Eaton Crouse-hinds series User manual

DOCUMENT
2623
REVISION
H
May 27,2019
Instruction Manual
Style II
In-pavement FAA Approach Light Fixture
FAA-E-2952
FAA-E-2968
FAA-L-850E
Eaton Crouse-Hinds Series
Airport Lighting Products
1200 KennedyRoad
Windsor, CT 06095
Copyright ©2019 Cooper Technologies Company
For Parts or Technical Service Call [phone]

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1.0 Revisions
Revision
Issue/Reissue
LetterNumber
Description Created/Updated Checked Approved
A A206-218 INITIALRELEASE 6/23/06 KWF JMM
B A206-433
7.1, deleted fixture fits on L-
867 base & also added do not
install on shallow base
11/9/06 KWF PG
C A206-452
9.3, Take care not to damage
mating surface. was
“Take…surface orthe o-ring.
& (P/N 21385 was (P/N10035-
62);9.8.5,(21385)was
(100035-62); Sec10 parts list
item2,P/N was 10035-33-272
& added post cured to
description
12/8/06 KWF PG
D A207-230
Pg 8, parts list item14 was
21276-X
8/2/07 KWF PG
E A209-153
Updated to include the 21480-
X Lens replacement kit,
which includes the P/N 21477
Lens Bracket and the P/N
21479 Lens gasket;Added
note on how to address
fixtures build and installed
before thesechangeswere
made in June 2009. Revised
copyright to 2009.
9/24/09 JRC
F A215-426
Added L-850Eversion; P/N
10000-514 was 10B08-019D16
for Section10 Parts List;
Revisedcopyright to 2016.
12/16/15 FPR
G A217-185
Revised title page & section2,
5; Updated section 8.1, 9.8
& Figure 5; Section9.4,
torque 55-60 was 30 in-lbs.
Added section 8.2
12/18/17 EB PG
H A219-076
Revised Copyright to 2019;
Updated section 8.1 extensively.
5/27/19 EB PG

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2.0 Product Warranty
Warranty
Refer to Eaton’s Crouse-Hinds Airport Lighting Products Terms and Conditions for product specific
warranty information.

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3.0 Warning Labels
DANGER:
DANGER
The hazard or unsafepractice willresultin severe injuryor death.
WARNING:
WARNING
The hazard or unsafepracticecouldresultin severe injuryor death.
CAUTION:
CAUTION
The hazard or unsafe practice could resultin minor injury.
NOTICE:
NOTICE
Possibly dangerous situation, goods mightbe damaged.
IMPORTANT:
IMPORTANT
Helpfulinformation.

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4.0 Safety 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:
4.1 Keep Away from Live Circuits
Operating and maintenance personnel must at all times observe all safety regulations. DO
NOT PERFORM MAINTENANCEON INTERNAL COMPONENTSOR RE-LAMP
WITH POWER ON.
4.2 Resuscitation
Maintenance personnel should familiarize themselves with the technique for resuscitation
found in widely published manuals of first aid instructions.
IMPORTANT:
See FAA Advisory Circular AC 150/5340-26 foradditional information.

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5.0 Table Of Contents
Title Page
i
1
Revisions
ii
2
Product Warranty
iii
3
Warning Labels
iv
4
Safety Notices
v
5
Table of Contents
vi
6
Part Number Explanation
1
7
General Description
2
7.1
FAA Approach Light
2
8
Installation
3
8.1 Installation Bolt Torque
3
8.2 Heico- lock installation guidelines (2014)
4
9
Maintenance
5
9.1
Cleaning Lenses
5
9.2
Relamping
5
9.3
O-Ring Replacement
6
9.4
Lens Replacement
7
9.5
Power Lead Feed-thru Replacement
7
9.6
Pressure Test
8
9.7
Cleanliness and Workmanship
8
9.8
Maintenance Program
9
10
Parts List
10
Figure 1
Exploded View of Fixture
11
Figure 2
Isometric View of Fixture
12
Figure 3
Top View of Fixture
13
Figure 4
Side View of Fixture
13
Figure 5
Bottom View of Fixture
14
Figure 6
Feed-thru detail
15

