Installation ManualInstallation Manual
THL - RIL, LED RWSL TakeAirfield
Lighting
Off
Hold
Light
and
Runway
Product Solutions Catalog
Intersection Light
L-850T, Style 3
96A0419, Rev. G,
www.adb-air.com
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
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.
LED Products of ADB manufacture are guaranteed against mechanical, electrical, and physical defects
for a period of four years after the date of installation and are guaranteed to be merchantable and fit for
the ordinary purposes for which such products are made.
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.
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
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
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
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
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
TABLE OF CONTENTS
A.0
Disclaimer / Standard Warranty ............................................................................................................................. II
A.1
A.2
A.3
A.4
A.5
A.6
A.7
CE certification ..................................................................................................................... ii
ETL certification ................................................................................................................... ii
LED Product Guarantee ........................................................................................................... ii
Standard Product Guarantee ..................................................................................................... ii
All Products ......................................................................................................................... ii
Liability ..............................................................................................................................iii
© ADB BVBA ......................................................................................................................... iv
1.0
Safety ....................................................................................................................................................................... 1
1.1 HAZARD Icons used in the manual ...............................................................................................
1.1.1 Qualified Personnel .........................................................................................................
1.2 To use this equipment safely: ....................................................................................................
1.2.1 Additional Reference Materials: ..........................................................................................
1.2.2 Intended Use .................................................................................................................
1.2.3 Fasteners .....................................................................................................................
1.2.4 Operation .....................................................................................................................
1.2.5 Storage ........................................................................................................................
1.2.6 Material Handling Precautions .............................................................................................
1.2.7 Action in the Event of a System or Component Malfunction ..........................................................
1.2.8 Maintenance ..................................................................................................................
1.2.9 Maintenance and Repair ....................................................................................................
2.0
1
1
2
2
2
2
3
3
3
4
4
4
THL (L-850T) ........................................................................................................................................................... 5
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
2.3 Installation .......................................................................................................................... 7
2.3.1 Installation on L-868 Base .................................................................................................. 7
2.3.2 Torquing and Installation Guidance for In-pavement Fixtures ....................................................... 9
2.3.2.1 Installation on a Shallow Base ..................................................................................... 10
2.3.3 Installation in a Base Can ................................................................................................. 10
2.3.3.1 Connection of the Series Transformer and the Light Connectors ............................................ 10
2.3.3.2 Earth Ground Connection .......................................................................................... 11
2.4 Maintenance ....................................................................................................................... 12
2.4.1 Troubleshooting ............................................................................................................ 12
2.4.2 THL Light Maintenance Schedule ........................................................................................ 12
2.4.2.1 Fixture Component Maintenance.................................................................................. 13
2.4.2.2 Cleaning the Light Channel and Prism ........................................................................... 13
2.4.2.3 Lifting Optical Unit Out of Base ................................................................................... 13
2.4.3 Repair Procedures .......................................................................................................... 14
2.4.3.1 Opening Optical Unit................................................................................................ 14
2.4.3.2 Replacing L-823 Cordset............................................................................................ 17
2.4.3.3 Testing for Leaks .................................................................................................... 19
2.4.3.4 Torquing the Mounting Bolts ....................................................................................... 19
3.5 Parts ................................................................................................................................. 21
3.5.1 Spare Components ......................................................................................................... 25
4.0
Appendix A ............................................................................................................................................................ 27
4.1 Installation Guidance for In-pavement Fixtures .............................................................................. 27
4.1.1 Reference Documents ..................................................................................................... 27
4.1.2 Mounting Systems .......................................................................................................... 27
4.2 L-868 base can installation (load bearing) .................................................................................... 28
© ADB Airfield Solutions All Rights Reserved
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THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
TOC
4.2.1 Use of Ceramic Bolts ...................................................................................................... 32
L-867 base can installation (non-load bearing) .............................................................................. 33
Shallow base can installation ................................................................................................... 36
4.4.1 Parts: ......................................................................................................................... 36
4.4.2 Tools: ........................................................................................................................ 37
4.4.3 Prepare ...................................................................................................................... 37
4.4.3.1 Fixture with toe-in only ............................................................................................. 37
4.4.4 Install ........................................................................................................................ 37
4.4.4.1 Lubricate and connect............................................................................................... 37
4.4.5 Screws ....................................................................................................................... 38
4.4.6 Standard toolkit ............................................................................................................ 39
4.5 Checking Bolt Torque ............................................................................................................ 40
4.3
4.4
vi
© 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
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THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
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
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
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 THL (L-850T)
L-850T Style 3 LED RWSL Take-Off Hold Light (THL) installation manual.
