Manual: IREL-L ICAO 60 m
Contents
1. o El RB TPL CSS it A o Blos o ce B C6 2 ES 4140476 REV S gee C 8 ASSY DEP dct ZS So eg H Ee Qe O r rap Zi E List as eee CEP e Ge Li Fre ERES MESES APPLY JUMPER TO CENTER PINS AS SHOWN THIS MODIFICATION CHANGES THE DUAL DRIVER PCB TO SINGLE DRIVER 2012 ADB Airfield Solutions All Rights Reserved 17 60m Runway Edge Light Style 2 LED 96A0463 Rev B Maintenance 9 9 14 2 5 4 1 Replacing L 823 To replace the L 823 cordset perform the following procedure Cordset 1 See Figure 11 Remove both screws F7 from the cordset connector F9 2 Unplug the cordset assembly Figure 11 L 823 Cordset Replace the cordset by plugging in the new cordset 4 Attach the two screws Do not use a power screw driver Compress the cord rubber by no more than 1 32 0 79 mm 5 Return the light to service Figure 12 IREL L Cordset and Heater Wiring Diagram 18 2012 Airfield Solutions Rights Reserved 96A0463 Rev B 60m Runway Edge Light Style 2 LED 9 9 14 Maintenance 2 5 5 Replacing the PCB Figure 13 IREL PCB 1 Open the optical unit Refer to Opening Optical Unit on page 15 2 Disconnect the LED Assemblies from the PCB and disconnect the fast on connectors J42. Runway Edge Transport Canada TP 312 par 5 3 10 11 and 5 3 10 14 and Appendix B Fig B 1 11 for 60 m runways Military Runway Edge Photometry complies with UFC 3 535 01 Fig 4 2 B for runways 60 m 200 feet or more wide 2 2 2 Uses L 850C L e Runway edge on category Il and IIl runways Military runway edge applications 60m 200 feet wide 2 2 3 Features Average LED life of 56 000 hours under high intensity conditions and more than 150 000 hours under typical operating conditions resulting in significant reduction or even elimination of ongoing maintenance costs and periodic re lamping expenses For L 850C white runway edge applications use of LED light source eliminates color shifts at lower CCR step settings For red yellow or green runway applications use of LED light source eliminates filter replacement and color shifts when viewed at various angles or CCR step settings e FAA Style 2 Low protrusion above ground of 0 50 inch reduces vibrations caused by aircraft landing gear in both light fixture and landing gear increasing lamp life Canbeinstalled on existing series circuits with no modifications to existing CCR or isolation transformer Operates on either 3 or 5 step ferroresonant or thyristor CCRs that are designed in compliance with IEC or FAA requirements Very low power rating for LED lights contributes to a lower life cycle cost Limits cost for supporting equipment such as CCRs to strict mi
3. User Manual 96A0463 Rev B 9 9 14 Retain for future use ICAO Runway Edge Annex 14 Vol 1 par 5 3 9 7 and 5 3 9 10 Fig A2 10 for 60 m runways T C Runway Edge Transport Canada TP 312 par 5 3 10 11 and 5 3 10 14 and Appendix B Fig B 1 11 for 60 m runways Military Runway Edge Photometry complies with 3 535 01 Fig 4 2 B for runways 60 m 200 feet or more wide ADE Airfield Solutions 60m Runway Edge Light Style 2 LED IREL L 60m Runway Edge Light Style 2 LED 96A0463 Rev B 9 9 14 Disclaimer This manual could contain technical inaccuracies or typographical errors ADB Airfield Solutions reserves the right to revise this manual from time to time in the contents thereof without obligation of ADB Airfield Solutions to notify any person of such revision or change Details and values given in this manual have been compiled with care They are not binding however and ADB Airfield Solutions disclaims any liability for damages or detriments suffered as a result of reliance on the information given herein or the use of products processes or equipment to which this manual refers No warranty is made that the use of the information or of the products processes or equipment to which this manual refers will not infringe any third party s patents or rights Warranties LED Products of ADB Airfield Solutions manufacture are guaranteed against mechanical electrical and physical defects for a period
4. ordered separately See Figure 17 2 3 6 Earth Ground Earth ground should be connected to the UL 467 Rated Earth ground screw The cross Connection sectional area of the cable should be at least 6 AWG 13 29 mm with a minimum wire length of 48 inches Some installations will require a 72 inch wire NOTE A braided ground strap may also be used instead of a ground wire Figure 4 Base Can Cross section Transformer In pavement Light Assembly round Connection I3 X TF 2 4 lt Counterpoise Wire Provide 3 feet of slack lt Conduit for Connections 10 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev 60m Runway Edge Light Style 2 LED 9 9 14 Troubleshooting WARNING Read the instructions in their entirety before starting troubleshooting 2 4 Troubleshooting 2 4 1 Troubleshooting Problem Possible Cause Corrective Action Check constant current regulator output current levels Check the label on the isolation transformer and replace if Input current too high necessary Failed LED or internal PCB short life span For example incorrectly installing a 6 6A 20A transformer will cause very short fixture component life Inspect the prism Open light assembly Clean dry and inspect light assembly Replace O ring Verify fixture is sealed See Cleaning the Light Channel and Prism on page 13 Broken dam
5. 2012 Airfield Solutions All Rights Reserved
