Hali-Brite L-807 Manual
Table of Contents
CHAPTER 1
Introduction
About This Manual
..................................................................4
Model Configurations
..............................................................4
Reference Material
...................................................................5
Warranty
.........................................…......................................5
Disclaimers
...............................................................................6
CHAPTER 2
Safety Precautions
Safety Statements
.....................................................................7
General Practices
......................…............................................8
Electrical Practices
...................…............................................
9
Qualified Personnel
......................…........................................
9
Proper Usage
..........................................................................10
CHAPTER 3
Specifications
Electrical Specifications
.........................................................11
Physical Specifications
..........................................................11
CHAPTER 4
Getting Started
Shipping and Unpacking
........................................................14
Taking Inventory
....................................................................15
Tools
and Supplies Needed
....................................................17
2
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
CHAPTER 5
Installing the L-807 Wind Cone
Installing the
L-807 Wind Cone
Anchor
................................19
Positioning the Swing
Arm
......................... ...........................22
Placing
the Base of
the Pole
onto the
Anchor
........................22
Attaching the Basket to the
Pole
.... ........................................24
Installing Lights
........................ .............................................25
Installing the External Lighting Kit ..............................................25
Installing the Internal Lighting Kit ..............................................27
Wiring the Lights
to the Power
Source
............. .....................28
Installing
the Wind Sock
to the
Basket
................... ...............29
Raising the Top
Half of
the Pole
............................... .............29
CHAPTER 6
Installing the L-806 Wind Cone
Installing Lights
............................... ................ ......................31
Installing the External Lighting Kit ..............................................32
Installing the Internal Lighting Kit ..............................................33
Installing
the Wind Sock
to the
Basket
.......... ........................34
Assembling the Pole to the Baseplate
............... .....................35
Wiring the Lights
to the Power
Source
............. .....................35
Attach the Pole Assembly to the
Base Can
......... ...................36
CHAPTER 7
Maintaining and Servicing the Wind Cones
Tools Required
........................................... ............................37
Lowering the Top
of the L-807 Pole
......................................37
Inspecting Wind Cone Components
.......................................38
Replacing Lamps
......................................... ...........................39
Replacing an Internal Floodlight Lamp
.................................40
Replacing an External Floodlight Lamp
................................40
Replacing an Obstruction
Lamp
................ ............................41
CHAPTER 8
Spare Parts
How
to Order Parts
................................................................42
Recommended Spare Parts
.....................................................42
CHAPTER 9
Wiring Diagrams
L-807 and L-806
Wind
Cone Installation and Maintenance
Manual
3
Introduction
CHAPTER 1
Introduction
About This Manual
The information in this manual is provided to assist installation and
maintenance personnel in the proper installation, upkeep, and maintenance
of the L-806, L-806(L), L-807 and L-807(L) Wind Cones. The (L) suffix
denotes models with LED lamps. This manual also includes installation and
maintenance instructions for all equipment sold as options to the basic unit.
Model Configurations
This manual covers the models listed below:
TABLE 1. Wind Cone Models
L-807 and L-807(L) Models L-806 and L-806(L) Models
L807-S1-UN-NON-ON-N L806-S1-UN-NON-ON-N
L807-S1-EX-120-ON-5 L806-S1-EX-120-ON-5
L807-S1-EX-230-ON-5 L806-S1-EX-230-ON-5
L807-S1-EX-66A-ON-5 L806-S1-EX-66A-ON-5
L807-S1-IN-120-ON-5 L806-S1-IN-120-ON-5
L807-S1-IN-230-ON-5 L806-S1-IN-230-ON-5
L807-S1-IN-12-ON-5 L806-S1-IN-12-ON-5
L807-S1-IN-120-ON-N L806-S1-IN-120-ON-N
L807-S1-EX-12-ON-5 L806-S1-EX-12-ON-5
L807-S1-IN-66A-ON-5 L806-S1-IN-66A-ON-5
L807-S2-UN-NON-ON-N
L807-S2-IN-120-ON-5
L807-S2-IN-230-ON-5
L807-S2-IN-12-ON-5
L807-S2-EX-120-ON-5
L807-S2-EX-230-ON-5
L807-S2-EX-66A-ON-5
L807-S2-IN-120-ON-N
L807-S2-EX-12-ON-5
L807-S2-IN-66A-ON-3
4
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
Warranty
Reference Material
•
Store this manual or any reference material within easy reach of personnel
installing, operating, maintaining, or repairing this equipment.
