Instruction Manual - Cooper Industries · Instruction Manual PRO APF IN-PAVEMNT OMNI-DIRECTIONAL UTILITY LIGHT vi 3 Safety Notices This equipment is normally used or connected to

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Instruction Manual

PRO APF SERIES

IN-PAVEMENT

OMNI-DIRECTIONAL UTILITY LIGHT

Eaton Crouse-Hinds Series

Airport Lighting Products

1200 Kennedy Road

Windsor, CT 06095

Copyright © 2016 Cooper Technologies Company

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Table of Contents

1 Revisions ............................................................................................................................... iv

2 Product Warranty .................................................................................................................... v

3 Safety Notices ........................................................................................................................ vi

3.1 Keep Away from Live Circuits ....................................................................................... vi

3.2 RESUSCITATION ......................................................................................................... vi

4 Safety Symbols .................................................................................................................... vii

4.1 Danger ........................................................................................................................... vii

4.2 Warning ......................................................................................................................... vii

4.3 Caution .......................................................................................................................... vii

4.4 Warning: Notice ............................................................................................................ vii

4.5 Warning: Important ....................................................................................................... vii

5 Recommended Test Equipment and Tools ......................................................................... viii

6 General Information ............................................................................................................... 1

6.1 General Description – Taxiway Omni-Directional Light ................................................. 1

Table 1, Part number Explanation .................................................................................................. 3

Figure 1, Fixture Dimensions ......................................................................................................... 4

7 Installation .............................................................................................................................. 5

7.1 ANSI Installation Bolt Torque and Installation Method .................................................. 7

7.2 Heico-Lock Installation Guide (2014) ............................................................................. 8

Figure 2, 19999 Installation (Lifting) Tool ..................................................................................... 9

8 Maintenance .......................................................................................................................... 10

8.1 General ........................................................................................................................... 10

8.2 Recommended Spares .................................................................................................... 10

8.3 Cleaning Lens ................................................................................................................ 11

8.4 O-Ring Replacement ...................................................................................................... 11

8.5 Feed-thru Replacement .................................................................................................. 12

8.6 Outer Lens/Heater Replacement .................................................................................... 12

8.7 LED Replacement .......................................................................................................... 13

8.8 Power Supply Replacement (Series Circuit Powered Units) ......................................... 14

8.9 Power Supply Replacement (Voltage Powered Fixtures) .............................................. 15

8.10 8 Inch Fixture External Gasket Replacement ................................................................. 15

8.11 Pressure Test .................................................................................................................. 16

8.12 Cleanliness and Workmanship ....................................................................................... 16

8.13 Maintenance Program .................................................................................................... 16

9 Troubleshooting .................................................................................................................... 18

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9.1 Visual Inspection ............................................................................................................ 18

9.2 Electrical Inspection, Series Circuit Powered Fixtures .................................................. 18

Figure 3, Power Supply, Series Circuit Fixtures ........................................................................... 19

Wiring Diagrams, Series Circuit Powered Fixtures ...................................................................... 20

Jumper Diagram, Series Circuit Powered Fixture ........................................................................ 21

Figure 4, Part Identification ......................................................................................................... 22

10 Fixture Mounting Bolts & 2-Piece Washers ......................................................................... 30

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1 Revisions

Rev.

No.

Issue/Reissue

Number Letter Description Checked Approved

A A216-212 Initial release PG 6/1/16

B A216-365

Page 4, Fig 852UL-AP1-XXX-12X, Added base flange

diameter “Z”, Ø9.94 for -12A & -12C versions &

Ø9.19 for -12B & -12D versions.

IM 10/5/16

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2 Product Warranty

Warranty Refer to Eaton’s Crouse-Hinds Airport Lighting Products Terms and Conditions for product

specific warranty information.

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3 Safety Notices

This equipment is normally used or connected to circuits that may employ voltages which

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:

3.1 Keep Away from Live Circuits

Operating and maintenance personnel must at all times observe all safety regulations. Do

not perform maintenance on internal components or service with power ON.

DANGER:

DANGER DO NOT PERFORM MAINTENANCE ON INTERNAL

COMPONENTS OR SERVICE WITH POWER ON.