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6 Part Number Explanation
8506 A - XXX - P1
FIXTURE TYPE:
850 = RUNWAY
6 = MODEL 6
C-H STYLE:
A = APPROACH
FAA SPECIFICATIONS:
C52 = FAA-E-2952, CLEAR
G52 = FAA-E-2952, GREEN
R52 = FAA-E-2952, RED
C68 = FAA-E-2968, CLEAR
G68 = FAA-E2968, GREEN
85E = FAA L850E, GREEN
L-823 CONNECTION:
P1 = ONE PLUG

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7 General Description
7.1 FAA Approach Light
The Crouse-Hinds FAA Approach Light is a Style II, (≤1/2 inch) fixture that meets the
photometric requirements of FAA-E-2952, FAA-E-2968 and L-850E with the appropriate
lamp(s) and colored lens/lenses installed. It is designed for installation at the runway
threshold or any other location where visual guidance of moving aircraft is desirable. The
fixture is designed to fit on a FAA L-868 (do not install on shallow base), steel, size B light
bases per FAA AC 150/5345-42 (latest version), and have a total height above grade/ground
level of <.500 inch. The fixture is uni-directional, projecting the beam of light in one
direction. It is weatherproof and will endure roll over loads without damage. The light fixture
consists of a 1-piece aluminum optical assembly. The aluminum optical assembly is mounted
to a light base with six bolts (3/8-16 UNC x 7/8 lg., stn. stl., hex bolt) and lock washers (3/8,
2-piece locking stn. stl.) The aluminum housing has a sand cast bottom cover that is attached
using 6 screws. A silicone o-ring is used to provide a watertight seal between the inner cover
and the optical housing. The lamp(s) are secured to an installed bracket, which is fastenedto
the bottom housing using vibration isolators. Electrical connections are made at a feed-thru
assembly in the inner cover. The feed-thru has an ITS verified L-823 plug for connecting to
FAA L-830/ L-831 Isolation Transformer. The outer lens is held into the aluminum housing
with a bracket, gasket, molded elastomeric boot and 2 screws. The light beam color is
obtained by coloring the lens to the appropriate color for the application. All hardware is type
18-8 stainless steel. The complete light unit is 11.94 inches in diameter, 5.13 inches deep, and
weighs 16 lbs.
CAUTION:
Never handle the light assembly by the leads asthis can break the waterproof seal.

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8 Installation
The style 2 FAA light units are shipped complete 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, 24 inch deep minimum, L-868 Light Base per FAA AC
150/5340-4 (latest revision). Place the properly sized isolation transformer in the light base
and make necessary primary power connection using L-823 connectors. The light unit
requires a 6.6A secondary transformer. 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 from the light unit to the secondary of the
previously installed isolation transformer. Installation tool, Crouse-Hinds P/N 19999, will
ease in the installation and removal of the light unit. 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. Secure the light fixture to the base per section 8.1. After installation, the mounting
bolts shall be periodically checked for proper torque to ensure a secure installation. See
section 9.8.4.
8.1 Installation Bolt Torque
•Use fully threaded, 3/8-16 bolts meeting requirements of FAA EB83A. (P/N 21716 is
recommended.)
•Use Heico-Lock or Nord-Lock stainless steellock-washers per FAA specifications*.
•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.
•Apply marine grade anti-seize (K=.18) per manufacturer’s instructions to each bolt.
•Install the 3/8-16 bolts with lock-washers per lock-washer manufacturer’s guidelines.
•See Section 8.2 for Heico-Lock installation guidelines (2014)
•Achieve a full final torque of 28 FT-LBS (37.9 N-m) ±10% with a calibrated torque
wrench.
•Impact wrenches are notrecommended as installation tools.
•Check torque and re-torque all bolts within 2 weeks of initial installation.
•Maintain all bolts by checking and re-torqueing per FAA specifications*.
•If any 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.

