Operational and maintenance manual for LED HAPI · Led Hapi D8215647 has a spread of 10° on the horizontal plane and 20° on the vertical plane. On the vertical plane the beam is

Emesso da / Issued by: Verificato da / Verified by: Approvato da / Approved by:

Engineering Resp. Progetto / Project Mgr. Resp. Qualità / Quality Mgr.

Calzoni S.r.l.Sede Legale: Via A. De Gasperi, 7 - 40012 Calderara di Reno (Bologna) Italy - Tel: +39 0514137 7 - Fax: +39 0514137555 / +39 0514137581 (Amministrazione) / +39 0514137523 (Acquisti)

Ufficio di Milano: Via Rimini, 22 - 20142 Milano Italy - Tel: +39 0258188 1 - Fax: +39 0258188250E-mail: [email protected] / [email protected] - Web: www.calzoni.comCapitale sociale: € 2.550.000 - C.F. e R.I. di BO 12846910151 - P. IVA 02088221201 -

S.r.l. con unico socio, soggetta a direzione e coordinamento di L-3 Communications Corporation, NY, USA

ILD8142814 Rev. D V. 1

Contr.:CDRL N.: -N. di pag. / No. of pages : 33File : ILD8142814D.doc

Operational and maintenance manual for LED HAPI

Prepared for: Customer

Prepared by: Calzoni S.r.l.Calderara di Reno, Bologna – ItalyMilano - Italy

Property Information: This document and all information contained herein are property of Calzoni S.r.l. and must not be duplicated, transmitted in any form, transferred to other document or disclosed to third parties, neither in total nor its part, without the express written authorization of Calzoni S.r.l.

01/09/2014 01/09/2014 01/09/2014

ALBERTO PADOVAN FABIO FERRACANE MARIO PACI


ILD8142814 Rev.D V.1

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REVISIONI / REVISIONS

RevDataDate

Redatto daPrepared by

Descrizione delle modificheDescription of the changes

- 16/11/2012 FX First issue

A 27/03/2013 FX Added wiring image and step intensity detail

B 23/07/2013 RV Added F12 warning

C 18/09/2013 FX Added code D8215647 for Led-Hapi with Reduced beam in azimuth

D 01/09/2014 FX Correction of Power Supply frequency



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SOMMARIO / TABLE OF CONTENT

REVISIONI / REVISIONS ....................................................................................................................................................... 2

SOMMARIO / TABLE OF CONTENT.................................................................................................................................... 3

LISTA DELLE FIGURE / TABLE OF FIGURES................................................................................................................... 4

LISTA DELLE TABELLE / TABLE OF TABLES.................................................................................................................. 4

1. INTRODUCTION............................................................................................................................................................. 5

1.1 COMPLIANCE............................................................................................................................................................... 51.2 SCOPE AND OPERATION PRINCIPLE................................................................................................................................ 5

2. REFERENCE DOCUMENTS .......................................................................................................................................... 7

2.1 STANDARD AND REGULATIONS..................................................................................................................................... 7

3. DESCRIPTION................................................................................................................................................................. 8

3.1 TECHNICAL CHARACTERISTICS .................................................................................................................................... 83.1.1 Optical features performance.................................................................................................................................. 9

3.2 GENERAL DESCRIPTION ............................................................................................................................................. 103.2.1 External Case ....................................................................................................................................................... 113.2.2 Mechanical/electronic assembly............................................................................................................................ 113.2.3 Support................................................................................................................................................................. 12

4. HANDLING INSTRUCTION......................................................................................................................................... 14

5. DISPLAY MENUS – ADJUSTMENTS AND CALIBRATION INSTRUCTIONS....................................................... 15

6. INSTALLATION............................................................................................................................................................ 19

6.1 INSTRUCTIONS FOR INSTALLATION ............................................................................................................................. 196.2 WIRING INSTRUCTION................................................................................................................................................ 196.3 OPTICAL AXIS ALIGNMENT PROCEDURE ...................................................................................................................... 20

