Eaton Crouse-Hinds 8506A-CS-P1 User manual

DOCUMENT
2421
REVISION
L
December 11, 2017
Instruction Manual
In-pavement ICAO Approach Light Fixture
ANNEX 14, APPENDIX 2
Figures A2-1, A2-2, A2-3, A2-4, A2-8
Eaton Crouse-Hinds Series
Airport Lighting Products
1200 Kennedy Road
Windsor, CT 06095 C
Co op py yr ri ig gh ht t © © 2 20 01 17 7 C Co oo op pe er r T Te ec ch hn no ol lo og gi ie es s C Co om mp pa an ny y
For Parts or Technical Service Call [phone]

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1.0 Revisions
Revision
Issue/Reissue
Letter Number
Description Created/Updated Checked Approved
See record copy for revision
history
K A215-119
Updated installation bolt
torque range and torque
method; Added section 7.1, 7.2,
and 7.3
CS KF 4/23/15
L A217-185
Revised title page & section 2;
Section 8.4, torque 55-60 was
30 in-lbs; Updated section 8.8
& Figure 5 for grounding lug.
EB PG 12/11/17

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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 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:
3.1 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.
3.2 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.

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4.0 Table Of Contents
Title Page…………………………………………………………………………………..1
1. Revisions……………………………………………………………………..….....2
2. Product Warranty…………………………………………………...…...................3
3. Safety Notices………………………………………………………......……….....4
4. Table of Contents……………………………………………………………….…5
5. Part Number Explanation………………………………………….........................6
6. General Description…………………………………………………………….….7
6.1 ICAO Approach Light……………………………………………………..7
7. Installation…………………………………………………………………………8
7.1 Metric Base Installation Bolt Torque and Installation Method..……..........8
7.2 ANSI Base Installation Bolt Torque and Installation Method………...…..9
7.3 Heico-Lock Installation Guidelines (2014)……….…………………….....9
8. Maintenance………………………………………………………………............10
8.1 Cleaning Lenses……………………………………………………..........10
8.2 Relamping………………………………………………………………...10
8.3 O-Ring Replacement………………………………………………….......10
8.4 Lens Replacement………………………………………………………...11
8.5 Power Lead Feed-Thru Replacement…………………………………..…12
8.6 Pressure Test…………………………………………………………..…..12
8.7 Cleanliness and Workmanship……………………………………………13
8.8 Maintenance Program……………………………………………………..13
9. Parts List…………………………………………………………………………..14
Figure 1. Exploded View of Fixture………………………………………................15
Figure 2. Isometric View of Fixture…………………………………………..…..…16
Figure 3. Top View of Fixture……………………………………………………….17
Figure 4. Side View of Fixture…………………………………………………..…..17
Figure 5. Bottom View of Fixture……………………………………………….…..18
Figure 6. Feed-Thru Detail………………………………………………………......19

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5 Part Number Explanation
8506 A -XXX -XX
FIXTURE TYPE:
850 = RUNWAY
6 = MODEL 6
C-H STYLE:
A = ICAO APPROACH
ICAO FIGURES:
CS = FIGURE 2.1; CLEAR, STRAIGHT, UNIDIRECTIONAL
R2L = FIGURE 2.2, TOE-LEFT; RED UNIDIRECTIONAL
R2R = FIGURE 2.2, TOE-RIGHT; RED UNIDIRECTIONAL
G3L = FIGURE 2.3, TOE-LEFT; GREEN UNIDIRECTIONAL
G3R = FIGURE 2.3, TOE-RIGHT; GREEN UNIDIRECTIONAL
G2L = FIGURE 2.4, TOE-LEFT; GREEN UNIDIRECTIONAL
G2R = FIGURE 2.4, TOE-RIGHT; GREEN UNIDIRECTIONAL
RS = FIGURE 2.8; RED, STRAIGHT, UNIDIRECTIONAL
GR = G3L / RS; BIDIRECTIONAL
RG = G3R / RS; BIDIRECTIONAL
GS = GREEN, STRAIGHT, UNIDIRECTIONAL
L-823 CONNECTION:
P1 = ONE PLUG
P2 = TWO PLUGS (GR AND RG UNITS ONLY)

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6General Description
6.1 ICAO Approach Light
The Crouse-Hinds ICAO Approach Light is a Style II, (≤1/2 inch) fixture that meets the
photometric requirements of ICAO Annex 14 fixtures 2.1, 2.2, 2.3, 2.4, and 2.8 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 base 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 or bi-directional when used as a threshold wingbar or siderow light with a red
end light. 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 and six 2-piece lock washers. 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 fastened to the bottom housing using vibration isolators. Electrical
connections are made at one or two feed-thru assemblies in the inner cover. The feed-thru has
an ITS verified L-823 plug for connecting to FAA L-830/ L-831 Isolation Transformers. 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
CAUTION:
Never handle the light assembly by the leads as this can break the
waterproof seal.

