1154 (rev e) - cooper industries manual pro apf led inset runway guard light faa type l-852g iii 2...

DOCUMENT 1154 REVISION E January 22, 2016

Instruction Manual

Pro APF Series LED Inset Runway Guard Light

FAA Type L-852G

EATON Crouse-Hinds Series 1200 Kennedy Road Windsor, CT 06095

Copyright © 2016 Cooper Technologies Company

For Parts or Technical Service Call (860) 683-4300

DOCUMENT 1154REV. E

Instruction Manual

Pro APF LED Inset Runway Guard Light FAA Type L-852G

ii

1 Revisions

Revision Issue/Reissue Letter Number

Description Checked Approved

A A214-046 INITIAL RELEASE KF SB, TR

B A213-215 ITEM 10 WAS 21122 KF AC

C A214-236

UPDATED FIGURES 2, 3, 7 THRU 14 WITH REVISED POWER SUPPLY. UPDATED TABLE 1 WITH REVISED JUMPER SETTINGS. ADDED SECTIONS 3 & 9.1.

KF CS

D A215-020 ADD SECTION 11.1 BLUETOOTH INSTRUCTIONS, RENUMBER SUBSEQUENT SECTIONS

KF CS

E A215-193

ADDED FLASH-SYNCING INSTALLATION INSTRUCTIONS AND BOLT TORQUE INSTRUCTIONS

KF CS

DOCUMENT 1154REV. E

Instruction Manual


iii

2 Product Warranty

Warranty Refer to Cooper Crouse-Hinds Airport Lighting Products Terms and Conditions for product specific warranty information.

DOCUMENT 1154REV. E

Instruction Manual


iv

3 Warning Labels

DANGER:

DANGER The hazard or unsafe practice will result in severe injury or death.

WARNING:

WARNING The hazard or unsafe practice could result in severe injury or death.

CAUTION:

CAUTION The hazard or unsafe practice could result in minor injury.

NOTICE:

NOTICE Possibly dangerous situation, goods might be damaged.

IMPORTANT:

IMPORTANT Helpful information.

DOCUMENT 1154REV. E

Instruction Manual


v

4 Safety Notices

DANGER

DANGER: This equipment is normally used or connected to circuits that may employ voltages that are dangerous and may be fatal if accidentally contacted by operating or maintenance personnel. Extreme caution should be exercised when working with this equipment. While practical safety precautions have been incorporated in this equipment, the following rules must be strictly observed:

4.1 Keep Away from Live Circuits

IMPORTANT

DANGER: Operating and maintenance personnel must at all times observe all safety regulations. DO NOT PERFORM MAINTENANCE ON INTERNAL COMPONENTS OR RE-LAMP WITH POWER ON.

4.2 Resuscitation

Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of first aid instructions.

IMPORTANT

IMPORTANT:

See FAA Advisory Circulars AC 150/5340-30, AC 150/5345-46, and EB/67 for additional information.

5 Test Equipment and Tools

There is a wide variety of tools and equipment needed to safely and correctly perform airfield lighting equipment installation and maintenance. In addition to the obvious tools (screwdrivers, wrenches, etc.), there is specialized equipment needed to do the job. The following list should be used as a guide for procuring equipment to service the light units;

DOCUMENT 1154REV. E

Instruction Manual


vi

Multimeter, One of the most important pieces of test equipment is the Multimeter. It is used to measure voltages, currents, and resistances. Almost every single maintenance task requires the use of a multimeter at one point or another. A calibrated true rms meter is a must because airfield lighting power distribution equipment produces non-sinusoidal waveforms, traditional average reading meters are inaccurate and have very limited use. Checking or adjusting equipment based upon incorrect current readings may dramatically reduce light source life and adversely affect power equipment performance. A meter with TRUE RMS measuring capability and a current clamp-on probe is needed to accurately measure distorted or chopped waveforms. Crouse-Hinds Airport Lighting recommends the following ‘TRUE RMS’ Multimeters from Fluke: Manufacturer Model Number Fluke 87V, 287

It is also recommended to purchase the Fluke I800 current clamp with the Fluke 87V meter. Refer to the equipment manufacturer’s manuals for the proper use, maintenance and calibration (if necessary) of all meters. Torque Wrench, Crouse-Hinds Airport Lighting recommends torque values for the attachment hardware in order to properly secure the components and the light unit to their mountings. The internal parts require torques in the range of 4 in-lbs to 55 in-lbs. The light unit mounting hardware requires a torque per section 9.1. There are many brands and styles of torque wrenches in the market to choose from. Crouse-Hinds Airport Lighting recommends the use of a properly calibrated torque wrench when performing the job.