2.1 About this manual
The manual shows the information necessary to:
•
2.1.1 How to work with
the manual
Install and maintain the L-850T Style 3 LED RWSL Take-Off Hold Light (THL).
1. Become familiar with the structure and content.
2. Carry out the actions completely and in the given sequence.
2.1.2 Record of changes
Page
Rev
All
A
B
Updated the Disclaimer
JR
ER
1/4/13
All
C
update the entire manual
DM
ER
4/10/13
7-8
D
Install and repair
RW
JC
8/29/14
All
E
All
RW
JC
2/15/15
A
F
Torque Information Added to Appendix
RW
JC
2/25/16
© ADB Airfield Solutions All Rights Reserved
Description
Released Manual
Checked Approved
DM
ER
Date
6/25/12
5
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Introduction
2.2 Introduction
WARNING
Read the instructions in their entirety before starting installation.
Compliance with Standards
L-850T(L) AC 150/5345-46 (Current Edition) and the FAA Engineering Brief No. 67. ETL
Certified.
Complies with FAA Runway Status Light System Take-off Hold Light (THL) and Runway
Intersection Light (RIL) requirements in FAA AC 150/5340-30 Appendix 7 and FAA
Engineering Brief 64.
Uses
RWSL L-850T -– Used in FAA Runway Status Light THL applications.
Fixture is unidirectional traffic signal red.
Operating Conditions
Temperature: -40 °C to +55 °C (-40 °F to +131 °F)
Altitude: Sea level to 10,000 feet (3000 m)
Relative Humidity: Up to 100%
Electrical Supply
It is recommended that the RWSL LED fixture be powered from a dedicated CCR and that
separate remote controls are available. RSWL LED lights have been designed to work with
any FAA-compliant transformer up to 150 W without affecting the performance or lifetime of
the light fixture or transformer.
L-850T(L)/RWSL LED
Fixture
Load*
Isolation
Transformer
Isolation
Transformer
Load
CCR Load
Without Heater
62 VA
65 W
10 VA
72 VA
With Heater
90 VA
100 W
12 VA
112 VA
* Load includes ADB BRITE III Remote device.
Dimensions
Outside diameter: 11.94 in (30.33 cm)
Bolt-circle diameter (L-868B): 11.25 in (28.58 cm)
Bottom cover outside diameter(max.): 9.94 in (25.25 cm)
Depth* : 4 in (10.16 cm)
* From the bottom of the top cover to the bottom of the fixture
Packaging
6
In cardboard box:
7 x 13 x 13 in (17.8 x 33 x 33 cm)
Weight with packing:
22 lb (9.98 kg)
Weight without packing:
17.75 lb (8.05 kg)
© ADB Airfield Solutions All Rights Reserved
2.3 Installation
WARNING
Read the instructions in their entirety before starting installation.
Do not unpack or remove the BRITE Remotes from their boxes until reading
all these instructions.
This section provides installation instructions for the L-852T, THL Light Fixture.
Input Requirement Summary
The F-Range 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.
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 and carefully remove the top packing material. Thread
an eyebolt into each of the two opposite threaded holes. Run a rod through the eyebolts and
lift the light assembly from the shipping carton. 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.
2.3.1 Installation on L-868
Base
The light assembly is shipped complete, including the lamp, 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 spacer 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. Remove the six fixing bolts and anti-vibration washers.
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
Never hold the light fixture by the wires. Doing so may damage the
insulation, break the waterproof seal and cause insulation faults and water
leakage.
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 6 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 150/5340-30 and project plans and specifications. Make sure items
© ADB Airfield Solutions All Rights Reserved
7
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Installation
such as spacers, shims and gaskets are installed on the light base as indicated on site
plans, specifications and drawings. Remove the eyebolts and lifting rod.
WARNING
Ensure that the cord set wires are NOT pinched between the base can and
the fixture. Pinched wires can cause water to be drawn inside the fixture.
8. Turn on the power to verify the fixtures illuminate. Operate for a minimum of five minutes.
CAUTION
The light assembly may be hot after this test. Allow time for the assembly
to cool before proceeding.
9. See “Torquing and Installation Guidance for In-pavement Fixtures” on page 9.
8
© ADB Airfield Solutions All Rights Reserved
2.3.2 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 27 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.
