abcd
AIRPORT EQUIPMENT
INSTALLATION AND MAINTENANCE INSTRUCTIONS
and
SPARE PARTS LIST
for the
TYPE ZA480 SERIES, 12” DIA. HIGH INTENSITY, INSET LIGHTS
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 1 of 25
abcd
CONTENTS
ISSUE RECORD, SAFETY ADVICE NOTICE, TOOLS AND CONSUMABLES.........3
ZA480 12” DIA. HIGH INTENSITY, INSET LIGHT..........................................4
1.
INTRODUCTION.....................................................................................................4
2.
SITE PREPARATION FOR INSTALLATION OF ZM480 SEATING POT .....................5
3.
INSTALLATION INTO ZM480 SEATING POT OR ADAPTER ...................................5
4.
REMOVAL ................................................................................................................6
5.
ON-SITE MAINTENANCE........................................................................................6
6.
WORKSHOP MAINTENANCE .................................................................................7
6.1
PREPARATION AND CLEANING.................................................................8
6.2
SEPARATION OF BODY CASTING ASSEMBLY FROM BOTTOM COVER
ASSEMBLY ...............................................................................................................8
6.3
BODY CASTING ASSEMBLY MAINTENANCE .............................................9
6.4
BOTTOM COVER ASSEMBLY MAINTENANCE .........................................12
6.5
RE-ASSEMBLY OF BOTTOM COVER AND BODY CASTING ASSEMBLY ..16
7.
SPARES ..................................................................................................................17
7.1
SPARES PARTS ORDERING........................................................................17
SPARE PARTS SCHEDULE ........................................................................18
EXPLODED VIEW OF ZA480 FITTING .......................................................18
APPENDIX 'A' ........................................................................................22
APPENDIX 'B' ........................................................................................17
APPENDIX 'C' - SAFETY ADVICE ...............................................................24
1.
COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL .....................................24
2.
GUIDANCE NOTES FOR USERS ON THE SAFETY OF PERSONNEL ....................24
3.
INSTALLATION, OPERATION AND MAINTENANCE ............................................24
4.
VOLTAGES GREATER THAN 50V A.C./120V D.C................................................25
5.
APPARATUS SUPPLIED AS LOOSE ITEMS, CHASSIS ETC......................................25
6.
ACCESS TO THE APPARATUS DESCRIBED IN THIS MANUAL ..............................25
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 2 of 25
abcd
ISSUE RECORD
Issue Status
ISSUE
2
3
4
DATE:
DEC 98
JUL 99
June 2003
P DWELLY
R K FARMER
A L Landless
PMH
PMH
P M Humber
AUTHOR:
AUTHORISED:
SAFETY ADVICE NOTICE
Please ensure that personnel are made aware of all aspects. Appendix ‘A’ contains safety
advice and this appendix can be copied and used to record authorised personnel.
TOOLS AND CONSUMABLES
•
Flat blade screwdriver – electrical.
•
11mm A/F Hex socket and wrench. (For pressure test plug).
•
5mm A/F Allen key (For general assembly and dis-assembly).
•
Rubber lubricant emulsion, International Products Group P80.
•
23mm A/F open ended spanner (For cable gland).
•
Torque wrench & 5mm A/F Hex driver.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 3 of 25
abcd
ZA480 SERIES, 305MM (12”) DIA. HIGH INTENSITY, INSET
LIGHT FITTINGS
1.
INTRODUCTION
The ZA480 series of high intensity inset fittings have been designed to meet ICAO
requirements for Categories I, II and III, all weather operation lighting systems.
The various fitting types available in the range are generally as follows (see
Appendices ‘A‘ & ‘B’ for details of variants):
ZA480
ZA481
ZA482
ZA483
ZA484
ZA485
ZA486
ZA487
ZA480 Series
ZA489
Approach.
Supplementary Approach.
Runway End.
Runway Edge.
Runway centreline & TDZ. (Included in FAA L850 range below).
Threshold.
Threshold Wingbar.
Combined Threshold & Runway End.
FAA L850 A, B, C, D & E Options (see Appendix ‘B’).
