Service BulletinService Bulletin

Installation Guidance for Airfield Lighting In-pavement Fixtures Product Solutions Catalog ALN173, Rev. A, 2/26/16

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A DISCLAIMER / WARRANTY

A.0 Disclaimer / Standard Warranty A.1 CE certification A.2 ETL certification A.3 LED Product Guarantee

The equipment listed as CE certified means that the product complies with the essential requirements concerning safety and hygiene. The directives that have been taken into consideration in the design are available on written request to ADB. The equipment listed as ETL certified means that the product complies with the essential requirements concerning safety and FAA Airfield regulations. The directives that have been taken into consideration in the design are available on written request to ADB. Where applicable, per FAA EB67(applicable edition), ADB L858(L) Airfield Guidance Signs are warranted against electrical defects in design or manufacture of the LED or LED specific circuitry for a period of 4 years. ADB LED light fixtures (with the exception of obstruction lighting) are warranted against mechanical and physical defects in design or manufacture for a period of 12 months from date of installation; and are warranted against electrical defects in design or manufacture of the LED or LED specific circuitry for a period of 4 years per FAA EB67 (applicable edition). NOTE: See your sales order contract for a complete warranty description. In some specific cases, deviations are (to be) accepted in the contract, which will supersede the standard warranty.

A.4 Standard Product Guarantee

Products of ADB manufacture are guaranteed against mechanical, electrical, and physical defects (excluding lamps) which may occur during proper and normal use for a period of one year from the date of installation or 2 years from date of shipment and are guaranteed to be merchantable and fit for the ordinary purposes for which such products are made. ADB L858 Airfield Guidance Signs are warranted against mechanical and physical defects in design or manufacture for a period of 2 years from date of installation per FAA AC 150/5345-44 (applicable edition). NOTE: See your sales order contract for a complete warranty description.

A.5 All Products

LED Products of ADB, manufactured and sold by ADB or its licensed representatives, meets the corresponding requirements of FAA, ICAO and IEC. ADB will correct by repair or replacement per the applicable guarantee above, 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 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 furthers reserves the right to require the return of such goods to establish any claim. ADB’s 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’s liability under no circumstances will exceed the contract 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’s 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.

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A DISCLAIMER / WARRANTY

A.6 Liability

WARNING Use of the equipment in ways other than described in the catalogue leaflet and the manual may result in personal injury, death, or property and equipment damage. Use this equipment only as described in the manual.

ADB cannot be held responsible for injuries or damages resulting from non-standard, unintended uses of its equipment. The equipment is designed and intended only for the purpose described in the manual. Uses not described in the manual are considered unintended uses and may result in serious personal injury, death or property damage. Unintended uses includes the following actions: — Making changes to equipment that have not been recommended or described in this manual or using parts that are not genuine ADB replacement parts or accessories. — Failing to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable safety standards if not in contradiction with the general rules. — Using materials or auxiliary equipment that are inappropriate or incompatible with your ADB equipment. — Allowing unskilled personnel to perform any task on or with the equipment.

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A DISCLAIMER / WARRANTY

A.7 © ADB BVBA

This manual or parts thereof may not be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, nor otherwise, without ADB BVBA’s prior written consent. This manual could contain technical inaccuracies or typographical errors. ADB BVBA reserves the right to revise this manual from time to time in the contents thereof without obligation of ADB BVBA to notify any person of such revision or change. Details and values given in this manual are average values and have been compiled with care. They are not binding, however, and ADB BVBA 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. The information given does not release the buyer from making their own experiments and tests.

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TABLE OF CONTENTS A.0

Disclaimer / Standard Warranty ............................................................................................................................. II

A.1 A.2 A.3 A.4 A.5 A.6 A.7

CE certification ..................................................................................................................... ii ETL certification ................................................................................................................... ii LED Product Guarantee ........................................................................................................... ii Standard Product Guarantee ..................................................................................................... ii All Products ......................................................................................................................... ii Liability ..............................................................................................................................iii © ADB BVBA ......................................................................................................................... iv

1.0

Safety ....................................................................................................................................................................... 1

1.1 HAZARD Icons used in the manual ............................................................................................... 1.1.1 Qualified Personnel ......................................................................................................... 1.2 To use this equipment safely: .................................................................................................... 1.2.1 Additional Reference Materials: .......................................................................................... 1.2.2 Intended Use ................................................................................................................. 1.2.3 Fasteners ..................................................................................................................... 1.2.4 Operation ..................................................................................................................... 1.2.5 Storage ........................................................................................................................ 1.2.6 Material Handling Precautions ............................................................................................. 1.2.7 Action in the Event of a System or Component Malfunction .......................................................... 1.2.8 Maintenance .................................................................................................................. 1.2.9 Maintenance and Repair .................................................................................................... 2.0

