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L-852C-D ITCL Taxiway Centerline Inset Lights

Repair

©

2007 Siemens Airfield Solutions

96A0311F

Page 6-1

All rights reserved

Issued 3/05

Section 6

Repair

This section describes procedures for repairing and replacing parts in the
FAA L-852 inset fixture. It includes opening the optical assembly, and
replacing the film disc cutout assembly, LED assembly, and prism and
prism gasket. It also describes how to close the optical assembly.

NOTE:

If the cordset needs servicing, contact the ADB Airfield Solutions

Sales department.

To open the optical assembly, perform the following procedure:

1.

Turn the light unit upside-down.

2.

See Figure 6-1. Remove the pressure release screw

Figure 6-1 Removing Pressure Release Screw Figure 6-2 Removing Inner Pan Screws

1.

Introduction

2.

Opening Assembly

Pressure Release
Screw

Pan Head Screw

Inner Pan

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Summary of Contents for Signature Series

Page 1: ...ne Inset Light Document No 96A0311 Issued March 2 2005 Rev F Nov 08 2009 ETL Certified to FAA AC 150 5345 46C and FAA LED Performance Specification per Engineering Brief 67 ADB Airfield Solutions Copyright 2009 by ADB Airfield Solutions All rights reserved ...

Page 2: ...2 0 2 3 7 2 B Added artic kit wattage and corrected typo in Table 2 1 and Fig 7 1 01397 WT WT 3 7 05 Iii 3 5 C Corrected formatting in Section 3 01413 WT WT 4 8 05 Cover pgs 2 1 2 3 2 5 2 7 D Removed L852A and C certification notation from manual 01840 WT WT 10 4 07 All E Removed references to L852A and L852B Revised part order code numbers 01842 WT WT 10 8 07 all F Edited header and footer parts ...

Page 3: ...Repair 1 4 Section 2 Description 2 1 1 Introduction 2 1 2 Optical Assembly 2 2 3 Optical Assembly 2 3 4 Inner Pan Subassembly 2 3 5 6 F Range Light Fixture Required Equipment 2 4 7 Specifications 2 4 Input 2 4 Light Source 2 4 Expected LED Life 2 4 Light Source 2 4 Photometric Data 2 5 Isolation Transformers 2 5 Prisms 2 5 Light Beam 2 5 Mounting 2 5 Environmental Operating Conditions 2 5 Dimensio...

Page 4: ... Optical Assembly Parts 7 3 5 Numerical Parts List and Recommended Spare Parts 7 9 Figure 2 1 L 852C D F Range Inset Light Fixture 2 1 Figure 2 2 Optical Assembly 2 2 Figure 2 3 Prisms 2 3 Figure 2 4 Inner Pan Subassembly 2 3 Figure 3 1 Typical Installation on FAA L 868B Base 3 2 Figure 3 2 Mounting 3 5 Figure 3 3 Input ID Marker 3 5 Figure 4 1 Retorquing Mounting Bolts 4 3 Figure 4 2 Pressure Tes...

Page 5: ...blies 7 8 Table 2 1 F Range Series Light Fixtures 2 1 Table 2 2 Required Equipment Supplied 2 4 Table 2 3 Required Equipment Not Supplied 2 4 Table 2 4 Photometric Data 2 5 Table 2 5 Light Beam 2 5 Table 2 6 Connectors Supplied 2 5 Table 2 7 F Range Light Dimensions 2 6 Table 3 1 Determining Torque Based on K Factor 3 4 Table 4 1 F Range Light Fixture Maintenance 4 1 Table 4 2 Determining Torque B...

Page 6: ...dition as when the defect therein was discovered ADB Airfield Solutions furthers 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 par...

Page 7: ...tails and values given in this manual are average values and 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 pro...

Page 8: ...ns and touching any parts Refer to FAA Advisory Circular AC 150 5340 26 read and become familiar with the general safety instructions provided in this section of the manual before installing operating maintaining or repairing this equipment read and carefully follow the instructions given throughout this manual for performing specific tasks and working with specific equipment store this manual wit...

Page 9: ...he term qualified personnel is defined here as individuals who 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 the company o...

