User ManualUser Manual L-850C(L) and L-850D(L) Airfield Lighting Style 2 LED Runway Edge Product Solutions Catalog and Runway Threshold and Runway End Light IREL 96A0439, Rev. H, 6/21/16 www.adb-air.com L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H DISCLAIMER / WARRANTY A.0 Disclaimer / Standard Warranty A.1 CE certification A.2 ETL certification A.3 LED Product Guarantee The equipment listed as CE certified means that the product complies with the essential requirements concerning safety and hygiene. The directives that have been taken into consideration in the design are available on written request to ADB. The equipment listed as ETL certified means that the product complies with the essential requirements concerning safety and FAA Airfield regulations. The directives that have been taken into consideration in the design are available on written request to ADB. Where applicable, per FAA EB67(applicable edition), ADB L858(L) Airfield Guidance Signs are warranted against electrical defects in design or manufacture of the LED or LED specific circuitry for a period of 4 years. ADB LED light fixtures (with the exception of obstruction lighting) are warranted against mechanical and physical defects in design or manufacture for a period of 12 months from date of installation; and are warranted against electrical defects in design or manufacture of the LED or LED specific circuitry for a period of 4 years per FAA EB67 (applicable edition). NOTE: See your sales order contract for a complete warranty description. In some specific cases, deviations are (to be) accepted in the contract, which will supersede the standard warranty. A.4 Standard Product Guarantee Products of ADB manufacture are guaranteed against mechanical, electrical, and physical defects (excluding lamps) which may occur during proper and normal use for a period of one year from the date of installation or 2 years from date of shipment and are guaranteed to be merchantable and fit for the ordinary purposes for which such products are made. ADB L858 Airfield Guidance Signs are warranted against mechanical and physical defects in design or manufacture for a period of 2 years from date of installation per FAA AC 150/5345-44 (applicable edition). NOTE: See your sales order contract for a complete warranty description. A.5 All Products LED Products of ADB, manufactured and sold by ADB or its licensed representatives, meets the corresponding requirements of FAA, ICAO and IEC. ADB will correct by repair or replacement per the applicable guarantee above, at its option, equipment or parts which fail because of mechanical, electrical or physical defects, provided that the goods have been properly handled and stored prior to installation, properly installed and properly operated after installation, and provided further that Buyer gives ADB Airfield Solutions written notice of such defects after delivery of the goods to Buyer. Refer to the Safety section for more information on Material Handling Precautions and Storage precautions that must be followed. ADB reserves the right to examine goods upon which a claim is made. Said goods must be presented in the same condition as when the defect therein was discovered. ADB Airfield Solutions furthers reserves the right to require the return of such goods to establish any claim. ADB’s obligation under this guarantee is limited to making repair or replacement within a reasonable time after receipt of such written notice and does not include any other costs such as the cost of removal of defective part, installation of repaired product, labor or consequential damages of any kind, the exclusive remedy being to require such new parts to be furnished. ADB’s liability under no circumstances will exceed the contract price of goods claimed to be defective. Any returns under this guarantee are to be on a transportation charges prepaid basis. For products not manufactured by, but sold by ADB Airfield Solutions, warranty is limited to that extended by the original manufacturer. This is ADB’s sole guarantee and warranty with respect to the goods; there are no express warranties or warranties of fitness for any particular purpose or any implied warranties of fitness for any particular purpose or any implied warranties other than those made expressly herein. All such warranties being expressly disclaimed. ii © ADB Airfield Solutions All Rights Reserved L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H DISCLAIMER / WARRANTY A.6 Liability WARNING Use of the equipment in ways other than described in the catalogue leaflet and the manual may result in personal injury, death, or property and equipment damage. Use this equipment only as described in the manual. ADB cannot be held responsible for injuries or damages resulting from non-standard, unintended uses of its equipment. The equipment is designed and intended only for the purpose described in the manual. Uses not described in the manual are considered unintended uses and may result in serious personal injury, death or property damage. Unintended uses includes the following actions: — Making changes to equipment that have not been recommended or described in this manual or using parts that are not genuine ADB replacement parts or accessories. — Failing to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable safety standards if not in contradiction with the general rules. — Using materials or auxiliary equipment that are inappropriate or incompatible with your ADB equipment. — Allowing unskilled personnel to perform any task on or with the equipment. © ADB Airfield Solutions All Rights Reserved iii L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H DISCLAIMER / WARRANTY A.7 © ADB BVBA This manual or parts thereof may not be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, nor otherwise, without ADB BVBA’s prior written consent. This manual could contain technical inaccuracies or typographical errors. ADB BVBA reserves the right to revise this manual from time to time in the contents thereof without obligation of ADB BVBA to notify any person of such revision or change. Details and values given in this manual are average values and have been compiled with care. They are not binding, however, and ADB BVBA disclaims any liability for damages or detriments suffered as a result of reliance on the information given herein or the use of products, processes or equipment to which this manual refers. No warranty is made that the use of the information or of the products, processes or equipment to which this manual refers will not infringe any third party’s patents or rights. The information given does not release the buyer from making their own experiments and tests. iv © ADB Airfield Solutions All Rights Reserved 96A0439 Rev. H 6/21/16 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light Disclaimer TABLE OF CONTENTS A.0 Disclaimer / Standard Warranty ......................................................................... II Table of Contents A.1 CE certification ...................................................................................................... ii A.2 ETL certification .................................................................................................... ii A.3 LED Product Guarantee ....................................................................................... ii A.4 Standard Product Guarantee ................................................................................ ii A.5 All Products ........................................................................................................... ii A.6 Liability ..................................................................................................................iii A.7 © ADB BVBA ....................................................................................................... iv 1.0 Safety .................................................................................................................... 1 Installation Introduction Safety 1.1 HAZARD Icons used in the manual ...................................................................... 1 1.1.1 Qualified Personnel ...................................................................................... 1 1.2 To use this equipment safely: ............................................................................... 2 1.2.1 Additional Reference Materials: .................................................................... 2 1.2.2 Intended Use ................................................................................................ 2 1.2.3 Fasteners ...................................................................................................... 2 1.2.4 Operation ...................................................................................................... 3 1.2.5 Storage ......................................................................................................... 3 1.2.6 Material Handling Precautions ...................................................................... 3 1.2.7 Action in the Event of a System or Component Malfunction ........................ 4 1.2.8 Maintenance ................................................................................................. 4 1.2.9 Maintenance and Repair .............................................................................. 4 2.0 IREL ....................................................................................................................... 5 © 2014 ADB Airfield Solutions All Rights Reserved Schematics Parts Operation 2.1 About this manual ................................................................................................. 5 2.1.1 How to work with the manual ........................................................................ 