3.2 RESUSCITATION

Maintenance personnel should familiarize themselves with the technique for resuscitation

found in widely published manuals of first aid instruction.

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4 Safety Symbols

4.1 Danger

DANGER:

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

4.2 Warning

WARNING:

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

4.3 Caution

CAUTION:

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

4.4 Warning: Notice

WARNING:

NOTICE Possibly dangerous situation, goods might be damaged.

4.5 Warning: Important

WARNING:

IMPORTANT Helpful information.

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5 Recommended 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 a specialized equipment needed to do the job.

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 quality meter in good repair and calibration 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 reading may dramatically reduce lamp life and

adversely affect power equipment performance. A meter with TRUE RMS measuring capability

with a current clamp-on accessory is needed to accurately measure distorted or chopped

waveforms. All meter manufacturers offer TRUE RMS measuring meters. The following is a

short list of TRUE RMS Multimeters from Fluke:

Manufacturer Model Number

Fluke 287

Our recommended multimeter is the Fluke 287 with the Fluke I800 current clamp accessory.

Refer to the equipment manufacturer’s manuals for the proper use, maintenance and calibration

(if necessary) of all meters.

Thread Lubricant

Anti-seize (marine grade preferred, Henkel/Loctite P/N 34395 or 34026 or equal customer

supplied [ http://www.henkelna.com/adhesives/product-search-

1554.htm?nodeid=8797882515457]) with a K factor of 0.18 for fully coating the fixture

installation bolts.

Drive and Ratchet

A 3/8 inch square drive socket and ratchet (use ratchet for loosening bolts only and a torque

wrench to tighten), size 9/16 or 14 mm for the fixture 3/8-16 UNC hex installation (customer

supplied) bolts installed into a FAA L-867 or L-868 base.

Torque Wrench

A calibrated torque wrench (micrometer adjustable solid audible/tactile “click” impulse when

torque value attained with an accuracy of +/- 4%) to fit a 9/16 or 14 mm socket for drive size of

the socket to tighten the fixture hex bolts per Sections 7.1 and 7.2. Torque wrenches: Sturtevant

Richmont P/N 810748, range 100 to 600 in-lbs or equal, or Sturtevant Richmont P/N 810782,

http://www.henkelna.com/adhesives/product-search-1554.htm?nodeid=8797882515457

http://www.henkelna.com/adhesives/product-search-1554.htm?nodeid=8797882515457

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range 10 to 50 Nm or equal. Certificate of calibration included with suggested torque wrenches.

Note, never loosen bolts with a torque wrench.

Torque Screwdriver

A calibrated adjustable torque screwdriver to torque the smaller internal hardware and the

bottom cover external screws if the fixture is opened for maintenance. Sturtevant Richmont P/N

810568 (comes with bits [hex, slotted, Torx, Phillips, sq. recess, bit holder, socket adapter], case and

certificate of calibration), range 2 to 36 in-lbs/0.2 to 4 Nm or equal. Note, never loosen screws with a

torque screwdriver.

Pliers

Needle nose pliers for installing the extremely small header jumper onto a spare Power Supply

J203 header when required, or removing the flag type fast-on terminals from the power supply.

Xcelite P/N NN54-2 miniature pliers, fine needle nose, ESD-Safe or equal.

ESD Protection

A grounded ESD Wrist Strap when working on or handling fixture power supplies or LED/Heat

sink assemblies. ESD Wrist Straps, also known as anti-static Wrist Straps, are used to prevent

electrostatic discharge (ESD) by safely grounding a person working with electronic equipment or

at an electronic assembly facility. It consists of a band of fabric with fine conductive fibers

woven into it. The fibers are usually made of carbon-filled rubber, and the strap is bound with a

stainless steel clasp or plate. They a usually used in conjunction with an ESD table mat on the

workbench, or a special static-dissipating plastic laminate on the workbench. ESD Products

brand ( http://www.esdproduct.com/esd_wrist_straps.php ) or equal.

Fixture Installation/ Removal Tool

A Crouse-Hinds P/N 19999 installation tool to aid in the installation and removal of 12 inch

diameter fixtures (only available from Crouse-Hinds).