7. PERIODICAL MAINTENANCE................................................................................................................................... 24

7.1 CLEANING OF THE PROJECTOR’S FRONT TRANSPARENT................................................................................................ 247.2 INTERNAL CLEANING OF THE LED HAPI .................................................................................................................... 24

8. TROUBLESHOOTING AND REPAIR ......................................................................................................................... 25

8.1 GENERAL .................................................................................................................................................................. 258.2 MONITORED FAILURES............................................................................................................................................... 258.3 OTHER FAILURES ....................................................................................................................................................... 278.4 CORRECTIVE ACTIONS ............................................................................................................................................... 28

8.4.1 Led board Replacement (A4)................................................................................................................................. 288.4.2 Dimmer board Raplacement (A3).......................................................................................................................... 288.4.3 PLC Replacement (A2).......................................................................................................................................... 288.4.4 Power Supply Replacement (PS1) ......................................................................................................................... 288.4.5 Fuse Replacement (F1) e (F2)............................................................................................................................... 298.4.6 Proximity Sensor Replacement (MT1) ................................................................................................................... 298.4.7 Movement Motor Replacement (B1) ...................................................................................................................... 298.4.8 Clinometric Transducer Replacement (MT3)......................................................................................................... 298.4.9 Crepuscular Sensor Replacement (S3)................................................................................................................... 30



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8.4.10 Green and/or Red Filter Replacement ............................................................................................................... 308.4.11 Thermostat failure ............................................................................................................................................ 31

9. SPARE PARTS LIST...................................................................................................................................................... 32

10. ENVIRONMENTAL INSTRUCTIONS..................................................................................................................... 33

LISTA DELLE FIGURE / TABLE OF FIGURES

FIGURE 1: HAPI’S BEAM SECTOR AND CODING .............................................................................................................................. 5FIGURE 2: HELICOPTER APPROACH PATH INDICATOR LED HAPI................................................................................................... 6FIGURE 3: HELICOPTER APPROACH PATH INDICATOR LED HAPI VISUAL CODING .......................................................................... 6FIGURE 4: BEAM MINIMUM LUMINOUS INTENSITY ........................................................................................................................ 10FIGURE 5: LED HAPI REAR WITH MAIN SWITCH AND HEAT-SINK .................................................................................................. 11FIGURE 6: LED HAPI INTERNAL VIEW ......................................................................................................................................... 12FIGURE 7: T-SHAPE ZINC PLATE SUPPORT .................................................................................................................................... 12FIGURE 8: DETAIL OF LED HAPI LEGS WITH ADJUSTMENT AND FRANGIBLE PARTS ........................................................................ 13FIGURE 9: CORRECT AND INCORRECT WAY TO LIFT WEIGHTS........................................................................................................ 14FIGURE 10: FIXING WALL FOR D5422175 TOOL ........................................................................................................................... 20FIGURE 11: UPPER NUTS ON HAPI LEG ........................................................................................................................................ 21FIGURE 12:FRONT LOWER NUTS .................................................................................................................................................. 21FIGURE 13: FRONT LOWER NUTS UNDER THE FRANGIBLE.............................................................................................................. 22FIGURE 14: REAR LEG................................................................................................................................................................. 23FIGURE 15: TILT CABLE ............................................................................................................................................................. 26

LISTA DELLE TABELLE / TABLE OF TABLES

TAB. 1: MONITORED FAILURES ................................................................................................................................................... 25TAB. 2: OTHER FAILURES............................................................................................................................................................ 27TAB. 3: SPARE PART LIST ............................................................................................................................................................ 32



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1. INTRODUCTION

1.1 COMPLIANCE

a. The Helicopter Approach Path Indicator LED HAPI has been designed to be fully compliant to the ICAO Annex 14, Vol. II, par. 5.3.4 requirements and FAA AC 150-5345/26 L-883 Style A Class II (-55°C + 55°C).

b. The LED HAPI is compliant to the safety requirements “Machinery Directive” 2006/42/CEE, “Low Voltage Directive” 2006/95/CEE and “Electromagnetic Compatibility

Directive” 2004/108/CEE for marking.