DOCUMENT 1154REV. E

Instruction Manual


vii

6 Table Of Contents

TableofContents

1 Revisions ............................................................................................................................. ii

2 Product Warranty ............................................................................................................................ iii

3 Warning Labels ............................................................................................................................... iv

4 Safety Notices ................................................................................................................................... v

4.1 Keep Away from Live Circuits ......................................................................................................... v

4.2 Resuscitation ..................................................................................................................................... v

5 Test Equipment and Tools ................................................................................................................. v

6 Table of Contents ........................................................................................................................... vii

7 Part Number Explanation / Data Sheet .............................................................................................. 1

8 General Description of Inset Runway Guard Light – LED ............................................................... 2

9 Installation ......................................................................................................................................... 2

9.1 Installation Bolt Torque..................................................................................................................... 3

9.2 Heico Lock Installation Guidelines (2014) ....................................................................................... 4

10 Maintenance ...................................................................................................................................... 4

10.1 Cleanliness and Workmanship .......................................................................................................... 5

10.2 Maintenance Program........................................................................................................................ 5

10.3 Cleaning Lenses ................................................................................................................................ 6

10.4 Replacing the LED Module ............................................................................................................... 6

10.5 O-Ring Replacement ......................................................................................................................... 7

10.6 Lens and Arctic Kit Replacement ...................................................................................................... 8

10.7 Power Lead/Feed-Thru Replacement ................................................................................................ 9

10.8 Power Supply Expansion Board Replacement ................................................................................ 10

10.9 Power Supply Replacement ............................................................................................................. 10

10.10 Pressure Test ................................................................................................................................... 11

11 Troubleshooting .............................................................................................................................. 12

11.1 Bluetooth Instructions ..................................................................................................................... 12

11.2 Visual Inspection ............................................................................................................................. 13

11.3 Electrical Inspection ........................................................................................................................ 15

12 Spare/Replacement Parts List .......................................................................................................... 17

13 Figures and Tables .......................................................................................................................... 18

DOCUMENT 1154REV. E

Instruction Manual


1

7 Part Number Explanation / Data Sheet

Ordering Information

DOCUMENT 1154REV. E

Instruction Manual


2

8 General Description of Inset Runway Guard Light - LED

The Crouse-Hinds Airport Lighting LED equipped Inset Runway Guard Light (IRGL) is a Style II, (≤ 1/2 inch) light unit that meets the requirements of FAA Advisory Circular AC 150/5345-46 (latest version), Type L-852G and EB67 (latest version). It is designed for installation at taxiway/runway intersections or any other location where visual guidance of moving aircraft is desirable. The light unit is designed to fit on a FAA L-868 steel, size B light base per FAA AC 150/5345-42 (latest version), and have a total height above grade/ground level of ½ inch. The light unit is mounted to the light base with six bolts and lock washers. It is weatherproof and will endure roll over loads without damage. The light unit is an assembly, consisting of a 1-piece aluminum optical (light) housing, and a 1-piece aluminum sand cast inner housing (cover) bolted together with 6 flat head screws. A silicone o-ring is used to provide a watertight seal between the inner cover and the optical housing. The LED optical light engines are secured in place using brackets, which are fastened to the light housing. The power board and components are secured into the inner cover. Electrical connections are made at one feed-thru assembly in the inner cover. The feed-thru has an ITS verified L-823 plug for connecting to FAA L-830/ L-831 isolation transformers. Each outer lens is held into the aluminum housing with a bracket, gasket, molded elastomeric boot and 2 screws. The yellow light beam color is produced using amber LEDs with optics. All hardware is type 18-8 stainless steel. The complete light unit is 11.94 inches in diameter, 6 inches deep, and weighs 14 lbs. All units leave the factory pressure tested. If the unit is serviced during it lifetime, it must be re-tested to ensure it remains waterproof.

CAUTION

CAUTION: Never handle the light assembly by the leads as this can break the

waterproof seal.

9 Installation

The light units are shipped complete and are ready for installation as received. Installation of a light unit is to be done with primary POWER OFF and SECURED. At each light location, install one steel, size-B, L-868 light base per FAA AC 150/5340-4 (latest revision). If installation is replacing existing light units, it is necessary that the mounting surface and inside locating diameter of the light bases are free of rust and debris. If necessary, use appropriate methods to clean these surfaces. The light unit requires an isolation transformer. Isolation transformer requirements are dependent on a light unit’s heater option and whether or not it is used with a Logitrac device. Minimum isolation transformer requirements can be found in Section 13, Table 2. All isolation transformers are 6.6 ampere secondary models. Place the properly sized isolation transformer in the light base and make necessary primary power connection using L-823 connectors. Verify that the mounting flange on the light base is clean and the o-ring (optional on deep cans) is coated with Dow Corning FS 1292 grease and is in place on the light base. Connect the plug from the light unit to the secondary of the previously installed isolation transformer. Installation tool, Crouse-