Most tools indicated above can be purchased from MSC Industrial Supply Co. (

http://www.mscdirect.com/ ), or McMaster-Carr ( http://www.mcmaster.com/ ).

http://www.esdproduct.com/esd_wrist_straps.php

http://www.mscdirect.com/

http://www.mcmaster.com/

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6 General Information

6.1 General Description – Taxiway Omni-Directional Light

The Crouse-Hinds Utility Light part number 852UL-AP1-XXX-XXX is a Omni-directional Style

3 in-pavement fixture per FAA AC 150/5345-46 (latest revision). It is designed for installation

at the taxiway edge or any other location where visual guidance of moving aircraft or ground

vehicles is desirable. The fixture is designed to fit on a FAA L-868, size B (-12A) or FAA L-

867 size B (-12B) light base per FAA AC 150/5345-42 (latest version), and have a total height

above grade/ground level of .250 inch. Part Number 852-AP1-008 fits Crouse-Hinds Shallow

Bases 21431-X-X. The fixture is Omni-directional, projecting the beam of light 360° in the

horizontal direction. It is weatherproof and will endure roll over loads without damage. The

LED “AP1” series circuit power supply can be used with either a 3 (4.8, 5.5, 6.6A output) or 5

step (2.8, 3.4, 4.1, 5.2, 6.6A output) Constant Current Regulator (CCR), 50 or 60 Hz. The power

supply has a power factor of 0.99 in all steps, and an efficiency greater than 80% at 6.6A. The

series circuit power supply is compatible with all known CCR types, has a 3.5 crest factor to

ensure compatibility with series CCRs, has a 0.88 second switch-on time, a typical initial turn on

voltage of 1.5V, high frequency 400 Hz PWM to help eliminate flicker perception, and a

10k/5kA surge protection.

The LED(s) have a projected life of greater than L70 (L70 = elapsed operating time in hours

over which the LED light source maintains 70% of its initial output) @ 50,000 hours at 6.6A. If

an Arctic Kit is ordered (available on 6.6A units only) with the fixture, it will comply with the

requirements of FAA EB67 (latest), which will raise the light emitting surface temperature 15

degree C (59 degrees F) after 30 minutes of operation at the CCR high step of 6.6A. The arctic

kit heating filament is applied directly to the glass dome interior and does not obstruct the

photometric output. Units can be supplied with a parallel powered (voltage) LED supply for

12VDC, 24VDC and 100-277VAC. Parallel powered units are not available with Artic Kits. All

fixtures are factory illuminated.

The light fixture consists of a 1-piece aluminum optical assembly. The 12 inch diameter

aluminum optical assembly is mounted to a FAA size B light base with six bolts and six 2-piece

locking washers (order separately, see Section 10). The 8 inch diameter aluminum optical

housing assembly is mounted to a Crouse-Hinds shallow base, P/N 21431-X-X (order separately)

which is supplied with mounting hardware. All fixtures have aluminum housing and a die cast

bottom cover that is attached using 4 screws. A O-ring is used to provide a watertight seal

between the inner cover and the optical housing. An LED module is secured to the lens bracket,

which is fastened to the optical housing. The power supply is secured to the inner cover using a

bracket. Electrical connections are made at one feed-thru assembly in the inner cover. The feed-

thru is a 2 conductor molded cable and has an ITS verified L-823 plug for connecting to FAA L-

830/ L-831 isolation transformer. Parallel powered (voltage) units are also supplied with a

secondary receptacle with two leads for the customer to make waterproof butt splices to to

introduce their power. The outer lens is held into the aluminum housing with a bracket, gasket,

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molded elastomeric boot and 12 screws. All hardware is type 18-8 stainless steel except for the

12 screws holding the outer lens bracket onto the aluminum housing, which are type 410 heat-

treated black oxide stainless steel. The complete 852UL-AP1-12A or 852UL-AP1-12B light unit

is 11.94 inches in diameter, 2.75 inches deep from grade, and weighs 10.5 lbs. The 8 inch unit is

the same depth as the 12 inch unit. The series powered (constant current) fixture requires a

minimum 6.6A/6.6A, 10/15 watt series isolation transformer without the arctic (heater) kit

(minimum 20/25 watt or 30/45 watt with the arctic kit).