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*Refer to the following specifications for FAA installation and maintenance recommendations:
•AC150/5340-26 “Maintenance of Airport Visual Aids”
•AC150/5345-46 “Specification for Runway and Taxiway Light Fixtures”
•FAA Engineering Brief No. 83A “In-pavement Light Fixture Bolts”
WARNING:
WARNING
12”Approach lightopticalassembliesaredesignedto withstand a maximum
torque of 28 ft-lb (336in-lb) per bolt, assuming K=.18 lubricantandappropriate
superior-grade 3/8”hardware, howeverother components within the lightfixture
installation (i.e. base-can, extensionrings, spacerrings, etc.)may notbe capable of
supporting sucha load. Crouse-Hinds recommends following the installation bolt
torque values andmethodology outlined in Section 8.1.
8.2 Heico- Lock Installation Guidelines (2014)
Step 1: Hand tighten to ensure that 2-3 threads extend beyond the nut on through-bolt
applications.
Step 2: Tighten each bolt to one-third of the final required torque following the pattern as
shown below.
Step 3: Increase the torque to two-thirds following the pattern shown below.
Step 4: Increase the torque to full torque following the pattern shown below.
Step 5: Perform one final pass on each bolt working clockwise from bolt 1, at the full final
torque.

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9 Maintenance
The preferred method of maintaining these lights is to periodically and systematically replace
the units and return them to the maintenance shop for renovation. As an alternative, the units
can be serviced in the field. However, it is recommended that field servicing be limited to
cleaning the lens only as described in section 9.1.
9.1 Cleaning Lenses
With a compressed air blast or suitable brushes, remove all accumulated debris from the light
channel. Clean the outer lens surface with a detergent solution. If the lens is coated with a
substance impervious to the detergent, a suitable solvent should be sparingly applied with a
wad of cotton or a patch of cloth on the end of a wood splint. After the solvent has acted the
remaining solvent and softened coating should be removed with a clean piece of cotton or
cloth. Care should be taken to avoid excessive contact between the solvent and the lens seal.
Remove all remaining solvent from lens and seal. A gentle air blast may be used.
9.2 Relamping
Remove and secure powerto the fixture. Turn the fixture upside down and remove the six
screws holding the inner cover to the light housing. Disconnect the lamp leads. Inspect the feed-
thru terminal for signs of corrosion. Replace feed-thru assemblies per paragraph 9.5. Install the
new lamps by reversing the procedure above making sure that the Teflon tubing
completely covers the lamp terminals. Inspect/replace the optical housing’s o-ring per
paragraph 9.3. Assemble the inner cover onto the light housing. Tighten the mounting screws
to 30 in-lbs. Clean the mounting flange area of the base. Install the light fixture into the base
per section 8.1
NOTICE:
Warranty is void if other than Crouse-Hindsparts are used to relamp or rebuild
the fixture.
NOTICE:
The lamp ishot when fixture isenergized and remainshot for a
short time afterfixture isturned off.

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9.3 O-Ring Replacement
Every time the unit is opened, the o-ring must be closely examined and replaced, if necessary.
Any o-ring that is stretched, torn, has permanent set, or some other defect, which would prevent
it from forming a watertight seal, must be replaced with a new o-ring.
Remove the old o-ring from the groove in the optical housing. Carefully clean the o-ring
groove and flange mating surface on the inner cover. Take care not to damage the mating
surface. Clean the new o-ring (P/N 21385) with denatured alcohol. Position the new o-ring in
the center of the groove and press it into place. Torque the inner cover screws to 30 in-lbs.
Perform a pressure test as described in paragraph 9.6. Clean the mounting flange area of the
base. Install the light fixture into the base per section 8.1
NOTICE:
A bad o-ring seal isthe most common causeof inset fixture leaks.
A new o-ring must be installed every time the
Optical Assembly is opened
NOTICE:
The groove is designed to be wider than the o-ring. This providesroom for the
displacement of the o-ring when compressed between the housing and mating
surface. Properly tightened screws are important in obtaining a complete seal.

