Airport Lighting L862 User manual

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 1
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
High Intensity LED Runway Light
L-862(L), L-862E(L) LED
OWNER'S MANUAL
An ISO 9001:2015 Certied Company

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 2
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Elevated High Intensity
L-862(L), L862E(L) LED
LED Runway Light
Owner's Manual
In accordance with:
FAA
Advisory Circular AC-150/5345-46
Engineering Brief 67
ICAO Annex 14
Transport Canada TP312
Manufactured by:
Airport Lighting Company
108 Fairgrounds Drive
Manlius, New York 13104
[phone]
Email: [e-mail]
Website: www.airportlightingcompany.com
Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com
[MAN] Elevated High-Intensity Runway Light, LED Rev2

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 3
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
●Long Life LEDs for over 56,000 hours of service
●Light clarity ensured for years with glass lens.
●Dimmable to FAA intensity curve from 2.8 amp to 6.6 amps
●Plug and Know circuit design. Dynamic controller
senses the attached light engines, allowing for greater
service exibility.
●Daytime recognition provided on lens retainers
●Leveling surface and sighting cross on cap eliminates the
need for an aiming device
●Fixture surface area designed to meet LED
thermal requirements
Key Features
Compliances
FAA: L-862(L) and L-862E(L) AC 150/5345-46 and Engineering Brief No. 67 (Current Edition)
Canada: TP 312
ICAO: Annex 14, Volume 1
Applications
Runway Edge, Threshold, Displaced Threshold, Threshold/End, Displaced Threshold Precision IFR Runways
L-862(L), L-862E(L) High Intensity LED Light
DATA SHEET
Side A
W = White
Y = Yellow
R = Red
G = Green
O = Opaque
EHL---
Example: EHL-RG-24 is 24” high with
Red on Side A and Green on Side B.
Side B
W = White
Y = Yellow
R = Red
G = Green
O = Opaque
Mounting
Height
14 = 14”
20 = 20”
24 = 24”
30 = 30”
General
Catalog
Numbers
Options
5 = Arctic Kit
Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com
[MAN] Elevated High-Intensity Runway Light, LED Rev2

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 4
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Specications
DATA SHEET
4
View runway edge lights from runway centerline perpendicular to xture
when determining color in conjunction with right-hand and left-hand
xtures. The rst color will be on the left toe-in side of the light xture.
Dimensions & Weight
Height, head assembly 6.8 inches
Height, w/ slip tter 8.9 inches
Width 5.5 inches
Length 5.2 inches
Weight 7.2 pounds
The L862 xtures ship in a single box (9 1/8 x 5 ¾ x 7) or in a case of 18 (18 x 17 x 16).
Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com
[MAN] Elevated High-Intensity Runway Light, LED Rev2

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 5
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
TABLE OF CONTENTS
How to Get Help ..........................................................................................1
Warranty ...................................................................................................2
Safety .......................................................................................................3
Description ................................................................................................4
Catalog Ordering Information ......................................................................4
L862 Fixtures ..........................................................................................4
L862E Fixtures .........................................................................................5
ICAO / TP312 Fixtures ................................................................................6
Fixture Loads ..........................................................................................7
Dimensions ............................................................................................7
Storage .................................................................................................7
Installation ................................................................................................8
FAA References and Siting Requirements ........................................................8
Installation .............................................................................................8
Tools Required for Installation .....................................................................8
Tools Required for Maintenance ...................................................................8
Installation Precautions .............................................................................8
Install Proper Transformer ..........................................................................8
Install Fixture ..........................................................................................9
Install Frangible Coupling ...........................................................................9
Aim Fixture ............................................................................................9
Level Fixture ......................................................................................... 10
Torque Bolts ......................................................................................... 10
Operation ................................................................................................ 11
Plug and Know LED Circuit ....................................................................... 11
Multiple Light Devices ............................................................................. 11
Arctic Kit .............................................................................................. 11
Maintenance ............................................................................................ 12
Daily Maintenance ................................................................................. 12
Monthly Maintenance ............................................................................. 12
Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com
[MAN] Elevated High-Intensity Runway Light, LED Rev2