This is a Class A product. In a domestic place this product may cause radio interference. In this case users may have to take adequate safety measures

1.2 SCOPE AND OPERATION PRINCIPLE

The helicopter approach path indicator Led HAPI, (see Fig. 2) is a unit purposely designed to highlight the correct landing slope to the pilot during the landing procedure through a suitable light beam.

The optical information is obtained, as shown at Figure 1, using:

- Flashing green for ABOVE

- Steady green for ON SLOPE

- Steady red for SLIGHTLY BELOW

- Flashing red for BELOW

Figure 1: HAPI’s beam sector and coding

The correct slope, steady green, can be adjusted in elevation to satisfy any slope requirement.



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Figure 2: Helicopter Approach Path Indicator LED HAPI

Figure 3: Helicopter Approach Path Indicator LED HAPI visual coding



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2. REFERENCE DOCUMENTS

[D8214591] Led HAPI – Led Helicopter Approach Path Indicator Assembly

[D8215647] Led HAPI with reduced beam in azimuth - assembly

[D8115077] LED HAPI Electrical diagram

[D8115078] Led HAPI - Overall dimension and drilling layout

2.1 STANDARD AND REGULATIONS

[ICAO Annex XIV VOL. II] Heliport – par. 5.3.4

[FAA AC 150-5345/52] L-883 Style A Class II (-55°C + 55°C) as GENERIC VISUAL GLIDESLOPE INDICATORS (GVGI)

[EN 60529] IP protecton grade

[2006/42/CEE] Machinery Directive

[2006/95/CEE] Low Voltage Directive

[2004/108/CEE] Electromagnetic Compatibility Directive



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3. DESCRIPTION

3.1 TECHNICAL CHARACTERISTICS

Dimensions : as per dwg. D8115078

Weight : 50.5 kg

Power supply : 115V-230V 10% - 50/60Hz

Absorption : 1.2A

Power : 200W

Enclosure : IP66 (according to CEI EN 60529).

Protective coating : Orange polyurethane (RAL 2004/ FED STD12197).

Temperature range : -20° +55°C (-55° +55° with optional heater kit).

Elevation adjustment : Continuous from 0° 12°

Calibration : by internal PLC, through display for the indication of the elevation and longitudinal angle, with precision of 0.1°.

Light intensity adjustment : automatic 100% to 30% daylight/nighttime operation with possibility of further remote adjustment from 30% to 10%. Is not possible to switch from 100% to 10% directly, 30% step of intensity is required first

Safety :

a. automatic shut-down device in case of deviation from the vertical by more than 0.5° and alarm message indication

b. automatic shut-off of led board if 25% of LED is faulty and alarm message indication.

c. automatic gate in case of flashing failure to hide the flashing sectors and alarm message indication.

d. Automatic set of minimum intensity level in case of faulty communication between PLC and Dimmer board

The helicopter approach path indicator Led HAPI complies with the requirements of ICAO Annex 14 VOL. II , par. 5.3.4 and FAA AC 150-5345/26 L-883 Style A Class II (-55°C + 55°C).



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3.1.1 Optical features performance

a. The light beam emitted by the standard approach path indicator LED HAPI D8214591 has a conical shape (with an elliptical section), with a spread of 30° on the horizontal plane and of 20° on the vertical plane. Led Hapi D8215647 has a spread of 10° on the horizontal plane and 20° on the vertical plane.

On the vertical plane the beam is divided in four sectors of light, as indicated below (seeFig. 1):

(1) - Upper sector, 9°15’ amplitude, green color (according to CIE norms), flashing light.