•
Refer to the FAA Advisory Circular AC 150/5340-26, Maintenance of Air-
port Visual Aids Facilities, for instructions on safety precautions.
Warranty
Hali-Brite®products are guaranteed against mechanical, electrical, and physical
defects (excluding lamps) for a period of one year from the date of installation
or a maximum of two years from the date of shipment and are guaranteed to be
merchantable and fit for the ordinary purposes for which such products are
made. Inaddition,Hali-Brite®productswhichareFAAcertifiedtoEngineeringBrief
67Dshallhaveafouryearwarranty,fromdateofinstallation,ontheLEDlamp(s)and
theassociatedpowersupply.Hali-Brite®will correct by repair or replacement, at
its option, equipment or parts which fail because of mechanical, electrical or
physical defects, provided that the goods have been properly handled and stored
prior to installation, properly installed and properly operated after installation
(left in upright position at all times except for service), and provided further
that Buyer gives Hali-Brite®written notice of such defects after delivery of the
goods to Buyer. Hali-Brite®reserves the right to examine goods upon which a
claim is made. Said goods must be presented in the same condition as when the
defect therein was discovered. Hali-Brite®further reserves the right to require
the return of such goods to establish any claim. Hali-Brite’s obligation under
this guarantee is limited to making repair or replacement within a reasonable
time after receipt of such written notice and does not include any other costs
such as the cost of removal of defective part, installation of repaired product,
labor or consequential damages of any kind, the exclusive remedy being to
require such new parts to be furnished. Hali-Brite’s liability under no
circumstances will exceed the contract price of goods claimed to be defective.
Any returns under this guarantee are to be on a transportation charges prepaid
basis. For products not manufactured by, but sold by Hali-Brite®, warranty is
limited to that extended by the original manufacturer. This is Hali-Brite’s sole
guarantee and warranty with respect to the goods; there are no express
warranties or warranties of fitness for any particular purpose or any implied
warranties of fitness for any particular purpose or any implied warranties other
than those made expressly herein. All such warranties are expressly disclaimed.
Details and values given in this manual are average values and have been com-
piled with care. They are not binding, however, and Hali-Brite®disclaims any
liability for damages or detriments suffered as a result of reliance on the infor-
mation given herein or the use of products, processes or equipment to which
this manual refers. No warranty is made that the use of the information or of the
products, processes or equipment to which this manual refers will not infringe
any third party’s patents or rights. The information given does not release the
buyer from making their own experiments and tests.
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
5
Introduction
Disclaimers
This manual is published for informational purposes only and the information
provided should not be considered as all-inclusive or covering all contingen-
cies. If further information is required, Hali-Brite Inc. should be contacted.
Sale of the product shown in this manual is subject to Hali-Brite’s terms and
conditions including, but not limited to, the Hali-Brite®Warranty. Such
terms and conditions are available upon request.
Hali-Brite’s warranty will not apply to any products which have been “so
repaired or altered outside the manufacturer’s plants as, in the manufacturer’s
judgment, to affect its reliability and performance.”
No warranties, express or implied, including warranties of fitness for a particu-
lar purpose or merchantability, or warranties arising from course or dealing or
usage of trade, are made regarding the information, recommendations, and
descriptions contained herein. The manufacturer is not responsible and will not
be held liable in contract or in tort (including negligence) for any special, indi-
rect or consequential damages, including injury or damage caused to vehicles,
contents or persons, by reason of the installation of any Hali-Brite®product or
its mechanical or electrical failure.
