Flight Light HL490 User manual

Rev. A 7/6/2018
wwww.flightlight.com
1.800.806.3548 916.394.2800
Fax: [phone]
2708 47th Avenue,
Sacramento
CA 95822-3806
Installation Manual 490 UL

Your Flight Light HL490 light fixtures have been designed to provide you years of service if you
follow the recommendations outlined in this guide. Flight Light recommends any installation of
our heliport or helideck fixtures follow NEC (National Electrical Code) 2014 and any other
applicable local electrical codes.
Our fixture is compliant with:
•UL 1598 Standard
•FAA AC 150/5390-2B Heliport Design Guide
•Exceeds FAA Engineering Brief 87 Specifications
•ICAO Annex 14, Volume II for TLOF
•Transport Canada TP14371, AGA 7.16
•Buy American Act
•IP68 Rating
Our newest feature: Night Vision Compatibility, allows pilots to see the lights while wearing
Night Vision Goggles due to the IR (infrared) LED. The light is compatible with all generation
goggles.

Contents
1. Introduction .......................................................................................1
1.1 About the manual .........................................................................1
2. Safety Measures.................................................................................2
3. Installation Procedures ......................................................................3
3.1 Unpacking......................................................................................3
3.2 Helideck Mounting Instructions ....................................................3
3.3 Heliport (In-Pavement) Mounting Instructions ............................3
3.4 Tools and Supplies Needed ...........................................................6
4. Wiring .................................................................................................6
4.1 LED Lights AC.................................................................................7
4.2 LED AC Lights with IR.....................................................................8
5. Maintenance ......................................................................................8
6. Replacement part...............................................................................9
7. LED Replacement .............................................................................10
8. Warranty ..........................................................................................11

1
1. Introduction
The Flight Light model 490 is a 304 stainless steel nitric acid passivated light suitable for marine
environments. The passivated stainless steel body makes it corrosion resistant, increases wear
resistance, increases abrasion resistance and flame resistance. The 490 light is available for use
as a helideck or helipad light in order to ensure proper visual guidance. Available in VDC and
VAC, the light conforms to the FAA requirements.
For surface applications, the inset lights should always be installed using the Flight Light 6” base
can and following the below instructions as well as the local NEC codes.
The Base Can must be purchased separately.
The installation and maintenance should be done by authorized personnel only.
For questions or guidance during the installation process, please contact our office as engineers
and technician are always available to help you.
Phone number: 1-800-806-3458
916-394-2800
OR sent an email request to [email protected]
1.1 About the manual
This manual contains the needed instructions to complete a successful installation. Also it
contains information regarding the additional needed tools and products. Note that not all the
items that will be needed to complete the installation are coming with the light.
See the maintenance section for information regarding replacement parts and troubleshooting
guidelines.

2
2. Safety Measures
You must know whether your heliport lighting system is powered by AC or DC before installing
the fixture. AC models work on either 120VAC or 240VAC if Halogen or on a range of 100 to
240VAC if LED. DC models operate from 10 to 30VDC. The lights are designed to be installed in a
parallel circuit, which maintains a constant voltage ad brightness for all lights.
Ensure power is off before installing or servicing heliport fixtures!
Follow the local NEC code!
Make sure the equipment is rated and approved for the environment in which you are
intending to use it. Do not operate this equipment in humid, flammable, or explosive
environments unless it has been rated for safe operation in these environments.
Use only electrical wire of sufficient gauge and insulation to handle the rated current and
voltage demand.
Route electrical wiring along a protected path. Make sure they will not be damaged by moving
equipment.
Protect components from harsh environment conditions.
Protect equipment with safety devices as specified by applicable safety regulations.
Before starting this equipment, check all safety interlocks, fire –detection systems, and
protective devices such as panels and covers. Make sure all devices are fully functional. Do not
operate the system if these devices are not working properly.
Never operate equipment with a known malfunction.
Do not attempt to operate or service electrical equipment if standing water is present.
Do not touch exposed electrical connections on equipment while the power is ON!
Wiring and electrical design should be authorized by an electrical contractor.

3
3. Installation Procedures
3.1 Unpacking
Each inset light is packed in its own box 8”x 8” x 8”. Carefully remove the light from its box and
inspect for damages. If any damages are found, file a claim with the carrier.
3.2 Helideck Mounting Instructions
1. For surface mounting, cut a 4.75” diameter hole in the helideck. Place the HL-492 fixture
in the hole and secure with four ¼ -20 stainless steel flathead screws.
2. For mounting under a deck, use an adapter ring or pieces of uni-strut.
3. The incoming cable from the helideck should connect to a weatherproof junction box.
All luminaire electronic parts are inside a weatherproof enclosure. A water immersion
test is performed on all HL-492 light fixtures to ensure moisture sealing before shipping.
3.3 Heliport (In-Pavement) Mounting Instructions
1. For mounting in pavement, a base can must be used for support. Flight Light provides a
6” Diameter base can that the light fits in.
2. Proper drainage is critical for longevity of the fixture since water intrusion can destroy
the electronics inside the fixture. The fixture is weatherproof and some water is
expected to enter the base can, but provisions must be made to drain the water. Figure
1 outlines the suggested installation for proper drainage:
4 ft. cord

4
Figure 1
I. The Drain Rock should be encased in a filter fabric material to avoid soil infiltration
II. The recommended depth of drain rock unit varies dependent upon the type of
existing soils.
III. Where existing soils are granular and permeable the depth of the drain rock unit can
be limited to 1 foot.
IV. Where existing soils are fine graded and have low permeability the depth of the
drain rock unit should be increased to 3 feet or greater to provide a reservoir for
short term retention.

