Airsafe EBL-RE-II User manual

Advanced Airport Lighting System
Elevated Runway Edge Light (Type II)
EBL-RE-Ⅱ(PBL-620)
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
C.SY
W.GL
Nov. 20, 2008
2
Design changed
V2.0
Z.H
C.SY
Aug. 2, 2016

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Table of Content
1.0 Foreword...............................................................................................................................................................1
1.1 Illustrations and Meanings........................................................................................................................... 1
1.2 Safety Rules and Notices............................................................................................................................. 2
1.3 Quality Assurance and Responsibility......................................................................................................... 3
2.0 Introduction ..........................................................................................................................................................4
2.1 Technical Specifications .............................................................................................................................. 5
2.2 Application Environment............................................................................................................................. 5
2.3 Application Scope........................................................................................................................................ 5
2.4 Technical Parameters................................................................................................................................... 5
2.5 Technical Features ....................................................................................................................................... 6
2.6 Structure....................................................................................................................................................... 7
3.0 Installation ............................................................................................................................................................8
3.1 Installation Methods .................................................................................................................................... 8
3.2 Installation Tools.......................................................................................................................................... 9
3.3 Screw and Torsion ....................................................................................................................................... 9
3.4 Direction Installation of Flange................................................................................................................. 10
4.0 Operation and Control ........................................................................................................................................11
4.1 Light Wiring Schematic Diagram...............................................................................................................11
4.2 Light Intensity Adjustment and Control .....................................................................................................11
5.0 Replacement of Components of Lighting Fixtures.............................................................................................12
5.1 How to Replace Optical Cover.................................................................................................................. 13
5.2 How to Replace Lamp ............................................................................................................................... 14
5.3 How to Replace Frangible Pole ................................................................................................................. 15
6.0 Maintenance of Lighting Fixtures.......................................................................................................................16
6.1 Daily Maintenance..................................................................................................................................... 16
6.2 Regular Spot Check and Troubleshooting ................................................................................................. 17
7.0 List of Components and Ordering of Spare Articles andAccessories ................................................................18
8.0 Packaging, Transportation and Storage ..............................................................................................................20
8.1 Packaging and Weight................................................................................................................................ 20
8.2 Transportation Mode.................................................................................................................................. 20
8.3 Storage....................................................................................................................................................... 20

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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.
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 lamp or other component of 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 the lamp.
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.
※Falling to the ground may cause damage of the optical cover or other internal
components of the lighting fixtures and injury of personnel.
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 optical cover 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:
EBL-RE-II-------------------------------Elevated Runway Edge Light
Type of Elevated Runway Edge Light (EBL-RE-II):
Type
EBL-RE -II= Elevated runway edge light
Power
Beam color
YC = window 1–yellow and window 2–white
CY = window 1–white and window 2–yellow
CC = window 1–white and window 2–white
CR = window 1–white and window 2–red
RC = window 1–red and window 2–white
Window 2
Window 1
Window 1
Window 2
Clockwise
Clockwise
Runway Centerline

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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;
Federal Aviation 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.
2.3 Application Scope
Elevated runway edge light can be used for Category 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
Life of Light Source at 6.6A
Runway edge light
EBL-RE-II-150-XX
150W
≥1,500h

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2.5 Technical Features
○Optical cover made of the high borosilicate glass makes good optical performance and heat
resistance;
○The filter employs advanced coating technology, with high light transmittance, firm coating and
good thermostability;
○International standard PK30D preset focus lamp has accurate positioning and high light
distribution accuracy;
○Optical parts have self-positioning design and recalibration is unnecessary for replacing the
optical components and lamp;
○Compact structure, attractive appearance, small windward area and strong wind resistance
capability;
○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;
○High precision components machining ensures dimensional quality and precision of the
lighting fixtures;
○Forged frangible device with precise machining, complying with FAA standards and ensuring
stable and reliable performance;
○The overall IP rating of the lighting fixtures reaches IP65, and it is difficult for the dust to be
deposited in them;
○The lighting fixtures can be connected to 1 inch or 2 inches frangible tube, which ensures
convenient and secure installation;
○The lighting fixtures may be maintained without tools, which are easily dismantled. The lamp
may be replaced on site with a hand;

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2.6 Structure
1. Optical cover
2. Color filter lens
3. Optical cover
4. Optical cover gasket
5. Optical cover holder
6. Lamp
7. Hinge
8. Body gasket
9. Fixed base of terminal
10. Light body
11. Waterproof Gland
12. Frangible pole
13. Flange
14. Plug

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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 Methods
○Mounted on L- 867 deep base (Figure 3-1).
○Directly mounted with flange (Figure 3-2).
○Mounted on embedded pipe (Figure 3-3).
Figure 3-1 Figure 3-2 Figure 3-3
Confirm window color and lighting direction before installation.
※To avoid rework or any other problem.