6
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
Safety Statements
CHAPTER 2
Safety Precautions
To help you install and maintain this equipment safely and efficiently make sure
you read and understand all safety information in this manual prior to per-
forming any procedure. Failure to do so may result in personal injury, property
damage, or possible death.
Safety Statements
The following safety statements are used throughout this manual. They will
alert you to possible safety hazards and conditions that could result in personal
injury, death, or property and equipment damage.
CAUTION: Indicates hazards or unsafe practices which could
result in minor personal injury, product, or property damage.
WARNING: Indicates hazards or unsafe practices which could
result in severe personal injury or death.
DANGER: Indicates immediate hazards which will resultin severe
personal injury or death.
L-807 and L-806
Wind
Cone Installation and Maintenance
Manual
7
Safety Precautions
General Practices
Read and become familiar with the general safety instructions provided in this
section of the manual before installing, operating, maintaining, or repairing this
equipment.
•
Do not attempt to assemble or install this equipment if it has been damaged
from shipping.
•
Do not attempt to install or maintain this equipment if you or the equipment
is standing in water.
•
Only qualified personnel should perform maintenance on this equipment.
•
Always use proper tools (as mentioned in this manual) to perform installa-
tion and maintenance.
•
Use caution when cranking the winch. Always crank slowly and grasp the
handle securely.
•
Use proper hand and eye protection as needed when installing or maintain-
ing this equipment.
•
Make sure you have adequate first aid supplies available when installing
this equipment.
•
Do not modify this equipment as this could create a safety hazard and void
your Hali-Brite®warranty.
•
Only use Hali-Brite®replacement parts.
•
Read and carefully follow the instructions given throughout this manual for
performing specific tasks and working with specific equipment.
•
Follow all applicable safety procedures required by your company, industry
standards, and government or other regulatory agencies.
•
Make sure all equipmentis rated and approved forthe environment in which
you are using it.
•
Follow all instructions for installing components and accessories.
•
Protect components from damage, wear, and harsh environment conditions.
•
Allow ample room for maintenance, wiring accessibility, and cover
removal.
8
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
Electrical Practices
Electrical Practices
•
Do not attempt to make electrical connections with the power on.
•
Disconnect and lock out electrical power before touching any electrical con-
nections. Refer to FAA Advisory Circular AC 150/5340-26.
•
Install all electrical connections to local code.
•
Use only electrical wire of sufficient gauge and insulation to handle the
rated current demand. All wiring must meet local codes.
•
Route electrical wiring along a protected path. Make sure it will not be
damaged by moving equipment.
•
Protect equipment with safety devices as specified by applicable safety reg-
ulations.
•
If safety devices must be removed for installation, install them immediately
after the work is completed and check them for proper functioning.
•
Always use rated electrical tools when performing electrical work.
•
Always make sure electrical connections are tight.
•
Make sure electrical covers are in place after installation.
•
Do not touch hot lamps with bare hands.
Qualified Personnel
Qualified personnel are those that are trained and experienced with installing
or maintaining Hali-Brite®equipment. Only qualified personnel should install
or maintain Hali-Brite®equipment and auxiliary features.
No one should:
•
Attempt to install or perform maintenance on this or any Hali-Brite®equip-
ment if they are physically impaired or under the influence of alcohol or non
prescription drugs.
•
Maintain or install this equipment without correct training, supervision or
experience in mechanical or electrical equipment.
•
Attempt to maintain or install this equipment without the correct tools as
specified in this manual.
L-807 and L-806
Wind
Cone Installation and Maintenance
Manual
9
Safety Precautions
Proper Usage
Always use this equipment as specified in this manual. Improper usage may
result in serious personal injury, property damage, or possible death.
•
Do not modify any equipment that has not been recommended by Hali-
Brite®.
•
Do not use any replacement parts that are not purchased from Hali-Brite®.