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 6
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
TABLE OF CONTENTS
Troubleshooting ....................................................................................... 13
Tech Support ........................................................................................ 13
Replacing Electronic Parts ....................................................................14-15
Replacing Lens, Gasket, and Light Engine ..................................................... 16
Parts ..................................................................................................17-20
Wiring Diagrams ...................................................................................21-23
Notes ...................................................................................................... 24
List of Figures
Figure 1: Light Placement ..............................................................................4
Figure 2: Side A, Side B ..................................................................................5
Figure 3: Fixture Dimensions ..........................................................................7
Figure 4: Fixture Aiming ................................................................................9
Figure 5: Leveling, Front View ....................................................................... 10
Figure 6: Leveling, Side View ........................................................................ 10
Figure 7: Electronic Component Assembly ...................................................... 14
Figure 8: How to Remove Ferrule ................................................................... 15
Figure 9: Lens Assembly .............................................................................. 16
Figure 10: Parts Diagram ............................................................................. 18
Figure 11: Arctic Kit Parts ............................................................................. 19
Figure 12: Schematic, Bi-directional Fixture .................................................... 22
Figure 13: Schematic, Bi-directional Arctic Kit .................................................. 23
Figure 14: Schematic, Uni-directional Arctic Kit ................................................ 24
Figure 15: Schematic, Uni-directional with Arctic Kit ......................................... 25
List of Tables
Table 1: PF and VA ........................................................................................7
Table 2: Torque .......................................................................................... 10
Table 3: Troubleshooting ............................................................................. 13
Table 4: Light Engines ................................................................................. 17
Table 5: Columns and Cords ......................................................................... 17
Table 6: Bill of Materials ............................................................................... 20
Table 7: Arctic Kit Bill of Materials .................................................................. 21
Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com
[MAN] Elevated High-Intensity Runway Light, LED Rev2

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 1
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Have Questions? Contact Us:
108 Fairgrounds Drive
Manlius, New York 13104
HOW TO GET HELP
An ISO 9001:2015 Certied Company
PHONE: [phone]
EMAIL: [e-mail]
WEBSITE: www.airportlightingcompany.com

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 2
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Statement of Warranty
Products manufactured by Airport Lighting Company (ALC) which use LEDs as a light source are warranted against
mechanical and physical defects in design or manufacture for a period of 2 years from date of installation per the
applicable FAA Advisory Circular and against electrical defects in design or manufacture of the LED or LED specic
circuitry for a period of 4 years per FAA EB67D. ALC will correct such defects by repair or replacement, at its option,
provided the products have been properly handled and stored prior to installation, properly installed and operated
after installation, and provided further that the Buyer has notied ALC in writing within the warranty period and
within a reasonable time after notice of such defects. Refer to handling, storage, installation and operational
instructions for proper procedural guidance that must be followed to maintain warranty provisions.
This warranty is in eect for the specied term as long as the equipment, in ALC's judgment, has not been altered in
such a way as to aect the equipment adversely, subject to accident, negligence, improper storage, and has been
operated and maintained in accordance with accepted FAA guidelines as described in AC 150/5340-26 and ALC’s
published operational guidelines.
ALC reserves the right to examine products about which a claim has been made. Equipment must be presented
in the same condition as when the defect was discovered. ALC also reserves the right to require the return of
equipment to establish any claim.
Disclaimer: ALC's obligation under this warranty is limited to repair or replacement of defective equipment sold by
ALC at no cost to Buyer. This does not include any other costs such as the cost of removal, shipping, or installation
of the defective part or repaired or replaced product, including labor or any consequential damages of any kind.
Warranty services provided under this agreement do not assure uninterrupted operations of LED illuminated
equipment. ALC shall not be liable for any indirect or consequential damages.
ALC's liability under no circumstances will exceed its sales price of the products claimed to be defective. All
transportation costs under this warranty are the responsibility of the purchaser. Replacement parts and/or
equipment provided under this warranty are covered under the same terms until the expiration of the original
warranty period that began upon the rst installation of the equipment.
This is ALC's sole and exclusive warranty with respect to the equipment sold to the Buyer. There
are no express or implied warranties of tness for any particular purpose or any implied warranties other than those
made expressly herein.
ALC shall not be liable to the purchaser of this product or third parties for indirect or consequential damages, or for
damages arising from the use of any options or parts other than those designated by ALC as approved products.
Damage caused by lightning, ood and other natural or manmade causes are outside the scope of this warranty.
WARRANTY