© ADB Airfield Solutions All Rights Reserved
9
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Installation
2.3.2.1 Installation on a
Shallow Base
Installing the F-Range 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, 3.4 - Installation on L-868 Base,
when connecting, installing and powering the fixture.
See 96A0396 and 96A0397 for BRITE III/AGLAS remote/master
See 96A0199 and 96A0200 for BRITE I/BRITE II remote/master
2.3.3 Installation in a Base
Can
NOTE: BRITE III or AGLAS Only: For best results, place the BRITE Remote in the can with
the ground screw face down.
If several BRITE Remotes are installed in a single base can or manhole, they must be spaced
with a distance of at least 2-inches (50mm) from each other and from the series transformers.
The distance between the transformers should also not be less than 2-inches (50mm).
2.3.3.1 Connection of the
Series Transformer and the
Light Connectors
1. The 2-pin plug on cable X1 is connected to the socket for the secondary circuit of the
series transformer via the Y-connector. The light (input #2) is connected to the 2-pin
socket X3 of the BRITE Remote.
2. The remaining lead X2 from the Y-connector, attached to the transformer, is then
connected to the Power connector of the light assembly. See Figure 1
Figure 1:
THL base
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.
10
© ADB Airfield Solutions All Rights Reserved
2.3.3.2 Earth Ground
Connection
NOTE: BRITE III or AGLAS Only: To protect it against over-voltages generated by lightning,
each BRITE Remote must be provided with a separate, low induction and low resistance
earth connection via the earth ground screw. The earth ground cable must be connected to
the earth ground screw by means of a suitable cable lug. The cross-sectional area of the
cable should be at least 8 AWG (6 mm) with a maximum cable length of 3.28-Feet (1m.)
Figure 2:
Base Can Cross-section
Transformer
BRITE Remote
Y-Connector
In-pavement
Light Assembly
Ground Connection
Ground Wire
Provide 3-feet of slack
Conduit for Connections
Ground Rod
© ADB Airfield Solutions All Rights Reserved
11
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Maintenance
2.4 Maintenance
WARNING
Read the instructions in their entirety before starting installation.
2.4.1 Troubleshooting
Problem
Short LED
life
Distorted
light beam
output
Possible Cause
Corrective Action
Current too high
(series circuit
applications)
Check constant current regulator output current levels.
Check the label on the isolation transformer and
replace if necessary. For example, incorrectly
installing a 6.6A/20A transformer will cause very fixture
component life.
Water in assembly
Inspect the prism and gasket. Open the light
assembly. Clean, dry and inspect light assembly.
Replace O-ring. Verify fixture is sealed. See “Cleaning
the Light Channel and Prism” on page 13
Broken, damaged or
Check parts list and install correct prism
wrong prism installed
Damaged or missing
Replace both prism seals. Replace top cover O-ring.
prism seals or top
Verify that the fixture is sealed.
cover O-ring
Water inside
optical
Fixture wires pinched
chamber
between base can
and fixture
A break in the fixture wire insulation will cause water to
be drawn into the fixture during the fixture's heating
and cooling cycle (when switched on and off). Replace
fixture leads.
Use care when remounting the fixture on the base can
to ensure that the wires do not get pinched.
NOTE: Once power from the CCR is turned off for 3-seconds and then on again, the BRITE
system will re-establish timing with all Remotes and reset any Remotes with replaced
components.
2.4.2 THL Light
Maintenance Schedule
Interval
Weekly
Maintenance
Task
Check for dirty
channel and
prism.
Monthly
Visually check
(more often during for moisture in
rainy seasons)
the light fixture.
12
Action
Clean channel and prism.
Inspect the light fixture through
the prism. Clean, dry, and
inspect the light assembly if
moisture is present. Replace
O-ring.
Refer to:
Cleaning the Light
Channel and Prism
—
Every 60 days
(also whenever the
light assembly is
serviced)
Check for
improper torque
on hold-down
bolts.
Retorquing Mounting
Torque the six bolts holding the
Bolts and Installation
fixture to the base.
on L-868 Base
After snow
removal
Check for
damaged light
fixtures.
Replace damaged fixtures.
Use a power broom for snow
removal, if practical.
© ADB Airfield Solutions All Rights Reserved
2.4.2.1 Fixture Component
Maintenance
WARNING
Turn off the circuit before replacing fixture(s). Failure to observe this
warning may result in personal injury, death, or equipment damage.