1 1 2 2 2 2 3 3 3 4 4 4

Appendix A .............................................................................................................................................................. 5

2.1 Installation Guidance for In-pavement Fixtures ............................................................................... 5 2.1.1 Reference Documents ...................................................................................................... 5 2.1.2 Mounting Systems ........................................................................................................... 5 2.2 L-868 base can installation (load bearing) ..................................................................................... 6 2.2.1 Use of Ceramic Bolts ....................................................................................................... 10 2.3 L-867 base can installation (non-load bearing) ............................................................................... 11 2.4 Shallow base can installation ................................................................................................... 14 2.4.1 Parts: ......................................................................................................................... 14 2.4.2 Tools: ......................................................................................................................... 15 2.4.3 Prepare ...................................................................................................................... 15 2.4.3.1 Fixture with toe-in only ............................................................................................ 15 2.4.4 Install ......................................................................................................................... 15 2.4.4.1 Lubricate and connect .............................................................................................. 15 2.4.5 Screws ........................................................................................................................ 16 2.4.6 Standard toolkit ............................................................................................................ 17 2.5 Checking Bolt Torque ............................................................................................................. 18

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A TOC

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1.0 Safety

1.1 HAZARD Icons used in the manual

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. For all HAZARD symbols in use, see the Safety section. All symbols must comply with ISO and ANSI standards. 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.

DANGER - RISK OF ELECTRICAL SHOCK OR ARC FLASH • Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury, death, or equipment damage. ARC Flash may cause blindness, severe burns or death.

WARNING - WEAR PERSONAL PROTECTIVE EQUIPMENT • Failure to observe may result in serious injury.

WARNING - DO NOT TOUCH • Failure to observe this warning may result in personal injury, death, or equipment damage.

CAUTION • Failure to observe a caution may result in equipment damage.

1.1.1 Qualified Personnel

IMPORTANT INFORMATION The 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 operating this equipment to ensure that its personnel meet these requirements. Always use required personal protective equipment (PPE) and follow safe electrical work practices.

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A To use this equipment safely:

1.2 To use this equipment safely:

WARNING Read installation instructions in their entirety before starting installation. • Become familiar with the general safety instructions in this section of the manual before installing, operating, maintaining or repairing this equipment. • 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.

Failure to follow these warnings may result in serious injury or equipment damage.

1.2.1 Additional Reference Materials:

IMPORTANT INFORMATION • • • • •

IEC - International Standards and Conformity Assessment for all electrical, electronic and related technologies IEC 60364 - Electrical Installations in Buildings FAA Advisory: AC 150_5340_26 (current edition) Maintenance of Airport Visual Aid Facilities ANSI/NFPA 79, Electrical Standards for Metalworking Machine Tools. National and local electrical codes and standards.

1.2.2 Intended Use

WARNING IMPROPER USE 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.

THESE WARNINGS MAY RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE.

1.2.3 Fasteners

WARNING FOREIGN OBJECT DAMAGE - FOD • Only use fasteners of the same type as the one originally supplied with the equipment. • Always tighten the fasteners to the recommended torque. Use a calibrated torque wrench and apply the recommended adhesive type. • Obey the instructions of the adhesives necessary for the fasteners.

Failure to follow these warnings may cause the fasteners to loosen, damage the equipment, potentially to loosen the equipment. This can lead to a highly dangerous situation of FOD, with potential lethal consequences.

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1.2.4 Operation

CAUTION IMPROPER OPERATION • Only qualified personnel, physically capable of operating the equipment and with no impairments in their judgment or reaction times, should operate this equipment. • Read all 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 work 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. • 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 been rated for safe operation in these environments. • Never touch exposed electrical connections on equipment while the power is ON.

Failure to follow this instruction can result in equipment damage.

1.2.5 Storage

CAUTION IMPROPER STORAGE 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 equipment damage.

1.2.6 Material Handling Precautions

CAUTION ELECTROSTATIC SENSITIVE DEVICES 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.

Failure to follow this instruction can result in equipment damage.

WARNING UNSTABLE LOAD • Use extreme care when moving heavy equipment. • Verify that the moving equipment is rated to handle the weight. • When removing equipment from a shipping pallet, carefully balance and secure it using a safety strap.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A To use this equipment safely:

1.2.7 Action in the Event of a System or Component Malfunction

DANGER ARC FLASH AND ELECTRIC SHOCK HAZARD • Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the system OFF immediately. • An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter. • Never unplug a device from a constant current circuit while it is operating. Arc flash may result. • 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.