FAA L852 S & G Options (see Appendix ‘B’).
Two body styles are used within the range of fittings. See figs.1 & 2 for Bi-directional
& uni-directional styles.
Fig. 1. ZA480 Series, Bi-directional body style
Fig. 2. ZA480 series, Uni-directional body style
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 4 of 25
abcd
Fittings are normally supplied complete with 1, 2 or 3 long life, 6.6A, 105W cold
reflector lamps with one, two or three high temperature B type plug leads.
When required as an option, internal lamp by-pass devices are assembled into the
fitting.
The fitting is lightweight and robust due to its predominantly aluminium alloy
construction which also gives good protection against corrosion. The glass prisms or
aluminium prism blanks are accurately located in the main body casting, secured by a
retaining clamp, without the need for sealing compounds.
The optical system employed is adjustment free on installation and in service,
considerably simplifying installation and maintenance.
The fitting is suitable for installation into a 305mm (12 inch) diameter, ZM480 seating
pot, dry or wet versions of which are available, or FAA L-868 load bearing canisters
supplied separately to order. Alternatively a range of PSA adaptors are available for
15.5" and 19.5" mountings.
2.
SITE PREPARATION FOR INSTALLATION OF ZM480 SEATING POT
Instruction manual ‘Imm-zm-seating-pots’ contains detailed installation instructions.
3.
INSTALLATION INTO ZM480 SEATING POT OR ADAPTOR
It is assumed that the seating pot and transformer secondary socket lead(s) have been
installed.
•
Check that the fitting is of the correct type/option for the relevant position on the
runway. (See site plan).
•
Check that the Air Pressure Test plug (11.0 A/F Hex Head) is tight.
•
Remove the six holding down nuts and washers in the seating pot; Check that the
studs themselves are in good condition and fully secured into the seating pot, ie.
do not project above the rim of the pot.
•
Clean out any debris from the pot seating area. Check that there are no internal
protrusions or casting faults especially on the seating surface.
•
Check the underside seating surface of the fitting for debris, which could prevent
the fitting being installed securely.
•
Wipe clean the leads and mating surfaces of the moulded plug and socket
connector(s). Ensure that the female contacts are free from debris.
•
When required, flush out the socket with a suitable contact cleaner aerosol.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 5 of 25
abcd
•
Connect the secondary lead(s) plug to the appropriate transformer secondary
lead(s) socket in accordance the site layout information. Take care to observe
correct pin polarisation.
When two and three lead versions are being installed, to refer to Drawing F28967 in
appendix A for clarification of which lead supplies which lamp.
•
Insert the light unit into the seating pot, oriented correctly to the site plan, using the
extractor tool ALSTOM type ZM500/4 (SLC21290). Take care not to trap any
leads between mating surfaces.
WARNING
•
DO NOT USE THE EXTRACTOR TOOL FOR CARRYING FITTING TO
OR FROM THE SEATING POT.
Re-assemble crinkle washers and M10 nuts to secure the light unit in the seating
pot. Tighten each nut progressively until a torque of 40Nm (30 lbsf.ft) is achieved
on each nut.
Routine Checking
•
4.
Routinely check the tightness of the M10 nuts securing the fitting, at a torque
setting on the torque spanner of 35Nm (25 lbsf. ft) maximum. Use a break type
torque spanner with a 100mm extension bar to apply the correct load and avoid
any over-tightening.
REMOVAL
For all light fittings:
•
Release and remove the securing nuts and washers and discard any damaged
items. Safely store items in good condition for re-use when re-assembling a
fitting.
•
Lift the light fitting out of the seating pot using the extractor tool recommended for
this purpose ALSTOM type SLC21290.
WARNING
5.
DO NOT USE THE EXTRACTOR TOOL FOR CARRYING THE FITTING
TO OR FROM THE SEATING POT.
ON-SITE MAINTENANCE
On-site maintenance is normally be restricted to prism cleaning, and inspection for
damage to the prisms and their seals.
•
Clean dirt and oil from the exposed surfaces using a suitable detergent applied
with a bristle paint brush. See Fig. 3.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 6 of 25
abcd
Fig. 3. ZA480 Series, close up of external prism face.