•
Hali-Brite®cannot be responsible for injuries or damages resulting from non-
standard, unintended applications of its equipment. This equipment is
designed and intended only for the purpose described in this manual. Uses
not described in this manual are considered unintended uses and may result
in serious personal injury, death, or property damage.
10
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
CHAPTER 3
Specifications
Part
Number
See
Notes
FAA
Size
FAA
Style
Power
Source
Lamp
Type
VA
Watts
Weight
(pounds)
L806-S1-UN-NON-ON-N
1
II Unlighted
none
None
0
0
45
L806-S1-EX-120-ON-5
1
I-A External
120 VAC
LED
15
14
58
L806-S1-EX-230-ON-5
2
1
I-A External
230 VAC
LED
15
14
58
L806-S1-EX-66A-ON-5
3
1
I-A External
6.6 AMP
LED
58
52
57
L806-S1-IN-120-ON-5
1
I-B Internal
120 VAC
LED
32
19
59
L806-S1-IN-230-ON-5
2
1
I-B Internal
230 VAC
LED
40
21
59
L806-S1-IN-120-ON-N
2
1
I-B Internal
120 VAC
Halogen
316
316
57
L806-S1-EX-12-ON-5
1
I-A External
12 VDC
LED
6
6
57
L806-S1-IN-12-ON-5
2
1
I-B Internal
12 VDC
LED
6
6
57
L806-S1-IN-66A-ON-5
3
1
I-B Internal
6.6 AMP
LED
72
65
57
L807-S1-UN-NON-ON-N
1
II Unlighted
None
None
0
0
187
L807-S1-EX-230-ON-5
2
1
I-A External
230 VAC
LED
15
14
198
L807-S1-EX-66A-ON-5
3
1
I-A External
6.6 AMP
LED
58
52
197
L807-S1-IN-120-ON-5
1
I-B Internal
120 VAC
LED
32
19
200
L807-S1-IN-230-ON-5
2
1
I-B Internal
230 VAC
LED
40
21
200
L807-S1-EX-120-ON-N
2
1
I-A External
120 VAC
Halogen
191
191
196
L807-S1-IN-120-ON-N
2
1
I-B Internal
120 VAC
Halogen
316
316
198
L807-S1-EX-12-ON-5
1
I-A External
12 VDC
LED
6
6
197
L807-S1-IN-12-ON-5
2
1
I-B Internal
12 VDC
LED
6
6
197
L807-S1-IN-66A-ON-5
3
1
I-B Internal
6.6 AMP
LED
72
65
198
L807-S2-UN-NON-ON-N
2
II Unlighted
None
None
0
0
199
L807-S2-IN-120-ON-5
2
I-B Internal
120 VAC
LED
60
32
212
L807-S2-IN-230-ON-5
2
2
I-B Internal
230 VAC
LED
76
36
212
L807-S2-EX-230-ON-5
2
2
I-A External
230 VAC
LED
22
21
210
L807-S2-EX-66A-ON-5
3
2
I-A External
6.6 AMP
LED
58
52
209
L807-S2-EX-120-ON-N
2
2
I-A External
120 VAC
Halogen
191
191
208
L807-S2-IN-120-ON-N
2
2
I-B Internal
120 VAC
Halogen
516
516
210
L807-S2-EX-12-ON-5
2
I-A External
12 VDC
LED
10
10
210
L807-S2-IN-12-ON-5
2
2
I-B Internal
12 VDC
LED
10
10
210
L807-S2-IN-66A-ON-3
4
2
I-B Internal
6.6 AMP
LED
95
88
210
Notes:
1. Power consumption specifications include the L-810 obstruction light
2. This FAA Style is not ETL certified
3. Requires 100 watt L-830 transformer, sold separately.
4. Requires 200 watt L-830 transformer, sold separately.
Additional Specifications:
1. Wind Sock
a. Size 1 dimensions: 18 inch throat diameter, 8 foot length
b. Size 2 dimensions: 36 inch throat diameter, 12 foot length
c. Color: International Orange
2. Pole Material: Steel tubing
3. Temperature Range: -55C to +55C (-67F to +131F)
4. Wind Indication
a. Indicates true direction when wind velocity exceeds 3 knots
b. Wind sock full extension when wind velocity exceeds 15 knots
5. Dimensions
a. Type L-806 and L-806(L): see Figure 2
b. Type L-807 and L-807(L): see Figure 1
L-807 and L-806
Wind
Cone Installation and Maintenance
Manual
11
Specifications
With Lighting
246" w/18"
basket
or
264" w/36"
basket
214" w/18"
basket
or
232" w/36"
basket
192"
18"
or
36"
77"
0
HBA116
Figure 1.
L-807 Dimensions
12
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
Physical Specifications
122"
117”
90”
18"
72"
0
Figure 2.
L-806 Dimensions
HBA143
L-807 and L-806
Wind
Cone Installation and Maintenance
Manual
13
Getting Started
CHAPTER 4
Getting Started
Shipping and Unpacking
All components needed for assembly and installation of the L-807, L-807(L),
L-806 and L-806(L) are shipped on a standard 10 ft pallet. If additional
components or more than one unit is ordered the shipping pallet may be larger.
All components are fas- tened to the shipping pallet, tools will be needed to
unfasten these components prior to installation.
After unfastening all the components from the pallet inspect them for damage.
If you find components that have been damage from shipping please report
them to the shipping company and file a claim.
NOTE: You may want to photograph the damaged components in place on
the shipping pallet. This will help you in placing a claim with the shipping
company.
CAUTION: Some components are very heavy. Always use correct
lifting practices when removing these components from the
shipping pallet. If components are too heavy find additional help
in removing these components.
If excessive damage has occurred, not allowing assembly of the wind cone,
contact Hali-Brite®for replacement parts.
14
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
Taking Inventory
Taking Inventory
Inventory all components prior to installation. Verify that you have everything
required to assemble and install the L-807 or L-806 Wind Cone. If there are
any missing components contact Hali-Brite®.
CAUTION: Always take care in handling individual components
to prevent damage or injury.
The following components are standard or optional components shipped with an
L-807 wind cone.
10
2
1
3
11
9
4
8
5
7
6
Figure 3.
L-807 Wind Cone
Components
HBA149
L-807 and L-806
Wind
Cone Installation and Maintenance
Manual
15
Getting Started
1.
Exterior Floodlights (optional)
8.
Wind
Sock
2.
Obstruction
Light
9.
Cable Straps (placed in box)
3.
Interior
Floodlight Kit (optional)
10.
Anchor Bar with:
4.
Pole (bottom half)
5.
Swing Arm
6.
Pole (top half)
3/4" Lock Washers (4)
3/4" Flat Washers (8)
3/4" Nuts
(8)
7.
18" or 36" Basket
11
Touch-Up
Paint
The following components are standard or optional components shipped with an
L-806 wind cone.
7
1
6
2
5
3
4
HBA152
Figure 4.
L-806 Wind Cone
Components
1.
Interior Floodlight Kit consisting
of:
* Light
pole assembly
w/obstruction light
* 2-light configuration (optional)
5.
Wind Sock
2.
Exterior Floodlights (optional)
6.
Touch-Up
Paint
3.
Pole
7.
18"
Basket
4.
Frangible Coupling
16
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
Tools and Supplies
Needed
Tools and Supplies Needed
After all components on the shipping pallet have been inventoried you will
need to accumulate the following tools. These tools are required for assem-
bling the L-807 or L-806 wind cone.
3
4
5 6 7
8
2
1
12
11
10
9
HBA148
Figure 5.
Required
Tools
1.
Anti-Locking Compound
(Used
to prevent threaded compo-
nents from seizing)
2.
12" or
larger Carpenter Level
(Used
to level the
anchor)
3.
9/16" Open End Wrench
(Used to install the
swing arm bolts)
4.
Two
5/8" Open End Wrenches
(Used
to secure the hinge bolts)
5.