(2) - Upper intermediate sector, 45’ amplitude, green color (acc. to CIE norms), steady light.

(3) - Lower intermediate sector, amplitude 15’, red color (acc. to CIE norms), steady light.

(4) - Lower sector, amplitude 9°45’, red color (acc. to CIE norms) flashing light.

b. The maximum light intensity in the center of the beam is more than 9000cd; the emission diagram, according to ICAO, is given in Fig. 4. For D8215647, the intensity value are the same, in the restricted beam area.

c. The intermittence frequency of the flashing sectors is between 2 and 3Hz.

d. The on/off ratio of the intermittent signal is 1:1, on the vertical symmetry plane.

e. The modulation depth is over 80%.

f. Transition from one color to the other is not higher than 3’ at a distance of 300m.

g. Transmittance of red/green filters, at the max. light intensity, is not less than 20%.



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Figure 4: Beam minimum luminous intensity

3.2 GENERAL DESCRIPTION

The system can be logically divided in the following subassemblies.

a. External case with heat-sink for heat dissipation

b. Mechanical/electronic assembly, composed by:

- Mechanical support

- Optical assembly

- Shutters

- 24Vdc power supply

- PLC with display

- Dimmer board for led board control

- Fan for air recirculation

- Thermostat

- Light dependent relay (Crepuscular sensor)

c. Support with frangible fitting



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3.2.1 External Case

Major characteristics:

a. Case in stainless steel, with anticorrosion surface treatment and orange polyurethane coating (RAL 2004);

b. Main switch, positioned in the rear part of the cover, to switch off the system before opening;

Figure 5: Led HAPI rear with Main switch and heat-sink

c. External lens in the front part of the item.

d. External heat-sink permits LED board heat dissipation outside the body

3.2.2 Mechanical/electronic assembly

The subassembly is mainly composed by:

a. Mechanical support: base plate in stainless steel, to support all the mechanical and electronic devices. On this plate a stainless steel cover is fixed by means of 8 M6x16 screws.

b. Optical assembly: the assembly includes all the lenses required for the projection of the light beam coming from the led board. This assembly is fixed on a light alloy vertical plate, treated against corrosion, perpendicular to the above mentioned base plate.

c. Shutters: mechanical system that allows, through a motor with a cam, the movement of a gate that creates the flashing path. An additional gate is released by a solenoid to hide the flashing beams in case of failure of the flashing device, allowing the operating only of the central part of the beam (fixed red and green sectors).

d. AC/DC 115-230Vac to 24Vdc power supply: to supply all the electronic devices.

e. PLC with display.

f. Dimmer board for LED supply and control.

g. Fans: on the lower part of the plate (under the shutter motor) for heat recirculation.

h. Light dependent relay (Crepuscular sensor) to automatically switch night (30% intensity light) and day (100% intensity light) operations.



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i. Safety internal thermostat

Figure 6: Led HAPI internal view

3.2.3 Support

Major characteristics:

a. T-shape zinc plate support to interface concrete/steel interface with interposed frangible legs (FAA compliant).

Figure 7: T-shape zinc plate support

HeatSink

Dimmer board

DigitalClinometer

Shutter motor

Optical assembly

LED board

PLC with display

Shutters

Power supply



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b. 3 threaded legs, stainless steel, for elevation adjustment, hinged to the base and fitted out with adjustment and fixing nuts in the upper part.

Figure 8: Detail of Led HAPI legs with adjustment and frangible parts



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4. HANDLING INSTRUCTION

The handling of the system could be risky for the operator due to the weight of the equipment (see Fig. 9).

Please refer to the local laws and requirement and use the following as recommendation.

For the handling of the Led HAPI, since the weight higher than 30 kg, the best is to use a crane to rise the system (using belts). Where it is not possible, please handle with care, rising the HAPI minimum two persons keeping the equipment sideways (under the stainless steel base plate).