NB: DO NOT USE abrasives on the prism surfaces, or detergents with high alkalinity.
When a fitting requires replacing ensure that an identical unit is used.
A fitting must be removed to a workshop environment for any repairs. See section 6.
When light fittings are removed from the seating pot.
•
Check that the M10 studs are tight in the seating pot.
When one or more studs can be rotated by hand:
6.
•
Ensure the studs and seating pots are as dry as possible.
•
Use two 10mm nuts, locked together, to remove the stud. Clean and apply Loctite
grade 648 to the stud, bottom thread portion only.
•
Re-assemble the stud until 18 to 19mm protrudes above the seating pot flange
face (ie. level with the top of the rim), assemble two M10 standard nuts to the top
of the stud and lock together. Secure the stud using a spanner on the top
locknut.
•
Unlock and remove both top nuts. Wipe off any remaining Loctite from the studs
to ensure that the top nut/washer will not adhere to the stud or flange.
•
Re-assemble the fitting to the seating pot and, re-assemble M10 nuts and crinkle
washers and hand tighten the M10 nuts.
•
Allow at least 30 minutes for the loctite 648 to cure.
•
Torque tighten the fitting into seating pot, to 35Nm (25 lbsf.ft) maximum.
WORKSHOP MAINTENANCE
Each time the fitting is dis-assembled, either for lamp changing or at planned
maintenance intervals.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 7 of 25
abcd
•
Undertake a comprehensive inspection. (Future failures in service may be
prevented and an efficient spares policy defined).
•
Generate local site documentation and record the status of fittings and major
components.
Alstom recommend that component failures should be corrected by using approved
replacement parts only.
•
6.1
Re-assemble the fitting in the reverse order of dis-assembly. In addition lightly
smear the M6 screws with silicone grease to ensure correct torque is achieved
when tightened.
PREPARATION AND CLEANING
When repairing the light fitting, use a workshop environment that is free from dust,
vapours and other atmospheric pollutants likely to cause contamination of prism, lamp
and reflector surfaces.
Prior to opening the light fitting for any reason:
6.2
•
Clean any dirt or oil from its external surfaces, (to avoid internal contamination),
using a suitable household detergent applied with a stiff bristle paint brush.
•
Clean the prisms, DO NOT USE abrasive substances and detergents with high
alkalinity. See Fig. 3.
•
Wash in clean water and remove all traces of moisture from the exterior surfaces
using a dry cotton cloth or tissue. DO NOT USE compressed air on the prism
surfaces.
DIS-ASSEMBLE THE BODY ASSEMBLY FROM BOTTOM COVER ASSEMBLY
•
Place the light fitting on a clean, flat, work surface with its bottom cover
uppermost. See Fig. 4.
Fig. 4 ZA480 Series, fitting inverted on the work bench.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 8 of 25
abcd
•
Release the four M6 cap head screws attaching the bottom cover to the body
assembly. Discard any damaged items. Safely store the screws and crinkle
washers that are in good condition, for re-assembly. See Fig. 4.
•
Carefully lift off the bottom cover assembly and place ‘right way up’ on the work
surface. See Fig. 5.
Fig. 5 ZA480 Series, Bottom cover assembly on the work bench.
6.3
BODY ASSEMBLY MAINTENANCE
6.3.1 Removal & Replacement of Prism
•
Check prisms, both inside and outside surfaces, for contamination, physical
damage, chips and cracks.
•
Check sealing around prisms for obvious signs of physical damage or for evidence
of water ingress. Replace when any evidence of damage is present.
(Note: The prism gaskets will adhere to the prisms after a reasonable time in service.
When they are not damaged in any way, they can be re-used, but do not try to
remove the gasket).
When removing a prism that is intact:
Note: USE SUITABLE PROTECTIVE GLOVES WHEN REMOVING OR REPLACING
PRISMS.
•
Place body assembly on some cushioning material such as bubble wrap,
underside uppermost.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 9 of 25
abcd
Fig. 6 ZA480 Series, body assembly ready for prism removal.