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Table 1, Part number Explanation

852UL - AP1 - - - -

FIXTURE TYPE:

SERIES VERSION:

FIXTURE DIAMETER:

In-Pavement Utility Light

AP1 = Pro APF1

008 = 8" Fixture with mounting bolt pattern per IEC specifications

12A = 12" Fixture with 11.25" mounting BC for FAA L-868 base can12B = 12" fixture with 10.25" mounting BC for FAA L-867 base can

OPTIONS:

1 = Artic Kit (6.6A Input Units Only)

COLOR:

B = Blue (Not Available For 6.6A Units, Use P/N 852T-AP1)G = GreenY = YellowR = RedW = White

INPUT POWER:

066 = 6.6A Constant Current012 = 12VDC Input (Not Available With Option 1)024 = 24VDC Input (Not Available With Option 1)120 = 100-277 VAC Input (Not Available With Option 1)

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Figure 1, Fixture Dimensions

852UL-AP1-XXX-008

Note, there are two blind holes on the underside of the optical forging to accept the 21431

Shallow Base pins/studs.

852UL-AP1-XXX-12X

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7 Installation

WARNING:

NOTICE

852UL-AP1 base can pavement specifications and design are the

responsibility of the installer and/or airport. Transformer housing,

series isolation transformers, primary connector kits, heat shrink

kits, series loop primary wire, counterpoise cable/wire, grounding

rods, ground wire and connectors, waterproof splices, fixture

mounting bolts and 2-piece washers are not included as part of the

852UL-AP1. Additionally, the electrical power originating from the

CCR and any electrical equipment required to bring utility power or

generator power to the CCR or fixture(s) is the responsibility of the

installer and/or airport. Underlined items may be ordered from

Crouse-Hinds Airport Lighting. See Section 10 for mounting bolts

and 2-piece washer part numbers.

a. Refer to your agency’s your airport construction plans for installation and fixture spacing

recommendations.

DANGER:

DANGER

Lock out electrical power at its source that will power the fixture at its

source before attempting any electrical connections/splices per your

safety procedures.

WARNING:

IMPORTANT

Check the fixture for shipping damage upon arrival and in all cases,

check for damage prior to installation.

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CAUTION:

CAUTION

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

waterproof seal.

b. A list of tools which can help during installation are referenced in Section 5, “Recommended

Test Equipment and Tools”.

c. Check the fixture part number before installation to be sure it will be installed at the correct

location.

d. Be sure the correct series isolation transformer size is installed for the fixture; minimum

10/15 watt, 6.6/6.6A secondary without an arctic (heater) kit, or a minimum 20/25 watt or

30/45 watt 6.6/6.6A secondary for fixtures with the arctic kit installed if the fixture is series

circuit (CCR) powered.

WARNING:

IMPORTANT

Crouse-Hinds P/N 19999 will ease in the installation and removal of 12

inch diameter fixtures (see Figure 2). The threaded eyebolts on the

lifting tool screw into threaded holes in the fixture.

e. Plug the fixture’s L-823 plug into the series isolation transformer secondary receptacle

located in the base can if series powered. Apply electrical tape to this connection to keep

this secondary connection from possible disconnection in the base due to freeze/thaw cycles

that may occur from water intrusion into the base can. Note, if you are using a Crouse-

Hinds type SIB-8 Shallow Base, the series isolation transformer will not be located in the

shallow base. A secondary extension cable (length dependent on installation) will be

required to make the connection between the fixture and series isolation transformer

secondary plug and receptacle.

f. Plug the fixture’s L-823 plug into the supplied L-823 receptacle after waterproof butt splices

have been made to voltage power on parallel powered units. Note, for DC powered units,

the small diameter plug/receptacle pin is the positive (+) side. Failure to connect power

polarity correctly will result in power supply/LED damage.

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g. Verify that the mounting flange on the fixture base can is clean and the O-ring (optional on

deep cans) is coated with Dow Corning FS 1292 grease and is in place on the base can.