Large Crescent
Wrench
(Used
to tighten nuts
to the anchor
bracket)
6.
1-1/16"
Open End Wrench
(Used
to level the
anchor nuts)
7.
18" Pipe Wrench
(Used to
secure
external light kit
to the pole)
8.
6 ft Ladder
(Used
to access hinge on pole)
9.
Electrician Tools
(Used to
wire lighting kit to power source)
10.
50 ft
Fishtape
(Used
to route lighting cable to
base of
pole)
11.
Tape Measure
(Used to
set anchor height)
12.
3/16" Allen Hex Wrench
( to
remove
electrical access cover plate)
L-807 and L-806
Wind
Cone Installation and Maintenance
Manual
17
Installing the L-807 Wind Cone
CHAPTER 5
Installing the L-807 Wind Cone
In order to simplify the installation of the L-807 wind cone, the process can be
broken down into the following subtasks. Perform them in the order they are
listed below.
1.
“Installing the L-807 Wind Cone Anchor” on page 19
2.
“Positioning the Swing Arm” on page 22
3.
“Placing the Base of the Pole onto the Anchor” on page 22
4.
“Attaching the Basket to the Pole” on page 24 or
5.
“Installing Lights” on page 25
6.
“Wiring the Lights to the Power Source” on page 28
7.
“Installing the Wind Sock to the Basket” on page 29
8.
“Raising the Top Half of the Pole” on page 29
18
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
Installing the L-807 Wind Cone Anchor
Installing the L-807 Wind Cone Anchor
The installation process begins with creating a firm base to which the pole
assembly will be mounted. The installation contractor is responsible for the
design of the base according to local codes and conditions. The following pro-
cedure is only provided as a general guideline for installing the anchor. You
may have to modify this procedure to accommodate your location and condi-
tions.
To install the anchor, perform the following steps.
1.
Remove the anchor from the shipping pallet.
2.
Remove the nuts and washers from each of the anchor’s four threaded cor-
ner posts.
3.
Acquire four 1/2" x 5 ft pieces of rebar.
NOTE: Rebar is not supplied by Hali-Brite®.
4.
Use wire to tie each 5 ft piece of rebar to each of the four corner posts, see
Item #6 in Figure 7 on page 21.
5.
Dig a hole deep enough to accommodate the anchor and attached rebar
legs. The hole should be approximately 7.5 ft deep.
6.
Lower the anchor assembly into the hole.
7.
Acquire a 1/2" piece of conduit approximately 4 ft long.
NOTE: Conduit is not supplied by Hali-Brite®.
8.
Place a 90 degree bend approximately 20" from one end of the conduit, see
Item #7 in Figure 7.
9.
Place this end of the conduit between the four corner posts and 18" below
grade. If possible wire the conduit in place, see Figure 7 on page 21.
10.
Position the anchor assembly to ensure the anchor threads will protrude 4-
5" above the grade of the finished concrete.
11.
Fill the hole with concrete. Concrete specifications are to be determined by
the installation contractor.
12.
Use a carpenter level to level the anchor in all directions, see Figure 6.
Check this several times as the concrete is curing.
13.
After the concrete has cured, turn a 3/4" nut onto each of the four threaded
corner posts. The nut must be turned down as far as it will go.
14.
Place a level across two of the 3/4" nuts, see Item #2 in Figure 6. Raise or
lower the nuts until they are level, in all directions. This ensures that the
post will be level when placed onto the anchor.
15.
Place a flat washer on top of each of the four 3/4" nuts, see Figure 6.
L-807 and L-806
Wind
Cone Installation and Maintenance
Manual
19
Installing the L-807 Wind Cone
2
3
1
Figure 6.
Leveling
the
Anchor Nuts for the L-807 Wind
Cone
1.
3/4" Nut
2.
Carpenter Level
3.
3/4" Flat
Washer
20
L-807
and L-806 Wind Cone Installation and
Maintenance Manual
This manual suits for next models
33
Table of contents