6. Screw the T handles down to seperate the fixture from the mounting base Lift the optical unit out of the base or adapter ring and place it next to it Lifting Tool 1411 19 550 Ordered separately 3 Disconnect the light fixture wires from the power wires coming from the transformer s 4 Mount a serviced or new fitting See Installation on L 868 Base on page 8 5 Take the optical unit back to the maintenance shop where it can be serviced entirely 14 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 60m Runway Edge Light Style 2 LED 9 9 14 Maintenance 2 5 3 Repair Procedures 2 5 3 1 Opening Optical Unit To open the optical unit perform the following procedure 1 Turn the light unit upside down 2 See Figure 5 Remove the pressure release screw NOTE Removing the pressure release screw equalizes the pressure inside and outside the fixture making it easier to break the seal and remove the inner cover Figure 5 Pressure Release Screw Ee Pressure Release E i Screw EU x Z Ze crews The use of an impact driver may be required to 3 See Figure 6 Remove the 10 S unlock the screws Figure 6 Removing Screws L 850C TOP COVER 44A7180 XXXX 07 O RING TOP COVER 7 7080 90 710 INTERMEDIATE PAN ASSY 44A7223 XXXXX M5 X 10 FLT PHIL 3 p 15 64 092510 c 4 Insert small or medium flat blade screwdriver in the machined recess slot between c
7. Airfield Solutions shall not be liable to the purchaser of this product or third parties for damages losses costs or expenses incurred by purchaser or third parties as a result of accident misuse or abuse of this product or unauthorized modifications repairs or alterations to this product ADB Airfield Solutions shall not be liable against any damages arising from the use of any options or parts other than those designated as approved products Copyright 2012 by ADB Airfield Solutions All rights reserved ii 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 60m Runway Edge Light Style 2 LED 9 944 TABLE OF CONTENTS 1 0 Sdfety EE 1 1 1 To use this equipment EEN 1 1 1 1 Additional Reference Materials AAA 1 1 1 2 Qualified Personnel rainira n ro he EORR S 1 11 3 Intended Use eg Re n P Ale ERRORI ELI be 1 A ER 1 TA AA ee TEE 2 1 1 4 2 Material Handling Precautions AN 2 1 1 4 3 Action in the Event of a System or Component Malfunction 2 1 1 4 4 Maintenance and Hepair 2 20 VRE Diss 2 eut Rouen ditat e Ded Pedes 3 2 4 Aboutthis manual 5 5 cnr tet e e rette ah de 3 2 1 1 How to work with the manual nenne 3 2 12 Record of CHANGES cash in t qe T Pe tbi petiit epa der 3 2 1 3 Icons used in the manual eene 3 RCM 0 EE 4 2 2 1 Compliance with Standards AA 4 2 2 2 S68 iio EDO EROR BONIS dE 4 2 2 9 Feal r68
8. FAA AC 150 5200 23 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 9 9 14 2 5 2 Fixture Component Maintenance 2 5 2 1 Cleaning the Light Channel and Prism 60m Runway Edge Light Style 2 LED Maintenance WARNING Turn off the circuit before replacing fixture s Failure to observe this warning may result in personal injury death or equipment damage The preferred method of maintaining the IREL in pavement high intensity runway edge light is to periodically and systematically replace the light assembly and return the replaced assembly to the maintenance shop for renovation As an alternative you can service the light assembly in the field It is recommended however that field servicing be limited to cleaning lenses and removing moisture To clean the light channel and prism perform the following procedure 1 Use a suitable fiber brush to remove all accumulated debris from the light channel 2 Clean the outer surface of the prism using liquid glass cleaner If the prism is coated with a substance impervious to the cleaner apply a suitable solvent sparingly with a wad of cotton or a patch of cloth After the solvent has acted remove the softened coating with a clean piece of cotton or cloth Dry the prism with gently dry oil free compressed air at a pressure no greater than 10 psi 69 KN m2 to evaporate or remove all remaining cleaner 2012 ADB Airfield Solutions All Rights Reserved 13 6
9. and J5 3 Disconnect the power from J1 and J2 4 Remove the PCB 5 Replace the PCB and reconnect all wires NOTE PCB Is 2 chan by default add shunt to J7 pins amp 4 to change it to 1 Apply jumper to center pins 3 amp 4 This modification changes the dual driver PCB to single driver 6 Close the unit and test for leaks see Testing for Leaks on page 20 2012 ADB Airfield Solutions All Rights Reserved 19 60m Runway Edge Light Style 2 LED 96A0463 Rev B Maintenance 9 9 14 WARNING The unit must have all its screws installed and correctly torqued prior to pressurizing to 20 psi maximum 2 5 5 1 Testing for Leaks High pressure may cause the fixture to explode causing damage to fixture personal injury or death Always test for leaks after opening the fixture for any reason To perform this test Figure 14 Remove pressure release screw E11 see Figure 14 2 Screw the pressure test fitting hand tight into the pressure relief port see figure below The relief port is the opening created when the pressure release screw is removed 3 Attach an air line to the lock hose plug sleeve shown below 4 Pressurize to 20 psi maximum 5 Submerge the fixture in a bucket or tank filled with water Check for air bubbles which would indicate a leak Pressure P N 4446104 may be purchased separately from ADB Airfield Solutions Lock hose plug sleeve KE 6 Lo
10. 00 Volts and a peak current of 5 000 Amps Includes a UL 467 rated ground lug which accepts an AWG 6 earth ground wire e Environment friendly precision cast aluminum alloy cover optical support and inner cover assembly with stainless steel hardware 4 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 9 9 14 2 2 4 Dimensions 2 2 5 Packaging 2012 ADB Airfield Solutions All Rights Reserved 60m Runway Edge Light Style 2 LED Introduction Low temperature lights Temperature rise at center of top cover remains below FAA specified limit of 320 F 160 C Figure 1 Light Beam Location G d RIGHT TOE IN LEFT TOE IN E ch E g n L GEN mn L D RW D Wee LEFT TOE IN RIGHT TOE IN A NOTE Triangle embossed on the top cover should point toward the centerline to ensure correct toe in position Outside Diameter 11 94 in 30 33 cm Bolt Circle Diameter L 868B 11 25 in 28 58 cm Max Bottom Cover O D 9 94 in 25 25 cm Max Bottom Cover O D 9 92in 25 20 cm down to depth of 1 63 in 4 14 cm 8 69 in 22 07 cm from depth of 1 63 in 4 14 cm to 3 88 in 9 86 cm Compatible with L 868B Top Sections where the overall height of the Top Section is less than 4 in 10 16 cm Bottom Cover Depth 3 88 in 9 9 cm In cardboard box 7x13x 13 in 17 8 x 33 x 33 cm Weight with packing 18 5 Ib 8 4 kg Weight without packing 15 5 Ib 7 kg 60m Runway