The 8 inch diameter fixture, P/N 852UL-AP1-XXX- 008 comes with a gasket on the bottom

cover exterior to seal it to a Crouse-Hinds Shallow Base having an inner bore diameter of

6.61 inches. This gasket should also be coated with the Dow Corning grease if using this

size fixture.

WARNING:

IMPORTANT

Failure to apply anti-seize to fixture mounting bolts at installation

may result in difficult removal of a mounting bolts and poor

clamping force. The correct “k” value anti-seize must be used in

addition to 2-piece locking washers as described in Section 7.1 to

maintain to correct boly clamping force.

h. Torque the fixture installation bolts per Section 7.1 instructions.

i. Return power to the circuit per your safety procedures.

7.1 ANSI Installation Bolt Torque and Installation Method

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 Advisory

Circular (AC)150/5345-30 (latest) and AC 150/5340-26 (latest) FAA Engineering

Brief (EB)83 (latest).

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 7.2 for Heico-Lock installation guidelines (2014)

Achieve a full final torque of 225 in-lb (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 AC 150/5345-26

(latest).

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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 bas

7.2 Heico-Lock Installation Guide (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.

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Figure 2, 19999 Installation (Lifting) Tool

(Note, fixture illustrated in not a Omni-Directional)

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8 Maintenance

8.1 General

The preferred method of maintaining a light unit is to periodically replace the unit and return it to

the maintenance shop for renovation. As an alternative, the optical assembly can be serviced in

the field. Work on electrical circuits should only be performed by qualified electricians with a

working knowledge of airfield lighting circuits. However, it is recommended that field servicing

be limited to bolt torque checks per Section 7.1 and cleaning the lens as described in Section 8.3.

Users should also reference FAA AC 150/5340-26 (latest), “Maintenance of Airport Visual Aid

Facilities” for their recommended practices for runway and taxiway edge lighting systems. A

list of tools which can help during maintenance are referenced in Section 5, “Recommended Test

Equipment and Tools”. Figure 4 will aid in part identification and in replacement part numbers.

8.2 Recommended Spares

The number of recommended spare fixtures is 2% installed at the airfield. If the quantity for each

type is less than 50, then at least two fixtures. The number of individual spare parts should be at

least 3% of the total fixtures installed at the airfield. This number may vary greatly if aggressive

snow removal operations occur.

WARNING:

IMPORTANT Do not open any light fixture unless the warranty period has expired.

Opening a light fixture will void the warranty.

DANGER:

DANGER

Lock out electrical power to the series loop that will power the fixture

at its source before attempting servicing to the fixture.

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DANGER:

DANGER

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.

WARNING:

WARNING

A buzzing or humming noise coming from the isolation transformer

may indicate a failed power supply or LED. It is also an indicator of

dangerous voltage on the primary and secondary sides of the isolation

transformer.

8.3 Cleaning Lens

Clean the outer surface of the glass lens 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 seal. A gentle

air blast may be used.

8.4 O-Ring Replacement

Every time the fixture is opened, the O-ring must be replaced.

WARNING:

IMPORTANT

Every time a fixture is opened, its O-ring and fixture exterior gasket

(present on 8 inch fixtures only) is recommended to be replaced. O-

rings and gaskets will develop a permanent deformation over time. A

bad O-ring is the most common cause of in-pavement fixture leaks.

Failure to replace them when the fixture is opened may result in a

fixture leak. Apply Dow Corning FS 1292 grease to the fixture O-ring

and exterior gasket.

Remove and secure power to the fixture. Remove and discard the old O-ring from the

groove in the optical housing using a plastic, or comparably soft, tool. Carefully clean the

O-ring groove and flange mating surface on the inner cover. Take care not to damage the

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mating surface or the new O-ring. Coat the new O-ring with a thin layer of Dow Corning

FS 1292 lubricating grease. Position the new O-ring concentric with the groove and press

it into place. Torque the inner cover screws to 30 in-lbs. Perform a pressure test as

described in paragraph 8.11. Connect the light unit lead(s) from the isolation transformer(s).

Clean the mounting flange area of the fixture and base. Install the fixture into the base per

Section 7.1.