5 2.1.2 Record of changes ....................................................................................... 5 2.2 Introduction ........................................................................................................... 6 2.2.1 Compliance with Standards .......................................................................... 6 2.2.2 Uses ............................................................................................................. 6 2.2.3 Features ....................................................................................................... 6 2.2.4 Dimensions ................................................................................................... 7 2.2.5 Packaging ..................................................................................................... 7 2.2.6 Electrical Supply ........................................................................................... 8 2.3 Installation ............................................................................................................. 9 2.3.1 Input Requirement Summary ........................................................................ 9 2.3.2 Unpacking ..................................................................................................... 9 2.3.3 Connection of the Series Transformer and the Light Connectors ................ 9 2.3.4 Installation on L-868 Base .......................................................................... 10 2.3.5 Installation on a Shallow Base .................................................................... 11 2.3.6 Torquing and Installation Guidance for In-pavement Fixtures .................... 11 2.3.7 Earth Ground Connection ........................................................................... 11 2.4 Troubleshooting .................................................................................................. 12 2.5 Maintenance ........................................................................................................ 13 2.5.1 IREL Maintenance Schedule ...................................................................... 13 2.5.2 Fixture Component Maintenance ............................................................... 14 2.5.2.1 Cleaning the Light Channel and Prism .............................................. 14 2.5.2.2 Lifting Optical Unit Out of Base.......................................................... 15 2.5.3 Repair Procedures ...................................................................................... 16 2.5.3.1 Opening Optical Unit.......................................................................... 16 2.5.3.2 Replacing Prism................................................................................. 17 2.5.4 Replacing LED Assembly ........................................................................... 18 2.5.4.1 Replacing L-823 Cordset ................................................................... 19 2.5.5 Replacing the PCB ..................................................................................... 20 2.5.5.1 Calibration ......................................................................................... 20 v L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H 6/21/16 Disclaimer 2.5.5.2 Testing for Leaks................................................................................ 21 3.0 Appendix A..........................................................................................................23 Table of Contents 3.1 Installation Guidance for In-pavement Fixtures ...................................................23 3.1.1 Reference Documents ................................................................................23 3.1.2 Mounting Systems ......................................................................................23 3.2 L-868 base can installation (load bearing) ...........................................................24 3.2.1 Use of Ceramic Bolts ..................................................................................28 3.3 L-867 base can installation (non-load bearing) ...................................................29 3.4 Checking Bolt Torque ..........................................................................................32 4.0 Parts ....................................................................................................................33 Safety 4.1 Parts ....................................................................................................................33 4.1.1 IREL Components ......................................................................................34 4.1.2 Optional Snow Plow Ring ...........................................................................35 Introduction Installation Operation Parts Schematics vi © 2014 ADB Airfield Solutions All Rights Reserved 1.0 Safety 1.1 HAZARD Icons used in the manual This section contains general safety instructions for installing and using ADB Airfield Solutions equipment. Some safety instructions may not apply to the equipment in this manual. Task- and equipment-specific warnings are included in other sections of this manual where appropriate. For all HAZARD symbols in use, see the Safety section. All symbols must comply with ISO and ANSI standards. Carefully read and observe all safety instructions in this manual, which alert you to safety hazards and conditions that may result in personal injury, death or property and equipment damage and are accompanied by the symbol shown below. WARNING • Failure to observe a warning may result in personal injury, death or equipment damage. DANGER - RISK OF ELECTRICAL SHOCK OR ARC FLASH • Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury, death, or equipment damage. ARC Flash may cause blindness, severe burns or death. WARNING - WEAR PERSONAL PROTECTIVE EQUIPMENT • Failure to observe may result in serious injury. WARNING - DO NOT TOUCH • Failure to observe this warning may result in personal injury, death, or equipment damage. CAUTION • Failure to observe a caution may result in equipment damage. 1.1.1 Qualified Personnel IMPORTANT INFORMATION The term qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations and have been trained to safely install, operate, maintain and repair the equipment. It is the responsibility of the company operating this equipment to ensure that its personnel meet these requirements. Always use required personal protective equipment (PPE) and follow safe electrical work practices. © ADB Airfield Solutions All Rights Reserved 1 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H To use this equipment safely: 1.2 To use this equipment safely: WARNING Read installation instructions in their entirety before starting installation. • Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. • Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. • Make this manual available to personnel installing, operating, maintaining or repairing this equipment. • Follow all applicable safety procedures required by your company, industry standards and government or other regulatory agencies. • Install all electrical connections to local code. • Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. • Route electrical wiring along a protected path. Make sure they will not be damaged by moving equipment. • Protect components from damage, wear, and harsh environment conditions. • Allow ample room for maintenance, panel accessibility, and cover removal. • Protect equipment with safety devices as specified by applicable safety regulations. • If safety devices must be removed for installation, install them immediately after the work is completed and check them for proper functioning prior to returning power to the circuit. Failure to follow these warnings may result in serious injury or equipment damage. 1.2.1 Additional Reference Materials: IMPORTANT INFORMATION • • • • • IEC - International Standards and Conformity Assessment for all electrical, electronic and related technologies IEC 60364 - Electrical Installations in Buildings FAA Advisory: AC 150/5340-26 (current edition) Maintenance of Airport Visual Aid Facilities ANSI/NFPA 79, Electrical Standards for Metalworking Machine Tools. National and local electrical codes and standards. 1.2.2 Intended Use WARNING IMPROPER USE Using this equipment in ways other than described in this manual may result in personal injury, death or property and equipment damage. Use this equipment only as described in this manual. THESE WARNINGS MAY RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. 1.2.3 Fasteners WARNING FOREIGN OBJECT DAMAGE - FOD • Only use fasteners of the same type as the one originally supplied with the equipment. • Always tighten the fasteners to the recommended torque. Use a calibrated torque wrench and apply the recommended adhesive type. • Obey the instructions of the adhesives necessary for the fasteners. Failure to follow these warnings may cause the fasteners to loosen, damage the equipment, potentially to loosen the equipment. This can lead to a highly dangerous situation of FOD, with potential lethal consequences. 