Page 10: ...e inappropriate or incompatible with your ADB Airfield Solutions equipment allowing unqualified personnel to perform any task Read the installation section of all system component manuals before installing your equipment A thorough understanding of system components and their requirements will help you install the system safely and efficiently WARNING Failure to follow these safety procedures can ...

Page 11: ...t deactivate or bypass automatic safety interlocks or locked out electrical disconnects or pneumatic valves Never operate equipment with a known malfunction Do not attempt to operate or service electrical equipment if standing water is present Use this equipment only in the environments for which it is rated Do not operate this equipment in humid flammable or explosive environments unless it has b...

Page 12: ...uipment Ground all conductive equipment Use only 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 Do not attempt to service electrical equipment if standing water is present Use caution when servicing electric...

Page 13: ...t Above Grade The FAA standard fixture is 12 inch diameter and mounts directly on a FAA L 868B deep light base The fixture is intended for use on 4 8 A 6 6 A 3 Step airfield series circuits The L 852C D fixtures are also available in a 10 inch version that mounts on a FAA L868A light base and the L852C and L 852D 2 piece mounts on a L 868B light base Table 2 1 F Range Series Light Fixtures Use Tax...

Page 14: ...A yellow dot refers to a corresponding yellow LED source Dot is placed above each window area See Figure 2 2 for the optical assembly See Figure 2 3 for the L852C and L852D prism The F Range series light fixture optical assembly consists of one or two unidirectional or two bi directional LEDs and prisms Refer to Specifications in this section for details on LEDs and prisms Figure 2 2 Optical Assem...

Page 15: ...852C Green Yellow L 852D Yellow Only Figure 2 3 Prisms See Section 7 Fig 7 8 7 9 7 10 for detailed information See Figure 2 4 The inner cover assembly is comprised of the inner cover L 823 cordset s and pressure release screw Figure 2 4 Inner Pan Assembly 3 Optical Prisms 4 Inner Pan Cover Assembly Pressure Relief Screw Inner Pan Cover Assembly L823 cordset s ...

Page 16: ...nsformer See Table 2 5 1 or 2 Set of fiber brushes 1 Set of socket wrenches 1 2 in 12 7 mm drive 1 Set of screwdrivers one with 3 8 in 9 525 mm minimum blade width 1 Silicone grease As required Joint sealing filler As required Pressure test fitting assembly See parts list 1 Lifting tool See page 3 9 1 This subsection provides specifications for the F Range Type L 852C D ITCL inset light fixtures 6...

Page 17: ...2B D Yellow Wide Only See Figures 7 8 7 9 and 7 10 in Section 7 Table 2 6 Light Beam F Range Type Light Beam L 852C D Switchable light direction bi directional L 852C D Bi directional standard L 852C D Unidirectional standard The F Range light fixtures mount on an optional ADB Airfield Solutions shallow base or on a 12 inch 304 8 mm diameter deep L 868B light base standard Refer to Table 2 6 for c...

Page 18: ...0 feet 3000 m Relative Humidity Up to 100 Table 2 8 F Range Light Dimensions FAA Type FAA Style FAA Class Outside Diameter Bolt circle diameter L852C D 12 Inch 3 2 11 94 in 303 28 mm 11 25 in 285 75 mm L852C D 10 Inch 3 2 9 94 in 252 47mm 9 25 in 234 95mm The weight of the L 852C D light fixture is 14 7 lb 6 7 kg Options 1 or 2 L823 Cordsets Bidirectional or Unidirectional Arctic Kit Dimensions We...

Page 19: ...ocal codes 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 and carefully remove the top packing material Thread an eyebolt into each of the two opposite threaded holes Run a rod through the eyebolts and lift the light assembly from t...

Page 20: ... inset fixture is installed Inset fixture may also be mounted directly to the light base flange See Note Quantity of these items will increase if inset light has switchable option CAUTION Remove all debris found on all mounting surfaces of the light base or associated spacers flange rings etc before installing the light fixture Failure to remove debris can induce damaging stresses in the light fix...

Page 21: ...ected with the mating secondary receptacle from the L 830 isolation transformer in the light base Make sure that the connection is solid and secure Refer to Specifications in the Description section for required isolation transformers Refer to Mounting and Connections in this section 5 Turn on the power Operate the light assembly for a minimum of five minutes Turn off the power 6 Using the lifting...