8.5 Feed-thru Replacement

Remove and secure power to the fixture. Remove the two bolts and 2-piece locking

washers (8 inch fixture) or six bolts and 2-piece locking washers (12 inch fixture) securing

the fixture to the base. Disconnect the light unit lead(s) from the isolation transformer(s).

Turn the fixture upside down and remove the four screws holding the bottom cover to the

fixture housing. Disconnect the power supply leads /ferrite leads from the feed-thru

terminals. Remove the feed-thru by unscrewing its round retaining collar. Clean the

mounting surfaces with denatured alcohol and allow to dry. Apply a thin coat of Dow

Corning FS 1292 grease to the mounting flange of a new feed-thru. Apply a drop of

Loctite 243 to the feed-thru adapter threads. Screw the feed-thru retaining collar onto the

adapter. Torque the round retaining collar to 25-30 in-lbs. Reconnect the power supply leads/

ferrite leads to the feed-thru terminals. Replace the optical housing’s O-ring per section

8.4. Install the fixture into the base per Section 7.1.

8.6 Outer Lens/Heater Replacement

Outer Lens:

If the outer glass lens is broken, leaks, or is badly pitted or scarred, it must be replaced.

It is highly recommended that this task be performed in a clean shop environment. Outer

Lens Replacement Kit P/N 21332 contains all necessary parts to change a lens. Remove

and secure power to the fixture. Remove the two bolts and 2-piece locking washers (8

inch fixture) or six bolts and 2-piece locking washers (12 inch fixture) securing the fixture to

the base. Disconnect the light unit lead from the isolation transformer. Turn the fixture

upside down and remove the four screws holding the bottom cover to the fixture housing.

Remove the 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. Thoroughly clean the lens opening

with isopropyl alcohol and let dry. Inspect the lens opening for scratches or pits; a damaged

lens opening surface will not seal properly. Place a new lens boot (P/N 21256) over the

replacement outer lens (P/N 21254). 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 (P/N 21258), fasten the lens retaining bracket

(P/N 21297) to the light housing. Torque the mounting screws to 39-43 in-lb.

Inspect/replace the optical housing’s O-ring per Section 8.4. Assemble the bottom cover

onto the light housing. Torque the mounting screws to 30 in-lbs. Perform a pressure test

per Section 8.11. Clean the mounting flange area of the fixture and base. Install the

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fixture onto the base and torque the mounting bolts with anti-seize applied along with 2-

piece locking washers for each bolt per Section 7.1.

Outer Lens with Heater (Series Circuit Powered Fixtures Only):

Outer Lens/Heater Replacement Kit P/N 21332 and Heater/Bracket

Assembly/Thermoswitch Kit P/N 21761 contain all necessary parts to change a

lens/heater assembly. Do as stated above; however, this fixture will not have a lens

retaining gasket since it is incorporated into the heater assembly and make sure that when

mounting the lens retaining bracket, the heater wires are aligned with the slot on the lens

retaining bracket so the wires are not pinched. The thermostat and its bracket is also part

of the replacement kit.

For Heater installation:

Clean the underside of the outer lens with alcohol and allow to dry.

Peal the adhesive strip (not the insulating foil side) from the heater (round disc

the leads attached) and adhere to the underside of the outer lens. Make sure when

adhering the heater to the outer lens that they remain concentric to each other so

light will not be blocked.

Clean the back side of the heater (insulation foil side) with alcohol and allow to

dry.

Peal the adhesive strip from the foam rubber pad (replaces flat circular hard outer

lens gasket) and adhere the heater to the foam rubber pad; making sure when

adhering the heater to the foam rubber pad that they remain concentric to each

other so light will not be blocked.

8.7 LED Replacement

WARNING:

NOTICE

A grounded ESD Wrist Strap should be worn by personal working on

or handling fixture LED assemblies. ESD Wrist Straps, also known as

anti-static wrist straps, are used to prevent electrostatic discharge

(ESD) by safely grounding a person working with electronic

equipment.

LED Replacement Kit P/N 21486-B1 contains all necessary parts to change the

LED module. Remove and secure power to the fixture. Remove the two bolts and 2-

piece locking washers (8 inch fixture) or six bolts and 2-piece locking washers (12 inch

fixture) securing the fixture to the base. Disconnect the light unit lead from the isolation

transformer. Turn the fixture upside down and remove the four screws holding the bottom

cover to the fixture housing. Disconnect the LED module leads from the power supply.