2 © ADB Airfield Solutions All Rights Reserved 1.2.4 Operation CAUTION IMPROPER OPERATION • Only qualified personnel, physically capable of operating the equipment and with no impairments in their judgment or reaction times, should operate this equipment. • Read all system component manuals before operating this equipment. A thorough understanding of system components and their operation will help you operate the system safely and efficiently. • Before starting this equipment, check all safety interlocks, fire-detection systems, and protective devices such as panels and covers. Make sure all devices are fully functional. Do not operate the system if these devices are not working properly. Do not deactivate or bypass automatic safety interlocks or locked-out electrical disconnects or pneumatic valves. • Protect equipment with safety devices as specified by applicable safety regulations. • If safety devices must be removed for installation, install them immediately after the work is completed and check them for proper functioning. • Route electrical wiring along a protected path. Make sure they will not be damaged by moving equipment. • Never operate equipment with a known malfunction. • Do not attempt to operate or service electrical equipment if standing water is present. • Use this equipment only in the environments for which it is rated. Do not operate this equipment in humid, flammable, or explosive environments unless it has been rated for safe operation in these environments. • Never touch exposed electrical connections on equipment while the power is ON. Failure to follow this instruction can result in equipment damage. 1.2.5 Storage CAUTION IMPROPER STORAGE If equipment is to be stored prior to installation, it must be protected from the weather and kept free of condensation and dust. Failure to follow this instruction can result in equipment damage. 1.2.6 Material Handling Precautions CAUTION ELECTROSTATIC SENSITIVE DEVICES This equipment may contain electrostatic sensitive devices. • Protect from electrostatic discharge. • Electronic modules and components should be touched only when this is unavoidable e.g. soldering, replacement. • Before touching any component of the cabinet you should bring your body to the same potential as the cabinet by touching a conductive earthed part of the cabinet. • Electronic modules or components must not be brought in contact with highly insulating materials such as plastic sheets, synthetic fiber clothing. They must be laid down on conductive surfaces. • The tip of the soldering iron must be grounded. • Electronic modules and components must be stored and transported in conductive packing. Failure to follow this instruction can result in equipment damage. WARNING UNSTABLE LOAD • Use extreme care when moving heavy equipment. • Verify that the moving equipment is rated to handle the weight. • When removing equipment from a shipping pallet, carefully balance and secure it using a safety strap. Failure to follow these instructions can result in death, serious injury, or equipment damage. © ADB Airfield Solutions All Rights Reserved 3 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H To use this equipment safely: 1.2.7 Action in the Event of a System or Component Malfunction DANGER ARC FLASH AND ELECTRIC SHOCK HAZARD • Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the system OFF immediately. • An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter. • Never unplug a device from a constant current circuit while it is operating. Arc flash may result. • Disconnect and lock out electrical power. • Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component according to instructions provided in its manual. Failure to follow these warnings will result in death or equipment damage. 1.2.8 Maintenance WARNING ELECTRIC SHOCK HAZARD • Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the system OFF immediately. • Disconnect and lock out electrical power. • Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component according to instructions provided in its manual. Failure to follow these warnings will result in death or equipment damage. 1.2.9 Maintenance and Repair DANGER ARC FLASH AND ELECTRIC SHOCK HAZARD Allow only qualified personnel to perform maintenance, troubleshooting, and repair tasks. • Only persons who are properly trained and familiar with ADB Airfield Solutions equipment are permitted to service this equipment. • An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter. • Never unplug a device from a constant current circuit while it is operating. Arc flash may result. • Disconnect and lock out electrical power. • Always use safety devices when working on this equipment. • Follow the recommended maintenance procedures in the product manuals. • Do not service or adjust any equipment unless another person trained in first aid and CPR is present. • Connect all disconnected equipment ground cables and wires after servicing equipment. Ground all conductive equipment. • Use only approved ADB Airfield Solutions replacement parts. Using unapproved parts or making unapproved modifications to equipment may void agency approvals and create safety hazards. • Check the interlock systems periodically to ensure their effectiveness. • Do not attempt to service electrical equipment if standing water is present. Use caution when servicing electrical equipment in a high-humidity environment. • Use tools with insulated handles when working with airfield electrical equipment. Failure to follow these warnings will result in death or equipment damage. 4 © ADB Airfield Solutions All Rights Reserved 2.0 IREL 2.1 About this manual L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light. The manual shows the information necessary to: • 2.1.1 How to work with the manual Install and maintain the IREL Style 2 LED Runway Edge Light. 1. Become familiar with the structure and content. 2. Read the Safety Instructions. 3. Carry out the actions completely and in the given sequence. 2.1.2 Record of changes Page Rev Description All A Released Manual B Updated Warranty Checked Approved Date DM ER 9/2012 All C Updated and Added the L-850D(L) info DM ER 4/01/13 front D ETL Certified JH ER 5/4/13 10 E Added the O-ring for shallow base installations RW ER 12/5/13 All F Install, Maintenance and Parts sections RW ER 02/14/14 parts G parts and maintenance RW JC 8/5/14 All H parts, torque info RW JC 6/21/16 © ADB Airfield Solutions All Rights Reserved 5 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Introduction 2.2 Introduction 2.2.1 Compliance with Standards FAA: L-850C(L) and L-850D(L) AC 150/5345-46 (Current Edition) and the FAA Engineering Brief No. 67 “Light Sources other than Incandescent and Xenon for Airport Lighting and Obstruction Lighting Fixtures.” ETL Certified. ICAO: Runway Edge: Annex 14, Vol. I, par. 5.3.9.7 and 5.3.9.10; Fig. A2-9 for 45 m runways Runway End: Annex 14, Vol. I, par. 5.3.11; Fig. A2-8. (Unidirectional red only) T/C: Runway Edge: Transport Canada TP 312 par. 5.3.10 and Appendix B, Figure B-10 for 45 m runways. Runway End: Transport Canada TP 312 par. 5.3.12. and Appendix B, Fig. B.1.9. Military: Runway Edge: Photometry complies with UFC 3-535-01 Fig. 4-2 for runways less than 200 feet (60 m) wide. 2.2.2 Uses L-850C(L) • • Runway edge on category I, II, and III runways Military runway edge applications less than 200 feet wide L-850D(L) • • Runway displaced threshold light (unidirectional green) Runway threshold/end (bidirectional red/green) ICAO & T/C 2.2.3 Features 6 • • Runway edge applications less than 60 m (200 feet) wide • Average LED life of 56,000 hours under high-intensity conditions and more than 150,000 hours under typical operating conditions, resulting in significant reduction or even elimination of ongoing maintenance costs and periodic re-lamping expenses. • For L-850C white runway edge applications, use of LED light source eliminates color shifts at lower CCR step settings. For red, yellow or green runway applications, use of LED light source eliminates fi lter replacement and color shifts when viewed at various angles or CCR step settings. • FAA Style 2. Low protrusion above ground of 0.50 inch reduces vibrations caused by aircraft landing gear in both light fixture and landing gear, increasing lamp life. • Can be installed on existing series circuits with no modifications to existing CCR or isolation transformer. • Operates on either 3- or 5-step ferroresonant or thyristor CCRs that are designed in compliance with IEC or FAA requirements. • Very low power rating for LED lights contributes to a lower life cycle cost. Limits cost for supporting equipment, such as CCRs, to strict minimum. • When quartz-incandescent fixtures are replaced with LED fixtures, airport staff can add more lights without increasing CCR size. • LED photometric performance will be maintained longer due to a cleaner lens. The lower temperature of the lens prevents the “baking effect” that causes contaminants to stick to the surface of the lens. • LED photometric performance will be maintained longer due to a cleaner lens. The lower temperature of the lens prevents the “baking effect” that causes contaminants to stick to the surface of the lens. • Offers longer maintenance intervals and requires fewer spare parts, resulting in lower life cycle cost • “Smart electronics” control current to LED, so light output matches existing incandescent fixtures at all brightness levels without sacrificing any light characteristics. Actual light output is determined based on a continuous light output curve. Therefore, light output truly represents input current, even if series circuit input current is not within FAA specification limits. Allows for a low cost and progressive evolution of the airfield lighting toward new LED-based technology. Runway end (Unidirectional red only) © ADB Airfield Solutions All Rights Reserved • Unique double-barrier cord set design eliminates risk for water incursion in case the cord set becomes damaged. Cord set can also be easily replaced without opening fi xture. • Light channel in front of prism windows protects prisms from damage and prevents rubber buildup thereby maintaining optimal light output • Environment-friendly, precision-cast aluminum alloy cover, optical support, and inner cover assembly with stainless steel hardware • Low-temperature lights. Temperature rise at center of top cover remains below FAAspecified limit of 320 °F (160 °C). • • Includes a UL 467 rated ground lug, which accepts an AWG 6 earth ground wire Rugged lightning protection that complies with ANSI/IEEE C62.41-1991 Location Category C2 given in FAA Eng. Brief 67. Category C2 is defined as a 1.2/50ìS – 8/20 ìS combination wave, with a peak voltage of 10,000 Volts and a peak current of 5,000 Amps Figure 1: Light Beam Location NOTE: Triangle embossed on the top cover should point toward the centerline to ensure correct toe-in position. 