The preferred method of maintaining the F-Range inset 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.
2.4.2.2 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.
2.4.2.3 Lifting Optical Unit Out
of Base
To lift the optical unit from the light base, perform the following procedure:
1. Remove the six fixing screws and washers or self locking nuts.
2. Fit the appropriate lifting tool 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.
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.
5. Take the inset fixture unit back to the maintenance base where it can be serviced entirely.
NOTE: Never hold the light fixture by the wires. This may damage the insulation, break
the waterproof seal, and cause insulation faults and water leakage.
© ADB Airfield Solutions All Rights Reserved
13
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Maintenance
2.4.3 Repair Procedures
2.4.3.1 Opening Optical Unit
To open the optical unit, perform the following procedure:
1. Turn the light unit upside-down.
2. See Figure 3. Remove the pressure release screw (E11).
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 3:
Pressure Release Screw
3. See Figure 4. Remove the ten screws (E10). The use of an impact driver may be required
to unlock the screws.
Figure 4:
Removing Screws
4. See Figure 5. 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.
Figure 5:
Separating Inner Cover from Top Cover
Replacing the LED Assembly
To replace the optical unit, perform the following procedure:
1. Remove the LED Assembly by loosening the two 6-32 fixing screws.
2. Disconnect the wires from the PCB.
14
© ADB Airfield Solutions All Rights Reserved
Figure 6:
Removing LED Assembly from Light Assembly
INSTALL 61A0459 PRIOR TO 60A4047
HEATER ELEMENT IS TO BE ORIENTED
UNDER FLANGE OF 60A4047, TYP.
RWSL TOP COVER MACHING, ONE WINDOW
62A2187-3
HEATER DISC, 2 LEADS
61A0459
8-32 X 3/8 PAN HD PHIL
64A0191/6
#6 EXT LOCKWASHER
66A0039/4
SEE NOTES 1 & 2
RWSL LED LIGHT ENGINE, RED
48A0419/RED
PRISM KEEPER PLATE
60A4047
PRISM FLAT SEAL
63A1120
IRCL/TDZL PRISM
63A1119-1
RWSL TOP COVER MACHING, ONE WINDOW
62A2187-3
#6-32 X 1/2 FLAT HEAD PHILLIPS
64A0026/8
M5 X 10 FLT PHIL SS
64A0925-10
O-RING TOP COVER F-RANGE
7080.90.335
SEE NOTE 1 & 2
THRMSTAT, NO-HERM STUD, N.O. C80F-O60F
54A0022-8060
PRISM CLAMP
60A4046
3. Position the new optical (48A0405-THL) unit with new grommet.
4. Torque the fixing screws to 3.5 ± 0.5 N•m (31 ± 4 inch-pounds).
5. Connect the new LED assembly wires to the PCB.
© ADB Airfield Solutions All Rights Reserved
15
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Maintenance
Replacing Prism
Replace the prism if it is broken or its surface is badly pitted or scarred.
To replace the prism, perform the following procedure:
1. Remove the prism-clamp and prism-keeper plate secured in the inner pan assembly.
Figure 7:
48A0419/RED
THL LIGHT
ENGINE RED
Replacing Prism
64A0026/8
6-32x1/2" FLT HD PHIL
64A0925-10
M5 X 10 FLT PHIL SS
60A4046
PRISM CLAMP
THL TOP
ONE WINDOW
PRISM FLAT
SEAL
Prism Seal
PRISM
SHOULDER SCREW
M5 X 13MM
PRISM
KEEPER
PLATE
2. See Figure 7. Remove the flat seal.
3. Push the prism with the sock seal towards the inside of the cover.
4. Clean and degrease 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 lubricant MOLYKOTE 3452 INERTA in the prism chamber using a
small brush.
6. Install a new sock seal over the prism.
7. Push the prism/gasket assembly in the prism pocket from the inside and clean the inner
surface of the prism.
8. Install a new flat seal over the prism-keeper plate.
9. See Figure 7. Reinstall hardware with the Phillips pan head screws. Apply a droplet of
sealant Loctite 270 to the last threads. Torque to 3.5 ± 0.5 N•m (31 ± 4 inch-pounds).
16
© ADB Airfield Solutions All Rights Reserved
2.4.3.2 Replacing L-823
Cordset
To replace the L-823 cordset, perform the following procedure:
1. Open the optical unit. Refer to “Opening Optical Unit” on page 14.
2. Disconnect the LED Assemblies from the PCB.
3. Remove the PCB.
4. See Figure 8. Remove both screws (F7) and the wire clamp (F6).
NOTE: Replace the wire grommets (F5) when damaged or aged.
