ALS RB/IN-WW(L)-C User manual

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[e-mail] www.alsukltd.co.uk
12 Inch LED Inset Runway Edge Light
with Circular Guidance
Instruction Manual

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[e-mail] www.alsukltd.co.uk
User Manual
UM-2101, Rev. 1.01, 2021.9.16
Disclaimer and standard warranty
CE mark
The equipment marked CE means that the product complies with the essential
requirements.
ICAO certification
The equipment complies with the essential requirements concerning ICAO Airfield
regulations.
CAAC certification
The equipment complies with the requirements concerning CAAC standards.
Standard Products Guarantee
Products of ALS manufacture are guaranteed against mechanical, electrical, and physical
defects which may occur during proper and normal use for a period of two years from the
date of delivery ex-works.
Liability
Use of the equipment in ways other than described in the manual may result in personal
injury, death, or property and equipment damage. Use this equipment only as described in
the manual.
ALS cannot be held responsible for injuries or damages resulting from non-standard,
unintended uses of its equipment. The equipment is designed and intended only for the
purpose described in the manual. Uses not described in the manual are considered
unintended uses and may result in serious personal injury, death or property damage.
Unintended uses, includes the following actions:
Making changes to equipment that have not been recommended or described in this
manual or using parts that are not genuine ALS replacement parts or accessories.
Failing to make sure that auxiliary equipment complies with approval agency requirements,
local codes, and all applicable safety standards.
Using materials or auxiliary equipment that are inappropriate or incompatible with your ALS
equipment.
Allowing unskilled personnel to perform any task on or with the equipment.
User manual

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[e-mail] www.alsukltd.co.uk
This manual or parts thereof may not be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photocopying, recording,
nor otherwise, without ALS's prior written consent.
This manual could contain technical inaccuracies or typographical errors. ALS reserves the
right to revise this manual from time to time in the contents thereof without obligation of
ALS to notify any person of such revision or change. Details and values given in this
manual are average values. They are not binding, however, and ALS disclaims any liability
for damages or detriments suffered as a result of reliance on the information given herein
or the use of products, processes or equipment to which this manual refers. No warranty
is made that the use of the information or of the products, processes or equipment to which
this manual refers will not infringe any third party's patents or rights.

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[e-mail] www.alsukltd.co.uk
Table of Contents
1. Safety ............................................................................................................................ 1
1.1. Safety Symbols .................................................................................................. 1
1.2. Professional ....................................................................................................... 1
1.3. Introduction to safety ......................................................................................... 2
2. Equipment Information ................................................................................................. 4
2.1. Fixtures in this manual ....................................................................................... 4
2.2. Compliance with standards ............................................................................... 6
2.3. Features ............................................................................................................. 6
2.4. Power and power factor..................................................................................... 7
2.5. Dimensions and Weight ..................................................................................... 8
3. Installation ..................................................................................................................... 9
3.1. Tools and Material ............................................................................................. 9
3.2. Installation steps ................................................................................................ 9
3.3 Installation Bolt Torque ......................................................................................... 11
3.4Top-Lock Installation Guidelines ........................................................................... 11
4. Maintenance ............................................................................................................... 13
4.1 Basic Maintenance Program ................................................................................ 13
4.2 Workshop Maintenance ........................................................................................ 14
4.2.1 Tools and accessories ....................................................................................... 14
4.2.2 Remove a light fixture from its base .................................................................. 15
4.2.3 Remove and replace light source ...................................................................... 16
4.2.4 Replace the prism and its sealing gasket ......................................................... 17
4.2.5 Waterproof test .................................................................................................. 18
5. Spare Parts ................................................................................................................. 19

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
1. Safety
This section contains general safety instructions for installing and using ALS equipment.
1.1. Safety Symbols
Carefully read and observe all safety instructions in this manual, which alert you to safety
hazards and conditions that may result in personal injury, death or property and equipment
damage and are accompanied by the symbol shown below.
WARNING
Failure to observe a warning may result in personal injury, death or
equipment damage.
DANGER - Risk of electrical shock or ARC FLASH
Disconnect equipment from line voltage. Failure to observe this warning
may result in personal injury, death, or equipment damage. ARC Flash
may cause blindness, severe burns or death.
CAUTION
Failure to observe a caution may result in equipment damage.
1.2. Professional
Professional is defined as individuals who thoroughly understand the equipment and its
safe operation, maintenance and repair. Qualified personnel are physically capable of
performing the required tasks, familiar with all relevant safety rules and regulations and
have been trained to safely install, operate, maintain and repair the equipment.