2.2.4 Dimensions Outside Diameter: 11.94 in (30.33 cm) Bolt Circle Diameter (L-868B): 11.25 in (28.58 cm) Max. Bottom Cover O.D.: 9.94 in (25.25 cm) Max Bottom Cover O. D.: • • 9.92 in (25.20 cm) down to depth of 1.63 in (4.14 cm) 8.69 in (22.07 cm) from depth of 1.63 in (4.14 cm) to 3.88 in (9.86 cm) Compatible with L-868B Top Sections where the overall height of the Top Section is less than 4 in (10.16 cm). 2.2.5 Packaging Bottom Cover Depth: 3.88 in (9.9 cm) In cardboard box: 7 x 13 x 13 in (17.8 x 33 x 33 cm) Weight with packing: 18.5 lb (8.4 kg) Weight without packing: 15.5 lb (7 kg) © ADB Airfield Solutions All Rights Reserved 7 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Introduction 2.2.6 Electrical Supply It is recommended that the L-850C(L) LED fixture be powered from a dedicated CCR and that separate remote controls are available. IREL LED lights have been designed to work with any IEC or FAA-compliant transformer up to 200 W without affecting the performance or lifetime of the light fixture or transformer. See catalog sheet 3035 for more details on recommended isolation transformers (XF) specified below. L-850C(L) & L-850D(L) Fixture Load Isolation Transformer Load CCR Load 30/45 W 8 VA 29 VA 17 VA 53 VA 8 VA per XF 29 VA per side (58 VA total) Isolation Transformer Without Heater Unidirectional 21 VA Bidirectional 1 36 VA 65 W Bidirectional 2 21 VA per side (42 VA total) 30/45 W per side With Heater Unidirectional 49 VA 65 W 15 VA 64 VA Bidirectional1 64 VA 65 W 13 VA 77 VA Bidirectional2 49 VA per side (98 VA total) 65 W per side 15 VA per XF 64 VA per side (128 VA total) 1 One cord set 2 One cord set per side 8 © ADB Airfield Solutions All Rights Reserved 2.3 Installation WARNING Read installation instructions in their entirety before starting installation. • Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. • Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. • Follow all applicable safety procedures required by your company, industry standards and government or other regulatory agencies. • Install all electrical connections to local code. • Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. • Route electrical wiring along a protected path. Make sure they will not be damaged by moving equipment. • Protect components from damage, wear, and harsh environment conditions. Failure to follow these warnings may result in serious injury or equipment damage. This section provides installation instructions for the L-850C, IREL Light Fixture. 2.3.1 Input Requirement Summary The IREL light fixture is designed for connection to a 6.6 A or 20 A series lighting circuit via an L-830 (for 60Hz) or L-831 (for 50Hz) isolation transformer. 2.3.2 Unpacking Each unit is individually packaged in a durable, cushioned, corrugated cardboard carton. To avoid unnecessary damage to the light assembly, unpack the carton at the installation site. To unpack the carton, open the flaps, carefully remove the top packing material and remove the fixture. Set the light assembly in a protected area. If damage to any equipment is noted, file a claim form with the carrier immediately. The carrier may request to inspect the equipment. 2.3.3 Connection of the Series Transformer and the Light Connectors 1. The 2-pin plug on cable 1 is connected to the socket for the secondary circuit of the series transformer. See Figure 2. NOTE: The IREL also may have 2 power leads, one for each side. Figure 2: IREL with Power Lead Power Lead Ground NOTE: All connections should be sealed with self-bonding insulation tape and then covered with electrical tape in accordance with local airport practices. If your airport does not require this, it is highly recommend that you at least wrap the connection with electrical tape. © ADB Airfield Solutions All Rights Reserved 9 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Installation 2.3.4 Installation on L-868 Base The light assembly is shipped complete, and ready for installation. To install the fixture on an L-868 base, see FAA AC 150/5340-30 and the project site-specific plans and specifications for details on L-868 base installation. NOTE: Mounting bolts are not supplied with the fixture. Mounting bolts and anti-rotation lock washers are normally supplied with the base can or flange ring. If a flange ring is used, the bolt length is 1-1/4” (32mm) plus the thickness of the flange ring. Also read the following guidelines: 1. Clean the base receptacle. Make sure the base receptacle is completely clean and dry. The mating surfaces must be clean and free of foreign particles. 2. Count out the six fixing bolts and anti-vibration washers required. 3. Fit an appropriate lifting tool into both holes, which are located 180° apart in the cover. NOTE: The lifting tool can be made from two 1/2 x 13 eyebolts (1-in. ID) and a 1/2-in. diameter, 16 in. (406mm) long rod or pipe inserted through the eyebolts. 4. If present, lift the old or faulty optical unit out of the base. CAUTION Read installation instructions in their entirety before starting installation. • Never hold the light fixture by the wires. Doing so may damage the cordset. Failure to follow this warnings may result in equipment damage. 5. Carry the new light assembly to the base. 6. Place the light assembly beside the opening in the L-868 base so that the L-823 Power connector can be connected with the mating receptacle from the L-830 or L-831 isolation transformer in the base. Make sure that the connection is solid and secure. Refer to “Electrical Supply” on page 8 for required isolation transformers. 7. Position the light assembly over the L-868 base and set it onto the base. Align the light according to FAA AC 150/5345-30 and project plans and specifications. Make sure items such as spacers and shims are installed on the light base as indicated on site plans, specifications and drawings. Remove the eyebolts and lifting rod. CAUTION Read installation instructions in their entirety before starting installation. • Ensure that the cord set wires are NOT pinched between the base can and the fixture. Pinched wires can short the input power, preventing the light from operating properly. Failure to follow these warnings may result in equipment damage. See “Torquing and Installation Guidance for In-pavement Fixtures” on page 11. 10 © ADB Airfield Solutions All Rights Reserved 2.3.5 Installation on a Shallow Base Installing the IREL light fixture on a shallow base involves preparing the pavement recess and wireways, then installing the light fixture on a shallow base. See FAA AC 150/5345-30 and the project site-specific plans and specifications for details on shallow base installation. Also follow the applicable instructions in the previous section, “Installation on L-868 Base” on page 10, when connecting, installing and powering the fixture. Place an O-ring seal between topcover and shallow base, for F-Range 12" ADB# (7080.90.650) 2.3.6 Torquing and Installation Guidance for In-pavement Fixtures In-pavement fixtures must be installed according to the plans and specifications; the applicable regulatory guidance; and the following guidance. The importance of using the proper fixture clamping components and bolt torque to minimize the risk for fixture failure or loosening of clamping components cannot be overemphasized. Refer to “Appendix A” on page 23 for torque and installation guidelines for this fixture. WARNING Read installation instructions in their entirety before starting installation. • Failure to follow the installation guidance could result in bolt loosening or bolts breaking off, resulting in catastrophic failure of the fixture and/or the mounting system components. Failure to follow these warnings may result in serious injury or equipment damage. 