5. Unplug the fast-on connectors from the cable assembly wiring.
6. Pull the cordset out of the unit.
7. Replace the cordset by slipping the cords through the wire clamp (F6) wire grommets (F5)
and the optical base.
8. Replace the PCB.
9. Attach the fast-on connectors to the PCB.
10. Close the optical unit.
11. Test for leaks, see “Testing for Leaks” on page 19.
Figure 8:
THL Base Assembly
INNER PAN CABLE CLAMP
4071.50.090
GROMMET CORDSEAL F-RANGE
63A1014
M4x. SPEC PHIL HD7 INT LW
64A0964-10
F-RANGE INNER PAN 12 IN - CORD
62A2162
PRESSURE RELEASE SCREW F-RANGE
60A2602
SCREW DIA 20 3/8-16UNC
4070.77.140
TORQUE PRESSURE RELEASE SCREW
(60A2602) TO 4.5 Nm (40 IN-LBS).
INSTALL PRESSURE RELEASE SCREW
FITTING (4070.77.140) WITH HIGH
STRENGTH LOCTITE 270 OR 262.
Optional Ground Lug Kit 94A0574/2
10-32 X 1/2 HX WASHER HEAD S.S SELF TAPPING
64A1011/8
66A0039/6
#10 EXTERNAL LOCKWASHER
67A0100
ANTI-OXIDANT - QTY IN .01 OZ.
72A0401
GROUND LUG AlCu / UL 467
© ADB Airfield Solutions All Rights Reserved
L823 CORDSET, STYLE 6, LED ELEVATED
73A0133-31
17
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Maintenance
Figure 9:
Cordset Wiring to PCB
ASSY. REV.X
RSWL PCB 41A0445
ASSEMBLY 44A7020
ARTWORK ID: REV B
J3
J4
PLC
J5
J8A
J8B
J1A
J1B
PWR
P2
50
PLC
CORDSETS ARE TO BE RUN UNDER PCB.
ROUTE ALL WIRES TO PREVENT
PINCHING AND INTERFERENCE. DO NOT
RUN WIRES OVER HEATSINKS OR TALL
COMPONENTS.
POWER
PAN CUT AWAY
FOR CLARITY
50HZ SHUNT POSTION (DEFAULT IS 60HZ)
ONLY USED WITH EXTERNAL TRIGGER
( /11100 & /12100)
18
© ADB Airfield Solutions All Rights Reserved
2.4.3.3 Testing for Leaks
WARNING
The unit must have all its screws installed and correctly torqued prior to
pressurizing to 20 psi (138 kPa) maximum.
High pressure may cause the fixture to explode causing damage to fixture,
personal injury, or death.
Always test for leaks after opening the fixture for any reason. To perform this test:
1. Remove pressure release screw (E11), see Figure .
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 (138 kPa) 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.
2.4.3.4 Torquing the Mounting
Bolts
NOTE: See “Torquing and Installation Guidance for In-pavement Fixtures” on page 9.
© ADB Airfield Solutions All Rights Reserved
19
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Maintenance
20
© ADB Airfield Solutions All Rights Reserved
3.5 Parts
Figure 10:
Ordering Codes
Ordering Code
THL-
Frequency
1 = 60 Hz
2 = 50 Hz
Arctic Kit
1 = No
2 = Yes
Grounding
0 = FAA RWSL Applications1
Note
1
Includes 10-32 x 1/2 hex head earth ground lug.
Y-Harness Adapter1
70A0761
Note
1
For controlled applications, the adapter is required to use a
xture with ADB’s BRITE III Remote.
Figure 11:
Top Cover Prism Assembly
INSTALL 61A0459 PRIOR TO 60A4047
HEATER ELEMENT IS TO BE ORIENTED
UNDER FLANGE OF 60A4047, TYP.