Page 22: ...16 175 180 In Lbs 0 17 180 190 In Lbs 0 18 197 207 In Lbs NOTE Always torque the bolts across the corners Refer to Retorquing Mounting Bolts in the Maintenance section To torque the outer bolts across corners tighten bolts in noted sequence 1 and 4 then 2 and 5 then 3 and 6 See Fig 4 1 NOTE Applying more than one drop of Loctite to the bolt threads will create future difficulty in removal of the b...

Page 23: ...se numbers match with Input 1 and Input 2 See Figure 3 3 cast into the inner cover just above the L 823 entrance These numbers are used when a bi directional fixture has two cordset for the switchable feature Figure 3 2 Mounting FAA L852C D Figure 3 3 Input ID Marking 5 Mounting and Connection Lamp Light Channel Marker Number ID Mounting Bolt Hole 6 Holes 60 degrees apart for mounting directly to ...

Page 24: ...nce of moisture in fixture Weekly For obstruction in light output channel Clean channel and prism surface Refer to Cleaning Light Channel and Prism in this section Monthly or more frequently during rainy seasons For presence of moisture or water visual inspection for condensation on inner side of prisms 1 Open up light assembly 2 Clean dry and inspect light assembly 3 Replace cover inner cover gas...

Page 25: ...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 KNt m2 to evaporate or remove all remaining cleaner To retorque mounting bolts perform the following procedure 1 If thread locking adhesive is used apply only one drop of Grade AV Loctite to each of the six 3 8 inch 9 525 ...

Page 26: ...orners tighten bolts in noted sequence 1 and 4 then 2 and 5 then 3 and 6 NOTE Applying more than one drop of Loctite to the bolt threads will create future difficulty in removal of the bolts NOTE After several re lampings 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 bru...

Page 27: ...d washers or self locking nuts 2 See Figure 3 2 in the Installation section and Figure 2 1 in the Description section To lift the inset screw 13 Eye Bolt into each of the tapped holes located 180 apart in the cover Align the two eyebolts and then insert a 3 8 diameter bar through the eyebolts and lift the inset fixture off of the light base 3 Disconnect the light fixture wires from the power wires...

Page 28: ... relief screw is removed Screw fitting hand tight Figure 4 2 Pressure Test Fitting Assembly 1 Pressure Test Fitting 2 Lock Hose Plug Sleeve 3 Attach the shop airline to the lock hose plug sleeve 2 4 Pressurize to 20 psi 5 Submerge the pressure test fitting in a water tank Check for air bubbles Air bubbles indicate a leak 6 Locate the leak source depressurize replace the seal that is leaking reasse...

Page 29: ...he circuit and lock out the circuit or regulator so that the circuit cannot be energized by remote means before attempting to service the fixture This section contains troubleshooting information This information covers only the most common problems that you may encounter If you cannot solve the problem with the information given here contact your local ADB Airfield Solutions representative for he...

Page 30: ...ck transformer output current with true RMS ammeter Check power line between the light fixture and the transformer including connectors 2 Weak light output Partial short circuit in primary loop Check cable assembly Defective isolation transformer Replace transformer Dirty prism Incorrect current to fixture Clean prism Refer to Cleaning Light Channel and Prism in the Maintenance section Check the c...

Page 31: ...n prism loose screws or damaged wire insulation 3 Clean dry inspect or replace damaged components 5 Flashing LED Incorrect current Check the current to the fixture to ensure it is within FAA specifications for the selected step If not adjust the CCR or repair circuit issues Ensure that the isolation transformers have adequate capacity to run the fixture especially if using arctic kit Underloaded C...

Page 32: ...ilm disc cutout assembly LED assembly and prism and prism gasket It also describes how to close the optical assembly NOTE If the cordset needs servicing contact the ADB Airfield Solutions Sales department To open the optical assembly perform the following procedure 1 Turn the light unit upside down 2 See Figure 6 1 Remove the pressure release screw Figure 6 1 Removing Pressure Release Screw Figure...

Page 33: ...blade to separate it CAUTION Be careful Do not pull on the flat cable when you lift the inner pan This might damage the connections Disconnect the connectors before laying the inner pan on the table 5 See Figure 6 3 Disconnect the LED assemblies from the main PCB by pulling out the connectors J1 and J3 J3 is used only in a bi directional light Use a small flat screw driver to separate the connecto...