Figure 9: Correct and incorrect way to lift weights



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5. DISPLAY MENUS – ADJUSTMENTS AND CALIBRATION INSTRUCTIONS

At the power ON, after the initial internal test, the display of the control board shows the MENU 1:

MENU 1 (pushing the button 1 from any MENU the operator comes back to MENU 1)

Pushing the button 4 the display shows the MENU 2 ADJUSTMENTS:

Pushing the button 2 the operator enter on the MENU 3

To store the position of desired glide path push the button 8.

The display will show the MENU 4:



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Pushing the button 4 the value of axis X and Y will be stored and it come again to MENU 2; pushing the button 1 the operator comes back to MENU 1.

From MENU 1 pushing the button 2 the operator goes in the MENU VISUALIZATION:

MENU 6:

Pushing the button 2 the operator goes in the MENU 7:

The parameters indicated on the display refer to the values of the equipment at the moment on which we see it on the axis y (horizon); the indications SX+ DX- are taken from behind the equipment seeing on the direction of the light beam; the left side is higher than the right side. Pushing the button 4 the operator comes again to the MENU 6.

Pushing the button 3 the display shows the MENU 8:

Errore.



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This MENU indicates the stored position for the desired glide path.

Pushing the button 4 the operator comes again to MENU 6.

Pushing the button 4 the display indicates the MENU 9:

This menu shows the fault codes when a malfunction occurs.

Pushing the button 8 the operator enter on the MENU 10 in order to delete the error:

Errore.

Pushing the button 4 the stored fault is deleted if the fault has been removed and the operator comes again on the MENU 6; pushing the button 7 the operator comes again on the MENU 6and we don’t operate on the memory.

Pushing the button 7 from the MENU 6 the operator can see some internal parameters on the MENU 11:

where:

T is the temperature measured from the sensor on the PCB.

I is the current of the LED board.

Cx is the value of the calibration voltage of the x-axis (Volt).



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Cy is the value of the calibration voltage of the y-axis (Volt).

Sx is the value of the stored Set-point of x-axis (degrees).

Sy is the value of the stored Set-point of y-axis (degrees).

Pushing the button 4 the operator comes again to the MENU 6.

In order to do the calibration, e.g. to link the mechanical zero with the voltage value given by the clinometer (assumed as electric zero) operate from the MENU 2 ADJUSTMENTS :

Push the button 5 and enter on the MENU 12:

To store (memorize) the voltage value, push the button 5; the following MENU 13 will be displayed:

Pushing the button 4 the a.m. value will be stored and automatically the operator exit from this MENU; pushing the button 7 the operator exit from the MENU without store the voltage value and comes again to the MENU 2.



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6. INSTALLATION

WARNING !

During maintenance/installation procedure please be sure that the main switch is in the OFF position.

6.1 INSTRUCTIONS FOR INSTALLATION

The customer to position and secure the system in the Helipad must perform this operation.

a. Before starting any installation activity, it is necessary to prepare a flat area not subject to high vibrations of a minimum dimension of 700x700 mm.

The concrete must be perfectly leveled on the horizontal plane with a maximum error of 2°.

b. With reference to overall dimension and drilling layout dwg. D8115078, drill the D = 12.5 mm interface holes.

c. By using expansion bolts (or other equivalent devices) fix the HAPI to the concrete.

6.2 WIRING INSTRUCTION

a. The electrical connection of the indicator shall be performed according to electrical interface drawing D8115077.

b. Power supply cable, three conductors of BROWN (phase), BLUE (neutral) and YELLOW/GREEN colors.

c. Internal terminals with external gland to connect a cable coming from the switchboard to:

- Terminals 1 and 2 of TB4 are used, if necessary and required, to control from the main switchboard the brightness of the light. In the switchboard it should be N.O.

- Terminals 3,4,5 are fault alarms from the HAPI to the switchboard, where 5 is common, 4 is N.C. and 3 is N.O.