11. 0m Runway Edge Light Style 2 LED 96A0463 Rev B Maintenance 9 9 14 2 5 2 2 Lifting Optical Unit Out There are two methods that can be used to lift the fixture fB 0r BaSe Method 1 Use eyebolts to lift the fixture 1 Remove the six mounting bolts and washers 2 Fit the eyebolts into both threaded holes located 180 degrees apart in the cover lift the optical unit out of the base and place the optical unit next to the base NOTE Lifting Tool is two 1 2 inch x 13 Eyebolts 1 in ID and a 1 2 in dia rod pipe x 16 in long placed between the eyebolts 3 Disconnect the light fixture wires from the power wires coming from the transformer s 4 Mount a serviced or new light fixture as described in Installation on L 868 Base in the Installation section NOTE Torque the six screws to 185 5 in Ib 20 902 0 565 Nem If lubricant is used on the bolts contact the base can manufacturer for recommended torque values 5 Take the in pavement fixture unit back to the maintenance shop where it can be serviced entirely NOTE Never hold the light fixture by the wires This may damage the insulation Method 2 Use a lifting tool To lift the optical unit out of the base receptacle or adapter ring proceed as follows 1 Remove the mounting bolts and washers NOTE Never hold the light fixture by the wires This may damage the insulation 2 Fit the appropriate lifting tool into lifting holes A located 180 apart in the cover
12. EDIATE PAN ASSY 50 60HZ 44A7223 XXXXX Figure 20 M5 X 10 FLT PHIL SS 64A0925 10 Description Part No Cord set L 823 Style 6 2 pin 18 FAA 4072 42 351 Cord set L 823 Style 6 2 pin 10 ICAO 4072 24 950 LED light engine L 850C L white 48A0450 WHT2 LED light engine L 850C L red 48A0450 RED LED light engine L 850C L yellow 48A0450 YEL LED PCB Assembly 44A7228 00201 Lens 4072 18 336 Lens retainer plate 4072 18 350 Lens seal 4072 18 362 Lens retainer seal 4072 18 380 O Ring pressure release screw 63B0267 011 O Ring top cover 7080 90 710 Pressure release screw 60A2602 Bar Lifting Tool 1411 19 550 Set of spare anchor hooks for lifting tool 1411 19 550 1411 19 560 O ring seal between top cover and shallow base for F Range 12 7080 90 650 Must replace both light engines on the same side at the same time Quantity 2 needed Depending on installation method and snow plowing technique used a snow plow ring may be necessary Snow plow rings are available for either standard or stainless steel adjustable Size B L 868 cans Contact the ADB Sales Department for additional details 2012 ADB Airfield Solutions All Rights Reserved 23 60m Runway Edge Light Style 2 LED 96A0463 Rev B Parts 9 9 14 Figure 18 Top Cover Assembly M5 X 12 Pan Hd Phil Mach Screw SS L 850C HEATER MOUNTING PLATE ASSEMBLY 64A1012 12 STD APPLY SMALL AMOUNT OF 67A0094
13. Edge Light Style 2 LED Introduction 2 2 6 Electrical Supply 96A0463 Rev B 9 9 14 It is recommended that the L 850C L LED fixture be powered from a dedicated CCR and that separate remote controls are available IREL LED lights have been designed to work with any IEC or FAA compliant transformer up to 200 W without affecting the performance or lifetime of the light fixture or transformer See catalog sheet 1215 on our Web site at http www adb air com for more details on recommended isolation transformers XF specified below Isolation Isolation IREL L Fixture Load Transformer CCR Load Transformer Load Without Heater Unidirectional 21 VA 30 45 W 8 VA 29 VA Bidirectional 36 VA 65W 17 VA 53 VA Vue 2 21 aide 29 per side Bidirectional 42 VA total 30 45 W per side 8 VA per XF 58 VA total With Heater Unidirectional 49 VA 65 W 15 VA 64 VA Bidirectional 64 VA 65W 13 VA 77 2 49 aide e 64 VA per side Bidirectional 98 VA total 65 W per side 15 VA per XF 128 VA total 1 One cord set 2 One cord set per side 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 9 9 14 2 3 Installation 2 3 1 Input Requirement Summary 2 3 2 Unpacking 2 3 3 Connection of the Series Transformer and the Light Connectors 60m Runway Edge Light Style 2 LED Installation WARNING Read the instructions in their entirety before starting installati
14. LED 96A0463 Rev B Parts 9 9 14 Figure 20 Bottom Pan Order Codes 44A7223 XXXXX L 0 FAA OBS USE 1 1 FAA amp ICAO MONITORING 0 NO PCB DRIVER 1 SINGLE 2 DUAL FREQUENCY 1 50 60HZ CORDSET 1 ONE 2 TWO 26 2012 ADB Airfield Solutions All Rights Reserved Registered office ADB Airfield Solutions LLC 977 Gahanna Parkway Columbus OH 43230 USA ADB BVBA Leuvensesteenweg 585 B 1930 Zaventem Belgium ADB Airfield Solutions LLC 5500 North Service Road Suite 1108 Burlington Ontario L7L 6W6 Canada ADB Airfield Technologies Ltd China Room 901 9F Fang Heng Intl Plaza Building C No 6 Futong East Road Chaoyang District Beijing 100102 P R China im ADB BVBA Niederlassung Deutschland Von der Tann Str 31 90439 N rnberg Deutschland ADB Airfield Solutions Ltd 2nd Floor 3 Rivonia Village Cnr Mutual Road and Rivonia Boulevard South Rivonia 2128 South Africa ADB Succursale France Paric Nord 2 22 Avenue des Nations BP 55428 Villepinte F 95944 Roissy Charles de Gaulle France A 10 01 Level 10 Empire Tower Jalan SS16 1 45700 Subang Jaya Selangor Malaysia ADB Dubai Silicon Oasis Wing D Office D 309 P O Box 341218 United Arab Emirates DI E SCH Suite 4 110 High Street Maidenhead Berkshire SL6 1PT United Kingdom Tel 1 614 861 1304 Fax 1 614 864 2069 Web www adb airfield com T