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3.2 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.
○Special tool- Elevated light nut wrench: be used to dismount
the lighting fixtures, and available directly from the
manufacturer or any distributor.
○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.
3.3 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
M6 screw
Internal hexagonal
wrench
5 N·m
2
M4 screw
Force measuring
screwdriver with cross
screwdriver (PH2)
1.5 N·m
Please use torque wench or other special tool for installation.
※Informal tools may cause damage to fasteners or personal injury.

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3.4 Direction Installation of Flange
○Install the flange onto the base, with its dimension shown in Figure above;
○After the flange is installed (see Figure 3-4), connect the secondary cable according to the
construction requirements and screw the frangible pole of the lighting fixture into the threaded
hole of its chassis (see Figure 3-5).
○After pre-tightening the lighting fixtures, screw down the lighting fixtures with special wrench.
(See Figure 3-6 and Figure 3-7).
Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7
○Unscrew the set screw with a socket head wrench (see Figure 3-8).
○The arrow on the outer cover of the lighting fixtures points at the runway centerline and the
inner cover partition may be perpendicular to the centerline (see Figure 3-8).
○Then tighten screw. (See Figure 3-9).
Figure 3-8
Figure 3-9
Secondary
cable
Elevated light nut
wrench
Inner cover partition
Runway centerline
Locking screw

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4.0 Operation and Control
The lighting fixtures are applicable to CCR power supply 6.6A circuit special for airports,
which forms a secondary circuit with the lighting fixtures through secondary outgoing line of
isolation transformer connected on primary circuit. Due to the use of isolation transformer, the
damage of lamp of single lighting fixture will not affect whole series circuit.
4.1 Light Wiring Schematic Diagram
4.2 Light Intensity Adjustment and Control
In actual use, according to weather visibility, light intensity of the lighting fixtures may be
adjusted through different current output by CCR, and varies significantly.
If it is used on occasion of lower than rated current (6.6A), it may greatly improve the service
life of lamp.
Halogen lamp
Secondary connector
Isolation transformer
Primary connector
Single lamp
Elevated runway edge
light
Secondary plug
Isolation transformer
Primary connector
Primary connector
Isolation transformer
Secondary plug
Elevated runway edge light
Elevated runway edge
light
Secondary plug
Isolation transformer
Primary connector
Primary connector
Isolation transformer
Secondary plug
Elevated runway edge
light

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5.0 Replacement of Components of Lighting Fixtures
When any damage or failure occurs to any consumable or other component of the lighting
fixtures, it is required to timely dismantle the lighting fixtures for replacement of the component.
Replacement of components needs to dismount the lighting fixtures, so any minor error will cause
adverse consequences. The manufacturer requires users to attach importance to the following
warnings. It is required to be careful during disassembly, to conduct comprehensive inspection of
lighting fixtures, to replace some vulnerable parts as required, and to ensure the performance of the
lighting fixtures after disassembly.
Replacement of components must be conducted by personnel who have received
professional training.
※To avoid various failures of the lighting fixtures.
It is suggested that maintenance of the lighting fixtures be carried out in lighting
station or workshop.
※Any impurities mixed in the lighting fixtures may cause any failure of the
lighting fixtures.
The manufacturer suggests that various gaskets should be replaced during each
maintenance of the lighting fixtures.
※Aging and damage of gaskets are the main reasons for the leakage of lighting
fixtures.