DOCUMENT 1154REV. E

Instruction Manual


3

Hinds Airport Lighting P/N 19999, will ease the installation and removal of the light unit. The threaded eyebolts on the lifting tool screw into threaded holes in the light unit. Lower the light unit straight down onto the base. The light unit is subject to optical misalignment or mechanical damage if not seated properly. Secure the light unit to the base per section 9.1. All 852G-AP1 light units are flashing lights. For light units with the “YO” designator in the part number, the light will flash ON first in the cycle. For light units with the “YF” designator in the part number, the light will flash OFF first in the cycle. This allows the light installers to arrange either an alternating flashing bar of lights (i.e. YO---YF---YO---YF---YO---YF---… etc.), in which the YOs flash on while the YFs flash off in an alternating fashion, or a solid bar of lights that flashes in unison (i.e. YO---YO---YO---YO---YO---YO---… etc.). In the case of an accidental undesirable light bar installation (i.e. YO---YF---YF---YO---YO---YO---…etc.), each 852G-AP1 light unit’s immediate powered flashing state is reprogrammable using Bluetooth technology. See Section 11.1 for Bluetooth access instructions.

9.1 Installation Bolt Torque

The following recommendations apply to the 3/8-16 bolts used to mount a light unit (fixture) into a base can.

Use fully threaded, cold-worked 18-8 stainless steel 3/8-16 bolts. (P/N 21715 is recommended. Use Heico-Lock or Nord-Lock stainless steel lock-washers per FAA specifications*. Mounting base holes must be degreased, cleaned, and dried prior to bolt installation. Base-to-fixture mating surfaces must be degreased, cleaned, and dried prior to installation. Apply marine grade anti-seize (K=.18) per manufacturer’s instructions to each bolt. Install the 3/8-16 bolts with lock-washers per lock-washer manufacturer’s guidelines. See section 9.2 for Heico-Lock installation guidelines (2014) Achieve a full final torque of 225 in-lbs (25.4 N-m) +10%, -0% with a calibrated torque wrench. Impact wrenches are not recommended as installation tools. Check torque and re-torque all bolts within 2 weeks of initial installation. Maintain all bolts by checking and re-torqueing per FAA specifications*. If any lubricants or thread locking compounds are used (not recommended), torque must be

recalculated based on K factor provided by lubricant or compound manufacturer. New bolts and lock-washers shall be used each time a light unit is removed from its base.

*Refer to the following specifications for FAA installation and maintenance recommendations: AC150/5340-26 “Maintenance of Airport Visual Aids” AC150/5345-46 “Specification for Runway and Taxiway Light Fixtures” FAA Engineering Brief No. 83 “In-pavement Light Fixture Bolts”

WARNING:

DOCUMENT 1154REV. E

Instruction Manual


4

WARNING

Pro APF IRGL optical assemblies are designed to withstand a maximum torque of 23 ft-lb (276 in-lb) per bolt, assuming K=.18 lubricant and appropriate superior-

grade 3/8” hardware, however other components within the light fixture installation (i.e. base-can, extension rings, spacer rings, etc.) may not be capable of supporting such a load. Crouse-Hinds recommends following the installation bolt

torque values and methodology outlined in section 9.1.

9.2 Heico-lock Installation Guidelines (2014)

Step 1: Hand tighten to ensure that 2-3 threads extend beyond the nut on through-bolt applications. Step 2: Tighten each bolt to one-third of the final required torque following the pattern as shown below. Step 3: Increase the torque to two-thirds following the pattern shown below. Step 4: Increase the torque to full torque following the pattern shown below. Step 5: Perform one final pass on each bolt working clockwise from bolt 1, at the full final torque.

10 Maintenance

The preferred method of maintaining these lights is to periodically and systematically replace the units and return them to the maintenance shop for renovation. As an alternative, the units can be serviced in the field. However, it is recommended that field servicing be limited to checking bolt torque per section 9.1 and cleaning the lens only as described in Section 10.3.

NOTICE

NOTICE: The warranty is void if other than Crouse-Hinds Airport Lighting Products parts are used

to re-lamp or rebuild the light unit.

DOCUMENT 1154REV. E

Instruction Manual


5

WARNING

WARNING: The warranty is void if the screws holding the L852G optical housing to the inner cover are

loosened or removed.

10.1 Cleanliness and Workmanship

Service life depends upon the entire assembly being waterproof. All surfaces must be clean, dry and free of all foreign matter if the light unit is to operate for extended periods without requiring maintenance.

10.2 Maintenance Program

In order to insure maximum light unit life, the installed units should be subject to a maintenance program in accordance with the following: A daily operation check should be made of the lighting unit. The lights should be energized and visually inspected. If any units are not lit and/or partially lit, the location of the unit, along with the pocket that is out, should be recorded for future troubleshooting. A replacement light unit should be installed per instruction in Section 9 with the primary POWER OFF and SECURED. The affected light unit can be troubleshot in a clean, safe working area or returned to Crouse-Hinds Airport Lighting for repair.