15. LOCTITE 262 50ML BOT MED TO HI STRENGTH TYP 6 INT LOCKWASHER 66A0038 3 6 32 HX NUT L 850C LENS RETAINER PLATE We 4072186350 65A0015 11 HEATER DISC 2 LEADS 61A0459 APPLY A THIN LAYER OF THERMAL COMPOUND 67A0033 TO UNDER SIDE OF HEATER DISK THERMOSTAT amp UNDERSIDE OF MOUNTING PLATE PRIOR TO ASSEMBLY L 850C LENS RETAINER SEAL 4072 18 380 H WM e L 850C LENS 4072 18 336 APPLY THIN LAYER OF GREASE PRIOR TO ASSEMBLY L 850C LENS SEAL 10218362 L 850C LIGHT ENGINE 48A0450 XXXX THRMSTAT NO HERM STUD N O C80F O60F 54A0022 8060 APPLY ATHIN LAYER OF THERMAL COMPOUND 67A0033 TO UNDER SIDE OF HEATER DISK THERMOSTAT amp UNDERSIDE OF MOUNTING PLATE PRIOR TO ASSEMBLY 24 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 60m Runway Edge Light Style 2 LED 9 9 14 Parts Figure 19 IREL Toeing ADB LOGO LOCATED OPPOSITE SIDE SIDE 1 LEFT TOE IN SIDE 1 LEFT TOE IN DIRECTION DIRECTION ARROW LOCATION OPPOSITE SIDE SIDE 2 RIGHT TOE IN DIRECTION SIDE 2 RIGHT TOE IN DIRECTION 44A7180 XXXX L 0 FAA 1 FAA amp ICAO SEE SHEET 4 ARCTIC KIT 1 NO 2 YES SIDE 2 COLOR amp TOE IN OBS 0 1 WHT STRAIGH 2 WHTIRIGH 1 COLOR amp TOE IN FT GRN STRAIGH N A GRN LEFT 2012 ADB Airfield Solutions All Rights Reserved 25 60m Runway Edge Light Style 2
16. Plate hardware with the Phillips pan head screws Apply a droplet of sealant Loctite 270 to the last threads Torque to 31 4 inch pounds 8 5 0 5 Nem 10 Close the Optical Unit 11 Test for leaks see Testing for Leaks on page 20 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 60m Runway Edge Light Style 2 LED 9 9 14 Maintenance 2 5 4 Replacing LED Figure 9 IREL LED Assembly Assembly L 850C LIGHT ENGINE 48A0450 XXXX BI DIRECTIONAL MACHINED 62A2213 20 Open the Optical Unit see Opening Optical Unit on page 15 Disconnect the LED Assembly wires at the PCB by pulling gently upward Remove the three Phillips Head screws clean the mounting surface of the top cover Replace the LED Assembly attach with three Phillips Head screws apply a drop of Loctite 242 and torque to 2 5 0 5N m 22 4 IN LBS 5 Connect the LED Assembly to the PCB 6 Close the Optical Unit 7 Testfor leaks see Testing for Leaks on page 20 Figure 10 LED Light Engine Connections QIN USE J4 ONLY PLUG LIGHT ENGINE ADAPTER HARNESS 44A7308 WHT OR 44A7308 RED AS REQUIRED ge Y Abs B na E gs OF H oe 5 L On O ai o gu csso AI Ne uH o
17. Retorquing Mounting Bolts AA 21 PN IH 22 2 61 IREE Components i Ie eic d eren 23 2 6 2 Optional Snow Plow Ring essseneeneeenenneeneen rennen 23 2012 ADB Airfield Solutions All Rights Reserved iii 60m Runway Edge Light Style 2 LED 96A0463 Rev B 9 9 14 fe 5 5 7 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 9 9 14 1 0 Safety 1 1 To use this equipment safely 1 1 1 Additional Reference Materials 1 1 2 Qualified Personnel 1 1 3 Intended Use 1 1 4 Storage 60m Runway Edge Light Style 2 LED Safety This section contains general safety instructions for installing and using ADB Airfield Solutions equipment Some safety instructions may not apply to the equipment in this manual Task and equipment specific warnings are included in other sections of this manual where appropriate WARNING Read installation instructions in their entirety before starting installation Refer to the FAA Advisory Circular AC 150 5340 26 Maintenance of Airport Visual Aids Facilities for instructions on safety precautions Observe all safety regulations To avoid injuries always disconnect power before making any wiring connections or touching any parts Refer to FAA Advisory Circular AC 150 5340 26 Become familiar with the general safety instructions in this section of the manual before installing operating maintaining or repairing this equipm
18. aged or Distorted light wrong prism installed Check parts list and install correct prism beam output Improper toe on the LED Check the toe of the LED assembly Adjust if necessary assembly Damaged or missing prism seals or top cover O ring Water inside optical chamber Replace both prism seals Replace top cover O ring Verify that the fixture is sealed 2012 ADB Airfield Solutions All Rights Reserved 11 60m Runway Edge Light Style 2 LED Maintenance 2 5 Maintenance 2 5 1 IREL Maintenance Schedule Interval Maintenance Task Action 96A0463 Rev B 9 9 14 Refer to Weekly Check for dirty channel and prism Clean channel and prism Cleaning the Light Channel and Prism on page 13 Monthly more often during rainy Seasons Every 60 days also whenever the light assembly is serviced After snow removal 12 Check for moisture in the light fixture by looking through the lens Check for improper torque on hold down bolts Check for damaged light fixtures Open up the light fixture if moisture is present Clean dry and inspect the light assembly Replace the O ring Torque the six bolts holding the fixture to the base Replace damaged fixtures Use a power broom for snow removal if practical Opening Optical Unit on page 15 Retorquing Mounting Bolts on page 21 Follow recommended snow removal techniques described in
19. cate the leak source depressurize replace the leaky seal or part reassemble and repeat the test 7 Ifthe leak is fixed depressurize and reinstall the pressure release screw 20 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 60m Runway Edge Light Style 2 LED 9 9 14 Maintenance 2 5 5 2 Retorquing Mounting When retorquing mounting bolts apply one drop of Grade AV Loctite to each of the six Bolts 3 8 inch 9 525 mm diameter mounting bolts Torque the bolts to 185 5 inch pounds 20 902 0 565 Nem Torque the bolts in opposite pairs See Figure 15 To torque the outer bolts in a star pattern tighten bolts in noted sequence 311 and 4 then 2 and 5 then 3 and 6 NOTE Applying more than one drop of Loctite to the screw and bolt threads will create future difficulty in removal of the bolts If lubricant is used on the bolts contact the base can manufacturer for recommended torque values After several fixture maintenance cycles threaded holes may accumulate with dirt and excessive Loctite If this occurs screws may not seat properly Clean holes with light weight oil or diesel fuel using a small fiber brush Wipe the holes clean with alcohol to remove all oil or diesel fuel and dirt Clean with dry oil free low pressure air Figure 15 Sequence for Torquing Mounting Bolts Bolt 2 Bolt 5 2012 ADB Airfield Solutions All Rights Reserved 21 60m Runway Edge Light Style 2 LED 96A0463 Rev B Pa