Failure to follow these warnings will result in death or equipment damage.

1.2.8 Maintenance

WARNING ELECTRIC SHOCK HAZARD • Do not 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.

Failure to follow these warnings will result in death or equipment damage.

1.2.9 Maintenance and Repair

DANGER ARC FLASH AND ELECTRIC SHOCK HAZARD 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. • An open airfield current circuit is capable of generating >5000 Vac and may appear OFF to a meter. • Never unplug a device from a constant current circuit while it is operating. Arc flash may result. • 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. • 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 the interlock systems periodically to ensure their effectiveness. • Do not attempt 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 airfield electrical equipment.

Failure to follow these warnings will result in death or equipment damage.

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2.0 Appendix A 2.1 Installation Guidance for Inpavement Fixtures

In-pavement fixtures must be installed according to the plans and specifications; the applicable regulatory guidance; and the following guidance. The importance of using the proper fixture clamping components and bolt torque to minimize the risk for fixture failure or loosening of clamping components cannot be overemphasized.

WARNING Read installation instructions in their entirety before starting installation. Failure to follow the guidance below could result in bolt loosening or bolts breaking off, resulting in catastrophic failure of the fixture and/or the mounting system components. Failure to follow these warnings may result in serious injury or equipment damage.

2.1.1 Reference Documents

2.1.2 Mounting Systems

•

FAA Cert Alert No. 14-03 (Preventive Maintenance of In-pavement Lighting Systems), is available at: http://www.faa.gov/airports/airport_safety/certalerts/

•

Transport Canada Civil Aviation Safety Alert Document CASA 2014-05 (Preventive Maintenance Of Inpavement Lights) is available at: https://www.tc.gc.ca/eng/civilaviation/opssvs/managementservices-referencecentrecasa-2014-05-2124.html

•

FAA AC 150/5340-30, Design and Installation Details for Airport Visual Aids, is available at: http://www.faa.gov/airports/resources/advisory_circulars/

•

FAA AC 150/5340-26, Maintenance of Airport Visual Aid Facilities, is available at: http://www.faa.gov/airports/resources/advisory_circulars/

•

FAA Engineering Brief 83, In-Pavement Light Fixture Bolts, is available at: http://www.faa.gov/airports/engineering/engineering_briefs/

In-pavement fixtures may be installed on one of several types of mounting systems:

• • •

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Deep base FAA L-868 base cans (Load bearing) Deep base FAA L-867 base cans (Non-Load bearing) Shallow base cans

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A L-868 base can installation (load bearing)

2.2 L-868 base can installation (load bearing)

Following are specific requirements to insure that an in-pavement fixture is properly installed.

WARNING Read installation instructions in their entirety before starting installation. Make sure power is off before you install or remove any fixture. Failure to follow these warnings may result in serious injury or equipment damage.

CAUTION Make sure that: — The fixture is supplied with 6.6A maximum from the isolation transformer secondary via a series circuit. — The series circuit is powered by a Constant Current Regulator that complies with FAA AC 150/5345-10 or IEC 61822. — Depending on installation location, the isolation transformer is a series transformer that complies with FAA AC 150/5345-47, IEC 61823, or CSA C22.2 No. 180. — The base can is correctly earth grounded. Failure to do so will void the warranty for any damage that occurs as a result of voltage surges. — Never hold the fixture by the cable leads. This can damage the insulation, break the waterproof seal and cause insulation faults and water leakage. Make sure that the fixture is completely assembled. Make sure that the fixture has been operationally tested. Verify that a certified L-868 base can that has been listed in FAA AC 150/5345-53D, Appendix 1 Addendum is being used. Verify that the number of spacer rings is not in excess of the requirements defined in FAA AC 150/5340-30, Design and Installation Details for Airport Visual Aids. Insure that all base can mounting surfaces are flat and free of dust, dirt or debris. Use compressed air or a solvent spray to remove debris prior to installation. Use safety glasses to prevent injury from any flying debris or solvent. Inspect the threads in the light base upper flange to insure that the threads are clean and corrosion free. If necessary, use a wire brush to clean the holes or use compressed air or a solvent spray to remove debris prior to the insertion of any mounting bolts. Use safety glasses to prevent injury from any flying debris or solvent. If the base can threads are damaged, use a tap to attempt to restore them. If the threads are severely damaged and will not allow the proper torque, use an appropriate insert to repair the threaded hole. Inspect the condition of the flange ring O-ring and replace the O-ring if necessary. Mount the fixture using 3/8” x 16 Type 304 (18-8) Stainless Steel Hex Cap Screws. The bolt must be fully threaded. Insure that the bolt’s specific chemistry and physical characteristics and source of supply are known. Use a bolt that is marked “F593C” or a verified equivalent. At a minimum, choose a bolt length that insures a ½” (13 mm) thread engagement in the base can top flange. Further, the bolt length should be chosen to insure at least 1/8” (3.2 mm) to ½” (13 mm) extends below the base can top flange. However, note that installing bolts that are excessively long can increase the risk that the bolt will break off in the flange during removal, after the bolt has been installed a long period of time. Always use a new bolt. Never reuse existing bolts.