•
Release and remove the two M6 socket head screws securing each prism clamp
and remove complete with associated gasket. See Fig. 6.
•
Reverse the body assembly on the work surface so that the top is uppermost.
Fig. 7 ZA480 Series, normal removal of a prism.
•
Place both thumbs on the outer surface of the prism and press the prism/gasket
assembly back through into the lamp cavity, in the same direction as the light
channel, until free of the casting.
In certain cases it may be necessary to apply a greater force to remove a prism:
•
Use a ‘soft wood drift’ and soft faced hammer to dislodge the prism/gasket
assembly. See Fig. 8.
Fig. 8 Removing a ‘stuck’ prism.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 10 of 25
abcd
•
Check the prism gasket for damage and or signs of deterioration.
When the prism gasket is to be replaced, on an intact prism:
•
Remove the ‘old’ prism gasket. Ensure that all traces of the ‘old’ gasket have
been removed from the prism.
NOTE :
WHEN HANDLING A COLOURED PRISM, TAKE CARE NOT TO
SCRATCH OR OTHERWISE DAMAGE THE DICHROIC COATING ON
THE REAR FACE.
Re-assembly of the prism/gasket assembly is a reversal of the removal procedure, with
the addition of:
•
Apply a rubber lubricant emulsion (ie International Products Group P80) sparingly
to the outer surface of the prism gasket.
•
Assemble the gasket/prism assembly to the body casting.
•
Re-assemble the prism clamps and gaskets to retain the prisms.
•
Apply ‘Ambersil’ 1008A high temperature sealant, to the M6 screws.
•
Re-assemble and tighten the M6 prism clamp retaining screws progressively to a
torque of 9Nm (6.7 lbsf.ft).
NOTE:
TO AVOID DAMAGE TO THE PRISMS, DO NOT OVER TIGHTEN THE PRISM
CLAMP RETAINING SCREWS.
6.3.2 Sealing Gasket (Body to Base)
When the fitting is dis-assembled examine the sealing gasket for evidence of ageing.
Fig. 9 The sealing gasket in the body recess.
Indicators of a possible gasket failure include contamination of internal components
and casting surfaces. Replace the gasket when it shows signs of deterioration or
damage,
•
Remove the gasket from the recess in the body casting.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 11 of 25
abcd
6.4
•
Clean the gasket mating surfaces to remove any debris which could prevent the
gasket from producing an effective pressure seal during re-assembly.
•
Re-assemble a new gasket to the body casting.
BOTTOM COVER ASSEMBLY MAINTENANCE
6.4.1 Lamp Replacement
Fig. 10 Top photo. A lamp in position & bottom photo. a lamp being removed.
•
Push the lamp retaining spring fingers back from the lampholder using two fingers
of one hand. With the other hand pull the lamp back until the reflector rim is
clear of the lampholder enabling the lamp to be lifted clear of the
spring/lampholder assembly.
•
Disconnect the lamp leads to release the lamp. Take care not to touch or
otherwise contaminate the bulb of the lamp or reflector surface.
Re-assembly is a reversal of the removal procedure. Ensure that the lamp gasket is
seated correctly in the lampholder.
•
Locate the ‘new’ lamp in the lampholder.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 12 of 25
abcd
•
Re-connect electrical terminations.
Fig. 11 Termination arrangement, (Moulded terminal blocks) .
6.4.2 Lampholder/Lamp Retaining Spring
Fig. 12 Lampholder with retaining spring behind it.
Check the lampholder and lamp retaining spring for damage. When damaged
replace either/both item(s):
•
Release and remove the two M6 cap head screws. See Fig. 12.
•
Re-assemble both lampholder and lamp retaining spring.
•
Apply Ambersil 1008A high temperature sealant to the M6 screws and reassemble.
•
Torque tighten to a torque of 9Nm (6.7 lbsf.ft).
6.4.3 Lamp Gasket
•
Check lamp gasket for signs of deterioration or damage and replace if necessary.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 13 of 25
abcd
6.4.4 Lamp Bypass Disc Assembly (When fitted)
Fig. 13 The moulded terminal block with a bypass disc in place.