2.3.7 Earth Ground Connection Earth ground should be connected to the UL 467 Rated Earth ground screw. The crosssectional area of the cable should be at least 6 AWG (13.29 mm2) with a minimum wire length of 48-inches. Some installations will require a 72-inch wire. NOTE: A braided ground strap may also be used instead of a ground wire. Figure 3: Base Can Cross-section Transformer In-pavement Light Assembly Ground Connection Counterpoise Ground Wire Wire Provide 3-feet of slack Conduit for Connections Ground Rod © ADB Airfield Solutions All Rights Reserved 11 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Troubleshooting 2.4 Troubleshooting WARNING Read installation instructions in their entirety before troubleshooting. • Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. • Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. • Follow all applicable safety procedures required by your company, industry standards and government or other regulatory agencies. • Install all electrical connections to local code. • Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. • Route electrical wiring along a protected path. Make sure they will not be damaged by moving equipment. • Protect components from damage, wear, and harsh environment conditions. Failure to follow these warnings may result in serious injury or equipment damage. Table 1: Problem Failed LED (short life span) Troubleshooting table Possible Cause Corrective Action PCB set incorrectly See “Replacing the PCB” on page 20 Water in assembly Inspect the prism. Open light assembly. Clean, dry and inspect light assembly. Replace O-ring. Verify fixture is sealed. See “Cleaning the Light Channel and Prism” on page 14. Check constant current regulator output current levels. Failed internal Input current too high PCB PCB set incorrectly Broken, damaged or Distorted light wrong prism installed. beam output Improper toe on the LED assembly. Water inside optical chamber 12 Damaged or missing prism seals or top cover O-ring Check the label on the isolation transformer and replace if necessary. For example, incorrectly installing a 6.6A/20A transformer will cause very short fixture component life. See “Replacing the PCB” on page 20 Check parts list and install correct prism. Check the toe of the LED assembly. Adjust if necessary. Replace both prism seals. Replace top cover Oring. Verify that the fixture is sealed. © ADB Airfield Solutions All Rights Reserved 2.5 Maintenance 2.5.1 IREL Maintenance Schedule Interval Maintenance Task Action Refer to: Weekly Check for dirty channel and prism. Monthly (more often during rainy seasons) Check for moisture in Open up the light fixture if moisture is present. “Opening Optical Unit” on the light fixture by Clean, dry, and inspect the light assembly. page 16. looking through the lens. Replace the O-ring. Every 60 days (also whenever the light assembly is serviced) Check for improper torque on hold-down bolts. After snow removal Check for damaged light Replace damaged fixtures. Use a power fixtures. broom for snow removal, if practical. © ADB Airfield Solutions All Rights Reserved Clean channel and prism. Torque the six bolts holding the fixture to the base. “Cleaning the Light Channel and Prism” on page 14. Refer to: “Torquing and Installation Guidance for Inpavement Fixtures” on page 11. 13 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Maintenance 2.5.2 Fixture Component Maintenance WARNING Read installation instructions in their entirety before performing maintenance. • Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. • Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. • Turn off the circuit before replacing fixture(s). Failure to observe this warning may result in personal injury, death, or equipment damage. • Follow all applicable safety procedures required by your company, industry standards and government or other regulatory agencies. • Install all electrical connections to local code. • Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. • Route electrical wiring along a protected path. Make sure they will not be damaged by moving equipment. • Protect components from damage, wear, and harsh environment conditions. Failure to follow these warnings may result in serious injury or equipment damage. The preferred method of maintaining the IREL in-pavement high-intensity runway edge light is to periodically and systematically replace the light assembly and return the replaced assembly to the maintenance shop for renovation. As an alternative, you can service the light assembly in the field. It is recommended, however, that field servicing be limited to cleaning lenses and removing moisture. 2.5.2.1 Cleaning the Light Channel and Prism To clean the light channel and prism, perform the following procedure: 1. Use a suitable fiber brush to remove all accumulated debris from the light channel. 2. Clean the outer surface of the prism using liquid glass cleaner. If the prism is coated with a substance impervious to the cleaner, apply a suitable solvent sparingly with a wad of cotton or a patch of cloth. After the solvent has acted, remove the softened coating with a clean piece of cotton or cloth. Dry the prism with gently, dry, oil-free compressed air at a pressure no greater than 10 psi (69 KN/m2) to evaporate or remove all remaining cleaner. 14 © ADB Airfield Solutions All Rights Reserved 2.5.2.2 Lifting Optical Unit Out of Base There are two methods that can be used to lift the fixture: Method 1: Use eyebolts to lift the fixture 1. Remove the six mounting bolts and washers. 2. Fit the eyebolts into both threaded holes located (180 degrees apart) in the cover, lift the optical unit out of the base and place the optical unit next to the base. NOTE: Lifting Tool is two 1/2 x 13 Eyebolts (1 in. ID) and a 1/2 in. dia. rod/pipe x 16 in. long (placed between the eyebolts). 3. Disconnect the light fixture wires from the power wires coming from the transformer(s). 4. Mount a serviced or new light fixture as described in Installation on L-868 Base in the Installation section. NOTE: Refer to: “Torquing and Installation Guidance for In-pavement Fixtures” on page 11. 5. Take the in-pavement fixture unit back to the maintenance shop where it can be serviced entirely. NOTE: Never hold the light fixture by the wires. This may damage the insulation. Method 2: Use a lifting tool To lift the optical unit out of the base receptacle or adapter ring, proceed as follows: 1. Remove the mounting bolts and washers. NOTE: Never hold the light fixture by the wires. This may damage the insulation. 2. Fit the appropriate lifting tool into lifting holes (A) located (180° apart) in the cover. Screw the T-handles down to seperate the fixture from the mounting base. Lift the optical unit out of the base or adapter ring and place it next to it. Lifting Tool 1411.19.550 Ordered separately A 3. Disconnect the light fixture wires from the power wires coming from the transformer(s). 4. Mount a serviced or new fitting. See “Installation on L-868 Base” on page 10. 5. Take the optical unit back to the maintenance shop where it can be serviced entirely. © ADB Airfield Solutions All Rights Reserved 15 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Maintenance 2.5.3 Repair Procedures 2.5.3.1 Opening Optical Unit To open the optical unit, perform the following procedure: 1. Turn the light unit upside-down. 2. See Figure 4. Remove the pressure release screw. NOTE: Removing the pressure release screw equalizes the pressure inside and outside the fixture, making it easier to break the seal and remove the inner cover. Figure 4: Pressure Release Screw Pressure Release Screw 3. See Figure 5. Remove the (10) screws. The use of an impact driver may be required to unlock the screws. Figure 5: Removing Screws L-850C TOP COVER,W-S/W-S,W/AK 44A7180-1120 O-RING TOP COVER 7080.90.710 INTERMEDIATE PAN ASSY 2-CORD, 50/60HZ 44A7223-21100 M5 X 10 FLT PHIL SS 64A0925-10 4. Insert small or medium flat blade screwdriver in the machined recess slot between cover and inner cover and turn it vertically to separate the inner cover from the cover. 16 © ADB Airfield Solutions All Rights Reserved 2.5.3.2 Replacing Prism Table 2: Parts List for Replacing Prism Part Number Description Quantity 4072.18.336 Lens, optical glass 2 or 4 4072.18.380 Lens Retainer Seal 2 or 4 4072.18.362 Lens Seal 2 or 4 Note To replace the prism, perform the following procedure: 1. See Figure 6. Remove the LED Assembly by removing the four Phillips Head screws. 2. Remove the lens retainer plate and Lens Retainer Seal secured in the inner pan assembly. Also see Figure 21. Figure 6: Lens Retainer Seal and Lens Lens Retainer Seal Figure 7: Lens Seal for Lens Lens Seal Lens 3. See Figure 7. Push the Lens with the Lens Seal towards the inside of the cover. 4. Clean and remove grease from the prism chamber with any effective solvent. NOTE: Never use any abrasive substance. This will scratch or frost the prism. 5. Apply a thin layer of Dow Corning Molykote 3452 or equivalent in the prism chamber using a small brush. 6. Install a Lens Seal over the Lens 7. Push the Lens and Seal assembly in the lens pocket from the inside and clean the inner surface of the lens. 8. Install a Lens Retainer Seal over the Lens. 9. Reinstall the Lens Retainer Plate hardware with the Phillips pan head screws. Apply a droplet of sealant Loctite 270 to the last threads. Torque to 31 ± 4 inch-pounds (3.5 ± 0.5 N•m). 10. Close the Optical Unit. 11. Test for leaks, see “Testing for Leaks” on page 21. © ADB Airfield Solutions All Rights Reserved 17 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Maintenance 2.5.4 Replacing LED Assembly Figure 8: IREL LED Assembly Lens Retainer Plate LED Assembly 1. Open the Optical Unit, see “Opening Optical Unit” on page 16. 2. Disconnect the LED Assembly wires at the PCB by pulling gently upward. 3. Remove the three Phillips Head screws, clean the mounting surface of the top cover. 4. Replace the LED Assembly, attach with three Phillips Head screws, apply a drop of Loctite 242 and torque to 2.5 ± 0.5N·m (22 ± 4 IN-LBS). 5. Connect the LED Assembly to the PCB. 6. Close the Optical Unit. 7. Test for leaks, see “Testing for Leaks” on page 21. Figure 9: LED Light Engine Connections USE J4 "ONLY", PLUG LIGHT ENGINE ADAPTER HARNESS 44A7308/WHT OR 44A7308/RED AS REQUIRED. APPLY JUMPER TO CENTER PINS AS SHOWN. THIS MODIFICATION CHANGES THE DUAL DRIVER PCB TO SINGLE DRIVER 18 © ADB Airfield Solutions All Rights Reserved 2.5.4.1 Replacing L-823 Cordset To replace the L-823 cordset, perform the following procedure: 1. See Figure 10. Remove both screws (F7) from the cordset connector (F9). 2. Unplug the cordset assembly. Figure 10: L-823 Cordset F9 F7 3. Replace the cordset by plugging in the new cordset. 4. Attach the two screws. Do not use a power screw driver. Compress the cord rubber by no more than 1/32” (0.79 mm). 5. Return the light to service. Figure 11: IREL LED, Cordset and Light Engine Wiring Diagram # 2 - HEATER THERMOSTAT M M F F M # 1 - HEATER M F F CONNECTION TO POWER CORDSET IN BASE CONNECTION TO J1A PCB POWER CONN IN BASE PCB J1 J2 M F M F BASE CORDSET TO POWER J1, J2 TWO HEATER ONE THERMOSTAT WIRING CONFIGURATION © ADB Airfield Solutions All Rights Reserved 19 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Maintenance 2.5.5 Replacing the PCB Figure 12: IREL PCB J7 J1 and J2 J4 and J5 1. Open the optical unit. Refer to “Opening Optical Unit” on page 16. 