AirTAPAirTAP Fall Forum Fall ForumAirport Lighting MaintenanceAirport Lighting Maintenance

Oct. 17, 2007Oct. 17, 2007

University of MinnesotaUniversity of Minnesota

Transportation ResearchTransportation Research

Airport Technical Assistance ProgramAirport Technical Assistance Program

Prepared by:Prepared by:

John SchroederJohn Schroeder

Mn/DOT - AeronauticsMn/DOT - Aeronautics

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What You Will LearnWhat You Will Learn

Lighting Equipment Examples/SpecsLighting Equipment Examples/Specs

Equipment Installation ProceduresEquipment Installation Procedures

Techniques for Routine MaintenanceTechniques for Routine Maintenance

Techniques for Advanced MaintenanceTechniques for Advanced Maintenance

What Newly Applied Technology is on theWhat Newly Applied Technology is on theMarketMarket

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Typical Lighting Equipment Typical Lighting Equipment

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Examples of Light IntensitiesExamples of Light Intensities

MIRL 45 watt white lamp - 125 CandelaMIRL 45 watt white lamp - 125 Candela

HIRL 125 watt quartz halogen - 10,000 HIRL 125 watt quartz halogen - 10,000 CdCd..

REIL strobe light - 10,000 to 20,000 REIL strobe light - 10,000 to 20,000 CdCd. . •• REIL - Runway End Identifier LightREIL - Runway End Identifier Light

Beacon - 50,000 CandelaBeacon - 50,000 Candela

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FAA GL600-1FAA GL600-1Typical Installation DrawingsTypical Installation Drawings

Provide recommended layouts forProvide recommended layouts forequipment locationequipment location

Provide details for footingsProvide details for footings

Provide details for installation of wiringProvide details for installation of wiring

Provide standards for alignmentProvide standards for alignment

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Base Can Installation DetailBase Can Installation Detail

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Stake Mount Installation DetailStake Mount Installation Detail

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Water Proof Cable Splice DetailWater Proof Cable Splice Detail

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Guidance Sign Installation DetailGuidance Sign Installation Detail

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REIL Installation DetailREIL Installation Detail

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PAPI Footing Installation DetailPAPI Footing Installation Detail

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VASI Installation Footing DetailVASI Installation Footing Detail

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ConsultantConsultant’’s Projects ProjectSpecifications and PlansSpecifications and Plans

In The Electrical SectionIn The Electrical Section•• Installation of underground cablesInstallation of underground cables

–– Equipment and MaterialsEquipment and Materials–– Electrical cable, Counterpoise, cable connectionsElectrical cable, Counterpoise, cable connections

–– Construction MethodsConstruction Methods–– Installation of cable in duct or conduitInstallation of cable in duct or conduit

–– Trenching, wire installation & back fillingTrenching, wire installation & back filling

–– Cable plowingCable plowing

–– Cable markersCable markers

–– Splicing & testingSplicing & testing

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ConsultantConsultant’’s Projects ProjectSpecifications and Plans Cont.Specifications and Plans Cont.

In The Electrical SectionIn The Electrical Section•• Installation of Airport Underground ElectricalInstallation of Airport Underground Electrical

DuctDuct–– Steel ConduitSteel Conduit

–– Plastic ConduitPlastic Conduit

•• Construction MethodsConstruction Methods–– Installing ducts without concrete encasementInstalling ducts without concrete encasement

–– Duct markersDuct markers

–– Back fillingBack filling

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In The Electrical SectionIn The Electrical Section•• Installation of airport Lighting SystemsInstallation of airport Lighting Systems

–– Insulating tape - Scotch tape Numbers 23 & 88Insulating tape - Scotch tape Numbers 23 & 88

–– Light bases - FAA type L-867Light bases - FAA type L-867

–– Isolation Transformers - FAA type L-830Isolation Transformers - FAA type L-830

–– RetroreflectiveRetroreflective markers markers

–– MIRL, MITL Light Fixtures - L861, L861E, L861TMIRL, MITL Light Fixtures - L861, L861E, L861T

–– Constant Current regulators - L828Constant Current regulators - L828

–– Electrical Vault - L854, S-1 Cutouts, Contactors, etcElectrical Vault - L854, S-1 Cutouts, Contactors, etc

ConsultantConsultant’’s Projects ProjectSpecifications and Plans Cont.Specifications and Plans Cont.