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9.4 Lens Replacement
If an outer lens is broken, leaks, or is badly pitted or scarred, it must be replaced. It is highly
recommended that this task be performed in a clean shop environment. Lens Replacement Kit
P/N 21480-X contains all necessaryparts to change a lens. Remove and secure powerto the
fixture. Turn the fixture upside down and remove the six screws holding the inner cover to the
light housing. Remove the lens retaining bracket screws from the light housing. Remove the lens-
retaining bracketanddiscard the lens-retaining gasket. Firmly push the lens/boot assemblyfrom the
outside of the light housing; discard the old lens and boot. Thoroughly clean the lens opening with
isopropyl alcohol and let dry. Inspect the lens opening for scratches or pits; a damaged lens-opening
surface willnot sealproperly. Place a new lens boot (P/N 21277) over the replacement lens (P/N
21276-X). Apply a thin coat of Dow Corning FS 1292 grease over the entire outside surface of
the lens boot. Align the lens/boot assembly in the lens opening and press it into place. Verify
that the lens boot is not pinched in the lens opening. Using a new lens-retaining gasket (P/N
21479), fasten the lens-retaining bracket (P/N 21477) to the light housing. Torque the mounting
screws to 55-60 in-lbs. Inspect/replace the optical housing’s o-ring per paragraph 9.3.
Assemble the inner cover onto the light housing. The screw-hole patterns in the inner cover and
light housing are offset to insure proper alignment. Torque the mounting screws to 30 in-lbs.
Perform a pressure test per paragraph 9.6. Clean the mounting flange area of the base. Install
the light fixture into the base per Section 8.1.
NOTE: Lighting Fixtures built/installed before June 2009 will require the 21276-X Lens
Replacement Kit. The 21276-X Kit contains the P/N: 21101 lens-retaining gasket and the P/N:
21100 lens-retaining bracket. Lighting Fixtures built/installed after June 2009 require the
21480-X as listed above.
9.5 PowerLead/ Feed-thru Replacement
The power leads are connected to water tight feedthrus in the inner cover. There is a coating
of RTV over the connections, and an epoxy material to encapsulate the entire assembly. The
power cord and feedthru components can be replaced, but shipping restrictions prohibit
Crouse-Hinds from supplying the epoxy encapsulating material. The complete inner cover
assembly, with leads is part number 21286-X. Follow the instructions below to rebuild the
power lead/feedthru assembly.
Remove andsecure powertothe fixture. Turn the fixture upside down and remove the six
screws holding the inner cover to the light housing. Remove the Teflon leads inside the cover. Cut
the powerleads offat the encapsulating material. Using a hammerandchisel, separate the
encapsulating materialfrom the inner cover. Be carefulto not damage the inner cover. Remove
and discard the feedthru assemblies. Carefullycleanthe feed-thru mounting area in the inner
cover,inspect for anymechanicaldamage thatwould preventa water tightseal. Replace the feed-
thru components; refer to Figure 6 for part numbers and orientation. Replace the Teflonleads
inside the cover. Replace the opticalhousing’s o-ring per paragraph 9.3. Assemble the inner

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cover onto the light housing. The screw-hole patterns in the inner cover and light housing are
offset to insure proper alignment. Torque the mounting screws to 30 in-lbs. Performa pressure
test per paragraph 9.6. Clean the mounting flange area of the support ring. Install the light fixture
into the base per Section 8.1.
9.6 Pressure Test
A light fixture should be subjected to a 20-psi air pressure test to verify that it is waterproof
whenever it has been opened or components have been replaced. A tire valve style pressure
fitting is located on the bottom of the inner cover. Pressurize the fixture to 20-psi then place it
in a tub of water or use a soap solution to locate escaping air bubbles. Carefully inspect the
areas around the lens, inner cover seal, and feed-thru adapter for leaks. Relieve the internal air
pressure before installing the fixture or attempting to repair a leak.
9.7 Cleanliness and Workmanship
Service life depends upon the entire assembly being waterproof. All surfaces must be clean,
dry and free of all foreign matter if the light fixture is to operate for extended periods without
requiring maintenance.
WARNING:
Do not exceed 20-psi when pressure testing the fixture. Serious injury and/or
permanent damage to the fixture may result if a higherair pressure is used. Once
the pressure test is complete, be sure to relieve the air pressure.