WARNING



10.2.1 Regular cleaning is necessary to insure inset lighting units operate at maximum efficiency. The lens should be cleaned periodically per Section 10.3. The weather and the location of the units will dictate the regularity and type of cleaning.

10.2.2 Inset light hold-down bolts should be checked for proper torque per section 9.1 and whenever a unit is serviced regardless of the season. Light units in and around the touchdown zone area are specially prone to vibration damage if the mounting bolts are not properly torqued. The mounting surface of the light base must be clean and free of foreign matter when checking mounting bolts.

10.2.3 Snowplow operators should exercise extra care not to strike the light units with snowplow blades. Use rubber blades for added protection to the unit. After snow removal operations, inspect all light units to locate and replace, if necessary, any damaged light assemblies. Passes over the light

DOCUMENT 1154REV. E

Instruction Manual


6

rows should be made with a power broom only if practical. Whenever snowplows must traverse in-pavement light units, they should be traveling at less than 5 mph or have the blades lifted clear of the unit. Recommended snow removal techniques are described in AC 150/5200-23.

10.2.4 The light is designed to exclude both ground and surface water from entering. If the lights are not properly maintained (i.e., bolts tightened and seals in good condition) water may enter the unit. To prevent this from occurring, it is recommended that each unit be inspected for the presence of water at least once a month. More frequent inspection is desirable during and following rainy seasons.

10.2.5 If any light unit contains water, the water should be removed and the entire unit cleaned and dried. If any of the electronics have been damaged, it may not be cost effective to make a field repair, but rather send it back to Crouse-Hinds Airport Lighting for rebuild. Perform a pressure test per Section 10.10 to locate the source of the leak. Refer to the o-ring, lens, and power lead sections, 10.5, 10.6, & 10.7 as needed to make repairs. After any repair, pressure test again per Section 10.10.

10.3 Cleaning Lenses

With a compressed air blast or suitable brushes, remove all accumulated debris from the light channel. Clean the outer lens surface with a detergent solution. If the lens is coated with a substance impervious to the detergent, a suitable solvent should be sparingly applied with a wad of cotton or a patch of cloth on the end of a wood splint. After the solvent has acted, the remaining solvent and softened coating should be removed with a clean piece of cotton or cloth. Care should be taken to avoid excessive contact between the solvent and the lens seal. Remove all remaining solvent from lens and lens seal. A gentle air blast may be used. It is good practice to inspect for damage to the optical housing and/or water intrusion into the unit anytime a lens is cleaned. Water droplets would be visible on the inside of the lens if moisture had entered the unit. If it is determined that moisture has entered the unit, refer to Section 10.2.5 for possible causes and maintenance procedures.

10.4 Replacing the LED Module

WARNING

WARNING: The Warranty is void if the screws holding the L852G optical housing to the inner cover

are loosened or removed.

NOTICE

NOTICE: The LED PCB is warm when light unit is energized and remains warm for a short time

after unit is turned off.

DOCUMENT 1154REV. E

Instruction Manual


7

Refer to Section 12 to determine the appropriate replacement kit for your light unit(s). First, remove and secure power to the light unit. Disconnect the light unit lead(s) from the isolation transformer(s). Turn the light unit upside down and remove the six screws holding the inner cover (referred to as the ‘bottom’ cover) to the light housing (sometimes refer to as the ‘optical’ housing). Being careful not to pull and strain the LED wire cables, gently lift the inner cover up and rotate to the side. Support the inner cover, on edge, adjacent to the light housing, again being careful not to pull and strain the LED wire cables. Disconnect the LED leads (6 white wire bundle) from all (3) LED boards by gently pulling the wires at the connection while adding a slight side-to-side motion to disengage the connector. The inner cover can then be rested safely on the work surface. The LED assembly(ies) can be disassembled from the optical housing by removing the #8-32 phillips-head screws. Clean the mounting surfaces of the optical housing with denatured alcohol, and apply a small amount of thermal grease to the mating bracket surface. Install the new LED assembly into the optical housing. Press parts together with a rotating motion to spread the thermal grease evenly. Install the #8-32 screws and torque to 15-20 in-lbs. Inspect/replace the optical housing’s o-ring per Section 10.5. Re-connect the LED wire cables, ensuring that the connectors have fully seated. Check the connections at the power supply (other end of LED lead) to ensure they are still fully engaged. Assemble the inner cover onto the optical housing. Note: 1 of the 6 mounting holes is offset, acting as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure test as described in Section 10.10. Re-install in field per instructions in Section 9.

10.5 O-Ring Replacement

Refer to Section 12 to determine the appropriate replacement kit for your light unit(s). Every time the unit is opened, the o-ring must be closely examined and replaced, if necessary. Any o-ring that is stretched, torn, has permanent set, or some other defect which would prevent it from forming a watertight seal, and must be replaced with a new o-ring.