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Insure that a new anti-vibration washer is used with each new bolt. Anti-vibration washers are effective in preventing bolt loosening caused by high dynamic loads. See Figure 1. Antivibration washers consist of a pair of unique washers. There are stepped cams between the face of washers that is greater than the pitch of the bolt. The rise of the cams creates tension that positively locks the bolt. Figure 1:

Anti-vibration washer

Always use a new anti-vibration washer. Never reuse an existing anti-vibration washer. Recommended stainless steel anti-vibration washers are:

• •

Heico Part Number HLS-3/8” SS [ADB part number ACC0375] Nordlock Part Number NL 3/8 SS

Insure that the anti-vibration washer is installed properly. An anti-vibration washer consists of two halves. Insure that the stepped cams between the face of washer halves face each other (see Figure 1). The pair of washers are typically glued together for easy assembly to the bolt. Never use only one part of a 2-part anti-vibration washer. The outside of the each washer half has serrations that grip and seat the mating surfaces. Never reverse the halves such that the serrations face each other. If anti-seize (lubricant) is used on the bolt, the following products are recommended:

•

Loctite LB 8009™ Heavy Duty Anti-Seize. This is also available in stick form as Loctite LB 8070™ Heavy Duty Anti-Seize Stick.

•

If the airport is located in a more corrosive environment, such as an airport located by the ocean, use Loctite LB 8023™ Marine Grade Anti-Seize.

If a threadlocker is used on the bolt, the following is recommended:

•

Loctite 243 Removable Strength Threadlocker.

Consistency of use of anti-seize or threadlocker is important. If anti-seize was previously used on a base can, completely clean out the base can threads before applying threadlocker. Also, it is good practice to blow out or remove any loose threadlocker residue before applying new threadlocker. See Figure 2. It is recommended that the bolt coating be applied in three locations:

• • •

Under the top of the bolt head. In the area underneath the bottom of the anti-vibration washers that contacts the inpavement fixture. The entire area of the bolt thread that attaches to the base can.

Applying a coating in these areas reduces the friction that occurs that resists the bolt from achieving sufficient clamping force. It is not recommended to install the bolt dry (i.e., with no coating).

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A L-868 base can installation (load bearing)

Figure 2:

Applying a coating to reduce friction during torquing

Connect the fixture plug into the isolation transformer receptacle. Wrap 3 overlapping layers of electrical tape around the connection joint. Install the fixture on the base can, while insuring that the cordset does not become pinched between the fixture and the top of the base can. Insure that the fixture is aimed in the proper direction. Check if the fixture fits correctly on top of the base can.

CAUTION Do not use the bolts to force the fixture onto the base can. If this happens the threaded hole in the base can be damaged. Torque each bolt to 500 ±10 in-lbs. (56.5 ± 1.1 N·m). Use a manual calibrated torque wrench to tighten the bolt.

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Alternately, use an automatic wrench set at a low torque value (for example: 25 in-lbs. [2.8 N·m]). Then use a manual calibrated torque wrench to finalize the torque.

WARNING When a stainless steel base can is used, take steps to insure that galling does not occur. Galling is often referred to as a cold-welding process, which can occur when the surfaces of male and female threads come in contact under heavy pressure. The risk of galling can be minimized with the following measures: — Thread lubrication is one of the most effective measures to lessen the potential for galling. The lubricant reduces friction, which is a key element in thread galling. Avoid installing a stainless steel bolt dry with no lubricant. — Heat contributes significantly to thread galling. Installing a bolt generates heat and high-speed installation generates significantly more heat. Torque the bolt slowly into the base can. — Do not use an impact wrench to torque the bolt quickly, resulting in a torque beyond 500 ±10 in-lbs. (56.5 ± 1.1 N·m). If the fastener is over tightened, the threads can begin to yield which will induce friction between the mating surfaces. Always torque the bolts in opposing pairs. 12 inch, 6-bolt fixture (See Figure 3): — Tighten bolt #1, then tighten bolt #4. Next tighten bolts #2 and #5. Finally, tighten bolts #3 and #6. (Not shown) 8 inch, 4-bolt fixture: — Tighten any bolt designated as #1, then tighten bolt #3. Next tighten bolts #2 and #4. (Not shown) 8 inch, 2-bolt/2-pin fixture: — Simply tighten bolt #1, then tighten bolt #2. Figure 3:

6-Bolt Torque Sequence

Use the above guidance for any bolted connection on a load bearing base can. This includes:

• • • • •

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6 bolts used on a 12-inch in-pavement fixture. 6 bolts used with an 8-to-12 inch in-pavement fixture adapter ring. 4 bolts used on an 8-inch in-pavement fixture. 2 bolts/2-pins 4 bolts used on an 8-inch fixture. Snow plow ring used on any fixture.

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A L-868 base can installation (load bearing)

2.2.1 Use of Ceramic Bolts

Refer to FAA Engineering Brief 83 (In-pavement Light Fixture Bolts) for guidance on use of fluoropolymer metallic-ceramic coated SAE J429 Grade 2 carbon steel bolts.

WARNING Read installation instructions in their entirety before starting installation. — Do not use an impact type of torque wrench to tighten ceramic bolts. — Do not torque ceramic bolts to 500 in-lbs. (56.5 N·m). Do not use antiseize or threadlocking compounds with ceramic bolts. Tighten to the bolt manufacturer’s recommendation. Failure to follow these warnings may result in serious injury or equipment damage.

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2.3 L-867 base can installation (non-load bearing)

Non-load bearing base cans are not normally subject to high shear levels. Following are specific requirements to insure that either an elevated or an in-pavement fixture is properly installed.

WARNING Read installation instructions in their entirety before starting installation. Make sure power is off before you install or remove any fixture. Failure to follow these warnings may result in serious injury or equipment damage.

CAUTION Make sure that: — The fixture is supplied with 6.6A maximum from the isolation transformer secondary via a series circuit. — The series circuit is powered by a Constant Current Regulator that complies with FAA AC 150/5345-10 or IEC 61822. — Depending on installation location, the isolation transformer is a series transformer that complies with FAA AC 150/5345-47, IEC 61823, or CSA C22.2 No. 180. — The base can is correctly earth grounded. Failure to do so will void the warranty for any damage that occurs as a result of voltage surges. — Never hold the fixture by the cable leads. This can damage the insulation, break the waterproof seal and cause insulation faults and water leakage. Make sure that the fixture is completely assembled. Make sure that the fixture has been operationally tested. Verify that a certified L-867 base can that has been listed in FAA AC 150/5345-53D, Appendix 1 Addendum is being used. Insure that all base can mounting surfaces are flat and free of dust, dirt or debris. Use compressed air or a solvent spray to remove debris prior to installation. Use safety glasses to prevent injury from any flying debris or solvent. Inspect the threads in the light base upper flange to insure that the threads are clean and corrosion free. If necessary, use a wire brush to clean the holes or use compressed air or a solvent spray to remove debris prior to the insertion of any mounting bolts. Use safety glasses to prevent injury from any flying debris or solvent. If the base can threads are damaged, use a tap to attempt to restore them. If the threads are severely damaged and will not allow the proper torque, use an appropriate insert to repair the threaded hole. For elevated fixtures mounted on a baseplate, inspect the condition of the gasket and replace it if necessary. Mount the in-pavement fixture or baseplate using a one inch (25.4 mm), 3/8” x 16 Type 304 (18-8) Stainless Steel bolt. The bolt must be fully threaded. To insure that the bolt’s material characteristics are known, verify that the bolt comes from a known source of supply. Always use a new bolt. Never reuse existing bolts. If the base can is an area that may be subject to vibration, consider using an appropriate vibration resistant washer. If anti-seize (lubricant) is used on the bolt, the following products are recommended:

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Loctite LB 8009™ Heavy Duty Anti-Seize. This is also available in stick form as Loctite LB 8070™ Heavy Duty Anti-Seize Stick 11

Installation Guidance for In-pavement Fixtures ALN173 Rev. A L-867 base can installation (non-load bearing)

•

If the airport is located in a more corrosive environment, such as an airport located by the ocean, use Loctite LB 8023™ Marine Grade Anti-Seize.

If a threadlocker is used on the bolt, the following is recommended:

•

Loctite 243 Removable Strength Threadlocker Duty Anti-Seize.