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
1.3. Introduction to safety
WARNING
This equipment may contain electrostatic devices and hazardous voltages.
• Read installation instructions in their entirety before starting installation.
• Become familiar with the general safety instructions in this section of the manual
before installing, operating, maintaining or repairing this equipment.
• Make this manual available to personnel installing, operating, maintaining or
repairing this equipment.
• Follow all applicable safety procedures required by your company, industry
standards and government or other regulatory agencies.
• Install all electrical connections to local code.
• Use only electrical wire of sufficient gauge and insulation to handle the rated
current demand. All wiring must meet local codes.
• Protect components from damage, wear, and harsh environment conditions.
• Protect equipment with safety devices as specified by applicable safety
regulations
• If safety devices must be removed for installation, install them immediately after
the work is completed and check them for proper functioning prior to returning power
to the circuit.
• Never touch exposed electrical connections on equipment while the power is
ON.
Failure to follow this instruction can result in serious injury or equipment damage
Electric Shock Hazard

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
• Do not operate a system that contains malfunctioning components. If a
component malfunctions, turn the system OFF immediately.
• Allow only qualified personnel to make repairs. Repair or replace the
malfunctioning component according to instructions provided in its manual.
• Live operation is not allowed.
Failure to follow this instruction can result in serious injury or equipment damage

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
2. Equipment Information
2.1. Fixtures in this manual
This manual covers the following 12-inch fixtures:
Light Fixture Ordering Code Optical Toe-in Color Sketch
Runway Edge Light
（width of runway
is 45m）
RB/IN-WW(L) -
C Toe-in 3.5° White, White
Runway Edge Light
（width of runway
is 60m）
RB/IN-WW(L) -
C Toe-in 4.5° White, White
Runway Edge Light
（width of runway
is 45m）
RB/IN-WR(L) -C Toe-in 3.5° White, Red
Runway Edge Light
（width of runway
is 60m）
RB/IN-WR(L) -C Toe-in 4.5° White, Red
Runway Edge Light
（width of runway
is 45m）
RB/IN-RW(L) -C Toe-in 3.5° Red ,White,

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
Runway Edge Light
（width of runway
is 60m）
RB/IN-RW(L) -C Toe-in 4.5° Red ,White,
Runway Edge Light
（width of runway
is 45m）
RB/IN-WY(L) -C Toe-in 3.5° White, Yellow
RunwayEdge Light
（width of runway
is 60m）
RB/IN-WY(L) -C Toe-in 4.5° White, Yellow
Runway Edge Light
（width of runway
is 45m）
RB/IN-YW(L)-C Toe-in 3.5° Yellow ,White
Runway Edge Light
（width of runway
is 60m）
RB/IN-YW(L)-C Toe-in 4.5° Yellow ,White
Runway Edge Light
（width of runway
is 45m）
RB/IN-YR(L)-C Toe-in 3.5° Yellow, Red
Runway Edge Light
（width of runway
is 60m）
RB/IN-YR(L)-C Toe-in 4.5° Yellow, Red

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
Runway Edge Light
（width of runway
is 45m）
RB/IN-RY(L)-C Toe-in 3.5° Red,Yellow
Runway Edge Light
（width of runway
is 60m）
RB/IN-RY(L)-C Toe-in 4.5° Red,Yellow
2.2. Compliance with standards
ICAO Annex 14 Volume 1
IEC TS 61827
FAA AC 150/5345-46
FAA Engineering Brief No. 67
EASA CS-ADR-DSN
NATO STANAG 3316
CAAC AC-137-CA-2015-01
CAAC AC-137-CA-2015-03
CAAC AC-137-CA-2017-03
2.3. Features
 Low protrusion of less than 6.3mm above ground level
 Modulized electrical driver and LED assembly for simplicity of maintenance
 Efficient and stable optical output, suitable for operation with 6.6A and 2.2A CCRs
 Unique optical design, ensuring luminous efficacy and color consistency
 At any brightness level, the intensity of circling guidance beam is no less than 50cd
 Strict thermal management solution increasing life expectancy
 Highly conductive aluminum mechanical components with special treatment
suitable for various weather conditions