WARNING



First, remove and secure power to the light unit. Disconnect the light unit lead(s) from the isolation transformer(s). Open the light unit and disconnect the LED wires as described in Section 10.4. Remove the old o-ring from the groove in the optical housing. Carefully use a lint-free cloth to clean the o-ring groove and flange mating surface on the inner cover with denatured alcohol. Take care not to damage the mating surface. Clean the new o-ring with denatured alcohol. Position the new o-ring into the groove and press it into place. Re-connect the LED wire cables, ensuring that the connectors have fully seated. It does not matter which cable goes where. Check the connections at the power supply (other end of LED lead) to ensure they are still fully engaged. Assemble the inner cover onto the light housing. Note: 1 of the 6

NOTICE

NOTICE: A bad o-ring seal is the most common cause of inset light unit leaks. A new o-ring must be

installed every time the optical assembly is opened

DOCUMENT 1154REV. E

Instruction Manual


8

mounting holes is offset, acting as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure test as described in Section 10.10. Re-install in field per instructions in Section 9.

10.6 Lens and Arctic Kit Replacement

WARNING



If an outer lens is broken, leaks, or is badly pitted or scarred, it must be replaced. Lens replacement kits contain all necessary parts to change a lens. Units with arctic kits (heaters) will require arctic kit replacement kits, which include replacement lenses. Refer to Section 12 to determine the appropriate replacement kit(s) for your light unit(s). It is highly recommended that this task be performed in a clean shop environment. First, remove and secure power to the light unit. Disconnect the light unit lead(s) from the isolation transformer(s). Turn the light unit upside down and remove the six screws holding the inner cover to the optical housing. Follow the instructions in Section 10.4 to disconnect the LED wires and remove the LED assy. Disconnect the power supply lead(s) from the LED modules. Remove the two screws holding the LED module to the optical housing. If you are replacing an arctic kit, remove the #6 tie-down screw which fastens the end of the arctic kit’s flexible circuit heater to the optical housing. Remove the two lens retaining bracket screws from the light housing. Remove the lens-retaining bracket and discard the lens-retaining gasket. Firmly push the lens/boot assembly from the outside of the light housing; discard the old lens and boot. If you are replacing an arctic kit, discard the arctic kit assembly as an electronic assembly. Thoroughly clean the lens opening with denatured alcohol and allow it to dry. Inspect the lens opening for scratches or pits; a damaged lens opening surface will not seal properly. Place a new lens boot over the replacement lens. Apply a thin coat of Dow Corning FS 1292 grease over the entire outside surface of the lens boot. Align the lens/boot assembly in the lens opening and press it into place. Verify that the lens boot is not pinched in the lens opening. Using a new lens retaining gasket, fasten the lens retaining bracket, and heater tie-down screw on arctic kit versions, to the light housing. Torque the lens retaining bracket mounting screws to 25-30 in-lbs and the heater tie-down screw, if applicable, to 8-11 in-lbs. See Figure 9 as an arctic kit visual reference. Re-install the LED assy per Section 10.4. Inspect/replace the optical housing’s o-ring per Section 10.5. Assemble the inner cover onto the optical housing. Note: 1 of the 6 mounting holes is offset, acting as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure test as described in Section 9.10. Re-install in field per instructions in Section 9.

NOTICE

NOTICE: The groove is designed to be wider than the o-ring. This provides room for the

displacement of the o-ring when compressed between the housing and mating surface. Properly tightened screws are important in obtaining a complete seal.

DOCUMENT 1154REV. E

Instruction Manual


9

10.7 Power Lead/Feed-thru Replacement

WARNING

WARNING: The warranty is void if the screws holding the L852G optical housing to the

inner cover are loosened or removed.

Refer to Section 12 to determine the appropriate replacement kit for your light unit(s). First, remove and secure power to the light unit. Disconnect the light unit lead(s) from the isolation transformer(s). Turn the light unit upside down and loosen the knurled retaining collar on the power lead with a pair of pliers or small channel-locks. Unscrew the ring completely and then carefully remove the rubber flanged grommet from the male threaded adapter with a gentle twisting action. The key is to keep the internal wires attached to the power lead. Carefully pull the power lead grommet with attached internal wires a couple of inches away from the light unit. Unplug the internal wires from the power lead and install them onto the new power lead. It does not matter which lead goes where. Apply a thin coat of Dow Corning FS 1292 grease to the rubber grommet and slide it into the threaded adapter. Apply a drop of Loctite 243 to the feed-thru adapter threads. Screw the feed-thru retaining collar onto the adapter; refer to Figures 6 & 7 for proper inner cover/ feed-thru orientation. Torque the retaining collar to 30 in-lbs. If the internal leads did not stay connected to the old power lead, or if one wishes to open the light unit, then the following instruction should be followed for the power lead replacement. Open the light unit and disconnect the LED wires as described in Section 10.4. The power leads inside the inner cover have female flag-type crimped terminals which can be pulled from the L-823 feed-thru power terminal. Remove the feed-thru by unscrewing the retaining collar. Clean the mating surfaces with isopropyl alcohol and allow it to dry. Feed the black power leads from inside the inner cover thru the feed-thru adapter and press the flag terminals onto the new L-823 lead. It does not matter which lead goes where. Apply a thin coat of Dow Corning FS 1292 grease to the mounting flange of a new feed-thru power lead and slide it into the adapter. Apply a drop of Loctite 243 to the feed-thru adapter threads. Screw the feed-thru retaining collar onto the adapter. Torque the retaining collar to 30 in-lbs. Inspect/replace the optical housing’s o-ring per Section 10.5. Assemble the inner cover onto the optical housing. Note: 1 of the 6 mounting holes is offset, acting as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure test as described in Section 10.10. Re-install in field per instructions in Section 8.