20. d ready for installation B uid To install the fixture on an L 868 base see FAA AC 150 5345 30 and the project site specific plans and specifications for details on L 868 base installation NOTE Mounting bolts are not supplied with the fixture Mounting bolts and anti rotation lock washers are normally supplied with the base can or flange ring If a flange ring is used the bolt length is 1 1 4 32mm plus the thickness of the flange ring Also read the following guidelines 1 Clean the base receptacle Make sure the base receptacle is completely clean and dry The mating surfaces must be clean and free of foreign particles 2 Count out the six fixing bolts and anti vibration washers required 3 Fit an appropriate lifting tool into both holes which are located 180 apart in the cover NOTE The lifting tool can be made from two 1 2 x 13 eyebolts 1 in ID and a 1 2 in diameter 16 in 406mm long rod or pipe inserted through the eyebolts 4 If present lift the old or faulty optical unit out of the base CAUTION Never hold the light fixture by the wires Doing so may damage the cordset 5 Carry the new light assembly to the base 6 Place the light assembly beside the opening in the L 868 base so that the L 823 Power connector can be connected with the mating receptacle from the L 830 or L 831 isolation transformer in the base Make sure that the connection is solid and secure Refer to Electrical Supply on page 6 for req
21. eer RU PER EU lauren b e ier teense 4 2 2 4 Dimensions aero RU ROBO HU ERIS 5 2 2 5 Packaglhgis s i dioere eint eoe t de Prec 5 2 2 6 Electrical Supply neret cete ee edes 6 2 3 Installatlon EE ume e Pe sees 7 2 3 1 Input Requirement Summary esses 7 2 3 2 Uripacking 3 53 5 Hem pt Decretos e Ie 7 2 3 3 Connection of the Series Transformer and the Light Connectors 7 2 3 4 Installati n orn 868 Base ie cette pes 8 2 3 5 Installation on a Shallow Base 10 2 3 6 Earth Ground Connection sse 10 2 4 Troubleshooting ute eee ted ee deni ra iniu 11 2444 Troubleshooting deeem P 11 2 5 Maintenance at t pi eee eden eae e gu e eiit eter 12 2 5 1 IREL Maintenance Schedule seen 12 2 5 2 Fixture Component Maintenance sse 13 2 5 2 1 Cleaning the Light Channel and Prism 13 2 5 2 2 Lifting Optical Unit Out of Base 14 2 5 3 Repair Procedures eese ien entente 15 2 5 3 1 Opening Optical Unit ter ce deer deet eda 15 2 5 3 2 Replacing Prism se ei 16 2 5 4 Replacing LED Assembly AAA 17 2 5 4 1 Replacing L 823 Cordset A 18 2 5 5 Replacing the e EE 19 2 5 5 1 Testing for Leaks need tee etn E 20 2 5 5 2
22. el 32 2 722 17 11 Fax 32 2 722 17 64 Email info adb air com Tel 1 905 331 6887 Fax 1 905 331 9389 Web www adb airfield com Tel 86 10 8476 0106 Fax 86 10 8476 0090 Tel 49 0 911 2105 61 60 Fax 49 0 911 2105 61 61 Email info ADB GER adb air com Tel 27 0 11 525 9340 Fax 27 0 11 525 9348 Email info sa adb air com Tel 33 1 49 89 66 30 Fax 33 1 49 89 17 81 Tel 603 8941 4868 Fax 603 8942 4869 Tel 971 4372 4970 Fax 971 4372 4975 Fax 01628784865 Customer Services 01628672906 Sales amp General 01628785339 ADB Italia Via Quasimodo 46 Primo Maggio 40013 Castelmaggiore BO Italia ADB Equipamentos Para Aeroportos Ltda Avenida Moaci n 395 Conjunto 91 Moema CEP 04083 000 Sao Paulo SP Brasil ADB Doha C O Watad Group PO Box 192 Doha Qatar ADB bvba Taiwan Branch 6th floor No 283 Section 2 FU Hsing South Road Taipei 106 Taiwan R O C Tel 55 11 5096 2169 Fax 55 11 5049 2304 Tel 00974 44 35 38 03 Fax 00974 44 35 44 89 ADB Airfield Solutions USA 977 Gahanna Pkwy Columbus Ohio 43230 USA Telephone 41 614 861 1304 Fax 1 614 864 2069 www adb airfieldsolutions com The information contained in this document is subject to change without notice ADB reserves the right to make changes and improvements to its products and assumes no responsibility for making these modifications on any equipment previously sold 96A0463
23. ent Read and carefully follow the instructions throughout this manual for performing specific tasks and working with specific equipment Make this manual available to personnel installing operating maintaining or repairing this equipment Follow all applicable safety procedures required by your company industry standards and government or other regulatory agencies Install all electrical connections to local code Use only electrical wire of sufficient gauge and insulation to handle the rated current demand All wiring must meet local codes Route electrical wiring along a protected path Make sure they will not be damaged by moving equipment Protect components from damage wear and harsh environment conditions Allow ample room for maintenance panel accessibility and cover removal Protect equipment with safety devices as specified by applicable safety regulations If safety devices must be removed for installation install them immediately after the work is completed and check them for proper functioning prior to returning power to the circuit NFPA 70B Electrical Equipment Maintenance NFPA 70E Electrical Safety Requirements for Employee Workplaces ANSI NFPA 79 Electrical Standards for Metalworking Machine Tools OSHA 29 CFR Part 1910 Occupational Health and Safety Standards National and local electrical codes and standards The term qualified personnel is defined here as individuals w
