Airsafe APPS-12-LED User manual

Advanced Airport Lighting System
12 Inches LED In-pavement Runway Lighting Fixtures (6mm)-
Uni-directional Passageway
In-pavementApproach Centerline Light and Cross Bar Light, In-pavement Approach
Side-row Light and In-pavement Runway Threshold Wing Bar Light
APPS-12-LED,APSS-12-LED and THWS-12-LED
Operation Manual
Please read this manual carefully before construction, installation and operation of the product.
Please keep this manual properly for further reference.
This manual is subject to change without prior notice.
Airsafe Airport Equipment Co., Ltd.

Advanced Airport Lighting System
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Revision Description
No.
Description
Version
No.
Revised
by
Approved
by
Date
1
First release
V1.0
Y.MZ
C.SY
Aug. 10, 2016

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Table of Content
1.0 Foreword........................................................................................................................................1
1.1 Illustrations and Meanings.....................................................................................................2
1.2 Safety Rules and Notices .......................................................................................................3
1.3 Quality Assurance and Responsibility ...................................................................................4
2.0 Introduction....................................................................................................................................5
2.1 Technical Specifications.........................................................................................................7
2.2 Application Environment.......................................................................................................7
2.3 Application Scope ..................................................................................................................8
2.4 Technical Parameters .............................................................................................................8
2.5 Technical Features..................................................................................................................9
2.6 Structure...............................................................................................................................11
2.7 Fault Detection or Lamp Bypass Functions.........................................................................12
3.0 Installation....................................................................................................................................13
3.1 Installation Dimension.........................................................................................................13
3.2 Identification of Different Types of Lighting Fixtures.........................................................14
3.3 Installation Tools..................................................................................................................14
3.4 Screw and Torsion................................................................................................................15
3.5 Configuration of Lighting Fixtures and Relevant Installation Fittings................................15
3.6 Installation Process ..............................................................................................................16
4.0 Replacement of Components of Lighting Fixtures......................................................................18
4.1 How to Dismount the Lighting Fixtures from Base.............................................................19
4.2 How to Open Light Body.....................................................................................................19
4.3 How to Replace Light Source Components.........................................................................20
4.4 How to Replace Prism and its Gasket Sleeve......................................................................21
4.5 How to Replace Gasket........................................................................................................23
4.6 Airtight Test of Lighting Fixtures ........................................................................................24
5.0 Operation and Control..................................................................................................................25
5.1 Light Wiring Schematic Diagram ........................................................................................25
5.2 Light IntensityAdjustment and Control...............................................................................25
6.0 Maintenance of Lighting Fixtures................................................................................................26
6.1 Daily Maintenance...............................................................................................................26
6.2 Regular Spot Check and Troubleshooting ...........................................................................27
7.0 List of Components and Ordering of Spare Articles and Accessories.........................................28
8.0 Packaging, Transportation and Storage........................................................................................30
8.1 Packaging and Weight..........................................................................................................30
8.2 Transportation Mode............................................................................................................30
8.3 Storage .................................................................................................................................30

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1.0 Foreword
ICAO Airport Service Manual Part 9 “Airport Maintenance Practices” and FAA
AC150/5345-26 Maintenance of Airport Visual Aid Facilities are the highest criterions for site
installation and maintenance of such lighting fixtures. This manual was compiled with considerable
reference to these two criterions.
The content stated in this manual is absolutely important, so construction personnel must read
it carefully before construction. After properly understanding the entire content of this manual,
construction personnel should carry out the construction in strict accordance with the methods
specified herein, to ensure that the product is safely and properly installed in place.
Routine airport maintenance personnel should carry out the routine maintenance in strict
accordance with the methods specified by relevant provisions, to ensure that the lighting fixtures
are in the best operation condition.
Related personnel must strictly follow safety criterion. Any personnel without specialized
training is strictly forbidden to touch the lighting fixtures and devices. Live line work should be
avoided under any circumstances. Construction or maintenance personnel should get acquainted
with first-aid knowledge, in case of any unexpected events.

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1.1 Illustrations and Meanings
○Following illustrations will appear in this manual where necessary to remind or warn
construction or maintenance personnel.
○Please continue reading the subsequent content of this manual after properly understanding the
meanings of these illustrations.
To remind that the behavior may cause serious injury or death.
※Detailed description will be given in the box.
To remind that the behavior may cause injury to people or damage to product.
※Detailed description will be given in the box.
To notify that the behavior is prohibited.
※Detailed description will be given in the box.