RWSL TOP COVER MACHING, ONE WINDOW
62A2187-3
HEATER DISC, 2 LEADS
61A0459
8-32 X 3/8 PAN HD PHIL
64A0191/6
#6 EXT LOCKWASHER
66A0039/4
SEE NOTES 1 & 2
RWSL LED LIGHT ENGINE, RED
48A0419/RED
PRISM KEEPER PLATE
60A4047
PRISM FLAT SEAL
63A1120
IRCL/TDZL PRISM
63A1119-1
RWSL TOP COVER MACHING, ONE WINDOW
62A2187-3
#6-32 X 1/2 FLAT HEAD PHILLIPS
64A0026/8
M5 X 10 FLT PHIL SS
64A0925-10
O-RING TOP COVER F-RANGE
7080.90.335
SEE NOTE 1 & 2
THRMSTAT, NO-HERM STUD, N.O. C80F-O60F
54A0022-8060
© ADB Airfield Solutions All Rights Reserved
PRISM CLAMP
60A4046
21
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Parts
Figure 12:
44A7036 - THL Bottom Pan Assembly (bottom view)
INNER PAN CABLE CLAMP
4071.50.090
GROMMET CORDSEAL F-RANGE
63A1014
M4x. SPEC PHIL HD7 INT LW
64A0964-10
F-RANGE INNER PAN 12 IN - CORD
62A2162
PRESSURE RELEASE SCREW F-RANGE
60A2602
SCREW DIA 20 3/8-16UNC
4070.77.140
TORQUE PRESSURE RELEASE SCREW
(60A2602) TO 4.5 Nm (40 IN-LBS).
INSTALL PRESSURE RELEASE SCREW
FITTING (4070.77.140) WITH HIGH
STRENGTH LOCTITE 270 OR 262.
Optional Ground Lug Kit 94A0574/2
10-32 X 1/2 HX WASHER HEAD S.S SELF TAPPING
64A1011/8
66A0039/6
#10 EXTERNAL LOCKWASHER
67A0100
ANTI-OXIDANT - QTY IN .01 OZ.
72A0401
GROUND LUG AlCu / UL 467
L823 CORDSET, STYLE 6, LED ELEVATED
73A0133-31
44A7036/ X X
APPLICATIONS:
0 = W/PLC
1 = W/O PLC
FREQUENCY : (SHUNT POSITION)
1 = 60HZ ( STD. W/O JUMPER)
2 = 50HZ
NOTES
22
© ADB Airfield Solutions All Rights Reserved
Figure 13:
44A7036 - THL Bottom Pan Assembly (top view)
JUMPER
LOCATION 50Hz
F-RANGE INNER PAN 12 IN - DOUBLE CORD
62A2162
F-RANGE INNER PAN 12 IN - SINGLE CORD
62A2162
JUMPER LOCATION
FOR W/O PLC
44A7020 RWSL PS PCB
60Hz STD W/O JUMPER
RWSL PCB & BRACKET ASSEMBLY
44A7044
PCB STANDARD, NO JUMPER 60HZ
M4x8mm PNHD PHIL W/CAP
LWASH ZINC SLFTAP
64A0982-08
J3
J4
J5:
REL: NO JUMPER REQUIRED, TWO
LIGHT ENGINES
THL: JUMPER REQUIRED, ONE LIGHT
ENGINE CONNECT TO J3
CONNECT CENTER CORDSET
TO J1A & J1B. REFERENCE THL
OR REL DOCUMENT FOR ARCTIC
KIT CONNECTIONS
NO THERMAL COMPOUND NECESSARY
UNDER PCB BRACKET TO BASE.
POWER
CONNECT OUTER CORDSET
TO J8A & J8B
M4x. SPEC PHIL HD7 INT LW
64A0964-10
L823 CORDSET, STYLE 6, LED ELEVATED
73A0133-31
CONTROL
CORDSETS ARE TO BE RUN UNDER PCB.
ROUTE ALL WIRES TO PREVENT
PINCHING AND INTERFERENCE. DO NOT
RUN WIRES OVER HEATSINKS OR TALL
COMPONENTS.
© ADB Airfield Solutions All Rights Reserved
23
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Parts
Figure 14:
PCB connections
ASSY. REV.X
RSWL PCB 41A0445
ASSEMBLY 44A7020
ARTWORK ID: REV B
J3
J4
J5
Jumper
P2
50
J1A
J1B
J8A J8B
LT. ENGINE #1
THL
24
© ADB Airfield Solutions All Rights Reserved
3.5.1 Spare Components
Table 1:
Reparable Components and Parts
Description
Part No.
Cable clamp
4071.50.090
Cord set, L-823
73A0133-31
Cord set grommet
63A1014
Cord set terminal, female
70A0329
LED light engine, RWSL, red
48A0419-RED
LED PCB, RWSL
44A7044
O-ring, bottom cover seal
7080.90.335
O-ring, pressure release screw
63B0267-011
Pressure release screw
60A2602
Prism
63A1119-1
Prism gasket sleeve
61A0444
Prism clamp
60A4046
Prism flat seal
63A1120
Prism keeper plate
60A4047
Table 2:
Other Components
Description
Part No.