10.8 Power Supply Expansion Board Replacement

Refer to Section 12 to determine the appropriate replacement kit for your light unit(s). Remove and secure power to the light unit. Separate the optical assembly from the light base by removing the six bolts. Disconnect the light unit lead(s) from the isolation transformer(s). Turn the optical assembly upside down and remove the six screws holding the inner cover to the optical housing. Disconnect the LED module cables from the expansion board, located on top of the main power supply in the inner cover assembly. Remove the single screw and washer and spacer which secure the expansion board to the power supply underneath it. Note: The

DOCUMENT 1154REV. E

Instruction Manual


10

spacer is sandwiched between the expansion board and power supply. Remove the expansion board form the power supply by securing the power supply against the inner cover while gently pulling the expansion board up and away from the power supply. Discard the old expansion board as an electronics assembly. Align and engage the connectors of the new expansion board with the power supply and press it into place. Place and align the spacer between the expansion board and power supply. Insert the mounting screw through the washer, expansion board, spacer, and power supply, in that order. Torque the screw to 16-8 in-lbs. Connect the ends of the LED cables to the new expansion board. Inspect/replace the optical housing’s o-ring per Section 10.5. Assemble the inner cover onto the optical housing. Note: 1 of the 6 mounting holes is offset, acting as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure test as described in Section 10.10. Re-install in field per instructions in Section 9.

10.9 Power Supply Replacement

CAUTION:

CAUTION Power supply is hot when light unit is energized and remains hot for a short time after light unit is turned off.

Refer to Section 11 to determine the appropriate replacement kit for your light unit(s). Remove and secure power to the light unit. Remove the expansion board per the instructions in Section 10.8. With the expansion board removed; disconnect the power supply leads from the power supply. On P2 units, disconnect the contact closure cables from the power supply. For units with an arctic kit (heater), disconnect the heaters’ power and temperature sensor cables form the power supply. See Section 12 for visual reference and wiring diagram figures. Remove the remaining two screws holding the power supply to the inner cover. Discard the old power supply as an electronics assembly. Configure the new power supply’s J203 jumper settings per Table 1 in Section 13.

IMPORTANT:

IMPORTANT

The jumpers must be placed in the correct position(s) for proper operation of the appropriate fixture.

The heater will remain on indefinitely with the temperature sensor disconnected.

Apply thermal grease to the bottom/mating surface of the power supply. Secure the power supply to the bottom using two screws on one end of the power supply. Reconnect the expansion board per Section 10.8. Tighten all 3 screws to 16-18 in-lbs. Reconnect internal cables per the appropriate wiring diagram, Figures 11 through 14, depending on your light unit options.

DOCUMENT 1154REV. E

Instruction Manual


11

IMPORTANT:

IMPORTANT

The jumpers must be placed in the correct position(s) for proper operation of the appropriate fixture.

The heater will remain on indefinitely with the temperature sensor

disconnected. Apply thermal grease to mating surface of the power supply and fasten it to the power supply bracket. Torque the top power supply’s screws to 1.8-2.0 N-m (16-18 in-lbs). Reconnect the power supply(ies) to the feed-thru terminal(s) and LED assembly(ies) and arctic kit(s), if applicable. Inspect/replace the optical housing’s o-ring per Section 10.5. Assemble the inner cover onto the optical housing. Inspect/replace the optical housing’s o-ring per Section 10.5. Assemble the inner cover onto the optical housing. Note: 1 of the 6 mounting holes is offset, acting as an alignment hole. Identify this hole and align to the appropriate mating hole. Be careful not to pinch the LED wire cables between the covers. Install all 6 phillips flat-head screws first until snug, then tighten the mounting screws in a star pattern to 25-30 in-lbs. Perform a pressure test as described in Section 10.10. Re-install in field per instructions in Section 9.