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Lighting Installation OverviewLighting Installation Overview

Complete runway/taxiway surfacesComplete runway/taxiway surfaces

Survey station locations of all edge lights,Survey station locations of all edge lights,REILS, VASIS or PAPIS, guidance signs,REILS, VASIS or PAPIS, guidance signs,windconewindcone, beacon , duct banks, & markers, beacon , duct banks, & markers

Auger holes for all base or junction cansAuger holes for all base or junction cans

Trench or plow series circuit wires (duct)Trench or plow series circuit wires (duct)

Tamp hole bottoms & install Pea rockTamp hole bottoms & install Pea rock

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Lighting Installation OverviewLighting Installation OverviewContinuedContinued

Install SONOTUBES around cans & PourInstall SONOTUBES around cans & Pourconcrete surrounds, pads, & all footingsconcrete surrounds, pads, & all footings

Complete trenching to cansComplete trenching to cans

Install wiring to cans- precut and labelInstall wiring to cans- precut and label

Install can covers and light fixturesInstall can covers and light fixtures

Install & align VASI, PAPI, REILS, and signsInstall & align VASI, PAPI, REILS, and signs

Install Install windconewindcone and beacon structures and beacon structures

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Lighting Installation OverviewLighting Installation OverviewContinuedContinued

Install regulators, Install regulators, panelboardspanelboards, L854 relay, L854 relaycontroller, contactors & S-1 Cutouts in Vaultcontroller, contactors & S-1 Cutouts in Vault

Test systemTest system

Provide spare sets of Inst. & Provide spare sets of Inst. & MaintMaint docs. docs.

PrefinalPrefinal and final inspection and final inspection•• Punch ListsPunch Lists

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Installation - Base Can AugerInstallation - Base Can Auger

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Installation - UNIDUCT on RollInstallation - UNIDUCT on Roll

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Installation - Duct GrabberInstallation - Duct Grabber

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Installation - Plowing UNIDUCTInstallation - Plowing UNIDUCT

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Installation - UNIDUCT W/WireInstallation - UNIDUCT W/WirePull Cord at Can HolePull Cord at Can Hole

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Installation - Plowing WireInstallation - Plowing Wire

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INSTALLATION - Plowing WireINSTALLATION - Plowing Wire

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Installation - Trenching to CanInstallation - Trenching to Can

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Installation - Wiring Installed inInstallation - Wiring Installed inCanCan

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Installation - Sign FormsInstallation - Sign Forms

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Installation - Duct LocationInstallation - Duct LocationMarkersMarkers

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Installation - PAPI at WorthingtonInstallation - PAPI at Worthington

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Installation - REIL at WorthingtonInstallation - REIL at Worthington

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Installation - MALS Threshold BarInstallation - MALS Threshold Barat Warroadat Warroad

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Installation - MALS Station 1000Installation - MALS Station 1000ft. Bar at Warroadft. Bar at Warroad

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Installations - Gone WrongInstallations - Gone WrongVASI at Redwood FallsVASI at Redwood Falls

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Installations - Gone WrongInstallations - Gone WrongSign Pad at LongvilleSign Pad at Longville

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Installations - Gone WrongInstallations - Gone WrongVASI at VASI at HallockHallock

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Installations - Gone WrongInstallations - Gone WrongLight Base at LongvilleLight Base at Longville

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Installations - Gone WrongInstallations - Gone WrongLight Base at EvelethLight Base at Eveleth

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Installations - Gone WrongInstallations - Gone WrongVASI at WarroadVASI at Warroad

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Installations - Gone WrongInstallations - Gone WrongPAPI at EvelethPAPI at Eveleth

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Installations - Gone WrongInstallations - Gone WrongREIL footing at AitkinREIL footing at Aitkin

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REIL Installed too Low to GroundREIL Installed too Low to Ground

Area has poorArea has poordrainagedrainage

Water ponds underWater ponds underREIL and enters cab.REIL and enters cab.