Remove the lens retaining bracket screws from the optical housing. Remove the lens-

retaining bracket and remove the LED heat sink from it unscrewing the screws. Install the

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new LED module heat sink torque the screws in a star pattern to 30 in-lb; tightening the

lens retaining bracket screws to a torque greater than 35 in-lb may cause failures under

high loads. For the heater option fixture, make sure that the heater wires are aligned with

the slot on the lens retaining bracket so that they are not pinched at final assembly.

Replace the optical housing’s O-ring per Section 8.4. Install the fixture into the base per

Section 7.1

8.8 Power Supply Replacement (Series Circuit Powered Units)

CAUTION:

CAUTION Power supply is hot (temperature) when the fixture is energized and

remains hot for a short time after the fixture is turned off.

WARNING:

NOTICE

A grounded ESD Wrist Strap should be worn by personal working on

or handling fixture power supplies. ESD Wrist Straps, also known as

anti-static wrist straps, are used to prevent electrostatic discharge

(ESD) by safely grounding a person working with electronic

equipment.

WARNING:

IMPORTANT

The jumpers (on power supply J203) must be in the correct position(s)

for proper operation of the fixture to achieve outputs the fixture is

specified for.

WARNING:

NOTICE

Applying input current to the power supply without the arctic kit

heater or the heater jumper lead assembly installed on the power

supply will cause damage to the power supply.

WARNING:

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IMPORTANT Applying a constant voltage greater than 50V (AC or DC) to the input

will cause damage to the power supply on series powered units.



the fixture to the base. Disconnect the light unit lead from the isolation transformer. Turn the

fixture upside down and remove the four screws holding the bottom cover to the fixture

housing. Remove the three power supply bracket screws. Disconnect internal cables to

power supply termination points. Remove the power supply bracket with attached power

supply. Remove the three power supply screws and discard the old power supply as an

electronics assembly. Configure the J203 jumper settings for the new power supply per

Jumper Diagrams in Section 9. Reconnect internal cables per the appropriate Wiring

Diagrams. Apply thermal grease to the mating surface of the new power supply and secure it

to the bracket using the three supplied screws. Torque the screws to 22-24 in-lb. Secure the

power supply bracket. Torque the bracket mounting screws to 25-30 in-lb. Replace O-ring

per Section 8.4. Install the fixture to the base per Section 7.1

8.9 Power Supply Replacement (Voltage Powered Fixtures)



the fixture to the base. Disconnect the fixture L-823 plug from the L-823 receptacle going to

voltage power. Turn the fixture upside down and remove the four screws holding the

bottom cover to the fixture housing. Remove the two power supply bracket screws.

Disconnect power supply cables at connection points. Install a new gap pad and power

supply using the existing bracket. Torque the bracket screws to 25-30 in-lb. Make

connections for the corresponding voltage power supply per Figure 4 power supply

illustration connection points indicated. Replace O-ring per Section 8.4. Install the fixture to

the base per Section 7.1

8.10 8 Inch Fixture External Gasket Replacement


washers (8 inch fixture) securing the fixture to the base. Disconnect the light unit lead

from the isolation transformer. Any gasket that is stretched, torn, has a permanent set or

some other defect, will allow water to enter the light base. Remove the old gasket from

the inner cover by carefully scraping with a plastic, or comparably soft, tool. Take care

not to damage the inner cover. Clean the sealing surface. Form a thin bead of high

temperature silicone adhesive, such as GE RTV 106, on the inner cover sealing surface.

Position the new gasket on the inner cover in the same location as the old gasket. Apply a

thin coat of Dow Corning FS 1292 grease over the entire outside surface of the gasket

before placing the optical assembly onto the base. Install the fixture onto the base per

Section 7.1.

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8.11 Pressure Test

A light unit should be subjected to a 20-psig air pressure test to verify that it is

waterproof after it has been opened or components have been replaced. A tire valve

style pressure fitting is located on the bottom of the inner cover. Pressurize the unit to

20-psig 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-through

adapter for leaks. Relieve the internal air pressure before installing the light unit or

attempting to repair a leak.