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1.2 Safety Rules and Notices
Using the light fixtures outside of airport is strictly prohibited.
※Inadequate maintenance or casual touch will cause light faults.
Using power supply other than CCR is strictly prohibited.
※Other power supply may cause damage to the lighting fixtures, or even malfunctions of
power supply.
Making sure that CCR is on power-off state before the installation or maintenance of the
lighting fixtures.
※Current surge produced during the installation of the lighting fixtures may cause damage
to light source.
Non-professional electricians are strictly forbidden to maintain any electrical fault of the
lighting fixtures.
※It may damage any electrical component of the lighting fixtures or cause bigger fault.
Live line maintenance of the lighting fixtures is strictly prohibited; in case of lightning
and/or thunderstorm, maintenance of the lighting fixtures is prohibited.
※It may cause electric shock accident.
Be careful when handling the lighting fixtures.
※Drop or collision may damage the parts or cause personal injury.
Replace the lead immediately in case the jacket of second cable is damaged.
※It may cause short circuit, electric shock or other failure.
Don’t touch the damaged prism or other glass directly with hands.
※Glass fragments may scratch hands.
Touching the lighting fixtures with wet hand is strictly prohibited.
※It may cause electric shock or other accident.

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1.3 Quality Assurance and Responsibility
Any defect in design, material or workmanship, which may occur during proper and normal
use over a period of one year from date of installation but less than 15 months from date of
shipment, or within the warranty period of the tender, will be repaired or preplaced by
manufacturer free of charge. The warranty doesn’t cover the failures resulting from lamp burnt out,
improper maintenance, installation or operation, or damages due to snow ploughs. Manufacturer
shall not be liable to any further claims or particularly claims for damages not affecting the goods
themselves.

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2.0 Introduction
This manual involves the following series lighting fixtures:
APPS-12-LED---------------------------- In-pavement Approach Centerline Light and Cross
Bar Light
APSS-12-LED---------------------------- In-pavement Approach Side-row Light
THWS-12-LED--------------------------- In-pavement Runway Threshold Wing Bar Light
Type of In-pavement Approach Centerline Light and Cross Bar Light (APPS-12-LED):
Type of In-pavement Approach Side-row Light (APSS-12-LED):
Type
APPS-12= 12 inches 6mm
in-pavement approach centerline light
and cross bar light
Beam direction
L= left toe-in
R=right toe-in
S= straight
emission
Runway top
Left toe-in
Right toe-in
Straight emission
Light source
LED= LED lamp
Beam color
C=White
Optional function
M= single lamp fault detection function

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Type of In-pavement Runway Threshold Wing Bar Light (THWS-12-LED):
Type
APSS-12=12 inches 6mm
in-pavement approach side-row light
Beam direction
L= left toe-in
R= right
toe-in
Runway top
Left toe-in
Right toe-in
Light source
LED= LED lamp
R=Red
Beam color
Optional function
M= single lamp fault detection function
Type
THWS-12=12 inches 6mm in-pavement
runway threshold wing bar light
Beam direction
L= left toe-in
R= right toe-in
Runway top
Left toe-in
Right toe-in
Light source
LED= LED lamp
Beam color
G=Green
Optional function
M= single lamp fault detection function

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2.1 Technical Specifications
This product conforms to the provisions of the following standards or technical specifications.
For dated standards or technical specifications, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
International Electrotechnical Commission (IEC) TS 61827;
Convention on International Civil Aviation Annex 14- Aerodromes Volume 1;
International Civil Aviation Organization (ICAO)- Aerodrome Design Manual- Part 4: Visual
Aids;
Federal Aviation Administration (FAA) AC150/5345-46;
FederalAviation Administration (FAA) EB 67;
GB/T 7256 General Requirements of Lighting Fixtures for Civil Airport;
Department of Airport of Civil Aviation Administration of China: Advisory Circular, Technical
Requirements for Runway and Taxiway Aid Lighting Fixtures (AC-137-CA-2015-03)
Department of Airport of Civil Aviation Administration of China, Advisory Circular, General
Technical Requirements for Civil Airport LED Aid Lighting Fixtures (AC-137-CA-2015-01)
2.2 Application Environment
○Altitude: below 4,000m;
○Outdoor: -55°C ~ +55°C;
○Relative air humidity: not more than 95%;
○In rain, snow, ice and water;
○Expose to corrosive salt atmosphere
○Basic earthquake intensity VII.