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Is not possible to move from 100% intensity step to 10% intensity step directly by short circuit TB4-1 and TB4-2 terminals. In order to switch on the 10% step by external control switchboard, 30%step is required (crepuscular sensor signal activated)

d. The YELLOW/GREEN conductor of the supply cable, that shall be adequately grounded, is intended for the bonding connection of the equipment.

6.3 OPTICAL AXIS ALIGNMENT PROCEDURE

a. Open the cover

b. Put the specific tool D5422175 on the Shutter wall and fix it with one screw

Figure 10: Fixing wall for D5422175 tool

c. Put an external level on this tool

d. Loosen all the 3 upper fixing nuts on the 3 legs.

Position and fixing hole for D5422175

X-AXIS

Y-AXIS



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Figure 11: Upper nuts on HAPI leg

e. Operating on the front lower nuts, set at 0° the X AXIS referring to the external level

Figure 12:Front lower nuts

f. Tighten the two front upper nuts.

g. Rotate the external level and put it along the optical axis Y

h. Loosen the 3 nuts (front and rear) under the frangible parts (pay attention to don’t unscrew completely this nuts).

Upper nuts

Front Lower nuts for X-AXIS regulation



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Figure 13: Front lower nuts under the frangible

i. Operating on the rear lower nut, set at the elevation angle (referring the external level) the Y AXIS as required by the operational conditions.

Front Lower nuts under the frangible



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Figure 14: Rear leg

j. Tight all the upper and lower nuts to lock all the legs.

k. Switch on the system.

l. To memorize the operating position follow the indications of the above par. 5. Enter the menu 3 and push button 8 to store the value.

m. Delete any error event that can be appeared

n. Switch “OFF” and then “ON” the equipment and verify the correct operating.

Rear Lower nuts to regulate Y-axis

Rear Upper nut



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7. PERIODICAL MAINTENANCE

7.1 CLEANING OF THE PROJECTOR’S FRONT TRANSPARENT

To be periodically performed, according to the climate in which the indicator has been used, by means of a soft cloth of the type used for cleaning glasses.

7.2 INTERNAL CLEANING OF THE LED HAPI

The cleaning procedures shall be periodically performed, according to the climate and environment in which the indicator has been used, as follows:

a. Switch “OFF” the switch located on the front panel of the control board.

b. Open the external case.

c. Clean with low-pressure compressed air jet.

d. Close the system by following the procedure described at previous points a. and b. In reverse order.

Never use water to clean the system



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8. TROUBLESHOOTING AND REPAIR

8.1 GENERAL

In accordance with the ICAO requirements, the system has to continue to be operative, even if with reduced performance, in case of well-defined failures. In this case the system will monitor these failures and will provide an ALARM to the switchboard so to highlight that the system is not operating in the proper conditions.

Beside this, other failures can happen, compromising the functioning of the system but not monitored by the internal CPU: in this case a different failure analysis is required.

WARNING!!

Inside the Indicator there are voltages such as to be of danger for the personnel involved in operating the powered system. Be sure that before any activity the switch is positioned in OFF.

8.2 MONITORED FAILURES

In case of a failure detection an ALARM in raised on the display of the PLC and the fault output is activated. An error code will be shown on the PLC display to understand the root cause and so to repair the system. In case of a warning condition is detected the fault output become flashing and the warning code is shown on the PLC display. The fault/warning signal remains until the alarm/warning condition is removed.

Error codes and meaning are as per follows:

Tab. 1: Monitored failures

Code Failure Corrective action

F01 LED Board failure (more than 25% led failure)

Check the damaged led string in the submenu and then See par.8.4.1

F02 Dimmer board communication failure

Check the wirings and then see par. 8.4.2

F03 B1 motor failure See par. 8.4.7

F04 Clinometer communication failure See par. 8.4.8

F05 Dimmer board failure See par. 8.4.2

F09 Internal Temperature +70C Switch off the system, wait the temperature goes down 70°C,

switch on the system

F10 Tilt error (> 0.5 degrees respect Reset the right position and restart



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to the operating position) the system; see also par. 4.