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7 Installation
The style 2 IAL 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(s) 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 7.1 or 7.2, depending on your base
type.
7.1 Metric Base Installation Bolt Torque and Installation Method
•Use fully threaded A4-70 M10x1.5 bolts. (P/N 21738 is recommended)
•Use Heico-Lock or Nord-Lock stainless steel lock-washers per FAA specification*.
•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 M10 bolts with lock-washers per lock-washer manufacturer’s guidelines.
•See section 7.3 for Heico-Lock installation guidelines (2014).
•Achieve a full final torque of 26.8 N-m (237 in-lbs) +10%, -0% 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.
•Maintain all bolts by checking torque and re-torqueing per FAA specifications*.
•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.
*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. 83 “In-pavement Light Fixture Bolts”

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7.2 ANSI Installation Bolt Torque and Installation Method
•Use fully threaded, cold-worked 18-8 stainless steel 3/8-16 bolts. (P/N 21715 is recommended.
•Use Heico-Lock or Nord-Lock stainless steel lock-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 7.3 for Heico-Lock installation guidelines (2014)
•Achieve a full final torque of 225 in-lbs (25.4 N-m) +10%, -0% 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.
•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.
*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. 83 “In-pavement Light Fixture Bolts”
7.3 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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8 Maintenance
The preferred method of maintaining these lights is to periodically and systematically replace
the units and return it 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 8.1.
8.1 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.
8.2 Relamping
Remove and secure power to 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 8.5. 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 8.3. Assemble the inner cover onto the light housing. Tighten the mounting screws
to 30 in-lbs. Secure the light fixture to the base per section 7.
8.3 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.
NOTICE
NOTICE:
Warranty is void if other than Crouse-Hinds ALP parts are used to
relamp or rebuild the fixture.
NOTICE
NOTICE:
The lamp is hot when fixture is energized and remains hot for a
short time after fixture is turned off.

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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 8.6. Secure the light fixture to the base per
section 7.
8.4 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 necessary parts to change a lens. Remove and secure power to 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 bracket and discard the lens-retaining gasket. Firmly push the lens/boot assembly from
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 will not seal properly. 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 8.3. 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 8.6. Clean the mounting flange
area of the base. Secure the light fixture to the base per section 7.
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.
NOTICE
NOTICE:
A bad o-ring seal is the most common cause of inset fixture leaks.
A new o-ring must be installed every time the
Optical Assembly is opened
NOTICE
NOTICE:
The groove is designed to be wider than the o-ring. This provides room 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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8.5 Power Lead/ Feedthru 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 and secure power to the 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 power leads off at the encapsulating material. Using a hammer and chisel, separate the
encapsulating material from the inner cover. Be careful to not damage the inner cover. Remove
and discard the feedthru assemblies. Carefully clean the feed-thru mounting area in the inner
cover, inspect for any mechanical damage that would prevent a water tight seal. Replace the
feedthru components, refer to Figure 6 for part numbers and orientation. Replace the Teflon leads
inside the cover. Replace the optical housing’s o-ring per paragraph 8.3. 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 8.6. Secure the light fixture to the base per section 7.
8.6 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.
WARNING
WARNING:
Do not exceed 20-psi when pressure testing the fixture. Serious injury and/or permanent
damage to the fixture may result if a higher air pressure is used. Once the pressure test is
complete, be sure to relieve the air pressure.

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8.7 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.
8.8 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 8.2)
8.8.1 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.
8.8.2 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.
8.8.3 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.
8.8.4 ICAO approach fixtures hold-down bolts should be checked for proper torque per section 7.
8.8.5 If any fixture contains water, the water should be removed and the entire fixture cleaned and
dried. Perform a pressure test per paragraph 8.6 to locate the source of the leak. Replace the
o-ring (21385), see Section 8.3.

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9 Parts Lists
ITEM NO.
8506A-XXX-PX
PART NUMBER
DESCRIPTION
1
SEE TABLE
21287
HOUSING, OPTICAL, ASS'Y, ICAO 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
10B08-019D16
PAN HD, #10-32 x .5 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
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-CS-P1
21287-3C
21286-1
21295-CS
8506A-RS-P1
21287-1
21286-1
21295-RS
8506A-R2L-P1
21287-3R
21286-1
21295-R2L
8506A-R2R-P1
21287-3R
21286-1
21295-R2R
8506A-G2L-P1
21287-2
21286-1
21295-G2L
8506A-G2R-P1
21287-2
21286-1
21295-G2R
8506A-G3L-P1
21287-2
21286-1
21295-G3L
8506A-G3R-P1
21287-2
21286-1
21295-G3R
8506A-RG-P1
21287-4
21286-1
21295-RG
8506A-RG-P2
21287-4
21286-2
21295-RG
8506A-GR-P1
21287-4
21286-1
21295-GR
8506A-GR- P2
21287-4
21286-2
21295-GR
8506A-GS-P1
21287-2
21286-1
21295-GX

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Figure 1: Exploded View of Fixture

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Figure 2: Isometric View of Fixture

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

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Figure 5: Bottom View of Fixture

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NOT SHOWN A/R A/R 10048-63 RTV 116
NOT SHOWN 1 2 21038 LEAD ASSEMBLY, L-823
8 2 4 10035-33-010 O-RING
7 2 4 10030-100 WASHER, SHOULDER,INSULATING
6 2 4 10030-108 WASHER, FLAT, INSULATING
5 4 8 10030-57 WASHER, FLAT, SS, #1/4
4 2 4 20017 LEAD LUG
3 2 4 10K04-025D NUT, HEX, SS, #1/4-20
2 2 4 11A12-016D LOCKWASHER, SPLIT, #8, SS
1 2 4 10A06-016D10 SCREW, PAN HD, #8-32X5/16, SS
ITEM NO. 21286-1 QTY 21286-2 QTY PART NUMBER DESCRIPTION
Figure 6: Feedthru detail
FEEDTHRU REPLACEMENT INSTRUCTIONS
1. Torque item 3 to 30 in-lbs
2. Coat items 3, 4, 5 and lead terminals, on the outside of the
cover only, with item 10. Allow to cure for 8 hours.
3. Encapsulate feedthru assembly with Emerson & Cummings
catalyst 9 / resin 2651 or Mavidon catalyst 4195B / resin
4195A. Allow to cure per manufacturer’s instructions. The
wire leads exit the bottom of the inner cover, not the sides. A
temporary dam must be placed across the inner cover side to
hold the epoxy in place as it cures.