PCA assembliesPCA assembliesCorrodeCorrode

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TRAILWAY INCURSIONSTRAILWAY INCURSIONS

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Techniques for RoutineTechniques for RoutineMaintenanceMaintenance

Typical Routine Maintenance IssuesTypical Routine Maintenance Issues•• Lamp replacementLamp replacement

•• Frangible coupling replacementFrangible coupling replacement

•• Lens, lamp, and filter cleaningLens, lamp, and filter cleaning

•• Rodent entry - insulation damageRodent entry - insulation damage

•• Cabinet rust - Cabinet rust - periodically oil theperiodically oil the hinges hinges

•• Windsock replacement- State distributionWindsock replacement- State distributionprogprog

•• Grass cutting and Snow removal Grass cutting and Snow removal

•• VASI and PAPI alignmentVASI and PAPI alignment

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Techniques for RoutineTechniques for RoutineMaintenance ContinuedMaintenance Continued

Rotating Beacon Pole Base AttachmentRotating Beacon Pole Base Attachment•• Typically (Four) 1 Typically (Four) 1 –– 1.25 In. Bolts 1.25 In. Bolts

•• Check For Broken Bolts In Concrete Footing byCheck For Broken Bolts In Concrete Footing byNut TighteningNut Tightening

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Lamp ReplacementLamp Replacement

Always Disable powerAlways Disable powerbefore re-lampingbefore re-lamping

Wear clean glovesWear clean gloves

On some voltage fedOn some voltage fedVASI - GrasshopperVASI - Grasshopperfuse blows when lampfuse blows when lampburns out - keepsburns out - keepsother two lamps litother two lamps lit

New lamp will be dimNew lamp will be dimif fuse not replacedif fuse not replaced

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Lamp ProcurementLamp Procurement

State Contract with J. H. Larson Electrical inState Contract with J. H. Larson Electrical inGolden Valley (Golden Valley (OsramOsram Sylvania) Sylvania)

Some types not available at discount likeSome types not available at discount likeGE and Manufacturer sourcedGE and Manufacturer sourced

Better Prices from Better Prices from Bulbs.comBulbs.com and Genesis and Genesislamp (888-455-2800 & 800-685-5267)lamp (888-455-2800 & 800-685-5267)

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Frangible Coupling ReplacementFrangible Coupling Replacement

Used the correctUsed the correctreplacementreplacement

Avoid FiberglassAvoid Fiberglasscouplingscouplings

Apply Apply ““Anti SeizeAnti Seize””grease to threadsgrease to threads

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Couplings - Waiting to beCouplings - Waiting to beReplacedReplaced

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Examples of Snow RemovalExamples of Snow Removal

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Examples of Snow Removal Cont.Examples of Snow Removal Cont.

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Examples of Grass CuttingExamples of Grass Cutting

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VASI AlignmentVASI Alignment

Use Walker barUse Walker bar•• Check tool calibrationCheck tool calibration

•• Check Frangible Check Frangible CplgsCplgs

•• Set upwind at 3 deg.Set upwind at 3 deg.