Consistency of use of anti-seize or threadlocker is important. If anti-seize was previously used on a base can, completely clean out the base can threads before applying threadlocker. Also, it is good practice to blow out or remove any loose threadlocker residue before applying new threadlocker. See Figure 4. It is recommended that the bolt coating be applied in three locations:

• •

Under the top of the bolt head.

•

The entire area of the bolt thread that attaches to the base can.

In the area underneath the bottom of the washers (if used) that contacts the in-pavement fixture or baseplate.

Applying a coating in these areas reduces the friction that occurs that resists the bolt being fully torqued. Figure 4:

Applying a coating to reduce friction during torquing

Connect the fixture plug into the isolation transformer receptacle. Wrap 3 overlapping layers of electrical tape around the connection joint. If an in-pavement fixture is being installed on the base can, insure that the cordset does not become pinched between the fixture and the top of the base can. Insure that the fixture is aimed in the proper direction. Check if the baseplate or fixture fits correctly on top of the base can.

CAUTION Do not use the bolts to force the baseplate or fixture onto the base can. If this happens the threaded hole in the base can be damaged. Torque each in-pavement fixture bolt to 500 ±10 in-lbs. (56.5 ± 1.1 N·m).

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Torque each elevated baseplate fixture bolt to 120 ±30 in-lbs. (13.6 ± 3.4 N·m). Do not over-torque elevated baseplate bolts as this may damage the baseplate gasket. Use a manual calibrated torque wrench to tighten the bolt. Alternately, use an automatic wrench set at a low torque value (for example: 25 in-lbs. [2.8 N·m]). Then use a manual calibrated torque wrench to finalize the torque.

WARNING When a stainless steel base can is used, take steps to insure that galling does not occur. Galling is often referred to as a cold-welding process, which can occur when the surfaces of male and female threads come in contact under heavy pressure. The risk of galling can be minimized with the following measures: — Thread lubrication is one of the most effective measures to lessen the potential for galling. The lubricant reduces friction, which is a key element in thread galling. Avoid installing a stainless steel bolt dry with no lubricant. — Heat contributes significantly to thread galling. Installing a bolt generates heat and high-speed installation generates significantly more heat. Torque the bolt slowly into the base can. — Do not use an impact wrench to torque the bolt quickly, resulting in an overtorqued bolt. If the bolt is over tightened, the threads can begin to yield which will induce friction between the mating surfaces. Always torque the bolts in opposing pairs. 12 inch, 6-bolt fixture (See Figure 5, which shows an in-pavement fixture. Use the same procedure for a baseplate.): — Tighten bolt #1, then tighten bolt #4. Next tighten bolts #2 and #5. Finally, tighten bolts #3 and #6. Figure 5:

6-Bolt Torque Sequence

Use the above guidance for any bolted connection on a non-load bearing base can. This includes:

• • •

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6 bolts used on a 12-inch in-pavement fixture. 6 bolts used on either an 8-to-12 inch in-pavement fixture adapter ring. All bolts used on an 8-inch fixture mounted in an 8-to-12 inch snow plow ring.

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Installation Guidance for In-pavement Fixtures ALN173 Rev. A Shallow base can installation

2.4 Shallow base can installation

Shallow base cans may be non-load bearing or load bearing depending on location or fixture application. Following are specific requirements to insure that an either an elevated or an inpavement fixture is properly installed.

WARNING Read installation instructions in their entirety before starting installation. Fasteners: — Only use fasteners of the same type as the one originally supplied with the mounting support. — Always tighten the fasteners to the recommended torque. Use a calibrated torque wrench and apply the recommended adhesive type. See “Screws” on page 16. — If this is not the case, this may cause the fasteners to loosen, damage the fixture, potentially to loosen the fixture. This can lead to a highly dangerous situation of FOD, with potential lethal consequences. — Obey the instructions of the adhesives necessary for the fasteners. — Only install the fixture on mounting supports: — That ADB has approved; — That are installed according to the Instruction Manual of the mounting support. — Failure to do so can result in a highly dangerous situation of FOD, with potential lethal consequences. — Make sure the power is OFF when you install or remove any fixture. Failure to follow these warnings may result in serious injury or equipment damage.

CAUTION Make sure that: — The fixture is supplied from a 6.6 A series circuit; — The series circuit is powered by a Constant Current Regulator that complies with IEC 61822; — The transformer is an AGL series transformer that complies with IEC 61823. — The power of the series transformer shall not exceed 200 W, for versions with the monitoring option. — The mounting support is correctly earthed. Failure to do so will void the warranty for all damages that occur as a result of voltage surges. — Never hold the fixture by the cable leads. This can damage the insulation, break the waterproof seal and cause insulation faults and water leakage. See the Instruction Manual of the mounting support for instructions on how to earth the mounting support.