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2.3 Application Scope
In-pavement approach centerline light and cross bar light, in-pavement approach side-row light and
in-pavement runway threshold wing bar light for Categories I, II and III airports.
Using the lighting fixtures beyond the specified scope is strictly prohibited.
※Application beyond the specified scope will cause damage or risk to any component.
2.4 Technical Parameters
Description
Type
Rated
Power
Power
Factor
Life of Light
Source
In-pavement Approach
Centerline Light and Cross
Bar Light
APPS-12-S-LED-C-M
70VA
＞0.9
≥50,000h
APPS-12-L-LED-C-M
70VA
＞0.9
≥50,000h
APPS-12-R-LED-C-M
70VA
＞0.9
≥50,000h
In-pavement Approach
Side-row Light
APSS-12-L-LED-R-M
45VA
＞0.9
≥50,000h
APSS-12-R-LED-R-M
45VA
＞0.9
≥50,000h
In-pavement Runway
Threshold Wing Bar Light
THWS-12-L-LED-G-M
65VA
＞0.9
≥50,000h
THWS-12-R-LED-G-M
65VA
＞0.9
≥50,000h

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2.5 Technical Features
○Long life, energy saving, maintenance free and other characteristics of LED will bring huge
economic benefits to customers;
○Proprietary prism structure and manufacturing process, making the optical efficiency excellent;
○Strict LED color management ensures the consistency of light color;
○Dimming curve of the lighting fixtures is consistent with the change of halogen lamp, and
meets the requirements of FAA;
○Proprietary drive circuit and thermal management solution greatly improve the reliability and
service life of the lighting fixtures.
○Power factor is greater than 0.9, which minimizes the grid interference;
○Optional single lamp fault detection function enables the light to be open as halogen lamp once
LED fails;
○Specifically designed lighting fixture structure and the lighting fixture is only 6.35mm
protruded above the pavement;
○The luminous surface of the upper cover of the lighting fixture is flat, and thus it is difficult for
ponding and the luminous efficiency is high;
○The upper cover of the lighting fixture employs the constant strength design and forging
process, with good mechanical property and high bearing capacity and shock resistance
capacity;
○The upper cover of the lighting fixture is smooth, without sharp corner angle to ensure that the
aero tyre is not damaged;
○Main body of the lighting fixtures is made of the special high conduction aluminum alloy
material and thus the lighting fixtures have good heat dissipation;
○Main body of the lighting fixtures is made of aluminum alloy material with special anodizing
surface treatment, and all fasteners are made of stainless steel, thus being applicable to all
kinds of harsh environment;

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○High precision components machining ensures dimensional quality and precision of the
lighting fixtures.
○The overall IP rating of the lighting fixtures reaches IP68, which may bear 138KPa internal
pressure or water pressure formed by impact of the aircraft on the window;
○Optional double plugs respectively control the light of two windows, so as to achieve the
intelligent circuit control;
○The components are of modularized design for common use, which are applicable to various
12 inches LED in-pavement runway lights (6mm), effectively reducing the spare parts
inventory.

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2.6 Structure
1. Upper cover 2. Prism gasket sleeve 3. Prism 4. LED lamp assy 5. Prism gasket
6. Prism pressing bracket 7. Light body gasket 8. Inner cover assy 9. Temperature control switch

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2.7 Fault Detection or Lamp Bypass Functions
This product complies with the requirements of FAA EB67 and GB/T 7256, and integrates
single lamp fault detection function; Or, it can provide the option of lamp bypass function in
accordance with the requirements of FAAAC150-5345/46.
Single lamp fault detection function: The light will take automatic action to cut off the input
when any malfunction occurs on the lamp and achieve an effect similar as the open circuit of
ordinary halogen light once it is burnt. This function is generally used in conjunction with single
lamp controller, to help single lamp control and monitoring system to identify any failed light. And
it is integrated into the interior of the lighting fixtures, without need of any external device. Please
specify this function during the ordering if needed.
Isolation
transformer
Lighting
fixture
Isolation
transformer
Lighting
fixture
Normal
lighting
Lamp fault
Automatic
open circuit
In case of no special requirements, 100W isolation transformer lighting is recommended.
※Any isolation transformer whose power is greater than 100W shall not be used for the
fixture that has the single lamp fault detection function.
Lamp bypass function: After any failure occurs to the lamp, relatively, the input terminal of light
will be short to the isolation transformer. This function is generally applicable to occasions that one
isolation transformer carries multiple lighting fixtures. If one or more of these lighting fixtures is or
are damaged, the remaining lighting fixtures will not go out thereby. This function is integrated into
the interior of the lighting fixtures, without need of any external device. Please specify this function
during the ordering if needed.
Isolation
transformer
Lighting
Fixture 1
Normal
lighting
Lighting
Fixture 2
Normal
lighting
Lighting
Fixture n
Normal
lighting
Isolation
transformer
Lighting
Fixture 1
Normal
lighting
Lighting
Fixture 2
Lamp fault
Internal bypass
Lighting
Fixture n
Normal
lighting