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5.1 How to Replace Optical Cover
○Unscrew the M4×10 screws with a cross screwdriver to remove the pressing bracket and take
out the outer cover (see Figure 5-1).
○Loosen the steel wire fixing the inner cover to take out the inner cover (see Figure 5-2).
○Put a new inner cover into the holder and fix it with a steel wire; the outer cover is aligned with
the set hinge on the holder and then fix it with the pressing bracket and M4×10 cross pan head
screws (see Figure 5-3).
Touching the inner and outer covers directly with hands is strictly prohibited.
During operation, the clean white gloves shall be worn.
※Prevent the glass edge from scratching the fingers.
※The fingerprint may be left on the glass to impact the optical property.
Figure 5-1 Figure 5-2 Figure 5-3

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5.2 How to Replace Lamp
○Open the hinge in the direction indicated by the arrow, remove the optical cover holder and pull
the lamp pin out of the ceramic wire holder (Figure 5-4).
○Push the lamp in the arrow direction to make it leave the neck on the other end, overturn it
downwards and take it down (see Figure 5-5).
○Fetch a new lamp to make its square opening stick to the gasket and make its the other end
enter the neck and press it down; after the lamp is fixed, insert its pin into the wire holder;
finally buckle the hinge. Please note that the lamp wire shall not be pressed (see Figure 5-6).
Figure 5-4 Figure 5-5 Figure 5-6
The lamp wire shall not be pressed by any other articles.
※The wire is easily damaged, which causes electric shock.
Touch the lamp with hands directly is strictly prohibited. The clean white
gloves shall be worn during operation.
※The oil and fat on skin may cause crack of the lamp during use.
Local view A
Scale 2:5

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5.3 How to Replace Frangible Pole
○Separate the lighting fixture from the base with a nut wrench of the elevated light, pull out the
lighting fixture and separate the secondary connector (see Figure 5-7).
○Unscrew the set screw on the light body with a socket head wrench and pull out the frangible
pole (see Figure 5-8).
○Fetch a new frangible pole, insert it into the connecting sleeve of the lighting fixture and
tighten the set screw with a socket head wrench (see Figure 5-9).
○Insert the lighting fixture into the base and fix it on the base with a nut wrench of the elevated
light (see Figure 5-9).
Figure 5-7 Figure 5-8 Figure 5-9
Please use torque wench or other special tool for installation.
※Informal tools may cause damage to fasteners or personal injury.
Force of the wrench must be applied to the lower part of the frangible groove.
※Applying force on the upper part of the frangible groove may make the
frangible pole broken.
Set screw

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6.0 Maintenance of Lighting Fixtures
Suggestions for daily maintenance provided in this section are only for reference. Airports may
formulate their own daily maintenance guidelines with reference to other provisions or maintenance
experience of airport staff; the manufacturer does not provide any hard-and-fast rules.
Maintenance of the lighting fixtures for airports shall be conducted by professionals as stated
in 1.0 Foreword.
6.1 Daily Maintenance
Interval
Check
Activity
Every day
No light output or flashing
Replace LED lamp assy.
Light output is lower
1. If optical cover surface is dirty, wipe it up.
2. Check deviation or moisture of the lighting
fixtures.
3. Check aging or displacement of LED.
Every week
Obstacles to light output channel
Clean surface of route and optical cover.
Every month
Existence of moisture and water
(Visual check of internal surface
of prism)
1. Open the body.
2. Clean, dry and check.
3. Replace gasket and any other damaged
components.
Every two
months
Tighten the screws
Check whether screw for tightening light body is
locked.
After snow
removal
Damage to lighting fixtures
1. Replace seriously damaged light.
After snow
removal
Light output is lower
1. Sweep snow on the optical cover away.
2. If optical cover surface is dirty, wipe it up.
3. Check deviation or moisture of the lighting
fixtures.
4. Check aging or displacement of LED.
The manufacturer suggests that times of daily maintenance should be increased
in rainy season.
※To ensure normal operation of lighting fixtures.
The manufacturer suggests that LED lamp assy should be systematically
replaced when service life of LED lamp is up to 80%.
※To ensure the consistency of light intensity of whole circuit.
It is necessary to use torque wrench. Power wrench is strictly prohibited.
※Otherwise, it may damage screw and thread, and thus cause an accident.

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6.2 Regular Spot Check and Troubleshooting
Serial No.
Failure Phenomenon
Possible Reasons
Countermeasures
1
LED lamp assy failure
LED aging or other
unknown failure
Replace LED lamp assy or
send lighting fixtures back to
factory for repair.
2
The lighting fixtures is
darker
There are some stains on
optical cover surface
Clean up stains on optical
cover surface.
3
Existence of moisture
and water
Damage to front glass or
gasket
Replace front glass or gasket.