24. f you start with Bolt 1 then tighten Bolt 4 Next tighten Bolts 2 and 5 Bolt 57 N Bolt 4 Then tighten Bolts 43 and 6 2 Applying more than one drop of Loctite to the bolt threads will make the bolts very difficult to remove After several re lampings threaded holes may accumulate dirt and Loctite If this occurs screws may not seat properly Clean the holes with lightweight oil using a small fiber brush Wipe the holes clean with alcohol to remove all oil or diesel fuel and dirt Clean with dry oil free low pressure air After a bolt has been retorqued three times replace it with a new bolt If a bolt is continuously loose inspect the tapped thread in the light base flange for damage If the threads are damaged contact the ADB Airfield Solutions Sales Department for a field repair insert kit 60m Runway Edge Light Style 2 LED 96A0463 Rev B Installation 9 9 14 2 3 5 Installation on a Installing the IREL light fixture on a shallow base involves preparing the pavement recess Shallow Base and wireways then installing the light fixture on a shallow base See FAA AC 150 5345 30 and the project site specific plans and specifications for details on shallow base installation Also follow the applicable instructions in the previous section Installation on L 868 Base on page 8 when connecting installing and powering the fixture Place an O ring seal between top cover and shallow base for F Range 12 ADB 7080 90 650
25. ho thoroughly understand the equipment and its safe operation maintenance and repair Qualified personnel are physically capable of performing the required tasks familiar with all relevant safety rules and regulations and have been trained to safely install operate maintain and repair the equipment It is the responsibility of tne company operating this equipment to ensure that its personnel meet these requirements Always use required personal protective equipment PPE and follow safe electrical work practices WARNING Using this equipment in ways other than described in this manual may result in personal injury death or property and equipment damage Use this equipment only as described in this manual ADB Airfield Solutions cannot be responsible for injuries or damages resulting from nonstandard unintended applications of its equipment This equipment is designed and intended only for the purpose described in this manual Uses not described in this manual are considered unintended uses and may result in serious personal injury death or property and equipment damage Unintended uses may result from taking the following actions Making changes to equipment that are not recommended or described in this manual or using parts that are not genuine ADB Airfield Solutions replacement parts Failing to make sure that auxiliary equipment complies with approval agency requirements local codes and all applicable safety standards Usi
26. ng materials or auxiliary equipment that are inappropriate or incompatible with ADB Airfield Solutions equipment Allowing unqualified personnel to perform any task CAUTION If equipment is to be stored prior to installation it must be protected from the weather and kept free of condensation and dust Failure to follow this instruction can result in injury or equipment damage 2012 ADB Airfield Solutions All Rights Reserved 1 60m Runway Edge Light Style 2 LED 96A0463 Rev B To use this equipment safely 9 9 14 1 1 4 1 Operation WARNING Only qualified personnel physically capable of operating the equipment and with no impairments in their judgment or reaction times should operate this equipment Readall system component manuals before operating this equipment A thorough understanding of System components and their operation will help you operate the system safely and efficiently Before starting this equipment check all safety interlocks fire detection systems and protective devices such as panels and covers Make sure all devices are fully functional Do not operate the System if these devices are not working properly Do not deactivate or bypass automatic safety interlocks or locked out electrical disconnects or pneumatic valves Protect equipment with safety devices as specified by applicable safety regulations If safety devices must be removed for installation install them immediately after the wo
27. nimum When quartz incandescent fixtures are replaced with LED fixtures airport staff can add more lights without increasing CCR size LED photometric performance will be maintained longer due to a cleaner lens The lower temperature of the lens prevents the baking effect that causes contaminants to stick to the surface of the lens Offers longer maintenance intervals and requires fewer spare parts resulting in lower life cycle cost e Smart electronics control current to LED so light output matches existing incandescent fixtures at all brightness levels without sacrificing any light characteristics Actual light output is determined based on a continuous light output curve Therefore light output truly represents input current even if series circuit input current is not within FAA specification limits Allows for a low cost and progressive evolution of the airfield lighting toward new LED based technology Unique double barrier cord set design eliminates risk for water incursion in case the cord set becomes damaged Cord set can also be easily replaced without opening fixture Light channel in front of prism windows protects prisms from damage and prevents rubber buildup thereby maintaining optimal light output Rugged lightning protection that complies with ANSI IEEE C62 41 1991 Location Category C2 given in FAA Eng Brief 67 Category C2 is defined as a 1 2 50 uS 8 20 uS combination wave with a peak voltage of 10 0
