any dam
maged or burneed cables. Repllace damaged L
LED module(ss) per Section 99.2. Replace
daamaged power supply(ies) peer Section 9.7. Refer to Sectioon 10 to determ
mine the approppriate replacem
ment
kiit for your light unit.
11.2
Electrical
E
Inspection
WARN
NING:
WARN
NING
Contact
C
Cro
ouse-Hinds Airport
A
Lightting for assisstance priorr to operatingg
a failed fixtu
ure. There ma
ay be dangeerous voltagee present on the input AC
C
pins
p of the ppower supplyy.
It is recomm
mended thatt a ferro style
le constant ccurrent regullator (2.8 to
6.6ARMS) with a 10/15
5W isolationn transformeer or a voltagge limited
constant DC
D current source
s
be useed to test faiiled fixtures to limit the
input vvoltage.
A buzzing orr humming noise
n
comingg from the issolation trannsformer mayy
indicate a fa
ailed power supply or LE
ED module. It is also ann indicator off
dangerrous voltagee on the prim
mary and seccondary sidess of the
transfo
former.
NOT
TICE:
NOTICE
Applying a constant vo
oltage greateer than 50V ((AC or DC) to the input
will cau
use damage tto the powerr supply.
Applying
A
inp
put current to
t the powerr supply withhout the heatter or jumper
installed
i
willl cause dam
mage to the ppower supplyy.
Fo
ollow the stepss in Section 9.7
7 to open the fiixture and remooving the top ppower supply aas required. Thhe
po
ower supply co
ontinuously mo
onitors the statu
us of the LED module. Theree is a green status LED (see F
Figure
2)) that may be visible
v
through the potting. Th
he LED will noot be visible inn P2 or B1 conffigured fixtures
12
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
without removing the top power supply. A blinking LED indicates the power supply has detected a fault
condition.
Fault conditions include:
 Disconnected or ‘Open’ LED module
o Replace cable if damaged or ‘open’.
 Incorrect jumper setting or missing jumpers
o See Table 1 for proper jumper setting.
 More than 25% of the driven LED ‘Shorted’
o Replace LED module per Section 9.2.
Figure 2: Power Supply Status LED Location
If the status LED is not visible or not lit, replace the power supply per Section 9.7 or contact Crouse-Hinds
Airport Lighting Products for assistance. Refer to Section 10 to determine the appropriate replacement kit
for your light unit.
13
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
12 Tables & Figures
Figure 3: 19999 Installation (Lifting) Tool
14
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
Figure 4: Top View of Light Unit
15
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
Figure 5: Side View of Light Unit
16
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
Figure 6: Sectioned View of Light Unit (Support Ring Not Shown)
17
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
LED MODULE SIDE A
J201
FEED THRU ASSEMBLY P1
P100
P101
J301
P103
P102
J203
Figure 7: Unidirectional P1 Configuration, Without Heater
LED MODULE SIDE A
J201
FEED THRU ASSEMBLY P1
LED MODULE SIDE B
P100
P101
J301
P103
P102
J203
Figure 8: Bidirectional P1 Configuration, Without Heater
Figure 9: Unidirectional P1 Configuration, With Heater
18
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
LED MODULE SIDE A
J201
FEED THRU ASSEMBLY P1
LED MODULE SIDE B
P100
P101
J301
P103
P102
J203
HEATER SIDE B
HEATER SIDE A
Figure 10: Bidirectional P1 Configuration, With Heater
LED MODULE SIDE A
J201
FEED THRU ASSEMBLY P1
P100
P101
J301
P103
P102
J203
LED MODULE SIDE B
J201
FEED THRU ASSEMBLY P2
P100
P101
J301
P103
P102
J203
Figure 11: Bidirectional P2 Configuration, Without Heater
19
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
Figure 12: Bidirectional P2 Configuration, With Heater
20
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
LED MODULE SIDE A
J201
FEED THRU ASSEMBLY P1
P100
P101
J301
P103
P102
J203
LED MODULE SIDE B
J201
P100
P101
J301
P103
P102
J203
Figure 13: Bidirectional Unit, B1 Configuration, Without Heaters
21
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
Figure 14: Bidirectional Unit, B1 Configuration, With Heaters
22
DOCUMENT 1144
REV. A
Instruction Manual
Pro APF Series LED
8-inch RCL & TDZ
L850A Light unit Part Number
850A‐AP1‐WW‐XX‐XXX‐P1‐X‐X
19
17
15
13
11
9
7
20
18
16
14
12
10
8
850A‐AP1‐WW‐XX‐XXX‐P2/B1‐X‐X
19
17
15
13
11
9
7
20
18
16
14
12
10
8
850A‐AP1‐WN‐XX‐XXX‐P1‐X‐X
19
17
15
13
11
9
7
20
18
16
14
12
10
8
W:
19
17
15
13
11
9
7
20
18
16
14
12
10
8
R:
19
17
15
13
11
9
7
20
18
16
14
12
10
8
850A‐AP1‐RN‐XX‐XXX‐P1‐X‐X
19
17
15
13
11
9
7
20
18
16
14
12
10
8
850B‐AP1‐WN‐XX‐XXX‐P1‐X‐X
19
17
15
13
11
9
7
20
18
16
14
12
10
8
850A‐AP1‐WR‐XX‐XXX‐XX‐X‐X L850B J203 Jumper Setting
5
3
1
4
2
5
3
1
4
2
5
3
1
4
2
5
3
1
4
2
5
3
1
4
2
5
3
1
4
2
5
3
1
4
2
Table 1: Light Unit Part Numbers and Jumper Settings
Fixture Diameter L850A 8"/12" 8"/12" 8"/12" 8"/12" WR RN L850B P1‐Uni XMFR VA P1‐Bi XMFR VA 12.4 ‐ 9.8 12.4 18.8 20/25W
‐ ‐ ‐ ‐ ‐ ‐ 10/15W ‐ 10/15W 10/15W P2/B1
P2 VA 24.8 22.2 ‐ ‐ XMFRS 10/15W 10/15W ‐ ‐ B1 XMFR 65W 65W ‐ ‐ Table 2: Minimum Isolation Transformer (XFMR) Requirements
(See Table 3 for arctic kit units)
Fixture L850A WR RN L850B Diameter P1‐Uni XMFR VA Heater P1‐Bi P2/B1 XMFR VA VA 8"/12" 8"/12" 8"/12" 8"/12" 28.4 30/45W
‐ ‐ 25.8 30/45W
28.4 30/45W
50.8 ‐ ‐ ‐ 65W ‐ ‐ ‐ 56.8 54.2 ‐ ‐ P2 XMFRS 65W 65W ‐ ‐ Table 3: Minimum Isolation Transformer (XFMR) Requirements
23
B1 XMFR 100W 100W ‐ ‐