2. Disconnect the LED Assemblies from the PCB and disconnect the fast-on connectors J4 and J5. 3. Disconnect the power from J1 and J2. 4. Remove the PCB. 5. Replace the PCB and reconnect all wires. NOTE: PCB Is "2-channel" by default; add shunt to J7 pins 3 & 4 to change it to "1channel". Apply jumper to center pins 3 & 4. This modification changes the dual driver PCB to single driver. 2.5.5.1 Calibration For L-850C fixtures after replacing the PCB: 1. Insert a jumper between J7 pins 5 and 6. 2. Turn the CCR ON to B1. 3. Turn the CCR OFF. 4. Remove the jumper from the J7. 5. Turn on the CCR to B5 – 6.6A. 6. The light engines will gradually rise at a low intensity. NOTE: Observe the light engine brief blinking followed by a gradual rise for a full brightness. (Each light engine will calibrate individually. One will be on while the other is off.) 7. Turn the CCR off. 8. Close the unit and, test for leaks, see “Testing for Leaks” on page 21. 20 © ADB Airfield Solutions All Rights Reserved 2.5.5.2 Testing for Leaks WARNING Read installation instructions in their entirety before performing maintenance. • Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. • Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment. • The unit must have all its screws installed and correctly torqued prior to pressurizing to 20 psi maximum. • High pressure may cause the fixture to explode causing damage to fixture, personal injury, or death. Failure to follow these warnings may result in serious injury or equipment damage. Always test for leaks after opening the fixture for any reason. To perform this test: Figure 13: 1. Remove pressure release screw (E11), see Figure 13. 2. Screw the pressure test fitting hand-tight into the pressure relief port (see figure below). The relief port is the opening created when the pressure release screw is removed. 3. Attach an air line to the lock hose plug sleeve, shown below. 4. Pressurize to 20 psi maximum. 5. Submerge the fixture in a bucket or tank filled with water. Check for air bubbles, which would indicate a leak. Pressure test fitting P/N 44A6104 (may be purchased separately from ADB Airfield Solutions) Lock hose plug sleeve 6. Locate the leak source, depressurize, replace the leaky seal or part, reassemble and repeat the test. 7. If the leak is fixed, depressurize and reinstall the pressure release screw. © ADB Airfield Solutions All Rights Reserved 21 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Maintenance 22 © ADB Airfield Solutions All Rights Reserved 3.0 Appendix A 3.1 Installation Guidance for Inpavement Fixtures In-pavement fixtures must be installed according to the plans and specifications; the applicable regulatory guidance; and the following guidance. The importance of using the proper fixture clamping components and bolt torque to minimize the risk for fixture failure or loosening of clamping components cannot be overemphasized. WARNING Read installation instructions in their entirety before starting installation. Failure to follow the guidance below could result in bolt loosening or bolts breaking off, resulting in catastrophic failure of the fixture and/or the mounting system components. Failure to follow these warnings may result in serious injury or equipment damage. 3.1.1 Reference Documents 3.1.2 Mounting Systems • FAA Cert Alert No. 14-03 (Preventive Maintenance of In-pavement Lighting Systems), is available at: http://www.faa.gov/airports/airport_safety/certalerts/ • Transport Canada Civil Aviation Safety Alert Document CASA 2014-05 (Preventive Maintenance Of Inpavement Lights) is available at: https://www.tc.gc.ca/eng/civilaviation/opssvs/managementservices-referencecentrecasa-2014-05-2124.html • FAA AC 150/5340-30, Design and Installation Details for Airport Visual Aids, is available at: http://www.faa.gov/airports/resources/advisory_circulars/ • FAA AC 150/5340-26, Maintenance of Airport Visual Aid Facilities, is available at: http://www.faa.gov/airports/resources/advisory_circulars/ • FAA Engineering Brief 83, In-Pavement Light Fixture Bolts, is available at: http://www.faa.gov/airports/engineering/engineering_briefs/ In-pavement fixtures may be installed on one of several types of mounting systems: • • • Deep base FAA L-868 base cans (Load bearing) Deep base FAA L-867 base cans (Non-Load bearing) Shallow base cans © ADB Airfield Solutions All Rights Reserved 23 DRE, ITCL-LP, ISTB-LP (Low Protrusion) and L-852-S Stop Bar Light 96A0473 Rev. E L-868 base can installation (load bearing) 3.2 L-868 base can installation (load bearing) Following are specific requirements to insure that an in-pavement fixture is properly installed. WARNING Read installation instructions in their entirety before starting installation. Make sure power is off before you install or remove any fixture. Failure to follow these warnings may result in serious injury or equipment damage. CAUTION Make sure that: — The fixture is supplied with 6.6A maximum from the isolation transformer secondary via a series circuit. — The series circuit is powered by a Constant Current Regulator that complies with FAA AC 150/5345-10 or IEC 61822. — Depending on installation location, the isolation transformer is a series transformer that complies with FAA AC 150/5345-47, IEC 61823, or CSA C22.2 No. 180. — The base can is correctly earth grounded. Failure to do so will void the warranty for any damage that occurs as a result of voltage surges. — Never hold the fixture by the cable leads. This can damage the insulation, break the waterproof seal and cause insulation faults and water leakage. Make sure that the fixture is completely assembled. Make sure that the fixture has been operationally tested. Verify that a certified L-868 base can that has been listed in FAA AC 150/5345-53D, Appendix 1 Addendum is being used. Verify that the number of spacer rings is not in excess of the requirements defined in FAA AC 150/5340-30, Design and Installation Details for Airport Visual Aids. Insure that all base can mounting surfaces are flat and free of dust, dirt or debris. Use compressed air or a solvent spray to remove debris prior to installation. Use safety glasses to prevent injury from any flying debris or solvent. Inspect the threads in the light base upper flange to insure that the threads are clean and corrosion free. If necessary, use a wire brush to clean the holes or use compressed air or a solvent spray to remove debris prior to the insertion of any mounting bolts. Use safety glasses to prevent injury from any flying debris or solvent. If the base can threads are damaged, use a tap to attempt to restore them. If the threads are severely damaged and will not allow the proper torque, use an appropriate insert to repair the threaded hole. Inspect the condition of the flange ring O-ring and replace the O-ring if necessary. Mount the fixture using 3/8” x 16 Type 304 (18-8) Stainless Steel Hex Cap Screws. The bolt must be fully threaded. Insure that the bolt’s specific chemistry and physical characteristics and source of supply are known. Use a bolt that is marked “F593C” or a verified equivalent. At a minimum, choose a bolt length that insures a ½” (13 mm) thread engagement in the base can top flange. Further, the bolt length should be chosen to insure at least 1/8” (3.2 mm) to ½” (13 mm) extends below the base can top flange. However, note that installing bolts that are excessively long can increase the risk that the bolt will break off in the flange during removal, after the bolt has been installed a long period of time. Always use a new bolt. Never reuse existing bolts. 24 © ADB Airfield Solutions All Rights Reserved Insure that a new anti-vibration washer is used with each new bolt. Anti-vibration washers are effective in preventing bolt loosening caused by high dynamic loads. See Figure 14. Anti-vibration washers consist of a pair of unique washers. There are stepped cams between the face of washers that is greater than the pitch of the bolt. The rise of the cams creates tension that positively locks the bolt. Figure 14: Anti-vibration washer Always use a new anti-vibration washer. Never reuse an existing anti-vibration washer. Recommended stainless steel anti-vibration washers are: • • Heico Part Number HLS-3/8” SS [ADB part number ACC0375] Nordlock Part Number NL 3/8 SS Insure that the anti-vibration washer is installed properly. An anti-vibration washer consists of two halves. Insure that the stepped cams between the face of washer halves face each other (see Figure 14). The pair of washers are typically glued together for easy assembly to the bolt. Never use only one part of a 2-part anti-vibration washer. The outside of the each washer half has serrations that grip and seat the mating surfaces. Never reverse the halves such that the serrations face each other. If anti-seize (lubricant) is used on the bolt, the following products are recommended: • Loctite LB 8009™ Heavy Duty Anti-Seize. This is also available in stick form as Loctite LB 8070™ Heavy Duty Anti-Seize Stick. • If the airport is located in a more corrosive environment, such as an airport located by the ocean, use Loctite LB 8023™ Marine Grade Anti-Seize. If a threadlocker is used on the bolt, the following is recommended: • Loctite 243 Removable Strength Threadlocker. Consistency of use of anti-seize or threadlocker is important. If anti-seize was previously used on a base can, completely clean out the base can threads before applying threadlocker. Also, it is good practice to blow out or remove any loose threadlocker residue before applying