The bypass disc is placed in parallel with the lamp.
•
Check the female receptacles and male tabs on the terminal block for signs of
contamination or arcing due to water ingress or loose connections
•
Remove the disc from underneath its retaining spring on the terminal block and
check for any surface contamination that may prevent the electrical bypass from
functioning correctly during a future lamp failure.
When contamination is evident on the disc, and it can not be wiped off.
•
Replace the bypass disc.
•
Inspect the disc mating surfaces of the terminal block and, when necessary, clean
contact surfaces using a fine grade of emery paper (or similar).
•
Check that the disc is not in a short circuit state, using a low voltage multi-meter.
Note: When fittings have a lamp bypass facility that is not in use, it must have an
insulation disc assembled under the retaining spring.
6.4.5 Plug Lead/Cable Gland
WARNING: USE ONLY HIGH TEMPERATURE PLUG LEADS AS REPLACEMENTS.
•
Check for damage to the plug lead or protective cover including nicks, cuts and
cracks, especially where the two separate insulated cables enter the moulded
connector housing, the bottom cover cable gland and cable clamp.
•
Check for physical or arcing damage to the cable plug pins.
•
Check for looseness and evidence of arcing of the cable tail receptacles and
overheating of the cable cores.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 14 of 25
abcd
When there is evidence of water ingress:
•
Check for a faulty gland seal, using the Air Pressure Test procedure detailed in
section 6.6.
To replace a plug lead:
•
Release and remove 4 x M6 screws to release the lampholder mounting plate
assembly.
•
Slacken the M6 socket head cable clamp screw to free the plug lead.
•
Unscrew the cable gland nut and withdraw plug lead and gland assembly from
bottom casting.
Fig. 14 Close up of Cable Gland. Note the spiral protection sleeve fitted
as standard.
•
Check the gland entry for debris and clean when required.
•
Check the gland components for deterioration and replace the compression bush
at each change of plug lead or gland.
•
Assemble the protective cover onto the ‘new’ plug lead.
•
Assemble gland components onto a ’new’ plug lead in the order - gland nut, skid
washer and compression bush. Leave 100mm of lead protruding through the
gland.
•
Re-assemble the ‘new’ plug lead into the cable entry position in the bottom cover
until the lead projects approximately 100mm into the inner chamber of the bottom
cover.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 15 of 25
abcd
Fig. 15 Showing a new plug lead in place and clamped.
6.5
•
Tighten gland nut fully into cable entry hole to create a water tight seal. (An air
pressure test will confirm the seal in due course. See section 6.6).
•
Strip the insulation for approximately 10mm from the ends of the two plug lead
cables and terminate each one with a 6mm female spade terminal.
•
Position plug lead cables correctly under clamp and re-tighten the M6 screw to
secure plug lead. Ensure that the insulation is not being damaged by the clamp.
•
Replace PTFE sleeves and reconnect terminals.
•
Re-position the PTFE sleeves over the terminals
RE-ASSEMBLY OF BOTTOM COVER AND BODY ASSEMBLIES
Re-assembly of the fitting is generally the reverse of dis-assembly. It is assumed that
any faulty components have been replaced and re-wired correctly as described in
previous sections.
•
Place the body assembly flat on a clean work surface, joint face uppermost.
•
Locate the sealing gasket correctly inside the recess in the body casting .
•
Re-assemble the bottom cover assembly, noting the orientation of the lamps.
•
Re-assemble and tighten 4 x M6 socket head screws with crinkle washers,
progressively, to a torque of 9Nm (6.7 lbf.ft).
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 16 of 25
abcd
6.6
AIR PRESSURE TEST THE FITTING
Fig. 16 Air Pressure Test tank and immersed fitting.
•
Connect a compressed air line to the test plug hole, using a 1/8" BSP adapter.
•
Apply an air pressure of 350 mbar (approx. 5 p.s.i.) to the fitting and immerse in a
tank of clean water. Check for the emission of air bubbles from the areas around
the bottom cover joint, prism seals, and the cable gland(s).
On completion of a satisfactory test:
•
Refit the pressure test plug. DO NOT OVER TIGHTEN THE TEST PLUG.