Page 34: ...ed Issued 3 05 6 Remove the inner pan from the cover NOTE See Figure 6 3 Always replace the cover inner cover gasket and the 3 pan head screws C2 with washers by new ones when a light is opened and closed again This guarantees light fixture water tightness Figure 6 4 Replacing LED Assembly 2 Opening Light Assembly contd ...

Page 35: ... The LED module has been notched to clear the Arctic Kit thermostat Note B The collimator is included in the LED Assembly and should not need to be replaced unless damaged Note C The Flat seal is included in the LED Assembly and should not need to be replaced unless it has been damaged To replace the LED assembly perform the following procedure 1 Open the light assembly Refer to Opening Light Asse...

Page 36: ...ture Refer to Closing Light Fixture in this section Refer to Table 6 4 for parts referred to in Figure 6 8 Table 6 2 Parts List for Replacing Prism and Prism Gasket Item Description Part Number Quantity Note C2 Phillips pan head screws 64A0972 14 3 Prism L 852D curved Green Only 1428 00 700 A Prism L 852C straight Green Yellow 1428 00 710 Prism L852D curved Yellow Only 1428 00 720 B1 Prism gasket ...

Page 37: ...1 Open the light assembly Refer to Opening Light Assembly in this section 2 See Figure 6 4 Unscrew the eight Phillips pan head screws C2 Figure 6 2 Replacing Prism and Prism Gasket 3 Remove the LED assembly C1 Note the collimator B4 and the flat seal B3 are a part of the LED Assembly C1 4 Push the prism B2 with the prism gasket B1 toward the inside of the cover A1 5 Clean the prism recess in the c...

Page 38: ...gasket B1 over the prism B2 and gently push the prism gasket assembly in the prism recess from the inside Clean the inner surface of the prism 8 Install the LED assembly over the prism Re install the Phillips pan head screws C2 with washers and tighten them Refer to Retorquing Mounting Bolts in the Maintenance section NOTE If the flat seal has been damaged replace the seal 9 Close the light fixtur...

Page 39: ...paired or contact SAS sales dept and order a replacement top cover assembly See numerical parts list table in Section 7 If thermostat failed proceed as follows 1 Disconnect the two thermostat leads from PCB disconnects 2 Remove the two screws holding the thermostat in place and then de solder the other thermostat leads Replace the thermostat and re solder the leads and then install the new thermos...

Page 40: ...ead screws D4 with washers Refer to Retorqing Mounting Bolts in the Maintenance section 7 Check the electrical insulation from two pole plug to frame by means of a 500 V insulation tester Apply an AC current not exceeding 6 6 A on the two pole plug and observe normal operation of the LEDs CAUTION The electronic circuit is designed to be fed from a regulated AC current generator only for example a ...

Page 41: ...illustrated The Description column gives the part name as well as its dimensions and other characteristics when appropriate Indentions show the relationships between assemblies subassemblies and parts The Part Number column gives the ADB Airfield Solutions part number Part Number Description Notes xxxxxxxx Assembly A xxxxxxxx Part xxxxxxxx Part or Assembly xxxxxxxx Assembly Note A Unless items in ...

Page 42: ...ing Code Arctic Option 0 Without Artic Option 1 With Arctic Option Cord Set Monitoring 1 Two L 823 cord sets 2 Two leads with shallow base 3 Single L 823 Cordset for L868 Mounting 4 Single Lead for Shallow Base 5 One L 823 Cord Set 6 Two L 823 Cord Sets 7 One L 823 Cord Set with monitoring 8 Two L 823 Cord Sets with monitoring J One cord set bottom entry for L 868A 10 inch extension LED Color 1 Ye...

Page 43: ... Figure 7 2 thru 7 X See Numerical and Spare Parts List for full description Figure 7 2 L852C Figure 7 3 L852D 4 F Range L 852A D Light Fixture Parts L852C Assembly ITCL 1230 ITCL 1231 ITCL 1240 ITCL 1330 ITCL 1331 ITCL 1530 ITCL 1630 L852D Assembly ITCL 2230 ITCL 2231 ITCL 2240 ITCL 2330 ITCL 2331 ITCL 2530 ITCL 2531 ITCL 2630 ITCL 2631 ...