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
 Built-in surge protection
 Optional omnidirectional beam
 Optional Fail Open System
2.4. Power and power factor
Light Fixture Ordering Code Power Power factor
Runway Edge Light RB/IN-WW(L)-C 65VA >0.90
Runway Edge Light RB/IN-WR(L)-C 54VA >0.90
Runway Edge Light RB/IN-RW(L)-C 54VA >0.90
Runway Edge Light RB/IN-WY(L)-C 62VA >0.90
Runway Edge Light RB/IN-YW(L)-C 62VA >0.90
Runway Edge Light RB/IN-YR(L)-C 48VA >0.90
Runway Edge Light RB/IN-RY(L)-C 48VA >0.90

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
2.5. Dimensions and Weight
Packing Data
6
-
φ
11

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
3. Installation
3.1. Tools and Material
 Spanner 17 mm
 Torque wrench with a 16/17 mm socket
 Brush or cloth
 Six M10×25 bolts
 Sixφ10 Locking washers
3.2. Installation steps
The installation process of light fixtures includes locating installation holes on the pavement,
wiring, base embedding and mounting of lights. The installation of light fixture has a great
influence on the function and service life of the lights. Proper and adequate trainings are
recommended by the manufacturer to all installation personnel.
Drawings of light fixture
Direction of installation
There are color and direction indication marks near the window of light output channel on
each light to provide information on the main beam.
Select correct light categories and beam directions in accordance to the specific
regulations of ICAO, FAA and CAAC

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
The letter indicates the light color of this window:
W-White, R-Red, Y-Yellow
The arrow indicates the toe-in direction of the main
beam (the figure on the right indicates toe-in left).
No arrow indicates no toe-in.
Installation Steps
1-12-in shallow base
2-light fixture
3-Ø10 lock-washers
4-M10×30 bolt
1. Carefully clean all contact surfaces of the light fixture and the base.
2. Put the O-ring gasket in the gasket track on the base.
3. Connect the connector(s) of the light fixture to the base supply cable(s). Check that
the A- and B-side are connected to corresponding circuit if two connectors are used.
4. Place the connector under the light fixture and install in the base.
5. For an installation on bases, use a torque limiting box spanner of 16/17 mm, install
and tighten the six fixing bolts or nuts to a torque value according to specification. For
other base manufacturers, refer to their specifications.
6. After installation, make sure that each light fixture functions properly.

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
7. In order to bond the light fixture to ground, use the
supplied screw to attach the braided ground strap to the
grounding point on the light fixture. The grounding point is
indicated by a grounding symbol and located on the
bottom side.
3.3 Installation Bolt Torque
●Use fully threaded A2-70(or A4-70) M10x1.5 bolts .
●Use Model TL10 Top-Lock lock-washers .
●Mounting base holes must be degreased, cleaned, and dried
prior to bolt installation.
●Base-to-fixture mating surfaces must be degreased, cleaned, and dried prior to
installation. .
●Install the M10 bolts with lock-washers per lock-washer manufacturer’s guidelines.
●See Section 2 for Top-Lock installation guidelines.
●Achieve a full final torque of 26.9 Nm. （Use GTP600 lubricants to 33 Nm.）with a
calibrated torque wrench.
●Impact wrenches are not recommended as installation tools.
●Check torque and re-torque all bolts within 2 weeks of initial installation.
●If other lubricants or thread locking compounds are used (not recommended), torque
must be recalculated based on K factor provided by lubricant or compound
manufacturer.
●New bolts and lock-washers shall be used each time a light unit is removed from its
base.
3.4Top-Lock Installation Guidelines
Step1: Hand tighten to ensure that 2-3 threads extend beyond the nut on through-bolt
applications.
Step2: Tighten each bolt to 9 Nm.（Use GTP600 lubricants to 11 Nm.） torque following
the pattern as shown below.
The grounding point

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
Step3: Increase the torque to 17.9 Nm. （Use GTP600 lubricant to 22 Nm.） following
the pattern shown below.
Step4: Increase the torque to 26.9 Nm. （Use GTP600 lubricant to 33 Nm.） following
the pattern shown below.
Step5: Perform one final pass on each bolt working clockwise from bolt 1, at 26.9 Nm.
（Use GTP600 lubricant at 33 Nm.） torque.
12-inch Inset Light 8-inch Inset Light
WARNING
The inset lights are designed to withstand a maximum torque of 31.2
Nm.（Use GTP600 lubricant to 38.3 Nm.）per bolt, assuming appropriate
superior-grade M10 hardware and lubricant, however other
components within the light fixture installation (i.e. base-can,
extension rings, spacer rings, etc.) may not be capable of supporting
such a load. We recommend following the installation bolt torque
values and methodology outlined in this Section.