F12 LED Board warning (less than 25% led failure)

Check the damaged led string in the submenu

NOTE on TILT ERROR F10:

It is possible to deactivate TILT ERROR if necessary when LED HAPI is mounted on very unstable surface: in order to do this is necessary to connect the TILT cable between TB2-7 cable pin and TB2-5 pin and between TB2-8 cable pin and TB2-4 pin (see D8115077). In this way F10 error doesn’t come out anytime.

Figure 15: TILT cable

Error code RESET

When a fault is present, the display of the PLC visualizes the fault code. Repairing the failure the display of the electronic card will continue to display the fault code until the user deletes the fault code (see above par. 4).

To correctly perform a repair operations follow the procedure indicated below:

a. Read on the display the error code.

b. Read on the table “Failure Code” the meaning of the fault code (related failure).

c. Delete the errors (see par 4)

d. Power OFF the HAPI.

e. Replace the failed component with a new one.

f. Power ON the HAPI checking its correct operating (delete the fault code from the card memory as specified in above par. 4).



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8.3 OTHER FAILURES

In case of other failures please refer to the following table:

Tab. 2: Other failures

Trouble Potential Cause Corrective Action

1. The system is switched off

1.1. Clinometric transducer failure

See par. 8.4.8

1.2 PLC failure See par. 8.4.3

1.3 Fuse failure See par. 8.4.5

1.4 Wiring interruption Check the wiring and, if necessary, restore the wiring (see dwg. D8115077)

1.5 Thermostat failure See par. 8.4.11

1.6 AC/DC failure See par. 8.4.4

2. The light is not coming out

2.1 LED board failure See par. 8.4.1

2.2 Dimmer board failure See par. 8.4.2

2.3 Fuse failure See par. 8.4.5

2.4 Wiring interruption Check the wiring and, if necessary, restore the wiring (see drw. D8115077)

2.5 AC/DC failure See par. 8.4.4

3. The system is not flashing

3.1 Proximity sensor failure

See par. 8.4.6

3.2 Motor failure See par. 8.4.7

3.3 Wiring interruption Check the wiring and, if necessary, restore the wiring (see drw. D8115077)

4. The light cannot be dimmed

4.1 Crepuscular sensor failure

See par. 8.4.9

4.2 PLC failure See par. 8.4.3



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4.3 Wiring Interruption Check the wiring and, if necessary, restore the wiring (see drw. D8115077)

5. Light beam optical characteristics deteriorated

5.2. Colored filters damaged

See par. 8.4.10

8.4 CORRECTIVE ACTIONS

8.4.1 Led board Replacement (A4)

a. Switch off the system and open the cover.

b. Take away the led board and replace it with a new one (add some thermal paste).

c. Reconnect all the connectors

d. Close the cover and switch on the system

8.4.2 Dimmer board Raplacement (A3)


b. Take away the Dimmer board and replace it with a new one.

c. Reconnect all the connectors

d. Close the cover and switch on the system

8.4.3 PLC Replacement (A2)


b. Disconnect the wiring of the Module A2.

c. Replace the broken Module with a new one with the same program installed on and restore the wiring.

d. Close the cover and switch on the system.

8.4.4 Power Supply Replacement (PS1)


b. Disconnect the wiring of the Power Supply Unit PS1.

c. Remove the Power Supply Unit PS1 loosing the fixing screws.

d. Replace the broken Power supply unit with a new one of the same characteristics and restore the wiring.



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8.4.5 Fuse Replacement (F1) e (F2)


b. Remove the cap from the fuse-holder (TB1-F1 / TB2-F2).

c. Replace the burned fuse with one of the same Ampere value (see cap 9 or D8115077).

