Cooper Crouse-Hinds Pro AFP Series User manual

DOCUMENT
1331
REVISION
A
October 15, 2019
Instruction Manual
Pro AFP Series LED
Inset Runway Guard Light
FAA Type L-852G
8-inch aluminum optical housing with
ductile iron support ring
Cooper Lighting Solutions
Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095
Copyright © 2019 Cooper Lighting Solutions
For Parts or Technical Service Call [phone]

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
1
1Table of Contents
1Table of Contents....................................................................................................................1
2Revisions ................................................................................................................................2
3Product Warranty....................................................................................................................3
4Warning Labels.......................................................................................................................4
5Safety Notices.........................................................................................................................5
5.1 Keep Away From Live Circuits.......................................................................................5
5.2 Resuscitation....................................................................................................................5
6Recommended Test Equipment and Tools.............................................................................5
7Part Number Explination........................................................................................................8
8General Description................................................................................................................8
9Installation..............................................................................................................................9
9.1 Installation Bolt Torque .................................................................................................10
9.2 Heico-Lock Installation Guidlines.................................................................................10
10 Maintenance..........................................................................................................................11
10.1 Cleanliness and Workmanship.......................................................................................11
10.2 Maintenance Program ....................................................................................................12
10.3 Cleaning the Lenses .......................................................................................................13
10.4 Replacing the LED Modeule..........................................................................................13
10.5 O-Ring Replacement......................................................................................................14
10.6 Lens Replacement..........................................................................................................15
10.7 Power Lead/Feedthru Replacement ...............................................................................16
10.8 Power Supply Bluetooth Board Replacement................................................................16
10.9 Power Supply Troubleshooting and Replacement .........................................................17
10.9.1 Visual Inspection................................................................................................17
10.9.2 Electrical Inspection...........................................................................................18
10.9.3 Power Supply Replacement................................................................................19
10.9.4 Resetting a IRGL Power Supply’s E-Prom ........................................................20
10.10 Pressure Test ................................................................................................................21
11 Tables and Figures................................................................................................................22

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
2
2Revisions
Revision
Issue/Reissue
Letter Number
Description
Checked
Approved
A
A219-XXX
Initial Issue

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
3
3Product Warranty
Warranty
Refer to Cooper Crouse-Hinds Airport Lighting Products Terms and Conditions for product specific
warranty information.
(f) EXCEPT FOR THE EXPRESS WARRANTY SET FORTH ABOVE, SELLER
PROVIDES PRODUCTS AS-IS AND MAKES NO OTHER REPRESENTATIONS OR
WARRANTIES, EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE,
REGARDING THE PRODUCTS, THEIR FITNESS FOR ANY PARTICULAR
PURPOSE, THEIR MERCHANTIBILITY, THEIR QUALITY, THEIR
NONINFRINGEMENT, OR OTHERWISE. IN NO EVENT SHALL SELLER BE
LIABLE FOR THE COST OF PROCUREMENT OR INSTALLATION OF
SUBSTITUTE GOODS.

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
4
4Warning Labels
DANGER:
DANGER
The hazard or unsafe practice will result in severe injury or death.
WARNING:
WARNING
The hazard or unsafe practice could result in severe injury or death.
CAUTION:
CAUTION
The hazard or unsafe practice could result in minor injury.
NOTICE:
NOTICE
Possibly dangerous situation, goods might be damaged.
IMPORTANT:
IMPORTANT
Helpful information.