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
4. Maintenance
This section describes the steps of lamp maintenance. Be sure to read and understand the
safety instructions before starting maintenance. If a new lamp is used to replace an existing
lamp, it is necessary to confirm whether the lamp model is correct through the label at the
bottom of the lamp before replacement. If the internal parts of the lamp need to be replaced,
it is also necessary to confirm that the model of the replaced parts is the same as the
prototype number. For more information, please refer to the spare parts list in the manual
or contact our company for assistance.
CAUTION
Using incorrect combination of washer, bolt and nut will cause serious
damage to product installation and cause a variety of safety risks.
Ignoring these warnings may result in equipment damage or airport foreign
objects.
CAUTION
When a light fixture is removed from the base, a cover or a spare lamp must
be put in its place.
ICAO, Airport Services Manual Part 9, Airport Maintenance Practice and FAA AC 150/5340-
26, Maintenance of airport visual aids facilities.
The light fixture is designed for outdoor operation, however storing the light fixture outside
without using it is a risk for damage to light fixture components. For a longer storage time
(more than a week), it is recommended to store the light fixture indoors in a dry and dust
free environment and at room temperature. Proper storage ensures trouble free
replacement procedures. It is strongly recommended not to store any electrical equipment
outside.
4.1 Basic Maintenance Program
Weekly Visual inspection of the light fixture.
Removal of dust from external surfaces of the light fixture.

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
Monthly Check of the optical window, check for mechanical damage.
Check for proper fixing of the light fixture in its base.
Yearly Detailed inspection of the light fixture.
Check of the body resistance, check for mechanical damage (for example
cracks around prism windows).
Clean of the optical windows.
4.2 Workshop Maintenance
The workshop maintenance includes the following:
• Replacement of light fixtures
• Checking water tightness
• Replacement of a prism and its gasket
• Replacement of LED module
CAUTION:
Be sure to read and understand the safety instructions before you start.
4.2.1 Tools and accessories
The following standard tools and accessories are required for maintenance of the unit:
 One angled socket spanner of 16 or 17 mm
 One Torque limiting spanner with 16 or 17 mm socket
 One hexagonal key (Allen key) of 3, 4, and 5 mm
 Torx 10, 20, 25, and 30
 Two large flat blade screwdrivers
 Silicone grease
 CC-Patron grease
 One brush or cloth
 Non-alcohol based cleaner

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
4.2.2 Remove a light fixture from its base
1. Use a torque socket wrench to remove the M10×30 bolts, spring washer and flat
washer.
2. Pry up the lighting fixture with the 8 inches lighting fixture pry bar.
3. After the light fixture and base are separated, vertically lift the light fixture with the light
fixture handle and dismount the ground lead with the cross screwdriver, then
disconnect the secondary cable connectors.

Airfield Lighting Systems UK Limited
Aviation House, Russell Gardens, Wickford
Essex SS11 8BF Tel [phone]
[email protected] www.alsukltd.co.uk
4.2.3 Remove and replace light source
1. Place the light fixture upside down, remove the six m5
× 16 hexagon screws, and separate the upper cover
from the bottom cover (if the upper cover and the bottom
cover are adhered too tightly, pry it open with the help of
a large slotted screwdriver).
2. Unplug the connector between the LED module and
the electrical driver and separate the upper cover and
the bottom cover.
3. Remove the four M4 × 10 cross pan head screws and
get out the LED light source assembly.
4. Attach the new LED assembly on the prism pressing
block in diagonal order with four m4 × 10 cross pan head
screws. (Confirm that the color and model of the light
source are consistent with the removed light source),
5. Connect the connector LED module to the electrical
driver in the bottom cover. Align the bottom cover with
the pin hole on the upper cover, and screw in the six m5
× 16 inner hexagon cap screw to fasten firmly.
6. Perform water-tightness test. If air leaks out of the
light fixture, locate the leaking point and open the lamp
for repair. After rechecking, assemble the light fixture
and perform the water-tightness test again.