Airsafe EBL-RE-LED User manual

Advanced Airport Lighting System
LED Elevated Runway Edge Light
EBL-RE-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
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........................................................................................................................................................6
2.7 Fault Detection or Lamp Bypass Functions..................................................................................................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......................................................................................................................................12
4.1 Light Wiring Schematic Diagram...............................................................................................................12
4.2 Light Intensity Adjustment and Control .....................................................................................................12
5.0 Replacement of Components of Lighting Fixtures...........................................................................................13
5.1 How to Replace Frangible Pole ..................................................................................................................14
5.2 How to Replace Front Glass and its Gasket Sleeve....................................................................................15
5.3 How to Replace Gasket ..............................................................................................................................16
6.0 Maintenance of Lighting Fixtures ....................................................................................................................17
6.1 Daily Maintenance......................................................................................................................................17
6.2 Regular Spot Check and Troubleshooting ..................................................................................................18
7.0 List of Components and Ordering of Spare Articles and Accessories ..............................................................19
8.0 Packaging, Transportation and Storage ............................................................................................................21
8.1 Packaging and Weight.................................................................................................................................21
8.2 Transportation Mode...................................................................................................................................21
8.3 Storage........................................................................................................................................................21

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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 light source 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 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.
※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-LED ------------------------------ LED Elevated Runway Edge Light
Type of LED Elevated Runway Edge Light (EBL-RE-LED):
Type
EBL-RE = Elevated runway edge light
Light source
LED = LED lamp
Beam color
Window 2
Window 1
Window 2
Window 1
Runway Centerline
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
M = single lamp fault detection function
Optional function
Clockwise
Clockwise

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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
Runway edge light for Category I, II, 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
LED Elevated Runway Edge
Light
EBL-RE-LED-XX-
XX
36VA
>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;
○Dimming curve of the lighting fixtures is consistent with the change of halogen lamp, and
meets the requirements of FAA;
○Strict LED color management ensures the consistency of light color;
○Proprietary drive circuit and thermal management solution greatly improve the reliability and
service life of the lighting fixtures;
○Optional single lamp fault detection function enables the light to be open as halogen lamp once
LED fails;
○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 lighting fixtures can be connected to 1 inch or 2 inches frangible tube, which ensures
convenient and secure installation;
2.6 Structure
1 - Cover bracket
2 - Optical cover gasket
3 - Optical cover
4 - LED lamp assy
5 - Light body
6 - Body gasket
7 - Transformer
8 - Drive assy
9 - Bottom cover
10 - Waterproof gland
11 - Frangible pole
12 - Plug

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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
Light
apparatus
Isolation
transformer
Light
apparatus
Normal
shining
Light source
failure
Automatic
open circuit
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
Light
Fixture 1
Normal
shining
Light
Fixture 2
Normal
shining
Light
Fixture n
Normal
shining
Isolation transformer
Light
Fixture 1
Normal
shining
Light
Fixture 2
Light source damage
Internal bypass
Light
Fixture n
Normal
shining

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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
○This manual does not give any guidance to installation of chassis. Please seek for technical
support from construction side. Dimension of chassis to be installed is as follows:
○After installation of chassis (embedded pile) (See Figure 3-4), in accordance with construction
requirements, connect secondary cable, and screw frangible pole of the lighting fixtures in the
threaded hole on flanges. (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).
○Then tighten screw. (See Figure 3-8).
Figure 3-4
Figure 3-5
Expansion screw
Secondary cable

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Figure 3- 6
Figure 3-7
Figure 3-8
Elevated light nut wrench
Tighten 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.
LED lamp
Secondary connector
Isolation transformer
Primary connector
Open circuit
monitoring
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 Frangible Pole
○Loosen fastening screw on the body, hold the head, and disconnect the lighting fixtures from
flanges with elevated light nut wrench. (See Figure 5-1)
○Separate secondary plug; take new frangible pole, insert it in working position, and screw it
down with internal hexagonal wrench. (See Figure 5-2)
○Connect to secondary plug, screw frangible pole in flanges, and fix the lighting fixtures on
chassis with elevated light nut wrench. (See Figure 5-3)
Before screwing frangible pole in or out of flanges, fastening screw must be
loosened.
※It may damage secondary line.
Figure 5-1 Figure 5-2 Figure 5-3
Fastening screw
Fastening screw

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5.2 How to Replace Front Glass and its Gasket Sleeve
Figure 5-4 Figure 5-5
○Twist off four screws which fix front glass junk ring, and remove front glass junk ring. (See
Figure 5-4)
○Take out old front glass and gasket sleeve, replace them with new front glass and gasket sleeve,
pay attention to gasket sleeve direction and front glass direction, and make “TOP” inscription
upward. (See Figure 5-5)
○Install junk ring, and tighten four screws in mode of opposite angle.
It is strictly forbidden to directly touch outer and inner covers with hand. During
operation, it is required to wear clean white gloves.
※To prevent glass edge from scratching any fingers.
※Fingerprint will be left on glass and affect optical performance.

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5.3 How to Replace Gasket
Figure 5-6 Figure 5-7 Figure 5-8
○Twist off four screws which fix the body and tray (See Figure 5-6).
○Remove old gasket of body, and install new gasket of body (See Figure 5-7).
○Close the body and tray (See Figure 5-8).
Sealing tape or washer should not be taken out from bag before assembly.
※If sealing tape or washer is stained with any impurities, it may cause water
seepage of the lighting fixtures.
It is required to carefully check sealing and sealing slot to ensure that they are
not stained with any impurities.
※Impurities being clipped in the middle is the main reason for the leakage of the
lighting fixtures.

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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.