•• Set downwind at 2.5 DgSet downwind at 2.5 Dg

•• Level Horizontally Level Horizontally FrontFront& Back of & Back of CabimetCabimet

•• Align tilt SW to levelAlign tilt SW to level

•• Verify tilt circuit worksVerify tilt circuit works

•• Verify day/night modeVerify day/night mode

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Aligned VASI Indication to PilotAligned VASI Indication to Pilot

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VASI APPROACH - OBSTACLEVASI APPROACH - OBSTACLECLEARANCECLEARANCE

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Additional VASI MaintenanceAdditional VASI Maintenance

Repaint Black contrasting for better visibilityRepaint Black contrasting for better visibility

Screen-in bottom of units to keep out birds/miceScreen-in bottom of units to keep out birds/mice

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PAPI AlignmentPAPI Alignment

Check calibration ofCheck calibration ofalignment toolalignment tool

Align unit nearest r/wAlign unit nearest r/wedge to 3 deg 30 min.edge to 3 deg 30 min.

Next unit to 3 deg 10 mNext unit to 3 deg 10 m

Next unit to 2 deg 50 mNext unit to 2 deg 50 m

Outer unit to 2 dg 30 mOuter unit to 2 dg 30 m

Verify horizontal levelVerify horizontal level

Align tilt Align tilt asmasm to level to level

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Aligned PAPI Indication to PilotAligned PAPI Indication to Pilot

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PAPI APPROACHPAPI APPROACH

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REILS ON APPROACHREILS ON APPROACH

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Techniques for AdvancedTechniques for AdvancedMaintenanceMaintenance

Advanced Maintenance IssuesAdvanced Maintenance Issues•• NOTAM OTS Equipment: Call FSS 1-877-487-6867NOTAM OTS Equipment: Call FSS 1-877-487-6867

•• Lightning damage to electronic assembliesLightning damage to electronic assemblies

•• Series circuit isolation transformer failuresSeries circuit isolation transformer failures

•• Electrical cable connector failuresElectrical cable connector failures

•• Guidance sign or Regulator current adjustmentGuidance sign or Regulator current adjustment

•• Series Circuit and unit TroubleshootingSeries Circuit and unit Troubleshooting

•• REIL, PAPI, VASI, and Power control TroubleshootingREIL, PAPI, VASI, and Power control Troubleshooting

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Lightning Damage to REIL PCALightning Damage to REIL PCA

Lightning enteredLightning enteredunderground powerunderground powercircuitcircuit

ReplacementReplacementavailable thruavailable thrumanufacturermanufacturer

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Series Circuit TroubleshootingSeries Circuit Troubleshooting

If Not qualified, call an electricianIf Not qualified, call an electrician•• Open circuit voltages in the loop are Open circuit voltages in the loop are FATALFATAL

•• You need a foolproof safety routineYou need a foolproof safety routine–– Shut down regulator(s) circuit breakerShut down regulator(s) circuit breaker

–– Take Plug cut-out units with you in the truckTake Plug cut-out units with you in the truck

–– Lock the electrical vaultLock the electrical vault

–– Always assume the circuit is energizedAlways assume the circuit is energized

•• Consult FAA Advisory 150/5340-26Consult FAA Advisory 150/5340-26Maintenance of Airport Visual AidsMaintenance of Airport Visual Aids

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Lighting 6.6 Amp Series CircuitLighting 6.6 Amp Series Circuit

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Series Circuit Series Circuit ““S1S1”” Cut-Out Cut-Out

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Guidance Sign or RegulatorGuidance Sign or RegulatorCurrent AdjustmentCurrent Adjustment

For Qualified personnel onlyFor Qualified personnel only•• Using a true RMS digital meter and clampUsing a true RMS digital meter and clamp

around wire current probe verify regulatoraround wire current probe verify regulatoroutput or sign lamp currentoutput or sign lamp current

–– lamp life time is half if current is only 5% highlamp life time is half if current is only 5% high

•• Adjust current level pots in Guidance signs toAdjust current level pots in Guidance signs tomanufacturers specs.manufacturers specs.