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3.0 Installation
Requirements for installation should be learned thoroughly before installation including
installation tools and site requirement, etc., to avoid malfunction of the light due to incorrect
installation
3.1 Installation Dimension
○Directly mounted on the 12 inches deep base (Figure 3-1).
○Directly mounted on the 12 inches shallow base (Figure 3-2).
Figure 3-1 Figure 3-2

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3.2 Identification of Different Types of Lighting Fixtures
○The model of each lighting fixture is attached to its bottom.
○The colorful dot identification mark is attached to the light outlet of each lighting fixture,
respectively meaning the luminous color and direction of the window where the colorful dot is
located.
○According to the specific provisions of FAA, correctly select the lighting fixtures and ensure
their window directions.
Before installing the lighting fixture, confirm the window color and luminous direction.
※Avoid rework or other problems.
3.3 Installation Tools
Choosing right tools not only can ensure the correct and reliable installation of the lighting
fixtures, but also can reduce unnecessary safety accidents. Special Tools listed in the table may be
purchased from the manufacturer or any distributor. Universal tools are available on local hardware
market. Please pay attention to measurement range during procurement.
○Universal tool: Torque wrench: be used to tighten the screw,
which may be used with various sleeve wrenches and directly
purchased from various hardware stores, manufacturer or
agent.
Recommended range is 10-40N·m.
○Universal tool- Torque screwdriver: be used to dismount
screw, equipped with PH2 cross screwdriver, and sellable in
various hardware stores.
Recommended range is 1-6N.m
Left red dot: means red light and
left toe-in
Middle white dot: means white
light and no toe-in
Right green dot: means green light
and right toe-in e
This sign means the light color and
internal toe-in direction.

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3.4 Screw and Torsion
The torque listed in this section is only for reference by maintenance personnel. Correct
fastening force of screw can ensure normal operation of the lighting fixtures. If screw is too tight, it
will easily damage the lighting fixtures; on the contrary, if screw is easy to fly out, it may cause an
accident.
Serial No.
Screw Type
Tool
Torque
1
M10
Torque wrench with 17# sleeve
25 N·m
2
M5
Force measuring screwdriver with
cross screwdriver (PH2)
3 N·m
3
M4
Force measuring screwdriver with
cross screwdriver (PH2)
1.5 N·m
4
M3
Force measuring screwdriver with
cross screwdriver (PH1)
0.63 N·m
Please use torque wench or other special tool for installation.
※Informal tools may cause damage to fasteners or personal injury.
3.5 Configuration of Lighting Fixtures and Relevant Installation Fittings
1、M10×30 screw
2、Ø10 spring washer
3、Lighting fixture
4、12 inches shallow base
5、A7 twin-core receptacle

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3.6 Installation Process
The installation process of lighting fixtures includes settings of the pavement mounting hole,
wiring, base pre-burial and installation of lighting fixtures. The installation of lighting fixtures will
greatly impact their use and service life. The manufacturer recommends that all installers should
receive the professional training.
3.6.1 Base installation
a There is scribed line on the base edge
and the luminous direction of the lighting
fixtures is often parallel to the runway
centerline. When the lighting fixture base
with the internal toe-in requirements is
installed, the internal inclination angle is
not considered. The scribed line is
parallel to or overlapped with the
centerline;
b The base embedment is constructed according to the airport design plan and the manufacturer
does not recommend the plan; the base entry may be divided into the side entry and bottom entry.
Base direction sign
Base direction sign
Secondary cable (side
entry)
Secondary cable (bottom
entry)

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3.6.2 Installation
a Before installing the lighting fixtures, clean the waste in the seal groove to keep good seal. Put the
O-gasket (part No.: 41115) into the working position in the seal groove.
b Connect the secondary plug of the lighting fixtures with the base receptacle to keep good contact.
c Load the lighting fixtures into the base, identify the direction, screw the screws into the screw
holes in successive and please note the torsion when screwing them.
The ground lead must be connected in strict accordance with the provisions.
※During daily maintenance, electric shock accident may be caused.
During installation, the oily lubricating agent shall not be used to lubricate the sealing
components.
※The oily lubricant may cause aging or fault of the sealing components.
The weight of the isolation transformer shall not be directly applied to the lead.
※It may cause cable break, short circuit, drop, injury or other faults.
During installation, the lead shall not be damaged by the lighting fixtures.
※It may cause electric leakage or short circuit of the lighting fixtures.
Directly pulling the lead is prohibited when the lighting fixtures are handled.
※It may cause line break, short circuit, drop, injury or other faults.
When installing them, clean
the waste in the groove.
Lighting fixtures
O-gasket
Screw and elastic washer
Base
STYLE 6 plug
STYLE 7 plug