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9.8 Maintenance Program
In order to insure maximum light fixture life, the installed units should be subject to a
maintenance program in accordance with the following: A daily operation check should be
made of the lighting fixture. The lights should be energized and visually inspected. If any
fixtures are out, the location of the fixture should be recorded and the lamps replaced at a time
when the circuit is de-energized. (See Section 9.2)
9.8.1 Regular cleaning is necessary in order to insure that inset lighting fixtures operate at
maximum efficiency. The lens should be cleaned periodically with a soft cloth and solvent.
The weather and the location of the fixtures will dictate the regularity and type of cleaning.
9.8.2 Snowplow operators should exercise extra care not to strike the light fixtures with snowplow
blades (use rubber blades for added protection to the fixture.) After snowplow removal
operations, inspect all light fixtures to locate and replace if necessary, any damaged Light
Assemblies. Passes over the light rows should be made with a power broom only if practical.
Whenever snowplows must traverse in-pavement light fixtures, they should be traveling at
less than 5 mph or have the blades lifted clear of the fixture.
9.8.3 The light is designed to exclude both ground and surface water from entering. If the lights are
not properly maintained (i.e., bolts tightened and seals in good condition) water may enter the
fixture. To prevent this from occurring, it is recommended that each fixture be inspected for
the presence of water at least once a month. More frequent inspection is desirable during and
following rainy seasons.
9.8.4 FAA approach fixtures hold-down bolts shall be checked for proper torque per Section 8.1
9.8.5 If any fixture contains water, the water should be removed and the entire fixture cleaned and
dried. Perform a pressure test per paragraph 9.6 to locate the source of the leak. Replace the
o-ring (21385), see Section 9.3.

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10 Parts Lists
ITEM NO.
8506A-XXX-P1
PART NUMBER
DESCRIPTION
1
SEE TABLE
21287
HOUSING, OPTICAL, ASS'Y,FAA APPROACH
2
1
21385
O-RING, SIZE #2-273, 70 DUROMETER, SILICONE, POST CURED
3
SEE TABLE
21286
COVER, BOTTOM, ASS'Y, ICAO APPROACH
4
SEE TABLE
21295
BRACKET, BASE, ASS'Y, ICAO APPROACH
5
8
20356
GROMMET
6
4
19143-2
SPACER
7
4
10000-514
SCREW, TRUSS HEAD, PHILLIPS, #10-32 x 1/2 LG, SSTL
8
6
10000-470
SCREW, 100° FLAT HD/DRI-LOC, #10-32 x 7/16 LG, 18-8 SS
9
A/R
21128
105 WATT LAMP
10
A/R
10047-417
MALE TERMINAL FOR LEAD ASSEMBLY
11
A/R
10048-25
SILICONE GREASE
12
A/R
10037-865
FEED-THRU
13
1
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A/R
21480-X
LENS REPLACEMENT KIT G=Green; R=Red; c=Clear
NOTE: Lighting Fixtures built/installed before June 2009 will require the 21276-X Lens
Replacement Kit. The 21276-X Kit contains the P/N: 21101 lens-retaining gasket and the P/N:
21100 lens-retaining bracket. Lighting Fixtures built/installed after June 2009 require the
21480-X as listed above.
P/N
ITEM 1
ITEM 3
ITEM 4
8506A-C52-P1
21287-3C
21286-1
21295-C52
8506A-G52-P1
21287-2
21286-1
21295-G52
8506A-R52-P1 21287-3R 21286-1 21295-R52
8506A-C68-P1 21287-1C 21286-1 21295-C68
8506A-G68-P1
21287-2
21286-1
21295-G52
8506A-85E-P1
21287-2
21286-1
21295-85E

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Figure 1: Exploded View of Fixture

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Figure 2: Isometric Viewof Fixture

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Figure 3: Top View of Fixture
Figure 4: Side View of Fixture

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Figure 5:BottomViewofFixture