10.10 Pressure Test

A light unit should be subjected to a 20-psi maximum air pressure test to verify that it is waterproof whenever it has been opened or components have been replaced. A tire valve style pressure fitting is located on the inner of the inner cover. Pressurize the light unit to 20-psi using a regulated/controlled air source, then place it in a tub of water or use a soap solution to locate escaping air bubbles. Carefully inspect the areas around the lens, inner cover seal, and feed-thru adapter for leaks. Relieve the internal air pressure before installing the light unit or attempting to repair a leak.

11 Troubleshooting

If a light unit is under warranty, please contact Crouse-Hinds Airport Lighting for assistance. DO NOT open a unit. If the unit is opened, the warranty is VOID. If the warranty period has expired and

WARNING

WARNING: Do not exceed 20-psi when pressure testing the light unit. Serious injury

and/or permanent damage to the light unit may result if a higher air pressure is used. Once the pressure test is complete, be sure to relieve the

air pressure.

DOCUMENT 1154REV. E

Instruction Manual


12

troubleshooting is required, follow the steps below to find the root cause. Replacement parts will be required for testing of the different components of the light unit.

WARNING:

WARNING

Do not remove the fixture from the base can while the fixture is powered. Dangerous voltage may be present on the primary and

secondary sides of the isolation transformer.

Contact Crouse-Hinds Airport Lighting for assistance prior to operating a failed fixture. There may be dangerous voltage present on

the input AC pins of the power supply.

11.1 Bluetooth Access Instructions

Contact Crouse-Hinds Airport Lighting to obtain a copy of the application software for supported devices and assistance with installation.

IMPORTANT:

IMPORTANT

The lighting fixture to be accessed must be powered and can only be accessed during the first one hour of operation. You need to be within

10 to 20 feet of the lighting fixture to connect to it.

Turn on the application and press the Scan button located at the bottom of the screen.

Any fixtures within the range of the hand held device will appear on the screen. The fixtures will be listed by signal strength. The strongest signal should be the closest. Wait for the scanning process to complete or press the Stop button at the bottom of the screen to continue.

Press the Connect button of the desired fixture. Enter the pin number, factory set: 529194. The pin number can be changed

through the Configuration Menu if desired.

The light from the fixture will shut off for a few seconds to indicate connection. The Main Menu will open on the screen.

DOCUMENT 1154REV. E

Instruction Manual


13

Chose the Configuration Menu to set: o Blink Phasing; Odd, Even, Alternate o Blinking Ramp rate; how fast it transitions o Turn blinking off

Choose the Diagnostics Menu to check: o Operating Data to see current step the fixture reads o Temperature Data to see temperature in the fixture o Operating Hours for a running total at each current step o Error Logs for under/over current occurrences o Firmware revision

11.2 Visual Inspection

Follow the steps in Section 10.8 to open the fixture. Verify that all wires are not pinched or damaged and that the wire insulation is intact. Verify the input AC is connected to the feed thru (see Figures 6 & 7). Verify the power supply connections and appropriate jumper setting (see Figure 1 & Table 1).

Figure 1: Power Supply Connections

IMPORTANT:

DOCUMENT 1154REV. E

Instruction Manual


14

IMPORTANT

The heater will remain on indefinitely with the temperature sensor disconnected.

Replace any damaged or burned cables. Replace damaged LED module(s) per Section 10.4. Replace damaged power supply per Section 10.9. Replace damaged expansion boards per Section 10.8. Refer to Section 12 to determine the appropriate replacement kit(s) for your light unit(s).

NOTICE:

NOTICE

J400, J401 and J501 on the expansion board are not used on the L852G.

The jumper used on L852G sets the ‘first on’ or ‘first off’ option only. Reference Table 1 for jumper settings. A power supply with no jumper

will default to ‘first on’.

11.3 Electrical Inspection

WARNING:

WARNING

Contact Crouse-Hinds Airport Lighting for assistance prior to operating a failed fixture. There may be dangerous voltage present on the input AC

pins of the power supply.

It is recommended that a ferro style constant current regulator (2.8 to 6.6ARMS) with a 30/45W isolation transformer or a voltage limited

constant DC current source be used to test failed fixtures to limit the input voltage.

A buzzing or humming noise coming from the isolation transformer may indicate a failed power supply or LED module. It is also an indicator of

dangerous voltage on the primary and secondary sides of the transformer.

NOTICE:

DOCUMENT 1154REV. E

Instruction Manual


15

NOTICE

Applying a constant voltage greater than 50V (AC or DC) to the input will cause damage to the power supply.

Applying input current to the power supply without the heater or jumper

installed will cause damage to the power supply.

The expansion board used on the L852G will block direct sight of the status LED.

Follow the steps in Section 10.8 to open the fixture.

The power supply continuously monitors the status of the LED module. There is a green status LED (see Figure 2) that may be visible through the potting. A blinking LED indicates the power supply has detected a fault condition.