Fig. 17 Close up of the Air Pressure Test Plug.
7.
SPARES
7.1
SPARES PARTS ORDERING
When ordering spare PARTS refer to the parts schedule identifying those items
required by stating:
Fitting type
Item description
Part no. or stock list code.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 17 of 25
abcd
SPARE PARTS SCHEDULE
(Item Nos. refer to exploded Drawing, Fig. 18, on Page 21)
Key to Abbreviations:
ST STL
Hex
I/D
Skt Hd
RHT
=
=
=
=
=
Stainless Steel
Hexagonal
Inside Diameter
Socket head
Right hand toe
LG
A/R
ALT
Ch Hd
LHT
=
=
=
=
=
Long
As required
Alternative
Cheese head
Left hand toe
Item
No.
Part No
Stock
List
Code
2
28821 A
16069
Clear Prism
ALT
28821 B
19141
Red Prism
ALT
28821 C
19153
Yellow Prism
1
ALT
28821 D
19154
Green Prism
2 or 3
ALT
YT
19153 a
Yellow Prism (traffic Colours)
2
ALT
RT
19141a
Red Prism (traffic colours)
2
ALT
28835
40092
Blank for Prism Aperture
1 or 2
3
28981
33075
Prism Gasket
3
4
28826
32037
Prism Retaining Clamp
3
5
28918
33069
Prism Clamp Gasket
6
28978
33076
Body to Base Sealing Gasket
1
7
28957 A
40112
Base Casting (Single Lead)
1
ALT
28957 B
40113
Base Casting (Twin Lead)
1
ALT
28957 C
40114
Base Casting (Three Lead)
1
8
29075
13026
‘B’ Type high temp. Lead
1,2 or 3
9
28983
21282
M20 ST ST Gland Nut
1,2 or 3
10
28984 A
21284
Compression Bush
1,2 or 3
11
28985 A
21283
PTFE Skid Washer
1,2 or 3
12
28988
21281
Cable Clamp
1, 2 or 3
13
08075
6.6A Cold Reflector Lamp 105W
1, 2 or 3
ALT
08074
6.6A Cold Reflector Lamp 49W
1 or 2
32040
Lampholder
14
28824
Description
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Qty per
Fitting
1, 2 or 3
1 or 3
1, 2 or 3
1,2 or 3
Lights.
Date : June 2003
Author : ALL
Page : 18 of 25
abcd
Item
No.
Part No
Stock
List
Code
15
28825
32039
Lamp Retaining Spring
1, 2 or 3
16
28877
33077
Lamp Gasket
1,2 or 3
17
29074 A
Short Lamp Link 65mm LG (Female To Female)
1 or 2
18
29074 B
Intermediate Lamp Link 110mm LG (Female To
Female)
1
19
29074 C
Long Lamp Link 220mm (Male To Female)
2, 4 or 6
PTFE Sleeving 45LG x 6.81 I/D
2, 4 or 6
20
Description
Qty per
Fitting
21
28934
21256
Pressure Test Plug
1
22
28980 ASW
21278
Mounting Plate - Approach, Siderow and
Wingbar
1
ALT
28980 EDG
21280
Mounting Plate - Runway Edge
1
ALT
28980 TAE
21279
Mounting Plate - Threshold (Axial), Runway End
1
ALT
28980 TLE
21287
Mounting Plate - Threshold (LHT), Runway End
1
ALT
28980 TRE
21286
Mounting Plate - Threshold (RHT), Runway End
1
ALT
28980 RGS
21286
Mounting Plate - Runway Guard, Stop Bar
1
23
28979
21285
Lampholder Support Block 30 Deg.