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
5
5Safety Notices
This equipment is normally used or connected to circuits that may employ voltages that are
dangerous and may be fatal if accidentally contacted by operating or maintenance personnel.
Extreme caution should be exercised when working with this equipment. While practical safety
precautions have been incorporated in this equipment, the following rules must be strictly
observed:
5.1 Keep Away from Live Circuits
Operating and maintenance personnel must at all times observe all safety regulations. Do not
perform maintenance on internal components or re-lamp with power ON.
5.2 Resuscitation
Maintenance personnel should familiarize themselves with the technique for resuscitation found
in widely published manuals of first aid instructions.
IMPORTANT:
IMPORTANT
See FAA Advisory Circular AC 150/5340-26 for additional information.
6 Recommended Test Equipment and Tools
There is a wide variety of tools and equipment needed to safely and correctly perform airfield
lighting equipment installation and maintenance. In addition to the obvious tools (screwdrivers,
wrenches, etc.), there is a specialized equipment needed to do the job.
Multimeter
One of the most important pieces of test equipment is the Multimeter. It is used to measure
voltages, currents, and resistances. Almost every maintenance task requires the use of a
multimeter at one point or another. A quality meter in good repair and calibration is a must
because airfield lighting power distribution equipment produces non-sinusoidal waveforms,
traditional average reading meters are inaccurate and have very limited use. Checking or
adjusting equipment based upon incorrect current reading may dramatically reduce lamp life and
adversely affect power equipment performance. A meter with TRUE RMS measuring capability
with a current clamp-on accessory is needed to accurately measure distorted or chopped
waveforms. All meter manufacturers offer TRUE RMS measuring meters. The following is a
short list of TRUE RMS Multimeters from Fluke:

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
6
Manufacturer
Model Number
Fluke
287
Our recommended multimeter is the Fluke 287 with the Fluke I800 current clamp accessory.
Refer to the equipment manufacturer’s manuals for the proper use, maintenance and calibration
(if necessary) of all meters.
Anti-seize (marine grade preferred, Henkel/Loctite P/N 34395 or 34026 or equal
(http://www.henkelna.com/adhesives/product-search-1554.htm?nodeid=8797882515457) with a
K factor of 0.18 for fully coating the frangible coupling threads. This will help facilitate removal
of sheared frangible couplings or fixtures for replacement/maintenance. Only use an anti-seize,
as other materials may wash away.
WARNING:
IMPORTANT
Failure to apply anti-seize at installation will result in near
impossible to impossible removal of a frangible coupling from a
threaded hub over time.
A calibrated torque wrench (micrometer adjustable solid audible/tactile “click” impulse when
torque value attained with an accuracy of +/- 4%) to fit a 9/16 or 14 mm socket for drive size of
the socket to tighten the fixture base plate 3/8-16 UNC hex bolts to 336 in-lbs -0, +0% [37.9 -0,
+10%] with an anti-seize that has a K factor of 0.18 applied to fully cover the bolt threads.
Torque wrenches: Sturtevant Richmont P/N 810748, range 100 to 600 in-lbs or equal, or
Sturtevant Richmont P/N 810782, range 10 to 50 Nm or equal. Certificate of calibration
included with suggested torque wrenches. Note, never loosen bolts with a torque wrench.
A calibrated adjustable torque screwdriver to torque the external ground screw to 6 in-lbs
[1.81Nm] minimum. Sturtevant Richmont P/N 810568 (comes with bits [hex, slotted, Torx,
Phillips, sq. recess, bit holder, socket adapter], case and certificate of calibration), range 2 to 36
in-lbs/0.2 to 4 Nm or equal. Note, never loosen screws with a torque screwdriver.
Needle nose pliers for installing the extremely small header jumper onto a spare Power Supply
J203 header when required or removing the flag type fast-on terminals from the power supply.
Xcelite P/N NN54-2 miniature pliers, fine needle nose, ESD-Safe or equal.

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
7
A grounded ESD Wrist Strap when working on or handling fixture power supplies or LED/Heat
sink assemblies. ESD Wrist Straps, also known as anti-static Wrist Straps, are used to prevent
electrostatic discharge (ESD) by safely grounding a person working with electronic equipment or
at an electronic assembly facility. It consists of a band of fabric with fine conductive fibers
woven into it. The fibers are usually made of carbon-filled rubber, and the strap is bound with a
stainless-steel clasp or plate. They a usually used in conjunction with an ESD table mat on the
workbench, or a special static-dissipating plastic laminate on the workbench. ESD Products
brand (http://www.esdproduct.com/esd_wrist_straps.php) or equal.
A #2 x 4 inch (101.6 mm) long Phillips head screw driver for installing the Isolation
Transformer’s FAA L-823 Style 8 secondary receptacle retainer plate screws into one of the
recommended base plates for a L-867 base.
Most tools indicated above can be purchased from MSC Industrial Supply Co.
(http://www.mscdirect.com/), or McMaster-Carr (http://www.mcmaster.com/).