Ground lug kit
94A0574/1
Cord set terminal, female
6111.87.140
Notes
Dow Corning Molykote 3452
As needed
or equivalent
70A0761
For controlled applications, the adapter is
required to use a fixture with ADB’s Power
Line Carrier Remote.
L-852S(L) LED / RWSL REL
94A0559
Prism Kit
Prism kit contains a light engine, prism,
gasket sleeve, screws, seal, prism keeper
plate, prism clamp and o-ring
Y-Harness Adapter
© ADB Airfield Solutions All Rights Reserved
25
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Parts
26
© ADB Airfield Solutions All Rights Reserved
4.0 Appendix A
4.1 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.
4.1.1 Reference
Documents
4.1.2 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
27
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
L-868 base can installation (load bearing)
4.2 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.
28
© 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 15.
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 15:
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 15). 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 16. 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
29
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
L-868 base can installation (load bearing)
Figure 16:
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.
30
© 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 17):
— 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 17:
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
31
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
L-868 base can installation (load bearing)
4.2.1 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.
32
© ADB Airfield Solutions All Rights Reserved
4.3 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
33
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
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 18. 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 18:
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).
34
© 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 19, 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 19:
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
35
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Shallow base can installation
4.4 Shallow base can
installation
Shallow base cans may be non-load bearing or load bearing depending on location or fixture
application. Following are specific requirements to insure that an either an elevated or an inpavement fixture is properly installed.
WARNING
Read installation instructions in their entirety before starting installation.
Fasteners:
— Only use fasteners of the same type as the one originally supplied with
the mounting support.
— Always tighten the fasteners to the recommended torque. Use a
calibrated torque wrench and apply the recommended adhesive type.
See “Screws” on page 38.
— If this is not the case, this may cause the fasteners to loosen, damage
the fixture, potentially to loosen the fixture. This can lead to a highly
dangerous situation of FOD, with potential lethal consequences.
— Obey the instructions of the adhesives necessary for the fasteners.
— Only install the fixture on mounting supports:
— That ADB has approved;
— That are installed according to the Instruction Manual of the mounting
support.
— Failure to do so can result in a highly dangerous situation of FOD, with
potential lethal consequences.
— Make sure the power is OFF when 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 from a 6.6 A series circuit;
— The series circuit is powered by a Constant Current Regulator that
complies with IEC 61822;
— The transformer is an AGL series transformer that complies with IEC
61823.
— The power of the series transformer shall not exceed 200 W, for
versions with the monitoring option.
— The mounting support is correctly earthed. Failure to do so will void the
warranty for all damages that occur 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.
See the Instruction Manual of the mounting support for instructions on how
to earth the mounting support.
4.4.1 Parts:
36
— Fasteners of the mounting support.
© ADB Airfield Solutions All Rights Reserved
4.4.2 Tools:
— Adhesive A. See “Standard toolkit” on page 39.
— Cleaning tap for blind holes (preferably a tap with a right spiral groove).
— Compressed air blower with dry, oil-free air.
4.4.3 Prepare
1. Make sure that the fixture is completely
assembled.
2. Make sure that the fixture is operationally tested.
3. Make sure a new labyrinth gasket (A) is installed.
4. Make sure that the contact surfaces of the fixture
with the mounting support and the gaskets are
clean and smooth.
5. With the cleaning tap for blind holes, clean all
fixation holes of the mounting support.
6. Make sure that all remains of adhesive are
removed from the fixation holes.
A
7. With the compressed air blower, blow out all the
fixation holes of the mounting support.
4.4.3.1 Fixture with toe-in only
1. Make sure the arrow (A) points to the
center of the runway.
CAUTION
A toe-in right (B) must be at
the left side of the runway
(C). A toe-in left (D) must be
at the right side of the
runway.
B
C
D
A
4.4.4 Install
4.4.4.1 Lubricate and connect
1. Lubricate the labyrinth gasket (A) with water.
NOTE: To facilitate the use, add some soap to
the water.
CAUTION
Do not use silicon or any
other type of grease. Avoid
the use of soap that
contains silicone or
glycerin.
B
A
2. Apply adhesive on the first three threads of the threaded holes in the mounting support.
Use adhesive A.