new threadlocker. See Figure 15. It is recommended that the bolt coating be applied in three locations: • • • Under the top of the bolt head. In the area underneath the bottom of the anti-vibration washers that contacts the inpavement fixture. The entire area of the bolt thread that attaches to the base can. Applying a coating in these areas reduces the friction that occurs that resists the bolt from achieving sufficient clamping force. It is not recommended to install the bolt dry (i.e., with no coating). © ADB Airfield Solutions All Rights Reserved 25 DRE, ITCL-LP, ISTB-LP (Low Protrusion) and L-852-S Stop Bar Light 96A0473 Rev. E L-868 base can installation (load bearing) Figure 15: Applying a coating to reduce friction during torquing Connect the fixture plug into the isolation transformer receptacle. Wrap 3 overlapping layers of electrical tape around the connection joint. Install the fixture on the base can, while insuring that the cordset does not become pinched between the fixture and the top of the base can. Insure that the fixture is aimed in the proper direction. Check if the fixture fits correctly on top of the base can. CAUTION Do not use the bolts to force the fixture onto the base can. If this happens the threaded hole in the base can be damaged. Torque each bolt to 500 ±10 in-lbs. (56.5 ± 1.1 N·m). Use a manual calibrated torque wrench to tighten the bolt. 26 © ADB Airfield Solutions All Rights Reserved Alternately, use an automatic wrench set at a low torque value (for example: 25 in-lbs. [2.8 N·m]). Then use a manual calibrated torque wrench to finalize the torque. WARNING When a stainless steel base can is used, take steps to insure that galling does not occur. Galling is often referred to as a cold-welding process, which can occur when the surfaces of male and female threads come in contact under heavy pressure. The risk of galling can be minimized with the following measures: — Thread lubrication is one of the most effective measures to lessen the potential for galling. The lubricant reduces friction, which is a key element in thread galling. Avoid installing a stainless steel bolt dry with no lubricant. — Heat contributes significantly to thread galling. Installing a bolt generates heat and high-speed installation generates significantly more heat. Torque the bolt slowly into the base can. — Do not use an impact wrench to torque the bolt quickly, resulting in a torque beyond 500 ±10 in-lbs. (56.5 ± 1.1 N·m). If the fastener is over tightened, the threads can begin to yield which will induce friction between the mating surfaces. Always torque the bolts in opposing pairs. 12 inch, 6-bolt fixture (See Figure 16): — Tighten bolt #1, then tighten bolt #4. Next tighten bolts #2 and #5. Finally, tighten bolts #3 and #6. (Not shown) 8 inch, 4-bolt fixture: — Tighten any bolt designated as #1, then tighten bolt #3. Next tighten bolts #2 and #4. (Not shown) 8 inch, 2-bolt/2-pin fixture: — Simply tighten bolt #1, then tighten bolt #2. Figure 16: 6-Bolt Torque Sequence Use the above guidance for any bolted connection on a load bearing base can. This includes: • • • • • 6 bolts used on a 12-inch in-pavement fixture. 6 bolts used with an 8-to-12 inch in-pavement fixture adapter ring. 4 bolts used on an 8-inch in-pavement fixture. 2 bolts/2-pins 4 bolts used on an 8-inch fixture. Snow plow ring used on any fixture. © ADB Airfield Solutions All Rights Reserved 27 DRE, ITCL-LP, ISTB-LP (Low Protrusion) and L-852-S Stop Bar Light 96A0473 Rev. E L-868 base can installation (load bearing) 3.2.1 Use of Ceramic Bolts Refer to FAA Engineering Brief 83 (In-pavement Light Fixture Bolts) for guidance on use of fluoropolymer metallic-ceramic coated SAE J429 Grade 2 carbon steel bolts. WARNING Read installation instructions in their entirety before starting installation. — Do not use an impact type of torque wrench to tighten ceramic bolts. — Do not torque ceramic bolts to 500 in-lbs. (56.5 N·m). Do not use antiseize or threadlocking compounds with ceramic bolts. Tighten to the bolt manufacturer’s recommendation. Failure to follow these warnings may result in serious injury or equipment damage. 28 © ADB Airfield Solutions All Rights Reserved 3.3 L-867 base can installation (non-load bearing) Non-load bearing base cans are not normally subject to high shear levels. Following are specific requirements to insure that either an elevated or an in-pavement fixture is properly installed. WARNING Read installation instructions in their entirety before starting installation. Make sure power is off before you install or remove any fixture. Failure to follow these warnings may result in serious injury or equipment damage. CAUTION Make sure that: — The fixture is supplied with 6.6A maximum from the isolation transformer secondary via a series circuit. — The series circuit is powered by a Constant Current Regulator that complies with FAA AC 150/5345-10 or IEC 61822. — Depending on installation location, the isolation transformer is a series transformer that complies with FAA AC 150/5345-47, IEC 61823, or CSA C22.2 No. 180. — The base can is correctly earth grounded. Failure to do so will void the warranty for any damage that occurs as a result of voltage surges. — Never hold the fixture by the cable leads. This can damage the insulation, break the waterproof seal and cause insulation faults and water leakage. Make sure that the fixture is completely assembled. Make sure that the fixture has been operationally tested. Verify that a certified L-867 base can that has been listed in FAA AC 150/5345-53D, Appendix 1 Addendum is being used. Insure that all base can mounting surfaces are flat and free of dust, dirt or debris. Use compressed air or a solvent spray to remove debris prior to installation. Use safety glasses to prevent injury from any flying debris or solvent. Inspect the threads in the light base upper flange to insure that the threads are clean and corrosion free. If necessary, use a wire brush to clean the holes or use compressed air or a solvent spray to remove debris prior to the insertion of any mounting bolts. Use safety glasses to prevent injury from any flying debris or solvent. If the base can threads are damaged, use a tap to attempt to restore them. If the threads are severely damaged and will not allow the proper torque, use an appropriate insert to repair the threaded hole. For elevated fixtures mounted on a baseplate, inspect the condition of the gasket and replace it if necessary. Mount the in-pavement fixture or baseplate using a one inch (25.4 mm), 3/8” x 16 Type 304 (18-8) Stainless Steel bolt. The bolt must be fully threaded. To insure that the bolt’s material characteristics are known, verify that the bolt comes from a known source of supply. Always use a new bolt. Never reuse existing bolts. If the base can is an area that may be subject to vibration, consider using an appropriate vibration resistant washer. If anti-seize (lubricant) is used on the bolt, the following products are recommended: • Loctite LB 8009™ Heavy Duty Anti-Seize. This is also available in stick form as Loctite LB 8070™ Heavy Duty Anti-Seize Stick © ADB Airfield Solutions All Rights Reserved 29 DRE, ITCL-LP, ISTB-LP (Low Protrusion) and L-852-S Stop Bar Light 96A0473 Rev. E L-867 base can installation (non-load bearing) • If the airport is located in a more corrosive environment, such as an airport located by the ocean, use Loctite LB 8023™ Marine Grade Anti-Seize. If a threadlocker is used on the bolt, the following is recommended: • Loctite 243 Removable Strength Threadlocker Duty Anti-Seize. Consistency of use of anti-seize or threadlocker is important. If anti-seize was previously used on a base can, completely clean out the base can threads before applying threadlocker. Also, it is good practice to blow out or remove any loose threadlocker residue before applying new threadlocker. See Figure 17. It is recommended that the bolt coating be applied in three locations: • • Under the top of the bolt head. • The entire area of the bolt thread that attaches to the base can. In the area underneath the bottom of the washers (if used) that contacts the in-pavement fixture or baseplate. Applying a coating in these areas reduces the friction that occurs that resists the bolt being fully torqued. Figure 17: Applying a coating to reduce friction during torquing Connect the fixture plug into the isolation transformer receptacle. Wrap 3 overlapping layers of electrical tape around the connection joint. If an in-pavement fixture is being installed on the base can, insure that the cordset does not become pinched between the fixture and the top of the base can. Insure that the fixture is aimed in the proper direction. Check if the baseplate or fixture fits correctly on top of the base can. CAUTION Do not use the bolts to force the baseplate or fixture onto the base can. If this happens the threaded hole in the base can be damaged. Torque each in-pavement fixture bolt to 500 ±10 in-lbs. (56.5 ± 1.1 N·m). 30 © ADB Airfield Solutions All Rights Reserved Torque each elevated baseplate fixture bolt to 120 ±30 in-lbs. (13.6 ± 3.4 N·m). Do not over-torque elevated baseplate bolts as this may damage the baseplate gasket. Use a manual calibrated torque wrench to tighten the bolt. Alternately, use an automatic wrench set at a low torque value (for example: 25 in-lbs. [2.8 N·m]). Then use a manual calibrated torque wrench to finalize the torque. WARNING When a stainless steel base can is used, take steps to insure that galling does not occur. Galling is often referred to as a cold-welding process, which can occur when the surfaces of male and female threads come in contact under heavy pressure. The risk of galling can be minimized with the following measures: — Thread lubrication is one of the most effective measures to lessen the potential for galling. The lubricant reduces friction, which is a key element in thread galling. Avoid installing a stainless steel bolt dry with no lubricant. — Heat contributes significantly to thread galling. Installing a bolt generates heat and high-speed installation generates significantly more heat. Torque the bolt slowly into the base can. — Do not use an impact wrench to torque the bolt quickly, resulting in an overtorqued bolt. If the bolt is over tightened, the threads can begin to yield which will induce friction between the mating surfaces. Always torque the bolts in opposing pairs. 