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
8
7Part Number Explanation –Inset Runway Guard Light, L852G
8 General Description
The Cooper Lighting Solutions Inset Runway Guard Light (IRGL) is a Style 3, ITS verified FAA
L-852G per FAA AC 150/5345-46 and EB67 (latest versions). It is designed for installation at
the intersection of runways and taxiways or any other location where visual guidance of moving
aircraft or ground vehicles is desirable. The fixture is designed to fit on a FAA L-868, steel, Size
B, light base per FAA AC 150/5345-42(latest version) and have a total height above
grade/ground level of .250 inch. The fixture is uni-directional, and flashes on/off in unison
within a hold bar. It is weatherproof and will endure roll over loads without damage. The light
fixture consists of a ductile iron support ring and a removable aluminum optical assembly. The
ductile iron ring is mounted to a light base with six bolts (3/8-16 UNC x 7/8 lg., 410 black oxide
stn. stl.) and lock washers (3/8, stn. stl.). The aluminum housing is secured to the ductile iron ring
using two high-strength bolts and two high-strength shear pins. The aluminum housing has a die
cast bottom housing that is attached using 4 screws. A polyurethane O-ring is used to provide a
watertight seal between the inner cover and the optical housing. Electrical connections are made
at one feed-thru assembly in the inner cover. The feed-thrus have ITS verified L-823 plugs for
connecting to FAA L-830/ L-831 Isolation Transformers. Lenses are held into the aluminum

DOCUMENT 1331
REV. A
Instruction Manual
PRO AFP Series LED
Inset Runway Guard Light L-852G
9
housing with a bracket, gasket, molded elastomeric boot and two screws. The yellow light beam
color is produced using white LED’s and optics with a dichroic coating on the lenses All
hardware is type 18-8 stainless steel. The complete light unit is 11.94 inches in diameter, 5.00
inches deep and weighs 25 lbs. All units leave the factory pressure tested. if the unit is serviced
during its lifetime, it must be re-tested to ensure it remains waterproof.
IMPORTANT
IMPORTANT:
Do not open any fixture unless the warranty period has expired.
Opening a fixture will void the warranty
CAUTION
CAUTION:
Never handle the light assembly by the leads as this can break the
waterproof seal
9 Installation
The Style 3 IRGL units are shipped complete, including the LED module(s), and are ready for
installation as received. Installation of a light unit is to be done with primary POWER OFF
and SECURED. At each light location, install a steel, Size B, 12 inch deep minimum, L-868
Light Base per FAA AC 150/5340-4 (latest revision). Place the properly sized isolation
transformer(s) in the light base and make necessary primary power connections using L-823
connectors. All isolations transformers are 6.6 ampere secondary models. Verify that the
mounting flange on the light base is clean and the O-ring (optional on deep cans) is coated with
Dow Corning FS 1292 grease and is in place on the light base. Connect the plug(s) from the light
unit to the secondary of the previously installed isolation transformer(s). Installation tool, Crouse-
Hinds P/N 19999, will ease in the installation and removal of the light unit (See Figure 4). The
threaded eyebolts on the lifting tool screw into threaded holes in the light fixture. Lower the light
unit straight down onto the base. The light fixture is subject to optical misalignment or
mechanical damage if not seated properly. Verify the light beam is properly orientated for the
individual location. Secure the light unit to the base per section 9.1.
All 852G-AP1 light units are flashing lights. For light units with the “YO” designator in the part
number, the light will flash ON first in the cycle. For light units with the “YF” designator in the
part number, the light will flash OFF first in the cycle. This allows the light installers to arrange
either an alternating flashing bar of lights (i.e. YO---YF---YO---YF---YO---YF---… etc.), in
which the YOs flash on while the YFs flash off in an alternating fashion, or a solid bar of lights
that flash in unison (i.e. YO---YO---YO---YO---YO---YO---… etc.). In the case of an accidental
undesirable light bar installation (i.e. YO---YF---YF---YO---YO---YO---…etc.), each 852G-AP1