3. Connect the plug (B) to the receptacle.
NOTE: For a fixture with two plugs, INPUT 1 feeds side 1 and INPUT 2 feeds side 2.
© ADB Airfield Solutions All Rights Reserved
37
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Shallow base can installation
4. Carefully move the fixture (A) vertically into
the mounting support (B). Make sure that
you do not pinch the cable leads.
C
D
5. Check if the fixture fits correctly in the
mounting support.
A
6. Make sure the dents of the washers (D) face
upwards.
7. Gradually tighten the fasteners of the
mounting support (C). See “Screws” on
page 38 (torque).
B
CAUTION
Do not use the fasteners to
force the fixture in the mounting
support. If it happens at all, the
threaded hole in the mounting
support will be damaged.
4.4.5 Screws
Screw
Type
Name
Details
Torque
(N·m)
Adhesive
Type1
G
Prism screws
Screw M5x14 DIN 7985-T- A2-LOCK
2045
7100.10.211
4.0
Not required
J
Optical assy screws
Screw M4x10 DIN 7985-T- A2-LOCK
2045
7100.10.101
2.5
Not required
L
Inner cover screws
Screw M5x14 DIN 7985-T- A2-LOCK
2045
7100.10.211
3.5
Not required
M
Pressure release screw
assy
2.5
Not required
O
2.5
Not required
21-23
A
Assy (screw + gasket)
4072.24.940
Gasket only
7080.90.012
Cable lead screws
Screw M4x10 DIN 7985-T- A2-LOCK
2045
7100.10.101
Fasteners of the mounting
support (not supplied with
the fixture)
Screw FT.HEX M10x25, SST, Hex Head
or Screw FT.HEX 3/8” - 16UNCx7/8”
1
38
Part Number
See “Standard toolkit” on page 39.
© ADB Airfield Solutions All Rights Reserved
4.4.6 Standard toolkit
Identifier
Details
Part Number
Complete tool kit. The toolkist consists of the components listed below.
1411.19.421
Tool case
6169.01.007
Adhesive A
Loctite 2701
7870.05.130
Adhesive B1
Loctite 222
7870.05.140
Adhesive C1
Loctite 638
7870.05.097
Adhesive D
Loctite 243
7870.05.160
Lubricant A
Vacuum silicone grease (50 g) to install O-ring gaskets
7850.42.220
Lubricant B
Molykote HP870 Inerta (100 g) to replace prism
7850.05.061
Tool A
Torque wrench
8061.06.255
Tool B
Socket, hex 3/8”, screw 3/8”, J9/16LA
8961.06.008
Tool C
Socket, hex 3/8”, screw M10, J 17LA
8961.06.000
Tool D
Socket, 1/4”, 1.6x8 Flat, RS.8E
8961.05.050
Tool E
Socket, 1/4”, Pozidriv2, RD.2
8961.05.060
Tool F
Extension, 1/4”, R.210
8961.06.220
Tool G
Adaptation, 1/4”-3/8”, R.232
8961.06.010
Tool H
Hinged handle - sort
8961.06.110
Tool I
Pliers
8981.10.110
Tool J
Opening tool
4071.53.220
Tool K
Screwdriver, flat blade AG. 8x150
8961.06.250
Tool L
Screwdriver, pozidriv AD.2x125
8961.05.220
Tool M
Torque screwdriver
8961.06.255
Tool N
Screwdriver, Torx ANX20x100
8961.05.300
Tool O
Screwdriver, Torx ANX25x100
8961.05.290
Tool P
Attack driver
8961.04.100
Tool Q
Hammer 212A50s
8961.04.110
Tool R
Bit holder
8961.04.120
Tool S
Bits END202, Pozidriv2
8961.04.130
Tool T
Bit, Torx TX20 EX.620
8961.06.020
Tool U
Bit, Torx TX25 EX.625
8961.06.025
1
1
1
Obey the instructions of the manufacturer of the adhesive.
© ADB Airfield Solutions All Rights Reserved
39
THL - RIL, LED RWSL Take-Off Hold Light and Runway Intersection Light
96A0419 Rev. G
Checking Bolt Torque
4.5 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 150/5340-26C 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.
40
© ADB Airfield Solutions All Rights Reserved
p
y
Company Offices
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Room 901, 9F, Fang Heng Intl. Plaza
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ADB Airfield Solutions
ADB Airfield Solutions LLC
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585
977 Gahanna Parkway
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Zaventem
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