28. of four years after the date of installation and are guaranteed to be merchantable and fit for the ordinary purposes for which such products are made ADB Airfield Solutions will correct by repair or replacement at its option equipment or parts which fail because of mechanical electrical or physical defects provided that the goods have been properly handled and stored prior to installation properly installed and properly operated after installation and provided further that Buyer gives ADB Airfield Solutions written notice of such defects after delivery of the goods to Buyer Refer to the Safety section for more information on Material Handling Precautions and Storage precautions that must be followed ADB Airfield Solutions reserves the right to examine goods upon which a claim is made Said goods must be presented in the same condition as when the defect therein was discovered ADB Airfield Solutions further reserves the right to require the return of such goods to establish any claim ADB Airfield Solutions obligation under this guarantee is limited to making repair or replacement within a reasonable time after receipt of such written notice and does not include any other costs such as the cost of removal of defective part installation of repaired product labor or consequential damages of any kind the exclusive remedy being to require such new parts to be furnished ADB Airfield Solutions liability under no circumstances will exceed the contrac
29. on This section provides installation instructions for the IREL Light Fixture The IREL light fixture is designed for connection to a 6 6 A or 20 A series lighting circuit via an L 830 for 60Hz or L 831 for 50Hz isolation transformer Each unit is individually packaged in a durable cushioned corrugated cardboard carton To avoid unnecessary damage to the light assembly unpack the carton at the installation site To unpack the carton open the flaps carefully remove the top packing material and remove the fixture Set the light assembly in a protected area If damage to any equipment is noted file a claim form with the carrier immediately The carrier may request to inspect the equipment 1 The 2 pin plug on cable 1 is connected to the socket for the secondary circuit of the series transformer See Figure 2 NOTE The IREL also may have 2 power leads one for each side Figure 2 IREL with Power Lead M M Ar Power Lead Ground NOTE All connections should be sealed with self bonding insulation tape and then covered with electrical tape in accordance with local airport practices If your airport does not require this it is highly recommend that you at least wrap the connection with electrical tape 2012 ADB Airfield Solutions All Rights Reserved 7 60m Runway Edge Light Style 2 LED 96A0463 Rev B Installation 9 9 14 2 3 4 Installation on L 868 The light assembly is shipped complete an
30. over and inner cover and turn it vertically to separate the inner cover from the cover 2012 ADB Airfield Solutions All Rights Reserved 15 60m Runway Edge Light Style 2 LED Maintenance 2 5 3 2 Replacing Prism 16 96A0463 Rev B 9 9 14 Table 1 Parts List for Replacing Prism Part Number Description Quantity Note 4072 18 336 Lens optical glass 20r4 4072 18 380 Lens Retainer Seal 20r4 4072 18 362 Lens Seal 20r4 To replace the prism perform the following procedure 1 See Figure 7 Remove the LED Assembly by removing the four Phillips Head screws 2 Remove the lens retainer plate and Lens Retainer Seal secured in the inner pan assembly Also see Figure 18 Figure 7 Lens Retainer Seal and Lens Lens Retainer ii Seal 1 Lens Figure 8 Lens Seal for Lens Lens Seal Lens ZS I P 2 2 3 See Figure 8 Push the Lens with the Lens Seal towards the inside of the cover 4 Clean and remove grease from the prism chamber with any effective solvent NOTE Never use any abrasive substance This will scratch or frost the prism 5 Apply a thin layer of Dow Corning Molykote 3452 or equivalent in the prism chamber using a small brush 6 Install a Lens Seal over the Lens 7 Push the Lens and Seal assembly in the lens pocket from the inside and clean the inner surface of the lens 8 Install a Lens Retainer Seal over the Lens 9 Reinstall the Lens Retainer
31. rk is completed and check them for proper functioning Route electrical wiring along a protected path Make sure they will not be damaged by moving equipment Never operate equipment with a known malfunction Do not attempt to operate or service electrical equipment if standing water is present Usethis equipment only in the environments for which it is rated Do not operate this equipment in humid flammable or explosive environments unless it has been rated for safe operation in these environments Never touch exposed electrical connections on equipment while the power is ON 1 1 4 2 Material Handling Precautions CAUTION A This equipment may contain electrostatic sensitive devices Protect from electrostatic discharge Electronic modules and components should be touched only when this is unavoidable e g soldering replacement Before touching any component of the cabinet you should bring your body to the same potential as the cabinet by touching a conductive earthed part of the cabinet Electronic modules or components must not be brought in contact with highly insulating materials such as plastic sheets synthetic fiber clothing They must be laid down on conductive surfaces The tip of the soldering iron must be grounded Electronic modules and components must be stored and transported in conductive packing 1 1 4 3 Action in the Event of a System or Component WARNING Malfunction Do no
32. rts 9 944 2 6 Parts Figure 16 IREL Ordering Code Ordering Code IREL LED Colors Side 1 i 1 0 Obscured 3 White Left Toed A 6 Red Left Toed 9 Yellow Left Toed Number of Cord Se ts 1 One 2 Two Cord Set Style and Length Style 6 2 pin 18 long FAA standard Style 1 SO Jacketed cable 2 pin 18 long FAA standard Style 6 2 pin 10 long Style 6 3 pin 10 long German Style 1 2 pin 10 long German Style 1 3 pin 10 long French Style 3 pin 10 long e O Ul amp CJ Wo n m HW I Notes Fixtures with 18 cord sets are for installation on deep base cans and therefore are not supplied with an external o ring gasket Fixtures with 10 cord sets are for installation on shallow bases and are supplied with an external o ring gasket Typically used for intensive winter service where sand is applied to runways and rotating brushes are used 4 Not ETL Certified M w 22 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 9 9 14 2 6 1 IREL Components 2 6 2 Optional Snow Plow Ring 60m Runway Edge Light Style 2 LED Figure 17 IREL Parts Parts L 850C TOP COVER 44A7180 XXXX Figure 19 APPLY SILICONE GREASE 67A0009 TO O RING ON TOP COVER ASSEMBLY O RING TOP COVER F RANGE paw 7080 90 710 fo O ring seal for shallow base F Range 12 7080 90 650 Ordered separately INTERM