Fault conditions include:

Disconnected or ‘Open’ LED module o Replace cable if damaged or ‘open’.

More than 25% of the driven LED ‘Shorted’ o Replace LED module per Section 10.4.

Figure 2: Power Supply Status LED Location

If the status LED is not visible or not lit, replace the power supply per Section 10.9 or contact Crouse-Hinds Airport Lighting Products for assistance. Refer to Section 12 to determine the appropriate replacement kit(s) for your light unit(s).

DOCUMENT 1154REV. E

Instruction Manual


16

12 Spare/Replacement Parts List

Item Part Number Description

LED Module Replacements*

1 21673‐1 852G‐AP1 LED Module Replacement Kit, QTY 1 LED Module

2 21673‐3 852G‐AP1 LED Module Replacement Kit, QTY 3 LED Module

Lens Replacements

3 21674‐1 852G‐AP1 Lens Replacement Kit, Replaces QTY 1 Lens

4 21674‐3 852G‐AP1 Lens Replacement Kit, Replaces QTY 3 Lens

5 21674‐1‐AK 852G‐AP1 Arctic Kit Replacement Kit, Replaces QTY 1 Arctic Kit

6 21674‐3‐AK 852G‐AP1 Arctic Kit Replacement Kit, Replaces QTY 3 Arctic Kit

Power Supply Replacements*

7 21675 852G‐AP1 Power Supply Replacement Kit

8 21675‐AK 852G‐AP1 Power Supply Replacement Kit, Arctic Kit Support

Expansion Board Replacements

9 21676 852G‐AP1 Power Supply Expansion Board Replacement Kit

Feed‐thru Assembly

10 K3326992 Lead Assembly

O‐Ring, Optical Housing

11 21385 O‐Ring, 852G Optical Assembly Seal

2‐Piece Lock Washer Kit

DOCUMENT 1154REV. E

Instruction Manual


17

12 21647‐6 2‐Piece Washer Replacement Kit, QTY 6 (For mounting 852G optical assembly to light base. *Washers Included with LED module and power supply replacement kits.)

13 21647‐XXXX 2‐Piece Washer Replacement Kit, Customer Specified QTY

DOCUMENT 1154REV. E

Instruction Manual


18

13 Figures and Tables

Figure 3: Isometric View of Light Unit

DOCUMENT 1154REV. E

Instruction Manual


19

Figure 4: Top View with Reference Dimensions

DOCUMENT 1154REV. E

Instruction Manual


20

Figure 5: Section View A-A

Power Supply

LED Module

Primary Lens Components See figure 10

DOCUMENT 1154REV. E

Instruction Manual


21

Figure 6: Front View with Reference Dimensions

Feed‐thru fitting with knurled collar

DOCUMENT 1154REV. E

Instruction Manual


22

Figure 7: Installation View of Inner Cover

Expansion Board

Power Supply

Contact Closure Cables

P2 Feed Thru Terminals

AC Input Cable

AC Input Feed Thru Terminals

DOCUMENT 1154REV. E

Instruction Manual


23

Figure 8: Component Installation Side of Optical Housing

Lamp label

DOCUMENT 1154REV. E

Instruction Manual


24

Figure 9: Component Installation Side of Optical Housing w/ Arctic Kit

Heater strain relief washer and tie‐down

Artic kit prism heater

Clearance‐cut gasket

DOCUMENT 1154REV. E

Instruction Manual


25

Figure 10: Exploded View of Lens Replacement Components

DOCUMENT 1154REV. E

Instruction Manual


26

Figure 11: L-852G, P1 Configuration, Without Heater

Figure 12: L-852G, P1 Configuration, With Heater

DOCUMENT 1154REV. E

Instruction Manual


27

Figure 13: L-852G, P2 Configuration, Without Heater

Figure 14: L-852G, P2 Configuration, With Heater

DOCUMENT 1154REV. E

Instruction Manual


28

Light unit Part Number J203 Jumper Setting

L852G 852G‐AP1‐YO‐F1‐12U‐PX‐X‐0 19 17 15 13 11 9 7 5 3 1

20 18 16 14 12 10 8 4 2

852G‐AP1‐YF‐F1‐12U‐PX‐X‐0 19 17 15 13 11 9 7 5 3 1

20 18 16 14 12 10 8 4 2

Table 1: Light Unit Part Numbers and Jumper Settings

Light Unit Part Number Used with Logitrac Watts (Isolation XFMR @6.6A)

852G‐AP1‐YX‐F1‐12U‐PX‐0‐0 No 30/45

Yes 65

852G‐AP1‐YX‐F1‐12U‐PX‐1‐0 No 100

Yes 100

Table 2: L852G Minimum Isolation Transformer Power

1154 (rev e) - cooper industries manual pro apf led inset runway guard light faa type l-852g iii 2...

Documents