2.4.1 Parts:

14

— Fasteners of the mounting support.

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2.4.2 Tools:

— Adhesive A. See “Standard toolkit” on page 17. — Cleaning tap for blind holes (preferably a tap with a right spiral groove). — Compressed air blower with dry, oil-free air.

2.4.3 Prepare

1. Make sure that the fixture is completely assembled. 2. Make sure that the fixture is operationally tested. 3. Make sure a new labyrinth gasket (A) is installed. 4. Make sure that the contact surfaces of the fixture with the mounting support and the gaskets are clean and smooth. 5. With the cleaning tap for blind holes, clean all fixation holes of the mounting support. 6. Make sure that all remains of adhesive are removed from the fixation holes.

A

7. With the compressed air blower, blow out all the fixation holes of the mounting support. 2.4.3.1 Fixture with toe-in only

1. Make sure the arrow (A) points to the center of the runway.

CAUTION A toe-in right (B) must be at the left side of the runway (C). A toe-in left (D) must be at the right side of the runway.

B

C

D

A 2.4.4 Install 2.4.4.1 Lubricate and connect

1. Lubricate the labyrinth gasket (A) with water. NOTE: To facilitate the use, add some soap to the water.

CAUTION Do not use silicon or any other type of grease. Avoid the use of soap that contains silicone or glycerin.

B

A

2. Apply adhesive on the first three threads of the threaded holes in the mounting support. Use adhesive A. 3. Connect the plug (B) to the receptacle. NOTE: For a fixture with two plugs, INPUT 1 feeds side 1 and INPUT 2 feeds side 2.

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15

Installation Guidance for In-pavement Fixtures ALN173 Rev. A Shallow base can installation

4. Carefully move the fixture (A) vertically into the mounting support (B). Make sure that you do not pinch the cable leads.

C D

5. Check if the fixture fits correctly in the mounting support.

A

6. Make sure the dents of the washers (D) face upwards. 7. Gradually tighten the fasteners of the mounting support (C). See “Screws” on page 16 (torque).

B

CAUTION Do not use the fasteners to force the fixture in the mounting support. If it happens at all, the threaded hole in the mounting support will be damaged.

2.4.5 Screws Screw Type

Name

Details

Torque (N·m)

Adhesive Type1

G

Prism screws

Screw M5x14 DIN 7985-T- A2-LOCK 2045

7100.10.211

4.0

Not required

J

Optical assy screws

Screw M4x10 DIN 7985-T- A2-LOCK 2045

7100.10.101

2.5

Not required

L

Inner cover screws

Screw M5x14 DIN 7985-T- A2-LOCK 2045

7100.10.211

3.5

Not required

M

Pressure release screw assy

2.5

Not required

O

2.5

Not required

21-23

A

Assy (screw + gasket)

4072.24.940

Gasket only

7080.90.012

Cable lead screws

Screw M4x10 DIN 7985-T- A2-LOCK 2045

7100.10.101

Fasteners of the mounting support (not supplied with the fixture)

Screw FT.HEX M10x25, SST, Hex Head or Screw FT.HEX 3/8” - 16UNCx7/8”

1

16

Part Number

See “Standard toolkit” on page 17.

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2.4.6 Standard toolkit Identifier

Details

Part Number

Complete tool kit. The toolkist consists of the components listed below.