8.12 Cleanliness and Workmanship

Service life depends upon the entire assembly being waterproof. All internal surfaces

must be clean, dry and free of all foreign matter if the light unit is to operate for extended

periods without requiring maintenance.

8.13 Maintenance Program

In order to ensure 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 units. The lights should be

energized and visually inspected. If any units are out, the location of the unit should be

recorded and replaced with a spare at a time when the circuit is de-energized.

Regular cleaning is necessary to ensure that in-pavement lighting units operate at

maximum efficiency. The lens should be cleaned periodically with a soft cloth and

solvent. The weather and the location of the units will dictate the regularity and type

of cleaning.

Snowplow operators should exercise extra care not to strike the light units with

snowplow blades. After snow removal operations, inspect all fixtures and replace if

any damaged fixtures. Passes over the light 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 units.

Recommended snow removal techniques are described in AC 150/5200-23.

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.

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Fixture mounting bolts should be checked for proper torque per section 7.1 and

whenever a unit is serviced regardless of the season. Light units in and around the

touchdown zone area are especially prone to vibration and shock 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.

If any light unit contains water, the water should be removed and the entire light unit

cleaned and dried. Perform a pressure test per Section 8.11 to locate the source of

the leak. Repair the leak and replace the fixture O-ring per Section 8.4.

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9 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 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.

Review all DANGER, WARNING, IMPORTANT and NOTICE statements in Section

8. All still apply when troubleshooting.

9.1 Visual Inspection

Follow the steps in Section 8 to open the fixture. Verify all the wires are not pinched or

damaged and that the wire insulation is intact. Verify the input AC is connected to the

feed thru secondary plug. Verify the power supply connections. Verify the appropriate

J203 jumper settings per Wiring Diagrams, Jumper Diagrams and Figure 3 for series

circuit power fixtures. Replace any damaged or burned cables. Replace damaged LED

per Section 8.7. Replace damaged power supply per Section 8.8 or 8.9. Refer to Figure 4

part identification to determine the appropriate replacement part/kit for your fixture.

9.2 Electrical Inspection, Series Circuit Powered Fixtures

Follow the steps in Section 8 to open the fixture. The power supply continuously

monitors the status of the fixture LED. There is a green status LED (see Figure 3) that

may be visible through the potting. A blinking status 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’.

Incorrect jumper setting or missing jumpers

o See Jumper Diagrams for proper jumper setting.

More than 25% of the driven LED ‘Shorted’

o Replace LED module per Section 8.7.

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Figure 3, Power Supply, Series Circuit Fixtures

Connections

See Jumper Diagrams and Wiring Diagrams for connections for the Part Number

installed.

Status Indicator

When powered, if the status LED is not visible or not lit, replace the power supply per

Section 8.8 or contact Crouse-Hinds Airport Lighting Products for assistance.

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Wiring Diagrams, Series Circuit Powered Fixtures

Without Heater, 6.6A Input

With Heater, 6.6A Input

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Jumper Diagram, Series Circuit Powered Fixture

Power Supply J203 Jumper Positions for Part Numbers

852UL-AP1-066-XXX

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Figure 4, Part Identification

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Power Supply Shown For Series (CCR) Powered Fixtures

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21486-_ & 21486- _1 LED/ Heat Sink Module Replacement Kits

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21761 Heater, Thermostat, Thermostat Bracket and Power Cables Replacement Kit,

Option 1 Fixtures

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21757-1 Bottom Cover

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852UL-AP1-X-012-XXX (12 VDC) and 852UL-AP1-X-024-XXX (24 VDC)

Power Supply

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852UL-AP1-X-120-XXX (100-277 VAC) Power Supply

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Ferrite Placement Without Heater, 066 Input Power Fixtures

Ferrite Placement with Heater, 066 Input Power Fixtures with Option 1

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10 Fixture Mounting Bolts & 2-Piece Washers

P/N 21647-XXXX 2-Piece Washer Replacement Kit, customer specified quantity

P/N 21715-XX Bolt, Hex-Head, 3/8-16, cold worked 18-8 stainless steel, customer

specified length, quantity 1

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