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 3
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Safety
It is not safe to work on a constant current power system when the power is on. Make sure the power is o before
installing a runway light xture. A lock out, tag out, procedure should be used. An additional safety measure is to
test that the circuit is o by using a clamp-on ammeter. By using a clamp-on ammeter, clamped over the primary
cable of the isolation transformer, the installer can conrm that the circuit being worked on is o by verifying that
no current is owing thru the primary cable.
SAFETY

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 4
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Description
The High Intensity LED Runway Lights are elevated bi-directional and uni-directional runway lights. The High
Intensity LED Runway Light operate on a 2.8 - 6.6 Amp series runway circuit.
FAA: This product line meets the requirements for L862 and L862E
ICAO: This product line meets the standards as shown Appendix 2, A2-3 (green threshold light), A2-8 (red
runway end light), and A2-10 (white, yellow and red runway edge light where width of runway is 60m).
TP312: This product line meets the standards as shown in Appendix B.1.3 (green threshold light), B.1.9.3 (red
runway end light), and B.1.11 (white, yellow and red runway edge light where width of runway is 60m).
Catalog Ordering Information
L-862(L) Fixtures
Example: EHL-WY-24 is 24” high xture with white on side A and yellow on side B.
Figure 1: Light Placement
EHL---
Color Height Options
Color Height Options
WW = White / White 14 = 14” (36cm) 5 = Arctic Kit
WY = White / Yellow 20 = 20” (51cm)
YW = Yellow / White 24 = 24” (61cm)
WR = White / Red 30 = 30” (76cm)
RW = Red / White Other heights available
GY = Green / Yellow
YG = Yellow / Green
RY = Red / Yellow
YR = Yellow / Red
DESCRIPTION

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 5
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Catalog Ordering Information Continued
L-862E(L) Fixtures
Example: EHL-RG-24 is 24”high with red on side A and green on side B.
Figure 2: Side A, Side B
EHL---
Color Height Options
Color Height Options
RR = Red / Red 14 = 14” (36cm) 5 = Arctic Kit
RG = Red / Green 20 = 20” (51cm)
GR = Green / Red 24 = 24”(61cm)
RO = Red / Obscure 30 = 30” (76cm)
OR = Obscure / Red Other heights available
GO = Green / Obscure
OG = Obscure / Green
DESCRIPTION

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 6
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Catalog Ordering Information Continued
ICAO / TP312 Fixtures
EHL---
Color Height Options
Color Height Options
WW = White / White 14 = 14” (36cm) 5 = Arctic Kit
WY = White / Yellow 20 = 20” (51cm)
YW = Yellow / White 24 = 24” (61cm)
WR = White / Red 30 = 30” (76cm)
RW = Red / White Other heights available
RY = Red / Yellow
YR = Yellow / Red
RR = Red/Red
RO = Red / Obscure
OR = Obscure / Red
IO = Green Threshold / Obscure*
OI = Obscure / Green Threshold*
Example: EHL-IO-24 is 24” high uni-directional xture with green on side A.
*I = Green Threshold for ICAO and TP312
White, Yellow and Red (W, Y, R) meet the runway light requirements for a runway 60m wide as stated in
Annex 14, Appendix 2, A2-10 and TP312, Appendix B.1.11.
Red (R) meets the requirement for a runway end light as stated in Annex 14, Appendix 2, A2-8 and TP312,
Appendix B.1.9.3
Green (I) meets the requirements for a threshold light as stated in Annex 14, Appendix 2, A2-3 and TP312,
Appendix B.1.3.
Note: G represents a green light engine that does NOT meet ICAO or TP312 specications. The green ICAO
and TP312 threshold light must designated as I when ordering a xture.
DESCRIPTION