•• Set regulator to manual modeSet regulator to manual mode

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Properties of Tungsten FilamentsProperties of Tungsten Filaments

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RegulatorRegulator

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REIL TroubleshootingREIL Troubleshooting

For QualifiedFor Qualifiedpersonnalpersonnal only only

Some Brands haveSome Brands haveswapableswapable modules modules

Ensure power is offEnsure power is off

Ensure Ensure HV HV bleeddownbleeddownWhen cabinet door isWhen cabinet door isopened.opened.

Allow 1 minute to passAllow 1 minute to passbefore swapping partsbefore swapping parts

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REIL Cabinet Intrusion ProtectionREIL Cabinet Intrusion Protection

Pad locked for safetyPad locked for safety

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VASI Troubleshooting DiagramsVASI Troubleshooting DiagramsVoltage PoweredVoltage Powered

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VASI Troubleshooting DiagramVASI Troubleshooting DiagramRegulator PoweredRegulator Powered

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PAPI TroubleshootingPAPI Troubleshooting

Manufacturers Troubleshooting ChartManufacturers Troubleshooting Chart

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Troubleshooting With LadderTroubleshooting With LadderDiagramsDiagrams

L-854 Relay Controller (Pilot Controlled Lighting)L-854 Relay Controller (Pilot Controlled Lighting)

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Newly Applied TechnologyNewly Applied Technology

IGBT Power Factor Improved RegulatorsIGBT Power Factor Improved Regulators

Light Emitting Diode IlluminationLight Emitting Diode Illumination•• LED lighted windsocks LED lighted windsocks –– HALI-BRITE, Inc. HALI-BRITE, Inc.

•• FAA certified blue taxiway edge lightsFAA certified blue taxiway edge lights

•• FAA certified obstruction lightsFAA certified obstruction lights

•• Solar powered blue taxiway edge lightsSolar powered blue taxiway edge lights

•• White, red and White, red and greengreen MIRL edge lights in the process of MIRL edge lights in the process ofbeing certifiedbeing certified

Ultra Low Bandwidth Remote lamp MonitorUltra Low Bandwidth Remote lamp Monitor

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IGBT RegulatorsIGBT Regulators

Higher efficiency thru high power factorHigher efficiency thru high power factor

Close to sine wave current output Close to sine wave current output vsvs square squarewave outputwave output

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LED Illuminating TechnologyLED Illuminating Technology

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LED Illumination TechnologyLED Illumination Technology

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Light DefinitionsLight Definitions

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Lamp Lumen Evolution - Source:Lamp Lumen Evolution - Source:Display & Indicators - Display & Indicators - PentonPenton Pub Pub

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IlluminanceIlluminance Conversion Chart Conversion Chart Source: EIS Source: EIS LtgLtg handbook 8th ed. handbook 8th ed.

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Luminance Conversion ChartLuminance Conversion Chart(Source: EIS (Source: EIS LtgLtg handbook 8th ed) handbook 8th ed)

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Remote Lamp Monitoring SystemRemote Lamp Monitoring System

Detection of very low frequency signalsDetection of very low frequency signalsover regulator or 120 VAC circuitover regulator or 120 VAC circuit•• Each lamp has a transmitter which is on aEach lamp has a transmitter which is on a

different frequencydifferent frequency

•• Receiver board has current loop detectorReceiver board has current loop detector

•• PC or Embedded Processor looks for presencePC or Embedded Processor looks for presenceof known quantity of transmittersof known quantity of transmitters

•• Reports location of burnt out lampsReports location of burnt out lamps

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Remote Lamp Monitoring SystemRemote Lamp Monitoring SystemContinuedContinued

Can monitor over 100 lamps per receiverCan monitor over 100 lamps per receiver

Additional receivers for additional circuitsAdditional receivers for additional circuits(regulators)(regulators)

Can monitor runway lights, VASI, PAPI,Can monitor runway lights, VASI, PAPI,WindconeWindcone, Beacon, MALSR, Beacon, MALSR

Keeps data logsKeeps data logs

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THATTHAT’’S ALL THERE ISS ALL THERE IS……. THANK YOU!. THANK YOU!