1411.19.421

Tool case

6169.01.007

Adhesive A

Loctite 2701

7870.05.130

Adhesive B1

Loctite 222

7870.05.140

Adhesive C1

Loctite 638

7870.05.097

Adhesive D

Loctite 243

7870.05.160

Lubricant A

Vacuum silicone grease (50 g) to install O-ring gaskets

7850.42.220

Lubricant B

Molykote HP870 Inerta (100 g) to replace prism

7850.05.061

Tool A

Torque wrench

8061.06.255

Tool B

Socket, hex 3/8”, screw 3/8”, J9/16LA

8961.06.008

Tool C

Socket, hex 3/8”, screw M10, J 17LA

8961.06.000

Tool D

Socket, 1/4”, 1.6x8 Flat, RS.8E

8961.05.050

Tool E

Socket, 1/4”, Pozidriv2, RD.2

8961.05.060

Tool F

Extension, 1/4”, R.210

8961.06.220

Tool G

Adaptation, 1/4”-3/8”, R.232

8961.06.010

Tool H

Hinged handle - sort

8961.06.110

Tool I

Pliers

8981.10.110

Tool J

Opening tool

4071.53.220

Tool K

Screwdriver, flat blade AG. 8x150

8961.06.250

Tool L

Screwdriver, pozidriv AD.2x125

8961.05.220

Tool M

Torque screwdriver

8961.06.255

Tool N

Screwdriver, Torx ANX20x100

8961.05.300

Tool O

Screwdriver, Torx ANX25x100

8961.05.290

Tool P

Attack driver

8961.04.100

Tool Q

Hammer 212A50s

8961.04.110

Tool R

Bit holder

8961.04.120

Tool S

Bits END202, Pozidriv2

8961.04.130

Tool T

Bit, Torx TX20 EX.620

8961.06.020

Tool U

Bit, Torx TX25 EX.625

8961.06.025

1

1

1

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Obey the instructions of the manufacturer of the adhesive.

17

Installation Guidance for In-pavement Fixtures ALN173 Rev. A Checking Bolt Torque

2.5 Checking Bolt Torque

An established schedule for checking light fixture bolt torque and bolt condition is mandatory. This is particularly true for areas that are subject to high impact loads from aircraft such as runway status lights, runway touchdown zone lights, runway centerline lights, and taxiway lead-off lights. Although AC 150/5340-26 offers a recommended schedule for periodic checks, these checks should be tailored to the facility based on local conditions such as environmental issues and runway traffic load. FAA Cert Alert No. 14-03 refers to AC 150/5340-26C for the frequency of checking bolt torque. AC 150/5340-26C paragraph 5.3.4.1.4, Bi-Monthly Checks states: “The torque of the bolts attaching the light fixture to its base should be checked with a calibrated torque wrench – never use an impact wrench.” Regular inspection as outlined in FAA Cert Alert No. 14-03, Canada Civil Aviation Safety Alert Document CASA 2014-05, and any other applicable regulatory guidelines is critical in insuring torque on all bolts is restored to optimum values. Bolts that loosen more often should be inspected and re-torqued on a more frequent basis. It is especially important to maintain a regular inspection schedule for LED fixtures. Since LED fixtures operate more reliably and are not subject to removal/replacement/retorquing as frequently as would be seen with incandescent fixtures, it is even more important to implement regular torque inspections. It is critical that remedial action be taken if bolts are found to be loose or missing during inspection. If this occurs, it is important to carefully inspect all structural elements of the mounting system as defined in paragraph 1.2. Also inspect the base can for general structural conditions such as:

•

Is the base can solidly mounted in the pavement, and not moving or rocking during rollovers?

•

If a base can extension is present, are all extension attachment bolts tight?

If poor base can structure or mounting system components are not in accordance with regulatory requirements or are in poor condition, it is the airport’s responsibility to:

•

Increase the frequency of bolt torque inspection to insure that no bolts become loose or missing.

•

Quickly replace/repair the mounting system components, which may include replacing the entire base can.

Airport operators must also ensure these maintenance activities are properly documented.

18

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p

y

Company Offices ADB BVBA Leuvensesteenweg 585 B-1930 Zaventem Belgium Tel: 32/2/722.17.11 Fax: 32/2/722.17.64 Email: [email protected] 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 Tel: +86 (10) 8476 0106 Fax: +86 (10) 8476 0090 ADB Airfield Solutions LLC 977 Gahanna Parkway Columbus, OH 43230 USA Tel: +1 (614) 861 1304 Fax: +1 (614) 864 2069 Web: www.adb-air.com Email: [email protected] LUCEBIT GmbH Airport Technology Konrad-Zuse-Ring 6 D - 68163 Mannheim Deutschland Tel:+49 621 87 55 76-0 Fax: +49 621 87 55 76-55 Email: [email protected]

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Manufacturing Offices ADB BVBA Leuvensesteenweg 585 B-1930 Zaventem Belgium Tel: 32/2/722.17.11 Fax: 32/2/722.17.64 Email: [email protected] 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 Tel: +86 (10) 8476 0106 Fax: +86 (10) 8476 0090

ADB Airfield Solutions

ADB Airfield Solutions LLC

Leuvensesteenweg 585 977 Gahanna Parkway Columbus, OH 43230 B-1930 Zaventem Belgium USA Phone: +32 (2) 722.17.11 Tel: +1 (614) 861 1304 [email protected] Fax: +1 (614) 864 2069

www.adb-air.com Web: www.adb-air.com Email: [email protected]

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