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 7
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Fixture Loads
Table 1: PF and VA
Fixture Load Iso Tran Load VA PF
WW 44.8 13.5 58.3 0.95
WW arctic kit 58.8 10.6 69.4 0.98
Green unidirectional (GO) 24.4 14.3 38.7 0.96
GO arctic kit 31.4 11.1 42.5 0.97
Dimensions
Height, head assembly: 6.8 inches, (173mm)
Height, w/ slip tter: 8.9 inches, (226mm)
Width: 5.5 inches, (140mm)
Length: 5.2 inches, (132mm)
Weight: 5 pounds, (2.3kg)
Single Box
(9 1/8 x 5 ¾ x 7 inches) or (232 x 178 x 1468mm)
9 Fixtures in a Box
(17 x 16 ½ x 10 inches) or (432 x 420 x 254mm)
Storage
The Elevated High Intensity xtures should be stored indoors and kept dry.
Storage Temperature: -55C (-67F) to +55C (131F).
Figure 3: Fixture Dimensions
DESCRIPTION

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An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
FAA References and Siting Requirements
The requirements for siting of high intensity runway edge lights are explained in FAA advisory circular
150/5340-30J.
The L862E xtures, bidirectional red/green and red/red, and unidirectional red or green will come with red and/or
green lens retainers to provide daytime recognition.
Installation
Installation Precautions
It is not safe to work on a constant current power system when the power is on. Make sure the power is o before
installing a light xture. A Lock Out Tag Out procedure is strongly recommended. An additional safety measure
is to test circuit by using a clamp on current meter. By clamping over the primary cable in the xture can, the
installer has performed an additional safety check by checking the circuit they are working on is o. At the vault
make sure the Constant Current Regulator powering the circuit is o and has been tagged out. At the xture,
place a clamp-on ammeter over the primary cable and verify that the current measures zero amps.
Install Proper Transformer
It is recommended to use the specied transformer to power the High Intensity LED Runway Light. A smaller
transformer will not allow the xture to work properly. An oversized transformer can be used but will not work as
eciently. A 30/45-Watt isolation transformer is specied for all xtures without an arctic kit. All xtures that have
an optional arctic kit require a 65W isolation transformer.
Tools Required for Installation:
• 7/16 wrench
• 1 ½ inch wrench
Tools Required for Maintenance:
• 7/16 wrench
• 1 ½ inch wrench
• Torx T20 driver
INSTALLATION

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 9
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Install Fixture
Loosely install the column to the xture and pass the secondary cable thru the column and frangible coupling.
Connect the secondary to the transformer. Fasten the column to the frangible coupling with a torque of 64 inch-
pounds (5.3 foot-pounds).
Install Frangible Coupling
Install frangible coupling into baseplate and torque to 50 ft-lbs. (68Nm). For a 62-1060 coupling into a 2in
NPS baseplate, connect the 62-1060 to a 2in to 1 1/2in reducer, then install the reducer and coupling into the
baseplate with a torque of 50 ft-lbs. (68Nm).
INSTALLATION
Aim Fixture
The arrows on the xture cap should be pointed towards the runway centerline. The shorter cross on top of the
cap is used to sight the xture for alignment with the row of edge lights, the longer member of the cross can be
used to align with the threshold lights.
Figure 4: Fixture Aiming

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 10
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
INSTALLATION
Level Fixture
Place a level on top of the cap and level the xture. If a torpedo level is used, level in both directions of the cross.
A bull’s eye level can be used at the cross intersection.
Torque Bolts
Once the xture has been aimed and leveled, torque the ¼-20 fasteners to 64 inch-pounds (5.3 foot-pounds).
Recheck the level of the xture.
Figure 5: Leveling, Front View Figure 6: Leveling, Side View
Table 2: Torque
Inch-pounds Foot-pounds Newton-meters
#8 18.4 1.5 2.1
¼-20 63.6 5.3 7.2
1 ½ & 2 na 50 68