5
3. Installation requires a 4 ¼“ bolt circle base can to house the light fixture. The base can is
grounded through the fixture mounting bolts.
The base cans comes with the following accessories:
The plywood cover imitates the height of the casting of the 490 fixture- .25”.
Once the light is set in the base can, use the four bolts received to secure it.
Silicone is recommended to be used to feel the gap in between the fixture and the concrete.
Plywood cover 6” Diameter ¾”Thick
4 x Bolts
2 x Grommets
The 490 is a semi flush fixture with an
inclined casting. This will stand above
the level of the pad with about .86”

6
3.4 Tools and Supplies Needed
Besides the accessories Flight Light Inc. is providing, the following items may be needed to
complete a successful installation:
1. Junction box
2. Silicone
3. Electric Tape
4. Wiring
The installation of lights is recommended to be done in a parallel circuit with the splice in a
secure, waterproof junction box. Junction boxes are not provided with the lights.
The gauge of the electrical wire is to be calculated by the electrical engineer and should be
sufficient to handle the rated current and voltage demand.

7
4.1 LED Lights AC
4 ft. cord

8
4.2 LED AC Lights with IR
WARNING! Do not look at Infrared Light Fixtures while they are ON! Infrared light
output is hazardous to your eyes.
5. Maintenance
The following general maintenance procedures will help ensure maximum performance and
long component life:
• Lenses should be cleaned periodically as an accumulation of dirt, can decrease light output.
• Line voltage should be checked at the fixture and compared with the power supply to be sure
it is within the prescribed limits.
• Make certain polarity is correct for DC light fixtures
• Be sure the fixtures are properly grounded.

9
6. Replacement part

10
7. LED Replacement
To properly replace the LED board and to insure correct seal, follow the below instructions:
•Turn the light upside down and remove the four bottom cover screws
•Unplug connectors coming from the power converter to the LED board
•Remove the 4 mounting screws that hold the LED board in place
•Remove LED board
•Discard the LED board, bottom casting with the existing cord and the power
converter
•Remove the blue film from the new LED board and put it in place
•Reinstall mounting screws for the LED board
•Verify the connection in between the LED board and the Power Converter
•Make sure the bottom cover gasket is seated properly
•Install the four bottom cover screws to close the fixture
Power
Converter
Connectors
Mounting Screws
LED Board
Gasket
Bottom
Casting

11
8. Warranty
Duration of the Warranty: Flight Light Inc. warrants all of the goods which it has manufactured
to be free of material defects for the following durations.
Lamps: For a period of 90 days from the date of shipment to Buyer. Product liability is limited to
lamp replacement and does not include incidental labor.
FAA products: For a period of one year from the date of installation or two years from the date
of shipment to Buyer.
LED Light Fixtures: For a period of 2 years from the date of shipment to Buyer. Complete
Systems: Systems including at least one Flight Light Inc. Controller and one Flight Light Inc. LED
Light Fixture, for a period of 5 years from the date of shipment to Buyer.
Buyer’s Remedies: If any such goods are found to be materially defective within the warranty
period, Flight Light Inc. agrees to attempt to repair, and if unable to repair, to replace the
defective goods without charge to Buyer.
Buyer’s remedy with respect to such goods is limited to repair or replacement. For goods not
manufactured by FLI, Buyer agrees to accept as its sole remedy the warranty, if any, offered by
the manufacturer or manufacturers of such goods. FLI makes no warranties, express or implied,
other than those stated in this paragraph.
Warranty Exclusions: Flight Light Inc. shall not be liable under this warranty if any of the
following conditions apply:
1) Unauthorized personnel attempt any repairs to Flight Light Inc. products without
Flight Light Inc. consent.
2) Products are damaged by natural phenomenon, misuse, abuse, accident, alteration,
or incorrect electrical current or voltage.
3) Products are improperly installed, or damaged in shipping.
Warranty Limitations
FLI makes no warranties, express or implied, other than those stated herein. FLI does not
warranty the workmanship of the installer, damage caused by acts of nature, vandalism,
improper installation, or damage caused by improper maintenance. The warranty period of LED
fixtures covered under the 5-year system warranty is reduced to two years when fixtures are
subjected to abrasive materials or chemicals. FLI reserves the right to either repair or replace
any defective component covered under the terms of any of its warranties. FLI is not an
engineering firm and makes no expressed or implied warranty as to the applicability of its
products or systems in any specific situation, application or location: such decisions are the
responsibility of the owner, design engineer and/ or others. Therefore, as to all goods sold by
FLI, FLI hereby disclaims any implied warranty of merchantability or implied warranty of fitness
for a particular purpose and Buyer agrees that FLI shall not be liable for any special, indirect,
incidental, consequential or liquidated damages of any kind, whether the Buyer’s or any other
claim is based upon contract, tort or any other legal theory.