1,2 or 3
24
28261 B
Connector Block/By-Pass Body
1,2 or 3
25
29584
Insulating Block
1,2 or 3
26
12653-411031
21288
6mm Male Connectors
4, 8 or 12
27
M6 x 16 ST STL, SKT Hd Screw
3, 5, 7 or
9
28
M4 x 10 ST STL Pan Head Screw (For Lampholder
Support Block) - Not Shown
2, 4 or 6
29
M4 Crinkle Washer - Not Shown
2, 4 or 6
30
M3 x 25 ST STL Ch Hd Screw (For Connector
Block)
2, 4 or 6
31
M3 Plain Washer ST STL (For Connector Block)
4, 8 or 12
32
M3 ST.SL Single Coil Lock Washer (For Connector
Block)
4, 8 or 12
33
M3 Nut ST STL (For Connector Block)
2, 4 or 6
34
4815920G2
35
28300
21135
100W By-Pass disc (Optional) - Not Shown
2 or 3
Retaining Contact (Optional) - Not Shown
2 or 3
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 19 of 25
abcd
Item
No.
Part No
36
29585
Description
Stock
List
Code
Qty per
Fitting
Insulating Bush
2,4 or 6
37
M6 ST STL Crinkle Washer
17,19 or
21
38
M6 x 20 ST STL Skt Hd Screw
10
39
M6 x 40 ST STL Skt Hd Screw
4
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 20 of 25
abcd
Fig 18. Exploded view of ZA480 series fitting, (Uni-directional body style shown).
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 21 of 25
abcd
APPENDIX ‘A’
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 22 of 25
abcd
APPENDIX ‘B’
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 23 of 25
abcd
APPENDIX ‘C’ - SAFETY ADVICE
1.
COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL
The purchaser/user is advised to comply with the instructions and information in this
manual and ensure that all personnel to be associated with the apparatus under this
contract are made familiar with the information contained herein.
2.
GUIDANCE NOTES FOR USERS ON THE SAFETY OF PERSONNEL
Every employer shall ensure that his employees are informed, trained and supervised
and use a safe system of work to ensure their safety. He is advised to comply with the
information provided, to maintain the plant in a safe condition.
Electrically skilled personnel may have to gain access to apparatus which is not
completely isolated. The burden of responsibility, for the safety of such personnel
carrying out the work, rests on those under whose authority they act.
3.
INSTALLATION, OPERATION AND MAINTENANCE
The purchaser/user is advised to ensure that each piece of apparatus supplied to the
purchaser's order is correctly installed, in a suitable location, by technically qualified
and competent persons experienced in the class of work involved. The rules for
ensuring the safety of personnel can be summarised as follows:During normal use, ensure that plant operators:l
are fully conversant with all controls, particularly those for emergency shut
down,
l
comply with safety warning notices and keep all enclosures shut,
l
are trained to recognise signs of mal-operation and know what action to take
in the event of trouble or difficulty.
During Maintenance, Testing etc., ensure that only suitably skilled persons are
permitted to carry out work and that they:l
comply with user's safe system of work and safe working procedures,
l
isolate the apparatus completely, where possible, before opening enclosures
and starting work,
l
are conversant with the information provided particularly on measures relating
to their safety,
l
recognise the hazards which can arise when working on live apparatus and
take all the necessary precautions,
l
comply with all local safety regulations.
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 24 of 25
abcd
4.
VOLTAGES GREATER THAN 50V A.C./120V D.C.
The purchaser/user is advised to ensure that apparatus operating on a voltage greater
than 50V a.c./120V d.c. is isolated and made safe before any work is carried out
upon it.
5.
APPARATUS SUPPLIED AS LOOSE ITEMS, CHASSIS ETC.
The purchaser/user responsible for installing such apparatus is advised that, when
live, it could constitute a safety hazard and relevant safety procedures are necessary.
6.
ACCESS TO THE APPARATUS DESCRIBED IN THIS MANUAL
It is the purchaser's/user's responsibility to ensure that all personnel obtaining access
to the apparatus are competent and work in accordance with the user's safe system
of work.
Record of Personnel made aware of Safety Advice
Position/job title:
……………………………………………………….
Signature:
……………………………………………………….
Date:
……………………………………………………….
: 4
: ZA480 Series of Inset Approach and Threshold
: L:\Avd\IMM CURRENT\immza480-4
©2003 ALSTOM T & D Ltd
ALSTOM T & D Ltd
Issue
Fitting
Ref
Lights.
Date : June 2003
Author : ALL
Page : 25 of 25