Page 44: ...e assembly except the gasket seal pressure screw and the L 823 Cordset F Range L 852C D Light Fixture Parts cont d L852C D Inner Cover Assembly 4071 97 121 Gasket Seal 4071 86 251 Pressure Relief Screw 60A2602 O Ring 63B0267 011 M4 x 19 Phillips Head Screw 3 places 64A0964 10 Split Lockwasher 66A0026 15 Cable Clamp 4071 50 090 Cable Clamp Grommet 63A1014 Phillips Head Screw 2 places 64A0964 10 Spl...

Page 45: ...between the glass prism and the LED assembly and prevent the collimator and LED strip from falling out of the LED module assembly when it is being bolted to the top cover Figure 6 7 and Numerical Parts list table for LED Assembly part numbers F Range L 852C D Light Fixture Parts cont d L852 LED Green Assembly 1413 05 100 L852 LED Yellow Assembly 1413 05 010 Gasket 4071 96 150 M4 x 14 Phillips Head...

Page 46: ... 8 L852D Prism Figure 7 9 L852C Prism Figure 7 10 L852D Prism F Range L 852C D Light Fixture Parts cont d Prism L852C Green and Yellow 1428 00 710 4 Prismatic Areas w LIGHT GRAY Coating Prism L852D Green Wide Only 1428 00 700 7 Prismatic Areas w LIGHT GRAY coating Prism L852D Yellow Wide Only 1428 00 720 7 Prismatic Areas w DARK GRAY coating ...

Page 47: ...All rights reserved Issued 3 05 Figure 7 11 L852A D Prism Seal Figure 7 12 Arctic Kit Thermostat F Range L 852C D Light Fixture Parts cont d Prism Seal 4072 00 181 Arctic Kit Thermostat 54A0017 8060 Thermal Joint Compound 67A0033 6 32 x 25 Phillips Pan Head Screw 64A0198 4 6 Split Lockwasher 66A0026 11 ...

Page 48: ...e where the Arctic Kit Thermostat is located uses a notched out LED cover to fit behind the thermostat See Numerical Parts List for part number and descriptions L852 LED Green Assembly 1413 05 100 L852 LED Yellow Assembly 1413 05 010 L852 LED Green Assembly Arctic Kit side 62A2161 2 L852 LED Yellow Assembly Arctic Kit Side 62A2161 1 L852 Top Cover w heater 44A6463 1 Unidirectional 44A6463 2 Bi dir...

Page 49: ...scured 1 L 823 cordset Inset Assembly A B ITCL 2230 7 3 L 852D green green 1 L 823 cordset Inset Assembly A B ITCL 2231 L 852D green green 1 L 823 cordset Inset Assembly W Arctic Kit A B ITCL 2240 L 852D green green 1 L 823 cordset Inset Assembly W Shallow Base A B ITCL 2330 L 852D yellow green 1 L 823 cordset Inset Assembly A B ITCL 2331 L 852D yellow green1 L 823 cordset Inset Assembly W Arctic ...

Page 50: ...sembly for Arctic Kit side A B 63B0267 011 7 4 Pressure relief screw o ring B 63A1014 7 4 Grommet 2 B 64A0198 4 7 12 6 32 x 25 Lg Phillips Pan Head Screw 2 B 64A0964 10 7 4 M4 X 19 Phillips Head Screw 3 B 64A0964 14 7 6 M14 X 14 Phillips Head Screw 8 B 66A0026 11 7 12 6 Split Lockwasher 2 B 66A0026 15 7 4 7 6 7 12 Split Lockwasher 3 8 2 B 67A0033 7 12 Thermal Joint Compound for Artic Kit Thermosta...

Page 51: ... 4071 50 090 7 4 F Range Cable Clamp B 4071 96 150 7 7 Flat seal LED 2 B 4071 86 251 7 5 Inner Cover TLP Gasket B 4071 97 121 7 4 L852C D Inner Cover Assembly A B 4071 95 760 7 7 Collimator 1 for a unidirectional 2 for a Bidirectional B 4072 00 181 7 11 Prism seal 1 for a unidirectional 2 for a Bidirectional B 64A0964 14 7 6 Screw M4 x 14 DIN7985 Z A2 B 66A0026 15 7 6 Lock washer M4 DIN 127B A2 B ...

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