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 11
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
OPERATION
Operation
The L862 LED product line is designed to work on a constant current electrical supply that delivers current from
2.8 amps to 6.6 amps. The xture measures the input current and automatically adjusts the light intensity. The
xture contains an input board, a controller, and light engine(s). The xture senses which color will be emitted by
the light engine and adjusts its power accordingly. Change of light engine to a dierent color requires no
user adjustments.
Inspect that the xture is properly installed and connected to the correct isolation transformer. Turn on the xture
and the LEDS come on. Step the current level and the light intensity will adjust to the correct intensity. When
stepping current, allow a few seconds for the intensity to readjust.
Plug and Know LED Circuit
The ALC L-862 light engines use a 6-pin connector. 2 of the 6 pins provide power to the LEDs. The remaining 4
pins are used to identify the light engine. When a light engine is connected to the xture, the xture knows which
light engine has been connected. This allows the circuit to properly drive each light engine to its correct intensity.
Multiple Light Devices
The light engines are made up of multiple LEDS. FAA requires the xture to shut o if 25% of the LEDs fail. The
circuit is constantly looking at the LEDs. When 25% or more fail, the circuit will power down within 2 minutes and
a minute later it will shut the xture o. If the xture is o, do not touch the xture. There is still power going to
the xture. If a xture appears to be o, cycle the power o and on. Observe the light engines. Replace the light
engine that does not have all the LEDs working.
Arctic Kit
The optional arctic kit operates in series with the L-862(L) xture. A thermostat determines whether the arctic
kit is needed. If the temperature is low, the thermostat sends power to the heater(s) and the glass lens is heated.
If the temperature is high, the thermostat shorts and only the xture sees power.

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 12
An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
Daily Maintenance
Monthly Maintenance
• Check that all lights are working.
• Check that all lights have similar light output.
• Check that the lenses are clean.
• Check that all xtures are aimed properly.
• Check that all xtures are level on 2 axes.
• Check that the xture is secure, and all fasteners are tight.
• Check that all LEDs are illuminated.
• Clean the lenses.
MAINTENANCE

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An ISO 9001:2015 Certied Company
[MAN] Elevated High-Intensity Runway Light, LED Rev2
TROUBLESHOOTING
Problem Cause Solution
Light output too low Glass is dirty Clean lens
Wrong current level Check current on CCR
Isolation transformer too small Install the proper sized transformer
LED light engine is failing Replace light engine
Controller is failing Replace controller
Only one side of xture has light output LED light engine is disconnected Check light engine connection
LED light engine has failed Replace light engine
Controller has failed Replace controller
Both sides of xture, no light output Connection failed Check all connections
LED light engine(s) failed Replace light engine(s)
Controller failed Replace controller
Power input board failed Replace power input board
Arctic Kit has open circuit Check arctic kit connections
Condensation inside lens Excess humidity It will clear itself
Tech Support
Outside of aiming, leveling, and cleaning, the L-862 LED should require very little maintenance. The end user
has the option to use this manual to perform advanced maintenance, to call tech support at Airport Lighting
Company at [phone] or to contact us by email at [e-mail].
Tech support can provide the end user with an RMA, Return Merchandise Authorization number. Once the xture
has been evaluated by ALC, you will be either granted a warranty replacement, the option to repair the xture or
the option to purchase a new xture.
Table 3: Troubleshooting

Airport Lighting Company | 108 Fairgrounds Drive | Manlius, NY, USA 13104 | [phone] | airportlightingcompany.com 14
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[MAN] Elevated High-Intensity Runway Light, LED Rev2
TROUBLESHOOTING
Replacing Electronic Parts
When the light is out the cause can be in a few areas. The way to isolate the problem is to start with a known
good xture. Test each part from the inoperable xture in the known good xture, one at a time, until the
problem is isolated. Then replace the defective part.
• Note which side is side A and which side is side B.
• Remove the 4 screws that hold the cap in place.
• Remove the cap.
• Carefully pull the connector board upward to disconnect.
• Remove the 2 screws that hold the side A lens retainer in place.
• Remove side A LED light engine.
• Remove the 2 screws that hold the Side B lens retainer in place.
• Remove side B LED light engine.
• Pull the connector board upward and out of the xture.
• Remove the 4 screws holding the bottom to the body.
Figure 7: Electronic Component Assembly