33. t operate a system that contains malfunctioning components If a component malfunctions turn the system OFF immediately Disconnect and lock out electrical power Allow only qualified personnel to make repairs Repair or replace the malfunctioning component according to instructions provided in its manual 1 1 4 4 Maintenance and Repair WARNING Allow only qualified personnel to perform maintenance troubleshooting and repair tasks Only persons who are properly trained and familiar with ADB Airfield Solutions equipment are permitted to service this equipment Disconnect and lock out electrical power Always use safety devices when working on this equipment Follow the recommended maintenance procedures in the product manuals Do not service or adjust any equipment unless another person trained in first aid and CPR is present Connect all disconnected equipment ground cables and wires after servicing equipment Ground all conductive equipment Useonly approved ADB Airfield Solutions replacement parts Using unapproved parts or making unapproved modifications to equipment may void agency approvals and create safety hazards Check interlock systems periodically to ensure their effectiveness Donotattempt to service electrical equipment if standing water is present Use caution when servicing electrical equipment in a high humidity environment Use tools with insulated handles when working with electrical eq
34. t price of goods claimed to be defective Any returns under this guarantee are to be on a transportation charges prepaid basis For products not manufactured by but sold by ADB Airfield Solutions warranty is limited to that extended by the original manufacturer This is ADB Airfield Solutions sole guarantee and warranty with respect to the goods there are no express warranties or warranties of fitness for any particular purpose or any implied warranties of fitness for any particular purpose or any implied warranties other than those made expressly herein All such warranties being expressly disclaimed Trademarks General notice other product names used here are for identification purposes only and may be trademarks of their respective companies Proprietary Information This information carrier contains proprietary information which shall not be used for other purposes than those for which it has been released nor be reproduced or disclosed to third parties without the prior written consent of ADB Airfield Solutions No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical photocopy recording or otherwise without the prior written permission of ADB Airfield Solutions No patent liability is assumed with respect to the use of the information contained herein Neither is any liability assumed for damages resulting from the use of the information contained herein ADB
35. uipment 2 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 9 9 14 2 0 IREL 2 1 About this manual 2 1 1 How to work with the manual 2 1 2 Record of changes 2 1 3 Icons used in the manual 60m Runway Edge Light Style 2 LED IREL 60m Runway Edge Light Style 2 LED The manual shows the information necessary to Install and maintain the IREL Style 2 LED Runway Edge Light Become familiar with the structure and content 2 Read the Safety Instructions 3 Carry out the actions completely and in the given sequence Page Rev Description Checked Approved Date All A Released Manual DM ER 2 12 14 B Updated PCB information RW ER 8 6 14 For all WARNING symbols see the Safety section Carefully read and observe all safety instructions in this manual which alert you to safety hazards and conditions that may result in personal injury death or property and equipment damage and are accompanied by the symbol shown below WARNING Failure to observe a warning may result in personal injury death or equipment damage CAUTION Failure to observe a caution may result in equipment damage 2012 ADB Airfield Solutions All Rights Reserved 3 60m Runway Edge Light Style 2 LED 96A0463 Rev B Introduction 9 9 14 2 2 Introduction 2 2 1 Compliance with ICAO Standards Runway Edge Annex 14 Vol 1 par 5 3 9 7 and 5 3 9 10 Fig A2 10 for 60 m runways T C
36. uired isolation transformers 3 E Ei D 5 8 2012 ADB Airfield Solutions All Rights Reserved 96A0463 Rev B 9 9 14 2012 ADB Airfield Solutions All Rights Reserved 60m Runway Edge Light Style 2 LED Installation 7 Position the light assembly over the L 868 base and set it onto the base Align the light according to FAA AC 150 5345 30 and project plans and specifications Make sure items such as spacers and shims are installed on the light base as indicated on site plans specifications and drawings Remove the eyebolts and lifting rod WARNING Ensure that the cord set wires are NOT pinched between the base can and the fixture Pinched wires can short the input power preventing the light from operating properly 8 If using thread locking adhesive apply only one drop of Grade AV Loctite to each of the six 3 8 in 9 525mm diameter mounting bolts Torque the bolts to 185 5 in Ib 20 902 10 565 m See Notes On Torque Sequence below If lubricant is used on the bolts contact the base can manufacturer for recommended torque values 9 Turn on the power to verify the fixtures illuminate Operate for a minimum of five minutes in each CCR step setting Figure3 Light Fixture Torque Sequence Notes On Torque Sequence Bolt 1 Bolt 42 2 1 Always torque the bolts in opposing pairs do SO tighten bolts in the following sequence see figure at right Bolt 6 Bolt 3
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