12 inch, 6-bolt fixture (See Figure 18, which shows an in-pavement fixture. Use the same procedure for a baseplate.): — Tighten bolt #1, then tighten bolt #4. Next tighten bolts #2 and #5. Finally, tighten bolts #3 and #6. Figure 18: 6-Bolt Torque Sequence Use the above guidance for any bolted connection on a non-load bearing base can. This includes: • • • 6 bolts used on a 12-inch in-pavement fixture. 6 bolts used on either an 8-to-12 inch in-pavement fixture adapter ring. All bolts used on an 8-inch fixture mounted in an 8-to-12 inch snow plow ring. © ADB Airfield Solutions All Rights Reserved 31 DRE, ITCL-LP, ISTB-LP (Low Protrusion) and L-852-S Stop Bar Light 96A0473 Rev. E Checking Bolt Torque 3.4 Checking Bolt Torque An established schedule for checking light fixture bolt torque and bolt condition is mandatory. This is particularly true for areas that are subject to high impact loads from aircraft such as runway status lights, runway touchdown zone lights, runway centerline lights, and taxiway lead-off lights. Although AC 150/5340-26 offers a recommended schedule for periodic checks, these checks should be tailored to the facility based on local conditions such as environmental issues and runway traffic load. FAA Cert Alert No. 14-03 refers to AC 150/5340-26 for the frequency of checking bolt torque. AC 150/5340-26C paragraph 5.3.4.1.4, Bi-Monthly Checks states: “The torque of the bolts attaching the light fixture to its base should be checked with a calibrated torque wrench – never use an impact wrench.” Regular inspection as outlined in FAA Cert Alert No. 14-03, Canada Civil Aviation Safety Alert Document CASA 2014-05, and any other applicable regulatory guidelines is critical in insuring torque on all bolts is restored to optimum values. Bolts that loosen more often should be inspected and re-torqued on a more frequent basis. It is especially important to maintain a regular inspection schedule for LED fixtures. Since LED fixtures operate more reliably and are not subject to removal/replacement/retorquing as frequently as would be seen with incandescent fixtures, it is even more important to implement regular torque inspections. It is critical that remedial action be taken if bolts are found to be loose or missing during inspection. If this occurs, it is important to carefully inspect all structural elements of the mounting system as defined in paragraph 1.2. Also inspect the base can for general structural conditions such as: • Is the base can solidly mounted in the pavement, and not moving or rocking during rollovers? • If a base can extension is present, are all extension attachment bolts tight? If poor base can structure or mounting system components are not in accordance with regulatory requirements or are in poor condition, it is the airport’s responsibility to: • Increase the frequency of bolt torque inspection to insure that no bolts become loose or missing. • Quickly replace/repair the mounting system components, which may include replacing the entire base can. Airport operators must also ensure these maintenance activities are properly documented. 32 © ADB Airfield Solutions All Rights Reserved 4.0 Parts 4.1 Parts Figure 19: IREL Ordering Code Ordering Code IREL- 0 LED Colors - Side 1 0 = Obscured 3 = White Left Toed (L-850C only) 4 = Red Straight (L-850D only) 2 6 = Red Left Toed (L-850C only) 9 = Yellow Left Toed (L-850C only) C = Green Left Toed 1 LED Colors - Side 2 0 = Obscured 2 = White Right Toed (L-850C only) 4 = Red Straight (L-850D only) 2 5 = Red Right Toed (L-850C only) 8 = Yellow Right Toed (L-850C only) B = Green Right Toed 1 Power 1 = 50 Hz 2 = 60 Hz 0 Number of Cord Sets 1 = One 2 = Two Arctic Kit 1 = No 2 = Yes Cord Set Style and Length 0 = Style 6 (2-pin), 18” long (FAA standard) 3 1 = Style 1 (2-pin) SO Jacketed cable, 18” long (FAA standard) 3 2 = Style 6 (2-pin), 10” long 4 3 = Style 6 (3-pin), 10” long 4 4 = German Style 1 (2-pin), 10” long 4 5 = German Style 1 (3-pin) 10” long 4 6 = French Style (3-pin), 10” long 4 Application Leave blank for FAA, Military or 45 m applications 3 = FAA, Military or 45 m with heavy-duty abrasion-resistant lens coating 5,6 Notes • ETL Certified for the following L-850D configurations: IRELC4X0XX0, IREL-4BX0XX0, IREL-C0X0XX0, IREL-40X0XX0, IREL0BX0XX0, and IREL-44X0XX0. 1 Green complies with only FAA photometric requirements. 2 Red runway end complies with FAA/ICAO/TP312 photometric requirements. 3 Fixtures with 18” cord sets are for installation on deep base cans and are not supplied with an external o-ring gasket. 4 Fixtures with 10” cord sets are for installation on shallow bases and are supplied with an external o-ring gasket. 5 Typically used for intensive winter service where sand is applied to runways and rotating brushes are used. 6 Not ETL Certified. © ADB Airfield Solutions All Rights Reserved 33 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Parts Figure 20: IREL Parts L-850C TOP COVER 44A7180-XXXX INTERMEDIATE PAN ASSY 50/60HZ 44A7223-XXXXX APPLY SILICONE GREASE 67A0009 TO O-RING ON TOP COVER ASSEMBLY. O-RING TOP COVER F-RANGE 7080.90.710 O-ring seal for shallow base, F-Range 12" 7080.90.650 Ordered separately M5 X 10 FLT PHIL SS 64A0925-10 4.1.1 IREL Components Description Part No. Cable Clamp 4072.42.380 Cord set 18” (FAA) 4072.42.351 Cord set 10” (ICAO) 4072.24.950 LED light engine, L-850C(L), white 48A0454-WHT1 LED light engine, L-850C(L) and L-850D(L), red 48A0454-RED1 LED light engine, L-850C(L), yellow 48A0454-YEL1 LED light engine, L-850C(L) and L-850D(L), green 48A0454-GRN1 LED PCB Assembly dual driver 44A7228-00201 LED PCB Assembly single driver 44A7228-00101 Lens 4072.18.336 Lens retainer plate 4072.18.350 Lens seal 4072.18.362 Lens retainer seal 4072.18.380 O-Ring, pressure release screw 63B0267-011 O-Ring, top cover 7080.90.710 Pressure release screw 60A2602 Bar Lifting Tool 1411.19.550 Set of spare anchor hooks for lifting tool 1411.19.550 1411.19.560 O-ring seal between top cover and shallow base, for F-Range 12" 7080.90.650 1 34 Must replace both light engines on the same side at the same time. (Quantity. 2 needed) © ADB Airfield Solutions All Rights Reserved 4.1.2 Optional Snow Plow Ring Depending on installation method and snow plowing technique used, a snow plow ring may be necessary. Snow plow rings are available for either standard or stainless steel adjustable Size B L-868 cans. Contact the ADB Sales Department for additional details. Figure 21: Top Cover Assembly HEATER DISC, 2 LEADS 61A0459 L-850C HEATER MOUNTING PLATE ASSEMBLY 44A7182-10 APPLY A THIN LAYER OF THERMAL COMPOUND 67A0033 TO UNDER SIDE OF HEATER DISK, THERMOSTAT & UNDERSIDE OF MOUNTING PLATE PRIOR TO ASSEMBLY. M5 X 12 Pan Hd Phil Mach Screw SS 64A1012/12 APPLY SMALL AMOUNT OF 67A0094 LOCTITE 262 50ML BOT MED TO HI STRENGTH, TYP. #6 INT LOCKWASHER 66A0038/3 #6-32 HX NUT 65A0015/11 L-850C LENS RETAINER PLATE 4072.18.350 L-850C LENS RETAINER SEAL 4072.18.380 L-850C LENS 4072.18.336 APPLY THIN LAYER OF GREASE PRIOR TO ASSEMBLY. L-850C LENS SEAL 4072.18.362 THRMSTAT, NO-HERM STUD, N.O. C80F-O60F 54A0022-8060 APPLY A THIN LAYER OF THERMAL COMPOUND 67A0033 TO UNDER SIDE OF HEATER DISK, THERMOSTAT & UNDERSIDE OF MOUNTING PLATE PRIOR TO ASSEMBLY. © ADB Airfield Solutions All Rights Reserved 35 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Parts Figure 22: IREL Toeing > SIDE 1 LEFT TOE-IN >> >> >> >> SIDE 1 LEFT TOE-IN > LEFT TOE-IN DIRECTION ADB LOGO LOCATION OPPOSITE SIDE ARROW LOCATION OPPOSITE SIDE SEE NOTE 1 TYP > >> >> > >> >> SIDE 2 RIGHT TOE-IN SIDE 2 RIGHT TOE-IN 36 RIGHT TOE-IN DIRECTION © ADB Airfield Solutions All Rights Reserved Figure 23: IREL Base 44A7228-00101 PCB ASSY, LED PWR SUPPLY 50/60Hz, SINGLE DRIVER, NO MON, FAA / ICAO 44A7228-00201 PCB ASSY, LED PWR SUPPLY 50/60Hz,DUAL DRIVER, NO MON, FAA / ICAO POWER INTERFACE BOARD LEAD LENGTH - 1 44A7273-1 MACHINING INTERMEDIATE PAN INPUT-1 & 2 62A2215-200 MACHINING INTERMEDIATE PAN INPUT-1 62A2215-100 A THIN LAYER OF THERMAL COMPOUND 67A0033 IS TO BE APPLIED BETWEEN PCB BRACKET AND BASE PAN CENTER SUPPORT, TYP. © ADB Airfield Solutions All Rights Reserved 37 L-850C(L) and L-850D(L) Style 2 LED Runway Edge and Runway Threshold and Runway End Light 96A0439 Rev. H Parts 38 © ADB Airfield Solutions All Rights Reserved p y Company Offices ADB BVBA Leuvensesteenweg 585 B-1930 Zaventem Belgium Tel: 32/2/722.17.11 Fax: 32/2/722.17.64 Email: info@adb-air.com ADB Airfield Technologies Ltd. China Room 901, 9F, Fang Heng Intl. Plaza Building C, No. 6 Futong East Road, Chaoyang District Beijing 100102 P.R. 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China Room 901, 9F, Fang Heng Intl. Plaza Building C, No. 6 Futong East Road, Chaoyang District Beijing 100102 P.R. China Tel: +86 (10) 8476 0106 Fax: +86 (10) 8476 0090 ADB Airfield Solutions ADB Airfield Solutions LLC Leuvensesteenweg 585 977 Gahanna Parkway Columbus, OH 43230 B-1930 Zaventem Belgium USA Phone: +32 (2) 722.17.11 Tel: +1 (614) 861 1304 info.adb@adb-air.com Fax: +1 (614) 864 2069 www.adb-air.com Web: www.adb-air.com Email: adb-sales.us@adb-air.com © ADB bvba All Rights Reserved www.adb-air.com