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.