8.4.6 Proximity Sensor Replacement (MT1)


b. Disconnect the wiring of the proximity sensor to the connector P2 (MT1) (the three conductors are screwed on the connector), unscrew nut M18 and remove the proximity sensor (MT1).

c. Replace the proximity sensor with a new one, repeat operations as of point a., b., and restore the wiring.

NOTE: The distance between the sensor and the stop plate must be comprised

between 3 and 5mm.

8.4.7 Movement Motor Replacement (B1)


b. Disconnect the wiring of the solenoid B1 from its terminal board TB3.

c. Unscrews the two fixing nuts M10 of the solenoid.

d. Unscrew the nut M6 (fixing the solenoid shaft to the ball joint).

e. Unscrew the solenoid shaft until to free the ball joint.

f. Replace the solenoid with a new one with the same characteristics, fix the ball joint and restore the wiring.

g. Actuate manually the solenoid B2 and bring the safety gate in the upper position (normal operating position).

8.4.8 Clinometric Transducer Replacement (MT3)


b. Disconnect the connector from the clinometric transducer.

c. Unscrew the four screws that secure the clinometric transducer (MT3) to the support.

d. Replace the clinometric transducer with a new one

e. From the MENU 3 page of PLC (see Cap 5) check that the position of x and y axis is 0° ± 0.3°. Move the clinometer in order to adjust this value

f. When the x and y value is good, tighten the fixing screw



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g. Close the cover and restart all the system

8.4.9 Crepuscular Sensor Replacement (S3)

a. Switch off the system.

b. Extract the sensor from its housing (under the base plate).

c. Disconnect the wiring of the sensor and replace it with a new one with the same characteristics.

d. Restore the wiring.

8.4.10 Green and/or Red Filter Replacement


b. With reference to drawing below, loosen the two screws M4x16 UNI 5931 and remove the support id.n. D5418351. Take away the filter-holder frame id.n. D5418350.

c. Loosen the screw M2x5 UNI 6107 that secures the plate id.n. D5418356 that, in its turn, has the filter-press spring id.n. D5418357. Loosen the 6 screws M2x6 UNI 6109 and remove the two straps id.n. D5418355. Remove the coloured filters id.n. D5418353 (red) / D5418354 (green).

d. Replace the damaged filter with a new one; before installation, cleaning it with a soft cloth for glasses avoiding touching it with fingers. After having positioned the filters in their housing, check that the two ground surfaces perfectly mate. The filter-press spring id.n. D5418357 will help the operator to perform this operation.

e. Repeat operations as of points a., b., c., d. in reverse order.



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8.4.11 Thermostat failure


b. Disconnect the wiring of the thermostat MT2 from its terminal board.

c. Take away the thermostat broken from the external side and replace it with a new one (of the same characteristics).

d. Restore the wiring.



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9. SPARE PARTS LIST

Tab. 3: Spare part list

Calzoni P/N Description

D8314263 Led board

D8314916 Inclinometer

D5413746 Transducer (MT1)

D5622247 Motor for shutter movement

D0607655 Solenoid for descent of safety shutter

D8315086 Dimmer Board for LED HAPI

Fuses F1 and F2 6,3 Ampere nominal



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10. ENVIRONMENTAL INSTRUCTIONS

The crossed out wheeled bin label that can be found on your product indicates that the electrical/electronic product should not be disposed of via the normal household waste stream. To prevent possible harm to the environment or human health, please separate this product from other waste streams to ensure that it can be recycled in an environmentally sound manner.

This information only applies to customers in the European Union, according to Directive 2002/96/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL OF 27 January 2003 on waste electrical and electronic equipment (WEEE) and legislation trasporting and implementing it into the various national legal systems. For other countries or more details on available collection facilities please contact your local government office or the retailer where you purchased this product.

Documents

Operational and maintenance manual for LED HAPI · Led Hapi D8215647 has a spread of 10° on the horizontal plane and 20° on the vertical plane. On the vertical plane the beam is